tender document for augmentation of 33/11kv substation ...

SECURITY PAPER MILL, HOSHANGABAD-461005(M.P.) (A unit of Security Printing & Minting Corporation of India Ltd.) Wholly owned by Government of India

TENDER DOCUMENT FOR AUGMENTATION OF 33/11KV SUBSTATION, CONSTRUCTION OF 11/0.415 KV SUBSTATION ALONG WITH SWITCHGEARS, CABLING, GROUNDING, LIGHTNING PROTECTION SYSTEM AND CIVIL WORK -DESIGN, SUPPLY, INSTALLATION & COMMISSIOING ON TURNKEY BASIS

Not Transferable Security Classification: Non-Security Item TENDER DOCUMENT FOR “AUGMENTATION OF 33/11KV SUBSTATION, CONSTRUCTION OF 11/0.415 KV SUBSTATION ALONG WITH SWITCHGEARS, CABLING, GROUNDING, LIGHTNING PROTECTION SYSTEM AND CIVIL WORK.-DESIGN, SUPPLY, INSTALLATION & COMMISSIOING ON TURNKEY BASIS”

Tender No. 14(35)/33-11-0.415KV/Vol.III/Adv. No.125/3225 This Tender Document Contains 559 Pages. Tender Documents is sold to:

M/s _______________________ Address

Details of Contact person in SPM regarding this tender:

Name, Designation

:

Shri. Rajkumar R Officer Materials

Address

:

Security Paper Mill Hoshangabad M.P-461005

Phone

:

07574-279847

Fax

:

07574-255170

Email

:

[email protected]

1

Dated 05.03.2012

CONTENTS SECTION

DESCRIPTION

Page No.

Section I

Notice Inviting Tender (NIT)

2

Section II

General Instruction to Tenderers (GIT)

32

Section III

Special Instruction to Tenderers (SIT)

03

Section IV

General Conditions of Contract (GCC)

28

Section V

Special Conditions of Contract (SCC)

05

Section VI

List of Requirements(LR)

10

Section VII

Technical Specifications(TS)

273

Section VIII

Quality Control Requirements(QCR)

06

Section IX

Qualification / Eligibility Criteria

01

Section X

Tender Form(TF)

01

Section XI

Price Schedule(PS)

02

Section XII

Questionnaire

01

Section XIII

Bank Guarantee Form for EMD

01

Section XIV

Manufacturer’s Authorization Form

01

Section XV

Bank Guarantee Form for Performance Security

01

Section XVI

Contract Form

02

Section XVII

Letter of Authority for attending a Bid Opening

01

Section XVIII

Shipping Arrangements for Liner Cargoes

01

Section XIX

Performa of Bills for Payments

01

Section XX

Drawings

55

Appendix - E

93

2

(Section – I)

NOTICE INVITING TENDER (NIT) Tender No. 14(35)/33-11-0.415KV/Vol.III/Adv.No.125/3225

Dated: 05.03.2012

1. Sealed tenders are invited from eligible and qualified tenderers for s u p p l y of following g o o d s & S e r vi ce s: Schedule No.

1.

Brief Description of Goods/ Services ‘AUGMENTATION OF 33/11KV SUBSTATION, CONSTRUCTION OF 11/0.415 KV SUBSTATION ALONG WITH SWITCHGEARS, CABLING, GROUNDING, LIGHTNING PROTECTION SYSTEM AND CIVIL WORK - DESIGN, SUPPLY, INSTALLATION & COMMISSIOING ON TURNKEY BASIS’ as per List of Requirement section VI on turnkey basis

Quantity (with unit)

Earnest Money (in Rs.)

As per List of Requirements Section VI of this tender document

Rs. 12,75,000/(Rupees Twelve Lakhs Seventy Five Thousand Only)

Type Of Tender

Single stage (three packet), NCB

Tender Cost

Rs. 5000/- (Rs. Five Thousand Only)

Date and time of Pre-bid conference

05.04.2012 at 11.00 AM

Place of Pre-bid conference

Security Paper Mill, Hoshangabad

Closing date and time for receipt of tenders

Up to 14.00 Hrs till 27.04.2012

Place of receipt of tenders

Security Paper Mill, Hoshangabad

Time and date of opening of tenders

15.00 Hrs On 27.04.2012

Place of opening of tenders Nominated Person/ Designation for receive bulky tenders

Security Paper Mill, Hoshangabad Officer – Materials

2. Interested tenderers may obtain further information about this requirement from the above Office selling the tender document. They may also visit our website mentioned above for further details. 3

3. Tender documents may be purchased on payment of non-refundable fee of Rs.5000/- per set in the form of account payee demand draft/ cashier’s cheque/ certified cheque, drawn on a scheduled commercial bank in India, in favour of The General Manager, Security Paper Mill payable at Hoshangabad. 4. If requested, the tender documents will be mailed by registered post/speed post to the domestic Tenderers, for which extra expenditure per set will be Rs. 100/- (Rupees Hundred) for domestic post. The tenderer is to add the applicable postage cost in the non-refundable fee mentioned in para 3 above. 5. Tenderers may also download the tender documents from the web site http://spmhoshangabad.spmcil.com and submit its tender by utilizing the downloaded document along with the required non-refundable fee as mentioned in Para 3 above. 6. Tenderers shall ensure that their tenders, duly sealed and signed, complete in all respects as per instructions contained in the Tender Documents, are dropped in the tender box located at the address given below on or before the closing date and time indicated in the para 1 above, failing which the tenders will be treated as late and rejected. ADDRESS The General Manager, Security Paper Mill, Hoshangabad - 461 005 (M.P.) India. 7. In the event of any of the above mentioned dates being declared as a holiday/ closed day for the purchase organization, the tenders will be sold/ received/ opened on the next working day at the appointed time. 8. The tender documents are not transferable.

(Rajkumar. R) Officer Materials Security Paper Mill, Hoshangabad, M.P-461 005 Ph.No: 07574-279847, 07574-279791 Fax No: 07574-255170 For and on behalf of The General Manager

4

(Section – II)

GENERAL INSTRUCTIONS TO TENDERERS (GIT)

Kindly refer http://spmhoshangabad.spmcil.com/spmcil/uploaddocument/GIT.pdf for further details. (GIT contains 32 Pages)

5

(Section – III)

SPECIAL INSTRUCTION TO TENDERER The following special instructions to tenderers will apply for this purchase these special instructions will modify/ substitute/ supplement the corresponding General Instructions to Tenderers (GIT) incorporated in Section II. The corresponding GIT clause numbers have also been indicated in the text below. In case of any conflict between the provision in the GIT and that in the SIT, the provision contained in the SIT shall prevail. Sl. No. 1. 2. 3. 4. 5. 6. 7. 8

1.

GIT Clause No. 8 18 19 21 43 33 21.1, 24.1

Topic Pre Bid Conference Earnest Money Deposit (EMD) Tender validity Submission of Tenders Parallel Contracts Evaluation Criteria Corrections in GIT Clauses Coordination with Statuary outside Agencies

Bodies

&

SIT Provision 1. 2. 3. 4. 5. 6. 7. 8

PRE-BID CONFERENCE Pre-bid conference will be held on 05.04.2012 at 11 AM for this tender at SPM Hoshangabad.

2.

EARNEST MONEYDEPOSIT (EMD) Tender should be accompanied with Earnest Money Deposit (Non-interest bearing) of Rs.12, 75,000/- (Rupees Twelve Lakhs Seventy Five Thousand Only) in the forms as given below. a) Account Payee Demand Draft or b) Fixed Deposit Receipt or c) Banker’s cheque The demand draft, fixed deposit receipt or banker’s cheque shall be drawn on any scheduled commercial bank in India, in favor of Account specified in the Clause 3 of NIT. The earnest money shall be valid for a period of forty five days beyond the validity period of the tender.

3. 3.1 3.2

TENDER VALIDITY The tender shall remain valid for acceptance for a period of 165 days after the date of tender opening prescribed in the tender document. Any tender valid for a shorter period shall be treated as unresponsive & rejected. In exceptional cases, the tenderers may be requested by SPM to extend the validity of their tenders up to a specified period. Such request(s) and responses thereto shall be conveyed by surface mail/E-mail/Telex/Cable followed by surface mail. The tenderers, who agree to extend the tender validity, are to extend the same without any change or modification of their original tender and they are also to extend the validity period of the EMD accordingly. 6

3.3 3.4

In case the day up to which the tenders are to remain valid falls on/ subsequently declared a holiday or closed day for SPM, the tender validity shall be extended up to the next working day. Compliance with the clauses of this Tender document: Tenderer must comply with all the clauses of this tender document. No deviations with any of the clauses of this tender are permitted to the bidder.

4. SUBMISSION OF TENDERS: Pre-Qualification bid, Technical bid and financial bid are to be submitted in three separate doubled sealed envelopes on or before the due date of submission of tenders. It may be noted that the price is not to be quoted either in the pre-qualification or in technical bid. It shall only be quoted in price bid. Non-adherence to this shall make tender liable for rejection. The envelopes containing bids shall be superscribed “Pre-qualification bid”, “Technical bid”, “Price bid”, as the case may be, for “Tender Document for augmentation of 33/11KV substation, construction of 11/0.415 KV substation along with switchgears, cabling, grounding, lightning protection system and civil work-design, supply, installation &commissioning on turnkey basis”. The sealed envelopes shall be again be put in another sealed cover and should be superscribed “Tender Document for augmentation of 33/11KV substation, construction of 11/0.415 KV substation along with switchgears, cabling, grounding, lightning protection system and civil workdesign, supply, installation & commissioning on turnkey basis” due on 27.04.2012 up to 14.00 Hrs (IST). Late tenders shall not be accepted. Tenderers shall submit their offers only on prescribed forms. Tender by Telegram/Fax/E-mail shall not be accepted. Tender by Post/Hand/courier received on or before the due date and time shall be accepted. Postal delay/ delay by courier service etc. shall not be condoned. 4.1 Tenders shall be submitted in parts as below:PART – I –PRE-QUALIFICATION BID i) Containing un-priced tender consisting of complete Qualification/ Eligibility of the tenderer as per the format specified under Section I X in this document. ii) One original and one duplicate copy shall be submitted. It should not have any price aspects. iii) Earnest Money Deposit. iv) Power of Attorney/authorization with the seal of the company of person signing the tender documents. v) Tender document fee Rs.5,000/PART – II - TECHNO-COMMERCIAL BID i) The tenderer shall submit detailed technical offer as per Technical Specifications as per Section VII of this tender document. ii) The tenderer has to submit acceptance of all sections of this tender document (GIT, SIT, SCC, Quality control requirements, Tender form, Questionairre, etc.,) iii) One original and one duplicate copy shall be submitted. iv) Containing un-priced tender consisting commercial package including all terms and conditions. No price details to be given in this tender. v) Containing Blank price Bid (No price details to be given in this tender.) PART- III - PRICE BID: The tenderers shall quote the prices as per the proforma given in Section – XI of the tender document. Insertion, post script, addition and alteration shall not be recognized unless confirmed by the tenderers. 5

PARALLEL CONTRACTS No parallel contracts shall be awarded for this tender. 7

6

EVALUATION CRITERIA FOR L1 BIDDER The pre-qualification bids are to be opened in the first instance, at the prescribed time and date. These bids shall be scrutinized and evaluated by the competent committee/ authority with reference to the parameters prescribed in the eligibility criteria. Thereafter, in the second stage, the technical bids of only pre-qualified bidders (as decided in the first stage) shall be opened at a later date and time for further scrutiny and further evaluation. These bids shall be scrutinized and evaluated by the competent committee/ authority with reference to the parameters prescribed in the tender document. Subsequently, in the third stage the financial bids of only the technically acceptable offers (as decided in the second stage shall be opened for further scrutiny and evaluation. Intimation regarding to opening of technical and financial bids shall be given to acceptable Tenderers to enable them to attend the technical and financial bid opening, if they so desire. The method of evaluation of L1 bidder for awarding the Contract shall be on consolidated grand total offer by the bidder and will be decided taking into consideration of the total offered price including Parts(A+B+C) as per Section-XI (Price schedule)of this tender document.

7

CORRECTIONS in GIT Clauses GIT CLAUSE 21.1

WRITTEN AS IN GIT CORRECTED AS IN SIT In 3rd line of procurement manual the “Para 1 of NIT” words “Para 11 of NIT”

21.1

In 6th line of procurement manual the “Clause 1 of NIT” words “Clause 11 of NIT” In 2nd line of procurement manual the “Clause 1 of NIT” words “Clause 11 of NIT”

24.1

8. CO-ORDINATION WITH STATUTORY BODIES AND OUTSIDE AGENCIES The Contractor shall be fully responsible for carrying out all co-ordination & liaison work as may be required with Electrical Inspector, Factory Inspector & other statutory bodies for implementation of the work. The application on behalf of the Owner for submission to the Electrical Inspector & other statutory bodies along with copies of drawings complete in all respects shall be done by the Contractor & approval/certificates taken well ahead of time so that the actual commissioning of equipment is not delayed for want of inspection and approval by the Inspector & statutory bodies. The actual inspection work by the Electrical Inspector shall be arranged by the Contractor. However, official fees paid to Electrical Inspector/ statutory bodies, etc. in this regard shall be borne by the Owner.

8

(Section – IV)

GENERAL CONDITIONS OF CONTRACT (GCC)

Kindly refer http://spmhoshangabad.spmcil.com/spmcil/uploaddocument/GCC.pdf for further details. (GCC contains 28 Pages)

9

(Section – V)

SPECIAL CONDITIONS OF CONTRACT (SCC) The following Special Conditions of Contract (SCC) will apply for this purchase. The corresponding clauses of General Conditions of Contract (GCC) relating to the SCC stipulations have also been incorporated below. These Special Conditions will modify/ substitute/ supplement the corresponding (GCC) clauses. Whenever there is any conflict between the provision in the GCC and that in the SCC, the provision contained in the SCC shall prevail. Sl. No GCC Clause No.

1.

2.

Topic

SCC Provision

1

1

Abbreviations – in conjunction with GCC

1

2

9

Inspection and Quality Control

2

3

11.2

Transportation of Domestic Goods

3

4

12

Insurance

4

5

14

Incidental Services

5

6

16

Warranty

6

7

21.2

Taxes and Duties

7

8

22

Terms and Mode of Payment

8

9

Security Rules

9

10

Compliance with contract labour Act

10

Abbreviations “SPM/OWNER/PURHCASER” means Security Paper Mill, Hoshangabad. “SPMCIL” means Security Printing and Minting Corporation of India Limited “DCPL” means Development Consultants Private Limited, Kolkata “BIDDER”/”TENDERER”/”CONTRACTOR” means the individual/firm who quotes against this tender enquiry . Inspection and Quality Control

2.1 SPM and/ DCPL or its nominated representative(s) will, without any extra cost to SPM, inspect and/ or test the ordered work and the related services to confirm their conformity to the contract specifications and other quality control details incorporated in the contract. SPM shall inform the contractor in advance, in writing, SPM's programme for such inspection and, also the identity of the officials to be deputed for this purpose. 2.2 The Technical Specification and Quality Control Requirements incorporated in the contract shall specify what inspections and tests are to be carried out and, also, where and how they are to be conducted. If such inspections and tests are conducted in the premises of the contractor, all reasonable facilities and assistance, including access to relevant drawings, design details and production data, shall be furnished by the supplier to SPM's inspector at no charge to SPM. 2.3 If during such inspections and tests the contracted work fail to conform to the required specifications and standards, the inspector may reject them and the contractor shall either replace the rejected work or make all alterations necessary to meet the 10

specifications and standards, as required within the original delivery period and as specified in the contract free of cost to SPM and resubmit the same to the inspector for conducting the inspections and tests again. 2.4 In case the contract stipulates pre-despatch inspection of the ordered work at contractor’ s premises, the contractor shall put up the work for such inspection to SPM’s or DCPL’s inspector well ahead of the contractual delivery period, so that the inspector is able to complete the inspection within the contractual delivery period. 2.5 If the contractor tenders the goods to the inspector for inspection at the last moment without providing reasonable time to the inspector for completing the inspection within the contractual delivery period, the inspector may carry out the inspection and complete the formality beyond the contractual delivery period at the risk and expense of the contractor. The fact that the goods have been inspected after the contractual delivery period will not have the effect of keeping the contract alive and this will be without any prejudice to the legal rights and remedies available to SPM under the terms & conditions of the contract. 2.6 Work accepted by SPM and/ or its inspector at initial inspection and in final inspection in terms of the contract shall in no way dilute SPM's right to reject the same later, if found deficient in terms of the warranty clause of the contract, as incorporated under GCC Clause. 2.7 Travelling expenses, Lodging and boarding charges of SPM officer for pre-shipment inspection shall be borne by SPM. 3. Transportation of Domestic Goods The supplier shall arrange transportation of the ordered goods up to the SPM and further transportation up to the Project site. 4. Insurance 4.1 The Supplier shall arrange for insuring the goods the goods against loss or damage incidental to manufacture or acquisition, transportation, storage and delivery in the following manner: 4.2 The supplier shall be responsible till the entire stores contracted for arrive in good condition at destination. The transit risk in this respect shall be covered by the Supplier by getting the stores duly insured. The insurance cover shall be obtained by the Supplier in its own name and not in the name of SPM or its Consignee. 4.3 Insurance in respect of damages to persons and property during equipment erection: 4.3.1

The Contractor shall be responsible for all injury or damage to persons, animals or things and for all damage to property which may arise from any factor omission on the part of the CONTRACTOR or any of their employees. The liability under this clause shall cover also inter-alia any damage to structures, whether immediately adjacent to the works or otherwise, any damage to roads, streets, footpaths, bridges as well as damage caused to the building and other structures and works forming the subject matter of this contract. The Contractor shall also be responsible for any damage caused to the buildings and other structures and works forming the subject matter of this contract due to rain, wind, frost or other inclemency of weather. The Contractor shall indemnify and keep indemnified the SPM and hold him harmless in respect of all and any loss and expenses arising from any such injury or damage to persons or property as aforesaid and also against any claim made in respect of injury or damage, whether under any statute or otherwise and also in respect of any award 11

or compensation or damage consequent upon such claims. The Contractor shall, at his own expense, effect and maintain till issue of the virtual completion certificate under this contract, with an insurance company approved by the SPM, an All Risks Policy for Insurance for the full amount of the contract including earth quake risk in the joint names of the SPM and the Contractor (the name of the former being placed first in the policy) against all risks as per the standard all risk policy for Contractor’s and deposit such policy or policies with the Owner before commencing the works. 4.3.2

The Contractor shall reinstate all damage of every sort mentioned in this clause so as to do delivery of the whole of the works complete and perfect in every respect and so as to make good or otherwise satisfy all claims for damage to property or third parties.

4.3.3

The Contractor shall also indemnify and keep indemnified the SPM against all claims which may be made against the SPM by any person in respect of anything which may arise in respect of the works or in consequence thereof and shall at his own expense, effect and maintain until the virtual completion of the contract, with an Insurance Company approved by the SPM a policy of Insurance in the joint names of the SPM and the Contractor (name of the former being placed first in the policy) against such risks and deposit such policy or policies before commencement of the works.

4.3.4

The minimum limit of the coverage under the policy shall be Rs.2 Lakhs per person for any one accident or occurrence and Rs.5 Lakhs in respect of damage to property for any one accident or occurrence. The Contractor shall also indemnify the SPM against all claims which may be made upon the Owner, whether under the Workmen’s Compensation Act or any other

4.4

statute in force, during the currency of this contract or at Common Law in respect of any employee of the Contractor and shall be at his own expense, effect and maintain until the Virtual Completion of the Contract with an Insurance Company approved by the SPM a policy of Insurance against such risks and deposit such policy or policies with the SPM from time to time during the currency of this contract.

4.4.1

In default of the Contractor insuring as provided above, the SPM may so insure and may deduct the premiums paid from any money due or which may become due to the Contractor.

4.4.2

The Contractor shall be responsible for any liability which may not be covered by the insurance policies referred to above and also for all other damages to any person, animal or defective carrying out of this contract, whatever, may be the reasons due to which the damage shall have been caused.

4.4.3

The Contractor shall also indemnify and keep indemnified the SPM against all and any costs, charges or expenses arising out of any claim or proceedings relating to the works and also in respect of any award of damage or compensation arising there from.

4.4.4

Without prejudice to the other rights of the SPM against Contractors in respect of such default, the SPM shall be entitled to deduct from any sums payable to the Contractor the amount of any damages, compensation costs, charges and other expenses paid by the Owner and which are payable by the Contractor under this clause. 12

4.4.5

The Contractor shall upon settlement by the insurer of any claim made against the insurer pursuant to a policy taken under this clause, proceed with due diligence to rebuild or repair the works destroyed or damaged. In this event all the money received from the insurer in respect of such damage shall be paid to the Contractor and the Contractor shall not be entitled to any further payment in respect of the expenditure incurred for rebuilding or repairing of the materials or goods destroyed or damaged.

4.4.6

The Contractor, in case of re-building or reinstatement after damage shall be entitled to such extension of time for completion as the SPM and/ or DCPL may deem fit, but shall, however, not be entitled to reimbursement by the SPM of any shortfall or deficiency in the amount finally paid by the insurer in settlement of any claim arising as set out herein.

5. Incidental Services 5.1 Subject to the stipulation in the Technical Specification (Section - VII), the supplier shall be required to perform any or all of the following services. a) Providing required jigs and tools for assembly, start-up and maintenance of the goods b) Supplying required number of operation & maintenance manual for the goods c) Installation and commissioning of the goods d) Training of SPM’s operators for operating and maintaining the goods e) Providing after sales service during the tenure of the contract f) Providing maintenance service after expiry of the warranty period of the goods if so incorporated in the contract 5.2 Prices to be paid to the supplier by SPM for any of the required incidental services, if not already included in the contract price during the placement of the contract, shall be settled and decided in advance by SPM and the supplier. However, such prices shall not exceed the contemporary rates charged by the supplier to other customers for similar services. 6. Warranty 6.1 The supplier warrants that the goods supplied under the contract is new, unused and incorporate all recent improvements in design and materials unless prescribed otherwise by SPM in the contract. The supplier further warrants that the goods supplied under the contract shall have no defect arising from design, materials (except when the design adopted and / or the material used are as per SPM's specifications) or workmanship or from any act or omission of the supplier, that may develop under normal use of the supplied goods under the conditions prevailing in India. 6.2 This warranty shall remain valid for twelve months after the goods or any portion thereof as the case may be, have been delivered to the final destination and installed and commissioned at the final destination and accepted by SPM in terms of the contract or for eighteen months from the date of despatch from the supplier's premises whichever is later. 6.3 In case of any claim arising out of this warranty, SPM shall promptly notify the same in writing to the supplier. 6.4 Upon receipt of such notice, the supplier shall, with all reasonable speed and time, repair or replace the defective goods or parts thereof, free of cost, at the ultimate destination. The supplier shall take over the replaced parts/ goods after providing their 13

replacements and no claim, whatsoever shall lie on SPM for such replaced parts/ goods thereafter. 6.5 In the event of any rectification of a defect or replacement of any defective goods during the warranty period, the warranty for the rectified/ replaced goods shall be extended to a further period of twelve months from the date such rectified / replaced goods starts functioning to the satisfaction of SPM. 6.6 If the supplier, having been notified, fails to rectify/ replace the defect(s) within a delivery period, SPM may proceed to take such remedial action(s) as deemed fit by SPM, at the risk and expense of the supplier and without prejudice to other contractual rights and remedies, which SPM may have against the supplier. 7. TAXES and DUTIES: TDS or any other applicable taxes shall be deducted from the firms bill. 8. TERMS AND MODE OF PAYMENT

a. 80% payment of the value of goods as per PART A of section XI of this tender document shall be made on receipt and acceptance of goods by the consignee at destination and on production of all required documents by the supplier. b. 20% payment of the value of goods as per PART A of section XI of this tender document shall be made on successful installation, commissioning, charging the installation after getting the clearance from Central Electrical Inspector and other related Statutory Bodies, successful load trial of the installation and acceptance by the consignee. c. 100% payment of the value of civil works as per PART B of section XI of this tender document shall be made after successful completion of civil works and acceptance by consignee. d. 100% payment of the value of installation and commissioning as per PART C of section XI of this tender document shall be made on successful installation and commissioning, charging the installation after getting the clearance from Central Electrical Inspector and other related Statutory Bodies, successful load trial of the installation and acceptance by the consignee. 9.

SECURITY RULES

9.1 The Contractor shall strictly abide by the security rules and regulations enforced by the SPM from time to time. The Contractor shall provide proper identity cards, badges etc., to his employees whenever directed by the DCPL/SPM. 9.2 The Contractor shall arrange for police verification certificates for all his employees/worker/supervisor and the contractor and submit it to CISF(SPM) before starting of the work to obtain the gate pass of the concerned person. 10. COMPLIANCE WITH CONTRACT LABOUR ACT The contractor shall comply with all the provisions of the EPF rules, Workmen Compensation Act 1923, Minimum Wages Act, 1948, and Contract Labour (Regulation and Abolition) Act, 1970 amended from time to time and rules framed there under. The provision of building and other Construction Worker’s Regulation of Employment & Condition of Service Act, 1996 amended from time to time and rules framed therein to be followed. 14

(Section – VI)

LIST OF REQUIREMENTS Schedule No.

Brief description of work and services (Related specifications etc. are in Section-VII)

Accounting unit

Quantity

1.

Design, Engineering, Manufacture, assembly/ pre-assembly, tests at manufacturer’s works, insulation work, shop painting, delivery properly packed for transport, supply, complete erection, final checkup, testing at site, successful commissioning, conducting performance and acceptance tests at SPM site of ‘AUGMENTATION OF 33 / 11KV SUBSTATION, CONSTRUCTION OF 11/0.415 KV SUBSTATION ALONG WITH SWITCHGEARS, CABLING, GROUNDING, LIGHTNING PROTECTION SYSTEM AND CIVIL WORK.-DESIGN, SUPPLY, INSTALLATION & COMMISSIOING ON TURNKEY BASIS.’ as per detail list of requirement A,B,C given below and specified under Section – VII of this tender document complete with all accessories. On Turnkey basis

As per detail list of requirement A, B, C given below and specified under Section – VII of this tender document complete with all accessories. On Turnkey basis

As per detail list of requirement A, B, C given below and specified under Section – VII of this tender document complete with all accessories. On Turnkey basis

15

Amount of Earnest Money

Rs. 12,75,000/(Rupees Twelve Lakhs Seventy Five Thousand Only)

LIST OF REQUIREMENT “A” S.No.

DESCRIPTION

UNIT

QTY

1

Material as per SUB SEC-II OF TECHNICAL SPECIFICATION SECVII of this Tender Document

LOT

1

2

Material as per SUB SEC-III OF TECHNICAL SPECIFICATION SECVII of this Tender Document

LOT

1

3

Material as per SUB SEC-IV OF TECHNICAL SPECIFICATION SECVII of this Tender Document

LOT

1

4

Material as per SUB SEC-V OF TECHINCAL SPECIFICATION SECVII of this Tender Document

LOT

1

5

Material as per SUB SEC-VI OF TECHNICAL SPECIFICATION SECVII of this Tender Document

LOT

1

6

Material as per SUB SEC-VII OF TECHNICAL SPECIFICATION SECVII of this Tender Document

LOT

1

7

Material as per SUB SEC-VIII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

8

Material as per SUB SEC-IX OF TECHNICAL SPECIFICATION SECVII of this Tender Document

LOT

1

9

Material as per SUB SEC-X OF TECHNICAL SPECIFICATION SECVII of this Tender Document

LOT

1

10

Material as per SUB SEC-XI OF TECHNICAL SPECIFICATION SECVII of this Tender Document

LOT

1

11

Material as per SUB SEC-XII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

LIST OF REQUIREMENT – “B” S.No.

DESCRIPTION

UNIT

QTY

1

CIVIL WORK as per SUB SEC-XIII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document.

LOT

1

UNIT

QTY

LOT

1

LIST OF REQUIREMENT – “C” S.No

DESCRPTION SERVICES (Installation & Commissioning)

1

Complete Erection, Testing, Start Up, & Commissioning fulfilment of guaranteed performance obligation including training of Purchaser’s operation and maintenance staff.

Required Completion Schedule : Twelve (12) months from the date of issue of Notification of Award of contract or Purchase Order whichever is earlier. (Including Supply, Erection & Commissioning) Detail Schedule of completion as Time schedule (D) below. 16

1. TIME SCHEDULE – “D” 1.1

TIME SCHEDULE 1.1.1 1.1.2

1.1.3 1.1.4 1.1.5

1.2

The work shall be executed strictly as per the time schedule given below. The Bidder shall furnish a proposed time schedule by CPM/bar-chart along with his quotation. The time schedule should indicate the details considering the date of intimation of award of contract as the zero date and should show completion of various activities there from. The time schedule shall clearly include all important events regarding engineering, procurement, construction, testing and handing over for each area, commensurate with the overall time schedule. The time schedule shall form a part of the Contract Document. BI-WEEKLY Progress reporting shall be done by the Contractor for engineering, procurement and construction activities on mutually agreed formats. Reports on such formats will be sent regularly in soft copies with six (6) copies of print as per frequency / periodicity agreed upon from time to time.

DETAIL TIME SCHEDULE A.

Weeks from issue of Notification of Award of contract or Purchase Order (D)

Substation drawings

Electrical & Mechanical 1. Key Single line diagram & vendor list 2. Electrical Layout Plan & Elevation, Clearance diagram 3. Sag tension calculation 4. Short circuit force & Spacer span calculation 5. Equipment short circuit & Post Insulator span calculation 6. Direct Stroke Lightning protection calculation 7. Switchyard Structural layout 8. Control building equipment layout 9. Grounding design 10. Grounding layout 11. Cable trench layout 12. Control building cable trench layout 13. DC System design & drawings 14. AC System design & drawings 15. Switchyard Erection drawing, list of hardware Erection sag chart

D+3 D+4 D+4 D+4 D+4 D+4 D+4 D+4 D+4 D+4 D+4 D+4 D+5 D+5 D+7

Civil & Structural 1. Design & drawing of Gantry Structure 2. Civil design & drawing of existing Control building 3. Design & drawing of Switchyard 4. Design & drawing of Switchyard Equipment structure 5. Design & drawings of Equipment foundation 6. Design & drawing of Cable Trench outdoor area 17

D+4 D+6 D+5 D+6 D+7 D+8

7. Design & drawing of Transformer foundation 8. Design & drawing of Switchyard Roads, Drains, fence, gate B.

Manufacturer’s Drawings, Data, Manuals 1. Technical Particulars 2. GA and Part List 3. Schematic drawing with Terminal numbers 4. QAP, Test Schedule 5. Spares list 6. Installation, Commissioning & Operating Manuals

C.

D+8 D+8

D+6

D+9

Manufacturer’s Drawings, Data, Manuals for Substation Control, Protection and Management System 1. Technical Particulars & system write-up 2. Schematic drawing with Terminal numbers 3. QAP, Test Schedule 4. Spares list 5. Installation, Commissioning & Operating Manuals 6. Protection settings

D+7 D+8 D+6 D+8 D+9 D+8

D. cable Schedule & Interconnection

D+8

E. PROJECT MILE STONES i) Supply & Installation of 11/.415 KV Distribution System along with the all the necessary requirement for completion of erection ,commissioning & charging the substation (i.e. 3 MVA transformer 3nos., Switchgear,415 PCC,PMCC, Non segregated 3 phase Sandwich Bus duct etc)

ii) Supply & Installation of 33/11 KV in Main Receiving Substation System along with the all the necessary requirement for completion of erection ,commissioning & charging the substation (i.e. 2 nos. of 10 MVA transformer ,cable trench,HV Switchgear, etc)

iii) Project completion & handing over in all respect

Required Terms of Delivery Preferred Mode of Transportation

: F.O.R SPM Hoshangabad : Road

18

D+8 Months

D+10 Months

D+12 Months

LIST OF SAFETY AND HEALTH INSTRUCTIONS TO BE COMPLIED BY CONTRACTOR 2. SAFETY AND HEALTH INSTRUCTIONS FOR COMPLIANCE BY THE CONTRACTOR AS BELOW During installation, the Contractor shall follow all the Safety Policy and Plant Safety rules of SPM and also the various provisions of M.P. Factories Rules, 1962 made under Factories Act, 1948. This instruction gives broad guidelines to be followed by the Contractor for ensuring safe working conditions in and around the site. 2.1

SAFETY ORGANISATION Contractor at site shall organize a Safety Group headed by a Safety Officer who shall be responsible for providing, supervising and monitoring safe working conditions at all times for their workers. The Safety Officer shall be experienced in maintaining safe conditions for workers at site and shall be responsible for and shall have authority to enforce safe conditions for the workers. The Contractor shall have a declared Safety Policy and shall get the same approved by the SPM and/or DCPL. The approved Safety Policy shall be displayed prominently in the Contractor’s site office. The Contractor shall take active interest and participate in the development and operation of safety programs at site. His responsibility does not cease with establishment of Safety Group and approval of its various activities. He shall demonstrate his involvement by regular participation in safety meetings, review of safety records and taking corrective action where required, introduction of safety promoting bulletins, posters, suggestions and awards and by setting example by strictly observing safety rules. The Contractor shall remove all waste material and debris from and around the work area and properly clean up the area at the end of each day before leaving the work site. The Contractor shall take all necessary precautions not only for safe working of his own workmen but also deploy all precautions to ensure safety of structures, equipment and workmen of other agencies in and around his work site. The Contractor shall ensure that his workmen do not trespass into prohibited areas. The SPM and/or DCPL shall have the right to inspect at any time, all items of machinery or equipment brought to site by the Contractor, his agents or workmen and to prohibit the use on the site of any item, which in the opinion of the SPM and/or DCPL is or may be detrimental to the safety of the site. The exercise of such right or the omission to exercise it in any particular case shall not absolve the Contractor or his agents or workmen of their responsibility of adhering to the safe working practices. The Contractor shall execute the work in a manner causing the least possible interference with the business of the SPM and/or DCPL, or with the work of any other Contractor who may be engaged on the premises and shall at all times cooperate with the other Contractors working at site. The Contractor shall obtain work permit from the SPM and/or DCPL before starting any work at site. The work permits are issued to prevent the Contractor from working in un-authorized areas and shall be valid for specific area for a stipulated period The Contractor shall ensure at all times that his workers do not lie down or sleep under or around any machine, equipment, vessel, vehicle or structures in his work area.

19

2.2

RESPONSIBILITIES OF THE CONTRACTOR’S SAFETY OFFICER He is responsible and accountable for: a) Preventing injury to personnel, damage to plant and equipment and fires. b) Instituting ways to improve existing work methods from safety point of view. c) Legal and contractual requirements affecting safety, health, and welfare of his workmen d) Provision and use of protective clothing and equipment and use of firefighting equipment e) Suitability of new and hired equipment from a safety viewpoint f) Identifying potential hazards. g) Changes in safety requirements and fire precautions h) Carrying out site surveys to see that only safe work methods are in operation, health and safety requirements are being observed and welfare and first aid facilities are adequate and properly maintained. i) Determining the cause of an accident or dangerous occurrence and recommend means of preventing recurrence. j) Supervising the recording and analysis of information on injuries, damage and production loss. Assess accident trends and review overall safety performance. k) Assisting with training of employees at all levels. Organizing periodic demonstration of practicing safe working conditions by experienced safety instructors. l) Taking part in discussions on injury, damage and loss control. m) Keeping up-do-date with recommended codes of practice and safety literature. Circulating information applicable to each level of employees. n) Fostering within the company an understanding that injury prevention and damage control are an integral part of business and operational efficiency. o) Attending job progress meetings where safety is an item on the agenda. Report on job safety performance. The Safety Officer shall inspect and ensure the following: a) All electrical equipment are securely earthed. b) Standard access platforms and ladders are provided for inspection, operation and maintenance of equipment. c) The equipment are periodically inspected for their condition, maintained d) Properly and operated by trained personnel at design speeds and loads.

