3-Bid Document Volume-III-Substation Specifiations - 1

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Volume – III, Sub-Station Specifcations
GOVERNMENT OF ANDHRA PRADESH

WATER RESOURCES DEPARTMENT
(Volume – III)
SUB-STATION SPECIFICATIONS
NIT No. 1 SE /2020-21 Dt. 15 .07.2020
Name of work::Rayalaseema Lift scheme to draw and utilize 3 TMC per day
from Sangameswaram to SRMC at K.M 4.00 from
Pothireddipadu Head Regulator- Under EPC Turnkey
System.
SUPERINTENDING ENGINEER,
SRBC Circle 1 ,Nandyal
CONTRACTOR SUPERINTENDING ENGINEER

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SUB-STATION SPECIFICATIONS
INDEX
SECTION
ITEM
NO.
1 SS01 SURGE ARRESTERS
2 SS02 ISOLATORS CUM EARTHING SWITCHES
3 SS03 CIRCUIT BREAKERS
4 SS04 INSTRUMENT TRANSFORMERS
5 SS05 ACSR "MOOSE" CONDUCTOR
6 SS06 ANTI - FOG ZINC SLEEVE DISC INSULATORS
7 SS07 POWER TRANSFORMERS
8 SS08 BATTERY & BATTERY CHARGERS
9 SS09 CONTROL AND RELAY PANELS

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TECHNICAL SPECIFICATION OF
ELECTRO MECHANICAL AND CIVIL WORKS OF SUBSTATION
The works include:
A. CIVIL WORKS IN THE SWITCHYARD

Excavation for main Towers and equipment structure foundations, cable laying, earthing
etc.
i. RCC/CC foundations for structures and circuit breaker plinths etc.
ii. Back filling for foundations
iii. Leveling of sub-station site with gravel or excavated earth including clearing of
site.
iv. Construction of compound Fencing.
v. Construction of cable duct including cable ducts crossing.
vi. Formation of walkways.
vii. Spreading of HBG metal
The contractor shall execute the works to the extent required to complete the
work as a whole for substation.
B. ERECTION WORKS
i) Erection of main Towers and auxiliary structures including supply of raw steel,
fabrication and galvanization of structures and equipment including Marshalling
Boxes.
ii) Erection of all substation/bay equipment including Panels & Marshalling Boxes,
instrument and Power Transformers, circuit breakers, isolators, surge/lightning
arresters etc.
iii) Stringing of bus bars, jumpering, connections between equipment, buses, etc.
iv) Supply & stringing of ground wire
v) Earthening system including Design, supply and laying of Earth mat and C.I. pipes
and B.H. coke for earth pits
vi) Cable laying and terminations from equipment in switchyard to the marshalling
kiosk/boxe.
vii) supply, erection of light fixtures for Yard illumination including cabling upto the
lighting marshalling box in the switchyard(Marshalling box with MCB’s and
switches, cables, wires & conduits etc. required for lighting are in the scope of the
contractor)
Viii) Portable fire extinguishers
1.0." TYPE OF CONSTRUCTION
The switch yard structures shall be lattice type galvanized structures. The foundations of
400KV main structures are stub type and other structures are foundation bolt type. The
400KV bus and interconnecting of equipment is strung with Moose/ZEEBRA ACSR
conductor.

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2.0." DRAWINGS
The contractor shall furnish the Switchyard Layout, earth mat / earthing system
design and structures design drawings for approval.
3.0." CODES AND STANDARDS
All equipment materials fabrication galvanizing and tests shall conform to the latest
applicable standards, codes etc. mentioned here in or to equivalent applicable
international standards approved by the Superintending Engineer, NTR TGP Circle, Kadapa
or representatives nominated by Super intending Engineer, NTR TGP Circle, Kadapa.
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Sl. STANDARD TITLE
No.
1. IS 8112/1989 43 grade ordinary Portland cement

2. IS 1786/1985 High strength deformed steel bars and
wires for concrete reinforcement
3. IS 456/1978 Code of practice for plain and reinforced
Concrete.
4. IS 383/1970 Course and fine aggregates from natural
sources for concrete
5. IS 2062/1992 Steel for general structural purposes
6. IS 432(Part-1& /21982) Mild steel and medium tensile steel bars and
hard drawn steel wire for concrete reinforcement.
7. IS 12427/1988 Transmission Tower Bolts
8. IS 1367 (part II) Technical supply conditions for

threaded steel fasteners - Product grade and
tolerances
9. IS 1363 (part III) Hexagon Nuts(size range M5 to M64)
10. IS3063/1994 Fasteners - single coil rectangular
Section spring washers

11. IS2629/1985 Recommended practice for Hot dip
galvanizing on Iron & Steel
12. IS4759/1984 Hot dip Zinc coatings on structural

steel and allied products
13. IS7181/1986 Horizontally C.I double flanged pipes
for water, gas and sewage
valve fittings for compressed gas
14. IS5039/1983 Distribution pillars for voltages not
exceeding 1000 volts

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15. IS4072/1975 Steel for spring washers
16. IS1573/1986 Electroplated Coatings of Zinc on
Iron &Steel
17. IS5561/1970 Electric power connectors
18. IS486(Part-I)/1993 Metal fittings of Insulators for

Overhead power lines with normal
voltage greater than 1000V - General
requirements & Tests
19. IS2486(Part-2)/1986 Insulator fittings for overhead power

Lines with a nominal voltage greater
Than 1000V Dimensional
Requirements IS2486
Hardware fittings, clamps and
connectors
4.0." COMPLIANCE WITH REGULATIONS

Unless otherwise specified works shall be carried out in accordance with the Indian
Electricity Act. 1910, Indian Electricity Rules 1956 or any other revisions thereof which may
be issued during the currency of the contract and the requirements of any other
regulations and Acts in India to which the employer may be subjected to.
The contractor himself has to arrange for the permits required for the operation of the
vehicles used in construction works and such other permits not being arranged by the
employer/Engineer-In-Charge.
5.0." CLEARING-UP THE SITE :
During construction the contractor shall keep the work site and storage area used by him
free from accumulation of waste materials or rubbish and before completing the works the
contractor shall, at his own cost, remove or dispose off in a manner satisfactory to the
Engineer-In-Charge. All temporary structures, waste and debris shall be cleaned, all holes
in the ground shall be filled in and the land restored to its original state as far as practicable
and the entire premises should be in a neat and tidy condition of cleanliness as the
Engineer-In-Charge may direct. Any damage done to the permanent or temporary work of
the Department by the contractor shall be made good at contractor’s expenses.
6.0." SITE STORES:
The successful Contractor shall establish a temporary store at his cost at the sub-station
site for storing cement, equipment such as panels etc. This store should be dismantled and
site cleared after the work is completed by him.
7.0." SITE CONDITIONS:

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The Contractor is expected to familiarize with the site conditions and facilities available
before quoting. Regarding water supply and electric power supply arrangements, Clause of
technical specification is applicable.
8.0." LEVELLING:
Substation switch yard should be leveled as per directions of Engineer-In-Charge with the
surplus earth left over after back filling structure foundations. If surplus earth is not
adequate for leveling, the leveling should be done by excavating earth in any portion of
substation site whatever type of soil is met with and filling should be done with such earth
for leveling switchyard. If this is not sufficient, the switchyard is to be leveled by supplying
gravel from the approved borrowed areas. Clearing of the entire site by removing bushes,
hedges, unwanted plant growth and other things are in the scope of leveling work. The
work shall be carried out as per IS 301,302 and 138.
9.0." COMPACTION: Compaction shall be achieved by the use of smooth wheeled rollers,
pneumatic type rollers, sheep’s foot rollers, vibrating plates, frog rammers, power
rammers and such other equipment as shall be specified. Compaction shall be carried out
on each layer of thickness not more than 150mm. Density tests shall be made on each
compacted layer and the density attained shall not be less than 95% of maximum dry
density (standard proctor for the type of material used). A record of the density tests
conducted on each layer shall be recorded in a register maintained by field staff.
10.0." ANTI WEED TREATMENT AND ANTI TERMITE TREATMENT:-
Anti weed treatment and anti termite treatment for excavation in the site shall be done
as per Technical Specification.
11.0." EXCAVATION & FOUNDATIONS FOR STRUCTURES:
These shall be as per drawing for structure foundations and as per the Technical
specifications for excavation, CC/RCC, Back filling etc. The scope of work is detailed here
under.
12.0." FOUNDATIONS
12.1." FOUNDATION EXCAVATION:
Earth excavation has to be done in all types of soils which can be excavated with pick axe
& crow bars in all conditions such as dry, wet, slushy etc., and in hard rock requiring
blasting including shoring, shuttering and dewatering wherever necessary covering initial
lead and lift.
12.2." FOUNDATION CONCRETE:
Laying foundation for main and auxiliary structures, transformer plinths etc., including
dewatering the pits before and during the process of laying concrete in the proportion of
RCC 1:2:4 using 20mm HBG metal and CC 1:4:8 using 40mm HBG metal as per the
drawings for structural foundations enclosed to the specification and curing for 14 days
including cost of cement, reinforcement steel.
12.3." BACK FILLING:
Back filling of foundations with excavated soils including watering and consolidating in
150mm layers and consolidated upto 95% proctor density for normal soils. Providing sand
cushion for foundations and flooring area including cost of sand, watering and
consolidation upto standard specifications for BC soils.
12.4." PLASTERING:

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Plastering foundation plinths 12mm thick in (1:3) cement mortar and white washing (two
coats) with Janathacem cement paint. All projections of plinths and masonry above ground
level shall also be provided with Janathacem cement paint.
13.0." CABLE DUCT:
The cable duct in the switchyard shall be constructed as per approved drawing. It
comprises of 280 mm thick brick work in cement mortar (1:6) on either sides. The depth
and width of the duct shall be 500mm and 960mm respectively. Cables are to be buried in
sand in this duct over CC (1:4:8) with 40mm HBG metal bed of 50mm thick. The cable duct
shall be covered with a RCC slab of 50mm thick of proportion 1:2:4 with 10 to 12mm HBG
metal with 8mm tor steel placed at 100mm and150mm c/c in either directions. The cable
duct covering slab shall be in flush with the top of the brick work.
14.0." PROCUREMENT OF STEEL, FABRICATION, GALVANISATION AND SUPPLY OF STEEL
STRUCTURES:
Procurement of steel such as MS angles, plates, Channels and M.S Rounds required for
fabrication of structures is with in the scope of contract. The structures shall be fabricated
as per the structural drawings and galvanized. The Contractors are required to fabricate
proto type structure and submit shop drawings for all the structures, stub setting
templates. Mass fabrication of the structures shall be done after their approval.
Galvanised bolts, nuts, pack and spring washers required for the assembly of the
fabricated pieces to form into a composite structure of standard quality shall be supplied
by the contractor. The 'U' bolts for Bus stringing and foundation bolts for main and/or
auxiliary structures are also to be fabricated and galvanised by the contractor. The
Galvanised nuts required for these bolts are also to be procured and supplied by the
contractor.
15.0." ERECTION OF STRUCTURES :
The Structures shall be erected by piece-meal method on the foundations, after allowing
the required curing time for the foundations. The members shall not be strained or
bent during the course of erection. Care shall be taken to see that the jointing surfaces are
clean and free from dirt or grit and fit properly. The structures shall be erected strictly in
accordance with the approved drawings. After erection of structures the bolts shall be
checked to ascertain that all nuts are fully tight. The contractor shall ensure that none of
the bolts are left out. The structures must be truly vertical after erection and no straining
will be permitted to bring them to vertical position. The tolerance allowed for verticality
is 1 in 360 structure height.
16.0." STRINGING OF BUSBAR & GROUND WIRE :
The 400 kV busbar will be formed with Moose/Zebra ACSR conductor and shall be strung
to required tension as per site Engineer –In - Charge In Charge's direction and as per
switchyard layout drawing.
16.1." The stringing of bus conductors covers installation of tension insulator strings, suspension
insulator strings, post type insulator stacks and other accessories along with tensioning of
conductor and clamps. The jumpering to various equipment and the ground wire stringing
are also under the scope of this work. The G.I. Ground wire shall be strung as detailed in the
layout drawing.
16.2." The insulator strings shall be assembled on the ground. These shall be cleaned,
and examined before hoisting. All the parts including current carrying parts shall

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be clean without grease, paint and dirt. Insulators with cracks or chips or those
having glazing defects shall not be used.
16.3." The sag of bus conductor shall not be more than 1%. Damaged conductors shall
not be used. No joints are to be made. The conductor surface shall be clean and
smooth without any projections, sharp points, cuts or abrasions, etc., and the
conductor shall be continuous in span.
17.0." EARTHING SYSTEM:
17.1." The M.S.Flat of sizes 100x16mm and 75x8mm confirming to IS 2062 shall be
procured by the successful Contractor. The earth mat shall be as per the
approved drawing and extend over the entire switchyard. The earth mat shall be
formed with the MS flats buried in the ground at a depth of 500 mm on edge. G.I.
wire shall be used to connect the overhead ground wires to the ground mat, along
the structures at all the locations.
17.2." All the junctions of the steel flats while forming the earth mat and taking GI risers
from the earth mat for giving earth connections to equipment, steel
structures, conduits cable sheaths shall be properly welded. All joints shall be
provided with suitable angle pieces for proper contact between Two flats.
17.3." Provisions shall be made for thermal expansion of the steel flats by giving
smooth circular bends, as per the sketch shown in the earth mat layout. Bending
shall not cause any fatigue in the material of bends.
17.4." The earth mat shall be formed by welding 75 x 8 mm steel flat to the 100 x 16 mm
peripheral earth conductor. The grounding grid shall be spaced about 5 meters, in
longitude and about 5 meters in the transverse directions and the contractor shall
be guided by the same and the advice of the Engineer-In-Charge. After
completion of earth mat, the earth resistivity may be measured. In case the earth
resistance is more than one ohm, earth mat may be extended with additional 100
X 16 mm earth flats to the Tail race channel earth mat of the Power house so that
the earth resistance is less than one Ohm.
17.5." All fence corner posts and gate posts shall be connected to the ground by
providing 32 mm dia M.S. Rods of 3 meter length near the posts and connected
to the main grounding mat.
17.6." All paint, enamel and scale shall be removed from surface of contact in metal
surface before making ground connection.
17.7." Earth flat is to be aligned along the main structure supporting structure for the
equipment. The GI risers of 50 X 8 mm taken along the main switchyard
structures and equipment structures (upto their top) shall be clamped to the
structures at an interval of not more than one metre. The risers over the ground
level shall be galvanized of size 50 X 8 mm .other items of steel coming over the
ground and exposed to atmosphere shall also be galvanised. Welded joints shall
be painted with zinc rich epoxy paint the cost towards this shall be included in the
respective main items.
17.8." 75 x 8 mm (flat) ground conductor shall be run in cable routes and shall be
connected to the ground mat at an interval of 10 metres.
17.9." Grounding electrodes of 32mm dia 3mtr. Long M.S. rods shall be provided at
the peripheral corners of the earth mat. The grounding rods shall be driven into

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the ground and their tops shall be welded to a clamp and the clamp together
with the grounding rods shall be welded to the ground mat.
17.10." Lightning arrestors shall be provided with earth pits near them for earthing (as
per the standard practice). Cast iron pipes 125mm in dia, 2.75 metres long and
9.5 mm thick weighing 94.84 kg and confirming to IS:7181/1974 shall be buried
vertically in the pits and finely broken coke/ Bentonite compound , shall be
filled atleast 150 mm around the pipe for the entire depth. Where it is not
possible to go to a depth of 2.75 metres,1.3 x 1.3 M M.S plates, 25mm thick
shall be buried vertically in pit of 2 metres depth and surrounded by finely broken
coke atleast 2 metres away from any building or structure foundation. The plates
shall be atleast 15 metres apart. These earth pits in turn shall be connected to the
earth mat. Earth pits are to be provided with RCC collars of 1 mt diameter, 50
mm thick and 600 mm height and these should be fixed inside the earth pit.
17.11." The joints and tap offs when welding is done shall be given a coat of Bitumen
paints and then covered with hessain tape to avoid rusting.
17.12." Drawing for earth mat shall be furnished by the Contractor for approval.
18.0." LAYING OF CABLES:
18.1." This section covers laying of cables, in cable trenches, cable ducts in switch yard
between the Equipment and Marshalling Boxes. cable termination at both ends
and testing of the complete cable installation.
18.2." The control cables will be copper wires of 1.5, 2.5 , 4 sq.mm with number of
cores being 2,4,7,10 or 14.
18.3." The cable schedules shall be provided by the contractor. The cable laying shall be
done strictly in accordance with these schedules.
18.4." All the electric equipment is to be set in place and aligned. Contractor shall
provide power and auxiliary connection to the equipment and shall work in
cooperation with suppliers representative in obtaining correct direction of
rotation and commissioning of the equipment. Cable laying shall also include
termination of cables i.e. at both ends of cable of equipment switchgear, control
and protection panels, etc., as well as equipment to marshalling boxes and
marshalling boxes to switcher panels.
18.5." Secondary terminals of CTs/CVTs/PTs shall be connected to marshalling boxes
through cables and then further connected up by cables panels or other
equipment within switchyard.
18.6." All cables termination shall be done with suitable Ring type copper lugs and these
cable lugs shall be provided by the contractor. Dressing/bunching of all individual
cores of the cables shall be done in a neat fashion. The contractor shall drill holes
suitable for the cables in cable gland plates of equipment and Marshalling
Boxes. Cable glands as required shall be provided by the contractor
18.7." Cable lugs shall be compressed on the conductor ends by means of tools.
Insulating sleeves shall be furnished and covered over the bare ends of the
connections so as to prevent accidental contact with the ground or with the
adjacent terminals.
18.8." The insulating sleeve shall be fire resistant, and long enough to over pass the
conductor insulation and shall be of correct size of the conductor used.

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18.9." Spare glands shall be sealed for control panels and marshalling boxes.
18.10." Sharp bending and kinking of cables shall be avoided.
18.11." At cable terminal points where the conductor and cable insulation will be
terminated, termination shall be made in a neat, workman like and approved
manner by men specialized in this class of work.
18.12." Before any cable terminal connections are made, conductor's insulation shall be
pulled out, at the end and identifying ferrules shall be fixed according to the
wiring diagrams. Connection shall be made according to the wiring diagram to be
supplied by the purchaser.
18.13." Polarity, or phasing shall be checked before connections are made and
corrections of polarity, phasing or rotation shall be made by the contractor
without additional cost.
19.0." LIGHTING SYSTEM
The equipment such as lighting distribution boards, lighting panels for normal
and emergency lighting, lighting fixtures, luminaries, lamps, wiring between
Junction Boxes and Light fixtures, accessories, junction boxes ,conduits, conduit
accessories, fittings etc. and materials as would be found necessary for
illuminating the switchyard with S.V lamps, Bulkhead fittings shall be supplied by
the Contractor as per the specification here under.
19.1." The high pressure sodium Vapour lamps with fittings conforming to relevant IS
where applicable with latest revisions of reputed make of 250 Watts capacity or
equivalent for yard lighting of EHT sub stations are to be offered. The luminary
shall have deep drawn anodized single piece aluminum body with circular/oval
lamp compartment with suitable control gear consisting of low loss heavy duty
electronic ballast like OPAL make, power factor improved capacitor, external
electronic igniter and also provided with detachable parabolic reflectors. The
certificates conforming to relevant IS should be submitted and approval obtained
before dispatch of the light fittings. These fittings shall be provided for A.C lighting
as per lighting arrangement specified in the drawing. The locations of the light
fittings in the switchyard will be indicated by the Engineer-In-Charge.
19.2." Emergency lighting: 10 no.s 100W capacity DC lighting fixtures suitable for EHT
out door substation shall be provided ( They shall meet the relevant IS standard ).
These fittings shall be provided for D.C emergency lighting as per lighting
arrangement specified in the drawing. The locations of the light fittings in the
switchyard will be indicated by the Engineer-In-Charge.
19.3." Cables required for extending supply to the fixtures from Lighting marshalling box
along with other materials and labour has to be arranged by the contractor.
19.4." The lighting system shall consist of normal AC lighting from 3 phase 415 volts
supply.
19.5." The lighting marshalling box shall be erected in the switchyard by the Contractor.
The box shall be grouted in C.C. 1:4:8 with 40 mm HBG metal with foundation
bolts. Foundation bolts required for the work shall be provided by the
contractor himself.
19.6." SUPPORTS FOR FIXTURES:

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i. The lights shall be mounted on structures with necessary cantilever arrangement to

be arranged by the contractor. All the accessories G.I. Pipes, clamps, etc., required for
mounting the fixtures shall be supplied for lighting on the switch yard structures by
the contractor.
ii. The steel mounting arrangements shall be galvanised. The mounting arrangement shall
be earthed at two locations with 8 SWG GI Wire to be supplied by the contractor.
Mounting arrangement of fixtures is to be procured by the contractor.
iii. All lighting fixtures shall be mounted in accordance with the standard installation
practice.
iv. All lighting fixtures shall be assembled, installed and wired. Splices in lighting circuits
shall be avoided. Required size of fuses shall be provided for each light junction boxes.
Contractor after completing the connections to all outlets shall try out all portions of
the lighting system to ensure satisfactory operation.
19.7." Drawing for Lighting system shall be furnished by the Contractor for approval.
19.8 ERECTION OF EQUIPMENT:
The contractor has to make his own arrangements for transport of the materials/
equipment as given in the bill of quantities and its Annexure to switchyard/ substation site.
He is fully responsible to take delivery of materials/equipment loading, transporting to the
works and Unloading at site and erect the same as per the directions of the Engineer-In-
Charge. However, the contractor shall provide insurance to cover risks during transit from
employers stores, storage and erection at site for all equipment like CBs, CTs, PTs, CVTs,
LAs ,insulators etc. In case of materials/ equipment not covered by insurance, the
contractor shall be very careful in handling them. However, the contractor shall take
utmost care in handling the equipment during transport, storage and erection. Crane
required for the erection of equipment shall be arranged by the contractor and any
expenditure incurred towards the same shall be borne by the contractor himself.
On completion of the works, all materials left surplus from those supplied by the
employer for erection shall be handed over to the Engineer-In-Charge at Switchyard site.
Empty drums of conductor, cables shall be returned to the Engineer-In-Charge. The
contractor shall provide and make all necessary arrangements for the safety of his
staff and labourers, at the site of works. The Employer will not in any way be responsible
for any accident, minor or fatal to any person at the site of works or for any damages
arising there from during erection and this shall be the contractor's responsibility. The
staff insurance charges, if any, shall be borne by the contractor.
All tools and plant, consumables and any instruments required for erection of the
equipment shall be arranged by the contractor himself. Special tools if any as suggested
and supplied by the Equipment manufacturer will be arranged by the supplier for
commissioning.
The scope of work shall include taking delivery of equipment from the Power house
Stores, handling transport to substation site and erection. The contractor shall move all
the equipment covered under this section to the proper location, unload and shall
accurately level, align and anchor the equipment. The contractor will be responsible for
the safety of equipment from the time of his taking over the equipment for erection until
the Board takes over.

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20.0." The scope of work shall also include:

20.1." Painting/Writing names and other details on equipment, Marshalling boxes,
Marshalling kiosks etc., with the superior quality white /blue/ black enamel paint
including cost of brushes, labour charges etc., complete as per the directions of
Engineer-In-Charge.
20.2." Painting/Marking of RYB Colour on structures, equipment, isolators, LA’s etc with superior
quality enamel paint including cost of paint, brushes, labour charges etc., complete as per
the directions of Engineer-In-Charge.
The manufacturer's installation drawings / instructions and recommendations will
be furnished to the successful Contractor. The instructions shall be correctly followed in
handling, setting, test, commissioning and maintenance of all the equipment. In case of
doubt as to the correct interpretation of the manufacturer's drawings or instructions,
necessary clarifications shall be obtained from the Engineer-In-Charge in-charge of the
work. The contractor shall be responsible for the proper erection of the equipment and
he will be held responsible for any damage consequent to incorrect handling.
21.0." SPREADING OF HBG METAL:
The work involves spreading of 40 mm HBG metal for 100 mm depth in switch yard. Kerb wall shall
be provided in the switchyard to retain the metal all along the periphery of the metal spreading
wherever it is required. The Kerb wall shall be plastered in CM (1:3) and painted with 2 coats of
Janata Cem. Before spreading the HBG metal, care shall be taken to remove all the vegetation and
roots of the plant. The trimming of the earth surface for perfect level ground should be carried out
and the surface should be watered and rammed for consolidation with suitable means and the earth
surface should be given chemical treatment for anti-vegetation growth.
Required metal quantity may be stacked at suitable area for easy handling for pre- measurement.
Higher size metal may be separated and removed from the stacks. The crushed metal shall be free
from dust. HBG metal shall be brought from the approved Quarry as directed by Engineer-In-
Charge-in-charge and samples of the HBG metal to be used may be shown to the Engineer-In-
Charge in-charge and prior approval of the Engineer-In-Charge shall be taken before use. Spreading
should be carried out by dumping the metal at lower heights.
22.0." ENVIRONMENTAL PROTECTION
The contractor shall ensure the following for Environmental Protection.
22.1." All installations are made in accordance with the Electricity Supply Act, 1948 and IE rules
1956 which will be inspected by the Engineer-In-Chargeand clearance given.
22.2." The contractor shall carryout the ground clearing operation by manual or mechanical
methods. No chemical methods that lead to chemical contamination of the site shall be
used.
22.3." The contractor shall provide sufficient drainage arrangements to prevent flooding and
erosion of slopes etc., in the site or tower areas.
22.4." The contractor shall be fully acquainted with the environmental mitigation measures and
shall implement as per the directions of the Engineer-In-Charge-in-charge of the project.
22.5." The contractor shall take necessary precautions while stringing so as to prevent accidents.
22.6." The contractor shall also ensure during the construction.
i. Monitoring of quality of the foundations for the tower pads and transformers in
substations.
ii. that all safety norms during construction are followed to prevent avoidable accidents
during construction.
iii. Handling and placing of the equipment to avoid damage of the equipment and accidents.

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iv. Monitoring whether standard rules are being followed while pulling and tightening the
conductors.
v. All necessary protection barricades are to be provided to ensure safety and prevention of
spreading of cement dust etc.
Contractor ensures that necessary mitigation measures are implemented
23.0." TECHNICAL SPECIFICATION FOR MARSHALLING BOXES FOR Bay equipment And Lighting
23.1." Bay Marshalling Boxes The box should be made of 3 mm thick Galvanized M.S.
Sheet of size 750x400x150 mm with hinged type door, vermin proof and weather proof.
Rubber beading has to be provided around the door. Necessary brackets on the back
side of the box should be provided for mounting on the structures. Doors of the box
should be provided with panel type look. The top portion of the box shall be slanting so
that rain water will fall away easily. Two rows having 200 Nos. terminals.50 nos
terminals shall be of CATDM4 disconnecting type of ELMEX or eqvlt make and 150 nos
terminals shall be of CATM4 suitable for ring type lugs termination. 2 no.s TTB’s shall be
provided in each Marshalling Box and shall have facility for easy earthing, shorting,
isolating and testing. 2 Sets of Earthing stud of 1/2" dia with suitable nuts, flat and
spring washers are to be provided as shown in drawing.
23.2." Marshalling boxes for Bus PT bay : The box should be made of 3 mm thick Galvanized
M.S. Sheet of size 750x400x150 mm with hinged type door, vermin proof and weather
proof. Rubber beading has to be provided around the door. Necessary brackets on the
back side of the box should be provided for mounting on the structures. Doors of the
box should be provided with panel type look. The top portion of the box shall be
slanting so that rain water will fall away easily. Two rows having 100 Nos. terminals.50
nos terminals shall be of CATDM4 disconnecting type of ELMEX or eqvlt make and 50
nos terminals shall be of CATM4 suitable for ring type lugs termination. 2 no.s TTB’s
shall be provided in the Marshalling Box and shall have facility for easy earthing,
shorting, isolating and testing. 2 Sets of Earthing stud of 1/2" dia with suitable nuts,
flat and spring washers are to be provided as shown in drawing.

