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TECHNICAL SPECIFICATION FOR ELECTRICAL SYSTEM

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CONTENTS

I II III IV

TECHNICAL SPECIFICATION FOR ELECTRICAL GENERAL TECHNICAL SPECIFICATION FOR 415V PMCC & DB, CAPACITOR PANEL TECHNICAL SPECIFICATION FOR HT & LT POWER & CONTROL CABLES TECHNICAL SPECIFICATION FOR ELECTRICAL ERECTION

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Technical Specification for Electrical - General

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1.0.0 1.1.0 1.1.1

GENERAL Intent of Specification This specification is intended to cover complete design, manufacture, supply and efficient erection, testing and commissioning of various Electrical equipment, as per enclosed Schedule of Work, as specified hereinafter and as per drawings inclusive of the supply of all labour, supervision, tools, implements and equipment/erection materials as necessary at BL, Head Office at 21, N. S. Road, Kolkata 1 site. The scope of work shall also include the design, manufacture, assembly, testing at manufacturers works, supply and delivery, properly packed for transport F.O.R. site of electrical equipment, erection material, specified hereinafter complete with all materials and accessories for efficient and trouble-free operation. The specification shall be read in conjunction with the General Condition of Contract and Special Conditions of Contracts as enclosed with this Specification. Standards & Codes The complete supply and installation work for the equipment and accessories covered under this specification shall be designed, manufactured, erected, tested and commissioned in accordance with the latest ISS. In cases where ISS are not available, the equipment and accessories shall conform to the latest publication of IEC or other recognised National Standard Institutions. All electrical equipment and installation work shall also conform to Indian Electricity Rules 1956 with latest amendment, National Electrical Code 1985, local Pollution Control Board, local Electric Supply Authority, OISD guideline and Fire Insurance Regulations as regards safety, earthing and other essential provisions specified therein for installation and operation of electrical systems. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility.

1.1.2

1.1.3 1.2.0

1.3.0

System Description At present, power is received from CESC through 6.6 KV switchgear. There are two nos. 6.6KV/433V transformers of 630 KVA and 330 KVA capacity respectively connected to LT Boards by LT cables. Presently, the 630 KVA transformer is catering the normal building load through Main MCC located in MCC Room and the 330 KVA transformer is catering the Central AC Plant load through Air Conditioning DB located in DG Room. The Main MCC and the Air Conditioning DB is connected by cable. One no. 315 KVA DG Set is connected to Main MCC to cater the emergency load. Two nos. Capacitor Panel with APFC relays and capacitor units are connected to the Main MCC.

1.4.0

Design Basis Existing 6.6 KV system is 3 phase, 50Hz, solidly grounded. 415 volt system shall be 3 phase and neutral (4 wire), 50 Hz, solidly grounded. All equipment and system shall be designed to suit the following voltage and frequency variation : i) ii) In case of 415/240 V variation : (+/-) 10% In case of 6.6 KV variation : (+/-) 10%

The frequency variation shall be +/- 5% in both cases. All equipment shall be designed for smooth, efficient and trouble free operation in tropical humid climate for a maximum ambient temperature of 400C. The derating of all equipment shall be done accordingly. Maximum relative humidity of 100% shall also be taken into account. Maximum temperature and relative humidity however may not occur together. The earthing system design and lightning protection system shall be necessarily augmented to meet the requirement of CESC. Two independent earth pits shall be provided for each

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transformer and DG neutral. The body of all electrical equipment shall be earthed at two separate points to meet IS requirements. DG installation and chimney height shall meet the local Pollution Control Board requirement. Earth grid for electrical system, static electricity protection and lightning protection shall be made separate from each other. 2.0.0 2.1.0 SCOPE OF WORK The details of various equipment relevant to the electrification work have been elaborated in the subsequent sections of this document and in the Schedule of Work. For procurement of materials / components items etc. the list of make enclosed with this specification shall be strictly followed. Major work to be done under this contract are as follows : a. Supply and installation of 3 nos. 100A/5A duel core CT at CESC incomer feeder of BL HT Switchgear. This work also includes recalibration of measuring equipments mounted on the BL HT Switchgear after changing of CTs. Testing and calibration of protection relays in BL HT Swgr. (consisting of one CESC incoming breaker and two transformer outgoing breaker). Installation and commissioning of owner supplied 1 no. 1000KVA, 6.6KV/433V, Dry type Transformer. The existing 330 KVA transformer to be dismantled, transported and store to the location indicated by BL within the BL, HO premises. Supply, laying and termination of HT power cable connecting BL HT Swgr and 1000 KVA dry type transformer. M-seal / Raychem make cold shrinkable termination kits shall be used for the termination of HT cables. Supply, laying and termination of LT power cable connecting BL LT Swgr and 1000 KVA dry type transformer. M-seal / Raychem make cold shrinkable termination kits shall be used for the termination of LT cables. Supply, installation, commissioning of new LT PMCC. The new LT PMCC will have three incomers : one from 630 KVA Trf., one from 1000 KVA Trf., one from DG AMF Panel. The incomers shall be electrically interlocked so that one incomer can be closed at a time and can be changed over automatically depending upon incoming power situation. During changeover of electrical loads from old MCC to new LT PMCC, temporary arrangement for uninterrupted power for BL, HO to be made. Arranging DG of adequate capacity, temporary distribution board, temporary connections and providing temporary supply to building electrical loads without disrupting the normal operation of the office activities during dismantling of existing Main MCC & ACDB and installation, commissioning of the new LT PMCC and shifting the loads from old Main MCC to new LT PMCC is under the scope of this contract. If necessary, this work may have to be carried out in night shift / on holidays on emergency basis. The work also includes dismantling of old Main MCC & ACDB and store it at the location indicated by BL within the BL, HO premises. i. Supply, installation of new capacitor banks and new APFC relay and complete rewiring of the existing Capacitor Panels as per Single Line Diagram.

b. c. d. e.

f.

g.

h.

2.2.0

The electrical cabling and grounding work shall include but not limited to : MS site fabricated / galvanised perforated cable tray and accessories as required for cable laying in trenches or otherwise. Bricks, sand, precast slab etc. for underground cable laying in outdoor area, including cable

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markers. Fire seals to cable penetration to buildings. Danger boards, Shock treatment charts etc. Earthing materials and connection for underground and above ground earthing system. Structural Steel for support of local starters, isolators, Lighting panels etc. All necessary erection materials, consumables and sundry items to complete the erection. Galvanised steel rigid/flexible conduits and accessories, ferrules, lugs, glands, terminal blocks, galvanised / sheet steel junction boxes, push button stations, cable fixing clamps, nuts & bolts etc. as required. Cable termination and jointing kits, cable glands and lugs as necessary. 2.2.1 2.2.2 2.3.0 2.3.1 All equipment, materials, hardware and accessories to be supplied by the bidder shall be brand new ones of reputed make. All relevant drawings, data sheet and technical leaflets on each piece of device. Scope Of Services Furnishing of all labour, skilled and unskilled, supervisory personnel, erection tools and tackles, testing equipment, implements, supplies, consumables and hardware for timely and efficient execution of the erection work. Transport vehicle necessary for efficient transportation of equipment from the owner's stores to site of erection and excess materials back to owner's stores. Complete assembly, erection and connection, testing and commissioning, putting into successful and satisfactory commercial operation of the above mentioned electrical equipment. The item of work to be performed on all equipment and materials shall include but not be limited to the following: Receiving, unloading and transportation at site (to owner's / contractor's stores and from their up to actual place of erection). Opening, inspection and reporting all damages and short supply of items. Arranging to repair and/or re-order all damaged and short supply items. Storing at site with suitable all weather protection. Assembly, erection and complete installation. Necessary co-ordination between works done by the other contractors. Final check-up, testing and commissioning in presence of owner's representative. Trial run for seven days, rectification of defects, if any and adjustment as necessary. Re-rolling of cables on new drums if so desired by the owner. Compilation and submission of test-reports and Drawings, follow-ups/ liaison with the local Electricity Authority & Central Electricity Authority, on behalf of Client for obtaining approval on the total installation of the Electrical System. 2.3.5 Field modification carried out shall be marked up red on one set of erection drawings.

2.3.2 2.3.3 2.3.4

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2.3.6 2.3.7 2.3.8 2.4.0 2.4.1 2.4.2 2.4.3 3.0.0 3.1.0

Preparation of cable schedule Preparation of AS BUILT DRAWINGS and submission of the same in soft copies (in Auto cad 2004 / Microsoft Word/excel format) as well as in three hard copies. Reference shall be drawn to the "Schedule of Work and Prices for quantity of major items. Facilities to be arranged by Contractor Contractor will be given a place for storing his materials, tools, tackles. Construction power will be given by the owner. The Contractor shall also arrange for storing material with weather protection wherever necessary and proper security arrangement till the installation is taken over by the owner. TECHNICAL DATA/DRAWINGS/DOCUMENTS TO BE FURNISHED Along with the Offer Technical Particulars of all Supply-items covered under the scope.

3.2.0

After Award of Contract Confirmed Technical Particulars, Technical Catalogs, GA Dwgs, Control schematics & interlocks, type test certificates and routine test certificates of the all the supply items.

4.0.0 4.1.0

TESTS Routine Tests The major electrical equipments shall be tested at factory as per applicable IS before dispatch by Third Party Inspection Agency (TPIA). The TPIA test certificates shall be submitted to the owner in three copies for approval. The materials shall be dispatched from works only after obtaining owners written approval on TPIA test certificate. Quoted prices shall include Bidders charges towards testing and inspection by TPIA. List of 3rd parties for inspection: LRIS / CEIL / PDIL / BAXCOUNSEL / BVQI.

4.2.0 4.2.1 4.2.2 4.3.0 4.3.1

Type Tests Type Test Certificates, as stipulated in Indian Standard Specification for the major supply items are to be furnished by the tenderer along with their offer. All equipment shall be demonstrated to operate in accordance with the requirements of this specification. Pre-commissioning Tests at site The installation work shall be tested by the contractor after completion of his erection work with an advance notice to the engineer so that he or his authorised representative may witness the same also. The contractor shall prepare the pre-commissioning test program of each equipment / work / system indicating the data of each equipment / work / system, the tests to be carried out in seriatim and the test result to be tabulated. The program shall be submitted to the owner for approval. The contractor shall carry out HV Test of all electrical items as per relevant IS.

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After completion of the tests, the results shall be submitted to the owner for his approval and acceptance. 4.3.2 The test result of any installation or equipment or its part, if considered satisfactory to the engineer, the concerned installation / equipment and its accessories shall be properly rectified by the contractor and shall be properly rectified by the contractor and shall be tested again to the satisfaction of the engineer by the contractor at his own cost. The contractor shall also be responsible for obtaining approval of the Chief Electrical Inspector / CEA / State Electricity Board on the overall installation, covered under his Scope. The contractor shall carry out the following pre-commissioning checks as indicative minimum in addition to other checks and tests recommended by the manufacturers. Transformer Installation Check i. Check for damages on accessories like Bushings, Tap Switch etc. ii. Check for tightness of all joints. iii. Check for ratio at all taps. iv. Check IR value v. Check phase sequence and vector group. vi. Check for magnetic balance test and compare with shop results. vii. Short circuit test at convenient low voltage and see any abnormality.

4.4.0 4.5.0 4.5.1

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ANNEXURE - I LIST OF APPROVED MAKE

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13

Item Description Cable Light Fittings LT Components for Board / DB Meters Energy Meters CT / PT Switch/Receptacles Capacitor Units Relays Lighting Cable & Wire Cable Glands (NFLP type) Cable Lugs Terminal Blocks

Preferred Make CCI/RPG Asian/Universal/Fort Gloster Industrial cable / Torrent / Finolex / Polycab Philips / Bajaj / GE / Havells Siemens/L&T/GE/Alstom/ Schnider/ Havells/ BCH / Standard / ABB AE/IMP/MECO/Rishab Secure / Jayco Jyoti/C&S/Kappa/L&T/Pragati/approved eqv. Anchor/Northwest/Clipsal/MK ABB / Universal / Khatau Junkar/L&T Alstom / ABB / Siemens / GE Finolex/RPG Asian/Anchor/Nicco/KDK Electromeg/Comet Dowel/Connectwell Elmax/Connectwell

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Technical Specification For 415V PMCC & DB, Capacitor Panel

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1.00.00

SCOPE OF WORK This specification intends to cover the design, manufacture, testing at the manufacturer's works, supply, delivery for transport F.O.R site of 415V Power & Motor Control Centre (PMCC), Capacitor Panel, DBs, MLDBs, as specified hereinafter complete with all accessories, fittings and auxiliary equipment as required for efficient and trouble-free operation. The scope of work covered under this section may be taken out of the overall scope of this tender document and may be awarded as an independent package, if so, warranted in the overall interest of the project.

1.01.00 1.01.01 1.01.02

Scope of Supply For detail scope of work refer SOR of this document. Following Panels are under scope of supply of this specification : i) 415V LT PMCC : (One) 1 no. The new PMCC shall have three incomers Incomer- I : From 1000 KVA Transformer Incomer- II : From 630 KVA Transformer Incomer- III : From 330 KVA DG AMF Panel The three incomers shall be electrically interlocked for automatic changeover depending upon incoming power situation. Rewiring and commissioning of existing Capacitor Panel with new three phase capacitor units and new APFC relay as per enclosed SLD.

ii) 1.01.03 1.01.04 1.01.05 1.01.06 1.02.00

The base channel frame with hardware, nuts, bolts, washers etc., hanging & support structure of busduct. One set of special tools and tackles. Spare parts All relevant drawings, data and instruction manuals. Scope of Services The purchaser may indent for the service of a Senior Engineer experienced in erection and commissioning of the equipment of similar type and rating on per diem basis. The work includes but not limited to : Complete checking of materials at site and advising the Owner of any discrepancy thereof. Advice on procedure of erection to be followed. Installation, testing, commissioning and putting the equipment into successful commercial operation.