2.3

WORKING AT HEIGHTS For carrying out work at heights exceeding 2 meters or near openings in floors and roofs etc. precautions as given in following paras shall be taken. Adequate safety precautions like use of safety belts, crawling-ladders, safety nets etc. shall be taken. The workers shall wear safety belts with hook properly fastened. All workmen engaged on work at heights shall be experienced in such work. Written permission of the SPM and/or DCPL shall be obtained before undertaking work on roofs. Wherever possible, steel staging or platform shall be erected. Staging with toe guards shall be provided with simple safety rails or ropes at waist height throughout its length on all open sides. Staging supports shall be All Purpose Scaffolding (APS) steel tubes scaffolding, safety secured and supported on firm level footings or slung from overhead beams. The supports shall be situated at maximum distance of 2.5 metres apart and the staging shall be secured to each support. 20

Wherever it is not possible to put up staging and/or use of safety belts, safety nets shall be slung beneath the place of work for safety. When working over open process vessels or tanks, safety belts and safety nets shall always be used whether or not staging and scaffolding is provided. Safe access to all points of works shall be provided in the form of suitable ladders and stairways etc. Area around the work place shall be barricaded suitably or fenced off to avoid injuries to personnel passing by. Suitable warning boards and signs shall be put up. 2.4

LIFTING GEAR The Contractor shall submit a valid Test Certificate to the SPM and/or DCPL, from approved certifying authorities for all of his lifting gear and hoists, slings, chains, wire ropes, hooks, chain-pulley blocks, winches, hoists and cranes etc. before commencing work. These certificates shall be available at site in the Contractor’s office for inspection as and when required.

2.5

PRESSURE AND LEAK TESTING Pressure and leak testing of equipment shall be carried out hydraulically. However, in special cases where pneumatic testing is specified, written approval shall be obtained from the SPM and/or DCPL before starting work. Under no circumstance gases other than nitrogen, carbon dioxide, air or steam shall be used for testing. In case nitrogen or carbon dioxide is used for testing, the equipment shall be adequately ventilated and gas tested to ensure oxygen content of 21% before permitting a worker to enter the equipment.

2.6

WORK INSIDE AN EQUIPMENT OR DRAINAGE SYSTEM All equipment and associated piping shall be isolated, completely drained, purged and well ventilated before entry of a worker. The atmosphere inside the vessel or equipment shall be tested to ensure absence of toxic and flammable gases. Toxic and flammable liquids and gases in the equipment shall be safely disposed off as per the statutory requirements to the satisfaction of the SPM and/or DCPL. Workers carrying out drainage, purging and testing operations shall wear gas masks and other protective gear appropriate to the material being handled. While a worker has entered equipment or a drainage system, another worker shall be present outside at all times to assist the worker inside in the event of an emergency.

2.7

ELECTRICAL Portable power tools rated for above 50 V supply and hand lamps rated for above 24 V supply shall not be used at site. An armored cable with a 3 pin Reyrolle type plug, properly earthed shall be provided between the Contractor’s DG set and step down transformer. All power supply and distribution boards shall have canopy for protection and all the distribution boards shall be earthed securely. All supply points shall have proper plug and socket. The Contractor shall check tightness of connection of cable terminations and joints before starting the work.

2.8

WELDING Only qualified welders shall be employed at the work site. The Contractor shall organize the qualifying test at site for his welders and the SPM and/or DCPL shall approve the welders. All welders shall have to undergo qualifying test and only on passing the test, they shall be allowed to work at site. 21

For all welding work at site, generator sets shall be used instead of AC transformer sets. AC transformer sets are banned for welding jobs inside vessels (both open and closed top type). The Contractor shall get his welding sets certified by the SPM and/or DCPL before starting work. These certificates shall have to be renewed every two months. A copy of the certificates shall be displayed on respective welding sets. Only cables in good condition and insulated holders shall be used. The length of supply cable to welding site shall not exceed 8 meters and the welding set body shall be properly earthed. A charged fire extinguisher of CO2 type shall be carried with each welding set. The Contractor shall keep Halon or equivalent type fire extinguishers near hot jobs like cutting oil lines. The welder shall not use a building structure, pipeline or railway track etc. as a return path of the current. Adequately rated circuit breaker shall be provided in the power circuit for human protection on all power supply points. 2.9

HOT WORK Before starting any hot work like gas cutting, welding and grinding etc., the Contractor shall obtain hot work permit from the SPM and/or DCPL. The permit shall be renewed on day-to-day basis. The Contractor shall ensure purging of piping and equipment to make it totally safe before carrying out any hot work. Smoking is strictly prohibited in work areas inside the SPM premises No combustible material shall be stored on or near any source of heat like hot pipes, welding or gas. Before leaving the place of work or the Contractor’s sheds, the Contractor’s workmen shall ensure that no material or item that could start a fire is left at site. Special attention shall be paid to collection and disposal of oil soaked cotton waste or rags. On no account are these to be dropped into corners, pushed below equipment or left hanging on pipes. Gas cylinders shall be used in a safe manner. These shall not be dropped from heights or dragged on the floor. Trolley with rubber rimmed wheels shall be used for transporting gas cylinders within the site. Acetylene cylinders shall be kept in upright position. Oxygen cylinders shall not be kept near inflammable materials like oil etc. Tarpaulins shall not be used in the vicinity of welding and gas cutting jobs. The Contractor’s supervisor of the rank of a foreman or equivalent shall examine the arrangements made for hot work before commencement of work and shall satisfy himself that all reasonable safety precautions have been taken. The Contractor shall return the hot work permit after completion of welding work.

2.10

PERSONAL PROTECTIVE EQUIPMENT Workmen at site shall wear protective clothing, head, leg and eye protection safety equipment at all times as per the job requirements. These are to be supplied and provided by the Contractor. Adequate number of IS approved safety helmets shall be available at site. Welders shall wear good quality insulated welding gloves, goggles, face shield, shoes and overalls while at work.

2.11

ACCIDENTS In case of injury or serious illness of a worker, the CONSULTANT or OWNER shall be notified immediately. All accidents shall be recorded by filling in the ‘Accident Report’ form, which shall be kept in easy accessible location in the site office of the Contractor. Any ‘Near Miss’ incident shall also be reported by the Contractor and recorded. 22

2.12

INSURANCE All the Contractor’s workmen shall be covered under the Employees State Insurance Scheme, Medi-Claim Policy or any other scheme which may be specified by the Statutory Authorities from time to time.

2.13

REVIEW MEETING The SPM and/or DCPL shall conduct fortnightly Safety Review Meeting to review the safety conditions practiced at work areas by the Contractor.

2.14

WORK AFTER NORMAL WORKING HOURS Extra care shall be taken for jobs to be carried out after normal working hours with due revalidated work permit and supervised by the Contractor’s site in-charge. The site-in-charge shall make available his residential address and telephone number to the SPM and/or DCPL so that he can be contacted in case of an emergency. Proper lighting shall be ensured at the workplace for any work carried out after the normal working hours.

2.15

CONVEYANCE FOR EMERGENCY The Contractor shall ensure that conveyance and person with driving license is available at site at all times of work execution so that in case of an accident, the victim can be rushed to nearest medical Centre.

2.16

SAFETY PRACTICES Avoid working under un-insulated live conductors or working on freshly painted steel, which is still wet. Stairs and railing shall be in place as long as necessary. Ladders shall be periodically checked for any defects. Ladders shall be securely fastened to prevent movement while in use. The Contractor shall advise his workmen to take the following precautions while using ladders: a) While ascending or descending, face the ladder. Use both hands for holding. b) Do not climb higher than the third rung from top on straight or extension-ladders and second rung from top on set ladders. c) Step-ladders shall be fully open before use. d) Sliding down a ladder shall be prohibited. e) Make shift ladders such as clear fastened across a single rail and short ladders spliced together shall never be used. f) Ladders shall be kept free from dirt and grease. g) Defective ladders shall be removed from use. h) Ladders shall not be left un-attended unless these are securely anchored at top and bottom. i) While using ladders, shoes shall not be greasy, muddy or otherwise slippery. j) Ladder shall not be used during severe windy conditions. Lumber shall be piled out of the work area. Nails shall be removed or bent while handling lumber to avoid injury to workmen. While tearing down plaster or brickwork, dust shall be controlled with water. Walls shall not be subjected to lateral pressure or impact from materials stored or falling materials. The safety valves for boilers shall be set by trained personnel and shall be sealed or padlocked at safe working pressure. Only authorized person shall change the setting 23

of safety valves. The safety valve relieving pressures shall be checked as recommended by the manufacturer and applicable codes. Blow down valves shall be operated strictly as per instructions. If blow cock is not marked with an arrow to show open and close position, the same shall be marked at site. Safety slogans and safety instructions shall be prominently displayed in English, Hindi and local language at strategic locations. 2.17

EMERGENCY PROCEDURES The Contractor shall familiarize himself with the emergency procedures, which apply to plants and areas in which his men are working. First Aid Box shall be kept in the Contractor’s site office. The Contractor’s site-incharge and his key supervisors shall be trained in administering first aid, preliminary treatment for electrical shocks, fall from height and burns etc. When an emergency condition exists or on hearing the ‘Stop Work Alarm’ every supervisor shall ensure: a) All work is stopped at once. b) All equipment is shutdown. c) All men are evacuated to a pre-determined assembly point. d) A roll call is taken and every man is accounted for. e) No one shall be permitted to return to work until notification has been received from a responsible authorized agency that it is safe to do so.

2.18

REPONSIBILITY OF THE CONTRACTOR’S SITE IN CHARGE His primary responsibility is safety of personnel and equipment. He shall: Understand the company’s policy on maintaining safe working environment and appreciate the responsibility allocated to each grade of supervision. Know the safety requirements and relevant Government Regulations, and ensure their implementation. Ensure that sound, safe working methods and reasonable welfare facilities are provided for workers. Determine at the planning stage the following: 2.18.1 The most appropriate order and method of working 2.18.2 Allocation of responsibilities to supervisors 2.18.3 Storage areas and access etc. 2.18.4 Hazards which may arise from overhead or underground services 2.18.5 Facilities for welfare, first aid and sanitation 2.18.6 Work permit procedures and requirements 2.18.7 Basic fire precautions 2.18.8 Provide written instructions to establish work methods, to explain the sequence of operations, to outline potential hazards at each stage and to indicate precautions to be adopted.

24

(Section – VII)

TECHNICAL SPECIFICATIONS OVERALL CONTENTS

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SL.NO.

DESCRIPTION

SUB-SECTION

1.00.00

GENERAL ELECTRICAL SPECIFICATION

SUB-SECTION-I

2.00.00

10 MVA POWER TRANSFORMER

SUB-SECTION-II

3.00.00

LT AUX. TRANSFORMER

SUB-SECTION-III

4.00.00

NEUTRAL GROUNDING RESISTOR

SUB-SECTION-IV

5.00.00

11 KV HV SWITCHGEAR

SUB-SECTION-V

6.00.00

415 V PCC/PMCC/MCC, 415V AC AND 220V DC DB /FB, 220V DC STARTER AND 415 V NON-SEGREGATED PHASE SANDWICH TYPE BUSDUCT

SUB-SECTION-VI

7.00.00

BATTERY & BATTERY CHARGE

SUB-SECTION-VII

8.00.00

33 KV OUTDOOR SWITCHYARD

SUB-SECTION-VIII

9.00.00

415 V EMERGENCY DIESEL GENERATOR

SUB-SECTION-IX

10.00.00

POWER & CONTROL CABLES

SUB-SECTION-X

11.00.00

ELECTRICAL INSTALLATION

SUB-SECTION-XI

12.00.00

CABLING & GROUNDING

SUB-SECTION-XII

13.00.00

CIVIL WORKS

SUB-SECTION-XIII

25

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION - I GENERAL ELECTRICAL SPECIFICATION

26

SUB-SECTION - I GENERAL ELECTRICAL SPECIFICATION CONTENTS CLAUSE NO.

DESCRIPTION

1.00.00

INTENT OF SPECIFICATION

1

2.00.00

SCOPE OF WORK

2

3.00.00

GENERAL REQUIREMENT

7

4.00.00

SITE CONDITION

9

5.00.00

CO-ORDINATION WITH STATUTORY BODIES AND OUTSIDE AGENCIES

9

6.00.00

FACILITIES TO BE ARRANGED BY CONTRACTOR

9

7.00.00

CO-ORDINATION WITH OTHER CONTRACTORS AND OWNER’S SYSTEM

10

8.00.00

DRAWINGS, DATA AND MANUALS

10

9.00.00

PREFFERRED MAKE LIST

PAGE NO.

11

ATTACHMENTS ANNEXURE - A

SYSTEM DETAILS

12

ANNEXURE - B

LIST OF TENDER DRAWINGS

14

27

GENERAL ELECTRICAL SPECIFICATION 1.00.00

INTENT OF SPECIFICATION

1.01.00

This specification is intended to cover complete design, engineering, manufacture, assembly, testing at manufacturer's works, supply and delivery, properly packed for transportation F.O.R. SPM,Hoshangabad of all equipment and accessories, steel structures including complete erection, testing, commissioning & putting into successful commercial operation of Plant Electrical system inclusive of supply of all labour; supervision, tools, implements and supplies as required for new PM-5 and Up gradation project of SECURITY PAPER MILL, Hoshangabad, India on turnkey basis.

1.02.00

All items of equipment and system covered under this specification shall be complete in all respect and any item of equipment or accessory not specifically mentioned in this specification but considered essential for efficient and satisfactory operation of individual equipment and system as a whole shall be included in the offer. Specification of equipment / system as well as drawings enclosed herewith shall be read in conjunction with this section of specification and rating/quantity/system/design shall be finalized and substantiated accordingly. Any conflict/discrepancy shall be brought to the notice of Client/Consultant by Bidder for resolution during bidding stage. Any such issue not raised at bidding stage but raised after award of contract, decision of Client/Consultant shall be binding on successful Bidder.

1.03.00

The equipment shall conform in all respect to high standards of engineering design and workmanship and should be capable of performing continuous commercial operation within the parameters guaranteed.

1.04.00

Standard designs are preferred, provided they meet the requirements of this Specification, and serve the intended purpose. Alternative design may be offered if the same provide substantial technical improvements or economic advantages. However, it will be at the discretion of the Owner to accept such alternative proposed design. All equipment are intended for continuous duty at the specified ratings without forced cooling under the specified climatic conditions, unless else specified.

1.05.00

All material and equipment supplied under this specification shall be new and unused.

1.06.00

The work is subject to all the terms and conditions detailed in the documents listed below, which shall form part of this specification as if bound together.

1.07.00

a.

Tender Notice

b.

Instruction to Bidders

c.

General conditions of contract for supply, delivery & installation of plant and materials.

In the event of any discrepancy with listed documents, the most stringent one shall govern.

28

1.08.00

Before bid submission, Bidder is advised to visit existing plant & substation to acquaint himself with the detailed technical requirement, terminal points, facilities available, space & layout etc. for consideration in Bid accordingly. Failure to do so by Bidder shall not be a reason for Owner to accept any additional commercial implication of successful Bidder for interfacing with existing system.

2.00.00

SCOPE OF WORK

2.01.00

SCOPE OF SUPPLY

2.01.01

Broad scope of electrical works under this package is outlined below. Items that are not specifically mentioned but are required to make the system complete in all respect shall be deemed to be included in the scope without any extra cost implication. The scope of supply includes involves timely procurement of items based on design guidelines as per this specification’s subsections, delivery to site, storing at site as detailed in the respective specifications of those stated in the following table: i)

33/11 KV 10 MVA Power Transformers

ii)

3 MVA, 11KV/ 415V LT Aux. Transformers

iii)

Neutral Grounding Resistors

iv)

11 KV HV Switchgear

vi)

415V LT Switchgear with APFC controllers with harmonic tuner, Power cum motor control centers(PMCC), Motor Control Centers (MCC), AC Dist. Boards & Fuse boards, DC Dist. Boards &Fuse boards and 415 V Non –segregated phase sandwich type bus duct .

vii)

Local control boards/panels, Local isolating switch units, Local push button stations

viii)

Battery and battery chargers

ix)

33 KV Outdoor switchyard equipment and accessories.

x)

415 V Emergency Diesel Generator

xi)

Power and Control Cable

xii)

Associated Civil work for 33KV Substation and outdoor cable trench/ Cable tray work from 33 KV MRSS to PM#5 Mill Building Substation.

xiii)

Erection - cabling, grounding and lightning protection system.

xiv)

Erection – indoor and outdoor electrical equipment.

29

2.02.00

SCOPE OF INSTALLATION

2.02.01

The scope of installation work includes erection, testing, commissioning and putting into successful commercial operation of all concerned equipment’s, grounding system and cabling work, lightning protection system as detailed in accompanying specifications described above including supply of all labor, materials, tools, tackles etc.

2.02.02

Installation work shall be in conjunction with/not limited to the followings and the requirements of the attachments, drawings and Bill of Materials issued along with this specification. a. Installation work shall be carried out in accordance with good engineering practices and also manufacturer’s instructions/ recommendations where the same are available. b. Equipment shall be installed in a neat workmanlike manner so that it is level, plumb, square and properly aligned and oriented. c. The equipment shall be furnished in disassembled condition as received at site. Bidder shall assemble all those parts, mount and wire-up loose equipment, fittings and accessories and complete all connections. d. The equipment will be generally supplied with base frame. All bolts, nuts, anchors etc. shall be supplied to complete the installation. e. All erection work shall be carried out in strict compliance with manufacturer’s instructions and shall include all necessary adjustments, checks and measurements. f.

All internal wiring of the equipment which has been left incomplete because of shipping split or which requires minor modifications shall be carried out by the contractor.

g. The contractor shall record results of all erection tests and measurements. The contractor shall submit copies of those test results to the Owner for his reference and record. h. Boards etc. will be split up in sections for ease of transportation and handling. All bus wires, relays, meters and control switches etc. supplied loose to be mounted and connected at site. i.

Base frames shall be properly anchored with foundation. Inter-shipping section connections shall be made. If any civil modification work is required, same shall be done by the Bidder.

j.

All connections in the Cabinets, distribution boards etc. shall be completed, checked and adjusted to ensure safety and satisfactory operation of the equipment. In some cases, modifications may have to be carried out at site in the wiring of an equipment to meet the requirements of the desired control scheme.

k. Bidder shall follow all standard safety regulations and site specific procedures to adopt effective safe working practices to ensure safety of personnel with an objective of zero fatalities and zero lost time due to injuries. 30

l.

Steel Fabrication

m.

2.02.03

ƒ

Installation, fabrication and painting with one coat of anti-rust primer and two finished coats of approved synthetic enamel paint on structural steel for mounting of various equipment’s and for cable tray supporting arrangement.

ƒ

Contractor shall use all existing available steel structures, cable rack supports, hangers and brackets as per as possible. Additional racks, supports, hangers and brackets wherever necessary shall be supplied and fabricated by the contractor.

ƒ

Steel for fabrication shall be straightened and cleaned of rust and grease. All fabrication shall be free of sharp edges.

ƒ

GA drawing and related technical particulars shall be furnished by Owner/Consultant’s review.

Miscellaneous items ƒ

The contractor shall install miscellaneous items such as local starters, fuse boards, start-stop push button station, ventilation fan etc. as required.

ƒ

These equipment will be generally wall or column mounted excepting a few which may be floor mounted. The exact locations will be as decided by the Owner's Engineer at site and as shown in the final drawings.

ƒ

All welding, cutting, chipping and grouting as and when necessary shall be carried out by the Contractor at no extra cost.

Providing all equipment’s / instruments / materials / components required at site for entire scope of services under this specification including handling, protection, testing, oil filtration, welding, cutting, bending, pulling, civil & structural work etc. shall be under scope of Bidder, including but not limited to the followings in the indicative list: a)

Stream line filter machine for adequate capacity suitable for filtration of oil of transformers of various ratings mentioned in the specification, along with power supply equipment’s and accessories

b)

Test kit for transformer oil (BDV etc.)

c)

Hi-pot test kit (AC & DC)

d)

Primary & secondary injection test kit

e)

Phase sequence meter

f)

Ratio tester for transformer

g)

Welding machine

h)

Crimping tools for various sizes of cables

i)

Erection crane

31

2.03.00

SCOPE OF SERVICES

2.03.01

Furnishing all labor, skilled & unskilled, supervisory personnel, erection tools & tackles, testing equipment, implements, supplies and transport for timely and efficient execution of the erection work.

2.03.02

Scope of service shall include supply, erection, installation, testing and commissioning of all Electrical Equipment’s and accessories as mentioned in clause no.2.01.01 above.

2.03.03

The items of work to be included under the scope of services of the contractor as specified below: a) Erection, Testing & Commissioning of all equipments with all fittings and accessories supplied under this contract b) Laying, termination, testing & commissioning of Power and Control Cable supplied under this Contract. c) Installation, testing & commissioning of grounding and lightning protection materials for grounding of all equipments, cable trench/tray, gantry, structure, fencing etc. d) Erection, testing & commissioning of pre-fabricated cable trays with all accessories supplied under this contract. e) Fabrication & Installation of fence supports, fence, etc. supplied under this Contract. f)

Laying of earth material and equipment including Risers,. Earthing of all equipment & Numerical relays, Bay Controllers by using separate electronic Earth pits.

g) Dismantling and removal of following equipments from 33KV MRSS i) Two (2) nos. 33KV /11 KV 3MVA, Power Transformers. ii) Eight (8) nos. 33KV Disc. Switches. iii) Six(6) nos. 33KV Lightning Arrestors iv) Two(2) nos. 33KV, 1250A VCBs v) Six(6) nos. CTS. vi) 33KV bus bars and conductors. vii) Misc. items such as existing structures, transformer foundation etc. xv) Two(2) nos. 33KV Transformer control panels. 2.03.04

Proper storing arrangement and protection of equipment and materials at site at Contractor’s expense. The Contractor shall be held responsible for any loss or damage until the work is fully and finally accepted.

2.03.05

All testing equipment as required for testing & commissioning of equipment/system shall be arranged by the bidder.

2.03.06

The contractor shall also carry out the following services but not be limited to: a)

Taking delivery of the owner supplied equipment and materials from the Owner’s stores, if any, and safe transportation up to the place of erection and excess material back to Owner’s store. 32

2.04.00

b)

Opening of Packing Cases and inspecting the equipment and materials at site and reporting damages or any discrepancy thereof, if and observed immediately after opening, to the Owner.

c)

Supervision of civil work for major electrical equipments.

d).

Repair of all minor damages such as removal of paint, loosening of components of the assembly etc.

e)

Complete assembly, erection and commissioning.

f)

Pre-commissioning checkup to ensure correctness of erection as per actual manufacturer instructions.

g)

Testing and commissioning in presence of Owner’s engineers.

h)

Obtaining Engineer’s approval and written acceptance of satisfactory operation.

i)

Handing over of installation for commercial operations.

j)

Preparation and submission of drawings & job compliance report and obtaining drawing approval and charging permission from the electrical inspectorate for the project

SCOPE OF DESIGN WORK The scope of design work shall include detail design for construction and installation of entire electrical system of the Plant.

2.04.01

Design Work - Electrical o

Design Memorandum for various Equipment & Systems

o

Design Calculation, Bill of Material

o

Electrical Single Line Diagrams.

o

Electrical layouts, showing equipment location, cable trays/ trenches, overhead cable routes, etc.

o

Control, metering, protection equipment and the system.

o

Cable schedule and interconnection charts.

o

List of equipment and respective ratings.

o

Cabling and cable tray system.

O

Grounding and lightning protection system including underground grounding mat, over ground grounding grid, air terminal network, lightning mast, Earth Pits.

33

and

signaling

scheme

of

each

O

Relay co-ordination and recommended co-ordination, sag-tension curves.

settings,

insulation

o

Preparation of installation, commissioning, operation and maintenance manuals.

3.00.00

GENERAL REQUIREMENT

3.01.00

CODES & STANDARDS

3.01.01

All electrical equipment and materials shall conform to latest applicable standard publications of International Electro-technical Commission (IEC) or equivalent standards published by the Bureau of Indian Standards (BIS) and other standards mentioned in the various volumes of sections of this specification. In case of a conflict between IEC and other standards, the requirement of IEC shall govern. The provisions of tender specifications (except the clauses of codes and standards of individual specifications) shall however have precedence over all other standards

3.01.02

The electrical installation shall meet the requirements of Indian Electricity Rules as amended up-to-date, relevant IS code of Practice for respective equipment and National Electrical code of India. In addition, other rules & regulations applicable to the work shall be followed. In case of discrepancies, most restrictive rules shall be binding.

3.02.00

COMPLETENESS OF SUPPLY & INSTALLATION

3.02.01

It is not the intent to specify completely herein all details of the equipment & installation. Nevertheless, the equipment & installation shall be complete & operative in all aspects and shall conform to highest standard of engineering, design & workmanship.

3.02.02

Any material or accessory which may not have been specifically mentioned but which is necessary or usual for satisfactory & trouble free operation & maintenance of the equipment shall be furnished without any extra charge.

3.02.03

The Contractor shall supply all brand new equipment & accessories as specified herein with such modification and alteration as agreed upon in writing & after mutual discussion.

3.03.00

PROPOSAL DATA The proposal data sheets annexed to this specification shall be filled in without any ambiguity by typing in appropriate place on each page. These pages must be properly signed by authorized representative of the Bidder as verification of the data and submitted along with the bid to form part of the Bidder's formal proposal.

3.04.00

PERFORMANCE The performance figures quoted in Technical Particular sheets shall be complied within the tolerance permitted by relevant standards. In case of failure of the equipment, the equipment may be liable for rejection.

34

3.05.00

DRAWING APPROVAL

3.05.01

Before starting manufacture of any equipment, the Contractor shall have to take approval of relevant drawings and data from SPM/ DCPL in writing.

3.05.02

Any manufacture done prior to the approval of drawings/data shall be rectified in accordance with the approved drawings/data by the Contractor at his own cost and the equipment shall be supplied within the stipulated period.

3.06.00

QUALITY ASSURANCE

3.06.01

Contractor shall follow his standard procedures for quality assurance and control. However, said standard procedures shall be submitted to the SPM/ DCPL for review and approval.

3.06.02

The procedures shall be in such a form as to clearly delineate the manufacturing sequence and major inspection points and to reference Bidder's test and inspection procedures.

3.06.03

The SPM/ DCPL will inform the Contractor as to which of the inspection points and tests will be witnessed. As a minimum, a final inspection of the equipment will be made prior to shipment.

3.06.04

Manufacturing and quality control procedures shall be available for audit to the SPM/ DCPL and/or its representative at the place of manufacture.

3.06.05

The SPM/ DCPL and/or its representative reserves the right to inspect the equipment at the point of manufacture and witness factory and other such tests as may be necessary to ensure conformance to the specification.

3.06.06

The SPM/ DCPL and/or its representative may inspect the Contractor's facilities prior to award of contract.

3.06.07

The SPM/ DCPL and/or its representative may witness any or all of the tests described. The SPM/ DCPL and/or its representative may conduct surveillance of the Contractor's facilities for compliance to his standard procedures of quality assurance and quality control while work on the specified equipment is in progress.

3.06.08

4.00.00

SITE CONDITION The plant is located in SPM, Hoshangabadin the state of MP. The site is approachable from Mumbai by the state highway. The nearest broad gauge rail link is at Hoshangabad, and the nearest airport is at Raja Bhoj Airport, Bhopal. The apparatus shall be suitable for satisfactory operation in the following environment:Altitude

:

302 m above MSL

Design Ambient Temperature

:

500 C max. / 3.30 C min.

Relative humidity

:

91% max.

35

Basic wind speed as per IS: 802

2.1 m /sec

Seismic zone as per IS: 1893

III

Pollution level according to IEC60815

(heavy)

Isoceraunic level

As per IS: 2309

Switchyard formation level

Bidder to submit

Equipment & Tower foundation plinth level

300 mm (above formation level)

Bay control room / Main control building Plinth level

500 mm (above formation level)

Substation road level

200 mm (above formation level)

5.00.00

FACILITIES TO BE ARRANGED BY CONTRACTOR

5.01.01

The Contractor will be given a plot of land at site for building his site office stores for construction activity only. Electricity will be provided at one point only. It will be the responsibility of the contractor to arrange for further distribution. The contractor shall also arrange for storing of materials with weather protection wherever necessary & proper security arrangement till the installation.

5.01.02

6.00.00

CO-ORDINATION WITH OTHER CONTRACTORS & OWNER’S SYSTEM The Contractor shall be fully responsible for carrying out all co-ordination work required with other contractors as well as with Purchaser & Owner’s System for execution & completion of his work.

7.00.00

DRAWINGS, DATA & MANUALS

7.01.00

Drawings, Data and Manuals shall be submitted in four (4) nos. of copies with the bid and in quantities and procedures as specified in General Conditions on Contract and/or elsewhere in this specification for approval and subsequent distribution after the issue of Notification of Award of

contract or Purchase Order

7.02.00

To be submitted with the Bid

7.02.01

Typical general arrangement drawings of the equipment indicating space requirement, etc.

7.02.02

Proposal Technical Particulars, leaflets on equipment and special tools explaining construction features, principle of operation, special features etc.

7.02.03

Type test certificate of the offered model of the for the specified type tests.

7.03.00

To be submitted for SPM/ DCPL Approval and Distribution after issue of Notification of Award of contract or Purchase Order (A) : ‘Approval Category’ (R) : ‘Reference Category’ 36

Quantities: Hard Copy: 3 Initial submissions, 6 Final approved copies Soft copy Auto Cad Version: Initial & Final 7.03.01

Guaranteed Technical Particulars (A) & Quality assurance plan.(R)

7.03.02

Dimensional general arrangement drawing showing disposition of various fittings, (A)

7.03.03

Structure Plan with details and loading. (R)

7.03.04

Foundation loadings for all equipment and supporting structure ( R)

7.03.05

Assembly drawing for erection at site with part numbers and schedule of materials Transport/shipping dimensions with weights (R)

7.03.06

Control schematic (A) and wiring diagrams (R).

7.03.07

Grounding arrangement and ground bus details (A) including Manufacturer’s recommendation on Grounding of reinforcement bars of Column foundation.

7.03.08

Any other relevant drawing or data necessary for satisfactory installation, operation and maintenance.

7.03.09

Instruction manuals on all HT & LT Equipments and its accessories (R) The manual shall clearly indicate method of installation, checkups and tests to be carried out before commissioning of the equipment.

7.04.00

The drawings and documents marked with (A) above are of ‘Approval’ category and are subject to review by SPM/ DCPL. Those marked (R) are for ‘reference’ category. The Owner may review the documents marked (R) if thought necessary. The contractor shall note that the approval of drawings & documents by the Owner does not relieve him of his contractual obligation.

7.05.00

The bidder may note that the drawings, data and manuals listed herein are minimum requirement only. The bidder shall ensure that all other necessary write-up, curves, etc require to fully describe the equipment are to be submitted with the bid.

7.06.00

All drawings shall be prepared by using AutoCAD and documents shall be generated using Electronic version. The paper copy of the drawings & document shall be submitted for approval & reference. All final drawings and documents shall be submitted in CD in AutoCAD 2000 and MS office format as applicable for Owner’s future reference. Also AutoCAD version of Main GA drawings is to be submitted for Owner’s layout finalization.

37

8.00.00

MAKE LIST: Bidder has to consider following make list of major electrical Equipment:I)

33KV vacuum circuit breaker – ABB, Siemens, CGL, BHEL, AREVA

ii)

33/11KV ,10 MVA power transformer - ABB, Siemens, CGL, BHEL, AREVA

iii)

Neutral grounding resistor – RSI Switchgear,RESITECH,NARKHEDE

iv)

11KV switchgear – BHEL, Siemens, ABB, CGL,AREVA

v)

LT Switchgear &MCC – L&T, Siemens, SCHNEIDER,ABB

vi)

415V Sandwich Bus duct–ABB, L&T, Siemens

vii)

11/0.415 KV 3MVA LT Transformer – ABB, BHEL, CGL, AREVA

viii)

Battery & Battery Charger – Exide, Amaron, AMCO

ix)

HT & LT Power Cable – Finolex,Universal, POLYCAB , Fort Gloster,

x)

Numerical Relays – ABB, Siemens, AREVA

xi)

ACB – ABB, Siemens, L&T

xii)

DG Set – Cummins, Kirloskar, Crompton Greave

38

ANNEXURE-A SYSTEM DETAILS EHV / HV System

33KV

11KV 11KV

1.0

Rated Voltage

:

33KV

2.0

Frequency

:

-----50 Hz +3% to -3%-----

3.0

Phase

:

--------------3------------------

4.0

System Neutral

:

Effectively Earthed

5.0

Fault Level (Sym) rms :

6.0

Insulation Level

6.1

Basic Insulation level

6.2

Switching Impulse level

7.0

Power Frequency withstand voltage dry/wet

8.0

Maximum radio Interference voltage level between 0.5 and 2 MHz at 320KV rms phase to ground (Voltage in micro-volts)

Non-Effectively Earthed thru resistance.

-----31.5KA for 1 sec.-----

KVrms

650 KVp

170KVp

230KV

70KV

-------

9.0

Minimum Visual Corona Extinction Voltage (KV rms)

--------

10.0

Minimum Clearance

10.1

Phase to Phase (mm) (Rod-Conductor) (Cond.-Cond.)

1300

320

10.2

Phase to Earth

1300

320

11.0

Safety Clearances

11.1

Sectional Clearance (mm)

4000

2800

11.2

Height of the lowest live point on the insulator from the ground

12.0

Minimum creepage distance

(mm)

(mm)

-------------2440----------------------------31mm / KV-----------

39

13.0

Auxiliary Power Supply

13.1

A.C. Supply

:

415V ±10%, 3phase, 50Hz ± 3% 4 wire, effectively earthed system. Fault level 50 KA r.m.s. symm.

13.2

D.C. Supply

:

110V + 10%, - 15%, 2 W, ungrounded system. Fault level 15 KA.

14.0.

Bus Configuration

1M+1T

15.0

Conductor

15.1

Main Bus

Dog Type ACSR

15.2

Equipment Interconnection

3.0” IPS Al tube

15.3

Phase to phase equipment spacing

2750

16.0

Bus Height

17.1

Main Bus (mm)

5500

17.2

Equipment Connection

4000

17.3

Jack Bus

8500

Note: The above figures are for general guidance only. The switchyard layout shall meet the requirements of CBIP standards and IE rules.

40

ANNEXURE-B LIST OF TENDER DRAWINGS

SL.NO.

DRAWING NO.

TITLE / DESCRIPTION

1.

11P01-DWG-E-100, Rev-e

Key Single line diagram

2.

11P01-DWG-M-111-050.01, Rev 2

Plot Plan

3.

11P01-DWG-E-111-050.01, Rev 0

33KV Switchyard Layout

4.

A- SPM PM5 BUILDING, Rev.0

Single Line Diagram

5.

1327-001377 Sht.1 of 2

Earthing Layout Basement Level PM5

6.

1327-001377 Sht.2 of 2

Earthing Layout Machine Level PM5

7.

1002-0000110350, Rev.1.0 (4 Sheets)

Typical Grounding Details for PM5 Building

8.

11P01-DWG-E-40-ND-400 (14 Sheets)

10.

11P01-DWG-E-53-2341 (28 Sheets)

General Arrangement of cable tray, Trench & support details Grounding notes and details

11.

Part List TPE1/TPE2/TPE3 (3 Sheets)

Bidder’s Scope of Supply

41

SPECIFICATION NO. : 11P01-SPC-E-291-53.02 SUB-SECTION: II 10 MVA POWER TRANSFORMERS

42

SUB-SECTION: II

10 MVA POWER TRANSFORMER

CONTENTS CLAUSE NO

DESCRIPTION

PAGE NO.

