Technical Specification PDF

STANDARD BIDDING DOCUMENT
FOR
RURAL ELECTRIFICATION WORKS OF XXXX (NAME

OF DISTRICT) DISTRICT OF XXXX (NAME OF STATE)
UNDER RAJIV GANDHI GRAMEEN VIDYUTIKARAN
YOJANA (RGGVY) UNDER XII PLAN
VOLUME-II
(TECHNICAL SPECIFICATION, DRAWINGS,
PMS, QUALITY ASSURANCE MECHANISM)
Section-I: Civil works and Soil Investigation
Section-II: Technical Specifications
Section-III: Tender Drawings
Section-IV: PMS, Quality Assurance Mechanism (QAM) &
Documentation
SPECIFICATION No.:………………..
DOCUMENT NO.:……………………
Volume-II : Section-I 1
Civil Works & Soil Investigation
CIVIL WORKS AND SOIL INVESTIGATION
1. GENERAL
The provisions of this section of specification shall only be applicable to the extent of
scope of works indicated in Bid Proposal Sheet (BPS). The intent of specification covers
the following:
Design, engineering, and construction of all civil works at sub-station. All civil works shall
also satisfy the general technical requirements specified in other Sections of this
Specification and as detailed below. They shall be designed to the required service
conditions/loads as specified elsewhere in this Specification or implied as per National/
International Standards.
All civil works shall be carried out as per applicable Indian Laws, Standards and Codes. All
materials shall be of best quality conforming to relevant Indian Standards and Codes.
The Contractor shall furnish all design, drawings, labour, tools, equipment, materials,
temporary works, constructional plant and machinery, fuel supply, transportation and all
other incidental items not shown or specified but as may be required for complete
performance of the Works in accordance with approved drawings, specifications and
direction of Employer.
The work shall be carried out according to the design/drawings to be developed by the
Contractor and approved by the owner based on Tender Drawings Supplied to the
Contractor by the Owner. For all buildings, structures, foundations etc. necessary layout
and details shall be developed by the Contractor keeping in view the functional
requirement of the substation facilities and providing enough space and access for
operation, use and maintenance based on the input provided by the Owner. Certain
minimum requirements are indicated in this specification for guidance purposes only.
In case of R&M of existing substations, Contactor shall visit site to ascertain the amount
of repair and strengthening of structures and foundations, dismantling and new
construction of structures and foundations works are to be done before quoting.
Contractor must furnish the design and drawings in support of the activities mentioned
above that are to be carried out in the R&M of existing substation site.
The rate quoted by the bidder for all type of civil work shall be firm irrespective of the
type of terrain and depth of filling.
However, the Contractor shall quote according to the complete requirements.
RGGVY/XII Plan/R1
2. GEOTECHNICAL INVESTIGATION
2.1. The Contractor shall perform a detailed soil investigation to arrive at sufficiently accurate,
general as well as specific information about the soil profile and the necessary soil
parameters of the site. So that the foundation of the various structures can be designed
and constructed safely and rationally.
A report to the effect will be submitted by the Contractor for Owner’s specific approval
giving details regarding data proposed to be utilised for civil structures design.
2.2. The Contractor should visit the site to ascertain the soil parameters before submitting the
bid. The topography is uneven steeply sloping at few places requiring cutting and filling
operations including slope stability and protection measures (if slopes encountered). Any
variation in soil data shall not constitute a valid reason for any additional cost & shall not
affect the terms & condition of the Contract. Tests must be conducted under all the
critical locations i.e. Control Room Building. Tower locations, transformer etc.
3. SCOPE OF WORK
This specification covers all the work required for detailed soil investigation and
preparation of a detailed report. The work shall include mobilisation of necessary
equipment, providing necessary engineering supervision and technical personnel, skilled
and unskilled labour etc. as required to carry out field investigation as well as, laboratory
investigation, analysis and interpretation of data and results, preparation of detailed Geo-
technical report including specific recommendations for the type of foundations and the
allowable safe bearing capacity for different sizes of foundations at different founding
strata for the various structures of the substation. The Contractor shall make his own
arrangement for locating the co-ordinates and various test positions in field as per the
information supplied to him and also for determining the reduced level of these locations
with respect to the benchmark indicated by the Owner.
All the work shall be carried out as per latest edition of the corresponding Indian
Standard Codes.
3.1. Bore Holes
Drilling of bore holes of 150 mm dia. in accordance with the provisions of IS: upto 10 m
depth or to refusal which ever occur earlier. (By refusal it shall mean that a standard
penetration blow count (N) of 100 is recorded for 30 cm penetration). For a new
substation, minimum three (3) bore holes shall be done to find out the geological profile
of the area. If any unconformity encountered then more bore holes shall be drilled with
the approval of Engineer-in-charge for the new projects. However in case deep pile
foundations are envisaged the depths have to be regulated as per codal provisions. In
cases where rock is encountered, coring in one borehole per bay shall be carried out to
1.5 M in bedrock and continuous core recovery is achieved.
RGGVY/XII Plan/R1
Performing Standard Penetration Tests at approximately 1.5 m interval in the borehole

starting from 1.5 m below ground level onwards and at every change of stratum. The
disturbed samples from the standard penetrometer shall also be collected for necessary
tests.
Collecting undisturbed samples of 100/75 mm diameter 450 mm long from the boreholes
at intervals of 2.5 m and every change of stratum starting from 1.0 m below ground level
onwards in clayey strata.
The depth of Water table shall be recorded in each borehole.
All samples, both disturbed and undisturbed, shall be identified properly with the
borehole number and depth from which they have been taken.
The sample shall be sealed at both ends of the sampling tubes with wax immediately
after the sampling and shall be packed properly and transported to the Contractor’s
laboratory without any damage or loss.
The logging of the boreholes shall be compiled immediately after the boring is completed
and a copy of the bore log shall be handed over to the Engineer-in-charge.
3.2. Electrical Resistivity Test
This test shall be conducted to determine the Electrical resistivity of soil required for
designing safe grounding system for the entire station area. The specifications for the
equipments and other accessories required for performing electrical resistivity test, the
test procedure, and reporting of field observations shall confirm to IS: 3043. The test
shall be conducted using Wagner’s four electrode method as specified in IS: 1892,
Appendix-B2. Unless otherwise specified at each test location, the test shall be conducted
along two perpendicular lines parallel to the coordinate axis. On each line a minimum of 8
to 10 readings shall be taken by changing the spacing of the electrodes from an initial
small value of 0.5 m upto a distance of 10.0 m.
3.3. Water Sample
Representative samples of ground water shall be taken when ground water is first
encountered before the addition of water to aid drilling of boreholes. The samples shall
be of sufficient quantity for chemical analysis to be carried out and shall be stored in
airtight containers.
3.4. Back Filling of Bore Holes
On completion of each hole, the Contractor shall backfill all bore holes as directed by the
Owner. The backfill material can be the excavated material and shall be compacted
properly.
RGGVY/XII Plan/R1
3.5. Laboratory Test
1. The laboratory tests shall be carried out progressively during the field work after
sufficient number of samples have reached the laboratory in order that the test
results of the initial bore holes can be made use of in planning the later stages of
the field investigation and quantum of laboratory tests.
2. All samples brought from field, whether disturbed or undisturbed shall be

extracted/prepared and examined by competent technical personnel, and the test
shall be carried out as per the procedures laid out in the relevant I.S. Codes.
The following laboratory tests shall be carried out
a) Visual and Engineering Classification
b) Liquid limit, plastic limit and shrinkage limit for C-
c) Natural moisture content, bulk density and specific gravity.
d) Grain size distribution.
e) Swell pressure and free swell index determination for expensive soil
only.
f) Consolidated un-drained test with pore pressure measurement.
g) Chemical tests on soil and water to determine the carbonates,

sulphates, nitrates, chlorides, Ph value, and organic matter and any
other chemical harmful to the concrete foundation.
h) C.B.R value
i) Rock quality designation (RQD), RMR in case of rock is

encountered
3.6. Test Results and Reports
3.6.1 The Contractor shall submit the detailed report in two (2) copies wherein information
regarding the geological detail of the site, summarised observations and test data, bore
logs, and conclusions and recommendations on the type of foundations with supporting
calculations for the recommendations. Initially the report shall be submitted by the
Contractor in draft form and after the draft report is approved, the final report in two (3)
copies shall be submitted. The test data shall bear the signatures of the Investigation
Agency, Vendor and also site representative of XXXX (Name of Employer).
3.6.2. The report shall include but not limited to the following:
RGGVY/XII Plan/R1
a) A plan showing the locations of the exploration work i.e. bore holes, dynamic cone
penetration tests etc.
b) Bore Logs: Bore logs of each bore holes clearly identifying the stratification and
the type of soil stratum with depth. The values of Standard Penetration Test (SPT)
at the depths where the tests were conducted on the samples collected at various
depths shall be clearly shown against that particular stratum.
Test results of field and laboratory tests shall be summarised strata wise as well in
combined tabular form. All relevant graphs, charts tables, diagrams and
photographs, if any, shall be submitted along with report. Sample illustrative
reference calculations for settlement, bearing capacity, pile capacity shall be
enclosed.
3.7. Recommendations: The report should contain specific recommendations for the type of
foundation for the various structures envisaged at site. The Contractor shall acquaint
himself about the type of structures and their functions from the Owner. The
observations and recommendations shall include but not limited to the following:
a) Geological formation of the area, past observations or historical data, if available,

for the area and for the structures in the nearby area, fluctuations of water table
etc. Slope stability characteristics and landslide history of the area shall be
specifically highlighted. Remedial measures to be adopted shall also be given.
b) Recommended type of foundations for various structures. If piles are

recommended the type, size and capacity of pile and groups of piles shall be
given after comparing different types and sizes of piles and pile groups.
c) Allowable bearing pressure on the soil at various depths for different sizes of the
foundations based on shear strength and settlement characteristics of soil with
supporting calculations. Minimum factor of safety for calculating net safe bearing
capacity shall be taken as 3.0 (three). Recommendation of liquefaction
characteristics of soil shall be provided.
d) Recommendations regarding slope of excavations and dewatering schemes, if

required. Required protection measures for slope stability for cut & fill slopes of
switchyard and approach road with stone pitching/retaining walls shall be clearly
spelt out. Calculation shall also be provided for stability adequacy.
e) Comments on the Chemical nature of soil and ground water with due regard to
deleterious effects of the same on concrete and steel and recommendations for
protective measures.
RGGVY/XII Plan/R1
f) If expansive soil is met with, recommendations on removal or retaining the same

under the structure, road, drains, etc. shall be given. In the latter case detailed
specification of any special treatment required including specification or materials
to be used, construction method, equipments to be deployed etc. shall be
furnished. Illustrative diagram of a symbolic foundation showing details shall be
furnished.
g) Recommendations for additional investigations beyond the scope of the present

work, if considered such investigation as necessary.
4. SITE PREPARATION
The contractor shall be responsible for proper leveling of switchyard site as per layout
and levels of switchyard finalised during detailed engineering stage. The Contractor at
his own cost shall make the layout and levels of all structure etc from the general grids
of the plot and benchmarks set by the Contractor and approved by the Owner. The
Contractor shall give all help in instruments, materials and personnel to the Owner for
checking the detailed layout and shall be solely responsible for the correctness of the
layout and levels. Site leveling shall be in the scope of the contractor. Bidder may decide
the level of the sites. However, the level shall be such that it is 300 mm higher than the
highest flood level (HFL) of the site. If HFL is not available, then nearby road level shall
be assumed as HFL.
Whenever for bay extension works the existing substation are to be modified or
strengthen, contractor should keep same as EGL of existing sub-station so that FFL shall
be same for both and all the necessary arrangements are to be carried out in this regard
by the contractor.
5. SCOPE OF WORKS
This clause covers the design and execution of the work for site preparation, such as
clearing of the site, the supply and compaction of fill material, slope protection by stone
pitching/retaining walls depending on the site location & condition, excavation and
compaction of backfill for foundation, road construction, drainage, trenches and final
topping by brick soling/stone filling.
5.1. General
1) The Contractor shall develop the site area to meet the requirement of the
intended purpose. The site preparation shall conform to the requirements of
relevant sections of this specification or as per stipulations of standard
specifications. Contractor shall also carry out necessary protection of slope of
switchyard area and approach road.
RGGVY/XII Plan/R1
2) The fill material if required shall be suitable for the above requirement. The fill
shall be such material and the site so designed as to prevent the erosion by wind
and water of material from its final compacted position or the in-site position of
undisturbed soil.
3) Material unsuitable for founding of foundations shall be removed and replaced by

suitable fill material and to be approved by the Owner.
4) Backfill material around foundations or other works shall be suitable for the purpose
for which it is used and compacted to the density described under Compaction.
Excavated material not suitable or not required for backfill shall be disposed off in
areas as directed by owner upto a maximum lead of 1 km.
5.2. Excavation and backfill
1. Excavation and backfill for foundations shall be in accordance with the relevant
code.
2. Whenever water table is met during the excavation, it shall be dewatered and
water table shall be maintained below the bottom of the excavation level during
excavation, concreting and backfilling.
3. When embankments are to be constructed on slopes of 15% or greater, benches

or steps with horizontal and vertical faces shall be cut in the original slope prior to
placement of embankment material. Vertical faces shall measure not more than 1
m in height.
4. Embankments adjacent to abutments, culverts, retaining walls and similar

structures shall be constructed by compacting the material in successive uniform
horizontal layers not exceeding 20 cm in thickness (of loose material before
compaction). Each layer shall be compacted as required by means of mechanical
tampers approved by the Owner. Rocks larger than 10 cm in any direction shall
not be placed in embankment adjacent to structures.
5. Earth embankments of roadways and site areas adjacent to buildings shall be

placed in successive uniform horizontal layers not exceeding 20 cm in thickness
in loose stage measurement and compacted to the full width specified. The
upper surface of the embankment shall be shaped so as to provide complete
drainage of surface water at all times.
6. The land required for borrowing earth shall be arranged & selected by
contractor. The identified land shall be got approved by site in charge. The
quoted rates shall include cost of earth, taxes, duties, royalty, compensation for
the land identified for borrow earth. The rate shall also be inclusive of all leads,
lifts, ascent, descent and testing required for completion of work in all respect.
RGGVY/XII Plan/R1
7. The ground levels for all measurements shall be taken at every 5 meter distance
in uniformly sloping ground and at closer distance where pits/undulations are
met with. In fairly leveled area, levels shall be taken at 15 mt. apart at the
discretion of Engineer in Charge. The ground levels shall be recorded and
plotted on plans. The same is signed by the contractor and the Engineer in
Charge before the earth work is started. All labor, material, tool, equipment etc
required for the above work shall be arranged by the contractor at his own cost.
5.3. Compaction
1. The density to which fill materials shall be compacted shall be as per relevant IS
and as per direction of Owner. All compacted sand filling shall be confined as far
as practicable. Backfilled earth shall be compacted to minimum 95% of the
Standard Proctor’s density at OMC. The sub-grade for the roads and embankment
filling shall be compacted to minimum 95% of the Standard Proctor’s density at
OMC. Cohesion less material sub grade shall be compacted to 70% relative
density (minimum).
2. At all times unfinished construction shall have adequate drainage. Upon

completion of the road’s surface course, adjacent shoulders shall be given a final
shaping, true alignment and grade.
3. Each layer of earth embankment when compacted shall be as close to optimum

moisture content as practicable. Embankment material, which does not contain
sufficient moisture to obtain proper compaction, shall be wetted. If the material
contains any excess moisture, then it shall be allowed to dry before rolling. The
rolling shall begin at the edges overlapping half the width of the roller each time
and progress to the center of the road or towards the building as applicable.
Rolling will also be required on rock fills. No compaction shall be carried out in
rainy weather.
5.4. Requirement for fill material under foundation
All foundations shall rest below virgin ground level and the minimum depth of foundation
below the virgin ground level shall be at least 500 mm. For small equipment and minor
foundations like marshalling kiosk, Switch board stand, earth switch and main box
support etc. may be reduced to 300 mm with specific approval of the owner.
6. STONE FILLING & ANTIWEED TREATMENT
6.1. Scope of Works
The Contractor shall furnish all labour, equipment and materials required for complete
performance of the work in accordance with the drawings, specification and direction of
the Owner.
RGGVY/XII Plan/R1
Stone filling shall be done in the areas of the switchyard wherever equipments and or
structures are to be provided under present scope of work covering entire fencing area.
Prevailing practice of stone filling is to be adopted for the bay extension works of existing
substations. Contractor shall verify the existing practice prevailing at site before quoting.
Before taking up stone rolling, antiweed treatment shall be applied in the switchyard area
where stone filling is to be done and the area shall be thoroughly de-weeded including
removal of the roots. The recommendation of local agriculture/horticulture department
shall be sought where ever feasible while choosing the type of chemical to be used.
Nevertheless the effectiveness of chemical shall bedemonstrated by the contractor in a
test area of size 10 meterx 10 meter (approx..). The final approval based on the result
shall be given by Engineer-in-charge. Antiweed treatment shall be procured from reputed
manufacturer. The dosage and application of chemical shall be strictly as per the
manufacturer’s recommendation. The contractor shall be requested to maintain the area
free of weed for a period of one year from the date of application of the first dose of the
chemical.
7. GENERAL REQUIREMENT
7.1 The material required for site surfacing shall be free from all types of organic materials
and shall be of standard quality, and as approved by the Owner.
The material to be used for stone filling/ site surfacing shall be uncrushed/ crushed/
broken stone of 20 mm nominal size (single sized) conforming to table 2 of IS: 383-
1970. Hardness, flakiness shall be as required for wearing courses are given below.
(a) Sieve analysis limits/Gradation

Sieve size % passing by weight
40mm 100
20mm 85-100
10mm 0-20
4.75mm 0-5
(b) Hardness
Abrasion value (IS: 2386 part-IV) not more than 40%
Impact value (IS: 2386 part-IV) not more than 30%
(c) Flakiness Index

As per (IS: 2386 part-IV) and maximum value is 25.
RGGVY/XII Plan/R1
7.2 After all the structures/equipments are erected, the surface of the switchyard area shall
be maintained, rolled/compacted to the lines and grades as decided by Engineer-in-
Charge. De-weeding including removal of roots shall be done before rolling is
commenced. Engineer-in-Charge shall decide final formation level so as to ensure that
the site appears uniform. The final formation level shall however be very close to the
formation level indicated in the drawing using half-ton roller with suitable water sprinkling
arrangement to form a smooth and compact surface.
7.3 A base layer of uncrushed/crushed/broken stone of 20 mm nominal size (single sized)

shall be spread and rolled/compacted by using half ton roller with 4 to 5 passes and
water sprinkling to form a minimum 50 mm layer on the finished ground level of the
specified switchyard area excluding roads, drains, cable trench and tower and equipment
foundations as indicated in the drawing.
7.4 Over the base layer of site surfacing material, a final surface course of minimum 50 mm
thickness of 20 mm nominal size (single sized) broken stone as specified above shall be
spread and compacted by light roller using half tones steel roller (width 30" and 24" dia
meter) with water sprinkling as directed by the Engineer-in-Charge. The water shall be
sprinkled in such a way that bulking does not take place.
7.5 In areas that are considered by the Engineer-in-Charge to be too congested with
foundations and structures for proper rolling of the site surfacing material by normal
rolling equipments, the material shall be compacted by hand, if necessary. Due care shall
be exercised so as not to damage any foundation structures or equipment during rolling
compaction.
8. SITE DRAINAGE
1. Adequate site drainage system shall be provided by the Contractor in new and existing
substation. In case of bay extension of existing substation, drainage layout shall be
prepared by the contractor in such away that it should satisfy the technical parameters
stated below while designing the drainage system so that flow of water of the existing
part of substation remain uninterrupted and the same should be approved by the
owner. The technical parameters stated below also to be taken into account while
designing the drainage system for new substation as well.
The Contractor shall obtain rainfall data and design the storm water drainage system,
(culverts, ditches, drains etc.) to accommodate run off due to the most intense rainfall
that is likely to occur over the catchments area in one hour period on an average of
once in ten years. The surface of the site shall be sloped to prevent the ponding of
water.
2. The maximum velocity for pipe drains and open drains shall be limited to 2.4m/sec and
1.8m/sec respectively. However, minimum non-silting velocity of 0.6m/sec shall be en-
sured. Longitudinal bed slope shall not be milder than 1 in 1000.
RGGVY/XII Plan/R1
3. The drains shall be constructed using Brick masonry except at road crossings etc.
where RCC pipe shall be used. The RCC pipe for drains and culverts shall be as per
IS:456 and IS:783.
4. The Contractor shall ensure that water drains are away from the site area and shall
prevent damage to adjacent property by this water. Adequate protection shall be given
to site surfaces, roads, ditches, culverts, etc. to prevent erosion of material by water.
5. The drainage system shall be adequate without the use of cable/pipe trenches. (Pipe
drains shall be provided in areas of switchyard where movement of crane will be
necessary in operating phase of the substation).
6. For pipe drains, concrete pipe of class NP2 shall be used. However, for road crossings
etc. higher strength pipe of class NP3 shall be provided. For rail crossings, pipes
conforming to railway loading standards or at least NP4 class shall be provided.
Manholes shall be provided at every 30m interval, at connection points and at every
change of alignment.
7. Open surface drains for new s/s shall be provided with brick masonry in 1:6 (1 cement:
6 coarse sand) cement mortar with 12 mm thick, 1:4 (1 cement: 4 sand) cement
plaster inside and exposed surface of drains as per approved drawing. For bay
extension at existing substations, prevailing practice of the respective substation shall
be adopted.
8. Pipe drains shall be connected through manholes at an interval of max. 30m. Effluents
shall be suitably treated by the Contractor to meet all the prevalent statutory
requirements and local pollution control norms and treated effluents shall be conveyed
to the storm water drainage system at a suitable location for its final disposal.
9. Invert of the drainage system shall be decided in such a way that the water can easily
be discharged above the High Flood Level (HFL) outside substation boundary at
suitable location upto a maximum 50M beyond boundary wall of substation or actual
whichever occurs earlier and approved by Owner.
10. All internal site drainage system, including the final connection/disposal to owner
acceptance points shall be part of Supplier’s scope including all required civil works.
The Contractor shall connect his drain(s) at one or more points to outfall points as
feasible at site.
11. The drainage scheme and associated drawings shall be got approved and constructed
as per enclosed tender drawing.
RGGVY/XII Plan/R1
9. ROADS AND CULVERTS
1. The main approach road including modification of existing road to meet the site
conditions, roads for access to equipment and buildings with in substations
(including bay extension in existing substations) are in the scope of bidder. Layout
of the roads shall be based on General detail & Arrangement drawing for the
substation. If extra road is required for functional point of view, which has not
been mentioned in the layout drawing, Contractor should provide the same
without extra cost to the owner.
2. All substation roads shall be constructed so as to permit transportation of all

heavy equipment. The roads shall have min. 3.0 m wide RCC road as per enclosed
tender drawing.
3. Road construction shall be as per IRC standards.
4. Adequate provision shall be made for road drainage. Protection of cut and
embankment slopes of roads as per slope stability requirement shall be made.
5. All the culverts and its allied structure (required for road/rail, drain trench
crossings etc.) shall be designed for class A loading as per IRC standard / IS code
and should be checked for loading.
6. All roads shall be designed for class ‘D’ of traffic as per IRC-37 Guide-lines for the
design of rigid pavements.
10. TRANSFORMER FOUNDATION
The Contractor shall provide a road system integrated with the transformer foundation to
enable installation and the replacement of any failed unit by the spare unit located at the
site. This system shall enable the removal of any failed unit from its foundation to the
nearest road.
If existing/failed transformer is required to be replaced by new one in augmentation/bay

extension works of existing substations then the foundation supporting that equipment
shall be strengthen by modifying the foundation itself or the foundation shall be
dismantle and recast new foundation as per site conditions. However, contractor must
furnish the design calculation incorporating all those changes so that safety of the
structure and foundation remain adequate.
Similarly all types of equipment foundations with /without supporting structures shall be
treated in similar manner as stated for transformer foundations.
Contractor must access the amount of work involve for augmentation/bay extension of
existing substations while quoting.
RGGVY/XII Plan/R1
11. CABLE & PIPE TRENCHES
1. The cable trenches and precast removable RCC cover (with lifting arrangement)
shall be constructed using RCC of M20 grade for new substation whereas for bay
extension of existing substation size and material of cable trenches shall be same
as the existing one and pre-cast removable RCC cover (with lifting arrangement)
shall be constructed using RCC of M20 grade. Cable trenches must be designed
for the design criteria stated below, whether it is of concrete or brick for both new
substations and bay extension works in existing substations.
2. The cable trench walls shall be designed for the following loads.
(i) Dead load of 100 kg/m length of cable support + 75 Kg on one tier at the
end.
(ii) Triangular earth pressure + uniform surcharge pressure of 1T/m2.
3. Cable trench covers shall be designed for self-weight of top slab + concentrated load
of 200 kg at centre of span on each panel.
4. Cable trench crossing the road/rails shall be designed for class A. Loading of
IRC/relevant IS Code and should be checked for transformer loading.
5. Trenches shall be drained. Necessary sumps be constructed and sump pumps if

necessary shall be supplied. Cable trenches shall not be used as storm water drains.
6. The top of trenches shall be kept at least 100 mm above the finished ground level for
the new substation. The top of cable trench shall be such that the surface rainwater
does not enter the trench.
The top of trench shall be kept same as existing one to maintain uniformity of the
cable trenches structure in case of bay extension works of existing substations.
7. All metal parts inside the trench shall be connected to the earthing system.
8. Cables from trench to equipments shall run in hard conduit pipes.
9. Trench wall shall not foul with the foundation. Suitable clear gap shall be provided.
10. The trench bed shall have a slope of 1/500 along the run & 1/250 perpendicular to
the run.
11. Cable trenches shall be blocked at the ends if required with brick masonry in cement
sand mortar 1:6 and plaster with 12mm thick 1:6 cement sand mortar.
12. Cable trench contains cable trey that shall be supported on ISA. The size and spacing
of angle section shall be as per design criteria mentioned above.
RGGVY/XII Plan/R1
13. Cable trench shall be constructed as per enclosed tender drawing.
12. FOUNDATION /RCC CONSTRUCTION
12.1. General
1. Work covered under this Clause of the Specification comprises the design and
construction of foundations and other RCC constructions for switchyard structures,
equipment supports, trenches, drains, control cubicles, bus supports, transformer,
marshalling kiosks, auxiliary equipments & systems, buildings, tanks, boundary
wall or for any other equipment or service and any other foundation required to
complete the work. This clause is as well applicable to the other RCC
constructions.
However, for the augmentation/bay extension works of existing substation, type

of RCC structures and foundations etc. shall be similar to one already existing at
the existing substation and for which design shall be furnished in support of safety
of those RCC structures and foundations etc. Contractor must access the amount
of work involved for the construction of switchyard structures, equipment
supports, trenches, drains, control cubicles, bus supports, transformer,
marshalling kiosks, auxiliary equipments & systems, buildings, tanks, boundary
wall or for any other equipment or service and any other foundation required to
complete the work for the existing substations.
2. Concrete shall conform to the requirements mentioned in IS: 456 and all the tests
shall be conducted as per relevant Indian Standard Codes as mentioned in
Standard field quality plan appended with the specification
A minimum grade for PCC and RCC shall be used for all structural/load-bearing
members as per latest IS 456.
3. If the site is sloppy, the foundation height will be adjusted to maintain the exact
level of the top of structures to compensate such slopes.
4. The switchyard foundation’s plinths and building plinths shall be minimum 300mm
and 500 mm above finished ground level respectively.
5. Minimum 75mm thick lean concrete shall be provided below all underground
structures, foundations, trenches etc. to provide a base for construction.
6. Concrete made with Portland slag cement shall be carefully cured and special
importance shall be given during the placing of concrete and removal of
shuttering.
RGGVY/XII Plan/R1
7. The design and detailing of foundations shall be done based on the approved soil
data and sub-soil conditions as well as for all possible critical loads and the
combinations thereof. The Spread footings foundation or pile foundation as may
be required based on soil/sub-soil conditions and superimposed loads shall be
provided.
8. If pile foundations are adopted, the same shall be cast-in-situ driven/bored or

precast or under reamed type as per relevant parts of IS Code 2911. Only RCC
piles shall be provided. Suitability of the adopted pile foundations shall be justified
by way of full design calculations. Detailed design calculations shall be submitted
by the bidder showing complete details of piles/pile groups proposed to be used.
Necessary initial load test shall also be carried out by the bidder at their cost to
establish the piles design capacity. Only after the design capacity of piles has
been established, the Contractor shall take up the job of piling. Routine tests for
the piles shall also be conducted. All the work (design & testing) shall be planned
in such a way that these shall not cause any delay in project completion.
12.2. Design
1. Foundations shall be of reinforced cement concrete for new substation but for the
augmentation / bay extension works of existing substation it could be of RCC/
PCC depending on type of structures and materials used for the similar type of
structures in those bay extension works of existing substation. Design
requirement shall be fulfilled by the contractor and furnished for approval for both
new substation and existing substation (for bay extension works) as specified in
the scope of work. The design and construction of RCC/ PCC / Masonry structures
shall be carried out as per IS: 456 and relevant IS code/CBIP manual/NBC etc and
minimum grade of concrete shall be as per relevant IS code. Higher grade of
concrete than specified above may be used at the discretion of Contractor without
any additional financial implication to the Owner.
2. Limit state method of design shall be adopted unless specified otherwise in the
specification.
3. For detailing of reinforcement IS: 2502 and SP: 34 shall be followed. Cold twisted
deformed bars (Fe=415 N/mm2) conforming to IS: 1786 shall be used as
reinforcement. However, in specific areas, mild steel (Grade I) conforming to IS:
432 can also be used. Two layers of reinforcement (on inner and outer face) shall
be provided for wall & slab sections having thickness more than 150 mm. Clear
cover to reinforcement towards the earth face shall be minimum 40 mm.
4. RCC water retaining structures like storage tanks, etc. shall be designed as un-
cracked section in accordance with IS: 3370 (Part I to IV) by working stress
method. However, water channels shall be designed as cracked section with
limited steel stresses as per IS: 3370 (Part I to IV) by working stress method.
RGGVY/XII Plan/R1
5. The procedure used for the design of the foundations shall be the most critical
loading combination of the steel structure and or equipment and/or
superstructure and other conditions, which produces the maximum stresses in the
foundation or the foundation component and as per the relevant IS Codes of
foundation design. Detailed design calculations shall be submitted by the bidder
showing complete details of piles/pile groups or isolated /combined footings
proposed to be used.
6. Design shall consider any sub-soil water pressure that may be encountered
following relevant standard strictly.
7. Necessary protection to the foundation work, if required shall be provided to take

care of any special requirements for aggressive alkaline soil, black cotton soil or
any other type of soil which is detrimental/harmful to the concrete/masonry
foundations.
8. RCC columns /pedestals shall be provided with rigid connection at the base.
9. All sub-structures shall be checked for sliding and overturning stability during both
construction and operating conditions for various combinations of loads. Factors
of safety for these cases shall be taken as mentioned in relevant IS Codes or as
stipulated elsewhere in the Specifications. For checking against overturning,
weight of soil vertically above footing shall be taken and inverted frustum of
pyramid of earth on the foundation should not be considered.
10. Earth pressure for all underground structures shall be calculated using co-efficient
of earth pressure at rest, co-efficient of active or passive earth pressure
(whichever is applicable).
11. In addition to earth pressure and ground water pressure etc., a surcharge load of
1T/Sq.m shall also be considered for the design of all underground structures
including channels, sumps, tanks, trenches, substructure of any underground
hollow enclosure etc., for the vehicular traffic in the vicinity of the structure.
12. Following conditions shall be considered for the design of water tank in pumps
house, channels, sumps, trenches and other underground structures:
a) Full water pressure from inside and no earth pressure & ground water
pressure & surcharge pressure from outside (application only to structures,
which are liable to be filled up with water or any other liquid).
b) Full earth pressure, surcharge pressure and ground water pressure from
outside and no water pressure from inside.
RGGVY/XII Plan/R1
c) Design shall also be checked against buoyancy due to the ground water
during construction and maintenance stages. Minimum factor of safety of
1.5 against buoyancy shall be ensured ignoring the superimposed loadings.
13. The foundations shall be proportioned so that the estimated total and differential
movements of the foundations are not greater than the movements that the
structure or equipment is designed to accommodate.
14. The foundations of transformer and circuit breaker shall be of block type
foundation. Minimum reinforcement shall be governed by IS: 2974 and IS: 456.
15. The tower and equipment foundations shall be checked for a factor of safety of
2.0 for normal condition and 1.5 for short circuit condition against sliding,
overturning and pullout.
12.3. Admixtures & additives
1. Only approved admixtures shall be used in the concrete for the Works. When
more than one admixture is to be used, each admixture shall be batched in its
own batch and added to the mixing water separately before discharging into the
mixer. Admixtures shall be delivered in suitably labeled containers to enable
identification.
2. Admixtures in concrete shall conform to IS: 9103. The water proofing cement
additives shall conform to IS: 2645. Owner shall approve concrete Admixtures/
Additives.
3. The Contractor may propose and the Owner may approve the use of a water-
reducing set-retarding admixture in some of the concrete. The use of such an
admixture will not be approved to overcome problems associated with inadequate
concrete plant capacity or improperly planned placing operations and shall only be
approved as an aid to overcoming unusual circumstances and placing conditions.
4. The water-reducing set-retarding admixture shall be an approved brand of Ligno-

sulphonate type admixture.
5. The waterproofing cement additives shall be used as required / advised by the

Owner.
12.4. GATES AND BOUNDARY WALL
1. The Gate frame shall be made of medium duty MS pipe conforming to relevant IS
with welded joints.
RGGVY/XII Plan/R1
2. The gates shall be fabricated with welded joints to achieve rigid connections. The
gate frames shall be painted with one coat of approved steel primmer and two
coats of synthetic enamel paint.
3. Gates shall be fitted with approved quality iron hinges, latch and latch catch.
Latch and latch catch shall be suitable for attachment and operation of pad lock
from either side of gates. Hinges shall permit gates to swing through 180 degree
back against fence. Gates shall be earthed by G I wire.
4. Gates shall be fitted with galvanized chain hook or gate hold back to hold gates
open. Double gates shall be fitted with centre rest and drop bolt to secure gates
in closed position.
5. Gates shall be installed in locations shown on drawings. Next to the main gate, a
men gate (1.25 m wide, single leaf) shall also be provided.
6. Bottom of gates shall be set approximately 40mm above ground surface and
necessary guiding mechanism shall be fitted.
7. The Contractor shall design and construct boundary wall around substation area
as per requirements. The boundary wall shall be of height 2.0M and shall be
made of RCC frame construction with RCC column and plinth beam arrangement
and panels filled with one brick thick wall in cement sand mortar 1:6. The
boundary wall shall be plastered on both external and internal faces with cement
and sand plaster 1:6 of thickness 18 mm and 12 mm respectively. An additional
barbed Y-shaped arm of MS angle 50x50x6 with 3-rows (6 nos) barbed wire A-4
IS: 278. Expansion joints shall be provided as per codal requirements. MS grating
shall be provided at required locations for drainage purposes. The boundary wall
shall be painted with minimum two coats of color wash over a base coat of white
wash with lime. The front portion of boundary wall shall however be with a RC jail
and 12 mm square MS bar top above brick work and pebble dash plaster finish
with colour pigment. The steel work shall be given two coats of synthetic enamel
paint of approved make over one coat of primer. Boundry wall and gate shall be
constructed as per enclosed tender drawing.
13. BUILDINGS - GENERAL REQUIREMENTS
13.1. General
The scope for new control room building includes the design, engineering and construc-
tion including anti-termite treatment, plinth protection, DPC of Building including
sanitary, water supply, electrification, false ceiling etc. of control room building. The
buildings shall be of RCC framed structure of concrete of M20 grade (Min.). Following
design criteria shall be adopted for design purposes for new substation.
RGGVY/XII Plan/R1
If any extension of the Control Room building is required in augmentation / bay

extension works of existing substation then extension part shall be compatible to
existing one structurally and architecturally but following design criteria shall be adopted
for design purposes for R&M of existing substation.
13.2. Control room Building
Minimum floor area requirements shall be 10000×120000 mm excluding space for wash
room which may be increased at the time of detailed engineering to suit project
requirements. The layout of the control room shall be finalised as per detailed
engineering to suit project requirements .The minimum dimension of different rooms
required for C.R.building shall be as per drawing. The CR building shall consist of the
following:
a. Control room
b. S/s In-charge room
c. Battery room
d. Store room
e. Toilet
An open space of 1 m minimum shall be provided on the periphery of the rows of panel
and equipment generally in order to allow easy operator movement and access as well
as maintenance.
Any future possibility of annexe building shall be taken care of while finalizing the layout
of the control room building.
Minimum headroom of 3 M below soffit of beams/false ceiling shall be considered for

rooms. The roof shall have four side sloping roof or flat roof as finalised during detailed
engineering.
13.2.1. Design
a) The buildings shall be designed:
1. To the requirements of the National Building Code of India, and the

standards quoted therein.
2. For the specified climatic & loading conditions.
3. To adequately suit the requirements of the equipment and apparatus

contained in the buildings and in all respects to be compatible with the
intended use and occupancy.
4. With a functional and economical space arrangement.
RGGVY/XII Plan/R1
5. For a life expectancy of structure, systems and components not less than
that of the equipment, which is contained in the building, provided regular
maintenance is carried out.
6. Be aesthetically pleasing. Different buildings shall show a uniformity and

consistency in architectural design.
7. To allow for easy access to equipment and maintenance of the equipment.
8. With, wherever required, fire retarding materials for walls, ceilings and
doors, which would prevent supporting or spreading of fire.
9. Suitable expansion joints shall be provided in the longitudinal direction

wherever necessary with provision of twin columns.
10. Individual members of the buildings frame shall be designed for the worst
combination of forces such as bending moment, axial force, shear force,
torsion etc.
11. Permissible stresses for different load combinations shall be taken as per
relevant IS Codes.
12. The building lighting shall be designed in accordance with the

requirements of relevant section.
13. Sesmic considerations as applicable.
13.2.2. Design loads
Building structures shall be designed for the most critical combinations of dead loads,
superimposed loads, equipment loads, wind loads, seismic loads, and temperature
loads.
Dead loads shall include the weight of structures complete with finishes, fixtures and
partitions and should be taken as per IS: 1911.
Super-imposed loads in different areas shall include live loads, minor equipment loads,
cable trays, small pipe racks/hangers and erection, operation and maintenance loads.
Equipment loads shall constitute, if applicable, all load of equipments to be supported on
the building frame.
The wind loads shall be computed as per IS 875, Seismic Coefficient method shall be
used for the seismic analysis as per IS 1893 with importance factor 1.5.
Wind and Seismic forces shall not be considered to act simultaneously.
RGGVY/XII Plan/R1
Floors/slabs shall be designed to carry loads imposed by equipment, cables piping,

equipment and other loads associated with building. Floors shall be designed for live
loads as per relevant IS. Cable and piping loads shall also be considered additionally for
floors where these loads are expected.
For consideration of loads on structures, IS: 875 shall strictly adhere to. Any other load
coming in the structure, not mentioned in IS 875 shall be calculated as per relevant IS
code and NBC.
13.2.3. Submission
The following information shall be submitted for review and approval to the Owner:
1. Design criteria shall comprise the codes and standards used, applicable climatic
data including wind loads, earthquake factors maximum and minimum
temperatures applicable to the building locations, assumptions of dead and live
loads, including equipment loads, impact factors, safety factors and other relevant
information.
2. Structural design calculations and drawing (including construction/fabrication) for

all reinforced concrete and structural steel structures.
3. Fully, dimensioned concept plan including floor plans, cross sections, longitudinal
sections, elevations and perspective view of each building. These drawings shall
be drawn at a scale not smaller than 1:75 and shall identify the major building
components.
4. Fully dimensioned drawings showing details and sections drawn to scales of

sufficient size to clearly show sizes and configuration of the building components
and the relationship between them.
5. Product information of building components and materials, including walls

partitions flooring ceiling, roofing, door and windows and building finishes.
6. A detailed schedule of building finishes including colour schemes.
7. A door & window schedule showing door types and locations, door lock sets and
latch sets and other door hardware.
Approval of the above information shall be obtained before ordering materials or starting
fabrication or construction as applicable.
RGGVY/XII Plan/R1
13.2.4. Finish Schedule
(a) The finishing schedule is given in subsequent clauses.
(b) M.S. Ladder should be provided to access the control room roof from outside.
Ladder shall be made up of ISMC 75x40 which will run as beam one meter apart and
intermediate steps will be made up of 45x45x5 angle with rise of 300 mm. Red oxide
premier shall be applied initially, then two coats of rich zinc paint shall be applied to
avoid corrosion.
13.2.5. Flooring
Flooring in various rooms of control room building shall be as for detailed schedules given
in Table -1
13.2.6. Walls
Control room buildings shall be of framed superstructure. All walls shall be non-load
bearing walls. Min. thickness of external walls shall be 230 mm (one brick) with 1:6
cement sand mortar.
13.2.7. Plastering
All internal walls shall have minimum 12mm and 15 mm thick 1:6 cement sand plaster on
either side of wall. The ceiling shall have 6mm thick 1:4 cement sand plaster.
13.2.8. Finishing
All external surfaces shall have 18 mm cement plaster in two coats, under layer 12 mm
thick cement plaster 1:5 and finished with a top layer 6 mm thick cement plaster 1:6
(DSR 13.19) with water proofing compound. The paint shall be antifungal quality of
reputed brand suitable for masonry surfaces for high rainfall zone. White cement primer
shall be used as per manufacturer’s recommendation.
RGGVY/XII Plan/R1
Internal finish Schedule is given Table - 1 below:

TABLE-1
Sl.No Location Flooring & Wall Internal Ceiling Doors, Windows,

. Skirting Ventilators
150mm high
1. Control Room, Precast Oil bound washable White Wash 1) Standard steel rolled
Relay Room Terrazo tiles distemper on (DSR’02 – section frames with 5
(DSR’02, item smooth surface 13.70.1) mm glass. DSR’02 –
no. 11.29A.2 applied with 2mm 10.12, 10.13 & 10.14
& 11.31.2 thick Plaster of Paris
putty. (DSR’02 – 2) Flush door shutters -
13.40 A & 13.77.2) DSR’02 – 9.25.2
2. Sub-station Precast Oil bound washable White Wash 1) Standard steel rolled
Incharge, Office, Terrazo tiles distemper on (DSR’02 – section frames with 5
corridor, staff (DSR’02, item smooth surface 13.70.1) mm glass. DSR’02 –
room. no. 11.29A.2 applied with POP 10.12, 10.13 & 10.14
& 11.31.2 putty. (DSR’02 –
13.40 A & 13.77.2) 2) Flush door shutters -
DSR’02 – 9.25.2
3. Battery room Acid and Alkali Dado of acid Acid 1) Standard steel rolled
Resistant tiles. resistant tile 1.2 M resistant section frames with 5
DSR’02 – high & Paint above Paint. mm glass. DSR’02 –
11.36 C. 1 & 1.2 M to ceiling. DSR’02 – 10.12, 10.13 & 10.14
11.36 C.1.1 DSR’02 – 11.36 C. 13.96.1
2.1, 11.36C.2 & 2) Flush door shutters -
13.96.1 DSR’02 – 9.25.2
Painted with acid

resistant Paint. DSR’02 –
13.96.1
4. Toilet Ceramic DADO glazed tile White Wash 1) Standard steel rolled
glazed tiles in 2.1M high for toilet (DSR’02 – section frames with 5
flooring (DSR 02 - 11.73) 13.70.1) mm glass. DSR’02 –
DSR’02 – 10.12, 10.13 & 10.14
11.74
2) Flush door shutters -
DSR’02 – 9.25.2
5. Other areas not Terrazo tiles Oil bound White Wash
specified (DSR’02 - distemper, (DSR’02 –
11.29A.2 & DSR’02 - 13.40A & 13.70.1)
11.31.20 13.77
Note: DSR item references (DSR-2002) to be read with CPWD specifications are only for
material and workmanship guidance of the Contractors.
RGGVY/XII Plan/R1
13.2.9. Roof
Roof of the C.R. Building shall consist of Cast-in-situ RCC slab treated with a water
proofing system which shall be an integral cement based treatment conforming to CPWD
specification (item no. 25.8 of DSR 2002). The water proofing treatment shall be of
following operations:
(a) Applying and grouting a slurry coat of neat cement using 2.75 kg/m2 of cement
admixed with proprietary water proofing compounds conforming to IS: 2645 over
the RCC slab including cleaning the surface before treatment.
(b) Laying cement concrete using broken bricks/brick bats 25mm to 100mm size with
50% of cement mortar 1:5 (1 cement: 5 coarse sand) admixed with proprietary
water proofing compound conforming to IS: 2645 over 20mm thick layer of cement
mortar of min 1:5 (Cement: 5 coarse sand) admixed with proprietary water proofing
compound conforming to IS: 2645 to required slope and treating similarly the
adjoining walls upto 300mm height including rounding of junctions of walls and
slabs.
(c) After two days of proper curing applying a second coat of cement slurry admixed
with proprietary water proofing compound conforming to IS: 2645.
(d) Finishing the surface with 20mm thick joint less cement mortar of mix 1:4 (1
cement: 4 course sand) admixed with proprietary water proofing compound
conforming to IS: 2645 and finally finishing the surface with trowel with neat cement
slurry and making of 300 x 300 mm square.
(e) The whole terrace so finished shall be flooded with water for a minimum period of
two weeks for curing and for final test. All above operations to be done in order and
as directed and specified by the Engineer-in-charge.
With average thickness of 120 mm and minimum thickness at khurra at 65 mm.
13.2.10. Glazing
Minimum thickness of glazing shall be 5.0 mm. as per IS: 2835.
13.2.11. Doors and Windows
The details of doors and windows of the control room building shall be as per finish
schedule Table-1 and tender drawing with the relevant IS code. Rolling steel shutters
and rolling steel grills shall be provided as per layout and requirement of buildings.
Paints used in the work shall be of best quality specified in CPWD specification.
RGGVY/XII Plan/R1
13.2.12. Plumbing & Sanitation
(i) All plumbing and sanitation shall be executed to comply with the requirements of
the appropriate byelaws, rules and regulations of the Local Authority having
jurisdiction over such matters. The Contractor shall arrange for all necessary
formalities to be met in regard to inspection, testing, obtaining approval and
giving notices etc.
(ii) PVC syntax or equivalent make Roof water tank of adequate capacity depending
on the number of users for 24 hours storage shall be provided. Minimum 1 Nos.
500 liters capacity shall be provided.
(iii) Galvanized MS pipe of medium class conforming to IS: 1239 shall be used for
internal & external piping work for potable water supply.
(iv) Sand CI pipes with lead joints conforming to IS: 1729 shall be used for sanitary
works above ground level.
(v) Each toilet shall have the following minimum fittings.
(a) WC (Western type) 390 mm high with toilet paper roll holder and all fittings
Or
WC (Indian Type) Orissa Pattern (580 x 440 mm) with all fittings (both types of
WCs shall be provided at alternate locations).
(b) Urinal (430 x 260 x 350 mm size) with all fittings.
(c) Wash basin (550 x 400 mm) with all fittings.
(d) Bathroom mirror (600 x 450 x 6 mm thick) hard board backing
(e) CP brass towel rail (600 x 20 mm) with C.P. brass brackets
(f) Soap holder and liquid soap dispenser.
(vi) All fittings, fastener, grating shall be chromium plated.
(vii) All sanitary fixtures and fittings shall be of approved quality and type
manufactured by well known manufacturers. All items brought to site must bear
identification marks of the type of the Manufacturer.
(viii) Soil, waste and drain pipes, for underground works shall be stoneware for areas
not subject to traffic load. Heavy-duty cast iron pipes shall be used otherwise.
RGGVY/XII Plan/R1
(ix) In case of Augmentation/R&M of existing substation, amount of work

shall be envisaged by contract for lump sum quotation.
14. MISCELLANEOUS GENERAL REQUIREMENTS
14.1. Dense concrete with controlled water cement ratio as per IS-code shall be used for all
underground concrete structures such as pump-house, tanks, water retaining structures,
cable and pipe trenches etc. for achieving water-tightness.
14.2. All joints including construction and expansion joints for the water retaining structures
shall be made water tight by using PVC ribbed water stops with central bulb. However,
kicker type (externally placed) PVC water stops shall be used for the base slab and in
other areas where it is required to facilitate concreting. The minimum thickness of PVC
water stops shall be 5 mm and minimum width shall be 230 mm.
14.3. All steel sections and fabricated structures that are required to be transported on sea
shall be provided with anti corrosive paint to take care of sea worthiness.
14.4. All mild steel parts used in the water retaining structures shall be hot-double dip
galvanised. The minimum coating of the zinc shall be 750 gm/sq. m. for galvanised
structures and shall comply with IS: 2629 and IS: 2633. Galvanizing shall be checked and
tested in accordance with IS: 2633.The galvanizing shall be followed by the application of
an etching primer and dipping in black bitumen in accordance with BS: 3416.
14.5. A screed concrete layer not less than 100 mm thick and of grade not weaker than M10
conforming to IS: 456-1978 shall be provided below all water retaining structures. A
sliding layer of bitumen paper or craft paper shall be provided over the screed layer to
destroy the bond between the screed and the base slab concrete of the water retaining
structures.
14.6. Bricks having minimum 75kg/cm2 compressive strength can only be used for masonry
work. Contractor shall ascertain himself at site regarding the availability of bricks of
minimum 75kg/cm2 compressive strength before submitting his offer.
14.7. Doors and windows on external walls of the buildings (other than areas provided, with
insulated metal claddings) shall be provided with RCC sunshade over the openings with
300 mm projection on either side of the openings. Projection of sunshade from the wall
shall be minimum 450 mm over window openings and 750 mm over door openings.
14.8. Service ladder shall be provided for access to all roofs.
14.9. Angles 45x45x5 mm (minimum) with lugs shall be provided for edge protection all round
cut outs/openings in floor slab, edges of drains supporting grating covers, edges of RCC
cable/pipe trenches supporting covers, edges of manholes supporting covers, supporting
edges of manhole precast cover and any other place where breakage of corners of
concrete is expected.
RGGVY/XII Plan/R1
14.10. Anti termite chemical treatment shall be given to column pits, wall trenches, foundations
of buildings, filling below the floors etc. as per IS: 6313 and other relevant Indian
Standards.
14.11. All rungs for ladder shall also be galvanised as per IS: 277 medium classes.
14.12. For all civil works covered under this specification, nominal mix by volume batching as
per CPWD specification is intended. The relationship of grade of concrete and ratio of
ingredients shall be as below:
------------------------------------------------------------------------------------------
Sl.No. Mix Cement Sand Coarse aggregate of

20 mm down grade
as per IS 383
------------------------------------------------------------------------------------------
1. M 10 1 3 6
2. M 15 1 2 4
3. M 20 1 1.5 3
------------------------------------------------------------------------------------------
The material specification, workmanship and acceptance criteria shall be as per relevant
clauses of CPWD specification and approved standard Field Quality Plan.
14.13. The details given in tender drawings shall be considered along with details available in
this section of the specification while deciding various components of the building.
14.14. Items/components of buildings not explicitly covered in the specification but required for
completion of the project shall be deemed to be included in the scope.
15. INTERFACING
The proper coordination & execution of all interfacing civil works activities like fixing of
conduits in roofs/walls/floors, fixing of foundation bolts, fixing of lighting fixtures, fixing of
supports/embedment, provision of cutouts etc. shall be the sole responsibility of the
Contractor. He shall plan all such activities in advance and execute in such a manner that
interfacing activities do not become bottlenecks and dismantling, breakage etc. is
reduced to minimum.
RGGVY/XII Plan/R1
16. WATER SUPPLY
(i) Contractor shall make its own arrangement for construction water.
(ii) The contractor shall carry out all the plumbing/erection works required for supply
of water in control room building.
(iii) The details of tanks, pipes, fittings, fixtures etc for water supply are given
elsewhere in the specification under respective sections.
(iv) A scheme shall be prepared by the contractor indicating the layout and details of
water supply which shall be got approved by the Owner before actual start of
work including all other incidental items not shown or specified but as may be
required for complete performance of the works.
(v) Bore wells and pumps for water supply are in the scope of contractor meeting
the day-to-day requirement of the water supply.
(vi) If the water is supplied by Municipal Corporation then bore well for water supply
purposes is not required to be carried out by contractor. Contractor shall also
make necessary arrangement /formalities to receive water connection from
corporation.
17. SEWERAGE SYSTEM
(i) Sewerage system shall be provided for control room building.
(ii) The Contractor shall construct septic tank and soak pit suitable for 5 users if
outside of Municipal Corporation zone. Otherwise, all necessary arrangement for
the disposal of sewerage to the Municipal Corporation’s end shall be arranged by
the contractor at his own cost for regularizing the disposal activity.
(iii) The septic tank and soak pit shall be constructed as per enclosed tender drawing.
18. STATUTORY RULES
18.1. Contractor shall comply with all the applicable statutory rules pertaining to factories act
(as applicable for the State). Fire Safety Rules of Tariff Advisory Committee, Water Act for
pollution control etc.
18.2. Provisions for fire proof doors, no. of staircases, fire separation wall, plastering on
structural members (in fire prone areas) etc. shall be made according to the
recommendations of Tariff Advisory Committee.
18.3. Statutory clearance and norms of State Pollution Control Board shall be followed as per
Water Act for effluent quality from plant.
RGGVY/XII Plan/R1
18.4. Requirement of sulphate resistant cement (SRC) for sub structural works shall be decided
in accordance with the Indian Standards based on the findings of the detailed soil
investigation to be carried out by the Bidder.
18.5. Foundation system adopted by Bidder shall ensure that relative settlement and other
criteria shall be as per provision in IS: 1904 and other Indian Standards
18.6. All water retaining structures designed as un-cracked section shall also be tested for
water tightness at full water level in accordance with clause no. 10 of IS: 3370 (Part-I).
18.7. Construction joints shall be as per IS: 456.
18.8. All underground concrete structures like water retaining structures etc. shall have
plasticizer cum water proofing cement additive conforming to IS: 9103. In addition, limit
on permeability as given in IS: 2645 shall also be met with. The concrete surface of these
structures in contact with earth shall also be provided with two coat of bituminous
painting for water/damp proofing. In case of water leakage in the above structures,
Injection Method shall be applied for repairing the leakage.
18.9. All building/construction materials shall conform to the best quality specified in CPWD
specifications if not otherwise mentioned in this specification.
18.10. All tests as required in the standard field quality plans have to be carried out.
19. FENCING
19.1. Product materials for fencing
The minimum requirements are as follows:
19.1.1. Chain Link fence fabric in accordance to IS-2721
1. Size of mesh : 75 mm
2. Nominal wire size : 4.0 mm dia
3. Width of chain link : 2000 mm
4. Class of zinc coating : medium
5. Zinc coated after weaving.
RGGVY/XII Plan/R1
19.1.2. Posts
Angle Section
Intermediate : L 65 x 65 x 6
Straining posts : L 65 x 65 x 6
Stay post : L 65 x 65 x 6
1. All structural steel shall conform to IS: 2062 and shall be painted with a coat of
approved steel primer and two coats of synthetic enamel paint.
2. The Chain Link fabric shall be fixed to the post at the top and bottom of the fence by
welding/fixing 50 mm MS flat all through its length.
3. Fencing top shall be either of galvanised barbed wire or tape. Barbed wire shall conform
to IS: 278.
4. The barbed wire may consist of not more than two splices per reel. The barbed wire
shall be formed by twisting two line wires, one containing the barbs. The barbed wire
shall be designated as A-4 IS: 278 and shall be galvanized.
5. Above chain link, 3-rows (6 nos) of barbed tape/wire shall be provided in each arm of
the Y shaped barbed arm at top.
6. With barbed tape/wire above the chain link fence, the total fence height shall be
minimum 2500 mm above finished gravel level.
7. Barbed tape/wire arms shall be same as intermediate and straining post.
8. Tension wire: single strand, high tensile, galvanised steel wire, 4 mm diameter.
9. Fittings and hardware: cast aluminum alloy or galvanized steel, malleable or ductile cast
iron turnbuckles to be drop forged.
10. GI chain link mesh shall be as per IS: 2721. Mesh size 75 mm and nominal wire size
shall be 4.0 mm diameter.
On the results of these additional tests, the whole or portion of the barbed wire/tape
shall be accepted or discarded by the Purchaser, as the case may be.
19.2. INSTALLATION
1. Contractor shall submit the fencing drawing Fence shall be installed along lines
shown on approved drawings.
RGGVY/XII Plan/R1
2. Post holes shall be excavated by approved methods.
3. Intermediate posts shall be spaced 2.5 m apart measured parallel to ground

surface.
4. Straining posts shall be installed at equal intervals not exceeding 25.0 m.
5. Straining posts shall be installed at sharp changes in grade, at corners, at change

of direction and where directed.
6. All corner post will have two-stay post and every tenth post will have a transverse
stay post.
7. Posts shall be set in 1:2:4 plain cement concrete Blocks of minimum dimension
400 mm x 400 mm x 1000 mm deep Concrete work shall conform to relevant
clause. Post shall be braced and held in plumb position and true alignment and
elevation until concrete has set.
8. Fence fabric shall not be installed until concrete has cured a minimum of 7 days.
9. Bottom and top of the fence fabric shall be fixed with MS flats of 50 mm x 6mm
(min).
10. Fence fabric shall be laid out with barbed edge on top, stretched tightly and shall
be fastened to intermediate, post gate and straining post with 50 x 6 flats.
11. Fabric shall be secured to tension wires with tie wires at 400 mm intervals. Tie
wires shall be given not less than two twists.
12. Barbed tape shall be spliced with standard wire splices.
13. Barbed tape shall be stretched to have uniform tension.
14. Barbed tape shall be attached to barbed wire arms with approved metal clips.
15. Toe wall of one Brick/Random Rubble masonry, with notches over 75 mm thick
PCC (1:4:8) shall be provided below all fencing and shall be minimum 200 mm
above and 200 mm below finished ground level. All exposed surfaces of brick toe
wall shall be provided with 1:6 cement sand plaster and coated with two coats of
colour wash with a base coat of white wash with lime. Rubble masonry toe wall
shall be with raised & cut pointing and 50 mm PCC (1:2:4) band coping.
16. Proper earthing shall be done for fencing also.
RGGVY/XII Plan/R1
VOLUME – II : Section-II (A)
General Technical Instructions
(This document is meant for the exclusive purpose of bidding against this Package and
shall not be transferred, reproduced or otherwise used for purposes other than that for
which it is specifically issued.)
Volume-II : Section-II (A) 1
Technical Specification of XII Plan RGGVY
Contents
1.1 33 KV Line support ...........................................................................................3
1.2 11 KV line Support including Distribution Substation support ...................3
1.3 Route And Terrain ............................................................................................4
1.4 Detailed Survey.................................................................................................4
1.5 Profile Plotting ...................................................................................................4
1.6 Road Crossing ...................................................................................................5
1.7 Railways Crossings ...........................................................................................5
1.8 Telecommunication, LT or HT Line Crossing................................................5
1.9 Details En-route ................................................................................................5
1.10 Clearances - General ....................................................................................6
1.11 Electrical System Data..................................................................................8
1.12 Pole Location ...............................................................................................8
1.13 Construction...................................................................................................8
1.14 Erection of DP Structure for Angle Locations ...........................................9
1.15 Concreting ......................................................................................................9
1.16 Providing Of Guys To Supports...................................................................9
1.17 Guy Strain Insulators..................................................................................10
1.18 Fixing Of Cross-Arms..................................................................................10
1.19 Insulators And Bindings .............................................................................11
1.20 Conductor Erection .....................................................................................11
1.21 Tensioning and Sagging Operations ........................................................13
1.22 Clipping In....................................................................................................13
1.23 Fixing of Conductors and Earthwire Accessories ...................................14
1.24 Replacement ................................................................................................14
1.25 Tying Of Conductor On Pin Insulators .....................................................14
1.26 Kind And Size Of Tie Wire To Be Used ....................................................15
1.27 Rules Of Good Tying Practice....................................................................15
1.28 Conductors At Different Voltages On Same Supports ...........................15
1.29 Earthing ........................................................................................................16
1.30 Anti-Climbing Devices.................................................................................17
1.31 Testing And Commissioning ......................................................................17
1.32 River Crossing ...............................................................................................18
RGGVY/XII Plan/R1
1.33 Guarding.......................................................................................................18
1.34 Repair to conductors ..................................................................................19
1.35 LT Lines and Service connection ..............................................................19
RGGVY/XII Plan/R1
1.1 33 KV Line support
1.1.1. 9m long PCC Pole or 11 KV long PCC pole (or PCC Pole as per state
practice shall be used for 33 KV line support). 13 meters long
152x152mm RS Joist (37.1kg/m)1 or Steel Tubular Poles (11m) can also
be used as support in hilly area where head load shifting is the only
option. Cement concreting shall be used for support foundation in mixture
1:3:6 (1: cement, 3: coarse sand and 6 Stone ballast 40mm sizes). Each
support shall be concrete (0.5mx0.5mx2m) = 0.5 cmt. 0.014 cmt shall
also be used in muffing of the support. PCC pole shall not be provided
with muffing.
1.1.2. Pole base plates as per REC specifications shall be put below the support
before placing the support for erection.
1.1.3. Pole earthing shall be performed through 25mm, 2.5 meter long earth
spikes duly connected with 4 SWG wire (in 33KV lines). The GI wires
between pole structure and the spikes should not be used in cut length.
Wherever, cut is evitable, proper nut bolt, washer and binding should be
made as per REC specifications. The GI wire between support and earth
spike should be placed 1 meter below the ground level.
1.1.4. Earth spikes should not be inserted in the foundation pit excavated for the
support erection. It should be placed 1 meter away from the support.
1.2 11 KV line Support including Distribution Substation support
1.2.1. 8.0 meters or equivalent PCC Poles2 as per prevailing practices of the
state shall be used for 11 KV line and substation support. The single pole
supports shall be erected with Stone bolder/stone ballast mixed with
excavated earth. Double Pole structures’ supports, turning point pole,
poles in water logging area and Distribution Transformer Substation
Supports’ shall be cement concrete in mixture of 1:3:6 (1: cement, 3:
coarse sand and 6 Stone ballast 40mm sizes). Each support shall be
concrete (0.6mx0.6mx1.35m)= 0.486 cmt. of the support. In special
location, wherever, Engineer – in Charge specifically decides, to enhance
additional strength, concreting may be used as support foundation.
1
In hilly and difficult terrain, steel tubular support may be accepted, they shall be concreted as per
speculations,
In hilly and difficult terrain, steel tubular support may be accepted, they shall be concreted as per
2
speculations,
RGGVY/XII Plan/R1
In forest, wherever special care is to be made for elephant corridors, 13m

long, 152x152mm RS Joist (37.1kg/m) may be used for 11 KV line
support.
1.2.2. Pole base plates as per specifications (stone plates, RCC made base plate,
PCC thick of 100mm may be used for poles shall be put below the
support before placing the support for erection.
1.2.3. Pole earthing shall be performed through 25mm, 2.5 meter long earth
spikes duly connected with 8 SWG GI wire (in 11KV Lines). The GI wires
between pole structure and the spikes should not be used in cut length.
Wherever, cut is evitable, proper nut bolt, washer and binding should be
made as per specifications. The GI wire between support and earth spike
should be placed 1 meter below the ground level.
1.2.4. Earth spikes should not be inserted in the foundation pit excavated for the
support erection. It should be placed 1.2 meter away from the support.
1.3 Route And Terrain
1.3.1. The scope of HT/LT length of feeder are enclosed with the tender
documents. On award of the contract, contractor shall perform village
wise foot survey to access the route, pole location and thus Single Line
Diagram of the line works. The survey shall be approved by Engineer-in-
charge. Accordingly requirements of materials shall be finalized by the
turnkey contactor in association with Engineer.
1.4 Detailed Survey
1.4.1. The detailed survey shall be carried out for the approved feeders/spur
lines by the contractor and submitted for owner approval.
1.5 Profile Plotting
1.5.1. Span: The number of consecutive spans between the section points shall
not exceed design length considering wind pressure, type of poles and
size of conductor.
1.5.2. Extension: An individual span shall be as near to the normal design span
as possible. In case an individual span becomes too short with normal
supports on account of undulation in ground profile, one or both the
supports of the span may be extended by inserting standard body
extension designed for the purpose according to technical specification.
RGGVY/XII Plan/R1
1.5.3. Loading: There shall not be any upward force on poles under normal
working conditions and the suspension poles shall support at least the
minimum weight span as provided in the design. In case uplift is
unavoidable, it shall be examined if the same can be overcome by adding
standard body extensions to the poles failing which tension poles
designed for the purpose shall be employed at such positions.
1.5.4. Horizontal Tensions on pin insulators are to be avoided by proper

alignment of the line. In case where installation of DP structure is not
possible to erect for turning the line, “two pins” arrangement with suitable
jumpering shall be provided at all those locations where pins are
subjected to horizontal tension. Bridling type V Cross arms for such
installations shall be used by the agency accordingly.
1.6 Road Crossing
At all road crossings, the poles shall be fitted with horizontally aligned disc
type tension insulator string(s) depending on the type of poles and line
but the ground clearance at the roads under maximum temperature and
in still air shall be such that it should not fall below 6.1m in case of 33 KV
and 11 KV lines. Also, cradle guarding is to be used at all the road
crossing locations as per drawings / specifications enclosed.
1.7 Railways Crossings
Railway Crossings at pre-planned locality shall be selected in such a way

that minimum feeder length shall be re-routed. The line crossing should
be executed as per given drawings. Required permission to block the
Railways traffic shall be arranged by the owner. All liaison works shall be
performed by turnkey contractor.
1.8 Telecommunication, LT or HT Line Crossing
The angle of crossing shall be as near 90 degrees as possible. However,

deviation to the extent of 30 degree may be permitted under
exceptionally difficult situations. Cradle guarding is to be used at all such
crossing locations as per drawings / specifications enclosed.
1.9 Details En-route
All topographical details, permanent features, such as well, trees, building

etc. 75 m on either side of the alignment shall be detailed on the profile
plan.
RGGVY/XII Plan/R1
1.10 Clearances - General
For the purpose of computing the vertical clearance of an over-head line,

the maximum sag of any conductor shall be calculated on the basis of the
maximum sag in still air and the maximum design temperature. Similarly,
for the purpose of computing any horizontal clearance of an over-head
line, the maximum deflection of any conductor shall be calculated on the
basis of the wind pressure specified by the State Government under rule
76 (2) (a) [or may be taken as 35º, whichever is greater]. Following
clearances shall be maintained by the contractor while executing the
work:
1.10.1. CLEARANCE ABOVE GROUND OF THE LOWEST CONDUCTOR:

No conductor of an over-head line, including service lines,
erected across a street shall at any part thereof be at a height
less than
(a) For low and medium voltage lines 5.8 metres
(b) For high voltage lines 6.1 metres
1.10.2. No conductor of an over-head line, including service, lines,

erected along any street shall at any part thereof be at a
height less than
a. For low, medium and high voltage lines upto and including
11,000 volts, if bare - 4.6 metres
b. For low, medium and high voltage lines Upto and including
11,000 volts, if insulated - 4.0 metres
c. For high voltage lines above 11,000 volts - 5.2 metres
For extra-high voltage lines the clearance above ground shall

not be less than 5.2 meters plus 0.3 meter for every 33,000
volts or part thereof by which the voltage of the line exceeds
33,000 volts:
Provided that the minimum clearance along or across any

street shall not be less than 6.1 meters.
1.10.3. CLEARANCE FROM BUILDINGS OF LOW AND MEDIUM

VOLTAGE LINES AND SERVICE LINES:
Where line is to cross over another line of the same voltage or

lower voltage, pole with suitable extensions shall be used.
Provisions to prevent the possibility of its coming into contact
RGGVY/XII Plan/R1
with other overhead lines shall be made in accordance with the

Indian Electricity Rules, 1956. The contractor will required to
under cross higher voltage lines by erecting gantries/suitable
Rail Pole structures.
Where a low or medium voltage over-head line passes above

or adjacent to or terminates on any building, the following
minimum clearances from any accessible point, on the basis of
maximum sag, shall be observed:-
a) For any flat roof, open balcony, verandah roof and lean-to-
roof
i. When the line passes above the building a vertical

clearance of 2.5 meters from the highest point; and
ii. When he line passes adjacent to the building a
horizontal clearance of 1.2 meters from the nearest
point, and
b) For pitched roof
i. When the line passes above the building a vertical

clearance of 2.5 meters immediately under the lines,
and
ii. When the line passes adjacent to the building a
horizontal clearance of 1.2 meters.
The horizontal clearance shall be measured when the line is at

a maximum deflection from the vertical due to wind pressure.
1.10.4. CLEARANCE FROM BUILDINGS OF HIGH AND EXTRA-HIGH

VOLTAGE LINES:
Where a high or extra-high voltage over-head line passes

above or adjacent to any building or part of building it shall
have on the basis of maximum sag a vertical clearance above
the highest part of a building immediately under such line, of
not less than
(a) For High Voltage Lines up 3.7 m

to and including 33,000
volts
(b) For Extra High Voltage 3.7 m plus 0.3 m for
Lines every additional 33 KV or
part thereof.
RGGVY/XII Plan/R1
1.11 Electrical System Data

33 KV 11KV
Nominal voltage 33 kV 11KV
Maximum system voltage 36 kV 12KV
BIL (Impulse) 170 kVp 75KV
Power frequency withstand voltage (wet) 75 kV (rms) 28KV
Minimum corona extinction voltage for Not less than 27 kV, 50 Hz ac system
under Dry condition (rms) phase to earth
Radio interference voltage at one MHz for Not exceeding 1000 micro-volts
27 kV (dry condition)
1.12 Pole Location

In locating poles on lines, the following general principles should be kept in
mind:-
1. Keep spans uniform in length as far as possible.
2. Locate to give horizontal grade.
3. By locating the poles on high places short poles can be used and
will maintain proper ground clearance at the middle of the span.
In extremely hilly or mountainous country, poles are located on
ridges there by greatly increasing the spans without greatly
increasing the pull on the conductor. This is possible because the
sag can be made very large and will maintain the required ground
clearance. Special attention should be given to the locations of
poles, where the ground washes badly. Poles should not be placed
along the edges of cuts at or embankment or along the banks of
creeks of streams.
1.13 Construction
The construction of overhead-lines may be divided into the following parts:-
(1) Pit marking, pit digging.

(2) Erection of supports and concreting.
(3) Providing of guys to supports.
(4) Mounting cross-arms, pin and insulators, and pin binding.
(5) Paying and stringing of the conductor.
(6) Sagging and Tensioning of Conductors.
(7) Crossings.
(8) Guarding.
(9) Earthing.
(10) Testing and Commissioning.
RGGVY/XII Plan/R1
1.14 Erection of DP Structure for Angle Locations
For angles of deviations more than 10 degree, DP structure may be

erected. The pit digging should be done along the bisection of angle of
deviation.
After the poles are erected, the horizontal/cross bracings should be fitted
and the supports held in a vertical position with the help of temporary
guys of Manila rope 20/25 mm dia.
Wherever space is not found sufficient to install double Pole structure,

single pole cut point may be installed. The support so erected must be
grouted.
1.15 Concreting
The concreting mixture of one cum 1:3:6 ratios would mean 1 part
cement, 3 parts coarse sand and 6 part 40 mm aggregate size stones. It
may be noted that while preparing the concrete mixture, large quantities
of water should not be used as this would wash away cement and sand.
1.16 Providing Of Guys To Supports
Guys are installed at locations where terminal poles are erected at

sectional cut points. These cut points may be in same alignment or at
turn points. Guys are installed to nullify tension on supports resulted due
to conductors tension. In spite of careful planning and alignment of line
route, certain situations arise where the conductor tries to tilt the pole
from its normal position due to abnormal wind pressure and deviation of
alignment, etc. When these cases of strain arise, the pole is strengthened
and kept in position by guys. One or more guys will have to be provided
for all supports where there is unbalanced strain acting on the support,
which may result in tilting/uprooting or breaking of the support.
Guys are braces fastened to the pole. In this work anchor type guy sets
are to be used. These guys are provided at (i) angle locations (ii) dead
end locations (iii) T - off points (iv) Steep gradient locations and (v)
where the wind pressure is more than 50 kg / Sq.m.
The fixing of guys stays will involve (i) pit digging and fixing stay rod (ii)
fastening guy wire to the support (iii) Tightening guy wire and fastening
to the anchor. The marking of guy pit, digging and setting of anchor rod
must be carefully carried out. The stay rod should be placed in a position
so that the angle of rod with the vertical face of the pit is 30º/45º as the
case may be.
RGGVY/XII Plan/R1
Before start of erection of Stay sets, required concreting materials like

Cement, Sand, Stone Chips and Construction water need to be made
available near the pit.
G.I. stay wires of size 7/3.15 mm (10 SWG) & 7/4.00 mm (8 SWG), for
16 mm/20 mm stay rods respectively, are to be provided. 8.5 Kg. Stay
Wire (7/4.00 mm) per Stay with 20 mm Stay rod for 33 KV line and 5.5
Kg. Stay Wire (7/ 3.15 mm) per Stay with 16 mm Stay rod for 11 KV lines
are to be used. For double pole structure (DP), four stays along the line,
two in each direction and two stays along the bisection of the angle of
deviation (or more) as required depending on the angle of deviation are
to be provided. Hot dip galvanized stay sets are to be used. One stay to
counter the angular deformation force shall be used.
After concreting, back filling and ramming must be done well and allowed
7 days to set. The free end of the guy wire/stay wire is passed through
the eye of the anchor rod, bent back parallel to the main portion of the
stay/guy and bound after inserting the G.I. thimble, where it bears on the
anchor rod. If the guy wire proves to be hazardous, it should be
protected with suitable asbestos pipe filled with concrete of about 2 m
length above the ground level, painted with white and black strips so
that, it may be visible at night. The turn buckle shall be mounted at the
pole end of the stay and guy wire so fixed that the turn buckle is half way
in the working position, thus giving the maximum movement for
tightening or loosening.
1.17 Guy Strain Insulators
Guy insulators are placed to prevent the lower part of the Guy from
becoming electrically energized by a contact of the upper part of the guy
when the conductor snaps and falls on them or due to leakage. No guy
insulator shall be located less than 2.6 m from the ground. Guy insulators
are to be used in stay wires only. All stay conductors are to be provided
with guy insulators as per following specifications.
11 KV line stay Type C guy insulator (1 No)
33 KV line stay Type C guy insulators (2Nos)
1.18 Fixing Of Cross-Arms
After the erection of supports and providing guys, the cross-arms are to
be mounted on the support with necessary clamps, bolts and nuts. The
practice of fixing the cross arms before the pole erection is also there. In
case, the cross-arm is to be mounted after the pole is erected, the
lineman should climb the pole with necessary tools. The cross-arm is then
RGGVY/XII Plan/R1
tied to a hand line and pulled up by the ground man through a pulley, till
the cross-arm reaches the line man. The ground man should station
himself on one side, so that if any material drops from the top of the
pole, it may not strike him. All the materials should be lifted or lowered
through the hand line, and should not be dropped.
1.19 Insulators And Bindings
Line conductors are electrically insulated from each other as well as from
the pole by ‘Insulators’. Following two type of insulators shall be used for
the line insulation:
(1) Pin type

(2) Strain type
The pin type insulators will be used for straight stretch of line. The
insulator and its pin should be mechanically strong enough to withstand
the resultant force due to combined effect of wind pressure and weight of
the conductor in the span.
The strain insulators are intended for use at terminal locations or dead
end locations and where the angle of deviation of line is more than 10º.
Strain insulators are also intending to use at major road crossing
locations.
The pins for insulators are fixed in the holes provided in the cross-arms
and the pole top brackets. The insulators are mounted in their places
over the pins and tightened. In the case of strain or angle supports,
where strain fittings are provided for this purpose, one strap of the strain
fittings is placed over the cross-arm before placing the bolt in the hole of
cross-arms. The nut of the straps is so tightened that the strap can move
freely in horizontal direction.
All HT/LT insulators shall be tested for insulation tests before installation
on line. They shall be dipped into water for 24 hrs and then tested for
insulation resistance tests at the stores. The insulators found fit in IR
testing shall be sent to site for erection. 11KV na d33 KV insulators shall
be tested by at-least 1 KV megger whereas LT insulators shall be tested
by 500 Volts megger.
1.20 Conductor Erection
The main operations are:-
(a) Transportation of Conductor to works site.
RGGVY/XII Plan/R1
(b) Paying and Stringing of Conductor

(c) Jointing of Conductor
(d) Tensioning and Sagging of Conductor
While transporting conductors drums to site, precautions are to be taken

so that the conductor does not get damaged/injured. The drum could be
mounted on cable drum support, which generally is made from crow-bar
and wooden slippers for small size conductor drums. The direction of
rotation of the drum has to be according to the mark in the drum so that
the conductor could be drawn. While drawing the conductor, it should not
rub causing damage. The conductor could be passed over poles on
wooden or aluminum snatch block (pulley) mounted on the poles for this
purpose.
When approaching the end of a drum length at least three coils shall be
left in place when the stringing operations are stopped. These coils are to
be removed carefully and if another length is required to be run out a
joint shall be made as per the recommendations of the accessories
manufacturer.
The mid span jointing is done through compressions or if helical fittings

are used the jointing could be done manually. After completing the
jointing, tensioning operation could be commenced. The conductor is
pulled through come-along clamps to stringing the conductor between
the tension locations.
Conductor splices shall not crack or otherwise be susceptible to damage

in the stringing operation. The Contractor shall use only such equipment /
methods during conductor stringing which ensures complete compliance
in this regard.
All the joints on the conductor and earth-wire shall be of the compression
type, in accordance with the recommendations of the manufacturer, for
which all necessary tools and equipment like compressors, dies, etc., shall
be obtained by the Contractor. Each part of the joint shall be cleaned by
wire brush till it is free of rust or dirt, etc., and be properly greased with
anti-corrosive compound. If required and as recommended by the
manufacturer, before the final compression is carried out with the
compressors.
All the joints or splices shall be made at least 15 meters away from the
pole. No joints or splices shall be made in spans crossing over main
roads, railways and small river spans. Not more than one joint per sub-
conductor per span shall be allowed. The compression type fittings shall
be of the self-centering type or care shall be taken to mark the
RGGVY/XII Plan/R1
conductors to indicate when the fitting is centered properly. During

compression or splicing operation, the conductor shall be handled in such
a manner as to prevent lateral or vertical bearing against the dies. After
compressing the joint, the aluminum sleeve shall have all corners
rounded; burrs and sharp edges removed and smoothened.
During stringing of conductor to avoid any damage to the joint, the

contractor shall use a suitable protector for mid span compression joints
in case they are to be passed over pulley blocks / aerail rollers. The
pulley groove size shall be such that the joint along with protection can
be passed over it smoothly.
1.21 Tensioning and Sagging Operations
The tensioning and sagging shall be done in accordance with the

approved stringing charts or sag tables. The “initial” stringing chart shall
be used for the conductor and “final” stringing chart for the earth-wire.
The conductors shall be pulled up to the desired sag and left in running
blocks for at least one hour after which the sag shall be rechecked and
adjusted, if necessary, before transferring the conductors from the
running blocks to the suspension clamps. The conductor shall be clamped
within 36 hours of sagging in.
The sag will be checked in the first and the last section span for sections
up to eight spans and in one additional intermediate span for sections
with more than eight spans. The sag shall also be checked when the
conductors have been drawn up and transferred from running blocks to
the insulator clamps.
At sharp vertical angles, conductor and earth-wire sags and tensions shall
be checked for equality on both sides of the angle and running block. The
suspension insulator assemblies will normally assume verticality when the
conductor is clamped.
Tensioning and sagging operations shall be carried out in calm weather

when rapid changes in temperature are not likely to occur.
1.22 Clipping In
Clipping of the conductors into position shall be done in accordance with

the manufacturer’s recommendations. Jumpers at section and angle
towers shall be formed to parabolic shape to ensure maximum clearance
requirements. Fasteners in all fittings and accessories shall be secured in
position. The security clip shall be properly opened and sprung into
position.
RGGVY/XII Plan/R1
1.23 Fixing of Conductors and Earthwire Accessories
Conductor and earth-wire accessories supplied by the Contractor shall be

installed by the Contractor as per the design requirements and
manufacturer’s instruction within 24hours of the conductor / earth-wire
clamping. While installing the conductor and earth-wire accessories,
proper care shall be taken to ensure that the surfaces are clean and
smooth and that no damage occurs to any part of the accessories or of
the conductors.
1.24 Replacement
If any replacements are to be effected after stringing and tensioning or

during maintenance e.g. replacement of cross arms, the conductor shall
be suitably tied to the pole at tension points or transferred to suitable
roller pulleys at suspension points.
Sagging of conductor has to be in accordance to the Sag Tension chart.

