M.P.Poorv Kshetra Vidyut Vitaran Co.Ltd.7th Block, 3rd Floor, Shakti Bhawan, Rampur, Jabalpur – 482008 Phone No.0761-2702463, 2702434. Fax No.0761-2660128. Email:
[email protected] No.CMD/EZ/FS/F-02/ 6794 Jabalpur, dated: 20.09.2010 INVITATION OF EXPRESSION OF INTEREST (EOI) FOR EMPANELMENT OF VENDERS IN DISCOM-EZ The Chief Engineer(FS) on behalf of Madhya Pradesh Poorv Kshetra Vidyut Vitran Co. Ltd. hereinafter referred to as “MPPKVVCL” invites the offers from manufacturers of various material to be used in various schemes / projects finance by REC /PFC/ADB/APDRP under the jurisdiction of MPPKVVCL for empanelment of vendors in Discom-EZ. The tentative requirement for 24 months is indicated as below:SN 1 Description Distribution transformer 25 KVA 11/.4 KV AAA Rabbit Conductor 11KV Polymer Lightning Arrestor Unit No. No. 31000 SN 10 Description 11KV Control panel with relay for feeder protection 11KV CT PT (metering unit) LT 3 ph. 4 wire 3x240 volts 40-200 Amp Static (Electronic) Trivector Energy Meter of Class-I accuracy with GSM modem (GPRS enabled) LT 3 ph. 4 wire 10-40 Amp Static whole current Meter of Class-I accuracy with LPR / Infrared communication optical port. LT single ph. 2 wire 5-30 Amp Static whole current Meter of Class-I accuracy with Infrared communication port. AB Cable three phase 4 wire 50 sq.mm, 25 sq.mm and 16 sq.mm with bare carrier wire. AB Cable single Phase 3 wire 16 sq.mm, with bare carrier wire. Distribution Box for AB Cable Accessories (Clamps) suitable for AB Cables 11KV HT CT 200/100/5 Unit No. No. 1700 2 3 Km No. 1.30 lacs 93000 11 12 No. No. 1700 35,500 4 11KV Polymer Disc Insulator No. 2.5 lacs 13 No. 13000 5 11KV Composite Polymer Insulator PVC Cable Armoured twin Core 2.5 sq.mm PVC Cable Armoured twin Core 4.0 sq.mm PCC Pole 140 kg 8 Meter long 11KV VCB No. 16.00 lacs 7500 14 No. 6.00 lacs 20000 6 Km 15 Km 7 Km 350 16 Km 7000 8 9 No. No. 7.00 lacs 1700 17 18 19 No. No. No. 3.00 lacs 6.00 lacs 5100 2. (i) (ii) (iii) (iv) Minimum eligibility criteria for empanelment of vendors. The firm should be qualified manufacturer who regularly manufacture the material of type specified, have adequate technical knowledge and practical experience. The firm have adequate financial stability and status to meet the financial obligations They have adequate plant and manufacturing capacity available to perform the assignment expeditiously within the time period. The material must have a type tested design of our specification from NABL Lab. The type test report should not be more than three years old as on 30.09.2010. (v) SN 1 The manufacturer must have supplied minimum quantity to SEBs / Power Utilities as indicated below:Description Distribution transformer 25 KVA 11/.4 KV AAA Rabbit Conductor 11KV Polymer Lightning Arrestor Unit No. No. 1000 SN 10 Description 11KV Control panel with relay for feeder protection 11KV CT PT (metering unit) LT 3 ph. 4 wire 3x240 volts 40-200 Amp Static (Electronic) Trivector Energy Meter of Class-I accuracy with GSM modem (GPRS enabled) LT 3 ph. 4 wire 10-40 Amp Static whole current Meter of Class-I accuracy with LPR / Infrared communication / optical port. LT single ph. 2 wire 5-30 Amp Static whole current Meter of Class-I accuracy with Infrared communication port. AB Cable three phase 4 wire 50 sq.mm, 25 sq.mm and 16 sq.mm with bare carrier wire. AB Cable single Phase 3 wire 16 sq.mm, with bare carrier wire. Distribution Box for AB Cable Accessories (Clamps) suitable for AB Cables Unit No. No. 500 2 3 Km No. 2200 3000 11 12 No. No. 500 20,000 4 11KV Polymer Disc Insulator No. 7500 13 No. 1.00 lacs 5 11KV Composite Polymer Insulator PVC Cable Armoured twin Core 2.5 sq.mm PVC Cable Armoured twin Core 4.0 sq.mm PCC Pole 140 kg 8 Meter long 11KV VCB No. 31000 14 No. 1.00 lacs 600 6 Km 100 15 Km 7 Km 100 16 Km 200 8 9 No. No. 7000 500 17 18 No. No. 10000 10000 3. The prospective vendors interested for empanelment as vendor shall submit following documents to this office by 15.10.2010 :(i) 3 sets of type test report of material of exactly of our specification (not more than 3 years old as on 30.09.2010) of NABL Lab. Original type test report should be presented for attestation which may be taken back after verification. 3 sets of drawings approved by NABL Lab. 3 sets of GTP. List of supplies made to SEBs / Power Utilities during last three years with documentary evidence. (ii) (iii) (iv) 4. This may be noted that, this is not invitation of bid for procurement of material, it is a process is for empanelment of vendors only. 5. The MPPKVVCL reserve the right, without prior notice to change the procedure for identification / registration of bidders without assigning any reason(s) thereof. The bidders shall have no cause of action or claim against MPPKVVCL or its officers / employees, successor or assignees for rejection of any “Expression of Interest”. No correspondence in this regard shall be entertained by the MPPKVVCL. 6. The detailed documents alongwith technical specification of the material against aforesaid “Expression of Interest” are available on our website mpezelectricity-discom.nic.in. The bidders may download the documents / specification from the website. 7. The already registered vendors need not apply. Encl: Technical Specification of all items. Chief Engineer(FS) 1.0 TECHNICAL SPECIFICATION OF THREE PHASE 11/0.4 33 KV, 25 KVA RATING OUTDOOR TYPE COMPLETELY SELF PROTECTED DISTRIBUTION TRANSFORMERS. 1.1 SCOPE: Specification covers the design, engineering, manufacture, assembly, stage testing, inspection and testing at manufacturer’s works before supply and delivery at site of Oil immersed, Oil Natural Air Natural (ONAN) outdoor type 11KV/433 V, three phase, 50 Hz, double wound core type, outdoor type EC grade aluminum wound Distribution Transformer of 25 KVA ratings, complete with fittings and accessories for metering and protection unit on LT side of Distribution Transformer for use in Distribution System. 1.1.2 Tolerances on all the dimensions shall be in accordance with provisions made in the relevant Indian/ IEC standards and in these specifications. Otherwise the same will be governed by good engineering practice in conformity with required quality of the product. 1.2 APPLICABLE STANDARDS: Unless otherwise modified in the specifications, the distribution transformers, including various accessories, shall generally comply with the following Indian Standards / REC Specifications. The standard(s) shall be with latest amendment, if any. Note: Wherever ISS are mentioned, equivalent or better International standards are also acceptable. Sr. No. 1 Specification IS: 1180 (PART-I) Details about Specifications for outdoor type three phase distribution transformers up to and including 100 KVA, 11 KV Class. Guide for loading of oil immersed Transformers New insulation oils for Transformers Dimension of Porcelain parts & Transformer bushing (1.1 KV)- for LT Metal parts for 2 3 4 IS:6600-1978 IS:335-1983 IS:3347 (Part-I Sec. 1 & 2) IS:3347 (PART-III / Sec-1 & 2) 5 Dimensions of Porcelain parts & Metal Transformer bushing (17.5 KV)- for 11 kV parts for 6 IS:7421 Porcelain Transformer Bushings for low voltage – up to 1 KV. Porcelain Transformer bushing for AC volts above 1000 volts. Fittings & accessories for Transformers Code of practice for maintenance & supervision of insulating oil in service. Specifications for Aluminum wire rods. Specifications for insulating kraft paper. Specifications for solid insulating press Boards for electrical purposes. Specification for paper covered Aluminum round conductors Specification for paper covered Aluminum rectangular conductors Ready mixed paint, brushing zinc chromate, painting Testing of steel sheets and strips for magnetic circuits. Determination of water content in oil for transformers. Dimensions for clamping arrangements for bushings. Rectangular conductor for electrical machines. 7 8 9 IS:2099-1986 IS:3639-1966 IS:1866-1978 10 11 12 13 14 15 16 17 18 19 IS:5484 IS:9335 IS:1576 IS:616 (Part I) IS:6162(Part II) IS:104 IS:649 IS:2362 IS: 4257 IS 6160 20 21 22 IS:10028 IS:3401 - REC Specification No. 2 - REC Specification No. 39/1993 - CEA Specification Chapter 4 Selection, Installation and maintenance of transformers Silica gel Materials conforming to other internationally accepted standards, which ensure equal or higher quality than the standards mentioned above would also be acceptable. 1.3 SERVICE CONDITIONS: The distribution transformers to be supplied against this specification shall be suitable for satisfactory continuous operation under the following climatic conditions as per IS: 2026 (Part- I) latest revision. i) ii) iii) Peak ambient temperature Maximum yearly weighted average ambient temperature Maximum relative humidity (Some time approaches saturation points) iv) Minimum relative humidity v) Average number of thunder storm days per annum vi) Average number of rainy days per annum vii) Average annual rainfall viii) Number of months of tropical monsoon conditions ix) Maximum wind pressure x) Altitudes : 50° C : 35° C : 95 % : 10% : 40 : 90 : 125 cm : 3 Months : 100 Kg/mt² : Not exceeding 1000 mtrs 1.4 PRINCIPAL PARAMETERS 1.4.1 The Transformer shall be suitable for outdoor installation with three phase 50 Hz 11 KV system in which the neutral is effectively earthed and should be suitable for outdoor service as step down transformer under fluctuations in supply voltage up to (+) 10% to minus (-) 15 % and frequency variation of +/- 3% from the rated frequency. The transformer should be suitably designed for with-standing the unbalanced voltages developed due to single phasing operation during load regulatory measures in 11KV distribution system. It should be capable of withstanding the disturbance of back e.m.f., magnetic characteristic and consequential mechanical inter-play of forces, if any, under such single phasing. 1.4.2 The 25 KVA Transformer shall confirm to the following specific parameters: i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) Continuous rated capacity System Voltage (Max.) Rated HT voltage Rated LT voltage Frequency No. pf phases Primary connection (HT) Secondary connection (LT) Vector Group Percentage impedance at 75° C Taps (off circuits) Type of cooling Fault level of the system : 25 KVA : 12.5 KV : 11 KV : 433 V (P-P) / 250 V (P-N) : 50 Hz : THREE : DELTA : STAR : Dyn-11 : 4.5 % : TAPS NOT REQUIRED : ON AN : 500 MVA 1.4.3 Primary winding shall be DELTA connected and the secondary winding shall be STAR connected (vector symbol Dyn-11), so as to produce a positive displacement of 30° from the primary to the secondary vectors of the same phase. The neutral of the secondary winding shall be brought out to a separate insulated terminal. The transformers shall be Aluminum wound (EC grade). 1.4.4 The transformer shall be designed and constructed to withstand without damage the thermal and dynamic stresses of an external short circuit. The Manufacturer / Bidder/manufacturer shall furnish all relevant design data and calculations in support of having fulfilled this requirement as stipulated in IS:2026 (Part-I) 1.5 NO LOAD VOLATGE RATIO: The No load voltage ratio(s) shall be 11000/ 433 Volts. 1.6 LOSSES: 1.6.1 The No-load Loss and Load Loss for 11 KV Distribution Transformers of 25 KVA rating shall not exceed the values indicated below: MAX. NO LOAD LOSS WATTS (Fixed Losses) 100 IN MAX. LOAD LOSS IN WATTS (at 75° C) 685 RATING (KVA) 25 1.6.2 The above specified loss values are maximum guaranteed, without any positive tolerance. In case the actual loss values exceed the above guaranteed values, the transformers shall be rejected at the risk, cost and responsibility of the Bidder/manufacturer. 1.7 TEMPERATURE RISE: 1.7.1 The temperature rise test shall be conducted by feeding total guaranteed losses calculated at 100° C o as against 75 C in the ISS and tested in accordance with IS:2026 or equivalent standards and the same shall not exceed the limits of 50° above ambient temperature (measured by resistance method) for transformer C windings and 40° above ambient temperature (measured by thermometer) for top oil. In case the temperature C rise exceeds the above values, transformers shall be rejected at risk, cost and responsibility of the Bidder/manufacturer. The losses fed during temperature rise test for 25 KVA rating shall be as under: RATING 25 KVA Total Losses to be fed (No load losses + Load Losses corrected to 100 C) 100 + 742 = 842 Watts o 1.7.2 It must be noted carefully that readings for hot resistance after shut down shall be taken separately for HV & LV windings, which means, after completing the readings for one winding (HV or LV), the transformer shall be connected again and rated current passed for another 60 minutes (min.) and shut down taken again to take hot resistance readings for the remaining winding. This is in line with the requirement of CBIP manual, to ensure proper resistance v/s time curves. 1.7.3 The Hot spot temperature at annual weighted average ambient temperature of 35 C shall not exceed o 98 C, when calculated as per IS: 2026 (Part-II) However, the transformer shall be designed for class ‘A’ insulation. 1.8 UNBALANCE CURRENT The maximum value of unbalanced current in transformers shall not exceed 2% of full load current. 1.9 IMPEDANCE: The percentage impedance at rated current and at 75° shall be 4.5 % with (+/-) 10 % tolerance. C 1.10 TAPPINGS: No taps are to be provided in these transformers. 1.11 FREQUENCY: o Transformers shall be designed for normal frequency of 50 Hz, but shall be capable of giving the rated output with the variation of (+/-) 3 % from the rated frequency. 1.12 ELECTRICAL CLEARANCES (A) EXTERNAL (IN AIR) Minimum external electrical clearances after mounting the bimetallic terminal connectors in position shall be maintained, as under; however, positive tolerance shall be acceptable without any ceiling. Clearance Voltage Medium Phase to phase 11000 Volt 433 Volt AIR AIR 255 mm 75 mm Phase to earth 140 mm 40 mm B) INTERNAL (IN OIL) The following minimum internal clearances shall be maintained as per details given hereunder: PARTICULARS a) Between HT outside surface & tank inside (non bushing side) b) Between HT outside surface & tank inside. (HV bushing side) c) Between HT outside surface & tank inside. (LV bushing side) d) Between HV windings & yokes (end insulation) e) Between LV windings to core(Bare conductor) f) From top of yoke to inside of top cover of tank (with gasket) g) Between LT/HT winding (Radial bare conductor Clearance ) h) Phase to Phase Clearance between HV limbs 25 KVA 25 mm 40 mm 25 mm 20 mm 3.5 mm 125 mm 11 mm 10 mm The aforesaid external and internal clearances are minimum clearances and no negative tolerance on these clearances shall be allowed. 1.13 TEST VOLTAGE: Transformers shall be capable of withstanding the power frequency and impulse test voltage prescribed below: Nominal system Voltage (RMS) 11 KV 0.433 KV Highest system voltage (RMS) 12.5 KV ---Impulse voltage 75 KV (PEAK) ---withstand Power frequency test voltage in (RMS) 28 KV 3 KV The transformer shall have fully insulated windings designed for the above impulse level. foot plate insulation. ii) CONSTRUCTION: The High-tension windings shall be concentric with the Low-tension windings. The placement of top header pipe to the tank body shall be above the top of yoke. 2 mm thickness will be used. Necessary calculations in this regard shall be furnished by the Bidder with their Bid. 2 mm press board shall be used for base support insulation and core clamping channel insulation. KVA .4 1. HV/LV bushing pocket shall not be considered for purpose of above calculations). required clearances.3 Cooling area of the tank/radiators should be sufficient to dissipate the guaranteed losses (at 100° C) satisfactorily. For the purpose of heat dissipation calculations. 20 mm press Han paper making thickness of the cylinder 1. headers.14 HEAT DISSIPATION (COOLING) / RADIATOR CALCULATIONS & E T R (ELLIPTICAL TUBE RADIATORS) PLACEMENT 1. 1. The LT conductor shall be rectangular in shape. Top layer of all HV coil shall be given one coat of air drying insulation varnish. the above tolerances are subject to maintaining the min.1.2 The radiator tubes shall be arranged in two equal banks fixed at two opposite non bushing sides. vertical spacers between HV and LV coils and radial spacers (tick leys)/ blocks etc. shall be of PC Board only. WINDING AND INSULATION: i) MATERIALS: Double paper covered Aluminum conductors shall be used for 11 KV class transformer of 25 rating. There shall not be any price preference for providing of either type of radiators. The arrangement of the windings shall be robust in electrical and mechanical construction and shall permit free circulation of oil and avoid hot spots. Insulation cylinder made from electrical grade pre-compressed board(s) having minimum total thickness of 1. However. The material and thickness of various insulation provided for phase barrier.5 mm shall be used between HV and LV windings.14.14. only PC board of min.5 mm having similar electrical properties may also be used. ii) Elliptical tube of section 57 1. The header pipe connecting radiator bank to the tank shall be rectangular in shape with approximate size of 100x20 mm (for elliptical tube radiators) or the header pipe connecting radiator flange to the tank shall be of round pipe of dia 32 mm (for pressed steel radiators). Also. Elliptical tube radiators of section 57 of gauge 18 (with tolerance as per relevant ISS) or pressed steel radiators having sheet thickness of 1. the following criteria shall be adopted: i) Plain surface of tank – 500 W / m 2 (Note: The area of top/bottom tank surface. A tolerance up to plus/minus 1% shall be permissible on ID and OD and axial length of HV and LV coils. For bottom and top yoke insulation.1 The transformers shall be capable of giving a continuous output without exceeding the specified temperature rise as indicated in para 1. Alternatively.14. to facilitate cooling for hot oil sump over top yoke.7 above. yoke insulation and core clamp insulation shall be clearly indicated in the drawing and in any case shall not be inferior to those used in type tested transformers. The covering shall conform to IS: 6162 (part I & II). Two layers of electrical grade insulation craft paper of 2 mm thickness or one layer of minimum 4 mm thickness shall be used for interlayer insulation both for HV and LV Coils.20 mm (with tolerance as per relevant ISS) on the transformers shall be acceptable. of 1 mm thick press board shall be used for covering the tie rods.14. For phase barrier. Tie rods shall be covered by craft paper of suitable size in addition. 1. 2 Nos.15 -- 55 watts/meter length. Minimum number of coils on HV side shall be 4 (four) per phase for 25 KVA rating transformers. Dovetailed shaped radial spacers shall be placed between HV coil sections, suitably – locked with vertical spacers around the circumference of the coils. The number of such spacers shall be minimum 4(four). iii) INSULATION MATERIAL Electrical grade insulating Kraft paper of only Tribeni / Ballarpur / Cauvery or equivalent/ better make shall be used subject to approval of the Employer. Press Board used shall be of senapathy whitely / Raman make or equivalent/ better quality subject to approval of the the Employer. Perma wood or haldu wood blocks shall be used for Top and Bottom yoke insulation. iv) CONNECTIONS AND TERMINATIONS: A) HV Winding: The following method shall be adopted for taking out HV connectionsa) The coil series connections shall be made by soldering / brazing only, after completely removing the insulation from the ends. Starting and finishing leads of HT coils shall be covered with empire sleeve(s) of proper size. These leads should be clamped with the body of the winding with the help of cotton twine during manufacture of the coils. All delta leads from the HT coils as well as HT line leads shall be taken out through multiple paper covered (MPC) copper wires of sufficient cross section area to impart the desired mechanical strength. The current density in HV lead wire shall not exceed 0.8 A/mm². These lead wires shall be provided with multi layer paper insulation of minimum 1.0 mm thickness i.e. increase in diameter due to paper insulation shall not be less than 2 mm. The layer of glass sleeves/ glass tape shall also be provided on the delta MPC wire and it should be further covered with craft paper. b) c) d) All the above leads shall then be clamped tightly with cotton twine directly on to the special frame/ bracket making “Pie” shape connection. This structure could be made up of Bakelite/ Permalli wood/ laminated PC board flats, having minimum size of 25x4.5 mm. Line leads leading to the HV bushing terminals shall be directly clamped to the horizontal support bar of the “Pie” structure so that any tension which may develop in the HT leads due to jerks or at the time of making the connection, is not passed to the HT coils. Delta joint and lead from delta joint to bushing rod shall be made by brazing only. e) B) LV Winding : a) The LV connection shall be taken out by cut on the top yoke channel duly reinforced to compensate for the mechanical strength. b) The layers in LT Coil may be either even or odd in numbers but minimum layers shall be two. c) LV star point shall be formed of Aluminum flat of sufficient strength. Leads from winding shall be connected to the flat by brazing. d) Firm connection of LT winding to bushing shall be made of adequate size of “L shape flat”. of LT coils to L shape flat shall be by brazing only. e) “L” shape Flat shall be clamped to LV Bushing metal part(s) by using nut, lock nut and washer. f) Neutral of the Secondary winding (LV) shall be brought out to a separate insulated bushing. Connection g) For Aluminum windings, L&T, ALKAPEE Aluminum brazing rods with suitable flux will be used. 1.16 CORE CONSTRUCTION & CORE COIL ASSEMBLY DETAILS: (i) The core shall be of high grade cold rolled grain oriented (CRGO) annealed steel laminations, having low loss and good grain properties, coated with hot oil proof insulation, bolted together to the frames firmly to prevent vibration or noise. All core clamping bolts shall be effectively insulated. The complete design of core must ensure the permanency of the core losses with continuous working of the transformers. The value of the flux density allowed in the designs and grade of laminations used shall be clearly stated, along with the curves. The transformer core shall be constructed out of the prime class of materials. CRGO Lamination used shall be of prime grade and not second grade steel laminations. (ii) It will be mandatory for all the transformer manufacturers to use only PRIME grade CRGO Laminations with specific loss of 0.89 watt per kg. at 1.5 Tesla or any other combination of better grades with any thickness subject to maximum specific loss of 0.89 watt per kg. at 1.5 Tesla will also be acceptable. The bidder shall furnish the core loss (watt/Kg.) and power (VA/Kg) curves of the laminations used. The core shall be properly stress relieved by annealing in inert atmosphere. The transformer shall be suitable for over fluxing (due to combined effect of voltage and frequency) upto 12.5% without injurious heating. The operating flux density shall be such that there is a clear safe margin of 12.5%. over the fluxing limit. (iii) Full mitered core construction technique shall be adopted. Top yoke & bottom yoke pieces shall all be in one single piece and no cut pieces shall be acceptable. The cross sectional area of yoke & limb shall be approximately same. (iv) Transformer core shall not get saturated for any value of V/f ratio to the extent of 115% of the rated value of V/f ratio (i.e. 11000/ 50) due to combined effect of voltage and frequency without injurious heating at full load conditions. The bidder shall furnish necessary design data in support of this situation. (v) Flux density at rated voltage and frequency of core and yoke shall not be more than 1.60 Tesla. The Over fluxing shall be limited to 12.5 % of rated value. The No Load Current (magnetizing current) at rated voltage and at 112.5% of rated voltage shall not exceed the values given below: Maximum permissible magnetizing current in percentage of rated full load current Transformer Capacity (In KVA) 25 At 100% rated voltage 3.25 At 112.5% rated voltage 6.50 (B) CORE-COIL ASSEMBLY: The core joints shall be interleaved and with full miter design, as mentioned above. Ample provision for free circulation of oil in the radial gap between the core & LV coils shall be made. Eyes or lugs of sufficient size shall be provided for lifting core and winding assembly out of the tank. The core shall be effectively earthed through tinned copper earthing plate bolted on core frame channels, after removing the channel paint. For top yoke channels, if cut or holes are made for taking LV connections, suitable reinforcement to channels shall be made by providing adequate size of MS Flat of the thickness not less than 6 mm. On the core-coil assembly, core clamping channels, tie rods, core studs, spacers, assembly base supports, etc. shall be provided as per details given hereunder: Sr. Item No. a) Tie rods Minimum 4 Nos. of 12 mm each properly insulated and covered with Kraft paper. Tie rods shall also be provided with lock nuts. Minimum 4 Nos. of 12 mm each properly insulated and covered with Kraft paper. The core studs shall also be provided with lock nuts. Minimum 4 Nos. dovetail type with min. peripheral coverage of 30%. Particulars b) c) Core studs Spacers d) Support of core assembly base 2 Nos. MS channels of 75x40 mm. e) Channels for clamping core coil assembly 4 MS Channels of 75 x 40 mm size (applicable for CRGO transformers) Guides on all the four sides shall be provided to prevent shifting of the active parts and thereby accidental touching the tank. Alternatively brass nut arrangement at the top of core coil assembly to lock the same with the transformer tank be provided. The assembly fixing brass nut(s) are to be welded, 20-30 mm off the centre line (and diagonally) of the tanks, so that assembly movement during transport etc. is prevented. MS Channel, tie Rods etc should be painted with hot oil and corrosion resistant paint after phosphate. All core-coil assembly shall be punched on core channel / a identity plate welded on core channel with following details: 1. 2. 3. Name of Bidder/manufacturer: Order / TN No: Rating: In case the above marking is not found on the core assembly of physically opened transformer selected for physical verification during final inspection then no further inspection shall be carried out and reinspection charges shall be payable by the Bidder/manufacturer. 1.17 TRANSFORMER TANK: (a) Transformer tank shall be rectangular in shape, robust in construction and with adequate strength to withstand the pressures developed at the time of severe fault conditions. The tank body shall be suitably stiffened to achieve the objective. The tank sheet shall be electrically welded both from inside and outside to impart proper mechanical strength and to prevent leakage of oil. All joints of tank and fittings shall be oil tight and no bulging shall occur during service. The tank design shall be such that the core and windings can be lifted freely. The tank plates shall be of such strength that the complete transformer when filled with oil may be lifted bodily by means of lifting lugs provided. The stiffeners shall be welded full length. All the welding shall be continuous. The top cover plate shall be sloping down by more than 15 mm, opposite LV bushings side. The top cover instead of bending shall be extended by 5 mm by all the sides beyond the flange of the top cover. Accordingly length of the lifting hooks shall be extended. The top cover shall have no cut at point of lifting lug. No negative tolerance in the tank dimensions is acceptable in actual supply. The tank shall be fabricated by welding at corners. No horizontal or vertical joints in tank side walls and its bottom and top cover will be allowed. (b) Minimum size of MS Sections to be used in construction of transformer tanks shall be as under: Sr. No. 1 2 3 4 Tank Cover plate thickness (mm) Tank Sides wall thickness (mm) Tank bottom plate thickness (mm) No. of stiffeners (To be welded with one face while the other side of the angle forms inverted “L”) 1 5 5 6 Conservator body (mm) Size of M. S. stiffener (mm) Tank Top flange size (mm) 2.0 40x40x 6 angle 50 x 6 Flat 5.0 3.15 5.0 I T E M S 25 KVA 7 8 9 Cover Bolt Size Cover Bolt spacing (Maximum) Lifting lugs M10/ 3/8 x 1.5” 75 mm 2 Nos. 8t mm flat 10 Tank Base Channel (ISMC Type) 2 ( 75 x 40 mm) NOTE: Each cover bolt shall be complete with two flat washers, one nut and one spring washer. The above mentioned M S sections shall be subject to tolerance as per ISS. (c) Lifting Lugs: Two Nos. welded heavy duty lifting lugs of MS plate of 8 mm thickness, suitably reinforced by vertical supporting flat welded edge wise below the lug on side wall shall be provided, these shall be so extended that cutting of bent plate is not required (d) Top cover gasket & Bolt : i) ii) iii) iv) v) The gasket provided in between top cover plate and tank shall be of min. 6 mm thick neoprene rubberized oil resistant cork sheets conforming to type B or C as per IS:4253 part II. G.I. Nut bolts shall be of size M 10 x 40 mm / 3/8x1.5” long with two flat washers, suitably spaced (as specified) to press the cover. Height of the tank shall be such that minimum clear height of 125 mm is achieved between top of yoke and under side of the tank cover (with gasket in place). All steel screws, nuts and fasteners exposed to atmosphere shall be either galvanized or cadmium plated or electroplated. All sealing washers / gaskets shall be made of oil and heat resistant neoprene or nit rile rubber. Gaskets made of natural rubber sheet are not permissible. The minimum thickness of gaskets shall not be less than 6 mm for tank cover and gasket washers. vi) 4mm for HT/LT Talbros make neoprene/nitrile based rubberized cork sheet – grade RC-70-C shall only be used as gasket material. Alternatively, other makes of gaskets having type designations as under can also be used, if ‘Talbros’ make gasket is not available: Name of the firm Commercial name of gasket manufactured by the firm. P. Ltd. Nu-Cork (Neoprene) Nu-Cork 999 RC-70-C S. No. 1. 2. M/s. Nu-Cork Gurgaon Products M/s. Bharat Corrub Ind. Vadodara Chetak (Neoprene) RC-70-C 3. M/s. Grindbeck. Gujarat Zebra (Neoprene) RC-70-C 4. M/s Goodwill Rubber Ind. (P) Ltd., Calcutta. Mayur (Neoprene) RC-70C (e) Tank shall be reinforced by continuously welded angle on all the four sides of the walls, on the edge of tank, as specified above. The permanent deflection shall not be more than 5 mm upto 750 mm length and 6.5 mm up to 1250 mm length when transformer tank without oil is subjected to the vacuum of 250 mm of Mercury. (f) PAINTING & FINISHING: Steel surface shall be prepared by sand / shot blast or chemical cleaning including phospating, as per IS 3618. Heat resistance paint (Hot oil proof) shall be provided inside the tank. On external surface, one coats of thermo-setting powder paint or 2 coats of Zinc chromate followed by two coats of synthetic enamel paint of dark admiral grey shade, confirming to shade No. 632 of IS: 5-1961, shall be applied. The requirement for paint and the material to be used shall be as below. Paint Type a) Powder Paint b) Thermo Setting Powder LIQUID PAINT a) Zinc Chromate (Primer) b)synthetic Enamel or powder coating (finish coat) c) Hot Oil Paint Inside 01 Outside Outside 02 02 Area to be Painted Inside Outside No. of coats 01 01 All steel screws, nuts and fasteners exposed to atmosphere shall be either galvanized or cadmium plated. 1.18 FITTINGS & ACCESSORIES: The following standard fittings shall be provided on each transformer: a) b) c) Earthing terminals of M10/ 3/8x1.5” with tinned lugs and symbol – (2 Nos.) Lifting lugs – (2 Nos. for main tank). Rating and terminal marking plate (non-detachable), details to be included in one plate only. The plate shall be of stainless steel only, with details clearly marked d) e) (1 No.) Bi-metallic terminal connectors on HT/LT bushings and it may be ensured before dispatch that connectors are fitted. Oil level gauge of minimum 150 mm length of prismatic glass, indicating three positions of oil, marked as follows, shall be provided: 1) 2) 3) -5 ° - Min. C 30 ° - Nor. C 98 ° – Max. C f) Silica Gel Breather shall be Aluminum/ metal – (1 No.) g) Thermometer pocket, 12.5 mm dia with cap. shall be provided –– (1 No.) h) HV Bushings. These shall be of 17.5 KV/250 A class, with non adjustable, single gap type arcing horns – (3 Nos.) i) LV Bushings. 1.1 KV class, 250A (M12 stem) – (4 Nos.) j) Under carriage: For transformers of 25 KVA rating shall conform to REC specifications. k) Brass rod 12 mm diameter for HT – (3 Nos.) l) Brass rod 12 mm diameter for LT – (4 Nos.) Note: LV/ HV Connectors shall not be the integral part of the bushing stems. 1.19 CONSERVATOR: 1.19.1 The oil gauge and the breathing device shall be fixed to the conservator. In addition, the cover of the main tank shall be provided with a self-sealing pressure release device designed to operate at minimum pressure of 8 PSI (0.564 Kg./cm. Sq.) to enable release of air trapped within the main tank, unless the conservator is so located as to eliminate the possibility of air being trapped within the main tank. The conservator shall be of cylindrical shape and it should be provided above the HV bushing with a minimum clearance of 50 mm and suitably inclined to maintain the clearance. 1.19.2 The total inner volume of conservator shall be minimum 10 ltr. for 25 KVA transformer. The inside diameter of the pipe connecting the conservator to a main tank shall be min. of 30 mm and it should be projected into conservator in such a way that its end is approximately 25 mm above the bottom of conservator so as to create a sump for collection of impurities. The min. oil level (corresponding to – 5 deg. C.) should be above the sump level. The connecting pipe from conservator tank to main tank shall have a sloping flap so that oil falling from pipe shall not fall directly on the active job. 1.20 SILICAGEL BREATHER: 1.20.1 Body of breather shall be of Aluminum/ metal and inside container for Silica gel shall be of tin sheet. The breather shall be only from reputed and approved manufacturer and as per the approved drawing. The gel capacity shall be of 250 grams. Inverted U shape pipe shall be used for breather. Mounting arrangement of the breather shall be flanged/ threaded type as per details given in the illustrative drawing attached. 1.20.2 The design shall be such that the condition of Silica gel is clearly visible from a distance, even after years of service. 1.21 H V BUSHING TERMINAL DETAILS : 1.21.1 3 Nos. 17.5 KV / 250 A class bushings, conforming to IS:3347 & IS:2099, shall be fitted on a pocket made on top cover. These pockets shall be such that the HV bushing is tilted more towards the HV side. The bushing of R & B phases may be tilted sidewise also to maintain the required electrical clearances. 1.21.2 The clamping ring of HV bushing shall be of galvanized MS Sheet having minimum thickness of 1.6 mm. The total weight of all the 12 Aluminum caste member of HV bushing shall not be less than 210 grams. 1.21.3 The inner porcelain portion of bushings shall be projecting approx. 50% of the length inside the conical pocket. 1.21.4 The arcing horn(s) shall be single gap and fixed type. HV bushings shall be of reputed make such as BEPCO, JAYSHREE, WSI, SESHASAYEE or any other make - approved by the Employer. The HV bushings shall generally conform to IS: 3347 and IS: 2099. Embossing showing the manufacturer’s name and month & year of manufacture shall be clearly visible on HV bushings, even after fixing on transformer(s). 1.21.5 As mentioned earlier, suitable bi-metallic connectors shall be provided having capacity of about 1.5 times the rated current of the transformer, as per drawing enclosed. 1.22 L V BUSHING TERMINAL DETAILS: 1.22.1 LV Bushing side shall be opposite to the HV Bushing side. 4 Nos. LV Bushings (1.1 KV/ 250 A) shall be mounted on a special pocket on the tank wall. Projection of the LV pocket shall be such that inner portion of the LV stem shall not project more than 20 mm inside the tank, to facilitate unhindered lifting of the core coil assembly. Bushing stem of M12 size shall be of brass. Rest of the components shall conform to the requirement of IS:3347 (Part I/section 2). The LV bushings shall be of reputed make such as JSI, JAIPUR GLASS or any other make approved by the Employer. The LV bushings shall generally conform to IS: 3347 and IS: 7421. 1.23 TRANSFORMER OIL: 30.23.1 The transformer shall be supplied complete with first filling of EHV Grade transformer oil, up to the normal oil level. The oil shall conform to IS: 335-1983 (latest amended) and should be ISI marked and having the specified aging characteristics. 1.23.2 The transformer oil sample taken from the transformer shall be subjected to testing as per provisions of IS:1866. 1.23.3 The oil manufacturer’s test certificate shall be made available at the time of inspection to the inspecting officer. 1.24 IDENTIFICATION DETAILS: a) Rating & terminal marking plate: Each Transformer shall be provided with non detachable name, rating and terminal marking plate fitted in a visible position. All details shall be given on one plate. Material of the plate shall be stainless steel only. Thickness shall be 0.9 mm (with a tolerance of ±0.1 mm). The plate shall be made absolutely un-detachable either through welding or riveting or through any other approved method. Each HV & LV terminal shall be duly marked with its terminal numbers. (e.g. HV terminal with capital letter 1U, 1V, 1W and LV terminal by corresponding small letters) 2u, 2v, 2w and the neutral terminal by 2n). In the diagram to be given on the name plate, the relative position of various terminals- when viewed from top – shall be clearly shown. Dispatch instruction will not be issued, unless all these details are verified by the Inspecting Officer. Besides other particulars, following details shall also be given on the name plate: i) ii) iii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) P.O. No. - Month & year. Sr. No. of transformer. Date of dispatch - month & year Date of expiry of guarantee period – month & year Maximum Guaranteed No Load & Load Loss Figures Recommended fuse sizes for HV & LV sides. Name & Full address of the manufacturer. Weight of oil (In Kg). Total Weight (In Kg). Vol of oil (In Liter) Rating of the transformer. Impedance volt. (%). Volts at HV&LV. Frequency (Hz) Vector group (Dyn11) ALL DETAILS ON THE NAME RATING AND DIAGRAM PLATE SHALL BE INDELIBLY MARKED i.e. BY ENGRAVING, STAMPING or PUNCHING. b) Identification Plate: M.S. plate of size 75 x 75 x 2.5 mm having following details punched with letters of size 8mm X 6mm shall be continuously welded to the main tank body below the middle HV bushing and on top cover of tank in clearly visible position : MPPKVVCL ……… KVA , MAKE ……………. c) Identification mark:- Serial Number of Transformer is to be engraved on transformer tank just below the name plate with the letter size of 10 mm x 8 mm. 1.25 GUARANTEED AND OTHER TECHNICAL PARTICULARS FOR TRANSFORMER: 1.25.1 Guaranteed Technical Particulars of the transformer offered shall be furnished in A-4 size paper by the Bidder in the proforma appended herewith. Complete details shall be furnished. Tolerances on weight, quantity and dimension figures shall be ± 5% at the tender stage, subject to maintaining the minimum electrical clearances as per the specification. However, no negative tolerance shall be allowed on the short circuit type tested design. Electrical performance data shall be subject to tolerances as per ISS, unless otherwise specified in this specification. However, the No Load loss and Load loss figures shall be maximum guaranteed without any positive tolerance. S.NO. ………. 1.26 TYPE TEST CERTIFICATES: 1.26.1 The contractor/manufacturer shall furnish type test certificates in accordance with IS:2026 (Part I to III) for the offered transformer, which should not be more than 3 years old as on the date of submission of Bid. i) Short circuit test for dynamic and thermal ability: The short circuit test for dynamic and thermal ability shall be arranged at CPRI, Bangalore/ Bhopal or ERDA, Vadodara on one unit of each rating. Impulse voltage withstand test: The impulse voltage withstand test shall be arranged at any testing house accredited to NABL for the purpose of impulse test. The cost of above Type Tests shall be borne by the Contractor/approved manufacturer. ii) 1.26.2 1.27 DRAWINGS AND OTHER DOCUMENTS: 1.27.1 The Bid shall be accompanied with the following drawings / Calculation sheets, as per the offered designs. The drawings shall be only on A-3 (420 x 297 mm) size paper and calculation sheet shall be on A-4 size paper only. a) b) c) d) e) f) g) h) 1.28 Name rating / diagram plate drawing. Outline and general arrangement drawing. Core-coil assembly drawing. Core section (for limb and yoke) along with flux density calculation sheet / drawing. Cooling area calculation sheet. Thermal Ability short circuit calculation sheet. Core loss and magnetization curves of the laminations. Heat dissipation calculations (heat dissipation by tank walls excluding top and bottom should be 500 W/sq. meter. QUALITY ASSURANCE PLAN: 28.1 The Contractor/manufacturer shall furnish the details in respect of the items specially indicated in the schedules prescribed herein and annexed with this specification, failing which the offer is liable for rejection. 1.29 INSPECTION AND TESTING: The inspection and testing shall be conducted at the place of manufacture. The transformers shall be completely assembled and tested at the factory. The inspection may be carried out by the Employer at any stage of manufacturing. 1.30 STAGE INSPECTION: 1.30.1 The Employer’s representative may carry out stage inspection of the transformers during manufacturing/ assembling stage. The Employer shall have absolute right to reject the raw material/ component/ sub assemblies or complete equipment not found to be conforming to the requirement of specification or being of poor quality/ workmanship. The stage inspection will particularly include the following tests/ checks besides the general routine tests to be conducted during manufacturing stages as per manufacturer’s standard practice. Physical inspection/checking of winding, insulating material, core material for annealing and prime quality and other accessories / fittings of Transformer. b) Measurement of core area and flux density. c) Verification of H.V. & L.V. coils, Conductor size, I.D., O.D. Axial length, weight, insulation covering etc. d) Measurement of thickness of tank plates (Top, bottom and sides) and to conduct Air pressure & vacuum tests as specified in the specification, to ensure the adequate strength of the Transformer tank body. e) Sample testing of core material for checking specific loss and thickness of core plates. f) Visual and dimensional check during assembly stage of core. g) Check for proper provisions of spacers and bracings to arrest the movement of core and winding assembly inside the tank. h) Check complete transformer against approved outline drawing, provision for all fittings, finishing etc. 1.30.2 The Employer at his option may collect the sample of the following raw material/ component for independent testing: a) CRGO Laminations - One specimen sheet of 300-500mm length and 50- 75mm width (for each lot). a) 30. Magnetic Balance Test (See note below) Oil Leakage Test (See note below) . Air pressure test on empty tank of transformer opened for physical verification test. (See note below) Measurement of unbalance current. KVA 11.. 10.1 All the assembled/ finished transformers prior to dispatch shall be subjected to routine tests as per IS: 2026. Minimum 10% of the offered lot size samples subject to minimum 5 Nos will be taken for routine and acceptance tests. individual weights of HV and LV winding core laminations etc. 2. 1. Physical verification of core – coil dimension. Measurement of No load current at 100 % and 112. 5. The physical verification shall be conducted on units equivalent to one unit per 25 Nos or part thereof of offered quantity randomly selected from the offered lot.31. 9. material. Checking of manufacturer’s test certificates and invoices for major raw materials shall be done and copies thereof duly signed by Bidder/manufacturer’s representatives and inspecting officers shall be enclosed with the inspection report. oil quantity. provisions of required oil ducts in the HV and LV winding.31.coil assembly. 3.30. The Bidder/manufacturer shall invariably furnish manufacturer’s routine test certificate along with inspection call of the offered transformers for pre-dispatch inspection.1250 mm length specimen for each type. tank sheet thickness. conductor sizes. fittings and accessories. 8.b) c) d) HV winding wire LV winding wire Transformer oil. . At least 25% of the transformers shall be offered in the shape of finished core . Oil dielectric strength (break down voltage) test. Measurement of No load losses at rated voltage and normal frequency. 7. finish.coil assemblies. paint thickness and workmanship as per purchase order and contract drawings. the Bidder/manufacturer should intimate complete schedule of manufacturing programme of the transformers preferably 15 days in advance. 1. internal clearances. 1. with reference to contract drawings and type test report(s) by dismantling selected unit(s). .3 Following tests shall also be carried out at manufacturer’s works on one complete unit of 25 Transformer unit : i) ii) iii) iv) v) Temperature rise test (in the first lot and may be repeated in subsequent lots if desired by the Employer). The inspecting officers during the course of stage inspection may seal this core .2 samples of 5 liters each. ROUTINE/ ACCEPTANCE TESTS: 1.31 .4 1. 4. 12. Checking of rating and terminal marking plate. 1. 6.1250 mm length specimen for each type.5% of rated voltage and normal frequency. The inspection offers without furnishing of routine test certificates as per ISS of all the transformers offered for final inspection shall not be entertained. Checking of weights. 13. The dismantled unit(s) after re-assembly shall be accepted by the Employer after routine testing in presence of his representative.3 To facilitate stage inspection. and any delay on this account shall be to Bidder/manufacturer’s account.31. Insulation resistance Separate source voltage withstand test Induced over voltage withstand test Measurement of windings resistance cold (at or near the test bed temperature) Measurement of Voltage ratio and check of voltage vector relationship Measurement of Impedance voltage and load losses at rated current and normal frequency.2 The selected samples shall be subjected to the following routine / acceptance tests at the manufacturer’s works in accordance with the relevant ISS: 1. . dimensions. The testing house shall be advised to arrange to send type test results directly to Employer along with drawings duly attested by the testing authority for scrutiny and approval. 800 400 0 11000 Volts (HV) 433 Volts (LV) ii) 30 C. 50 25 0 AIR PRESSURE TEST : This test shall be conducted as type test at the time of inspection of first lot. The type-tested transformer(s) shall also be accepted as part of the supplies.4 Preferably Fifteen days clear notice shall be arranged for pre-dispatch inspection by Employer’s representative. rating and diagram plate. NOTE: i) INSULATION RESISTANCE MEASUREMENT: Insulation resistance of selected samples shall be measured with a 2500 V Megger. not to be insisted on the Bidder/manufacturer who has arranged Dynamic & Thermal Ability to withstand Short Circuit . shall be as indicated in the table below: 20 C. after pressure has been released. M/s Sakova.32. 1. The pressure gauge and vacuum gauge shall be duly calibrated and sealed by an independent recognized test lab(s).4 The requirement of arranging short circuit & impulse voltage withstand test shall however. The minimum insulation resistance. 100 50 0 60 C. in Mega Ohms. The measured voltages shall satisfy the conditions detailed as above. The application of voltage to the end limbs will induce greater voltage in the middle limb and less voltage in the other end limb. Transformer complete in all respects shall be subjected to the pressure corresponding to 0. iv) OIL LEAKAGE TEST: The oil leakage test shall be conducted on one unit selected from the offered lot. for 30 minutes.1. The test procedure shall be as detailed below : The tank shall be fixed with a dummy cover with all fittings including bushings in position and shall be subjected to air pressure of 0. identification plate (on tank body & Top cover) as specified in this specification. if so decides.31. the inspecting officer will ensure that all the offered transformers are complete and duly fitted with name.3 The programme indicating date and place of type test(s). Permanent deflection of flat plate. M/s Wako. The procedure for the test shall be as under : a) b) c) Apply 250 Volts between LV terminals 2u-2n and measure voltages between 2v-2n & 2w –2n.5 After successful inspection. Apply 250 Volts between 2v-2n and measure voltages between 2u-2n & 2w-2n. 1. the inspecting officer shall seal all the inspected transformers by numbered seals on diagonally opposite bolts of top cover for identification. 1. No leakage should occur. Uniformity of induced voltages shall confirm the healthiness of the transformer windings.5 Kg / cm² and maintained for three hours.5 mm This test shall be conducted as an additional test on one sample transformer from each lot offered for inspection.0 mm 6.32./ cm² (gauge pressure). 200 100 0 50 C. Vignole or Metrawatt. Apply 250 Volts between 2w-2n and measure voltages between 2u-2n & 2v-2n.8 Kg. Before sealing. to depute his representative to witness the test. at the manufacturer’s works.31. be intimated to enable Employer. The application of low voltage to the middle limb will induce approximately equal voltages on the two end limbs. M/s Evershed. shall not exceed the values given below: Length of plate up to 750 mm 751 to 1250 mm iii) MAGNETIC BALANCE TEST: Deflection 5. 400 200 0 40 C. of standard make such as M/s AVO. b) In case if dispatch instructions are less than 25 Nos. Impedance voltage and Load Losses at rated current.5% of rated voltage). however.2 Measurement of No Load Losses and Load Losses (i) After pre-dispatch inspection of material at manufacturer’s works the transformers will be subjected to the following test(s): a) One transformer will be selected out of every lot of 25 Nos. Further. 13947/I/1993 for Degree of Protection I. The Bidder/manufacturer will have to carry out suitable improvement in the design of the transformer and get it type tested in presence of Employer’s representative at his own cost.1 The Employer may select transformer(s) from the supplied lot(s) at random for conducting the routine tests. In case the selected transformer from the first lot fails in routine test.35 ATTACHMENT DETAILS FOR TAMPER PROOF PROTECTION UNIT: Tamper Proof Protection unit shall be manufactured in accordance with the following standards as given in drawing no/EZ-50 as given in Volume II.Test/ impulse voltage withstand test within last 3 years as on the date of opening of the tender on similar design and make. unloading and to & fro transportation up to the test house(s). The Employer shall have option to test the samples selected at random from the lot of 25 No received at site and shall be subjected to routine testing as per IS:1180 and 2026 (with latest amendments) at MTRU. no further supply shall be accepted.33. This process will continue in subsequent lots also. single pole MCCB shall be in accordance with I. SP MCCB with wiring in sheet steel cabinet duly powder coated. It is only after the transformer successfully passes the type test.33 RANDOM SELECTION AND TESTING (RST): (i) Inspection of material before dispatch or waiver of inspection will. not relieve.S. No Load current (at 100% and 112. one unit from the next lot shall be sent to the identified laboratory for carrying out routine tests at Bidder/manufacturer’s cost. In case of otherwise. Bhopal.33. Three No. 13947/II/1993 amended up to date. the penalty towards delayed supplies shall be to manufacturer’s account (if any). Vadodara/any other NABL accredited Laboratory. Bangalore/ERDA.33. 1. (ii) (iii) 1. at any test house(s) as mentioned above. than one sample shall be selected from each store (s) and the test result so obtained shall be for the quantity consigned / received by the store (s).. no charges will be reimbursed. 1. General Technical Particulars: The outdoor type distribution box is to be manufactured and supplied along with 3 No. the supplies shall be resumed which shall again be subject to random test as above before acceptance of the lot. One no. or part thereof from which sample was drawn.S. 1. In case the transformer fails again in any or all routine test. LT post insulator for neutral connections shall be provided. CPRI.P. the Bidder/manufacturer from his responsibility to supply the material strictly in accordance with the specification. The Enclosure Box shall comply with the requirement of I. The transformers available at site supplied against the current order shall have to be taken back by the Bidder/manufacturer at his own cost. The testing shall be arranged either at Employer’s own testing lab and / or at independent test lab. Jabalpur/ CPRI. 1.34 GUARANTEE PERIOD: i) The defect liability period of plants/ equipments shall be as indicated in GCC 27 of Sec 7 and GCC 27. The charges for such tests shall be reimbursable to the Bidder/manufacturer on actual basis on production of documentary evidence in case the selected sample successfully withstands type test(s). The testing charges for such tests shall be borne by the Employer. or part thereof for measurement of No load Losses at rated voltage. The test results will be applicable to the respective lot of 25 Nos. The Bidder/manufacturer shall arrange these tests including loading. .10 of Sec 8 of the bid document Vol. iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xv) NOTE: All dimensions are in MM. All hole meant for cable entry / exit to be provided with rubber. The box shall be provided to cover the LV bushing as shown in the drawing. earthing bolt size 25x10mm with 2 nos.Protection Box: The Enclosure shall be fabricated by using CRCA sheet steel of not less than 16 SWG thickness & shall comply with the requirement of I. washers and one nut are to be provided.1 MAIN FEATURES OF THE PROTECTION BOX: The box shall be as per drawing no DISCOM/EZ-50 given in Volume II. 13947/I/1993.35. All Hinges to be MIG Welded strictly. Box Door – down side up opening. Earth stickers or color embossing with Earth Symbol are to be provided.S. 2 Nos. and may be more to suit the size of MCCBs. Name plate One door locking Patti (25x40 mm) provided with MIG welded for pad lock and sealing hole arrangement. Sheet steel thickness: 2. Single Panel Door. . 1 Nos. All connecting wire ends should be fitted with proper lugs and properly connected except meter terminals.0 mm (min) Paint shade: Exterior & Interior – D. All louvers are to be provided with fine wire mesh from inside. The over all dimension of protection box shall be 450 mm x 500 mm x 170 mm. 1. Grey shade 632 of IS:5 Degree of enclosure protection IP:33 Cable entry at bottom as per drawing. Danger Plate 125x38mm with Hindi Language with “440V AC”. hole provided at bottom in Cable Gland Hole. The size of box shown in mm. i) ii) iii) The single door panel shall be provided with down side up opening. 2 Nos. Pad lock of 6 levers to be supplied and welded on the door of make Harison/Jainson/Navtal. Drawing no DISCOM/EZ/ 50 covering the above aspects is given in Volume II. – 33 as per I. Box is to be provided with MCCB fixing arrangement such that front & back as well as up & down with tilting adjustment can be done to accommodate various type & make of MCCB. Flat Gasket of size 20x2mm is to be fixed with adhesive (fevibond) inside door.P. Louvers are to be provided on both sides and in the bottom of MCCB Chamber. 1 No.A.mm to be provided. out coming terminal lug size 35 sq. 4 P.4 P. Single 50 °C.V.II & III complete with certified drawings. be that of the bidder/contractor. Terminals of Transformer to MCCB by 25 Sq. 2. 0. at 240 V AC.) IS 13947 Part-2 (latest) . Single pole MCCB is to be provided on LV side for overload protection and magnetic trip release for instantaneous tripping in the wake of short-circuits. 433 V.35. The Bidder shall submit the type test reports as per I.mm 4 Core Aluminum armoured cable. The MCCB’s shall be manually independent & shall have quick make. The successful bidder shall be required to furnish the guarantee certificate of three (3) years obtained from the MCCB manufacture.S. 10 KA at 0.Seimens / L & T / ABB / GE Power / Schneider – France / SPACEAGE _Hyundai/ HAVELS. No DISCOM/EZ/ 50 given in Volume II. at 240 V AC. 13947/1993 as amended up to date. If during the course of 36 months subsequent to the date of commissioning of MCCB. Single Pole MCCB of 40 Amps. shall be provided. The MCCB shall be provided with push to trip facility. The rated uninterrupted current of MCCB shall be 40 Amp. the same shall be replaced / repaired by the bidder/contractor free of all charges. however.4 (lag. The liability of guarantee shall.S. The wiring from L.) Application Standard Time current characteristics Outdoor (enclosed). 1.F. The MCCB shall not cause any nuisance tripping due to switching current of motor & capacitor loads. Overall Dimensional Checking. .2 SPECIFICATION OF MCCB: The following makes of MCCB shall be acceptable: . ‘A’ (IS: 13947/1993) as amended upto date.1993 To co-ordinate with HV fuse. the detailed specification of MCCB shall be as under: Application Utilization category Type Number of poles Peak ambient temperature Rated insulation level Rated operational voltage Continuous current rating Ultimate Short Circuit Breaking capacity (ICU) Rated service Short Circuit Breaking capacity (ICS) Power factor for Short Circuit (max. The complete protection box shall be covered with single panel door and the panel door shall be down side up opening. Acceptance Tests: The following tests shall be carried out by the Employer’s representative on MCCB on the sample numbers equivalent to the number of transformer samples. The MCCB’s shall be marked with ‘Brand Name’ of manufacture and Ics in KA by embossing only whereas other particulars may be marked as per the manufacturers standard practice. fittings shall be provided with a lock of ISI mark and with pad locking and sealing arrangement.General Arrangement of Chamber: General arrangement of chamber of the box shall be kept as per drawing covering the above aspects is given in drg. All necessary arrangements on this account will be made by the bidder/contractor. High Voltage test at 3 kV for one minute. The contacts of MCCB should be self-wiping type so as to keep the contacts clean and milli-volt drop low.F. Thermal-Magnetic trip free mechanism. These MCCB’s shall be confirming to I. Oscillograms and approved drawing from NABL approved laboratory along with the offer. any of the goods is found to be defective in materials or workmanship or develops defects during service. 600 V. quick break Mechanism. 1. 40 A 10 KA at 0. 13947/1993 for test sequence I. 3. . Insulation resistance test. Sl.Instruction and operation Manual The successful bidder shall be required to submit 5 copies of Instruction and Operation manual for each lot of 100 Transformers (or part thereof) supplied. & Dimensions of steel channel used for clamping of core (l) (i) Size & No. In case the MCCB trips or switched OFF. This instruction manual should give complete details about the pre-commissioning tests/checks and 1. When the MCCB is reset and switched ON.433 KV Dyn 11 Nos. No. of steps Dimensions of core steps Core diameter Core length (leg centre) Window height Insulation between bottom of core & Base channel (h) Core height (inclusive of Base channel and insulation in between) (i) (j) (k) Gross core area Effective core area 1. Signal light shall be arranged to avoid damages while handling the MCCB enclosure at site.) to indicate tripping of MCCB. the relay contacts are closed which turns ON the LED indicating lamp. Rating (KVA) Normal Ratio of Transformation Method of Connection (Vector Group) Maximum temperature rise of winding by resistance Maximum temperature rise of oil by thermometer Flux Density Type of transformer CORE : (a) (b) (c) (d) (e) (f) (g) Core Material & Grade No. GUARANTEED TECHNICAL PARTICULARS FOR 25 KVA DISTRIBUTION TRANSFORMERS. the indicating lamp switches OFF.) Core type 2 Particulars 25 KVA (Al.6 Wb/m (Max. 1 2 3 4 5 6 7 8 Continuous Max. An auxiliary relay with changeover contacts may be used to connect LED indicating lamp to the transformer secondary terminals if MCCB is not having auxiliary contacts.35.3 Signal Light (LED Indicating Lamp) The MCCB enclosure shall be provided with LED indicating lamp (Three Nos.of : Core bolts (ii) Tie rods (m) Insulation of core bolts .wound) 11/0. (p) Size of support channel for core base cut channels are not acceptable).As per Iss- 10 Current Density (i) (ii) HV winding LV winding 11 WINDINGS (a) Material (iii) (b) HV winding (iv) LV winding Size of winding wires for (i) (ii) (c) H. Core bolts & Tie Rods (o) Whether top yoke is cut or holes are made for LV connections. whether Enforcement is done.T. If yes. L. (q) Weight of core only (without Channels etc.) (r) Whether yoke construction is in one piece: (a) Top (ii) Bottom 9 Magnetizing current (% of rated current): (a) (b) (c) (d) at 90% Voltage at 100% Voltage at 112.Sl.wound) (ii) Tie rods (n) Painting of core channel. No.5% Voltage Tolerance .T. (i) Core bolts Particulars 25 KVA (Al. Type of insulation of (i) (ii) HV winding LV winding (d) Internal & external diameter of . The one end of HV winding brazed with copper wire and other end of copper wire bolted with HV stud by forming eye loop and using washer of proper size. No. of turns per coil (i) (ii) HV LV (g) Method of connection of winding ends to bushing terminals: (i) For HV .) .wound) No.Sl. (h) Resistance/phase at 75ºC (i) (ii) (i) (j) HV LV Height of HV coil Wire used for delta formation:(i) (ii) Material Diameter (Cross Sectional Area must be Min 1. (iii) Method of forming of Star Connection:All the three ends of LV windings crimped with proper size of Aluminum/copper lugs and then bolted with Aluminum/copper Flat of 6mm thick & cotton tape wrapped over it. (ii) For LV-Other end of LV winding crimped with Aluminum/Copper lugs and then bolted with LV stud terminals with proper size of washers.5 time of Cross Section area of HV winding wire) 12 13 Fixed losses at normal ratio (KW) (Max. coils/phase (i) (ii) HV LV (f) No.) Load losses at normal ratio at 75oC (KW) (Max. (i) (ii) (e) HV coil LV coil Particulars 25 KVA (Al. of 2x1 mm Press Board to cover the tie rods) d) Between winding & body i) ii) Length wise Breadth wise e) f) g) h) End insulation Thickness of locking spacers between HV coils Axial wedges between HV & LV coils Clearance between : (i) top cover and top of yoke i) No.) Tolerance on losses at normal ratio.2/50 Micro second wave. Impedance voltage at normal ratio between HV & LV windings at 75oC. 14 15 16 Particulars Total losses at normal ratio (KW) (Max. 25 KVA (Al.Sl. No.wound) 17 Impulse test level of HV & LV windings at 1. 18 INSULATION OF MATERIAL:Insulation material used & its thickness: a) b) c) d) e) f) Between core & LV Spacers Inter layer Between HV & LV winding Between phases End insulation 19 CLEARANCES:a) b) LV to Core (Radial) Between HV & LV (Radial) c) Phase to phase Between HV conductor (with providing min. of radial spacers per phase between HV coil g) Size of duct between LV & HV . 3.. 10......V..... DESCRIPTION Core grade Core diameter Gross Core area Net Core area Flux density Wt. 5.--... 9. 16... of L. 12. 11... of LV coils / Phase No.. of the Core Loss per kg...V winding amps/mm 2 2 Current density of H.. No. of core at the specified Flux Density 8.-...Conductor bare covered (mm) Size of H.. 7. 1...No..V winding amps/mm 17.Conductor bare covered (mm) No.. 6. 20....V. 18. Of the LV winding copper / Aluminum Wt. mm sq cm sq cm tesla ) ) Core window height Centre to centre distance No. of parallels Current density of L.....NO. 2... 14.....V.....SOURCE OF MATERIALS / PLACES OF MANUFACTURE.Lamination Aluminum Core plates Steel castings Tank Radiators Insulating cylinders Insulating paper Bushing HV/LV Oil Insulated winding wire a) Tap changer b) Thermometer c) Pressure relief vent ADDITIONAL DETAILS SL......V. 4. Wt. of HV coils/ Phase Height of LV winding mm .-------------------------------------------------------Sl... of H. Size of L. Of the HV winding copper / Aluminum for Transformer Kg.Turns. 13...Turns No. 19. TESTING AND INSPECTION ---------.... Item Source of Material Place of manufacture Place of testing & inspection .......... 21. 15.. ........... Height of HV winding mm ID/DD of LV winding mm ID/DD of HV winding mm Size of the duct in LV winding mm Size of the duct in HV winding Size of the duct between HV & LV HV winding to LV clearance mm HV winding to tank clearance mm Calculated Impedance HV to earth creep age distance LV to earth creep age distance mm mm DEPARTURE FROM SPECIFICATION ............. 25..........-..... 26...........-.MANFACTURER’S AND PLACES OF MANUFACTURE TESTING & INSPECTION ..........No.... 32........................... Equipment Contents of Individual Packages ............................-.....DESCRIPTIVE LITERATURE AND FULL PARTICULARS OF THE EQUIPMENT OFFERED ..............................No.....-..No..........................S........ 28................................Sl.......... 29................................................. 31................................-..........................-...... Description Manufacturer Place of Place of testing & Inspection Manufacture ..WEIGHT AND DIMENSIONS OF PACKAGES OF DESPATCH ..Sl............-..........................-................................... 24.......22..... Item No.... 27........................ Description .-.........................Sl........................... Dimensions ...- ........ of this specification Departures............Weight Kg............................. 30.............No Reference to Clause No.................. 23.......................................-. 5 meters Any tolerance on negative or positive side shall not be accepted. Joists. in all respect. yearly weighted average temperature Max. Flats. Sl No 1 2 3 2. to the high standard of design and workmanship and shall be capable of performing duties specified herein. mentioned shall also be acceptable.23% MAX. which ensures equal or better quality than the standards.S.2 2. the material meeting any other authoritative international standards.6 (i) (ii) R.S.1 SCOPE: 2. M. Channels.S. SERVICE CONDITIONS: CLIMATIC CONDITIONS: The Steel Sections to be supplied against this specification shall be suitable for satisfactory continuous operation under the following tropical conditions:Location Max. However.3 Standard No Title IS:2062 Grade `A’ Specification for R.S. Joists 175x85 mm R.2 The materials shall conform. Please attach photocopy of all such standards according to which the materials have been offered. 2. daily average ambient air temperature Max. ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS: In the paragraph 2. the same is also acceptable.S. CONFORMING TO BE: 2062/84 CHEMICAL COMPOSITION CHEMICAL COMPOSITION C -FOR Fe 410 WA GRADE 0. Angles & M. 175x85mm and 150x80mm. ambient air temperature Max. M.5 1 2 3 4 5 6 7 8 9 10 11 2. Materials offered shall be complete in all respect.4 2.0 TECHNICAL SPECIFICATION OF STEEL STRUCTURES AND SUPPORTS 2.3g 0 0 2.1 This specification calls for manufacture. packing and delivery of R.2 above relevant Indian standards specification have been mentioned. 2.S. Joists. Joists 150x80 mm 9 meters to 11 meters 1. inspection and testing before dispatch. Relative Humidity Max.7 CHEMICAL COMPOSITION AND PHYSICAL PROPERTIES OF R. ambient air temperature Min. stage testing. STANDARDS: Materials shall conform to the latest applicable Indian standards. meter 50 0. In case bidders offer Steel Section and supports conforming to any other international specifications which shall be equivalent or better than IS.1.2. Quality IS:2062 Chemical and physical composition of material IS:1852 Rolling and cutting tolerances for Hot rolled steel products.S.1. altitude above mean sea level Average Annual rainfall Max wind pressure Isoceraunic level (Average Number of thunderstorm days per year) Seismic level (Horizontal acceleration) LENGTH:The materials to be supplied shall be in the following lengths: At various substations in the State of Madhya Pradesh 50 C 1C 0 40 C 0 32 C 95% (Sometimes approaches saturation point) 1000 Meters 125 cm 150 Kg/sq. 1 .S. JOISTS. the relevant British standards and IEC recommendations will be applicable. Material for which Indian Standards are not available. 40% 0.23% Bend test (internal Dia) .050% 0.No.24 kgf/mm OR 240 N/mm 2 2 . The testing charges whatsoever shall be to the Bidder’s account. Is required to submit a copy of the valid ISI License clearly indicating size and range of rollable product against respective ISS. That the materials offered shall bear ISI certification marks. The BILLETS/INGOTS from which materials shall be re-rolled and supplied to us shall be of tested quality as per IS: 2830/6914 (Latest revision) respectively and shall be arranged from their own source..S Joists Technical Particulars Name of Manufacturer & address Chemical composition Tensile strength Yield stress Elongation Length in Meters Dimension of cross section Particulars 2.42% MAX.5% 0. Elongation %( min. Sr. GUARANTEED TECHNICAL PARTICULARS OF R.8. The mark shall be in legible English letters given with marking dies of minimum 18 mm size at the Interval of 3 meter mentioned as “ DISCOM-EZ”.Min-3 t (t – is the thickness of the material) 2. (b) MARKING:It is desirable that the manufacture should put his identification marks on the finished materials.) – 42 Kgf/mm or 410 N/mm 2.26 kgf/mm OR 250 N/mm 2 2 . Tensile strength (min. for thickness/diameter < 20 mm 20 – 40 mm > 40 mm 2 . MAX.050% 0. MAX.23 kgf/mm OR 230 N/mm 2 3. The Employer may get the material tested in the accredited laboratory by NABL. 1 2 3 4 5 6 7 . The Bidder is required to specifically indicate that the approved manufacturer:(i) (ii) (iii) 2. The chemical composition and physical properties of the finished materials shall be as per relevant specification indicated in Schedule-III enclosed.9.8 (a) M E C H A N I C A L P R O P E R T I E S 2 2 1. The materials shall be tested in ISI approved Laboratory of the approved Manufacturer having all facilities available for conducting all the tests as prescribed in relevant ISS. INSPECTION AND TEST CERTIFICATE: The materials to be supplied will be subject to inspection and approval by the representative of Employer.) . MAX. Yield stress Min.10 Holds valid ISI License against respective ISS.2 3 4 5 6 Mn S P SI CE (Carbon Equivalent) ------ 1. 2. The Bidder is required to offer the finished material for inspection well in advance to the Employer. MAX. Material for which Indian Standards are not available. The manufacture is required to specifically indicate that. Materials offered shall be complete in all respect. 3.3. in all respect. The size of the channel. the same is also acceptable.1 APPLICABLE STANDADS The materials shall conform. 3. M. i) Channel a) 100x50x6 mm b) 75x40x6 mm ii) Angle a) 50x50x6 mm b) 65x65x6 mm iii) Flat a) 50x6 mm The above list is merely indicative and not comprehensive. TEST: Steel Sections shall be tested in IS approved Laboratory or standard Laboratory of the Bidder country having all facilities available for conducting all the tests as prescribed in relevant IS or IEC or to any equivalent International Standard or from any recognized and reputable International laboratory or Institutions. 3. The Chemical composition and Physical properties of the finished materials shall be as per the relevant standards. (i) (ii) They hold valid IS (or equivalent IEC) License. angles & flats. RAW MATERIAL: The Steel Sections shall be re-rolled from the BILLETS/INGOTS of tested quality as per latest version of IS:2830 or to any equivalent International Standard and shall be arranged by the contractor from their own sources. angle and flat normally used for Distribution transformers structures. However. IS:2062 Quality Grade ‘A’ Title Specification for M. Flat Chemical and Physical composition of material Rolling and Cutting Tolerances for Hot Rolled Steel products 2 3 IS:2062-1969 IS:1852-1985 3.0 GALVANIZED MILD STEEL CHANNEL. Channel and M. the material meeting any other authoritative international standards. Please attach photocopy of all such standards according to which the materials have been offered.S. Steel Sections offered are bearing requisite IS certification or equivalent IEC marks.2 3. testing at works and supply of various sizes of mild steel channels.1 STANDARDS: Materials shall conform to the latest applicable Indian standards.2 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS: All relevant Indian standards specifications have been mentioned. ANGLE AND FLAT This specification covers the manufacture. the relevant British standards and IEC recommendations will be applicable. to the high standard of design and workmanship and shall be capable of performing duties specified herein. which ensures equal or better quality than the standards.1.S.S. Angles. In case bidders offer Steel Section and supports conforming to any other international specifications which shall be equivalent or better than IS. 11 KV line structures and LT line structures are as follows.3 . mentioned shall also be acceptable.1. S No 1 Standard No. 8 3.42% MAX. The mass of zinc coating and uniformity in thickness shall be determined as per relevant standards IS: 6745-1972 and IS: 26331986.40% MAX. Inspection before dispatch shall not. PARAMETERS UNIT VALUES Angle 1 2 1 2 3 4 5 6 Name and address of manufacture Chemical composition C Mn S P SI CE (Carbon Equivalent) FOR Fe 410 WA GRADE (Max) 0.The contractor are required to submit a copy of the valid IS (or equivalent IEC) License clearly indicating size and range of product against respective ISS or any equivalent International Standards along with their offer.S. Channel Flat .S. 0. documents for which shall be made available at the time of inspection to the board’s representative.6 All fabricated items shall be hot dipped galvanized as per IS: 2629-1985. M. 3. FLAT CONFORMING TO IS:2062-84 The mild steel shall conform to be: 2062 grade ‘a’ modified up to date or equivalent international standard for steel materials.5 GENERAL REQUIREMENTS The steel sections have chemical compositions and mechanical & properties confirming to IS:20621969 (latest revision). 1.4 CHEMICAL COMPOSITION AND PHYSICAL PROPERTIES OF M.23% MAX. The mark shall be in “legible English letters” given with marking dies of minimum 18 mm size.050% MAX. STEEL SECTION NO. relieve the bidder of his responsibility to supply the steel structures strictly in accordance with the specification. 0. CHANNELS AND M.10 QUALITY ASSURANCE PLAN: 3. The galvanizing is to be done in such a way that it leaves smooth surface. MARKING: It is desirable that the manufacture should put his identification marks on the finished materials. The galvanizing is to be done as per relevant IS specification. INSPECTION AND TEST CERTIFICATES: The materials to be supplied will be subject to inspection and approval by the Employer’s representative before dispatch. 3. 0. however. 0.7 3.9 3. 3. 3.050% MAX. ANGLES. 3.5% MAX. Rolling and weight tolerances shall be as per latest version of IS:1852 or to any equivalent International Standard.S. TOLERANCE: Variation in ordered quantity for any destination and over-all ordered quantity shall be only to the extent of ± 2%.11 He Bidders must establish that the approved manufacturer is following a proper quality assurance program for manufacture of steel sections.12 All the fabricated structures shall be hot dipped galvanized. PARAMETERS UNIT VALUES Angle Channel 2 2 Flat 3 4 Tensile strength Yield stress Thickness/Diameter) Less than 20 mm Between 20 to 40 mm More than 40 mm Elongation % Length in meters (For 42.5 to 13 meters 50x6 mm 7 Dimension of cross section A 65x65x6 mm 100x50x6 mm 8 Bend Test (Internal Dia) Min-3t (t – is the thickness of the material) .5 Kgf/mm or 410 N/mm A B C 5 6 26 kgf/mm² OR 250 N/mm² 24 kgf/mm² OR 240 N/mm² 23 kgf/mm² OR 230 N/mm² 23% 7 to 13 meters 5.NO.5 to meters 13 5. Long rod insulators shall be of tongue & clevis type.4. effectively earthed 11 kV O/H distribution system in a moderately polluted atmosphere. spacing. and selection in respect of polluted conditions shall be generally in accordance with the recommendation of IEC-60815/IS: 13134.1 Composite insulators long rod type for tension locations: The insulators shall be suitable for 3 phase.2 4.2. Long rod Insulators 11 12 9 35 75 240 45 16 Note: Creep age distances have been considered in line with IS-13134 (which specifies 20mm/ kV for moderately polluted environment). Insulators shall have sheds with good self-cleaning properties.2. minimum creep age distance and mechanical strength along with hardware fittings shall be as follows: Type of composite Insulator Nominal system voltage (rms) Highest system voltage kV (rms) Visible discharge test voltage kV(rms) Wet power frequency withstand voltage kV (rms) Impulse withstand voltage kV (rms) Minimum creep age distance (mm) Min.1 TECHNICAL DESCRIPTION OF COMPOSITE INSULATORS: Service condition: The polymer insulators to be supplied shall be suitable for satisfactory continuous operation under condition s as specified below: (i) (ii) (iii) Maximum temperature of air in shed Minimum temperature of air in shed Maximum relative humidity 45 C 4C 95% (The humidity some time approaches saturation point) 10 % 40 days 90 days 3 months o o (iv) (v) (vi) (vii) Minimum relative humidity Average number of dust-storm days per annum Average number of rainy days per annum Number of months conditions per annum Average annual rainfall Maximum wind pressure Altitude not exceeding o of tropical monsoon (viii) (ix) (x) 1250 mm 150 Kg / Sq.2 4. failing load KN Pin ball shank dia meter (mm) 4.0 4. mm 1000 meters o (The limit of ambient temperature shall be 45 C peak and 35 C average over a period of 24 hours) 4. Insulator shed profile. projection etc.2.3 SN kV i. The size of Composite insulator. 50 Hz. . 7. 4. no negative tolerance shall be applicable to creep age distance. BASIC FEATURES Design and construction: The composite insulator shall have a core. speed and safety. No part shall be subjected to excessive localized pressure.4 Weather sheds: The composite polymer weather sheds made of silicone electrometric compound or silicon alloy shall be firmly bonded to the sheath. However. . diameter.7. Where. 4. It shall be extruded or directly molded on the core and shall have chemical bonding with the FRP rod.7. The matrix of the FRP rod shall be Hydrolysis resistant. vulcanized to the sheath or molded as part of the sheath and shall be free from imperfections. Sheath material in the bulk as well as in the sealing/bonding shall be free from voids. Glass fibers shall be Boron free electrically corrosion resistant (ECR) glass fiber or Boron free E-Glass and shall exhibit both high electrical integrity and high resistance to acid corrosion. length and creep age distance shall be allowed as follows in line with-lEC 61109: ± {0.2 Core: It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod). d being the dimensions in millimeters for diameter. housing & weather shed of insulating material and steel/aluminum alloy hardware components for attaching it to the support/conductor. external pollution and humidity. 4.6. without cuts.7. It should protect the FRP rod against environmental influences. 4.3 Housing (Sheath): The FRP rod shall be covered by a seamless sheath of a silicone electrometric compound or silicone alloy compound of a thickness of 3mm minimum.6 4.025d-r-6J mm when d>3GQ mm.4.1 4. The strength of the bond shall be greater than the tearing strength of the polymer. The FRP rod shall be void free.5 Corona and Rl Performance:All surfaces shall be clean. The insulator and metal parts shall be so designed and manufactured that it shall avoid local corona formation and not generate any radio interference be end specified limit under the operating conditions. 4. Glass fibers and resin shall be optimized in the FRP rod. length or creep age distance as the case may be.04d+1.1 Maintenance:The composite Insulators offered shall be suitable for use of hot line maintenance technique so that usual hot line operation can be carried out with ease.3 Dimensional Tolerance of Composite Insulators:The tolerances on all dimensions e. abrasions or projections. smooth. ± (0. The weather sheds should have silicon content of minimum 30% by weight. 4.g.7 4.5) mm when d<300 mm.4 Interchangeably:The composite Insulators including the end fitting connection shall be of standard design suitable for use with the hardware fittings of any make conforming to relevant IEC/IS standards. The FRP rod shall be manufactured through Pollution process. The design.9 4. They shall be clean. They shall be made of spheroidal graphite cast Iron.8.3 4.8. smooth. The galvanized metal parts shall be guaranteed to withstand at least four successive dips each lasting for one H) minute duration under the standard preece test. 4.8 WORKMANSHIP: shall be in accordance with the standard dimensions 4. System of attachment of end fitting to the rod shall provide superior sealing performance between housing.7 4. The zinc used for galvanizing shall be of purity 99.8.5 End Fittings: End fittings transmit the mechanical load to the core. air holes and rough edges.8. manufacturing process and material control at various stages shall be such as to give maximum working load. malleable cast iron or forged steel or aluminum alloy. 4.m.7.5 4.8. Weather sheds shall be uniform in quality. The gap between fitting and sheath shall be sealed by a flexible silicone electrometric compound or silicone alloy compound sealant.2 4.9. seamless sheath and metal connection.5% as per IS: 4699. seams. The galvanizing shall be carried out only after any machining. i. The sealing must be moisture proof.2 One 10mm thick ring or 20 mm thick spot of suitable quality of paint shall be marked on the end fitting of each composite long rod of particular strength in case of 33 kV Insulators for easy identification in case both types of Insulators are procured by the utility.1 All the materials shall be of latest design and conform to the best engineering practices adopted in the high voltage field. All surfaces of the metal parts shall be perfectly smooth with out projecting points or irregularities. or 87µ m thickness and shall be in accordance with the requirement of IS: 4759. bulky white deposits and blisters.4 4. sound. highest mobility. and smooth and shall be free from defects and excessive flashing at parting lines.9. good finish and elimination of sharp edges and corners.8.1 (c) 4. They shall be connected to the rod by means of a controlled compression technique. between sheds and sheath (housing] shall be free from voids. shrinks. adherent. The dimensions of end fittings of Insulators stated in IS: 2486 / IEC: 60120.8. which may cause corona. End fittings shall be free from cracks. best resistance to corrosion. End fittings should be effectively sealed to prevent moisture ingress. failing toad/guaranteed mechanical strength in kilo Newton followed by the word 'KN' to facilitate easy identification. The zinc coating shall be uniform. The design of the Insulators shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration. ash rust stains. reasonably bright continuous and free from imperfections such as flux. All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent to 610 gm/Sq. Bidders shall offer only such Insulators as are guaranteed by them to be satisfactory and suitable for continued good service in power transmission lines. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly. The paint shall not have any deteriorating effect on the insulator performance. The interface.e. Following codes shall be used as identification mark: For 45 kN long rod unit : Blue . Manufacturer’s name/Trade mark 4. The core shall be sound and free of cracks and voids that may adversely affect the Insulators.6 4. if any. effectiveness of sealing system must be supported by test documents. EQUIPMENT MARKING: Each insulator unit shall be legibly and indelibly embossed/engraved with the following details as per IEC-61109: (a) (b) Month &Year of manufacture Min.The strength of the weather shed to sheath interface shall be greater than the tearing strength of the polymer. 2) As per IEC 61 109 (clause 6 4) As per IEC 61109 (clause 6.10.10 4.10.1 Design tests: Manufacturer should submit test reports for Design Tests as per IEC . The Contractor shall furnish along with the proposal outline drawing (3 copies) of each insulator unit including a cross sectional view of the long rod insulator unit.13 4.3 The Bidder shall submit type test reports as per IEC 61109 along with the bid.61109 (clause .4) .3 The contractor shall submit full dimensioned manufacturing insulator drawings containing all the details in four (4) copies along with copies of all the type tests. materials or complete strings: 4. 4.1 4. .5) along with the bid. The drawing shall include but not be limited to the following information: (a) (b) (c) (d) Long rod diameter with manufacturing tolerances Minimum Creep age distance with positive tolerance Protected creep age distance Eccentricity of the long rod unit (i) Axial run out (ii) Radial run out Unit mechanical and electrical characteristics Size and weight tongue & clevis Weight of composite long rod unit. TESTS AND STANDARDS: Insulators offered shall be manufactured with the same configuration & raw materials as used in the Insulators for which design & type test reports are submitted. after SN 1.11.2 Type Tests: The following type tests shall be conducted on a suitable number of individual insulator units. 4. 2. Additional type tests as required below shall be carried out by the manufacturer.1) Ai per IEC 61 109 (clause 6. Description of type test Dry lightning impulse withstand voltage test Wet power frequency test Mechanical load-time test Radio interference test Ten procedure/standard As per IEC 61109 (clause 6..For 70 kN long rod unit : Red (Not applicable) 4.11. Additionally following tests shall be carried out or reports for the tests shall be submitted after award of contract: + UV test: The test shall be carried out in line with clause 7. The design & type test reports submitted shall not be more than 05 years old.2 DRAWINGS: The Contractor shall furnish full description and illustration of the material offered.11. The manufacturer shall submit a certificate for the same. Materials (i) Identification mark (ii) Manufacturer's catalogue number (e) (f) (g) (h) 4. components.11 4. 3.2 of ANSI C29.10. 12 4. Chemical analysis. Brittle fracture resistance test 4.14 Tests during Manufacture Following tests shall also be carried out on all components as applicable a) b) Chemical analysis of zinc used for galvanizing Chemical analysis.2 IEC: 61109.2 4.13 Verification of dimensions Verification applicable of the locking : system : Clause 7. all without any extra cost to the Owner.12. 6. The contractor shall offer at least three times the quantity of materials required for conducting all the type tests for sample selection. mechanical.2 in addition to routine & acceptance test shall be carried out on insulator along with hardware fittings wherever required.4 IEC: 611 09. Recovery of Hydrophobicity test Chemical composition test for silicon content 7. Additional Tests: The Employer reserves the right to get any other test(s) of reasonable nature carried out at Bidder/manufacturer's premises. Acceptance (sample) Tests For Composite Insulators (a) (b) (c) (d) 4. Sample Batch for Type Testing The contractor shall offer material for sample selection for type testing only after getting Quality Assurance Programme approved by the Owner. Co-ordination for Testing: c) 4.1 As per IEC 61 109 Clause 8.15 4. metallographic test and magnetic particle inspection for malleable castings. 4. acceptance and routine tests to ensure that the material complies with the specifications.3 4.15. Clause 7. In case of evidence of non compliance.17 . The Employer also reserves the right to conduct ail the tests mentioned in this specification at his own expense on the samples drawn from the site at Bidder/manufacturer's premises or at any other test center. 8.2 As per IEC: 61 109 Clause 8.5 All the type test given in Clause No. at site.1 4. or in any other place in addition to the aforesaid type.11.16. The sample foe type testing will be manufactured strictly in accordance with the Quality Assurance Programme approved by the Employer.4 It shall be the option of the Employer to accept the Insulators based on type test reports submitted by the Bidder/ approved manufacturer.16.16 4. hardness tests and magnetic particle inspection for forgings. 4.1 Galvanizing test : Verification of the specified mechanical load : Routine Tests: sn Description 1 2 3 Identification of marking Visual Inspection Mechanical routine test Standard As per IEC: 61 109 Clause 8. The Employer may get type test done in the presence of their authorized representative.5.1 4.3 IEC: 61 109 IS:2633/IS:6745 Clause 7.11. it shall be binding on the part of the Bidder/manufacturer to prove the compliance of the items to the technical specifications by repeat tests or correction of deficiencies or replacement of defective items. 2 of Sec 7 – GCC.1 4. One copy shall be returned duly certified by the employer. The employer shall select samples at random from the packed lot for carrying out acceptance tests.23.17.21. The gross weight of the crates along with the material shall not normally exceed 100 Kg to avoid handling problem.24. 7 ply duly paletted or wooden crates. The test procedure shall be in accordance with IS:326B /I EC : 437/CISPfi 18-2. The crates shall be suitable for outdoor storage under wet climate during rainy season.22 4. storage at site and subsequent handling in the field.23. 4.2 4.22. . All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and faulty or illegible markings. In the later case also the material shall be dispatched only after satisfactory testing specified herein has been completed.3 4.5 4.3 4. PACKING: Al I Insulators shall be packed in strong corrugated box of min. Suitable cushioning.21. 4.23.21. protective padding.4. The bidder shall provide instructions regarding handling and storage precautions to be taken at site. Each wooden case/crate/corrugated box shall have all the markings stenciled on it in indelible ink.23 4.20 Quality assurance plan: The successful contractor shall submit information as per details in Part A of specification. or dunnage or spacers shall be provided to prevent damage or deformation during transit and handling.2 4. The packing shall be of sufficient strength to withstand rough handling during transit. 4.18 4. The lot offered for inspection shall be homogeneous and shall contain Insulators manufactured in 3-4 consecutive weeks.21 4.22. only after which the commercial production of the concerned material shall start Record of routine test reports shall be maintained by the Bidder/manufacturer at hi^ works for periodic inspection by the Owner's representative. INSPECTION: The material for final inspection shall be offered by the Bidder/manufacturer only under packed condition.23.1 Test Reports:At least three copies of type test reports shall be furnished. These shall be produced for verification as and when desired by the Owner.24 Tests on Insulator Units 4.4 4. No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived off by the employer in writing.23.2 4. Guarantee: The Bidder/manufacturer of Insulators shall guarantee overall satisfactory performance of the insulators for the period as mentioned in clause 27. Test certificates of test during manufacture shall be maintained by the Bidder/manufacturer.1 The Bidder/manufacturer shall have to co-ordinate testing of Insulators with hardware fittings to be supplied by other Bidder/manufacturer and shall have to guarantee overall satisfactory performance of the Insulators with the hardware fittings.19 4.1 RIV Test (Dry):The insulator string along with complete hardware fittings shall have a radio interference voltage level below 100 micro volts at one MHz when subjected to 50 Hz AC voltage of 10 kV& 30 kV for 11 kV& 33 kV class insulators respectively under dry condition.1 4. The test may be carried out at CPRI or any other NABL accredited laboratory. 