1.00.00

CODES AND STANDARDS

1

2.00.00

SCOPE OF WORK

1

3.00.00

DESIGN CRITERIA

2

4.00.00

SPECIFIC REQUIREMENTS

3

5.00.00

TESTS

8

6.00.00

SPECIAL TOOLS & TACKLES

10

7.00.00

INSTALLATION REQUIREMENTS

10

ATTACHMENTS ANNEXURE - A

RATINGS AND REQUIREMENT

11

ANNEXURE - B

FITTINGS AND ACCESSORIES

14

ANNEXURE – C

AUXILIARY EQUIPMENT

16

43

10 MVA POWER TRANSFORMERS 1.00.00

CODES & STANDARDS

1.01.00

All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification.

1.02.00

The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed.

1.03.00

Accountability of transformer loss

1.03.01

Transformer losses will be taken into account during bid evaluation.

1.03.02

The loss figures quoted shall be guaranteed under penalty. The test values for losses will be compared with the corresponding guaranteed figures subject to I.S/IEC. Tolerances for computation of penalties.

2.00.00

SCOPE OF WORK

2.01.00

SCOPE OF SUPPLY Type, rating and connections of the equipment listed below are detailed in the Annexure A. The equipment shall be offered in strict compliance with the same.

2.01.01

Copper Wound 33KV/11 KV, 10 MVA HT Transformers:

2.01.02

Each transformer shall be furnished complete with :a.

Fittings and accessories

b.

Auxiliary equipment

c.

First filling of oil including 10% extra

2.01.03

One (1) set of special tools and tackles

2.01.04

All relevant drawings, data and instruction manuals.

2.02.00

SCOPE OF SERVICES

Two (2) Nos.

The services of supervisor must have supervisory license from State Electricity licensing authority / Qualified Electrical Engineer, experienced in the erection and commissioning of the equipment of similar type and rating on per diem basis. The work includes but not limited to: 2.02.01

Complete checking of materials at site and advising the Owner/Purchaser any discrepancy thereof.

2.02.02

Advice on procedure of erection to be followed.

2.02.03

Regular supervision and following up of erection work done by others. 44

2.02.04

Testing, commissioning and putting the equipment into successful commercial operation.

2.03.00

DELIVERY SCHEDULE

2.03.01

The delivery period shall be as mentioned in the delivery Time Schedule (D)from the date of issue of Notification of Award of contract or

Purchase Order

2.03.02

Delivery period shall be inclusive of the time to be allowed for approval of drawings & test certificates and shall include transportation time to site.

2.03.03

Delivery date shall be reckoned as the date of receipt of the complete equipment & materials at site.

2.03.04

Mandatory spares, special tools and tackles shall be supplied with the first consignment.

3.00.00

DESIGN CRITERIA

3.01.00

The transformer will be used to supply power for SECURITY PAPER MILL, HOSHANGABAD-461005(M.P.)

3.02.00

The transformer will be installed in hot, humid and tropical atmosphere. All equipment, accessories and wiring shall be provided with tropical finish to prevent fungus growth.

3.03.00

The transformer shall be capable of continuous operation at rated output under the following condition: a.

Voltage variation

: 33KV ± 5%

b.

Frequency variation

: 50Hz ±3%

c.

Combined voltage and frequency variation (absolute sum)

: 8%

3.04.00

The transformer shall be capable of withstanding the short circuit stresses due to a terminal fault on one winding with full voltage maintained on the other winding for minimum period of two (2) seconds.

3.05.00

The transformer shall be free from annoying hum or vibration. The design shall be such as not to cause any undesirable interference with radio or communication circuits.

3.06.00

The transformer shall be so designed that it is capable of operation at 125% rated voltage for a period of one minute and 140% rated voltage for a period of five seconds due to sudden load throw off.

3.07.00

The noise level shall be limited to the value specified by NEMA Standard Publication No. TR-1-1993 when measured in accordance with conditions outlines in ANSI/IEEE C57.12.90-1999/IS13964/CBIP publication.

45

4.00.00

SPECIFIC REQUIREMENTS

4.01.00

TANKS

4.01.01

The tank shall be fabricated from good commercial grade low carbon steel of suitable thickness to the project..

4.01.02

The tank wall shall be reinforced by stiffener to ensure rigidity so that it can withstand without any deformation (a) mechanical shock during transportation, (b) oil filling by vacuum, (c) Short circuit forces and (d) continuous internal pressure of 35 kN/m2 over normal hydrostatic pressure of oil.

4.01.03

All removable covers shall be provided with weatherproof, hot oil resistant, resilient gaskets. The design shall be such as to prevent any ingress of water into or oil from the tank.

4.01.04

The tank shall be provided with one set of bi-directional flanged wheels for rolling the transformer parallel to either center line over 1676 mm rail gauge. In case more than two rails are required to be provided the rail gauge of 1676 mm shall be maintained between two adjacent rails.

4.01.05

Jacking pads, lifting eyes and pulling lugs shall be provided to facilitate movement of the transformer. All heavy removal parts shall be provided with eyebolt for ease of handling.

4.01.06

Manholes / hand-holes of sufficient size shall be provided for access to leads, windings, bottom terminals of bushings and taps.

4.01.07

Suitable guide shall be provided in the tank for positioning the core and coil assembly.

4.01.08

Inside of tank shall be painted with varnish/hot oil resistant paint. The top cover of the tank shall be slightly sloping to drain rain water.

4.02.00

CORE & COILS

4.02.01

The core shall be built up with high grade, non-aging, low loss, high permeability, grain oriented, cold-rolled silicon steel laminations especially suitable for core material. They should be bolted together and to the frames firmly to prevent vibration or noise.

4.02.02

The coils shall be manufactured from electrolytic copper conductor and fully insulated for rated voltage. However, HV winding shall be non-uniformly graded for voltage class above about 33KV. Insulation shall be of Class A.

4.02.03

Insulating material shall be of proven design. Coils shall be so insulated that impulse and power frequency voltage stresses are minimum.

4.02.04

Coil assembly shall be suitably supported between adjacent sections by insulating spacers and barriers. Bracing and other insulation used in assembly of the winding shall be arranged to ensure a free circulation of the oil and to reduce the hot spot of the winding.

4.02.05

All leads from the windings to the terminal board and bushings shall be 46

rigidly supported to prevent injury from vibration or short circuit stresses. Guide tube shall be used where practicable. 4.02.06

The core and coil assembly shall be securely fixed in position so that no shifting or deformation occurs during movement of transformer or under short circuit stresses.

4.02.07

The value of the maximum flux density allowed in the design and grade of lamination used shall be clearly mentioned in the offer. The transformers core shall be suitable for over fluxing (due to combined effect of voltage and frequency) up to 12.5% without injurious heating at full load conditions and shall not get saturated.

4.03.00

TAPINGS

4.03.01

Off circuit tap changer (OCTC) as specified in the Annexure-A shall be provided on the high voltage winding.

4.03.02

The transformer shall be capable of operation at its rated KVA on any tap provided the voltage does not vary by more than ±10% of the rated voltage corresponding to the tap.

4.03.03

The winding including the tapping arrangement shall be designed to maintain electromagnetic balance between HV and LV windings at all voltage ratios.

4.04.00

Off Circuit TAP CHANGER (OCTC)

4.04.01

The OCTC switch contacts shall be located in a separate oil-filled chamber complete with its own oil preservation system, Oil Surge relay, shut-off valves, oil level gauge, gas vent etc.

4.04.02

OCTC mechanism and associated controls shall be housed in an outdoor weather-proof cabinet (IP 55 minimum). Internal illumination lamp and thermostat controlled space heater shall be provided in the cabinet.

4.04.03

The tap change equipment shall be so designed that if the mechanism is stuck in an intermediate position, the transformer shall be capable of delivering full load without any injury.

4.04.04

The OCTC gear shall be suitable For local manual control. Further, there shall be provision of automatic operation through voltage sensing relay wherever specified.

4.04.05

The hand cranking arrangement shall be such that it can be operated at standing height from ground level. Further the mechanism shall be provided with a tap position indicator and an operation counter.

4.04.06

Interlock shall be provided to ensure the following:a. Positive completion of tap changing step once initiated. b. Blocking of reverse tap change command during a forward tap change already in progress until the mechanism rests and vice-versa. c. Cutting out of electrical circuit during manual operation. 47

4.04.07

The tap changing gear shall have local selector switches with RTCC-LocalTest-Central positions. Provisions of various modes of operation of the tap changers of transformers, like individual operation (Master / follower operation for 3 off 1- Ph. Bank), remote/local operation; operation from voltage regulating relays(where specified), etc. and for various interlocks shall be kept in the Remote Tap Changer Cubicle (RTCC) as well as local OCTC cabinet. Necessary equipment switches, relays, etc., shall be provided in these panels. The following minimum components shall be provided in the RTCC panel. Any other feature desired for proper and safe operation of equipment shall be provided. All indicating lamps shall be LED type. a)

Voltage regulating relay for auto operation where specified.

b)

Auto-manual selector switch where auto operation specified

c)

Selector switch for master follower solo operation.

d)

Raise-Lower control switch

e)

Necessary relays and accessories.

f)

Tap position indicator

g)

Indication lamps for “Tap change in Progress” and “Control supply healthy”.

h)

Red lamp to indicate master position

i)

Annunciations for :

• • • • •

Tap position in progress Mechanism stuck Control supply failure Tap changer A.C. supply failure Oil surge relay operated

4.04.08

Provisions shall be kept in the RTCC for control from DCS.

4.04.09

The construction and other details of the RTCC shall be similar to those described elsewhere in this specification.

4.05.00

INSULATING OIL

4.05.01

The transformer shall be filled with mineral insulating oil of adequate voltage grade suitably inhibited to prevent sludging.

4.05.02

First filling of oil along with 10% excess shall be furnished for each transformer. Oil shall be supplied in non-returnable containers suitable for outdoor storage.

4.05.03

Oil preservation shall be by means of bellows / diaphragm sealed conservator tank with silica gel breather to avoid direct connection between atmosphere and transformer oil. It shall be complete with level gauges, pipes, drain valve etc. The level gauges shall be so placed that same can be readable standing from ground. Necessary device shall be kept to provide annunciation in the event of rupturing of bellow. 48

Diaphragm seal type constant oil pressure system shall have following system: a) Contact of the oil with atmosphere is prohibited by using a flexible urethane or nitride rubber reinforced with nylon cloth air cell. b) Diaphragm shall be suitable for 100deg C temp continuous operation c) The connection of air cell at the top of the reservoir is by air proof seal permitting entrance of air into the cell only. d) Diaphragm shall with stand vacuum during instillation/ maintenance; otherwise provision shall be made to isolate conservator from main tank during vacuum by providing vacuum sealing valve in the pipe connecting main tank with conservator. 4.06.00

BUSHING

4.06.01

Bushing rated 52 KV class and above shall be oil impregnated paper condenser bushings. Bushing rated below 52 KV voltage class shall be solid porcelain or oil communicating type.

4.06.02

Condenser type bushing shall be provided with oil level gauge, bottom drain plug and test terminal for measurement of loss factor (tan-delta) and capacitance.

4.06.03

Bushings shall be provided with terminal connectors of approved type and size. Arcing horns shall be provided on HV bushings.

4.06.04

Bushing location shall provide adequate phase and ground clearances as per relevant IS and CBIP recommendation.

4.07.00

TERMINAL ARRANGEMENTS

4.07.01

The physical position of the terminals and the markings shall be as per relevant IS/IEC unless otherwise shown in the enclosed drawing.

4.07.02

High voltage terminals shall be brought out through top cover mounted bushings for connection to overhead ACSR/AAAC/Al tube conductors .

4.07.03

Low voltage terminals shall be brought out through top cover mounted bushings with matching flanges around each bushing for connection cable as specified in Annexure. A detachable type cable end-box with disconnect link shall be furnished.

4.07.04

Low voltage winding neutral shall be brought out through side wall mounted bushing to a detachable cable end-box with disconnect link for connection to neutral grounding resistor through copper cable..

4.07.05

The LV cable-end box shall be self-supporting, air filled type complete with all hardware such as gland plate, brass glands, tinned copper lugs, armour clamps etc. Supports shall be provided for all vertically rising cables Cable shall be terminated using stress relieving plug in elbow connectors

4.07.06

In general, the arrangement shall be such as to permit removal of transformer without dismantling the cable connection. 49

4.08.00

COOLING SYSTEM

4.08.01

The transformer cooling system (ONAN only) and number of cooling banks and capacity of each bank shall be as specified in the annexure. The cooling system shall comprise number of cooling units each complete with its radiator banks and other accessories.

4.08.02

The radiators shall be detachable type with top and bottom isolation valves to permit the removal of the same without drainage of oil from the tank.

4.09.00

MARSHALLING BOX

4.09.01

A sheet steel, weatherproof, IPW55, marshaling box shall be provided for the transformer. The box shall contain all auxiliary devices except those which must be located directly on the transformer.

4.09.02

All terminal blocks for Owner/Purchaser's cable connection shall be located in this box.

4.09.03

The marshaling box shall be provided with cubicle lamp with door switch, space heater with thermostat and removable cable gland plate.

4.10.00

WIRING

4.10.01

All control, alarm and indication devices provided with the transformer shall be wired upto the terminal blocks.

4.10.02

Wiring shall be done with flexible, 1100V / 650V grade PVC insulated copper wires in conduit or PVC armored cable. Minimum wire size shall be 2.5 mm2 copper. Not more than two wires shall be connected to a terminal. 10% spare terminals shall be provided.

4.10.03

Multi-way terminal block complete with mounting channel, binding screws and washers for wire connections and marking strip for circuit identification shall be provided for terminating the panel wiring. Terminals shall be stud type, suitable for terminating 2 nos. 2.5 mm2 stranded copper conductor and provided with acrylic insulating cover. Terminals for C.T. secondary leads shall have provision for shorting and grounding.

4.10.04

All devices and terminal blocks shall be identified by symbols corresponding to those used in applicable schematic or wiring diagram. Each wire shall be identified, at both ends, with interlocking type permanent markers bearing wire numbers as per Contractor's Wiring Diagrams. AC / DC wiring shall have separate color-coding.

4.10.05

Wire termination shall be made with crimping type connectors with insulating sleeves. Wires shall not be spliced between terminals.

4.11.00

GROUNDING

4.11.01

The grounding pads, located on the opposite sides of the tank, shall be provided for connection to station ground mat.

4.11.02

Grounding pad shall have clean buffed surface with two tapped holes, M10 G.I. bolts and spring washers for connection to 50x6 mm Cu. flat. 50

4.11.03

Ground terminals shall be also provided on marshaling box to ensure its effective earthing.

4.11.04

For continuity of earth connection, all gasketted joints shall be provided with braided copper wire jumpers.

4.12.00

AUXILIARY SUPPLY

4.12.01

A.C. supply will be made available to each transformer by two separate feeders one normal and the other standby.

4.12.02

Isolating switch fuse unit shall be provided for each of the incoming supply along with automatic changeover scheme to switch on to the standby source in case of failure of the normal supply.

4.13.00

AUXILIARY EQUIPMENT

4.13.01

Neutral bushing current transformers and phase bushing transformers shall be furnished when specified in the annexure.

4.13.02

The arrangement shall be such that the C.T. can be removed from the transformer without removing the tank cover.

4.13.03

CT secondary leads shall be wired upto the terminal blocks.

4.14.00

PAINTING

4.14.01

All steel surfaces shall be thoroughly cleaned by sand blasting or chemical agents as required, to produce a smooth surface free of scales, grease and rust.

4.14.02

The internal surfaces in contact with insulating oil shall be painted with heat resistant insulating varnish which shall not react with and be soluble in the insulating liquid used.

4.14.03

The external surfaces, after cleaning, shall be given a coat of high quality red oxide or yellow chromate primer followed by filler coats.

4.14.04

The transformer shall be finished with two coats of battle ship grey (IS Shade # 632).synthetic enamel paint.

4.14.05

The paints shall be carefully selected to withstand tropical heat, rain etc. The paint shall not scale off or crinkle or be removed by abrasion due to normal handling.

4.14.06

Sufficient quantity of touch up paint shall be furnished for application after installation at site.

4.14.07

If it is considered necessary, the transformer may be given a further coating at site by the Owner/Purchaser. The Bidder shall therefore indicate the type and quality of the paint with full specification for this purpose.

4.14.08 4.15.00

All supporting structures and hardware shall be hot dip galvanized. TRANSPORTATION 51

current

4.15.01

Transformer tank shall be dispatched filled with oil and transformer should be filled with nitrogen. In case the tank is filled with oil, sufficient space is left above the oil to take care of the expansion of the oil. The space is filled with pure dry air or inert gas under atmospheric pressure.

5.00.00

TESTS

5.01.00

ROUTINE TESTS During manufacture and on completion, all transformers shall be subjected to the routine tests in accordance with latest IEC 60076 and its different parts. In addition, the following tests shall be performed on each transformer:

5.01.01

Transformer tank with coolers shall be tested for leaks with normal head of oil plus 35 KN/m2 for a period of 8 hours. If any leak occurs, the test shall be conducted again after all leaks have been repaired.

5.01.02

During fabrication stage, the tank shall be pressure tested with air at a pressure corresponding to twice the normal head of oil or normal pressure plus 35KN/m2 whichever is lower for a period of one hour. Also the tank designed for full vacuum shall be tested for maximum internal pressure of 3.33KN/m2 for one hour. The permanent deflection of flat plates shall not exceed CBIP specified figures on release of excess pressure of pressure test and on release of vacuum.

5.01.03

After assembly, each core shall be pressure tested for one minute at 2KV (r.m.s.) A.C. between all bolts, side plates, structural steel works and the core.

5.01.04

The wiring for auxiliary power and control circuitry shall be subjected to withstand one minute power frequency test with 2.0KV (r.m.s.) to earth

5.01.05

Dielectric special tests as per IEC60076-3

5.01.06

Determination of capacitances windings-to-earth and between windings

5.01.07 5.01.08

Frequency Response Analysis test (This test shall also be undertaken by the manufacturer at site after transformer is installed.) Measurement of acoustic sound level

5.01.09

Measurement of power consumption of fans

5.01.10

Measurement of zero sequence impedance(s) on three-phase unit

5.01.11

Measurement of dissipation factor (tan delta) of insulation system capacitances

5.02.00

TYPE TESTS Following type tests shall be performed on one transformer in accordance with relevant standard: a. Dielectric type test (IEC60076-3) b. Temperature rise test. Cost of such tests, if extra, shall be quoted separately by the Bidder. 52

5.03.00

MISCELLANEOUS All component parts and auxiliary equipment such as oil, bushings, C.Ts etc. shall be routine tested as per relevant Indian Standards.

5.04.00

TEST WITNESS Tests shall be performed in presence of Owner/Consultant representative if so desired by the Owner/Consultant. The Contractor shall give at least seven (7) days' advance notice of the date when the tests are to be carried out

5.05.00

TEST CERTIFICATES

5.05.01

Certified reports of all the tests carried out at the works shall be furnished in six (6) copies for approval of the Owner/Consultant.

5.05.02

The equipment shall be dispatched from works Owner/Consultant's written approval of the test reports.

5.05.03

Type test certificates on any equipment, if so desired by the Owner/Consultant, shall be furnished. Otherwise the equipment shall have to be type tested, free of charge, to prove the design. SPECIAL TOOLS & TACKLES

6.00.00

only

after

receipt

of

6.01.00

A set of special tools & tackle which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment shall be supplied.

6.02.00

The tools shall be shipped in separate containers, clearly marked with the name of the equipment for which they are intended.

7.00.00

INSTALLATION REQUIREMENTS

7.01.00

The Contractor shall perform erection, testing and commissioning along with oil filtration & dissolved gas analysis test but excluding the construction of foundation. Job includes safe storage at place of installation, unpacking, positioning in place, site assembly of loosely furnished accessories, connection & assembly of loose supply items, auxiliary circuits, topping up with oil and testing of oil with Contractor's own test equipment, including Erection of MB, fixing of nuts and bolts etc., including all labour and materials, as per approved drawings, specifications of this tender and directions of Engineer-in-Charge/Manufacturer's supervisor.

7.02.00

The contractor shall place the transformer on its foundation, assemble parts and erect the sheet steel chamber with danger plate fixed on the same.

7.03.00

The storage and installation of transformer shall be carried out in strict compliance with manufacturer's instruction.

53

ANNEXURE-A RATINGS AND REQUIREMENTS 1.0

Application

2.0

Service Winding

3.0

Type

: Oil immersed

4.0

Environment

: Highly Humid

5.0

Reference standard

:

IS 2026 & IEC 60076

6.0

Rated power

:

10MVA

7.0

Rated voltage ratio (line to line)

:

33 / 11 KV

8.0

No. of phases

:

3

9.0

Rated frequency

:

50 Hz

10.0

Cooling system

10.1

Type of Cooling

10.2

Nos. of cooling units & each capacity

11.0

Temperature rise

11.1

Design ambient temperature

11.2

Temperature rise above design ambient temperature.

12.0

13.0

: Outdoor type : Outdoor, step down, two (2)

nos. Cu Winding.

: ONAN :

2X 50%

:

50 degree Centigrade

a)

in oil by thermometer

:

40 oC

b)

in winding by resistance

:

45 oC

Insulation level (SI: Switching Impulse Voltage, LI: Lightning Impulse Voltage, AC: Short duration induced & separate source AC withstand Voltage) E.HV- (SI/Li/AC)

:

170KVp / 70 KV rms

HV-

:

75 KVp / 28 KV rms

:

Dyn 11

(LI/AC)

Vector group 54

14.0

Short-circuit impedance at 75C at principal tap

: 10 % on base MVA

14.1

Short circuit withstand time

:

15.0

Parallel operation of transformer

:

16.0

Type of taps provided

:

on load, full capacity

16.1

Taps provided on

:

H.V. winding

16.2 TC

Range of taps

:

+10% @ 1.25% OC

16.3

Method of Tap charge control: : : :

YES YES YES NO

33 KV SIDE

:

Solidly earth

11 KV SIDE through

:

Non-effectively

a) b) c) d) 17.0

18.0

Manual local Electrical local Electrical Remote Automatic

2 Sec. Yes, momentary

System earthing -

resistance to limit the fault current to 300 A

Terminal arrangement 33 KV SIDE

:

ACSR/ Al tube

11 KV SIDE

:

Cu XLPE cable

19.0

Transformer bushing

:

33KV

19.1

Voltage class

:

36

19.2

Material

19.3

Min. Creepage distance

19.4

Min. Ph-Ph clearance mm

19.5

Min. Ph-Gr clearance mm

20.0

System fault Level

21.0

earthed

KV (r.m.s.)

LV/LV-N 12

:

Solid Porcelain

: :

31mm per KV HV LV As per CBIP

:

As per CBIP

33 KV Side

:

31.5 KA (rms.)

11KV Side

:

40 KA (rms.)

Max. Flux density in any part of core & Yoke under any tap position

:

1.7 Tesla

mm

55

at 110% rated voltage 22.0

Max. Noise level in accordance with Conditions specified in NEMA Std. TR-1

:

65 dB

23.0

Auxiliary supply (AC)

:

415/230V, 3 ph., 50 Hz 

DC wire

:

110V +10%, -15% 2

24.0

Maximum guaranteed losses at principal tap at full load and 75 Deg Centigrade must not exceed the following values

No Load Loss

: …….KW (to be filled by bidder)

Load Loss

: …….KW (to be filled by bidder)

Above losses are subject to the IS tolerance.

56

ANNEXURE - B FITTINGS AND ACCESSORIES Transformer shall be equipped with fittings and accessories as listed below:1.

Rubber back type oil conservator with filler cap, drain plug, plain oil level gauge and alarm contacts for rupturing of bellows/diaphragm.

2.

Rubber back type oil preservation system complete with accessories.

3.

Air release plugs of adequate no over tank cover and one no over each radiator tube link

4.

Pressure release device with alarm/trip contacts. Explosion vent, if provided, should be double diaphragm type with a gauge glass in intermediate chamber.

5.

Equalizer pipe connection with conservator if explosion vent is provided.

6.

250 mm dial magnetic oil level gauge with low level alarm contacts

7.

150 mm dial oil temperature indicator with maximum reading pointer and electrically separate contacts for trip and alarm and embedded temperature detectors (PT-100) with suitable output for remote indication (data logging).

8.

150 mm dial winding temperature indicator with maximum reading pointer and electrically separate sets of contacts for trip, alarm and cooler control and embedded temperature detectors (PT-100) with suitable output for remote indication (data logging).Winding temperature detector shall be 3 Wire duplex type.

9.

Remote winding temperature indicator for mounting on remote control panel with a separate detector element.

10.

Separate CTs and temperature detector element- One each for local indicating temp and remote winding temp.

11.

Thermometer pockets.

12.

Double float Buchholz relay with gas release cock, shut-off valve on either sides with separate sets of contacts for trip and alarm.

13.

Filter valve with threaded adopter (top and bottom).

14.

Drain valve with threaded adopter.

15

Sampling valve.

Necessary valves for detachable cooler units. 16.

Jacking pads, handling and lifting lugs. 57

17.

Cover lifting eyes.

18.

Bi-directional flanged wheels and skids for rolling transformer over a 1676 rail gauge.

19.

Clamping device with bolts & nuts.

20.

Man-hole of sufficient size for access to interior of the tank.

21.

Two-grounding pads.

22.

Ladder with safety device for access to the top of transformer tank.

23.

Weather proof marshaling box for housing control equipment and terminal connections.

24.

H.V. and L.V. bushing terminal connectors.

25.

Rating and terminal marking plates.

26.

Cooler units complete with valves(isolation valves shall be provide at both end of each cooler bank )

27.

Tap-changing gear complete with tap position indicator, operation counters etc. For OCTC gear (where specified), oil surge relay (OSL) with shut-off valve, Local control cabinet and Remote (RTCC) panel

28.

Prismatic oil level gauge (required no to cover entire depth of conservator)

Note

All indication, alarm, trip contacts provided shall be rated for 2A at 110 V D.C. and 5A at 230 V A.C.

58

ANNEXURE-C

AUXILIARY EQUIPMENT Transformer shall be provided with phase (where specified) and neutral bushing current transformers as specified as indicated below:Phase CT Application

Neutral CT

:

Current Ratio

:

PS

Class

:

Burden

:

30 VA

Knee point voltage

:

…V

Excitation current at Vk/2

:

.. mA

Secondary resistance at 75oC

:

...ohm

Rated frequency

:

50 HZ (max)

Voltage class

:

12 KV

59

5P10

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION: III LT AUX. TRANSFORMER

60

SUB-SECTION: III LT AUX. TRANSFORMER CONTENTS CLAUSE NO.

DESCRIPTION

PAGE NO.

1.00.00

CODES AND STANDARDS

1

2.00.00

SCOPE OF WORK

1

3.00.00

DESIGN CRITERIA

2

4.00.00

SPECIFIC REQUIREMENTS

2

5.00.00

TESTS

6

6.00.00

SPECIAL TOOLS AND TACKLES

7.00.00

INSTALLATION REQUIREMENTS

7

ATTACHMENTS ANNEXURE – A

RATINGS AND REQUIREMENT

8

ANNEXURE – B

FITTINGS AND ACCESSORIES

9

61

LT AUX. TRANSFORMER 1.00.00

CODES AND STANDARDS

1.01.00

All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification.

1.02.00

The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed.

1.03.00

Accountability of transformer loss

1.03.01

Transformer losses will be taken into account during bid evaluation.

1.03.02

The loss figures quoted shall be guaranteed under penalty. The test values for losses will be compared with the corresponding guaranteed figures subject to I.S/IEC. Tolerances for computation of penalties.

2.00.0

SCOPE OF WORK

2.01.00

SCOPE OF SUPPLY

2.01.01

Type, rating and connections of the equipment listed below are detailed in the Annexure A. The equipment shall be offered in strict compliance with the same. i) Copper Wound Three (3) nos. 3000KVA, 11KV/415 V oil filled ONAN transformers.

2.01.02

Each transformer shall be furnished complete with:a.

Fittings and accessories

b.

Auxiliary equipment

c.

First filling of oil including 10% extra

2.01.03

One set of special tools and tackles

2.01.04

All relevant drawings, data and instruction manuals.

2.02.00

SCOPE OF SERVICES

2.02.01

The services of supervisor must have supervisory license from State Electricity licensing authority / Qualified Electrical Engineer, experienced in the erection and commissioning of the equipment of similar type and rating on per diem basis. The work includes but not limited to:-

2.02.02

Visiting site prior to dispatch of equipment to check readiness of foundation, and survey access to site. Providing labor, equipment and specialized services for unloading the transformer and placing the same on foundation. 62

2.02.03

Complete checking of materials at site and advising the Owner/Purchaser any discrepancy thereof.

2.02.04

Advice on procedure of erection to be followed.

2.02.05

Regular supervision and following up of erection work done by others.

2.02.06

Supervision of testing, commissioning and putting the equipment into successful commercial operation.

2.03.0

DELIVERY SCHEDULE

2.03.01

The delivery period shall be as mentioned in the delivery Time Schedule D from the date of issue of Notification of Award of

contract or Purchase Order

2.03.02

Delivery period shall be inclusive of the time to be allowed for approval of drawings & test certificates and shall include transportation time to site.

2.03.03

Delivery date shall be reckoned as the date of receipt of the complete equipment & materials at site.

2.03.04

Mandatory spares, special tools and tackles shall be supplied with the first consignment.

3.00.00

DESIGN CRITERIA

3.01.00

These transformers will be used for supply of power to various 415V PCC s / MCC s for SECURITY PAPER MILL, HOSHANGABAD-461005(M.P)The high voltage winding (11 kV) will be connected to new 11KV HT Switchgear which will be located in existing 33KV MRSS. The 415 V winding will be connected to respective 415 V PCC/MCC in the Mill building.

3.02.00

The transformer will be installed in hot, humid and tropical atmosphere. All equipment, accessories and wiring shall be provided with tropical finish to prevent fungus growth.

3.03.00

The transformer shall be capable of continuous operation at rated output under the following condition: a.

Voltage variation

:

± 5%

b.

Frequency variation

:

± 3%

:

8%

c.

Combined voltage and frequency variation

3.04.00

The transformer shall be capable of withstanding the short circuit stresses due to terminal fault on one winding with full voltage maintained on the other winding for minimum period of two (2) seconds.

3.05.00

The transformer shall be free from annoying hum or vibration. The design shall be such as not to cause any undesirable interference with radio or communication circuits.

63

4.00.00

SPECIFIC REQUIREMENT

4.01.00

Tanks

4.01.01

Tanks shall be of all welded construction and fabricated from good commercial grade low carbon steel of adequate thickness. All seams shall be double welded. All welding shall be stress relieved.

4.01.02

The tank wall shall be reinforced by stiffener to ensure rigidity so that it can withstand without any deformation (a) mechanical shock during transportation and (b) oil filling by vacuum.

4.01.03

All removable covers shall be provided with weatherproof, hot oil resistant, resilient gaskets. The design shall be such as to prevent any leakage of water into or oil from the tank.

4.01.04

Each transformer tank shall be provided with one set of bi-directional rollers for rolling the transformer parallel to either centre line.

4.01.05

Jacking pads, lifting eyes and pulling lugs shall be provided to facilitate movement of the transformer. All heavy removal parts shall be provided with eye bolt for ease of handling.

4.01.06 Manholes/hand holes of sufficient size shall be provided for access to leads, windings, bottom terminals of bushings and taps. 4.01.07

Suitable guide shall be provided in the tank for positioning the core and coil assembly.

4.02.00

Core & Coils

4.02.01

The transformer may be of core or shell type. The core shall be built up with high grade, non-aging, low loss, high permeability grain oriented cold-rolled silicon steel laminations specially suitable for core material.

4.02.02

The coils shall be manufactured from electrolytic copper conductor and fully insulated for rated voltage.

4.02.03

The core and coil assembly shall be securely fixed in position so that no shifting or deformation occurs during movement of transformer or under short circuit stresses.

4.02.04

Insulating material shall be of proven design. Coils shall be so insulated that impulse and power frequency voltage stresses are minimum.

4.02.05

Coil assembly shall be suitably supported between adjacent sections by insulating spacers and barriers. Bracing and other insulation used in assembly of the winding shall be arranged to ensure a free circulation of the oil and to reduce the hot spot of the winding.

4.02.06

All leads from the windings to the terminal board and bushings shall be rigidly supported to prevent injury from vibration or short circuit stresses. Guide tube shall be used where practicable.

4.03.00

Tappings

4.03.01 Off-circuit taps as specified shall be provided on the high voltage winding. 4.03.02 4.03.03

4.04.00

The transformer shall be capable of operation at its rated KVA on any tap provided the voltage does not vary by more than ± 5% of the rated voltage corresponding to the tap. The winding including the tapping arrangement shall be designed to maintain electromagnetic balance between HV and LV windings at all voltage ratios.

Off-Circuit Tap Changer (OCTC) 64

4.04.01

The off-circuit tap changing will be effected by a 3-phase gang operated switch. Arrangement shall be such that switch can be operated at standing eight from ground level.

4.04.02

The operating handle can be padlocked at any tap position. The design shall be such that the lock cannot be inserted unless the contacts are correctly engaged.

4.04.03

The mechanism shall be provided with a mechanical tap position indicator and an operation counter.

4.04.04

All contacts shall be silver plated and held in position under strong contact pressure to ensure low contact drop and avoid pitting.

4.05.00

Insulating Oil

4.05.01

The transformer shall be filled with mineral insulating oil (as per IS:335) suitably inhibited to prevent slugging.

4.05.02

First filling of oil along with 10% excess shall be furnished for each transformer. Oil shall be supplied in non-returnable containers suitable for outdoor storage.

4.05.03

Oil preservation shall be by means of conservator tank complete with silica gel breather and oil seal.

4.06.00

Bushing

4.06.01

Bushing rated 52 KV class and above shall be oil impregnated paper condenser bushings. Bushing rated below 52KV voltage class shall be solid porcelain or oil communicating type.

4.06.02

Condenser type bushing shall be provided with oil level gauge, bottom drain plug and test terminal for measurement of loss factor (tan-delta) and capacitance.

4.06.03

Bushings shall be provided with terminal connectors of approved type and size.

4.06.04

Bushing location shall provide adequate phase and ground clearances.

4.07.00

Terminal Arrangements

4.07.01

Terminals for bus duct connection shall be brought out through top-cover mounted bushings with matching flange.

4.07.02

Terminals for cable connection shall be brought out through top cover/side wall mounted bushings to a detachable cable-end box with disconnect links.

4.07.03

Cable-end box shall be self-supporting, weatherproof, air filled type with sufficient space inside for termination and connection of cables.

4.07.04

In general, the arrangement shall be such as to permit removal of the transformer without dismantling the bus duct/cable installation.

4.07.05

A separate L.V. neutral bushing shall be provided for connection to station 65

ground mat (50 x 6 Cu flat). 4.08.00

Marshaling Box

4.08.01

A sheet steel, weatherproof, IPW55 marshaling box shall be provided for each transformer. The box shall contain all auxiliary devices except those which must be located directly on the transformer.

4.08.02

All terminal blocks for auxiliary cable connection shall be located in this box.

4.08.03

The marshaling box shall be provided with cubicle lamp with door switch, space heater with thermostat and removable cable gland plate.

4.09.00

Wiring

4.09.01

All control, alarm and indication devices provided with the transformer shall be wired upto the terminal blocks.

4.09.02

Wiring shall be done with PVC Insulated Copper wires in conduit or PVC armored cable. Minimum wire size shall be 2.5 mm2 copper. Not more than two wires shall be connected to a terminal. 10% spare terminals shall be provided.

4.09.03

All devices and terminal blocks within the marshaling box shall be identified by symbols corresponding to those used in applicable schematic or wiring diagram.