In order to achieve it, it is preferred to pull the conductor to a tension a
little above the theoretical value so that while transferring it from the
snatch blocks to the pit insulators and to take care of temperature
variation. Proper sag could achieve. Sagging for 33/11 KV line is mostly
done by “Sighting”. A horizontal strip of wood is fixed below the cross-
arm on the pole at the required sag. The lineman sees from other end
and the sag is adjusted by increasing or decreasing the tension. The
tension clamps could then be finally fixed and conductor be fixed on pin-
insulators. All fittings, accessories like guys, cross-arms, etc., could be
checked as they should not have de-formalities.
The maximum permissible spans for all the lines of 33/11/0.4 KV are
prescribed according to the design of the supports. Sag-tension charts for
these conductors are to be followed.
1.25 Tying Of Conductor On Pin Insulators
Conductors should occupy such a position on the insulator as will produce

minimum strain on the tie wire. The function of the wire is only to hold
the conductor, in place on the insulator, leaving the insulator and pin to
take the strain of the conductor.
In straight line, the best practice is to use a top groove insulator. These
insulators will carry grooves on the side as well. When the conductor is
RGGVY/XII Plan/R1
placed on the top groove, the tie wire serves only to keep the conductor
from slipping out.
On corners and angles (below 5 degree deviations) the conductors should

be placed on the outside of the insulators. On the far side of the pole,
this pulls the conductor against the insulator instead of away from the
insulator.
1.26 Kind And Size Of Tie Wire To Be Used
Helically formed fittings are to be used for tying the insulators, end
terminal connectors etc.. The tie should always be made of soft annealed
wire so that it may not be brittle and injure the line conductor. A tie wire
should never be used for second time. Specifications of helically formed
fittings are given in this section.
1.27 Rules Of Good Tying Practice
a. Use only helically formed fittings.

b. Use of size of tie wire which can be readily handled yet one which
will provide adequate strength.
c. Use length of tie wire sufficient for making the complete tie,
including an allowance for gripping with the hands. The extra
length should be cut from each end if the tie is completed.
d. A good tie should
(a) Provide a secure binding between line wire insulator

and tie wire.
(b) Have positive contacts between the line wire and the
tie wire so as to avoid any chattering of the contacts.
(c) Re-enforce line wire in the vicinity of insulator.
e. Apply without use of pliers.

f. Do not use the wire which has been previously used.
g. Do not use hard drawn wires for typing.
1.28 Conductors At Different Voltages On Same Supports
In urban area, lines are to be erected with provision for forming lines of
two different gradients as under
a) 11 KV Line and LT Lines

b) 33 KV Line and LT Lines
RGGVY/XII Plan/R1
Where conductors forming parts of systems at different voltages are

erected on the same supports, the contractor shall make adequate
provision to guard against danger to linesmen and others from the lower
voltage system being charged above its normal working voltage by
leakage from or contact with the higher voltage system; and the methods
of construction and the clearances between the conductors of the two
systems shall be as described in the specifications.
The agency shall be intimated by the Engineer in Charge in writing about

the locations where such provisions is intended by him. At all such
locations, the contractor shall make adequate provision to guard against
danger to linesmen and others from the lower voltage system being
charged above its normal working voltage by leakage from or contact
with the higher voltage system.
1.29 Earthing
Earthing shall generally be carried out in accordance with the

requirements of Indian Electricity Rules, 1956 and the relevant
regulations of the Electricity Supply Authority concerned and as indicated
below:
a) All metallic supports shall be earthed.

b) For PCC poles the metal cross-arms and insulator pins shall be
bonded and earthed at every pole for HT lines.
c) All special structures on which switches, transformers, fuses, etc.,
are mounted / likely to mount should be earthed.
d) The supports on either side of the road, railway or river crossing

should be earthed.
e) All supports (Steel & PCC) HT lines passing through inhabited

areas, road crossings and along such other places, where Earthing
of all poles is considered desirable from safety considerations
should be earthed.
f) In special locations and special structures, road crossings etc.,

pipe/rod Earthing should be done on either side of the
construction.
g) At other locations the coil Earthing may be adopted. The coil

Earthing consists of 10 m length of 8 SWG. G.I. wire compressed
into a coil 450 mm length and 50 mm dia and buried 1500 mm
deep as per REC standard J-1.
RGGVY/XII Plan/R1
Following shall be the earthing requirements:
No Description Type of Earthing

1 Single Pole - PCC/RS Joist/steel tubular 1 No. Spike Earthing at each SP
2 Double pole - PCC/RS Joist/steel tubular 2 Nos. Spike Earthing at each DP
3 Substation Poles structure - PCC/RS GI Pipe Earthing 3 Nos
Joist/steel tubular
4 Road crossing GI Pipe earthing on either side one
each
5 Telephone line crossing GI Pipe earthing on either side one
each
6 DP with Isolating switch Spike earthing 2 Nos and GI Pipe
earthing 1 No
1.30 Anti-Climbing Devices
In order to prevent unauthorized persons from climbing any of the

supports of HT lines without the aid of a ladder or special appliance,
certain anti-climbing devices are provided to the supports. Barbed wire
binding is to be adopted for this purpose at a distance of 30 to 40 cm at a
height of 3.5 to 4 m from ground level. The barbed wire shall conform to
IS – 278 (Grade A1). The barbed wired shall be given chromatin dip as
per procedure laid down in IS: 1340. At-least 3.5 kgs barbed wire is to be
used per pole for the purpose.
1.31 Testing And Commissioning
When the line is ready for energisation, it should be thoroughly inspected

in respect of the following:-
a) Poles-Proper alignment, concerting and muffing.

b) Cross-arms – Proper alignment.
c) Finishing of fabricated steel items used.
d) Insulators – Proper finish, cleanliness, insulation resistance.
e) Binding, clamps and jumpers – To check whether these are in reach.
f) Conductor and earth wire – Proper sag to check whether there are
any cuts, etc.
g) Guys: To check whether the Guy wire is tight and whether the Guy
insulators are in tact.
h) Earthing System: To check whether the earthing connections of
supports and fittings are intact. Measure earth resistance with earth
tester.
After the visual inspection is over and satisfied, the conductor is tested
for continuity/ground, by means of megger. At the time of testing
RGGVY/XII Plan/R1
through megger person should not climb on the pole or touch the
guarding, conductor, guy wire etc.
a. Before charging any new line, it should be ensured that the required
inspection fee for the new line is paid to the Electrical Inspector and
approval obtained from him for charging the line.
b. The line should be energized before the officer who has been
authorized by the Board in this regard.
c. Before energizing any new line, the contractor of the line shall notify
to the workmen that the line is being energized and that it will no
longer be safe to work on line. Acknowledgement of all the workmen
in writing should be taken in token of having intimated them.
d. Wide publicity by Tom-toming should be arranged in all the localities

through which the line, that is to be energized passes, intimating the
time and date of energizing and warning public against the risk in
meddling with the line.
e. The Officer-in-charge of the line shall personally satisfy himself that

the same is in a fit state to be energized.
1.32 River Crossing
No special structures are to be erected for this work. River crossing more
than normal span of poles are not considered under the package. For
small rivers etc., data for the highest flood-level should be obtained for
previous years. The structures should be located at such places that they
should be approached under flood condition. Normal DP structures are to
be used for such crossings on approval of Engineer in Charge.
In case of river crossing with longer span, special designed structures are
to be used for the purpose.
1.33 Guarding
Guarding is to be provided for the lines, so that a live conductor, when

accidentally broken, is prevented to come in contact with other electric
lines, telephone or telegraph lines, roads, and persons or animals and
carriages moving along the road, by providing a sort of cradle below the
main electric line.
Guarding is not required for crossings of 66 KV and higher voltage lines

where the transmission line is protected by fast acting relay operated
RGGVY/XII Plan/R1
circuit breaker of modern design with a tripping time of the order of 0.25
sec. from occurrence of fault to its clearance. For all other crossings,
guarding is essential for all telecommunication lines and major road
crossing.
The guarding shall consist of GI guard cross arm of length 2.5 mtrs made
out of 65x65x6 mm angle & shall be hot dipped galvanized generally
conforming to IS : 2633/72. The clamps shall also be hot dipped
galvanized generally conforming to IS: 2633/72 & suitable for 13 m 52
kgs/m rail pole & for 8.0 meters longs RCC poles. Guarding shall be
erected with ground & line clearances as per the I.E. rules. Cradle guard
wire should be of 8 SWG GI Wire provided with lashing of 10 SWG GI
wire at a distance of 2 m along the length of the guarding. Tension
clamps, threaded eye bolts, turn buckles, thimble, tying wires and
hardware are as per specified in the specifications. A sketch showing
arrangement of guarding at road crossing is enclosed with tender
drawing.
The minimum height between any guard wires and live crossing
conductor shall not be less than 1.5 m in case of a railway crossing.
1.34 Repair to conductors
The conductor shall be continuously observed for loose or broken strands

or any other damage during the running out operations. Repair to
conductors, if necessary, shall be carried out with repair sleeves.
Repairing of the conductor surface shall be carried out only in case of
minor damage, scuff marks, etc. The final conductor surface shall be
clean, smooth and free from projections, sharp points, cuts, abrasions,
etc. The Contractor shall be entirely responsible for any damage to the
poles during stringing.
1.35 LT Lines and Service connection
1.35.1. The LT line shall be erected of single phase or three phases depending on
site requirements. However, in both the arrangements, GI earth wire of
8mm diameter shall be laid to extend earth connection to single phase
users. Every 6th pole of LT line shall be earthed with GI spike/GI Coil as
per specifications. The single phase line shall have two wires arrangement
– one wire for phase and other one is for neutral. In three phase
arrangements, 4-wires shall be erected. Three wires for phase current
and 4th one is for neutral.
RGGVY/XII Plan/R1
1.35.2. In all those locations where LT line is to be erected on the same support
in which 11KV or 33KV line is also erected, proper isolation is to be
maintained.
1.35.3. All single phase service connections released under the RGGVY
programme shall be provided with one earth point near the energy meter.
This point is connected with the proper earthing system through GI wires.
10mm diameter earth knob in form of bolt and nut is to be installed on
energy meter board. This earth point is to be maintained by service
providing Distribution Company after installation and energisation. In up-
stream network, this earth point is to be connected with earth point.
1.35.4. Service connection is to be issued on proper surveying of the location so

that excessive erection of LT line or 11 KV line may be avoided. The
service wire is to be hanged on supportive GI wire between pole support
and the house. Before installing service wires and GI wire, GI pipe on the
consumer premises is to be erected using clamps/ nails/proper binding
etc. In case of hut or poor structure at consumer premises, GI pipe is to
clamp on wooden planks/wooden structure existing in the house. The GI
pipe should be supported for neutralizing tension by means of GI tie wire
support. In pukka/brickwork/cement concrete foundations, house, GI
support pipe is to be clamped by means of MS clips.
1.35.5. The consumer meter shall be installed at the premises of consumers at

suitable height and at place which is not in direct approach of sun-light
and rain water. Meters should be installed under the covering shade.
RGGVY/XII Plan/R1
Volume-II Section (B)
Technical Specification for Equipments
All materials required to complete the work as per given specifications & drawings etc. must be
manufactured and supplied using fresh raw material. Re-moulded, re-circulated materials are
not acceptable. The procurement of materials must be made by the contractor directly from
manufacturer or through authorized dealer/distributors. Documentary evidences to this effect
are to be made available to Employer for necessary checks/verification of source of supply of
materials. Second hand materials/ partial used materials/ used materials would not acceptable.
Climatic condition details are given with various materials specifications however, bidder shall
note that materials covered under project specific RGGVY works shall be utilized in that
particular project only. Hence, the geographical location of that particular project site and its
associated climatic condition shall be applicable for all the materials of that particular project.
Index
S.No. Equipments Page No.
1 Three phase 33/11kv Power Transformers A
2 Three phase DTR Transformer - B
3 Single phase DTR Transformer C
4 11 & 33 KV Potential Transformer D
5 11 & 33 KV Current Transformer E
6 11 \KV and 33 KV Vacuum Circuit Breakers F
7 Indoor Control Panels For 11 & 33 KV Breaker G

8 Hard Drawn Stranded Aluminium And Steel Cored Aluminium H
Conductors For Overhead Power Lines
9 11 KV XLPE Cables I
10 Aerial Bunched Cable Having XLPE Insulated L.T. Cable for Working J
Voltage Upto 1100 V
11 PVC Insulated & PVC Sheathed LT Cables K
12 LT PVC Power Cable L
13 1.1 KV Grade Control Cable M
14 XLPE 11 KV 1 & 3 Core N
15 PSC Pole (F.O.S. 2.5 ) For 11 KV And LT Lines O
16 Pre-Stressed Concrete Poles For 33 KV Lines P
17 LT Switch Board For Distribution Transformer Q
18 Steel Tubular Pole R
19 33 & 11 KV Station Class And Distribution Class LA S
20 11 KV And 33 KV Air Break Switches T
21 11 KV And 33 KV Isolators U
22 Porcelain Insulators And Insulator Fittings For 33 KV Overhead Power V
Lines
23 Porcelain Insulators And Insulator Fittings For 415/240V Overhead W
Power Lines
24 11KV Porcelain Insulators & Fittings X
25 Helically Formed Fittings For 11 KV & LT Lines Y
26 Guy Strain Insulators Z

Index
S.No. Equipments Page No.
27 Horn Gap Fuse AA
28 HRC Fuse AB
29 MCCB AC
30 Triple Pole Switch Fuse Units With Neutral Links AD
31 Batteries & Chargers AE
32 Cable Glands & Lugs AF
33 Cables Tags & Markers AG
34 Accessories For Anchoring, Suspending & Making Connections To AH
Aerial Bunched Cables Rated 1100
35 Material Properties And Other Technical Requirements For Heat AI
Shrinkable Cable Terminations And Joints Suitable For 11 KV XLPE
Cables
36 Energy Meter AJ
37 Earth Knobs For LT Lines AK
38 Earthing Coil AL
39 Earthing Conductors AM
40 Earthing AN
41 GI Earthing Pipe AO
42 GI Stay Wires AP
43 GS Stay Sets AQ
44 GI Wires AR
45 Hot Dip Galvanized GS Solid Wire AS
46 LT Line Spacers AT
47 Hot Rolled Steel Beam AU
48 ISI Mark Galvanized Mild Steel Hexagonal Head Bolts And Nuts AV
49 11 KV Drop Out Fuse Cut Outs AW
50 11kV Automatically Switched Capacitor Banks At Sub-Stations AX
51 33 KV And 11 KV Post Insulator AY
52 Clamps And Connectors AZ
53 Epoxy Based Protective Paint BA
54 Fire Fighting Equipments BB
55 High Tensile Steel Wires For PCC Poles BC
56 Mid Span Compression Joint & Repair Sleeve BD
57 Mild Steel Channel BE
58 Re-Wireable Type Porcelain Fuse Units For Ratings From 32 Amp 415 BF
Volt upto and 300 Amp
59 Terminal Block BG
60 Wiring BH
61 Equipment Erection Notes BI
62 Laying And Commissioning Of 11 KV XLPE U.G cable BJ
63 Danger Notice Plates BK
64 Meter Board BL
65 Number Plate BM
66 11 KV Circuit Breakers For Controlling Capacitors BN
67 33/0.4KV, 100 KVA Station Service Transformer BO
68 Indoor 11 KV VCB BP
69 LED Ballasted Lamp BQ

70 16 KVA three phase distribution transformer BR
Volume-II : Section-II (B) 1
Technical Specification
3.15, 5 & 8 MVA 33/11KV THREE PHASE POWER TRANSFORMERS
1 SCOPE
1.1 This Specification provides for design, engineering, manufacture, assembly, stage inspection, final
inspection and testing before dispatch, packing and delivery at destination Sub-station by road transport,
transit insurance, unloading at site /stores of 3.15/5/8 MVA, 33/11 KV Power Transformer(s), complete
with all fittings, accessories, associated equipments, spares, 10% extra Transformer Oil, required for it’s
satisfactory operation in any of the sub-stations of the Purchaser.
1.2 The core shall be constructed either from high grade, non-aging Cold Rolled Grain Oriented (CRGO)
silicon steel laminations conforming to HIB grade with lamination thickness not more than 0.23mm to
0.27mm or better( Quoted grade and type shall be used). The maximum flux density in any part of the
cores and yoke at normal voltage and frequency shall not be more than 1.5 Tesla. The Bidder shall
provide saturation curve of the core material, proposed to be used. Laminations of different grade(s) and
different thickness (s) are not allowed to be used in any manner or under any circumstances.
1.3 The scope of supply includes the provision of type test. The equipment offered should have been
successfully type tested within five years from date of tender and the designs should have been in
satisfactory operation for a period not less than three years as on the date of bid opening. Compliance
shall be demonstrated by submitting, (i) authenticated copies of the type test reports and (ii)
performance certificates from the users, specifically from Central Govt./State Govt. or their undertakings.
1.4 The Power Transformer shall conform in all respects to highest standards of engineering, design,
workmanship, this specification and the latest revisions of relevant standards at the time of offer and the
employer shall have the power to reject any work or material, which, in his judgment, is not in full
accordance therewith. The Transformer(s) offered, shall be complete with all components, necessary for
their effective and trouble free operation. Such components shall be deemed to be within the scope of
supply, irrespective of whether those are specifically brought out in this specification and / or the
commercial order or not.
The Engineer reserves the right to reject the transformers if on testing the losses exceed the declared
losses beyond tolerance limit as per IS or the temperature rise in oil and / or winding exceeds the value,
specified in technical particular or impedance value differ from the guaranteed value including tolerance
as per this specification and if any of the test results do not match with the values, given in the
guaranteed technical particulars and as per technical specification.
2 SPECIFIC TECHNICAL REQUIREMENTS
1 Rated MVA (ONAN rating) 3.15/5/8 MVA

2 No. of phases 3
3 Type of installation Outdoor
4 Frequency 50 Hz (± 5% )
5 Cooling medium Insulating Oil (ONAN)
6 Type of mounting On Wheels, Mounted on rails.
7 Rated voltage
a) High voltage winding 33KV
b) Low voltage winding 11KV
8 Highest continuous system voltage
a) Maximum system voltage ratio (HV / LV ) 36KV / 12 KV
b) Rated voltage ratio (HV / LV ) 33KV /11 KV
A
9 No. of windings Two winding Transformers

10 Type of cooling ONAN (Oil natural / Air natural)
11 MVA Rating corresponding to ONAN 100%
Cooling system
12 Method of connection:
HV : Delta
LV : Star
13 Connection symbol Dyn 11
14 System earthing Neutral of LV side to be solidly earthed.
15 Percentage impedance voltage on normal tap MVA Rating % Impedance Tolerance
%
and MVA base at 750 C corresponding to HV/ 3.15 6.25 10
LV rating and applicable tolerances : 5 7.15 10
8 8.35 10
(No negative tolerance will be allowed)
16 Intended regular cyclic overloading As per IEC –76-1, Clause 4.2

of windings
17 a) Anticipated unbalanced loading Around 10%
b) Anticipated continuous loading of 110 % of rated current
windings (HV / LV)
18 a) Type of tap changer ( For 5 & 8 MVA only) Off-load tap changer.
b) Range of taping + 5% to – 15% in 9 equal steps of 2.5%
each on HV winding
19 Neutral terminal to be brought out On LV side only
20 Over Voltage operating capability and duration 112.5 % of rated voltage ( continuous )
21 Maximum Flux Density in any part of the core 1.5 Tesla
and yoke at rated MVA, rated voltage i.e 33 KV /
11 KV and system frequency of 50 HZ
22 Insulation levels for windings :- 33KV 11KV
a) 1.2 / 50 microsecond wave shape Impulse 170 95
withstand (KVP)
b) Power frequency voltage withstand (KVrms) 70 28
23 Type of winding insulation

a) HV winding Uniform
b) LV winding Uniform
24 Withstand time for three phase short circuit 2 Seconds
25 Noise level at rated voltage and frequency As per NEMA Publication No. TR-1.
26 Permissible Temperature Rise over ambient temperature
of 50˚C
a) Of top oil measured by thermometer. 40˚C
b) Of winding measured by resistance. 45˚ C
A
27 Minimum clearances in air (mm) :- Phase to Phase Phase to ground

a) HV 400 320
b) LV 280 140
28 Terminals
a) HV winding line end 36 KV oil filled communicating type
porcelain bushings (Anti-fog type)
b) LV winding 12 KV porcelain type of bushing (Anti-
fog type) – for outdoor 11 KV breakers
(11KV Power cables shall be used for extending supply to 11KV breakers in case of indoor
circuit breakers. The termination of 11 KV cables on LV bushing shall be through extended
copper bus bars suitable to hold power cables termination. A metallic cable termination
box, completely sealed, shall be installed on LV side of the transformer in which cables
shall enter from bottom gland plates.)
29 Insulation level of bushing HV LV
a) Lightning Impulse withstand (KVP) 170 95
b) 1 Minute Power Frequency withstand 70 28

voltage (KV –rms )
c) Creepage distance (mm) (minimum) 900 300
30 Material of HV & LV Conductor Electrolytic Copper
31 Maximum current density for HV and LV 2.4 A/ mm²
winding for rated current
32 Polarisation index i.e ratio of megger values Shall be greater than or equal to 1.5, but
at 600 sec. to 60 sec for HV to earth, L.V to earth less than or equal to „5‟
and HV to LV.
33 Core Assembly Boltless type
34 Temperature Indicator
a) Oil One number
b) Winding One number
35. Losses:- The losses shall not exceed the value given below
MVA Rating No-load losses Load losses at 75°C

(Fixed loss) KW KW
3.15 4.5 23
5 6.5 34
8 8.5 50
2.1 MARSHALLING BOX

A metal enclosed, weather, vermin and dust proof marshalling box fitted with required glands, locks,
glass door, terminal Board, heater with switch, illumination lamp with switch etc. shall be provided with
each transformer to accommodate temperature indicators, terminal blocks etc. It shall have degree of
protection of IP 55 or better as per IS: 2147 (Refer Clause 3.12).
A
2.2 CAPITALIZATION OF LOSSES AND LIQUIDATED DAMAGES
The Capitalization of guaranteed losses of the transformer shall be calculated and considered while
evaluating the bids.
2.3 PERFORMANCE
i) Transformer shall be capable of withstanding for two seconds without damage to any external short
circuit, with the short circuit MVA available at the terminals.
ii) The maximum flux density in any part of the core and yoke at rated MVA. Voltage and frequency
shall be 1.5 Tesla (maximum).
iii) Transformer shall under exceptional circumstances due to sudden disconnection of the load, be
capable of operating at the voltage approximately 25% above normal rated voltage for a period of
not exceeding one minute and 40% above normal for a period of 5 seconds.
iv) The transformer may be operated continuously without danger on any particular tapping at the rated
MVA ± 12.5% of the voltage corresponding to the tapping.
v) The thermal ability to withstand short circuit shall be demonstrated by calculation.
vi) Transformer shall be capable of withstanding thermal and mechanical stress caused by any
symmetrical and asymmetrical faults on any winding.
2.4 DRAWINGS/ DOCUMENTS INCORPORATING THE FOLLOWING PARTICULARS SHALL BE

SUBMITTED WITH THE BID
a) General outline drawing showing shipping dimensions and overall dimensions, net weights and
shipping weights, quality of insulating oil, spacing of wheels in either direction of motion, location
of coolers, marshalling box and tap changers etc.
b) Assembly drawings of core, windings etc. and weights of main components / parts.
c) Height of center line on HV and LV connectors of transformers from the rail top level.
d) Dimensions of the largest part to be transported.
e) GA drawings / details of various types of bushing
f) Tap changing and Name Plate diagram
g) Type test certificates of similar transformers.
h) Illustrative & descriptive literature of the Transformer.
i) Maintenance and Operating Instructions.
2.5 MISCELLANEOUS
i) Padlocks along with duplicate keys as asked for various valves, marshalling box etc. shall be
supplied by the contractor, wherever locking arrangement is provided.
ii) Foundation bolts for wheel locking devices of Transformer shall be supplied by the Contractor.
2.6 DELIVERY
The full quantity of the equipments shall be delivered as per the delivery schedule appended to this
specification.
A
2.7 SCHEDULES
All Schedules annexed to the specification shall be duly filled by the bidder separately.
2.8 ALTITUDE FACTOR
If the equipment is to be installed in the hilly area, necessary correction factors as given in the Indian
Standard for oil temperature rise, insulation level etc. shall be applied to the Standard Technical
Parameters given above.
2.9 NAME PLATE
Transformer rating plate shall contain the information as given in clause 15 of IS-2026 (part-I). The
details on rating plate shall be finalized during the detailed engineering. Further, each transformer shall
have inscription of Employer’s name. The name plate shall also include (i) The short circuit rating , (ii)
Measured no load current and no load losses at rated voltage and rated frequency, (iii) measured load
losses at 75° C ( normal tap only ), (iv) D.C resistance of each winding at 75° C.
3. SERVICE CONDITIONS
The service conditions shall be as follows: (To be confirmed by PIA as per locality of project)
Plane Hilly area

area
maximum altitude above sea level 1000m 5000m
maximum ambient air temperature 50° C 50° C
maximum daily average ambient air 35° C 40° C
temperature
minimum ambient air temperature -5° C -30° C
maximum temperature attainable by an 60 ° C 60 ° C
object exposed to the sun
maximum yearly weighted average ambient 32° C 32° C
temperature
maximum relative humidity 100 100
% %
average number of thunderstorm days per 70 70
annum (isokeraunic level)
average number of rainy days per annum 120 120
average annual rainfall 1500 1500 mm
mm
maximum wind pressure 260Kg/m² 260Kg/m²
Environmentally, the region where the equipment will be installed includes coastal areas, subject to high
relative humidity, which can give rise to condensation. Onshore winds will frequently be salt laden. On
occasions, the combination of salt and condensation may create pollution conditions for outdoor
insulators. Therefore, outdoor material and equipment shall be designed and protected for use in
exposed, heavily polluted, salty, corrosive, tropical and humid coastal atmosphere.
A
4 SYSTEM CONDITIONS
The equipment shall be suitable for installation in supply systems of the following
characteristics.
Frequency 50 Hz± 5%
Nominal system voltages
33 KV
11 KV
Maximum system voltages 33KV System 36.3 KV

11 KV System 12 KV
Nominal short circuit level ( Basing on apparent power ) 33KV System 31.5KA
11 KV System 13.1KA
Insulation levels : 33KV System 170KV (peak)

1.2/50 μ sec impulse withstand voltage 11 KV System 75 KV (peak)
Power frequency one minute withstand (wet and dry) 33KV System 70KV (rms)
voltage
11 KV System 28KV (rms)
Neutral earthing arrangements 11 KV System Solidly earthed
5 CODES & STANDARDS
5.1 (i) The design, material, fabrication, manufacture, inspection, testing before dispatch and
performance of power transformers at site shall comply with all currently applicable statutory
regulations and safety codes in the locality where the equipment will be installed. The equipment
shall also conform to the latest applicable standards and codes of practice. Nothing in this
specification shall be construed to relieve the contractor of this responsibility.
5.2 The equipment and materials covered by this specification shall conform to the latest applicable
provision of the following standards.
IS:5 Colour for ready mixed paints

IS:325 Three Phase Induction Motors
IS:335 New insulating oil for transformers, switch gears
IS:1271 Classification of insulating materials for electrical
machinery and apparatus in relation to their stability in
services
IS:2026(Part I to IV) Power Transformer
IS:2071 Method of high voltage testing
IS:2099 High voltage porcelain bushings
IS:2147 Degree of protection
IS:2705 Current Transformers
IS:3202 Code of practice for climate proofing of electrical
equipment
IS:3347 Dimensions for porcelain Transformer Bushings
IS:3637 Gas operated relays
IS:3639 Fittings and accessories for power Transformers
IS:5561 Electric Power Connectors
IS:6600/BS:CP‟10:0 Guide for loading of oil immersed Transformers
IS:10028 Code of practice for selection, installation and
maintenance of transformers, Part I. II and III
C.B.I.P. Publication Manual on Transformers
A
If the standard is not quoted for any item, it shall be presumed that the latest version of Indian
Standard shall be applicable to that item.
The equipment complying other internationally accepted standards, may also be considered if they
ensure performance superior to the Indian Standards.
5.3 DRAWINGS
a) The contractor shall furnish, within fifteen days after issuing of Letter of Award. Six copies each of the
following drawings/documents incorporating the transformer rating for approval.
i) Detailed overall general arrangement drawing showing front and side elevations and plan of the
transformer and all accessories including radiators and external features with details of
dimensions, spacing of wheels in either direction of motion, net weights and shipping weights,
crane lift for un-tanking, size of lugs and eyes, bushing lifting dimensions, clearances between
HV and L.V terminals and ground, quantity of insulating oil etc.
ii) Assembly drawings of core and winging and weights of main components / parts
iii) Foundation plan showing loading on each wheel land jacking points with respect to centre line
of transformer.
iv) GA drawings details of bushing and terminal connectors.
v) Name plate drawing with terminal marking and connection diagrams.
vi) Wheel locking arrangement drawing.
vii) Transportation dimensions drawings.
Viii) Magnetization characteristic curves of PS class neutral and phase side current transformers, if
applicable.
ix) Interconnection diagrams.
x) Over fluxing withstand time characteristic of transformer.
xi) GA drawing of marshalling box.
xii) Control scheme/wiring diagram of marshalling box.
xiii) Technical leaflets of major components and fittings.
xiiv) As built drawings of schematics, wiring diagram etc.
xv) Setting of oil temperature indicator, winding temperature indicator.
xvi) Completed technical data sheets. xvii) Details including write-up of tap changing gear.
xviii) HV conductor bushing. xix) Bushing Assembly.
xx) Bi-metallic connector suitable for connection to 100 mm2 up to 232 mm2 AAAC Conductor.
xxi) GA of LV cable Box.
xxii) Radiator type assembly.
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b) All drawings, documents, technical data sheets and test certificates, results calculations shall be
furnished.
5.4 Any approval given to the detailed drawings by the Employer’s shall not relieve the contractor of the
responsibility for correctness of the drawing and in the manufacture of the equipment. The approval
given by the employer shall be general with overall responsibility with contractor.
6. GENERAL CONSTRUCTIONAL FEATURES
6.1 All material used shall be of best quality and of the class most suitable for working under the conditions
specified and shall withstand the variations of temperature and atmospheric conditions without
distortion or deterioration or the setting up of undue stresses which may impair suitability of the various
parts for the work which they have to perform.
6.2 Similar parts particularly removable ones shall be interchangeable.
6.3 Pipes and pipe fittings, screws, studs, nuts and bolts used for external connections shall be as per the
relevant standards. Steel bolts and nuts exposed to atmosphere shall be galvanized.
6.4 Nuts, bolts and pins used inside the transformers and tap changer compartments shall be provided with
lock washer or locknuts.
6.5 Exposed parts shall not have pockets where water can collect.
6.6 Internal design of transformer shall ensure that air is not trapped in any location.
6.7 Material in contact with oil shall be such as not to contribute to the formation of acid in oil. Surface in
contact with oil shall not be galvanized or cadmium plated
6.8 Labels, indelibly marked, shall be provided for all identifiable accessories like Relays, switches current
transformers etc. All label plates shall be of in corrodible material.
6.9 All internal connections and fastenings shall be capable of operating under overloads and over-excitation,
allowed as per specified stands without injury.
6.10 Transformer and accessories shall be designed to facilitate proper operation, inspection, maintenance and
repairs.
6.11 No patching, plugging, shimming or other such means of overcoming defects, discrepancies or errors
will be accepted.
6.12 Schematic Drawing of the wiring, including external cables shall be put under the prospane sheet on the
inside door of the transformer marshalling box.
6.13 Painting
6.13.1 All paints shall be applied in accordance with the paint manufacturer‟s recommendations. Particular
attention shall be paid to the following:
a) Proper storage to avoid exposure as well as extremes of temperature.

b) Surface preparation prior to painting.
c) Mixing and thinning
d) Application of paints and the recommended limit on time intervals between coats.
e) Shelf life for storage.
6.13.1.1 All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles, patchiness, brush
marks or other defects.
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6.13.1.2 All primers shall be well marked into the surface, particularly in areas where painting is evident, and
the first priming coat shall be applied as soon as possible after cleaning. The paint shall be applied by
airless spray according to the manufacturer‟s recommendations. However, wherever airless spray is
not possible, conventional spray be used with prior approval of Employer.
6.13.1.3 The supplier shall, prior to painting protect nameplates, lettering gauges, sight glasses, light fittings
and similar such items.
6.13.2 Cleaning and Surface Preparation
6.13.2.1 After all machining, forming and welding has been completed, all steel work surfaces shall be
thoroughly cleaned of rust, scale, welding slag or spatter and other contamination prior to any
painting.
6.13.2.2 Steel surfaces shall be prepared by Sand/Shot blast cleaning or Chemical cleaning by Seven tank
process including Phosphating to the appropriate quality.
6.13.2.3 The pressure and Volume of the compressed air supply for the blast cleaning shall meet the work
requirements and shall be sufficiently free from all water contamination prior to any painting. 6.13.2.4
Chipping, scraping and steel wire brushing using manual or power driven tools cannot remove firmly
adherent mill-scale and shall only be used where blast cleaning is impractical.
6.13.3 Protective Coating As soon as all items have been cleaned and within four hours of the subsequent
drying, they shall be given suitable anticorrosion protection.
6.13.4 Paint Material
Followings are the type of paints that may be suitably used for the items to be painted at shop and
supply of matching paint to site:
i) Heat resistant paint (Hot oil proof) for inside surface.
ii) For external surfaces one coat of Thermo Setting Paint or 2 coats of Zinc chromate followed by 2
coats of POLYURETHANE . The color of the finishing coats shall be dark admiral grey conforming to
No.632 or IS 5:1961.
6.13.5 Painting Procedure
6.13.5.1 Al painting shall be carried out in conformity with both specifications and with the paint manufacture’s
recommendations. All paints in any one particular system. Whether shop or site applied, shall originate
from one paint manufacturer.
6.13.5.2 Particular attention shall be paid to the manufacture’s instructions on storage, mixing, thinning and
pot life. The paint shall only be applied in the manner detailed by the manufacturer e.g. brush, roller,
conventional or airless spray and shall be applied under the manufacturer’s recommended conditions.
Minimum and maximum time intervals between coats shall be closely followed.
6.13.5.3 All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours
whichever is sooner. Chemical treated steel surfaces shall be primed as soon as the surface is dry and
while the surface is warm.
6.13.5.4 Where the quality of film is impaired by excess film thickness,(wrinkling, mud cracking or general
softness) the supplier shall remove the unsatisfactory paint coatings and apply another. As a general
rule, dry film thickness should not exceed the specified minimum dry film thickness by more than 25% .
In all instances, where two or more coats of the same paints are specifies, such coatings may or may
not be of contrasting colors.
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6.13.5.5 Paint applied to items that are not be painted, shall be removed at supplier‟s expense, leaving the
surface clean, un-stained and undamaged.
6.13.6 Damages to Paints Work
6.13.6.1 Any damage occurring to any part of the painting scheme shall be made good to the same standard
of corrosion protection and appearance as that originally employed.
6.13.6.2 Any damaged paint work shall be made as follows:
a) The damaged area, together with an area extending 25mm around its boundary, shall be cleaned
down to bare metal.
b) A priming coat shall immediately applied, followed by a full paint finish equal to that originally
applied and extending 50mm around the perimeter of the originally damaged.
6.13.6.3 The repainted surface shall present a smooth surface. This shall be obtained by carefully chamfering
the paint edges before & after priming.
6.13.7 Dry Film Thickness
6.13.7.1 To the maximum extent practicable, the coats shall be applied as a continuous film of uniform
thickness and free of pores. Over-spray, skips, runs, sags and drips should be avoided. The different
coats may or may not be same color.
6.13.7.2 Each coat of paint shall allowed to hardened before the next is applied as per manufacture‟s
recommendations.
6.13.7.3 Particular attention must be paid to full film thickness at edges.
6.13.7.4 The requirement for the dry film thickness (DFT) of paint and the material to be used shall be as
given below:
Sl.No Paint Type Area to be No of Total Dry film

painted Coats thickness(Min)
1 Liquid paint
a) Zinc Chromate(Primer) Out side 02 45 micron
b) POLYURETHANE Out side 02 35 micron
Paint (Finish Coat)
c) Hot Oil paint inside 01 35 micron
7.0 DETAILED DESCRIPTION
7.1 Tank
7.1.1 The Transformer tank and cover shall be fabricated from high grade low carbon plate steel of tested
quality. The tank and the shall be of welded construction.
7.1.2 Tank shall be designed to permit lifting by crane or jacks of the complete transformer assembly filed with
oil. Suitable lugs and bossed shall be provided for this purpose.
7.1.3 All breams, flanges, lifting lugs, braces and permanent parts attached to the tank shall be welded and
where practicable, they shall be double welded.
7.1.4 The main tank body of the transformer, excluding tap changing compartments and radiators, shall be
capable of withstanding pressure of 760mm of Hg.
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7.1.5 Inspection hole(s) with welded flange(s) and bolted cover(s) shall be provided on the tank cover. The
inspection hole(s) shall be of sufficient size to afford easy access to the lower ends of the bushings,
terminals etc.
7.1.6 Gaskets of nitrile rubber or equivalent shall be used to ensure perfect oil tightness. All gaskets shall be
closed design (without open ends) and shall be of one piece only. Rubber gaskets used for flange type
connections of the various oil compartments, shall be laid in grooves or in groove-equivalent sections on
bolt sides of the gasket, throughout their total length. Care shall be taken to secure uniformly
distributed mechanical strength over the gaskets and retains throughout the total length. Gaskets of
neoprene and / or any kind of impregnated / bonded core or cork only which can easily be damaged by
over-pressing are not acceptable. Use of hemp as gasket material is also not acceptable.
7.1.7 Suitable guides shall be provided for positioning the various parts during assemble or dismantling.
Adequate space shall be provided between the cores and windings and the bottom of the tank for
collection of any sediment.
7.2 Tank Cover
The transformer top shall be provided with a detachable tank cover with bolted flanged gasket joint.
Lifting lugs shall be provided for removing the cover. The surface of the cover shall be suitable sloped
so that it does not retain rain water.
7.3 UNDER CARRIAGE
7.3.1 The transformer tank shall be supported on steel structure with detachable plain rollers completely filled
with oil. Suitable channels for movement of roller with transformer shall be space accordingly, rollers
wheels shall be provided with suitable rollers bearings, which will resist rust and corrosion and shall be
equipped with fittings for lubrication. It shall be possible to swivel the wheels in two directions, at right
angle to or parallel to the main axis of the transformers.
7.4 CORE
7.4.1 Each lamination shall be insulated such that it will not deteriorate due to mechanical pressure and the
action of hot transformer oil.
7.4.2 The core shall be constructed either from high grade, non-aging Cold Rolled Grain Oriented (CRGO)
silicon steel laminations conforming to HIB grade with lamination thickness not more than 0.23mm to
0.27mm or better( Quoted grade and type shall be used). The maximum flux density in any part of the
cores and yoke at normal voltage and frequency shall not be more than 1.5 Tesla. The Bidder shall
provide saturation curve of the core material, proposed to be used. Laminations of different grade(s)_
and different thickness (s) are not allowed to be used in any manner or under any circumstances.
7.4.3 The bidder should offer the core for inspection starting from the destination port to enable Employer for
deputing inspecting officers for detail verification as given below and approval by the Employer during
the manufacturing stage. Bidder‟s call notice for the purpose should be a ccompanied with the following
documents as applicable as a proof towards use of prime core material: The core coils, if found suitable,
are to be sealed with proper seals which shall be opened in presence of the inspecting officers during
core- cutting at the manufacturer’s or it’s sub-vendor’s premises as per approved design drawing.
a) Purchase Order No. & Date.

b) Invoice of the supplier
c) Mills test certificate
d) Packing list
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e) Bill of lading
f) Bill of entry certificate to customs
Core material shall be directly procured either from the manufacturer or through their accredited
marketing organization of repute, but not through any agent.
7.4.4 The laminations shall be free of all burrs and sharp projections. Each sheet shall have an insulting
coating resistant to the action of hot oil.
7.4.5 The insulation structure for the core to bolts and core to clamp plates, shall be such as to withstand
2000 V DC voltage for one minute.
7.4.6 The completed core and coil shall be so assembled that the axis and the plane of the outer surface of
the core assemble shall not deviate from the vertical plane by more than 25mm.
7.4.7 All steel sections used for supporting the core shall be thoroughly shot or sand blasted, after cutting,
drilling and welding.
7.4.8 The finally assembled core with all the clamping structures shall be free from deformation and shall not
vibrate during operation.
7.4.9 The core clamping structure shall be designed to minimize eddy current loss.
7.4.10 The framework and clamping arrangements shall be securely earthed.
7.4.11 The core shall be carefully assembled and rigidly clamped to ensure adequate mechanical strength.
7.4.12 Oil ducts shall be provided, where necessary, to ensure adequate cooling inside the core. The welding
structure and major insulation shall not obstruct the free flow of oil through such ducts.
7.4.13 The design of magnetic circuit shall be such as to avoid static discharges, development of short circuit
paths within itself or to the earth clamping structure and production of flux component at right angle to
the plane of the lamination, which may cause local heating. The supporting framework of the cores shall
be so designed as to avoid the presence of pockets, which would prevent complete emptying of the
tank through the drain valve or cause trapping of air during filling.
7.4.14 The construction is to be of boltless core type. The core shall be provided with lugs suitable for lifting
the complete core and coil assembly. The core and coil assemble shall be so fixed in the tank that
shifting will not occur during transport or short circuits.
7.4.15 The temperature gradient between core & surrounding oil shall be maintained less than 20 deg.
Centigrade. The manufacturer shall demonstrate this either through test (procurement to be mutually
agreed) or by calculation.
7.5 INTERNAL EARTHING
7.5.1 All internal metal parts of the transformer, with the exception of individual laminations and their
individual clamping plates shall be earthed.
7.5.2 The top clamping structure shall be connected to the tank by a copper strap. The bottom clamping
structure shall be earthed by one or more the following methods:
a) By connection through vertical tie-rods to the top structure.
b) By direct metal to metal contact with the tank base.
c) By a connection to the structure on the same side of the core as the main earth connection to the
tank.
7.5.3 The magnetic circuit shall be connected to the clamping structure at one point only and this shall be
brought out of the top cover of the transformer tank through a suitably rated insulator. A disconnecting
link shall be provided on transformer tank to facilitate disconnections from ground for IR measurement
purpose.
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7.5.4 Coil clamping rings of metal at earth potential shall be connected to the adjacent core clamping structure
on the same side as the main earth connections.
7.6 WINDING
7.6.1 Winding shall be subjected to a shrinking and seasoning process, so that no further shrinkage occurs
during service. Adjustable devices shall be provided for taking up possible shrinkage in service. 7.6.2 All
low voltage windings for use in the circular coil concentric winding shall be wound on a performed
insulating cylinder for mechanical protection of the winding in handling and placing around the core.
7.6.3 Winding shall not contain sharp bends which might damage the insulation or produce high dielectric
stresses. No strip conductor wound on edge shall have width exceeding six times the thickness.
7.6.4 Materials used in the insulation and assembly of the windings shall be insoluble, non catalytic and
chemically inactive in the hot transformer oil and shall not soften or the otherwise affected under the
operating conditions.
7.6.5 Varnish application on coil windings may be given only for mechanical protection and not for
improvement in dielectric properties. In no case varnish or other adhesive be used which will seal the
coil and prevent evacuation of air and moisture and impregnation by oil.
7.6.6 Winding and connections shall be braced to withstand shocks during transport or short circuit.
7.6.7 Permanent current carrying joints in the windings and leads shall be welded or brazed. Clamping bolts
for current carrying parts inside oil shall be made of oil resistant material which shall not be affected by
acidity in the oil steel bolts, if used, shall be suitably treated.
7.6.8 Terminals of all windings shall be brought out of the tank through bushings for external connections.
7.6.8.1 The completed core and coil assemble shall be dried in vacuum at not more than 0.5mm of mercury
absolute pressure and shall be immediately impregnated with oil after the drying process to ensure the
elimination of air and moisture within the insulation. Vacuum may be applied in either vacuum over or
in the transformer tank.
7.6.8.2 The winding shall be so designed that all coil assembles of identical voltage ratings shall be
interchangeable and field repairs to the winding can be made readily without special equipment. The
coils shall have high dielectric strength.
7.6.8.3 Coils shall be made of continuous smooth high grade electrolytic copper conductor, shaped and braced
to provide for expansion and contraction due to temperature changes.
7.6.8.4 Adequate barriers shall be provided between coils and core and between high and low voltage coil. End
turn shall have additional protection against abnormal line disturbances.
7.6.8.5 The insulation of winding shall be designed to withstand voltage stress arising from surge in
transmission lines due to atmospheric or transient conditions caused by switching etc.
7.6.8.6 Tapping shall not be brought out from inside the coil or from intermediate turns and shall be so
arranged as to preserve as far as possible magnetic balance of transformer at all voltage ratios.
7.6.8.7 Magnitude of impulse surges transferred from HV to LV windings by electromagnetic induction and
capacitance coupling shall be limited to BILL of LV winding.
7.6.8.8 The current density adopted in all winding shall not exceed 2.4 A/mm2. The total net cross sectional
area of the strip conductors for calculating current density for each winding shall be obtained after
deducting the copper area lost doe to rounding up of the sharp edges at the rectangular conductors.
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7.7 INSULATING OIL
7.7.1 The insulating oil for the transformer shall be of EHV grade, generally conforming to IS: 335. No
inhibitors shall be used in the oil.
7.7.2 The quantity of oil required for the first filling of the transformer and its full specification shall be stated
in the bid. transformer shall supplied complete with all fittings, accessories and new transformer oil
required for first filling plus 10% extra oil. The extra quantity of oil shall be supplied in non-returnable
drums along with the oil required for the radiator banks.
7.7.3 The design and materials used in the construction of the transformer shall be such as to reduce the risk
of the development of acidity in the oil.
7.7.4 The contractor shall warrant that oil furnished is in accordance with the following specifications.
S.No. Characteristic Requirement Method of Test
1 Appearance The oil shall be clear & A reresentative sample of oil

tranparent & free From shall be examined in a 100 mm
Suspended matter or sediment thik layer at ambient temp.
2 Density at 20°c 0.89 g/cm3 Max. IS:1448

3 Kinematic Viscosity 27 CST IS:1448
at 27 deg. C Max
4 Interfacial tension at 0.03 N/m IS:6104

27 °C Min.
5 Flash Point 136 °C IS:1448
6 Pour Point Max. 72.5 KV IS:1448

7 Nautralisation Value 0.03 mg KOH/gm IS:335
(Total Acidity) Max.
8 Electric strength 72.5 KV IS:6792
Breakdown (voltage)
Min.
9 Dielectric dissipation 0.03 Max IS:6262
factor tan delta at
90°C
10 Min specific 35X1012 ohm cm (min.) IS:6103
resistance(resistively)
at 90°C
11 Oxidation stability
12 Neutralization value 0.40mg KOH/g

after oxidation
13 Total sludge after 0.10% by weight max.
oxidation
14 Presence of oxidation The oil shall not contain anti- IS:335

Inhibitor oxidant Additives.
15 Presence of oxidation The oil shall not contain anti- IS:335
Inhibitor oxidant Additives
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7.8 VALVES
i) Valves shall be of forged carbon steel upto 50mm size and of gun mental or of cast iron bodies with gun
metal fittings for sizes above 50mm. They shall be of full way type with screwed ends and shall be
opened by turning counter clockwise when facing the hand wheel. There shall be no oil leakage when
the valves are in closed position.
ii) Each valve shall be provided with an indicator to show the open and closed positions and shall be
provided with facility for padlocking in either open or closed position. All screwed valves shall be
furnished with pipe plugs for protection. Padlocks with duplicate keys shall be supplied along with the
valves.
iii) All valves except screwed valves shall be provided with flanges having machined faced drilled to suit the
applicable requirements, Oil tight blanking plates shall be provided for each connection for use when
any radiator is detached and for all valves opening to atmosphere. If any special radiator valve tools are
required the contractor shall supply the same.
i) Each transformer shall be provided with following valves on the tank:
a) Drain valve so located as to completely drain the tank & to be provided with locking
arrangement.
b) Two filter valves on diagonally opposite corners of 50mm size & to be provided with locking
arrangement.
c) Oil sampling valves not less than 8mm at top and bottom of main tank & to be provided
with locking arrangement.
d) One 15mm air release plug.
e) Valves between radiators and tank. Drain and filter valves shall be suitable for applying
vacuum as specified in the specifications.
7.9 ACCESSORIES
7.9.1 Bushing
i) All porcelain used in bushings shall be homogeneous, non-porous, uniformly glazed to brown colour
and free from blisters, burns and other defects.
ii) Stress due to expansion and contraction in any part of the bushing shall not lead to deterioration.
iii) Bushing shall be designed and tested to comply with the applicable standards.
iv) Bushing rated for 400A and above shall have non-ferrous flanges and hardware.
v) Fittings made of steel or malleable iron shall be galvanized
vi) Bushing shall be so located on the transformers that full flashover strength will be utilized. Minimum
clearances as required for the BIL shall be realized between live parts and live parts to earthed
structures.
vii) All applicable routine and type tests certificates of the bushings shall be furnished for approval.
viii) Bushing shall be supplied with bi-metallic terminal connector/ clamp/ washers suitable for fixing to
bushing terminal and the Employers specified conductors. The connector/clamp shall be rated to
carry the bushing rated current without exceeding a temperature rise of 550 C over an ambient of
500 C. The connector/clamp shall be designed to be corona free at the maximum rated line to
ground voltage.
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ix) Bushing of identical voltage rating shall be interchangeable.
x) The insulation class of high voltage neutral bushing shall be properly coordinated with the insulation
class of the neutral of the low voltage winding.
xi) Each bushing shall be so coordinated with the transformer insulation that all flashover will occur
outside the tank.
xii) The extended bushing bus bars shall be used for termination of 11 KV cables. LV busing shall be
housed in completely sealed metallic enclosure.
xiii) Sheet steel, weather, vermin and dust proof cable box fitted with required glands, locks, glass door,
terminal Board, heater with switch, illumination lamp with switch, water- tight hinged and
padlocked door of a suitable construction shall be provided with each transformer to accommodate
11 KV cables etc. The box shall have slopping roof and the interior and exterior painting shall be in
accordance with the specification. Padlock along with duplicate keys shall be supplied for
marshalling box. The degree of protection shall be IP-55 or better. To prevent internal
condensation, a metal clad heater with thermostat shall be provided. The heater shall be controlled
by a MCB of suitable rating mounted in the box. The ventilation louvers, suitably padded with felt,
shall also be provided. The louvers shall be provided with suitable felt pads to prevent ingress of
dust. All incoming cables shall enter the kiosk from the bottom and the minimum 4mm thick, non-
magnetic, gland plate shall not be less than 600 mm from the base of the box. The gland plate and
associated compartment shall be sealed in suitable manner to prevent the ingress of moisture from
the cable trench – for those transformers which are used in partly indoor substation,
7.9.2 Protection & Measuring Devices
i) Oil Conservator Tank
a) The Conservator tank shall have adequate capacity between highest and lowest visible levels to
meet the requirement of expansion of the total cold oil volume in the transformer and cooling
equipment.
b) The conservator tank shall be bolted into position so that it can be remove for cleaning
purposes.
c) The conservator shall be fitted with magnetic oil level gauge with low level electrically insulated
alarm contact.
d) Plain conservator fitted with silica gel breather.
ii) Pressure Relief Device.
The pressure relief device provided shall be of sufficient size for rapid release of any pressure that may
be generated in the tank and which may result in damage of the equipment. The device shall operate at
a static pressure of less than the hydraulic test pressure of transformer tank. It shall be mounted direct
on the tank. A pair of electrically insulated contract shall be provided for alarm and tripping.
iii) Buchholz Relay
A double float type Buchholz relay shall be provided., Any gas evolved in the transformer shall collect in
this relay. The relay shall be provided with a test cock suitable for a flexible pipe connection for
checking its operation. A copper tube shall be connected from the gas collector to a valve located about
1200 mm above ground level to facilitate sampling with the transformer in service. The device shall be
provided with two electrically independent potential free contracts, one for alarm on gas accumulation
and the other for tripping on sudden rise of pressure.
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iv) Temperature Indicator
a) Oil Temperature Indicator (OTI)
The transformers shall be provided with a mercury contact type thermometer with 150 mm dial for top
oil temperature indication. The thermometer shall have adjustable, electrically independent potential
free alarm and trip contacts. Maximum reading pointer and resetting device shall be mounted in the
local control panel. A temperature sensing element suitably located in a pocket on top oil shall be
furnished. This shall be connected to the OTI by means of capillary tubing. Accuracy class of OTI shall
be ± 1% or better. One No electrical contact capable of operating at 5 A ac at 230 volt supply.
b) Winding Temperature indicator(WTI)
A device for measuring the hot spot temperature of the winding shall be provided. It shall comprise the
following.
i) Temperature sensing element.
ii) Image Coil.
iii) Mercury contacts.
iv) Auxiliary CTS, If required to match the image coil, shall be furnished and mounted in the local
control panel.
v) 150mm dial local indicating instrument with maximum reading pointer mounted in local panel and
with adjustable electrically independent ungrounded contacts, besides that required for control
of cooling equipment, one for high winding temperature alarm and on for trip.
vi) Calibration device.
vii) Two number electrical contact each capable of operating at 5 A ac at 230 Volt supply.
7.9.3 Oil Preservation Equipment
7.9.3.1 Oil Sealing
The oil preservation shall be diaphragm type oil sealing in conservator to prevent oxidation and
contamination of oil due to contact with atmospheric moisture.
The conservator shall be fitted with a dehydrating filter breather. It shall be so designed that.
i) Passage of air is through a dust filter & Silica gel.
ii) Silica gel is isolate from atmosphere by an oil seal.
iii) Moisture absorption indicated by a change in colour of the crystals of the silica gel can be easily
observed from a distance.
iv) Breather is mounted not more than 1400 mm above rail top level.
7.10 MARSHALLING BOX
i) Sheet steel, weather, vermin and dust proof marshalling box fitted with required glands, locks,
glass door, terminal Board, heater with switch, illumination lamp with switch, water- tight hinged
and padlocked door of a suitable construction shall be provided with each transformer to
accommodate temperature indicators, terminal blocks etc. The box shall have slopping roof and
the interior and exterior painting shall be in accordance with the specification. Padlock along with
duplicate keys shall be supplied for marshalling box. The degree of protection shall be IP-55 or
better.
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ii) The schematic diagram of the circuitry inside the marshalling box be prepared and fixed inside the
door under a prospone sheet.
iii) The marshalling box shall accommodate the following equipment:
a) Temperature indicators.
b) Space for accommodating Control & Protection equipment in future for the cooling fan (for
ONAF type cooling, may be provided in future).
c) Terminal blocks and gland plates for incoming and outgoing cables.
All the above equipments except c) shall be mounted on panels and back of panel wiring shall be
used for inter-connection. The temperature indicators shall be so mounted that the dials are not
more than 1600 mm from the ground level and the door (s) of the compartment(s) shall be
provided with glazed window of adequate size. The transformer shall be erected on a plinth
which shall be 2.5 feet above ground level.
iv) To prevent internal condensation, a metal clad heater with thermostat shall be provided. The
heater shall be controlled by a MCB of suitable rating mounted in the box. The ventilation
louvers, suitably padded with felt, shall also be provided. The louvers shall be provided with
suitable felt pads to prevent ingress of dust.
v) All incoming cables shall enter the kiosk from the bottom and the gland plate shall not be less than
450 mm from the base of the box. The gland plate and associated compartment shall be sealed
in suitable manner to prevent the ingress of moisture from the cable trench.
7.11 TAPCHANGER
7.11.1 OFF-LOAD TAP-CHANGERS
i) The 5 MVA & 8 MVA transformers shall be provided with Off-load Taps. 3.15 MVA transformer are
not required with off load tap changing facility.
ii) The Transformer with off-load tap changing gear shall have taps ranging from +5% to -15% in 9
equal steps of 2.5% each on HV winding for voltage variation
iii) The tap changing switch shall be located in a convenient position so that it can be operated from
ground level. The switch handle shall be provided with locking arrangement along with tap
position indication, thus enabling the switch to be locked in position
7.12 FITTINGS AND ACCESSORIES
The following fittings and accessories shall be provided on the transformers:
i) Conservator with isolating valves, oil filling hole with cap and drain valve. The conservator vessel
shall be filled with constant oil pressure diaphragm oil sealing system.
ii) Magnetic type oil level gauge (150 mm dia) with low oil level alarm contacts.
iii) Prismatic/ toughened glass oil level gauge.
iv) Silica gel breather with oil seal and connecting pipe complete with first fill of activated silica gel or
Alumina mounted at a level of 1300 mm above ground level.
v) A double float type Buchholz relay with isolating valve. Bleeding pipe and a testing cock, the test
cock shall be suitable for a flexible (pipe connection for checking its operation). A 5mm dia.
Copper pipe shall be connected from the relay test cock to a valve located at a suitable height
above ground level to facilitate sampling of gas with the transformer in service. Interconnection
between gas collection box and relay shall also be provided. The device shall be provided with
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two electrically independent ungrounded contacts, one for alarm on gas accumulation and the
other for tripping on sudden oil surge. These contacts shall be wired upto transformer
marshalling box. The relay shall be provided with shut off valve on the conservator side as well
as on the tank side.
vi) Pressure relief devices (including pressure relief valve) and necessary air equalizer connection
between this and the conservator with necessary alarm and trip contacts.
vii) Air release plugs in the top cover.
viii) Inspection cover, access holes with bolted covers for access to inner ends of bushing etc.
ix) Winding temperature (hot spot) indicating device for local mounting complete in all respects.
Winding temperature indicator shall have two set of contacts to operate at different settings :
a) To provide winding temperature high alarm
b) To provide temperature too high trip
x) Dial thermometer with pocket for oil temperature indicator with one set of alarm and one set of trip
contacts and maximum reading pointer.
xi) Lifting eyes or lugs for the top cover, core and coils and for the complete transformer.
xii) Jacking pads
xiii) Haulage lugs.
xiv) Protected type mercury / alcohol in glass thermometer and a pocket to house the same.
xv) Top and bottom filter valves on diagonally opposite ends with pad locking arrangement on both
valves.
xvi) Top and bottom sampling valves.
xvii) Drain valve with pad locking arrangement
xviii) Rating and connection diagram plate.
xix ) Two numbers tank earthing terminals with associated nuts and bolts for connections to
Employer’s grounding strip. Bi-directional flagged rollers with locking and bolting device.
xx) Marshalling Box (MB)
xxi) Shut off valve on both sides of flexible pipe connections between radiator bank and transformer
tank.
xxii) Cooling Accessories :
a) Requisite number of radiators provided with :-
- One shut off valve on top
- One shut off valve at bottom
- Air release device on top –
Drain and sampling device at bottom
- Lifting lugs.
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b) Air release device and oil drain plug on oil pipe connectors:
xxiii) Terminal marking plates for Current Transformer and Main Transformer
xxiv) Off- Load Tap Changer
xxv) Oil Preservation Equipment
xxvi) Oil Temperature indicator
xxvii) Transformer shall be supplied with all control cable,WTI & OTI, sensing cable, glands, lugs etc
(complete control).
Note :
1. The fittings listed above are indicative and any other fittings which are generally required for
satisfactory operation of the transformer are deemed to be included in the quoted price of the
transformer.
2. The contacts of various devices required for alarm and trip shall be potential free and shall be
adequately rated for continuous, making and breaking current duties as specified.
7.13 CONTROL CONNECTIONS AND INSTRUMENT AND WIRING TERMINAL BOARD AND FUSES
i) Normally no fuses shall be used anywhere instead of fuses MCB‟s (both in AC & DC circuits)
shall be used. Only in cases where a MCB cannot replace a fuse due to system requirements, a
HRC fuse can be accepted.
ii) All wiring connections, terminal boards, fuses MCB‟s and links shall be suitable for tropical
atmosphere. Any wiring liable to be in contact with oil shall have oil resisting insulation and the
bare ends of stranded wire shall be sweated together to prevent seepage of oil along the wire.
iii) Panel connections shall be neatly and squarely fixed to the panel. All instruments and panel
wiring shall be run in PVC or non-rusting metal cleats of the compression type. All wiring to a
panel shall be taken from suitable terminal boards.
iv) Where conduits are used, the runs shall be laid with suitable falls, and the lowest parts of the
run shall be external to the boxes. All conduit runs shall be adequately drained and ventilated.
Conduits shall not be run at or below ground level.
v) When 400 volt connections are taken through junction boxes or marshalling boxes, they shall be
adequately screened and 400 volts Danger Notice must be affixed to the outside of the junction
boxes or marshalling box. Proper colour code for Red, Yellow, Blue wires shall be followed.
vi) All box wiring shall be in accordance with relevant ISS. All wiring shall be of stranded copper (48
strands ) of 1100 Volt grade and size not less than 2.5 sq.mm
vii) All wires on panels and all multi-core cables shall have ferrules, for easy identifications, which
bear the same number at both ends, as indicated in the relevant drawing.
viii) At those points of interconnection between the wiring carried out by separate contractors, where
a change of number can not be avoided double ferrules shall be provided on each wire. The
change of numbering shall be shown on the appropriate diagram of the equipment.
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ix) The same ferrule number shall not be used on wires in different circuits on the same panels.
x) Ferrules shall be of white insulating material and shall be provided with glossy finish to prevent
the adhesion of dirt. They shall be clearly and durably marked in black and shall not be affected
by dampness or oil.
xi) Stranded wires shall be terminated with tinned Ross Courtney terminals, claw washers or crimped
tubular lugs. Separate washers shall be suited to the size of the wire terminated. Wiring shall, in
general, be accommodated on the sides of the box and the wires for each circuit shall be
separately grouped. Back of panel wiring shall be arranged so that access to the connecting
items of relays and other apparatus is not impeded.
xii) All circuits in which the voltage exceeds 125 volts, shall be kept physically separated from the
remaining wiring. The function of each circuit shall be marked on the associated terminal
boards.
xiii) Where apparatus is mounted on panels, all metal cases shall be separately earthed by means of
stranded (48 No.) copper wire of strip having a cross section of not less than 2 sq. mm where
strip is used, the joints shall be sweated. The copper wire shall have green coloured insulation
for earth connections.
xiv) All wiring diagram for control and relay panel shall preferably be drawn as viewed from the back
and shall show the terminal boards arranged as in services.
xv) Terminal block rows should be spaced adequately not less than 100 mm apart to permit
convenient access to external cables and terminations.
xvi) Terminal blocks shall be placed with respect to the cable gland ( at a minimum distance of 200
mm) as to permit satisfactory arrangement of multicore cable tails .
xvii) Terminal blocks shall have pairs of terminals for incoming and outgoing wires. Insulating barriers
shall be provided between adjacent connections. The height of the barriers and the spacing
between terminals shall be such as to give adequate protection while allowing easy access to
terminals. The terminals shall be adequately protected with insulating dust proof covers. No live
metal shall be exposed at the back of the terminal boards. CT terminals shall have shorting
facilities. The terminals for CTs should have provision to insert banana plugs and with isolating
links.
xviii) All interconnecting wiring, as per the final approved scheme between accessories of transformer
and marshalling box is included in the scope of this specification and shall be done by the
Transformer supplier.
xix) The schematic diagram shall be drawn and fixed under a transparent prospane sheet on the inner
side of the marshalling box cover.
xx) To avoid condensation in the Marshalling Box, a space heater shall be provided with an MCB and
thermostat.
xxi) Suitable MV, CFL light shall be provided in the Marshalling Box for lightning purpose.
7.14 RADIO INTERFERENCE AND NOISE LEVEL
Transformers shall be designed with particular care to suppress at least the third and fifth harmonic
voltages so as to minimize interference with communication circuits. Transformer noise level when
energized at normal voltage and frequency shall be as per NEMA stipulations.
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8 INSPECTION AND TESTING
(i) The Contractor shall carry out a comprehensive inspection and testing programme during
manufacture of the transformer. This is, however, not intended to form a comprehensive
programme as it is contractor‟s responsibility to draw up and carry out such a programme duly
approved by the Employer.
(ii) Transformer of each rating will be as per pre-type tested design.
(iii) The pre-shipment checks shall also be carried out by the contractor.
(iv) The requirements on site tests are as listed in the specifications.
(v) Certified test report and oscillograms shall be furnished to the Employer Consultants for
evaluation as per the schedule of distribution of documents. The Contractor shall also evaluate
the test results and rectify the defects in the equipment based on his and the Employers
evaluations of the tests without any extra charges to the Employer. Manufacturer’s Test
Certificates in respect of all associated auxiliary and ancillary equipment shall be furnished.
(vi) The bidder shall state in his proposal the testing facilities available at his works. In case full
testing facilities are not available, the bidder shall state the method proposed to be adopted so
as to ascertain the transformer characteristics corresponding to full capacity.
8.1 INSPECTION
Transformers not manufactured as per Type- Tested design shall be rejected.
i) Tank and Conservator
a) Inspection of major weld.
b) Crack detection of major strength weld seams by dye penetration test.
c) Check correct dimensions between wheels, demonstrate turning of wheels, through 900
and further dimensional check.
d) Leakage test of the conservator.
ii) Core
a) Sample testing of core materials for checking specific loss, properties, magnetization
characteristics and thickness.
b) Check on the quality of varnish if used on the stampings.
c) Check on the amount of burrs.
d) Visual and dimensional check during assembly stage.
e) Check on completed core for measurement of iron loss, determination of maximum flux
density,
f) Visual and dimensional checks for straightness and roundness of core, thickness of limbs and
suitability of clamps.
g) High voltage DC test (2 KV for one minute) between core and clamps.
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iii) Insulating Material
a) Sample check for physical properties of materials.
b) Check for dielectric strength
c) Check for the reaction of hot oil on insulating materials.
iv) Winding
a) Sample check on winding conductor for mechanical and electrical conductivity.
b) Visual and dimensional checks on conductor for scratches, dent mark etc.
c) Sample check on insulating paper for PH value, electric strength.
d) Check for the bonding of the insulating paper with conductor.
e) Check and ensure that physical condition of all materials taken for windings is satisfactory
and free of dust.
f) Check for absence of short circuit between parallel strands.
v) Checks Before Drying Process
a) Check condition of insulation on the conductor and between the windings.
b) Check insulation distance between high voltage connections, between high voltage
connection cables and earth and other live parts.
c) Check insulating distances between low voltage connections and earth and other parts.
d) Insulating test for core earthing.
vi) Check During Drying Process
a) Measurement and recording of temperature and drying time during vacuum treatment.
b) Check for completeness of drying
vii) Assembled Transformer
a) Check completed transformer against approved outline drawing, provision for all fittings,
finish level etc.
b) Jacking test on the assembled Transformer.
viii) Oil All standard tests in accordance with IS: 335 shall be carried out on Transformer oil sample
before filling in the transformer.
ix) Test Report for bought out items The contractor shall submit the test reports for all bought out /
sub contracted items for approval.
a) Buchholz relay
b) Sudden pressure rise relay on Main Tank
c) Winding temperature indicators (for TX capacity 5 MVA )
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d) Oil temperature indicators
e) Bushings
f) Bushing current transformers in neutral (If Provided)
g) Marshalling box
h) Off Load Tap changer
i) Any other item required to complete the works.
j) Porcelain, bushings, bushing current transformers, wherever provided, winding coolers, control
devices, insulating oil and other associated equipment shall be tested by the contractor in
accordance with relevant IS . If such requirement is purchased by the contractor on a sub-
contract, he shall have them tested to comply with these requirements.
8.2 FACTORY TESTS
i) All standards routine tests in accordance IS: 2026 with dielectric tests corresponding as per latest
amendments to IS: 2026 shall be carried out.
ii) All auxiliary equipment shall be tested as per the relevant IS. Test certificates shall be submitted
for bought out items.
iii) High voltage withstand test shall be performed on auxiliary equipment and wiring after complete
assembly.
iv) Following additional routine tests shall also be carried out on each transformer:
a) Magnetic Circuit Test Each core shall be tested for 1 minute at 2000 Volt DC
b) Oil leakage test on transformer
8.2.1 Type Test
8.2.1.1 The measurements and tests should be carried out in accordance with the standard specified
in each case as indicated in the following table if the same tests were not conducted earlier at
CPRI or any NABL accredited Laboratory on the transformers of the offered design without any
cost implication and employer.
Table 6: Transformer type tests

Type Test Standard
Temperature Rise Test IEC 76/IS

2026/IS660
0
Impulse Voltage Withstand Test, including Full Waves IEC 76/IS 2026
and
Chopped Waves as listed below
Noise Level Measurement IEC 551
Short Circuit Test IEC 76 / IS 2026
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In accordance with IEC 76-3 the following sequence of impulses should have been/ should be
applied;
• One full wave at 50% BIL;

• One chopped wave at 50% BIL
• Two chopped waves at 100% BIL and
• Two full waves at 100% BIL.
8.2.1.2 If the type test report(s) submitted by the bidder do not fulfil the criteria, as stipulated in
this technical specification/ Bidder’s offer, the relevant type test(s) has/ have to be conducted
by the Bidder at his own cost in CPRI/ NABL accredited laboratory in the presence of
employers representative(s) without any financial liability to employer in the event of order
placed on him.
8.2.1.3 The offeres transformer must be manufactured as per type tested design. A copy of type
test certificate must be submitted by manufacturer to Engineer/Employer. Transformers
offered without type tested however design shall not be accepted. In case manufacturer
agrees for type testing of transformers, testing shall be conducted on manufacturer’s cost. No
claim shall be acceptable towards type testing. The transformers shall be accepted only on
acceptane of type testing results by employer.
8.2.1.4 The supplier shall furnish calculations in accordance with IS: 2026 to demonstrate the
Thermal ability of the transformers to withstand Short Circuit forces.
8.2.2 STAGE INSPECTION
The supplier shall offer the core, windings and tank of each transformer for inspection by the
Employers representative(s). During stage Inspection, all the measurements like diameter,
window height, leg centre, stack width, stack thickness, thickness of laminations etc. for core
assembly, conductor size, Insulation thickness, I.D., O.D, winding height, major and minor
insulations for both H.V and L.V windings, length, breadth, height and thickness of plates of
Transformer tank, the quality of fittings and accessories will be taken / determined. The
supplier can offer for final inspection of the transformers subject to clearance of the stage
Inspection report by the Employer.
8.2.3 Routine Tests
Transformer routine tests shall include tests stated in latest issue of IS: 2026 (Part –1). These
tests shall also include but shall not be limited to the following :
(i) Measurement of winding DC resistance.
(ii) Voltage ratio on each tapping and check of voltage vector relationship.
(iii) Impedance voltage at all tappings.
(iv) Magnetic circuit test as per relevant ISS or CBIP manual or latest standard being followed.
(v) Measurement of Load losses at normal tap and extreme taps.
(vi) No load losses and no load current at rated voltage and rated frequency, also at 25% to
120 % of rated voltage in steps.
(vii) Absorption index i.e insulation resistance for 15 seconds and 60 seconds ( R 60/ R 15 )
and polarization index i.e Insulation Resistance for 10 minutes and one minute (R 10 mt / R 1
mt).
(viii) Induced over voltage withstand test.
(ix) Separate source voltage withstand test.
(x) Tan delta measurement and capacitance of each winding to earth (with all other windings earthed)
& between all windings connected together to earth.
(xi) Measurement of zero sequence impedance
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(xii) Tests on off- load tap changer (fully assembled on transformer) as per IEC: 214/ 1976 and BS:
4571/ 1970.
(xiii) Auxiliary circuit tests
(xiv) Oil BDV tests
(xv) Measurement of neutral unbalance current which shall not exceed 2% of the full rated current of
the transformer.
(xvi) Magnetic balance test
(xvii) Leakage test.
Six (6) set of certified test reports and oscillographs shall be submitted for evaluation prior to
dispatch of the equipment. The contractor shall also evaluate the test results and shall correct
any defect indicated by his and Employers evaluation of the tests without charge to the
Employer.
8.4 TANK TESTS
a) Oil leakage Test :
The tank and oil filled compartments shall be tested for oil tightness completely filled with air or oil of
viscosity not greater than that of insulating oil conforming to IS : 335 at the ambient temperature and
applying a pressure equal to the normal pressure plus 35 KN/ m2 measured at the base of the tank.
The pressure shall be maintained for a period of not less than 12 hours of oil and one hour for air and
during that time no leak shall occur.
b) Pressure Test
Where required by the Employer, one transformer tank of each size together with its radiator,
conservator vessel and other fittings shall be subjected to a pressure corresponding to twice the normal
head of oil or to the normal pressure plus 35 KN / m2 whichever is lower, measured at the base of the
tank and maintained for one hour.
c) Vacuum Test
One transformer tank of each size shall be subjected to the vacuum pressure of 60 mm of mercury. The
tanks designed for full vacuum shall be tested at an internal pressure of 3.33 KN/m2 (25 mm of
mercury) for one hour. The permanent deflection of flat plates after the vacuum has been released shall
not exceed the value specified in C.B.I.P. Manual on Transformers (Revised 1999) without affecting the
performance of the transformer.
8.5 PRE-SHIPMENT CHECK AT MANUFACTURERS WORKS
i) Check for proper packing and preservation of accessories like radiators, bushings, explosions vent,
dehydrating breather, rollers, buchholz relay, control cubicle connecting pipes and conservator etc.
ii) Check for proper provision of bracing to arrest the movement of core and winding assembly inside the
tank.
iii) Gas tightness test to conform tightness.
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8.6 INSPECTION AND TESTING AT SITE
On receipt of transformer at site, shall be performed detailed inspection covering areas right from the
receipt of material up to commissioning stage. An indicative program of inspection as envisaged by the
Engineer is given below.
8.6.1 Receipt and Storage Checks
i) Check and record conditions of each package visible parts of the transformers etc for any
damage.
ii) Check and record the gas pressure in the transformer tank as well as in the gas cylinder.
iii) Visual check of core and coils before filling up with oil and also check condition of core and
winding in general.
8.6.2 Installation Checks
i) Inspection and performance testing of accessories like tap changers etc.
ii) Check choking of the tubes of radiators
iii) Test on oil samples taken from main tank top and bottom and cooling system. Samples should
be taken only after the oil has been allowed to settle for 24 hours.
iv) Check the whole assembly for tightness, general appearance etc.
v) Oil leakage tests.
8.6.3 Pre-Commissioning Tests
After the transformer is installed, the following pre-commissioning tests and checks shall be done before
putting the transformer in service.
i) Dry out test
ii) Megger Test
iii) DC Resistance measurement of windings
iv) Ratio test on all taps
v) Phase relationship test ( Vector grouping test )
vi) Buchholz relay alarm & surge operation test
vii) Low oil level ( in conservator ) alarm
viii) Temperature Indicators
ix) Marshalling kiosk
x) Protective relays
xi) Magnetising current
xii) Tests on OLTC
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8.6.4 The following additional checks shall be made :
i) All oil valves are incorrect position closed or opened as required
ii) All air pocket are cleared.
iii) Thermometer pockets are filled with oil
iv) Oil is at correct level in the bushing, conservator, diverter switch & tank etc.
v) Earthing connections are made.
vi) Colour of Silica gel is blue.
vii) Bushing arcing horn is set correctly and gap distance is recorded.
Viii) C T polarity and ratio is correct.
8.7 PERFORMANCE
The performance of the transformer shall be measured on the following aspects.
i) The transformer shall be capable of being operated without danger on any tapping at the
rated KVA with voltage variations and ± 10% corresponding to the voltage of the tapping
ii) Radio interference and Noise Level
ii) The transformer shall be designed with particular attention to the suppression of third and
fifth harmonics so as to minimize interference with communication circuits.
8.8 FAULT CONDITIONS
a) The transformer shall be capable of withstanding for two(2) seconds without damages any
external short circuit to earth
b) Transformer shall be capable of withstanding thermal and mechanical stresses conveyed by

symmetrical or asymmetrical faults on any winding. This shall be demonstrated through
calculation as per IS : 2026.
c) Transformer shall accept, without injurious heating, combined voltage and frequency fluctuation
which produce the 125% over fluxing condition for one minute and 140% for 5 seconds.
8.9 WITNESSING OF TESTS AND EXCESSIVE LOSSES
ii) The Employer reserves the right to reject the Transformer if losses exceed the maximum specified as per
Clause No 2. SPECIFIC TECHNICAL REQUIREMENTS (STANDARD CONDITIONS), item-35 of this
specification or if temperature rise of oil and winding exceed the values specified at item -26 of the
above clause.
9 LIQUIDATED DAMAGES FOR EXCESSIVE LOSSES
There is no positive tolerance on the guaranteed losses offered by the bidder. However, the
transformer(s) shall be rejected out rightly, if any of the losses i.e. no load loss or load loss or both
exceed (s) the guaranteed maximum permissible loss figures quoted by the bidder in the Technical Data
Schedule with the bid.
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10.1 SPARE PARTS
In case the manufacturer goes out of production of spare parts, then he shall make available the
drawings of spare parts and specification of materials at no extra cost to the Employer to fabricate or
procure spare parts from other sources.
Mandatory Spare Parts
The suppliers shall provide the following mandatory spare s for each of Transformer supplied
1. H.V. & L.V. Bushing & Studs –Each 2 Nos
2. Bimetallic connector for H.V & L.V. Bushings – Each 2 sets
10.2 INSTRUCTION MANUAL
Eight sets of the instruction manuals shall be supplied at least four (4) weeks before the actual dispatch
of equipment. The manuals shall be in bound volumes and shall contain all the drawings and
information required for erection, operation and maintenance of the transformer. The manuals shall
include amongst other, the following particular:
a) Marked erection prints identifying the components, parts of the transformer as dispatched with
assembly drawings.
b) Detailed dimensions, assembly and description of all auxiliaries.
c) Detailed views of the core and winding assembly, winding connections and tapings tap changer
construction etc. These drawings are required for carrying out overhauling operation at site.
d) Salient technical particulars of the transformer.
e) Copies of all final approved drawings.
f) Detailed O&M instructions with periodical check lists and Performa etc.
10.3 COMPLETENESS OF EQUIPMENT
All fittings and accessories, which may not be specifically mentioned in the specification but which are
necessary for the satisfactory operation of the transformer, shall be deemed to be included in the
specification and shall be furnished by the supplier without extra charges. The equipment shall be
complete in all details whether such details are mentioned in the specification or not, without any
financial liability to the Employer under any circumstances.
11.0 TOOLS AND TACKLES
All the necessary tools and tackles required for normal operation & maintenance of the transformers shall
be supplied by the Contractor
12.0 COMMISSIONING
The equipments shall be commissioned as per CBIP manual, IS: 10028 and manufacturer‟s
recommendations. All the related drawings and manuals shall be pre-requisite for release of final
payment.
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VOLUME -II : Section-II(B) 1
DISTRIBUTION TRANSFORMER
PART 1: GENERAL
1. SCOPE
1.1 The specification covers the design, engineering, manufacture, stage inspection, testing, pre-delivery
inspection, supply, delivery, loading, unloading and performance requirements of 11/0.433 KV non-sealed type
aluminum wound BEE specified 3 Star Distribution Transformers for outdoor. The transformers shall be double
wound, three phase, CRGO M3 Grade (0.23mm) or better, oil immersed with ONAN cooling with Oil filled up to
maximum permissible level. The ratings required under this specification are 25 KVA, 63 KVA & 100 KVA with
Aluminum windings.
1.2 The equipment offered should have been successfully type tested within five years from date of tender and
the designs should have been in satisfactory operation for a period not less than one years as on the date of Bid
opening. Compliance shall be demonstrated (i) authenticated copies of the type test reports and (ii) performance
certificates from the users, specifically from Central Govt. / State Govt. or their undertakings.
2. CODES & STANDARDS
2.1 Except where modified by this specification, the transformers shall be designed, manufactured and tested in
accordance with the latest editions of the following standards.
IEC/ISO Indian Standard Subject
IEC 71 Insulation Coordination

IEC 76 IS 2026 Power Transformers.
IS 1180 Outdoor Single phase Distribution Transformers up
to 500 KVA, 11/ 0.433 KV, Non- Sealed Type
IEC 137 IS 2099 Bushing for Alternating Voltages above 1000V
IEC 156 Method of determining Electri Strength of

Insulating Oils.
IEC 296 IS 335 Specifications for Unused Mineral Insulating Oils

for Transformers and Switchgear.
IS 6792 Method of determination of electric strength of

insulating oils.
IEC 354 IS 6600 Loading Guide for oil immersed Transformers

IEC 437 Radio Influence Voltage Measurement.
IEC 551 Determination of Transformer and Reactor Sound
Levels
IEC 616 Terminal and Tapping markings for power
transformers.
IEC 722 Guide to the Lightning and Switching impulse
testing of Power Transformers and Reactors
ISO 1460/BS 729 Galvanizing
This list is not to be considered exhaustive and reference to a particular standard or recommendation in this
specification does not relieve the Supplier of the necessity of providing the goods complying with other
relevant standards or recommendations.
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3. SERVICE CONDITIONS
The service conditions shall be as follows: (To be confirmed by PIA as per locality of project)
Plane Hilly area

area
maximum altitude above sea level 1000m 5000m
maximum daily average ambient air temperature 40° C 40° C
maximum temperature attainable by an object exposed to the 60 ° C 60 ° C
sun
maximum yearly weighted average ambient temperature 32° C 32° C
maximum relative humidity 100% 100%
average number of thunderstorm days per annum 70 70
(isokeraunic level)
average annual rainfall 1500 mm 1500 mm
maximum wind pressure 260Kg/m2 260Kg/m2
Environmentally, the region where the equipment will be installed includes coastal areas, subject to high relative
humidity, which can give rise to condensation. Onshore winds will frequently be salt laden. On occasions, the
combination of salt and condensation may create pollution conditions for outdoor insulators.
Therefore, outdoor material and equipment shall be designed and protected for use in exposed, heavily
polluted, salty, corrosive, tropical and humid coastal atmosphere.
4. SYSTEM CONDITIONS:
The equipment shall be suitable for installation in supply systems of the following characteristics.
♦ Frequency 50 Hz ± 5%
♦ Nominal system voltages 11 KV System 11 KV
LV System 433/250 V
♦ Maximum system voltages 11 KV System 12 KV

LV System 476 V
♦ Minimum LV voltage (NEC) 392 V
♦ Nominal short circuit apparent power of the 11 KV System 500 MVA (IS:2026)
system
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♦ Insulation levels :
11 KV System 95 KV peak (As Per
1.2/50 µ sec impulse withstand
BEE, Clause No.10 )
♦ Power frequency one minute withstand 11 KV System 28 KV (rms)
(wet and dry)
LV System 3 KV (rms)
♦ Neutral earthing arrangements : LV System Solidly earthed
PART 2 : TECHNICAL
SPECIFIC TECHNICAL REQUIREMENTS
1 Rated KVA (ONAN rating) 25KVA. 63 KVA, 100 KVA 11/0.433 KV
2 No. of phases 3
6 Type of mounting On Channels.
7 Rated voltage
a) High voltage winding 11 KV
b) Low voltage winding 0.433 KV
8 Highest continuous system voltage
a) Maximum system voltage ratio (HV / LV ) 12 KV / 0.476 KV
b) Rated voltage ratio (HV / LV ) 11 KV / 0.433 KV
10 Type of cooling ONAN ( Oil natural / Air natural )
11 KVA Rating corresponding to ONAN 100%
cooling system
HV: Delta
LV: Star
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14 System earthing Neutral of LV side to be solidly earthed.
15 Percentage impedance voltage on normal: % Impedance + Tolerance %
tap and KVA base at 750 C corresponding to 4.5 + 10%
HV/ LV rating and applicable tolerances (No negative tolerance will be allowed)
16 Intended regular cyclic overloading of As per IEC –76-1, Clause 4.2
windings
b) Anticipated continuous loading of windings 110 % of rated current
(HV / LV)
18 a) Type of tap changer NA
b) Range of taping No Tap
20 Over Voltage operating capability and 112.5 % of rated voltage ( continuous )
duration
21 Maximum Flux Density in any part of the 1.5 Tesla
core and yoke at rated KVA, rated voltage
i.e 11 KV / 0.433 KV and system frequency
of 50 HZ
22 Insulation levels for windings :-
a) 1.2 / 50 microsecond wave shape Impulse HV: 95 LV: N.A.
withstand (KVP)
b) Power frequency voltage withstand (KVrms) HV: 28 LV: 03
24 Withstand time for three phase short circuit 2 Seconds
25 Noise level at rated voltage and frequency As per NEMA Publication No. TR-1.
26 Permissible Temperature Rise over ambient
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temperature of 500C
a) Of top oil measured by thermometer. 350C
b) Of winding measured by resistance. 400 C
27 Minimum HV clearances in air (mm) :-
a) Phase to Phase 280
b) Phase to ground 140
28 Bushings & Terminals
a) HV winding line end 12 KV oil filled porcelain communicating

type of bushings ( Antifog type )
b) LV winding 0.4 KV porcelain type of bushing

(Antifog type)
a) Lightning Impulse withstand (KVP) 95 Not applicable
b) 1 Minute Power Frequency withstand 28 3
voltage (KV –rms )
c) Creepage distance (mm) (minimum) 25 mm/ KV
30 Material of HV & LV Conductor EC grade Aluminum
31 Maximum current density for HV and LV
winding for rated current 1.6 Amp/ mm2.
32 Polarisation index i.e. ratio of megger Shall be greater than or equal to 1.5, but
values at 600 sec. to 60 sec for HV to earth, less than or equal to ‘5’.
L.V to earth and HV to LV.
33. Core Assembly Boltless type
34. Losses:- The losses shall not exceed the value given below
KVA No-load Load

Rating losses losses at
(Fixed 75°C
loss) Watts
Watts
25 100 685
63 180 1235
100 260 1760
B
6. TYPE OF TRANSFORMER
6.1 The transformers shall be of core type construction, double wound, three phase, oil immersed, 11/0.433KV, 50
Hz with natural oil and air cooling (ONAN) to be used as step down transformers for outdoor use. The design of the
tank, fittings, bushings, etc shall be such that it will not be necessary to keep the transformer energized to prevent
deterioration as the transformers may be held in reserve, outdoors, for many years.
7. PERFORMANCE , CAPACITY AND SHORT CIRCUIT RATINGS
7.1 The following ratings are covered under this specification
• 25 KVA,11/0.433 KV, Aluminum wound

7.2 The transformer shall be capable of supplying a continuous load equal to its KVA rating, under the following
conditions :
Continuous steady load;

Design at maximum ambient air temperature of 50˚C;
40˚C average winding temperature rise and 35˚C top oil temperature rise for conventional breathing
transformers.
7.3 The transformer may be overloaded during emergency up to 150% of its continuous rating in accordance with
IEC Publication 354 or IS: 6600. Bushings. and other current-carrying parts shall also be designed for this
condition.
7.4 The transformer shall be capable of withstanding for two seconds without damage to any external short
circuit, with the short circuit MVA available at the terminals of either winding with rated voltage on the other
winding. If short circuit tests have been carried out on the particular design of transformer offered, the test results
shall be supplied with the bid.
7.5 The thermal ability to withstand short circuit shall be demonstrated by calculation.
7.6 The transformer shall be capable of withstanding the thermal and dynamic effects of short circuits, as
specified in IEC 76-5 or IS: 2026: Ability to withstand short circuits.
7.7 The maximum flux density in any part of the core and yoke at rated KVA, Voltage and frequency shall not
exceed 1.5 Tesla.
8. VOLTAGE RATIO & TAPPING RANGE
8.1 The transformers shall have the following ratio :-

 the nominal voltage ratio shall be 11,000/ 433 V for 25 KVA, 63 KVA, 100 KVA 11/0.4KV transformers;
 Tolerance on the voltage ratio shall be ± 0.5%.
 transformers up to 100 KVA, 11/0.4 KV no tap changer is required.
8.2 The bidder shall state in the technical schedule, the percentage regulation at full load, power factor 1.0 and at
full load, power factor 0.85 lagging.
Transformers shall be suitable for parallel operation with each other.
B
9. PERCENTAGE IMPEDANCE
9.1 The Percentage of Impedance at 75˚C shall be 4.5 % for 25 KVA,63 KVA & 100 KVA transformers. No negative
tolerance on percentage Impedance is allowed.
10 LOSSES
The load losses shall not exceed the values given below:-
KVA Rating No-load losses (Fixed Load losses at 75°C

loss) Watts Watts
25 100 685
63 180 1235
100 260 1760
10.1 The above losses are maximum allowable and there should not be any positive tolerance. Transformer having
losses more than above values shall be rejected.
10.2 The offered transformer(s) should have been type-tested designed at CPRI/ NABL Accredited laboratory. The
bid shall be accompanied with type-test reports (short circuit test and Impulse test) conducted at Central Power
Research Institute / NABL Accredited laboratory for the offered transformers within five years from date of tender.
The short circuit test report(s) must contain the measured no load loss and load loss, determined by CPRI/ NABL
Accredited laboratory.
In case of any doubts, Employer reserves the right to verify the original type test reports of CPRI/ NABL Accredited
laboratory or ask the supplier to conduct the type tests at CPRI/ NABL Accredited laboratory at his (supplier’s) cost
for re-confirmation of the test results particularly no load losses, load losses and percentage impedance.
10.3 If the bidder quotes lower values of losses than the CPRI’s measured losses, he has to prove the same by
conducting the Impulse & short Circuit tests at CPRI/ NABL Accredited laboratory along with measurement of no
load losses and load losses at his own cost in presence of Contractor/manufacturer authorized representative
without any financial liability to Employer
10.4 However, if the loss figures will exceed the stipulated values as per specification, the transformer(s) shall be
out rightly rejected.
11. VECTOR GROUP
11.1 The transformers shall be connected delta-star, in accordance with vector group reference Dyn11 of IEC – 76/
IS-2026
11.2 The LV neutral shall be brought out to a terminal bushing, which shall be identical to the phase bushings in all
respects.
12. LOSSES
12.1 Transformers would be out rightly rejected if losses exceed the values indicated at clause-10 above.
13. FLUX DENSITY
The flux density at rated voltage & rated frequency shall not exceed. 1.5 Tesla. The transformer must be capable
of operating at 10% over voltage and at frequency of 48.5 Hz without saturation.
14. INSULATION LEVELS
The insulation levels as defined in IEC 76-C/ IS: 2026 Insulation levels and dielectric test shall apply as per Table 2:
B
Table 2: Transformer insulation level
HV LV Winding
Winding
Basic Impulse voltage 95 Not
Level (Kvp) (1.2/50 Applicable
micro. sec.
Wave )
Power Frequency 28 3
voltage withstand level,
Wet and Dry
(KV)
Bushings and terminals shall be adequate for the winding insulation tests and shall flash over externally before
puncture or internal failure can occur.
15. NOISE LEVEL

The average noise level of the transformers shall not exceed 51 db. The measurement shall be carried out in
accordance with IEC 551 at a distance of 300mm from the envelope of the transformer.
16. RADIO INFLUENCE VOLTAGE

The maximum radio influence voltage shall be 250 µ V, measured as specified in IEC 437.
17 CORE AND WINDINGS
17.1 Core
17.1.1 Stage level inspection for core construction shall be carried out by the owner.
17.1.2 Each lamination shall be insulated such that it will not deteriorate due to mechanical pressure and the action
of hot transformer oil.
17.1.3 The core shall be constructed from high grade, non-ageing, Cold Rolled Grain Oriented (CRGO) silicon steel
of M3 Grade (0.23mm) or HIB grade laminations only. No other core materials shall be entertained. Bidders are
requested to note that only PRIME CORE M3 Grade (0.23mm) materials HIB grade is to be used. In no case, second
grade core material is to be used. The employer at his discretion, may select samples from the core laminations and
get the same tested in CPRI/ NABL Accredited laboratory to prove the quality of the core material.
17.1.4 For the above purpose, the supplier shall have to offer every batch of core laminations received from his
Sub-Vendor along with Invoice of the sub-vendor, Mills test certificate, packing list, Bill of landing, Bill of entry
certificate to customs etc. towards proof of prime core materials for verification by the Employer’s representative
without any cost to the Employer. Besides, the contractor must mention in his bid about the type of CRGO /
Amorphous laminations to be utilized for the offered transformers along with a copy of the specific core loss curve at
different flux densities.
17.1.5 Core materials should be directly procured either from the manufacturer or through their accredited
B
The core and winding shall be capable of withstanding shocks during transport, installation and service. Provision
shall be made to prevent movement of the core and windings relative to the tank during these conditions and also
during short circuits.
17.1.6 The design shall avoid the presence of pockets which would prevent the complete emptying of the tank
through the drain valve. The core material offered in the tender to be checked for its correctness before core coil
assembly. For this, the tendered must ask for core and coil inspection before its tanking.
17.1.7 The laminations shall be free of all burrs and sharp projections. Each sheet shall have an insulting coating
resistant to the action of hot oil.
17.1.8 The insulation structure for the core to bolts and core to clamp plates shall be such as to withstand 2000 V
DC voltage for one minute.
17.1.9 The completed core and coil shall be so assembled that the axis and the plane of the outer surface of the
core assemble shall not deviate from the vertical plane by more than 25mm.
17.1.10 all steel sections used for supporting the core shall be thoroughly shot or sand blasted, after cutting,
17.1.11 the finally assembled core with all the clamping structures shall be free from deformation and shall not
vibrate during operation.
17.1.12 the core clamping structure shall be designed to minimize eddy current loss.
17.1.13 the framework and clamping arrangements shall be securely earthed.
17.1.14 the core shall be carefully assembled and rigidly clamped to ensure adequate mechanical strength.
17.1.16T the design of magnetic circuit shall be such as to avoid static discharges, development of short circuit
paths within itself or to the earth clamping structure and production of flux component at right angle to the plane of
the lamination, which may cause local heating. The supporting framework of the cores shall be so designed as to
avoid the presence of pockets, which would prevent complete emptying of the tank through the drain valve or cause
trapping of air during filling.
17.1.17 the construction is to be of boltless core type. The core shall be provided with lugs suitable for lifting the
complete core and coil assembly. The core and coil assembly shall be so fixed in the tank that shifting will not occur
during transport or short circuits.
17.2.1 All internal metal parts of the transformer, with the exception of individual laminations and their
individual clamping plates shall be earthed.

c) By a connection to the structure on the same side of the core as the main earth connection to the tank.
17.2.3 The magnetic circuit shall be connected to the clamping structure at one point only and this shall be
brought out of the top cover of the transformer tank through a suitably rated insulator. A disconnecting link shall be
provided on transformer tank to facilitate disconnections from ground for IR measurement purpose.
B
17.3 Windings
during service. Adjustable devices shall be provided for taking up possible shrinkage in service.
17.3.2 All low voltage windings for use in the circular coil concentric winding shall be wound on a performed
insulating cylinder for mechanical protection of the winding in handling and placing around the core.
17.3.4 The winding insulation shall be free from insulating compounds which are liable to soften, ooze out, shrink
or collapse. It shall be non catalytic and chemically inert in hot transformer oil during normal service.
17.3.5 The stacks of windings are to receive adequate shrinkage treatment.
17.3.6 The windings and connections are to be braced to withstand shocks during transport, switching, short
circuit or other transient conditions.
17.3.7 Permanent current carrying joints in the windings and leads shall be welded or brazed. Clamping bolts for
current carrying parts inside oil shall be made of oil resistant material which shall not be affected by acidity in the oil
steel bolts, if used, shall be suitably treated.
17.3.9 The windings shall be uniformly insulated and the L.V neutral points shall be insulated for full voltage.
17.3.10 The completed core and coil assemble shall be dried in vacuum at not more than 0.5mm of mercury
absolute pressure and shall be immediately impregnated with oil after the drying process to ensure the elimination
of air and moisture within the insulation. Vacuum may be applied in either vacuum over or in the transformer tank.
17.3.11 The winding shall be so designed that all coil assembles of identical voltage ratings shall be
interchangeable and field repairs to the winding can be made readily without special equipment. The coils shall have
high dielectric strength.
17.3.12 Coils shall be made of continuous smooth high grade electrolytic copper or aluminium conductor, shaped
and braced to provide for expansion and contraction due to temperature changes.
17.3.13 Adequate barriers shall be provided between coils and core and between high and low voltage coil. End
17.3.14 The insulation of winding shall be designed to withstand voltage stress arising from surge in transmission
lines due to atmospheric or transient conditions caused by switching etc
17.3.15 Tapping shall not be brought out from inside the coil or from intermediate turns and shall be so arranged
as to preserve as far as possible magnetic balance of transformer at all voltage ratios.
17.3.16 Magnitude of impulse surges transferred from HV to LV windings by electromagnetic induction and
capacitance coupling shall be limited to BIL of LV winding.
17.3.17 The winding conductor shall be of Aluminum. The current density shall not exceed 1.6 Amp/ mm² for
aluminium at normal full load current.
B
18. BUSHINGS AND TERMINATIONS
18.1 Bushings
18.1.1 Bushings shall be of the outdoor type and easily replaceable. Cemented in types will not be accepted. They
shall be sufficiently robust to withstand normal transport and erection hazards and shall confirm to IEC 137 /IS 3347
and 2099.
18.1.2 All bushings shall have a minimum creepage distance of 25 mm /KV and shall have a continuous rating of
200% of the transformer rating. The protected creepage distance shall not be less than 50% of the total.
The following minimum 11 KV clearance shall be provided:

External (Air) for 11 KV
Phase to phase 255 mm
Phase to earth 140 mm
18.1.3 The 11 KV bushings of transformers shall be provided with a bi-metallic terminal connector or suitable
device to receive 35–100 mm² AAAC or ACSR conductor directly without any bi-metallic action.
18.1.4 The dia of HT bushing stud should not be less than 12.5 mm. The secondary bushings of transformers shall
be fitted with non ferrous threaded terminals of dia not less than 20 mm. With the exception of brass the terminals
shall be protected from atmospheric deterioration by suitable tinning or by some other approved coating.
18.1.5 The terminals are to be supplied with one 16mm bolt, one conic spring washer, one matching flat washer,
one nut and one lock nut for each hole in the terminal plate.
18.2 Bushing Labels
18.2.1 The HV bushings shall be labeled U, V and W and the LV bushing u, v, w and n. Marking letters shall be at
least 12 mm high. The means of marking shall be either,
 engraved metal plate; or
 etched anodized aluminum.
Phase identification by adhesive stickers shall not be acceptable.
18.2.2 If labeling is to be carried out on the tank, it is preferred that one plate be used rather than individual
markings for each phase, in order to prevent incorrect phase markings. Labels shall conform to the requirements of
the section on labels in this specification.
18.3 Earthing Terminals

All transformers shall be provided with two earthing terminals conforming to relevant Standards and M12 ISO metric
bolt and nut which shall be non ferrous. It shall include a spring washer and lock washer.
19 TANK FABRICATION
19.1 All transformer sizes, the tank shall be of bolted type construction in accordance with IS 1180 (Part 2).
• The tank shall be at atmospheric pressure at an internal temperature of 10˚C;
• The tank shall be designed for an internal pressure of 100 Kg/m² at 50˚C ambient conditions. It shall be capable
of withstanding an unlimited number of 24 hours cyclic variations of internal pressure from atmospheric to this
value.
B
• The tendered shall state the top oil temperature at which the tank internal pressure shall reach the value of
100 kN/m² and the value of steady load which will result in this top oil temperature with an ambient temperature of
45˚C.
• Adequate space shall be provided at the bottom of the tank for collection of sediments.
19.2 Transformer tanks of all types shall be designed so that the completed transformer can be lifted and
transported without permanent deformation or oil leakage. Stiffeners provided on all the four side walls for rigidity
should be so designed that there is no accumulation of water.
19.3 The Tank shall be of rectangular shape with round edges fabricated from tested quality mild steel plates
with minimum thickness of 3.15 mm. for the side walls while top cover and the bottom plate of the tank shall have a
minimum thickness of 5 mm. The transformer tank and the top cover shall be designed in such a manner as to leave
no external pockets in which water can log, or any internal pocket where air/ gas can accumulate.
Edge of Top cover should be bend downwards so as to avoid water through cover plate gasket. The width of the
bend plate shall be 25mm minimum.
19.4 All sealing washers / gaskets shall be made of oil and heat resistant neoprene rubber or neoprene bonded
cork seals suitable for temperature as stipulated in this specification. Surfaces at gasketted joints shall be such that
an even face is presented to gasket, thereby eliminating the necessity for the gasket to take up surface
irregularities.
19.5 All pipes, radiators, stiffeners or corrugations which are welded to the tank wall shall be welded externally
and shall be double welded wherever possible. All welds shall be stress relieved.
19.6 The transformer tank shall be complete with all accessories, lifting lugs etc. and shall be designed to allow
the complete transformer filled with oil to be lifted by crane or jacks without risk of any damage and can be
transported by Rail/ Road without straining any joints and without causing any leakage of oil.
19.7 Provision of Cable End Box with suitable gland.
19.8 The height of the tank shall be such that minimum vertical clearance up to the top cover plate of 80mm is
achieved from the top of the yoke.
20 PRESSURE RELIEF DEVICES

Transformers shall be fitted with a pressure relief device in the form of explosion vent.
The tendered shall state the pressure at which it is designed to operate.
21 OIL LEVEL GAUGE
A suitable oil level gauge (Magnetic type of dia 100 mm) shall be fitted on the transformers and so located that it
can be easily read from ground level. The gauge fitted with the conservator shall be graduated for temperatures of
5˚C, 30˚C and +98˚ C.
22 CONSERVATORS AND BREATHERS
All the transformers shall be provided with a conservator tank.
22.1 The conservator tank shall be so designed and located as to eliminate any trapping of air in the transformer or
pipe work. It shall be inclined at an angle of about 5 degrees to the horizontal towards the drain plug and the pipe
connecting the main tank to the conservator should project about 20 mm above the bottom of the conservator so as
to create a sump for the collection of impurities. Minimum oil level corresponding to 5˚C shall be well above the
sump level.
B
22.2 All transformers shall be fitted with a silica gel breather of weatherproof design at a convenient height with oil
seal at the bottom, draw in plug and filling holes with covers to isolate the silica gel from the atmosphere. The
breather pipe should be connected at top of the conservator tank with two bends at right angles. The cover of the
main tank and bushings turrets shall be provided with air release plug to enable the trapped air to be released.
23 FITTINGS AND ACCESSORIES
23.1 The following standard fittings and accessories shall be provided :

 Rating, diagram and terminal marking plate.
 Two earthing terminals.
 Lifting lugs/ platform lugs.
 Pressure relief device or explosion vent.
 Silica gel breather.
 A magnetic oil level gauge 100 mm dia for all transformers indicating three position ( 3) of oil - minimum. 5˚C,
30˚C and 98˚C.
 Top filter valve with locking arrangement.
 Bottom filter valve with locking arrangement.
 Air release plugs at transformer top cover, bushing turrets etc.
 Set of Radiators.
 Conservator Tank
Bi-metallic terminals on the bushings for connection with over head ACSR/ AAAC conductor. The Specification and
brief details of the salient features of these terminals should be stated.
24 RATING AND CONNECTION PLATE
Each transformer shall be provided with a rating plate of weatherproof material showing the following items indelibly
marked :
 type of transformer
 standard to which it is manufactured (preferably IEC 76)
 manufacturer’s name
 transformer serial number
 year of manufacture
 rated frequency in Hz (50)
 rated voltages in KV (11/0.433)
 number of phases (3)
 rated power in KVA
 type of cooling (ONAN)
 rated currents in A
 vector group symbol (Dyn11)
 1.2/50µs wave impulse voltage withstand level in KVp
 power frequency withstand voltage in KV
 impedance voltage at rated current and frequency in percentage at 75˚C at normal tap
 Measured load loss in KW at rated current and at 75˚C at normal tap
 Measured no-load loss in KW at rated voltage and rated frequency
 continuous ambient temperature at which ratings apply in ˚ C
 top oil and winding temperature rise at rated load in ˚ C
 winding connection diagram
 Total weight in kg with complete oil filled.
 Total weight of the transformer without oil
 Volume of oil in liters.
 weight of core and windings in kg; and
 Name of the employer
 DISCOM, RGGVY-XII Plan Programme
The rating plate shall conform to the requirements of the section of Labels in this specification.
B
25. BASE MOUNTING ARRANGEMENT

The under base of all transformers up to 100 KVA capacity shall be provided with two 75x40 mm channels, 460 mm
long with holes of 14 mm dia at a centre to centre distance of 415 mm to make them suitable for fixing on a
platform or plinth.
26 (a) PUNCHINGS: Non-erasable Punching and embossing of Volume of oil in litres, name of the Employer,
Name of the Supplier – M/s -------------------------------, Year of Manufacture, Guarantee Period ( i.e. 2 years from the
date of installation )and Sl. No. of each transformer is to be made on top core channel, top cover, side walls and
name plates of transformers.
26 (b) 3 STAR LEVEL: In addition to above, the supplied Distribution Transformers must contain 3 Star Level
with style and information provided by the Bureu of Energy Efficiency (B.E.E), Ministry of Power, Government of
India.
27. PAINTING
27.1 All paints shall be applied in accordance with the paint manufacturer’s recommendations. Particular
attention shall be paid to the following:
27.2
27.3 All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles, patchiness, brush marks
or other defects.
27.3.1 All primers shall be well marked into the surface, particularly in areas where painting is evident, and the
first priming coat shall be applied as soon as possible after cleaning. The paint shall be applied by airless spray
according to the manufacturer’s recommendations. However, wherever airless spray is not possible, conventional
spray be used with prior approval of employer.
27.3.2 The supplier shall, prior to painting protect nameplates, lettering gauges, sight glasses, light fittings and
similar such items.
27.4 Cleaning and Surface Preparation
27.4.1 After all machining, forming and welding has been completed, all steel work surfaces shall be thoroughly
cleaned of rust, scale, welding slag or spatter and other contamination prior to any painting.
27.4.2 Steel surfaces shall be prepared by Sand/Shot blast cleaning or Chemical cleaning by Seven tank process
including Phosphating to the appropriate quality.
27.4.3 The pressure and Volume of the compressed air supply for the blast cleaning shall meet the work
requirements and shall be sufficiently free from all water contamination prior to any painting.
27.4.4 Chipping, scraping and steel wire brushing using manual or power driven tools cannot remove firmly
27.5 Protective Coating

28.5.1 As soon as all items have been cleaned and within four hours of the subsequent drying, they shall be given
suitable anticorrosion protection.
B
27.6 Paint Material
Followings are the type of paints that may be suitably used for the items to be painted at shop and supply of
matching paint to site:
i) Heat resistant paint (Hot oil proof) for inside surface.
ii) For external surfaces one coat of Thermo Setting Paint or 2 coats of Zinc chromate followed by 2 coats of P.U
(Poly-urethane) paint. The color of the finishing coats shall be dark admiral gray.
27.7 Painting Procedure
27.7.1 All painting shall be carried out in conformity with both specifications and with the paint manufacture’s
recommendations. All paints in any one particular system. Whether shop or site applied, shall originate from one
paint manufacturer.
27.7.2 Particular attention shall be paid to the manufacturer’s instructions on storage, mixing, thinning and pot
life. The paint shall only be applied in the manner detailed by the manufacturer e.g. brush, roller, conventional or
airless spray and shall be applied under the manufacturer’s recommended conditions. Minimum and maximum time
intervals between coats shall be closely followed.
27.7.3 All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours whichever is
sooner. Chemical treated steel surfaces shall be primed as soon as the surface is dry and while the surface is warm.
27.7.4 Where the quality of film is impaired by excess film thickness, (wrinkling, mud cracking or general softness)
the supplier shall remove the unsatisfactory paint coatings and apply another.
As a general rule, dry film thickness should not exceed the specified minimum dry film thickness by more than 25%.
In all instances, where two or more coats of the same paints are specifies, such coatings may or may not be of
contrasting colors.
27.7.5 Paint applied to items that are not be painted, shall be removed at supplier’s expense, leaving the surface
clean, un-stained and undamaged.
27.8 Damages to Paints Work
Any damage occurring to any part of the painting scheme shall be made good to the same standard of corrosion
protection and appearance as that originally employed. Any damaged paint work shall be made as follows:
a) The damaged area, together with an area extending 25mm around its boundary, shall be cleaned down to
bare metal.
b) A priming coat shall immediately applied, followed by a full paint finish equal to that originally applied and
extending 50mm around the perimeter of the originally damaged. The repainted surface shall present a smooth
surface. This shall be obtained by carefully chamfering the paint edges before & after priming.
27.9 Dry Film Thickness
To the maximum extent practicable, the coats shall be applied as a continuous film of uniform thickness and free of
pores. Over-spray, skips, runs, sags and drips should be avoided. The different coats may or may not be same color.
Each coat of paint shall be allowed to harden before the next is applied as per manufacture’s recommendations.
Particular attention must be paid to full film thickness at edges.
B
The requirement for the dry film thickness(DFT) of paint and the material to be used shall be as given below:
Sl.
Area to be
No Paint Type No of Total Dry film
painted
Coats thickness(Min)
1 1. Liquid paint
a) Zinc Chromate (Primer) Out side 01 30 micron
b) P.U. Paint (Finish Coat) Out side 02 45 each
c) Hot Oil paint

inside 01 35/10 micron
The colour of the finishing coat shall be Sky Blue/ Dark Admiral Gray/ Deep Green or any other colour as decided by
the Employer
28 SEALING GASKETS
All sealing washers / gaskets shall be made of oil and heat-resistant Nitrile/ Neoprene rubber/ synthetic rubber
bonded cork type RC-70C gaskets. Gaskets made of natural rubber or cork sheet are not permissible.
29 SUPRESSION OF HARMONICS
The transformer shall be designed with attention to the suppression of harmonic voltage, especially the third and
fifth.
30 TESTS
30.1 Routine Tests

Routine tests shall be carried out on all transformers and the tests shall be conducted in accordance with relevant
National/ International Standards. No sampling is allowed. In addition, tank tests in accordance with IS: 1180 shall
be carried out.
The following routine measurements and tests shall be carried out in presence of Employer’s authorized
representative(s):
a) Measurement of winding resistance.

b) Voltage ratio measurement and check of polarity and vector group. Bushing positions shall have permanent
markings at this stage of production;
c) Measurement of impedance voltages/ short circuit impedance at rated current and frequency
d) Measurement of load loss at full load and 75˚C;
e) Measurement of neutral unbalance current;
f) Temperature rise test on one transformer of each rating and measurement of hot resistance.
g) Measurement of no-load loss and no-load currents at full, 50%, 75%, 90%, 110%, 112.5% and 120% of rated
voltages;
h) Induced over voltage withstand test at 22KV for 60 sec on the HV windings;
i) Power frequency voltage withstand tests on HV and LV windings;
B
j) Magnetic balance test

k) Polarization Index test P.I. value shall be not less than 1.5. P.I. = IR at 600 sec / IR at 60 sec.
l) Oil leakage test: The criterion of leakage shall be discoloration by oil of whitewash applied externally to
suspected parts at an oil temperature of 90˚C or other method, as approved by the Employer;
m) Pressure test on transformer tank on one unit for each rating. Bushings and oil shall be subject to the following
routine tests.
n) Bushing routine test: in accordance with IEC 137/IS 3347;
o) Oil dielectric and moisture content test: conforming to IEC 156 or IS 335.
Routine test certificates shall include in addition to the test results, the employer’s order number, the transformer
serial number, outline drawing number and transformer KVA rating.
Any other applicable tests shall be conducted at the discretion of the Employer without any extra cost to Employer.
30.2 Type Tests

30.2.1 The measurements and tests should be carried out in accordance with the standard specified in each case
as indicated in the following table if the same tests were not conducted earlier at CPRI or any NABL accredited
Laboratory on the transformers of the offered design without any cost implication and employer.

