PHT MARKET, UPPAL EXTERNAL ELECTRICAL WORKS

ELECTRICAL TECHNICAL SPECIFICATIONS

PROJECT: PHT MARKET, UPPAL,

HYDERABAD, TELANAGANA

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TENDER FOR EXTERNAL ELECTRICAL WORKS

1. SPECIAL CONDITIONS

2. SITE SAFETY REQUIREMENTS

3. TECHNICAL SPECIFICATIONS

Chapter 1 11KV HT VCBs

Chapter 2 TRANSFORMERS

Chapter 3 BATTERY & BATTERY CHARGER

Chapter 4 POWER CONTROL CENTERS

Chapter 5 POWER CAPACITORS & CAPACITOR CONTROL PANEL

Chapter 6 MEDIUM AND HIGH VOLTAGE CABLES & ACCESSORIES

Chapter 7 LAYING OF CABLES

Chapter 8 UPS

Chapter 9 EARTHING

Chapter 10 LIGHTNING PROTECTION

Chapter 11 RECOMMENDED MAKES OF MATERIALS

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1. SPECIAL CONDITIONS
1. General:

1.1 These special conditions shall be read in conjunction with the description of the item of work in the
Bill(s) of Quantities, the particular Specifications, Local Statutory Regulations, Indian Standards
Specifications/Codes and the drawings. All the above quoted documents shall be considered
supplementary to each other. However, in the case of conflict amongst the various provisions, the
owner's and the consultant’s opinion will be final and shall be adopted.

1.2 The tender is advised to inspect the site to ascertain the nature of site, access thereto, local facilities
for procurement of materials and working labour rates prevalent in the area, in fact all matters affecting
his prices and execution of the work. The tender shall be deemed to have full knowledge of the site and
drawings whether or not he actually inspects them.

2. Rates

2.1 The rates quoted shall be deemed to allow for all minor extras and constructional details which are
not specifically shown on drawings or given on the specifications but are essential in the opinion of the
Engineer-in-charge to the execution of works to confirm to good workmanship and sound engineering
practice. The Consultant/Employer reserves the right to make any minor changes during the execution
without any extra payment.

2.2 The Consultants decision to clarify any item under minor changes, minor extras and constructional
details shall be final, conclusive and binding on the Contractor.

2.3 The rates quoted by the Contractor shall be net so as to include all requirements described in the
contract agreement and no claim whatsoever due to fluctuations in the price of material and labour will
be entertained.

2.4 The rates quoted by the Contractor shall include for supplying materials and labour necessary for
completing the work in the best and most workmanship like manner to the satisfaction of the
Consultant/Employer and which in the opinion of the Consultant cannot be made better, and for
maintaining the same. The rates shall be complete in all respects also including cost of materials,
erection, fabrication, labour, supervision, tools and plant, transport, sales and other taxes royalties,
duties and materials, contingencies, breakage, wastage, sundries, scaffoldings, etc., on the basis of
works contract. The rates quoted shall include all taxes, duties, transport, insurances, octroi, or any
other levies applicable under the statute.

3.0 Materials:

3.1 The Contractor shall ensure to the satisfaction of the Consultant/Employer that the materials
are packed in original sealed containers/packing bearing manufacturer’s markings and brands etc.,
except where the gross quantity required is a fraction of the smallest packing. Materials not complying
with this requirement shall be rejected.

3.2 Testing of Materials:

a) When required by the Consultant, the Contractor shall provide all facilities at site or at manufacturer's
works or in an approved laboratory for testing the materials and/or workmanship. All the expenditure in
respect of this shall be borne by the Contractor unless specified otherwise in the Contract. The
Contractor shall, when required to do so by the Consultant shall submit at his own cost, manufacturer's
certificate of tests, proof sheets, mill sheets etc., showing that the materials have been tested in
accordance with requirements of these specifications.

b) Neither the omission by the Consultant to test the materials nor the production of manufacturer(s)
certificate etc., as aforesaid shall affect the right of the Consultant to reject, after delivery the materials
found unsuitable or not in accordance with the specifications.

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4 Drawings:

4.1 Clarifications required or discrepancies, if any, noted by the Contractor in the various drawings
supplied by the Consultant must be obtained well before tendering, failing which the decision of the
Consultant shall be final and binding on the Contractor with regard to detailing and general acceptance
of the Contract.

5.0 Rectification of Defects:

5.1 Any defect in the work done or materials used in the works pointed out by the Consultant shall be
rectified within a week or such extended time as may be allowed in this failing which the Consultant at
the risk and cost of the Contractors shall be rectified the said defect.

6.0 Cables Layout:

6.1 All these drawings shall be issued by us and the Bidder shall execute strictly as per our drawings.
The Contractor shall study the drawings thoroughly before execution and bring out any discrepancies in
the drawings

7.0 Regulations & Standards:

7.1 The installation shall conform in all respects to Indian Standard Code of Practice for Electrical Wiring
Installation IS: 732 and IS: 2274. It shall also be in conformity with the current Indian Electricity Rules
and Regulations and requirements of the local Electric Supply Authority in so far as these become
applicable to the installation. However, in the case of conflict amongst the various provisions the owner's
and the consultant’s opinion will be final and shall be adopted.

8.0 Shop Drawings:

8. The Contractor shall prepare and submit to the Consultant for the approval of detailed fabrication
drawings for Distribution Board, switch board, special any other equipment to be fabricated by
Contractor within 60 days of signing of the contract.

9.0 Completion Drawings:

9.1 At the completion of the work and before issuance of certificate of virtual completion the
contractor shall submit to the consultant/Employer layout drawings drawn at approved scale
indicating the complete system "As Installed". These drawings shall in particular, give the following
information.

(a) Run and size of Cables/ Busduct/trays.

(b) Location of panels/ Dg set.

(c) Size of Dg sets/ acoustic enclosures

(d) Locations of all earthing stations, routes and size of all earthing conductors, manholes etc.

Five Sets of Prints and One set of Drawings on RTF & Soft copy shall be submitted after completion of
work.

10.0 Manufacturer's Instructions:

10.1 Where manufacturers have furnished specific instructions, relating to the materials used in this job,
covering points not specifically mentioned in the documents, these instructions shall be followed in all
cases.

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11.0 Completion Certificate:

11.1 On completion of the Electrical Installation a certificate shall be furnished by the Contractor counter
signed by a licensed supervisor, under whose direct supervision the installation was carried out.

This certificate shall be in the prescribed form as required by the local supply authority. The Contractor
shall be responsible for getting the drawings and Electrical Installation inspected and approved by the
local Authority concerned. Only Statutory Fees, if any applicable, only will be paid and Incidental
expenses will not be paid.

12.0 Qualified Competent Supervision:

12.1 The Contractor shall employ competent fully licensed, qualified full time Engineer to direct the work
of Electrical installation in accordance with drawings and specifications. The Engineer shall be
available at all times on the site to receive instructions from Consultant in the day to day
activities, through out the duration of the contract. The foremen shall co-relate the progress of the
work in conjunction with all relevant requirements of the supply authorities.

13.0 Sub Contractor :

13.1 If the Main Contractor proposes to subcontract the part/ whole of the Electrical/ Communication
systems Work, the sub contractor’s credentials shall be submitted and get the same approved before
employment. The Sub contractor shall be licensed to execute works unto 33KV or the class of Voltage
as applicable.

14.0 Approvals from Electrical Inspectorate

14.1 The Contractor shall liaison with CEIG and PCB and obtain approval for Drawings and Final
installation.

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2. SIT E SAF E TY R E Q UI RE M E NT S

The Contractor, his Sub-Contractors and nominated sub-contractors, shall comply with the safety
precautions, protective measures, house keeping requirements, etc. The Client with due intimation shall
have the right to stop the work at site, if in his opinion proceeding with the work will lead to an unsafe
and dangerous condition. The contractor shall get the unsafe condition removed or provide protective
equipment. The contractor shall ensure that all workmen are aware about the nature of risk involved in
their work and have adequate knowledge for carrying out their work safely.

The instructions issued herein are indicative and not exhaustive. Therefore the contractor shall be
responsible to ensure that adequate safety measures have been adopted in the course of execution of
the contract in accordance with safety standards / statutory regulations, as applicable.

The contractor shall be held responsible for non-compliance if any of the safety measures and delays,
implications, injuries, fatalities and compensation arising out of such situations or incidents.

1. TRAFFIC

1.1 The contractor shall organize operations by taking approval to use the existing
roads, if any, from Client.
1.2 The contractor shall exercise full care to ensure that no damage is caused by him or workmen,
during the operation, to the existing water supply, sewerage, power or telecommunication lines
or any other services or works. The contractor shall provide and erect before construction,
substantial barricades, guardrails, and warning signs. He shall furnish, place and maintain
adequate warning lights, signals, etc., as required by Client.

2. SAFE MEANS OF ACCESS

2.1 Adequate and safe means of access and exit shall be provided for all work places, at all
elevations.

2.2 Suitable scaffolds shall be provided for workmen for all works that cannot safely be done from
the ground, or from solid construction except such short duration work as can be done safely
from ladders. Ladder shall be of rigid construction having sufficient strength for the intended
loads and made of metal and all ladders shall be maintained well for safe working condition.
Suitable footholds and handholds shall be provided on the ladder. The ladder shall be given an
inclination not steeper than 1 in 4 (1 horizontal and 4 vertical).

2.3 Scaffolding or staging more than 3.5m above the ground or floor, swung or suspended
from an overhead support or erected with stationary support shall have a standard guard-rail
properly attached, bolted, braced or otherwise secured at least 1m high above the floor or
platform of such scaffolding or staging. The guardrail shall extend along the entire exposed
length of the scaffolding with only such opening as may be necessary for the delivery of
materials. Standard railing shall have posts not more than 2m apart and an intermediate rail half
way between the floor and platform of the scaffolding and the top rail. Such scaffolding or
staging shall be so fastened as to prevent it from swaying from the building or structure.
Scaffolding and ladder shall conform to relevant IS specification (IS 3696-1966).
TIMBER/BAMBOO SCAFFOLDING SHALL NOT BE USED.

2.4 Working platforms of scaffolds shall have toe boards at least 15cm in ht. to prevent materials
from falling down.

2.5 A sketch of the scaffolding proposed to be used shall be prepared prior to start of erection of
scaffolding. Safety engineer shall examine all scaffolds before using.

2.6 Safe means of access shall be provided to all working platforms and other elevated working
places. Every ladder shall be securely fixed. No single portable ladder shall be over 9m in
length. For ladders, up to 3m in length the width between side rails in the ladders shall in no

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case be less than 300mm. For longer ladders, this width shall be increased by at least 20mm
for each additional meter of length. Step spacing shall be uniform and shall not exceed 300mm.

2.7 Adequate precautions shall be taken to prevent danger from electrical lines and equipment. No
scaffolding, ladder, working platform, gangway runs, etc. shall exist within 3 meters of any
un-insulated electric wire. Whenever electric power and lighting cables are required to run
through (pass on) the scaffolding or electrical equipment are used, such scaffolding
structures shall have minimum two earth connections with earth continuity conforming to IS code
of practice.

3. DEMOLITION

• Before any demolition work is commenced and also during the progress of the work the
contractor shall ensure that the power on all electric service lines is shut off and the lines cut or
disconnected at or outside the demolition site.

• If it is necessary to maintain electric power during demolition operation, the required service
lines shall be adequately protected against damage.

• Persons handling heavy materials/equipment shall wear safety shoes.

4. PERSONAL PROTECTIVE EQUIPMENT

All necessary personal protective equipment shall be kept available for the use of the persons employed
on the site and maintained in a condition suitable for immediate use. Also the contractor shall take
adequate steps to ensure proper use of equipment by those concerned. The personal protective
equipment to be provided by the contractor are:

a) All persons employed at the construction site shall use safety helmets.

b) Persons engaged in welding and gas-cutting works shall use suitable aprons, leather
gloves and welding face shields. The persons who assist the welders shall use suitable
goggles. Protective goggles shall be worn while chipping and grinding.

c) All persons working at heights more than 4.5m above ground or floor and exposed to
risk of falling down shall use safety belts, unless otherwise protected by cages, guard railings,
etc. In places where the use of safety belts is impractical, suitable net of adequate strength
fastened to substantial supports shall be employed.

5. LIFTING MACHINES AND TACKLES

5.1Use of lifting machines and tackles including their attachments, anchorage and supports shall
conform to the following standards or conditions:

Lifting machines and tackles shall be of good mechanical construction, sound material and adequate
strength and free from any defects and shall be kept in good repair and in good working order.

Every rope used in hoisting or lowering materials or as a means of suspension shall be of good quality
and adequate strength and free from any defect.

Every crane operator or lifting appliance operator shall be properly qualified. No person under the age of
21 years shall be in charge of any hoisting machine or give signal to operator of such machine.

In case of every lifting machine (and of every chain, ring, hook, shackle, swivel and pulley block used in
hoisting or as means of suspension) the safe working load shall be ascertained and clearly marked. In
case of a lifting machine having a variable safe working load, each safe working load and the conditions
under which it is applicable shall be clearly indicated. No part of any machine or any gear referred to
above in this paragraph shall be loaded beyond the safe working load except for the purpose of testing.
The safety engineer shall approve this.

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The safety engineer shall note the safe working load. Regarding other machines, the contractor shall
notify the safe working load of the machine to the safety engineer, whenever he brings any machinery to
site of work and gets it verified by the safety engineer.

Thorough inspection and load testing of lifting machines and tackles shall be done by a competent
person at least once every 2 months and records of such inspection and testing shall be maintained.

5.2 Motors, gearing transmission, couplings, belts, chain drives and other moving parts of hoisting
appliances shall be provided with adequate safeguards. Hoisting appliances shall be provided with such
means as will reduce to the minimum the risk of any part of a suspended load becoming accidentally
displaced or lowered. Barricades shall be erected around the place of hoisting the equipment(s).

6. WELDING AND GAS CUTTING

6.1Welding and gas cutting operations shall be done by qualified and authorized persons and as per IS
specifications and code of practice.

6.2 Welding and gas cutting shall not be carried out in places where flammable or combustible
materials are kept and where there is danger of explosion due to presence of gaseous mixtures.

6.3 Welding and gas cutting equipment including hoses and cables shall be maintained in good
condition.

6.4 Barriers shall be erected to protect other persons from harmful rays from the work. When
welding or gas cutting is done in elevated positions, precautions shall be taken to prevent sparks or hot
metal falling on persons or flammable materials.

6.5 Suitable type of protective clothing consisting of fire resistant gauntlet gloves, leggings, boots
and aprons shall be provided to workers as protection from heat and hot metal splashes. Welding
shields with filter glasses of appropriate shade shall be worn as face protection.

6.6 Adequate ventilation shall be provided while welding in confined space or while brazing, cutting
or welding zinc, brass, bronze, galvanized or lead coated materials.

6.7 Welding and gas cutting shall not be done on drums, barrels, tanks or other containers unless
they have been emptied cleaned thoroughly and it is made certain that no flammable material is present.

6.8 Fire extinguishers shall be available near the location of welding operations. Fire safety permit shall
be obtained for working at vulnerable areas and operating areas before flame cutting/welding is taken
up.

6.9For electric (Arc) welding the following additional safety precautions shall be taken:

When electrical welding is undertaken near pipelines carrying flammables, such pipelines shall not be
used as part of earth conductor but a separate earth conductor shall be connected to the machine
directly from the job.

Personnel contact with the electrode or other live parts of electric welding equipment shall be avoided.

Extreme caution shall be exercised to prevent accidental contact of electrodes with ground.

The welding cable shall not be allowed to get entangled with power cables. It shall be ensured that
movement of materials does not damage the cables.

7. GRINDING

7.1 All portable grinders shall be used only with their wheel guards in position to reduce the danger
from flying fragments should the wheel break during the use.

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7.2 Grinding wheels of specified diameter only shall be used on a grinder – portable or pedestal - in
order not to exceed the prescribed peripheral speed.

7.3 Goggles shall be used during grinding operation.

8. HOUSE KEEPING

8.1 The contractor shall at all times keep his work site, site office and surroundings clean and tidy from
rubbish, scrap, surplus materials and unwanted tools and equipment.

8.2 Welding and other electrical cables shall be so routed as to allow safe traffic by all concerned.

8.3 No materials on any of the sites of work shall be so stacked or placed as to cause danger or
inconvenience to any person or the public.

8.4 At the completion of the work, the contractor shall ensure removal from the work premises all
scaffoldings, surplus materials, rubbish and all huts and sanitary arrangements used/installed for
workmen on the site.

9. FIRE SAFETY

All necessary precautions shall be taken to prevent outbreak of fires at the construction site. Adequate
provisions shall be made to extinguish fires, should they still break out.

a) Quantities of combustible materials like timber, bamboo, coal, paints, etc. shall be the minimum
required in order to avoid unnecessary accumulation of combustibles at site.

b) Containers of paints, thinners and allied materials shall be stored in a separate room, which shall be
well ventilated, and free from excessive heat, sparks, flame or direct rays of the sun. The containers
of paint shall be kept covered and properly fitted with lid and shall not be kept open except while
using.

c) Fire extinguishers shall be located at the construction site at appropriate places.

d) Adequate number of workmen shall be given education and training in fire fighting and extinguishing
methods

10. WORK IN RADIATION AREA

The contractor shall follow the stipulated procedure regarding work in the radiation area and other works
related with radiography.