4.10.00

Grounding

4.10.01

Two grounding pads, located on the opposite sides of the tank, shall have clean buffed surface with two tapped holes, M10 G.I. bolts and spring washers for connection to 50 x 6 mm Cu flat.

4.10.02

Marshaling box shall also be grounded effectively.

4.10.03

For continuity of earth connection, all gasketted joints shall be provided with braided copper wire jumpers.

4.11.00

Auxiliary Equipment

4.11.01

Neutral bushing current transformers shall be furnished where required by the specified protection scheme. The arrangement shall be such that the C.T. can be removed from the transformer without removing the tank cover.

4.11.02

C.T. secondary leads shall be wired upto the terminal blocks. The terminals for C.T. secondary leads shall have provision for shorting.

4.12.00

Painting

4.12.01

All steel surfaces shall be thoroughly cleaned by sand blasting or chemical agents, as required, to produce a smooth surface free of scales, grease and rust.

4.12.02

The internal surfaces in contact with insulating oil shall be painted with heat resistant insulating varnish which shall not react with and be soluble in the insulating liquid used. 66

4.12.03

The external surfaces, after cleaning, shall be given a coat of high quality red oxide or yellow chromate primer followed by filler coats.

4.12.04

The transformer shall be finished with two coats of battle ship grey (IS Shade # 632) synthetic enamel paint.

4.12.05

The paints shall be carefully selected to withstand tropical heat, rain and the highly corrosive atmosphere prevailing at site.

4.13.00

Auxiliary Supply

4.13.01

A.C. supply will be made available to each transformer by two separate feeders one normal and the other standby.

4.13.02

Isolating switch fuse unit shall be provided for each of the incoming supply along with automatic changeover scheme to switch on to the standby source in case of failure of the normal supply.

5.00.00

TESTS

5.01.00

Routine Tests During manufacture and on completion, all transformer shall be subjected to the IS routine tests. In addition, the following tests shall be performed on each transformer:

5.01.01

During fabrication stage, the tank shall be pressure tested with air at a pressure corresponding to twice the normal head of oil or normal pressure plus 35KN/m2 whichever is lower for a period of one hour. Also the tank designed for full vacuum shall be tested for maximum internal pressure of 3.33KN/m2 for one hour. The permanent deflection of flat plates shall not exceed CBIP specified figures on release of excess pressure of pressure test and on release of vacuum.

5.01.02

After assembly, each core shall be pressure tested for one minute at 2KV (r.m.s.) A.C. between all bolts, side plates, structural steel works and the core.

5.01.03

The wiring for auxiliary power and control circuitry shall be subjected to withstand one minute power frequency test with 2.0KV (r.m.s.) to earth

5.01.04

Dielectric special tests as per IEC60076-3

5.01.05

Measurement of acoustic sound level

5.01.06 Measurement of zero sequence impedance(s) on three-phase unit

5.02.00

Type Tests

5.02.01

Following type tests shall be performed on one transformer in accordance with relevant standard: a) Dielectric type test (IEC60076-3) b) Temperature rise test Cost of such tests shall be quoted separately by the Bidder as an optional item. 67

5.02.02

Type and special tests as per requirements of the IEC standards shall be carried out with the exception of “short circuit” test. A type test certificate on an identical transformer and confirmation that the cable boxes have been designed to the short circuit levels specified is acceptable.

6.00.00

SPECIAL TOOLS & TACKLES

6.01.00

A set of special tools & tackle which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment shall be supplied.

6.02.00

The tools shall be shipped in separate containers, clearly marked with the name of the equipment for which they are intended.

7.00.00

INSTALLATION REQUIREMENTS

7.01.00

The Contractor shall perform erection, testing and commissioning along with oil filtration & dissolved gas analysis test but excluding the construction of foundation. Job includes safe storage at place of installation, unpacking, positioning in place, site assembly of loosely furnished accessories, connection & assembly of loose supply items, auxiliary circuits, topping up with oil and testing of oil with Contractor's own test equipment, including Erection of MB, fixing of nuts and bolts etc., including all labour and materials, as per approved drawings, specifications of this tender and directions of Engineer-inCharge/Manufacturer's supervisor.

7.02.00

The contractor shall place the transformer on its foundation, assemble parts and erect the sheet steel chamber with danger plate fixed on the same.

7.03.00

The storage and installation of transformer shall be carried out in strict compliance with manufacturer's instruction.

68

ANNEXURE – A RATINGS AND REQUIREMENT 1.0

Application

:

2.0

Service

: Outdoor, step-down

4.0

Type

:

Oil immersed

4.0

Rated output

:

3000 KVA

5.0

Cooling

:

ONAN

6.0

Rated voltage (line - line)

:

11kV/415 V

7.0

Number of phases

:

3

8.0

Rated frequency

:

50 Hz

9.0

Temperature rise above 50oC

10.0

L.T. Aux. Transformer

a. in oil by thermometer

:

50 oC

b. in winding by resistance

:

55 oC

Insulation level -

H.V.

:

…75../28….. KV (peak/rms)

L.V.

:

3/2. KV (peak/rms)

11.0

Vector group

: Dyn11

12.0

Parallel operation of transformer

:

14.0

Type of taps provided

: OCTC

14.0

Taps provided on

15.0

Range of taps

16.0

Percentage impedance at 75 oC

17.0

Terminal arrangement:

18.

Yes, momentary

: :

H.V. winding + _ 2.x 2.5% : 7%

H.V.

:

H. V. Cable ( 1/C-500mm² min.)

L.V. & N

:

Sandwich Bus duct

L.V. Neutral

:

50x6 Cu flat

Maximum guaranteed losses at principal tap at full load and 75 Deg Centigrade must not exceed the following values No Load Loss

: …..KW (to be filled by Bidder)

Load Loss

: …..KW(to be filled by Bidder) Above losses are subjected to the IS tolerance. 69

ANNEXURE-B FITTINGS AND ACCESSORIES Each transformer shall be equipped with fittings and accessories as listed below :o

Oil conservator with filler cap, drain plug and plain oil level gauge.

o

Oil preservation system complete with accessories.

o

Silica gel breather with connecting pipe and oil seal.

o

Air release plugs.

o

Pressure release device. Explosion vent, if provided, should be double diaphragm type.

o

150mm dial magnetic oil level gauge with low level alarm contacts.

o

150 mm dial oil temperature indicator with maximum reading pointer and electrically separate contacts for trip and alarm.

o

150 mm dial winding temperature indicator with maximum reading pointer and electrically separate sets of contacts for trip and alarm.

o

Thermometer pockets.

o

Double float Buchholz relay with gas release cock, shut-off valve on either side and separate sets of contacts for trip and alarm.

o

Filter valve with threaded adopter (top and bottom).

o

Drain valve with threaded adopter.

o

Sampling valve.

o

Jacking pads, handling and lifting lugs.

o

Cover lifting eyes.

o

Bi-directional rollers and skids.

o

Handhole of sufficient size for access to interior of the tank.

o

Two-grounding pads.

o

Weatherproof marshaling box for housing control equipment and terminal connections.

o

Rating and terminal marking plates.

o

Cooler banks (if applicable) complete with isolation valve at both ends for each bank.

70

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION-IV NEUTRAL GROUNDING RESISTOR

71

SUB-SECTION-IV NEUTRAL GROUNDING RESISTOR CONTENTS

CLAUSE NO.

DESCRIPTION

PAGE NO.

1.00.00

SCOPE OF SUPPLY

1

2.00.00

CODES AND STANDARDS

1

3.00.00

DESIGN CRITERIA

1

4.00.00

SPECIFIC REQUIREMENTS

2

5.00.00

TESTS

3

6.00.00

SPECIAL TOOLS & TACKLES

4

7.00.00

INSTALLATION REQUIREMENTS

4

ATTACHMENT ANNEXURE-A

RATINGS AND REQUIREMENTS

72

5

NEUTRAL GROUNDING RESISTOR 1.00.00

SCOPE OF SUPPLY

1.01.00

Type, rating and connection of the equipment listed below are detailed in the Annexures. The equipment shall be offered in strict compliance with the same.

1.02.00

Two (2) nos. 21.17 Ohms, 11500 Volts, 300 Amps for 10 seconds Neutral Grounding Resistor as required.

1.03.00

Each Resistor shall be furnished complete with :

a)

Fittings and accessories.

b)

Auxiliary Equipment

b)

All supporting steel work and hardwares.

1.04.00

One set of Special Tools and Tackles.

1.07.00

All relevant drawings, data and instruction manuals.

2.00.00

CODES AND STANDARDS

2.01.01

All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification.

2.01.02

The electrical installation shall meet the requirements of Indian Electricity Rules as amended up to date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed.

3.00.00

DESIGN CRITERIA

3.01.00

The Neutral Grounding Resistor (NGR) shall be used for non-effective grounding of 11000 volt System of the plant and will be connected to LV-N of the 10 MVA Power transformers.

3.02.00

Neutral Grounding Resistor shall be used to limit the magnitude of earth fault current so that damage of electrical equipment is reduced, safety of personnel is increased and sensitive, selective earth fault protection can be provided.

3.03.00

The NGR will be installed in dust prone, hot, humid and tropical atmosphere. All equipment, accessories and wiring shall be provided with tropical finish to prevent fungus growth. The Resistor unit shall be air-cooled type suitable for installation at outdoor locations.

3.04.00 3.05.00

The resistor enclosure shall be made of sheet steel and shall have minimum thickness of 2 mm.

73

4.00.00

SPECIFIC REQUIREMENTS

4.01.00

Resistor

4.01.01

The resistor element shall be made of non-aging stainless steel or equivalent corrosion resistant material having high Electrical Resistivity and low temperature co-efficient of resistant.

4.01.02

The resistor unit shall consist of a no. of elements. All the elements shall be mounted inside the cubicle so as to ensure ease of inspection and replacement of individual element.

4.01.03

Each Resistor element shall possess a balanced combination of both Mechanical and Electrical properties over the entire intended operating temperature range without any harmful effect on the elements and their accessories.

4.01.04

All the resistor elements constituting the NGR shall be assembled and supported inside the cubicle in such a way that no distortion or breakage will occur during the passage of through fault current to earth.

4.01.05

All element connections shall be bolted type to ensure stable resistance value throughout the working life of the unit.

4.01.06

Wet process type brown glaze porcelain insulators shall be used for supporting resistor elements. Porcelain insulators shall have high creepage value suitable for heavily polluted atmosphere charged with dust particles.

4.02.00

Enclosure

4.02.01

Each neutral grounding resistor shall have structural steel work enclosed on all sides and also on top by sheet steel having a minimum thickness of 2 mm. Suitable ventilating louvers shall be provided on sides to ensure proper ventilation. The louvers shall be provided with fire wire mesh to make it vermin proof.

4.02.02

Each enclosure shall be self-supporting, weather proof type suitable for outdoor mounting having a protection class as indicated in annexure.

4.02.03

Each cubicle shall be complete with a front access door with handles, lock and also a removable bolted cover. All doors and removable covers shall be properly gasket with neoprene rubber gaskets. All cubicle door hinges shall be concealed type.

4.02.04

Each cubicle shall be complete with a suitably mounted cable end box fitted with removable gland plate for fixing cable gland. The cable size shall be as indicated in the annexure. Double compression cable glands and tinned copper lugs shall be provided.

4.02.05

Each cubicle shall be provided with suitable base channels for direct bolting to the foundation at site. All necessary galvanized bolts, nuts, washers etc. shall be supplied by the Tenderer for installation of Cubicle at site.

74

4.03.00

Cubicle lamp and sockets

4.03.01

Each cubicle shall be provided with 5A, 3 pin plug socket and door-switch controlled cubicle illumination lamp.

4.03.02

Two pole switch fuse unit shall be provided for receiving 240 V single phase AC supply for cubicle lamp and illumination circuit.

4.04.00

Wiring

4.04.01

All internal wiring between equipment and terminal block shall be carried out by PVC insulated 650 V grade 2.5 Sq.mm Stranded copper conductor wires.

4.04.02

All wiring shall be suitably ferruled with corresponding wiring identification marks used in the Schematic/wiring diagrams.

4.04.03

All devices and terminal blocks within the terminal box shall be clearly identified by symbol corresponding to those used on applicable schematic/wiring diagram. 20% spare terminals shall be provided in terminal block.

4.05.00

Grounding

4.05.01

All parts of enclosure, supporting structures, equipment frames etc. shall be properly grounded at two points separately.

4.05.02

Each cubicle shall be completed with two (2) nos. ground pads, tapped holes and bolts suitable for connection of 50 x 6 mm Cu flats.

4.06.00

Painting

4.06.01

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

4.06.02

After cleaning, the surfaces shall be given a phosphate coating followed by 2 coats of high quality primer and stoved after each coat.

4.06.03

The equipment shall be finished with two coats of approved shade as stated in the annexure.

4.06.04

Sufficient quantity of touch-up paint shall be furnished for application at site.

5.00.00

TESTS

5.01.00

Routine Tests Each equipment shall be completely assembled, wired, adjusted and routine tested as per relevant standards at manufacturer's works. The tests shall include :

5.01.01

Resistance measurement

5.01.02

Voltage measurement

5.01.03

Insulation resistance measurement

5.01.04

Dielectric test 75

5.02.00

Type Test

5.02.01

Temperature test ( on one unit of each rating)

5.03.00

Test Witness

5.03.01

All tests shall be performed in presence of Owner/Consultant's representative, if so desired by the Purchaser.

5.03.02

The Contractor shall give at least seven (7) days advance notice of shop tests.

5.04.00

Test Certificates

5.04.01

Certified copies of all tests carried out at works and at site shall be furnished in six (6) copies for approval of the Owner/Consultant.

5.04.02

Equipment shall be dispatched from works only Owner/Consultant's written approval of shop test reports.

5.04.03

Type test certificate on equipment, shall be furnished along with the tender. In case the Type Test Certificates of identical equipment of the offered items are not submitted, the bidders shall have to conduct the Type test on the offered equipment before delivery free of charge to the Purchaser. Type test performed beyond years (5) time are not acceptable.

6.00.00

SPECIAL TOOLS & TACKLES

6.01.00

A set of special tools & tackle which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment shall be supplied.

6.02.00

The tools shall be shipped in separate containers, clearly marked with the name of the equipment for which they are intended.

7.00.00

INSTALLATION REQUIREMENTS

7.01.00

The Contractor shall perform erection, testing and commissioning of complete NGR but excluding the construction of foundation. Job includes safe storage at place of installation, unpacking, positioning in place, site assembly of loosely furnished accessories, connection & assembly of loose supply items, auxiliary circuits, including erection of MB, fixing of nuts and bolts etc., including all labour and materials, as per approved drawings, specifications of this tender and directions of Engineer-in-Charge/Manufacturer's supervisor.

7.02.00

The contractor shall place the NGR on its foundation, assemble parts and erect the sheet steel chamber with danger plate fixed on the same.

7.03.00

The storage and installation of NGR shall be carried out in strict compliance with manufacturer's instruction.

76

after

receipt

of

ANNEXURE-A

RATINGS AND REQUIREMENTS 1.0

General

1.1

Applicable Standard

:

IEEE-32

1.3

Service

:

Outdoor, free standing

1.4

Rated system voltage

:

11KV + 10%

1.4

Rated frequency and allowable variation

:

2.0

Rating

2.1

Rated Voltage

KV

2.2

Rated current at rated time duration

Amp :

300

2.3

Rated time duration

Sec. :

10

2.4

Resistance in design ambient temp.

Ohm :

21.17 Ω

2.5

Allowable Tolerance in resistance value

%

:

±10

2.6

Design ambient Temperature

°C

:

50

2.7

Temperature rise of resistor

°C

:

350

2.8

Temp rise of Enclosure

°C

:

30

2.9

Insulation class of insulating material

2.10

Basic Insulation level and system insulation class a)

b)

:

:

50Hz±3%

12KV

Over 220°C Class C

System insulation class for line end & ground end

KVrms :

75/28KV (peak/r.m.s)

Insulation level(applied 1min. power frequency potential)

KVrms :

75/28KV (peak/r.m.s)

3.0

NGR & NGR Cubicle

3.1

Materials of resistor

11KV :

------ Non-aging, ---punched ------ Stainless steel.-------

3.2

Resistor element combination

:

-- Series-parallel (6 X6) ---

3.3

Enclosure material

:

------- Sheet steel

77

------

3.4

Min.Thickness of aluminum sheet

3.5

Enclosure protection class

3.6

Finish paint of interior & exterior

mm

:

------

2

:

------

IP33

Through cable------

a)

shade as per IS-5

:

b)

Base

:

-----------

3.7

Terminal arrangement

:

------

3.8

Type & size of cable to be terminated

:

-- 2-1/C-70sq. mm XLPE -

4.0

Insulator

4.1

Type

:

------ Support insulator ----

4.2

Materials

:

------ Porcelain

4.3

Bushing rating

KVrms :

12 KV

4.4

Creepage distance

mm

------

78

:

-----

3.6 KV 31 MM/KV --------

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION-V HT SWITCHGEAR

79

SUB-SECTION-V HT SWITCHGEAR CONTENTS CLAUSE NO.

DESCRIPTION

PAGE NO.

1.00.00

CODES & STANDARDS

1

2.00.00

SCOPE OF WORK

1

3.00.00

DESIGN CRITERIA

2

4.00.00

SPECIFIC REQUIREMENTS

2

5.00.00

TESTS

12

6.00.00

SPECIAL TOOLS & TACKLES

13

7.00.00

INSTALLATION REQUIREMENT

14

ATTACHMENTS ANNEXURE- A

RATINGS AND REQUIREMENTS

15

ANNEXURE - B

PROTECTIONS

19

ANNEXURE – C

TYPICAL LIST OF DIGITAL I/O AND ANALOG SIGNALS

22

80

HT SWITCHGEAR 1.00.00

CODES & STANDARDS

1.01.00

All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification.

1.02.00

Equipment and material conforming to any other standard which ensures equal or better quality, may be accepted. In such case, copies of the English version of the standard adopted shall be submitted along with the bid.

1.03.00

The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed.

2.00.00

SCOPE OF WORK

2.01.00

Scope of Supply Type and rating of the equipment listed below are detailed in the annexure. The equipment shall be offered in strict compliance with the same.

2.01.01

One( 1) sets of 11000V switchgears as detailed below :a. Two(2) nos. 1250 A incomers VCB b. One (1) no. 1250 A VCB Bus coupler c. Three(3) nos. 1250A outgoing VCB for 3 MVA Transformers.

2.01.02

Base channel frame of the switchgear with hardware, if called for in panel design.

2.01.03

Set of accessories as detailed below :Earthing equipment suitable for earthing the bus/cables.

:

As required.

2.01.04

Special tools and tackles.

:

As required

2.01.05

All relevant drawings, data and instruction manuals.

2.02.00

Scope of Services The services of supervisor must have supervisory license from State Electricity licensing authority / Qualified Electrical Engineer,, experienced in the erection and commissioning of the equipment of similar type and rating on manday basis. The work includes but not limited to :-

2.02.01 2.02.02 2.02.03 2.02.04

Complete checking of materials at site and advising the Owner / Consultant of any discrepancy thereof. Advice on procedure of erection to be followed. Regular supervision and following up of erection work done by others. Testing, commissioning and putting the equipment into successful commercial operation. 81

2.04.00

Delivery Schedule

2.04.01

The delivery period shall be as mentioned in the delivery Time Schedule D from the date of issue of Notification of Award of contract or

Purchase Order

2.04.02

Delivery period shall be inclusive of the time to be allowed for approval of drawings & test certificates and shall include transportation time to site.

2.04.03

Delivery date shall be reckoned as the date of receipt of the complete equipment & materials at site.

2.04.04

Auxiliary equipment, mandatory spares, recommended spares, special tools and tackles shall be supplied with the first consignment.

3.00.00

DESIGN CRITERIA

3.01.00

The switchgear shall be used to supply power to 3MVA Transformers for Security paper plant.

3.02.00

The switchgear shall be located in a clean but hot, humid and tropical atmosphere.

3.03.00

Switchgear ratings and quantities are detailed in the enclosed drawings and annexure. Equipment shall be furnished in strict accordance with the same.

3.05.00

For continuous operation at specified ratings, temperature rise of the various switchgear components shall be limited to the permissible values stipulated in the relevant standards and/or this specification.

3.06.00

The Switchgear and components thereof shall be capable of withstanding the mechanical forces and thermal stresses of the short circuit current listed in the annexure without any damage or deterioration of material.

3.07.00

Circuit breaker shall not produce any harmful over-voltage during switching off induction motors, unloaded lines and unloaded transformers. If required, surge protective device shall be provided in the scope of supply to limit overvoltage. to 2.2 times the peak value of rated phase to neutral voltage.

4.00.00

SPECIFIC REQUIREMENT

4.01.00

Construction

4.01.01

The switchgear shall be indoor, metal-clad, floor mounted, self standing, dust proof construction, draw out type. Design and construction shall be such as to allow extension at either end The Switchgear, where specified in the annexure, shall be internal arc tested and shall conform to partition guideline as per latest edition of relevant IEC.

4.01.02

The switchgear enclosure shall conform to the degree of protection IP-4X. The minimum thickness of CRCA sheet steel used shall be 2 mm.

82

4.01.03

The switchgear assembly shall comprise a continuous, dead-front, line-up of free standing, vertical cubicles. Each cubicle shall have a front hinged door with latches and a removable back cover. All covers and doors shall be provided with neoprene gaskets.

4.01.04

Switchgear cubicle shall be so sized as to permit closing of the front access door when the breaker is pulled out to TEST position. The working zone shall be restricted within 750 mm to 1800 mm from floor level.

4.01.05

Circuit breakers, instrument transformers, bus-bars, cable compartment etc., shall be housed in separate compartments within the cubicle. The design shall be such that failure of one equipment shall not affect the adjacent units and the design should conform to the stipulation of Loss of Service Continuity and Partition guideline as per the latest edition of relevant IEC. The sides of the Switchgear & Control gear, which are accessible according to the testing arrangement, shall be specially designed to withstand internal explosions to prevent personnel injury.

4.01.06

Pressure relief device (at the option of Owner/Purchaser) shall be provided in each panel and shall prevent the possibility of spreading the fault to other compartments and panels. The pressure relief device shall not be deterrent to achieving the degree of protection of Switchgear Panel.

4.01.07

All panels shall come fitted with infrared inspection windows along with the removable plate for measuring the temperature of joints/hotspots during charged condition. The plate shall be removable from outside the panel, exposing the termination joint for scanning by Infra red Camera.

4.01.08

All relays, multifunctional meter (at the option of Owner/Purchaser), breaker control switches, selector switches and indicating lamps shall be flush mounted on the respective cubicle door or on control cabinet built on the front of the cubicle. AC/DC auxiliary supply switches / isolation switches for cubicle space heater, cubicle lamp, spring charging motor circuit shall be located inside metering compartment

4.01.09

Dummy panel shall be provided in the switchgear line up, if required, for easy termination access of power and control cables. Dummy panel / bus trunking panel shall be of full cubicle with closed roof and rear door similar to enclosures for active cubicles.

4.02.00

Bus and Bus Taps

4.02.01

The main buses and connections shall be of high conductivity copper and may be bare or coated and sized for specified current ratings with maximum temperature at the connection point limited to the following :

4.02.02

a.

For bolted joints (Bare)

:

90oC

b,

For bolted joints (Tin coated)

:

105oC

c.

For bolted joints (Silver coated)

:

115oC

Bus bars shall be of same size for the entire length of the switchgear. Continuous current rating of bus connections / dropper shall be same as that of continuous “in panel” current rating of associated breaker.

83

4.02.03

Adequate contact pressure shall be ensured by means of two bolts connection with plain and spring washers and locknuts. Bimetallic connectors shall be furnished for connections between dissimilar metals.

4.02.04

Bus bars and connection shall be fully insulated for maximum system voltage with adequate phase/ground clearances. Insulating sleeves for bus bars and cast-resin shrouds for joints shall be provided, suitable for maximum temperature rise of bus bars corresponding to maximum system voltage.

4.02.05

Bus support insulator shall be flame-retardant, track resistant type with creepage distance suitable for heavily polluted atmosphere.

4.02.06

All buses and connections shall be supported and braced to withstand stresses due to maximum short circuit current and also to take care of any thermal expansion.

4.02.07

Bus bars shall be color coded for easy identification and so located that the sequence R-Y-B shall be from left to right, top to bottom or front to rear, when viewed from front of the switch-gear assembly.

4.03.00

Circuit Breaker

4.03.01

Circuit breaker shall be triple pole, single throw Vacuum type. Ratings of circuit breakers shall be as per enclosed single line diagram mentioned in Section XX. The continuous ratings specified shall be achieved under installation conditions i.e. specified ambient temperature when installed within the breaker cubicle and without use of cooling fans.

4.03.02

Circuit breakers shall be horizontal isolation and horizontal draw out type, having SERVICE, TEST and DISCONNECTED positions with positive indication for each position.

4.03.03

Circuit breakers of identical rating shall be physically and electrically interchangeable.

4.03.04

Circuit breaker shall have motor wound spring charged trip free mechanism with anti pumping-feature and shunt trip. In addition facility for manual charging of spring shall be provided.

4.03.05

For motor wound mechanism, spring charging shall take place automatically after each breaker closing operation. One open-close-open operation of the circuit breaker shall be possible after failure of power supply to the motor.

4.03.06

Mechanical safety interlock shall be provided to prevent : a.

The circuit breaker from being racked in or out of the service position when the breaker is closed.

b.

Racking in the circuit breaker unless the control plug is fully engaged.

c.

Rack In/Out of the CB from Test to Service and vice versa with cubicle door open.

d.

The enclosure cannot be open and the low voltage circuits cannot be disconnected when the withdrawable part is in the service or intermediate position. 84

4.03.07

Automatic safety shutters shall be provided to fully cover the female primary disconnects when the breaker is withdrawn.

4.03.08

Each breaker shall be provided with an emergency manual trip, mechanical ON-OFF, indication, an operation counter and mechanism charge/discharge indicator.

4.03.09

Each breaker shall be provided with following : a.

Auxiliary switch, with 6 NO + 6 NC contacts, mounted on the draw out portion of the switchgear.

b.

Position/cell switch with 3 NO + 1 NC contacts, one each for TEST and SERVICE position.

c.

Auxiliary switch, with 4 NO + 4 NC contacts, mounted on the stationary portion of the switchgear and operated mechanically by a sliding lever from the breaker in SERVICE position.

4.03.10

Switch contact shall be rated 10 A AC. and 2A DC at their respective operating voltage.

4.04.00

Control & Indication The circuit breaker shall be wired up for local & remote operation. Each breaker cubicle shall be equipped with following :-

4.04.01

One (1) TEST-NORMAL-TRIAL selector switch stay put type with pistol grip handle and key interlock.

4.04.02

Two (2) heavy-duty oil tight, push buttons for TRIP & CLOSE.

4.04.03

Three (3) indicating lights on front of compartments:GREEN

:

Breaker Open and Spring Charged

RED

:

Breaker Closed

AMBER

:

Trip/Trip circuit trouble

4.04.04

Lamps shall be clustered type LED module pilot lights in thermoplastic enclosure with polycarbonate lens and diffuser. LED shall be protected by inbuilt fuse with surge suppressor and leakage voltage glow protection. Lamp and lens shall be replaceable from front.

4.05.00

Current Transformer

4.05.01

Current transformers shall be cast resin type. All secondary connections shall be brought out to terminal blocks where wye or delta connection shall be made.

4.05.02

The Current Transformers shall be capable of withstanding the stresses arising out of making, breaking and symmetrical short circuit currents for the specified durations as mentioned in the annexure. For Switchgear of 3 Sec. short circuit rating, CT s for outgoing motor feeders and transformer feeders may be provided with 1 Sec. rating. 85

4.05.03

Accuracy class of the Current Transformers shall be:a.

Class PS for differential relaying (or as required depending on the type of relay selected).

b.

Class 5P20 (5P15 or 5P10, if specified in the drawing) for other relaying.

c.

Class 1.0 and ISF 550 KPSl (3.80 Gpa)

:

> 440 KPSl (3.00 Gpa)

d)

Dynamic Fatigue

:

> 20

e)

Static Fatigue

:

> 20

f)

Change in attenuation measured at 1550 nm when fiber is coiled with 100 turns on 30 + 1.0 mm radius mandrel

:

< 0.10 dB.

g)

Fiber Curl

:

> 4 Meter radius of Curvature

h)

Fiber micro bend (1 turn around 32 + 0.5 mm diameter mandrel)

229

:

< 0.5 dB at 1550 nm

Material Properties Fiber Materials a)

The substances of which the fibers are made

b)

Protective material requirement

:

to be indicated by the manufacturer

:

It shall meet the requirement of Fibre coating stripping force

i)

The physical and chemical properties of the material used primary coating and for single jacket fiber

ii)

The best way of removing protective: coating material

c)

Refractive Index of fiber

:

To be indicated by the manufacturer

d)

Fiber Spool Length

:

Minimum 16 km shall be used for manufacturing of Optical Fiber Cable

230

To be indicated by the manufacturer

ANNEXURE-E

CABLE SIZES Sl. No.

Cable Size

Conductor

Insulation

1.0

H. T. CABLES

1.1

1 core 630 Sq.mm

Cu

Armored XLPE (FRLSH)

1.2

1 core 500 Sq.mm

Cu

Armored XLPE (FRLSH)

1.3

3 core 240 Sq.mm

Cu

Armored XLPE (FRLSH)

1.4

3 core 300 Sq.mm

Cu

Armored XLPE (FRLSH)

1.5

1 core 70 Sq.mm

Cu

Armored XLPE (FRLSH)

2.0

L. T. POWER CABLES

2.1

3 core 2.5 Sq.mm

CU

Armored (FRLSH)

2.2

2 core 16 Sq.mm

CU

Armored (FRLSH)

2.3

3 core 16 Sq.mm

CU

Armored (FRLSH)

2.4

4 core 16 Sq.mm

CU

Armored (FRLSH)

2.5

2 core 35 Sq.mm

CU

Armored (FRLSH)

2.6

3 core 35 Sq.mm

CU

Armored (FRLSH)

2.7

4 core 35 Sq.mm

CU

Armored (FRLSH)

2.8

3 core 95 Sq.mm

Cu

Armored (FRLSH)

2.9

3.1/2 core 95 Sq.mm

Cu

Armored (FRLSH)

2.10

3 core 185 Sq.mm

Cu

Armored (FRLSH)

2.11

3.1/2 core 185 Sq.mm

Cu

Armored (FRLSH)

2.12

3 core 240 Sq.mm

Cu

Armored (FRLSH)

2.13

3.1/2 core 240 Sq.mm

Cu

Armored (FRLSH)

2.14

3 core 300 Sq.mm

Cu

Armored (FRLSH)

2.15

3.1/2 core 300 Sq.mm

Cu

Armored (FRLSH)

2.16

1 core 630 Sq.mm

Cu

Armored (FRLSH)

231

Sl. No. 3.0

Cable Size CONTROL CABLE

Conductor

Insulation

3.1

2 core 2.5 Sq.mm

Cu.

HRPVC (FRLSH)

3.2

3 core 2.5 Sq.mm

Cu.

HRPVC (FRLSH)

3.3

5 core 2.5 Sq.mm

Cu.

HRPVC (FRLSH)

3.4

7 core 2.5 Sq.mm

Cu.

HRPVC (FRLSH)

3.5

9 core 2.5 Sq.mm

Cu.

HRPVC (FRLSH)

3.6

12 core 2.5 Sq.mm

Cu.

HRPVC (FRLSH)

3.7

20 core 2.5 Sq.mm

Cu.

HRPVC (FRLSH)

3.0

FS POWER CABLES

3.1

3 core 2.5 Sq.mm

CU

EPR

3.2

2 core 16 Sq.mm

CU

EPR

3.3

3 core 16 Sq.mm

CU

EPR

3.4

4 core 16 Sq.mm

CU

EPR

3.5

2 core 35 Sq.mm

CU

EPR

3.6

3 core 35 Sq.mm

CU

EPR

3.7

4 core 35 Sq.mm

CU

EPR

3.8

3 core 95 Sq.mm

CU

EPR

3.9

3.1/2 core 95 Sq.mm

CU

EPR

4.0

FS CONTROL CABLE

3.1

2 core 2.5 Sq.mm

Cu.

EPR

3.2

3 core 2.5 Sq.mm

Cu.

EPR

3.3

5 core 2.5 Sq.mm

Cu.

EPR

3.4

7 core 2.5 Sq.mm

Cu.

EPR

3.5

9 core 2.5 Sq.mm

Cu.

EPR

3.6

12 core 2.5 Sq.mm

Cu.

EPR

232

SPECIFICATION NO. : 11P01-SPC-E-291-53.02

SUB-SECTION-XI

ELECTRICAL INSTALLATION, TESTING & COMMISSIONING

233

SUB-SECTION-XI ELECTRICAL INSTALLATION, TESTING & COMMISSIONING CONTENTS

CLAUSE NO.

DESCRIPTION

PAGE NO.

1.00.00

CODES AND STANDARDS

1

2.00.00

SCOPE OF WORK

1

3.00.00

SPECIFIC REQUIREMENTS – SUPPLY

3

4.00.00

SPECIFIC REQUIREMENTS – SERVICES

4

5.00.00

TESTS

10

6.00.00

SPECIAL TOOLS & TACKLES

11

7.00.00

DRAWINGS, DATA & MANUALS

11

ANNEXURES ANNEXURE-A

SCHEDULE OF PRE-COMMISSIONING TESTS

234

12

ELECTRICAL INSTALLATION, TESTING & COMMISSIONING 1.00.00

CODES AND STANDARDS

1.01.01

All equipment and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) except where modified and/or supplemented by this specification.

1.01.02

Equipment and materials conforming to any other standard which ensures equal or better quality may be accepted. In such case, copies of the English version of the standard adopted shall be submitted along with the bid.

1.01.03

The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto date and relevant IS Codes of Practice. In addition, other rules or regulations applicable to the work shall be followed. In case of any discrepancy, the more restrictive rule shall be binding.

2.00.00

SCOPE OF WORK

2.01.00

Scope of Supply

2.01.01

The work involves timely procurement and transportation to site in properly packed condition of all hardware, materials and miscellaneous items as required to complete the erection of equipment, cabling and grounding work under this specification. These materials and miscellaneous items shall include but not limited to the followings: a)

All necessary erection materials, hardware, consumables and sundry items to complete the installation for satisfactory and trouble free operations.

b)

Any materials and accessories which may not have been specifically mentioned but which is usual and/or necessary shall be supplied free of cost to the Owner.

All materials and accessories to be supplied by the Bidder shall be brand new ones of reputed make. The contractor shall furnish data sheets and technical leaflets on each piece of materials. 2.02.00

Scope of Services The work includes but not limited to the followings:

2.02.01

Furnishing of all labour, skilled and unskilled, supervisory personnel, erection tools and tackles, testing equipment, implements, supplies, consumables & hardware, and transport for timely and efficient execution of the contract work.

2.02.03

Complete assembly, erection and connection, testing and commissioning, 235

putting into successful and satisfactory commercial operations of all electrical equipment and accessories::

2.02.04

2.02.05

a)

33 KV Outdoor circuit Breakers

b)

33 KV Disconnecting switches

c)

33 KV Lightning Arresters

d)

33 KV steel Structures for 33 KV switchyard

e)

All civil and structural work for 33 KV switchyard

f)

10 MVA, 33 KV/11 KV power transformers

g)

11 KV switchgear

h)

Electrical Control and Relay Panels

i)

11 KV Neutral Grounding Resistors

j)

11 kV Power cable including cable termination

k)

3000 KVA, 11 KV/433 V Distribution Transformers

l)

415 V L.T. Distribution Boards

m)

LV Power and Control cable

n)

Battery and charger

o)

415 V Emergency DG Set

p)

Grounding system

q)

Civil works, structural steel work

t)

Necessary miscellaneous hardware/software complete in all respect

The scope of work shall also include erection, testing and commissioning of following equipment/materials. a)

All interconnecting Power & control cables covering all electrical equipment including installation, connection, testing and commissioning.

b)

All concrete foundation works for 33 KV switchyard.

c)

Supply of steel materials for different fabrication purposes.