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24.0." TECHNICAL SPECIFICATION FOR MARSHALLING KIOSKS

The marshalling kiosk shall be of out door type suitable for operation in humid, dusty and
tropical atmosphere with seasonal wet, dry and dusty condition as per clause-6.1 of I.S
5039/1969.The kiosk should be made of 3mm Galvanized M.S Sheet of size
1200x800x450mm.Each kiosk shall consist of (as per drawing enclosed.)
a) Detachable blank gland plate at the bottom as per drawing enclosed.
b) 200/100 Nos Heavy duty terminals stud type (5mm Sq) of rating 15 Amps to take 4
Sqmm copper conductors.
c) 2 Amps HRC fuses.
d) Provision for Two Numbers test terminal blocks.
e) Local illumination lamps - 2 Nos.
f) 2 /3- Pin 5/15 Amps. Multi point Plug with Switch - 1 Nos.
f) The terminal blocks shall be provided in vertical formation as shown in drawing. They
shall be fully enclosed with removable covers made of barrier moulded integrally. Such
block shall have washer and binding screw for external connection and white marking
strip for ex-circuit identification and moulded plastic cover. All terminals shall be clearly
marked with identification markers.
h) Arrangement of terminals shall be as to safely connect or disconnect terminals on live
circuits and replace the fuse links.
i) Adequate space heaters shall be provided in the Marshalling kiosk as required.
j) The box shall be provided with self supporting Galvanized M.S.Channel
100x50mm.,welded to the bottom side of the Box (as detailed in drawing enclosed.)
and 4 Nos. holes are to be provided (suitable for 3/4" dia bolts) for fixing to the plinth
with galvanized bolts. The required 4Nos bolts of length 300mm, with galvanized nuts
and washers are to be supplied.
k) The Kiosk shall be provided with a set of double hinged doors at the front and back. The
doors shall be provided with 2Nos panel locks and 1No.pad lock as detailed in drawing.
It shall have a door switch operated AC illuminated lamps which gets switched on when
door is opened and gets switched off when closed. Two No. studs shall be provided
on the body for giving earth connection to Marshalling Boxes.
25.0." TECHNICAL SPECIFICATION FOR Fire Extinguishers
1." Trolley mount 22.5 KG capacity co2 fire extinguishers – 6no.s
2. Trolley mount 50 ltrs capacity foam type fire extingushers – 6 no.s
3. Fire buckets with stand 8 Nos

15
SS01 SURGE ARRESTERS
1.0.GENERAL:
1.1.Scope:
This specification covers the design, manufacturing, shop testing, supply, delivery
at site including unloading, testing and commissioning of 400kV gap less surge
arresters.
The Surge Arresters are required complete with discharge counters, insulating
base and all associated accessories and auxiliaries. The scope also includes
terminal connectors.
The offered equipment shall be atleast conform to design, engineering,
workmanship and standards mentioned in clause 2.0 and be capable of performing
in continuous commercial operations atleast up to the Contractor's guaranteed
data and service life. The offered equipment shall be complete with all
components necessary for its effective and trouble free operation and interfacing
along with specified associated equipment, interlocks, control and protection
schemes etc. Material and components not specifically stated in this specification
but which are necessary for satisfactory operation of the offered equipment and
accessories specified in this specification shall be deemed to be included unless
specifically excluded and shall be supplied without any extra cost.
It is intended to install sub-station monitoring systems in the above
400/400kV SS control rooms. Components/Switches/Modules/Contacts required to
be provided with Surge Arresters for interfacing with the monitoring system shall
also be the responsibility of the supplier in consultation with the Purchaser.
1.2.STANDARDS:
The surge arresters covered in this specification shall conform in general to IEC
60099-4 (1998) or its latest version and the applicable provisions of IS:3070 (1993)
except to the extent modified in the specification. All accessories, terminal
connectors etc. shall conform to relevant standards as amended to date.
The equipment shall conform to the following standards of latest issue.
i. Application Guide for Metal Oxide : IEEE Std.C62-22

Surge Arrester for AC System 1991
ii. Lightning Arresters : IS:3070 (1993)

IEC-60099-4
iii. Large hollow porcelain for
use in Electrical installation : IS:5621
iv. Tests on hollow insulators for : IEC:60233

use in electrical equipment
v. Method of HV Testing : IS:2071(Part I,
II & III)

16
vi. H.V. Test Techniques : IEC-60060,

Part 1,2
vii. Method of partial discharge : IS:6209

Measurement
viii. Partial discharge measurements : IEC-60270 (1981)
IS:3070(Part-III)
ix. Artificial pollution testing on : IEC:60099-3(1990)
Surge Arresters IEC:60815(1996)
IEC:60507(1991)
x. Electromagnetic compatibility (EMC) : IEC:61000
xi. Radio Interference test on high- : IEC:60437(1997)
voltage insulators
xii. Electrical equipment for : IEC:61326(2000)
measurement, control and
Laboratory use-EMC requirements
xiii. Recommended practice for hot dip
galvanising of Iron and Steel : IS:2633
xiv. Terminal connectors : IS:5561
xv. Precision and semi-precision
hexagon bolts, screws, nuts &
lock nuts : IS:1364
xvi. Insulation Coordination : IEC 60071-1,2
(P1-1993, P2-1990)
1.3.QUALIFYING REQUIREMENTS:
1.3.1." The manufacturers whose surge arresters are offered should have
Designed, manufactured, supplied , tested as per IEC/IS or
equivalent.
1.3.2." The 400kV class Surge Arresters being offered are from
manufacturer (s) who have established production line in India for
these equipments, based on technological support of a parent
company or collaborator for the Surge Arrester can also be
considered provided .Such manufacturer (s) has designed,
manufactured, type tested and supplied the 400kVor above class
Surge Arresters.
1.4."DRAWINGS:
1.4.1." The Contractor shall furnish the following drawings along with the offer.
1.4.1.1." Drawing showing general outline of the complete arrester including
discharge counters.
1.4.1.2." The detailed dimensional drawing of porcelain housing giving internal
and external diameter, thickness height, shed profiles, creepage distance
dry arcing distance, name of the manufacturer of the porcelain housing etc.
1.4.1.3." TOV characteristic curve and V-I characteristic curve of Zno
elements/blocks.
1.4.1.4." Manufacturer of ZNo element.

17
1.4.2." After receipt of the order, the successful Contractor will be required to furnish
six prints of the following drawings for approval. The Purchaser shall
communicate his comments/approval on the drawings to the Supplier. The
Supplier shall modify the drawings and resubmit three copies of the modified
drawings for Purchaser's approval. After receipt of Purchaser's approval, the
Supplier shall,submit six printed sets and one soft copy in latest auto cad
version of the approved drawings after incorporating all the corrections.
a) Drawing showing general outline of the complete arresters.
b) Drawing showing mounting/installation details with recommended
minimum clearances.
c) Drawing showing details of pressure relief device.
d) Drawing showing details of surge monitor.
e) Drawing showing details of terminal connectors, insulating base,
grading rings.
f) Detailed drawing of mounting structure.
g) The detailed dimensional drawing of porcelain housing giving internal and
external diameter, thickness height, shed profiles, creepage distance dry
arcing distance etc.
h) V-t and V-I characteristic curves of ZNo elements/blocks.
1.4.3." The Contractor may submit any other drawing considered necessary in addition to
the drawings stated above.The drawings and design as approved shall be
submitted by the Contractor to all the field officers.The Contractor shall also
furnish one set of reproducible of all reference drawings, documents/designs
after approval. The drawings and design approved by I & CAD / CEIG shall be
submitted in both hard copy as well as soft copy in CD in requisite numbers.
1.4.4." The manufacturing of the equipment shall be strictly in accordance with the
approved drawings and no deviation shall be permitted without the written
approval of the Purchaser. All manufacturing and fabrication work in
connection with the equipment prior to the approval of the drawing shall be at
the Contractor's risk.
1.4.5." Approval of drawings/work by Purchaser shall not relieve the Contractor of his
responsibility and liability for ensuring correctness and correct interpretation of
the latest revision of applicable standards, rules and codes of practices.
1.4.6." Prior to dispatch of the equipment final approved drawing sets, operation,
maintenance and erection manuals shall be supplied to the Purchaser in 6
copies. Also a soft copy of the drawings in Auto cad version shall also be
supplied.
1.4.7." Six sets of the type test reports, duly approved by the Purchaser, shall be
submitted by the Supplier for distribution, before commencement of supply. Test
copies of acceptance and routine test certificates, duly approved by the Purchaser,
shall accompany the dispatched consignment.
approval of the Purchaser. All manufacturing and fabrication work in connection

18
with the equipment prior to the approval of the drawing shall be at the Supplier's
risk.
1.4.9." Approval of drawings/work by Purchaser shall not relieve the Supplier of his
1.5.Instruction Manuals:
Ten copies of the erection, operation and maintenance manuals in English shall be
supplied for each type of Surge Arresters one month prior to dispatch of the
equipment. The manual shall be bond volumes and shall contain all drawings and
information required for erection, operation and maintenance of the Surge Arrester
including but not limited to the following particulars:
1.5.1." Marked erection prints identifying the component parts of the Surge
Arrester as shipped with assembly drawings.
1.5.2." Detailed dimensions and description of all auxiliaries.
1.5.3." Detailed views of the insulator stacks, metallic’s, structure, spare parts
etc.
1.6." COMPLETENESS OF THE OFFER
Equipment shall be offered complete with all parts and accessories which are useful
and necessary for its efficient economic and safe operation and proper connection. Such
parts and accessories shall be deemed to be within the scope of this specification whether
specifically mentioned herein or not, and the bid price quoted is deemed to have been
included all the above and inspection.
1.7." INSPECTION
The inspection may be carried out by the Superintending Engineer, NTR TGP Circle,
Kadapa/representatives at any stage of manufacture. The successful Contractor shall grant
free access to the Superintending Engineer, NTR TGP Circle, Kadapa/representatives at a
reasonable time when the work is in progress. Inspection and acceptance of any
equipment under this specification by the Purchaser, shall not relieve the Supplier of his
obligation of furnishing equipment in accordance with the specification and shall not
prevent subsequent rejection if the equipment is found to be defective. The Supplier shall
keep the Purchaser informed in advance, about the manufacturing program so that
arrangement can be made for inspection.
The Purchaser reserves the right to insist for witnessing the acceptance/routine testing of
the bought out items.
1.8." QUALITY ASSURANCE PLAN:
1.8.1." The successful Contractor shall, submit following information to the Purchaser.
i) List of raw materials as well as bought out accessories, and the names of Sub-
Suppliers selected from the lists furnished with the offer.
ii) Type test certificates of the raw material and bought out accessories.
iii) Quality assurance plan (QAP) with purchaser’s hold points Purchaser's hold points
shall be discussed between the Purchaser and Supplier before the QAP is finalised.
1.8.2." The successful Contractor shall submit the routine test certificates of bought out
accessories at the time of review of routine tests performed on the fully assembled
Surge Arrester.

19
1.9." PACKING AND FORWARDING

1.9.1."The equipment shall be packed in crates suitable for vertical/ horizontal transport, as the
case may be, and suitable to withstand handling during transport and outdoor storage. The
cabinets shall be covered with plastic film so as to prevent the cabinet from damage during
transportation. The plastic film shall be removed at the time of commissioning. The
Supplier shall be responsible for any damage to the equipment during transit, due to
improper and inadequate packing. The easily damageable material shall be carefully
packed and marked with the appropriate caution symbols. Wherever necessary, proper
arrangement for lifting, such as lifting hooks etc. shall be provided. Any material found
short inside the packing cases shall be supplied by Supplier without any extra cost. The
packages requiring covered storage shall be compulsorily marked.
1.9.2." Each consignment shall be accompanied by a detailed packing list containing the following
information:
i) Name of the Consignee
ii) Details of consignment
iii) Destination
iv) Total weight of consignment
iv) Handling and unpacking instructions
v) Bill of material indicating contents of each package Purchase Order Reference
1.9.3." The Supplier shall ensure that the packing list and bill of material are approved by the
Purchaser before dispatch.
1.10." DUTY REQUIREMENTS:
1.10.1." The surge arresters shall be of heavy duty station class and gap less
type.
1.10.2." The surge arresters shall be adequately designed to withstand
specified dynamic over-voltages. The Contractor shall furnish the data
for the duration and over-voltage factors which the offered arresters
can withstand after absorption of energy equivalent to specified
energy discharge class. (Two long duration discharge current
impulses).
1.10.3." The surge arresters shall be capable of discharging over-voltage
occurring during switching off loaded transformers, reactors and long
lines.
1.10.4." The surge arresters shall be capable of discharging energy equivalent
to line discharge class 3 of IEC:60099 for 245kV and 245kV systems
1.10.5." The reference current of the surge arresters shall be high enough to
eliminate the influence of grading and stray capacitance on the
measured reference voltage of the arrester units (with designed
grading system).
1.10.6." Arresters shall be designed with sufficient cantilever strength to meet
stress due to specified wind speed and seismic acceleration.
1.10.7." Arresters shall require no routine maintenance upkeep, or attendance,
except as required to remove pollution contaminants.

20
1.10.8." The Surge arresters are provided to protect the following equipment
whose insulation levels are indicated as under:
Equipment to be Lightning impulse Switching Surge (kVp) Lightning impulse (kVp)

protected (kVp) for 245kV for 245kV system for 245kV system
system
1 2 3 4
Power transformer + 1300 + 1050 + 950
Instrument + 1425 + 1050 + 1050
transformer
CB/Isolator Phase to + 1425 + 1050 + 1050
ground
Across open contacts + 1425 (-/+ 240) + 900 (-/+ 345) + 1200
1.10.9." The duty cycle of Circuit Breakers taken in this substation shall be 0-0.3
secs-CO-3 minutes-CO.
1.11." CONSTRUCTIONAL FEATURES:
1.11.1." The constructional features of surge arresters shall be generally in
accordance with the requirements stipulated hereunder.
1.11.2." The surge arresters shall be of hermetically sealed units, self
supporting construction suitable for vertical mounting on a galvanized
horizontal steel structure /steel tubular plat form.
1.11.3." The non-linear blocks shall be of sintered metal oxide material. These
shall be provided in such a way as to obtain robust construction with
excellent mechanical electrical properties even after repeated
operations.
1.11.4." The surge arresters shall be fitted with pressure relief devices suitable
for preventing shattering of porcelain housing in the event of arrester
failure.
1.11.5." Arresters shall incorporate an anti-contamination feature to prevent
arrester failure consequent to uneven voltage gradient across the
stack, in event of contamination of the arrester porcelain.
1.11.6." A corrosion-resistant nameplate with clearly legible lettering shall be
permanently attached to each surge arrester at an easily visible place.
The name plate shall be readily legible from the ground and shall meet
the requirements of IEC recommendation.
1.11.7." The arrester housing, fittings and accessories and surge monitor shall
conform to the requirements.
1.11.8." The arrester assembly shall consist of arrester unit, line terminal, earth
terminal, insulating base and other hardware required for installation.
1.11.9." The arrester offered shall be suitable for hot line washing. A copy of
the instructions for hot line washing shall be furnished with the bid.
1.11.10."The manufacturer shall submit data on rejection rate of Zno blocks
during manufacturing/operation for the past three years.

21
1.11.11."The nameplate shall conform the requirements of IEC incorporating

the year of manufacture.
1.11.12."The heat treatment cycle details along with necessary quality checks
used for individual blocks along with insulation layer formed across
each block are to be furnished. Metalizing coating thickness for
reduced resistance between adjacent discs is to be furnished with
additional information schedule of bid proposal sheets along with
procedure for checking the same Details of thermal stability test for
uniform distribution of current on individual disc is to be furnished.
1.11.13."The constructional features of surge arrester housing shall be generally
in accordance with the requirements stipulated hereunder.
1.11.14."Arrester housing shall be manufactured and tested in accordance with
IEC:60233/IS:5621.
1.11.15."Housing insulators shall be manufactured from high quality porcelain.
Porcelain used shall be homogenous, free from laminations, cavities
and other flaws or imperfections that might affect the mechanical or
dielectric quality and shall be thoroughly vitrified and impervious to
moisture.
1.11.16."Glazing of the porcelain shall be uniform brown in colour, free from
blisters, burrs and similar other defects. Housing shall incorporate
suitable profile preferably of self cleaning type (aerofoil design)
meeting with IEC-815/IS:2544 and with required minimum creepage
distance in order for arrester to function satisfactorily under specified
pollution environment.
1.12." TESTS:
1.12.1." The surge arrester and the housing must have been type tested and
shall be subjected to acceptance and routine tests listed in relevant
IS/IEC standards. However in switching surge operating duty test
sample shall be preheated to 70 deg.C instead of 60 deg.C prior to
application of long duration surges.
1.12.2." The equipment/material offered against this tender should have been
successfully type tested in line with the specified standards and this
Technical Specification. The Contractor shall furnish 4 copies of the
Type test reports with the offer. In case these type tests were carried
out earlier to the five years period mentioned above or some type
tests were not carried out at all as per the present specification, all the
relevant type tests as per relevant standards shall be carried out by the
successful Contractor in the presence of Purchaser's representative at
the cost of the successful Contractor.
1.12.3." If there is any change in the components or design in the equipment
since after earlier passing of the Type Test, the Contractor shall bring
out in his offer all such changes made in the components, materials,
designs, etc. In such case the Contractor shall carry out the type tests
at his cost and in presence of the Purchaser's representative.

22
1.12.4." If the equipment/material does not withstand the type test, the
equipment/ material supplied till then will be liable for rejection.
The supplier, in such an eventuality, shall be allowed to modify
the equipment and type test the same again at his cost in the
presence of the Purchaser's representative. These type tests
shall however be conducted by the Supplier within a reasonable
time. After successful passing of the type tests, all the
equipment/materials supplied earlier shall be modified in line
with the equipment/materials which has successfully passed the
type test. In case Supplier fails to carry out the type test within
reasonable time or does not agree to carry out the type test at
his cost, his equipment/material supplied earlier shall be
rejected and order placed shall be cancelled and payment made
earlier for these Suppliers shall be recovered by the Purchaser.
1.12.5." The type tests should have been either conducted in a recognised
institution or laboratory and should have been witnessed by a
purchaser or an independent agency. The name(s) of the
institutions/Laboratories where the Contractor intends to get type
testes performed shall be indicated in the bid.
1.12.6." The type tests shall include
a) Insulation Withstand Test
b) Long Duration Current Impulse withstand Test
c) Residual Voltage Tests
d) Operating Duty Cycle Tests
e) Pressure Relief Withstand Tests
f) Contamination Tests
g) Partial discharge test
h) Seal leakage test
Pressure Relief Withstand test shall be conducted at 3 different
values of short circuit currents i.e., the rated short circuit current and 2 reduced
short circuit currents for each arrester type.
1.12.7." Special Test:
1.12.7.1." Thermal Stability Test: The surge arrester shall be

opened subsequent to all tests. If inspection of the internal parts
reveal evidence of overheating, flashover or parts cracking or
breaking, the surge arrester shall be considered to have failed
the test.
1.12.8." The routine/acceptance tests shall include as minimum:
a) Measurement of reference voltage as per section 2.35 and 5.2 of
IEC 60099. The measured values shall be within the range
specified.

23
b) Residual voltage at 5kA (8/20us), 10 kA (8/20 us) and 20 kA

(8/20us) as per provisions of clause 8.1 (b) of IEC:99-4.
c) Power losses are measured at 0.8 times rated voltage on each
arrester unit.
d) Check of internal corona made at 1.05 times COV. Each unit is
checked to have a steady internal corona level less than 50 pC in
a pass/no-pass test.
e) Tightness check to be made on each unit in pass/no-pass test.
Maximum permissible leakage is 0.0001 cc/sec at a pressure
difference of 0.1 MPa.
f) Verticality check on completely assembled surge arrester as a
sample test on each lot.
g) Lightning Impulse Residual Voltage Test.
h) Partial discharge test.
i) Dimensional Verification.
j) Galvanizing Test.
k) Porosity Test.
l) Tests on Surge Monitor
1.12.9." Copies of certificates of the type and special tests conducted (on same
model as offered) according to the IS 3070 and IEC standards shall be
furnished along with the bid failing which the bid is liable for rejection.
1.12.10."The type & special tests should have been either conducted in a
recognized independent institution/laboratory or should have been
witnessed by a purchaser or an independent agency.
1.12.11."Additional Type Tests:
The following additional type tests shall be case of 400kV class surge
arrester
i) Radio interference voltage test (as per IS:8263).

ii) Seismic withstand test.
iii) Contamination test (As per ANSI-C62-11-1987).
iv) Temporary over voltage withstand test.
The Contractor shall furnish test procedure for, Additional Type Tests along with
the bid and the same shall be got approved by the purchaser.
1.13." Tests on Surge Monitors:
The surge monitors shall also be connected in series with the test specimens
during residual voltage and current impulse withstand tests to verify efficacy of
the same. The surge monitor with current meter shall have practically no effect
on protection level and performance of surge arrester. Additional
routine/functional tests with one 100A and 10kA current impulse, (8/20 micro
sec.) shall also be performed on the surge monitor. The surge monitor shall
conform to IP 55 degree of protection. The provision shall be made to connect the
surge monitor to the control room.

24
1.14." Tests on Arrester Housing:

Arrester housing shall be type tested as per IEC 60233/IS:5621. All routine
tests shall be conducted on the hollow column insulators as per standards in
addition to the following.
i) Ultrasonic test as a routine test IEC-60383 and IS:4318
ii) Bending test as acceptance test IS:3070 (1993)
iii) Pressure test as a routine test
iv) Burst pressure test as a sample test
1.15." FITTINGS AND ACCESSORIES:
1.15.1." Arresters shall be complete with insulating bases, fasteners for
stacking units together discharge counters with leakage current
meters and terminal connectors.
1.15.2." The end fittings shall be of non-magnetic and corrosion proof material
suitable for outdoor installations. All ferrous parts exposed to
atmosphere shall be hot dip galvanized as per relevant standard.
1.15.3." Grading corona control rings, if necessary shall be provided on each
complete arrester pole for proper stress distribution.
1.15.4." The terminal connectors shall be suitable for twin ACSR conductor or
Aluminum tube for horizontal or vertical takeoff. The terminal pad
shall be of high conductivity bronze alloy of copper or aluminum.
Copper-alloy terminal pads shall be completely and uniformly hot
flowed electro tinned with commercially pure tin to a minimum
thickness of 0.0127 mm (0.0005"). The exact size of terminal
connectors shall be intimated to the successful Contractor.
1.15.5." The ground terminal shall be suitable for 75 x 12 mm M. S. Flat for
connection to grounding system.
1.15.6." Ground conductor connections between arresters and discharge
counters shall be furnished and shall be insulated and insulator
supported suitably as approved by the purchaser to prevent
conductor movement.
1.16." Surge Counter / Discharge Counter: Self contained discharge counters
suitably enclosed for outdoor use. Fully weather proof and sealed for life and
requiring no auxiliary or battery supply for operation shall be provided with a
suitable cyclo metric counter for each pole of surge arrester to record the number
of discharges through the surge arrester. The discharge counters shall be capable of
counting at least 9999 discharges. It shall not be possible to reset the counter. A
leakage current meter with suitable scale range to measure the leakage current of
the surge arrester shall also be provided with the discharge counter. Surge
counter comprising discharge counter and leakage current meter shall conform to
environment protection corresponding to IP:55.
1.16.2." The material used in the discharge counter shall be such that it can safely
withstand discharge current of the surge arrester.
1.16.3." Following performance is desired from the discharge counter:

25
i) The discharge counter shall operate for a minimum lightning impulse

current (8/20) of 100 amps and a maximum of high current impulse 4/10,
100kA peak (2 application).
ii) The discharge counter shall operate perfectly if the interval time of
multiple lightning strokes is more than 0.1 second.
iii) The discharge counter shall have negligible effect on the protection level
of the surge arrester.
iv) Long duration current impulses corresponding to the discharge class of
the surge arrester with which it is to be used.
v) Normal discharge current corresponding and discharge current of the
surge arrester with which it is to be used.
vi) The potential across the discharge counter shall be less than 10V (rms.)
under normal conditions.
1.16.4." Discharge counter shall be so designed as to be mounted on the supporting
structure. The connecting wire used between the discharge counter and the
surge arrester shall be supplied along with the equipment. The surge
monitor shall be mounted at a height of 1.5m above ground level and away
from direction of pressure release vent.
1.16.5." An inspection window shall also be provided through which the readings can
be taken. The Contractor shall give a detailed description along with block
diagrams of the discharge counter.
1.16.6." Functional test reports on discharge counters shall also be submitted along
with the tender. The supplier will be responsible for proper functioning of
the discharge counters with the surge arresters. The Contractor shall submit
along with the tender test certificates of tests conducted to prove that the
discharge counter will register every impulse of more than 100 amps and
discharge counter with current meter will have practically no effect on the
arrester performance and its residual voltage.
1.17. Technical Parameters of Arrester Housing:
245kV
a) Rated voltage 216kV
b) Impulse withstand 1050kVp

voltage
c) Switching surge 1050kVp
withstand voltage
(dry and wet)
d) Power frequency 460kV
withstand voltage (rms)
(dry and wet)
e) Total creep age 6125
distance

26
SS02 ISOLATORS CUM EARTHING SWITCHES
2.0.SCOPE
This specification covers design, manufacture, assembly, inspection and testing at
manufacturer's works, packing and delivery at site of the 245kV outdoor type air break
Isolators with associated earthing switches and auxiliary equipment for. The scope also
includes supervision of erection, testing and commissioning for 245kV Isolators after
erection by the successful Contractor.
2.1." It is not the intent to specify all details of the design and construction of
equipment to be supplied under this contract. The offered equipment shall be capable of
performing in continuous commercial operation up to the supplier's guarantee in a manner
acceptable to the purchaser, who will interpret the meanings of drawings and specification
and shall have the power to reject any work or material, which in his judgment, is not in
accordance there with. The offered equipment shall be complete with all components
necessary for its effective and trouble free operation and interfacing along with specified
associated equipment, interlocks, control and protection schemes etc. Such components
shall be deemed to be within the scope of Contractor's supply, irrespective of whether
those are specified or not without any extra costs. All similar parts particularly removable
ones shall be interchangeable.
2.2." It is intended to install sub-station monitoring system 400kV Substation control
room. Components/ Switches/ Modules/ Contacts required to be provided with Isolators
for interfacing with the monitoring system shall also be the responsibility of the supplier in
consultation with the Purchaser and Supplier of Control & Relay panels.
2.3." STANDARDS
The equipment covered by this specification shall conform to the latest National and
International Standards and the provisions of the following standards (as amended up
to date) except where specified otherwise.
__________________________________________________________
Sl.No. Standard No. Title
____________________________________________________________
1. IS:1818 Alternating current isolators

IS:9921 (Part I to V) (disconnectors) and earthing
switch
2. IEC:60129(Amd1-1992) Alternating current

disconnectors and
earthing switches
3. IS:2544/1996 } Tests on indoor and outdoor

IEC:60168 } post insulators of ceramic
material or glass
4. IEC:60273(1990) Characteristic of indoor and
outdoor post insulators
5. IS:731/1971 }
IS:5350/1970/71/73 } Porcelain insulators
IS:2099-1986 }

27
6. IEC:60233(Amd1-1988) Test on hollow insulators for

use in electrical equipment
7. IS:2147 & Degree of protection
IS:4691 provided by enclosures.
8. IEC:60815(1986) Guide of the selection of
insulators in respect of
polluted conditions
9. IEC:60507 (1991) Artificial pollution tests on
high-voltage insulators to be
used on a a.c. system
10. NEMA Pub.107 Radio Influence Voltage
IEC:60437 (1997) Tests Radio Interference
Test on high- voltage
insulators
11. IEC:61000 Electromagnetic capability
12. IS:325 & IS:996 Three phase induction
motors.
_________________________________________________________________
Sl.No. Standard No. Title
_________________________________________________________________
13. IS:4722 Rotating electrical machines.
14. IS:2699 Recommended practice for

hot dip galvanizing of iron
and steel.
15. IS:4759 Hot dip galvanization coating
on structural steel.
16. IS:2633 Method of testing weight

thickness and uniformity of
coating on fasteners.
17. IS:1573 Electro plated coating of zinc
on iron and steel.
18. IS:3033/3063 Spring washers
19. IS:2016 Plain washers
20. I.E. Rules Indian electricity Rules 1956

(up to date)
21. CISPR Pub.1-1972 International special committee
on Radio Interference on Measuring
current for RIV Tests.
22. IS:5561 Power connectors
23. IS:1554-1988 PVC cables

28
24. IS:375 Marking and arrangement for

switchgear bus bar main
connectors and auxiliary wiring.
25. IS:3961-1967,68 Recommended current rating

for PVC insulated & PVC
sheathed heavy duty cables.
26. IS:1239 Standard for ERW pipes
2.4. Equipment and material meeting the requirement of JIS or any other equivalent
internationally recognized standard which ensure quality equal to or better than
as per the standards shall also be acceptable. Where the equipment conform to
any other standard(s), the points of difference between the standard(s) adopted
and those prescribed in this specification shall be clearly explained in the tender
and a copy of the applicable standard if it is in other than English language its
English version shall also be enclosed with the tender.
2.5.QUALIFYING REQUIREMENTS
a) The manufacturers whose isolators are offered should have designed,
manufactured, supplied, tested as per IEC/IS or equivalent standard and
commissioned at least the following equipment.
b) The 245kV class Isolators being offered are from manufacturer(s) who have
established production line in India for these equipments, based on technological
support of a parent company or collaborator for the Isolators can also be
considered provided.
Such manufacturer (s) has designed, manufactured, type tested and supplied the
245 kVor above class Isolators.
ii) The parent company (Principals) or collaborator meets qualifying
requirements stipulated under, and
iii) The 245 kV class Isolator manufacturer(s) furnishes
a) A legally enforceable undertaking (jointly with the parent
company or collaborator) to guarantee quality, timely
supply, performance and warranty obligations as specified
for the equipment(s); and
c) A confirmation letter from the parent company or collaborator along
with the bid stating that parent company or collaborator shall furnish
performance guarantee for an amount of 10 % of the cost of such equipment(s).
This performance guarantee shall be in addition to Contract Performance
Guarantee to be submitted by the Contractor.
2.6." DRAWINGS
2.6.1." The successful Contractor shall be required to furnish two (2) prints of the
following drawings and any other drawings which the Contractor may consider
necessary for approval.
a) General arrangement drawings showing plan, front and side elevations of
isolators, with/without earthing switches with all accessories including the
earthing / grounding terminals showing dimensional details, net and shipping
weights etc. Dimensions shall be marked in metric units.
b) Drawing of mounting details and their recommended method of mounting.

29
c) Control and wiring diagrams of operating mechanism showing salient details

required for connecting or interfacing with control equipment at site.
d) Detailed assembly drawings showing the parts properly identified for field
assembly of equipment.
e) Complete bill of materials listing out all the equipment / materials and hardware’s
to be supplied.
f) Drawing showing complete particulars of foundation and structural drawings
including weights of all components, forces acting and impact loading.
g) Drawing showing complete details of insulator stack including dimensions,
electrical and mechanical clarifications, name of manufacturer, dry arcing distance
etc.
2.6.2." One print of such drawings/documents will be returned to the Contractor marked
approved/approved with corrections. After final approval of the drawing the
Contractor shall furnish to the Purchaser Six prints and one reproducible original
of the drawings after incorporating all corrections. The drawings and design as
approved shall be submitted by the Contractor to all the field officers/engineers.
2.6.3." The drawings submitted by the Contractor shall be reviewed by the Purchaser as
far as practicable. The Contractor shall resubmit the drawings after necessary
corrections which the comments have been communicated to the Contractor. Any
delays arising out of the Contractor to rectify the drawings shall not alter the
Contract completion time.
2.6.4."The Contractor shall also furnish one set of reproducible of all reference drawings,
documents/designs after approval. The drawings and design approved by I & CAD/
CEIG shall be submitted in both hard copy as well as soft copy in CD in requisite
numbers.
approval of the Purchaser. All manufacturing and fabrication work in connection
with the equipment prior to the approval of the drawing shall be at the
Contractor's risk.
2.6.6." Approval of drawings/work by Purchaser shall not relieve the Contractor of his
2.6.7."One month prior to dispatch of the equipment final approved drawing sets,
operation, maintenance and erection manuals shall be supplied to the Purchaser
in 6 copies. Also a soft copy of the drawings in Auto cad version shall also be
supplied.
2.6.8."After final testing and commissioning, any corrections in the, field test, actual
erection, testing and commissioning shall be incorporated in the drawings and 6
copies of drawing/manuals shall be.
2.7." TYPE AND DUTY REQUIREMENTS :
2.7.1." 245 kV Motor operated horizontal Centre Break Isolator cum Earthing switches shall
be a set of three individual poles single horizontal centre break type having two
rotating posts per pole with one/two earthing blades per pole suitable for fixing
mechanically on either side of the pole. Necessary inter pole cabling is also included in
the scope of supply.