11. MEDICAL FACILITIES

11.1 The contractor shall arrange for medical aid and treatment for his staff and workers engaged on the
work site including the first-aid facilities if they are not available at the project site.

11.2 First-aid appliance including sterilized dressing, cotton wool and antiseptic cream shall be made
available at readily accessible places at every work site. These shall be maintained in good order under
the charge of a responsible person.

11.3 At large work places, where hospital facilities are not available within easy reach of the work first-
aid posts shall be established. Ambulance availability shall be identified during the entire period of work
for attending to injury cases.

12. SAFETY COORDINATOR

The contractor shall have a Safety Office or a Supervisor to be designated as a Safety Coordinator in
order to specifically look into the implementation of different safety requirements of the site work. The
person thus designated will in general co-ordinate on matters of safety and in particular ensure that the

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Safety Manual is complied with. His name shall be displayed on the Notice Board at a prominent place
at the work site.

13. REPORTING OF ACCIDENT

13.1 All accident leading to property damage and/or personnel injuries shall be reported to the
concerned authorities viz. Insurance Co. Police, Head Office, Regional Office, etc.

13.2 The contractor shall also submit a monthly statement of accidents to the Client by 4th of every
month showing details of accident, nature of injury including disability, days lost, treatment provided,
etc., and the extent of property damage.

14. PUBLIC PROTECTION

The contractor shall make all necessary provisions to protect the public. He shall be held responsible for
defense of every action of other proceedings at law that may be brought by any person for injury
sustained owing to neglect of any precaution required to taken to protect the public.

15.OTHER STATUTORY PROVISIONS

All operations involving the transport, handling, storage and use of explosive shall be as per the standing
instructions and conform with the latest Indian Explosives Act and the explosives Rules. Handling,
transport, storage and use of compressed gas cylinders and pressure vessels shall conform to the latest
Gas Cylinder Rules and Static and Mobile Pressure Vessels (Unfired) Rules. In addition, The Indian
Electricity Act and Indian Electricity Rules - latest, the Atomic Energy Act, the Radiation Protection Rules
- latest, Radiation Protection Manual of Nuclear Facilities and the Atomic Energy (Factories) Rules –
latest, and various latest rules and Act related to mining shall also be strictly complied with.

16. GUIDELINES AND GENERAL PROCEDURES FOR SUPPLY AND USE OF

ELECTRICITY AT SITE

16.1 Following safety requirements shall be complied with before the contractor uses the power
supply.

16.1.1 The contractor shall submit a list of licensed electrical staff to be posted at Site.

16.1.2 It shall be the responsibility of the contractor to provide and maintain complete installation on the
load side of the supply point with regard to the safety requirements at Site. All cabling and
installation shall comply with the appropriate latest statutory requirements given below and shall
be subject to approval of the Project Manager:

Indian Electricity Act.

Electricity (Supply) Act.
Indian Electricity Rules.
National Electricity Code.
Other relevant rules of Local Bodies and Electricity Boards.

The power supply shall be regulated as per the terms and conditions of the supply of the
respective electricity boards.

16.1.3 Where distribution boards are located at different places the contractor shall submit schematic
drawing indicating all details like size of wires, Overhead and Cable feeders, earthling etc. The
position and location of all equipment and switches shall be given.

16.1.4 The contractor shall make his own arrangement for main earth electrode and tapings thereof.
The existing earth points available at site can be used at the discretion of Client with prior
permission. Method of earthling, installation and earth testing results shall conform to relevant
I.S. Specifications (IS-3043).

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16.1.5 All three phases’ equipment shall be provided with double earthling. All light fixtures and
portable equipment shall be effectively earthed to main earthling.

16.1.6 All earth terminals shall be visible. No gas pipes and water pipes shall be used for earth
connection. Neutral conductor shall not be treated as earth wire.

16.1.7 The contractor shall not connect any additional load without prior permission of Client.

16.1.8 Joints in earthling conductors shall be avoided. Loop earthling of equipment shall not be
allowed. However, tapings from an earth bus may be done.

16.1.9 The entire installation shall be subjected to the following tests before energisation of installation
including portable equipment: -
• Insulation resistance test.
• Polarity test of switches.
• Earth continuity test.
• Earth electrode resistance.

The test procedures and their results shall conform to relevant standards.

16.2 Following guidelines are provided for general observations: -

16.2.1 INSTALLATION
a. Only persons having valid wireman’s license/competency certificate shall be employed for
carrying out electrical work and repair of electrical equipment, installation and maintenance at
site. A qualified licensed Supervisor shall supervise the job.

b. Electrical equipment and installations shall be installed and maintained as to prevent danger
from contact with live conductors and to prevent fires originating from electrical causes like short
circuits, overheating etc. Installation shall not cause any hindrance to movement of men and
materials.

c. Materials for all electrical equipment shall be selected with regard to working voltage, load and
working environment. Such equipment shall conform to the relevant standards.

d. The minimum clearance to be maintained for all overhead lines along roads and across roads
shall be as per the statutory requirements.

e. Grounding conductor of wiring system shall be of copper or other corrosion-resistant material.

An extra grounding connection shall be made in appliances/equipment where chances of
electric shock are high.

f. Electric fuses and/or circuit breakers installed in equipment circuits for short circuit protection
shall be of proper rating. It is also recommended that high rupturing capacity (HRC) fuses are
used in all circuits. For load of 5 kW or more earth leakage circuit breaker shall be provided in
the circuits.

g. Wherever cables or wires are laid on poles, a guard wire of adequate size shall be run along the
cables/wires and earthen effectively. Metallic poles as a general rule, shall be avoided and if
used shall be earthen individually. Anti climbing guards and danger notices shall be provided on
poles. Each equipment shall have an isolating switch.

h. Wires and cables shall be properly supported and an approved method of fixing shall be
adopted. Loose hanging of wires and cables shall be avoided. Lighting and power circuits shall
be kept distinct and separate.

i. Reinforcement rods or any metallic part of structure shall not be used for supporting wires and
cables, fixtures, equipment, earthing etc.

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j. All cables and wires shall be adequately protected mechanically against damages. In case the
cable is required to be laid under ground, it shall be adequately protected by covering the
same with bricks, Plain Cement Concrete (PCC) tile or any other approved means.

k. Using suitable cable glands shall properly terminate all armoured cables. Using cable
lugs/sockets shall connect multi-stranded conductor cables. Cable lugs shall preferably be
crimped. They shall be of proper size and shall correspond to the current rating and size
of the cable. Twisted connections will not be allowed.

l. All cable glands, armoring and sheathing of electric cable, metal circuits and their fittings,
metallic fittings and other non-current carrying parts of electrical equipment and apparatus shall
be effectively grounded.

m. All the Distribution Boards, Switch Fuse Units, Bus bar chambers, ducts, cubicles etc. shall have
MS enclosures and shall be dust, vermin and waterproof. The Distribution Boards,
switches etc. shall be so fixed that they shall be easily accessible. Changes shall be done only
after the approval of the Project Manager.

n. The contractor shall provide proper enclosures/covers for protection of the entire switchboard,
equipment etc. against rain. Exposed live parts of all electrical circuits and equipment shall be
enclosed permanently. Crane trolley wires and other conductor, which cannot be completely
insulated, shall be placed such that they are inaccessible under normal working conditions.

o. Ironclad industrial type plug outlets are preferred for additional safety.

p. Open type distribution boards shall be placed only in dry and ventilated rooms; they shall not be
placed in the vicinity of storage batteries or otherwise exposed to chemical fumes.

q Isolating switches shall be provided close to equipment for easy disconnection of electrical
equipment or conductors from the source of supply when repair or maintenance work has to be
done on them.

r. In front of distribution boards a clear space of 90 cm shall be maintained in order to have

easy access during an emergency.

s. Adequate working space shall be provided around electrical equipment, which requires
adjustment or examination during operation.

t. As far as possible electrical switches shall be excluded from a place where there is danger of
explosion. All electrical equipment such as motors; switches and lighting fittings installed in
workroom where there is possibility of explosion hazard shall be explosion proof.

u. All connections to lighting fixtures, starters or other power supplies shall be provided with PVC
insulate, PVC sheathed twin/three/four core wires to have better mechanical protection for
preventing possible damage to equipment or injury to personnel. Taped joints shall not be
allowed and the connections may be made in looping system. Electric starter of motors,
Switches shall not be mounted on wooden boards. Only sheet steel mounting or iron framework
shall be used.

v. All the lighting fixtures and lap holders shall be of good quality and in good condition. Badly
repaired or broken holders, etc. shall not be used.

w. Only PVC insulated and PVC sheathed wires or armoured PVC insulated and sheathed cables
shall be used for external power supply connections of temporary nature. Weatherproof
rubber wires shall not be used for any temporary power supply connections. Taped joints in the
wires shall not be used.

y. The bulbs/lamps used for illumination and testing purpose shall have cover or guard to protect
them from accidental breakage. Only 24 V supply system shall be used for hand lamps etc.
while working inside metallic tanks or conducting vessels.

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16.3 OPERATION & MAINTENANCE

a. All persons, who work with electrical installation/equipment, shall be aware of the electrical
hazards, use to protective devices and safe operational procedures. They shall be given
training in fire fighting, first aid and artificial resuscitation techniques.

b. The contractor shall instruct the workers in the proper procedure, specify and enforce the use of
necessary protective equipment such as adequately insulated pliers, screw drivers, fuse pulleys,
testing lamps and similar hand tools. Only wooden ladders shall be used to reach the heights in
electrical work.

c. No material or earthwork shall be allowed to be dumped below or in the vicinity of the bare
overhead line conductors.

d. Before any maintenance work is commenced on electrical installations/ equipment,the circuits

shall be de-energised and ascertained to be dead by positive test with an approved voltage-
testing device. Switches shall be tagged or the fuse holders withdrawn before starting the work.
Adequate precautions shall be taken in two important aspects viz.

e. That there shall be no danger from any adjacent live parts and

f. That there shall be no chances of re-energisation of the equipment on which the persons are
working.

g. While working on or near a circuit, whenever possible the use of one hand may be practiced
even though the circuit is supposed to be dead. The other hand may preferably be kept in
pocket.

h. When it is necessary to touch electrical equipment (for example when checking for overload of
motors) back of the hand may be used. Thus, if accidental shock were tocause muscular
contractions, one would not ‘freeze’ to the conductor.

I. Operations of electrical equipment shall be avoided which standing on wet floor or when hands
are wet.

j. Before blown fuses are replaced, the circuit shall be locked out and an investigation shall be
made for the cause of the short circuit or overload.

k. When two persons are working within reach of each other, they shall never work on
difference phases of the supply.

l. When structural repairs, modification or painting work are to be undertaken, appropriate

measures shall be taken for the protection of persons whose work may bring them into the
priority of live equipment/circuit.

m. It shall be ensured that the insulation and wire size of extension cords are adequate for the
voltage and current to be carried.

n. While tapping electricity from the socket, plug top must be used. It shall be ensured that no
extension boards are over loaded while tapping. Only standard three pin plugs shall be used
for tapping electricity. Broken sockets/plugs shall be replaced immediately with good ones.
Only joints free cables shall be used for connecting equipment/ apparatus.

o. Floors shall be kept free from tailing electrical cables to avoid tripping hazard.

P. Power supply to the entire machines and lighting fixture shall be switched off when not in use.

q. Temporary electrical connections shall be removed as soon as the stipulated work is over. After
completion of the works, the contractor shall dismantle the distribution boards and the other
facilities erected at site.

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r. Unauthorized tapping of power by others from distribution boards shall be prohibited at all
circumstances.

s. No flammable materials shall be stored in any working area near the switchboards.

“MEN ON LINE” “DO NOT SWITCH ON” “DANGER” OR “CAUTION” boards as applicable shall
be used during maintenance works on the electrical equipment.

16.4 PORTABLE ELECTRICAL EQUIPMENT

a) Portable electrical equipment shall be regularly examined, tested and

maintained to ensure that the equipment and its leads are in good order.
Register shall be maintained for inspection recording the testing dates and
results of the equipment.

b) All portable appliances shall be provided with tree core cable and three-pin plug. The
third pin of the plug shall invariably be earthen. It shall be ensured that the metal part of the
equipment shall be effectively earthen.

c) All connections to portable equipment or machines from the panel/distribution

board/extension board shall be taken using 3 core double insulated PVC flexible copper wire in
one length. No joints shall be allowed in this flexible wire. In case single length of wire is not
sufficient for a particular location then the supply can be tapped by providing another extension
board comprising of switch and socket.

d) Flexible cables for portable lamps, tools and apparatus shall be regularly
examined, tested periodically and maintained to ensure safety.

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TECHNICAL SPECIFICATIONS
CHAPTER – 1
HT SWITCHGEAR
1.0 HT SWITCHGEAR
1.1 General
The Panel shall be metal clad, totally enclosed, rigid, compartmentalized design, floor mounting,
air insulated, extensible, cubicle type, outdoor/indoor type in conformity with IP54 protection for
use on 11 kV, 3 Phase, 50 Hz system.

The equipment shall be designed for operation in high ambient temperature and high humidity,
tropical atmospheric conditions. Means shall be provided to facilitate case of inspection,
cleaning and repairs for use in installations where continuity of operation is of prime importance.

1 .2 Construction
The switchboard shall be:

a. Of metal enclosed, modular in construction, indoor, floor mounted cubicle type factory
built assembly.

b. Provided with dust, vermin and damp protection.

c. Readily extendible as required by the addition of vertical sections after removal of the
end covers.

d. Only CRCA steel sheets shall be used for fabricating the cubicle.

e. A removable gland plate with required number of knockout for the cable type and size
shall be provided.

f. A base channel of 75 mm shall be provided for the panel.

g. The thickness tolerance for sheets shall be as applicable in relevant IS.

1.3 Metal Treatment And Finish

Generally the treatment and finish of the metal surface shall be as specified in Section 16425,
Clause 8.4

1.4 Bus Bars

The bus bars shall be made of high conductivity high strength for 11000V, 3 wire, 50 Hz system.

The bus bars shall be suitably supported with 11 kV insulation mounts, number of supports and
its spacing shall be adequate enough to withstand required short circuit levels.

High tensile bolts and spring washers shall be provided at all bus bar joints. The bus bars shall
have uniform cross section throughout and shall be capable of carrying the rated current at
11000 V continuously. A current density of 1.2 A/Sq.mm shall not be exceeded for copper and
0.8 A/Sq.mm for Aluminum bus bars.

Bus bar chamber shall be of air insulated type suitable for an 11000V, 3 Phase, 50 Hz system.

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1.5 11KV 350MVA VCB

HT panel switchboard shall comprise of:

a. totally enclosed single bus bar

b. A draw-out type Triple pole Vacuum Circuit Breaker (VCB) suitable for installation in 3
phase, 3-wire, 50 Hz effectively earthed supply system having fault level of 350 MVA at
11000 V. The VCB shall be floor mounting, metal clad, indoor/outdoor, extensible type
flush fronted construction, having a horizontal draw out facility.

The circuit breaker shall be equipped with:

a) Housing for circuit breaker carriage

b) Mechanical interlock and automatic safety shutter gear including padlocking arrangement

c) Specified Amperage, 350MVA at 11000V vacuum circuit breaker with interrupters, epoxy
support insulators, self-aligning finger type isolating contacts.

d) Truck having integral racking in device for insertion and withdrawal of VCB complete with
necessary interlocks.

e) Manually/Electrically (230V, AC) operated spring charging mechanism, with ON/OFF/TRIP

indication.

f) Mechanical operation counter.

g) Electrical closing coil of 24Volts DC

h) Shunt trip coil of 24V DC

i) Breaker operated auxiliary switch – with 6 NO and 6 NC contacts

j) Breaker chamber including a set of 3 phase bus bars.

k) 230 volts AC single phase strip heaters, panel lamp and 15/5A switched socket.

l) Current transformers chamber incorporating 3 nos, single-phase, resin cast CTs of specified
ratio with output burden/accuracy class of 15VA/Class 0.5 per core.

m) The CTs shall be suitable for short time rating of 18.4 kA for 1 second.

n) Potential transformer chamber incorporating resin cast PT of ratio 11000/110V and of suitable
burden.

o) Rear cable termination facility for terminating 11kV XLPE Cable of required size.

p) Instrument panel fitted with 96 x 96 mm CT operated Ammeter with 3-way and off selector
switch, over current and earth fault relay and red and green indicating lamp, 96mm x 96 mm PT
operated Voltmeter with selector switch, Frequency and PF meters.

q) The switch gear panel shall be complete with all internal wiring and circuit labels.

r) The VCB feeding transformer shall have 2Nos of over-current plus one No. of earth fault
element relay and other auxiliary relays for transformer protection as specified in the datasheet.

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1.6 Storing

The H.T. panel shall be stored in a well-ventilated dry place. Suitable polythene covers shall be
provided for necessary protection against moisture till they are energized.

1.7 Erection

The H.T. panel shall be installed over the PCC pedestal in 1:3:6 PCC to a suitable height.

