SRI ANDAL PAPER MILLS LTD.

110/11kV Substation EPC Package

December-2019

DOCUMENT NO. SAPM-100-E- DOC -6122

ISSUE : P0

MECH TECH PROJECTS

113A, Railway Station Road - 3rd Lane, Sidco Industrial Estate, Ambattur Industrial Estate
(North), Ambattur, Chennai - 600 098- Tamilnadu, India. Phone: +91- 44- 2624 2278,
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SECTION - 1

REQUIREMENTS FOR 110/11KV SUBSTATION

AND

SINGLE CIRCUIT TRANSMISSION LINE

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TABLE OF CONTENTS

PAGE
Sl.No DESCRIPTION
NO.

1.0 Introduction 3

2.0 General Specifications and scope of works 3

3.0 Site data and System parameters 4

4.0 Standards to be adopted 5

Brief description on scope of works & specification for
5.0 110KV Transmission Line 8

6.0 110kV Circuit Breaker specification 9

7.0 110kV Current transformer specification 10

8.0 110kV Potential Transformer specification 10

9.0 110kV Isolator specification 11

10.0 Power Transformer specification 13

11.0 96kA Surge arresters specification 33

12.0 Control, protective relays specifications 34

13.0 Technical Specification for 11kV switchgear 41

14.0 Steel structures 52

15.0 Substation Auxiliaries Battery and Battery Charger 54

Miscellaneous materials Earthing, Conductors, In sulators,
16.0 Illumination & Cables 60

17.0 Communication system Equipment with TANGEDCO 72

Neutral Grounding Resistor
18.0 76
Civil works
19.0 77
Technical Guarantees for all 110kV equipment’s
20.0 80
Bill Of Materials for 110KV Substation
21.0 81

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1.0 INTRODUCTION:

• SRI ANDAL PAPER MILLS PVT LTD (SAPM) has a large paper manufacturing
Plant at Pasuvapalayam, Erode District, Tamilnadu. SAPM proposes to
produce a capacity to 700 Tonne/day with introduction of a modern Open
Corrugated Container process and a Paper Machine.
• This project involves construction of a new electrical distribution system to
support the increase in plant production.

2.0 GENERAL SPECIFICATION AND SCOPE OF WORKS:

The scope of work will cover

• Design Engineering, Manufacture, Supply, Installation, Testing and
Commissioning of 2.0 km long 110 KV single circuit Transmission line
• Design Engineering, Manufacture, Supply, Installation, Testing and
Commissioning of 110 /11KV outdoor Substation
• The detailed requirement for 110/11kV substation comprises of all the
necessary 110kV outdoor equipment, power transformer and the 11kV
Switchgear.
• SAPM has indicated clearly the locations for the outdoor substation in the
Mill layout drawing, Drawing No. SAPM-100-C-LAY-2800 R9B .
• The requirement also involves a construction of the control building to
accommodate 110kV control and relay panels, 3 Panel- 11kV switchgear,
415V LT power supply system, 110V DC Battery & Battery Charger and
PLCC equipments etc., which shall be part of the complete substation
design.
• The work also involves the complete Civil & Structural works comprising of
the Steel structures for Towers/Girders, equipment support structure, Cable
Trenches, Compound wall Mansory Brick wall & Gates and all the required
foundations for 110kV equipment & Power transformer.
• The work also involves the design of Earthing and Lightning protection for
substation area.
• The Illumination for this substation shall be designed for the outdoor area
and control building.

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3.0 SITE DATA AND SYSTEM PARAMETERS

3.1 SITE DATA

• Location of site: Rayagada, Orissa, India. The Mill site is located at

77.2500 0 E longitude, 11.5167 0 N latitude
• Altitude: about 239 m above MSL.
• Nearest river- Bhavani
• Road connectivity: The nearest highway is the state highway connecting
Rayagada district and Berhampur district and lies at about one km away from
the mill.
• Railway connectivity: The nearest railway station is nearest railway station
– Erode.
• Temperature:
- Minimum temperature 19°C
- Maximum temperature 40°C
- Design temperature 50°C
• Rainfall: The Maximum annual rainfall is 150 mm and major rainfall occurs
Oct- Dec.
• Wind speed: The Wind speeds are in Min- Max range of 120 to 180 km/h.
The predominant wind direction at the project site is West to East
• Soil: The soil bearing capacity is 40ton/sq.m (Soft rock).
• Ground water: The ground water table is about 20 m below ground lev el in
the study area.
• Earthquake Zone: ZONE II: IS: 1893 – 2002

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3.2 SYSTEM PARAMETERS

SYSTEM
110kV 11kV 0.415kV
VOLTAGE

System 3 Phase, 3 Wire 3 Phase, 3 Wire 3 Phase, 4 Wire

Frequency 50Hz +3% 50Hz +5% 50Hz +5%

Initial symmetrical
short circuit 31.5KA, 3Sec 25KA, 3Sec 50KA, 1Sec
current

System Earthing Solidly earthed Resistance earthed Solidly earthed

Auxiliary power
• AC control voltage 240 VAC
• DC control voltage 110 VDC

4.0 STANDARDS TO BE ADOPTED

All installations shall be designed and specified in compliance with the
recommendations, codes and standards, as follows:
▪ The Indian Electricity Rules, 1956

▪ The Indian Electricity Act, 1908

▪ The National Electrical Code, 1985

▪ The Indian Standard Specifications

▪ The Indian Standard Codes of Practice

▪ The Tariff Advisory Committee for Fire Insurance Regulations

▪ The British Standard Specifications or the IEC specifications where Indian

Standard Specifications are not available.

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▪ Standards prescribed by the Electrical Inspectorate

▪ Tamil Nadu Electricity regulations, I.E.E. wiring regulations,

▪ IS 2026 and IEC 60076 (Power transformer)

▪ IEC 60214 (on-load tap changer)

▪ IEC 60296 (Fluids for electro technical applications)

▪ IEC 60694: Specifications for High-voltage Switchgear and Control

gear Standards

▪ IEC 60298: AC Metal-enclosed Switchgear and Control gear for

Voltages 1kV to 52 kV

▪ IEC 62271-100: and 62271- 102 High-voltage AC Circuit Breakers

▪ IEC 60185: Current Transformers

▪ IEC 60186: Voltage Transformers

▪ IEC 60801/IEC: 255 Control gear

▪ IEC 60529: Degrees of Protection Provided by Enclosures

▪ IEC 60076-1 to 60076-5: Power transformers IS 325 and IEC 34

(Three phase Induction motors)

▪ IS 335/148 and IEC 60296 (Insulating oils for Transformers and

switchgear)

▪ IS 778 (Gun metal gate, globe and check-valves for general purpose)

▪ IS 1886 (Code of practice for installation and maintenance of

transformers)

▪ IS 2099 IEC 60137 (Bushings for alternating voltage above 1000 V)

▪ IS 2147 (Degrees of protection. Provided by enclosures for low voltage

switchgear & control gear)

▪ IS 2705 and IEC 60185 (Current Transformers)

▪ IS 3203 (Code of practice of climatic proofing of electrical equipments)

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▪ IS 3347 (Dimensions for porcelain Transformer Bushings)

▪ IS 3401 (Silica Gel)

▪ IS 3637 (Gas operated relays)

▪ IS 3639 (Fittings & Accessories for power transformers)

▪ IS 5561 (Electric Power Connector)

▪ IS 6600 (Guide for loading of oil immersed transformers)

▪ IS 9434 (Guide for sampling and analysis of dissolved gas in oil filled
equipments)

▪ IS 12676 (Oil impregnated paper insulated condenser Bushing

Dimension and requirements)

▪ IEC 60071 (Insulation Co-ordination)

▪ IS: 335 1993 New insulating oils.

▪ IS: 398 Aluminium conductors for overhead, transmission purposes.

▪ IS: 731 1971 Porcelain insulators for overhead, power lines with a
national voltage, greater than 1000V.

▪ IS:739 1992 Wrought aluminium and aluminium alloy-wire

▪ IS:800 1984 Code of practice for general construction in steel

▪ IS: 802 Part-1-Sec-1 1995, Part-1-Sec-2 1992, Part-2 1978& Part-3

1978 Code of practice for use structural steel in overhead transmission
line towers.

▪ IEEE Standard Construction of Composite Fiber Optic Overhead Ground

Wire (OPGW) for Use on Electric Utility Power Lines

▪ IS:2309 1989 Code of Practice for the protection of buildings and allied
structures against lightning

▪ IS:2486 Part 1 to Part 4 -Metal fittings of insulators for overhead power

lines with a nominal voltage > 1000V

▪ IS: 3043 1987 Code of practice for earthing.

▪ IS: 3070 Part 1 to Part 3 Lightning arrestors for alternating current

systems.

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▪ IS: 3156- Part 1 to Part 4- Voltage transformers.

▪ IEEE-80 IEEE- Guide for safety in AC Substation Grounding

▪ IS: 8623 Part-1 1993 Specification for Low-Voltage Switchgear and

Control gear, Assemblies - Requirements for Type, Tested and Partially
Type-Tested, Assemblies

▪ IS:8623 Part-2 1993 Specification for Low-voltage Switchgear and

Control gear, Assemblies - Particular Requirements for Busbar Trunking
Systems (Busway)

▪ IS :8623 Part-3 1993 Specification for Low-Voltage Switchgear and

Control gear, Assemblies - Particular Requirements for Equipment
Where Unskilled Persons have Access for Their Use

▪ IS: 13947 Part-1 to Part -5 1993 Specification for Low-voltage

Switchgear and Control gear – General Rules.
▪ IS 11448 (2000): Application Guide for ac Electricity Meters
▪ IS 2026 1977 Power Transformers – General

5.0 BRIEF DESCRIPTION ON SCOPE OF WORKS &SPECIFICATION FOR

110KV SINGLE CIRCUIT TRANSMISSION LINE:

SRIANDAL project requirement is to Design and install 110KV Single Circuit

Transmission line from Tap off Point at TANGEDCO’s Transmission line as
shown in Drawing No. SAPM100CLAY2800-Rev 9A-OVER ALL LAYOUT.

Bidder’s scope includes

a. complete survey of the land along the TL route as shown in above drawing

And prepare the TL route layout, t.

b. Prepare TL route layout drawing

c. Design and supply and installation of Towers, Conductors,

Insulators, Clamps / Hardwares, Earthing of Towers.

d. Obtain approval from TANGEDCO for the TL route and design.

SriAndal hereby indicate that entire Route of TL and Towers are within their Own
land and way leave for TL route shall be limited to obtaining their approval only.

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TECHNICAL SPECIFICATION FOR OUTDOOR SWITCHYARD EQUIPMENTS

6.0 110kV CIRCUIT BREAKERS:

This specification is for three pole operated outdoor 110kV circuit breaker together
with controls and ancillary equipment.

CONSTRUCTION

• The circuit breakers shall be single pole operated, out-door type, Trip free SF6
gas insulated and shall comply with the requirements of IEC 56 and IS 2516.
• The circuit breaker shall be live tank type.
• All the three poles of circuit breakers shall be operated by local electrical and
remote/electrical from the mechanism in the housing.
• The circuit breaker shall have SF6 gas for electrical interrupting medium.
• The SF6 gas shall comply with the requirement of IEC 376 and be suitable for
use in the circuit breaker when it is operated under the service and system
conditions.
• Sufficient gas shall be provided for filling the circuit breaker at installation with
additional 20% for any losses. SF6 Gas filling equipment with Gas leak
Detector and all accessories, and necessary volume of SF6 Gas with Cylinder .
• Insulation creepage distance shall not be less than 25 mm per kV of rated
voltage between phases.

OPERATING MECHANISM

• The operating mechanism shall be suitable for mounting at the circuit breaker
supporting structure, and below the circuit breaker in a weather -proof, dust-
proof, vermin-proof and well-ventilated housing.

• Operating duty shall be standard and operating mechanism shall be trip free
during the entire closing sequence.

• Operating mechanism shall be provided with either motor wound spring or

pressure actuated mechanism with provision for hand charge.

• Motor operating voltage shall be 110 Volts D.C.

• A set of at least ten normally closed and ten normally open spare potential
free contacts shall be provided for remote electrical indication as well as
electrical interlocking and shall be wired to a terminal block in the housing.

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• Potential free contacts shall be provided for alarming spring charge failure or
control oil pressure low. Potential free contacts shall be provided for alarms
for SF6 gas low and SF6 Trip Block.

• A minimum of twenty (20) spare terminals shall be provided for connection to

the current and voltage transformers.

• The circuit breaker shall be provided with Local/Remote selector switch. The
selection of local operation shall inhibit the operation of the circuit breaker
from any remote source and selection of remote inhibits operation from local
operation.

• The circuit breaker shall be provided with a local switch for

Open/Neutral/Close Operation.

• Mechanically operated indication to show the status of the circuit breaker operations
(open/close and springs charged/discharged) shall be provided.

• Local pressures Gauge to indicate the SF6 Gas pressure

7.0 110 KV CURRENT TRANSFORMERS:

➢ SCOPE

This specification is for current transformers for use with electrical instruments
and electrical protective devices on systems with maximum operating voltage of
123kV.

➢ CONSTRUCTION

The current transformer shall be outdoor, oil-filled, hermetically sealed and shall
comply with the requirement of IEC 185. The current transformer shall be
suitable for vertical installation on steel structure.

8.0 110 KV POTENTIAL TRANSFORMERS:

➢ SCOPE

• This specification is Potential transformers for use with electrical instruments

and electrical protective devices on system with maximum operating voltage
up to 123kV.

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• The voltage transformers will be connected to overhead system operating at

a nominal voltage of 110kV and a maximum voltage of 123kV which are
generally of earthed construction.

• The voltage transformer will be connected between line and earth of a 3 -

phase 3-wire system with the neutral point solidly earthed.

➢ CONSTRUCTION

• The voltage transformer shall be Single phase, out-door, oil-immersed,

hermetically sealed and shall comply with the requirement of IEC 186.

• The voltage transformer shall be suitable for installation on steel structure.

The voltage transformer shall be fitted with lugs.

• The porcelain portion of the voltage transformer shall be made of high -grade
brown glazed porcelain. All other external parts shall be either inherently
resistant to atmospheric corrosion or hot dip galvanized.

• The voltage transformer shall have primary, secondary and earth terminals.

• The primary terminal shall be tin-plated, suitable for both copper and
aluminium connectors. The secondary terminal shall be brought out to a
separate terminal box, complete with protection MCB. The MCB should have
auxiliary contacts for indication, alarm and distance relay input.

9.0 110 KV ISOLATORS:

➢ SCOPE

• This specification is for 110kV, 1250 Amps Isolator OFF LOAD type for use
online disconnection, isolation of substation apparatus.

• This specification covers both the 110 kV isolators with and without earth
switch.

➢ CONSTRUCTION

• The isolator shall be center rotating type, double break, horizontal upright
mounting isolator for use on a 110kV, 50 Hz, 3 - phase system.

• The isolator shall be complete with supporting base, phase coupling details,
operating rod, unions and guides.

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• The operating mechanism shall be provided with a universal joint to allow for
a reasonable degree of out-of alignment of the operating rod.

• The isolator shall be Motorized and also fitted with manual operation facility.
There should be a remote selection to allow for operation of the isolator from
the control room. The remote selection should block any local electrical or
manual operation.

• The supporting under-base shall be hot dip galvanized steel as per the
requirement of BS 729. The under-base shall be suitable for mounting on a
steel structure.

• All the three switches shall be arranged so that the phase units are moun ted
independently and then finally interconnected with coupling tubes so as to
ensure simultaneous operation of all switches by drive rods and operating
handle for both manual and motor operation.

• The operating mechanism shall be fixed at the base frame, i n a

weatherproof, vermin proof and dust proof housing. The degree of protection
shall be class IP 54 as per IEC144.

• Auxiliary dry contacts, five normally open and five normally closed shall be
provided for electrical interlocks such that the isolator and a ssociated 110 kV
circuit breaker can be interlocked with each other. The contacts shall be
rated to continuously carry at least 10Amps at voltages up to 500V dc/ac

• Each phase shall be mounted on a spiral type solid core post insulator
conforming to IEC 60273, and shall be fitted with clamp connector for the
suitable conductor/connector.

• The isolator shall be designed such that in fully open position, it shall provide
adequate electrical isolation between the contacts on all the three switches.

• All current carrying parts shall be made of electrolytic hard drawn copper
with switch contacts silver plated.

• The earth switch shall consist of a hinged type earthing switch fixed at the
base frame. The earth switch shall have the same rating as the isolator.

• The isolator shall be provided with both mechanical and electrical

interlocking devices between the isolator and earth switch so that during
operations, it is only possible to operate the earth switch with the isolator in
the open position and the isolator with the earth switches in the open
position.

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• Ten normally open and ten normally closed auxiliary contacts shall be
provided on the switch for future use.

• Five normally open and five normally closed auxiliary contacts shall be
provided on the earth switch for future use.

