Vol-II-Tech Spec Ayakara Bhawan 1

TENDER DOCUMENTS FOR
Construction of 11kV Line from 33/11kV Sishubhawan Substation to Ayakara Bhawan at Cuttack, Odisha
Volume II Technical Bid
CENTRAL ELECTRICITY SUPPLY UTILITY OF ORISSA (CESU)
IDCO TOWER, 2nd Floor, Janpath, Bhubaneswar-751022 TELEPHONE: (0674) - 2542895, 2545681, 2541727 FAX: 0674 2543125
TENDER NO: CESU. H.Qrs./P&S/523/12-13/24764/Dt: 30.07.2012
Tender Specification for Technical Requirements of 11kV Line Ayakara Bhawan / CESU / Odisha
CENTRAL ELECTRICITY SUPPLY UTILITY OF ODISHA (CESU)

Head Office: IDCO TOWER, 2nd Floor, Janpath, Bhubaneswar-751022 TELEPHONE: (0674) - 2542895, 2545681, 2541727 FAX: 0674 2543125
BID ENQUIRY NO: CESU. H.Qrs./P&S/523/12-13/24764/Dt: 30.07.2012
BIDDING DOCUMENTS
Central Electricity Supply Utility of Orissa
Page 2
BID DOCUMENTS CONSIST OF THE FOLLOWING VOLUMES VOLUME- I (COMMERCIAL REQUIREMENTS)

1. Section I 2. Section II 3. Section III 4. Section IV 5. Section V :-Invitation For Bids :-General Terms and Conditions of the Contract :-Price Schedule Format :-BID Proposal Letter :-ANNEXURE GTCC PSF BPL ANNEX IFB
VOLUME-II (TECHNICAL REQUIREMENTS)

1. Section I 2. Section II 3. Section III 4. Section IV 5. Section V 6. Section VI 7. Section VII 8. Section VIII :-General :- Porcelain clad 11kV Switch Gear :- 11kV UG Cable :- HT cable joints and terminating kits. :- Cable Laying Methodology :- Lightning Arrestor :- 11kV AB Switch :- Proposed route map
VOLUME- III (BID PROPOSAL SHEETS)

1. PART A :-PRICE SCHEDULE SHEETS WITH BOQ
Page 3
Section-I General
Page 4
1.0. INTRODUCTION:
The CENTRAL ELECTRICITY SUPPLY UTILITY OF ODISHA,

hereinafter called CESU/OWNER is inviting Bids in respect of Total Turnkey Package for construction of 11KV UG Cable DC Feeder (Main + Standby) by using 3x400mm2 ,11KV, XLPE Cable from Sishubhawan 33/11kV S/s to Ayakar Bhawan at Shelter Chhaka, Cuttack, Odisha on Total Turn Key basis including supply of all Equipments/Materials Erection (including Civil Works), Testing and Commissioning as per the Scope detailed in the Bid Documents. 2.0. NATURE OF WORK: The work covered by this Specification is for 11kV distribution lines as specified herein and in the attached Schedules. The Underground distribution lines will form a part of the CESUs distribution System. 3.0. SCOPE: Construction of 11kV Line from Sishubhawan 33/11kV S/S to Ayakar Bhawan at Shelter Chhaka, Cuttack, through underground Cables and accessories. The work Involves:
a) Establishing additional 11kV Terminal bay with all 11 kV switch gear equipments and other
modification works at existing 33 /11kV Substation at Sishubhawan, Cuttack.
b) Laying of double circuit of UG cable (Main + Standby) using 3core x 400mm2, 11kV, aluminium,
XLPE insulation armoured dry cured power cable for a Circuit length of 1.85km(double ckt.).
c) Installation of 11KV metering unit at the proposed 6 pole structure at Ayakar Bhawan. d) Erection of 11 kV Lightning Arrestors (6 nos). e) Erection of 2 set of 400Amp,AB Switch unit. f) Straight through Jointing kits (3 core/ 3 phase) with Heat shrinkable type suitable for 11kV class, 3 core 400 sq. mm HT, XLPE UG Cable (22 nos) g) Jointing of Indoor terminating end kit (3 core/ 3 phase) with Heat shrinkable type suitable for 11kV class, 3 core 400 sq. mm HT XLPE UG Cable (2 nos) h) Jointing of Outdoor terminating end kit (3 core/ 3 phase) with Heat shrinkable type suitable for 11kV class, 3 core 400 sq. mm HT XLPE UG Cable (2 nos) i) Installation of 4 sets of earthing Device with Earthing pit of 2.5 mtr. long excavation for end termination of cable (including supply of 40NB, 3mtr of GMS pipe, 80mmx12mm Earthing GI strip, Salt & charcoal). j) Erection of rigid PVC pipes of size 200 mm diameter of length 25mtrs.
Page 5
Bill Of Material for construction of 11KV UG Cable DC Feeder (Main + Standby) by using 3x400mm, 11KV, XLPE Cable from Sishubhawan 33/11kV S/s to Ayakar Bhawan at Shelter Chhaka, Cuttack, Odisha on Total Turn Key basis
Sl No 1 2
Particulars Supply of materials for new 11KV bay one no at Sisubhawan S/s with CT, PT, Breaker, Isolator & Structure etc. Supply of materials for Underground Cabling work i) Supply of 3core x 400mm, 11KV XLPE Under Ground Cable (2 runs = Main + Standby)( Cable supply =(1.85 x 2)+ 16% extra =4.3km) ii) Supply of Cable Jointing kit (3 core/ 3 phase) for 400mm, 11KV XLPE Cable (straight through) iii) Supply of Cable Jointing kit of Indoor Terminating (3 core/ 3 phase) for 400mm, 11KV XLPE Cable iv) Supply of Cable Jointing kit of Outdoor Terminating (3 core/ 3 phase) for 400mm2, 11KV XLPE Cable V) Supply of Earthing materials for cable with 2.5 mtr. long (including supply of 40NB, 3mtr of GMS pipe, 80mmx12mm Earthing GI strip, Salt & charcoal). Vi)11KV ,AB Switch 400Amps Vii)11KV, LA at both terminating end of cable Vii)PVC Pipe for cable erection at 6 pole structure,200mm dia"
Unit
Quantity
No
Km
4.3
Nos.
22
Nos.
Nos.
Nos.
Set Nos. mtr
2 6 25
Supply of Materials for installation for 11kV Metering Unit at the proposed 6pole structure
i) 11KV Metering Unit ii) 11KV LA iii) 30mm GI Pipe iv) 2.5mm ,7core armoured control copper cable for connecting to meter v) TP Box for HT TV Meter (out door type) vi) 30mm GI Bend vii) 30mm GI Socket viii) 30mm GI Elbow ix) 100 X 50 X 6mm MS Channel No Nos Mtr Mtr No No No No MT CESU Supply 3 12 15 1 2 2 1 0.13
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x) 50 X 40 X 6mm MS Angle xi) No. 6 GI Wire xii) Nut & Bolt of different sizes xiii) Earthing Device (40mm dia GI) with materials xiv) Sundries for Ampere Tape ,PVC Tape, Sockets etc.
MT Kg Kg nos LS
0.02 2 6 4
4.0. Methodology: The complete procedures for the execution of the project are explained herewith in details.
i. Detailed survey of the area and routes from Sishubhawan 33/11kV S/S to Ayakar Bhawan at Shelter Chaka, Cuttack, as shown in the Geographical diagram / Schematic diagram of the tender document and preparation of fresh Geographical & schematic diagrams showing the position of Laying of Cables to be done by the bidder. ii. Complete manufacture, including shop testing & supply of all materials / equipments from the approved vendor or from his manufacturing units. iii. Providing Engineering drawing, data, operational manual, etc for the Purchasers approval; iv. Packing and transportation from the manufacturers works to the site. v. Receipt, storage, preservation and conservation of equipment at the site. vi. Pre-assembly, if any, erection testing and commissioning of all the equipment. vii. Reliability tests and performance and guarantee tests on completion of commissioning. viii. Loading, unloading and transportation as required. ix. Laying of 11kV, XLPE UG cable by Horizontal Directional Drilling method . x. Formation of additional one 11 kV outdoor bay and installation of outdoor 11kV Porcelain clad switch gear for new 11kV feeder at Sishubhawan sub station. xi. Erection of 11 kV Lightning Arrestors. xii. Erection of 11 kV AB switch Unit. xiii. Installation of 11KV metering unit at the proposed 6 pole structure of Ayakar Bhawan. xiv. Jointing of 400mm2, 11KV, XLPE cable:- straight through and end termination. xv. Testing, Commissioning of 11kV, HT, UG cables, 11kV Switch gear ,AB switches, Lightning arrestors etc xvi. Storing before erection
Central Electricity Supply Utility of Orissa Page 7
xvii. Getting the complete 11kV network system inspected by Electrical Inspector after completion of work. xviii. Cable route marking by standard methodology. xix. Cable looping at the either sides of the cable.
5.0. Technical specifications for supply of materials: The supply of all the required materials for this TOTAL TURN KEY project is in the scope of the contractor. The technical specifications for the major materials required are dealt herewith in the following sections of this volume. The following is the list of the Technical specifications for materials/equipments 1. 11kV Class HT 3core UG cables, XLPE insulated, 400 mm, Aluminium 2. 11kV class XLPE insulated straight through jointing Kits and end Terminations for HT UG Cables of 400mm size. 3. 11 kV class Lightning arrestor. 4. 11kV class 11 kV AB switch.
5. 11KV metering unit at the proposed 6 pole structure 6. 11kV class Porcelain clad circuit Breakers for 33/11kV substation. 7. Laying of HT UG Cables.
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Section-II Porcelain clad 11kV Switch Gear
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TECHNICAL SPECIFICATION OF 11KV CLASS PORCELAIN CLAD SWITCHGEAR 1.0

SCOPE: The scope of this specification is for design, manufacture, testing, and supply of outdoor 11 KV class porcelain clad switchgear suitable for installation for use in a 3-phase 50Hz, 11KV solidly earthed system. The switchgear assembly shall consist of complete with all components such as circuit breakers, control gear, instrument transformers, meters, relays, switches, indicating lamps, test blocks, current transformers, voltage transformers etc. which are required in each panel for satisfactory and efficient performance of the switchgear. The switchgear shall suit outdoor installation.
2.0
APPLICABLE STANDARDS : The switchgear shall confirm to the following standards namely BIS Bureau of Indian Standards and IEC International Electro Technical Commission.
Sl No 1 2 3 4 5
IS / IEC Nos IS 5 IS 513 IS 641 IS 722 IS 722 Parts(1)to(5) (7)to(9) IS 1730 IS 1951 IS 2419 IS 2516 /13118 IS 2750 Parts I to IV IS 2959 IS 3156 parts I to III IS 3231 IS 3427
Equipments & components. Paints, Finishing Exterior Cold rolled low carbon steel sheets and strips. Paints, Finishing interior White A.C. Electricity meters Direct acting indicating analogue electrical measuring Instruments and their accessories. Steel sheet and strip dimensions PVC sleeving for electrical purpose. Dimensions for panel mounted indicating instruments. and electrical recording Specification for alternating current Breakers Current Transformers AC & DC Contractors Voltage Transformers Electrical relays for power system protection Metal enclosed switchgear and control gear for voltages above 1000 V but not exceeding 11000 V Page 10
6 7 8 9 10 11 12 13 14
15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35
IS 3842 Parts I to XII IS 4146 IS 4201 IS 477 IS 4794 parts I to II IS 5608 Parts I to IV IS 6236 IS 6875 IS 7118 IS 8130 IS 8197 IS 8686 IS 9224 Parts I to II IS 9954 IS 10118 IS 10276 IS 11431 IEC 56 IEC 694 IEC 687 IS 14697
Application guide for Electrical relays for protection and other relays. Application guide for voltage Transformers Application guide for current transformers Performance tests for protective schemes used in protective of light gauge steel against corrosion Push button switches PVC wires and sheaths Direct recording electrical measuring instruments Control Switches Recommendation for direction movement for control device, operating electrical devices. Conductors for insulated Electric cables. Terminal markings of electrical measuring instruments and accessories. Static protective relays. Pictorial surface preparation standards for painting of steel surfaces. Code of practice for installation of switchgear Code of practice for installation of switchgear Edison screw lamp holders Code of practice for packaging of electrical I Indicating and recording instruments High voltage alternating current circuit breakers1987 Common clauses for high voltage switchgear and control gear standards. Static watt-hour meters for class 0.25 and 0.5 Static transformer operated watt-hour and VAR hour meters class 0.25 and 0.5
3.0
NORMAL SERVICE CONDITIONS :
Generally as per (1) clause 2.1(a) to 9(e) of Is 13118 Clause 2.