1.8 SUBSTATION EQUIPMENT:

1.8.1 Single breaker panel at Metering Point(Outdoor)

1. Circuit Breaker: The panel shall be fabricated with CRCA sheet and powder coated with
Siemens Grey paint

1.1 Quantity : As per Schedule

1.2 Installation : Outdoor

1.3 Nominal system voltage : 11 KV, 3 phase

1.4 Highest system voltage : 12 KV, 3 phase

1.5 System frequency : 50 Hz +/- 5%

1.6 Details of neutral earthing : Solidly earthed

1.7 Rated current : As per schedule

1.8 Rated insulation level : 28 KV

1.9 Rated symmetrical short

Circuit breaking capacity : 350 MVA for 11KV

1.10 Operating duty : As per IS: 2516 (part 1 sec.3) or latest revision.
The circuit breaker is not intended for rapid auto-
reclosing. Operating Duty: O-0.3sec - CO- 3min-CO

1.11 Type of breaker : VCB

1.12 Closing mechanism : Motor operated (230V AC) spring charged electrically
released true trip free closing mechanism with 6 NO &
6NC auxiliary Contacts. With suitable Inbuilt power pack

1.13 Tripping mechanism : Shunt trip coil suitable for 24V DC with Inbuilt power pack

1.14 Fittings : Operation counter; space heater; incoming and outgoing

bushings.

1.15 Special tools : Portable hoisting gear crank for manual charging of
Springs and other tools required for maintenance.

1.16 Mechanical & Electrical : Nil

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2. Current Transformers

2.1 Quantity : As per schedule/SLD

2.2 Type : Indoor epoxy resin cast. type suitable for effectively
Earthed system.

2.3 Rated voltage : 11 KV, 3 phase

2.4 Rated primary current : 120A-60A

2.5 Rated secondary current : 5 Amp.

2.6 No. of secondary : Two - 1 for metering; 1 for Protection

2.7 Rated burden : 15 VA for each winding

2.8 Insulation level : 75KV

2.9 Short time current : 18.1KA min.for 1 second rating

2.10 Class of accuracy : 0.5 – Metering 5 p - Protection

2.11 Reference standard : IS 2705

2A. Potential Transformer

2A.1 Quantity : As per schedule

2A.2 Type : Indoor, epoxy resin cast.

2A.3 Rated Primary voltage : 11/ SQRT3 KV

2A.4 Rated secondary voltage : 110/ SQRT3 V

2A.5 No. of windings : One

2A.6 Accuracy class : 0.5

2A.7 Rated burden : 100 VA for main winding

2A.8 Impulse withstand : 28 KV rms (induced voltage) 75 KV peak for 11KV

2A.9 Reference standard : IS: 3156

3. Relays

3.1 The following shall be provided on the panel.

A) Metering:

i) 1 No. Ammeter, Analog type, suitable for operation from 5Amp. CT secondary, 96 mm sq. flush
mounting. Selector switch shall be provided with each ammeter.

ii) 11KV Digital load manager with RS485 protocol, class 0.5 Accuracy with Modbus connectivity

iii) 1 No. Voltmeter, Analog type, along with PT of 11000/110V Selector switch shall be provided with
each Voltmeter.

iv) Digital PF Meter

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B) Protections

i) 1 No. - Three Element IDMTL Over-current cum Earth Fault Relay (EEMake CDG 31 (or) equivalent)
Horizontal version in flush pattern, draw out cases

ii) Master trip relay type VAJH13 of EE make or equivalent

iii) PT fuse failure relay with indication

iv) Auxiliary relays (VAX 31)

C) Indications:

i) “Auto trip" indicating lamp.

ii) Indicating lamps for ON-OFF position of the circuit breaker.

iii) Breaker spring charged indication

iv) R, Y, B Indications

v) Trip Circuit Healthy

4. Fault Annunciation (8 windows for Incomer & Outgoing Breakers)

Suitable scheme shall be provided for annunciating trip & non-trip faults with separate annunciators and
lamps with necessary relays and push buttons for accept & reset. High speed trip relay type VAJH13 of
EE shall be used for tripping circuit breaker. The general Specifications of the Annunciator are given
below.

i) Face: Translucent Glass / Plastic Window with Engraving

ii)Operation :

a) On Occurrence of Fault: Audible Hooter and flashing of Indication lamp.

b) Acknowledge Button Pressed: Audible hooter and flashing of Indication lamp shall stop.
Indication lamp shall become steady.

c) Reset Button Pressed: If Fault is removed then Indication lamp shall go off

d) Test Button Pressed: All lamps shall Glow.

iii) Monitoring: Power supply to Annunciator shall be monitored.

iv) Indications: The Indications shall be provided for following

Incomer VCB: Breaker On/ Breaker Off/ O.C Trip/ E/F Trip
Outgoing VCB: Breaker On/ Breaker Off/ O.C Trip/ E/F Trip,

5. The breaker shall have the BMS monitoring & operation provision with potential free contacts for the
following:
a. For Monitoring :- ON/OFF, Trip status.
b. For operation : - Open, Close.

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1.8.2 Three breaker panel (outdoor kiosk type) for Transformers control

1. Circuit Breaker: The panel shall be fabricated with CRCA sheet and powder coated with
Siemens Grey paint

1.1 Quantity : As per Schedule & Drawings (One Incomers & Two
Outgoing)

1.2 Installation : Outdoor as per schedule

1.3 Nominal system voltage : 11 KV, 3 phase

1.4 Highest system voltage : 12 KV, 3 phase

1.5 System frequency : 50 Hz +/- 5%

1.6 Details of neutral earthing : Solidly earthed

1.7 Rated current : As per schedule

1.8 Rated insulation level : 28 KV

1.9 Rated symmetrical short

Circuit breaking capacity : 350 MVA for 1 sec

1.10 Operating duty : As per IS: 2516 (part 1 sec.3) or latest revision.
The circuit breaker is not intended for rapid auto-
reclosing. Operating Duty: O-0.3sec - CO- 3min-CO

1.11 Type of breaker : VCB

1.12 Closing mechanism : Motor operated (230V AC) spring charged electrically
released true trip free closing mechanism with 6 NO &
6NC auxiliary Contacts.

1.13 Tripping mechanism : Shunt trip coil suitable for 24V DC.

1.14 Fittings : Operation counter; space heater; incoming and outgoing

bushings.

1.15 Special tools : Portable hoisting gear crank for manual charging of
Springs and other tools required for maintenance.

1.16 Mechanical & Electrical : Nil

2. Current Transformers
2.1 Quantity : As per schedule/SLD

2.2 Type : Indoor epoxy resin cast. type suitable for effectively
Earthed system.

2.3 Rated voltage : 11 KV, 3 phase

2.4 Rated primary current : Incomer : 120-60A

Outgoings: 60-30A

2.5 Rated secondary current : 5 Amp.

2.6 No. of secondary : Two - 1 for metering; 1 for Protection

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2.7 Rated burden : 15 VA for each winding

2.8 Insulation level : 75KV

2.9 Short time current : 18.1KA min.for 1 second rating

2.10 Class of accuracy : 0.5 – Metering 5 p - Protection

2.11 Reference standard : IS 2705

2A. Potential Transformers

2A.1 Quantity : As per schedule

2A.2 Type : Indoor, epoxy resin cast.

2A.3 Rated Primary voltage : 11/ SQRT3 KV

2A.4 Rated secondary voltage : 110/ SQRT3 V

2A.5 No. of windings : One

2A.6 Accuracy class : 0.5

2A.7 Rated burden : 100 VA for main winding

2A.8 Impulse withstand : 28 KV rms (induced voltage) 75 KV peak

2A.9 Reference standard : IS: 3156

3. Relays

3.1 The following shall be provided on the panel.

A) Metering:

i) 1 No. Ammeter, Digital type, suitable for operation from 5Amp. CT secondary, 96 mm sq. flush
mounting. Selector switch shall be provided with each ammeter.

ii) 11KV Digital load manager with RS485 protocol, class 0.5 Accuracy (Make similar to ENERCON)
with Modbus connectivity

iii) 1 No. Voltmeter, Digital type, along with PT of 11000/110V Selector switch shall be provided with
each Voltmeter.

iv) Digital PF Meter

B) Protections

i) 1 No. - Three Element IDMTL Over-current cum Earth Fault Relay (EEMake CDG 31 (or) equivalent)
Horizontal version in flush pattern, draw out cases.( For all Breakers)

ii) Master trip relay type VAJH13 of EE make (or) equivalent.( For all Breakers)

iii) PT fuse failure relay with indication for incomers only

iv) Auxiliary relays (VAX 31)

C) Indications:

i) “Auto trip" indicating lamp.

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ii) Indicating lamps for ON-OFF position of the circuit breaker.

iii) Breaker spring charged indication

iv) R, Y, B Indications

v) Trip Circuit Healthy

vi) Winding Temperature Alarm & Trip (For Outgoing feeders to Transformers only)

4. Fault Annunciation (12 Windows for Transformer Breakers & 8 windows for Incomer Breaker)

Suitable scheme shall be provided for annunciating trip & non-trip faults with separate annunciators and
lamps with necessary relays and push buttons for accept & reset. High speed trip relay type VAJH13 of
EE shall be used for tripping circuit breaker. The general Specifications of the Annunciator are given
below.

i) Face: Translucent Glass / Plastic Window with Engraving

ii) Operation :

a) On Occurrence of Fault: Audible Hooter and flashing of Indication lamp.

b) Acknowledge Button Pressed: Audible hooter and flashing of Indication lamp shall stop.
Indication lamp shall become steady.

c) Reset Button Pressed: If Fault is removed then Indication lamp shall go off

d) Test Button Pressed: All lamps shall Glow.

iii) Monitoring: Power supply to Annunciator shall be monitored.

iv) Indications: The Indications shall be provided for following

Incomer VCB : Breaker On/ Breaker Off/ O.C Trip/ E/F Trip
Outgoing VCB: Breaker On/ Breaker Off/ O.C Trip/ E/F Trip,
Buchholtz’s alarm & Trip, Oil Temp Alarm& Trip, Winding Temp alarm & Trip
OLTC surge Alarm
5. The breaker shall have the BMS monitoring & operation provision with potential free contacts for the
following:
a. For Monitoring :- ON/OFF, Trip status.
b. For operation : - Open, Close.

II. INSPECTION AND TESTING SCHEDULE AT MANUFACTURE'S WORKS

The supplier shall offer the above equipment for following inspections / Tests which may be witnessed
by the purchaser / purchasers representatives. The supplier shall be responsible for providing
instruments of correct range and accuracy that may be required for carrying out these tests. All tests
shall be carried out as per relevant Indian standard specifications or other approved International
standard specifications.

1. CIRCUIT BREAKER
01 Visual Inspection

a) Layout of component dimensions bus bar mounting arrangements and bill of materials as per the
approved drawings.

b) Checking tightness of joints, phase markings, electrical clearance etc.

c) Routing of control wiring and power cables, their termination etc.

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d) Verification of test certificates for bought out components.

e) General workmanship, finish, interchangeability, compartmentalization, identification, tags etc.

f) Check of earth arrangements, provision of shutters and mechanical interlock arrangement.

g) Verification of Conformity to Engineering Standards

02 Routine Tests

a) Measurement of resistance of main circuit.

b) Operation tests including measurement of closing & opening time on oscilloscope.

c) One minute power frequency voltage dry withstand test on circuit breaker.

d) One minute power frequency voltage dry withstand tests on auxiliary circuits.

Routine tests mentioned above shall be carried out as per IS: 2516 (part -II / sec.2) latest revision.

2. CURRENT TRANSFORMER
01 Visual Inspection

a) Dimensional check and general arrangement.

b) Terminal marking.

c) Name plate details.

02 Routine Tests

a) Determination of error according to the requirements of appropriate accuracy class.

b) Verifications of terminal markings and polarity.

c) High voltage power frequency test on primary and secondary windings.

Routine tests shall be carried out as per IS: 2705 (part-I) - latest revision.

3. RELAYS
01 Visual Inspection
- For layout components, bus mounting, compartmentalization etc. as approved drawings.
- For checking of dimensions, electrical clearances, phase marking, tightness of joints etc. p73
- General workmanship, finish identification labels, routing and termination of control and power wires /
cables etc.
- Verification of test certificates for bought out components.

02 Running Tests
- High voltage power frequency withstand test
- Insulation resistance test
- Functional test including simulation test on relay.

III) Manuals & Guarantee Cards :

The successful Contractor shall submit all the Operation and Maintenance
Manuals for all Major equipment (in 3 Sets)

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CHAPTER 2
POWER TRANSFORMER
1.0 General

1.1 Scope

The transformer shall be manufactured to the relevant IS specifications. The transformer shall
be supplied with first fill of oil.

Scope covers manufacturing, supply, storage, installation, testing and commissioning of power
transformers and associated equipment of required ratings.

1.2. Codes and Standards

The design, material, construction, manufacture, inspection, testing and performance of power
transformer shall comply with all currently applicable standards, regulations and safety codes in
the locality where the equipment shall be installed. The equipment shall also conform to the
latest applicable standards and codes of practice.

In case of conflict between the applicable standards and this specification, this specification
shall govern.

The transformer shall generally conform to IS 1180 & IS 2026 Part 1 to 4 latest editions.

1.3 Rating

The Transformer shall be continuously rated for a full load temperature rise not exceeding 50
deg.C by thermometer in oil and 55 deg.C by resistance method.

1.4 Equipment

The transformer shall be complete and also have the following:

a. Oil conservator with filling hole and cap, oil level indicator, fresh dehydrated silica gel.

b. Silica gel breather with first fill of charge.

c. Plain oil level gauge with max. /min. level indication.

d. One No. drain valve

e. One No. filter valve

f. Thermometer pockets

g. Diagram and Rating plate

h. Two earthing terminals

i. Lifting arrangement and jacking bolts

j. Four Nos. - Bi-directional rollers

k. First filling of filtered oil with di-electric strength of 40kV/mm or more.

l. PRV / Double diaphragm explosion vent with Oil Sight Glass

m. Dial type oil temperature indicator with Maximum Reading Position [MRP] and Resetting
Device [RSD]: With alarm and trip contacts

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n. Dial type winding temperature indicator with: MRP and RSD and with alarm and trip
contacts.

o. Double float Bucholtz relay with alarm and trip contacts and gas collecting hand cock

p. Thermo junction box.

q. Magnetic Oil Level gauge with low level alarm contacts.

r. One No. Neutral CT shall be provided mounted inside the tank and its Secondary
Winding connection wired to a marshalling box.

s. Air Release Device on tank

t. Base channel with towing hook/hole

u. Maintenance Instructions

1.5 Tap Changing Arrangement

The transformer shall be provided with ON Load Tap Changing Gear on 11KV side
Transformers and shall be provided with OLTC, RTCC and AVR

1.5.1 Tap Change Switch (General Requirement):

The On Load Tap Changer (OLTC) shall be provided in the HV winding and shall
permit constant voltage on LV side. OLTC gear shall be motor operated for local as well as for
remote operation. An external hand wheel / handle shall be provided for local manual operation.
The OLTC shall be suitable for power flow on either direction. The transformer shall give
full load out put on all taps.
Arrangement shall be made for securing & padlocking the tap changer wheel in any of the
working positions & it shall not be possible for setting or padlocking the wheel in any
intermediate position. Arrangement shall be such that no padlock key can be inserted
unless all contacts are correctly engaged & switch set in a position where no open or short
circuit is possible. An indicating device shall be provided to show the tap in use.

1.5. 2 On Load Tap Changing Gear (OLTC):

The details of the method of diversion of the load current during tap changing, the
mechanical construction of the gear and the control features for OLTC gear shall be
submitted with the bid. Information regarding the service experience on the gear and a list of
important users shall be furnished, The tap changer shall change the effective
transformation ratio without producing phase displacement.

a. The current diverting contacts shall be housed in a separate oil chamber not
communicating with the oil in main tank of the transformer. The chamber shall be
provided with a means of releasing the gas produced by the arcing.

b. The contacts shall be accessible for inspection without lowering oil level in the main tank
and the contact tips shall be replaceable.

c. For reduction of make & break arcing voltage due to overloads & short circuits, the arcing
switch/arc suppressing tap selector shall be provided with reactors/resistors.
Necessary tools & tackles shall be furnished for maintenance of OLTC gear.

d. The OLTC oil chamber shall have oil filling and drain plug, oil sampling valve, relief vent and
level glass, It shall also be fitted with a Buchholtz relay the outlet of which shall be
connected to a separate conservator tank.

e. The diverter switch or arcing switch shall be so designed as to ensure that its
operation once commenced shall be completed independently of the control relays or
switches, failure of auxiliary supplies etc.