45 KN 1. No. Note HC classification. Or until an HC of 6 or 7 is obtained. The rod should be held at 80% of SML for the duration of the test. The rod should not fail within the 96 hour test duration. iii) iv) 4. GUARANTEED TECHNICAL PARTICULARS OF 11 KV 45 KN. The test shall be done for 100 hrs.. Name of Manufacturer Address: (a) registered Office (b) Factory 3.3 Recovery of Hydrophobicity & Corona test:The test shall be carried out on 4mm thick samples of 5cm x 7cm i) The surface of selected samples shall be cleaned with isopropyl alcohol.HC 2 within 24 to 48 hours.2 Brittle Fracture Resistance Test:Brittle fracture test shall be carried out on naked rod along with end fittings by applying "1 n HNO3 acid" (63 g cone. Allow the sample to recover and repeat hydrophobiticiy measurement at several lime intervals. Description 11KV. 4. Test arrangement should ensure continuous wetting of the rod with Nitric acid. 2. Type of Insulators Standard specification to which the Insulators manufactured and tested 5.4. COMPOSITE POLYMER INSULATORS LONG ROD TYPE) SUITABLE FOR T&C TYPE HARDWARES Sl. Dry the surface and repeat the corona treatment as at clause 7 above. Corona is continuously generated by applying 12 kV to a needle like electrode placed 1mm above the sample surface. Immediately after the corona treatment.24. Dry the sample surface. Dry the sample surface. HN03 added to 937 g water) to the rod.24. 4. ii) The sample shah subjected to mechanical stress by bending the sample over a ground electrode. Allow the surface to dry and spray with water Record the Hydrophobicity classification in line with STRI guide for Hydrophobicity classification.24. Name of material used in manufacture of the Insulator (with class / grade) (a) Material of core rod . depending on the material and the intensity of the corona treatment.4 Chemical composition test for Silicon content The content of silicon in the composite polymer shall be evaluated by EDX (Energy Dispersion X-ray) Analysis or Thermo-gravimetric analysis. spray the surface with water and record the HC classification. Repeat the cycle for 1000 hrs. Silicone rubber should recover to HC 1 . 7. No. Description 11KV. Method of fixing of sheds to housing specify ):. 45 KN (b) (c) (d) 6. . 10.single mould or modular construction (injection molding/compression molding) 11. v. vi. iii. ii. iv. Dimensions of Insulator: Weight (Kg. (a) (b) (c) (d) (e) (f) (g) Material of Housing & weather sheds (silicon content by weight) Material of end fittings : tongue/clevis Sealing compound for end fitting Color Glaze of Insulator Electrical Characteristics: Nominal system Voltage (KV rms) Highest System Voltage (KV rms) Dry power frequency withstand (KV rms) Wet power frequency withstand (KV rms) Dry flash over voltage (KV rms) Wet flash over voltage (KV rms) Dry lighting impulse withstand voltage (a) Positive (b) Negative (h) Dry lighting impulse flashover voltage (a) Positive (KV peak) (b) Negative (KV peak) (i) (j) 8.) Dia of FRP rod (mm) Length of ERP rod (mm) Dia of weather sheds (mm) Thickness of housing (mm) Dry arc distance (mm) Dimensioned drawings of Insulator (including weight with tolerances in weight) enclosed. i. RIV at 1 MHz when energized at 10kV/30kV (rms) under dry condition (microvolt) Creep age distance (min) mm Mechanical Characteristics: Minimum failing load (KN) 9.Sl. These tests should have not been conducted earlier. Visual examination tests Verification of dimensions Galvanizing/electroplating test Mechanical Tests Ultimate Strength test 5. All the above three tests have been described in IS:2486 (Part-I)-1993. Any other particulars which the bidder may like to give. The type tests are intended to prove the general qualities and design of a given type of insulator fittings.1 TYPE TEST CERTIFICATE The following shall constitute the type tests for clamps. 2. No. 5. Galvanizing tests for Hot Dip ferrous material shall be carried out in accordance with IS:2633-1986 and satisfy the requirements in . 2.0 STRAIN HARDWARE FITTINGS 11KV DISC INSULATORS (FOR 11 KV LINES SUITABLE FOR USE WITH TONGUE & CLEVIS DISC INSULATORS (CONVENTTIONAL TYPE FITTINGS) 5. 1. (b) No. 2. 5. Packing details (a) Type of packing. of Insulators in each pack (c ) Gross weight of package 15. than 5 years from the date of opening of tender. 13.Sl. 4.2 ACCEPTANCE TESTS The following shall constitute the acceptance tests:1. Visual examination Verification of dimensions Slip strength tests Ultimate strength tests Galvanizing/Electroplating tests. 3. 5. Visual examination tests Mechanical routine tests on Conductor Tension clamp only The routine tests will be carried out on each of insulator fittings to check requirement which are likely to vary during production. No. 3. of weather sheds Type of sheds (i) Aerodynamic (ii) With under ribs 14. 5. 3. Description 11KV. 45 KN 12. 4.3 ROUTINE TESTS The following shall constitute the routine tests:1. The clamp shall be manufactured by the process of die casting or pressure die casting and shall be free from blow holes and other defects.A.4 GENERAL REQUIREMENTS All fittings shall be of same type and design manufactured under similar conditions of production. 5. clevis and holes. mm Item Stranding and Wire Dia of A. Trade Mark of manufacturer Please note that the marking should be legible and permanent (preferable die caste).5 MARKING ON CLAMPS The clamps shall have the following markings for their identification as per ISS. All ferrous fittings and the part other than those of stainless steel shall be galvanized by the Hot Dip process. All forging and castings shall be of good finish and free from flaws and other defects. The nuts shall conform to property 4. (A) 11KV STRAIN HARDWARE FITTINGS (T&C) TYPE Each Hardware fittings of the Strain insulators shall comprise of:Hot dip galvanized cross arms & straps. Electro-galvanized ferrous fittings shall be checked in accordance with IS:1573-1986. Washers. The edges on the outside of fittings.15mm) 55 Sq. Different fittings shall be packed . plain & spring washers. Plain washer and 4mm dia split pin as per figures 26 of IS:2486 (Part-II).81mm) 200 Sq.6 PACKING Strain clamps and related hardware shall be packed in double gunny bags or wooden cases if deemed necessary.8 of IS:1367 (Part-6)-1980. nuts may be electroplated galvanized. However one Sample from each lot will be tested as per IS:4759-1984. Alloy (7/3. The gross weight of the packing shall not exceed 50 Kg. 5. shall be rounded. The clamp made with process of sand casting shall not be accepted. Spring. properly profiled and suitable for use on 75/100 mm channel cross arms with 16mm dia hot dip galvanized Bolts. mm Actual Area The ultimate strength of the clamp should not be less than 4500 Kg. such as the eye. Nuts. 5. The split pin to be used on the collar pin shall be of phosphor bronze conforming to IS:7814-1975 or Stainless Steel conforming to IS:5577-1992 or brass conforming to IS:410-1977 with a minimum hardness of 160 HV. No.1984 and its latest amendment: Spoil type clamp with clevis eye suitable for 11KV system for following sizes of AAA conductors:S. i AAA Conductor (Rabbit) Iii AAA Conductor (Panther) (7/3.IS:4759-1984. The Clamp shall be made by process of Die-casting. All dimensions of cleaves and tongue connections shall be as per figure-25 of the IS: 286 (Part-II) 1989 and its latest amendments. Only small fittings like. The collar pins shall be provided with Galvanized Mild Steel Flat Washers in addition to split pins. . except on the hardware. except on the hardware. surface blisters. the clamp height (top of the mounting pad to center line of the tube) should be same. Nuts & plain washers Hot dip galvanized mild steel for sizes M12 and above.7 5. The packing shall be fit to withstand rough handling during transit and storage at destination. Clamps & connectors shall conform to type tests and shall be subjected to routine and acceptance tests on minimum 3 samples per lot as per IS:5561. the Contractor shall furnish tensile test. They shall be designed and manufactured to have minimum contact resistance. In both the cases. No current carrying part of a clamp or connector shall be less than 10 mm thick. Flexible connectors. 5. The clamps and connectors shall be made of materials listed below: For connecting AAA conductors Aluminum alloy casting. conforming to designation A6 of IS:617 and shall be tested for all tests as per IS: 617 For connecting equipment terminals made of copper with AAA conductor Bimetallic connectors made from Aluminum alloy casting conforming to designation A6 of IS:617 with 2mm thick Bimetallic liner and shall be tested as per IS:617 For connecting GS shield wire Galvanized mild steel Bolts.in different bags or cases and shall be complete with minor accessories fitted in place. indelibly marked) on each components of the clamp/ connector. For Bimetallic clamps or connectors.1 CLAMPS & CONNECTORS Clamps & connectors shall conform to IS:5561. braids or laminated strips made up of copper/ aluminum for the terminal clamps for equipment shall be suitable for both expansion or through (fixed/ sliding) type connection of IPS Aluminum tube as required. Type tests report for all clamps and connectors for temperature rise test. Clamp shall be designed to carry the same current as the conductor and the temperature rise shall be equal or less than that of the conductor at the specified ambient temperature. All sharp edges and corners shall be blurred and rounded off.e. Clamps and connector shall be designed corona controlled. cracks and cavities. Size of the terminal/conductor for which the clamp/connector is suitable shall be embossed/punched (i. shall also be indelibly marked on each component of the clamp/connector. copper alloy liner of minimum 2 mm thickness shall be provided. for which the clamp/ connector is designed with respect to the specified reference ambient temperature. and electro-galvanized for sizes below M12 Spring washers for items ‘a’ to ‘c’ Electro-galvanized mild steel suitable for at Least service condition 4 as per IS:1573-1986. All the nuts shall be hand tightened over the bolt and screwed upto the farthest point with split pin in position. All castings shall be free from blowholes. The rated current.7. The Composite Pin Insulators shall be of the following type:i) Long rod type Pin Insulators intended to be mounted rigidly on a supporting structure to support following size of conductor:(a) For 11KV AAAC Rabbit (b) For 33KV AAAC Dog 6. shall be referred while accessing conformity of Insulators with these specifications. In case of award.) Process for casing the clamps (Die / Pressure) Die casting H I 6. salient features of comparison between the standards proposed by the Bidder and those specified in this document will be provided by the Supplier to establish equivalence. . which shall mean latest revision. with amendments/changes adopted and published. Requirement To be specified B D E F G For galvanizing whether zinc conforms to grade Zn 98 of IS 209-1966 and galvanizing of ferrous material is done in accordance with the IS: 2633: 1986 and satisfied the requirements in IS: 4759-1984 Weight of complete unit (Kgs.) Materials for clamp 3000 Kg (Min.2 APPLICABLE STANDARDS:: Standards:Following Indian/International Standards. the Bidder shall confirm in his bid that these standards are equivalent or better to those specified.0 11 KV PIN INSULATORS TECHNICAL SPECIFICATION FOR COMPOSITE POLYMER PIN INSULATORS FOR USE IN 11KV 6. In the event of supply of Insulators conforming to standards other than specified.GTP of 11KV ALLUMINIUM ALLOY STRAIN HARDWARE FITTINGS (T&C) TYPE Sl. of Spring washer and its thickness suitable for the quoted items Ultimate Strength (Kgs. A Particulars Whether clevis and tongue parts are according to figure 25 of IS-2486 (Part-2) 1989 and its latest amendments Whether cross arm straps with 16mm dia bolt are according to figure 26 of IS-2486 (Part-2) 1989 and its latest amendments No. unless specifically stated otherwise in the Specification.1 SCOPE:: This specification covers design. testing and supply of Composite Polymer Pin Insulators for use in the 11KV & 33KV overhead transmission lines. manufacture.) High strength aluminum alloy. IS:4759 IS:2629 IS:6745 Hot dip zinc coatings on structural steel & other allied products. Standard for Insulators. test methods and acceptance criteria for composite Insulators for a. Recommended practice for Hot Dip galvanization for iron and steel Determination of weight of zinc coating on zinc coated Iron and steel articles. Standard specification for glass fiber standards.92/1 CISPR 18. Specification for Insulator fittings for overhead power lines with a nominal voltage greater than 1000V General Requirements and Tests Dimensional Requirements locking devices. Guide for the selection of insulators in respect of polluted condition. Radio interference characteristics of overhead power lines and high voltage equipment. Hydrophobicity Classification Guide. c.Distribution Dead-end Type. IS: 731 Porcelain insulators for overhead power lines with a nominal voltage greater than 1000V. No.Composite. Characteristics of string insulator units of the long rod type. Testing of Uniformity of coating of zinc coated articles. Thermal Mechanical performance test and mechanical performance test on string Insulators units. overhead lines above 1000V. 1 Indian Standard Standard Title International Standard Definition. Methods of High Voltage Testing. Methods of testing of local thickness of electroplated coatings.Sl. IEC:61109 2 IEC: 60383 3 4 IS:2071 IS:2486 IEC:60060-1 IEC:60120 IEC:60372 IEC:60575 5 - 6 7 8 9 IS: 13134 - IEC: 60815 IEC: 60433 STRI guide 1. for compositional analysis by Thermo- ASTM D 578-05 19 IS:4699 Specification for refined secondary zinc .13-2000 ISO:1459 ISO:1461(E) ISO:1460 15 16 17 IS:3203 IS:2633 - ISO:2178 ASTM D 578-05 18 - Standard specification gravimetery. Methods of RI Test of HV Insulators.2 Part 2 10 11 12 13 14 IS:8263 IEC:60437 ANSI C 29. 3. spacing.3. 6. 11KV Pin Insulator 33KV Pin Insulator 11 12 75 320 5 ii. 6. projection etc. mm 1000 metres (The limit of ambient temperature shall be 45oC peak and 35oC average over a period of 24 hours) 6. Insulator shed profile.3.3.5 Insulators shall have sheds with good self-cleaning properties.2 Composite Insulators long rod type to support conductor on 11KV & 33KV Over head Power Lines:- 6. The Bidder shall furnish necessary evidence in support of the above along with the bid.3. 50 Hz. which can be in the form of certification from the utilities concerned. 33 36 27 75 170 900 10 . 6.6 The size of Composite insulator. and selection in respect of polluted conditions shall be generally in accordance with the recommendation of IEC-60815/IS: 13134. failing load KN i. or any other documents to the satisfaction of the owner.3 6.1 Technical Description of Composite Insulators:: Service condition:- The polymer Insulators to be supplied shall be suitable for satisfactory continuous operation under condition s as specified below: (i) (ii) (iii) Maximum temperature of air in shed Minimum temperature of air in shed Maximum relative humidity 45oC 4oC 95% (The humidity some approaches saturation point) 10 % 40 days 90 days 3 months time (iv) (v) (vi) (vii) Minimum relative humidity Average number of dust-storm days per annum Average number of rainy days per annum Number of months of tropical monsoon conditions per annum Average annual rainfall Maximum wind pressure Altitude not exceeding (viii) (ix) (x) 1250 mm 150 Kg / Sq.3 The Insulators shall be suitable for 3 Φ.6. minimum creepage distance and mechanical strength along with hardware fittings shall be as follows: SN Type of composite Insulator Nominal system voltage kV (rms) Highest system voltage kV (rms) Visible discharge test voltage kV(rms) 9 Wet power frequency withstand voltage kV (rms) 35 Impulse withstand voltage kV (rms) Minimum creepage distance (mm) Min.4 Bidder must be an indigenous manufacturer and supplier of composite Insulators of rating 11KV or above OR must have developed proven in house technology and manufacturing process for composite Insulators of above rating OR possess technical collaboration/ association with a manufacturer of composite Insulators of rating 11KV or above.3. effectively earthed 1IkV and 33kV O/H distribution system in a moderately polluted atmosphere. The weather sheds should have silicon content of minimum 30% by weight.g.3. Glass fibers and resin shall be optimized in the FRP rod. It shall be one-piece housing using Injection Molding Principle to cover the core. Glass fibers shall be Boron free electrically corrosion resistant (ECR) glass fiber or Boron free E-Glass and shall exhibit both high electrical integrity and high resistance to acid corrosion. However.04d+1.4 End Fittings:- End fittings transmit the mechanical load to the core.5) mm when d<300 mm. No part shall be subjected to excessive localized pressure. external pollution and humidity. 6. The elastomer housing shall be designed to provide the necessary creepage distance and protection against environmental influences.2 Core:- It shall be a glass-fiber reinforced epoxy resin rod of high strength (FRP rod). Housing shall conform to the requirements of IEC 61109/92-93 with latest amendments. They shall be connected to the rod by means of a controlled compression technique. The matrix of the FRP rod shall be Hydrolysis resistant. without cuts.4. Weather sheds:The composite polymer weather sheds made of a silicone elastomeric compound or silicone alloy compound shall be firmly bonded to the sheath. 6. d being the dimensions in millimeters for diameter. diameter. Where.1 BASIC FEATURES:: Design and construction:- The Composite Pin Insulator shall have a core.Insulator Note: Creepage distances have been considered in line with IS-13134 (which specifies 20mm/ kV for moderately polluted environment and 25mm/KV for heavily polluted area) Dimensional Tolerance of Composite Insulators :The tolerances on all dimensions e. smooth. length and creepage distance shall be allowed as follows in line with IEC 61109: ± {0. The insulator and metal parts shall be so designed and manufactured that it shall avoid local corona formation and not generate any radio interference beyond specified limit under the operating conditions. malleable cast iron or forged steel or aluminum alloy. As the main duty of the end fittings is the transfer of mechanical loads to the core the fittings should be properly attached to the .4.4 6. no negative tolerance shall be applicable to creepage distance. between sheds and sheath (housing) shall be free from voids. if any. The interface. The FRP rod shall be void free. 6. The material used in fittings shall be corrosion resistant. The strength of the weather shed to sheath interface shall be greater than the tearing strength of the polymer. abrasions or projections. 6. housing & weather shed of insulating material and steel/aluminum alloy hardware components for attaching it to the support/conductor. The FRP rod shall be manufactured through Pultrusion process. 6.4. They shall be made of spheroidal graphite cast Iron.7 Corona and Rl Performance:- All surfaces shall be clean.3 Housing (Sheath):- The FRP rod shall be covered by a seamless sheath of a silicone elastomeric compound or silicone alloy compound of a thickness of 3mm minimum. vulcanized to the sheath or molded as part of the sheath and shall be free from imperfections It should protect the FRP rod against environmental influences.4. ± (0. length or creepage distance as the case may be.025d+6J mm when d>300 mm. 1 Equipment Marking:: Each insulator unit shall be legibly and indelibly marked with the following details as per IEC-61109: Month &Year of manufacture (b) Min. reasonably bright continuous and free from imperfections such as flux.5. smooth and shall be free from defects and excessive flashing at parting lines.5 Weather sheds shall be uniform in quality. The gap between fitting and sheath shall be sealed by a flexible silicone electrometric compound or silicone alloy compound sealant. failing toad/guaranteed mechanical strength in kilo Newton followed by the word 'KN' to facilitate easy identification. The size of the fittings shall be in such a way that conductor could be bound firmly so that it may not slip from the groove while in service even under adverse conditions.6. threaded portion of end fittings Dia of rod Upper end fittings shall be suitable to hold AAAC Dog for 33KV and AAAC Rabbit for 11KV. All load bearing surfaces shall be smooth and uniform so as to distribute the loading stresses uniformly. ash rust stains. 6.m.5. highest mobility. bulky white deposits and blisters.5. shrinks. seams. The zinc coating shall be uniform. 6. No. 6. seamless sheath and metal connection. 11KV 33KV 150 mm 150 mm 100 mm 100 mm 20 mm 24 mm Item Length of end fittings to be fixed Min.5.4 The core shall be sound and free of cracks and voids that may adversely affect the Insulators. sound.5.6 End fittings shall be free from cracks. best resistance to corrosion.5. 6. 6. or 87µ m thickness and shall be in accordance with the requirement of IS: 4759. air holes and rough edges. smooth. The zinc used for galvanizing shall be of purity 99. manufacturing process and material control at various stages shall be such as to give maximum working load.e. .core by a coaxial or hexagonal compression process & should not damage the individual fibers or crack the core. System of attachment of end fitting to the rod shall provide superior sealing performance between housing. the drawing given is for indicative purpose.5% as per IS: 4699. ii. Bidders shall offer only such Insulators as are guaranteed by them to be satisfactory and suitable for continued good service in power transmission lines. which may cause corona. adherent.7 All ferrous parts shall be hot dip galvanized to give a minimum average coating of zinc equivalent to 610 gm/Sq.1 All the materials shall be of latest design and conform to the best engineering practices adopted in the high voltage field. effectiveness of sealing system must be supported by test documents. The dimensions of end fittings of Insulators has been shown in the drawing (11KV & 33KV both separately). 6. They shall be clean. The sealing must be moisture proof. i. Since we are purchasing these items for the first time. The galvanized metal parts shall be guaranteed to withstand at least four successive dips each lasting for one H) minute duration under the standard preece test. The galvanizing shall be carried out only after any machining.6 6.5 Workmanship:: 6. The details of end fittings for fixing the same with V-Cross Arms and top clamps are given below:Sl. End fittings should be effectively sealed to prevent moisture ingress. good finish and elimination of sharp edges and corners. All surfaces of the metal parts shall be perfectly smooth with out projecting points or irregularities. 6. i.2 The design. 6.3 The design of the Insulators shall be such that stresses due to expansion and contraction in any part of the insulator shall not lead to deterioration.5. 1 Bid Drawings:: The Bidder shall furnish full description and illustration of the material offered. 6. manufacturing insulator drawings (FS-EZ). the same design. The drawing shall include but not be limited to the following information: (a) (b) (c) (d) Long rod diameter with manufacturing tolerances Minimum Creepage distance with positive tolerance Protected creepage distance Eccentricity of the long rod unit (i) Axial run out (ii) Radial run out Unit mechanical and electrical characteristics Weight of composite long rod unit. Jabalpur. materials and method of manufacture (technology). When a composite insulator is subjected to the design tests. 6.7. the same method of attachment.8 Tests and Standards:: Insulators offered shall be manufactured with the same configuration & raw materials as used in the Insulators for which design & type test reports are submitted.7.1 of IEC 61109 / 92-93 with latest amendments.1 Design Tests:- For polymeric insulators it is essential to carry out design test as per clause 4. The design tests are intended to verify the suitability of the design. The design & type test reports submitted shall not be more than 05 years old.7 6. The manufacturer shall submit a certificate for the same.4 After placement of award the Supplier shall also submit fully dimensioned insulator crate drawing for different type of Insulators for approval of the owner. and sheds and same manufacturing method. MPPKVVCL. layer thickness of the shed material over the core (including a Same or greater sheath where used). Materials (i) Identification mark (ii) Manufacturer's catalogue number 6.8. which are represented by the one tested and having the following characteristics: • • Same materials for the core. the result shall be considered valid for the whole class of insulators. Same material of the fittings.3 After placement of award.2 The Bidder shall furnish along with the bid the outline drawing (3 copies) of each insulator unit including a cross sectional view of the long rod insulator unit.(c) Manufacturer’s name/Trade mark 6.7.7. 6. the Supplier shall submit three sets of full dimensioned containing all the details to The Chief Engineer (e) (f) (g) 6. . Same or smaller between fittings ratio of all mechanical loads to the smallest core diameter Same or greater diameter of the core. Same or smaller ratio of the highest system voltage to insulation length. 8. The following type tests shall be conducted on a suitable number of individual insulator units.2 Type Tests:- The tenderer shall furnish detailed type test reports of the offered composite Insulators as per clause 8. Manufacturer should submit test reports for Design Tests as per IEC-61109 (clause. for the purpose of facilitating the type tests. Verification of dimensions Verification of the locking system (if applicable) Galvanizing test Verification of tightness of the interface between end fittings & Insulator housing Clause 7.3 It shall be the option of the owner to accept the Insulators based on type test reports submitted by the manufacturer.10.2 in addition to routine & acceptance test shall be carried out on Pin Insulators wherever required.5) along with the bid.2 of the Technical Specifications at the NABL approved laboratories to prove that the composite Insulators offered meet the requirements of the specification.2 of ANSI C29.8. 6. components & materials and the test report should invariably be submitted with the bid:SN 1. These Type Tests should have been carried out within five years prior to the date of opening of this tender.8. Brittle fracture resistance test Annexure .1) As per IEC 61 109 (clause 6. The owner shall be free to repeat the type test & may witness the same. Description of type test Dry lightning impulse withstand voltage test Wet power frequency test Mechanical failing load test Radio interference test Recovery of Hydrophobicity test Ten procedure/standard As per IEC 61109 (clause 6.4 All the type test given in Clause No. Chemical composition test for silicon content Annexure-A Or any other test method acceptable to the owner 7. 5. Note: The owner.The tested composite insulators shall be identified by a drawing giving all the dimensions with the manufacturing tolerances. b. 6.2) As per IS:731 (Clause.13.4 IEC:61109 amendment 1 of 1995 .8. 2. c.5 Acceptance (sample) Tests a. c.4) Annexure-A This test may be repealed every 3 yrs by the manufacturer 6.The purchase may like to conduct any other test(s) in addition to above tests at bidder’s cost to establish the performance of material as per system requirement.A Note:. may ask the bidders to quote test charges separately 6. 6.3 IEC: 61 109 IS:2633/IS:6745 Clause 7.8. 3. 4.2 IEC: 61109 Clause 7. Additionally following tests shall be carried out or reports for the tests shall be submitted after award of contract: UV test: the test shall be carried out in line with clause 7.8.2) As per IEC 61109 (clause 6. 2 The Owner reserves the right at his own expenses.10.9.4 6. hardness tests and magnetic particle inspection for forgings c) a) Chemical analysis of zinc used for galvanizing b) Chemical analysis.10 6. 6. mechanical. 6. hardness tests and magnetic particle inspection for forgings. c) 6. or in any other place in addition to the aforesaid type. Level of automation achieved and lists of areas where manual processing exists. their grades along with names of sub-suppliers for raw materials.9 Tests during Manufacture Following tests shall also be carried out on all components as applicable:a) b) Chemical analysis of zinc used for galvanizing Chemical analysis. 6. 2. Chemical analysis.5 List of manufacturing facilities available. fist of standards according to which the raw materials are tested. Additional Tests:- 6. .9. at site.2 Quality assurance plan:The successful bidder shall submit following information to the owner: Test certificates of the raw materials and bought out accessories.10. mechanical.1 As per IEC 61 109 Clause 8.10. acceptance and routine tests to satisfy himself that the material comply with the Specifications.d.2 As per IEC:61109 / IS:731 6. 3.10.3 Statement giving list of important raw materials.1 Chemical analysis. List of tests normally carried out on raw materials in presence of bidder's representative.3 The Owner also reserves the right to conduct all the tests mentioned in this specification at his own expense on the samples drawn from the site at Supplier's premises or at any other test center. metallographic test and magnetic particle inspection for malleable castings. metallographic test and magnetic particle inspection for malleable castings. In case of evidence of non compliance.4 IEC: 611 09 / IS:731 The test samples after having withstood the routine test shall be subjected to the following acceptance tests:Routine Tests:- SN 1.9. Description Identification of marking Visual Inspection Mechanical routine test Standard As per IEC: 61 109 Clause 8. it shall be binding on the part of the Supplier to prove the compliance of the items to the technical specifications by repeat tests or correction of deficiencies or replacement of defective items. for carrying out any other test(s) of reasonable nature carried out at Supplier's premises. all without any extra cost to the Owner. Verification of the specified mechanical load Clause 7.1 6.10. 6. 7 ply duly paletted or wooden crates.7 List of testing equipments available with the bidder for final testing of equipment along with valid calibration reports.10.12. The gross weight of the crates along with the material shall not normally exceed 100 Kg to avoid handling problem.12. The lot offered for inspection shall be homogeneous and shall contain Insulators manufactured in 3-4 consecutive weeks. where stage inspections are normally carried out for quality control and details of such tests and inspections. raw materials. 6.12 Packing:: 6. and its component parts shall be manufactured and the representatives shall have full facilities for unrestricted inspection of the Supplier's and sub-Supplier's works.11.11.6 List of areas in manufacturing process. 6.8 The manufacturer shall submit Manufacturing Quality Plan (MQP) for approval & the same shall be followed during manufacture and testing. 6.11. 6. 6. 6.11.11. or dunnage or spacers shall be provided to prevent damage or deformation during transit and handling.1 Inspection:: 6. 6.3 Suitable cushioning. 6.5 The bidder shall provide instructions regarding handling and storage precautions to be taken at site.6. storage at site and subsequent handling in the field.10. manufacture of the material and for conducting necessary test as detailed herein.6 The acceptance of any quantity of material shall in no way relieve the Supplier of his responsibility for meeting all the requirements of the specification and shall not prevent subsequent rejection. In the later case also the material shall be dispatched only after satisfactory testing specified herein has been completed. 6.10.12. protective padding. where insulator.4 The Supplier shall keep the Owner informed in advance of the time of starting and the progress of manufacture of material in their various stages so that arrangements could be made for inspection.3 The material for final inspection shall be offered by the Supplier only under packed condition.11.4 All packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination and to avoid the possibility of goods being lost or wrongly dispatched on account of faulty packing and faulty or illegible markings.11 Guarantee:- The Supplier of Insulators shall guarantee overall satisfactory performance of the Insulators for the period of 18 months from the date of supply.2 The packing shall be of sufficient strength to withstand rough handling during transit.12. The owner shall select samples at random from the packed lot for carrying out acceptance tests.2 The owner's representative shall at all times be entitled to have access to the works and all places of manufacture.10. The crates shall be suitable for outdoor storage under wet climate during rainy season.5 No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested unless the inspection is waived off by the owner in writing. 6. Each wooden case/crate/corrugated box shall have all the markings stenciled on it in indelible ink. 6.9 The successful bidder shall submit the routine test certificates of bought out raw materials / accessories and central excise passes for raw material at the time of inspection.12.1 All Insulators shall be packed in strong corrugated box of min. 6. 6. 6. if such materials are later found to be defective. . . Corona is continuously generated by applying 12 kV to a needle like electrode placed 1mm above the sample surface. ii) The sample shall be subjected to mechanical stress by bending the sample over a ground electrode. Dry the sample surface. iv) Allow the sample to recover and repeat hydrophobiticiy measurement at several lime intervals. Dry the sample surface. The test may be carried out at CPRI or any other NABL accredited laboratory. The test shall be done for 100 hrs. Test arrangement should ensure continuous wetting of the rod with Nitric acid. spray the surface with water and record the HC classification. 3 Recovery of Hydrophobicity & Corona test:- The test shall be carried out on 4mm thick samples of 5cm x 7cm The surface of selected samples shall be cleaned with isopropyl alcohol.Annexure-A Tests on Insulator Units 1 RIV Test (Dry):- The insulator string along with complete hardware fittings shall have a radio interference voltage level below 100 micro volts at one MHz when subjected to 50 Hz AC voltage of 10 kV& 30 kV for 11 kV& 33 kV class insulators respectively under dry condition.. 2 Brittle Fracture Resistance Test:- Brittle fracture test shall be carried out on naked rod along with end fittings by applying "1 n HNO3 acid" (63 g cone. Note HC classification.HC 2 within 24 to 48 hours. or until an HC of 6 or 7 is obtained. The test procedure shall be in accordance with IS:326B/IEC : 437/CISPfi 18-2. Dry the surface and repeat the corona treatment as at clause 7 above. Allow the surface to dry and spray with water Record the Hydrophobicity classification in line with STRI guide for Hydrophobicity classification. depending on the material and the intensity of the corona treatment. The rod should not fail within the 96 hour test duration. HN03 added to 937 g water) to the rod. iii) Immediately after the corona treatment. 4 Chemical composition test for Silicon content The content of silicon in the composite polymer shall be evaluated by EDX (Energy Dispersion X-ray) Analysis or Thermo-gravimetric analysis. Silicone rubber should recover to HC 1 . Repeat the cycle for 1000 hrs. The rod should be held at 80% of SML for the duration of the test. Name of Manufacturer Address: (a) registered Office (b) Factory 3. Name of material used in manufacture of the Insulator (with class / grade) (a) (b) (c) (d) 6.Annexure-B Guaranteed Technical Particulars OF 11KV Composite Polymer PIN Insulators (To be filled and kept in envelops containing Technical Offer) Sl. (a) (b) (c) (d) (e) (f) (g) Material of core rod Material of Housing & weather sheds (silicon content by weight) Material of end fittings : tongue/clevis Sealing compound for end fitting Colour Glaze of Insulator Electrical Characteristics: Nominal system Voltage (KV rms) Highest System Voltage (KV rms) Dry power frequency withstand (KV rms) Wet power frequency withstand (KV rms) Dry flash over voltage (KV rms) Wet flash over voltage (KV rms) Dry lighting impulse withstand voltage (a) Positive (b) Negative (h) Dry lighting impulse flashover voltage (a) Positive (KV peak) (b) Negative (KV peak) . 7. Type of Insulators Standard specification to which the Insulators manufactured and tested 5. 4. Description 11KV 33KV 1. No. 2. RIV at 1 MHz when energized at 10kV/30kV (rms) under dry condition (microvolt) Creepage distance (min) mm Mechanical Characteristics: Minimum failing load (KN) 9. Dimensions of Insulator: Weight (Kg. 13. iv. iii. No. Description 11KV 33KV (i) (j) 8. Packing details (a) Type of packing. 10. Method of fixing of sheds to housing specify ):. v. Any other particulars which the bidder may like to give.Sl. . of weather sheds Type of sheds (i) Aerodynamic (ii) With under ribs 11. (b) No.) Dia of FRP rod (mm) Length of ERP rod (mm) Dia of weather sheds (mm) Thickness of housing (mm) Dry arc distance (mm) Dimensioned drawings of Insulator (including weight with tolerances in weight) enclosed. 14. vi. ii. of Insulators in each pack (c ) Gross weight of package 15.single mould or modular construction (injection moulding/compression moulding) No. i. 12. 2. C Minimum Ambiant Air Température Deg. Heavy lightning is usual in the area during the month of May to November. The rated voltage of Arrestors shall be 9KV (rms) for 11 KV system. India.0 1. The temperature variation between the daily minimum and maximum is large. SYSTEM CONDITIONS:(i) (ii) (iii) (iv) Nominal system voltage Highest system voltage Frequency Fault level 11KV 12KV 50 Hz 250MVA 4. C Average Daily Ambient Air Temperature Deg. 4. which is to be protected. SPECIAL CONDITIONS:- The atmosphere at places is laden with dust in suspension during the dry months and subject to fog in cold months. . 50 2 32 90 1200 Not more than 1000 meters (Average 200 to 600 Mtrs) (viii) (ix) (x) Isoceraunic level (Day/annum) Maximum Wind Pressure (kg/sq. (i) CLIMATIC CONDITIONS:Location In the State of Madhya Pradesh. testing at manufacturers works supply and delivery of single phase outdoor metal oxide Polymeric housed distribution type gapless surge arresters for use in effectively earthed system with the transformer neutral effectively earthed with normal voltage of 11 KV for 9 KV Lightning arrestors.meters) Seismic level (Horizontal acceleration) 20/50 45 0. The winding of transformer.1 g (ii) (iii) (iv) (v) (vi) (vii) Maximum Ambiant Air Température Deg. 4. is connected in delta formation. TECHNICAL SPECIFICATION OF 9KV GAPLESS POLYMER LIGHTENING ARRESTORS SCOPE: This specification covers design manufacture assembly.1 The system is 3 phase 50 Hz solidly grounded system with earth fault protection. The area is also subjected to heavy monsoon rains 80% to 90% of the annual participation during the months of June to October.7.2 We will place one set of surge arresters at the entry of the each line (feeder) in the substation and one set near to the transformers for 33KV system & only one set each on 11 KV Distribution transformer. C Maximum Relative humidity (%) Average rainfall per annum (mm) Maximum Altitude above mean sea level (meters) 3. Considering 20% safe margin as per IEC the impulse voltage of more than 136 KVp should not appear across the 33 side of transformer. 38 11. Maximum residual voltage shall comply with the requirement given hereunder:The surge arresters meeting any other authoritative standards. which ensure equal or better performance than mentioned above. discharge capability NA 8 9. Rated Arrestor voltage KV rms Maximum continuous voltage KVrms Nominal discharge (8/20 micro sec) KA Minimum (KJ/KV) operating 9 7. 6. current rating 5. which are to be protected having BIL 170 KVp for 33KV winding & 75 KVp for 11KV winding. wave. 6. Applicable Standard IEC 60099-4 IS 3070 Part-III latest Amendment.3 The insulation level provided in our transformer is 170KVp for 33KV System and in case of 11KV System. Similarly. Long duration discharge class Maximum residual voltage at nominal discharge current of 8/20 micro sec.1 The technical requirement have been detailed out below: The supplier should offer nearest rating of surge arresters. shall be acceptable.4. impulse voltage of more than 60 KVp should not appear across 11KV winding of transformer. 75KVp. (Peak) Minimum prospective current (KA) symmetrical NA 12.No. 5.0 7. KV Peak NA 32 10. Particulars Nominal system voltage Type of Arrestor Requirements 9KV Gap-less (Metal Oxide) 3. 2. We will be installing our LAs at a distance of 5/10 meters from transformer (another 5 meters be added towards height of LAs lead length and bushing of transformers). 5. STANDARD:- The surge arresters shall strictly conform to IEC 60099-4 /IS-3070 Part-3 .3 Required Technical particulars: S. 6. 4.1993 with latest amendment if any in all respects. Maximum switching impulse residual voltage at 500 Amp. 1. 15 . 6.2 The transformers. KV peak Maximum steep current impulse residual voltage at nominal discharge current.2 6. radio interference voltage at 1000 Hz (micro volts) Overall temporary over voltage withstand capacity (KVrms) a) 1. 19. - 16.4 Residual voltage for 8/20 micro sec. Terminal arrangement Built in clamping Type. Impulse withstand voltage (KVP) Current impulse withstand level 75 18 impulse of long duration Current 200 Amp peak for 2000 micro secs. The base of L.No. Particulars current (KA) Requirements 13. Impulse high current short duration discharge of 4/10 micro sec.A. 65 14. can be adjusted for Horizontal & Vertical take off to suit conductor Size squirrel to raccoon. Min. creepage distance (mm) 300 21. shall be provided with two separate terminal / distinctly marked for connection to earth 22.5 c) 100. 17. wave of nominal discharge current KA are specified above.S. 9. Pressure relief device N.0 Sec. The firms are requested to offer nearest energy rating of LAs for both single and double shot.0 Sec. As per IEC 99/4 18. Disconnecting device As per required specification IEC 99 20. -- 15. Earthing Terminal 6. we will prefer still lower residual voltage to ensure better protection. wave (KAP) Max.5 The requirement of energy is very specific based on our system. however.A. .0 Sec. 10 b) 10. 6. surface blisters. All sharp edges and corners shall be blurred and rounded off. but having no integrated series or parallel spark gaps. 7. The surge Arrester housing shall be made with silicone Rubber (polymeric) of reputed manufacturer. A surge arrester with a housing made of polymeric material without air voids neither between the housing and the metal-oxide resistors nor the housing itself.5 All necessary bolts. 7. homogeneous.3 All current carrying parts shall be designed and manufactured to have minimum contact resistance.8 7. NAME PLATE: rigidly at arrestor The arresters shall be provided with non-corrosive legible name plate fitted body with indelibly marked with the following information :- .. connected in series. required for mounting on support structure shall be included in the scope of supply. The contact surface must be machined smooth to obviate excessive current density.12. crakes and cavities. & duration 2000 micro secs. This shall be connected in series with the ground lead and should not effect the sealing system of the arrestor. 8. insulators and arresters) in country.The surge arrester should be made without any internal gas volume.3.2 A surge arrester having one or several non-linear metal-oxide resistors with highly non-linear voltagecurrent characteristics. 8.5kv as per IEC 587.Current impulse withstands level . stabilized against UV radiation and have proven records in similar applications (like MV/HV cable terminations. 8. The adhesion between the polymeric housing and the metal-oxide resistors or any other metallic or non-metalic parts inside the housing must be strong enough. The Silicone rubber used for housing should pass the tracking & erosion test of 4.5 The terminal connector shall be manufactured out of Aluminum alloy grade LM 9 or 25 as per IS and by gravity die casting process only. All exposed ferrous parts shall be hot dip galvanized as per IS:2633. 7.4 The terminal connector for connection of conductor should be suitable for ACSR Squirrel to Raccoon conductor with Universal take off arrangement (can be adjusted for both horizontal & vertical take off) and should have adequate current carrying capacity. 9. The terminal connector drawings should be submitted separately with the tender documents. 7.6. 7.4 (1991II) clause 5. Line terminal pads and ground terminal pads should be hot dip galvanized.2 8. 7. TERMINAL CONNECTORS:- Terminal connectors shall be manufactured and tested as per IS:5361 and should be type tested. 7.1 DISCONNECTING DEVICE: - The arrestor for 9 KV system be provided with a suitable disconnecting device.The 9KV arrestors shall withstand 18 impulse of long duration current with a peak level of 200 Amp. The disconnecting device shall conform to the requirement specified in IS:3070 (Part-II)1993 & IEC 99 . 8. 8.4 All the units of arresters of same rating shall be interchangeable type without adversely affecting the performance. nuts clamps etc.7 The polymer material which is used for the arrester housing must be tracking and erosion resistant.1 All casting shall be free from blow holes.9 8.6 The base of the Polymer Lightning Arrestor shall be provided with two separate terminal distinctly marked for connection to earth. robust and resistant to thermal cycles and environmental stresses. . Insulation withstand test. DRAWINGS:- The supplier shall furnish two sets of following drawings for our approval before commencing the supplies:i) General outlines drawings of the complete arrester with technical parameters. Rated voltage. 11. profile of petticoats angle of inclination and gap between successive petticoats total creep age distance etc.1 Type Test Certificates :. 10. of the equipment to be protected Year of manufacture The nameplate should be fitted rigidly so that during life of arrestor. TESTS & TEST CERTIFICATES: 11. Type Rated frequency Nominal discharge current Long duration discharge class Rated Short Circuit current . Note:.1 of IEC 99/4/IS-3070 Part-III latest amendment:1. Residual voltage test .2 TYPE TESTS:- (A) The following type tests shall be made in accordance with Clause 7. Maximum continuous operating voltage.Type test report of manufacturer’s laboratory shall not be acceptable. JABALPUR Order No.L. 11.PD [FS] MPPKVVCL. vi) The detailed dimensional drawing of polymeric housing such as ID. & date. NTL. Volt time characteristics of surge arresters. B. CPRI. thickness and insulator details such as height. approved laboratories i. Details of the terminal and ground terminals.1 of IEC 99/4 and IS-3070 (Part-III). OD.The complete type test certificate from Govt. there should not be any possibility of removal of name plate. ERDA etc. It should cover all the type tests as prescribed in Clause 7. NFL. 2.e. ii) Drawings showing clearance from grounded and other live objects and between adjacent poles of surge arresters required at various heights of surge arresters. for the LAs of all the types/rating as per IEC 99/4 /IS 3070 (Part III) shall compulsorily be submitted in support of evidence of compliance of the specifications & guaranteed particulars. Manufacturer’s name or trade mark and identification Serial Number of the arrester. iii) iv) v) Mounting clamp details of surge arresters.I. the equipment/material shall be dispatched only after satisfactory testing for all tests specified herein has been completed.3. ACCEPTANCE TESTS: The following tests as per clause 8. Visual/dimensional examination. 4. The lot offered without routine test reports shall not be considered & delay in acceptance of the offer will be on firm’s account:a) b) Measurement of the reference voltage on the complete arresters. Long duration current impulse withstand test Operating duty test Test of Arrestor Dis-connectors (for 9 KV LAs) Partial discharge test. c) Test to verify the efficacy of sealing. 12. In the later case also. 5.1 The purchaser’s representative shall at all times be entitled to have access to the works and all places of manufacture where equipment/material shall be manufactured and the representative shall have full facilities for unrestricted inspection of the supplier’s works raw materials and process of manufacture for conducting necessary tests as detailed herein. Lightning impulse residual voltage test at nominal discharge current on complete arresters. Partial discharge test. Partial discharge test INSPECTION:- 12.2 of IEC 99/4 and IS-3070 Part-I & Part-II shall be done on the lower whole number of the cube root of the number of arresters to be supplied. 7. Accelerated ageing test Power frequency voltage versus time characteristic. (B) The following additional tests are to be also made 1. Galvanizing test on exposed steel parts. unless the inspection is waived off by the purchaser in writing. d) 12.4 Power frequency reference voltage test at reference current on complete arresters. 3. a) b) c) d) e) 11. 2. (C) 11. ROUTINE TESTS:- The following routine tests as per Clause 8.3 Moisture ingress test Weather aging test Galvanising test on steel metal parts For energy calculation. Residual voltage test at nominal discharge current on the complete arresters or sections.3 No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested.2 The supplier shall keep the purchaser informed in advance of the time of starting and of the progress of manufacture of equipment/material in its various stages so that arrangements can be made for inspection. 12. .1 of IEC 99/4 / IS-3070 Part-1/Part-III are to be conducted by the manufacturer on offered lot for pre-despatch inspection. 6. 8. set of type test reports should be submitted. 4 The acceptance of any quantity of material shall in no way relieve the supplier of any of his responsibilities for meeting all requirements of the specification.5 The number of sample selected to carry out the acceptance test shall be as per provision in the respective IS. GUARANTEED TEHCNICAL PARTICUARS OF 9KV POLYMER LIGHTNING ARRESTERS Sr. between them Maximum Switching Serge protection level at 500A Maximum equivalent front of wave protection level (KVp) 5 KA 10 KA .1 sec. 1 2 3 4 Particulars Name of manufacturer & place of manufacture Type Model Applicable standard 9 KV LA 5 6 7 8 9 No. of units (no. No. For 100 secs. For 10 secs. For 1 sec.) Rated voltage (KV rms) Rated frequency (Hz) Maximum continuous operating voltage (KV r m s) Maximum leakage current at Amps) continuous operating voltage (micro 10 (a) (b) (c) (d) 11 12 13 (a) (b) 14 15 16 (a) (b) Temporary power frequency over voltage capacity (KV rms) For 0.12. 12.6. Nominal discharge current (KA)(8/20 micro sec wave) Energy class Minimum discharge capability (KJ/KV) For single impulse energy For 2 consecutive discharge with 50/60 sec. The purchaser has the right to have the tests carried out by an independent Agency subject to recovery of testing expenditure in case of failure. and shall not prevent subsequent rejection if such material is later found to be defective. 12. whenever there is dispute regarding the quality of supply. (c) 17 Particulars 20 KA Maximum steep current Impulse residual voltage at nominal discharge current(KVP) Maximum switching impulse Residual voltage at 500 Amp. Long duration current impulse withstand : Current peak (Amps. Peak Minimum prospective symmetrical current (KA) Impulse high current short duration discharge of 4/10 Micro sec wave (KAP).e.) Maximum radio interference voltage at 100 KHz (micro volts/DB) Pressure relief device capability (Short circuit capability) High current (Amps. Reference current (MAP) Partial discharge i.) Virtual duration (Micro sec.) Low current (Amps. No. dia (mm) Complete height of arrestor (mm) from base to line side(mm) Total creepage of distance of arrestor housing (mm) Net weight of each arrestor (Kg) Construction of arrester Material of valve .) Protective ratio + 9 KV LA 18 19 20 21 (a) (b) 22 23 (a) (b) 24 25 26 27 28 29 (a) (b) 30 31 32 33 (a) (b) (c) (d) 34 (a) (RDV/BIL) Total creepage distance mm Impulse withstand voltage Kvp.Sr. PICO Power frequency withstand voltage of arrestor Housing (KVrms) Dry Wet Lightning impulse withstand voltage of arrestor housing (KVP) Current impulse withstand level Type of dis-connective device Dimensions of Arrestor : Max. (mm) Clearance required from ground equipment at various heights of arrester units.4 8.3 STANDARD The isolator shall comply in all respects with IS: 9921 or IEC Publication No: 129.4. Equipment meeting any other authoritative standard which ensures an equal or better quality than the standard mentioned above will also be accepted.1 11 KV ISOLATORS SCOPE This specification provides for design. 8. very short lengths of cables and current of voltage transformers. (mm) Earthing arrangement provided for earthing side of arrester (whether as per our requirement) 9 KV LA 41 8. The isolators will be double break type. gang operated out-door type silver plated contacts with horizontal operating blade and isolators posts arranged vertically. 129. fixing details etc. so that the break is distinct and clearly visible from the ground level. The equipment offered by the contractor shall be designed for a normal current rating of 630 amps for 11 KV suitable for continuous service at the system voltage specified herein. All isolators shall operate through 90 degree from their fully closed position to fully open position. The isolators are not required to operate under load but they must be called upon to handle magnetization currents of the power transformers and capacitive currents of bushings.3 . which are reproduced below 8.0 8. the design of turn & twist arrangement shall be subject to employer’s approval.4. (b) (c) (d) 35 36 37 38 39 40 Particulars Details of sealing Description of pressure relief system No.e. testing at manufactures works. delivery of outdoor station type 11KV (Local) manual operating mechanism isolating complete in all respect with bimetallic connectors.2 8. Type of terminal arrangement (Whether as per tender Specification) Size of line/ground terminals Minimum recommended spacing between Centre to centre of LA.Sr. triple pole single throw. (Banging type feature is not acceptable). Rotating blade feature with pressure relieving contacts is necessary i. 8. shall be as described herein. The rated insulation strength of the equipment shall not be lower than the levels specified in IS 9921 JEC publication No. of unit per arrester Type & Dimensions of clamping bracket Material of Top & Bottom metal cap. bus-bars connections. The nominal system voltages are 11 KV. However. 8.1 TYPE & RATING Isolators shall have three posts per phase.2 PARTICULARS OF THE SYSTEM The isolators to be provided under this specification are intended to be used on 3 phase AC 50 cycles. No. the isolator shall be described in detail along-with the offer. Operating mechanism. manufacture.4. effectively grounded system. 2. 4.4 The 11 KV isolators are required with post insulators but without mounting structures. 6.4.6 ISOLATOR INSULATION Isolation to ground.7. bolts and washers for mounting on the structured.3 1.1 MAIN CONTACTS All isolators shall have heavy duty self aligning and high pressure line type fixed contacts of modern design and made of hard drawn electrolytic copper. The thickness of ‘C’ clamp shall be adequate. This spring shall be made of stainless steel with adequate thickness.mm and Aluminum parts shall be less than 1 Amp/sq. Wiping action during closing and opening. 3. 5. The pad for connection of terminal connector shall be of aluminum with thickness not less than 12 mm.mm. . Self alignment assuring closing of the switch without minute adjustment.changeability of similar components. The fingers of fixed contacts shall be preferably in two pieces and each shall form the reverse loops to hold fixed contacts. Thermal withstand ability during short circuit. the male and female contact assemblies shall be of robust construction and design of these assemblies shall ensure the same.Standard declared voltage kv/rms Rated voltage of the Isolator Standard withstand positive (peak) Across isolating distance Kv Impulse Voltage polarity One minute power frequency withstand voltage KV (RMS) the To earth and between poles Across isolating distance 45 the To earth and between poles 11 KV 12 85 75 35 8. The fixed contact should be of reverse loop type.2 8. The various parts shall be accordingly finished to ensure inter. insulation between open contacts and the insulation between phases of the completely assembled isolating switches shall be capable of withstanding the dielectric test voltage specified above. 8. These contacts shall be liberally dimensioned so as to withstand safely the highest short circuit and over voltage that may be encountered during service. This channel shall be welded on an insulator mounting plate of 8mm thickness.4. The spring of fixed contact shall have housing to hold in place. The fixed contacts would be placed in ‘c’ clamp. 8. The isolators should be suitable for mounting on the Boards standard structures. Constant contact pressure even when the live parts of the insulator stacks are subjected to tensile stresses due to linear expansion of connected bus bar of flexible conductors either because of temperature verification or strong winds.7. This channel shall be placed on a channel of adequate thickness.7 8. Electro-dynamic withstands ability during short circuit without any risk of repulsion of contacts.7. The thickness of silver plating shall not be less than 15 microns for 11 KV.5. In nut shell. The current density in the copper parts shall not be less than 2 Amp/sq. The isolators shall be supplied with base channels along with fixing nuts. 8. 8. The switch blades forming the moving contacts shall be made from tubular section of hard drawn electrolytic copper having outer dia not less then 38 mm and thickness 3 mm. TEMPRATURE RISE The maximum temperature attained by any part of the equipment when in service at site under continues full load conditions and exposed to the direct rays of Sun shall not exceed 45 degree centigrade above ambient temperature. The surfaces of the contacts shall be rendered smooth and silver plated. free from flaws or imperfections that might affect the mechanical or dielectric quality. cracks and cavities. The cap and base of the insulators shall be interchangeable with each other.3 time the actual dry flash over voltage of the unit. 7. burns and other similar defects. One minute with stand KV (rms) Wet PF one minute withstand KV (rms) P. No part of the clamp shall be less than 12 mm thick. The terminal connector shall be manufactured and tested as per IS: 5561.1 CONNECTORS The connectors for 11KV isolator shall be made of Aluminum alloy LM-9 or LM-25 and shall be suitable for ACSR Panther for 11KV with horizontal and vertical take off arrangement. 6. The insulator stack shall conform to the latest applicable Indian or IEC standard and in particulars to the IS. 2. The post insulators for the above 11 KV isolators shall comprise of three numbers 11 KV insulators per stack and 9 such stack shall be supplied with each isolator. 4. The groove provided in the connection should be able to accommodate conductor size mentioned above smoothly.8. The glazing of the porcelain shall be uniform brown color. Impulse voltage withstand test KV Visible discharge test KV voltage (peak) 75 9 . All castings shall be free from blow holes. 2. The clamps to be offered should be manufactured by gravity die-casting method only and not by sand casting process. POST INSULATOR 11KV insulators shall be of reputed make subject to employer approval. the number of bolts to be provided. 5. All current carrying parts shall be designed and manufactured to have minimum contact resistance. surface blisters. 4. All the sharp edges shall be blurred and rounded off. 8. 5.8 8. 3. Insulators of the same rating and type shall be interchangeable. The details in regard to dimensions. The contractor shall furnish with the offer technical guaranteed particulars of insulators offered by them.F. Wherever necessary. The design of clamps shall be to the Employer for approval.9. The porcelain used for manufactures of insulators shall be homogeneous. bi-metallic strip of standard quality and adequate dimension shall be used.1 Each 11KV Insulators used in the isolators should have technical particulars as detailed below:11KV 1.8. Nominal system voltage KV (rms) Highest system voltage KV (rms) Dry P.8. and they shall be thoroughly vitrified. 6. Connectors shall be designed to be corona free in accordance with the requirement of IS: 5561. All nuts and bolts shall be made of stainless steel only.9. tough and impervious to moisture. material and manufacture shall be furnished by the bidder for Employer approval before manufacturing. Each cap and base shall be of high-grade cast steel or malleable steel casting and they shall be machine faced and smoothly 67dispatch.2 1. Please note that isolators without type test certificates will not be accepted. free from glisters. 2544 specification for porcelain post insulators. It is necessary that suitable clamps are offered along with the isolator and also it is obligatory to give complete technical particular of clamps along with the drawing.F. as per details given above and also as per following detail. Bimetallic sleeve/liner shall be 2 mm thick 8. 8. 7. 3. The porcelain and metal parts should be assembled in such a manner that any thermal expansion differential between the metal and the porcelain parts throughout the range of temperature variation shall not loosen the parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. Puncture withstand test voltage KV 11 12 35 35 1. The Isolators and Isolators inclusive of their operating mechanism should be such that they cannot come out of their open or close position by gravity wind pressure. 8. Isolators should be capable of resisting in closed position. The pipe shall be terminated in to suitable universal type joints between the insulator bottom bearing and operating mechanism.e.2 Creep age distance mm (min) Tensile strength in KN Operating Mechanism for 11KV Isolators:- 320 10KN All Isolators shall have separate dependent manual operation. Provision for earthing of operating handle by means of 8 SWG GS wire must be made.The bidder should therefore keep the same in view while submitting their offers: Description Center distance between Poles (Center to Center) i. vibrations reasonable shocks or accidental touching of connecting rods of the operating mechanism. suitable holes shall be provided on this base channel to facilitate it’s mounting on our standard structures. Phase to Phase clearance 75 Cm Distance between center lines of outer posts on same pole 11 KV Isolator 60 Cm . 9.10 PIPES Tandem pipes operating handle shall be class B ISI marked type having at least 24mm internal diameter for 11KV/33KV isolator. 8. the dynamic and thermal effects of maximum possible short circuit current at the installation point. The Isolator should be provided with padlocking arrangements for locking in both end position to avoid unintentional operation. The operating mechanism should be of robust construction and easy to operate by a single person and conveniently located for local operation in the switchyard.8. The operating pipe shall also be class B ISI marked with internal diameter of at least 32 mm for 11 KV isolators. To withstand total weight of isolator and insulator and also all the forces that may encounter by the isolator during services. The steel channel in each phase shall be mounted in vertical position and over it two mounting plates at least 8mm thick with suitable nuts and bolts shall be provided for minor adjustment at site. 8. 8. For this purpose Godrej make 5 lever brass padlocks having high neck with three keys shall be provided.9. They shall be so constructed that they do not open under the influence of the short circuit current. The isolating distances should be visible for isolators.12 CLEARANCES We have adopted the following minimum clearance for isolators in our system .11 BASE CHANNEL The Isolator shall be mounted on base fabricated from steel channel section of adequate size not less than 75x40x6 mm for 11KV . Strip for fixed contact & Cu. make and country of origin Make Type Maximum permissible continuos service voltage (KV) Clearance in air (minimum) Between Phases (mm) Between Live Parts & Earth (mm) Distance between centers of outer stacks of insulators (mm) Power Frequency withstand assembled switches Against Ground Dry KV Wet KV Across Open Contacts Dry KV Wet KV Impulse withstand Test voltage of completely assembled isolator switch with 1. Tube for moving contact 75 KVP 85 KVP 85 KVP 45 KV 45 KV 35 KV 35 KV test voltage for completely 750 mm 508 mm 600 mm 12 KV Requirement To be specified a i ii b i ii 6 a b c 7 a i ii b Moving Contacts Material c i ii d Size Fixed Contact Moving Contacts Current Density (Amps / mm ) 2 25x5 copper strip-2 No. i ii 2 3 a b 4 5 Particular Type.2 / 50 micro second impulse wave Against ground KV (Peak) Across the open ends of the phase KV (Peak) Between Phases KV (Peak) Particulars of the Contact Type Fixed Contacts Pressure relieving reverse loop type contact Tubular type moving contact Electrolytic Cu.GTP of 11 KV ISOLATORS No 1. OD 38xID32 mm copper tube . of operation which the switch can withstand without deterioration of contacts No. (ºC) Maximum Transformer magnetizing breaking current which can be safely interrupted by the switch Maximum current that can be safely interrupted between equipment bus bars Maximum capacity current which can be safely interrupted by the isolator Number of times isolator can be operated without any need for inspection No. (ºC) For 3 Sec.0 A 1.No i ii iii iv e Particular Fixed Contacts Moving Contacts Current take off assembly Aluminum Pad Surface treatment and thickness of surface coating Requirement 2A 2.7 Amps at 0.) Short Time Current Rating KA (rms) For 1 sec. of Break per Phase 9 10 a b 11 12 13 a b i ii 14 630 Amps 25 KA for 3 Second 62 KA Peak 25 KA Within limit of IS As per IS As per IS 0. (KA rms) Rated peak short Circuit Current KA (peak) Momentary Current KA (rms) Temperature Rise Corresponding to Maximum continuous rated current rated at 50ºC ambient Short time Current Rating For 1 Sec.15 PF 800 Amps 15 16 800 Amps 17 1000 Nos.0 A Contact area silver plated. 500 Sqmm Adequate MS Flat (HDG) 2 Amp/Sqmm To be specified f g h 8 Contact Area Contact Pressure Contact support of fixed Contact Current density at the minimum cross section of switch blade (Amp / Sq. 19 Two break phase per 20 Terminal Connectors . (KA rms) For 3 sec.0 A 2.) Continuous Current Rating (Amp. thickness 15 micron.mm. 18 1000 Nos. material & grade in other parts 22 Material and size of plate provided below & on top of insulators 23 a b Bearings Material & Size of Bearing No. MS Electroplated MS Plate 8 mm thick on top of Insulator and 75x40 channel provided below insulator b Size.) Design of Clamp e f To be indicated Suitable for Dog – AAA conductor 21 a Nuts and Bolts Size. Class & No. B-class 1 No.No a b Particular Clamp Body alloy composition Bolts & Nuts size. of Bearing / Bush Down pipe size and class Type of Universal joints (a) Between bearing and down pipe As per IS <1” GI pipe B-Class Swivel Joint ( Universal Joint) . For isolator b 25 26 No. Bearing at center post rotating Ball Bearing To be indicated by Bidder/manufacturer To be indicated by Bidder/manufacturer c d Type of bearing Shaft dia of bearing e Distance between two bearing 24 a Tandem Pipe Size. material and grade in current carrying path 3/8. of Pipe 1” GI Pipe. ¼” size MS Electroplated 3/8. of bearings (location & size) To be indicated 2 Nos. material & tensile strength Requirement Aluminum alloy MS Electroplated standard Spring washer plain washer As per IS & To be specified c Type of Washers used d Temperature rise when carrying rated current at 50ºC ambient (deg. C) Weight of each type of Clamp (Kg. ¼” size M-12. 320 mm) i) Nominal system voltage j) Highest system voltage k) Visible discharge voltage l) One minute dry withstand voltage KV (rms) m) Power frequency flash over voltage KV n) Impulse flash over voltage KV (peak) o) Impulse withstand voltage KV (peak) p) Puncture voltage KV JSI/AC/Jaipur Class Post type insulator 10 KN 5 Kg. These shells will be used for manufacturing of 11 KV 3-phase AB Switches or in other equipment in the system. The glazing of the porcelain shall be of uniform brown color. Creep age distance should be adequate for highly polluted outdoor atmosphere in open execution.1 POST INSULATOR SCOPE The specification covers Porcelain Post Insulator shells with metallic cap and base. Insulators of the same rating and type shall be interchangeable. free from blisters.No Particular (b) Between down pipe and operating mechanism Requirement To be indicated 1 To be indicated 20 KGm(Approx) To be specified 27 28 29 30 Safety factor taken into account while designing the isolator Weight of one three pole isolating switch (Kg) Torque required to open the switch Particulars of post insulator a) Make b) Type c) Tensile Strength d) Weight e) Nos.2 STANDARDS Post Insulator should conform to latest applicable Indian / IEC standards and in particular to the IS:2544 specification for Porcelain Post Insulators. The porcelain and metal parts shall be assembled in . 2 Nos. 160 mm 254 mm 320 mm 11 KV 12 KV 9 KV 35 KV rms 80 KV rms 105 KV 75 KV 1.0 9. 9. 3 times the actual dry flash over voltage of the unit 9. The porcelain used for manufacture of post insulator shall be homogeneous free from flaws or imperfections that might affect the mechanical or dielectric quality. They shall be thoroughly vitrified through and impervious to moisture. of units per stack f) Diameter of stack in mm g) Height of stack in mm h) Creep age distance in mm (min. Polygon or compact solids core or long rod insulator is also acceptable. burns and other similar defects. 9.such a manner that any thermal expansion differential between the metal and porcelain parts through the range of temperature variation shall not loosen the parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. The corrections proposed shall be stated in the Bid and shall be subject to approval of the Employer. The cap and base shall be properly cemented with insulators to give perfect grip.3 TEMPERATURE RISE The maximum temperature attained by any part of the insulator when in service at site under continuous full load conditions and exposed to the direct rays of sun shall not exceed 45 degree centigrade above ambient temperature. test certificates giving the results of type tests. 9. Nature of load will be transverse. made on not less than 2 post insulators and post insulators unit identical in all . 9. 9. Each cap and base shall be of high-grade cast steel or malleable steel casting and they shall be machine faced and smoothly galvanized.4 INSULATOR CHARACTERISTICS The insulator shall have the electrical and mechanical characteristics. 9. The withstand and flashover voltage are referred to the reference climatic conditions. Excess cementing shall be avoided. which are given below:Highest system voltage Dry one minute power frequency withstand voltage Wet one minute power frequency with stand voltage Power frequency puncture with stand voltage 12 KV (rms) 35 KV (rms) 35 KV (rms) 1.6 CREEPAGE DISTANCE The minimum creep age distance of 11 KV Post Insulators shall be 320 mm for highest system voltage of 12 KV. 9.3 times the actual dry flash over voltage of the unit Impulse voltage withstand voltage Visible discharge voltage 75 KV (peak) 9 KV (rms) In this standard power frequency voltages are expressed as peak values divided by ½ and impulse voltage is expressed as peak values.8 TEST The insulator shall comply with following tests as per IS:2544 -1973.9 TYPE TESTS Type tests are normally carried-out once and unless otherwise agreed to.7 PACKING All insulators shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail and road transport.5 MECHANICAL CHARACERISTICS The insulators shall be suitable for the minimum failing load of 10 KN. 9. The cap and base of the insulator shall be interchangeable with each other. 4. 3. Visual examination Electrical routine test 9. 9. 3. Post insulator. The Bidder/manufacturer shall invariably enclose with offer the type test certificates and guaranteed technical particulars. 2. 3. 4.13 DESIGN. 2. 9. 4. MATERIALS AND WORKMANSHIP The Bidder shall assume full responsibility for co-ordination and adequate design.essential details with those to be supplied are regarded as evidence of compliance. 2. without above markings shall not be accepted under any circumstances. Visual examination Verification of dimensions Visible discharge test Impulse voltage withstand test Wet power frequency voltage withstand test Dry power frequency voltage withstand test Temperature cyclic test (B) TEST ON FIRST INSULATORS 1. 2. All materials used in the manufacturing of Insulator shall be of the appropriate class well finished and of approved design and make. 2. 4. The tests should be carried out on two samples in the order mentioned below: (A) TEST ON BOTH INSULATORS 1.10 ROUTINE TESTS The following shall be carried out as routine tests: 1. 6. Verification of dimensions Temperature cyclic test Mechanical strength test Puncture test Porosity test Galvanizing test Tolerance in insulator dimensions shall be as per the relevant Indian Standards. 6. .12 MARKING Each insulator shall be legibly and indelibly marked to show the following: 1. 5. Name and trade mark of the manufacturer Month and year of manufacturing Minimum failing load in KN Country of manufacturing The above marking on porcelain shall be engraved and shall be applied before firing. 3.11 ACCEPTANCE TEST The test samples after having withstand the routine test shall be subject to the following acceptance tests in the order indicated below: 1. Mechanical strength test Porosity test Puncture test Galvanizing test 9. 5. All similar parts should be accurately finished and interchangeable. 7. 2 .7. 10. silicon alloy having composition appropriate to the technical and electrical properties as specified in Table-I of IS:398 (Pt-IV)-1994. The lay ratio of the layer shall be within the limit given below under clause 10. to extremely service exposure.3. of Wires Final modulus of 2 Elasticity GN/mm (Practical) 0.7.2 STANDARD: The conductor shall strictly comply with the Indian Standard Specification IS:398 (Part-IV)-1994 with the latest amendments unless otherwise stipulated in this specification.plus/minus 1%.3 10. 10.2 MATERIAL: The conductors shall be of best quality and workmanship.1 10. to atmospheric moisture and to long period of high ambient temperature. of 20° C AAAC 7 23. MODULUS OF ELASTICITY AND CO-EFFICIENT OF LINEAR EXPANSION The values of the final modulus of elasticity and co-efficient of linear expansion of AAA Conductor shall be as given hereunder: Item No. 10. as it will be subject to ring service. In all construction.All ferrous parts including Bolts & Nuts etc. 10.0 HARD DRAWN STRANDED ALL ALUMINUM ALLOY CONDUCTOR FOR OVERHEAD POWER LINES SCOPE: This specification provides for the manufacture.3.6324×10 kg/cm 6 2 10. resulting in reduction in cross-sectional area over the entire length.8. supply and delivery of ISI marked All Aluminum Alloy (AAA) conductor. The outer most layer being right handed. The wires in each layer shall be evenly and closely stranded. 10. magnesium. Alloy) 3 The wires of Aluminum Alloy Conductor shall be of heat treated aluminum. The wires shall be smooth and free from all imperfections such as spills and splits and rolling and wire drawing defects etc.1 STRANDING The wires used in the manufacture of a stranded conductor before stranding satisfy all requirement of IS:398 (Part-II & IV)-1976 & 1994 with its latest amendments.6 JOINTS IN WIRES: In AAA Conductors there shall be no joint in any wire/stranded conductor containing wires except those made in the base rod or wire before final drawing.5 Co-efficient linear expansion per O° C Density at temp.4 i) 10. or any other International Standards which ensure equal or better quality material and workmanship. TOLERANCE: The following tolerance shall be permitted: Tolerance on Nominal diameter wires .0x10 Aluminum Alloy -6 2. the successive layers shall have opposite directions of lay. Specific attention shall be paid to tropical treatment to the entire insulator.1 10.7 10. 10.7 kg/cm (Al. used on the post insulators shall be heavily hot dip galvanized. testing before dispatch. Before reeling.3 LAY RATIO: The lay ratio (ratio of the axial length of a complete turn of the helix formed by an individual wire in a stranded conductor to the external diameter of the helix) shall be within the limit given below. 10.10. Min. 10. . 10. Preservative treatment for antitermite/anti-fungus shall be applied to the entire drum with preservatives of a quality which is not harmful to the conductor.1 The reels/drums shall be of such constructions as to assure delivery of conductors free from displacement and damage and should be able to withstand all stresses due to handling and the stringing operation so that the conductor surface is not dented. shall be acceptable to the maximum extent of 10% of the total quantity. polythene sheet etc.3 All wooden components shall be manufactured out of seasoned wood of good quality free from defect that may materially weaken the component parts of the Drums. cardboard or other suitable material shall be secured to the drum and inside flanges of the drums. After reeling the conductor. grit and damage during transportation and handling and also prevent ingress of rain water during storage/transport.11 STANDARD LENGTH AND GROSS WEIGHT OF CONDUCTOR: The gross weight of each package shall not exceed 1000 Kg subject to a tolerance of + 10%.7. & Identification Number Size of Conductor Number & lengths of pieces of Conductor on each Drum Gross Mass of the Packing Net Mass of Conductor ISI or relevant International Standard specification mark. of Wires Lay ratio for Aluminum Alloy wire Central Aluminum Alloy 1 Total Max.g. transport and erection. the exposed surface should be wrapped with suitable soft material e.2 The conductor drum should be suitable for wheel mounting. as indicated above. PACKING AND MARKING: The conductor shall be wound in non-returnable reels or drums conforming to IS: 1778-1961 (Specifications for reels and drums for bare wire) or the latest version thereof. The standard wire length for AAA conductor shall be 2 Kms. Short lengths of not less than 50% of the standard lengths. 10. if any Name and address of the Consignees PACKING CONDITION 10.9 Trade mark.8 a) Item Outer Aluminum Alloy 6 AAA Conductor 7 14 10 Manufacturer’s Name b) c) d) e) f) g) h) i) 10. The conductor shall be properly lagged on the Drums. across the flanges to protect the conductor from dirt. scratched or damaged in any way during manufacture. The drums shall be marked with the following details:No.10. if any Drum No.10.10. Longer lengths shall be acceptable. the determining factor will be weight/length ratio of the sample(s) inspected at the manufacturer’s premises of the lot of which the drum under measurement at the consignee’s end.1 Where length of conductor is verified by weighment basis the determining factor will be length/weight ratio of the sample drums verified at the Bidder/manufacturer’s/Manufacturer’s premises of the lot of which the drum under measurement at the consignee’s end forms a part. normally used for winding the conductor should also be weighed. 10.14. 10. The factors of weight/length ratio shall however be made available to the Employer in the dispatch instructions itself.2 meters from the outer end of the finished conductor from not more than 10% of the reels.12 TESTS 10.10.2 In case. In case of empty conductor drums. . If such factors are not available due to some reasons. b) Arrangements should be made available in the works of the manufacturer for transferring the conductor from one reel to another at the same time measuring the length of the conductor so transferred by means of Length measurement machines. where the recorded weight on the drum tallies with the measured weight at consignee end. Net weight of the conductor should be calculated by subtracting the average weight of the six empty drums from the gross weight of the conductor and drums. If samples are taken after stranding they shall be obtained by cutting 1. Having known the weight of the conductor. At least 5% of the total number of drums of conductors taken at random shall be checked to ascertain the lengths of conductor adopting either of the following two methods:a) The drum along with the conductor should be weighed and six empty drums along with protective laggings & studs etc.2 The mechanical tests shall be carried out on single wires only and not on complete conductor.3 The following type tests and acceptance test shall be carried out on Aluminum Alloy Wires as per detailed procedure given in IS:398 (Part-IV)-1994:a) b) c) d) Breaking Load Test Elongation Test Resistance Test Wrapping Test 10.1 Samples of individual aluminum alloy wires for tests shall be taken before stranding from not less than 10% of the spools/coils. 10. forms a part.12. then the conductor length shall be accepted as recorded on the drum. 10. 10. the length of the conductor can be computed.14.12.12.13 CHECKING AND VERIFICATION OF LENGTH OF CONDUCTORS The contractor/manufacturer of conductor shall arrange for the inspection by the representative of the Employer authorized for this purpose. Percentage shortage if any in the length thus obtained and as declared by the Bidder/manufacturer/Manufacture in the packing list shall be applied to all the drums. actual measurement of diameter shall be made and weight/length ratio shall be obtained for the purpose of computing length.12.4 The rejection and re-test procedure shall be followed as stipulated in IS:398 (Part-II)-1976 and IS:398 (Part-IV)-1994. In other cases.14 CHECK MEASUREMENT 10. a check weighment of every one in ten empty drums shall also be done before the conductors are wound on the drums. 6210 Approximate Calculated breaking load mm Rabbit 55 2 mm 7/3.793 2 After Stranding 9 KN 2.03 ii) PROPERTIES OF ALUMINUM ALLOY WIRES USED IN THE CONSTRUCTION OF AAA CONDUCTORS Diameter Gross Sectional Area of Nominal Dia.12 4 (mm) 3. wire Min.15 i) SIZE AND PROPERTIES OF AAA CONDUCTORS For AAA Conductors (As per IS:398 (Pt-IV)-1994) Conductor (Code word) Actual Area Stranding & Wire Dia Approximate overall Dia Approximate Mass Calculated Maximum resistance at 20° C Ohm/km 0. Max.20 KN 16.45 Kg/km 149.18 6 (Kg/Km) 21.) Size (Codeword) Nominal Before Stranding 5 (mm ) 7.29 1 mm 55 (Rabbit) 2 2 (mm) 3.10. Mass Resistance 20° C Breaking Load (Min.41 .15 mm 9.290 8 KN 2.15 3 (mm) 3.04 7 Ohm/Km 4. 0 Zinc N. 2 2. 1 Nominal Maximum Minimum 2.A. 1 a) Min.GUARANTEED TECHNICAL PARTICULARS OF ALL ALUMINUM ALLOY CONDUCTOR To be categorically specified by the tenderer Sr No Parameters Unit AAAC RABBIT AAAC Panther 1 Particulars of Raw-material Aluminum Rods Complete Conductor Aluminum 1. Aluminum Strands after stranding Diameter 2. purity of Aluminum b) Max. 3 Min. 0 1/6 Layer Min / Max 4 Modulus of elasticity and coefficient of linear expansion a) Final Modules of elasticity GN/m b) Coefficient of linear expansion /ºC 2 5 DC Resistance of Conductor at 20 deg C Standard length of conductor Ohm/ Km . Copper Content % % 1. 2 2. Breaking load of strand Mm Mm Mm KN Max. Resistance of 1 m length at 20ºC Ohm/ Km Lay ratio of Conductor 3. Of Cold Pressure butt welding available at works No.2 Fittings for Strain Insulators: The Fittings shall consist of the following components: • • Cross arm strap conforming to IS:2486 (Part-II) – 1989. The thimble shall have clevis dimensions as per IS:2486 (Part – II)-1989. Elastomer pad for insulator shall be used with the ties to avoid abrasion of the conductor coming into direct contact with the insulator. The thimble shall be suitable for all sizes of conductors ranging from 7/2. 11. 11.1 HELICALLY FORMED FITTINGS: Pin Insulator ties: Helically formed insulator ties shall be suitable for specified conductor size.11mm to 7/3. The thimble clevis shall be attached to the insulator by a steel cutter pin used with a non-ferrous split pin of brass or stainless steel. The ties shall be suitably for pin insulator dimensions and conductor sizes to be specified by the Employer. 8 Direction of lay for outside layer Linear mass of the Conductor 9 a) Standard b) Minimum c) Maximum Kg/Km Kg/Km Kg/Km 10 No.0 11. Aluminum alloy die cast thimble – clevis for attaching to the tongue of Strain insulator at one end and for accommodating the loop of the helically formed dead-end fitting at the other end in its smooth internal contour.To be categorically specified by the tenderer Sr No Parameters Unit AAAC RABBIT AAAC Panther 6 Mtr 7 Tolerance on standard length Mtr. Helically formed ties used for holding the conductor on the pin insulator shall be made of aluminum alloy or aluminized steel or aluminum-clad steel wire and shall conform to the requirement of IS:12048-1987. . Tests: The ties shall be subjected to the tests specified in IS:12048-1987.35mm AAAC. B.• Helically formed dead-end grip having a prefabricated loop to fit into the grooved contour of the thimble on one end for application over the conductor at the other end.I voltage withstand for one Minute 75 KVp Power frequency withstand voltage 28 KV for one Minute x.0 SPECIFICATION FOR 11 KV VACUUM CIRCUIT BREAKERS (VCBs) TECHNICAL SPECIFICATION FOR 11 KV V. L. of 11 KV Porcelain Clad Vacuum Circuit Breakers complete with all accessories required for its satisfactory operation for the Transmission/Sub T transmission solidly grounded system.) the rated breaking current xi. operation & maintenance of the ordered circuit breaker shall be supplied with each breaker. Drawings of VI (Vacuum Interrupter) shall be submitted before commencement of supplies. The Breaker shall be used for Feeder Control/ protection in the system. Particulars Number of Poles Frequency Nominal system voltage Highest system voltage Interrupting capacity at nominal system voltage 11 KV 3 50 cycles 11 KV 12 KV 500 MVA The The above is m Rated continuous current 630 Amps Short-time current rating 25 KA for 1 sec. The formed fitting shall conform to the requirement of IS:12048-1987. 6 copies of manual for installation. The other hardware fittings shall be tested as per IS:2486 (Part-I). vi. viii ix. i.n. SCOPE :This specification covers design. vii. iv) . TYPE AND RATING :The circuit breaker shall be suitable for outdoor operation under the climatic conditions as specified in Tender Specification without any protection from sun and rain. Phase to Phase 280 mm (-10 mm+…) b. The capacity of breaker to interrupt inductive and capacitive currents shall be as indicated in GTP. Make. manufacturing. Between live parts & ground 2750 mm circuit breakers shall comply with the requirements of IS:13118(1991) or IEC 62271-100 with latest amendment thereof. v. iv. The 11 KV circuit breakers shall have the following rating:s. iii.-CO-3 min-CO Minimum clearances a. . Operating duty for gang operation O-0. Phase to earth 190 mm c.3sec.C. rating and source of vacuum interrupter with relevant details shall be as indicated in GTP. Total break-time for any current up to 5 cycles (max. ii. testing. 12.) 300 mm d.C. Tests: The helically formed fittings for Strain insulators shall be subjected to tests as per IS:120481987. The vacuum circuit breakers shall consist of three identical phase units with a common operating mechanism. The circuit breaker shall confirm following:i) ii) iii) The breakers should be suitable for out-door duty. Creepage distance (min. xii. Control circuit voltage 30 Volt D. type. 6.6. an indicator/means to indicate status of contact erosion should be provided. To know the residual life of vacuum interrupter.3 12.3 12. The mechanism shall be strong.12.1. TEMPERATURE RISE The maximum temperature attained by any part of the equipment. Mechanism shall also be capable of performing satisfactorily.3 .1.2 12. quick in action and removable without disturbing other parts of the circuit breaker. the insulation between open contacts and the insulation between phases of the completely assembled circuit breaker shall be capable of withstanding satisfactorily di-electric test voltage corresponding to specified basic insulation level in the standard. As the efficiency of the breaker depends on the degree of vacuum inside. exposed to the direct rays of the sun.4 12.2 The circuit breakers shall have operation counter and mechanical “open” and “closed” indicator.6 12.1. The limits of temperature rise shall be as per relevant standard.1 12. The puncture strength of the insulators shall be greater than the flash over value.1. They shall be designed to have ample insulation. 12. All working parts in the mechanism shall be of corrosion resistant materials and all bearings which require greasing shall be equipped with pressured grease fittings. All insulators of identical ratings shall be inter-changeable.1. Manufacturer’s catalogue of vacuum bottle.1. the re-closing duty cycles. The mechanism shall be trip free electrically and mechanically. under continuous full load conditions. shall not exceed 45˚ C above ambient temperature. it has to be ensured by the that manufacturer that the it is maintained consistently during service.5 INSULATORS Basic insulation level of the insulator and insulating porcelains shall be as specified and porcelain shall be homogenous and free from cavities and other flaws. The operating mechanism shall be of the spring charging type. 12. Operating mechanism should be motor operated spring charged type preferably without chain drive. 12. when in service at site.6 12. The metal/alloy used for the fixed and moving contacts shall have very low resistivity and low gas content. The interrupter design should ensure rapid de-ionization of the gap so that normal electrical strength of the gap is restored instantaneously. Motor for spring charging shall be suitable to perform satisfactorily for input supply voltage of 230V AC 50 Hz with a variation of plus 10 and minus 20 percent.6. Provision should also be made 12. An operation counter shall also be provided in the common operating mechanism.C. in addition to facilities for remote electrical indication. motor should have overload protection. A. Mechanism and breaker shall be such that the failure of any spring will not prevent tripping and will not cause tripping or closing.1 OPERATING MECHANISM The circuit breaker shall be designed for remote control from the control room and in addition there shall be provision for manual operation of circuit breakers during maintenance and for local tripping and closing by normal means.5 12. indicating all the details shall essentially be submitted. CTs on it with provision of suitable supports from ground. The mechanical indicator and operation counter shall be located in a position where it shall be visible to a man standing on the ground level with the mechanism housing doors are in closed position. mechanical strength and rigidity for satisfactory operation under conditions specified above. 12. INSULATION OF THE CIRCUIT BREAKER The insulation to ground. They should be resistant to arc erosion and the contact should have no tendency to get cold welded under the high vacuum in the interrupter. Insulating ceramic body of the interrupter should have high mechanical strength and it should be capable of withstanding high temperature without any significant deterioration in its mechanical and electrical properties. by electric control under normal operation.1 VACUUM INTERRUPTER(VI) The design of the vacuum interrupter shall be such that it gives trouble free operation under normal load and fault conditions throughout the life of the equipment.2 MOUNTING OF CTs The offered steel structures for breakers should also have adequate strength to accommodate 3 nos. The metallic bellow or any other similar vacuum sealing arrangement should be provided at the moving contact and should have a long fatigue life.4 12. copper control cable.14 . 12. fabricated from sheet steel of minimum 2. so as to avail full advantage of second trip coil. mm. 3-pin 5A socket with individual ON-OFF switches. The mechanical arrangement should be provided to facilitate manual tripping of circuit breaker for emergency trip under emergent condition i. (v) Motors shall be capable of giving rated output without reduction in expected life span when operated continuously in the system having the particulars as given in principle parameters. protection. Bearing shall be so constructed that the loss of grease and its creeping along with shaft into motor housing is prevented.8 CONTROL CUBICLE A common control cubicle shall be provided to house electrical controls.5 sq. These shall be capable of starting and accelerating to the rated speed along with the driven equipment without exceeding acceptable winding temperature even when supply voltage drops down to 80% of the rated voltage. It shall also prevent dirt and water from getting into the motor. Also the two trip coils shall have separate DC circuits. failure of DC supply. (ii) Motors shall be of self ventilated type having TEFC (totally enclosed fan cooled) enclosure.5 sq. (iii) Depending upon the capacity and loading conditions Bidder/manufacturer shall design suitable grease lubricated or oil lubricated bearings for above motors. internal illumination lamp.11 12.e. Cubicle shall be IP-55 of gasketed weather-proof construction. The cubicle shall have front access door with lock and keys. Circuit diagram of control circuit of VCB along with operating instructions (DO’S/ DON’T) shall be embossed on metallic plate duly laminated and the same shall be fixed on the rear door of the control cubicle from inside. monitoring devices and all other accessories. so that in the event of any short circuit/ damage in any one of the trip coil. 12. WIRING (i) Wiring shall be completed in all respects to ensure proper functioning of the control. Cable glands provided may therefore be suitable for 1 no. Circuit breaker shall be provided with trip free mechanism so that tripping instructions could over-ride the closing instructions. without any additional efforts. mechanism being defective while arc quenching media is healthy.13 12.10 12. Space heater.for mounting of mechanism box at an adequate height and gear ratios shall be so chosen that one man should be able to charge the spring. The second coil shall have separate tripping lever arrangements in the mechanism. The cables used for operation are un-armoured 2. Shunt tripping coils shall be designed to operate satisfactorily within 70% to 110% and shunt closing coil within 85% to 110% of the rated DC voltage. 