The items of work to be carried out on all equipment and materials shall include but not limited to the following: a)

Proper storing arrangement at plant site with suitable enclosure for protection from weather and pilferage of items under their scope of supply and materials issued by the owner/suppliers of the material.

b)

Assemblies, erection and complete installation.

c)

Pre-commissioning check-up to ensure correctness of erection as per actual manufacturer’s instruction.

236

d)

Final checking, testing and commissioning of all equipment in presence of SPM representatives including checking of interlocks and correctness of wiring as per scheme. (include DCPL also.)

e)

Satisfactory routine and emergency maintenance of the equipment/systems erected and commissioned by the contractor till the completion of the contract.

f)

Obtaining engineer’s approval and owner’s/DCPL written acceptance of satisfactory performance.

g)

Abiding to all rules and regulations in vogue at owner’s premises in reference particularly to the administration, security, safety etc.

3.00.00

SPECIFICREQUIREMENT - SUPPLY

3.01.00

Accessories and Materials

3.01.01

Accessories and materials shall comply with description, rating, type and size as detailed in this specification, drawings and annexures.

3.01.02

Accessories and materials furnished shall be complete and operative in all details.

3.01.03

All accessories, fittings, supports, hangers, anchor bolts etc. which are necessary for safe and satisfactory installation and operation of the equipment shall be furnished.

3.01.04

All parts shall be made accurately to standard gauges so as to facilitate replacement and repair. All corresponding parts of similar accessories shall be interchangeable.

3.01.05

After the treatment of steel surface damaged during transit sufficient quantity of anti-corrosive paint shall be applied and subsequently finished with two coats of final paint of approved shade.

3.02.00

Conduits and Accessories

3.02.01

Conduits shall be of rigid steel, hot-dip galvanized, furnished in standard length of 3 meters, threaded at both ends.

3.02.02

Conduits diameter upto and including 25mm size shall be of 16 SWG and conduits above 25 mm diameter shall be of 14 SWG. Minimum diameter of conduits shall be 19 mm.

3.02.03

Each piece of conduit shall be straight, free from blister and other defects, internal surface shall be of smooth finish and covered with capped bushings at both ends.

3.02.04

Flexible conduits shall be made with bright, cold rolled, annealed and electrogalvanized mild steel strips coated internally with epoxy and the sizes shall be 19, 32,51,63 & 76m.

237

3.03.00

Terminals

3.03.01

Multiway terminal blocks of approved type, complete with screws, nuts, washers and marking strips shall be furnished for connection of incoming/outgoing wires.

3.03.02

Each control cable terminal shall be suitable for connection of 2 nos. 2.5 sq.mm. stranded copper conductors without any damage to the conductor or looseness of conductors.

3.04.00

Cable Termination & Jointing Kits

3.04.01

The Bidder shall supply cable termination and jointing kits for H.T. Power Cables, L.T. Power and Control Cables along with all accessories.

3.04.02

For the cable terminations and straight through joints for HT / LT power and control cables, supply of jointing kit including necessary boxes, if any, sealing compound, ferrules, tapes, lugs, glands etc., shall be of RAYCHEM or M-Seal make. Cable end terminations on HV electrical equipment shall be suitable for indoor & outdoor uses, as the case may be.

3.05.00

Cable Glands Cable glands shall be tinned brass gland, double compression type complete with necessary armor clamp and tapered washer etc. Cable glands shall match with the sizes of different H.T./L.T./Control cables.

3.06.00

Cable Lugs Cable lugs shall be tinned brass lugs suitable for termination of different crosssections of H.T./L.T./Control cables. Lugs for power cables shall be compression type whereas lugs for Control shall be crimping type.

4.00.00

SPECIFICREQUIREMENTS - SERVICES

4.01.00

Responsibility of Erection

4.01.01

The Contractor shall be fully and finally responsible for proper erection, safe and satisfactory operation of plant and equipment under his scope of work to the entire satisfaction of the Engineer.

4.01.02

The work shall be executed in accordance with the directions, instructions, drawings and specifications of each electrical equipment under scope of erection.

4.01.03

If in the opinion of the Contractor any work is insufficiently specified or require modification, the Contractor shall refer the same in writing to the Engineer and obtain his instruction/ approval before proceeding with the work.

4.01.04

If the Contractor fails to refer such instances any excuse for the faulty erection, poor workmanship or delay in completion shall not be entertained.

4.01.05

Equipment and material which are wrongly installed shall be removed and reinstalled to comply with the design requirement at the Contractor's expense, to the satisfaction of the Engineer. 238

4.02.00

Supervision

4.02.01

The Engineer shall have the overall responsibility for coordination of Contractor's work and his direction shall be final.

4.02.02

Such direction and supervision however shall not relieve the Contractor of his responsibility of correctness and quality of workmanship and of other obligation under the contract.

4.03.00

Drawings

4.03.01

Drawings and schedules enclosed with this sub-specifications are for general guidance of the Bidder to assess the type and volume of work involved.

4.03.02

These drawings and schedules will be revised to suit the actual requirement in related systems. Additional drawings and schedules will also be furnished to Contractor if/when necessary. Final drawings and schedules will be furnished to the Contractor from time to time as detailed designs are developed.

Note :-

Pls check all the necessary drawing shall be provided by the contractor during & after the project like G.A,SLD,Layout,PID ,As built, Wiring diagram etc.

4.05.00

Methods and Workmanship

4.05.01

All work shall be installed in a first class, neat workmanlike manner by mechanics/ electricians skilled in the trade involved.

4.05.02

The erection work shall be supervised by competent supervisors holding relevant supervisory license from the Government.

4.05.03

All details on installation shall be electrically and mechanically correct.

4.05.04

The installation shall be carried out in such a manner as to preserve access to other equipment installed.

4.06.00

Protection of Work

4.06.01

The Contractor shall effectively protect his work, equipment and materials under his custody from theft, damage or tampering.

4.06.02

Finished work where required shall be suitably covered to keep it clean and free from defacement or injury.

4.06.03

For protection of his work Contractor shall provide fencing and lighting arrangement, connect up space heaters and provide heating arrangement as necessary or directed by the Engineer.

4.06.04

Contractor shall be held responsible for any loss or damage to equipment and material issued to him until the same is taken over by the Owner according to contract.

4.07.00

Safety Measures

4.07.01

All safety rules and codes as applicable to work shall be followed without exception. 239

4.07.02

All safety appliance and protective devices including belts, hand gloves, aprons, helmets, shields, goggles etc. shall be provided by the Contractor for his personnel.

4.07.03

The Contractor shall provide guards and prominently display caution notices if access to any equipment/area is considered unsafe and hazardous.

4.08.00

Co-operation

4.08.01

The Contractor shall at all times work in close coordination with the Owner's supervising personnel and afford them every facility to become familiar with erection and maintenance of the equipment.

4.08.02

The Contractor shall arrange his schedule of work and the method of operation to minimize inconvenience to other Contractors working on the Project.

4.08.03

In case of any difference between Contractors, the decision of the Engineer shall be final and binding on all parties concerned.

4.09.00

Erection Programmes and Progress

4.09.01

The Contractor shall submit at such times and in such forms as may be requested by the Engineer, schedule showing the programmes and the order in which the Contractor proposes to carry out the work with dates and estimated completion time for various parts of the work.

4.09.02

Such schedules shall be approved by the Engineer prior to starting the erection. The Contractor shall adhere to this approved programmes for all practical purposes. If for any reason the work is held up, the Contractor shall bring it to the attention of the Engineer in writing without any delay.

4.09.03

During the progress of work the Contractor shall submit monthly progress report and such other reports on erection work and organization as the Engineer may direct.

4.10.00

Consumables and Hardware

4.10.01

The Contractor shall furnish all erection materials, hardware and consumables required for the completed installation.

4.10.02

The materials shall include but not limited to the following : a.

Consumables :

Welding rods & gas, oil and grease, cleaning fluids, paints, electrical tape, soldering materials etc.

b.

Hardware

Bolts, nuts, washers, screws, brackets, supports, clamps, hangers, saddles, cleats, sills, shims etc.

:

Supply of steel, cement, sand, stone etc. required for execution of the contract shall be the responsibility of contractor.

240

4.11.00

Erection Tools & Tackles

4.11.01

The Contractor shall provide all tools, tackle, implements, mobile equipment such as crane, trailers, scaffoldings, ladders, welding machines, gas cutting, bending machine, hand cart, chain pulley blocks wire clues, hydraulic jack/ motorized jack, wooden slipper, drill machine, hand/hydraulic compression tools for cable termination, vacuum cleaners box spanner of various size etc. which are required for transportation, handling and erection of the plant and equipment.

4.12.00

Testing Equipment

4.12.01

All testing equipment, to be required for testing of all electrical equipment under scope of erection, testing and commissioning, shall be arranged by the Contractor.

4.13.00

Taking Delivery

4.13.01

The Contractor shall take delivery of materials of his own from his store yard / shed or railway siding.

4.13.02

Materials delivered shall be brought to the erection site, stored or erected as necessary.

4.13.03

Indents for materials shall be placed sufficiently in advance so as to enable the Owner to arrange for the delivery from store in time.

4.13.04

The Contractor shall submit a detailed account of materials issued to him after completion of work and transport back the excess materials to Owner's stores.

4.14.00

Installation - General

4.14.01

Installation work shall be carried out in accordance with good engineering practices and also manufacturer's instructions/ recommendations where the same are available.

4.14.02

Equipment shall be installed in a neat workmanlike manner so that it is level, plumb, square and properly aligned and oriented.

4.14.03

The equipment will be furnished in a dis-assembled condition as received at site. The contractor shall assemble all these parts, mount and wire-up loose equipment, fittings and accessories and complete with all connections.

4.14.04

Equipment will be generally supplied with necessary floor/support steel, holding down bolts, nuts, anchors etc. In case of non-supply of these items with the equipment, following procedure shall be followed : i)

Owner will arrange for floor/support steel as necessary and contractor shall fabricate and install them.

ii)

Contractor shall furnish and install all bolts, nuts, screws and anchors as required to complete the installation.

241

4.14.05

Any internal wiring of the equipment which has been left incomplete because of shipping split or which requires minor modifications shall be carried out by the Contractor.

4.14.08

All erection work shall be carried out in strict compliance with manufacturer’s instructions and shall include all necessary adjustments, checks & measurements.

4.14.09

The contractor shall record results of all erection tests & measurements. The contractor shall submit copies of those tests results to the owner for his reference & record.

4.15.00

Conduit and Accessories a.

Conduit/pipes shall be used only in short lengths in certain areas where required and/or as directed by the Engineer.

b.

The Contractor shall furnish all conduits complete with accessories as required.

c.

Conduits shall be rigid type in general. However, flexible type conduit if required shall also be supplied by the Contractor.

d.

Except for inside an enclosure wherever the cable enters or leaves the conduit, the conduit end shall be sealed by suitable sealing compound, having fire withstand capability

4.16.00

Excavation and Backfilling

4.16.01

The Contractor shall perform all excavation and backfilling as required for buried cable and ground connections.

4.16.02

Excavation shall be performed upto the required depth. Such sheeting and shoring shall be done as may be necessary for protection of the work.

4.16.03

The Contractor shall make use of his own arrangements for pumping out any water that may be accumulated in the excavation.

4.16.04

All excavation shall be backfilled to the original level with good consolidation

4.17.00

Painting

4.17.01

All equipment shall be given touch-up paint as required after installation.

4.17.02

All damaged galvanized surfaces shall be coated with cold galvanizing paint.

4.17.03

All equipment after erection shall be touched-up where required with coats of finish paint.

4.17.04

All primer & paint including touch-up paint shall be supplied by the Bidder.

242

4.18.00

Cleaning up of Work Site

4.18.01

The Contractor shall, from time to time, remove all rubbish resulting from execution of his work. No materials shall be stored or placed on passage or drive ways.

4.18.02

Upon completion of work, the Contractor shall remove all rubbish, tools, scaffoldings, temporary structures and surplus materials etc. to leave the premises clean and fit for use.

4.19.00

Commissioning and Trial Run

4.19.01

Following successful inspection and testing, the equipment shall be commissioned and put on trial run along with the main plant in a manner mutually agreed upon based on the commissioning schedule of main plant.

4.19.02

The Contractor shall assist the Owner in commissioning and trial run with men and material as required and/or as directed by the SPM.

4.20.00

Inspection & Testing

4.20.01

On completion of erection works, the Contractor shall request the SPM for inspection and tests with minimum fourteen (14) days advance notice.

4.20.02

The Engineer shall arrange for joint inspection of the installation for completeness and correctness of the work. Any defect pointed out during such inspection shall be promptly rectified by the Contractor.

4.20.03

The installation shall be then tested and commissioned in presence of the SPM and put on trial run for stipulated contract period.

4.20.04

All rectification, repair or adjustment work found necessary during inspection, testing, commissioning and trial run shall be carried out by the Contractor without any extra cost.

4.21.00

Taking over of Installation

4.21.01

On successful testing, commissioning and trial run, the Contractor shall request SPMin writing for taking over the installation.

4.21.02

The SPM, on receipt of the request, shall arrange to take over the installation either wholly or in part as the case may be after a final inspection.

4.21.03

Till such taking over, the responsibility of the whole installation against theft or damage of any kind shall remain with the Contractor.

4.22.00

Guarantee In the installation if any trouble arises due to the use of defective or faulty material and/or bad workmanship within a period of 12 months from the date of taking over, the Contractor shall guarantee to replace or repair the defective part or parts at site to the entire satisfaction of the Engineer free of charge. 243

5.00.00

TESTS

5.01.00

Site Tests

5.01.01

Contractor shall thoroughly test and meggar all cables, wires and equipment to prove the same are free from ground and short circuit after erection and installation at site.

5.01.02

If any ground or short circuit is found, the fault shall be rectified or the cable and/or equipment replaced.

5.01.03

All equipment shall be demonstrated to operate in accordance with the requirements of this specification.

5.01.04

All equipment shall be subjected to High Potential test.

5.01.05

All protective relays shall be checked for correctness of operations.

5.01.06

All current transformers shall be subjected to Primary Injection test.

5.01.07

Generator Bus-duct Polarization Index (P.I. value) shall be measured.

5.02.00

Test Witness

5.02.01

All tests shall be performed in presence of Owner/Consultant’s representatives, if so desired by the Owner.

5.02.02

The Contractor shall give at least thirty (30) days advance notice of shop tests and seven (7) days advance notice of site tests.

5.03.00

Test Certificates a.

6.00.00

Certified copies of all tests carried out at site shall be furnished in six (6) copies for approval of the Owner/Consultant.

SPECIAL TOOLS & TACKLES

A set of special tools & tackles supplied by different manufacturers of Equipment which are necessary or convenient for erection, commissioning, maintenance and overhauling of the equipment may be made available to the Contractor at the discretion of Engineer. 7.00.00

DRAWINGS, DATA & MANUALS

7.01.00

Drawings, data and manuals shall be submitted in triplicate with the bid and in quantities and procedures as specified in the General Condition of Contract and/or elsewhere in this specification for approval and subsequent distribution after the issue of Notification of Award of contract or Purchase Order.

244

7.02.01

To be submitted with the Bid

7.02.01

A network showing the proposed construction schedule specifically indicating the milestone event.

7.02.02

List of tools and tackles available with Bidder for erection, testing and commissioning along with their capacity and rating.

7.02.03

Make, type and catalogue number of different equipment and accessories along with technical leaflets, data sheets, curves etc.

7.02.04

Typical general arrangement drawings showing constructional features, fixing arrangement of pre-fabricated cable trays.

7.02.05

Bill of Materials for cable trays, conduits & accessories.

7.02.06

List of past experience as per format.

7.02.07

List of technical personnel with their qualification & experience.

7.02.08

Type test certificates.

7.03.00

To be submitted for Approval and Distribution

7.03.01

Network showing construction schedule

7.03.02

Dimensional drawings and data sheets for different equipment supplied under this specification.

7.03.03

Technical leaflets and data sheet on each piece of equipment/ device .

7.03.04

Complete relay setting calculation, co-ordination & charts for all equipment under scope of erection of this package.

7.03.05

Complete pre-commissioning/commissioning check lists for all equipment under scope of erection of this package.

245

ANNEXURE-A SCHEDULE OF PRE-COMMISSIONING TESTS 1.0

2.0

Transformers a)

Physical checking of various parts/equipment’s,

b)

Drying out by using Stream line filter, centrifuge and heater set.

c)

Insulation resistance of oil in both main and OLTC chamber.

d)

Insulation Resistance of windings

e)

Checking of Phase Sequence Test

f)

Continuity Test

g)

No load voltage ratio at all tap positions

h)

Checking of Vector Group

i)

Tap changer operation check (Mechanical and Electrical) including indication and alarm circuits.

j)

Magnetizing Current Check at 415V, 3 Phase, 50 Hz supply for all the three phases.

k)

Magnetic balance test

l)

Measurement of Winding resistance.

m)

Cooler control, indication and alarm circuits

n)

Breather (Check for Silica gel)

o)

Buchholz's relay operation

p)

Low oil level for Main tank/OLTC chamber

q)

Physical line connections as per phasing diagram

r)

Neutral connection to earth effectively.

s)

Calibration of different temperature indicators, relays and switches

Switchgear a)

Physical checking of various parts/equipment

b)

I.R. Test on each pole with HV megger

c)

I.R. test on Control Circuit 246

3.0

4.0

5.0

d)

Measurements of control resistance (in micro- ohms) for all the three phase of circuit breaker.

e)

Measurement of resistance of the closing and tripping coils

f)

Checking the close trip operation at 70% and 100% of the rated auxiliary D C Voltage.

g)

Checking the auxiliary circuits

h)

Checking of interlock provided and tripping of breaker through relay

i)

Space heater operation check

Current Transformer a)

Polarity

b)

Continuity

c)

I.R. value of windings

d)

Checking of all ratios on all cores by primary injection of current (ratio identification test)

e)

Connection to correct taps (if any)

f)

Checking CT magnetization characteristics

Potential Transformer a)

Polarity

b)

I.R. value of winding

c)

Ratio test

d)

Connection to proper taps (if any)

Distribution Board a)

Physical checking of various parts/connections

b)

I.R. test

c)

Checking of control circuit

d)

Checking of overload relay & other protective devices

247

6.0

7.0

8.0

9.0

Relay / Meters a)

Calibration test

b)

Operation test

c)

Secondary injection test for in site checking

Battery & Battery Charger a)

Physical checking of various parts/connections

b)

Electrolyte filling & topping up

c)

Charging & discharging of batteries.

d)

Checking cell voltage and specific gravity

e)

Functional check of battery charger

Cables a)

Physical checking of laying & termination

b)

Checking continuity of connections

c)

I.R. Test

d)

High Voltage test

Grounding a)

Physical checking of connections

b)

Continuity of grounding connection

NOTE :

The tests specified above are not exhaustive. Any other pre-commissioning and field test not included in the above list but specified in the relevant standards, Electricity Rules, Code of practice and/or recommended by the manufacturer of the equipment shall also be deemed to be included under the scope of this specification.

248

SPECIFICATION NO. : 11P01-SPC-E-291-53.02 SECTION-XII ERECTION, CABLING, GROUNDING AND LIGHTNING PROTECTION SYSTEM

249

SECTION-XII ERECTION, CABLING, GROUNDING AND LIGHTNING PROTECTION SYSTEM CONTENTS CLAUSE NO.

DESCRIPTION

PAGE NO.

1.00.00

CODES AND STANDARDS

1

2.00.00

SCOPE OF WORK

1

3.00.00

SCOPE OF SUPPLY

1

4.00.00

DESIGN CRITERIA

4

5.00.00

SPECIFIC REQUIREMENTS – SUPPLY

8

6.00.00

METHODS AND WORKMANSHIP

14

7.00.00

INSTALLATION

15

8.00.00

TESTS

23

9.00.00

DRAWINGS, DATA & MANUALS

24

ATTACHMENTS ANNEXURE-A

GENERAL PRACTICE FOR APPLICATION / INSTALLATION SCHEME FOR FIRE STOP MORTAR SEAL & FIRE RETARDANT CABLE COATING COMPOUND

250

29

ERECTION CABLING, GROUNDING AND LIGHTNING PROTECTION SYSTEM 1.00.00

CODES AND STANDARDS

1.01.01

All cable and materials shall be designed, manufactured and tested in accordance with the latest applicable Indian Standards (IS) and IEC except where modified and/or supplemented by this specification.

1.01.02

The electrical installation shall meet the requirements of Indian Electricity Rules as amended up to date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work shall be followed.

2.00.00

SCOPE OF WORK

2.01.00

The scope of work covers Erection, Testing and Commissioning of complete Electrical system including cabling, grounding & lightning protection system, Fire Stop mortar seal, fire retardant cable coating system. The scope shall broadly cover, but not be limited to: 1.

Paper Machine#5 Building.

2.

Boiler area,.

3.

33 KV switch yard and 11KV switchgear building.

4.

All auxiliary buildings including electrical substation.

5.

Pipe cum cable rack.

6.

All electrical equipment as described in different sections.

The scope of work shall also include all civil and structural works necessary for successful installation and commercial operation of all electrical equipment to be erected under this specification.

3.00.00

SCOPE OF SUPPLY

3.01.00

The scope of supply shall include but not be limited to the followings:

3.01.01

Timely procurement and transportation to site in properly packed condition of all materials and miscellaneous items required to complete the erection work under this specification.

These materials and miscellaneous items shall include but not be limited to the following: a)

Galvanized steel pre-fabricated cable trays, coupler plates, nuts, bolts & washers, reducers, covers, wall brackets, hanger clamps, straight run, elbows, bends etc.

b)

Galvanized steel rigid/flexible conduits and accessories, ferrules, lugs, glands, terminal blocks, galvanized sheet steel junction boxes, cable fixing clamps, nuts & bolts etc. as required. 251

3.01.02

c)

Cable termination and jointing kits as necessary.

d)

All necessary erection materials, consumables and sundry items including arc welding rods to complete the installation for satisfactory and trouble free operation.

e)

Stranded Copper cables and Copper flats required for grounding and lightning protection system shall be supplied in standard lengths.

f)

Fire Stop mortal seal, fire retardant cable coating system.

g)

Any item of works or erection materials which have not been specifically mentioned but are necessary to complete the work involved shall be deemed to be included in the scope of this specification and shall be furnished by the contractor without any extra charge to the Purchaser.

a)

Main Ground Mat Laying underground conductors and cad welding the conductors at each crossing and straight run (lap joint). The conductors at the periphery of the mat shall be 1 no. 240 mm² (min) bare stranded copper cable and the internal cross conductors of the mat shall be 1 no. 240 mm²(min) bare stranded copper cable. Suitable pigtails shall be provided and shown in the layout drawing for connection with existing plant ground grid.

b)

Grounding Electrode Fabrication and driving into ground 20 mm (min) diameter 3000 mm long copper cladded steel rod and connecting them to the grounding mat by welding.

c)

Column Grounding i)

Concrete Columns Erection of 1 no. 20 mm (min) dia. Copper cladded steel rod from grounding mat to all concrete columns including necessary fixing, welding of one end of the rod with ground mat and the other end with the column above ground by welding with a short Cu flat to edge angles.

ii)

Steel Columns Erection and connection of 1 No. 20 mm (min) diameter copper cladded steel rod from grounding mat to all steel columns including necessary fixing welding with ground mat and the other end with the column above ground with a short Cu flat.

252

d)

Risers Erection and connection of all risers from underground mat to above ground levels where the ends will be left free for connecting to the equipment. Each riser will be 1 No. 240 mm² (min) bare copper conductor and Minimum 600 mm above grade level/concrete floor level.

e)

All other ancillary works in connection with the items of work described above which are not specifically mentioned but are necessary to complete the work, shall be under the scope of this specification.

3.02.00

All materials and accessories to be supplied by the Bidder shall be brand new ones of reputed make.

3.03.00

Necessary drawings, data sheets and Technical leaflets on each piece of material.

3.04.00

Scope of Services The scope includes but is not limited to the followings :

3.04.01

Furnishing of all erection tools and tackles, testing equipment, implements, supplies, hardware and transport for timely and efficient execution of the erection work.

3.04.02

The items of erection work shall be performed with respect to the following equipment/materials: a)

Power Cables

b)

Control, instrument and special cables

c)

Entire cable tray and cable shaft arrangements inside building & other areas including outdoor cable trench & bridges and all associated civil and structural works including foundation and cable trenches.

d)

Supply and Erection of Grounding system.

e)

Supply and erection of lightning Protection system.

f)

Fire Stop mortal seal, fire retardant cable coating system .

Note :- Cables directly laid or buried in ground is not accepted. 3.05.00

Erection Schedule

3.05.01

The entire erection work shall be carried out in a phased manner. A schedule of the work showing the sequence of erection shall be submitted by the tenderer for this purpose. 253

3.05.02

The erection schedule, as approved by the Owner's Engineer shall be strictly followed by the contractor. If, for any reason beyond the control of the Contractor, the work is held-up then the Contractor shall bring it to the notice of the Owner's Engineer without any delay.

4.00.00

DESIGN CRITERIA

4.01.00

Grounding System

4.01.01

Grounding shall follow the relevant standards/codes amended till date as below: a. b. c. d. e. f.

Indian Electricity rules National Electrical Code Code of Practice of Earthing IS 3043 Protection of building and allied structures against lightning IS 2309 IS- 732, IS 226, IS 2629, IS 2633 & IS 4759 IEEE -80, IEEE-665

The station grounding system shall be an interconnected network of Copper conductor and Cu ground rods. The system shall be provided to protect plant personnel and equipment from the hazards, which can occur during power system faults and lightning strikes Design Basis The station grounding system shall be designed in compliance with the IEEE80/ IEEE- 665 considering fault current of 50kA for 1 sec. and shall be subject to approval of owner/consultant. Actual soil resistivity measurement shall be carried out at proposed site for new units during dry season. These data’s along with above mentioned data’s shall be considered and the bidder shall use the higher value of Soil resistivity i.e. between the measured value and the value used for existing units. However, the surface resistivity shall be considered as 1000-ohm meter. a)

Major items of equipment, such as generator, switchgear, transformer, motor, relay panels and control panels etc shall have integral ground buses or connection points which shall be connected to the station ground grid.

b)

Electronic panels and equipment, where required, shall be grounded utilizing an insulated ground wire connected in accordance with the manufacturer's recommendations. Where practical, electronics ground loops shall be avoided. Where this is not practical, isolation transformers shall be furnished. All indoor and outdoor electrical equipment and associated non-current carrying system, metal works, support structures, buildings columns, fence, neutrals, masts, arrestors, etc shall be connected to the plant ground system.

c)

Instrumentation cable screens shall be single point bonded to the instrument earth network to minimize the effects of electrical interference.

d)

For Signal/case/intrinsically safe signal, grounding of control room instruments, separate earth pit not connected to main ground grid shall be used. Control cabinets shall be connected to this separate earth pit.

e)

A single copper flat as grounding conductor shall be routed parallel to all power conductors operating above 240 volts.

f)

All ground wires installed in conduits shall be non-insulated. 254

g)

Embedded grounding grid of 50x6mm Cu flat at basement/grade slab as well as upper floor/suspended slabs shall be provided.

h)

In addition tinned Copper ground pads at different locations i.e. on wall/floor/ceiling inside the buildings/tunnels/trenches shall be provided. These pads will be in turn connected to below ground level earth mat through copper flat or riser. Each ground pad shall have provision for connection of at least four 50x6mm Cu flats.

i)

Treated earth pit shall be provided for system earthing at locations where generator and transformer neutrals are grounded. Two pits shall be provided for each neutral.

j)

Dedicated treated earth pit shall be provided for lightning protection system.

k)

Clean earthing for instrumentation shall be provided with dedicated earthing system and separate treated earth pits below the main control room .

4.01.02

In order to meet the above objectives, ground grid mesh will be provided for the main plant mill complex. viz.33KV switchyard, boiler area, all auxiliary buildings. Interconnection between existing grid and new plant ground grid shall be done at least four points. All electrical equipment, non-current carrying metal parts, structures, building steel, lightning protection system, transformer neutrals will be connected to this station ground grid. The major aspects to be considered for grounding system design are given below:

4.01.03

4.01.04

Ground Grid Conductor a)

Minimum 240 mm² stranded bare copper cable shall be used as Ground grid conductor for the plant.

b)

The minimum conductor section to be determined on the basis of ground fault current. This section is then increased by an allowance to account for the soil corrosion loss of 0.3 mm per year over the design life of 30 years.

Above Ground Connections a)

Copper flats of50x6mm shall be used for all connections above earth.

b)

Inside building, ground conductors will be run for each floor supported on building steel and/or cable trays. These ground conductors in turn will be connected to the station ground grid through riser (at least two) coming up along building columns/cable shafts.

c)

Two separate and distinct ground connections will be provided for each electrical equipment in compliance with I.E. Rules.

d)

All connections above ground will be welded type except connection to equipment/structures which shall be bolted type.

255

4.01.05

Equipment Ground Connection Equipment ground connections will be sized to carry the available ground fault current. Considerations shall also be given to mechanical ruggedness of the connections and to limit the number of sizes.

4.01.06

The minimum ground conductor sizes for various equipment and structures are given in enclosed drawings for grounding.

4.01.07

Entire erection of grounding work shall be carried out in such a way as to be capable of withstanding the intended services of carrying full short circuit level currents to ground mat without any damage/deformation.

4.02.00

Lightning Protection System Lighting protection system design shall be as per IS:2309

4.02.01

The main purposes of lightning protection system are to : a)

Provide protection to structures from lightning strokes.

b)

Provide a low resistance-conducting path to lightning discharge.

4.02.02

Lightning protection shall be provided for Main Mill building & 33KV switch yard and other auxiliary buildings.

4.02.03

Lightning protection will be provided where the overall rise factor exceeds 10-6 as per IS: 2309 or Building higher than 55 meters in height

4.02.04

For metal structures which are electrically continuous down to the ground level, no lightning protection is required except adequate grounding connections.

4.02.05

System Design a)

Air termination network with down conductors and earthing electrodes will be provided on the basis of IS Code of Practice.

b)

Horizontal air termination shall be so laid out that no part of the roof will be more than 9 meters from the nearest conductor.

c)

The vertical air terminal rods shall be installed at the roof of buildings (including power house building), to protect these objects from lightning strokes.

d)

Shielding angle for one vertical air termination shall be 45 degrees. For more than one rod, shielding angle between the rods shall be taken as 60 Degrees.

e)

Down conductors will run along the outer surfaces of the building and shall have a test joint about 1500 mm above ground.

f)

An earth electrode will be provided at the connection point of the down conductor with the station ground.

256

g)

Copper cladded steel rods and flats will be generally used for air termination and connections. All connections will be welded type.

4.03.00

Cabling System

4.03.01

Erection of cabling work shall be carried out in such a way as to provide a reliable and assured electric power supply system to all station auxiliaries.

4.03.02

Cable routing will be done on unit basis as far as possible.

4.03.03

Cables will generally be laid on cable trays, cable rack, overhead supported from building steel/structures or cable bridge/cable trestle. Cables shall be run in concrete trenches only in transformer yard, concrete trenches is not accepted for other areas/ buildings . Cables buried directly in ground is not acceptable. In indoor pumps, mechanical equipment areas overhead cable trays shall generally be used.

4.03.04

For underground crossing of railways, road etc. additional protection shall be provided in form of Hume pipe or concrete encased rigid steel conduits (duct bank).

4.03.05

A.C. and D.C. circuit will not be run in same cable. Further, separately fused circuit will run in separate cables.

4.03.06

Cables for redundant equipment system shall be run in separate trays, as far as possible.

4.03.07

Erection of cabling work shall be executed keeping in view all necessities and requirements of fire fighting codes for paper plant having an adverse industrial environment. Vertical Cable Tray arrangement shall be adopted in dust ingested areas .

4.03.08

Suitable embedded steel inserts shall be provided on wall/floor/ ceiling surfaces for welding of cable tray bracket in order to make the cable tray system withstand horizontal/vertical accelerations due to seismic forces for indoor trays and also wind load for outdoor trays in addition to normal tray cable loadings.

4.04.00

All erection work to be carried out under this specification shall conform to the notes and details given in Drawing for cabling to this specification.

5.00.00

SPECIFIC REQUIREMENTS – SUPPLY

5.01.00

Equipment and Material

5.01.01

Equipment and material shall comply with description, rating, type and size as detailed in this specification, drawings and annexures.

257

5.01.02

Equipment and materials furnished shall be complete and operative in all details.

5.01.03

All accessories, fittings, supports, hangers, anchor bolts etc. which form part of the equipment or which are necessary for safe and satisfactory installation and operation of the equipment shall be furnished.

5.01.04

All parts shall be made accurately to standard gauges so as to facilitate replacement and repair. All corresponding parts of similar equipment shall be interchangeable.

5.02.00

Pre-fabricated Cable Trays

5.02.01

Cable trays shall be pre-fabricated ladder type, perforated type cable trays sheet steel with hot dip galvanizing furnished in standard length of 2.5 metres. In areas, where acid/alkali ingration is likely to occur, glass reinforced plastic trays with fire retardant corrosion resistance properties shall be used.

5.02.02

Cable trays shall be of standard width specified in Annexure-A.

5.02.03

Cable trays shall be complete with all necessary hot dip galvanized sheet steel accessories such as coupler plates, ground continuity connections, nuts, bolts, washers, hangers, clamps etc. Also horizontal/vertical bends, horizontal/vertical Tee, Reducers, Horizontal cross-pieces, protective covers shall be supplied along with straight runs in order to take care of cable tray alignments in different routes.

5.02.04

All fittings like horizontal/vertical elbow, horizontal crosspiece, reducer, horizontal tee etc. should be prefabricated.

5.02.05

Cable trays, fittings & accessories as well as elbows, reducers, tees, crosses etc. shall be fabricated out of 14 gauge (2 mm thick) hot rolled mild steel sheets.

5.02.06

Contractor shall supply 14 gauge (2 mm thick) perforated type hot rolled mild steel sheet covers for vertical cable shafts up to a height of 2.5 metres from floor level. The perforated covers used for the vertical raceways may be of one or more pieces along the width of the raceway, depending on the width of the raceway and shall be bolted to the structural framework of the raceway.

5.02.07

The cable trays, fittings and accessories including all bolts, nuts, screws, washers etc. shall be hot dip galvanized after fabrication as per IS:2629. Galvanizing shall be uniform, clear, smooth and free from acid spots. Should the galvanizing of the samples be found defective, the entire batch of steel will have to be regularized at Contractor's cost. The amount of zinc deposited shall not be less than 610 gms per square meter of surface area and in addition the thickness of the zinc deposit at any spot whatsoever, shall not be less than 75 microns. The Owner reserves the right to measure the thickness of zinc deposit by Elco meter or any other instrument and reject any component, which shows thickness of zinc at any location to be less than 75 microns.

258

5.02.08

Each 2.5M long section of all types of cable trays & each fittings like elbow, tees, crosses etc. shall be provided with two nos. hot dip galvanized side coupler plates & associated bolts, nuts and washers on each side.

5.02.09

The Contractor shall perform all tests necessary to ensure that the material and workmanship conform to the relevant standards and that such tests are adequate to demonstrate that the equipment will comply with the requirement of this specification. The tolerance on dimensions shall be in accordance with appropriate Indian Standards. The extent of the tests to be performed by the contractor shall include but not be limited to the following: Deflection Test A 2.5 meter straight section of each type of cable trays shall be simply supported at the two ends. A uniformly distributed load of 100 Kg per meter will be applied along the length of the tray. The maximum deflection at mid span shall not exceed 7 mm.