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f. Tap changer shall be so mounted that bell cover of transformer can be lifted without
removing connections between windings and tap changer.

g. Drive mechanism chamber shall be mounted on the tank in accessible position, It

should be adequately ventilated and provided with anti-condensation metal clad
heaters. All contactors, relay coils and other parts shall be protected against
corrosion, deterioration due to condensation, fungi. Pad locking arrangement for
hinged door of the cubicle and cable glands for all incoming cables, etc., shall be
provided. The tap change driving motor shall be suitable for operation with 415 V, 3 phase,
50 Hz external power supply.

h. Each transformer unit shall be provided with a local OLTC control cabinet and a
remote OLTC control panel. The control feature shall provide following:

➢ Local remote selector switch mounted in the local control cubicle shall switch
control of OLTC in the following manner:
A. When the selector switch is in LOCAL position, it shall be possible to operate
the RAISE-LOWER control switches specified in section (ii) below.
B. Remote control of RAISE-LOWER functions shall be prevented.
C. When the selector switch is in REMOTE the local control cubicle
mounted RAISE - LOWER switches specified in section (ii) shall be
inoperative,
D. Remote control of the raise - lower function shall be possible from the remote
control panel.
E. The LOCAL - REMOTE selector switch shall have at least two spare contacts
per position which are closed in that position but open in the other position.

➢ A RAISE-LOWER CONTROL SWITCH shall be provided in the Local Control

Cubicle. The switch shall be spring loaded to return to the center 'OFF' position and
shall require movement to the RIGHT to raise the voltage of the transformer.
Movement to the left shall lower the voltage. This switch shall be operative only
when 'local remote', selector switch is in local position.

➢ 'Step by step' operation to ensure only one tap change takes place even if the tap
change control switch is stuck or held in the operated position. Seal in circuits to
ensure positive completion of a tap change impulse once initiated. Interlock to
prevent an impulse being give to reverse the tap change direction while a
tap change operation is already under progress, until the mechanism comes to rest
and resets the circuits for fresh operation.

➢ On load tap changer shall be equipped with a time delay for 'INCOMPLETE
STEP’ in alarm consisting of a normally open contact which closes, if the
tap changer fails to make a complete tap change. The alarm shall not operate
for momentary loss of auxiliary power.

➢ The OLTC load tap changer shall be equipped with a fixed resistor network
capable of providing discrete voltage steps for input to the supervisory system.

i. Limit switches shall be provided to prevent over running of the mechanism and shall be
directly connected in the circuit of the operating motor. In addition, a mechanical stop shall
be provided to prevent over - running of the mechanism under any condition. Limit
switches may be connected in the control circuit of the operating motor provided that
a mechanism-de-clutching mechanism is incorporated.

j. Thermal device or other means shall be provided to protect the motor and control
circuit. All relays, switches, MCCB / MCB etc. Shall be mounted in the drive mechanism
chamber and shall be clearly marked for the purpose of identification.

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k. A permanently legible lubrication chart shall be fitted within the driving mechanism chamber.
A five digit counter shall be fitted to the tap changing equipment to indicate the
number of operations completed.

l. All relays and operating devices shall operate correctly at any voltage between the limits
specified.

m. It shall not be possible to operate the electric drive when the manual operating gear is in
use.

n. It shall not be possible for any two controls to (i.e., manual, local electrical and
remote) be in operation at the same time.

o. The equipment shall be suitable for supervisory control & indication with make before
break multi-way switch, having one potential free contact for each tap position. This
switch shall be provided in addition to any other switch/ switches, which may be
required for remote tap position.

p. All electrical control switches and the local operating gear shall be clearly labeled in a
suitable manner to indicate the direction of tap changing.

1.5.3 Manual Control:

The cranking device for manual operation of the OLTC gear shall be removable and
suitable for operation by a man standing on ground level. The mechanism shall be
complete with the following:

• Mechanical tap position indicator which shall be clearly visible from near the
transformer.
• A mechanical operation counter.
• Mechanical stops to prevent over cranking of the mechanism beyond the extreme
tap positions.
• The manual control considered as back up to the motor operated on load tap
changer control shall be interlocked with the motor to block motor -start-up
during manual operation. The manual operating mechanism shall be labeled to show
the direction of operation for raising the primary and vice-versa.

1.5.4 Electrical Control:

This includes the following:
a) Local Electrical control.
b) Electrical remote control from remote control panel.

Remote Electrical Group Control:

The OLTC control scheme offered shall have provision of remote electrical group control during
operation of transformers. This is in addition to independent control of OLTC. It shall be possible
to operate No. of transformers by group control of OLTC. For this, a flexible circuit arrangement
shall be provided for addition of transformers at a later date.
A four position selector switch having MASTER, FOLLOWER, INDEPENDENT and OFF
position shall be provided in the remote OLTC control panel for each transformer. This
shall be wired to enable operator to select operation of OLTC in Master, follower or
independent mode.

Out of step relays with timer contacts shall also be provided to give alarm and
indication in case of tap positions in all the transformers under group control being not in
identical position. There should be an automatic lock out of the combined control when
any one of the units fails to fall in steps, due to mal operation of its gear.

Under abnormal condition such as may occur if the contactor controlling one tap changer
sticks, the arrangement must be such as to switch off supply to the motor so that an out of step
condition is limited to one tap difference between the units.

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Master position:
If the selector switch is in MASTER position, it shall be possible to control the OLTC units in
the FOLLOWER MODE by operating the controls of the MASTER UNIT. Independent
operation of the units under FOLLOWER mode shall have to be prevented. However, the units
under independent mode will be controlled independently.

Follower Position:
If the selector switch is in follower mode, control of OLTC shall be possible only from MASTER
panel.

Independent Position:
In this position of selector switch, control of OLTC of individual unit only shall be possible.

1.5.5 Remote Tap Changer Control Panel (RTCC Panel)

The auxiliary devices for remote electrical control of the OLTC shall be housed in a
separate panel to be placed in the control room. The panel shall be made of sheet steel of not
less than 3mm and it shall be duly finished with stove enamel paint.

The size of the control cubicle to be supplied shall be as per suppliers practice. The color of the
finishing paint shall be as specified by Purchaser for panel exterior.

Control and signal devices required to be mounted in the RTCC Panel shall comprise of the
following:

a) Local - Remote maintained contact selector switch for OLTC

b) Actuating switch/push button for electrical raise / lower control,
c) Remote tap position indicator with tap nos. and corresponding rated voltage marked
on the instrument. The tap position indicators shall be digital type.
d) One potential free contact per tap for tele- transmission of tap position from
switchyard and control room to load dispatch center shall be provided.
e) A four position selector switch having master follower, independent and off position.
g) Name plate for each component.
h) Initiating devices and contacts for alarm as well as for indications for discordance in
the tap changer in any of the operating transformers
i) Cubicle lamp actuated by door switch, space heater, power sockets etc., shall
be provided inside RTCC panel.

j) The OLTC shall be suitable for supervisory control and indication with make before
break multi-way switch having one potential free contact for each tap position. This
switch shall be provided in addition to any other switch/switches which may be
required for remote tap position indication.

k) Annunciator (facia-type) scheme complete with accessories for the following:

• Tap change in progress.
• Tap changer out of step
• Tap changer motor trip.
• Failure of AC supply to the OLTC local control Kiosk.
• 415V OLTC Supply failure.

l) Signal lamps for:

• Healthy supply to control gear.
• 415 Volts OLTC supply ' 0N '.

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1.5.6 Specification for Control Cabinets

Control cabinet for the tap changer driving motors shall be housed in a local kiosk
mounted adjacent to or on the transformer.

Control cabinet of the operating mechanism shall be made out of 3mm thick sheet steel. Hinged
door with handle shall be provided with padlocking arrangement. Sloping rain hood shall be
provided to cover all sides 15 mm thick neoprene or better type of gaskets shall be provided to
ensure degree of protection of at-least IP55 as per IS : 2147. The colour of paint shall be light
gray in accordance with shade No. 631 of IS-5.

Motors rated 1 KW and above being controlled from the control cabinet would be
suitable for operation on a 415V, 3 phase, 50Hz system. Fractional KW motors would be
suitable for operation on a 240 V, single phase, 50 Hz supply system,

Isolating switches shall be group operated units (3 pole for use on 3 phase supply
system and 2 pole for single phase supply systems) quick make and break type, capable of
breaking safely and without deterioration, the rated current of the associated circuit. Switch
handle shall have provision for locking, in both fully open and fully closed positions,

Push button shall be rated for not less than 6 Amps, 415V AC or 2 Amps 110 V DC and shall be
flush mounted on the cabinet door and provided with appropriate name plates. Red, Green and
Amber indicating lamps shall be flush mounted.

For motors up to 5 KW, contactors shall be direct-on-line, air break, single throw type and shall
be suitable for making and breaking the stalled current of the associated motor which shall be
assumed equal to 6.5 times the full load current of the motor at 0.2 pf. For motors above 5 KW,
automatic star delta type starters shall be provided.

3 Pole contactors shall be furnished for 3 phase motors and 2 pole contactors for single phase
motors. Reversing contactors shall be provided with electrical interlocks between forward and
reverse contactors. If possible, mechanical interlocks shall also be provided. Contactors shall be
suitable for uninterrupted duty and shall be of duty category class AC4 as defined. in IS : 2959.

The main contacts of the contactors shall be silver plated and the insulation class for the coils
shall be class E or better. The dropout voltage of the contactors shall not exceed 70% of the
rated voltage.

Contactors shall be provided with a three element, positive acting, ambient temperature
compensated time lagged, hand reset type thermal overload relay with adjustable setting.
Hand reset button shall be flush with The front door of the cabinet and suitable for resetting with
starter compartment door closed.

Single phasing preventer relay shall be provided for 3-phase motors to provide positive
protection against single phasing.

Mini starter shall be provided with no volt coils whenever required.

Power cables will be of 1100 Volts grade stranded copper conductor. All necessary
cable terminating accessories such as glands, crimp type tinned copper lugs etc., for
power as well as control Cables shall be included in bidder's scope of supply. Suitable brass
cable glands shall be provided for cable entry. The required quantity of cable glands
suitable for cable size of 19 X 2.5 sq.mm control cable shall be provided.

Dummy plates for cable glands shall be provided for Owner/PMC's use if necessary.

Wiring for all control circuits shall be carried out with 1100 Volts grade PVC insulated
tinned copper stranded conductors of sizes not smaller than 2.5 sq. mm. At least 20% spare
terminal blocks for control wire terminations shall be provided on each panel. The terminal

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blocks shall be of non- disconnecting stud type. All terminals shall be provided with ferrules
indelibly marked or numbered and these identifications shall correspond to the designations on
the relevant wiring diagrams, The terminals shall be rated for adequate capacity, which
shall not be less than 10 Amps.

Separate terminal blocks shall be provided for terminating circuits of various voltage
classes. CT loads shall be terminated on a separate block and shall have provision for short
circuiting the CT secondary terminals.

Control cabinet shall be provided with 240V, 1-phase, 50Hz, 20W fluorescent light fixture and a
suitably rated 240V, 1-phase, 5 Amps, 3 pin socket for hand lamps. The 3-pin socket
shall be provided with protective electrical and mechanical cover with chain.

Strip heaters shall be provided inside each cabinet complete with thermostat (preferably
differential type) to prevent moisture condensation. Heaters shall be controlled by suitably rated
double pole miniature circuit breakers,

Signal lamps provided shall be of neon screw type with series resistors, enclosed in
Bakelite body. Each signal lamp shall be provided with a fuse integrally mounted in the lamp
body.

Items inside the cabinet made of organic material shall be coated with a fungus resistant
varnish.

Motors shall be 'squirrel cage' three phase induction motors of sufficient size capable of
satisfactory operation for the application and duty as required for the driven equipment. Motors
shall conform to IS: 325.

1.6 HV Terminal Arrangements

A three pole, one gland cable box, shall be provided suitable to receive one run of 11 kV, 3
Core, XLPE earthed, aluminum cable, sized up to 300 Sq.mm.

Heat-shrinkable terminal kits or Heat shrink sleeves shall be used for HV cable termination.
Suitable cable box: clearances shall be provided.

Care shall be taken in the installation of cable potheads and Heat shrink sleeves.

1.7 LV Terminal Arrangement

A four-pole flange box shall be provided suitable to receive 3200A Aluminum conductor Bus
Duct.

If additional neutrals are required, these shall be brought out through an Outdoor Bare Bushing.

Care shall be taken in the installation of Bus Duct.

1.8 General Constructional Features

The Transformer shall be constructed and supplied as per State Power supply company
Specifications

1.9 Rated Output

The transformer shall:
a) be capable of delivering the rated current at a voltage equal to 110% of the rated voltage without
exceeding the limiting temperature rise.

b) be capable of operation continuously, in accordance with the applicable standard loading guide
at its rated kVA and at any of the specified voltage ratios.

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c) be complete with cable boxes designed and constructed to withstand without damage, the
effects of external short circuits as per the specified Standards. Account shall be taken of the
different forms of system faults that can arise in service such as line to earth faults and line to
line faults associated with the relevant system and transformer earthing conditions.

d) The dynamic ability to withstand short circuit shall be demonstrated by tests or by reference to
tests on identical transformers.

e) All rated parameters such as voltage ratios, impedance, regulation, load losses, and no load
losses subject to the suppliers' guarantees shall be within the tolerances given in the applicable
Standards.

1.10 Tests
The tests listed below shall be carried out on the transformer and shall be deemed to be
included in the Contractor's scope.

a. Routine tests as per IS.

b. 2kV withstand test for all central wiring circuits.
c. Oil leakage test
d. Dimensional Check
e. Visual
f. Bushing Creep age Measurement
g. Vector group
h. Tan delta (if not included in IS)
i. Oil gas dissolved test (if not included in IS)

2.0 Data Sheet for Distribtuion Transformer

2.1 Quantity : As per Schedule

2.2 Number of phases : Three phase

2.3 Frequency : 50 Hz +/- 5%

2.4 Type of cooling medium : Mineral oil as per IS: 335

2.5 Rated KVA irrespective : 315kVA & 160 KVA

of tap position

2.6 Highest system voltage : 12 KV

2.7 Method of system earthing : Solidly earthed Neutral

2.8 Insulation level : 11 KV side - 75 KV

2.9 Rated voltages : HV winding - 11 KV

LV winding - 433V

2.10 Tapping : On Load tap changer with RTCC & AVR

Type for variation of Voltage from +5% to
-15% in steps of 1.25%

2.11 Type of tap changer : On Load

2.12 Connection : Delta/star

2.13 Vector group : Dyn11.

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2.14 Neutral terminal : Solidly earthed on LV side.

2.15 Insulation to : Uniform

Earth of winding

2.16 Impedance : As per IS 1180

2.17 Type of cooling : ONAN

2.18 Installation : Outdoor

2.19 Temp. rise : As per IS 1180/2026

2.20 Termination : HV side - cable end box

Suitable for 1 run of 11 KV 185sq.mm
XLPE cable.

LV side - suitable for Bus Duct

Connection of 3200A

2.21 Supply variation : The transformer shall be suitable for

continuous working
At a voltage variation of +/- 15%
Of rated voltage with frequency
variation of +/- 3% both not
occurring simultaneously. The
combined variation shall be
considered as 15%.

2.22 Max. efficiency : As per IS 1180.Level-I

2.23 Protections : i) Bucholtz's relay with double floats, one

for alarm and one for trip.
Bucholtz’s relay shall be provided with
isolating valves on both sides and
flanged connection piece shall be
Supplied for use when bucholtz’s
realy is not in use.
ii) Dial type thermometer with alarm and
Trip contacts for oil temp. Monitoring.
iii) Dial type thermometer with alarm and trip
contacts for winding temperature monitoring
iv) Magnetic type oil level detector with
alarm & trip contacts for main conservator.
v) Plain oil level indicator for conservator.
vi) OLTC surge alarm

2.24 Fittings : Oil conservator with shut off valve drain

cock.
Silica gel breather with silica gel & oil seal.
Explosion vent./ PRV
Inspection cover
Air release plug on tank cover
Oil filling hole & cap
Two earthing terminals
Thermometer pockets
Bi-directional rollers
Rating & terminal marking plate

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Filter valve
Drain valve with plug or blanking plate.
Marshalling box complete with wiring etc.
It shall also be provided with illumination
lamp & suitable cable glands & Lugs.
Lifting lugs for complete transformer & for
other components wherever necessary
Manufacturer's name plate
Base channel with towing holes/ Lugs.
Skid arrangement
Flexible copper links between tank
cover & tank body for earth continuity.

2.25 Finish : To be painted with suitable gray.

Paint as per shade 631 of IS-5.

2.26 General : i) The transformer shall be copper wound.

ii) The transformer shall be supplied with first
filling of oil.
iii) 11 KV winding bushings shall be suitable for 75
KV impulse strength.
iv) The transformer shall be suitable for
parallel operation & sharing electrical load
in proportion to its ratings.
v) 5% extra quantity of oil to be supplied
in non returnable drums.
3.0 Installation Of Transformer

Transformer shall be installed and commissioned as per the requirements of IS 1886 (latest
edition) and regulations of local authorities.

4.0 Handling

Transformer and all its accessories shall be handled carefully in its upright position as indicated
on the packing case. Lifting lugs and jacking pads shall be used for lifting of the transformer.
While using jacking pads utmost care shall be taken in proper application of jacks. Where
transformer is dragged or pulled on sleeper or rollers the traction eyes provided at the bottom
frame shall be used with suitable wire ropes and shackles.

5.0 Storage

Transformer shall be stored under shelter in a place free from fire and explosion hazards. Care
shall be taken to see that moisture will not contaminate oil inside the tank by checking all
gaskets, bolts, nuts and accessories.