12. 4 core un-armoured 2. 8 core and 2 nos. For local operation following shall be provided: a) b) LOCAL/REMOTE selector switch TRIP/NORMAL/CLOSE control switches with pistol grip handle. except those which must be located on individual poles.7 MOTORS: (i) Motors shall be single phase self-starting induction motor of appropriate capacity for satisfactory operation for the application and duty as required for driving equipment. supply is available in the other one. trip coil burnt. AC Power supply for auxiliaries will be available at 230V single phase 50 Hz. Necessary cable glands for the cables of the operating mechanism shall be provided. (vi) All induction motors shall be suitable for full voltage direct-on-line starting.5 mm. thickness. An additional tripping coil shall also be provided in the trip circuit. copper control cables of 1100 V grade.12 12. 12. mm.9 The control circuits shall be designed to operate on 30V DC and it shall be possible to adopt to work on other voltages by simply changing the operating coils. monitoring and interlocking schemes. (iv) Continuous motor rating (name plate rating) shall be at least ten (10) percent above the maximum load demand of the driven equipment at design duty point and the motor shall not be overloaded at any operating point of driven equipment that will arise in service. All spare contacts of auxiliary switches etc. shall be provided. Clamps shall be designed adequately to take care of any bimetallic effect. except hardware. Wiring shall be so arranged that individual wires of an external cable can be connected to consecutive terminals.16 TERMINAL CONNECTORS (i) All circuit breakers shall be provided with 6 nos. Conductor shall be tightened by at least four bolts. terminal connectors suitable to receive Dog ACSR/AAA conductors. 12. any type of groove in the clamp body for fixing of nuts should be avoided. bolts & washers used in the current path shall be stainless steel.mm or approved equivalent. Not more than two wires shall be connected to any terminals. All castings shall be free from blow holes. : 1 No. (ii) Terminal block shall be such located that it allows easy access. : 2 Nos. Therefore. so that heating of clamp by throttling action of current may be avoided.17 AUXILIARY CONTACTS Eight numbers each of auxiliary contacts both of the normally open and normally closed types shall be provided in each circuit breaker for use in remote indication and control scheme of the circuit breaker and for providing safety interlocking. mm. : 1 No. Sand die-casted connectors are not acceptable. All current carrying parts shall be designed and manufactured to have minimum contact resistance. Portion of clamp to hold the conductor should be flat and straight and not zigzag in construction at both the sides. 12. equal in number to 20% of active terminals. .5 sq. temperature rise. Size of terminal connector for which the clamp is designed and also rated current under site conditions shall be embossed/ punched on each part of clamps. Terminal connectors should be made of A6 Aluminum Alloy and manufactured by gravity diecasting process only.18 ACCESSORIES Circuit breaker shall be supplied as a complete unit with internal wiring installed and terminated in mechanism box and equipped with the following accessories :(i) Motor operated spring charged mechanism (Motor voltage . Each wire shall be identified at both ends with permanent markers bearing wire numbers as per wiring diagram. if required. Wire termination shall be done with crimping type connectors with insulating sleeves. : 1 No. 12. so that it may be possible to open the nuts and bolts by normal spanners. cracks and cavities. Conductor hold length must not be less than 60 mm. shall be wired up to terminal blocks in the control cubicle. Bimetallic strips/sleeve copper alloy liner of minimum thickness of 2mm shall be cast integral with Aluminum body.230 V AC. there shall be provision to add more auxiliary contacts at a later date. Control switch having Trip /normal /close position (v) Local/remote selector switch (vi) Spring Charged indicator (vii) Manual operating handle for maintenance (viii) Facility for manual charging of spring : 1 No. : 1 No. surface blisters. box clamp type ELMEX 10 sq. Surface of clamps to be tightened by bolts should be flat in shape. Wires shall not be spliced between terminals. Terminal connectors shall be tested for short circuit current capability.B. All auxiliary contacts shall be placed in a weather proof casing and current rating of the contacts shall be as mentioned in the bid. Space of at least 50% of diameter of nuts should be available after hole at both the sides of conductor holding portion for better mechanical strength. Wherever required. Provision shall be available to convert these spare “normally-open” contacts to “normallyclosed” type and vice versa. : 1 No. Nuts. All sharp edges and corners shall be blurred and rounded off. Spare terminals. Special contacts for use with trip coils which permit for relative adjustment with respect to the travel of the circuit breaker shall also be provided. : 1 No.(ii) (iii) (iv) (v) All wiring shall be carried out with 1100V grade PVC insulated stranded copper conductor of 2. 12. No part shall be less than 12 mm thick.15 TERMINAL BLOCKS (i) Terminal blocks shall be of 1100V grade. ii) a) b) c) d) e) f) g) h) i) j) k) l) Terminal connector shall also meet the following requirements: Terminal connectors shall be manufactured & tested as per IS:5561. 50 Hz) (ii) Trip coil suitable for 30 V DC (iii) Closing coil suitable for 30 V DC (iv) Pistol grip C. 20.4 At the time of inspection.20. (xiii) Cubicle illuminating lamp with protective cage and on/off switch Spare terminals block Mechanical ON/OFF Indicator MCB for both AC and DC supply Space heater with thermostat and ON/ OFF switch (xviii) 3-Pin 5 A socket with on/off switch (xiv) Earthing terminals (xx) Foundation Bolts (xxi) Cable glands (ix) (x) (xi) (xii) : 1 No.8 NC) Anti pumping device suitable for 30 V DC Bimetallic terminal connectors suitable for connecting Dog ACSR/AAA conductor. (xiv) (xv) (xvi) (xvii) : 20% of the Total active terminals : 1 No. as per IS:13118 or IEC 62271-100 with latest amendment thereof. (iii)Type tests should not have been conducted on the equipment earlier than 3 years from the date of opening of bids. The Employer reserves the right to carry out stage inspections at all stages. : 1 No. : 6 Nos. Bidder/manufacturer should indicate the manufacturing programme and the The Employer will have a right to depute inspecting officers during the manufacture of the equipment.20 ACCEPTANCE AND ROUTINE TEST :- 12. at the time of routine testing of the fully assembled breaker 12.19 TYPE TESTS (i) Type test certificates for the following tests. from any of the NABL accredited Laboratory shall invariably be furnished a. : 1 No.2 No material shall be dispatched from its point of manufacture unless the material has been satisfactorily inspected and tested.20. Bidder/manufacturer shall identify each and every item/accessories of the particular Circuit Breaker under testing. Power Frequency withstand voltage test (dry & wet) g.3 Bidders shall indicate the inspections and checks carried out at various stages of manufacture of the circuit breakers. Temperature rise test d.20. The Employer reserves the right to insist for witnessing acceptance/routine testing of the bought out items.Operation counter Auxiliary contacts (8 NO . The Bidder/manufacturer shall submit the routine test certificates of bought out items and raw material also. : 1 Set : 2 Nos. : As per requirement : As per requirement Other accessories which are not specified above. 12. Short time withstand current and peak withstand current tests c. (iv) In case of any change in design/type of breaker already type tested and the one being offered against this specification. : 1+1 No. duly sealed & signed by type testing authority. raw materials. : 1 Set : 1 No. Unless all the items are identified. Various tests stipulated in IS/IEC shall be performed in the presence of . the manufacture will not be treated as complete. should also be provided without any extra cost. Short circuit duties test b. for which advance intimation shall be given and all necessary cooperation shall be rendered by the manufacturer. Complete record of stage inspection would be kept by the Bidder/manufacturer and this record should be made available for inspection by the representative of the Employer. but are required for efficient and trouble free operation of breaker. Degree of protection IP-55 as per IS:13947:93(Part-I)/IEC 60529:89 (ii) Type test certificates must accompany drawing of type tested equipment. 12. manufacture of all the accessories and for conducting necessary tests as detailed herein. Single Capacitor bank switching test h.1 Employer shall have access at all times to the works and all other places of manufacture where the Circuit Breakers are being manufactured and the Bidder shall provide all facilities for unrestricted inspection of the Bidder/manufacturer’s works. 12. the Employer reserves the right to demand repetition of some or all tests without any extra-cost at NABL accredited lab. 12. Lightning impulse voltage withstand test f. Mechanical endurance test e. in such a case. The Employer shall communicate his comments/approval on the drawings to the Bidder/manufacturer within two weeks.5 It is expected that before circuit breaker is finally offered for inspection. All external paintings shall be as per shade no. 12.3 Successful bidders shall also furnish two sets each of bound manuals covering erection. design calculations and loading data for support structures. submit 4 prints per breaker and two set of good qualities reproducible of the approved drawings for the Employer's use. commissioning.21. All steel surfaces in contact with insulating oil. Schematic diagrams of breaker offered for control supervision and reclosing.the Employer’s engineers or when the inspection waiver has been given. 12. Each manual shall also contain one set of all the approved .7 Acceptance of any quantity of circuit breaker & its accessories shall in no way relieve the successful bidder of his responsibility for meeting all the requirement of this specification and shall not prevent subsequent rejection if such equipments are later found to be defective.23. if necessary. 12. After receipt of the Employer's approval. Structural drawing.2 Successful bidders shall. 12. General arrangement of foundation and structure mounting plan including weights of varnish components and impact loading data for foundation design. arcing chambers. shall be hot dip galvanized or stainless steel or electro-galvanized.21. internal testing of the same for various important parameters are already done.6 In case for any reason. the Bidder/manufacturer shall. within three weeks. greases or other adhering foreign matter.20. support channels. Details on the rating plate shall be as per ISS and shall also indicate manufacturer name. inspection is not completed or equipment is not found to be complete with all accessories as per confirmation given with the letter of inspection call. 12. All ferrous parts & steel structure including all sizes of nuts. and month & year of dispatch. Routine test report for such tests shall also accompany the letter of inspection call so that the Inspecting Officer at the time of inspection may verify the parameters brought out in the preliminary report. (a) (b) (c) (d) (e) (f) (g) General outline drawings showing dimensions and shipping weights. All machine finished or bright surfaces shall be coated with a suitable preventive compound and suitably wrapped or otherwise protected.1 Bidders shall furnish four sets of relevant descriptive and illustrative published literature.20. Paints shall be carefully selected to withstand tropical heat and extremes of weather within the limits specified..2 All interiors and exteriors of tanks.22 12. enclosures. 697 of IS:5 or polyurethane paint having shade siemens graph RAL7032. order no. serial no. etc. testing shall be done at the manufacturer's works as per IS/IEC stipulations and same should be confirmed by documentary evidence by way of Test Certificate which shall be got approved by the Employer. 12.1 Each circuit breaker shall be provided with a detailed rating plate. Type test reports.20. Short circuit oscillogram & certificates for similar type tested breakers. Sectional views showing the general constructional features of the circuit breaker including operating mechanism.3 All metal surfaces exposed to atmosphere shall be given two primer coats of zinc chromate and two coats of epoxy paint with epoxy base thinner or hot dip galvanized or two packs of aliphatic polyurethane finished paint. submit four sets of final version of all the above drawings for the Employer's approval. modify the drawings and resubmit four copies of the modified drawings for the Employer's approval within two weeks from the date of comments. structures. insulating paint. operation and maintenance instructions and all relevant information and drawings pertaining to the main equipment as well as auxiliary devices alongwith each breaker.23. scales.21 RATING PLATES & SURFACE FINISH PAINTING & GALVANISING:12. shall be painted with not less than two coats of heat resistant.23. contacts with lifting dimensions for maintenance.23 DOCUMENTATION: List of Drawings and Documents: 12. 12. . Details of all tests should be clearly brought out. mechanism. cabinets and other metal parts shall be thoroughly cleaned to remove all rust. Marked erection drawings shall identify the component parts of the equipment as shipped to enable erection by the Employer’s own personnel. the Employer will reserve the right to recover complete cost of deputation of inspecting team to the works of the manufacturer. bolts. Paint shall not scale off or wrinkle or be removed by abrasion due to normal handling. within two weeks of placement of order. 12. All drawings & data typical and recommended schematic diagram for control supervision & reclosing shall be annotated in English. corrosion. 12.21. oil insoluble. as far as accessible. All metal parts not accessible for painting shall be made of corrosion resistant material. plain and spring washers. pamphlets and following drawings for preliminary study. Bidder/manufacturer shall. 23. in his judgment.4 Manufacturing of equipments shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the Employer. Bidder/manufacturer shall be responsible for and make good at his own expense any or all damage to the equipment during transit. shall be provided. arc extinction. full arcing. Each consignment shall be accompanied by a detailed packing list containing the following information: (a) (b) (c) (d) (e) (f) (g) Name of the consignee.26 A list of all the accessories which will be supplied with the breakers should be furnished. proper arrangement for lifting such as lifting hooks etc. Details of consignment. type test reports as well as acceptance reports of the corresponding consignment dispatched.30 . items which will be manufactured by the Bidders and balance items.23. 12. 12.5 Approval of drawings/work by the Employer shall not relieve the bidders of any of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of the applicable standards rules and codes of practices. the bid may be treated as non-responsive 12. and open position. arc initiation. due to improper and inadequate packing and handling. Sign showing upper/lower side of the crate. Equipment shall conform in all respects to high standards of engineering.23.31 SCHEDULE OF REQUIREMENT OF ACCESSORIES ETC It is obligatory on the part of bidders to furnish Schedule of Requirement of Accessories provided with equipment in the Schedule A attached. Destination. Easily damageable materials shall be carefully packed and marked with the appropriate caution symbols. Equipment shall be packed in suitable crates in such a manner to protect it from damage and withstand handling during transit. Total weight of consignment. (c) Effect of non-simultaneity between contacts within a pole or between poles and also how it is covered in the guaranteed total break time. 12. is not in full accordance therewith. While furnishing the list of accessories.6 Additional data to be furnished along with the bid: (a) Drawing. Handling and unpacking instructions. 12.25 COMPLETENESS OF EQUIPMENT AND BOUGHT OUT ITEMS: Bidders must furnish following information along with technical bid. GUARANTEED TECHNICAL PARTICULARS: It is obligatory on the part of bidders to furnish Guaranteed Technical Particulars enclosed with the bid document duly filled in complete in all respects. In case Guaranteed Technical Particulars duly filled in complete in all respects is not furnished.24 PACKING AND FORWARDING: Equipment shall be prepared for ocean shipment (foreign equipment) or rail road transport (local equipment). showing contacts in close. 12. design. which will be procured from sub-Bidder/manufacturers should be clearly identified and stipulated in the bid. Bill of material indicating contents of each package and spare material. workmanship and latest revisions of relevant standards at the time of supply and the Employer reserves the right to reject any equipment or material which. Wherever necessary.drawings. Any material found short inside the packing cases shall be supplied by the Bidder/manufacturer without any extra cost. (b) Data on capabilities of circuit breakers in terms of time and number of operations at duties ranging from 100% fault currents to load currents of the lowest possible value without requiring any maintenance or checks. 12. 12. supply for spring charging motor b) Spring charging motor rating/make c) Spring charging motor time (ms) d) Detail of overload protection provided for spring charging motor Rated supply of tripping/ closing coils Power required for tripping/ closing coils No. Natural frequency iii. designation (c) Voltage/Current rating (d) STC rating & Duration (e) Type of contacts (f) Material of contacts (g) Contact pressure at no load (h) Electrical life (i) At rated normal current (ii) At rated short circuit current (i) Mechanical life Maximum temp. (25KA) Rated operating sequence a) Rated Aux./type. of breaks/pole Class (outdoor) Applicable standards Type of Operating mechanism Vacuum Interrupter details (a) Make (b) Model No.12. Symmetrical at rated service voltage c. At 10% breaking capacity b. At rated interrupting capacity Arcing time in milli-sec a. Phase factor 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 . It may be carefully noted that filling/ reply of each and very clause described below is a must. Symmetrical b.32 GUARANTEED TECHNICAL PARTICULARS FOR 11 KV VCBs NOTE: This schedule of guaranteed technical particulars is to be submitted by the Bidders. No 1 2 3 4 5 6 7 8 9 10 11 12 13 GUARANTEED TECHNICAL PARTICULARS FOR 11KV Particulars 11 KV Name of manufacturer & Place of manufacture Manufacturer’s type Designation of VCB Rated Nominal voltage (KV) Rated Highest Voltage (KV) Rated Normal Current (Amps) Rated frequency (HZ) Rated short circuit breaking current (KA) Rated short circuit making current (KAp) Rated PF withstand voltage (KV) Rated LI withstand voltage (KVp) Rated Short Time Current for 1 sec. Breaking capacity (KA) a. At 100% breaking capacity Minimum closing time from the instant of trip coil energisation (ms) Rated transient recovery voltage a) Data on re-striking voltage i. At 10% rated interrupting capacity b. Amplitude factor 100% & 50% of rated capacity ii. of poles No. rise over ambient temp. Sr. Asymmetrical Total break time in milli second a. Type of insulator containing VI creep age distance Total length of break per phase Total break time (milli-sec) Opening time (milli-sec) Closing time (milli-sec) Opening speed (Meter/Sec) Closing speed (Meter/Sec) DC component of rated short circuit breaking current First pole to clear factor Number of auxiliary contact provided & type i. weight of mounting structure Procedure followed to ensure achievement of parameters Simultaneity of contact. Live parts to ground level Make. creep age distance Make. R.29 30 31 32 33 34 35 36 37 38 39 40 41 42 iv.V. if any. Normally closed iii.R. Between phase & Earth ii. Contact speed Please indicate measures provided to trap moisture. Normally open ii. Contact travel. Volts/micro second Minimum clearance in air (mm) i. Those adjustable with respect to the position of main contacts Accessories to be supplied with each breaker (a) Rated cable charging breaking current (b) Rated back to back on capacitor bank breaking current (c) Rated capacitor bank inrush making current Rated single capacitor breaking current Maximum over voltage on switching transformer on No-load and the charging current Total weight of one complete Breaker Overall dimension of VCB (mm) including structure Dimension. Between phases iii. inside the hollow porcelain containing the vacuum interrupter Measures provided to indicate for loss of vacuum Measures provided to indicate for wear/ tear of contacts 43 44 45 46 47 48 49 50 51 . Type of support insulators. B. unarmored copper control cable Provision of circuit diagram with operating instructions (DO’S & DON’T) embossed on metallic plate duly laminated to be fixed on inside wall of rear door of control cubicle. 8 core cable glands suitable for 2. 24 .PANEL HAVING GEAR MECHANISM & CONTROL CIRCUIT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Sheet thickness of breaker panel Size of control wiring GI Mounting Structure (Breaker & CT) Color code for control wiring Type of Operating Mechanism Rating of Diode protection (in case of D. Control switch having Trip/Normal/Close Position Make & Rating of Local/Remote selector switch 3 Pin 5 Amps Socket with on/off switch Nos.5 sq.C. 4 core and 1 no. & Size of foundation Bolts Material supplied in loose with each VCB Provision of double trip coil Provision of 2 nos. Spring charging motor) Make & Rating of Heater & thermostat Color shade of VCB control panel Make & Rating of Anti-pumping relay Make & Type Operation counter Spring charged indicator Mechanical ON/OFF Indicator Facility for manual charging of breaker Auxiliary contact 8 NO + 8NC Cubical illumination lamp with protective cage & on/off switch Make & Rating of MCB for AC/DC circuits Make & Rating of C.mm.. links. foundation bolts.0 SPECIFICATION FOR 11 KV INDOOR CONTROL PANELS SCOPE This section contains the technical specification for the multi circuit indoor control. The interior of the panels shall be painted with egg shell white. as per following Indian Standard Specifications with latest amendment thereof :(i) IS-3842 (Part-I):1967 : Application guide for electric relays for A. This color finish shall be applied to all the exterior steel work of the panels. The control and relay panels and other requirements specified under this section shall be complete in themselves with all main and auxiliary relays. base frame. annunciation relay.2 PROTECTIVE RELAYS AND INSTRUMENTS:The protective relays shall be manufactured. cable glands etc. illumination. 13. earthing terminals.current relays for Feeders and Transformers (ii) IS-3842 (Part-IV):1967 : Application guide for electric relays for A.C. Particulars Qty. Systems over.SCHEDULE A DETAILS OF FITTING & ACCESSORIES TO BE PROVIDED WITH 11KV VACUUM CIRCUIT BREAKERS S. terminal blocks. indication. 13. fuses.C. wiring. 275 of BS: 381C (1948). The exterior finish shall be semi glossy only and shall not be fully glossy. switches. Equivalent colors as per relevant Indian Standards or any other standard are also acceptable.system thermal protection relays (iii) IS-3231 (1965) : Electric relay for power system protection (iv) IS-1885 (Part-I&II) : Electro-technical vocabulary Electrical relays & Electrical power system protection (v) IS-4483 : Preferred panel cut-out (vi) IS-1248 : Indicating instruments . relay and metering panels for control of associated line or transformer through outdoor switchgear at various 33/11 KV Zonal sub-stations.1 PANEL FINISH AND COLOUR:The purchaser has standardized that the colour finish shall be opaline green as per color no. labels. Rating Make 13. tested and supplied with the guaranteed particulars. No. (iv) Design. 13. the intensity of light should be minimum 100 mcd at 20 mA..supply. 50Hz neutral grounded A. fire resistant.(vii) All indicating instruments shall conform to IS-722 or BS-89 or any equivalent or better international standards.R. polycarbonate lens in desired color shades of Red. supply (b) H. (c) All H. The lamp/tube shall be located at the ceiling and guarded with protective cage. Indicating lamp should be suitable to operate on 30 Volt DC supply source.I & II). Equipment for which Indian Standards are not available the relevant British Standards and IEC recommendations will be applicable. frequency variation ±4% ii) 30V (+ 10% to -15%) D.C. subject to specific approval of purchaser. Green. 13.. All control panels and switchgear cubicles shall be made absolutely vermin-proof. Pre-treatment & painting of panels shall be done as per the procedure detailed in clause-22 of this schedule. The panels shall have sufficient structural re-enforcement to ensure a plane surface to limit vibration and to provide rigidity during dispatch and installation. However.C. power supplies. (ii) The panels shall have the following dimensions :Height 1475 mm Depth 300 mm Width 600 mm No deviation in height and depth is permitted. The equipment meeting any other authoritative standards which ensures equal or better quality than the standards mentioned above shall also be acceptable. . screw or bolts head apparent from the exterior surface of the Control Panels.C. outside and inside with no works of welds.3 TYPE/ ACCEPTANCE TEST CERTIFICATES FOR RELAYS:Following type test certificates of relays as per IS: 3231 or any equivalent international standard are required to be submitted by the bidder:(i) Performance test and operating characteristic tests (ii) Thermal requirement test (iii) Accuracy test (iv) Re-set value test (v) Re-set time test (vi) Over shoot time test (vii)Rated burden & impedance test (viii)Insulation requirement test (ix) Mechanical requirement test (x) Contact performance test NOTE Regarding testing of relays. fuses shall be provided by the supplier for both the A. and D. 13. the purchaser will provide the following :i) 230V (+10% to -20%) single phase 2-wire. to accommodate instruments.4 PANEL CUT OUT AND DIMENSIONS:(i) The panels shall be fabricated from 2mm steel sheet free from all surface defects. increase in panel width alone is permitted. 13. (iii)The preferred panel cut out dimensions for mounting of the relays shall be as per Indian Standard Specification IS-4483 (Part .7 AUXILIARY SUPPLY:(a) For each Control Panel. 13.5 PANEL LIGHTING:a) For interior illumination. Yellow etc.C. reference may please be made to BS-142-19.C.8 CONTROL WIRING:(a) The supplier shall provide complete wiring up to the terminal block for the equipment. b) One 3 pin-5 Amp. receiptable socket with On/Off switch and fuse shall be provided in each control panel.6 INDICATING LAMPS:The indicating lamps should be supplied with low voltage protection circuit (LVGP) and surge suppressor circuit having LED indication.C. non. control and indication gadgets of different make. rivets. Lamp assembly should be of fire retardant glass epoxy PCB.R. instrument devices mounted in the control panel strictly according to the wiring diagram prepared by the supplier based on the purchaser’s information and schematic diagram and get approved from the purchaser. material selection and workman-ship shall be such as to present a neat appearance.hygroscopic DMC material. relays. Amber. 13. The bidder has to submit copies of all applicable standards along with the offer. industrial heat resistant. fuses and links shall be with holder. the base of fuse holder shall be mounted on slant support with identification labels. The On/Off switch shall be mounted on one of the sidewalls and shall be easily accessible. 11/15 Watt CFL operating at 230V AC 50 Hz with On/Off switch shall be provided in each panel. Red for Positive. (h) All series connected devices and equipment shall be wired-up in sequence. don’t All unused potential free contacts of relays and switches if any shall be wired up to the terminal block.C. 13. shall be provided with 3 cable glands for 8 core. However. the wiring shall be carried out with 1100V grade PVC insulated stranded copper conductor of size 2. For PT and for control circuits the wiring shall be carried out with 1100 V Grade PVC insulated stranded copper conductor of size 1. shall be provided with 2 cable glands for 8 core.mm.C. The supplier shall take approval for the system of wire numbering. and Green for earthing.5 sq. a number of wires will run from one point to another. Adjacent rows of terminal block shall be spaced not less than 100 mm apart. For CT circuits. Black for Neutral & Green for Earthing. The bottom of terminal blocks shall be spaced at least 200 mm the cable gland of incoming multi-core cables. Circuit:-Red for Phase. since the same may create problems in case any wire is to be removed.5 sq. as per wiring diagram based on latest revision of IS-375 to denote the different circuit functions. (l) Blank plastic channels should be provided by the sides of the panel to accommodate the incoming cables from switchyard through the cable glands. (k) Since. Yellow for Negative. iii) D. All wire shall have crimp type termination and direct connection at any place is not at all required. it is desired that the support arrangement should be adequate and neat. (ii) The cover plate of base box for 11 KV and 33 KV SINGLE CIRCUIT C&R panels. ready for purchaser’s external connections at the terminal blocks.C. (d) The Control Panels shall be supplied completely wired. Inspection/removal of wires should be possible by sliding the covers.5 sq. Circuit: . protection and metering schemes. disconnectable type terminal connectors with shorting facility may be limited to CT & PT circuits only. ii) Single Phase A. as far as possible and the common buses shall normally be made through the terminal block for better reliability of testing and maintenance. The terminal block shall be suitable for receiving at least 2x2.mm stranded copper conductor wire per terminal. (m) The circuit diagram of control circuit along with operating instructions (DO/DO’NT) embossed on metallic plate duly laminated shall be provided on rear side of the door. 13. . Circuit: . (f) Each wire shall be identified at both ends with wire designation number by plastic ferrules.5 sq. (i) The cover plate of base box for 11 KV and 33 KV MULTI CIRCUIT C&R panels.8 TERMINAL BLOCKS:(a) Multi-way terminal blocks complete with necessary binding screws and washers for wire connections and marking strips for circuit identification shall be provided for terminating the panel wiring and outgoing cables. iv) Control Wiring: . either direct from main supply fuses or the bus wires.mm unarmored copper control cable. suitably.(b) The wiring shall be complete in all respects so as to ensure proper functioning of control.Red for R Phase. Each such group shall be fed through separate fuses. Wires shall not be tapped or spliced between terminal points. (e) Color coded wires should be used to facilitate easy tracing.mm unarmored copper control cable. The panel-side and outgoing wires should be disconnectable just by opening the disconnecting links. 2 cable glands for 4 core and 2 cable glands for 2 core 2. mm. The box base shall have 3 mm thick cover. (b) Terminal blocks shall have shorting and disconnection facilities. The conventional method of bunching of wire should not be adopted.Gray for annunciation and other control circuits. as under:i) Three Phase A. These shall be mounted vertically at the sides of the cubicle and set obliquely towards rear doors to give easy access of terminating end to enable ferrule number to be read without difficulty. Blue for B Phase Black for Neutral. which slide up/down or left/right without dislodging the wires from their position. Yellow for Y Phase. (d) The terminal blocks shall be grouped according to circuit functions and each terminal block group shall have at least 20% spare terminals. Loop-in/loop-out system of wiring shall be avoided. 5 cable glands for 4 core and 3 cable glands for 2 core 2. (i) Fuses and links shall be provided for isolation of individual circuit from the bus wires without disturbing the other circuits and equipments. (c) Instrument transformer wires shall be terminated through suitably mounted test terminal blocks for site testing facility. The wires should be accommodated in plastic channel with sliding plastic cover mounted inside the panel.9 CABLE ENTRY:(a) The control panel shall have provision of cable entry from the bottom. (j) The DC trip and DC voltage supplies and wiring to main protective gear shall be segregated from these for back up protection and also for protective apparatus for special purposes.5 Sq. (g) All wire termination shall be made with compression type connectors. (c) For fixing cable glands on the box base cover. (b) Each continuous length of ground bus shall have provision of two terminals at two separate points for connection to main ground grid of the sub-station. (d) Wherever a circuit is shown grounded in the drawings. below the panel and fixing of gland plate for control cable entry to suit the supplier’s requirement. shall be 5 Amps. 13. relays and accessories:Sr Particulars 11 KV (2F) N I 3 pole 5 Amp Numeric IDMT relay 30 V DC with self-reset contacts and hand reset flag (Flush pattern) shall be suitable for selecting following settings :a. 13.11 DOORS:Each panel shall be complete with end enclosing sheets on both sides and door in the rear. the terminal block shall have an identification indicating that is for CT circuit. (b) The wiring through terminal blocks shall be such located so that it is convenient for floor opening. Suitable clamps shall also be provided in plastic channel for holding cables. E/F Element (2% to 80%) .14 PROTECTION SCHEME:13. shall be provided for each circuit. 13. a single wire for the circuit shall run independently to the ground bus and connected to it.1 The control panels are required for protection of the following equipments:a) 11 KV Overhead sub-transmission lines The protection schemes are described in the following clause:13. O/C Element (2% to 200%) 2 nos. For example. as well as on the inside wall. All indicating instruments.2 The labeling for the circuits shall be provided at the front control panel. The secondary rating of C. in addition to outside.14. 13. Proper rubber sealing gasket shall be provided on the door.14. 700 mm above the box base top with semaphore for breaker position indicator etc. The instruments and relays shall be flush mounted pattern.T. The relay shall be of draw out type with CT shorting facility.15. The current settings of O/C relay element shall be from 2 % to 150% in equal step of 1-2 % each and of E/F relay element from 2 % to 80%. (c) Potential and current transformer neutrals shall be grounded only at the terminal blocks where they enter the control panel from the instrument transformers. all meters and relays shall be mounted in the front. E/F elements with high set.The gland plate shall be covered with dummy plate.12. clearly indicating type of supply ‘AC & DC identification circuits’ control (metering/protection) and instruments identification. A type test report from the recognized Government. The rear door shall be fitted with handle and also turn twist locks at top and bottom. 13. 13. They shall be suitable to work on 30 Volt D.C. protection etc. The numerical relays having programmable characteristics as per above requirements are required. This will be in the form of a IDMT relay having 2 Nos. the relay shall have self re-set contacts and hand re-set flag arrangement. meters and important components shall have identification labels from inside also. laboratory or NABL approved lab on degree of protection test IP-55 shall be furnished by the supplier. The purchaser will arrange for necessary floor opening.12. 13. detachable gland plates of 4 mm thick shall be mounted at least 100 mm above the floor level. Further.2 Feeder Protection :11 KV Feeder Control circuit in the Panel is required for control/protection of 11KV sub-transmission lines. The control and indication apparatus. O/C and 1 No.3 A mimic diagram showing single bus arrangement. relay each with 2 O/c and 1 E/f element with high set b.12.12 CONTROL AND RELAY PANELS:13. supply. The tripping shall be routed through a high speed master trip relay with hand reset facility and flag relay.1 CONTROL AND INDICATION CIRCUITS: - 11 KV two feeders (2F): 11 KV multi circuit control & relay panel for control of two feeders shall have the following instruments. (d) The cable gland plate and rear door shall be properly rubber gasketted to ensure IP-55 protection. metering. (e) Rigid supports shall be provided along the terminal block for holding plastic channel. The bidder has to provide all required material to ensure IP55 protection.1 The control panels required for installation at all the sub-stations shall be of simplex type for multi circuit control.10 GROUNDING:(a) 25mm x 6mm x 250mm copper ground bus shall be provided inside the panel for effectively grounding all metal structures. The terminal block shall have identification labels attached to them. for 4 core 3 nos.4 The bidders are required to submit C&R panel general arrangement and schematics indicating all relevant details of all relays and gadgets along with bill of material.5 The mimic of 10X3 mm thick Aluminum strip painted black showing single bus arrangement and breaker position semaphore indicator shall be provided 700 mm above the box type base channel on each C&R panel. The lamp should have the indication on demand when breaker is on.2 A trip healthy lamp shall be provided for each circuit breaker and connected in such a way as to indicate the healthy condition of the trip circuit. DC Fail ( separate for each circuit ) Push buttons A Alarm accept B Alarm reset c. without any extra cost.1 All relays. for 2 core 1 set XII XIII XIV XV XVI 1 set 1 1 As required 2 13. . Set of Foundation bolts for grouting panel box base with panel Illumination CFL 11/15 Watt lamp with protective cage & On/Off Switch. pre and post close trip supervision facility on demand is required and shall be included. 13. 13.3 The automatic tripping of the circuit breaker due to operation of protective relays shall be indicated by a common audible DC alarm. except where otherwise approved. MIMIC (10X3 mm) made of Aluminum strip painted black showing single bus and breaker position semaphore indicator Semaphore CB position indicator 1 With Multiple characteristics 2 2 (200-100 ) Range 0 to 125 or 250 2 2 IV V VI 2 2 2 2 2 2 2 2 2 2 2 2 1 VII VIII IX X XI 3 nos. Box type base of 100 mm height painted with water resistant black rubber paint complete with 3mm thick cover plate fitted with cable gland box and cover.0 RELAYS:16.0. CB-ON (RED) b. DC Fail test(Separate for each circuit ) Alarm Bell (DC) 30 Volt DC Alarm Bell (AC) 230 Volt AC Cable glands with dummy cover suitable for 2. TCH coil-2 e. Ampere meter selector switch Hand Reset Master trip Relay separate for each circuit Indicating Lamps a. NOTE: Any other indications or control equipments which are required for proper protection/ operation of circuit breaker should be provided in control panel.16. platinum or other better materials and shall be suitable for efficient and reliable operation of protection scheme. 13. Pre close Trip Circuit check coil-1 d.15. In brief.mm size flush pattern CT operated 5 Amp Accuracy class 1.15.5 sq.mm Unarmored copper control cable fitted on cover plate. TCH coil-1 d.15. shall be capable of breaking the maximum current which shall not be affected by vibration or by external magnetic fields. The DC fail alarm shall be indicated by a common audible AC bell for each of the multi circuit panel 13. 3 pin-5 A power socket with On/Off Switch. Auto trip f. CB-OFF (GREEN) c.15. Pre close Trip Circuit check coil-2 E Auto trip f. but it should be possible to check the trip circuit condition before closing the circuit breaker. Such indication is also necessary when the breaker is off.II III c. The contacts shall be of silver. Operating Time plug setting Pistol grip Circuit Breaker Control switch T-N-C Digital Ammeter of 96X96. for 8 core 5 nos. 4 All instruments.16. if so desired by the purchaser.2 All relays /auxiliary relay. The marking on the dials shall be restricted to the scale marking. Voltmeter.2 The tests shall include wiring continuity tests.3 The test procedures shall have prior approval of the purchaser. It shall not be possible to operate any relay by hand without opening case. vii) Rinse in deorylyte bath at 70 to 80˚C to neutralize any traces of salts. 13. 13. iii) Rinse in cold water in two tanks to remove traces of acids. They shall have long clearly divided and indelibly marked scales of engraved or enameled and the pointers shall be of clean outline. insulation tests and functional tests to ensure operation of the control scheme and individual equipment. The contactor/auxiliary relay will get energized through the self reset alarm contacts of protective relay and will remain actuated by its own seal-in contact. wired.17. Each indicator. The uniform phosphate coating of 4 to 5 gms per sq. rinse with cold water thoroughly. iv) Treat with phosphoric acid base neutralizer. v) PHOSPHATING :Immerse in grenadine Zinc phosphate solution for about 20 minutes at 80 to 90 degree centigrade. 16.17. All indicating instruments.22 PRE-TREATMENT AND PAINTING PROCESS:The Control Panel sheet steel shall be subjected to pre-treatment process before painting. 16. Further. prior to dispatch of the equipment from the works. 18.20 TEST WITNESSING:The routine/ acceptance tests results shall be witnessed by purchaser’s representative.17.2 The bidders shall arrange to furnish type test certificate for Ammeter and Voltmeter and all relays along with the bid. meter shall be achieved. for removal of chlorine from the above acid pickling and again wash with running water.0 accuracy. which are connected to complete the tripping circuit of the breaker coil. 13. meters and relays shall be tested and calibrated in accordance with relevant standards. shall be capable of being reset by hand. . The offered alarm scheme shall be complete in all respects including one DC bell for trip alarm with a contactor/ auxiliary relay suitable to handle breaking of DC bell current. (A) METAL TREATMENT:i) DEGREASING :This can be achieved either by immersing in hot alkaline degreasing bath or in hot di-chloro-ethelene solution.4 The numerical Over current and earth fault relays shall have inverse definite minimum time limit having programmable characteristics as per above requirements. shall be provided with approved flag indication.19 TEST CERTIFICATE:Each control & relay panel should be tested by the manufacturer at their works for all routine and acceptance tests and copies of test certificate in duplicate giving results of these tests shall be furnished to the purchaser along with letter / offer for inspection. In case degreasing is done by alkaline bath. Each indicator shall be so designed that it can not move before the relay has completed its operation. The procedure can broadly be divided as “Metal treatment” and “painting”. 18. prior to dispatch. vi) Swill in cold water. The supplier shall give at least Fifteen (15) days advance notice of the date when the tests are to be carried out. 13. A push button shall be provided to accept alarm by breaking the seal in contact. Relays and Control Switch shall be produced at the time of inspection and shall be enclosed with the inspection report. It may also be noted that they should organize services of their engineer at any site if any problem is reported either by the purchaser or field units.21 TEST CERTIFICATE OF COMPONENTS:Test certificate for important components like Ammeter.3 It may be carefully noted by the Bidder that automatic tripping of the circuit breaker due to operation of protective relay shall be indicated by audible alarm. 13. 13. shall be provided with non-reflecting glass type fronts. 18. without opening the relay case. The design of pointers and scales shall be got approved. All indicating instruments shall be of class 1.1 All indicating instruments shall conform to IS-1248 and shall be of type and sizes specified in GTP. 13. adjusted and tested at the factory. these relays shall have self reset contacts with hand reset flag arrangement.17.3 All relays shall be so arranged that on opening the case it shall be impossible for any dust which may have collected in or upon the case to fall on the relay mechanism.18 TESTS:18. viii) Seal the above phosphate coating with hot dilute chromate solution. They shall be capable of carrying their full load currents continuously without heating. The process shall be carried out as under. which whenever possible shall be mechanically operated type.0 INSTRUMENTS:13. The relay rating shall be 5 Amps. 13. whether of the electrically or mechanically operated type. ii) PICKLING :This is to remove rust and metal scales by immersing in diluted sulphuric acid (approximately 20%) at nearly 80 degree centigrade until scale and rust are totally removed. Indicators shall also be provided on such additional relay elements as it will enable identification the type & phase of fault condition to be identified.1 Each control panel shall be completely assembled. Apply putty several times to get the perfectly smooth finish.Spray second coat of primer as per (i) above or grey primer surface on wet and stove for 30 to 40 minutes at 150 degree centigrade. vi) Surfacing:. of completion of metal treatment. However. iv) Primer:. “High Luster” Zinc chromate primer and stove at 150 to 160 degree centigrade for 25 to 30 minutes. v) Finish Paint: . iii) Surfacing:.Rub down dry and spray first coat of synthetic enamel finish paint on wet and stove for 30 minutes. ii) Rubbing and putting: . if any.Sand down with mechanical abrasive and stove for 20 minutes.ix) Dry with compressed air. NOTE:i) Necessary stiffeners may be welded between large cut outs to provide rigidity before painting process. iii) Small coating shall be supplied along with equipment for touching up at site. Alternatively.Sand down or rub dry to prepare for final finish. Spray 2 coats of synthetic enamel finish paint on wet and stove it at 150 degree centigrade for 30 minutes. ii) Painting process shall be done within 24 Hrs.Apply putty to fill up the scar. former process is preferred. . to present smooth surface and stove 15 to 20 minutes. (B) PAINTING:Sequence of process shall be as follows: i) Spray one coat on wet surface by specially developed. Red-Oxide primer with zinc chromate content may be used. 5 sq.mm stranded copper for CT. Make ii. RedPositive. PT circuits & control circuits (2. Model no. Type. PT circuits & 1.Y. 19 20 . 5A. Type & Rating of Terminal Connector for CT/PT circuits (disconnectable type) Make. No 1 2 3 Provisions Dimension H x D x W (1475 X 300 X 600 mm) Thickness of steel sheet in mm (minimum 2mm) Arrangement of rear door(Provision of turn twist locks at top & bottom with handle) Interior illumination (CFL with protective cage & On/Off switch) Provision of detachable Gland Plate (4mm thick at 200 mm above base of the panel) Make.SCHEDULE-III GUARANTEED TECHNICAL PARTICULARS OF MULTI CIRCUIT 11 KV FEEDER CONTROL & RELAY PANELS Particulars Sr.mm for other circuits ) Wiring colour codes for R. B Phase & Black Neutral (AC).5 sq. 0 to125 or 250V Make & Rating of Ammeter Selector switch (current rating shall not be less than 15A) 4 5 6 7 8 9 10 11 12 13 14 15 17 18 Type & thickness of gaskets provided in the rear door & cable gland plate Make. Type & Rating of Breaker controls switch IDMT O/C and E/F Relays:Feeder Control (numerical) with high set i. scale of Ammeter (96 Sq. Grey. yellow-Negative(DC).control circuit Instruments identification (labels to be provided) CT/PT/AC/DC/ Circuit Identification (labels to be provided) Final outside finish (Opaline green color) Inside finish(Egg shell white) Make.mm. Type & rating of Terminal Connectors for control circuits (Non-disconnecting type) Provision of Spare terminal connectors (20%extra) Size of conductor used for Wiring of CT. Flush Mounting Type Dual Range. Green-Earthing. No iii. Rating of HRC Fuses & Total nos. Rating) Type of wire termination to terminal blocks & instruments (Crimp tag/lugs termination) Provision of Plastic Channels with sliding covers for wiring Provision of Spare Plastic channels with sliding cover Ferruling of wires at both ends Provision of 3-Pin 5A Socket with On/off switch Provision of lifting Eye-Bolts & their size Provision of circuit diagram on rear side of back door of the panel Provision of Pocket with adequate space with transparent cover on top of panel for identification name of feeder / transformer panel. Type. of NO and NC Contacts(Hand/self reset) viii. of PBs. Type & Rating of indicating lamps & Total nos. IDMT Particulars Provisions vi. O/C Setting iv. of fuses (Rating wise) Provision of copper Earthing Bus (25mm x 6 mm x 250 mm)size Provision of Alarm cancellation relay (Give Make.Sr. Provision of engraved rating plate 29 30 31 32 33 34 35 36 . Make. E/F Setting v. Hand or Self Reset Flag 21 23 24 25 26 27 28 Make. Configuration (Horizontal) vii. Total nos. of lamps Make. Type & Rating of Pistol grip breaker control switch Make. Type & Rating of Push Buttons & Total nos. terminals.4 The current transformers shall have the following specification :s.1 SCOPE: This specification covers design. epoxy molded.5.0 14. neoprene or any other improved material shall be used. 14. epoxy molded dry type suitable for the services indicated. 14.2. the ratio and phase angle error shall be maintained within the specified limit applicable for normal loading conditions.5. have suitable mounting holes at the base channel. 14.0 TECHNICAL SPECIFICATION FOR 11 KV OUTDOOR TYPE EPOXY MOULDED DRY CURRENT TRANSFORMERS 14.3 The current transformers shall be sealed properly to eliminate and prevent air. Epoxy Molded Dry type Current Transformers for relaying and metering services in 11 KV solidly grounded system.5.P. GENERAL REQUIREMENT:14. terminal connectors clamps etc.3 Further. For gasketted joints. of cores (with the following accuracies) Core Purpose Rated output Accuracy class 11 KV 11 KV 12 KV 50 cycles Effectively grounded 28/75 KV 250 MVA 13.2 14. testing. 14. 14.5 GENERAL: 14. are required to be designed considering the continuous over loading of 25 percent.14. moisture from entering the tank. manufacturing. III & IV) or IEC-185 with latest amendment thereof. nitrite butyl rubber gaskets. The CTs should be suitable for operation under the climatic conditions. 14.2. when in service. non-ageing electrical silicon laminated steel of low hysterisis loss and high permeability to ensure high accuracy at both normal and over-currents. dry type design and suitable for operation in humid atmospheres and in the tropical direct sun-light with temperature up to 50 degree centigrade. i ii iii iv v vi vii viii ix x xi xii Particulars Nominal system voltage Highest system voltage Frequency Earthing of the system Insulation level Short circuit level Minimum one second short time current rating Minimum creep age distance Rated secondary current Tank sheet thickness CT Ratio No.n. shall not exceed 45 degree centigrade above ambient. 14.1 KA 300 mm 5 Amps Minimum 3mm 200-100/5-5 Amps 300-150/5-5 Amps 2 Core-I Core-II Relaying/ Metering Protection 15 VA 10 VA 10P10 1. 14. II. 14. In any case welding in horizontal plane shall be avoided.4 STANDARDS:The current transformers shall comply with the latest issue of Indian Standard 2705 (Part-I. single phase. complete in all respect conforming to the modern practices of design and manufacturing. Thickness of steel tank sheet shall not be less than 3 mm. Welded joints have to be minimized.1 11 KV current transformers shall be of outdoor type.5. prevailing in the State of M. the above CTs are required to be mounted on an out door structure in the switchyard.2 The above CTs should be suitable for use in areas subject to heavy lightning storms.1 The 11 KV current transformers shall be outdoor single phase.3 DESIGN: 11 KV CT after providing insulation between core and windings shall be molded in epoxy compound and thereafter shall be housed directly in the tank.2.5. . For 25 percent continuous over loading.2 The core shall be of high grade.5 The primary winding. temperature rise for 125 percent loading shall be within the permissible limits specified in the relevant IS. Further. inspection before dispatch at manufacturers works and delivery of 11 KV Outdoor Single Phase. under continuous full load conditions and exposed to direct rays of sun. whenever used. CTs will therefore.4 The maximum temperature attained by any part of the equipment.2. for clamping it on the structure. 1 The current transformers core to be used for metering and instrumentation shall be of accuracy class specified in Clause 2. separately mounted. 14. nuts and washers shall be brass nickel plated.1 The current transformers shall be single phase.6.3 The rating of the secondary windings shall be 5 Ampere.4 The CTs are required only of outdoor type having fitted with outdoor type porcelain bushings. 14.2 The insulators shall be prepared from wet process porcelain with arrangement for sealing hermetically the metallic tank containing the core and the secondary winding.7. The studs. Copper Cable. 14. (i) ii) a) . 14.4 (xii) above.6. 14. shall be hot dip galvanized conforming to IS: 2633.8. The magnetization curves for these cores shall be furnished along with the drawings of CTs.5 Amps/Sq.2 The exterior of the CT tank shall be thoroughly cleaned.7. In respect of the terminal connector following shall be ensured:All current transformers shall be provided with terminal connectors suitable to receive on Raccoon/Dog AAAC conductors.6.mm. 14.8 INSULATION WITH STAND CHARACTERISTICS:14.8.2 Current transformer cores to be used for protective relaying purposes shall be of accuracy class specified or appropriate class suitable for over current protection. provided on Circuit Breaker’s structure.6. The secondary taps shall be adequately re-enforced to with-stand normal handling.7. free standing type for outdoor installation. 14. The cores shall be designed for a minimum saturation factor of 10 for the highest setting. the secondary terminals shall be provided with short circuiting arrangement.1 Insulation withstand characteristics of 11 KV CTs shall be as per IS:2705 as shown in the table below :Nominal voltage 11 KV (rms) system Highest voltage 12 KV(rms) system Power frequency withstand Voltage (for 1 minute) 28 KV(rms) Lightning Impulse withstand Voltage (for 1 minute) 75 KV (peak) 14. 14.mm. temperature rise.10 TERMINAL CONNECTORS:The terminal connectors required for connection of the current transformer to owner’s equipment/ bus shall be in Bidder/manufacturer’s scope. nuts and fasteners exposed to atmosphere. 14. PVC Insulated 2.3 Change in CT ratio will be obtained by providing tapings in the secondary windings. The outer cover of the secondary terminal box shall have proper arrangement of sealing. 14. 14.5 sq. The terminal connector shall also meet the following requirements :Terminal connectors shall be manufactured & tested as per IS: 5561. Terminal connectors shall be tested for short circuit current capability.14. All steel bolts.4 Secondary terminal studs shall be provided with at least three nuts and adequate plain and spring washers for fixing the leads. The terminals of primary and secondary winding shall be clearly marked according to relevant standards. without damage. The minimum outside diameter of the studs should not be less than 6 mm.3 The primary terminals of current transformer shall be of non-ferrous corrosion-proof material and shall be provided with suitable terminals connectors to receive ACSR Dog Conductors. The CTs will be dead tank design and live tank design CTs are not acceptable. 14. The terminal connector shall be suitable for DOG AAAC Conductor.8. Compound filled CTs are not acceptable.7. The length of at least 15 mm shall be available on the stud for inserting the leads.6. scraped and giving a primary coat and two coats of durable oil and weather resisting enamel paint or hot dip galvanized. For secondary connections. The terminal connector shall be conforms to latest version of IS: 5561 or equivalent International Standard. multi core. cable glands suitable for 4 core 1100 Volt grade. 14. while the primary will have only one winding.6 WINDINGS: 14. The primary winding shall be designed considering current density not exceeding 1. Further.9 TYPE OF MOUNTING: The CTs shall be mounted on CT bracket.7 INSULATION:14. The dimension of terminal box and its opening shall be adequate to enable easy access and working space with use of normal tools.5 The CT secondary terminals shall be brought out to a suitable weather proof sheet metal terminal box for termination of multi core cables. threaded studs terminal shall be provided and brought out in a compartment on side of current transformer for easy access. The saturation factor of this core shall be low enough not to cause any damage to measuring instruments in the event of maximum short circuit current.8. The terminal box shall be provided with two nos. Clamps shall be designed adequately to take care of any bimetallic effect. bolts & washers used in the current path shall be stainless steel. d) High voltage Power Frequency wet withstand voltage tests e) Determination of errors according to the requirements of the appropriate accuracy class. The conductor shall be tightened by at least four bolts. All sharp edges and corners shall be blurred and rounded off. at both the sides. The terminal connectors should be made of A6 Aluminum Alloy and manufactured by gravity diecasting process only. b) Temperature rise test. Further. Type test certificates of CT with type tested drawings duly sealed and signed by the Testing Authority should be submitted within twenty eight days of the date of Notification of the Award. (B) ROUTINE TESTS:Each CT shall be subjected to following routine tests as per Indian Standard 2705 at the manufacturer works and test reports in duplicate giving results of these tests shall be submitted for the Employer’s approval before dispatch of the equipment. b) Dynamic Rating: Peak value of the rated dynamic current which CT can withstand without being damaged electrically or mechanically with the secondary winding short circuited shall not be less than 2. Size of terminal connector for which the clamp is designed and also rated current under site conditions shall be embossed/ punched on each part of clamps. All insulators of identical ratings shall be inter-changeable. if so desired by the Employer. The type tested insulators shall be provided in the CT. so that heating of clamp by throttling action of current may be avoided. The portion of clamp to hold the conductor should be flat and straight and not zigzag in construction. The surface of clamps to be tightened by the bolts should be flat in shape.12 BUSHING: Basic insulation level of the bushing shall be as specified and porcelain shall be homogenous and free from cavities and other flaws.13 (I) Short time current ratings:Out door type CTs shall comply with the following requirements in respect of short time current ratings:a) Thermal Ratings: Short time thermal current rating assigned to the CTs for the rated time of 1 second shall be 13. 14.5 times the rated short time thermal current. Space of at least 50% of diameter of nuts should be available after hole at both the sides of conductor holding portion for better mechanical strength. This shall be so designed as to have ample insulation and mechanical strength. Further. 14.b) c) d) e) f) g) h) i) j) k) l) All castings shall be free from blow holes. at a rated frequency and at a rated burden. c) Lightning Impulse Voltage withstand test.5 times that of the primary winding. a) Short time current tests. the primary studs shall be so designed as to have current carrying capacity of at least 1.150/5-5 Amps CTs. surface blisters. 14.1 KA. Minimum size of stud should be 12 mm for 200-100/5-5 Amps and 16mm for 300. MS flat. The nuts. prior to dispatch of the CTs:- . any type of groove in the clamp body for fixing of nuts should be avoided. Sand die-casted connectors are not acceptable. shall not exceed 45˚C above ambient. Minimum 2 nuts with a check nut and washer should be provided on upper side of stud. All current carrying parts shall be designed and manufactured to have minimum contact resistance. except hardware. Conductor hold length must not be less than 60 mm.14 (A) TYPE TEST:CTs shall be fully type tested for the following tests as per IS-2705/1992 with latest amendment thereof from independent NABL accredited Laboratory. cracks and cavities.so that it may be possible to open the nuts and bolts by normal spanners. No part shall be less than 12 mm thick. Each CT shall be provided with two separate terminals for bolted connection to 50x8 mm. above test results shall be witnessed at the manufacturer works.11 STUDS: Length of the primary studs available for clamping terminals shall not be less than 50 mm. Therefore. TESTS: (II) 14. Temperature Rise Temperature rise of the CTs of outdoor type when carrying a primary current equal to continuous thermal current. TESTS. The bimetallic strips/ sleeve liner of minimum thickness of 2 mm shall be cast integral with Aluminum body. GUARANTEED TECHNICAL PARTICULARS OF 11 KV CURRENT TRANSFORMRS S.16 RATING PLATE: CT shall be provided with a rating plate with dimensions and marking as per the latest version of IS:2705/IEC-185.15 In case of any change in design/ type of CT already type tested. windings Over-Voltage inter-turn test Determination of errors according to the requirements of the appropriate accuracy class Partial discharge test 14. This rating plate shall also contain the Employer’s order no. & date. 14.a) b) c) d) e) f) Verification of terminal markings and polarity Power frequency dry withstand tests on primary windings Power frequency dry withstand tests on sec. Particulars 11 KV 1 Manufacturer’s manufacturing name & place of 2 3 4 5 6 Manufacturer’s type designation of CT Rated Voltage (KV) Rated Primary Current (Amps) Rated Secondary Current (Amp) Short time thermal current for 1 sec. Marking shall be punched/ engraved and not painted. (KA) Rated Dynamic Current (KAp) Frequency (Hz) Insulation level (KV/KVp) Number of cores Epoxy composition (i) Resin:(a) Make (b) Type I Ratio. are offered against this specification. process of making (Hot or Cold) (ii) Filler:(a) Make (b) Type I Ratio process of making (Hot or Cold) 7 8 9 10 11 . the Employer reserves the right to demand repetition of some or all the tests without any extra cost at NABL accredited Laboratory.N. month & year of dispatch. of primary turns/cross section Winding material:(i) Primary (ii) Secondary 17 Rated continuous current .(iii) Hardener:(a) Make (b) Type I Ratio process of making (Hot or Cold) 12 13 Weight of CT after epoxy molding (A) Metering Core:(i) Rated Burden (ii) Class of accuracy (iii) ISF (B) Protection Core :(i) Rated Burden (ii) Class of accuracy (iii) ALF (iv) Knee point voltage(Min) (v) Secondary limiting EMF (a) Lower Ratio (b) Higher Ratio (vi) Composite error (a) Lower Ratio (b) Higher Ratio (vii) Exciting current (A) (a) Lower Ratio (b) Higher Ratio (viii) Secondary Winding resistance at 75 ºC (a) Lower Ratio (b) Higher Ratio 14 No. of secondary turns/cross section 15 16 No. with latest amendment thereto: Indian Standard specification IS 2705: 1992 IS: 3156:1992 IS: 335:1983 IS: 2099:1986 IS:5561 IS:4201 Title 15. STANDARDS: The 11 KV oil immersed CT: PT (metering equipment) Unit and the associated accessories shall conform in all respect to the following relevant standard specification.Ts conforming to IS-2705: 1992 and 1 no three phase PT conforming to IS: 3156:1992.4% and voltage fluctuation of + 9% / -13. Size of Primary and Secondary studs Make of HV bushing & its creep age distance 25 26 27 15. of oil used Dimensions of CT:(a) Length (b) Width (c) Height N.1 TECHNICAL SPECIFICATION OF 11KV OIL IMMERSED CT/PT (METERING EQUIPMENT) UNITS SCOPE: This specification covers design. engineering.0 15. 15.A.18 19 Class of insulation Thickness of sheet steel enclosure of CT Total weight of CT with enclosure Weight/Qty. testing and inspection before dispatch and delivery. 20 21 22 23 24 Size of base channel Vertical height between bottom of the terminal to the base of the mounting plate Provision of 2 nos. 11 KV ME units shall be suitable for 50 Hz frequency & for service under the system conditions having frequency fluctuations of +/.5%.2 The specification covers Oil immersed naturally Air cooled (type ONAN) outdoor type 11 KV metering equipment (ME) units which shall comprise 3 nos C. Bimetallic Terminal connector suitable for AAAC Dog conductor.3 Specification for Current Transformer Specification for Voltage Transformers Specification of Transformers Oil Specification for bushing for AC voltage above 1 KV Specification for terminal connector Application guide for current Transformer . manufacture. 5%. 11 KV CT/ PT (metering equipment) Unit shall be required to operate satisfactorily and continuously under the following tropical climatic conditions: (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) Maximum ambient air temperature Maximum ambient air temperature in shed Maximum temperature attainable by the ME exposed to sun Minimum ambient temperature Average daily ambient air temperature Maximum relative humidity Number of months of tropical monsoon condition Maximum altitude above mean sea level Average annual rain fall Maximum wind pressure Isoceraunic level (days per year) Seismic level (horizontal accn. 15. cold.) Permitted noise level 50 C 45 C 85 C (-) 5 C 40 C 95% 4 months 1000 m 150 cms 150 kg/sq.P.5 PRINCIPAL PARAMETERS: 11 KV combined CT/PT (ME) units shall be suitable for 50 Hz frequency & for service under the system conditions having frequency fluctuations of +/.db o o o o o All the parts & surface. 5. 1. 6. which are subject to corrosion shall either be made of such material or shall be provided with such protective finish. tropical and dusty climate and solar radiation typically existing in the State of M. 3. 2.15. which provides protection from any injurious effect of humidity. CT/ PT (metering equipment) units shall be hermetically sealed and suitable for service under the system conditions as per following specific parameters: Sl.m 50 0. 4.30 g 45.4 CLIMATIC SERVICE CONDITIONS: The 11 KV oil immersed CT/ PT (metering equipment) unit to be supplied against this specification should be capable of performing and maintaining required accuracy under extreme hot. No. Solidly grounded .4% and voltage fluctuation of + 9% / -13. Parameters Particulars Type of installation System frequency Normal System Voltage Highest System Voltage for substantially long period System voltage fluctuations System earthing Outdoor 50 Hz ±4% 11KV 12KV + 9% & -13.5%. 15. Normal current density shall not be more than 1. . The 11 KV metering unit should be suitably designed for with-standing the unbalanced voltages developed due to single phasing operation during load regulatory measures in 11KV distribution system.. three phase PT conforming to IS-3156: 1992 and should not exceed the ratio error and phase replacement as prescribed therein. spring washer & check nut suitable for Rabbit AAAC conductor. The primary winding has to be designed for unearthed neutral for the highest system voltage i. if any. On secondary side of PT four terminals shall be marked as r. magnetic characteristic and consequential mechanical inter-play of forces. b and n.Min 5 mm for top cover and bottom . PT ratio ii iii iv VA burden per phase Class of accuracy Power Frequency withstand voltage 11KV/√3 110V/√3 30 VA 0.7. in primary winding of the CT.Min 3mm for tank sides 6 nos to be provided 3 4 v Lightning impulse with stand voltage vi Winding connection Maximum attainable winding temperature a Minimum phase to phase distance b Shortest distance between metal part & earth c Creep age distance of HV bushing Gauge of the MS tank Bi-metallic terminal connector with a nut.24 sq. 5 6 15.7. plain washer. PT winding should have uniform insulation throughout from terminal to neutral end. no.15. It should be capable of withstanding the disturbance of back e. No PT fuses are to be provided either on primary side or on secondary side.2 Primary of PTs shall be 3 phase star connected with HV side neutral floating. 1 2 A As per schedule I(B) 300-150/5A 0.1 11 KV combined metering equipment unit shall comprise of 3 nos.6 TECHNICAL REQUIRMENT: The 11 KV oil immersed combined CT:PT (metering equipment) units shall conform to the following specific parameters Particulars Requirement Frequency. The CT secondary winding shall be suitable for transformer oil filled equipment.mm.mm.5 10 VA 28 KV(rms) 75 KV (peak) 13. CTs conforming to IS-2705: 1992 and should not exceed the current ratio error and phase displacement error as prescribed therein and 1 no.7.4 Conductor in secondary winding of the CT shall not be less than of 14 SWG/3. if any. and not the graded insulation.m. Secondary winding of PT should be three phase star connected with neutral brought out.5 Amps/ sq. 15. 50 HZ S. 12 KV for 11 KV.7.f. y. under such single phasing.5 28 KV (rms) 75 KV peak Star/ Star 85° C 255mm 190 mm 300mm (Min) . The oil characteristics shall be conforming to IS-335: 1983 & with latest amendments and upgrade.3 15. Specification of CT and PT of Metering Unit Current Transformer i CT Ratio ii Dual CT ratio for Energy Audit iii Accuracy Class iv VA burden v Power Frequency withstand voltage vi vii Lightning impulse with stand voltage Short time thermal current rating in KA. B Potential Transformer (VT) i.e.1 KA for 2 Sec for dual ratio. 7.5 Primary winding shall be of adequate cross section to carry continuously rated current plus 20% overload.15. . the secondary box may be provided on side wall of the tank with side cover. having oil level gauge.4 ME shall be supplied complete with duly filled transformer oil conforming to IS:335–1982 with latest amendment thereof.8. 15.8. Fixing of conservator on the top cover of metering unit shall be such as to avoid collection of air pockets inside tank. bushings on incoming and 3 nos.8. Ratio changing arrangement (for dual ratio ME only) should be provided on secondary side. 15. ME shall be hermetically sealed and shall be provided with a oil conservator.11 Metering equipment shall have a built-in secondary terminal box.10 Insulating materials for winding between HV & LV between interlayer of the winding and for end turn shall be as per relevant ISS. The quality of gasket should be selected keeping in mind the ambient temperature of 50ºC. Minimum electrical clearance between phases and phase to earth shall be provided as specified in relevant ISS.7 15.1 TANK Metering equipments shall be contained in a weather proof out door double pole mounting type M.8. end turns have to be provided with enhanced insulation and lead connecting bushing shall be provided extra insulation of fiber glass sleeve.8.5 Kg/sq. Secondary terminal box cover should have 8 nos. if any. 15. A pressure release safety device suitable for operation at a pressure of 0. Normally minimum 3% quantity of the total oil shall be contained in the conservator.mm armored copper cable shall be supplied with ME.8. Metallic cable gland to suit 12 core 2.5 15. Total volume of conservator shall be such as to contain 10% quantity of the oil. Gasket shall be fitted in properly machined groove with adequate space for accommodating the gasket under compression.8 Kg/sq. It should be ensured that the quality of gaskets used between the joints and also for mounting of oil level indicator will be of best quality to avoid leakage of oil.8. holes should be provided on the cover & flange of secondary terminal box at the corners & middle of each face for fixing nut bolts.cm. (mains side & load side).8. 15.4 to 0.2 3 nos.8 15. The volume above the oil level in the conservator tank shall be filled with Nitrogen gas conforming to commercial grade as per IS:1747:72. Oil in the ME shall be filled under vacuum. nuts & bolts with hole for sealing arrangement. with M and L marking embossed on the top cover of MS tank to identify incoming and outgoing terminals of the metering unit. 15. gland & check nut. Pressure of Nitrogen gas.8. For gasketed joints. ME shall be fitted on HV side with outdoor type porcelain bushings of appropriate voltage & current and shall conform to IS:2099:1986.8.15. For this. shall be provided. 15. shall be provided at the top of the conservator tank An explosion vent diaphragm shall be provided opposite side of the ME secondary terminal box which should operate at a pressure of 0. wherever used. The dimensions and electrical characteristics of the bushing shall be in accordance with relevant ISS and its subsequent amendments. pressure release device and explosion vent diaphragm shall be properly coordinated.8.631-IS-5 on all external surfaces. Entry of cable into the box on the dual ratio metering unit shall be through one no.8. tank with 6 nos.6 to 0. The end turns insulation of PT HV winding towards bushing side should be appropriately enhanced. .12 For Dual ratio MEs.9 15. of adequate size to facilitate expansion/contraction of oil due to change in temperature. nitrite butyl rubber gaskets/neoprene or any other improved material shall be used. of 11 KV weather proof bushings with brass studs as per rating of combined CT: PT (metering equipment) units.6 15.8. sealing arrangement shall be such that oil should not leak out from the bushing/ME tank. bushings on outgoing terminals i. Test certificate of oil being used shall be provided at the time of inspection.e.5 Sq.cm. The Bidder/manufacturer has to produce the test/calibration certificate for proper operation of the device at the defined pressure.13 Top cover flange of metering unit should be provided with holes for proper sealing arrangement at all four corners of the tank and cover.8 15.3 Tank should be given three coats of rust preventing paint and finished with light grey No. Oil drain valve or sampling cock or non return type oil filling valve provided to facilitate factory processing shall be sealed before dispatch of MEs. The internal surface of the tank shall be painted with two coats of a suitable oilinsoluble paint. However. 8 nos. 15. Top of the tank will have slope to drain the rainwater.S. Further. of metering unit. four terminals shall be marked as r. The tank shall be reinforced by welded angle of size 25 x 25 x 3mm on the entire outside wall on the edge of the tank to form two equal compartments. Power frequency dry withstand test on secondary winding of CT and PT of metering unit. All sharp edges should be rounded off. b. All joints of the tank and fitting shall be oil tight. d. 15. f.e. month and year of dispatch etc. In respect of terminal connectors following should be ensured. & date. ERDA or any other NABL accredited lab. a. On secondary side of PT. 15.14 Metering unit shall be provided with non-detachable anodized Aluminum name plate showing position of terminals. Welded joints of the metering unit shall be strengthened by providing 25 x 25 x 3mm angle all along the welded length and welded properly inside the tank. lightning impulse test. temperature rise test. type. sr. base mounting channels size 75 x 40 mm across length of metering unit. of unit.15. high voltage power frequency voltage withstand test as per IS2705/1992 and IS-3156/1992 (with latest amendment) from CPRI. (v) Provision of 6 nos. Terminal connector should be made of A6 Aluminum Alloy and manufactured by gravity diecast.2 ROUTINE TEST Each of completely assembled metering unit shall be subjected to the following routine tests at the manufacturer’s works in accordance with the details specified in IS:2705 and IS:3156:- 15. 15. The terminal connector shall conform to the latest version of IS:5561. class of accuracy. Information about gasket material used for the metering unit should be mentioned in the offer.8. rated burden.1 TYPE TEST The design of metering unit shall be type tested for short time current test. Over Voltage inter turn test on CT of metering unit. (iii) 2 Nos. voltage ratio. Earthing: The assembly comprising of chassis. accuracy test. no.2 of IS:3156 (part-I).16 Mounting of the bushing on the metering equipment should be in oblique plane particularly in case of single ratio metering unit. The metering unit shall have the following: (i) Riveted Rating and Diagram plate. CT primary and secondary terminals shall be marked clearly as indicated in Annexure-C of IS: 2705. Determination of errors or other characteristics according to requirements and class of accuracy of CT and PT of combined Metering Equipment. e. Tank shall be of robust construction having thickness of top and bottom sheet of minimum 5mm and all the sides of tank made up of minimum 3 mm sheet. (iv) 2 Nos. frame work and the fixed parts of the metal casing of the combined CT:PT metering equipment shall be provided with two separate earthing terminals in accordance with clause 5. One face of reinforcement angle should be continuous welded with the tank surface such that other side of the angle forms inverted "L".10 a. No part of clamp shall be less than 12 mm thick d. Further. Conductor hold must not be less than 50 mm.15 gaskets used should be of best quality having a thickness of 3 mm or more.8. (ii) 2 Nos. the terminal marked P1 of primary and S1 of secondary in case of current Transformer and correspondingly in case of PT shall have the same polarity at any instant. order no.10. connection diagram along with the information as specified in IS: 2705 and IS: 3156 i.10.8. CT ratio. . b and n. b. cracks and cavities. y. surface blisters. Verification of terminal marking and polarity test of CT and PT of metering unit Power frequency dry withstand test on primary winding of CT and PT of metering unit. MS plate size 125 x 125 mm is got welded on wider side of metering unit for fixing of the nameplate. Bi-metallic clamps suitable for AAAC Rabbit conductor for 11 KV. TESTS: 15. The test certificates should not be more than three years old on the date of opening of tender. earthing terminals with lugs. All castings shall be free from blow holes. 15. c. their marking. welded lifting lugs of MS plate 4 mm thick. Conductor should be tightened by minimum 4 bolts. e.9 Bimetallic strips/sleeves shall be minimum 2 mm thick All nuts/bolts/washers shall be of stainless steel. c. mm Saturation factor Normal current density of primary winding Potential Transformer i Type ii PT ratio iii iv v Rated output VA/phase Class of accuracy Insulation level 5. Pressure test on tank of metering unit at 0. B. 6.f. no 1 2 3 4 A Particulars Nominal System Voltage Highest System Voltage Frequency. h. Insulation Resistance test with 1 KV megger. Induced voltage test on PT of metering unit. Specification of CT & PT of Metering Unit Current Transformer i Type ii Accuracy Class iii Rated output iv Insulation level v vi vii B Short time thermal current rating Requirement 11 KV 12 KV 50 HZ Offered Oil immersed 0. Break down voltage test of transformer oil. A. 7.5 Amps per Sq. GUARANTEED TECHNICAL PARTICULARS OF OUTDOOR OIL IMMERSED 11 KV CT: PT (ME) UNITS.5 28KVrms/ 75 KVpk Star/ Star To be indicated To be indicated To be indicated To be indicated To be indicated 8. j. 10 11 ii Primary winding iii Secondary winding Quantity of oil in KL To be indicated Total weight of complete metering unit To be indicated including all accessories and oil Resistance of primary & secondary winding at 75° C per phase :a CT Winding (i) Primary To be indicated (ii) Secondary To be indicated b PT Winding (i) Primary To be indicated (ii) Secondary To be indicated Maximum attainable winding temperature 85° C 12 a b a 13 Minimum phase to phase distance Shortest distance between metal part & earth Make & type of HT bushing 255mm 190 mm To be indicated .cm. Top. 9.5 10 VA 28KVrms/ 75 KVpk 13.1KA for 2 second To be indicated 1. vi Winding connection vii Rated voltage factor & duration Dimension of MS tank a Height mm b Breadth mm c Length mm Thickness of MS Tank Side walls.8 kg. i./ sq. S. Ratio & phase angle error test of CTs of metering unit. g. Bottom Weight of core and winding Current transformer i Core ii Primary winding iii Secondary winding Potential transformer i Core Oil immersed 11 KV/√3 110V/√3 30 0. b. ii c i. ii.14 15 16 17 18 19 A b Creepage distance of HV bushing 300mm (Min) Bi-metallic terminal connector with nut. 6 nos to be provided plain washer. Cross section area of each turn of CT winding (in sq.) Type of core material To be indicated Size & capacity of conservator tank To be indicated Type & thickness of gasket used on a Top cover tank To be indicated b Secondary terminal box To be indicated c HV bushings To be indicated Type & thickness of explosion vent diaphragm Details of Metering Unit CT details a i. of turns Primary winding Secondary winding Winding material Primary winding Secondary winding To be indicated To be indicated To be indicated To be indicated To be indicated B PT details a Cross Section area of each turn of PT (in sq. ii. mm. ii Secondary winding Number of turns Primary winding Secondary winding Winding materials Primary winding Secondary winding To be indicated To be indicated To be indicated To be indicated To be indicated 20 21 22 Method of identification of i. Primary winding of CT/PT with primary terminals ii Secondary windings of CT/PT with secondary terminals . mm. ii. spring washer & check nut suitable for DOG ACSR Conductor (Dia 14 mm Approx. Primary terminals ii Secondary terminals a CTs b PTs Size and material of i. Primary winding To be indicated ii b i.) i. c. Primary studs jj Secondary studs Method of jumper connection of (Bidders to indicate) i. i. i.) Primary winding To be indicated Secondary winding No. one for each phase. SCOPE: This specification covers design. 2. 1. capable of performing functions of tariff meters for energy audit in sub-transmission system & load survey applications.) Permitted noise level 45 C 60 C (-) 5 C 40 C 95% 4 months 1000 meters 150 cms 200 kg/sq.e. IEC:62053-22 and CBIP report no.1 TECHNICAL REQUIREMENT & DESIGN CRITERION Meters are required for installation in the premises of HT consumers or in sub-stations. Accuracy .m 40 0.db o o o o 3.4 4.0 TECHNICAL SPECIFICATION OF HT TRI VECTOR METER 16.88. o a Maximum ambient air temperature 55 C B C D E F G h I J K L m Maximum ambient air temperature in shade Maximum temperature attainable by the meter exposed to sun Minimum ambient temperature Average daily ambient air temperature Maximum relative humidity Number of months of tropical monsoon condition Maximum altitude above mean sea level Average annual rain fall Maximum wind pressure Isoceraunic level (days per year) Seismic level (horizontal accn. with its latest amendment.5S accuracy and shall meet all the requirements specified in standard specifications IS:14697/1999.5S The meters shall have Non Volatile Memory (NVM) for storage of Billing and Tamper data. manufacturing. Computation of demand shall be on the basis of Real Time Clock of the meter itself.16.0. There shall be no battery back up for retaining data. 5 Amps Meters shall be designed on 3 phase 4 wire measurement principle & should have 3 current & 3 voltages measuring circuit i.30 g 45. The basic system parameters for which these meters will be used shall be as under:Primary voltage Secondary voltage Primary current Secondary current 11KV/√3 (phase to neutral) 110/√3 volts (phase to neutral) 11KV – 100Amp. 4.2 4.3 4. testing and supply of high precision three phase four wire static tri-vector energy meters of accuracy class 0. The meters shall be designed for 5Amps CT Secondary and 200% overloading. STANDARD APPLICABLE : The meters shall be of class 0. 4. . CLIMATIC CONDITIONS : The meter shall be suitable for operating under the following climatic conditions and shall be capable of maintaining desired accuracy under duly hot tropical climates.5S or better.1.5 4.6 The meters shall work satisfactorily in the absence of neutral and shall work even if any two voltage wires are extended to the meter. 7 Meters covered under this specification shall be fully static type with non volatile memory to register various billing parameters and complete with other features as detailed in this specification. It should also be possible to change from (lag+Lead) to lag principle with the help of MRI & BCS.5 Hz to 52. Provision shall be made to seal the optical coupler to ensure proper security.19.17 4. The display Parameters and their Sequence should be as mentioned below:On pressing of Read push button i.47.3 a) DD: MM: YY HH:MM:SS KWh/MWh KWh/MWh .e. billing dates etc. better than this specification and as per relevant IEC/IS shall also be acceptable. if any persist at the meter terminals. frequency 50 Hz) 4.9 4. Meters shall be designed for satisfactory operation with the following supply voltage/frequency variation:Voltage Frequency . The meter constants shall be freeze and it shall not be possible by the manufacturer or the user to alter the meter constants at factory or at site. S = Sa + Sb + Sc 2 2 2 Sa =Pa + Qa 2 2 2 Sb =Pb + Qb 2 2 2 Sc =Pc + Qc S stands for Total apparent power Sa.Meters shall be suitable for measurement of billing parameters with specified accuracy for PF range Zero (lag) – unity – Zero (lead) Computation of apparent energy shall be based on following principle.13 KVAh computation shall be on the basis of power factor lag+lead Principle / lag only principle.19.8 4. Any other design meeting technical specification requirements or features/accuracy etc. The energy & demand shall be displayed in KWH & KVA or MWH & MVA respectively depending on CT and PT ratio.15 4. register and display various parameters as per standards. billing parameters i ii iii iv v LCD segment check Date Time Cumulative active energy import Cumulative active energy export 4.12 4.11 4. Dial multiplying factor for the specified CTs & PTs ratio shall be unity.19. This arrangement can be through an optical coupler or any other suitable device galvanically isolated from meter circuit. 4. Meters shall be suitable for measurement of energy and other billing parameters within the specified limits of errors under balanced and unbalanced loads conditions in a poly phase network.16 4. POWER FACTOR RANGE:.14 4.Ref + 15% to -30% as per standards . the meters shall measure. Sb & Sc stands for apparent power in phase A.6 digits having minimum character height of 10 mm and additionally minimum 3 digits after decimal.1 DISPLAY PARAMETERS The data shall be displayed on LCD display (backlit type).5 Hz (ref. The display shall have ‘ON’ time of at least 10 seconds of each measured value. The display of energy & also demand shall have minimum seven digits with fixed decimal..2 4.4. It should be possible to easily identify the displayed parameters through symbols / legend on the meter display itself. Indications shall be provided on display to show the healthiness of phase voltage and also the status of abnormal electrical connections. The meter shall be programmable by the user for TOD timings. Display parameters shall move forward if button pressed prior to the programmed time for display of each parameter. Provision shall be made to read various billing parameters and also load survey data through a Common Meter Reading instrument.19 4.18 For above voltage and frequency range. The display of the following parameters shall be continuously scrolling one after another through push button.V. B & C P stands for Active energy Q stands for Reactive energy 4.10 4. which shall be clearly visible from distance in 7 segment. ) Instantaneous reactive Power KVAr/MVAr v.) Reactive energy import while KWh import ii. ix.) Instantaneous active Power KW/MW iv.) Billing TOD MD xi. Meter Reading at Power Outage: Provision to read the meter in no power condition shall be made.) Reactive energy export while KWh export v.) Apparent TOD energy registers xiv.) Reactive energy import while KWh export iv.) KVAH cumulative Import/Export v. i.) Billing active TOD energy xiii.) Date DD:MM:YY ii.) Billing main active energy xii.) KVA (RISING DEMAND) Import/Export xvi.) Maximum demand during the month KW/MW Import & Export viii.) Reactive energy export while KWH import x. Reading through MRI shall also be possible in power outage condition. c) 4.20.) Billing active TOD energy xix.) Reactive energy export while KWH export xii.) Billing main apparent energy xiv.4 4.) Billing apparent TOD energy Auto display: i.19.) TOD MD xv.) Time HH:MM:SS iii.) KVA Maximum demand during the month Import/ Export vi.) TOD MD x.) Instantaneous PF vii.) Active TOD energy registers viii.) Billing main apparent energy xx. there shall be three updates of 10 minutes or 5 minutes for 30 minutes or 15 minutes integration .) Reactive energy export while KWh import.vi vii viii ix x xi xii b) Cumulative apparent energy during KWh import Cumulative apparent energy during KWh export Maximum demand during the month Import mode Maximum demand during the month Export mode Cumulative Maximum demand during Import & Export mode separately MD reset counter Tamper Information KVAh/MVAh KVAh/MVAh KVA/MVA KVA/MVA KVA/MVA No.) Phase Voltage KV iii.) Active TOD energy registers xiii.) Billing main active energy xviii. A suitable internal/ external device could be used so that display of readings could be possible at least twice considering that continuous power outage will not be for a period of exceeding 24 Hrs. For sliding window MD.) Tamper information. iii.) Billing apparent TOD energy VIEW PARAMETERS (display/information required through MRI/BCS) i.20 4.) Reactive energy import while KWH import ix.) Reactive energy import while KWH export xi.) Billing TOD MD xvii.1 MAXIMUM DEMAND REGISTRATION Maximum demand computation shall be based on sliding window concept/ block interval concept (user selectable) with integration period of 30 minutes or 15 minutes programmable.) KWH cumulative Import/Export iv.) Instantaneous power factor vii.KVA/MVA vi. The same push button shall be used for display the readings during power outage.) Instantaneous demand KVA/MVA vi.) Frequency Hz viii.) Present demand . of reset Programmable Optional Requirements of display on pressing push button.) Apparent TOD energy register ix.) Power Factor vii.) Phase Current A ii.) All balance parameters of (a) & (b) above. . MD reset. LOW LEVEL RIGHT Set time. This will allow the user to choose whether to use passwords to prevent readings in particular. changes in energy definition. The meter shall record 200 events of aforementioned tampers (occurrence + restoration) along with date and time of occurrence and restoration of each and every event.2 The MD integration cycle shall be on the basis of real time. Period as to when automatic reset of maximum demand is required shall be programmable. Password Security level 1 2 3 Operation READ ONLY OPERATIONS Read only such as Readings. to be selected for design of tamper logics shall be in consultation with the purchaser. date and time of last tamper restore and cumulative number of tampering shall be indicated. Passwords shall be zero for all 3 levels initially. In every case the design shall include provision of updating of cumulative demand register with updating of reset counter.period respectively. the value of voltage. and transactions like change of energy definition.21 a) b) c) d) Along with the information. By default computation shall be based on sliding window concept and integration period should be 15 minutes with 5 minutes update. The event recording shall be compartment-wise roll over type i. three-phase currents and three-phase power factors to elaborate the existing condition during all the type of tamper events. The identification of phase. 4. number of cumulative tampers (any one or two phase’s reversal). Load survey configuration. For computation of maximum demand the internal clock of the meter shall be made use of. The billing parameter at the time of automatic reset of the MD along with one previous record shall be stored and display shall be possible on demand.to indicate number of hours there has been over current beyond the CT ratio limits. password change.The meter shall have the following unique security feature for different levels described below. External magnetic influence – In the event of logging of presence of abnormal magnetic induction with date and time the positive variation of error may be beyond the prescribed limit as prescribed in relevant standard/CBIP-88 report with latest amendments. 2 and 3. 