Type Test Standard

2026/IS6600
Impulse Voltage Withstand Test, including Full Waves and IEC 76/IS 2026
In accordance with IEC 76-3 the following sequence of impulses should have been/ should be applied;

30.2.2 If the type test report(s) submitted by the bidder do not fulfil the criteria, as stipulated in this technical
specification/ Bidder’s offer, the relevant type test(s) has/ have to be conducted by the Bidder at his own cost in
CPRI/ NABL accredited laboratory in the presence of employers representative(s) without any financial liability to
employer in the event of order placed on him.
30.2.3 The offeres transformer must be manufactured as per type tested design. A copy of type test certificate
must be submitted by manufacturer to Engineer/Employer. Transformers offered without type tested however
design shall not be accepted. In case manufacturer agrees for type testing of transformers, testing shall be
conducted on manufacturer’s cost. No claim shall be acceptable towards type testing. The transformers shall be
accepted only on acceptane of type testing results by employer.
B
30.2.4 The supplier shall furnish calculations in accordance with IS: 2026 to demonstrate the Thermal ability of
the transformers to withstand Short Circuit forces.
30.3 TEST VOLTAGE

Transformers shall be capable of withstanding the Power frequency and Impulse test voltage as described below:
Nominal Highest Power

system voltage System Impulse Test frequency
voltage voltage test
voltage
433 V (rms) 3 KV (rms)
11 KV (rms) 12 KV (rms) 95 KV (Peak) 28 KV (rms)
31 COMPLIANCE WITH SPECIFICATION
The transformers shall comply in all respects with the requirements of this specification
32 COMPLIANCE WITH REGULATIONS
All the equipment shall comply in all respects with the Indian Regulations and acts in force.
The equipment and connections shall be designed and arranged to minimize the risk of fire and any damage which
might be caused in the event of fire.
33 INSPECTIONS AND TESTING
33.1 The Employer shall have free entry at all times, while work on the contract is being performed, to all parts of
the manufacturer’s works which concern the processing of the equipment ordered. The manufacturer shall afford
the Employer without charge, all reasonable facilities to assure that the equipment being furnished is in accordance
with this specification. After approval of Drawings by the Employer, the manufacture shall manufacture a Prototype
Model as per the Approved Drawing and offer the same for inspection. The Inspection of the Prototype Model shall
be carried out as per the Format prescribed at Clause 41 of our Tender Specification. The Supplier shall offer the
core, windings and tanks of each transformer for inspection by the Employer’s representative(s). During stage
inspection of the Prototype Model, all the measurements like diameter, window, height, leg centre, stack width,
stack thickness, thickness of laminations etc for core assembly, conductor size, insulation thickness, I.D., O.D.,
Winding height, major and minor insulations for both HV and LV windings, length, breadth, height and thickness of
plates of transformer tanks, the quality of fittings and accessories will be taken/ determined.
The Inspection Report for the Tests conducted by our Authorized Inspectors in presence of the manufacturer’s
representative, for the Prototype Model offered for inspection with suggested modifications, if any shall be
submitted to the undersigned for approval.
After Inspection, the Prototype Model shall be kept sealed, in the premises of the manufacturer till the completion of
delivery of final consignment, for future reference during subsequent Inspections.
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The Supplier can offer for final inspection of the transformers subject to clearance of the stage inspection report by
the Employer.
33.2 The equipment shall successfully pass all the type tests and routine tests mentioned in the above Clauses
and those listed in the most recent edition of the standards given in Clause 2 of this specification.
33.3 The Employer reserves the right to reject an item of equipment if the test results do not comply with the
values specified or with the data given in the technical data schedule.
33.4 Routine tests shall be carried out by the Supplier at no extra charge at their works.
Adequate facility with calibrated testing equipment must be provided by the manufacturer free of cost to carry out
the tests. Type test certificates must be furnished along with the tender for reference of the Employer.
33.5 The Employer will witness all required tests. In order to facilitate this, the Supplier shall give the Employer
a minimum of 10 days notice that the materials are ready for testing.
33.6 The supplier shall submit to the Employer five signed copies of the test certificates, giving the results of the
tests as required. No materials shall be dispatched until material dispatch clearance is not issued by employer.
The test certificates must show the actual values obtained from the tests, in the units used in this specification, and
not merely confirm that the requirements have been met.
In the case of components for which specific type tests or routine tests are not given in this specification or in the
quoted standards in Clause 2, of this specification, The Supplier shall include a list of the tests normally required for
these components. All materials used in the Contract shall withstand and shall be certified to have satisfactorily
passed such tests.
33.7 The Employer at his discretion may re-confirm the Routine Test Results, particularly no load losses, load
losses and percentage impedance in his own laboratory or laboratory of his choice.
No inspection or lack of inspection or passing by the Employer’s Representative of equipment or materials whether
supplied by the Supplier or sub-supplier, shall relieve the Supplier from his liability to complete the contract works in
accordance with the contract or exonerate him from any of his guarantees.
However in case of future discrepancy, if any, after acceptance of equipments, observed at any stage during
guarantee period, the matter may be referred to Bureau of Energy Efficiency (B.E.E) for random testing of
equipments supplied. In such cases the observation of B.E.E shall be binding to both parties.
34 GUARANTEE
The supplier shall guarantee the following:
 Quality and strength of materials used;
 Satisfactory operation during the guarantee period from the date of commissioning, as per general terms
of condition of the contract.
 Performance figures as supplied by the tendered in the schedule of guaranteed particulars;
 The offered surface treatment shall protect the treated metal from corrosion for a period of not less than
five years from the date of delivery.
35 PACKING AND SHIPPING
35.1 Packing
The equipment and any supporting structures are to be transported adequately sealed against water ingress. All
accessories and spares shall be packed and securely clamped against movement in robust, wooden, non returnable
packing cases to ensure safe transit in rough terrain, cross country road conditions and in heavy rains from the
manufacturer’s works to the work sites/ earmarked destinations.
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35.1.1 All accessories shall be carefully packed so that they are fully protected during transport and handling
operations and in storage. Internal surfaces of loose accessories shall be sealed by means of gaskets and blanking
off plates. All parts liable to rust shall receive an anti-rusting coat and shall be suitably protected. It shall be the
responsibility of the Supplier to make good any damage caused through insufficient packing. Each packing case shall
be indelibly marked, on two adjacent sides and on the top, with the following:
 Individual serial number;

 Employer’s name;
 Contract number;
 Destination;
 A colour coded marking to indicate destination;
 Supplier’s name;
 Description and numbers of contents;
 Manufacturer’s name;
 Country of origin;
 Case measurements;
 Gross and net weight in kilograms: and
 All necessary slinging and stacking instructions.
35.1.2 Each crate or container shall be marked clearly on the outside of the case to show TOP and BOTTOM
positions with appropriate signs to indicate where the mass is bearing and the correct positions for slings. All
component parts which are separately transported shall have permanent identification marks to facilitate correct
matching and assembly at site. Welded parts shall be marked before welding. Six copies of each packing list shall be
sent to the Employer prior to dispatching the equipment.
35.2 Transportation
The contractor shall be responsible for the transport of all plant and equipment supplied by them and for the
transport of all goods to the various specified destinations including all road clearance, offloading, warehousing and
insurance. The Supplier shall inform himself fully as to all relevant transport facilities and requirements and loading
gauges and ensure that the equipment as packed for transport conform to these limitations. The Supplier shall also
be responsible for verifying the access facilities specified.
The contractor shall be responsible for the transportation of all loads associated with the contract works and shall
take all reasonable steps to prevent any highways or bridges from being damaged by his traffic and shall select
routes, choose and use vehicles and restrict and distribute loads so that the risk of damage shall be avoided. The
Supplier shall immediately report to the Employer any claims made against the Supplier arising out of alleged
damage to a highway or bridge. All transport accessories, such as riding lugs, jacking pads or blanking off plates
shall become the property of the Employer.
All items of equipment shall be securely clamped against movement to ensure safe transit from the manufacturer’s
facilities to the specified destinations.
The Supplier shall advice the storage requirements for any plant and equipment that may be delivered to the
Employer’s stores. The Supplier shall be required to accept responsibility for the advice given in so far as these
arrangements may have a bearing on the behavior of the equipment in subsequent service.
36 Hazardous substances
The Supplier shall submit safety data sheets for all hazardous substances used with the equipment. The Supplier
shall give an assurance that there are no other substances classified as hazardous in the equipment supplied. No oil
shall be supplied or used at any stage of manufacture or test without a certificate acceptable to the Employer that it
has a PCB content of less than 2 mg/ kg. The Supplier shall accept responsibility for the disposal of such hazardous
substances, should any be found. The Supplier shall also be responsible for any injuries resulting from hazardous
substances due to non compliance with these requirements.
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37 SUBMITTALS
37.1 Submittals required to employer is for approval of manufacturing of transformer
The following shall be for employer approval before start of manufacturing:

 Completed technical data schedule;
 Descriptive literature giving full technical details of equipment offered;
 Outline dimensions drawing for each major component, general arrangement drawing showing component
layout and general schematic diagram;
 Type test certificates (short circuit withstand test and impulse test) of the offered transformers conducted
at CPRI/ or any NABL Accredited laboratory without which proposal will be out rightly rejected.
 Sample routine test reports;
 Detailed reference list of customers already using equipment offered along with performance certificates of
such equipment, during the last 3 (three) years with particular emphasis on units of similar design and
rating;
 Details of manufacturer’s quality assurance standards and programme and ISO 9000 series or equivalent
national certification;
 Deviations from this specification. Only deviations approved in writing before award of contract shall be
accepted;
 List of recommended spare parts and consumable items for five year of operation with prices and spare parts
catalogue with price list for future requirements.
37.2 Submittals required after contract award
37.2.1 Programme
Five copies of the programme for production and testing
37.2.2 Operation and Maintenance Instructions
A copy of installation and commissioning instructions and of the operation and maintenance instructions and
troubleshooting charts shall be supplied with each transformer.
37.3 Drawings
37.3.1 Within 15 days of award of contract, the Supplier shall submit 4 complete sets of drawings as detailed
below describing equipment in details. These drawings would be duly approved by the Employer after due
securitization and approval will be communicated within 15 days of receipt of these drawings. After the drawings are
approved and communicated to the supplier, he would supply ten complete sets of final drawings.
37.3.2 All detail drawings submitted for approval shall be to scale not less than 1:20. All important dimensions
shall be given and the material of which each part is to be constructed shall be indicated on the drawings. All
documents and drawings shall be submitted in accordance with the provisions of this specification and shall become
the property of the Employer.
37.3.3 All drawings and calculations, submitted to the Employer, shall be on international standard size paper,
either A0, A1, A2, A3 or A4. All such drawings and calculations shall be provided with a contract title block, which
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shall include the name of the Employer and shall be assigned an unique project drawing number; the contract title
block and project numbering system shall be agreed with the Employer.
37.3.4 Script sizes and thickness of scripts and lines be selected so that if reduced by two stages the alphanumeric
characters and lines are still perfectly legible so as to facilitate microfilming.
37.3.5 For presentation of design drawings and circuit documents IEC Publication 617 or equivalent standards for
graphical symbols are to be followed. The drawing approval will be communicated within 15 days from the receipt of
drawings from the Bidder and for any delay in furnishing the drawings, if delivery period will be delayed, no
extension of delivery time will be granted due to this.
37.3.6 The following drawings for each item are to be submitted as part of this Contract.
a. Out line dimensional drawings of transformers and accessories

b. Assembly drawings and weights of main component parts.
c. Transportation drawings showing dimensions and weights of each package.
d. Drawings giving the weights for foundations each.
e. Drawing showing details such as clamping arrangements of core, core assembly showing oil duct section of HT
and LT coils with conductor size showing insulation arrangements of windings and their reinforcement to
withstand short circuit stresses, in side tank dimensions showing core assembly. Details of core and windings,
as enumerated at Cl. No. 17 of this part of Specification shall be indicated in the above drawings.
f. Schematic diagram showing the flow of oil in the cooling system as well as each limb and winding. Longitudinal
and cross- sectional views showing the duct sizes, cooling pipe etc. for transformer/ heat exchanger, drawn to
scale shall be furnished.
g. Large Scale drawings of high and low tension winding of the transformers showing the nature and
arrangements of insulation and terminal connection.
h. Test Reports
38 FASTENERS
38.1 All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the appropriate Indian
Standards for metric threads, or the technical equivalent.
38.2 Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring terminals. All nuts
and pins shall be adequately locked.
38.3 Wherever possible, bolts shall be fitted in such a manner that in the event of failure of locking resulting in the
nuts working loose and falling off, the bolt will remain in position.
38.4 All ferrous bolts, nuts and washers placed in outdoor positions shall be of anti-corrosive materials except high
tensile steel bolts and spring washers which shall be electro galvanized to service condition stated elsewhere in the
Specification. Appropriate precautions shall be taken to prevent electrolytic action between dissimilar metals where
bolts are used on external horizontal surfaces and where water can collect, methods of preventing the ingress of
moisture to the threads shall be provided. Each bolt or stud shall project at least one thread but not more than
three threads through the nut, except when otherwise approved for terminal board studs or relay stems. If bolts
nuts are placed so that they are inaccessible by means of ordinary spanners, special spanners shall be provided. The
length of the screwed portion of the bolts shall be such that no screw thread may form part of a shear place
between members. Taper washers shall be provided where necessary. Protective washers of suitable material shall
be provided front and back on the securing screws.
39. LABELS
39.1 All apparatus shall be clearly labelled indicating, where necessary, its purpose and service positions. The
material of all labels and plates, their dimensions, legend and the method of printing shall be subject to approval of
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the Employer. The surfaces of all labels and plates shall have a mat or satin finish to avoid dazzle from reflected
light. Colours shall be permanent and free from fading. Labels mounted on black surfaces shall have white lettering.
Danger plates shall have white lettering on a red background. All labels and plates for outdoor use shall be of in-
corrodible material. Where the use of enameled iron plates is approved, the whole surface including the back and
edges, shall be properly covered and resistant to corrosion. They shall be engraved in English. Name plates shall be
white with black engraved lettering and shall carry all the applicable information specified in the applicable items of
the Standards. No scratching, corrections or changes will be allowed on name plates.
39.2 Name plates shall be provided of white background with black engraved lettering carrying all the applicable
information specified in the standards and other details as required by the Employer. The name plate inscription and
the size and lettering shall be submitted to the Employer for approval.
40.PROFORMA FOR STAGE INSPECTION OF DISTRIBUTION TRANSFORMERS
(A) GENERAL INFORMATION:
1. Name of Firm :
2. Order No and Date :
3. Rating –wise quantity offered :
4. Details of offer
(a) Rating
(b) Quantity
(c) Serial Numbers
5. Details of last stage inspected lot :

(a) Total quantity inspected
(b) Serial Numbers
(c) Date of stage inspection
(d) Quantity offered for final inspection of
6.
(A) Inspection of BEE 3 Star Level/ Embossing / Punching requirement: whether satisfies the Specification: deviation
if any to be mentioned
(B) Availability of material for offered quantity
(C) Position of manufacturing stage of the offered
QUANTITY :
(a) Complete tanked assembly

(b) Core and coil assembly ready
(c) Core assembled
(d) Coils ready for assembly
(i) HV Coils
(ii) LV Coils
NOTE:
(i) A quantity if more than 100 no’s shall not be entertained for stage inspection
(ii) The stage inspection shall be carried out in case:-
(a) At Least 25% quantity offered has been tanked and
(b) Core coil assembly of further at least 30% of the quantity offered has been completed.
(iii) Quantity offered for stage inspection should be offered for final inspection within 15 days from the date of
issuance of clearance for stage inspection, otherwise stage inspection already cleared shall be liable for cancellation.
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VOLUME –II: Section-II (B) 1
Single Phase, 16 KVA Distribution Transformer

1 SCOPE
1.1 The specification covers the design, engineering, manufacture, stage inspection, testing, pre-delivery
inspection, supply, delivery, loading, unloading and performance requirements of 11/0.250 KV non-sealed type
aluminium wound distribution transformers for outdoor use in the networks. The transformers shall be double
wound, single phase, CRGO oil immersed with ONAN cooling with Oil filled upto maximum permissible level. The
ratings required under this specification are 16KVA with Aluminium windings.
1.2 The equipment offered should have been successfully type tested within five years from date of tender and
the designs should have been in satisfactory operation for a period not less than one year. Compliance shall be
demonstrated by submitting (i) authenticated copies of the type test reports and (ii) performance certificates from
the users, specifically from Central Govt./ State Govt. or their undertakings.
2. CODES & STANDARDS
IEC/ISO Indian Standard Subject
IEC 71 Insulation Coordination

IEC 76 IS 2026 Power Transformers.
IS 1180 Outdoor Single phase Distribution Transformers up to
500 KVA, 11/ 0.433 KV, Non- Sealed Type
IEC 137 IS 2099 Bushing for Alternating Voltages above 1000V
IEC 156 Method of determining Electric Strength of Insulating Oils.
IEC 296 IS 335 Specifications for Unused Mineral Insulating Oils for
Transformers and Switchgear.
IS 6792 Method of determination of electric strength of insulating

oils.
IEC 354 IS 6600 Loading Guide for oil immersed Transformers

IEC 437 Radio Influence Voltage Measurement.
IEC 551 Determination of Transformer and Reactor Sound Levels
IEC 616 Terminal and Tapping markings for power transformers.

IEC 722 Guide to the Lightning andSwitching impulse testing of
Power Transformers and Reactors
ISO 1460/BS 729 Galvanizing
This list is not to be considered exhaustive and reference to a particular standard or recommendation in this
specification does not relieve the Manufacturer of the necessity of providing the goods complying with other
relevant standards or recommendations.
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3.SERVICE CONDITIONS
The service conditions shall be as follows:(To be confirmed by PIA as per locality of project)
Plane area Hilly area
maximum altitude above sea level 1000m 5000 m

maximum temperature attainable by an object exposed to the sun 60 ° C 60 ° C
average number of thunderstorm days per annum (isokeraunic level) 70 70
Environmentally, the region where the equipment will be installed includes coastal areas, subject to high relative
humidity, which can give rise to condensation. On shore winds will frequently be salt laden. On occasions, the
combination of salt and condensation may create pollution conditions for outdoor insulators.
Therefore, outdoor material and equipment shall be designed and protected for use in exposed, heavily polluted,
salty, corrosive, tropical and humid coastal atmosphere
4. SYSTEM CONDITIONS:
The equipment shall be suitable for installation in supply systems of the following characteristics.
Frequency 50 Hz ± 5%
Nominal system voltages 11 KV System 11 KV

LV System 250 V
Maximum system voltages 11 KV System 12 KV
LV System 275 V
Minimum LV voltage (NEC) 225 V
Nominal short circuit apparent power of the system 11 KV System 500 MVA (IS: 2026)
Insulation levels :
1.2/50 μ sec impulse withstand 11 KV System 75 KV peak

Power frequency one minute withstand 11 KV System 28 KV (rms)
(wet and dry) LV System 3 KV (rms)
Neutral earthing arrangements :earthed LV System Solidly
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PART 2 : TECHNICAL
SPECIFIC TECHNICAL REQUIREMENTS
1 Rated KVA (ONAN rating 16KVA , 11/0.250 KV
2 No. of phases single
6 Type of mounting On Channels.
7 Rated voltage
a) High voltage winding 11 KV
Low voltage winding 0.250 KV
Highest continuous system voltage
a) Maximum system voltage ratio (HV / LV ) 12 KV / 0.275 KV
b) Rated voltage ratio (HV / LV 11 KV / 0.250 KV
10 Type of cooling ONAN ( Oil natural / Air natural
11 KVA Rating corresponding to ONAN cooling system 100%
HV: Series
LV: Series/Parallel
14 System earthing Neutral of LV side to be soilidly
earthed
15 Percentage impedance voltage on normal tap and % Impedance + Tolerance %
KVA base at 750 C correspondingto HV/ LV rating and
applicable tolerances:
(No negative tolerance will be allowed)
16 Intended regular cyclic overloading of windings As per IEC –76-1, Clause 4.2
b) Anticipated continuous loading of windings(HV / LV) 110 % of rated current
18 a) Type of tap changer NA

b) Range of taping No Tap
20 Over Voltage operating capability and duration 112.5 % of rated voltage (
continuous
21 Maximum Flux Density in any part of the core and 1.5 Tesla
yoke at rated KVA, rated voltage i.e 11 KV / 0.433 KV
and system frequency of 50 HZ
22 Insulation levels for windings :-

a) 1.2 / 50 microsecond wave shape Impulse HV: 75 LV:N.A. withstand (KVP)
b) Power frequency voltage withstand (KVrms) HV: 28 LV: 03
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24 Withstand time for single phase short circuit 2 Seconds
25 Noise level at rated voltage and frequency As per NEMA Publication No. TR-
1.
26 Permissible Temperature Rise over ambient
temperature of 50°C
a) Of top oil measured by thermometer 35°C
b) Of winding measured by resistance. 40° C
27 Minimum HV clearances in air (mm) :-
a) Phase to Phase 280
b) Phase to ground 140
28 Bushings & Terminals
a) HV winding line end 12 KV highly polluted porcelain
type of bushings ( Antifog type )
b) LV winding (Antifog type) 0.25 KV porcelain type of
bushing
a) Lightning Impulse withstand (KVP) 75 Not applicable
b) 1 Minute Power Frequency withstand voltage (KV – 28 3
rms )
c) Creepage distance (mm) (minimum) 25 mm/ KV
30 Material of HV & LV Conductor EC grade Aluminum
31 Maximum current density for HV and LV winding for 4 Amp/ mm².
rated current
32 Polarisation index i.e ratio of megger values at 600 Shall be greater than or equal to
sec. to 60 sec for HV to earth 1.5, but less than or equal to ‘5’
33 Core Assembly boltless types

34 Maximum permissible no load losses at rated voltage & frequency and load losses at rated current & at 75 ͦ
C.
Transformer rating Maximum No Max. Load
Load Loss at losses at rated
Normal Voltage Current & at 75ͦ ͦ C (Watts).
in watts
a) 16KVA 45 230
6. TYPE OF TRANSFORMER
6.1 The transformers shall be of core type construction, double wound, single phase, oil immersed, 11/0.250KV, 50
Hz with natural oil and air cooling (ONAN) to be used as step down transformers for out door use. The design of the
tank, fittings, bushings, etc shall be such that it will not be necessary to keep the transformer energised to prevent
deterioration as the transformers may be held in reserve, outdoors, for many years.
7.PERFORMANCE , CAPACITY AND SHORT CIRCUIT RATINGS

7.1 The following ratings are covered under this specification
 16 KVA,11/0.250 KV, Aluminium wound
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7.2 The transformer shall be capable of supplying a continuous load equal to its KVA rating, under the following
conditions:
 continuous steady load;
 Design at maximum ambient air temperature of 50°C;
 40°C average winding temperature rise and 35°C top oil temperature rise for conventional breathing
transformers.
7.3 The transformer may be overloaded during emergency up to 150% of its continuous rating in accordance with
IEC Publication 354 or IS: 6600. Bushings and other current-carrying parts shall also be designed for this condition.
7.4 The transformer shall be capable of withstanding for two seconds without damage to any external short circuit,
with the short circuit MVA available at the terminals of either winding with rated voltage on the other winding. If
short circuit tests have been carried out on the particular design of transformer offered, the test results shall be
supplied with the bid.
7.5 The thermal ability to withstand short circuit shall be demonstrated by calculation.
7.6 The transformer shall be capable of withstanding the thermal and dynamic effects of short circuits, as specified
in IEC 76-5 or IS: 2026: Ability to withstand short circuits.
7.7 The maximum flux density in any part of the core and yoke at rated KVA, Voltage and frequency shall not
exceed 1.5 Tesla.
8. VOLTAGE RATIO
8.1The transformers shall have the following ratio:-
 the nominal voltage ratio shall be 11,000/ 250 V for 16KVA transformers;
 tolerance on the voltage ratio shall be ± 0.5%.
8.2 The bidder shall state in the technical schedule, the percentage regulation at full load, power factor 1.0 and at
full load, power factor 0.85 lagging.
Transformers shall be suitable for parallel operation with each other.
9. PERCENTAGE IMPEDANCE
9.1 The Percentage of Impedance at 75 °C shall be 4.0+10 % for 16KVA transformers . No negative tolerance
on percentage Impedance is allowed.
10 LOSSES
The load losses shall not exceed the values given below:-
KVA Maximum No Load Loss at Normal Maximum load losses at rated

Rating Voltage in watts current & at 75˚C (Watts)
16 KVA 45 230
10.1The above losses are maximum allowable and there should not be any positive tolerance. If individual losses
are found more than above values; the transformer shall not be accepted.
10.2 The offered transformer(s) should have been type-tested at CPRI/ National Govt. approved laboratory. The bid
shall be accompanied with type-test reports (short circuit test and Impulse test) conducted at Central Power
Research Institute / National Govt. approved laboratory for the offered transformers within five years from date of
tender. The short circuit test report(s) must contain the measured no load loss and load loss, determined by CPRI/
National Govt. approved laboratory.
In case of any doubts, EMPLOYER reserves the right to verify the original type test reports of CPRI/ National Govt.
approved Laboratory or ask the manufacturer to conduct the type tests at CPRI/ National Govt. approved
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Laboratory at his (manufacturer’s) cost for re-confirmation of the test results particularly no load losses, load losses
and percentage impedance.
10.3 If the bidder quotes lower values of losses than the CPRI’s measured losses, he has to prove the same by
conducting the Impulse & short Circuit tests at CPRI/ National Govt. approved laboratory along with measurement
of no load losses and load losses at his own cost in presence of EMPLOYER’ s authorized representative without any
financial liability to EMPLOYER.
10.4 However, if the loss figures will exceed the stipulated values as per specification, the transformer(s) shall be
out rightly rejected.
11. VECTOR GROUP

11.1 The transformers shall be connected delta-star, in accordance with vector group reference Dyn11 of IEC - 76/
IS - 2026.
11.2 The LV neutral shall be brought out to a terminal bushing, which shall be identical to the phase bushings in all
respects.
12. LOSSES
12.1 Transformers would be out rightly rejected if losses exceed the values indicated at clause-10 above.
13. FLUX DENSITY

The flux density at rated voltage & rated frequency shall not exceed. 1.50 Tesla. The transformer must be capable
of operating at 10% over voltage and at frequency of 48.5 Hz without saturation.
14. INSULATION LEVELS

The insulation levels as defined in IEC 76-C/ IS: 2026 Insulation levels and dielectric test shall apply as per Table 2:
Table 2 : Transformer insulation level
HV Winding LV Winding
Basic Impulse voltage Level (KVp) 75 Not Applicable

(1.2/50 micro. sec. Wave )
Power Frequency voltage withstand 28 3
level, Wet and Dry (KV)
Bushings and terminals shall be adequate for the winding insulation tests and shall flash over externally before
puncture or internal failure can occur.
15. NOISE LEVEL

The average noise level of the transformers shall not exceed 51db. The measurement shall be carried out in
accordance with IEC 551 at a distance of 300mm from the envelope of the transformer.
16. RADIO INFLUENCE VOLTAGE

The maximum radio influence voltage shall be 250μ V, measured as specified in IEC 437.
17 CORE AND WINDINGS

17.1 Core
17.1.1 Stage level inspection for core construction shall be carried out by the owner.
17.1.2 Each lamination shall be insulated such that it will not deteriorate due to mechanical pressureand the
action of hot transformer oil.
17.1.3 The core shall be constructed from high grade, non-ageing, Cold Rolled Grain Oriented (CRGO), M4 or
better silicon steel laminations only. No other core materials shall be entertained. Bidders are requested to note that
only PRIME CORE materials are to be used. In no case, second grade core material is to be used. The Employer at
his discretion, may select samples from the core laminations and get the same tested in CPRI/ Approved National
Govt. Laboratory to prove the quality of the core material.
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17.1.4 For the above purpose, the manufacturer shall have to offer every batch of core laminations received
from his Sub-Vendor along with Invoice of the sub-vendor, Mills test certificate, packing list, Bill of landing, Bill of
entry certificate to customs etc. towards proof of prime core materials for verification by the Employer’s
representative without any cost to the Employer. Besides, the contractor must mention in his bid about the type of
CRGO laminations to be utilized for the offered transformers along with a copy of the specific core loss curve at
different flux densities.
17.1.5 Core materials should be directly procured either from the manufacturer or through their accredited
The core and winding shall be capable of withstanding shocks during transport, installation and service. Provision
shall be made to prevent movement of the core and windings relative to the tank during these conditions and also
during short circuits.
17.1.6 The design shall avoid the presence of pockets which would prevent the complete emptying of the tank
through the drain valve. The core material offered in the tender to be checked for its correctness before core coil
assembly. For this, the renderer must ask for core and coil inspection before its tanking.
17.1.7 The laminations shall be free of all burrs and sharp projections. Each sheet shall have an insulting
coating resistant to the action of hot oil.
17.1.8 The insulation structure for the core to bolts and core to clamp plates, shall be such as to withstand
2000 V DC voltage for one minute.
17.1.9 The completed core and coil shall be so assembled that the axis and the plane of the outer surface of
the core assemble shall not deviate from the vertical plane by more than 25mm.
17.1.10 All steel sections used for supporting the core shall be thoroughly shot or sand blasted, after cutting,
17.1.11 The finally assembled core with all the clamping structures shall be free from deformation and shall
not vibrate during operation.
17.1.12 The core clamping structure shall be designed to minimize eddy current loss.
17.1.13 The framework and clamping arrangements shall be securely earthed.
17.1.14 The core shall be carefully assembled and rigidly clamped to ensure adequate mechanical strength.
17.1.16 The design of magnetic circuit shall be such as to avoid static discharges, development of short circuit
paths within itself or to the earth clamping structure and production of flux component at right angle to the plane of
the lamination, which may cause local heating. The supporting framework of the cores shall be so designed as to
avoid the presence of pockets, which would prevent complete emptying of the tank through the drain valve or
cause trapping of air during filling.
17.1.17 The construction is to be of boltless core type. The core shall be provided with lugs suitable for lifting
the complete core and coil assembly. The core and coil assembly shall be so fixed in the tank that shifting will not
occur during transport or short circuits.

17.2.1 All internal metal parts of the transformer, with the exception of individual laminations and their individual
clamping plates shall be earthed
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c) By a connection to the structure on the same side of the core as the main earth connection to the tank.
17.2.3 The magnetic circuit shall be connected to the clamping structure at one point only and this shallbe
brought out of the top cover of the transformer tank through a suitably rated insulator. Adisconnecting link shall be
provided on transformer tank to facilitate disconnections fromground for IR measurement purpose
17.3 Windings
during service. Adjustable devices shall be provided for taking up possible shrinkage in service.
17.3.2 All low voltage windings for use in the circular coil concentric winding shall be wound on a performed
insulating cylinder for mechanical protection of the winding in handling and placingaround the core.
17.3.4 The winding insulation shall be free from insulating compounds which are liable to soften, ooze out, shrink
or collapse. It shall be non catalytic and chemically inert in hot transformer oil during normal service.
17.3.5 The stacks of windings are to receive adequate shrinkage treatment.
17.3.6 The windings and connections are to be braced to withstand shocks during transport, switching, short
circuit or other transient conditions.
17.3.7 Permanent current carrying joints in the windings and leads shall be welded or brazed. Clamping bolts for
current carrying parts inside oil shall be made of oil resistant material which shall not be affected by acidity in the oil
steel bolts, if used, shall be suitably treated.
17.3.9 The windings shall be uniformly insulated and the L.V neutral points shall be insulated for full voltage.
17.3.10 The completed core and coil assemble shall be dried in vacuum at not more than 0.5mm of mercury
absolute pressure and shall be immediately impregnated with oil after the drying process to ensure the elimination
of air and moisture within the insulation. Vacuum may be applied in either vacuum over or in the transformer tank.
17.3.11 The winding shall be so designed that all coil assembles of identical voltage ratings shall be
interchangeable and field repairs to the winding can be made readily without special equipment. The coils shall have
high dielectric strength.
17.3.12 Coils shall be made of continuous smooth high grade electrolytic copper or aluminium conductor, shaped
and braced to provide for expansion and contraction due to temperature changes.
17.3.13 Adequate barriers shall be provided between coils and core and between high and low voltage coil. End
17.3.14 The insulation of winding shall be designed to withstand voltage stress arising from surge in transmission
lines due to atmospheric or transient conditions caused by switching etc
17.3.15 Tapping shall not be brought out from inside the coil or from intermediate turns and shall be so
arranged as to preserve as far as possible magnetic balance of transformer at all voltage ratios.
17.3.16 Magnitude of impulse surges transferred from HV to LV windings by electromagnetic induction and
capacitance coupling shall be limited to BIL of LV winding.
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17.3.17 The winding conductor shall be of Aluminium. The current density shall not exceed 1.4 Amp/ mm² for
aluminium at normal full load current.
18 BUSHINGS AND TERMINATIONS

18.1 Bushings
18.1.1 Bushings shall be of the outdoor type and easily replaceable. Cemented in types will not be accepted. They
shall be sufficiently robust to withstand normal transport and erection hazards and shall confirm to IEC 137 /IS 3347
and 2099.
18.1.2 All bushings shall have a minimum creepage distance of 25 mm /KV and shall have a continuous rating of
200% of the transformer rating. The protected creepage distance shall not be less than 50% of the total.
The following minimum 11 KV clearance shall be provided:
External (Air) for 11 KV
Phase to phase 280 mm 280mm
Phase to earth 140 mm 140mm
18.1.4 The 11 KV bushings of transformers shall be provided with a bi-metallic terminal connector orsuitable
device to receive 35 –100 mm2 AAAC or ACSR conductor directly without any bimetallic action.
18.1.4 The secondary bushings of transformers shall be fitted with non ferrous threaded terminals. With the
exception of brass the terminals shall be protected from atmospheric deterioration by suitable tinning or by some
other approved coating
.
18.1.5 The terminals are to be supplied with one 16mm bolt, one conic spring washer, one matching flat washer,
one nut and one lock nut for each hole in the terminal plate.
18.2 Bushing Labels

18.2.1 The HV bushings shall be labeled U, V and W and the LV bushing u, v, w and n. Marking letters shall be at
least 12 mm high. The means of marking shall be either,
 engraved metal plate; or
 etched anodized aluminium.
Phase identification by adhesive stickers shall not be acceptable.
18.2.2 If labeling is to be carried out on the tank, it is preferred that one plate be used rather than individual
markings for each phase, in order to prevent incorrect phase markings.
Labels shall conform to the requirements of the section on labels in this specification.
18.3 Earthing Terminals

All transformers shall be provided with two earthing terminals conforming to relevant Standards and M12 ISO metric
bolt and nut which shall be non ferrous. It shall include a spring washer and lock washer.
19 TANK FABRICATION
19.1 All transformer sizes, the tank shall be of bolted type construction in accordance with IS 1180 (Part 2).
 The tank shall be at atmospheric pressure at an internal temperature of 10°C;
 The tank shall be designed for an internal pressure of 100 Kg/ m2 at 50° C ambient conditions. It shall be
capable of withstanding an unlimited number of 24 hours cyclic variations of internal pressure from
atmospheric to this value.
 The tenderer shall state the top oil temperature at which the tank internal pressure shall reach the value of
100 kN/ m2 and the value of steady load which will result in this top oil temperature with an ambient
temperature of 45°C.
Adequate space shall be provided at the bottom of the tank for collection of sediments.
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19.2 Transformer tanks of all types shall be designed so that the completed transformer can be lifted and
transported without permanent deformation or oil leakage. Stiffeners provided on all the four side walls for rigidity
should be so designed that there is no accumulation of water.
19.3 The Tank shall be of rectangular shape with round edges fabricated from tested quality mild steel plates
with minimum thickness of 3.15 mm. for the side walls while top cover and the bottom plate of the tank shall have
a minimum thickness of 5 mm. The transformer tank and the top cover shall be designed in such a manner as to
leave no external pockets in which water can log, or any internal pocket where air/ gas can accumulate.
19.4 All sealing washers / gaskets shall be made of oil and heat resistant neoprene rubber or neoprene bonded
cork seals suitable for temperature as stipulated in this specification. Surfaces at gasketted joints shall be such that
an even face is presented to gasket, thereby eliminating the necessity for the gasket to take up surface
irregularities.
19.5 All pipes, radiators, stiffeners or corrugations which are welded to the tank wall shall be welded externally
and shall be double welded wherever possible. All welds shall be stress relieved.
19.6 The transformer tank shall be complete with all accessories, lifting lugs etc. and shall be designed to allow
the complete transformer filled with oil to be lifted by crane or jacks without risk of any damage and can be
transported by Rail/ Road without straining any joints and without causing any leakage of oil.
20 PRESSURE RELIEF DEVICE

Transformers shall be fitted with a pressure relief device in the form of explosion vent. The tenderer shall state the
pressure at which it is designed to operate.
21 OIL LEVEL GAUGE

A suitable oil level gauge (Magnetic type) shall be fitted on the transformers and so located that it can be easily
read from ground level. The gauge fitted with the conservator shall be graduated for temperatures of 5°C, 30° C
and +98° C.
22 CONSERVATORS AND BREATHERS

All the transformers shall be provided with a conservator tank.
22.1 The conservator tank shall be so designed and located as to eliminate any trapping of air in the transformer or
pipe work. It shall be inclined at an angle of about 5 degrees to the horizontal towards the drain plug and the pipe
connecting the main tank to the conservator should project about 20 mm above the bottom of the conservator so as
to create a sump for the collection of impurities. Minimum oil level corresponding to 50 C shall be well above the
sump level.
22.2 All transformers shall be fitted with a silica gel breather of weatherproof design at a convenient height with oil
seal at the bottom, draw in plug and filling holes with covers to isolate the silica gel from the atmosphere. The
breather pipe should be connected at top of the conservator tank with two bends at right angles. The cover of the
main tank and bushings turrets shall be provided with air release plug to enable the trapped air to be released.
23 FITTINGS AND ACCESSORIES

23.1 The following standard fittings and accessories shall be provided :
 rating, diagram and terminal marking plate.
 Two earthing terminals .
 lifting lugs/ platform lugs.
 pressure relief device or explosion vent.
 silica gel breather.
 a magnetic or prismatic oil level gauge for all transformers indicating three position ( 3) of oil - minimum.
5°C, 30°C and 98°C.
 Top filter valve with locking arrangement.
 Bottom filter valve with locking arrangement.
 Air release plugs at transformer top cover, bushing turrets etc.
 Set of Radiators.
 Conservator Tank
Bi-metallic terminals on the bushings for connection with over head ACSR/ AAAC conductor. The Specification
and brief details of the salient features of these terminals should be stated.
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25 TRANSFORMER OIL
The transformers shall be supplied complete with first filling of transformer oil upto maximum permissible level. The
quantity of oil required for the first filling of the transformer and its full specification shall be stated in the bid. The
complete first filling shall be of new oil free from inhibitors and additives up to maximum permissible level for the
supplied Transformer. The bidder shall quote the price of transformer including the cost of Transformer Oil required
for initial filling.
The insulating oil for the transformer shall be of EHV grade, generally conforming to IEC: 296/ BS: 148/ REC: 39/
1993 or latest version of IS: 335/ 1983 whichever is more stringent. No inhibitors shall be used in the oil. The
dielectric strength of the oil shall not be less than 60 KV at 2.5 mm. gap when tested in accordance with IS: 6792/
1972. If an anti-oxidant inhibitor is recommended, its use shall be subject to the Employer’s approval.
The design and materials used in the construction of the transformer shall be such as to reduce the risk of the
development of acidity in the oil.
The contractor shall warrant that oil furnished is in accordance with the following specifications.
S.No Characteristic Requirement Method of Test
01 Appearance The oil shall be clear & A representative

transparent & free from sample of oil shall be
suspended matter or examined in a 100 mm
sediment thick layer at ambient
temp.
02 Density at 20˚C 0.89 g/cm3 Max. IS:1448
03 Kinematic Viscosity at 27 27 CST IS:1448

deg. C Max
04 Interfacial tension at 0.03 N/m IS:6104
27deg.C Min.
05 Flash Point 136°C IS:1448
06 Pour Point Max. -6°C IS:1448
07 Nautralisation Value 0.03 mg KOH/gm IS:335

(Total Acidity) Max.
08 Electric strength 72.5 KV IS:6792
Breakdown (voltage) Min.

09 Dielectric dissipation 0.03 Max IS:6262
factor tan delta at 90° C
10 Min specific resistance 35X1012 ohm cm (min.) IS:6103
(resistively) at 90 deg.C
11 Oxidation stability
12 Neutralization value after 0.40mg KOH/g

oxidation
13 Total sludge after 0.10% by weight max.
oxidation
The oil shall not contain
14 Presence of oxidation anti- IS:335
Inhibitor oxidant Additives.
15 Water content Max: Less than 25ppm IS:2362
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26. RATING AND CONNECTION PLATE

Each transformer shall be provided with a rating plate of weatherproof material showing the following items
indelibly marked :
 type of transformer
 standard to which it is manufactured (preferably IEC 76)
 manufacturer’s name
 transformer serial number
 year of manufacture
 rated frequency in Hz (50)
 rated voltages in KV (11/0.250)
 number of phases (1)
 rated power in KVA
 type of cooling (ONAN)
 rated currents in A
 vector group symbol (Dyn11)
 1.2/50µs wave impulse voltage withstand level in KVp
 power frequency withstand voltage in KV
 impedance voltage at rated current and frequency in percentage at 75° C at normal tap
 Measured load loss in KW at rated current and at 75° C at normal tap
 Measured no-load loss in KW at rated voltage and rated frequency
 continuous ambient temperature at which ratings apply in °C
 top oil and winding temperature rise at rated load in °C
 winding connection diagram
 total weight in kg with complete oil filled.
 total weight of the transformer without oil
 volume of oil in litres.
 weight of core and windings in kg; and
 name of the Employer –RGGVY XI Plan
 The rating plate shall conform to the requirements of the section of Labels in this specification The rating
plate shall conform to the requirements of the section of Labels in this specification.
27. BASE MOUNTING ARRANGEMENT

The under base of all transformers up to 100 KVA capacity shall be provided with two 75x40 mm channels, 460
mm long with holes of 14 mm dia at a centre to centre distance of 415 mm to make them suitable for fixing on a
platform or plinth.
27 (a) PUNCHINGS: Punching and embossing of Volume of oil in litres, name of the Employer-EMPLOYER, Name
of the Manufacturer – M/s ------------- , Year of Manufacture, Guarantee Period and Sl. No. of each transformer is to
be made on top core channel, top cover, side walls and name plates of transformers alongwith word- RGGVY XII
plan.
28. PAINTING
28.1 All paints shall be applied in accordance with the paint manufacturer’s recommendations. Particular attention
shall be paid to the following:
28.2
28.3 All paints, when applied in normal full coat, shall be free from runs, sags, wrinkles, patchiness, brush marks or
other defects.
28.3.1 All primers shall be well marked into the surface, particularly in areas where painting is evident, and the first
priming coat shall be applied as soon as possible after cleaning. The paint shall be applied by airless spray according
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to the manufacturer’s recommendations. However, wherever airless spray is not possible, conventional spray be
used with prior approval of Employer.
28.3.2 The manufacturer shall, prior to painting protect nameplates, lettering gauges, sight glasses, light fittings
and similar such items.
28.4 Cleaning and Surface Preparation
28.4.1 After all machining, forming and welding has been completed, all steel work surfaces shall be thoroughly
cleaned of rust, scale, welding slag or spatter and other contamination prior to any painting.
28.4.2 Steel surfaces shall be prepared by Sand/Shot blast cleaning or Chemical cleaning by Seven tank process
including Phosphating to the appropriate quality.
28.4.3 The pressure and Volume of the compressed air supply for the blast cleaning shall meet the work
requirements and shall be sufficiently free from all water contamination prior to any painting.
28.4.4 Chipping, scraping and steel wire brushing using manual or power driven tools cannot remove firmly
28.5 Protective Coating

28.5.1As soon as all items have been cleaned and within four hours of the subsequent drying, they shall be given
suitable anticorrosion protection.
28.6 Paint Material

Followings are the type of paints that may be suitably used for the items to be painted at shop and supply of
matching paint to site:
i) Heat resistant paint(Hot oil proof) for inside surface.
ii) For external surfaces one coat of Thermo Setting Paint or 2 coats of Zinc chromate followed by 2 coats of
Synthetic Enamel paint. The color of the finishing coats shall be dark admiral grey conforming to No.632 or IS
5:1961.
28.7 Painting Procedure

28.7.1 Al painting shall be carried out in conformity with both specifications and with the paint manufacture’s
recommendations. All paints in any one particular system. Whether shop or site applied, shall originate from one
paint manufacturer.
28.7.2 Particular attention shall be paid to the manufacturer’s instructions on storage, mixing, thinning and pot life.
The paint shall only be applied in the manner detailed by the manufacturer e.g. brush, roller, conventional or airless
spray and shall be applied under the manufacturer’s recommended conditions. Minimum and maximum time
intervals between coats shall be closely followed.
28.7.3 All prepared steel surfaces should be primed before visible re-rusting occurs or within 4 hours whichever is
sooner. Chemical treated steel surfaces shall be primed as soon as the surface is dry and while the surface is warm.
28.7.4 Where the quality of film is impaired by excess film thickness,(wrinkling, mud cracking or general softness)
the manufacturer shall remove the unsatisfactory paint coatings and apply another. As a general rule, dry film
thickness should not exceed the specified minimum dry film thickness by more than 25%. In all instances, where
two or more coats of the same paints are specifies, such coatings may or may not be of contrasting colors.
28.7.5 Paint applied to items that are not be painted, shall be removed at manufacturer’s expense, leaving the
Surface clean, un-stained and undamaged.
28.8 Damages to Paints Work

Any damage occurring to any part of the painting scheme shall be made good to the same standard of corrosion
protection and appearance as that originally employed.
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Any damaged paint work shall be made as follows:
a) The damaged area, together with an area extending 25mm around its boundary, shall be cleaned down to bare
metal.
b) A priming coat shall immediately applied, followed by a full paint finish equal to that originally applied and
extending 50mm around the perimeter of the originally damaged. The repainted surface shall present a smooth
surface. This shall be obtained by carefully chamfering the paint edges before & after priming.
28.9 Dry Film Thickness

To the maximum extent practicable, the coats shall be applied as a continuous film of uniform thickness and free of
pores. Over-spray, skips, runs, sags and drips should be avoided. The different coats may or may not be same
color.
Each coat of paint shall be allowed to harden before the next is applied as per manufacture’s recommendations.
Particular attention must be paid to full film thickness at edges.
The requirement for the dry film thickness(DFT) of paint and the material to be used shall be as given below:
Sl. Paint Type Area to be No of Total Dry film

No painted Coats thickness(Min)
1. Powder Paint Inside 01 30 Micron
(2) Thermo setting powder Outside 01 60 Micron
2. Liquid paint
a) Epoxy (Primer) Out side 01 30 micron
b) P.U.Paint(Finish Coat) Out side 02 25 each
c) Hot Oil paint /Varnish inside 01 35/10 micron
29 SEALING GASKETS
All sealing washers / gaskets shall be made of oil and heat-resistant Nitrile/ Neoprene rubber/ synthetic rubber
bonded cork type RC-70C gaskets. Gaskets made of natural rubber or cork sheet are not permissible.
30 SUPRESSION OF HARMONICS
The transformer shall be designed with attention to the suppression of harmonic voltage, especially the third and
fifth.
31 TESTS
31.1 Routine Tests
Routine tests shall be carried out on all transformers and the tests shall be conducted in accordance with relevant
National/ International Standards. No sampling is allowed. In addition, tank tests in accordance with IS:1180 shall
be carried out.
The following routine measurements and tests shall be carried out in presence of Employer’s authorized
representative(s):
a) measurement of winding resistance.
b) voltage ratio measurement and check of polarity and vector group. Bushing positions shall have permanent
markings at this stage of production;
c) measurement of impedance voltages/ short circuit impedance at rated current and frequency
d) measurement of load loss at full load and 75°C;
e) measurement of neutral unbalance current;
f) temperature rise test on one transformer of each rating and measurement of hot resistance.
g) measurement of no-load loss and no-load currents at full, 50%, 75%, 90%, 110%, 112.5% and 120% of rated
voltages;
h) induced over voltage withstand test at 22KV for 60 sec on the HV windings;
i) power frequency voltage withstand tests on HV and LV windings;
j) magnetic balance test
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k) Polarization Index test P.I. value shall be not less than 1.5. P.I. = IR at 600 sec / IR at 60 sec.
l) oil leakage test : The criterion of leakage shall be discoloration by oil of whitewash applied externally to
suspected parts at an oil temperature of 90°C or other method, as approved by the Employer;
m) pressure test on transformer tank on one unit for each rating.
Bushings and oil shall be subject to the following routine tests.
n) bushing routine test: in accordance with IEC 137/IS 3347;
o) oil dielectric and moisture content test: conforming to IEC 156 or IS 335.
Routine test certificates shall include in addition to the test results, the Employer’s order number, the transformer
serial number, outline drawing number and transformer KVA rating. Any other applicable tests shall be conducted at
the discretion of the Employer without any extra cost to Employer.
31.2 Type Tests

31.2.1 The measurements and tests should be carried out in accordance with the standard specified in each
case as indicated in the following table if the same tests were not conducted earlier at CPRI or any NABL
accredited Laboratory on the transformers of the offered design without any cost implication and employer.

Type Test Standard

2026/IS6600
Impulse Voltage Withstand Test, including Full Waves and IEC 76/IS 2026
In accordance with IEC 76-3 the following sequence of impulses should have been/ should be applied;

31.2.2 If the type test report(s) submitted by the bidder do not fulfil the criteria, as stipulated in this technical
specification/ Bidder’s offer, the relevant type test(s) has/ have to be conducted by the Bidder at his own cost
in CPRI/ NABL accredited laboratory in the presence of employers representative(s) without any financial
liability to employer in the event of order placed on him.
31.2.3 The offeres transformer must be manufactured as per type tested design. A copy of type test
certificate must be submitted by manufacturer to Engineer/Employer. Transformers offered without type
tested however design shall not be accepted. In case manufacturer agrees for type testing of transformers,
testing shall be conducted on manufacturer’s cost. No claim shall be acceptable towards type testing. The
transformers shall be accepted only on acceptane of type testing results by employer.
31.2.4 The supplier shall furnish calculations in accordance with IS: 2026 to demonstrate the Thermal ability
of the transformers to withstand Short Circuit forces.
31.3 TEST VOLTAGE

Transformers shall be capable of withstanding the Power frequency and Impulse test voltage as described below:
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Nominal system Highest System ImpulseTest Power frequency

voltage voltage voltage test voltage
250 V (rms) 3 KV (rms)
11 KV (rms) 12 KV (rms) 75 KV (Peak) 28 KV (rms)
32. COMPLIANCE WITH SPECIFICATION

The transformers shall comply in all respects with the requirements of this specification.
33. COMPLIANCE WITH REGULATIONS

All the equipment shall comply in all respects with the Indian Regulations and acts in force. The equipment and
connections shall be designed and arranged to minimize the risk of fire and any damage which might be caused in
the event of fire.
34.2 The equipment shall successfully pass all the type tests and routine tests mentioned in the above Clauses and
those listed in the most recent edition of the standards given in Clause 2, of this specification.
34.3 The Employer reserves the right to reject an item of equipment if the test results do not comply with the
values specified or with the data given in the technical data schedule.
34.4 Routine tests shall be carried out by the Manufacturer at no extra charge at their works. Adequate facility with
calibrated testing equipment must be provided by the manufacturer free of cost to carry out the tests. Type test
certificates must be furnished along with the tender for reference of the Employer.
34.5 The Employer will witness all required tests. In order to facilitate this, the Manufacturer shall give the
Employer a minimum of two weeks
34.6 The manufacturer shall submit to the Employer five signed copies of the test certificates, giving the results of
the tests as required. No materials shall be dispatched until issuance of dispatch clearance.
In the case of components for which specific type tests or routine tests are not given in this specification or in the
quoted standards in Clause 2, of this specification, The Manufacturer shall include a list of the tests normally
required for these components. All materials used in the Contract shall withstand and shall be certified to have
satisfactorily passed such tests.
34.7 The Employer at his discretion may re-confirm the Routine Test Results, particularly no load losses, load losses
and percentage impedance in his own laboratory or laboratory of his choice. No inspection or lack of inspection or
passing by the Employer’s Representative of equipment or materials whether supplied by the Manufacturer or sub-
manufacturer, shall relieve the Manufacturer from his liability to complete the contract works in accordance with the
contract or exonerate him from any of his guarantees.
35 GUARANTEE
The manufacturer shall guarantee the following:

 Satisfactory operation during the guarantee period from the date of commissioning, by the Employer
following delivery, whichever is earlier;
 Performance figures as supplied by the tenderer in the schedule of guaranteed particulars;
 The offered surface treatment shall protect the treated metal from corrosion for a period of not less than five
years from the date of delivery.
36 PACKING AND SHIPPING

36.1 Packing
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The equipment and any supporting structures are to be transported adequately sealed against water ingress. All
accessories and spares shall be packed and securely clamped against movement in robust, wooden, non returnable
packing cases to ensure safe transit in rough terrain, cross country road conditions and in heavy rains from the
manufacturer’s works to the work sites/ earmarked destinations.
36.1.1 All accessories shall be carefully packed so that they are fully protected during transport and handling
operations and in storage. Internal surfaces of loose accessories shall be sealed by means of gaskets and blanking
off plates. All parts liable to rust shall receive an anti-rusting coat and shall be suitably protected. It shall be the
responsibility of the Manufacturer to make good any damage caused through insufficient packing.
Each packing case shall be indelibly marked, on two adjacent sides and on the top, with the following:
 Destination;
 Name and address of manufacturer
36.1.2 Each crate or container shall be marked clearly on the outside of the case to show TOP and BOTTOM
positions with appropriate signs to indicate where the mass is bearing and the correct positions for slings. All
component parts which are separately transported shall have permanent identification marks to facilitate correct
matching and assembly at site. Welded parts shall be marked before welding. Six copies of each packing list shall be
sent to the Employer prior to dispatching the equipment.
36.2 Transportation
The Manufacturer shall be responsible for the transport of all plant and equipment supplied by them and for the
transport of all goods to the various specified destinations including all road clearance, offloading, warehousing and
insurance.
The Manufacturer shall inform himself fully as to all relevant transport facilities and requirements and loading
gauges and ensure that the equipment as packed for transport conform to these limitations. The Manufacturer shall
also be responsible for verifying the access facilities specified.
The Manufacturer shall be responsible for the transportation of all loads associated with the contract works and
shall take all reasonable steps to prevent any highways or bridges from being damaged by his traffic and shall select
routes, choose and use vehicles and restrict and distribute loads so that the risk of damage shall be avoided. The
Manufacturer shall immediately report to the Employer any claims made against the Manufacturer arising out of
alleged damage to a highway or bridge. All transport accessories, such as riding lugs, jacking pads or blanking off
plates shall become the property of the Employer.
All items of equipment shall be securely clamped against movement to ensure safe transit from the manufacturer’s
facilities to the specified destinations.
The Manufacturer shall advice the storage requirements for any plant and equipment that may be delivered to the
Employer’s stores. The Manufacturer shall be required to accept responsibility for the advice given in so far as these
arrangements may have a bearing on the behavior of the equipment in subsequent service
37 Hazardous substances
The Manufacturer shall submit safety data sheets for all hazardous substances used with the equipment. The
Manufacturer shall give an assurance that there are no other substances classified as hazardous in the equipment
supplied. No oil shall be supplied or used at any stage of manufacture or test without a certificate acceptable to the
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Employer that it has a PCB content of less than 2 mg/ kg. The Manufacturer shall accept responsibility for the
disposal of such hazardous substances, should any be found.
The Manufacturer shall also be responsible for any injuries resulting from hazardous substances due to non
compliance with these requirements.
38 SUBMITTALS
38.1 Submittals required with the bid
The following shall be required with each copy of the bid :
 Completed technical data schedule;
 Descriptive literature giving full technical details of equipment offered;
 Outline dimensions drawing for each major component, general arrangement drawing showing component
layout and general schematic diagram;
 Type test certificates ( short circuit withstand test and impulse test ) of the offered transformers conducted
at CPRI/ or any National Govt approved Laboratory without which tender will be out rightly rejected.
 Sample routine test reports;
 Detailed reference list of customers already using equipment offered along with performance certificates of
such equipment, during the last 3 (three) years with particular emphasis on units of similar design and
rating;
 Details of manufacturer’s quality assurance standards and programme and ISO 9000 series or equivalent
national certification;
 Deviations from this specification. Only deviations approved in writing before award of contract shall be
accepted;
 List of recommended spare parts and consumable items for five year of operation with prices and spare
parts catalogue with price list for future requirements.
38.2.1 Programme

A copy of installation and commissioning instructions and of the operation and maintenance instructions and trouble
shooting charts shall be supplied with each transformer.
38.3 Drawings
38.3.1 Within 15 days of award of contract, the Manufacturer shall submit 4 complete sets of drawings as detailed
describing equipment in details. These drawings would be duly approved by the Employer after due scrutinisation
and approval will be communicated within 15 days of receipt of these drawings. After the drawings are approved
and communicated to the manufacturer, he would supply ten complete sets of final drawings.
38.3.2 All detail drawings submitted for approval shall be to scale not less than 1:20. All important dimensions shall
be given and the material of which each part is to be constructed shall be indicated on the drawings. All documents
and drawings shall be submitted in accordance with the provisions of this specification and shall become the
property of the Employer.
38.3.3 All drawings and calculations, submitted to the Employer, shall be on international standard size paper,
either A0, A1, A2, A3 or A4. All such drawings and calculations shall be provided with a contract title block, which
shall include the name of the Employer and shall be assigned an unique project drawing number; the contract title
block and project numbering system shall be agreed with the Employer.
38.3.4 Script sizes and thickness of scripts and lines be selected so that if reduced by two stages the alphanumeric
characters and lines are still perfectly legible so as to facilitate microfilming.
38.3.5 For presentation of design drawings and circuit documents IEC Publication 617 or equivalent standards for
graphical symbols are to be followed. The drawing approval will be communicated within 15 days from the receipt
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of drawings from the tenderer and for any delay in furnishing the drawings, if delivery period will be delayed, no
extension of delivery time will be granted due to this.
d. Drawings giving the weights for foundations each .
e. Drawing showing details such as clamping arrangements of core, core assembly showing oil duct section of HT
and LT coils with conductor size showing insulation arrangements of windings and their reinforcement to withstand
short circuit stresses, in side tank dimensions showing core assembly. Details of core and windings, as enumerated
at Cl. No. 17 of this part of Specification shall be indicated in the above drawings.
f. Schematic diagram showing the flow of oil in the cooling system as well as each limb and winding. Longitudinal
and cross- sectional views showing the duct sizes, cooling pipe etc. For transformer/ heat exchanger, drawn to scale
shall be furnished.
g. Large Scale drawings of high and low tension winding of the transformers showing the nature
and arrangements of insulation and terminal connection.
h. Test Reports
39 FASTENERS
39.1 All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the appropriate Indian
Standards for metric threads, or the technical equivalent.
39.2 Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring terminals. All nuts
and pins shall be adequately locked.
39.3 Wherever possible, bolts shall be fitted in such a manner that in the event of failure of locking resulting in the
nuts working loose and falling off, the bolt will remain in position.
39.4 All ferrous bolts, nuts and washers placed in outdoor positions shall be of anti-corrosive materials except high
tensile steel bolts and spring washers which shall be electro-galvanized to service condition stated elsewhere in the
Specification. Appropriate precautions shall be taken to prevent electrolytic action between dissimilar metals where
bolts are used on external horizontal surfaces and where water can collect, methods of preventing the ingress of
moisture to the threads shall be provided. Each bolt or stud shall project at least one thread but not more than
three threads through the nut, except when otherwise approved for terminal board studs or relay stems. If bolts
nuts are placed so that they are inaccessible by means of ordinary spanners, special spanners shall be provided.
The length of the screwed portion of the bolts shall be such that no screw thread may form part of a shear place
between members. Taper washers shall be provided where necessary. Protective washers of suitable material shall
be provided front and back on the securing screws.
40. LABELS
40.1 All apparatus shall be clearly labelled indicating, where necessary, its purpose and service positions. The
material of all labels and plates, their dimensions, legend and the method of printing shall be subject to approval of
the Employer. The surfaces of all labels and plates shall have a mat or satin finish to avoid dazzle from reflected
light. Colours shall be permanent and free from fading. Labels mounted on black surfaces shall have white lettering.
Danger plates shall have white lettering on a red background. All labels and plates for outdoor use shall be of in-
corrodible material. Where the use of enameled iron plates is approved, the whole surface including the back and
edges, shall be properly covered and resistant to corrosion. They shall be engraved in English. Name plates shall be
white with black engraved lettering and shall carry all the applicable information specified in the applicable items of
the Standards. No scratching, corrections or changes will be allowed on name plates.
40.2 Name plates shall be provided of white background with black engraved lettering carrying all the applicable
information specified in the standards and other details as required by the Employer. The name plate inscription and
the size and lettering shall be submitted to the Employer for approval.
41. PROFORMA FOR STAGE INSPECTION OF DISTRIBYUTION TRANSFORMERS

1. Name of Firm :
4. Details of offer
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(a) Rating
(b) Quantity
(c) Serial Numbers
(b) Serial Numbers
6.
(A) Inspection of Embossing / Punching requirement: whether satisfies the Specification :
deviation if any to be mentioned :
(c) position of manufacturing stage of the offered
QUANTITY :
(c) Core assembled
(i) HV Coils
(ii) LV Coils
NOTE:
(i) A quantity if more than 100 NOs shall not be entertained for stage inspection
(iii) Quantity offered for stage inspection should be offered for final inspection within 15 days from the date of
issuance of clearance for stage inspection, otherwise stage inspection already cleared shall be liable for cancellation.
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33 & 11 KV OUTDOOR TYPE POTENTIAL TRANSFORMER
1. INTRODUCTION
This chapter covers specification of 33kV and 11kV Potential Transformer suitable for outdoor service. Any other
parts not specifically mentioned in this specification but otherwise required for proper functioning of the equipment
should be included by the tender in the offer.
2. APPLICABLE STANDARDS
Unless otherwise modified in this specification, the Potential Transformer shall comply with the latest version of
relevant standards (IS 3156, IS 2099, IS 5621, IS 335, IS 13947(Part I), IEC 186, Indian electricity Rules 2003, IEC
815) or better international standards. This list of standards is for guidance only. The contractor shall be solely
responsible to design & manufacture the PT suitable for 33 kV/11kV systems.
3. AMBIENT CONDITIONS
The PT supplied against this specification shall be suitable for satisfactory continuous operation under the tropical
conditions as detailed in general technical requirement.
4. SYSTEM PARTICULARS
a) Nominal System Voltage 33kV 11kV
b) Highest system Voltage 36kV 12kV
c) Rated Frequency 50Hz 50Hz
d) No of phases Three Three
e) System neutral earthing ---Solidly Earthed--
f) One minute Power Freq. 70kV 28kV

Withstand voltage (rms)
g) Lighting Impulse withstand Voltage 170kVp 75kVp
h) System fault level ---25 kA for 3sec---
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5. TECHNICAL PARAMETERS OF PT
a) Rated primary Voltage 36 KV 12 KV

b) Type Single phase potential transformer
c) Voltage/ Ratio(kV) 33/0.11 11/0.11
d) Rated voltage factor 1.2continuous 1.5 – 30seconds-
e) One minute power freq. Withstand voltage for
Primary Terminals 70 kV(rms) 28 kV

Secondry winding 36 kV 12 KV
f) Min. Creepage Distance 25 mm/kV of Highest System Voltage
g) Detail of secondaries Core I Application Metering
Accuracy 0.5 0.5

Burdan (VA) 100 100
Note: The ratings indicated for instrument transformer are tentative only and may be changed to meet the
requirements.
6. PORCELAIN HOUSING
It shall be single piece of homogeneous, vitreous porcelain of high mechanical & dielectric strength. It will be glazed
with uniform Brown or Dark brown colour with smooth surface finish. The creepage distance for the porcelain
housing shall be at least 25mm per kV.
The contractor shall clearly detail in his bid the details of attaching the metallic flange to porcelain, pressure release
valve and also how primary & secondary terminals shall be brought out.
7. WINDING
i. PRIMARY WINDING
It shall be made of insulated electrolytic copper wire. The neutral end of the winding shall be brought
outside for earthing.
The primary terminal shall be of standard size of 30 mm dia x 80 mm length of heavily tinned (min. thickness 15
micron) electrolytic copper of 99.9 % conductivity.
ii. SECONDARY WINDING
It shall be made of insulated copper wire of electrolytic grade. The terminal box shall be dust free & vermin proof.
The size of the terminal box shall be big enough to enable easy access and working space with the use of normal
tools.
The secondary terminals studs shall be provided with at least 3 nuts and two plain washers. These shall be made of
brass duly nickel plated. The min. stud outer dia shall be 10 mm & length 15 mm. The min spacing between the
centres of the adjacent studs shall be 1.5 time the outer dia of the stud.
iii. POLARITY
The polarity shall be marked on each PT at the primary and secondary terminals.
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8. TANK & HARDWARES
It shall be fabricated of MS steel sheet of min. 3.15 mm for sides & 5 mm for top & bottom. The tank will be finished
with min. 2 coats of zinc rich epoxy paint externally. The inner surface shall be painted with oil resistance white
enamel paint.
All ferrous hardwares, exposed to atmosphere shall be hot dipped galvanized.
9. INSULATION OIL
The first filling of oil in PT shall be in contractor’s scope. The oil shall be as per IS 335.To ensure prevention of oil
leakage, the manufacturer will give following details supported by drawings:
i) Location of emergence of Primary & Secondary terminals
ii) Interface between porcelain & metal tanks
iii) Cover of the secondary terminal box
Any nut & bolt and screw used for fixation of the interfacing porcelain bushing for taking out the terminals shall be
provided on flanges cemented to the bushings & not on the porcelain.
If gasket joints are used, Nitrite Butyl Rubber gasket shall be used. The grooves shall be in machined with adequate
space for accommodating gasket under pressure.
The PT shall be vacuum filled with oil after processing. It will be properly sealed to eliminate breathing & to prevent
air & moisture from entering the tank. The sealing methods/arrangement shall be described by the contractor & be
approved by the owner.
10. OIL LEVEL INDICATOR
The PT shall be fitted with prismatic type oil sight window at suitable location so that the oil level is clearly visible
with naked eye to an observer standing at ground level.
To compensate oil volume variation due to temperature variation, Nitrogen cushion or the stainless steel bellows shall
be used. Rubber diaphragms are not permitted for this purpose.
11. EARTHING
Two earthling terminals shall be provided on the metallic tank of size 16 mm dia & 30 mm length each with one plain
washer & one nut for connection to the station earth mat
12. Junction Box
The junction box shall be of MS sheet having thickness of 2mm, synthetic enamel painted as per procedure
mentioned in General technical Requirement (Min. thickness 55 micron). The shade of junction box shall be 697 of
IS: 5. Disconnecting type terminal blocks for PT secondary lead shall be provided. The junction boxes shall be
weather proof type with gaskets as per section-I (Introduction and general technical requirements) conforming to IP-
55 as per IS-13947 (Part-I).
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One junction box shall be provided for 3 numbers of single phase CT’s and PT’s.
13. LIFTING & MOUNTING ARRANGEMENT
The PT shall be provided with two lifting eyes to lift the PT. This shall be so positioned so as to avoid any damage to
the PT during lifting for installation or transportation purpose. This shall be detailed in General Arrangement drawing.
The PT shall be of pedestal mounting type suitable for outdoor installation on steel/cement concrete structures. All
the clamps, bolts, nut and washers etc. required for mounting the PT on the structure shall be supplied along with
the PT and shall be galvanized. The contractor shall supply all the terminal connectors etc. required for connection to
the PT.
14. TESTING
All Type and Routine Tests shall be as per relevant IS and /or IEC.
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11 & 33 KV OUTDOOR TYPE CURRENT TRANSFORMER
1 INTRODUCTION
This section covers the specification of 33 kV and 11kV Current Transformer suitable for outdoor service. Any
other parts not specifically mentioned in this specification but otherwise required for proper functioning of the
equipment should be included by the tender in the offer. The CTs should normally be installed above VCB. The VCB
& CT should be installed on common mounting structure. In places, where VCB are not provided in the Substation
separate CT mounting structure shall be provided with CTs.
2 APPLICABLE STANDARDS
Unless otherwise modified in this specification, the Current Transformer shall comply with the latest version of
relevant standards (IS 2165, IS 2705(I-IV), IS 2099, IS 5621, IS 2071, IS 335, IS 13947(part I), IEC 185, IEC 270,
IEC 44(4), IEC 171, IEC 60, IEC 8263, IEC 815, Indian electricity Rules 2003) or better international standards. This
list of standards is for guidance only. The contractor shall be solely responsible to design & manufacture the CT
suitable for 33kV & /11 kV systems.
3 AMBIENT CONDITIONS
The CT supplied against these specifications shall be suitable for satisfactory continuous operation under the
tropical conditions. The detail condition is mentioned in General Technical requirement.
4 SYSTEM PARTICULARS
a) Nominal System Voltage 33kV & 11kV
b) Highest system Voltage 36kV & 12kV
c) Rated Frequency 50Hz & 50Hz
d) No of phases Three & Three
e) System neutral earthing -Solidly Earthed-
f) One minute Power Freq. 70kV & 28kV

withstand voltage (rms)
g) Lighting Impulse withstand Voltage 170kVp & 75kVp
i) System fault level -25kA for 3sec-
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5 TECHNICAL PARAMETERS OF CT
a) Type Single phase, dead

tank, outdoor, oil
filled & hermetically
sealed
b) Type of mounting Pedestal type
c) Rated primary current As per BPS
d) Rated Continuous thermal current 120 % of rated

Primary current
e) Rated short time withstand As per IS 2705 Pt. I

Requirement for sec. Winding
f) Rated short time withstand 25kA(RMS)

Current
i) Duration (for primary current 3Sec
of 150amps and above)
ii) Duration (for primary current 1Sec

below 150amps)
g) Rated dynamic withstand 62.5

Current (KA rms)
h) Max temp rise As per IEC-185/ IS 2705
i) Minimum creepage distance 25 mm /KV

of porcelain housing(mm)
j) One minute power frequency 3 kV

Withstand voltage between
Secondary terminal & earth
k) Detail of Secondary Cores Metering Protn.
Current ratio (As per BPS)
Accuracy class 0.5 5P10
Burden (VA) 30 30
Instrument security Factor ≤5 -
Accuracy Limit Factor - 10
Note: The ratings indicated for instrument transformer are tentative only and may be changed to meet the
requirements.
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6 PORCELAIN HOUSING
It shall be single piece of homogeneous, vitreous porcelain of high mechanical & dielectric strength. It will
be glazed with uniform Brown or Dark brown colour with smooth surface finish. The creepage distance for the
porcelain housing shall be at least 25 mm per kV.
7 WINDING
7.1 PRIMARY WINDING
It shall be made of high conductivity rigid copper wire. The primary winding current density shall not exceed
the limit of 1.6 Amp per sq. mm for normal rating.
The design current density for short circuit current as well as conductivity of metal used for primary winding shall be
as per IS 2705. The calculation for the selection of winding cross section shall be furnished by contractor.
The primary terminal shall be of standard size of 30 mm dia x 80 mm length of heavily tinned (min. thickness 15
micron) electrolytic copper of 99.9 % conductivity.
7.2 SECONDARY WINDING
It shall be made of insulated copper wire of electrolytic grade. Type of insulation used shall be described in the offer.
For multi ratio design, the multi ratio will be achieved by reconnection of the primary winding or secondary winding.
The excitation current of the CT shall be as low as possible. The contractor shall furnish the magnetization curves for
all the cores.
The terminal box shall be dust free & vermin proof. The size of the terminal box shall be big enough to enable easy
access and working space with the use of normal tools.
The secondary terminals studs shall be provided with at least 3 nuts and two plain washers, these shall be made of
brass duly nickel plated. The min. stud outer dia shall be 6 mm & length 15 mm. The min spacing between the
centres of the adjacent studs shall be 1.5 time the outer dia of the stud.
7.3 POLARITY
The polarity shall be marked on each CT at the primary and secondary terminals.
7.4 TANK & HARDWARES
The CT will be dead tank type. The tank shall be fabricated of MS steel sheet of min. 3.15 mm for sides & 5 mm for
top & bottom. The tank will be finished with min. 2 coats of zinc rich epoxy paint externally. The inner surface shall
be painted with oil resistance white enamel paint.
All ferrous hardwares, exposed to atmosphere shall be hot dipped galvanized.
7.5 INSULATION OIL
The first filling of oil in CT shall be in contractor’s scope. The oil shall be as per IS 335.
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To ensure prevention of oil leakage, the manufacturer will give following details supported by
drawings:
i) Location of emergence of Primary & Secondary terminals
ii) Interface between porcelain & metal tanks
iii) Cover of the secondary terminal box
Any nut & bolt and screw used for fixation of the interfacing porcelain bushing for taking out the terminals shall be
provided on flanges cemented to the bushings & not on the porcelain.
If gasket joints are used, Nitrite Butyl Rubber gasket shall be used. The grooves shall be machined with adequate
space for accommodating gasket under pressure.
The CT shall be vacuum filled with oil after processing. It will be properly sealed to eliminate breathing & to prevent
air & moisture from entering the tank. The sealing methods/arrangement shall be described by the contractor & be
approved by the owner.
7.5.1 OIL LEVEL INDICATOR
The CT shall be fitted with prismatic type oil sight window at suitable location so that the oil level is clearly
visible with naked eye to an observer standing at ground level.
To compensate oil volume variation due to temperature variation, Nitrogen cushion or the stainless steel
bellows shall be used. Rubber diaphragms are not permitted for this purpose.
7.6 EARTHING
Two earthling terminals shall be provided on the metallic tank of size 16 mm dia & 30 mm length each with
one plain washer & one nut for connection to the station earth mat
7.7 Junction Box
The junction box shall be of MS sheet having thickness of 2mm, synthetic enamel painted as per procedure
mentioned in General Technical Requirement (Min. thickness 55 micron). The shade of junction box shall be 697 of
IS: 5. Disconnecting type terminal blocks for CT secondary lead shall be provided. The junction boxes shall be
weather proof type with gaskets, as per section-I (Introduction and general technical requirements) conforming to
IP-55 as per IS-13947 (Part-I).
7.8 LIFTING & MOUNTING ARRANGEMENT
The CT shall be provided with two lifting eyes to lift the CT. This shall be so positioned so as to avoid any
damage to the CT during lifting for instillation or transportation purpose. This shall be detailed in General
Arrangement drawing.
The CT shall be of pedestal mounting type suitable for outdoor installation on steel/cement concrete
structures. All the clamps, bolts, nut and washers etc. required for mounting the CT on the structure shall be
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supplied along with the CT and shall be galvanized. The contractor shall supply all the terminal connectors etc.
required for connection to the CT.
7.9 TESTING
All Type and Routine Tests shall be as per relevant IS and/or IEC.
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11 KV AND 33 KV VACUUM CIRCUIT BREAKERS
1) SCOPE
This specification covers design, manufacturing, testing at manufactures works, supply of 11KV and 33 KV Vacuum
Circuit Breakers complete with all accessories required for their satisfactory operation for the sub-transmission
system. The Breakers shall be used for Transformer protection or Feeder Control, in the system.
2) TYPE AND RATING
The circuit breakers shall be suitable for outdoor operation under the climatic conditions, as specified in Tender
specification, without any protection from sun and rain.
The circuit breakers shall have the following rating:-
S.No. PARTICULARS 33 KV 11 KV
i) Number of Poles 3 Nos.
ii) Frequency 50 Cycles
iii) Nominal System Voltage 33 KV 11 KV
iv) Highest System Voltage 36 KV 12 KV
v) Interrupting Capacity at nominal system voltage 1500 MVA 1500 MVA
vi) Rated Continuous Current 1250 Amps 1250 Amps
vii) Short-time Current Rating for 3 Secs. 25 KA 25 KA
viii) Basic Insulation Level 170 KV 75 KV
ix) Power Frequency Withstand Voltage for one Minute 70 KV 28 KV
x) Total Break-time for any Current up to the rated breaking 5 cycles (max.)
current
xi) Control Circuit Voltage 30 Volt D.C.
xii) Operating duty for gang operation O – 0.3 Sec – CO – 3 Min – CO
xiii) The VCBs shall be suitable for one reclosing followed by one
delayed reclosing and lock out
Minimum clearances
a) Between Phases 430 mm 280 mm
b) Between Live Parts & Ground 3700 mm 2750 mm
c) Creepage Distance 900 mm 300 mm
The above are our minimum requirements. The manufacturers may offer their standard design, keeping in view our
minimum requirements.
3) STANDARDS
The circuit breakers shall comply with the requirements of IEC 56 or IS 13118 (1991) with latest amendment thereof,
except wherein specified otherwise. Equipment, meeting any other authoritative standard, which ensures equal or
better quality then the standard mentioned above, would also be acceptable. The bidders shall clearly indicate the
applicable standards to which their equipments complies-with. A copy of such standard may also be enclosed.
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4) GENERAL
The circuit breaker shall be of porcelain clad vacuum type. The breaker, complete in all respect, shall be supplied
with all accessories in-place and all internal wiring installed and terminated in the mechanism housing and the
equipment shall be complete in all respects.
The circuit breakers shall provide rapid and smooth interruption of current under all conditions, completely
suppressing all undesirable phenomena, even under the most severe and persistent short-circuit conditions or when
interrupting small currents or leading/ lagging reactive currents. The details of any device incorporated to limit or
control the rate of rise of Restriking voltage across the circuit breaker contacts shall be stated. The over voltage
caused by the circuit breaker switching on inductive or capacitive load shall not exceed 3.2 times the normal phase to
neutral voltage. The total break-time for the circuit breaker, throughout the range of breaker operating duty, shall be
stated in the tender and shall be guaranteed. The breaker shall be fit for capacitor switching for 5 MVAr Bank.
The breakers shall be provided with trip free mechanism.
The circuit breakers shall be suitable for mounting on steel structures. The cost of necessary frames for mounting the
circuit breakers shall be included in the offered prices. Strongly supported bracket or frame, for mounting associated
3 nos.11 KV / 33 KV CTs, shall also be provided. All the structures shall be hot dip galvanized with 3 dips. Please note
that cantilever type supports for mechanism box are not acceptable. The mechanism box shall have firm supports
from bottom. This is necessary to minimize vibration of mechanism box, which in turn may disturb various settings.
The agency shall indicate clearly the vibration level of the breaker during fault / normal ON OFF operations in all
three directions.
The owner intends to operate 11 KV and 33 KV feeders with automatic reclosing scheme, the arrangement envisaged
is as under:-
On the occurrence of a fault the concerned protective relay will open the circuit breaker as per its own characteristic.
Thereafter, the breakers shall re-close but after pre-set time delay, which shall be adjustable (say range 4 – 10 sec.
or near about). There shall be no further automatic reclosing. A simple type of reclosing relay (reputed make) for this
purpose shall be provided under this kind of operation. It is also necessary that the breaker shall be suitable for this
reclosing duty. The auto-recloser relay is to be installed in respective indoor control panels.
5) SPECIFICATION FOR CIRCUIT BREAKERS
The circuit breakers shall consist of three identical phase units with a common operating mechanism. While offering
the circuit breaker, the following details should be confirmed and furnished with the tender:-
i) Complete construction details of the equipment offered. It should be noted that the breakers should be
suitable for out-door duty. Indoor breakers accommodated in out-door kiosks are not acceptable.
ii) Type, make & source of vacuum bottles with relevant details shall be indicated in the offer, clearly.
iii) The capacity of breaker to interrupt inductive and capacitive currents shall be indicated in the offer
(rating of capacitor bank should be stated and type test report shall be furnished).
iv) Spare availability of vacuum interrupter should be confirmed by the bidder for the designed expected
life of the breakers being offered.
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6) VACUUM INTERRUPTER
The design of the vacuum interrupter shall be such that it gives trouble free operation under normal load and fault
conditions throughout the life of the equipment. As the efficiency of the breaker depends on the degree of vacuum
inside the interrupter, manufacturer shall ensure that the same is maintained consistently during service. To know
the residual life of vacuum interrupter, an indicator to indicate the status of contact erosion shall be provided.
The insulating ceramic body of the interrupter should have high mechanical strength and it should be capable of
withstanding high temperature without any significant deterioration in its mechanical and electrical properties
The metal/ alloy used for the fixed and moving contacts shall have very low resistivity and low gas content. They
should be resistant to arc erosion and the contact should have no tendency to get cold-welded under the high
vacuum in the interrupter.
The interrupter design should ensure rapid de-ionization of the gap so that normal electrical strength of the gap is
restored instantaneously.
The metallic bellow or any other similar vacuum sealing arrangement should be provided at the moving contact and
should have a long fatigue life.
Manufacturer’s catalogue on vacuum bottle, indicating all the details shall essentially be submitted with the tender.
7) MOUNTING OF 11 KV / 33 KV CTs
The offered steel structures for breakers to be supplied by the bidders should have provision and adequate strength
to accommodate 3 nos. 11 KV / 33 KV CTs on it after provision of suitable supports from ground.
8) TEMPERATURE RISE
The maximum temperature attained by any part of the equipment, when in service at site, under continuous full load
conditions, exposed to the direct rays of the sun, shall not exceed 45° Centigrade, above ambient temperature. The
limits of temperature rise shall be as per relevant standards. The corrections proposed shall be stated in the tender
and shall be subject to approval of the owner.
9) INSULATION OF THE CIRCUIT BREAKER
The insulation to ground, the insulation between open contacts and the insulation between phases of the completely
assembled circuit breaker shall be capable of withstanding satisfactorily di-electric test voltage corresponding to
specified basic insulation level in the standard.
10) INSULATORS
The basic insulation level of the Insulator and insulating porcelains shall be as specified and porcelain shall be
homogenous and free from cavities and other flaws. They shall be designed to have ample insulation, mechanical
strength and rigidity for satisfactory operation under conditions specified above. All insulators of identical ratings shall
be inter-changeable. The puncture strength of the insulators shall be greater than the flash over value. The
insulators shall be type tested from independent Govt. Laboratory as per relevant standards or at any recognized and
reputed international laboratory or testing institutions.
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11) OPERATING MECHANISM
The circuit breakers shall be designed for remote control from the control room and in addition there shall be
provision for manual operation of circuit breakers during maintenance and for local tripping and closing by the
normal means.
The circuit breakers shall have operation control and mechanical “open” “close” indicator, in addition to facilities for
remote electrical indication.
The operating mechanism shall be of the spring charging type, by electric control under normal operation. The
mechanism shall be trip free electrically and mechanically. The mechanism shall be capable of performing
satisfactorily, the reclosing duty cycles indicated above, within the time specified. All working parts in the mechanism
shall be of corrosion resistant material and all bearings, which require greasing, shall be equipped with pressured
grease fittings. The mechanism shall be strong positive quick in action and shall be removable without disturbing the
other parts of the circuit breaker. The mechanism and breaker shall be such that the failure of any spring will not
prevent tripping and at the same time will not cause any false tripping or closing. The operating Mechanism should
be motor operated spring charged type preferably without chain drive. The motor for spring charging shall be
suitable to perform satisfactorily for input supply voltage of 230 Volt A.C. 50 Hz with a variation of plus 10 and minus
20 percent. The A.C. Motor should have overload protection. Provision should also be made for mounting of
mechanism box at an adequate height and gear ratios shall be so chosen that one man should be able to charge the
spring, without any additional efforts.
12) CONTROL CUBICLE
A common control cubicle shall be provided to house electrical, controls, monitoring devices and all other accessories,
except those which must be located on individual poles. The cubicle shall be gasketed and shall have weather-proof
construction, fabricated from sheet steel of minimum 2.5 mm thickness. The type test report on degree of protection
test (IP-55) shall also be furnished.
The cubicle shall have front access door with lock and keys, space heater, internal illumination lamp, 3 pins 5 Amp
socket with individual ON-OFF switches shall be provided in the cubicle.
For local operation following shall be provided:-
a) LOCAL / REMOTE selector switch

b) TRIP / NORMAL / CLOSE control switches with pistol grip handle
The control circuits shall be designed to operate on 30 Volt DC, as indicated in the schedule and it shall be possible
to adopt to work on other voltages by simply changing the operating coils. The shunt tripping coils shall be designed
to operate satisfactorily within 110% and 70% of the rated DC supply voltage and the shunt closing coils should
operate up to 85% of the rated DC voltage. These checks shall be repeated during pre-commissioning checks at site
before putting the breakers in service.
AC Power supply for auxiliaries will be available at 230 Volt (+/- 10% variation) single phases 50 C/s at substation.
The agency shall be required to extend this supply, using proper protection, to desired location through cable.
Necessary double compression type cable glands for the cables of the operating mechanism shall be provided. The
cables used for operation are all un-armoured 2.5 sq. mm copper control cables of 1100 V grade. The cable glands
shall be suitable for 1 no. 8 core and 2 nos. 4 core cables and cables as per site requirements. The gland plate
should be made of non-magnetic materials and suitably drilled at site to suit the cable entry.
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The Circuit breaker shall be provided with trip free Mechanism so that tripping instructions could over-ride the closing
instructions. An additional tripping coil shall also be provided in the trip circuit. The second coil shall have separate
tripping lever arrangements in the mechanism, so as to avail full advantage of second trip coil. Also the two trip coils
shall have separate fuses in the DC circuit, so that in the event of any short circuit/damage in any one of the trip
coils, the supply is available to the other one.
The circuit diagram of Control circuit of VCB along with operating instructions (DOS/ DON’T) shall be embossed on
metallic plate duly laminated and the same shall be fixed on the rear door of the control cubicle from inside.
13) WIRING
Wiring shall be completed in all respects to ensure proper functioning of the control, protection, monitoring and
interlocking schemes.
All the wiring shall be carried out with 1100 V grade, PVC insulated stranded copper conductor of 2.5 sq. mm as per
IS: 1554.
Each wire shall be identified at both ends with permanent markers bearing wire numbers as per wiring diagram.
Wire termination shall be done with crimping type connectors with insulating sleeves. Wires shall not be spliced
between terminals.
All spare contacts of auxiliary switches etc. shall be wired up to terminal blocks in the control cubicle.
14) TERMINAL BLOCKS
Terminal blocks shall be of 1100 V grade, box clamp type ELMEX 10 sq. mm or approved equivalent. Not more than
two wires shall be connected to any terminal. Spare terminals, equal in number to 20% of active terminals, shall be
provided.
Terminal block shall be such located to allow easy access. Wiring shall be so arranged that individual wires of an
external cable can be connected to consecutive terminals.
15) TERMINAL CONNECTORS
6 Nos. Terminal bi-metallic connector suitable for Dog conductors shall be supplied with each breaker. For ensuring
quality and uniformity, the owner may decide to specify the design of terminal connector, the material of terminal
connector and thickness of clamps. Further compliance of which will have to be done by the agency without any
extra cost. Suitable earth connector for earthing connections shall also be supplied. The connector drawing shall be
got approved from the owner.
16) AUXILIARY CONTACTS
Eight numbers each of auxiliary contacts both of the normally open and normally closed types shall be provided in
each circuit breaker for use in the remote indication and control scheme of the circuit breaker and for providing
safety interlocking. Special contacts for use with trip coils, which permit for relative adjustment with respect to the
travel of the circuit breaker contact, shall also be provided, wherever required. There shall be provision to add more
auxiliary contacts at a later date, if required.
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17) ACCESSORIES
The vacuum circuit breaker shall be supplied as a complete unit with internal wiring installed and terminated in
mechanism box and equipped with the following accessories:
1 Motor operated spring charged mechanism 1 No.