6.0 Cabling and Earthing

Cables shall be terminated at cable boxes only after IR values are measured and found to be in
order. Cable termination shall be carried out with utmost care and H.T. cable box shall be filled
with compound after jointing and termination. The neutral of the transformer shall be connected
to two separate and distinct earth stations through a double run of copper flats of suitable size.
The body of the transformer shall also be provided with effective earthing as per the drawings
and specifications.

7.0 Pre - commissioning Tests

The Consultant / Employer/ State Power Supply Company shall witness the pre-commissioning
tests and the erection of the transformer.

The Consultant / Employer will perform a general inspection of bolts, nuts, gaskets and checking
of all accessories and checking of oil level.

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8.0 Mounting and Erection

The transformer shall be lifted by lugs or shackles or by any other suitable means (such as
dragging on rollers) and mounted on the rails, which are embedded in concrete prepared for the
purpose. Care shall be taken to see that the transformer is not tilted during lifting and erection of
the transformer. The rollers shall be checked to prevent movement of the transformer after
being positioned on the rails. Adequate and necessary clearance from walls, and other
equipment, shall be provided as indicated in the drawing and as per regulation of local
inspection authorities. After positioning of the transformer stoppers are to be welded to the rails
so that transformer is finally fixed at its place.

All the accessories and parts such as conservator tank, breather, radiators, explosion vent,
thermometer etc. shall be mounted on the transformer. Tighten all bolts and nuts and check for
any leakage. Any leakage shall be rectified. Check the oil level and top up, if necessary, with
new oil.

Phasing out tests shall be performed with 415 Volts applied to HV windings and voltage across
LV winding checked.

Measurement of neutral and body earth resistance shall be performed using an earth testing
megger. The values shall not exceed 1 to 2 Ohms respectively.

Functioning of thermometers, oil level indicator, Bucholtz relay shall be checked and adjusted, if
necessary. The transformer shall be charged only after the above tests are conducted and
approval of local authorities is obtained. The earthing of neutral and body of the transformer
shall be done as per I.E. regulations and the requirements and of local authorities.

However, general mode of earthing arrangement is indicated on the drawings. The Contractor
shall supply all the material and labour for erection and commissioning of the transformer.

9.0 Warranty and Maintenance

The installation shall be guaranteed against faulty workmanship for minimum of one year from
the date of practical completion. All faulty workmanship shall be replaced and restored to full
operation at no cost to the Employer within the guarantee period.

Manufacturer's guarantees and warranties shall be obtained as agreed. The warranty period
shall be for eighteen months commencing from the date of installation or twelve months from the
date of practical completion, whichever is the first to occur.

10.0 VISUAL INSPECTION OF POWER TRANSFORMER

10.1 Visual Inspection

a) For general and mounting arrangements as per approved drawings.

b) For dimensional check of tank, roller distances, flanges /cable boxes etc.

c) General workmanship, finish and painting and provision of accessories as specified.

d) Tank, cooler, attachment, valves, etc. tests for leakage.

10.2 Routine Tests

a) Measurement of windings resistance.

b) Ratio, polarity and phase relationship for vector group verification.

c) Measurement of No-load losses and No-load current

d) Measurement of load losses.

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e) Impedance voltage test

f) Insulation Resistance test

g) Induced over voltage withstand test

h) Operation of OLTC, WTI and OTI etc.

i) Separate source voltage withstands.

10.3 Type Tests (Certificates to be furnished for the same type capacity transformer)
a) Temperature rise test
b) Impulse voltage withstand test
c) Zero sequence impedance measurement.

Routine & type tests mentioned above shall be carried out as per IS: 2026 – latest
revision.

11.0 Manuals & Guarantee Cards:

The successful Vendor shall submit all the Operation and Maintenance Manuals for all Major
equipment (in 3 Sets)

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Chapter - 3
Battery & Battery charger

3.1 Battery
Quantity : As per Schedule

Type of cell : Sealed Maintenance Free

No. of cells : 12

Nominal Cell Voltage : 2Volts DC each

Rating : 100 AH SMF type

Battery Bank Voltage : 24V DC (Nominal)

Duty : Substation duty

Accessories : The battery set shall be complete with stand

Inter-cell connectors, floats, nuts & bolts, inter row connectors,
insulators and MS mounting stand.

Reference standard : IS-1651 & 1652

3.2 Battery Charger

The Float cum boost charger shall consists of one three phase double wound charger input transformer,
rectifier power bridge, Charger Control Card, LC Filter circuit, and Auto/Manual Float/Manual Boost
Charging mode selector switch.

The Charger shall be manufactured utilizing thyristors and diodes, which are connected in full wave half
controlled bridge configuration. The Charger output voltage regulation and over load drooping
characteristics shall be achieved by carefully determining the precise moment to fire the thyristors by
supplying proper gate pulses. Charger control card shall accomplish this function.

The charger shall work with Single phase, 230V 50Hz AC input supply. The Charger shall be capable of
delivering the full rated current at the specified voltage at output terminals. The voltage shall be
maintained for an AC input voltage variation of + 10% and load current variation from 10 to 100% of
rated full load.

The Charger charges the battery in Auto or Manual Float or Manual Boost modes depending on the
mode selector switch position. In auto mode, the battery shall be charged either in float or boost mode
depending on the battery charging current. When charging current exceeds a preset value Charger shall
operate in float mode automatically.

All the circuits shall be housed in a single cabinet of folded sheet steel construction. All the meters,
indications, pushbuttons and control & switches shall be brought on to the front panel.

3.2.1 TECHNICAL SPECIFICATION OF CHARGER

Scheme : Float Cum Boost Charger

Type : Full Wave Half Controlled
Rating : 24V/20A suitable for VRLA battery

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AC INPUT

Voltage : 230V AC + 10%

Frequency : 50Hz + 5%
Phase : Single Phase

DC OUTPUT

Float voltage : 45V DC adjustable by +2%, -5%

Boost voltage : 45V DC adjustable by +/-5%
Regulation : Better than + 0.5V DC of set value
Ripple : Less than 3% RMS
Current : 20A
Efficiency : Better than 70% at full load

METERS : Following analog type meters of size 96x96 Sq.mm with

90 degree deflection shall be provided in the system.

e) DC Voltmeter with selector Switch (0-200V)

f) DC Ammeter.(0-20A) (Two quadrant operation)

INDICATIONS : Long life LED indicators shall be provided for the

following conditions with audio alarm for abnormal
conditions

7 AC supply ON (Neon lamp)

8 Charger ON
9 Charger fail
10 DC over voltage
11 DC under voltage

PROTECTIONS : Following protections shall be

provided.
7 AC Input Circuit Breaker
8 Fast acting semiconductor fuse for Charger bridge
9 DC over voltage cutback.
10 DC over load
11 DC output Circuit Breaker
12 Battery input fuses.

CONTROLS & SWITCHES :

a. Float voltage adjust Potentiometer
b. Boost voltage adjust Potentiometer
c. Auto/Float/Boost mode selector switch
d. DC voltmeter selector switch
e. AC Input Circuit Breaker
f. DC output Circuit Breaker

SPECIAL FEATURES :
• Soft start on DC side.
• Class-F insulation for all magnetics.
• Automatic voltage regulation using digital control logic.
• Filter circuit to limit ripple.
• Charger current limiting.
• Automatic Float/Boost changeover, based current drawn by
battery.
• Auto restart on input power restoration.

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DCDB : Built in DCDB.

a. Incomer : 63A-2P-ON/OFF MCB-1No.
b. Outgoing feeders : 16A-2P-ON/OFF MCBs-4Nos.

GENERAL
a. Cabinet : Free standing, Floor mounting cabinet, sheet steel
construction, easy access for installation and commissioning
cable entry at bottom. Necessary Cooling fans to be provided to
limit the temp rise or electronic components.

b. Temperature range : 0Deg.C to 50Deg.C of operation

c. Relative Humidity : 0% to 95% non-condensing.

d. Paint : Light Grey - 631 of IS: 5

e. Protection : IP - 42 as per IS 2147.

Accessories : The battery set shall be complete with Copper inter-cell

connectors, nuts & bolts, inter row connectors, strain insulators and
a rack to mount Cells.

Reference standard : IS-1651 & 1652

1.3 INSPECTION AND TESTING SCHEDULE AT MANUFACTURE'S WORKS

1.3.1 Batteries
01 Visual Inspection

02 Dimensional checks

1.3.2 Battery Chargers

01 Visual Inspection

a) General arrangements, layout of components, cleanliness,

Compartmentalization and dimension etc.

b) General workmanship finish identification labels, taps,

Caution plates, routing and termination of power and
Control cables etc.

c) Verification of test certificates for bought out

components.

02 Routine Tests
a) Scheme and functional check

b) Voltage regulation check

c) High voltage withstand test

4 Insulation resistance test.

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Chapter - 4
POWER CONTROL CENTRES

1.0 Scope :

This specification is to cover the requirement of design, supply, installation, testing and commissioning
of LT power control centers / main switch boards with all components, Instruments, fittings and
accessories for efficient operation without any trouble.

2.0 Standards :

The PCC specified herein, unless otherwise stated shall conform to the relevant and latest revisions
of Indian standards ,Indian Electricity Rules and IEC Standards.

IS 5 Colors for Ready Mixed Paints

IS 375 Specification for Marking & Gen Arrangement of Switchgear, Bus bars,
Main Connection & Aux. Wiring

IS 398 Specification for Hard Drawn Stranded Aluminium & Steel Cored
Aluminium Conductors for Overhead Power Transmission Purpose

IS 513 Cold Rolled Low Carbon Steel Sheet & Strips

IS 722 Specification for A. C. Electricity Meters. (Integrity Meters)

IS 1248 Specification for Direct Acting Electrical Instruments.

IS 1822 AC Motor Starters of Voltages not exceeding 1000

IS 1841 Specification for EC grade Aluminium Rod Produced By Rolling

IS 1897 Specification for Copper Strips for Electrical Purposes

IS 1901 Visual Indicator Lamps.

IS 2147 Degree of Protection provided by Enclosure for Low Voltage Switchgear

IS 2208 Specification for HRC Fuse Links upto 650 Volts

IS 2516 A.C. Circuit Breaker Requirement for Voltages not Exceeding 1000 V (Part -
I, Sec - I + Part - II, Sec-II)

IS 2705 Specification for Current Transformers.

IS 2834 Specification for Capacitors for Power System

IS 2959 AC Contactors for voltages not exceeding 1000 V

IS 3202 Code of Practice for Climate Proofing of Electrical Equipment

IS 3231 Electrical Relays for Power System Protection.

IS 3247 Switchgear General Requirements

IS 3427 Metal Enclosed Switchgear & Control gear

IS 4064 Specs for Heavy Duty Air Break Switches Fuses for Voltages not
exceeding 1000 V.

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IS 4237 General Requirement for Switchgears & Controlgear for Voltage not
exceeding 1000 V

IS 6875 Control Switches / Push Buttons

IS 8623 Factory Built Assemblies of Switchgears & Control Gear.

IS 8828 Miniature Circuit Breaker

IEC 60947 LV Switchgear and Control Gear.

3.0 Design and construction :

3.1 Design requirements : The power control centers shall be suitable for operation on
600/440volt, 3 phase,4wire 50HZ system to withstand a short circuit level of 50 KA RMS symmetrical or
75KA as per switchgear.

The PCC shall be designed for operation in high ambient temperature up to 55 degrees centigrade and
high humidity up to 95% and tropical atmospheric conditions. Means shall be provided to facilitate ease
of inspection, Maintenance and Servicing.

3.2 Constructional requirements :

The power control center shall be of

i) Metal clad, cubicle, indoor, free standing type suitable for Mounting on Built up Trenches with U
Channels of adequate size.

ii) Made up of the requisite vertical sections, which when coupled together shall form continuous dead
front switch board.

iii) Dust and damp protected, the degree of protection shall be better than IP - 54 as specified in IS-
2147, if specified in schedule

iv) Readily extendable on both sides by the addition of vertical sections after removal of the end covers.
v) Single front construction with the circuit breaker feeder and switch fuse/MCCB feeders suitable for
operation from the front of the panel.

The PCC shall have the feeder ratings as per the schematic diagrams enclosed with the schedule and
constructed only of materials capable of withstanding the mechanical, electrical and thermal stresses
as well as the effects of humidity, which are likely to be encountered in normal service.

3.3 Vertical Sections :Each vertical section shall comprise a front framed structure rolled folded sheet
steel channel section of minimum 2 mm thickness rigidly bolted together. This structure shall house
the components contributing the major weight of the equipment such as circuit
breaker, switch fuse units, main horizontal bus bars, vertical risers and other front mounted accessories.
The structure shall be mounted on a rigid base frame of folded sheet steel of minimum of 2.5mm
thickness and 100mm height. The design shall ensure Structural stability during Transit and also
during Operation after Commissioning Suitable cable chamber housing the cable end connections and
power / control cable terminations shall be provided. The design shall ensure generous availability of
space for ease of installation and maintenance of cabling and adequate safety for working in one
vertical section without coming into accidental contact with live parts in the adjacent section.

A cover plate at the top of the vertical section shall be provided with necessary ventilating
arrangements. Any aperture for ventilation shall be covered with a perforated sheet having less than
1 mm diameter perforations to prevent entry of vermin.

The Height of Panel shall be not more than 2.2M including base channel.

3.4 Sheet Steel Cubicle :

3.4.1 The sheet steel cubicle shall be designed in fully segregated multi tier formation. Each cubicle

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shall have hinged front access door with easy operating fasteners. All the doors and covers shall be
heavily gasketed to make the compartment dust tight. Each cubicle shall have a covering at the
bottom to make a dust and vermin proof construction. Door hinges shall be of concealed type.

The cubicle shall be of minimum 2.5 mm thick sheet steel. Sheet steel shrouds and partitions shall be
of minimum 2.5 mm thickness. All sheet steel work forming the exterior of switch boards shall be
smoothly finished, leveled and free from flaws. The corners shall be rounded. The minimum Thickness
of Gland plates shall be 3mm.

3.4.2 The apparatus and circuits in the power control centers shall be so arranged as to
facilitate their operation and maintenance at the same time to ensure the necessary degree of safety.

Apparatus forming part of the control centers shall have the following minimum clearance.

i) between phases - 25 mm,

ii) between phase and neutral - 25 mm,

iii) between phases and earth - 25 mm,

iv) Between neutral and earth - 25 mm,

When, for any reason, the above clearances are not available suitable insulation shall be provided.
Clearance shall be maintained during normal service conditions. Creepage distances shall comply with
those specified in relevant standards.

3.4.3 All insulating materials used in the construction of the equipment shall be non hygroscopic
duly treated to withstand the effect of high humidity, high temperature and tropical ambient service
conditions.

3.4.4 Functional units such as circuit beakers and fuse switches shall be arranged in multitier
formation, except that not more than One air circuit breaker housed in a single vertical section.

3.4.5 Metallic/insulated barriers shall be provided within vertical sections and between adjacent
sections to ensure prevention of accidental contact with :

i) Main busbars and vertical risers during operation, inspection or maintenance of functional units and
front connected accessories.

ii) Cable terminations of one functional unit, when working on those of adjacent unit/units.

3.4.6. All doors / covers providing access to live power equipment / circuits shall be provided with tool
operated fasteners to prevent unauthorized access.

3.4.7 Provisions shall be made for permanently earthing the frames and other metal parts of the
switchgear by two independent connections. The earth connections shall be extended to the bases of
SFUs

3.5 Metal treatment and finish :

All steel works used in the construction of the switch boards shall have undergone a suitable
rigorous metal treatment process so as to remove oxide scales and rust formation and to facilitate a
durable coating of the paint on the metal surfaces and also to prevent the spreading of rust, in the
event of the paint film being mechanically damaged.

Two coats of Anti Corrosive primer followed by a finishing coat of Epoxy powder coating of the shade
631 of IS : 5 (ie Siemens grey) shall be given. The total thickness of paint shall not be less than 50
micron.

The painting of all the metal part shall be with minimum seven tank process followed by powder coating

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as per the standard.

3.6 Bus Bars :

3.6.1 The busbars shall be housed in non-segregated sheet steel compartments in the cubicle at
convenient locations with provision for access to the buses from the front of the panel. The busbar
shall be suitably braced with DMC/SMC supports to provide a through fault with stand capacity of 50
KA RMS symmetrical for one second and a peak short circuit withstand capacity 150 KA minimum. The
neutral as well as the earth bus shall be capable of withstanding the above fault level.

3.6.2 Large clearance and creeping distance shall be provided on the busbar system to minimise the
possibility of a fault.

3.6.3 High tension bolts, nuts and spring washers shall be provided at all busbar joints.

3.6.4 The continuous rating of the bus bar shall be 0.8A/sq.mm for Aluminium and 1.2A/Sq.mm for
Copper. Maximum temperature of the bus and the connections shall not exceed 85 degrees centigrade.
The busbars shall be of liberal design The main phase busbars shall have continuous current rating
through out the length of each power control center and the neutral busbars shall have continuous rating
of at least 50% of phase busbars. Vertical/Horizontal Bus current rating shall be of Main incomer rating
of the panel. For feeders upto 63A Copper conductor FRLS insulated wires are also acceptable. The
size of wires shall be upto 10A-2.5sq.mm, above 10A to 20A- 4sq.mm, 32A-6sq.mm, 40A-10sq.mm
63A-16sq.mm

3.6.5 Connections from the main busbars to functional circuits shall be arranged and supported so
as to withstand without any damage or deformation, the thermal and dynamic stresses due to short
circuit currents. All busbars and tappings shall be provided with colour coded heat shrinkable sleeves
for phase identification.