2.00.00 2.01.00

CODES & STANDARDS All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) except where modified and/or supplemented by this specification. Equipment and materials conforming to any other standard which ensures equal or better quality may be accepted. In such case, copies of the English version of the standard adopted shall be submitted along with the bid. The electrical installation shall meet the requirements of Indian Electricity Rules as amended

2.02.00

2.03.00

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up to data and relevant IS Codes of Practice. In addition, other rules or regulations applicable to the work shall be followed. In case of any discrepancy, the more restrictive rule shall be binding. 2.04.00 The following codes and standards shall be strictly followed in the manufacturing of the Power and Motor Control Centre (PMCC) / Panel boards. IS:375 IS:2147 IS:4237 IS:8623 IS:1248 IS:2516 IS:2705 IS:2959 IS:3231 IS:2208 IS:4064 IS:6875 3.00.00 3.01.00 3.02.00 3.03.00 Marketing and arrangement of bushes Degree of protection provided by enclosure for low voltage switchgear and control gear. General requirement of switchgear and control gear for voltage not exceeding 1000 volts. Factory build assemblies of switchgear and control gear Indicating Instruments Air Circuit Breakers Current Transformer Auxiliary Contractors Relays HRC Fuse links Fuse Switch and Switch fuse units. Control Switches and Push Buttons

DESIGN CRITERIA The PMCC, Capacitor panel and Auxiliary Panel boards shall be used to provide power supply in the building. All the equipment will be located in a hot, humid and tropical atmosphere. Duty involves direct-on-line / star-delta starting of large induction motors and also under certain emergency conditions manual transfer of loads from one source of supply to other. For DOL starts motor staring current varies from 6 to 8 times full load current with maximum of 3 starts per hour. For Star-Delta starts motor staring current varies from 2.0 to 2.5 times full load current with maximum of 3 starts per hour. Equipment ratings and quantities are detailed in the enclosed drawings and appendices. Equipment shall be furnished in strict compliance with the same. For continuous operation at specified ratings, the temperature rise of various equipment / components shall be limited to the permissible values stipulated in relevant standards and/or this specification. All equipment and components thereof shall be capable of withstanding the mechanical forces and thermal stresses of the short circuit currents listed in the Appendices without any damage or deterioration of the materials. Circuit breaker shall not produce any harmful over voltage during switching off induction motors. If required, surge protective devices shall be included in the scope of supply to limit over voltage. SPECIFIC REQUIREMENTS CONSTRUCTION PMCC / Capacitor Panel and DBs shall be indoor, metal-clad, floor mounting, air insulated and modular in construction. The design construction shall be such as to allow extension at either end. The PMCC shall be of double front construction and non-draw-out fixed type construction. The breaker modules shall be draw out type. The Capacitor Panel / DBs shall be of single front construction and fixed type. Enclosure of the boards shall be dust and splash proof, conforming to degree of protection IP-

3.04.00 3.05.00

3.06.00

3.07.00

4.00.00 4.01.00 4.01.01

4.01.02

4.01.03

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54. Capacitor Panel shall have sufficient screened louvers for proper ventilation. Minimum thickness of sheet metal used shall be 2 mm. 4.01.04 The PMCC/Capacitor Panel/DB shall comprise a continuous line up of single/multi tier cubicles. The installations of circuit breaker however shall be limited to the bottom two tiers only. All PMCC/Capacitor Panel/DBs shall be front wired & front connected. The design shall be fully compartmentalised with metal/insulating partitions between compartments. The working height shall be limited within 300 mm to 1800 mm from floor level. Each control module shall be housed in a separate compartment, complete with an individual front access door. All doors and covers shall be gasketted with neoprene gasket. All push buttons, lamps, indicating instruments shall be flush/semi-flush mounted on respective module compartment. A full height vertical cable chamber with cable supports shall be provided in each section to facilitate unit wiring. The chamber shall be liberally sized to accommodate all cables and shall have removable cover at the front for access. Each Breaker/Capacitor module shall be housed in a separate cubicle, complete with an individual front access door having sufficient opening with concealed type hinges. Each vertical section of single front panels shall have a removable back cover. All doors and covers shall be gasketed. PMCC/MCC cubicle shall be so sized as to permit closing of the front access door when the breaker is pulled out to ISOLATED position. For PMCC/Capacitor panel all switches, lamps and indicating instruments shall be flush mounted on the respective cubicle door whereas relays and other auxiliary devices may be mounted on a separate cubicle. For PMCC/Capacitor Panel/DB shall have a full height vertical cable chamber with cable supports shall be provided in each section to facilitate unit wiring. The chamber shall be liberally sized to accommodate all cables and shall have removable cover at the front for access. Full height vertical busbar chamber shall be provided alongside each vertical panel to facilitate maintenance access from the front. For PMCC/Capacitor Panel/DB shall have a horizontal wire way extending the entire length shall be provided at the top of each panel for inter panel wire. Incomer/Tie shall be provided at the two ends of the panel line-up and Bus section, if not specified elsewhere. Lifting lugs shall be provided for each individual shipping section. Switchboards shall be supplied with base frames made out of structural steel sections along with all necessary mounting hardware required for bolting/welding base frames to the foundation. After isolation of power and control circuits connections, it shall be possible to safely carry out maintenance in a compartment with the busbar and adjacent circuit in live condition. Necessary shrouding arrangement shall be provided for this purpose over the cable terminations located in cable alley. The minimum clearance in air between phases and between phases and earth for the entire run of horizontal and vertical busbars shall be 25 mm. For all other components, the clearance between two live parts, a live part and an earthed part and isolating distance shall be at least ten (10) mm throughout. Wherever it is not possible to maintain these clearances,

4.01.05

4.01.06 4.01.07 4.01.08

4.01.09

4.01.10 4.01.11

4.01.12

4.01.13 4.01.14 4.01.15 4.01.16 4.01.17

4.01.18

4.01.19

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insulation shall be provided by sleeving or barriers. However, for horizontal and vertical busbars the clearance specified above should be maintained even when the busbars are sleeved or insulated. All connections from busbars upto fuses shall be fully shrouded to minimise the risk of phase to phase and phase to earth shorts. 4.01.20 Wherever two compartments are provided in the same vertical section, insulating barriers and shrouds shall be provided in the rear cable compartment to avoid accidental touch with the live parts of one circuit when working on the other circuit. BUS AND BUS TAPS The main buses and bus connections for PMCC/Cap. Pnl and DBs shall be of high conductivity aluminium/aluminium alloy or copper as specified in Appendices. These shall be sized for specified current ratings with maximum temperature limited to 850C (i.e. 450C rise over 400C ambient). 4.02.02 All bus connections shall be silver plated. Adequate contact pressure shall be ensured by means of two bolt connection with plain and spring washers and lock nuts. Bimetallic connector shall be furnished for connection between dissimilar metals. Busbars shall be supported and braced to withstand the stresses due to maximum short circuit current and also to take care of any thermal expansion. Busbar compartments shall be completely enclosed for separately running horizontal and vertical busbars. Minimum current rating for vertical Busbars shall not be less than 200A. Busbars and connections shall be fully insulated for working voltage with adequate phase/ground clearances. Insulating sleeves for busbars and shrouds for joints shall be provided. Bus insulators shall be, non-hygroscopic flame-retardant, track resistant, high strength, sheet molded compound or equivalent polyester fiber glass molded type. Separate support shall be provided for each phase and neutral bus bar. Bolted disconnect links shall be provided for all incoming and outgoing feeders for isolation of neutral, if necessary. Busbars shall be colour coded for easy identification and so located that the sequence R - Y B shall be from left to right, top to bottom or front to rear when viewed from the front of the assembly. AIR CIRCUIT BREAKER As indicated in the drawings/appendices, circuit breakers shall be provided in the 415 Volt PMCC having minimum interrupting capacity equal to the listed fault level. Circuit breaker shall be three / four pole, single throw, air-break type with motorised spring charging, stored energy, trip-free mechanism and shunt trip. Circuit breaker shall be drawout type, having service, test and isolated position with positive indication for each position. Circuit breakers of identical rating shall be physically and electrically interchangeable. Each circuit breaker shall be provided with three (3) adjustable over current relays and one (1) adjustable earth fault relay. Protective relay characteristics shall be suitable for coordination with downstream fuses and shall be IDMTL type. Mechanical safety interlock shall be provided to prevent the circuit breaker from being racked

4.02.00 4.02.01

4.02.03 4.02.04 4.02.05 4.02.06

4.02.08

4.02.09 4.02.10

4.03.00 4.03.01 4.03.02 4.03.03 4.03.04 4.03.05

4.03.06

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in or out of the service position when the breaker is closed. 4.03.07 4.03.08 4.03.09 4.03.10 Automatic safety shutters shall be provided to cover up the stationary disconnects when the breaker is withdrawn. Each breaker shall be provided with an emergency manual trip, mechanical ON-OFF indicator/an operation counter and mechanism for charge/discharge indicator. Circuit breakers shall have motor wound spring charged mechanism. For motor wound mechanism, spring charging shall take place automatically after each breaker closing operation. One open-close-open operation of the circuit breaker shall be possible after failure of power supply to the motor. Mechanical safety interlock shall be provided to prevent the circuit breaker from being racked in or out of the service position when the breaker is closed. In addition to the auxiliary contacts required for normal breaker operation and indication, each breaker shall be provided with following for interlocking purpose : Position / cell switch with 4NO + 4NC contacts. Auxiliary switch, with 6NO + 6NC contacts, mounted on the stationary portion of the switchgear and operated mechanically by a sliding lever from the breaker in SERVICE position. Alternatively electrically reset latching relay, EE type VAJC11 or, equal, may be used for the purpose. Limit/auxiliary switches shall be convertible type, that is, suitable for changing NO contact to NC and vice-versa. Control & Indication The circuit breaker shall be wired up for local & remote operation. Each breaker cubicle shall be equipped with following : Breaker Control Switch for TRIP & CLOSE. The breaker control switch shall have four (4) positions : Close, Normal after Close, Trip and Normal after Trip. Each position shall have at least two potential free contacts for use. Three (3) indicating lights on front of compartment : Breaker open & Spring charged Breaker closed Breaker Tripped / Trip circuit unhealthy GREEN RED AMBER

4.03.11 4.03.12 4.03.13 4.03.14

4.03.15 4.03.16 4.13.17

Lamps shall be low watt, filament type with series resistor. Lamp and lens shall be replaceable from the front. The general scheme of connections for control, interlock and protection is shown in the enclosed drawings. Detailed requirements of individual circuits and control scheme drawings shall be developed and furnished by the bidder. The incomer breaker shall be provided with three position (Auto-Off-Manual) lockable type selector switch with the key withdrawable in locked condition at any position. The switch shall have following contacts :a. b. c. Auto position 4 contacts Off position 2 contacts Manual position - 4 contacts

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The contacts of the switch shall be rated for making and continuous causing of 10A at 240V A.C. 4. 04.00 4.04.01 4.04.02 4.04.03 4.04.04 MODULED CASE CIRCUIT BREAKERS (MCCB) These shall comprise a switching mechanism, contact system, arc extinguishing device and a tripping unit contained in a compact moulded case and cover. The insulating case and cover shall be made of high strength heat resistant and flame retardant thermosetting insulating material. The switching mechanism shall be quick-make/quick-break type utilising a trip free toggle mechanism. The arc extinguishing device shall consist of a series of grid plates mounted in parallel between the supports of insulating material so that the arc is confined, divided and extinguished. The MCCBs shall have in-built overload and short circuit release and these elements shall be provided in such a manner as to prevent single phasing in the event of fault, occurring on any of the phases. Overload and short circuit settings shall be adjustable type. The MCCBs shall be fitted with remote trip facility. Minimum interrupting capacity of the MCCBs shall be equal to the listed short circuit level. PMCC CONTROL MODULES Fixed type control module shall have power/control disconnects. All disconnects shall be silver plated to ensure good contacts. The design shall be such as to permit easy withdrawal/reinsertion of the drawout unit with guide rails to ensure correct alignment without any trouble. Control Module shall house the control components for a circuit such as switch, fuse, contactors, relays, push buttons, lamps etc. as detailed in the bill of materials. Only the push button actuator, lens of indicating lamps and transparent window for meters shall be mounted on module door such that when the module is withdrawn the cubicle door shall provide specified IP-54 protection class in closed position. The equipment layout shall provide sufficient working space in between the components and subject to Owner's approval. Various module/compartment sizes shall be multiple of one basic unit to facilitate modifications at site. Suitable provision for this purpose should also be incorporated in the vertical busbars. Drawout type control module shall have three distinct positions as below : Service Test Isolated 4.05.06 4.06.00 4.06.01 Drawout type control modules of same size and type shall be electrically and physically interchangeable. AIR BREAK SWITCHES Switches shall be triple pole / four pole (as per SLD), air break, AC23 for motor feeders and AC22 heavy duty for other feeders.

4.04.05

4.04.06 4.04.07 4.05.00 4.05.01 4.05.02 4.05.03

4.05.04 4.05.05

4.05.06

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4.06.02 4.06.03

Motors duty switches shall be capable of safely making and breaking the locked rotor current of the associated motor circuit. The switch shall have a quick-make, quick-break mechanism operated by a suitable external handle, complete with position indicator. This handle shall have provision for padlocking in ON and OFF position. The compartment door shall be interlocked mechanically with the switch such that the door cannot be opened unless the switch is in OFF position. Means shall be provided for releasing this interlock at any time. Switches shall be capable of withstanding the let-through fault current of back-up fuses or circuit breakers. All incoming and outgoing feeders shall be provided with bolted disconnect link for isolation of neutral as per requirement. FUSES Fuses shall be HRC, link type, with a minimum interrupting capacity equal to the listed Short Circuit Current. Fuses shall be furnished complete with fuse bases and fittings of such design as to permit easy and safe replacement of fuse element. Visible indication shall be provided on blowing of the fuse. Motor fuse characteristics and ratings shall be chosen to ride over starting period without blowing. The fuse on incoming feeder, if specified, shall be chosen to provide discrimination with motor/feeder fuses. A. C. STARTER Contactor The Contactors shall be three pole, air break type designed for duty class III - Category AC3 with non-bouncing silver/silver alloy contacts unless otherwise specified. Each Contactor shall be provided with at least two (2) normally open and two (2) normally closed auxiliary contacts rated 10 A at 240V A.C. Reversing contacts shall be electrically and mechanically interlocked. Contactors with delayed dropout feature shall be provided for some essential auxiliaries if so detailed in the Annexures. These Contactors shall not dropout on power failure if the voltage is restored within 3 seconds.

4.06.04

4.06.05 4.06.06 4.07.00 4.07.01 4.07.02 4.07.03 4.07.04

4.08.00 4.08.01

4.08.02

Thermal Overload Thermal overload relays shall be three element, positive acting, ambient temperature compensated with adjustable settings. Single phasing preventer shall be provided, as an inbuilt feature of thermal overload. Single phasing preventer shall not be too sensitive to negative sequence current and shall be adequately stable during motor starting, normal voltage unbalance etc. Relays shall have provision for selection of Auto or Manual mode of resetting with one changeover contact. Resetting of relays shall be possible with compartment door closed. Colour of the resetting button shall be BLACK. Relays may be direct acting or C. T. operated, depending on current rating. C.T.s shall be included in the scope of supply.

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Relays for fan motor having long starting time shall be provided with saturable core CTs. 4.09.00 4.09.01 4.09.02 CONTROL AND INDICATION Push button shall be heavy duty, push to actuate type with integral escutcheon plate marked with its function. Contact faces shall be of silver alloy. Each push button shall have one (1) normally open and one (1) normally closed contacts rated as follows :

4.09.03

Make and carry continuously 10A Breaking current of 0.5A at 110V D.C. Breaking current of 10A at 240V A.C.