DEFINITIONS AND TERMINOLOGY : As per Central Electricity Supply Utility of Orissa Page 11
Ref Nos i ii IS-3427 IEC-56
Ref Clauses Clause- 2 and sub clauses there of for switch gear. Clause - 3 and sub clauses there of for circuit breakers Clause - 3 and sub clauses there of for circuit breakers Part- I to IV clause-2 &sub clauses there of for current transformers. Part -I clause-2 &sub clauses there of for voltage transformers
iii IS-13118 iv v IS-2705 IS -3516
4.0
4.1 4.1.1
DESIGN AND CONSTRUCTION: GENERAL. The Circuit breaker shall be provided with vacuum interrupters hermetically Sealed. The vacuum bottles are to be mounted in side porcelain enclosure and Placed on a sheet metal enclosure having main operating links. The mechanism is to be placed under this and connected by a link, which transmits mechanical power to circuit breaker. The entire assembly shall be mounted on an elevated structure to provide live point clearance as per IS 10118.
4.1.2 Control and relays shall be mounted in out door sheet steel KIOSK. The minimum thickness of the galvanized steel sheet shall not be less than 3.5 mm for the base and load bearing members and not less than 3.0 mm for the top cover, side sheets, doors and partitions. Galvanized Sheet steel shall be cold rolled confirming to IS 513. The panel door shall be provided with louvers and with translucent plastic covered windows directly opposite to the close/open indicating lamps and spring status indicator. The panel door shall be hinged, swing door provided with pad locking facility. Rear door shall also be hinged on one side and bolted on the other side. 4.1.3 The design and construction shall be with the following features: a) b) c) d) e) f) Compact and robust construction. Dust protected and vermin proof Safe and positive interlocks. Easy interchangeability of identically rated components Extremely reliable operation. All relays, instruments, and switches mounted on the instruments panel shall be accommodated at a height in between 0.5 to 2.0 meters from ground level in the outdoor control panel. 4.1.4 Auxiliary devices and circuits : Generally as per clause 3.2.7 of IS 3427. Central Electricity Supply Utility of Orissa Page 12 including breakers.
4.2 4.3
INTERLOCKS : Generally as per clause 3.4(e) with mechanical interlocks of IS 3427. EARTHING : Generally as per 3.5 of IS 3427. However the earthing conductor shall be of copper flat shall not be less than 25 X 6 mm. Earthing shall be suitable to receive 50 X 6 mm GI flat of station earthing in the 2 bolts of M.12 size.
4.4
SWITCHGEAR COMPONENTS: The following shall be components in the PC, VCBs. Vacuum interrupters mounted in porcelain enclosures Current transformer Instruments and protective relays selector switches Interconnections between breaker and instrument transformers Terminal connectors to receive ACSR Lynx conductor Control switches, indicating lamps, contactors and test terminal blocks Voltage transformer. Control cabling from instrument transformers secondary box to control and relay kiosk with cable glands.
4.5 4.6 4.7 4.8
GENERAL ARRANGEMENT OF COMPONENTS: Various switchgear components are to be arranged. The interconnections are in scope of supply of the tenderer. The following shall be provided in each panel as applicable a) Cubicle space heater with thermostat b) View glass for breaker position indication c) Names plates d) Danger board e) Operation counter for the breaker f) Spring charging handle
5.0 4.1
GENERAL ARRANGEMENT OF THE SWITCHGEAR PANELS: The kiosk where control equipments are housed shall be provided with a lean to drain water to the rear of the panel. The proof shall be projecting on all sides so that rain water shall not enter into the body of the panels.
4.2
The central annunciator panel shall be suitable for mounting indoor. Remote close / Trip facility shall be provided on this panel itself for remote closing /opening of individual breakers.
6.0 6.1
SWITCHGEAR RATINGS: CHARACTERISTICS :
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Rated voltage as per clauses 4.2 if IS 3427 for nominal system voltage of 11 KV Rated insulation level 28KV / 75KV peak for 11KV nominal system voltage. Rated frequency 50Hz Rated normal current 1250A for incomer /800A for feeder. Rated short time current 20 KA Rated Peak short time current,. As per clause 4.7 of IS 3427 and in conjunction with sub-clauses (e) supra. Degrees of protection. Corresponding to IP 55 of Is-12063. The temperature rise limits for the various materials shall be as per table V of IEC 694. 7.0 SWITCHGEAR COMPONENTS: Rated values of the components forming part of the meal enclosed switchgear and control gears are detailed here below individually against each component. 7.1 Circuit breakers : a) Type : vacuum b) Rated voltage 11KV rms. c) Highest system voltage 12KV rms. d) Frequency 50Hz e) Number of poles three f) Class outdoor.
g) Power frequency withstand voltage: 258KV rms. h) Impulse with stand voltage- 75KVP i) j) Rated normal current 630 A. Rated symmetrical breaking current- 25KA
k) Rated transient recovery voltage: as per clauses 4.102.2,4.102.3 of IEC 56, table II A for 12KV rated voltage. l) Rated making current peak : 50 KVA
m) Short time withstand current 25KA for 3 seconds. n) Operating sequence : As per clause 4.104 (a) of IEC 56 0-3min-co o) Rated supply voltage of opening /closing devices with operating limits. 6.1.1 Closing coil- 110V.DC to operate satisfactorily between 85 to 110 % of rated voltage. ii) Opening coil (shunt trip coil) 110V DC to operate satisfactorily between 70 to 100% of rated Voltage
p) Rated voltage of auxiliary supplies.
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i)
Space heater -AC 230V, S.Ph 50 Hz.
ii) Spring charging motor AC 230V, S.Ph 50 Hz. iii) Cubical illumination AC 230V, S.Ph. 50 Hz.
q) Method of closing and opening The breaker shall be capable of discharging the energy stored in spring. These springs should be capable of being compressed or charged by an AC motor. It should be possible to charge the springs manually by means of a spring charging handle or lever. During manual charging of the springs an electromechanical device shall be provided to prevent charging of the same by the motor. The springs should also be capable of being charged even with the breaker in the closed position so as to restore tension in the springs. Besides, there should be provision to automatically cut off power supply to the motor when the springs are fully charged and also to automatically switch on the power supply to the motor when the springs are fully discharged. There shall also be provision to indicate springs status namely FREE / Charged by means of a mechanical lever at the panel. This shall be arranged through potential free auxiliary contacts or limit switches. The mechanism shall be provided with an anti pumping device to prevent closing impulses from being transmitted, to the closing coil when the breaker is in the closed position. r) Auxiliary Contacts : 8 No+8NC conforming to clause 5.4 of IEC 694. s) Name Plates . As per clause 5.9 of IEC 56. t) Requirements for simultaneity of poles As per Clause 5.101 7.2 CURRENT TRANSFORMERS 7.2.1 The current transformers shall conform in all respects to IS 2705 parts I to IV.The arrangement of current transformers in porcelain clad switch gear is shown in sketch 1&2. 7.2.2 7.2.3 CTs shall be encapsulated resin cast or poly crate to suit outdoor instalation. CT ratio changing is preferred on Secondary side. of IEC 56.
7.2.4 Rating characteristics: a. b. c. d. e. f. Nominal voltage Highest system voltage Frequency : : : 11kV rms. 12kV rms 50 Hz. 28kV rms 75kVp 3 cores 20-10/1-1-1A Page 15
Power frequency withstand Voltage : Impulse with stand voltage Ratio and Cores : :
g.
Accuracy class- burden Core 1 (metering ) Core 2 (OCR,EFR & REFR Protection) Core 3 (differential Protection)
0.5/15VA
5 P20/15VA
: : :
PS/VK Min 300V 5 at all ratios As per clause 4.3 of IS 2705 (part-1)
h. i. j. i. ii. k. l. 7.3 7.3.1
Instrument security factor Earthing Short time current Rating Thermal rating : Dynamic rating : Terminal Marking : Rating Plate :
25 KA for 1 second As per clause 562 of IS2705 part-I As per Clause 6.2 of IS 2705 part-I As per Clause 6.1 & 7.1 of 2705
METERING INSTRUMENTS: Meters to be mounted shall conform with IS 1248 Parts (I to IX) and dimension shall conform to IS-2419.
7.3.2 All meters shall be CT/VT Secondary operated instruments and shall be flush mounted with only the bezels projection. 7.3.3 7.3.4 7.3.5 7.3.6 All meters shall be wired at the back and shall be provided with tropicalised dials, to ensure freedom from warping, iscoloration or fading. The lettering/Numbering on dials shall be in bold black on white dial background. All meters shall be magnetically shielded. All indicating analog meters shall be provided with a screw type zero adjuster for the needle with facility to operate from the front of the panel without having to remove the cover of the meter.
7.3.7 All meters shall be wired through test terminal blocks to facilitate independent calibration of meters. 7.3.8 TYPE RATING AND CHARACTERISTICS: A) AMMETER: i) One No. to be provided. The ammeter shall be provided with a selector switch to read the current in each of the phases.
ii ) Moving Iron. iii) Size 96*96 mm Iv) Accuracy.1.0 V) Scale 0 5 10 - 20 Page 16
B) Watt meter: I. II. III. IV. V. VI. One number to be provided in each panel. Type: 3 phase3 wire two element dynamometer. Size 96 X 96 mm. Accuracy class: 1.5. Range: 0-200 KWS Scale : 90 degrees and end suppressed
C) VAR Meter: I. II. III. IV. V. VI. One number to be provided in each panel. Type: 3 phase 3 wire two element dynamometer. Size 96 X 96 mm. Accuracy class: 1.5. Range: 0-200 KVAR Scale: 90 degrees and end suppressed
D) Electronic Tri vector Meter: I. One number to be provided
II. It shall be static type 3 phase, 3 wire, 2 element, suitable for 1 amp CT & 110 volts phase to phase V.T secondaries. It must be flush mounted type & tropicalised. It shall have separate registers for recording kWHr & kVAHr consumption seperately, maximum demand (with resetting facility), both for import and export modes. III. The accuracy class shall be 0.5. IV.The meter shall have legible LED/ LCD minimum 6 digit auto cycle display and non volatile memory with out battery back up. V.The meter shall have galvanically isolated optical. VI.The meter shall be capable of storing the complete half hourly data required for load analysis & energy audit for a period of 35 days VII.communication port for down loading the data to an MRI or to DCD or to a modem. VIII.The meter shall have self diagnostic feature to check its circuits for any malfunctioning. 7.4 Protective Relays: The relays to be mounted in front of the panel Electornic draw out type, suitable for 3ph, one amp CT secondary current , 110 volts ph to ph VT secondary, and 110 volts D.C. auxiliary. Central Electricity Supply Utility of Orissa Page 17
The following relays are to be provided. a) Electronic Relay: Combined unit for OCR & EFR for line side. 7.5 Control switches: 7.5.1 General : The control switch shall contain two electrically independent double break contacts and shall be moulded in a self extinguishing plastic compound with inherent arc quenching and high insulating property enclosed moulding giving a high degree of dust protection. The back of control switch is to be shrouded in transparent cover, automatic spring return to neutral switch type to be provided. The switches shall be suitable for 20 Amps continuous rating and 110V DC. 7.5.2 Requirement : a. One No. in each outgoing panel. b. One No. for each outgoing breaker in the annunciator panel for remote operation. 7.6 SELECTOR SWITCHES (FOR AMMETER AND VOLTMETERS)
7.6.1 General : These shall be slow break, quick-make, rotary type, stay put switches, and shall be suitable for flush mounting. These switches shall be suitable for being operated by flush mounting. These switches shall be suitable for being operated by a knob from the front face of the panel. They shall be suitable for 10 Amps continuous rating and 415V AC. The ammeter selector switches shall short circuit the CT secondary before it is broken and remove the short circuit after the ammeter is inserted in the circuit. All the switches shall have position indication plates 4 ways i.e., R, Y, B and OFF. 7.7 Indication lamps: 7.7.1 Indication lamps shall be integral LED module type 0.5 watts, suitable for 110 volts D.C.and these shall be integral self contained LED indicator units which can be directly mounted in the panel. The rated input voltage can be directly applied to the module input as all the controlling circuitary is built is built in to the module body it self. These modules shallbe suitable for panel cut outs of size 22.5mm dia with the use of crome plated standard mounting adopter / bezel sets and colours RED, GREEN,ABMER/YELLOW, WHITE, & BLUE. The axial light intensity should be min 40 milli candella.
7.7.2 COLOUR CODE FOR LAMPS: Breaker open Breaker Closed Auto trip Spring charged Trip Circuit Healthy : : : : : Green Red Amber Violet / Blue White Page 18
7.7.3 REQUIREMENT OF LAMPS a) One set of green, amber and red lamps in each incomer and outgoing panels along with spring status violet / Blue and trip circuit healthy white on command. b) One set of green, red, amber, violet / blue and white lamps for indicating the status of each incomer and outgoing breakers in the remote indoor annunciation panel 7.7.4 10% of the total of integral LED module type lamps for each panel shall be supplied as spare without extra cost. 7.8 FUSES: 6.8.1 GENERAL: All fuses shall be moulded bakelite complete with fuse bases, fuse carriage and HRC cartridge fuses. All fuse fittings should be labeled by etching on an anodized plate with details of the fuse rating and the circuit for which the fuse is provided. 6.8.2 RATING: i. ii. 1.8.3 AC 115V for all supply fuses. DC 110V for DC circuits
Rated Current : AS per clause 5.3 of IS 9224 (Part-I) 1979 (Preferred value of rated current 32 Amps)
6.8.4
REQUIREMENTS: All AC and DC circuits shall be provided with suitable fuses and fuse links for each phase / pole.
6.8.5
10% of the H.R.C fuse cartridge shall be supplied as spares without Extra cost.
7.9 WIRING: 7.9.1 GENERAL: The wiring shall be done by using PVC-insulated 660 V annealed, stranded Copper wire. The wires shall run straight and shall be given right angle bends wherever necessary so as to give a pleasing appearance. The size of wiring in difference circuits shall not be less than the sizes specified below: a) b) Metering and Relay circuits : 2.5 Sq.mm connection from CTs and VTs All terminal connections to the equipments and terminal blocks shall be done by using Tin coated Copper lugs. All the outgoing wiring from the panel shall be terminated on the terminal block mountd in the front of the panel with suitable provision for connection to the interconnecting control cable. The wiring shall conform to IS 375 with latest amendments if any. Central Electricity Supply Utility of Orissa Page 19
c)
All wiring shall be provided with alphanumeric ferules at either ends as per the wiring schedule.
d)
All terminals shall be nut & stub type of brass coated with Nickle of size M6.
7.10 TEST TERMINAL BLOCKS: The Test terminal blocks required are for testing while in service and shall be of the 3 phase 4 wire, front adjustable, link type, projected, mounted with screwed cover and wired at the rear, rated for 10 Amps, The wiring shall be so as to short circuit the CT phase to the star point and it shall be possible to calibrate through external injection. 7.11 Galvanising 7.11.1 All the steel frame work and surface of the steel panels shall be fully galvanized to with stand saline weather in the coastal areas. 7.11.2 Block No. shall be assigned for each compartment and the same shall be stencilized in white paint on the inside of panel. 7.12 TERMINAL PAD / CONNECTORS: The Terminal Connectors for CTs and porcelain clad breakers shall suit to receive ACSR Lynx of 10 mm dia minimum 4 bolt connection. 7.13 FOUNDATION BOLTS: Foundation bolts with 10% spares are in the scope of supply of the supplier. 7.14 AUXILARY DC SUPPLY : The auxiliary 110 V D.C. supply will be arranged from station battery panel. 7.15 AUXILIARY AC SUPPLY: The auxiliary A.C. supply at 3phase 415 volts will be arranged from the Biomass generating unit 1 & 2 7.16 INDOOR TYPE COMBINED REMOTE CONTROL & ANNUNCIATOR PANEL. 7.16.1 General: Sloping desk type / free standing panel, with audio visual annunciator facia windows on the inclined slope along with annunciator lamp test, accept and reset push buttons. All control switches in the run of the mimic bus with indicating lamps mounted on the horizontal desk. The base of the desk shall be provided with vermin proof sheet metal cover and cable gland, to receive the control cables from the outdoor panels. The annunciator shall be electromechanical.
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7.16.2 Wiring: All wiring from the outdoor panel shall be terminated on the terminal blocks inside the cubicle. The terminal block shall be Brass stud and nut type of size M6. The terminal blocks shall be of moulded resin type provided with plastic shrouds. Sufficient spare terminals shall be provided on the terminal blocks. Paint shade of annunciator panel shall be opaline green of shade No. 275 of IS 5 7.16.3 Annunication facia windows shall be with plastic facia sheet engraved with letters of 5 mm size. The inscriptions shall be visible only when the facia is lighted. The lamps shall be suitable for 110 V DC with an in built resistor. The initiation of annunciation shall be through NO-NC contracts of the relay. A hooter suitable for 110V DC shall be installed in the annunciator panel for alarms
7.16.4
REQUIREMENT OF ENGRAVING IN THE ANNUNICIATOR DESK:
i.
No. of Windows OCR R Phase operated OCR B phase operated EFR operated Deferential relay operated 1 DC fuse failure No. of windows spare Master trip relays
5 1 > 1 > Trip alarm 1 >
1 > Non Trip 1 1 1 1
ii. Breaker open indication lamp iii. Breaker close indication lamp
iv. Spring free/charged indication lamp 2 v. Breaker auto trip vi. Trip/Neutral/Close switch 1 1
8.0 TESTS: 8.1 TESTS ON SWITCH GEAR: 8.1.1 Type tests: As per clause 8.1.1 (a) to (e) and (h) and (j) of IS 3427 1969. Central Electricity Supply Utility of Orissa Page 21
8.1.2 Routine Tests: As per clause 8.12 (1), (b) & (e) of IS 3427 1969. 9.1 TESTS ON CIRCUIT BREAKERS: 9.1.1 TYPE TESTS: As per clause 6.0 of IS 13118. 9.1.2 ROUTINE TEST: As per clause 7.0 of IS 13118. 9.2 9.2.1 TEST ON CURRENT TRANSFORMERS : TYPE TEST : a) As per clause 7.1.1(a) to (h) of IS 2705 (Part-I)-1981. e) f) g) h) 9.3.1 TYPE TESTS: i) As per clause 6.1.1 of IS 3156(part-1)-1978. a. b. i) As per clause 8.1 of IS 3156(part-II), 1978. As per clause 9.1 of IS 3156(part-III)-1978. As per clause 8.1 of IS 2705 (Part-II)- 1981. As per clause 8.2 of IS 2705(Part-III)-1981. As per clause 8.3 of IS 2705(Part-III)-1981. As per clause 6 of IS 2705(Part-iv).
9.3 TEST ON VOLTAGE TRANSFORMERS :
9.3.2 ROUTINE TESTS: As per clause 8.1.2 of IS 3156(part-I)-1978. ii) As per clause 8.2 of IS 3156(part-II- 1978. As perclause 9.2 of IS 3156(part-III)-1978. 9.4 TESTS ON RELAYS: 9.4.1 Type tests and routine tests as per IS 3231 and IEC 255 shall be conducted. 9.4.2 TYPE TESTS: Type test reports not older than 5 years on the date of bid opening, pertaining to all type tests stipulated in IS 3231 and other tests conducted shall be furnished along with the bid document. 9.4.3 All routine tests shall be carried out in the presence of the owners representative for which sufficient advance intimation shall be given. 9.5 10.0 All instruments, relay, and other components shall be provided with name plates at their rear and shall be supplied separately as dissembled components. INDOOR COMBINED ANNOUNCIATOR AND REMOTE CONTROL PANEL: a) Control Switch.---- one number for each breaker. Central Electricity Supply Utility of Orissa Page 22
b) Indicating lamps.--- one set of the following for each breaker. I. Green. II. Red. III. Amber. IV. Violet. /Blue. V. White c) Fuse.------------------- one No. d) Bell.-------------------- one No. e) Hooter .---------------- one No. f) Electromechanical announciator relay. g) Push button i. Accept,--- one No. ii Reset.---- one No. iii Lamp test.-- one No. iv Hooter test.--- one No
Page 23
Section-III 11kV UG Cable
Page 24
TECHNICAL SPECIFICATIONS FOR 11KV, XLPE INSULATED UG CABLE 1.0 SCOPE :