1. Current unbalance . MD reset options.to indicate identification of phase. e) f) g) Over current .to indicate number of hours there has been unbalance of current beyond the prescribed limits. With zero passwords the operations will be available without getting password clearance. change bill dates.20. or to use only the authenticators to validate any data change transactions at levels 2 and 3.e. Load Survey Event Reading. Change of passwords for level 1. Persistence time change. Logics for design of above indicated tamper.The meter should log power down and power up event. are required to be included as in information in the VIEW PARAMETERS.20.3 4. Tamper reset HIGH LEVEL RIGHT Tariff definitions. it shall always maintain record of last 200 events occurred. current. change of tariff for TOD 2. the meter shall also record the instantaneous values of all three-phase voltages. However the real time clock of the meter shall be used only for the purpose of time matching. Give tamper/fraud evidence where it is not possible to be tamper / fraud proof. date and time of first occurrences. time etc. TAMPER DETECTION FEATURES : Missing Potential . Recording may include lock/unlock. Security . Power Fail . Reversal of CT . 4. Provision should also be made for automatic reset of MD at pre-defined period.to indicate loss of potential in any or two phases of potential supply. This means that meter has to record all authenticated transactions performed with it and communicate the recorded data in meter readings. The tamper at (a) above is to be included in the DISPLAY PARAMETERS and information regarding rest of the tampers/unbalance etc. billing date programming. In addition reset of maximum demand shall be possible through a hand held terminal capable of communicating with the meter. tariff. MD IP change etc. tamper reset. load survey configuration. operation which involve change in meter configuration given in BCS scheduling with date and time. . -KWH Import -KWH Export -KVAH Import (KVA While active import) -KVAH Export (KVA While active import) -RKVAH Import While KWH Import(KVAr lag with Active import) -RKVAH Export While KWH Import(KVAr lead with Active import) -RKVAH Import while KWH Export (KVAr lag while Active export) -RKVAH Export while KWH Export(KVAr lead while Active export) It should be possible to retrieve load survey data by hand held meter reading device through the communication port provided on the energy meter.4.25 4. the load survey memory shall be capable of accommodating and storing every 15 minutes data of at least four parameters. The demand and energy consumed shall be recorded separately under energy Import and energy Export periods. Out of the above-indicated parameters included in the load survey capability it shall be possible to select up to four parameters for load survey data. To clarify.29 BILLING POINT REQUIREMENTS: The predefined date and time for registering the billing parameters of active . Supplier has to ensure the blinking optical signal is of weighted pulse and this can be effectively used for verification of accuracy & should also be ensured that the intensity of blinking signal is sufficient for detection by the optical sensor. The accuracy of the built in calendar and clock shall be better than one minute per month. The main control for this change along with proper security password/code should be available on the computer located at the metering office.28 Load Survey Capability: It should be possible to store previous data of at least 31 days x 4 Parameters for interval of 15 minutes or 62 days x 4 parameters for interval of 30 minutes or 62 days x 2 parameters for interval of 15 minutes etc. Sufficient registers shall be provided to record and display the "display parameters” (Billing parameters) i. .e.00 hours of the first day of each calendar (billing) month or any predefined date of the month. TOD Tariff/Demand: The meter shall be capable of registering time of day energy consumption data on stand-alone basis. (depending upon integration period and number of parameters) of energy consumed and also demand i.Programmable time display of each billing parameters.e. Provision shall be made for MD reset push Button with provision to seal it.Programmable time of display cycle. All billing parameters shall be transferred to billing registers .26 4. export & import active and apparent energy and demands for each time zone. apparent energies of import and export along with its supported TOD registers and MD/ TOD MD as well as Tamper Count and Power-On hours readings shall be at 00. The meter shall be provided with an internal time clock and timer both controlled by a quartz crystal with a battery totally independent of power supply and shall be capable of being set into a minimum of 6 time zones in a 24 hour cycle to cover morning and evening peak and off peak periods separately. Meter shall be programmed for auto display of billing parameters with provision of:.). It should be possible to change the time period for these registers through the hand held meterreading device with special authenticated command from the BCS so that only authorized person(s) can make such changes. An operation indicator in the form of blinking optical Signal shall be provided to indicate that the meter is operating satisfactorily. The demand to be recorded in the load survey shall match with the demand recorded in the "DISPLAY PARAMETERS".27 4. 4.23 4. By default the meters shall be programmed and supplied with following parameters:-KVA Import -KVA Export -RKVAH Import While KWH Import (KVAr lag with Active import) -RKVAH Export While KWH Import (KVAr lead with Active import) 4. Load survey based on MD integration period shall be selectable from the following parameters. load survey is needed for the demand and energy consumed in every MD integration time cycle (15 min.reactive. (The meter should be able to record energy consumption up to the specified time of day {as programmed} to help conducting regular energy balance study). or 30 min. The choice of selecting any four parameters out of the parameters indicated above shall be user's selectable. Tamper information shall be roll over type and shall be FIFO based with facility to reset the same through MRI.22 4.24 Provision shall be made for push button to initiate display parameter in the front of the meter. The necessary base computer software (BCS) for this purpose shall be provided by the supplier with complete details. will be monitored remotely through computer installed in central station. apart from instantaneous parameters like voltage. tamper information and instantaneous parameters data shall all be retrievable through the meter's communication port through a common meter reading instrument (CMRI) and shall be transferred (downloaded) to a PC with Windows based software to get complete details in numerical and/or graphic form. and readings of billing parameters. the following additional parameters should be made available at the BCS end: a) MD reset count. The life of the lithium battery for supplying energy to real time clock during no voltage or power off condition should not be less than 10 years. Meters shall be four Quadrant meter capable of recording active reactive and apparent energy and also demand in four quadrants. Meter shall be capable to measure fundamental frequency energy and total energy. It is obligatory on the part of bidder to confirm this requirement and also to submit a type test/test report confirming successful performance 4. PF. It will be obligatory on the part of the bidders to supply the software in adequate copy needed for remote meter reading.The above billing data. In the cases the instantaneous parameters. The other D-port/RJ-11 is exclusively for remote meter reading purpose only. Output Device:. In the forthcoming paragraphs requirement of a D-port/RJ-11 for tele-metering purpose has been described. 4. The meters shall give high-resolution energy values directly to meter reading instrument. The data from meter will be transferred to the central station through GSM/GPRS communication links as such meter should have capability of remote meter reading. A detail of protocol used is necessarily required to be intimated by the supplier to the purchasers.The meters shall have a test out put in the form of a blinking LED for testing of the meters accuracy. Testing shall also be possible through optical port accessible from the front and can be monitored with Meter Reading Instrument having high-resolution display. No separate cost will be borne by the purchaser on this account.31 Necessary software for various programmable features as discussed above in the meter and also necessary software for the IBM compatible computer as described below to obtain various details as discussed above and additional if any shall be provided by the supplier. 4. b) Billing Parameters for last 12 Histories.30 It should be possible to down load view parameters and load survey data on to compatible computer and obtain full details of demand and consumption in statement form and also in graphic form. energy registers. current. In case any proprietary protocol/API is used.5S. 4.. Meters shall have two numbers RS-232 communication port out of which one shall be galvanically isolated type and other D/RJ11 type for collection of data through the meter reading instrument and remote meter reading purpose. load survey data.33 Lithium or any better quality battery of adequate storage energy shall be used for energy supply to real time clock during no voltage or power off condition.32 4. Provision for sealing shall be made for both communication ports. load survey data and tamper information etc. it will be obligatory on the part of the bidders to furnish complete details of proprietary protocol to the purchasers so that there may not be any difficulty in extraction of data from the meter through the available ports when connected to the communication bus (prepared for some other data communication purpose). Communication with meter through this port (D/RJ-11) for programming purpose should not be possible. an indication shall appear on MRI/Laptop/BCS. A specific confirmation that these considerations have been taken care of shall be made by the bidder. The software shall include provision for load survey. TOD register's data. No separate cost towards remote metering reading software will be born by the purchaser. due care shall be taken and it shall be ensured that damage to the meter/meter’s circuitry is not possible by injecting magnetic/electrical charges through these ports. The port for load survey data collection shall be suitable to receive the coupler of MRI and certain changes in the meter configuration as discussed else where in the tender should be possible through this and only this port. While designing these ports. Meters shall be designed to withstand EMI-EMC level in accordance with clauses as mentioned in IEC/IS Standards for Class 0. TOD registers etc.34 . graphic presentation and other reports generation in BCS from the data collected from the meter through meter reading instruments. For the output ports available in the meter standard internationally approved protocol shall be adopted. Further. Under battery weak condition. Meters covered under this tender will be employed for metering at our Sub-stations or in the premises of HT consumers for tariff applications. The resolution will be sufficient to enable conduction of the starting current and accuracy test in less time. C. The software shall be capable of preparing CMRI to read the meter information or time setting of the meter.38 4. Support Display: There shall be "user friendly" approach for viewing meter data for the reading collected now or for the reading collected in the past. This information shall be displayed in the sequence in which it happened in cumulative format as well as summary format.39 4.37 4. maximum demand and their respective TOD register reading. weekly. EDP department of purchaser can generate its own DBF (data base files) to download all the required information into it. d) Location. It shall be possible to retrieve/locate data on the basis of either one of the following particulars: a) Consumer's ID/Numbers. b) Meter Sr. electrostatic discharge. The basic meter shall be designed for overloading up to 200% No setting point / setting register etc.41 BASE COMPUTER APPLICATION SOFTWARE For efficient and speedy recovery of data read through CMRI/HHU. ii. and monthly format. The software shall have the facility to convert all the consolidated information / data of selectable parameters into ASCII format. These energy snap shots shall be possible to view at BCS level. It shall be possible to view this data daily.35 The meter should have provision for testing of meter in the meter testing laboratory or testing of meter at site with the help of ESS and phantom load test set in order to reduce test time high resolution display on MRI should be provided. All the load survey data shall be available in numerical as well as graphical format. of every day and shall be maintained for last 35 day on FIFO basis. Windows based Base computer software shall be supplied.00 Hrs. harmonics. All the information about abnormality events shall be accompanied with date and time stamping along with 'snap-shot' of respective electrical conditions. Platform : The BCS shall be executable on all WINDOWS system. billing register readings shall be shown in a manner which user can easily understand.4. The BCS shall be suitable to run on IBM compatible PC hardware platform. iii. circuits etc. All information about a particular consumer will be sorted out and available at one place so that locating any consumer 's past data is easy.36 4. Current in A. No.40 4. Base computer software shall be supplied having the following specifications as below: The BCS software shall be user friendly. Meter shall operate and record satisfactorily independent of phase sequence of input supply so long as phase association between voltage and current circuits is in order. The load survey graph will show values where the cursor is placed for the selected or for all parameter.C. Midnight energy data: Cumulative energies shall be logged at 00. shall be provided for adjustment of measurement errors. Daily energy snap shot for following energy shall be maintained:(i) (ii) (iii) (iv) Cumulative active energy KWH import/Export Reactive lag while active import Reactive lead while active import Cumulative apparent energy import/Export 4. . external magnetic field and injection of D. Base Computer software shall give all details adequate for analysis and load surveys parameters. Meter Data Display :The software shall show electrical condition existing at the time of reading the meter in tabular forms as well as graphical format (Phase diagram) All the information about energy. The performance of meter should not be affected by the external electromagnetic interference such as electrical discharge of cable and capacitor. c) Date of meter reading. i. viii. Configurability :It shall be possible to have selective printing of all available data of the meter. 5 5.1 CONSTRUCTION OF THE METER Body of the meter shall be designed suitable for projection mounting. to transport and immune to vibration and shocks involved in transportation/handling. Help: The exhaustive online help shall be available with the software so that user can use all the features of the software by just reading the help contents. 4. two (2) seals on the terminal block cover and one seal each on maximum device and communication port shall be provided. 5. tamper evident sticker seals between the base and cover of the meter body. The auto dialing and reading mode shall have enough flexibility to define different groups and their priority orders to read the meter etc. Beside body seal provided by the manufacturer. The configurable of passwords shall be user definable. the field width selection etc. vii.iv. provision shall also be made to provide utility lash wire seals on the body. All insulating material used in the construction of the meter shall be non-hygroscopic non ageing and of tested quality. what data to export. 2 nos. Here again an "Export wizard" or similar utility shall be available whereby user can select file format. Suitability of such a use shall also be confirmed. Meter body cover and base shall be solidly welded (seamless) such that it should not be opened without breaking the meter body. Rear side sealing arrangement will not be preferred. Meters shall be installed in Sub-stations/lines/HT consumer's premises out door inside a metal box. The meter body one sealing screw shall be provided with good quality 7 digits numbered polycarbonate seal or any superior body sealing arrangement with embossing on sides. Print out shall not include anything and everything available with the BCS. vi. The first level shall allow the user to enter the system. All parts that are likely to develop corrosion shall be effectively protected against corrosion. one side with the logo of firm and other side “MPEZ” The nos. .4 SEALING OF THE METER: Proper sealing arrangement shall be provided on the meter to make it tamper proof and avoid mishandling by unauthorised person. The software installed on one PC shall not be copiable on another PC. The meter should be compact and reliable in design e. of the seal shall be unique and should not be repeated in any case. directly under the sun and extreme weather conditions. Remote Meter Reading option: It should be possible to read remote end meter using dial up network/ GSM infrastructure with configurable auto reading mode and manual mode. The meter should be made of high quality raw materials to ensure higher reliability and longer life. v.3 5. BCS shall have facility to export data to ASCII or spreadsheet format for integrating with the purchaser's billing system. The use of the software need not revert back to the supplier of the software for modifying the software just to print what he desires. Access to the working part should not be possible without breaking the seals. Security: The BCS shall have multilevel password for data protection and security. The software shall support "print wizard" whereby user can decide what to print out.42 APPLICATION PROGRAMME INTERFACE (API) The bidder shall provide Application Programme Interface (API) to read their meters and convert the meter data as per IEEMA MIOS standard.g. The polycarbonate seals shall have proper locking to avoid opening of the seal in any case by means of tampering. The different software features shall be protecting by different passwords.2 5. All the seals should be provided on front side only. The Data Transfer :It shall be possible to transfer data to and fro from CMRI through serial interface. The construction of the meter shall be suitable for its purpose in all respects and give stable and consistent performance under all conditions especially during dust storms/heavy rains/very hot days. At least two (2) seals on the body. Supply of API with the meter is mandatory. Meter terminals shall also be marked and should appear in the above diagram. Type and description d.88 shall be carried out on the meter.e.5 TERMINAL BLOCK COVER: The terminal block cover for the meter shall be extended transparent type. 6. Meter constant shall invariably be indicated. & date and month/year of manufacturing shall be printed.All acceptance test as per IS:14697/1999.3 7 ACCEPTANCE TEST:. The bidder should have the necessary minimum testing facilities for carrying out the following tests.The type test certificate for all tests as indicated in relevant standards (with latest amendments) or CBIP report No.88 shall be furnished along with the bid. storage. procurement. Manufacturer’s name and trademark b. In addition this facility should produce Test Reports for each and every Meter.88 and this specification.All routine tests as per IS-14697. IS:14697 /IEC:62053-22 & CBIP report No. the conductor fixing screws and 10mm of the external conductors and their insulation for which the terminal cover shall be of extended type.10 of SCC in Section 8 of the Bid document. PRE DESPATCH INSPECTION: All acceptance tests and inspection of meter/software shall be carried out at the place of manufacturer unless otherwise specially agreed upon by the manufacturer and purchaser. The terminal cover shall enclose the actual terminals.1 TYPE TEST:. Type test report. CONNECTION DIAGRAM & TERMINAL MARKING:The connection diagram of the meter shall be clearly shown on inside portion of terminal cover and should not fade with time. removal and disposal etc. f. Type test certificate from educational institute(s) will not be accepted. 8 GUARANTEE The Defect liability period shall be as mentioned in clause GCC 27. record keeping. Meter shall have a name plate clearly visible.TRACKING SOFTWARE FOR SEALS: It is mandatory to provide Tracking and recording software for all new seals so as to track total movement of seals starting from manufacturing. Name of the owner. The type test certificate shall not be more than 24 months old as on the date of opening of bid. Relevant ISS/IEC No. along with ISI certificate mark. The terminals shall not be accessible without removing the seals of the terminal cover when energy meter is mounted on the meter board.6 5. wherever available. voltage and frequency e. purchase order no. IEC:62053-22 & CBIP report No. Type test certificates from any one of the standard laboratories NABL accredited for particular equipment/test shall only be considered. i) A. installation. Rated current. which can be sealed independently & over the meter cover. IEC:62053-22 & CBIP report No. Serial number c. 9 MINIMUM TESTING FACILITIES: Manufacturer should posses fully computerized Meter Test Bench for carrying out routine and acceptance tests as per relevant ISS. amongst other details. 5. Guarantee Period 5. h. secured against removal & indelibly and distinctly marked with all the essential particulars as per relevant standards i. should contain the following information clearly: Type of meter Class of Accuracy. a. g. Voltage test ii) Insulation Resistance Test iii) Test on limits of errors . ROUTINE TEST:. The Discom’s representative/Engineer attending the above testing will carry out testing as per. series of inspections.2 6.88 shall be carried out on all the meters. free of charge for inspection and testing to satisfy him that the material is being supplied in accordance with this specification.C. The manufacturer shall offer to the inspector representing the purchaser all the reasonable facilities.7 ISI CERTIFICATION MARK: The meters must bear “ISI” certification mark 6 TEST 6. failing which his bid shall be liable for rejection. List of testing equipments available with the bidder for final testing of equipment specified and testplant limitations. Information shall be separately given for individual type of material offered. iii. b. d. The details of testing facilities available for conducting (a) The routine tests and (b) Acceptance tests shall be furnished with tender document. Further. Information and copies of test certificates as in (i) above in respect of bought out accessories.forms and maintaining constant voltage. list of standards according to which the raw materials are tested. names of sub-suppliers for the raw materials. (b) At insertion stage. 10 QUALITY ASSURANCE PLAN: The designed life of the meter shall be minimum 20 years and to prove the designed life.as per MPEZ Specification The manufacturer should have duly calibrated ESS meter of class 0. current and frequency as per the relevant standards.iv) v) vi) vii) viii) ix) x) Test on meter constant Test of starting condition Test of no load condition Repeatability of error test Test of power consumption Vibration test Tamper conditions . The testing rooms shall be temperature and humidity controlled as per relevant standards. The factory shall be completely dust proof. vis-à-vis type. (c) Complete assembled and soldered PCB should undergo functional testing using Automatic Test Equipments (ATEs). . List of areas in manufacturing process. i. The testing and calibrating equipments should be automatic and all test equipment shall have their valid calibration certificates. special acceptance and routine tests specified in the relevant standards and this specification. (ii) Quality control should be ensured at the following stages: (a) At PCB manufacturing stage.1 or higher accuracy. (ii) (iii) (iv) (v) (vi) (vii) 11 MANUFACTURING ACTIVITIES:(i) Meter should be manufactured using SMT components and by deploying automatic SMT pick and place machine and reflow solder process. These limitations shall be very clearly brought out. if any. e. where stage inspections are normally carried out for quality control and details of such tests and inspections. list of tests normally carried out on raw material in presence of bidder’s representative and copies of test certificates. The manufacturer’s laboratory must be well equipped for testing of the meters. wave. Level of automation achieved and list of areas where manual processing exists. During the manufacturing of the meters the following checks shall be carried out. (i) Statement giving list of important raw materials. The Bidder shall invariably furnish the following information along with his bid. lease or sub-contract) of above facilities. Power supplies used in testing equipment shall be distortion free with sinusoidal. c. computerized test bench and the results shall be printed directly without any possibility of human errors. all components should undergo computerized testing for conforming to design parameters and orientation. The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated. ii. the firm shall have at least the following Quality Assurance Plan:- a. the Bidder should own or have assured access (through hire. The meters shall be batch tested on automatic. List of manufacturing facilities available. They must have computerized standard power source and standard equipment calibrated not later than a year (or as per standard practice). each board shall be subjected to computerized bare board testing. Meter frame dimensions. c) The bidder shall furnish details of memory used in the meter. All other details such as general arrangement. Average Power consumption of the modem shall be 3 VA approx under idle condition and 6 VA approx during data transfer. c. 15. shall be furnished by the bidder. TECHNICAL SPECIFICATION OF INTELLIGENT GSM MODEM The overall system setup shall consist of the following: Meter end (consumer premises) – • • • GSM modem (GPRS enabled) with high gain antenna Suitable communication cable between modem and meter External Antenna with cable Central Station end – • • Transparent GSM modem (GPRS enabled) with communication cable and External Antenna Base Computer Software The modem shall be suitable for communication with electronic energy meters to be installed at various feeders. 50 Hz. The system shall be used for remote meter reading of the consumer meters via GSM infrastructure. 13 DRAWING AND TECHNICAL LEAFLETS:Individual meters should contain connection diagram on transparent terminal cover. 14 GENERAL:a) Principle of operation of the meter. 1. The modem should be capable of proper functioning within the power supply range of 77 to 299V AC. b. The packing cases should be marked to indicate the fragile nature of the contents. potential divider as to how they can be considered superior in maintaining ratio and phase angle for variation of influencing quantities during its service period. outlining the methods and stages of computation of various parameters starting from input voltage and current signals including the sampling rate. if applicable. 12 PACKING:Each meter should be shrink packed to avoid any scratches on meter body.(d) Prior to final testing and calibration. (iii) The calibration of meters shall be done in house. The communication and reading shall be enabled with suitable Base Computer Software (BCS). dust from entering etc.1. all meters shall be subjected to aging test (i. The modem shall have an AC input supply of 110V/230V + 30%.1 Power Supply Section Input supply a. should be given in the manual. Two sets of such manuals shall be supplied to each consignee and two sets to this office. After 72 hours meters should work satisfactorily to eliminate infant mortality. The modem shall offer in-built intelligence and high speed data transfer rate or a kind of store–forward facility by which all instantaneous and stored data of the meter is read at regular intervals and stored in modem’s internal memory and forward to remote central station (as configured) for viewing billing and reporting via Base Computer Software. meters will be kept in ovens for 72 hours at 55° temperature and atmospheric humidity under real life condition at its full C load current. Various features of GSM modem (to be installed with electronic energy meter) are described as below: 2. The modem provided with Store and forward facility shall also be capable to transfer the meter data directly from meter to the PC. .e. installation details operation instructions etc. b) The bidder shall indicate the method adopted to transform the voltage and current to the desired low values with explanation on devices used such as CT/shunt.1 2. which shall be supplied to the consignee. and should be packed in a cushion cartoon of 10 meter or any appropriate quantity. Note: Power consumption may vary from site to site depending on signal strength at that particular location. 2. Mechanical Specifications The Mechanical Specifications of the modem shall be as follows: a. Interlocking facility shall be provided under the device cover. The SIM Card shall be of 3V Interface. The RS232 output shall be provided on a 9-pin female connector which can be connected to electronic energy meter’s optical / serial communication port through suitable communication cable. 6.1.2. The antenna should be of minimum 3dbi gain.3 2.1. Above values are typical values. Input terminals: The power supply input shall be through a suitable two core integrated cable coming out from modem box. The modem shall be compliant with ETSI GSM Phase 2+ Standard.e. The GSM modem shall comply with IP50 rating. 2. c.3 2. The modem shall have capability to work under continuous power on condition.1. . Mounting Arrangement: A suitable wall mounting arrangement shall be provided.0 kV.2. b. Electrostatic Discharge IEC61000-4-2 Fast Transient Burst IEC61000-4-4 Surges Immunity IEC61000-4-5 (Under Line to Earth & Line to Line immunity) Conducted Emission CISPR22 (class B) d.2 2. Network Identification Section For determining the health of the device an LED shall be provided on the modem which shall depict the current functioning status (power up/ registered in network/ transmitting data). a SIM Card Holder shall be provided on the GSM motherboard and shall be accessible only by removing the cover of the GSM modem.4 Withstand capacity against surges should be according to Indian conditions i. Class 4 (2W) @ 900 MHz Class 1 (1W) @ 1800/1900 MHz 2. 3. 4.2. Provision shall also be made to connect 14db high gain external yagi antenna to improve poor signal strength. b.2.1 2. RF section A SMA interface shall be provided on the GSM modem to which either a fixed or a wired (with magnetic base) Dual Band Antenna can be connected.2 GSM Section The GSM module shall comply with the following: The modem shall operate in GSM 900/1800/1900 MHz Band. However the data transfer rate for remote meter reading shall depend on meter compatibility. It shall have auto dial feature.2 2. EMI/EMC Specifications The GSM modem shall meet the following EMI/EMC specifications: a.4 The modem shall support Point-to-Point transmission and Cell Broadcast features. Communication Interface A RS232 Serial Link supporting up to 9600 bauds with an auto-bauding option shall be provided. SIM Card Section For placing the SIM Card. modem shall automatically dial to a particular GSM number (number of modem placed at central station end along with BCS server) at specified time (once in a day/week/month) for the purpose of meter reading. Sealing Arrangement: The Top and Base Cover shall have a suitable sealing arrangement so that the GSM SIM Card cannot be tampered with. (e) The feature of event based dialing shall be user configurable. (b) If modem at consumer end could not establish connection to the modem at central station at specified time. d. Outbound Dialing In case the data is required by dialing from the Central station end (Server end).2 6.1 . The mobile number shall be configurable via BCS. The modem shall be housed in an enclosure of ABS Plastic. then priority shall be given to outbound call rather than data collection from meter.3. Functional specifications The modem should be an intelligent device and capable of providing the following functionalities: Inbound dialing (a) The modem should have inbound dialing facility i. Environmental specifications The modem shall meet the following environmental specifications: Temperature: Humidity: 10 degrees to +55 degree 95% RH (non – condensing) 6. Provision of enabling and disabling of the feature shall be provided (a) 6. without waiting for the interrogation from central station (BCS server) and meter data shall be sent to the central station (b) Further. (c) Event based dialing and SMS shall be applicable for the event types (tamper/anomaly) as supported/recorded by the meter (d) When the modem is busy in collecting the data from the meter and the call comes to get the data. (b) User shall have option to get the data directly from the meter or the data already available in the memory of intelligent modem.c.e. This configuration of the modem shall be made available to the user via offered Base Computer Software.1 6. then it shall retry the same as configured. 5. then connection shall be established by the server to the device using AT commands and transparent communication mode shall be established. the modem shall have feature of event based dialing in case of logging of tamper by the meter. Event based dialing (a) Other than regular dialing. the modem shall send an SMS to predefined mobile number and the SMS shall contain meter serial no. the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled. if so considered necessary to ensure that the quality of meters being offered for inspection is same as already got type tested. b) i) Acceptance test On receipt of subsequent consignment of individual DI in Area Stores. may be utilized in the field during the period of testing. The guarantee period of quantity already supplied & used shall be doubled and payment for used meters shall be arranged after deducting 10% cost. purchaser may allow the supplier to re-offer the material after change/ modification in the design of meters. The balance material shall be accepted only after successful Testing. In case of successful type test results. The type test charges shall be borne by the supplier. . In case of repeat failure in acceptance test(s). iv) The purchaser also reserves the right to get additional samples for all or any of the selected tests at purchaser's cost at any independent test house at any stage of supply. supplies shall be continued. However. Repeated failure/poor results in the testing may render cancellation of order. the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled. In case of repeat failure in type test(s). set of meters as per relevant standards shall be selected randomly and sent to CPRI/ERDA for conducting acceptance test as per the prescribed procedure. ii) iii) The supplies. at the option of purchaser. in case the meter(s) do not meet the requirement as per ISS/CBIP/Specification in type test(s).VERIFICATION/TESTING OF MATERIAL SUPPLIED a) Type test In case of order. three (3) samples for Type Test shall be selected & sealed by authorized person of MPPKVVCL from the first lot received in Company’s Area stores. the guarantee period of the quantity already supplied by the supplier shall be doubled and purchaser reserves the right to cancel the balance quantity. The Testing charges shall be borne by the supplier. In case of failure. the similar testing procedure as described shall be repeated on another lot and if the lot fails consecutive second time the entire quantity of respective lot/sub-lot shall be rejected and shall have to be replaced by the supplier at his own cost. three more samples shall be selected from the supplies already received to get them type tested at supplier’s cost. c) In case of failure in type test or acceptance test. The selected samples shall be sent with complete details for type test at CPRI / ERDA / any NABL accredited test house. In case of failure of samples of lot/ sub-lot in the test(s) detailed in ISS. 0. out of which One optical port for load survey facility and another D-type or RJ-11 port for transfer of meter data through modem/RTU.A 1 2 3 Name of manufacturer Type & make Standard Applicable IS:14697/1999. Particulars PART .1% of Ib 9 Power loss at rated frequency & reference temperature (i) Current circuit at rated current per phase (ii) Voltage circuit at rated current per phase (iii) Meter load on PTs As per ISS/ CBIP 88 As per ISS / CBIP 88 As per IEC 62053-22/ CBIP 88 As per IEC 62053-22/ CBIP 88 6 KV AC The meter shall be provided with two output ports.N.GUARANTEED TECHNICAL PARTICULAR FOR TRIVECTOR STATIC (ELECTRONIC) ENERGY METER S. IEC:62053-22. loading(Imax) 0. • 10 11 12 Momentary over voltage Dielectric voltage withstand Communication port .5 sec.5s 110/ √3 (P-N) Secondary 5 Amps 50 Hz ± 5% As per relevant ISS > 200% of Ib 200% of Ib 6 (i) Continuous current rating (Amp) (ii) Running with no load Voltage applied 115% of reference voltage 5 Amps as the case may be No creeping 7 8 Short time over current Starting current (Min) at which meter shall run & continue to run 20 times of Imax for 0. CBIP report 88 with latest amendment Minimum requirement Offered by the Firm 4 5 Model Rating (i) Accuracy class (ii) Rated voltage (iii) Rated current (iv) Rated frequency (v) Power factor range (vi) Minimum saturation current (vii) Shall work within accuracy up to max. Only for real time clock lithium battery backup is required during no voltage or power off condition. .4 of the TS Two One One To provide utility lash wire seals (ii) Sealing of meter cover to Base (iii) Sealing of terminal cover (iv) MD Button (v) communication port (vi) provision shall also be made on the body 17 Performance of meter in tamper condition Should work within specified accuracy as per electrical conditions Meter shall record energy accurately.do . -Meter shall be provided with indication of weak battery condition. 5/3mm Red Should withstand severity level 4 or as per CBIP:88 latest amendment 18 19 20 Reverse phase sequence Size of calibration LED and color Electromagnetic compatibility EMI/EMC severity level) . 14 Type of material used (i) Base High impact strength flame retardant. of Digits display (ii) Character size of display 16 Fixing/ Sealing arrangement (i) Fixing of meter 3 fixing holes (one at top and two at bottom terminal block) As per clause 4.4 x 6 mm 7 segment LCD 6 digits 7 Segment LCD display (High resolution display for the energy shall be provided.do Nickel plated Brass M . UV stabilized polycarbonate/ Engineering plastic. In which minimum three digits after decimal shall be provided additionally) 10x5 mm or better (ii) Terminal block (iii) Meter cover (iv) Terminal cover (v) Screw (v) Screw size 15 Type of display (i) No.do .13 Battery backup -Battery backup is not required for memory. 7. of report No. of Test bench Accuracy of RSS/ESS duly calibrated To be indicated Whether following in-house testing facility available: Insulation resistance Must be available Running on no load -doStarting current Must be available Accuracy requirement -doPower consumption -doRepeatability of error -doVibration test -doTamper condition -doElectromagnetic compatibility -doWhether offered meter type tested as per ISS 14697/199 9 Table-16 for all the following tests (indicate name of laboratory/ Ref. capacitor switching and harmonics etc.4 Name of Lab Type test report no. Ref.7.3 12. i) ii) 2.7.7.2 12. external magnetic field & DC current in AC supply or in neutral.B Manufacturing activity Whether SMT components & technology SMT component & technology used necessary Whether submitted quality assurance Required to submit plan Testing facility Whether fully automatic computerized Must available meter test bench with print out facility available Make & S.6. page no. Effect of accuracy in tamper condition Should work within accuracy as per CBIP 88/ IEC:62053-22 22 Should work within specified accuracy as per standards Please specify 23 Cut off voltage (at which meter stop working) Input voltage & frequency variation within which meter works satisfactory 24 + 15% to -30% of Vref ±5% of reference frequency 25 Relative humidity 95% (some times approaches to saturation) 27° C -5 to 55° C No Drift in accuracy in measurement with time Secured and indelibly marked name plate (rating plate) will be fixed to the meter under display window.6 12. temperature Temperature range of operation Drift in accuracy of measurement with time Fixing arrangement of name plate 29 30 31 Approximate weight of meter Type of body 1.21 Effect on accuracy of external electromagnetic interference of electrical discharge. & dt. To be mentioned Projection type 26 27 28 Rf.No.) Clause of ISS 12.6.6. of offer I) i) ii) iii) II) Test of Insulation properties Impulse voltage test AC high voltage test Insulation test Test of Accuracy Requirement . i) ii) iii) iv) a) b) c) d) e) f) g) h) i) 3. PART . i) ii) iii) iv) v) vi) vii) viii) III) i) ii) iii) iv) IV) i) ii) iii) iv) V) i) ii) iii) VI) i) ii) iii) iv) v) 4. 5. Test on limits of error Interpretation of test results Test of meter constant Test of starting condition Test of no load condition Test of ambient temperature influence Test of repeatability of error Test of influence quantity Test of Electrical Requirement Test for power consumption Test of influence of supply voltage Test of influence short time over current a) Test of influence of self- heating b)Test of influence of heating Test for Electromagnetic compatibility Radio interference measurement Fast transient burst test Test of immunity to electrostatic discharges Test of immunity to electromagnetic HF field Test for climatic influence Dry heat test Cold test Damp heat cyclic test Test for mechanical Requirement Vibration test Shock test Spring hammer test Protection against penetration of dust and water Test of resistance to heat and fire Guaranteed life of meter BIS license No. & dt. with its validity for ISI certification mark on different meter (If available) ISO license No. & dt. with its validity Past experience Order received up to date of submission of offer 110 Volt static trivector meters Qty. supplied up to date of submission of offer (Note - copy of order be enclosed specifically along with its technical specification) Other parameters/features not covered in the above GTP 11.1 12.15 12.14 12.13 12.12 12.11 12.16 12.10 12.7 12.7.1 12.7.2 12.7.3 12.7.4 12.7.5 12.8 12.8.5 12.8.4 12.8.2 12.8.2 12.6 12.6.1 12.6.2 12.6.3 12.3 12.3.2 12.3.1 12.3.3 12.5 12.4 10 years minimum To be mentioned 6. 7. i) a) ii) To be mentioned Ord.No.& dt. Qty. Name of SEB/ Power Utility. To be indicated/ submitted 8. Shall conform to specification of IS14697/1999,IEC:687 & CBIP report No.88 (Revised version with its latest amendment (1) Certified that all the information/parameters indicated above shall exist in the meter offered & shall stood all the tests specified above within the variation of current/voltage frequency and climatic conditions specified therein. Even if any feature or parameter not specifically covered in this GTP, but essential as per the detail specification, is deemed to be covered in the GTP. (2) 17.0 17.1 Copper control cables: SCOPE: Specification calls for design, manufacture, stage testing, inspection and testing before dispatch, packing and delivery of Copper control cables and Aluminum power cables for 33/11 KV substations in the state of Madhya Pradesh. The control and power cables shall be ISI marked, 1.1 KV Grade. The cores shall have a size of 2.5 sq.mm for control cables and 4 sq. mm. power cable, using solid/starnded Copper conductor with different number of cores as specified below:- 17.1.1 COPPER CONTROL CABLES: Unarmoured i) 12 Core 2.5 sq.mm, solid conductor i) 8 Core 2.5 sq.mm., solid conductor. ii) 4 Core 2.5 sq.mm., solid conductor iii) 2 Core 2.5 sq.mm., solid conductor 17.2.1 STANDARDS: The control and power cables shall conform to the latest applicable Indian Standards. In case bidders offer control and power cables conforming to any other International Standards which shall be equivalent or better than IS, the same is acceptable. Standard Ref. No. IS: 1554 Title S. No. 1 PVC insulated (Heavy Duty) Control Cables for working voltage & including 1100 Volts. Recommended current ratings for PVC insulated and PVC sheathed heavy duty cables Methods of random sampling PVC insulation and sheath of electric cables Conductors for insulated electric cables and flexible cords Wooden drums of electric cables Methods of tests for cables 2 IS: 3961 4 5 6 7 8 IS: 4905 IS: 5831 IS: 8130 IS: 10418 IS: 10810 17.2.2 ACCEPTANCE OF OTHER AUTHORITATIVE STANDARDS In above paragraph relevant Indian Standard have been mentioned. However, the cables meeting any other authoritative International Standard which ensures equal or better quality than the standards mentioned, shall also be acceptable. Cables for which Indian Standards are not available, the relevant equivalent International Standards will be applicable. Please attach photocopy of all such standards according to which the cables have been offered. 17.2.3 CLIMATIC CONDITIONS: The Control and Power cables to be supplied against this specification shall be suitable for satisfactory continuous operation under the following tropical conditions :- 1 Location At various substations in the State of Madhya Pradesh 50° C 1° C 40° C 32° C 95% (Sometimes saturation) 1000 Metres 125 cm 150 Kg/Sq. metre 50 approaches 2 3 4 5 6 Maximum ambient air temperature Minimum ambient air temperature Maximum Daily average ambient air temperature Maximum Yearly Weighted average temperature Maximum Relative Humidity 7 8 9 10 Maximum altitude above mean sea level Average Annual Rainfall Maximum Wind Pressure Isoceraunic level (Average Number of thunderstorm days per year) Seismic Level (Horizontal acceleration) 11 0.3 g 17.3 SYSTEM PARTICULARS: Cables offered under this specification shall conform to the parameters given below : S. No. 1 2 Particulars System Voltage Frequency Earthing 50 Hz Effectively Earthed 17.4 GENERAL TECHNICAL REQUIREMENTS AND CONSTRUCTIONAL DETAILS: Cables shall be suitable for laying on racks, in ducts, trenches, conduits and underground buried installation with chances of flooding by water. Cables shall be designed to withstand mechanical, electrical and thermal stresses developed under steady-state and transient operating conditions as specified elsewhere in this specification. 17.5 COPPER CONTROL CABLES: Control cables shall be of 1.1 KV grade, multicore (as specified in Clause 1.3 above), PVC insulated, PVC inner sheathed, unarmoured, PVC outer sheathed with solid copper conductor conforming to latest version of IS: 1554 or equivalent International Standards. 17.6 CONDUCTOR: The conductor shall be made from high conductivity copper rods complying with latest version of IS:613 or equivalent International Standards. The conductor shall consist of annealed copper wires complying with IS: 8130 with latest amendments or equivalent International Standards. 17.7 POWER CABLES: Power cable shall be of 1.1 KV grade, multicore (as specified in Clause 1.3 above), PVC insulated, PVC inner sheathed, PVC outer sheathed with stranded stranded conductor. 17.8 INSULATION: Conductor shall be provided with PVC insulation applied by extrusion in accordance with latest version of IS: 5831 or equivalent International Standards. The average thickness of insulation shall be in accordance with the IS: 1554 (Part-I) with latest amendments or equivalent International Standards. Insulation shall be so applied that it fits closely on the conductor and shall be possible to remove it without damages to the conductor. 17.9 CODE IDENTIFICATION: Colouring of insulation shall identify cores of the cables of upto 5 cores. Following colour schemes shall be adopted:SN 1 2 3 4 5 6 Number of Cores 1 Core 2 Cores 3 Cores 4 Cores 5 Cores 6 Cores and above Colour Scheme Red, Black, Yellow or Blue Red and Black Red, Yellow and Blue Red, Yellow, Black and Blue Red, Yellow, Black, Blue and Grey Two adjacent cores (counting and direction core) in each layer, Blue and Yellow, remaining cores Grey or in accordance with the scheme given in IS: 1554 Clause 10.3 For reduced neutral conductors, the insulation colour shall be Black. Cables having more than 5 cores, as an alternate to the provision of (6) above, core identification may be done by numbers as indicated in latest version of IS: 1554 (PART-I) 10 core identification. 17.10 LAYING UP OF CORES: In multi-core cables, the cores shall be laid up together with a suitable lay, the outer most layer shall have right-hand lay and successive layer shall be laid with opposite lay, where necessary, the interstices shall be filled with non hygroscopic materials. 17.11 INNER SHEATH: The laid up cores shall be provided with inner sheath applied by extrusion. It shall be ensured that the shape be as circular as possible. The inner sheath shall be so applied that it fits closely on the laid up cores and it shall be possible to remove it without damage to the insulation. Thickness of inner sheath shall be conforming to latest version of IS: 1554 (Part-I) or equivalent International Standards. 17.12 FILLER AND INNER SHEATH: Filler and inner sheath shall be of the following: • • • Unvulcanised rubber, or Thermoplastic materials, or Proofed tape (for inner sheath only) Unvulcanised rubber or thermoplastic material used shall not be harder than PVC used for insulation and outer sheath. Material shall be chosen to be compatible with temperature ratings of the cable and shall have no deterious effect on any other component of the cable. 17.13 OUTER SHEATH: The outer sheath shall be applied by extrusion. It shall be applied: • Over the inner sheath in case of unarmoured multicore cables. Outer sheath shall be so applied that it fits closely over insulation / inner sheath / armouring. It shall be possible to remove it without damage to the insulation / inner sheath. The colour of the outer sheath shall be black. Thickness of outer sheath insulation shall conform to latest version of IS: 1554 Part-I or equivalent international standards. 17.14 IDENTIFICATION: In addition to manufacurer’s identification on cable as per clause-17.1 of IS: 1554 (Part-I) with latest amendments, following marking shall also be embossed over outer sheath at every three meters:- • • • Cable size and voltage grade Word “MPPKVVCL” and Name of manufacturer ISI marking and sequential marking by means of embossing The embossing shall be in line throughout the length of the cable and shall be legible and indelible. 17.15 PACKING AND MARKING: Cables shall be supplied in non-returnable drums. The surface of the drum and outer most cable layer shall be covered with waterproof layer. Both the ends of the cables shall be properly sealed with heat shrinkable PVC or rubber caps, secured by ‘U’ nails so as to eliminate ingress of water during transportation storage and erection. Following information should be stenciled on the drum: • • • • • • • • • • • • • Reference to relevant Indian or International Standard. Manufacturer’s name, brand name or trade mark Type of cable and voltage grade Number of cores Nominal cross-sectional area of the conductor Cable code Colour of cores Length of cable on the drum Number of lengths on drum (if more than one) Direction of rotation of drum by means of an arrow Approximate gross weight Running end of cable Country of manufacturer and year of manufacture As mentioned, the cable drum must bear relevant Indian/International Standard certification Mark. In this connection, a certified photostat copy of valid standard marking license rights duly attested must be submitted along with the inspection offer as documentary evidence. In absence of these documents, the inspection offer will not be considered. 17.16 STANDARD DRUM LENGTH: Standard drum length for cable shall be 500/250 metres. 17.17 TOLERANCE: Tolerance on the overall diameter of the Cable shall be ± 2 mm over the declared value in the techanical data sheets of Guaranteed Technical Particulars. Length per drum shall be subjected to maximum tolerance of ± 5% of the standard drum length. The Employer shall have option to reject cable drums with shorter length. Over all tolerance in total quantity for each type and size of cables shall be ± 2%. 17.18 TESTS: All types and sizes of cable being supplied shall be subjected to Type tests, Additional test, Routine tests and Acceptance tests as specified below at the expense of Agency and according to relevant standards. 17.18.1 TYPE TESTS AND ADDITIONAL TESTS: It is essential to furnish all the type test reports for each type and size of cable as stipulated in latest version of IS: 1554 (Part-I) and following Additional Tests: • • • • • Loss of mass test Heat shock test Thermal stability test Accelerated water absorption test Dielectric strength retention test Above tests shall be conducted in NABL approved Testing laboratories only. 17.18.2 ACCEPTANCE TEST Acceptance test shall be caried out on each type and size of cables on cable drumsselected at random as per following plan :S.No. Numbers of Drums in the Tests Number of Drums to be taken as samples 2 5 13 20 32 1 2 3 4 5 Upto 50 Upto 51 to 100 From 101 to 300 From 301 to 500 Above 501 The following shall constitute acceptance tests :• • • • • • • • Annealing Test Conductor Resistance Test Wraping Test Tensile Test Test for Thickness of Insulation and Sheath Tensile Strength and elongation test before ageing and after ageing at break of insulation and sheath High Voltage Test (Water Immersion Test) High Voltage Test at Room Temperature 17.18.3 ROUTINE TESTS: Routine test shall be carried out for each drum of cables of all types and sizes. Following shall constitute routine tests : • • • Conductor Resistance Test Resistance Test High Voltage Test at Room Temperature details of A B 7 8 A B 9 A B C D 10 11 12 A B C 13 14 .(forcables laid direct in ground) from Deg. C Variation in ambient temp. 40ºC and for maximum conductor temperature 70ºC Derating factor for the following Variation in ambient temp. C in steps of Deg. (for cables laid direct in air) from Deg. 1 2 3 4 5 6 Particulars Name of Manufacturer Adress of Manufacturer Standard applicable Rated Voltage Suitable for earthed or unearthed system Permissible voltage & frequency variation for satisfactory operation Voltage Frequency Continuous current rating when laid in air in an ambient temp. C in steps of Deg.COPPER CONTROL CABLE S. C Furnish chart showing derating factor for different spacing of cables considering multicore cables installed in horizontal formation in single row as well as in different tiers under the following methods of laying Cables laid in formed concrete cable trenches with removable covers Cables laid in cable trays Cables laid in ground Cables laid in pipes or ducts Depth of laying for cables laid directly in the ground Depth for variation in thermal resistivity of the soil Current carrying capacity Short Circuit Amps (rms) Duration of short circuit Conductor temperature allowed for Short Circuit Loss tangent at normal Frequency Dielectric constant at normal frequency Provision made/Give make. rating etc.No. rating etc. please confirm Calculated diameter over the stranded cores Thickness Tolerance on thickness Received from (Bidder/manufacturer’s name) Outer sheath details Material Extruded.S. please confirm Calculated diameter under the sheath Thickness Tolerance on thickness Received from (Bidder/manufacturer’s Name) Armour Type of Armour Nominal diameter over the inner sheath Nominal dimension of strip or diameter of round wires Provision made/Give make. details of . 15 A B C D 16 A B C D E F 17 18 A B C D E F 19 A B C D E F 20 A B C Particulars Conductor details Material Nominal cross section area Number and diameter of Wires Received from (Bidder/manufacturer’s name) Insulation details Composition Thickness Tolerance on thickness Approximate diameter of Sheath Specific insulation resistance at 60ºC Received from (Bidder/manufacturer’s name) Colour scheme for identification Innder sheath details Material Extruded.No. Type and size of lettering to be done in Hindi is indicated in the specimen danger notice plates and . danger notice plates in Hindi with the signs of skull and bones is required to be provided on power line supports and other installations. The dimensions of the letters. figures and their respective position shall be as shown in figs. 1 to 4. DIMENSIONS: Two No of Danger Notice Plates as follows are to be installed at each substation: For display at 11 KV installations .35 of Indian Electricity Rules. All lettering shall be centrally spaced. The size of letters in the words in each language and spacing between them shall be so chosen that these are uniformly written in the space earmarked for them. Unless otherwise modified in this specification. Insulation resistance at 20ºC per Km or Volume resistivity at 27ºC & 90ºC Conductor temperature corresponding to maximum continuous current Dearating factor using Class Q cartridge Class Q semi enclosed fuse Test Voltage High Voltage test After immersion test voltage Recommended minimum installation radius Safe pulling force when pulled by pulling eye Cable Drum Dimensions of the Drum Approximate Weight of Drum Maximum length per drum for each size of the cable Net weight of cable (Kg per Km) Provision made/Give make.S.250 x 200 mm For display at 415V installations – 200 x 150 mm The thickness of sheet (plate) should not be less than 2. the Danger Notice Plates shall comply with IS 2551-1982 or the latest version thereof.No. 1956.0 DANGER BOARD: As per provisions of IE Rules 1956. This specification covers danger notice plates to be displayed in accordance with Rule No. rating etc.0mm Corners of the plate shall be rounded off. Reactance at 50 Hz per Km. Capacitance at 50 Hz Per Km. details of 26 27 A B 28 A B 29 30 31 A B C 32 18. D 21 22 23 24 25 Particulars Received from (Bidder/manufacturer’s name) Overall diameter of cable over the outer sheath Conductor resistance at 20ºC per Km. 2 19. Test no. Flat washers and spring washers shall be provided wherever necessary and shall be of positive lock type. Test for resistance to ageing as per cl.6 mm thick or Hot Press Compression Moulded sheets made out of Sheet Moulding Compound confirming to IS 13410 & shall be min. Adequate space has been provided in the specimen danger notice plates for having the lettering in local language for the equivalent of ‘Danger’. however for SMC material screen Print with letters. figures and conventional skull and cross bones in signal red color IS 5-1978 on the front side. ‘11000’ and ‘Volts’. Material should confirm Heat Deflection Temperature min. Visual examination as per IS:2551-1982 2.0 GALVANISED MILD STEEL HEXAGONAL HEAD BOLTS AND NUTS 19. Spring washers shall be electro-galvanized. 19. Shear strength of bolt for 5. per 10. All bolts shall be threaded to take the full depth of the nuts and threaded enough to permit the firm gripping of the component parts but no further. Bolts up to M16 and having length up to 10 times the diameter of the bolt should be manufactured by cold forging and thread rolling process to obtain good and reliable mechanical properties and effective dimensional control.those in English are shown in REC specification.6 19. 2. and square with the shank.5 19.000 nos. All nuts shall fit and tight to the point where shank of the bolt connects to the head.3 19. The length of the bolt shall be such that the threaded portion shall not extend into the place of contact of the component parts. for acceptance test of each lot offered for inspection MARKING: Maker’s name and trade mark and the purchaser’s name shall be marked in such a manner and position on the plates that it does not interfere with the other information. Bolts should be provided with washer face in accordance with IS:1363 (Part – I) to ensure proper bearing. Exposure to flame Self Extinguishing as per IS 4249 & Melting Point as per IS 13360 PRINTING: In case of MS Sheet it should be vitreous enameled white with letters.7 . All bolts and nuts shall have hexagonal heads. Fully threaded bolts shall not be used.1984. SAMPLING: 1 no from 1st lot for Type test and 10 nos. i & ii are to be performed during inspection.4 mm oversize on effective diameter for size up to M16.4 19.16 IS 14772 All the tests are to be considered for Type Testing where as for Acceptance Tests as well as Routine Test only. figures and the conventional skull and cross-bones in signal red colour (refer IS:5-1978) on the front side requires. The Bidder/manufacturer should ensure that nuts should not be over tapped beyond 0.1 All bolts and nuts shall conform to IS: 6639-1972 and shall be galvanized as per IS:1367 (Part 13) & IS: 2629-1985. The rear side of the plate should also be enamled. which must be perfectly straight. Nuts should be double chamfered as per the requirement of IS:1363 (Part – III). Thickness of washers shall conform to IS: 2016-1967. 19. the heads being forged out of solid truly concentric.12 IS 14772 & resistance to rusting as per cl.0 mm thick and of white colour. Dimensional check as per IS:2551-1982 with tolerance of this specs 3. TESTS: The following tests shall be carried out: 1. The Bidder shall furnish bolt schedules giving thickness of components connected the nut and the washer and the length of shank and the threaded portion of bolts and size of holes and any other special details of this nature.170oC as per IS 13411. It shall be ensured that the threaded portion of the bolt protruded not less than 3 mm and not more than 8 mm when fully tightened.6 grade should be 310 MPA minimum as per IS:12427. PROPERTY OF MATERIAL: The plate shall be made from Mild steel sheet of atleast 1. The front side of the plate shall be suitably coated with transparent coating. shear strength.9 19. burns. SPECIFICATION OF FINISHED PRODUCTS: Bolts & Nuts shall be ISI Marked Mild Steel of galvanized Grade “B” and shall be round with hexagonal head. 67 & max. 19. “A”. i. Bolt head and nut shall be chamfered on one face only and other face shall be machined made.10 RAW MATERIALS MS round 16mm / 12mm used shall be tested for quality as per IS:2062 Gr. loose fill etc. For nuts Vicker’s Hardness min.8 are not to be used. ACCEPTANCE TESTS The Bidder/manufacturer shall furnish test certificate from his own/recognized Govt. Tensile strength test on full size (for bolts min. Dimensions of the bolts & nuts and tolerances should conform to IS:1363 with their latest amendments in all respect. 302.11 PRE-DESPATCH INSPECTION AND TEST The contactor shall arrange to carryout acceptance tests in presence of Board’s inspecting officer in his own laboratory. Bolts at the joints shall be so staggered that nuts may be tightened with spanners without fouling. Brielle hardness tests or Rockwell Hardness or Vickers’s Hardness tests for bolts min-114 & max. 400 N/ Sq. eccentricity. in-house. In case testing facilities are not available at his works he will make necessary arrangements for carrying out these tests at a Govt. . taper. The agency should also have proper Quality Assurance system which should be in line with the requirement of this specification and IS –14000 services Quality System standard. Fasteners of grade higher than 8. splits. mm). The bolts & nuts shall be free from forging and threading defects such as cuts. Proof Stress (Min 610 N/Sq. Galvanizing test. Bolts & nuts shall be supplied in well-cleaned conditions and suitably protected against corrosion in individual bags of 50 kgs.mass of zinc 19. other testing facilities etc. 209 or min. The eccentricity and angular errors of various elements shall be within specified limits as per IS:1367-1967 with its latest amendments. 120 & max. Bolts and Nuts shall be manufactured by Hot/Cold forging process neatly and cleanly finished and shall have metric threads as per IS:4218-1967 with its latest amendments.19. The test certificate shall be in respect of the following for all sizes of both bolts & nuts as applicable given below:Dimensional particulars (Sampling in accordance with IS:2614 for both bolts & nuts (tolerance as per drawing). bulging. Mechanical property requirement of tester shall conform to IS:1367 (Part-III)-1979 property class 4. Laboratory giving the results of tests as per IS:1367 (Part-III) –1979 & IS:1367 (Part-VI) -1980 witnessed by the Employer’s representative for each lot under inspection. 220 respectively. 95 or min. it shall not connect aggregate thickness more than three time its diameter. ii.8 To obviate bending stress in bolt.mm and for Nuts. To ensure effective in-process quality control it is essential that the manufacturer should have all the testing facilities for tests like weight of zinc coating.6 for bolts & property class-5 for nuts as per IS:1367 (Part VI) – 1980. Power load test on full size bolts and M-12-51400 N for 15 Sec. which may affect their serviceability. 130 & max. (with Head soundness tests for bolts (no fracture). recognized lab at his own expense(s) and will provide all testing arrangement for Board’s representative to witness the tests. there shall be identification marking of the manufacturer as well as property class “4.iii. MARKINGS On the bolt head. .6”. If possible property class “5” shall be marked on Nuts also. 209. These should conform to the ISS: 1363 Part-1. Min.3-1984 with latest amendment & sampling in accordance with the IS:2614-1969 D M E S B K Pitch of thread Tolerance of nominal length To be indicated by the Bidder/manufacturer To be indicated by the Bidder/manufacturer To be indicated by the Bidder/manufacturer To be indicated by the Bidder/manufacturer To be indicated by the Bidder/manufacturer To be indicated by the Bidder/manufacturer To be indicated by the Bidder/manufacturer Iv a) Tensile strength of bolts (in N/mm. Sq. Min 67. 220 (respectively) Ix X Xi Xii Result of Vickers’s hardness test for nuts Results of yield stress test for Bolts Percentage elongation after fracture Confirm that Bolts and Nuts are ISI marked Min 130 Max 302 To be indicated by the Bidder/manufacturer To be indicated by the Bidder/manufacturer To be indicated by the Bidder/manufacturer .2.) --------------------------400/N mm --------------------------------------------------------------Not applicable -------------------------Min 35300 N Min 95800 N No fracture To be indicated by the Bidder/manufacturer 2 V a) Result of proof load test on bolt b) Result of proof load test on nut Vi Vii Result of head soundness test Confirm that threads are as per IS:4218 1967 (metric threads) Results Brinell/Rockwell/Vicker’s/hardness for bolts of test Viii Min – 114 & Max.Max 95.Sq.GUARANTEED TECHNICAL PARTICULARS of Nut & Bolt No Particulars 16 mm dia 17 mm dia 200 mm 160 mm 140 mm 90 mm 65 mm 40 mm 140 mm 120 mm I Ii Iii Tenderer Name Tenderer Address Dimensional particulars with reference to the enclosed drawing. – 120 & Max.) b) Tensile strength of Nuts (in N/mm. 1 2 3 4 5 6 Size Bolts Nuts Symbol D (Bolt shank diameter) M (Nut thickness) E (Width across concerns) S (Width across flats) B (Length of thread) F (Thickness of bolt head) of & D M E* S* B K Nom Max.2 & 3) OF IS 1984 (Drawing Not to Scale) Sl. IS: 2633-1986 and IS: 4826-1979 with latest amendments. Nom Max.85 18 18 17. S & Pitch are same NOMINAL LENGTH TOLERANCE 20 . for length above 200 mm Earthing Coils shall be fabricated from soft GI Wire Hot Dip Galvanized.3 15 15. Dip Test Shall stand 3 dips of 1 minute and one dip of ½ minute before coiling and 43 dips of 1 minute after coiling as per IS:4826-1979.16 38 44 57 10 12mm dia 12 12. for length between 126 to Length 20. B1 B2 B3 Nom 16mm dia 16 16.7 15.e.7 11.2 10. Nom Max.5 *for Bolts & Nuts both E. Min.57 30 36 49 7. for 200 mm i.e.9 14.90 mm .3 12. Min.1 26. 20.DIMENSIONAL PARTICULARS OF BOLTS & NUTS AS PER IS: 1363 (PART – 1.0 mm 200mm Thread B1 B2 for < 125 mm i. ii) . The Hot Dip galvanized wire shall have clean surface and shall be free FROM paint enamel or any other poor conducting material.1 i) Galvanizing Tests Minimum Mass of Zinc 2 a) ON GI Wire used 280 gm/m 2 b) After Coiling – 266 gm/m .e. for length upto 125mm for > 125 mm i.0 EARTHING COIL B3 for > 200 mm i. The Hot Dip galvanizing shall conform to IS:2629-1985. Min.± 3. Min. Galvanizing should be heavily coated and should stand for the following tests.± 2.17 24 24 23.e. The certificate from recognized laboratory shall be submitted towards mass of zinc.3 11.200 mm .0 mm Use 91 .4 19. The coil shall be made as per REC constructions standard J-1 (drawing enclosed). 0 PRESTRESSED CEMENT CONCRETE POLES FOR 11 KV & LT. 21.850 Kg 21. suitable for use in overhead 11 kV and L. 50 mm 460 mm 2500 mm 1. Methods of test for concrete poles for over-head power and telecommunication lines. b) IS:2905-1966. Weight of Earthing Coil (Min) 4mm + 2.850 Kg. NO.0 meter long / 140 kgs. power lines and double pole structures for 11/0.) – 1. LINES (8.T. traction and telecommunication lines. of turns External dia of coil Length of coil (Min) Free length of GI Wire @ end of the coil. External dia of Coil (Min) – 50 mm Length of Coil (Min) – 460 mm Free length of GI Wire at one end coil (Min.0 m. a) IS:1678-1978. HOT DIP GALVANIZED EARTHING COILS OF MIELD STEEL WIRE 4 MM DIA S.1 21.2 APPLICABLE STANDARDS: Except when they conflict with specific requirements in this specification.): SCOPE: This specification covers PCC poles with an overall length of 8.) – 2500 mm The turns should be closely bound. the poles shall comply with the relevant provisions made in the following Indian Standard Specification. of turns – 115 Nos.4 kV substations. Adhesion test – As per IS: 4826 – 1979.20. Specification for pre-stressed concrete poles for overhead power.2 THE DIMENSIONAL REQUIREMENT SHALL BE AS FOLLOWS a) b) c) d) e) Nominal dia of GI Wire 4 mm (Tolerance + 2. 1 2 PARTICULAR Manufacturer Name & Address Standard according to which Earthing coil shall be manufactured and tested IS-2062/1984 IS-2629/1996 IS-2633/1972 IS-4826/1979 with latest amendment 3 Tolerance in dimensions (if any) To be indicated Bidder/manufacturer by REQIURED To be specified categorically 4 A B C D E 5 Dia Dia of GI wire (mm) Minimum no.5% 115 Nos.5%) Minimum no. Weight of one finished Earthing Coils (min. . 1). Potable water will be generally suitable. A-5 B-6 8. The nominal maximum size of aggregate shall in no case exceed 12 mm. lines) 21. 21. LOAD FACTOR: The ratio of ultimate transverse load to the transverse load at first crack. Code of practice for selection. 75 kg/m and 100 kg/ m in accordance with REC construction standards referred to in the following table:Pole Length Line Description Ref. TRANSVERSE: The direction of the line bisecting the angle contained by the conductor at the pole.3 TERMINOLOGY: For the purpose of this standard. other salts and organic matter.. the following definitions shall apply:AVERAGE PERMANENT LOAD: That fraction of the working load. the transverse load at first crack shall be taken as not less than the value of the working load. should conform to IS:1785(Part-I)-1966 (Specification for plain hard-drawn steel wire for pre-stressed concrete. that is ever likely to occur. sulphates.0 M POLES: These poles shall be used at tangent locations for 11 kV and LT lines in wind pressure 2 2 2 zones of 50 kg/m . or IS:6003-1970 (Specification for intended wire for . WORKING LOAD: The maximum load in the transverse direction. handling and erection of concrete poles for over-head power and telecommunication lines. when it is applied at a point 600 mm below the top and perpendicular to the axis of the pole along the transverse direction with the but end of the pole planted to the required depth as intended in the design.0 M 11 KV Line with Earth Wire LT Lines.4 MATERIALS: CEMENT: The cement used in the manufacture of pre-stressed concrete poles shall be ordinary or rapid hardening Portland cement conforming to IS:269-1976 (Specification for ordinary and low heat Portland cement) or IS:8041 E–1978 (Specification for rapid hardening Portland cement). PRESTRESSING STEEL: The pre-stressing steel wires. to Rec. this will be normal to the run of the line. TRANSVERSE LOAD AT FIRST CRACK: For design. including those used as un-tensioned wires (see Annex. Vertical Formation The adoptable spans shall be as per REC construction standards A-8 (for 11 kV lines) and B-8 (for L. 8. AGGREGATES: Aggregates used for the manufacture of pre-stressed concrete poles shall conform to IS:383-1970 (specification for coarse and fine aggregates from natural sources for concrete). including the wind pressure on the pole.c) IS:7321-1974. ULTIMATE FAILURE: The conditions existing when the pole ceases to sustain a load increment owing to either crushing of concrete. In the case of a straight run. IS:1785 (Part–II)–1967 (Specification for plain hard-drawn steel wire). which may be considered or long duration over a period of one year. Construction Standards. or snapping of the pre-stressing tendon or permanent stretching of the steel in any part of the pole. This load is assumed to act at a point 600 mm below the top with the other end of the pole planted to the required depth as intended in the design.T. WATER: Water should be free from chlorides. Part –I cold drawn stress relieved wire). ULTIMATE TRANSVERSE LOAD: The load at which failure occurs. ADMIXTURES: Admixtures should not contain calcium chloride or other chlorides and salts which are likely to promote corrosion of pre-stressing steel. 5.8 times the cube strength. Part. which should go round all the wires. The un-tensioned reinforcement should be held in position by the use of stirrups.2 kg/cm for M420 concrete. If it becomes necessary to add water to increase the workability. The working load on the poles should correspond to those that are likely to come on the pole during their service life. 2 The concrete strength at transfer should be at least 210-kg/ cm . / cm ensured in the 2 2 h) i) j) For model check calculations of the design of poles.6 m from top.e. The average permanent load should be 40 % of the working load.0.I – Design Aspects. The mix should contain as low water content as is consistent with adequate workability. . against first crack load shall be 1. reference may be made to the REC “Manual on Manufacturing of solid PCC poles. permissible tensile stress in concrete shall be 30 kg. The concrete strength at transfer shall not be less than half the 28 days strength 2 design. 21. Cm .O.6 MANUFACTURE: All pre-stressing wires and reinforcements shall be accurately fixed and maintained in position during manufacture.S. Applied to 0. The F. All wires shall be accurately stretched with uniform pre-stress in each wire. The mix should contain at least 380 kg. 420 x 0. 2 21. And 200 kg. Care shall be taken to see that the anchorages do not yield before the concrete attains the necessary strength. At the design value of first crack load. Each wire or group of wires shall be anchored positively during casting.pre-stressed concrete). Of cement per cubic mater of concrete. The maximum compressive stress in concrete at the time of transfer of pre-stress should not exceed 0. The type designs given in Annexure – I are for plain wires of 4 mm diameter 2 with a guaranteed ultimate strength of 175 kg/ mm . a) b) c) d) Minimum works cube strength at 28 days should be at least 420 kg/cm . i.5 = 210 kg. At average permanent load. The provisions of holes for fixing cross-arms and other fixtures should conform to the REC standards referred to in clause 4 of this specification and in accordance with the construction practices adopted by the State Electricity Boards. The concrete mix shall be designed to the requirements laid down for controlled concrete (also called design mix concrete) in IS:1343-1980 (code of practice for pre-stressed concrete) and IS:456-1978 (code of practice for plain and reinforced concrete).5 meters. subject to the following special conditions. the modules of rupture shall not exceed 55.” DIMENSIONS AND REINFORCEMENTS: The cross-sectional dimensions and the details of prestressing wire should conform to the particulars given . Designs given in drawing are for 140 kg. The factor of safety for all these poles shall not be less than 2. The ultimate moment capacity in the longitudinal direction should be at least one fourth of that in the transverse direction.5 a) b) c) d) e) f) g) DESIGN REQUIREMENTS: The poles shall be designed for the following requirements: The poles shall be planted directly in the ground with a planting depth of 1. the cement content also should be raised in such a way that the original value of water cement ration is maintained. 1 COVER: The cover of concrete measured from the outside of the pre-stressing tendon shall be normally 20 mm. measured from the end. should be perpendicular to the board face of the pole. i. 21.15 times the overall length from the ends.6. The earth wire shall not be allowed to come in contact with the pre-stressing wires. at 250 mm. at a distance equal to 0. if provided for lifting purposes. shocking or other suitable mechanical means. if provided. The cubes cast for the purpose of determining the strength at transfer should be cured. result of compressive test conducted in accordance with IS:456-1964 (code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used for the poles.6. vibrating. Stacking should be done in such a manner that the broad side of the pole is vertical.6. 21. Each tier in the stack should be supported of timber sleepers located at 0. The rate of de-tensioning may be controlled by any suitable means either mechanical (screw type) or hydraulic. as far as possible. EARTHING: Earthing shall be provided by having a length of 8 SWG GI wire embedded in concrete during manufacture and the ends of the wires left projecting from the pole to a length of 50 mm. a reference may be made to REC “Manual on Manufacturing of Solid PCC Poles Part II Manufacturing Aspects”. 22. 210 kg/cm ). Welding shall not be allowed in any case. The timber supports in the stack should be aligned in a vertical line. The erections of the pole should be carried out in such a way that the erection loads are applied so as to cause moment with respect to the major axis. should be properly anchored and should be on the face that has the shorter dimension of the cross-section.4 CURING: The concrete shall be covered with a layer of sacking.7 TESTS TRANSVERSE STRENGTH TEST: Poles made from ordinary Portland cement shall be tested only on the completion of 28 days and poles made from rapid-hardening cement only on the completion of 14 days. The manufacturer shall supply when required by the Employer or his representative.e.3 COMPACTING: Concrete shall be compacted by spinning. Poles should be transported with their broad faces placed vertically and in such a manner that shocks are avoided. after the day of manufacture. 21.15 times the overall length. However. Thereafter.e. The transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified strength indicated above is reached. Hand compaction shall not be permitted. 21. the rope used for hoisting the pole should be parallel to the broader face of the pole. canvas. the interval should depend on the atmospheric humidity and temperature.15 times the overall length.6 Handling & Transport: Separate eyehooks or holes shall be provided for handling and transport. If the Employer so desires. The poles shall not be de-tensioned or released by cutting the pre-stressing wires using flames or bar croppers while the wires are still under tension. from top and 150 mm below ground level. Hessian or similar absorbent material and kept constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of concrete at transfer of pre-stress. the pole may be removed from the mould and watered at intervals to prevent surface cracking of the unit. GENERAL: For further details on the process of manufacture. from either end of the pole. without imparting shock or sudden load to the poles. one each at a distance of 0. . Holes.6. Eye-hooks. Supports should be so arranged that they are located approx.2 WELDING AND LAPPING OF STEEL: The high tensile steel wire shall be continuous over the entire length of the tendon. under conditions similar to those under which the poles are cured.5 DE-Tension: The pre-stressing wires shall be de-tensioned only after the concrete has attained the 2 specified strength at transfer (i. The de-tensioning shall be done by slowly releasing the wires. Thereafter the test on concrete shall be carried out as detailed in IS:13431960 (code of practice for pre-stressed concrete).6. jointing or coupling may be permitted provided the strength of the joint or coupling is not less than the strength of each individual wire.6.21. 21. the manufacturer shall supply cubes for test purposes and such cubes shall be tested in accordance with IS:456-1964 (code of practice for plain and reinforced concrete). Load shall be applied at a point 600 mm from the top of the pole and shall be steadily and gradually increased to design value of the transverse load at first crack. The acceptance or otherwise of a sub-lot shall be determined on the basis of the performance of samples selected from it. The mean value of the measured cover should not differ by more than 21 mm from the specified cover. accordance with Col. provisions shall be made to compensate for the overhanging weight of the pole. A pre-stressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage prior to the application of the design transverse load for the first crack. If these requirements are not met. 1. The pole shall be rigidly supported at the butt end for a distance equal to the agreed depth of planting i.8 meters from the butt end of the pole. If tested in horizontal position. The number of poles to be selected from a lost or a sub-lot shall depend upon its size and shall be in SAMPLE SIZE AND CRITERION FOR CONFORMITY Dimensional Requirement Size of lot or Sub-lot Sample Size Permissible No. the workmanship with reference to aligning of the end plates and pre-stressing wires and assembly of moulds should be improved and inspection at pre-production stage tightened suitably. for this purpose the over-hanging portion of the pole may be supported on a movable trolley or similar device. This procedure shall be repeated until the load reaches the value of 80% of the minimum ultimate transverse load and thereafter increased by 5 % of the minimum ultimate transverse load until failure occurs.6 meter from the top and the third at an intermediate point and the mean value compared with the specified value. The individual values should not differ by more than (+) (-) mm from specified value. 21. it shall be held for 2 minutes. the lot shall be divided into a suitable number of sub lots such that the number of poles in any sub-lot shall not exceed 500. Sub-lot: If the numbers of poles in a lot exceed 500. The cover of the pole shall be measured at 3 points. all poles of the same class and same dimension shall be grouped together to constitute a lot. The deflection at this load shall be measured. and held up for 2 minutes. The load shall then be reduced to zero and increased gradually to a load equal to the first crack load plus 10% of the minimum ultimate transverse load.5 M. The load applied to pre-stressed concrete pole at the point of failure shall be measured to the nearest five Kg. of Defective Samples 1 1 2 3 No. Each time the load is applied.e. of Poles for Transverse Strength Test Up to 100 101 to 200 201 to 300 301 to 500 10 15 20 30 * 3 4 5 * The number of Poles to be tested shall be as approved by the Employer. the second within 0. MEASUREMENT OF COVER: After completion of the transverse strength test.The pole may be tested in either horizontal or vertical position. 1 and 2 of the following table:- .8 SAMPLING AND INSPECTION SCALE OF SAMPLING: Lot: In any batch. the sample pole shall be taken and checked for cover. one within 1. a) b) c) d) Month and year of manufacture Transverse strength of pole in kg.9 NUMBER OF TESTS All the poles as selected in 16. 21. All the poles tested for transverse strength test shall satisfy the requirements of the test. (+) (-) 3 mm on cross sectional dimensions and 0. 4 of the above table.11 MARKING The pole shall be clearly and indelibly marked with the following particulars either during or after manufacture but before testing at a position so as to be easily read after erection in position. every nth pole may be included in the sample. 21. twice the number of poles originally tested shall be selected from those already selected and subjected to the test.8. 3 of Table in 16. 21.5 % on uprightness.These poles shall be selected at random. cross-section and uprightness. and those not satisfying the requirements shall be rejected. all the poles in the lot or the sub-lot may be arranged in a serial order and starting from any random pole. The tolerance shall be (+) (-) 15 mm on overall length. the lot or the sub-lot shall be considered to have satisfied the requirement of this test. Maker’s serial no. and mark. Word MPEZ. If one or more poles fail. If there is no failure among these poles. In order to ensure randomness. cross-section and uprightness shall not exceed the corresponding number given in Col. The number of poles to be tested for transverse strength test shall be accordance with col. .8 shall be tested for overall length. These poles may be selected from those already tested in 16. The number of poles which does not satisfy the requirements of overall length. all poles in the lot or sub-lot shall be tested for these requirements.10 CRITERIA FOR CONFORMITY A lot of sub-lot shall be considered as conforming to this specification if the conditions are satisfied.8 if the number of such poles exceeds the corresponding number. being the integral part of N/n where N is the size of the lot or the sub-lot and n is the sample size. vi. TURN BUCKLE : (A) EYE BOLT WITH 2 NUTS To be made of 16mm dia MS Rod having an overall length of 450 mm. Details of welding are indicated below and also shown in the enclosed drawing No. . The other end of the rod to be made into a round eye having an inner dia of 40mm with best quality welding. v.6mm and one MS hexagonal nut conforming to IS:1367-1967 & IS:1363-1967.0 GALVANIZED MS STAY SETS (16 MM DIA) 22. ANCHOR PLATE SIZE 200x200x6MM To be made out of MS plate of 6mm thickness. of 4 mm HT wire Working Load Earthing Wire Planting Depth (mm) 380 Kg 100 mm x 100 mm 276 x 100 mm Two on same side 10 no. 4.1 enclosed herewith.DISCOM/EZ-29. (A) BOW WITH WELDED ANGLE To be made out of 16mm dia MS rod. the apex or top of the bow shall be bent at an angle of 10 R. 140 Kgs. The finished bow shall have an overall length of 995mm and height of 450 mm as shown in the enclosed drawing No. Dimensional and other details are indicated in the enclosed drawing No. 1 1500 22. The other end of rod shall be rounded into a circular eye of 40mm inner dia with proper and good quality welding as described below.DISCOM/EZ-29 and details of welding are indicated below. The other end shall be welded with proper and good quality welding to a MS angle 180mm long having a dimension of 50x50x6mm. Both washer and nut to suit threaded rod of 16mm dia. ANCHOR ROD WITH ONE WASHER AND NUT Overall length of rod should be 1800 mm to be made out of 16 mm dia MS Rod. The anchor plate should have at its centre 18mm dia hole.1 (A) 16 MM DIA STAY SETS GALVANIZED (i) The stay sets (Line Guy set) will consist of the following components :- iv.Guaranteed technical particulars of 8 Mtr/140 Kgs long PCC Poles To be categorically specified by the Bidder 1 Length of Pole 8 Meter 2 3 4 5 6 7 8 9 Weight of Pole Top Dimensions (mm) Bottom Dimensions (MM) No of lifting Hooks No. The angle shall have 3 holes of 18mm dia each as per drawing No. one end of the rod to be threaded upto 300 mm length with a pitch of 5 threads per cm and provided with two MS Hexagonal nuts of suitable size conforming to IS:1363-1967 & IS:1367-1967. one end threaded upto 40mm length with a pitch of 5 threads per cm and provided with one square MS washer of size 40x40x1. 1. 22.1. found short in lengths or not done properly as required shall be rejected. ii. No assistance will be given in arranging the raw material by the Board. (MINIMUM) (EXCLUDING NUTS THIMBLES AND WASHERS) 8. The nuts should be of a size compatible with threaded portion of rods and there should be no play or slippage of nuts./Recognized testing laboratory giving results of following tests along with their offer & inspection report of material of first lot in individual size separately for 16mm & 20mm sizes in case of regular Bidder/manufacturer.4. On account of this. 22. iv. For this. The welding shall be conforming to relevant IS:823-1964 or its latest amendment. Minimum length of weld to be provided at various places in the stay sets shall be as shown in the enclosed drawing No. TEST CERTIFICATE The Bidder/manufacturer shall be required to furnish the test certificates from Govt.6 each for anchor rod & Eye bolt and property clause 4 for nuts as per IS:1367-1967. Minimum 6 mm fillet weld or its equivalent weld area should be deposited in all positions of the job i. The nuts shall be conforming to the requirement of IS:1367-1967 & have dimensions as per IS:163-1967. This should be engraved on the stay plate and on stay rods to ensure proper identification of the materials. iii. AVERAGE WEIGHT OF FINISHED 16MM STAY SETS 7. no extra charges will be paid.3 THREADING The threads on the Anchor Rod. v. thimbles and washers shall not be less than the weight specified above :- . the firm must engrave identification mark of about 3 capital letters. Welding wherever required should be perfect and should not give way after erection. Eye Bolt & Nuts shall be as per specification IS: 4218-1967 (ISO Metric Screw Threads).3 & 4 for details of components and welding. Tensile Load of 3100 Kg/4900 Kg. IDENTIFICATION MARK All stay sets should carry the identification mark of the manufacturer. Applied for one minute on the welding & maintained for one minute for 16 mm and 20 mm dia stay sets respectively.2 WELDING The minimum strength of welding provided on various components of 16mm dia stay sets shall be 3100 kg. NOTE i) ii) Please see attached drawing No.702 KG. (MAXIMUM) i. Welding if. The mechanical property requirement of fasteners shall conform to property clause .vii.445 KG. In view of non submission of above test certificates inspection report shall not be acceptable. TOLERANCES The tolerances for various components of the stay sets are indicated below subject to the condition that the average weight of finished stay sets of 16mm dia excluding nuts.2.e. THIMBLE To be made on 1. at any point of the weld length.5 mm thick MS sheet into a size of 75x22x40mm and shape as per details given in attached drawing No. 4 The complete stay set shall be galvanized as per the relevant IS specification IS: 2629-1985 & IS: 4759-1986.5% .3% Length 1800mm + 0.5% MS Round 16mm dia MS Round 16mm dia Rounded Eye 40 mm inside dia + 3%.3% Length 450mm + 1% Threading 300mm + 1% Round Eye 40mm inside dia + 3% + 1% Length 995mm + 1% 16mm dia MS Round 16mm dia MS Angle MS Round 16mm dia 22. .5 3 Turn Bow Buckle 16 mm dia + 5% .No 1 Item Anchor Plate Section Tolerances 6mm thick + 12. The Manufacturer/Bidder/manufacturer shall furnish the tests report for the stay set as well as galvanizing from NABL accredited Laboratory.5% Fabrication Tolerances 200x200mm + 1% Material MS Plate 6mm thick 2 Anchor Rod 16mm dia + 5% . Threading 40mm+11% .3% Length 180mm 50x50x6mm 4 Eye Bolt Rod 16mm dia + 5% . 5% 40mm +11% -5% 5.MS GUY/STAY SETS 16 MM DIA (Hot Dip Galvanized) S.00 Size of MS Nut Bolt.6 Washers confirming to IS 1367 (1967) mm and IS 1363 (1967) Inner dia of round eye made at other 40 mm + 3% end of the rod Anchor Plate Size of the MS anchor plat 200x200mm + 1% e 4 A B Dia of the hole made at the centre of 18mm the plate 5 Turn Buckle (A) Eye Bolt with two nuts a B C D E Dia of the eye bolt Length of the eye bolt 16 mm dia + 5% & 3% 450mm + 1% - Length of the threaded portion of the 300mm + 1% bolt Pitch of ht thread 5. No. Description 1 2 Name of Bidder Manufacturer Name & Address 3 Anchor Rod Overall length of Anchor Rod Length of threaded portion Pitch of Thread Length 1800mm + 0. confirming to IS Yes 1363 (1967) and IS 1367 (1967) Inner dia of the circular eye made at 40 mm + 3% other end of the bolt F (B) Bow with welded channel A Dia of the MS rod used for bow 16 mm dia + 5% & 3% 995 mm + 1% B Overall length and height of the bow 450 mm + 1% C Magnitude of the angle in radians by 10 R which bow is bended at the top Length and size of the MS channel welded at the order end of the bow 180 mm + 1% 50x50x6. Square MS 16 mm Sq washer 40x40x1.0 mm Angle - D .00 Requirement To be categorically specified a b c d Size of MS Nut Bolt. 3 GALVANISING Hot dip galvanizing shall be as per IS:2629-1985 & IS:4826-1979 with up to date amendments.3. No.8.055% and Carbon 0. lay & elongation of each wire and full strand shall conform to IS: 21411968 & IS: 2141-1972 in the tensile grade given above). Zinc shall conform to grade Zen 98 specified ARE 209-1966 & ARE 2141-1968. thimble and washers Minimum Maximum 7.0 HOT DIP GALVANIZED MS STRANDED WIRE The hot dip galvanized MS Stranded wire of sizes 7/3.5 TENSILE PROPERTIES Tensile properties of each strand ensuring MS Wire mechanical properties as per IS:280-1972 (Cl.702 Kg.3.3) . Description E F Requirement To be categorically specified Number of holes made in the MS 3 channel / Angle Dia of the holes 18 mm (3 Nos.1 to 8.2 ZINC COATING Zinc coating shall be in accordance with IS:4826-1979 (heavily coated hard quality Grade-4 as per table-1) with up to date amendments.3) and after galvanizing each wire shall be of tensile strength minimum 700N/mm2 (71 Kgs/mm2).25%.4 UNIFORMITY OF ZINC COATING Uniformity of Zinc coating shall be determined as per IS:2633-1986 with up to date amendments.6 CONSTRUCTION Construction shall be as per IS: 2141-1979 (Cl. 8.1 MATERIAL MS Wire used for each strand shall have the chemical composition (maximum) Sulphur & Phosphorus – 0. 