(Motor voltage – 230 V AC)
2 Trip coil suitable for 30 V DC 2 Nos.
3 Closing Coil suitable for 30 V DC 1 No.
4 Pistol grip C.B. Control switch having Trip/ Normal/ Close position 1 No.
5 Local/ Remote selector switch 1 No.
6 Spring Charged indicator 1 No.
7 Manual operating handle for maintenance 1 No.
8 Facility for manual charging of spring 1 No.
9 Operation counter 1 No.
10 Auxiliary contacts (8 NO-8 NC) 1 Set
11 Anti-pumping device suitable for 30 V DC 1 No.
12 Terminal connectors suitable for connecting Dog Conductor 6 Nos.
13 Cubicle illuminating lamp with cage and switch 1 No.
14 Spare terminals connectors 20% of Total
Terminals
15 Mechanical ON/OFF Indicator 1 No.
16 MCB for both AC and DC supply 1 No. each
17 Space heater and ON-OFF switch in the mechanism box 1 No.
18 Power Type 3 Pin Socket with ON-OFF switch 1 Set
19 Earthing Terminals 2 Nos.
20 LED indicating lamps Complete set
Indicating Bulbs: The indicating lamps should be supplied with Low Voltage protection Circuit (LVGP) and surge
suppressor circuit having LED indication. Lamp assembly should be of fire – retardant glass epoxy PCB, industrial
heat resistant, fire resistant, non- Hygroscopic DMC material , chrome – plated corrosion resistant solid brass bezel ,
polycarbonate lens in desired colour shades of Red , Green, Amber, Yellow etc. the intensity of light should be
minimum 100 mcd at 20 mA . Indication lamp should be suitable to operate on 30 V Direct Current supply source.
18) TYPE TESTS
Type test certificates on VCB for the following tests, strictly as per IS 13118, with latest amendment thereof, from
any of the independent Govt. Laboratory, or at any recognized and reputed international laboratory or testing
institution, shall invariably furnished :-
 Short Circuit Duty Tests

 Short Time Current Rating Tests
 Mechanical Endurance Test
 Temperature Rise Test
 Lightning Impulse Voltage withstand Test
 Capacitor Switching Duty Test for Single Bank of 5 MVAR capacity
 Power Frequency withstand Voltage Test dry & wet
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 Degree of protection IP-55 for control cubicle
The above type test certificates must accompany drawing of type tested equipment, duly signed by type testing
authority.
The above tests must not have been conducted on the equipment earlier than 5 years from the date of opening of
bids.
In case of any change in design/type of Breaker already type tested and the one offered against this specification,
the owner reserves the right to demand repetition of type tests, without any extra cost.
19) ACCEPTANCE AND ROUTINE TESTS
All acceptance and routine tests, as stipulated in relevant standards, shall be carried out by the manufacturer, in
presence of owner’s representative.
Immediately after finalization of the programme of type testing, the manufacturers shall give, fifteen days advance
intimation to the owner, to enable him depute his representative for witnessing the tests.
20) RATING PLATES
The detailed rating plate shall be as per IS and in addition, shall indicate serial number of the equipment,
manufacturer’s name, our order number and date.
21) EXPERIENCE
Minimum 3 years’ experience in the field of design and manufacture of the equipment offered is essential for the
bidder. Details in this regards shall be clearly stipulated in the offer.
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INDOOR CONTROL PANELS FOR 11 KV & 33 KV VCBs
1) SCOPE: This section contains the technical specification for the Indoor Control, indication, relay and
metering panels associated with the outdoor switchgear for use at various sub-stations. The control and relay
panels and other requirements specified under this section shall be complete in themselves with all main and
auxiliary relays, fuses, links, switches, wiring, labels, terminals blocks, earthing terminals, foundation bolts,
illumination, cable glands etc.
2) PANEL FINISH AND COLOUR: The owner has standardized that the colour finish of control panel shall
be opening green as per colour no. 275 of BS: 381C (1948). Equivalent colour as per relevant Indian Standards or
any other standard shall be acceptable. This colour finish shall be applied to all the exterior steel work of the panels.
The exterior finish shall be semi-glossy only and shall not be fully glossy. The interior of the panels shall be painted
with egg shell white.
3) PROTECTIVE RELAYS AND INSTRUMENTS: The protective relays shall be manufactured, tested and
supplied with the guaranteed particulars, as per following Indian Standard Specifications with latest amendment
thereof :-
i IS-3842 (Part-I) 1967 Application guide for electric relays for A.C. Systems over-
current relays for Feeders and Transformers
ii IS-3842 (Part-IV) 1967 Application guide for electric relays for A.C. System thermal
protection relays
iii IS-3231 (1965) Electric Relay for Power System Protection
iv IS-1885 (Part-I & II) Electro-technical vocabulary Electrical Relays & Electrical Power
System Protection
v All indicating instruments shall conform to IS-722 or BS-89
The equipment meeting any other authoritative standard which ensures equal or better quality than the standards
mentioned above shall also be acceptable. Equipment for which Indian Standards are not available the relevant
British Standards and IEC recommendations will be applicable.
4) STATIC/ MICRO-PROCESSOR BASED OVER CURRENT & EARTH FAULT RELAY:
Static/ Micro Processor based non-directional triple pole IDMT over current and earth fault relays with 2 over current
and 1 earth fault elements. However for transformer protection control panel the relay shall have all the three over
current elements. Relays shall be suitable for 5 Amp. C.T. secondary current and 30 Volts DC auxiliary supply with
1.3/0.6 seconds operating time at 10 times current setting and instantaneous cut off features with setting 4 to 10
times of rated current with arrangement to bypass the features, when not required.
5) CURRENT SETTING RANGE:

 50% to 200% in seven equal steps of 25% for over current elements.
 10% to 40% in seven equal steps of 5% for earth fault element.
However, setting in more than seven steps will be preferred. Further, change of settings under load condition
should be possible without interruption of feeder.
Resetting Current: More than 90% of setting value.
Transient over reach less than 3% on maximum and 5% on minimum setting for primary source angle upto 75
degree. Time of operation 30 seconds at times setting.
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Over shoot time of maximum 80 secs. at 10 times current.

Pick Up Current: 1.1 times the current rating.
Operating Time : 1.3/0.6 secs. at 10 times current with time multiplier 1.0.
The setting should be in 10 times more, fixed calibrated steps from 0.01 to 1.0 and in between variable separately
for over current and earth fault relays.
Resetting Current : More than 90% of setting value.

Resetting Time : Less than 5 m sec.
Burden : Less than 1 VA.
Accuracy : Clause 5
6) CONTACTS :- Two sets of NO contacts (for Trip and Annunciation) self-rest type suitable for make and
break having continuous rating 1250 W/VA and 30 W/VA respectively.
Operational Indicator: Should be provided by way of LED for, ON, O/C 1, O/C 2, E/F, and should fulfill the
following requirements:
 Must give permanent visual signal after fault is cleared and relay has been reset.
 Should operate with pulse time of less than 20 m sec..
 Should not give indication until the trip pulse is being executed.
Other: Facility to re-set indicating lamp manually should be provided. During testing / calibration of relays, facility
for blocking tripping should be provided. Facility for self -monitoring / test should be provided, so that hardware and
software are constantly monitored and irregularities are immediately detected and signaled.
In case of non-draw out type relays test socket alongwith test prob should be provided, so that calibrated current
and values are checked as also current can be injected through and adaptor.
Since the static relay are being procured by us to replace existing Electro Mechanical relays the relays should be
provided with a blanking plate of 18 SWB MS sheet having dimension of 550x250mm and duly painted with gray
paint.
7) TYPE TEST CERTIFICATES FOR RELAYS: The bidders should submit the following type test certificates in
respect of relays offered by them for their control panels:
i) 5 KV Impulse peak voltage test on the relays. This type test report is essential for over current and earth fault
relays.
ii) Type test report for vibration test to prove the stability of relays under vibration normally encountered and also
vibration under abnormal conditions.
iii) Type test report for overshoot time for IDMT relays.
NOTE: Regarding testing of the relays, reference may please be made to BS - 142 - 19. The tenders not
accompanied with the above type test reports shall be rejected.
8) PANEL CUT OUT AND DIMENSIONS:
i) The panels shall be fabricated from 14 SWG steel sheets free from all surface defects. The panels shall have
sufficient structural reinforcement to ensure a plain surface to limit vibration and to provide rigidity during dispatch
and installation. All control panels and switchgear cubicles shall be made absolutely vermin-proof and subjected to
the approval of the owner.
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ii) The panels shall have the following dimensions:-
Height 1475 mm
Width 700 mm
Depth 300 mm
No deviation in height/ depth will be permitted. However, width can be increased depending upon the actual
requirement, which shall be subjected to approval from the owner.
iii) The preferred panel cut out dimensions for mounting of the relays shall be as per Indian Standard Specification
IS-4483 (Part – I & II).
iv) The design, material selection and workmanship shall be such as to present a neat appearance, outside and
inside with no works of welds, rivets, screw or bolt heads apparent from the exterior surface of the Control Panels.
9) PANEL LIGHTING:
a) For interior illumination, an incandescent lamp/ 2 feet fluorescent tube operating at 230 Volt 50 Hz with switch
shall be provided in each panel. The lamp/ tube shall be located at the ceiling and guarded with protective cage.
The switch shall be mounted on one of the side walls and shall be easily accessible.
b) One 5 Amp. 3 Pin receptacle with plug, switch and fuse shall be provided in each control panel.
10) AUXILIARY SUPPLY:
a) For each Control Panel, the owner will provide the following:-
i) 230 V plus 10% minus 20%, 50 Hz neutral grounded A.C. supply.

ii) 30 V ± 10% D.C. supply.
b) H.R.C. fuses shall be provided by the agency for both the A.C. and D.C. power supplies.
c) All H.R.C. fuses and links shall be with holder. The base of fuse holder shall be mounted on slant support and
with identification labels.
11) CONTROL WIRING:
a) The agency shall provide complete wiring up to the terminal block for the equipment, instrument devices
mounted in the control panel strictly according to the wiring diagram prepared by the bidder based on the owner’s
information and schematic diagram and get approved from the owner.
b) The wiring shall be completed in all respects so as to ensure proper functioning of the control, protection and
metering schemes. Agency shall supply, lay and terminate all the control cables between VCB panel, Control panel
(Indoor) and CT.
c) All spare contacts of relays and switches shall be wired up to the terminal block.
d) The Control Panels shall be supplied completely wired ready for owner’s external connections at the terminal
blocks. For CT circuits the wiring shall be carried out with 1100 V Grade PVC insulated stranded copper
conductor of size 2.5 sq. mm. For PT circuits and also for control circuits, the wiring shall be carried out with
1100 Volt Grade PVC insulated stranded copper conductor of size 1.5 sq. mm.
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e) Colour coded wires should be used to facilitate easy tracing, as under:-
i) Three Phase A.C. Circuit:-

Red for R Phase
Yellow for Y Phase
Blue for B Phase
Black for Neutral
ii) Single Phase A.C. Circuit:-

Red for Phase
Green for Earthing
Black for Neutral
iii) D.C. Circuit:-

Red for Positive
Black for Negative
iv) Control Wiring:-

Gray for annunciation and other control circuits.
f) Each wire shall be identified at both ends with wire designation number by plastic ferrules, as per wiring
diagram based on latest revision of IS-375 to denote the different circuit functions. The agency shall take
approval for the system of wire numbering.
g) All wire termination shall be made with solderless compression type connectors. Wires shall not be tapped or
spliced between terminal points. All wire shall have crimp type termination and direct connection at any place is
not at all required.
h) All series connected devices and equipment shall be wired-up in sequence. Loop-in/loop-out system of wiring
shall be avoided, as far as possible and the common buses shall normally be made through the terminal block
for better reliability of testing and maintenance.
i) Fuses and links shall be provided for isolation of individual circuit from the bus wires without disturbing the
other circuits’ and equipments.
j) The DC trip and DC voltage supplies and wiring to main protective gear shall be segregated from these for back
up protection and also for protective apparatus for special purposes. Each such group shall be fed through
separate fuses, either direct from main supply fuses or the bus wires.
k) Since a number of wires will run from one point to another, it is desired that the support arrangement should
be adequate and neat. The conventional method of bunching of wire should not be adopted, since the same
may create problems in case any wire is required to be removed. The wires should be accommodated in plastic
channel with sliding plastic cover mounted inside the panel, suitably. Inspection/removal of wires should be
possible by sliding the covers.
l) Blank plastic channels should be provided by the sides of the panel to accommodate the incoming cables from
switchyard through the cable glands.
m) The circuit diagram of control circuit along with operating instructions (DOS/DON’TS) embossed on metallic
plate duly laminated shall be provided on rear side of the door.
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12) TERMINAL BLOCKS
a) Multi-way terminal blocks complete with necessary binding screws and washers for wire connections and
marking strips for circuit identification shall be provided for terminating the panel wiring and outgoing cables.
The terminal block shall be suitable for receiving atleast 2×7/0.737 mm stranded copper or aluminum conductor
wire per terminal.
b) Terminal blocks shall have shorting and disconnection facilities. The panel-side and outgoing wires should be
dis-connectable just by opening the disconnecting links which slide up or down without dislodging the wires
from their position. Asea-Kirloskar type sliding links shall be provided. However, dis-connectable type terminal
connectors may be limited to CT & PT circuits only.
c) The terminal blocks shall be grouped according to circuit functions and each terminal block group shall have at
least 20% spare terminals.
13) CABLE ENTRY
a) The control panel shall have provision of cable entry from the bottom. One no. cable gland for 8 cores and 2
nos. for 4 core 2.5 sq mm unarmoured cables duly fitted in gland plate and covered shall also be provided. The
agency will arrange for necessary floor opening, below the panels to suit the requirement. Agency shall also be
responsible for laying of control cable in trench, floor opening below the panel, trench cutting and making the
damages good as per the satisfaction of Engineer in charge inside the control room.
b) The wiring through terminal blocks shall be such located so that it is convenient for floor opening.
c) The control panel shall have provisions inside for fixing the multi-core cable glands which shall be included by
the bidder in scope of supply. For fixing these cable glands, detachable gland plates of 4 mm thickness shall be
mounted at least 200 mm above the floor level.
d) The cable gland plate and rear door shall be properly gasketed.
e) Rigid supports shall be provided along the terminal block for holding plastic channel. Suitable clamps may also
be provided in plastic channel for holding cables.
14) GROUNDING
a) 25 mm × 6 mm copper round bus shall be provided extending along with the entire length of the panel and
effectively grounding all metal structures. The earth bus should be designed for suitable inter connection with
adjacent control panel which are to be placed side by side in the control room.
b) Each continuous length of ground bus shall have provision of two terminals at two separate points for
connection to ground.
c) Potential and Current transformer neutrals shall be grounded only at the terminal blocks where they enter the
control panel from the transformer.
d) Wherever a circuit is shown grounded in the drawings, a single wire for the circuit shall run independently to
the ground bus and connected to it.
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15) DOORS
Each panel shall be completed with end enclosing sheets on both sides and door in the rear. There shall be one
door with handle and also turn twist locks at top and bottom. Proper gasketing shall be provided on the door. A
type test report from the recognized Govt. Laboratory on degree of protection test (IP-55) shall also be furnished
with the tender. The doors should be grounded with flexible braided copper conductor of 10 sq.mm.
16) CONTROL AND RELAY PANELS
The control panels required for installation at all the sub-stations shall be of simplex type. The control and indication
apparatus, all meters and relays shall be mounted in the front. The instruments and relays shall be flush pattern.
The labeling for the circuits shall be provided at the front control panel, as well as on the inside wall. All indicating
instruments, meters and important components shall have identification labels from inside also, in addition to
outside. The terminal block shall also have identification labels to them, clearly indicating phase’s identifications and
also circuits and instruments identification. For example, the terminal connector shall have an identification
indicating that CT circuit for metering, for protection etc. Labeling should be provided by using 2 mm thick
aluminium strip embossed with desired information and fitted in the panel sheet by means of rivets.
17) PROTECTION SCHEME
The protection schemes to be supplied under this control shall cover the following equipments:
a) Transformers
b) Overhead sub-transmission lines
The protection schemes are described in the following clauses:-
18) TRANSFORMER PROTECTION :-
Transformer Control Panel is required for control/ protection on both 33 KV and 11 KV sides of 33/ 11 KV
transformers. This will be in the form of a relay set having 2 Nos. O/C and 1 No. E/F elements in 11 KV Control
Panel. In 33 KV Control Panel the relay set shall have 3 Nos. O/C elements. The current settings of O/C relay
elements shall be from 50 to 200% and of E/F relay element from 10 to 40%. They shall be suitable to work on 30
Volt D.C. supply. The secondary rating of C.T. shall be 5 Amps. The over current and earth fault relays shall have
operating time of 1.3 sec. at 10 times of plug setting current. The relays shall be of draw out type with CT shorting
facility. Further, the relays shall have self re-set contacts and hand re-set flag arrangement. Besides this provision
for alarm and tripping due to Buchholtz relay operation, OTI and WTI may be kept in the panel.
19) FEEDER PROTECTION :-
a) Feeder Control Panel is required for control/ protection of both 33 KV & 11 KV sub-transmission lines. This will
be in the form of a relay having 2 Nos. O/C and 1 No. E/F elements. The current settings of O/C relay element
shall be 50 to 200% and of E/F relay element 10 to 40%. They shall be suitable to work on 30 Volt D.C. supply.
The secondary rating of C.T. shall be 5 Amps. The over current and earth fault relays shall have operating time
of 0.6 sec. at 10 times of plug setting current (in case of 11 KV Control Panels) and 1.3 sec. at 10 times of plug
setting current (in case of 33 KV Control Panels). In this case also, the relays shall be of draw out type with C.T.
shorting facility. Further, the relays shall have self re-set contacts with hand reset flag arrangement.
b) The feeder control panel shall also have auto re-closing scheme. The re-closing relay time shall be adjustable
between 4 to 10 sec. or near about in case of 11 KV Control Panel. In case of 33 KV Control Panel the reclosing
relay time shall be adjustable between 10 sec. to 60 sec. for 1 st shot and 30 to 180 sec. for 2nd shot after the
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repeat of tripping pulse from the protective relay. Suitable adjustment knob for the same shall be provided on
the front of the relay for this purpose.
20) CONTROL AND INDICATING CIRCUITS
The control and relay panels shall have the following instruments, relays and accessories:-
1 no. - 3 Pole static type / software based relay, flush pattern, having 3 Nos. O/C element (settings 50 to 200%),
suitable for operation on 30 V DC and 5 Amp. CT secondary rating (for 33 KV Transformer Control Panel). The relay
shall have operating time of 1.3 seconds at 10 times of plug setting current, as mentioned above.
1 no. - 3 Pole static type / software based relay, flush pattern, having 2 Nos. O/C element (settings 50 to 200%)
and 1 No. E/F element (settings 10 to 40%), suitable for operation on 30 V DC and 5 Amp. CT secondary rating (for
33 KV Feeder Control Panel, 11 KV Feeder Control Panel and 11 KV Transformer Control Panel). The relay shall have
operating time of 1.3/ 0.6 seconds at 10 times of plug setting current, as mentioned in above para.
1 Set – provision for alarm and tripping due to Buchholtz relay operation, OTI and WTI may be kept in the 33 KV
transformer control panel.
1 Set - Auto reclosing relay with adjustable time delay between 4 seconds to 10 seconds.
(for 11 KV Feeder Control Panel only).
1 Set - Auto reclosing relay with adjustable time delay between 10 seconds to 60 seconds for 1 st shot and 30 to
180 seconds for 2nd shot (for 33 KV Feeder Control Panel only).
1 no. - Auto/ manual selector switch (for panels with auto reclosing relays).
1 no. - Circuit Breaker Control switch (Push Button type) having Trip/ Neutral/ Close positions.
4 nos. - Lamps for circuit breaker “ON”, “OFF”, “TRIP CKT HEALTHY” and “AUTO TRIP” indications. LED indicating
lamp complete with static circuits and features should be supplied with Low voltage protection circuit (LVGP) and
surge suppressor circuit having LED indication. Lamp assembly should be of fire – retardant glass epoxy PCB ,
industrial heat resistant, fire resistant, non hygroscopic DMC material, chrome – plated corrosion resistant solid
brass bezel, polycarbonate lens in desired colour shades of Red, Green , Amber, Yellow etc. the intensity of light
should be minimum 100 mcd at 20 mA . Indication lamp should be suitable to operate on 30 V direct current
supply source. Acceptable make are BINAY Opto Electronic Private Ltd. or equipment.
1 no. - Ammeter 96 sq. mm. Square MISC type flush pattern having class 1.0 accuracy. The ammeter shall have
dual scale 0-200/100 Amps. or 0-300/150 Amps as per requirement.
1 no. - Ammeter selector switch to indicate current in three R, Y and B phases.
1 no. - Voltmeter 96 sq.mm. Square MISC type flush pattern having class 1.0 accuracy with selector switch (for
Transformer Control Panel. (The range of Voltmeter shall be 0-15 KV for 11 KV Control Panel and 0-40 KV for 33 KV
Control Panel).
1 no. - Alarm bell for circuit breaker trip alarm.
1 no. - Alarm cancellation relay for C.B. trip alarm
2 nos.- Push Buttons for alarm “ACCEPT” & “RESET”
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1 no. - DC Failure Visual indication by way of providing a lamp.
2 nos.- Push Button for testing healthy condition of trip circuit. (Separate circuits for Supervision of healthiness of
two trip coils are required. Accordingly, the DC circuit complete with fuses etc. shall be separate for the two trip
coils).
1 no. - Illumination lamp with cage and switch.
1 no. - Space heater with associated ON-OFF switch.
1 no. - Power type 3 pin 5 Amps plug and socket with ON-OFF switch and fuse.
A trip healthy lamp shall be provided for each circuit breaker and connected in such a way as to indicate the healthy
condition of the trip circuit. The lamp should have the indication on demand when breaker is on. Such indication is
also necessary when the breaker is off, but it should be possible to check the trip circuit condition before closing the
circuit breaker. In brief, pre and post close trip supervision facility on demand is required and shall be included.
The automatic tripping of the circuit breaker due to operation of protective relays shall be indicated by a common
audible alarm. The audible alarm shall be cancelled by the flag cancellation of relay, in case of relays of hand-reset
type. Space shall be provided for provision of KWH meter, with proper sealing.
NOTE: - Any other indications which are required for proper protection/ operation of circuit breaker should be
provided in control panel, without any extra cost.
21) RELAYS
All relays, except where otherwise approved, shall be capable of breaking the maximum current which shall not be
affected by vibration or by external magnetic fields. The contacts shall be of silver, platinum or other approved
materials and shall be capable of repeated operation, without deterioration.
All relays, which are connected to complete the tripping circuit breaker coil of the auxiliary tripping relay shall be
provided with approved flag indication, which whenever possible, shall be mechanically operated type. Indicators
shall also be provided on such additional relay elements as it will enable the type and phase of the fault condition to
be identified. Each indicator, whether of the electrically or mechanically operated type, shall be capable of being
reset by hand, without opening the relay case. Each indicator shall be so designed that it cannot move before the
relay has completed its operation.
It shall not be possible to operate any relay by hand without opening case.
All relays shall be so arranged that on opening the case it shall be impossible for any dust, which may have
collected in or upon the case to fall on the relay mechanism.
Over current relays shall be of static type / software based and shall have inverse definite minimum time limit
characteristics with separately adjustable time and current settings. Unless otherwise approved, the definite
minimum time shall be continuously variable from 0.2 seconds and current setting range shall be variable between
50% and 200% in six equal steps of 25% each. The relay rating shall be 5 Amps.
All relays shall be of draw out type and also that O/C and E/F relays shall have characteristics 1.3 second for
protection of transformer on both primary as well as on secondary sides and 0.6 second characteristics for
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protection of 11 KV feeders. In case of 33 KV feeder protection, the characteristics operating time shall be 1.3
seconds. Further, these relays shall have self-re-set contacts with hand re-set DC operated flag arrangement.
Type test certificates for relays shall be submitted.
22) INSTRUMENTS
All indicating instruments shall conform to IS – 1248 and shall be of types and sizes specified under Sr. No. 15
above. They shall be capable of carrying their full load currents continuously without heating. They shall have long
clearly divided and indelibly marked scales of engraved or enameled metal and the pointers shall be of clean outline.
The pointers and scales shall be subject to approval. The marking on the dials shall be restricted to the scale
marking. All indicating instruments, shall be provided with non-reflecting glass type fronts. All indicating instruments
shall be of class 1.0 accuracy.
Type test certificate for Ammeter and Voltmeter shall be submitted.
The following may be carefully noted:-
i) The components of alarm scheme shall be strictly in accordance with tender specification and shall be explained
very clearly. The alarm scheme is required with Transformer Control Panel only.
ii) The scheme incorporated should ensure that flag resetting of relay is “self-hand operated” type. Thus it should
not be necessary to reset the flag at the time alarm/ annunciation is accepted in case of fault. It should be possible
to separately reset the flag, after the fault is attended.
The automatic tripping of the circuit breakers due to operation of protective relays shall be indicated by audible
alarm. The offered alarm scheme shall be complete in all respects including one DC bell for trip alarm with a
connector/ auxiliary relay suitable to handle breaking of DC bell current. The contactor/ auxiliary relay will get
energized through the self-reset alarm contact of protective relay and will remain actuated by its own seal-in
contact. A push button shall be provided to accept the alarm by breaking the seal-in circuit.
23) TESTS
o Each control panel shall be completely assembled, wired, adjusted and tested at the factory prior to despatch.
o The tests shall include wiring continuity tests, insulation tests and functional tests to ensure operation of the
control scheme and individual equipment.
o The test procedures shall have prior approval of the owner.
o All instruments, meters and relays shall be tested and calibrated in accordance with relevant standards.
o All auxiliary instrument transformers shall be tested in accordance with procedure as laid down in relevant
standards.
24) TEST WITNESSING
The tests shall be performed in presence of owner’s representative. The agency shall give atleast fifteen (15) days
advance notice of the date when the tests are to be carried out.
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25) TEST CERTIFICATE
Copies of test certificates for all routine and acceptance tests shall be furnished to the owner for approval before
dispatch of the equipment from the works. Test certificates for important components used shall also be furnished
along with drawings.
26) PRE-TREATMENT AND PAINTING PROCESS
The control panel sheet steel shall be subjected to pre-treatment process before painting. The process shall be
carried out as under.
The procedure can broadly be divided as “Metal Treatment” and “Painting”.
A. METAL TREATMENT
i) DEGREASING
This can be achieved either by immersing in hot alkaline degreasing bath or in hot dry chlorothelene solution. In
case, degreasing is done by alkaline bath, rinse with cold water thoroughly.
ii) PICKLING
This is to remove rust and metal scales by immersing in diluted sulphuric acid (approximately 20%) at nearly 80°C
until scale and rust are totally removed.
iii) Rinse in cold water in two tanks to remove traces of acids.
iv) Treat with phosphoric acid base neutralizer, for removal of chlorine from the above acid pickling and again
wash with running water.
v) PHOSPHATING
Immerse in grenadine Zinc phosphate solution for about 20 minutes at 80 to 90°C. The uniform phosphate coating
of 4 to 5 gms. per sq. meter shall be achieved.
vi) Swill in cold water.
vii) Rinse in decxy to bath at 70 to 80°C to neutralize any traces of salts.
viii) Seal the above phosphate coating with hot dilute chromate solution.
ix) Dry with compressed air
B. PAINTING
i) Spray one coat wet on wet specially developed, “High Lusture” Zinc chromate primer and stove at 150 to
160°C for 25 to 30 minutes. Alternatively, Red-oxide primer with chromate content may be used. However,
former process is preferred.
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ii) Rubbing and putting :-
Apply putty to fill up the scar, if any, to present smooth surface and stove 15 to 20 minutes. Apply putty
several times to get perfectly smooth finish.
iii) Surfacing :-
Sand down with mechanical abrasive and stove for 20 minutes.
iv) Primer :-
Spray second coat of primer as per(i) above or grey primer surface wet on wet and stove for 30 to 40 minutes
at 150°C.
v) Finish Paint :-
Rub down dry and spray first coat of synthetic enamel finish paint wet on wet and stove for 30 minutes.
vi) Surfacing :-
Sand down or rub dry to prepare for final finish. Spray 2 coats o synthetic enamel finish paint wet on wet and
stove it at 150°C for 30 minutes.
NOTE :-
i) Necessary stiffness may be welded between large cut outs to provide rigidity before painting process.
ii) Painting process shall be done within 24 Hrs. of completion of metal treatment.
iii) Small coating shall be supplied along with equipment for touching up at site.
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HARD DRAWN STRANDED ALUMINIUM AND STEEL CORED ALUMINIUM CONDUCTORS FOR
OVERHEAD POWER LINES
1. SCOPE
This Specification covers the details of the conductors for use on 33 KV, 11 KV and LT overhead
lines in rural electric distribution systems. The sizes of conductors standardised for lines of different voltages
are indicated below :
33KV Lines
i) ACSR 7/3.35mm (50mm2 aluminium area)

ii) ACSR 7/4.09 mm (80mm2 aluminium area)
iii) ACSR 6/4.72 mm + 7/1.57 mm (100mm 2 aluminium area)
11 KV Lines
i) ACSR 7/2.11 mm (20mm2 aluminium area)
iii) ACSR 7/3.35 mm (50mm2 aluminium area)
LT Lines
i) ACSR 7/2.11 mm (20mm2 aluminium area)
iii) ACSR 7/3.35 mm (50mm2 aluminium area)
iv) AAC 7/2.21 mm (25mm2 aluminium area)
v) AAC 7/3.10 mm (50mm2 aluminium area)
Except when they do not comply with the specific requirements in this specification, the conductors shall
comply with the Indian Standard Specification IS:398 (Pt.I)-1976 and IS:398 (Pt.II)-1976 or the latest
version thereof.
3. SIZES
The sizes and properties of Stranded Aluminium and Steel cored Aluminium Conductors shall be as under:
TABLE – I
STANDARD ALUMINIUM STRANDED CONDUCTORS
Nominal Stranding Sectional Approx. Approx. Calculated Approx.

Aluminium and Wire Area Overall Mass Resistance at Calculated
Area Diameter Diameter 200 C Max. Breaking load
1 2 3 4 5 6 7
mm.sq. mm mm.sq. mm Kg./Km Ohm./Km KN

25 7/2.21 26.85 6.63 74 1.086 4.52
50 7/3.10 52.83 9.30 145 0.5525 8.25
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TABLE – II
STRANDED STEEL CORED ALUMINIUM CONDUCTORS
Nominal Stranding & Wire Sectional Total Approx. Approx. Calculated Approx.
Aluminium Diameter Area of Sectional Overall Mass Resistance Calculated
Area Aluminium Area Diameter at 200C Breaking
Max. Load
AL. Steel
1 2 3 4 5 6 7 8 9
mm.sq Mm mm mm.sq. mm.sq. mm Kg./Km. Ohm./Km KN
20 6/2.11 1/ 2.11 20.98 24.48 6.33 85 1.394 7.61
30 6/2.59 1/ 2.59 31.61 36.88 7.77 128 0.9289 11.12

50 6/3.35 1/ 3.35 52.88 61.70 10.05 214 0.5524 18.25
80 6/4.09 1/ 4.09 78.83 91.97 12.27 319 0.3712 26.91
100 6/4.72 7/ 1.57 105.00 118.50 14.15 394 0.2792 32.41
4. ALUMINIUM WIRES
The aluminium strands shall be hard drawn from electrolytic aluminium rods of EC grade having purity not less
than 99.5% and a copper content not exceeding 0.04%. They shall have the same properties and
characteristics as prescribed in IEC: 889-1987.
The properties of aluminium wires to be used in the construction of the stranded conductors shall be as under
TABLE – III
SOLID ALUMINIUM WIRES USED IN THE CONSTRUCTION OF STRANDED ACSR CONDUCTORS
Diameter Cross Mass Resistance Breaking Load Min.

Sectional At 200 C
Area of
Nominal
Nominal Min. Max. Diameter Before After
Wire Stranding Stranding
1 2 3 4 5 6 7 8
mm mm mm mm.sq. Kg./Km Ohm./Km. KN KN
2.11 2.09 2.13 3.497 9.45 8.237 0.63 0.60
2.21 2.19 2.23 3.836 10.37 7.503 0.68 0.65
2.59 2.56 2.62 5.269 14.24 5.490 0.89 0.85
3.10 3.07 3.13 7.548 20.40 3.818 1.24 1.18
3.35 3.32 3.38 8.814 23.82 3.265 1.43 1.36
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4.09 4.05 4.13 13.140 35.51 2.194 2.08 1.98
4.72 4.67 4.77 17.500 47.30 1.650 2.78 2.64
5. STEEL WIRES
The steel wire strands shall be drawn from high carbon steel wire rods produced by either the acid or the basic
open-hearth process, or the electric furnace process, or the basic oxygen process and shall conform to the
following requirements as to the chemical composition as prescribed in IS 398 (Pt. II)- 1996:
Element % Composition
Carbon 0.50 to 0.85
Manganese 0.50 to 1.10
Phosphorous Not more than 0.035
Sulphur Not more than 0.045
Silicon 0.10 to 0.35
The properties of steel wires to be used in the construction of the stranded ACSR conductors shall be as under
TABLE – IV
SOLID STEEL WIRES USED IN THE CONSTRUCTION OF STRANDED ACSR CONDUCTORS
Diameter Cross Sectional Mass Breaking Load Min.

Area of Nominal
Nominal Min. Max. Before Stranding After Stranding
Diameter Wire
1 2 3 4 5 6 7
Mm mm mm mm.sq. Kg./Km KN KN
1.57 1.54 1.60 1.936 15.10 2.70 2.57
2.11 2.07 2.15 3.497 27.27 4.60 4.37
2.59 2.54 2.64 5.269 41.09 6.92 6.57
3.35 3.28 3.42 8.814 68.75 11.58 11.00
4.09 4.01 417 13.140 102.48 17.27 16.41
6. FREEDOM FROM DEFECTS

The wires shall be smooth and free from all imperfections, such as spills & splits.
7. JOINTS IN WIRES & CONDUCTORS

7.1 All aluminium conductors : No joints shall be permitted in any wire.
7.2 Aluminium Conductor Steel Reinforced:
Aluminium Wires: No joints shall be permitted in outer layer.
Steel Wires: No joints shall be permitted in any wire.
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8. STRANDING
8.1 The wires used in construction of a stranded conductor shall, before stranding satisfy all
the requirements of this standard for solid wires.
8.2 Lay Ratio :

(i) The lay ratio for aluminium wires in case of AAC shall be within limits given below :
No. of wires in conductors Lay Ratio

Min. Max.
7
10 14
(ii) The lay ratio for aluminium and steel wire in case of ACSR shall be within limits given below :
No. of wires Ratio Lay ratio for Steel wire Lay Ratio for
Aluminium (6 wire layer) Aluminium wire
wire dia to
Al. Steel Min. Max. Min. Max.
steel
wire dia
6 1 1.000 - - 10 14
6 7 3.000 13 28 10 14
9. TESTS
The samples of individual wires for the tests shall normally be taken before stranding. The manufacturer shall
carry out test on samples taken out at least from 10% of aluminium wire spools and 10% of steel wire
coils. However, when desired by the purchaser, the test sample may be taken from the stranded wires.
a) The wires used for all aluminium conductors shall comply with the following tests as per IS:398(Pt.I)-
1976.
i) Breaking load test
ii) Wrapping test
iii) Resistance test
b) The following tests to be conducted for ACSR conductors shall conform to IS 398 (Pt. II) - 1996 and IEC
: 888 & 889. The procedure for conducting these tests is given below:
1 Type Tests
The following tests shall be conducted once on a sample/samples of conductor (ACSR/AAAC) for every 1500
Kms. of production from each manufacturing facility:
(a) UTS test on stranded conductor
(b) DC resistance test on stranded conductor
2 Acceptance Tests
(a) Visual and dimensional check on drum
(b) Visual check for joints scratches etc. and length measurement of conductor by rewinding
(c) Dimensional check on steel and aluminium/Al-alloy strands
(d) Check for lay-ratio
(e) Galvanising test on steel strands
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(f) Torsion and Elongation tests on steel strands

(g) Breaking load test on steel and Aluminium strands
(h) Wrap test on steel & Aluminium strands
(i) DC resistance test on Aluminium strands
(j) Procedure qualification test on welded joint of Aluminium strands
Note: All the above tests except (j) shall be carried out on aluminium and steel strands after stranding only.
3 Routine Test
(a) Check to ensure that the joints are as per Specification.
(b) Check that there are no cuts, fins etc. on the strands.
(c) Check that drums are as per Specification.
(d) All acceptance test as mentioned above to be carried out on each coil.
4 Tests During Manufacture

(a) Chemical analysis of zinc used for galvanizing
(b) Chemical analysis of Aluminium used for making Aluminium strands
(c) Chemical analysis of steel used for making steel strands
PROCEDURE FOR CONDUCTING TESTS ON ACSR CONDUCTORS
i UTS Test on Stranded Conductor

Circles perpendicular to the axis of the conductor shall be marked at two places on a sample of conductor of
minimum 5 m length between fixing arrangement suitably fixed on a tensile testing machine. The load shall be
increased at a steady rate upto 50% of minimum specified UTS and held for one minute. The circles drawn
shall not be distorted due to relative movement of strands. Thereafter the load shall be increased at steady
rate to minimum UTS and held for one minute. The Conductor sample shall not fail during this period. The
applied load shall then be increased until the failing load is
reached and the value recorded.
ii D.C. Resistance Test on Stranded Conductor
On a conductor sample of minimum 5m length two contact-clamps shall be fixed with a predetermined bolt
torque. The resistance shall be measured by a Kelvin double bridge by placing the clamps initially zero metre
and subsequently one metre apart. The test shall be repeated at least five times and the average value
recorded. The value obtained shall be corrected to the value at 20°C as per IS:398-(Part-V)-1982. The
resistance corrected at 200C shall conform to the requirements of this Specification.
iii Chemical Analysis of Aluminium and Steel

Samples taken from the Aluminium and steel ingots/coils/strands shall be chemically/spectrographically
analysed. The same shall be in conformity to the requirements stated in this Specification.
iv Visual and Dimensional Check on Drums

The drums shall be visually and dimensionally checked to ensure that they conform to the requirements of this
Specification.
v Visual Check for Joints, Scratches etc.

Conductor drums shall be rewound in the presence of the Owner or his representative. The Owner/his
representative shall visually check for scratches, joints etc. and that the conductor generally conforms to the
requirements of this Specification. Ten percent (10%) drums from each lot shall be rewound in the presence of
the Owner's representative.
vi Dimensional Check on Steel and Aluminium Strands

The individual strands shall be dimensionally checked to ensure that they conform to the requirement of this
Specification.
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vii Check for Lay-ratios of Various Layers

The lay-ratios of various layers shall be checked to ensure that they conform to the requirements of this
Specification.
viii Procedure Qualification test on welded Aluminium strands.

Two Aluminium wire shall be welded as per the approved quality plan and shall be subjected to tensile load.
The breaking strength of the welded joint of the wire shall not be less than the guaranteed breaking strength
of individual strands.
ix Chemical Analysis of Zinc
Samples taken from the zinc ingots shall be chemically/ spectrographically analysed. The same shall be in
conformity to the requirements stated in the Specification.
x Galvanising Test
The test procedure shall be as specified in IEC : 888. The material shall conform to the requirements of this
Specification. The adherence of zinc shall be checked by wrapping around a mandrel four times the diameter
of steel wire.
xi Torsion and Elongation Tests on Steel Strands

The test procedures shall be as per clause No. 10.3 of IEC : 888. In torsion test, the number of complete
twists before fracture shall not be less than 18 on a length equal to 100 times the standard diameter of the
strand. In case test sample length is less or more than 100 times the stranded diameter of the strand, the
minimum number of twists will be proportioned to the length and if number comes in the fraction then it will
be rounded off to next higher whole number. In elongation test, the elongation of the strand shall not be less
than 4% for a gauge length of 250 mm.
xii Check on Barrel Batten strength of Drums

The details regarding barrel batten strength test will be discussed and mutually agreed to by the Contractor &
Owner in the Quality Assurance Programme.
xiii Breaking load test on individual Aluminium and Galvanized steel wires
The test shall be conducted on both Aluminium and Galvanized steel wires. The breaking load of one specimen
cut from each of the samples taken shall be determined by means of suitable tensile testing machine. The load
shall be applied gradually and the rate of separation of the jaws of the testing machine shall be not less than
25 mm/min. and not greater than 100 mm./ min. The ultimate breaking load of the specimens shall be not less
than the values specified in the Specification.
xiv Resistance test on Aluminium wire

The test shall be conducted on aluminium wires only, conforming to procedure as per IEC: 889. The electrical
resistance of one specimen of aluminium wire cut from each of the samples taken shall be measured at
ambient temperature. The measured resistance shall be corrected to the value corresponding to 20 degree C.
by means of following formula.
1
R20 = RT -------------------
1+alpha x (T-20)
Where
R20 = Resistance corrected at 20 degrees C.
RT = Resistance measured at T degrees C.
alpha = Constant mass temperature coefficient of resistance 0.004.
T = Ambient temperature during measurement
This resistance calculated to 20 degrees C. shall be not more than the maximum value specified in the
specification.
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10. PACKING & MARKING

The conductors shall be wound in reels or drums conforming to IS:1778-1980 Specification for Reels and
Drums for bare wire’ or the latest version thereof.
As an alternative to wooden drum supplier may also supply the conductors in nonreturnable painted steel drums.
After preparation of steel surface according to IS: 9954, synthetic enamel paint shall be applied on one coat of
primer. Wooden/Steel drum will be treated at par for evaluation purpose.
10.1 Packing
10.1.1 The gross mass for various conductors shall not exceed by more than 10% of the values given in the
following table :
Conductor Size Gross Mass

AAC
25mm2 Al. area (7/2.21 mm) 500 Kg.
2
50mm Al. area (7/3.10 mm) 500 Kg.
ACSR
20mm2 Al. area (7/2.11 mm) 1000 Kg.
2
30mm Al. area (7/2.59 mm) 1000 Kg.
50mm2 Al. area (7/3.35 mm) 1500 Kg.
2
80mm Al. area (7/4.09 mm) 1500 Kg.
2
100mm Al. area (6/4.72mm + 7/1.57mm) 2000 Kg.
10.1.2 The normal length of various conductors shall be as given in the following table:
Conductor Size Normal conductor length

AAC
25mm2 Al. area (7/2.21mm) 1.0 Km.
2
50mm Al. area (7/3.10mm) 1.0 Km.
ACSR
20mm2 Al. area (7/2.11 mm) 2.0 Km.
2
30mm Al. area (7/2.59 mm) 2.0 Km.
50mm2 Al. area (7/3.35 mm) 2.0 Km.
2
80mm Al. area (7/4.09 mm) 1.5 Km.
2
100mm Al. area (6/4.72mm + 7/1.57mm) 2.0 Km.
10.1.3 Longer lengths shall be acceptable.

10.1.4 Short lengths, not less than 50% of the standard lengths, shall be acceptable to the maximum extent
of 10% of the quantity ordered. A single drum may contain more than one length of conductor.
10.2 Marking : The following information shall be marked on each package :

a) Manufacturers’ name
b) Trade mark, if any
c) Drum or identification number
d) Size of conductor
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e) Number and lengths of conductor

f) Gross mass of the package
g) Net mass of conductor
h) I.S.I certification mark, if any
11. INSPECTION
All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed
upon by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the inspector
representing the purchaser all reasonable facilities without charge, to satisfy him that the material is being
furnished in accordance with this Specification.
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11 KV XLPE CABLES
1. SCOPE
This Specification covers requirements of 11 KV Cross Linked Polyethylene (XLPE) insulated and PVC
sheathed aluminium cables for use in Rural Distribution.
2. APPLICABLE STANDARD
Except when it conflicts with the specific requirements of this specification, the cables shall comply with the
latest version of IS : 7098 (Pt. II) - 1985 - Specification for Cross Linked Polyethylene Insulated PVC Sheathed
Cables.
3. RATED VOLTAGE AND TEMPERATURE

The rated voltage of the cables shall be 6.35KV/11KV and the maximum operating voltage shall be 12 KV.
Maximum continuous operating temperature (combination of ambient temperature and temperature rise
due to load) shall be 90o C under normal operation and 250 degree C under short circuit conditions.
4. TYPE OF CABLES
The type of cables covered in this specification shall be (i) single-core armoured (non-magnetic) screened
and (ii) three-core armoured screened.
5. STANDARD SIZES OF CABLES

The standard sizes of cables which can be used for various applications are as mentioned below :
5.1 Single core Cables : 25 sq.mm., 35 sq.mm., 50 sq.mm., 70 sq.mm., 95 sq.mm., 120 sq.mm., 150
sq.mm., 185 sq.mm., 240 sq.mm., 300 sq.mm., 400 sq.mm., 500 sq.mm., 630 sq.mm.
5.2 Three Core Cables : All the above sizes upto and including 500 sq.mm., may be treated as preferred
sizes.
5.3 For standard recommended sizes of XLPE cables in 33/11 KV Sub-stations (for 33/11KV transformers and
for 11 KV outgoing feeders) please refer REC Standard .
6. CONTINUOUS CURRENT AND SHORT CIRCUIT RATINGS
The indicative values of the continuous current carrying capacities (for design purposes by field engineers)
of the various sizes of the cables are given in the tables in clause 6.1 and 6.2.
6.1 Single Core cables :
S. No. Size of cable Indicative values of continuous

sq.mm. current carrying capacity in Amps
at maximum conductor
temperature of 90o C.
In Ground In Air
1 25 93 105
2 35 111 130
3 50 138 159
4 70 170 198
5 95 200 240
6 120 230 280
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7 150 255 325

8 185 290 365
9 240 335 430

10 300 380 495
11 400 429 528

12 500 481 680
13 630 541 780
6.2 Three Core Cables :
S. No. Size of cable Indicative values of continuous

sq.mm. current carrying capacity in Amps at
maximum conductor temperature of
90o C.
In Ground In Air
1 25 93 95
2 35 110 115
3 50 130 140
4 70 160 175
5 95 185 200
6 120 205 230
7 150 235 265
8 185 270 310
9 240 305 345
10 300 340 396
11 400 395 460

12 500 455 590
6.3 The short circuit rating for the various sizes of the cables (single core and three core) calculated for a
duration of 1 second at maximum temperature of 250o C is given below :-
Sl. No. Size (sq. mm.) (3– Conductor Short Circuit

phase/and Single rating (KA) (rms
phase) value)*
1 25 2.35
2 35 3.29
3 50 4.70
4 70 6.58
5 95 8.93
6 120 11.3
7 150 14.1
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8 185 17.4
9 240 22.6
10 300 28.2
11 400 37.6
12 500 47.0
13 630 59.2
* For guidance only
7. DETAILS OF CABLES
7.1 Conductor: The cable conductors shall be of round, stranded and compacted aluminium of nominal size
as stipulated in Table under Clause 5. Corresponding wire diameter and number of wires in the conductor shall
be as given in IS: 8130.
7.2 Conductor Screen: Conductor screening shall be provided over the conductor by applying non-metallic
semi-conducting tape or by extrusion of semi-conducting compound or a combination of the two.
7.3 Insulation: The insulation shall be of extruded cross linked polyethylene (XLPE) of nominal insulation
thickness 3.6 mm and its properties shall conform to IS : 7098 (Pt. II).
7.4.1 Insulation screen: The insulation screen shall consist of two parts; namely, metallic and non-metallic.
Non-metallic part shall be applied directly over the insulation of each core and shall consist of either a semi-
conducting tape or extruded semi-conducting compound or a combination of the two or either material with
semi-conducting coating.
7.4.2 The metallic part shall consist of either tape, or braid or concentric serving of wires or a sheath; shall
be non-magnetic and shall be applied over the non-metallic part. For single-core armoured cables, the armouring
may constitute the metallic part of the screening.
7.5 Core-identification & laying up of cores: The core identification and laying up of cores shall be as per
IS : 7098 (Pt. II). For identification of different cores in three-core cable, use of coloured stripes, red, yellow and
blue, or use of numbered strips shall be employed.
7.6 Inner Sheath: The laid up cores shall be covered with inner sheath made of thermoplastic material
applied either by extrusion or wrapping. It shall be ensured that the shape is as circular as possible. Thickness of
inner sheath shall conform to IS : 7098 (Pt. II). Single Core cables shall have no inner sheath, but in case of
cables having both metallic part of screen and armour, there shall be an extruded inner sheath between them.
7.7 Armouring: Armouring shall be applied over non-metallic part of insulation screening or the inner sheath
as the case may be for single-core cables and over the inner sheath for 3–core cables. The method, type,
dimensions, joints, conductance etc. of armour shall conform to IS : 7098 (Pt. II).
7.8 Outer Sheath: The outer sheath shall be applied over the armouring. The minimum thickness and
properties of outer sheath shall conform to the requirement of IS : 7098 (Pt. II).
8. TESTS
8.1 The following tests shall be carried out on the cables as per IS : 7098 (Pt. II).
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8.1.1 Type Tests

a) Tests on conductor :
i) Tensile test
ii) Wrapping test
iii) Resistance test
b) Tests for armouring wires/strips
c) Tests for thickness of insulation and sheath
d) Physical tests for insulation
i) Tensile strength and elongation at break
ii) Ageing in air oven
iii) Hot test
iv) Shrinkage test
v) Water absorption
e) Physical Tests for outer sheath
i) Tensile strength and elongation at break
ii) Ageing in air oven
iii) Shrinkage test
iv) Hot deformation
v) Bleeding and blooming test
f) Partial discharge test
g) Bending Test
h) Dielectric power factor test :
i) As a function of voltage
ii) As a function of temperature
i) Insulation resistance test (volume resistivity)
j) Heating cycle test
k) Impulse withstand test
l) High voltage test
m) Flammability test
8.1.2 Acceptance Tests

a) Tensile test
b) Wrapping test
c) Conductor resistance test
d) Test for thickness of insulation and sheath
e) Hot set test for insulation
f) Tensile strength and elongation at break test for insulation and sheath
g) Partial discharge test
h) High voltage test
i) insulation resistance (volume resistivity) test
8.1.3 Routine Tests

a) Conductor resistance test
b) Partial discharge test
c) High voltage test
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9. PACKING AND MARKING

9.1 Packing: The cables shall be supplied in wooden drums conforming to IS : 10418. The standard length
of cable in each drum shall be 0.5 KM (± ) 5%.
9.2 Marking: The cable drum shall carry the information as per requirement of IS : 7098 (Pt. II).
9.3 The manufacturer’s name or trade-mark, the voltage grade, year of manufacture etc. may be printed or
embossed on the cable as stipulated in IS : 7098 (Pt. II).
10. INSPECTION
All the tests and inspection shall be made at the place of manufacture unless otherwise especially agreed
upon by the manufacturer and purchaser at the time of purchase. The manufacturers shall afford the inspector
representing the purchaser all reasonable facilities without charge, to satisfy him that material is being furnished
in accordance with the Specification.
The purchaser has the right to have tests carried out at his own cost by an independent agency whenever
there is a dispute regarding the quality of supply.
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AERIAL BUNCHED CABLE HAVING XLPE INSULATED L.T. CABLE FOR WORKING VOLTAGE UPTO
1100 VOLT
1. SCOPE :
The specification covers design, manufacture, testing before despatch, transportation, supply and delivery
of ISI marked 1100V Aerial Bunched Cable having XLPE insulated Cable (three Power Core) with stranded
compact circular aluminium conductors twisted over an insulated aluminium alloy messenger wire for use as
overhead distribution feeders, with/without one street lighting core with stranded compacted circular
aluminium conductor XLPE insulated suitable for use on 3-Phase AC System conforming to IS-14255/1985
with up to date amendments.
2. LOCATION:
Aerial bunched Cables for use in L.T. overhead lines are preferred than conventional L.T.overhead lines with
bare conductors as those are not subjected to frequent faults as happens with the bare conductors and also
to minimise problem of tree clearance etc. ABC System is safer and eliminates use of insulators and
associated hardware’s required for bare conductors.
3. APPLICABLE STANDARDS:
Unless otherwise stipulated in this specification, the following standard with up to date amendment shall be
applicable.
IS 14255-1995 Specification for AERIAL Bunched Cables for working Voltage Up to & including 1100 Volts.
IS : 8130 Specification for Conductors for Insulated Cables.
IS : 398 (Part-IV) Specification for Aluminium Alloy Conductor.
4. RATED VOLTAGE :
The rated Voltage of LT AB Cables shall be 1100 Volts.
5. CONDUCTORS :
The Aluminium Conductors for phase/street lightning conductor shall be H2 of H4 grade Aluminium
complying with the requirements of IS-8130-1984 with up to date amendments. For messenger wire
stranded All Aluminium Conductor shall be of heat treated Aluminium Magnesium-Silicon Alloy Wires
containing approximate 0.5% magnesium and 0.5% silicon conforming to IS-398 (Part-IV)/1984 with up to
date amendments. The stranded conductor shall be clean & reasonably uniform in size and shape and its
surface shall be free from sharp edges. Not more than two joints shall be allowed in any of the wires
forming every complete length of conductor and no joint shall be within 300 mm. of any other joint in the
same layer. The joint shall be brazed, silver soldered or electric or gas welded. No joint shall be made in the
conductor, once it has been stranded.
6. INSULATION :
The Conductor (with protective barrier, wherever applied) shall be provided with cross linked polyethylene
applied by extrusion conforming to the standard Specification as per IS 4255/95.The average thickness of
insulation when measured in accordance with relevant clause of the specification, shall not be less than
standard value specified. Upper surface of Cable insulation should be Ultra Violet Ray resistant Colour of
insulation shall be black.
7. CORE IDENTIFICATION :
The Phase Conductors shall e insulated with black weather resistant, XLPE suitable for 1100 Volt insulation.
The Phase Conductor shall be provided with one, two and three ridges for quick identification. The individual
cores thus formed shall then be laid up around insulated messenger wire. The insulated messenger wire
shall have four ridges as per IS 14255:1995. The insulated street lighting conductor shall not have any
identification mark.
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8. MESSENGER-CUM-NEUTRAL WIRE :
The insulated messenger wire shall be of aluminium alloy, generally conforming to IS 398 (Part-IV)/1994
and suitably compacted to have smooth round surface to avoid damage to the other insulating sheath of
phase conductor twisted around the messenger.
9. LAYING UP :
Three Power Cores having Ridges one, two and three and one street lighting without any ridge, if any
should be twisted over insulated messenger wire with right hand direction of lay. This will from the Aerial
Bunched Cable. Lay ratio shall be as specified in IS:14255/ 1995.
10. TESTS FOR CABLES :
10.1 Type test reports not older than 5 years of at least two sizes of Aerial Bunched Cables with & without
street lighting core being procured and as specified in relevant IS & IEE and detailed in Clause 5:1 got
conducted from independent recognised Test House shall be furnished by the bidders along with the bid.
The bid not accompanied with test reports may not be considered for evaluation.
TYPE TEST REPORTS SHALL CONTAIN DETAILS OFFOLLOWING TYPE TESTS AS PER IS 8130-1984 & IS
10810
1. Tests on Phase/Street Light Conductor :

i) Tensile Test
ii) Wrapping Test.
iii) Resistance Test.
2. Test on Messenger Conductor ;

i) Breaking Load.
ii) Elongation Test.
iii) Resistance Test.
3. Physical Test for XLPE insulation :

i) Tensile Strength and elongation at break.
ii) Ageing in on even.
iii) Hot Set Test.
iv) Shrinkage Test.
v) Water Absorption (Gavimetric)
4. Test for thickness insulation.

5. Insulation performance (Volume resistivity) Test.
6. High Voltage Test.
Report of above and any other type test provided in the relevant Indian Standards shall also be supplied.
10.2 ROUTINE TEST ;

These shall be carried out on all sizes of all drums of unamoured Cables by the supplier as given in Clause
5.1 and shall be got approved before despatch.
The Cable shall be inspected and tested at the manufacturer’s works before despatch as per ISS mentioned
in schedule of requirement. The manufacturer shall arrange all the necessary machinery, apparatus and
labour required for the testing purpose.
The routine tests embodied in the respective ISS are as per list given below :
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1. Conductor Resistance Test.

2. High Voltage Test at room temperature.
3. Cold Bend Test (optional)
Any other routine test provided in the relevant Indian Standards shall also got conducted by the suppler.
10.3 ACCEPTANCE TEST :
These tests as per relevant IS & IEC shall be carried out in the presence of the purchaser’s representative if
so desired by the purchaser. The following shall constitute the acceptance tests.
(a) Tensile Test (for phase/street light conductor)
(b) Wrapping Test (for phase/street light conductor)
(c) Breaking Load Test for messenger Conductor.
(d) Elongation test for messenger conductor.
(e) Conductor resistance test.
(f) Test for thickness of insulation.
(g) Tensile Strength and Elongation at Break Test.
(h) Hot Set Test for XLPE insulation.
(i) Insulation resistance test and
(j) High Voltage Test.
11. SEQUENTIAL MARKING :

Due to technical difficulty Marking of the Sequential Length is not required. Instead the Weight of Cable for
all sizes shall have to be mentioned for Per K.M. Length.
12. PACKING & MARKING :
The Cable shall be supplied on suitable sized wooden non-returnable drum of robust construction for each
length of Cables as per I.S. 10418. A layer of water proof paper shall be applied to the surface of the drums
and over the outer cable layer. A clear space at least 40 mm. shall be left between the Cable and Logging.
Wood preservative shall be applied to the entire drum. Each metre length shall be embossed with the Trade
Name of Manufacturer and the work ‘Employer (RGGVY XII Plan Projects). Packing shall be sturdy to protect
the Cable from any injury during transportation handling and storage. Both Cable ends shall be sealed with
PVC/Rubber Caps to eliminate ingress of moisture. Each Cable Drum shall have following information
stencilled on it.
a) Manufacturer’s Name, Brand Name of Trade Mark.

b) Year of Manufacture.
c) Nominal Cross-Sectional area of the Cable Conductor.
d) Type of Cable and Voltage Grade.
e) Length of the Cable.
f) Number of the Cores.
g) ISI Certification Mark, IS reference.
h) Colour of outer sheath.
i) No. of lengths in Drum (if more than one)
j) Cable Code.
k) Direction of rotation of drum (by means of an arrow)
l) Approximate gross weight in Kg./Km.
The standard Drum Length will be 500 mtrs. in each Drum for all sizes subject to a tolerance of + 5%.
13. INSPECTION :
The Cable shall be inspected at manufacturer’s works before despatch as per IS-7098 (Part-I)/1988 (with
upto date amendments) & IS 14255/1995. All the acceptance tests embodied in the above shall be
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performed by the Inspecting Officer. The Manufacturer shall arrange without making any extra charges with
all the necessary machinery, apparatus and labour requirement for the testing purpose. The Cable
requirement for testing shall be to Firm’s Account.
14. LITERATURE AND MANUAL :
To be submitted as per General Terms & Conditions of Contract.
15. GUARANTEED TECHNICAL PARTICULARS :
To be submitted along with Tender documents.
A. DESCRIPTION OF 1.1 KV AERIAL BUNCHED CABLES :
Size
Description
Ph.Wire + St.Light Wire + Messenger-
CumNeutral Wire
1100V Grade L.T. Aerial Bunched Cable having three

Power Core & One Neutral-Cum-messenger Core of 1) 3x25 + 1x16 + 1x25 sq.mm.
stranded compacted circular Aluminium Black coloured 2) 3x35 + 1x16 + 1x25 sq.mm.
XLPE insulated & Core identification by ridges, one, 3) 3x50 + 1x16 + 1x35 sq.mm.
two and three & four respectively. One Street Lighting 4) 3x70 + 1x16 + 1x50 sq.mm.
Core of stranded, compacted Circular Aluminium
Conductor, Black coloured XLPE insulated without any
identification mark. Messenger-CumNeutral Wire (Provision for street light conductor is
should be of stranded compacted Circular Aluminium optional and as per requirement)
Alloy Conductor conforming to IS 8130/1984, IS-
398(Part-IV)/1979 and IS-14255/1995 with upto date
amendments, if any.
[ Sizes of Power Conductor & Messenger Wire may vary as per requirement ]
B. ACCESSORIES REQUIRED FOR DRAWAL OF L.T. OVERHEAD LINE WITH1100V GRADE AERIAL
BUNCHED CABLES ON PCE POLE SUPPORT
Sl.No. Description
1 Anchor Clamp (3-Bolt and 2 Bolt Type)
2 Eye hook with Suspension Clamp Assembly.
3 PCC Pole Clamp.

4 Insulation Piercing Connectors with cover or P.G.Connectors with insulation cover.
5 Water Proof pre-insulated Hexagonal Compression Connectors & Lugs.
NOTE: Offer for L.T. Aerial Bunched Cables should cover required accessories with details of dimensions,
materials and provisional quantity per K.M. of L.T. O/H Line.
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DIMENSIONAL AND ELECTRICAL PARAMETERS:
LT ABC: The standard sizes and technical characteristics for Single Core Cable.
Nominal Sectional Area of Conductors (sq.mm.)
Parameters 16 25 35 50 70
No. of Strands
4 7 7 7 7
Dia. of Compacted Conductor

4.4 5.5 6.8 7.9 9.4
(MM)
Approx. Mass (Kg./Km.) 42
65 95 12 7 170
Max. DC resistance at 200C 1.91

1.20 0.868 0.641 0.443
(ohm/km.)
Insulation Thickness (mm.) 1.2
1.2 1.2 1.5 1.5
Current rating at 400C in air.
60 85 100 120 155
Note : The resistance values given in the Table are the max. Permissible one.
TECHNICAL CHARACTERISTIC OF INSULATED MESSENGER-CUM-NEUTRAL WIRE FOR LT ABC :
Nominal Dia.of Compacted Approx. mass Max. D.C. Minimum

Sectional Conductor (mm.) (Kg./Km.) resistance Tensile
Area (mm.) At 20C Strength (KN)
(Ohm./Km.)
25 5.9 65 1.38 7.4

35 6.9 95 0.986 10.3
50 7.9 127 0.689 14.0
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PVC INSULATED & PVC SHEATHED LT CABLES
1. SCOPE
This specification covers details of PVC Insulated & PVC Sheathed LT cables for use on Service Connections and
Distribution Transformers in rural electrification system.
Except when it conflicts with the specific requirements of this specification, PVC insulated & PVC Sheathed
LT cables shall comply with the latest versions of the following Indian Standards.
a Service cables IS:694 (Part-II)(PVC Insulated & PVC

Sheathed Cables for working voltages upto
and including 1100 V with
aluminium conductors)
b Transformer Cables IS:4288 (PVC Insulated and PVC sheathed
i) Three-core, solid sector- solid aluminium conductor cables of voltage
shaped, aluminium armoured rating not exceeding 1100 Volts).
cables
OR
ii) Single-core and four- IS:1554 (Part-I) (PVC Insulated & PVC
core unarmoured aluminium Sheathed Heavy Duty Electric Cables
cables for working voltages upto and including
1100 V).
3. SIZE AND TYPE

The size and type of PVC insulated & PVC Sheathed LT cables for different applications shall be as in
Table-I below :
Table-I
Sl. Size Type Use

No.
A Service Cables
I 2.5mm2 Twin-core (unarmoured) as per IS: i) Single-phase service connections upto 2KW connected load
694-Pt-II ii) Three –phase Agrl./Indl. Service connections upto 2.2KW
(3-HP) connected load (2 runs to be used)
II 4.0mm2 Twin-core (unarmoured) as per IS: i) Single-phase service connections above 2KW &upto 4KW
694-Pt-II connected load.
ii) Three –phase Agrl./Indl. Service connections above 2.2KW
(3-HP) and upto 3.7KW (5-HP) connected load (2 runs to be
used)
III 6.0mm2 Four-core (unarmoured) as per IS: i) Three –phase Agrl./Indl. Service connections above 3.7 KW
694-Pt-II (5-HP) and upto 7.5 KW (10-HP) connected load.
K
IV 10.0mm2 Four-core (unarmoured) as per IS: i) Three –phase Agrl./Indl. Service connections above 7.5KW
694-Pt-II (10-HP) and upto 11KW (15-HP) connected load.
B Transformers cables
1(a) 16.0mm2 Four-core (unarmoured) as per IS:

1554-Pt-I
25 KVA distribution transformers
(b) 10.0mm2 Single-core (unarmoured) as per
IS: 1554-Pt-I
2(a) 70.0mm2 Three - core solid sector-shaped

aluminium (armoured) cable as per
IS:4288 OR Four- core
(unarmoured) with reduced neutral
of 35mm2 as per IS: 1554 Pt.-I.
63 KVA distribution transformers
2(b) 50.0mm2 Single-core( unarmoured) as per

IS:1554-PT-I
(a) 120.0mm2 Three - core solid sector-shaped 100 KVA distribution transformers
aluminium (armoured) cable as per
IS: 4288 OR Four core
(unarmoured) with reduced neutral
of 70mm2 as per IS: 1554 Pt.-I.
3(b) 95.0mm2 Single-core (unarmoured) as per

IS: 1554-Pt-I
4. SHAPE OF CABLE
All twin-core cables shall be of flat shape and single 3 or 4-core cables of circular shape.
5. CONDUCTORS
5.1 Aluminium conductor complying with IS:8130-1976 shall be used.
5.2 The conductors of service cables (2.5mm2 to 10mm2) shall be either solid or stranded, as required by
the purchaser.
6. TESTS
All the type tests, acceptance tests and routine tests shall be carried out as per the relevant I.S. indicated
in clause 2 above.
7. PACKING
7.1 Service cables of 2.5, 4, 6 and 10mm2 size shall be packed in coils of 100 metres length each. Each
coil shall be protected against damage by polythene wrapping.
7.2 Transformer cables shall be supplied in wooden drums with 100 or 250 metres length, as required by
the purchaser.
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7.3 The cable reels/drums shall comply with IS: 10418-1982 (Specification on 'Drums for Electric Cables').
8. MARKING
The following information shall be marked on the reel/drum carrying transformer cables or contained in a
label attached to the coils in case of service cables:
a) Manufacturer's name, brand name or trade mark
b) Type of cable and voltage grade
c) Number of cores
d) Nominal cross-sectional area of conductor
e) Length of cable on reel/drum or coil
f) Direction of rotation of drums (by means of an arrow)
g) Approximate gross weight
h) Country of manufacture
i) Year of manufacture and
j) Name of the purchaser
9. INSPECTION
All tests and inspection shall be made at the place of manufacture unless otherwise agreed to
especially by the manufacturer and purchaser at the time of purchase. The manufacturer shall afford the
inspector, representing the purchaser, all necessary facilities (without charge) to satisfy him that the
material is being supplied in accordance with the Specification.
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K
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PVC INSULATED & PVC SHEATHED ARMOURED CABLE FOR WORKING VOLTAGE
UPTO AND INCLUDING 1100 VOLTS
1 Scope:
This Specification covers the requirement of PVC insulated & PVC Sheathed 3.5 Core, armoured Cables for
working voltages upto and including 1100 Volts suitable for LV side of Distribution Transformers, any other LV
use in 3-Phase (Earthed) System.
2 Location:
2.1 The Cable shall be laid/buried directly in ground anywhere in RGGVY Projects and terminated for outdoor
connection.
2.2 The Cables may be laid within covered Cable Trenches in Cable Racks/Ladder/Air for certain portion of length.
3 Standards:
The Cables all conform broadly, to the latest issue of the following standards including all additional, alterations
and modifications thereof.
3.1 IS: 1554 (Part-I) : 1988 (Specification for PVC insulated heavy duty Electric Cables for working voltages upto
and including 1100 Volts)
3.2 IS: 8130: 1984
4.0 Shape of Cables:

All Cables shall be of circular/sector shaped with neutral conductor as per relevant IS
5.0 Conductors:
5.1 Aluminum Conductor complying with IS: 8130:1984 shall be used.
5.2 The Conductors shall be stranded for Cross Section above 10 sq.mm. & Solid Single Conductor for Cross
Section of 4 sq.mm. 6 sq. mm. & 10 sq.mm.
6.0 Insulation:
6.1 The Conductor shall be provided with PVC insulation applied by extrusion. Thickness of insulation should be as
per IS: 1554 (Part-I) 1988 latest amendment.
6.2 Inner Sheath: The laid up cores shall be provided with Inner Sheath applied by extrusion. It shall be ensured
that the shape of Cable is as circular as possible. Thickness of Inner Sheath should be as per IS:1554 (Part-
I)1988.
6.3 Outer Sheath: The outer sheath shall be applied by extrusion over the inner sheath in case of unarmoured
cable & over the armouring in case of armoured Cable. The colour of outer sheath is black unless otherwise
specified Thickness of outer sheath should be as per IS:1554 (Part-I) 1988.
7 Tests
7.1 All the type tests and routine tests shall be carried out in the Manufacturer’s Works as per IS:1554(Part-I)
1988 or latest amendment thereof.
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7.2 The tests commensurate under ‘Acceptance Tests’ in the relevant IS shall becarried out as ‘Acceptance Test’ In
addition to above, the following tests for PVC insulation and sheath should also be carried out as per
IS:5831:84 during acceptance.
a) Physical tests for insulation and sheath.
i) Tensile strength and Elongation at break.
ii) Ageing test (Optional)
iii) Shrinkage test.
iv) Hot-deformation test (Optional)
b) Fire-Resistance test (Optional)
7.3 All tests shall be performed in presence of Employer’s representative, if so desired by the Employer. The
manufacturer shall give at least thirty (30) days advance notice of shop tests.
7.4 All tests carried out at Works shall be furnished in six(6) copies for approval of the Employer.
7.5 The Cable shall be dispatched from Works only after receipt of Employer’swritten approval of shop test reports.
8 MANUFACTURER’S IDENTIFICATION:
The Manufacturer’s Name or Trade Mark shall be identified throughout the length of the Cable either by
embossing on the sheath or by means of a tape bearing the following particulars.
(a) Manufactuer’s Name or Trade Mark

(b) Voltage Grade
(c) Nominal Section & material of Conductor and Number of Cores
(d) Year of Manufacture.
(e) Inscription for length of Cables at 10 meters interval
(f) Name of the Employer : Name- RGGVY XII Plan
(g) Marking “RGGVY” shall be embossed throughout the length of the Cable at 10 meter spacing (for PVC
Cable conforming to IS:1554 only)
9 PACKING:
9.1 The Cable shall be supplied in non-returnable wooden drums each containing length of 250 Meters of Cable
with tolerance of + 5% 9.2 The drums shall be proofed against attack by white ant or termite, conforming
to IS:10418:1982
10 ARMOURING : Galvanised Flat Steel Strip armouring shall be done for 3 ½ Core / 2Core/4 Core and for
Single Core, the armouring shall be of any metallic non-magnetic Wire, Strip.
11 MARKING :
The following information shall be marked on each drum :
(a) Drum identification No.
(b) Manufacturer’s Name, Brand Name or Trade Mark.
(c) Nominal cross-sectional area of the Conductor of the Cable.
(d) No. of Cores.
(e) Type and Voltage of the Cable.
(f) Length of the Cable on the drum.
(g) Direction of rotation of Drum (by means of an arrow)
(h) Approximate Weight : Tare : Gross
(i) Year of Manufacture.
(j) Purchase Order No.
(k) Month of Delivery.
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(l) Name of the Employer : Name -RGGVY XII Plan)
11.1 The Drums may also be marked with ISI Certificate Mark, if applicable.
12 DESCRIPTION :
1.1 KV Grade multicore stranded Aluminium Conductor PVC insulated, extruded PVC inner sheathed, galvanised
steel strip armoured, extruded PVC outer sheathed conforming to IS:1554 (Part-I)1988 read with its latest
amendment and desired (as per tenderspecification) technical specification.
1.1 KV Grade multicore (4-Core 4 sq.mm. 6 sq.mm. &10 sq.mm.) Solid Aluminium Conductor PVC insulated,
extruded PVC inner sheathed, galvanized steel wire armoured, extruded PVC outer sheathed, conforming to
IS:1554 (Part-I) 1988 read with its latest amendment anddesired (as per tender specification) technical
specification.
13 DRAWING DATA &MANUAL :

The following information shall be furnished intriplicate along with Tenders :
(a) Manufacturer’s leaflet giving construction details, dimensions andcharacteristics of different Cables.
(b) Current rating of Cables including de-rating factor due to grouping,ambient temperatureand type of
various installations.
(c) Write up, sketch illustrating the manufacturer’s recommendation and spliting, jointing and termination of
cables.
(d) List of customers to whom the cable of similar rating has been supplied.
14 Type Test
Report TYPE TEST REPORTS for the type tests conducted in accordance with IS:1554 (Part-I for similar type
of Cables (as per Tender Specification) Type Test Report conducted on similar type of Cable from NABL/
Central Govt./ approved Accredited Testing Laboratory within 5 years is to be submitted along with Tender
Papers.
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1.1 KV GRADE COPPER STRANDED CONTROL CABLE
1. SCOPE:
The specification cover the design, manufacture, at manufacturer’s works, supply and delivery of Copper Control
Cables screened/armoured for use in different EHT/HT /Grid Sub-Stations.
2 GENERAL INFORMATIONS:
The Control Cables are required for the control, protection, instrumentation, auxiliary Power Supply.Each tender
must be accompanied by full information required in the bidding schedule together with pertinent manufacturer’s
literatures, drawings, instruction manuals to enable the purchaser to make an appraisal of the qualityand
suitability of the materials offered. Failure to comply with the provision maybe sufficient reasons to reject the bid.
3 STANDARDS AND REGULATIONS:

All materials shall comply with the applicable provisions of the latest edition ofIndian Standards, Indian Electricity
Rules, Indian Electricity Act and otherapplicable statutory provisions, rules and regulations.
The following standards would apply to the specification.

1. IS-1554 (Part-I) – PVC insulated heavy duty.
2. IS-8130-Conductors for PVC insulated Cables.
3. IS-3961 (Part-II) - Recommended current ratings for Cables.
4. IS-5831-PVC insulated and sheath of Electric Cable.
5. Other relevant standards for screening.
4 CLIMATIC AND ISOCERAUNIC CONDITIONS:
4.1 The climatic conditions at site under which the material shall operate
Satisfactory are as follows;
a) Maximum ambient temperature of the air-in shade (˚C): 50
b) Minimum temperature of the air in shade (˚C): 4
c) Maximum daily average ambient temperature (˚C): 45
d) Maximum Yearly average ambient temperature (˚C): 30
e) Maximum relative humidity (%): 100
f) Average number of thunderstorm days per annum. : 100
g) Average annual rainfall (cm): 200
h) Maximum wind pressure (Kg/M2): 150
i) Earthquake acceleration (g): 0.04 x 2 g
j) Height above Sea Level (m): Not exceeding1000
4.2 The material offered shall be suitable for continuous operation at the full rated capacity under the above
conditions.
5 DESIGN CRITERIA:
The Cables will be used for control protection and instrumentation, auxiliary Power Supply connections of the
various equipment.
5.1 The Cable will be laid in ground or on ladder type traps or drawn in conduit in a hot, humid and tropical
atmosphere. The trays may be over head, suspended orrun in concrete trenches with removable covers. The
tenderer shall indicateclearly the de rating factor for the above conditions.
5.2 The maximum conductor temperature for various classes and type of cables shall be limited to safe value as
per applicable I.S. Cables shall be marked with ISI Certification Mark, if any.
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6.0 SPECIFIC DESIGN REQUIREMENTS:
6.1 1100 Volts Grade Heat Resisting (HR) Copper Cables suitable for use where the combination of ambient
temperature and temperature rise due to load results in conductor temperature not exceeding 85 deg.C under
normal continuous operation and 160 deg.C under short-circuit condition with stranded annealed copper
conductor, HR PVC insulated, HR extruded PVC inner sheathed, round galvanised steel wire armoured (for
multicore cable only) and overall HR extruded PVC sheathed shall generally conform to latest revision of
IS:1554(Part-I). The cores shall be colour coded as per I.S. for easy identification.
Each Conductor shall consists of multi Strands copper wire for 2.5 sq.mm cross section. Conductor wire shall be
stranded. The PVC material for insulation and outer sheathing shall have smooth finish. Armouring shall be of
single layer of 1.6/1.4 mm. dia. G.I.Steel Wires though enough to withstand mechanical stressed during handling
and shall be resistant to action of oil, acid and alkali. The above cable shall beused for control, identification,
inter-link and instrumentation etc.
6.2 CURRENT RATING:

The Cables will have current rating derating factors for an ambient temperature of 45 deg.C and ground cable is
required to be taken into consideration. Thecurrent ratings shall be based on the maximum temperature
85 deg.C for continuous operation at the rated current.
6.3 OPERATION:
Cables shall be capable of satisfactory operation under Power Supply System frequency variation of + 5% and
voltage variation of + 10%.
7DRUM LENGTH OF CABLES:

7.1 The Cables shall be packed in non-returnable wooden drums. The wooden drums should be bearing
distinguishing number with following information duly stenciled on the outer side of one flange.
1. Name of the Manufacturer.