1.1 The scope of this specification covers the design, manufacture, stage inspection at works, inspection and testing the finished cables 6.35 /11KV aluminum conductor. Three Core, 400 mm, XLPE insulated screened, underground cables at manufacturers works.
2.0 RATED VOLTAGE

2.1 The rated voltage of the cable shall be 11000 Volts AC with the highest system voltage of 12000 Volts between phases of the effectively earthed three phase-distribution system.
3.0 APPLICABLE STANDARDS:

3.1 Unless otherwise stipulated in the specifications, the latest version of the following Standards shall be applicable. a. IS 8130 Conductors for Insulated electrical cables and flexible cords b. IS 10810 (series) Methods of tests for cables c. IS 10418 Drums for electrical cables. d. IS 7098 (Part 2) Cross linked Polyethylene Insulation for Cables. e. IS 3975 Specification for mild steel wires, strips and tapes for armoring of cables. f. IS 5831 Specification for PVC insulation sheath for electric cables. Dimensions of protective coverings of cables Part 1 Elastomeric and thermoplastic insulated cables. 3.2 The Cables manufactured to any other Internal Standards like BSS, IEC or equivalent standards not less stringent than Indian Standards are also acceptable. In such cases, the Bidders shall enclose a copy of the equivalent international standard, in English language, along with the bid.
4.0 CONSTRUCTION:
4.1 Conductor :- The conductor shall be composed of compacted circular aluminum wires complying with IS 8130. 4.2 Insulation : - The insulation shall be cross linked polyethylene conforming to the following requirements.
Sl.NO.
1. 2.
Properties
Tensile Strength Elongation to break Aging in air oven : Treatment : Temperature Duration Tensile Strength variation : Elongation variation: Hot set : a) Treatment : Temperature: Time under load Mechanical stress
Requirements
12.5N/mm2, Min. 200 percent, Min
3.
135+_30 C 7 Days
+ 25 percent, Max + 25 percent, Max 200 + 30 C 15 min 20N/cm2
4.
Page 25
b) Elongation under load

175 percent, Max
c) Permanent elongation (set) after cooling

15 percent, Max
5.
Shrinkage: a) Treatment : Temperature Duration
130+ 30 C 1 hour 4 percent, Max
b) Shrinkage 6.
Water absorption (Gavin metric) :
a) Treatment : Temperature Duration b) Water absorbed
85+ 20 C 14 days 1 mg / cm2, Max
7.
Volume Resistivity a) at 270 C b) at 700 C
1 x 1014 ohm-cm, Min 1 x 1013 ohm-cm, Min
4.3 The screening shall consist of non-metallic semi conducting compound and copper tape, shielded cores laid up with fillers, inner sheath of extruded PVC, Galvanized steel strip Amour and PVC ST-2 overall sheath. 4.4 The cables should be suitable for use in solidly earthed system. 4.5 The 6.35/11KV underground cables shall be manufactured to the highest quality, best workmanship with scientific material management and quality control. The bidder shall furnish the quality plan, giving in detail the quality control procedure / management system. 4.6 The successful Bidder shall give sufficient advance notice to the purchaser of not less than fifteen days to arrange for stage inspection and inspection of quality assurance program during manufacture, at the works.
5.0 SYSTEM DETAILS General Technical particulars General Technical particulars Sl No Particulars 1 Nominal system voltage (rms) (U) 2 Highest system voltage (rms) (Um) 3 Phase to Earth voltage (rms) (U0) 4 Number of Phase 5 Frequency 6 Variation in Frequency 7 Type of Earthing 8 Basic impulse insulation level (1.2/50 S wave) 9 Total relay & circuit breaker Operating time 10 One Minutes power frequency withstand voltage
Values 11KV 12KV 6.35 KV 3 50Hz + / - 3% Solidly Earthed 75 KV 15-20 cycles 28 KV rms
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6.0 INSTALLATION CONDITIONS :

6.1 The cables are laid directly buried in ground, in the bores formed by horizontal boring method. The Nominal depth of laying is up to 2000 mm (from top, of ground to centre of cable).However, in trenchless horizontal bore method, the bore can go upto a depth of a maximum of 2 meter. Nature of soil is heterogeneous, sandy, Soil resistivity varies between 18 to 100 ohmmeter and the Thermal resistivity is around 1200 to 1500 C/ Cm/w.
7.0 CLIMATIC CONDITIONS :

7.1 The climatic conditions where these 11KV cables will be installed are as under : Climatic conditions Sl No Particulars 1 Location: 2 Altitude 3 4 5 6 7 8 9 Max Daily average air temp : Minimum ambient air temp : Ground temperature at depth of laying assumed : Isoceraunic level Avg. annual rainfall : Avg. number of rainy days per annum: Climate:
Details Cuttack, Orissa As is coastal area, altitude will Not exceed 100 M above MSL. 45 0 C 10 0 C 350 (Max) 50 C (Min) 45 2500 mm 90 Tropical moderately hot and humid. likelihood of subsoil water at certain location at the depth of burial of cables.. Normally wet
10
Soil :
8.0 DESIGN CRITERIA :

8.1 The cables that are covered in these specifications are intended for use in the Coastal belt of state of Orissa for Power distribution purposes, under the climatic conditions and installation conditions described in the technical specification. 8.2 Any technical features, not specifically mentioned here, but is necessary, for the good performance of the product, shall be incorporated in the design. Such features shall be clearly brought out under Technical deviations schedules only, in the offer made by the bidder, giving technical reasons, and justifying the need to incorporate these features. 8.3 For continuous operation of the cables, at specified rating, the maximum conductor temperature shall be limited to the permissible value as per the relevant standard, generally not exceeding 90 C under normal operation and 250 C under short-circuit conditions. 8.4 The cables in service will be subject to daily load cycles, of two peaks during a day; morning peak and evening peak, with around 50% loading during the nights. 8.5 The materials used for outer sheaths shall be resistant to oils, acids and alkalis. 8.6 The cables shall have the mechanical strength required, during handling and laying. 8.7 The cables shall be designed to withstand the thermo-mechanical forces and electrical stresses during normal operation and transient conditions. 8.8 The cables shall be designed to have a minimum useful life span of Thirty years.
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9.0 MANUFACTURE PROCESS:

9.1 Cross-linking of the insulation materials (pre compounded polyethylene) shall be conforming to IS :7098 (Part-II) 9.2 The conductor screen shall be extruded semi conducting compound. The insulation screen shall consist of the nonmetallic part, extrude semi conducting compound with non-magnetic metallic part. The XLPE insulation and the shield for conductor and insulation shall be extruded in one operation.
10.0
MATERIALS
10.1 Conductor: - The conductor shall be of standard construction. The material for conductor shall consist of the plain aluminum of H2 or H4 grade as per clause 3 of IS 8130 / 1984. 10.2 The Number of wires in the conductor, shall be not less than the appropriate minimum number given in table 2 of IS 8130 / 1984.
11.0
SCREENING :
11.1 The conductor screening shall be provided over the conductor by applying non-metallic semi-conducting compound. The metallic screen shall withstand the operating temperature of the cable and shall be compatible with the insulating material. 11.2 The insulation screen shall be applied over the insulation. The insulation screening shall consist of two parts; namely metallic and non-metallic. The non-metallic part shall be applied directly over the insulation of each core and shall consist of a semi conducting tape and extruded semi conducting compound with a semi conducting coating. The metallic part of the insulation screen shall consist of either tape, or braid, or concentric serving of wires or a sheath; shall be non-magnetic and shall be applied over the non-metallic part.
12.0
CORE IDENTIFICATION:
12.1 The core identification for 3 core cables shall be provided, by suitable means, like, by application of colored stripes, or by numerals or by printing on the cores as per clause 13 of IS : 7098 Part 2. 12.2 For identification of different coloring of XLPE insulation, or by using colored strips, red, yellow and blue colors respectively shall be used to identify the phase conductors.
13.0
LAYING UP OF CORES:
13.1 For multicore cables, the cores shall be laid together with a suitable right hand lay. The interstices at the center shall be filled with a non-hygroscopic material.
14.0
INNER SHEATH (COMMON COVERING)