30
2.7.2." 245kV Motor operated Horizontal Double Break Isolator cum earthing
Switches shall be three phase gang operated horizontal double break type
having one rotating post per pole and turn and twist type moving blades and
with one/two earthing switches. Each 245 kV three phase Isolator shall
consist of three identical poles linked together mechanically and shall be
suitable for triple pole operation and shall open and close in a horizontal
plane.
2.7.3." The isolators shall be capable of making/breaking normal currents when
no significant change in voltage occurs across the terminals of each pole of
the isolator on account of make/break operation. A documentary proof in
support of this shall be furnished by the Contractor along with the bid.
2.7.4." The isolators shall be capable of making/breaking the magnetizing and
capacitive currents of 0.7 amp. at 0.15 power factor.
2.7.5." The isolators offered both in closed & Open conditions after erection shall be
suitable to with stand earthquake forces corresponding earthquake
accelerating Coefficient of 0.3g. The supporting documents shall be furnished
with the bid.
2.7.6." Insulation to ground, insulation between open contacts and the insulation
between phases of the assembled isolator-cum- earthing
switches shall be capable of withstanding the dielectric test voltages specified herein.
2.7.7." The isolator design shall be such that it is free from visible corona discharge in both closed
and open position at the visible discharge test voltage specified for the insulators.
Necessary grading rings or shields shall be provided to meet these requirements.
2.7.8." The earthing switches shall be capable of discharging trapped charges of the transmission
lines
2.7.9." The isolator cum earthing switches shall be able to bear on the terminals the total forces
including wind loading and electro dynamic forces on the attached conductor without
impairing reliability or current carrying capacity. The safety factor against break of an
isolator cum earthing switches shall be at least 1.25 times the simultaneously acting forces
plus operating forces. This shall be supported by furnishing calculations of tests
performed, if any, along with the bid.
2.7.10." The isolators cum earthing switches shall be so designed as to discourage the building of
bird's nest and this aspect shall be brought out in the bid.
2.7.11." Service conditions require that the isolators and earthing switches shall remain alive and in
continuous service for a period of upto two years without operation or maintenance.
2.7.12." The isolator-cum-earthing switches shall be capable of withstanding the dynamic and
thermal effects of the rated short circuit current of the systems in their closed position.
They shall be constructed such that they do not open under the influence of short circuit
current
2.7.13." Unless otherwise explained separately by the Contractor in the schedules of deviations, the
isolator-cum-earthing switches offered shall be deemed to conform to the specification in
all respects. All deviations from the specification shall be brought out in the schedule of
deviations. The discrepancies between the specification and the catalogues or literature
submitted as part of the offer shall not be considered as valid deviations unless specifically
brought out in the schedule of deviations
.
2.7.14." Any deviation from the specification, which is not specifically brought out in the schedule
of deviations will not be considered.

31
2.8." CONSTRUCTIONAL FEATURES:
2.8.1." The features and constructional details of isolators, earth switches and accessories shall be
in accordance with the requirements given below.
2.8.2." The purchaser's 400kV bus (equipment inter connecting bus) is made up of 100mm (4") dia
IPS aluminum tubes. Height of the centre line of this tubular bus is 8.30 meters from
ground level.
2.8.3." All live parts shall be designed to have smooth surfaces without any edge, sharp point of
other corona producing surfaces so as to eliminate corona at specified extinction voltage
or at 1.1 times the rated voltage if extinction voltage is not specified.
2.8.4." Nuts, bolts and washers of 16mm and higher size shall be hot dip galvanized. The bolts
used on tapped holes of insulator cap shall be galvanized by centrifuge process to avoid
excess deposition of zinc on threads. Nuts, bolts and washers of less than 16mm size shall
be of stainless steel when used on live parts and nickel plated brass in other parts.
2.8.5." Contacts:
2.8.5.1." The horizontal break type isolators and earthing switches shall have heavy
duty self-aligning and high pressure contacts. The contacts shall be made
of hard drawn electrolytic grade copper strip. High pressure type
contacts shall wipe the contact surface while opening and closing. The
contacts shall be so designed that the wiping action shall not cause
scouring or abrasion on the contact surfaces. The wiping action shall be
sufficient to remove any film of oxide which may be formed during the
operation of the switches and so designed that binding cannot occur
after remaining closed for prolonged periods of time in polluted
atmosphere. The features involving wiping action shall be brought out in
the bid.
2.8.5.2." The contacts and other current carrying parts shall be so designed that
their temperature rise under specified conditions of operation shall
not exceed the values stipulated in relevant standard. The temperature
rise due to the passage of rated short circuit current for a period of 1
second shall not cause any annealing or welding of contacts.
2.8.5.3." Moving contacts shall be dimensioned to withstand the rated short circuit
current during service. The surface of the contact shall be rendered
smooth and shall be silver plated. The thickness of silver plating shall
not be less than 25 microns.
2.8.5.4." No uneven wear or scuffing shall be evident during the mechanical
endurance tests. Contacts and spring shall be designed in such a way that
re-adjustments in contact pressure shall not be necessary throughout
the life of the isolator or earthing switch. Each contact or pair of contacts
shall operate so that always full pressure is maintained on all contacts.
2.8.5.5." Contact springs shall not carry any current and shall not alter their
design characteristics due to heating effects.
2.8.5.6." The female contact and its tensioning by spring shall be designed such that
there will be always a positive contact with adequate pressure to give
enough contact surface for the passing of current. The springs
provided shall not go out of alignment or get entangled with the male
contact during operation.

32
2.8.5.7." Necessary arrangement shall be provided for proper alignment of the

contacts. Factory adjustment shall be arranged on each pole that no
changes in the field are required on the isolator-cum-earthing
switches supplied. Gang operated links shall be so designed that all
phases shall make and break simultaneously.
2.8.6." Blades:
2.8.6.1." All metal parts shall be of non-corroding metal. Current carrying parts shall
be of non-ferrous material. Bolts screws and pins shall be provided with
lock washers. Keys or equivalent locking facilities, if provided on current
carrying parts, shall be made of non-ferrous and non-corroding material.
All castings except current carrying parts, shall be made of cast iron or
cast steel. No grey iron shall be used in the manufacture of any part of
the isolator.
2.8.6.2." In the case of 245kV HCB Isolators moving arms can be of Aluminum. But
the main contacts/Tips shall be of Copper with silver plating of thickness
of minimum 25 microns. In the case of 245kV HDB isolators, fixed &
moving arms and contacts shall be of Copper only.
2.8.6.3." The live parts shall be designed to eliminate sharp joints, edges and other
corona producing surfaces. Where this is impracticable adequate
corona shields shall be provided. Corona shields/rings shall be made of
Aluminum / Aluminum alloy. The price for such shields/rings is deemed
to have been included in the bid price.
2.8.6.4." Isolators and earthing switches including their operating parts shall be
designed such that they cannot be displaced from their open or closed
positions by short circuit forces, wind pressure, vibrations, shocks or
accidental touching of the connecting rods of the operating mechanism.
2.8.6.5." The isolators and earthing switches shall be designed such that lubrication
of any part is not required at frequent intervals. Self- lubricating
components shall be preferable and this aspect shall be brought out in
the bid.
2.8.6.6." The design of isolator-cum-earthing switches shall provide for positive
control of blades in all positions with the minimum of mechanical stress
on the insulators. Fixed guides shall be so provided that proper seating
of contacts shall be obtained when a blade is out of alignment even by
25mm in either direction. All movable parts which may be in current
path shall be shunted by flexible copper conductors of adequate
cross-section and strength.
2.8.6.7." The isolators and earth switches shall be so constructed that the switch
blade shall be locked in the open/closed position and shall not fall to the
closed/open position in case the operating shaft gets disconnected.
The details of the mechanism employed shall be described in the bid.
2.8.7." Base :
2.8.7.1." Each pole of the isolator shall be provided with a complete galvanized steel base
provided with holes and designed for mounting on a supporting structure.
The base shall be rigid and self supporting and shall require no guying or
cross bracing between phases other than the supporting structures.
2.8.7.2." The position of movable contact (main blades) of each of the isolators and earthing
switches shall be indicated by a mechanical indicator. The indicator shall be of
metal and shall be visible from operating level.

33
2.8.7.3." The base for each isolator pole shall have levelling screws for easily adjusting
insulator columns in relation to the base.
2.8.7.4." Both the base and energized portion of the isolator shall be drilled for direct
connection to post-type insulators.
2.8.7.5." The base shall be provided & marked with two earthing terminals to connect the
earth lead from the ground mat .
2.8.8." Turn and Twist Mechanism for 245kV Isolator-cum-earthing switches:
Turn and twist mechanism shall be provided with adequate locking to avoid opening or
loosening by wind, short circuit force etc. on moving blade. The springs shall be made out
of stainless steel or phosphor bronze of any other better material to have adequate
strength and resilience and shall be encased with grease to avoid exposure to rain. The
clamps and plates shall be made out of at least 10 mm thick M.S. plate or flat. Fasteners
with nylock nuts shall be fabricated by tubular gas cutting or milling. The entire
mechanism shall be fabricated in suitable jig and template to avoid deviations during
production.
2.8.9." Insulators:
2.8.9.1." The type of insulators used for the isolators and isolator cum-earthing switches
shall be as specified in Section Auxiliaries. The porcelain used shall conform to
the requirements stipulated in Section-Auxiliaries and shall comply with the
requirements of IS: 2544 (as amended up-to-date). The insulators shall be
manufactured by the wet process. The porcelain and metal parts shall be
assembled together with such material and in such manner that any thermal
expansion of the metal and the porcelain part throughout the range of
operating temperature shall not loosen the parts or create undue stress
adversely affecting the mechanical and electrical strength. The solid core
insulators to be used shall have creep age distance of 25mm/kV.
2.8.9.2." 245 kV Insulator shall be routine tested as per standards. Besides following
additional tests shall also be conducted.
i) Bending load test in four directions at 50% minimum bending load guaranteed for
insulators, as a routine test as per IEC 60168 or IS 2544, BS 3297.
ii) Bending load test in four directions at 100% minimum bending load as a sample
test on each lot as per IEC 60168, IS 2544, BS 3297.
iii) Torsional test on sample insulators of a lot.
iv) Ultrasonic test as a routine test as per IEC 60383 and IS 4318.
2.9." EARTHING SWITCHES
2.9.1." Earthing switches shall be operated locally only.
2.9.2." The earthing switches shall be motor operated and mechanically
interlocked with the isolator so that the earthing switches can be
operated only when the isolator is open.
2.9.3." The earthing switches shall be of the same current carrying capacity
including the capacity to carry fault currents as the main blades of the
associated isolator and shall with stand all dynamic stresses, which
might occur. Each earthing switch shall be provided with flexible copper
strips for connection to grounding system. These strips shall have the
same short time current rating as the earthing switch blade. The
transfer of fault current through swivel connection will not be accepted.
All electrical clearances and characteristics of the earthing switch shall
be fully coordinated with the associated isolator. The earthing switches
shall be supplied with auxiliary contacts and interlocking devices.

34
2.9.4." The earthing switch shall be of non-ferrous material and the design
shall match the quality with that of the main isolating switch except
that high- pressure contacts are not required.
2.9.5." Earthing blade in case of 245kV HCB isolators shall be of aluminum
but the main contact/tips shall be of copper with Silver plating of
thickness of minimum 25 microns.
2.9.6." The plane of movement and final position of the earth blades shall be
such that adequate electrical clearances are obtained from adjacent live
parts.
2.9.7." The isolators shall be designed to permit adding of earthing switches on
either side, if required at a future date.
2.9.8." The frame of each isolator and earthing switch shall be provided with
two reliable earth terminals for connection to the earthing system.
2.9.9." Earthing switches shall consist of three earthing links per isolator, which
will normally rest against the frames when the connected isolator is in
closed position. The earthing links for three phases shall be capable of
being fitted on either side of the isolator.
2.9.10." Where earthing switches are specified complete operating mechanism
and auxiliary contacts shall be included in the Bid.
2.10." OPERATING MECHANISM OF ISOLATOR-CUM-EARTHING SWITCHES:
2.10.1." A three phase AC motor operated type with well synchronized operating
mechanism shall be provided for each pole of 245kV H.C.B. Isolator. The H.C.B.
Isolator shall be remote controlled. Manual operating mechanism shall be
provided for H.C.B. isolator and earthing switches. Interpol cables required for
245kV H.C.B isolators shall be in the supplier's scope.
2.10.2." The 245kV isolators shall be operated by one mechanically coupled three-phase
AC motor and remote controlled. Manual operation facility shall be provided.
2.10.3." Displacement for any part of the mechanism shall not be possible, after final
adjustment has been made. Any point in the travel shall be sufficient enough to
allow improper functioning of the isolator when the isolator is opened or closed
at any speed. All holes in cranks, linkages etc. having moving pins shall be drilled
to accurately fit so as to maintain the minimum amount of slack and lost motion
in the entire mechanism.
2.10.4." Limit switches for control shall be fitted on the isolator-cum-earthing switch
shaft, within the cabinet to control the open and close positions of the isolator-
cum-earthing switches.
2.10.5." A "Local/Remote" selector switch and a set of open/close push buttons shall be
provided on the MOM panel of the 245 kV /12kVisolator-cum-earthing switches
to allow its operation locally or remote. The remote push buttons will be
arranged by the Purchaser. Provision shall be foreseen for individual electrical
control of each switch pole of the isolator-cum-earthing switches for test
purposes when the selector switch is in the LOCAL position.
2.10.6." Provision shall be made in the MOM Panel to disconnect power supply to
prevent local/remote Electrical operation during manual operation.
2.10.7." Motor shall be an AC motor and conform to the requirements of Section-
Auxiliaries. Suitable reduction gearing shall be provided between the motor
and the drive shaft of isolator-cum-earthing switches. The mechanism shall stop
rapidly when motor supply is switched off. If necessary a quick electro
mechanical brake shall be fitted on the higher speed shaft to effect rapid
braking. Gear should be of forged material suitably chosen to avoid
bending/jamming on operation after a prolonged period of non-operation. Also

35
all gear and connected material should be so chosen/surface treated to avoid

any kind of corrosion. Motor operated mechanism shall be subjected to blocked
rotor test as sample test/type tests at no extra cost to owner.
2.11." OPERATION”
2.11.1." The height of the operating handle for manual operation shall be approximately
1000 mm above ground level. Earthing switch shall be suitable for manual
operation for all types of isolators-cum-earthing switches. Manual operation
facility should be provided with necessary interlock to disconnect motor.
2.11.2." The operating mechanism operating time for a complete open to close or close
to open operation shall not exceed 12 sec.
2.11.3." The manual operation mechanism shall be of torsion type suitable for operation
in the horizontal plane with an operating force not greater than 22 Kg. The
manually gang-operated mechanism shall effect a smoothly controlled
movement during the entire operating cycle.
2.11.4." The isolator shall be provided with positive continuous control throughout the
entire cycle of operation. The operating pipes and rods shall be sufficiently
rigid to maintain positive control under the most adverse conditions and
when operated in tension or compression for isolator closing. They shall
also be capable of withstanding all torsional and bending stresses due to
operation of the isolator. The operating rods/pipes shall be provided with
suitable universal couplings to account for any angular misalignment.
2.11.5." All isolators and earth switches shall be provided with operating handles with
padlocking arrangements. All brackets, angles or other members necessary for
attaching the operating mechanism to the isolator supporting structure shall
be supplied as an integral part of the isolator. Corrosion free pins and bearings
of the bronze bush, ball or roller type shall be furnished.
2.11.6." Each rotating insulator stack shall be supported on double roller or ball
bearings. These shall be protected from moisture by means of cover and grease
retainers. The roller or ball bearing shall be adjustable and shall be easily
accessible for dismantling in the field. Bearings pressure shall be kept low to
ensure long life and ease of operation. Locking pins wherever used shall be
rustproof. Self lubricating type of bearings shall be preferable with life
equivalent to the main equipment.
2.11.7." The vertical operating shaft of requisite length shall be supported on ball or
roller thrust bearings. Guide bearings shall be provided on the vertical shaft at
intervals of not less than 1.2 mtrs.
2.11.8." The signaling of closed position shall not take place unless it is certain that the
movable contacts will reach a position in which rated normal current, peak
withstand current and short time withstand current can be carried safely.
Signaling of open position shall not take place unless movable contacts have
reached a position such that clearance between contacts is at least 80% of the
isolating distance.
2.11.9." Counter balance springs/weight shall be provided for counter balancing the
isolators to prevent impact at the end of travel both on opening and closing of
the isolator. The spring shall be made of non-rusting type alloy.
2.11.10."Auxiliary switches if installed on the frame of isolators & earth switches shall be
suitably protected against accidental arcing from the main Contacts.
2.11.11."The design shall be such as to provide maximum reliability under all service
conditions. All operating linkages carrying mechanical loads shall be designed
for negligible deflection. The length of inter insulator and Interpol operating
rods shall be capable of adjustments, by means of screw thread which can be

36
locked with a lock nut after an adjustment has been made. The isolator and
earth switches shall be provided with suitable device in the operating
mechanism to prevent accidental opening by wind, vibration, short circuit
forces or movement of the support structures.
2.12." TERMINALS, CONNECTORS AND EARTHING TERMINALS
2.12.1." The isolator-cum-earthing switches shall be provided with aluminum alloy
bimetallic clamp type terminal connectors suitable for SCA conductor or
aluminum tube for taking line and bus connections. The exact size of the
conductor will be intimated to the successful Contractor.
2.12.2." Each isolator-cum-earthing switch and control mechanism shall be provided
with at least two numbers of grounding terminals and clamps for receiving
ground connection.
2.13." INTERLOCKING
2.13.1." The earth switch shall be mechanically interlocked so that the earth switch can
be operated only when the isolator is opened.
2.13.2." In addition to the constructional interlock, isolator and earth switch shall have
provision to prevent their electrical and manual operation unless the other
interlocking conditions are met
2.13.3." Interlocks are required to be provided for:
i) to prevent opening of the isolators on load;

ii) to prevent closing of the earthing switch when the isolator is closed;
iii) to prevent closing of the line isolator when the earth switch is closed.
The earthing switch shall be operated only when the isolator and the circuit breaker at the
HV, MV & LV side(s) of the transformer are opened.
2.13.4." Provision shall also be made for interlocking isolators with circuit breakers so
that these are closed before the circuit breaker is closed and opened after
the circuit breaker is opened.
2.13.5." The electrical interlocking scheme shall operate on 400 V D.C. supply as
specified in the specification. It shall not be possible to operate the isolator
either manually or electrically when the 400 V DC core of the electro magnet is
not energized.
2.13.6." The details of interlocking system shall be furnished by the Contractor and
shall be subject to the purchaser's approval.
2.14." AUXILIARY SWITCHES:
2.14.1." Auxiliary switches (contacts) shall be provided for automatic indication of the
isolator and isolator-cum-earthing switch position, control, interlocking and
other supervisory purposes. They shall be mechanically actuated by the
operating mechanism of its associated isolator and isolator-cum-earthing
switch. Design, which permits the change of normally closed contact to a
normally open contact or vice versa with minimum modification would be
preferred.
2.14.2." Auxiliary switches shall be mounted in a weather-proof housing confirming to
IP55 which shall have provision for entry of conduits of proper sizes or for
fixing of cable glands.
2.14.3." The Contractor shall give details of arrangements provided for protecting the
auxiliary switches against accidental arcing from the main circuit.

37
2.14.4." CT leads of bus bar protection may be routed through auxiliary switches of bus
isolators. Auxiliary switches shall be suitable for this application, if required.
Necessary make-before-break contacts shall be incorporated for bus bar
protection.
2.14.5." The auxiliary switch shall be tested for following tests:
a) Electrical endurance test - A minimum of 2000 operations for 2A D.C. with a
time constant greater than or equal to 20 milliseconds with a subsequent
examination of MV drop/visual defects/temperature rise test.
b) Mechanical endurance test. A minimum of 1,00,000 operations with a
subsequent checking of contact pressure test/visual examination.
c) Heat run test on contacts.
d) IR/HV test etc.
2.15." PADLOCKS :
2.15.1." Padlocks or other locking devices shall be provided for locking the operating
handle of each isolator and earthing switch in the 'ON' or 'OFF' positions.
Padlock permanently fixed shall be preferable.
2.15.2." The locking arrangements shall be of approved designs and all locks shall be
provided with two ordinary, keys each. In addition, a master key shall also be
provided.
2.16." GALVANISATION
All ferrous parts of the isolators shall be hot-dip galvanized as per IS:2629-1969 (as
amended up-to-date) or any other equivalent authoritative standard (refer to Section -
Auxiliaries).
2.17." CONTROL WIRING, CONTROL CABINET & TERMINAL CONNECTORS
Control wiring, control cabinets and terminal connectors shall meet the requirements as
stipulated in Section - Auxiliaries.
2.18." NAME PLATE :
2.18.1." The name plate shall conform to the requirements of IS:9921.
2.18.2." The name plate shall be corrosion proof and shall be mounted in such a
position that it shall be visible in the position of normal service installation. It
shall carry the details duly engraved or punched on it.
Isolator :
Name of the Manufacturer
P.O.No.
Type designation
Manufacturer's serial number
Rated voltage
Rated normal current
Rated short time current(kA rms)
and duration in sec.
Rated short time peak current(kAp)
Weight
Motor Operating Mechanism:
Name of the Manufacturer
Type designation
Reduction gear ratio
A.C. Motor
(i) Rated auxiliary voltage
(ii) Starting current
(iii) Designation of A.C motor as per IS: 4722
(iv) Starting torque at 80% of supply voltage

38
(v) Over travel in degrees after cutting off supply

Total operating time in seconds
(i) Close operation - Electrical
- Manual
(ii) Open operation - Electrical
- Manual
Space Heater
Rated voltage and power
Auxiliary contacts
(i) Rated current (Amps)
(ii) Time constant (ms)
(iii) No. of contacts used (NC & NO)
(iv) No. of free contacts (NC & NO)
Terminal blocks & wiring
(i) Rated current
(ii) Voltage grade and type
2.19." CONTROL DEVICES “
2.19.1." Control device shall store OPEN and CLOSE command even if the
corresponding switch is momentarily pressed until the command is fully
executed and the components get de energized after execution. Failure of
auxiliary power supply or loose contact shall not cause faulty operation.
2.19.2." An out of step relay for the three poles in case of center break and double
break isolators with proper stop shall be supplied with each isolator to give
a remote discrepancy alarm.
2.20." CONTROL CIRCUIT:
The control circuit shall be so arranged that necessary inter locks with associated
breakers and earthing switches can be incorporated in it. In this regard the Contractor
shall fully co-ordinate with the supplier of the circuit breakers.
2.21." TANDEM PIPES FOR 245kV ISOLATORS
For 400 kV Isolators Tandem galvanized pipes shall be of at least 25 mm internal diameter
(ID) and class B. Base plate of insulators for connection of Tandem pipe shall be made out
of one piece 10mm. thick M.S. plate. Bolt and shackle device shall be used to connect
tandem pipe to the base plate.
2.22." DOWN PIPES
50 mm ID class B galvanized pipe shall be provided for operating the disconnect. The pipe
shall be terminated into a suitable swivel or universal type joint between the insulator
bottom bearing and the operating mechanism to take care of marginal angular
misalignment at site. All brackets, guides etc. shall be mounted on the base of the isolator.
Arrangement of mounting any guide, bracket, part etc. on support structure except the
operating mechanism and the base shall not be accepted.
2.23." COMPLETENESS OF THE OFFER
Equipment shall be offered complete with all parts and accessories which are useful
and necessary for its efficient economic and safe operation and proper connection. Such
parts and accessories shall be deemed to be within the scope of this specification whether
specifically mentioned herein or not, and the bid price quoted is deemed to have been
included all the above and inspection.

39
2.24." TESTS
2.24.1." The isolator-cum-earthing switches shall comply with all the type tests and shall
be subjected to all the routine tests as per IS:9921/IEC:60129.
2.24.2." The equipment/material offered against this tender should have been successfully
type tested in line with the specified standards and this Technical Specification.
These tests should have been conducted within a period of 5 years prior to the
date of opening of the Part-I “Pre-qualification and Technical Bid”, subject to no
alteration in the design. The Contractor shall furnish 4 copies of the Type test
reports with the offer. In case these type tests were carried out earlier to the five
years period mentioned above or some type tests were not carried out at all as per
the present specification, all the relevant type tests as per relevant standards shall
be carried out by the successful Contractor in the presence of Purchaser's
representative at the cost of the successful Contractor.
2.24.3." If there is any change in the components or design in the equipment since after
earlier passing of the Type Test, the Contractor shall bring out in his offer all such
changes made in the components, materials, designs, etc. In such case the
Contractor shall carry out the type tests at his cost and in presence of the
Purchaser's representative.
2.24.4." If the equipment/material does not withstand the type test, the
equipment/material supplied till then will be liable for rejection. The supplier, in
such an eventuality, shall be allowed to modify the equipment and type test the
same again at his cost in the presence of the Purchaser's representative. These
type tests shall however be conducted by the Supplier within a reasonable time.
After successful passing of the type tests, all the equipment/materials supplied
earlier shall be modified in line with the equipment/materials which has
successfully passed the type test. In case Supplier fails to carry out the type test
within reasonable time or does not agree to carry out the type test at his cost, his
equipment/material supplied earlier shall be rejected and order placed shall be
cancelled and payment made earlier for these Suppliers shall be recovered by the
Purchaser.
2.24.5." The type tests should have been either conducted in a recognized institution or
laboratory and should have been witnessed by a purchaser or an independent
agency. The name(s) of the institutions/Laboratories where the Contractor intends
to get type testes performed shall be indicated in the bid.
2.24.6." During type tests the isolator-cum-earthing switches shall be mounted on its own
support structure or equivalent support structure installed with its own operating
mechanism to make the type tests representative. Drawing of equivalent support
structure if any and mounting arrangements made for type tests shall be furnished
for Purchaser's approval
2.24.7." The type tests shall be conducted on the isolator-cum-earthing switches along with
approved insulators and terminal connectors.
2.24.8." Mechanical endurance test shall be conducted on the isolator as well as earth
switch of one isolator-cum-earthing switch of each type.
2.25." Additional type tests
i) Tests for measuring radio interference level as per IS:8263 and IEC:60437.
ii) Corona extinction voltage test only for 245 kV.
iii) Artificial pollution test (on insulators only) as per IEC: 60815..
iv) Seismic withstand test
The tests shall be performed with: Isolator open and earth switch closed, Isolator
open & earthing switch open and isolator closed & earthing switch opened.

40
2.26." All acceptance and routine tests as stipulated in the relevant standards shall be
carried out by the Supplier in presence of Purchaser's representative. The tests to be
conducted on Insulators shall also include
i) Bending load test in four directions at 50% of minimum bending load guaranteed
on all insulators as routine test.
ii) Bending load test in four directions at 100% of minimum bending load as a sample
test on each lot.
iii) Torsional test as on sample insulators of a lot
iv) Ultrasonic test as a routine test
2.27." Mechanical operation test (routine test) shall be conducted on the complete
assembled isolator-cum-earthing switch at Supplier's works and a certified test
report be furnished to the Purchaser. Alternatively the Contractor may offer to
conduct this test at Purchaser's substation. The Purchaser shall make necessary
arrangement to erect the isolator at his substation site under supervision of
Contractor's representatives (if necessary) in case this test is offered to be conducted
at site. Expenses of Contractor's representatives for supervision shall not be borne
by the Purchaser.
2.27.1." All identical parts shall fit correctly and operate satisfactorily in any set of isolator-
cum-earthing switch. The Supplier shall assemble the isolator-cum-earthing switch
after selection of identical parts from the lot offered for inspection by the inspector
and carry out the routine test satisfactorily.
2.27.2." Immediately after finalization of the program of type/ acceptance/additional tests,
the Supplier shall give three weeks' advance intimation to the Purchaser, to enable
him to depute his representative for witnessing the tests.
2.27.3." The Contractor shall furnish, for the isolator-cum-earthing switches being offered six
copies of reports of all routine tests for approval.
2.27.4." Record of Routine tests shall be made available to the purchaser for the review.
2.27.5." Tests on galvanized components shall be conducted according to IS:2633 or any
other equivalent authoritative standard.
2.28." SPECIAL TESTS
2.28.1." The following special tests shall be carried out in the presence of Purchaser's
representative.
LIST OF SPECIAL TESTS
__________________________________________________________________________
Sl.No. Name of the Test Standard to which it conforms
__________________________________________________________________________
1. Test for visible Corona * NEMA Pub.No.107-1964

and Radio interference voltage CISPR Pub.No.1-1972
(RIV) on isolators and terminal (for 245kV isolators)
connectors. IEC:60437
2. Tests on insulators IS:2544, IEC:60168

including those given in
Cl.19.5.1
3. Tests on terminal connectors IS:5561
4. Tests on galvanized components IS:2623

41
5. Tests on extra items Relevant
6. Stalled torque test on motor At 110% of supply voltage

operating mechanism
7. Operation test on operating As per relevant standards

mechanism, pole discrepancy,
motor protection etc.
8. Endurance test on auxiliary As per relevant standards

switches, limit switches,
contactors etc.
__________________________________________________________________________
* This test shall be conducted on a clean and new isolator and earthing switch. The
isolator and earthing switch shall be subjected to dry power frequency voltage.
The voltage shall be raised till visual corona appears on the equipment. The
voltage during the test need not be raised beyond 245 kV (rms) if the visual corona
does not appear. The voltage shall be brought down to 70 kV (rms) and raised
again to visual corona inception level. Such raising and lowering of the test voltage
shall be done a few times. Finally, the voltage may be raised till the visual corona
appears. The test voltage shall then be reduced to 245 kV (rms). Corona shall not
be visible on the equipment at this voltage. During the test the earthed objects in
the proximity of the equipment shall be kept beyond a distance of 3.5 meters. The
CORONA and RIV tests shall be conducted on the disconnects along with all types
of approved terminal connectors and insulators.
2.28.2." Test certificates and documents of the following items shall be furnished
at the time of routine tests:
a) Chemical analysis of copper along with a copy of excise certificate

indicating genuine source of procurement of electrolytic grade
copper.
b) Bearings
c) Fasteners
d) Universal/swivel joint coupling
e) Insulators
f) Motor
g) Gears
h) Auxiliary switch
i) Limit switch
j) Timer
k) Over load/single phase preventing relay
l) Interlocking devices
m) Terminal block
n) Terminal Clamps
The Purchaser may at his discretion, request additional test certificates for
other items as reasonably required to substantiate the quality of the same.