5.02.10

For other details refer CABLING NOTES AND DETAILS annexed to this specification.

5.03.00

Conduits and Accessories

5.03.01

Conduits shall be of rigid steel, hot-dip galvanized, furnished in standard length of 5 meters, threaded at both ends.

5.03.02

Conduits diameter upto and including 25mm size shall be of 16 SWG and conduits above 25 mm diameter shall be of 14 SWG. Minimum diameter of conduits shall be 20 mm.

5.03.03

Each piece of conduit shall be straight, free from blister and other defects, internal surface shall be of smooth finish and covered with capped bushings at both ends.

5.03.04

The contractor shall provide and install all rigid steel conduits, mild steel pipes, flexible conduits rigid PVC pipes etc. complete with accessories such as tees, bends, adopters, locknuts, pull boxes, conduit plugs, caps etc as required for the cabling work.

5.03.05

Steel conduits with interior coating of silicon epoxy ester for ease of wire/cable pulling shall be seamed by welding and flo-coat metal conduit/hot-dip galvanized. These shall be supplied in standard length of 5M with minimum wall thickness as specified in IS: 9537. In chemical handling areas, Battery Room etc., the exterior surface shall be further coated with chromate and polymer for better resistance to corrosion. HDPE conduits shall be used for these areas. Conduits, fittings & accessories shall have ISI mark.

5.03.06

For sizes above 63 mm mild steel pipes with necessary fittings & accessories shall be provided and installed by the contractor. Pipes shall be manufactured by electric welding process. These pipes shall be of heavy duty class as per IS:1239 and shall have ISI mark. Pipes shall be supplied in lengths of approximately 5 meters. Pipes, fittings & accessories shall be hot dip galvanized both on inside and outside. 259

5.03.07

Flexible conduits shall comply with IS:3480. They shall be made with bright, cold rolled, annealed and electro-galvanized mild steel strips. Flexible conduits shall be used between embedded conduits/pipes and the motor terminals. Flexible conduits shall also be used between fixed conduit and any equipment terminal boxes where vibration is anticipated or equipment that require regular removal.

5.03.08

Rigid PVC conduits conforming to IS:4985 shall generally be used for control & instrumentation cables in some areas where cable trays do not exist and where the runs are straight ones generally the PVC pipes with special Bell Mouthing shall be of 110 mm,160 mm & 200 mm outside diameter and shall be suitable for working pressure of 6 kg/sq. cm. The length of each pipe shall be 5 to 6 meters. Necessary fittings & accessories as may be required for the installation shall also be provided.

5.04.00

Junction Boxes

5.04.01

Glass Fiber Reinforced Junction Boxes 1. No. of Ways:12 / 24 / 36 / 48 with 20% spare terminals. 2. Design: Junction boxes shall be Glass Fiber Reinforced with saturated polyester informing to standards like DIN 16911 type 803 / 16913 type 834, 5 selfextinguishing in accordance with ASTM D 635 / UL 94 VO. Junction boxes for use in outdoor or damp locations shall be sturdy construction. Temperature resistance between – 10 to 100oC. Impact resistance shall be greater than 7 Nm, (EN 50 014). Protective insulation shall be in line with VDE 0100, dielectric strength shall be greater than 10 KV / mm, halogen free toxicity, the enclosure and door cover shall be painted and electrostatically powder coated (preferably in RAL 7032). Earth connection (studs size shall be M 6) shall be provided on the cover as well as door. Doors: With integrated viewing window of 3 mm resistant Flexi – glass or equivalent. The doors shall have industrial heavy – duty hinges. The doors shall be easily but firmly lockable with quick release fastener. a. Protection Class: Protection Category shall be IP 66 to EN60 529. There shall be guaranteed perfect seal to meet Protection class IP 66 providing sealing arrangement like highly elastic foamed in special type seal like polyurethane / chloroprene. The sealing rubber shall not have aging effect and shall retain its sealing characteristics for more than 20 yrs. Bidder shall indicate this in data sheet. The rubber seal should be pasted at its place with pasting technology for like more than 20 yrs. ( double sealing arrangement is preferred).

260

b. Mounting clamps and accessories: Suitable for mounting on walls, columns and structure. Brackets, bolts, nuts, screws, glands and lugs required for erection shall be of brass. The accessories like mounting plants etc. of steel shall be powdered coated. The support rails for terminal box shall be zinc coated. c. General: i.

JBs shall have small canopy at the top.

ii.

There shall be rainwater collection arrangement from top and side of the outer ages to ensure that any leakage in to the junction box shall be avoided and it shall fall outside.

iii.

Cable entry shall be from bottom side only.

iv. Ensure gland plate sealing perfect. It shall be of the same quality and arrangement as that of door to cover arrangement. 5.04.02

Steel Junction Boxes: a. No. of Ways:12 / 24 / 36 / 48 with 20% spare terminals. b. Design: Junction boxes shall be designed in accordance with NEC, article 370, paragraph 18, 20 or equivalent standards. c. Enclosure: Junction boxes for use in outdoor or damp locations shall be sturdy steel construction. The enclosure and door cover shall be surface finished clean , degreased, phosphate, deep coated primed (preferably in RAL 7044 ) and electro statically powder coated (preferably in RAL 7032). Earth connection (studs size shall be M 6) shall be provided on the cover as well as door. The sheath steel thickness shall be minimum 2 mm. d. Doors: The doors shall be hinged and lockable. The doors shall have industrial heavy – duty hinges. The doors shall be easily but firmly lockable with quick release fastener. e. Protection Class: Protection Category shall be IP 66 to EN60 529 / 10.91 complies with NEMA 4.. There shall be guaranteed perfect seal to meet Protection class IP 66 providing sealing arrangement like highly elastic foamed in special type seal like polyurethane. There shall be an arrangement like multifold protection channel for additional stability and prevention of ingress of dust and water when the enclosure is open. The sealing rubber shall not have aging effect and shall retain its sealing characteristics for more than 20 yrs. Bidder shall indicate this in data sheet. 261

The rubber seal should be pasted at its place with pasting technology for like more than 20 yrs (double sealing arrangement is preferred). f. Mounting clamps and accessories: Suitable for mounting on walls, columns and structure. Brackets, bolts, nuts, screws, glands and lugs required for erection shall be of brass. General: i.

JBs shall have small canopy at the top.

ii.

There shall be rainwater collection arrangement from top and side of the outer ages to ensure that any leakage in to the junction box shall be avoided and it shall fall outside.

iii.

Cable entry shall be from bottom side only.

iv.

Ensure gland plate sealing perfect. It shall be of the same quality and arrangement as that of door to cover arrangement.

5.05.00

Terminals

5.05.01

Multi way terminal blocks of approved type, complete with screws, nuts; washers and marking strips shall be furnished for connection of incoming/outgoing wires.

5.05.02

Each control cable terminal shall be suitable for connection of 2 nos. 2.5 sq.mm. stranded copper conductors without any damage to the conductor or looseness of conductors.

5.06.00

Cable Termination & Jointing Kits

5.06.01

The Bidder shall supply cable termination and jointing kits in requisite quantity for H.T. Power Cables, L.T. Power, Control Cables, Instrumentation Cables etc. along with all accessories & consumables required for making termination and joints complete. All the materials and components of the termination/joints shall be suitable and compatible with the type of cables for which the terminals/joints are intended.

5.06.02

For HT cables, the end terminations & jointing kits shall be of heat shrinkable type of Raychem, REPL, CCI or of approved make. For LT cables, the jointing kits & termination kits shall be Raychem/REPL/CCI/ Mahindra (M-seal) or of approved make. Cable joint or end terminations on Electrical equipment shall be suitable for Indoor & Outdoor use, as the case may be.

5.06.03

Glands and lugs required for termination of H.T., L.T. and instrumentation cables shall be supplied by the Contractor in required quantity.

5.07.00

Cable Glands Cable glands shall be nickel plated gland, double compression type complete with necessary armour clamp and tapered washer etc. Cable glands shall match with the sizes of different HT/LT/Control cables.

262

5.08.00

Cable Lugs All cable lugs shall be Cd plated copper. Cable lugs shall be suitable for termination of different cross-sections of H.T./L.T./Control/Instrumentation cables and shall be of following types: i) Copper tubular terminal end for solder less crimping to copper conductors. Solder less crimping of terminals shall be done by using corrosion inhibiting compound. The cable lugs shall suit the type of terminals provided on the equipment. Lugs for control/instrumentation cables shall be PVC insulated/sleeved type. ii) Cable lugs for control cable termination shall be insulated. These lugs shall be flat type/ring type/U type to suit the terminals provided in the panels.

5.09.00

Consumables and Hardware

5.09.01

The Contractor shall furnish all erection materials, hardware and consumables required to complete the installation.

5.09.02

The materials shall include but not be limited to the following : Consumables

:

Welding rods & gas, oil and grease, cleaning fluids, paints, electrical tape, soldering materials etc.

Hardware

:

Bolts, nuts, washers, screws, brackets, supports, clamps, hangers, saddles, cleats, sills, shims etc. 5.09.03 Supply of cement, sand, stone etc. required for the execution of the contract shall be the responsibility of the Contractor.

5.10.00

Testing Equipment

5.10.01

The major testing equipment that are required to be provided by the Contractor are listed below : a)

Insulation Tests i)

Power operated Meggar- 2.5 KV to 10 KV grade

ii)

Hand operated Meggar- 1 KV grade

b)

Hand driven earth Resistance Meggar, range 0-1/3/30 ohms.

c)

High potential testing set - roller mounted type.

d)

Tong testers of suitable ranges.

e)

Contact resistance measuring set for micro-ohms.

f)

Torque wrench of various sizes.

g)

Multi meters, test lamp, field telephone with buzzer set, different gauges etc. 263

5.10.02

The list of equipment is indicative only. Any other test equipments will be arranged by the Contractor.

6.00.00

METHODS AND WORKMANSHIP

6.01.00

All work shall be installed in a first class, neat workmanlike manner by mechanics/electricians skilled in the trade involved.

6.02.00

The erection work shall be supervised by competent supervisors holding relevant supervisory license from the Government.

6.03.00

All details on installation shall be electrically and mechanically correct.

6.04.00

The installation shall be carried out in such a manner as to preserve access to other equipment installed.

7.00.00

INSTALLATION

7.01.01

Installation work shall be carried out in accordance with good engineering practices and also as per manufacturer's instructions/ recommendations where the same are available.

7.01.02

Equipment shall be installed in a neat workmanlike manner so that it is level, plumb, square and properly aligned and oriented.

7.01.03

Cable installation work shall mean erection of cable trays/racks, supports, hangers, junction boxes, conduits, laying of cables either in ground or on trays inside trenches tunnels/overhead trays in conduits etc. dressing and clamping, jointing and termination inclusive of supply of necessary jointing/termination kits, lugs, glands, ferrules, tapes etc. and other accessories, grounding of cable armour. In case of direct laying in ground, all excavation work, necessary back-filling, supply of bricks and protective concrete slabs, removal of excess earth shall be part of the installation work.

7.01.04

Grounding installation work shall mean erection, jointing/ brazing/welding, connection and painting, testing of ground conductors including supply of necessary steel/copper.

7.01.05

Lightning protection system installation work shall mean erection, jointing, welding, connection and painting, testing of air termination network, down conductors, shielding masts, connection to ground grid, electrodes, risers, horizontal conductors etc. of lightning protection system.

7.02.00

Cable Trays

7.02.01

Pre-fabricated cable trays and accessories shall be assembled & erected at site. Adequate spaces will be provided to facilitate installation of cable system and to allow routine inspection and modification after installation.

7.02.02

Cable trays either inside concrete trenches or inside buildings and racks inside cable shafts shall be aligned and leveled properly. All tray runs shall be installed parallel to the trench/building walls and floors except otherwise noted in the approved drawings. 264

required

7.02.03

As far as practicable, cable trays shall be supported from one side only in order to facilitate installation and maintenance of cables from the other side.

7.02.04

The cable trays shall be supported in general at a span of exceeding 1.25 metres horizontally and 1.0 metre vertically.

7.02.05

Sufficient spacing not less than 300 mm shall be provided between trays and maintained to permit adequate access, for installing and maintaining the cables. In areas like Boiler, CHP etc. where excessive dust coal ingression is expected Vertical Tray Arrangement shall be provided. In areas, where acid/alkali ingression is likely to occur, Fire Retardant, Corrosion resistance trays of glass reinforced plastic shall be used.

7.02.06

Complete cable tray support structure after installation shall be inspected/tested for welding strength, straightness, accuracy, use of proper sizes and compliance to drawings.

7.02.07

Complete cable tray and accessory installation work shall be inspected/tested for proper alignment, leveling, use of proper accessories, high quality workmanship etc.

7.02.08

The Contractor shall remove the RCC/steel trench covers whenever required and shall again place the same in their positions after the erection work in the particular area is completed or when further work is not likely to be taken up for some time.

7.02.09

Whenever any pipe/conduit/cable tray emerges out or enters into a building care should be taken to ensure that no water enters into the building.

7.02.10

Cable trays in areas subject to excessive coal dust, oil spillage, mechanical damage or accessible to personal contact shall be provided with raised sheet metal tray covers, installed on upper tray in horizontal run and front in vertical run.

7.02.11

Cable trays/racks shall be so arranged that they do not obstruct or impair clearances of passage way.

7.02.12

Cable tray/conduit system will be so designed as to accommodate maximum pulling tension and minimum bending radius of cable.

7.02.13

Cable tray/conduit system will be constructed to prevent drainage of water into equipment or building.

7.02.14

Cable tray/conduit system shall be electrically continuous and grounded.

7.02.15

Different voltage grade cables will be laid in separate trays when trays are run in tier formation. Power cables will normally be on top trays and control/instrumentation cable on bottom trays.

265

7.03.00

Cable and Conduits

7.03.01

The Contractor shall install, terminate and connect up all cable and conduits as per approved drawings and cable schedules.

7.03.02

The drawings shall be strictly followed except where obvious interference occurs. In such cases, the routing shall be changed as directed and/or approved by the Engineer.

7.03.03

Approximate lengths of cable and conduit runs will be shown by the contractor in the cable schedule for guidance only. Before commencement of work the Contractor shall take actual measurements and prepare his own cable-cutting schedule to reduce wastage to a minimum.

7.03.04

The Contractor shall also maintain and submit when requested, a record of cable insulation value when drawn from store, after laying, before and after termination/jointing.

7.03.05

Where direct heat radiation exists, heat isolating barriers, shall be adopted for cabling system.

7.03.06

Cabling/wiring in offices, laboratories, control rooms etc. shall be taken through concealed G.I. or rigid PVC pipes as directed by the owner's Engineer.

7.03.07

At certain places where hazardous fumes/gasses may cause fire to the cables, cable trenches after installation of cables shall be sand filled.

7.04.00

Conduit and Accessories

7.04.01

Conduit/pipes shall be used only in short lengths in certain areas where required and/or as directed by the Engineer.

7.04.02

The Contractor shall furnish all conduits complete with accessories as required.

7.04.03

Conduits shall be flexible type in general. However, rigid type steel conduit if required shall also be supplied by the Contractor.

7.04.04

Except for inside an enclosure wherever the cable enters or leaves the conduit, the conduit end shall be sealed by suitable sealing compound, having fire withstand capability.

7.04.05

The entire metallic conduit system, when embedded or exposed shall be electrically continuous and grounded.

7.04.06

Where it is possible for water or other liquids to enter conduits, sloping of conduit runs and drainage of flow points shall be considered.

7.04.07

Pull boxes will be installed between termination points where required to facilitate cable pulling, but at a maximum interval of 30 meters.

7.04.08

Conduits shall be firmly fastened within 900 mm of each junction box/pull box/cabinet/fitting etc. Conduits shall be supported at least every 2000 mm. 266

7.05.00

Cables : Storage and Handling

7.05.01

Cable drums shall be stored on hard and well-drained surface so that they may not sink. In no case shall the drum be stored on the flat, i.e., with flange horizontal.

7.05.02

Rolling of drums shall be avoided as far as practicable, for short distance, the drums may be rolled provided they are rolled slowly and in proper direction as marked on the drum.

7.05.03

In absence of any indication, the drums may be rolled in the same direction as it was rolled during taking up the cable.

7.05.04

For unreeling the cable, the drum shall be mounted on jacks or on cable wheel. The spindle shall be strong enough to carry the weight without bending.

7.05.05

The drum shall be rolled on the spindle slowly so that the cable should come out over the drum and not below the drum.

7.05.06

While laying cable, cable rollers shall be used at an interval of 2000 mm. The cables shall be pushed over the roller by a gang of people positioned in between rollers over a suitable distance. Care shall be taken so that kinks and twists or any mechanical damage does not occur in cables. Only approved cable pulling grips or other devices shall be used. Cables shall not be dragged on ground or along structure while laying out from cable drums.

7.05.07

Cable shall not be pulled from the end without having intermediate pushing arrangement. Bending radius of the cable during installation shall not be less than what is specified by the manufacturer.

7.05.08

Empty cable drums shall be returned to the owner.

7.06.00

Cable Laying

7.06.01

Cable shall generally be installed in ladder type prefabricated trays uniformly loaded proportionate to the size of the tray except for some short run in rigid/flexible conduit for protection or crossings. Trays shall be away from steam, oil, coal pipelines and hot ducting.

7.06.02

Cables laid on trays and risers shall be neatly dressed and clamped as stated subsequent clauses at an interval of 750 mm. for horizontal and 500mm for vertical runs, in case of both power, control and instrumentation cables.

7.06.03

All single core power cables for 3 Ph. AC circuits shall be laid in trefoil formation and suitably clamped with self-locking type fire resistant nylon trefoils clamps at an interval of 750 mm for horizontal run or 500mm for vertical run.

7.06.04

All H.T. multicore power cables and L.T. multicore power cables with cross-sectional area including & above 95 sq.mm shall be clamped individually by glass reinforced nylon claw type clamps.

7.06.05

L.T. power cables of cross sectional area less than 95 sq. mm. and all control and Instrumentation cables shall be clamped in bunches with 25x3 mm Aluminum strip. The number of cable in one bunch shall not exceed eight (8). 267

7.06.06

Prior to laying of cables inside the indoor and outdoor trenches, the contractor shall properly clean the trenches.

7.06.07

When cables crosses road/railway track, adequate protection shall be provided in the form of hume /galvanized iron pipes laid at a minimum depth of 1 meter below ground.

7.06.08

After completion of installation and prior to connection, all power cables shall be subjected to a high potential test. Machine ferruling shall be adopted.

7.07.00

Cable Tags & Markers

7.07.01

Each cable and conduit run shall be tagged with numbers that appear in the cable and conduit schedules. Cables and conduits shall be tagged at their entrance, bends, every 30.0M and exit from any equipment, junction box. When a cable/conduit passes through a wall, tags shall be fitted on both sides of the wall.

7.07.02

The tags shall be of aluminum with the number punched on it and securely attached to the cable by not less than two turns of 16 SWG G.I. wire. For single core cable the wire shall be of non-magnetic material.

7.07.03

The location of cable joints, if any, shall be clearly indicated with cable marker with an additional inscription 'cable-joint'.

7.07.04

The Contractor shall furnish and install all tags and markers stated above.

7.07.05

For buried cable, the marker shall project 150 mm above ground and shall be spaced at an interval of 30 meters and at every change of direction.

7.08.00

Cable Termination and Connection

7.08.01

The termination and connection of cables shall be done strictly in accordance with manufacturer's instruction, drawings and/or as directed by the Engineer.

7.08.02

The work shall include all clamping, fitting, fixing, soldering, tapping, compound filling, cable jointing, crimping, shorting and grounding as required for the complete job. All equipment required for all such operations shall be of Contractor's procurement.

7.08.03

Furnishing of all consumable materials such as soldering material, electrical tape, sealing material as well as cable jointing kits shall be included in the offer.

7.08.04

Cable joint kits for all cables shall be supplied by Contractor under this specification. Responsibility for proper termination shall lie on the contractor. Guarantee for termination shall also have to be given by Contractor.

7.08.05

The equipment will be generally provided with blank bottom plates for cable/conduit entry and cable end box for power cables.

7.08.06

The Contractor shall perform all drilling, cutting on the blank plate and any minor modification work required to complete the job.

268

7.08.07

If the cable end box or terminal enclosure provided on the equipment is found unsuitable and requires major modification, the same shall be carried out by the contractor.

7.08.08

Control/instrumentation cable cores entering control panel/ switchgear/MCC etc. shall be neatly bunched and served with PVC perforated tape to keep it in position at the terminal block.

7.08.09

The Contractor shall put ferrules on all control cable cores in all junction boxes and at all terminations. The ferrules shall carry terminal numbers as per drawings. All ferrules shall be colored, plastic & interlocked type.

7.08.10

Spare cores shall be similarly ferruled, crimped with lug and taped on the ends. Spare cores shall be ferruled with individual cable number. Machine ferruling shall be adopted.

7.08.11

Termination and connection shall be carried out in such a manner as to avoid strain on the terminals.

7.08.12

All cable entry Points shall be properly sealed and made vermin and dust proof. Unusual opening, if any, shall be effectively closed. Sealing work shall be carried out with approved sealing compound having fire withstand capability for at least three hours.

7.09.00

Termi-point Connection a)

The conductor (solid or stranded) is forced against the contact area of the 2.4 x 0.8 mm or 1.6 x 0.8 mm connection pin by means of a tin-coated bronze clip, which maintains a constant pressure. In the Maxitermi-point method, 2.4 x 0.8 mm pins is used without exception.

b)

The conductor is "shot" onto the pin together with the clip. The resulting friction causes both the wire and the contact area of the pin to be cleaned and any oxide layers to be penetrated.

c)

Apart from this the wire and the clip are deformed in such a way that a gas-tight connection with very good electrical and mechanical properties is established.

d)

A special manually or pneumatically driven gun is required. Up to 3 adjacent connections can be "shot" onto one pin. In most cases only one clip at the base of the pin is attached. The sections above usually remain vacant. Any part of a connection pin may be reused several times after removal of the existing clip connection. Contact areas below existing connections that have become vacant can be reused by pushing the connections above the vacant space downwards, so that the new connection can be "shot" on above the top connection. The single jumper wires need not be specially prepared as the end insulation is stripped within the tool.

e)

This connection method requires special insulation of the wires. The diameter of solid conductors is 0.8 mm the cross-section of stranded conductors 0.5 Sq.mm. 269

f)

The conductor is deformed greatly when attached and is to be shortened by 3 mm when disconnected and reused.

g)

Strips and special tools for termi-point connection shall be supplied by the Contractor.

7.10.00

Cable Joints

7.10.01

Cable shall be installed without joints as far as practicable.

7.10.02

If however jointing becomes necessary, it shall be made only by qualified cable jointer and strictly in accordance with manufacturer's recommendation.

7.11.00

Grounding

7.11.01

The Contractor shall carryout the interconnection among various peripheral earthing grids/mats, steel structures, lightning protection system as well as grounding of all electrical equipment, etc. The grounding work shall be carried out as per provisions of I.E. rules Indian standards and enclosed grounding and lightning protection notes and details.

7.11.02

The grounding shall be done by conductors of sizes as laid down in grounding drawings and the same shall be connected to the risers of main ground mat.

7.11.03

For fabricated cable trays, a separate ground conductor (50x6 mm Cu flat) shall run along the entire length of each route of cable tray being suitably clamped on the cable tray. Individual cable trays of each section shall be connected to above ground conductor through 50x6 mm Cu flat or copper jumper to maintain continuity of ground path.

7.11.04

All ground conductor connections shall be made by electric arc welding/brazing unless otherwise specified. Ground connections shall be made from nearest available station ground grid risers.

7.11.05

All ground conductors shall be painted green for easy identification.

7.11.06

Equipment ground connections, after being checked and tested by the Engineer, shall be coated with anti-corrosive paint.

7.11.07

Whether specifically shown or not, all conduits, trays, cable armour and cable end box, electrical equipment such as motors, switchboards, panels, cabinets, junction boxes, lockout switches, fittings, fixtures, etc. shall be effectively grounded.

7.11.08

If there is no provision to ground the L.T. transformer neutral at transformer end, to make an effectively earthed 415V system the neutral bus of all 415V distribution boards shall be connected to ground grid at two different and distinct points.

7.11.09

The underground mat will be made of 240 mm² stranded bare copper cable laid underground in length and breadth of the area at a depth shown in drawing but not less than 1 metre below grade level. All crossings and straight run shall 270

be cad welded for good electrical continuity. Ground conductors, when crossing underground trenches, directly laid underground pipe and equipment foundation, if any, shall be at least 300 mm below the bottom elevation of such trenches/pipes as shown in the relevant drawing. The Contractor will plan and organize works to lay the grounding mat in the same sequence in which the building and equipment foundation is being done. 7.11.10

Ground Electrode Ground electrodes will be 40mm (min) dia and 3 metre long M.S. rod. These are to be fabricated and driven into the ground by the side of mat conductor. All connections to the conductors shall be done by are wilding process.

7.11.11

Risers Risers are required for connecting the equipment and structures with the ground mat. These will be 1 No. 40 mm (min) dia M.S. rod. laid from ground mat to above ground level properly clamped or supported along the outer edge of the concrete foundation. Connection to the ground mat shall be done by arc welding and the other end is to be kept free at least 300 mm above grade level/concrete floor level unless otherwise shown.

7.11.12

Column Grounding All columns are required to be grounded by 1 no. 40mm(min) dia M.S. rod from ground mat. Laying, supporting along with foundation, connecting at ground mat are within the scope of this specification. At least 300 mm length of the above rods shall be left free above the grade level/concrete floor level for connection with columns.

7.12.00

Painting

7.12.01

The Contractor shall paint steel fabrications at site with two (2) coats of red oxide primer and two (2) coats of battleship grey (shade no. 632 of IS:5) synthetic enamel paint.

7.13.00

Galvanizing

7.13.01

The galvanizing shall be uniform, clean, smooth, continuous and free from acid spots. Should the galvanizing of the samples be found defective, the entire batch of steel has to be re-galvanized, at Contractor's cost. The amount of zinc deposit shall not be less than 610 grams per square meter of surface area and in addition, the thickness of the zinc deposit at any spot whatsoever shall not be less than 75 microns. The Owner reserves the right to measure the thickness of zinc deposit by Elko meter or any other instrument and reject any component which shows thickness of zinc at any location less than 75 microns.

7.14.00

Excavation and Back Filling

7.14.01

The Contractor shall perform all excavation and backfilling as required for buried cable and ground connections. 271

7.14.02

Excavation shall be performed up to the required depth. Such sheeting and shoring shall be done as may be necessary for protection of the work.

7.14.03

The Contractor shall make use of his own arrangements for pumping out any water that may be accumulated in the excavation.

7.14.04

All excavation shall be backfilled to the original level with good consolidation.

7.15.00

Steel Fabrication

7.15.01

All racks, trays, supports, hangers & brackets wherever necessary shall be fabricated by the Contractor.

7.15.02

Steel for fabrication shall be straightened and cleaned of rust and grease. All fabrication shall be free of sharp edge and burns so as not to cause any damage to personnel or cables.

7.16.00

Cleaning up of Work Site

7.16.01

The Contractor shall, from time to time, remove all rubbish resulting from execution of his work. No materials shall be stored or placed on passage or drive ways.

7.16.02

Upon completion of work, the Contractor shall remove all rubbish, tools, scaffoldings, temporary structures and surplus materials etc. to leave the premises clean and fit for use.

8.00.00

TESTS

8.01.00

Shop Tests

8.01.01

All equipment shall be completely assembled, wired, adjusted and routine tested as per relevant Indian Standards at manufacturer's works.

8.01.02

Tests on panels/junction boxes shall include: a)

Wiring continuity tests.

b)

High voltage and insulation tests.

c)

Operational tests.

8.02.00

Site Tests

8.02.01

Contractor shall thoroughly test and Meggar all cables, wires and equipment to prove the same are free from ground and short circuit.

8.02.02

If any ground or short circuit is found, the fault shall be rectified or the cable and/or equipment replaced.

272

8.02.03

All power cables after installation and prior to connections shall be subjected to High Potential tests. Also the insulation resistance values shall be measured both before and after Hipot test for comparison. The leakage current shall also be measured during the Hipot test at site.

Cable cores shall be tested for : a)

Physical damage

b) c)

Continuity Correctness of connections as per relevant wiring diagram

d)

Insulation resistance to earth

e)

Insulation resistance between conductors

f)

Proper earth connections of cable glands, cable boxes, cable armour, screens etc.

8.02.04

All equipment shall be demonstrated to operate in accordance with the requirements of this specification.

8.03.00

Test Certificates

8.03.01

Type test certificate on any equipment, if so desired by the Owner, shall be furnished. Otherwise the equipment shall have to be type tested, free of charge, to prove the design.

9.00.00

DRAWINGS, DATA & MANUALS

9.01.00

To be submitted with the Bid.

9.01.01

Make, type and catalogue number of different electrical items and accessories along with technical leaflets, data sheets etc.

9.01.02

Typical General arrangement drawings showing constructional features, fixing arrangement of pre-fabricated cable trays.

9.01.03

Bill of Materials for cable trays and accessories, conduits & accessories.

9.01.04

Layout of Grounding system and lightning protection system showing connection and other details along with backup design calculations and detailed write up.

9.01.05

Bill of materials for grounding and lightning protection system.

9.01.06

Drawing showing details of equipment grounding.

9.02.00

To be submitted after Award of Contract 273

9.02.01

Make, type and catalogue number of cable termination kits, joints and accessories.

9.02.02

Detail dimensional drawings showing constructional features, grounding, fixing arrangement etc.

9.02.03

Bill of Materials for Pre-fabricated cable tray and accessories, Conduits & accessories.

9.02.04

Dimensional G.A. drawings and data sheets for different equipment and items supplied under this specification.

9.02.05

Layout drawing of Grounding system and Lightning protection system showing connection details along with backup design calculation and detailed write up.

9.02.06

Bill of material for grounding system and lightning protection system.

9.02.07

Drawing showing details of equipment grounding system.

274

ANNEXURE-A NOTES AND DETAILS FOR CABLING SYSTEM 1.00.00

GENERAL

1.01.00

These notes and details shall be read and construed in conjunction with Specification and the drawings meant for cable tray details and supporting arrangements in Trench, Racks etc., enclosed elsewhere. In case of conflict between these notes and drawings, the latter shall prevail.

1.02.00

The Cabling System installation work shall conform to the requirements of the latest revisions of the following standards/codes a)

Indian Electricity Rules, 1956, with up to date amendment.

b)

I.S. Code of Practice.

2.00.00

CABLE ROUTING/LAYING

2.01.01

Cables shall generally be laid on ladder type cable trays either in trenches or overhead supported from building steel/structures except in some cases cables may have to be laid underground and for short runs in conduits for protection or crossing.

2.01.02

For underground crossing of railways, roads etc. hume pipes shall be used and shall be laid at a depth of minimum 1000 mm such that cables shall not be damaged.

2.01.03

Different voltage grade cables shall be laid in separate trays when trays are arranged in tiers. Power cables shall be on top trays and Control/Instrumentation cables on bottom trays, and it is recommended that trays for cables of different voltage levels be stacked in descending order with higher voltage level above.

2.01.04

Cables for redundant equipment/system shall be run in separate trays in separate route.

2.01.05

Cables from two different services viz. supply from station board and supply from unit board shall be fully segregated to prevent simultaneous damage due to fire in one of the services.

2.01.06

Low level signal cables and other special Instrumentation and Control cables shall run in separate trays. In general, a minimum of 1500 mm clearance shall be maintained between these cables and noise generating equipment (large motors, generators, transformers etc.).

2.01.07

The floor of the cable spreader rooms will have to be made water proof so that water does not percolate to lower levels in the event of fire fighting operations. Adequate arrangement for efficient drainage of water shall be provided. The cable raceways should also be suitably curved to avoid water entry through this place.

275

2.02.00

Cable Trays/Supports

2.02.01

Cable trays and covers shall be pre-fabricated type, constructed from minimum 14 SWG sheet steel for trays and 16 SWG for covers and hot-dip galvanized after fabrication.

2.02.02

Cable tray supports shall be cantilever type for each installation. All supports and hardware shall be hot-dip galvanized.

2.02.03

Standard cable tray width shall be 600 mm. However, trays with 450, and 300, 150 mm width may be used in some places considering the requirement and space restrictions. For instrumentation and control purpose, some perforated type cable trays of width 150 and/or 100mm may be used particularly in Boiler Platform area, and 600, 450, 300 mm perforated trays may be used depending on site requirement.

2.02.04

Cable trays shall be ladder type with 250 mm rung spacing, 100 mm depth and rung width not less than 50 mm.

2.02.05

All weld for cable tray supports shall have a minimum throat thickness of 6 mm.

2.02.06

Cable trays in areas subjected to excessive coal dust, or mechanical damage will have hot-dip galvanized sheet metal tray cover installed on front tray in vertical run and inverted `V' type on upper tray in horizontal run. Where covers are used on trays containing power cables, consideration should be given to ventilation requirements. In area where acid/alkali ingression is like to occur, cable trays of glass fibre reinforced plastic with fire retardant & corrosive resistance properties shall be used.

2.03.00

Conduits

2.03.01

Conduits shall be rigid steel coated type; minimum size of conduit shall be limited to 19mm.

2.03.02

Steel conduits shall be seamed by welding and flo-coat metal conduit/hot-dip galvanized. These shall be supplied in standard length of 5M with minimum wall thickness as specified in IS: 9537 Part-II. In Chemical Handling Area, Battery Room, WTP, etc. HDPE conduits shall be used for better resistance to corrosion

2.03.03

Conduit runs shall be supported at an interval of 750 mm for vertical run and 1000 mm for horizontal run.

2.03.04

Conduits shall be sized so that conduit fill (ratio of total cable area to conduit area) shall not exceed the following:

2.03.05

One Cable

:

53%

Two Cable

:

31%

Three Cables & Up

:

40%

Conduit runs shall be provided with necessary bends as required. 276

2.04.00

Installation

2.04.01

The Contractor shall install, terminate and connect up all cables and conduits with supporting arrangements as per drawings, cable schedules and interconnection chart/drawings.

2.04.02

The HV power cables of 11 KVKV shall be laid in trays or racks as follows: a)

In single layer only.

b)

3 core cables to be laid giving one diameter gap of the largest diameter adjacent cable.

c)

Single core cables to be laid in trefoil formation with spacing equal to diameter of the trefoils.

2.04.03

1100V grade power cables shall be laid in single layer in trays.

2.04.04

1100V grade multicore power cables above and including 95 sq. mm shall be laid in single layer giving one diameter gap of largest cable’ & single core cables shall be laid in trefoil formation with gap of 2D between trefoils.

2.04.05

Control and Instrumentation cables can be laid up to a maximum of three layers in each tray.

2.04.06

The trays shall be run with a vertical spacing of 300 mm for overhead cable trays as well as inside cable trenches. A minimum of 225 mm clearance shall be provided between the top of tray and beams, cold piping, 500 mm clearance for hot piping/object to facilitate installation of cables in tray.

2.04.07

Adequate pull boxes shall be provided in conduit run to facilitate cable pulling in long runs and also to ensure that there will be no more than 270 Deg. bends between pull points.

2.04.08

Cable tray/conduit system shall be installed to accommodate cable manufacturer's recommended maximum pulling tension and minimum bending radius.

2.04.09

All openings in the floor and wall for cable access shall be sealed after installation of the cable system with non-inflammable materials, as follows : i)

Fire stop/Penetration seal shall be installed in the cable spreaders and cable raceways.

ii)

Similarly in the trenches fire stop/penetration seals shall be provided at suitable interval to avoid spread of fire.

iii)

For all H.T., L.T., Relay and Control panels, Control desk, instrumentation panels, battery charger, D.C. Dist. boards and other miscellaneous panels, fire-stops should be provided below base plate.