14.1 The laid up cores shall be provided with inner sheath applied either by extrusion or bv wrapping. It shall be ensured that the shape is as circular as possible. The inner sheath shall be so applied that it fits closely on the laid up cores and it shall be possible to remove it without damage to the insulation. 14.2 The thickness of the inner sheath (common covering) shall be given as follows: Calculated diameter over laid up cores in accordance With 15.3 of IS 10462 (Part 1) (mm) Thickness of inner sheath (mm)
Over 25
Up to and including 25 35
0.3 0.4
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35 45 55
45 55 -
0.5 0.6 0.7
When one or more layers of binder tapes are applied over the laid up cores, the thickness of such tapes shall not be construed as a part of inner sheath. 14.3 For multi core cables, the interstices at the center shall be filled with a non-hygroscopic material. The interstices around the laid up cores shall be covered with PVC compound type ST-2. This will form the Inner sheath for multi core-single core cables.
15.0
ARMOURING:
15.1 Armoring shall be applied over the inner sheath as closely as practicable. The Amour shall be galvanized steel strip complying with the requirements of IS 3975. A binder tape may be applied on the Amour. The direction of the lay of the amour shall be left hand. For double armored cables, this requirement applies to the inner layer. The outer layer shall be applied in the reverse direction to the inner layer, and there should be a separator of the non hygroscopic material; such as plastic tape, bituminized cotton tape, rubber tape, proofed tape between inner and outer layers of Amour. 15.2 The dimensions of galvanized steel strips shall be as below: Calculated diameter over Amour [IS 10462 Part 1] (mm)
Nominal thickness of Steel Strip(mm)
Over Upto and including 13 13 25 0.8 25 40 0.8 40 55 1.4 55 70 1.4 70 1.4 15.3 The joints in the strips shall be made by brazing or welding and the surface irregularities removed. A joint in the strips shall not be less than 300 mm away from the nearest joint in any other strip in the completed cable. 15.4 Bidders shall furnish the calculation / data sheet for the short circuit carrying capability of the Armour.
16.0
OUTER SHEATH :
16.1 The outer sheath over the Armoring shall consist of poly vinyl chloride (PVC) compound, conforming to the requirements of type ST-2 of IS 5831. Suitable additives shall be added to give anti termite protection. 16.2 The minimum thickness of the PVC outer sheath shall not fall below the following value by more than 0.2 mm + 0.2 ts Nominal thickness of the Outer sheath (ts) - mm 1.8 2 Page 29
Calculated diameter under the outer sheath [IS 10462 Part 1] - mm Over 15 Upto and including 15 25
25 35 40 45 50 55 60 65 70 75
35 40 45 50 55 60 65 70 75 -
2.2 2,4 2.6 2.8 3 3.2 3.4 3.6 3.8 4
17.0
IDENTIFICATION :
17.1 The outer sheath shall have the following information embossed or indented on it; the manufacturers name or trade mark, the voltage grade, the year of manufacture and the letters CESU. The identification shall repeat every 300/350-mm along the length of the cable. 17.2 Note: The outer sheath of the cable should be embossed withCESU.
18.0
INSPECTION AND QUALITY CONTROL :

18.1 The Bidder shall furnish a complete and detailed quality plan for the manufacturing process of the cable. All raw materials shall conform to relevant applicable standards and tested for compliance to quality and requirement. During the manufacturing process, at all stages, inspections shall be made to check the physical and dimensional parameters, for verification to compliance to the standards. The bidder shall arrange, for inspection by the purchaser, during manufacture, if so desired by the purchaser, to verify the quality control process of the Bidder.
19.0
TYPE TESTS :
19.1 The offered cables with same designs shall have been type tested and Test certificates shall not be later than 5 years on the date of bid opening. Otherwise the supplier / Turnkey contractor shall arrange for type testing at his own cost.. The supplier /Turn Key contractor shall conduct all type tests as per IS : 7098 part-II 1985, with up to date amendments or equivalent International standard, and supplies made only after approval of test reports from the purchaser. 19.2 All type tests if required, routine; acceptance test shall be conducted in the presence of the purchaser / representative. 19.3 The supplier shall give 15 days advance notice for inspections, and witnessing of tests by the purchaser or his representative. 19.4 The following type tests will be conducted on the cable if the type test certificates are more than 5 years old (a) Test on conductor. (b) Test on Amour. (c) Test for thickness of XLPE insulation and inner and outer sheaths (d) Physical test on XLPE insulation.
Page 30
(e) (f) (g) (h) (i)
Physical test for outer sheath Bleeding and blooming test for outer sheath Partial discharge test. Bending test Di-electric power factor test i. As a function of voltage As a function of temperature (j) Insulation resistance (volume resistivity) test (k) Heating cycle test (l) Impulse withstand test (m) High voltage test (n) Flammability test
19.5 The following test shall be performed successfully on the same test sample of completed cable, not less than 10 M in length between the test accessories: I. Partial discharge test II. Bending test followed by partial discharge test III. Dielectric power factor as a function of voltage. IV. Dielectric power factor as a function of temperature V. Heating cycle test, followed by dielectric power factor as a function of voltage and partial discharge tests. VI. Impulse withstand test VII. High voltage test.
20.0
ACCEPTANCE TEST:
20.1 20.2 The sampling plan for acceptance test shall be as per IS 7098 part-II, Appendix A The following shall constitute the acceptance test. a) Tensile test for aluminum b) Wrapping test for aluminum c) Conductor resistance test d) Test for thickness of insulation e) Test for thickness of inner and other sheath f) Hot-set test for insulation g) Tensile strength and elongation at break test for insulation and outer sheath. h) Partial discharge test (on full drum length). i) High voltage test. j) Insulation resistance (volume resistivity test).
21.0
ROUTINE TEST :
21.1 The following shall constitute routine tests : a) The following shall constitute routine tests: b) Conductor resistance test c) Partial discharge test on full drum length d) High voltage test.
22.0
PACKING :
22.1 The cables, as per specified delivery lengths, shall be securely wound /packed in nonreturnable, well seasoned sturdy wooden drums, with strong reinforcement so as so to
Page 31
withstand rough handling during transport by rail, Roads etc., The packing should withstand storage conditional in open yards. The cable drums shall conform to IS 10418 1982 or equivalent standard. 22.2 The drawings of the cable drums with full detail shall be furnished, and got approved before dispatch.
23.0
SEALING OF CABLE ENDS ON DRUMS :

23.1 The cable ends shall be sealed properly so that Ingress of moisture is completely prevented. The individual core endings shall be sealed effectively with water resistant compound applied over the core ad provided with a heat shrinkable or push-on or Tapex or cold shrinkable type cap of sufficient length with adequate cushion space so that the conductor does not puncture the cap in case of movement of the core during unwinding or laying. Before sealing, the semi conducting layer on the cores may be removed for about 2 mm at each end, to facilitate checking the insulation resistance from one end, without removing the sealing cap at the other end. 23.2 The three cores should have an overall heat shrinkable or push-on or Tapex or cold shrinkable type cap with adequate end clearance, and sufficient cushioning to prevent puncturing of the overall sealing cap due to stretching of the cores. The sealing cap shall have sufficient mechanical strength and shall prevent ingress of moisture into the cable. The ends of single core cable shall also be sealed on the same lines to prevent entry of moisture.
24.0
CABLE LENGTHS :
24.1 The cables shall be supplied in continuous lengths of 250M in case of 3 core cable with tolerance of + or 5% of drum length. It is preferable to manufacture the cable to required lengths as required by the field conditions to have minimum joints. The turn key contractor will furnish the required drum lengths in advance
25.0
QUANTITY TOLERANCE
A +3% tolerance shall be allowed on the ordered quantity.
26.0
MARKING:
26.1 The packed cable drum shall carry the following information, clearly painted or stenciled a) The letters CESU b) Reference to Standard and ISI mark c) Manufacturers Name or trade mark. d) Type of cable & voltage grade e) Number of cores f) Nominal cross-sectional area of conductor. g) Cable code h) Length of cable on the drum i) Direction of rotation j) Gross weight k) Country of Manufacture l) Year of Manufacture
Page 32
m) Purchase order and date n) Address of consignee
27.0
GUARANTEED TECHNICAL PARTICULARS:

Guaranteed technical particulars of the cables to be furnished with the Bid are enclosed.
28.0
DRAWING & LITERATURE

28.1 The following shall be furnished along with the tender a) Cross sectional drawings of the cables, giving dimensional details for each size of cable. b) An illustrated literature on the cable, giving technical technical information, on current ratings, cable constants, short circuit ratings, derating factors, for different types of installation, packing date, weights and other relevant information.
Page 33
GURANTEED TECHNICAL PARTICULARS TO BE FURNISHED BY THE BIDDER