• The isolator and earth switch shall be provided with a padlocking facility such
that the mechanism can be locked in OPEN or CLOSED position.

10.0 110/11KV, 10 MVA POWER TRANSFORMER:

➢ SCOPE

• This specification is for newly manufactured outdoo r oil type power

transformer as described below:

• 10 MVA, 110/11kV, 50Hz, Dyn11, ONAN three phase power transformer.

• The specification also covers inspection and test of the transformer as well
as schedule of Guaranteed Technical Particulars to be filled, signed by the
manufacturer and submitted for tender evaluation.

• The specification stipulates the minimum requirements for 10 MVA, 110/11kV

power transformer acceptable for use in the company and it shall be the
responsibility of the manufacturer to ensure adequacy of the design and
good engineering practice in the manufacture of the transformer.

➢ SYSTEM CHARACTERISTICS

➢ The primary HV system is 110,000 volts, 3 phase, 3 wire, 50Hz, with neutral
point solidly earthed.

➢ The secondary MV system is 11,000 volts, 3 phase, 3 wire, 50Hz, with neutral
point Resistance earthed.

➢ The Transformer shall be operated at a high loading factor.

➢ GENERAL REQUIREMENTS

➢ The transformer shall be outdoor, oil-immersed, of ONAN classification and

core type (lamination stackings). All offers shall comply with the
requirements of IEC 60076. Any deviations/additional requirements shall
be as stated in this specification.

➢ The transformer shall be a two winding type three -phase integral unit.

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➢ The transformer shall be of the free breathing type. A dehydrating cobalt free
breather of approved design shall be provided.

➢ The transformer and accessories shall be designed to facilitate operation,

inspection, maintenance and repairs. All apparatus shall be designed to
ensure satisfactory operation under such sudden variations of load and
voltage as may be met with under working conditions on the system,
including those due to short circuits.

➢ The design shall incorporate every reasonable precaution and provision for
the safety of all those concerned in the operation and maintenance of the
equipment keeping in view the regulatory requirements.

➢ All material used shall be of the best quality and of the class most suitable
for working under the conditions specified and shall withstand the variatio ns
of temperatures and atmospheric conditions arising under working conditions
without undue distortion or deterioration or the setting up of undue stresses
in any part, and also without affecting the strength and suitability of the
various parts for the work which they have to perform.

➢ Corresponding parts liable to be replaced shall be interchangeable.

➢ All outdoor apparatus, including bushings insulators with their mountings,

shall be designed so as to avoid pockets in which water can collect.

➢ All connections and contacts shall be of ample section and surface for
carrying continuously the specified currents without undue heating and fixed
connections shall be secured by bolts or set screws of ample size,
adequately locked. Lock nuts shall be used on stud connections carrying
current. All leads from the winding to the terminals and bushings shall be
adequately supported to prevent injury from vibration including a systematical
pull under short circuit conditions.

➢ All apparatus shall be designed to minimize th e risk or accidental short-

circuit caused by animals, birds or vermin.

➢ In tank on-load-tap changers shall be located such that the space above the
diverter switch chamber will be free of inter-connecting pipes etc. for lifting
the diverter switch unit for inspection and maintenance purposes.

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➢ Galvanizing shall be applied by the hot-dipped process to ISO 1461 and for
all parts other than steel wires shall consist of a thickness of zinc coating
equivalent to not less than 610g of zinc per square meter of su rface. The zinc
coating shall be smooth, clean and of uniform thickness and free from
defects. The preparation of galvanizing and the galvanizing itself shall not
adversely affect the mechanical properties of the coated material. The quality
will be established by tests as per ISO 1461.

➢ All bolts, nuts, and washers exposed to atmosphere and in contact with non -
ferrous parts which carry current shall be of phosphor bronze. If bolts and
nuts are placed so that they are inaccessible by means of ordinary spanners,
suitable special spanners shall be provided by the supplier. Except for
hardware, which may have to be removed at site, all external surfaces shall
receive at least four coats of paint. The total dry film thickness shall be
between 100 and 130 microns.

➢ Descriptive labels for mounting indoors or inside cubicles and kiosks shall be
of material that will ensure permanence of the lettering. A matt or satin finish
shall be provided to avoid dazzle from reflected light. Labels mounted on
dark surface shall have white lettering on a black background. Danger
notices shall have red lettering on a white background.

➢ All interior surfaces of chambers or kiosks that are in contact with air shall
receive at least three coats of paint, of which the topcoat shall be of a light
shade.

➢ The design and all materials and processes used in the manufacture of the
transformer, shall be such as to reduce to a minimum the risk of the
development of acidity in the oil.

➢ Every care shall be taken to ensure that the design and manufac ture of the
transformers and auxiliary plant shall be such to have minimum noise and
vibration levels following good modern manufacturing practices. The
maximum noise levels shall be stated in the bid.

RATINGS

➢ The windings of the transformer shall be rated at 10 MVA ONAN.

➢ The rating specified in this clause shall be the continuous rating at the
maximum ambient temperature.

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➢ The transformer shall be capable of carrying its full normal rating

continuously at any tap under the conditions without undue stre ss,
overheating, or the temperature rise in the hottest region exceeding 55ºC and
60ºC in oil and windings respectively.

➢ The loading capabilities shall be demonstrated by a temperature – rise test.

This test shall be done at site.

➢ The transformer shall be capable of withstanding the maximum fault level at

its rated voltage and impedance for 2 seconds. The design should cater for
the expected lifetime of the transformer.

WINDING AND CONNECTIONS

➢ The transformer shall be wound Dyn11 to be checked with respect to the 110
kV and 11 kV windings as per IEC 60076.

➢ The transformers shall be capable of operation without danger on any

particular tapping at the rated MVA when the voltage may vary by ± 10% in
steps of 1.25% of the voltage corresponding to the tapping.

➢ The windings and connections as well as the insulating material shall not
soften, ooze, shrink or collapse during service. The materials shall be non -
catalytic and chemically inactive in transformer oil during service.

➢ No strip conductor wound on edge shall have a width exceeding six times its
thickness. The conductors shall be transposed at sufficient intervals to
minimize eddy currents and equalize the current and temperature distribution
along the windings.

➢ The windings and connections shall be properly braced to withstand shocks

during transportation or due to short circuit and other transient conditions
during service.

➢ Adequate pre-shrinkage of the coil assembly using pre-compressed press

board material having low moisture content for the radial spacer blocks shall
be ensured by the manufacturers so that there is no displacement of the
radial spacer blocks due to frequent short circuits on the transformers.

➢ All windings after being wound and all fibrous hygroscopic materials used in
the construction of the transformer shall be dried under vacuum and
impregnated with hot oil.

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➢ The coil clamping rings wherever used shall preferably be of flat insulated
steel laminations.

➢ The radial spacer blocks must be made of pre -compressed pressboard

material, which will not soften while in contact with oil or fray out into fibers
or edges. The slots should be so dimensioned that the blocks will not come
out of the slots.

➢ All joints shall be brazed/crimped considering the vibrations due to short

circuits and load fluctuations.

➢ During inspection they will check the built-up winding for its quality, weight of
copper, insulation and overall weight of coil assembly. The size of conductor
used for different windings shall also be checked during stage inspection to
check the current density.

➢ The transformer shall be designed with particular attention to the suppression

of harmonic voltage, especially the third and fifth, so as to eliminate wave -
form distortion and from any possibility of high frequency disturbances,
inductive effects or of circulating currents between the neutral points at
different transforming stations reaching such a magnitude as to cause
interference with communication circuits.

➢ The windings shall be designed to reduce to a minimum the out -of-balance

forces in the transformer at all voltage ratios.

TAPPING

➢ TAPPING RANGE

➢ The transformer shall be provided with tapping on the 110-kV winding for a
variation of no-load primary voltage for parallel operation, with Tap No. 1
having the highest voltage assignment, as follows:

110000 volts + or – 10% in steps of 1.25 %

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CORE AND FLUX DENSITY

a) CORE

➢ The core shall be constructed from the laminations of high-grade cold rolled
non-aging, grain-oriented silicon steel known as M4 High B Grade or superior
grade CRGO steels of maximum 0.27mm or less lamination thickness
especially suitable for transformer core. The grade of CRGO shall be stated
in the bid.

➢ The design of the magnetic circuit shall be such as to avoid static

discharges, development of short-circuit paths within itself or to the earthed
or to the clamping structure and the production of flux components at right
angles to the plane of the laminations which may cause local heating.

➢ Every care shall be exercised in the selection, treatment and hand ling of
core steel to ensure that as far as practicable, the laminations are flat and
the finally assembled core is free from distortion.

➢ Adequate oil ducts shall be provided in the core for cooling. Tinned copper
strip bridging pieces shall be used for maintaining electrical continuity
wherever the magnetic circuit is provided into pockets by such ducts or
insulating material thicker than 0.25mm.

➢ There shall be no movement of the core assembly relative to the tank during
transport, installation as well as in service due to sudden jerks caused by
short circuits and fluctuating loads.

➢ All steel sections used for supporting the core shall be thoroughly sand
blasted or shot blasted after cutting, drilling and welding. Any non -magnetic
or high resistance alloy shall be of established quality.

➢ Adequate lifting lugs shall be provided to enable core and winding to be

lifted.

➢ The supporting framework of the Cores shall be so designed as to avoid the

presence of pockets which would prevent complete emptying of the tan k
through the drain valve, or cause trapping of air during filling.

➢ The insulation structure for the core to bolts and core to clamp plate shall be
such as to withstand a voltage of 2kV AC for one minute.

b) FLUX DENSITY

➢ The primary voltage variation, which may affect the flux density at every tap,
shall be kept in view while designing the transformer.

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➢ The transformer shall be so designed that the working flux density shall not
exceed 1.6 Tesla at normal voltage, frequency & ratio. Tenders with higher
flux density than specified shall not be considered.

➢ Tender shall indicate the continuous allowable maximum flux for one minute
and five seconds.

➢ The limit of flux density at which core material used saturates shall also be
stated in the tender. The name and grade of core material shall be stated in
the tender.

➢ The successful tenderer shall be required to furnish magnetization curve of

the core material, design calculations and such other data/documents
deemed fit by the purchaser for being satisfied that flux density is as desired.

NOTE:
The above flux density has been specified to meet with the over fluxing of the
core due to temporary over voltage of the orders of 25% for one minute and
40% for five seconds that may appear in abnormal conditions such as the
one obtained following sudden loss of large loads.

LOSSES, REGULATION AND IMPEDANCE

➢ Losses of the transformer shall be stated and shall be subject to tolerances

in accordance with IEC 60076. The fixed losses shall be as low as is
consistent with good design, reliability and economical use of materials.

➢ Voltage regulation from no-load to continuous rated output at unity power

factor, at 0.8 lagging and 0.8 leading power factor with constant voltage
across the higher voltage windings shall be stated in the bid.

➢ The impedance voltage at extreme tappings and at principal tapping shall be

stated and shall be subject to tolerances in accordance with IEC 60076.

TERMINALS ARRANGEMENT & BUSHINGS

➢ The 11kV and 110kV windings shall be brought out separately through open
bushings of outdoor, weatherproof design in accordance with the latest IEC
standard.

➢ Bushings for 110kV terminals shall be of oil-filled condenser type

construction, draw-out type and shall each have a capacitance test point.
Bushings for 11kV terminals shall be of the solid porcelain type.

➢ The neutral bushing of the transformer shall be identical to the corresponding

phase terminal bushings for 11kV Bushings.

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➢ Spacing and air clearances shall be so co-ordinated as to render the

probability of a flashover from the terminal of one winding to the terminal of
another winding negligible.

➢ Leakage distance of bushings shall not be less than 25mm/kV, based on

operating phase to phase voltage.

➢ Bushing terminals shall be clamp type suitable for both copper and
aluminium Bus bars of sizes up to 76mm diameter.

➢ Each bushing of the 11kV windings shall be mounted on a turret. Each turret
shall be suitable for accommodating at least three sets of current
transformers.

➢ Terminal arrangement on the HV and LV sides shall be 1U,1V,1W and 2U,

2V, 2W & 2 N, respectively.

CURRENT TRANSFORMERS TO BE FITTED

➢ Current transformers shall be installed in the Neutral bushing turrets and

shall be of the following quantities, ratios, ratings and class:

11KV NEUTRAL

CORE 1

➢ Neutral side -;15 VA 600-/1A, cl. 5P20- for Standby Earth fault Protection.

CORE 2

➢ Neutral Side - ;15VA 600/1A, cl.PS -for Restricted Earth fault Protection

➢ Current transformers of suitable rating and class for winding temperature

indicators shall be installed to adequately cover the transformer as indicated
above for guidance.

➢ Current transformers shall comply with the requirements of IEC 60044.

➢ Full technical particulars of current transformers offered, including type test

results from an International reputable Testing Authority or a National
Testing Authority shall be submitted with tender.

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AIR CLEARANCE

➢ When totally assembled, as in service, electrical clearances in air shall be

adequate to withstand the assigned impulse withstand test volta ges.

➢ Care shall be taken to ensure that all fittings are suitably positioned so as
not to interfere with the external connection to the bushing terminals.

➢ Minimum external air clearances shall be as shown under.

NOMINAL SYSTEM VOLTAGE BETWEEN PHASES 11kV 110 kV

Minimum clearance phase-to-earth and phase-to-

mm 320 1300
neutral
Minimum clearance phase-to-phase between
mm 320 1300
phases of the same winding

INSULATION LEVELS

The complete transformer arranged for service, shall be capable of withstandi ng the
following voltages and shall comply fully with the requirements of IEC 60076 Part 3,
including the latest amendments.

Nominal system Highest system Lightning Impulse Power frequency

Voltage Voltage (kV, withstand voltage withstand voltage
(kV, rms) rms) (kV, peak) (kV, rms)

11 12 28 75

110 123 550 230

ON LOAD TAP CHANGER AND MECHANISM BOX

➢ The transformer shall be complete with vacuum type on -load, electrically

driven tap changing mechanism of the high-speed resistor transition type and
shall comply with the requirements of IEC 214 and 512. The equipment shall
be suitable for remote operation from a control panel supplied with the
transformer as well as for local operation from the Motor Drive Unit (MDU)
mounted on the transformer body.

➢ The mechanism shall be so designed as to ensure that when a tap change

operation is in progress, it shall be able to complete the task independently
irrespective of operation of any relays or switches.

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➢ Adequate means shall be provided to safeguard the transformer and its

auxiliary circuits from damage should a failure of the auxiliary supply or any
other mal operation occur during the progress of tap changing that may
prevent it from completing its task.

➢ Means shall be provided in the marshalling kiosk for mechanical isolation of

the supply to the Motor Drive Unit, and a suitable thermal overload device
(details to be submitted with tender) shall be provided in the MDU for the
protection of the motor.

➢ The possibility of over-running the mechanism at each end of the voltage

range shall be prevented by means of limit switches and mechanical stops.
Other techniques used to prevent tap changer runaway shall be indicated.

➢ A mechanically operated device shall be provided to indicate the tap position

locally, and a suitable tap position transmitter shall be provided for the
remote tap position indication.

➢ A counter shall be provided on the tap changing mechanism box to indicate

the total number of operations completed by the equipment.

➢ Contactors and associated equipment for the control circuit for local/remote
and manual operations of the tap changer mechanism shall be housed in the
mechanism box.

➢ The tap changer (diverter switch) shall be housed in a separate compartment

and shall be Vacuum Type. Sufficient documentation for the vacuum switch
in form of manuals, instructions, drawings, technical characteristics, certified
type test certificates and reports (from an International Testing/ Standards
Laboratory), manufacturing and export experience of the suppl ier shall be
submitted with the tender for technical evaluation.

➢ The Motor Drive Unit shall have the following in addition to what has been
stated above:

(a) Isolating switch in the transformer marshalling box for the supply to the
tap changer Motor Drive Unit,

(b) Raise/lower contactors for tap changer motor operation, and associated
single phase protection/overload relay,

(c) Switch for selection of local/remote tap changer control,

(d) Switch or switches for local tap changer operation,

(e) Provisions shall be made available for hand operation in the mechanism
box.

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➢ The tap changer shall be of internationally reputable manufacture and proven

reliability in service. Detailed documentation and copies of certificates shall
be submitted with the tender for evaluation.

REMOTE TAP CHANGER CONTROL PANEL

The remote tap changer control panel shall contain the following devices:

➢ Automatic Voltage Regulating Relay (to be of proven design and technical

details submitted with tender).

➢ Off/Manual/Automatic switch for the Relay.

➢ Raise /Lower control switch.

➢ Raise, Lower, ‘out of step’ and tap change in progress indication lamps

➢ Dial type Tap position indicator (technical details to be submitted with the
tender).

➢ Master/Follower/Independent Scheme and selector switch. The Tap Changer

shall employ, negative reactance or circulating current principle scheme for
parallel operation with other three similar transformers but of different rating.