3.6.6 The Panel shall be fully compartmentalized with all doors on the front only. When
compartment door is opened, busbar and cable alley shall be shrouded by barrier plates.

All joints/tapping points of the buses shall be suitably shrouded to prevent accidental contact.

4.0 Air Circuit Breakers :

4.1 General :

4.1.1 Circuit breakers shall be of triple pole / four pole, air break, horizontal draw out /Fixed type,
as given in the schedule of work and comply with the requirements of relevant IS with latest
amendments conforming to IS-13947/1&2 and shall have the following:

i) A short circuit breaking capacity (Ics r.m.s of not less than 65/50KA RMS at 500 volts, 50 Hz
AC.( as given in the schedule of work)

ii) A short circuit making capacity (Icm peak) of 130/105 KA.

iii) Rated ultimate short circuit breaking capacity, (Icu r.m.s ) of 65/50kA

iv) A short time withstand capacity (Icw) of 65/50KA for one second.

v) Dielectric test of 2.5 KV applied for one minute on main circuits

vi) Ics = 100%Icu

4.1.2 The circuit breakers shall be fitted with detachable arc chutes on each pole designed to
permit rapid dispersion, cooling and extinction of the arc. Inter phase barriers shall be provided to
prevent flash over between phases.

4.1.3 Arcing contacts shall be of hard wearing material copper tungsten or silver tungsten and

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shall be easily replaceable. Main contacts shall be of silver plated copper of high pressure type and
generous cross section.

4.2 Operating Mechanism :

The operating mechanism shall be of robust design, with minimum number of linkages to ensure
maximum reliability. Manually operated circuit breakers shall be provided with spring operated
closing mechanism which are independent of speed of manual operation. Electrically shall be
independent of the motor which shall be used slowly for charging the closing spring.

The operating mechanism shall be such that the breaker is at all times free to open immediately when
the trip coil is energized.

Mechanical operation indicators shall be provided to show open and close positions of the breaker.
Electrically operated breakers shall be additionally provided with mechanical indications to show
charged and discharged conditions of the charging spring.

Means shall be provided for slow closing and opening of the breaker for maintenance purposes, and
for manual changing and closing of electrically operated breakers during emergencies,

4.3 Protection :

Provisions shall be available for fitting a minimum of five trip devices - three over current, as shunt
trip and an under voltage release or two over current and earth fault release, a shunt trip and one
under voltage release. The breakers shall be of the shunt or series trip type as specified in the
schedule.
The protection release must be Electronic /Micro Processor based , True RMS sensing compatible to
EMC and with a provision of malfunctioning indications.

Following setting must be available on the relay :

i) Over current setting(Ir ) 50% to 100% of In
ii) Short circuit setting (Id) 1.25 to 10 of In

4.4 Housing of Circuit Breaker :

Circuit breakers shall be individually housed in sheet metal castle provided with hinged doors. The
breaker along with its operating mechanism shall be mounted on a robust carriage moving on
guide rollers with in the castle. Isolating contacts for both power and control circuits shall be of robust
design and fully self aligning. The assembly shall be designed to allow smooth and easy movement
of the breakers within its castle.

The breaker shall have three distinct positions within the castle as follows :
i) ` Service' position : With main and auxiliary contacts connected.

ii) `Test' position : with power contacts fully disconnected and control circuit contacts connected.
iii) `Isolated' position : with both power and control circuit contacts fully disconnected.

It shall be possible to achieve any of the above positions with the castle doors closed. Mechanical
position indicators shall be provided for the three positions of the breakers.

4.5 Interlocking :

4.5.1. The moving portion of the circuit breaker shall be interlocked so that :

i) It shall not be possible either to isolate it from the connected position, or to plug it in from the
isolated position with the breaker closed.

ii) The circuit breaker can be closed only when it is in one of the three positions or when it is fully out of
the castle.

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iii) It shall not be possible to open the hinged door of the castle unless the breaker is drawn to the
isolated position.

iv) Inadvertent withdrawal of the circuit breaker too far beyond the supporters is prevented by the
suitable stops.

4.5.2 Provisions shall be available for the padlocking of the circuit breaker accessible in any of the
three positions.

4.5.3 Automatically operated safety shutters shall be provided to screen the fixed isolating contacts
when the breaker is drawn out from the castle.

4.5.4 The moving portion of the circuit breaker shall be provided with a heavy duty, self aligning
earth contact, which shall make before and break after the main isolating contacts during insertion
into withdrawal from the service position of the breaker. Even in the isolated position positive earthing
contact should exist.

4.5.5 Auxiliary switches directly operated by the breaker operating mechanism and having 4 `NO' and
4 `NC' contacts, shall be provided on each breaker. The auxiliary switch contacts shall have a minimum
rated thermal current of 10 amps.

5.0 Moulded Case Circuit Breakers (MCCBs)

5.1 If specified in the BOQ, MCCB’s shall be provided in the switchboards for the circuit protection.
MCCBs rating shall be as indicated in the switchboard data sheet.

5.2 MCCB shall be of triple pole /four pole as given in the schedule of work and comply with the
requirements of relevant IS with latest amendments confirming to IS 13947/1&2 and shall confirm to
isolation standard and shall have the following

Rated ultimate short circuit breaking capacity (Icu r.m.s) should be equal to A short circuit breaking
capacity (Ics). Ics = 100%Icu

The type of breakers based on no of poles are classified as :

4P- Four Pole (Three phase & Neutral)
TP/3P – Triple Pole (Three Phase)
TPN- Triple Pole with Neutral link.
DP – Double Pole
SPN- Single Pole with Neutral link
SP – Single Pole

5.3 MCCB upto 160A shall be provided with adjustable type overload (70-100% of In) and S.C. setting of
2 to10times of Ir tripping device with inverse time characteristics for over load protection and
instantaneous characteristics for short circuit protection.

Up to 25KA, thermal shall be variable / adjustable & Magnetic shall be fixed type.

Above 160A MCCBs the protection release must be Electronic /Microprocessor based ,True RMS
sensing ,inbuilt with adjustable threshold and time delay, compatible to EMC and with a provision of
malfunctioning indications.

Microprocessor and thermal-magnetic trip units shall be adjustable and it shall be possible to fit lead
seals to prevent unauthorized access to the settings

Microprocessor trip units shall comply with IEC 60947-2 standard (measurement of rms current
values, electromagnetic compatibility, etc.)

Protection settings shall apply to all poles of circuit breaker.

All Microprocessor components shall withstand temperatures up to 125 °C

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5.4 MCCBs shall be provided with spring assisted quick make/break manually operated trip mechanism.
Wherever specified ,MCCB shall be suitable for remote tripping operation and the tripping device shall
be suitable for the specified control supply voltage.

5.5 ‘ON’ and ‘OFF’ position of the operating handle of MCCB shall be displayed and the operating
handle shall be mounted on the door of the compartment housing.

5.6 MCCB shall be provided with minimum 1 NO + 1NC auxiliary contacts.

If specified in the data sheet, the MCCBs shall be provided with solenoid /Motorized closing solenoid
/motor shall be suitable for specified control supply voltage.
Wherever specified in the schedule, the MCCB shall be provided with Earth leakage relays. However all
MCCBs whether specified or not shall have shunt trip device.

6. Earth Leakage Relays:

The Earth Leakage relays shall be static type .

The ELR shall have variable Current sensitivity and Tripping time to 0.15-3.0 seconds
The unit shall be flush mounting type

The unit shall have an LED for visual fault indication

The input voltage shall be 440V AC 50Hz

The Core Balance CT shall be of cast Resin type size as required

The unit shall have built in 1NO +1NC potential free contacts.

The contact rating shall be 6A/230V AC

The current rating shall be suitable for Temp range of 0-50DegC

The Breakdown Voltage of the unit shall be 2KV for one Minute

The Unit shall be of 96X96 mm size

7. Current Transformers.

Current transformers shall comply with the requirements of relevant latest IS. They shall have ratios,
outputs and accuracy as specified in the schedule. The CTs shall be resincast type.

8. Indicating / Integrating Meters :

All indicating instruments shall be of flush mounted industrial pattern conforming to the relevant
latest amended IS. The instrument shall have non reflecting bezels, clearly, divided and indelibly
marked scales, and shall be provided with zero adjusting devices in the front. Integrating instruments
shall be of flush mounted switch board pattern complying with the requirements of relevant latest IS.

9. Control switches/Selector switches :

Control switches/Selector switches shall be of the heavy duty rotary type, with plates clearly marked to
show the operating position. They shall be of semi-flush mounted type with only the front plate and the
operating handle projected. Circuit breakers control switches shall be of the spring return to neutral
type.

Each ACB shall have selector switches for Local/Remote

Each ACB shall have ON/OFF Push buttons or TNC switch.

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10. Indicating lamps and push buttons :

Indicating lamps shall be of the LED type of low watt consumption, provided with series resistors where
necessary and with translucent lamp covers. Bulbs and lenses shall be easily replaceable from the
front.

Each ACB shall have ON/OFF Push buttons and ON/OFF/Trip Indication lamps.

All Incomers shall have ON/OFF/Trip Indication lamps & outgoing feeders of the panel shall have
indications as specified in the BOQ.

Push buttons shall be of the momentary contact, push to actuate type fitted with self-reset contacts
and provided with plates marked with its junctions.

11. Cable terminations :

Cable entries and terminals shall be provided in the switch board to suit the number, type and size of
aluminum conductor power cables and copper conductor control cables as indicated in the schematic
diagram.

Provision shall be made for top or bottom entry of cables as required. Generous size of cabling
chambers shall be provided, with the position of cable glands and terminals such that cables can be
easily and safely terminated.

Barriers or shrouds shall be provided to permit safe working at the terminals of one circuit without
accidentally touching that of another live circuit.

Cable riser shall be adequately supported to withstand the effects of rated short circuit currents
without damage and without causing secondary faults.
Cable sockets shall be of Bimetallic crimping type.

12. Control wiring :

All control wiring shall be carried out with 1100 V grade Single core/Multistrand Copper FRLS
cable/Wires conforming to relevant IS having stranded copper conductors of minimum 2.5 sq.mm
section for CT Circuit and 1.5sq.mm for other Control wiring.

Wiring shall be neatly bunched, adequately supported and properly routed to allow easy access and
maintenance.

Wires shall be identified by numbered ferrules at each end.

The ferrules shall be of the ring type of non-deteriorating material. They shall be firmly located on each
wire so as to prevent free movement.

All control circuit fuses/MCBs shall be mounted in front of the panel and shall be easily accessible.

13. Terminal blocks and labels :

Terminal block shall be of 650/500 volts grade of the stud type. Insulating barriers shall be provided
between adjacent terminals.

Terminal block shall have minimum current rating of 10 amps and shall be shrouded.

Provisions shall be made for label inscriptions.

10% spare terminals shall be provided on each terminal block. Sufficient terminals shall be
provided on each terminal block, so that not more than one outgoing wire is connected per terminal

Labels shall be made of anodized aluminum, with white engraving on black background. They shall

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be properly secured with fasteners. Danger plate of size and descriptions as recommended in the
relevant IS shall be provided on the PCC.

14. Tests :

i) The power control center shall be completely assembled, wired, adjusted and tested for operation
under simulated conditions to ensure correctness of wiring and interlocking and proper functioning of
all components.

ii) Each power control center and components shall be subjected to standard routine tests as per
applicable clauses of relevant standards.

iii) All current carrying parts and wiring of power control center shall be subjected to power frequency
voltage withstand test.
iv) The panel shall be tested in accordance with IEC-60947

v) Testing and setting the relay set point and co-ordination between relay on LT/HT breaker, setting
shall be done by contractor.

vi) The relay should be tested by reputed agencies and test report of the relays should be submitted by
the contractor.

vii) Testing of panels shall be as per following codes:

IS: 8623 (Part -I) 1977 for factory built assemblies of switch gear for voltages upto and including
1000 VAC.

IS: 13947: 1993 Degree of protection

IS: 5578 & 11353:1985 Arrangement of bus bars.

15. Drawings : After the award of the contract, the contractor shall submit three copies of the following
drawings for approval of the Department.

i) Outline dimensional drawing of the PCC showing the general arrangement indicating the
following :
a) Bus bar clearances;
b) power and control cable entry points;
c) Configuration of bus bars;
d) Details of support insulations and spacing’s;
e) Outgoing power cable termination arrangements.

ii) Single line diagram of power control center showing Protection, Metering etc.
iii) Cubicle wiring diagram.
iv) List of Fitments with Ratings & makes / Models

16. Installation Testing and commissioning :

The power control centre shall be installed over the cable trench/cable pit using suitable size of MS
channel including grouting of the channel with necessary bolts and nuts. Proper earthing of PCC shall
be done using two independent copper/GI strip of sizes as indicated in the schedule. The channel
shall be painted with one coat of red oxide primer and two coats of anticorrosive enamel paint of
proper shade as directed by the Engineer-in-charge.

Space Heaters Shall be provided in all LT Panels.

The pre-commissioning tests as required shall be done and the PCC shall be commissioned.

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CHAPTER - 5
POWER CAPACITORS & CAPACITOR CONTROL PANEL

1.1 Scope

Design, manufacture, supply, erection, testing and commissioning of Indoor type power
correction capacitor banks for power factor improvement as per specification given below:

1.2 Standard

Unless otherwise stated below, the APFC system shall comply with the following standards (and
their latest amendments):
IS 2834: Capacitors
IS 13340-1993, IS 13341-1992, IEC 60831-1+2: Capacitors with self-healing features
IS 13585: capacitors
IS 13985: Mixed Di-electric capacitors
IS 12672: Capacitors with over pressure disconnectors

General
a) The capacitor banks shall be complete with all parts that are necessary or essential for efficient
operation. Such parts shall be deemed to be within the scope of supply whether specifically mentioned
or not.

b) The capacitor bank shall be complete with the required capacitors along with the supporting post
insulators, steel rack assembly, copper bus bars, copper connecting strips, foundation channels, fuses,
fuse clips, etc. The steel rack assembly shall be hot dip galvanized.

c) The capacitor bank may comprise of suitable number of single phase units in series-parallel
combination. However, the number of parallel units in each of the series racks shall be such that failure
of one unit shall not create an over voltage on the units in parallel with it, which will result in the failure of
the parallel units.

d) i. The assembly of the banks shall be such that it provides sufficient ventilation for each unit.
ii. Each capacitor case and the cubicle shall be earthed to earth bus.

e) Each capacitor unit/bank shall be fitted with directly connected continuously rated, low loss
discharge device to discharge the capacitors to reduce the voltage to 50Volts within one minute in
accordance with the provisions of the latest edition of IS:2834.

f) Capacitors shall be of MPP type with internal element fuses completely impregnated type non PCB oil.

g) Each unit shall satisfactorily operate at 135% of rated KVAR including factors of over voltage,
harmonic currents and manufacturing tolerance. The units shall be capable of continuously withstanding
satisfactorily any over voltage upto a maximum of 10% above the rated voltage, excluding transients.

h) Capacitors shall have built in surge suppression coils.

i) The Capacitor Banks shall be suitable for Operation with Automatic relays.
j) The capacitors shall be rated for 525V and connected in Delta.

2. Unit Protection:
Each capacitor unit shall be individually protected by a MCCB suitably rated for load current and
interrupting capacity, so that a faulty capacitor unit shall be disconnected by the fuse without causing the
bank to be disconnected. Thus, the fuse shall disconnect only the faulty unit and shall leave the
rest of the units undisturbed. An operated fuse shall give visual indication so that it may be detected
during periodic inspection. The fuse breaking time shall co-ordinate with the pressure built up within the
unit to avoid explosion. Mounting of the individual fuse may be internal or external to the capacitor case.

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3.0 Each Capacitor Bank shall have the following: ON/OFF Indication lamps Ammeter with 10VA CTs
and selector switch Auto/ Manual Selector switch with 1set of ON/OFF Push buttons for Manual
Operation. All contactors shall be heavy duty type.The cubicle shall have panel mounted exhaust fans
for ventilation.

4.0 Drawing and Data

The following shall be furnished as part of the Tender:

a) General Arrangement showing plan, elevation, and typical section views.
b) Technical literature on the equipment offered.

5.0 The following shall be furnished after award of contract for purchaser’s approval

a) Fully dimensioned general arrangement drawings of capacitor banks with panel showing
elevation, side view, and sectional view and foundation details.
b) Foundation plan showing location of fixing channels, floor opening etc.
c) Schematic diagram for the capacitor bank and switching equipment
Terminal block arrangement and terminal numbers

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CHAPTER 6
MEDIUM AND HIGH VOLTAGE CABLES
& ACCESSORIES
1.0 SCOPE

This specification along with data sheets covers requirements for design, manufacturer and supply of
PVC /XLPE cables and cable jointing / terminating accessories for high voltage systems.