1. CABLES a) Manufacturer b) Trade Name 2. Type of Cable 3. Applicable specification & Standards 4. Voltage Class 5. Whether suitable for extrusion technique is employed in the manufacture of conductor screen 6. Whether triple extrusion technique is employed in the manufacture of conductor screen 7. Permissible voltage and frequency variation for satisfactory operation 8. Continuous Current Rating for standard conditions indicated in specifications: c) Air (450 C Ambient) d) In Ground (350 C) e) In Duct f) In Trench 9. De-rating factors for various laying conditions 10. Conductor a) Material b) Shape of conductor c) Nominal area of cross section d) Number of strands per core e) Diameter of Wire (before compacting and stranding) f) Diameter and size of conductor 11. Conductor Screening a) Type b) Material c) Nominal thickness d) Continuos working temperature e) Maximum allowable temperature at the termination of short circuit 12. Insulation a) Material b) Thickness of Insulation c) Thickness of Insulation between cores d) Thickness of Insulation between cores and inner sheath e) Tolerance of thickness in insulation f) Diameter of core over insulation 13. Specific Insulation Resistance at 900C 14. Process of curing 15. Whether XLPE Insulation filled or unfilled 16. Insulation Screening: a) Material Thickness b) Thickness of semi conducting part c) Thickness of metallic part d) Size of copper tape e) Whether overlapping provided Page 34
f) Current carrying capacity for continuous rating g) Current carrying capacity for short circuit rating for 1 minutes h) Diameter of cable over screening i) Whether insulation screen is removable without the application of heat 17. Inner Sheath a) Material b) Extruded c) Minimum thickness d) Diameter of cable over inner sheath 18. Armouring: a) Material b) Type of Armouring c) Diameter of wire d) Whether galvanized e) Diameter of cable over Armouring f) Current carrying capacity of Armor 19. Outer Sheath: a) Material b) Minimum thickness of sheath c) Tolerance over thickness of sheath d) Overall diameter of cable 20. Scheme for identification of cable 21. Allowable/attainable maximum conductor temperature when carrying rated current continuously 22. Cable constants: a) DC Resistance per core 200 C b) AC Resistance per core at operating temperature c) Reactance d) Capacitance e) Insulation Resistance at 270C f) Loss tangent g) Dielectric constant Maximum cable charging current at normal operating voltage 23. Factory Tests (Enumerate in detail for each type of cable) 24. Is the offered cable guaranteed to safely withstand continuous conductor temperature at 900C and also safely withstand temperature upto 1300C for a duration of one hundred hours per year. 25. Are the offered Three core cable guaranteed to perform satisfactorily under installation conditions specified? If Yes furnish relevant calculations in support including the following data: a) Induced voltage in the Amour when a 500 mtr long cable is carrying current b) Induced voltage and the circulating current in the copper tape
Page 35
Section-IV HT cable joints and terminals
Page 36
TECHNICAL SPECIFICATIONS FOR HEAT SHRINKABLE CABLE JOINT KITS FOR CABLE TERMINATIONS AND JOINTS 1.0 GENERAL: 1.1. he term heat shrink refers to extruded or moulded polymeric materials which are cross linked to develop elastic memory and supplied in expanded or deformed size or shape. 2.0 QUALIFYING EXPERIENCE: 2.1. The kits should have satisfactory performance record in India in excess of 5 years supported with proof of customers having had satisfactory use of these kits in excess of 5 years. 3.0 HEAT SHRINKABLE MATERIAL: 3.1. The heat shrinkable material component used in the joint shall have been produced in a systematic procedure as follows: a) The required materials shall be mixed and extruded into the required shape and then crosslinked by irradiation or any other appropriate chemical process. The components are then warmed and stretched by a predetermined amount and allowed to cool in the extruded shape. The cross-linking shall create a memory and when heated again, the same shall come back to its original shape at which it was cross-linked. Heat shrinkable tubes can be reduced to 30% of its expanded dimension by heating. b) The volume resistivity of the sleeves shall be 108 ohm-cm and the dielectric constant of around 15 to 30. The limiting temperature shall not be less than 100 C for longer duration and 250 C for one minute. 4.0 TYPE TEST REPORTS: The Joints and terminations should have been subjected to all the type tests and type test reports not later than 5 years on the day of Bid opening shall be furnished for verification. 5.0 ELECTRICAL CLEARANCES: The electrical clearances required for a Indoor/Outdoor termination and a straight through joint is shall be as per standards 6.0 COMPRESSION TYPE TUBULAR TERMINAL ENDS: The materials used in the terminals shall be Aluminum of grade 19501 conforming to IS 5082 - Specifications for wrought aluminum and aluminum alloys bars, rods, tubes and sections for electrical purposes. The finish inside the barrel shall either be suitably roughened throughout the crimping length of terminal end or provided with suitable grease based compound with abrasive action. Edges and corners shall be free from burrs and sharp edges. The terminals shall meet the requirements of IS 8309 - Specification for Compression type tubular terminal ends for aluminum conductors of insulated cables.
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7.0 JOINT KITS: The requirements contained in a typical joint Kit are as follows: a) Heat shrinkable or push-on or Tapex or cold shrinkable type clear insulating tubes b) Stress control tubing where necessary c) Ferrule insulating tubing for joints. d) Conductive cable break outs for terminations, non tracking, erosion and e) Weather resistant tubing both outer / inner f) Non tracking erosions and weather resistant outdoor sheds in case of terminations g) High permittivity mastic wedge Insulating mastic. h) Aluminum crimping lugs of ISI specification. i) j) l) Tinned copper braids Wrap around mechanical protection for joints. Plumbing metal. and test conditions. The kit shall contain a leaflet consisting of detailed installation instructions and shall be properly packed with shelf life of over 3 years.
k) Cleaning solvents, abrasive strips. m) Binding wire etc. adequate in quantity and dimensions to meet the service
Page 38
ANNEXURE - I SPECIFICATIONS FOR MATERIAL PROPERTIES AND OTHER TECHNICAL REQUIREMENTS FOR HEAT SHRINKABLE CABLE TERMINATIONS AND JOINTS SUITABLE FOR 11 kV SCREENED CABLES/XLPE CABLES 1.0 GENERAL: The term heat shrink refers to extruded or moulded polymeric materials which are cross linked to develop elastic memory and supplied in expanded or deformed size or shape. The subsequent heating results in shrinking down to original size and shape. The manufacturer of kits besides stating the properties of each component of the kit as indicated below and as per the detailed specifications given in Enclosures-I(A), I(B) & I(C) should also state the source of origin of each component viz; whether locally manufactured or imported in raw material form and processed. The manufacturing activity carried out on each component should be stated. Also, in case the kit is assembled with components imported from two or more foreign suppliers, the manufacturers should give documentary proof supported by the foreign manufacturers confirming that the kit assembled utilizing components of different suppliers are guaranteed by them. 2.0 QUALIFYING EXPERIENCE: The kits should have satisfactory performance record in India in excess of 5 years supported with proof of customers having had satisfactory use of these kits in excess of 5 years. 3.0 PERFORMANCE TESTING AT CPRI or any other authorized Govt.Laboratory. The successful contractor/bidder should undertake the testing of termination and jointing kits at Lab in the presence of CESU Engineers as per the performance type test sequence given below. For this purpose, the kit shall be selected by CESU Engineers in the manufacturers premises and sealed by the Engineer before taking it to Lab.
Typical atmospheric conditions during the tests SL No. 1 Amb. Temperature Particulars Details Maximum 450 C Minimum 100 C 2 3 Atmospheric pressure Relative Humidity 963 to 987 m. bar 50 90 %
Page 39
Test sequence
Sl No Test Sequence Test Voltage Test results shall be as follows
Impact a wedge shaped weight of 4 kg having a 90
angle with a 2 mm radius shall be dropped freely 6 times from a height of 2.0M. On to the sample. The drops shall be distributed over the length of the joint and at right angles to the axis of the joint,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,,, .(Electricity Council Engg.C.81) AC voltage withstand (IEC Pub 60) 1 min 35 kV
No visual damage
Shall withstand satisfactorily
Indoor -75 kV 10 positive and 10 negative 1.2/50 micro seconds between each conductor & the grounded sheath or screen
Impulse voltage withstand test (IEC Pub 60 & 230)
-doOutdoor95 kV
Load Cycling
63 cycles, 5 hrs heating, 3hrs cooling conductor temperature
15 kV
-do-
screened : 75 C
Thermal short circuit
1 Sec. symmetrical fault with sheath temp. as per cable Spec. Repeat 4 hrs 15 kV 24 kV Indoor -75 kV
-do-
6 7
Load Cycling A/C voltage withstand
-do-do-
Impulse voltage withstand
Repeat Outdoor95 kV
-do-
D/C voltage withstand
30 Min. Conductivity 800 S/Cm., 100 hrs spray rate 0.41/Cu. M/h
48 kV
-do-
10
Humidity indoor termination
7.5 kV
-do-
Page 40
11 12
Dynamic short circuit (VDE 0278) Salt frog outdoor terminations
63 kA 224 Kg/m 7.5 kV
-do-do-
ENCLOSURE I (A) MATERIAL SPECIFICATION FOR HEAT SHRINKABLE TUBING Test Test Method Requirement Ferrule insulating tubing
Non-Tracking Tubing
Stress Control Tubing

14 N/mm Min. 250 % Min.
Clear insulating tubing

12 N/mm Min. 200 % Min.
Inner Outer tubing for Joint

14 MPa Min. 500 % Min.
Tensile Strength Ultimate Elongation Accelerate d Ageing 168 Hrs. at 120C Tensile Strength Ultimate Elongation Thermal Endurance Electric Strength
ISO 37
8 N/mm Min. 300 % Min.
10 N/mm Min. 300 % Min.
ISO 37
ISO 188
ISO 37 Min. ISO 37 IEC 216
7.5 N/mm Min. 200 % Min. 110 C Min. Wall Elec. Thkn. Strn. (Normal) KV/CM
13 N/mm Min. 130 % Min. 90 C Min.
10 N/mm Min. 300 % Min. 105 C Min. Wall Elec. Thkn. Strn. (Normal) KV/CM
12 N/mm Min. 200 % Min. 110 C Min. Wall Elec. Thkn. Strn. (Normal) KV/CM
14 MPa Min. 300 % Min. 120 C Min. 100 kV/CM Min.
IEC 243
3.0 mm.
Volume Resitivity IEC 93
100 Min.
5 10 OHM-CM Min.
3.0 mm.
100 Min.
*1.3 100 mm. Min.

1 10 OHMCM Min. 1 10 OHM-CM Min.
1 10 OHM-CM Min.
1 10 OHM-CM Min.
Dielectric Tracking and erosion resistance
IEC 250 ASTM D2303
5.0 Max. No tracking erosion to top surface or flame failure after: 1 HR at 2.5 kV 1 HR at 2.75 kV 1 HR at 3.0 kV
15.0 Min. -
5.0 Max.
3.5 Max.
5.0 Max.
KA 3C
KA 1
Page 41
20 Mins at 3.25kV
Water absorption
ISO/R 62 Procedure A
1 % Max. AFT. 14 days at (23 2)C
1 % Max. AFT. 14 days at (23 2) C
1 % Max. AFT. 14 days at (23 2)C
0.5 % Max. AFT. 14 days at (23 2) C
0.2 % Max. AFT. 14 days at (23 2) C
Resistance to liquids Transformer oil to VDE 0370 immersion & days at (23 2)C Tensile Strength
ISO 1817
5 N/mm Min. ISO 37
13 N/mm Min. 250 % Min.
7.5 N/mm Min.
14 MPa Min.
-Ultimate Elongation
ISO 37
250 % Min.
250 % Min.
300 % Min.
MATERIAL SPECIFICATION FOR HEAT SHRINKABLE MOULDED PARTS Requirement Sl No Test Test Method Sheds 1 2 3 Tensile Strength Ultimate Elongation Accelerated Ageing 168 Hrs. at 120C Tensile Strength ISO 37 ISO 37 ISO 188 9 N/mm Minimum. 150 % Minimum. 105C Minimum. 8 N/mm 300 % Minimum. Conductive Break-outs 9 N/mm 230%
ISO 37
7.5 N/mm Minimum. 200 % Minimum. 110C Minimum. Wall Elec. Thkn. Strn. (Normal) KV/CM <3.0 100 mm. Minimum.
Ultimate Elongation
ISO 37
Thermal Endurance
IEC 216
Electric Strength
IEC 243
Volume Resistivity
IEC 93
1 10 OHM-CM Minimum.
200 OHM-CM Max.
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Dielectric constant
IEC 250
5.0 Maximum. No tracking erosion to top surface or flame failure after: 1 HR at 2.5 kV 1 HR at 2.75 kV 1 HR at 3.0 kV 20 Mins. at 3.25 kV 1 % Max. AFTER. 14 days at (23 2) C
10
Tracking and erosion resistance
ASTM D2303
11 12
Water absorption Resistance to liquids
ISO/R 62 Procedure A ISO 1817
1 % Max. AFTER. 14 days at (23 2)C
13
Transformer oil to VDE 0370 immersion & days at (23 2) C 7.5 N/mm Minimum. 150 % Minimum.
Tensile Strength 14 Ultimate Elongation
ISO 37 ISO 37
5 N/mm
Minimum.
250 % Minimum.
ENCLOSURE- I(C) MATERIAL SPECIFICATION FOR HEAT SHRINKABLE ADHESIVE/SEALANTS Requirement Test Test Method Black Insulator Mastic Sealant break-out and sheds
Softening Point Electric Strength
ASTM E28
(115 10) C
IEC 243
130 kV/CM Min.
80 kV/CM Min.
Volume resistivity
IEC 93
1 10 OHM-CM
Min. 1 % Max. AFT. 1 day Water absorption ISO/R 62 Procedure A
1 % Max. AFT. 1 day at
at (23 2) C
(23 2) C
Corrosive effect 16 Hrs.
ASTM D2671 Method-B
No corrosion
Page 43
at 121 C
Adhesive peel strength substrate 2/1 NTR/ NTR NTR/ CON NTR/ AL NTR/ Pb
as detailed in master Spec.
Below- 30 C
25N/25 mm Min. 20N/25 mm Min. 20N/25 mm Min. 20N/25 mm Min. No tracking erosion to top surface or flame failure after : 1 HR at 2.0 kV 1 HR at 2.5 kV 1 HR at 2.75 kV
T.E.R.T
ASTM D2303
ANNEXURE I(D) CLASSIFICATION OF SOIL STRATA 1.00 Ordinary Soil: This shall comprise of vegetable or organic soil, turf, sand, sandy soil, silt, loam, clay, mud, red earth, suade, peat, black cotton soil, soft shale, loose murrum, mud debris, concrete below ground level, a mixture of all these and similar material which yields to the ordinary application of pick, shovel, rake or other ordinary digging implement. Removal of gravel or any other modular material having diameter in any one direction not exceeding 75 mm, such occurring strata shall be deemed to be covered under this category. 2.00 Hard Soil: This shall include : 1) Stiff heavy clay, hard shale or compact murrum requiring grifting tool or pick or both and shovel closely applied. 2) Gravel, soft laterite, kankar and cobble stone having maximum diameter in any one direction between 75 mm and 300 mm. 3) Soliding of road paths, etc., and hard core. Central Electricity Supply Utility of Orissa Page 44
4) Macadam surfaces such as water bound and bitumen/tar bound. 5) Lime concrete, stone masonry in lime/cement mortar below ground level. 6) Soft conglomerate, where the stones may be detached from the matrix with picks.
7)
Generally any material which requires the close application of picks or sacrifiers to loosen and not affording resistance to digging greater than hardest of any soil mentioned in item (1) to (6) above.
3.00
Ordinary Rock: 1) Ordinary rock comprising of lime stone, sand stone, hard laterite, fissured rock, conglomerate or other soft or disintegrated rock which may be quarried or split with crow bars. 2) Unreinforced cement concrete which may be broken up with crow bars or picks and stone masonry in cement mortar below ground level. 3) Boulders which do not require blasting having maximum diameter in any direction of more than 300 mm found lying loose on the surface or embedded in river bed, soil, talus slope wash and terrace material of dissimilar origin. NOTE : Hard laterite does not require blasting. It is to be classified under ordinary rock which does not require blasting.
4.00
Hard Rock: This shall comprise: 1) Any rock or cement concrete or RCC for the excavation of which the use of mechanical plant or blasting is required.
Section-V Cable Laying Methodology
Page 45
CABLE LAYING
1.0.
Notwithstanding anything stated in these specifications, CESU reserves the right to assess the bidders capability to fulfill the scope of the bid, should the circumstances warrant such assessment.
2.0. DESIGN WORKMANSHIP AND INTERPRETATION OF CLAUSES :

2.1 The design and quality of goods supplied and the workmanship shall be in accordance with the best engineering practice to ensure satisfactory performance of the system throughout the service life. 2.2 The goods and accessories offered shall be complete in all respects. Any material and / or component thought not specifically stated in this specification but is necessary for trouble free and successful operation shall be deemed to be included. components, accessories, etc., shall be supplied at no extra cost. All such
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2.3
The goods supplied shall be such that components, accessories of the same type shall be interchangeable. Likewise similar or corresponding parts, components / accessories shall also be interchangeable.
2.4
Wherever and whenever a material or article is specified or described by the name of a particular brand, manufacturer, vendor, the specific item mentioned shall be understood as establishing type, function, quality and not as limiting competition. However bidders may offer other similar components / accessories provided they meet with the required standards, design, duties and performance.
2.5
Goods and accessories so offered shall conform to type test and shall also be subjected to acceptance and routine tests in accordance with the requirements stipulated in this specification. The CESU reserves the right for repeating any or all of the type tests to be conducted on the goods supplied.
3.0.
STANDARDS
3.1. Except as modified by this specification all materials to be supplied shall conform to the requirements of the latest editions of the following standards: a) b) c) d) e) f) g) h) i) j) IS 1255 Code of practice for Installation and maintenance of power cables up to 33kV and including 11 KV rating IS 7098 (Part 2 ) Cross linked Polyethylene PVC sheathed cables. IEC 332 Tests on erected cables IEC 1329 Allied steel, tubes, tubular and other rough iron fittings. IEC 2629 Recommended practice for hot dip galvanizing of iron & steel. ASTM-D : 2671 Standard method of testing heat shrinkable or push on Tapex or cold type tubing for electrical use. ASTM-D 3111 Flexibility determination of hot melt adhesives by mandrel bend test method. IEC 60 High Voltage test IS 3043 Code of practice for Earthing IS 8309 Compression type tubular terminals for aluminum conductors of cable. insulated
4.0. DEVIATION IN SPECIFICATION:

4.1. 4.2. All deviations in specification shall be brought out by the bidder and detailed clause by clause in appropriate annexure form. Deviations brought out elsewhere or in any other format will not be considered and are liable for rejection. The CESU in such an event shall also deem that the bidder has conformed to the clauses in this specification scrupulously.
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4.3.
Deviation in specification shall if possible be quoted with reference to standards. The bidder shall then furnish an authentic English version of such standards.
5.0. LOCAL CONDITIONS :

5.1. It will be imperative on each bidder to fully inform himself of the local conditions and factors which may have any effect on the execution of the supply and services covered under these documents and specification. 5.2. It shall be understood and agreed that such factors will have been properly investigated and considered in any bid that is submitted. The purchaser will entertain no claim for financial adjustment to the contract awarded under these specifications and documents. No change in the time schedule of the contract, or any financial adjustment arising thereof that are based on incorrect information, or its effect on the cost of the contract to the bidder shall be permitted by the Purchaser. 5.3. Bidders are advised to visit the various areas where the U.G. cables are access, road /drain / footpath crossings to enable them to make proper costing and then quote accordingly.
6.0. DETAILS OF WORK :

a) The scope of work involves Supply and laying, testing and commissioning of 11KV, 3 Core, 400 Sq.mm XLPE UG cable. b) Laying of 3 core, 11 kV, 400 sq mm UG Cables by trenchless technology adopting horizontal Boring (HDD) by machines with adequate drawing capacity. 6.1. The contract will be on the turnkey basis and all the required materials as per specifications are to be procured by the contractor himself. The specifications for the major equipment to be procured are as follows : a) XLPE Cables of above size as per specifications enclosed.
b) Cable jointing termination and straight through kits as per specifications enclosed. 6.2. All the other materials like coarse and fine aggregate sand, joint markers, sealing, route markers, cable support clamps, terminals and inline connectors, sealing compounds etc., whether specifically mentioned or not in these specifications are deemed to have been included in the scope of supply and installation. Similarly, the contractor has to arrange for all the tools and plants required for the works at his own cost.
7.0. SERVICE CONDITIONS :

7.1. 7.2. The cables are being laid in the Cuttack district, Odisha, where temperature, humidity effect is heavily experienced. The climatic conditions are prone to wide variations in ambient temperature, humidity etc., and the accessories offered shall be suitable for installation under the above Central Electricity Supply Utility of Orissa Page 48
tropical conditions, where moderately hot and humid conditions conducive to dust, rust and fungi growth, prevail at site. 7.3. The underground cables are to be laid along Ring Road of Kathajodi River, where other utility services like telephone,EHT lines and PHD lines are encountered.
8.0. CLIMATIC CONDITIONS

Sl No 1 2 3 4 5 6 7 8 9 Climatic conditions Particulars Location Altitute Max. Ambient air temperature : Max. Daily average air temp : Minimum ambient air temp : Ground temperature at depth of laying assumed : Isoceraunic level : Avg. annual rainfall : Avg. number of rainy days per annum Details Cuttack,Odisha Not exceed 100 M above MSL- Almost at the Sea level 45 C 38 C 10 C (Max) 5 C (Min) 35 C (Max) 45 1450 mm 60 The climate in the city of Cuttack is Tropical moderately hot and humid. subsoil water at certain location at depth of burial of cables may be anticipated . Normally wet
10
Climate :
11
Soil :
9.0. COMPLIANCE WITH REGULATIONS :

9.1. All services carried out by the bidder / sub contractor shall be as per the requirements of the I.E.Act-2003 & Indian electricity Rules 1956, OERC and all other applicable statutory laws governing the services in the state of Odisha 9.2. Particular attention is drawn to the necessity of consulting the local authorities and the administrative heads concerned with the operation and maintenance of roads, railways, telegraph and telephone services, water supply and sewerage and other public utilities. 9.3. The CESU will assist in obtaining permission from civil authorities for boring in the Roads, cutting roads. However the necessary charges shall be paid by the bidder sufficiently in advance. CESU will also co-ordinate with the traffic police authorities for regulation of traffic during cutting of roads.
10.0. INSPECTION BY ELECTRICAL INSPECTOR
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10.1. 10.2. 10.3.
All Electrical installations and equipments are to be inspected and approved by the Chief Electrical Inspector to the Government of Odisha, before commissioning. The Contractor will arrange for the payment of the necessary fees for inspection. Any defects pointed out by the Electrical Inspector, shall be corrected or attended by the bidder /subcontractor at his own cost and he shall pay, for subsequent inspection charges to the Electrical Inspector, for obtaining approval.
11.0. INSTALLATION OF U.G. CABLES

11.1. Method Of Ug Cable Laying : Laying 11 kV HT UG cables at a depth not more than 3 Mtrs, by trenchless technology ,adopting horizontal boring using appropriate standard machines. Boring & Drawing of cable including preparation at site 11.2.
ROUTE PLANS: Tentative cable route plans will be furnished to the contractors,
indicating the roads road crossings, findings by excavating trial holes by the contractor / sub contractor. The work should be taken upon only after CESU Engineers approve the final route. The CESU reserves the right to change, alter deviate the route on technical reasons.
11.3.
TRIAL PITS
The bidder shall excavate trial pits, for alignment purpose at
appropriate distance apart as warranted by the local conditions, keep a record of the findings and close the trial holes properly to avoid hindrance / accidents to pedestrian traffic. The final route / alignment of the cables shall be decided based on the finding of the trial holes. 11.4. 11.5. It is the responsibility of the bidder to maintain as far as possible the required statutory clearances from other utility services. Any damage caused, inadvertently to any utility services shall be the sole responsibility of the contractor.
12.0.
STATUTORY NOTICES AND WAY LEAVES

12.1. The Contractor shall arrange the necessary way leaves from the concerned public utility authorities and CESU shall give the required assistance to the contractor in completing the project.
13.0. LAYING OF CABLES

13.1. 11 kV H.T 3 core HT UG cables: Laying 11 kV HT UG cables by trenchless technology by adopting horizontal boring at a depth not more than 3 Mtrs using appropriate standard machines.
14.0. LAYING OUT THE CABLE :

14.1. 11 kV H.T 3 core HT UG cables: Page 50
The cable shall be pulled / drawn smoothly in the bored holes by the horizontal boring machine itself. The excavated cable trench shall be drained of all water and bed surface shall be smooth, uniform and fairly hard before laying out the cable. The cable shall be pulled in the trench only on cable rollers spaced out at uniform intervals to prevent damage to cable. The laying out process shall be smooth and steady, without subjecting the cable abnormal tension. The cable laid out shall be smoothly and evenly transferred to the ground after providing sand cushion and shall never be dropped. All the snake bends in the cable shall be straightened out. 14.2. Loop Cable : One complete loop of the cable has to be kept at each termination point.
15.0. FLAKING
15.1. Wherever it is not possible to lay of the entire cable drum length, the cable should be cut and properly sealed and if it is necessary to remove the cable from the drum, it should be properly flaked. Such cable lengths should be properly stored at site.
16.0.CABLES AND OVER BRIDGES :

16.1. 16.2. Wherever the cable route crosses bridges the cable shall be laid in the ducts, if provided, by removing and replacing the R.C.C. covers and filled with sand cushion. In the absence of the cable ducts over bridges, the cable shall be laid in suitable size steel/G.I. pipes or as directed by the engineer-In-charge and the pipe covered by cement concrete if necessary to protect from direct sunrays.
17.0.CABLE CROSSING OPEN DRAINS WITH LONG SPAN :

17.1. Wherever the cable to cross open drains with a long span, the cable shall be laid in suitable size G.I. pipe, properly jointed with suitable collars. The GI pipe shall be firmly supported on pillars, columns, or suitable support of R.C.C. foundation with stone masonry in cement mortar 1:4 17.2. Wherever the U.G. cable has to cross the sewerage or water supply line the U.G. cable has to be taken below them maintaining adequate clearance. Further wherever the U.G. cable runs parallel to the telephone cable a separation distance of at east 300-mm shall be maintained. 17.3. The cables shall be laid in stoneware pipe wherever the cable and trench crosses private roads, gates, etc. In order to avoid inconvenience the stoneware pipe should be laid first after excavation and excavated trench shall be back filled, compacted and surface properly redone to restore that original condition.
18.0. CABLE AND JOINT MARKERS

Central Electricity Supply Utility of Orissa Page 51
18.1.
Permanent means of indicating the positions of joints on site should be provided. During the course of permanent reinstatement cable and joint markers, should be laid directly above the route of the cable and the position of the joint respectively.
18.2.
Wherever it is not possible to place the marker directly over the cable route or joint the marker should be suitably placed near the cable route or joint on which the distance of the cable route or joint at right angles to and parallel to the marker should be clearly indicated.
18.3.
The position of fixing the markers will be at the discretion of the Engineer-In-charge.
19.0. JOINTING OF CABLES

19.1. GENERAL: It shall be noted that the U.G. cables are of XLPE insulation and needs special care in jointing. The cable jointer and his assistant shall have experience in making joints / terminations. Jointing work should commence as soon as two or three lengths of cables have been laid. All care should be taken to protect the factory-plumbed cap/seal by laying the end solid in bitumen until such time as the jointing is commenced. 19.2. Jointing of cables in carriage ways, drives, under costly paving, under concrete or asphalt surfaces and in proximity to telephone cables and water mains, should be avoided whenever possible. 19.3. JOINT PITS: The joint pits should be sufficient dimensions as to allow jointers to work with as much freedom of movement and comfort as cables proposed to be jointed. The sides of the pit should be draped with tarpaulin sheet to prevent loose earth from falling on the joint during the course of making. The pit should be well shored with timber, if necessary. An overlap of about 1.0 mtr of the cables to be jointed may be kept, for allowance to adjust the position of the joint. When two or more cables are laid together the joints shall be arranged to be staggered by 2 to 2.5 mtr. 19.4. SUMP PITS: When jointing cables in water logged ground or under monsoon conditions, a sump pit should be excavated at one end of the joint pit in such a position so that the accumulating water can be pumped or bailed out by buckets without causing interference to the jointing operation. 19.5. TENTS: A tent should be used in all circumstances wherever jointing work is carried out in the open irrespective of the weather conditions. The tent should be so covered as to have only one entrance and the back facing the direction of the wind. The tent cover should be properly weighted or tied down on the sides. 19.6. MEASUREMENT OF INSULATION RESISTANCE: Before jointing is commenced the insulation resistance of both sections of the cable to be jointed should be checked by insulation resistance testing instrument. An insulation resistance testing instrument of Central Electricity Supply Utility of Orissa Page 52
2.5/5 kV shall be used. The Insulation Resistance values, between phases and phase to earth shall be recorded. The actual jointing operation shall start only after the approval of the engineer in charge of works. 19.7. PRECAUTIONS BEFORE MAKING A JOINT OR CUTTING A CABLE. The cable end seals should not be opened until all necessary precautions have been taken to prevent circumstances arising out of rainy/inclement weather conditions, which might become uncontrollable. The cable seals should be examined to ascertain if they are intact and also that the cable ends are not damaged, if the seals are found broken or the lead sheath punctured, the cable ends should not be jointed until after due examination and testing by the engineer-in-charge of the works. 19.8. PRECAUTIONS TO BE TAKEN ON LIVE CABLES IN SERVICE Sometimes it becomes necessary that a H.V. cable, which is in service, be cut for making a straight joint with a new cable. In such cases work on joint should start only after the in service cable is properly identified, isolated, discharged, tested and effectively earthed. Search coils interrupters or cable-identifying instruments should be used for this purpose. 19.9. IDENTIFICATION NUMBERS / COLOURS AND PHASING : The cables should be laid and jointed number to number or colour to colour shown on the core identifying marks and prevent cross jointing. In all cases, the cables should be tested and phased out, and more particularly so when the cable terminates at Ring Main Unit / Sub-station. 19.10. MAKING A JOINT: The Heat shrinkable joints used shall be conforming to the specification vide Sec-iv. Alternatively push-on or Tapex or cold shrinkable type can be used with the approval of CESU. The contractor should furnish all the technical particulars of these joints and obtain approval only in case they are found superior to the heat shrinkable joints. Epoxy based joints are not permitted. Comprehensive jointing instructions obtained from the manufacturer of joint kits shall be meticulously followed. The connection of the earth wires should be done using flexible bonds connected to cable sheath using clips or soldering. Aluminum conductor strands shall be joined be joined by mechanical compression method, using suitable die and sleeve with a good quality tool. The joints shall conform to specification as per IS 13573-1992. 19.11. TRANSITION JOINTS: Wherever straight through joints will have to be made with existing cables under the following conditions, the contractor shall arrange such type of joints and execute them with skilled jointers. (1) (2) Between cables having two different types of insulation viz., paper and XLPE Between cables having two different types of conductor material, viz. copper and aluminum. Page 53
(3)
Or a combination of the above The transition joints shall conform to IS 13705 Transition joints for cables for working voltages from 11 KV upto and including 33 KV performance requirements and type tests.
19.12. CABLE TERMINATIONS: Cable terminations required are both indoor and outdoor type and invariably be of heat shrinkable type conforming to the specifications vide Sec-iv. . Alternatively push-on or Tapex or cold shrinkable type can be used with the approval of CESU with appropriate sheds for rainwater in case of outdoor terminations. All the technical particulars to establish the superiority in the performance of these joints shall be furnished while seeking approval. The terminations shall conform to specifications as per IS 13573 1992. The instructions furnished by the manufacturer of termination boxes/kits should strictly be followed. 19.13. Whenever a cable raised from the trench to end in termination, to be finally connected to an overhead line or transformer, the following instructions should be complied with (i) (ii) (iii) (iv) One coil to made and left in the ground for future needs The rise of cable, immediately from the ground level should be enclosed in suitable diameter GI pipe to height of 2 mt. The balance portion of the cable should be neatly curved, in S shape. The cable and pipe should be properly fastened by using appropriate clamps /support. (v) The hardware of clamps shall be painted with red oxide and enamel paint or galvanized. The lugs on the termination shall be compressed with a suitable compression tool.
20.0.EARTHING AND BONDING