2. Normal sectional area of the Conductor of the Cable.
3. Number of Cores.
4. Type of Cable & Voltage for which it is suitable.
5. Length of Cable in this drum.
6. Direction of rotation of Drum (an arrow)
7. Gross Weight.
8. Purchase Order No. & Date.
9. Year of Manufacture.
10. Property of XXXXX (Name of Employer; RGGVY-XII Plan Projects).
11. Date of Delivery.
7.2 Drums shall be proofed against attack by white ant and termite, Conforming to IS-10418-1982.
7.3 The Cables shall be supplied in Drum lengths of 250/500 Mtr. which shall besubject to tolerance of not more
than + 5% and the variation in the total quantity of Cables due to tolerance in individual drum length shall be
limited to+ 2.5% for all types of Cable. Non-standard drum length shall not be acceptable.However, before
packing the Cables on Drums, the successful bidders will be required to obtain purchaser’s approval for the drum
lengths.
7.4 Embossing on the outer sheath of the Cable with marking “Name of Employer; RGGVY-XII Plan” and length
of the Cable in meters at suitable intermittent distance, preferably 1Mtr.should be done.
8 DRAWING DATA & MANUAL:

The following information shall be furnished in triplicate along with the tenders:
a) Manufacturer’s leaflets giving construction details, dimensions and characteristics of different Cables.
b) Current rating of cables including derating factor due to grouping, ambient temperature and Type of various
installations.
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c) Write up sketch illustrating the manufacturer’s recommendation for splitting, jointing and termination of
different type of cables.
d) List of customers to whom the cable for similar rating has been supplied.
9 TESTS:
9.1 Routine tests in accordance with the provision of relevant standard specificationshall be carried out for each
drum of finished cable lengths.Type Tests and acceptance tests on the samples taken on random basis from
thelot of cables offered for inspection shall have to be carried out as per relevant Indian Standard Specification
to prove the general qualities and design of agiven type of cable and for the purpose of acceptance of the lot.
TYPE TEST REPORTS for the type tests conducted in accordance with IS:1554(Part-I for similar type of Cables
(as per Tender Specification) Type Test Report conducted on similar type of Cable from NABL/ Central Govt./
approved Accredited Testing Laboratory within 5 years is to be submitted.
9.2 WITNESSING OF TESTS:

The tabulation for each test result shall contain corresponding I.S. specifiedlimiting figures to facilitate checking
of test Results. Six (6) copies of type tests certificate lot-wise for each type of cables should be sent to the
Employer for acceptance. Type Test Certificate for each lot and routine test certificate foreach drum of cables
shall be submitted to the Employer for approval before dispatch of cables from the Works. The test certificates
shall be completed withall results.
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CROSS-LINKED POLYETHYLENE INSULATED XLPE, 1-CORE AND 3-CORE 185 mm2, 11KV CABLES
1) SCOPE:
The scope of this package, covers the design, manufacture, stage inspection at works, inspection and testing of
finished cables at manufacture’s works, testing at independent test house, packing transport and delivery to
consignee’s address of 6.35/11 KV three core, 185 mm 2aluminium conductor, XLPE insulated, screened,
underground cables as per specified construction.
2) TECHNICAL REQUIREMENT:
Three core cable
3 core 6.35/11 KV grade, 900 C rating heavy duty power cable with stranded, compacted, circular, aluminum
conductor shielded with extruded semi conducting compound, cross linked, polyethylene insulated, shielded with
extruded semi conducting compound and copper tape, shielded cores laid up with fillers, inner sheath of extruded
PVC, Galvanized steel strip Armour and PVC ST-2 overall sheath.
The cables should be suitable for use in solidly earthed system.
3) STANDARDS:
The 6.35/11KV U.G cable shall, in general, meet the requirements of the latest edition of the Bureau of Indian
standards, (generally referred as IS) IS 7098 ( Part 2) 1985. The cables manufactured to, and meeting the
testing requirements of international standards, like B.S.S. IEC or equivalent standards are also acceptable. The
Manufacturers shall enclose a copy of the equivalent international standard, in English language, along with the
bid.
The cable and components in general shall meet the requirements of the following standards published by the
Bureau of Indian standards with latest amendments or equivalent international standards.
( Part – 2) 1985 : Specification for cross linked polyethylene

insulated PVC sheathed cables, up to 33KV.
1984 : Specification for conductors for insulated
Electric cables.
1979 : Specification for mild steel wires, strips and
tapes for armouring of cables.
1984 : Specification test on cable.
1984 : Specification for PVC insulation and sheath of
electric cables.
1982 : Specification for drums for electric cables
(part – I) 1983 : Fictitious calculation method for

determination of dimensions of protective
coverings of cables part – 1 Elastomeric and
thermoplastic insulated cables.
The 6.35/11KV underground cables shall be manufactured to the highest quality, best workmanship with scientific
material management and quality control. The manufacturer shall furnish the quality plan, giving in detail the
quality control procedure / management system.
The successful Manufacturer shall give sufficient advance notice to the Employer of not less than fifteen days to
arrange for stage inspection and inspection of quality assurance programme during manufacture, at the works.
4) SYSTEM DETAILS:
General Technical particulars
N
Nominal system voltage ( rms) (u) .. 11KV

Highest system voltage ( rms) ( Um) .. 12KV
Phase to Earth voltage ( Uo) .. 6.35 KV
Number of Phase ( for 3 core cables) .. 3
Number of Phase ( for single core cables) .. 1
Frequency ... 50Hz
Variation in Frequency ... +/- 3%
Type of Earthing .. Solidly Earthed
Basic impulse level .. 75KV
( 1.2/50 Micro second wave)
Total relay & circuit breaker .. 15 – 20 Cycles
operating time
One Minute power frequency ..28 KV
withstand voltage
5) INSTALLATION CONDITIONS:
Mostly, directly buried in ground, partly in RCC / Hume pipes or stoneware pipes at road crossing in case of 3
core cables.
Metallic coverings are connected solidly to earth at both ends of the run for 3 core cables.
Normal depth of laying is 900mm to 1000mm ( from top, of ground to centre of cable).
Nature of soil – Normally black cotton soil, but sometimes sandy or stone may also come up for excavation
enroute.
Soil resistivity : variable 18 to 100 ohm-meter
Soil Thermal resistivity ( assumed) 1200 to 1500 C/ Cm/w.
6) DESIGN CRITERIA:
The cables that are covered in these specifications are intended for use in the state of XXXX (Name of State) for
Power distribution system, under the climatic conditions and installation conditions prevailing in the area.
Any technical feature, not specifically mentioned here, but is necessary, for the good performance of the product,
shall be incorporated in the design. Such features shall be clearly brought out under Technical deviations
schedule only, in the offer made by the manufacturer, giving technical reasons, and justifying the need to
incorporate these features.
For continuous operation of the cables, at specified rating, the maximum conductor temperature shall be limited
to the permissible value as per the relevant standard, generally not exceeding 900C under normal operation and
2500C under short – circuit conditions.
The cables in service will be subject to daily load cycles, of two peaks during a day; morning peak and evening
peak, with around 50% loading during the nights.
The materials used for outer sheaths shall be resistant to oils, acids and alkalies.
The cables shall have the mechanical strength required, during handling and laying.
The cables shall be designed to withstand the thermo mechanical forces and electrical stresses during normal
operation and transient conditions.
The cables shall be designed to have a minimum useful life span of Thirty years.
Core identification: The core identification for 3 core cables shall be provided, by suitable means, like, by
application of coloured stripes, or by numerals or by printing on the cores as per clause 13 of IS: 7098.
7) MANUFACTURE PROCESS, CROSS LINKING OF INSULATION:
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Cross linking of the insulation materials (pre compounded polyethylene) shall be conforming to IS: 7098 ( Part –
II). The conductor screen shall be of extruded semi conducting compound. The insulation screen shall consist of
the nonmetallic part, extruded semi conducting compound with non-magnetic metallic part. The XLPE insulation
and the shields for conductor and insulation shall be extruded in one operation.
8) MATERIALS:
Conductor : The conductor shall be of stranded construction. The material for conductor shall consist of the
plain aluminum of H2 or H4 grade as per clause – 3 of IS: 8130/ 1984.
The No. of wires in the conductor shall be not less than the appropriate minimum number given in table – 2 of IS:
8130/ 1984.
Insulation: The insulation shall be cross linked polyethylene conforming to the requirements given in the table –
1 of IS : 7098 Part – II.
9) SCREENING:
The screening shall consist of semi conducting compound. The metallic screen for core shall consists of copper
tape.The semi-conducting compound shall withstand the operating temperature of the cable and shall be
compatible with the insulating material.
10) FILLER AND INNER SHEATH FOR MULTICORE AND SINGLE CORE CABLES:
For multi-core cables, the interstices at the center shall be filled with a non-hygroscopic material.
The interstices around the laid up cores shall be covered with PVC compound type ST-2. This will form the inner
sheath for multicore/ single core cables.
11) ARMOURING FOR 3 CORE AND SINGLE CORE CABLES:
For three core cables the armour shall be galvanized steel strip, complying with the requirements of IS: 3975.
The single core cables shall be armoured with hard drawn Aluminium round wire. A binder tape may be applied
on the armour.
Manufacturers shall furnish the calculation / data sheet for the short circuit carrying capability of the armour.
12) OUTER SHEATH:
The outer sheath shall consist of poly vinyl chloride ( PVC) compound, conforming to the requirements of type
ST-2 of IS: 5831. Suitable additives shall be added to give anti termite protection.
13) CONSTRUCTION:
The general constructional features of the cables shall be as follows:
3 CORE CABLES:
1. Stranded, compacted, circular, aluminium conductor,

2. Conductor screen of extruded semi conducting compound.
3. Cross linked polyethylene insulation, cross linking shall be conforming to IS : 7098 (Part-II).
4. Insulation screen consisting of non metallic part of extruded semi conducting compound and the metallic
part of copper tape (s).
5. Extruded PVC inner sheath.
6. Armour (Galvanized steel strip).
7. Outer PVC sheath with anti-termite treatment.
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CONDUCTOR :
The conductor shall be stranded, compact, circular of aluminium wires of H2 or H4 grade plain aluminium
wires.The conductor shall be clean, uniform in size and shape smooth and free from harmful defects.
Not more then two joints shall be allowed in any one of the single wire forming every complete length of
conductor and no joint shall be with in 300mm of any other joint in the same layer. The joint shall be made by
brazing, silver soldering or electric or gas welding.
No joints shall be made in the conductor after it has been stranded.
CONDUCTOR SCREEN:
The conductor screen shall be provided over the conductor consisting of extruded non- metallic semi conducting
compound.
INSULATION:
The insulation shall be provided over the screened conductor with cross linked polyethylene, applied by extrusion
and shall be of high quality, cross linked, insulation shall conform to IS:7098 (Part– II).
THICKNESS OF INSULATION:
The average thickness of XLPE insulation shall not be less than the nominal value subject to the applicable
tolerance as specified in table 2 of IS:7098.
The insulation shall be applied to closely fit on the conductor screen, and it shall be possible to remove it without
damaging the conductor.
The thickness of semi conducting screen over insulation should not be included in the thickness of insulation.
INSULATION SCREENING:
The insulation screen shall be applied over the insulation.

The non metallic part of the insulation screen shall consist of extruded semi conducting compound.
The metallic part of the insulation screen shall consist of non magnetic material, consisting of copper tape or
tapes, and shall be applied over the non metallic part. For single core armoured cable the armouring shall
constitute the metallic part of armouring.
LAYING UP OF CORES:
For multicore cables, the cores shall be laid together with a suitable right hand lay. The interstices at the center
shall be filled with a non – hygroscopic material.
Inner sheath for Multi core cables:
The cores shall be laid up with a suitable right hand lay and the interstices should be filled with PVC compound
type ST-2 conforming to IS:5831 or equivalent standard. The filling up of interstices shall be by pressure
extrusion and this shall form the inner sheath. This inner sheath shall be of circular shape and shall bind the
cores also.
In case of single core cables where there are both metallic screening and armouring, there shall be extruded inner
sheath between them.
The minimum thickness of the inner sheath shall conform to Table – 3 of IS: 7098 (Part -II), 1985 or equivalent
standard.
The inner sheath shall be so applied that it fits closely on the laid up cores and it shall be possible to remove it
without damage to the insulation cables.
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ARMOURING FOR 3 CORE CABLES:
Application
The armour consisting of galvanised steel strip shall be applied over the inner sheath for multi core cables.
The single core cables armour consisting of hard drawn aluminum round wire shall be applied over the inner
sheath.
The armour wires shall be applied as closely as possible.
The dimensions of the galvanized steel strip and Hard drawn aluminium wires shall conform to IS:7098 part (II).
A binder tape may be applied on the armour.
The joints in the armour wires shall be brazed / welded with joint surface and rendered smooth. The joints shall
be staggered by at least 300mm from the nearest joint in any other armour wire in the completed cable.
OUTER SHEATH:
The PVC Outer sheath with anti termite treatment shall be extruded over the armouring for 3 core cables and
single core cables.
The color of the outer sheath shall be black.
The Thickness of outer sheath shall be not less than the minimum value specified in column 5 of table 5 of IS:
7098 ( part II) 1985.
IDENTIFICATION:
The outer sheath shall have the following information embossed or indented on it; the manufacturer’s name or
trade mark, the voltage grade, the year of manufacture and the letters “RGGVY”. The identification shall repeat
every 300/350 mm along the length of the cable
Note: The outer sheath of the cable should be embossed with “RGGVY Project& name of Employer” at the time of
supply.
14) INSPECTION:
Quality control: The Manufacturer shall furnish a complete and detailed quality plan for the manufacturing
process of the cable. All raw materials shall conform to relevant applicable standards and tested for compliance
to quality and requirement.
During the manufacturing process, at all stages, inspections shall be made to check the physical and dimensional
parameters, for verification to compliance to the standards.
The manufacturer shall arrange, for inspection by the Employer, during manufacture, if so desired by the
Employer, to verify the quality control process of the Manufacturer.
15) TYPE TESTS :
Notwithstanding, that type test have been conducted earlier, the manufacturer shall conduct all type tests as per
IS : 7098 part-II, 1985, with upto date amendments or equivalent international standard, and supplies made only
after approval of test reports from the Employer. The Employer reserves the right to wave the repetition of the
type test.
All type tests, routine, acceptance test shall be conducted in the presence of the Employer/ representative.
The manufacturer shall give 15 days’ advance notice for inspections, and witnessing of tests by the Employer or
his representative.
The following type tests will be conducted on the cable.
a) Test on conductor.
b) Test on armour.
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c) Test for thickness of XLPE insulation and inner and outer sheaths
d) Physical test on XLPE insulation.
e) Physical test for outer sheath.
f) Partial discharge test.
g) Bending test
h) Di-electric power factor test
i) As a function of voltage
ii) As a function of temperature
i) Insulation resistance (volume resistivity ) test
j) Heating cycle test
k) Impulse withstand test
l) High voltage test
m) Flammability test
The following test shall be performed successively on the same test sample of completed cable, not less than 10
M in length between the Test accessories.
I. Partial discharge test.
II. Bending test followed by partial discharge test.
III. Dielectric power factor as a function of voltage.
IV. Dielectric power factor as a function of temperature.
V. Heating cycle test, followed by dielectric power factor as a function of voltage and partial discharge
tests.
VI. Impulse withstand test
VII. High voltage test.
16) ACCEPTANCE TEST :
The sampling plan for acceptance test shall be as per IS ; 7098 part -II 1985, Appendix ‘A’.
The following shall constitute the acceptance test.
a) Tensile test for aluminium.
b) Wrapping test for aluminium.
c) Conductor resistance test.
d) Test for thickness of insulation.
e) Test for thickness of inner and outer sheath.
f) Hot-set test for insulation.
g) Tensile strength and elongation at break test for insulation and outer sheath.
h) partial discharge test (onfull drum length).
i) High voltage test.
j) Insulation resistance (volume resistivity) test.
17) ROUTINE TEST :
The following shall constitute routine tests :

a) Conductor resistance test.
b) partial discharge test on full drum length.
c) High voltage test.
18) PACKING :
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The cables, as per specified delivery lengths, shall be securely wound /packed in non-returnable, well seasoned
sturdy wooden drums, with strong reinforcements so as to withstand rough handling during transport by rail,
Road, etc. The packing should withstand storage conditions in open yards. The cable drums shall conform to IS :
10418-1982 or equivalent standard.
The drawings of cable drums with full detail shall be furnished, and got approved before dispatch.
19) SEALING OF CABLE ENDS ON DRUMS:
The cable ends shall be sealed properly so that ingress of moisture is completely prevented.
The individual core endings shall be sealed effectively with water resistant compound applied over the core and
provided with a heat shrinkable cap of sufficient length with adequate cushion space so that the conductor does
not puncture the cap in case of movement of the core during unwinding or laying. Before sealing, the semi
conducting layer on the cores may be removed for about 2 mm at each end, to facilitate checking the insulation
resistance from one end, without removing the sealing cap at the other end.
The three cores should have a overall heat shrinkable cap with adequate end clearance, and sufficient cushioning
to prevent puncturing of the overall sealing cap due to stretching of the cores. The sealing cap shall have
sufficient mechanical strength and shall prevent ingress of moisture into the cable.
The ends of single core cables shall also be sealed on the same lines to prevent entry of moisture.
20) CABLE LENGTHS :
The cables shall be supplied in continuous lengths of 500M in case of 3 core cable with a tolerance of + or –
5% of drum length.
21) QUANTITY TOLERANCE
+3% tolerance shall be allowed on the ordered quantity.
22) MARKING:
The packed cable drum shall carry the following information, clearly painted or stenciled.
a) The letters “RGGVY PROJECT and name of Employer”.
b) Reference to Standard and ISI mark.
c) Manufacturer’s Name or trade mark.
d) Type of cable & voltage grade.
e) Number of cores.
f) Nominal cross sectional area of conductor.
g) Cable code.
h) Length of cable on the drum.
i) Direction of rotation.
j) Gross weight.
k) Country of Manufacture.
l) Year of Manufacture.
m) Purchase order and date.
n) Address of consignee.
23) DRAWING & LITERATURE:
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The following shall be furnished along with the tender

a) Cross sectional drawings of the cables, giving dimensional details for each size of cable.
b) An illustrated literature on the cable, giving technical information, on current ratings, cable constants, short
circuit ratings, de-rating factors for different types of installation, packing date, weights and other relevant
information.
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PRESTRESSED CEMENT CONCRETE POLES (F.O.S. 2.5) FOR 11 KV AND LT LINES

1. SCOPE
This Specification covers PCC poles with an overall length of 7.5 M, 8.0 M and 9.0 M suitable for use in
overhead 11 KV and L.T. power lines and double pole structures for 11/0.4 KV substations.
Except when they conflict with specific requirements in this Specification, the poles shall comply with
the relevant provisions made in the following Indian Standard Specifications:
a) IS: 1678-1978, Specification for prestressed concrete poles for overhead power, traction and
telecommunication lines.
b) IS: 2905-1966. Methods of test for concrete poles for over-head power and telecommunication lines.
c) IS: 7321-1974. Code of practice for selection, handling and erection of concrete poles for over-head
power and telecommunication lines.
3. TERMINOLOGY
3.0 For the purpose of this standard, the following definitions shall apply:
3.1 Average Permanent Load
That fraction of the working load which may be considered of long duration over a period of one year.
3.2 Load Factor
The ratio of ultimate transverse load to the transverse load at first crack.
3.3 Transverse
The direction of the line bisecting the angle contained by the conductor at the pole. In the case of a
straight run, this will be normal to the run of the line.
3.4 Transverse Load at First Crack
For design, the transverse load at first crack shall be taken as not less than the value of the working load.
3.5 Working load
The maximum load in the transverse direction, that is ever likely to occur, including the wind pressure on
the pole. This load is assumed to act at a point 600 mm below the top with the butt end of the pole planted to
the required depth as intended in the design.
3.6 Ultimate Failure
The conditions existing when the pole ceases to sustain a load increment owing to either crushing of concrete,
or snapping of the pressurising tend on or permanent stretching of the steel in any part of the pole.
3.7 Ultimate Transverse Load
The load at which failure occurs, when it is applied at a point 600 mm below the top and perpendicular to the
axis of the pole along the transverse direction with the butt end of the pole planted to the required depth as
intended in the design.
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4. APPLICATION
4.1 7.5 M and 8.0 M Poles
These poles shall be used at tangent locations for 11KV and L.T. lines in wind pressure zones of 50
kg/M2, 75 Kg/M2 and 100 Kg/M2 in accordance with REC Construction Standards referred to in the following
table.
Pole Line description Reference to

length REC Constn. Stds.
7.5M 11KV lines without earthwire L.T. lines, A-4, B-5

horizontal formation
8.0M 11KV lines with earthwire L.T. lines, vertical A-5, B-6
formation
The adoptable spans shall be as per REC Construction Standards A-8 (for 11 KV Lines) and B-8 (for L.T. Lines)
4.2 9.0 M Poles
These poles shall be used for double pole structures of distribution transformer centres as per REC
Construction Standards F-1 to F-4 and for special locations in 11 KV and L.T. Lines, such as road crossings
etc.
5. MATERIALS
5.1 Cement
The cement used in the manufacture of prestressed concrete poles shall be ordinary or rapid hardening
Portland cement conforming to IS: 269 - 1976 (Specification for ordinary and low heat portland cement)
or IS : 8041 E-1978 (Specification for rapid hardening portland cement).
5.2 Aggregates
Aggregates used for the manufacture of pre-stressed concrete poles shall conform to IS: 383 -
1970 (Specification for coarse and fine aggregates from natural sources for concrete). The nominal
maximum size of aggregates shall in no case exceed 12 mm.
5.3 Water
Water should be free from chlorides, sulphates, other salts and organic matter. Potable water will be generally
suitable.
5.4 Admixtures
Admixtures should not contain Calcium Chloride or other chlorides and salts which are likely to promote
corrosion of pre-stressing steel.
5.5 Pre-stressing Steel
The pre-stressing steel wires, including those used as untensioned wires (See Annex.I), should conform
to IS : 1785 (Part-I) - 1966 (Specification for plain hard-drawn steel wire for prestressed concrete. Part-I
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cold drawn stress relieved wire), IS: 1785 (Part-II) - 1967 (Specification for plain hard-drawn
steel wire)., or IS : 6003 - 1970 (Specification for indented wire for pre-stressed concrete). The type
designs given in Annexure-I are for plain wires of 4 mm diameter with a guaranteed ultimate strength of 175
Kg/mm2.
5.6 The concrete mix shall be designed to the requirements laid down for controlled concrete (also
called design mix concrete) in IS : 1343 - 1980 (Code of practice for prestressed concrete) and IS : 456
- 1978 (Code of practice for plain and reinforced concrete), subject to the following special conditions;
a) Minimum works cube strength at 28 days should be at least 400 Kg/cm2.
b) The concrete strength at transfer should be at least 200Kg/cm2.
c) The mix should contain at least 380 Kg. of cement per cubic meter of concrete.
d) The mix should contain as low a water content as is consistent with adequate workability. If it becomes
necessary to add water to increase the workability, the cement content also should be raised in such a way
that the original value of water cement ratio is maintained.
6. DESIGN REQUIREMENTS
The poles shall be designed for the following requirements:
a) The poles shall be planted directly in the ground with a planting depth of 1.5 meters.
b) The working load on the poles should correspond to those that are likely to come on the pole during
their service life. Designs given in Annexure-I are for 140 Kg. and 200 Kg. Applied at 0.6 M from top.
c) The factor of safety for all these poles shall not be less than 2.5.
d) The average permanent load should be 40% of the working load.
e) The F.O.S. against first crack load shall be 1.0.
f) At average permanent load, permissible tensile stress in concrete shall be 30 Kg/cm2.
g) At the design value of first crack load, the modulus of rupture shall not exceed 55.2 kg/cm2 for M-40
concrete.
h) The ultimate moment capacity in the longitudinal direction should be at least one fourth of that in
the transverse direction.
i) The maximum compressive stress in concrete at the time of transfer of prestress should not
exceed 0.8 times the cube strength.
j) The concrete strength at transfer shall not be less than half the 28 days strength ensured in the design,
i.e. 400 x 0.5= 200 Kg/cm2.
For model check calculations on the design of poles, referred to in Annexure-I, a reference may be
made to the REC “Manual on Manufacturing of solid PCC poles, Part-I - Design Aspects”
6.1 Dimensions and Reinforcements
The cross-sectional dimensions and the details of prestressing wire should conform to the particulars given in
Annexure-I.
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The provisions of holes for fixing cross-arms and other fixtures should conform to the REC
standards referred to in clause 4 of this specification and in accordance with the construction practices
adopted by the State Electricity Boards.
7. MANUFACTURE
7.1 All prestressing wires and reinforcements shall be accurately fixed as shown in the drawings
and maintained in position during manufacture. The untensioned reinforcement, as indicated in the
drawings, should be held in position by the use of stirrups which should go round all the wires.
7.2 All wires shall be accurately stretched with uniform prestress in each wire. Each wire or group of wires
shall be anchored positively during casting. Care shall be taken to see that the anchorages do not yield
before the concrete attains the necessary strength.
7.3 Cover
The cover of concrete measured from the outside of the prestressing tendon shall be normally 20 mm.
7.4 Welding and Lapping of Steel
The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be
allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or
coupling is not less than the strength of each individual wire.
7.5 Compacting
Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical means. Hand
compaction shall not be permitted.
7.6 Curing
The concrete shall be covered with a layer of sacking, canvas, hessian or similar absorbent material and kept
constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of
concrete at transfer of prestress. Thereafter, the pole may be removed from the mould and watered at
intervals to prevent surface cracking of the unit, the interval should depend on the atmospheric humidity
and temperature.
7.7 The prestressing wires shall be detensioned only after the concrete has attained the specified strength
at transfer (i.e. 210 Kg/cm2). The cubes cast for the purpose of determining the strength at transfer should
be cured, as far as possible, under conditions similar to those under which the poles are cured. The
transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified
strength indicated above is reached. Thereafter the test on concrete shall be carried out as detailed in IS :
1343 - 1960 (Code of practice for prestressed concrete). The manufacturer shall supply when required by
the employer or his representative, result of compressive test conducted in accordance with IS : 456 -
1964 (Code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used
for the poles. If the employer so desires, the manufacturer shall supply cubes for test purposes and such
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cubes shall be tested in accordance with IS : 456 – 1964(Code of practice for plain and reinforced
concrete).
The detensioning shall be done by slowly releasing the wires, without imparting shock or sudden load to the
poles. The rate of detensioning may be controlled by any suitable means either mechanical (screw type) or
hydraulic.
The poles shall not be detensioned or released by cutting the prestressing wires using flames or bar
croppers while the wires are still under tension.
7.8 Separate eye-hooks or holes shall be provided for handling and transport, one each at a distance of
0.15 times the overall length, from either end of the pole. Eye-hooks, if provided, should be properly
anchored and should be on the face that has the shorter dimension of the cross-section. Holes, if provided
for lifting purposes, should be perpendicular to the broad face of the pole.
Stacking should be done in such a manner that the broad side of the pole is vertical. Each tier in the
stack should be supported on timber sleepers located at 0.15 times the overall length, measured from the
end. The timber supports in the stack should be aligned in a vertical line.
Poles should be transported with their broad faces placed vertically and in such a manner that shocks are
avoided. Supports should be so arranged that they are located approx. at a distance equal to 0.15 times the
overall length from the ends. The erection of the pole should be carried out in such a way that the erection
loads are applied so as to cause moment with respect to the major axis. i.e. the rope used for hoisting the
pole should be parallel to the broader face of the pole.
7.9 Earthing
7.9.1 Earthing shall be provided by having a length of 8 SWG GI wire embedded in concrete during
manufacture and the ends of the wires left projecting from the pole to a length of 50 mm. At 250 mm from top
and 150 mm below ground level.
7.9.2 The earth wire shall not be allowed to come in contact with the prestressing wires.
7.10 General
For further details on the process of manufacture, a reference may be made to REC “Manual on Manufacturing
of Solid PCC Poles Part II Manufacturing Aspects”.
8. TESTS
8.1 Transverse Strength Test
8.1.1 Poles made from ordinary Portland cement shall be tested only on the completion of 28
days and poles made from rapid-hardening cement only on the completion of 14 days, after the
day of manufacture.
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8.1.2 The pole may be tested in either horizontal or vertical position. If tested in horizontal position,
provisions shall be made to compensate for the overhanging weight of the pole, for this purpose the over-
hanging portion of the pole may be supported on a movable trolly or similar device.
8.1.3 The pole shall be rigidly supported at the butt end for a distance equal to the agreed depth of planting
i.e. 1.5 M.
8.1.4 Load shall be applied at a point 600 mm from the top of the pole and shall be steadily and gradually
increased to design value of the transverse load at first crack. The deflection at this load shall be measured.
A prestressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage
prior to the application of the design transverse load for the first crack.
The load shall then be reduced to zero and increased gradually to a load equal to the first crack load
plus 10% of the minimum ultimate transverse load, and held up for 2 minutes. This procedure shall be
repeated until the load reaches the value of 80 per cent of the minimum ultimate transverse load
and thereafter increased by 5 per cent of the minimum ultimate transverse load until failure occurs. Each
time the load is applied, it shall be held for 2 minutes. The load applied to prestressed concrete pole at the
point of failure shall be measured to the nearest five Kilograms.
The pole shall be deemed not to have passed the test if the observed ultimate transverse load is less than the
design ultimate transverse load.
8.2 Measurement of Cover
After completion of the transverse strength test, the sample pole shall be taken and checked for cover. The
cover of the pole shall be measured at 3 points, one within 1.8 meters from the butt end of the pole, the
second within 0.6 metre from the top and the third at an intermediate point and the mean value compared
with the specified value.
The mean value of the measured cover should not differ by more than(±)1 mm from the specified
cover. The individual values should not differ by more than (±) 3 mm from specified value.
If these requirements are not met, the workmanship with reference to aligning of the end plates
and prestressing wires and assembly of moulds should be improved and inspection at pre-production stage
tightened suitably.
9. SAMPLING AND INSPECTION
9.1 Scale of Sampling
9.1.1 Lot: In any batch, all poles of the same class and same dimensions shall be grouped together to
constitute a lot.
9.1.1.1 Sub-lot: If the number of poles in a lot exceed 500, the lot shall be divided into a suitable number of
sub lots such that the number of poles in any sub-lot shall not exceed 500. The acceptance or otherwise of a
sub-lot shall be determined on the basis of the performance of samples selected from it.
9.1.2 The number of poles to be selected from a lot or a sub-lot shall depend upon its size and shall be
in accordance with Col. 1 and 2 of the following table:
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SAMPLE SIZE AND CRITERION FOR CONFORMITY
(Clauses 9.1.2, 9.2.2 & 9.3.2)
Scale of sampling & permissible no. of defectives
No. of poles in Dimensional requirement Transeverse Transverse

the lot Strength strength
Sample size Acceptance no.
test ultimate
1. 2. 3. 4. 5.
Up to 100 10 1 2 1
101-200 15 1 3 1
201-300 20 2 4 1
301-500 30 3 5 2
*The number of poles to be tested shall be subject to the agreement between the employer and manufacturer
9.1.3 These poles shall be selected at random. In order to ensure randomness, all the poles in the lot or the
sub-lot may be arranged in a serial order and starting from any random pole, every rth pole may be included
in the sample, being the integral part of N/n where N is the size of the lot or the sub-lot and n is the sample
size.
9.2 Number of Tests
9.2.1 All the poles as selected in 9.1.2 shall be tested for overall length, cross-section
and uprightness. The tolerance shall be (±) 15 mm on overall length(±)5 mm on crosssectional dimensions
and 0.5 per cent on uprightness.
9.2.2 The number of poles to be tested for transverse strength test shall be accordance with Col. 4 of the
above table. These poles may be selected from those already tested in 9.2.1.
9.3 Criteria for Conformity
9.3.1 A lot or sub-lot shall be considered as conforming to this specification if the conditions under 9.3.2
and 9.3.3 are satisfied.
9.3.2 The number of poles which does not satisfy the requirements of overall length, cross-section and
uprightness shall not exceed the corresponding number given in Col. 3 of Table in 9.1.2. If the number of such
poles exceeds the corresponding number, all poles in the lot or sub-lot shall be tested for these requirements
and those not satisfying the requirements shall be rejected.
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9.3.3 All the poles tested for transverse strength test shall satisfy the requirements of the test. If one or more
poles fail, twice the number of poles originally tested shall be selected from those already selected and subjected
to the test. If there is no failure among these poles, the lot or the sub-lot shall be considered to have satisfied
the requirements of this test.
10. MARKING
The pole shall be clearly and indelibly marked with the following particulars either during
or after manufacture but before testing at a position so as to be easily read after erection in position.
a) Month and year of manufacture
b) Transverse strength of pole in Kg.
c) Maker’s serial No. and mark
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PRESTRESSED CONCRETE POLES FOR 33 KV LINES
1. SCOPE
This specification covers solid rectangular and Virendeel type PCC poles with F.O.S 2.5 with an overall
length of 9.0 and 9.5M suitable for use in overhead 33 KV power lines.
Except when they conflict with specific requirements in this Specification, the poles shall comply with
the relevant provisions made in the following Indian Standards or the latest versions thereof.
a) IS: 1678-1978, Specification for prestressed concrete poles for overhead power, traction
andtelecommunication lines.
b) IS: 2905-1966. Methods of test for concrete poles for overhead power and
telecommunicationlines.
c) IS: 7321-1974. Code of Practice for selection, handling and erection of concrete poles foroverhead
power and telecommunication lines.
3. TERMINOLOGY
For the purpose of this standard, the following definitions shall apply:-
3.1 Average Permanent Load

That fraction of the working load which may be considered of long duration over a period of one year.
3.2 Load Factor

The ratio of ultimate transverse load to the transverse load at first crack.
3.3 Transverse
The direction of the line bisecting the angle contained by the conductor at the pole. In the case of a
straight run, this will be normal to the run of the line.
3.4 Transverse Load at First Crack

For design, the transverse load at first crack shall be taken as not less than the value of the working load.
3.5 Working Load
The maximum load in the transverse direction, that is ever likely to occur, including the wind pressure on
the pole. This load is assumed to act at a point 600mm below the top with the butt end of the pole planted
to the required depth as intended in the design.
3.6 Ultimate Failure

The condition existing when the pole ceases to sustain a load increment owing to either crushing of concrete,
or snapping of the prestressing tendon or permanent stretching of the steel in any part of the pole.
3.7 Ultimate Transverse Load

The load at which failure occurs, when it is applied at a point 600 mm below the top and perpendicular to the
axis of the pole along the transverse direction with the butt end of the pole planted to the required depth as
intended in the design.
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4. APPLICATION
4.1 9.0 M Poles
These poles shall be used at tangent locations of 33 KV lines using conductor formation and clearances as
per REC Construction Standard M-3. The requirement of working loads of the poles in different wind pressure
zones would be as per REC Construction Standard M-2, which is reproduced below:
Working load of Pole Zone
a) 200kg 50 kg/M2
b) 300 kg 75 kg/M2
c) 400 kg 100 kg/M2
The maximum permissible spans shall be as per REC Construction Standard .
4.2 9.5 M Poles

These poles shall be used for special locations of 33 KV lines such as road crossings etc. in
the same wind pressure zones, as in Clause 4.1.
4.3 The poles are not suitable for use in cyclone affected Coastal areas, or in areas with higher wind
pressures than indicated in Clause 4.1. Special designs of poles would have to be evolved for such areas.
5. MATERIAL
5.1 Cement
The cement used in the manufacture of prestressed concrete poles shall be ordinary or rapid hardening
portland cement conforming to IS : 269-1976 (Specification for ordinary and low heat portland cement) or IS :
8041 E-1978 (Specification for rapid hardening portland cement), or high strength ordinary portland
cement conforming to IS : 8112-1976 (Specification for high strength ordinary portland cement).
5.2 Aggregates
Aggregates used for the manufacture of prestressed concrete poles shall confirm to IS : 383-1970
(Specification for coarseand fine aggregates fromnatural sources forconcrete).The nominal maximum size of
aggregates shall in no case exceed 10 mm.
5.3 Water
Water should be free from chlorides, sulphates, other salts and organic matter. Potable water will be generally
suitable.
5.4 Admixture
Admixtures should not contain Calcium Chloride or other chlorides and salts which are likely
to promote corrosion of prestressing steel.
5.5 Pre-stressing steel

The pre-stressing steel wires, including those used as untensioned wires (See Annex.I and II), should
conform to IS : 1785(Part-I)-1983 (Specification for plain hard-drawn steel wire for prestressed concrete, Part-
I cold drawn stress relieved wire)
or
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IS:6003-1983 (Specification for indented wire for prestressed concrete) or the latest versions thereof. The
type designs given in Annexure-I and II are for plain wires of 4 mm diameter with a guaranteed ultimate
strength of 175 kg/mm2 and for plain wires of 5 mm diameter with a guaranteed ultimate strength of 160
kg/mm2.
5.6 The concrete mix shall be designed to the requirements laid down for controlled concrete (also called
design mix concrete) in IS : 1343-1980 (Code of practice for prestressed concrete) and IS : 456-1978 (Code of
practice for plain and reinforced concrete), subject to the following special conditions:
a) Maximum works cube strength at 28 days should be at least 400 kg/cm2.

b) The concrete strength at transfer should be atleast 200 kg/cm2.
c) The mix should contain at least 380 kg of cement per cubic meter of concrete.
d) The mix should contain as low a water content as is consistent with adequate workability. If it
becomes necessary to add water to increase the workability, thecement content also should
be raised in such a way that the original value of water cement ratio is maintained.
6. Design requirements
The poles shall be designed for the following requirements:
a) The poles shall be planted directly in the ground with a planting depth as per IS : 1678-19.
b) The working load on the poles should correspond to those that are likely to come on the
poleduring their service life. designs given in Annex. I and II are for 200 kg., 300 kg. and
400 kg. applied at 0.6 M from top.
c) The factor of safety for all these poles shall not be less than 2.5.
d) The average permanent load shall be 40% of the working load.
e) The F.O.S. against first crack load shall be 1.0.
f) At average permanent load, permissible tensile stress in concrete shall be 30 kg/cm2.
g) At the design value of first crack load, the modulus of rupture shall not exceed 53.0 kg/cm2for
M-400 concrete.
h) The ultimate moment capacity in the logitudinal direction should be at least one fourth of thatin
the transverse direction.
i) The maximum compressive stress in concrete at the time of transfer of prestress should not
exceed 0.8 times the cube strength.
j) The concrete strength at transfer shall not be less than half the 28 days strength ensured in
the design, i.e. 400 x 0.5 = 200 kg/cm2.
6.1 Dimensions and Reinforcements

The cross-sectional dimensions and the details of prestressing wires should conform to the particulars given
in Annexure-I and II.
The provisions of holes for fixing cross-arms and other fixtures should conform to the REC
standards referred to in clause 4. of this specification and in accordance with the construction practices
adopted by the State Electricity Boards.
7. MANUFACTURE
7.1 All prestressing wires and reinforcements shall be accurately fixed as shown in drawings and maintained
in position during manufacture. The untensioned reinforcement, as indicated in the drawings, should be held
in position by the use of stirrups which should go round all the wires.
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7.2 All wires shall be accurately stretched with uniform prestress in each wire. Each wire or a group of
wires shall be anchored positively during casing. Care should be taken to see that the anchorages do not yield
before the concrete attains the necessary strength.
7.3 Cover
The cover of concrete measured from the outside of pre-stressing tendon shall be normally 20 mm.
7.4 Welding and Lapping of Steel

The high tensile steel wire shall be continuous over the entire length of the tendon. Welding shall not be
allowed in any case. However, jointing or coupling may be permitted provided the strength of the joint or
coupling is not less than the strength of each individual wire.
7.5 Compacting
Concrete shall be compacted by spinning, vibrating, shocking or other suitable mechanical means. Hand
compaction shall not be permitted.
7.6 Curing
The concrete shall be covered with a layer of sacking, canvass, hessian or similar absorbent material and
kept constantly wet up to the time when the strength of concrete is at least equal to the minimum strength of
concrete at transfer of prestress. Thereafter, the pole may be removed from the mould and watered at
intervals to prevent surface cracking of the unit, the interval should depend on the atmospheric humidity
and temperature.
7.7 The prestressing wires shall be detensioned only after the concrete has attained the specified strength
at transfer (i.e. 200 kg/cm2). The cubes cast for the purpose of determining the strength at transfer should
be cured, as far as possible, under conditions similar to those under which the poles are cured. The
transfer stage shall be determined based on the daily tests carried out on concrete cubes till the specified
strength indicated above is reached. Thereafter the test on concrete shall be carried out as detailed in IS :
1343-1980 (Code of practice for prestressed concrete). The manufacturer shall supply, when required by the
employer or his representative, result of compressive test conducted in accordance with IS : 456-
1978 (Code of practice for plain and reinforced concrete) on concrete cubes made from the concrete used
for the poles. If the employer so desires, the manufacturer shall supply cubes for test purposes and such
cubes shall be tested in accordance with IS : 456-1978 (Code of practice for plain and reinforced concrete).
The detensioning shall be done by slowly releasing the wires, without imparting shock or sudden load to
the poles. The rate of detensioning may be controlled by any suitable means either mechanical (screw type)
or hydraulic.
The polesshall not be detensioned or released by cutting the pre-stressing wires using flames or bar
croppers while the wires are still under tension.
7.8 Separate eye-hooks or holes shall be provided for handling the transport, one each at a distance of
0.15 times the overall length, from either end of the pole. Eye-hooks, if provided, should be properly
anchored and should be on the face that has the shorter dimension of the cross-section. Holes, if provided
for lifting purposes, should be perpendicular to the broad face of the pole.
Stacking should be done in such a manner that the broad side of the pole is vertical. Each tier in the stack
should be supported on timber sleepers located as 0.15 times the overall length, measured from the end.
The timber supported in the stack should be aligned in a vertical line.
Poles should be transported with their broad faces placed vertically and in such a manner that shocks are
avoided. Supports should be so arranged that they are located approximately at a distance equal to 0.15
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times the overall length from the ends. The erection of the pole should be carried out in such a way that the
erection loads are applied so as to cause moment with respect to the major axis, i.e. the rope used
for hoisting the pole should be parallel to the broader face of the pole.
7.9 Earthing
7.9.1 Earthing shall be provided by having length of 8 SWG GI wire embedded in concrete during
manufacture and the ends of the wires left projecting from the pole to a length of 100mm at 250 mm from top
and 150 mm below ground level.
7.9.2 Earth wire shall not be allowed to come in contact with the prestressing wires.
7.9.3 The possible location of earth wire for different varieties of poles has been shown in Drawing Nos. 1
to 8.
8. TESTS
8.1 Transverse Strength Test
8.1.1 Poles made from ordinary portland cement shall be tested only on the completion of 28 days
and poles made from rapid hardening cement only on the completion of 14 days, afterthe day of
manufacture.
8.1.2 The poles may be tested in either horizontal or vertical position. If tested in horizontal
position, provisions shall be made to compensate for the overhanging weight of the pole, for this purpose, the
overhanging portion of the pole may be supported on a movable trolley or similar device.
8.1.3 The pole shall be rigidly supported at the butt end for a distance equal to the agreed depth of planting.
8.1.4 Load shall be applied at a point 600 mm from the top of the pole and shall be steadily and gradually
increased to the design value of the transverse load at first crack. The deflection at this load shall be
measured.
A prestressed concrete pole shall be deemed not to have passed the test if visible cracks appear at a stage
prior to the application of the design transverse load for the first crack.
The load shall then be reduced to zero and increased gradually to a load equal to the first crack load
plus 10% of the minimum ultimate transverse load, and held up for 2 minutes. This procedure shall be
repeated until the load reaches the value of 80 per cent of the minimum ultimate transverse load
and thereafter increased by 5 per cent of the minimum ultimate transverse load until failure occurs. Each
time the load is applied, it shall be held for 2 minutes. The load applied to prestressed concrete pole at
the point of failure shall be measured to the nearest five Kilograms.
The pole shall be deemed not to have passed the test if the observed ultimate transverse load is less than
the design ultimate transverse load.
8.2 Measurement of Cover

After completion of the transverse strength test, the sample pole shall be taken and checked for cover. The
cover of the pole shall be measured at 3 points, one within 1.8 meter from the butt end of the pole, the second
within 0.6 meters from the top and the third at an intermediate point and the mean value compared with the
specified value.
The mean value of the measured cover should not differ by more than (±) 1mm from the specified
cover. The individual values should not differ by more than (±) 3mm from the specified value.
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If these requirements are not met, the workmanship with reference to aligning of the end plates
and prestressing wires and assembly of moulds should be improved and inspection at pre-production stage
tightened suitably.
9. SAMPLING AND INSPECTION
9.1 Scale of Sampling

9.1.1 Lot:In any batch, all poles of the same class and same dimensions shall be grouped together to
constitute a lot.
9.1.1.1 Sub-lot: If the number of poles in a lot exceeds 500, the lot shall be divided into a suitable number of
sub lots such that the number of poles in any sub-lot shall not exceed 500. The acceptance or otherwise of
sub-lot shall be determined on the basis of performance of samples selected from it.
9.1.2 The number of poles to be selected from a lot or a sublot shall depend upon its size and shall be
in accordance with Col. 1 and 2 of the following table:
SAMPLE SIZE AND CRITERION FOR CONFORMITY

Clause 9.1.2, 9.2.2 & 9.3.2
Size of lot or Dimensional Requirement No. of poles for
sub-lot Sample Permissible No. of transverse
size defective samples strength test
1 2 3 4
Upto 100 10 1 *
101 to 200 15 1 3
201 to 300 20 2 4
301 to 500 30 3 5
* The no. of poles to be tested shall be subject to the agreement between employer&manufactuer.
9.1.3 These poles shall be selected at random. In order to ensure randomness, all the poles in the lot or the
sub-lot may be arranged in a serial order and starting from any random pole, every rth pole may be included
in the sample, r being the integral part of N/n where N is size of the lot or the sub-lot and n is the sample size.
9.2 Number of Tests

9.2.1 All the poles as selected in 9.1.2 shall be tested for overall length, cross-section
and uprightness. The tolerance shall (±)3 mm on cross sectional dimensions and 0.5 percent on uprightness.
9.2.2 The number of poles to be tested for transverse strength test shall be in accordance with Col. 4 of the
above table. These poles may be selected from these already tested in 9.2.1
9.3 Criteria for Conformity

9.3.1 A lot or sub-lot shall be considered as conforming to this specification if the conditions under 9.3.2
and 9.3.3 are satisfied.
9.3.2 The number of poles which does not satisfy the requirements of overall length, cross-section and
uprightness shall not exceed the corresponding number given in Col. 3 of Table in 9.1.2. If the number of
such poles exceeds the corresponding number, all poles in the lot or sub-lot shall be tested for these
requirements and those not satisfying the requirements shall be rejected.
9.3.3 All the poles tested for transverse strength test shall satisfy the requirements of the test. If one or
more poles fail, twice the number of poles originally tested shall be selected from those already selected and
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subjected to the test. If there is no failure among these poles, the lot or the sub-lot shall be considered to have
satisfied the requirements of this test.
10. MARKING
The pole shall be clearly and indelibly marked with the following particulars either during
or after manufacture but before testing at a position so as to be easily read after erection in position:
a) Month and year of manufacture
b) Transverse strength of pole in Kg.
c)
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THIS SECTION COVERS TECHNICAL SPECIFICATION FOR LT SWITCH BOARD OF 16,25,63 & 100 KVA
(SINGLE/ 3-PHASE) DISTRIBUTION TRANSFORMER
A. LT SWITCH BOARD FOR 16 and 25 KVA (Single/ 3-Phase) DISTRIBUTION TRANSFORMER
1. GENERAL
This specification covers LT switchboards required for 415 Volts system voltage for 3 Phase 4 wires and single
phase 2 wires with neutral solidly grounded system. They are to be provided in distribution substations on
secondary side of transformer.
LT switchboard shall be provided with insulated handles.
The box shall have two compartments each lockable separately. The LT connections through copper
cable/conductor from LT bushing of DT shall terminate at SPN MCB/TP MCCB . The output from SPN MCB/TP
MCCB shall be extended to the lower compartment of the box. In the lower compartment, LT buses including
neutral bus shall be mounted.
The switchboard shall comprise of MS outdoor housing containing incoming and outgoing feeders to match with the
capacity of the Distribution Transformer to be controlled as indicated below.
S.No. Type of DTR Incomer Outgoing Mounting

Arrangement
A 16 KVA 1-Phase DTR 63 A SPN MCB 2 X 32 A SPN MCB Channel Frame
B 16 KVA 3-Phase DTR 63 A TP MCCB 2X40 A TP MCCB Channel Frame
C 25 KVA 3-Phase DTR 100 A TP MCCB 3 X 40 A TP MCCB Channel Frame
All outgoing LT feeders (numbers to be decided by utility based on number of service connection/
outgoing feeders) shall emanate from LT buses get connected to LT feeder through respective SPN MCB/TP
MCCB. Suitable no. of holes with cable glands along with IS approved gaskets shall be provided in the lower
compartment of the distribution. Neoprene Rubber gasket shall be used in the door to avoid ingress of moisture
and other elements in the distribution box. The distribution box shall have painting as per relevant IS standards.
The Switchboard shall be made of MS of thickness not less than 2.5 mm. door panel and 4 mm Body panel
and shall be dust, moisture, vermin and weather proof with degree of protection IP 55 as per IS: 13947 suitable
for outdoor use. Box shall be mounted on distribution transformer / pole structure.
All parts, doors, movable covers and panels shall be fitted all around with neoprene gaskets. The gaskets shall
be provided along a channel on periphery of the doors and covers. Ventilating louvers shall be provided with
brass screen and filters.
The Switchboard shall have neat appearance inside and outside with all equipment mounted flush having no
visible welds, with all exterior surfaces even and smooth.
The door is to be provided in front with internal hinges. Cable entries shall be from bottom. Cable gland plate
and gland shall be provided at the bottom plate. The wiring shall be such that terminals are accessible by use of
ordinary tools. Connections shall be provided with adequate clearance to avoid short circuits and risk of fire and
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ease in connection and disconnection. All internal wiring should be with fire resistance low smoke PVC insulated
cables of copper core size 2.5 sq. mm minimum complying with IS: 1554.
2. GOVERNING STANDARDS
The equipment will be manufactured in conformity with the following Indian Standard Specification (latest editions).
IS:2950 A.C. Connectors
IS:8623/1993 Low Voltage Switchgear and Control gear Assemblies
IS:9676/1980 Temperature weather condition.
3. SPN MCB/TPMCCB
Incoming and Outgoing circuits shall be provided with SPN MCB/TP MCCB .
4. BUS BAR AND CONNECTIONS
Phase and neutral bus bar shall be provided along with links and connectors of electrolytic aluminium with 99.9
percent purity of approved make. The phase bus bars should be insulated with PVC or heat shrinkable sleeves of
phase code coloured i.e. red, yellow and blue or suitably painted with plastic insulating compounds.
The bus bars shall be suitably supported on insulators to stand the mechanical and electric forces on account of short
circuit on the system.
The bus bar conductors shall be uniform throughout its length and in no case tapered. The size shall be so chosen to
limit current density to 1.0 Amps per sq. mm.
The electrical contacts between bus bars and connecting link shall be bolted type and lavish contact surface shall be
provided. Bus bars shall be enclosed in a separate compartment with link arrangement for extension.
The neutral bus bar should be of the same size and current carrying capacity as that of phase bus bar.
All bus bar joints, live bolted connections; joints between cable terminals and switchgear terminals etc. shall be
covered with electric insulating non-corrosive sealing compound or heat shrinkable tapes to avoid accidental contact
and flashover.
5. EARTHING
Suitable Earthing arrangement shall be provided.
6. TESTS
Each type of LV Switchboard shall be completely assembled, wired, adjusted and tested at the factory as per the
relevant standards and during manufacture and on completion.
Routine Test
The tests shall be carried out in accordance with IS 13947 and 8623 include including but not necessarily limited to
the following:
(a) Visual Check
(b) Verification of Component Rating
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(c) Other Checks
i) Easy Accessibility and Maintenance
ii) Colour Coding provided by coloured tapes.
iii) Bus bar dimensions
iv) Degree of Protection check by paper.
(d) Dimension check
(e) Insulation Resistance Tests
(f) Mechanical Operation Tests
(g) Bus bar support and clearances
(h) Continuity of circuits and Function
(i) Painting
(j) Overload Release setting of the Circuit Breakers
Type Test
All type tests shall be performed in accordance with IS 13947 and 8623
7. ENERGY METER
Each incoming panel shall be provided with the energy meter. (Details of the energy meter shall be given
separately by purchaser)
8. PROTOTYPE SAMPLE
A prototype sample of each category of the LV Switchboard should be initially manufactured and submitted for
approval of purchaser before taking up mass manufacture.
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B. LT SWITCH BOARD FOR 63 and 100 KVA DISTRBUTION TRANSFORMERS
1. GENERAL
This specification covers LT switchboards required for 415 Volts system voltage for 3 phase, 4 wires, neutral solidly
grounded system. They are to be provided in distribution substations on secondary side of transformer.
The switchboard shall comprise of MS outdoor housing containing incoming and outgoing feeders to match with the
capacity of the Distribution Transformer to be controlled as indicated below.
Sl. No. Transformer Full Load Incoming Outgoing Mounting

Capacity Current Circuit Circuits Arrangement
KVA Amps Configuration Configuration
A 63 88 Amp 125 A TP MCCB 3 X 63 A TP MCCB Channel Frame
B 100 139 200 A TP MCCB 2 X 63 A TP MCCB Channel Frame

& 1 X 100 A TP
MCCB
The Switchboard shall be MS of thickness not less than 2.5 mm. door panel and 4 mm Body panel and shall be dust,
moisture, vermin and weather proof with degree of protection IP 55 as per IS: 13947 suitable for outdoor use. They
shall be of freestanding structure, independent floor mounting design or mounted on a channel frame at a suitable
height of about 1.2 meters from the floor. It shall have sufficient channel and angle re-enforcement to resist
vibrations and rigidity during transportation, erection and operation.
All parts, doors, movable covers and panels shall be fitted all around with neoprene gaskets. The gaskets shall be
provided along a channel on periphery of the doors and covers. Ventilating louvers shall be provided with brass
screen and filters.
The Switchboard shall have neat appearance inside and outside with all equipment mounted flush having no visible
welds, with all exterior surface even and smooth. The door is to be provided in front with internal hinges.
Cable entries shall be from bottom. Cable gland plate and gland shall be provided at the bottom plate. The wiring
shall be such that terminals are accessible by use of ordinary tools. Connections shall be provided with adequate
clearance to avoid short circuits and risk of fire and ease in connection and disconnection. All internal wiring should
be with fire resistance low smoke PVC insulated cables of copper core size 2.5 sq. mm minimum complying with IS:
1554.
The entire switchboard shall be suitable to withstand short circuit current equivalent to 25 MVA 415 Volts for one
second.
2. OPERATION AND SAFETY
All operations shall be from the front.
3. GOVERNING STANDARDS
The equipment will be manufactured in conformity with the following Indian Standard Specification (latest editions).
IS:2950 A.C. Connectors
IS:8623/1993 Low Voltage Switchgear and Control gear Assemblies
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IS:9676/1980 Temperature weather condition;
4. TP MCCB FUSE SWITCH
Incoming and Outgoing circuits shall be provided with TP MCCB Fuse Switch.
5. BUS BAR AND CONNECTIONS
Triple pole and neutral bus bar shall be provided along with links and connectors of electrolytic aluminium with 99.9
percent purity of approved make. The phase bus bars should be insulated with PVC or heat shrinkable sleeves of
phase code coloured i.e. red, yellow and blue or suitably painted with plastic insulating compounds.
The bus bars shall be suitably supported on insulators to stand the mechanical and electric forces on account of short
circuit on the system.
The main bus bars shall run horizontally at top and the branch bus bars vertically with connections to the individual
breaker panels.
The bus bar conductors shall be uniform throughout its length and in no case tapered. The size shall be so chosen
to limit current density to 1.0 Amps per sq. mm. Sufficient ventilation shall be conceived not to allow temperature
rise above 30 Deg. C.
The electrical contacts between bus bars and connecting link shall be bolted type and lavish contact surface shall be
provided. Bus bars shall be enclosed in a separate compartment with link arrangement for extension.
The neutral bus bar should be of the same size and current carrying capacity as that of phase bus bar.
All bus bar joints, live bolted connections; joints between cable terminals and switchgear terminals etc. shall be
covered with electric insulating non-corrosive sealing compound or heat shrinkable tapes to avoid accidental contact
and flashover.
6. EARTHING
Earthing arrangement shall be provided with earth bars of electrolytic aluminium and earthing terminals at two
ends similar to the arrangement described in General Technical Specification. The earth bar shall be of
electrolytic aluminium running from end to end of the switchboard terminating in two earthing terminals at the
two ends. Earthing shall be accomplished as described in General Technical Specification.
7. ENERGY METER
Each incoming panel shall be provided with the energy meter. (Details of the energy meter shall be given
separately by purchaser)
8. TESTS
Each type of LV. Switchboard shall be completely assembled, wired, adjusted and tested at the factory as per
the relevant standards and during manufacture and on completion.
Routine Test
The tests shall be carried out in accordance with IS 13947 and 8623 include including but not necessarily limited
to the following:
(a) Visual Check
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(b) Verification of Component Rating
(c) Other Checks
i) Easy Accessibility and Maintenance
ii) Colour Coding provided by coloured tapes.
iii) Bus bar dimensions
iv) Degree of Protection check by paper.
(d) Dimension check
(e) Di-electric Test of circuits
(f) Insulation Resistance Tests
(g) Mechanical Operation Tests
(h) Bus bar support and clearances
(i) Continuity of circuits and Function
(j) Painting
(k) Verification of wiring
Type Test
All type tests shall be performed in accordance with IS 13947 and 8623
9. PROTOTYPE SAMPLE
A prototype sample of each category of the LV Switchboard should be initially manufactured and submitted for
approval of purchaser before taking up mass manufacture.
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TUBULAR STEEL POLES FOR OVERHEAD LINES
1 SCOPE:
This specification covers the general requirements towards design, manufacture, testing at manufacturers
works, supply and delivery for tubular steel poles of circular cross section ( swaged type ) for overhead lines.
2 STANDARD:
2.1 The tubular steel poles shall conform to the latest edition of Indian Standard specification IS: 2713
(Part – I, III): 1980 or any other authoritative standards (as amended up-to- date) except where specified
otherwise in this specification.
3 Topography and Climatic Condition:
3.1 The materials offered, shall be suitable for operation in tropical climate and will be subjected to the
sun and inclement weather and shall be able to withstand wide range of temperature variation. For the purpose
of design, average atmospheric temperature may be considered to be 50ºC with humidity nearing saturation.
4 Materials:
4.1 The materials used in construction of tubular steel poles shall be of the tested quality of steels of
minimum tensile strength 540 MPa (: 55 Kgf/mm2).
4.2 The materials, when analysed in accordance with IS: 228 (Part-III: 1972) and IS : 228 ( Part-IX) shall
not show sulpher and phosphorous contents of more than 0.060 percent each.
5 Types, Size and construction:
5.1 Tubular Steel Poles shall be swaged type.
5.2 Swaged poles shall be made of seamless or welded tubes of suitable lengths swaged and jointed
together. No circumferential joints shall be permitted in the individual tube lengths of the poles. If welded tubes
are used they shall have one longitudinal weld seam only: and the longitudinal welds shall be staggered at each
swaged joint.
5.3 Swaging may be done by any mechanical process. The upper edge of each joint shall be chamfered if
at an angle of about 45o. The upper edge need not be chamfered if a circumferential weld is to be deposited in
accordance with clause No. 5.3 2 of IS: 2713 ( Part-I):1980.
5.4 The length of joints on swaged poles shall be in accordance with clause No. 5.4 of IS: 2713 (Par-I):
1980.
5.5. Poles shall be well-finished, clean and free from harmful surface defects. Ends of the poles shall be cut
square. Poles shall be straight, smooth and culindrical. The weld joints, if any, shall be of good quality, free from
scale, surface defects, cracks, etc.
5.6. Tolerances for outside diameter, thickness, length, weight and straightness shall be in accordance with
IS: 2713 (Part-I) : 1980.
5.7. The poles shall be coated with black bituminous paint conforming to IS: 158-1968 throughout,
internally and externally, upto the level which goes inside the earth. The remaining portion of the exterior shall
be painted with one coat of red oxide primer as specified in IS: 2074-1979.
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6 Earthing Arrangements:
6.1 For earthing arrangement a through hole of 14mm diameter shall be provided in each pole at a height
of 300mm above the planting depth.
7 Tests and Test Certificates:
7.1 The following tests shall be conducted on finished poles :
A. Tensile test and chemical analysis for sulpher and phosphorous,

B. Deflocation test,
C. Permanent set test, and
D. Drop test.
7.2 In addition to above verification of dimensions as per IS: 2713 (Part-III) : 1980 shall be carried out
during acceptance lots.
7.3 Number of poles selected for conducting different tests shall be in accordance to clause No. 10.1.1
and No. 10.1.12: of IS: 2713 (Part-I) 1980.
7.4 Tests shall be carried out before supply of each consignment at the manufacturers woks and test
certificates should be submitted to the purchaser for approval prior to delivery.
7.5 Re-tests, if any, shall be made in accordance with IS: 2713 (Part-I) 1980.
7.6 Purchaser reserves the right to inspect during manufacturing and depute his representative to
inspect/test at the works.
7.7 If any extra cost is required for carrying out the above specified tests, the same shall be borne by the
supplier.
8 Marking:
8.1 The poles shall be marked with designation, manufacturer’s identification, year of manufacture and
name of the purchaser: Employer Name; RGGVY XII Plan
8.2 The poles may also be marked with the ISI certification mark.
9 Guaranteed technical particulars:
9.1 The tenderer shall furnish all necessary guaranteed technical particulars in the prescribed Performa
enclosed hereinafter.
10 Performance:-
10.1 The supplier shall furnish a list of the major supplies effected during the last 3 (three) years indicating
the volume of supply and actual delivery dates along with the bids.
10.2 Supplier may not be considered if the past manufacturing experience is found to be less that 3 (three)
years.
11 Deviation:-
11.1 Any deviation in technical specification shall be clearly indicated with sufficient reasons thereof.
Purchaser shall however reserve the right to accept and/or reject the same without assigning any reasons what-
so-ever.
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ANNEXURE –‘A’
SPECIFIC TECHNICAL REQUIREMENTS FOR

TUBULAR STEEL POLES : SWAGED TYPE
9 meters 11 meters 13 meters

long long long
1) Standard IS: 2713 ( Pat-I and III): 1980 as amended upto date
2) Type of Pole Swaged Type
3) Designation 540 SP 28 540 SP 52 540 SP 72
4) Overall Length 9 meters 11 meters 13 meters
5) Planting depth 1.5 meters 1.8 meters 2.0 meters
6) Height above ground 7.5 meters 9.2 meters 11.0 meters
7) Effective length of
Each section.
a) Bottom 5.0 meters 5.6 meters 5.80 meters
b) Middle 2.0 meters 2.7 meters 3.60 meters
c) Top 2.0 meters 2.7 meters 3.60 meters
8) Outside diameter and
Thickness of each Section.
a) Bottom 139.7x 4.50 mm 165.1x4.50 mm 219.1x5.90 mm
b) Middle 114.3x3.65 mm 139.7x4.50 mm 193.7x4.85 mm
c) Top 88.9x3.25 mm 114.3x3.65 mm 165.1x4.50 mm
9) Joint Length ( in cm.):
a) Bottom (J2) 30 cm. 35 cm. 45 cm.
b) Top (J1) 23 cm. 30 cm. 40 cm.
10) Approximate weight 113 Kg. 175 Kg. 343 Kg.
of Pole
11)Point of application of
load below/top (mtr.) 0.3 mtr. 0.6 mtr. 0.6 mtr
12) Breaking load ( inKgf ) 478 567 1084
13) Working load with factor
of Safety : 2.5 ( in Kgf ) 191 227 435 Kg.
14) Crippling load ( inKgf ) 339 403 770 Kg.
15) Load for permanent set
Not exceeding 13mm (in Kgf) 232 276 527 Kg.
16) Load for Temporary
Deflection of 157.5 mm (in Kgf) 76 74 121
17) Tolerance As per IS : 2713 ( Part-I & Part-III): 1980
18) Finish -do-
19) Manufacturing clause -do-
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33 & 11 KV STATION CLASS LIGHTNING ARRESTOR & 11 KV DISTRIBUTION CLASS SURGE

ARRESTORS
1. 33kV VOLTAGE CLASS SURGE ARRESTORS

Lightning Arrestors at Grid Substation shall be of Station class only in 33 & 11 KV System.
1.1. INTRODUCTION
The section covers the specification of 33kV voltage level, 10 kA, and Station class heavy duty, gapless metal (zinc)
oxide Surge Arrestors complete with insulating base, terminal clamps, complete fittings & accessories for installation
on outdoor type 33kV switchgear/transmission lines / transformers.
1.2. STANDARDS
The design, manufacture and performance of Surge Arrestors shall comply with IS: 3070 Part-3 and
other specific requirements stipulated in the specification. Unless otherwise specified, the equipment, material and
processes shall conform to the latest applicable Indian/International Standards as listed hereunder:
IS:2071-1993 (Part-1) Methods of High Voltage Testing General Definitions & Test
Requirements.
IS:2071-1974(Part-2) Test Procedures
IS:2629-1985 Recommended Practice for hot dip galvanizing on Iron &
Steel
IS:2633-1986 Method for Testing uniformity of coating of zinc coated
Articles.
IS:3070-1993 (Part – 3) Specification for surge arrestor for alternating current systems.
Metal-Oxide lightening Arrestors without gaps
IS:4759-1996 Specification for hot dip zinc coating on Structural Steel and
Other allied products.
IS:5621-1980 Hollow Insulators for use in Electrical Equipment.
IS:6209-1982 Methods of Partial discharge measurement.
IS:6745 Method for determination of mass of zinc coating on zinc
coated iron and steel articles
ANSI/IEEE-C.62.11 Metal oxide, Surge Arrestor for AC Power Circuits.
IEC –60099-4 Surge Arrestors
The equipment complying with any other internationally accepted standards shall also be considered
if it ensures performance equivalent to or superior to the Indian Standards.
1.3. GENERAL REQUIREMENT

1.3.1. The metal oxide gap less Surge Arrestor without any series or shunt gap shall be suitable for protection of
33kV switchgear, transformers, associated equipment and 33 kV lines from voltage surges resulting from natural
disturbance like lightning as well as system disturbances.
1.3.2. The surge arrestor shall draw negligible current at operating voltage and at the same time offer
least resistance during the flow of surge current.
1.3.3. The surge arrestor shall consist of non-linear resistor elements placed in series and housed in electrical
grade porcelain housing / silicon polymeric of specified creepage distance.
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1.3.4. The assembly shall be hermetically sealed with suitable rubber gaskets with effective sealing system
arrangement to prevent ingress of moisture.
1.3.5. The surge arrestor shall be provided with line and earth terminals of suitable size. The ground side
terminal of surge arrestor shall be connected with 25x6 mm galvanized strip, one end connected to the
surge arrestor and second end to a separate ground electrode. The bidder shall also recommend the
procedure which shall be followed in providing the earthing system to the Surge Arrestor.
1.3.6. The surge arrestor shall not operate under power frequency and temporary over voltage conditions but
under surge conditions, the surge arrestor shall change over to the conducting mode.
1.3.7. The surge arrestor shall be suitable for circuit breaker performing 0-0.3sec.-CO-3 min-CO- duty in the
system.
1.3.8. Surge arrestors shall have a suitable pressure relief system to avoid damage to the porcelain/silicon
polymeric housing and providing path for flow of rated fault currents in the event of arrestor failure.
1.3.9. The reference current of the arrestor shall be high enough to eliminate the influence of grading and stray
capacitance on the measured reference voltage.
1.3.10. The arrestors for 33 kV system shall be suitable for mounting on transformers, Bus, Line & structure as
per scheme. The supplier shall furnish the drawing indicating the dimensions, weights etc. of the surge arrestors for
the design of mounting Structure.
1.3.11. The arrestor shall be capable of handling terminal energy for high surges, external pollution and transient
over voltage and have low losses at operating voltages.
1.4. ARRESTOR HOUSING
1.4.1. The arrestor housing shall be made up of porcelain/silicon polymeric housing and shall be homogenous,
free from laminations, cavities and other flaws of imperfections that might affect the mechanical and dielectric
quality. The housing shall be of uniform brown (for porcelain)/Grey (for silicon polymeric) colour, free from
blisters, burrs and other similar defects.
Arrestors shall be complete with fasteners for stacking units together and terminal connectors.
1.4.2. The housing shall be so coordinated that external flashover shall not occur due to application of any
impulse or switching surge voltage up to the maximum design value for arrestor. The arrestors shall not fail due to
contamination. The 33 kV arrestors housing shall be designed for pressure relief class as given in Technical
Parameters of the specification.
1.4.3. Sealed housings shall exhibit no measurable leakage.
1.5. FITTINGS & ACCESSORIES
1.5.1. The surge arrestor shall be complete with fasteners for stacking units together and terminal connectors.
1.5.2. The terminals shall be non-magnetic, corrosion proof, robust and of adequate size and shall be so located
that incoming and outgoing connections are made with minimum possible bends. The top metal cap and base of
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surge arrestor shall be galvanized. The line terminal shall have a built in clamping device which can be adjusted for
both horizontal and vertical take off.
1.6. TESTS
1.6.1. Test on Surge Arrestors

The Surge Arrestors offered shall be type tested and shall be subjected to routine and acceptance tests in
accordance with IS : 3070 (Part-3)/IEC-60099-4. In addition, the suitability of the surge arresters shall also be
established for the followings
i) Acceptance tests
a) Measurement of power frequency reference voltage of arrester units.
b) Lightning impulse residual voltage on arrester units (IEC clause 6.3.2)
c) Internal ionization or partial discharge test
ii) Special Acceptance tests
a) Thermal stability test (IEC 99-4clause 7.2.2)

b) Watt loss test.
iii) Routine tests

a) Measurement of reference voltage
b) Residual voltage test of arrester unit
d) Sealing test
e) Verticality check on completely assembled surge arresters as a sample test on each lot if applicable.
iv) Type Tests

Following shall be type test as per IS 3070 (Part 3): 1993 or its latest amendment.
1. Insulation Withstand test

a) Lightning Impulse
b) Power Frequency (Dry/Wet)
2. Residual Voltage Test

a) Steep current impulse residual voltage test
b) Lightning impulse residual voltage test
c) Switching Impulse Residual voltage test
3. Long duration current impulse withstand test
4. Switching surge operating duty test
5. Power frequency voltage Vs. Time characteristics
6. Accelerated Ageing test
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7. Pressure relief test

a) High Current
b) Low Current
8. Artificial pollution test (for porcelain housing)
9. Seismic Test
10. Partial Discharge test
11. Bending test
12. a) Temperature cycle test (for porcelain housing)

b) Porosity test (for porcelain housing)
13. Galvanising test on metal parts
14. Seal Leakage test (for porcelain housing)
15. Seal leak test and operation tests ( for surge monitor)
16. Weather ageing test (for polymer housing)
1.6.2. The maximum residual voltages corresponding to nominal discharge current of 10 kA for steep
current, impulse residual voltage test, lightning impulse protection level and switching impulse level shall generally
conform to Annex-K of IEC-99-4.
1.6.3. The contractor shall furnish the copies of the type tests and the characteristics curves between the
residual voltage and nominal discharge current of the offered surge arrestor and power frequency voltage
v/s time characteristic of the surge arrestor subsequent to impulse energy consumption as per clause 6.6.7
of IS:3070 (Part-3) offered along with the GTP/Drawing.
1.6.4. The surge arrestor housing shall also be type tested and shall be subjected to routine and acceptance tests
in accordance with IS: 5621.
1.6.5. Galvanization Test
All Ferrous parts exposed to atmospheric condition shall have passed the type tests and be subjected to
routine and acceptance tests in accordance with IS:2633 & IS 6745.
1.7. NAME PLATE

1.7.1. The name plate attached to the arrestor shall carry the following information:
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- Rated Voltage
- Continuous Operation Voltage
- Normal discharge current
- Pressure relief rated current
- Manufacturers Trade Mark
- Name of Sub-station
- Year of Manufacturer
- Name of the manufacture
- Name of Client-“ “
- Purchase Order Number along with date
1.8. DRAWINGS AND INSTRUCTION MANUALS

Within 15 days of receipt of the order, the successful tenderer shall furnish to the purchaser the following
drawings and literature for approval:
(i) Outline dimensional drawings of Surge Arrestor and all accessories.

(ii) Assembly drawings and weights of main component parts.
(iii) Drawings of terminal clamps.
(iv) Arrangement of earthing lead.
(v) Minimum air clearance to be maintained of line components to ground.
(vi) Name plate
(vii) Instructions manual
(viii) Drawing showing details of pressure relief valve
(ix) Volt-time characteristics of surge arrestors
(x) Detailed dimensional drawing of porcelain housing/Silicon polymeric i.e. internal diameter, external
diameter, thickness, height, profile, creepage distance, dry arcing distance etc.
1.9. TECHNICAL PARTICULARS
1.9.1. The surge arrestors shall conform to the following standard technical requirements. The Insulation values
shall be enhanced considering the altitude of operation & other atmospheric conditions.
System Parameters:
Nominal system voltage : 33 kV
Highest system voltage : 36 kV
System earthing : Solidly earthed system
Frequency (Hz) : 50
Lightning Impulse withstand Voltage (kVP) : 170
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Power frequency withstand Voltage (kV rms) : 70

Connection to system : Phase to earth
1.9.2. Surge Arrestors
Type of Surge Arrestor : Gapless Metal oxide outdoor
Arrestor rating (kV rms) : 30

Continuous Operating voltage (kV rms) : 25
Standard Nominal Discharge Current Rating (kA) : 10
(8x20 micro impulse shape)
Line discharge class : 2
Degree of protection : IP-67
Lightning Impulse at 10 kA : 85
Partial discharge at 1.05 COV not greater than : 50 (PC)

Energy capability corresponding to
a) Arrestor rating (kj/kV) : 4.5
b) COV (kJ/kV) : 4.9
Peak current for high current impulse operating : 100

duty of arrestor classification 10 kA
1.9.3. Insulator Housing
Power frequency withstand test voltage : 70

(wet) (kV rms)
Lightning impulse withstand/tests voltage (kVP) : 170
Pressure Relief Class : 40

Creepage distance not less than : 900 mm
1.9.4. Galvanisation
Fabricated Steel Aticles

-- 5 mm thick cover : 610 g/m2
-- Under 5 mm but not less than 2 mm thickness : 460 g/m2
-- Under 2 mm but not less than 1.2 mm : 340 g/m2

thickness
Castings
-- Grey Iron, malleable iron : 610 g/m2
Threaded works other than tubes & tube fittings
-- Under 10 mm dia 270 g/m2
--
10 mm dia & above 300 g/m2
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2. 11kV VOLTAGE CLASS SURGE ARRESTORS
2.1. INTRODUCTION
This section covers the specification of 11kV voltage station Surge Arrestors for installation on outdoor type 11kV
switchgear, transmission lines, transformers etc. 11kV side of which is not enclosed in a cable box. Station class
surge arrestors shall be complete with fasteners for stacking units.
2.2. STANDARDS
The design, manufacture and performance of Surge Arrestors shall comply with IS: 3070 Part-3
and other specific requirements stipulated in the specification. Unless otherwise specified, the equipment, material &
processes shall conform to the latest amendments of the following:
IS:2071-1993 (Part-1) Methods of High Voltage Testing General Definitions &

Test Requirements.
IS:2071-1974 (Part-2) Test Procedures.
IS: 2629-1985 Recommended Practice for hot dip galvanizing on Iron &
Steel.
IS: 2633-1986 Method for Testing uniformity of coating of zinc coated
Articles.
IS:3070-1993 (Part – 3) Specification for surge arrestor for alternating current
systems. Metal-Oxide lightening Arrestors without gaps.
IS: 4759-1996 Specification for hot dip zinc coating on structural steel
and other allied products.
IS: 5621-1980 Hollow Insulators for use in Electrical Equipment.
IS: 6209-1982 Methods of Partial discharge measurement.
IS: 6745 Method for determination of mass of zinc coating on zinc
coated iron and steel articles.
ANSI/IEEE-C.62.11 Metal oxide, Surge Arrestor for AC Power Circuits.
IEC –60099-4 Surge Arrestors.
The equipment complying with any other internationally accepted standards shall also be considered if it
ensures performance equivalent to or superior to the Indian Standards.
11 kV side of power transformers, associated equipment and 11kV lines from voltage surges resulting from natural
disturbance like lightning as well as system disturbances.
2.3.3. The surge arrestor shall consist of non-linear resistor elements placed in series and housed in electrical
grade porcelain housing / silicon polymeric of specified Creepage distance.
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2.3.5. The surge arrestor shall be provided with line and earth terminals of suitable size.
The ground side
surge arrestor and second end to a separate ground electrode. The bidder shall also recommend the
procedure which shall be followed in providing the earthing system to the Surge Arrestor.
2.3.7. The surge arrestor shall be suitable for circuit breaker performing 0-0.3 min-CO-3 min-CO- duty in the
system.
2.3.8. Surge arrestors shall have a suitable pressure relief system to avoid damage to the porcelain/ silicon
polymeric housing and providing path for flow of rated fault currents in the event of arrestor failure.
2.3.10. The Surge Arrestor shall be thermally stable and the bidder shall furnish a copy of thermal stability test
with the bid.
2.3.12. The surge arrestor shall be provided with line and earth terminals of suitable size.
2.4.1. The arrestor housing shall be made up of porcelain/silicon polymeric housing and shall be homogenous,
free from laminations, cavities and other flaws of imperfections that might affect the mechanical and dielectric
quality. The housing shall be of uniform brown (for porcelain)/Grey (for silicon polymeric) colour, free from
blisters, burrs and other similar defects.
Arrestors shall be complete with fasteners for stacking units together and terminal connectors.
2.4.2. The housing shall be so coordinated that external flashover shall not occur due to application of any impulse
or switching surge voltage upto the maximum design value for arrestor. The arrestors shall not fail due to
contamination. The 11kV arrestors housing shall be designed for pressure relief class as given in Technical
Parameters of the specification.
2.5. ARRESTOR MOUNTING
The arrestors shall be suitable for mounting on 4 pole/2 pole structure used for pole/plinth mounted transformer and
for incoming and outgoing lines. Arrestor may also be required to be mounted on a bracket provided in the
Transformers.
2.6.1. The surge arrestor shall be complete with fasteners and terminal connectors.
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2.7. TESTS
accordance with IS : 3070 (Part-3)-/IEC:600994. In addition, the suitability of the surge arresters shall also be
established for the followings.
i) Acceptance tests
a) Measurement of power frequency reference voltage of arrester units.

b) Lightning impulse residual voltage on arrester units (IEC clause 6.3.2)
ii) Special Acceptance tests:
a) Thermal stability test (IEC clause 7.2.2)

b) Watt loss test.
iii) Routine tests
a) Measurement of reference voltage

b) Residual voltage test of arrester unit
d) Sealing test
e) Verticality check on completely assembled surge arresters as a sample test on each lot if applicable.
iv) Type Tests
Following shall be type test as per IS 3070 (Part 3): 1993 or its latest amendment

a) Lightning Impulse
b) Power Frequency (Dry/Wet)
b) Lightning impulse residual voltage test
c) Switching Impulse Residual voltage test
4. Switching surge operating duty test
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7. Pressure relief test
c) High Current
d) Low Current
9. Seismic Test
10. Partial Discharge test
11. Bending test

13. Galvanising test on metal parts
14. Seal Leakage test (for porcelain housing)
15. Seal leak test and operation tests ( for surge monitor)
v/s time characteristic of the surge arrestor subsequent to impulse energy consumption as per clause 6.6 of
IS:3070 (Part-3) offered alongwith the bid.
2.7.4. The surge arrestor housing shall also be type tested and shall be subjected to routine and acceptance
tests in accordance with IS :5621.
2.7.5. Galvanization Test

All Ferrous parts exposed to atmospheric condition shall have passed the type tests and be subjected to
routine and acceptance tests in accordance with IS:2633 & IS 6745.
2.8. NAME PLATE
- Rated Voltage
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- Pressure relief rated current
- Name of Sub-station
- Name of Client-

Within 15 days of receipt of the order, the successful tenderer shall furnish to the purchaser, the following
drawings and literature for approval:

(vi) Name plate
(vii) Surge monitor, if applicable.
(viii) Instructions manual
(ix) Drawing showing details of pressure relief valve
(x) Volt-time characteristics of surge arrestors
(xi) Detailed dimensional drawing of porcelain housing/Silicon polymeric i.e. internal diameter, external
diameter, thickness, height, profile, creepage distance, dry arcing distance etc.
2.10.1. The surge arrestors shall conform to the following standard technical requirements. The Insulation
values shall be enhanced considering the altitude of operation & other atmospheric conditions.
System Parameters
i) Nominal system voltage 11kV
ii) Highest system voltage 12 kV
iii) System earthing Effectively earthed system
iv) Frequency (Hz) 50
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v) Lightning Impulse withstand 75 Voltage (kVP)
vi) Power frequency withstand 28 Voltage (kV rms)
vii) Arrestor duty

-- Connection to system Phase to earth
-- Type of equipment to be protected transformers & switchgear
i) Type Gapless Metal oxide outdoor
ii) Arrestor rating (kV rms) 9
iii) Continuous Operating voltage 7.65 (kV rms)

iv) Standard Nominal Discharge Current 10 Rating (kA) (8x20 micro impulse shape)
v) Degree of protection IP 67
vi) Line discharge Class 2
vii) Steep current at 10 kA 45
viii) Lightning Impulse at 10 kA 40
ix) Energy capability corresponding to

a) Arrestor rating (kj/kV) 4.5
b) COV (kj/kV) 4.9
x) Peak current for high current 100

impulse operating duty of Standard TS fo
arrestor classification10 kA
2.10.3. Insulator Housing
i) Power frequency withstand test voltage (Wet) (kV rms) 28

ii) Lightning impulse withstand/tests voltage (kVP) 75
2.10.4. Galvanisation
i) Fabricated Steel Aticles

a) 5 mm thick cover 610 g/m2
b) Under 5 mm but not less than 2 mm thickness 460 g/m2
c) Under 2 mm but not less than 1.2 mm thickness 340 g/m2
ii) Castings
Grey Iron, malleable iron 610 g/m2
iii) Threaded works other than tubes & tube fittings
a) Under 10 mm dia 270 g/m2
b) 10 mm dia & above 300 g/m2
NOTE- Surge Monitor shall have to be provided if coverded in BPS.
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3. DISTRIBUTION CLASS SURGE ARRESTORS

To be used in distribution Transformer Substations only.
3.1. INTRODUCTION
This section covers the specification of Distribution class Surge Arrestor for 11kV transmission lines, transformers etc.
3.2. STANDARDS
The design, manufacture and performance of Surge Arrestors shall comply with IS: 3070 Part-3 and
other specific requirements stipulated in the specification. Unless otherwise specified, the equipment, material and
processes shall conform to the latest applicable Indian/International Standards as listed hereunder:
IS:2071- 1993 (Part-1) : Methods of High Voltage Testing General Definitions & Test
Requirements.
IS:2071-1974 (part-2) : Test Procedures
IS:2629-1985 : Recommended Practice for hot dip galvanizing on Iron &
Steel
IS:2633-1986 : Method for Testing uniformity of coating of zinc coated
Articles.
IS3070-1993 (Part–3) : Specification for surge arrestor for alternating current
systems. Metal-Oxide lightening Arrestors without gaps
IS:4759-1996 : Specification for hot dip zinc coating on Structural Steel and
Other allied products.
IS:5621-1980 Hollow Insulators for use in Electrical Equipment.
IS:6209-1982 Methods of Partial discharge measurement.
IS:6745 Method for determination of mass of zinc coating on zinc

coated iron and steel articles
ANSI/IEEE-C.62.11 : Metal oxide, Surge Arrestor for AC Power (1982)
Circuits.
IEC –60099-4 Surge Arrestors
3.2.1. The equipment complying with any other internationally accepted standards shall also be
considered if it ensures performance equivalent to or superior to the Indian Standards.