23.) 6 Thimble A B Thickness of the MS sheet used for 1.445 Kg 8 A B 23. 23. 5.S.5 mm thimble Size of the thimble 75x55x40 mm 7 Minimum strength of the welding provided on various components of 3100 Kg. 23. Tensile strength.1 to 5. bending load. Guy/Stay sets (IS: 823 / 1964) Average weight of finished Guy/Stay sets excluding nuts. 23. 1979 with up to date amendments. 23.15 mm diameters shall conform to the relevant ISS specification as detailed below: 23. 7.15mm S.1) and as per latest amendments is required.9 PACKING Each coil shall be between 50-100 Kgs. 11).6 respectively).1mm .1) 6594-1979 & 21411979 (Cl. 1 2 3 4 5 To be categorically specified Particulars Requirement Number of Wire in Strand Nominal Diameter of each Wire Tolerance in diameter Sectional area of each Wire Minimum Tensile Strength (corresponding to grade 4) of each wire before stranding 7 3. GTP of GALVANIZED MS STRANDED WIRES 7 / 3.5% 12. Max. No.15mm 3698 Kgf 6% 113.8. 23.1.8 TESTS ON WIRE BEFORE MANUFACTURE As per IS:2141-1979 (Col.23.1.mm of each wire tested Before Stranding After Stranding Type of Coating on each Wire Variety of each Wire Ductility Test (Wrap Test) of each wire before manufacture Complete Turns of Wrap Dia of mandrel on which to be wrapped Min.89 1.4mm 170.1 to 8.1 to 7.7 FREEDOM FROM DEFECTS Freedom from defects be ensured as per IS: 2141-1979 (clause 4.10 & 10. 23. % elongation corresponding to grade 4) Length of lay of strand Min. 23.4 Kgf/ mm2 6 7 Minimum breaking load of each wire before stranding Elongation Test – The elongation shall be subject to a reduction of not more than Weight of zinc gms/sq. Breaking Load after Stranding Elongation Test (Min. 556 10% 8 i) ii) 9 10 11 a) b) 12 13 14 240 228 Heavy Hard 8 3.15 mm + 2. Packed as per IS: 2141-1968 (Cl. 9.2) shall be done.1) and IS: 2141-1979 (Cl.2.10 MARKING As per IS: 2141-1968 (Cl. Phosphorus – 0.0 ANTI-CLIMBING DEVICES In order to prevent unauthorized persons from climbing any of the supports of HT & LT lines without the aid of a ladder or special appliance. galvanizing shall be between 55-95 Kg/Sq.055%. Zinc shall conform to grade Zen 98 specified in IS:209-1966 & IS: 4826-1979 with up to date amendments.15 mm diameters shall conform to the relevant ISS specification. 25. The barbed wire shall conform to IS: 278 (Grade A1).055%.055% 0. 15 a) Particulars Requirement To be categorically specified Number of dips the coating each wire is able to withstand at 18 ± 2ºC Before Stranding 2 dips minute 1 dips minute As pr ISS of 1 b) After Stranding of ½ 16 17 a) b) c) Freedom from Defects Chemical Composition.25%.5 to 4 m from ground level.2 ZINC COATING Zinc coating shall be in accordance with IS: 4826-1979 (Cl.1) for heavily coated hard quality.3. 25.0 HOT DIP GALVANISED GS SOLID WIRE The hot dip galvanized MS Solid wire of sizes 5 mm.S.4 UNIFORMITY OF ZINC COATING Uniformity of Zinc coating shall be determined as per IS:2633-1972 with up to date amendments. 25. Carbon 0.1 MATERIAL The Mild Steel wire shall have the chemical composition maximum sulphur .mm (heavily coated Hard as per IS:4826-1979 Tables-1) ensuring MS wire Mechanical properties as per IS:28-1972 8. The barbed wired shall be given chromating dip as per procedure laid down in IS:1340. certain anti-climbing devices are provided to the supports.1 to 8. Barbed wire binding is to be adopted for this purpose at a distance of 30 to 40 cm at a height of 3.055% 0. 4 mm and 3.3 GALVANIZING Galvanizing shall be as per IS:2629-1985 and IS:4826-1979 with up to date amendments.. .5 kgs barbed wire is to be used per pole for the purpose.25 % 24.2.4. 25.5 TENSILE PROPERTIES The tensile strength of the wire after. At least 3. The MS Wire used shall not exceed Sulphur Phosphorous Carbon 0. No. 25. briefed here below: - 25. 7 TESTS5 During the process of manufacture/ fabrication and finish all tests for chemical. 25.1) & IS:4826-1979 (Cl. IS:2629-1966. 25. 4. 4.8 PACKING Packing shall be as per IS:280-1979 (Cl. Adhesion test as per IS:1755-1961. 1. Tensile strength and breaking load and elongation determined as per IS:1521-1972 with up to date amendments. IS:2629-1966.25. IS:1755-1961.1. IS:6745-1972 & IS:4826-1979 be carried out. Test certificate towards. 3. . IS:1521-1972.1 & 14. Coating test as per IS:1755-1961.3) & with up to date amendments.1) is required. chemical composition (as per above) shall be submitted for each lot offered for inspection. The following tests shall be conducted in presence of owner’s representative. mechanical. IS:2633-1972.3. Visual Physical inspection and measurement of specified dimensions. 2. 6. IS:4826-1979 & IS: 6745-1972. IS:2633-1972.6 FREEDOM FROM DEFECTS To be ensured as per IS: 2629-1985 (Cl.9 MARKING As per IS:280-1972 (Cl. 25. IS:4826-1969 & 1979 – IS:67451972. galvanizing as per IS:280-1979.1) and each coil shall be between 50-100 Kg.14. No.5 HEAVY HARD 275 3 DIPS OF 1 MIN & 1 DIP OF ½ MINUTE b) Max.5% 19. 1 2 3 4 To categorically specified be Particulars Requirement Nominal Diameter of Wire Tolerance in diameter Sectional Area Tensile Strength a) Min. 55 95 10/9. mm.) Min. complete turn of wrap b) Dia of mandrel on which wrapped 10 16 TIME OF DI 30 MM 11 Bend Test a) Angle b) Dia Round a formet to be bent 90 10 MM 12 13 Freedom from defect Chemical composition the MS Wire used shall not exceed Sulphur 0. Kfg/mm 5 6 7 8 9 2 Minimum breaking load (Kgf) Type of coating Heavy / Medium / Light Variety Hard/Soft Weight of Zinc Coating (Gms/Sq. No.25 % . Mtr. Kgf/mm 2 5 mm + 2. of dips the coating is able to withstand as 18 ± 20ºC 10 Adhesion Test (Wrap Test at 1 turn per second coiling while stress not exceeding % nominal tensile strength a) Min.055% Carbon 0.055% To be indicated Phosphorous 0.GTP of GALVANIZED SOLID WIRE 5 mm S.625 Sq. complete turn of wrap b) Dia of mandrel on which wrapped 10 24MM 11 Bend Test a) Angle b) Dia Round a formet to be bent NA NA 12 13 Freedom from defect Chemical composition the MS Wire used shall not exceed Sulphur 0.) Min. Particulars Requirement 1 2 3 4 Nominal Diameter of Wire Tolerance in diameter Sectional Area Tensile Strength a) Min.5% 12.8 HEAVY HARD 260 3 DIPS OF 1 MIN EACH b) Max.56 Sq.GTP of GALVANIZED SOLID WIRE 4 mm To be categorically specified by the tenderer S. of dips the coating is able to withstand as 18 ± 20ºC 10 Adhesion Test (Wrap Test at 1 turn per second coiling while stress not exceeding % nominal tensile strength a) Min. Mtr. 226 To be indicated Phosphorous 0. No.S.055% Carbon 0. Kfg/mm 5 6 7 8 9 2 Minimum breaking load (Kgf) Type of coating Heavy / Medium / Light Variety Hard/Soft Weight of Zinc Coating (Gms/Sq. mm. Kgf/mm 2 4 mm + 2. 55 95 690. No.055% amendments if any I.25 % . ) Min. of dips the coating is able to withstand as 18 ± 20ºC 10 Adhesion Test (Wrap Test at 1 turn per second coiling while stress not exceeding % nominal tensile strength a) Min.5% 7. mm.6 MM 11 Bend Test a) Angle b) Dia Round a formet to be bent NA NA 12 13 Freedom from defect Chemical composition the MS Wire used shall not exceed Sulphur 0.055% To be indicated Phosphorous 0. complete turn of wrap b) Dia of mandrel on which wrapped 10 14 TIME OF DI 12.055% Carbon 0.25 % . 1 2 3 4 Particulars Nominal Diameter of Wire Tolerance in diameter Sectional Area Tensile Strength a) Min.4 HEAVY HARD 240 3 DIPS OF 1 MIN EACH b) Max. No. No.789 To be categorically specified Sq. Kgf/mm 2 Requirement 3. 55 95 428.15 mm S. Mtr.GTP of GALVANIZED SOLID WIRE 3.15 mm + 2. Kfg/mm 5 6 7 8 9 2 Minimum breaking load (Kgf) Type of coating Heavy / Medium / Light Variety Hard/Soft Weight of Zinc Coating (Gms/Sq. This shall be ‘D’ type and out-door lift off type suitable for manual operation by an operating rod from the ground level.5 POST INSULATORS Each 11KV DO Fuse shall have two Nos 11 KV Post Insulators. The glazing of the porcelain shall be of uniform brown color free from blisters. shall be suitable for 11KV three phase 50 C/S solidly grounded earthed neutral systems. burns and other similar defects.2 APPLICATION The D. These shall be suitable for mounting on the structure. i ii iii Particulars Nominal system voltage KV (rms) Highest system voltage KV (rms) Dry Power Frequency with stand voltage KV (rms) 11KV 11 12 35 . Each cap and base pin shall be made of high-grade cast steel or malleable steel casting and they shall be machine faced and smoothly galvanized.1 11 KV DO FUSE UNITS SCOPE This specification provides for manufacture.3 APPLICABLE STANDARD Unless otherwise modified in this specification. Insulators shall be of the same rating and type and shall be interchangeable. They shall be thoroughly vitrified tough and impervious to moisture. The Bidder/manufacturer/Manufacturer shall submit the type test certificate of DO Fuse along with certified copy of the drawing and other relevant technical guaranteed particulars. This covers outdoor open.O. the drop out fuse shall conform to IS: 9385 (Part-I to III) as amended from time to time. Fuses are intended for use on Distribution transformers for protection/isolation of the same during overload or fault conditions. 26. The drop out operation will be angular in vertical plane. Excess use of cement shall be avoided. drop-out expulsion type fuses suitable for installation in 50Hz 11KV distribution system.4 DROP OUT FUSES The drop-out fuses shall be expulsion type. The cap and base shall be properly cemented with insulators to give perfect grip.26.0 26. testing at works before dispatch and delivery of 11 KV DO Fuse units. bolts and washer for mounting on the structures. Each 11KV Post Insulators should have technical parameters as detailed below:Sl. The drops out fuses are required with Post Insulators. 26. The porcelains and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts through range of temperature variation shall not loosen parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. The equipment offered. 26. The bracket/channel hardware for DO Fuses shall be provided with adequate sizes of nuts. The porcelain used for manufacture of DO Fuse units shall be homogeneous. 26. The insulator shall conform to IS: 2544 -1973 with latest amendment. free from flaws or imperfections that might affect the mechanical or dielectric strength. It shall be designed for a normal current rating of 200 Amps. 1. All the sharp edges shall be rounded off. 26. 26. properly aligned and made from Brass material.7 RATED CURRENT The rated current shall be 200 Amp. These contacts shall be so designed to withstand highest short circuit breaking current that may be encountered during service.8 RATED LIGHTNING IMPULSE WITHSTAND VOLTAGE VALUES FOR THE FUSE BASE The rated lightning impulse withstands voltage both for positive and negative polarities shall be as given below:11KV a b To earth and between poles Across the isolating distance of fuse base 75 KV Peak 85 KV Peak 26. Fuse shall be suitable for heavy duty. 26. These shall have good finish and smooth surface and shall be silver-plated. Submission of type test certificate of rated breaking capacity in case of 11KV DO FUSE Unit is essential. for 11KV DO Fuses 26.iv Power Frequency puncture voltage KV (rms) 1.11 MAIN CONTACTS The main contacts of the D. Fuse without adjustment. .3 times the actual flashover voltage 75 9 320 6. Thermal withstands ability during short circuits. Electrodynamics withstands ability during short circuit without any risk of repulsion of contact.O. 3. In nutshell the contact assembly shall ensure.10 RATED BREAKING CAPACITY The rated breaking capacity shall be 8KA (A symmetrical). Proper alignment to ensure smooth operation of D. 4. 2.6 RATED VOLTAGE The rated voltage shall be 11KV for 11KV DO Fuses respectively.O. Constant contact pressure even when the lower parts of the insulator stacks are subjected to tensile stresses due to linear expansion of connected bus bar or flexible conductors either because of temperature variation or strong winds.60 dry v vi vii viii Impulse withstand voltage KV (rms) Visible discharge voltage KV (rms) Creep age distance in mm (minimum) Cantilever strength (KN) As stated above unless otherwise modified in this specification the drop out fuse set shall conform to IS:9385 (Part-I to III) and as amended from time to time.9 RATED ONE MINUTE POWER FREQUENCY WITHSTAND VOLTAGE (DRY AND WET) VALUES FOR THE FUSE BASE To earth and between poles Across the isolating distance of fuse base 28KV Peak 32KV Peak 75KV Peak 80KV Peak a) b) 26. BARRELS The D. Water absorption in 14 hours Resistance to Hot Oil Cohesion between layers : : : . The arrangement shall be made to ensure that the fuse wire runs centrally inside the SRBP tube after tightening. All ferrous parts should be hot dip galvanized as per the latest version of IS: 2629-1985 and IS: 4579-1984.(32 degree C) at 14KV rms at 50 C/s. wrapping in 12” length of the tube Axial electric strength (Proof test in oil at 90 degree C at 25KV rms 50 C/s) iv. Spring washer should be Electro galvanized. Nuts and bolts shall conform to IS:1364 and should be hot dip galvanized. Dimensión a) b) c) External dia Wall thickness Internal dia : : The barrel should with stand this test satisfactorily for one minute : : : ii. Fuse Barrels shall be made from SRBP and shall conform to BSS:1314. viii.) : -do- v.O.16 D. All brass parts should be silver plated for corrosion resistance and efficient current flow. However.O. Surface electric strength (Proof test in air : -do- at room temp. speed of operation shall not depend on the inclination of the fuse. 26.14 SPRING STRIPS The spring strips shall be of phosphone bronze multiline brush type having a high pressure contacts and should retain its tension under minimum continuous service current of 200 Amps at 90 degree C. 26. vi. Max. The nut shall be provided with one flat washer of 25mm dia. 26. vii.15 OPERATING HOOKS The brass operating hook shall be fixed over the SRBP tube in such a way that the barrel can be removed for replacing the fuse element by operating rod from the ground level. the inclination of the fuse barrel shall be adjusted in such a way that the barrel does not drop by gravitational force. The connectors should be bolted type having 4 bolts & groove to hold the conductor. The drop out fuse units shall operate efficiently. 26.13 FLY NUTS These shall be provided at both the ends of SRBP tube for tightening the fuse elements.26. Radial electric strength (Proof test in oil at 90 degree C at 19KV rms 50 C/s.12 CONNECTORS The connectors shall be made from Brass suitable for ACSR/AAAC Weasel. iii. The test certificates of SRBP barrel should indicate the following test results:- i. The agency shall furnish the test certificate for the fuse barrels offered for use in the drop out fuses along with each lot offered for inspection to the inspecting officer. The barrels should have the properly to resist fire whenever the fuse is blown off. All similar parts should be accurately finished and interchangeable.Volts Please note paper should not be used for name plate. Flat G.19 DIMENSION Sl.O. Aluminum sheet of at least 2 mm thick embossed with above marking should be provided on the equipment for identification. Particulars Dimension of D. The following shall be indicated on the plate:1.ix. MATERIALS AND WORKMANSHIP All materials used in the construction of the equipment shall be of the appropriate class. 26.S. well finished and of approved design and material. Machine ability : The agency should indicate the name of manufacturers of SRBP roles from where they will purchase the barrels to make available the test certificate. Fuse units shall strictly comply with requirement of all the type tests and shall be subjected to all routine tests stipulated in the relevant standard.O. 26. 3. G. Fuse Unit in mm 11KV 1 2 3 4 5 i ii iii iv Drawing No. No. the agency should invariably furnish Routine Test Certificate of DO Fuse barrels & Post insulator from their respective manufacturers. Channel Fuse Barrels Lower Contact Hinge of Barrel Connectors Hinge Contact Length -doWidth 60x60x6 95 85 To be submitted 245 x 25 x 6 330x25x14 Thickness of Hinge Outer Inner 5 4 . Amps…………………. Along with the inspection report of D. No material should be dispatched without prior approval of the tests certificate by the owner.O. 26. All tests shall be made prior to dispatch in the presence of the representative of the owner. After cementing the insulator should be cured adequately in water to attain good gripping. Fuse Units. It should not catch fire easily during blowing off of fuse element inside the barrel which causes short time high temperature.S. Each DO Fuse shall be provided with name plate of size 2” x 1” on steel strip in case of 11KV and size 4” x 2” on steel channel and shall be either riveted bolted or pasted.18 TESTS Each D. The material should be packed in Wooden cartoons. of the equipment Rating……………………. Name of manufacturer Sl. 2.17 DESIGN. The connecting of cap and pin with insulator should be perfect to avoid any kind of loosening. Sl.5 25 4 30 25 3 mm .O. Particulars Dimension of D. Fuse Unit in mm 11KV 6 i ii iii iv v 7 i ii iii iv 8 i ii iii iv v 9 i ii iii 10 Barrel take out hook Width Thickness Length Inner dia meter Thickness between inner outer dia Operating Hook Width Thickness Inner Radius Outer Radius Female contact Main contact width Strip thickness Strip Length Width Female contact height Female contact Holder Length Upper width Lower width Creep age of insulator 74 34 40 320 65 1.5 100 20 75 18 3 19 22. T.3 times the actual dry flash over voltage 320 mm . make & country of origin Maximum permissible continuos service voltage (KV) Power Frequency withstand test voltage (One Minute) Dry KV Wet KV Impulse withstand test voltage of completely assembly unit within 1.6 KN To be provided by Bidder/manufacturer One 162mm 254 mm 1.G. C Bracket type Made from suitable for conductor BSS 1314 Brass AAA 15 35 KV 35 KV 12 KV 75/85 KV 5 a) b) c) Material Surface Treatment & Thickness 6 7 8 9 10 Continuous Current Rating (Amps) Breaking Capacity Type Test Report for Thermal Limited Current Type of Mounting (Bracket/Channel) Details of Connectors provided 11 12 i ii iii Iv V vi vii viii Ix SRBP Barrels conform to Particulars of Post Insulators Type Make Strength Weight No.O. FUSE UNITS S. 1 2 3 i ii 4 To categorically specified be Particulars Requirement Type.P of 11 KV D. of Units per Stack Diameter of Shed mm Height of Stack mm Puncture voltage KV Creep age Distance mm 11 KV Post insulator ISI make 6.2/50 micro second impulse wave against ground KV (Peak) Particulars of the main contact Type High pressure spring strip Brass & Cu alloy Silver plated microns 200 8 KA Asymmetrical 50 Deg. No. 27. iii) IS:5831 -1984 Specification for PVC Insulation and sheath of Electric cables. 27. The average thickness of insulation shall be not less than nominal value specified in table 5 of IS: 694-1990.0.3.0 27. 27. manufacture and testing of “ISI” marked 1100 volt grade.Methods of test for cables IS:4905 -1968 Methods for random sampling 27. if any :i) IS:694 -1990 PVC Insulated Cables for working voltages upto and including 1100 V ii) IS:8130 -1984 Specification for conductors for insulated Electric cables.. three and a half core 25 sq mm. iv) v) IS:10810-1984 .3 PVC insulation shall be suitable for continuous conductor temperature of 70 C under normal operation.2 PVC INSULATION PVC Insulation used shall comply to requirement of IS: 5831-1984 with latest amendments. The smallest of the measured values of thickness of insulation (te) shall not fall below nominal value (ti) specified in table 5 of IS: 694-1990 o . Aluminum conductor. 9.1 PVC INSULATED AND PVC SHEATHED CABLES THREE AND A HALF CORE. PVC sheathed cable suitable for outdoor use. 9. No. The conductor shall be stranded type conforming to Class-2 of IS: 8130-1984 for three and a half core 25 sqmm cable.MM.1 GENERAL TECHNICAL REQUIREMENT CONDUCTOR Aluminum conductor used in cables shall comply to the requirement to IS:8130-1984 with latest amendments and shall be in accordance with clause 4. 9.1.1. Insulation shall be of “Type A” PVC compound. of IS:694-1990 with latest amendments.3 27.1.3. X Particulars Requirement To categorically specified be One minute Power Frequency Dry withstand voltage KV (rms) Power Frequency Flashover voltage KV (rms) Impulse flashover voltage KV (Peak) Impulse withstand voltage KV (Peak) Applicable Standard specifications Applicable Drawing 35 70 105 80 IS:9385 xi xii xiii 13 14 27. 25 SQ.2 APPLICABLE STANDARD All the cables shall conform to the requirements of following standards with latest amendments. unarmored PVC Insulated.2.S. SCOPE The specification covers the design.3. The insulation shall be applied by extrusion so that it fits closely on the conductor and it shall be possible to remove it without damage to the conductor.2 ts.5 CORE IDENTIFICATION i) Core shall be identified by different coloring of PVC Insulation in accordance with Clause-11 of IS:694-1990 by following coloring of PVC Insulation:ii) 27.3. In this connection.3.3. lengths. 27. The color of sheath shall be black.3.4 SHEATH The sheath shall be of type S71 PVC Compound conforming to the requirements of IS:5831-1984.2 mm Plus 0. The Sheath shall be so applied that it fits closely on laid up cores and it shall be possible to remove it without damage to insulation. ISI monogram.1mm + 0. PACKING & MARKING Manufacturer’s Identification In addition to manufacturer’s identification on cable as per clause 17. Cable size and voltage grade. 27. The cable should carry the following information on the reel or drum or contained in a label attached to it :- (c) i) Reference to Indian Standard IS:694-1990 ii) Manufacturer’s name. a certified Photostat copy of valid “ISI” Marking License rights duly attested must be submitted along with the Bid as documentary evidence. 27.6 27. drum or coil (if more than one) x) Direction of rotation of drum by means of an arrow xi) Approximate gross mass xii) The word suitable for outdoor use xiii) Country of Manufacturer & xiv) Year of manufacturer “ISI” certification Mark The cable packed coil (reel. The sheath shall be applied by extrusion over the insulation in case of Single Core Cables and over the laid up cores in multi-core cables.3. The packing shall be robust enough for rough handling that is occasioned during transportation by Rail / Road. brand name on trade mark iii) Type of cable and voltage grade iv) Number of cores v) Nominal cross-sectional area of the conductor vi) Cable code vii) Color of core viii) Length of cable on the reel.by more than (0.1 of IS:694-1990 following marking shall also be embossed over the sheath at every one meter. drum or coil ix) Number of lengths on reel.9 Standard Length The standard length of cable shall be 500 mtrs.3.8 Packing & Marking (a) (b) The cable should be packed in coil of 500 Mtrs. Balance quantity of . The thickness of PVC sheath shall not be less than the nominal value (ts) specified in table-5 of IS:694-1990 and the smallest of measured value shall not below the nominal value (ts) specified in Table-5 of (IS:694-1990 by more than 0.7 Four Core Red. Yellow. Blue and Black IDENTIFICATION.1 ti). drum) must bear ISI certification mark. a) b) c) d) Outer cable layer should be sky blue. Word ‘MPPKVVCL’ The embossing and not printing shall be done. automatic in line throughout the length of the cable and shall be legible and indelible. 27. A maximum of 5% (Five percent) of each consignment in short lengths varying from 100 (Hundred) meters and above shall be accepted. ) f. Length only.4.order shall be supplied in 500 Mtrs.) Tensile Test (for aluminum) Wrapping Test (for aluminum) Conductor resistance test Test for thickness of insulation and sheath Tensile strength & elongation at break of insulation and sheath.) b. plus minus 1% tolerance in length shall be permitted. This shall be indicated clearly and on individual coil.4 TESTS Following type tests.) g. (A) i ii iii (B) Tests For requirement Ref.1 Acceptance Tests: The following shall constitute acceptance tests:a.5. 13. 27. acceptance tests and routine tests are to be carried out in accordance with clause-15 of IS:694-1990 with its least amendments as indicated below: 27. To For test method Ref. Insulation resistance test High voltage test at Room temperature .) e.1 TYPE TESTS The following shall constitute type tests: Sl.) c. of IS:10810 TEST ON CONDUCTOR Tensile Test Wrapping Test Conductor Resistance TEST FOR OVERALL DIMENSIONS AND THICKNESS OF INSULATION & SHEATH PHYSICAL TEST FOR INSULATION AND OUTER SHEATH Tensile Strength and elongation at break Ageing in Air oven Shrinkage Test Hot deformation Loss of mass test Heat shock Test Test for bleeding and blooming pigments INSULATION RESISTANCE TEST High Voltage Test (Water immersion test) Flammability test IS:5831-1984 -do-do-do-do-do-doIS:5831-1984 Clause 16.) d. No. to Part No. However. 27.2 of IS:694 Clause 16.5 of IS:694 7 11 12 15 10 14 19 43 45 53 IS:8130-1984 IS:8130-1984 IS:8130-1984 Clause 10.14 Table5 of IS:694-1990 2 3 5 6 (C) i ii iii iv v vi vii (D) (E) (F) Manufacture/Bidder/manufacturer shall furnish the Type test certificate from the NABL accredited Laboratory. Creep age distance should be adequate for highly polluted outdoor atmosphere in open execution.0 28. which were actually incurred for arranging the testing through independent agency. burns and other similar defects. the inspecting officer shall check quality of raw material. They shall be thoroughly vitrified through and impervious to moisture. 27.6 Inspection: The Bidder/manufacturer/Manufacturer shall offer all reasonable facilities to the Employer. In addition. on cable drum selected at random as per following sampling plan:No. These shells will be used for manufacturing of 11 KV 3-phase AB Switches or in other equipment in the system. 28. without charges. shall be recovered from the Bidder/manufacturer/Manufacturer. 28. to satisfy him that the material is being supplied in accordance with the specification. the inspection offer shall not be considered and all complication arising out of this shall be to the Bidder/manufacturer’s/Manufacturer’s account.) Flammability test The Employer’s representative will carry out all the above acceptance tests at the time of material inspection. the testing charges along with the other charges.5. In case the material fails to pass the test as per specification. In absence of routine test certificates. Acceptance test shall be carried out in each type and size of cable.2 Routine Test: The following shall constitute routine test:a) b) c) Conductor Resistance test High voltage test at room temperature The Bidder/manufacturer/Manufacturer. obtain necessary invoices in proof that raw material used is of desired quality. the lot offered for inspection shall be rejected.1 POST INSULATOR FOR 11 KV THREE PHASE AB SWITCH: SCOPE The specification covers Porcelain Post Insulator shells with metallic cap and base. in accordance with relevant ISS.2 STANDARDS Post Insulator should conform to latest applicable Indian / IEC standards and in particular to the IS:2544 specification for Porcelain Post Insulators. Polygon or compact solids core or long rod insulator is also acceptable.h. of drums/ coils/Reels in the lot Up to 25 No. The Employer has the right to have any or all types of acceptance test carried out by NABL accredited laboratory whenever there is dispute regarding the quality of supply. for the purpose of clearing the lot offered by the Bidder. of drums/coils/Reels to be taken as sample 3 5 8 13 20 Permissible defectives 0 0 0 1 1 number of 26 to 50 51 to 100 101 to 300 301 & above 27. The porcelain used for manufacture of post insulator shall be homogeneous free from flaws or imperfections that might affect the mechanical or dielectric quality. Insulators of the . free from blisters. as per relevant ISS. The glazing of the porcelain shall be of uniform brown color. In order to ensure that quality of raw-material used during manufacturing of PVC Cables is as per requirement of IS: 694-1990. shall conduct the above routine test and test certificate in proof of this shall be submitted to the Employer along with each inspection offer. Nature of load will be transverse. 28.same rating and type shall be interchangeable. 28. Withstand and flashover voltage are referred to the reference climatic conditions.6 CREEPAGE DISTANCE The minimum creepage distance of 11 KV Post Insulators shall be 320 mm for highest system voltage of 12 KV.3 TEMPERATURE RISE The maximum temperature attained by any part of the insulator when in service at site under continuous full load conditions and exposed to the direct rays of sun shall not exceed 45 degree centigrade above ambient temperature. The porcelain and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts through the range of temperature variation shall not loosen the parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. Excess cementing shall be avoided. 28.9 TYPE TESTS Type tests are normally carried-out once and unless otherwise agreed to.8 TEST The insulator shall comply with following tests as per IS:2544 -1973.3 times the actual dry flash over voltage of the unit Impulse voltage withstand voltage Visible discharge voltage 75 KV (peak) 9 KV (rms) In this standard power frequency voltages are expressed as peak values divided by ½ and impulse voltage is expressed as peak values. 28.4 INSULATOR CHARACTERISTICS The insulator shall have the electrical and mechanical characteristics. The cap and base of the insulator shall be interchangeable with each other. 28. 28. 28.7 PACKING All insulators shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail and road transport. The cap and base shall be properly cemented with insulators to give perfect grip. The corrections proposed shall be stated in the Bid and shall be subject to approval of the Employer. which are given below:Highest system voltage Dry one minute power frequency withstand voltage Wet one minute power frequency with stand voltage Power frequency puncture with stand voltage 12 KV (rms) 35 KV (rms) 35 KV (rms) 1. test certificates giving the results of type tests. Each cap and base shall be of high-grade cast steel or malleable steel casting and they shall be machine faced and smoothly galvanized. made on not less than 2 post insulators and post insulators unit identical in all .5 MECHANICAL CHARACERISTICS The insulators shall be suitable for the minimum failing load of 10 KN. The tests should be carried out on two samples in the order mentioned below: - .essential details with those to be supplied are regarded as evidence of compliance. 7. All materials used in the manufacturing of Insulator shall be of the appropriate class well finished and of approved design and make. 12. 28. Mechanical strength test Porosity test Puncture test Galvanizing test 28.11 ACCEPTANCE TEST The test samples after having withstand the routine test shall be subject to the following acceptance tests in the order indicated below: - 7. 9. 13. 10. Visual examination Electrical routine test 28.12 MARKING Each insulator shall be legibly and indelibly marked to show the following: 5. 4. Post insulator. 6. 10. 28. All similar parts should be accurately finished and interchangeable. 8. 7. 11. 11. 6. Verification of dimensions Temperature cyclic test Mechanical strength test Puncture test Porosity test Galvanizing test Tolerance in insulator dimensions shall be as per the relevant Indian Standards. . Name and trade mark of the manufacturer Month and year of manufacturing Minimum failing load in KN Country of manufacturing The above marking on porcelain shall be engraved and shall be applied before firing. The Bidder/manufacturer shall invariably enclose with offer the type test certificates and guaranteed technical particulars.10 ROUTINE TESTS The following shall be carried out as routine tests: - 3. Visual examination Verification of dimensions Visible discharge test Impulse voltage withstand test Wet power frequency voltage withstand test Dry power frequency voltage withstand test Temperature cyclic test (B) TEST ON FIRST INSULATORS 5. 8. 8. without above markings shall not be accepted under any circumstances.13 DESIGN. 12. 9. 14.(A) TEST ON BOTH INSULATORS 8. MATERIALS AND WORKMANSHIP The Bidder shall assume full responsibility for co-ordination and adequate design. 0 29. as it will be subject to ring service. Insulators of the same rating and type shall be interchangeable. 11KV AB Switches : 1 No. Excess cementing must be avoided. 11KV Post Insulator per stack The post insulators should conform to the latest applicable Indian standards IS:2544 Specification for Porcelain Post insulator of compact solid core or long rod insulators is also acceptable.1 11 KV AIR BREAK SWITCHES SCOPE This specification provides for manufacture.2 AB SWITCHES The 11KV Air Break Switches are required with two poles in each phase.) Dry Power Frequency one kV minute withstand voltage (rms) in KV Wet Power frequency one minute withstand voltage (rms) in KV Values 11 12 35 35 . The cap and base shall be properly cemented with insulators to give perfect grip.All ferrous parts including Bolts & Nuts etc. operating rod and operating handle. Each 11KV Post Insulators should have technical particulars as detailed below: Sn i ii iii iv Particulars Nominal system voltage kV (rms) Highest system voltage kV (rms. free from blisters. The 11KV AB switches shall conform to IS:9920 (Part-I to IV) 29. The porcelain and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts through the range of temperature variation shall not loose the parts or create undue internal stresses which may affect the electrical or mechanical strength. to extremely service exposure. It shall be manually gang operated and vertically break and horizontal mounting type. Specific attention shall be paid to tropical treatment to the entire insulator. burns and other similar defects. The porcelain used for manufacture of AB Switches should be homogeneous free from flaws or imperfections that might affect the mechanical dielectric quality. testing at works and supply of 11KV AB switches. The phase to phase spacing shall be 750 mm. to atmospheric moisture and to long period of high ambient temperature. They shall be thoroughly vitrified. 29. The 11KV AB Switches are required with post insulators. tough and impervious to moisture. The AB switches should be suitable for mounting on the structure. The glazing of the porcelain shall be of uniform brown in color. Cap and base of the insulators shall be interchangeable with each other.3 POST INSULATORS The complete set of three phase AB Switches shall have stacks of post insulators. Creepage distance should be adequate for highly polluted outdoor atmosphere in open atmosphere. 29. The AB Switches shall be supplied complete with phase coupling shaft. used on the post insulators shall be heavily hot dip galvanized. The equipment offered by the bidder shall be designed for a normal current rating of 400 Amps and for continuous service at the system voltage specified as under: i) 11 KV AB Switch: 11KV + 10% continuous 50 C/s solidly grounded earthed neutral system The length of break in the air shall not be less than 400 mm for 11KV AB Switches. 3 times the actual dry flashover voltage 75 9 320 vi vii viii Impulse withstand voltage kV (Peak) Visible discharge voltage kV (rms) Creepage distance in mm (minimum) The rated insulation level of the AB Switches shall not be lower than the values specified below:Sl. This contact shall have dimensions to withstand safely the highest short-circuit currents and over voltage that may be encountered during service. 2.v Power Frequency puncture kV (rms) voltage 1. The various parts should be accordingly finished to ensure interchangeability of similar components. 1.6 OPERATING MECHANISM All AB Switches shall have separate independent manual operation. They should be provided with ON/OFF indicators and padlocking arrangements for locking in both the end positions to avoid unintentional operation. Constant contact pressure even when the lower parts of the insulator stacks are subjected to tensile stresses due to linear expansion of connected bus bar of flexible conductors either because of temperature variations or strong winds. In nutshell the male and female contact assemblies shall ensure. Fault alignment assuring closing of the switch without minute adjustments. The moving contacts of the switch shall be made from hard drawn electrolytic copper brass. Thermal withstands ability during short circuits. No Standard declared voltage KV/RMS Rated Voltage of the AB Switches Standard impulse with stand voltage (positive & negative polarity kV (Peak) One Minute power frequency withstand voltage kV (rms) 30.5 Across the Isolating distance i 11KV 12KV 85KV To earth between poles & Across Isolating distance the To earth & between poles TEM PER ATU RE RISE 75KV 32KV 28KV Temperature Rise The maximum temperature attained by any part of the equipment when in service at site under continuous full load conditions and exposed to the direct rays of sun shall not exceed 45 degree above ambient. The isolating distances should also be visible for the AB Switches. . 29. 4. The surface of the contact shall be rounded smooth and silver-plated. Wiping action during closing and opening. 3. The connector should be 4 -bolt types. 29.4 MAIN CONTACTS AB Switches shall have heavy duty self-aligning type contacts made of hard drawn electrolytic copper/brass.5 CONNECTORS The connectors shall be made of hard drawn electrolytic copper or brass suitable for AAA Weasel conductor for both 11KV AB Switches. 29. Electro-dynamic withstands ability during short circuits without any risk of repulsion of contacts. 5. 6. All current carrying parts shall be of non-ferrous metal or alloys and shall be designed to limit sharp points/edges and similar sharp faces. iii The AB Switches shall be capable to resist any chance of opening out when in closed position.9 DESIGN. 29. The vertical down rod should be provided with adequate joint in the mid section to avoid bending or buckling. Test to prove capability of rated peak short circuit current and the rated short time current. The operating Mechanism should be of robust constructions.2 Special attention shall be paid to tropical treatment to all the equipment.7 ARCING HORNS It shall be simple and replaceable type.3 The Bidder/manufacturer should have the following type test certificate. as it will be subjected during service to extremely severe exposure to atmospheric moisture and to long period of high ambient temperature. The GI pipe shall conform to ISS:1239-1968 and ISI marked by embossing. Along with the type test certificate. All iron parts should be hot dip galvanized. 5. Power Frequency voltage dry test and wet test Temperature rise test Mill volt drop tests 6. 6. 29. They should be capable of interrupting line-charging current. well finished and of approved design and material. 2. the certified copy of the drawing (from the testing lab) should also be kept for inspection of our officer.0 meter 25MM ii Phase coupling square rod (GI) ISI mark Hot dip galvanized Operating handle (GI) Length 1800 mm Size 25x25 mm 1 No. They shall be made from highly polished Bronze metal with adequate provision for periodic lubrication through nipples and vent. 3. Lightning impulse voltage test with positive & negative polarity. 29. manufactured as per owner approved drawing with the specification. All brass parts should be silver-plated and all nuts and bolts should be hot dip galvanized.10. MATERIALS AND WORKMANSHIP 6.10.8 BUSH The design and construction of bush shall embody all the features required to withstand climatic conditions specified so as to ensure dependable and effective operations specified even after long periods of inaction of these Air Break Switches. Additional leverage should be provided to maintain mechanical force with minimum efforts. The type test should be from CPRI or NABL accredited Lab:1. They shall be of first make and after break type. The rated short time current should correspond to minimum of 10K Amp and the peak short circuit current should correspond to minimum of 25K Amps. All similar parts should be accurately finished and interchangeable.10.10.1 All materials used in the construction of the equipment shall be of the appropriate class. 4. .4 The above tests should be performed on the AB Switches. Also the test certificates should not be older than 5 years from the date of opening of Bid.The AB Switch will be supplied with following accessories: Sl No i Item Size of 11KV AB Switch Operating Rod (GI dia) ISI mark Length 5. easy to operate by single person and to be located conveniently for local operation on the line. The operating mechanisms together with down pipe operating handle etc.) Tolerance 5%. Ii) Contact Iii) GI cover v) Spring Moving Contact Assembly i ii iii iv Base Assembly Moving Bush Thickness of Grooves 135x25x8 180x25x9 Bronze Metal 7 Connectors i Connector 60x50x8 (Moving & fix both) 6. The base channel for the mounting of AB Switches shall also be included in the scope of AB Switches. mechanical inter works and arcing horns sets.10. Sl. set of insulators. are also included in the scope of supply. i ii Particulars MS Channel Creepage distance of Post Insulator Highest shell of Port 11KV AB Switch 450x75x40 320mm (Min) iii 254 mm iv i) Base 165x36x8 70x30x6 110x44 6 Nos. .5 The bidder should provide AB Switches with terminal connectors.Dimension of 11 AB Switches in (Max. 2/50 micro second impulse wave KV (Peak) 100% impulse flashover voltage of completely assembled switch with arcing horns with 1.GTP OF 11 KV A.e. Amps Short Time Current Rating KA (rms) min.B. make & country of origin Maximum permission continuous service voltage (KV) Length of the Break/Phase (Min. SWITCHES No 1 2 Particulars Type.) Phase to Phase Spacing Power Frequency withstand test completely assembled switches Against ground Dry KV Wet KV Across open contact Dry KV Wet KV Between Phases Dry KV Wet KV Impulse withstand test voltage of completely assembled switch without arcing horns with 1.2/50 micro second impulse wave KV (Peak) Particulars of the main contacts i. for 1 sec . fixed contacts and moving contacts Type Spring loaded fixed & knife type moving contacts Hard drawn copper alloy electrolytic 28 KV 28 KV 32 KV 32 KV 28 KV 28 KV voltage for 12 KV 400 mm 750 mm Requirement To be categorically specified 3 4 5 A) i ii B) i ii C) i ii 6 85 KV 7 85 KV 8 a b Material c Surface Treatment & Thickness of Silver Coating Silver plated of thickness of 5 micron 25 KG 400 amps 16 KA d 9 10 Contact Pressure Continuous Current Rating. The glaze. free from defects.No 11 12 Particulars Rated Peak Short Circuit Current (KA Peak) No. . The design of the insulator shall be such that the stresses due to expansion and contraction in any part of the insulator shall not lead to its deterioration.2 30.4 C Designation of insulators 30. thoroughly vitrified and smoothly glazed. of operations which the switch can withstand without deterioration of contacts Type of Mounting Type & Material used in connector Location and Type of Bushing Requirement 25 KA 2000 Horizontal up right mounting Brass/ Bronze strips Bush bearing at rotating insulator To be categorically specified 13 14 15 16 i ii iii iv v vi viii ix Particulars of Post Insulators Make( ISI make) Type Strength Weight No.3 DIMENSIONS: The dimensions of guy strain insulators shall be in accordance with REC specifications. the insulators shall comply with IS: 5300–1969 or the latest version thereof. unless otherwise specified.0 GUY STRAIN INSULATOR 30.) / unit One 254 mm 320 mm x xi xii xiii Power Frequency Flashover voltage KV (rms) Impulse flashover voltage KV (Peak) Impulse withstand voltage KV (Peak) Puncture voltage (KV) 70 KV 85 KV 80 KV (peak) 105 KV 30. of units per stack Height of stack mm Creepage distance mm One Minute Power Frequency Dry withstand voltage KV (rms) 65 KV To be indicated 11 KV Post insulator type 10 KN 5 Kg (approx.1 APPLICABLE STANDARDS: Except when they conflict with the specific requirements of this specification. The recommended type of guy strain insulators for use on guy wires of overhead lines of different voltage levels are as follows: Power line voltage 11000 V 30. The glaze shall cover the entire porcelain surface parts except those areas that serve as supports during firing. TYPE OF INSULATORS: The standard guy system insulators shall be of designations ‘A’ and ‘C’ as per IS:5300. GENERAL REQUIREMENTS: The porcelain insulator shall be sound. shall be brown in color. • • • • • • • • • • Routine Test: Visual examination type Test Visual examination Verification of dimensions Temperature cycle test Dry one-minute power-frequency voltage withstand test Wet one-minute power-frequency voltage withstand test Mechanical strength test Porosity test Acceptance Tests: (to be conducted in the following order) • • • • Verification of dimensions Temperature cycle test Mechanical strength test Porosity test 30. if any.1 PORCELAIN FUSE UNITS: Scope: This specification provides for manufacturing of rewireable type Porcelain fuses without sheet metal cover consisting of fuse carriers and fuse bases as mentioned in Schedule – I. . Marking on porcelain shall be applied before firing. NUMBER PLATE: Separate number plate is not required.7 TESTS: The insulators shall comply with the following routine.8 • • • • MARKING: Each insulator shall be legibly and indelibly marked to show the following: Name of trade mark of the manufacturer Year of manufacturer ISI certificate mark.6 MECHANICAL STRENGTH: The insulators shall be suitable for the minimum failing loads specified as under: Designation of Insulator A C Minimum failing load (KN) 44 88 30. 31. Numbers are to be written on poles/supports itself.5 BASIC INSULATION LEVELS: The test voltage of the insulators shall be as under: Designation of Insulator Dry one-minute power frequency withstand voltage KV (rms) A C 18 27 Wet one-minute power frequency withstand voltage KV (rms) 8 13 30.0 32. 30. type and acceptance test as per IS:5300. Wooden separators shall be fixed between the insulators to keep individual insulators in position without movement within the crate.0 32.30.9 PACKING: All insulators shall be packed in wooden crates suitable for easy but rough handling and acceptable for rail transport. 10 The side leaves on the base should be sufficiently thick and stiff to ensure tight fittings of ‘U’ contacts with base block. . ‘U’ Contact Extension strips for fixing lugs Side leaves Tin plated Brass/Copper strips Not to be provided 4.6 32.5 Width 17+. 32.5 Dia.5 Thick 1+. 16 Amp/ 415V 20+1 Width 8+.3 Iron and steel shall not be used for current carrying part including screws provided in base terminal block.5 32. hole 4.9 The minimum weight of current carrying parts shall not be less than as indicated 16 A /415 V 18.2 Technical Particulars: (i) (ii) The porcelain rewireable type electric fuses having fuse carriers and fuse bases of specified ratings must conform to IS:2086-1993 or with latest amendments. The screws used on terminal block for fixing of incoming and outgoing wires to the terminal should be of brass and of adequate dimension. The dimensions of terminal holes of the fuse units must be adequate for the suitable cable entry as under:For fuse units of 16 Amp rating the terminal hole should be suitable for 6 sq. ‘U’ contact should penetrate full depth of based contacts.8 The contacts used shall be of excellent quality and alignment should be perfect so as to provide easy but perfect contact. 3.N Ratings ‘U’Contact Dimension (mm) Length 1.No.16 amps ratings should be as under: S.5 32.4 32. The dimension of ‘U’ contacts and terminal block used in. 32. The insulating resin used to protect accidental contact of screws should be of good quality so that it should not melt off at full load. Terminal Block Tin plated cast brass metal 2.5 Length 12+. Where fuse wire is made to pass through the hole provided in the porcelain carrier. Particulars Ratings 16 Amp 415 Volt 1. 32.5+. The material to be used for various current carrying/non-ferrous parts shall be as tabulated below:S. Gm below:- 32.11 Care has to be taken to ensure that no corrosion takes place between aluminum and copper/brass of the fuse terminal being of different types of materials.12 The guaranteed technical particulars should be strictly as per schedule-III enclosed. Tin plated Phosphor bronze.32. 32.5 Terminal block dimension (mm) Height 10+. an asbestos tube must be inserted in the hole to avoid direct heating of the porcelain. mm aluminum cables. 32.7 Asbestos sheet (and not asbestos cloth) shall be used in porcelain fuse units to avoid short circuit between earth and fuse wire. which might have not form an integral part of the PF units.13 The P. units: a) b) Name of the manufacturer MPPVVKCL logo indicated but 32.1 SCOPE: 9 18 gm This specification cover the details of the porcelain insulators for use of 415/240 V overhead power line within electric distribution system. i) Temp. width and depth of base terminal block Minimum weight of current carrying parts 3x6 1x8 brass 6 3x8 33.F.T. .16 The following acceptance tests should be performed on each lot (rating-wise) offered for inspection:- a) b) c) d) e) f) g) h) Visual Examination Test for dimensions Test for mechanical endurance Test for withdrawal force Test for temp. SHACKLE INSULATORS (Size 90 x 75 mm) 7 24 swg.0 L. cycle test ii) test. rise Insulation resistance test High voltage test Test on ceramics material.F. 32.32.2086 16 Amp 415 V 12 C 2 3 Temperature rise of base as per IS 2086 Insulation resistance i) Between live terminal & exposed metal part ii) Between incoming live terminal & outgoing live terminal 10 C Above 10 Mohm Above 10 Mohm 4 5 Size of fixing screws provided for fixing fuse Thickness and width of ‘U’ contact and metal used in ‘U’ contact Dimension of screws provided on terminal block for fixing the fuse wire made of brass Thickness and width of base leaves and metal used for base leaves Length.15 Acceptance Test: 32. Water absorption S No 1 Particulars Temperature rise of fuse carrier as per IS. units should be supplied complete with all accessories.14 The following embossing should be done on either side of base of P. brass 8 7x10x12 33. 5 DRAWING AND DIMENSIONS: As per enclosed Technical Specification.2 STANDARDS: Unless otherwise modified in this specification. 33.5 4.9 53. 33. 33. the insulator shall comply with IS: 1445-1977 with or the latest version thereof.5 3.1 Zero Net permissible size Maximum 95.5 36. Power frequency puncture withstand test. Acceptance Tests & routine tests shall be as per ISS:1445-1977 with latest amendment.9 Minus (-) 5.1 4. Permissible tolerances in sizes are as under (All dimensions are in mm) S.3 GENERAL REQUIREMENTS: The porcelain shackle be sound free from the defects.9 3.1 2.1 17. Wet power frequency voltage withstand test. The insulators should of size 90x75 mm with a central hole of minimum 15 mm dia and shall conform to Shackle insulator type I of IS:1445-1977. A B C D E F G 90 75 85 50 40 15 10 5.5 80. 33.0 33.9 3.No.1 4.1 1. Porosity test.9 12.5 4. test certificate from NABL Accredited laboratory giving results of following test as per IS:1445-1977 with latest amendments:(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) Visual examination Verification of Dimensions.9 70.1 2.9 Minimum 84.4 WHITE GLAZED PORCELAIN SHACKLE INSULATORS.1 The Employer’s representative shall at all times be entitled to have access to the works and all places of manufacture where equipment/material shall be manufactured and the representative shall .1 11.1 46.1 79. Temperature cycle test.9 10.5 3.7 INSPECTION: 33.5 43.. Dry power frequency voltage withstand test. White glazed Porcelain Shackle Insulators without hard ware fittings suitable for low tension 660 Volts grade overhead power lines. Particulars Drawing of Size specified Permissible tolerance Plus (+) 1 2 3 4 5 6 7.6 TEST CERTIFICATE: The Bidder/manufacturer/Manufacturer shall be required to furnish with their offer.5 89. Mechanical failing load test.7. thoroughly vitrified and smoothly white glazed.33. 33. . Handling and unpacking instructions. The quality assurance of plan and Employer’s hold points shall be discussed between the Employer and Bidder/manufacturer. Type test certificate of raw material and bought out accessories. Total weight of consignment. the equipment/material shall be dispatched only after satisfactory testing for all tests specified herein has been completed.10.1 The equipment shall be packed in cerates suitable for vertical/horizontal transport. 34.have full facilities for unrestricted inspection of the Bidder/manufacturer’s works raw materials and process of manufacture for conducting necessary tests as detailed herein. Wherever necessary. and shall not prevent subsequent rejection if such material is alter found to be defective. proper arrangement for lifting.7.5 The number of sample selected to carry out the acceptance test shall be as per provision in the respective IS. before AQP is finalized.3 No material shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested.10. Details of consignment.2 MARKING: Each consignment shall be accompanied by a detailed packing list containing the following information: (a) (b) (c) (d) (e) (f) Name of consignee. Any material found short inside the packing cases shall be supplied by Bidder/manufacturer without any extra cost. 33. The easily damageable material shall be carefully packed and marked with the appropriate caution symbols. All manufacturing and fabrication work in connection with the equipment prior to the approval of the drawing shall be at Bidder/manufacturer’s risk. Bill of material indicating contents of each package.6 The Employer has the right to have the tests carried out by NABL accredited laboratory or an independent Agency subject to recovery of testing expenditure in case of failure. 33. due to improper and inadequate packing. (i) (ii) (iii) List of raw material as well as bought out item accessories and the names of subBidder/manufacturers selected form those furnished along with offer. The Bidder/manufacturer/Manufacturer shall be responsible for any damage to the equipment during transit. 33. 33. Quality assurance plan (QAP) with hold points for the Employer’s inspection. Destination. 33.7.10 PACKING AND FORWARDING: 33. shall be provided. 33. if any.8 The successful Bidder/manufacturer/Manufacturer shall within 30 days of placement of order submit following information to the Employer. 33. as the case may be and suitable to withstand handling during transport and outdoor storage during transit.7. such as lifting hooks etc.3 On each packages/crates containing the material/equipment following information shall be distinctly on it in indelible ink along with other essential data. In the later case also. whenever there is dispute regarding the quality of supply.9 DOCUMENTATION: The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the Employer.4 The acceptance of any quantity of material shall in no way relieve the Bidder/manufacturer of any of his responsibilities for meeting all requirements of the specification.7.10. unless the inspection is waived off by the Employer in writing. 33.2 The Bidder/manufacturer/Manufacturer shall keep the Employer informed in advance of the time of starting and of the progress of manufacture of equipment/material in its various stages so that arrangements can be made for inspection.7. 3 X the actual Dry flashover voltage 11.04d+1) mm (where d = dimensions) White glazed As per specification As per specification 23 KV (rms.) 10 1. No Particulars Required Offer by bidder the 1 Standard specification to which the insulator shall conform Dimensions Hole diameter Tolerance in dimensions (in mm) various IS:1445/1977 with latest amendments 2 3 4 90x75 mm 15 mm (+) (0.5 KN 11 Minimum Mechanical failing load .) IS 5 6 Colour Dry flashover voltage 7 Wet flashover voltage IS 8 Dry one minute power frequency withstand voltage Wet one minute power frequency withstand voltage Power frequency withstand voltage puncture 9 10 KV (rms.(i) (ii) (iii) (iv) (v) (vi) (vii) Contact Award letter number Name and address of consignee Manufacturer’s name and address Name of item Quantity Gross weight Arrow marking for stacking/opening Guaranteed Technical Particulars for LT shackle Insulators S. with 1x25 Sq. The insulated conductors shall generally conform to the standards IS-14255:1995. The thickness of insulation shall not be less than 1.IV/1994: Aluminum alloy conductor. 35. GENERAL: The cable covered under this specification should be suitable for use on three phase.Alloy Messenger wire 34. 35. Conductors for insulated cables.mm+1x16 sq. APPLICABLE STANDARDS: Unless otherwise stipulated in this specification the following standards shall be applicable.4 The standard size and technical characteristics of the phase conductors shall be as shown in the Table1.34 TECHNICAL SPECIFICATION FOR `ISI' MARKED XLPE INSULATED AND PVC SHEATH 1100 VOLTS AERIAL BUNCHED CABLE 34. insulated street light conductor 16 mm² XLPE insulated and both shall be PVC sheathed and the messenger conductor shall be 35/25 mm² bare heat treated silicon containing 0.4.mm.mm bare Al.2 mm up to 35 mm and shall not less than 1.mm bare Al.5% silicon confirming to IS: 398 (Part-IV):1979 and its latest amendment.5. RATED VOLTAGE: The rated voltage of the cables shall be 1100 volts 34. It should conform to the relevant standards stated above and others if applicable.2 The phase conductors shall be provided with one.Alloy Messenger wire.Alloy Messenger wire iv) 3x16 Sq. In addition to XLPE insulation each XLPE insulated core shall have BLACK PVC coating over XLPE insulation having thickness of 1 mm and identification of core shall be on coating. 4 wire earthed system for working voltage up to 1100 V.mm+1x16 sq.mm bare Al.Alloy Messenger wire iii) 3x16 Sq. (i) IS – 14255/1995: (ii) IS – 8130/1984: AB cables up to 1100 volts. (iii) IS – 398/Pt. (iv) IS – 10418/1982: Drums for electric cables 34.mm.3.5 2 mm for above 35mm at any point and insulation shall be so applied that it fits closely on the conductor and it shall be possible to remove it without damaging the conductor.mm.5.3 The tensile strength of the aluminum wire used in the conductor shall not be less 90 N/mn². if any. 35.2. PHASE & NEUTRAL CONDUCTORS: 35.mm with 1x25 Sq.mm bare Al. 34. two & three ‘ridges’ for easy identification. manufacture.5. testing and delivery at places anywhere in MP for the following cables suitable for LT overhead lines:1100 Volts ISI marked Aluminum Conductor XLPE Insulated & PVC sheathed Aerial Bunched cable conforming to IS:14255/ 1995 with latest amendment and as per technical specification of following sizes i) 3x50 Sq.1.mm+1x16 sq. with 1x25 Sq.5% magnesium and approximately 0. with 1x35 Sq. SCOPE: The specification covers the design.5.1 The phase and street light conductors shall be provided cross linked poly ethylene insulation applied by 2 extrusion. . ii) 3x25 Sq.5. The phase conductors shall be 50/25/16 mm² XLPE. MESSENGER WIRE: 35.20 0.8 7.4 10.5 Insulation Thickness In mm NOTE: 1) The resistance values given above are the max. mass Kg/Kms. 2) Tolerance of + 5% is allowable on dimension. DC Résistance at 20ºc (Ohm/km) Minimum Ten sile Stre ngth (KN) NOTE: 1) The resistance values given above are the max. permissible. mass Kg/Kms. permissible.5 6.8 65 95 1. 2) Tolerance of + 5% is allowable on dimension.986 7.6. of Strands Diameter of compacted conductor in mm.868 0.6. TABLE –2 Nominal sectional area in mm² No.30 Approx.6.3 The sizes and other technical characteristics of the messenger wire shall be as given in the Table No. 4. of Strands Diameter of comp acted condu ctor in mm.5 6.380 0. 35.91 1. DC Résistance at 20ºc (Ohm/km) 42 65 95 127 1.2.9 Approx.2 There shall be no joint in any wire of the stranded messenger conductor except those made in the base rod or wires before final drawing.1 The bare messenger wire shall be of Aluminum alloy generally confirming to IS–398/Pt.0 1.IV/94 composed of 7 strands and shall be suitable compacted to have smooth round surface to avoid damages to the overall insulation of phase & neutral conductor twisted around the messenger.TABLE-I Nominal sectional area in mm² 16 25 35 50 7 7 7 7 No. . 35.0 1.4 5.6. 25 35 7 7 5. Max.2 1. Max.641 1. 34. + 25% Max 200° C 15 minutes 20 N /cm². TYPE TEST: (A) Test for Phase/Street Light Conductors a) Tensile Test (IS-8130) b) Wrapping Test (IS-8130) c) Conductor Resistance Test (IS-8130) (B) Test for Messenger: 12.IV/1994) c) Resistance test (IS . XLPE INSULATION: The insulation shall generally conform to IS-7098(Part-I):85 Property Requirement Tensile Strength Elongation at break Ageing in air over a. IV /1994) (C) Physical test for XLPE insulation i) Tensile strength and Elongation at break ii) Ageing in air oven iii) Hot set test iv) Shrinkage test .398 / Pt.5 N / mm² Min 200 % Min 135° ± & 7 days C +25% Max. 17.5 % max 130° for 1 hours C 4% max 85 + 2° 14 days C 1 mg. / cm² max a) Breaking load test (to be made on finished conductor) –(IS-398 / Pt.34.IV / 1994 with latest revision) b) Elongation test (IS .7.398 / Pt. Duration Water absorbed 34.8. Treatment: temperature & duration Tensile strength variation+ Elongation variation 4a Treatment temperature Time under load mechanical stresses Elongation under load Treatment temperature & duration Shrinkage Water absorption (Gravimetric) Treatment – Temp. Content & 2. Test for thickness of insulation g. It shall be than unwound and the process shall be repeated after turning the sample around its Axis 180° The cycle of . cracks visible to the naked eye are allowed. 34. Dispersion (D) Test for thickness of insulation (E) Insulation Resistance (Volume Resistivity) Test (F) High Voltage Test (G) Bending test on complete cable: Bending test shall be performed on a sample of complete cable. Tensile test (for Phase / Street light conductor) b.9.2 Bending Test on complete cable: Bending test shall be performed on a sample of complete cable as under. Tensile strength and elongation at break test h.1 Tests for Phase / Street Light Conductors : a. The Bidders should submit all the above type test within 28 days of the Letter of Award.e. The sample shall be wound around a test mandrel at room temperature for at least one complete turn. Insulation Resistance test j. The cycle of this operation shall be then repeated twice. Hot set test ( For XLPE insulation) i.9. It shall then be unwound and the process shall be repeated after turning the sample around its axis 180. cir scrutiny circle diameter) d = Actual diameter of the conductor in mm No. the min. ACCEPTANCE TESTS: 34. Where D = Actual diameter of cable (i. The sample shall be bent around a test mandrel at room temperature for at least one complete turn. Breaking load test for messenger conductor d. Where D = Actual diameter of cable d = Actual diameter of the conductor in mm . The diameter of mandrel shall be 10 (D+d). Conductor Resistance test f.9. these operation shall than be repeated twice.v) Water absorption (Gravimatric) vi) Carbon black 1. Elongation test for messenger conductor e. Wrapping test (for Phase / Street light conductor) c. The dia of the mandrel shall be 10 (D+d). High voltage test 34. 3 The cable drums should be suitable for wheel mounting.14. without charge. TYPE TEST CERTIFICATES: The bidders have to submit type test certificate as per IS from any NABL accredited lab along with their offer for the offered or higher size.2 The drums shall be of such a construction as to assure delivery of conductor in field free from displacement and damage and should be able to withstand all stresses due to handling and the stringing operation so that cable surface not dented. INSPECTION: All tests and inspections shall be made at the place of manufacturer unless otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase.10. 34. 35. STANDARD LENGTH: The standard length of drum will be 500 metre with ± 5% Non-standard Length: Non standard length not less than 50% of the standard length shall be accepted to the extent of 10% of the ordered quantity.No cracks visible to the naked eye shall be permitted. 34.11. .10.10. 34. The manufacturer shall afford the inspector representing the purchaser all reasonable facilities. scratched or damaged in any way during transport and erection. 34. PACKING MARKING: 34.1 The cable shall be wound in non returnable drums conforming to IS-10418/1982 “Specification for Reels and Drums for bare wire” of the latest version thereof. 34. to satisfy him that the material is being furnished in accordance with this specification. The cable shall be properly lugged on the drums. The drums shall be marked with the following: a) Manufacturers name b) Trade mark. if any c) Drum number d) Size of Conductor e) Size of Messenger f) Voltage grade g) Number of lengths of pieces of Cable in each drum h) Gross mass of the packing i) Net mass of Cable j) ISI mark.10.12. mm.mm with 1x25 Sq.mm+1x16 sq. ii) 3x25 Sq.mm+1x16 sq. IS: 14255/1995 d. with 1x25 Sq. 1100Volts c. length up to 10% of ordered qty.mm bare Al.IV/1994 12 Maximum phase Conductor resistance at 20ºC a.mm. Alloy Messenger wire sn 1 Particulars Cable shall be manufactured and supplied conforming to IS: 14255/1995 with latest amendment if any Cable drums/label shall bear ISI Mark ISI License shall remain valid till order is Completed Colour of XLPE Insulation – Black Shape – compacted Standard length in case of drum of 500 metres ± 5 % Non-Standard length 50% of Std.mm Conductor – 0.GUARANTEED TECHNICAL PARTICULARS OF CABLE Bidders have to confirm following important requirements separately for each size: i) 3x50 Sq.50 sq.mm bare Al.mm Alluminium Alloy as per IS 398/ Pt.641 Ohm/Km b.mm bare Al.mm bare Al. Year of manufacture e. with 1x25 Sq. Alluminium as per IS 8130/1984 (ii) For Messanger wire a) Material (Grade) b) 35 sq.mm Conductor – 1.Alloy Messenger wire iv) 3x16 Sq.Alloy Messenger wire iii) 3x16 Sq.mm.91 Ohm/Km 13 Maximum Messenger Conductor resistance 35 sq.mm.Alloy Messenger wire. with 1x35 Sq.mm.16 sq. Packing shall contain only one Length Packing material Wooden drums as per IS:10418/ 1982 duly painted Following shall be embossed on cable a. Trade Mark Marking on drum shall be as per IS:14255/1995 11 (i) Conductor For Phase a) Material (Grade) b) 50 & 16 Sq.mm+1x16 sq. at 20ºC Size of Cables 2 3 4 5 6 7 8 9 10 . MPEZ b. Elongation % d. Thickness of sheath in mm(min) b.14 15 Thickness of insulation (min in mm) Volume resistivity of insulation at 27° C at 70° C 16 a. Tensile strength of Insulation (Min) b. Cold impact 18 Overall Tolerance in supply of ordered total quantity shall be ±2 % 19 Approx weight of complete cable per Km . Tensile Strength (Min) c. Elongation at break of Insulation 17 a. Cold Bend e. of pole clamps should be got confirmed invariably before supply.5 ANCHORING CLAMP/ DEAD END CLAMP ASSEMBLY: (a)The anchoring clamp/ dead end assembly shall conform to NFC 33-041 standards. The hardware /accessories will be supplied with Suspension Clamps and Eye Hook with PCC/ Girder Pole Clamps. REC E-34. However.5% silicon conforming to IS:398 (Part-IV) 1979 and its latest amendment.33-004 : Electrical Ageing Test. Dead End Clamp / Anchoring Clamp and Eye Hook with PCC/ Girder Pole Clamp.5% magnesium and approximately 0. (Any other standard applicable for these clamps shall also be acceptable. ii. Wedge type clamps shall be used for clamping the messenger without damaging the strands of the bare messenger. The rope should have sufficient flexibility to ease the torsional movement of the ABC system (f)The anchoring clamp/ dead end assembly shall be provided with suitable Eye Hook & Pole Clamp to erect them on 8M PCC/ Girder Poles having top and bottom dimensions as per NFC 33-041 standards. neutral messenger should be fixed by an adjustable grip device. e) The design of clamp shall be bolt-less. IS:2629 & IS:2633: Suspension Clamp.’ 35. iii. of pole clamps should be confirmed invariably before supply. Bolts. 35. The clamp shall be of aluminium body with fully insulating type of mechanical and weather resisting thermoplastic wedges. sharp radius of curvature and edges shall be suitably rounded off. g) The suspension clamp shall be provided with suitable Eye Hook & Pole Clamp to erect them on 8M PCC / Girder Poles having top and bottom dimensions as per NFC 33-040 standard. E-35. IS 14255 : LV Aerial Bunched Cable.) NFC . Alloy messenger wire size of 25sq. c) The suspension clamp shall be capable of holding bare Al. f) The Suspension clamp shall be made fully of insulating type of mechanically strong and weather resistant plastic for protection of phase cable.mm respectively. h) The performance/ test requirements shall be as per NFC 33-040 standards. no tools required to clamp the messenger wire. of hardware/ accessories suitable for LT Aerial Bunched XLPE insulated PVC sheathed phase conductor (Aluminum) cables with bare messenger wire for LT overhead lines suitable for working voltage up to & including 1100 Volts as per relevant REC construction standards. Insulation Piercing Connectors along with Nuts. sharp radius of curvature and edges shall be suitably rounded off.0 TECHNICAL SPECIFICATION FOR ACESSORIES (CLAMPS). SUITABLE FOR AERIAL BUNCHED CABLE 35. 35. iv.35. Alloy messenger wire size of 50/ 35 /25 sq.’ 35. (b)The anchoring clamp (dead end assembly) shall be capable of holding bare Al.1 SCOPE : This specification covers manufacturing. However.6 INSULATION PIERCING CONNECTORS: . the size and no. There should not be any loos-able part in the process of clamping.e.mm. and Washers. if any. 35sq.33-020 : Insulation Piercing Connectors NFC . etc.. Dead End Clamp. 35. (c) The anchoring clamp/ dead end assembly shall have good finish and shall be free from all flaws. (e)The Anchoring Clamp shall be supplied with a stainless steel flexible Rope to connect the Tension Clamp to the Eye Hook.mm and 50sq.mm. The flexible Rope forming part of clamp should be of length to maintain at least 150mm distance between Eye Hook and body of clamp. the size and no. b) The suspension clamp shall provide sufficient flexibility to allow for movement of clamp at both straight run and angle locations. testing before dispatch. d) The suspension clamp shall have good finish and shall be free from all flaws.3 GENERAL REQUIREMENTS: The hardware/accessories should be suitable for AB Conductor required as under: 2 2 2 2 The phase conductors shall be 50mm /35mm /25mm and street light conductor 16mm XLPE 2 2 insulated PVC sheathed (1mm) and neutral cum messenger conductor shall be 35mm /25mm bare heat treated Aluminum silicon containing 0. (g)The performance/ test requirements shall be as per NFC 33-041 standards.4 SUSPENSION CLAMP ASSEMBLY: a) The suspension clamp shall conform to NFC 33-040 standard.2 APPLICABLE STANDARDS Unless otherwise stipulated in this specification the following standards with latest amendments shall be applicable: i. (d)The design of clamp shall be boltless i. 16-50 Sq. The piercing teeth shall be made of Copper Alloy. Insulation Piercing Connectors shall conform to NFC-33-020. mm. 16-50 Sq. The End cap shall be rigid of slide type enabling easy positioning and unloosable after the tap cable is positioned. i) Rubber seal around piercing teeth shall be compatible with grease used. k) The Insulation Piercing Connectors shall have good finish and shall be free from all flaws. e) The Insulation Piercing Connectors must be suitable for application by one worker working alone with a 17mm/ 13mm/ 10mm wrench. 3. XLPE or PVC XLPE or PVC 1. sharp radii of curvature and suitably rounded off.mm.T. Standard to which material conforms Are GA drawings enclosed? Are experience certificate enclosed? Suitable for (size of messenger)? Material used in manufacture . c) The L. Insulating Piercing Connectors are used for making Tee or Tap off connections to an Aerial Bunched Cables suitable upto 1.mm.T. Exposed metallic parts shall be potential free during & after connector mounting.T. bare messenger wires. Insulation Piercing Connectors shall be following type: ----------------------------------------------------------------------------------------------Type Main Cable Tap Off Cable End Cap suitable for Sealing Branch --------------------------------------------------------------------------------------------I 16-50 Sq. The End cap shall be equipped with a water tightness seal. f) The Insulation Piercing Connectors must be equipped with Aluminum alloy shear heads with minimum & maximum torque as indicated by the manufacturer and within the range specified in NFC 33-020. The bolt & washers shall be made of Mild Steel conforming to IS:1573 The Boltless wedge type earthing connectors conforming to REC construction standards shall also be acceptable.7 EARTHING CONNECTOR: Earthing connector shall be one bolt type made of Extruded Aluminum Alloy conforming to IS:617-75 and shall be suitable for 25 to 50 sq. service voltage 0.mm. Dead end/ Anchor clamp 2. Name & Address of manufacturer II 16-50 Sq. Insulation Piercing Connectors are designed to make a connection between the uncut main conductor & a branch cable conductor without removing the insulation and with single tightening. 4.5-10 Sq. 6.mm. 1. j) All the insulating material used shall be UV resistant & fire retardant.5-10 Sq. and then make good electrical contact between the main & the branch conductor while simultaneously insulating & sealing the connection.T.6 KV.mm.mm. The IPC will first pierce the insulation. g) The Insulation Piercing Connectors shall be water proof & the water tightness shall be ensured by appropriate elastomer material h) The Connector shall have removable end cap for sealing cut end of the branch cable enabling tapping on either side of the connector with the connector being in its vertical position with bolt head upward.1 KV.a) The L. Metallic parts shall be noncorrosive surface treatment. PARTICULARS Suspension Clamp N 1. l) The performance/ test requirements of insulation piercing connectors shall be as per NFC Standards 33-020. Rubber parts shall comprised of material that exhibit resistance to aging caused by heating or other weather conditions. 35. 5. b) The L. XLPE or PVC XLPE or PVC ---------------------------------------------------------------------------------------------d) The L. Rubber seal shall be designed in a manner to provide proper sealing around the piercing & to avoid the damage to conductor insulation beyond piercing point. GUARANTEED TECHNICAL PARTICULARS FOR (i) SUSPENSION /DEAD END CLAMP ASSEMBLY FOR BARE MESSENGER WIRE S. 17. Branch (Tap off): 1. N PARTICULARS TO BE SPECIFIED 1. 19. Tensile Load slippage/break. 8. Name of Bidder Name & Address of manufacturer of Piercing Connector Are GA drawings enclosed? Are experience certificate enclosed? Insulation Piercing Connectors range Main : 16 .10 mm 6. 8. (Kg) on Branch conductor for no 7. in each cycle (Deg. 14. 9. 13. 9. Tensile Load for no Break down of main conductor. 15. Voltage withstand under water immersion Electric aging test report enclosed? No.50 mm . 9.5 . 2 2 Is any metallic part carrying potential in operation exposed during installation? Material used for teeth Surface Finish of teeth Are end caps for branch cable provided? Slide on type Rigid Are torque limiting shear heads provided on tightening bolts? Rated tightening torque (Nm) Torque for establishing connection between Main & Branch (Nm) Max. (Kg) Max.7. 12.2 10. 11.1 9. 4. 3. 18. 16. 5. width & thickness of complete connector/ assembly (ii) INSULATING PIERCING CONNECTOR FOR AERIAL BUNCHED CABLE S. Temp. Method of Manufacturing Tension load Test voltage (Min 6 KV AC for 1 minute) Length.) Over current test current . 2. of cycles Max. 10. The process adopted for manufacture of these boxes should be injection/Hot press Compression moulding process.T. c. three phase connections as per drawing no. The thickness of both the box should be 2 mm + 2%. 21. manufacture. Moulded casing of Bus Bar shall be made of Nylon glass filled capable of Fire Retardency test at 950° as per Specification No. COMPONENTS a. The heat deflection temperature of the box material should be 1250C @ 0.i. DISTRIBUTION BOX SPRING LOADED CONSTANT PRESSURE MULTICONNECTION TYPE FOR 3 PHASE AND SINGLE PHASE SUPPLY SCOPE:. supply & delivery of UV resistant Fire Retardant Polycarbonate box suitable for connection of 5 nos. The box shall have concealed type hinges. Name & Address of manufacturer of CLAMP FOR NEUTRAL CONNECTION Are GA drawings enclosed? Are experience certificate enclosed? Materials Conductor range (mm ) a) Length. of bolts along with nuts and washers Particulars of Galvanisation 2 2. 6. 4.2 a. 7. Discom/EZ/43-44. single phase connections or 2 nos. The other Dimensions & General details shall be as per Specification / GTP.3. ii) The internal dimensions of the box (enclosure) for three phase 1 incoming and 2 outgoing should be : 350x270x200 mm + 2%. 3. IEC Publication 695-2-1. specification will supersedes all. 36. Ii 20. MATERIAL AND CONSTRUCTION OF THE ENCLOSURE The box (enclosure) shall be made of UV resistant Fire Retardant Polycarbonate or thermosetting plastic (Glass reinforced polyester Sheet Moulding Compound) SMC conforming to IS-13410:1992 capable of withstanding boiling water for 10 minutes without deformation of box material. b. 36. approved by the purchaser and suitable to purchaser’s requirement.45 mpa. width & thickness of complete connector b) No. Value (Amps) Duration (Sec) Resistance change duration Is Corrosion test report enclosed? Is Climate Ageing test report enclosed? (iii) EARTHING CONNECTOR (CLAMP FOR NEUTRAL CONNECTION) S.This specification provides for design. 22. C Dimension & General details shall be as per GTP and specs. The flammability rating of the material as per UL 94 should be V0. i) The internal dimensions of the box (enclosure) for single phase 1 incoming and 5 outgoing should be :250x250x160 mm + 2%. 36. 5. PARTICULARS TO BE SPECIFIED N 1. no screws/rivets visible from outside .In the event of disrepency between drawing and specifications. The purpose of distribution box is to provide service connection from AB XLPE cable to consumer meter through service line. testing.1 L.0 36. Four Sets of Busbar molded casing for three phase supply and Two sets of Busbar molded casing for single phase supply each containing two copper bus bars and spring loaded system along with pressure plates should be provided. mm approx (Two Busbars of 37. Neoprene Rubber gasket to be provided all around the cover. mm). mm approx (Two Busbars of 37. Arrangement for mounting of Box on Pole : .0 mm. The minimum length of copper bus bars should not be less than 63 mm. g.b. l. The pressure plate sheet thickness should not be less than 2 mm. and diameter of spring wire should not be less than 2. The springs are required to be retained in the housing by means of a stainless steel rod at the bottom end of the housing so as to exert pressure on the pressure plate when cable is inserted in the Bus Bar.2 mm sheet Gland Plate with 6 Nos. Bolts & Washers. Nylon 6 triangular key should be provided with the box. The four ends of the Nylon supports shall be suitably affixed with the base of box by providing Nuts. n. Also. mm). Hot Dip Galvanised 1. making a total of 75 Sq. One set of Mounting arrangements for fixing of box shall be supplied free of cost with each box. The Busbars meeting the requirement of aforesaid current rating and maximum current density be provided in two identical pairs for Phase as well as for neutral. The minimum current rating of Busbars should be 200 Amps. Both are to be made of stainless steel only.5 Sq. of holes is to be provided for one incoming and two outgoing cables from each phase and neutral as per drawings. each connected cable shall have a pressure applied to it at the point of connection to provide connection integrity and eliminate loose connections. ii). Arrangement: The busbar housings shall be arranged and mounted at a suitable stepped angle so that making new connections is easy without much bending the cables. j. m. In case of Three Phase : There shall be a provision of one incoming + two outgoing circuits on each of three phase and neutral busbars. c. The pressure plates which keep pressing the cable conductor & springs with sufficient strength of thickness 2mm. Spring loading system: The connections system shall be spring loaded so that no fasteners are required to add a new connection from the distribution system. o. The four ends of the Nylon supports shall be suitably affixed with the base of box by providing Nuts. mm each.5 Sq. The minimum current rating of Busbars should be 200 Amps.25 mm and wire dia of 2mm. p. triangular keylock locking system has to be provided in the box. The Pressure Plates and Busbar System should be suitable for incoming up to 50 Sq mm Aluminium/Copper Cable and up to 35 Sq mm Aluminium/Copper Cable for outgoing circuits. zinc passivated U clamps with holes. 1 No. One no. f. k. At bottom side of the enclosure. Two sets of Nylon supports are to be provided at the ends of Bus Bar casings to enable it to be fixed at Base at an easy to wire angle. i). In case of Single Phase : There shall be a provision of one incoming circuit of single phase & Neutral & 5 outgoing connections of single phase and neutral in the bus bars. i. of holes is to be provided for One incoming and Five outgoing cables for single phase and 3 Nos. d. The minimum length of copper bus bars should not be less than 125 mm. Bolts & Washers. making a total of 75 Sq. The key lock should be made of brass / stainless steel / steel nickel plated. The Busbars meeting the requirement of aforesaid current rating and maximum current density be provided in two identical pairs for each Phase as well as for neutral. The minimum spring size should be about 35 mm from end to end with a outer diameter of 14. h. For Three Phase : The Bus bars should be made of EC grade copper and with a total cross section of 75 sq. a M. SEALING OF BOX : The enclosure cover shall have a U clamp sealing system with 2 Nos. mm each.S. Two sets of Nylon supports are to be provided at the ends of Bus Bar casings to enable it to be fixed at Base at an easy to wire angle. Bus bars: For Single Phase : The Bus bars should be made of EC grade copper and with a total cross section of 75 sq. Muradnagar testing laboratory or a COFRAC certified laboratory. Bhopal/ CPRI. The principal outer dimensions of each item. IS:2629 & IS:2633. However bidders are advised to submit their own design/drawings of respective item duly type tested as per relevant standards. double the sample lot is to be drawn and there should be no failure/defect exceeding half the permissible defects (rounded down) shown in the chart. The procedure of installation with diagram shall be provided with each box kept inside.2 % nil 1 2 2 + For Tests Marked ** Sample Size Max 1 2 2 4 Nil Nil Nil 1 Lot Size Upto 100 101-500 501-2500 2501 & above permissible Defects permissible Defects 10 % of additional sample qty . Type test:.5 TESTS & TESTS CERTIFICATES: (i) The Hardware / accessories should meet the requirement of all tests as specified in respective REC construction and NFC standard. Hot Dip Galavanised mounting channels of thickness 1. Bangalore / CPRI. The successful bidder within two weeks of placement of order shall furnish three sets of final versions of all drawings of hardware/ accessories for purchaser’s approval along with sample finalized. Jabalpur should be embossed or suitable method shall be adopted for indelibly print on the cover of the box in big font. ii.The following shall constitute Type tests for Suspension and Dead end Clamps i) Tensile Test on Brackets ii) Tensile / Mechanical Test on sub-assembly iii) Slippage Test (for suspension Clamp only) iv) Voltage test on assembly v) Corrosion Test vi) Climatic Test vii) Endurance test under Mech and Thermal Stress (for Anchor Clamps only) Acceptance Tests:. of M.4 i. E-35.REC E-34. DRAWINGS: A drawing / picture clearly showing principal parts & dimensions for all products should be submitted along with the offer. IS:617-75 and IS:1573 along with other relevant standards and their latest amendments.The following shall constitute acceptance tests: For Anchor Assemblies i) Visual * ii) Dimensional (as per SCD and Overall dimensions submitted with tender ) * iii) Mechanical Test on bracket ** iv) Mechanical test on clamp ** v) Voltage Test * For Suspension Assemblies vi) Visual * vii) Dimensional (as per SCD and Overall dimensions submitted with tender) * viii) Mechanical Test on Bracket ** ix) Mechanical tests on Clamp ** x) Voltage Test * The above tests are to be carried out as per sampling plan below. q. The MPPKVVCL shall reject the offer of the bidder who does not have valid type test report. 1 x b x w in mm and weight in gms should be submitted along with the offer. (ii) The bidder shall furnish latest complete type test certificates (should not be older than 5 years) prescribed in respective REC construction and NFC standard from any NABL Accredited / CPRI. Few examples of drawings of various accessories are shown in Schedule-II(B). In case of random failure/defect. NFC-33-020. Property of MPPKVVCL. 6 mm thick MS Pole mounts are to be provided as per the drawing enclosed.6 mm and 2 Nos.The box shall be provided with 2 Nos. 36. r.S. 36. For tests Marked * Sample Size Max 2 5 10 10 + 0. In case of other particulars of the place such testing is proposed to be conducted during the course of inspection shall be indicated with the offer. Standard IS:14772 AS per specs & GTP IS:14772 IS:14772 Clause 7 9 12 Requirement Marking Dimensions Protection against electric shock Resistance to aging to humid conditions.8 ACCEPTABILITY OF SUPPLIED MATERIAL: .5KV 17 IS:11000-I/ IEC Glow wire test at 95° of C 695-2-1 molded casing of bus bar 18 Of/ At NABL Lab Bus bar casing material identification 36.5. Inspection and acceptance of any equipment / material under this specification by the purchaser shall not relieve the supplier of his obligation of furnishing equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment / material are found to be defective.45 MPa C 12 IS:4249 3. In absence of these tests the tender will be liable for rejection.The bidder must also clearly indicate various testing facilities available at their works for testing the material as per relevant standard.7 INSPECTION: (iii) A T T T T A The inspection may be carried out by the purchaser at any stage of manufacture. The purchaser reserves the right to insist for witnessing the acceptance /routine tests of the bought out items.1 Test for self extinguishing properties 13 IS:11731-II Flammability test 14 Of/ At NABL Lab Enclosure material identification Following tests are to be conducted for bus bar 15 Temperature rise at 200 Amp 16 IS:2683-I Verification of electric properties of molded casing of bus bar at 2. (iv) (v) (vi) 36. to ingress solid object & to harmful ingress of water IP:55 Test for mechanical strength Resistance to heat Resistance to rusting Resistance to tracking Glow wire test at 95° C Type T T T T Test Particulars Routine Acceptance A A R _ - S N 1 2 3 4 5 6 7 8 9 10 IS:14772 IS:14772 IS:14772 IS:14772 IS:14772/ 695-2-1 IS:8623 13 14 16 17 IEC T T T T T T T T T T - - Verification of dielectric properties 11 IS:13411 Heat deflection test of 150° at 0. The supplier shall keep the purchaser inform in advance about the manufacturing program so that arrangement can be made for inspection. The acceptance tests shall be carried out as per relevant REC construction/ NFC standards/ ISS as applicable. 36.6 Type test on Distribution box ‘The following tests have to be done on any one model of spring loaded constant pressure multi connection busbar in insulated box from NABL accredited laboratories only. The successful bidder shall grant free access to the purchaser’s representative at reasonable time when the work is in progress. 10 GUARANTEED TECHNICAL PARTICULARS FOR DISTRIBUTION BOX S. Bangalore/ Bhopal. of Busbar completed with fitting .9 EMBOSSING & IDENTIFICATION: It should be provided in each piece as per provision of bid document st 36. Manufacturer Name 2 Material of Box Enclosure UV resistant Fire Retardant polycarbonate or SMC 2 mm. CPET or any NABL accredited testing laboratory. of 37.5Sq. minimum Single Phase : 250x250x160 mm 3 Thickness 4 Dimension of the enclosure Three phase : 350x270x200 mm 5 Material of insulation for mounting Busbar (Bus Bar Supports) Nylon Glass Filled FR Single Phase : 1 incoming + 5 outgoing Three Phase : 1 Incoming + 2 outgoing Nylon 6 Glass filled 30% & Fire Retardant passing 950° Test as per C IEC Publication 695–2–1 EC Grade Copper.One sample from the 1 Lot of Hardware of each size as received in purchaser's store shall be sealed for getting it type tested as per relevent REC construction standard /NFC Standard/ISS from any of CPRI. 36. N Particulars Requirement Offered 1.mm (2Nos.m each) 6 No. of circuits both incoming & outgoing in the Busbar 7 Material of Insulation for Busbars molded casing 8 Material of Bus Bar 9 Cross Section area of Bus Bar 10 No. electrical class “A” Total 75sq. Triangular Keylock system alongwith 1 No.Single phase box 2 Sets (one for phase & one for neutral) 4 Sets (Three for Phase & One for Neutral).C. built in type hinges.S.2 mm Zinc Passivated As per requirement of size M6×20 mm Earthing symbol Center to Center distance 35 . IP 55 2 Nos. No screws/rivets visible from outside.M. nylon triangular key Three phase box 11 Length of Copper Bus Bar with Tin/Silver Plating 12 Pressure Plate 13 Insulation level 14 Earthing Plate 15 16 17 Earthing Bolt Earthing Logo Distance between BusBars 18 Hinges 19 20 i Ii IP Level Sealing U Clamp Arrangement for external lock 21 Locking System .5KV A. Single phase 1+5 : 125 mm Three phase 1+2 : 63 mm Thickness 2.0mm stainless 2. R.2 mm Zinc passivated Required 1 No. as per IS: 8623 (Part I) 1993 1 No 1.40mm 2 Nos. 1. However. as per requirement given in this specification. (1.f. 2 Nos. 5 mm thick MS pole mounts / clamps as per dimensions given in the drawing. The meters shall be supplied in a push fit type meter box made of transparent engineering plastic.6 mm Thick sheet steel Zinc plated/ passivated) 1 No. In addition the meters shall have provision for recording time of day (TOD) energy parameters. The meters should be suitable for single phase two wire system.35 Sq mm Aluminium cable Dark grey / gray/other Property of MPPKVVCL.Zero Lead. capable to record and display monthly average p.2 mm Zinc plated/ passivated As per Drawing 50/35 Sq mm Aluminium cable 1. manufacture. who will interpret the meanings of drawings and specification and shall have the right to reject any work or material which in his judgment is not in accordance therewith.5 . stage-inspection. engineering. These LT Meters should record total energy at basic frequency & harmonics. 1. The offered materials shall be complete with all components. accessories and required software’s necessary for their effective and trouble free operation in the System for measurement of electricity supplied to the consumers. (b) It is not the intent to specify completely herein all the details of the design and construction material.. energy in KWH. and demand in “KW” including other electrical quantities. The meter and push fit type meter box shall be supplied in suitable packing so as to withstand transit shocks during road transport. design and workmanship and shall be capable of performing in continuous commercial operation in a manner acceptable to the employer. the material shall conform in all respects to high standards of engineering.1 SCOPE:(a) This specification covers design. Single phase two wire current rating 5-30 Amp solid state (static) whole current electronic LT energy meters of accuracy class 1. Such components shall be deemed to be within the scope of Bidder’s . testing and supply of A. The meters shall be capable to record over full power factor range of Zero Lag-Unity.C.0 with backlit LCD display and communication port for data downloading as per requirement given in this specification.22 Pole Clamp for fixing the box on the pole 23 Mounting channels MS 2 Nos. which shall be weather proof having flame retardant properties conforming to relevant specification. Jabalpur in big font 24 A B Gland Plate Tolerances Suitable for incoming cable size C Suitable for outgoing cable size 25 Colour 26 Marking 37 TECHNICAL SPECIFICATIONS FOR SINGLE PHASE LT STATIC WHOLE CURRENT SOLIDS STATE ELECTRONIC ENERGY METERS WITH BACKLIT LCD DISPLAY 37. 37.e. (c) It is compulsory that the offered LT meters shall bear BIS certification i. the meters shall be ISI marked and the bidder shall have to furnish valid ISI license along with the offer.2 STANDARDS: These LT meters and the associated accessories shall conform in all respects to the following relevant Standard Specifications with latest amendment there to:Indian Standard No.supply irrespective of whether those are specifically brought out in this specification and/ or the commercial order or not. which. may be verified by the Employer. 