20.1. The metal sheath and Armour should be efficiently bonded and earthed at all terminals to earth electrodes provided. The cross sectional area of the bond shall be such that the resistance of each bond connection shall not exceed the combined resistance of an equal length of the metal sheath and Armour of the cable.
21.0.TESTING AFTER LAYING AND JOINTING

21.1. 21.2. 21.3. All cables after laying and jointing works are completed should be tested systematically and insulation and pressure tests should be made on all underground cables. All test results should be recorded in tabular form in logbooks kept for the purpose The cable cores should be tested for :(i) Continuity (ii) Absence of cross phasing (iii) Insulation resistance to earth; insulation resistance between conductors. Central Electricity Supply Utility of Orissa Page 54
22.0.H.V. TESTS
22.1. After the laying and jointing work is completed, a high voltage test should be applied to the cable to ensure that the cable has not been damaged during or after the laying operations and there is not defect in the joining 22.2. The high voltage tests should be as per IS 1255 or as per international standards. The H.V. testing instruments shall be brought by the turn key contractor.
23.0.TESTING AND RECORD OF CABLE CONSTANTS :

23.1. When the cable is ready, just before commissioning, the cable constants viz, the resistance, capacitance and inductance of each conductor should be determined and recorded, along with frequency at which the values of capacitance and inductance are determined.
24.0.GUARANTEE
24.1. All the cable joints / termination done by the contractor shall be guaranteed for 12 months from the date of energisation of the complete cable. In the event of failure during the guarantee period, the restoration work shall be done free of cost by the contractor within 24 hours of giving notice or else the expenditure incurred by CESU to re-do the joint / termination will be recovered from the performance guarantee amount held with the CESU.
25.0.CABLE RECORDS
25.1. 25.2. 25.3. Accurate neat plans / sketches, drawn to suitable scale (1 cm = 10M) should be prepared and furnished by the contractor after the completion of each work. All relevant information should be collected at site, during the progress of work and preserved for preparation of drawings. The following essential data should be incorporated on all drawings a) Size, type of cable or cables. b) Location of the cable in relation to prominent land mark property, Kerb-line etc., with depths. c) The cross section showing where cables are laid in piper or ducts, giving their sizes, type and depths. d) Position and type of all joints e) Location of other cables which run alongside or across the cable route. f) Position and depths of all pipers, ducts, etc., which are met as obstruction to the cable route. g) Accurate lengths from joint to joint h) Manufacturers name and drum number of the cable, between sections / joint to joint.
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Two transparencies and six blue print copies of the cable records prepared as above shall be given to the CESUs engineer as a part of the contract as soon as the cable is charged.
Section-VI Lightning Arrestor
Page 56
TECHNICAL SPECIFICATION OF 11 KV LIGHTNING ARRESTOR (VOLTAGE CLASS SURGE ARRESTORS)

The specification covers the design, manufacture, shop & laboratory testing before despatch, supply delivery of 11 KV, Station class heavy duty, gapless metal oxide Surge Arrestors, insulating base, clamps, complete fittings & accessories suitable for 33 KV transformers/feeders including arrester's electrode earthing. 1.0 STANDARDS The design, manufacture and performance of Surge Arrestors shall comply with IS: 3070 Part-3 and other specific requirement stipulated in the specification Unless otherwise, specified, the equipment, material and processes shall conform to the latest applicable Indian/International Standards as listed hereunder: IS: 2071-1993 (Part-1) IS: 2071-1974 (Part-2) IS: 2633-1986 IS: 3070-1993 (Part-3)
:
Methods of High Voltage Testing General Definitions & Test Requirements. Test Procedures Methods for Testing uniformity of zinc coated Articles. Specification for surge arrestor for alternating current system Metal-Oxide lightening Arrestors without gaps.
: : :
Page 57
IS:4759-1996 IS: 5621-1980 IS: 6209-1982 IS: 6745-1980 IEC:TC-37
Specification for hot dip zinc coating on Structural Steel and other allied products. Hollow Insulators for use in Electrical Equipment. Methods of Partial discharge measurement. Methods for determination of mass of zinc coating on zinc coated iron and steel articles. Test Procedures. Metal Oxide, Surge Arrestor for A.C. Power Circuits. Surge Arrestors.
: : :
ANSI/IEEE-C.62.11(1982) : IEE-99-4
:
The equipment complying with any other internationally accepted standards shall also be considered if it ensures performance equivalent to or superior to the India Standards. 2.0 GENERAL REQUIREMENT 2.1 The Metal Oxide gap less Surge Arrestor without any series or shunt gap shall be suitable for protection of UG cable, associated equipment from voltage surges resulting from natural disturbance like lightening as well as system disturbances. The surge arrestor shall draw negligible current at operating voltage and at the same time offer least resistance during the flow of surge current. The surge arrestor shall consist of non-linear resistor elements placed in series and housed in electrical grade porcelain housing/silicon polymeric of specified creepage distance. The assembly shall be hermetically sealed with suitable rubber gaskets with effective sealing system arrangement to prevent ingress of moisture. The surge arrestor shall be provided with line suitable for cable for vertical and horizontal take off. The earth terminals shall be provided of suitable size. The groundside terminal of surge arrestor shall be connected with 50x6mm- galvanized strip, one end connected to the surge arrestor and second end to a separate ground electrode (Electrode type of earthing). The contractor shall also recommend the procedure which shall be followed in providing the ear thing/system to the Surge Arrestor. The surge arrestor shall not operate under power frequency and temporary over voltage conditions but under surge conditions, the surge arrestor shall change over to the conducting mode. Surge arrestor shall have a suitable pressure relief system to avoid damage to the porcelain/silicon polymeric housing and providing path for flow of rated fault currents in the event of arrestor failure. The reference current of the arrestor shall be high enough to eliminate the influence of grading and stray capacitance on the measured reference voltage.
2.2
2.3
2.4
2.5
2.6
2.7
2.8
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2.9
The surge arrestor shall be thermally stable and the contractor shall furnish a copy of thermal stability test with the bid. The arrestors for 11 KV system shall be suitable for mounting on transformers as well as in the yard. The supplier shall furnish the drawing indicating the dimensions, weight etc. of the surge arrestors for the design of mounting brackets. The arrestor shall be capable of handling terminal energy for high surges, external pollution and transient over voltage and have low losses at operating voltage.
2.10
2.11
3.0 ARRESTOR HOUSING 3.1 The arrestor housing shall be made up of porcelain/silicon polymeric housing and shall be homogenous, free from laminations, cavities and other flaws of imperfections that might affect the mechanical and dielectric quality. The housing shall be uniform brown colour, free from blisters, burrs and other similar defects. Arrestors shall be complete with insulating cases, fasteners for stacking units together and terminal connectors. The housing shall be so coordinated that external flashover shall not occur due to application of any impulse or switching surge voltage upto the maximum design value for arrestor. The arrestors shall not fail due to contamination. The 11KV arrestors housing shall be designed for pressure relief class as given in Technical Parameters of the specification. Sealed housing shall exhibit no measurable leakage. TESTS Test on Surge Arrestors The Surge Arrestors offered shall be type tested not earlier than 5 years before the date of opening of this tender. The surge arrestors shall be subjected to routine and acceptance tests in accordance with IS: 3070(Part3)-1993. In addition, the suitability of the Surge Arrestors shall also be established for the following: * * * * * * * * Residual voltage test Reference voltage test Leakage current at M.C.O.V. P.D. Test Sealing test Thermal stability test Aging and Energy capability test Watt loss test
3.2
3.3
4.0 4.1
Each metal oxide block shall be tested for guaranteed specific energy capability in addition to routine/acceptance test as per IEC/IS. 4.2 The maximum residual voltages corresponding to nominal discharge current of 10KA for steep current, impulse residual voltage test, lightning impulse protection level and switching impulse level shall generally conform to Annexure-K of IEC-99-4. The bidder shall furnish the copies of the type tests and the characteristics curves between the residual voltage and nominal discharge current of the offered surge arrestor and Page 59
4.3
power frequency voltage V/s time characteristic of the surge arrestor subsequent to impulse energy consumption as per clause 6.6 of IS: 3070 (Part-3) offered along with the bid. 4.4 4.5 The surge arrestors housing shall also be type tested and shall be subjected to routine and acceptance tests in accordance with IS: 2071. Galvanization Test All Ferrous parts exposed to atmospheric condition shall have passed the type test and be subjected to routine and acceptance test in accordance with IS: 2633 & IS: 6745.
5.0 5.1
NAME PLATE The nameplate attached to the arrestors shall carry the following information: * * * * * * * Manufacturing Trade Mark Year of Manufacture Rated Voltage Continuous Operation Voltage Pressure relief rated current Name of ClientPurchase Order Number along with date. INSPECTION All tests and inspection shall be made in the manufacturers works unless otherwise specifically agreed upon by the manufacturer and purchaser at the time of placement of purchase order. The manufacturer shall afford to the inspector representing the purchaser, al reasonable facilities, without charge to satisfy him that the material being furnished is in accordance with these specifications. The purchaser reserves the right to get an component/material being used by the manufacturer of the Surge Arrestor tested from any recognized test house. The inspection by the purchaser or his authorized representative shall not relieve the contractor of his obligation of furnishing equipment in accordance with the specifications. DRAWING AND INSTRUCTION MANUALS Within 15 days of receipt of the order, the successful tenderer shall furnish to the purchaser the following drawings and literature for approval: a. Outline dimensional drawings of Surge Arrestor and all accessories. b. Assembly drawings and weights of main component parts. c. Instructions manual d. Drawing showing details of pressure relief value e. Volt-time characteristics of surge arrestors. f. Detailed dimensional drawing of porcelain housing/ Silicon polymeric
6.0
6.1
6.2
7.0
i.e. internal diameter, external diameter, thickness, height profile, Central Electricity Supply Utility of Orissa Page 60
creepage distance, dry arching distance etc.
GURANTEED TECHNICALPARTICULARSFOR 11KVLIGHTNINGARRESTOR

(To be submitted along with offer) Sl. No. Particulars Name of manufacturer. Type Designation Model (Drawing No.) Applicable Standard No. of units per Arrestors Rated Voltage Nominal discharge current 8/20 micro second wave (KA) Maximum continuous operating Voltage Insulation withstand voltage power frequency. Maximum Lightning Impulse Residual voltage (8/20 micro second wave Page 61 Bidders Offer
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
11.
Maximum steep current Impulse Residual voltage at 10 KA of micro second front time. Maximum Switching Impulse Residual voltage 50 x 100 micro seconds at 500 Amps. Current Impulse withstand capability. i) Long duration discharge class. ii) Minimum energy discharge capability
12.
13.
14. 15. 16.
Protective Ratio High current impulse withstand value (4 x10 Micro seconds) Pressure relief class. i) High current ii) Low current
17. 18.
Reference current of the arresters Ambient Current at M.C.O.V. (Maximum Continuous i) Resistive Current IR ii) Capacitive voltage IC
19.
Temporary over voltage capability i) 0.1 second ii) 1.0 Second iii) 10.0 Second iv) 100 second
20 21.
a) Total Creepage Distance b) Protected Creepage Distance Over all dimensions i) Height ii) Diameter
22. 23. 24
Cantilever strength KG-M Mounting flange dimensions Minimum Clearance i) Between Arrestors ii) Arrestor and adjoining - objects
Page 62
Section-VII 11kV AB Switch
Page 63
TECHNICAL SPECIFICATIONS FOR 11kV AB Switch