42
2.29." INSPECTION
The inspection may be carried out by the Purchaser at any stage of
manufacture. The successful Contractor shall grant free access to the Purchaser's
representative at a reasonable time when the work is in progress. Inspection and
acceptance of any equipment under this specification by the Purchaser, shall not
relieve the Supplier of his obligation of furnishing equipment in accordance with the
specification and shall not prevent subsequent rejection if the equipment is found to
be defective. The Supplier shall keep the Purchaser informed in advance, about the
manufacturing program so that arrangement can be made for inspection. The
Purchaser reserves the right to insist for witnessing the acceptance/routine testing of
the bought out items.
2.30." SITE TESTS
All routine tests including 50 operation test, except power frequency dry voltage withstand
test on isolator shall be repeated on completely assembled isolator of each type at site.
2.30.1." The Contractor shall indicate other tests recommended to be carried out
during installation and commissioning to ensure satisfactory performance
of all the equipment supplied. These tests shall be carried out by the
Contractor in case the order is placed on him along with those specified.
2.30.2." After erection at site, the contractor shall carryout the following tests to
demonstrate proper assembly and operation of the offered and erected
equipment:.
1. Closing and opening of isolators and earthing switches.
2. Measurement of resistance across the main contacts of isolators.
3. Measurement of resistance between the contacts of earthing switches.
4. Verification of proper functioning of interlocking scheme.
5. Verification of proper operation of auxiliary contacts and signaling.
6. Verification of ground connection.
7. Resistance of operating and interlock rods
2.31.1." The Contractor shall invariably furnish the information shall be separately given for
individual type of the isolator-cum-earthing switches.
2.31.2." The successful Contractor shall, submit following information to the Purchaser.
i). List of raw materials as well as bought out accessories, and the names of
Sub-Suppliers selected from the lists furnished with the offer.
ii). Type test certificates of the raw material and bought out accessories.
iii). Quality assurance plan (QAP) with purchaser’s hold points Purchaser's

43
hold points shall be discussed between the Purchaser and Supplier before the QAP is
finalized.
2.31.3." The successful Contractor shall submit the routine test certificates of bought out
accessories at the time of review of routine tests performed on the fully assembled
isolator-cum-earthing system.

44
SS03 CIRCUIT BREAKERS
3.0." GENERAL:
The Circuit Breakers and accessories shall conform to IEC: 62271-100,

IEC: 60694 and other relevant IEC standards except to the extent
explicitly modified in the specification
3.0.1" 245kV Circuit Breakers offered would be of Sulphur Hexafluoride (SF6)

type only and of class C1-M1 as per IEC and 12kV VCBs as per relevant
IS code.
3.0.2" The Circuit Breaker shall be complete with terminal connectors,

operating mechanism, control cabinets, piping, inter pole cable, cable
accessories like glands, terminal blocks, marking ferrules, lugs, pressure
gauges, density monitors (with graduated scale), galvanized support
structure for CB, their foundation bolts and all other circuit breaker
accessories required for carrying out all the functions the CB is required
to perform. All necessary parts to provide a complete and operable
Circuit Breaker installation such as main equipment, terminals, control
parts, connectors other devices whether specifically called for herein or
not shall be provided.
3.0.3" The support structure of circuit breaker as well as that of control cabinet
shall be hot dip galvanized. All other parts shall be painted as per shade
697 of IS-5.
3.1."DUTY REQUIREMENTS:
3.1.1." The circuit breaker shall be restrike free as per IEC under all duty conditions and
shall be capable of performing their duties without opening resistors.
3.1.2." The circuit breaker shall meet the duty requirements for any type of fault or
fault location also for line switching when used on a 245kV effectively
grounded system, and perform make and break operations as per the
stipulated duty cycles satisfactorily.
3.1.3." PRE INSERTION RESISTER
245 kV circuit breakers wherever specified shall be provided with single step
preinsertion closing resistors to limit the switching surges to a value of less than 2.3 p.u. The
value of the pre-insertion resistor and the duration of pre-insertion time shall be as given in this
section. The resistor shall have thermal rating for the following duties:
i) TERMINAL FAULT
Close………..1 Min……….Open………Close open 2 min…….. close ……….1

Min ……… open close open.

45
ii) RECLOSING AGAINST TRAPPED CHARGES
Duty same as under (i) above. The first, third and fourth closures are to
be on de energized line while second closing is to be made with lines
against trapped charge of 1.2 p.u of opposite polarity.
iii) OUT OF PHASE CLOSING
One closing operation under phase opposition that is with twice the
voltage across the terminals.
iv) No allowance shall be made for heat dissipation of resistor

during time interval between successive closing operations.
The resistors and resistor supports shall perform all these
duties without deterioration. Calculations and test reports of
resistors proving thermal rating for duties specified above shall
be furnished along with the bid. The calculations shall take
care of adverse tolerances on resistance values and time
settings.
v) The breaker shall be capable of interrupting the steady state
and transient magnetizing current corresponding of power
transformers.
3.1.4." The circuit breaker shall also be capable of:
i) Interrupting line/cable-charging current as per IEC without use of

opening resistors.
ii) Clearing short line fault (Kilometric faults) with source impedance
behind the bus equivalent to symmetrical fault current specified.
iii) Breaking 25% of the rated fault current at twice rated voltage
under phase opposition condition.
iv) The Breaker shall satisfactorily withstand the high stresses
imposed on them during fault clearing, load rejection and re-
energisation of lines with trapped charges. The breaker shall also
withstand the voltages specified in this Section.
3.2." TOTAL BREAK TIME :
3.2.1." The total break time as specified under this section shall not be exceeded
under any of the following duties :
i) Test duties 1,2,3,4,5 : (TRV as per IEC : 62271-100)

ii) Short line fault L75, L90 : (TRV as per IEC : 62271-100)
3.2.2." The Contractor may please note total break time of the breaker shall not
be exceeded under any duty conditions specified such as with the
combined variation of the trip coil voltage, (70-110%),
pneumatic/hydraulic pressure and arc extinguishing medium pressure
etc. While furnishing the proof of the total break time of complete

46
circuit breaker, the Contractors may specifically bring out the effect of
non-simultaneity between contacts within a pole or between poles and
show how it is covered in the guaranteed total break time. The values
guaranteed shall be supported with the type test reports.
3.3." CONSTRUCTIONAL FEATURES ;
The features and constructional details of circuit breakers shall be in

accordance with requirements stated hereunder :
3.3.1." Contacts:
3.3.1.1."The gap between the open contacts shall be such that it can
withstand at least the rated phase to ground voltage for 8 hours at
zero gauge pressure of SF6 gas due to the leakage. The breaker
should be able to withstand all dielectric stresses imposed on it in
open condition at lock out pressure continuously (i.e 2 p.u. across
the breaker continuously).
3.3.1.2."If multibreak interrupters are used, these shall be so designed and

augmented that a uniform voltage distribution is developed across
them. Calculations/test reports in support of the same shall be
furnished. The thermal and voltage withstand of the grading
elements shall be adequate for the service conditions and duty
specified.
3.3.1.3."The SF6 Circuit Breaker shall meet the following additional

requirements :
a) The circuit breaker shall be single pressure type. The design and
construction of the circuit breaker shall be such that there is a
minimum possibility of gas leakage and entry of moisture. There
should not be any condensation of SF6 gas on the internal insulating
surfaces of the circuit breaker.
b) All gasketted surfaces shall be smooth, straight and reinforced, if

necessary, to minimize distortion and to make a tight seal, the
operating rod connecting the operating mechanism to the arc
chamber (SF6 media) shall have adequate seals. The SF6 gas leakage
should not exceed 1 % per year. In case the leakage under the
specified conditions is found to be greater than 1 % after one year of
commissioning of circuit breaker, the manufacturer will have to
supply free of cost, the total gas requirement for subsequent ten (10)
years, based on actual leakage observed during first year of
operation after commissioning.

47
c) In the interrupter assembly there shall be an absorbing product

box to minimize the effect of SF6 decomposition products and moisture.
The material used in the construction of the circuit breakers shall be such
as fully compatible with SF6 gas decomposition products.
d) Each pole shall form an enclosure filled with SF6 gas independent
of two other poles, the SF6 density of each pole shall be monitored. A
suitable adopter for filling up the SF6 Gas shall be supplied per each Sub-
Station.
e) The dial type SF6 density monitor shall be adequately
temperature compensated to model the pressure changes due to
variation in ambient temperature within the body of circuit breaker as a
whole. The density monitor shall have graduated scale and shall meet the
following requirements :
i) It shall be possible to dismantle the density monitor for
checking / replacing without draining the SF6 gas by providing suitable
interlocked non return valve coupling.
f) Each Circuit Breaker shall be capable of withstanding a vacuum of
minimum 8 millibars without distortion or failure of any part.
g) Sufficient SF6 gas including that will be required for gas analysis
during filling shall be provided to fill all the circuit breakers installed. In
addition spare gas of 10 % of total gas requirement shall be supplied in
separate unused cylinders.
3.3.1.4." Provisions shall be made for attaching an operational analyzer

after installation of circuit breakers at site to record contact travel, speed
and making measurement of operating timings, preinsertion timings of
closing resisters if used, synchronization of contacts in one pole. In case
operation analyzer is already available at a particular site, the supplier shall
have to supply a suitable adopter / transducer so that the offered Circuit
Breaker can be used with the operational analyzer.
3.4." SULPHUR HEXAFLUORIDE GAS (SF6 GAS) AND INSULATORS :
a) The SF6 gas shall comply with IEC 376, 376A & 376B shall be
suitable in all respects for use in the Switchgear under the
operating conditions.
b) The high-pressure cylinders in which the SF6 gas is shipped and
stored at site shall comply with requirements of the relevant
standards and regulations.
3.4.1." INSULATORS:
a) The porcelain of the insulators shall conform to the requirements.
b) The mechanical characteristics of insulators shall match with the

requirements specified under this Chapter.

48
c) All insulators shall conform to IEC-61264 (for pressurized hollow

column insulators) and IEC-233 (for other). All routine and
sample tests shall be conducted on the hollow column insulators
as per these standards with requirements and procedures
modified as under and the test reports from the sub-vendor shall
be submitted.
i) Pressure test as a routine test.
ii) Bending load test as a routine test
iii) Bending load test as sample test on each lot
iv) Burst pressure test as a sample test on each lot
v) In addition to above, ultrasonic test shall be carried out as
additional routine test.
d) Hollow Porcelain for pressurized columns/ chambers should be in
one integral piece in green and fired stage.
3.5." OPERATING MECHANISM AND CONTROL
3.5.1." General Requirements: Circuit Breaker shall be operated by pneumatic
mechanism or spring charged mechanism or hydraulic mechanism or a
combination of these.
3.5.2." The operating mechanism shall be strong, rigid, not subject to rebound
and shall be readily accessible for maintenance for a man standing on
ground.
3.5.3." The mechanism shall be anti pumping and trip free (as per IEC definition)
under every method of closing.
3.5.4." The mechanism shall be such that the failure of any auxiliary spring will
not prevent tripping and will not cause trip or closing operation of the
power operating devices.
3.5.5." A mechanical indicator shall be provided to show open and close position
of the breaker. It shall be located in a position where it will be visible to
a man standing on the ground level with the mechanism housing closed.
An operation counter shall also be provided in the central control
cabinet.
3.5.6." Working parts of the mechanism shall be corrosion resisting material,
bearings which require grease shall be equipped with pressure type
grease fittings. Bearing pin, bolts nuts and other parts shall be
adequately pinned or locked to prevent loosening or changing
adjustment with repeated operation of the breaker.
3.5.7." The Contractor shall furnish detailed operation and maintenance
manual of the mechanism along with the operation manual for the
circuit breaker. The instruction manual shall contain exploded diagrams
with complete storage, handling, erection, commissioning,
troubleshooting, servicing and overhauling instruction.

49
3.6."CONTROL :
3.6.1." The close and trip circuits shall be designed to permit use of
momentary contact switches and push buttons.
3.6.2." 245 kV Circuit Breakers shall be provided with two (2) trip coils per
pole. Provision shall be made for supervision of each trip coil both
in open/closed condition of the breaker by wiring necessary NC/NO
contacts in series with trip coils. The trip circuit supervision relays
would be provided by the owner in the control/protection panels.
The trip coils shall be suitable for trip circuit supervision. Each trip
coil shall be designed to get DC supply from two different sources.
3.6.3." Each trip coil shall be connected to separate DC sources (trip coil-I
on DC source-I and trip coil-II on DC source-II) closing coil shall be
connected to one of the above two sources.
3.6.4." DC supply monitoring relays shall be provided for monitoring DC
source-I and DC source-II.
3.6.5." In the event of failure of any one DC source the other DC source
shall take over for DC supply to all pressure gauges and other
appliances of the breaker.
3.6.6." The circuit breakers when specified to have duplicated tripping
circuit shall have each tripping circuit and coil galvanically
separated. It shall be designed such that one of the tripping circuit
would be on the same circuit of the closing mechanism of the
breakers and is independent of the other tripping circuit.
3.6.7." The breaker shall have provision for supervision of tripping circuits
both in open and closed condition.\
3.6.8." The breaker shall normally be operated by remote electrical
control. Electrical tripping shall be performed by shunt trip coils.
However, provisions shall be made for local electrical control. For
this purpose a local / remote selector switch and close and trip
control switch / push buttons shall be provided in the Breaker
central control cabinet.
3.6.9." Closing coil and associated circuits shall operate correctly at all
values of voltage between 85% and 110% of the rated voltage.
Shunt trip coil and associated circuits shall operate correctly under
all operating conditions of the circuit breaker upto the rated
breaking capacity of the circuit breaker and at all values of supply
voltage between 70% and 110% of rated voltage. However, even at
50% of rated voltage the breaker shall be able to operate. If
additional elements are introduced in the trip coil circuit their
successful operation and reliability for similar applications on
outdoor circuit breakers shall be clearly brought out in the
additional information schedules.
3.6.10."Density Meter contacts and pressure switch contact shall be
suitable for direct use as permissive in closing and tripping circuits.
Separate contacts have to be used for each of tripping and closing
circuits. If contacts are not suitably rated and multiplying relays are

50
used then fail safe logic / schemes are to be employed. DC supplies

for all auxiliary circuits shall be monitored and provision shall be
made for remote annunciations and operation lockout in case of
D.C. failures. Density monitors are to be so mounted that the
contacts do not change on vibration during operation of circuit
breaker.
3.6.11."The auxiliary switch of the breaker shall be positively driven by the
breaker-operating rod.
3.6.12."Pneumatically operated mechanism :
a) Each pneumatic operated breaker shall be equipped with
compressed air system as indicated in this section.
b) The breaker local air receivers shall comply with the requirements
indicated in this section and shall have sufficient capacity for at
least two CO operations of the breaker at the lowest pressure of
auto reclosing duty without refilling.
c) Independently adjustable pressure switches with potential free,
ungrounded contacts to actuate a lock out device shall be
provided. This lockout device with provision of remote alarm
indication shall be incorporated in the circuit breaker to prevent
operation whenever the pressure of the operating mechanism is
below that required for satisfactory operation of the circuit
breaker. The scheme should permit operation of all blocking and
alarm relays as soon as the pressure transient present during the
rapid pressure drop has been damped and a reliable pressure
measurement can be made. Such facilities shall be provided for
following conditions :
i) Trip lockout pressure : 2 Nos.
ii) Close lockout pressure : 1 No.
iii) Auto reclose lockout pressure : 1 No.
iv) Extreme low pressure : 1 No.
d) The compressed air mechanism shall be capable of operating the
circuit breaker under all duty conditions with the air pressure
immediately before operation between 85% and 110% of the
rated supply pressure. The make /break time at this supply
pressure shall not exceed the specified make / break time within
any value of trip coil supply voltage as specified.
e) The compressed air piping shall comply to requirements indicated
in this section.
3.7."Spring operated mechanism :
a) Spring operated mechanism shall be complete with motor in
accordance with Section-GTR. Opening spring and closing spring
with limit switch for automatic charging and other necessary
accessories to make the mechanism a complete operating unit
shall also be provided.
b) As long as power is available to the motor, a continuous sequence
of the closing and opening operations shall be possible. The
motor shall have adequate thermal rating for this duty.

51
c) After failure of power supply to the motor one close open operation shall
be possible with the energy contained in the operating mechanism
d) Breaker operation shall be independent of the motor which shall be
used solely for compressing the closing spring. Facility for manual
charging of the closing spring shall also be provided. The motor rating
shall be such that it requires not more than 30 seconds for full charging
of the closing spring.
e) Closing action of circuit breakers shall compress the opening spring
ready for tripping.
f) When closing springs are discharged after closing a breaker, closing
springs shall be automatically charged for the next operation and an
indication of this shall be provided in the local and remote control
cabinet.
g) Provisions shall be made to prevent a closing operation of the breaker
when the spring is in the partial charged condition. Mechanical
interlocks shall be provided in the operating mechanism to prevent
discharging of closing springs when the breaker is already in the closed
position.
h) The spring operating mechanism shall have adequate energy stored in
the operating spring to close and latch the circuit breaker against the
rated making current and also to provide the required energy for the
tripping mechanism in case the tripping energy is derived from the
operating mechanism.
3.8." Hydraulically operated mechanism :
a) Hydraulically operated mechanism shall comprise of operating unit with
power cylinder, control valves, high and low pressure reservoir, motor
one number hand pump set shall also be provided for emergency
operation of the circuit breaker etc. Electrically driven motor shall
comply to Section -GTR.
b) The hydraulic oil used shall be fully compatible for the specified
temperature range.
c) The oil pressure switch controlling the oil pump and pressure in the
high pressure reservoir shall have adequate number of spare contacts
to be used for continuous monitoring of low pressure, high pressure
etc.
d) The mechanism shall be suitable for at least two close open
operations after failure of AC supply to the motor starting at pressure
equal to the lowest pressure of auto reclose duty plus pressure drop
for one close open operation.
e) The mechanism shall be capable of operating the circuit breaker
correctly and performing the duty cycle specified under all conditions
with the pressure of hydraulic operated fluid in the operating
mechanism at the lowest permissible pressure before make up. The
opening time at the lowest pressure for a particular operation shall
not exceed the guaranteed operating time within any value of trip coil
supply voltage as specified.

52
f) Trip lockout shall be provided to prevent operations of the circuit

breaker below the minimum specified hydraulic pressure. Alarm
contacts for loss of Nitrogen shall be provided.
g) All hydraulic joints shall have no oil leakage under the site
conditions and joints shall be tested at factory against oil leakage
at a minimum of 1.5 times maximum working pressure.
3.9."SUPPORT STRUCTURE:
a) The structure design shall be such that during operation of circuit
breaker vibrations are reduced to minimum.
b) If required, the Contractor shall provide suitable platform with
steps on both sides of the circuit breaker for easy accessibility of
the structure mounted operating mechanism box for monitoring
the density / pressure of gas.
3.10." TERMINAL CONNECTOR PAD:
The circuit breaker terminal pads shall be made up of high quality
electrolytic copper or aluminum. The terminal pad shall have
protective covers which shall be removed before interconnections.
3.11." INTERPOLE CABLING :
3.11.1" All cables to be used by contractor shall be armored and shall be
as per IS-1554 (1100 Volts Grade). All cables within & between
circuit breaker poles shall be supplied by the Circuit Breaker
manufacturer.
3.11.2" Only stranded conductor shall be used. Minimum size of the
conductor shall be 2.5 sq.mm. (Copper).
3.11.3" The cables shall be with oxygen index Min-29 and temp. index as
250 degree Celsius as per relevant standards.
3.12." FITTINGS AND ACCESSORIES:
3.12.1."Following is a partial list of some of the major fittings and
accessories to be furnished by Contractor in the Central
Control cabinet. Number and exact location of these parts
shall be indicated in the bid.
i)Cable glands (Double compression type), Lugs, Ferrules etc.
ii) Local/remote changeover switch
iii) Operation counter
iv) Pneumatic/hydraulic pressure gauges
v) Control switches to cut off control power supply
vi) Fuses as required
vii) The number of terminals provided shall be adequate enough to
wire out all contacts and control circuits plus 24 terminals spare
for future use.
viii) Anti pumping relay
ix) Pole discrepancy relay
x) D.C Supervision relays
xi) Rating and diagram plate in accordance with IEC incorporating
year of manufacture.
3.12.2." Additional fittings for pneumatically operated circuit breaker

53
a) Unit compressed air system

b) Breaker air receivers
c) Pressure gauge, spring loaded safety valve and pressure switch
with adjustable contacts.
d) Pressure switch to initiate an alarm if the pressure in the auxiliary
reservoir remains below a preset level for longer than it is
normally necessary to refill the reservoir
e) Stop, non-return and other control valves, pilings and all
accessories up to breaker mechanism housing.
3.13." ADDITIONAL DATA TO BE FURNISHED
a) Drawing, showing contacts in close, arc initiation, full arcing, arc
extinction and open position.
b) The temperature v/s pressure curves for each setting of density
monitor along with details of density monitor.
c) Method of checking the healthiness of voltage distribution
devices (condensers) provided across the breaks at site.
d) Data on capabilities of circuit breakers in terms of time and
number of operations at duties ranging from 100% fault currents
to load currents of the lowest possible value without requiring
any maintenance or checks.
e) The effect of non-simultaneity between contacts between poles
and also show how it is covered in the guaranteed total break
time.
f) Sectional view of non-return couplings if used for SF6 pipes.
g) Details & type of filters used in interrupter assembly and also the
operating experience with such filters.
h) Details of SF6 gas :
i) The test methods used in controlling the quality of gas used in
the circuit breakers particularly purity and moisture content.
ii) Proposed tests to assess the conditions of the SF6 within a
circuit breaker after a period of service particularly with
regard to moisture contents of the gas.
iii) The precise procedure to be adopted by maintenance
personnel for handling equipment who are exposed to the
products of arcing in SF6 gas so as to ensure that they are not
affected by possible irritants of the skin and respiratory
system. Recommendations shall be submitted for suitable
protective clothing, methods of disposal of circuit breaker
cleaning utensils and other relevant matters.
i) The Contractors shall furnish along with the bid, curves supported
by test data indicating the opening time under close open
operation with combined variation of trip coil voltage and
pneumatic / hydraulic pressure.
j) Detailed literature and schematic diagrams of switching
mechanism for closing resistor showing the duration of insertion
shall also be furnished along with the calculations in respect of
thermal rating of resistors for the duties.

54
k) All duty requirements as applicable to 420kV & 245kV CBs with

the support of adequate test reports to be furnished.
l) Field test report or laboratory test report in case of CB meant for
reactor switching duty.
3.14." TESTS :In accordance with the requirements stipulated under
Section-GTR the circuit breaker along with its operating mechanism
should have been successfully type tested as per IEC: 62271-
100/IEC- 60694.
3.14.1." The test reports of the type tests and the following additional type
tests as per relevant IEC/IS shall also be submitted for Purchaser’s
review along with the tender.
i) Corona extinction voltage test.
ii) Out of phase closing test.
iii) Line charging breaking current for proving the specified
parameters in IS codes.
iv) Test to demonstrate the Power Frequency withstand capability of
breaker in open condition at zero Gauge pressure and at lockout
pressure.
v) Seismic withstand in unpressurised condition.
vi) Verification of the degree of protection
vii) Low & high temperature test
viii) Humidity test
ix) Static Terminal Load test
x) Critical Currents test (if applicable)
xi) Switching of Shunt Reactors.
3.14.2."Routine Tests: Routine tests as per IEC: 62271-100 shall be performed on
all circuit breakers. In addition to the mechanical and electrical tests
specified by IEC, the following tests shall also be performed.
1) Speed curves for each breaker shall be obtained with the help of
a suitable operation analyzer to determine the breaker contact
movement during opening, closing, auto-reclosing and trip free
operation under normal as well as limiting operating conditions
(control voltage, pneumatic/hydraulic pressure etc). The tests
shall show the speed of contacts directly at various stages of
operation, travel of contacts, opening time, closing time, shortest
time between separation and meeting of contacts at break make
operation etc. This test shall also be performed at site for which
the necessary operation analyzer along with necessary
transducers, cables, console, etc. where included in scope of
supply shall be furnished and utilized. In case of Sub-Station
where operational analyzer is existing the Contractor shall utilize
the same. However necessary adopter and transducer etc if
required shall have to be supplied by the Contractor.
2) Measurement of Dynamic Contact resistance measurement for
arcing & main contacts. These Dynamic contact resistance
measurements shall be taken as reference for comparing the

55
same during operation and maintenance in order to ascertain the

healthiness of contacts.
3.14.3." Site Tests :
All routine tests except power frequency voltage dry withstand
test on main circuit breaker shall be repeated on the completely
assembled breaker at site.
3.15." UNIT COMPRESSED AIR SYSTEM FOR CIRCUIT BREAKERS:
The unit compressed air system shall meet the following
requirements:
a) The compressed air system shall be provided with necessary
piping, piping accessories, control valves, safety valves, filters,
reducing valves, isolating valves, drain ports, etc. Also the Unit
compressed air system shall be provided with suitable anti
vibration pads.
b) The compressors or pumps shall be of the air cooled type and
mounted within the operating mechanism housing or a separate
weather-proof and dust-proof housing.
c) The air receiver shall have stored energy for 2 CO operations of
the breaker at the blocking pressure for auto reclosing duty
without refilling. The unit compressor shall be capable of building
up required pressure for another 2 CO operations with 30
minutes.
d) The size of the compressor shall be determined by the
Contractor. The compressor shall be of sufficient capacity for
performing all the operations above mentioned.
3.15.1."Air Compressor :
a) The air compressor shall be of air-cooled type complete with
cylinder lubrication, drive motor etc. The compressor shall be
rated for the following duty:
i) Total running time of Not exceeding
80minutes
compressor to build up
the rated pressure from
atmospheric pressure
ii) Normal running air charging Not exceeding 15min
considering 10% leakage/day.
iii) Air charging time after one
close-open operation from rated Not exceeding 15min
pressure.
b) Compressor shall be driven by automatically controlled motors
conforming to requirements of Section - GTR.
c) The compressor shall be provided with automatic adjustable
unloading device during starting.
d) The compressor shall be equipped with a Time totaliser and a
Pressure gauge.

56
3.15.2." Intercooler and After cooler : (If applicable)

Intercooler between compressor stage and after cooler at
discharge if any of H.P. cylinder shall be included in Contractor’s
scope. They shall be of air cooled type and shall be designed as
per ASME Code of IEMA Standards. The design pressure on the air
side of cooler shall be 1.25 times the working pressure. A
corrosion allowance of 3 mm shall be included for all steel parts.
3.15.3."Air Receivers:
a) Air receiver shall be designed in accordance with the latest
edition of the ASME Code for Pressure Vessel – Section VIII of BS :
5179. A corrosion allowance of 3.0 mm shall be provided for shell
and dished ends.
Receivers shall be coated on the inside face with antirust medium
if it is not hot dip galvanised.
b) Connections for air inlet and outlet, drain and relief valves shall
be flanged type or screwed type. Pressure gauge and pressure
switch connections shall be screwed type only.
c) Accessories such as suitable sized safety valve to relieve full
compressor discharge at a set pressure equal to 1.1 times the
maximum operating pressure, blow off valve, auto drain tap with
isolating and by pass valve, dial type pressure gauge with isolating
and drain valve and test connection shall be provided.
d) Air receiver shall be offered with at least 50% spare capacity,
calculated on the basis of total air requirement for 2 CO
operations.
3.15.4."Quality of Air :
Compressed air used shall be dry and free of dust
particles and fully compatible with the materials used in the
pneumatic operating mechanism. Arrangement for conditioning the
compressed air if required shall be provided as an integral part of air
compressor system.
3.16." Control and Control Equipment :
a) The compressor control shall be of automatic start/stop type
initiated by pressure switches.
b) Incoming supply of 415V, AC shall be provided by the Employer at
switchyard bay marshalling box from where the Contractor shall
take the feed to the operating mechanism.
c) All the necessary compressor control equipment shall be housed
in a totally enclosed sheet steel cabinet. Pressure gauges and
other indicating devices, control switches shall be mounted on
the control cabinet.
d) A glass widow shall be provided for viewing the indicating
instrument/gauges. The max. height shall be 2000mm.

57
3.17." Compressed Air Piping, Valves and Fittings :

a) The flow capacity of all valves shall be at least 20% greater than
the total compressor capacity.
b) The high pressure pipe and air system shall be such that after one
O-0.3 sec CO-operation the breaker shall be capable of
performing one CO operation within 3 minutes.
c) All compressed air piping shall be bright annealed, seamless
phosphorous Deoxidized Non-Arsenical Copper alloy as per BS :
2874 or stainless steel pipe (C –106 of BS : 2871-1957)
d) All joints and connections in the piping system shall be brazed or
flared as necessary.
e) All compressed air piping shall be carried out in accordance with
BS : 162.
f) Compressed air piping system shall be complete with Saddle
clamps to support the piping system at suitable intervals.
Necessary bolts, nuts, pipe fixing clamps etc shall be included in
the scope of Contractor.
3.18." Tests :
In accordance with the requirements stipulated under
relevant IS/IEC codes, the compressors and its accessories shall
conform to the type tests and shall be subjected to routine tests as
per applicable standards.
3.19." 12 kV Vacuum circuit breakers specifications and testing as per
relevant IS codes. All speciation’s shall be approved by Engineer-In-Charge.