17/03/06 IS:9000 IS:11731 IS: 11000 CEA Regulation . if considered necessary. IS:13779-1999 read latest amendments with Title Specification for AC static watt hour meter for class 1 & 2 CBIP Technical report No. Specification for engineering plastic Resistance to heat & fire On installation of meters of.88 (with latest amendments) IS:5133-1969 (Part II) Specification for AC static Electrical Energy Meters Specification for boxes for the enclosure of electrical accessories Basic environmental and other Testing for Electronic & Electrical items. tropical and dusty climate and solar radiation typically existing in State of M.30 g 45db o o o o o (a) (b) (c ) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) All the parts & surface.40% neutral solidly grounded.3 SERVICE CONDITIONS (CLIMATIC CONDITIONS): (i) The LT meters to be supplied against this specification should be capable of performing and maintaining required accuracy under extreme hot. of phases System earthing Resistance to surge voltage of 1. 5.m 40 0.2/50 Micro sec. Item Specification 3. which ensures total protection from any injurious effect of humidity. cold. 4. 2. 37. 1. No. Type of installation System neutral) voltage (phase to Indoor/Outdoor 240V + 20% to . 4KV RMS for 1 minute including latest amendments in relevant IS. which are subject to corrosion shall either be made of such material or shall be provided with such protective covering and finish. Test voltage at 50 Hz 50 Hz ±5% 1 phase 2 wire (single Phase +Neutral) Solidly grounded As per relevant IS 7.4 PRINCIPAL PARAMETERS: These LT meters shall conform to the following specific parameters: Sl. System frequency No.37.P. The LT meter shall be required to operate satisfactorily and continuously under the following tropical climatic conditions: Maximum ambient air temperature Maximum ambient air temperature in shade Maximum temperature attainable by the meter exposed to sun Minimum ambient temperature Average daily ambient air temperature Maximum relative humidity Number of months of tropical monsoon condition Maximum altitude above mean sea level Average annual rain fall Maximum wind pressure Isokeraunic level (days per year) Seismic level (horizontal accn.) Permitted noise level 55 C 45 C 60 C (-) 5 C 40 C 95% 4 months 1000 meters 150 cms 200 kg/sq. 6. . The supplier should indicate hardness. long trouble free life. oxidizing agents. acids. iii. The meter chamber shall be dust proof and moisture proof. petro-chemical products.37. iv. The meters shall have a case. The meter shall conform to the degree of protection IP51 of IS: 12063 for protection against ingress of dust. which shall be solidly welded to the meter base so that access to the internal parts should not be possible without breaking the meter case. moisture and vermin.7 RATINGS: The LT meters as specified in scope of this tender shall be rated as follows: (a) (b) (i) (ii) Voltage Current Basic current (Ib) Rated max. safety against electric shock. All electrically live screws shall be of heavily tinned brass/nickel or zinc plated steel. flame retardant. zinc plated steel. The meter should be immune against jump during sudden switching of heavy loads or transient voltage spikes. ii. The material should be corrosion resistant. vii. continuous current (Imax) Frequency Accuracy 5A 30A 240V (c ) (d) 50 Hz Class 1. ± 5% of rated frequency Zero (lag) – unity – Zero (lead) . melting temperature and tensile yield strength of the material and necessary test certificate of the same shall be furnished. The meter casing material should be glass reinforced. The engineering plastic used shall conform to IS: 11731 besides meeting the test requirement of heat deflection test and as per IS 11000(Part2 sec1) for resistance to heat and fire as per glow wire test specified in the relevant standard. spread of fire and effects of excessive temperature. inert to chemicals.5 CONSTRUCTIONAL REQUIREMENTS: The meters including meter case and push fit type meter box shall be fully transparent designed and constructed in a manner to avoid any danger during use under normal working condition including personal safety against electric shock. 37. The terminal inserts shall be of heavily tinned brass/ nickel or silver plated copper. All other screws shall be electro plated. vi.6 MATERIAL USED FOR METER CASE AND PUSH FIT TYPE METER BOX: i. as it operates under its normal operating conditions would be as under: Voltage Current Frequency PF range +20% to – 40% of rated voltage 120% of Imax. unbreakable engineering plastic material to ensure high reliability. v. The meter base and cover should be sturdy enough to prevent damage during transportation and installation. The material of meter body (base and cover) shall be made of Engineering plastic.0 37.8 POWER SUPPLY VARIATION: The extreme power supply variations which the LT meter should withstand without damage and without degradation of its metering characteristics. salts and ultraviolet radiation. The meter case and push fit type box should comply following parameters:- 37. (b) With each current circuit of the meter carrying rated maximum current and with each voltage circuit (and those auxiliary voltage circuits which are energized for periods of longer duration than their thermal time constant) carrying 1.11 RUNNING WITH NO LOAD: When 115% of rated voltage is applied with no current flowing in current circuit. reference temperature and reference frequency shall not exceed 1. with the ambient temperature between 25ºC to 45ºC. the temperature rise of the external surface shall not exceed by more than 20ºC.9. winding and insulation shall not reach a temperature.5 Watts and 8 VA respectively as per IS:13779.9. reference frequency and reference temperature shall not exceed 4 VA as per IS:13779.12 INFLUENCE QUANTITIES: The single & three phase LT meter shall work satisfactory with guaranteed accuracy as per limit prescribed in IS:13779 under presence of the following quantities:(i) (ii) (iii) (iv) (v) (vi) (vii) 37. (i) When the LT meter remains at a constant temperature of 65 C for a period of 30 minutes.9.10 STARTING CURRENT: The LT meter should start registering energy at 0. which might adversely affect the operation of these LT meters.13 External magnetic field Electromagnetic field Radio frequency interference Vibration Harmonic wave form Voltage fluctuation Electromagnetic high frequency field TEMPERATURE RISE: (a) Under normal conditions of use at Imax current.2 Current Circuit: The apparent power taken by each current circuit (per phase) at basic current. 37. The LCD shall be of STN (Super Twist Nematic) type designed suitably to withstand o o temperature of 80 C (storage) & 65 C (operation).9 POWER CONSUMPTION: 38.20 times the rated voltage. the percentage errors shall not exceed the limits as specified in IS: 13779. The backlit should not glow during power off condition.14 LIMITS OF ERRORS: When the LT meter is under reference conditions. the character of LCD should not deform.15 DISPLAY: The LT meters shall have bright LCD Electronic display with backlit & with minimum 6 digits to read up to one tenth of KWh with another digit for legend. The decimal digits shall be clearly distinguished from integer digits. 37.1 Voltage Circuit: The active and apparent power consumption in each voltage circuit (per phase) including power supply of LT meter at reference voltage. 38. the test output of the LT meter shall not produce more than one output pulse count as per IS: 13779. 37. 37. 37. 38.The LT meter shall work over wide PF range and the limits of errors with the variation of PF shall be as per CBIP 88 (latest amendments)/IS: 13779 37. o .4% of basic current at UPF as per IS: 13779.3 Auxiliary Power: The LT meter shall draw power for working of electronic circuit from phase & neutral. unity. 37.this shall be displayed when tampered with following. (With sign of lead/lag) (a) (b) (c) (d) (e) . The minimum character height X width shall be 8. for each calendar month and for previous six months.f. The LCD segment check shall be on meter display for minimum 2 seconds. The display shall have ON time of at least 10 seconds for each measured value.5 X 5 mm for whole digits of kWh Display.17 AUTO SCROLL DISPLAY MODE: The LT meters shall have following parameters in auto scroll display i) ii) i) Date: DD: MM: YY Real Time: HH:MM o o o Cumulative Active Energy KWH Instantaneous load in Watt.00 Hrs on the last day of the month for each calendar month and the same should go to memory.F. The meter shall make use of non-volatile memory capable of storing and retaining all the data required to be stored. The display of various parameters in push button mode shall be scrolling one after another. without the help of any power source or battery back up and shall have a minimum retention time of 12 years under un-powered condition.5 mm. (i) Tamper information. 37. The accuracy of display for all parameters shall be matching with the accuracy class of meter as per IS. The LT meter should also have provision for automatic recording and storing of required parameters at 24. In addition display of the required parameters should be in two different modes as stated hereunder:37. The meter shall be capable to measure and display continuously “Active Energy KWh” at all loads and in full power factor range of zero lag. The display shall not be affected by electrical and magnetic disturbances. Large viewing area with large display icons is desired. LCD display should work as in normal conditions.16 DISPLAY SEQUENCE: The Liquid Crystal Display register for single and three phase LT meter should display the measured value(s). except LCD segment check. Display parameters shall move forward if button is pressed prior to the programmed time for display of each parameter. (c) Number of time meter tampered. The display shall have ‘ON’ time of minimum 10 seconds of each measured value.18 DISPLAY PARAMETER (PUSH BUTTON) MODE: The display of the following parameters shall be scrolling one after the other through push button. (f) Cumulative active energy KWH for each calendar month for previous six months with programmed billing date. (b) Time of last tamper occurrence. The registered parameters shall not be affected by loss of power. LCD segment check Meter serial number Real date and time (Date DD-MM-YY. Maximum demand of the month in KW by default up to two decimal (since last auto reset) with date & time with 15 minutes integration period. for clear visibility of the display of the meter reading.zero lead. (j) Instantaneous phase voltage (k) Instantaneous line current (l) Instantaneous p. Time HH-MM) Cumulative active energy (KWH) register. (a) Date of last tamper occurrence. The LCD display should have a wide viewing angle of 45 to 60 up to one-meter distance. (g) Maximum Demand in KW up to two decimal for each calendar month for previous six months with date and time of such demand (h) Average P.(ii) After keeping the LT meter at a constant temperature of 80 C for a period of 30 minutes and when restores at normal temperature. Dot-Matrix type LCD display is not acceptable. The height of the display character should be minimum 8. Meter Reading Instrument (MRI) through this port to facilitate for auto-reading and downloading the data for billing and historical data to base computer. The display with push button shall be auto off type after completion of the display cycle it should revert back to normal auto scroll mode approximately after 10 seconds. 37.5 metres in front of the meter box. any change in language or any other reasons. Arrangement shall be made to get such a reading even at the time of power failure. The same push button shall be used for display of parameters of.01 KWh. The internal least count of the energy recording shall not be more than 0. and every 0. Infrared transmitter and receiver should be compliant to the latest IrDA Physical Layer Standard. f.20 LCD LEAST COUNT:The kWh display shall be with one decimal digit in push button mode and in auto scroll mode.(m) Instantaneous load in Watt (n) High resolution Energy value (resolution will be sufficient to enable conduction of the starting current and accuracy test in less time. In any case.) Since meters are required duly fitted with push fit type meter box.19 METER READING DURING POWER OUTAGE: The meter shall have provision to read the meter in no-power condition.00 hours of the first day of each calendar (billing) month and all the billing parameters shall be transferred to billing registers. resetting of demand and tamper in formation. b.21 COMMUNICATION CAPABILITY The meter shall have wireless communication facility for remote reading through infrared Communication Port.22 BILLING POINT REQUIREMENTS: The predefined date and time for registering the billing parameters of energy. with the MRI. the data transfer from the meter to CMRI and further to Base computer should be fully secured and any unauthorized attempt/change in data should be indicated on computer system. an arrangement should be made on top cover of push fit type meter box with its mechanical connection to the meter’s body as described in the Specification of meter box to activate the display push button of meter. The compatibility of transferring data from the meter to MRI and then to the base computer system (BC) should be easily established. . The meter shall have facility for communicating with a hand held terminal (HHT) i. RTC Battery Power shall not be used for display under no-power condition. The infrared module of the meter shall have no physical access from outside the meter. Fresh button press will be required after resumption of auto scroll cycle to display the above parameters again. There should be multi level password on the base computer system and in the meter to prevent any unauthorized change of billing parameters.e. auto scroll mode during power outage. It should not be possible to reset the energy reading in the meter or make any change in the data stored in the meters either current or historical. consumption shall be internally stored. PF and MD as well as Tamper Count and Power-On hours details shall be at 00. The interface for communication between MRI & Base computer shall be supplied free of cost.01 KWh. d. The software required for MRI and Base Computer System with necessary security provisions shall also be supplied free of cost with the following features: a. the supplier shall modify it at his own cost within the guarantee period. 37. 37. For the purpose of data security. 37. e. c. It should be possible to read the meter through external MRI via infrared media from a minimum distance of 1. hence for reading purpose. The billing parameters at the time of automatic reset of MD shall be programmed such that it will transfer from rate registers to their respective billing registers. The software shall have the facility to convert all the consolidated information / data of selectable parameters into ASCII format. The Base Computer software shall give all details adequate for analysis. 37. Meter Data Display: The software shall show electrical condition existing at the time of reading the meter in tabular forms as well as graphical format (Phase diagram) All the information about energy. Support Display: There shall be "user friendly" approach for viewing meter data for the reading collected now or for the reading collected in the past. Date of meter reading. billing register readings shall be shown in a manner which user can easily understand. The LT meters shall also give high-resolution energy values on the display. The main control of this system along with proper security password/code should be made available on one or more identified computers located at the authorized location(s) as per the directions to be given by the Empployer. tamper information and instantaneous parameters data shall all be retrievable through the meter's communication port through a common meter reading instrument (CMRI) and shall be transferred (downloaded) to a PC with Windows based software to get complete details in numerical and/or graphic form. The main control of this system along with proper security password/code should be available on one or more computers located at the authorized location(s) as per the directions to be given by the Purchaser. It shall be possible to retrieve/locate data on the basis of either one of the following particulars: Consumer's ID/Numbers.24 TEST OUTPUT DEVICE: The LT meters shall have a test out put device in the form of calibrating LED of red colour having minimum intensity 10 M (Milli-candela) accessible from the meter front and shall be capable of being monitored conveniently with suitable testing equipment while operating at site. .g. The necessary base computer software (BCS) for this purpose shall be provided by the supplier with complete details. It should be possible for the Purchaser to generate its own DBF (data base files) to down load all the required information into it. The resolution will be sufficient to enable conduction of the starting current and accuracy test in less time. No separate cost will be borne by the purchaser on this account. The BCS shall be suitable to run on IBM compatible PC hardware platform. The change of the TOD time-period(s) or defining TOD registers should be possible through CMRI with special authenticated command from the BCS so that only authorized person(s) can make such changes. Necessary compatible meter application software for various programmable features as discussed above in the meter and also necessary software for the IBM compatible computer to obtain various details as discussed above shall be provided by the supplier. The location of the calibrating LED should be such that the calibrating pulses can be sensed easily through sensor for site testing of the LT meter’s accuracy. Provision should be made for automatic reset of maximum demand at the end of pre-defined period (e. The software shall be capable of preparing CMRI to read the meter information or time setting of the meter. maximum demand and their respective TOD register reading. The time registers shall be programmable by the purchaser.25 BASE COMPUTER APPLICATION SOFTWARE: For efficient and speedy recovery of data read through CMRI/HHU. Meter Sr. end of the month). Base computer software shall be supplied having the following specifications stated as under: The BCS software shall be user friendly Windows based.The above billing data.23 TOD TARIFF/DEMAND The meter should be capable of registering the time-of-day energy (TOD) and maximum demand. The meter should have in-built capacity to define up to six registers. 37. 37. No. All information about a particular consumer will be sorted out and available at one place so that locating any consumer’s past data is easy. The meter should also have capacity to define multiple time zones within the registers. Platform: The BCS shall be executable on all WINDOWS system. TOD register's data. c. of meter Date & Time Instantaneous current Instantaneous voltage e. iv. Sr. The manufacturer shall provide the protocol and other information to interpret the transmitted billing data. Data Transfer: It shall be possible to transfer data to and fro from CMRI through serial interface. The use of the software need not revert back to the supplier of the software for modifying the software just to print what he desires. 37. BCS shall have facility to export data to ASCII or spreadsheet format for integrating with the purchaser's billing system. Configurability: It shall be possible to have selective printing of all available data of the meter. the field width selection etc. Help: The exhaustive online help shall be available with the software so that user can use all the features of the software by just reading the help contents. The MRI shall have facility to store minimum 1000 nos. 37. Here again an "Export wizard" or similar utility shall be available whereby user can select file format.26 COMMON METER READING INSTRUMENT (MRI) The Bidder should carefully note that a. The software shall support "print wizard" whereby user can decide what to print out. of meters free of cost along with battery charger. No. Security: The BCS shall have multilevel password for data protection and security. Further. The MRI shall be capable for down loading readings of other makes of meters. what data to export. The configurable of passwords shall be user definable. there should be a facility in MRI to provide the transfer of meter data to computer through RS 232 or USB port. The MRI shall continuously transmit the data until an acknowledgement is received from the SBM (Spot Billing Machine). After successful downloading. d. The following minimum parameters should be downloaded by CMRI. The communication software shall be capable to transfer the billing data and meter serial number required for automatic Spot Billing Machine to automatically generate the energy consumption bills at consumer premises without any human intervention after the data is collected by the MRI. . The data storage inside the MRI and communication of MRI with the meter shall be encrypted so that there is no possibility of tampering with the downloaded data. MPPKVVCL shall exchange the communication protocols of successful bidders. f. The data download time shall not exceed 5 (+2) sec per meter. indication shall be available on both meter and MRI and repeated downloading from the same meter shall be disabled for a minimum period of 5 min. ii. The software installed on one PC shall not be copy able on another PC.Location. The first level shall allow the user to enter the system. b. to use the CMRI for reading and retrieving the data from the meter and to download the data to Base Computer on free of cost basis till the expiry of guarantee period. infrared. The different software features shall be protecting by different passwords. i. The bidder shall give an undertaking to this effect. of meter’s data. The MRI shall be supplied in the ratio of one for each 200 nos. Print out shall not include anything and everything available with the BCS. h. The infrared mode of MRI shall have a feature to read multiple meters within the range without pre-programming the meter serial numbers in advance. iii. It shall be responsibility of the meter manufacturer to provide the required software and all the facilities and support required by the purchaser.27 READINGS TO BE DOWNLOADED WITH CMRI: The CMRI should support in down loading all-important data stored in meter whether specified or not required essentially for deriving billing parameters including MD parameters. g. The MRI shall have possibility to read all of the three communication types of meters purchased by MPPKVVCL – optical port. The CMRI shall possess easily replaceable battery and shall be capable of storing data for at least 1000 nos. the manufacturer shall indicate such features in their offer without demanding additional cost. free of cost for the use of software at multiple data collection and billing premises of the utility. The metering data stated above including integration etc shall be independent of battery. in case of failure of power supply. The total downloading time (from meter to MRI) shall not exceed 5 sec for each meter (with +2 sec. viii. The downloaded data along with date and time stamp of such reading shall remain on CMRI with suitable encryption and it should not be possible to pre-program or manipulate the recorded data on the CMRI before downloading the same on computer. Arrangement in the meter should be such that. max tolerance time). It shall store the maximum demand with date and time.2. 37.2. x. meters at one time.29 REAL TIME CLOCK AND BATTERY: The MD integration cycle shall be on the basis of Real time clock of the meter. it should be possible to download the data. A lithium battery of adequate storage energy shall be used for energy supply to real time clock during no voltage or power off condition.2. The LT meter shall possess a suitable fast and reliable Infrared communication port for automatic transfer of data from Meter to CMRI. v. Maximum demand of the month shall be in KW up to two decimal digits.6 Cum. which cannot be changed/ altered. during any consecutive 15 minutes during the calendar month .28 MAXIMUM DEMAND REGISTRATION AND MD RESETS: The Meter shall continuously monitor and calculate the maximum demand at the point of supply. xvii. The maximum demand shall automatically reset at 24.---.6 Billing KWh registers Tamper information including cover open tamper Any other information whether specified or not. KWh register(Programmable) TOD 1. The maximum drift in real time clock of the meter shall not exceed ± 3 minutes per year and crystal should be temperature o o compensated for temperature range of 0 C to 50 C. when it occurred. an indication on MRI or meter or both for confirmation of successful data transfer shall be provided. xvi. During this period the energy recording should not be affected. xi. The minimum life of battery should be ten years. xv.Cumulative Active energy (KWh) MD during the month Instantaneous load in Watt Instantaneous Power factor (sign of lag or lead) Cumulative active energy in KWh for the last 6 months Maximum demand in KW for the last 6 months up to two decimal Average PF of the last 6 months TOD 1.---.6 MD register KW up to two decimal (Programmable) TOD 1. .---.---. 37. vi.00 Hrs of the last date of each calendar month for which minimum 30 years calendar shall be programmed by the manufacturer. After successful downloading of meter data to CMRI. The CMRI shall possess a specific serial number. xiii.6 Billing MD registers TOD 1. which shall not be complicated and shall be easily understandable by utility officials to ensure compatibility between meters and CMRIs of different makes. xii. which is in the opinion of manufacturer is necessary for satisfactory performance of the meter. Necessary upgrades shall be possible in CMRI software and shall be supplied free of cost for downloading simultaneously the existing parameters and any parameters added in future specifications of meters.2. ix. 37.30 CALIBRATION: The meters should be software based factory calibrated and there shall not be any mechanical adjustment in calibration after freezing the parameters at works. This is to ensure that the meter cannot be calibrated at site. vii. xiv. The Supplier shall provide meter-reading protocols free of cost. A copy of operation manual shall be supplied along with each CMRI. The Supplier shall supply Software (compatible with Windows 98 system and/or higher) and training. 37.5mm to accommodate the insulation of conductor and shall be of adequate length in order to have proper grip of conductor with cage clamp arrangement /crimping pins with the help of two screws such that there is no risk of loosening or undue heating. The requisite fixing screws shall be supplied with each meter. 37. The current circuit shall be appropriately insulated and potential circuit shall be appropriately encapsulated.33 CURRENT AND VOLTAGE CIRCUITS: The current and voltage circuits shall be made of appropriate material such as enamelled copper wire of EC grade.35 METER FIXING ARRANGEMENT: Every meter shall have at least three fixing holes one at the top and two at the bottom. It shall be an integral part of the meter base. The top hole shall be provided with a special clip at the back of the meter so that holding screw is not accessible after the fixing of the meters. The terminal block shall have provision with single/two screws for fixing to the meter board. EM CT/Shunt currents should be compared and higher of the two should be used for measurement. It is necessary to ensure accurate recording by the meters during the condition when DC component exists in the load. A firm connection shall be established within the meter case to energize the voltage/current circuit. All parts that are likely to develop corrosion shall be effectively protected against corrosion by providing suitable protective coating. Specific confirmation shall be submitted by the bidders that accuracy of measurement will not suffer due to utilization of shunt on account of thermal variation and temperature o coefficient up to an operational temperature of 80 C. 37. 37. The voltage circuit and current circuit shall be solidly connected inside the meter body without any link. All connection screws and washers should be tinned/ nickel-plated brass/ Zinc plated steel.34 CT/SHUNT FIXING ARRANGEMENT: The CTs/Shunts & other measurement devices when provided in the meter shall be mounted through proper fixing arrangement so that it should have a firm support and should not move from its position in any case. The terminal screws shall not have pointed end at the bottom. . Further. Electrical connection shall be so designed that contact pressure is not transmitted through insulating material. It shall not be possible to remove the meter from the hanging screw without removing the screws from the terminal block. The meter design shall be based on CT or CT and shunt combination or shunts. Sufficient clearance shall be allowed between terminals. The lower fixing screws shall be provided under the terminal block. PT less design shall be used for power supply to PCB. the supporting webs between the two terminals of the terminal block should be sufficiently high to ensure that the two neighbouring terminals do not get bridged by dust or it is not possible to have flashed over between adjacent terminals of terminal block.31 CONSTRUCTION: Meter shall be designed and constructed to be capable of withstanding all severe stresses and vibration and dust environments likely to be encountered in actual field conditions. The connections shall be as per the recommended methods given in IS-13779. All terminals shall have two screws. 37.32 TERMINALS AND TERMINAL BLOCK: The terminals may be grouped in a terminal block having adequate insulating properties and mechanical strength. Terminal holes shall be of minimum 6. The terminals shall be properly bound in the insulating material of terminal block. The terminal block should be made from best quality non-hygroscopic. flame retardant material (capable of passing the flammability tests given in IS:11731) with nickel plated brass for connecting terminals. Required number of pins along with one additional pair shall be supplied with each meter. The terminals shall be of suitable rating to carry 200% of Imax and shall be made of electro-plated (or tinned) brass. The cross section of current circuit shall be designed to withstand the o temperature rise of 50 C over the ambient temperature at maximum current. It may be noted that the approved logics used in designing tampers are explained to our field officers. All the seals should be provided on front side only.). The energy register shall advance for low voltage up to 120 Volts. the value of voltage. 37.39 SEALING ARRANGEMENT: The meters should be software calibrated at factory and sealed suitably before dispatch. outgoing neutral is connected to earth through resistance and load is connected to earth. The provision shall also be made to provide additional lash wire seals on the meter body by the MPPKVVCL.38 NON FLAMMABILITY: The terminal block. company logo and shall be additionally laser marked with serial no. input and output interchange. 37.42 Neutral Missing: .36 CONNECTION DIAGRAM & TERMINAL MARKINGS: The connection diagram of the meter shall be clearly shown on the nameplate of meter and shall be of permanent nature. The meter shall be provided with 2 nos.40 TAMPER AND FRAUD PROTECTION: Logics for design of various tampers. It shall not be ignited by thermic over load of live parts in contact with them. to be selected for design of tamper shall be done in consultation with the purchaser. and the meter case shall be such as to ensure reasonable safety against spread of fire. all the parts shall fulfill the conditions of the glow wire test as per relevant standard. Neutral (out). matching with that of meter. 37. To comply with this requirement. The event recording shall be roll over type i. time etc.41 Load Earthing: (i) The meter shall record correctly when earth is used as a return path for load fully or partially even when phase and neutral connection are reversed. The meter shall continue to register active energy accurately even under following conditions: The meter should register energy consumption correctly in forward direction irrespective of the direction of current in the current circuit (i. and based on their input the bidder have to modify logic if necessary (The last tamper date and time of occurrence and tamper counts must appear in the DISPLAY and rest of the details in VIEW PARAMETERS). 37. polycarbonate tamper evident seals which shall be marked with “MPEZ”. The meter should have tamper & fraud protection features and shall record selected tamper information with date & time stamp. 37.37. The meter shall record and store last 100 events of tampers (occurrence + restoration) along with date and time of occurrence and restoration of each and every event. the arrangement should be provided such that power LED starts blinking when incoming voltage is below 200 Volts.37 TERMINAL ARRANGEMENT: Connecting terminals of the meter shall be in the following sequence: Phase (in) Neutral (in). current.e. (ii)When incoming neutral is disconnected. and can be easily viewed to check duplication attempts for the purpose of keeping track of meter seals.e. Phase (out) 37. The serial number of meter is to be laser–etched on the base as well as the cover of the meter box. phase and neutral connections interchange etc. The meter terminals shall also be marked and this marking should appear in the above diagram. it shall always maintain record of last 100 events occurred of selected tampers for logging. Access to the working part should not be possible without breaking the seals. The single-phase meter should register energy even if both the incoming and outgoing neutrals are disconnected and load is drawn through local earth. the meter alone should comply up to 0. 37.3 lag and 0. as per class of accuracy of meter. The meter shall record energy proportional to the current and rated voltage with Unity pf when any of the enclosed tamper circuits are used to tamper energy by more than 10% using a diode. rated frequency and Unity power factor in proportion to the current drawn. or a variable resistance or a variable capacitance. The positive error may be beyond the limit of 4% but not exceeding power value equivalent to the product of rated voltage and maximum current. When meter is subjected to approx. 20% and 30% of rated voltage.46 Application of abnormal voltage /frequency: A) The accuracy of the meter.01-10 mm spark gap in any of the following manner when applied for 10 minutes: a) On any of the phases or neutral terminals b) On any connecting wires of the meter c) At any place in load circuit d) Spark on meter body. B) Meter should also be immune for tamper by application of remote loop induction device (jammer).43 Cover opening : If attempt is made to open the meter body.45 External Magnetic Influence: The meter shall not get influenced by any external magnetic fields (AC Electro Magnet or DC Magnet) in accordance with the test procedures specified in IS: 13779 with its latest amendment for AC Magnetic Field.27 Tesla DC. 37. Meter shall have provision to record the tamper of Neutral Missing with date and time of occurrence and restoration. Real time clock disturb. 37. This should be irrespective of the position of phase. the meter shall detect /log with date and time of meter body opening tamper. it should not hang and in case if it hang once it should remain hanged permanently. The threshold current for this feature should not exceed 20% of Ib and the assumption should be rated voltage. meter functioning hang up etc. This tamper shall also be displayed on the meter LCD with tamper information. Meter shall have provision to record the tamper of abnormal magnetic induction with date and time of occurrence and restoration. The meter accuracy or accuracy in display under normal conditions shall not be affected by placement of a permanent magnet of not less than 0.44 DC Immunity: The meter should not saturate on passing of direct current which can cause the meter either to stop recording or record inaccurately as per IS: 13779 (latest version).47 EMC/EMI Test: The meter shall also pass all EMC/EMI tests as per IS:13779 with latest amendments. However. Further the bidder shall carefully note and confirm that: . 37. should not occur with the application of abnormal voltage/ frequency such as spark discharge of approximately 35KV with 0.5 lead power factor shall be verified immediately after this test. On application of external DC magnetic field of higher intensity against which meter is not immune. The meter will be tested in these conditions such that the measured terminal voltage is reduced by 10%. 35 KV abnormal high voltage/ frequency burst and remote loop induction device (jammer). Memory data corruption. the meter should log the events of abnormal magnetic induction with date and time. even in absence of supply.27 Tesla anywhere on the surface of meter without meter box. 37. The meter accuracy at 0. loading up to 120%Imax.Green LED indicator or Icon on LCD (iv) Power supply ON and Phase indication . Except KWh indicator. 440 Volts) is applied for 5 minutes between phase and neutral of the meter. The meter shall be compact in design. Even if phase to phase voltage (i. the meter should not get damaged and continue to record correctly within class 1. Meter shall be suitable for accurate measurement and display of energy and other billing parameters within the specified limits of errors under balance and unbalanced load conditions in a poly phase network. The meter shall not get affected by any remote device. Provision shall be there to do the billing operation automatically at a predefined date by programming the meter.48 LED INDICATIONS : The following LED indications must be provided on single and Three phase indication: (i) KWh indicator for Meter calibration (ii) Input and output reversal reversal (iii) Earth Tamper indication .LED or ICON on LCD for line ‘ON’ All the LEDs shall be of low power consumption and distinctly visible from distance.1. 37. without the help of any power source or battery back up. Along with the tamper information.0 accuracy after restoration of normal supply. currents and power factors to simulate and elaborate the existing condition during the tamper events. The meter shall also withstand impulse Voltage without any damage in accordance with the clause 12. better than this specification and manufactured as per relevant IEC/IS/CBIP report shall also be acceptable. The bidder should furnish detailed explanation as to how the meter is able to detect/Protect recording the above tamper and fraud features with sketches and phaser Diagram.9.7. Any other design meeting technical specification or features/accuracy etc. The entire design and construction shall be capable of withstanding stresses likely to occur in actual service and rough handling during transportation/loading/unloading etc. . 2. Meters covered under this specification shall be fully static type with non-volatile memory to register various billing parameters and complete with other features as detailed out in this specification. all the other indications may be provided as Icon on backlit LCD. The earth LED should glow only when measurement is through neutral circuit. if any.. Meter shall work within accuracy up to max. 37. Additional features.2 of IS: 13779:1999.3lag and 0.e.Yellow LED indicator or ICON on Indication / current LCD .Red (Calibration LED-Imp/KWh) . the meter shall also record the instantaneous values of voltages.2. 3.3 of IS:13779. The short time over current rating shall be 30 Imax for one half cycle at rated frequency as per clause No.5 lead power factor.6. The meters shall remain within ±1% accuracy when tested at basic current at rated voltage at 0. The measurement of meter shall not be influenced by injection of AC voltages/ chopped signal/DC signal and harmonics on the outgoing leads of the meter. Computation of demand shall be on the basis of Real Time Clock of the meter itself.49 SALIENT FEATURES: The meter shall have the following additional features. The meter shall be convenient to transport and immune to shock and vibration during transportation and handling. in the meter may also be clearly indicated. Indication shall be provided on display to show the healthiness of phase voltage. The meter shall make use of Non Volatile Memory capable of storing & retaining all the data required to be stored. C. and A.50 SELF DIAGNOSTIC FEATURE The meter shall be capable of performing complete self-diagnostic check and continuously monitor all the circuits for any malfunctioning and ensure integrity of data memory location at all time. For security reasons the meter operating software should have at least “two level write protection” against any modification/editing of the parameters. except those required for billing data. . The voltage circuit and current circuit shall be solidly connected inside the meter body without any link. moisture and vermin’s. non-inflammable highgrade and good quality engineering plastic.F. The connections shall be as per the recommended methods given in IS-13779 37. The meter shall conform to the degree of protection IP51 of IS: 12063/IEC: 529 for protection against ingress of dust. appended with this specification. magnetic fields Electromagnetic H. the same may be furnished against the last item of that Annexure. fire-resistant. 37. The offered whole current meter shall also withstand DC Immunity test for main and neutral circuit at Iref = Imax/ root 2 as per IS:13779 so as to ensure that the meter current circuits do not saturate on passing of direct current. The meter shall be convenient to transport and immune to shock and vibrations during transportation and handling. The meter shall have display indication for unsatisfactory/nonfunctioning/malfunctioning of the following: a) Time and date on meter display b) All display segments on meter display c) Real Time Clock (RTC) status in meter reading print out at BCS end d) Non-volatile Memory (NVM) status in meter reading prints out at BCS end.52 GUARANTEED TECHNICAL PARTICULARS: The bidder shall furnish all the necessary information as desired in the Schedule of Guaranteed Technical Particulars and data.The meter shall be fully programmable by the user for TOD timing and billing dates etc. If the bidder desires to furnish any other information(s) in addition to the details as asked for.C. settings etc. TOD metering. A firm connection shall be established within the meter case to energize the voltage/current circuit. The entire design and construction shall be capable of withstanding stresses likely to occur in actual service and rough handling transportation. fields Electrostatic discharges Radio frequency interference suppression. The following information should appear on the name plate affixed on to the meter:(i) Manufacturer’s name or trade-mark and place of manufacture. The disturbance(s) to be considered are: (viii) (ix) (x) (xi) (xii) (xiii) (xiv) ` 37. Harmonics Voltage dips and short interruptions Fast transient burst test External D.51 ELECTROMAGNETIC COMPATIBILITY AND INTERFERENCE REQUIREMENT: The meter shall meet EMI/EMC requirements as specified in the relevant standards and shall also be protected against radiated interference from either magnetic or radio frequency sources. (ii) Designation of type (iii) Number of phases and number of wires for which the meter is suitable. The meter base & meter cover shall be made of high grade. The meter shall be designed in such a way that the conducted or radiated electromagnetic disturbances as well as electrostatic discharge do not damage or influence the meter.53 NAME PLATE AND MARKING: Every meter shall have a name plate clearly visible and indelible and distinctly marked in accordance with IS:13779 (latest version). 37. data. 53 TESTS: (A) Type Test: The type test certificate for all tests as indicated in IS:13779-1999 (with latest amendments) shall be furnished along with the bid.5 lead power factor. The accuracy of the meter. (B) Additional Type Test: In addition to the tests mentioned at (A) above. v.(iv) (v) (vi) (vii) (viii) (ix) (x) (xi) (xii) (xiii) (xiv) (xv) (xvi) (xvii) Guarantee period – 5 years from the date of commissioning or 5-1/2 years from the date of supply . Special accuracy test – the meters shall remain within ±1% accuracy when tested at basic current at rated voltage at 0. Memory data corruption. Immunity from remote loop induction device (jammer) The accuracy and above indicated parameters of meter shall be checked before and after the application of above device(s) with site conditions. whichever occurs first. meter functioning hang up etc. iii. year and month of manufacture Principal unit in which the meter records Reference voltage Basic current and rated maximum current Reference frequency in Hz Meter constant (Imp/KWh) Accuracy class Reference tamperature ISI mark and license number 37. It is desired that when meter is subjected to 35 KV abnormal voltage. Voltage variation test ii. Real time clock disturb. Type test certificates from any one of the standard laboratories NABL accredited for particular equipment/test shall only be considered. frequency burst and remote loop induction . bidder shall have to furnish the type test reports of compliance of anti-tamper features as per tender specification. Permanent magnet test iv. The type test certificate shall not be more than 24 months old as on the date of opening of bid. Type test report. iv. Month & Year of manufacture Sign of Insulation Class Connection diagram Serial number.01-10 mm spark gap in any of the following manner when applied for 10 minutes: a) On any of the phases or neutral terminals b) On any connecting wires of the meter c) At any place in load circuit d) Spark on meter body. Bar coding of SN. should not occur with the application of abnormal voltage/ frequency such as spark discharge of approximately 35KV with 0. Purchase Order No.3lag and 0. Type test certificate from educational institute(s) will not be accepted. (D) Verification during Inspection: Inspecting officer shall verify that no DC supply/ signal is given to reference meter during the DC injection test. i. Accuracy tests under all anti tamper conditions. (C) Acceptance tests: All Acceptance tests as laid down in this tender specification shall be carried out. & Date. should contain the following information clearly: (i) Type of meter and display (ii) Class of Accuracy. Property of MPPKVVCL. amongst other details. The accuracy of display parameters shall be verified at the time of inspection in line with class of accuracy of meter. .device(jammer) it should not hang and in case if it hangs once it should remain hanged permanently. Purchaser may select meters at random from a lot of meters supplied and sent to CPRI/ERDA/ERTL/any NABL accredited testing laboratory for acceptance test . The Supplier shall provide all reasonable facilities without demanding any charge to the inspector representing the Purchaser to satisfy him that the equipment is being furnished in accordance with this specification. the entire lot will be rejected and testing charges shall be recovered from the supplier.55 INSPECTION: The Purchaser’s authorized representative may carry out the inspection at any stage of manufacture.54 TEST FACILITIES AVAILABLE WITH THE MANUFACTURER: The tests shall be carried out as per relevant Standards and test certificates shall be furnished for approval. Bidders should carefully note that the standard meters used for conducting tests shall be calibrated periodically at NABL Accredited Test Laboratories and test certificates shall be available at Works for verification by Employer’s representative. 37. All acceptance tests and inspection shall be made at the place of Supplier/Manufacturer. or Box from any of the lots received at any Destination Stores at Supplier’s expenses. The Supplier/Manufacturer shall grant free access to the Purchaser’s representative at a reasonable time when the work is in progress.56 SAMPLE: Sample before Commencement of supplies: The Supplier shall submit sample of offered meter along with the meter box having all the features conforming to the prescribed specification for our approval before commencement of supply. The sample meters shall be selected randomly from the lot and will be sent to CPRI for acceptance test as per relevant ISS and as per procedure prescribed in following paras. The Purchaser reserves the right to get type tests done in respect of any meter. The Supplier shall give 15 days advance intimation to enable the Purchaser to depute his representative for witnessing the acceptance and routine tests. Inspection and acceptance of any equipment under this specification by the Purchaser shall not absolve the Supplier of his obligation of furnishing the equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment is found to be defective. 37. If the sample fails in the above tests. The bidder shall indicate the sources of all materials.57 RANDOM SAMPLE TESTING AFTER RECEIPT OF METERS AT STORES: The consignment of meters received at Area Store shall be accepted only after testing of sample meters at CPRI as stated in following paras. The Supplier shall indicate the details of the equipment available with him for carrying out the various tests as per relevant Standards. manufacturing/readiness activities so that arrangement can be made for inspection. 37.(E) Routine Tests: All the routine tests as stipulated in IS:13779 and in addition tamper and fraud protection tests as per TS shall be carried out and test certificates shall be furnished for approval of the Purchaser. The Supplier/Manufacturer shall keep the Purchaser informed in advance. about the The Purchaser reserves the right to insist for witnessing the acceptance/routine testing of the bought out items. The Bidder/Manufacturer shall have at least the following testing facilities to ensure accurate calibration: (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) Insulation resistance measurement Running at no load Starting current test Limits of error Power loss in voltage and current circuit Repeatability of error Transportation test Low load run test Heating test 37. (b) The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated.58 QUALITY ASSURANCE PLAN: The designed life of the meter shall be minimum of 20 years and to prove the designed shall have to follow at least the following Quality Assurance Plan:life. (xi) List of manufacturing facilities available.as per relevant ISS. (iv) During the manufacturing of the meters the following checks shall be carried out. (iii) The electronic components shall be mounted on the printed circuit board using latest Surface Mounted Technology (SMT) except power components by deploying automatic SMT pick and place machine and re-flow solder process. The electronic components used in the meter shall be of high quality. The PCB material should be of glass epoxy FR-4 grade conforming to relevant standards. The Supplier/Manufacturer shall furnish the following information. These limitations shall be very clearly brought out in schedule of deviations. the Supplier should own or have assured access (through hire. ICs used in the manufacture of the meter shall be of highest quality and reputed make to ensure higher reliability. (ii) The testing rooms shall be temperature and humidity controlled as per relevant standards. (c) The meters shall be batch tested on automatic. special acceptance and routine tests specified in the relevant standards and this specification. (iii) Power supplies used in testing equipment shall be distortion free with sinusoidal. computerized test bench and the results shall be printed directly without any possibility of human errors. current and frequency as per the relevant standards.59 MANUFACTURING ACTIVITIES: (i) All the materials. (ix) Statement giving list of important raw materials. electronics and electrical components. If the sample fails in the above tests. The testing and calibrating equipments should be automatic and all test equipment shall have their valid calibration certificates. longer life and sustained accuracy. 37. where stage inspections are normally carried out for quality control and details of such tests and inspections. (xiii) List of areas in manufacturing process. (xiv) List of testing equipments available with the Supplier for final testing of equipment specified and test-plant limitations. Information shall be separately given for individual type of meters offered. (xii) Level of automation achieved and list of areas where manual processing exists. (ii) The Manufacturer should use Application Specific Integrated Circuit ASIC or Micro controller for metering functions. vis-à-vis type. (a) Meter frame dimensions. The details of testing facilities available for conducting (a) The routine tests and (b) Acceptance tests shall be furnished in Schedule annexed with tender document. They must have computerized standard power source and standard equipment calibrated not later than a year (or as per standard practice). (x) Information and copies of test certificates as in (i) above in respect of bought out accessories. the entire lot will be rejected and testing charges shall be recovered from the Supplier. . The Supplier/Manufacturer’s laboratory must be well equipped for testing of the meters. if any. list of standards according to which the raw materials are tested. wave forms and maintaining constant voltage. lease or sub-contract) of the above mentioned facilities. Further. 37. names of sub-suppliers for the raw materials. the firm (i) The factory shall be completely dust proof. list of tests normally carried out on raw material in presence of Supplier’s representative and copies of test certificates. The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the employer. The contractor shall. The details of testing facilities available for conducting the routine and acceptance tests and other special tests on the meter shall be furnished with the bid. (v) Quality should be ensured at the following stages : (a) At PCB manufacturing stage. The Supplier shall also give the details of quality assurance procedures followed by him in respect of the bought-out items. electrical connections etc. non-aging and of tested quality. 1. The equipment shall conform in all respect to high standards of engineering. The Supplier/Manufacturer should submit the list of all components used in the meter along with the offer. submit three sets of final versions of all the drawings as stipulated in the contract for employer’s approval. One set of routine test certificates shall accompany each dispatched consignment. . The facility available if any for conducting type test may also be furnished. rules and codes of practices. Technical leaflets (user’s manual) giving operating instructions. 4. within 2 weeks of notification of award of contract. in his judgment. (d) Prior to final testing and calibration. Approval of drawings by employer shall not absolve the contractor of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of application standards. List of drawings and documents: The Supplier/Manufacturer shall furnish the following: (i) (ii) (iii) Two sets of drawing clearly indicating the general arrangements. All manufacturing and fabrication works in connection with the equipment prior to the approval of the drawing shall be at the contractor’s risk. submit 10 prints and two good quality report copies of the approved drawings for employer’s use.60 DOCUMENTATION: All drawings shall conform to International Standards Organization (ISO “A” series of drawing sheet/India Standards Specifications IS: 656. All drawings shall be in ink and suitable for micro filming. modify the drawings and resubmit three copies of the modified drawings for approval. Units. Three copies of dimensional drawings of the quoted item. All dimensions and data shall be in S. The employer shall communicate his comments/ approval on the drawings to the contractor within two weeks. Additional copies of sets of operating manuals/technical leaflets in the numbers as may be desired by the employer shall have to be supplied to the consignee or field officers. The successful bidder shall. each board shall be subjected to bare board testing. 3. workmanship and latest revisions of relevant standards at the time of ordering and Purchaser shall have the power to reject the materials which. all components should undergo testing for conforming to design parameters and orientation. 2. The calibration of meters shall be done in-house. Sets of operating manuals/technical leaflets per 100 meters shall be supplied to each consignee in the first instance of supply.I. All parts that are likely to develop corrosion shall be effectively protected against corrosion by providing suitable protective coating. all meters shall be subjected to accelerated ageing test to eliminate infant mortality. 37. A detailed list of bought-out items which are used in the manufacture of the meter should be furnished indicating the name of firms from whom these items are procured. (b) At insertion stage. is not fully in accordance therewith. fitting details. The contractor shall within two weeks. design. (c) Complete assembled and soldered PCB should undergo functional testing using test equipments (testing zig).(iv) All insulating materials used in the construction of meters shall be non-hygroscopic. if necessary. The acceptance test certificates in case of pre-despatch inspection or routine test cases where inspection is waived shall be got approved by the employer certificates in . proper arrangement for lifting. .2. Each consignment shall be accompanied with a detailed list containing the following information. if applicable.10 of SCC of Section 8 of the bid document. However. 37.63 GENERAL : a) Principle of operation of the meter. The Supplier shall be responsible for any damage to the equipment during transit.37.62 PACKING & FORWARDING: The equipment shall be packed in crates suitable for vertical/horizontal transport as the case may be. Any material found short inside the packing cases shall be supplied immediately by Supplier without any extra cost. due to improper and inadequate packing. such as lifting hooks etc. shall be furnished by the bidder. e) The procedure for Verification/Testing of Material supplied described in para 39.61 GUARANTEE: (i) The defect Liability period shall be as mentioned in clause GCC 27. a) b) c) d) e) f) Name of the consignee Details of consignment Destination Total Weight of Consignment Handling and packing instruction Bill of material indicating contents of each package The packing shall be done as per the Manufacturer’s standard practice. VT or potential divider as to how they can be considered superior in maintaining ratio and phase angle for variation of influencing quantities during its service period.. d) The Technical Specification of Push Fit Type Meter Box Made Of Engineering plastic has been described in para 39. b) The Supplier shall indicate the method adopted to transform the voltage and current to the desired low values with explanation on devices used such as CT. and suitable to withstand handling during transport and outdoor storage during transit. he should ensure the packing is such that the material should not get damaged during transit by Rail/Road.0.1 shall be followed f) It is mandatory to conform compliance of guaranteed technical particular of ac single phase electronic KWH meter with LCD display as described in para 39. 37. Wherever necessary. If the defective meters are not replaced within the above specified period. the same shall be treated as breach of performance of the contract and shall be liable for consequential penal action. The easily damageable material shall be carefully packed and marked with the appropriate caution symbol. (ii) The meter found defective within the above guarantee period shall be replaced by the supplier free of cost within one month of the receipt of intimation. c) The Supplier shall furnish details of memory used in the meter. shall be provided. outlining the methods and stages of computation of various parameters starting from input voltage and current signals including the sampling rate. Tamper circuits . Thickness of the base should be at least 2 mm and cover should be of not less than 0. However. The box should have proper mounting arrangement so that it could be mounted on the wall or the pole. the clearance at bottom should be of 75 mm. The barrier shall have reinforce/locked at both sides to restrict its movement up and down even by applying external pressure through any tools. Type test of material is required to be furnished along with the sample. The meters shall be supplied duly mounted on the base of meter box and the cover shall be placed separately in the cartoon. The meter box comprises of base and cover shall pass the following tests. i) Unbreakability test:. 37. inserted in the box.8 mm. Bhopal / ERDA. The locks will be moulded in the cover and base and will not be separate pieces fixed later. There will be no holes to access the locks from any side. Clearance of 30 mm shall be maintained from top and both sides of the meter. from the meter and 45mm from the terminal block. ii) Boiling water test :. .37. it cannot be removed from the base and become an integral part with base. The top cover of meter Box should have spring loaded push button with spindle in moulded barrel perfectly in alignment to operate push button of the meter to read display parameter on push button mode. The top cover of the box. However.Shall not get damage or deform while dropping from a height of 10 ft.64 TECHNICAL SPECIFICATION OF PUSH FIT TYPE METER BOX MADE OF ENGINEERING PLASTIC The meter box shall be weather proof. Thus. The overall dimensions of the meter box shall vary according to the different make of meters. The incoming and outgoing gland shall be positioned such that they disable direct access to terminals through glands. hammer to test its unbreakability. tamper proof and made of transparent engineering plastic conforming to IS: 11731. should have arrangement/barrier so that after getting locked. the Serial Number of the meter should be indelibly engraved /marked on the base of meter box as well as on the cover of meter box. The samples so selected shall be sealed by at least 3-4 seals/stickers by the committee members. Vadodara / any NABL accredited test house. The meter box should be unbreakable un-deformable and should withstand the temperature up to 140 deg. it cannot be detached from latches even by applying external pressure through any means.It should pass the boiling water test as prescribed in IS:13010.65 VERIFICATION/TESTING OF MATERIAL SUPPLIED Three (3) sample meters shall be selected for conducting Type Test from the first lot of meters received in Contractor’s stores by a committee constituted by CE (W&P). no wire or any device can be. The employer however in first instance may pay testing charges to the testing agency. The top cover of the meter box should be of push fit type having at least 4 self locks so that once the top cover of the box is fitted with the base it cannot be removed without breaking the top cover. The type test charges shall be borne by the contractor. The meter box cover or base shall have a barrier so positioned that any possibility of fiddling the meter terminal from outside of the meter box through cable entry holes is not possible. Suitable circular holes with adjustable cable glands shall be provided at the bottom of the meter box for inlet and outlet of consumer’s service cables. provided with self-lock. there should be minimum clearance of 15 mm in the front from the face of meter. which shall be recovered by Dy. Director (Bills) from the bill of the supplier. so that after fixing the top cover. The selected samples shall be sent with complete details for type test and additional test/special tests as per specification at CPRI. and hammered with 2 kg. The boxes shall be specific to the meter mounted in it. temporary or permanently. it shall comply with the minimum requirements as described above. The individual meter manufacturers shall submit the specific drawing and sample accordingly to accommodate there make meter only. cent. The cover and base shall have groove all along with the fitting edge. Besides. Meter shall be fitted with the base of box through unidirectional type screw or by some other better means in such a way so that once the meter is fitted with the base. Additional provision to provide lash wire utility seals on meter box shall be made. as the case may be. in case the meter(s) do not meet the requirement as per ISS/CBIP/Specification in type test(s). the further testing shall be suspended and lot shall be declared as fail. of meters tested at sr. the guarantee period of the quantity already supplied by the supplier shall be doubled and employer reserves the right to cancel the balance quantity. Injection test. no. . Insulation test. In case of repeat failure in acceptance test(s). out above 32 Nos. The decision of MPPKVVCL regarding verification/ Testing of meters shall be final and binding on the supplier and the MPPKVVCL shall not be required to give any reason(s) in writing or otherwise at any time for the rejection of material.In case of successful type test results. No failure shall be allowed out of 3 nos. However. The Type Testing charges shall be borne by the supplier. The balance material shall be accepted only after successful Type Testing. In case of failure in more than 1 no. (i) of above table. no.C. 3. The guarantee period of quantity already supplied & used shall be doubled and payment for used meters shall be arranged after deducting 10% cost. (iv) of above table. Test of meter constant. The supplies. the further testing shall be suspended and lot shall be declared as fail. meters shall be allowed out of 32 nos.No Particulars of tests No. three more samples shall be selected from the supplies already received to get them type tested at contractor’s cost. In case of repeat failure in type test(s). D. further testing shall be suspended and lot shall be declared as fail. Shock test and Fast transient burst test. In case of failure of any meter. (iii) of above table. Immunity Test. 35 KV abnormal high voltage/ frequency burst & loop induction device (Jammer) burst test. Repeated failure/poor results in the testing may render cancellation of order. the further testing shall be suspended and lot shall be declared as fail. 3 nos. the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled. In case of failure in more than one meter. 4. 3 nos. supplies shall be continued. of meters tested at sr.27 Tesla). no. out above 8 Nos. Failure of any one meter shall be allowed out of 8 nos. In case of successful test results. of samples to be tested 32 Nos. meter.C. However. Accuracy test after application of 440 Volts for 5 minutes. 8 nos. of (i) (ii) Starting Current test and No load test AC high Voltage test. Repeatability of error (iii) of (iv) Voltage variation. of meters tested at sr. out above 8 Nos. (ii) of above table. of Following procedure shall be adopted to clear the tested lot: 1. no. the similar testing procedure as described shall be repeated on another lot and if the lot fails consecutive second time the entire quantity of respective lot/sub-lot shall be rejected and shall have to be replaced by the supplier at his own cost. may be utilized in the field during the period of testing. 2. a set of 32 meters shall be selected randomly and sent to CPRI for conducting acceptance test as per the prescribed procedure S. In case of failure. supplies shall be continued. Magnetic Immunity test (Permanent magnet test of 0. The employer also reserves the right to get additional samples for all or any of the selected tests at employer's cost at any independent test house at any stage of supply. Power consumption test. Failure of more than 2 nos. the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled. of meters tested at sr. D. Failure of any one meter shall be allowed out of 8 nos. employer may allow the contractor to re-offer the material after change/ modification in the design of meters. if so considered necessary to ensure that the quality of meters being offered for inspection is same as already got type tested. Imax for 30 minutes test. Tamper & fraud protection. Limits of error. at the option of employer. meters. Failure of any 2 nos. In case of failure of samples of lot/ sub-lot in the test(s) detailed above. On receipt of consignment of subsequent lot in Contractor’s Stores. 2.Unity – Zero lead 120% of Imax 5.66 GTP FOR AC SINGLE PHASE ELECTRONIC KWH METER WITH INFRARED COMMUNICATION & LCD DISPLAY Sl. . loading Class-1. Starting current at which meter shall run & continue to run 30 Amps. 1. Requirement Offered 2.0 240V (+ 20% -40%) Ib-5 Amp. No creeping 6. name & number (Model) Standard Applicable To be mentioned IS:13779/1999. (a) (b) 9. Type.) Running with no load and 115 % of rated voltage Short time over current for one half cycle at rated frequency. 30 Imax 7. 0. Barrier of adequate size shall be provided between neighbouring terminals.4% of Ib at rated voltage and unity power factor 8. Less than 4 VA Less than 1. Engineering plastic of min. Name of manufacturer To be mentioned Particular Min. flame retardant.37.0 mm thick ---As above --High Impact strength non hygroscopic. non-hygroscopic. (i) (ii) Continuous current rating (Amp. 4. (a) Power loss at rated frequency & reference temperature Current circuit at rated current Voltage circuit at rated current Type of material used Base Material and thickness High Impact strength. Imax 30 Amp 50 Hz ± 5% Zero lag . flame retardant material. No. CBIP-88 with its latest amendment as on date. (i) (ii) (iii) (iv) (v) (vi) Rating Accuracy Class Rated Voltage Rated current Rated frequency Power factor Shall work within accuracy up to max.5W/8VA (b) (c) Meter cover material Terminal Block material (d) Colour Meter cover shall be fully transparent. 3. Type of communication provided for data downloading shall be as per TS Please indicate the type .(e) (i) (ii) 10. 11. of Digits Size of Numerals (min. 6. Screw Material Size Internal diameter of Terminal Hole Centre to Centre clearances between adjacent terminals Transducers Input CT/Shunt or combination and potential divider (PT less) Digital LCD with Backlit LCD suitable for operation up to 65 & o 80 C as per TS 6 including decimal digit (5+1) 8. 14.) Display Sequence ( display should be self explanatory) Auto Scroll Mode Date and Time DD: MM: YY HH:MM KWh Watt (As per specification) (ii) (iii) 14.Brass 5-6 mm dia Min. (i) Output Type of display Operation suitability (ii) (iii) 14.2 Cumulative active energy Instantaneous load Push button mode 15 Type of push button arrangement Spring loaded push button to be provided on top cover of meter box to activate the push button of meter to read parameters Meter shall be able to display reading 16. (i) (ii) 13. (i) It shall be long life having at least 10 years of life (ii) The drift in time shall not exceed ± 3 minutes per year 18.1 (i) No.5 x 5 mm o Nickle Plated .5 mm More than 13 mm 12. (i) (ii) Reading condition during power-off Type of arrangement made to display in power off condition Battery of Real time clock Please provide 17. (i. (v) The meter shall record energy proportional to the current and rated voltage with Unity pf when any of the enclosed tamper circuits are used to tamper energy by more than 10% using a diode. (b) Incoming neutral disconnected. (i) Fixing/sealing arrangement Fixing of meter Min.19. matching with that of meter also marked with MPEZ and firm’s logo.) (ii) (iii) Performance of meter in tamper conditions Phase-neutral interchanged Main & load wire are interchanged (a) Load is not terminated back to meter & current is drawn through local earth fully or partially even when phase and neutral connection are reversed. company logo and shall be additionally laser marked with serial no. polycarbonate irreplaceable tamper evident seals which shall be marked with “MPEZ”. or a variable resistance or a variable capacitance . Should work within specified accuracy ----do------do---- LED start blinking when incoming voltage is below 200V and Energy register shall advance for low voltage up to 120V (iv) Neutral disconnected from both incoming & outgoing and load drawn through local earth Provision should be there not to exceed threshold current of 20% of Ib and start recording energy. and can be easily viewed to check duplication attempts for the purpose of keeping track of meter seals with serial no. Meter shall have provision to record the tamper of Neutral Missing with date and time of occurrence and restoration. (b) provision shall also be made to provide additional lash wire seals on the meter body by the Utility (c) Seals shall be provided on front side only. The serial number of meter is to be laser –etched on the base as well as the cover of the meter box. (d) Meter cover shall be permanently and solidly welded with Base so that it could not be opened without breaking. The top fixing screw shall not be accessible after meter is fixed to meter box base. matching with that of meter. outgoing neutral connected to earth through resistance and load is connected to earth. (ii) Sealing of meter cover to Base 20. 3 fixing holes (one at top & two at bottom under terminal block). (a) At least 2 nos. e. Low Power 3mm or 5mm. Electromagnetic compatibility (EMC/ EMI severity level) Effect on accuracy of external electromagnetic interference of electrical discharge. Effect of accuracy in tamper conditions Cut off voltage (at which meter stop working) Ref. Calibration LED of Red colour is essential. external magnetic field & DC current in AC supply or in neutral Should withstand severity level 4 24. even in absence of supply. However for Immunity to external DC magnetic field. the performance of meter should not get affected on application of DC magnet of not less than 0. Temperature 26. it should permanently remain hanged. Should work within accuracy specified in IS:13779 with latest amendment • Please specify 25. Suitability of meter to sustain over voltage i.27T) the meter shall record energy not exceeding the product of rated voltage and maximum current (Imax).(vi) Indication condition in above tamper “Reverse” indication for (i) & (ii).27 Tesla size at different locations of meter body. 27. • Meter shall have provision to record the tamper of abnormal magnetic induction with date and time of occurrence and restoration. This tamper shall also be displayed on the meter LCD Should work normal and the accuracy should not be affected after removal of such device. 27 C o . Should sustain (vii) Application of abnormal frequency and voltage of the order of 35 KV voltage burst with the help of external device Meter should also be immune for tamper by application of remote loop induction device (jammer). 21. The meter should not exhibit intermittent recording operation and if it hangs during any desired testing method. “Earthed” indication for (iii) above & (iv) (LED or ICON) (vi) If attempt is made to open the meter body. Under the influence of abnormal magnetic field (not less than 0. Rest of the LED’s as per TS or Icon on LCD. The meter shall detect /log with date and time of meter body opening tamper. The meter should not hang during any desired method of test. Should work within accuracy complying with standards with its latest amendment as on date. 23. phase to phase voltage injected between phase & neutral Size of calibration LED and other LED/Icon 22. Repeatability of error Transportation test Low load run test Heating test Whether offered meter are Type Tested as per IS:13779 at NABL accredited Lab Name of the Lab Guarantee period of meter printed on name plate. With its validity for ISI certification mark on offered Must be available --do---do---do---do---do-- g) h) i) j) 36. (i) Type of body Calibration CT/Shunt fixing arrangement Manufacturing activity Mounting of components on PCB shall be SMT type Compliance to quality assurance Testing facility Fully automatic meter bench with print out facility shall be available.28. 32. 38 Please provide . Please indicate o o 30. 29. Insulation resistance Running on no load Starting current Limits of error Range of Adjustment Power loss in voltage and current circuit. of Test bench Accuracy of ESS Type of technology SMT type and ASIC technology (ii) 35. Make and S. Temperature range of operation Drift in accuracy of measurement with time Fixing arrangement of name plate -5 C to 60 C No Drift in accuracy in measurement with time Plastic nameplate fixed in side the meter.(i) --do---do---do---do-YES/NO (ii) 37. 33 34. It should contain all the details as per ISS Projection type Software calibrated at factory. 31. Please provide 5½ years from the date of supply.No. (i) Please confirm Must be available (ii) (iii) (iv) (v) a) b) c) d) e) f) To be indicated ---do--Digital/Analog Following in house testing facility shall be available. BIS licence No. & dt. assembly.e. Piercing screws shall be used in the meter for voltage connection The meter should be capable to record and display active energy. The meter shall have provision in such a way that LV side cable of Distribution Transformer shall be directly passed through the meter for current measurement. Conform to Technical specification and IS:13779/1999 (with its latest amendment). The complete meter unit i. (i) (ii) YES/NO 42 YES/NO 43. testing at manufacturers Works before dispatch and supply of high precision three phase four wire 3x240 volt.0.meter 39 (i) (ii) (iii) (iv) (v) (vi) Details of meter design for which above BIS certification has been obtained: Ratio of Ib to Imax Material of meter body Type of energy registering counter Type of technology Grade of printed circuit Board material Type of assembly of component used (SMT) Meter constant (Imp/KWh) Auxiliary power circuit (with PT or PT less) Current circuit (CT/Shunt combination or only shunt) Accuracy Class ISO accreditation no. reactive energy and maximum demand KW/KVA for 3 phase 4 wire AC balanced/ unbalanced . 40-200 Amp static Electronic tri-vector energy meter of accuracy class 1. Please provide Please provide 41. Whether meter has Six programmable Time of use facility Other parameters/features covered in the above GTP not YES/NO Please provide Please provide Please provide Please provide Please provide Please provide (vii) (viii) Please provide Please provide (ix) Please provide (x) 40.1 SCOPE: This specification covers the design. Confirm whether copy of the orders along with technical specification is enclosed with the tender. inspection. & dt. manufacture. capable of primarily performing functions of tariff meters and GSM modem (GPRS enabled) with store and forward facility with suitable accessories for automatic and remote data transfer from Electronic energy meters. with its validity Past Experience Whether the details of orders received and quantity supplied is indicated in the schedule of past experience. engineering. internal CTs and modem shall be housed in the same encloser. apparent energy. meter. 38 TECHNICAL SPECIFICATION OF 3 PHASE 4 WIRE STATIC TRIVECTOR ENERGY METERS FOR DTR METERING 38. the performance and testing of the meters shall conform to the following Indian/International Standards and all related Indian/International standards to be read with upto-date and latest amendments/revisions thereof: Indian Standard No.P.88 (with latest amendments) IS 12063 Specification for AC static watt hour meter for class 1 & 2 Specification for AC static Electrical Energy Meters Specification for degree of protection for enclosure. Title International & Internationally recognized standard IEC 62053-21 IS:13779/1999 with latest amendment CBIP Technical report No.3 CLIMATIC CONDITIONS: The meters to be supplied against this specification should be capable of performing and maintaining required accuracy under extreme hot.2 STANDARD APPLICABLE: Unless otherwise specified elsewhere in this specification. 38.m 40 0. cold. Specification for engineering plastic IS 5133/1969 (Part II) IS:9000 IS:11731 38. Meters shall be supplied along with basecomputer software’s (BCS) suitable to read the meter remotely as per the details given in this specification. Specification for boxes for the enclosure of electrical accessories Basic environmental and other Testing for Electronic & Electrical items. tropical and dusty climate and solar radiation typically existing in state of M.) Permitted noise level 55 C 45 C 60 C o o o (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (-) 5 C 40 C 95% 4 months 1000 meters 150 cms 200 kg/sq.loads for a power factor range of 0 lag. The meter shall be required to operate satisfactorily and continuously under the following tropical climatic conditions: (a) (b) (c ) Maximum ambient air temperature Maximum ambient air temperature in shade Maximum temperature attainable by the meter exposed to sun Minimum ambient temperature Average daily ambient air temperature Maximum relative humidity Number of months of tropical monsoon condition Maximum altitude above mean sea level Average annual rain fall Maximum wind pressure Isoceraunic level (days per year) Seismic level (horizontal accn. unity and 0 lead.30 g 45.db o o . RUNNING WITH NO LOAD: When 115% of rated voltage is applied with no current flowing in current circuit. 1.4 TECHNICAL REQUIREMENT & DESIGN CRITERION Meters are required for installation in the premises of LT consumers. reference frequency and reference temperature shall not exceed 4 VA as per IS:13779.38. 2. Item Type of installation System voltage (phase to neutral) System frequency No. The meters shall work satisfactorily in the absence of neutral and shall work even if any two voltage wires are extended to the meter.No. without the help of any power source or battery back up. RADIO INTERFERENCE SUPPRESSION AND ELECTROMAGNETIC CAPABILITY: The meter shall not generate. Auxiliary Power: The meter shall draw power for working of electronic circuit from phase & neutral.0 38. 38. Overall Accuracy offered to the system shall be – Class 1. STARTING CURRENT: The meter should start registering energy at 0. which would interface with the other requirement.5 POWER CONSUMPTION Voltage Circuit: The active and apparent power consumption in each voltage circuit (per phase) including power supply of meter at reference voltage.6 SALIENT FEATURES The meters shall make use of Non Volatile Memory capable of storing & retaining all the data required to be stored. Current Circuit: The apparent power taken by each current circuit (per phase) at basic current. 2 KV RMS for 1 minute The meter shall be 3 phase 4 wire type. The above shall conform to the requirement listed in the applicable standards. Computation of demand shall be on the basis of Real Time Clock of the meter itself. reference temperature and reference frequency shall not exceed 2 Watts and 10 VA respectively.4% of basic current at UPF as per IS:13779. 4. 3.40% three phase 50 Hz ±5% 3 phase 4 wire Solidly grounded 6 KV peak 7. 5. Meter shall have facility to allow downloading of selective data at faster speed to save the time while reading the meter for billing purpose through AMR or MRI. The downloading of billing data should be possible in less than 3 minutes. suitable for continuously 240 VAC (Phase to Neutral) and shall be capable of withstanding twice the nominal voltage between phase to neutral (or earth) for short duration. 6. The basic system parameters wherein these meters will be installed shall be as under:Sl.2/50 Micro sec. conduct or radiated noise. . the test output of the meter shall not produce more than one output pulse count as per IS:13779. of phases System earthing Resistance to surge voltage of 1. Test voltage at 50 Hz Specification Indoor/Outdoor 3x240V + 20% to . It shall. shall be provided for adjustment of measurement errors. Any other design meeting technical specification or features/accuracy etc. The meter shall have provision in such a way that outgoing cable of transformer shall be directly passed through the meter for measurement. billing shall also be possible with the press of MD reset button. The above activities should not be possible at site through the use of user software or any such means. As the cable directly passed through the meter. moisture and vermin’s. If required. Piercing screws shall be used in the meter for voltage connection. settings etc. The meter shall be suitable to accommodate aluminum cable of 100A current carrying capacity. Provision shall be made to seal the optical port to ensure proper security. data. Provision shall be made to read various billing parameters and tamper data recorded by meter through a meter reading instrument. better than this specification and manufactured as per relevant IEC/IS/CBIP report shall also be acceptable.7 POWER FACTOR RANGE: The meters shall be capable to record over full power factor range of Zero Lag-Unity. 38. except those required for Billing data. Meters covered under this specification shall be fully static type with non-volatile memory to register various billing parameters and complete with other features as detailed out in this specification. However for specified accuracy the power factor range shall be as per IS. 38. For security reasons. the meter operating software should have at least “two level write protection” against any modification/editing of the parameters. the meter constants shall be freezed and it shall not be possible by the manufacturer or the user to alter the meter constants either at factory or at site. No setting points/setting registers etc..Provision shall be there to do the billing operation automatically at a predefined date by programming the meter.resistant. TOD metering.9 DISPLAY: The meters shall have bright LCD Electronic display with backlit & with minimum 7 digits to read up to one tenth of KWh with another digit for legend. The LCD shall be of STN o o (Super Twist Nematic) type designed suitably to withstand temperature of 80 C (storage) & 65 C (operation). Indications shall be provided on display to show the healthiness of phase voltage. Meters shall be suitable for accurate measurement and display of energy and other billing parameters within the specified limits of errors under balanced and unbalanced load conditions in a poly phase network. Once finalised. be possible to check the accuracy in the field by means of the test output. non-inflammable. No device. The back lit should not glow during power off condition. CONFIGURATION & PROGRAMMING The Meter should be only factory calibrated. The meter-base & meter-cover shall be made of high grade. configured and programmed. fire. Design should support thread through concept where connecting cable directly passed through the meter for measurement. highgrade and good quality engineering plastic. such as potentiometers shall be used which can result in change of calibration at site. This arrangement can be through an optical port. The meter shall be fully programmable by the user for TOD timings and billing dates etc. 38. the offered meter should not have provision for meter terminal connection as well as terminal block. The meter connection arrangement should be such that so there is no need to remove insulation for connecting cable for current measurement.Zero Lead. The meter shall be convenient to transport and immune to shock and vibrations during transportation and handling. however. . The meter shall conform to the degree of protection IP 54 of IS: 12063/IEC: 529 for protection against ingress of dust. The decimal digits shall be clearly distinguished from integral digits. The entire design and construction shall be capable of withstanding stresses likely to occur in actual service and rough handling during transportation.8 CALIBRATION. (ii) After keeping the meter at a constant temperature of 80oC for a period of 30 minutes and when restores at normal temperature.(i) When the meter remains at a constant temperature of 65 C for a period of 30 minutes. The minimum character height X width shall be 10 X 5 mm. i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) xv) xvi) xvii) xviii) xix) xx) xxi) xxii) LCD segment check Date DD:MM:YY Time HH:MM Rising demand register MD reset count Cumulative kWh energy register Cumulative kVArh lag energy register Cumulative kVArh lead energy register Cumulative kVAh energy register KW / KVA MD register Cumulative MD register KW/KVA Instantaneous P.--. The registered parameters shall not be affected by loss of power. The meter shall make use of non-volatile memory capable of storing and retaining all the data required to be stored.--. The display shall have ‘ON’ time of at least 10 seconds of each measured value.--.--. There shall be 7 segments 7 digits for display of parameters value. The LCD display should have a wide viewing angle of 45 C to 60 C and up to one-meter distance. Display parameters shall move forward if button pressed prior to the programmed time for display of each parameter.2. without the help of any power source or battery back up and shall have a minimum retention time of 12 years under un-powered condition.6 Cum.6 Cum. The accuracy of display parameters for all parameters shall be matching with the accuracy class of meter as per IS.6 MD KW Average power factor of the last month Billing MD kW/KVA Billing MD date Billing MD time TOD 1. KWh TOD 1.10 DISPLAY PARAMTERS AND SEQUENCE The meter shall display the required parameters in two different modes as follows:a) General Requirements (I) Auto display mode i) Date DD:MM:YY ii) Time HH:MM iii) Cumulative kWh iv) MD KW/KVA v) Instantaneous P. KVAh TOD 1.--.F with sign of Lag / lead vi) Average power factor of the last month vii) Main Billing active KWh viii) TOD 1.2. The display of various parameters shall be scrolling one after another.6 Billing MD registers Main Billing KWh register . Large viewing area with large display icons is preferred. The display shall have ON time of at least 10 seconds for each measured value.6 Billing active KWh ix) Billing MD kW/KVA o o o (II) Display Parameter Push Button mode The display of the following parameters shall be continuously scrolling one after another through push button.2. The display shall not be affected by electrical and magnetic disturbances. The LCD segment check shall be on meter display for minimum 2 seconds. LCD display should work as in normal conditions. 38.F with sign of Lag / lead Frequency TOD 1.2.2. for clear visibility of the display of the meter reading. the character of LCD should not deform. except LCD segment check. 6 Billing KWh registers Main Billing KVAh register TOD 1.6 Billing KVAh registers Tamper information-This shall be displayed when tampered with following.--.xxiii) xxiv) xxv) xxvi) TOD 1. xii.2. iv.F. xiii. ix. v.--.2. of last 3 months Tamper information Present demand KW/ KVA Instantaneous Power factor In two digit with indication of lag/lead Load survey All balance parameters of (a) and (b) above . ii. iii. xi. vi. x. a) Date of last tamper occurrence b) c) Time of last tamper occurrence Number of times meter tampered b) Programmable Optional Requirements: i) Phase wise current ii) Phase wise Voltage iii) Instantaneous Power - A V KW/ KVA c) View Parameters:(Information required through meter reading instrument on BCS) i. Phase wise current A Phase wise voltage V Active energy KWh Reactive energy lag KVArh lag Reactive energy lead KVArh lead Apparent energy KVAh MD during the month KW/ KVA Avg. P. vii. viii. 38. i) Missing potential detection: The meter shall detect Potential missing and record this information along with date & time of occurrence and restoration of the event and phase indication. The meter shall monitor during each integration period of the month & display maximum value occurred. which includes resetting any maximum demand registers that are in operation. 38. When a billing operation occurs.15 LOAD SURVEY The meter shall have non-volatile memory for recording load survey for KW or KVA (programmable). Pressing the left-hand button shall then cause a billing operation. the contents of the rate registers shall be transferred to there billing equivalents.14 CUMULATIVE DEMAND REGISTERS The cumulative demand registers keep a running total of the value of maximum demand registers.12 MAXIMUM DEMAND REGISTRATION Maximum demand computation shall be updated based on sliding window principle only and demand integration period of 15 minutes programmable with updates of 5 minutes for 15 minutes IP. However. The following tamper information shall be available in the meters to detect common ways of tamper & fraud. 38. On user specified/programmed day the billing operation shall occur at 00:00 hrs. The load survey data shall be logged for last minimum 35 days for interval of 15 minutes. The meter shall display the maximum demand reset count. 38.38. the real time clock of the meter shall be used only for the purpose of time matching and for computation of maximum demand the internal clock of meter shall be made use of. The same push button shall be used for display the auto scroll mode during power outage.13 BILLING REGISTERS/ MD RESET: Each register shall have an associated billing register. Subsequent presses of the MD reset button shall be ignored if a manual billing operation has already occurred within 15 minutes.16 TAMPER FEATURES a. A suitable internal/ external device could be used so that display of readings could be possible at least twice considering that continuous power outage will not be for a period of exceeding 24 Hrs. and are updated each time billing occurs. Only one manual billing operation shall be possible in any given 15 minutes. The MD integration cycle shall be on the basis of real time. Manual Billing The left-hand button on the front of the meter shall be capable of reset maximum demand. Billing operation may be caused by any of the following means: Automatic Billing Automatic billing operation shall also be supported.11 METER READING AT POWER OUTAGE: Provision to read the meter in no power condition shall be made. Normally this option shall be disabled. CT reversal Detection: ii) . Electronic Billing Sending a secure MD reset message to meter via the optical port shall cause a billing operation. 