1.0 SCOPE:This specification provides for manufacture, testing at works and delivery For supply of 11KV AB switches. The 11KV AB switches shall conform to IS: 9920 (Part-I to IV) 2.0 AB SWITCHES:The 11KV Air Break Switches are required with two poles in each phase. The AB Switches shall be supplied complete with phase coupling shaft, operating rod and operating handle. It shall be manually gang operated and vertically break and horizontal mounting type. 2.0.1 The AB Switch shall be designed for a normal current rating of 400 Amps and for continuous service at the system voltage specified as under: 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. 2.0.2 The 11KV AB Switches are required with post insulators. The AB switches should be suitable for mounting on the structure. The mounting structure will be arranged by the purchaser separately. However, the AB Switches shall be supplied with base channel for mounting on the structure which will be provided by the purchaser. The phase to phase spacing shall be 750mm in case of 11KV AB Switches. 3.0 POST INSULATORS:The complete set of three phase AB Switches shall have post insulators. 11KV AB Switches Central Electricity Supply Utility of Orissa : 11KV Post Insulators Page 64
The post insulators should conform to the latest applicable Indian standards IS: 2544 Specification for Porcelain Post insulator Polycon or of compact solid core or long rod insulators are also acceptable. Creepage distance should be adequate for highly polluted outdoor atmosphere in open atmosphere. The porcelain used for manufacture of AB Switches should be homogeneous free from flaws or imperfections that might affect the mechanical dielectric quality. They shall be thoroughly vitrified, tough and impervious to moisture. The glazing of the porcelain shall be of uniform brown in colour, free from blisters, burns and other similar defects. Insulators of the same rating and type shall be interchangeable. 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. Cap and base of the insulators shall be interchangeable with each other. The cap and base shall be properly cemented with insulators to give perfect grip. Excess cementing must be avoided. The tenderers shall in variably enclose with the offer, the type test certificate from NABL accredited testing laboratory and other relevant technical guaranteed particulars of insulators offered by them. Please note that AB Swiches without type test certificates will not be accepted.
4.0
Each 11KV Post Insulators should have technical particulars as detailed below: 11 KV 11 12 35 35 1.3 times the actual dry flashover voltage 75 9 320
i ii iii iv v
Nominal system voltage kV (rms) Highest system voltage kV (rms.) Dry Power Frequency one kV minute withstand voltage (rms) in Wet Power frequency one minute withstand voltage (rms) in KV Power Frequency puncture kV (rms) voltage
vi Impulse withstand voltage kV (Peak) vii Visible discharge voltage kV (rms) viii Creepage distance in mm (minimum)
5.0 The rated insulation level of the AB Switches shall not be lower than the values specified below:Standar d declared voltage Rated Voltage of the AB Switches Standard impulse with stand voltage (positive & negative polarity KV (Peak) Across To earth the & Isolating between distance poles One Minute power frequency withstand voltage kV (rms) Across the Isolating distance To earth & between poles
Sl. No
Page 65
11KV
12KV
85KV
75KV
32KV
28KV
6.0 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. 7.0 MAIN CONTACTS:AB Switches shall have heavy duty self-aligning type contacts made of hard drawn electrolytic copper/brass. The various parts should be accordingly finished to ensure inter changeability of similar components. The moving contacts of the switch shall be made from hard drawn electrolytic copper brass. This contact shall have dimensions as per drawing attached so as to withstand safely the highest short-circuit currents and over voltage that may be encountered during service. The surface of the contact shall be rounded smooth and silver-plated. In nut shell the male and female contact assemblies shall ensure. (i) (ii) (iii) (iv) (v) Electro-dynamic withstands ability during short circuits without any risk of repulsion of contacts. Thermal withstands ability during short circuits. 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. Wiping action during closing and opening. Fault alignment assuring closing of the switch without minute adjustments.
8.0 CONNECTORS:The connectors shall be made of hard drawn electrolytic copper or brass suitable for Raccoon/Dog ACSR conductor for both 11KV AB Switches. The connector should be 4 -bolt type. 9.0 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. The isolating distances should also be visible for the AB Switches. The AB Switch will be supplied with following accessories: Sr. No i ii iii Item Operating Rod (GI dia) Phase coupling square rod (GI) Hot dip galvanized Operating handle (GI) Size of 11KV AB Switch Length 5.50 meter dia 25 mm Length 1800 mm Size 25x25 mm 1 No.
The AB Switches shall be capable to resist any chance of opening out when in closed position. The operating Mechanism should be of robust constructions, easy to operate by single person and to be located conveniently for local operation in the switchyard. The GI pipe shall conform to ISS: 1239-68 and the vertical down rod should be provided with adequate joint in the mid section to avoid bending or buckling. Additional leverage should be Central Electricity Supply Utility of Orissa Page 66
provided to maintain mechanical force with minimum efforts. All iron parts should be hot dip galvanized. All brass parts should be silver plated and all nuts and bolts should be hot dip galvanized. 10.0 ARCING HORNS:It shall be simple and replaceable type. They should be capable of interrupting line- charging current. They shall be of first make and after break type. 11.0 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. They shall be made from highly polished Bronze metal with adequate provision for periodic lubrication through nipples and vent. 12.0 DESIGN, MATERIALS AND WORKMANSHIP:The successful tenderers shall assume full responsibility for co-ordination and adequate design. All materials used in the construction of the equipment shall be of the appropriate class, well finished and of approved design and material. All similar parts should be accurately finished and interchangeable. Special attention shall be paid to tropical treatment to all the equipment, as it will be subjected during service to extremely severe exposure to atmospheric moisture and to long period of high ambient temperature. 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. The firm should submit the following type test certificate along with the certified copy of the drawing (from NABL Testing Lab). The type test should be from NABL accredited testing laboratory & should not be older than 5 years from the date of opening of tender. 1. 2. 3. 4. 5. Test to prove capability of rated peak short circuit current and the rated short time current. 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. Lightning impulse voltage test with positive & negative polarity. Power Frequency voltage dry test and wet test Temperature rise test Mill volt drop tests
13.0 Dimension of 11KV AB Switches in (Max.) Tolerance 5%. Sr. i ii iii iv v Particulars Drawing No. MS Channel Creepage distance of Post Insulator Highest of Port shell Fixed contact assembly i) Base ii) Contact 11KV AB Switch EB/P-6/MPSEB/7 (revised) dated 01.05.88 450x75x40 320mm (Min) 254 mm 165x36x8 70x30x6 Page 67
vi i ii iii iv
iii) GI cover Spring Moving contract assemble Base Assembly Moving Bush Thickness of Grooves
110x44 6 Nos. 135x25x8 180x25x9 Bronze Metal 7
14.0 CONNECTORS:i Connector (diamentions of each pad) 60x50x8 (Moving & fix both) 60x50x8 (Moving & fix both)
The bidder should provide AB Switches with terminal connectors, set of insulators, mechanical inter works and arcing horns sets. The base channel for the mounting of AB Switches shall also be included in the scope of AB Switches. The operating mechanisms together with down pipe operating handle etc. are also included in the scope of supply. 15.0 ROUTINE TEST CERTIFICATE : The Routine test certificate should invariably be submitted in duplicate of each lot offered for inspection as per ISS: 9920 (part-I to IV). The offers received without Routine test certificate shall not be entertained. 16.0 ACCEPTANCE TEST : At the time of inspection following test shall be carried out: a. b. c. d. e. f. Physical verification and measurement of dimension. Power frequency high voltage test. Temperature rise test. Mechanical endurance test / operation test. Milli volt drop test. Galvanising test as per ISS: 2633.
17.0 NAME PLATE: The name plate in the following design shall be fixed on each AB Switch. i) ii) iii) iv) v) Name of supplier Name of purchaser Order No. and date Rating serial number of unit : : : : :
The size of name plate shall be 2 x 1 for 11 kV AB Switch.
Page 68
Schedule of Guaranteed Technical Particulars for 11 KV AB Switches

To be specified by the Bidder
No 1 2 3 4 5 A) i ii B) i ii C) i ii
Particulars Type / make Maximum permission continuous service voltage (KV) Length of the Break/Phase (Min.) Phase to Phase Spacing Power Frequency withstand test voltage for completely assembled switches Against ground Dry KV Wet KV Across open contact Dry KV Wet KV Between Phases Dry KV Wet KV
Requirement To be indicated 12 KV 400 mm 750 mm
28 KV 28 KV 32 KV 32 KV 28 KV 28 KV
Page 69
Impulse withstand test voltage of completely assembled switch without arcing horns with 1.2/50 micro second impulse wave KV (Peak) 7 100% impulse flashover voltage of completely assembled switch with arcing horns with 1.2/50 micro second impulse wave KV (Peak) 8 Particulars of the main contacts i.e. fixed contacts and moving contacts a Type
85 KV
85 KV
b Material c Surface Treatment & Thickness of Silver Coating d Contact Pressure 9 Continuous Current Rating, Amps 10 Short Time Current Rating KA (rms) min. for 1 sec 11 Rated Peak Short Circuit Current (KA Peak) 12 No. of operations which the switch can withstand without deterioration of contacts 13 Type of Mounting 14 15 16 i ii iii iv v vi viii ix x xi xii xiii Type & Material used in connector Location and Type of Bushing Particulars of Post Insulators Make( ISI make) Type Strength Weight No. of units per stack Height of stack mm Creepage distance mm 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) Puncture voltage (KV)
Spring loaded fixed & knife type moving contacts Hard drawn electrolytic copper alloy Silver plated of thickness of 5 micron 25 KG 400 amps 16 KA 25 KA 2000 Horizontal up right mounting Brass/ Bronze strips Bush bearing at rotating insulator
To be indicated 11 KV Post insulator type 10 KN 5 Kg (approx.) / unit One 254 mm 320 mm
65 KV 70 KV 85 KV 80 KV (peak) 105 KV
Page 70
Page 71
Section-VIII Proposed Route Map
Page 72
Proposed 11kV UG Cable From Sishubawan 33/11kV S/S to Ayakar Bhawan near Shelter Chhaka
Shelter Chhaka
Proposed 11kV XLPE UG Cable
Ayakar Bhawan Sishubhawan 33/11kV Sub-Station
CDA Chhaka Corporate Bhawan ABIT College Bidanasi 220/132/33kV Grid S/S Ram Mandir Kathajodi River
Proposed 11kV UG Cable From Sishubawan 33/11kV S/S to Ayakar Bhawan near Shelter Chhaka
Client
CENTRAL ELECTRICITY SUPPLY UTILITY OF ORISSA
Regd. Office: 2nd Floor, IDCO TOWER Janpath, Bhubaneswar -751022
DWG No:
- 01
Page 74

Vol-II-Tech Spec Ayakara Bhawan 1

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TENDER DOCUMENTS FOR

Volume II Technical Bid

CENTRAL ELECTRICITY SUPPLY UTILITY OF ORISSA (CESU)

TENDER NO: CESU. H.Qrs./P&S/523/12-13/24764/Dt: 30.07.2012

CENTRAL ELECTRICITY SUPPLY UTILITY OF ODISHA (CESU)

Central Electricity Supply Utility of Orissa

BID DOCUMENTS CONSIST OF THE FOLLOWING VOLUMES VOLUME- I (COMMERCIAL REQUIREMENTS)

VOLUME-II (TECHNICAL REQUIREMENTS)

VOLUME- III (BID PROPOSAL SHEETS)

Central Electricity Supply Utility of Orissa

Central Electricity Supply Utility of Orissa

The CENTRAL ELECTRICITY SUPPLY UTILITY OF ODISHA,

Central Electricity Supply Utility of Orissa

Set Nos. mtr

Central Electricity Supply Utility of Orissa

Central Electricity Supply Utility of Orissa

Section-II Porcelain clad 11kV Switch Gear

Central Electricity Supply Utility of Orissa

TECHNICAL SPECIFICATION OF 11KV CLASS PORCELAIN CLAD SWITCHGEAR 1.0

Central Electricity Supply Utility of Orissa

NORMAL SERVICE CONDITIONS :

Generally as per (1) clause 2.1(a) to 9(e) of Is 13118 Clause 2.

Ref Nos i ii IS-3427 IEC-56

iii IS-13118 iv v IS-2705 IS -3516

4.5 4.6 4.7 4.8

SWITCHGEAR RATINGS: CHARACTERISTICS :

Central Electricity Supply Utility of Orissa

p) Rated voltage of auxiliary supplies.

Central Electricity Supply Utility of Orissa

Space heater -AC 230V, S.Ph 50 Hz.

Central Electricity Supply Utility of Orissa

h. i. j. i. ii. k. l. 7.3 7.3.1

ii ) Moving Iron. iii) Size 96*96 mm Iv) Accuracy.1.0 V) Scale 0 5 10 - 20 Page 16

Central Electricity Supply Utility of Orissa

D) Electronic Tri vector Meter: I. One number to be provided

Central Electricity Supply Utility of Orissa

Central Electricity Supply Utility of Orissa

REQUIREMENT OF ENGRAVING IN THE ANNUNICIATOR DESK:

5 1 > 1 > Trip alarm 1 >

1 > Non Trip 1 1 1 1

9.3 TEST ON VOLTAGE TRANSFORMERS :

Central Electricity Supply Utility of Orissa

Section-III 11kV UG Cable

Central Electricity Supply Utility of Orissa

TECHNICAL SPECIFICATIONS FOR 11KV, XLPE INSULATED UG CABLE 1.0 SCOPE :

2.0 RATED VOLTAGE

3.0 APPLICABLE STANDARDS:

Central Electricity Supply Utility of Orissa

b) Elongation under load

c) Permanent elongation (set) after cooling

Shrinkage: a) Treatment : Temperature Duration

130+ 30 C 1 hour 4 percent, Max

a) Treatment : Temperature Duration b) Water absorbed

85+ 20 C 14 days 1 mg / cm2, Max

Volume Resistivity a) at 270 C b) at 700 C

1 x 1014 ohm-cm, Min 1 x 1013 ohm-cm, Min

Central Electricity Supply Utility of Orissa

6.0 INSTALLATION CONDITIONS :

7.0 CLIMATIC CONDITIONS :

8.0 DESIGN CRITERIA :

Central Electricity Supply Utility of Orissa

9.0 MANUFACTURE PROCESS:

INNER SHEATH (COMMON COVERING)

Central Electricity Supply Utility of Orissa