➢ Local /Remote switch

➢ KV meter (technical details to be submitted with the tender)

➢ Door operated lamp and anti-condensation heater.

➢ Heater switch ON/OFF to control anti-condensation heater

➢ Various control circuits controlled by Miniature Circuit Breakers

AUTOMATIC VOLTAGE REGULATING RELAY

The relay shall be of Numerical type proven design and shall incorporate the
following features;

➢ Rated voltage 110V AC.

➢ Rated Current 1 Amp.

➢ Initial time delay range 5-100 seconds, and ability to select Integrated

delay or Definite time delay.

➢ Inter-tap delay 1-80 seconds

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➢ Relay voltage setting, adjustable in steps of 1V from 85 - 130V

➢ Line drop compensation 0-20 V at rated current for both reactive

and resistive setting

➢ Under voltage inhibit range 70%-90% & over current inhibit

range 150%-250%

➢ Bandwidth range 0.5-5 % of voltage level

➢ Over voltage inhibit

➢ The AVR should have a selector switch with OFF/Manual/Auto

➢ Should be of Numeric Design.

➢ Tap changer Maintenance, by maintaining Tap Operation count.

➢ Tap Changer Mechanism Failure.

➢ Sufficient documentation in form of instruction manuals, drawings,

technical characteristics and test certificates from
international/national testing/standards laboratory of the country of
manufacture shall be submitted with the tender to facilitate technical
evaluation.

MARSHALLING KIOSK (Box)

The marshalling kiosk shall be of outdoor, IP 55, weatherproof, vermin-proof type

with a hinged, lockable door fitted with a glass panel to facilitate reading of oil and
winding temperature gauges without opening the door. The kiosk shall be
mounted so that its window is approximately 1600mm above ground level; and
shall accommodate at least the following items: -

1. Winding temperature indicator for both HV and MV with a maximum pointer

drag hand type with a resetting knob and three separately adjustable
mercury contacts for alarm, trip and operation of cooler control circuits as
required.

2. Oil temperature indicator with a maximum pointer drag hand type with a
resetting knob and two separately adjustable mercury contacts for alarm and
trip.

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3. Mechanical isolating switch for the incoming 3 phase , 4 wire, 415V 50Hz
supply to the marshalling kiosk. 415 volts and 240 volts socket outlets
(square pins) shall also be provided in the kiosk.

4. A mechanical isolating switch for the outgoing 3 phase 4 -wire 415V 50Hz
supply to the OLTC Motor drive unit.

5. An internal standard screw type illumination lamp and heater for the kiosk
with respective switches. The lamp shall be door switch operated.

6. Wiring, fuses, links, terminal boards and cable glands for bottom entry of
multicore cables.

7. Anti-condensation heater with a switch.

8. Thermostat for anti-condensation heater control.

9. Hygrostat for anti-condensation heater control.

10. MCB control for each of the circuits.

11. Phase sequence relay for detection of wrong phase rotation for the supply to
the fans and the OLTC Motor Drive Unit. Detailed technical details, drawings,
and schematics shall be submitted with the tender

AUXILIARY SUPPLIES

Equipment shall be rated for the following auxiliary power supplies:

(a) Tap changer control: 240 V, single phase, 50Hz

(b) Tap changer motor: 415 V, three phase, 50Hz

TRANSFORMER TANK AND TANK COVER

➢ The tank shall be constructed of mild steel plates of sufficient thickness and
strength and shall be complete with all accessories. It shall be designed so
as to allow the complete transformer when filled with oil to be lifted by crane
or jacks, transported by road, rail or on water without overstraining any joints
and without causing subsequent leakage of oil.

➢ The base of the tank shall be so designed that it shall be possible to mo ve

the complete transformer unit in any direction without injury when using
rollers, and/or plates

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➢ The tank and its accessories shall be so designed as to prevent collecting or

trapping of gases. Where this cannot be avoided, pipes shall be provided to
vent the gas into the main expansion pipe. The vent shall have a minimum
outside diameter of 19mm except for short pipes which may be 6.35mm
minimum inside diameter.

➢ All joints, other than those that may have to be broken shall be welded.
Caulking of unsatisfactorily welded joints is forbidden.

➢ The main tank body shall be pressure tested and a certificate issued by the
national standards and testing laboratory ascertaining the soundness of all
welded joints. A certified copy of the certificate shall be submitted with the
tender for evaluation.

➢ Tank shall be provided with lifting lugs suitable for lifting the complete
transformer with oil. Furthermore, a minimum of four accessible jacking
positions shall be provided to enable the complete transformer to be raise d
or lowered using jacks.

➢ The transformer tank and all attachments normally under oil shall be capable
of withstanding full vacuum. The oil conservator shall withstand at least 35%
full Vacuum.

➢ Tank cover shall be of such a design and construction as to pr event

accumulation of water and shall be bolted to the flange on the tank top to
form a weatherproof joint.

➢ Inspection openings shall be provided as necessary to give easy access to

bushings, tapping switch and for testing or general inspection.

➢ Tank cover and inspection covers shall be provided with suitable lifting
arrangements. Inspection covers shall not weigh more than 25 kg apiece.

➢ The tank cover shall be fitted with isolated pockets for oil and winding
temperature instrument bulbs. Protection shall be provided where necessary
for each capillary tube. The pocket shall be fitted with a captive screwed cap
to prevent the ingress of water. Detailed drawings shall be provided.

➢ The pocket shall be located in a position of maximum oil temperature at

continuous maximum rating and it shall be possible to insert and remove the
instrument bulbs without lowering the oil in the tank.

➢ Gaskets for weather and oil-tight joint faces shall be of synthetic rubber-and-
cork composition and shall have a minimum thickness of 5mm, except that
where jointing faces are precision-machined thinner gaskets may be used.

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PAINT WORK

➢ Cleaning and painting shall be in accordance with the following

requirements. Any deviations in methodology shall be stated and may only
be those that will produce demonstrably superior results.

➢ A test report issued by the national standards and testing laboratory shall be
produced at the time of acceptance testing of the transformer.

TANKS AND ACCESSORIES

➢ External and internal surfaces of all transformer tanks and chambers and
other fabricated steel items shall be cleaned of scale, rust and surface dirt by
blast cleaning or other suitable approved method. After cleaning, these
surfaces should be immediately covered with paint.

➢ The exterior shall be thoroughly cleaned by shot blasting or other approved

method and given priming coat followed by two coats of contrasting colors of
durable weather-resisting paint. The final coat shall be high gloss of shade
No. 632 (Admiralty Grey) according to BS 381C.

➢ The interior of all transformer tanks and other oil-filled chambers shall be
cleaned of all scale and rust by shot blasting or other approved method. Hot
oil resistant varnish on white synthetic enamel/proxy paint is to be used for
painting the inside of all oil filled chambers, including transformer tanks. The
final coat shall be of a light-colored anti-condensation finish.

RADIATORS

➢ Radiators shall be thoroughly degreased and treated externally by phosphate

and/or other rust-inhibiting process.

➢ Radiators shall be flood-painted with a primer and two coats of durable

weather and oil resisting paint. The final external coat shall be high gloss of
shade No.632 (Admiralty Grey) according to BS 381C. The total paint
thickness shall not be less than 80μm at any point.

➢ Each section of Radiator shall be an Isolating Valve.

FITTINGS

CONSERVATOR

➢ Conservators shall be Air-cell type.

➢ The transformer shall be provided with a conservator having a filling orifice,

an isolating valve, a drain valve and a cobalt free dehydrating breather (with
oil seal) which shall be accessible from ground level. The drainpipe shall be

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located at the lowest point in the conservator in its final installed position and
welded such that it can drain all the sludge in the conservator.

➢ The conservator shall be partitioned proportionately to separate the main

tank oil and the tap changer oil. Each compartment to be fitted with a
breather and an oil level indicator with electrical contacts for alarms. The
conservator complete with drain valve shall be in such a position as not to
obstruct the electrical connections to the transformer. An oil gauge shall be
provided at one end of the conservator marked with oil levels that can be
read by a person standing on the ground. Expansion joints may be provided
in the inlet and outlet pipes to the transformer as necessary.

GAS AND OIL ACTUATED RELAY (Transformer Main tank)

➢ Transformers shall be provided with a gas and oil actuated relay (Buchholz
relay) of double float type with tripping contacts to detect accumulation of
gas and sudden changes of oil pressure. Shut off valves and flange
couplings shall be provided to facilitate easy removal of the relay without
lowering oil level in the main tank. A bleed valve for gas venting, a test valve
and a terminal box suitably wired to the marshalling kiosk shall also be
provided. The gas venting pipe shall be brought down to a height reachable
from ground level and shall be fitted with a gas sampling device at the end.

➢ Provision should be made on the relay for simulation of gas and oil surge for
testing purposes.

GAS AND OIL ACTUATED RELAY (Tap changer compartment)

➢ Tap changer compartment shall be provided with a gas and oil actuated relay
(Buchholz relay) of double float type with tripping contacts to detect
accumulation of gas and sudden changes of oil pressure. Shut off valves and
flange couplings shall be provided to facilitate easy removal of the relay
without lowering oil level in the tap changer compartment. A bleed valve for
gas venting, a test valve and a terminal box suitably wired to the marshalling
kiosk shall also be provided. The gas venting pipe shall be brought down to a
height reachable from ground level and shall be fitted with a gas sampling
device at the end. Provision should be made on the relay for simulation of
gas and oil surge for testing purposes.

PRESSURE RELIEF DEVICE

➢ A pressure relief device shall be provided for the main tank, complete with
trip contacts suitably wired to the marshalling kiosk. The devi ce shall be
resettable after an operation. Details of the device shall be submitted with
the offer.

WINDING TEMPERATURE INDICATOR

(a) The transformer shall be provided with winding temperature indicator,

maximum indicator and associated current transformer. The temperature
indicator shall have a scale ranging from 20°C to 150°C, preferably uniformly
divided and its type to be stated in the bid. The indicator shall have two sets
of independently adjustable contacts as follows:

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(i) Alarm Adjustable setting : 70°C to 150°C

Fixed differential : Not more than 5°C
(ii) Trip Adjustable setting : 70° to 150°C
Fixed differential : Not more than 5°C

(b) All contacts shall be adjustable to a scale and shall be accessible on

removal of the cover for dial type devices. For purposes of (i) and (ii) above,
the contacts shall be suitable for making or breaking 150VA between the
limits of 30 and 250 V a.c. or d.c., and making 500 VA between the limits of
the 110 and 250 V d.c.

(c) Isolating and test links shall be provided in a control cubicle to allow for
measuring the oil temperature and testing the heater coil.

(d) The current transformer providing winding temperature indication shall be

located at the discretion of the manufacturer, in the best pos ition for the duty.

(e) Calibration of indicator shall be related to the winding having the

maximum temperature rise.

(f) If the value on the winding temperature indicator varies by more than 3°C
from the values derived from the tests specified in clau se 5, then
adjustments shall be made to the equipment to achieve these limits.

OIL TEMPERATURE INDICATOR

Transformers shall be provided with an oil temperature indicator with a

maximum pointer and contacts for alarm and trip signals, similar to winding
temperature indicator above.

ACCESSORIES

The following shall be provided:

Valves with blank flanges fitted at the top and bottom for oil filtration
purposes, having the following features:

➢ The valve located at the bottom of the tank shall also be suitabl e
for draining oil from the transformer tank.
➢ All valves shall close with a clockwise rotation. The main inlet and
outlet valves shall be provided with “open” and “closed” position
indicators, visible from ground level.
➢ All valves shall have provision for padlocking in the open and
closed position for operation purposes. The hole for the padlock
shall have a clearance of not less than 8mm and not more than
10mm. Locking pin shall be of anti-rattle design to limit noise
emissions. The locking padlocks shall be provided.
➢ Closed/Open positions of all valves must be clearly marked

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➢ Oil sampling device appropriately located to obtain samples of

transformer oil from the top and bottom of the tank.
➢ Two earthing terminals located at diagonally opposite corners of
the tank.
➢ Air release valves or plugs for the main tank, suitably located.
➢ Non-deteriorating detailed diagram and rating plates.
➢ Other Fittings/accessories shall be included:
1. Diagram plate (as per IS2026, Part-2)
2. Plate of valves and oil piping.
3. Motor drive electrical and protection diagram.
4. Electrical scheme for operating this in parallel with other similar
units.
5. Detailed list of the transformer equipment & fittings including
their drawings, brochures & instruction manuals.
6. Detailed erection, installation, operation and maintenance
manuals in English language.

7. Testing Plan.
8. Impact recorder for the whole duration of transit and a report
provided afterwards.
9. Sets of keys for padlocking devices. (all control boxes as well as
valves to be padlocked)

TRANSFORMER OIL

The transformer and all associated oil immersed equipment shall be supplied oil filled. The
oil shall comply with all the requirements of IEC 296 (class 1: un-inhibited oil). Tenderer shall
provide the chemical composition and properties of the oil and the replacement cycle over
the expected life of the transformer.

CAPITALIZATION

Transformer losses shall be capitalized at the following rates to facilitate evaluation and
comparison of tenders.
Loss Capitalization will be calculated and loaded on Vendor’s offer. Loss capitalization
figures will be arrived based on Tamilnadu Regulatory Commissions Codes & Regulations.

NB: - Where tenders are being compared, losses will be capitalized at the above rate and
added to the bid evaluated price of the transformer.

QUALITY MANAGEMENT SYSTEM

➢ The supplier shall include a quality assurance programme (QAP) that will be
used to ensure that the transformer design, material, workmanship, tests,
service capability, maintenance and documentation, will fulfill the
requirements stated in the contract documents, standards, specifications and

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regulations. The QAP shall be based on and include relevant parts to fulfill
the requirements of ISO 9001:2000.

➢ The Manufacturer’s Declaration of Conformity to reference standards and

copies of quality management certifications including copy of valid ISO 9001:
2000 certificate shall be submitted with the tender for evaluation.

TESTS AND INSPECTION

➢ The transformer shall be inspected and tested in accordance with the

requirements of IEC 60076 and this specification. It shall be the
responsibility of the manufacturer to perform or to have performed all the
tests specified. Tenderers shall confirm the manufacturer’s capabilities in this
regard when submitting tenders. Any limitations shall be clearly specified.

➢ Certified true copies of previous Type Test Certificates and Type Test
Reports issued by the relevant International or National Testing/ Standards
Authority or ISO/IEC 17025/ILAC accredited laboratory shall be submitted
with the offer for evaluation (all in English Language). A copy of the
accreditation certificate for the laboratory shall also be submitted. Any
translations of certificates and test reports into English language shall be
signed and stamped by the Testing Authority.

Copies of type test certificates and reports for the transformer to be submitted shall
include:
1. Dielectric tests to IEC 60076 (Lightning Impulse and Power Frequency
withstand Tests).
2. Short circuit withstand test to IEC 60076.
3. Temperature rise test to IEC 60076.

➢ The transformer shall be subject to acceptance tests at the manufactures’

works before dispatch. Acceptance tests shall be witnessed by two
Engineers appointed by SAPM and shall include the following:

➢ Routine tests to IS2026/IEC 60076 (to be done during acceptance testing at

factory)
- Measurement of winding resistance
- Ratio test
- Vector group
- Separate source voltage withstand test
- Induced over-voltage
- Insulation resistance
- Oil leakage test on fully assembled transformer for 12 hours
- Measurement of impedance voltage
- Magnetic balance

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- Measurement of no-load loss and current

- Measurement of load loss (at normal & extreme taps)
- Tests on on-load tap-changer
- Tests on on-load tap-changer remote control panel
- Efficiency at 50%, 75%, 100% loading at unity p.f and rated terminal
voltage
- (Corrected to 75°C)
- Lightning impulse withstand test

➢ Type Tests to IS2026/ IEC 60076 (to be done during acceptance testing at
factory)
- Temperature rise test – To be performed on the two units
during acceptance testing.
• Additional tests (to be done during acceptance testing at factory)
- Insulation dissipation factor
- Condenser bushing capacitance and tan delta
- DGA (dissolved gas analysis) of the insulating oil. - To be
performed before and after temperature rise test
- Acoustic and sound level
- Sweep Frequency Response Analysis
- Insulation tests on the auxiliary wiring in the marshalling boxes
- Measurement of zero sequence impedance
- Measurement of harmonics no-load current
- CT ratio and polarity
- Measurement of zero phase sequence impedance
- Paint thickness
- Tank pressure test
-
➢ Testing Facility
The manufacture shall provide current e-mail address, fax and telephone
numbers and contact person at the International or National Standards and
Testing Facility of the country where the transformer is manufactured and
tested.

➢ Test reports for each transformer (including its individual components) shall
be submitted to SAPM for approval before shipment.

➢ On receipt of the transformer SAPM will inspect it and may perform or have
performed any of the relevant tests in order to verify compliance with the
specification. The manufacturer shall replace/rectify without charge to SAPM,
equipment which upon examination, test or use fail to meet any or all of the
requirements in the specification.