11 kV side of Distribution Transformers, associated equipment and 11 kV lines from voltage surges resulting from
natural disturbance like lightning as well as system disturbances.
3.3.3. The surge arrestor shall consist of non-linear metal oxide resistor elements placed in series and housed in
electrical grade porcelain housing / silicon polymeric of specified Creepage distance.
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3.3.5. The surge arrestor shall be provided with line and earth terminals of suitable size. The ground side
surge arrestor and second end to a separate ground electrode. The contractor shall also recommend the
procedure which shall be followed in providing the earthing/system to the Surge Arrestor.
3.3.7. The surge arrestor shall be suitable for circuit breaker performing 0-0.3 min-CO-3 min-CO- duty in the
system.
3.3.9. The Surge Arrestor shall be thermally stable and the contractor shall furnish a copy of thermal stability
test with the bid.
3.4.1. The arrestor housing shall be made up of porcelain/silicon polymeric housing and shall be
homogenous, free from laminations, cavities and other flaws of imperfections that might affect the mechanical and
dielectric quality. The housing shall be of uniform brown (for porcelain)/ Grey (for silicon polymeric) colour,
free from blisters, burrs and other similar defects.
3.4.2. The housing shall be so coordinated that external flashover shall not occur due to application of any
impulse or switching surge voltage upto the maximum design value for arrestor. The arrestors shall not fail due to
contamination.
3.5. ARRESTOR MOUNTING
The arrestors shall be suitable for mounting on 4 pole/2 pole structure used for pole mounted transformer and for
incoming and outgoing lines.
3.6.1. The surge arrestor shall be complete with disconnector and terminal connectors and all other accessories.
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3.7. TESTS
accordance with IS : 3070 (Part-3)-1993. In addition, the suitability of the surge arresters shall also be established
for the followings
a) Acceptance tests:
i) Measurement of power frequency reference voltage of arrester units.
ii) Lightning impulse residual voltage on arrester units (IEC clause 6.3.2)
iii) Internal ionization or partial discharge test
b) Special Acceptance tests:

i) Thermal stability test (IEC clause 7.2.2)
c) Routine tests:
Measurement of reference voltage
i) Residual voltage test of arrester unit
ii) Internal ionization or partial discharge test
iii) Sealing test
iv) Verticality check on completely assembled surge arresters as a sample test on each lot if applicable.
d) Type tests: Following shall be type test As per IS 3070 (Part 3)-/IEC;60094 or its latest
amendment

a) Lightning Impulse voltage test
b) Power Frequency (Dry & Wet)

b) Lightning Impulse Residual Voltage Test
4. High current impulse operating duty test
8. Partial discharge test
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9. Visual Examination (for porcelain housing)
11. Mechanical Failing Load test

(Bending Strength test)
12. Uniformity of Zinc coating, Mass of zinc coating
13. Time versus current curve (for disconnector)

v/s time characteristic of the surge arrestor subsequent to impulse energy consumption as per clause 6.6.7
of IS:3070 (Part-3) offered alongwith the GTP.
3.7.4. The surge arrestor housing shall also be type tested and shall be subjected to routine and acceptance
tests in accordance with IS: 5621
3.7.5. GALVANIZATION TEST

All Ferrous parts exposed to atmospheric condition shall have passed the type tests and be subjected to routine
and acceptance tests in accordance with IS:2633 & IS 6745.
3.7.6. TEST ON SURGE ARRESTOR DISCONNECTORS

The test shall be performed on surge arrestors which are fitted with arrestor disconnector or on the disconnector
assembly alone if its design is such as to be un-affected by the heating of adjacent parts of the arrestor in its
normally installed portion in accordance with IS:3070 (Part-3).
3.8. NAME PLATE

- Rated Voltage
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- Name of Client-
The successful bidder shall furnish to the purchaser the following drawings and literature for approval:
(vi) Name plate
(vii) Instructions manual
(viii) Drawing showing details of pressure relief valve
(ix) Volt-time characteristics of surge arrestors
(x) Detailed dimensional drawing of porcelain housing/Silicon polymeric i.e. internal diameter, external diameter,
thickness, height, profile, creepage distance, dry arcing distance etc.
3.10.1. The surge arrestors shall conform to the following standard technical requirements. The Insulation values
shall be enhanced considering the altitude of operation & other atmospheric conditions.
System Parameters
i) Nominal system voltage 11kV
ii) Highest system voltage 12 kV
iii) System earthing Solidly earthed system
iv) Frequency (Hz) 50
vii) Lightning Impulse withstand 75 Voltage (kVP)
viii) Power frequency withstand 28 Voltage (kV rms)
vii) Arrestor duty
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-- Connection to system Phase to earth

-- Type of equipment to be protected 11 kV transformers & switchgear

i) Type Gapless Metal oxide outdoor
ii) Arrestor rating (kV rms) 9
iii) Continuous Operating voltage (kV rms) 7.65

v) Nominal Discharge Current 5 Rating (kA) (8x20 micro impulse shape)
v) Long Duration discharge class Distribution class
vi) Maximum residual voltage (kV peak)

a) at 5 kA 27
vii) Partial discharge at 1.05 COV not greater than 50 (PC)
viii) High current impulse withstand voltage at 5 kA (kVp) 65
3.11. INSULATOR HOUSING
i) Power frequency withstand test voltage (Wet) (kV rms) 28

ii) Lightning impulse withstand/tests voltage (kVP) 75
iii) Creepage distance not less than (mm) 300
3.12. GALVANISATION
i) Fabricated Steel Aticles

a) 5 mm thick cover 610 g/m2
b) Under 5 mm but not less than 2 mm thickness 460 g/m2
c) Under 2 mm but not less than 1.2 mm thickness 340 g/m2
ii) Castings
Grey Iron, malleable iron 610 g/m2
iii) Threaded works other than tubes & tube fittings

a) Under 10 mm dia 270 g/m2
b) 10 mm dia & above 300 g/m2
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11 KV AND 33 KV AIR BREAK SWITCHES
1) SCOPE
This specification provides for manufacture, testing at works and supply of 11KV & 33KV AB switches. The 11KV and
33 KV AB switches shall conform to IS: 9920 (Part-I to IV)
2) AB SWITCHES
The 11KV & 33KV Air Break Switches are required with two poles in each phase. The AB Switches shall be supplied
complete with phase coupling shaft, operating rod and operating handle. It shall be manually gang operated and
vertically break and horizontal mounting type.
The equipment offered by the bidder shall be designed for a normal current rating of 200 Amps and
for continuous service at the system voltage specified as under:
i) 11 KV AB Switch : 11KV + 10% continuous 50 C/s solidly grounded earthed neutral system
ii) 33KV AB Switch : 33 kV + 10% -do-
The length of break in the air shall not be less than 400 mm for 11KV AB Switches and 500 mm for 33 KV AB
Switches.
The 11KV & 33KV AB Switches are required with post insulators. The AB switches should be suitable for mounting
on the structure. The mounting structure will be arranged by the bidder. However, the AB Switches shall be
supplied with base channel for mounting on the structure which will be provided by the owner. The phase to phase
spacing shall be 750mm in case of 11KV AB Switches & 1200mm in case of 33KV AB Switches.
3) POST INSULATORS
The complete set of three phase AB Switches shall have stacks of post insulators.
11KV AB Switches : 3 No. 11KV Post Insulator per stack

33KV AB Switches : 3 No. 33KV Post Insulator per stack
The post insulators should conform to the latest applicable Indian standards IS: 2544 Specification for Porcelain
Post insulator of compact solid core or long rod insulators are also acceptable. Creepage distance should be
adequate for highly polluted outdoor atmosphere in open atmosphere. The porcelain used for manufacture of AB
Switches should be homogeneous free from flaws or imperfections that might affect the mechanical dielectric
quality. They shall be thoroughly vitrified, tough and impervious to moisture. The glazing of the porcelain shall be of
uniform brown in colour, free from blisters, burns and other similar defects. Insulators of the same rating and type
shall be interchangeable.
The porcelain and metal parts shall be assembled in such a manner that any thermal expansion differential between
the metal and porcelain parts through the range of temperature variation shall not loose the parts or create undue
internal stresses which may affect the electrical or mechanical strength. Cap and base of the insulators shall be
interchangeable with each other. The cap and base shall be properly cemented with insulators to give perfect grip.
Excess cementing must be avoided.
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Each 11KV & 33KV Post Insulators should have technical particulars as detailed below:
11 kV 33 kV
i Nominal system voltage kV (rms) 11 33
ii Highest system voltage kV (rms.) 12 36
iii Dry Power Frequency one kV minute withstand voltage (rms) in KV 35 75
iv Wet Power frequency one minute withstand voltage (rms) in KV 35 75
v Power Frequency puncture kV (rms) voltage 1.3 times the actual dry
flashover voltage
vi Impulse withstand voltage kV (Peak) 75 170
vii Visible discharge voltage kV (rms) 9 27
viii Creepage distance in mm (minimum) 320 580
The rated insulation level of the AB Switches shall not be lower than the values specified below:-
Sl. Standard Rated Standard impulse with stand One Minute power frequency
No declared Voltage of voltage (positive & negative withstand voltage kV (rms)
voltage the AB polarity kV (Peak)
KV/RMS Switches
Across the To earth & Across the To earth &
Isolating between Isolating distance between poles
distance poles
i 11KV 12KV 85KV 75KV 32KV 28KV
ii 33KV 36KV 195KV 170KV 80KV 70KV
4) TEMPERATURE RISE
The maximum temperature attained by any part of the equipment when in service at site under continuous full load
conditions and exposed to the direct rays of Sun shall not exceed 45 degree above ambient.
5) MAIN CONTACTS
AB Switches shall have heavy duty self-aligning type contacts made of hard drawn electrolytic copper/brass. The
various parts should be accordingly finished to ensure interchangeability of similar components. The moving
contacts of the switch shall be made from hard drawn electrolytic copper brass. This contact shall have dimensions
as per drawing attached so as to withstand safely the highest short-circuit currents and over voltage that may be
encountered during service. The surface of the contact shall be rounded smooth and silver-plated. In nut shell the
male and female contact assemblies shall ensure.
1. Electro-dynamic withstands ability during short circuits without any risk of repulsion of contacts.
2. Thermal withstands ability during short circuits.
3. Constant contact pressure even when the lower parts of the insulator stacks are subjected to tensile
stresses due to linear expansion of connected bus bar of flexible conductors either because of temperature
variations or strong winds.
4. Wiping action during closing and opening.
5. Fault alignment assuring closing of the switch without minute adjustments.
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6) CONNECTORS
The connectors shall be made of hard drawn electrolytic copper or brass suitable for Raccoon/Dog ACSR conductor
for both 11KV & 33KV AB Switches. The connector should be 4 -bolt type.
7) OPERATING MECHANISM
All AB Switches shall have separate independent manual operation. They should be provided with ON/OFF indicators
and padlocking arrangements for locking in both the end positions to avoid unintentional operation. The isolating
distances should also be visible for the AB Switches.
The AB Switch will be supplied with following accessories:

Sl Item Size of 11KV AB Switch Size of 33KV AB Switch
No
i Operating Rod (GI dia) ISI mark Length 5.50 meter dia: 25MM Length 5.50 mtrs dia: 40MM
ii Phase coupling square rod (GI) Length 1800 mm Length 2700 mm
ISI mark Size 25x25 mm Size 40 x 40 mm
iii Hot dip galvanized Operating 1 No. 1 No.
handle (GI)
The AB Switches shall be capable to resist any chance of opening out when in closed position. The operating
Mechanism should be of robust constructions, easy to operate by single person and to be located conveniently for
local operation in the switchyard. The GI pipe shall conform to (‘B’ class or Medium class Blue strip) ISS: 1239-68
and ISI marked by embossing. The vertical down rod should be provided with adequate joint in the mid section to
avoid bending or buckling. Additional leverage should be provided to maintain mechanical force with minimum
efforts.
All iron parts should be hot dip galvanized as per IS 4759-1979 and zinc coating shall not be less than 610 gm/sq.
meter. All brass parts should be silver plated and all nuts and bolts should be hot dip galvanized.
8) ARCING HORNS
It shall be simple and replaceable type. They should be capable of interrupting line-charging current. They shall be
of first make and after break type.
9) BUSH
The design and construction of bush shall embody all the features required to withstand climatic conditions specified
so as to ensure dependable and effective operations specified even after long periods of inaction of these Air Break
Switches. They shall be made from highly polished Bronze metal with adequate provision for periodic lubrication
through nipples and vent.
10) DESIGN, MATERIALS AND WORKMANSHIP
All materials used in the construction of the equipment shall be of the appropriate class, well finished and of
approved design and material. All similar parts should be accurately finished and interchangeable.
Special attention shall be paid to tropical treatment to all the equipment, as it will be subjected during service to
extremely severe exposure to atmospheric moisture and to long period of high ambient temperature. All current
carrying parts shall be of non-ferrous metal or alloys and shall be designed to limit sharp points/edges and similar
sharp faces.
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The firm should have the following type test certificate. The type test should be from CPRI or equivalent lab:-
1. Test to prove capability of rated peak short circuit current and the rated short time current. The
rated short time current should correspond to minimum of 10K Amp and the peak short circuit
current should correspond to minimum of 25K Amps.
2. Lightning impulse voltage test with positive & negative polarity.
3. Power Frequency voltage dry test and wet test
4. Temperature rise test
5. Mill volt drop tests
The above tests should be performed on the AB Switches, manufactured as per owner approved drawing with the
specification. Along with the type test certificate, the certified copy of the drawing (from the testing lab) should also
be kept for inspection of our officer. Also the test certificates should not be older than 5 years from the date of
opening of tender.
Dimension of 11 & 33KV AB Switches in (Max.)Tolerance 5%.
Sl. Particulars 11KV AB Switch 33KV AB Switch

i MS Channel 450x75x40 675x100x50
ii Creepage 320mm (Min) 580mm (Min)
distance of Post
Insulator
iii Highest of Port 254 mm 368 mm
shell
iv Fixed contact assembly
i) Base 165x36x8 165x36x8
Ii) Contact 70x30x6 70x30x6
Iii) GI cover 110x44 140x44
v) Spring 6 Nos. 6 Nos.
11) Moving Contact Assembly
i Base Assembly 135x25x8 170x40x8

ii Moving 180x25x9 290x25x14
iii Bush Bronze Metal Bronze Metal
iv Thickness of Grooves 7 11
12) Connectors
i Connector 60x50x8 (Moving & fix 60x50x8 (Moving & fix both)
both)
The bidder should provide AB Switches with terminal connectors, set of insulators, mechanical inter works and arcing
horns sets. The base channel for the mounting of AB Switches shall also be included in the scope of AB Switches.
The operating mechanisms together with down pipe operating handle etc. are also included in the scope of supply.
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11 KV AND 33 KV ISOLATORS
1) SCOPE
This specification provides for design, manufacture, testing at manufactures works, delivery of outdoor station
type 11KV and 33KV (Local) manual operating mechanism isolating without/ with earthing blades and
complete in all respect with bi-metallic connectors. Operating mechanism, fixing details etc. shall be as
described herein.
2) PARTICULARS OF THE SYSTEM
The isolators to be provided under this specification are intended to be used on 3 phase A.C. 50 cycles,
effectively grounded system. The nominal system voltages are 11 kV & 33 kV respectively.
3) STANDARD
The Isolator shall comply in all respects with IS: 9921 or IEC Publication No.: 129. Equipment meeting any
other authoritative standard which ensures an equal or better quality than the standard mentioned above will
also be accepted.
4) TYPE & RATING
Isolators shall have three posts per phase, triple pole single throw, gang operated out-door type silver plated
contacts with horizontal operating blade and isolators posts arranged vertically. The isolators will be double
break type. Rotating blade feature with pressure relieving contacts is necessary i.e. the isolator shall be
described in detail along-with the offer. However, the design of turn & twist arrangement shall be subject to
owner’s approval. (Banging type feature is not acceptable). All isolators shall operate through 90 degree from
their fully closed position to fully open position, so that the break is distinct and clearly visible from the ground
level.
The equipment offered by the tenderer shall be designed for a normal current rating of 400 A for 11 KV &
630 A for 33 KV suitable for continuous service at the system voltage specified herein. The isolators are not
required to operate under load but they must be called upon to handle magnetization currents of the power
transformers and capacitive currents of bushings, bus-bars connections, very short lengths of cables and
current of voltage transformers.
The rated insulation strength of the equipment shall not be lower than the levels specified in IS 9921 JEC
publication No. 129, which are reproduced below
Standard Rated Standard Impulse One minute power frequency

declared voltage of withstand Voltage withstand voltage KV (RMS)
voltage the Isolator positive kV polarity
kv/rms (peak)
Across the To earth and Across the To earth and
isolating between poles isolating between poles
distance distance
11 KV 12 85 75 45 35
33 KV 36 195 170 100 75
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The 11 KV and 33 KV isolators are required with post insulators but with mounting structures. The isolators
should be suitable for mounting on the Boards standard structures. The isolators shall be supplied with base
channels along with fixing nuts, bolts and washers for mounting on the structured.
5) TEMPRATURE RISE
The maximum temperature attained by any part of the equipment when in service at site under continues full
load conditions and exposed to the direct rays of Sun shall not exceed 45 degree centigrade above ambient
temperature.
6) ISOLATOR INSULATION
Isolation to ground, insulation between open contacts and the insulation between phases of the completely
assembled isolating switches shall be capable of withstanding the dielectric test voltage specified above.
7) MAIN CONTACTS
All isolators shall have heavy duty self aligning and high pressure line type fixed contacts of modern design
and made of hard drawn electrolytic copper. The fixed contact should be of reverse loop type. The various
parts shall be accordingly finished to ensure interchangeability of similar components.
The fingers of fixed contacts shall be preferably in two pieces and each shall form the reverse loops to hold
fixed contacts. The fixed contacts would be placed in ‘c’ clamp. The thickness of ‘C’ clamp shall be adequate.
This channel shall be placed on a channel of adequate thickness. This channel shall be welded on an insulator
mounting plate of 8mm thickness. The spring of fixed contact shall have housing to hold in place. This spring
shall be made of stainless steel with adequate thickness. The pad for connection of terminal connector shall be
of aluminum with thickness not less than 12 mm.
The switch blades forming the moving contacts shall be made from tubular section of hard drawn electrolytic
copper having outer dia not less then 38 mm and thickness 3 mm. These contacts shall be liberally
dimensioned so as to withstand safely the highest short circuit and over voltage that may be encountered
during service. The surfaces of the contacts shall be rendered smooth and silver plated. The thickness of silver
plating shall not be less than 15 microns for 11 KV and 25 microns for 33 KV. In nut shell, the male and
female contact assemblies shall be of robust construction and design of these assemblies shall ensure the
same.
1. Electro-dynamic withstands ability during short circuit without any risk of repulsion of contacts.
2. The current density in the copper parts shall not be less than 2 Amp/sq.mm and aluminium parts shall be
less than 1 Amp/sq.mm.
3. Thermal withstand ability during short circuit.
4. Constant contact pressure even when the live parts of the insulator stacks are subjected to tensile stresses
due to linear expansion of connected bus bar of flexible conductors either because of temperature
verification or strong winds.
5. Wiping action during closing and opening.
6. Self alignment assuring closing of the switch without minute adjustment.
The earthing switch should be provided with three sets of suitable type of fixed contacts below the fixed
contacts assemblies of the main switch on the incoming supply side and the sets of moving contacts having
ganged operation. These contacts shall be fabricated out of electrolytic copper for 33 KV isolators with earth
switch and designed to withstand current on the line.
Arcing contacts / Horn: Arcing contacts are not required.
Auxiliary switches : Auxiliary switches are not required.
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8) CONNECTORS
The connectors for 11KV isolator shall be made of Aluminium alloy LM-9 or LM-25 and shall be suitable for
Squirrel, Weasel and Rabbit ACSR Conductors for 11KV and Raccoon/Dog conductors for 33 KV with horizontal
and vertical takeoff arrangement. The details in regard to dimensions, the number of bolts to be provided,
material and manufacture shall be furnished by the bidder for owner approval before manufacturing. The
groove provided in the connection should be able to accommodate conductor size mentioned above smoothly.
The clamps to be offered should be manufactured by gravity die-casting method only and not by sand casting
process. It is necessary that suitable clamps are offered along with the isolator and also it is obligatory to give
complete technical particular of clamps along with the drawing, as per details given above and also as per
following detail.
1. The terminal connector shall be manufactured and tested as per IS: 5561.
2. All castings shall be free from blow holes, surface blistors, cracks and cavities.
3. All the sharp edges shall be blurred and rounded off.
4. No part of the clamp shall be less than 12 mm thick.
5. All current carrying parts shall be designed and manufactured to have minimum contact resistance.
6. Connectors shall be designed to be corona free in accordance with the requirement of IS: 5561.
7. All nuts and bolts shall be made of stainless steel only. Bimetallic sleeve/liner shall be 2 mm thick
Wherever necessary, bi-metallic strip of standard quality and adequate dimension shall be used.
9) POST INSULATOR
11KV / 33KV insulators shall be of reputed make subject to owner approval. The post insulators for the above
11 KV isolators shall comprise of three numbers 11 KV insulators per stack and 9 such stack shall be supplied
with each isolator. Similarly, for 33 KV isolators, two numbers 33 KV insulators per stack and 9 stacks shall be
supplied with each isolator. The insulator stack shall conform to the latest applicable Indian or IEC standard
and in particulars to the IS; 2544 specification for porcelain post insulators. The porcelain used for
manufactures of insulators shall be homogeneous, free from flaws or imperfections that might affect the
mechanical or dielectric quality, and they shall be thoroughly vitrified, tough and impervious to moisture. The
glazing of the porcelain shall be uniform brown colour, free from glisters, burns and other similar defects.
Insulators of the same rating and type shall be interchangeable.
The porcelain and metal parts should be assembled in such a manner that any thermal expansion differential
between the metal and the porcelain parts throughout the range of temperature variation shall not loosen the
parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity.
Each cap and base shall be of high-grade cast steel or malleable steel casting and they shall be machine faced
and smoothly galvanised. The cap and base of the insulators shall be interchangeable with each other.
The tenders shall in variably enclose with the offer, the type test certificate and other relevant technical
guaranteed particulars of insulators offered by them. Please note that isolators without type test certificates
will not be accepted.
Each 11KV / 33KV Post Insulators used in the isolators should have technical particulars as detailed below:-
11KV 33KV
1. Nominal system voltage KV (rms) 11 33
2. Highest system voltage KV (rms) 12 36
3. Dry P.F. One minute with stand KV (rms) 35 75
4. Wet PF one minute withstand KV (rms) 35 75
5. P.F. Puncture withstand test voltage KV 1.3 time the actual dry flash over voltage of the unit.
6.Impulse voltage withstand test KV (peak) 75 170
7. Visible discharge test KV voltage 9 27
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8. Creepage distance mm (min) 320 580

9. Tensile strength in KN 10KN 16KN
10.Short time current rating for 3 Secs 25KA 25KA
For 33 KV Isolators: In place of 33 KV Post Insulator the composition of 2 units of 22KV Post Insulators per
stack complying the following parameters are acceptable:-
(a) Norminal system voltage : 33 KV

(b) Highest system voltage : 36 KV
(c) Impulse voltage withstand : 170 KV
(d) Power frequency wet withstand voltage : 75 KV
(e) Height of stack : 500 mm
(f) Creepage distance (Minimum) : 840 mm
(g) Tensile Strength : 30KN
(h) Bending strength : 4.5KN
Operating Mechanism for 11KV / 33KV Isolators:-

All Isolators and earthing switches shall have separate dependent manual operation. The Isolator should be
provided with padlocking arrangements for locking in both end position to avoid unintentional operation. For
this purpose Godrej make 5 lever brass padlocks having high neck with three keys shall be provided. The
isolating distances should be visible for isolators.
The Isolators and Isolators with earth switch inclusive of their operating mechanism should be such that they
cannot come out of their open or close position by gravity wind pressure, vibrations reasonable shocks or
accidental touching of connecting rods of the operating mechanism. Isolators should be capable of resisting in
closed position, the dynamic and thermal effects of maximum possible short circuit current at the installation
point. They shall be so constructed that they do not open under the influence of the short circuit current. The
operating mechanism should be of robust construction and easy to operate by a single person and
conveniently located for local operation in the switchyard. Provision for earthing of operating handle by means
of 8 SWG GS wire must be made.
10) PIPES
Tandem pipes operating handle shall be class B ISI marked type having atleast 24mm internal diameter for
11KV/33KV isolator. The operating pipe shall also be class B ISI marked with internal diameter of atleast 32
mm and 38 mm for 11 KV and 33KV isolators respectively.
The pipe shall be terminated in to suitable universal type joints between the insulator bottom bearing and
operating mechanism.
11) BASE CHANNEL

The Isolator shall be mounted on base fabricated from steel channel section of adequate size not less than
75x40x6 mm for 11KV and 100x50x6 mm for 33KV
To withstand total weight of isolator and insulator and also all the forces that may encounter by the isolator
during services, suitable holes shall be provided on this base channel to facilitates it’s mounting on our
standard structures. The steel channel in each phase shall be mounted in vertical position and over it two
mounting plates atleast 8mm thick with suitable nuts and bolts shall be provided for minor adjustment at site.
12) CLEARANCES
We have adopted the following minimum clearance for isolators in our system .The bidder should therefore
keep the same in view while submitting their offers: -
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Description Center distance between Poles (Center to Distance between center lines of
Center) i.e. Phase to Phase clearance outer posts on same pole
11 KV Isolator 75 Cm 60 Cm
33 KV Isolator 120 Cm 96 Cm
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PORCELAIN INSULATORS AND INSULATOR FITTINGS FOR 33 KV OVERHEAD

POWER LINES
1. SCOPE
This specification covers the details of the porcelain insulators and insulator fittings for use on 33 KV
lines in rural electric sub-transmission systems.
Unless otherwise stipulated in this Specification, the insulators shall comply with the
Indian Standard Specification IS:731-1971 and the insulator fittings with IS:2486 (Pt.I)-1971 and
IS:2486 (Pt.II)-1974 or the latest version thereof.
3. INSULATORS
3.1 General Requirements
3.1.1 The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed.
3.1.2 Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the porcelain
parts of the insulator except those areas which serve as supports during firing or are left unglazed for the
purpose of assembly.
3.1.3 The design of the insulator shall be such that stresses due to expansion and contraction in
any part of the insulator shall not lead to deterioration. The porcelain shall not engage directly with hard
metal.
3.1.4 Cement used in the construction of the insulator shall not cause fracture by expansion or loosening by
contraction and proper care shall be taken to locate the individual parts correctly during cementing. The
cement shall not give rise to chemical reaction with metal fittings, and its thickness shall be as uniform as
possible.
3.2 Classification
3.2.1 Only Type ‘B’ insulators as defined in Indian Standards shall be used.
3.2.2 The string insulators shall only be of ball and socket type.
3.3 Basic Insulation Levels
3.3.1 The test voltages of the insulators shall be as under :
Table (Clause 3.3.1)
Highest Visible Wet Power Frequency Puncture Impulse

System Discharge Power Withstand Test Voltage
Voltage Test Frequency Pin String Withstand
Withstand Insulator Test
Test Units
KV KV (rms) KV (rms) KV KV(rms) KV (Peak)
(rms) (rms)
36 27 75 180 1.3 times 170
the actual
dry flash
over
voltage of
the Unit.
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3.3.2 In this specification, power frequency voltages are expressed as peak values divided by 2 and
impulse voltages are expressed as peak values.
3.3.3 The withstand and flashover voltages are referred to the ‘Reference Atmospheric Conditions’ as per
Indian Standard.
3.4 Mechanical Load
The insulators shall be suitable for the minimum failing loads specified as under :
Pin Insulator String Insulator Units

Failing Loads Failing Load Recommended Pin Ball Shank Diameter
10KN 45KN 16mm
3.5 Creepage Distance
The minimum creepage distance shall be as under :
Highest System Normal and Moderately Heavily polluted

Voltage Polluted Atmosphere (Total) Atmosphere (Total)
1 2 3
36KV 580mm 840mm
Note : For insulator used in an approximately vertical position the values given in Col.(2) or (3) shall
apply. For insulators used in an approximately horizontal position, the value given in Col.(2) shall apply
but the value in Col.(3) may be reduced by as much as 20%.
3.6 Tests :
The insulators shall comply with the following tests as per IS:731-1971 and latest version thereof.
3.6.1 Type Tests
a) Visual examination,
b) Verification of dimensions,
c) Visible discharge test,
d) Impulse voltage withstand test,
e) Wet power-frequency voltage withstand test,
f) Temperature cycle test,
g) Electro-mechanical failing load test to be carried out as per procedure described at Sub-clause 3.6.4
h) Mechanical failing load test (for those of Type B string insulator units to which electro mechanical failing
load test (g) is not applicable) to be carried out as per procedure described at Sub-clause 3.6.4.
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i) Twenty four hours mechanical strength test (for string insulators only when specified by the purchaser.
j) Puncture Test
k) Porosity test and
l) Galvanising test
m) Thermal Mechanical Performance Test (for Strain insulators only) to be carried out as per procedure
described at Sub-clause 3.6.4.
The test samples after having withstood the routine tests shall besubjected to the following acceptance test in
the order indicated below :
a) Verification of dimensions.
b) Temperature cycle test
c) Twenty four hours mechanical strength test (for string insulator units only when specified by the
purchaser)
d) Electro-mechanical failing load test to be carried out as per procedure described at Sub-clause 3.6.4.
e) Puncture test.
f) Porosity test and
g) Galvanising test
3.6.3 Routine Test
a) Visual examination.
b) Mechanical routine test (for string insulator unitsonly) and
c) Electrical routine test (for string insulator units only)
d) Hydraulic Internal Pressure test on shells for strain insulators to be carried out as per procedure described at
Sub-clause 3.6.4.
3.6.4 Following procedure shall be used for conducting tests on insulators:
1.0 Hydraulic Internal Pressure Test on Shells (For Disc Insulators) The test shall be carried out on 100%
shells before assembly. The detail and methodology for conducting this test has been illustrated at attached
Annexure – 1.
2.0 Thermal Mechanical Performance Test (if applicable) Thermal Mechanical Performance Test shall be
performed in accordance with IEC-383-1-1993 Clause 20 with the following modifications:
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(1) The applied mechanical load during this test shall be 70% of the rated electromechanical or mechanical
value.
(2) The acceptance criteria shall be
(a) X greater than or equal to R + 3S.
Where
X- Mean value of the individual mechanical failing load.
R- Rated electro-mechanical / mechanical failing load.
S- Standard deviation.
(b) The minimum sample size shall be taken as 20 for disc insulator units.
(c) The individual electromechanical failing load shall be at least equal to the rated value. Also puncture
shall not occur before the ultimate fracture.
3.0 Electromechanical /Mechanical Failing Load Test.
This test shall be performed in accordance with clause 18 and 19 of IEC 383 with the
following acceptance
(i) X greater than or equal to R + 3S
Where
X- Mean value of the electro-mechanical/mechanical/failing load.
(ii) The minimum sample size shall be taken as 20 for disc insulators units. However, for larger lot size, IEC
591 shall be applicable.
(iii) The individual electro-mechanical/mechanical failing load shall be at least equal to the rated value. Also
electrical puncture shall not occur before the ultimate fracture.
HYDRAULIC PRESSURE TEST ON DISC INSULATOR SHELL 120 KG/CM sq +/-10 on the shell before cap and
pin assembly to check the integrity of porcelain
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3.7 Marking
3.7.1 Each insulator shall be legibly and indelibly marked to show the following :
a) Name or trade mark of the manufacturer
b) Month and year of manufacture
c) Minimum failing load in Newtons
d) Country of the manufacture and
e) ISI Certification mark, if any.
3.7.2 Marking on porcelain shall be printed and shall be applied before firing.
3.8 Packing
All insulators (without fittings) shall be packed in wooden crates suitable for easy but rough handling
and acceptable for rail transport. Where more than one insulator are packed in a crate, wooden separators
shall be fixed between the insulators to keep individual insulators in position without movement within
the crate. Disc insulators, however, may be assembled instring and packed inside a crate to prevent
movement.
4. INSULATOR FITTINGS
4.1 Pins for Pin Insulators
4.1.1 General Requirements

4.1.1.1 The pin shall be a single piece obtained preferably by the process of forging. It shall not be made by
joining, welding, shrink-fitting or any other process from more than one piece of material. It shall be of good
finish, free from flaws and other defects. The finish of the collar shall be such that a sharp angle between
the collar and the shank is avoided.
4.1.1.2 All ferrous pins, nuts and washer except those made of stainless steel shall be galvanised. The threads
of nuts shall be cut after galvanising and shall be well oiled and greased.
4.1.2 Type & Dimensions

4.1.2.1 Pins with large steel head Type L300N as per IS:2486 (Pt.II) having stalk length of 300 mm and
shank length of 150 mm with minimum failing load of 10 KN shall be used.
4.1.2.2 The complete details of the pin are given in Fig.1.
4.1.3 Tests
Insulator pins shall comply with the following tests as per IS:2486 (pt.I).
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4.1.3.1 Type Tests

a) Visual examination test
b) Checking of threads on heads
c) Galvanising test and
d) Mechanical test
4.1.3.2 Acceptance Tests
a) Checking of threads on heads
b) Galvanising test and
c) Mechanical test
4.1.3.3 Routine Test
Visual examination
4.2 String Insulator Fittings

4.2.1.1 All forgings and castings shall be of good finish and free of flaws and other defects. The edges on
the outside of fittings, such as at the ball socket and holes,shall be rounded.
4.2.1.2 All parts of different fittings which provide for interconnection shall be made such that sufficient
clearance is provided at the connection point to ensure free movement and suspension of the insulator string
assembly. All ball and socket connections shall be free in this manner but care shall be taken that too much
clearance between ball and socket is avoided.
4.2.1.3 All ferrous fittings and the parts other than those of stainless steel, shall be galvanised. Small fittings
like spring washers, nuts, etc. may be electro-galvanised.
4.2.2. Type and Dimensions

4.2.2.1 Only ball and socket type insulator sets shall be used. The nominal dimensions of the ball and
sockets, ball eye and cross-arm straps are given in Fig. 2. An assembly drawing of the complete insulator
string is given in Fig. 3.
4.2.2.2 Strain clamps shall be suitable for ACSR conductors 7/3.35 mm2 (50 mm2 Al. area), 7/4.09mm
(80mm2 Al. area) and 6/4.72mm + 7/1.57 mm (100 mm2 Al. area). The ultimate strength of clamps shall not
be less than 41 KN.
4.2.3 Tests
String insulator fittings shall comply with the following tests as per IS:2486 (Pt.I).
4.2.3.1 Type Tests
a) Slip strength test
b) Mechanical test
c) Electrical resistance test
d) Heating cycle test
e) Verification of dimensions
f) Galvanising/Electroplating test, and
g) Visual examination test
4.2.3.2 Acceptance Tests
a) Verification of dimensions
b) Galvanising/Electroplating test, and
c) Mechanical tests
4.2.3.3 Routine Tests
a) Visual examination test and
V
b) Routine mechanical test

4.2.4 Marking
4.2.4.1 The caps and clamps shall have marked on them the following :
a) Name or trade mark of the manufacturer and
b) Year of manufacture
4.3 Packing
4.3.1 For packing of GI pins, strain clamps and related hardware, double gunny bags (or wooden cases,
if deemed necessary) shall be employed. The heads and threaded portions of pins and the fittings shall be
properly protected against damage. The gross weight of each packing shall not normally
exceed 50 Kg. Different fittings shall be packed in different bags or cases and shall be complete with their
minor accessories fitted in place. All nuts shall be hand-tightened over the bolts and screwed upto the farthest
point.
4.3.2 The packages containing fittings may also be marked with the ISI certification mark.
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PORCELAIN INSULATORS AND INSULATOR FITTINGS FOR 415/240V OVERHEAD

POWER LINES
1. SCOPE
This Specification covers the details of the porcelain insulators and insulator fittings for use on 415/240
V overhead power lines met with in rural electric distribution systems.
Unless otherwise modified in this specification, the insulators shall comply with IS:1445-
1977 and the fittings with IS:7935-1975 or the latest versions thereof.
3. PORCELAIN INSULATORS
3.1.1 The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed.
3.1.2 The glaze, unless otherwise specified, shall be brown in colour. Except for the screw threads and the
parts on which the porcelain is supported during firing, which may be left unglazed, all other surfaces of the
insulator shall be effectively glazed.
3.1.3 The design of the insulator shall be such that stresses due to expansion and contraction in any part
of the insulator shall not lead to its deterioration.
3.1.4 The insulator shall be in one piece.
3.2 Type of Insulators
3.2.1 Pin Insulator : Pin insulator is an insulator consisting of a single piece of porcelain and intended
to be mounted rigidly on a supporting structure by a pin, which passes up inside the insulator. The pin
type insulator shall have a top groove and shall be threaded to take mild steel pins, the profile of threads being
as given in Fig. 5 of IS:1445-1977. The dimensions of pin insulator shall be as shown in Fig. 1.
3.2.2 Shackle Insulator : Shackle insulator is an insulator consisting of a single piece of porcelain
and intended to be mounted vertically or horizontally , between and in contact with the two ends of a ‘U’
strap or a pair of straps with its axis vertical and intended to secure a line conductor in tension. The
dimensions of shackle insulator shall be as shown in Fig. 3 & 4.
3.3 Basic Insulation Levels The test voltages of the insulators shall be as under :
Wet One-Minute Power Frequency

Type of Power Frequency Puncture Withstand Voltage
Insulator Withstand Voltage
KV (rms) KV (rms)
Pin 10 60
Shackle 10 60
Note : The withstand voltage in Column 2 above is referred to the “Reference Atmospheric Conditions” as
per IS:1445.
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3.4 Mechanical Loads
The insulators shall be suitable for the minimum failing load specified as under :
Pin Insulator KN Shackle Insulator KN

3.5 11.5 (Type 1)
- 16.0 (Type 2)
3.5 Tests
The insulators shall comply with the following tests as per IS:1445.
3.5.1 Type Tests
The following tests shall constitute the type tests :
a) Visual examination
b) Verification of dimensions
c) Wet power-frequency voltage withstand test
d) Temperature cycle test
e) Mechanical failing load test
f) Power-frequency puncture withstand test and
g) Porosity test
The test samples shall be subjected to the following acceptance tests in the order indicated below :
c) Mechanical failing load test (subject to mutual agreement between the purchaser and the supplier) and
d) Porosity test
3.5.3 Routine Test :
The visual examination shall be carried out on each insulator.
3.6 Marking
3.6.1 Each insulator shall be legibly and indelibly marked to show the following :
b) Year of Manufacture and
c) ISI certification mark, if any
3.6.2 Marking on porcelain shall be printed and shall be applied before firing.
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3.7 Packing
All insulators shall be packed in baskets, crates or boxes as per manufacturers’ standard practice but
suitable for rough handling.
4. INSULATOR FITTINGS
4.1 Pins
4.1.1.1 The pins shall be obtained by the process of forging. They shall be of good finish, free from flaws
and other defects. The finish of the collar shall be such that a sharp angle between the collar and the shank is
avoided.
4.1.1.2 All ferrous pins, nuts and washers except those made of stainless steel, shall be galvanised. The
threads of nuts shall be cut after galvanising and shall be well oiled or greased.
4.1.2 Dimensions
Pins shall have a stalk length of 135mm, shank length of 125 mm and minimum failing load of 2.0 KN. The
dimensions of the pin shall be as given in Fig. 2.
4.2 Shackle Insulator Fittings
4.2.1.1 All parts shall be of good finish and free from flaws and other defects. The edges on the outside of
fittings, such as at the holes etc. shall be rounded.
4.2.1.2 All ferrous fittings and the parts other than those of stainless steel shall be galvanised. Small fittings
like spring washers, nuts etc. may be electro-plated with zinc.
4.2.1.3 Strap type fittings shall consist of the following:
a) A pair of MS strap
b) 2 Nos. MS bolts with hexagonal head and nuts
c) 2 Nos. spring washers
d) Helically formed conductor dead-end fittings made of aluminium alloy or aluminium-clad steel conforming
to the requirements of REC Specification of Helically Formed Fitting for 11 KV & LT Lines.
4.2.1.4 The complete details of shackle fittings to be used with steel cross-arms are shown in Fig. 3 & 4.
4.2.1.5 Alternatively, ‘U’ clamp fittings shall be required. These would consist of :
a) MS ‘U’ - clamp
b) 1 No. MS bolt and nut
c) 1 No. spring washer
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d) Helically formed distribution side tie made of aluminium alloy or aluminium-clad steel conforming to the
requirements of REC Specification of Helically Formed Fitting for 11 KV & LT Lines.
Note: ‘U’clamp fittings are intended only for use on tangent locations or for service lines where load is
small; the strap fittings are meant for angle and dead-end locations.
4.2.2 Tests
Insulator fittings shall comply with the following tests as per IS:7935.
4.2.2.1 Type Tests : The following shall constitute the type tests :
c) Checking of threads on heads
d) Galvanising/electroplating test and
e) Mechanical strength test (for pin insulator fittings only)
4.2.2.2 Acceptance Tests : The following shall constitute the acceptance tests :
a) Checking of threads on heads and
b) Galvanising test
4.2.2.3 Routine Test : Visual examination test shall be carried out as routine test
4.3 Packing
For packing of insulator pins and shackle fittings, double gunny bags or wooden cases, if deemed necessary,
shall be employed. Helically formed fittings shall be packed in card board/wooden boxes. The gross weight of
each packing shall not normally exceed 50 Kg. All nuts shall be hand-tightened over the bolts and screwed up
to the farthest point.
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11KV PORCELAIN INSULATORS AND FITTINGS

Part-I : INSULATORS
1. SCOPE
This specification covers details of porcelain insulators (Pin and Strain Insulators) for use on 11 KV
overhead power lines in rural electric distribution system.
Except when it conflicts with the specific requirements of this specification, the insulators shall comply
with IS:731 and IS:3188 as amended from time to time.
3. GENERAL REQUIREMENTS
3.1 The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed.
3.2 Unless otherwise specified, the glaze shall be brown in colour. The glaze shall cover all the porcelain
parts of insulators except those areas which serve as support during firing or are left unglazed for the purpose
of assembly.
3.3 The design of insulators shall be such that stresses due to expansion and contraction in any part of the
insulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal.
3.4 Cement used in construction of insulators shall not cause fracture by expansion or loosening by
contraction and proper care shall be taken to locate the individual parts correctly during cementing. The
cement shall not give rise to chemical reaction with metal fittings and its thickness shall be as uniform as
possible.
3.5 The insulators should preferably be manufactured in automatic temperature - controlled kilns to
obtain uniform baking and better electrical and mechanical properties.
4. CLASSIFICATION AND DIMENSIONS

4.1 Both pin and strain insulators shall conform to Type B of IS:731.
4.2 The dimensions of pin insulators shall be as shown in Fig. 1.
4.3 The strain insulators shall be of Ball and Socket type or Tongue and Clevis type, as required by the
Purchaser. The dimensions of these insulators shall be as per Fig. 2.
5. TEST VOLTAGES
5.1 The test voltages of insulators shall be as under :
Highest Visible Wet Power Frequency Power Frequency Impulsevoltage
System Discharge withstand Test puncture withstand test withstand Test
voltage Test Pin Insulator Strain Insulator
KV(rms) KV(rms) KV(rms) KV(rms) KV(rms) KV(Peak)
12 9 35 105 1.3 times of the 75

actual dry flash
over voltage of
the Insulator
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6. FAILING LOAD
6.1 Mechanical Failing Load (For Pin Insulators only) The insulators shall be suitable for a minimum
failing load of 5 KN applied in transverse direction.
6.2 Electro-Mechanical Failing Load (For Strain Insulators) The insulators shall be suitable for a minimum
failing load of 45 KN applied axially.
7. CREEPAGE DISTANCE
The minimum creepage distance shall be as under :
Highest System Normal and Moderately Heavily Polluted atmosphere
Voltage polluted atmosphere
Pin insulator Strain insulator
KV mm mm Mm
12 230 320 400
Note : Higher value of creepage distance has been specified for strain
insulators as these are normally used in horizontal position in 11 KV lines.
8. TESTS
The insulators shall comply with the following tests as per IS:731 :-
8.1 Type Tests

c) Visible discharge test
d) Impulse Voltage Withstand Test
e) Wet Power Frequency Voltage Withstand Test
f) Temperature cycle test
g) Mechanical Failing load test (for Pin Insulators only) to be carried out as per procedure described at Sub-
clause 8.4
h) 24-hour Mechanical strength Test for Strain Insulators
i) Puncture Test
j) Porosity Test
k) Galvanising Test
l) Electro-mechanical failing load test (for Strain insulators only) to be carried out as per procedure described
at Sub-clause 8.4
m) Thermal Mechanical Performance Test (for Strain insulators only) to be carried out as per procedure
described at Sub-clause 8.4
8.2 ROUTINE TESTS:
b) Mechanical routine test (for strain insulator only)
c) Electrical routine test (for strain insulator only)
d) Hydraulic Internal Pressure test on shells for strain insulators to be carried out as per procedure described at
Sub-clause 8.4
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8.3 ACCEPTANCE TEST:

a) Verification of Dimensions
b) Temperature cycle Test
c) Electro-mechanical failing load test (for strain insulators only) to be carried out as per procedure described at
Sub-clause 8.4
d) Puncture test (for strain insulators only)
e) Porosity test
f) Galvanising test
8.4 Following procedure shall be used for conducting tests on insulators :
1.0 Hydraulic Internal Pressure Test on Shells (For Disc Insulators)

The test shall be carried out on 100% shells before assembly. The detail and methodology for conducting this test
has been illustrated at attached Annexure – 1.
2.0 Thermal Mechanical Performance Test (if applicable)

Thermal Mechanical Performance Test shall be performed in accordance with IEC- 383-1-1993 Clause 20 with the
following modifications:
value.
(a) X greater than or equal to R + 3S.

Where
X- Mean value of the individual mechanical failing load.
(c) The individual electromechanical failing load shall be at least equal to the rated value. Also puncture shall not
occur before the ultimate fracture.
3.0 Electromechanical/Mechanical Failing Load Test.

This test shall be performed in accordance with clause 18 and 19 of IEC 383 with the following acceptance
(i) X greater than or equal to R + 3S , Where

X- Mean value of the electro-mechanical/mechanical/ failing load.
X
9. MARKING
9.1 Each insulator shall be legibly and indelibly marked to show the following :
a) Name or trade mark of manufacturer
b) Month and year of manufacture
c) Minimum failing load in KN
d) ISI certification mark, if any
9.1.1 Markings on porcelain shall be printed and shall be applied before firing.
10. PACKING
All insulators (without fittings) shall be packed in wooden crates suitable for easy but rough handling
and acceptable for rail transport. Where more than one insulator is packed in a crate, wooden separators
shall be fixed between the insulators to keep individual insulators in position without movement within the
crate.
11. INSPECTION
11.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed
representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being
furnished in accordance with this specification.
11.2 The purchaser has the right to have the tests carried out at his own cost by an independent agency
whenever there is dispute regarding the quality of supply.
Part-II : INSULATOR FITTINGS
1. SCOPE
This specification covers details and test requirements for (i) Pins for 11 KV Insulators, (ii) Helically Formed
Pin Insulator Ties (iii) Fittings for Strain Insulators with Helically Formed Conductor Dead-Ends and (iv)
Fittings for Strain Insulators with conventional Dead-End Clamps.
Pins shall comply with the requirements of IS:2486 (Pt.I & II). Helically formed fittings shall comply
with IS:12048-1987. Fittings for strain insulators shall comply with the requirements of IS:2486Pt.I to IV.
3. PINS FOR INSULATORS
The pins shall be of single piece obtained preferably by the process of forging. They shall not be made by
joining, welding, shrink fitting or any other process using more than one piece of material. The pins shall be of
good finish, free from flaws and other defects. The finish of the collar shall be such that a sharp angle between
the collar and the shank is avoided. All ferrous pins, nuts and washers, except those made of stainless steel,
shall be galvanised. The threads of nuts and taped holes, when cut after galvanising shall be well oiled or
greased.
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3.2 Dimensions
Pins shall be of small steel head type S 165 P as per IS:2486 (Part-II) having stalk length of 165mm and
shank length of 150mm with minimum failing load of 5 KN. Details of the pins are shown in Fig. 3.
3.3 Tests
Insulator pins shall comply with the following test requirements as per IS:2486 (Part-I)-1993 or latest version
thereof:
3.3.1. Type Tests
b) Galvanising test
c) Visual examination test
d) Mechanical test
b) Galvanising test
c) Mechanical test
3.3.3 Routine Test
Visual examination test
4. HELICALLY FORMED PIN INSULATOR TIES
4.1 Helically formed ties used for holding the conductor on the pin insulator (Fig.4) shall be made of aluminium
alloy or aluminised steel or aluminium-clad steel wires and shall conform to the requirements of IS:12048-
1987.
4.2 The ties shall be suitable for pin insulator dimensions as per Fig. 1 of Pt. I and conductor sizes to be
specified by the purchaser.
Note : Helically formed insulators ties are made to suit specific sizes of conductors, which should
be clearly specified by the purchaser.
4.3 Elastomer pad for insulator shall be used with the ties to avoid abrasion of the conductor coming into
direct contact with the insulator.
4.4 Tests
The ties shall be subjected to the tests specified in IS:12048-1987.
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5. FITTINGS FOR STRAIN INSULATORS WITH HELICALLY FORMED CONDUCTOR DEAD-END GRIPS
5.1 Fittings for Strain Insulators of Tongue & Clevis Type
5.1.1 The fittings shall consist of the following components:
a) Cross arm strap conforming to IS: 2486 (Pt. II)-1989.
b) Aluminium alloy die cast thimble-clevis for attaching to the tongue of strain insulator
on one end and for accommodating the loop of the helically formed dead-end fitting at the other end in its
smooth internal contour. The thimble shall be suitable for all sizes of conductors ranging from 7/2.11mm
to 7/3.35mm ACSR. The thimble clevis shall be attached to the insulator by a steel cutter pin used with a
non-ferrous split pin of brass or stainless steel. The thimble shall have clevis dimensions as per IS:2486 (Pt.II)-
1989.
c) Helically formed dead-end grip having a pre-fabricated loop to fit into the grooved contour of the thimble on
one end and for application over the conductor at the other end. The formed fitting shall conform to the
requirement of IS:12048-1987.
Note : As the helically formed fittings are made to suit specific sizes conductors, the
purchase should clearly specify the number of fittings required for each size of conductor.
5.1.2 Nominal dimensions of the T&C type insulator fittings are shown in Fig. 5.
5.2 Fittings for Strain Insulators of Ball & Socket Type
5.2.1 The fittings shall consist of the following components:
a) Cross arm strap conforming to IS:2486 (Pt.II)-1989.
b) Forged steel ball eye for attaching the socket end of the strain insulator to the cross arm strap. Forgings
shall be made of steel as per IS:2004-1978.
c) Aluminium alloy thimble-socket made out of permanent mould cast, high strength aluminium alloy for
attaching to the strain insulator on one end and for accommodating the loop of the helically formed dead-end
fittings at the other end in its smooth internal contour. The thimble-socket shall be attached to the strain
insulator with the help of locking pin as per the dimensions given in IS:2486 (Pt.II)-1989 and
d) Helically formed dead-end grip as per clause 5.1.1(c) above.
5.2.2 Nominal dimensions of the Ball & Socket type insulator fittings are shown in Fig. 6.
5.3 Tests
The helically formed fittings for strain insulators shall be subjected to tests as per IS:12048-1987. The
other hardware fittings shall be tested as per IS:2486 (Part-I).
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6. FITTINGS FOR STRAIN INSULATORS WITH CONVENTIONAL DEAD-

END CLAMPS ALTERNATIVE TO FITTINGS COVERED IN CLAUSE 5)
6.1 Fittings for strain insulators with conventional dead-end clamps for use with tongue & clevis or ball &
socket type insulators shall consist of the following components :
a) Cross arms strap conforming to IS:2486 (Pt.II)-1989
b) Dead-end clamp made of aluminium alloy to suit ACSR conductors from 7/2.11mm to 7/3.35mm. The
ultimate strength of the clamp shall not be less than 3000 Kg. The shape and major dimensions of clamps
suitable for B&S and T&C insulators are shown in figures 7 & 8 respectively.
6.2 Tests
The fittings shall be subjected to type, routine and acceptance tests in accordance with the stipulations
of IS:2486 (Pt.I).
Note: Fittings for strain insulators as stipulated in Clause 5 are preferable to the fittings stipulated in Clause
6 both from the point of view of better quality of construction and ease of application.
7. PACKING
7.1 For packing of GI pins, strain clamps and related hardware, double gunny bags or wooden cases shall be
used. The heads and threaded portions of pins and the fittings shall be properly protected against damage.
7.2 The gross weight of the packing shall not normally exceed 50 Kg. Helically formed fittings shall be packed in
card-board / wooden boxes. Fittings for different sizes of conductors shall be packed in different boxes and
shall be complete with their minor accessories fitted in place and colour codes on tags/fittings shall be marked
to identify suitability for different sizes of conductors as per IS:12048-1987.
8. INSPECTION
8.1 All tests and inspection shall be made at the place of manufacture unless otherwise especially agreed
representing the purchaser all reasonable facilities, without charge, to satisfy him that the material is being
furnished in accordance with this specification.
8.2 The purchaser has the right to have the test carried out at his own cost by an independent agency
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ANNEXURE-I
HYDRAULIC PRESSURE TEST ON DISC INSULATOR SHELL
120 KG C/ M sq +/- 10 on the shell before cap and pin assembly to check the
integrity of Porcelain
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X
X
X
X
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HELICALLY FORMED FITTINGS FOR 11 KV AND LT LINES

1. SCOPE
This Standard specifies the requirements and tests for helically formed fittings for use on 11 KV and LT
overhead lines.
The following types of fittings are covered:-
a) Conductor dead end fittings
b) Distribution ties, side ties and double ties
c) Conductor splices
d) Guy grip dead-ends
e) Tap connectors
f) Service grip dead-ends
g) Lashing rods
2.1 Aluminium alloy, aluminium-clad steel and galvanised steel wires having required mechanical strength,
corrosion resistance and formability, depending on the type of application shall be employed in the
manufacture of the fittings. The material of the formed fittings shall be compatible with the conductors with
which it is used.
2.2 In case of formed wires, no joints shall be permitted except those in the base rod or wire before final
drawing.
2.3 Each formed set shall be marked with indelible and distinct colour to indicate starting/cross-over point
of application to facilitate its application on the conductor.
2.4 The ends of the individual wires of the formed fittings shall be suitably debarred to provide a smooth
finish so as to avoid any damage to the conductor due to sharp edges.
2.5 Suitable grit shall be applied to the gripping section of the formed fitting (except lashing rods) in order
to enhance its gripping strength.
3. PROPERTIES OF WIRES
3.1 Materials of the wires used in the manufacture of the fittings covered by this specification shall have
the mechanical and electrical properties as specified in Tables 1,2 and 3. Materials used for chloroprene
pad shall have the properties specified in Table 4.
Table 1
Aluminium Alloy Wires
Test Requirements
1. Visual a) No scratches
b) No pealing off
c) No speed crack
d) No cut mark
2. Dimensions after forming a) Diameter Tolerance (+) .000 mm
(-) .025 mm
b) Flattening (+) .000 mm
(-) .076 mm
2
3. Tensile strength of formed wires 35 Kg/mm
Y
4. Elongation of finished wire Min. 2% in a gauge length of 50 mm
5. Conductivity of finished wire Min. 39% as per IACS

6. Wrap test Min. number of twists on a mandrel of its own dia without
Wire diameter (mm) fracture at a rate of 15 turn per minute
Upto 3.07 18
From 3.08 to 3.45 16
From 3.46 to 3.71 14
From 3.72 to 4.24 12
From 4.25 and above 10
Table 2
Aluminium Clad Steel Wires
S.No. Test Requirements
1. Visual Free from splints, scale, inequalities, flaws and other

irregularities :
2. Dimentional Roundness to (±) 0.013mm

3. Tensile strength As per table 2a below
4. Weight of coating As per table 2b below
5. Wrap test (on a mandrel 2 times the dia of After close helix, the sample should not fracture
the sample and at the rate of 15
turns/minute)
6. Adherence of coating (in a close helix not No cracking or flacking to such an extent that the
exceeding 15 turns/minute) around a aluminium coating can be removed by rabbing with
cylindrical mandrel having a diameter the bare fingers
prescribed in table 2c.
Table 2a
Wire diameter (mm) Ultimate tensile strength Ultimate elongation (Min.) percent
(minimum) MPa in 254 mm
1.270 to 2.283 including 1280 3.0
2.286 to 3.045 including 1240 3.5
3.048 to 3.515 including 1210 4.0
3.518 to 3.782 including 1170 4.0
3.785 to 4.826 including 1140 4.0
Y
Table 2b
Wire diameter (mm) Min. weight of aluminium coating on uncoated wire
surface (gms/m2)
1.270 to 1.521 including 70

3.556 to 4.569 including 104
4.572 to 4.826 including 116
Table 2c
Wire diameter Min. ratio of mandrel diameter to wire diameter

Table 3
Zinc coated steel wire
Test Requirements
1. Visual Free from splints, scale, inequalities and other irregularities :
2. Dimentional Roundness to (±) 0.013mm
3. Tensile strength of finished wire As per table 3a below
4. Weight of zinc coating As per table 3b below
5. Wrap test (on a mandrel 2 times the After close helix of minimum 8 turns, the sample should not
dia of the sample and at the rate of 15 fracture.
turns/minute)
6. Adherence of coating (in a close helix No cracking or flacking to such an extent that zinc coating
not exceeding 15 turns/minute) can be removed by rabbing with the bare fingers
around a cylindrical mandrel having a
diameter prescribed in table 3c.
Y
Table 3 a
Wire diameter Ulitimate tensile strength Elongation in 200 mm gauge length

mm (Minimum) MPa minimum (%) mm
1.270 to 2.283 including 1450 3.0
2.286 to 3.045 including 1410 3.5
3.048 to 3.053 including 1410 4.0
3.556 to 4.022 including 1380 4.0
Table 3b
Wire diameter Minimum weight of zinc coating on uncoated wire surface

(mm) (gms/m2)
1.270 to 1.521 including 183
1.524 to 1.902 including 198
1.905 to 2.283 including 214
2.286 to 2.639 including 229
2.642 to 3.045 including 244
3.048 to 3.553 including 259
4.572 to 4.822 including 305
Table 3c
Wire diameter Ratio of mandrel diameter to wire diameter

(mm)
Table 4
Properties for Chloroprene pad
Chloroprene cushion shall have following properties :
1a) Tensile Strength Minimum 100Kg/cm2
b) Tensile strenght Loss of maximum 25% of the test value obtained in 1(a)
(after ageing)
2a) Elongation 250% minimum
b) Elongation (after Loss of maximum 25% of the test value obtained in 2(a)
ageing)
3a) Shore hardness ‘A’ 65 (±)5
b) Shore hardness (±)15% of test values obtained in 3(a)
(after ageing)
Note : Ageing should be carried out for 70 hours at 100oC.
Y
4. REQUIREMENTS OF FORMED FITTINGS FOR VARIOUS APPLICATIONS
4.1 Conductor Dead-end fittings
4.1.1 Formed conductor dead-end fitting for 11 KV lines consists of the following parts for use with disc
insulators of clevis and tongue type:
a) Cross arms strap for attaching the fittings to the pole on one side and the disc insulator on the other.
These fittings shall conform to the REC Specifications of 11 KV Porcelain Insulators and Fitting.
b) Aluminium alloy die cast thimble clevis for attaching the fitting to the tongue of disc insulator on one end
and for accomodating loop of the helically formed fitting at the other end in its smooth internal contour. The
thimble clevis is attached to the insulator through a steel cotter pin used with a non-ferrous split pin of brass
or stainless steel. The thimble clevis shall have clevis dimensions as per IS : 2486 (Part II) - 1989 and shall
have the minimum failing load strength of 3000 kg.
c) Helically formed fitting acting as the dead-end grip.
4.1.2 The die-cast aluminium alloy thimble clevis shall be manufactured with alloy A6 Designation of IS : 617 -
1975.
4.1.3 Nuts and bolts used shall be of galvanised steel conforming to IS : 1364 - 1967 and cotter pins
conforming to IS : 2004 -1978. Spring washers used shall be electro-galvanised.
4.1.4 The fitting for LT lines shall comprise of the helically formed fitting to suit the LT shackle insulator as
per REC Specification of Porcelain Insulators and Insulator Fittings For 415/240V Overhead Power Lines
4.1.5 The fittings shall be made to suit the following conductor sizes for 11 KV/LT
Lines conforming to REC Specification 1/1971(R-1993) and each fitting shall have a clear identification mark
on PVC/metallic/plastic tag, indicating size of the conductor and voltage. The following colour code shall be used
for the tag as also for the starting/cross-over marks for quick identification:
20 mm2 ACSR(Squirrel) Blue

30 mm2 ACSR(Weasel) Red
50 mm2 Yellow
ACSR (Rabbit)
50 mm2 Brown
ACSR (Rabbit)
50 mm2 Grey
AAC (Ant)
4.2 Distribution ties side ties and double ties
4.2.1 Helically formed ties are used to hold the conductor to pin insulators or shackle insulators.]
4.2.2 Chloroprene pad shall be provided with the formed ties for use on 11 KV lines to avoid abrasion of the
conductor
4.2.3 The conductor sizes and voltage class shall be clearly marked on each fitting and the fittings shall
also be identified by color code as per clause 4.1.5.
4.2.4 To ensure proper fitting of 11 KV pin insulator ties, the purchaser shall furnish full-dimensions
of the insulator top particularly the crown diameter, neck diameter etc. See REC specification 11KV porcelain
insulators and fittings.
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4.3 Conductor Splices

4.3.1 Conductor splices for ACSR conductors shall consist of (i) galvanised steel formed splice for
steel core (ii) aluminium alloy formed filler rod (iii) aluminium alloy formed splice for the aluminium strands of
the conductor. For AAC conductor, splice is formed with aluminium alloy only.
4.3.2 Repair Splice: Repair splices are non-tension splices and are used where some of the outer strands of
the conductor are damaged.
4.4 Guy Grip Dead-End
4.4.1 Guy grip dead ends have one leg shorter than the other and are suitable for gripping the guy wire.
These grips are applied on one side into the thimble eye of the stay rod and on the other side to the guy wire.
These can also be used directly with guy insulators.
4.4.2 The fittings shall be made of two sizes to suit stay wires of 7/3.15mm(7/10SWG) and 7/2.5
mm(7/12SWG) having UTS values 3625 kg and 2300 kg respectively.
4.4.3 The fittings shall be clearly identified on a PVC/mettalic/plastic tag for the size of stay wire with which
these are to be used and, in addition, the following colour codes for the tag as well as the corss-over marks
shall be adopted for proper identification:
Guy grip for 7/3.15 mm stay wire - Green

Guy grip for 7/2.5 mm stay wire - Black
4.4.4 The guy grip shall be supplied complete with thimble to suit the fitting. Thimble shall be made of hot-
dipped galvanized steel.
Note: The guy grips to be used with guy insulators shall take into account the standard sizes of insulators as
per REC specification and the type and size of the guy insulator shall be clearly specified by the purchaser.
4.5 Tap Connectors: Tap connectors consist of helically formed aluminium alloy wires for non-tension
tapping of conductors and cables from the main line. The sizes of conductors/cables for
which these tap connectors are to be used have to be clearly specified by the purchaser.
4.6 Service Grip Dead End: Service grip dead-ends are used with metallic knob to hold one or more service
bearer wires.
4.7 Lashing Rods: Lashing rods are helically formed wires to secure the bearer wire to the service cable.
The number of lashing rods will depend on the length of service.
5. DIMENSIONAL REQUIREMENTS OF THE FINISHED FORMED FITTINGS
5.1 The lay of the helix shall be right hand.
5.2 The diameter and number of formed rods used per set of fittings to be used on various sizes of
conductors shall be as per the approved drawings.
5.3 Tolerances of formed fittings: The various requirements of the helically formed fitting shall be within the
following toleranaces:
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Item Tolerances
a) Pitch length + 0.6 mm (-)0.12 mm
b) Internal diameter + 1% (-) 3%
c) Length of individual rod (±) 1%
d) Difference in length (±) 1% between the longest and the shortest rod in an
individual set
6. TESTS
6.1 Type Tests: The following tests shall constitute the type tests on the finished fittings:
S.NO. Test Applicable to

1 Visual examination All fittings
2 Verification of dimension All fittings
3 Tensile strength test All fittings
4 Electrical resistance test All aluminium alloy fittings
5 Wrapping test All fittings
6 Slip strength test Conductor dead-end, guy grip and

splices
7 Resilence test Conductor dead-end, guy grip and
conductor splices
8 Unbalanced holding Strength Test Ties only
9 Fatigue test Conductor dead-end, ties and splices
10 Galvanising test Hardwares and fittings using GI wire
11 Pull-off strength test Ties only
12 Electrical & Mechanical Test Tap Connectors
13. Tests for other requirements as per Tables 1,2, 3 & 4.
Acceptance Test: The following shall constitute the acceptance test:

1. Visual examination
2. Verification of dimension
3. Tensile Strength test
4. Electrical resistance test
5. Wrapping test
6. Slip Strength test
7. Resilience test
8. Unbalanced load
9. Galvanisation test
10. Pull-off strength
11. Electrical & Mechanical tests on tap connectors
12. The tests for other requirements as per Tables 1,2,3 & 4 on the individual wires used in making
the helically formed fittings and chloroprene pad (where used).
6.3 Routine Tests: The following shall constitute the routine tests:
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7. TEST PROCEDURE
7.1 Visual Examination: All fittings and individual wires shall be checked visualy for good workmanship,
smooth finish and other requirements indicated in Table 1, 2 and 3.
7.2 Verification of dimensions: The dimensins shall be checked as specified in the tables 1, 2, 3 and clause 5.
7.3 Tensile Strength Test:
7.3.1 Individual wire of the helically formed wires shall be straightened by light hammering and tested for
tensile strength and elongation in accordance within the IS:398(Part II)-1976. The tensile strength and the
elongation of the formed wires shall not be less than the values specified in tables 1, 2 and 3.
7.3.2 For thimbles and hardwares other than formed fittings:

The dead-end clevis thimble and straps shall be tested for tensile strength in accordance with the
requirements of mechanical failing load as per IS:2486(Part I)-1993.
7.4 Electrical Resistance Test: This test shall be done on straightened aluminium alloy formed wires only.
The conductivity of the wires should not be less than 39% IACS.
7.5 Wrapping Test: The individual wires of the formed fittings shall be tested as specified in tables 1, 2
and 3. The wires should not break or show fracture when tested as above.
7.6 Slip Strength Test: For the conductor dead-end and guy grip dead-end, the test shall be made in
accordance with IS:2486(Part I)-1993 and the value of slip/breaking strength shall not be less than 85% of the
breaking strength of the conductor for conductor dead-end fitting and 100% for guy wires dead
end fittings. In case of tension splices, the test shall be carried out as per IS:2121. No slippage or damage
to the fitting shall occur at a value less than 100% of breaking load of the conductor. This test should be
repeated after the resilence test.
7.7 Reslience Test: A set of helically formed fitting is wrapped and un-wrapped on a piece of conductor 3
times successively. The helical fitting should not lose its resilence even after three applications and should be
able to pass the slip strength test requirements mentioned in 7.6 thereafter.
7.8 Unbalanced Holding test: Unbalanced holding strength is the ability of the formed ties to maintain a
constant and uniform grip on the conductor when intermittent and repeated unbalanced loads impose a
tension imbalance in the span. These imbalances occur due to wind induced motion, impacts,
ice conditions and more so when the conductor is broken.
The test is intended to simulate the broken wire condition. A span of minimum 20 meters tensioned for 40%
of UTS of the conductor shall be erected in the laboratory and a pin insulator alongwith the insulator tie
under test shall be applied in the middle of span. The conductor used for this purpose shall be of the specific
size with which the insulator tie is to be used. The test set up shall be such that it should be possible to apply a
pull on one of the two dead ends of the conductor. For the purpose of this test, a steel replica of the insulator
will be used. During the test, tension on one side of the pin insulator shall be suddenly released and effect
observed. No slippage or damage to the fitting shall occur. After releasing tension from the other end, the
fitting should retain the original form. This test will not only check the holding strength of the fitting but will
also prove the resilence of the fitting in the event of broken wire.
The test shall be repeated. After releasing the conductor tension on one side, pulling force shall be slowly
applied on the other dead-end to pull the conductor till slippage/damage occurs. This force shall not be less
than 320 kg.
7.9 Fatigue Test: The fittings should be subjected to fatigue test alongwith the conductor by imparting
10 million cycles of peak to peak amplitude at a frequency above 30 cycles for minimum span length of 20
meters, at 40% of UTS of conductor. The amplitude of the vibrations at the antinodal points should be atleast
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50% of the diameter of the conductor. The test should be carried out for 10 million cycles as continuously as
possible after which the conductor fitting and insulator should be examined. There should be no damage to
the conductor or the insulator where the fitting is attached. The fitting should also be able to withstand the test
without any damage.
7.10 Galvanising Test: Galvanising test should be carried out in accordance with IS:4826-1979 for uniformity
and IS:6745-1972 for weight of zinc coating and the fittings will meet the requirements of Table 3.
7.11 Pull-Off Strength Test: This test is intended to simulate the conductor pull-off conditions
created by various factors including elevation difference of the supporting structures on the two sides of the
tie. A span of minimum 20 metres tensioned for 40% of UTS of the conductor shall be erected in the laboratory
with a conductor of the specified size with which the fitting is intended to be used. A steel replica of pin
insulator alongwith the insulator tie under test shall be applied in the middle of span so that a suitable pull-off
force can be applied on the pin by means of a machine. The pull-off strength of the tie shall not be less than
200 Kg. for all the three sizes of ACSR.
7.12 Electrical & Mechanical Test on Tap Connectors: The tap Connectors shall conform to all the
electrical and mechanical properties as per IS:5561.
8. PACKING AND MARKING

8.1 All helically formed items covered under this specification shall be carefully handled to prevent
distortion and damage. These items shall be packed and stored in suitable cartons.
8.2 Different colour codes shall be adopted for different conductor sizes and catalogue number and range of
outside diameter of the conductor shall be indicated on the packing.
8.3 Clevis thimbles and other hardwares for conductor dead-ends shall be packed in wooden crates with all
necessary markings.
8.4 The packings of the fittings should carry the following informations.
a) Purchaser’s name
b) Manufacturer’s name and trade mark
c) Size of conductor, line voltage (when required) and numbers
d) Batch number, date, month and year of manufacture
e) Any other marking agreed to between manufacturer and user.
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GUY STRAIN INSULATORS

1. SCOPE
This Specification covers porcelain guy strain insulators for use in rural electrification system.
Unless otherwise modified in this specification, the insulators shall comply with IS: 5300-1969 or the latest
version thereof.
3.1 The porcelain insulator shall be sound, free from defects, thoroughly vitrified and smoothly glazed.
3.2 The design of the insulator shall be such that the stresses due to expansion and contraction in any part
of the insulator shall not lead to its deterioration.
3.3 The glaze, unless otherwise specified, shall be brown in colour. The glaze shall cover the entire porcelain
surface parts except those areas that serve as supports during firing.
4. TYPE OF INSULATORS
4.1 The standard guy strain insulators shall be of designations ‘A‘ and ‘C‘ as per IS:5300.
4.2 The recommended type of guy strain insulators for use on guy wires of overhead lines of different voltage
levels are as follows :
Power Line Voltage Designation of Insulators
415/240V A
11000V C
33000V C (2 Insulators to be used in series)
5. DIMENSIONS
The dimensions of guy strain insulators shall be in accordance with Figs. 1 and 2.
6. BASIC INSULATION LEVELS

The test voltage of the insulators shall be as under :
Designation of Dry one minute power Frequency Wet one minute power Frequency
Insulator withstand voltage KV (rms) withstand voltage KV (rms)
A 18 8
C 27 13
7. MECHANICAL STRENGTH
The insulators shall be suitable for the minimum failing loads specified as under:
Designation of Insulator Minimum failing load (KN)
A 44
88
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8. TESTS
The insulators shall comply with the following routine, type and acceptance tests as per IS:5300.
8.1 Routine Test

Visual examination
8.2 Type Tests

c) Temperature cycle test
d) Dry one-minute power-frequency voltage withstand test
e) Wet one-minute power frequency voltage withstand test
f) Mechanical strength test
g) Porosity test
8.3 Acceptance Tests: (to be conducted in the following order)

c) Mechanical strength test
d) Porosity test
9. MARKING
9.1 Each insulator shall be legibly and indelibly marked to show the following :
b) Year of manufacture
c) ISI certification mark, if any.
9.2 Marking on porcelain shall be applied before firing.
10. PACKING
All insulators shall be packed in wooden crates suitable for easy but rough handling
and aeptable for rail transport. Wooden separators shall be fixed between the insulators to keep
individual insulators in position without movement within the crate.
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11 KV HORN GAP FUSE

1. INTRODUCTION :
This Chapter describes the hardware requirement, Technical Particulars and testing requirements for 11 KV
HG Fuse
1.1 11 KV HG Fuse
One set of fuse shall be suitable to protect a 3 phase DT on HT side.
1.2. MATERIALS
The various components shall conform to the following specifications.
1. M.S. Channel, Flat and Round (Steel) to conform to I.S. 2062 amended upto date (structural steel standard
quality having tensile strength of 42-54 Kg./mm sq.)
2. Bolt and Nuts: These shall conform to the following IS Specifications:
IS: 1367- 1980
IS 4218 - 1976
IS: 1363 - 1984
3. For galvanizing, zinc conforming to Grade 98.50 of IS-209 1979 specification for Zinc (Revised) shall be
used.
4. Insulators: Insulators used for the Horn Gap Fuse Unit shall conform to relevant IS Standards in all respects
with regard to mechanical and electrical requirements.
1.3. The electrical characteristics of the insulators shall be as follows:
System Voltage : 11 KV
Power frequency withstand voltage in KV : 28
Impulse withstand voltage in KV : 75
Creepage distance in mm : 300
1.4. GENERAL REQUIREMENTS
The Horn gap fuse sets are required for protection on 11 kV system. Current rating of HG Fuse shall be 200
A. They will be mounted outdoors on suitable structures. These sets will be exposed to atmospheric
conditions and therefore, shall be robust in construction. Pin type of insulators shall be used in construction
of the fuse units as per REC approved drawing.
1.5. WORKMANSHIP
The casting shall be of good finish and free from flaws, blow holes and other defects. The edges of the
fittings shall be smoothly rounded. The M.S. flat, round etc. before any work is done on them, shall be
carefully leveled, straightened and bent or forged to the shape given in the drawing by methods which will
not injure the materials. No rough edges shall be permitted any where through out the work. Similar parts
shall be uniform and inter changeable with each other. The welding work shall be carried out properly and
the same shall not open under adverse climatic conditions. Holes in channel shall be drilled or machine
punched. All burrs left by drilling or punch shall be completely removed. The Bolts and Nuts shall be well
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forged and free from inequalities, flaws and other defects. The heads shall be solid and in every respect well
formed and shall not fail when the bolts are tested to fracture at their full section for Tensile Stress. The
washers shall be clearly cut off or punched and entirely free from cracks after punching.
1.6. GALVANISING
All ferrous parts (bolts, nuts, washers, M.S. flats, clamps and M.S. round holding clamps etc. for the insulator
& horn gap fuses) shall be hot dip galvanized. The galvanizing shall conform to IS : 2629 in all respect an
uniform Zn Coating shall be as per IS: 2633. After galvanizing, the surfaces shall be free from all sharp edges
and metal. The threading on nut and bolt shall be cut before galvanizing.
1.7. TESTS
1. The manufacturer/ bidder shall clearly indicate what testing facilities they have got for testing the H.G.
Fuses.
2. The bidder shall carryout following routine tests on H.G. Fuses:
i) Dielectric Tests
ii) Temperature Rise Tests shall be done at rated current.
These tests shall be carried out as per procedures given in latest version of IS: 9385/80 (Part 2) or
thereof.
iii) The supplier will have to guarantee the composition of the aluminium used and strength by actual test.
The supplier/ bidder shall therefore mention in the offer the name of the manufacturer from whom
the raw materials are purchased and also submit the Test Certificate therefore.
iv) The supplier will clearly and specifically indicate the name of manufacturer of the pin insulator. Test
certificate showing the results of the routine and type tests carried out as per IS: 731/1971 will have to
be submitted along with the offer. The pin insulators will be inspected at the original manufacturer’s
factory.
AA
H.R.C. FUSE
The H.R.C. fuse links of 100 Amp, 200 Amp, 300 Amp ratings, should be ISI marked & conforming to ISS: 9224 -
1979 with latest amendment and to be supplied with suitable base of bakelite on DMC. The knife contact should be
made of tinned/silver plated copper complete with extension strips. The extension strips should be made of copper.
The thickness of the cooper strips should be 2mm for 100 Amp and 200 Amp, 3.0mm for 300 Amp. The strips
should be in one piece. The HRC Fuse units should also be supplied with suitable lugs for 3 core 95 sq.mm, 120
sqmm and 300 sq.mm. cables for 100, 200 and 300 Amps ratings respectively. The dimension of the lugs should be
as under
S.No. Ratings of HRC Cable sizes Minimum thickness of lugs Flat Minimum total length of lugs
Fuse unit (mm) / Rounded (mm) (mm)
1 100 Amp 95 sq.mm 4.2 / 2.1 64
2 200 Amp 120 sq.mm 4.6 / 2.3 73
3 300 Amp 300 sq.mm 7.0 / 3.5 15
The knife contact should have pressure springs to hold the fuse links. The extension strips shall be provided with GI
nut & bolts and plain and spring washer to both the end. The DMC or bakelite base should be provided with suitable
fixing alignment.
The following test certificates should invariably to be performed on the HRC Fuse Units.
1. Test for temperature rise at rated current

2. Current time characteristics
3. Determination of minimum fusing current and minimum non-fusing current
4. Test for duty
The breaking capacity of HRC Fuse Units should not be less than 80 KA.
The following tests shall be performed during pre-despatch inspection at manufacturer’s works: -
1. Insulation resistance test

2. Temperature rise test
3. High Voltage test
Marking on the fuse base and on the fuse links :
1. Name of the manufacturer

2. Rated current
3. Rated voltage
4. ISI marking and reference of 185 No. (only on fuse links)
5. Rated Power loss
6. Name of the Employer
AB
MCCB
The MCCBs provided in these boxes shall conform in all respects to the relevant IS: 2516 (Pt-I&II)/1977 or its latest
revision as applicable.
REQUIREMENT OF MCCBs: The moulded case circuit breakers should comprise of a switching mechanism, an
effective extinguishing device and a tripping unit contained in a compact moulded case cover made of high strength,
heat resistance and flame retardant thermo-insulating materials. They should comprise of a spring assisted quick
make/quick break type independent manual trip free mechanism rendering it easy to manually operate the MCCBs
and capable of clearly indicating “TRIPPED”, “ON” AND “OFF” positions from the position of the operating handle.
The contact tips should be made of a suitable alloy having high arc resistance and a long electrical and mechanical
life needing no replacement. The breakers should be designed with a common trip bar to break and make all the
three phase together even when fault occurs on any of the phases. The breakers should provide protection against
sustained overloads and short circuits through thermal-magnetic/fully magnetic releases. These MCCBs along with
terminal blocks are intended to be housed in the distribution boxes made out of sheet steel of 2mm gauge. The
assembly of the MCCBs and the terminal blocks should be compact, reliable from operation point of view and safe to
the operating personnel. As already mentioned earlier, the MCCBs should be fully maintenance free.
TECHNICAL PARTICULARS OF MCCBs: The LT MCCBs should have inverse current/time characteristics suitable
for protection of 63KVA, 100KVA, 200KVA & 315KVA 11.0.4KV Distribution Transformers against sustained over-loads
and short circuits for following operating conditions:-
i Rated Operating Voltage 3 Phase 415 Volts AC 50 cycles with neutral solidly
grounded system
ii Standard rated current ratings for MCCBs to be used with different sizes of transformers will be as follows:-
a) For 63KVA 11/0.4KV Dist. Transformer 90 Amps
b) For 100KVA 11/0.4KV Dist. Transformer 140 Amps
c) For 200KVA 11/0.4KV Dist. Transformer 300 Amps
d) For 315KVA 11/0.4KV Dist. Transformer 450 Amps
iii No. of Poles 3
iv Duty Un-interrupted
v Maximum ambient temperature 47oC in shade
vi Minimum ambient temperature 4oC in shade
vii Average altitude A maximum of 1000 meter
viii Maximum humidity Frequently approaches saturation point
TIME/CURRENT CHARACTERISTICS: The circuit breakers shall have time/current characteristics suitable for
following operating conditions :-
Multiple of normal current rating Tripping time

1.1 times After 4 hours
1.2 times Less than 50 minutes
2.5 times Less than 1 minute
6 times Less than 40 mili-seconds
12 times Less than 40 mili-seconds
Time/Current characteristic of the Circuit Breaker (MCCB) shall be tested in accordance with Clause-7.7.2.3 (b) (2) of
IS:2516-(Pt-I&II) Sec.I/1977 and the test shall be made with all the three phases loaded.
AC
For time/current characteristic, the reference calibration temperature of the MCCBs shall be 40 oC and durance, if any,
upto 50oC operating temperature in the enclosure shall not exceed 10% of the value indicated above in Clause (I)
above.
The MCCBs shall be calibrated and adjusted in the factory itself for the desired time/current characteristic.
The MCCB should have the following maximum resetting time under overload & short circuit conditions :-
Overload conditions - 3 minutes

Short Circuit conditions - Instantaneous
RATED SHORT CIRCUIT BREAKING CAPACITY: The rated short circuit breaking capacity of the MCCBs shall be
as follows: -
Transformer rating(KVA) Rated short circuit breaking capacity of the

breaker in Kilo-Amps
63 KVA A minimum of 3 Kilo-Amps
100 KVA A minimum of 5 Kilo-Amps
200KVA A minimum of 10 Kilo-Amps
315KVA A minimum of 15 Kilo-Amps
The short circuit breaking capacity test as specified above shall be based on short circuit tests carried out at 0.4
Power Factor (lagging). For the purpose of these tests, the following operating sequence shall be followed: -
Break-3 minutes interval-Make-Break-3 minutes interval-Make-Break.
AC
TRIPLE POLE SWITCH FUSE UNITS WITH NEUTRAL LINKS

(200A, 320A & 400A/415 VOLTS RATINGS)
This specification covers manufacture, testing before dispatch and delivery of Triple Pole Switch Fuse Units with
neutral Link and HRC cartridge type fuses suitable for AC 3 Phase 4 wire 415 V with neutral solidly grounded
system. The working conditions and technical requirements are as under:-
TECHNICAL REQUIREMENTS
a) Rated Current : 200 Amps, 320 Amps & 400 Amps
b) I) Rated Operational Voltage : 3 Phase 4 Wire, 415 Volts AC 50 Hz with

solidly earthed neutral
II) Highest System Voltage : 415V + 10%
c) Type of Fuse to be used : Non-deteriorating quick arcing type ISI marked

HRC Cartridge fuse Links suitable for Class-1
category of duty of IS:13703(Part-I). The
temperature rise shall be in accordance with
IS:13703 (Part-I) (with latest amendments)
over and above the ambient temperature
of 45oC. It shall be used for protecting the
distribution circuits and distribution transformers
and shall be capable of carrying continuously
the above stated rated current safely.
d) Number of Poles : Three
e) Neutral Link : One
f) Duty : Un-interrupted duty
g) Rated fused short circuit : 40KA for 1 second.

withstands current capacity at 415V
h) Utilization category as : AC-23 (B) as defined in IS: 13947 (Pt-III)/ 1993
GENERAL
1. CONTACTS AND BLADES & OPERATING MECHANISM
The switch shall be a combination of double beak per pole AB switch with HRC fuses in all the three phases.
The switch shall be spring assisted, quick make and quick break type having operating mechanism independent
of he speed of the operator to minimize the acing. If required, additional contact springs shall be provided to
maintain correct contact pressures throughout operating life of the switches. The switch shall be so constructed
that the alignment of its contacts & blades, which will be made of silver plated electrolytic copper/tinned
copper, is maintained under asymmetrical fault conditions also. The tenders should furnish in their offers about
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the details of switching mechanism and the contacts. The switch shall have positive break feature such that it is
possible to make it OFF even if the quick action spring fails due to ageing or other causes. The switch fuse unit
shall be provided with double break per pole to ensure complete isolation of HRC Fuses from both incoming and
outgoing circuits when the switch is in OFF position, in order to minimize the damage to the maintenance
personnel. Ample flash over distances shall be provided so as to make the unit suitable for controlling highly
inductive loads.
2. ENCLOSURES
The Triple Pole Switch fuse units shall be totally enclosed in robust enclosures made out of 16 guage/1.5 mm
pressed steel sheet (conforming to relevant ISS for M.S. sheet) designed to withstand humid and hot weather
conditions. The enclosures should have adequate strength and rigidity to withstand rough usage without
fracture or permanent distortion. Suitable mounting arrangement shall be provided on the enclosures for
mounting the units on a supporting structure.
3. INTER LOCK
It should not be possible to open the switch cover when the switch is in ‘ON’ position and also it should not be
possible to operate the switch ‘ON’ when the switch cover is open.
4. PAINTING
The inside and outside of the enclosure should be painted with a grey paint. Before painting the surface, the
same should be chemically cleaned for removing rust, grease etc. Then it should be given phosphate coating,
followed by two coats of anti-rust primer (i.e. Red zinc Chrome Primer), after which two coats of synthetic paint
of light grey colour shall be applied on internal and external surfaces of the enclosures with a spray gun. The
enclosures shall then be baked in oven so as to give an elegant and durable finish.
5. EARTHING
The enclosure shall be provided with earthing arrangements at two places.
6. TERMINAL CONNECTIONS
The switch shall be provided with aluminium lugs for termination of PVC coated aluminium cables of following
sizes: -
S.No. Capacity of TPN Size of Cable No. of cable sockets
Switches required
1 200 Amps 150 sq.mm. 3.5 Core 8 Nos. (3 Nos. phase leads
stranded aluminium and 1 natural lead for incoming
cable and also 3 Nos. phase leads and
1 neutral for outgoing
connections)
2 320 Amps 300 sq.mm. 3.5 Core -do-
stranded aluminium
cable
3 400 Amps 300 sq.mm. 3.5 Core -do-
stranded aluminium
cable
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7. All the surface contacts (e.g. lugs, connectors, fixed contacts, moving contacts etc.) should be fitted with GI
nuts & bolts having yellowish OR whitish passivation with good finish.
8. TESTING & TEST CETIFICATES FOR SWITCHES
The performance of the switch should conform to IS:10027/1981 with latest amendments. Accordingly,
certificates from reputed laboratories such as CPRI, ERDA, IITs, for the type tests in accordance with
IS:10027/1981 with latest amendment would necessarily be furnished by the tenderers along with offer. The
offers shall be ignored if test certificates of any Govt. Institute (like CPRI, Bangalore /Bhopal, EREDA etc.) of
the country are not furnished along with the offers and as such their price bid shall not be opened.
9. USE OF ISI MARK HRC FUSES
The HRC Fuses with ISI mark only should be used. These HRC fuses should conform to IS:13703 (Part-I)/1993
or as per its latest revision. The rated current of HRC fuses must be 200 Amps for 200 Amps Switches, 315
Amps for 320 Amps Switches and 400 Amps for 400 Amps Switches.
10. IMPORTANT NOTE
The firms must consider supply of ‘ISI’ certificate (valid on date) products on their offer in the tender, Other
certification such as ISO:9001 & 9002 shall be given due weightage while considering their offer, however, the
attested photo copies of such certification must be enclosed with the offer.
11. INSULATION FOR LIVE PARTS
All live parts shall be fully shielded with bakelite shrouds.
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BATTERIES AND CHARGER
Lead Acid or Ni-Cd, any one of these two can be used by contractor. Both the specification along with
specification for their charger are given below:
I. Ni-Cd ALKALINE BATTERIES (PARTIAL RECOMBINATION TYPE) WITH CHARGERS FOR

33/11 kV AND 66/11 kV SUB-STATIONS
Part-A : Ni-Cd ALKALINE BATTERIES (PARTIAL RECOMBINATION TYPE) FOR 33/11 kV AND 66/11 kV
SUB-STATIONS
1) SCOPE
This specification covers the requirements and tests for 24 V, 30 V 110 V, 220V partial recombination
type Nickel-Cadmium alkaline batteries with chargers, for use in 33/11 kV and 66/11 kV sub-stations.
The batteries covered in this specification are for indoor use. For out-door application a suitable enclosure
shall be provided, preferably made of an insulating material like FRP/SMC/DMC/Poly carbonate plastic
material, heat/alkali/humidity/UV resistant, confirming to S1 or D1 grade of IS: 13410/IS: 13411 or other
relevant international standard, in order to have rust free enclosure. The enclosure shall have rainproof
ventilating louvers backed with fine brass wire mesh & suitable canopy. The enclosures shall confirm to
IP: 52 degree of protection.
All standards, specifications and codes of practice referred to herein shall be the latest editions including
all applicable official amendments and revisions as on date of opening of bid. In case of conflict between
this specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. Unless
otherwise modified in this specification, the Ni-Cd batteries shall comply with latest version of IEC 62259.
All work shall be carried out as per the following standards and codes.
International Indian Description

Sl.No. Standards Standards
1 IEC: 62259 - Secondary cells and batteries containing alkaline or

other non-acid electrolytes-Nickel-cadmium prismatic
secondary single cells with partial gas recombination
2 IEC: 60623 IS: 10918 Secondary cells and batteries containing alkaline or
other non-acid electrolytes-vented Nickel_Cadmium
prismatic rechargeable single cells
3 IS: 1146 Rubber & Plastic container for lead acid storage
batteries
AE
International Indian Description

Sl.No. Standards Standards
4 IEEE: 1106 Recommended practice for maintenance, testing &

replacement of Ni-Cd storage batteries for generating
stations & substations
5 IEEE: 1115 Recommended practice for sizing of Ni-Cd batteries for

stationary applications
6 IS 13410 Glass reinforced Polyester sheet moulding compounds.
7 IS: 1248 Voltmeter
3. STANDARD RATING
The recommended voltage ratings of batteries, for use at 33/11 KV and 66/11 KV sub-stations, shall be 24
volts or 30 volts. The batteries for the above application shall have a rating of 45 Ah (Minimum) in case of
24 V battery system or as per the load requirement of the substation.
Note : Utilities may specify 110 or 220 V DC system if so required. For batteries intended for use with
individual or groups of breakers or with higher DC System voltage, lower Ah ratings can be used depending
upon the requirements.
4. CELL VOLTAGE
The nominal voltage of a single cell shall be 1.2 V
Nominal Nominal Float cell Number Permissibe End of

Voltage single voltage of cells D.C. System discharge cell
Rating of cell (to be voltage voltage (Min.)
battery voltage finalized) variation
(V) (V) (V) (V) (V) (V)
24 1.2 1.4 to1.42 19 21.7 to 27 1.14
30 1.2 1.4 to1.42 23 26.2 to 32.7 1.14
110 1.2 1.4 to 1.42 87 99.2 to 123.5 1.14
220 1.2 1.4 to1.42 170 193.8 to 241.4 1.14
Note: As the nominal cell voltage is 1.2 V, nominal battery bank voltage may not exactly match nominal
DC system voltage.
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5. CAPACITY AT 200C TEMPERATURE
Battery capacity shall be decided based on the following load cycle:-
(a) 800W for 1/2 minute to end cell voltage of not less than 1.14 V per cell considering loads (i) to (iv)
below.
(b) 300 W for 1 hour to end cell voltage of not less than 1.14 V per cell considering loads (iii) & (iv)
below.
(c ) 100W for 05 hrs to end cell voltage of not less than 1.14 V per cell considering loads (iv) below.
The load cycle has been decided based on the following considerations:-
(i) Tripping of 03 Nos. circuit breakers simultaneously with battery for which a total load of 500 W has
been considered.
(ii) Closing of 3 circuit breakers one after the other for which a load of 500 W per circuit breaker has
been considered.
(iii) Emergency lighting load of 200 W for 01 hour.
(iv) 100 W load for panel indication lamps, relays, PLCC/ VHF communication systems, computer etc.
for a period of 06 hours.
6. BATTERY SIZING
The supplier shall carry out battery sizing calculations based on the load cycle specified in line with IEEE
1115 and submit the same to the owner justifying the type/number of cells considered against the
requirement.
Following factors shall be considered while carrying-out battery sizing calculations:-
a) Ageing factor – 1.25

b) Design margin –1.0
c) State of charge –0.9
The number of cells shall be determined as per load cycle and the battery system voltage level.
The owner, if required for the battery system, may specify provision for the number of spare cells.
7. CONSTRUCTION
The cells shall have prismatic, spill-proof type of construction with partial recombination feature. The cells
shall be flooded type containing sufficient reserve electrolyte. Battery shall be equipped with nickel-plated
inter-cell connectors and terminals. The cells shall be housed in high-strength impact resistant & alkali-
resistant containers and should be transparent / translucent to facilitate checking of electrolyte level.
Container and Lid should be welded and should not cause leakage of electrolyte/gases during operation
even in case of normal mechanical/electrical abuses. O-rings of nitrile rubber with Epoxy sealing shall be
used to ensure proper sealing of bushings etc. Flip-top vent plugs/ valves with flame arrester feature shall
be provided. The regulating valve type design shall be of self-resealing type. Construction of cells shall be
so as to ensure proper air circulation between the cells for heat dissipation/ ventilation (by providing either
insulated button separators integral with the outer surface of the cell container or by suitably designing the
inter cell connectors). The containers shall be strong enough, so that excessive bulging of container does
not occur during service. Cells shall be supplied in filled & charged state or otherwise electrolyte in dry
form & battery water separately or electrolyte in liquid form shall be shipped as desired by the owner.
Battery shall have provision for water top up to ensure electrolyte level does not fall below recommended
level.
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8. ELECTRODES
Electrodes shall be deigned for maximum durability under all service conditions. + ve and –ve electrodes
shall be made by encapsulating/impregnating active material in order to ensure that the battery is able to
perform reliably over its life. +ve and –ve electrodes shall be separated by micro porous separators. The
structure of electrodes shall be elastic enough to absorb mechanical stresses & volume changes during
charge/discharge cycles.
9. ELECTROLYTE
The electrolyte shall be prepared from battery grade potassium hydroxide (KOH) confirming to IEC 60993.
The cells shall contain sufficient reserve electrolyte for efficient heat dissipation & to reduce water topping
up interval. Reserve electrolyte shall not be less than 06 ml/Ah.
10. CONNECTORS
Nickel-plated copper inter-cell connectors shall be used for connecting up adjacent cells and rows. Bolts,
nuts and washers shall be nickel-plated steel/stainless steel. All terminals and cell inter-connectors shall be
fully insulated or have insulation shrouds.
11. TERMINALS
Separate terminals shall be provided on the end cell for connecting load through DCDB and for connecting
charger leads. All terminals shall be of suitably sized nickel-plated steel. Suitable nickel-plated copper lugs
shall be provided by the supplier for use of the purchaser for connecting up the load wiring. All connectors
and leads shall be suitable for carrying 30-minute discharge current continuously and rated for short circuit
duty of 4kA for 01 second.
12. MANUAL OF INSTRUCTIONS
The manufacturer shall supply a copy of the instruction manual for commissioning & initial treatment of
the battery and maintenance during service with every battery bank ordered.
13. RECOMBINATION EFFICIENCY
In order to reduce topping-up frequency, recombination of Hydrogen & Oxygen gases evolved during
charging/discharging shall be achieved by using safe and reliable technology such as catalytic
conversion/valve regulation technique or both. Minimum recombination efficiency shall be 80%.
Recombination efficiency test shall be done in accordance with IEC 62259. In case the batteries are
operated at high temperatures & are frequently boost charged the water consumption may be higher &
topping-up frequency may increase.
14. BATTERY RACKS
Suitable corrosion resistant battery racks and cable supports shall be provided. Metallic racks shall be
properly earthed. The bottom tier of stand shall have a ground clearance of 150mm minimum above the
floor. Racks shall be made of alkali resistant powder coated steel or stainless steel or FRP to ensure
corrosion resistance.
15. TEMPERATURE RANGE
o o
Battery must be capable of continuous operation in temperatures range of -15 C to +50 C for
prolonged periods. No Air-conditioning shall be provided where batteries are to be installed.
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16. ACCESSORIES
The following accessories (BIS certified) shall be supplied with each set of battery:-
i) Clamp-on type digital multi-meter of AC/DC current range having ISI mark.
ii) Pair of gloves
iii) 10” Slide insulated wrench for opening terminal nuts
iv) Plastic/glass syringe
v) Alcohol thermometer
vi) Hydrometer for use while filling electrolyte.
17. CHARGE RATE
Fully discharged batteries should be able to get recharged in 7 hours maximum to 90% of capacity with
charging current in the range of 0.1 to 0.4 CmA rate at 20ºC. At higher temperatures, the charging time
may be more. The trickle charge rate shall be 1-2 mA/Ah.
18. CELL DESIGNATION
The practice as per IS: 10918 (latest version) shall be followed.
19. POLARITY MARKING
The polarity of the terminals shall be marked for identification. Positive terminal may be identified by 'P' or
a (+) sign or red colour mark and negative terminal may be identified by 'N' or (-) sign or blue colour mark.
Marking shall be permanent and non-deteriorating.
20. WARNING MARKING
The battery shall be furnished with a warning plate located at conspicuous place specifying the use
of 'ALKALINE ELECTROLYTE ONLY' (in block letters) and specifying proper filling level of the electrolyte.
21. PACKING
The batteries shall be securely packed in wooden crates suitable for handling during transit by rail/road and
secured to avoid any loss or damage during transit. Carton boxes duly palletized shall also be acceptable.
22. TESTS
The batteries shall be tested for type, acceptance and routine tests in line with IS: 10918 & IEC: 62259
(latest versions). The owner may at their discretion to accept the batteries based on type tests already
carried-out. In such cases, Type test reports for tests carried out not earlier than 05 years from bid
opening date from NABL accredited labs shall be acceptable.
Note : In case Type tests are repeated, life cycle test may not be insisted upon Ni-Cd battery of the
specific ratings to be ordered, as this test takes a long time (2-3 years). However, satisfactory evidence is
to be furnished for having made this test on cell of any other Ah capacity of the same design.
23. BUYBACK OF USED/UNSERVICEABLE BATTERIES
Manufacturer shall buyback used/unserviceable batteries from the substations where batteries are
replaced. The owner shall confirm the following particulars of used/unserviceable batteries to enable the
bidder to quote buyback rates:
i) Type & number of cells for disposal
ii) Make
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iii) Year of make/purchase

iv) Capacity
v) Condition of cells
The bidder should quote their rates for buyback considering the salvage value of the above cells.
24. SAFE DISPOSAL OF UNSERVICEABLE BATTERIES
The bidder shall have facilities for proper treatment & disposal of used/unserviceable batteries that are
bought back from the users, in line with the environmental protection rules & regulations of the country.
25. GUARANTEE
The batteries shall be guaranteed for a period of 36 months from the date of commissioning.
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Part B : CHARGER FOR Ni-Cd BATTERY (RECOMBINATION TYPE)
1. SCOPE
This specification covers the requirements and tests for Battery charger for partial recombination type
Nickel-Cadmium alkaline batteries for use in 33/11 KV and 66/11 KV sub-stations.
2. CODES AND STANDARDS
2.1. All standards, specifications and codes of practice referred to herein shall be the latest editions including all
applicable official amendments and revisions as on date of opening of bid. In case of conflict between this
specification and those (IS codes, standards etc.) referred to herein, the former shall prevail. All work shall
be carried out as per the following standards and codes.
2.2.
International Indian standards Description
standards
Sl.No
1 IS:5 Colours for ready mix paints.
2 IS : 1248 Direct acting indicating analogue electrical

measuring instruments.
3 IEC : 947-1 IS : 13947 Prt-1 Low voltage switchgear and control gear -
General.
4 IEC : 947-2 IS : 13947 Prt.-2 Low voltage switchgear and control gear -
Circuit Breaker
5 IEC : 947-3 IS : 13947 Prt-3 Specification for low voltage switchgear

and control gear – Switches,
Disconnectors, Switch disconnectors &
Fuse combination units.
6 IEC : 947-4 IS : 13947 Prt-4 Specification for low voltage switchgear

and control gear –Contactors
7 IS : 13947 Prt-5 Specification for low voltage switchgear

and control gear – Control Circuit Devices
& Switching Elements
8 IEC: 439 IS:8623 Low voltage switch-gear and control-gear

assemblies
9 IS:8686 Static protective relays
10 IEC:225 IS : 3231 Electrical relays for power system

protection.
11 IS : 3842 Application guide for Electrical relays for

AC System
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12 IEC 146 IS : 3895 Mono-crystalline semi-conductor Rectifier