For breaker operated modules one (1) TRIP-NORMAL-CLOSE switch shall be provided. The breaker control switch shall have four (4) positions : Close, Normal after Close, Trip and Normal after Trip. Each position shall have at least two potential free contact blocks of 1NO+1NC EACH for use. Lamps shall be low-watt, filament type with series resistor and coloured lens. Lens and lamps shall be replaceable from the front. Push button/indicating lamp size shall not exceed 22.5 mm in diameter. Control supply arrangement for contactor operated modules shall be taken as a tap-off from control supply busbar. Each contactor operated motor feeder shall have a three position selector switch (Auto-OffMCC), with two (2) NO of contact each in Auto and MCC positions. The contacts shall be rated for making and continuously carrying 10A 240V AC/48V DC/24V DC, and breaking 0.5A at 110V AC/48V DC/24V DC. CAPACITOR BANK AND CONTROL Construction 1 no 10 KVAR, 1 no 25 KVAR and 8 nos. 50KVAR, 415 Volt three phase Capacitor Banks with necessary control shall be provided in the Capacitor Control Panel for improving the plant power factor. The capacitor banks shall be placed in tier formation. The control elements like relays, contactors, protective elements, indicating devices etc. shall be housed in the Panel in a separate module. The capacitor bank shall be placed at one end of the board with ventilating louvers at the back.

4.09.04

4.09.05 4.09.06

4.10.00 4.10.01

4.10.02

Control The internal control wiring shall be done by 1.5 mm sq. stranded copper wire and the control supply shall be tapped through control fuse from any of the incoming phase at a single point and distributed to individual module through separate control fuses. In no case the control supply shall be tapped from individual module bus. Each bus-connected module of the panel shall house ON/OFF Isolator, lamps, HRC Fuses and terminals for individual unit control, capacitor duty magnetic contactors of adequate rating etc.

4.10.03

Capacitor The capacitor shall be of super heavy duty, low loss, two layers of metallized polypropylene film foil type as dielectric and high purity soft annealed aluminum foil as conducting plate (type BMDXL of BCH make / type APP of GE make or, approved equivalent). Capacitor units

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shall be hermetically sealed to protect leaks and contamination of dielectric. All joints in the steel casing shall be welded and tested for liquid tightness. Capacitors shall be provided with proper discharge devices built into the units to reduce the residual voltage to a safe value within the specified time as recommended in the relevant standard after the capacitor has been disconnected from the supply. Capacitors shall be of insulation class I. Metal container of the capacitors shall be provided with two distinct earthing terminals with nuts, bolts, washers suitable for connecting 50 X 6 mm strip as such continuity conductor. Individual capacitor units shall be provided with internal element fuse for isolating the faulty element and thereby protecting other elements, which are connected in parallel. Capacitors shall be designed to take care of the inrush current which may arise out of switching of a particular unit while the parallel connected units are already energised. The capacitors shall have adequate margin of at least 30% built-in the capacity for harmonic currents. The capacitors shall be designed to withstand 10% over voltage for prolonged operation. The terminals of all capacitors shall be made easily accessible. 4.10.04 The capacitor control scheme shall be suitable for auto-manual operation for improving PF from 0.75 lag to 0.95 lag. Automatic Power Factor Correction Relay with 12 steps minimum of switching shall be provided for automatic operation. The relay shall have digital display of system power factor. This shall be of approved make only. The complete scheme of power factor correction shall be submitted to Purchaser for approval. CURRENT TRANSFORMERS Current transformers shall be cast resin type. All secondary connections shall be brought out to terminal blocks where star or, delta connection will be made. Accuracy class of the current transformers shall be : Class PS for differential protection Class 5P20 for other protection Class 1.0 ISP < 5 for metering 4.12.00 VOLTAGE TRANSFORMER Voltage transformers shall be cast-resin, drawout type and shall have an accuracy class of 1.0. Voltage transformer mounted on breaker carriage is not acceptable. The voltage transformer and fuses shall be completely disconnected and visibly grounded in fully drawout position. 4.13.00 4.13.01 4.13.02 4.13.03 RELAYS Relays shall be of drawout design with built-in testing facilities. Small auxiliary relays may be in non-drawout execution. Relays shall be rated for operation on 1A/5A secondary current and 110V secondary voltage; number and rating of relay contacts shall suit the job requirements. The Contractor shall furnish, install & co-ordinate all relays to suit the requirements of protection, interlock and bus transfer scheme as indicated in the annexures and drawings.

4.11.00

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4.13.04 4.14.00 4.14.01

Motor protection relays shall be English Electric make "MOTPRO" or equivalent. METERS Indicating instruments (96 x 96 mm) shall be switchboard type, with 90 Deg. Scale, antiglare glass and accuracy class of + 2% full scale. Each meter shall have zero adjuster on the front. Motor ammeter shall have an extended suppressed end-scale range to indicate starting current (6 to 8 times full-load current for DOL starters and 2.0 to 2.5 times full-load current for Star-Delta starters ). Watt-hour meter and Tri-vector meters shall be provided in drawout cases with built-in test facilities. Alternatively, they may have test block to facilitate testing of meter without disturbing C.T. or V.T. secondary connections. Meter selector switches shall be maintained contact, stay-put type, with knob-handle. Ammeter selector switch shall have make before break contacts. SECONDARY WIRING The PMCC shall be fully wired at the factory to ensure proper functioning of control, protection, transfer and interlocking schemes. Fuse and links shall be provided to permit individual circuit isolation from bus wires without disturbing other circuits. All spare contacts of relays, switches and other devices shall be wired upto terminal blocks. Wiring shall be done with flexible, 650V grade, PVC insulated switchboard wires with stranded copper conductors of 2.5 Sq. mm for control & current circuits and 1.5 Sq. mm for voltage circuits. Each wire shall be identified, at both ends, with permanent markers bearing wire numbers as per Contractor's wiring diagrams. Wire terminations shall be made with crimping type connectors with insulating sleeves. Wire shall not be spliced between terminals. TERMINAL BLOCKS Terminal blocks shall be 660V grade box-clamp type with marking strips, similar to ELMEX 10 Sq. mm or equal. Terminals for C.T. secondary leads shall have provision for shorting. Not more than two wires shall be connected to any terminal. Spare terminals equal in number to 20% active terminals shall be furnished. Terminal blocks shall be located to allow easy access. Wiring shall be so arranged that individual wires of an external cable can be connected to consecutive terminals. CABLE TERMINATION PMCC / Cap. Pnl / DBs shall be designed for cable entry from the top/bottom. Sufficient space shall be provided for ease of termination and connection. Cables shall be PVC insulated, armoured, PVC overall sheathed with 2.5 Sq. mm stranded copper conductor for control and stranded aluminium conductor for power circuits, as detailed in annexure and drawings, and twisted pair overall screened 0.5 Sq. mm. Cu. Cable for PLC interface. All provisions and accessories shall be furnished for termination and connection of cables, including removable gland plates, cable supports and terminal blocks.

4.14.02

4.14.03

4.14.04 4.15.00 4.15.01 4.15.02

4.15.03

4.15.04 4.15.05 4.16.00 4.16.01 4.16.02 4.16.03 4.17.00 4.17.01 4.17.02

4.17.03

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4.17.04 4.18.00 4.18.01 4.18.02 4.18.3

Gland plates shall be minimum 3 mm thick. The gland plate and supporting arrangement for 1/C power cables shall be non-magnetic type to prevent flow of eddy current. BUS DUCT CONNECTION Bus duct connections, when specified on drawings/annexures, shall be furnished along with transposition panel if required. Bus duct connections shall be generally from the top. All connecting bus work shall have the same continuous current rating as associated PMCC bus and shall be fully braced for the listed short circuit current. All provisions such as matching flange and other accessories shall be furnished for connection to bus duct being supplied by others. Necessary details for this purpose will be furnished later. GROUND BUS A ground bus, rated to carry maximum fault current, shall extend full length of the PCC / MCC / Cap. Pnl / DB. The ground bus shall be provided with two-bolt drilling with G.I. bolts and nuts at each end to receive 50 x 6 mm G.I. flat. Each stationary unit shall be connected directly to the ground bus. The frame of each circuit breaker and drawout V.T. unit shall be grounded through heavy multiple contacts at all times except when the primary disconnecting devices are separated by a safe distance. Wherever the schematic diagrams indicate a definite ground at the PCC / MCC / Cap. Pnl / DB, a single wire for each circuit thus grounded shall be run independently to the ground bus and connected thereto. C.T. & V.T. secondary neutrals shall be earthed through removable links so that earth of one circuit may be removed without disturbing others. NAMEPLATES Nameplates of approved design shall be furnished at the front as well as rear side of each cubicle and at each instrument &device mounted on or inside the cubicle. The material shall be lamicoid or approved equal, 3mm thick with white letter on black background. The name plate shall be held self-tapping screws. Name plate size shall be minimum 20 x 75 mm for instrument/devices & 40 x 150 mm for panels. Caution notice on suitable metal plate shall be affixed at the back of each vertical panel. SPACE HEATERS AND PLUG SOCKETS Each vertical section shall be provided with thermostat controlled space heater and 6A, 3 pin plug socket. In addition, motor feeder cubicle of 30 KW and above shall be wired-up for feeding the motor space heater through suitably rated breaker / contactor auxiliary NC contact and/or Contactor. Cubicle heater, Motor heater, Plug-socket circuit shall have individual switch fuse units. A.C./D.C. POWER SUPPLY FOR CONTROL AND SERVICE The following power supplies will be made available to each PCC / MCC / Cap. Pnl :

4.19.00 4.19.01 4.19.02 4.19.03

4.19.04

4.19.05 4.20.00 4.20.01 4.20.02 4.20.03 4.20.04 4.21.00 4.21.01 4.21.02

4.21.03 4.22.00 4.22.01

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A.C. supply : Single feeder 4.22.02 4.22.03 4.23.00 4.23.01 4.23.02 4.24.00 4.24.01 4.24.02 4.24.03 4.24.04 4.25.00 Isolating switch fuse units shall be provided at each switchgear for the incoming supplies, 4pole, single throw for A.C. Busbar of adequate capacity shall be provided to distribute the incoming supplies to different cubicles. Isolating switch-fuse units shall be provided at each cubicle for A.C. supplies. TROPICAL PROTECTION All equipment, accessories and wiring shall have fungus protection, involving special treatment of insulation and metal against fungus, insects & corrosion. Screens of corrosion resistant material shall be furnished on all ventilating louvers to prevent the entrance of insects. PAINTING All metal 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 switchgear shall be finished in light gray (Shade # 631 of IS:5) with two coats of synthetic enamel paint. Sufficient quantity of touch-up paint shall be furnished for application at site. ACCESSORIES The following accessories shall be furnished along with the PMCC : 5.00.00 Breaker lifting and handling truck (if required) Device for slow opening and closing of breaker (if required) Test cabinet with coupling cables for testing the breaker in drawout position (if required) Breaker racking in/out handle (if required) Fuse puller

TESTS All equipment shall be completely assembled, wired, adjusted and tested at the factory as per relevant standards.

5.01.00

ROUTINE TEST The tests shall include but not necessarily limited to the following : Operation under simulated service condition to ensure accuracy of wiring, correctness of scheme and proper function of the equipment. All wiring and current carrying part shall be given appropriate High Voltage Test. Primary currents and voltage shall be applied to all instrument transformers. Routine test shall be carried out on all equipment, such as circuit breakers, capacitors, switches, fuses, meters etc.

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5.02.00

TYPE TEST The certificate of following tests on panels having similar design shall be furnished for owner's approval : Temperature rise Test Short circuit Test

5.03.00

TEST WITNESS All factory test shall be performed in presence of TPI agency / Owner's representatives, as 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.

5.04.00

TEST CERTIFICATES Certified reports of all the tests carried out at the works shall be furnished in three (3) copies for approval of the Owner. The equipment shall be dispatched from works only after receipt of Owner's written approval of the test reports. Type test certificate of each equipment and bought out items, if so desired by the Owner, shall be furnished. Otherwise the equipment shall have to be type tested, free of charge, to prove the design.

6.00.00 6.01.00 6.02.00 7.00.00

SPECIAL TOOLS & TACKLES A set of special tools & tackles, which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment shall be supplied. The tools shall be shipped in separate containers, clearly marked with the name of the equipment for which they are intended. SPARES The bidder shall submit a list of recommended spare parts for three (3) years satisfactory & trouble free operation, indicating the itemized price of each item of the spares.

8.00.00

DRAWINGS, DATA & MANUALS Drawings, Data & Manuals shall be submitted in triplicate with the bid and in quantities and procedures as specified in General Condition of Contract and/or elsewhere in this specification for approval and subsequent distribution after the issue of Letter of Intent.

8.01.00

To be submitted with the bid a) b) c) d) e) f) g) General arrangement drawing showing constructional features, space required in front for withdrawals, power & control cable entry points etc. Single Line Diagrams, Bill of Materials Typical foundation plan Typical breaker control schematic, motor control schematic Matching flange & terminals for busduct termination Type test reports on panel boards Technical leaflets on i. Circuit breaker ii. Instrument transformers iii. Relays, meters, switches etc.

8.02.00

To be submitted for Approval & Distribution a) Outline dimensional drawing for the switchgear showing general arrangement, space

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requirements and busduct / cable entry points b) Cross-section with parts list c) Detailed Calculation for busbar sizing

d) Foundation plan & loading e) Single line diagram f) Control schematics

g) Wiring diagrams h) Consolidated bill of materials 8.03.00 Instruction Manuals of Switchgear & Individual Equipment. The manual shall clearly indicate the installation method, check-up and tests to be carried out before commissioning of the equipment. The Bidder may note that the drawings, data and manuals listed herein, are minimum requirements only. The Bidder shall ensure that the other necessary write-ups, curves etc.

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ANNEXURE-I RATINGS & REQUIREMENTS 1.0. 1.1 PMCC / DBS General Type Service Enclosure 1.2 System Voltage Phase Frequency Combined voltage & frequency Variation System 1.3 Rated Current at 40 Deg.C Bus bar Circuit breaker Switches 1.4 Short Circuit Rating Interrupting Short Time for 1 Second 1.5 1.6 Insulation Level A.C./D.C. Power Supply Control Voltage for Circuit Breaker Control Voltage for MCC Modules Service Voltage : : : 110V, 1 , 50 Hz + 5% A.C. 110V, 1 , 50 Hz + 5% A.C. 240V + 10%, 1 , 50 Hz + 5% A.C. : : : 50 KA 50 KA 2.5 KV for 1 min. : : : As per SLD As per SLD As per SLD : : : : : 415 Volt + 10% 3 50 Hz + 5 % 10% absolute Solidly grounded : : : Metal-clad, fixed type Indoor IP-54

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2.0 2.1 2.2

CIRCUIT BREAKER (Motor spring charging type) Duty Cycle Breaking Current A.C. Symmetrical A.C. Asymmetrical : : : 50 KA 50 KA 2.1 x 50 KA Peak : 0-3' -CO-3' -CO

2.3 2.4

Making Current Auxiliary Voltage Closing Tripping

: : :

110V A.C. (85 - 110%) 110V A.C (70 - 110%) Class III Category AC3 for unidirectional drives and AC4 for bi-directional and inching duty drives.