2.0 STANDARDS

The cables shall comply with the latest edition of the following standards as applicable:

2.1 IS : 1554 PVC insulated (heavy duty) electric cables.

2.2 IS : 7089 Cross-linked polyethylene insulated PVC sheathed cables.

2.3 IS : 8130 Conductors for insulated electric cables and flexible cords.

2.4 IS : 5831 PVC insulation and sheath of electric cables.

2.5 IS : 3975 Mild steel wires, strips and tapes for armouring of cables.

2.6 10810(part - 41) Methods of test for cables : Mass of zinc coating on steel armour

2.7 IS : 209 Specification for zinc.

2.8 IS : 3961(Pt-2) Recommended current ratings for cables: Part - 2 PVC insulated
and PVC sheathed heavy duty cables.

2.9 IS : 10418 Drums for electric cables.

2.10 IS : 10462(Pt-1) Fictitious calculation method for determination of dimensions of

protective of cables: Part - 1 Elastomeric and Thermoplastic insulated
cables.

2.11 IS : 10810(Pt-58) Method of test for cables: Part 58 Oxygen Index test.

2.12 IS : 10810(Pt61) Method of test for cables:Part 61Flame retardant test.

2.13 IS : 10810(Pt 62) Method of test for cables: Part 62 Fire retardance test for Bunched
cables.

2.14 IS : 13573 Joints and terminals for polymeric cables for working voltages
from 6.6KV upto and including 33KV. Performance requirements and
type tests.

2.15 IEC : 332-2 Tests on electric cables under fire conditions.

2.16 IEC : 502 Extruded solid dielectric insulated power cables for rated voltages
from 1 KV upto 30 KV.

2.17 IEC : 540& 540A Test methods for insulation and sheaths of electric cables and
cords.

2.18 ASTM: D2863 Standard method of test for Flammability of plastics using oxygen
index method the cables and accessories shall also conform to the
provisions of Indian Electricity Rules and other statutory regulations, as

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applicable.

3.0 GENERAL CONSTRUCTION

3.1 The cables shall be suitable for laying in trays, trenches, ducts, and conduits and for
underground buried installation with uncontrolled backfill and possibility of flooding by water and
chemicals.

3.2 Outer sheath of all PVC and XLPE cables shall be black in color and the minimum value of
oxygen index shall be as per IS. In addition suitable chemicals shall be added into the PVC
compound of the outer sheath to protect the cable against rodent and termite attack.

3.3 Sequential marking of the length of the cable in meters shall be provided on the outer sheath at
every one meter. The embossing / engraving shall be legible and indelible.

3.4 The overall diameter of the cables shall be strictly as per the values declared in the technical
information furnished along with bids subject to a minimum tolerance of 2 mm upto overall
diameter of 60 mm and 3 mm for beyond 60 mm.

3.5 PVC / Rubber end caps shall be supplied free of cost for each drum with a minimum or eight per
thousand meter length. In addition, ends of the cables shall be properly sealed with caps to
avoid ingress of water during transportation and storage.

3.6 The cables used in installations under the jurisdiction of Director General of Mines and safety
shall be of copper conductor only.

3.7 The vendors shall specifically note that any of the make of cable accessories listed in data sheet
will be used for termination or jointing of the cables offered.

3.8 PVC Cables

3.8.1 All power/ control cables for use on medium voltage systems shall be heavy duty type, 650/1100
V grade with aluminum / copper conductor, PVC insulated, inner sheathed, armoured and
overall PVC sheathed.

3.9.2 The conductor shall be solid for conductor of nominal area upto and including 6 mm and
stranded beyond 6mm. Conductors of nominal area less than 25 sq.mm shall be circular
shaped. Cables with reduced neutral conductor shall have sizes as per Table 1 of IS 1554(part
- 1).

3.9.3 The core insulation shall be with PVC compound applied over the conductor by extrusion and
shall conform to the requirements of type ‘A’ compound as per IS : 5831. The thickness of
insulation and the tolerance on thickness of insulation shall be as per Table 2 of IS: 1554 Part -
1. Control cables having 6 cores and above shall be identified with prominent and indelible
Arabic numerals on the outer surface of the insulation. Color of the numbers shall contrast with
the color of insulation with a spacing of maximum 50 mm between two consecutive numbers.
Color coding for cables upto 5 cores shall be per Indian Standard.

3.9.4 The inner sheath shall be applied over the laid-up cores by extrusion and shall be of PVC
conforming to the requirements of Type ST - 1 PVC compound as per IS: 5831. The thickness of
inner sheath shall be as per IS: 1554 Part - 1. Single core cables shall have no inner sheath.

3.9.5 If armouring is specified for multicore cables in the data sheet, the same shall be by single round
galvanised steel wires where the calculated diameter below armouring does not exceed 13 mm
and by galvanised steel strips where this dimension is greater than 13 mm. Requirement and
methods of tests for armour material and uniformity of galvanisation shall be as per IS - 3975
and IS - 10810 (Part 41). The dimensions of armour shall be as per methods (b) of IS - 1554
(part-1). If armouring is specified for single core cables in the data sheet, the same shall be with
H4 grade hard drawn aluminum round wire of 2.5 mm diameter.
The combined conductance of armour for mining cables shall be equivalent to 75% of the

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conductance of the largest conductor of the cable.

3.9.6 The outer sheath for the cable shall be applied by extrusion and shall be of PVC compound
conforming to the requirements of type St-1 compound as per IS : 5831. The thickness of outer
sheath shall be as per IS : 1554 (Part- 1) for unarmoured and armoured cables.

3.10 XLPE Cables

3.10.1 Power cables for 3.3 KV upto and including 33 KV system shall be Aluminum/ copper conductor,
XLPE insulated, sheathed, armoured and overall PVC sheathed.

3.10.2 The conductors shall be stranded and compacted circular all cables.

3.10.3 All cables rated 3.8 / 6.6 KV and above shall be provided with both conductor screening and
insulation screening. The conductors shall be provided with non-metallic extruded semi
conducting screen.

3.10.4 The core insulation shall be with cross linked polyethylene insulating compound dry cured,
applied by extrusion. It shall be free from voids and shall withstand all mechanical and thermal
stresses under steady state and transient operating conditions. It shall conform to the properties
given in Table - 1 of IS : 7098 (part -2).

3.10.5 The insulation screen shall consist of non-metallic extruded semi-conducting compound in
combination with a non-magnetic metallic copper screen. Unless specified otherwise, the copper
screen for all the three cores together shall be capable of carrying the single line into ground
fault current value and the duration specified in the data sheet. Vendor shall furnish calculation
in support of selection of the size of copper screen along with bids.

3.10.6 The conductor screen, XLPE insulation screen shall all be extruded in one operation by ‘Triple
Extrusion’ process to ensure perfect bonding between the layers. The core identification shall be
by coloured strips or by printed numerals.

3.10.7 The inner shall be applied over the laid up cores by extrusion and shall conform to the
requirements of type ST 2 compound of IS : 5831. The extruded inner sheath shall be of uniform
thickness. In case of single core cables, there shall be extruded inner sheath between insulation
metallic screen and armouring.

3.10.8 For multicore cables, the armouring shall be by galvanised steel strips as per method (b) IS -
7098 (part-2). If armouring is specified for single core cables in the data sheet, the same shall
be with H4 grade hard drawn aluminium round wire of 2.5 mm diameter.

3.10.9 The outer sheath of the cables shall be applied by extrusion over the armouring and shall be of
PVC compound conforming to the requirements of Type ST 2 compound of IS : 5831. The
thickness of outer sheath shall be as per IS : 7089 - part 2 for both unarmoured cables.

3.10.10 The dimensions of the insulation, inner sheath shall be governed by values given in IS : 7098
Part - 2.

3.10.11 Where specified, 1100 V grade power cables may also be XLPE insulated and shall meet the
requirement specified in IS - 7098(Part- 1).

4.0 CABLE ACCESSORIES

4.1 The termination and straight through jointing kits for use on the systems shall be suitable for the
type of cables offered as per this specification.

4.2 The accessories shall be supplied in kit form. Each component of the kit shall carry the
manufacturer’s mark of origin.

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4.3 The kit shall include all stress grading, insulating and sealing materials apart from conductor
fittings and consumable items. An installation instruction sheet shall also be included in each kit.

4.4 The contents of the accessories kit including all consumable shall be suitable foe storage
without deterioration at a temperature of 45 C , with shelf life extending to more than 5 years.

4.5 Terminating kits: The terminating kits shall be suitable for termination of the cables to an indoor
switchgear or to a weather- proof cable box of an outdoor mounted transformer / motor. For
outdoor terminations, weather shields / sealing ends and any other accessories required shall
also form part of the kit. The terminating kits shall be form one of the makes / types mentioned
in the data sheet.

4.6 Jointing Kits : The straight through jointing kits shall be suitable for the installation on overhead
trays, concrete lined trenches, and ducts and for underground burial with uncontrolled backfill
and possibility of flooding by water and chemicals. These shall have protection against any
mechanical damage and suitably designed to be protected against rodent and termite attack.
The inner sheath similar to that provided for cables shall be provided as part of straight through
joint. The jointing kits shall be from one of the makes / types mentioned in the data sheet.

5.0 TESTING AND INSPECTION

The cables shall be tested and inspected at the manufacturer’s works. All the materials
employed in the manufacture of the cable shall be subjected, both before and after manufacture,
to examination, testing and approval by PURCHASER / Owner. Manufacturer shall furnish all
necessary information concerning the supply to PURCHASER / owner’s inspectors. The
inspector shall have free access to the manufacturer’s works for the purpose of inspecting the
process of manufacture in all its stages and he will have the power to reject any material which
appears to him to be of unsuitable description or of unsatisfactory quality. The vendor shall give
at least 4 weeks advance notice to the purchaser, regarding the date testing to enable him or his
representative to witness the tests.

5.1PVC & XLPE Cables

5.1.1 After completion of manufacture of cables and prior to dispatch, the cables shall be subjected to
type, routine, acceptance and special tests as detailed below. PURCHASER / Owner reserves
the right to witness all tests with sufficient advance notice from vendor. The test reports for all
cables shall be got approved from the Engineer before dispatch of the cables.

5.1.2 All routine tests, acceptance tests, type tests and additional type tests for improved fire
performance shall be carried out on cables as listed in IS : 1554 Part - 1 , and IS : 7098 Part -
2.

5.1.3 The inner and outer sheath of XLPE cables shall be subjected to all the tests applicable for OVC
cables. The test requirements for insulation and sheath of PVC cables shall be as per latest
revision of IS : 5831.

5.2 Cable Accessories

Type tests should have been carried out to prove the general qualities and design of a given
type of termination/ jointing system as per IS - 13573. The type test certificates shall be
submitted along with offer. In case type test certificates are older than 5 years, vendor shall
carry out the type test at his own cost.

6.0 PACKING AND MARKING

6.1 Cables shall be dispatched in non-returnable wooden or returnable steel drums of suitable barrel
diameter, securely battened, with the take-off end fully protected against mechanical damage.
The wood used for construction of the drum shall be properly seasoned, sound and free from

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defects. Wood preservatives shall be applied to the entire drum. Ferrous parts used shall be
treated with a suitable rust preventive finish or coating to avoid rusting during transit or storage.

6.2 On the flange of the drum, necessary information such as project title, manufacturer’s name,
type size, voltage grade of cable, length of cable in meters, drum no., cable code, BIS
certification mark, gross weight etc. shall be printed. An arrow shall be printed on the drum with
suitable instructions to show the direction of rotation of the drum.

6.3 Unless otherwise specified, Cables shall be supplied in drum lengths as follows:

Medium voltage power cables upto and including 6 sq.mm -1000m

Medium voltage power cables from 10 sq.mm upto and including 300 sq.mm -500

Control cables upto and including 27 cores. -1000m

HV Power cables -

Upto 11 KV (E) grade, 3 x 400 mm - 500m

Upto 11 KV (E) grade, 1 x 630 mm - 1000m

A tolerance of plus or minus 3 % shall be permissible for each drum. However overall tolerance on each
size of cable shall be limited to 2%. Offers with short /non -standard lengths are liable for rejection. If
non-standard drum lengths are specified in the data sheet, the same shall be supplied.

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CHAPTER 7
LAYING OF CABLES
1.0 Scope :

This specification is intended to cover the requirements of installation and energising of

PVC/XLPE/PILCDSTA power cables including jointing of cables.

2.0 Standards :

The power cable and its fixing accessories shall comply with the latest relevant Indian Standards and
National Electrical Code.

3.0 Laying of Cables :

3.1 General :

3.1.1 Before the commencement of cable laying, it shall be ensured by the Engineer-in-Charge that
only ISI marked cables are used. It shall be the responsibility of the contractor to check the soundness
and correctness of the size of the cable while taking delivery of the cable from stores. Any defect noticed
shall be brought to the notice of the issuing authorities immediately. If any defects is noticed after the
cable is laid or during the process of laying, it shall be brought to the notice of the Engineer-in-Charge
and upon his satisfaction, that the cable is not damaged due to bad handling, it will be the entire
responsibility of the contractor to retrieve the cable already laid and return the defective cable to store
and take fresh length of the cable from the store and relay the same.

3.1.2 The material such as bricks, sand, cable route markers, RCC slab of best quality as approved by
the Engineer-in-Charge only shall be used for cable laying works.

3.1.3 The contractor shall provide all the necessary labour, tools, plants and other requisites at his own
cost for carrying out pumping of water and removing of water from trenches, if any, where required.

3.1.4 Installation shall be carried out in a neat, workman like manner by skilled, experienced and
competent workman in accordance with standard practices.

3.1.5 While laying the cable care shall be taken to avoid formation of kinks and also damage to the
cable. In the case of cable bends, it shall not have bent radius lesser than 20 times the overall diameter
of the cable.

3.1.6 A cable loop of about five meters length and as directed by the Engineer-in-Charge shall be
provided at the following locations.
a) Near the termination points
b) Near to the straight through joint

3.1.7 The method of cable laying and routing of cables, shall in every case be as directed by the
Engineer-in-Charge / consultant.

3.1.8 Whenever cable passes through hume pipes/GI pipes embedded across the wall in a building,
both the ends of the pipe shall be suitably sealed.

3.1.9 Identification tags indicating the size of the cable and feeder designation shall be securely attached
at both ends of the cable. Such tags shall also be attached to the cable at intervals of 250 Mtrs. The
materials of the tag shall be of either 12 SWG GI sheet or plastic. In case of plastic, the details have to
be engraved and incase of GI sheet, the details should be punched. Cable route markers shall be
provided at the intervals of 200 M with a minimum of one number route marker. The details of the route
makers shall be as per the drawing. At the locations of straight through joints, necessary joint-markers
shall be provided.

3.1.10 When cable runs vertically, it shall be clamped on mild steel flats or angle iron fixed on walls and
are spaced at such intervals as to prevent buckling of the cables. All steel work shall be painted with a

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coat of red oxide and thereafter finished with suitable anticorrosive paints.

3.2 Cable laid in ground :

3.2.1. All MV cables (up to 1.1 KV) shall be laid at a minimum depth of 0.75 M & HT cables (1.1 KV to 11
KV) shall be laid at a depth of 1.0 M when laid in ground. When cablepass through roads, nallahs
etc.they must be protected by either hume pipe or GI pipe of suitable dimensions.

3.2.2. Excavations of trenches shall be carried out as indicated in the drawing. The width of the trench at
the bottom shall be 0.4 M for one cable. In case the total number of cables laid in trenches is more than
one, then the width shall be such that the spacing between the cables is maintained as shown in the
drawing. Before the cable is laid in the trench the bottom of the trench shall be cleared from stones and
other sharp materials and filled with sand layers of 75 mm, as shown in the drawing.

3.2.3. While removing the cable from the drum, it shall be ensured that the cable drum is supported on
suitable jacks and the drum is rotated to unwind the cable from the drum. The cable should never be
pulled while unwinding from the drum. It shall be ensured that the cables are run over the wooden rollers
placed in the trench at intervals not exceeding 2 M.

3.2.4. After placing the cables in the trench shall be filled in layers ensuring that each layer is well
rammed by spraying water and consolidated. The extra earth shall be removed from the place of trench
and deposited at a place as directed by the Engineer-in-Charge/consultant.

3.2.5. The LT Cables shall be provided with protection using class 1 bricks at sides and top as indicated
in Drawing and the HT cables shall be provided with RCC slabs (marked HT cable) on top and class1
bricks on sides as protection.

3.3 Cables laid in built up trench :

3.3.1. Before the commencement of cable laying the cable trench shall be drained properly. Cable shall
be laid as explained in item 3.2. Cable shall be properly clamped to the cable supports which are
provided in the cable trench. The method of clamping shall suit the size of the cable and the cable
supports which are provided in the cable trench. The method of clamping shall suit the size of the cable
and the cable supports, as directed by the Engineer-in-Charge.

Care shall be taken while removing and replacing the trench cover slab. It is the responsibility of the
contractor to make good any damaged trench covers.

3.4. Cable terminations and straight through joints :

3.4.1. All cable jointing materials such as straight through joint boxes, cable compound, cable lugs,
insulation tapes etc. shall be of best quality and as approved by the Engineer-in-Charge.

3.4.2. Cable glands for strip / armoured cables shall include a suitable armour clamp for receiving and
securely attaching the armouring of the cable in a manner such that no movement of the armour occurs
when the assembly is subjected to tension forces.