58
SS04 INSTRUMENT TRANSFORMERS

4.0." GENERAL :
4.0.1." The instrument transformers and accessories shall conform to the latest version of
the standards specified below except to the extent explicitly modified in the
specification and shall be in accordance with the requirements in Section-General
Technical Requirement.
Current t transformers IEC : 44-1 / IS: 2705
Voltage transformers IEC : 186/358 / IS:3156)
4.0.2." The instrument transformers shall be complete with its terminal box and a
common marshalling box for a set of 3 instrument transformers.
4.0.3." The instrument transformer tank along with top metallic’s shall be invariably hot
dip galvanized .
4.0.4." The impregnation details along with tests/checks to ensure successful completion
of impregnation cycle shall be furnished for approval.
4.0.5." Qualifying Requirements
i) The manufacturers whose instrument transformers are offered should
have Designed, manufactured, supplied , tested as per IEC/IS or
equivalent standard and commissioned the following equipment.
a) 10 nos. 400 kV Current Transformers
b) 10 nos. 400 kV Capacitor Voltage Transformers
c) 10 nos. 400 kV Voltage Transformers
5 Nos. of each of the above equipment shall be in satisfactory
operation for at least 2 years as on the date of bid opening.
(OR)
ii) The 400 kV class Instrument Transformers being offered are from
manufacturer (s) who have established production line in India for
these equipments, based on technological support of a parent
company or collaborator for the Instrument Transformer (s) can also be
considered provided
a) Such manufacturer (s) has designed, manufactured, type tested
and supplied the 400kVor above class Instrument Transformers.
b) The parent company (Principals) or collaborator meets
qualifying requirements stipulated under above clause
mentioned above
c) A legally enforceable undertaking (jointly with the parent
company or collaborator) to guarantee quality, timely supply,
performance and warranty obligations as specified for the
equipment(s); and
d) A confirmation letter from the parent company or collaborator
along with the bid stating that parent company or collaborator
shall furnish performance guarantee for an amount of 10 % of
the cost of such equipment(s). This performance guarantee
shall be in addition to Contract Performance Guarantee to be
submitted by the Contractor.
4.1." CONSTRUCTION FEATURES :
The features and constructional details of instrument transformers shall be in
accordance with requirements stipulated here under:

59
4.1.1." Bushing / Insulators:

a) Instrument transformers shall be of 245 kV class, oil filled/SF6 Gas filled
with shredded porcelain/composite bushings / Insulators suitable for
outdoor service and upright mounting on steel structures.
b) Bushings/Insulators shall conform to requirements stipulated in
Section- General Technical Requirement. The bushing/insulator for CT
shall be one piece without any metallic flange joint.
c) Bushings shall be provided with oil filling and drain plugs, oil sight glass
of CT and for electromagnetic unit of CVT, etc. The bushing/insulator of
instrument transformer shall have a cantilever strength of not less than
500 kg and 350kg for 245 kV Instrument transformers respectively. Oil
filling and drain plugs are not required for SF6 gas filled CT.
d) Instrument transformers shall be hermetically sealed units.
Contractor/Manufacturer shall furnish details of the arrangements
made for the sealing of instrument transformers along with the bid.
Contractor/Manufacturer shall also furnish the details of site tests to
check the effectiveness of hermetic sealing for approval.
e) Polarity marks shall indelibly be marked on each instrument
transformer and at the lead terminals at the associated terminal block.
4.1.2." Terminal box / Marshalling box :

Terminal box shall conform to the requirements.
4.1.3." Insulating Oil /Gas
Insulating oil to be used for instrument transformers shall be of EHV grade
and shall conform to IS : 335.
The SF6 gas shall comply with IEC-60376,60376A& 60376B and shall be
suitable for use in the switchgear under operating condition.
4.1.4." Name Plate :
Name plate shall conform to the requirements of IEC incorporating the year of
manufacture. The rated current, extended current rating in case of current
transformers and rated voltage, voltage factor in case of voltage Transformers
shall be clearly indicated on the name plate. The rated thermal current in case
of CT shall also be marked on the name plate. The intermediate voltage in case
of capacitor voltage transformer shall be indicated on the name plate.
4.2." CURRENT TRANSFORMERS :
a) Current transformers shall have single primary either ring type, or hair pin type
and suitably designed for bringing out the secondary terminals in a weather
proof (IP 55) terminal box at the bottom. These secondary terminals shall be
terminated to stud type non disconnecting terminal blocks inside the terminal
box. In case “Bar primary” inverted type current transformers are offered the
manufacturer will meet following additional requirements :
(i) The secondaries shall be totally encased in metallic shielding
providing a uniform equipotential surface for even electric field
distribution.
(ii) The lowest part of the insulation assembly shall be properly
secured to avoid any risk of damage due to transportation
stresses.
(iii) The upper part of insulation assembly resting on primary bar
shall be properly secured to avoid any damage during
transportation due to relative movement between insulation
assembly & top dome.

60
(iv) Nitrogen if used for hermetic sealing (in case of live tank
design) should not come in direct contact with oil.
(v) Contractor/Manufacturer shall recommend whether any
special storage facility is required for spare CT.
b) Different ratios specified shall be achieved by secondary taps only and primary
reconnection shall not be accepted.
c) Core lamination shall be of cold rolled grain oriented silicon steel or other
equivalent alloys. The cores used for protection shall produce undistorted
secondary current under transient conditions at all ratios with specified CT
parameters.
d) The expansion chamber at the top of the porcelain insulators should be suitable
for expansion of oil.
e) Facilities shall be provided at terminal blocks in the marshalling box for star
delta formation, short circuiting and grounding of CT secondary terminals.
f) Current transformer’s guaranteed burdens and accuracy class are to be
intended as simultaneous for all cores.
g) For 245 kV class CTs, the rated extended primary current of the CTs
shall be 120% of rated primary on all tap ratio. However, at 2000/1,
ratio the CT shall be thermally rated for 200% for 15 minutes and 120%
continuous
h) For 245kV current transformer, characteristics shall be such as to
provide satisfactory performance of burdens ranging from 25% to 100%
of rated burden over a range of 10% to 100% of rated current in case of
metering CTs and up to the accuracy limit factor / knee point voltage in
case of relaying CTs.
i) The current transformer shall be suitable for horizontal transportation.
It shall be ensured that the CT is able to withstand all the stresses
imposed on it while transporting and there shall be no damage in
transit. The contractor shall submit the details of packing design to the
purchaser for review.
j) For 245 kV CTs the instrument security factor at all ratios shall be less
than five (5) for metering core. If any auxiliary CTs/reactor are used in
the current transformers then all parameters specified shall have to be
met treating auxiliary CTs as an integral part of the current transformer.
The auxiliary CTs/reactor shall preferably be inbuilt construction of the
CTs. In case these are to be mounted separately these shall be
mounted in the central marshalling box suitably wired up to the
terminal blocks.
k) The wiring diagram plate for the interconnections of the three single
phase CTs shall be provided inside the marshalling box.
l) The current transformer should be suitable for mounting on lattice
support structure in accordance with stipulations of Section- General
Technical Requirement. The required mounting bolts shall be supplied
with the Instrument Transformer.
m) The CT shall be designed as to achieve the minimum risks of explosion
in service. Contractor/Manufacturer shall bring out in his offer, the
measures taken to achieve this.
n) 420/245 kV current transformers shall be suitable for high speed auto

reclosing.

61
4.3." VOLTAGE TRANSFORMERS :

4.3.1." Capacitor Voltage Transformers:
a) 245kV Voltage transformers shall be capacitor voltage divider type with

electromagnetic units and shall be suitable for carrier coupling.
b) Voltage transformers secondaries shall be protected by HRC cartridge
type fuses for all the windings. In addition fuses shall be provided for
the protection and metering windings for fuse monitoring scheme. The
secondary terminals of the CVTs shall be terminated to the stud type
non-disconnecting terminal blocks in the individual phase secondary
boxes via the fuse.
c) CVTs shall be suitable for high frequency (HF) coupling required for
power line carrier communication. Carrier signal must be prevented
from flowing into potential transformer (EMU) circuit by means of a RF
choke/reactor suitable for effectively blocking the carrier signals over
the entire carrier frequency range i.e. 40 to 500 KHz. Details of the
arrangement shall be furnished along with the bid. H.F terminal of the
CVT shall be brought out through a suitable bushing and shall be easily
accessible for connection to the coupling filters of the carrier
communication equipment, when utilized. Further earthing link with
fastener to be provided for HF terminal.
d) The electromagnetic unit comprising compensating reactor,
intermediate transformer and protective and damping devices should
have separate terminal box with all the secondary terminals brought
out.
e) The damping device which should be permanently connected to one of
the secondary windings, should be capable of suppressing the
ferroresonance oscillations.
f) The accuracy of 0.2 on secondary III should be maintained throughout
the entire burden range up to 100 VA for 245 kV CVTs on all the
windings without any adjustments during operation.
g) 245 kV CVTs shall be suitable for mounting on tubular GI pipe in
accordance with stipulations of Section – General Technical
Requirement.
h) It should be ensured that access to secondary terminals is without any
danger of access to high voltage circuit.
i) A protective surge arrester shall be provided to prevent breakdown of
insulation by incoming surges and to limit abnormal rise of terminal
voltage of shunt capacitor / primary winding, tuning reactor /RF choke
etc. due to short circuit in transformer secondaries. In case of an
alternate arrangement, Contractor shall bring out the details in the bid.
j) The wiring diagram for the interconnection of the three single phase
CVTs shall be provided inside the marshalling box in such a manner that
it does not deteriorate with time.
4.3.2." Voltage Transformers: (Applicable for LT Side)
a) The Voltage transformer shall be of electromagnetic type single phase,
50Hz, oil-immersed and self cooled suitable for outdoor use in the
specified climatic conditions without protection from wind rain and
dust. The voltage transformers shall be complete in all respects and
shall conform to the latest practice of design and manufacture.

62
b) The core shall be made of non-ageing, cold rolled, laminated electrical

grade silicon steel of low hysterics loss and high permeability to ensure
high accuracy both under normal as well as over voltage conditions.
c) The voltage transformers shall be sealed to eliminate breathing and
prevent air and moisture from entering the tank. The voltage
transformer shall be provided with oil level gauge readable from
ground level and pressure relieving devices capable of releasing
abnormal internal pressure, without damage to the metal or porcelain
housings. Particulars of gas above the oil level and the means of
separation of gas from oil shall be indicated in the bid.
d) The Primary of the voltage transformer shall be connected phase to
neutral which shall be solidly grounded. The neutral of the system is
also solidly grounded.
e) All voltage transformers shall be provided with three separate
secondary windings. One winding shall be used for metering, the
second and third windings for protection. The class of accuracy and
rated burden of voltage transformers shall be as specified in this
section.
f) The voltage transformers shall withstand satisfactorily the dielectric
tests corresponding to basic insulation level specified in this section.
g) The voltage transformer shall be suitable for mounting on lattice type
steel structures. The necessary flanges, bolts etc. for base of voltage
transformers shall be supplied and these shall be galvanized. The data
regarding minimum clearance in relation to the adjacent metallic
grounded structure shall be stated in the tender.
h) Voltage transformers shall be provided with non-cutting and non-
corroding nameplates legibly and indelibly marked and securely
attached to the equipment in accordance with the applicable standard.
i) Before dispatch from manufacturer’s works, all components and fittings
shall be match marked.
j) Each voltage transformers shall comply with the type tests and
subjected to routine tests as specified in IS/IEC.
4.4." TESTS :
4.4.1." Current and Voltage Transformers should have been type tested and shall be
subjected to routine tests in accordance with IEC : 44-1/IS:2705 and IEC :
186/IS:3156 respectively.
4.4.2." The test reports of the type tests and the following additional type tests shall also
be submitted for the Purchaser’s review.
a) Current Transformers :
i) Radio interference test
ii) Seismic withstand test
iii) Thermal stability test, i.e. application of rated voltage and rated
extended thermal current simultaneously by synthetic test
circuit.
iv) Thermal co-efficient test i.e. measurement of tan delta as a
function of temperature (at ambient and between 80 degree
Celsius & 90 degree Celsius) and voltage (at 0.3, 0.7,1 .0 and
1.1 Um/ root3)

63
v) The current transformer shall be subjected to Fast Transient

test by any one of the following two methods given below to
assess the CT performance in service to withstand the high
frequency over voltage generated due to closing & opening
operation of isolators. Alternatively, method as per IEC
Oil sample shall be taken before and 3 days after the test and CT shall be
deemed to have passed the test if the increase in gas content before and after test is
not appreciable.
b) Voltage transformers:
i) High frequency capacitance and equivalent series resistance
measurement (as per IEC- 358)
ii) Seismic withstand test
iii) Stray capacitance and stray conductance measurement of the low
voltage terminal (as per IEC-358)
iv) Determination of temperature coefficient test (as per IEC – 358)
v) Radio interference test
vi) The Ferro-resonance type test shall be carried out on the complete
CVT.
vii) Natural Frequency of Capacitor unit, determination of Resonant
Frequency of Capacitor unit.
4.4.3." The current and voltage transformer shall be subjected to the following routine
tests in addition to routine tests as per IEC / IS.
a)" CURRENT TRANSFORMERS :
ROUTINE TESTS :
i) Measurement of Capacitance
ii) High voltage power frequency withstand test on Secondary Winding
iii) Over-voltage inter turn test (as per BS : 3938)
iv) Oil leakage test
v) Measurement of tan delta at 0.3, 0.7, 1.0and 1.1 UM/_3(as per IEC44-1)
vi) Measurement of partial discharge shall be carried out as per IEC 44-1
b) VOLTAGE TRANSFORMERS :
i) Capacitance and loss angle measurement before and after voltage test
(as per IEC : 358)
ii) Partial discharge test on capacitor dividers (as per IEC – 358).
iii) Sealing test (as per IEC- 358)
4.5." TESTING & COMMISSIONING

4.5.1." Current Transformers
(a) Insulation Resistance Test for primary and secondary.

(b) Polarity test
(c) Ratio identification test – checking of all ratios on all cores by primary
injection of current
(d) Dielectric test of oil (wherever applicable)
(e) Magnetizing characteristics test.
(f) Tan delta and capacitance measurement
(g) Secondary winding resistance measurement

64
4.5.2." Voltage Transformers / Capacitive Voltage Transformers
(a) Insulation Resistance test for primary (if applicable) and secondary
winding.
(b) Polarity test
(c) Ratio test
(d) Dielectric test of oil (wherever applicable).
(e) Tan delta and capacitance measurement between
i) HV – HF point
ii) HF Point – Ground Point of Intermediate Transformer
iii) HV- Ground Point of Intermediate Transformer primary winding
(f) Secondary winding resistance measurement.
4.6." REQUIREMENTS FOR 245kV CTs OF RATIO 1200 -800/1-1-1-1-1A,
Maximum
C.T Maximum
No. Output Minimum secondary exciting
Core Accuracy
of Application Current ratio burden knee point winding current in
No. class
cores (VA) voltage resistance mA at knee
(ohms) at point voltage
75 deg. C
1200 volt
30 on 1200/1
at 1200/1
Tap,
5 1 Bus diff 1200-800/1 --- PS ratio 6/4
45 on 800/1
800 volt at
Tap
800/1 ratio
1200 volt
30 on 1200/1
at 1200/1
Tap,
2 Bus diff 1200-800/1 --- PS ratio 6/4
45 on 1200/1
800 volt at
Tap
800/1 ratio
3 Metering 1200-800/1 20 VA 0.2 --- --- ---

1200 volt
Trans Back 30 on 1200/1
at 1200/1
up/Line Tap,
4 1200-800/1 --- PS ratio 6/4
protection 45 on 800/1
800 volt at
Main-II Tap
800/1 ratio
Trans Diff. 1200 volt
30 on 1200/1
protection at 1200/1
1200- Tap,
5 /Line --- PS ratio 6/4
800/1 45 on 800/1
protection 800 volt at
Tap
Main-I 800/1 ratio
Note:
1. All relaying CTs shall be of accuracy class (PS) as per IS: 2705
The Instrument security factor for metering core shall be less than five (5) at all ratios.
The CT ratios shall be achieved through secondary tapings only without any primary reconnection.

65
REQUIREMENTS FOR 245kV CTs OF RATIO 1200-800/1-1: 2000/1-1-1 A

Maximum C.T
Maximum
Minimum secondary
No. Output exciting
Current Accuracy knee winding
of Core No. Application burden current in
ratio class point resistance
cores (VA) mA at knee
voltage (ohms) at 75
point voltage
deg. C
1200 volt
at 1200/1 30 on 1200/1
1200- ratio and Tap,
5 1 Bus diff --- PS 6/4
800/1 800 volt 45 on 800/1
at 800 Tap
/1A
1200 volt
at 1200 30 on 1200/1
1200- /1 ratio Tap,
2 Spare --- PS 6/4
800/1 and 800 45 on 800/1
volt at Tap
800/1A
3 Metering 2000/1 20 VA 0.2 --- --- ---
OC / EF and
LBB 2000 volt
30 on 2000/1
4 Protection 2000/1 --- PS at 2000/1 10
Tap,
ratio
2000 volt
30 on 2000/1
5 Spare 2000/1 --- PS at 2000/1 10
Tap,
ratio
Note:
1. All relaying CTs shall be accuracy class (PS) as per IS: 2705
2. The Instrument security factor for metering core shall be less than five (5) at all ratios.
3. The CT ratios shall be achieved through secondary tapings only without any primary reconnection.
REQUIREMENTS OF 245kV CAPACITOR VOLTAGE TRANSFORMERS
Sl.No. Description Requirements
1 Rated voltage 400 /_/ 3 kV

primary
2 Type Single phase capacitor voltage transformer
3 No. of secondaries 3
4 Rated voltage 1.2 – continuous
factor 1.5 for 30 seconds
5 Capacitance 4400; + 10% ,- 5% Pico Farads
6 Rated secondary Secondary – I Secondary – II Secondary – III

voltage (V) 110 / _ /3 110 / _/3 110 / _/3
7 Application Protection Protection Metering
8 Accuracy 3P 3P 0.2
9 Out put burden 50 50 50
(VA) (Minimum)
4.7." 11 kV voltage and current transformer are as per relevant IS Codes/IEC codes. All specifications,
ratings and testing procedures are shall be approved by Engineer-In-Charge.

66
SS05 ACSR "MOOSE" CONDUCTOR

5.0.SCOPE
This Specification provides for design, manufacture, engineering, inspection,
stage testing and testing before dispatch, packing ,delivery and unloading at
site/stores of ACSR Moose Conductor .
5.1." ACSR "Moose" Conductor of size 54/7/3.53 mm.
The Contractors shall be responsible for quality of material offered and shall
withstand the environmental conditions in the area in respect of heavy
pollution / Cyclone wind conditions and humidity.
5.2." STANDARDS
The Power conductor shall conform to the following Indian/ International
Standards, which shall mean latest revisions, amendments/changes adopted
and published, unless otherwise specified herein before. International and
Internationally recognized standards to which these standards generally
correspond are also listed below:
----------------------------------------------------------------------------------------------
Sl. Indian Title
International
No. Standard Standards
----------------------------------------------------------------------------------------------
1. IS:209-1992 Specification for Zinc BS-3436
2. IS:398 Specification for Aluminum IEC-601089-1991

conductors for overhead IEC - 601232
transmission purposes.
Part V-1992 Aluminum conductors
galvanized steel reinforced
3. IS:1521-1972 Method of Tensile Testing ISO/R89

of Steel wire
4. IS:1778-1980 Reels and Drums for Bare BS-1559

conductors
5. IS:1841-1978 E.C .Grade Aluminum rod

produced by rolling
6. IS:2629-1985 Recommended practice for Hot

Dip Galvanizing of iron and steel
7. IS:2633-1986 Method of testing uniformity

of coating of zinc coated articles.
8. IS:4826-1979 Galvanized coatings on round ASTM A472-729

steel wires. BS-443
9. IS:5484-1978 E.C. Grade Aluminum rod
produced by continuous casting
and rolling

67
10. IS:6745-1972 Methods of determination

BS-443
of weight of zinc-coating
of zinc coated iron and
steel articles
11. IS:8263-1976 Method of radio-interference
IEC:437-1973
tests on high voltage NEMA:107
installations.
However, in an event where the Supplier offers ACSR conductor conforming to

International standards, including JIS, other than the above, then the salient
points of comparison between the standards adopted and the standards
quoted herein and in support of the guaranteed technical particulars to be
furnished in the respective proforma shall be detailed in relevant schedule
with an authenticated English version of such standards referred to.
ACRONIMS USED:
UTS : Ultimate tensile strength

Kg : Kilogram
kV : Kilo volts
KN : Kilo Newton
Max : Maximum
Min : Minimum
% : Percentage
mm : Millimeter
Deg : Degrees
C : Celsius
5.3." PRINICIPAL PARAMETERS :
5.3.1." ACSR "MOOSE" CONDUCTOR
1. Conductor : ACSR " Moose "
2. IS applicable : IS-398 (Part-V)-1992

Latest version acceptable to
International Standards.
3. No./Wire diameter
Aluminum (mm) : 54/3.53
Steel (mm) : 7/3.53
4. Number of strands:
Steel centre : 1
1st steel layer : 6

68
1st Aluminum layer : 12

2nd Aluminum layer : 18
3rd Aluminum layer : 24
5. Sectional Area of : 528.50

Aluminum (Sq. mm.)
6. Total Sectional Area (Sq. mm.) : 597.00
7. Overall diameter (mm) : 31.77
8. Approximate weight (Kg./Km.) : 2004
9. Calculated D.C. resistance : 0.05552

at 20 deg C,max.(ohm/km.)
10. Ultimate tensile strength,(kN) : 161.2
6
11. Final modulus of elasticity : 0.703 x 10
(Kg./Cm.)
-6
12. Coefficient of Linear : 19.30 x 10
expansion per deg. C
13. Lay-Ratio Maximum Minimum
Steel core 6 wire layer 18 16

Aluminum
1st layer (12 wire) 14 12
2nd layer (18 wire) 13 11
3rd layer (24 wire) 12 10
14. Technical particulars of Aluminum Steel

steel and aluminum strands : (galvanized)
a) Diameter
Standard mm 3.53 3.53

Maximum mm 3.55 3.60
Minimum mm 3.51 3.46
b) Cross-sectional area : 9.787 9.787

of nominal diameter wire
(Sq.mm.)
c) Weight,(Kg./km.) : 26.45 76.34
d) Minimum breaking load

69
Before stranding,(kN) : 1.57 12.86

After stranding : 1.49 12.22
15. D.C. Resistance at : 2.921 -

20 degrees C.(Ohm/Km)
16. Zinc coating of steel core :

a) Number of 1 minute dips. :3
b) Coating,(gms/Sq.m.) : 260
c) Process of Galvanizing : Hot dip Galvanizing
d) Quality of Zinc : IS-209/1979 or Latest addition.
17. Joints in strands

a) Steel :Not permitted
b) Aluminum :No Joint shall be permitted in the

Aluminum strands in the outer
most layer of the conductor
permitted in the inner layers
such that no two such joints are
within 15 meters of each other in
the complete stranded
conductor.
c) Ultimate tensile strength : 15.20
of joint Kg.
18. Chemical composition of
high carbon steel wire
Element % Composition
i) Carbon 0.5 to 0.85
ii) Manganese 0.5 to 1.10
iii) Phosphorus Not more than 0.035
iv) Sulphur Not more than 0.045
v) Silicon 0.10 to 0.35
5.4." GENERAL TECHNICAL REQUIREMENTS
The ACSR conductor shall be suitable for being installed directly in air
supported on suspension insulator strings or anchored through tension
insulator strings.
The conductor shall be suitable for satisfactory operation under the tropical
climatic conditions in which the Lines are passing. The applicable design
particulars of the conductor to be used on the lines .
5.5." Physical constants of materials :
5.5.1." Physical constants for Hard-drawn Aluminum wire :
Physical constants for Hard-drawn Aluminum are taken as per IS-398 Part -
V,1992.
5.5.1.1." Resistivity :

70
The resistivity of aluminum depends upon its purity and its physical condition.
For the purpose of this specification the maximum value permitted is
0.028264 at 20 Deg.C for "Moose" conductor. This value has been used for
calculation of the maximum permissible value of resistance.
NOTE : It is not intended to check the resistivity from the measured values of
resistance.
5.5.1.2."Density :
At a temperature of 20 Deg.C the density of Hard-drawn aluminum has been
taken as 2.703 g/cu.cm.
4.2.1.4 Constant - Mass Temperature Co-efficient of Resistance at a

temperature of 20 Deg C:
The Constant-mass temperature co-efficient of resistance of Hard drawn
aluminum measured between two potential points rigidly fixed to the wire
when the metal being allowed to expand freely has been taken as 0.004 per
degree Celsius.
5.5.1.3." Co-efficient of Linear Expansion :

The Co-efficient of linear expansion of hard-drawn aluminum at 20 Deg C has
been taken as 23.0 x 10 -6 per deg C. This value holds good for all practical
purposes over the range of temperatures from 20 Deg.C to highest safe
operating temperature.
5.5.2." Physical constants for Galvanized steel wire:
5.5.2.1." Density :
At a temperature of 20 Deg. C, the density of galvanized steel wire is to be

taken as 7.80 Kg/cubic dm.
5.5.2.2." Co-efficient of Linear Expansion:
The co-efficient of linear expansion of galvanized steel wire at 20 Deg C has

been taken as 11.5 x 10 -6 per deg C. This value holds good for all practical
purposes over the range of temperatures from 20 Deg. C to highest safe
operating temperature.
5.6." MATERIALS AND WORKMANSHIP
Important technical particulars are given here under :
5.6.1." The material offered shall be of best quality and workmanship. The ACSR
Aluminum conductor strands shall consist of hard drawn aluminum wire
manufactured from not less than 99.5% pure electrolytic aluminum rods of
E.C. grade and copper content not exceeding 0.04%. The steel wire for
both ACSR shall be made from material produced either by the acid or basic
open hearth process or by electric furnace process or basic oxygen process.
Steel wire drawn from Bessemer Process shall not be used.

71
5.6.2." The galvanized steel wires shall be evenly and uniformly coated with
electrolytic high grade, 99.95% purity zinc complying with the latest issue of
IS-209 for zinc. The uniformity of zinc coating and the weight of coating
shall be in accordance with clause 3.0 of this Section and shall be tested and
determined according to the latest IS-2633 or any other authoritative
standard. The steel strands shall be hot dip galvanized and shall have a
minimum zinc coating of 260 gm/Sq.m after stranding. The coating shall be
smooth, continuous, and of uniform thickness, free from imperfections and
shall withstand minimum three dips after stranding in standard preece test.
The steel strands shall be pre-formed and post-formed in order to
prevent spreading of strands in the event of cutting of composite core wire.
5.7."CONDUCTOR PARAMETERS:
5.7.1." The Parameters of individual strands and ACSR conductor, shall be in

accordance as per IS Codes.
5.7.2." Creep in a conductor is attributed partly due to settlement of strands and

partly due to non-elastic elongation of metal when subjected to load. The
manufacturer of conductor shall furnish the amount of creep which will
take place in 10, 20, 30, 40 and 50 years along with the supporting
calculations. The calculations should be based on everyday temperature of
32 degree C and everyday tension of 22% of UTS of conductor of 400kV
Lines .
5.8.TOLERANCES
The following tolerances shall be permitted on standard diameter of

aluminum steel wires.
5.8.1." A tolerance of plus or minus 0.5 percent for ACSR conductor shall be permitted
on standard diameter of aluminum wires.
5.8.2." A tolerance of plus or minus 2.0 percent for ACSR conductor shall be
permitted on the standard diameter of the galvanized steel wires.
5.8.3." The cross-section of any wire shall not depart from circularity by more
than an amount corresponding to the tolerance on the standard diameter.
5.8.4." The details of diameters, lay ratios of Aluminum and steel wires shall be in
accordance with the Clause 3.0 of this Section.
5.9." SURFACE CONDITIONS
5.9.1." All aluminum and steel strands shall be smooth, and free from all
imperfections, spills/and splits. The finished conductor shall be smooth,
compact, uniform and free from all imperfections including spills and splits,
die marks, scratches, abrasions, scuff marks, kinks (protrusion of wires), dents
press marks, cut marks, wire cross-over, over-riding looseness, pressure and/or

72
unusual bangle noise on tapping, material inclusions, white rust, powder

formation or black spots (on account of reaction with trapped rain water etc.,),
dirt, grit, etc. The surface of conductor shall be free from points, sharp edges,
abrasions or other departures from smoothness or uniformity of surface
contour that would increases radio interference and corona losses. When
subject to tension up to 50% of the ultimate strength of the conductor, the
surface shall not depart from the cylindrical form nor any part of the
component parts or strands move relative to each other in such a way as to
get out of place and disturb the longitudinal smoothness of the conductor.
5.10." JOINTS IN WIRES
5.10.1." ALUMINIUM WIRES:
No Joint shall be permitted in the outermost layer of aluminum wires

of the ACSR Moose conductor. Joints in the individual aluminum wires in the
inner layers (12 wire & 18 wire layers) are permitted, but no two such joints are
within 15 meters of each other in the complete stranded conductor. Such
joints shall be made by the cold pressure butt-welding.
5.10.2." STEEL WIRES:
There shall be no joints in steel wires forming the core of the ACSR conductor.
5.10.3." STRANDING
5.10.3.1." The wires used in construction of the stranded conductor, shall

before stranding, satisfy all requirements of IS-398 Part-V,1992 .
5.10.3.2." In all constructions, the successive layers shall be stranded in opposite

directions. The wires in each layer shall be evenly and closely stranded round
the underlying wire or wires. The outermost layer of wires shall have a right
hand lay.
5.10.4." LENGTHS
5.10.4.1." The conductor shall be supplied in the standard lengths of 1800 mts. A
tolerance of plus or minus 5% on the standard length offered by the Contractor
shall be permitted. All lengths shorter than the min permissible length shall be
treated as random lengths. Not less than 90% of the total quantity of the
conductor shall be supplied in standard lengths.
Thus the quantity of the conductor in random lengths shorter than standard
ones shall not exceed 10% of the total quantity to be supplied. Further no
single conductor length in respect of such 10% (maximum) supply in random
lengths, shall be shorter than 70% of the standard length. Only one standard
length or random length of conductor shall be wound on each drum.
The conductor in lengths in excess of the standard length with 5% tolerance

shall not be accepted unless specifically indented by the purchaser. All short

73
lengths should be supplied in a batch of six or twelve to the declared

destination. They shall also be distributed uniformly to the declared
dispatching stations depending upon the quantity of conductor allocated for
each station.
The contractor shall keep records of all the lengths of conductor manufactured
from metal of the same heat and store the conductor by heat/batch at his
works before dispatch. The dispatch of the conductor shall be done in multiples
of 12 drums ensuring all drums of the same length are grouped by heat/batch.
Each drum shall be marked to easily identify the heat/batch of the conductor
thereon. This marking shall be agreed with the Purchaser.
5.10.4.2." The Contractor shall also indicate the maximum single length above the
standard length, he can manufacture with Principal parameters specified in
clause 3.0 (Principal Parameters) of this Section. This is required for special
stretches like river crossing etc. The purchaser reserves the right to place
order for the above and below lengths on the same terms and conditions
applicable for the standard lengths during contract period. The drums used
for the conductor over and above the standard lengths shall be strong
enough to withstand rough handling during loading, transit and unloading.
5.11." TESTS:
5.11.1." The Type, Acceptance and Routine tests and tests during
manufacture, shall be carried out on the conductor.
5.11.2." Type tests shall mean those tests, which are to be carried out to prove
the process of manufacture and general conformity of the material to
this specification. These tests shall be carried out on samples prior
to commencement of commercial production against the order. The
Contractor shall indicate his schedule for carrying out these tests in
the activity schedule. The bids of the Contractors who have not carried
out type tests will be treated as technically non-responsive. The
Contractor shall furnish along with the bid the latest type test reports of
the type tests conducted not later than 5 years subject to no alteration
in the design.
5.11.3." Acceptance Tests shall mean those tests, which are to be carried out
on samples taken from each lot offered for pre-dispatch inspection,
for the purposes of acceptance of that lot.
5.11.4." Routine Tests shall mean those tests which are to be carried out on
each strand/spool/length of the conductor to check requirements
which are likely to vary during production.
5.11.5." Tests during manufacture shall mean those tests, which are to be carried
out during the process of manufacture and end inspection by the
Contractor to ensure the desired quality of the end product to be
supplied by him.