2.5

Contractor Duty

2.5

Switch Duty Motor Feeder Other Feeder : : AC23 AC22

3.0

CAPACITOR CONTROL General

3.1 3.2 3.3 3.4 3.5 3.6

Mode of Control Service Enclosure Type Rated Output Proposed PF

: : : : : :

Both manual & automatic Indoor IP-54 Hermetically sealed As per SLD 0.95 lag

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ANNEXURE-II
PROTECTION

1.0

The minimum protections to be provided for different types of circuits are listed below : a) Incoming Feeder with ACB : 3-O/C relay with highset instantaneous unit (50/51 : CDG61) with 1-Inverse time O/C relay (51N : CDG11) for Earth fault 2-Inverse time O/C relays (51: CDG31) for phase fault. 1-Inverse time O/C relay (51N : CDG11) for Earth fault. All inverse time O/C relay shall be 1.3 sec version.

b)

Outgoing Feeder with ACB

2.0

Apart from protection relays, each breaker shall be provided with anti pumping (94 : VAA11), trip annunciation (30 : VAA33), lockout (86 : VAJH13) and trip supervision (74 : VAX31) relays. Lockout relay shall be hand reset type. 3 nos. under voltage relays (27 : VAGM22) and their auxiliary relays (27x : VAA33) along with one timer (1-10 sec.) shall be provided for each incomer panel. Preferred make of protective relays shall be EE. For detail, please refer schematics attached along with this tender document.

3.0 4.0 4.0

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ANNEXURE-III
TECHNICAL PARTICULARS

A. 1.0 1.1 1.2 1.3 1.4 1.5 1.6

PMCC PMCC ASSEMBLY Make Type Reference Standard Voltage (Nom./Max.) Phase, Frequency Short Circuit Rating a) b) Interrupting Symmetrical Short-time for 1 Sec. KV No., Hz : : : : :

KA rms. KA rms.

: :

1.7

Insulation Level 1-min. 50 Hz Voltage Withstand KV rms. Yes/No : : : mm : :

1.8 1.9 1.10 1.11 2.0 2.1

Metal-enclosed Construction ? Degree of Protection Minimum thickness of Sheet metal used

PMCC completely assembled, Wired & tested at factory Yes/No CONSTRUCTION Drawout features provided for a) Circuit breaker with SERVICE, TEST & ISOLATED position

Yes/No

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b) c) c) 2.2

Voltage Transformer Protective Relays Switch-fuse units

Yes/No Yes/No Yes/No

: : :

Breaker Cubicle a) Breaker cubicles Restricted to bottom Two tiers only

Yes/No

b)

Cubicle door can be Closed with Breaker in ISOLATED position Yes/No Working height limits from floor level mm

: :

c) 2.3

MCC Module a) b) c) Completely compartmentalized ? : Working height limit From floor level mm :

Control compartment provided With individual front access Door ? Yes/No

2.4

Switchgear/MCC Section provided with a) b) Removable back cover ? Full height cable chamber ? : :

2.5

Horizontal wire ways for interPanel wiring provided for each MCC ? Yes/No All meter, switch and relays Flush mounted type Yes/No

: :

2.6 2.7

Minimum clear space required at a) b) Front for breaker Withdrawal Rear mm mm : :

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2.8

Vertical Section for a) b) Overall Dimension (L x B x H) Approximate Weight mm Kg

: : :

Incomer/Tie

Feeder/Motor

3.0 3.1 3.2 3.3 3.4

BUSBAR Make Material & Grade Reference, Standard Cross Sectional area a) b) Main Busbar (PH/N) Vertical Busbar (PH/N) Sq.mm : : : : :

3.5

Continuous current (at site Condition, 40 Deg.C Ambient and within cubicle) a) b) Main Busbar Vertical Busbar (minimum) Amp Amp : :

3.6 3.7 3.8

Max. temp. rise over 40 Deg.C Short-time current for 1 sec.

Deg.C KA rms.

: :

Separate enclosure/phase Barriers/shrouding provided for : a) b) c) Main busbar Vertical droppers ACB connections : : :

3.9

Bus Connections a) b) Silver plate Made with anti-oxide grease : :

3.10

Minimum clearance of bare busbar and connection

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a) b) 3.11 3.12 3.13

Phase to phase Phase to ground

mm mm mm

: : : :

Busbar support spicing Busbars colour coded Bus Support Insulator a) b) c) d) e) f) g) Make Type Reference Standard Voltage class Minimum Creepage Distance Cantilever Strength Net Weight

: : : KV mm : :

Kg/Sq.mm : Kg :

4.0 4.1 4.2 4.3 4.4 4.5 4.6 4.7

CURCUIT BREAKER Make Type Reference Standard Rated Voltage Rated Frequency No. of Poles Rated Currents a) Continuous (at site condition, 40 Deg.C ambient & within cubicle) Short-time Current for 1 second KV Hz No. : : : : : :

Amp. KA rms. Deg.C

: : :

b) 4.8

Max. temp. rise over 40 Deg.C ambient

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4.9 4.10

Rated Operating Duty Interrupting Capacity at rated Voltage and Operating duty a) b) Symmetrical Asymmetrical KA rms. KA rms.

: :

4.11 4.12

Rated Making Current Transient Recovery Voltage a) b) Rate of Rise Peak Voltage

KA peak :

KV/ms KV

: :

4.13

Insulation Level 1-minute 50 Hz voltage withstand KV rms. :

4.14

At 100% interrupting capacity a) b) c) Opening time Arcing time Total tripping time ms. ms. ms. ms. : : : : : mm mm : :

4.15 4.16 4.17 4.18 4.19

Total closing time Number of breaks per pole Total length of breaks Per pole Total length of contact Travel Rate of Contact Travel a) b) at tripping at closing

m/s m/s

: :

4.20

No. of breaker operations permissible without requiring inspection, replacement of contacts and other main parts :

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a) c) 4.21

at 100% rated current at 100% rated interrupting current

: :

Type of Contacts a) b) Main Arcing : :

4.22

Material of Contacts a) b) c) d) Main Arcing Whether contacts are silver plated Thickness of silver plating Kg : : : : :

4.23 4.24

Contact Pressure at no load Minimum clearance in air a) b) Between poles Between live parts & ground

mm mm

: : :

4.25 4.26

Type of arc control device ? Operating Mechanism a) b) c) c) Type No. of breaker Operations stored Trip free or fixed trip? Anti-pumping features Provided ?

: : : :

4.27 Spring Charging Motor a) b) d) Rating Voltage Permissible Voltage KW V : :

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variation 4.28 Closing Coil a) b) c) Voltage Permissible Voltage variation Closing current at rated voltage

V % A

: : :

4.29 Tripping Coil a) b) d) 4.30 Voltage Permissible Voltage variation Trip current at rated voltage V % A : : :

For trip circuit supervision can the tripping coil be connected in series with : a) b) Green lamps when breaker is open Red lamps when breaker is closed : :

4.31

Breaker/Cubicle Accessories Accessories such as control switch, indication lamps, relays furnished as specified a) b) c) d) f) g) h) Mechanical safety interlock Automatic safety shutter Emergency manual trip Manual spring charging device Operation counter Charge/Discharge indication Cell switch with 4 No + 4 NC contacts

: : : : : : : :

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i)

Spare auxiliary switch with 6 No + 6 NC contacts for interlock mounted on stationary parts as specified

4.32

Cell/Auxiliary Switch a) b) Are switch contacts Convertible type ? Contact rating 240V AC i) Make & Continuous Amp Amp Kg : : : :

ii) Break (Inductive) 4.33 4.34 Net weight of the breaker

Impact load for foundation design (to include dead-load plus impact values on opening at maximum interrupting rating)Kg Overall Dimension (L x B x H) Type test report on identical Breaker furnished SWITCHGEAR/MCC MODULE a) b) Fully drawout for Switchgear Yes/No mm

: : :

4.35 4.36 5.0 5.1

: : :

Full drawout for MCCs Yes/No

5.2 5.3

Power/Control disconnectors silver Plated for good contact Drawout modules of same type and rating are physically & electrically interchangeable SWITCHES/CHANGE OVER SWITCHES Make Type Reference Standard

6.0 6.1 6.2 6.3

: : :

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6.4

Switch furnished with a) b) a) Operating handle Door interlock Provision for padlocking in ON & OFF positions : : : : FUSE : : : KA rms (sym) : MCCB MCB

6.5 7.0 7.1 7.2 7.3 7.4 7.5

All feeders provided with bolted disconnect link FUSE/MCCB/MCB Make Type Reference standard Rupturing capacity Continuous current at 50 Deg.C ambient & within cubicle Cut off currents Fuse characteristics furnished for various fuse ratings CONTACTORS Make Type Reference standard Duty class Utilization category Operating Coil voltage a) b) c) Rated Pick-up Drop-out

Amps

7.6 7.7

KA peak :

8.0 8.1 8.2 8.3 8.4 8.5 8.6

: : : : : : : : :

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8.7 8.8

Continuous Current rating At 50 Deg.C & within cubicle Power Consumption a) b) During closing After closing

VA VA

: :

8.9

Auxiliary Contacts furnished per Contactor : a) b) Normally open (NO) Normally closed (NC) Nos Nos : :

8.10

Auxiliary Contact rating a) c) Make & Continuous Break (Inductive) at : 240 V A C. 110 V D. C. Amp Amp : : Amp :

8.11

Time range of delayed dropout contactors furnished

Sec.

9.0

THERMAL OVERLOAD RELAY a) b) c) d) b) c) Temperature compensated ? Provided with built in single phasing preventer ? No. & type of contacts Thermal overload characteristics furnished Provided with both Auto-Manual mode of resetting facility Tolerance on current injection 1-pole 2-pole 3-pole : : : : : : : :

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10.0 10.1

CONTROL & INDICATIONS Push Buttons a) b) c) Make Type & Cat. No. Contact rating i) Make & Continuous Amp Amp : : : : : 240V AC

ii) Break (Inductive) 10.2 Lamps a) b) c) d) d) 10.3 Make Type & Cat. No. Watts/Voltage

: : : : :

Series resistance in Ohm Lamp & Lens replaceable from front

Selector Switch a) b) c) d) Make Type & Cat. No. 3-position stayput type Contact rating i) Make & Continuous Amp Amp : : : : : : : 240V AC

ii) Break (indicative) e) 11.0 11.1 11.2 11.3 11.4

Key interlock furnished ?

CURRENT TRANSFORMER Make Type Reference Standard C. T. Ratios as per : : :

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drawings ? 11.5 11.6 Rated frequency Class/ALF or ISF/VA burden furnished for a) b) c) 11.7 Differential relaying CT Protection CT Metering C. T.

: :

: : :

Short-Circuit Withstand a) b) Short-time current for 1 sec. Dynamic current KA rms. :

KA peak : : : : : : : : : Current Voltage Watt

11.8 11.9

Class of Insulation Temp. rise over 50 Deg.C ambient KV rms

11.10 Basic Insulation level 12.0 12.1 12.2 12.3 12.4 13.0 13.1 13.2 13.3 13.4 13.5 13.6 13.7 TRANSDUCER Make Type Reference Standard Range VOLTAGE TRANSFORMER Make Type Reference Standard Voltage ratio Rated frequency Accuracy class VA burden

: : : : : : :

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13.8

Over Voltage factor a) b) Continuous 30 seconds : : : : :

13.9

Class of Insulation

13.10 Temp. rise over 50 Deg.C ambient 13.11 Basic Impulse Level 13.12 Winding Connection a) b) 13.13 Fuses a) b) 14.0 14.1 14.2 14.3 14.4 14.5 Continuous rating Symmetrical fault rating Amp. KA rms. Primary Secondary KVP

: : : : : H.V. L.V.

RELAYS Drawout type with built in test facilities Type of mounting ? Reference Standard All relays furnished as per the catalog furnished ? All relevant relay leaflets and catalog furnished ? : : : : : : Make Type Range

14.6.1 Relays Details Incoming Feeders a) b)

3-IDMTL O/C relay with inst. Set for phase fault 50/51 : 1-IDMTL O/C relay for earth fault 51N :

14.6.2 Miscellaneous relay a) Anti pumping relay 94 :

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a) c) b) c)

Trip supervision relay Time delay relay Under Voltage relay Frequency compensated Auxiliary relay with 4 pairs of contacts 110V AC Hand reset 110V DC Self reset 240V AC Self reset

74 2/62 27

: : :

86 ..X ..Y

: : : :

f) 15.0 15.1 15.2 15.3 15.4 15.5 15.6 15.7

High speed syn-check relay 25

METERS Make Type Reference Standard Size Scale Accuracy class Meter Switch a) b) c) Make Type Cat. No. : : : : : : : : :

16.0 16.1 16.2 16.3 16.4

SECONDARY WIRING Type of Insulation Voltage grade Conductor material Conductor Size (Minimum) : : :

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a) b) 16.5 17.0 17.1 17.2 17.3 17.4 17.5

Potential Circuit Control & Current Circuit

: : :

Wires identified at both ends with markers TERMINAL BLOCK Make Type Cat. No. Voltage grade 20% spare terminals furnished CABLE TERMINATION Cable termination / connection furnished as specified Cable termination kit a) b) c) Make Type Complete with all accessories

: : : : :

18.0 18.1 18.2

: : :

18.3

Cable Lugs a) b) Type Material : :

18.4

Cable Gland a) b) c) d) Type Material With tapered washer With armour clamp : : : :

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18.5

Removable Gland Plate a) b) c) Material for multi core cable Material for I/C cable Thickness of the plate : : :

19.0 19.1

BUSDUCT CONNECTION Busduct connection suitable for a) b) Top entry Side entry Yes/No Yes/No Yes/No : : :

19.2 20.0 20.1 20.2 20.3 21.0 21.1 21.2 21.3

Busduct connection as Per drawing furnished GROUND BUS Ground bus furnished Material Size NAME PLATE Material Thickness Size for : a) b) c) Panel Equipment/Device Letter height

: : :

: :

: : :

22.0 22.1

SPACE HEATER/PLUG SOCKET Cubicle Heater a) b) c) Thermostat controlled Wattage Voltage : : :

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22.2

Plug Socket a) b) Type Rating : :

22.3

Motor Heater a) b) c) Provision made for motor heater supply Separate contactor furnished If so, contactor rating : : :

22.4

Cubicle heater, motor heater & plug socket circuit provided with individual switch fuse unit ? A.C./D.C. .SUPPLY Isolating switches fuse unit for incoming supply : a) A.C. - type & rating

23.0 23.1

23.2

Isolating switch fuse unit at each cubicle : a) A.C. - type & rating :

24.0 24.1 24.2 25.0 25.1

TROPICAL PROTECTION Any special treatment for tropical protection Screems are of corrosion resistant materials PAINTING Finish of switchgear a) b) Inside Outside : : : :