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MARKING, LABELLING AND PACKING

➢ The transformer and associated components shall be packed in a manner as

to protect it from any damage in transportation and handling.

➢ Each assembly and package of items associated with the transformer shall
be suitably marked.

➢ In addition to markings and labels required elsewhere in the specification,

each equipment and component shall be marked in accordance with the -
relevant IEC standard. Each transformer shall be provided with a rating plate
of weatherproof material, fitted in a visible position, showing the appropriate
details listed in IEC60076. The entries on the plate shall be indelibly marked
(either by etching, engraving or stamping).

➢ In addition, the name plate shall include load and no-load losses for the
highest, lowest and principle tap positions, temperature class of insulation,
connection diagram and the inscription 'PROPERTY OF SAPM.

11.0 96KV, SURGE ARRESTER:

SCOPE

➢ This specification is for 96kV Zinc-oxide type surge arresters without spark
gaps for AC system.

CONSTRUCTION
➢ The surge arrester shall be metal-oxide type without spark gaps and
constructor as per the requirement of IEC 99-4. 3.6.2.2. The metal-oxide
used shall be of quality to ensure thermal stability under service duty of the
surge arrester.

➢ The completed surge arrester shall be housed in a silicone rubber. The

silicone rubber insulator shall be dimensioned to provide a leak free interface
with the end caps. The housing shall withstand the lighting impulse voltage
of the arrester.

➢ The surge arrester shall be sealed (end caps) with a controlled permanent
seal to ensure no moisture absorption or deterioration of the metal -oxide
element for the surge arrester.

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➢ The surge arrester shall be supplied with fixing accessories and fitted with
pad type clamp connectors suitable for both copper and aluminium tubes of
up to 76.2mm diameter. The steel plates or straps shall be galvanized as per
the requirement of BS 729. The mounting brackets shall be suitable for both
horizontal and vertical mounting on a steel channel.

12.0 CONTROL, PROTECTIVE RELAYS:

SCOPE
➢ This subsection covers the design, detailing, manufacture testing before
shipments, packing, transport to site, erection and tests at the site of the
following equipment:

➢ Set of Protective relays, controls and accessories for 110kV switchgear

REQUIREMENTS FOR DESIGN

➢ The equipment for the control system shall be highly reliable, durable and
suitable for continuous operation.

➢ The equipment shall be designed to be fail – safe for the possible failure of
any major circuit during the operation and shall provide a safe guard against
possible surges, fail – safe against disrupted surges against disrupted
signals due to outside interference that would normally be associated with
the cable communication lines and any other provisions necessary for the
efficient operation of the equipment.

➢ All instrument scales, coils, relay contacts and other features shall be
suitable for the apparatus controlled or the purpose intended.

➢ The control and relay panels provided under this subsection shall be located
in the control rooms of the substation.

➢ It shall be the contractor’s responsibility to properly design the electrical

control, protective relaying, alarm and indication schemes related to all
equipment to be provided under this contract and to co-ordinate with the
existing control and relaying system.

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➢ The Contractor shall prepare arrangement and detailed drawings, equipment

lists and wiring diagrams based on the requirements for meters, relays,
control switches, indicating lamps and other devices including those to be
supplied under other subsections.

PROTECTION AND ALARM

➢ GENERAL

Protection against electrical faults and abnormal conditions on 110kV

switchgear shall be conducted by the protective relays and switches.

ELECTRICAL PROTECTIVE RELAYS AND PANELS

➢ GENERAL

➢ The electrical Measuring protective relays for the 110-kV line shall be of
Numeric Design type suitable for operation with the current transformer
secondary of 1A and the voltage transformer secondary of 110V, as shown
on the single line diagrams.

➢ Auxiliary relays of Static or Electromechanical Design are acceptable.

➢ The protective relays and their auxiliary relays shall operate successfully for
any value of the DC supply voltage between 85% and 120% of the rated
voltage of 110V without exceeding the temperature rise limits for the
operating coils.

➢ Each protective relay shall be of the flush mounted, back connected,

dustproof switch board type with rectangular case. Each relay shall have a
removable transparent cover or cover with a transparent window, with
provision for sealing. It is preferred that each measuring relay shall be of a
withdrawable type from the front of the panel with sliding contacts, without
opening the current transformer secondary circuits, disturbing external
circuits or requiring disconnection of leads on the rear of the panels. Each
protective relay shall be equipped with a red operation indicator and contacts
for operation on 110volt DC for each phase, and external, front operated,
manual-resetting device.

➢ Each protective relay shall be equipped with adequate electrically

independent contacts of adequate rating for trip and alarm functions. Test
facilities shall be provided as an integral part of each protective Switchgear
relay panel for testing of current and voltage transformer secondary circuits
and trip circuit using secondary injection test equipment.

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➢ DETAILED SPECIFICATIONS FOR RELAYS & METERS

These specifications indicate the required performance characterist ics.

➢ PROTECTION RELAYS:

This must satisfy the requirements for distance, Three Phase Overcurrent and
Earth Fault Relay, Sensitive Earth Fault Relay and Auto reclose Relay
facilities.
Grid Isolation Relay during Parallel operation with TG

There should be suitable Protection for both the TGs to Isolate the Grid during
any External Fault at Grid Section.

A. RESTRICTED EARTH FAULT RELAY

➢ Relay must be of Numerical type

➢ Relay should reject harmonics produced by C.T saturation

➢ The offer should include the associated stabilizing resistor and voltage
dependent resistor (metrosil)

➢ Current setting range (0.01 to 0.8 In)

➢ Operating time < 25ms at 5 times the setting

B. THREE PHASE OVERCURRENT AND EARTH FAULT RELAY

➢ Relay must be of Numerical Type

➢ Current setting range for overcurrent relay (0.01 to 0.8 In)

➢ Current setting range for earth fault relay (0.01 to 0.8 In)

➢ I.D.M.T characteristics according to BS142 or IEC255

➢ Time setting multiplier 0.05 - 1.0

➢ Broken conductor protection feature

➢ Negative sequence Protection Feature

➢ High set Element for both overcurrent and earth fault

➢ Protection, with a setting range of 1-30In.

➢ Thermal Protection

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➢ Dedicated Breaker Fail Protection.

➢ Circuit Breaker Maintenance

➢ Fault records, Event Records and disturbance records.

➢ Configurable output relays with ability to output starting elements to control

Tripping of other upstream Protection relays.

➢ Drop off /pickup ratio >90%

➢ Low transient overreach < 10%

C. EARTH FAULT RELAY (Numerical Type)

➢ Current setting range (0.01 to 0.8 In)

➢ I.D.M.T characteristics according to BS142 or IEC255

➢ Time setting multiplier 0.05 - 1.0

➢ High set Element with a setting range of 1-30In.

➢ Circuit Breaker Maintenance

➢ Fault records, Event Records and disturbance records.

➢ Configurable output relays with ability to output starting elements to control

Tripping of other upstream Protection relays.

➢ Drop off /pickup ratio >90%

➢ Low transient overreach < 10%

D. THREE- PHASE DIRECTIONAL OVERCURRENT AND EARTH FAULT RELAY

➢ Relay must be of Numerical design.

➢ Current setting range for overcurrent relay 0.5In-2.4In

➢ Current setting range for earth fault relay 0.05In -0.8In

➢ Quadrature connection for polarizing voltage (Vn=110)

➢ Applicable on the LV side of a 1 to Check transformer

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➢ High set Element, with a setting range of 1 -32In

➢ The phase and earth directional elements should be individually selectable.

➢ I.D.M.T characteristics according to BS 142 or IEC 255 and Definite time

characteristic

➢ The normal operating boundary shall be +/-90 degrees from relay

characteristic angle

➢ Relay sensitivity should be 1% of rated value of current and current

polarising voltage at an angle equal to the relay characteristic angle.

➢ Time setting multiplier 0.05 - 1.0

➢ Broken conductor protection feature

➢ Negative sequence Protection Feature

➢ High set Element for both overcurrent and earth fault Protection, with a
setting range of 1-30In.

➢ Thermal Protection.

➢ Dedicated Breaker Fail Protection.

➢ Circuit Breaker Maintenance

➢ Incorporate Fault records, Event Records and disturbance records.

➢ Configurable output relays with ability to output starting elements to control

Tripping of other upstream Protection relays.

E. MASTER TRIP RELAY

➢ This relay shall be independent and not as part of Numerical Main Protection
relay

➢ High burden tripping relay, immune to capacitance discharge currents and

leakage currents

➢ At least 8 pairs of outputs contacts two of which should be normally closed

(NC) contacts

➢ Instantaneous operation, t <12ms

F. TRIP CIRCUIT SUPERVISION RELAY

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➢ This relay shall be independent and not as part of Numerical Main Protection
relay

➢ The relay should have the following features

➢ Continuous supervision of trip circuit for circuit breaker in both OPEN&

CLOSE position

➢ Trip circuit fail - Red L.E.D

➢ Trip Circuit Healthy – Green L.E.D

➢ Contacts should be available to wired for annunciation and scada

➢ Two normally closed and three normally open output contacts

➢ NB: The relay LEDs should be visible from the front of the panel without
opening the panel door(s).

G. ANNUNCIATOR UNIT

➢ Should have Silence, Accept and Reset

➢ Accommodate 18 alarm Elements

➢ Relay output for audible alarm and self supervision

➢ Integrated event register to provide analysis of the latest five (5) events

H. DISCREPANCY SWITCH FOR CIRCUIT BREAKER CONTROL

➢ At least 2 pairs of contacts for CB closing

➢ At least 2 pairs of contacts for CB tripping

➢ For operation up to 110 V dc

I. SEMAPHORE FOR ISOLATOR AND EARTH SWITCH POSITION INDICATION

➢ Preferably with Red L.E.D for ON indication and Green L.E.D for OFF
Indication.

J. AUTO RECLOSE RELAY FOR 110 KV LINE

➢ Selectable 1 - 3 auto reclose shots

➢ Independent set dead time for each shot

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➢ Auto reclose inhibit after manual close

➢ Separate input for overcurrent high set element and I.D.M.T element

➢ Auto reclose inhibition for over current high set element.

➢ Synchro-check facility and single pole auto reclose and delayed auto reclose
facility.

➢ Incoming Line bay and Transformer bay shall be provided with Numerical
type Protection relays and with all features for SCADA system

L. DIFFERENTIAL PROTECTION FOR A TWO WINDING TRANSFORMER

➢ Relay Must be of Numerical design

➢ Pick up setting range (0.05 to 0.5 In)

➢ Should incorporate a high-set Element with a setting range of up to 20In.

➢ Magnetizing current inrush restraint

➢ Integral CT ratio compensation (0.1-2) and vector group compensation

➢ Measurement and indication on the MMI, of phase (HV&LV), differential and

bias currents.

➢ Storage of Fault records and Event records; the Fault flags should be
accessible on the relay LCD screen without opening the relay cover.

➢ Separate function that performs overfluxing protection with alarm and trip
functions.

➢ 5th harmonic restraint feature on the differential Element.

➢ Appropriate Dual Bias characteristic to ensure relay stability for heavy

through faults

➢ Should incorporate a disturbance recorder feature.

➢ Red L.E.D to indicate Tripping

➢ Relay Self diagnostic and Alarm feature

➢ Ability to Latch output contacts to prevent Transformer re -energisation before

carrying out investigations.

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13.0 TECHNICAL SPECIFICATIONS AND SCOPE OF SUPPLY OF 11KV SWITCHGEAR

13.1 SCOPE OF SUPPLY AND SERVICES

➢ This specification covers the technical requirements for the design,

engineering and supply of 11 kV, 25 kA/3 Sec switchgear and its accessories
required for the power distribution for SAPM Project

➢ Scope Include 3 Panel 11kV switchgear Board as per details indicated in

Single line Diagram. SAPM-100-E-SLD-6900 P0

➢ All items of equipment covered by these specifications shall be complete with

all accessories and devices, which are essential for correct operation of
equipment. Any other auxiliary items of equipment not specifically
mentioned, but required for completeness and satisfactory operation, shall
also be included in the offer.

➢ The scope of supply shall include preparation and submission of all design
details, drawings, technical information, operating and maintenance
instructions, test certificates, recommended quantities of consumables and
spares.

13.2 VARIATION IN EXTENT OF SUPPLY

➢ The quantities (the number of panels in each switchboard) defined in the

scope of supply are for tender purposes only and SAPM reserves the right to
amend these quantities prior to placement of order.

13.3 DESCRIPTION OF SCOPE

➢ The scope of supply for the Supplier shall include, but not be limited to, the
following switchboards along with provision of protective relays and
associated current transformers, metering and indicating instruments and
associated current transformers, and tripping/control supply battery unit.

3 Panel 11kV switchgear Board as per details indicated in Single line

Diagram. SAPM-100-E-SLD-6900 P0
The Panels shall comply the following basic requirements:

❖ Applicable standards Conforming to IEC 298 with latest amendment

❖ Degree of Protection IP4x

❖ Execution Indoor metal clad cubicle

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❖ Type of breaker Draw out type

❖ Type of breaker VCB

❖ Type of isolation Horizontal

❖ Closing method Motor operated spring closing mechanism

❖ Voltage 11 kV

❖ Phase 3

❖ Frequency 50 Hz

❖ Interrupting current 40 kA

❖ Short time rating 3 sec

❖ Rated current As per SLD

❖ Basic insulation level 75 kV (peak)

❖ Bus bar rating As per SLD

❖ Bus bar arrangement Air insulated bus bars - Duplicate/single as

required in the scheme

❖ Operating duty 0-0.3 sec - CO - 3 min - CO

❖ AC voltage for spring 415/240 V

charge motor

❖ DC voltage for trip 110 VDC

supply

13.4 EQUIPMENT SPECIFICATION

13.4.1 GENERAL REQUIREMENT

➢ Equipment shall be suitable for operation on the voltage, frequency and

system as defined within these specifications and shall have the full load,
interrupting and making capacities as specified, for the stated ambient
conditions.

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➢ Equipment shall be designed for indoor operation having front and back
access and shall have an enclosed construction for damp and dust protection
and to prevent entry of vermin that may create electrical short -circuits or
malfunction. The switchboard circuits shall have a degree protection
conforming to IPH4x.

➢ Equipment shall be designed to approved safety requirements and have all

necessary interlock devices to ensure correct and safe operation. Safe
access shall be provided in and around equipment for operating and
maintenance functions. Warning signs shall be fitted to all hazardous parts
of the equipment as required by Indian Regulations.

➢ Equipment shall be designed for maximum interchangeability of components,

with ease of replacement to minimize downtime.

13.5 CONSTRUCTIONAL DETAILS

13.5.1 SWITCHBOARD

➢ Each switchboard shall be of sheet steel construction of 2.5 mm thickness on

all sides and 2 mm on rear side, constructed on the unit principle and shall
be suitable for extension from either end.

➢ The switchgear shall be of metal clad construction, totally enclosed,

conforming to degree protection IPH6, self-supporting, having a continuous
bus bar of rated current throughout the complete assembly.

➢ The Breaker shall be drawn from service position to Isolation position without
opening of Front Door

➢ The switchgear shall have VCB circuit breakers.

➢ Where access doors are provided at the front of the panel, these shall be of
hinged construction and fitted with lockable securing handles.

➢ Each panel shall have separate enclosed chambers for bus bars, circuit
breaker, power cable terminations, control cable terminations, controls,
instruments and protection relays.

➢ Control cables terminations shall be fully accessible without removal of

covers, which expose live bus bars or terminals.

➢ Power cable terminations shall be designed to accommodate the size, type

and quantity of cables as scheduled. The cable chamber portion of panels,
having the same ratings, shall be identical for ease of interchangeability.

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➢ Each panel shall have provision for earthing the frames and metal work of
the switchgear to a common earth system.

➢ All controls, indicators, relays and meters shall be located on the front of the
panel. Control switches shall be close/neutral/trip with spring return to the
neutral position, and local/remote, where required. An approved means of
locking the switch in the neutral position shall be provided.

➢ Pad locking facilities shall be provided for all shutters and for locki ng the
circuit breaker in the open and closed position.

➢ The finish of the switchgear shall be painted as per manufacturer's standard.

➢ Each switchboard assembly shall have an engraved label in English

language fixed to the front of the assembly stating the switchboard title.
Major components shall be clearly labeled to indicate their purpose and
function. Manufacturer's name, date of manufacture and all rating details
shall also be shown on the switchgear.

13.5.2 BUSBARS AND BUSBAR CONNECTIONS

➢ Air insulated busbars shall be provided in the switchgear with high

conductivity aluminium busbars having adequate section for the full load and
short circuit rated requirements.

➢ Provision shall be made, where necessary, for the expansion and contraction
of busbars and connections caused by rating and ambient conditions.