277

2.04.10

All floor/wall openings for cable entry to the electrical equipment and accessories shall be sealed with non-inflammable materials, after completion of cable installation. Thickness of such materials shall be equal to the thickness of floor/wall unless specified otherwise.

2.04.11

The portion of galvanized steel, which, if required, undergoes any welding at site shall be coated with two (2) coats of cold galvanizing anti-corrosive paint after welding.

2.04.12

The cables shall be coated with fire protection coating as specified elsewhere.

2.05.00

Identification

2.05.01

The complete cabling system shall be properly identified. Methods for identification of cabling system shall be furnished to the successful tenderer and the Contractor shall strictly adhere to the said methods.

2.05.02

Each cable and conduit run shall be tagged with numbers that appear in the cable and conduit schedule.

2.05.03

Location of cables laid directly underground shall be clearly indicated with cable marker made of galvanized iron plate, projected above ground level.

2.05.04

Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure), on both sides of a wall or floor crossing, on each duct/conduit entry, at each bend and at every thirty (30) meters in cable tray/trench runs. Cable tags shall also be provided inside the switchgear, MCC, control & relay panels etc. wherever required for cable identification, such as where a number of cables enter together through a gland plate.

278

ANNEXURE-B GENERAL PRACTICE FOR APPLICATION / INSTALLATION SCHEME FOR FIRE STOP MORTAR SEAL & FIRE RETARDANT CABLE COATING COMPOUND. A) Fire Barriers using Fire Stop Mortar Seal shall be installed at following locations. The thickness of Fire Barrier shall be Minimum 225 mm to achieve 3 hr fire rating. Control Room / Cable Vaults and in plant area. 1) Panel bases in control room shall be sealed (wherever any other type of fire sealing system is not already installed and wherever it is structurally and maintenance wise feasible to install.) 2) All wall openings and floor openings in control room / cable vaults shall be sealed. 3) All cable entry openings from trenches or overhead cable trays racks shall be sealed. Trenches 1) Barriers shall be installed inside the trenches at every intersection or Tee joints and bends at every 2 meters from center line of cable rack inside the trench. 2)

Barriers shall be installed at every 15 meters in straight runs of trenches.

B) Fire Protective Coating shall be applied at following locations. The average thickness of the coating shall be 2 mm. Control Room / Cable Vaults and in plant area. 1) All vertical cables coming out below the panels shall be coated to a full length of vertical drop from bottom of panel plus 1.5 to 2.5 mtrs. Horizontal run after the bend. 2) All vertical cable runs anywhere in the area are to be coated full. 3) All horizontal cable runs to be coated for a length of 1.5 mtrs at an interval of every 2 to 3 mtrs. At bends / intersections and Tee joints, coating should be done 2 mtrs from center line of cable tray on each side. Trenches 1) All vertical cables coming down into the trenches from the equipment are to be coated full. 2) At the intersection / joints / bends in the trenches all cables to be coated 2 mtrs from center line of the cable tray rack. 3) All horizontal cable runs to be coated for a length of 3 mtrs in the center of every 15 mtrs i. e. at the center of two fire stop mortar seal barriers and in the same proportion if the distance is less than 15 mtrs and more than 6 mtrs. NOTE :

The above instructions are general and the application shall be carried out as per suitability to individual site condition to achieve maximum fire protection.

279

ANNEXURE-B TECHNICAL SPECIFICATION FOR FIRE STOP MORTAR SEAL Fire Seal shall be dry cement with other chemical ingredients capable of controlled swelling, non-shrinking, homogeneous and smoke/gas-tight fire seal for cable and pipe penetration. Composition

:

Colour

:

It shall consists of inorganic binders, filters and lightweight aggregates with special additives and agent Preferably – Grey colour

Bulk Density

:

Approx. 550 gm./litre (Minimum)

Toxicity

:

It shall be Non-toxic

Combustibility

:

It shall be Non-combustible

P(H) value

:

10.0 (at working consistency)

Storage temperature :

+ 5 deg.C to 50 deg.C in dry conditions.

Shelf life

:

Minimum Two years, in original unopened packing stored in a dry place.

Packaging

:

Shall be packed in Gunny bags containing not more than 50 Kg.Fire Seal Compound.

Density of cured : Material Compressive Strength : Yield :

Approx. 0.6 gm. per CC. Approx. 6-7 N per Sq.mm. 1 kg Dry Fire Seal shall yield approx. 1.5 litre mixture of wet mortar

Fire Resistance

:

Fire Seal shall provide 3 Hrs. Fire Resistance.

Expansion

:

Approx. 3% by volume at 20 Deg.C

Recommended Uses :

Recommended for both wall openings and floor cut-outs

Approval

:

The FIRE SEAL should have approval of the Institution like CBRI for its fire retardant properties

Experience

:

The application should have been done successfully preferably in Power Stations

280

ANNEXURE-B FIRE RETARDANT COATING COMPOUND Fire Retardant coating compound shall be a ready to mix and easily brushable one. Composition

:

Fire Retardant coating compound shall be water based, solvent free coating comprising of thermoplastic resins, certain flame retardant chemicals and other inorganic incombustible fibers, filters and pigments. Fire Retardant should not contain asbestos fibers.

Colour

:

Preferably – Off White colour

Density

:

1.25 to 1.35 gm per cc.

Solid contents

:

70 to75% by weight

PH value

:

6-8

Odour

:

It shall be odourless

Toxicity

:

It shall be Non-combustible one

Storage temp.

:

Max 50 Deg.C, must be protected from freezing

Shelf Life

:

Shall be 2 years, in original unopened packing & min. 18 months in unpacked condition, at room temperature.

Coating Thickness

:

Recommended Coating Thickness, min 2.0 mm

Packing

:

Shall be packed in Plastic drums containing not more than 50 Kg. Fire Retardant Compound

Thinning

:

Shall be only by water

Specific Gravity

:

1.5 to 1.6

Drying Time

:

8 hrs. touch dry.

Surface Gravity

:

Rough

Fire Resistance resistance

:

Fire Retardant Coating shall provide minimum 30 minutes fire

Approval

:

Experience

:

: The FIRE RETARDANT COATING COMPOUND should have approval of the Institution like CBRI for its fire retardant properties The application should have been done successfully preferably in Power Stations

281

ANNEXURE-B

FIRE RETARDANT COATING COMPOUND – SPECIAL FEATURES Water Resistance

:

A Fire Retardant coated cables shall not show any effect when dipped in water at 40 Deg.C for 10 days

Salt Water Resistance :

A Fire Retardant coated cable shall not show any effect when dipped in salt water for 16 days.

Acid Resistance

:

A Fire Retardant coated cable shall not show any effect on application of 2% Conc. Sulphuric Acid

Alkali Resistance

:

A Fire Retardant coated cable shall not show any effect on application of 10% soap solution for half an hour and 2% solution of Sodium Bicarbonate for an additional half an hour.

Current Carrying Capacity of Cables

:

On application of Fire Retardant coating, there shall be no effect on the current capacity of the cable.

Resistance to Heat

:

15 to 80 Deg.C Cycle

Flexibility

:

Fire Retardant Coated HRPVC Cable may be bent 20 Times radius without cracking or peeling off.

Hydrocarbon Solubility

:

Shall have no effect.

Mineral Oil Resistance:

Shall be highly Resistance to immersion in mineral oil For 48 hours at room temp. There shall be no physical and chemical changes observed.

Ant rodent

Dry film of Fire Retardant shall be ant rodent

:

Effect of Atmospheric : Conditions

Shall be Highly Resistant to moisture and humidity.

282

SPECIFICATION NO. : 11P01-SPC-E-291-53.02 SUB-SECTION - XIII CIVIL WORKS

283

SUB-SECTION - XIII CIVIL WORKS CONTENTS

CLAUSE NO.

DESCRIPTION

PAGE NO.

1.0

SCOPE OF WORK

1

2.0

SITE PREPARATION

2

3.0

ANTI-WEED TREATMENT & STONE SPREADING

4

4.0

TRANSFORMER FOUNDATION

5

5.0

CABLES & PIPE TRENCHES

7

6.0

FOUNDATION / R.C.C. CONSTRUCTION

7

7.0

CHAIN LINK FENCING, GATE

11

8.0

BUILDINGS / STRUCTURES - GENERAL REQUIREMENTS 13

9.0

STORM WATER DRAINAGE FOR SWITCHGEAR BUILDINGS 18

10.0

MISCELLANEOUS GENERAL REQUIREMENTS

18

11.0

INTERFACING

20

12.0

WATER SUPPLY

20

13.0

STATUTORY RULES

20

284

CIVIL WORKS 1.0

SCOPE OF WORK The specification covers the following:

1.1

Design, engineering, and construction of all civil works at 33KV existing Switchyard& 11 KV switchgear building and outdoor area cable trenches from 33KV MRSS to PM5 substation. All civil works shall also satisfy the general technical requirements specified in other Sections of this Specification and as detailed below.

1.2

They shall be designed to the required service condition / loads as specified elsewhere in this Specification or implied as per National and International Standards. All civil works shall be carried out as per applicable Indian Laws, Standards and Codes. All materials shall be of best quality conforming to relevant Indian Standards and Codes.

1.3

The Contractor shall furnish all design, drawings, labour, tools, equipment, materials, temporary works, constructional plant and machinery, fuel supply, transportation and all other incidental items not shown or specified but as may be required for complete performance of the Works in accordance with approved drawings, specifications and direction of Purchaser.

1.4

The work shall be carried out according to the design/drawings to be developed by the Contractor and approved by the purchaser based on Tender Drawings supplied to the Contractor by the Purchaser. For all buildings, structures, foundations etc. necessary layout and details shall be developed by the Contractor keeping in view the functional requirement of the substation facilities and providing enough space and access for operation, use and maintenance based on the input provided by the Purchaser. Certain minimum requirements are indicated in this specification for guidance purposes only. However, the Contractor shall quote according to the complete requirements covered under the scope of work.

1.5

The Contractor shall consider following major civil work in his scope :a) All civil Foundation for 33/11 KV & 11/0.415 KV transformers including common oil pit. b) All Civil work for cable trenches, drains, gravel filling fencing etc inside the 33KV switchyard. c) All civl work for 11KV NGRs d) Modification of existing 11 KV Switchgear building inside 33 KV switchyard. e) All civil work for cable trench from 33KV MRSS upto PM5 substation. f) All minor chipping, leveling, alignment, minor modification required to complete this package.

285

2.0

SITE PREPARATION

2.1

Scope The design and execution of the work for site preparation, such as clearing of the site, the supply and compaction of fill material, excavation and compaction of backfill for foundation, road construction, drainage, trenches and final topping by stone (broken hard stone).

2.2

General

2.2.1

The Purchaser shall make fairly leveled land available to the Contractor. The layout and levels of all structure etc shall be made by the Contractor at his own cost from the general grids of the plot and benchmarks set by the Contractor and approved by the Purchaser. the Contractor shall give all help in instruments, materials and personnel to the Purchaser for checking the detailed layout and shall be solely responsible for the correctness of the layout and levels.

2.2.2

The Contractor shall develop the site area to meet the requirement of the intended purpose. The site preparation shall conform to the requirements of relevant sections of this specification or as per stipulations of standard specifications.

2.2.3

If fill material is required, the fill material shall be suitable for the above requirement. The fill shall be such a material and the site so designed as to prevent the erosion by wind and water of material from its final compacted position or the in-situ position of undisturbed soil.

2.2.4

Material unsuitable for founding of foundations shall be removed and replaced by suitable fill material and to be approved by the Purchaser.

2.2.5

Backfill material around foundations or other works shall be suitable for the purpose for which it is used and compacted to the density described under Compaction. Excavated material not suitable or not required for backfill, shall be disposed off in area's as directed by purchaser upto a maximum lead of 2 km

2.3

Site Grading The land has been developed by separate agency and done by cutting and filling so that net difference between cutting & filling shall remain minimum. The filling at places varies from 1 to 2 meter. The top of tentative formation level are mentioned in the tender drawing as a guide line to the Contractor. The Contractor shall finally fix the top of grades to suit actual site condition matching all functional requirements and be approved by the Owner prior to execution.

2.4

Excavation and Backfill

2.4.1.

Excavation and backfill for foundations shall be in accordance with the relevant code. Whenever water table is met during the excavation, it shall be dewatered and water table shall be maintained below the bottom of the excavation level during excavation, concreting and backfilling.

2.4.2.

286

2.4.3.

When embankments are to be constructed on slopes of 15% or greater, benches or steps with horizontal and vertical faces shall be cut in the original slope prior to placement of embankment material. Vertical face shall measure not more than 1 m in height.

2.4.4.

Embankments adjacent to abutments, culverts, retaining walls and similar structures shall be constructed by compacting the material in successive uniform horizontal layers not exceeding 15 cm in thickness. (of loose material before compaction). Each layer shall be compacted as required by means of mechanical tampers approved by the Purchaser. Rocks larger than 10 cm in any direction shall not be placed in embankment adjacent to structures.

2.4.5.

Earth embankments of roadways and site areas adjacent to buildings shall be placed in successive uniform horizontal layers not exceeding 20 cm in thickness in loose stage measurement and compacted to the full width specified. The upper surface of the embankment shall be shaped so as to provide complete drainage of surface water at all times.

2.5

Compaction

2.5.1.

The density to which fill materials shall be compacted shall be as per, relevant IS and as per direction of Purchaser. All compacted sand filling shall be confined as far as practicable. Backfilled earth shall be compacted to minimum 95% of the Standard Proctor's density at OMC. The sub grade for the roads and embankment filling shall be compacted to minimum 95% of the Standard Proctor's density at OMC. Cohesion less material sub grade shall be compacted to 70% relative density (minimum).

2.5.2.

At all times unfinished construction shall have adequate drainage. Upon completion of the road's surface course. adjacent shoulders shall be given a final shaping, true alignment and grade.

2.5.3

Each layer of earth embankment when compacted shall be as close to optimum moisture content as practicable. Embankment material which does not contain sufficient moisture to obtain proper compaction shall be wetted. If the material contains any excess moisture, then it shall be allowed to dry before rolling. The rolling shall begin at the edges overlapping half the width of the roller each time and progress to the center of the road or towards the building as applicable. Rolling will also be required on rock fills. No compaction shall be carried out in rainy weather

2.6

Requirement for Fill Material Under Foundation The thickness of fill material under the foundations shall be such that the maximum pressure from the footing, transferred through the fill material and distributed onto the original undisturbed soil will not exceed the allowable soil bearing pressure of the original undisturbed soil. For expansive soils the fill materials and other protections etc. to be used under the foundation is to be got approved by the Purchaser.

287

3.0

ANTIWEED TREATMENT & STONE SPREADING

3.1

Scope The Contractor shall furnish all labour, equipment and materials required for complete performance of the work in accordance with the drawings specification and direction of the Purchaser. Stone spreading shall be done in the areas of the switchyard wherever equipments and or structures are to be provided under present scope of work.

3.2

General Requirement

3.2.1

The material required for site surfacing shall be free from all types of organic materials and shall be of standard quality, and as approved by the Purchaser.

3.2.2

The material to be used for stone filling/site surfacing shall be uncrushed/crushed/broken stone of 20 mm nominal size (ungraded single size) conforming to Table 2 of IS:383 - 1970. Hardness, Flakiness shall be as required for wearing courses are given below : ƒ

Sieve Analysis limits (Gradation) (IS: 383 - Table - 2) Sieve Size

% passing by weight

40mm

100

20mm

85 – 100

10mm

0 – 20

4.75 mm

0-5

'One Test' shall be conducted for every 500 cu.m. ƒ

Hardness Abrasion value (IS:2386 Part-IV) - not more than 40% Impact value (IS:2386 Part-IV) - not more than 30% and frequency shall be one test per 500 cum with a minimum of one test per source.

ƒ

3.2.3

Flakiness Index One test shall be conducted per 500 cum of aggregate as per TS:2386 Part I and maximum value is 25%

After all the structures/equipments are erected and anti-weed treatment is complete, the surface of the switchyard area shall be maintained, rolled/compacted to the lines and grades as decided by SPM/DCPL. Deweeding including removal of roots shall be done before compaction is commenced. Engineer-in-Charge shall decide final formation level so as to ensure that the site appears uniform devoid of undulations. 288

-...

3.2.4

A base layer of uncrushed/crushed/broken stone of 20 mm nominal size (ungraded single size) shall be spread, and rolled/compacted by using half ton roller with 4 to 5 passes and water sprinkling to form a minimum 50 mm layer on the finished ground level of the specified switchyard area excluding roads, drains, cable trench and tower and equipment foundations as indicated in the drawing.

3.2.5

Over the base layer of site surfacing material, a final surface course of minimum 50 mm thickness of 20 mm nominal size (single size ungraded) broken stone as specified above shall be spread and compacted by light roller using half tone steel roller (width 30" and 24" dia meter) with water sprinkling as directed by the Engineer-in-Charge. The water shall be sprinkled in such a way that bulking does not take place.

3.2.6

In areas that are considered by the Engineer-in-Charge to be too congested with foundations and structures for proper rolling of the site surfacing material by normal rolling equipments, the material shall be compacted by hand, if necessary. Due care shall be exercised so as not to damage any foundation structures or equipment during rolling compaction.

3.2.7

Before taking up stone filling, anti-weed treatment shall be applied in the switchyard area wherever gravel filling is to be done, and the area shall be thoroughly de-weeded including removal of roots. The recommendation of local agriculture or horticulture department shall be sought wherever feasible while choosing the type of chemical to be used. Nevertheless the effectiveness of the chemical shall be demonstrated by the contractor in a test area of 10M x 10M (approx.) and monitored over a period of two to three weeks by the Engineer-in-Charge. The final approval shall be given. by Engineer-in-Charge and final approval given based in the results.

3.2.8.

The anti-weed chemical shall be procured from reputed manufacturers. The dosage and application of chemical shall be strictly followed as per manufacturer's recommendation. The contractor shall execute the work in such a manner so that the area should remain free from weeds for a period of 1 year from the date of completion of work in all respects.

4.0

TRANSFORMER FOUNDATION The Contractor shall provide a RCC foundation with rails at top to enable installation and the replacement of any failed unit. The transformer/reactor track system shall be suitable to permit the movement of any failed unit fully assembled (including OLTC), and oil, without the de-energisation of any other equipment in the station. This system shall enable the removal of any failed unit from its foundation to the nearest road. If trench / drain crossings are required then suitable R.C.C. culverts shall be provided in accordance with I.R.C. Code / relevant IS. The rail shall be of commercial quality flat bottom. A pylon support system shall be provided, if required, for supporting the fire fighting system by the Contractor.

289

4.1

Description of Oil Recovery System

4.1.1

Pit below Transformer The oil recovery system shall be provided for transformer / reactor (containing insulating oil or any inflammable or polluting liquid) in order to avoid spread of fire by the oil, and for environmental protection. Each transformer/reactor including oil conservator tank and cooler banks etc. shall be placed in a self sufficient pit surrounded by retaining walls (Pit walls). The clear distance of the retaining wall from the transformer/reactor shall be 20% of the transformer/reactor height or 0.8 m whichever is more. The oil collection pit thus formed shall have a void volume equal to 1/3rd volume of total oil in the transformer/reactor. The MS grating placed at the formation level shall be covered with 100 mm thick layer of broken / crushed / noncrushed stone 40 mm nominal size which acts as an extinguisher for flaming oil. Each oil collection pit shall be drained towards a sump pit within the collection pit whose role is to drain water and oil due to leakage within the collection pit so that collection pit remains dry & clean. The pit shall be connected by 150 mm diameter GI pipe at 1:96 slope to common oil pit.

4.1.2

Common Oil Pit in Transformer Yard A common RCC oil pit shall be constructed for all the transformers/reactors for drain away of transformer pit. The effective volume of the oil pit shall be calculated based on the following •

Quantity of oil in the largest transformer

•

Quantity of water for sprinkler system based on 10.2 liter/min/sq meter of transformer surface area and 10 minutes operation of spray system

•

Rainwater collection 7% of total transformers

oil quantity of associated

The pit shall be provided with one permanently installed sump pump to remove regular rain water collection to nearest surface drain. The sump pump shall be started manually, however shall stop automatically if level falls to certain level. 4.2

Materials The retaining walls which make up the oil collection pit shall be made of fire resistant material such as reinforced cement concrete, fire brick etc. and shall be impervious to oil. The minimum height of the retaining walls shall be 1.5 cm above the finished level of the ground to avoid outside water pouring inside. The bottom of the pit shall have an uniform slope towards the sump pit

290

5.0

CABLE & PIPE TRENCHES

5.1.

The cable trenches and pre-cast removable RCC cover (with lifting arrangement) shall be constructed using RCC of M25 grade.

5.2.

The cable trench walls shall be designed for the following loads.: ƒ Dead load of 155 kg/m length of cable support + 75 Kg on one tier at the end. ƒ Triangular earth pressure + uniform surcharge pressure of 2T/m2.

5.3.

Cable trench covers shall be designed for self weight of top slab + UDL of 2000 Kg/m2 + concentrated load of 200 kg at center of span on each panel.

5.4.

Cable trench crossing the road/rails shall be designed for class AA. loading of IRC/relevant IS Code and should. be checked transformer/reactor loading.

5.5.

Trenches shall be drained. Necessary sumps be constructed and sump pumps if necessary shall be supplied. Cable trenches shall not be used as storm water drains

5.6.

The top of trenches shall be kept at least 100 mm above the finished ground level. The top of cable trench shall be such that the surface rain water do not enter the trench.

5.7.

All metal parts inside the trench shall be connected to the earthing system

5.8.

Cables from trench to equipments shall run in hard conduit pipes.

5.9.

Trench wall shall not foul with the foundation. Suitable clear gap shall be provided.

5.10.

The trench bed shall have a slope of 1/500 along the run & 1/250 perpendicular to the run.

5.11.

All the construction joints of cable trenches i.e. between base slab to base slab and the junction of vertical wall to base slab as well as from vertical wall to wall and all the expansion. joints shall be provided with approved quality PVC water stops of approx. 230 x 5 mm size for those sections where the ground water table is expected to rise above the junction of base slab and vertical wall of cable trenches.

5.12.

Cable trenches shall be blocked at the ends if required with brick masonry in cement sand mortar 1:6 and plaster with 12mm thick 1:6 cement and mortar

6.0

FOUNDATION / RCC CONSTRUCTION

6.1

General

6.1.1.

Work covered under this Clause of the Specification comprises the design and construction of foundations and other RCC constructions for switchyard structures, equipment supports, trenches. drains, jacking pad. pulling block. control cubicles, bus supports, Autotransformer/Reactors, marshaling kiosks, auxiliary equipments& systems buildings, tanks or for any other equipment. or 291

service and any other foundation required to complete the work. This clause is as well applicable to the other RCC constructions. 6.1.2.

Concrete shall conform to the requirements mentioned in IS: 456 and all the tests shall be conducted as per relevant Indian Standard Codes as mentioned in Standard field quality plan appended with the specification. A minimum grade of M25 concrete shall be used for all structural/load bearing members as per latest IS:456 (latest revision).

6.1.3.

If the site is sloppy, the foundation height will be adjusted to maintain the exact level of the top of structures to compensate such slopes.

6.1.4.

The switchyard foundation's plinths and building plinths shall be minimum 300mm and 500 mm above finished ground level respectively.

6.1.5.

Minimum 75mm thick lean concrete (1:4:8) shall be provided below all underground structures, foundations, trenches etc. to provide a base for construction.

6.1.6.

Concrete made with Portland slag cement shall be carefully cured and special importance shall be given during the placing of concrete and removal of shuttering.

6.1.7.

The design and detailing of foundations shall be done based on the approved soil data and sub-soil conditions as well as for all possible critical loads and the combinations thereof. The Spread footings foundation or pile foundation as may be required based on soil/sub-soil conditions and superimposed loads shall be provided.

6.1.8

If pile foundations are adopted, the same shall be cast-in-situ driven/bored or pre-cast or under-reamed type as per relevant parts of IS Code 2911. Only RCC piles shall be provided. Suitability of the adopted pile foundations shall be justified by way of full design calculations. Detailed design calculations shall be submitted by the bidder showing complete details of piles/pile groups proposed to be used. Necessary initial load test shall also be carried out by the bidder at their cost to establish the piles design capacity. Only after the design capacity of piles have been established, the Contractor shall take up the job of piling. Routine tests for the piles shall also be conducted. All the work (design & testing) shall be planned in such a way that these shall not cause any delay in project completion.

6.2

Design

6.2.1.

All foundation shall be of reinforced cement concrete. The design and construction of RCC structures shall be carried out as per IS :456 and minimum grade of concrete shall be .M-25.

6.2.2

Limit state method of design shall be adopted unless specified otherwise. in the specification..

6.2.3.

For detailing of reinforcement IS:2502 and SP:34 shall be followed. Cold twisted deformed bars conforming to IS:1786 shall be used as reinforcement. However, in specific areas mild steel (Grade I) conforming to IS:432 can also be used. Two layers of reinforcement (on inner and outer face) shall be provided for wall & slab sections having thickness of 150 mm and above. Clear cover to reinforcement towards the earth face shall be minimum 40 mm 292

6.2.4.

RCC water retaining structures like storage tanks, etc. shall be designed as uncracked section in accordance with IS:3370 (Part I to IV) by working stress method. However, water channels shall be designed as cracked section with limited steel stresses as per IS:3370 (Part I to IV) by working stress method.

6.2.5.

The procedure used for the design of the foundations shall be the most critical loading combination of the steel structure and or equipment and/or superstructure and other conditions which produces the maximum stresses in the foundation or the foundation component and as per the relevant IS Codes of foundation design. Detailed design calculations shall be submitted by the bidder showing complete details of piles/pile groups proposed to be used.

6.2.6.

Design shall consider any sub-soil water pressure that may be encountered following relevant standard strictly.

6.2.7.

Necessary protection to the foundation work. if required shall be provided to take care of any special requirements for aggressive alkaline soil. black cotton soil or any other type of soil which is detrimentallham1ful to the concrete foundations.

6.2.8.

RCC columns shall be provided with rigid connection at the base.

6.2.9.

All sub-structures shall be checked for sliding and overturning stability during both construction and operating conditions for various combinations of loads. Factors of safety for these cases shall be taken as mentioned in relevant IS Codes 01' as stipulated elsewhere in the Specifications, For checking against overturning. weight of soil vertically above footing shall be taken and inverted frustum of pyramid of earth on the foundation should not be considered.

6.2.10.

Earth pressure for all underground structures shall be calculated using coefficient of earth pressure at rest. co-efficient of active or passive earth pressure (whichever is applicable). However, for the design of substructures of any underground enclosures, earth pressure at rest shall be considered.

6.2.11.

In addition to earth pressure and ground water pressure etc., a surcharge load of 2T/Sq.m shall also be considered for the design of all underground structures including channels, sumps, tanks, trenches, and substructure of any underground hollow enclosure tec., for the vehicular traffic in the vicinity of the structure.

6.2.12.

Following conditions shall be considered for the design of water tank in pumps house, channels, sumps, trenches and other underground structures : a)

Full water pressure from inside and no earth pressure & ground water pressure & surcharge pressure from outside (application only to structures, which are liable to be filled up with water or any other liquid).

b)

Full earth pressure, surcharge pressure and ground water pressure from outside and no water pressure from inside.

c)

Design shall also be checked against buoyancy due to the ground water during construction and maintenance stages. Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring the superimposed loadings. 293

6.2.13.

Base slab of any underground enclosure shall also be designed for empty condition during construction and maintenance stages with maximum ground water table (GWT). Minimum factor of safety of 1.5 against buoyancy shall be ensured ignoring the super-imposed loadings.

6.2.14.

Base slab of any underground enclosure like water storage tank shall. also be designed for the condition of different combination of pump sumps being empty during maintenance stages with maximum GWT. Intermediate dividing piers of such enclosures shall be designed considering water in one pump sump only and the other pumps sump being empty for maintenance.

6.2.15.

The foundations shall be proportioned so that the estimated total and differential movements of the foundations are not greater than the movements that the structure or equipment is designed to accommodate.

6.2.16.

The foundations of transformer/reactor and circuit breaker shall be of block type foundation. Minimum reinforcement shall be governed by IS:2974 and IS:456.

6.2.17.

The tower and equipment foundations shall be checked for normal condition and also for short circuit condition against sliding, overturning and pullout..

6.3

Admixtures & Additives

6.3.1.

Only approved admixtures shall be used in the concrete for the Works. When more than one admixture is to be used, each admixture shall be batched in its own batch and added to the mixing water separately before discharging into the mixer. Admixtures shall be delivered in suitably labeled containers to enable identification.

6.3.2.

Admixtures in concrete shall conform to IS: 9103. The water proofing cement additives shall conform to IS: 2645. Concrete Admixtures/ Additives shall be approved by Purchaser.

6.3.3.

The contractor may propose and the Purchaser may improve the use of a water-reducing set-retarding admixture in some of the concrete. The use of such an admixture will not be approved to overcome problems associated with inadequate concrete plant capacity or improperly planned placing operations and shall only be approved as an aid to overcoming unusual circumstances and placing conditions.

6.3.4.

The water-reducing set-retarding admixture shall be an approved brand ofLigno-sulphonate type admixture.

6.3.5.

The waterproofing cement additives shall be used as required/advised by the Purchaser.

7.0

MISCELLANEOUS GENERAL REQUIREMENT

7.1

Dense concrete with controlled water cement ratio as per IS-code shall be used for all underground concrete structures such as pump-house, tanks, water retaining structures, cable and pipe trenches etc. for achieving watertightness. 294

7.2

All joints including construction and expansion joints for the water retaining structures shall be made water tight by using PVC ribbed water stops with central bulb. However, kicker type (externally placed) PVC water stops shall be used for the base slab and in other areas where it is required to facilitate concreting. The minimum thickness of PVC water stops shall be 5 mm and minimum width shall be 230 mm.

7.3

All steel sections and fabricated structures which are required to be transported on sea shall be provided with anti corrosive paint to take care of sea worthiness.

7.4

All mild steel parts used in the water retaining structures shall be hot-double dip galvanized. The minimum coating of the zinc shall be 750 gm/sq. m. for galvanized structures and shall comply with IS:2629 and IS:2633. Galvanizing shall be checked and tested in accordance with IS:2633. The galvanizing shall be followed by the application of an etching primer and dipping in black bitumen in accordance with BS:3416.

7.5

A screed concrete layer not less than 100 mm thick and of grade not weaker than M10 conforming to IS:456-1978 shall be provided below all water retaining structures. A sliding layer of bitumen paper or craft paper shall be provided over the screed layer to destroy the bond between the screed and the base slab concrete of the water retaining structures.

7.6

Bricks having minimum 75 kglcm2 compressive strength can only be used for masonry work. Contractor shall ascertain himself at site regarding the availability of bricks of minimum 75 i\:g/cm2 compressive strength before submitting his offer.

7.7

Doors and windows on external walls of the buildings (other than areas provided, with insulated metal claddings) shall be provided with RCC sunshade over the openings with 300 mm projection on either side of the openings. Projection of sunshade. from. the wall. shall be. minimum 450mm over window openings and 750 mm over door openings. ..

7.8

All stairs shall have maximum riser height of 150 mm and a minimum tread width of 300 mm. Minimum width of stairs shall be 1500 mm. Service ladder shall be provided for access to all roofs. RCC fire escape staircase shall be provided in control buildings.

7.9

Angles 50x50x6 mm (minimum) with lugs shall be provided for edge protection all round cut outs/openings in floor slab, edges of drains supporting grating covers, edges of RCC cable/pipe trenches supporting covers, edges of manholes supporting covers, supporting edges of manhole pre-cast cover and any other place where breakage of comers of concrete is expected.

7.10

Anti termite chemical treatment shall be given to column pits, wall trenches, foundations of buildings, filling below the floors etc. as per IS:6313 and other relevant Indian Standards.

7.11

Hand-railing minimum 900mm high shall be provided around all floor/roof openings, projections/balconies, walk ways, platforms, steel stairs etc. All handrails and ladder pipes shall be 32 mm nominal bore MS pipes (medium 295

class) and shall be galvanized (medium-class as per IS:277). All rungs for ladder shall also be galvanized as per IS:277 medium class. For RCC stairs, hand railing with 20 mm square MS bars, balustrades with suitable MS flats & aluminum handrails shall be provided. 7.12

The details given in tender drawings shall be considered along with details available in this section of the specification while deciding various components of the building.

7.13

Items/components of buildings not explicitly covered in the specification but required for completion of the project shall be deemed to De included in the scope.

8.0

INTERFACING The proper coordination & execution of all interfacing civil works activities like fixing of conduits in roofs/walls/floors, fixing of foundation bolts, fixing of lighting fixtures, fixing of supports/embedment, provision of cutouts etc. shall be the sole responsibility of the Contractor. He shall plan all such activities in advance and execute in such a manner that interfacing activities do not become bottlenecks and dismantling, breakage etc. is reduced to minimum.

9.0

WATER SUPPLY i)

Water shall be made available by purchaser at any feasible point near scope boundary at single point to the contractor. Contractor shall state the total water requirement both in terms of quantity and head to the Purchaser.

ii)

The Contractor shall carry out all the plumbing/erection works required for supply of water in control room building beyond the single point as at (i).

iii)

A scheme shall be prepared by the Contractor indicating the layout and details of water supply which shall be got approved by the Purchaser before actual start of' work including all other incidental items not shown or specified but as may be required for complete performance of the works.

iv)

Bore wells and pumps for water supply is not in the scope of contractor.

10.0

STATUTORY RULES

10.1

Contractor shall comply with all the applicable statutory rules pertaining to factories act (as applicable far the State). Fire Safety Rules of Tariff Advisery Committee. Water Act for pollution control etc.

10.2

Provisions for fire proof doors, no. of staircases, fire separation wall. plastering on structural members (in fire prone areas) etc. shall be made according to the recommendations of Tariff Advisory Committee.

10.3

Statutory clearance and norms of State Pollution Control Board shall be followed as per Water Act for effluent quality from plant.

296

~ 10.4

Foundation system adopted by Bidder shall ensure that relative settlement and other criteria shall be as per provision in IS: 1904 and other Indian Standards.

10.5

All water retaining structures designed as uncracked section shall also be tested for water tightness at full water level in accordance with clause no. 10 of IS :33 70 (Part-I).

10.6

Construction joints shall be as per IS: 456.

10.7

All underground concrete structures like basements, pumps houses, water retaining structures etc. shall have plasticizer cum water proofing cement additive conforming to 18:9103. In addition, limit on permeability as given in 18:2645 shall also be met with. The concrete surface of these structures in contact with earth shall also be provided with two coat of bituminous painting for water/damp proofing. In case of water leakage in the above structures, Injection Method shall be applied for repairing the leakage.

'

'

..

297

(Section VIII)

QUALITY CONTROL REQUIREMENTS 1.00.00

QUALITY ASSURANCE PROGRAMME

1.01.00

To ensure that the equipment and services under the scope of Contract whether manufactured or performed within the Contractor's works or at his Sub-contractor's premises or at the Purchaser's Site or at any other place or work are in accordance with the specifications, the Contractor shall adopt suitable quality assurance programme to control such activities at all points, as necessary. Such programmes shall be detailed by the Contractor and shall require acceptance and approval by the Purchaser/Authorized representative before the award of Contract. A quality assurance programme of the Contractor shall generally cover the following: a) His organization structure for the management and implementation of the proposed quality assurance programme. b) Qualification data for key personnel. c) Use of suitably qualified and experienced personnel in required number for each type of work. d) The procedure for quality assurance in design & engineering. e) The methods, procedures and programme for presenting, collating and assessing information from the various sources, and its incorporation in designed submissions. f) Documentation control system. g) The procedure for purchase of materials, parts, components and selection of Sub-contractor's services including vendor analysis, source inspection, incoming raw-material inspection, verification of materials purchased etc. h) The method of protection, storage, stock control and issue of materials at site. i) System for shop manufacturing and site erection control including process controls and fabrication and assembly controls. j) Inspection, sampling, testing, and acceptance procedures for plant and materials delivered to site. k) Control of non-conforming items and system for corrective actions. l) Inspection and test procedure both for manufacture and all site related works. m) Control of calibration and testing of measuring and testing equipment. n) System for quality audit and self-monitoring of QA Systems. o) System for indication and appraisal of inspection status.