26.0 26.1

NO. OF ACCESSORIES FURNISHED Breaker lifting/handling turck :

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26.2 26.3

Device for slow opening & closing of breaker Test cabinet with coupling cables for testing the breaker Racking in/out handle Fuse puller TESTS Routine tests to be performed on Switchgear a) b) c)

: : :

26.4 26.5 27.0 27.1

27.2

Type tests : a) b) c)

28.0

DRAWINGS/DATA Typical drawings furnished for :

28.1 28.2 28.3 28.4 28.4

General Arrangement Foundation Plan Breaker Control Schematic Motor Control Schematic Bill of Material

: : : : :

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Technical Specification for HT & LT Power & Control Cable

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1.00.00 1.01.00 1.02.00 1.03.00 1.04.00 1.05.00 1.06.00 1.07.00 1.08.00 1.09.00

GENERAL REQUIREMENT The cables will be used for connection of power, control and instrumentation circuits of the auxiliary electrical systems. Cables are to be suitable for transmission of signals and measuring values, which require protection against disturbances caused by stray fields. Cables will be generally laid in ladder type trays or, drawn through rigid steel conduits. For interplant connection cables may be directly buried in ground The insulation and sheath materials shall be resistant to oil, acid and alkali and shall be tough enough to withstand mechanical stresses during handling. For continuous operation at specified rating, maximum conductor temperature shall be limited to permissible value as per relevant standard and / or this specification. The outer sheath have flame retardant low smoke (FRLS) characteristics, which shall meet the requirements of additional tests specified for that purpose. Armouring shall be single round wire of galvanised steel for multicore cables and aluminium for single core cables. Core identification for multicore cables shall be provided by colour coding. Multicore control cables shall generally have commissioning spare cores in accordance with the following chart when used for control and indication, interlock and annunciation purpose: Conductors Required 1 or 2 3 or 4 5 or 6 7 or 8 9 or 10 11, 12 or 13 14 to 18 Above 19 core The spare cores of control cables shall be earthed. Cables 1-3/C 1-5/C 1-7/C 1-9/C 1-12/C 1-16/C 1-20/C 2 or more of above cables

2.00.00 2.01.00

SPECIFIC REQUIREMENT HV Power Cable The HT cable shall be designed, manufactured and tested in accordance with IS: 7098, IS: 8130, IS: 5831, IS: 3975. The cable shall be 6.6KV/ 6.6KV grade, 90 Deg.C rating heavy duty XLPE power cable suitable for use in 6.6KV non-effectively earthed system. Conductor : Stranded and compacter electrical conductor grade. Aluminium of grade H2 and class 2 for all sizes.

Conductor Screen: Extruded semiconducting compound. Insulation : Extruded cross-linked polyethylene.

Insulation Screen: Extruded semi-conducting compound with a layer of non-magnetic metallic tape. For single core armoured cable, the armouring shall constitute the metallic part of screening. Core Identification : By coloured strips applied on cores or by numbers.

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(for 3-core cable) Inner Sheath: Armour : Extruded PVC Compound conforming to type ST2 for three core cables. Single core cables shall have no inner sheath. Galvanised single round steel wire armour for three core cables. Nonmagnetic hard-drawn aluminium single round wire conforming to H4 grade for single core cable. Extruded FRLS PVC compound conforming to ST2.

Overall sheath: 2.02.00 LV Power Cable

The LT Power cable shall be designed, manufactured and tested in accordance with IS: 7098, IS: 8130, IS: 5831, IS: 3975. The cable shall be 1.1KV grade, 90 Deg.C rating heavy duty XLPE power cable. Conductor : Stranded and compacter electrical conductor grade. Aluminium of grade H2 and class 2 for all sizes.

Conductor Screen: Extruded semiconducting compound. Insulation : Extruded cross-linked polyethylene.

Insulation Screen: Extruded semi-conducting compound with a layer of non-magnetic metallic tape. For single core armoured cable, the armouring shall constitute the metallic part of screening. Core Identification : By coloured strips applied on cores or by numbers. Inner Sheath: Armour : Extruded PVC Compound conforming to type ST2 for three core cables. Single core cables shall have no inner sheath. Galvanised single round steel wire armour for three core cables. Nonmagnetic hard-drawn aluminium single round wire conforming to H4 grade for single core cable. Extruded FRLS PVC compound conforming to ST2.

Overall sheath: 2.03.00 LV Control Cable

The LT control cable shall be designed, manufactured and tested in accordance with IS: 1554, IS: 8130, IS: 5831, IS: 3975. The cable shall be 1100 V grade, 70 Deg.C rating ordinary PVC control cable. Conductor : Insulation : Inner Sheath: Armour : Stranded, non-compacted and circular, class 2 high conductivity untinned anneled copper. Extruded PVC Compound conforming to type A. Extruded PVC Compound conforming to type ST1 for three core cables. Single core cables shall have no inner sheath. Galvanised single round steel wire armour for three core cables. Nonmagnetic hard-drawn aluminium single round wire conforming to H4 grade for single core cable. Extruded FRLS PVC compound conforming to ST1.

Overall sheath: 2.04.00

Drum Length & Tolerance Where cables are supplied in wooden drums, each containing minimum 500 meters length of

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cable, the allowable tolerance on individual drum length is 5% & allowable tolerance of 2.5% on overall length of single size and type. Owner may accept non-standard lengths at his own discretion. 2.05.00 Cable Identification Cable identification shall be provided by embossing on the outer sheath the following: i) ii) iii) iv) v) vi) vii) 3.00.00 3.01.00 TESTS Type Tests Type test certificates for type tests, as stipulated in Indian Standard carried out on cable of identical type and rating shall be furnished by the Tenderer along with his offer. 3.02.00 Shop Tests The cables shall be subject to shop tests in accordance with relevant standards to prove the design and general qualities of the cables as below:i) ii) Routine test on each drum of cables. Acceptance tests on drums chosen at random for acceptance of the lot. Manufacturers name or trademark Voltage grade Year of manufacture Type of insulation, e.g. HR85 for HRPVC etc. Type of outer sheath e.g. FRLS etc. ISI mark Owners identification e.g. IOCL etc.

iii) Type tests on each type of cable, inclusive of measurement of armour D.C. resistance of power cables. 3.03.00 Additional Tests To prove the FRLS characteristics, each type of cable shall also be subject to the following additional type tests at works:i) Oxygen index test as per ASTM D 2863. Minimum value of oxygen index shall be 30.

ii) Flammability tests on finished cable as per requirement of IEEE-383, IEC 332-3, Category-C and Swedish standard SS 4241475 clause F3. iii) Smoke generation by outer sheath under fire as per ASTM D 2843.The cable shall meet the requirement of light transmission of minimum 40% after the test. The minimum value of temperature index shall be 250 Deg.C. iv) Acid gas generation by outer sheath under fire as per IEC-754-1 and the maximum acid gas generation shall be less than 20% by weight. 3.04.00 Test Witness Tests shall be witnessed TPI or, Owner's representatives at the manufacturer's premises. The Contractor shall give at least fifteen (15) days advance notice of the test when the tests are to be carried out. 3.05.00 Test Certificates Certified reports of all the tests carried out at the works shall be furnished in three (3) copies

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for approval of Owner. Test reports shall be completed with all details and shall also contain IS specified limit values, wherever applicable, to facilitate review. The cables shall be despatched from works only after receipt of Owner's written approval of the test reports. 4.00.00 DRAWINGS, DATA AND MANUALS Drawings, Data and Manuals shall be submitted in triplicate with the bid and in quantities and procedures as specified in General Conditions of Contract and/or elsewhere in this specification for approval and subsequent distribution after the issue of Letter of Intent. 4.01.00 To be submitted with the Bid : i) Manufacturer's catalogues giving cable construction details and characteristics.

ii) Cable current ratings for different types of installation, inclusive of derating factors for ambient temperature, grouping, etc. iii) Write-up on Manufacturer's recommended method of splicing, jointing, termination, etc. of the cables. iv) Type test report on H.V. power cable. v) Proposal data as per Annexure. 4.02.00 To be furnished for approval and distribution : i) ii) iii) Confirmed cable data. Type test certificates. Shop test reports.

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ANNEXURE-I TECHNICAL PARTICULARS OF HT AND LT. CABLES 1.00.00 1.01.00 1.02.00 1.03.00 1.04.00 1.04.01 1.04.02 1.04.03 1.04.04 1.05.00 1.05.01 1.05.02 1.06.00 1.06.01 1.06.02 1.06.03 1.06.04 1.07.00 1.07.01 1.07.02 1.07.03 1.08.00 1.08.01 1.08.02 1.09.00 1.09.01 1.09.02 H.T. CABLES Name of the Manufacturer Type Applicable Standard Voltage Class: Rated system voltage/ Maximum system voltage Voltage grade of the cable Type of system earthing Rated voltage between two KV conductors Maximum Conductor Temperature Continuous Short time Conductor Material Cross sectional area sq.mm : : : : C C KV/KV KV : : : : : : : : : :

No. & diameter of wire in No./mm each conductor No. of conductors in the cable Shielding on Conductor Material Type Thickness Insulation Material Thickness Shielding of Insulation Material Type mm mm

: : :

: :

: :

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1.09.03 1.10.00 1.10.01 1.10.02 1.10.03 1.11.00 1.11.01 1.11.02 1.12.00 1.12.01 1.12.02 1.13.00 1.14.00 1.15.00 1.16.00 1.16.01 1.16.02 1.16.03 1.17.00 1.17.01 1.17.02 1.17.03 1.17.04 1.17.05 1.18.00 1.18.01 1.18.02 1.18.03 1.19.0

Thickness Inner Sheath Material/Type Thickness Approx. outside diameter over sheath Armouring Material Size (diameter) Overall Sheath Material Thickness

mm

: mm mm : :

: mm : : : mm : : : : : Amps.: Amps. Amps. : :

Approximate overall diameter Standard drum length Net weight of cable meter Kg/Km

Continuous current rating for standard condition laid direct In ground In duct In air Short circuit current for : 0.1 second 0.2 second 0.5 second 1.0 second 2.0 second KA KA KA KA KA

: : : : :

Electrical parameters at maximum operating temperature Resistance Reactance at 50 Hz Impedance Ohm/Km : Ohm/Km : Ohm/Km : :

Recommended minimum bending radius (times overall diameter)

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1.20.0 1.20.01 1.20.02 1.20.03 1.20.04 1.20.05 1.21.0

Derating factor for following ambient temperature in air ground At 30C At 35C At 40C At 45C At 50C Group factor for following Nos. of: cables laid 2 x diameter center to center apart/touching each others 3 Nos. 4 Nos. 5 Nos. 6 Nos. Impulse withstand voltage between each peak conductor and screen (1.2/50 sec. wave) KV : : : : : : : : : :

1.21.01 1.21.02 1.21.03 1.21.04 1.22.00

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ANNEXURE-I 2.00.00 2.01.00 2.02.00 2.03.00 2.04.00 2.04.01 2.04.02 2.04.03 2.04.05 2.05.00 2.05.01 2.05.02 2.06.00 2.06.01 2.06.02 2.06.03 2.06.04 2.07.00 2.07.01 2.07.02 2.08.00 2.08.01 2.08.02 2.08.03 2.09.00 2.09.01 2.09.02 2.09.00 L.T. CABLES Name of the Manufacturer Type Applicable Standard Voltage Class: Rated system voltage/ Maximum system voltage Voltage grade of the cable Type of system earthing Rated voltage between two KV conductors Maximum Conductor Temperature Continuous Short time Conductor Material Cross sectional area No. & diameter of wire in each conductor sq.mm : : C C KV/KV KV : : : : : : : : : :

No./mm : :

No. of conductors in the cable Insulation Material Thickness Inner Sheath Material/Type Thickness Approx. outside diameter over sheath Armouring Material Size (diameter) Overall Sheath mm mm mm mm

: :

: : :

: : :

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2.09.01 2.09.02 2.10.00 2.11.00 2.12.00 2.13.00 2.13.01 2.13.02 2.13.03 2.14.00 2.14.01 2.14.02 2.14.03 2.14.04 2.14.05 2.15.00 2.15.01 2.15.02 2.15.03 2.16.00 2.17.00 2.17.01 2.17.02 2.17.03 2.17.04 2.18.05 2.19.00

Material /Type Thickness Approximate overall diameter Standard drum length Net weight of cable mm mm meter Kg/Km

: : : : : : : : :

Continuous current rating for standard condition laid direct In ground In duct In air Short circuit current for : 0.1 second 0.2 second 0.5 second 1.0 second 2.0 second KA KA KA KA KA Amps. Amps. Amps.

: : : : :

Electrical parameters at maximum operating temperature Resistance Reactance at 50 Hz Impedance Ohm/Km : Ohm/Km : Ohm/Km: :

Recommended minimum bending radius (times overall diameter) Derating factor for following ambient temperature in air ground At 30C At 35C At 40C At 45C At 50C

: : : : :

Group factor for following Nos. of cables: laid 2 x diameter center to center apart/touching each others 3 Nos. :

2.19.01

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2.19.02 2.19.03 2.19.04

4 Nos. 5 Nos. 6 Nos.

: : :

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Technical Specification for Electrical Erection

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1.00.00 1.01.00 1.01.01

SCOPE OF WORK Scope of Supply The work involves timely procurement and transportation to site in properly packed condition of all materials and miscellaneous items required to complete the erection, cabling and grounding work. The quantum of each item shall be as indicated elsewhere in this document. These materials and miscellaneous items shall include but will not be limited to the followings : a) Site fabricated cable trays and supports painted with two coats of primer followed by two coats of epoxy-based paints of approved shade. b) Galvanised steel rigid/flexible conduits and accessories, ferrules, lugs, glands, terminal blocks, galvanised sheet steel/Aluminium junction boxes, cuble fixing clamps, nuts & bolts etc. as required. c) Cable termination and jointing kits as necessary.

1.01.02

d) GI wires and galvanised steel flats as required for grounding. e) Fire seals for cable penetration and fire retardant coating. f) The scope of supply shall include but will not be limited to all necessary erection materials, consumables and sundry items to complete the installation for satisfactory and troublefree operation. Any material or, accessory, which may not have been specifically mentioned nut which is usual and / or necessary shall be supplied free of cost to the Purchaser.

1.01.03 1.01.04 1.02.00

All materials and accessories to be supplied by the Bidder shall be brand new ones of reputed make. Data sheets and Technical leaflets on each piece of material. Scope of Services The work includes but is not limited to the followings :

1.02.01

Supply of all labour (skilled, semi-skilled and unskilled), supervisory and administrative personnel, all erection tools including crane, trailer, trucks, filter machine, vacuum pump, welding machine, testing equipment as mentioned elsewhere in this specification etc. Broadly the work shall include receipt and unloading from transporters vehicle, storage and safe custody at the Contractor/Owner's store, transportation from Contractor/Owner's store to erection site, unpacking and carrying out inspection, erection as per drawings/Owner's instructions, testing and commissioning of all electrical equipments and accessories related to the plant. The items of cabling and grounding work shall be performed with respect to the following equipment/materials. a) Power, Control, instrument and special cables to be laid on cable trays/laid directly buried in ground/laid in embedded conduits as per the respective cable tray layout drawings and cable schedule. b) Entire cable tray and cable shaft arrangements inside Plant. c) Fabrication, erection and painting of cable trays, cable shaft, supports, brackets and accessories.