The cable gland shall not impose on the armouring, a bending radius not less than the diameter of the
cable. The clamping ring shall be solid and of adequate strength.

Provision shall be made for attachment of an external earthing bond between the metallic covering of the
cable and the metallic structure of the apparatus to which the cable box is attached.

3.5 Sealing boxes :

3.5.1 A sealing box, irrespective of the class of insulation of the cable for which it is intended, shall be so
designed that it may be filled with compound after connecting the cable specially in flame
proof/hazardous areas.

3.5.2 All parts and connection for attaching the armouring, wiping or clamping the metallic sheath in a
sealing box, shall be easily accessible. This may be achieved by splitting the box or by providing a

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suitable cover or other such means.

3.5.3 The joints in the box shall prevent leakage of the compound.

3.5.4 Provision shall be made to ensure that the cores of the cable are efficiently sealed to prevent
moisture penetrating along the strands or the cable conductors.

3.5.5 The sealing box shall be provided with compound filling orifices with suitable covers or plugs of
size that will permit easy pouring of the compound.

In all cases where screwed plugs are used, one or more air vents shall be provided to ensure complete
expulsion of air and total filling of the box with compound.

3.5.6 The box shall be of sufficient length to allow for manipulation of the insulated cover without
damage to them or to the insulation.

3.5.7 A sealing box intended to be attached directly to the apparatus shall be designed such that the
box together with the connected cable may be detached from the apparatus without disturbing the
sealing compound.

3.5.8 Cable sealing and dividing boxes intended for use in the flame proof areas shall comply
additionally with the relevant requirements of IS:2148-1968.

4.0 Testing
Once cable is laid, following tests shall be conducted in the presence of Engineer-in-Charge, before
energising the cable:
i) Insulation resistance test (Sectional and Overall).
ii) Sheathing continuity test.
iii) Continuity and conductor resistance test.
iv) Earth test.
v) High voltage test.
Tests conducted shall be as per Indian Standards and National Electrical Code.

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Chapter - 8
UPS SYSTEMS
1 SCOPE

This specification defines the minimum requirements for the supply of UPS complete with Digital
Control Circuit and other accessories as specified in the performance requirements.

The UPS shall be provided with 63A 25KA TP MCCBs (for 2KVA), on Input & Output sides. UPS
shall have isolation transformer and provision of parallel redundant mode with static by pass.

1.1 PERFORMANCE REQUIREMENTS FOR FOLLOWING UPS

Rating : 2KVA-2 No’s.

Quantity : As per schedule

Overall Efficiency : Better Than 92%

Input :

Voltage : 415V (-30%-+25%)

Frequency : 50HZ (+/-6%)

No. of Phases : 3 & Neutral

Output

Voltage : 400V (+/- 1%)

Frequency : 50HZ

No. of Phases : 3 & Neutral

Frequency : 50Hz ( 0.05%)

Wave form : Sine Wave

Charger :

DC Bus Voltage : 120V to 384 V(Nominal)

Charger type : Fully automatic float cum boost

charger

Output : 400 V Three Phase

Technology : High Frequency PWM using IGBT

Transient Variations : Less than 5V for 100% step Load change

Transient Recovery : Less than 4m seconds for 100% step

load change

Distortion Factor : Less than 2% with linear Load.

Less than 10% with Non Linear load

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Crest Factor : Better than 5:1

Control : Microprocessor Based / Digital

Over Load : Invertor 105% Continuous 125% for

10min, 150% for 1 Min Static Switch
200% Continuous, 600% for 10 ms

Recharge Time : 6 to 8 hours

Noise Level : Less than 50 db

Protection : Input High /Low, Output High/

Low, Over Load, Short Circuit, Battery Low, Over
charge.

Alarms : Audible Alarm for Low Battery/Main Failure

Battery Backup : 30 Mins

Ambient Temp : -5 to 55 C

Cooling : Forced Air Cooling

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Chapter - 9
EARTHING

1.0 SCOPE:
This specification is intended to cover the requirements of supply, installation, testing and
commissioning of
a) Pipe earthing b) Plate earthing c) Strip earthing

2.0 STANDARDS:
Earthing installations shall conform to the Indian Electricity Rules - 1956, as amended from time to time
and IS 3043-1989 “code of practice for earthing", with latest amendments.

3.0 Earth electrode arrangement:

3.1 Pipe electrode:

3.1.1 Electrode shall be made of CI pipe having a clean surface and not covered with paint, enamel or
poorly conducting material. Galvanized pipe shall not be smaller than 100 mm ID. Earthing with pipe
electrode shall be done as per the details indicated in IS : 3043/87 .

3.1.2 Electrodes shall be embedded below permanent moisture level.

3.1.3 The length of pipe electrodes shall not be less than 2.5 m. if rock is encountered, pipes shall be
driven to a depth of not less than 2.5 m with suitable inclination. Pipe shall be in one piece and deeply
driven.

3.1.4 To reduce the depth of burial of an electrode without increasing the resistance, a number of rods or
pipes may have to be connected together in parallel. The distance between two electrodes in such a
case shall not be less than twice the length of the electrode. The earthing lead shall be connected
by means of a through bolt, nuts and washers and cable socket.

3.2 Plate electrode:

For plate electrodes, minimum dimensions of the electrode shall be as under.

3.2.1 GI plate electrode: 600 x 600 x 6 mm thick.

3.2.2 Copper plate electrode: 600 x 600 x 3.15 mm thick

3.2.3 The electrode shall be buried in ground, with its faces vertical and top not less than 2.5 M from the
surface of the ground.

3.2.4 Earthing using plate electrode shall be done as per details, indicated in drawing.

3.2.5 Plate electrodes shall have a galvanized iron water pipe, buried vertically and adjacent to the
electrode. One end of pipe shall be at least 5 cm above the surface of the ground and need not be more
than 10 cm. The internal diameter of the pipe shall be at least 19 mm. The length of pipe under the
earth's surface shall be such that it shall be able to reach the center of the plate. The earthing lead shall
be securely bolted the plate with two bolts, nuts, check nuts and washers.

3.3. Strip or conductor electrodes:

3.3.1. Strip electrode shall not be smaller than 25 x 1.6 mm, if of copper and 25 x 3 mm, if of galvanized
iron and steel. If round conductors are used as earth electrodes, their cross sectional area shall not be
smaller than 3 sq.mm, if of copper and 6 sq.mm, if galvanized iron and steel.

3.3.2. Conductor shall be buried in trenches not less than 0.5 m deep.

4.0 General:

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i) All materials used for connecting the earth lead with electrode shall be of GI in case of GI pipe and
GI plate electrodes, and of tinned brass in case of copper plate electrode. The earthing lead shall be
securely connected at the other end to the main board.

ii) The earthing lead from electrode onwards shall be suitably protected against mechanical injury by
routing the earth wire / strip through a suitable size of GI pipe.

iii) All medium voltage equipments shall be earthed by two separate and distinct connections with the
earth. In the case of high and extra high voltages, the neutral points shall be earthed by not less than
two separate and distinct connections with the earth, each having its own electrode at the generating
station or substation.

iv) All materials, fittings etc. used in earthing shall conform to Indian standard specifications wherever
they exist. In the case of materials for which Indian standard specifications do not exist, such materials
shall be approved by the Engineer-in-Charge.

v) The earth electrode shall be kept free from paint, enamel and grease.

vi) It shall be ensured that similar materials for respective earth electrodes and earth conductors are
used.

vii) Earth electrode shall not be installed in proximity to a metal fence.

viii) Copper/GI strip shall be connected to the respective earth electrodes, either by brazing or welding
respectively. The Copper/GI strip shall be jointed only either by brazing or by riveting at the end of over
lapping portions. The over lap shall not be less than 50 mm.

ix) Earthing clamps used for supporting earth strips shall be made of such materials so as to avoid
bimetallic action between strip and clamps.

5.0 Testing :
The earth resistance of each electrode shall be measured by using a reliable and calibrated earth
Meggar and the value shall be as per IS/IE rules.

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Chapter – 10
LIGHTNING PROTECTION

1.0 Scope :

This specification is intended to cover the requirements of supply, installation and testing of lightning
protection system at places specified by the department.

2.0 Standards :

The lightning protection system shall conform to the IS:2309/1989 and National Electrical code.

3.0 Terminology :

i) Air termination (lightning conductor) or Air termination net work: Those parts of lightning protection
system that are intended to collect the lightning discharges from the atmosphere.

ii) Bonds: Electrical connection between the lightning protection system and other metal work, and
between various portions of the latter.

iii) Down conductors: Conductors which connect the air terminations with the earth terminations.

iv) Earth terminations or earth terminations net work: Those parts of the lightning protection system
which are intended to distribute the lightning discharges into the general mass of the earth. All parts
below the testing point in a down conductor are included in this term.

v) Earth electrodes: A metal plate, pipe or other conductor or an array of conductors electrically
connected to the general mass of the earth. These include those portions of the earth terminations
that make direct electrical contact with the earth.

vi) Lightning protection system: The whole system o interconnected conductors used to protect a
structure from the effects of lightning.

vii) Side flash: A spark occurring between nearby metallic objects or between such objects and the
lightning protection system to earth.

viii)Testing points: Joints in down conductors or in bonds or in earth conductors connecting earth
electrodes, so designed and situated as to enable resistance measurements to be made.

4.0 Materials to be used :

Materials to be used in the lightning protection system shall be reliably resistant to corrosion or
adequately protected against corrosion. The materials to be used are.

i) Copper : Solid, or flat copper strips or stranded copper wire of 98 per cent conductivity when
annealed, shall be used.

ii) Galvanised : It shall be protected against corrosion by zinc coating.

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5.0 Lightning protection system :

The lightning protection system comprises of the following major components.

i) Air terminations
ii) Down conductors
iii) Joints and bonds
iv) Testing points
v) Earth terminations
vi) Earth electrodes
vii) Fasteners

5.1 Air terminations :

It shall consist of a vertical conductor on a tall structure, a single horizontal conductor for a small building
and system of horizontal and vertical conductors for the protection of bigger buildings.

A vertical air termination shall project at least 30 cm above the building on which it is fixed.

All horizontal air terminations shall be interconnected such that no part of the roof is more than 5 m
away from the nearest horizontal conductor. For a flat roof, horizontal air terminations shall be fixed
along the outer perimeter of the roof.

Horizontal air termination shall be fixed along contours of the roof of the buildings in such a way as to
join each air termination to the rest and shall themselves form a closed network.

All metallic finials, Chimneys, ducts, vent pipes, railings, gutters etc. on or above the main surface of
the roof of the structure shall be bonded to the air terminations network. A typical fixing detail of
vertical air termination on flat roof building are shown in drawing.

All terminals shall be firmly fixed to the building in order to avoid overturning.

5.2 Down conductors :

5.2.1 Down conductors shall be distributed around the outside walls of the structure and run along
the corners and other projections, considering the location of air terminations and earth terminations.
Lift shafts shall not be used for fixing down conductors.

5.2.2 The down conductors shall be routed in the most direct path possible between the air
termination, avoiding sharp bends, up turns and kinks. Joints shall be avoided in down conductors.
Metal pipes shall not be used as protection for the conductors.

5.2.3 In buildings of cantilever construction, down conductors shall be taken straight down to
ground by routing through a non-metallic, non-combustible internal duct. Any covered recess not
smaller than 75 x 15 mm or any vertical service duct running the full height of the building shall also be
used for this purpose, provided it does not contain an unarmoured or non-metal sheathed cable.

The routing of the down conductor shall be such that its accessibility for inspection, testing and
maintenance is ensured.

5.2.4 It shall be ensured that the same material is used for both air termination and down conductor.
For example if GI strip is used for air termination, the down conductor shall also be of GI strip.

5.2.5 The shapes and minimum sizes of conductors for use above ground and below ground given
in IS:2309 - 1989 is reproduced below for ready reference.

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_____________________________________________________________________

Sl.No. Materials and Shape Minimum size

_____________________________________________________________________

(i) Above ground :

a) Round copper wire 6 mm diameter

b) Standard copper wire 50 mm sq.
c) Copper strip 20 x 3 mm
d) Round galvanised iron wire 8 mm diameter
e) Galvanised Irron Strip 20 x 3 mm
f) Round aluminium wire 9 mm diameter
g) Aluminium strip 25 x 3.15 mm

(ii) Below ground :

a) Round copper wire 8 mm diameter

b) Copper strip 32 x 6 mm
c) Round galvanised iron wire 10 mm dia
d) Galvanised iron strip 32 x 6 mm
_____________________________________________________________________

5.2.6 During installation of air terminations and down conductors, the following items shall be taken
into consideration.

i) The mechanical forces produced in case of lightning stroke.

ii) External local heating.

iii) The Architectural or aesthetic beauty of the building.

iv) Services entering the structure above and below ground.

v) Radio and television receiver aerials.

vi) Flag masts and roof level plant rooms.

5.3 Joints and bonds :

5.3.1 Joints: It shall be ensured that the joints are avoided in the lightning protection system as far
as possible. In case joints becomes necessary, the number of joints shall be kept as minimum as
possible and they shall be mechanically and electrically effective. The joints shall be either bolted,
crimped, riveted or welded. In case of over lapping joints the length of the overlap shall not be
less than 20 mm. In the down conductor below ground level, there shall not be any joint.

5.3.2 Bonds : The bond to the lightning protection system shall have a cross sectional area not less
than that employed for the main conductors. All bonds shall be suitably protected against corrosion
and shall be as short as possible.

5.4 Testing points:

Each down conductor shall be provided with a testing point at a height of 1.5M from the ground level. It
shall be ensured that there is no connection other than the direct connection to the earth electrode is
made below a testing point. The details of the test links are shown in the drawing.

5.5 Earth terminations :

Each down conducer shall have an independent earth termination and have provision for isolation for
testing purpose. Water pipe system shall not be bonded to the earth termination system. However if

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adequate clearance between the two cannot be obtained, they may be effectively bonded and the bonds
shall be capable of isolation and testing. The gas pipes, however shall in no case be bonded to
the earth termination.

5.6 Earth electrodes :

5.6.1 Earth electrodes shall consist of pipe, strips or plates. Metal sheaths of cables shall not be
used as earth electrodes. The earth electrode shall be constructed as per IS : 3043

5.6.2 When pipes are used they shall be driven into the ground as close as practicable but outside the
circumference of the structure.

5.6.3 When strips are used, they shall be buried at a depth not less than 0.5 m deep. The strips shall
be laid radially in two or more directions from the point of connection to a down conductor. If this is not
possible they shall be laid in one direction. If this is not possible they shall be laid in one direction. If the
space restriction requires the strips to be laid in parallel or on grid formation, the distance between
two strips shall not be less than 2m.

5.6.4 When plate electrodes are used they shall be buried in the ground so that the top edge of the
plate is at a depth not less than 2.5m from the surface of the ground. If two plate electrodes are to
be used in parallel, the distance between the two shall not be less than 8m.

5.7 Fastners:
The conductors used for lightning protection shall be securely attached to the building or other
object to be protected through fastners made of galvanised steel. The fastners shall be
substantial in construction not subjected to breakage and protected against corrosion. Guidelines
given in page 24 IS 2309-1969 shall be referred.

6.0 Testing:

On the completion of the installation of lightning protection system the following tests shall be carried
out.

i) Continuity test:

The continuity of all conductors and the efficiency of all bonds and joints shall be checked.

ii) Resistance tests:

The resistance of the lightning protection system complete with air terminations but without the earth
connection shall be measured and its value shall not exceed 1 ohms.

iii) Earth resistance test:

The earth resistance shall be measured and it should not exceed 10 ohms.

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CHAPTER 11
RECOMMENDED MAKES OF MATERIALS

1. MCBs/MCB Distribution boards : Legrand/Hager/Schneider/ABB/Siemens

2. MCCBs : Schneider/L&T/Siemens/ABB

3.Under ground LT Cables : Universal/Finolex/KEI/Havells

4. Cable Glands : HMI/Comet/Bracco

5. Cable Lugs : Dowell's/3D

6. MV Panels (PCCs) : Manufacturers with CPRI Test Certificate atleast since

past 2 years

7. Earth Leakage relay : Prok Dvs/Nagoba/Eqvt.

8. Indicating Meters : Conzerv/AE/ Prok DVsEqvt.

9. Selector switches : Vaishno/Salzer/Kaycee/Eqvt

10. Current Transformers : Kappa/Poweronics/ Kalpa/AE

11. Indication Lamps LED

(protected type) : Siemens/ Vaishno/ Binay

12. Capacitors Panel : P2 power solution(Delhi)/L&T

13. APFC Relay : Beluk/ Neptune/ Epcos

14. Transformer : Kirloskar / Volt-amp/RPG/Pro-lec(GE)/Schneider

15. HT VCBs : Kirloskar / Schneider/ABB/SEIMENS

16. HT Cables : Universal/Finolex/KEI

17. UPS : DB consul/Schneider/Delta/Emerson

18 PLC : SIMENS/ABB/Allen Bradley

19.Battery Charger : Amron/HBL-Nife/Universal

Note : Before use of any of the above brands for the Project, Prior Written permission shall be
taken from client/Consultant. The Client shall have choice to select any of the above approved
brands.

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