Cells and Stacks.
13 IEC 146 IS : 4540 Mono crystalline semi-conductor Rectifier

assemblies and equipment.
14 IS:6619 Safety Code for Semi-conductor Rectifier

Equipment.
15 IS : 9000 Basic environmental testing procedures for

electronic and electrical items.
16 IEC: 60269 IS:13703 Prt-4 Low voltage fuses for protection of

semiconductor devices.
17 IS:1901 Visual indicating lamps
18 IS:6005 Code of practice for phosphating of Iron

and Steel.
19 IEC: 227 IS:694 /IS: 1554 PVC Insulated Cable for working voltages
upto and including 1100 V.
2.3. Equipment complying with other internationally accepted standards such as IEC, BS, VDE. etc. will also be
considered if they ensure performance and constructional features equivalent or superior to standards
listed above. In such a case, the Bidder shall clearly indicate the standard(s) adopted, furnish a copy in
English of the latest revision of the standards along with copies of all official amendments and revisions in
force as on date of opening of bid and shall clearly bring out the salient features for comparison.
3. EQUIPMENT DESCRIPTION
3.1. a) The Battery Chargers as well as their automatic regulators shall be of static type. Battery chargers shall
be capable of continuous operation at the respective rated load in Float mode, i.e. Float charging the
associated Ni-Cd Batteries (partial recombination type) while supplying the D.C. loads. The Batteries shall
be Float charged at 1.4 to 1.5 Volts per cell. All chargers shall also be capable of Boost Charging the
associated Batteries at 1.42 to 1.7 Volts per cell at the desired rate. The Chargers shall be designed to
operate, as mentioned above, up-to an ambient air temperature of 50°C. Tapping arrangement in the
battery bank shall be provided to limit the over-voltage for supplying load within allowed voltage range
under boost charge conditions. The charger should automatically switchover to float charge & to boost
charge when the specified limit of voltage is approached. However, necessary timer circuit shall be used
to allow a finishing charge before switching over to float mode, as recommended by battery manufacturer
in order to ensure that battery gets fully charged. Recommended values of charger rating, tapping cell
and specified voltages for automatic changeover to float/boost mode are given in table below, however,
the manufacturer may suggest any changes in the recommended values with justification at the time of
supply :
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Rating of Charger Charger Rating Tapping Switching Switching

Charger Rating during Boost to be Voltage to Voltage to
during Float Charging at provided Boost Float
Charging at 1.42 to 1.7 V at ---th Mode Mode
1.4 to 1.45 V per cell cell
per cell
Volt Ampere Ampere n Volt Volt
24 10 25 15 22 32
30 10 25 18 26 38
110 5 5 69 94 146
220 5 5 136 194 285
Note : Charger rating shall be arrived at with charger in boost mode and also supplying 100% float load
i.e. charger current shall be sum of float & boost rating.
b) Battery Chargers shall automatically select the appropriate mode of operation i.e. Float or Boost. Means
shall be provided to avoid current/voltage surges of harmful magnitude/nature, which may arise during
changeover.
c) Soft start feature shall be provided to build up the voltage to the set value slowly within fifteen seconds.
The 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 characteristic shall be such that any sustained overload or short circuit in DC
system shall neither damage the Charger nor shall it cause blowing of any of the charger fuses. The
Charger shall not trip on overload or external short circuit. After clearance of fault, the Charger voltage
shall build up automatically when working in automatic mode.
During external short circuit, output of the charger shall be automatically reduced to near zero volt
till it is not isolated/disconnected & normal output voltage shall be restored by charger circuit on isolation
with out any harm to source transformer/protection/ regulator circuit
d) During Float charging, the Charger output voltage shall remain within ±1% of the set value for AC input
voltage variation of 230 +10% -15%, frequency variation of ±5%, a combined voltage and frequency
(absolute sum) variation of 10% and a continuous DC load variation from 5% to full load. Uniform and
stepless adjustments of voltage setting shall be provided on the front of the Charger panel covering the
entire Float charging output range specified. Stepless adjustment of the load limiter setting shall also be
possible from 80% to 100% of the rated output current for Float charging mode.
e) During Boost charging, the Battery Chargers shall operate on constant current mode with maximum
current limiter setting (When automatic regulator is in service).
f) Energising the Charger with fully charged battery connected plus 10% load shall not result in output
voltage greater than 110% of the voltage setting. Time taken to stabilise, to within the specified limits in
clause 3.1 (d), shall be less than five seconds.
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g) Momentary output voltage of the Charger, with the Battery connected shall be within 90% to 110% of the
voltage setting during sudden load Change from 80% to 20% of full load or vice-versa. Output voltage
shall return to, and remain, within the limits specified in clause 3.1 (d) in less than 1 second after the
above-mentioned change.
h) The Charger manufacturer may offer an arrangement in which the voltage setting device for Float
charging mode is also used as output voltage limit setting device for Boost charging mode, and the load
limiter of the float charging mode is also used as Boost charging current setting device.
i) Suitable filter circuits shall be provided in all the Chargers to limit the ripple content (peak to peak) in the
output voltage to 3 % irrespective of the DC load, even when they are not connected to a battery.
j) The DC System shall be ungrounded and float with respect to the ground potential when healthy.
k) Battery shall be isolated in case of short circuit on the load side.
l) Battery test circuit shall be provided with suitable resistance for discharging the battery for 30Sec at 5 hr
rate.
m) All potentiometers shall be electronically locked to contain the various parameters within allowable limits
even if the setting position of potentiometers is changed to extreme positions.
n) Insulation resistance shall be 5 M Ohm min.
3.2. MCB
AC MCCB shall be provided at the incomer. DC MCCB with provision of auxiliary contacts shall be provided
at the output of the battery charger.
3.3. Rectifier-Transformers and Chokes
The rectifier transformer and chokes shall be dry and air cooled (AN) type. The rating of the rectifier-
transformers and chokes shall correspond to the rating of the associated rectifier assembly. The rectifier-
transformers and chokes shall have class-B insulation as per IS : 4540. Rectifier transformer shall confirm
to all type tests as specified in IS 4540/IS 2026. Type test & routine test reports shall be submitted to the
owner.
3.4. Rectifier Assembly
The rectifier assembly shall be full wave bridge type and designed to meet the duty as required by the
respective Charger. The rectifier cells shall be provided with their own heat dissipation arrangement with
natural air-cooling. The rectifier shall utilise diodes/thyristors with heat sinks rated to carry 130% of the
load current continuously and the temperature of the heat sink shall not be permitted to exceed 85°C
absolute duly considering the maximum temperature inside charger panel with ambient temperature of
50°C. The Contractor shall submit calculations to show what maximum junction temperature will be and
what the heat sink temperature will be when operating at 130% and 100% load current continuously duly
considering the maximum surrounding air temperature for these devices inside the charger panel
assuming ambient temperature of 50°C outside the panel. Necessary surge protection devices and rectifier
type fast acting fuses shall be provided in each arm of the rectifier connections. Static silicon controlled
rectifiers and diodes complete with resistor/capacitor network for surge protection shall be provided
Design having IGBT or superior technology shall also be acceptable for which full justification & experience
shall be required for acceptance.
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3.5. Instruments
Analog or digital D.C. voltmeter, D.C. ammeter and A.C. voltmeter with 96 mm square display shall be
provided for all Chargers. The instruments shall be flush mounted type, dust proof and moisture resistant.
The instruments shall have easily accessible means for zero adjustments. The instruments shall be of 1.5
accuracy class.
3.6. Control and Selector Switches
Control and selector switches shall be of rotary stayput type of reputed make, confirming to relevant IS
with escutcheon plates showing the functions and positions. The switches shall be of sturdy construction
and suitable for mounting on panel front. Switches with shrouding of live parts and sealing of contacts
against dust ingress shall be preferred. The contact ratings shall be at least the following :
i) Make and carry continuously - 10 Amps.
ii) Breaking current at 220 V DC - 0.5 Amp. (Inductive)
iii) Breaking current at 230 V AC - 5 Amp. at 0.3 p.f.
3.7. Fuses
Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse carriers, which are mounted
on fuse bases. Wherever it is not possible to mount fuses on fuse carriers, they shall be directly mounted
on plug in type bases. In such cases one insulated fuse pulling handle shall be supplied for each charger.
Suitable fuse fail detector circuits with alarm contacts shall be provided for all D.C. fuses.
3.8. Indicating Lamps
The indicating lamp shall be of panel mounting, LED type and capable of clear status indication under the
normal room illumination. The lamp covers shall be preferably screwed type, unbreakable and moulded
from heat resistant material.
3.9. Blocking Diode
Blocking diode, wherever required, with full redundancy shall be provided in the output circuit of each
Charger to prevent current flow from the D.C. Battery into the Charger.
3.10. Annunciation System
Visual indications through indicating lamps/LEDs or annunciation facia shall be provided in all Chargers for
the following:
i. A.C. supply failure

ii. Rectifier fuse failure
iii. Surge circuit fuse failure
iv. Filter fuse failure
v. Load limiter operated
vi. Input AC MCCB trip
vii. Output DC MCCB trip
viii. Battery on Boost
ix. Load-side DC under-voltage & over-voltage alarm
x. Battery side DC over-voltage alarm
xi. AC available – Battery discharge (Mains available battery discharge) alarm
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xii. Potential free NO contacts shall be provided for following remote alarms:
a) Battery on boost
b) Charger trouble (this being a group alarm initiated by any of the faults other than ‘Battery on
Boost’)
3.11. Name Plates and Marking
The nameplates shall be made of non-rusting metal/3 ply Lamicoid and shall have black background with
white engraved letters and secured by screws. These shall be provided near top edge on the front as well
as on rear side of Charger. Nameplates with full and clear inscriptions shall also be provided on and inside
the panels for identification of various equipment.
3.12. Detailed dimensional drawings, commissioning and operating instructions and Test Certificates of the
manufacturer shall be supplied with the equipment.
4. CONSTRUCTION
4.1. The Chargers shall be indoor, floor mounted, self-supporting sheet metal enclosed cubicle type. The
Contractor shall supply all necessary base frames, anchor bolts and hardware. The Charger shall be
fabricated using cold rolled sheet steel not less than 1.6 mm thick. The panel frame shall be fabricated
using cold rolled sheet steel of thickness not less than 2.0 mm. Removable un-drilled gland plates of at
least 3.0 mm sheet steel and lugs for all cables shall be supplied by the Contractor. The lugs for cables
shall be made of electrolytic copper with tin plating. Cable sizes shall be advised to the Contractor at a
later date for provision of suitable lugs and gland plates. Ventilating louvers shall be backed with fine
brass wire mesh. All doors and covers shall be fitted with nitrile/neoprene/PU rubber gaskets. The
Chargers shall have hinged double leaf doors provided on front and/or 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-42. The construction shall meet the requirements of IS 6619. All
equipment mounted in the cabinet shall be provided with individual labels with equipment designation
engraved.
4.2. In case of outdoor mounting, the charger shall be provided with double doors on both front & back and
shall pass IP-42 requirement with one door open on both sides. The enclosure shall be provided with a
canopy.
4.3. The layout of Charger components shall be such that their heat losses do not give rise to excessive
temperature within the Charger panel. Location of the electronic modules will be such that temperature
rise, in no case, will exceed 10°C over ambient air temperature outside the Charger.
4.4. Each Charger panel shall be provided with an illuminating lamp (CFL or tube-light) and one 5 Amp. socket.
Switches and fuses shall be provided separately for each of the above.
4.5. Locking facilities shall be provided as following:
a) For locking Float/Boost selector switch in the float position only.
b) The Charger enclosure door shall have provision for padlocks. Padlocking arrangement shall allow ready
insertion of the padlock shackle but shall not permit excessive movement of the locked parts with the
padlock in position.
4.6 WIRING
4.5.1. Each Charger shall be furnished completely wired upto power cable lugs and terminal blocks, ready for
external connection. The power wiring shall be carried out with 1.1 kV grade PVC insulated cables
conforming to IS:1554 (Part-I). The control wiring shall be of 1.1kV grade PVC insulated stranded copper
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conductors of 1.5 sq.mm. minimum, conforming to IS:694. Control wiring terminating at electronic cards
shall not be less than 0.75 sq. mm. Control terminal shall be suitable for connecting two wires of 1.5
sq.mm. stranded copper conductors. All terminals shall be numbered for ease of connections and
identification. At least 20% spare terminals shall be provided for circuits.
4.5.2. Power and control wiring within panels shall be bundled separately. Any terminal or metal work which
remains alive at greater than 415 V, when panel door is opened, shall be fully protected by shrouding.
An air clearance of at least ten (10) mm shall be maintained throughout all circuits, except low voltage
electronic circuits, right upto the terminal lugs. Whenever this clearance is not available, the live parts
should be insulated or shrouded.
4.6. Painting
Pre-treatment & phosphating with 7 tank process shall be provided as per IS: 6005. The phosphate
coating shall be ‘class-C’ as specified in IS: 6005. Electrostatic powder painting with final shade – 692
(smoke grey) of IS: 5 shall be provided. The thickness shall not be less than 50 microns.
5. PACKING & DISPATCH
The equipment shall be dispatched securely packed in wooden crates suitable for handling during transit
by rail/road so as to avoid any loss or damage during transit.
6. QUALITY ASSURANCE PLAN
6.1. The vendor shall furnish the following information along with his bid; failing which the bid shall be liable
for rejection. Information shall be separately given for individual type of material offered.
i) The structure of Organization
ii) The duties and representatives assigned to staff ensuring Quality of work
iii) The system of purchasing, taking delivery and verification of materials
iv) The system for ensuring quality of workmanship
v) The quality assurance arrangements shall conform to the relevant requirement of ISO 9001 or
ISO 9002 as applicable
vi) Statement giving list of important raw materials/components, list of sub-suppliers, list of
standards according to which the raw materials are tested.
viii) List of manufacturing facilities available.
ix) Level of automation achieved and list of areas where manual process exists.
x) List of areas in manufacturing process, where stage inspections are normally carried out for
quality control and details of such tests and inspections.
xi) Lists of testing equipment available with the bidder for final testing of equipment 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.
6.2. The contractor shall also submit following information after award of contract:
i) Sub-suppliers of raw materials as well as bought out accessories & components. The
equipment supplied shall adhere to the list of components submitted & as per type-tested
equipment.
ii) Type test certificates of the raw materials and bought out accessories as required by the
owner.
iii) Manufacturing Quality Plan (MQP) shall be submitted. The owner hold points for stage
inspection shall be discussed between the owner and contractor at the time of award of
contract before the MQP is finalized.
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6.3. Makes of the following components (not restricted to) shall be subject to owner’s approval.
i) Relays
ii) Instruments
iii) SCR/IGBT
iv) Diodes
v) Annunciator
7. TESTS
Battery chargers including the components shall confirm to all type tests including heat run test as per
relevant Indian standards. Performance test on the chargers as per specification shall also be carried out
on each charger.
7.1. TYPE TESTS
7.1.1. Following type tests, in addition to the requirement of IS : 4540, should have been carried out on each
rating and type of Battery Charger for which reports are to be submitted.
i. Complete physical examination.

ii. Temperature rise test at full load (at highest voltage & highest current).
iii. Insulation resistance test.
iv. High voltage (power frequency) test on power and control circuits except low voltage electronic
circuits.
v. Ripple content test at
vi. No load
vii. Half load
viii. Full load
ix. Automatic voltage regulator operation test at specified A.C. supply variations at
a) No load
b) Half load
c) Full load
x. Load limiter operation test

xi. Short circuit test at full load and at no load for sustained short circuit of 1-minute minimum
shall be carried out. The charger shall not trip, no fuse shall blow and charger current shall be
limited to 150% of the rated current.
xii. Efficiency and power factor measurement.
xiii. Environmental Tests
Steady state performance tests (clause 7.2.2 (f) and (g)) shall be carried out before and after
the following tests.
i) Dry heat, Damp Heat, Vibration, Low temperature, Transportation, shock as per IS : 9000.
ii) Degree of protection test (IP-42).
xiv. Rectifier transformer – As per IS 4540.
7.1.2. If type tests are carried out against the contract, minimum 15 days notice shall be given by the
contractor. The contractor shall obtain the owner’s approval for the type test procedure before conducting
the type test. The type test procedure shall clearly specify the test set-up, instruments to be used,
procedure, acceptance norms, recording of different parameters, interval of recording, precautions to be
taken etc. for the type tests to be carried out.
7.1.3. In case the contractor has carried out the type tests within last five years as on the date of bid opening,
he may submit the type test reports from NABL accredited laboratory to the owner for waival of
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conductance of such type tests. These reports should be for the tests conducted on the equipment with
identical design to that proposed to be supplied under this contract. The owner reserves the right for
conducting any or all of the specified type tests under this contract.
7.2. ROUTINE TESTS :
7.2.1. Following routine tests shall be carried out on all Rectifier transformers in addition to tests required as per
IS-4540.
a) Insulation resistance test.

b) High voltage (power frequency) test.
7.2.2. Following routine tests shall be carried out on all Battery Chargers in addition to tests required as per IS-
4540 :
a) Complete physical examination.
b) Short circuit test at full load and at no load for sustained short circuit of 1-minute minimum shall
be carried out. The charger shall not trip, no fuse shall blow and charger current shall be limited
to 150% of the rated current.
c) Insulation resistance test.
d) High voltage (power frequency) test.
e) Ripple content test at
i) No load
ii) Half load
iii) Full load
f) Automatic voltage regulator operation test at specified A.C. supply variations at
i) No load
ii) Half load
iii) Full load
g) Load limiter operation test

h) Checking of proper operation of annunciation system.
i) Dynamic response test Overshoot/Undershoot in output voltage of the charger as a result of
sudden change in load from 100% to 20 % and 20% to 100% shall be measured.
j) Soak Test - All electronic modules shall be subjected to continuous operation for a minimum
period of 72 hours. During last 48 hours, the ambient temperature shall be maintained at 50 deg.
C. The manufacturer shall submit the record of carrying out this test to the owner’s engineer at
the time of inspection.
k) The charger shall be checked for gasketing arrangement as per drawing.
7.2.3. Following routine tests shall be carried out on annunciation system.
a) Soak test shall be carried out as per Cl. 7.2.2 (j).
7.3. ACCEPTANCE TESTS:
7.3.1. Following acceptance tests and checks shall be carried out by the owner at the manufacturer’s works:
a) Complete physical examination.

b) Checking of proper operation of annunciation system.
c) Temperature rise test at full load.
d) Insulation resistance test.
e) Automatic voltage regulator operation.
AE
f) Load limiter operation.

g) Dynamic response test.
h) Ripple content test
7.3.2. Overshoot/Undershoot in output voltage of the Charger as a result of sudden change in load from 100%
to 20% and 20% to 100% shall be measured with the Batteries connected/disconnected. Output voltage
of the Charger connected with Battery shall be within 90 % to 110 % of the voltage setting in above
conditions and shall return to, and remain, within the limits specified in clause 3.1 (d) in less than 2
seconds.
7.3.3. The Contractor shall furnish for inspection, the type and routine tests certificates for Chokes and
transformer whenever required by the Employer.
8. GUARANTEE
The battery charger shall be guaranteed for a period of 24 months from the date of commissioning.
AE
II. 30 VOLT 100 AH LEAD ACID BATTERY
Part A : 30 Volt 100 Ampere-Hour Lead Acid stationary Battery
1. SCOPE
This specification covers 30 Volt 100 Ampere-Hour Lead Acid stationary Battery, for use at 33/11KV
substations for feeding auxiliary supply to Switchgear equipment at the time of interruption in mains supply.
The battery is to be supplied along with wooden stand/rack as per description given below. Specifications of
battery rack are indicated separately.
The cells of Lead Acid Battery shall conform to the requirements of IS 1651: 1991 with latest amendment
thereof.
3. STANDARD RATINGS
The standards rating for 30 Volt Lead Acid Battery shall be 100 AH.
4. CELL VOLTAGE
The nominal voltage of a single cell shall be 2.1 to 2.2 Volts.
5. CAPACITY AT ROOM TEMPERATURE
The battery shall comprise of 15 cells with capacity not less than 100 AH at 10-hour rate of discharge to end
voltage of 1.85 Volts per cell at room temperature not exceeding 32 degree C.
6. GENERAL DESCRIPTION
Cells shall be supplied in glass containers having ample space provided below the plate for accumulation of
deposit. The glass containers shall be sufficiently robust, transparent and free from flaws. The bidder may
also quote for battery with hard rubber containers, which shall conform to IS 1146: 1981.
Lead acid battery, comprising of closed type cells shall be complete with plante / tubular type positive plate
assemblies, glass boxes, lids, micro porous plastic separators, polystyrene dowels and buffers, inter cell
connectors and bolts & nuts. The battery shall be complete with (i) inter row connectors and bolts & nuts,
acid jars and packing case, (ii) stands (iii) stand insulators (iv) cable sockets for end and tapping
connections.
The sulphuric acid and water used for the preparation and maintenance of electrolyte shall conform to IS
266: 1977 and IS 1069: 1964 respectively.
The separators used shall be either wooden or synthetic. The wooden separators when used shall conform
to IS 652:1960 and the synthetic separators to IS 6071: 1986.
The venting device shall be of anti-splash type with more than one exit hole and shall allow the gases to
escape freely but shall effectively prevent acid particles or spray from coming out.
A suitable electrolyte level indicator indicating lower and upper limits shall be fitted to facilitate checking of
electrolyte level in opaque containers. The materials used shall be acid proof and shall not deteriorate during
service.
AE
The manufacturer’s identification shall be embossed/impressed on the connectors. Where it is not possible
to bolt the cell terminals directly to assemble a battery, separate lead, copper or aluminium connectors of
suitable size shall be provided to enable connection of the cells.
The material for bolts and nuts shall be brass. Bolts and nuts for connecting the cells shall be effectively
lead-coated to prevent corrosion.
Open cells shall be provided with spray arrestors of adequate area over the plates. These may be of glass
sheet at least 3 mm thick and shall be adequately supported.
7. MOUNTING STAND
The cells shall be accommodated in double tier stand constructed of “SAL” wood and painted with 3 coats of
acid proof paint. Necessary paint for this purpose shall be supplied. No metal fastenings shall be used. Stand
should be self-supported and free from wrap & twist. The assembled stand / rack should be suitable for
bolting end to end to form continuous row. The stands shall be supported on insulators to obtain necessary
insulation from earth and there shall be insulators between each cell and stand. The price of stand shall be
included in the cost of the battery.
8. TERMINALS
Separate terminals shall be provided for connecting load and charger leads to the battery terminals. All
terminals shall be of M 12 size. The agency shall provide suitable copper lugs for use of the owner for
connecting the load wiring.
9. ACCESSORIES
The following accessories shall be supplied along with each battery and price for the same shall be included
in the cost of the battery:-
1. One battery logbook

2. Two copies of printed instruction sheet
3. One no. cell testing voltmeter (3-0-3 volts) complete with leads
4. One no. floating hydrometer
5. One no. syringe hydrometer
6. One no. thermometer (0 to 100 degree C)with specific gravity correction scale
7. One set of suitable insulated spanners
8. One no. acid resisting funnel
9. One no. acid resisting jar
10. One pair of rubber gloves
11. Lead platted 2 nut – bolts and 2 washers set = 30 + 4 extra =34 Nos.
12. Cell insulators for mounting of cells = 15X4+6 extra = 66 Nos.
13. Rack insulator for mounting of battery rack = 8 Nos. minimum
10. CHARGE RATE
Fully discharged batteries should normally be recharged at 10 Amps. for 10 hours at room temperature. New
batteries and old batteries at high temperatures may need more time. Trickle charge rate shall be about 50
to 100 mA,
11. CELL DESIGNATION AND MARKING
The practices indicated in relevant IS shall be followed for cell designation purpose.
AE
The following information shall be indelibly and durably marked on the outside of the cell:-
1. Indicating the source of manufacture

2. Ah capacity at 10-hour rate
3. Upper and lower electrolyte level in case of transparent containers
4. Year of manufacture and
5. Country of origin
6. Each cell and battery may also be marked with the Standard Mark.
The polarity of the terminals shall be marked for identification. The positive terminal may be identified by
“P” or (+) sign or Red colour mark and the negative terminal may be identified by “N” or (-) sign or a Blue
colour mark. Terminal marking shall be permanent and non-deteriorating.
The battery shall be supplied with a warning plate located at conspicuous place specifying the use of
“PARTICULAR ELECTROLYTE ONLY’ (in block letters) & specifying the proper filling level of the electrolyte.
12. TESTS
The following tests shall be carried out in accordance with IS 1651:1991 with latest version thereof.
13. TYPE TESTS
1. Verification of constructional requirements

2. Verification of marking
3. Verification of dimensions
4. Test for capacity
5. Test for voltage during discharge
6. Ampere-hour and watt-hour efficiency tests
7. Test for loss of capacity on storage
8. Endurance test
14. ACCEPTANCE TESTS
The following shall constitute acceptance tests: -
1. Marking and packing

2. Verification of dimensions
3. Test for capacity, and
4. Test for voltage during discharge
15. ROUTINE TESTS
The battery shall be tested after manufacture as per the requirement of IS: 1651-1991 (with latest
amendment, if any). Two copies of test certificates indicating the results obtained during the tests shall be
submitted.
16 MANUAL INSTRUCTIONS
The manufacturer shall supply one copy of instruction manual for initial treatment and routine maintenance
during service with each battery.
AE
The following information shall be provided on the instruction cards:-
1. Designation of cell or battery

2. Ampere – Hour capacity
3. Nominal voltage
4. Manufacturer’s instructions for filling, initial charging
5. Normal and finishing charging rates and
6. Maintenance instructions
16. GUARANTEE PARTICULARS
Expected life span of battery shall be minimum 10 years. Loss of capacity on storage of a fully charged
battery stored for 28 days should not be more than 3%. Battery should be capable to bear under floating &
over floating conditions.
The bidders shall essentially fill up the enclosed Schedule of Guaranteed Technical Particulars of Battery
offered by him.
17. PACKING
The battery shall be suitably packed in wooden crates suitable for handling during transit by rail/road, and
secured to avoid any loss or damage during transit.
AE
Part B: Battery Charger
1. SCOPE
This specification covers design, manufacturing, testing at manufacturer’s works before dispatch and supply
of 30 Volt 10 Ampere Single Phase Battery Charger required for charging of 30 Volt 100 Ampere-Hour Lead
Acid Battery and for feeding auxiliary supply to Switchgear equipments at 33/11 kV substations.
2. STANDARDS
Unless otherwise specified, the equipment shall conform to the latest applicable Indian standards and in
particular to the following standards:-
1 IS: 3895 Specification for Rectifier equipment’s in general
2 IS: 13947(Part II) Specification for MCB
3 IS: 1248 Indication instruments
4 IS: 2147 Degree of protection for cubicles
5 IS: 375 Specification for wiring
6 IS: 4540 Mono crystalline semiconductor rectifiers assemblies & equipment
7 IS: 6619 Safety code for semiconductor rectifier equipment
8 IS: 2026 Transformers
9 IS: 4237 General requirement for switchgear and control gear for voltage not
exceeding 1000 Volts
10 IS: 4064 Air Break switches and fuse combination units
11 IS: 6005 Code of practice for phosphating of Iron & Steel
12 IS: 5 Colour for ready mix paints
13 IS: 5921 Printed circuit Board
14 IS: 249 Printed circuit Board
15 IS: 5578 Guide for making insulated conductor
The agency shall clearly state the standards to which the equipment offered by him conforms.
3. DRAWING AND LITERATURE
The bidder shall furnish all such drawings, instruction manuals, descriptive literature etc., as may be
necessary for the proper understanding of the functioning of the charger.
The write-up should include the following:-
1. Technical specification of the charger.
AE
2. Detailed circuit description of the charger. It should also include the functions of various
components, protection circuits/cards, and relays along with their individual brief write-ups/leaflets.
3. List of the main components of the charger.
4. Following details are to be clearly indicated in the circuit diagram:-
a. Make and Rating of components used
b. All the fuses should be numbered and individual rating should be indicated.
4. GENERAL DESCRIPTION
The Charger shall be of simple design so as to ensure its reliable functioning and ease in
maintenance/repairing. Complicated circuitry shall be avoided, as for as possible. The bidder shall indicate,
as to how reliable functioning of the charger is achieved. He shall also indicate the quality control adopted
for the reliable product.
The battery charging equipment shall comprise of a selenium/solid state silicon rectifier suitable for
operation on 230/250 Volt Single Phase AC system. Associated transformer, regulatory resistance, switches
etc. shall be accommodated in a sheet steel cubicle arranged for continuous load of 3 Amps. Adjustable from
0 to 3 Amps trickle charge of the battery and manual provision to operate at a higher voltage to recharge
the battery of 100 AH capacity quickly at 10 Amp rate.
The equipment shall comprise of:-
1. AC mains switch/MCB 230/250 Volt Single Phase with fuses/MCB

2. Pilot lamp/LED type to indicate AC supply ON.
3. Ballast choke
4. Single Phase Double Wound Transformer for rectifiers
5. Main transformer single phase variac with rough and fine control to charge battery in steps of 6-12,
12-18, 18-24, 24-30, 30-36, 36-42 volts.
6. Full wave bridge connected plate/solid state silicon rectifier
7. Fuses for rectifier output
8. Moving Coil Ammeter 96-mm sq. flush mounting type (0-15 Amps.)
9. Moving Coil Voltmeter 96 mm sq flush mounting type (0-50 Volts)
10. Voltmeter fuses
11. DC ON/OF switches with fuses.
The sheet steel cubicle of the rectifier unit shall also accommodate the switches for charge rate selection,
incoming from battery and various apparatus for battery control.
The chargers should have in-built automatic input voltage stabilizer in the range of 180 volt to 275 volt to
facilitate steady output voltage and current from the charger.
5. CABINET
The charger shall be enclosed in a cabinet made of sheet steel of not less than 1.5 mm thickness and should
be suitable for mounting on a plane surface/floor with ventilation louvers on two sides and finish painted with
synthetic enamel paint of white on inside and opeline green on outside. Two coat of zinc primer shall be
applied before finishing synthetic enamel paint. The cabinet shall have vermin proof construction. The cabinet
legs shall be of adequate height and strength and should provide minimum clearance of 100 mm from
ground.
6. FRONT PANEL MOUNTINGS
The following provisions conforming to relevant ISS shall be made on the front panel:
1. Voltmeter to indicate battery/charger DC voltage
2. Voltmeter to indicate incoming AC voltage
3. Ammeter to indicate charging/load current
AE
4. Indicating LEDs to indicate:-
a. Supply of power;
b. Charger on;
c. Input voltage less than 180 Volt
5. Audio/Visual alarm to indicate:-
a. Power failure;
b. Charger failure;
c. Battery disconnection/failure;
d. Battery reverse; and
e. DC under/Over voltage.
In case of failure of charger on fault, it should give buzzer as well as LED indication. However, the buzzer
alarm should be provided with a reset switch. The indicating instruments shall be of class 1.0 accuracy
7. TRANSFORMER
The power transformer rectifier unit of the battery charger shall be designed for adequate VA rating but in
any case it should not be less than 700 VA and should be rated for 300 V at factor of safety of 3. The heat
dissipation and power control system should be designed with a factor of safety of 8. Rating of silicon
diode should not be less than 15 A.
Please note, necessary documentary evidence, showing transformer rating of 700 VA along with test
certificate from manufacturer, if bought-out, shall be enclosed, for approval of the owner.
8 PROTECTION
The charger should have built-in reverse polarity protection with indication lamp so as to protect the
battery from high drains. The charger should also have MCB in the output circuit for protection from short
circuits.
9. LIGHT EMITTING DIODES
For the purpose of indication LED indicators shall be provided.
10. SWITCHES AND FUSES
Control and instruments switches shall be of toggle type. All fuses shall be of HRC type and of English
Electric/L&T make only.
11. LABELS
All front panel mounted equipment as well as the equipment mounted inside the cabinet shall be provided
with individual labels with equipment designation engraved on aluminium plate (stickers are not
acceptable).
12. WIRING
The charger shall be supplied completely wired ready for external connections at the terminal blocks. All
the wiring shall be carried out with 1100 V Grade PVC insulated standard copper conductor of 2.5 Sq.mm.
Colour coded wires should be used to facilitate easy tracing, as under :-
A. Single Phase AC Circuit:-
AE
1. Red for Phase

2. Green for Earthling
3. Black for Neutral
B. D.C. Circuit:-
1. Red for Positive

2. Black for Negative
C. Control Wiring:-
Gray for annunciation and other control circuits.
13. FERRULES
Engraved core identification ferules, marked to correspond with the wiring diagram shall be fitted at
both ends of each wire.
14. EARTHING TERMINALS
The battery charger cabinet shall be provided with two separate suitable earthing terminals of good
quality and adequate size.
15. TESTING
The manufacturers on each battery charger shall carry out the following tests and copy of the tests
certificate for each charger shall be submitted:-
1. Checking of wiring and continuity of circuits and visual inspection

2. High voltage test on the equipment with accessories. (All equipment and wiring should be
tested for with-standing the power frequency voltage of 2 KV r.m.s. for 20 seconds.)
3. Checking of charging current and load currents.
4. Checking of relays operation, alarm circuit operation, lamp indication, charger failure, mains
failure, load fuse failure and annunciation (manufacturer’s test certificate for the instruments
shall also be furnished).
5. Regulation and Ripple tests.
6. Efficiency test.
7. Burn-out/Heat-run test (for 10 Hrs.)
16. CIRCUIT DIAGRAM AND WRITE-UP
It is desired that the complete schematic of the charger is provided on a permanently

laminated/engraved plate of suitable thickness, which has to be bolted/riveted at the four corners on the
inside face of rear door. In addition, one more plate of similar type and dimension shall be provided on
the outside of the rear door providing guidelines and instructions for operation of the charger. The
guidelines and schematic to be provided on the plates shall be as per our approval for which separate
drawings shall furnish, after award of contract.
17. TERMINALS
Separate terminals shall be provided for connecting load and battery leads to the charger. All terminals
shall be of M12 size. Suitable copper lugs for connecting the load wiring are to be provided.
It would be the bidder responsibility to prove the adequacy of its design by submitting all technical
particulars and relevant graphs to show suitability of charger for supplying load on continuous basis.
AE
18. PRINTED CIRCUTT BOARD
The printed circuit boards should be made out of glass fiber re-in forced epoxy boards and should be
coated with suitable protective coating for protection against humidity and corrosion.
19. POLARITY MARKING
The polarity marking of the terminals shall be marked for identification. The positive terminal may be
identified by “P” or (+) sign or red colour mark and the negative terminal may be identified by “N” or (-)
or blue colour. Terminal marking shall be permanent and non-deteriorating.
20. MANUAL OF INSTRUCTIONS
The manufacturer shall supply a copy of the Instruction Manual for commissioning and initial testing of the
charger and maintenance during service with every charger supplied.
21. PACKING
The charger shall be securely packed in wooden crates suitable for handling during transit by rail/road so
as to avoid any loss or damage during transit.
AE
CABLE GLANDS AND LUGS
Cable glands shall be Double compression type, tinned/Nickel plated (coating thickness not less than 20 microns in
case of tin and 10 to 15 microns in case of nickel) brass cable glands for all power and control cables. They shall
provide dust and weather proof terminations. They shall comprise of heavy duty brass casting, machine finished
and tinned to avoid corrosion and oxidation. Rubber components used in cable glands shall be neoprene and of
tested quality. Required number of packing glands to close unused openings in gland plates shall also be provided.
The cable glands shall be tested as per BS: 6121. The cable glands shall also be duly tested for dust proof and
weather proof termination.
Cables lugs shall be tinned copper solder less crimping type conforming to IS: 8309 and 8394 suitable for
aluminum or copper conductor (as applicable). The cable lugs shall suit the type of terminals provided. The cable
lugs shall be of Dowell make or equivalent.
AF
CABLES TAGS AND MARKERS
Each cable and conduit run shall be tagged with numbers that appear in the cables and conduit schedule.
The tag shall be of aluminum with the number punched on it and securely attached to the cable conduit by not
less than two turns of 20 SWG GI wire conforming to IS: 280. Cable tags shall be of rectangular shape for power
cables and of circular shape for control cables.
Location of cables laid directly underground shall be clearly indicated with cable marker made of galvanized iron
plate.
Location of underground cable joints shall be indicated with cable marker with an additional inscription “Cable
Joint”.
The marker shall project 150 mm above ground and shall be spaced at analysis interval 30 meters and at every
change in direction. They shall also be located on both sides of road and drain crossings.
Cable tags shall be provided on all cables at each end (just before entering the equipment enclosure), on both
sides of a wall or floor crossing and on each duct/ conduit entry. Cable tags shall be provided inside the
switchgear, motor control centers, control and relay panels, etc., wherever required for cable identification, such
as where a number of cables enter together through a gland plate.
The price of cable tags and markers shall be included in the installation rates for cables/ conduits quoted by the
contractor.
Specific requirements for cabling for cabling, wiring, ferrules as covered in respective equipment section shall
also be complied with.
CABLE GLANDS
Double compression type cable glands shall be provided by the Contractor for all power and control cables to
provide dust and weather proof termination. Required number of packing glands to close unused openings in
gland plates shall also be provided.
CABLE LUGS
Solderless crimping of terminals shall be done by using corrosion inhibitory compound. The cable lugs shall suit
the type of terminals provided. Crimping tool used shall be of approved design and make.
Storage and handling of cable drums
Cable drums shall be unloaded, handled and stored in an approved manner. Rolling of drums shall be avoided as
far as practicable. For short distances, the drums may be rolled provided they are rolled slowly and in proper
direction as marked on the drum. In absence of any indication the drums may be rolled in the same direction it
was rolled during taking up the cables.
CABLE SUPPORTS AND CABLE TRAY MOUNTING ARRANGEMENTS
Cable trenches in the control room are normally provided with embedded steel inserts on concrete floors/ walls.
The Contractor shall secure supports by welding to these inserts or available building steel structures.
Insert plates will be provided at an interval of 600 mm wherever cables are to be supported without the use of
cable trays, while at all other places these will be at an interval of 2000 mm.
AG
CABLE TERMINATIONS AND CONNECTIONS
The termination and connection of cables shall be done strictly in accordance with cable and termination kit
manufacturer’s instructions, drawing and/ or as directed by the Owner.
The work shall include all clamping, fittings, fixing, plumbing, soldering, drilling, cutting, taping, heat shrinking
(where applicable), connecting to cable terminal, shorting and grounding as required to complete the job.
The equipment will be generally provided with un-drilled gland plates for cables/ conduit entry. The Contractor
shall be responsible for drilling of gland plates, painting, and touching up. Holes shall not be made by gas
cutting.
The Contractor shall tag/ferrule the control cable cores at all terminations, as instructed by the Owner. In panels
where a large number of cables are to be terminated and cable identification may be difficult, each core ferrule
may include the complete cable number as well. Spare cores shall be similarly tagged with cable numbers and
coiled up.
Control cables shall have stranded copper conductor. Bare portion of the solid conductors shall be tinned after
removing the insulation and shall be terminated directly without using cable lugs.
All cable entry points shall be sealed and made vermin and dust proof. Unused openings shall be effectively
closed.
If the cable-end box or terminal enclosure provided on the equipment is found unsuitable and requires
modification, the same shall be carried out by the Contractor with the approval of the Owner.
DIRECTLY BURIED CABLES
The Contractor shall construct the cable trenches required for directly buried cables. The scope of work and unit
rates for construction of cable trenches for cables shall include excavation, preparation of sand bedding, soil
cover, supply and installation of brick or concrete protective cover, back filling and reaming, supply and
installation of route markers and joint markers. The Bidder shall ascertain the soil conditions prevailing at site,
before quoting the unit rates. Laying the cable and providing protective covering shall be as per approved
drawing.
Installation of cables
Power and control cables shall be laid in separate tiers. The order of laying of various cables shall be as follows:
 Power cables on top tiers.

 Control, instrumentation and other service cables in bottom tiers.
Single core cable in trefoil formation shall be laid with a distance of three times the diameter of cables between
trefoil center lines. All power cables shall be laid with a minimum center to center distance equal to twice the
diameter of the cable.
Power and control cables shall be securely fixed to the trays/ supports. Trefoil clamps for single core cables shall
be pressure die-cast aluminum (LM-6). Nylon-6 or fiber glass and shall include necessary fixing nuts. bolts,
washer, etc. These are required at every 2 meter of cable run. Vertical and inclined cable runs shall be secured
AG
with 25 mm wide and 2 mm thick aluminum strip clamps at every 2 m Horizontal runs in cable trays and
trenches shall be secured using 4 mm nylon cord at every 2 m.
Cables shall not be bent below the minimum permissible limit. The minimum bending radius of power cables
shall be 12D and that of control cables shall be 10D, where D is overall diameter of cable.
Where cables cross roads, drains and rail tracks, the cables shall be laid in reinforced spun concrete or steel
pipes, buried at not less than one meter depth.
In each cable run some extra length shall be kept at a suitable point to enable one (for LT Cables) or two (for
H.T. cables) straight through joints to be made, should the cable develop fault at a later date.
Selection of cable drums for each run shall be so planned as to avoid using straight through joints. Cable splices
will not be permitted except where called for by the drawings, unavoidable or where permitted by the Owner.
Control cable terminations inside equipment enclosures shall have sufficient lengths so that switching of
termination in terminal blocks can be done without requiring any splicing.
Metal screen and armour of the cable shall be bonded to the earthing system of the station, wherever required.
Rollers shall be used at intervals of about 2.0 meters, while pulling cables.
All due care shall be taken during unreeling, laying and termination of cable to avoid damage due to twist, kink,
sharp bends, etc.
Cable ends shall be kept sealed to prevent damage.
Inspection on receipt, unloading and handling of cables shall generally be in accordance with IS:1255 and other
Indian Standard codes or practices.
Wherever cables pass through floor or through wall openings or other partitions, wall sleeves with bushes having
a smooth curved internal surface so as not to damage the cables shall be supplied, installed and properly sealed
at no extra charges.
The erection work shall be carried out in a neat workmanlike manner and the areas of work shall be cleaned of
all scrap materials after the completion of work in each area every day. Contractor shall remove the RCC/steel
trench covers before taking up the work and shall replace all the trench covers after the erection work in that
particular area is completed or when further work is not likely to be taken up for some time.
Contractor shall furnish three copies of the report on work carried out in a particular week, such as cable
numbers and a date on which laid, actual length and route, testing carried out, terminations carried out, along
with the marked up copy of the cable schedule and interconnection drawing wherever the modifications are
made.
In case the outer sheath of a cable is damaged during handling/ installation, the Contractor shall repair it at his
own cost, and to the satisfaction of the Engineer-in- Charge. In case any other part of a cable is damaged, the
same shall be replaced by a healthy cable, at no extra cost i.e. the Contractor shall not be paid for supply,
installation and removal of the damaged cable.
All cable terminations shall be appropriately tightened to ensure secure and reliable connections. The Contractor
shall cover the exposed part of all cable lugs whether supplied by him or not with insulating type, sleeve or
paint.
AG
INSULATION PIERCING CONNECTORS, ANCHOR (DEAD END) & SUSPENSION

ACCESSORIES & OTHER ACCESSORIES FOR AERIAL BUNCHED CABLES FOR
WORKING VOLTAGE UPTO AND INCLUDING 1100 VOLTS
1.0 SCOPE
This specification covers the design, manufacture, assembly, testing and supply of Accessories for
anchoring, suspending & making connections to Aerial Bunched Cables rated 1100 volts and insulated
with cross-linked polyethylene.
2.0 STANDARD
The design, performance and test requirements shall confirm to this specification and the following
standards. However in case of any conflict, the requirements of this specification shall prevail.
 NFC 33-020 Insulation Piercing Connectors

 NFC 33-209 LV Aerial Bunched Cables
 NFC 20-540 Environment Testing for Outdoor
 NFC 33-004 Electrical Ageing Test
 NFC 33-040 Suspension Equipments
 NFC 33-041 Anchoring Devices
 IS 14255 LV Aerial Bunched Cables
The Devices shall also be compatible with the cables of sizes & dimensions as defined in the Cable
Specifications for the cables with which they are intended to be used.
3.0 CLIMATIC CONDITIONS

For the purpose of designing the climatic conditions as specified in annexure-1 shall be considered.
4.0 CABLE DATA

The standard sizes and characteristics of the phase and street lighting conductors, messenger wires
shall be as specified in IS: 14255-1995.
The Accessories of LT XLPE Insulated Aerial Bunched Cables (ABC) with insulated messenger cum
neutral are specified below:
a) The ABC accessories should be of proven design with minimum 2 years record of satisfactory operation
with a major utility. Order copies and Performance Certificates should be enclosed with the offer.
b) Since ABC accessories are to be used with insulated neutral-cum-messenger, their design should
incorporate specific features to prevent damage to the insulation which meeting the required electrical,
mechanical & thermal requirements.
c) All mechanical, electrical & thermal ratings should meet or exceed 90% of the corresponding ratings of
the cable, or the values specified herein, whichever are more stringent.
d) The accessories should provide “Double Insulation” so that a single point failure of insulation will not
result in the system tripping.
AH
5.0 THE ABC ACCESSORIES
The ABC Accessories shall consist of the following:
a) Insulation Piercing Connectors : For making tap-off/branch connectors/service

(IPC) connector to an ABC line.
b) Anchoring Assembly (AA) : For fitting onto a pole for anchoring the end of a
length of ABC, or for a major change in direction.
c) Suspension Assembly (SA) : For supporting a length of ABC at an intermediate
pole in a length, with small angle of deviation.
d) Service clamp (sc) : For anchor Insulated service lines (armoured or
unarmour)
e) Transformer Connections : For connection to the transformer bushing.
f) Junction Sleeves : For Phases, neutral messengers & Street lighting
conductor.
g) ABC Service Main : For Distribution of multiple no. of Service
Distribution Box Connections from Main AB cable.
5.1 Insulation Piercing Connectors (IPC)
5.1.1 Insulation Piercing Connectors (IPC) are used for making Tee/Tap-off/Service connectors to an
ABC/Bare Overhead Line.
5.1.2 Insulation Piercing Connectors are designed to make a connection between the uncut main conductor
and a branch cable conductor without having to strip either cable to expose the conductor instead the
tightening action of the IPC will first pierce the Insulation, then make good electrical contact between
the main end and branch conductor while simultaneously insulating and sealing the connection.
5.1.3. Constructional Features of IPC
5.1.3.1 The housing shall be made entirely of mechanical and weather resistant plastic insulation material
and no metallic part outside the housing is acceptable except for the tightening bolt.
5.1.3.2 Any metallic part that is exposed must not be capable of carrying a potential during or after
connector installation.
5.1.3.3 Screws or nuts assigned for fitting with IPC (Insulating Piercing connector), must be fitted with
torque limiting shear heads to prevent over tightening or under tightening (min & max torque values
to be specified by Manufacturer).
5.1.3.4 The IPC must perform piercing and connection on Main and Branch cable simultaneously.
5.1.3.5 The IPCs shall be water proof and the water tightness shall be ensured by appropriate elastomer
materials and not by grease, gel or paste alone.
5.1.3.6 Design of IPC should be such as to not cause damage to insulation of adjacent conductors due to
vibration and relative movement during service.
5.1.3.7 The connector shall have a rigid removable end cap which can be slide fitted onto the main
connector body on either right or left by the installer (depending on site requirement) for sealing the
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cut end of the branch cable. Once the connector is fitted, it should not be possible to remove the cap
without removing the connector.
5.1.3.8 All the metallic parts of the connector should be corrosion resistant and there should not be any
appreciable change in contact resistance & temperature after overloads & load cycling.
 The contact plates should be made of tinned copper.

 Connector teeth should be factory greased & sealed to retard water or moisture ingress &
corrosion.
 The Insulation material should be made of weather & UV resistant reinforced polymer.
 The outer metallic part should have potential free tightening bolts to allow safe installation on
live lines.
5.1.4 Mechanical Tightening and Electrical Continuity
5.1.4.1 Connectors shall be tightened upto 70% of the minimum torque indicated by the Manufacturer. At this
torque electrical contact should have occurred between conductors to be joined. Then connectors
shall be tightened up to the breakdown of the shear heads and lastly, upto 1.5 times the maximum
torque indicated by the manufacturer.
For the connector fitted with two screws on the same core, after the breakdown of the shear heads
tightening may be carried out manually and alternatively using a torque meter. The test conditions
shall be as close as possible to those defined for the use of the test machine as per NF-C standard.
5.1.4.2 At 1.5 times the maximum torque indicated by the manufacturer, there shall be no breakdown of any
part of the connector or the core conductor.
5.1.4.3 Maximum rated torque shall not exceed 20 N.m for conductor <95 sq.mm and30 for >95 but <150
sq.mm.
5.1.4.4 Tightening screws shall have hex. Heads of 10 mm, 13 mm or 17 mm only.
5.1.5 Effect of Tightening on Main Core of IPC
5.1.5.1 The connector shall be fitted approx. at the centre of the main core, which is secure between two
anchoring points 0.5 mtr. To 1.5 mtr.apart. At the time of fitting the connectors, the main core shall
be under longitudinal tension at 20% of the load indicated in Table-1:
Table-1
Nominal Cross – section (sq.mm.) Tensile Strength (Newton)
16 1200
25 1800
35 2500
50 3500
70 5000
150 10000
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5.1.5.2 Tensile strain shall be increased to the full value indicated in the Table 1 and held minute. There
should be no breakdown of the core conductor.
5.1.6 Effect of Tightening on Branch Core of IPC
5.1.6.1 Test specimen shall be made up as in clause 5.1.5.1 except that this shall be do the smallest cross
sections of main and branch conductors within its range.
5.1.6.2 An increasing tensile load shall be applied to the Branch Conductor along the axis of the recess for the
Branch cable. Load shall increase at 100 – 500 N/minute until it reaches the value specified in the
Table 2 and maintained for 1 minute.
Table-2
Nominal Cross – section (sq.mm.) Tensile Strength (Newton)
16 (Alu) 290
25 450
35 & above 500
5.1.6.3 No slippage or breaking of conductor shall occur.
5.1.7 Dielectric & Water Tightness Test of IPC
5.1.7.1 The connector is tightened up to the minimum torque indicated by the manufacturer.
5.1.7.2 Connectors are mounted on

 Minimum cross section of main core.
 Maximum cross section of main core.
5.1.7.3 In each case Branch is of minimum cross section.
5.1.7.4 Protection caps for the branch cable are to be used in accordance with the requirements of clause
5.1.3.7. An additional water tight cap of any design may be used to seal one end of the main cable if
it is immersed under water. No additional gel or any protection is to be provided while installing
connector.
5.1.7.5 The entire assembly shall be immersed at a depth of approx. 30cms. For 30 minutes with the free
ends of main and branch cable out of the water.
5.1.7.6 An AC voltage of 6 kV shall be applied between the water bath and each of the cores in turn for 1
minute. There shall be no flashover or electrical tripping with a trip setting of 10 mA + 0.5mA.
5.1.8 Electrical & Ageing Test of IPC
5.1.8.1 Two test configurations are used according to Table 3 with the connections tightened to the minimum
torque specified by their manufacturers and resistance recorded.
Table - 3
Configuration Main core cross section Branch core cross section
Tensile Strength (K.N)
1st Configuration Maximum Maximum
2nd Configuration Maximum Maximum
5.1.8.2 The configurations are subjected to 200 heat cycles by injecting suitable current into them. In each
cycle the temperature of the conductor shall be raised from ambient to 120 + 5°C as, measured by a
thermocouple.
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5.1.8.3 The duration of each heating cycle is chosen to maintain a sufficiently steady temperature of 120 +
5°C for 15 minutes. The duration of each cooling cycle is chosen to bring the conductor temperature
to within 2°C of ambient.
5.1.8.4 Nominal heating current is indicated in the Table-4. It shall be permissible to accelerate the
temperature rise by using a current up to 1.5 times the nominal current and to accelerate the cooling
period by use of a fan or air blower.
Table-4
Nominal Cross – section (sq.mm.) Nominal Heating Current (A)
16 102
25 139
35 175
50 225
70 283
95 350
120 412
150 480
185 545
240 670
5.1.8.5 The over current test of Clause 5.1.9 shall be done after 50 cycles if the connector is a safety
connector designed to ground a phase connector while the line is being worked on.
5.1.8.6 At the end of the 200 cycles the resistance shall again be measured. It shall not differ from the initial
value by more than 12%.
5.1.9 Over Current Test of IPC
5.1.9.1 Over current test is required to establish the performance of Safety Connectors that are intended to
provide a safe path to ground for the phases while the line is de-energised for working. It establishes
the performance of the connector under short term over load conditions.
5.1.9.2 After the first 50 cycles of clause 5.1.8, the connectors are subjected to 4 over currents of 1 sec
duration each.
5.1.9.3 The conductor temperature at the start of the over current test should be not more than 35ºC.
5.1.9.4 Current density during over current shall be 100 A/sq.mm for Aluminium and 95 A/sq.mm for
Aluminium – Alloy Conductor.
5.1.9.5 Variation in time of over current is permissible between 0.85 sec & 1.15 sec., provided if maintains the
relationship I2
t = K where,
I = rms value of over current in Amps.
t = time in seconds
K = Constant
5.1.9.6 After the over current test the electrical ageing test of clause 5.1.8 shall be resumed.
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5.1.10 Type Test of IPC
5.1.10.1 Type Test Reports should be submitted from an Independent Laboratory of Repute or the Works
Laboratory in case of a foreign manufacturer covering the following (on any convenient size of fitting
of same design made from the same materials).
5.1.10.2 The installation of the connectors shall be done by the laboratory following instructions provided by
the manufacturer.
5.1.10.3 The Test report shall record the embossing and marking on the connector.
5.1.10.4 The following shall constitute Type Tests for IPC :

 Electrical Ageing Test
 Dielectric and Water Tightness Test.
 Mechanical Tightening Test
 Effect of Tightening on main Core
 Effect of Tightening on Branch core
 Over-current Test (if applicable)
The following shall be Type Test for Suspension Assembly (SA)

 Mechanical Test
 Voltage Test
 Climatic Aging Test
 Corrosion Test
 Endurance Test under Thermal & Mechanical Stresses
The following shall be Type Tests for Anchoring Assemblies (AA)

 Mechanical Test
 Voltage Test
 Dynamic Test
 Climatic Aging Test
 Corrosion Test
 Endurance Test under Thermal & Mechanical Stresses
5.2 Anchoring Clamp for Insulated Messenger:
The clamps should be designed to Anchor LT-AB cable with insulated messenger. The clamp should
consists of an Aluminium alloy corrosion resistant castled body, bail of stainless steel and self adjusting
plastic wedges which shall anchor/hold the neutral messenger without damaging the insulation.
 No losable part in the process of clamping arrangement

 The clamp should conform to the standard NFC 33041 and 33042 or equivalent I.S. if any.
 The clamp body should be made of corrosion resistant Alluminium alloy, bail should be of
stainless steel and wedges should be weather and UV resistant polymer.
 Ultimate tensile strength of the clamp should not be less than 15 km for 50/70sq.mm insulated
messenger wire / 10 KN for 25/35 sq.mm insulated messenger wire.
 Slip load of the clamp should not be less than 3 KN for 50/70 sq.mm. messenger wire / 2 KN
for 25/35 sq.mm. messenger wire.
5.2.1 Anchoring assemblies are used to firmly attach the messenger of ABC to a support and transmit the
mechanical tension.
 at the end of a run or to the supporting structures
 at a major change in direction.
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5.2.2 Each Anchoring Assembly shall include.

 One number tension bracket.
 One number wedge type tension clamp
 Flexible Rope for fixing tension clamp to bracket.
5.2.3 Anchoring assemblies shall be supplied in sets to ensure compatibility of the materials against
corrosion or wear of moving parts.
5.2.1 Tension Bracket of AA
5.2.4.1 The tension bracket shall be made out of a single piece of Aluminium alloy suitable for attachment to
a pole either by
a) 16mm galvanized steel bolt (s) or

b) two stainless Steel straps of 20 x 0.7 mm.
5.2.4.2 The tension bracket should be designed to ensure the Flexible rope cannot slip out at any angle.
5.2.4.3 The tension bracket should be rated and tested for the loads specified in Table-5. The load shall be
applied at an angle of 45º from the normal to the surface of mounting of the bracket.
Table - 5
Conductor Size Rating Load for deformation Load for deformation

(Sq.mm.) <10mm (Newtons) <30mm & no-break
(Newtons)
25-35 1500 Kg. 12,000 15,000

50-95 2000Kg 15,600 19,500
5.2.5 Flexible Rope of AA
5.2.5.1 The Anchoring assembly shall be supplied with a stainless steel flexible Rope to connect the Tension
Clamp to the Tension Bracket.
5.2.5.2 The rope should have sufficient flexibility to ease the torsional movement of the ABC System.
5.2.5.3 The Rope should be pre-fitted with compression type end fittings to secure the tension clamp.
5.2.5.4 A wear resistant moveable saddle should be un-loosably fitted on the Rope to prevent abrasion at
the point of fitting into the tension bracket.
5.2.5.5. The Rope should have sufficient mechanical strength to withstand the mechanical test for the complete
assembly tests in this specification.
5.2.6 Wedge Type Tension Clamp of AA
5.2.6.1 Wedge type clamps shall be used for clamping the messenger without damaging the insulation.
5.2.6.2 The clamp shall be capable of clamping an uncut messenger so that it can continue without break to
the connecting point or next span.
5.2.6.3 The clamp shall be fully insulating type of mechanical and weather resisting thermoplastic.
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5.2.6.4 No bolts or loose parts are allowed as part of the Clamping system.
5.2.6.5 No tools shall be needed for fitting the messenger into the clamp.
5.2.6.6 The clamp shall be self tightening and capable of holding without slippage the load specified in the
Table-6.
Table - 6
Conductor Size Rating (Kg.) T start (I minute) T final
Sq. mm. Dia. (mm) (Newtons) (I minute)
(Newtons)
25-35 8-11 1000 Kg. 8,000 10,000
50-54 8-11 1500 Kg. 12,000 15,000
70-95 13.5-16 2000 Kg. 12,000 15,000
5.2.6.7 After fitting the insulated messenger in the clamp, load T start will be held for 1 minute & then load
increased to T final at rate between 5000 – 7,500 N/mtr. In each case there shall be no breakdown
of any part of clamp and slippage of messenger in relation to the clamp.
5.2.7 Voltage Test on Clamp of AA
5.2.7.1 Voltage test is carried out on anchor clamps to ensure no damage is caused to the insulated
messenger.
5.2.7.2 A conductive rod of dia. corresponding to the average dia. that can be accommodated in the clamp is
fitted into the clamp, protruding by approx. 50mm at each end of the tightening piece.
5.2.7.3 The rod and clamp is subjected to tensile load as stated in Table 7 below when fixed to a support in
its normal manner.
Table - 7
Conductor Size Normal rating Load Applied
Sq. mm. Dia. (mm) (kg) (N)
25-35 8-11 1000 2000

50-54 8-11 1500 4000
70-95 13.5-16 2000 4000
5.2.7.4 A power frequency voltage of 6 kV is applied for 1 minute between the rod and conductive part of
the clamp, or fixation point in absence of conductive part.
5.2.7.5 No breakdown or flashover shall occur. There shall be no tripping due to leakage with a setting of
10 + 0.5 mA.
5.2.8 Endurance under Mechanical & Thermal Stress of AA
5.2.8.1 This test is done on clamp rated 1500 Kg. or 2000 Kg. using insulated messenger 50 to 70 sq. mm.
5.2.8.2 A neutral messenger is fitted between two anchor clamps, with clamp spacing approx. 5 mtr. & 1
mtr. Of messenger protruding from the end. Marks are made to enable measurement of slippage.
5.2.8.3 The sample is subjected to 500 cycles of 90 minutes each as described below:
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5.2.8.3.1 Messenger temperature is raised by passing an AC current to 60 +3O C within 15 minutes. This
temperature is maintained for at least 30 minutes to give a total heating period of 45 mts.per cycle.
5.2.8.3.2 Messenger is allowed to cool naturally to ambient for further 45 minutes to complete 90mts. Cycle
time.
5.2.8.3.3 Mechanical load is applied during the cycle as per table 8 below. Load F1 is applied throughout the
cycle, except for a short period of 5 sec. to 60 sec. when it is gradually increased from F1 to F2 at
any time during the last 15 minutes of the 90 minute cycle.
Table - 8
Conductor Size Rating (Kg.) F1 (Newtons) F2 (Newtons)
Sq. mm. Dia. (mm)
25-35 8-11 1000 Kg. 2,200 5,000
50-54 8-11 1500 Kg. 4,000 7,500
70-95 13.5-16 2000 Kg. 4,500 10,000
5.2.8.3.4 There should be no slippage greater than 4 mm after 2 cycles or greater than 8 mm after 500 cycles.
5.2.8.3.5 Voltage test is done at the end of the 500 cycles by immersing the test specimen of neutral
messenger and clamps in water of resistively not less than 200 Ohm mtr. For 30 minutes.
5.2.8.3.6 A voltage of 10 kV ac is applied for 1 minute between messenger and water bath
using a trip setting of 10 + 0.5 am. There should be no breakdown or tripping.
5.3 Suspension clamp for insulated neutral messenger:
The clamp should be designed to hang L.T – AB cable with insulated neutral messengers. The
neutral messengers should be fixed by an adjustable grip device. A movable link should allow
longitudinal and transversal movement of the clamp body.
 No losable part in the process of clamping arrangement.

 The clamp should conform to the standard NFC 33040 or equivalent I.S, if any.
 The clamp and the link made of Polymer should provide an additional insulation between the
cable and the pole.
 The clamps and movable links should be made of weather and UV resistant glass fibre
reinforced polymer.
 Clamps should be fixed with pole by eye hook / bracket. Bracket should be made of corrosion
resistant alluminium alloy.
 Ultimate tensile strength of the clamp should not be less than 15 KN for 50/70 sq.mm.
Insulated messenger wire 4.3 KN for 25/35 sq.mm. Insulated messenger wire.
 Maximum allowable load of the clamp should not be less than 20 KN for 50/70 sq.mm.
insulated messenger sire/15 KN for 25/30 sq.mm insulated messenger wire.
5.3.1 Suspension Assembly is used for supporting an ABC by installation on the messenger at an
intermediate point of support such as a pole. It can accommodate small angles of deviation upto
30°.
5.3.2 Each Suspension Assembly shall consist of:
 One number Suspension Bracket.

 One number moveable (articulated) connecting link.
 One number Suspension Clamp.
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5.3.3 Suspension Assemblies shall be supplied in sets to ensure compatibility of the materials against
corrosion or wear of rotating/moving parts.
5.3.4 Suspension Bracket of SA
5.3.4.1 The Suspension Bracket shall be made from single piece alluminium alloy suitable for attachment to a
pole by either.
a) 16 mm galvanized steel bolt or

b) Two stainless steel straps.
5.3.4.2 The Suspension Bracket shall be provided with an upper bulge to prevent the clamp from turning
over on the Bracket for more than 45 O from the horizontal or to within less than 60 mm from the
pole / fixing structure.
5.3.4.3 The Suspension Bracket should be so designed to ensure that the articulated link cannot slip out
of it.
5.3.4.4 Suspension Brackets shall be designed to withstand a load applied at the anchoring point of the
movable link as per Table – 9 below without deformation of more than 10mm or breakdown at 33O
below horizontal (there should be no longitudinal component of load parallel to the plane of fixing).
Table - 9
Conductor Size Normal rating Load
Sq. mm. Dia. (mm) (kg) (N)
25-35 8-11 1500Kg. 12500

70-95 13-17 2000Kg. 14000
5.3.5 Movable (Articulated) Link of SA
5.3.5.1 Movable Links are used between the Suspension Bracket and Suspension Clamp to allow a degree of
movement and flexibility between the two.
5.3.5.2 Moveable Links should be made fully of insulating type of mechanical and weather resistant
thermoplastic. A metallic wear resistant ring should however be fitted at point of contact between
the Suspension Bracket and the movable link.
5.3.5.3 The Movable link should be unloosably fitted to the Bracket and the Clamp.
5.3.6 Suspension Clamp of SA
5.3.6.1 Suspension Clamps are used for locking the messenger of the ABC bundle without damaging the
insulation or allowing the messenger to become dismounted from the fitting.
5.3.6.2 The Suspension Clamp shall accommodate messenger wires from 25 to 95 sq.m.
5.3.6.3 The Suspension Clamp shall be made fully of insulating type of mechanically strong and weather
resistant plastic.
5.3.6.4 Bolts should not be used for clamping / locking the messenger in the Clamp.
5.3.6.5 There shall be no losable parts in the Suspension clamp.
5.3.6.6 The Suspension Clamp should be unloosably fitted to the rest of the Suspension Assembly.
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5.3.7 Mechanical Test on Clamp of SA
5.3.7.1 The Sub Assembly shall be subjected to a vertical load applied as per drawing in accordance with
Table-10. There shall be no breakdown or permanent deformation at load T initial for 1 minute or
when the load is increased to T final and released.
Table - 10
Conductor Size Rating (Kg.) T start (I minute) T final
Sq. mm. Dia. (mm) (Newtons) (I minute)
(Newtons)
25-54 8-15 1500 Kg. 9,600 12,000
70-95 13-17 2000 Kg. 12,800 16,000
5.3.7.2 A sample messenger shall be fitted into a fixed suspension clamp and subjected to a gradually
applied longitudinal load of 300 N. There shall be no permanent slip page.
5.3.8 Voltage Test of SA

A copper foil is wrapped at the clamping point around the maximum size of messenger allowed in
that clamp. An ac voltage of 6 KV is applied between the copper foil and nearest conductive point of
the clamp or into its absence to the point of fixation. The voltage should be withstood for 1 minute
without breakdown or flashover.
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5.3.9 Test Under Mechanical & Thermal Stress
5.3.9.1 The test specimen is made up of approx. 10mts. Of messenger wire strung between two anchor
clamps with a Suspension Clamp fixed in the middle. Masses of 40 Kg. are suspended at a distance
of 1-2mtr. On either side of the Suspension Clamp with a fixing mechanism of mass 2 + 1 Kg.
5.3.9.2 The specimen is subjected to 500 cycles of 90 minutes each. Each cycle consists of the following:
a) For first 75 minutes a constant longitudinal tension of 4000 N is applied to the messenger for
rating of 1500 Kg. and of 4500 N rating of 2000 Kg. while 64cycles right and left oscillation are
produced on the clamp 32ºon either side of the vertical.
b) During the first 45 minutes an intermittent current of 4-5 A/sq.mm is applied to maintain the
conductor temp at 60 + 3º C.
c) During the next 45 minutes of the cycle the conductor is allowed to cool down naturally to the
ambient.
d) At the 75th minute, after having completed 64 oscillations, the oscillations are stopped and the
longitudinal tension is increased to 7500 N for 1500 kg. Rating and 10000 N for 2000 Kg. Rating.
3.9.3 No messenger slippage should occur within the Suspension Clamp during the 500cycles.
5.3.9.4 At the end of the 500 cycles, the messenger is immersed in water for 30 minutes. It is then tested to
withstand 10 kV ac for 1 minute with a trip setting of 10 + 0.5 mA. There should be no breakdown
or flashover.
5.4 Acceptance Tests
5.4.1 The following shall constitute Acceptance Tests for Insulation Piercing Connectors(IPC) :
 Visual *
 Dimensional (as per SCD and overall dimensions submitted with Tender Offer)*
 Electrical Ageing Test ***
 Dielectric and Water Tightness Test. **
 Mechanical Tightening Test **
 Effect of Tightening on Main Core **
 Effect of Tightening on Branch Core **
The above tests are to be carried out as per sampling plan below. However electrical geing test on
IPC (market***) is to be done on only one connector of each type and size.
In case of random failure/defect, double the sample lot is to be drawn and there should be no
failure/defect exceeding half the permissible defects (rounded down) shown in the chart.
For tests Marked* For tests Marked**

Lot Size Sample Size Max. Sample Size Max.
permissible permissible
Defects Defects
Upto 100 2 nil 2 nil
101 to 1000 6 nil 4 nil
>1001 0.01% 0.1% of pieces 4 nil
subject to checked
min. 6 pieces
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5.4.2 The following shall constitute acceptance tests for Anchor Assemblies:
 Visual *
 Mechanical Test on Bracket**
 Mechanical Test on Clamp **
 Voltage Test *
5.4.3 The following shall constitute acceptance tests for Suspension Assemblies:
 Visual *
 Mechanical Test on Bracket**
 Mechanical Test on Clamp **
 Voltage Test *
The above tests (for AA & SA) are to be carried out as per sampling plan below. In case of random
failure/defect, double the sample lot is to be drawn and there should be no failure/defect exceeding
half the permissible defects (rounded down) shown in the chart.
For tests Marked* For tests Marked**

Lot Size Sample Size Max. Sample Size Max.
permissible permissible
Defects Defects
Upto 100 2 nil 1 nil
101 - 500 5 1 2 nil
501 - 2500 10 2 2 nil
2501 & 10 + 0.2 2 + 10% pf addl. 4 1
above % Sample quantity
6.0 SERVICE CLAMP

The clamps should be designed to anchor insulated service lines (armoured or unarmoured) with
2/4 conductors.
 The clamps should be made of weather and UV resistant polymer.

 No losable part in the process of clamping arrangement
 The clamp should conform to the standard NFC 33042 or equivalent I.S., if any. No losable
 Breaking Load of the clamp should not be less than 3 KN.
7.0 TRANSFORMER CONNECTION
 The connection to the transformer should be made with Pre-Insulated lugs for phase and
street lighting conductors and with an Aluminum Lug for neutral Messenger. If the Bus-bars-
bars are of copper, the Lugs should be preferably Bi-metallic type.
 The Barrel of the lug normally insulated with an Anti-UV black Thermoplastic tube sealed with
a flexible ring. Die reference, size and strip length are to be indicated on the plastic.
 Sizes covered 16-70 & upto 150 m2 Aluminium XLPE insulated cable.
 Reference standard NFC 33021 or equivalent I.S. if any.
8.0 JUNCTION SLEEVES

 The sleeves should be Pre-Insulated for phases, neutral messengers and street lighting
conductors.
 Sleeve should be made of Aluminum, insulated with an Anti-UV black thermoplastic tube
hermetically sealed two ends with 2 flexible rings.
 Die reference, size and strip length are indicated on the sleeve itself.
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 Sizes needed : 16-70 & upto 150 mm2 for Aluminum XLPE insulated cable.
 Reference standard : NFC 33021 or equivalent I.S. if any.
 Design as per furnished drawing.
9.0 EYE HOOKS

 Eye looks should be designed as to hold suspension clamps and Dead end clamps and to be
installed with the pole clamp.
 Eye-hooks should be made of forged Galvanized steel.
 The clamps corrosion resistance should conform the standards I.S. 2629 & I.S.2633.
 Bolts and nuts should be made of hot dip Galvanized steel according to VDE 0210 and VDE
0212.
 Ultimate Tensile strength (UTs) of the clamp should 20 KN.
 Design as per furnished drawing.
10.0 SERVICE MAIN DISTRIBUTION BOXES
10.1 Scope
This Distribution Box should be Weather & Moisture Proof with Spring loaded/Bolt& Nut type Bus Bar
system & should be able to carry a current according to specified capacity. It can have 1/3-phase
input & provision of 4 to 6 nos. of 3-phase or 1-phase outputs. The box should have the provision for
special key for locking & Proper arrangement of sealing. The boxes should be assembled on the pole
using Metal Tapes & Buckles or Bolts. No. of Boxes per pole may vary with supporting arrangement for
more no. of service connections. The Spring used should be of stainless steel having required capacity
to provide suitable pressure in the connector.
10.2 Construction
Distribution Boxes should be designed with Bus Bars with spring action contact, or screw-bolt
technique. For spring action contact only insertion of the conductor into the specified groove of the
Busbar is sufficient for proper connection whereas for Nut Bolt type proper washers & other
accessories are to be provided for connections. It should be used for multiple connections (3-phase or
1-phase) in low voltage Distribution Network. The boxes should be suitable for 1/3-phase (4 crores)
inputs &provision for 4 to 6 nos. of 3-phase or 1-phase outputs. Bus bars should be with a continuous
pair of contact bars with colour code to facilitate the identification of the correct energy phase.
The box should be able to incorporate the input or output cable dia. Of maximum16mm. (Equivalent
to 120Sq.mm.).
The Boxes should consist of special type Lock & key system as well as provision for sealing for
complete protection of the service connection contacts.
10.3 Current Ratings
The maximum current rating should be 140A/200A/250A & concerned authority should have the
liberty to choose among the above ratings as per their requirement.
10.4 Voltage Ratings:
The maximum voltage withstand capacity should be 600V.
10.5 Working Temp
Safe working temperature should be around 80 C for Outer Box & 100OC for metallic
Bus bars.
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10.6 Materials
Material used in the manufacturing process of the components of this product should be specified in
the respective product drawings & can be summarized as follows :
 Outer Box (Base & Cap) : With UV protection & Flame retardant characteristics(HB, as per UL
94-Tests for Flammability of Plastic materials) & preferably made up of ASA (Achylonitrile
Styrene Acrylate).
 Cable Grommets : Ethyelene-Propylene Rubber :
 Safety Key : PA 6.6 (Nylon).
 Safety Screw : Stainless Steel or Plating Finished steel.
 Insulation protection as per IP 44.
 Bus bars or Terminal Blocks : PA 6.6 (Nylon), Stainless Steel & Copper.
 Button & Cable Holder : PA 6.6 (Nylon) with 50% Glass Fibre.
 Busbar Insulation :Polymide.
10.7 Locking System

The boxes should consist of Special type Lock & Key arrangement as well as provision for sealing for
complete protection of the service connection contacts.
11.0 G.A. DRAWINGS ETC.
11.1 A drawing / picture clearly showing principal parts & dimensions for all products should be submitted
along with the offer.
11.2 The principal outer dimensions of each item, l x b x w in mm and weight in gms should be submitted
along with the offer.
11.3 The Employer may call for samples for verification & evaluation purposes.
12.0 GENERAL CONDITIONS OF MANUFACTURE

13.0 GTP
The Guaranteed Technical Particulars should be filled up in the given format of GTP.
14.0 TESTING STANDARD – Given in Annexure 2 & 3.
Note : 1) Any specific meteorological data other than those listed above applicable for a particular
equipment/item will be available in the technical specification for that equipment/item.
2) When values specified above contradicts with respective equipment TS, the later will prevail for
that equipment.
3) The atmosphere in the area is laden with industrial and town gases and smoke with dust in
suspension during the dry months and subject to tough colder months.
4) Heavy lightning is usual in the area during the months from May to November.
AH
ANNEXURE-1
GENERAL CONDITIONS FOR MANUFACTURE
The products shall be in accordance recognized standards used in L.T. ABC or equivalent I.S., if any.
Marking : Each product shall be clearly identified with manufacturer name or

trade mark, reference and capacity of the item and batch no.
Packaging : Manufacturer shall mention the packaging of each item. Installation
instruction should be included in packaging.
Type test : Each supplier should provide type test reports with the offer, carried
out in accordance with one of the reference standards in NABL
Accredited Laboratory.
Routine : Supplier shall provide a control plan, which will be implemented on

test
each item. Routine test reports should be submitted by the
manufacturer with inspection call.
Quality : All suppliers should preferably be ISO-9000 certified.
Anchoring and suspension clamps should be installable on existing poles using appropriate devices
(hooks, pigtails, brackets etc.).
All crimped connectors should be installed with mechanical or hydraulic hand crimping tools.
AH
ANNEXURE – 2
TESTING STANDARDS :
The Insulating Piercing Connector should conform to following std. :
Tests Tests Standard / Test Procedure
Corrosion As per NF C 33-020 (Jun ’98), or equivalent I.S., if any.
Qualification Test Exposure in Saline Environment : The exposure should be carried
out as per NF en 60068-2-11 (Aug. ’99) std. requirement. The
concentration of Saline solution must be of 5% + 1% in mass, & the
temperature of the test chamber must be maintained at 35°C + 2°C.
Exposure in Sulphur environment saturated of humidity – The
exposure should be carried out as per NF T 30-055 (Mar. ’74) std.
requirement. SO2 concentration in the chamber should be 0.067% in

volume. The temperature of the test chamber should be increased to
40°C + 3°C.
The total test should include four identical periods of 14 days, in
which 7 days of exposure in Saline environment & in other 7 days –
8 hrs. cycles in SO2 environment & 16 hrs. in laboratory

environment.
Electrical Ageing Test As per NF C 33-020 & NF C 33-004 (Jun ’98) or equivalent I.S., if
any.
Total no. of cycles 200, Heating time -60 mins., Cooling time -45
mins., Pause time – 2 mins.
Dielectric As per NF C 33-020 (Jun ’98) or equivalent I.S., if any. 15°C & 30°C & relative
Investigation Test in humidity between 25% & 75%. The tightening of the connectors should be at
water minimal value of the torque indicated by the manufacturer. The sample should
be placed in tank full of water on 30 cm height, after an immersion length
of30 mins. The set is subjected to a dielectric test under a voltage of 6 KV at
industrial frequency during 1 min. No flashover / breakdown should occur at 6
KV during 1 min.
Tests Tests Standard / Test Procedure
Mechanical Tests As per NF C 33-020 (Jun ’98) or equivalent I.S., if any.
For checking electrical continuity, shear heads & mechanical
behaviour of the connector’s suitable tests as per the above

specification have to conduct.
AH
Capacity needed :
For ABC 16 to 95 mm2
Model 1 for customer service Main 16 to 95 mn2
Tap 2.5 to 10 mm2 (For Street lighting/service connection)
Design as per furnished drawing
Model 2 for customer service Main 16 to 95 mm2
Tap 04 to 35 mm2 (for distribution box charging)
Design as per furnished drawing
Model 3 for customer service Main 25 to 95 mm2
Tap 25 to 95 mm2 (For ABC to ABC Tee Joint)
Design as per furnished drawing.
AH
ANNEXURE – 3
TESTING STANDARDS
Impact Resistance should be according to UL 746C. Insulation Protection should be as per IP 44. The Quter
Plastic box should conform to following std. –
Test / Standard Requirements Test Procedures
Degree of Protection IEC IP 44 – Protected against the First Digit : A 1.0mm

60529 penetration of solid objects diameter test wire should
exceeding 1.0mm in diameter not penetrate in any
and against penetration of water apparent opening (force = 1
jets that may affect the product N + 10%)
operation.
Second Digit : A spray
nozzle is used to spread a
water jet in all possible
directions.
Impact Resistance UL 746-C After the test the product The impact should be
should not show any evidence generated by dropping a
of : steel ball – with a diameter
- Live electrical parts accessible of 50.8 mm and a mass of
0.535 kg – from a specified
to the test probe, as described
height sufficient to produce
in this test specification.
an impact energy of 6.8 J
- Any results, which may affect
(0.69 13 kg.m.)
the mechanical performance of
the product.
- Any results, which may
increase the probability of
electrical shocks.
UV Resistance The sample physical properties According to ASTM G26,

average value after an Exposure Method 1, Xenon
UL 746-C
accelerated aging with UV Arc Lamp Type B or
radiation – should not be lower ASTM G 155, Exposure
than 70% of its initial value, Cycle I, with continuous
without aging, that is, a exposure to light and
variation of + 30% is allowed. intermittent exposure to
water jets, with
programmed cycles of 120
minutes, consisting of a 102
minutes light-only exposure
and a 18 minutes exposure
to light and water jets.
AH
Test / Standard Requirements Test Procedures

Withstanding Voltage UL Product should withstand the A 5 kV voltage should be
746-C specified voltage applied to the samples after
the 40 hours conditioning
cycle at 23 + 2°C and 50 +
5% relative humidity plus
96 hours at 35 + 2OC and
90+5% relative humidity.
Flammability After the UV radiation The test can be applied to

accelerated aging, the material test samples molded with
UL 94
should maintain the same the same material used for
original flammability level the base and the cap of the
(HB). box or taking a piece of
these components.
Flexural Strength After UV radiation accelerated A group of test samples

aging, the average value for this without aging should be
ASTM D790
test should not be lower than tested and the average
UL 746-C 70% of the original value, that values calculated. Another
is, a maximum variation of group should be aged under
30% is allowed. UV radiation then it should
be tested and the new
average should be
calculated and compared to
the initial average value.
Tensile Strength After aging with UV One of the test bodies must
be tested without being
ASTM D638 Radiation, the average value
submitted to accelerated
should not be lower than 70%
UL 746-C
aging and is computed over
of the initial values, that is, a
mean values. Another group
maximum variation of 30% is
is submitted to the radiation
allowed.
induced aging and then
tested and the new mean
value is computed and
compared to the first
computed mean value.
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TECHNICAL SPECIFICATIONS FOR MATERIAL PROPERTIES AND OTHER TECHNICAL

REQUIREMENTS FOR HEAT SHRINKABLE CABLE TERMINATIONS AND JOINTS SUITABLE FOR 11 KV
XLPE CABLES.
1) GENERAL: The term heat shrink refers to extruded or moulded polymeric materials which are cross linked
to develop elastic memory and supplied in expanded or deformed size or shape.
2) QUALIFYING EXPERIENCE: The kits should have satisfactory performance record in India in excess of 5
years supported with proof of customers having had satisfactory use of these kits in excess of 5 years.
3) TYPE TEST REPORTS: The Joints and terminations should have been type tested and type test reports
made available.
4) KITS CONTENTS : The Kits should generally consist of:
(a) Heat shrinkable clear insulating tubes

(b) stress control tubing where necessary,
(c) Ferrule insulating tubing for joints,
(d) Conductive cable break outs for terminations, non tracking, erosion and weather resistant tubing
both outer / inner
(e) non tracking erosions and weather resistant outdoor sheds in case of terminations
(f) high permittivity mastic wedge
(g) Insulating mastic.
(h) Aluminium crimping lugs of ISI specification.
(i) Tinned copper braids
(j) Wrap around mechanical protection for joints.
(k) Cleaning solvents, abrasive strips.
(l) Plumbing metal.
(m) Binding wire etc. adequate in quantity and dimensions to meet the service and test conditions.
The kit shall have installation instructions and shall be properly packed with shelf life of over 3 years.
AI
ENERGY METER
1.1 GENERAL
This Chapter describes the common requirement for static energy meter required for HT feeder, 3-phase
Distribution Transformer, 1-phase Transformer, Single phase whole current meter.
CMRI along with software shall be supplied for each package as per BPS. Necessary software for
downloading the data through CMRI and uploading to computer shall be provided.
The seals & sealing specifications are given in Annexure A
1.2 STANDARDS APPLICABLE
Unless otherwise specified elsewhere in this specification, the performance & testing of the meters shall
conform to the following Indian/International standards with updated and latest amendments/revisions
thereof.
S. No. Standard No. Title