➢ An integral, suitably sized continuous earth busbar shall be provided

throughout the length of each switchboard and located to provide access for
bonding of cable sheaths and for use with earthing devices.

13.5.3 CIRCUIT BREAKERS

➢ Circuit breakers shall be single pole, single throw VCB circuit breakers and
all the three poles linked suitably for simultaneous closing, operating
mechanism, control device, auxiliary contacts, wiring, interlock devices, all
mounted on a composite unit with free moving wheels.

➢ The circuit breakers shall be rated for the circuit applications as specified
and ambient conditions.

➢ The circuit breakers shall be capable of making and breaking the specified
fault current without affecting the reliability in operation of the circuit breaker
and supporting structure.

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➢ The design of the VCB circuit breaker offered shall not cause any induced
over voltage in the circuit being controlled. Supplier shall employ suitable
means of arresting the current chopping induced voltage, if necessary, by
surge suppressors, which shall be part of scope of supply.

➢ Type test certificates of a recognised independent testing authority shall be

submitted to prove compliance of the making and breaking capacit ies, and
load ratings.

➢ All current carrying parts of the circuit breaker shall be adequately sized for
the duty as indicated in the present system design.

➢ The operating mechanism shall be either of the stored energy quick release
type or solenoid closing and shall be non-pumping and trip free. The energy
storing mechanism shall be hand and motor operated. Motor operation shall
be from 240 V AC supply and solenoid closing through 110 V DC.
Requirement of power for closing through solenoid to be given.

➢ The closing and shunt trip releases shall be suitable for operation on 110 V
DC supply. Operation shall be achieved at all times for a variation between
75 and 110 percent of the DC supply voltage.

➢ Mechanical indication shall be provided to show the position of the breaker in

the open and closed position. In addition, indicating lamps shall be provided
showing the condition of the circuit breaker in the open or closed position.

➢ Where required, local/remote selector switches shall be provided.

➢ Key-release mechanical interlocks shall be incorporated in the operating

mechanism of circuit breakers, where specified, for circuit applications. Key
interlocks shall not be interchangeable between any of the circuit
applications.

➢ Suitable means of access shall be provided for either the busbar side of
selected circuits or the circuit side of feeders.

➢ Each circuit breaker shall have a tripping supply circuit test button and
indicating lamp, which shall indicate a healthy trip supply condition.

➢ MCBs shall protect all control circuits on the circuit breaker. Links shall be
provided only on an earthed pole of the circuit.

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➢ All circuit breakers shall have a separate mechanically operated trip button,
which shall release the tripping latch to open the circuit breakers
independently of the tripping supply.

13.5.4 AUXILIARY SWITCHES

➢ Each circuit breaker shall have minimum auxiliary switches for control,
indication and interlocking circuits with provision for mounting additional
switches. In addition to the breaker operation requirement, two separate
potential free contacts operated through breaker are to be provided duly
wired upto terminal block.

➢ The auxiliary switches shall be suitable for conversion to either normally

open or normally closed operation and shall be readily accessible for
maintenance, inspection and cleaning.

13.5.5 ISOLATION

➢ Means of bus selection on the double bus switchgear, through fixed offload
isolators shall be provided showing relevant features of operation and safety.
The isolators shall be mechanically and electrically interlocked to the circuit
breaker.

➢ In case the selection of busbars cannot be offered with isolators Supplier can
come out with alternatives by means of two sections of buses with breaker
plugged in either of the busbar with suitable in terlocks.

13.5.6 CURRENT TRANSFORMERS

➢ Current transformers shall be supplied of a suitable ratio for the particular

circuit rating, having a class of accuracy suitable for the specific
requirements of metering and protection.

➢ For protective relaying, current transformers shall maintain the ratio and
accuracy up to 20 times the rated current.

➢ Current transformers shall be cast resin insulated, mounted in a separate

chamber on the cable connected side of the circuit breaker.

➢ All current transformers shall be designed to withstand the fault currents of

the system for a time equal to the short time rating of circuit breaker.

➢ The secondary terminals of current transformers shall be brought out to

terminals located in a chamber outside the busbar assembly.

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13.5.7 VOLTAGE TRANSFORMERS

➢ Voltage transformers shall be supplied for metering and protection for the
specific circuits having a volt-ampere rating for the load requirements.

➢ Voltage transformers shall be arranged for connecting to the busbar or

incomer side of the switchgear as required having means of isolation by
withdrawing the transformer from the circuit connections.

➢ Voltage transformer connections shall be rated for the fault conditions

specified, having primary fusing to protect the transformer windi ngs.

➢ Voltage transformers shall be of resin encapsulated type having means of

horizontal isolation from the circuit connections.

➢ Each transformer shall have primary fuses on the high voltage winding
mounted within the transformer tank and secondary fuses i n shrouded
carriers mounted on the exterior of the tank. The fuses shall be cartridge
type.

➢ Earth continuity between the transformer unit and the switchgear unit shall
be maintained by suitable means when in the service position. The
transformer connections shall be automatically earthed when isolated.

➢ The secondary voltage shall be 110 V between phases and wired out to
terminals enclosed in a terminating chamber.

13.5.8 INDICATING AND METERING EQUIPMENT

➢ All meters and indicating equipment shall comply with the latest editions of
IEC and shall be rated for the secondary current rating of the metering
current transformers and the secondary voltage of the voltage transformers.

➢ Multi Function Digital meter shall be provided

➢ Indicating meters shall be capable of continuously carrying their rated full

load current and voltage across their pressure coils and shall not be
damaged due to overload or fault currents occurring for the maximum
permitted fault duration.

➢ Accuracy of the meters shall be such that over the effective range of the
meter the error, expressed as a percentage of the full-scale figure, shall not
exceed 0.5% at unity power factor.

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➢ Energy meters shall be suitable for a 3-phase unbalanced system, flush

mounting withdrawable type, where possible.

➢ Rotary selector switches shall be provided on ammeters circuits for

determining each line current and on voltmeter circuits for determining line -
to-line voltages. The selector switches shall have an off position.

➢ Indicating lamps shall be of low burden type and shall be mounted as an

assembly incorporating lamp holder, lens and resistor. The lamps shall be
accessible from the front of the cubicle.

➢ The indicating lamps shall have the following colour requirements:

❖ Equipment "ON" --RED

(e.g. circuit breaker closed)

❖ Equipment “OFF" --GREEN

(e.g. circuit breaker open)

❖ Normal function of equipment --WHITE

(e.g. trip circuit healthy)

❖ Abnormal function of equipment -- AMBER

(e.g. circuit protection trip)

13.5.9 PROTECTION RELAYS

➢ Microprocessor based static protection relays shall be supplied in

accordance with the circuit requirements as specified and shall comply with
the latest Indian Standard or equivalent.

➢ The relays shall be mounted on the fixed portion of the switchgear and shall
be of the flush mounting withdrawable type, enclosed in dust tight cases.

➢ The relays shall securely lock into position and shall not be susceptible to
damage or mal operation due to mechanical shock or vibration.

➢ On withdrawal, the relay trip circuits shall be isolated and current transformer
circuits effectively short-circuited.

➢ A circuit diagram shall be permanently fixed to each relay case with terminal
connections clearly identified.

➢ A relay test block shall be provided for testing the relays from the front of the
switchgear panel, mounted on the relay cubicle.

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➢ Auxiliary relays and timers may be of fixed pattern mounted within the relay
cubicle.

➢ The relaying scheme and the type of relays offered is provisional at this time
and shall be confirmed to the Supplier at the time of finalisation of Contract.

➢ The relaying scheme offered shall be suitable for future connection to

SCADA system as optional.

13.5.10 CONTROL WIRING

➢ Control wiring shall be flexible stranded copper wire of minimum 2.5 mm2
cross section, PVC insulated. Wiring for current transformer circuits shall be
of minimum 2.5 mm2 cross section.

➢ Wiring shall be continuous between terminations with no joints and sh all be

neatly laid together in a suitable channel or conduit.

➢ All wiring shall be identified by numbered ferrules at each termination point.

The ferrules shall be securely located to the wire so that they cannot easily
be disturbed.

➢ Control connections shall be suitably grouped in each unit in a terminal block

located in a terminal chamber.

➢ Each terminal block shall have an identification label and shall be provided
with 10% spare terminals.

13.5.11 CABLE TERMINATIONS

➢ The switchgear shall have suitable and adequate cable terminating

arrangements to accommodate the size and quantity of cables as required
Minimum of 600mm upto 750mm Space shall be provided at the rear of
switchgear.

➢ Appropriate size of cable sockets shall be supplied for the power cables,
complete with fixing bolts and washers. The cable sockets shall be suitably
pre tinned or plated for the type of cable conductor and busbar material to
prevent electrolysis between dissimilar materials.

➢ All cable-connected terminations shall be suitable for the following

preliminary size and type of power cable as follows:

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➢ 3 Core, 300 mm2 stranded aluminium conductor, cross-linked polyethylene

insulated 11 kV cables (suitable for non-effectively earthed systems).

➢ Control cable terminations shall be suitable for multicore copper conductor,

PVC insulated, steel wire armoured, and PVC sheathed, 650/1100 V cables.

➢ Suitable blanking plates shall be fitted to predrilled gland plates and bolted
covers fitted to flange terminations to prevent dirt and moisture ent ering the
terminating chamber during transportation and storage.

13.5.12 110 V DC SUPPLY

• The 110V DC supply for 110KV Switch Yard shall be derived from switchyard
DC source.

13.5.13 415 V AUXILIARY POWER SUPPLY

➢ One No. 250 KVA, 11kv/433V Auxiliary Transformer will feed all LT AC loads
inside 110KV Substation.

➢ A 415/240 V, 3 phase, 50 Hz supply will be made available for auxiliary

power supplies.

➢ Supplier shall specify the ampere rating of the 415/ 240 V required for each
switch board

13.6 TOOLS AND ACCESSORIES

➢ All tools, accessories and equipment for normal operation and maintenance
of the equipment shall be included in the scope of supply.

➢ Supplier shall also specify test equipment required for routine maintenance
and testing.

13.7 CONSUMABLES AND OPERATING SUPPLIES

➢ All consumable materials, like lubricants, required for installation and

commissioning shall be included in the scope of supply.

➢ Supplier shall specify the type, make and quantities of all consumables
required for installation and commissioning, and the annual requirement for
normal operation.

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13.8 SPARES

➢ Any spares required for start-up and commissioning of the Equipment shall
be included by Supplier.

➢ Supplier shall also submit separately prices for the supply of spares for the
Equipment offered.

13.9 TERMINAL POINTS

The terminal points for each assembly of switchgear shall be:

➢ The cable terminations and cable box on each incoming feeder circuit
breaker including gland plates and cable gland.

➢ The cable termination and cable box on each ou tgoing feeder circuit breaker
including gland plates and cable glands

13.10 INSPECTION AND TESTING

• Type test and routine tests shall be performed in accordance with IS 3424.
Routine tests shall include, but not limited to:

- Power frequency voltage dry test

- Voltage test on auxiliary circuits

- Mechanical operation test

- Tests of the auxiliary electrical devices (No load operation test)

- Verification of wiring (continuity of the wiring as per wiring diagram).

Additionally, checking of protective measures an d electrical continuity of the
protective circuits

➢ The scope of tender shall include for stage inspection and testing, which may
be witnessed by SAPM or his representative at Supplier's works. Supplier
shall not restrict access for such inspections/ tests at any time and shall
provide all facilities for such inspections/tests.

➢ Supplier shall specify a complete list of tests to be performed at the works

and on site. These shall include any tests required for procurement of
statutory test certificates from the Indian Government Authorities.

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➢ Test Certificates shall be provided for all tests performed, whether or not
witnessed by SAPM or its authorized representative. Six copies of the
certificates shall be supplied to SAPM on satisfactory completion of the tests.

➢ SAPM or its authorized representative reserves the right to inspect or

expedite any item of equipment at the works of the manufacturer or his
subcontractor at any stage during the course of manufacture, assembly or
testing. Any such inspection shall not absolve Supplier of his obligations
under the Contract or reduce any of his obligations.

13.11 TECHNICAL SCHEDULES

Technical schedules and other relevant data shall be furnished within one
(1) month from the date of signing of the Contract.

************************************************************************************************

14.0 STEEL STRUCTURES

➢ The Switch yard Girders, towers and equipment support structures shall be
of Lattice type.

➢ Grade of structural steel shall be mild steel conforming to IS:2062 Grade-A

and steel sections shall be in accordance to IS:808 – 1989 for Lattice
structures.

➢ For Lattice structures, the minimum thickness of members shall be as

follows:

- Main Leg Members: 5mm

- Bracing and other members: 4mm

- Redundant Members: 4mm

➢ All Switch yard structures shall be connected to foundation using base plate
and foundation bolts.

➢ Fasteners and Welding

- All fastening bolts and nuts shall be of mild steel conforming to IS:
6639/1363/1367.
- All foundation bolts shall conform to IS: 5624
- All plain washers shall conform to IS: 2016
- All spring washers shall conform to IS: 3063

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- Minimum diameter of bolts for steels structure shall be 12mm.

- Step bolts shall be of 16mm diameter 175mm long and shall conform to IS:
10238

- The base plates a stiffener shall be welded to the main leg. The welds shall
be minimum 6mm thick continuous fillet type weld.

➢ Galvanization

- All exposed switch yard steel structures shall be hot dip galvanized in
accordance with IS: 4759. The minimum coating thickness shall be
610g/sq.m.

- All foundation bolts and nuts, washers shall be hot dip galvanized with a
minimum coating thickness of 300g/sq. m. as per IS:1367.

- The spring washers shall be electro-galvanized as per IS:1573

➢ Wind Pressure
The wind pressure is considered as per IS: 875
➢ Design of Steel Structures
The design of Lattice structures shall conform to IS: 802,
Part-1, Section-2.

- The vertical loads of half the span of Conductors and Earth wire on either
side of the Girder shall be considered for design. Weight of man with tool
shall be considered as 150Kg. at the mid-phase of the girder, at peak of
tower and at top of equipment for design of structure

- Maximum slenderness ratios shall be as per IS:802

- Permissible stresses in compression and in tension for Lattice structures

shall be considered as per IS: 802, Part-1, Section-2.

- Foundation bolts shall be designed by working stress method as per IS: 800.

➢ Analysis of Structures

- Girder shall be analyzed as simply supported structure and towers as

cantilever structure.
- The Lattice girder shall be connected to the lattice tower by bolted joints.
➢ Fabrication
Fabrication of steel structures shall in general conform to IS: 802: Part II.

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15.0 Substation Auxiliaries:

15.1 Scope of supply include the following AC and DC auxilia ry supply

components:

1. 1 No. 250KVA, 11kv/415V, Station Auxiliary Transformer

2. 1 No AC Distribution Board
3. 1 No Main Lighting DB
4. 2 Nos Sub lighting Boards
1 No 200A, 3 Phase 5 Pin Outdoor Industrial Plug & Socket assembly
Suitable numbers of Indoor 16A 3 Pin Industrial Plug &Socket assembly for
small power.
250KVA, 11kV/415V transformer shall be Outdoor type and shall be installed
on RCC plinth at 1.5m Height with suitable Foundation and shall be located
outside control building.

15.2 DC System - BATTERY AND BATTERY CHARGER

15.2.1 BATTERY
➢ GENERAL
➢ The battery shall be led SMF VRLA type lead acid

➢ The plates shall be designed for maximum durability during all service
conditions including high rate of discharge and rapid fluctuation of load.

➢ CONSTRUCTION
➢ Each cell shall be assembled in heat resistant, shock absorbing, robust,
clear glass or hard rubber container with float type level indicator.

➢ The cells shall be supported on porcelain insulator fixed on to the rack with
adequate clearance between adjacent cells.

➢ The cell terminals posts shall be provided with connector bolts and nuts,
effectively coated with lead to prevent corrosion.

➢ Sufficient sediment space shall be provided so that the cells will not have to
be cleaned out during normal life.

➢ Lead or lead coated copper connectors shall be furnished to connect up cells

of Battery set.

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➢ Positive and Negative terminal posts shall be clearly and indelibly marked for
easy identification.

➢ Lead-coated bent copper plate, tubular copper lugs, teakwood clamp, bo lts,
nuts, washers, etc. shall be furnished for connection of outgoing Aluminum
conductor cables.

➢ Racks

- The racks for supporting battery cells shall be constructed of best quality
teakwood. Painted with at least three (3) coats of anti-acid paint of
approved shade

- Racks shall be free standing type, mounted on porcelain insulators.

- Numbering tags for each cell shall be attached on to the racks .

➢ Fittings & Accessories

Each battery shall be furnished complete with following:-

- Racks with 3 coats of anti-acid paints.

- Stand insulators 5% extra.
- Cell insulators plus 5% extra.
- Cell inter-connectors and end take-off.
- Lead-coated connection hardware plus 5% extra.
- Cell numbering tag with fixing arrangements.
- Cable clamps with hardware.
- One (1) Inter-connector bolt wrench.
- One (1) cell testing Voltmeter with leads.