38. f.The meters shall detect and indicate the occurrence of CT reversal on meters display along with phase indication and shall also store the date & time of occurrence and restoration in the non-volatile memory. meter functioning hang up etc. (The last tamper event as per above tamper is to be included in the DISPLAY and rest of the details in VIEW PARAMETERS). the meter should log the events of abnormal magnetic induction with date and time. Even if meter detects such a condition. The meter shall record min. to be selected for design of tamper logics shall be in consultation with the purchaser. .27 Tesla ± 5%. On application of external DC and AC magnetic field of higher intensity (abnormal magnetic induction) against which meter is not immune. power on event shall be recorded. the recording of KWh shall be done in positive direction only. g. The meter accuracy or accuracy in display under normal conditions shall not be affected by placement of a permanent magnet of 0. Provision shall be made for push button to initiate display parameter in the front of the meter. Phase Sequence Reversal: Meter shall operate and record satisfactorily irrespective of phase sequence of input supply so long as phase association between voltage and current circuits is in order. At the same time. Along with the information. v) Power ON/OFF: Meter shall be capable of detecting and recording power off of all voltages not present. anywhere on the surface of meter without meter box. iii) Current Imbalance (CT shorting/by-passing): In case of CT open or shorting. h. e. The event shall be recorded on the next power up. Real time clock disturb. c. current. time etc. When meter is subjected to 35 KV abnormal voltage. Neutral Missing: The meters shall work properly even if neutral is not available and shall work satisfactorily even if any two of potential wires are extended to it. 200 events of aforementioned tampers (occurrence + restoration) along with date and time of occurrence and restoration of each and every event. the meter shall also record the instantaneous values of all three-phase voltages. Application of abnormal voltage/frequency: (I) The accuracy of the meter. Logics for design of above indicated tamper. b. should not occur with the application of abnormal voltage/ frequency such as spark discharge of approximately 35KV with 0. three-phase currents and three-phase power factors to elaborate the existing condition during all the type of tamper events. frequency burst and remote loop induction device (jammer). which may result in the current imbalance between the phases. (II) Meter should also be immune for tamper by application of remote loop induction device (jammer).27 Tesla DC. Provision shall be made for maximum demand (MD) reset push button with provision of sealing. However. The positive error may be beyond the limit of 4% but not exceeding power value equivalent to the product of rated voltage and maximum current. iv) Voltage Unbalance: The meter shall be capable of detecting and recording occurrences and restoration of voltage unbalance as an event.01-10 mm spark gap in any of the following manner when applied for 10 minutes: i) On any of the phases or neutral circuit ii) On any connecting wires of the meter iii) At any place in load circuit iv) Spark on meter body. External Magnetic Influence: The meter shall not get influenced by any external magnetic fields (AC Electro Magnet or DC Magnet) as per value(s) specified in IS:13779 with its latest amendment for AC Magnetic Field. The event recording shall be compartment-wise roll over type i. the tamper indication should appear by means of measuring neutral current. Memory data corruption. it shall always maintain record of last 200 events occurred. it should not hang and in case it hangs once it should remain hanged permanently.e. the meter alone should comply up to 0. the value of voltage. d. 38. unless authentic command is received. Additional features. 38. TOD register's data. load survey data. No separate cost will be borne by the purchaser on this account. Necessary compatible meter application software for various programmable features as discussed above in the meter and also necessary software for the IBM compatible computer to obtain various details as discussed above shall be provided by the supplier. The necessary base computer software (BCS) for this purpose shall be provided by the supplier with complete details.19 TOD TARIFF/DEMAND The meter should be capable of registering the time-of-day energy and maximum demand. end of the month). The main control of this system along with proper security password/code should be available on one or more computers located at the authorized location(s) as per the directions to be given by the Purchaser.18 PERFORMANCE ON DC INJECTION: Apart from all the technical requirements as specified above.20 DATA SECURITY: . current. Manufacturer may confirm whether the blinking visible signal is of weighted pulse and this can be effectively used for verification of accuracy. The time zones shall be provided at the time of ordering. All billing parameters shall be transferred to billing registers and shall be displayed on auto cyclic display mode referred to as "BILLING PARAMETERS". Tamper information shall remain on display.An operation indicator in the form of blinking visible signal shall be provided to indicate that the meter is operating satisfactorily. b) Billing Parameters for last 6 Histories. 38. apart from instantaneous parameters like voltage. energy registers. Further.g. if any. 2. and readings of billing parameters. PF and KW/kVA MD as well as Tamper Count and Power-On hours readings shall be at 00. tamper information and instantaneous parameters data shall all be retrievable through the meter's communication port through a common meter reading instrument (CMRI) and shall be transferred (downloaded) to a PC with Windows based software to get complete details in numerical and/or graphic form. The change of the TOD time-period(s) or defining additional TOD zones should be possible through CMRI with special authenticated command from the BCS so that only authorized person(s) can make such changes. PF. In addition reset of maximum demand shall be possible through push button or through a hand held terminal capable of communicating with the meter.00 hours of the first day of each calendar (billing) month. The above billing data. The meter shall not get affected by any remote device.. in the meter may also be clearly indicated. Note : 1. the following additional parameters should be made available at the BCS end: a) MD reset count. The meter should have in-built capacity to define up to six time zones. it should also be ensured that meter should not stop and record consumption accurately even on injection of DC voltage in neutral. Provision should be made for automatic reset of maximum demand at the end of pre-defined period (e. The billing parameter at the time of automatic reset of the maximum demand shall be programmable. TOD registers etc. The manufacturer should furnish detailed explanation as to how the meter is able to detect/ protect recording the above tamper and fraud features with sketches and phaser diagram. 38.17 BILLING POINT REQUIREMENTS: The predefined date and time for registering the billing parameters of kWh. In every case the design shall include provision of updating of cumulative demand register with updating of reset counter. The software shall have the facility to convert all the consolidated information / data of selectable . The optical port shall be located in the front of the meter & shall have adequate sealing arrangement to seal it. The meters shall give high-resolution energy values directly to meter reading instrument. (ii) Optical port of the meter shall be extended suitably downwards. Serial communication Protocol shall be adopted for data communication.The data transfer from the meter to MRI and MRI to computer should be fully secured and any unauthorized change in data should be indicated on computer system. Testing shall also be possible through optical port accessible from the front and can be monitored with Meter Reading Instrument having high-resolution display. 38. The minimum life of lithium battery should be seven years. The information of meter including integration etc.24 BASE COMPUTER APPLICATION SOFTWARE For efficient and speedy recovery of data read through AMR/CMRI/HHU. of meter’s data. iii. ii. Modem shall be connected such that the galvanically isolated port of meter shall be free for the data downloading through CMRI. there should be a facility in MRI to provide the transfer of meter data to computer through RS 232 or USB port. Base computer software shall be supplied having the following specifications as below: The BCS software shall be user friendly. 38. Base Computer software shall give all details adequate for analysis and load surveys parameters.23 COMMUNICATION CAPABILITY: (a) The meters shall have galvanically isolated optical communication port so that it can be easily connected to hand held common meter reading instrument for data transfer. 1.5 meters above the ground level such that meter could be read easily through the MRI. The MRI shall have facility to store minimum 100 nos. The specification of modem is as per subsequent paras. 38. an indication shall appear on the BCS display. Under battery weak condition. Further. There should be multi level password on the base computer system and in the meter to prevent any unauthorized change of TOD timings or resetting of demand. 38. Remote communication mode for data retrieval: The meters would be mounted at height on the secondary of distribution transformers and it is difficult to take meter readings at height therefore reading of meter should be taken by choosing any one of the following means: (i) Through GSM Modem: The GSM Modem shall be provided with store and forward feature in the same enclosure of meter. shall be independent of requirement of battery. The MRI shall be capable for down loading readings of other makes of meters. Extended port shall be robust & well protected with locking and sealing arrangement. (b) (c) Meter Reading Instrument (MRI): i. of meters free of cost along with battery charger. to use the MRI for reading and retrieving the data from the meter and to download the data to Base Computer free of cost till the expiry of guarantee period. reading of meter etc. Windows based Base computer software shall be supplied. The bidder shall give an undertaking to this effect It shall be responsibility of the meter manufacturer to provide the required software and all the facilities required by the purchaser.21 A suitable battery of adequate storage energy shall be used for energy supply to real time clock during no voltage or power off condition. The MRI suitable for reading shall be supplied in the ratio of one for each 300 nos.22 OUTPUT DEVICE: The meters shall have a test out put in the form of a blinking LED for testing of the meters accuracy. The resolution will be sufficient to enable conduction of the starting current and accuracy test in less time. BCS shall have facility to export data to ASCII or spreadsheet format for integrating with the purchaser's billing system. Help: The exhaustive online help shall be available with the software so that user can use all the features of the software by just reading the help contents. billing register readings shall be shown in a manner which user can easily understand.26 CONSTRUCTION OF THE METER The components on the PCB shall be of surface mounted to ensure reliable performance even under shock/vibration. Print out shall not include anything and everything available with the BCS. xi. xii. Meter Data Display:The software shall show electrical condition existing at the time of reading the meter in tabular forms as well as graphical format (Phase diagram) All the information about energy. The first level shall allow the user to enter the system. The different software features shall be protecting by different passwords. The use of the software need not revert back to the supplier of the software for modifying the software just to print what he desires. The configurable of passwords shall be user definable. the field width selection etc. Date of meter reading. xiv. . xiii.g. Supply of API with the meter is mandatory. Here again an "Export wizard" or similar utility shall be available whereby user can select file format. The meter shall conform to the degree of protection IP 54 of IS: 12063/IEC: 529 for protection against ingress of dust. All information about a particular consumer will be sorted out and available at one place so that locating any consumer 's past data is easy. It shall be possible to retrieve/locate data on the basis of either one of the following particulars: e) f) g) h) Consumer's ID/Numbers. All the load survey data shall be available in numerical as well as graphical format. x. The Data Transfer: It shall be possible to transfer data to and fro from CMRI through serial interface. BCS shall have feature to read data through AMR in different modes through GSM/ GPRS infrastructure. Security:The BCS shall have multilevel password for data protection and security. xvi. No. EDP department of purchaser can generate its own DBF (data base files) to downloaded all the required information into it. The construction of the meter shall be suitable for its purpose in all respects and shall give assurance of stable and consistent performance under all conditions especially during dust storms/heavy rains/very hot days. The software shall support "print wizard" whereby user can decide what to print out. The BCS shall be suitable to run on IBM compatible PC hardware platform. The load survey graph will show values where the cursor is placed for the selected or for all parameter. It shall be possible to view this data daily. Platform: The BCS shall be executable on all WINDOWS system. ix. The meter should be made of high quality raw materials to ensure higher reliability and longer life. Meter Sr. 38. Body of the meter shall be designed suitable for projection mounting. 38. maximum demand and their respective TOD register reading. Support Display: There shall be "user friendly" approach for viewing meter data for the reading collected now or for the reading collected in the past. All the information about abnormality events shall be accompanied with date and time stamping along with 'snap-shot' of respective electrical conditions.parameters into ASCII format. Location. The software shall be capable of preparing CMRI to read the meter information or time setting of the meter. The software installed on one PC shall not be copiable on another PC. and monthly format.25 APPLICATION PROGRAMME INTERFACE (API) The bidder shall provide Application Programme Interface (API) to read their meters and convert the meter data as per IEEMA MIOS standard. This information shall be displayed in the sequence in which it happened in cumulative format as well as summary format. The meter should be compact and reliable in design e. to transport and immune to vibration and shocks involved in transportation/ handling. Configurability: It shall be possible to have selective printing of all available data of the meter. what data to export. moisture and vermin’s. xv. weekly. which should be sealed in such a way that the internal parts of the meter are not accessible unless body is broken. The construction of the meter shall be such as to be sealed independently and prevent unauthorised tampering. 38. Proper locking arrangement shall be provided to protect from unauthorised removal of meter from its mount. Meter terminals shall also be marked & this marking should appear in the above diagram. 38. procurement.29 MOUNTING ARRANGEMENT Suitable wall mounting arrangement for the complete meter unit shall be provided such that the mounting bolts shall be operated/ opened or accessible only after operation of a set of seal. which envelops all metal parts with the exception of small parts and should withstand an insulation test at 4 KV. The PT terminals shall not be accessible without removing the seals of the terminal cover when energy meter is mounted on the meter board/ wall. 38. reading button and optical port shall only be possible after opening the front cover. All the seals should be provided on front side only. including the terminal cover. it shall be possible to check the correctness of the connection to the meters and there polarity from the functioning of the meter with the help of CMRI under load condition. Minimum three sets of seals i. The . The case shall be so constructed that any temporary deformation may not effect the satisfactory operation of the meter. These should not be ignited by thermal overload of live parts in contact with them. Approach to the MD reset button.All insulating material used in the construction of the meter shall be non-hygroscopic non ageing and of tested quality. seals on front door. which can be sealed independently & over the meter cover. removal and disposal etc. seal each on maximum demand device and communication port. meter cover and the front door shall be provided.33INSTALLATION CHECK: While installing the meter. Suitability of such use shall also be confirmed. 38. (b) TRACKING SOFTWARE FOR SEALS: It is mandatory to provide Tracking and recording software for all new seals so as to track total movement of seals starting from manufacturing.27 METER CASE AND FRONT DOOR: The meter shall have a case. The front door shall be sealed independently & over the terminal cover. The nos. All parts that are likely to develop corrosion shall be effectively protected against corrosion. for Piercing screws. 38.30 INSULATION: The meter shall have durable and substantially continuous enclosure made of wholly insulating material. The meter unit shall have opaque front hinged door with suitable sealing arrangement (screws). storage. seals on the terminal cover shall also be made. of the seal shall be unique and should not be repeated in any case. The polycarbonate seals shall have proper locking to avoid opening of the seal in any case by means of tampering. Meters described above shall be installed out door. 2nos. 38. 38. polycarbonate tamper evident seals having 6 digit serial no.32 CONNECTION DIAGRAM & TERMINAL MARKINGS: The connection diagram of the meter shall be clearly shown on inside portion of terminal cover & shall be of permanent nature. Access to the working part should not be possible without breaking the seals. installation.e. (a) SEALING OF THE METER: The meter body shall be provided with 2 nos. series of inspections. Provision of at least 2nos.31 RESISTANCE TO HEAT AND FIRE: The terminal block and the meter case shall ensure reasonable safety against the spread of fire. record keeping. directly under the sun and extreme weather conditions.28 TERMINAL (PIERCING SCREW) COVER: The PT Piercing screw cover for the meter shall be extended type. Rear side sealing arrangement is not acceptable. 1 no. The meter shall be made of self extinguishing polycarbonate/Engineering Plastic. 36 NAME PLATE AND MARKING: Every meter shall have a nameplate clearly visible and indelible and distinctly marked in accordance with relevant standard (latest version). The following information should appear on the name plate affixed on to the meter:(i) Manufacturer’s name or trade-mark and place of manufacture. The accuracy of display parameters shall be verified at the time of inspection in line with class of accuracy of meter. 38. (ii) Designation of type (iii) Number of phases and number of wires for which the meter is suitable. NOTE: The standard meters used for conducting tests shall be calibrated periodically at reputed Government Accredited Test Laboratories and test certificates shall be available at Works for verification by purchaser’s representative. 38.34 GUARANTEED TECHNICAL PARTICULARS: The bidder shall furnish all the necessary information as desired in the Schedule of Guaranteed Technical Particulars and data. b. Routine Tests: All the routine tests as stipulated in relevant standards in addition tamper and fraud protection tests as per clause-22 shall be carried out and test certificates shall be furnished for approval of the purchaser. appended with this Specification. The Bidder shall indicate the details of the equipment available with him for carrying out the various tests as per relevant Standards. (iv) Guarantee period – 5-1/2 years. If the bidder desires to furnish any other information(s) in addition to the details as asked for. & Date.phase sequence and phased association of voltage and current can be checked with the help of CMRI. b) The manufacturer shall have at least the following testing facilities to ensure accurate calibration :(i) Insulation resistance measurement (ii) Running at no load . Type test certificates from any one of the standard laboratories NABL accredited for particular equipment/test. year and month of manufacture (x) Principal unit in which the meter records (xi) Reference voltage (xii) Basic current and rated maximum current (xiii) Reference frequency in Hz (xiv) Meter constant (xv) Accuracy class (xvi) Reference temperature (xvii) ISI mark and licence number 38. 38. Acceptance tests : All Acceptance tests as laid down in Indian Standards shall be carried out. 38. the same may be furnished against the last item of that Annexure.35TECHNICAL DEVIATIONS: Any deviation in Technical Specification as specified in the Specification shall be specifically and clearly indicated. (vi) Property of MPEZ.37 TESTS: a. The bidder shall indicate the sources of all materials.38 TEST FACILITIES: a) The tests shall be carried out as per relevant Standards and test certificates shall be furnished for approval. (vii) Bar coding of SN. Type Test : Meter shall be type tested as per relevant standards (with latest amendments). (v) Purchase Order No. Month & Year of manufacture (viii) Sign of Insulation Class (ix) Serial number. c. If the sample fails in the above tests. (ii) Information and copies of test certificates as in (i) above in respect of bought out accessories. The Bidder shall invariably furnish the following information along with his bid. routine test report of all the meters of offered lot shall be handed over to the Inspecting Officer prior to carrying out the acceptance test. list of standards according to which the raw materials are tested. (iv) Power supplies used in testing equipment shall be distortion free with sinusoidal.41 QUALITY ASSURANCE PLAN: The designed life of the meter shall be minimum 20 years and to prove the designed life. (iv) Level of automation achieved and list of areas where manual processing exists. The purchaser reserves the right to get type tests done in respect of any meter. where stage inspections are normally carried out for quality control and details of such tests and inspections. list of tests normally carried out on raw material in presence of bidder’s representative and copies of test certificates. (v) During the manufacturing of the meters the following checks shall be carried out. the entire lot will be rejected and testing charges shall be recovered from the supplier.(iii) (iv) (v) (vi) (vii) (viii) (ix) (x) c) Starting current test Limits of error Range of adjustment Power loss in voltage and current circuit Repeatability of error Transportation test Low load run test Heating test Routine Test: Each and every meter of the offered lot shall undergo the routine tests as well as functional tests as per relevant standards. .39 INSPECTION : a. (i) Statement giving list of important raw materials. the firm shall have at least the following Quality Assurance Plan:(i) The factory shall be completely dust proof. The meters shall be batch tested on automatic.forms and maintaining constant voltage. The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated. 38. or Box from any of the lots received at any Destination Stores at supplier’s expenses. (iii) The testing and calibrating equipments should be automatic and all test equipment shall have their valid calibration certificates. wave. Some sample of meters shall be selected randomly from a lot of meters supplied and sent to CPRI for acceptance test as per relevant ISS and as per procedure prescribed in following paras. (a) (b) (c) Meter frame dimensions. failing which his bid shall be liable for rejection. names of sub-suppliers for the raw materials.40 RANDOM SAMPLE TESTING AFTER RECEIPT AT STORES: The consignment of meters received at Area Stores shall be accepted only after acceptance test of meters at CPRI/ERDA or any NABL accredited lab. current and frequency as per the relevant standards. (v) List of areas in manufacturing process. 38. computerized test bench and the results shall be printed directly without any possibility of human errors. (iii) List of manufacturing facilities available. Information shall be separately given for individual type of material offered. (ii) The testing rooms shall be temperature and humidity controlled as per relevant standards. 38. if any. in his judgement. d. (vi) The calibration of meters shall be done in-house. lease or sub-contract) of the above mentioned facilities. The electronic components used in the meter shall be of high quality. each board shall be subjected to bare board testing. The PCB material should be of glass epoxy FR-4 grade conforming to relevant standards. (vii) The manufacturer’s laboratory must be well equipped for testing of the meters. electronics and electrical components. b. (c) Complete assembled and soldered PCB should undergo functional testing using test equipments (testing zig). 38. (d) Prior to final testing and calibration. (iv) All insulating materials used in the construction of meters shall be non-hygroscopic. electrical connections etc. All drawings shall be in ink and suitable for micro filming. Two sets of drawing clearly indicating the general arrangements. The details of testing facilities available for conducting (a) The routine tests and (b) Acceptance tests shall be furnished in Schedule annexed with tender document. all meters shall be subjected to accelerated ageing test to eliminate infant mortality. (b) At insertion stage. They must have computerized standard power source and standard equipment calibrated not later than a year (or as per standard practice). (ii) The manufacturer should use Application Specific Integrated Circuit ASIC or Micro controller for metering functions. All manufacturing and fabrication works in connection with the equipment prior to the approval of the drawing shall be at the supplier’s risk. (i) (ii) (iii) c. Three copies of dimensional drawings of the equipments. rules and codes of practices. vis-à-vis type. the Bidder should own or have assured access (through hire. special acceptance and routine tests specified in the relevant standards and this specification. List of drawings and documents: The manufacturer shall furnish the following. design.I. ICs used in the manufacture of the meter shall be of highest quality and reputed make to ensure higher reliability. All parts that are likely to develop corrosion shall be effectively protected against corrosion by providing suitable protective coating.43 DOCUMENTATION : a. (iii) The electronic components shall be mounted on the printed circuit board using latest Surface Mounted Technology (SMT) except power components by deploying automatic SMT pick and place machine and re-flow solder process. These limitations shall be very clearly brought out in schedule of deviations. (v) Quality should be ensured at the following stages: (a) At PCB manufacturing stage. longer life and sustained accuracy. workmanship and latest revisions of relevant standards at the time of ordering and purchaser shall have the power to reject the materials which. 38. Units. Further. is not fully in accordance therewith. The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the purchaser. Approval of drawings by purchaser shall not absolve the supplier of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of application standards.42 MANUFACTURING ACTIVITIES: (i) All the materials. all components should undergo testing for conforming to design parameters and orientation. . fitting details. All dimensions and data shall be in S. The equipment shall conform in all respect to high standards of engineering.(vi) List of testing equipments available with the bidder for final testing of equipment specified and test-plant limitations. Technical leaflets (user’s manual) giving operating instructions. All drawings shall conform to International Standards Organization (ISO “A” series of drawing sheet/India Standards Specifications IS:656. non-aging and of tested quality. One set of routine test certificates shall accompany each dispatch consignment. 38. such as lifting hooks etc. Above values are typical values. 38. submit 10 prints and two good quality report copies of the approved drawings for purchaser’s use . 6.e. due to improper and inadequate packing.47 GSM Section: The GSM module shall comply with the following: The modem shall operate in GSM 900/1800/1900 MHz Band. The system shall be used for remote meter reading of the consumer meters via GSM infrastructure. Wherever necessary.. The acceptance test certificates in case of pre-dispatch inspection or routine test certificates in cases where inspection is waived shall be got approved by the purchaser. Withstand capacity against surges should be according to Indian conditions i. shall be provided. The modem shall have capability to work under continuous power on condition. 38. and suitable to withstand handling during transport and outdoor storage during transit. if necessary. Ten sets of operating manuals/technical leaflets shall be supplied to each consignee for the first instance of supply. f. The easily damageable material shall be carefully packed and marked with the appropriate caution symbol. The modem shall offer in-built intelligence and high speed data transfer rate or a kind of store-forward facility by which data from the meter is read at regular intervals and stored in modem’s internal memory and forwarded to remote central station (as configured) for viewing billing and reporting via Base Computer Software.e. The supplier shall within two weeks. b) Each consignment shall be accompanied with a detailed list containing the following information. The supplier shall be responsible for any damage to the equipment during transit. proper arrangement for lifting. h.10 of SCC Section 8 of the Bid document.46 (a) Power Supply Section Input supply The modem shall be powered up with the meter itself. The modem shall be compliant with ETSI GSM Phase 2+ Standard. The purchaser shall communicate his comments/ approval on the drawings to the supplier within two weeks.46 TECHNICAL SPECIFICATION OF GSM MODEM The modem shall be built in the meter enclosure and connected internally. . Note: Power consumption may vary from site to site depending on signal strength at that particular location.0 kV. 38. he should ensure the packing is such that the material should not get damaged during transit. The supplier shall.44 GUARANTEE : (i) Defect Liability period shall as per clause GCC 27. However. Average Power consumption of the modem shall be 3 VA under idle condition and 6 VA during data transfer. The manufacturer within 2 weeks of notification of award of contract. i) Name of the consignee ii) Details of consignment iii) Destination iv) Total weight of consignment v) Handling and packing instruction vi) Bill of material indicating contents of each package vii) The packing shall be done as per the manufacturer’s standard practice.45 PACKING & FORWARDING: a) The equipment shall be packed in crates/boxes suitable for vertical/horizontal transport as the case may be. Various features of GSM modem (to be installed with electronic energy meter) are described as below: 38. g. modify the drawings and resubmit three copies of the modified drawings for approval. The communication and reading shall be enabled with suitable Base Computer Software (BCS). submit three sets of final versions of all the drawings as stipulated in the purchase order for purchaser’s approval. Any material found short inside the packing cases shall be supplied immediately by supplier without any extra cost. Class 4 (2W) @ 900 MHz Class 1 (1W) @ 1800/1900 MHz d. e. b) If modem at consumer end could not establish connection to the modem at central station at specified time. 38.49 Mechanical Specifications The Mechanical Specifications of the modem shall be as follows: a. then it shall retry the same as configured. 38.2 Electrostatic Discharge IEC61000-4-2 38.50 Environmental specifications The modem shall meet the following environmental specifications: Temperature: Humidity: 38. The antenna should be of minimum 3dbi gain.48 EMI/EMC Specifications The GSM modem shall meet the following EMI/EMC specifications: 38. SIM Card Section For placing the SIM Card.3 Fast Transient Burst IEC61000-4-4 38. RF section A SMA interface shall be provided on the GSM modem to which either a fixed or a wired (with magnetic base) Dual Band Antenna can be connected.5 Conducted Emission CISPR22 (class B) 38.53 Outbound Dialling (a) In case the data is required by dialing from the Central station end (Server end). -10 degrees to +55 degree . It shall have auto dial feature.4 Surges Immunity IEC61000-4-5 (Under Line to Earth & Line to Line immunity) 38. This configuration of the modem shall be made available to the user via offered Base Computer Software. Interlocking facility shall be provided under the device cover.52 Inbound dialing a) The modem should have inbound dialing facility ie. Provision shall also be made to connect 14db high gain external yagi antenna to improve poor signal strength. a SIM Card Holder shall be provided on the GSM motherboard and shall be accessible only by removing the sealable cover. Modem shall be located in meter enclosure such that it has separate sealable opening. modem shall automatically dial to a particular GSM number (number of modem placed at central station end along with BCS server) at specified time (once in a day/week/month) for the purpose of meter reading. then connection shall be established by the server to the device using AT commands and transparent communication mode shall be established.51 Functional specifications The modem should be an intelligent device and capable of providing the following functionalities: 38.The modem shall support Point-to-Point transmission and Cell Broadcast features. b. 38.95% RH (non – condensing) . Network Identification Section For determining the health of the device an LED shall be provided on the modem which shall depict the current functioning status (power up/ registered in network/ transmitting data). The SIM Card shall be of 3V Interface. The portion of the meter where modem is placed shall have a suitable sealing arrangement so that the GSM SIM Card cannot be tampered with. 54 Event based dialing Other than regular dialing. The type test charges shall be borne by the supplier. the modem shall have feature of event based dialling in case of logging of tamper by the meter. three more samples shall be selected from the supplies already received to get them type tested at contractor’s cost. The balance material shall be accepted only after successful Testing. Repeated failure/poor results in the testing may render cancellation of order. The guarantee period of quantity already supplied & used shall be doubled and payment for used meters shall be arranged after deducting 10% cost. The selected samples shall be sent with complete details for type test at CPRI / ERDA / any NABL accredited test house. The Testing charges shall be borne by the contractor. In case of successful type test results. if so considered necessary to ensure that the quality of meters being offered for inspection is same as already got type tested. However. the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled. d) Acceptance test v) On receipt of subsequent consignment of individual DI in contractor’s site Stores. employer may allow the contractor to re-offer the material after change/ modification in the design of meters. at the option of employer. viii) The employer also reserves the right to get additional samples for all or any of the selected tests at purchaser's cost at any independent test house at any stage of supply. e) In case of failure in type test or acceptance test. supplies shall be continued. The mobile number shall be configurable via BCS. Provision of enabling and disabling of the feature shall be provided (a) 38. (c) Event based dialing and SMS shall be applicable for the event types (tamper/anomally) as supported/recorded by the meter (d) When the modem is busy in collecting the data from the meter and the call comes to get the data. the guarantee period of the quantity already supplied by the contractor shall be doubled and employer reserves the right to cancel the balance quantity.(b) User shall have option to get the data directly from the meter or the data already available in the memory of intelligent modem. vi) In case of failure of samples of lot/ sub-lot in the test(s) detailed in ISS. (e) The feature of event based dialing shall be user configurable. without waiting for the interrogation from central station (BCS server) and meter data shall be sent to the central station (b) Further. the similar testing procedure as described shall be repeated on another lot and if the lot fails consecutive second time the entire quantity of respective lot/sub-lot shall be rejected and shall have to be replaced by the contractor at his own cost. the modem shall sent an SMS to predefined mobile number and the SMS shall contain meter serial no. the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled.55 VERIFICATION/TESTING OF MATERIAL SUPPLIED a) Type test Three (3) samples for Type Test shall be selected & sealed by authorised person of MPPKVVCL from the first lot received in contractor’s site stores. In case of repeat failure in type test(s). 38. In case of failure. then priority shall be given to outbound call rather than data collection from meter. In case of repeat failure in acceptance test(s). in case the meter(s) do not meet the requirement as per ISS/CBIP/Specification in type test(s). vii) The supplies. may be utilized in the field during the period of testing. . set of meters as per relevant standards shall be selected randomly and sent to CPRI/ERDA for conducting acceptance test as per the prescribed procedure. 0 3X240 V.38. Imax-100 Amps 50 Hz ± 5% 0 lag to unity to 0 lead As per CBIP-88 with latest amendments 100 Amps Should not produce more than one output pulse/count 30 Imax for one half-cycle 0.4 % of Ib 5 (i) Continuous current rating (ii) Running with no load & 115% rated voltage 6 7 Short time over current Meter shall start and continue to register at current (unity PF) 8 Power loss at rated frequency & reference temperature (i) Current circuit at rated current per phase (ii) Voltage circuit at rated current per phase Less than 4 VA Less than 2 W & 10 VA 9 10 11 Momentary over voltage Dielectric voltage withstand Type of connection As per relevant standard 6 KV AC or as per relevant standard The cable directly passes through the meter without any external CTs . +20% -40% Ib-40 Amps.56 GUARANTEED TECHNICAL PARTICULARS FOR 3 PHASE 4 WIRE AC STATIC TRIVECTOR ENERGY METERS FOR DTR S N 1 Name of manufacturer To be mentioned Particulars Minimum requirement Offered 2 Model To specify 3 Standard Applicable IS:13779/ CBIP report 88 with latest amendment 4 Rating (i) Accuracy class (ii) Rated voltage (iii) Rated current (iv) Rated frequency (v) Power factor (vi)Magnetic immunity Class -1. Suitability of such use shall also be confirmed. of Digits display (ii) Character size of display (iii)Operation suitability LCD 7 (One digit after decimal point) 10x5 mm (Min) 18 18. directly under the sun and extreme weather conditions. specify (ii) Meter cover (iii) Screw 15 Size of service cable passing Hole 16 Degree of protection Meter shall comply IP 54 of IS:12063/IEC: 529 for protection against ingress of dust.S N Particulars Minimum requirement Offered It should not be needed to remove insulation of consumer supply cable for current measurement of individual phases Provision of piercing screw for PT connection should be there.1 LCD suitable for operation up to o 80 C Display Sequence( display should be self explanatory) Auto Scroll Mode As per specification . 13 14 Life of RTC Battery Type of material used (a) Material (i) Base High impact strength Engineering plastic High impact strength flame retardant UV stabilised with window of UV transparent poly carbonate Nickel/Tin plated Brass Suitable to accommodate aluminum cable of 100A current carrying capacity Meters shall be installed in consumer premises out door or indoor. 12 Communication support Galvanically isolated optical port with sealing arrangement Built in GSM modem with store and forward feature connected internally with the meter with separate port such that optical port shall be free for CMRI communication. moisture and vermin’s. 17 Type of display (i) No. and are updated each time billing occurs.3 18. Meter shall have facility to allow downloading of selective data to save the time while reading the meter for billing purpose through MRI/AMR. 25 BASE COMPUTER APPLICATION SOFTWARE For efficient and speedy recovery of data read through CMRI/HHU/AMR. The load survey data shall be logged for last Min. the contents of the rate registers shall be transferred to there billing equivalents. -Demand integration period of 15 minutes programmable with updates of 5 minutes for 15 minutes IP. The time required for selective reading for billing parameter shall be less than 3 Min. When a billing operation occurs. -The meter shall monitor during each integration period of the month & display maximum value occurred Each register shall have an associated billing register. The meter shall display the maximum demand reset count. As per specification As per specification As per specification The cumulative demand registers keep a running total of the value of maximum demand registers. To be explained 21 Billing Registers/ MD Reset: Billing operation may be caused by any of the following means: 22 Automatic Billing Manual Billing Electronic Billing Cumulative Demand Registers 23 Load Survey 24 Downloading of selective data -Computation shall be updated based on sliding window principle only.S N 18.2 18.4 Particulars Minimum requirement Offered Push button Mode Programmable Optional Requirements: View Parameters : (Display/ information required through meter reading instrument on BCS) As per specification As per specification As per specification 19. and other activity as per TS .(i) (ii) 20 Reading in power off condition Type of arrangement made to display in power off condition Maximum Demand Registration Meter shall be able to display reading. The meter shall have non-volatile memory for recording load survey for KW/KVA (programmable). 35 days for interval of 15 min. Supply of API with the meter is mandatory. (iii) Sealing of front door 2 no. of the seal shall be unique Seal shall be provided on front side only. which can be sealed in such a way that the internal parts of the meter are accessible only after breaking minimum three sets of seals. company logo and 6 digit serial no. Meter cover shall be permanently / solidly welded with Base so that it could not be opened without breaking. 27 METER CASE AND FRONT DOOR: 28 Fixing/ Sealing arrangement (i) Fixing of meter Suitable wall mounting arrangement for the complete meter unit shall be provided such that the mounting bolts shall be operated/ opened or accessible only after operation of a set of seal. The nos. Seals marked with “MPEZ”. polycarbonate tamper evident seals or any superior sealing arrangement on front side of meter. seals front door shall be extended type and can be sealed independently & over the terminal (piercing screw) cover) (iii) Sealing of maximum demand device (iv) Sealing of communication port Provision for 1no. Proper locking arrangement shall be provided to protect from unauthorised removal of meter from its mount.S N 26 Particulars Minimum requirement Offered APPLICATION PROGRAMME INTERFACE The bidder shall provide application programme interface (API’s) to read their meters and convert the meter data as per IEEMA MIOS standard. meter shall have a case. seal (ii) Sealing of meter body Provision for 1no. seal . 2 nos. one that of Piercing screw cover. meter cover and the front door meter unit shall have opaque front hinged door with suitable sealing arrangement (screws). S N Particulars Minimum requirement Offered (v) Sealing of piercing screw Cover 2nos. storage. In case of CT open or shorting. procurement. Even if meter detects such a condition.e phase to phase voltage injected between phase & neutral Missing potential detection: As per TS Should sustain as per relevant standard The meter shall detect PT missing and record this information along with date & time of occurrence and restoration of the event and phase indication. The meters shall detect and indicate the occurrence of CT reversal on meters display along with phase indication and shall also store the date & time of occurrence and restoration in the non-volatile memory. seal piercing screw cover shall be extended type and can be sealed independently & over the meter cover) 29 Tracking software mandatory to provide Tracking and recording software for all new seals so as to track total movement of seals starting from manufacturing. (v) CT reversal Detection: (vi) Current Imbalance (CT shorting/ by-passing) (vii) Voltage Unbalance: . the tamper indication should appear by means of measuring neutral current. external magnetic field & DC current in AC supply or in neutral Suitability of meter to sustain over voltage i. which may result in the current imbalance between the phases. 30 (i) TAMPER FEATURES Injection of abnormal voltage and frequency of the order of 35 KV with the help of external device As per TS (ii) (iii) (iv) Effect on accuracy of external electromagnetic interference of electrical discharge. series of inspections. the recording of KWh shall be done in positive direction only. The meter shall be capable of detecting and recording occurrences and restoration of voltage unbalance as an event. removal and disposal etc. record keeping. installation. preferably red Should withstand EMI/EMC level IV 33 Should work within accuracy 34 + 20%. it shall always maintain record of last 200 events occurred. 31 32 Size of calibration LED & colour Electromagnetic compatibility EMI/EMC severity level) Effect of accuracy in tamper condition Input voltage & frequency variation within which meter works satisfactory Billing Point Requirement As per requirement. Meter cable passing holes shall also be marked & this marking should appear in the above diagram. The event recording shall be compartment-wise roll over type i. power on event shall be recorded. At the same time. three-phase currents and three-phase power factors to elaborate the existing condition during all the type of tamper events. (ix) Neutral Missing: (xi) Phase Sequence Reversal Along with the information.40% of voltage and ± 5% of 50 Hz As per specification The meter should be capable of registering the time-of-day energy and maximum demand The data transfer from the meter to MRI and MRI to computer should be fully secured 35 36 TOD Tariff/Demand 37 Data Security 38 Connection Diagram terminal Marking: and The connection diagram of the meter shall be clearly shown on meter and shall be of permanent nature. . The meter shall record 200 events of aforementioned tampers (occurrence + restoration) along with date and time of occurrence and restoration of each and every event. The event shall be recorded on the next power up.S N (viii) Particulars Minimum requirement Offered Power ON/OFF: Meter shall be capable of detecting and recording power off of all voltages not present. the meter shall also record the instantaneous values of all three-phase voltages. The meters shall work properly even if neutral is not available and shall work satisfactorily even if any two of potential wires are extended to it Meter shall operate and record satisfactorily irrespective of phase sequence of input supply so long as phase association between voltage and current circuits is in order. .e. TECHNICAL SPECIFICATION ‘ISI’ MARKED PVC INSULATE PVC SHEATH UNARMOURED ALLUMINIUM CABLE 6 SQ. 39.1 SCOPE :This specification covers design. The phase sequence and phased association of voltage and current can be checked with the help of CMRI. (iii) IS:5831-1984 . (v) IS:4905-1968 .PVC insulated Electric Cables for working voltage up to and including 1100 Volts.Methods for test for cables. No Drift in accuracy in measurement with time Should be secured 41 Drift in accuracy of measurement with time Fixing arrangement of name plate Type of body Guaranteed life of meter 42 43 44 Projection type 5 years from the date of commissioning or 5-1/2 years from date of supply whichever is earlier (shall be printed on name plate of meter) Shall conform to Technical specification and IS-13779/ IEC62053-21. 39. . . IEC62052-11 & CBIP report 88 (Revised version) with its latest amendments 45 Other parameters / features not covered in the above GTP 39. PVC sheathed Cable 6 sq. if any:(i) IS:694/1990. mm suitable for outdoor overhead service lines.Specification for conductor for insulated electric cables. (iv) IS:10810-1984 . manufacturing. Every meter shall have a nameplate clearly visible and indelible and distinctly marked in accordance with relevant standard (latest version) and as per specification. (ii) IS:8130-1984 . testing and delivery of ISI marked 1100 Volt grade.Methods for random sampling. MM.S N 39 Particulars Minimum requirement Offered Installation Check: 40 Name plate and Marking: While installing the meter. it shall be possible to check the correctness of the connection to the meters and there polarity from the functioning of the meter with the help of CMRI under load condition. weather proof unarmoured solid Aluminum conductor. PVC insulated.2 APPLICABLE STANDARDS:All the Cables shall conform to the requirements of following standards with latest amendments.Specification for PVC insulation and sheath of electric cables. 3. (a) Cable size and Voltage Grade. The thickness of extruded sheath and smallest of the measured value shall conform to the requirement of IS. 39. (b)The cable should carry the following information:(i) (ii) (iii) (iv) (v) (vi) Reference to Indian Standard (IS) Manufacturer’s name. automatic in line throughout the length of the cable and shall be legible and indelible. PACKING & MARKING: 41. The average thickness of insulation shall not be less than nominal value (ti) specified in relevant ISS.4.1 ti. The packing shall be suitable for rough handling that is occasioned during transportation.4 OVERALL DIMENSIONS: The mean overall dimensions of the cables shall be as specified in table5 of IS:694. The smallest of the measured values of thickness of insulation shall not fall below the nominal value (ti in mm) by more than 0.1 CONDUCTOR: . PVC insulation shall be suitable for continuous conductor temperature of 70ºC under normal operation and 160º C under short circuit conditions.1 Manufacturer’s Identification:.5 CORE IDENTIFICATION: Core shall be identified by Red & Black colouring of PVC in accordance with table-7 of IS:694-1990. 39.3.1 mm + 0. 40.Aluminum conductor used in cables shall comply to the requirement of IS: 8130-1984 with latest amendments and shall be in accordance with clauses of relevant ISS of cables with latest amendments. (b) Name of Manufacturer (b) Word MPEZ.As per of IS. 39.3. following marking shall be embossed over outer sheath at every 3 mtrs. It shall be so applied that it fits closely on the laid up cores and it shall be possible to remove it without damage to the insulation.3. The sheath shall be applied by extrusion over the laid up cores.PVC insulation used shall comply to requirement of IS: 5831-1984 with latest amendments.2 PVC INSULATION: . brand name or trade mark Type of cable and voltage grade Number of cores Nominal cross-sectional area of the conductor Cable code . 39.39.2 Packing & Marking : (a) The cables shall be supplied in coils of 100 metres each. Insulation shall be of ‘Type A’ PVC compound.4 IDENTIFICATION.4. The insulation shall be applied by extrusion so that it fits closely on the conductor and it shall be possible to remove it without damage.3 SHEATHING: The material of the sheath shall be of Type ST-1 PVC compound.3. The difference between maximum and minimum measured value of overall diameter of sheathed circular cables shall not exceed 15% of the maximum measured value.3 GENERAL TECHNICAL REQUIREMENT:40. 39. The 4 core shall be circular. The embossing & not printing shall be done. 5. drum or coil Number of lengths on reel.5.2 Acceptance Tests: The following shall constitute acceptance tests:Tensile Test (for aluminum. the inspection offer may not be considered. a certified photo-stat copy of valid ‘ISI’ Marking License rights duly attested must be submitted along with the inspection offer as documentary evidence.1 Type Tests: The tests given in Table-8 of IS:694/1990 shall constitute type tests. In this connection.(vii) (viii) (ix) (x) (xi) (xii) (xiii) (xiv) Colour of cores Length of cable on the reel. In absence of ‘ISI’ License documents. 39.5 TESTS: Following type tests. wherever applicable) Conductor resistance test Test for thickness of insulation and sheath Tensile strength and elongation at break of insulation and sheath Insulation resistance test High voltage test at room temperature Flammability test . 39. drum or coil (if more than one) Direction of rotation of drum by means of an arrow Approximate gross weight Country of Manufacturer Year of manufacture Word “suitable for outdoor use” (b) ISI Certification Mark:: The cable must bear ‘ISI’ Certification Mark. acceptance tests and routine tests are to be carried out in accordance with IS:694/1990 with its latest amendments as indicated below:39. wherever applicable) Wrapping Test (for aluminum. Standard Length: The standard length of cable shall be 100 mtrs. 6 IMPORTANT TECHNICAL REQUIREMENT Cables shall be designed to withstand mechanical electrical and thermal stress developed under steady state and transient operating conditions. to ascertain the quality of supply.The following shall constitute routine tests:(a) Conductor Resistance test (b) High voltage test The above routine tests shall be conducted by the supplier in accordance with relevant ISS and test certificate in proof of this shall be submitted to this office along with each inspection offer. 39. The above type test certificate should not be more than five years old on the date of opening of the tender.8 INSPECTION: All the tests and inspection may be conducted at the place of manufacturer unless otherwise specifically agreed upon by the manufacturer and purchaser at the time of purchase. In absence of routine test certificate the inspection offer shall be considered as fake and all complication arising out of this shall be to the supplier’s account.3 13 20 Routine Tests: . the Employer has the right to have any or all type/acceptance test carried out through an independent NABL accredited lab like ERDA. No. CPRI or any other NABL accredited laboratory is required to be submitted.5. ERDA. In addition to above. National Test House. the manufacturer shall offer all reasonable facilities to the purchaser without charges to satisfy him that the material is being furnished in accordance with the specification. CPRI etc.7 TYPE TEST CERTIFICATE: The certified photo copy of type test certificates in respect of each size of cables for type tests given in Table-8 of IS:694/1990 from the Govt. In case of inspection at works. of drums/Coils/ reels in the lot Upto 25 26 to 50 51 to 100 101 to 300 301 and above 39. obtain necessary invoices in proof that raw materials used are of desired quality. the inspecting officer shall check quality of raw material. of drums/Coils/ Permissible number Reels to be taken as sample of defectives 3 5 8 1 1 0 0 0 39. The supplier shall confirm that the material shall be supplied exactly of the design for which type tests have been conducted. the entire lot shall be rejected and the testing charges along with the other charges which may likely to be incurred for arranging . Acceptance test shall be carried out in each type and size of cable selected at random as per following sampling plan:No. In case the material fails to pass the test as per specification.All the above acceptance tests may be carried out by Discom’s representative as per relevant ISS at the time of material inspection for the purpose of clearing the lot offered by the manufacturer. on receipt of Cables at consignemt. In order to ensure that quality of raw materials used during manufacturing of PVC Cables is as per requirement of IS:694/1990. 39. Specification for mild steel wires. manufacturing. The average thickness of insulation shall not be less than nominal value (ti) specified in relevant ISS. The insulation shall be applied by extrusion so that it fits closely on the conductor and it shall be possible to remove it without damage. 40. PVC sheathed. 40. strips and tape for armouring of cable.3.3 FILLER AND INNER SHEATH:The filler and the inner sheath shall be of unvulcanised rubber or thermoplastic material or proofed tape. Unvulcanised rubber or thermoplastic material used shall not be harder than PVC used for insulation and outer sheath. The laid-up cores shall be provided with inner sheath applied either by extrusion or wrapping. MM. (vii) IS:8130-1984 . The inner sheath shall be so applied that it fits closely on the laid up cores and it shall be possible to remove it without damage to the insulation.3.P. (xi) IS:4905-1968 .Specification for conductor for insulated electric cables.2 APPLICABLE STANDARDS:All the Cables shall conform to the requirements of following standards with latest amendments. . .2 PVC INSULATION: PVC insulation used shall comply to requirement of IS: 5831-1984 with latest amendments.5 sq. action as deemed fit. It shall be ensured that the shape is as circular as possible. (x) IS:3961(Part-II) 1967 . (viii) IS:5831-1984 . 40 . PVC insulation shall be suitable for continuous conductor temperature of 70ºC under normal operation and 160º C under short circuit conditions.1 ti.Recommended current ratings for PVC insulated and PVC sheathed heavy duty cables. twin core 2.the testing through independent lab shall be recovered from the supplier.1 CONDUCTOR: Aluminum conductor used in cables shall comply to the requirement of IS:8130-1984 with latest amendments and shall be in accordance with clauses of relevant ISS of cables with latest amendments. 40. of ISI marked 1100 Volt grade. may be taken against the supplier. The thickness of inner sheath shall be as in Table-4 of IS:1554 (Part-I) 1988.3. 40. testing and delivery to sites located in M. (ix) IS:10810-1984 . TECHNICAL SPECIFICATION ‘ISI’ MARKED PVC INSULATED PVC SHEATHED ARMOURED ALUMINUM CABLE 2. mm cable.PVC insulated (Heavy Duty) Electric Cables for working voltage up to and including 1100 Volts. Insulation shall be of ‘Type A’ PVC compound. (xii) IS:10418-1972 .3 GENERAL TECHNICAL REQUIREMENT:- 41. The material shall be chosen to be compatible with temperature ratings of the cable and shall have no deleterious effect on any other component of the cable.1 mm + 0.5 SQ.Specification for PVC insulation and sheath of electric cables.1 SCOPE :This specification covers design. 40.Methods for random sampling.Wooden drum for electric cables. (xiii) IS:3975-1979 . The smallest of the measured values of thickness of insulation shall not fall below the nominal value (ti) by more than 0.Methods for test for cables. if any:(vi) IS:1554 (Part-I)/1988. weather proof armoured solid alluminium conductor PVC insulated. In addition to this. 1 of IS:1554 (Part-I) following marking shall be embossed over outer sheath at every 3 mtrs.The core shall be identified in accordance with Clause-10 of IS:1554 (Part-I) 1988.40. In such a case the thickness of extruded sheath shall not be less than the sum of the inner sheath thickness specified in table4 and the nominal outer sheath thickness specified in column 3 of table-7 of IS:1554.3. The outer sheath shall be applied by extrusion over the armouring and shall be so applied that it fits closely over armouring. Armouring shall be applied over the inner sheath. automatic in line throughout the length of the cable and shall be legible The cable shall be wound on a drum (ref. 40. 40. The packing shall be robust for rough handling that is occasioned during transportation.2 mm ± 0. The cable should carry the following information stenciled on the drum:(x) Reference to Indian Standard IS:1554 (Part-I) (xi) Manufacturer’s name. A binder tape should be provided on the armour.3 & 13.5 OUTER SHEATH:- The outer sheath shall be of type ST1 PVC Compound conforming to the requirements of IS:5831-1984.4.4 IDENTIFICATION. Type of armour. 13.C.6 CORE IDENTIFICATION:. The colour of outer sheath shall be black.4 of table-7 of IS:1554.2 ts. In case of unarmoured cable. 40. It shall be possible to remove it without damage to inner sheath. The embossing shall be increasive.4 ARMOURING:The galvanized steel strip/wire. procedure for its laying and joints shall comply with the requirement of Clause-13. (a) (b) and indelible. the bidders have also option to offer single sheath. PACKING & MARKING: 41.2. 13.3. Name of Manufacturer and Word MPPKVVCL.4. brand name or trade mark (xii) Type of cable and voltage grade (xiii) Number of cores (xiv) Nominal cross-sectional area of the conductor (xv) Cable code (xvi) Colour of cores (xvii) Length of cable on the drum (xviii) Number of lengths on drum (if more than one) (xv) Direction of rotation of drum by means of an arrow (xvi) Approximate gross weight .4. The ends of the cable shall be sealed by means of non-hygroscopic sealing material. 40. The minimum thickness of outer sheath shall not fall below the nominal value (ts) specified in Table-7 of IS: 1554 (Pt-I)/1988 by more than 0.3.3. used for armouring shall comply with the requirement of IS:3975-1979 with latest amendment. The D. The armour strips shall be applied as closely as practicable. The smallest of the measured value shall not be less than the sum of the inner sheath thickness specified in table-4 and the minimum value of outer sheath thickness specified in col.As per Clause-17.1 Manufacturer’s Identification:.2 Packing & Marking: Cable size and Voltage Grade. respectively of IS:1554 (Pt-I)/1988.IS:10418-1972) of suitable size and packed. resistance of galvanized steel strips armour shall be measured and the result when corrected at 20° C shall comply with approximate value given in Table-6 of IS: 1554 (Part-I)/1988. its dimension.1. The cable (Drum) must bear ‘ISI’ Certification Mark.2. acceptance tests and routine tests are to be carried out in accordance with clause-15 of IS:1554(Part-I)1988 with its latest amendments:40. 40. a certified photo-stat copy of valid ‘ISI’ Marking License rights duly attested must be submitted along with the inspection offer as documentary evidence.7 TESTS: Following type tests. to For Test method ref.4 of IS:1554 (Part-I) 7 11 12 15 10 14 43 45 45 53 . the inspection offer may not be considered.3.6 Standard Length:. to Part No of IS:10810 2 3 5 36 to 42 6 A i ii iii B C D i ii iii Iv V vi vii E F TEST ON CONDUCTOR Tensile Test Wrapping Test Conductor Resistance test TEST FOR ARMOURING STRIPS TEST FOR THICKNESS INSULATION AND SHEATH OF IS:8130-1984 IS:8130-1984 IS:8130-1984 Table -5 and IS:3975/1979 Table. 40.2 of IS:1554 (Part-I) Water immersion test Clause 16.The standard length of cable shall be 500 meters ± 5% tolerance. In this connection. of IS: 1554 (Part-I) Flammability Test Clause 16.5 ISI Certification Mark:.(xvii) Running end of cable (xviii) Country of Manufacturer (xix) Year of manufacture 40.1 TYPE TESTS: The following shall constitute type tests: Tests (Whichever is applicable) For requirement ref. 4 & 7 of IS:1554/(Part-I) G PHYSICAL TEST FOR INSULATION AND SHEATH Tensile Strength and elongation at break IS:5831-1984 Ageing in Air oven -----do----Shrinkage Test -----do----Hot deformation -----do----Loss of mass in air oven -----do----Heat shock test -----do----Thermal stability -----do----Insulation Resistance Test -----do----High Voltage Test at room temperature Clause 16.7. In absence of ‘ISI’ License documents. The above type test certificates should not be more than three years old on the date of opening of tender. d. e. without charges to satisfy him that the material is being manufactured in accordance with the specification. the Employerer has the right to have any or all type/acceptance test carried out through an independent NABL accredited lab like ERDA. In case the material fails to pass the test as per specification. . action as deemed fit. the inspecting officer shall check quality of raw material. may be taken against the supplier. b. 40. Routine Tests – The following shall constitute routine tests:(a) Conductor Resistance test (b) High voltage test at room temperature The above routine tests shall be conducted by the manufacturer in accordance with relevant ISS and test certificate in proof of this shall be submitted to this office along with each inspection offer. of drums to be taken as sample 2 5 13 20 32 Permissible number of defectives 0 0 0 1 2 40. to ascertain the quality of supply. In case of inspection at works. CPRI etc. Tensile test Wrapping test Conductor resistance test Test for thickness of insulation and sheath Tensile strength and elongation at break of insulation and sheath Insulation resistance test High voltage test at room temperature All the above acceptance tests may be carried out by Emplyers representative as per relevant ISS at the time of material inspection for the purpose of clearing the lot offered by the manufacturer.7. obtain necessary invoices in proof that raw materials used are of desired quality. on receipt of Cables at consignment. In addition to above.9 TYPE TEST CERTIFICATE: The bidders are advised to submit the certified photocopy of Type Test Certificate along with the tender in respect of the type tests indicated in Clause 4. c. CPRI etc.2 Acceptance Tests: The following shall constitute acceptance tests:a. for each size of quoted cables.40. The bidders shall confirm that they will supply the material exactly for the design for which type tests have been conducted. g. the offer is liable for rejection. In absence of routine test certificate the inspection offer shall be considered as fake and all complication arising out of this shall be to the supplier’s account. 40. Acceptance test shall be carried out on cable drum selected at random as per following sampling plan:No. In absence of Type Test Certificate for all the type tests.1 from NABL accredited lab like National Test House. ERDA. 40. the manufacturer shall offer all reasonable facilities to the purchaser.7. In addition to this.3. the entire lot shall be rejected and the testing charges along with the other charges which may likely to be incurred for arranging the testing through independent agency shall be recovered from the supplier. In order to ensure that quality of raw materials used during manufacturing of control Cable is as per requirement of IS:1554 (Pt-I)/1988. f.8 THER IMPORTANT TECHNICAL REQUIREMENT: Cables shall be designed to withstand mechanical electrical and thermal stress developed under steady state and transient operating conditions. of drums in the lot Upto 50 51 to 100 101 to 300 301 to 500 501 and above No.10 INSPECTION: All the tests and inspection may be conducted at the place of manufacturer unless otherwise specifically agreed upon by the manufacturer and purchaser at the time of purchase. Rated Voltage Continuous current rating when laid in air at an ambient temperature :Current in Amps Ambient temp. b. d.GUARANTEED TECHNICAL PARTICULARS OF ‘ISI’ MARKED PVC INSULATED (HEAVY DUTY) PVC SHEATHED UNARMOURED CABLE (To be kept in part-II Commercial/ Technical Bid) The following information should be furnished for the quoted size of P. Insulation : Type of insulation 4 core 6 mm 2 a. b. GUARANTEED TECHNICAL PARTICULARS: i) ii) iii) iv) Size of cable Brand name. 4. c. of wires in each conductor Diameter of each wire Source of receipt (Supplier’s Name) vii) a. b.° C Conductor temp. cable:1. & Validity 3. c.mm.C. vi) a. e.V. .) Conductor resistance per Km at 20° C No. c.° C Short Circuit Current : Short Circuit current(KA) Duration of S/C Conductor temperature allowed for the short circuit duty ° C Conductor : Grade of Aluminum Nominal Cross Sectional area (Sq. 2. f. Name of Manufacturer & Address Whether your product conforms to relevant ISS Relevant ISS No. if any. v) a. b. Source of receipt (Supplier’s Name) c. d. e. viii) a. b. Nominal thickness (mm) Minimum thickness (mm) Colour scheme for identification of cores. Sheath : Type of PVC Compound Source of receipt (Supplier’s Name) c. d. e. ix) x) a. b. xi) a. b. xii) a. b. xiii) ix) Extruded or wrapped Nominal thickness (mm) Minimum thickness(mm) Over all dimension of cable Insulation resistance constant per km at 27° C 70° C Volume resistivity OhmCm at 27° C 70° C High Voltage Test Voltage applied (KV) Duration (Min.) Standard length (Mtr.) Net weight of cable per coil of 100 mtr. (approx) SIGNATURE OF TENDERER NAME: DESIGNATION: GUARANTEED TECHNICAL PARTICULARS OF ‘ISI’ MARKED PVC INSULATED (HEAVY DUTY) PVC SHEATHED ARMOURED CABLE 2 2 2 SN. 1 2 3 Particulars Name of Manufacturers Standard applicable Whether material offered is having ISI mark. Give ISI marking no. & its validity period 2C x 2.5mm 2C x 4mm 4C x 10mm 4 5 6 Rated Voltage Suitable for earthed or unearthed system Continuous current rating when laid in air at an ambient 0 temp. 40 C and for maximum conductor temperature 0 70 C. Current carrying capacity a b c Short Circuit Amps (rms) Duration of short circuit Conductor temperature allowed for Short Circuit Conductor details a b c d Material Nominal cross section area Conductor resistance/Km at 20 C Source of Supply 0 7 8 9 a b c d Insulation details Composition and type Thickness Tolerance in thickness Received from (Supplier’s Name) 10 11 a b c Colour scheme for identification Inner sheath details Material Extruded/Wrapped, please confirm Calculated diameter over laid up cores d f Thickness Received from (Supplier’s Name) 12 a b c d Armour Type of armour Nominal diameter over the inner sheath Nominal thickness of steel strip/dia. of wire Received from (Supplier’s Name) 13 a b c d f g Outer sheath details Material Extruded, please confirm Calculated diameter under the sheath Thickness Tolerance on thickness Received from (Supplier’s Name) 14 15 Overall diameter of cable over the outer sheath Volume resistively at 27 C and 70 C 0 0 16 Conductor temperature corresponding to maximum continuous current Test voltage a b High Voltage test Water immersion test voltage Recommended minimum installation radius Cable Drum a b c Dimensions of the drum Approximate weight of Drum Maximum length per drum Net weight of cable (Kg/Km) 17 18 19 20 41 . TECHNICAL SPECIFICATION ACSR PANTHER CONDUCTOR :1.0 SCOPE:This specification provides for manufacture, testing before despatch and supply (for destination Ex-our Stores/Site Store any where within the state of Madhya Pradesh) of Panther ACSR size 30/7/3.00 mm. The Technical Specification contained in this section is for the guidance of the tenderers. Any deviations from purchaser’s specification will be considered on their relative merits or performance, efficiency, durability and over all economy consistent with the purchaser’s requirement herein after stipulated. Such deviation shall be clearly entered by the tenderer in Schedule-VI. 2.0 STANDARDS:The ACSR Conductor shall conform to the following Indian Standard/International Standards, which shall mean latest revisions/ amendments/changes adopted and published:IS:209 Zinc IS:398 IS:1521 IS:1778 IS:2629 IS:2633 IS:4826 IS:6745 IS:8263 Specification for Aluminum conductors for overhead transmission purpose Method of Tensile Testing of Steel Reel and drums for bare conductors Recommended practice for Hot Dip Galvanising Iron and Steel Method of Testing Uniformity of coating Zinc coated Articles. i. ii. iii. iv. v. vi. vii. viii. ix. Galvanized coating on Round Steel wires Method of Determination of weight of Zinc coating zinc coated Iron and Steel Articles. Radio influence voltage of high voltage insulators methods of measurement 3.0 3.1 RAW MATERIALS AND DIMENSIONS:ACSR Panther shall comprise of 30 strands of 3.00 mm dia of Aluminum and 7 strands of 3.00 mm hot dip galvanized High tensile steel and shall have conductivity equivalent to 130 sq. mm. Copper. The conductor shall conform to IS:398 Part-II and standard technical particulars as per Appendix-I of this specification. All strands containing magnetic materials shall be located in the central portion of the conductor. Each layer of the conductor shall be of uniform conductance and of the same kind or type of material. The conductor shall be capable of withstanding the normal handling, necessary for manufacture and erection (such as reeling, unreeling and pulling through stringing sheaves), under sufficient tension to keep the conductor off the ground etc. without being deformed from a circular cylindrical form in such a way so as not to increase radio interference and corona loss. 3.2 3.3 4. QUALITY:The Aluminum strands shall be hard drawn from electrolytic Aluminum rods having purity of not less than 99.5% and the copper content shall no exceed 0.04%. The producer’s test certificates, in respect of impurity content of Aluminum conductor etc., shall have to be furnished before manufacture of conductor in order to assess whether Aluminum rods of correct quality have been used for Aluminum strands. The steel wire strands shall be drawn from high carbon steel wire rods produced by either the acid or the basic open hearth process, or by the electric furnace process, or basic oxygen process and shall conform to the following requirements as to the chemical composition. Elements: Carbon Manganese : : % Composition 0.50 to 0.85 0.50 to 1.10 Phosphorus Sulphur Silicon : Not more than 0.035 : Not more than 0.045 : 0.10 to 0.35 The steel produced by Beesemer process shall not be used for drawing steel wire strands. The steel strands shall be hot dip galvanized and shall have zinc coating of minimum 240 grm/sq. meter of the uncoated wire surface. The zinc coating shall be reasonably smooth, continuous, of uniform thickness and free from imperfections not consistent with good commercial practice, and shall meet the test requirements specified hereinafter. The steel wires shall be of such quality and purity that, when drawn to the zinc of strands specified and coated with zinc, the finished strands and the individual wires shall be of uniform quality and have the same properties and characteristics as prescribed in relevant Indian Standard. The quality of electrolytic High Grade (HG) zinc shall conform to IS-209 and its purity shall have 99.95 percent. All the Aluminum as well as steel strands shall be smooth, uniform and free from all imperfections, such as spills and splits, die-marks, scratches, abrasions and kinks etc. after drawing and also after stranding. The finished conductor shall have a smooth surface without any surface cut, abrasion, scuff marks and shall be free from dirt, grit etc. Even if the damage to conductor is acceptable from mechanical considerations, it will not be acceptable from electrical considerations, and full care should be taken not to supply damaged conductor. The conductor when subjected to tension of 50% of the ultimate strength of the conductor, neither the surface shall depart from its cylindrical form nor the strands shall move relative to each other in such a way as to get out of place or disturb the longitudinal smoothness of the conductor. Failure of any sample to meet the above requirements shall be sufficient cause for rejection of the lengths of conductor represented by the sample. Particular care shall, therefore, be taken during manufacture, handling, packing and transportation of the conductor, to see that the surface is not denied out or damaged in any way. Joints in Strands:4.09.1. Aluminum Strands: a. Joints in the Aluminum strands in the 18 wire inner layers of the conductor shall be allowed as per Clause 8.1 of IS-398(part-II), i.e. not two such joints should be within 15 meters of each other in complete stranded conductor. These joints shall be made as per IS:398 and thereafter suitably annealed such that the tensile strength of the joint shall be more than 2 14.67 kg/mm and secondly the other physico-mechanical properties of the joints like, electrical resistance, elongation modulus of plasticity etc. are comparable with that of the unjointed strand. No joint shall be permitted in the Aluminum wires in the outermost layer (i.e. 18 wire) of conductor. The offers which do not conform to the above requirements of joints in the outermost layer of the conductor, shall not be considered :- b. c. 4.09.2 (a) Galvanised steel core strands:There shall be no joint of any kind in the finished steel strands entering into the construction of the core except those in the base rod or wire before final drawing. 5. CLEANING:The conductor shall be free from excessive amount of die, grease, metal particles and dirt. The tenderer shall describe in complete details the method which he proposes to use in formal production to clean the conductor. The effectiveness of the cleaning process shall be subject to verification. TEMPERATURE RISE CURVES OF CONDUCTOR:The tenderer shall furnish curves for current in amperes (50 cycles) versus temperature rise (Deg-C) for the ACSR Panther Conductor for various temperature conditions. STANDARD LENGTH:The conductor shall be supplied in the standard lengths of 1.5 kms. (1500 metres + 5%) Not less than 95% of the total quantity of the conductor shall be supplied in standard lengths. Thus, the quantity of the conductor in length shorter than standard one shall not exceed 5% of the total quantity to be supplied. Further, no single conductor length in respect of such 5% (max.) supply in random lengths, shall be shorter than 50% of the standard length. Each shorter length shall have to be packed in separate drum. 6. 7 7.01 7.02 8. 8.1 8.1.1 PACKING:General:The conductor shall be wound on non-returnable wooden drums strong enough and provided with lagging of adequate strength, manufactured to protect the conductor against all damage and displacement during transit, storage and subsequent handling and stringing operations in the field. The conductor may be supplied duly wound on steel/wooden drums. However, the purchaser reserves the right to award the contract for supply of conductor either with steel drum or wooden drum. The wooden drums shall generally conform to IS: 1778 as amended upto date. Only one conductor length shall be packed on each drum. The drums shall be suitable for wheel mounting. The general construction of wooden drums shall be as shown in the enclosed drawing No.FT/11/145. However, the drums shall be suitable for letting off the conductor under controlled tension of the order of 500 kg minimum. CONSTRUCTION OF WOODEN DRUMS:All wooden components shall be manufactured out of seasoned soft wood free from defects that may materially weaken the component part of the drums. Preservative treatment shall be applied to the entire drum of such a quality which is not harmful to the conductor. FLANGES:The flanges shall be of two ply construction with each ply at right angles to the other and nailed together. Further the outer face of the flange shall be reinforced with the circumferential battens fixed in octagonal shape. The nails shall be driven from the inside face of flange, punched and then clenched on the outer face. The flange board shall not be less than the nominal thickness by more than 2 mm. There shall be at least 3 nails per plank of ply with maximum nail spacing of 70-75 mm. Where a slot is cut in the flange to receive the inner end of the conductor, the entrance shall be in line with the periphery of the barrel. 5 mm M.S. Plate Triangular shape shall be provided at outer side of both the flanges, which shall be fitted on studs with the help of bolts and nuts as shown in enclosed drawing. SPINDLE HOLE:Spindle hole shall be provided at the centers of the planks of the plies and cast iron bushings of 100 mm. Dia holes shall be fitted on either side of both the flanges. BARREL AND SUPPORTS:The end supports shall be securely fixed to the flanges by nailing and may be of disc or segmented type. The middle barrel support of two ply construction of disc type with a 100 mm dia hole concentric with the holes in the flanges shall be provided at the centers of the barrel supports. BARREL:The wooden battens used for making the barrel of the conductor drum shall be of segmental type. These shall be nailed to the barrel supports with at least two nails. The battens shall be closely butted and shall provide a round barrel with smooth external surface. The edges of the battens shall be rounded or chamfered to avoid damage to the conductor. BARREL STUDS:M.S studs shall be used for construction of drums. The flanges shall be holed and the barrel supports slotted to receive them. The barrel studs shall be threaded over a length on either end, sufficient to accommodate washers, spindle plates and nuts for fixing flanges at the required spacing. IRON COMPONENTS:Normally, the nuts on the studs shall stand protrude of the flange. All the nails used on the inner surface of the flange and the drum barrel shall be counter sunk. The ends of barrel shall generally be flushed with the top of the nuts. PROTECTIVE ARRANGEMENT:The inner cheek of the flanges and drum barrel surface shall be painted with a bitumen based paint. Before reeling, cardboard or double corrugated or thick bituminised waterproof bamboo paper shall be secured on the drum barrel and inside of flanges of the drum by means of a suitable adhesive material. These protective wrapping and adhesive materials used shall be of quality, which is not harmful to the conductor. Medium grade kraft paper shall be used in between the layers of the conductor. After reeling the conductor the exposed surface of the outer layer of conductor shall be wrapped with water proof thick bitumninised bamboo paper/polythene sheet to prevent the conductor from dirt, grit and damage during transport and handling. After application of bituminised paper/polythene sheet protective lagging or circumferential battens of 15 mm thickness shall be provided suitably where conditions warrant such provision in order to protect conductor from damage during transit in the event of breakage/ damages of the external protective lagging. Minimum space of 125 mm shall be provided between the inner surface of the external protective lagging and outer layer of the conductor. 8.1.2 8.1.3 8.2 8.3 8.3.1 8.3.2 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 process control inspection. calibration system. Arrow marking for unwinding xii. verification of materials purchased etc. The outer end of the conductor shall be fastened while it is under tension. Drum number vi. Gross weight of the drum with protective lagging including conductor ix. Weight of empty drum with protective lagging x. Name of the destination v. MARKING:Each drum shall have the following information stenciled on it in indelible ink along with other essential data: i. The nails shall not protrude above the general surface and shall not have exposed sharp edges or allow the battens to be released due to corrosion.16 8. Each wrap shall be laid snugly against the side of the preceding wrap and each layer shall be wound neatly over the preceding layer. records. Lot number 9. 10. Maker’s name and address or trade mark. Length of the conductor in metres viii. Size of the conductor vii. 10. Any damage to the conductor due to non-fulfilling the above condition will be in the account of supplier and replacement of such conductor will be done by the supplier and replacement of such conductor will be done by the supplier free of cost. System for shop manufacturing and site erection controls including process controls and fabrication and assembly controls Control of non-conforming items and system for corrective actions. source inspection. quality audit. The tension shall be such that no looseness is transmitted to the internal layers.15 8. The conductor shall be securely fastened at each end to the real. xiii.02 The Quality Assurance Programme of the Contractor shall generally cover the following : a) b) c) d) e) f) g) h) i) j) k) l) m) n) Organizational structure for the management and implementation of the proposed quality assurance programme Documentation control system Qualification data for tenderers key personnel The procedure for purchase of materials. Position of the conductor end. Net weight of the conductor xi. necessary. the Contractor shall adopt suitable Quality Assurance Programme (QAP) to Control such activities at all points. which shall be finally accepted by the purchaser after discussions before the award of contract. parts.03 Quality assurance documents and their system for quality assurance.8.17 The thickness of the external protective lagging or circumferential battens shall be sufficient to withstand transit hazards. Name and address of the consignee iv. sub-vendor control and . 10. Contract/Specification No. The length of the nails shall be not less than twice the thickness of the battens. incoming raw-material inspection. Each batten shall be securely nailed across grains as far as possible to the flange edge with at least 2 nails per end.14 8. Such programme shall be outlined by the Contractor and furnished along with their offer. iii. deviation and rejection systems. components and selection of Subcontractor’s services including vendor analysis. The conductor ends shall be sealed with firms marking/monogram and secured with the help of `U’ nails or bolts on the side of one of the flanges to avoid loosening of the conductor layers during transit handling. ii. 10. System for quality audits System for authorizing release of manufactured product to the purchaser System for maintenance of records System for delivery A quality plan detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of equipment furnished. Inspection and test procedure both for manufacture and field activities Control of calibration and testing of measuring and testing equipments System for indication and appraisal of inspection status. The conductor shall be tightly and uniformly wound on the reel.01 QUALITY ASSUARANCE PROGRAMME:To ensure that the equipments and services under the scope of this contract whether manufactured or performed within the Contractor’s premises or at the Purchaser’s site or at any other place of work are in accordance with the specifications. a) Material test reports on components as specified in the specification. have been completed.01 INSPECTION:The Purchaser’s representative shall at all times. Verification of length Measurement of diameters of individual Aluminum & Steel wire Measurement of lay ratio Breaking load test on steel and Aluminum strands Ductility test (Torsion and elongation) Wrapping test on steel and Aluminum strands Resistance test on Aluminum Galvanizing test : : : : : : : : As per IS 398(Part-II) As per IS 398(Part-II) As per IS 398(Part-II) As per IS 398(Part-II) As per IS 398(Part-II) As per IS 398(Part-II) As per IS 398(Part-II) (b) (c) (d) (e) (f) (g) (h) . b) The inspection plan with verification. verification sketches. the manufacture of the conductor and for conducting necessary tests as detailed herein-after. c) Factory test results for testing required as per applicable codes and standards referred in the specification. 11.1 of the specification i. Visual and dimensional check on drums ii. if used and methods used to verify that the inspection and testing points in the inspection plan were performed satisfactorily.02 The supplier shall keep the Purchaser informed in advance of the time of starting and of the progress of manufacture of conductor in its various stages.system. 10. 12.04 Quality Assurance Documents:The contractor shall be required to submit the following Quality Assurance Documents within three weeks after award of the contracts. No conductor shall be dispatched from its point of manufacture before it has been satisfactorily inspected and tested/unless the inspection is waived off by the Purchaser in writing. 11. be entitled to have access to the works and all places of manufacture where conductor shall be made or prepared. scratches etc. 11. and shall not prevent subsequent rejection. For this purpose supplier are required to offer material for inspection 15 days in advance. Expenditure to carry out these acceptance tests will be on suppliers account. so that arrangement could be made for inspection. In the later case also the conductor shall be dispatched only after the satisfactory testing for all tests specified hereinafter.2 (a) TESTING:Test details mentioned below are to be carried out on ACSR Panther Conductor.1 12.04 The acceptance of any quantity of conductor shall in no way relieve the supplier of any of his responsibility for meeting all the requirements of the specification. Visual examination : Clause 14. if such conductor is later found to be defective. 11. 12. Visual check for joints. inspection plan check points. Acceptance test:To be carried out by the supplier in presence of Board’s representative. iii. organisation structure will be open for the inspection to the engineers or a team of representative of the Board. the raw materials. and the representative shall have full facilities for unrestricted inspection of the contractor’s works. 11.03 The material shall be inspected by our representative prior to despatch. The purchaser will have the right of having. 14. PARTICULARS 1 2 a) b) 3 4 5 ACSR Panther Size Stranding and wire dia in mm Aluminum Steel Overall dia in mm Approximate total weight (kg/km) Approximate current carrying capacity in Amps (40oC Ambient and 30oC rise) When corrected to standard weight calculated D. The reports shall clearly indicate the minimum values specified for each test and minimum/maximum value of diameter and lay-ratio permissible to facilitate checking of the test reports.00 7/3. scratches etc. The manufacturer should have arrangement for transferring the conductor from one drum to another and at the same time measuring the length of the conductor by means of a meter.00 6 0.01 13. and ensure that the conductor generally conform to the requirement of this specification. The length verification will be done in the quantity of drums as desired by the Inspecting Officer subject to a minimum of 5% of the total number of drums of a lot of conductor taken at random to ascertain the declared length of conductor. APPENDIX-I Schedule of Technical data of ACSR Panther Conductor S. resistance at 20o C (Ohm/km) Rated tension strength in Kg Lay Ratio 30/3. 13.:The conductor drums shall be rewound in the presence of the inspector. The length of conductor actually measured may be cross checked by taking weight of empty drum and drum with conductor wound on it. The inspector shall visually check for scratches.NO. joints etc. Visual check for joints.C. to satisfy that the material comply with the specification.01 i) ii) iii) Test Procedure:Visual examination test:Visual and dimensional check on drums:The drums shall be visually and dimensionally checked to ensure that they conform to the requirement of this specification.00 21. at his own expense any other test(s) of reasonable nature carried out at Suppliers premises or at site or in any other place in addition to the aforesaid tests.00 976 427 Value 37/3.1390 7 8 9127 . Verification of length:The supplier/manufacturer of conductor should arrange for the verification of length of conductor by the representative of the purchaser specially authorized for this purpose.4 Routine tests:The routine tests shall be same as acceptance test and shall be carried out on each strand/coil/length by the supplier.3 12. The test reports for the acceptance tests shall clearly state the designated numbers of the drums and net length of the conductor covered by the report.02 14.12. Test Reports:Copies of test reports for the above tests shall be furnished in at least two (2) copies for necessary approval before despatch of material. 13. 89 1.18 19.11 e. Aluminum HTGS Wire Strands Material Diameter in mm Nominal Minimum Maximum 3. C x 10–6 i) iii) 11 a b. Electrolytic high grade zinc – 99.i Steel core for ACSR (Max) Steel core for ACSR (Min) 28 13 ii Aluminum layers 12 wire layer (Max) (Min) 18 wire layer (Max) (Min) 16 10 14 10 0.29 8.17 1.686 x 106 9 10 Modulus of elasticity in Kg/Cm2 Co-efficient of linear expansion (per deg.069 c Cross sectional area for nominal diameter of wire in mm2 Mass in Kg/Km 55.97 3. Minimum breaking load in KN Before stranding After stranding 9.03 7.94 3. 