1.02.00

p) q) r) s)

System for authorising release of manufactured products to the Purchaser. System for handling, storage and delivery to site. Final inspection and certification of completed sections of work. Site security procedures. 298

t)

1.03.00

1.04.00

1.05.00

The recording and processing of variations to the Works and their incorporation on record drawings. u) System for maintenance of records. v) Furnishing of quality plans for design & engineering, manufacturing and field activities detailing out the specific quality control procedure adopted for controlling the quality characteristics relevant to each item of work. The Quality Assurance arrangements shall include the preparation of and adherence to documented quality plans. After approval by the Engineer the Quality Assurance arrangements shall form an integral part of the Contract. No changes shall be made without the prior written approval of the Engineer. The Bidder shall list his proposed sub-contractors and shall provide the following information in respect of each sub-contractor: a) The items which the Bidder proposes to sub-contract. b) The basis on which the Bidder has assessed, or proposes to assess, the quality assurance arrangements of the sub-contractors. c) How sub-contractors' quality plans/procedures will be approved, monitored and audited on site during the Contract period. d) The results of any recent evaluations and audits of the sub-contractor which have been performed by the Bidder or other organizations external to the sub-contractor. The Bidder shall also state the level of detail of the Quality Plan proposed for each sub-contracted item. The information supplied in response to the above in the Bid shall be deemed a part of the Bidder's proposed Quality Assurance arrangements.

1.06.00

The Contractor shall provide documentation in such a manner that the Engineer is thereby enabled to satisfy himself as to the effectiveness with which the Contractor is implementing those provisions of the agreed and accepted Quality Assurance arrangements which relate to the monitoring by the Contractor to sub-tier Quality Assurance arrangements. Audits of sub-tier Quality Assurance arrangements shall be recorded in such a manner that the relevant documentation constitutes, inter alia, objective evidence of the extent of the audits and of the effectiveness with which they have been conducted. All such documentation relating to any one audit shall be made available to the Engineer, on request, as a single self-contained document or as one discrete self-contained package of documents.

1.07.00

General Requirements - Quality Assurance

1.07.01

All materials, components, equipment and systems covered under this specification shall be designed, procured, manufactured, erected, commissioned and tested at all the stages, as per a comprehensive Quality Assurance Programme. Inspections, and tests at works including shop performance tests and test at site for all equipment and systems shall be as per respective codes and standards and also as required in the specification.

299

1.07.02

1.07.03

1.08.00

1.08.01

1.08.02

1.09.00

1.10.00

1.11.00

Bidder shall furnish a detailed and exhaustive list of all inspections and tests that he or his sub-contractors shall carry out at works and at site for all equipment and systems covered under this specification. The list shall have to be approved by the Purchaser/Consultant before Award of Contract. The Quality Plan for design and engineering shall cover the procedure for independent verification, validation and assessment of designs in terms of fitness for purpose, constructability, safety, compliance with standards, maintenance requirements, cost effectiveness etc. The detailed Quality Plans for manufacturing and field activities( where applicable) shall be drawn up by the Bidder separately and shall be submitted to Purchaser for approval. Schedule of finalization of such Quality Plans shall be finalized before award of Contract. Manufacturing Quality Plan will detail out for all the components and equipment, various tests/inspections to be carried out as per the requirements of this specification and standards mentioned therein and quality practices and procedures followed by Contractor's Quality Control organization, the relevant reference documents and standards, acceptance norms, inspection documents raised etc., during all stages of materials procurement, manufacture, assembly and final testing/performance testing. Field Quality Plans will detail out for all the equipment, the quality practices and procedures etc. to be followed by the Contractor's site Quality Control organization, during various stages of site activities from receipt of materials/equipment at site. The Bidder shall also furnish copies of the reference documents/plant standards/acceptance norms/tests and inspection procedure etc., as referred in Quality Plans along with Quality Plans. These Quality Plans and reference documents/standards etc. shall be subject to Purchaser's approval without which manufacture shall not proceed. These approved documents shall form a part of the Contract. In these approved Quality Plans, Purchaser/Authorized representative shall identify Customer Hold Points (CHP). A Customer Hold Point signifies a stage in any item of work which requires documented proof of approval based on tests/checks which shall be carried out in presence of the Purchasers Engineer or his authorized representative and beyond which the work shall not proceed without consent of Purchaser/Authorized representative in writing. All deviations to this specification, approved quality plans and applicable standards must be documented and referred to Purchaser/Authorized representative for approval. The Contractor shall submit to the Engineer complete field welding schedule for all field welding activities for approval. The field welding schedule shall be submitted along with all supporting procedures like welding procedures, heat treatment procedures, NDT procedures etc. No material shall be dispatched from the manufacturer's works before the same is accepted subsequent to pre-dispatch final inspection including verification of records of all previous tests/inspections by Purchaser's Engineer/Authorized representative, and duly authorized for dispatch.

300

1.11.01

1.11.02

1.12.00

1.13.00

1.14.00

1.15.00

1.16.00

Quality assurance/Inspection group of Purchaser or its representative would issue a Material Dispatch Clearance Certificate (MDCC) after the inspection clearance which will enable the Contractor to dispatch the equipment and claim the payment. Further the Contractor will also be required to ensure at all stages of shipment that packing of all shipments dispatched are suitable for ocean freight to Mumbai, the port of entry, inland transportation and preservation at site up to erection. All materials used or supplied shall be accompanied by valid and approved materials certificates and tests and inspection report. These certificates and reports shall indicate the sheet numbers or other such acceptable identification numbers of the material. The material certified shall also have the identification details stamped on it. Castings and forgings used for construction shall be of tested quality. Details of results of chemical analysis, heat treatment record, mechanical property test results shall be furnished. All welding and brazing shall be carried out as per procedure drawn and qualified in accordance with requirements of ASME Section-IX/BS-4870 or other International equivalent standard acceptable to the Purchaser. All brazers, welders etc. employed on any part of the contract at Contractor's/Sub-Contractor's works or at site shall be qualified as per ASME Section-IX or BS-4871 or equivalent international standard approved by the Purchaser. Such qualification tests shall be conducted in presence of Purchaser/ Authorized representative. All non-destructive examinations (NDT) shall be carried out in accordance with approved international standard. The NDT operator shall be qualified as per SNT-TC-IA (of American Society of non- destructive examination). Results of NDT shall be properly recorded and submitted for approval. All the sub-vendors proposed by the Contractor for procurement of equipment, material and services and their quality assurance plans shall be subject to Purchaser's approval.

1.16.01

The list of all major sub-contractors would be submitted along with the Bid the list would be submitted within six (6) months of the award of the Contract .

1.16.02

Quality Plans of the successful vendors shall be discussed finalized and approved by the Purchaser/Authorized representative and form part of the Purchase Order between the Contractor and the Vendor. All the purchase specifications for the major bought-out items, list of which shall be drawn up by the Contractor and finalized with the Purchaser shall be furnished to the Purchaser for comments and subsequent approval before orders are placed. Purchaser reserves the right to carry out quality audit and quality surveillance of the systems and procedures of the Contractor's or their sub vendor's quality management and control activities. The Contractor shall provide all necessary assistance to enable the Purchaser carry out such audit and surveillance. Quality audit/approval of the results of tests and inspection shall not prejudice the right of the Purchaser to reject an equipment not giving the desired

1.17.00

1.18.00

301

1.19.00 1.20.00 1.21.00 1.21.01

1.22.00 1.22.01

1.22.02

performance after erection and shall not in any way limit the liabilities and responsibilities of the Contractor in earning satisfactory performance of equipment as per specification. Quality requirements for main equipment shall equally apply for spares and replacement items. Repair/rectification procedures to be adopted to make any job acceptable shall be subject to the approval of the Engineer. Quality Assurance Document The Contractor shall be required to submit two (2) copies and two (2) sets of electronic files of the following Quality Assurance documents within three (3) weeks after dispatch of the equipment: a) Material mill test reports on components as specified by the specification. b) The inspection plan with verification, inspection plan check points, verification sketches, if used and methods used to verify that the inspection and testing points in the inspection plan were performed satisfactorily. c) Non-destructive examination results/reports including radiography interpretation reports. d) Factory tests results for testing required as per applicable codes and standards referred in the specification. e) Welder identification list listing welder's and welding operator's qualification procedure and welding identification symbols. f) Sketches and drawings used for indicating the method of traceability of the radiographs to the location on the equipment. g) Stress relief time temperature charts. h) Inspection and test reports duly signed by QA personnel of the Purchaser and Contractor for the agreed customer hold points. During the course of inspection, the following will also be recorded: i) When some important repair work is involved to make the job acceptable. ii) The repair work remains part of the accepted product quality. iii) Letter of conformity certifying that the requirement is in compliance with finalized specification requirements. Inspection, Testing and Inspection Certificates The Engineer, his duly authorized representative and/or an outside inspection agency acting on behalf of the Purchaser shall have access at all reasonable times to inspect and examine the materials and workmanship of the works during its manufacture or erection and if part of the works is being manufactured or assembled on other premises or works, the Contractor shall obtain for the Engineer and for his duly authorized representative permission to inspect as if the works were manufactured or assembled on the Contractor's own premises or works. The Contractor shall give the Engineer/Inspector fifteen (15) days written notice of any material being ready for testing. Such tests shall be to the Contractor's account except for the expenses of the Inspector. The Engineer/Inspector, unless the witnessing of the tests is virtually waived, will attend such tests 302

1.22.03

1.22.04

1.22.05

1.22.06

1.23.00

1.24.00

within fifteen (15) days of the date on which the equipment is notified as being ready for test/inspection failing which the Contractor may proceed with test which shall be deemed to have been made in the Inspector's presence and he shall forthwith forward to the Inspector duly certified copies of test reports in six (6) copies. The Engineer or Inspector shall within fifteen (15) days from the date of Inspection as defined herein give notice in writing to the Contractor, or any objection to any drawings and all or any equipment and workmanship which is in his opinion are not in accordance with the Contract. The Contractor shall give due consideration to such objections and shall either make modifications that may be necessary to meet the said objections or shall confirm in writing to the Engineer/Inspector giving reasons therein, that no modifications are necessary to comply with the contract. When the factory tests have been completed at the Contractor's or sub-contractor's works, the Engineer/Inspector shall issue a certificate to this effect fifteen (15) days after completion of tests but if the tests are not witnessed by the Engineer/ Inspectors, the certificate shall be issued within fifteen (15) days of the receipt of the Contractor's test certificate by the Engineer/Inspector. Failure of the Engineer/Inspector to issue such a certificate shall not prevent the Contractor from proceeding with the works. The completion of these tests, or the issue of the certificates shall not bind the Purchaser to accept the equipment should it, on further tests after erection be found not to comply with the Contract. In all cases where the contract provides for tests whether at the premises or works of the Contractor or any sub-contractor, the Contractor, except where otherwise specified shall provide free of charge such items as labour, materials, electricity, fuel, water, stores, apparatus and instruments as may be reasonably demanded by the Engineer/Inspector or his authorized representatives to carry out effectively such tests on the equipment in accordance with the Contractor and shall give facilities to the Engineer/Inspector or to his authorized representative to accomplish testing. To facilitate advance planning of inspection in addition to giving inspection notice as per Clause 9.22.02, the Contractor shall furnish quarterly inspection programme indicating schedule dates of inspection at customer hold points and final inspection stages. Updated quarterly inspection plans will be made for each three consecutive months and shall be furnished before beginning of each calendar month. Archiving In addition to the requisite number of hard copies as specified, four (4) copies of all quality assurance documents, final inspection and test certificates etc. shall be made available to the Purchaser in Compact Disks before handing over of the plant. The testing and inspection shall be carried out as per IS:3177 with latest amendments and those should also meet the requirements of the factories act. Final load testing shall be carried out at the Purchaser’s premises by the Vendor. However, necessary tests loads and slips shall be supplied by the Purchaser. 303

(Section IX)

QUALIFICATION / ELIGIBILITY CRITERIA 1. Bidder firm should have manufactured, supplied, installed and commissioned at least one (1) No. similar electrical substations of rating 33/11 kV or above with minimum 10 MVA installed capacity during last five (5) years ending March 31st, 2011. 2. Bidder must have an annual capacity to manufacture and supply of at least one (1) No. similar installations as above. 3. The average annual turn-over of the Bidder firm during the last three (3) financial years, ending March 31st, 2011 should be at least Rs.3.8 Crores. 4. The Bidder firm should not have suffered any financial loss for more than one (1) financial year during the last three (3) financial years ending March 31st, 2011. 5. The net worth of the Bidder firm should not have eroded by more than 30% during the last three (3) financial years ending March 31st, 2011. 6. Either the Indian agent on behalf of the principal/OEM or principal/OEM itself can bid both cannot bid simultaneously for the same item/product in the same tender. 7. If an agent submits bid on behalf of the principal/OEM, the same agent shall not submit a bid on behalf of another principal/OEM for the same item/product. Note: 1. All experience, past performance and capacity/capability related data should be certified by the authorized signatory of the Bidder firm. The credentials regarding experience and past performance to the extent required as per the above eligibility criteria as would be submitted by the Bidder should be verified from the parties for whom work has been done. 2. All financial standing data should be certified by certified accountants’ e.g. Chartered Accountants (CA) in India and Certified Public Accountant/ Chartered Accountant of other countries. MOST IMPORTANT NOTE: BIDDER TO FURNISH STIPULATED DOCUMENTS IN SUPPORT OF FULFILLMENT OF QUALIFYING CRITERIA. NON-SUBMISSION OR INCOMPLETE SUBMISSION OF DOCUMENTS MAY LEAD TO REJECTION OF OFFER.

304

(Section X)

TENDER FORM Date………. To ………………………………. ………………………………. ………………………………. (Complete address of SPM) Ref: Your Tender document No. …………………………dated ………… We, the undersigned have examined the above mentioned tender enquiry document, including amendment No.--------, dated--------- (if any), the receipt of which is here by confirmed. We now offer to supply and deliver………. (description of goods and services) inconformity with your above referred document for the sum of (total tender amount in figures and words), as shown in the price schedule(s), attached herewith and made part of this tender. If our tender is accepted, we undertake to supply the goods and perform the services as mentioned above, in accordance with the delivery schedule specified in the List of Requirements. We further confirm that, if our tender is accepted, we shall provide you with a performance security of required amount in an acceptable form in terms of GCC clause 6, read with modification, if any, in Section V – “Special Conditions of Contract”, for due performance of the contract. We agree to keep our tender valid for acceptance for a period up to 165,as required in the GIT clause 19, read with modification, if any in Section-III – “Special Instructions to Tenderers” or for subsequently extended period, if any, agreed to by us. We also accordingly confirm to abide by this tender upto the aforesaid period and this tender may be accepted any time before the expiry of the aforesaid period. We further confirm that, until a formal contract is executed, this tender read with your written acceptance thereof within the aforesaid period shall constitute a binding contract between us. We further understand that you are not bound to accept the lowest or any tender you may receive against your above-referred tender enquiry ………………………………… Dated this …………… day of ……………………………….. For and on behalf of (With seal) Signature Name In the capacity of (DULY AUTHORISED TO SIGN THE BID)

305

(Section XI)

PRICE SCHEDULE Name of Bidder

:

Offer No. & Date

:

Plant/ Item

:

SPM’s Enquiry Ref. :…………………

PART –A S.No.

DESCRIPTION

UNIT

QTY

1

Material as per SUB SEC-II OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

2

Material as per SUB SEC-III OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

3

Material as per SUB SEC-IV OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

4

Material as per SUB SEC-V OF TECHINCAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

5

Material as per SUB SEC-VI OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

6

Material as per SUB SEC-VII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

7

Material as per SUB SEC-VIII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

8

Material as per SUB SEC-IX OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

9

Material as per SUB SEC-X OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

10

Material as per SUB SEC-XI OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

11

Material as per SUB SEC-XII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document

LOT

1

12 13 14

Packing & Forwarding charges Freight charges Taxes as applicable(if any) TOTAL PRICE of 1 to 14 (IN FIGURES) F.O.R. SPM-HOSHANGABAD TOTAL PRICE of 1 to 14 (IN WORDS) F.O.R. SPM-HOSHANGABAD

306

PRICE (In Rs)

PART –B S.No.

DESCRIPTION

UNIT

QTY

1

CIVIL WORK as per SUB SEC-XIII OF TECHNICAL SPECIFICATION SEC-VII of this Tender Document.

LOT

1

2

Taxes as applicable (if any)

UNIT

QTY

LOT

1

PRICE (IN RS)

TOTAL PRICE of 1 to 2 (IN FIGURES) F.O.R. SPM-HOSHANGABAD TOTAL PRICE of 1 to 2 (IN WORDS) F.O.R. SPM-HOSHANGABAD

PART –C S.No 1 2

DESCRPTION SERVICES (Installation & Commissioning) Complete Erection, Testing, Start Up, & Commissioning fulfilment of guaranteed performance obligation including training of Purchaser’s operation and maintenance staff. Taxes as applicable (if any)

PRICE (IN Rs.)

TOTAL PRICE of 1 to 2 (IN FIGURES) F.O.R. SPM-HOSHANGABAD TOTAL PRICE of 1 to 2 (IN WORDS) F.O.R. SPM-HOSHANGABAD

GRAND TOTAL PART(A+B+C) In Words in Rs. :GRAND TOTAL PART(A+B+C) In Figures in Rs.:Note:The method of evaluation of L1 criteria for awarding the Contract shall be on consolidated offer by the bidder and will be decided taking into consideration of total offered price including Part (A+B+C) as above.

Bidder’s Signature

307

__________________

(Section XII) QUESTIONAIRE The tenderer should furnish specific answers to all the questions/issues mentioned below .In case a question/ issue does not apply to a tenderer, the same should be answered with the remark “not applicable”. Wherever necessary and applicable, the tenderer shall enclose certified copy as documentary proof/ evidence to substantiate the corresponding statement. In case a tenderer furnishes a wrong or evasive answer against any of the under mentioned question/ issues, its tender will be liable to be ignored. 1. Brief description of Work and services offered: 2. Offer is valid for acceptance up to ……………………………………………. 3. Your permanent Income Tax A/C No. as allotted by the Income Tax Authority of Government of India : Please attach certified copy of your latest /current Income Tax clearance certificate issued by the above authority. 4. Status : a) Are you currently registered with the Directorate General of Supplies & Disposals (DGS&D), New Delhi, and/or the National Small Industries Corporation (NSIC), New Delhi, and/or the present SPMICL and/or the Directorate of Industries of the concerned State Government for the goods quoted? If so, indicate the date up to which you are registered and whether there is any monetary limit imposed on your registration. b) Are you currently registered under the Indian Companies Act, 1956 or and other similar Act? Please attach certified copy(s) of your registration status etc. in case your answer(s) to above queries is in affirmative. 5. Please indicate name & full address of your Banker(s) : 6. Please state whether business dealings with you currently stand suspended/ banned by any Ministry/ Dep’t. of Government of India or by any State Govt. ………………………. (Signature with date) ………………………. ………………………. (Full name, designation & address of the person duly authorized sign on behalf of the tenderer) For and on behalf of (Name, address and stampof the tendering firm)

308

(Section XIII)

BANK GUARANTEE FORM FOR EMD

Not applicable

309

(Section XIV)

MANUFACTURER’S AUTHORIZATION FORM To ………………………… ………………………… (Name and address of SPM) Dear Sirs, Ref. Your Tender document No. …………………………………………… dated ………………… We, ………………………………………………………………. Who are proven and reputable manufacturers of ……………………………………… (name and description of goods offered in the tender) having factories at ………………………………………. hereby authorize Messrs. …………………………………………(name and address of the agent) to submit a tender, process the same further and enter in to a contract with you against your requirement as contained in the above referred tender enquiry documents for the above goods manufactured by us. We further confirm that no supplier or firm or individual other than Messrs. ………………........(name and address of the above agent) is authorized to submit a tender, process the same further and enter into a contract with you against your requirement as contained in the above referred tender enquiry documents for the above goods manufactured by us. We also hereby extend our full warranty, as applicable as per clause of the General Conditions of Contract read with modification, if any, in the Special Conditions of Contract for the goods and services offered for supply by the above firm against this tender document. Yours faithfully, …………………………………. (Signature with date, name and designation) For and on behalf of Messrs. …………………………………………. (name and address of the manufacturers) Note : This letter of authorization should be on the letter head of the manufacturing firm and should be signed by a person competent and having the power of attorney to legally bind the manufacturer.

310

(Section XV)

BANK GUARANTEE FORM FOR PERFORMANCE SECURITY __________________[insert :Bank’s Name, and Address of Issuing Branch or Office] Beneficiary __________________________[insert: Name and Address of SPM] Date: _________ PERFORMANCE GUARANTEE No.:

___________________

WHEREAS………………………………………………………………….………………………. (name and address of the supplier) (hereinafter called “the supplier”) has undertaken, in pursuance of contract no…………………………. dated …………. to supply (description of goods and services) (herein after called “the contract”). AND WHERE AS it has been stipulated by you in the said contract that the supplier shall furnish you with a bank guarantee by a scheduled commercial bank recognized by you for the sum specified therein as security for compliance with its obligations in accordance with the contract; AND WHERE AS we have agreed to give the supplier such a bank guarantee; NOW THEREFORE we here by affirm that we are guarantors and responsible to you, on behalf of the supplier, upto a total of…………………… …………… ………………….(amount of the guarantee in words and figures),and we undertake to pay you, upon your first written demand declaring the supplier to be in default under the contract and without cavil or argument, any sum or sums within the limits of (amount of guarantee) as aforesaid, without you needing to prove or to show grounds or reasons for your demand or the sum specified therein. We here by waive the necessity of your demanding the said debt from the supplier before presenting us with the demand. We further agree that no change or addition to or other modification of the term soft he contract to be performed thereunder or of any of the contract documents which may be made between you and the supplier shall in anyway release us from any liability under this guarantee and we here by waive notice of any such change, addition or modification. We undertake to pay SPM up to the above amount upon receipt of its first written demand, without SPM having to substantiate its demand. This guarantee will remain in force for a period of forty five days after the currency of this contract and any demand in respect thereof should reach the Bank not later than the above date. ……………………………. (Signature of the authorized officer of the Bank) ………………………………………………………. …………………………………………………………. Name and designation of the officer …………………………………………………………. Seal, name & address of the Bank and address of the Branch …………………………………………………………. Name and designation of the officer …………………………………………………………. ….………………………………………………………. Seal, name & address of the Bank and address of the Branch

311

(Section XVI)

CONTRACT FORM (Address of SPM’s office issuing the contract) Contract No…………. dated……………. This is In continuation to this office’ Notification of Award No………….., dated …………. 1. Name & address of the Supplier: ………………………………………………………….. 2. SPM’s Tender document No…………………… dated…………. Amendment No.…………., dated……… (If any), issued by SPM

and

subsequent

3. Supplier’s Tender No………………………………dated………………..and subsequent communication(s) No…………dated …….. (If any), exchanged between the supplier and SPM in connection with this tender. 4. In addition of this Contract Form, the following documents etc, which are included in the documents mentioned under paragraphs 2 and 3 above, shall also be deemed to form and be read and construed as part of this contract: i) ii) iii) iv) v) vi) vii) viii) ix)

General Conditions of Contract; Special Conditions of Contract; List of Requirements; Technical Specifications; Quality Control Requirements; Tender Form furnished by the supplier; Price Schedule(s) furnished by the supplier in its tender; Manufacturers’ Authorization Form (if applicable for this tender); SPM’s Notification of Award

Note : The words and expressions used in this contract shall have the same meanings as are respectively assigned to them in the conditions of contract referred to above. Further, the definitions and abbreviations incorporated under Section–V-‘General Conditions of Contract ‘of SPM’s Tender document shall also apply to this contract. 5. Some terms, conditions, stipulations etc. out of the above-referred documents are reproduced below for ready reference: i) Brief particulars of the goods and services which shall be supplied/provided by the supplier are as under: Schedule No.

Brief description of goods/ services

Accounting unit

Quantity to be supplied

Unit Price (in Rs.)

Total price

Any other additional services (if applicable) and cost thereof: ……………………….. Total value (in figure)

___________(In words)

(ii)

Delivery schedule

(iii)

Details of Performance Security

(iv)

Quality Control 312

____________________________

(a) Mode(s), stage(s) and place(s) of conducting inspections and tests. (b)Designation and address of SPM’s inspecting officer (v)

Destination and dispatch instructions

(vi)

Consignee, including port consignee, if any

(vii)

Warranty clause

(viii)

Payment terms

(ix)

Paying authority

………………………………. (Signature, name and address of SPM’s authorized official) For and on behalf of…………………… Received and accepted this contract …………………………………………………………………… (Signature, name and address of the supplier’s executive duly authorized to sign on behalf of the supplier) For and on behalf of ………………….……………………… (Name and address of the supplier) ……………………. ………………………. (Seal of the supplier) Date: Place:

313

(Section XVII)

LETTER OFAUTHORITY FOR ATTENDING A BID OPENING (Refer to clause 24.2 of GIT) The General Manager Security Paper Mill Hoshangabad M.P – 461 005 Subject : Authorization for attending bid opening on ___(date) in the ___________________________________________ __________________.

Tender

of

Following persons are hereby authorized to attend the bid opening for the tender mentioned above on behalf of ___________________________ (Bidder)in order of preference given below. Order of Preference

Name

Specimen Signatures

I. II. Alternate Representative Signatures of bidder or Officer authorized to sign the bid Documents on behalf of the bidder.

Note: 1. Maximum of two representatives will be permitted to attend bid opening. In cases where it is restricted to one, first preference will be allowed. Alternate representative will be permitted when regular representatives are not able to attend. 2. Permission for entry to the hall where bids are opened may be refused in case authorization as prescribed above is not produced.

314

(Section XVIII)

SHIPPING ARRANGEMENTS FOR LINER CARGOES

Not applicable

315

(Section XIX)

PROFORMA OF BILLS FOR PAYMENTS (Refer Clause 22.6 of GCC) Name and Address of the Firm..................................................................................... Bill No............................................................... Dated................................................. Purchase order No…………….........................Dated................................................ Name and address of the consignee ........................................................................... Sl.No. Authority for purchase

Description of Stores

Number or quantity

Rate Rs. P.

Price per Rs. P.

Amount Rs. P.

Total 1. 2. 3. 4. 5. 6. 7. 8.

C.S.T./Sales Tax Amount Freight (If applicable) Excise Duty(if applicable) Packing and Forwarding charges (if applicable) Others (Please specify) PVC Amount (with calculation sheet enclosed) (-) deduction/Discount Net amount payable (Rupees in Words)

Dispatch detail: RR No. /other proof of dispatch..........................Dated.......................... (enclosed) Inspection Certificate No..................................... Dated........................... (enclosed) Modvat Certificate No ................................................................................. (enclosed) Excise DutyGatepass……......................................................................... (enclosed) Received`............................. (Rupees in Words)......................................................... I hereby certify that the payment being claimed is strictly in term so the contract and all the obligations on the part of the supplier or claiming that payment has been fulfilled as required under the contract.

316

(Section XX)

SL.NO.

DRAWING NO.

TITLE / DESCRIPTION

1.

11P01-DWG-E-100, Rev-e

Key Single line diagram

2.

11P01-DWG-M-111-050.01, Rev 2

Plot Plan

3.

11P01-DWG-E-111-050.01, Rev 0

33KV Switchyard Layout

4.

A- SPM PM5 BUILDING, Rev.0

Single Line Diagram

5.

1327-001377 Sht.1 of 2

Earthing Layout Basement Level PM5

6.

1327-001377 Sht.2 of 2

Earthing Layout Machine Level PM5

7.

1002-0000110350, Rev.1.0 (4 Sheets)

Typical Grounding Details for PM5 Building

8.

11P01-DWG-E-40-ND-400 (14 Sheets)

General Arrangement of cable tray, Trench & support details

9.

11P01-DWG-E-53-2341 (28 Sheets)

Grounding notes and details

10.

Part List TPE1/TPE2/TPE3 (3 Sheets)

List of Groundings

317

DATE:- 28.02.12

LEGEND

DRAWN :

CHECKED :

SCALE

REVIEWED :

DATE

APPROVED :

JOB NO.

1

2

4

3

5

6

7

8

Main Power supply M

H

H

xxx A

MVSG

M

M

M

customer xxx A

xxx A

G

xxx A

G

Field Installation customer

Transformer Box

2 MVA

customer

F

T2

T1

T3

2 MVA

2 MVA

Field Installation

F

customer

M

PCC customer

M

3000 A

M

3000 A

3000 A

only Voith consumers are shown

E

E

M

M

xx A

2500 A

M

1500 A

M

250 A

xx A

500 A

M

M

M

M

300 A

250A

XXXX A

1500 A

Customer utilities 16 kW needed for lightening sheeter & winder

D

D cable by Voith

Field Installation

cable by Voith

customer

M

C

MCC 2

M

M

MCC Stockprep/WEP Chemical plant

winder C1

1500 A

2500 A

MCC PM area

Voith

Sheeter C2

M

MCC 4 300 A

250 A

Power distribution for wire workshop

MCC 3

1500 A

MMD

~ DC_Bus

N F = E

~ = xx A

xx A

xx A

= I N U

I N U

~ 800 kvar

C

variable speed drives

~

~ F

F

F

~C

~C

~C

~

800 kvar

B

B Field Installation Voith

Motors Voith

48 A 48 A

48 A

48 A

M

M

48 A

M

48 A

48 A

M

M

48 A

M

M

48 A

48 A

48 A

M

M

M

48 A

M

48 A

48 A

M

M

M

A

A Voith Paper Automation

Single Line Diagramm

Summe RDC 146 kW Summe inst. Power 243 kW

Hoshangabad PM5 Drawing no.

VPAH-passas

Hoshangabad_SLD_rev00b.vsd 1

File: Single Line

2

3

4

5

6

7

rev 0 Scale

A1:1

8

REV.

0 Sheet

1/1

1

2

3

4

5

6

7

8

H

H M

2000 A

T1

T2

T3

40 MVA 1730 A

40 MVA 1730 A

40 MVA 1730 A

M

M

SS1

M

SS3

SS2 56

G

3 M

nn

56 3 3 3

3 M

17

56 3 3 3

3 M

3 3 3

G

+342AR01

18

T1 40 MVA 1730 A

1

F

F

M

2000 A

E

E

D

D

C

C

B

B

A

A Voith Paper Automation

Single Line Diagramm

my Project Drawing no.

VPAH-prvs

Hoshangabad_SLD_rev00b.vsd 1

File: Single Line

2

3

4

5

6

7

XXX Scale

A1:1

8

REV.

0 Sheet

1/1

1

2

3

4

5

6

7

8

H

H Transformer Box Outside Building

Cable Room

Inside Building

Outside Building

Machine Hall

Inside Building Cable Room

G

G

Door Transformer Box

1,00

Machine level

Transformer Box

F

1,07

E

Grounding Plate/ Earthing fixpoint

E-Room level

0,50

3,13

3,49

F

Grounding Plate/ Earthing fixpoint

Electrical Room

Cable Room 0,17

Basement level

Basement level

Sideview

Sideview

Sideview

E

Grounding Plate/ Earthing fixpoint

Machine level

D

D

Machine level

1,00

Wall

Electrical Room

C

C

Grounding Bar Grounding Plate/ Earthing fixpoint

Transformer level

Grounding Bar

Basement level

Grounding Bar

E-Room level

B

Cable Room

Grounding Plate/ Earthing fixpoint

0,17

B

0,50

Grounding Plate/ Earthing fixpoint

0,20

Machine level

Basement level

Frontview from inside building

View from outside building

Frontview

Voith Paper Automation Grounding Plates

A

TPE1

TPE2

TPE3

VPAH-passas 2011_08_12 Hoshangabad PM5 grounding Typicals.vsd

1

2

3

4

5

6

7

A

Hoshangabad PM5 M 1:100

2010-10-26

Drawing no.

REV.

1.0

1002-0000110350

2011.03.10 12:01

1/4

8

1

2

3

4

5

6

7

Section A

Sideview

H

8

H

5

to Grounding Bar in Cable Room

G

G column

wall

for example Dehn PartNo.: 472207

F

F

Grounding Plate/ Earthing fixpoint E

E

1a 10 16mm²

9 120mm²

7 Grounding Plate/ Earthing fixpoint 1a

200

D

1b

A

800

120mm²

Transformer

350

7 2-5MVA 1070

13

160

500

5 14

---------

9

to door and door frame

Transformer level

315-800kVA 670

10

C

D

for example Dehn PartNo.: 478019

9

---------

rail

C

rail

120mm² 16mm² 120mm²

Basement level

B

B

Voith Paper Automation

Typical transformer box_TPE1

A

VPAH-passas 2011_08_12 Hoshangabad PM5 grounding Typicals.vsd

1

2

3

4

5

6

7

A

Hoshangabad PM5 M 1:100

2010-10-26

Drawing no.

REV.

1.0

1002-0000110350

2011.03.10 12:01

2/4

8

1

2

3

4

5

6

7

8

Section A

H

Frontview

H

5

cabinets G

E-Room

for example Dehn PartNo.: 472237

column

F

column

G

F PE

E-Room level

max. 10m

Grounding Plate/ Earthing fixpoint

9 120mm² grounding bar to transformer boxes

E

E 1a

9

16mm²

10

grounding bar to transformer boxes 120mm²

D

1b

to other erthing devices 16mm²

for example Dehn PartNo.: 478019

800

D

16mm²

10

10

to pipes

to Ventilation duct 16mm²

16mm² 16mm²

10

C

14

Cable-Room / MV Switch Gear

7 13

14 550

-

C

A

5

250

170

350

120mm² 250

1a Grounding Plate/ Earthing fixpoint

Machine level B

B

Voith Paper Automation

Typical cable room_TPE2

A

VPAH-passas 2011_08_12 Hoshangabad PM5 grounding Typicals.vsd

1

2

3

4

5

6

7

A

Hoshangabad PM5 M 1:100

2010-10-26

Drawing no.

REV.

1.0

1002-0000110350

2011.03.10 12:01

3/4

8

1

2

3

4

H

5

6

7

8

Section A

Frontview

H

5

machine level

G

Terminal box (example)

column

G

F

for example Dehn PartNo.: 472237

F

PE

Grounding Plate/ Earthing fixpoint

11 16mm²

E

E Tank, Reservoir

11

Motors (only with Siemens FU)

16mm² steel construction

70mm²

1a

M 3~

10

16mm² 70mm²

Machine level

steal construction Motors

steel construction to pipes cabletray connection

1b

16mm²

15

7

11

1000

750

16mm²

14 15

D

for example Dehn PartNo.: 478019

16mm² 500

D

10

A

10mm² – 70mm² 10mm² – 70mm²

5

C 120mm²

C

9 1a

250

250

Grounding Plate/ Earthing fixpoint

B

B Tank, Reservoir

M 3~

Motors (only with Siemens FU)

Earthing conductor

Basement level

steal construction Motors

Voith Paper Automation

Typical machine hall_TPE3

A

VPAH-passas 2011_08_12 Hoshangabad PM5 grounding Typicals.vsd

1

2

3

4

5

6

7

A

Hoshangabad PM5 M 1:100

2010-10-26

Drawing no.

REV.

1.0

1002-0000110350

2011.03.10 12:01

4/4

8