15.2.2 BATTERY CHARGER

GENERAL
➢ The charger shall be natural air cooled, solid state type with full wave,
fully controlled, bridge configurations. The type of Charger shall be Dual
Float, Float cum Boost Charger.

➢ The charger shall be provided with automatic voltage regulation, current

limiting circuitry smoothing filter circuit and soft start feature.

➢ Voltage control shall be step-less, smooth and continuous.

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➢ The charger shall be self-protecting against all A-C and D-C transients
and steady state abnormal currents and voltages.

➢ Voltage setters shall be provided for setting the output of float boost
charge. Setting shall be independent of each other so that setting of
one voltage shall not require resetting other.

➢ There shall be separate transformers for float and boost charger.

➢ Charger A-C input ad D-C output should be electrically isolated from

each other and also from panel ground.

➢ Isolation shall also be provided between power and control circuits.

➢ CONSTRUCTION

➢ The charger shall be free-standing, floor mounted with sheet steel

enclosure with all access from the front.

➢ The panel shall conform to the degree of protection IP 42. Minimum

thickness of sheet metal used shall be 2 mm.

➢ Access door shall be with concealed hinges and neoprene gaskets.

Ventilating louvers shall be covered with fine wire mesh.

➢ All equipment within the panels shall be arranged in modular units and
laid out with sufficient space for easy maintenance.

➢ Switches, meters, relays etc. shall be flush mounted on the front of the
panels. Nameplates of approved size and type shall be provided for all
circuits and devices.

CHARGER EQUIPMENT
➢ All power diodes and control rectifiers shall be silicon type. Rectifier
Transformer shall be dry type, double wound, with copper conductor
and class B insulation.

➢ Blocking diodes shall be fully rated and redundant so that failure of a

single diode shall not incapacitate the system in any way.

➢ Isolating switches shall be heavy duty, load break type, operated b y an

external handle with provision for padlocking in ON and OFF position.

➢ Changeover switch shall be 3 position, 4 pole, load break type with 2

NO + 2 NC auxiliary contacts.

➢ Contactor shall be air-break type with thermal overload relays having in

built single phase preventor.

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➢ Fuses shall be HRC type and arranged for easy replacement. Semi -
conducting device fuses shall be fast-acting.

➢ Indicating lights shall be low-watt filament type with series resistor. Both
lamp and lens shall be replaceable from front.

➢ Meters shall be 96 x 96mm switchboard type, 250 deg. scale, antiglare

glass, + 2% accuracy with zero adjuster on the front.

ALARMS
➢ One (1) ten-points alarm facia shall be provided on charger panel,
complete with proper actuating devices, circuitry and legends.

➢ The arrangement shall be such that on occurrence of a fault the

corresponding window will light up and stays lighted until the fault is
cleared and reset button is pressed.

➢ Each time a window lights up, a master relay will get energised to
provide group alarm signals for Owner’s remote panel.

➢ Following minimum annunciation shall be provided:

- A. C. Supply failure *
- Load On Battery
- D. C. Voltage low
- D. C. Voltage high
- D. C. System ground
- Charger overload *
- SCR fuse blown
- Filter fuse blown
- D. C. Output fuse blown
➢ One No Potential Free contact shall be wired up to Battery Charger
Terminal Block for remote Annunciation of battery trouble Alarm.

➢ Alarm contacts shall be rated 2A at 110V D. C. And 5A at 240V A.C.

➢ Outgoing Feeders

- Each Outgoing feeder shall be provided with double pole MCB.

- Outgoing feeders shall be located in separate module forming part of

charger panel with separate cable alley for terminated outgoing cable.
- with LAMP/ SPACE HEATERS/ RECEPTACLES

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➢ The charger panels shall be provided with: -

- Internal illumination lamp with door switch
- Space heater with thermostat control
➢ Lamp, heater circuits shall have individual switch fuse units.

WIRING / CABLING
➢ The panels shall be completely wired-up. All wiring shall be routed
through wiring troughs. Wires shall be ferruled at both ends for
identification.

➢ Panels shall have removable gland plates at the bottom for cable entry.
All incoming / outgoing cables shall be terminated in suitable terminal
blocks.

➢ Control terminal blocks shall be box-clamp type ELMEX 10 Sq. mm or

approved equal.

GROUNDING
➢ The charger panels shall be fully rated ground bus with two ground
terminals, one at each end.

➢ Each terminal shall comprise two-bolt drilling with M10 G.I. bolts and
nuts to receive Owner’s ground connection of 50 x 6 mm G.I. flat.

TROPICAL PROTECTION
➢ All equipment accessories and wiring shall have fungus protection,
involving special treatment of insulation and metal against fungus,
insects and corrosion.

➢ Screens of corrosion resistant material shall be furnished on all

ventilating louvers to prevent the entrance of insets.

PAINTING
➢ All surfaces shall be sand blasted, pickled and grounded as required to
produce a smooth, clean surface free of scale, grease and rust.

➢ After cleaning, the surfaces shall be given a phosphate coating followed

by 2 coats of high-quality primer and stoved after each coat.

➢ The charger panel shall be finished in Siemens Grey (Shade RAL 7032)
with two coats of Epoxy base synthetic enamel paint.

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TESTS
➢ All equipment and components there of shall be subject to shop tests as
per relevant IS standards. The tests shall include but not limited to: -

➢ Tests on battery charger.

- Dielectric tests.

- Voltage regulation checks from 0 to 100% load with + 10% input

voltage variation.

- Ripple content measurement.

- Heat run test on current limiting value.

TEST WITNESS

All tests shall be performed in presence of Owner’s representatives, if so

desired by the Owner. The contractor shall give at least fifteen (15) days
advance notice of the date when tests are to be carried out.
REQUIREMENT

a) Battery
Type : SMF VRLA
Nos. of Cells per Battery : 55
Battery nominal voltage : 110 V
Ten hour rating to : (Approx)
1.85 Volt/Cell at 27 deg. C.
Proposed Method of working
- Float charging (normal) : 2.15 Volt per cell.
- Boost charging (after : 2.75 Volt per cell.
Complete discharge)
Intermediate tapping : 44th Cell.
Mounting : Wooden racks

b) Battery Charger
Charger rating : Float & Float cum Boost.
Type : Rating shall be as required

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Full wave,fully controlled.

A.C. Input Supply : 415V, 3 Ph., 50 Hz, 4 wire.
Ripple content in charger : + 1% DC output.
Outgoing feeders : 12 Nos.Each withof DP MCB of 10-20A

16.0 MISCELLANEOUS MATERIALS

16.1 SWITCHYARD EARTHING

➢ Earthing arrangement in 110KV switchyard shall be strictly as per the

statutory regulations. The complete plant earthing shall include, - Provision
of earth electrodes for LAs, switchyard equipments, body earthing,
Transformer neutral earthing, earthing of structures, etc.

- Provision of earth mat as per IEEE 80

- Provision of lightning conductor over 110KV switchyard

- Provision of earthing grid conductor as per fault level considered.

- Lightning protection of Cogen Plant buildings including Earthing Electrodes

for Lightning, Down comers, Test Link boxes etc.

- The measurement of soil resistivity shall be done by Tenderer after award of

the assignment. For design purpose, the soil resistivity value of 100-ohm
meter shall presently be considered.

• The earthing in switchyard shall have following specifications,

- The entire earthing installation shall confirm to IS 3043

- Earthing electrode shall be CI Pipe type.
- The earthing electrode shall be 100mmDia, 13mmThk CI Pipe buried
under ground up to the level of 3 mtrs.
- Earthing terminal shall be complete with watering pipe, funnel screen &
earthing bus bars.
- Earthing pipe buried under ground shall be surrounded by 300 mm thick
homogeneous layer of charcoal and salt.
- Earthing chambers shall be provided with CI covers of size 450mm
- 450 mm or with circular cover.
- All the material required for the earthing system shall be supplied and
installed by the Tenderer. The main grid conductor shall be hot dip

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G.I. strips of 75 mm x 10 mm size.

- All the material required for making earthing stations/ pit like plate,
charcoal, salt etc. shall be supplied by the Tenderer.

- The entire earthing installation shall be done in accordance with IS

Specifications and standard engineering practices.

- The entire earthing system shall fully comply with Indian electricity act and
rules, The Tenderer shall carryout any changes desired by the electrical
inspector & state electricity board authorities in order to make the
installation conforming to I.E. rules at no extra cost.

- When the earthing strips are joined together minimum overlap of 100 mm
shall be provided. To have better joint, the overlapped portion shall be
properly welded and covered with tar tape.

- Conduits in which cables have been installed shall b e earthed bonded and
earthed. Cable amour shall be earthed at both ends by providing GI/
copper clamp and PVC wire of suitable size near each cable gland.

- The electrodes shall be tested for earth resistance by means of standard

earth tester.

- A disconnecting facility shall have individual earth pit to check earth

resistance.

- Earthing system includes provision of earthing to switchyard equipments,

structures, panels etc. with suitable earthing conductor.

- All paint, scale and enamel shall be removed before earthing connection
are made.

- Anchor bolts or fixing bolts shall not be used for earthing connections.

- Entire earthing system and lighting protection system shall be tested for
continuity by earth testing equipment after completion of the installation.

- Earth resistance value shall be checked and verified. If it is high, then

corrective measures such as addition of earth pit shall be taken to obtain
desired value.

- The record of earth resistance and test results shall be maintained for
future reference.

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- The locations of earth conductors, earth electrodes, earthing points of

equipment’s shall be determined by the Contractor in consultation with
Engineer in charge at site. Any changes in the methods, routing, size of
conductor etc. shall be subject to the approval of engineer in charge.

- Excavation and refilling of earth necessary for laying underground earth

conductor shall be in Contractor’s scope. There will not be a separate
agency employed by Owner for this purpose.

- The main earth grid shall be laid at a depth of 600 mm below Ground level.
In case of built in trenches, earth strip shall be laid along the trench and
shall be firmly cleated to the wall or cable supports. It shall be protected
against mechanical damage. Joints and tapping in the main earth grid
shall be made in such a way that reliable and good electrical connections
are permanently ensured. All joints below grade level shall be welded and
suitably protected by giving two coats of bitumen and covering with tar
tape.

16.2 CONDUCTORS AND FITTINGS

16.2.1 POWER CONDUCTOR

➢ The power conductor shall be Aluminium Conductor Steel Reinforced (ACSR)

-427.5 sq.mm ZEBRA ACSR and shall comply with IEC 60889. The
outermost layer of the conductors shall be right-handed lay (z-lay). The
Aluminium shall be of the highest purity commercially obtainable and shall
not be less than 99.5%. The Contractor shall submit certificates of analysis
giving the percentage and nature of impurities in the metal from which the
wires were made. There shall be no joints in the individual wire of the outer
layers of aluminium wires. All steel core wires unless specified to the
contrary shall be hot-dipped galvanized to comply with the requirements of
IEC 60888.

➢ Unless specified to the contrary all conductors shall be uniformly covered

with neutral grease as per IEC 61089. The minimum fill factor of grease shall
not be less than 70 percent. Each layer of wire except the outer layer shall
have, both lengthwise and peripherally, an even and continuous coating of
grease. Wax thickened greases shall be applied at a temperature above the
dropping point and shall be substantially free from contaminants.

➢ The grease shall protect the conductors from corrosion in service, not
corrode the steel or aluminium, be compatible with any wire drawing lubric ant
that might be applied on the conductor, not flow nor exude from the
conductor during storage, transport, erection or service at temperatures of up
to 100 degrees C. In addition, the grease should have adequate resistance to
oxidation and conform to relevant current health and safety requirements.

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16.2.2 TECHNICAL DETAILS OF POWER CONDUCTOR

Nominal section : 427.5 mm2

Conductor strand : 54/3/175 Al +7/3.175- Steel

Tolerance of diameter
Aluminium : + 1.0%
Steel : + 2.0%
Minimum tensile strength after stranding
Aluminium :
Steel :

Minimum coating weight of zinc : 240g/m2

Calculated section:
Aluminium : mm2
Steel : mm2
Total : mm2

Outside diameter : 28.58mm

Unit weight of conductor : /m

Ultimate tensile strength (UTS) :

DC resistance at 20 deg. C : /km

Approximate current carrying capacity :A

16.2.3 DRUMS

➢ The conductors shall be supplied on impregnated drums of approved

materials constructed so as to enable the conductors and earth wire to run
smoothly and those as spare materials shall be supplied on steel drums of
approved materials for storage for long duration. Length of conductors on
one drum shall not be less than 2,000m. Actual conductor lengths shall
depend on stacking chart stringing sections and drum schedule so prepared
shall be submitted for approval.

16.2.4 JOINTS AND REPAIR SLEEVES

➢ Tension joints of the conductors shall be of compression type and shall be

free from slipping off, causing damage to or failure of the complete
conductors, earth wire or any parts thereof at loads less than 95 per cent of
the ultimate breaking strength of the conductors and earth wire.

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➢ Electrical conductivity and current carrying capacity of the tension joints for
the power conductors shall not be less than those of equivalent length of the
conductors.

➢ The cut ends of steel wires and steel component inside the joint shall be
protected from the weather in an effective and permanent manner.

➢ Aluminium sleeves shall have plugholes for injecting compound.

➢ All tension joints shall be supplied with aluminium fool -proof gauges or anti-
displacement pins for correct positioning, adequate quantity of filling
compound in injectors and aluminium collars for gap filling.

➢ Full details of the joints including an illustration of practices for filling the air
gap between sleeves, method of correct positioning of steel sleeves, gauges
for ascertaining the compressed size, etc. shall be submitted with the tender.

➢ Repair sleeves for the power conductors shall be of the compression type
and the conditions stated above for the tension joints shall apply to the repair
sleeves where applicable.

16.2.5 ACCESSORIES FOR POWER CONDUCTORS AND EARTH WIRE

In order to prevent fatigue of power conductors and earth wir es due to repeated
vibrations caused by breeze, the following countermeasures shall be applied.

− Trunnion type suspension clamps

− Vibration dampers
− Armour rods.

16.2.5.1 TRUNNION TYPE SUSPENSION CLAMPS

➢ Suspension clamps shall be of trunnion type, made of aluminium alloy and as

light as possible. They shall be designed to avoid any possibility of
deforming the stranded conductors and earth wires and of separating the
individual strands and shall be free to pivot in the vertical plane containing
the conductors and earth wires.

➢ Suspension clamps except jumper suspension sets shall have a suitable

dimension for clamping the conductor with preformed armour rods; and shall
not permit the complete conductor with armour rods to split at load less than
2,250kg for ACSR. Particular attention shall be paid to the elimination of
corona emission from all parts of the suspension clamp.

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16.2.5.2 VIBRATION DAMPERS

➢ Vibration dampers shall be of Stockbridge type for both conductors and earth
wire. The dampers shall be applied in all conductors and earth wires in every
span except slack spans into the substations. The dampers shall be
designed to be attached to the conductors and earth wire in a manner, which
will prevent damage thereto and free drop of the weight in servi ce.

➢ Clamping bolts shall be provided with domed self -locking nuts designed to
prevent corrosion to the thread.

➢ The nominal weight of damper shall be 12 pounds (5.44kg) for the

conductors and 4 pounds (1.81kg) for the earthwire. The numbers of the
dampers to be installed per span shall be:

a) 2 pieces per conductor or earthwire for spans up to 600 m and,

b) 4pieces for the spans longer than 600 m.

➢ First and second dampers will be positioned at 1.1m and 2.2m for power
conductors and 0.6m and 1.2 m for earthwires respectively from the centre of
suspension clamps or from the mouth of tension clamps.

16.2.5.3 ARMOUR RODS

➢ Preformed armour rods shall be applied to all suspension points of the power
conductors except jumper suspension points.

➢ Suspension clamps for those conductors protected by armour rods shall be

suitable for the enlarged conductors.

16.2.6 CORONA AND RADIO INTERFERENCE

➢ The design of all line conductor fittings, vibration dampers, etc., shall avoid
sharp corners or projections which would produce high electrical stress in
normal working. The design of adjacent metal parts and matching surfaces
should be such as to maintain good electrical contact under service
conditions. Particular care shall be taken during manufacture of conductors
and fittings and during subsequent handling to ensure smooth surfaces free
from abrasion.

16.3 LINE INSULATION

➢ The transmission line for the project is aligned on an elevation level of 245m
above sea level. The area has high humidity levels, tropical sunshine and
prone to medium pollution by agricultural activities.

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➢ Silicon-rubber long-rod type Composite Insulators of the approved type shall

be used to support the power conductors of the Transmission line. All
insulator units will be composed of top and bottom arcing rings to equalize
the voltage distribution over the insulator. The top shed of the insulators
shall also have a larger diameter to prevent waste from birds and animals
tracking down along the insulator.