12.00 2.80 11.069 Steel 17.95% purity as per IS : 209-1966. Joints in strands .5 Aluminum 3.00 2.11 4.06 7.107 f g Maximum resistance at 20° C in Ohm/km Zinc coating of steel wire Minimum mass of coating Number of one minute dip for precee test Quality of zinc 240 g/m 2 3 nos. Joints in the individual Aluminum wires in the inner layers are permitted in addition to those made in the base rod or wire before final drawing.67 Kg/mm 2 b) Aluminum c) Ultimate tensile strength of joints in Aluminimum . 14. but no two such joints shall be less than 15 M apart in the complete stranded conductor.a) Steel There shall be no joints except those in the base rod or wire before final drawing No joint shall be permitted in the Aluminum wires in the outermost layer of the ACSR Conductor. Such joints shall be made by the cold pressure butt welding. mm. mm Steel strand in sq. mm) Stranding. 5. ii. ii. iii. . b. 2. Aluminum strand in sq. Maker’s name Aluminum rod Steel wire/rods Complete conductor Specification to which Raw materials pertain Conductor to be manufactured Particulars of raw materials Purity of Aluminum rods (%) Carbon in HTGS wire Size of HTGS wire Particulars of ACSR Conductor Copper equivalent area (sq. mm Total sectional area of conductor in sq. 3. 6. 1. iv. resistance/km of conductor when corrected to o standard weight at 20 C Section Area of i.C. a. i. i. i. Equivalent modulus of elasticity (average values from actual stress strand curves) Description Value 7. ii. total weight (kg/km) Steel Section (kg) Aluminum Section (kg) ACSR Conductor (kg) Guaranteed ultimate tensile strength Calculated D. ii. iii.No. iii. iii. lay and wire dia (mm) Nominal over all dia (mm) Approx. c. i. ii. 8.GUARANTEED TECHNICAL PARTICULARS OF ACSR PANTHER CONDUCTOR S. 4. i. c. Standard (kg) Maximum (kg) Minimum (kg) Aluminum Steel o o o o o ii. b. b.No. b. a. c. 12. ii. 9. iii. Aluminum (kg/cm ) Steel (kg/cm2) ACSR Conductor 2 Description Value Co-efficient of liner expansion Aluminum per C Steel per C ACSR Conductor per C Mean Lay-ratio First layer Second layer Third layer Continuous maximum current rating of conductor in still air at 40 C ambient temperature (amp) Temperature rise for the above current ( C) Standard length of conductor (km.) Tolerance in length (in percent) Random length in percent of ordered quantity Minimum length of Random length (Meters) Net weight of conductor in one drum (as per standard length) Weight of an empty drum in kg.a. b. ii. Particulars of strands Diameter Standard (mm) Maximum (mm) Minimum (mm) Standard sectional area (sq. c. c. a. iii. ii.mm) Weight per km. iii. a. d. c. .S. 13. a. i. 10. i. b. 11. i. iv. b. b. c. a. m. number and duration of dips (according to Preece test) Minimum weight of coating (gms/sq. d. Number of tie rods Size of packing washer of tie rods Size of hub plates Size of bolts of Hub plate Thickness and height of outermost octagonal reinforcement ply Value a. c.mm) Purity of zinc and the standard to which it will conform Minimum number of twists in 150 mm length (withstanding capacity) Dimensions of wooden drum Diameter of flange without outer most lagging Diameter of flange with outermost lagging Outer diameter of barrel with circumferential battens Inner Diameter of bush of the hub plate Outermost transverse width (end to end of flange) Inner Transverse width (between two inner cheeks of the flanges) Width of each ply of the flange Number of ply in each flange Diameter of mild steel tie rod in mm. . i. l. b.mm) Zinc coating Uniformity of coating. v. viii. vi.S. a. Description Minimum ultimate tensile strength (kg) Minimum breaking load for wire of Standard dia (kg) Minimum dia (kg) Calculated resistance per km at 20 oC when corrected to standard weight Standard (Ohm) Maximum (Ohm) Final stress (kg/sq. n. vii. j. h. g. k. b. f. 14. 15 a.No. e. Barrel batten size Flange lagging size Description Value Size of barrel supports . a. . h. f. o. l. q. b. 16.width of each ply Gap to be maintained between and inside surface of external lagging in mm Size of nails Depth of counter sunking of nails inside the wood Diameter of steel drums Diameter of flange without outer most lagging Diameter of flange with outermost lagging Outer diameter of barrel Inner diameter of spindle hole Outermost transverse width (end to end of flange) Inner transverse width (between two inner cheeks of flanges) Width of the flange Diameter of tie rod in mm Number of tie rods Size of packing washer of tie rods Size of bolts Gap to be maintained between outermost layer of conductor and inside surface of external lagging in mm.S. Type of paper and water proof material to be used for packing the conductor in drums Whether manufacturing facility for 37 strand ACSR is available with you Any other particulars which the tenderer may wish to give s. 18. 19. 17. c. i. p. e. j. r. g. t. d.No. k. stage-inspection. However. tropical and dusty climate and solar radiation typically existing in State of M. STANDARDS: These LT meters and the associated accessories shall conform in all respects to the following relevant Standard Specifications with latest amendment there to:Indian Standard No.. (c) It is compulsory that the offered LT meters shall bear BIS certification i. 17/03/06 SERVICE CONDITIONS (CLIMATIC CONDITIONS): (i) The LT meters to be supplied against this specification should be capable of performing and maintaining required accuracy under extreme hot. IS:13779-1999 read with latest amendments CBIP Technical report No. engineering. The meter and push fit type meter box shall be supplied in suitable packing so as to withstand transit shocks during road transport.Zero Lead. the material shall conform in all respects to high standards of engineering. energy in KWH. if considered necessary.88 (with latest amendments) IS:5133-1969 (Part II) IS:9000 IS:11731 IS: 11000 CEA Regulation Title Specification for AC static watt hour meter for class 1 & 2 Specification for AC static Electrical Energy Meters Specification for boxes for the enclosure of electrical accessories Basic environmental and other Testing for Electronic & Electrical items. These LT Meters should record total energy at basic frequency & harmonics.C. capable to record and display monthly average p.P. design and workmanship and shall be capable of performing in continuous commercial operation in a manner acceptable to the Purchaser. The offered materials shall be complete with all components. manufacture. may be verified by the Purchaser. In addition the meters shall have provision for recording time of day (TOD) energy parameters. testing and supply of A. which. (b) It is not the intent to specify completely herein all the details of the design and construction material. The meters shall be capable to record over full power factor range of Zero Lag-Unity. The LT meter shall be required to operate satisfactorily and continuously under the following tropical climatic conditions: (a) (b) (c ) (d) (e) (f) (g) (h) Maximum ambient air temperature Maximum ambient air temperature in shade Maximum temperature attainable by the meter exposed to sun Minimum ambient temperature Average daily ambient air temperature Maximum relative humidity Number of months of tropical monsoon condition Maximum altitude above mean sea level 55oC 45oC 60oC (-) 5oC 40oC 95% 4 months 1000 meters . TECHNICAL SPECIFICATIONS FOR THREE PHASE LT STATIC WHOLE CURRENT SOLID STATE ELECTRONIC ENERGY METERS WITH BACKLIT LCD DISPLAY SCOPE:(a)This specification covers design.0 with backlit LCD display and communication port for data downloading as per requirement given in this specification.e.f. cold. accessories and required software’s necessary for their effective and trouble free operation in the System for measurement of electricity supplied to the consumers.42. The meters shall be supplied in a push fit type meter box made of transparent engineering plastic. and demand in “KW” including other electrical quantities. which shall be weather proof having flame retardant properties conforming to relevant specification. Specification for engineering plastic Resistance to heat & fire On installation of meters of. as per requirement given in this specification. who will interpret the meanings of drawings and specification and shall have the right to reject any work or material which in his judgment is not in accordance therewith. Three Phase 4 Wire current rating 10-40 Amperes solid state (static) whole current electronic LT energy meters of accuracy class 1. Such components shall be deemed to be within the scope of Bidder’s supply irrespective of whether those are specifically brought out in this specification and/ or the commercial order or not. The meters should be suitable for single phase two wire system. the meters shall be ISI marked and the bidder shall have to furnish valid ISI license along with the offer. melting temperature and tensile yield strength of the material and necessary test certificate of the same shall be furnished. petro-chemical products. Item Type of installation System voltage (phase to neutral) System frequency No. 1. which shall be ultrasonically welded to the meter base so that access to the internal parts should not be possible without breaking the meter case.30 g 45db All the parts & surface. long trouble free life. 2. All other screws shall be electro plated. 4. CONSTRUCTIONAL REQUIREMENTS: The meters including meter case and push fit type meter box shall be fully transparent designed and constructed in a manner to avoid any danger during use under normal working condition including personal safety against electric shock. No. 4 KV RMS for 1 minute including latest amendments in relevant IS. The engineering plastic used shall conform to IS: 11731 besides meeting the test requirement of heat deflection test and as per IS 11000(Part2 sec1) for resistance to heat and fire as per glow wire test specified in the relevant standard. 6. moisture and vermin. . PRINCIPAL PARAMETERS: These LT meters shall conform to the following specific parameters: Sl. inert to chemicals. which ensures total protection from any injurious effect of humidity. which are subject to corrosion shall either be made of such material or shall be provided with such protective covering and finish. The meter shall conform to the degree of protection IP51 of IS: 12063 for protection against ingress of dust. 50 Hz ±5% 3 Phase 4 wire (three phase + neutral) Solidly grounded As per relevant IS 7. The meter should be immune against jump during sudden switching of heavy loads or transient voltage spikes.40%. Test voltage at 50 Hz Specification Indoor/Outdoor 3X240 V + 20% to .2/50 Micro sec. of phases System earthing Resistance to surge voltage of 1. The terminal inserts shall be of heavily tinned brass/ nickel or silver plated copper or zinc plated steel. flame retardant. oxidizing agents. The meter casing material should be glass reinforced. unbreakable engineering plastic material to ensure high reliability. The supplier should indicate hardness. spread of fire and effects of excessive temperature. safety against electric shock. salts and ultraviolet radiation. 5. The material of meter body (base and cover) shall be made of Engineering plastic. neutral solidly grounded.(i) (j) Average annual rain fall Maximum wind pressure (k) (l) (m) Isokeraunic level (days per year) Seismic level (horizontal accn. The meter chamber shall be dust proof and moisture proof. acids. The material should be corrosion resistant. All electrically live screws shall be of heavily tinned brass/nickel or zinc plated steel.) Permitted noise level 150 cms 200 kg/sq. 3. m 40 0. The meter base and cover should be sturdy enough to prevent damage during transportation and installation. The meter case and push fit type box should comply following parameters:Material Used for Meter case and Push Fit type Meter Box: The meters shall have a case. 0 POWER SUPPLY VARIATION: The extreme power supply variations which the LT meter should withstand without damage and without degradation of its metering characteristics. reference temperature and reference frequency shall not exceed 1. The backlit should not glow during power off condition. as it operates under its normal operating conditions would be as under: Voltage Current Frequency PF range +20% to – 40% of rated voltage 120% of Imax. with the ambient temperature between 25ºC to 45ºC. RUNNING WITH NO LOAD: When 115% of rated voltage is applied with no current flowing in current circuit.5 Watts and 8 VA respectively as per IS:13779. winding and insulation shall not reach a temperature.20 times the rated voltage.RATINGS: The LT meters as specified in scope of this tender shall be rated as follows: (a) (b) (i) (ii) Voltage Current Basic current (Ib) Rated max. continuous current (Imax) Frequency Accuracy 3x240 V 10 A 40A (c ) (d) 50Hz Class 1.4% of basic current at UPF as per IS: 13779. LIMITS OF ERRORS: When the LT meter is under reference conditions. DISPLAY: The LT meters shall have bright LCD Electronic display with backlit & with minimum 6 digits to read up to one tenth of KWh with another digit for legend. The LCD shall be of STN . the test output of the LT meter shall not produce more than one output pulse count as per IS: 13779. The decimal digits shall be clearly distinguished from integer digits. which might adversely affect the operation of these LT meters. ± 5% of rated frequency Zero (lag) – unity – Zero (lead) The LT meter shall work over wide PF range and the limits of errors with the variation of PF shall be as per CBIP 88 (latest amendments)/IS: 13779 POWER CONSUMPTION: Voltage Circuit: The active and apparent power consumption in each voltage circuit (per phase) including power supply of LT meter at reference voltage. Current Circuit: The apparent power taken by each current circuit (per phase) at basic current. (b) With each current circuit of the meter carrying rated maximum current and with each voltage circuit (and those auxiliary voltage circuits which are energized for periods of longer duration than their thermal time constant) carrying 1. the percentage errors shall not exceed the limits as specified in IS:13779. Auxiliary Power: The LT meter shall draw power for working of electronic circuit from phase & neutral. the temperature rise of the external surface shall not exceed by more than 20ºC. reference frequency and reference temperature shall not exceed 4 VA as per IS:13779. STARTING CURRENT: The LT meter should start registering energy at 0. INFLUENCE QUANTITIES: The single & three phase LT meter shall work satisfactory with guaranteed accuracy as per limit prescribed in IS:13779 under presence of the following quantities:(i) External magnetic field (ii) Electromagnetic field (iii) Radio frequency interference (iv) Vibration (v) Harmonic wave form (vi) Voltage fluctuation (vii) Electromagnetic high frequency field TEMPERATURE RISE: (a) Under normal conditions of use at Imax current. The display with push button shall be auto off type after completion of the display cycle it should revert back to normal auto scroll mode approximately after 10 seconds. DISPLAY SEQUENCE: The Liquid Crystal Display register for single and three phase LT meter should display the measured value(s). Tamper information. for clear visibility of the display of the meter reading.mm.5 mm. Dot-Matrix type LCD display is not acceptable. The MD shall be programmable from KW to KVA with 15 minutes integration on sliding window principle with sub integration period of not greater than 5 minutes. (c) Number of time meter tampered. (b) Time of last tamper occurrence.00 Hrs on the last day of the month for each calendar month and the same should go to memory.). (i) When the LT meter remains at a constant temperature of 65oC for a period of 30 minutes. In addition display of the required parameters should be in two different modes as stated hereunder:Auto scroll Display Mode: The LT meters shall have following parameters in auto scroll display i) Date: DD: MM: YY Real Time: HH:MM ii) Cumulative Active Energy KWH iii) Instantaneous load in KW by default and programmable to KVA. an arrangement should be made on top cover of push fit type meter box with its mechanical connection to the meter’s body as described in the Specification of meter box to activate the display push button of meter. The LT meter should also have provision for automatic recording and storing of required parameters meter at 24. without the help of any power source or battery back up and shall have a minimum retention time of 12 years under un-powered condition.F. The display of various parameters in push button mode shall be scrolling one after another. for whole digits of kWh Display. The display shall have ‘ON’ time of minimum 10 seconds of each measured value. The LCD display should have a wide viewing angle of 45o to 60o up to one-meter distance. (ii) After keeping the LT meter at a constant temperature of 80oC for a period of 30 minutes and when restores at normal temperature. The meter shall make use of non-volatile memory capable of storing and retaining all the data required to be stored. Fresh button press will be required after resumption of auto scroll cycle to display the above parameters again.This shall be displayed when tampered with following. The LCD segment check shall be on meter display for minimum 2 seconds.) each calendar month for previous six months with date and time of such demand. Large viewing area with large display icons is desired.5 X 5 mm. However. Cumulative active energy KWH for each calendar month for previous six months with programmed billing date . Average P. (With sign of lead/lag) Instantaneous load in KW by default and programmable to KVA High resolution Energy value (resolution will be sufficient to enable conduction of the starting current and accuracy test in less time.unity. The display shall not be affected by electrical and magnetic disturbances. LCD segment check Meter serial number Real date and time (Date DD-MM-YY. The display shall have ON time of at least 10 seconds for each measured value. Maximum Demand in KW by default up to two decimal (programmable for KVA when ever desired by the purchaser. Time HH-MM) Cumulative active energy (KWH) register. The registered parameters shall not be affected by loss of power. (a) Date of last tamper occurrence. Display parameters shall move forward if button is pressed prior to the programmed time for display of each parameter. except LCD segment check. for each calendar month and for previous six months. Instantaneous phase voltage Instantaneous line current Instantaneous p. The meter shall be capable to measure and display continuously “Active Energy KWh” at all loads and in full power factor range of zero lag. the display size area shall be approx 60x20 mm (1200 sq. the character of LCD should not deform. Display parameter (Push Button) Mode: The display of the following parameters shall be scrolling one after the other through push button. The height of the display character should be minimum 8. LCD display should work as in normal conditions. hence for reading purpose. The accuracy of display for all parameters shall be matching with the accuracy class of meter as per IS. .(Super Twist Nematic) type designed suitably to withstand temperature of 80oC (storage) & 65oC (operation).f.) Since meters are required duly fitted with push fit type meter box. The minimum character height X width shall be 8. Maximum demand of the month in KW by default up to two decimal (since last auto reset) with date & time.zero lead. the data transfer from the meter to CMRI and further to Base computer should be fully secured and any unauthorized attempt/change in data should be indicated on computer system. The meter should have in-built capacity to define up to six registers. any change in language or any other reasons. it should be possible to read the meter through external MRI via infrared media from a minimum distance of 1. RTC Battery Power shall not be used for display under no-power condition. it shall be possible to read the meter via RF up to minimum 20 metres in any spherical direction from the meter. The compatibility of transferring data from the meter to MRI and then to the base computer system (BC) should be easily established.5 metres in front of the meter box. consumption shall be internally stored. TOD register's data. tamper information and instantaneous parameters data shall all be retrievable through the meter's communication port through a common meter reading instrument (CMRI) and shall be transferred (downloaded) to a PC with Windows based software to get complete details in numerical and/or graphic form. Provision should be made for automatic reset of maximum demand at the end of pre-defined period (e. The infrared module or LPR module of the meter shall have no physical access from outside the meter. In case of infrared port. PF and MD as well as Tamper Count and Power-On hours details shall be at 00. It should not be possible to reset the energy reading in the meter or make any change in the data stored in the meters either current or historical. The main control of this system along with proper security password/code should be available on one or more computers located at the authorized location(s) as per the directions to be given by the Purchaser. Arrangement shall be made to get such a reading even at the time of power failure. end of the month). The above billing data. In case the meter is fitted with LPR port.e. COMMUNICATION CAPABILITY The meter shall have optical communication port or wireless communication facility for remote reading through LPR (low power radio) communication / infrared Communication Port. The interface for communication between MRI & Base computer shall be supplied free of cost. Meter Reading Instrument (MRI) through this port to facilitate for auto-reading and downloading the data for billing and historical data to base computer.01 KWh. LCD Least Count:The kWh display shall be with one decimal digit in push button mode and in auto scroll mode.Meter Reading during Power Outage: The meter shall have provision to read the meter in no-power condition.g. The same push button shall be used for display of parameters of auto scroll mode during power outage. The time registers shall be programmable by the purchaser.00 hours of the first day of each calendar (billing) month and all the billing parameters shall be transferred to billing registers.01 KWh. the port shall be extended up to the surface of the meter box with the help of suitable interface cable and with suitable sealing arrangement. The change of the TOD time-period(s) or defining TOD registers should be possible through CMRI with special authenticated command from the BCS so that only authorized person(s) can make such changes. The software required for MRI and Base Computer System to use the remote reading feature with necessary security provisions shall also be supplied free of cost with the following features: In case the meter is fitted with optical port. the supplier shall modify it at his own cost within the guarantee period. The meter should also have capacity to define multiple time zones within the registers. The meter shall have facility for communicating with a hand held terminal (HHT) i. with the MRI. BILLING POINT REQUIREMENTS: The predefined date and time for registering the billing parameters of energy. The main control of this system along with proper security password/code should be made available on one or more identified computers located at the authorized location(s) as per the directions to be given by the Purchaser Necessary compatible meter application software for various programmable features as discussed above in the meter and also necessary software for the IBM compatible computer to obtain various details as discussed above shall be provided by the supplier. The necessary base computer software (BCS) for this purpose shall be provided by the supplier with complete details. TOD TARIFF/DEMAND The meter should be capable of registering the time-of-day energy (TOD) and maximum demand. In any case. Infrared transmitter and receiver should be compliant to the latest IrDA Physical Layer Standard. There should be multi level password on the base computer system and in the meter to prevent any unauthorized change of billing parameters. No separate cost will be borne by the purchaser on this account. . For the purpose of data security. The billing parameter at the time of automatic reset of the maximum demand shall be programmable. Longer communication range is preferred. resetting of demand and tamper in formation. The internal least count of the energy recording shall not be more than 0. and every 0. The software shall have the facility to convert all the consolidated information / data of selectable parameters into ASCII format. The Data Transfer :It shall be possible to transfer data to and fro from CMRI through serial interface. The first level shall allow the user to enter the system.TEST OUTPUT DEVICE: The LT meters shall have a test out put device in the form of calibrating LED of red colour having minimum intensity 10 M (Milli-candela) accessible from the meter front and shall be capable of being monitored conveniently with suitable testing equipment while operating at site. Security: The BCS shall have multilevel password for data protection and security. Print out shall not include anything and everything available with the BCS. It should be possible for the Purchaser to generate its own DBF (data base files) to down load all the required information into it. The LT meters shall also give high-resolution energy values on the display The resolution will be sufficient to enable conduction of the starting current and accuracy test in less time. The location of the calibrating LED should be such that the calibrating pulses can be sensed easily through sensor for site testing of the LT meter’s accuracy. of meter’s data. Meter Data Display: The software shall show electrical condition existing at the time of reading the meter in tabular forms as well as graphical format (Phase diagram) All the information about energy. Further. Meter Sr. . maximum demand and their respective TOD register reading. The configurable of passwords shall be user definable. The software installed on one PC shall not be copy able on another PC. The Base Computer software shall give all details adequate for analysis. what data to export. there should be a facility in MRI to provide the transfer of meter data to computer through RS 232 or USB port. Support Display: There shall be "user friendly" approach for viewing meter data for the reading collected now or for the reading collected in the past. The MRI shall have facility to store minimum 1000 nos. Date of meter reading. MPPKVVCL shall exchange the communication protocols of successful bidders. The MRI shall be capable for down loading readings of other makes of meters. Location. billing register readings shall be shown in a manner which user can easily understand. BCS shall have facility to export data to ASCII or spreadsheet format for integrating with the purchaser's billing system. The use of the software need not revert back to the supplier of the software for modifying the software just to print what he desires. Configurability: It shall be possible to have selective printing of all available data of the meter. the field width selection etc. It shall be possible to retrieve/locate data on the basis of either one of the following particulars: Consumer's ID/Numbers. The MRI shall have possibility to read all of the three communication types of meters purchased by MPPKVVCL – optical port. infrared and LPR. The software shall support "print wizard" whereby user can decide what to print out. The bidder shall give an undertaking to this effect. Help: The exhaustive online help shall be available with the software so that user can use all the features of the software by just reading the help contents. The different software features shall be protecting by different passwords. Here again an "Export wizard" or similar utility shall be available whereby user can select file format. No. The BCS shall be suitable to run on IBM compatible PC hardware platform. of meters free of cost along with battery charger. BASE COMPUTER APPLICATION SOFTWARE For efficient and speedy recovery of data read through CMRI/HHU. Common Meter Reading Instrument (CMRI) The Bidder should carefully note that The MRI shall be supplied in the ratio of one for each 200 nos. All information about a particular consumer will be sorted out and available at one place so that locating any consumer’s past data is easy. Base computer software shall be supplied having the following specifications stated as under: The BCS software shall be user friendly Windows based. Platform: The BCS shall be executable on all WINDOWS system. The software shall be capable of preparing CMRI to read the meter information or time setting of the meter. The data storage inside the MRI and communication of MRI with the meter shall be encrypted so that there is no possibility of tampering with the downloaded data. After successful downloading of meter data to CMRI. it should be possible to download the data. the manufacturer shall indicate such features in their offer without demanding additional cost.2. free of cost for the use of software at multiple data collection and billing premises of the utility. of meter Date & Time Instantaneous current Instantaneous voltage Cumulative Active energy (KWh) MD during the month Instantaneous load in KW Instantaneous Power factor (sign of lag or lead) Cumulative active energy in KWh for the last 6 months Maximum demand in KW for the last 6 months upto two decimal (It shall support MD in KVA if programmed) Average PF of the last 6 months TOD 1. However. In case of wireless communication port the data transfer rate (from meter to MRI) should be at-least 100 kbps. In case of optical communication port the data transfer rate (from meter to CMRI) should not be less than 9. No. The communication software shall be capable to transfer the billing data and meter serial number required for automatic Spot Billing Machine to automatically generate the energy consumption bills at consumer premises without any human intervention after the data is collected by the MRI. max tolerance time). However. The following minimum parameters should be downloaded by CMRI. in case of failure of power supply. meters at one time.---.1 Readings to be downloaded with CMRI: The CMRI should support in down loading all-important data stored in meter whether specified or not required essentially for deriving billing parameters including MD parameters that shall be by default in KW programmable to KVA respectively. preprogramming the meter serial numbers in advance shall not be required. In case of wireless port after successful downloading.The optical. The manufacturer shall provide the protocol and other information to interpret the transmitted billing data. which shall not be complicated and shall be easily understandable by utility officials to ensure compatibility between meters and CMRIs of different makes. The data download time for wireless port (LPR / Infrared) shall not exceed 5 (+2) sec per meter and for optical port downloading time shall not exceed 5 Minute. It shall be responsibility of the meter manufacturer to provide the required software and all the facilities and support required by the purchaser. indication shall be available on both meter and MRI and repeated downloading from the same meter shall be disabled for a minimum period of 5 min.6 Billing MD registers TOD 1. Even in case of optical port. .2. The MRI shall continuously transmit the data until an acknowledgement is received from the SBM (Spot Billing Machine). The LT meter shall possess a optical port or suitable fast and reliable Infrared/ RF communication port for automatic transfer of data from Meter to CMRI.6 MD register. The CMRI shall possess a specific serial number. KWh register(Programmable) TOD 1. to use the CMRI for reading and retrieving the data from the meter and to download the data to Base Computer on free of cost basis till the expiry of guarantee period. 21. The downloaded data along with date and time stamp of such reading shall remain on CMRI with suitable encryption and it should not be possible to pre-program or manipulate the recorded data on the CMRI before downloading the same with the serial number of CMRI on computer. During this period the energy recording should not be affected.---. in KW up to two decimal (Programmable) TOD 1. The Supplier shall supply Software (compatible with Windows 98 system and/or higher) and training. an indication on MRI or meter or both for confirmation of successful data transfer shall be provided.6 Cum. Arrangement in the meter should be such that. Sr.2.6 kbps. which is in the opinion of manufacturer is necessary for satisfactory performance of the meter.---. 5 Minute.2. the total downloading time (from meter to CMRI) shall be approx.---.6 Billing KWh registers Phase wise power ON time in HH:MM in a calendar month for last 6 months Tamper information including cover open tamper Any other information whether specified or not. A copy of operation manual shall be supplied along with each CMRI. The CMRI shall possess easily replaceable battery and shall be capable of storing data for at least 1000 nos. Necessary upgrades shall be possible in CMRI software and shall be supplied free of cost for downloading simultaneously the existing parameters and any parameters added in future specifications of meters. the total downloading time (from meter to MRI) shall not exceed 5 sec for all types of communication for each meter (with +2 sec. which cannot be changed/ altered. The Supplier shall provide meter-reading protocols free of cost. infrared and LPR mode of MRI shall have a feature to read multiple meters within the range without pre-programming the meter serial numbers in advance. All connection screws and washers should be tinned/ nickel-plated brass. It is necessary to ensure accurate recording by the meters during the condition when DC component exists in the load. Specific confirmation shall be submitted by the bidders that accuracy of . CONSTRUCTION: Meter shall be designed and constructed to be capable of withstanding all severe stresses and vibration and dust environments likely to be encountered in actual field conditions. The maximum demand shall automatically reset at 24. Further. Sufficient clearance shall be allowed between terminals. The current circuit shall be appropriately insulated and potential circuit shall be appropriately encapsulated. The maximum drift in real time clock of the meter shall not exceed ± 3 minutes per year and crystal should be temperature compensated for temperature range of 0oC to 50oC. A lithium battery of adequate storage energy shall be used for energy supply to real time clock during no voltage or power off condition.00 Hrs of the last date of each calendar month for which minimum 30 years calendar shall be programmed by the manufacturer. during any consecutive 15 minutes during the calendar month as per sliding window principle with sub integration period not greater than 5 minutes. The meter design shall be based on CT or CT and shunt combination or shunts. The voltage circuit and current circuit shall be solidly connected inside the meter body without any link. The connections shall be as per the recommended methods given in IS-13779. flame retardant material (capable of passing the flammability tests given in IS:11731) with nickel plated brass for connecting terminals. PT less design shall be used for power supply to PCB. when it occurred. The terminals shall be properly bound in the insulating material of terminal block. The terminals shall be of suitable rating to carry 200% of Imax and shall be made of electro-plated (or tinned) brass. EM CT/Shunt currents should be compared and higher of the two should be used for measurement. The terminal block shall have provision with single/two screws for fixing to the meter board. The terminal block should be made from best quality non-hygroscopic. CALIBRATION: The meters should be software based factory calibrated and there shall not be any mechanical adjustment in calibration after freezing the parameters at works. the supporting webs between the two terminals of the terminal block should be sufficiently high to ensure that the two neighbouring terminals do not get bridged by dust or it is not possible to have flashed over between adjacent terminals of terminal block.5mm to accommodate the insulation of conductor and shall be of adequate length in order to have proper grip of conductor/crimping pins with the help of two screws such that there is no risk of loosening or undue heating. Terminal holes shall be of minimum 9. Electrical connection shall be so designed that contact pressure is not transmitted through insulating material.MAXIMUM DEMAND REGISTRATION AND MD RESETS: The Meter shall continuously monitor and calculate the maximum demand at the point of supply. Required number of pins along with one additional pair shall be supplied with each meter. The MD shall be programmable from KW to KVA REAL TIME CLOCK AND BATTERY: The MD integration cycle shall be on the basis of Real time clock of the meter. All parts that are likely to develop corrosion shall be effectively protected against corrosion by providing suitable protective coating. All terminals shall have two screws. The metering data stated above including integration etc shall be independent of battery. It shall be an integral part of the meter base. This is to ensure that the meter cannot be calibrated at site. TERMINALS AND TERMINAL BLOCK: The terminals may be grouped in a terminal block having adequate insulating properties and mechanical strength. CURRENT AND VOLTAGE CIRCUITS: The current and voltage circuits shall be made of appropriate material such as enamelled copper wire of EC grade. The terminal screws shall not have pointed end at the bottom. The minimum life of battery should be ten years. The cross section of current circuit shall be designed to withstand the temperature rise of 50oC over the ambient temperature at maximum current. A firm connection shall be established within the meter case to energize the voltage/current circuit. It shall not be possible to remove the meter from the hanging screw without removing the screws from the terminal block. It shall store the maximum demand with date and time. Maximum demand of the month shall be in KW by default & up to two decimal digits. earth load LED indication shall appear on meter and the maximum limit of error allowed is ±3% from the reference condition. The meter terminals shall also be marked and this marking should appear in the above diagram. B(in) B(out). Y(in) Y(out).e. The serial number of meter is to be laser –etched on the base as well as the cover of the meter box. . The provision shall also be made to provide additional lash wire seals on the meter by the MPPKVVCL TAMPER AND FRAUD PROTECTION: Logics for design of various tampers.). the tamper indication should appear by means of measuring neutral current. METER FIXING ARRANGEMENT: Every meter shall have at least three fixing holes one at the top and two at the bottom.e. and can be easily viewed to check duplication attempts for the purpose of keeping track of meter seals. The top hole shall be provided with a special clip at the back of the meter so that holding screw is not accessible after the fixing of the meters. Under this condition. main and load wire interchange .The CTs/Shunts & other measurement devices when provided in the meter shall be mounted through proper fixing arrangement so that it should have a firm support and should not move from its position in any case. in presence of any two phases and the load is drawn through local earth. Meter shall store the date & time of occurrence and restoration in the non-volatile memory. N(in) N(out). all the parts shall fulfill the conditions of the glow wire test as per relevant standard.measurement will not suffer due to utilization of shunt on account of thermal variation and temperature coefficient up to an operational temperature of 80oC. and the meter case shall be such as to ensure reasonable safety against spread of fire.e. The energy register shall advance for low voltage up to 120 Volts in each phase. TERMINAL ARRANGEMENT: Connecting terminals of meter shall be in the following sequence: R(in) R(out). The tamper information shall be available along with date & time of occurrence and restoration of the event and phase indication on which tamper was attempted. matching with that of meter. the value of voltage. Access to the working part should not be possible without breaking the seals. company logo and shall be additionally laser marked with serial no. The meter shall be provided with 2 nos. The requisite fixing screws shall be supplied with each meter. The meter shall record and store last 200 events of tampers (occurrence + restoration) along with date and time of occurrence and restoration of each and every event. time etc. CT/Shunt Fixing arrangement:. in presence of any one phase and neutral. It may be noted that the approved logics used in designing tampers are explained to our field officers. the arrangement should be provided such that power LED starts blinking when incoming voltage is below 200 Volts.e. (b) One phase and neutral are disconnected i. and based on their input the bidder have to modify logic if necessary (The last tamper date and time of occurance and tamper counts must appear in the DISPLAY and rest of the details in VIEW PARAMETERS). current. outgoing neutral is connected to earth through resistance and load is connected to earth. Current Imbalance (CT shorting/by-passing) : In case of CT open or shorting. To comply with this requirement. to be selected for design of tamper shall be done in consultation with the purchaser. NON FLAMMABILITY: The terminal block. polycarbonate tamper evident seals which shall be marked with “MPEZ”. which may result in the current imbalance between the phases. The event recording shall be roll over type i. Under this condition the meter should record correctly. It shall not be ignited by thermic over load of live parts in contact with them. it shall always maintain record of last 200 events occurred of selected tamper for logging. CONNECTION DIAGRAM & TERMINAL MARKINGS: The connection diagram of the meter shall be clearly shown on the nameplate of meter and shall be of permanent nature. The meter should continue to record energy even when (a) Any two phases are disconnected i. The meter shall to continue to register active energy accurately even under following conditions: The meter should register energy consumption correctly in forward direction irrespective of the direction of current in the current circuit (i. Provision shall also be made to seal the extended optical port on the side of the meter box. All the seals should be provided on front side only. SEALING ARRANGEMENT: The meters should be software calibrated at factory and sealed suitably before dispatch. (c) When incoming neutral is disconnected. The lower fixing screws shall be provided under the terminal block. The meter shall not get affected by any remote device.The measurement of meter shall not be influenced by injection of AC voltages/ chopped signal/DC signal and harmonics on the outgoing leads of the meter. Cover opening : If attempt is made to open the meter body.27 Tesla anywhere on the surface of meter without meter box. On application of external DC magnetic field of higher intensity against which meter is not immune. The positive error may be beyond the limit of 4% but not exceeding power value equivalent to the product of rated voltage and maximum current. Meter should continue to record in unbalance load condition when neutral is removed. The meter accuracy or accuracy in display under normal conditions shall not be affected by placement of a permanent magnet of not less than 0. However. the meter shall also record the phase wise instantaneous values of voltages. DC Immunity: The meter should not saturate on passing of direct current which can cause the meter either to stop recording or record inaccurately as per IS: 13779 (latest version).27 Tesla DC. . (ii). Further the bidder shall carefully note and confirm that: (i). the meter shall detect /log with date and time of meter body opening tamper.Power ON Time: The meter shall have provision to record the phase wise power ON time in HH:MM in a calendar month for last 6 months The meter should record energy as per IS for balanced and unbalanced load. The meter should record energy accurately irrespective of the phase sequence of supply. meter functioning hang up etc. if any. should not occur with the application of abnormal voltage/ frequency such as spark discharge of approximately 35KV with 0. Along with the tamper information. the meter alone should comply up to 0. When meter is subjected to 35 KV high frequency and voltage burst and remote loop induction device (jammer).01-10 mm spark gap in any of the following manner when applied for 10 minutes: a) On any of the phases or neutral terminals b) On any connecting wires of the meter c) At any place in load circuit d) Spark on meter body. in the meter may also be clearly indicated. In this condition maximum limit of the error allowed is ±3% from the reference condition. the meter should log the events of abnormal magnetic induction with date and time. B) Meter should also be immune for tamper by application of remote loop induction device (jammer). Application of abnormal voltage /frequency: A) The accuracy of the meter. Real time clock disturb. Meter shall have provision to record the tamper of abnormal magnetic induction with date and time of occurrence and restoration. even in absence of supply. External Magnetic Influence: The meter shall not get influenced by any external magnetic fields (AC Electro Magnet or DC Magnet) in accordance with the test procedures specified in IS: 13779 with its latest amendment for AC Magnetic Field. currents and phase power factors to simulate and elaborate the existing condition during all type of tamper events. Additional features. (iii)The bidder should furnish detailed explanation as to how the meter is able to detect/Protect recording the above tamper and fraud features with sketches and phaser Diagram. The three phase LT meter should continue to function when DC signals through Diodes from any or all three phases are injected on the neutral of the meter. Memory data corruption. This tamper shall also be displayed on the meter LCD with tamper information. EMC/EMI Test: The meter shall also pass all EMC/EMI tests as per IS:13779 with latest amendments. it should not hang and in case if it hang once it should remain hanged permanently. 3lag and 0.6. The short time over current rating shall be 30 Imax for one half cycle at rated frequency as per clause No. without the help of any power source or battery back up. data. The meters shall remain within ±1% accuracy when tested at basic current at rated voltage at 0.e. moisture and vermin’s. .5 lead power factor.LED INDICATIONS : The following indications must be provided on the meter: (i) (ii) KWh indicator for Meter calibration . Meter shall be suitable for accurate measurement and display of energy and other billing parameters within the specified limits of errors under balance and unbalanced load conditions in a poly phase network.. Indication shall be provided on display to show the healthiness of phase voltage.Yellow LED indicator or ICON on LCD Indication / current reversal (iii) Earth Tamper indication . The meter base & meter cover shall be made of high grade. the meter should not get damaged and continue to record correctly within class 1.LED or ICON on LCD for line1.3 of IS:13779. Any other design meeting technical specification or features/accuracy etc. All the LEDs shall be of low power consumption and distinctly visible from distance.7. 2 & 3. fire-resistant. The meter shall make use of Non Volatile Memory capable of storing & retaining all the data required to be stored. TOD metering. SALIENT FEATURES: The meter shall have the following additional features.2. Even if phase to phase voltage (i.2 of IS: 13779:1999.Red (Calibration LED-Imp/KWh) Input and output reversal . Provision shall be there to do the billing operation automatically at a predefined date by programming the meter.Green LED indicator or Icon on LCD (iv) Power supply ON and Phase indication . The earth LED should glow only when measurement is through neutral circuit.9. The meter shall be compact in design. better than this specification and manufactured as per relevant IEC/IS/CBIP report shall also be acceptable. The entire design and construction shall be capable of withstanding stresses likely to occur in actual service and rough handling during transportation/loading/unloading etc. Except KWh indicator. The meter shall be fully programmable by the user for TOD timing and billing dates etc.0 accuracy after restoration of normal supply. Computation of demand shall be on the basis of Real Time Clock of the meter itself. 440 Volts) is applied for 5 minutes between phase and neutral of the meter. The meter shall be convenient to transport and immune to shock and vibration during transportation and handling. Meters covered under this specification shall be fully static type with non-volatile memory to register various billing parameters and complete with other features as detailed out in this specification. The meter shall conform to the degree of protection IP 51 of IS: 12063/IEC: 529 for protection against ingress of dust. loading up to 120%Imax. except those required for billing data. Meter shall work within accuracy up to max. The meter shall also withstand impulse Voltage without any damage in accordance with the clause 12. settings etc. all the other indications may be provided as Icon on backlit LCD. For security reasons the meter operating software should have at least “two level write protection” against any modification/editing of the parameters. non-inflammable high-grade and good quality engineering plastic. The entire design and construction shall be capable of withstanding stresses likely to occur in actual service and rough handling transportation. The meter shall be designed in such a way that the conducted or radiated electromagnetic disturbances as well as electrostatic discharge do not damage or influence the meter. Month & Year of manufacture Sign of Insulation Class Connection diagram Serial number. year and month of manufacture Principal unit in which the meter records Reference voltage Basic current and rated maximum current Reference frequency in Hz Meter constant (Imp/KWh) Accuracy class Reference tamperature ISI mark and license number TESTS: (A) Type Test: . and A. & Date. The voltage circuit and current circuit shall be solidly connected inside the meter body without any link. The meter shall have display indication for unsatisfactory/nonfunctioning/malfunctioning of the following: a) b) c) d) Time and date on meter display All display segments on meter display Real Time Clock (RTC) status in meter reading print out at BCS end Non-volatile Memory (NVM) status in meter reading prints out at BCS end. The offered whole current meter shall also withstand DC Immunity test for main and neutral circuit at Iref = Imax/ root 2 as per IS:13779 so as to ensure that the meter current circuits do not saturate on passing of direct current.F. The meter shall be convenient to transport and immune to shock and vibrations during transportation and handling.C. A firm connection shall be established within the meter case to energize the voltage/current circuit. The following information should appear on the name plate affixed on to the meter:Manufacturer’s name or trade-mark and place of manufacture. Bar coding of SN. GUARANTEED TECHNICAL PARTICULARS: The bidder shall furnish all the necessary information as desired in the Schedule of Guaranteed Technical Particulars and data.C. Designation of type Number of phases and number of wires for which the meter is suitable. appended with this specification. Guarantee period – 5 years from the date of commissioning or 5-1/2 years from the date of supply . NAME PLATE AND MARKING: Every meter shall have a name plate clearly visible and indelible and distinctly marked in accordance with IS:13779 (latest version). The disturbance(s) to be considered are: Harmonics Voltage dips and short interruptions Fast transient burst test External D. Purchase Order No. fields Electrostatic discharges Radio frequency interference suppression. the same may be furnished against the last item of that Annexure. magnetic fields Electromagnetic H. If the bidder desires to furnish any other information(s) in addition to the details as asked for. ELECTROMAGNETIC COMPATIBILITY AND INTERFERENCE REQUIREMENT: The meter shall meet EMI/EMC requirements as specified in the relevant standards and shall also be protected against radiated interference from either magnetic or radio frequency sources. Property of MPPKVVCL. The connections shall be as per the recommended methods given in IS-13779 SELF DIAGNOSTIC FEATURE The meter shall be capable of performing complete self-diagnostic check and continuously monitor all the circuits for any malfunctioning and ensure integrity of data memory location at all time. whichever occurs first. Permanent magnet test Special accuracy test – the meters shall remain within ±1% accuracy when tested at basic current at rated voltage at 0. It is desired that when meter is subjected to 35 KV high frequency and voltage burst and remote loop induction device(jammer) it should not hang and in case if it hangs once it should remain hanged permanently. should not occur with the application of abnormal voltage/ frequency such as spark discharge of approximately 35KV with 0. (D) Verification during Inspection: Inspecting officer shall verify that no DC supply/ signal is given to reference meter during the DC injection test. Voltage variation test Accuracy tests under all anti tamper conditions. meter functioning hang up etc.3lag and 0.01-10 mm spark gap in any of the following manner when applied for 10 minutes: a) On any of the phases or neutral terminals b) On any connecting wires of the meter c) At any place in load circuit d) Spark on meter body. should contain the following information clearly: Type of meter and display Class of Accuracy. Type test certificates from any one of the standard laboratories NABL accredited for particular equipment/test shall only be considered. (B) Additional Type Test: In addition to the tests mentioned at (A) above. The Supplier shall indicate the details of the equipment available with him for carrying out the various tests as per relevant Standards. Memory data corruption. bidder shall have to furnish the type test reports of compliance of anti-tamper features as per tender specification. The type test certificate shall not be more than 24 months old as on the date of opening of bid.5 lead power factor.The type test certificate for all tests as indicated in IS:13779-1999 (with latest amendments) shall be furnished along with the bid. amongst other details. The Supplier/Manufacturer shall have at least the following testing facilities to ensure accurate calibration: Insulation resistance measurement Running at no load Starting current test Limits of error Power loss in voltage and current circuit Repeatability of error Transportation test Low load run test Heating test . The bidder shall indicate the sources of all materials. (C) Acceptance tests: All Acceptance tests as laid down in this tender specification shall be carried out. The accuracy of display parameters shall be verified at the time of inspection in line with class of accuracy of meter. Immunity from remote loop induction device (jammer) The accuracy and above indicated parameters of meter shall be checked before and after the application of above device(s) with site conditions. TEST FACILITIES AVAILABLE WITH THE MANUFACTURER: The tests shall be carried out as per relevant Standards and test certificates shall be furnished for approval. Bidders should carefully note that the standard meters used for conducting tests shall be calibrated periodically at NABL Accredited Test Laboratories and test certificates shall be available at Works for verification by Purchaser’s representative. Type test certificate from educational institute(s) will not be accepted. The accuracy of the meter. Type test report. Real time clock disturb. (E) Routine Tests: All the routine tests as stipulated in IS:13779 and in addition tamper and fraud protection tests as per TS shall be carried out and test certificates shall be furnished for approval of the Purchaser. During the manufacturing of the meters the following checks shall be carried out. The testing and calibrating equipments should be automatic and all test equipment shall have their valid calibration certificates. computerized test bench and the results shall be printed directly without any possibility of human errors. if any. manufacturing/readiness activities so that arrangement can be made for inspection. The Supplier shall provide all reasonable facilities without demanding any charge to the inspector representing the Purchaser to satisfy him that the equipment is being furnished in accordance with this specification. The Purchaser reserves the right to get type tests done in respect of any meter. about the The Purchaser reserves the right to insist for witnessing the acceptance/routine testing of the bought out items. the entire lot will be rejected and testing charges shall be recovered from the Supplier. names of sub-suppliers for the raw materials. special acceptance and routine tests specified in the relevant .INSPECTION: The Purchaser’s authorized representative may carry out the inspection at any stage of manufacture. List of areas in manufacturing process. Meter frame dimensions. If the sample fails in the above tests. the firm The factory shall be completely dust proof. Power supplies used in testing equipment shall be distortion free with sinusoidal. List of manufacturing facilities available. list of standards according to which the raw materials are tested. Information shall be separately given for individual type of meters offered. Information and copies of test certificates as in (i) above in respect of bought out accessories. Purchaser may select meters at random from a lot of meters supplied and sent to CPRI/ERDA/ERTL/any NABL accredited testing laboratory for acceptance test as per relevant ISS. QUALITY ASSURANCE PLAN: The designed life of the meter shall be minimum of 20 years and to prove the designed shall have to follow at least the following Quality Assurance Plan:life. The Supplier/Manufacturer shall keep the Purchaser informed in advance. The Supplier/Manufacturer shall grant free access to the Purchaser’s representative at a reasonable time when the work is in progress. RANDOM SAMPLE TESTING AFTER RECEIPT OF METERS AT STORES: The consignment of meters received at Area Store shall be accepted only after testing of sample meters at CPRI/ERDA/ERTL/any NABL accredited testing laboratory as stated in the Schedule-II(D). The Supplier shall give 15 days advance intimation to enable the Purchaser to depute his representative for witnessing the acceptance and routine tests. The Supplier/Manufacturer shall furnish the following information. The meters shall be batch tested on automatic. current and frequency as per the relevant standards. Level of automation achieved and list of areas where manual processing exists. the entire lot will be rejected and testing charges shall be recovered from the supplier. Statement giving list of important raw materials. If the sample fails in the above tests. All acceptance tests and inspection shall be made at the place of Supplier/Manufacturer. Inspection and acceptance of any equipment under this specification by the Purchaser shall not absolve the Supplier of his obligation of furnishing the equipment in accordance with the specification and shall not prevent subsequent rejection if the equipment is found to be defective. The assembly of parts shall be done with the help of jigs and fixtures so that human errors are eliminated. The testing rooms shall be temperature and humidity controlled as per relevant standards. vis-à-vis type. List of testing equipments available with the Supplier for final testing of equipment specified and testplant limitations. wave forms and maintaining constant voltage. SAMPLE: Sample before Commencement of supplies: The Supplier shall submit sample of offered meter along with the meter box having all the features conforming to the prescribed specification for our approval before commencement of supply. or Box from any of the lots received at any Destination Stores at Supplier’s expenses. where stage inspections are normally carried out for quality control and details of such tests and inspections. list of tests normally carried out on raw material in presence of Supplier’s representative and copies of test certificates. The sample meters shall be selected randomly from the lot and will be sent to CPRI for acceptance test as per relevant ISS and as per procedure prescribed in schedule-II(D). These limitations shall be very clearly brought out in schedule of deviations. They must have computerized standard power source and standard equipment calibrated not later than a year (or as per standard practice). The details of testing facilities available for conducting the routine and acceptance tests and other special tests on the meter shall be furnished with the bid. All insulating materials used in the construction of meters shall be non-hygroscopic. all meters shall be subjected to accelerated ageing test to eliminate infant mortality. . The PCB material should be of glass epoxy FR-4 grade conforming to relevant standards. The facility available if any for conducting type test may also be furnished. The electronic components shall be mounted on the printed circuit board using latest Surface Mounted Technology (SMT) except power components by deploying automatic SMT pick and place machine and re-flow solder process. The Supplier/Manufacturer’s laboratory must be well equipped for testing of the meters. (iii) Three copies of dimensional drawings of the quoted item. is not fully in accordance therewith. MANUFACTURING ACTIVITIES: All the materials. Approval of drawings by Purchaser shall not absolve the Supplier of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the latest revision of application standards. fitting details.I. The Manufacturer should use Application Specific Integrated Circuit ASIC or Micro controller for metering functions. All dimensions and data shall be in S. longer life and sustained accuracy. The successful Supplier shall. The Supplier shall within two weeks. Further. The manufacturing of the equipment shall be strictly in accordance with the approved drawings and no deviation shall be permitted without the written approval of the Purchaser. Units. in his judgment. List of drawings and documents: The Supplier/Manufacturer shall furnish the following: (i) Two sets of drawing clearly indicating the general arrangements. (ii) Technical leaflets (user’s manual) giving operating instructions. submit 10 prints and two good quality report copies of the approved drawings for Purchaser’s use. The electronic components used in the meter shall be of high quality. non-aging and of tested quality. The Supplier shall. the Supplier should own or have assured access (through hire. ICs used in the manufacture of the meter shall be of highest quality and reputed make to ensure higher reliability. within 2 weeks of notification of award of contract. (d) Prior to final testing and calibration. The Purchaser shall communicate his comments/ approval on the drawings to the Supplier within two weeks. All manufacturing and fabrication works in connection with the equipment prior to the approval of the drawing shall be at the Supplier’s risk. The calibration of meters shall be done in-house. (b) At insertion stage. All drawings shall be in ink and suitable for micro filming. DOCUMENTATION: All drawings shall conform to International Standards Organization (ISO “A” series of drawing sheet/India Standards Specifications IS: 656.standards and this specification. electrical connections etc. lease or sub-contract) of the above mentioned facilities. The Supplier shall also give the details of quality assurance procedures followed by him in respect of the bought-out items. (c) Complete assembled and soldered PCB should undergo functional testing using test equipments (testing zig). workmanship and latest revisions of relevant standards at the time of ordering and Purchaser shall have the power to reject the materials which. A detailed list of bought-out items which are used in the manufacture of the meter should be furnished indicating the name of firms from whom these items are procured. The details of testing facilities available for conducting (a) The routine tests and (b) Acceptance tests shall be furnished in Schedule annexed with tender document. All parts that are likely to develop corrosion shall be effectively protected against corrosion by providing suitable protective coating. modify the drawings and resubmit three copies of the modified drawings for approval. submit three sets of final versions of all the drawings as stipulated in the contract for Purchaser’s approval. each board shall be subjected to bare board testing. electronics and electrical components. The equipment shall conform in all respect to high standards of engineering. Quality should be ensured at the following stages : (a) At PCB manufacturing stage. The Supplier/Manufacturer should submit the list of all components used in the meter along with the offer. design. if necessary. all components should undergo testing for conforming to design parameters and orientation. rules and codes of practices. due to improper and inadequate packing. The easily damageable material shall be carefully packed and marked with the appropriate caution symbol. The Supplier shall furnish details of memory used in the meter. shall be provided. proper arrangement for lifting. One set of routine test certificates shall accompany each dispatched consignment. a) Name of the consignee b) Details of consignment c) Destination d) Total Weight of Consignment e) Handling and packing instruction f) Bill of material indicating contents of each package The packing shall be done as per the Manufacturer’s standard practice. GENERAL : Principle of operation of the meter. However. (ii) The meter found defective within the above guarantee period shall be replaced by the supplier free of cost within one month of the receipt of intimation. outlining the methods and stages of computation of various parameters starting from input voltage and current signals including the sampling rate. whichever occurs first. The Technical Specification of Push Fit Type Meter Box Made Of Engineering plastic has been described in Schedule-II(B) The procedure for Verification/Testing Of Material Supplied described in Schedule-II(D) shall be followed It is mandatory to conform compliance of guaranteed technical particular of ac three phase electronic KWH meter with LCD display as per Schedule-III . Any material found short inside the packing cases shall be supplied immediately by Supplier without any extra cost. The acceptance test certificates in case of pre-despatch inspection or routine test cases where inspection is waived shall be got approved by the Purchaser certificates in GUARANTEE: (i) The meters shall be guaranteed for a period of 5 years from the date of commissioning or 51/2 years from the date of supply. Additional copies of sets of operating manuals/technical leaflets in the numbers as may be desired by the purchaser shall have to be supplied to the consignee or field officers. PACKING & FORWARDING: The equipment shall be packed in crates suitable for vertical/horizontal transport as the case may be. Wherever necessary. if applicable. and suitable to withstand handling during transport and outdoor storage during transit.. The Supplier shall be responsible for any damage to the equipment during transit. shall be furnished by the bidder. such as lifting hooks etc. Each consignment shall be accompanied with a detailed list containing the following information. If the defective meters are not replaced within the above specified period. the same shall be treated as breach of performance of the contract and shall be liable for consequential penal action. VT or potential divider as to how they can be considered superior in maintaining ratio and phase angle for variation of influencing quantities during its service period. he should ensure the packing is such that the material should not get damaged during transit by Rail/Road.Sets of operating manuals/technical leaflets per 100 meters shall be supplied to each consignee in the first instance of supply. The Supplier shall indicate the method adopted to transform the voltage and current to the desired low values with explanation on devices used such as CT. Besides. The box should have proper mounting arrangement so that it could be mounted on the wall or the pole. inserted in the box. from the meter and 45mm from the terminal block. Thus. The top cover of the meter box should be of push fit type having at least 4 self locks so that once the top cover of the box is fitted with the base it cannot be removed without breaking the top cover.TECHNICAL SPECIFICATION OF PUSH FIT TYPE METER BOX MADE OF ENGINEERING PLASTIC The meter box shall be weather proof. tamper proof and made of transparent engineering plastic conforming to IS: 11731. Meter shall be fitted with the base of box through unidirectional type screw or by some other better means in such a way so that once the meter is fitted with the base. The meters shall be supplied duly mounted on the base of meter box and the cover shall be placed separately in the cartoon. The locks will be moulded in the cover and base and will not be separate pieces fixed later. The meter box cover or base shall have a barrier so positioned that any possibility of fiddling the meter terminal from outside of the meter box through cable entry holes is not possible. The incoming and outgoing gland shall be positioned such that they disable direct access to terminals through glands. i) Unbreakability test:. it cannot be removed from the base and become an integral part with base. it shall comply with the minimum requirements as described above.Shall not get damage or deform while dropping from a height of 10 ft.It should pass the boiling water test as prescribed in IS:13010. no wire or any device can be. there should be minimum clearance of 15 mm in the front from the face of meter. Additional provision to provide lash wire utility seals on meter box shall be made. However. . provided with self-lock. the Serial Number of the meter should be indelibly engraved /marked on the base of meter box as well as on the cover of meter box. it cannot be detached from latches even by applying external pressure through any means. ii) Boiling water test :. and hammered with 2 kg. temporary or permanently. The top cover of meter Box should have spring loaded push button with spindle in moulded barrel perfectly in alignment to operate push button of the meter to read display parameter on push button mode. The individual meter manufacturers shall submit the specific drawing and sample accordingly to accommodate there make meter only.8 mm. There will be no holes to access the locks from any side. the clearance at bottom should be of 75 mm. The overall dimensions of the meter box shall vary according to the different make of meters. The meter box comprises of base and cover shall pass the following tests. However. The meter box should be unbreakable un-deformable and should withstand the temperature up to 140 deg. Clearance of 30 mm shall be maintained from top and both sides of the meter. Thickness of the base should be at least 2 mm and cover should be of not less than 0. Suitable circular holes with adjustable cable glands shall be provided at the bottom of the meter box for inlet and outlet of consumer’s service cables. so that after fixing the top cover. hammer to test its unbreakability. The cover and base shall have groove all along with the fitting edge. The top cover of the box. cent. as the case may be. The boxes shall be specific to the meter mounted in it. Type test of material is required to be furnished along with the sample. The barrier shall have reinforce/locked at both sides to restrict its movement up and down even by applying external pressure through any tools. should have arrangement/barrier so that after getting locked. Vadodara / any NABL accredited test house.C. In case of repeat failure in acceptance test(s). (iv) of above table. the further testing shall be suspended and lot shall be declared as fail. Director (Bills) from the bill of the supplier. Imax for 30 minutes test. No failure shall be allowed out of 3 nos. Tamper & fraud protection. Bhopal / ERDA. 3 nos. at the option of employer. Limits of error. no. Injection test. if so considered . 3 nos. of meters tested at sr. supplies shall be continued. meters. meters shall be (i) (ii) Starting Current test and No load test AC high Voltage test. Following proced Failure of any 2 nos. 8 nos. The selected samples shall be sent with complete details for type test and additional test/special tests as per specification at CPRI. 35 KV abnormal high voltage/ frequency burst & loop induction device (Jammer) burst test. out of above 32 Nos. no. The samples so selected shall be sealed by at least 3-4 seals/stickers by the committee members. In case of failure in more than one meter. no. of meters tested at sr. Insulation test. which shall be recovered by Dy. a set of 32 meters shall be selected randomly and sent to CPRI for conducting acceptance test as per the prescribed procedure S. In case of repeat failure in type test(s). of meters tested at sr. Repeatability of error (iii) (iv) Voltage variation. (iii) of above table. Repeated failure/poor results in the testing may render cancellation of order. In case of successful type test results. D. the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled. of meters tested at sr. Shock test and Fast transient burst test. D. the similar testing procedure as described shall be repeated on another lot and if the lot fails consecutive second time the entire quantity of respective lot/sub-lot shall be rejected and shall have to be replaced by the supplier at his own cost. In case of failure of any meter. out of above 8 Nos. Power consumption test.VERIFICATION/TESTING OF MATERIAL SUPPLIED Three (3) sample meters shall be selected for conducting Type Test from the first lot of meters received in Contractor’s stores by a committee constituted by CE (FS). (i) of above table. The supplies. The employer however in first instance may pay testing charges to the testing agency. Failure of any one meter shall be allowed out of 8 nos. three more samples shall be selected from the supplies already received to get them type tested at contractor’s cost. Failure of more than 2 nos. On receipt of consignment of subsequent lot in Contractor’s Stores. of samples to be tested 32 Nos. in case the meter(s) do not meet the requirement as per ISS/CBIP/Specification in type test(s). no. meter. (ii) of above table. further testing shall be suspended and lot shall be declared as fail. Test of meter constant.27 Tesla). Immunity Test. allowed out of 32 nos. The employer also reserves the right to get additional samples for all or any of the selected tests at employer's cost at any independent test house at any stage of supply. In case of failure in more than 1 no. the further testing shall be suspended and lot shall be declared as fail. Magnetic Immunity test (Permanent magnet test of 0. In case of failure of samples of lot/ sub-lot in the test(s) detailed above. may be utilized in the field during the period of testing.No Particulars of tests No. the further testing shall be suspended and lot shall be declared as fail. The guarantee period of quantity already supplied & used shall be doubled and payment for used meters shall be arranged after deducting 10% cost.C. Failure of any one meter shall be allowed out of 8 nos. out of above 8 Nos. However. the order of balance quantity including the quantity lying unused in the stores/ field shall be cancelled. The type test charges shall be borne by the contractor. Accuracy test after application of 440 Volts for 5 minutes. necessary to ensure that the quality of meters being offered for inspection is same as already got type tested.T. 3.36 KA as per IS/IEC60947-2:2003 with Bus bar connection system. Transformer Protection cum Distribution System. manufacture. Testing & Supply of L. No. 1 or Protection Chamber.1 One chamber to house incoming. In case of failure.T. The decision of MPPKVVCL regarding verification/ Testing of meters shall be final and binding on the supplier and the MPPKVVCL shall not be required to give any reason(s) in writing or otherwise at any time for the rejection of material. Minimum Ambient Air Temperature Average Daily Ambient Air Temperature Maximum relative humidity Average rainfall per annum(mm) Maximum Altitude above mean sea level (meters) Isoceranic level (Day/annum) Maximum Wind Pressure meters) (Kg/Sq. GENERAL REQUIREMENTS : Particulars SCOPE SYSTEM Manufacture. as per IS/IEC60947-2:2003. Transformer Distribution System 415 Volts. This chamber may be called 4. In case of successful test results. SCOPE: This specification covers the design.1 g Seismic level (Horizontal acceleration) The system generally be for use in moderately hot and humid tropical climate. employer may allow the contractor to re-offer the material after change/ modification in the design of meters. CLIMATIC CONDITIONS: The climatic conditions at site under which the equipment shall operate satisfactorily are as under : 1 Location In the State of Madhya Pradesh. AC 3 Phase 4 Wire 50 C/S with effectively grounded neutral system SL. India 2 3 4 5 6 7 8 9 10 Maximum ambient air temp. Distribution Box for 100 KVA 11/. supply and delivery of 100 KVA L. Not more than 1000 mm (Average 200 to 600 mm) 815 120/50 45 0. the guarantee period of the quantity already supplied by the supplier shall be doubled and employer reserves the right to cancel the balance quantity. conducive to rust and fungus growth unless otherwise specified. . The balance material shall be accepted only after successful Type Testing. The Type Testing charges shall be borne by the supplier.3 . 50 °C (-) 1 °C 32 °C 90% Sometimes approached to saturation. This chamber may be called CHAMBER NO. SYSTEM DETAILS: LT Transformer Distribution System mainly consists of following main items detailed below : 4. testing before dispatch. i) ii) 4. Four Pole MCCB double make double break type 200 Amp. 36 KA double make/ double break capacity with outgoing Bus bar connections and neutral bus bar. supplies shall be continued. 2. However. 43 1.4KV Transformer. Other chamber to house 6 numbers of Single Pole MCCB's 100 Amp. one Isolator double make double break type 250 A . 1.25 mm 4.2. Further details of the above are : 4. Detailed technical parameters of Four Pole MCCB 200 Amp. 4. should be provided in this chamber for protection. Holes for incoming Cables : For incoming cable 4 Nos.5 4.7 Supporting MS Frame work for the above Chambers Nos. MCCB .2.4 4. The following make of Isolator shall be acceptable. and proper gap should be maintained between all phase and neutrals. 2. Arrangement of inter connection of Bus bar : Inter connection of bus bar should be done. 1 to 2. Hinges : Two Nos. .6 4. The following make of MCCB shall be acceptable. 2.9 Gland Plate : M. External Earthing Plate for earthing of connections.2.36 KA.4 Dimensions : Dimensions of the Chamber No.2 mm thick zinc plated yellow passivated gland plate should be provided at the incoming side of the box i. should be provided in this chamber for protection.0 mm + 0. 4.3 4. Isolator . Cable Clamps for incoming & outgoing cables.0 mm + 0.5 MCCB : Four Pole MCCB 200 Amp.8 4.S. The plate should be zinc plated and yellow passivative. DMC moulded support should be used to provide rigid support and insulation. 2 or Distribution Chamber.1 Construction Features : The box shall be adequately protected against rust. hole with insulated plastic glands on the base of the chamber shall be provided and gland plates with suitable holes for incoming cable shall be provided. The box shall be so constructed as to have roof tapering back side for easy flow of rain water.25 mm Cover : 3.2.0 mm + 0.A.2.36 KA A four pole MCCB of rating 150 Amp. of hinges should be provided to join base with cover from one side in such a manner that no screw or rivets will be visible from outside.9 4.S.0 mm + 0. The MCCBs shall be confirming to IS/IEC609472:2003 4.2.as per Schedule-c.36 KA as per Schedule . Spacers for connecting the chambers. Four Pole Isolator 250 Amp A four pole Isolator of rating 150 Amp. 1 : PROTECTION CHAMBER : 4.10 Rubber Gasket : The coller in the Base of Chamber shall be provided with good quality rubber 'O' ring.2 mm thick mounting bracket should be provided with proper mounting holes and clamps to accommodate four pole MCCB 200 Amp.1. : Siemens / L&T / ABB / GE POWER / MONTEL / SCHNEIDER / SPACEAGE Hyundai or any other make which conforms to the specifications. 2 or Protection Chamber will be as per drawing Thickness : Base : 3.6 Mounting Arrangement of Four Pole MCCB 200 Amp. Detailed technical parameters of Four Pole Isolator 250 Amp.2. The cover should be closed from top to bottom with pull push facility separately for box no. dust. The design of lining shall be such that it provides proper sealing between the cover and base of chamber to avoid penetration of dust and ingress of water.1 CHAMBER NO.36 KA : M.e. 1 and box 2 with moving lever arrangement each side of box as per drawing 4. water and corrosion both from inside and outside. .CHAMBER NO. : Siemens / L&T / ABB / GE POWER / MONTEL / SCHNEIDER / SPACEAGE Hyundai or any other make which conforms to the specifications. . This may be achieved by providing an U shape groove in the outer flange of the base and all around projection provided on the cover . 4. at the bottom of the box. .3. MCCB : Single Pole MCCB 100 Amp. dust etc. These vents shall be fixed / tightened from inside facing down as not to allow water inside.3.M.1 CHAMBER NO.0 mm + 0. The design of lining shall be such that it provides proper sealing between the cover and base of chamber to avoid penetration of dust and ingress of water. Neutral Bar : A pre drill and tapped neutral bar should be provided of cross sectional area 150 Sq.2. should be provided in this chamber.25 mm 4.3. mm + 2. 100 Amp. This will avoid ingress water.3. 4.B. 2 or Distribution System will be as per drawing Thickness : Base : 3. 36 KA Single Pole MCCBs.5% made of EC Grade Aluminium Covered with Phase identification PVC Colour Coding Sleeves.36 KA Six (6) numbers single pole MCCBs of rating 100 Amp.7 Mounting Arrangement of Single Pole MCCB 100 Amp.3 4.2. Moulded Bus bar holding supports should be mounted in the chamber so that all the bus bars can be interconnected through Chamber No. which keeps the 'O' ring pressed and also to provide an outside caller to cover the groove.9 4.3.14 Sealing Arrangement : 2 Nos. of hinges should be provided to join base with cover from one side in such a manner that no screw or rivets will be visible from outside. .5 Mounting arrangement of Bus bar : D. Detailed technical parameters of Single Pole MCCB 100 Amp. 2 with proper gap and insulation. .3 4. MCCBs. The box shall be adequately protected against rust. The plate should be zinc plated and yellow passivative.3. This may be achieved by providing an U shape groove in the outer flange of the base and all around projection provided on the cover periphery.2. 2. 4. of sealing bolts & nuts should be provided to seal the box and also to close the cover on base. 4. These plugs will provide breathing inside the chamber.10 Holes for incoming and outgoing : For outgoing connections 9 number of holes with Engineering Plastic glands will be provided at the bottom of the chamber. 4.C. The following make of MCCB shall be acceptable : Siemens / L&T / ABB / GE POWER / MONTEL / SCHNEIDER/ SPACEAGE Hyundai or any other make which conforms to the specifications. water and corrosion both from inside and outside. 4.S. This will avoid ingress water.3.13 Bus Bar : Size of Bus Bar should have cross sectional area of 50 x4 mm + 2.2.periphery. The cover should be closed from top to bottom with pull push facility separately for box no. 4.3.11 Ventilation : Ventilation plugs (Elbow type) has to be provided having built in mesh to protect against entry of insects and lizards. dust etc.12 Rubber Gasket : The collar of the body shall be provided with good quality rubber 'O' ring.12 Padlock Arrangement : Pad lock arrangement should be provided to lock / seal the base and cover.0 mm + 0.3.36 KA as per Schedule . dust. 4.6 4.5% to take the neutral for outgoing connections. incoming and outgoing Bus bar connections and neutral bus bar.36 KA : M. which keeps the 'O' ring pressed and also to provide an outside caller to cover the groove. 4. The IP rating of individual chambers should be IP 55 but the test has to be done on enclosures in which the holes have been blocked. 4. 2 : Six (6) Nos.S.36 KA. 1with Chamber No. The cross sectional area of Bus bars is to be 50 x4 mm. .11Hinges : Two Nos. A gland plate of M.0 mm thick zinc plated yellow passivated should be provided.4 Dimensions : Dimensions of the Chamber No. 2.3. 1 and box 2 with moving lever arrangement each side of box as per drawing 4.0 mm + 0.25 mm thick mounting bracket should be provided with proper mounting holes and clamps to accommodate 6 numbers of single pole 100 Amp.25 mm Cover : 3. . Construction Features : The base and cover should be made by means of MS sheet of IS: 2147/1962 or to equivalent any international standard. The spacers shall have openings for bus bars to pass through the joints and spacers. 1. 4. 4. These vents shall be fixed / tightened from inside facing down as not to allow water inside.0 mm + 2.4 Supporting MS Frame for Chamber Nos. with Chamber No. 1 with Chamber No. 4. 4. These plugs will provide breathing inside the chamber.15 Bus Bar : Size of main Bus Bar should be 50X4 mm + 2.5% made of EC Grade Aluminium.5% thick hot dip galvanised plate with 6 Nos. 4. 2. ******* . of M8x40 Nut.4. of sealing bolts & nuts should be provided to seal the box and also to close the cover on base. MS Frame should be Hot Dip Galvanised material.16 Sealing Arrangement : 2 Nos. 4.3. mm + 2.7 Cable Clamps for incoming Cables : Sufficient numbers of MS U Shaped bend clamps with bots and nuts should be fitted on metal frame to hold and support the incoming cables firmly.8 Cable Clamps for outgoing Cables : Sufficient numbers of MS U Shaped bend clamps with bots and nuts should be fitted on metal frame to hold and support the outgoing cables firmly. Each box is to be fixed at min. bolts and washer should be fitted on the bottom of chamber for providing earthing for outgoing connections. This spacer is sandwiched between 2 chambers in a fashion.5% and main bus bar should be connected to the 100 Amp.5 Spacers for connecting the Chambers : For joining the Chamber No.6 External Earthing Plate for Earthing : M. so it fit into the groove provided on the sides of the chambers and duly bolted with each other.13 Ventilation : Ventilation plugs (Elbow type) has to be provided having built in mesh to protect against entry of insects and lizards.3.5% with 6 mm flats in between should be used to make the back frame of the entire system. 4 places at Base. 1 to 2 : MS Angle 30x30x5 mm + 2. 4.3. It should be made in such a manner that entire back side edge / corner should be held by this frame rigidly.S. The IP rating of individual chambers should be IP 55 but the test has to be done on enclosures in which the holes have been blocked.3. MCCB by means of Aluminium strip of cross section of 45 sq. 4. 2 especially designed spacers are to be used with O ring all around on both sides to avoid ingress of water and dust.14 Padlock Arrangement: Pad lock arrangement should be provided to lock / seal the base and cover. Note : 01. Tolerances for metal parts should be : a) Thickness : + 2.5% b) Length : + 2.5% b) Length : + 2.5% ******** .5% 02. Tolerances for current carrying parts should be : a) Thickness : + 2. 1993 To co-ordinate with HV fuse. Four 50 °C. 600 V. 8500 1500 ******* . 433 V. ‘A’ (IS: 13947-1993) as amended up to date Thermal-Magnetic trip free mechanism.A TECHNICAL SPECIFICATION FOR FOUR POLE MCCB 200 Amp . 200A 36 KA 36 KA IS: 13947 Part-2 (latest) .SCHEDULE .36 KA FOR 100 KVA TRANSFORMER PROTECTION CUM DISTRIBUTION SYSTEM Application Utilization category Type Number of poles Peak ambient temperature Rated insulation level Rated operational voltage Continuous current rating Ultimate Short Circuit Breaking capacity (ICU) Rated service Short Circuit Breaking capacity (ICS) Application Standard Time current characteristics Durability (C-O Cycles) a) mechanical b) electrical Outdoor (enclosed). 100A 36 KA 36 KA IS: 13947 Part-2 (latest) . 8500 1500 ********* .100A FOR 63 KVA TRANSFORMER PROTECTION CUM DISTRIBUTION SYSTEM Application Utilization category Type Number of poles Peak ambient temperature Rated insulation level Rated operational voltage Continuous current rating Ultimate Short Circuit Breaking capacity (ICU) Rated service Short Circuit Breaking capacity (ICS) Application Standard Time current characteristics Durability (C-O Cycles) a) mechanical b) electrical Outdoor (enclosed). 433 V.1993 To co-ordinate with HV fuse.B TECHNICAL SPECIFICATION FOR MCCB . Single 50 °C. ‘A’ (IS: 13947-1993) as amended up to date Thermal-Magnetic trip free mechanism. 600 V.SCHEDULE . SCHEDULE . 750 V.250A FOR 100 KVA TRANSFORMER DISTRIBUTION SYSTEM Application Utilization category Type Number of poles Peak ambient temperature Rated insulation level Rated operational voltage Continuous current rating Rated service Short Circuit making capacity (ICM) Application Standard Short time withstand current (A rms) ICW 1 Sec-9000A 3 Sec-5000A 20 Sec-2300A 30 Sec-1800A Outdoor (enclosed). 690 V. Four 50 °C. ‘AC’ 23 A asIS/IEC 60947-2:2003 as amended upto date Thermal-Magnetic trip free mechanism. 250A 30 IS: 60947-2:2003 .C TECHNICAL SPECIFICATION FOR Four Pole Isolator . of Poles 2 Nos. of circuit on outgoing side I ISOLATOR 100 KVA 415 V 50 c/s 140 A 2 Nos. Single Pole Whether the MCCB is of approved make 8 (Then the details of guaranteed technical particulars need not be enclosed) . of any approved brand on incoming side. EC Grade Aluminium I DETAILS OF MCCB i) ii) iii) iv) Make of MCCB No. b) Whether the Isolator meets the technical requirement of specification.4KV TRANSFORMER N Particulars Specification Details Guaranteed Value I SYSTEM DETAILS a) KVA b) Voltage c) Frequency d) Full load current e) No. of ckts.mm. 80mm on incoming and 60mm on outgoing side.GTP of DISTRIBUTION CUM PROTECTION BOX FOR 100 KVA 11/./Phase 130 Amps. per Phase a) Triple Pole 250 Amps. Nominal current No. I a) Cross Section of the terminal strip of Isolator b) Length of the terminals of the Isolator c) Material of strip 50 x 4sq. S. PVC Insulation of standard colour code is to be provided on the bus bar Weather 4. As per drawing V ENCLOSURES 1 2 3 4 Size Material Thickness Arrangement for Pad Lock As per drawing M. Length of incoming side and outgoing side 1 Length of incoming side is 60 mm & outgoing side is 80 mm EC Grade Aluminium Material of strip 1 V BUS BAR DETAILS 1. Minimum clearance of the bus bar Top side.mm. between the bus bar coloured sleeve insulation has been provided on the bus bar & at joints M-seal compound has been painted.N Particulars Specification Details Guaranteed Value Size of terminal strip 9 50 x 4 sq. Material EC Grade Aluminium 2. Size of the main bus bar 50X4 sq.mm. Sheet 3 mm of all sides Arrangement for pad lock as per Drawing To be provided 5 Auto Lock with push pull facility . 3. mm. Hinges of the door is to be provided with Brass tube Duly enameled on both sides. . One no. suitable 150 sq. 1 Instructions to Lineman in Hindi Provided Hinges 1 1 Danger plate 1 Identification plate Identification plate is to be provided indicating the details as under :Name Rating of Box Sr.mm. No. size 1 Air Circulation Both sides Ventilation 1 Bottom Cleats Four Bottom Cleats of 75x40x3 mm thick M. provided To be provided on the back of the door of the box.S. 3 mm thick plain sheet 7 8 9 Colour of the Box Bottom Plate Thickness 1 Additional Support 1 Knock out holes 3 Nos.N Particulars Specification Details Guaranteed Value 6 Slopping of the roof Slopping of 5º from the front to back Grey Bottom Plate Should be made of 3 mm thick perforated and should be detachable. for outgoing side of 70 sq. with PVC Glands. on incoming side and 2 Nos. size or equivalent neutral bus bar to be provided along with lugs with steel washer Bimetallic lugs suitable for 150 sq. on outgoing side Cable holding clamp of 2 mm thick with 4 mm base strip to be provided As Per drawing 1 Earthing Bolts 2 Neutral Bus Bar 2 Lugs on Incoming side 2 Cable Holding Clamp 2 Opening of door from top to bottom with moving lever facility SPECIAL REMARKS V . 3-1/2 Core on incoming side & 70 sq. Earthing bolts to be provided of 50 x 12 mm on each side with one spring washer & two plain washers 50X4 sq.mm.mm.N Particulars Specification Details Guaranteed Value Date of Manufacturing Order No.mm. & Date 1 Nut & Bolts All nuts & bolts of the current carrying part should be made of stainless steel with washer.