74
5.11.6." Samples for individual wires for tests shall be taken before stranding
from not less than ten percent of the spools in the case of aluminum
wires and ten percent of the coils in the case of steel wires. If samples
are taken after stranding, they shall be obtained by cutting 1.2 mts.
from the outer end of the finished conductor from not more than ten
percent of the finished reels.
5.11.7." The standards and norms to which these tests will be carried out are
listed against them. Where a particular test is a specific requirement of
this specification, the norms and procedures of the test shall be as
specified IS/IEC codes or as mutually agreed to between the
Contractor and the Purchaser in the Quality Assurance Programme.
5.11.8." For all type and acceptance tests, the acceptance values shall be the
values guaranteed by the Supplier in the proforma for "Guaranteed
Technical Particulars", furnished in this Specification and accepted by
the Purchaser or acceptance value specified in this specification,
whichever is more stringent for that particular test.
5.11.9." The Contractor shall provide the names and addresses of his test
facilities together with all outside recognized agencies/ laboratories
where he proposes to have tests conducted. He shall also list which tests
he proposes to have conducted at each facility. The following tests shall
be carried out as per detailed procedures of IS:398(Part-V) -1992 .
5.11.10." Tests on individual strands before stranding to be produced for

verification by the inspecting officer at the time of inspection of finished
conductor.
5.11.11." Type Tests

a) Visual examination including check for joints.
b) Measurement of diameters of individual aluminum and steel wires
c) Breaking load test
d) Elongation test
e) Wrapping test
f) Torsion test
g) Resistance test
h) Galvanizing test
i) Chemical analysis of aluminum and steel
k) Procedure qualification test on welded joints of individual Aluminum
strands.
5.11.12."ROUTINE TESTS
a) Visual examination including a check of joints

b) Measurement of diameters of individual aluminum and steel
wires
c) Breaking load test
d) Elongation test
e) Wrapping test
f) Torsion test

75
g) Resistance test
h) Galvanizing test
5.11.13."Tests on complete conductor

a) Ultimate tensile strength Test
b). Corona extinction voltage Test
c). Radio interference voltage Test
d). Resistance Test
e) Stress - Strain Test on conductor
and steel core.
5.11.14." Acceptance tests
a) Visual check for joints, scratches etc., and length
measurement of conductor by rewinding
b) Check on lay ratio of various layers
c) Procedure qualification tests on welded joints of individual
aluminum strands
5.11.15."Tests on wooden drums - to be produced for verification by the

inspecting officer at the time of inspection of finished conductor.
5.11.16."Type tests
a) Visual check
b) Dimensional check
c) Drum material check
d) Barrel batten strength check
5.11.17."Acceptance tests
a) Visual check
c) Drum material check
d) Barrel batten strength check
e) Drum marking check
5.11.18."Routine tests
a) Visual check
c) Drum marking check
5.11.19."Tests during manufacture
a) Chemical analysis of the zinc used for Galvanizing.

b) Chemical analysis of the aluminum used to manufacture the
aluminum strands
c) Chemical analysis of the steel used to manufacture the steel
strands
d) Procedure qualification test on welded joints of individual
Aluminum strands.

76
5.12." REJECTION AND RETEST
5.12.1." Each coil or spool selected for testing shall be tested for
compliance with the requirements of IS: 398 or any other
equivalent authoritative standard. Should any selected coil or
spool not fulfill any of the test requirements, that particular coil
or spool shall be withdrawn. In respect of each failure, two test
pieces shall be selected from two different coils in the lot and
subjected to the test under which the failure occurred. If either of
the two retest pieces fails to pass that test, the lot concerned shall
be rejected.
5.12.2." If samples are taken for test after stranding and if any selected
reel fails in the retest, the manufacturer may test each and every
reel and submit them for further inspection. All rejected material
shall be suitably marked and segregated.
5.13." ADDITIONAL TESTS:
The Purchaser reserves the right of having any other test(s) of reasonable
nature carried out at Contractor's premises, at site, or in any other place
in addition to the aforesaid type, acceptance and routine tests, to satisfy
himself that the material comply with the specifications.
5.13.1." Sample Batch for type testing: The Contractor shall offer at least
three (3) drums for selection of samples required for
conducting all the type tests.
5.13.2." The Contractor is required to carry out all the acceptance tests
successfully in the presence of Purchaser's representative before
dispatch.
5.14." TEST REPORTS:
Copies of type test reports shall be furnished in at least six (6) copies
along with one original. One copy shall be returned duly certified by the
Purchaser only after which the material will be dispatched. Record of routine
test reports shall be maintained by the Contractor at his works for periodic
inspection by the Purchaser's representative. Test Certificates of tests
conducted during manufacture shall be maintained by the Contractor. These
shall be produced for verification as and when desired by the Purchaser.
5.15." INSPECTION
5.15.1." The Purchaser's representative shall, at all times, be entitled to have

access to the works and all places of manufacture where conductor
shall be manufactured and the representative shall have full facilities
for unrestricted inspection of the Contractor's works, raw materials
and process of manufacture and conducting necessary tests as detailed
herein.

77
5.15.2." The Contractor shall keep the purchaser informed in advance of the
time of starting and of the progress of manufacture of conductor in
its various stages so that arrangements can be made for inspection.
5.15.3." The contractor will intimate the purchaser about carrying out of the
tests at least 15 days in advance of the scheduled date of tests during
which the purchaser will arrange to depute his representative/s to be
present at the time of carrying out of the tests. Six (6) copies of the
test reports shall be submitted.
5.15.4." No material shall be dispatched from its point of manufacture before it

has been satisfactorily inspected and tested, unless the inspection is
waived off by the Purchaser in writing. In the later case also, the
conductor shall be dispatched only after satisfactory testing for all tests
specified herein has been completed and approved by the Purchaser.
5.15.5." Arrangements should be made available in the works of the

manufacturer for transferring the conductor from one reel to another
at the same time measuring the length of the conductor so transferred
by means of a meter. At least 5% of the total number of drums subject
to minimum of two in any lot put up for inspection, shall be selected at
random to ascertain the length of conductor by the following method.
The difference in the average length thus obtained and as declared by
the Contractor in the packing list shall be applied to all the drums if the
conductor is found short during checking.
5.15.6." The acceptance of any quantity of material shall in no way relieve the
Contractor of any of his responsibilities for meeting all requirements of
the specification, and shall not prevent subsequent rejection if such
material is later found to be defective.
A Quality Assurance Plan including customer hold points covering the

manufacturing activities of the material shall be required to be submitted by
the Contractor to the purchaser along with the bid. The Quality Assurance Plan
after the same is found acceptable, will be approved by the purchaser. The
contractor shall follow the approved Quality Assurance Plan in true spirit. If
desired by the purchaser, he shall give access to all the documents and
materials to satisfy the purchaser that the Quality Assurance Plan is being
properly followed.

78
SS06 ANTI - FOG ZINC SLEEVE DISC INSULATORS
6.0." SCOPE:
6.0.1." This section covers design, manufacture, stage testing, inspection and testing before
dispatch, packing, supply, delivery, unloading and stacking at site/stores of insulators
as specified herein complete with all accessories. The Contractors shall be responsible
for quality of material offered and shall withstand the environmental conditions in the
area in respect of pollution conditions and humidity.
6.0.2." PORCELAIN ANTIFOG ZINC SLEEVE DISC INSULATORS (Suspension) 305x145 mm, 120 kN
EM strength with creep age distance of 460 mm are covered under this scope.
6.1." STANDARDS
The insulators shall conform to the following Indian/ International Standards, which shall
mean latest revisions, amendments/changes adopted and published, unless otherwise
specified herein. International and Internationally recognized standards to which these
standards generally correspond are also listed below:
---------------------------------------------------------------------------------------------------------------
Sl. Indian Title International
No. Standard Standard
-------------------------------------------------------------------------------------------------------------
1. IS: 731-1971 Porcelain insulators BS:137
for overhead power (I & II)
lines with a nominal IEC: 60383-
Voltage greater than (Part-I)-1993
1000V (Part-II) 1992
2. IS: 209-1992 Specification BS: 3436

for Zinc
3. IS: 406 Method for Chemical

Analysis of Slab Zinc
4. IS: 2071 Methods of High Voltage

Part (1)-1993 Testing
Part (II)-1974
Part (III)-1976
5. IS: 2629-1985 Recommended practice

for Hot Dip Galvanization
for iron and steel
6. IS: 2633-1986 Method of testing

Uniformity of
Coating of Zinc
Coated articles

79
7. IS: 3188-1980 Characteristics of IEC: 60305

string Insulator
units
8. IS: 6745-1972 Methods of

determination of
weight of Zinc
coating on Zinc
coated iron and
steel articles
9. IS-7814 Specification for BS: 2870

Phosphor Bronze
rods and bars
sheet strip and wire
10. IS: 1570 Specification for

(Part-I) wrought steels for
general engineering
purposes. Steel specified
by tensile and/or
yield properties
11. IS: 2004-1978 Carbon Steel forgings

for general
engineering purposes
12. IS: 6603-1972 Stainless steel bars

and flats
13. IS: 8263-1976 Methods of RI Test IEC: 60437-1973

of HV Insulators. NEMA
PUBLICATION
NO.107/1964/
CISPR.
14. IS: 8269-1976 Methods for switching IEC: 60506-1975
Impulse test on HV
insulators.
15. Thermal Mechanical IEC: 60575-1977
performance test and
Mechanical performance
test on Insulator units.
16. IS: 2486 Specification for

insulators fittings
for overhead power
lines with a nominal
voltage greater than
1000 Volts.

80
Part I-1971 General requirements BS: 328- 1973

& Tests
Part II-1974 Dimensional requirements IEC: 60120 -1984
Part III-1966 Locking Devices IEC: 60372- 1984
17. IS: 1367-1980 Technical supply

conditions for
threaded steel
fasteners
18. IS: 2071(part-II) Method of Impulse

1974 Voltage testing
19. IS: 2107-1977 Specification for

white heart malleable
iron castings
20. IS: 2108-1977 Specification for
black heart malleable
iron castings
21. IS: 13134-1992 Guide for selection of IEC: 60815-1986 &

insulators in respect of IEC :60273- 1990
pollution conditions
22. IS: 8704 Artificial Pollution tests IEC: 60507-1991

on HV Insulators to be used
on AC systems
ACRONYMS USED:
UTS : Ultimate tensile strength

Kg : Kilogram
KV : Kilo Volts
KN : Kilo Newton
Max : Maximum
Min : Minimum
% : Percentage
mm : Millimeters
Deg : degrees
C : Celsius
EMS : Electro Mechanical Strength
6.2." CLIMATIC CONDITIONS
The insulators shall be suitable for being installed directly in air with Moose ACSR
conductor as detailed below :

81
They shall be therefore suitable for satisfactory operation under the tropical climatic
conditions listed below.
I. Location : Andhra Pradesh.

II. Temperature
1) Maximum ambient temperature : 50/45

(degree C)
2) Minimum ambient air temperature : 7.5

(degree C)
3) Daily average ambient temperature : 35

(degree C)
4) Maximum temperature (degree C)
a) Conductor : 75
b) Earth wire : 53
III. Relative humidity
1) Maximum : 100%
2) Minimum : 10%
IV. i) Annual Rainfall(max) mm : 925
ii) Average Rainfall (mm) : 1200

V Average number of rainy days : 90
per annum
VI Average number of thunderstorm days

per annum : 50
VII Number of Months of Tropical : 4
Monsoon Conditions ( Months )
VIII Maximum wind pressure : 150 Kg/ Sq-m.
IX Maximum altitude above mean sea level(mtrs) : up to 1000
X Seismic level
(Horizontal Acceleration) : 0.030 G
(Vertical Acceleration) : 0.015 G
6.3." PRINCIPAL PARAMETERS
6.3.1." DETAILS OF DISC INSULATORS

82
Porcelain Disc Insulators
The disc Insulators offered shall be suitable for operation on 3phase, 50Hz, effectively
earthed 400KV Transmission system and be of the Anti-Fog Zinc sleeve disc Porcelain
insulator type.
6.4." BID DRAWINGS
6.4.1." The Contractor shall furnish along with the bid the outline drawing (1 copy) of
each disc insulator unit including a cross sectional view of the insulator shell. The
drawing shall include but not be limited to the following information:
a) Diameter and spacing with manufacturing tolerances.
b) Ball and socket coupling designation.
c) Minimum creep age distance with positive tolerance
d) Eccentricity of the disc
i) Axial run out

ii) Radial run out
e) Unit mechanical and electrical characteristics
f) Size and weight of ball and socket parts of insulators discs

g) Weight of unit insulator disc
h) Materials for the shell, cap and pin of the insulator disc and standard to which they
conform.
i) Identification mark
j) Manufacturer's catalogue number
k) Brief installation instructions
l) Relevant technical details

m) Galvanization Process, weight of zinc and no. and duration of dips.
6.4.2." Drawings for complete Insulator strings may be furnished with following
information.
a) Dimensional drawings for different insulator strings.
b) EMS
c) No. of Porcelain insulator discs
d) Minimum air gap between the arcing horn and grading/ corona rings.
e) Weight of porcelain insulator discs, Hardware sets and total weight of tension and
suspension insulator strings (Porcelain).

83
f) Tolerance if any.
6.4.3." The drawings to be furnished by the Contractor, shall be as per his design and
manufacture and shall be distinct and separate from the specification drawings.
However the overall length of the string and length of insulator portion shall
conform to the values given on the drawing.
6.4.4." After getting approval from Purchaser and successful completion of all the type
tests, the Contractor shall submit 10 more copies of the same drawings to the
Purchaser in soft copy in Auto CAD Format in 2 CD’s for further distribution and
field use at Purchaser's end.
6.5." GENERAL TECHNICAL REQUIREMENTS

6.5.1." PORCELAIN
The porcelain used shall be ivory white, nonporous of high dielectric, mechanical and
thermal strength, free from internal stresses, blisters, laminations, voids, foreign matter,
imperfections or other defects which might render it in any way unsuitable for insulator
shells. Porcelain shall remain unaffected by climatic conditions, ozone, acid, alkalis, zinc
or dust. The manufacturing shall be by the wet slip process and an impervious character
obtained by thorough verification.
i. PORCELAIN GLAZE:
Surfaces to come in contact with cement shall be made rough by sanding. All other
exposed surfaces shall be glazed with ceramic materials having the same temperature
coefficient of expansion as that of the insulator shell. The thickness of the glaze shall be
uniform throughout and the color of the glaze shall preferably be brown. The glaze shall
have a good visible luster, smooth on surface and be subject to satisfactory performance
under extreme tropical climatic weather conditions and prevent ageing of the porcelain.
The glaze shall remain under compression on the porcelain body throughout the working
temperature range.
ii. CAP AND BALL PINS

Ball pins shall be made with drop forged steel and caps with malleable cast iron. They shall
be in one single piece and duly hot dip galvanized. They shall not contain parts or pieces
joined together, welded, shrink fitted or by any other process from more than one piece of
material. The pins shall be of high tensile steel, drop forged and heat-treated. The caps
shall be cast with good quality black heart malleable, cast iron/ spherodal graphite
iron/drop forged steel and annealed. Galvanizing shall be by the hot dip process with a
heavy coating of zinc of very high purity. The Contractor shall specify the grade,
composition and mechanical properties of steel used for caps and pins.
iii. ZINC SLEEVE

For Anti-fog type disc insulators, Zinc sleeves shall be provided on the shank of the ball pins.
The zinc to be used for making sleeve shall be 99.99% pure or as per latest acceptable
standards. The Zinc sleeves shall be fixed at the top position of the neck of the shank of
the ball pin. The length of the shank of the ball pin shall be suitably chosen to ensure easy
fixing into the socket of the next disc insulator. The zinc sleeve shall cover the top neck
portion of the shank of the ball pin to a minimum extent of 20 mm and embedded into the
cemented portion up to an extent of 10mm.

84
The thickness of the sleeve shall be 5mm. The Zinc sleeve shall be clamped and fused
together with the pin without forming any gap between the sleeve and the pin. Any gap
will cause corona discharge due to the moisture and the insulators with this defect will be
rejected outright.
iv. SECURITY CLIPS:
The security clips shall be made of stainless steel.
v. CEMENT:
Cement to be used as a fixing material shall be quick setting, fast curing Portland cement. It
shall not cause fracture by expansion or loosening by contraction. Cement shall not react
chemically with metal parts in contact with it and its thickness shall be as small and as
uniform as possible. Proper care shall be taken to correctly center and to locate individual
parts during cementing.
6.6." MATERIAL DESIGN AND WORKMANSHIP:
6.6.1." GENERAL:
(i) All raw materials to be used in the manufacture of the insulators shall
be subject to strict raw material quality control and to stage testing/quality
control during manufacturing stage to ensure the quality of the final end
product. Manufacturing shall conform to the best engineering practices adopted
in the field of extra high voltage transmission. Contractors shall therefore offer
insulators as are guaranteed by them and accepted by the Purchaser for
satisfactory performance on 400KV Transmission Lines & Sub-Stations.
(ii) The design, manufacturing, process and material control at various
stages be such as to give maximum working load, highest mobility, best resistance
to corrosion, good finish, elimination of sharp edges and corners to limit corona
and radio interference voltages.
(iii) The Contractor of insulator discs shall guarantee the minimum overall
creep age distance and protected creep age distance. No negative tolerance shall
be permitted on the creep age distances of the insulators.
6.6.2." INSULATOR SHELL:
The design of the Porcelain insulator shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
6.6.3." METAL PARTS:

(i) The pin and cap for disc insulators shall be designed to transmit the
mechanical stresses to the shell by compression and develop uniform mechanical
strength in the insulator. The cap shall be circular with the inner and outer
surfaces concentric and of such design that it will not yield or distort under loaded
conditions. The head portion of the pinball shall be suitably designed so that
when the insulator is under tension the stresses are uniformly distributed over

85
the pinhole portion of the shell. The pinball shall move freely in the cap socket
either during assembly of a string or during erection of a string or when a string is
placed in position.
(ii) Metal caps of disc insulators shall be free from cracks, seams, shrinks, air
holes, blow holes and rough edges. All metal surfaces shall be perfectly smooth
with no projecting parts or irregularities that may cause corona. All load bearing
surfaces shall be smooth and uniform so as to distribute the loading stresses
uniformly. Pins shall not show any microscopically visible cracks, inclusions and
voids.
6.6.4." GALVANISING:
All ferrous parts shall be hot dip galvanized in accordance with the latest edition of IS: 2629
and zinc conforming to IS: 209. The zinc coating shall be uniform, smoothly adherent,
reasonably bright, continuous and free from impurities such as flux, ash, rust stains, bulky
white deposits and blisters. Before ball pins are galvanized, all die flashing on the shank
and on the bearing surface of the ball shall be carefully removed without reducing the
designed dimensional requirements. The galvanized metal parts shall be guaranteed to
withstand at least six successive dips each lasting one-minute duration under the standard
preece test. The minimum weight of Zinc shall be 610 gm/sq.m.
6.6.5." CEMENTING:
The porcelain insulator design shall be such that the insulating medium shall not directly
engage with hard metal. The surfaces of porcelain and the metal parts shall be coated
with resilient paint to offset the effect of difference in thermal expansions of these
materials. There shall be no growth of cement to avoid failure of the shell in tension by
cracking. The cement used shall be subjected to autoclave testing to measure the
expansion of the cement.
6.6.6." SECURITY CLIPS (LOCKING DEVICES):

i. Socket fitting shall be provided with security clip in accordance with IS: 2486 (Parts III &
IV) to provide positive locking against unintentional disengagement of socket from the
ball of the insulator. The security clip shall be humped to maintain the clip in the
locked position and shall have both prongs spread to prevent complete withdrawal
from the socket. The clip end shall not project outside the recess of socket when the
clip is in locked position. The locking device should be resilient, corrosion resistant and
of suitable mechanical strength. There shall be no risk of the locking device being
displaced accidentally or being rotated when in position. Under no circumstances
shall the locking device allow separation of insulator units of strings.
ii. The hole for the security clip shall be on the side of the socket opposite to the socket
opening. The hole for the clip shall be countersunk. The clip eye shall be of such
design that the same may be engaged by a hotline clip puller to provide for
disengagement under energized conditions.
iii. The force required to pull the clip to its unlocked position shall not be less than 50 N or
more than 500N.
iv. The security clip shall be "R" type made of stainless steel of type AISI 302 or 304.
v. 2.5 % additional security clips shall be provided.
6.6.7." BALL AND SOCKET DESIGNATION:

The dimensions of the balls and sockets for 120 KN & 160 KN discs shall be of 20mm
designation in accordance with the standard dimensions stated in IS: 2486 (Part II).

86
6.6.8." DIMENSIONAL TOLERANCE OF INSULATOR DISCS:
It shall be ensured that the dimensions of the disc insulators are within the limits specified
below.

87
-----------------------------------------------------------------------------------------------
a) TYPE RATING DIAMETER OF DISC (mm)

STD MAX MIN
-----------------------------------------------------------------------------------------------
Anti fog 120kN 305 320 291
Zinc sleeved disc
Insulators
-----------------------------------------------------------------------------------------------
-----------------------------------------------------------------------------------------------
b) TYPE RATING BALL TO BALL SPACING OF DISCS(mm)
STD MAX MIN
-----------------------------------------------------------------------------------------------
Anti fog 120kN 145 149 141
Zinc sleeved disc
Insulators
-----------------------------------------------------------------------------------------------
6.6.9." INTERCHANGEABILITY:
The insulators inclusive of the ball and socket fittings shall be of standard design suitable
for use with hardware fittings of any make conforming to relevant Indian Standards.
6.6.10."CORONA AND RI PERFORMANCE:
All surfaces shall be clean, even, smooth, without cuts, abrasions or projections. No part
shall be subjected to excessive localized pressure. The metal parts and porcelain shall
not produce any noise generating corona under all operating conditions.
6.6.11."SUITABILITY FOR LIVE LINE MAINTENANCE:
The insulators shall be compatible for use with hot line or live line maintenance
techniques so that usual hot line operations can be carried out with ease, speed and
safety
6.6.12."METHODS AND PERIODICITY OF MAINTENANCE:
Contractors shall indicate the methods generally adopted in routine hot and cold line
maintenance of EHV lines for similar disc insulators supplied by them. Contractors shall
also indicate the recommended periodicity of such maintenance.
6.6.13."FREEDOM FROM DEFECTS:

Insulators shall have none of the following defects:
i) Ball pin shackle
ii) Cementing defects near the pin like small blow holes, small hair cracks, lumps, etc.,
iii) Sand fall defects on the surface of the insulator.
6.7." TYPE AND RATING OF INSULATOR STRINGS:

PARTICULARS OF DISC INSULATORS AND INSULATOR STRINGS OF PORCELAIN ANTI FOG WITH ZINC
SLEEVE OF 120kN RATING FOR 400kV SUB STATION

88
400 KV 400 KV
------------------ ------------------
Suspension Tension Suspension Tension
No. of disc insulator Strings/discs:
Main Bus: 2x25 2x25 1x15/2x15 2x15
Jack Bus: 2x25 2x25 1x15/2x15 2x15
EM strength of each string: 20 kN 120 kN 120 kN 120 kN
Size of discs (mm) (280 - 305) X 145 (280 - 305) X 145
Ball and socket (mm) 20 20
Creep age distance of each disc (mm) 460 460
6.8." STRING CHARACTERISTICS :
The Characteristics of complete porcelain string shall be as follows :
Sl.No Details Single/ Pilot / Single ‘V’

Suspension 400kV
1. Lighting impulse withstand voltage (dry) kV peak 1050
2. Power Frequency withstand voltage (wet) kV rms 460

3. Switching impulse withstand kV (peak) 1050
4. RIV at 1 MHz at 305kV (rms) MV 600
5. Corona extinction voltage kV 245
6. Voltage distribution across the string 9%
7. Mechanical failing load kN 1x120
8. No deformation load kN 1x96
Insulator units after assembly shall be concentric and coaxial within limits as permitted by
Indian/ International Standards.
The string design shall be such that when units are coupled together there should not be
contact between the shell of one unit and metal of the next adjacent unit.
6.9." TESTS:
The following tests shall be carried out on the Zinc sleeved disc insulator string and disc
insulators.
6.9.1." TYPE TESTS:
These shall mean those tests that are to be carried out to prove the design, process of
manufacture and general conformity of the material and product with the intents of this
bid. These tests shall be conducted on a representative number of samples from a test lot
of 2000 discs for each type of insulator prior to commencement of commercial
production. The Supplier shall indicate his schedule for carrying out these tests.
The copies of the type tests, particularly switching flashover, lightning flashover and power
frequency flashover shall also indicate the path of flash over. If during the testing the flash

89
over occurs other than between live and earthed metal then the test result shall be
reviewed by the Purchaser together with suppliers of the insulators and fittings.
6.9.2." ACCEPTANCE TESTS:
These shall mean those tests which are to be carried out on samples taken from each lot
offered for pre-dispatch inspection for the purpose of acceptance of the lot.
6.9.3." ROUTINE TESTS:
These shall mean those tests, which are to be carried out on each insulator to check the
requirements that are likely to vary during production, as per IS : 731/IEC 60383.
6.9.4." STAGE TESTS DURING MANUFACTURE:
Stage tests during manufacture shall mean those tests which are to be carried out during
the process of manufacture and end final inspection before dispatch to ensure quality
control such that the end product is of the designed quality conforming to the intent of
this bid.
6.9.5." TEST VALUES:
For all type and acceptance tests, the acceptance values shall be the values guaranteed by
the Contractor in the guaranteed technical particulars or the acceptance value
specified in this bid or the relevant standard whichever is more stringent for that
particular test.
6.9.6." TEST PROCEDURES AND SAMPLING NORMS:
The norms and procedure of sampling for the above tests shall be as per the relevant
Indian Standard or other Internationally accepted standards. The standards and norms
according to which these tests are to be carried out are listed against each test
6.9.7." TYPE TESTS ON DISC OR INDIVIDUAL UNITS

-----------------------------------------------------------------------------------------------
Sl. Type of Tests Standards
No. Insulators
----------------------------------------------------------------------------------------------
1. Antifog 1. Visual examination IS: 731-1971
Zinc Sleeved
Disc Insulators 2. Verification of dimensions IEC: 60383-1993
3. Visible discharge test (dry) IS: 731-1971
4. Impulse Voltage withstand and IS: 731-1971

Flashover test (dry)
5. Power Frequency voltage with- IEC: 60383-1993
stand and flashover test
i) dry ii) wet
6. Temperature cycle test IS: 731-1971
7. Electromechanical failing IS: 731-1971

90
load test IEC:60383-1,1993

8. Thermal Mechanical IEC: 60383-1993
Performance
9. RIV test (dry) IS: 8263-1976
IEC: 60437-1973
10.Verification of displacements IEC: 60383-1,1993
11.Verification of locking system IEC: 60383-1,1993
12.Puncture withstand test IS: 731-1971
13.Porosity test IS: 731-1971
14.Steep wave front test as per Annexure II
15. Galvanizing test IS: 731-1971
16. Metallurgical test IS: 21088 & IS: 2004
17.Residual strength testIEC: 60797
18. Salt fog pollution test IEC: 60507-1991

for Antifog insulators IS:8704-1995
19. Chemical analysis of Zinc As per code

Sleeve
-------------------------------------------------------------------------------------------------------
6.9.8." TYPE TESTS ON COMPLETE STRINGS
S.No. Type of Tests Standards

Insulators
1. Complete 1. Power Frequency Voltage IEC-60383-1993

Porcelain withstand test with
disc insulator corona control rings/
strings with grading ring and arcing
Hardware horns under wet & dry
and fittings conditions
2. Switching surge Voltage IEC: 60383-1993

withstand test under wet
condition.
3. Impulse Voltage withstand IEC: 60383-1993

test under dry condition
4. Impulse Voltage flashover IEC: 60383-1993

91
test under dry condition .
5. Voltage Distribution Test As per Code

of this Specification
6. Corona and RIV test As per code

under dry condition
7. Mechanical Strength Test As per code
8. Vibration Test As per code

9. Visual Examination As per code
10. Salt fog pollution test IEC: 60507-1991
11.Verification of IS: 731

Dimensions
-----------------------------------------------------------------------------------------------------------------------
NOTE: All the Type Tests given for complete insulator strings above shall be conducted on all
different types of Insulator strings.
6.9.9." ACCEPTANCE TESTS
--------------------------------------------------------------------------------------------------------------
No. Insulators
--------------------------------------------------------------------------------------------------------------
1. Antifog Zinc 1. Visual examination IS: 731-1971
Sleeved disc
Insulators 2. Verification of dimensions IEC: 60383-1993
3. Temperature cycle test IS: 731-1971
4. Electromechanical failing IS: 731-1971

load test IEC:60383-1,1993
5. Mechanical Performance IEC: 60383-1993

6. Porosity test IS: 731-1971
7. Galvanizing test IS: 731-1971
8. Residual strength test IEC: 60797
9. Test on locking device for IEC: 60373-1976
Ball and socket coupling
10.Eccentricity Test IEC: 60383-1993
11. Puncture test IEC: 60383-1993

92
6.9.10."ROUTINE TESTS
---------------------------------------------------------------------------------------------------------------
No. Insulators
---------------------------------------------------------------------------------------------------------------
1. Antifog Zinc 1. Visual Inspection IS: 731-1971
Sleeved Porcelain
Disc Insulators 2. Mechanical Routine test IS: 731-1971
3. Electrical Routine test IS: 731-1971

---------------------------------------------------------------------------------------------------------------
6.9.11."TESTS DURING MANUFACTURE (STAGE TESTS)

---------------------------------------------------------------------------------------------------------------
No. Insulators
---------------------------------------------------------------------------------------------------------------
1. On all 1.Chemical analysis of As per code/ supplier
Components Zinc practice sed for
galvanizing
as applicable
2. Chemical analysis, As per code
mechanical and of this specification
metallographic test
and magnetic particle
inspection for malleable
castings
3. Chemical analysis, As per code

hardness test and magnetic of this specification
particle inspection for
forgings
4. Hydraulic Internal As per code
Pressure tests on shell of this specification
5. Crack detection test As per code

for metal parts of this specification
6. Autoclave test on cement --- do ----

---------------------------------------------------------------------------------------------------------------
6.9.12."ADDITIONAL TESTS:
For 400 kV insulator strings, the Supplier is required to produce type test reports to the
satisfaction of the Purchaser.