1.02.02

1.02.03

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d) Excavation of earth, providing sand both below and above cables, placing protective concrete slabs, back filling, compaction, providing cable route markers and joint markers, removal of excess earth to a location allocated by owner and pumping out of accumulated water within excavation. e) For fixing of cable tray in concrete, insert plates will be provided in most of the places. In the event of non-availability of insert plates. The same shall be fabricated and fixed to concrete by "HILTE" gun by the Contractor for further fixing and routing of cable trays. f) Grounding of all equipment, cable tray and cabling system to be installed by Contractor.

g) Filling of sand in trenches in specified areas shown in the drawing. h) Providing assistance to the Owner while Testing & Commissioning of H.T./L.T. Motors installed by others (at the option of the Owner). 1.02.04 The Bidder shall also carry out the following services which shall include but will not be limited to : a) Receipt and unloading the equipment/cable from transporter's vehicle. b) Storage and safe custody of equipment at the Contractor/Owner's store or, under protective custody of the Contractor with all weather protection and requisite watch at the erection site. c) Safe transportation of the equipment and materials from Contractor/Owner's store upto the site of erection and of the excess materials back to the Owner's store.

d) Opening of Packing Cases and inspecting the equipment and materials at site and reporting damages, if any observed immediately after opening, to the Owner. e) Proper storing arrangement at Plant Site with suitable enclosure for weather protection. f) Repair of all minor damages such as removal of paint, loosening of components of the assembly etc.

g) Taking delivery of cables and other materials from the Owner's stores (if any) and safe transportation up to the place of erection. h) Reconciliation of cables and other free issue items whenever desired by the Owner. i) j) Returning to Owner's stores unused material after final reconciliation on completion of the job. Dewatering of cable trenches and excavations for laying of buried cables.

k) Installations of temporary light for installation and commissioning of equipment. l) Assemblies, Erection and complete Installation.

m) Checking of foundation/inserts with reference to the erection drawings and their rectification. If necessary. n) Necessary co-ordination between work done by other contractors(if any). o) Pre-commissioning check up manufacturers instructions. to ensure correctness of erection as per actual

p) Final check-up, testing and commissioning in presence of Owner's representative. q) Obtaining approval of electrical inspector.

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r) s) t)

Trial run for seven (7) days, rectification of defects, if any and adjustments as necessary. Rerolling of cables on new drums if so required by the Engineer. Obtaining Engineer's performance. approval and Owner's written acceptance of satisfactory

u) Handing over of installation for commercial operations. v) If the contractor fails to carry out any of the above-mentioned work within the due time, the owner will have full liberty to get the work carried out by any other agency and the actual cost will be deducted from the contractor. 1.02.05 1.03.00 1.03.01 Field modification carried out shall be marked-up in red on one (1) set of erection drawings and submission of "AS BUILT" drawings. Key Information The Contractor shall be given reasonable space depending upon the availability of same for Storage/Fabrication within site to construct stores etc. A small place for office may be given to him at site for office work subject to availability of Space. The Contractor shall have to construct his own office building/storage shed. The Contractor should mobilise the resources at site considering the project schedule after considering the period required by him for establishing site office, shed etc. so as to enable him to start the work accordingly. The Contractor should also plan to erect trays, supports, cable laying etc. to commission the pant as per project schedule. The date of handing-over to the Purchaser shall be considered as the date of completion of all work at site duly certified by the Purchaser and the date on which the Contractor vacates the site after clearing all the temporary installations done by him for the execution of contract. The Contractor shall have to re-arrange from time to time the schedule of work if needed so as to give priorities to work as informed by the Purchaser in the interest of the whole project. CODES & STANDARDS All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) except where modified and/or supplemented by this specification. Equipment and materials conforming to any other standard which ensures equal or better quality may be accepted. In such case, copies of the English version of the standard adopted shall be submitted along with the bid. The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto data and relevant IS Codes of Practice. In addition, other rules or regulations applicable to the work shall be followed. In case of any discrepancy, the more restrictive rule shall be binding. DESIGN CRITERIA Electrical equipment will be used for power supply for both normal and emergency operation of generating unit. As such all erection work of those equipment shall be carried out in a neat and efficient way so as not to impair their normal functioning in any way.

1.03.02

1.03.03 1.03.04

1.03.05

2.00.00 2.01.00

2.02.00

2.03.00

3.00.00 3.01.00 3.02.00

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3.03.00

The pre-commissioning checks as well as commissioning of different equipment shall be carried out as per guidance of actual manufacturer's supervisor, if available at site or as per written instructions in Erection manuals. In case of any site related problem in commissioning activities, contractor shall seek advise of owner's Engineers. Erection of cabling work shall be carried out in such a way as to provide a reliable and assured electric power supply system to all electrical loads. Erection of grounding system similarly shall ensure an effective and efficient system for quick dissipation of short circuit current to grounding system in case of faults in H.V./L.V. systems thereby ensuring personnel safety and reducing risk of damages to important equipment. Entire erection of grounding work shall be carried out in such a way as to be capable of withstanding the intended services of carrying full short circuit level currents to ground mat without any damage/deformation. Erection of cabling work shall be executed keeping in view all necessities and requirements of fire fighting codes for the Plant. Suitable embedded steel inserts shall be kept on wall/floor/ceiling surfaces for welding of cable tray brackets. The Contractor shall carefully examine those inserts and if necessary shall provide extra anchoring in order to make the cable tray system withstand horizontal/vertical accelerations due to seismic forces for indoor trays and also wind load for outdoor trays in addition to normal cable loadings of the trays. The assistance to testing and commissioning of HT/LT motors shall be provided as per the directives of the Motor Manufacturer. SPECIFIC REQUIREMENT - SUPPLY Equipment and materials furnished shall be complete and operative in all details. Equipment and material shall comply with description, rating, type and size as detailed in this specification, drawings and annexure. All accessories, fittings, supports, anchor bolts etc. which form part of the equipment or which are necessary for safe and satisfactory installation and operation of the equipment shall be furnished. After the treatment of steel surface damaged during transit, sufficient quantity of anticorrosive paint shall be applied and subsequently finished with two coats of final paint of approved shade.

3.04.00 3.05.00

3.06.00

3.07.00 3.08.00

3.09.00

4.00.00

4.01.00 4.01.01 4.01.02 4.01.03 4.01.04 4.02.00 4.02.01

Cable Trays & Cable Tray Supports Cable trays shall be site fabricated from steel sections in line with drawings enclosed with this specification. Fabricated trays and supports shall be free from all burrs and sharp cutting edges. Trays and supports shall be made free of scale, grease, rust and welding slags. Trays and supports shall be provided with two coats high quality primer and two coats of epoxy based paint. Conduits and Accessories Conduits shall be of rigid steel, hot-dip galvanised, furnished in standard length of 3 metres and threaded at both ends.

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4.02.02 4.02.03 4.02.04 4.03.00 4.03.01 4.03.02 4.03.03 4.03.04

Conduit diameter upto and including 25mm size shall be of 16 SWG and conduits above 25 mm diameter shall be of 14 SWG. Minimum diameter of conduits shall be 19mm. Each price of conduit shall be straight, free from blister and other defects, internal surface shall be of smooth finish and covered with capped bushings at both ends. Flexible conduits shall be made with bright, cold rolled, annealed and electro-galvanised mild steel strips coated internally with epoxy or steel wire reinforced PVC. Junction Boxes Junction boxes shall be of 16 SWG sheet or of cast iron and shall be hot dip galvanised, outdoor type, dust and damp proof, generally conforming to IP-55. Junction boxes shall be complete with gasketed inspection cover, conduit knock out/threaded hub and terminal blocks. Junction boxes for outdoor use shall be weather proof IPW-55 and those for hazardous locations shall be flame-proof type. Junction boxes shall be of two types viz one suitable for control wiring and the other with terminals for power cable terminations. Junction boxes for power cable terminations shall have minimum nine (9) nos. of terminals. The junction boxes shall have the following identifiable markings : Circuit nos. on top by white stenciled paint at site. Circuit nos. with ferrules (inside) as per approved drawings. Danger sign in case of 415 V circuit.

4.03.05

4.04.00 4.04.01 4.04.02 4.05.00 4.05.01 4.05.02

Terminals Multiway terminal blocks of approved type, complete with screws, nuts, washers and marking strips shall be furnished for connection of incoming/outgoing wires. Each control cable terminal shall be suitable for connection of 2 nos. 2.5 sq.mm. stranded copper conductors without any damage to the conductor or looseness of conductors. Cable Termination & Jointing Kits The Bidder shall supply cable termination and jointing kits for H.T. Power Cables, L.T. Power and Control Cables along with all accessories (if necessary). The cable termination kits of H.T. cable and straight through joints including necessary boxes, if any, shall be preferably of RAYCHEM make using either heat shrinkable/prefab push-fit type kits. Cable end terminations on H.V. Electrical equipment shall be suitable for Indoor & Outdoor uses, as the case may be. The Bidder, in some cases, may have to carry out modification work/provide extension chamber for Motor cable end boxes in order to make them suitable for termination of cable with termination kit being supplied under this specification. The Contractor shall carry out the necessary modification work with the approval of Engineer at site. For the cable termination and straight through joints for both L.T. Power and control cables, supply of items of jointing kit such as necessary boxes, if any, sealing compounds, ferrules, tapes, lugs, glands shall preferably of reputable make such as Raychem/M-Seal/3 M or equal. Supply of straight through ferrules shall be included in the supply of straight through jointing kits for both HT and LT cables. Cable Glands

4.05.03

4.05.04

4.05.05 4.06.00

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4.06.01

Cable glands shall preferably be tinned brass gland, double compression type complete with necessary armour clamp and tapered washer etc. Cable glands shall match with the sizes of different H.T./L.T./Control cables. Cable Lugs Cable lugs and straight through ferrules shall preferably be tinned copper/aluminium suitable for termination of different cross-sections of H.T./L.T./Control cables. Lugs for power cables shall be compression type whereas lugs for Control/Instrumentation/Signalling cables shall be crimping type. Supply of lugs for end termination of control cables shall be included in the end termination charges. Cable Opening Sealing Compound Sealing compound shall have adequate fire protection rating and shall be 'KBS' fire seal type or approved equivalent suitable for sealing both vertical & horizontal cable penetrations. The sealing compound in conjunction with mineral wool shall form effective fire seals and thickness of coating shall be at least 2 mm. The sealing compound shall have special property to allow for thermal expansion of cables both under normal and short circuit conditions. Cable Coating Cable coating shall be sprayable liquid suitable for spraying on cables and the thickness of coating shall be at least 2 mm. The coating shall be 'Flammastick' type or approved equivalent. Cables shall be suitably coated at least 1M before & after the penetration seals. Cable Clamps Cable clamps fabricated out of 25mm x 3mm aluminium strips sheathed in PVC or preferably self locking type cable clamps/ties of nylon/FRP material of requisite lengths shall be used for clamping of multi core control cable and multi core HT/LT power cables. Trefoil cable clamps (Nylon/FRP) suitable for single core HT/LT cables of size 630/500/185 Sq.mm. shall be used for clamping in trefoil formation at intervals of 1500 mm for horizontal tray and 900 mm for vertical tray. Necessary cable clamping hardwares shall also be supplied for fixing the same to the cable trays. Grounding Wires and Galvanised Steel Flats Specified quantity of 8 SWG GF ground wire and galvanised steel flats shall be supplied. SPECIFIC REQUIREMENTS - SERVICES Responsibility of Erection The Contractor shall be fully and finally responsible for proper erection, safe and satisfactory operation of plant and equipment under his scope of work to the entire satisfaction of the Engineer. The work shall be executed in accordance with the directions, instructions, drawings and specifications which shall be supplied to the Contractor by the Engineer from time to time. If in the opinion of the Contractor any work is insufficiently specified or require modification, the Contractor shall refer the same in writing to the Engineer and obtain his instruction/approval before proceeding with the work. If the Contractor fails to refer such instances, any excuse for the faulty erection, poor workmanship or delay in completion shall not be entertained. Equipment and material which are wrongly installed shall be remoded an re-installed to comply with the design requirement at the Contractor's expense, to the satisfaction of the Engineer.

4.07.00 4.07.01

4.08.00 4.08.01

4.09.00 4.09.01

4.10.00 4.10.01

4.10.02

4.11.00 4.11.01 5.00.00 5.01.00 5.01.01

5.01.02 5.01.03

5.01.04 5.01.05

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5.02.00 5.02.01 5.02.02 5.03.00 5.03.01 5.03.02

Supervision The Engineer shall have the overall responsibility for coordination of Contractor's work and his direction shall be final. Such direction and supervision however shall not relieve the Contractor of his responsibility of correctness and quality of workmanship and of other obligation under the contract. Drawings Drawings and schedules enclosed with this specification are for general guidance of the Bidder to assess the type and volume of work involved. These drawings and schedules will be revised to suit the actual requirement in related systems. Additional drawings and schedules will also be furnished to Contractor if/when necessary. Such revisions, corrections, additions to drawings and schedules shall not be considered to change the scope of work. The Contractor shall mark in red on one (1) set of drawings all deviations/alterations, not shown on drawings but carried out at field. After completion of work the Contractor shall furnish a set of "As Built" drawings to the Owner. Methods and Workmanship All work shall be installed in a first class, near workmanlike manner by mechanics / electricians skilled in the trade involved. The Erection work shall be supervised by competent supervisors holding relevant supervisory license for the Government. All details on installation shall be electrically and mechanically correct. The installation shall be carried out in such a manner as to preserve access to other equipment installed. Protection of Work The Contractor shall effectively protect his work, equipment and materials under his custody from theft, damage or tampering. Finished work where required shall be suitably covered to keep it clean and free from defacement or injury. For protection of his work Contractor shall provide fencing and lighting arrangement, connect up space heaters and provide heating arrangement as necessary or directed by the Engineer. Contractor shall be held responsible for any loss or damage to equipment and material issued to him until the same is taken over by the Owner according to contract. The Contractor shall have to make good all losses/damages to material when in the contractor's custody until taken over formally by the Owner. The Contractor shall insure all his workmen against accidental injury/death. The contractor shall also take out insurance policies which would cover the risk of losses/damage of his tools and tackles and Owner's material/equipment while in his custody. Safety Measures All safety rules and codes as, applicable to work shall be followed without exception.