16.3.1 INSULATORS DESIGN

➢ The insulator units shall be designed to withstand the design service

voltages including lightning, switching and power frequency, the mechanical
loads relevant to the installation service- maintenance conditions, the service
temperature and environmental effects. Internal stresses due to expansion
and contraction of any part of the insulator unit shall not lead to
deterioration.

➢ The insulators should withstand wind pressures of up to a maximum of as per

IS: 875.

➢ The design of insulator units shall be with end over mould or such as to
avoid local corona formation and no significant radio interferences shall be
exhibited. The long rod Insulator units shall comply with the requirements of
IEC 61109.

➢ Creepage distance for insulator shall be 31mm/kV, Antifog Type, as the

substation is considered as heavily polluted.

16.3.2 FITTINGS

➢ All fittings to make each composite insulator set complete for beneficiary use
shall be supplied and included in the rate for each insulator unit. Such bolts,
nuts, washers, cotter pins and retaining pins with necessary spares as may
be necessary for the use for erection shall be deemed to be included in the
appropriate it ems.

➢ Ball and socket couplings shall be in accordance with the requirements of

IEC 60120/16.

➢ Sockets shall have “R” type security clips in accordance with the
requirements of IEC 60372.

➢ Clevis tongue couplings shall be in accordance with the requirements of IEC

60471.

➢ All ferrous fittings shall be made of steel, ductile iron or malleable iron hot
dip galvanized, and shall have sufficient strength for abrasion and weariness
produced by repeated vibration.

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➢ Cotter pins shall be made of non-ferrous metal or stainless steel and

designed as the self-locking type.

➢ The arcing ring shall be provided for the top and bottom of each insulator
string and shall be of such design and shape that it reduces the voltage
across the part of the insulator adjacent to the conductor for each insulator
string, to a value which prevents visual corona formation on the metal caps
and pins of the insulators and shall minimize the Radio / Video interference
voltage from complete insulator and hardware assemblies when operated at
the voltage up to 420 KV.

➢ The arcing rings shall be of such design that when added to suspension and
tension assemblies, the resulting flash-over values of the complete insulator
string shall not be reduced below the percentage indicated hereunder, of
corresponding flash over values with the rings omitted.

➢ The percentages are:

− Wet 50 Hz: 100%

− 1.2 / 50 Impulse: 96%

➢ The rings shall be of hot dip galvanized steel or Aluminium tube having
outside diameter as required for corona control and minimum thickness of
2.5mm. Both inner and outer surfaces shall be galvanized to the required
specifications (BS 729). The details of the rings, brackets and methods of
mounting shall be of such design that the rings may be readily replaced
under ‘hotline’ maintenance.

➢ The horizontal distance between corona rings at suspension rings at

suspension insulator strings shall be kept as small as practicable to
accomplish the required reduction in Radio/Video Interference (RVI).

➢ All the accessories and the fitting offered against this specification shall be
subjected to corona test. The corona shall not take place and shall
extinguish at the voltages specified i.e. when a voltage of the specified value
applied (Phase to Neutral i.e. RMS) the corona shall appear and shall
disappear again at the specified value of voltage.

16.3.3 POLLUTION

The design of insulator units should take into account the principles
contained in the IEC 60815 for medium pollution environment. For this
project the minimum creepage value of 25 mm/kV shall be applied (Creepage
distance of 3988 mm).

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16.3.4 ZINC COLLARS

The insulator unit cap and pin shall be fitted with zinc -collared pins to prevent
cracking due to pin corrosion caused by the effects of pollution and high
humidity in the project area.

16.3.5 INSULATOR PROTECTIVE DEVICE

The design of insulator fittings including corona shields shall comply with the
following requirements:

a) Shall effectively protect the insulator unit and fittings from damage caused by
power arcs.
b) Shall effectively improve the voltage distribution along the insulator unit;
c) Shall effectively improve the corona performance of the insulator unit.
d) Shall be designed in such a way as not to subject to breakage fatigue due to
wind induced vibration;
e) Shall withstand the specified mechanical load
f) Shall be suitable for live line maintenance

16.3.6 MATERIALS

➢ The silicon rubber composite insulator shall comply with requirements of IEC
61109. The tension bearing material shall be E-CR Fiber Glass and the
housing and sheds made of HTV silicone rubber.

➢ Insulator caps and pin bases of malleable cast iron shall be manufactured
from a suitable grade of MCI complying with the requirement of BS EN 1563
for spheroidal graphite or BSEN 1562 for white heart and peralitic.

➢ Insulator end fitting of forged or cast aluminium alloy shall be manufactured

from a suitable grade of aluminium alloy complying with the requirements of
BS 1472 or BS 1490 and/or BSEN 1676 respectively.

➢ Security ‘R” clips shall be of phosphor-bronze composition in accordance

with the requirements of BS 2870 and supplied in the half-hard condition with
a minimum harness of 155 VPN

➢ Zinc collars shall have a total impurity not greater than 0.05 percent and
shall comply with the requirement of BS EN 1179.

➢ All insulator caps, bases and pins shall either be inherently resistant to
atmospheric corrosion or a suitably protected against corrosion, such as may
occur in transit, storage and in service.

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➢ All ferrous parts which will be exposed to the atmosphere in service, except
those made in the appropriate grade of stainless steel, shall be protected by
hot-dipped galvanising to comply with the requirements of BS 729.

16.3.7 TESTS

Type, sample and routine tests shall be undertaken on the insulator units in
accordance with the IEC 61109.

*********************************************************************************************

16.4 ILLUMINATION SYSTEM

➢ A complete lighting/Illumination system for the switchyard shall be supplied

and installed by the Contractor.

➢ Station lighting components of approved type shall be supplied and installed.

These shall include but not limited to:

16.4.1 LIGHTING FIXTURES

➢ Outdoor type LED lighting fixtures for AC 240V and shall be of high-power
factor suitable for stable operation in tropical climate and weatherproof type.

➢ Emergency Lighting system shall feed the Selected LED lighting fixtures
used in the substation outdoor and indoor areas; Emergency AC source shall
be with suitably sized inverters.

➢ For Indoor and Outdoor Lighting system, lighting fixtures shall be selected to
suit the functional requirements. Like:

• LED Flood lights for Outdoor

• Commercial LED Lights for Control and switchgear rooms

• LED Street Lights for Periphery of Building

• LED Vapour proof Lights for Battery room

16.4.2 LIGHTING SUPPORTS

➢ Lighting supports shall be steel poles painted with suitable colour, which will
be instructed by the Employer. Ballast, cut out, and terminals shall be
equipped in the pole and other attachments necessary for wiring and fixing of
the lighting fixtures shall also be provided with the pole. The ground level
shall be marked on the support for easy installation.

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➢ 600-volt PVC insulated wires of 3.5 square millimetres in size shall be laid in
the lighting pole for connection from the terminal box to the lighting fixtures.

➢ (c) Cabling and wiring shall be of approved type as well as all required
installation materials.

➢ (d) Lighting panel for outdoor lighting system shall be installed and shall be
with IP 55 when installed outdoor.

The lighting panel shall be indoor/Outdoor metal enclosed, wall/Structure

mounting type, dust and vermin proof construction and shall contain the following
equipment.

- Identification name plate

- No of single pole moulded case circuit breakers 600 V, shall be as per

requirement and with 20 % spares.

- Two Pole moulded case circuit breakers shall be used for incomer where rating
exceeds 25 A 600V, 100 A

- Internal wirings

- Neutral links

- Terminal boards

For Substation Emergency Lighting for Indoor and Outdoor areas, one Number
2 KVA Inverter (suitable for lighting system Application) shall be provided
inside Control Building and 10% of Light fixtures (In Indoor and Outdoor area
shall be connected to inverter to provide emergency Lighting for 4 Hours in
case of Main AC supply failure.

16.4.3 SPARE PARTS

➢ The following spares parts shall be supplied for the station - 3 sets of each
type of complete lighting fixtures with all accessories.

➢ Lighting for outdoor switchyard and access roads constructed under this
contract shall also be provided by the Contractor.

➢ The Contractor shall prepare and submit to the Employer for approval the
calculation sheets, the facilities drawings, the installation drawings and
wiring diagram.

➢ The power shall be supplied from the low-tension AC distribution panel in the
control building.

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➢ The mean illumination level of each location for AC power shall be as

follows:

- Outdoor operating area 30 lux

- Outdoor switchyard 5 lux

- Street lighting 10 lux

16.5 CABLING SYSTEMS

16.5.1 TYPE:

1100 V grade, single or multi-core, stranded aluminium conductor, XLPE

insulated, PVC inner sheath, steel round wire / strip armoured, with overall
PVC Sheath.

16.5.2 APPLICATION:

➢ 1.1KV LT power cables for 415V distribution from LT switchgear placed

at control building to the consumers of the switchyard equipments.

➢ 1.1 KV control cables for all the requirements of the equipment covered
in the new switchyard and its interface with the control and relay panels
placed inside the control building.

➢ 1.1 KV power cables for the distribution of DC supply to the control

system of the switchyard equipment.

16.5.3 DESIGN:

16.5.3.1 1.1 KV LT POWER CABLES:

➢ The Cable shall be XLPE insulated, suitable for working voltage up to

and including 1100 Volts confirming to standard mentioned above and
with ISI mark having aluminum H2 Grade, Class-I round conductor
complying with IS: 8130-1984

➢ The type of insulation shall be cross linked polyethylene as per IS: 7098
(Part-1) -1988 Colour of Insulation of each core shall be as specified in
IS

➢ The type of sheath shall be PVC compound ST-2 type as per IS:5831-
1984

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16.5.3 .2 LT CONTROL CABLES:

➢ 650 / 1100 V grade, multi-core, stranded annealed high conductivity

copper conductor extruded PVC compound type A insulated, cores
identified by numerals, cores laid up, inner sheathed with extruded PVC
compound type ST1, armoured with galvanized steel wire / strip and
outer sheathed with extruded FRLS PVC compound type ST1 cable
complying with is 1554.

17.0 PLCC EQUIPMENTS

17.1 GENERAL:
➢ TNEB has the following communication systems both wired and wireless
communication systems for communication needs

➢ Power Line Carrier Communication (PLCC) Used for Voice, Data and Inter
tripping.

➢ No Repeaters needed for even 500Kms.

➢ Limited Band Width (4KHz for Single channel)

➢ Testing, commissioning and maintenance of entire PLCC network is

Contractor’s responsibility

➢ The manufacturer whose PLCC panels are offered should be designed,

manufactured, tested, supplied and commissioned PLCC panels for the
specified voltage level.

➢ PLCC equipment is required for both ends of the Transmission line i.e at
SAPM end and at TANGEDCO’s Sathyamangalam 110Kv Substation The
technical compatibility shall be verified with TANGEDCO Electricity
authorities. The bidder shall include the cost of supply and delivery of all
materials required for the PLCC System., together with complete erection,
testing and commissioning of the equipment at both ends covered in the
contract. It is the bidder’s responsibility to collect Data from TANGEDCO to
match the PLCC equipment to be used from TANGEDCO authorities. SAPM
will extend logistic assistance to collect data from TANGEDCO based on the
questionnaire by the bidder after award of Contract.

➢ It is intended that the contractor should erect, commission and test the PLCC
equipment at both ends and simultaneously coordinate with TANGEDCO for
Suitable operation at both end and perform the commissioning tests details
accordingly.

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17.2 STANDARD

➢ All the PLCC equipment covered under the package shall conform to the
requirements of the latest edition of the relevant IEC/IS specifications or
equivalent national standards, except to the extent modified by this
specification.

17.3 LOCATION OF EQUIPMENT

➢ The PLCC equipment as specified shall be installed at the SAPM end &
TANGEDCO Substation end.

17.4 FREQUENCY PLANNING

➢ This shall be matched with other end TANGEDCO PLCC equipment

17.5 PROPOSED ARRANGEMENT

➢ The power line carrier communication equipment required is to provide

primarily efficient, secure and reliable information link for carrier direct
tripping of remote-end breaker and also for speech communication between
sub-stations. It shall include separate carrier terminals of multipurpose type
for speech purposes. Provision for super imposing telex and data signals
shall be made on speech terminals. All carrier terminals shall be suitable for
point to point speech communication also. Carrier aided protection is not
being provided on 110 kV and below transmission line in TANGEDCO.

➢ The requirement of carrier information on each link covered under this

specification is for speech communication signaling.

➢ The equipment for signals shall have high degree of reliability and speech. It
shall be guaranteed to function reliably in the presence of noise impulse
caused by isolator or breaker operation. It shall also be possible to effect
direct tripping of breaker at one end when the other end breaker opens out
either manually or by relays such as bus fault relays such as Bus fault relay
etc.

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➢ The time intervals between receipt of a trip command on the transmit side, its
transmission over the carrier link, reception at the far end and giving
command to the trip relays at the distant end shall not exceed 20 m.sec.
For permissive inter tripping and 30 m.sec for direct inter tripping even for
the longest line section. The above timings are inclusive of operating time for
auxiliary relays and interposing if any, included in the PLCC
equipment. However, this shall be checked with TANGEDCO officials before
Commissioning.

➢ For reasons of security and reliability, phase to Phase coupling for S/C lines
shall be employed. However, this shall be checked with TANGEDCO officials
before preparing the offer.

17.6 The proposed communication system under this specification shall be fibre
optic based and shall consist of overhead fibre optic communication links .

OPGW shall be used for Power Line communication as per latest guidelines
by TANGEDCO:

Bidder shall furnish, along with his bid copies of all type and routine test
conducted earlier on similar coupling device is accorda nce with relevant
standards.

17.7 Optical Fiber Ground wire & OFC Cable

➢ The OPGW cable comprises a ground wire (containing aluminium/

Aluminium alloys and steel) with optical fibres in the core or first
layer. The OPGW cable replaces the normal ground wires and therefore
has to fulfil all the electrical and environmental requirements which
affect the ground wire.
The fittings, accessories to be supplied shall be suitable for the OPGW
type. The OPGW Cables proposed will be used on 110kV transmission
lines

➢ OFC shall connect the coupling device installed in the switc hyard to the
PLCC Device terminal installed indoor. The OFC cable to be offered by
the bidder shall be suitable for being laid directly in trenches or in
ducts.

➢ The cable shall be selected as per TANGEDCO specification .

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➢ Bidder must enclose in his bid a detailed construction drawing of the

cable being offered, with electrical parameters.

➢ Type tests
The OFC cable shall conform to type tests and be subjected to routine
tests as per TANGEDCO guidelines.

TECHNICAL PARAMETERS OF OPGW (Following Indicative and Vendor to

provide parameters as per TANGEDCO regulations)
1 Overall Diameter 16 mm
2 Minimum Breaking Load >_50KN
3 Unit Mass < 500KG/KM
4 Max Sag at 0 Deg C-and No < 8.706 m for 250m span
wind
5 Everyday Tension @32 Deg <_ 25% of UTS of OPGW
C, No wind
6 Max tension @32 DEG C <_ 2610KG on Full projected area
250m Span
@ 135kg/m Wind speed
7 DC resistance @20 Deg C < 1.0 Ohms/ KM
8 Short Circuit Current >_ 6.32kA/ 1 sec

17.8 POWER LINE CARRIER TERMINAL

The offered Power Line Carrier terminal shall be matched with PLCC device
at other TANGEDCO end.

17.9 SPEECH COMMUNICATION

This shall match with equipment at TANGEDCO End

17.10 ELECTRONIC PRIVATE AUTOMATIC EXCHANGE (EPAX)

This shall match with equipment at TANGEDCO End

17.11 T ESTING AND MAINTENANCE EQUIPMENT

➢ The testing and maintenance equipment shall be as per

recommendations of the Manufacturer. Detailed write up on testing
maintenance equipment offered shall be furnished with the offer.

➢ As recommended in relevant standard

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18.0 NEUTRAL GROUNDING RESISTOR

GENERAL

Neutral Grounding Resistor shall be of outdoor type, weather and vermin proof,
structure mounted type with control cable terminal box. This includes supply and
erection of suitable GI mounting structures and foundation.

➢ 11kV, outdoor type Isolator with Motor operated mechanism shall be

connected between Transformer Neutral and NGR. The operation of the
Isolator in NGR Circuit shall be provided with Electrical interlock.

➢ The top of the enclosure shall have suitable sloped canopy such that the rainwater
shall not accumulate on the top and also it shall not drip inside the NGR.

➢ Suitable lifting arrangement shall be provided to lift the NGR.

➢ Necessary ventilation with mesh shall be provided.

➢ The NGR shall be painted with shade of 632 of IS5.

➢ Porcelain bushing shall be provided for High end connection with suitable box for
terminating neutral cable.

➢ Porcelain wall through bushing shall be provided for Low end connection.

➢ The terminal shall be suitable for connecting GI flat.

➢ The resistor elements shall be of punched stainless steel (AISI304) and supported by
porcelain insulators.

➢ Two earthing studs with necessary nuts and washers shall be provided.