93
6.9.13."TYPE TESTS AND TEST SCHEDULE:
6.9.13.1." TYPE TESTS: The equipment/material offered against this tender should
have been successfully type tested in line with the specified standards and
this Technical Specification. These tests should have been conducted within
a period of 5 years prior to the date of opening of the Part-I “Pre-qualification
and Technical Bid”, subject to no alteration in the design. The Contractor
shall furnish 4 copies of the Type test reports with the offer. In case these
type tests were carried out earlier to the five years period mentioned above
or some type tests were not carried out at all as per the present
specification, all the relevant type tests as per relevant standards shall be
carried out by the successful Contractor in the presence of Purchaser's
representative at the cost of the successful Contractor.
6.9.13.2." If there is any change in the components or design in the equipment since
after earlier passing of the Type Test, the Contractor shall bring out in his
offer all such changes made in the components, materials, designs, etc. In
such case the Contractor shall carry out the type tests at his cost and in
presence of the Purchaser's representative.
6.9.13.3." In case of any failure during testing on complete insulator string; the test
shall be repeated at the manufacturer's cost. In case of any dispute as to
which component of the string has failed during testing on the complete
insulator string the assessment of the Purchaser as to which item caused the
failure in a particular type test shall be final and Binding on part of the
insulator/ Hardware manufacturer.
6.9.13.4." In case of failure of any type test the Contractor whose material has
failed is either required to modify the design of the material and
successfully carryout all the type tests as has been detailed out in clauses
6.7 & 6.8 of this specification or to repeat that particular type test at least
three times successfully at his own expenses. The decision of the Purchaser
in this regard shall be final and binding. The Contractor whose material has
not failed in the test shall be required to supply the requisite quantity of
material (that is insulators or hardware fitting as the case may be) required

94
for repeat testing at the place of testing and the additional cost of supply
shall be borne by the Contractor whose material has failed in the testing.
The contractor whose material failed on test shall also pay all costs incurred
by the Purchaser’s representative in witnessing the repeat tests, including
time, travel and subsistence.
6.9.13.5." For type testing which involve the tests on the complete insulator string
with hardware fittings the manufacturer of hardware fittings shall supply the
necessary number of sets of hardware fittings at the place of the testing free
of cost. The Purchaser reserves the right to get the disc insulators of each
type tested along with hardware fittings of more than one manufacturer but
not more than three hardware manufacturers. However for evaluation
purpose testing with only two hardware manufacturers shall be considered.
6.9.13.6." Contractor shall indicate the laboratories in which they propose to

conduct the type tests. They shall ensure that the tests can be completed in
these laboratories within the time schedule guaranteed by them in the
appropriate schedule.
6.9.13.7." The entire cost of testing for acceptance and routine tests and during
manufacture specified herein shall be treated as included in the quoted unit
price of disc insulators . All acceptance tests as stipulated herein shall be
carried out by the supplier in the presence of purchaser's representative. The
record of routine tests and tests performed during manufacture, as and
when desired by the Purchaser shall be furnished by the Contractor. In the
event that acceptance or routine tests have to be repeated due to initial
failure, all costs, including time, travel and subsistence costs incurred by the
Purchaser’s Representative in attending the repeat tests shall be paid by the
Contractor.
6.9.13.8." Immediately after finalization of the programme of type/ acceptance

testing, the Supplier shall give sufficient advance intimation to the Purchaser,
to enable him to depute his representative for witnessing the tests.
6.10."INSPECTION:
6.10.1."

95
ii) Purchaser and his representatives shall at all times be entitled to

have access to the works and to all places of manufacturer
where insulators are manufactured and the Supplier shall
afford all facilities to them for unrestricted inspection of the
works, inspection of materials, inspection of manufacturing
process of insulators and for conducting necessary tests as
specified herein.
iii) The Supplier shall keep the Purchaser informed in advance of the
time of starting and of progress of manufacture of insulators in its
various stages so that arrangements could be made for
inspection.
iv) No material shall be dispatched from its point of manufacture

unless the material has been satisfactorily inspected and tested
and dispatch instructions issued by the Purchaser.
v) The acceptance of any quantity of insulators shall in no way

relieve the Supplier of his responsibility for meeting all the
requirements of this specification and shall not prevent
subsequent rejection, if such disc are later found to be defective.
6.11."IDENTIFICATION MARKING:
6.11.1." Each disc insulator unit shall be legibly and indelibly marked with the trade mark
of the manufacturer, the month and year of manufacture, the guaranteed
Combined mechanical and electrical strength in kilo Newton abbreviated by 'kN'
to facilitate easy identification and proper use.
6.11.2."The marking on the insulator shell shall be printed and not impressed and the
same shall be applied before firing.
6.11.3."ne 10mm thick ring of a suitable quality of Red paint shall be marked on the cap of
each 120kN disc insulator to enable the easy identification of the insulators
strength. The paint shall have no detrimental effect on the insulators
performance.
6.12."QUALITY ASSURANCE PLAN:
6.12.1."The Contractor shall invariably furnish following information along with his offer,
failing which the offer shall be liable for rejection. Information shall be separately
given for individual type of material offered.
6.12.2."Statement giving list of important raw materials, names of sub-suppliers for the
raw material, list of standards according to which the raw materials are tested,
list of tests normally carried out on raw materials in the presence of Contractor's
representative and copies of test certificates.
6.12.3."Information and copies of test certificates as in (i) above in respect of bought out
items.
6.12.4."List of manufacturing facilities available.
i. Level of automation achieved and list of areas where manual processing

exists.

96
ii. List of areas in manufacturing process, where stage inspections are

normally carried out in quality control and details of such tests and
inspections.
iii. Special features provided in the Insulators to make it maintenance free.
iv. List of testing equipment available with the Contractor for final testing of
Insulators specified and test plant limitation, if any, vis-à-vis the type,
special, acceptance and routine tests specified in the relevant standards.
These limitations shall be very clearly brought out in schedule of
deviations from specified test requirements.
6.12.5."The Supplier shall within 30 days of placement of order submit the following
information to the Purchaser.
i) List of raw material as well as bought out accessories and the name of the material
as well as bought out accessories and the names of sub-suppliers selected from
those furnished along with the offer.
ii) Type test certificates of the raw material and bought out accessories.
iii) Quality Assurance Plan (QAP) with customer hold points for Purchaser's
inspection. The QAP and Purchaser's hold points shall be discussed between
the Purchaser and the Supplier before the QAP is finalized.
6.12.6."The Supplier shall submit the routine test certificates of bought out items and raw
material at the time of routine testing of the Insulators.
6.13."TEST REPORTS:
i) Four copies of acceptance test reports shall be furnished to the Purchaser.

One copy will be returned, duly certified by the Purchaser and only thereafter shall
the materials be dispatched.
ii) All records of routine test reports shall be maintained by the Supplier at his
works for periodic inspection by the Purchaser.
iii) All test reports of tests conducted during manufacture shall be maintained by the
Supplier. These shall be produced for verification as and when requested for by
the Purchaser.
6.14."CO-ORDINATION FOR TESTING
The disc insulators supplier shall have to co-ordinate testing of the disc insulators with
hardware fittings to be supplied by hardware fittings supplier to the purchaser and shall
have to also guarantee overall satisfactory performance of disc insulators with hardware
fittings.
In case of electrical tests on strings complete with hardware, the responsibility of testing
and guarantee of the values of RIV, corona and voltage distribution test shall rest with the
hardware supplier and for all the other tests with the insulator discs supplier.
Contractors who have already performed the tests on the offered insulators, with
hardware manufactured by a hardware supplier, shall submit the test reports with the bid
specifically pointing out the name and address of the hardware manufacturer and the
name of the contact person of a power utility who has witnessed such tests.

97
6.15."PACKING & FORWARDING:
i) All insulators shall be packed in strong seasoned wooden crates. The gross weight
of the crates along with insulators shall not normally exceed 100 kg. to avoid
handling problem.
ii) The packing shall be of sufficient strength to withstand rough handling during
transit, storage at site and subsequent handling in the field.
iii) Suitable cushioning, protective padding, or dunnage or spacers shall be provided
to prevent damage or deformation during transit and handling.
iv) All packing cases shall be marked legibly and correctly so as to ensure safe
arrival at their destination and avoid the possibility of goods being lost or wrongly
dispatched on account of faulty packing and faulty or illegible markings. Each
wooden case/crate shall have all the markings stenciled on it in indelible ink. All
galvanized components shall be given a protective coating against formation of
white rust during sea transportation.
v) The drawing of the packing crate shall require approval of the Purchaser.
6.16."TEST PROCEDURES
6.16.1." MECHANICAL STRENGTH TEST:
The complete Zinc sleeved insulator string along with its hardware fitting excluding
arcing horn, and suspension assembly/dead end assembly shall be subjected to a load
equal to 50% of the specified minimum ultimate tensile strength (UTS) which shall be
increased at steady rate to 67% of the minimum UTS specified. The load shall be held for
five minutes and then removed. After removal of the load, the string components shall
not show any visual deformation and it shall be possible to disassemble them by hand.
Small hand tools may be used to remove cotter pins and loosen the nuts initially. The
string shall then be reassembled and loaded to 50% of UTS and the load shall be further
increased at a steady rate till the specified minimum UTS and held for one minute. No
fracture should occur during this period. The applied load shall then be increased until the
failing load is reached and the value recorded.
6.16.2."CHEMICAL ANALYSIS OF ZINC USED FOR GALVANIZING:
Samples taken from the zinc ingot shall be chemically analyzed as per IS:209. The purity of
zinc shall not be less than 99.95%.
6.16.3."TESTS FOR FORGINGS:
The chemical analysis hardness tests and magnetic particle inspection for forgings, will
be as per the internationally recognized procedures for these tests. The sampling will be
based on heat number and heat treatment batch. The details regarding test will be as
discussed and mutually agreed to by the Supplier and Purchaser in Quality Assurance
Programme.
6.16.4."TEST ON CASTINGS:
The chemical analysis, mechanical and metallographic tests and magnetic particle inspection
for castings will be as per the internationally recognized procedures for these tests. The

98
sampling will be based on heat number and heat treatment batch. The details regarding
test will be as discussed and mutually agreed to by the Supplier and Purchaser in Quality
Assurance Programme.
6.16.5."ECCENTRICITY TEST (Axial and Radial run out)
The insulator shall be vertically mounted on a fixture using dummy pin and socket. A vertical
scale with horizontal slider shall be used for the axial run out. The pointer shall be
positioned in contact with the bottom of the outermost petticoat of the disc. The disc
insulators shall be rotated with reference to the fixture and the slider shall be allowed to
move up and down on the scale but always maintaining contact with the bottom of the
outer most petticoat. After one full rotation of the disc the maximum and minimum
position the slider has reached on the scale can be found out. Difference between the
above two readings shall satisfy the guaranteed value for axial run out.
Similarly using a horizontal scale with vertical slider the radial run out shall be measured.
The slider shall be positioned on the scale to establish contact with the circumference of
the disc insulator and disc insulator rotated on its fixture always maintaining the contact.
After one full rotation the maximum and minimum position of the slider reached on the
scale are found out. The difference between the above readings shall satisfy the
guaranteed value for radial run out.
6.16.6."CRACK DETECTION TEST:
Crack detection test shall be carried out on each ball pin before assembly of disc unit. The
manufacturer shall maintain complete record of having conducted such tests on each and
every piece of ball pin. The Contractor shall furnish full details of the equipment available
with him for crack test and also indicate the test procedure in detail.
6.16.7."VOLTAGE DISTRIBUTION TEST
The voltage across each insulator unit shall be measured by sphere gap method. The result
obtained shall be converted into percentage. The voltage across any disc shall not exceed
the values given in Annexure-I, expressed as a percentage of the total voltage across the
string
6.16.8."VIBRATION TEST
The suspension string shall be tested in suspension mode and tension string in tension mode
itself in laboratory with a span of minimum 30 meters. In the case of suspension string a
load equal to 600 kg shall be applied along the axis of the suspension string by means of
turn buckle. The insulator string along with hardware fittings and two sub conductors
(each tensioned at 4500 Kg.) shall be secured with clamps. The system shall be suitable to
maintain constant tension on each sub conductor throughout the duration of the test.
Vibration dampers shall not be used on the test span. Both the sub conductors shall be
vertically vibrated simultaneously at one of the resonance frequencies of the insulator
string (more than 10 Hz) by means of vibration inducing equipment. The peak to peak
displacement in mm of vibration at the antinode point nearest to the string shall be
measured and the same shall not be less than (1000/f1.8) where f is the frequency of
vibration in cycles/sec. The insulator string shall be vibrated for not less than 10 million

99
cycles without any failure. After the test the disc insulators shall be examined for
looseness of pins and cap or any crack in the cement. The hardware for looseness shall
be examined for fatigue failure and mechanical strength test. There shall be no
deterioration of properties of hardware components and disc insulators after the
vibration test.
The disc insulators shall be subjected to the following tests as per relevant standards: -
Tests Percentage of
Insulator Units
to be tested
a) Temperature cycle test followed 60
by mechanical performance test
b) Puncture test 40
6.16.9."TIME LOAD TEST:
The insulator string shall first be subjected to 5minute power frequency routine test. After
successful completion of this test, the insulator string shall be mounted vertically/
horizontally and subjected to a load equal to 67% of the specified mechanical strength for
a duration of 24 hours.
After the completion of above period if the string is found to be intact on visual
examination, it shall again be subjected to 5 minutes power frequency routine test. The
string shall be deemed to have passed the time load test if it successfully withstands 5
minute power frequency routine test.
6.16.10."POLLUTION WITHSTAND VOLTAGE TEST
The test shall be carried out in accordance with the clean fog test method (solid layer
method) prescribed in Section 4 of IEC: 507-1991. Test procedure is as follows:-
First the test object is contaminated by dipping in contaminant solution, which is

composed of salt (NaCl), Insoluble material (Kaolin) and water. Insoluble deposit density
(NSDD) of 0.1 mg/ sq.cm and salt deposit density of 0.30 mg/sq.cm are required.
After having been contaminated and dried, the test object is installed in the fog chamber.
The specified constant test voltage as per IEC-507 is applied to the test object and then
artificial steam fog is generated. The applied voltage is maintained for 60 minutes or until
flashover occurred within 60 minutes. The above procedure is repeated at least three (3)
times on freshly contaminated test object.
6.16.11."STEEP WAVE FRONT TEST
The test shall be performed on disc insulator units selected at random from the lot offered
for selection of samples for type tests.
a) Each insulator unit shall be subjected to five (5) successive positive and negative impulse
flashovers with a wave having minimum effective rate of rise of 2500kV per Microsecond.
b) Each unit shall then be subjected to three (3) dry power frequency voltage flashovers.

100
An insulator shall be deemed to have met the requirements of this test if having been
subjected to the ten impulse flashovers, the arithmetic mean of the three subsequent dry
power frequency voltage flashover values equals or exceeds 95% of the rated dry power
frequency voltage.
An insulator shall be deemed to have failed to meet the requirement of the above test if,
a) It has not flashed over when the oscilloscope or peak voltage indicator shows a marked
reduction in voltage. or
b) Any one of the subsequent dry power frequency voltage flashover values is less than 80%
of the value specified.
Failure of any one unit in either the steep wave front or subsequent low frequency voltage
test shall be cause for testing on double the number of units.
6.16.12."THERMAL RUNAWAY TEST
The sample shall be placed in an oven at a temperature of 80 degrees C (+/- 2 degree C) for
at least 3 hours so as to ensure uniform heating of all discs. At that temperature each disc
shall be subjected to 50 kV (rms) power frequency voltage. The voltage shall be applied for
one hour and no puncture shall occur.
6.16.13."AUTOCLAVE TEST
The autoclave tests shall be conducted in accordance with ASTM C151-84.
6.17." TYPE TESTS
1) Contractors have to furnish type test reports of tests conducted earlier on equipment
similar to that offered.
2) Bid taking deviation from the type tests specified to be conducted are liable for
rejection.
-------------------------------------------------------------------------------------------------------
Sl. Name of Method of test Place of
No. Type Test and relevant testing
IS/IEC
----------------------------------------------------------------------------------------------------
I On disc insulator units:
1. Visual examination
2. Verification of dimensions
3. Visible discharge test (dry)
4. Impulse Voltage withstand
Flashover test (dry)

101
5. Power Frequency voltage with-

stand and flashover test
i) dry ii) wet
6. Temperature cycle
7. Electromechanical failing
load test
8. Thermal Mechanical Performance
9. RIV test (dry)
10. Verification of displacements
11. Verification of locking system
12. Puncture withstand test
13. Porosity test
14. Steep wave front test
15. Galvanizing test
16. Metallurgical test
17. Residual strength test
18. Salt fog pollution test
for Anti fog insulators
19. Chemical analysis of Zinc
Sleeve
----------------------------------------------------------------------------------------------------
Sl. Name of Method of test Place of
No. Type Test and relevant testing
IS/IEC
----------------------------------------------------------------------------------------------------
On Complete insulator string

With hardware fittings
1. Power frequency Voltage

Withstand test with corona control
rings/ grading ring and arcing horns
under wet & dry conditions.
2. Switching surge voltage withstand
Test under wet condition.
3. Impulse Voltage withstand test
under dry condition.
4. Impulse Voltage flashover test under
dry condition.
5. Voltage Distribution Test
6. Corona and RIV test under
dry condition
7. Mechanical Strength Test
8. Vibration Test
9. Visual Examination
10 . Pollution withstand Voltage Test
11. Verification of Dimensions

102
SS 07 POWER TRANSFORMERS
7.0."Scope:
The offer for supply of transformer shall include all parts and accessories which are
useful and necessary for the efficient and safe operation, such parts and
accessories shall be deemed to be within the scope of this specifications whether
specifically mentioned or not. Drawings showing the general arrangements
foundation details, fittings shall be furnished along with the offer. The schedule of
guarantees and technical particulars shall be furnished along with the offer for each
type of transformer. List of past supplies made to Govt. / Quasi Govt.
Corporation/Undertakings shall be enclosed. The rates quoted for the transformers
shall be for designs, manufacturer, supply and deliver at respective destinations.
Packing shall be sturdy and adequate to protect all assemblies, components and
accessories from injury by corrosion, dampness heavy rains, breakage, vibration
encountered during transportation, handling and storage at site
7.0.1. STANDARDS:
IS-2026 (Part 1 to 5 ) Power Transformers IEC-60076(Part I to 5)
IS-335 Insulating oil for transformers IEC-296,BS-148.
IS1866-2000 Electrical maintenance and Supervision

of mineral insulating oil in equipment.
IS-2099 Bushings for alternating Voltage above IEC-60137(2008)

1000V.
IS-2312 Fans (Cooler fans)
IS-2705. Current Transformers. IEC 60044
IS-325. Three phase Induction motors. IEC-34.
IS-375 &IS-996 Marking & arrangements for switch

gear, bus bars, main connections &
auxiliary wiring.
IS-3637. Gas & oil operated relays.
IS-10028(Part 1to3) Code of practice for installation and

maintenance of transformers.
IS-2147. Degree of protection provided by enclosures for IEC 60529,IEC60947

low voltage switch gear and control.
IS-5. Colours for ready mix paints.
IS-6272 Industrial cooling fans.
OLTC IEC 60214

103
IS 8478 Application Guide for OLTC IEC 60542
IS 10561 Application Guide for Power Transformer. IEC 60076-8
IS 13964 Method of measurement of Transformer

IS 6209 Methods for Partial Discharge Measurements IEC 60270
IS 2165 Insulation Coordination IEC 60071
IS 5561 Terminal connectors
Short Circuit Current – calculation of effects IEC 865(part I & II)
IS-5553 Shunt Reactors, Neutral/ Arc Suppression Coil IEC 60289
IS:335 Insulating oils for transformers and switchgears IEC:60296, BS:223
IS -1886 Code of practice for installation and IEC 60422

maintenance of transformers.
Supervision and Maintenance guide for
Mineral Insulating Oil in Electrical Equipment
Method of Sampling of Liquid dielectrics IEC 60475
7.1."400KV/11 KV, 3 Phase, 50 Hz outdoor type power transformers. With on load tap
changer complete with fittings accessories, spares, special tools & tackles etc. The
MVA capacity of transformer, as per Single Line Diagram of each Pump House.
Adequate stand by capacity shall be provided for trouble free operation of Pump
House in case of failure of one transformer.
7.1.1." Salient Features
1. Type : 2 winding core type

2. Vector Group : Dyn11
3. Basic Insulation Level : 900 kvp
4. Percentage of impedance : 12.5%
5. Rated voltage : 400±8x1.25%kV = 198 – 242 KV
6. No. of phases : 3
7. Frequency : 50 Hz
8. No. of windings : 2 (Two)
9. Type of cooling : OFAN/ONAN
10. Cooling Media : Transformer oil as per relevant
standards
11. Temperature rise of : 65 deg C.
oil and winding
12. Method of connection : HV in Delta LV in STAR
13. Tapings : Full capacity (rated KVA)on load taps
from -10% to +10% shall be provided
on HV winding in steps of 1.25% (17
taps)
14. Installation : Out door type
15. Method of system earthing : Solidly grounded neutral

104
system
16. HV bushings : Suitable for connection to overhead
400 KV bus. (Condenser type)
17. LV Bushings : Suitable for connection 11 KV
Aluminum
Segregated phase bus duct.
18. Neutral point : Star point of HV winding shall be
brought
out with phase terminals with
suitable bushing for connecting to
earth mat .
19. OLTC : On HV Side
7.2."Capitalization of losses:
The capitalization of losses of the transformer shall be calculated adopting the

following formula.
n
Cc = Initial cost + 8400 x [Ec (1 + r) - 1] x Wi
n
r (1 + r)
n
+ 8400 x [Ec (1 + r) - 1] x Ls x Wc
n
r (1 + r)
= C + 32869 Wi + 14199 Wc
or say Cc = C + 33000 Wi + 14000 Wc.

where
n = Service for 20 years
Cost of electrical equipment, Ec = Rs. 0.80
Rate of Interest, r = 20%
Loss factor, Ls = 0.432
LS = 0.3 LF + 0.7 (LF) ² Where LF = 60%
If the guaranteed losses are subject to tolerance as per the standard

specification, the maximum losses including the tolerance shall be taken for
capitalization.
For comparison of the different offers, and to arrive at competitive price, the
sum of the quoted price (F.O.R. destination) and the capitalized charges of the losses as
per the above formula in each offer shall be considered and the lowest of these shall be
considered as the most economical.
7.3." Penalty for deviations of Guaranteed loss:
Penalty will be levied for every KW of deviation of losses from the guarantee
value of transformer at the rate of Rs. 21900/- per KW of difference between total

105
losses and no load losses. Rs. 8800/- per KW for excess of auxiliary losses on the basis
of guaranteed loss figures. The penalty amount so calculated shall be recovered from
the contractor.
The purchaser reserves the right to reject or accept the transformer if the
losses are more than the declared losses beyond tolerance limits as per I.S. Transformer
should be mounted on wheels and rail track shall be provided from the transformer
assembly bay to the transformer location.
The offer for supply of transformer shall include all parts and accessories which
are useful and necessary for the efficient and safe operation, such parts and accessories
shall be deemed to be within the scope of this specifications whether specifically
mentioned or not.
Drawings showing the general arrangements foundation details, fittings shall be

furnished along with the offer. The schedule of guarantees and technical particulars shall
be furnished along with the offer for each type of transformer. List of past supplies made
to Govt. / Quasi Govt. Corporation/Undertakings shall be enclosed. The rates quoted for
the transformers shall be for designs, manufacturer, supply and deliver at respective
destinations. Packing shall be sturdy and adequate to protect all assemblies,
components and accessories from injury by corrosion, dampness heavy rains, breakage,
vibration encountered during transportation, handling and storage at site.
7.4." Construction Details:
7.4.1." The Transformer shall be copper wound Power Transformer.
7.4.2." The Transformer is of 3 phase, 50Hz. AC double wound, oil immersed Naturally
cooled, core type and suitable for outdoor installations. Transformers with ISI
marking shall be specifically mentioned in the tender. The transformer shall be
Delta-star connected with neutral brought out on LT Side, with Vector group
Dyn11.
7.4.3." The Transformers shall be supplied with first filling or transformer oil. The drain
valve shall be provided with locking arrangements. The transformer shall be
provided with LV cable box on LT side with a base plate and glands shall be
provided for cable entry. Temperature rise shall not increase 40 degrees
centigrade for oil and 55 degrees centigrade for winding over a maximum
ambient temperature of 45 degrees centigrade.
7.4.4." Deleted.
7.4.5." The LT cable boxes (of adequate size with sufficient space for free movement of
cables for connecting Aluminum armored cables) with cable entries, with
suitable cable glands suitable to receive purchasers incoming cable of the
following sizes shall be provided.
7.4.6." The bottom plate of the cable box shall be detachable type where the cable
glands are provided.

106
7.4.7." The Transformer shall be painted with one coat of red oxide initially and two
coats of epoxy gray enamel paint.
7.5." Each Transformer should contain the following fittings and accessories.
a) Air release devices : 1 No
b) Drain valve with locking arrangement : 1 No
c) Oil Filter Valve : 1 No.
d) Earthing terminals (Body) : 1 No.
e) Explosion vent with diagram : 1No.
f) Lifting tongs : 4Nos.
g) Bottom channels : 1set
h) Conservator with oil level gauge : 1set
i) Dehydrating breather with silica gel : 1No.
j) Thermometer pocket : 1No.
k) Paracillers on HT on LT : 1Set
l) Rating and Diagram plate : 1No.
m) Insulated earth point outside the LT cable box : 1 No.
n) On Load tap changer : 1 No.
o) Any other fittings and accessories as Per IS codes
7.6." Tests:
Routine tests shall be conducted on the transformer as per applicable Indian standards
and copies of Test Certificates shall be furnished to the employer and also one set to Regd.
Office. Impulse with stand test/certificate shall be submitted before, the guaranteed
period on a similar indenting call type of transformers manufactured by the supplier. All tests
shall be carried out in accordance with clause 16 of IS 2026/Part-l/1977 or any other
authoritative standard for power transformers.
7.6.1." ROUTINE TESTS:
All transformers shall be subject to routine test at the manufacturer's works. The
following tests are to be carries out.
I. Measurement of winding resistance.
II. Ratio, polarity and phase relationship.
III. Impedance Voltage.
IV. Load losses.
V. No-load losses and no-load current.
VI. Insulation resistance.
VII. Induced over voltage withstand test.
VIII. Separate source voltage withstand test.
IX. Unbalance test.
X. Dielectric test of Oil.

107
7.6.2." TYPE TESTS:
The following type tests shall be made on the transformers:

I. Temperature Rise Test
II. Lightning Impulse Voltage Test.

108
SS08 BATTERY & BATTERY CHARGERS
8.0.STANDARDS
1.1 The 400V, 400AH sealed maintenance free VRLA Batteries and associated suitable 40/100A
Float-Cum-Boost Chargers with accessories shall conform to the latest edition of the
following Indian Standard Specification (ISS) or equivalent IEC / JIS and International
Standards (as amended up to date) except where specified otherwise in this specification.
i) Stationary Value regulated lead acid batteries IS : 5549-2005
ii) Stationary Lead Acid Batteries IEC: 896-1987

General requirements and methods of test
iii) Lead Acid Stationary Cells & Battery BS: 6290-1984
(Part-II)
iv) Stationary batteries lead acid type with IS: 6304-1992
pasted positive plates
v) Stationary Lead-Acid Batteries IEC:896-2/

General requirements & methods of test BSEN 60896-2 Part-II
Valve Regulated type
vi) Methods of test for flammability of
solid electrical insulating materials IEC:707
vii) Synthetic separators for lead acid batteries. IS:6071

viii) Rubber and plastic containers IS:1146
for lead acid storage batteries.
ix) Sealing compound for lead acid IS:3116
batteries.
x) General requirements and methods of IS:8320

tests for lead acid storage batteries.
xi) Mono-crystalline, semi-conductor IS:3895
rectifier cells and stacks
xii) Mono-crystalline, semi-conductor IS:4540

rectifier assemblies & equipment.
xiii) MCBs/MCCBs IS:8828/IEC: 898
xiv) Direct acting analogue electrical indicating IS:1248(Part -I) - 1993

instruments- General Requirements and for IS:1248(Part -II) - 1983
Ammeter & Voltmeter
xv) Electrical relays for power system IS:3231

protection.
xvi) Electrical relays for AC system IS:3842

109
xvii) PVC insulated cable IS:1554(Part-I)
xviii) PVC/XLPE FRLS Cables IS:8130
xix) Code of practice for phosphate of Iron & Steel IS:6005
xx) Colours for ready mix paints IS:5
xxi) Tests on converters IS:8623
xxii) Stabilized power supplies, DC output IS:7204

(Parts-1,2,3&4)
xxiii) Distributions feeders for voltages not IS:5039

exceeding 1000V AC or 1200VDC
xxiv) Enclosed distribution fuse board and IS:2675

Cutout for voltages not exceeding
1000V AC or 1200V DC
xxv) Low voltage fuses, Supplementary IS:9224 (Part-4)

requirement for fuse link for the
production of semi-conductor devices
xxvi) Low voltages fuses, General requirements IEC: 269-1
xxvii) Low voltage fuses for voltages not exceeding IS:13703(Part–1)

1000V AC or 1500V DC
xxviii) Air Break Switches IS: 4064
xxix) All relevant standards pertaining to other type of suitable

Capacity batteries specified.
8.1." DRAWINGS
8.1.1." In addition to any other drawings which the Contractor may like to supply, one
set of the following/Bid drawings, relevant ISS/IEC/JIS and catalogues shall be
submitted.
i) Layout drawing of battery giving details of terminal posts and arrangement of
cable termination including general arrangement of cell.
ii) Charge and discharge performance curves of battery.
iii) Technical and descriptive literature giving details of the equipment offered and
sub assemblies
iv) General arrangement drawing of Battery & Battery Chargers.
v) Typical schematic diagram of Battery & Battery Chargers.
vii) Voltage vs Current characteristic curve of automatic voltage regulator on Float-
Cum-Boost Chargers.