5.03.03 5.03.04

5.04.00 5.04.01 5.04.02 5.04.03 5.04.04 5.05.00 5.05.01 5.05.02 5.05.03 5.05.04

5.05.05

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5.06.02 5.06.03 5.07.00 5.07.01 5.07.02

All safety appliance and protective devices including belts, hand gloves, aprons, helmets, shields, goggles etc. shall be provided by the Contractor for his personnel. The Contractor shall provide guards and prominently display caution notices if access to any equipment/area is considered unsafe and hazardous. Consumables and Hardware The Contractor shall furnish all erection materials, hardware and consumables required to complete the installation. The materials shall include but will not be limited to the following : a) Consumables : Welding rods & gas, oil and grease, anti-oxide grease, cleaning fluids, paints, electrical tape, soldering materials etc. b) Hardware : Bolts, nuts, washers, screws, brackets, supports, clamps, hangers, saddles, cleats, sills, shims etc. Supply of cement, sand, stone etc, required for the execution of the contract shall be the responsibility of the Contractor.

5.08.00 5.08.01

Erection Tools and Tackle The Contractor shall provide all tools, tackle, implements, mobile equipment such as crane, trailers, scaffoldings, ladders, etc. which are required for transportation, handling and erection of the plant and equipment. Special erection tools, if any, furnished by the manufacturer along with the equipment may be used by the Contractor. Such tools shall be returned in good conditions to the Owner on completion of work. Owner's tools and equipment may be made available on payment of charges if and when available. The contractor should be prepared to make his own arrangement for crane. Testing Equipment a) Power operated meggar of 5,000 V and 1,000 V grade for Insulation testing. b) Hand operated meggar of 1,000 V grade for Insulation testing. c) Hand driven earth resistance Meggar of range 0-1/3/30 ohms.

5.08.02

5.08.03 5.08.04 5.09.00

d) Tong testers of suitable ranges. e) High potential test set suitable for 660V and 415V systems. f) Contact Resistance measuring set for Micro-ohms.

g) Torque Wrench. h) Current Transformer Primary injection set. i) j) Relay testing and checking bench. Multimeters, test lamp, buzzer, spirit level, db-meter, different gauges etc.

k) BDV Testing kit for testing of Transformer Oil.

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Other testing equipment as required will be arranged by the Owner. Alternatively, the contractor may be asked to provide the same at a mutually agreed rate. 6.00.00 INSTALLATION Installation work shall be carried out in accordance with good engineering practices and also manufacturer's instructions/recommendations where the same are available. Equipment shall be installed in a neat workmanlike manner so that it is level, plumb, square and properly aligned and oriented. Equipment will be furnished in a dis-assembled condition as received at site. The contractor shall assemble all these parts, mount and wire-up loose equipment, fittings and accessories and complete with all connections. Equipment will be generally supplied with necessary floor/support steel, holding down bolts, nuts anchors etc. In case of non-supply of these items with the equipment, following procedure shall be followed : Arrange for floor/support steel as necessary and fabricate and install them. Contractor shall furnish and install all bolts, nuts, screws and anchors as required to complete the installation. Any internal wiring of the equipment which has been left incomplete because of shipping split or which requires minor modifications shall be carried out by the Contractor. 6.01.00 6.01.01 HT Switchgear / HT Metering Cubicle The 6.6 KV Switchgear shall be handled with care so that no damage is done to any component. The panel shall be lifted by means of lifting tackles using lifting lugs provided on the panel. Base channels shall be grouted, leveled in cement concrete wherever required. All the panels should be assembled, aligned and leveled and it should be ensured that panel to panel coupling bolts, bus bar links fit properly without any strain on part. After erection, all cubicles shall be cleaned and checked for tightness of components, phase sequence, polarity and wiring shall be checked for correctness as per drawing. All control wiring, line PT, line CT and other live parts shall be tested for proper insulation level by means of 500 / 1000 V megger. Electrical simulation tests shall be carried out for all the protective and auxiliary relays, annunciation circuit and control circuit. Minor modification may have to be carried out in the wiring to meet the requirement of the desired control scheme and the contractor shall have to do the same at no extra cost. Resetting of Metering Cubicle, if required, including recalibration / certification of meter shall be carried out by the contractor. Power Transformers and Auxiliary Transformers Dry/Oil type Auxiliary transformers will be shipped loose along with fittings, sheet steel cable end box chamber or accessories may be supplied separately. The storage and installation of transformer shall be carried out in strict compliance with manufacturer's instruction. Extreme care should be taken to prevent ingress of moisture and foreign materials inside all transformer. Transformer shall be placed on location decided by the Engineer and shall be checked for proper mounting. Wheels if provided, shall be locked by means of stoppers. Transformer shall be fitted with all accessories, loose supplied items and shall be made oil tight before topping up with oil. A sample of oil, taken from bottom of the tank shall be tested as per IS 1866 and IS:6782 for dielectric strength. Then the oil shall be filtered before the transformer is filled. It should be ensured during oil filling operation that no air pockets are left in the tank and that no dust or moisture enter the oil. All air vent should be opened. Oil should be filled

6.01.02

6.01.03 6.02.00 6.02.01 6.02.02

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through a streamline oil filter using metal hose. To prevent aeration of the oil, the transformer tank oil should be filled through the bottom drain valve. Sufficient time should be allowed for the oil to permeate the transformer and also the locked-up air bubbles to escape. 6.03.00 6.03.01 Motor Testing and Commissioning Motors shall be erected by the Mechanical Erection Contractor. The Electrical Contractor shall generally test and commission the motors. The insulation of the motors shall be tested by 500/1000 V megger and a value of 1 M-ohm shall be considered satisfactory. If the IR value is less, drying up of winding shall be carried out by placing heater/ lamps around and inside the case of the motor. The mechanical and electrical check shall be done as per relevant Indian Standard. Motors shall be started after de-coupling from the equipment. No load current, starting current shall be recorded and IR value shall be noted after motor has run for 4 hours. After no-load run checking of performance of motor and direction of rotation, the motor shall be coupled to load and shall be run on no load. LT Switchgear, Control Panels, MCCs, Distribution Boards Switchgear, Control Panels, motor control centres, distribution boards, etc, will be split up in sections for ease of transportation and handling. All breakers, busbars, relays, meters and control switches will be supplied loose to be mounted and connected at site as per the relevant drawings which shall be supplied to the Contractor for necessary mounting, wiring and connection work at site. All alignment, leveling, grouting, anchoring, tack welding, adjustments and oil conditioning shall be carried out in accordance with manufacturer's instructions and/or as directed by the Engineer. All connections in the switchgears, control boards, distribution boards, etc. shall be completed, checked and adjusted to ensure safety and satisfactory operation of the equipment. In some cases, some modifications may have to be carried out at site in the wiring of a equipment to meet the requirements of the desired control scheme and the contractor shall have to do same at no extra cost. Battery and Battery Charger All the cells of lead acid batteries will be furnished in dry and uncharged containers. These batteries will be used for control and monitoring of electrical system, instrumentation etc. Battery cells shall be installed on wooden stand and insulator. Electrolyte supplied in a separate container shall be filled as per manufacturers instruction. The contractor shall install the lead coated copper bus for inter-row and recharging shall also be carried out by the contractor as per manufacturers instruction. Lamp bank for discharging shall be provided by the contractor. The Battery charger, D.C. distribution board will be housed in a sheet steel cabinet and located in separate rooms. After erection and connection of the Battery Charger, the contractor shall complete the charging and discharging cycles recommended by the manufacturer. The contractor shall rig up a suitable discharge resistor for this purpose. Connection from Battery, terminals will be made by means of cables. Lead coated terminal connector shall be furnished for this purpose. Cable installation work shall consist of For laying on trays/racks and vertical cable shafts : i) Fabrication and erection of cable trays/racks, supports, hangers.

6.04.00 6.04.01

6.04.02

6.04.03

6.04.04

6.05.00 6.05.01 6.05.02

6.05.03 6.05.04

6.05.05 6.06.00 6.06.01

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ii) Laying of cables, dressing, clamping and fixing of cable tags including supply of tags. 6.06.02 For laying in ground : i) Excavation of earth up to 1000 mm for power & control cable and 600 mm for lighting cable only.

ii) Providing riddle earth of 150 mm depth. iii) Laying of cables, fixing of cable tags, dressing of cables, covering with 150 mm of riddle earth and placing protective concrete slab/tiles to be provided by the owner. iv) Back filling of earth, compaction and removal of excess earth, installation of cable route and joint markers. The cable route marker shall be placed at a distance of 30 mtrs. in case of straight run and at every bend of cable route. The supply of cable tags, route and joint markers as well as pumping out of accumulated water within excavation are included in scope of the Contractor. 6.06.03 For laying in conduit/GI pipes/hume pipes : i) Installation of conduits/pipes with accessories wherever required.

ii) Laying of cables in conduit/pipes, fixing of conduit tags including supply of tags. 6.06.04 For laying on surface : i) Laying of cables on surface of walls/beams/soffit/structures including supply of saddles, cleats, cable tags as required to complete the erection.

ii) Fixing of lugs including crimping. iii) Termination and connection using termination kits wherever required including splicing, soldering, taping, compound filling, putting ferrules etc. as required for the complete job including supply of consumable materials such as ferrules, soldering materials, electrical tape, compound/resin etc. 6.06.05 6.06.06 6.06.07 6.06.08 6.07.00 6.07.01 6.07.02 Straight through cable jointing inclusive of supply of consumables as required. Fire sealing of openings and anti fire propagation compound coating. Filling of sand in trenches in specified areas shown in the drawing. In licensed area all lugs shall be flameproof type. Cable Trays The Contractor shall fabricate and install all cable trays, racks, risers, shafts and supports. Overhead cable trays in outdoor areas, cable trays either inside concrete trenches or inside buildings and racks inside cable shafts shall be aligned and leveled properly. All tray runs shall be installed parallel to the trench/building walls and floors except otherwise noted in the drawings. Embedded steel inserts in wall/floor/ceiling surfaces shall be provided. The Contractor shall have to secure rack/tray supports by welding to those inserts or other available building steel surface. Outdoor trays shall be installed by welding on the steel/concrete structures with inserts. In case of non-availability of embedded steel inserts in certain tray routes, the Contractor shall have to secure the supports on wall/floor/ceiling surfaces by suitable anchoring system

6.07.03

6.07.04

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having adequate load bearing capability. 6.07.05 6.07.06 6.07.07 6.08.00 6.08.01 6.08.02 6.08.03 As far as practicable, cable trays shall be supported from one side only in order to facilitate installation and maintenance of cables from the other side. The cable trays shall be supported in general at a span of 1.5 meters horizontally and at a distance of 1.0 meter vertically. Sufficient spacing of not less than 250 mm shall be provided between trays and maintained to permit adequate access, for installing and maintaining the cables. Cable and Conduits The Contractor shall install, terminate and connect up all cable and conduits as per drawings and cable schedules. The drawings shall be strictly followed except where obvious interference occurs. In such cases, the routing shall be changed as directed and/or approved by the Engineer. Approximate lengths of cable and conduit will be given in the cable schedule for guidance only. Before commencement of work the Contractor shall take actual measurements and prepare his own cable cutting schedule to reduce wastage to a minimum. The cable cutting schedule will have to be approved by the Engineer. The Contractor shall also maintain and submit when requested, a record of cable insulation value when from store, after laying, before and after termination / jointing. Conduit and Accessories Conduit/pipes shall be used only in short lengths in certain areas where required and/or as directed by the Engineer. The Contractor shall furnish all conduits complete with accessories as required such as tees, bends, adapters, locknut, bush, pull boxes, straps, brackets etc. Exposed conduits shall be run in straight lines parallel to column, wall or beam and supported at a distance not exceeding 500mm. Embedded conduits shall be coated with an asphalt base compound to be supplied by contractor and anchored securely in position to preclude movement. Conduits shall be installed in such a manner as to avoid unnecessary bending and crossing and also entrapment of moisture. Conduit connection to general purpose enclosure shall be made with double lock nuts and bushing. Conduit connection to equipment where movement may occur or which may be disconnected for servicing shall be made with flexible conduit. Conduit ends shall be plugged or capped at all times during erection so as to prevent entry of foreign materials. Conduit and duct runs shall be thoroughly cleaned before pulling in the cables. Except for inside an enclosure wherever the cable enters or leaves the conduit, the conduit end shall be sealed by suitable sealing compound, having fire withstand capability. Cable - Storage and Handling Cable drums shall be stored on hard and well drained surface to that they may not sink. In so case shall the drum be stored on the flat, i.e., with flange horizontal. Rolling of drums shall be avoided as far as practicable, for short distance, the drums may be

6.08.04 6.09.00 6.09.01 6.09.02 6.09.03 6.09.04 6.09.05 6.09.06

6.09.07 6.09.08 6.08.09 6.09.00 6.09.01 6.09.02

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rolled provided they are rolled slowly and in proper direction as marked on the drum. 6.09.03 6.09.04 6.09.05 6.09.06 In absence of any indication, the drums may be rolled in the same direction as it was rolled during taking up the cable. For unreeling the cable, the drum shall be mounted on jacks or on cable wheel. The spindle shall be strong enough to carry the weight without bending. The drum shall be rolled on the spindle slowly so that the cable should come out over the durm and not below the drum. While laying cable, cable rollers shall be used at an interval of 200 m. The cables shall be pushed over the roller by a gang of people positioned in between rollers over a suitable distance. Cable shall not be pulled from the end without having intermediate pushing arrangement. Bending radius of the cable during installation shall not be less than what is specified by the manufacturer. Where cables are cut from the drums the ends of the cables at the drums shall be properly sealed. Whenever necessary the cable shall be re-rolled on drums as advised by Engineer of Owner. Cost of the same are deemed to be included in the quoted rates. Unused/empty drums are to be returned to the owner in good condition. Cable Laying Cable shall generally be installed in ladder type site fabricated trays except for some short run in rigid/flexible conduit for protection or crossings. Cables laid on trays and risers shall be neatly dressed and clamped at an interval of 1500mm and 900 mm for horizontal and vertical cable runs. Clamps for multi core cables shall be fabricated out of 25 x 3 mm PVC sheathed aluminium flats. All power cables shall be clamped individually and control cables shall be clamped in groups of three or four cables. All single core power cables shall be laid in tri-foil formation and suitably clamped with nylon/fiber glass mould pieces of appropriate quality and sizes. Prior to laying of cables inside both indoor and outdoor trenches, the Contractor shall properly clean inside those trenches. In outdoor areas, buried cables shall be laid and covered with riddled earth and protected from damage by precast slab at top. When buried cables cross road/railway track, additional protection shall be provided in the form of hume/galvanised iron pipes of adequate strength. For power cables exceeding 100 meters an underground cable loop of diameter 2.5 meters shall be provided near each terminating ends. The power and control cables shall be laid with a provision of extra length at one end. The exact length shall be confirmed by the Owner/Consultant's site engineer before laying. After completion of installation of cables on trays inside concrete trenches, the portion of the trench located in the vicinity of oil filled transformers/areas shown in the drawings shall be filled up with sand. Proper cable supporting arrangement with necessary clamps shall be installed by the bidder to hold the cables entering the equipment e.g. switchboards/transformers and the like from cable trays.