➢ Space heater with thermostat controlled by one MCB, industrial type 10A plug &
socket controlled by one MCB and CFL lamp with enclosure controlled by one MCB
shall be provided.

TECHNICAL PARTICULARS

a) System voltage : 11KV

b) Current : Limited to 100A
c) Resistance : Stainless steel suitable for the above voltage
current
d) Temperature Rise : Not more than 300°C
e) Continuous rating : 10 Secs
f) Current transformers : as shown in SLD
.

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19.0 CIVIL WORKS

19.1 GENERAL
The contractor is to design all civil work required for the installation of the all High
Voltage equipment in the switchyard.
The contractor is to design the civil work including:
Design include Design Calculations and all installation drawings .

➢ Surveys in order to determine the nature of the ground and design

various types of Tower foundations in 110kV Transmission Route.

➢ For 110Kv Substation all foundations for 110Kv Equip[ments,

Towers and Transformer foundation inside the fenced area, SBC
value shall be considered as 35T/ sq.m The Soil is Soft rock type

➢ Design of heavy-duty roadway inside switchyard for handling power

transformers.

➢ Design of support foundations for the towers, current transformers,

voltage transformers, circuit breakers, isolators, neutral GROUNDING
RESISTOR and LAs.

➢ Design of 11 kV cable Trench to the power secondary of transformer

with RCC cover slab.

➢ Design of Cable trench for running 11 kV and LT cables.

➢ Design of Control Building

➢ Design shall include proposal of Herbicide treatment and laying of

gravel over the entire switchyard.

➢ Design of Chain linked fencing for the Switchyard and the incoming
TANGEDCO Metering area inside switchyard.

➢ Design of 10 MVA Transformer and 250KVA Auxiliary Transformer

foundation.

➢ Design of any other Civil work not mentioned above, but required to
complete 110KV Substation Installation All required civil work.

➢ Design of Oil collection Pit for 10MVA transformer,

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19.2 TRANSFORMER PIT

➢ Transformer pit with foundation oil soak pit, rail, etc.

➢ The pits are to be leak-tight include a recovery sump and their

volumes are to be equal to 110% of the volume of oil, The drainage
sump is to be equipped with an oil separator and a pump for removing
rainwater, connected to the plant rain-water drainage system.

➢ Haulage spaces are to be planned to allow the installation and

removal of transformers.

19.3 FOUNDATIONS
Contractor shall design all foundations for 110kV equipments:

➢ Towers and Lightning Masts

➢ Lightning Arresters

➢ Disconnectors

➢ Circuit breakers

➢ Current transformers

➢ Capacitor Voltage transformers

➢ Power transformer

➢ Neutral Grounding Resistors

➢ Any other Outdoor equipment in Substation Area.

19.4 TRENCHES
Cables trenches of suitable sizes shall be designed with Brick Masonry work
with RCC coverslab of suitable Thickness

19.5 GRAVEL FILLING - YARD LEVELLING

Contractor provides for 110/11KV switchyard, 150mm thick gravel for the entire
equipped area.

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19.6 CIVIL WORK FOR MAIN CONTROL ROOM BUILDING (12m x 10 m)

Contractor provides Design (Design Only) for technical building for installation
of main 11kV switchgear elevated of 0.5 m) comprise:
➢ 1 Control room for 11 kV switchgear

➢ 1 control & Relay Panel and ACDB/DCDB/Battery charger room

➢ Battery (110V & 240V) room

➢ PLCC room

➢ 1 office room

➢ 1 Stotre room

➢ 2 Nos toilets

➢ Space for install the safety equipment

110kV Control room shall be provided with suitable Air-conditioning system

(Split Air conditioner of suitable capacity is preferable)
Supply of Air-conditoning unit is part of EPC contractor scope.
Scope of Civil works shall be Design of Control Building and shall Design of
include Plumbing , Sanitary, Over head water tank and water supply system.
Control building shall be designed with a staircase for access to First floor
rooftop.

19.7 COMPOUND WALL AND FENCE

Contractor design a Chain link type peripheral Fence (up to a height of 2.4m) on
South, East and west side of the Switchyard area and with gates on North side
adjoining the existing Road.
Separate gate shal be provided for TANGEDCO Metering Area.

19.8 RAINWATER DRAINAGE

Contractor shall Design (Design only) rain water drainage for roads and building
as per Practice Followed SRIANDAL and material & Installation shall be as
per relevant standards and approval by Consultant/ Client. Standards

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20.0 TECHNICAL SCHEDULES FOR ALL 110KV EQUIPMENTS PREAMBLE

1. The Technical Schedules shall be filled in and completed by the Bidder and
submitted with the Bid.

2. All documentation necessary to evaluate whether the equipment offered i s in

accordance with this Specification shall be submitted with the Bid.
3. All data entered in the Schedules of Technical Guarantees are guaranteed
values by the Bidder and cannot be departed from whatsoever.
4. All data entered in the Schedules of Informative. Data are also guaranteed
values by the Bidder. These data may only be altered following the
Engineer's written consent.

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TECHNICAL GUARANTEES FOR OUTDOOR 110KV EQUIPMENTS

20.1 OUTDOOR SWITCHGEAR-110KV SF6 CB

Item Particulars Unit Guaranteed Figure

1 Type
2 Breaking Medium SF6
3 Manufacturer
4 Applicable Standard
5 Rated voltage kV
6 Maximum service voltage kV
7 Rated frequency Hz
8 Rated continuous current A
9 One-minute power frequency withstand voltage,
dry and wet
a) Between line terminal & earth kV rms
b) Between terminals with circuit breaker open kV rms
10 Impulse withstand voltage 1.2/50 ms
-to earth kV peak
-across open breaker
Breaking capacity at rated voltage
-symmetrical kA rms
-asymmetrical kA rms
Making capacity kA peak
Rated inductive current switching Capacity A
Permissible 1 second short-time Current kA rms
Dynamic short-time current kA peak
Opening time, interval of time
between the instant of application ms
Make time, interval of time ms
Total break time, interval of time at 110% ms
breaking Capacity
Rate of rise of recovery voltage (RRRV) at
100% Short circuit Current
-3-phase kV/ms

-1-phase kV/ms

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RRRV out of phase duty kV/ms

Minimum temperature rises at
°C
rated current of main contact

Creepage distance mm

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20.2 OUTDOOR SWITCHGEAR-110KV CT

Item Particulars Unit Guaranteed Figure

1 Manufacturer
2 Applicable Standard
3 Rated voltage kV
4 Maximum service voltage kV
5 Rated frequency Hz
6 One-minute power frequency withstand
voltage of

-primary winding kV rms

-secondary winding kV rms
7 Lightning impulse withstand voltage (1.2/50 kV peak
μs)
8 Rated primary current A
9 Rated secondary current A
10 Short-time thermal rating
-1 second kA rms
11 Short-time dynamic rating kA peak
12 Burden and accuracy class of
-measuring core
-protection core

13 Instrument security factor of Measuring Core

14 Accuracy limit factor of the protection Core
15 Creepage distance mm

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20.3 OUTDOOR SWITCHGEAR-110KV VT

Item Particulars Unit Guaranteed Figure

1
Type

2 Manufacturer

3 Applicable Standard

4 Rated voltage Primary kV

5 No. of secondary’s

6 1Minpower frequency test voltage

-primary winding kV rms

-secondary winding kV rms

7 Lightning impulse withstand Voltage kV peak

8 Burden and accuracy class of

a. measuring winding
b. protection winding

9 Ratio

10 Creepage distance mm

11 Phase angle error mins

12 Rated total thermal burden VA

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20.4 OUTDOOR SWITCHGEAR- 110KV ISOLATOR

Guaranteed
Item Particulars Unit
Figure
1 Type
2 Manufacturer
3 Applicable Standards
4 Breaking Medium Air
5 Rated voltage kV
6 Maximum service voltage kV
7 Rated frequency Hz
8 Rated continuous current Amps
9 Creepage distance mm
10 Contact Resistance
Max temperature rise under rated voltage and
11
current
Rated Power Frequency Withstand Voltage
12 -to earth kV rms
-across open contacts kV rms

Impulse withstand voltage 1.2/50 ms kV peak

13 -to earth kV peak
-across open contacts

14 Breaking capacity at rated voltage

kA rms
-symmetrical
Current density kA rms
Moving Blade A/sq.mm
Terminal pad A/sq.mm
Contacts A/sq.mm
Terminal connector A/sq.mm
Breaking capacity of capacitive
current
Rated inductive current switching capacity
Permissible 1 second short time kA rms
current
Dynamic short-time current kA peak

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20.4 OUTDOOR SWITCHGEAR-110KV ISOLATOR Cont’d

Item Particulars Unit Guaranteed Figure

Auxiliary Supplies
- DC V
- AC V

-No. of spare auxiliary contacts

- disconnector
- earthing switches

-Auxiliary contacts’ current rating Amps Amps

- Motor rating Amps
- Level of galvanization Amps

Padlocking facility in both open and

closed position

Degree of Protection for Control box

Thickness of silver coating
Creepage distance mm
Operation
- Local (manual)
- Local (motorized)
- Remote (motorized)

- Interlocking with breaker

(electrical/mechanical)

-Interlocking with earth switch

(Mechanical)

- Position indication on control box

Clearances
-between phases mm
-between phase and ground mm

Type of break
Any special assembly tool

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20.5 110/11kV POWER TRANSFORMER

Item Description Unit Guaranteed Data

1 TYPE OUTDOOR
2 Continuous maximum rating on any tapping when
operation under the ambient conditions for
ONAN
HV winding MVA
LV winding MVA
.
Rated frequency Hz

Rated no-load voltage at rated frequency on:

HV, principal tapping kV
HV, extreme plus tapping kV
LV, extreme minus tapping kV
Load losses at 75oC at rated currents, the third
winding being open:
HV -LV, ONAN kW
Cooling plant power consumption kW
Total losses at 75oC on principal tapping and
unity power factor and rated currents:
ONAN kW
Impedance voltages at 75o referred to mutual
capacities at rated frequency and 100% rating:
Principal tapping:
HV -LV, ONAN %
Extreme plus tapping:
HV -LV, ONAN %
Extreme minus tapping:
HV -LV, ONAN %
Temperature rise after continuous operation with
11.
rated MVA
o
Top oil (by thermometer) C
o
Windings (by resistance) C
Efficiency on principal tapping max. temperature
12. of winding and unity power factor and TV winding
open:
-120% load, ONAN %
-100% load, ONAN %
-50% load, ONAN %
Inherent voltage regulation on principal tapping,
13. %
75oC and unity power factor:
14. Inherent voltage regulation on principal tapping,

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75oC and 0.8 power factor lagging:

15. Vector group
16. Type of cooling ONAN
Whether star connected windings shall be fully
insulated or graded
-HV winding
-LV winding
Insulation levels of star points
-HV winding kV
-LV winding kV
Method of system earthing:
-HV system
-LV system
Method of transformer earthing:
-HV windings -star point -
-LV windings -star point -

Whether TV windings are to be brought out to

-
separate bushing insulators
System highest voltage according to IEC:
-HV kV
-LV kV
Maximum flux density at rated voltage on
principal tapping and rated frequency:

Maximum current density in windings at rated

output:
HV, higher voltage, ONAN
A/mm2
LV, ONAN A/mm2
Magnetising current at rated nominal
voltage on principal tapping A
Maximum hot spot temperature of winding oC
Equivalent resistance referred to HV side ohms
Equivalent reactance referred to HV side ohms
Maximum current carrying capacity of bushings:
HV A
LV A
TV A

Rated Voltage of Bushings

HV kV
LV kV
HV, neutral kV
LV, neutral kV
38. Maximum noise level
-Transformer and tap changing equipment
dB
energised and at no-load with ONAN cooling

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20.6 96 KV LIGHTNING ARRESTER

Guaranteed
Item Particulars Unit
Figure
1
Type
2 Manufacturer
3 Applicable Standard
4 -Rated voltage kV
5 Nominal discharge current kA
Whether the results of the various tests like
6 voltage withstand tests, spark over voltage
tests, etc conform to relevant IS
Whether all specified fittings and
7 accessories, leakage current indicator etc
have been provided
Total/protected creepage distance of
8 mm/mm
supporting insulator

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20.7 ACSR CONDUCTOR

Guaranteed
Item Particulars Unit
Figure
1 Make
2 Standard
3 Diameter of overall conductor mm
4 Weight of complete conductor Kg/m
5 Characteristics of Protective grease
6 Ultimate tensile strength Kg
7 Modulus of elasticity Kg/cm2
8 Co-efficient of linear expansion deg C

9 Standard drum length m

20.8 - INSULATOR
Guaranteed
Items Particulars Unit
Figure
1 Make
2 Standards followed
3 Number of discs used per String insulator
assembly
4 Total creepage distance of

5 − Each disc insulator unit mm

6 − Complete string insulator assembly mm

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20.9 OPGW

Item Particulars Unit Guaranteed Figure

1 Make and Model No
2 Standards followed
3 Ultimate tensile strength kg
4 Diameter of complete wire mm
5 Weight of complete wire Kg/mm

20.10 STRUCTURE STEEL WORK

Item Particulars Unit Guaranteed Figure

1 Grade of steel for
2 Steel members
3 Nuts and bolts kg
4 Other fasteners mm

5 Minimum thickness of Steel used Kg/mm

for various members
6 Galvanizing details Kg/cm2
7 Minimum diameter of bolts m
Maximum tension Considered for
8 shield wire Kg

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BOM FOR 110kV Substation

Drawing reference: SAPM-100-E-SLD-6900 P0 (30.12.19)

S.NO DESCRIPTION QUANTITY

1 110kV Switchyard Equipment

12 MVA 110/11kV Transformer Dyn11,Power Transformer

a 1
with + - 10% On load Tap changer.

b 123 kV, 1250A,31.5kA 3 Ph. SF6 Circuit breaker 1

123 kV ,1250A,31.5kA/3 Sec. 3 Ph. Double break Type Isolator-Motor

c 2
Operated without Earth Switch , -101-89A & 101-89B (TANGEDCO)

123kV,1250A,31.5kA/3 Sec. 3 Ph. Double break Type Isolator Motor

d 1
Operated with Earth Switch -101-89C (SAPM)

e 75/1-1A ,123kV ,31.5kA/3 Sec Current Transformer,1Ph. (TANGEDCO) 3

f 150-75/1-1-1-1A ,123kV ,31.5kA/3 Sec Current Transformer,1Ph. (SAPM) 3

Potential Transformer ,
g 3
1 Ph.(110000V/√3)/(110V/√3)/(110V/√3)/(110V/√3) (TANGEDCO)

Potential Transformer ,
h 3
1 Ph.(110000V/√3)/(110V/√3)/(110V/√3)/(110V/√3) (SAPM)

i 96kV,10kA 1Ph. Lightning Arrester 6

2 BUSBAR Materials

a 3''IPS Al. Tube (Size.40) Lot

b 54/3.175+ 7/3.175 ," ZEBRA 'ACSR Conductors Lot

3 110kV Clamps and Connectors Lot

110kV Tension and Suspension

4 Lot
String assembly with handwares

5 110kV Bus post insulator 3

6 Bay Marshalling Kiosk , CT Junction Box , PT Junction Box Lot

7 Lightning Mast Lot

8 Switchyard control Room equipments:

a 1600A,12kV,25kA,3sec VCB Indoor Panel 1

BOM FOR 110kV SUBSTATION EQUIPMENT 92 DOC.NO.:SAPM-100-E-BOM-6123

MECHTECH PROJECTS SRI ANDAL PAPER MILLS PVT LTD.

b Main ACDB 1

c 110V DC DB 1

d Main Lighting DB 1

e Emergency AC lightning DB for Switchgear 1

f 250KVA ,11 KV /0-433KV Auxilliary Transformer 1

g 110kV Control & Relay panel Lot

h Communication Panel 1

i 110 V DC battery 150 AH and charger Lot

j Outdoor 200A 3Ph Industrial Socket for Oil Filtration

9 Cables

a 11kV ,3C 240Sq.mm.XLPE Al.Cable(UE) Lot

b 1.1kV Control & Auxiliary Power Cable Lot

c Cable Tray & Accessories Lot

10 Illumination

a 110kV Switchyard Lightning Lot

b 110kV Control Room Lightning Lot

Switchyard and Control Room earthing material (Main earth mat, Equipment
11 Lot
Risers etc.,)

12 Civil Works

a Transformer Foundation 1

b 110 kV Tower foundation 2

c 110 kVEquipment Support Structure Foundation Lot

d Switchyard Cable Trenches Lot

e Switchyard Drainage System Lot

f Transformer Oil Sump Pit Lot

g Site levelling & excavation if required Lot

h Completye Civil works for Centrol Room Building Lot

i Fire Protection System for Transformer Lot

j Switchyard Gravel Filling Lot

BOM FOR 110kV SUBSTATION EQUIPMENT 93 DOC.NO.:SAPM-100-E-BOM-6123