110
8.1.2." The successful Contractor will be required to furnish two prints of the above
drawings for approval. The Purchaser shall communicate his comments/ approval on
the drawings to the Contractor. The Contractor shall modify the drawings and
resubmit three copies of the modified drawings for Purchaser's approval for
Purchaser's comments. After receipt of Purchaser's approval, the Contractor shall be,
submit 10 printed sets and one soft copy in latest auto cad version of the approved
drawings.
8.1.3." The Contractor may submit any other drawing considered necessary in addition to
the drawings stated above. The manufacturing of the equipment shall be strictly in
accordance with the approved drawings and no deviation shall be permitted without
the written approval of the Purchaser. All manufacturing and fabrication work in
connection with the equipment prior to the approval of the drawing shall be at the
Contractor's risk. Approval of drawings/work by Purchaser shall not relieve the
Contractor of his responsibility and liability for ensuring correctness and correct
interpretation of the latest revision of applicable standards, rules and codes of
practices.
8.2." GENERAL
8.2.1." Battery system is required for providing independent and uninterrupted power
supply for operation, control, protection, alarm and indication etc. of switchgear
as well as for emergency lighting. The equipment offered shall be Indoor
type, suitable for interconnection with D.C. Distribution Board. 2 Nos. Battery
Banks shall be provided for 400KV Sub-station so that in case of outage of one
battery, other battery shall meet the D.C. load requirements of the Sub-station.
The lower optimum voltage to be maintained by chargers to maintain batteries in
fully charge condition and maximum battery life shall be indicated. Suitable means
shall also be provided for indicating and annunciating the fully discharge condition
of the battery.
8.2.2." Normally the battery shall be kept in a state of float charge by means of float
charging and also supply continuous D.C. load. Provision shall also be made for
boost charging of each battery. Voltage on D.C. bus bar during float as well as
boost charging should be constant without any manual control.
8.2.3." 3 Phase 50 Hz, 415 volt A.C supply for Battery Chargers shall be made available
by purchaser through FRLS PVC cables from A.C. distribution board. A.C supply to
charger shall be controlled by Air Break Switches. Incoming supply to D.C.
Distribution Board from batteries and charger as also the outgoing circuits shall
be controlled by the Air Break Switches.
8.2.4." Each battery shall be earthed through earth leakage sensing system which shall
operate in the event of battery earth leakage current exceeding 30 m.A and shall
give audible alarm and visual indication in D.C. distribution board and
simultaneously on Annunciation in the Control Room. It shall isolate the battery
bank by a Air Break switch.
8.2.5." All the components/sub-components shall be of minimum rating of 150% of the

required capacity.

111
8.2.6." Painting: All the sheet metal components shall be pre-treated using the Seven
Tank Process and painted with epoxy based powder paint. The standard shade is
631 of IS:5 (Light Grey Semi glossy). The painting shall be uniform appearance and
semi glossy finish (visually) without blistering. There shall not be any peeling at
intersecting points or joints.

112
8.2.7."
8.3." CONSTRUCTION
8.3.1." BATTERY :The Battery shall be Sealed Maintenance Free Valve Regulated Lead
Acid Type with lead calcium tin alloy or lead antimony cadmium alloy for positive
plate and lead calcium alloy for negative plate. Any other time proven alloy used
for manufacture of positive and negative plate shall also be acceptable subject to
providing the documentary proof. The battery shall be designed with excess
negative active material truly emitting positive electrode to evolve oxygen first
during charging. The negative electrode shall never becomes fully charged and
evolve hydrogen. The sealed battery shall provide means to immobilize the
electrolyte in such a way that the passage/voids remained present oxygen to
diffuse to the negative plate. The battery offered shall be suitable for
satisfactory operation at the ambient temperature of 50o C. The rating of each
2V individual cell offered shall be 400 AH capacity at 10 hours discharge rate at
an ECV of 1.85V. The battery shall be supplied in factory filled and charged
condition. The Contractor shall ensure that full battery capacity as per 5.1 of
IEC:896-2 shall be obtainable on first load cycle.
8.3.2." The supporting calculations for discharge characteristics of cell/battery for

different time durations (10 Hrs., 3 Hrs., 2 Hrs., 1 Hr. & 1 minute) at an ECV of
1.85V/Cell shall be furnished with the bid.
8.3.3." The battery shall be complete with flame retarding hard rubber or glass fiber
reinforced plastic containers or polypropylene flame retardant container, lead
plates, separators, vent plugs, inter- cell connectors, interbank connector, bolts
and nuts etc. as required.
8.3.3.1." Separators:
Separator shall be made of spun glass, micro porous matrix and shall be resistant
to sulphuric acid. It shall be capable of keeping all the electrolyte absorbed in the
separator with no free electrolyte. It shall be electrically insulated. Internal
resistance shall ensure discharge characteristics under all operating conditions.
Sufficient separator overlap to edges of the plates is to be provided to prevent
short circuit between the edges of adjacent plates.
8.3.3.2." Terminal pillars:

The terminal pillars shall be suitable for mechanical connections with lead or lead
alloy reinforced with copper/brass core inserts and current density shall not
exceed 15 A/mm2 at 1minute rate.
8.3.3.3." Containers and lids:
Container shall be flame retardant hard rubber or glass fiber reinforced plastic or
polypropylene. They shall be sufficiently robust and not liable to deformation
under internal operating pressures and within the temperature range naturally
encountered, leak proof, non-absorbent, resistant to the acid and free from flaws.
They shall be able to withstand without fracture for 5 hours at 200 C at an internal
pressure of 5 times the normal operating pressure. The Contractor shall indicate

113
the pressure which the enclosure is capable to withstand in the bid. The list of
tests and test certificates performed by the manufacturers of container shall be
enclosed along with the bid.
8.3.3.4." Pillar seal assembly:
The pillar to lid seal assembly shall be designed to remain gas-tight and
electrolyte-tight during the design life of the units. When tested in accordance
with relevant standards, the seal assembly shall after 200 days on test, show no
signs of acid penetration.
8.3.3.5." Vent plug assembly:
Each cell shall be equipped with one-way safety valve. The range of operating
pressure of the vent plug shall be indicated by the Contractor in the bid.
The vent plug shall be made with suitable grade of polypropylene copolymer
plastic material. Each valve opening shall be covered with flame barrier capable of
preventing the ingress of flame into the cell interior when the valve opens and
hydrogen/oxygen gas mixture is released.
8.3.3.6." Type and thickness of positive plates:
Flat pasted plate type with high corrosion resistant lead cadmium antimony or
lead calcium tin alloy or any other time proven alloy of suitable thickness to meet
the AH capacity of the cell.
8.3.3.7." Type and thickness of negative plates:

Flat pasted plate type with lead calcium alloy or any other time proven alloy of
suitable thickness to meet the AH capacity of the cell.
8.3.3.8." Electrolyte:
The electrolyte shall be prepared from the battery grade H2S04 conforming to
IS:266 and IS : 1069.
8.4." Connectors and Fasteners:
The connections between the cells shall preferably be bolted type. The
bolts and nuts, the connectors etc. shall be effectively lead-coated to prevent
corrosion. Terminal plates of each cell shall be clearly stamped as positive and
negative. Connection cable between the charger and the battery shall be made by
single core FRLS PVC cables, which shall be arranged separately by the Purchaser. All
connectors and lugs shall be capable of continuously carrying the 30 minutes
discharge current of battery and through short circuit current produced by the
battery. The Contractor shall furnish necessary calculation in support of this
requirement. Connectors may be supplied either as separate bars or alternately as
part of the cell structure i.e. as suitably elongated heavy-duty Lead plated copper strip
connectors. The connectors shall be lead coated copper of suitable size to join the
cells. The connectors, which shall be of suitably, designed copper connectors and
suitably coated to withstand corrosion due to sulphuric acid and may be used where

114
the cells are called upon to discharge at very high rates. The coating should be
adequate and tenacious.
8.5." The following information shall be indelibly marked on outside of each cell :
a) Manufacturer's name, address and trade mark.

a) Country and month & year of manufacture
b) Serial number
c) Nominal voltage
e) AH capacity at 10 hr. discharge rate, ECV etc.
f) Polarity marking
g) Voltage of float operation
8.6." Enclosure/Modules:
Batteries shall be installed in MS Enclosure/Modules to be supplied by the contractor to fit

in the battery/battery charger room. Layout of batteries in the battery room shall be
approved by the purchaser.
Enclosure/modules shall be so designed that cells are located within easy reach at
convenient height.
Minimum number of bolts and nuts should be used primarily for anchoring and joining.
Joining shall ensure proper and tight fit.
The supplier/Contractor shall provide insulator material for the bottom channel to avoid
leakage path from battery to earth.
In case cell arrangement in the steel enclosure is horizontal, the steel enclosure shall be
provided with flame retardant transparent front cover to prevent accidental contacts with
the battery terminal and painted only with details like Battery capacity, Design life etc.
Sealed batteries employing any new technology and meeting the performance
requirement stipulated in the specification shall only be acceptable. However, the
Contractor has to submit all relevant type test reports and copies of relevant standards
along with the bid.
8.7.Operation:
The DC battery will be operated without an internal ground. For indicating the
incidence and degree of a ground fault on the DC control circuitry, the midpoint of the battery shall
be earthed through a high resistance with an ammeter. The high resistance shall be so proportional
that the current flowing under the worst earth fault shall not exceed 100mA for 400V DC system.
8.8." Ventilation
The Contractor shall indicate the requirement of ventilation of the battery room.
The loss of battery life when operated at different temperatures up to a maximum ambient of 50
°C and duration shall be furnished by the Contractor with the bid.

115
8.9." Information for the package and the battery accommodation
8.9.1." Package
Safety recommendation required by national or international regulations shall be

included on the cell or battery, or in the package and shall be got approved from the
purchaser.
8.9.2." Battery accommodation:
The following information shall be shown in the battery accommodation:

a) Nominal voltage of the battery
b) Rated or nominal capacity expressed in ampere hours (Ah) with rate of discharge and
final voltage.
c) Name of installer.
d) Statements on safety recommendations, operation and maintenance.
8.10." BATTERY CHARGERS (2 Nos. Float-Cum-Boost Charger)
8.10.1." Charging System
The Battery Chargers as well as their automatic regulators shall be of static type. All
Battery Chargers shall be capable of continuous operation at the respective rated load in
Trickle charging mode, i.e., Trickle charging the associated VRLA Batteries at 2.05 to 2.25
Volts per cell while supplying the DC load. The chargers shall also be capable of Boost
Charging the associated VRLA type Batteries at 2.25 to 2.7 volts per cell at the desired rate.
However, the terminal voltage of battery across the load shall be limited to + 5% of the
rated battery voltage. During charging, the battery shall operate on constant voltage
mode with current limit. The manufacturer shall recommend the optimum float voltage
for the batteries so that the battery will draw the necessary trickle charging current from
the float charger. The Contractor shall indicate the requirement of ventilation of the
charger room. The fail – safe current limits of chargers for operation at various over load
conditions should be indicated in the bid considering the maximum ambient temperature
at site as 50°C.
8.10.1." Output Control
All Battery Chargers shall be provided with facility for both automatic and manual control
of output voltage and current. A selector switch shall be provided for selecting the mode
of output voltage/current control, whether automatic or manual. When on automatic
control mode during float charging, the charger output voltage shall remain within +1% of
the set value, for AC input voltage variation of +10%, frequency variation of +3% & -5%, a
combined voltage and frequency variation of + 5% and a DC load variation from zero to full
load.
8.10.2." Load Limiters

116
All chargers shall have load limiters which shall cause, when the voltage control is in
automatic mode, a gradual lowering of the output voltage when the DC load current
exceeds the load limiter setting of the Charger. The Load-limiter characteristics shall be
such that any sustained overload or short circuit in DC System shall not damage the
Charger. Soft start feature should be in variably provided to minimize the inrush current
from the float charger to discharged battery.
8.10.3." Adjustment of Voltage setting
Uniform and step less adjustments of voltage setting (in both manual and automatic
modes) shall be provided on the front of the Charger panel covering the entire, specified
float charging output range. Step less adjustments of the load-limiter setting shall also be
possible from 80% to 100% of the rated output current for charging mode.
8.10.4." Battery under voltage protection
During the period the main AC Voltage is cut-off and the battery feeding the load current,
a voltage relay should be provided to cut off the battery from load once it is drained to
sensing level of 203.5V (1.85 V / cell)
Filter Circuit
Suitable filter circuits shall be provided in the chargers. The ripple content (peak to peak)
in the output voltage shall not exceed 1%, irrespective of the DC load.
8.10.5." Contactors
All battery chargers shall have an AC contactors on the input side. It shall be of air break
type and suitable for continuous duty. The operating coil shall be rated for 415 Volts AC.
8.10.6." Thermal Overload Relay
A thermal overload relays incorporating a distinct single phasing protection (using

differential movement of bimetal strips) shall also be provided for the AC input. The relay
shall trip the above contactor.
8.10.7." MCB/MCCB
i) AC input and DC output MCB/MCCBs shall be provided to in all chargers as an alternative

to switch, fuse, contactor and thermal over load relay (clause 4.2.7 and 4.2.8) and they
shall be of heavy duty single through group operated quick make, quick break type
complying with IS: 8828 & IEC: 898-1987 and suitable for 415/240 V A.C and 400 V DC. All
MCCBs shall be suitable for continuous duty. MCCBs should have auxiliary contacts for
annunciation.
ii) MCB/MCCBs shall be so designed with suitable breaking capacity in conformity with above
IEC & ISI. The Contractor shall ensure that all MCCB/MCBs are adequately rated so as to
be fully protected during all abnormal operating conditions. Alternatively AC
contactors with HRC fuses and DC contactors with HRC fuses also may be offered.
iii) MCCB/MCB shall be flush mounted on Battery Chargers Panels.

117
iv) Suitable door inter locking lamps shall be provided with micro switches.
v) MCCB shall be provided with bimetallic & magnetic type release for over current & short
circuit protection. The setting of the thermal release shall be adjustable between 50% to
100% of the rated current.
vi) MCBs for A.C and D.C control supply and heaters wherever required shall be mounted in
side the chargers.
8.10.8." Rectifier Transformer

The rectifier transformer shall be copper wound resin cast continuously rated and natural
air cooled (N.A.) type. The rating of the rectifier, transformer shall correspond to the
rating of the associated rectifier assembly. The Contractor shall provide the supporting
calculations for the transformer capacity during design & detailed engineering.
Temperature rise of the transformer during fully loaded condition shall not cause damage
to the electronic components of the charger. Necessary ventilation arrangements have to
be made to limit the temperature rise to safe limits.
8.10.9." Rectifier Assembly
3 Phase rectifier bridge assembly shall be full wave controlled shall be provided for both
float and boost charger. The rectifier assembly shall be designed to meet the duty as
required by the respective Charger. The rectifier shall be provided with their own heat sink
having their own dissipation arrangements with natural air-cooling. Necessary surge
protection devices and semi conductor fuses shall be provided in each arm of the rectifier
connections.
8.10.10."Instruments
One each DC and AC voltmeter and one AC ammeter and DC ammeter (with shunt) shall
be provided for all Chargers. The instruments shall be flush type, dust proof and moisture
resistant. The instruments shall have easily accessible means for zero adjustment. The
instruments shall be of 1.5 accuracy class. A battery ammeter shall be provided with
centre zero scale and measuring range of 200A on either side.
Indicating lamps shall be provided for the 3 Phase AC and DC supply.
8.10.11." Fuses
All fuses where required shall be HRC link type.
Fuses shall be mounted on fuse carriers which are mounted on fuse bases. Wherever it is
not possible to mount fuses on carriers, fuses shall be directly mounted on plug-in type
base. In such cases one insulated fuse pulling handle shall be supplied for each charger.
Fuse rating shall be chosen by the Contractor depending on the circuit requirement and
these shall be subjected to the approval of the purchaser.
8.10.12." Blocking Diode

118
Blocking diode adequate rating shall be provided in the positive pole of the output circuit
of each charger to prevent current flow from the DC Battery into the Charger.

119
8.10.13."Annunciation System
Visual indications through bright LED with Mimic diagram shall be provided in all Chargers
for the following abnormalities:
i) AC Supply failure
ii) Rectifier charger fuse blown
iii) DC fuse failure
iv) Filter fuse failure
vi) Battery earth leakage
vii) DC under voltage/Load limiter operated
viii) Any other annunciation if required
Potential free NO Contacts for above abnormal conditions shall also be provided for local
& remote indication. 'CHARGER TROUBLE' in both Purchaser's Control Board and Sub-
station Monitoring System.
8.10.14."Name Plates and Marking
The name plates shall be white with black engraved letters. On top of each charger, on
front as well as rear sides, larger and bold name plates shall be provided to identify the
charger. Name plates with full and clear inscription shall also be provided on and inside of
the panels for identification of the various equipments and ease of operation and
maintenance.
8.11." Charger Construction
i) The Chargers shall be indoor, floor-mounted, self-supporting sheet metal enclosed cubicle
type with bottom cable entry and access for wiring & connections on the rear side. The
Contractor shall supply all necessary base frames, anchor bolts and hardware. The
Chargers shall be fabricated from 2.0mm cold rolled sheet steel or 2.5 mm Hot Rolled
Sheet and shall have folded type of construction. Removable gland plates for all cables
and lugs for power cables shall be supplied by the Contractor. The lugs for power cables
shall be made of electrolytic copper with tin coat. Power cable sizes shall be advised to the
Contractor at a later date for provision of suitable lugs and drilling of gland plates. The
Charger shall be tropicalised and vermin proof. Ventilation louvers, if provided shall be
backed with screens. All doors and covers shall be fitted with synthetic rubber gaskets.
The chargers shall have hinged double leaf doors provided on backside for adequate
access to the charger internals. All the charger cubicle doors shall be properly earthed.
The degree of protection of Charger enclosure shall be at least IP-54 as per IS: 2147.
ii) All indicating instruments and indicating lamps shall be mounted on the front side of the
charger.
iii) Each Charger shall be furnished completely wired up to power cable lugs and terminal
blocks ready for external connections. The control wiring shall be carried out with 1.1 KV
PVC insulated, 2.5 sq.mm. Stranded copper wires, Control terminals shall be suitable for
connecting two wires, with 2.5 sq.mm stranded copper conductors. All terminals shall be
numbered for ease of connections and identification. Each wire shall bear a ferrule or tag

120
on each end for identification. At least 20% spare terminals shall be provided for control
circuits.
iv) The insulation of all circuits except the low voltage electronic circuits shall withstand test
voltage of 2 kV AC for one minute. An air clearance of at least ten (10) mm shall be
maintained throughout for such circuits, right up to the terminal lugs. Whenever this
clearance is not available, the live parts shall be insulated or shrouded.
v) The low voltage electronic circuits tests shall be as per relevant standards and the
Contractor has to furnish supporting documents for low voltage electronic circuits.
8.12." Fixation of the Battery Chargers Capacity
The rating of 40/100 Float-Cum-Boost Charger along with 2x100% Diode Dropper
Regulations required to suit 400V 400AH Capacity Battery Bank.
8.12.1." Sizing Calculation:
The Contractor shall furnish the transformer sizing calculation details along with the bid.
8.13." TESTS
8.13.1." BATTERY
All type and routine tests shall be carried out on cells of each type as per
the latest IS:8320, and IEC:60896.
8.13.2." All acceptance tests as required by the relevant Standards including those given
below shall be carried out at manufacturers works. The capacity test shall be
carried out for 10 hour discharge rating.
Cell
a) Capacity test
b) Watt hour and AH efficiency test
c) Container pressure withstand capability test for 5 hours at 20o C
Battery
a) Visual check & dimensional check
b) Normal voltage test
c) Automatic Voltage regulation operation
d) Checking of proper annunciation system operation
e) Capacity (AH) test at 10 hours and 5 hours
The Contractor shall also submit test reports on accelerated life test for 20 years on similar
or higher rating battery witnessed by an independent laboratory/authority with the bid.
The parameters for conducting acceptance tests shall be got approved from the purchaser
before performance of the tests.
8.14." BATTERY CHARGER
8.14.1." Type tests and routine tests: The type and routine tests shall be carried out on the
Battery Chargers as per relevant ISS/IEC Standards. Rectifier transformer shall be

121
subjected to short circuit test in addition to type and routine tests as specified in
IS: 4540. Along with the offer, the Contractor shall submit the test certificates for
the following tests for similar equipment already supplied to other organizations.
i) Temperature rise/Heat run Test (8 hours)

(At specified AC supply and DC load variation)
ii) Load test
iii) Automatic Voltage Regulator operation
iv) High voltage test on power and control circuits
v) Performance test on the completed panel.
vi) Insulation resistance test
vii) Surge withstand capability test as per ANSI-C-37-90A.
viii) Load limiting feature of trickle charger.
ix) Degree of Protection test
x) Efficiency & Power Factor Measurement
xi) Short circuit test on no load at rated voltage for sustained short circuit
xii) Measurement of ripple by oscilloscope.
The contractor shall submit the details of manufacturers for purchaser approval on the
make of below mentioned equipment and produce original Manufacturer/Authorized Dealer’s
undertaking letter for conformation to relevant standards for the following components to the
inspecting officer at the time of inspection and testing of charger.
i) Switches
ii) Relays/MCCBS
iii) Instruments
iv) DC fuses
v) SCR
vi) Diodes
vii) Condensers
viii) Volt and Current meters
ix) Semi-conductors
x) Control wiring
xi) Push buttons for contactors
8.14.2." Acceptance tests: The Contractor shall have to demonstrate to the Purchaser that
the charger conform to the specification regarding continuous rating, ripple
content, voltage regulation and load limiter characteristics before dispatch and
after installation at site.
The following acceptance tests shall be carried out on the chargers in the presence
of the purchaser's representative before dispatch of the equipment.
i) Marking and packing.

ii) Visual check and verification of dimensions
iii) Insulation resistance
iv) All indication & alarms test
v) Voltage regulation test.
vi) Ripple content test.
vii) Full load & No load test.
viii) Load limiter characteristics test.

122
The following acceptance tests shall be carried out at site:
a) Insulation resistance test

b) Automatic Voltage Regulation Operation
c) Checking of proper annunciation system operation
The parameters for conducting acceptance/site tests shall be got approved from the
purchaser before performance of the tests.

123
SS09 CONTROL AND RELAY PANELS
9.0." SCOPE :
This specification covers the design, engineering, manufacture, assembly, shop
testing, dispatch to destination/receiving at stores and there after taking over at
stores and transportation to Sub-Station Control House, installation, testing and
commissioning of Control and Relay Panels complete with all necessary instruments,
meters, switches, relays and other miscellaneous equipment specified in this
specifications for new 400kV Sub-Station.
9.1." Limits of contract:
The various control and relay panels and other equipments specified under this
section and offered by the Contractor shall be complete in all respect, with all
main and auxiliary relays, fuses, links, switches, instruments, meters, timers,
annunciations, indicating lamps semaphore indicators, mimic diagrams, name
plates and other devices completely wired and assembled as per the approved
schematics including Interpanel wiring between adjacent panels, labels terminal
boards, earthing terminals, foundation bolts etc. No additional charges for any
components required for satisfactory operation during execution of contract shall
be born by the purchaser.
The Contractor shall also mount and completely wire the equipment to be
supplied by others (detailed in the list of equipment) for installation on these
boards.
Dummy panels are shall be supplied and erected only if necessary.
Foundation channels, bolts, vibration dampers and all other accessories, special
tools, testing equipment and instruments, spare parts, pamphlets, instruction,
operation and maintenance manuals for all equipments shall also be supplied
by the Contractor.
Preparation and furnishing of all drawings including schematic wiring, internal

wiring and external cable connections, all types of protection single line diagrams
etc. is also in the scope of this contract.
If any special cables are required for interconnection between event logger,
disturbance recorder and external equipment, the same shall also be included
in Contractor's scope and specially brought out in the bid. Equipment
furnished shall be complete in every respect.
All cable Schedule drawings for Inter panel wiring, panel to panels in the Control
room and switchyard to panels in the control room for each substation shall be
prepared and submitted by the Contractor.
The cable terminating arrangements, viz. the cable boxes, multicore cable
glands, sealing ends for other types of cables that may be specified shall also be
included, where required for connection to the equipments under this contract

124
in the tendered price. These shall be subject to approval from the purchaser/his
representative.
.
9.2.STANDARDS:
The design, manufacture and performance of all the equipment and material
provided under this specification shall generally conform to the latest issues of the
following:-
Indian Standard Title International &

Internationally
Recognized standards
IS: 3231 Electrical Relays for Power system Protection IEC-255
Part 1 to 3, BS:142
IS: 1248 & Indicating Instruments BS: 89
IS: 2419
IS: 6236 Recorders BS: 90
IS: 722 Energy Meters BS: 37/IEC-521
(Part-I to IX)
IS: 6875 Control Switches (LV switching devices for Control and IEC: 337 & 337-1
Auxiliary circuits)
IS: 1885 Electro-Technical Vocabulary, Electrical Relays & Electrical
(Part-I & II) Power System Protection
IS: 2705 Current Transformers IEC: 185
IS: 3156 Voltage Transformers IEC-186
IS: 375 Marking & Arrangements for Switchgear, Bus bar, Main
connection and Auxiliary wiring
IS: 5 Colours for ready mixed paints and channels stability tests BS: 142
IS: 1554 (Part) PVC insulated cables up to and including 1000 Volts.
IS: 3842 Application guide for Protective Relays
(Part-I to VIII)
IS: 4483 Preferred Panel Controls and Dimensions
(Part-I & II)
IS: 9224 HRC Cartridge fuse links
(Part-II)
IS: 2147 Degrees of Protection provided by enclosures for LV
switchgear and control gear
IS: 6005 Code of Practice for Phosphate Iron and Steel
IS: 8686 Specification for static protective relays & tests IEC-255 Part-V
& VI, IEC-801-4
IS: 4237 General requirement of switchgear and control gear for
voltages not excluding 1.1 kV
IS: 5578 Guide for marking of insulated conductors
IS: 11353 Guide for uniform system of marking and identification of
conductor & apparatus terminals
IS: 13010 Energy Meters
CBIP Manual on Protection of Generators, Generator
Pub No.274 Transformers and 400kV & 400kV network
CBIP Manual on Reliable fault clearance and Back up protection
Pub No: 296 of EHV & UHV Transmission Networks
9.3." Unless otherwise specified, all equipment and material shall

conform to the latest applicable Indian Standards. Equipments complying

125
with JIS or any other authoritative standards shall also be considered if it

ensures performance of equipment equal to or superior to Indian
standards.
9.4."In the event of supply of equipment conforming to any other

International or internationally recognized standard, the salient features
of comparison shall be brought out in the tender. Two copies of such
standard specifications in English language or their Certified English
translation shall be attached with the tender. The equipment shall also
comply with the revisions to Indian Electricity Act and Indian Electricity Rules
and any other applicable Statutory Provisions, Rules and Regulations applicable
to the locations where these are to be installed.
9.5."The tenderer should submit the following type test certificates and other
type tests specified in the relevant IS/IEC Standards in respect of relays offered
by them for the relay and protection panels.
i) 5 KV impulse peak voltage test on the relays (This type report is essential
for main protection and secondary protection i.e. for distance protection
relays, differential relays, over current & earth fault relays under
frequency relay and over voltage relays etc.)
ii) Type test for vibration test to prove the stability of relays under vibrations
normally encountered and also vibrations under abnormal conditions
(this type test report shall be furnished for all the main and back up relays
as listed in (i) above).
iii) Type test report for overshoot time: for IDMT relays.
iv) Also the following type test reports for all protection relays shall be
furnished.
a) Insulation tests as per IEC: 255-5

i) Dielectric (steady state voltage) test.
ii) Insulation resistance measurement test.
iii) Impulse voltage withstand test.
b) High frequency disturbance test as per IEC:255-4
c) Fast transient test as per IEC: 801-4.
d) Relay characteristic performance and accuracy test as per

IEC: 255-16.
i) Steady state characteristics and operating time.
ii) Dynamic characteristics and operating time.
e) Tests for thermal requirement as per IEC:255-6.
f) Tests for rated burden as per IEC:255-6.
g) Tests for mechanical requirements as per IEC:255-6.

126
h) Contact performance test as per IEC:255-0-20.
v) Application checks with calculations to prove the satisfactory operation of

the distance protection (Main-I and Main-II) under heavy load and
minimum fault level conditions along with characteristic curves of Zs/Zl
ratio versus operating time, characteristics of all 3-zone elements starters
and power swing blocking on the R-X' diagram shall be submitted.
In this connection reference may please be made to IEC 801, IEC 255 and
B.S.142-1966 regarding testing of the relays.
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Volume – III, Sub-Station Specifcations

GOVERNMENT OF ANDHRA PRADESH

CONTRACTOR SUPERINTENDING ENGINEER

1 SS01 SURGE ARRESTERS

2 SS02 ISOLATORS CUM EARTHING SWITCHES

3 SS03 CIRCUIT BREAKERS

4 SS04 INSTRUMENT TRANSFORMERS

5 SS05 ACSR "MOOSE" CONDUCTOR

6 SS06 ANTI - FOG ZINC SLEEVE DISC INSULATORS

7 SS07 POWER TRANSFORMERS

8 SS08 BATTERY & BATTERY CHARGERS

9 SS09 CONTROL AND RELAY PANELS

CONTRACTOR SUPERINTENDING ENGINEER

The works include:

A. CIVIL WORKS IN THE SWITCHYARD

CONTRACTOR SUPERINTENDING ENGINEER

1. IS 8112/1989 43 grade ordinary Portland cement

7. IS 12427/1988 Transmission Tower Bolts

8. IS 1367 (part II) Technical supply conditions for

10. IS3063/1994 Fasteners - single coil rectangular

Section spring washers

12. IS4759/1984 Hot dip Zinc coatings on structural

CONTRACTOR SUPERINTENDING ENGINEER

15. IS4072/1975 Steel for spring washers

16. IS1573/1986 Electroplated Coatings of Zinc on

17. IS5561/1970 Electric power connectors

18. IS486(Part-I)/1993 Metal fittings of Insulators for

19. IS2486(Part-2)/1986 Insulator fittings for overhead power

4.0." COMPLIANCE WITH REGULATIONS

7.0." SITE CONDITIONS:

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

i. The lights shall be mounted on structures with necessary cantilever arrangement to

CONTRACTOR SUPERINTENDING ENGINEER

20.0." The scope of work shall also include:

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

24.0." TECHNICAL SPECIFICATION FOR MARSHALLING KIOSKS

CONTRACTOR SUPERINTENDING ENGINEER

SS01 SURGE ARRESTERS

i. Application Guide for Metal Oxide : IEEE Std.C62-22

ii. Lightning Arresters : IS:3070 (1993)

iv. Tests on hollow insulators for : IEC:60233

CONTRACTOR SUPERINTENDING ENGINEER

vi. H.V. Test Techniques : IEC-60060,

vii. Method of partial discharge : IS:6209

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

CONTRACTOR SUPERINTENDING ENGINEER

1.9." PACKING AND FORWARDING

CONTRACTOR SUPERINTENDING ENGINEER

Equipment to be Lightning impulse Switching Surge (kVp) Lightning impulse (kVp)