6.09.07

6.09.08

6.10.00 6.10.01 6.10.02 6.10.03

6.10.04 6.10.05 6.10.06 6.10.07 6.10.08 6.10.09 6.10.10

6.10.11

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6.10.12

In order to prevent fire protection through cable penetrations of wall/floor/ceiling as well as through cable shaft openings, after laying, dressing & clamping of cables, all the openings shall be properly sealed by using pieces of mineral wool butted to one another and spraying with anti-fire propagation liquid such as "Flammastick" or aproved equivalent. Also the cable runs both before and after the fire seals shall be suitably sprayed with antifire propagation liquid at least for 1M length. After completion of installation and prior to connection, all power cables shall be subjected to a high potential test. All necessary assistance to testing shall be provided by the contractor. Cable Tags and Markers Each cable and conduit run shall be tagged with numbers that appear in the cable and conduit schedules, Cables and conduits shall be tagged at their entrance, every 30.0M and exit from any equipment, junction box. The tags shall be of aluminium (minimum 2 mm thick) with the number punched on it and securely attached to the cable by not less that two turns of 16 SWG G.I. wire. Alternatively, PVC/Nylon tags with embossed cable number secured to the cable with PVC/Nylon bands may be used. Routing of cables laid directly under ground shall be indicated clearly by cable marker of galvanised iron. The location of cable joints, if any, shall be clearly indicated with cable marker with an additional inscription "cable-joint". The Contractor shall furnish and install all tags and markers stated above. For buried cable, the marker shall project 150 mm above ground and shall be spaced at an interval of 30 meters and at every change of direction. Cable Termination and Connection The termination and connection of cables shall be done strictly in accordance with manufacturer's instruction, drawings and/or as directed by the Engineer. The work shall include all clamping, fitting, fixing, soldering, tapping, compound filling, cable jointing, crimping, shorting and grounding as required for the complete job. All equipment required for all such operations shall be of Contractor's procurement under this specification. Furnishing of all consumable materials such as soldering material, electrical tape, sealing material as well as cable jointing kits shall be included in the offer. Cable joint kits for all cables shall be supplied by Contractor under this specification. Responsibility for proper terminating shall lie on the Contractor, Guarantee for termination shall also have to be given by Contractor. The equipment will be generally provided with blank bottom plates for cable/conduit entry and cable end box for power cables. The Contractor shall perform all drilling, cutting on the blank plate and any minor modification work required to complete the job, Gas cutting will not be allowed. If the cable end box or terminal enclosure provided on the equipment is found unsuitable and requires major modification, the same shall be carried out by the Contractor at the discretion of Engineer. Control cable cores entering control panel/swithgear/MCC etc. shall be neatly bunched and served with PVC perforated tape to keep it in position at the terminal block. Alternatively, the neatly bunched control cable cores may be secured by Nylon self-locking cable securing bands.

6.10.13 6.11.00 6.11.01

6.11.02

6.11.03 6.11.04 6.11.05 6.11.06 6.12.00 6.12.01 6.12.02

6.12.03 6.12.04

6.12.05 6.12.06 6.12.07

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6.12.09

The Contractor shall put ferrules on all control cable cores in all junction boxes and at all terminations. The ferrules shall carry terminal numbers as per drawings. All ferrules shall be coloured, plastic and interlocked type. Spare cores shall be similarly ferruled, crimped with lug and taped on the ends. Spare cores shall be ferruled with individual cable number. Termination and connection shall be carried out in such a manner as to avoid strain on the terminals. All cable entry Points shall be properly sealed and made vermin and dust proof. Unusual opening, if any, shall be effectively closed. Sealing work shall be carried out with approved sealing compound having fire withstand capability for at least three hours. Power and control cables near their terminations at cable end box/marshalling box of transformers may require to be supported by clamping arrangement. The Contractor shall fabricate all such supports and provide clams as required to complete the job. Cable Joints Cables shall be installed without joints as far as practicable. If however jointing becomes necessary, it shall be made only by qualified cable jointer and strictly in accordance with manufacturer's recommendation. Jointing rates shall be inclusive of supply of splicing materials, jointing compound, tape, connectors etc., if not covered within supply price of jointing kits. Junction Box The Contractor shall install junction boxes wherever required for power/control cables at suitable as per direction of engineer. Fire seal and anti-flame propagation compound coating. In order to prevent fire propagation through cable penetration of wall/floor/ceiling as well as through cable shaft openings, after laying, dressing and clamping of cables, all the openings shall be properly sealed by using pieces of mineral wool butted to one another and spraying with out fire propagation liquid such as flammastick or approved equivalent. Also the cable runs both before and after fire seals shall be suitably sprayed with anti fire propagation compound at least for 1 M length on each side. Except for inside an enclosure, wherever cables enter or leave conduits, the conduit end shall be sealed by suitable sealing compound having fire withstand capability. Grounding of Electrical System The Contractor is to carry out the grounding of the entire electrical installation under the scope of this specification as directed by the Owners representative. 6.6 KV Swgr., Transformer, MCCs, all drive motors, junction boxes, joint boxes, switch boards, lighting fixtures, receptacles, conduits, cable, armours etc. and all non-current carrying metallic parts shall be earthed at two separate points. The equipment grounding shall be carried out by GI flat / wire of specified sizes and the same shall be connected to the risers of plant earth mat. In any case, the earth resistance of the grounding system shall be less than 1 ohm. The method adopted for system earthing as well as equipment earthing shall be in accordance with the Code of Practice for earthing IS:3043. It shall also comply with the relevant clauses of Local Electricity Rules. The main ground grid shall be buried in earth at a minimum depth of 800 mm. below finished grade level unless stated otherwise. The size of the ground grid conductor shall be bare 50 x

6.12.10 6.12.11 6.12.12

6.12.13

6.13.00 6.13.01 6.13.02 6.13.03 6.14.00 6.14.01 6.15.00 6.15.01

6.15.02 6.16.00 6.16.01

6.16.02

6.16.03

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6 mm GI flat and are connected to ground electrodes. 6.16.04 Earth grid for normal electrical earthing, earth grid for earthing, earth grid for lightning protection and earth grid for electronic equipment earthing shall be all isolated and independent from each other. All risers from the ground grid shall be 50 x 6 mm GI flat and shall be projected 300 mm above grade level / concrete floor level unless otherwise shown. Earth electrodes for earthing stations shall comprise GI pipes of 50 mm nominal diameter and 3.8 metre length in accordance with IS:3043. Bottom half of the pipe shall have holes drilled at intervals on its surface. Removable caps shall be provided at the top of pipe to facilitate pouring of water. The top portion of electrodes shall be enclosed in 300 x 300 x 300 mm M15 concrete & brick housing and provided with Cast Iron top cover and marker. Provision shall be kept at each earth station for testing earth resistance. Each earth station shall be completed with homogeneous layers of coke/charcoal and salt. All ground conductor connections shall be made by electric arc welding unless otherwise specified. Ground connections shall be made from nearest available plant ground grid risers. All ground conductors above ground shall be painted black for easy identification. In case of site fabricated cable tray/ladder, the runner angles shall be used as ground conductors and shall be made electrically continuous. Such grounding continuity work on runner angles of cable tray is to be included in erection price of cable trays/racks. Cable screens and armours shall be bonded to earthing system. Also metal pipes and conduits carrying cables shall be bonded and effectively earthed. In office buildings, laboratories etc. where concealed wiring is adopted, flats or wires for earthing shall be run along the pipes carrying lighting cables. In case where the earth conductors are to be taken through embedded pipe carrying cables, the same shall comprise aluminium conductor insulated cables of green colour for easy identification. The earthing shall be done by GI Flat or, GI wire of sizes as laid down in earthing drawings and the same shall be connected to the risers of main earth grid. The minimum size of galvanized MS flat earthing leads for various equipment shall generally be as given below unless a higher size is required from the view point of higher available fault current : Equipment Transformer Neutral Point HT Switchgear Cable Tray Emergency trip Push Button/ Receptacle / Ventilation Fan/LPBs 6.6 KV Metering Panel /Lighting Panel PMCC / DB 6.17.00 6.17.01 Lightning Protection System The method adopted for protection of buildings and allied structures against lightning shall be in accordance with relevant IS:2309. Size of GS Flat/Wire 1C x 120 mm sq. PVC unarmoured cable 1 x 50 x 6 mm 1 x 25 x 6 mm 16 SWG wire (twisted pair) 1x 25 x 6 mm 1 x 50 x 6 mm 2 nos. 2 nos. 1 no (continuous run) 2 nos. 2 nos. 2 nos.

6.16.05 6.16.06

6.16.07

6.16.08

6.16.09

6.16.10 6.16.11

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6.17.02 6.18.00 6.18.01 6.18.02 6.18.03 6.18.04 6.18.05 6.19.00 6.19.01 6.19.02 6.19.03 6.19.04 6.20.00 6.20.01 6.20.02 6.20.03 6.20.04 6.21.00 6.21.01 6.21.02 6.22.00 6.22.01 6.22.02

Generally the plant building shall be adequately earthed to ensure free conducting path for lightning stroke. Painting The Contractor shall paint steel fabrications at site with two (2) coats of primer and two (2) coats of battleship grey (shade no. 632 of IS : 5) epoxy-based paint. All damaged parts shall be cleaned and coated with two (2) coats red oxide primer paint followed by a finishing coat of approved colour. All damaged galvanised surfaces shall be coated with cold galvanising paint (minimum thickness 1 mm). All equipment after erection shall be touched-up where required with coats of finishing paint. All primer & paint including touch-up paints shall be supplied by the Bidder. Excavation and Back Filling The Contractor shall perform all excavation and backfilling as required for buried cable and ground connections. Excavation shall be performed up to the required depth. Such sheeting and shoring shall be done as may be necessary for protection of the work. The Contractor shall make use his own arrangements for pumping out any water that may be accumulated in the excavation. All excavation shall be backfilled to the original level with good consolidation. Steel Fabrication All racks, trays, supports, hangers and brackets wherever necessary shall be fabricated by the Contractor. Necessary steel shall be supplied by the Contractor. Steel for fabrication shall be straightened and cleaned of rust and grease. All fabrication shall be free of sharp edge. The Contractor shall maintain a register showing account of receipt of steel in the work and records shall be kept to the satisfaction of the Owner. For the purpose of certification and accounting the theoretical weights on the basis of relevant Indian Standards will be binding. Cleaning up of Work Site The Contractor shall, from time to time, remove all rubbish resulting from execution of his work. No material shall be stored or placed on passage or drive ways. Upon completion of work the Contractor shall remove all rubbish, tools, scaffoldings, temporary structures and surplus materials etc. to leave the premises clean and fit for use. Inspection & Testing On completion of erection works, the Contractor shall request the Engineer for inspection and tests with minimum fourteen (14) days advance notice. The Engineer shall arrange for joint inspection of the installation for completeness and correctness of the work. Any defect pointed out during such inspection shall be promptly rectified by the Contractor.

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6.22.03 6.22.04 6.23.00 6.23.01

The installation shall be then tested and commissioned in presence of the Engineer and put on trial run for stipulated contract period. All rectification, repair of adjustment work found necessary during inspection, testing, commissioned and trial run shall be carried out by the Contractor without aby extra cost. Commissioning the Trial Run Following successful inspection and testing, the equipment shall be commissioned and put on trial run alongwith the main plant in a manner mutually agreed upon based on the commissioning schedule of main plant. The contractor shall assist the purchaser in commissioning and trial run with men and material as required and/or as directed by the Engineer. Taking over of Installation On successful testing, commissioning and trial run, the Contractor shall request Engineer in writing for taking over the installation. The Engineer, on receipt of the request, shall arrange to take over the installation either wholly or in part as the case may be after a final inspection. Till such taking over, the responsibility of the whole installation against theft or damage of any kind shall remain with the Contractor. In the event of any theft/damage to the plant prior to the complete taking over of the installation the contractor shall arrange to lodge necessary F.I.R. with the local police authorities and provide all necessary help to the owner such that the owner may raise suitable claims form its underwriters. TESTS Site Tests All site tests on erected equipments will be carried out. The contractor shall provide suitable manpower for conducting all tests on equipments erected by them. Through testing and meggaring of all cables, wires and equipment to prove the same are free form ground and short circuit fault after erection and installation at site. Rectification or, replacement of cable and/or, equipment, if any ground or short circuit is found. All power cables after installation and prior to connection shall be subjected to High-Potential tests. Also the insulation resistance values shall be measured both before and after Hi-pot test for comparison. The leakage current shall also be measured during the Hi-pot test at site. All equipment shall be demonstrated to operate in accordance with the requirements of this specification. All equipment shall be subjected to High Potential test. All protective relays shall be checked for correctness of operations. All current transformers shall be subjected to Primary Injection test. Pre-commissioning tests of transformers and other equipments shall include but will not be limited to all necessary tests as per relevant standards for satisfactory operation of the same. Test Witness All tests shall be performed in presence of Owner's representatives, if so desired by the Owner.

6.23.02 6.24.00 6.24.01 6.24.02 6.24.03

7.00.00 7.01.00 7.01.01 7.01.02 7.01.03 7.01.04

7.01.05 7.01.06 7.01.07 7.01.08 7.01.09 7.02.00 7.02.01

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7.02.02 7.02.03 7.02.04 7.02.05

The Contractor shall give at least fifteen (15) days advance notice of shop tests and seven (7) days advance notice of site tests. Certified copies of all tests carried out at works and at site shall be furnished in three (3) copies for approval of the Owner. The equipment and accessories shall be dispatched from works only after receipts of Owner's written approval of shop test reports. Type test certificate on any equipment and accessories if so desired by the Owner, shall be furnished. Otherwise the equipment and accessories shall have to be type tested, free of charge, to prove the design. SPECIAL TOOLS & TACKLES A set of special tools & tackles supplied by different manufacturers of Equipment which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment may be made available to the Contractor at the discretion of Engineer.

8.00.00

9.00.00

DRAWINGS, DATA AND MANUALS Drawings, data and manuals shall be submitted in triplicate with the bid and in quantities and procedures as specified in the General Conditions of Contract and/or elsewhere in this specification for approval and subsequent distribution after the issue of Letter of Intent.

9.01.00 To be submitted with the Bid Make, type and catalog number of different electrical items and accessories along with technical leaflets, data sheets etc. Typical General arrangement drawings showing constructional features, fixing arrangement of pre-fabricated cable trays. Bill of Materials for cable trays and accessories, conduits and accessories. 9.02.00 To be submitted for Approval and Distribution Make, type and catalog number of cable termination kits, joints and accessories. Detail dimensional drawings showing constructional features, grounding, fixing arrangement etc. Bill of Materials for Pre-fabricated cable tray and accessories, Conducts and accessories. Dimensional G.A. drawings and data sheets for different equipment and items supplied under this specification.

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