1. IS 14697-1999 AC Static Watt-hour Meters for active energy Class 0.5 & 0.2
2. BIS 12063 Specification for degree of protection
3. IS 5133/1969 Specification for boxes for enclosure of electrical accessories
4. IEC 60687 Specific for AC static Watt hour meter class 0.5 & 0.2
5. IS 13779/1999 AC Static Watthour Meters for active energy Class 1.0 & 2.0
6. IEC 61036/1996 Specific for AC static Watt hour meter class 1.0 & 2.0
7. CBIP Report No.-88 Specification for AC Static Electrical Energy Meters
8. CBIP Technical Report No. Specification for common meter reading instrument
111
9. IS;9000 Basic environment testing procedure for electric and
electronic item
1.3 CLIMATIC CONDITION
The meter should be able to perform satisfactorily in moderately hot and humid climate, conducive to rust
and fungus growth as specified in Section-I. The climate conditions are also prone to wide variations in
the ambient conditions. The meter shall work satisfactorily even under lightning conditions and also the
meter performance and life shall not be affected due to smoke present in the atmosphere.
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* The specifications are applicable for meter installation upto an altitude of 2200 meter above mean sea
level. For meters to be used for an altitude of above 2200 MSL necessary corrections shall have to be
carried out in BIL and one minute power frequency with stand voltage capability as per relevant standard.
1.4 SUPPLY SYSTEM
Type of Input Input Burden Type Starting Accuracy

meter Voltage Current /Phase Current
HT Feeder 3 x 110 1A / 5A 1.5 Watts/phase or 3 phase 0.1 % of 0.5
meter volt ph-ph 10 VA/phase for 4 wire basic
voltage circuit and 1
VA phase for each
current circuit
3-phase DT 433±20% 5A 1.5 Watts/phase or 3 phase 0.1 % of 0.5
meter phase to 10 VA/phase for 4 wire basic
phase voltage circuit and 1
VA phase for each
current circuit
1-phase DT 240+20% 5A 1.5 Watts/phase or 1 phase 0.1 % of 0.5
meter -30% 10 VA/phase for 2 wire basic
phase to voltage circuit and 1
neutral VA phase for each
current circuit
1-phase 230 V 5-20 1.5 Watts/phase or 8 1 phase 0.4 % of 1.0
consumer Phase to VA/phase for voltage 2 wire basic
meter neutral circuit and 4 VA
phase for each
current circuit
3-phase 3x 230 V 10-60 1.5 Watts/phase or 8 3 phase 0.4 % of 1.0
consumer Phase to VA/phase for voltage 4 wire basic
meter neutral circuit and 4 VA
phase for each
current circuit
3 phase LT – 3x 230 V -/5 1.5 Watts/phase or 3 phase 0.1 % of 0.5
CT consumer Phase to 10 VA/phase for 4 wire basic
neutral voltage circuit and 1
VA phase for each
current circuit
HT 3 x 110 5A 1.5 Watts/phase or 3 phase 0.1 % of 0.5
consumer volt ph-ph 10 VA/phase for 4 wire basic
meter voltage circuit and 1
VA phase for each
current circuit
Note: The input voltage of CT operated meter and consumer meter will be 230 volts or 240
volts or 250 volts.
(BPS shall specify the required voltage for the project.)
1.5 POWER FACTOR RANGE
The meter shall be suitable for full power factor range from Zero (lag) to Unity to Zero (lead).
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1.6 POWER SUPPLY VARIATION
Energy meter along with its accessories shall withstand following extreme operating conditions.
Voltage : 70% to 120 % of V ref
Frequency : 50 ± 5% Hz
The manufacturer can also offer meters, which can withstand higher variations.
1.7 MAXIMUM CONTINUOUS CURRENT
The maximum continuous current in meters shall be the current at which the meter purports to meet the
accuracy requirement of the specification.
1.8 CALLIBERATION
The meter should be only factory calibrated and no modification of calibration should be possible at site to
ensure non tampering of meter at site.
1.9 COMMUNICATION CAPABILITY
The Meter shall be provided with a galvanically isolated optical communication port as per IEC-
1107/PACT/ANSI, with removable cover and with locking arrangement so that it can be easily connected to
a CMRI for data transfer.
The optical communication port shall also have sealing provisions. The manufacturer shall provide the
requisite meter software, protocol software or any other software and all facilities required by the owner to
use the WINDOWS based hand held CMRI for reading and retrieving the data from the meter and
download them in owner’s base computer station. The contractor shall demonstrate the data transfer
through hand held CMRI and generating the appropriate reports to owner.
1.10 NAME-PLATE MARKING OF THE METER
The marking on every meter shall be in accordance with relevant clauses of standard.
Every meter shall have name plate beneath the meter cover such that the name plate cannot be accessed
without opening the meter cover and without breaking the seals of the meter cover and the name plate
shall be marked distinctly and indelibly. The basic marking on the meter nameplate shall be as follows:
a) Name of Project -RGGVY

b) Manufacturer’s name & trade mark
c) Type Designation
d) No. of phases & wires
e) Serial number
f) Month and Year of manufacture
g) Reference Voltage
h) Rated secondary Current of CT, if applicable
i) Reference Standard as applicable
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j) Principal unit(s) of measurement

k) Meter Constant
l) Class index of meter
m) Property of <Name of owner>
n) Purchase Order No. & Date
o) Guarantee period
1.11 CALIBRATION AND TEST OUTPUT
The meter should have test output accessible from the front and be capable of being monitored with
suitable testing equipment. The operation indicator must be visible from the front. Test output device shall
be provided in the form of one common/separate LED for KWh and KVARh as applicable with provision of
selecting the parameter being tested. The test output device should have constant pulse rate in terms of
pulse/unit energy.
The meter shall be tested, calibrated and sealed at works before dispatch. Further, no modification or
calibration shall be possible at site by any means.
The resolution of the test output shall be sufficient to enable the static current test in less than 10 minutes.
1.12 INSTALLATION AND COMMISSIONING
The Bidder shall be responsible for total installation and commissioning of the meters (along with test
blocks, if supplied separately) as per Owner's advice, including unpacking and inspection on receipt at site,
mounting the meters, connection of input & output cables to the meters including any required rewiring,
functional testing, commissioning and handing over. The Bidder's personnel shall procure/carry the
necessary tools, equipment, materials and consumables (including insulated wires, lugs, ferrules, hardware
etc.).
As a part of commissioning of CMRI the Bidder shall load the software specified in this specification into
the PCs at the Base computer stations, and fully commission the total meter reading scheme. He shall also
impart the necessary instructions to Utility engineers.
1.13 DT meters: The Meter shall be suitably mounted in the DT Distribution box placed alongside the DT. The
optical communication port of the meter shall be taken out from the D.T Distribution box through a PVC
Pipe of adequate size, with proper clamping on the pole upto the height of 1.5 mtrs from the ground level.
A box with padlocking arrangement shall be provided at 1.5 mtrs height to house the user end of optical
communication port. At least 0.5 mtrs of cable shall be freely looped inside the box for ease of connection
with CMRI. The meter shall be installed in D.T Distribution box to be supplied by the contractor.
1.14 GUARANTEE
Manufacturer shall undertake a guarantee to replace the meters upto a period of 12 months from the date
of operation. The meters, which are found defective/inoperative at the time of installation, or became
inoperative/defective within the guarantee period, these defective/inoperative meters shall be replaced
within one month of receipt of report for such defective/inoperative meters.
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1.15 SERVICES
Manufacturer shall also extend services to repair the meters on chargeable basis, up to a period of 108
months from the date when the guarantee period is over i.e. after 12 months of successful operation of
the instant meter.
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2.0 3 PHASE 4 WIRE 0.5 CLASS ENERGY METER FOR FEEDER
2.1 GENERAL & CONSTRUCTIONAL REQUIREMENTS
2.1.1 Meters shall be designed and constructed in such a way so as to avoid causing any danger during use and
under normal conditions. However, the following should be ensured.
a) Personal safety against electric shock

b) Personal safety against effects of excessive temperature.
c) Protection against spread of fire
d) Protection against penetration of solid objects, dust & water
e) Detection against fraud
f) Detection against pilferage
2.1.2 The meter shall be designed with application specific integrated circuit and shall be manufactured using
SMT (Surface Mount Technology). Power supply and voltage divider circuits may be of PTH technology.
The meter should be housed in a safe, high grade engineering plastic / polycarbonate casing, which is of
projection mounting type and is dust/moisture proof, conforming to IP-51 of BIS 12063 / IEC 529.
2.1.3 All insulating material used in the construction of meters shall be non-hygroscopic, non-ageing and of
tested quality. All parts that are likely to develop corrosion shall be effectively protected against corrosion
during operating life by providing suitable protective coating.
2.1.4 The meter shall be supplied with a transparent extended terminal block cover (ETBC). The meter base,
meter cover, terminal block and ETBC shall be made of unbreakable high grade fire resistant non-
flammable reinforced, polycarbonate (not bakelite) or equivalent high grade engineering plastic, which
should form an extension of meter cases and have terminal holes and shall be of sufficient size to
accommodate insulation of the conductors, meeting the requirement of CBIP technical report CBIP.88.
2.1.5 The extended terminal block cover should be separately sealable at two places and housed at the bottom
of the meters and once sealed should prevent unauthorized tampering.
2.1.6 The terminal block should have sufficient insulating properties, mechanical strength and should have tin
plated solid brass terminals with two fixing screws per terminal. The terminals should be designed to
withstand high overload.
2.1.7 The meter should not get damaged or substantially influenced by the electromagnetic disturbances and
electrostatic discharges caused by harmonics, voltage dips and short interruptions, transients, DC and AC
magnetic field.
2.1.8 The meter shall have an operation indication device such as a blinking LED/ LCD. The operation indicator
shall be visible from the front window and capable of being monitored conveniently with suitable testing
equipment.
2.1.9 The meter shall conform to the degree of protection IP 51 but without suction in the meter as per IS:
12063/IEC: 529 for protection against ingress of dust, moisture and vermin’s.
2.1.10 The meter-base, meter cover, terminal block and ETBC shall be made of unbreakable, high grade, fire
resistant, reinforced, non-flammable, polycarbonate or equivalent high grade and good quality engineering
plastic.
2.1.11 The meter cover shall have one window. The window shall be of transparent, high grade engineering
plastic for easy reading of all the displayed values/parameters, name plate details and observation of
operation indicator. The window shall be ultrasonically welded with the meter cover such that it cannot be
removed undamaged without breaking the meter cover seals.
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2.1.12 The terminal block, the ETBC and the meter case shall ensure reasonable safety against the spread of fire.
They should not be ignited by thermic overload of live parts in contact with them.
2.1.13 The meter shall have tin plated brass terminals. The terminals shall have suitable construction with
barriers and cover to provide firm and safe connection of current and voltage leads of stranded copper
conductors or copper reducer type terminal ends (thimbles).
2.1.14 The manner of fixing the conductors to the terminal block shall ensure adequate and durable contact such
that there is no risk of loosening or undue heating. Screw connections transmitting contact force and
screw fixing which may be loosened and tightened several times during the life of the meter shall be such
that the risk of corrosion resulting from contact with any other metal part is minimized. Electrical
connections shall be so designed that contact pressure is not transmitted through insulating material. The
internal diameter of the terminal holes shall be 5.0 mm minimum. The clearance and creepage distance
shall conform to relevant clause of IS 14697:1999/CBIP technical report No.88.
2.1.15 The meter shall be compact in design. The entire and construction shall be capable of withstanding
stresses likely to occur in actual service and rough handling during transportation. The meter shall be
convenient to transport and immune to shock and vibration during transportation and handling.
2.1.16 The meter shall have a design to operate satisfactory for 10 years under normal electrical condition and
guaranteed life of 18 months from the date of commissioning against manufacturing and design defects.
The meters found defective with in guaranteed period shall be replaced by manufacturer free of cost with
in one month of intimation.
2.1.17 The meter shall be provided with accurate quartz crystal based real time clock and calendar with the
accuracy limit as per relevant standards. Meter shall have provision to synchronise the meter time with
standard time through CMRI with proper security system.
2.1.18 The integration period shall be set as 30 minutes and subsequently can be changed on real-time basis.
2.1.19 Vendor will give one copy of all the software’s (meter reading software for CMRI, software for uploading
data from CMRI to computer).
2.1.20 It should be possible to check the healthiness of phase voltages by displaying all the voltages on the meter
display.
2.1.21 The Meter should have appropriate facilities to be read in absence of Power Supply.
2.1.22 The meter should work accurately irrespective of phase sequence of the mains supply.
2.1.23 The meter should remain powered up and functional even when either any two phases are available to the
meter
2.1.24 The meter shall record active energy, even if one or more CT”s are reversed. The current vector direction
shall always be considered as positive (import) for computation of energy and shall be added in main
active energy register.
2.1.25 Data Security: The Meter shall have multilevel password for data protection and security. The meter data
retrieval shall be possible through authenticated CMRI. The meter shall support the event of change of
TOD register timings / no. of TOD registers, demand integration period and /or setting the meter time
through authenticated transaction and shall be logged as an event. The transaction events shall be
available for viewing at BCS end.
2.1.26 The meter data shall be retrievable through CMRI and will be downloaded in the Base computer software
for viewing, analysing and printing. The meter data downloaded at BCS end should be in user-friendly
formats. The manufacturer shall supply the required software for base computer system. The base
computer software shall have the facility to convert the required data (For billing, Energy Audit, tamper
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analysis purpose) in to ASCII format. This data should be possible to be used as input data for any other
software to generate desired reports as per the utility requirement.
2.1.27 The meter shall have radio interference suppression such that it should not generate noise, which could
interfere with the other equipment.
2.1.28 The meter shall have three fixing holes, one at the top and two at the bottom. The top hole shall be
provided with a special clip at the back of the meter so that holding screw is not accessible to the
consumer after fixing the meters. The lower fixing screws shall be provided under the sealed terminal
cover. The requisite fixing screws shall be supplied with each meter.
2.2 SEALING OF METER
Reliable sealing arrangement should be provided to make the meter tamper proof and avoid fiddling or
tampering by unauthorized persons. For this, at least two no. of seals on meter body, two no. of seals on
meter terminal cover and one no. of seal on each communication port shall be provided. All the seals shall
be provided in front side only. Please refer Annexure A for specification for sealing system.
2.3 CONNECTION DIAGRAM & TERMINAL MARKINGS
The terminals shall be marked properly on terminal block for giving external connections. A diagram of
connections should be provided inside the cover of terminal block. The terminal cover shall be extended
such that when it is placed in position it is not possible to approach the connections or connecting wires.
The terminals and the screws shall be suitable to carry upto 150% of Imax safely. The terminals shall have
suitable construction with barriers and covers to provide secure and safe connections.
2.4 REMOTE READOUT FACILITY, COMMUNICATION CAPABILITY
The meter also shall have a separate individually sealable RS-485 communication port to communicate
with Remote Terminal Unit (RTU) over Modbus protocol in multi-drop mode so that selected analog data
can be communicated to central location for SCADA / DMS application. The implementation detail of
MOSBUS protocol shall be furnished by the bidder.
2.5 SOFTWARE
Licensed copies of the software (meter reading software for CMRI, software for downloading/uploading
data from CMRI to computer) shall be made available and shall be installed on each common meter
reading instrument (CMRI) and Base computer by the manufacturer.
Common Meter Reading Instrument (CMRI) would be loaded with user-friendly software (MS-DOS 5.0 or
higher version compatible) for reading, downloading meter data and Time of Day (TOD) programming in
the meter.
Windows based user interactive Software for receiving data from CMRI and downloading instructions from
base computer to CMRI. This software should have, amongst other requirements, features and facilities as
described later in this specification, the facility to convert meter reading data into a user definable DBF
(Access) or spreadsheet or ASCII format or any other format for integrating with the Employer's billing
system as desired/required by the utility. Here again an "Export wizard" or similar utility shall be available
whereby user can select file format, the variable data to export, the field width selection of each variable
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so that it may be possible for the user to integrate the same with the user’s billing data and process the
selected data in desired manner.
The software shall have the flexibility to generate the following sets of reports.
 Load survey reports

 Tamper reports
Necessary software for loading application program into meter via CMRI serial port shall also be provided.
2.5.1 Tamper reports to include for a pre determined duration or month wise, tamper count, tamper duration
and tamper history for each of the meters.
2.5.2 Vendor will provide soft copy of all the software in CD form along with the meters supplied.
2.5.3 Vendor to install & demonstrate working of software programmes of other meter manufacturers on the
CMRI’s to be supplied with this package
The specification of CMRI are presented as Annexure B
2.6 DISPLAY
A real time quartz clock shall be used in the meter for maintaining time and calendar date. The maximum
drift shall not exceed 5 minutes per year. The uncertainty of setting initial time shall not exceed + 30
Seconds with respect to Indian standard time (Ref NPL New Delhi).
Facility for adjustment of real time shall be provided through CMRI with proper security.
The meter shall have a minimum 7 digits, 7segment display of liquid crystal display (LCD) or light emission
diode display (LED) with another digit for legend. The minimum character height shall be 10 mm.
Provision shall be made to read consumption in either whole units or decimal multiples or sub-multiples of
one possible to display content of relevant parameters with another digit displaying legend for
identification.
The display shall remain on the screen till operator presses button for subsequent display or 10 sec which
ever is earlier.
The meter should have non-volatile memory, so that the registered parameters will not be affected by loss
of power. A provision shall be made to read the meter parameters such as MD and consumption, etc.,
through the meter cover without actually opening the meter box cover. The non-volatile memory should
have a minimum retention time of 10 years under unpowered condition.
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2.7 DISPLAY SEQUENCE
The meter shall display the required parameters in two different modes as follows:
A. Auto Display Mode
Display test (LCD/LED Segment check)
 Real time & date

 Active energy forwarded
 Reactive energy lag
 Reactive energy lead
 Apparent energy forwarded
 Maximum Demand forwarded
 MD occurrence date and time
 Rising demand with elapsed time
 MD reset count
 Cumulative MD forwarded
 Instantaneous average 3  PF
 Instantaneous frequency
 Phase voltages R,Y,B
 Phase currents R,Y,B
 Cumulative power on hours of current month
B. Push Button Mode
All above & the following
 Tamper and fraud details

 Present CT status
 Last occurrence tamper ID
 Date and time of last tamper occurrence
 Last restoration tamper ID
 Date and time of last tamper restoration
 Cumulative tamper count
 TOD Register [Active forwarded energy (8 Nos)]
 TOD Register [Apparent forwarded energy (8 Nos)]
 TOD Register [Apparent forward MD (8 Nos)]
 Cumulative power on hours
C. Read Out Parameters with CMRI
All above including following
 Energy registers
 Billing registers
 TOD Registers
 Load survey data
 Tamper and fraud (all event details with date and time)
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 Self diagnostic details

 Real time calendar clock fail
 Battery bad flag
 History of monthly Energy Flow, Maximum Demand, Average power factor for the last 12 months
2.8 MAXIMUM DEMAND REGISTER
The maximum demand is to be monitored during each demand interval set with 30 minutes integration
and the maximum of these in a month shall be stored. Whenever MD is resent the maximum demand
value so registered shall be stored along with date and time. Under the current integration period, the
rising demand should be displayed continuously along with the elapsed time. The registered demand and
the number of times the MD is reset shall also be displayed and the information stored.
2.9 MAXIMUM DEMAND RESET
Facility for auto reset of MD at 00.00 hrs of first of every month shall be provided for which minimum 30
years calendar shall be programmed by the manufacturer.
The meter shall display the maximum demand reset count.
2.10 LOAD SURVEY CAPABILITY
Load survey shall be available for at least 35 days with 30 minutes load survey integration period for
following parameters. Vendor shall provide necessary facility to transfer data through CMRI/Public Switch
Telephone Network-PSTN/Low Power Radio (LPR)/GSM.
a. kWh forwarded
b. kVAh forwarded
c. kVARh lag
d. Voltage Phase wise
e. Current Phase wise
f. Daily maximum demand active & Apparent.
The load survey data, abnormality event information and instantaneous parameters data shall all be
retrievable through the meter's communication port from a common meter reading instrument (CMRI)/
Hand Held Unit and shall be transferred (downloaded) to a PC with user friendly Windows based software
to get complete details in numerical and/or graphic form. The necessary feature shall be available in the
software used for uploading data from CMRI to computer and shall be provided by the manufacturer with
complete details.
The meter shall have sufficient non-volatile memory for recording history of energy parameters for last
twelve billing cycles (Bill date shall be 00 hrs of the 1 st date of the calendar month by default –
programmable) and information should be made available at the BCS end:
2.11 TIME-OF-DAY (TOD) TARIFF/DEMAND
The meter should have provision of registering the time-of- day energy and maximum demand. It shall be
possible to define TOD register for active forwarded, apparent forwarded energy type.
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The meter should have in-built capacity to define up to eight (8) time zones through operation of
CMRI .The change of the TOD time-period(s) or changing number of TOD zones should be possible
through CMRI with special authenticated command from the software used for uploading data from CMRI
to computer so that only authorised person(s) can make such changes. The main control of this system
along with proper security password/code should be available on one or more computers located at the
authorised location(s) as per the directions to be given by the Employer
2.12 SELF DIAGNOSTIC FEATURE
2.12.1 The meter shall be capable of performing complete self diagnostic check to monitor the circuits for any
malfunctioning to ensure integrity of data memory location at all times. The meter shall have indications
for unsatisfactory/nonfunctioning/malfunctioning of the following:
a) Real Time and Date

b) All display segments as per the requirement
c) Nonvolatile memory (NVM) failure indication at BCS
d) Low battery indication at BCS
2.12.2 While installing the meter, it should be possible to check the correctness of Current and Voltage
Transformer connections to the meter and their polarity from the functioning of the meter for different
voltage injections with the help of vector/phasor diagrams. For this purpose a suitable software for field
diagnosis of meter connections with the help of Meter Reading Instrument should be supplied.
2.13 TAMPER & FRAUD PROTECTION
The meter shall function properly under following common abnormal conditions:
1. Phase sequence The meter shall keep working accurately irrespective of the phase
reversal sequence of the supply.
2. Current reversal/CT The meter shall log energy in forward direction even if the current is
polarity reversal flowing in reverse direction in one or more phases.
3 External magnetic The metering system shall be provided with adequate magnetic
influence shielding so that any external magnetic field (AC Electro Magnet or
DC Magnet) as per the values specified in CBIP Technical Report
No.88 (with latest amendments) applied on the metering system
shall not affect the proper functioning and recording of energy as
per error limits prescribed by CBIP.
Beside this the meter should have features to detect the occurrence and restoration of, at least, the
following common abnormal events:
i. Missing Potential & Potential imbalance: The meter shall be capable of detecting and recording occurrence
and restoration with date and time the cases of Potential failure which could happen due to disconnection
of potential leads (one or two), failure of phase line fuse from the Potential Transformer primary side.
Meter shall also detect and log cases of voltage unbalance (from 5% for more than 5 minutes or more
(programmable)) of voltages.
ii. Voltage High / Voltage Low: In case the average 3 phase voltage remains less (below 0.75Vref by default)
than or above (above 1.15Vref by default) for a predefined period (30 minutes by default), the meter shall
log such incidences with date & time. The voltage thresholds & persistence time shall be programmable
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using the CMRI & BCS. This abnormal condition shall be logged only when all the three-phase voltage is
available.
iii. Current imbalance: The meter shall be capable of detecting and recording occurrence and restoration with
date and time of Current unbalance (30% or more for more than 15 minutes, or as programmable).
iv. Current Circuit Short: The meter shall be capable of detecting and recording occurrences and restoration
of shorting of any one or two phases of current circuit to identify events like CT saturation, CT lead
shorting, CT inter turns short etc.
v. Current Circuit Open: The meter shall be capable of detecting and recording occurrences and restoration
of opening of any one or two phases of current circuit which can happen due to intentional / accidental
disconnection of current circuits. The meter shall be able to log abnormality conditions in current open
event like CT leads burns, loose connection, CT winding open etc in the meter memory. No load condition
should not be recorded in meter memory as a Current circuit open event.
vi. Power on/off: The meter shall be capable to record power on /off events in the meter memory. All
potential failure should be recorded as power off event.
The meter shall record the total duration of the above abnormalities, time and date of their occurrences &
restorations with a snap shot of electrical conditions viz. Voltage , current ,PF etc
Logic for calculation of voltage and current imbalance shall be furnished by the tenderer.
The meter shall keep records for the minimum last 250 events (occurrence + restoration) for above of
abnormal conditions. It shall be possible to retrieve the abnormal event data along-with all related snap-
shots' data through the meter's optical port with the help of a hand held unit (HHU) and download the
same to the BCS where it shall be available for viewing. All this information shall be made available in
simple and easily understandable format.
2.14 TAMPER LOGIC
Properly designed meter event logic should be provided. There shall be separate compartments for
logging of potential related event, current related event and power on/off event. The bidder should
explain the events details in each compartment under their offer.
The logging of various events in each compartment should be as under:
Once one or more compartments have become full, the last event pertaining to the same compartment
will be entered and the earliest (first one)-event should disappear. Thus, in this manner each succeeding
event will replace the earliest recorded event, compartment wise. Events of one compartment/category
should overwrite the events of their own compartment/category only.
A properly defined meter tamper logic should be provided. The tamper logic should be capable of
discriminating the system abnormalities from source side and load side and it should not log/record
tamper due to source side abnormalities.
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There shall be three separate compartments for logging of different types of tampers as follows:
 Compartment No. 1:
50 % of the tamper memory space shall be allocated for the following current related tampers
- CT open circuit
- CT short (bypass)
25 % of the tamper memory space shall be allocated for missing potential tampers.
25 % of the tamper memory space shall be allocated for current unbalance tampers
2.15 TESTS
Unless specifically waived off all test shall be witnessed by the Employer.
2.15.1 Type Test
Energy Meters offered shall be fully type tested as per IS 14697 / CBIP Technical Report No. 88 at any of
the NABL accredited test laboratories.
In case meters are not type tested in NABL accredited test laboratories the bidder shall arrange to carry
out type tests in any of the NABL accredited test laboratories at his own cost.
2.15.2 Acceptance Test
Acceptance test shall be carried out as specified in table 18 of CBIP Technical Report No. 88
2.15.3 Routine Test
All routine tests as specified in table 18 of CBIP Technical Report No. 88 shall be carried out on each
individual meter.
2.16 FIXING OF METERS
The meters shall be mounted in the panels.
2.17 OTHER SALIENT FEATURES

2.17.1 It should be possible to check the healthiness of phase voltages by displaying all the voltages on the meter
display.
2.17.2 The meter shall have provision of reading through communication port in the absence of power through an
external source.
2.17.3 The meter should work accurately irrespective of phase sequence of the mains supply
2.17.4 The meter should remain powered up and functional even when either of the two phases or one phase
along with neutral is available to meter.
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3.0 Three Phase, Four Wire, 0.5 Class, Energy Meter for 3-Phase DT
3.1 CT REQUIREMENT
The Meter shall be supplied with four nos of C.T’s with primary current capacity as required for its
intended use. The Accuracy class of C.T shall be 0.5.The meter shall be suitable for use with ring type /Coil
type [Epoxy/resin casted polyster] C.T whose Secondary current shall be 5 Amps. The C.T shall be wound
primary type.
3.2 DISPLAY
The Three phase meters shall be capable to measure & display continuously “Active Energy kWh” at all
loads and power factors. The meter should have provision for automatic recording of cumulative kWh at 24
hrs on the last day of the month for each calendar month and same should go to memory.
The digitally measured and processed value shall be displayed through LCD/LED having minimum six digits
to read upto one-tenth of kW hour with another digit for legend. The minimum character height shall not
be less than 8 mm.
The Meter should have appropriate facilities to be read in absence of Power Supply.
3.3 AUTO SCROLL DISPLAY
i) Cumulative kWh
ii) Instantaneous Voltages
iii) Instantaneous Currents
iv) Cummulative kVah
v) Instantaneous pf phase-wise
vi) Power on hours
3.4 DISPLAY PARAMETERS (PUSH BUTTON)
The display of following parameters shall be continuously scrolling one after another thru Push Button. The
display shall have “ON“ time of 10 to 12 secs for each measured value for display cycling.
i) Cumulative active Energy (kWh) for each calendar month for previous Six months.
ii) Cumulative apparent energy (kVah) for each calendar month for previous Six months
iii) Maximum demand (MD) in apparent for last billing month
iv) Maximum demand (MD) in apparent for current month
v) Tamper Data :
a) Present status of Tamper

b) Date & time of last tamper occurrence & tamper identification.
c) Date & time of last tamper removal.
d) Cumulative tamper occurrence count.
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3.5 LOAD SURVEY CAPABILITY & BILLING POINT REQUIREMENTS
Following load survey parameters for 35 days shall be logged for 30 minute:
 Individual phase wise kW value (one minute average) at peak kVA of 30 minute.
 R, Y, B Individual voltage of phases
 Power down time during 30 minute
 Active forwarded energy for 30 minute cumulative.
The predefined date and time for registering the billing parameters of kWh, kVAh, PF and kVA MD as well as
Tamper Count and Power-On hours readings shall be 00.00 hours of the first day of each calendar (billing)
month. All billing parameters shall be transferred to billing registers and shall be displayed on auto cyclic
display mode referred to as "BILLING PARAMETERS".
3.6 INTERFACE BETWEEN METER AND CMRI
The interface between a meter and CMRI shall be with a flexible cable of adequate length having suitable
female connector. This cable shall be supplied along with meter. The two ends of the cable shall be stress
relieved.
3.7 TAMPER &FRAUD PROTECTION
The meter registration shall be immune to reversal in current direction. The meter shall have following anti-
tamper features and shall record forward under the following conditions:
a) Potential failure: The meter shall be capable of detecting and recording occurrences and restoration
of potential failure (one phase/two phases) which can happen due to intentional / accidental
disconnection of potential leads. The meter should also record event as a potential failure, when one
phase line fuse failure from the main side.
b) Current Circuit Short: The meter shall be capable of detecting and recording occurrences and
restoration of shorting of any one or two phases of current circuit. A event detection logic should be
capable of discriminating the system abnormalities form source side and load side and it should not
log /record event due to source side abnormalities.
c) Current Circuit Open: The meter shall be capable of detecting and recording occurrences and
restoration of opening of any one or two phases of current circuit which can happen due to
intentional / accidental disconnection of current circuits. No load condition should record in meter
memory as a Current circuit open event.
d) Current Unbalance: The meter shall be capable of detecting and recording occurrences and
restoration of current unbalance as an event. The above information should be possible to download
from the meter through hand held unit and available at BCS end. The current unbalance more than
30 % should be recorded as an event in the meter memory.
e) Voltage Unbalance: The meter shall be capable of detecting and recording occurrences and
restoration of voltage unbalance as an event. The voltage unbalance more than 30 % should be
recorded as an event in the meter memory.
Minimum one hundred fifty (150) events (including occurrence & restoration) of all types of abnormality
event with date and time shall be available in the meter memory on first-in, first-out basis. It shall be
possible to retrieve the event data along-with all related snapshots' data through the meter's optical port
with the help of a hand held unit (HHU) and download the same to the BCS where it shall be available for
viewing. All this information shall be available in simple and easily understandable format.
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3.8 NON INFLAMMABILITY
The terminal block, the terminal cover and the case shall ensure reasonable safety against spread of fire.
They shall not be ignited by thermic over load of live parts in contact with them. To comply with this these
parts shall fulfill the conditions of the glow wire test as per clause 5.2.4 of CBIP Technical Report No.88.
3.9 CONSTRUCTIONAL REQUIREMENTS
Meters shall be designed and constructed in such a way so as to avoid causing any danger during use and
under normal conditions. The following should be ensured:-

b) Protection against spread of fire.
c) Protection against effects of excessive temperature.
e) Protection against fraudulence
f) Protection against pilferage
g) Meter base and meter cover should be ultrasonically welded
h) Protection against meter jamming by spurious signal injection/high magnetic field application.
The meter shall be designed with application of specific integrated circuit.
3.10 METER CASE
The meter should be housed in a safe, high grade engineering polycarbonate meter casing of projection
mounting type and is dust, vermin and moisture proof, with enclosure having degree of protection
conforming to IP-51 as per IS 13947. The meter case shall seal the meter such that the internal parts of
meter are accessible only after breaking the seals of meter cover. The meter case shall have provision with
deep cut for hanging the meter.
All insulating material used in the construction of meters shall be non-hygroscopic, non-ageing and of
tested quality. All parts that are likely to develop corrosion shall be effectively protected against such
corrosion during operating life by providing suitable protective coating.
3.11 COVER
The cover shall be transparent, made of scratch resistant UV stabilized silicon coated polycarbonate
material, which would enable easy reading the display. It should not fade in course of time and become
opaque causing inconvenience for reading.
The cover shall permit clear view of the register.
3.12 TERMINAL AND TERMINAL BLOCK
The meter shall have extended terminal blocks and be supplied with transparent non-detachable extended
terminal block cover (ETBC).
The combined meter block and ETBC shall ensure safety against the spread of fire. They should not be
ignited by overload of live parts in contact with them. To comply with this, these parts shall fulfill the
conditions of the glow wire test as per Clause 5.2.4 of CBIP Technical Report no 88.
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The Extended terminal block cover (ETBC) shall be transparent and shall be fixed to the meter terminal
block by at least one screw. The terminal block cover shall be provided with minimum one seal.
The Combined meter terminal block and terminal block cover shall be moulded type and made of high
grade non-hygroscopic, fire retardant, low tracking, reinforced poly-carbonate (not bakelite) or equivalent
high grade engineering plastic which should form an extension of the meter case and have terminal holes
and shall be of sufficient size to accommodate the insulation of the conductors. The terminals shall be of
suitable rating to carry 150% of Imax and made of electro-plated (or tinned brass. Terminals shall be of
adequate size so as to ensure proper tightening of the cable and shall be of replaceable type.
The terminal block shall have provision with two screws for fixing to a meter board.
3.13 TERMINATION
The terminals shall have suitable construction with barriers to provide firm and safe connection of current
and voltage leads of stranded copper conductors or copper reducer type terminal ends (thimbles).
Appropriate bi metallic lugs should be provided with each meter for fixing of the conductor.
The manner of fixing the conductors to the terminal block shall ensure adequate and durable contact such
that there is no risk of loosening or undue heating. Screw connections shall be such that the risk of
corrosion resulting from contact with any other metal part is minimized. Electrical connections shall be so
designed that contact pressure is not transmitted through insulating material. The internal diameter of the
terminal holes shall be 5.5 mm minimum. The clearance and creepage distance shall conform to relevant
clause of IS 14697:1999/CBIP technical report No. 88.
The meter shall have a design life of 10 years against manufacturing and design defects. The
Manufacturer shall stand 1 years Guarantee on the meter against any kind of failure/defects/mal-operation
within above period. Meter shall be replaced by manufacturer free of cost within one month of intimation
by owner / Employer. Manufacturer shall have to repair for further 5 years after the guarantee period is
over, on chargeable basis.
3.14 CONNECTION DIAGRAM
Each meter shall be indelibly marked with a connection diagram which shall be attached to the inner side
of the extended terminal block cover. In case any special precautions need to be taken at the time of
testing the meter, the same may be indicated along with circuit diagram. The meter terminals shall also be
marked and this marking should appear in the above diagram.
3.15 TERMINAL ARRANGEMENT
Three phase: The terminal arrangement and connection diagram shall be marked in accordance with
clause 7.2 of IS 14697.Terminal arrangement shall be in sequence : Ir(in), Vr, Ir(out), Iy(in), Vy, Iy(out),
Ib(in), Vb, Ib (out), Neutral (in),Neutral(out), Vn.
Reliable sealing arrangement should be provided to make the meter tamper evidence and avoid fiddling or
tampering by unauthorized persons by way of providing adequate no. of seals on meter, meter terminal
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cover, wherever necessary. All the seals shall be provided in front side only. Rear side sealing arrangement
will not be acceptable.
The manufacturer shall provide minimum two seals for the meter at the factory after calibration and
testing. The meter cover shall have provision for placing minimum two nos. additional seals by the
Employer. The manual switch and the terminal block cover shall be provided with minimum one seal each.
The holes for sealing wire shall be minimum 2 mm dia.
All the sealing screws when they are in open condition (i.e. not fixed) should not be easily detachable from
the respective covers. The meter should be designed and constructed in such a manner to make it pilfer
proof.
3.17 ELECTRO-MAGNETIC COMPATIBILITY AND INTERFERENCE
The meter shall remain un-influenced with EMI/EMC interference. The meter shall withstand surge test of
6 kV as per IS 14697-1999. It shall also withstand power frequency high voltage test of 2 kV rms for one
minute.
3.18 TESTS
3.18.1 Routine & Acceptance Tests : All routine & acceptance tests shall be carried out on each individual meter.
as stipulated in IS 14697 / CBIP Technical Report No. 88
3.18.2 Type Tests
3.19 The communication port of the meter will be brought out a Box to a suitable height (~ 1.5 m above GL)
for taking the meter reading through CMRI. The Box shall have suitable locking arrangement..
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4.0 SINGLE PHASE, TWO WIRE, ACCURACY CLASS 0.5, ENERGY METER FOR
SINGLE PHASE DT
4.1 CT EQUIREMENT
The Meter shall be supplied with C.T with primary current capacity required for its intended use. The
Accuracy class of C.T shall be 0.5.The meter shall be suitable for use with ring type /Coil type C.T whose
Secondary current shall be 5 Amps. The C.T shall be wound primary type. Two nos. CT shall be supplied
with each meter for Phase and Neutral circuit.
4.2 DISPLAY
The Single phase meters shall be capable to measure & display continiously “Active Energy kWh” at all
loads and power-factors. The meter should have provision for automatic recording of cumulative kWh at
24 hrs on the last day of the month for each calendar month and same should go to memory.
The digitally measured and processed value shall be displayed through LCD/LED having minimum six digits
to read upto one-tenth of kW hour with another digit for legend. The minimum character height shall not
be less than 8 mm.
The Meter should have appropriate facilities to be read in absence of Power Supply.
4.3 AUTO SCROLL DISPLAY
i) Cumulative kWh
ii) Instantaneous Voltages
iii) Instantaneous Currents
iv) Cummulative kVah
v) Instantaneous pf
vi) Power on hours
4.4 DISPLAY PARAMETERS (PUSH BUTTON)
The display of following parameters shall be continuously scrolling one after another thru Push Button. The
display shall have “ON “time of 10 secs for each measured value for display cycling.
i) Cumulative active Energy (kWh) for each calendar month for previous Six months.
ii) Cumulative apparent energy (kVah) for each calendar month for previous Six months
iii) Instantaneous voltages, currents
iv) Maximum demand (MD) in apparent for last billing month
v) Maximum demand (MD) in apparent for current month
vi) Tamper Data :
a. Present status of Tamper
b. Date & time of last tamper occurrence & tamper identification.
c. Date & time of last tamper removal.
d. Cumulative tamper occurrence count.
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4.5 LOAD SURVEY CAPABILITY & BILLING POINT REQUIREMENTS
Following load survey parameters for 35 days for 30 minute shall be logged:
 Average apparent demand

 Voltage
 Power down time during 30 minute
 Active forwarded energy.
The predefined date and time for registering the billing parameters of kWh, kVAh, PF and kVA MD as well as
Tamper Count and Power-On hours readings shall be 00.00 hours of the first day of each calendar (billing)
month. All billing parameters shall be transferred to billing registers and shall be displayed on auto cyclic
display mode referred to as "BILLING PARAMETERS".
4.6 INTERFACE BETWEEN METER AND CMRI
The interface between a meter and CMRI shall be with a flexible cable of adequate length having suitable
female connector. This cable shall be supplied along with meter. The two ends of the cable shall be stress
relieved.
4.7 TAMPER & FRAUD PROTECTION
The meter shall be capable of recording correctly in following anti-tamper condition:
i. The meter shall be capable of recording energy correctly even if input and output terminals are
interchanged. Also the meter shall record correctly even if phase and neutral are interchanged.
ii. The registration must occur whether input phase/neutral wires are connected properly or they are
interchanged at the input terminals.
iii. Performance of the meter should not be affected under influence of external DC/AC magnetic field of
high intensity as mentioned in CBIP report 88.
iv. The meter shall withstand phase-to-phase voltage between phase and neutral terminals for at least 30
minutes.
v. The Meter shall record even when the Neutral is removed or opened from both ends (source & load)
and when phase and Neutral are interchanged. When neutral is removed meter should start recording
energy for current of 2 (Two) amp and above.
Minimum one hundred fifty (100) events (including occurrence & restoration) of all types of abnormality
event with date and time shall be available in the meter memory on first-in, first-out basis. It shall be
possible to retrieve the event data along-with all related snapshots' data through the meter's optical port
with the help of a hand held unit (HHU) and download the same to the BCS where it shall be available for
viewing. All this information shall be available in simple and easily understandable format.
4.8 SELF DIAGONISTIC FEATURES
The contractor shall provide details of self diagnostics features available and indication on the three phase
meter for unsatisfactory / non-functioning of the following:
i) Time and calendar

ii) Real time clock battery
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iii) All display segments

iv) Non volatile memory
4.9 NON INFLAMMABILITY
The terminal block, the terminal cover and the case shall ensure reasonable safety against spread of fire.
They shall not be ignited by thermic over load of live parts in contact with them. To comply with this these
parts shall fulfill the conditions of the glow wire test as per clause 5.2.4 of CBIP Technical Report No.88.
4.10 CONSTRUCTIONAL REQUIREMENTS
under normal conditions. However, the following should be ensured:-
i) Personal safety against electric shock

j) Protection against spread of fire
k) Protection against penetration of solid objects, dust & water
l) Protection against fraudulence
m) Protection against pilferage
n) Meter base and meter cover should be ultrasonically welded
o) Protection against meter jamming by spurious signal injection/high magnetic field application.
The meter shall be designed with application of specific integrated circuit.
4.10.2 Meter Case:
The meter should be housed in a safe, high grade engineering polycarbonate meter casing of projection
mounting type and is dust, vermin and moisture proof, with enclosure having degree of protection
conforming to IP-51 as per IS 13947. The meter case shall seal the meter such that the internal parts of
meter are accessible only after breaking the seals of meter cover. The meter case shall have provision
with deep cut for hanging the meter.
All insulating material used in the construction of meters shall be non-hygroscopic, non-ageing and of
tested quality. All parts that are likely to develop corrosion shall be effectively protected against such
corrosion during operating life by providing suitable protective coating
4.10.3 COVER:
The cover shall be transparent, made of scratch resistant UV stabilized silicon coated polycarbonate
material, which would enable easy reading the display. It should not fade in course of time and become
opaque causing inconvenience for reading.
The cover shall permit clear view of the register.
4.11 TERMINAL AND TERMINAL BLOCK
The meter shall have extended terminal blocks and be supplied with transparent non-detachable extended
terminal block cover (ETBC).
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The combined meter block and ETBC shall ensure safety against the spread of fire. They should not be
ignited by overload of live parts in contact with them. To comply with this, these parts shall fulfill the
conditions of the glow wire test as per Clause 5.2.4 of CBIP Technical Report no 88.
The Extended terminal block cover (ETBC) shall be transparent and shall be fixed to the meter terminal
block by at least one screw. The terminal block cover shall be provided with minimum one seal.
The Combined meter terminal block and terminal block cover shall be moulded type and made of high
grade non-hygroscopic, fire retardant, low tracking, reinforced poly-carbonate (not bakelite) or equivalent
high grade engineering plastic which should form an extension of the meter case and have terminal holes
and shall be of sufficient size to accommodate the insulation of the conductors.
The terminals shall be of suitable rating to carry 150% of I max and made of electro-plated (or tinned brass.
Terminals shall be of adequate size so as to ensure proper tightening of the cable and shall be of
replaceable type.
The terminal block shall have provision with two screws for fixing to a meter board.
4.12 TERMINATION
The terminals shall have suitable construction with barriers to provide firm and safe connection of current
Appropriate bi metallic lugs should be provided with each meter for fixing of the conductor.
The manner of fixing the conductors to the terminal block shall ensure adequate and durable contact such
that there is no risk of loosening or undue heating. Screw connections shall be such that the risk of
corrosion resulting from contact with any other metal part is minimized. Electrical connections shall be so
designed that contact pressure is not transmitted through insulating material. The internal diameter of the
terminal holes shall be 5.5 mm minimum. The clearance and creepage distance shall conform to relevant
clause of IS 14697:1999/CBIP technical report No. 88.
4.13 CONNECTION DIAGRAM
Each meter shall be indelibly marked with a connection diagram which shall be attached to the inner side
of the extended terminal block cover. In case any special precautions need to be taken at the time of
testing the meter, the same may be indicated along with circuit diagram. The meter terminals shall also be
marked and this marking should appear in the above diagram.
4.14 TERMINAL ARRANGEMENT
Single phase: Connecting terminals of current and voltage shall be in following sequence: Phase (in),
Neutral (in), Neutral (out), phase (out).
Reliable sealing arrangement should be provided to make the meter tamper evidence and avoid fiddling or
tampering by unauthorized persons by way of providing adequate no. of seals on meter, meter terminal
cover, wherever necessary. All the seals shall be provided in front side only. Rear side sealing arrangement
will not be acceptable.
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The manufacturer shall provide minimum two seals for the meter at the factory after calibration and
testing. The meter cover shall have provision for placing minimum two nos. additional seals by the
Employer. The Terminal block cover shall be provided with minimum one seal each.
The holes for sealing wire shall be minimum 2 mm dia.
All the sealing screws when they are in open condition (i.e. not fixed) should not be easily detachable from
the respective covers. The meter should be designed and constructed in such a manner to make it pilfer
proof.
6 kV as per IS 14697-1999. It shall also withstand power frequency high voltage test as per above IS.
4.17 TESTS
4.17.1 Routine & Acceptance Tests: All routine tests shall be carried out on each individual meter and acceptance
tests as stipulated in IS: 14697 / CBIP Technical Report No. 88.
4.17.2 Type Tests
4.18 The communication port of the meter will be brought out a Box to a suitable height (~ 1.5 m above GL)
for taking the meter reading through CMRI. The Box shall have suitable locking arrangement.
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5.0 SINGLE PHASE WHOLE CURRENT STATIC ENERGY METER OF CLASS 1.0 FOR
CONSUMER
5.1 SCOPE
The static whole current meter shall offer current range of 5-20 A (first digit indicates the Basic Current &
second digit indicates the Maximum Current of the respective meters) for tariff purposes, as per
requirement given in this specification.
The bidder has to seal the meters, meter’s boxes and provide a record (in hard copy as well as soft copy)
of seals put on, progressively, every week. The record shall consist of following information of each
consumer where the meter is proposed to be installed:
Consumer Name & Address, Consumer No., D.T. No./Reference, 11 kV Feeder no./Reference, 33 kV Sub
station reference, Meter No. & Seals Nos.
The Employer shall provide the details other than Meter No. & Seal Nos. for each consumer before
installation of meter.
5.2 Running at no load
When voltage at 115% of Vref is applied and no current flows in the current circuit, the test output of the
meter shall not produce more than one pulse.
GENERAL & CONSTRUCTIONAL REQUIREMENTS
5.2.1 Meter Shall bear BIS mark

under normal conditions. However, the following should be ensured:-

b) Personal safety against effects of excessive temperature
c) Protection against spread of fire
e) Protection against fraudulence
f) Protection against pilferage
g) Meter base and meter cover should be ultrasonically welded
h) Protection against meter jamming by spurious signal injection/high magnetic field application.
The accuracy of the meter shall not be affected with the application of abnormal voltage /
frequency generating device such as spark discharge of minimum 35 kV. The meter shall be
tested by feeding the output of the device to meter in any of the following manner for 10
minutes.
1. On any of the phase or neutral terminals.

2. On any connecting wires of the meter (Voltage discharge with 0-10 mm spark gap).
3. At any place in load circuit.
The accuracy of the meter shall be checked before and after the application of above device.
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The vendor shall submit the compliance report to for this test carried out not before 5 year
from date of bid opening.
5.2.3 The meter shall be designed with application of specific integrated circuit and shall be manufactured using
SMT (Surface Mount Technology) components. Power supply and voltage divider circuits may be of PTH
Technology. The meter shall be housed in a safe, high grade engineering plastic/polycarbonate meter
block casing and which is of projection mounting type and is dust/moisture proof, conforming to IP-51 of
BIS 12063/IEC 529.
5.2.4 All insulating material used in the construction of meters shall be on-hygroscopic, non-ageing and of tested
quality. All parts that are likely to develop corrosion shall be effectively protected against corrosion
throughout during operating life by providing suitable protective coating.
5.2.5 The meter shall have an operation indication device such as a blinking LED. The operation indicator shall
be visible from the front window and capable of being monitored conveniently with suitable testing
equipment.
5.2.6 The meter shall conform to the degree of protection IP 51 as per IS:12063/IEC : 529 for protection against
ingress of dust, moisture and vermins.
5.2.7 The meter shall be supplied with a transparent non-detachable extended terminal block cover (ETBC). The
combined meter block and ETBC shall be made of unbreakable, high grade, fire resistant, reinforced, non-
flammable, polycarbonate or equivalent high grade and good quality engineering plastic.
5.2.8 The combined meter block and ETBC shall ensure safety against the spread of fire. They should not be
ignited by thermic overload of live parts in contact with them.
5.2.9 The meter block shall be of scratchless, transparent, high grade engineering plastic for easy reading of all
the displayed values/parameters, name plate details and observation of operation indicator. The
transparency of the box shall remain un-influenced with the environmental conditions. The meter block
shall be ultrasonically welded such that it cannot be removed undamaged without breaking the meter
block.
5.2.10 The terminal block shall be made of high grade non-hygroscopic, fire retardant, low tracking, fire resistant,
reinforced poly-carbonate (not bakelite) or equivalent high grade engineering plastic which should form
an extension of the meter case and have terminal holes and shall be of sufficient size to accommodate
the insulation of the conductors, meeting the requirement of IS 13779: 1999/CBIP Technical report-88.
5.2.11 The terminals shall have suitable construction with barriers to provide firm and safe connection of current
Appropriate bimetallic lugs should be provided with each meter for fixing of the conductor.
5.2.12 The manner of fixing the conductors to the terminal block shall ensure adequate and durable contact such
that there is no risk of loosening or undue heating. Screw connections transmitting contact force and
screw fixing which may be loosened and tightened several times during the life of the meter shall be
such that the risk of corrosion resulting from contact with any other metal part is minimized. Electrical
connections shall be so designed that contact pressure is not transmitted through insulating material.
The internal diameter of the terminal holes shall be 5.5 mm for meter. The clearance and creepage
distance shall conform to relevant clause of IS 13779:1999/CBIP technical report No. 88.
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5.2.13 The meter shall be compact in design. The meter block unit shall be capable of withstanding stresses likely
to occur in actual service and rough handling during transportation. The meter shall be convenient to
transport and immune to shock and vibration during transportation and handling.
5.2.14 The meter shall have three fixing holes, one at the top and two at the bottom. The top hole shall be
provided with a special clip at the back of the meter so that holding screw is not accessible to the
consumer after fixing the meters. The lower fixing screws shall be provided under the sealed terminal
cover. The requisite fixing screws shall be supplied with each meter.
5.2.15 The meter shall be provided with adequate protection against damage by high current/short circuit current.
Bidder should explain the security system.
5.2.16 The meter shall work satisfactory with guaranteed accuracy under presence of various influencing
conditions like external Magnetic Field, Electromagnetic Field, Radio Frequency Interference, Vibrations,
harmonic Distortion, Voltage/Frequency Fluctuations, electromagnetic High Frequency Fields etc. The
meter shall be capable of recording even in case of application by fraudulent means any of the tempering
methods. The Meter shall have following anti-tamper features :
vi. The meter shall be capable of recording energy correctly even if input and output terminals are
interchanged. Also the meter shall record correctly even if phase and neutral are interchanged.
vii. The meter shall register energy correctly even when the load is not terminated back to the meter and
instead current is drawn through a local earth under the conditions:-
a) When phase and neutral are connected correctly.

b) When phase and neutral wires are interchanged at the input terminals.
viii. The registration must occur whether input phase/neutral wires are connected properly or they are
interchanged at the input terminals.
ix. Performance of the meter should not be affected under influence of external DC/AC magnetic field of
high intensity as mentioned in CBIP report 88.
x. The meter shall be factory calibrated and shall be sealed suitably before dispatch.
xi. The meter shall withstand phase-to-phase voltage between phase and neutral terminals for at least 30
minutes.
xii. The Meter shall record even when the Neutral is removed or opened from both ends (source & load)
and when phase and Neutral are interchanged. When neutral is removed meter should start recording
energy for current of 2 (Two) amp and above. In case of metallic bodies, the earth terminal shall be
brought out and provided on the outside of the case.
The meter shall be capable of recording the following tamper events in memory (minimum 5 each)
with date and time stamp along with snapshots of V, I, PF and Kwh.
-Current reversal
-Neutral Disturbance
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All meter shall be sealed by the manufacturer at its works. In addition to the seal provided by the
manufacturer at its works, reliable sealing arrangement should be provided to make the meter tamper
evidence and avoid fiddling or tampering by unauthorized persons by way of providing adequate no. of
seals on meter, meter terminal cover, wherever necessary. The meter cover shall be sealable to the
meter base with at least 2 nos. seals. Also terminal cover shall have provision for sealing with at least
one seal. All the seals shall be provided in front side only. Rear side sealing arrangement will not be
acceptable. Please refer Annexure-A for specification for sealing system.
5.4 DISPLAY
5.4.1 The measured value(s) shall be displayed on a Liquid Crystal display (LCD) register. The height of the digit
shall be minimum 8.5 mm. The KWh energy registration shall take place with 6 complete digits. The
display shall have backlit capability for easy reading.
5.4.2 The data should be stored in non-volatile memory (NVM). The non-volatile memory should retain data for
a period of not less than 10 years under un-powered condition. Battery back-up memory will not be
considered as NVM.
5.4.3 The register shall be able to record and display starting from zero, for a minimum of 1500 hours, the
energy corresponding to rated maximum current at reference voltage and unity power factor. The
register should not roll over in between this duration.
5.4.4 In addition to providing serial number of the meter on the display plate, the meter serial number shall also
be programmed into meter memory for identification through communication port for CMRI/meter reading
print out.
5.5 DISPLAY SEQUENCE
The meter shall display the required parameters in two different modes as follows:
A) Auto Display Mode:
The following parameters hereinafter referred to as “Billing Parameters” (B.P) shall be displayed in an
auto-cycle mode, in the following sequence:-
1. LCD Test
2. Real Time
3. Date
4. Cumulative Active energy (forwarded) reading (kWh)
5. Last Bill Active Forwarded energy
6. Instantaneous Load (KW)
7. Last Bill Maximum demand (kW)
Each parameter shall be on meter display for 10 to 12 seconds and the time between two auto-cycles
shall be 120 seconds.
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B) Push Button Mode:-
In addition to the auto display mode parameters, the following parameters shall be displayed on pressing
the push button
1. LCD Test
2. Real Time
3. Date
4. Instantaneous voltage, current
5. Maximum demand kW for Current month
6. Supply Frequency
7. Instantaneous PF
The meter shall also be capable of offering a high resolution display which shall enable conducting of dial
testing by the user in the shortest possible time and as a minimum, the meter shall be capable of offering
a resolution of 4 digits after decimal (and 2 digits before decimal) for the high resolution KWh display.
5.6 MAXIMUM DEMAND REGISTRATION & RESET
Meter shall continuously monitor & calculate the average maximum demand for each demand interval time
of 30 minutes and maximum of these in a calendar month shall be stored along with date and time when it
occurred. The maximum demand shall automatically reset at 24:00 hrs. of the last date of each calendar
month for which minimum 30 years calendar shall be programmed by the manufacturer.
The integration period shall be set as 30 minutes, on real-time basis.
The billing purpose parameters (active forwarded energy, maximum demand in kW) shall be registered
and shall be available for a minimum period of atleast 6 month.
5.7 LOAD PROFILE RECORDING
The meter shall be capable of monitoring and recording load profile information for KW demand for every
30 minutes interval for at least 30 days duration.
5.8 SELF DIAGNOSTIC FEATURE
The meter shall be capable of performing complete self diagnostic check to monitor integrity of data
memory location at all time. The meter shall have indication for unsatisfactory /nonfunctioning
/malfunctioning of the following:
a) Time and date on meter display

b) All display segments on meter display
c) Real Time Clock (RTC) status in meter reading prints out at BCS end
d) Non-volatile Memory (NVM) status in meter reading prints out at BCS end
5.9 CMRI/BCS REQUIREMENTS
The Common Meter Reading Instrument (CMRI) should be capable of being loaded with user friendly
software (MS-DOS 5.0 or higher version compatible) for reading/downloading meter data. Windows based
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Base Computer Software (BCS) shall be provided for receiving data from CMRI and downloading
instructions from base computer software to CMRI.
This BCS should have, amongst other requirements, features and facilities described later in this
specification, the facility to convert meter reading data into user definable ASCII file format so that it may
be possible for the user to integrate the same with the user’s billing data and process the selected data in
desired manner. All the data available in the meter including energy, MD, and history data should be
convertible to user defined ASCII file format for integration with third party software. The vendor shall
supply necessary base computer software for reading / viewing of meter data and converting to user
defined ASCII files formats. The user shall have the flexibility to select the parameters to be converted into
ASCII file. The vendor shall also supply the necessary CMRI software.
5.10 DISPLAY POWER UP IN ABSENCE OF MAINS SUPPLY
The meter shall have the provision of providing the display of billing parameters in absence of main supply
through internal battery having minimum normal working life of 4 year.
5.11 CONNECTION DIAGRAM & TERMINAL MARKINGS
The connection diagram of the meter shall be clearly shown on the meter. The meter terminals shall also
be marked and this marking should appear in the above diagram.
6 kV as per IS 13779-1999.
5.13 TESTS
Unless specifically waived off all tests shall be witnessed by the Employer.
5.13.1 Type Tests
The Energy meter offered shall be type tested as IS 13779 at any of the NABL accredited test laboratories.
5.13.1.1 Sample Batch for Type Testing
i. The Manufacturer shall offer material for selection of samples for type testing only after getting Quality
Assurance plan approved from Owner’s Quality Assurance Deptt. The sample shall be manufactured
strictly in accordance with the Quality Assurance Plan approved by Owner.
ii. After final assembly 6 (six) meters shall be selected from 1st lot of 5000 meters. Type test shall be
applied to three meters; in the event of one specimen failing to comply in any respect, balance three
specimens shall comply with the requirements of the IS standard. In case any meters in second batch
also fails, the complete lot of 5,000 meters shall be rejected. The bidder/ manufacturer shall review
the design and submit a modified design and again sample selection & type test shall be repeated as
mentioned above.
iii. The Manufacturer is required to carry out all the Acceptance tests successfully in presence of Owner’s
representative before sample selection.
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5.13.2 Acceptance Test
Acceptance test shall be carried out as specified in table 18 of CBIP Technical Report No. 88.
5.13.3 Routine Tests
All routine tests as specified in table 18 of CBIP Technical Report No. 88 shall be carried out on each
individual meter.
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Annexure-A
SPECIFICATION OF POLY CARBONATE SEALS REQUIRED FOR SEALING

OF SINGLE / POLY PHASE METERS
1.01 Seal should be made of polycarbonate with ultra violet additive & should not be affected by boiling water
& acid.
1.02 The seal should withstand temperature up to 147  C.
1.03 Seal should be available in Clear / Red / Blue / Yellow / Amber / Green / Grey colour and should be
transparent.
1.04 Every seal should have 6” long, 20 gauge, twisted strand stainless steel wire.
1.05 Seal should have facility to print mono gram / name of company
1.06 Every Seals should have a unique seven-digit number. Numbers shall be printed on seal including the
anchor cap-using laser marking which shall not be erased using any tool or by any chemical reaction. Both
the seven digit seal numbers should be visible separately after closing the seal.
1.07 Seals should have tamper proof, internal “ anchor “ locking mechanism that permanently secures the wire
upon closing. The mechanism should be designed in such a way that its original position can’t be restored
after any effort of tamper or breaking of seals
1.08 Sealing mechanism shall be designed in such a way that it can be sealed without using any pliers or tools.
1.09 Seal should be constructed of two parts, first the main body (female type) & second the anchor (male
type) having locking mechanism. Both the part should be designed in such a way that once the seal is
closed the two parts can’t be separated.
1.010 Seal should be patented. Copy of patent shall be submitted along with offer.
1.011 Packaging: Seals shall be supplied in packet of 100 seals. Each packet shall be labelled for following
information
 Client Name
 Purchase order number &date
 Serial number range in the form of bar coding.
1.012 Seals shall be provided with tracking & recording software. The software shall have following features
 Software should have facility of defining the system controller

 Facility to enter serial number of seals with the help of bar code scanner.
 Receiving of seal in the system and with authentication like signature.
 Facility to identify the concern who is responsible for receiving of seals and nominated
by system supervisor.
 Provision to define different type of seals for various uses.
 Software should have facility of report generation for inventory & issue records.
 Facility to track for relevant data for individual seal entered in the system.
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Annexure-B
TECHNICAL SPECIFICATION FOR
COMMON METER READING INSTRUMENT (CMRI)
This specification covers supply and delivery of Common Meter Reading Instrument (CMRI) for
reading (uploading) the data of different make of meters and to have a capability to dump
(download) the same to the base computer system. The CMRI shall have memory / space to
reside software of reading at least 3 different makes of electronic meters as specified by
Employer.
A. Portable/hand-held Common Meter Reading Instrument (CMRI)
These shall be tailor-made for tapping all data stored in the memory of electronic meters of type,
three phase 3wire, three phase 3 wire HT/LT Trivector meters, whole current meters, single
phase meter, and faithfully transferring it to the local PC in the BCS. Each device shall be supplied
complete with
i) a lead with optical head for coupling it to the meter,
ii) a lead for plugging it to a personal computer;
iii) an internal battery for powering the devices;
iv) a case for safely carrying it about
v) a battery charger
The total arrangement shall be such that one (1) operator can carry out the whole operation
himself, in about five (5) minutes per meter.
B. The CMRI shall have a key for starting the data tapping from the coupled meter's memory, a key
to start data transfer to the PC, and a lamp, which would light up on completion of data collection,
remain 'on' while the data is held in the device and would go 'off' when all data has been
transferred to the PC. Data tapping operation shall not erase the data from the meter's memory,
or effect the meter operation in any way. The memory of the CMRI shall get automatically cleared
when the data has been transferred to the PC only then the CMRI shall accept data from another
meter. CMRIs shall also have the necessary provision for meter clock correction. CMRIs should
have adequate memory, to host application software, for enabling downloading of meter data of
3 makes of meters.
C. The Contractor shall provide the necessary software which would enable a local IBM-Compatible
PC to (i) accept the data from the CMRI and store it in its memory, (ii) display the collected data
on PC's screen, with forward/backward rolling, (iii) print out the data collected from one or more
meters, starting from a certain date and time, as per operator's instructions, (iv) transmit the
collected data through an appropriate communication link to the central computer, starting from a
certain date and time, as per operator's instructions, and (v) store the collected data on a floppy
disc.
D. The above software shall further ensure that absolutely no tampering (except total erasures) of
the collected metering data is possible during its handling by the PC. The software shall be
suitable for the commonly available PCs, and shall be supplied to SEB in a compatible form to
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enable its easy loading into the PCs available (or to be installed by the SEB) at the various
substations/ locations in the circle.
E CMRI should be compatible with Low Power Radio module to be provided by the bidder for
receiving the data from the meter to the CMRI/Hand Held UNIT and ultimately transferring to BCS
&vice versa for loading required instructions to the meters.
F. CMRI should conform to CBIP Technical Report No. 111with latest amendments with Level (2) IP
67 protection and following climatic condition & standards
1.0 Standards
The CMRI shall confirm in all respects to the following standards.
i) CBIP Technical Report no. 111 – Specification for common Meter reading Instrument.
ii) IEC – 529 – Degree of Protection provided by enclosures
iii) IS : 12063 : 1987 – Classification of Degree of Protection provided by enclosures of electrical
items
iv) IS 9000: 1979 – Basic environmental testing procedure for electronic & electronic items.
v) IEC – 1000 – Electromagnetic compatibility
vi) IEC – 1000-4-2 : 1995 – Electrostatic discharge immunity test
vii) IEC – 1000–4-3 : 195 – Radiated, radio – frequency electromagnetic field immunity test,
Magnetic immunity test
viii) CISPAR 22 – Limits and method of measurement of radio disturbance characteristics of
information technology equipment.
2.0 Climatic Conditions:
The detail climatic condition is specified in Section-I.
3.0 Principal Parameter
For downloading data from electronic meters of type, single phase,230 V, whole current, three
phase 415 V Whole current ,three phase 415 V,CT operated, 33kV,11kV,HT Trivector CT,PT
operated meters. The offered meter reading device should be portable, compact and battery
powered. It’s memory shall be adequate to enabling transfer of data from three makes of meters
equipped with suitable communication port and transferring them on to a base computer system
such as an IBM compatible PC or an external peripheral & vice-versa.
The offered CMRI should have capacity compatible to read minimum 20 meters for billing &
tamper data but without load survey and minimum 10 meters for billing and tamper data with
load survey.
CMRI shall be able to display phase / vector diagram of phase current, phase voltage with
respective phase angles and phase sequence of voltage at SITE when these data are read from
the meter.
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4.0 GENERAL TECHNICAL REQUIREMENT:
Physical Characteristics:
i. Size:
CMRI should be handy, lightweight and small in size for ease of portability.
ii. Enclosure:
CMRI casing shall be of electrical insulating material of high thermal stability and mechanical
strength. Its degree of protection confirms to IP 67 LEVEL (2) as per IS 12063 / IEC-529.The
enclosure should be solvent resistant and shall be provided with a suitable holding Strap for
proper gripping.
iii. Ruggedness: CMRI is able to withstand harsh field environment without physical damage
or loss of data.
iv. Display: The display of CMRI is having the following characteristics.
a) Easy readability in varying ambient light conditions.

b) 4 lines and 20 characters per line on the screen
c) The size of the character shall be 4 mm
d) The contrast and intensity control to get a clear display in varying ambient light.
v) Key Board: The keyboard of the CMRI is having the following attributes.
a) Long operation life i.e. minimum 100000 operations (typical).
b) Feed back for key press acknowledgement to user.
c) Legible and non-fading keypad imprints for all alphanumeric characters/symbols.
d) Each English alphabet shall have a separate key.
vi. Input / Output ports (I/O Ports) :
The CMRI shall be having two serial input/output Ports, one port shall be serial port RS 232C
compatible. Another optional port can be used for convenience of connecting peripherals such as
bar-code reader, printer, battery charger, loader charger etc.
The offered CMRI shall be able to provide power supply for optical sensor used for meter reading
applications.
5.0 Physical interface:
i. Interface between meter and CMRI:
The interface between a meter and CMRI shall consist of 2 parts.
a) Meter optical sensor terminating in to a 9 pin D type male connector with a cable of 500
mm +/- 10 mm. Length.
b) The interface between a meter and the offered CMRI shall be with a flexible shielded
cable of length 1500mm +/-10mm having 9 pin D-type female connector with electrical
circuit. This cable shall be supplied along with CMRI. The two ends of the cable is stress
relieved.
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Interface between CMRI and Base computer station:
Suitable flexible shielded cable of sufficient length for communication between CMRI and base
computer station shall be provided. This communication shall be serial RS232C. On the base
computer station end of the cable a 9 pin D-type female connector shall be provided. The two
ends of the cable are stress relieved.
This cable shall also be supplied along with the CMRI.
6.0 Hardware and Software requirement:
i. Operating system :
To facilitate use of various meters, specific MRI programs in one CMRI, MS DOS version
5.0 or higher system shall be used. The facility to upgrade the BIOS/OS by a CMRI
manufacturer shall be available without exposing the hardware of the CMRI.
The additional program necessary to transfer application programs with serial port shall
be provided.
ii. Memory:
a) The CMRI shall be having a minimum memory capacity of 3 MB Static RAM (SRAM) with
battery backup and upgradeable.
b) BIOS/OS on FLASH memory / EEPROM MEMORY
iii. Communication:
The CMRI shall be able to communicate for-
a) Down loading / up loading data from / to the meter

b) Uploading / downloading data to / from the Base computer station
c) CMRI shall be capable to read bar code information using a bar code scanner from
barcodes of ac static \ electromechanical electricity meters by using appropriate scanner
and bar code soft ware.
d) CMRI shall support flexible baud rate ranging from 300 Baud to 19200 (or higher) Baud
rates to cater communication needs stated above.
iv. Real time clock :
A real time clock is provided in the CMRI, which have the following features:
Power requirement : The clock shall have a minimum of 15 days battery back up.
Calendar : The clock shall have 20 years calendar.
Time drift : The time drift shall be negligible and shall not exceed 20 seconds per
day.
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v. Time Setting Facility:
The CMRI shall have the facility to get its time set from Base computer station. Proper security for
this is ensured using password
vi. Power supply (Battery) for CMRI:
The CMRI shall have the following features for its power requirements:
a) The CMRI shall be powered by rechargeable battery housed within its enclosure.
b) The average capacity of charged battery shall be sufficient to communicate with
meters and base computer station for at least :
i) 6 hours while communicating through optical interface of meters and

ii) 8 hours without powering Input / Output ports for optical interface.
c) To reduce the equipment down time and inventories, there shall be provision to charge
the CMRI battery without being removed from the equipment. A suitable battery charger
for charging of CMRI battery shall be provided.
d) There would be a provision for AUTO POWER SAVE, which force the instrument in the
power saving mode in case of no activity within 5 minutes.
e) The battery used for data retention in SRAM would have a minimum of 3 years backup
capacity.
f) The CMRI would have battery low indication and automatic cutoff to avoid further drain
of the battery.
7.0 Communication Protocol and Software
Software:
a) The following software shall be provided in the offered CMRI.
i) Operating system compatible to MS DOS 5.0 or (latest version ver 7.0).

ii) Necessary software for loading application programs via a serial port for uploading and
down loading between CMRI and Base computer Station (BCS)
b) i. Provision for loading the software into the CMRI of the specific makes of
the meters, for the purpose of reading and programming of the specific
make(s) of static meters, such Software shall be provided by respective
meter manufacturers.
ii. BCS software accepting data from CMRI, processing generating reports
and downloading instruction from BCS to CMRI.
c) Special Requirement:
The offered CMRI shall have provision for storing the third party software and can also
be loaded for special applications such as manual meter reading, data entry through
keyboard of CMRI, printing, display of balance memory etc.
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d) The CMRI shall have facility to draw/display vector diagram of the electrical conditions
existing at site to check the healthiness of the connections.
e) The CMRI shall have provision to read the energy registers so that accuracy testing can
be done at site with standards calibrating equipments.
f) The CMRI shall have the provision to read the various instantaneous electrical
parameters at site like voltages, current, PF, phase angles, power (kW, KVAr, and KVA)
frequency etc.
g) The CMRI shall have facility to estimate the memory space available before reading the
meter.
8.0 DATA SECURITY
The meter manufacturers are responsible for maintaining the security of the data extracted from
the meters using manufacturer specific algorithm in the software up to down loading to BCS.
9.0 CMRI shall be type tested as per clause 5 of CBIP Technical Report No. 111.
10.0 Acceptance Tests for CMRI and PC Software
All CMRI after final assembly and before dispatch from Bidder's/Manufacturer's works shall be
duly tested to verify that they are suitable for supply to the Employer. In particular, each and
every CMRI shall be subjected to the following acceptance test:
(i) Functional Checks

(ii) Downloading Meter Data from the Meter(s)
(iii) Compatibility with PC software
(iv) Downloading the meter data on PC
(v) Functioning of advance and retard time commands
(vi) Per meter downloading time verification
(vii) Capacity of CMRI for data storage
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EARTH KNOBS FOR LT LINES
1. SCOPE
This standard covers the requirements of knobs for supporting the neutral-cum-earth wire used for
earthing of metal parts of supporting structures of overhead power lines with a nominal voltage upto
1000V (refer Construction Standard B-3 & B-4).
Except when they conflict with the specific requirements of this specification, the earth knobs shall
conform to the latest version of IS:9511-1980.
3. MATERIALS
Earth knobs shall be made of cast iron.
Earth knobs shall not have blow holes, shrinkage and other casting defects. The top and bottom flat
portion of earth knob shall be smooth and plain.
5. SHAPE AND DIMENSIONS
The shape and dimensions of earth knob shall conform to Fig. 1.
6. ACCEPTANCE TESTS
The following acceptance tests shall be carried out atleast on one knob for every 1000 nos.
6.1 Electrical Resistance
6.1.1 The electrical resistance of the earth knob shall be measured using a Kelvin
bridge. Adequate electrical contact shall be ensured against the two surfaces of the knob preferably
by using brass washers, soldered to the leads going to the bridge circuit. The washers shall be of
adequate size to ensure sufficient area of contact.
6.1.2 The electrical resistance of the earth knob, measured as given in 6.1.1 between the two flat portions,
shall not exceed 200 m ohms.
6.2 Mechanical Strength
The breaking strength at the neck of the earth knob shall not be less than 11,500 kg. when force is
applied in the direction shown in Fig. 2.
7. MARKING
Each earth knob shall be marked with the name of the manufacturer or his trade mark.
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EARTHING COIL
Earthing Coils shall be fabricated from soft GI Wire Hot Dip Galvanized. The Hot Dip galvanized wire shall have
clean surface and shall be free from paint enamel or any other poor conducting material. The coil shall be made as
per REC constructions standard (Refer tender drawing No. REC-XI Plan-Gen-005). The Hot Dip galvanizing shall
conform to IS:2629/1966, 2633/1972 and 4826/1969 with latest amendments. Galvanizing should be heavily
coated and should stand for the following tests.
Galvanizing Tests
i) Minimum Mass of Zinc
a) ON GI Wire used 280 cm/m2

b) After Coiling – 266 gm/m2. The certificate from recognized laboratory shall be submitted towards
mass of zinc.
ii) Dip Test Shall stand 3 dips of 1 minute and one dip of ½ minute before coiling and 43 dips of 1 minute
after coiling as per IS : 4826/1979.
THE DIMENSIONAL REQUIREMENT SHALL BE AS FOLLOWS
a) Nominal dia of GI Wire 4 mm (Tolerance + 2.5%)

b) Minimum no. of turns – 115 Nos.
c) External dia of Coil (Min) – 50 mm
d) Length of Coil (Min) – 460 mm
e) Free length of GI Wire at one end coil (Min.) – 2500 mm
The turns should be closely bound. Weight of one finished Earthing Coils (min.) – 1.850 Kg.
Adhesion test – As per ISS 4826 – 1979.
AL
EARTHING CONDUCTORS
All conductors burred in earth and concrete and above ground level shall be galvanised steel.
Galvanised steel shall be subject to four one minute dips in copper sulphate solution as per
IS:2633.
AM
EARTHING
(AS PER IS 3043-1987)
Earthing shall generally be carried out in accordance with the requirements of Indian Electricity Rules 2003
amended from time to time and relevant regulations under Electricity Supply Authority concerned.
In case of high and extra high voltages, the neutral points shall be earthed by not less than two separate
distinct connections with earth, each having its own electrodes sub-station and will be earthed at any other
point provided no interference is caused by such earthing. If necessary, the neutral may be earthed through
suitable impedance.
As far as possible, all earth connections should be visible for inspection. Each earthing system shall be so
designed, that, the testing of individual earth electrodes is possible. It is recommended that the value of any
earth system resistance shall be such as to conform to the degree of shock protection desired.
It is recommended, that a drawing showing the main earth connections and earth electrodes be prepared for
each installation and submitted to Employer.
No addition to the current carrying system, either temporary or permanent, shall be made which will increase
the maximum available fault current on its duration until it has been ascertained that the existing arrangement
of earth electrodes, earth bus-bar etc., are capable of carrying the new value of earth fault current which may
be obtained by this addition.
All materials, fittings etc., used in earthing shall conform to Indian Standard Specifications, wherever they
exist.
GENERAL REQUIREMENTS AND PROCEDURES FOR EARTHING AT SUB-STATIONS.
The ground resistance for sub-stations should not exceed a value 2(two) ohms. The joints/connections in the
earthling, system shall be welded only, except the connections, which require opening for
testing/maintenance. Such connections should be bolted tightly, using spring and ring washers for proper
contact pressure. The G.S. flats to be provided for the horizontally laid earth grid should have overlap welded
joints, with length of welding at least twice the width of the flat, e.g., 100 MM for 50x6 MM G.S. flats. There
should not be any dirt, grease, oil, enamel, paint or any such non-conductive coatings on the surfaces being
joined/ connected. Only the finished joints/connections above ground may be provided with red-oxide or any
other protective coating. Underground earth electrodes and earth grid elements, when laid, should have a
clean metallic surface, free from paint, enamel, grease or any such non-conductive coatings.
As far as possible, all earth connections should be accessible for visual inspection. No cut-outs, links or
switches, other than linked switches arranged to operate simultaneously on the earthed or earthed neutral
conductor and the live wire shall be inserted in the supply system. Earth electrodes or mate should not be
installed in close proximity to metal fence to avoid possibility of fence becoming live. Separate earth
electrodes, isolated from the earth grid, are to be provided for grounding the fence wires.
Pipes or rods used as electrodes should be in one piece, as far as possible, with a minimum allowable length
of 3 mtrs. Except where rock or hard stratum is encountered, the pipe/rod electrodes should be driven into the
ground to a minimum depth of 3 mtrs. The strip electrodes, forming the horizontal gild, should be buried
underground to a minimum depth of 0.5 mtrs. The path of earth wire should be out of normal reach of any
person, as far as possible.
AN
For high resistivity soils, above 100 Ohm-mtrs., attempts should be made to bring the soil resistivity in the
range of 50 to 60 Ohm-mtrs. By digging and treating the soil mass around the earth grid/electrodes with a
mixture of salt and charcoal.
In case of rocky top soil and sub-stratum, having very high resistivity, with no scope of improvement by other
means, the procedure given below should be followed:
1. At least two bores of diameter little less than 40 mm, with a minimum distance of 10 mtrs. between them,
should be made in the ground at suitable locations inside the S/S yard. The boring should be done until soil
sub-stratum rich in moisture and low in resistivity is encountered. G.I. pipes of 40 MM dia. should be
descended in each bore, such that, the soil mass around the pipes grips them tightly, Back – filling of bores, if
required, with wet soil/clay may be done to ensure this condition. The G.I. pipes in these deep bores should
be interconnected with the main earthing grid of the S/S through 50x6 mm G.S. flat, with all the
joints/connections and terminations being either fully welded, or clamped/bolted and welded simultaneously.
The G.I. pipes in the bores should also be interconnected with each other. In extreme cases, the bores may
have to be made at remote locations i.e. outside the S/S yard, with inter-connections, through 50x6 MM flats,
as explained before.
2. The procedures to be observed stringently for making connections and joints between various elements of the
earthing system are as follows:
a. G.S. flat to Structure/flat - The G.S. flat should be welded to the metallic portion (leg) of the structure
after thoroughly cleaning the surfaces to be welded. The length of the welding should be at least twice
the width of the G.S. flat, e.g.-minimum 100 mm for 50x6 mm G.S. flat. Exactly similar procedure is to be
adopted for joints between two G.S. flats.
b. G.I. wire to structure. The G.I. wire should be bolted to the structure after making an eye formation and
kept tight with the help of spring and ring washer. Then, the entire arrangement should be welded.
c. G.I. wire to G.S. flat- The G.I. wire should be bolted and then welded to G.S. flat, as explained above.
d. G.I. rod to G.S. flat- The G.I. rod should be securely clamped to the G.S. flat with the help of bolts and
washers and the entire arrangement should then be welded.
e. G.I. wire to G.I. pipe – GI wire should be bolted to the G.I. pipe and then welded, keeping in view the
relevant precautions, mentioned before.
f. G.I. flat to G.I pipe – The GI flat should be bolted tightly to the G.I. pipe and then the connection should
be welded.
Before making connections and joints, it should be ensured that, the elements to be joined have a clean
metallic contact surface without any non-conductive coating.
EARTH GRID SYSTEM
Grid system of interconnected conductors forming a closed loop mesh is to be installed using 75x8 mm MS flat
for peripheral and branch conductors. Interconnections are made by welding them. This earth grid will be laid
at a depth of about 0.5 mtr. bonded to general mass of the earth by 3 mtrs. long earth electrode of solid MS
rod (or pipe) of dia 25mm. The G.I. pipe 40 mm. dia 3 mtrs. long in the earthing pits, driven vertically.
AN
It is to this earth grid that the transformer neutral, apparatus, frame work and other non-current carrying
metal work associated like transformer tank, switchgear frame etc. are to be connected. All these connections
should be made in such a way that reliable and good electrical connection is ensured. Aluminum/ other paint,
enamel, grease and scale should be removed from the point of contact before connections are made. No part
of the ground connection leads should be embedded in concrete.
Arrangement of connection of earth connection shall be as follow:
1. STRUCTURES:
Structures including frames, metal supports within the substation grid at least two legs, preferably
diagonally opposite (where more than two legs are provided) on each metal structure shall be
connected to earth grid with GI wire of 4mm dia or 6 mm dia.
2. ISOLATORS/ SWITCHES:
The operating handle shall be connected to earth grid independent of the structure earthing or
through the steel mounting structure, through 4 mm dia G.I. wire.
3. LIGHTNING ARRESTOR:
The bases of lightning arrestors shall be directly connected to the earth electrodes by 4 or 6 SWG
G.I. wires as short and as straight as practicable, to ensure minimum impedance. Separate earth
leads should be used for L.A. in each phase. In addition there shall be as direct connections as
practicable from the earthed side of the lightning arrestors to the frame of the apparatus being
protected. Surge counters, could also be inserted in the circuit where lightning incidences are high,
but in such cases, the lightning arrestor should be mounted on insulated base. Invariably, earth
connections for lightning arrestors should be separate, and in no case should they be joined looped
or meshed with other conductors. For lightning arrestors mounted near transformers, earthing
connections shall be done with the earthing pits and earthing leads shall be laid clear of the tank
and collars in order to avoid possible oil leakage caused by arcing. The earth connection should not
pass through iron pipes, as it would increase the reactive impedance of the connection.
4. POWER TRANSFORMER:
 The tank of the transformer shall be directly connected to the main earth grid. In addition there
shall be a separate and as direct a connection as practicable from the tank to the earth side of
protecting LA using 4 or 6 SWG GI wire.
 The earthing of the neutral shall be by two separate, distinct and direct connections of 50x6 mm
GS flat to earth pits, which form a part of the earth grid, and shall be run clear of the tank and
collars.
 The transformer track rails shall be connected to earth
5. OUT DOOR VCB:
At least two legs, preferably diagonally opposite of the supporting structure frame work of each
circuit breaker unit shall be connected to the earth grid, through 50x6 mm G.S. flats.
6. FENCING:
Fencing and gate should be earthed separately.
AN
7. CURRENT TRANSFORMERS / POTENTIAL TRANSFORMERS:
The bases of the current transformers should be directly connected to the earth grid through 4 or 6
SWG G.I. wires. The base (neural side) of the P.Ts. should be directly connected to the earth grid
through 4 or 6 SWG G.I. wires. Separate earth leads should be used for P.Ts. in each phase. The
termination of leads on the P.T. neutral should be bolted/clamped and not welded, to facilitate
opening of the earth connection for testing purposes. In addition, all bolted cover plates to which
bushings are attached, should be connected to the earth grid, both in case of C.Ts. and P.Ts.
8. Armoring of armored metal-sheathed cables within the station grid area shall be connected to the
earth grid.
9. Substation L.T. Supply Transformer: Same as above except that the neutral earthing conductor
used shall be 4 or 6 SWG G.I. wire.
AN
GI EARTHING PIPE
Earthing pipe should be made of 40 mm diameter ISI marked B class GI Pipe. 12 mm dia suitable holes on its
circumference shall be made as per approved drawing. The pipe should be in one piece. No joints or welding
would be allowed on its length. Clamps made of 50x6mm GI flat duly drilled with 12 mm size holes should be
welded at the top end for connection of earth conductor.
Pipe used shall be 40mm NB diameter, ISI marked Galvanized Mild Steel Tubes continuously welded Electric
Resistance Welded ERW/High Frequency Induction welded (HFIW)/Hot finished welded (HFW) type, conforming
to IS-554-1985 with latest amendment of MEDIUM quality (Class B).
1. MANUFACTURE:
GI earth pipe (40 mm diameter & 3 metre long) shall be made of tubes which shall be made from tested quality
steel manufactured by any approved process as follows:
a) Electric Resistance Welded (ERW).

b) High Frequency Induction Welded (HFIW) and
c) Hot finished Welded (HFW).
Tubes made by manual welding are not acceptable.
2. DIMENSIONS:
The dimensions and weights of tubes shall be in accordance with Table-I and Table-II of IS: 1239 (Part-I)/1990
with latest amendments, subject to tolerance permitted therein. Necessary 12 mm diameter holes across the
circumference shall be provided as per approved drawing. Drawings shall be approved by the owner before
start of the manufacturing work. The tube, earthing pipe shall be provided with 50x6mm GS clamps on one
end, one clamp is to be welded with the pipe and another is removable to enable measurement of earth
resistance of the pit. Other end of the earth pipe should be cut half in slop to make it a sharp.
3. GALVANIZING:
Tubes shall be galvanized in accordance with IS-4736-1986 with latest amendment for not dip zinc coating of
Mild Steel Tubes. The minimum mass of zinc coating on the tubes shall be in accordance with clause 5.1 of IS-
4736-1986 (specification for hot dip zinc) and when determined on a 100mm long test piece in accordance with
IS: 6745:1972 shall be 400 g/m 2. The zinc coating shall be uniform adherent reasonably smooth and free from
such imperfections as flux, ash and dross inclusions, bare patches, black spots, pimples, lumpiness, rust, stains,
bulky white deposits and blisters.
4. HYDRAULIC TEST:
(Before applying holes) Each tube shall withstand a test pressure of 5 M Pa maintained for at least 3 seconds
without showing defects of any kind. The pressure shall be applied by approved means and maintained
sufficiently long for proof and inspection. The testing apparatus shall be fitted with an accurate pressure
indicator.
5. TEST ON FINISHED TUBES AND SOCKETS:

The following tests shall be conducted by the manufacturer of finished tubes and sockets.
a) The tensile strength of length of strip cut from selected tubes when tested in accordance with IS-1894-
1972, (Method for tensile testing of steel tubes), shall be at least 320N/mm 2.
b) The elongation percentage on a gauge length of 5.65/so (where so is the original cross-sectional area of
test specimen) shall not be less than 20%.
AO
c) When tested in accordance with IS-2329-1985 (Method for Bend test on Metallic tubes) the finished tube
shall be capable of with standing the bend test without showing any sign of fracture or failure. Welded
tubes shall be bent with the weld at 90 degree to the plane of bending. The tubes shall not be filled for this
test.
d) Galvanized tubes shall be capable of being bent cold without cracking of the steel, through 90 degree round
a former having a radius at the bottom of the groove equal to 8 times the outside diameter of tube.
e) Flattening Test on Tubes above 50 mm Nominal Bore: Rings not less than 40 mm in length cut from the
ends of selected tubes shall be flattered between parallel plates with the weld, if any, at 90 degree (point of
maximum bending) in accordance with IS-2328-1983. No opening should occur by fracture in the weld
unless the distance between the plate is less than 75 percent of the original outside diameter of the pipe
and no cracks or breaks in the metal elsewhere than in the weld shall occur, unless the distance between
the plates is less than 60% of the original outside diameter. The test rings may have the inner and outer
edges rounded.
f) GALVANISHING TEST:
 Weight of zinc Coating: For tubes thickness upto 6 mm the minimum weight of zinc coating, when
determined on a 100 mm long test piece in accordance with IS-4736-1986 shall be 400 grm/m2.
 The weight of the coating expressed in gram/m2 shall be calculated by dividing the total weight of the zinc
(inside plus outside) by the total area (inside plus outside) of the coated surface.
 Test specimen for this test shall be cut approximately 100 mm in length from opposite ends of the length of
tubes selected for testing. Before cutting the test specimen, 50 mm from both ends of the samples shall be
discarded.
g) Free Bore Test: A rod 230mm long and of appropriate diameter shall be passed through relevant nominal
bore of the sample tubes to ensure a free bore.
h) Uniformity of Galvanized Coating: The galvanized coating when determined on a 100 mm long test piece
[see V (a) (iii)] in accordance with IS-2633-1986 (Method for testing uniformity of coating on zinc coated
articles) shall with stand 4 one minute dips.
6. WORKMANSHIP:
The tubes shall be cleanly finished and reasonably free from injurious defects. They shall be reasonably
straight, free from cracks, surface flaws, laminations, and other defects, both internally and externally. The
screw tubes and sockets shall be clean and well-cut. The ends shall be cut cleanly and square with the axis of
tube.
7. MARKING:
The medium class of tubes shall be distinguished by Blue colour bands which shall be applied before the tubes
leaves the manufacturers’ works. Tubes shall be marked with the standard mark.
AO
G I STAY WIRES
1. SCOPE
This Specification covers details of G.I. stranded stay wires for use in rural distribution system.
Except when they conflict with the specific requirements of this specification, the G.I. Stranded Wires shall
comply with the specific requirements of IS:2141-1979. IS:4826-1979 & IS:6594-1974 or the latest
versions thereof.
3. APPLICATION AND SIZES

3.1 The G.I. stranded wires covered in this Specification are intended for use on the overhead power line
poles, distribution transformer structures etc.
3.2 The G.I. stranded wires shall be of 7/2.5mm, 7/3.15mm and 7/4.0mm standard sizes.
4. MATERIAL
The wires shall be drawn from steel made by the open hearth basic oxygen or electric furnace process and
of such quality that when drawn to the size of wire specified and coated with zinc, the finished strand
and the individual wires shall be of uniform quality and have the properties and characteristics
as specified in this specification. The wires shall not contain sulphur and phosphorus exceeding 0.060%
each.
5. TENSILE GRADE
The wires shall be of tensile grade 4, having minimum tensile strength of 700 N/mm2 conforming to
IS:2141.
6.1 The outer wire of strands shall have a right-hand lay.
6.2 The lay length of wire strands shall be 12 to 18 times the strand diameter.
7. MINIMUM BREAKING LOAD

The minimum breaking load of the wires before and after stranding shall be as follows :
No. of wires Wire dia Min. breaking load of Single Min. breaking load of the
& const. (mm) wire before stranding (KN) standard wire (KN)
7(6/1) 2.5 3.44 22.86
7(6/1) 3.15 5.45 36.26
7(6/1) 4.0 8.79 58.45
8. CONSTRUCTION
8.1 The galvanised stay wire shall be of 7-wire construction. The wires shall be so stranded together
that when an evenly distributed pull is applied at the ends of completed strand, each wire shall take an
equal share of the pull.
8.2 Joints are permitted in the individual wires during stranding but such joints shall not be less than 15
metres apart in the finished strands.
AP
8.3 The wire shall be circular and free from scale, irregularities, imperfection, flaws, splits and other defects.
9. TOLERANCES
A tolerance of (±)2.5% on the diameter of wires before stranding shall be permitted.
10. SAMPLING CRITERIA

The sampling criteria shall be in accordance with IS:2141.
11. TESTS ON WIRES BEFORE MANUFACTURE

The wires shall be subjected to the following tests in accordance with IS:2141.
i) Ductility Test
ii) Tolerance on Wire Diameter
12. TESTS ON COMPLETED STRAND

The completed strand shall be tested for the following tests in accordance with IS:2141.
a) Tensile and Elongation Test :

The percentage elongation of the stranded wire shall not be less than 6%.
b) Chemical analysis
c) Galvanising Test :
The Zinc Coating shall conform to “Heavy Coating” as laid down in IS:4826
13. MARKING
Each coil shall carry a metallic tag, securely attached to the inner part of the coil, bearing the
following information:
a) Manufacturers’ name or trade mark
b) Lot number and coil number
c) Size
d) Construction
e) Tensile Designation
f) Lay
g) Coating
h) Length
i) Mass
j) ISI certification mark, if any
14. PACKING
The wires shall be supplied in 75-100 Kg. coils. The packing should be done in accordance with the
provisions of IS:6594.
AP
GS STAY SETS (16 MM AND 20 MM DIA)
1. 16MM DIA STAY SETS (GALVANIZED)
The stay sets (Line Guy set) will consist of the following components:-
a) ANCHOR ROD WITH ONE WASHER AND NUT: Overall length of rod should be 1800 mm to be
made out of 16 mm dia GS Rod, one end threaded upto 40mm length with a pitch of 5 threads per cm
and provided with one square GS washer of size 40x40x1.6mm and one GS hexagonal nut conforming
to IS:1367:1967 & IS:1363:1967. Both washer and nut to suit threaded rod of 16mm dia. The other
end of the rod to be made into a round eye having an inner dia of 40mm with best quality welding.
b) ANCHOR PLATE SIZE 200x200x6MM: To be made out of GS plate of 6mm thickness. The anchor
plate should have at its centre 18mm dia hole.
c) TURN BUCKLE & EYE BOLT WITH 2 NUTS: To be made of 16mm dia GS Rod having an overall
length of 450 mm, one end of the rod to be threaded upto 300 mm length with a pitch of 5 threads per
cm and provided with two GS Hexagonal nuts of suitable size conforming to IS:1363:1967 &
IS:1367:1967. The other end of rod shall be rounded into a circular eye of 40mm inner dia with proper
and good quality welding.
d) BOW WITH WELDED ANGLE: To be made out of 16mm dia GS rod. The finished bow shall have an
overall length of 995mm and height of 450 mm, the apex or top of the bow shall be bent at an angle of
10 R. The other end shall be welded with proper and good quality welding to a GS angle 180mm long
having a dimension of 50x50x6mm. The angle shall have 3 holes of 18mm dia each.
e) THIMBLE: To be made on 1.5 mm thick GS sheet into a size of 75x22x40mm and shape as per
standard shall be supplied.
f) Galvanizing: The complete assembly shall be hot dip galvanized.
g) WELDING: The minimum strength of welding provided on various components of 16mm dia stay sets
shall be 3100 kg. Minimum 6 mm fillet weld or its equivalent weld area should be deposited in all
positions of the job i.e. at any point of the weld length. The welding shall be conforming to relevant IS:
823/1964 or its latest amendment. Minimum length of weld to be provided at various places in the stay
sets shall be indicated by the bidder. Welding if, found short in lengths as per final approved drawings
shall be rejected.
h) THREADING: The threads on the Anchor Rod, Eye Bolt & Nuts shall be as per specification IS:
4218:1967 (ISO Metric Screw Threads). The nuts shall be conforming to the requirement of IS:
1367:1967 & have dimensions as per IS; 163:1967. The mechanical property requirement of fasteners
shall conform to property clause 4.6 each for anchor rod & Eye bolt and property clause 4 for nuts as
per IS: 1367:1967.
AVERAGE WEIGHT OF FINISHED 16MM STAY SETS 7.702 KG. (MINIMUM) (EXCLUDING NUTS THIMBLES AND
WASHERS) 8.445 KG. (MAXIMUM)
AQ
2. 20 MM DIA STAYS SETS FOR 33KV LINES (GALVANIZED)
THE STAY SET (LINE GUY SET) WILL CONSIST OF THE FOLLOWING COMPONENTS:
a) ANCHOR ROD WITH ONE WASHER AND NUT: Overall length of Rod should be 1800mm to be
made out of 20mm dia GS Rod, one end threaded upto 40mm length with a pitch of a threads per cm.
And provided with one square G.S. Washer of Size 50x50x1.6mm and one GS Hexagonal nut
conforming to IS:1367:1967 & IS:1363:1967. Both washer & nut to suit the threaded rod of 20mm. The
other end of the rod to be made into a round eye having an inner dia of 40mm with best quality
welding. Dimensional and other details are indicated and submitted by bidders for owner’s approval
before start of manufacturing.
b) ANCHOR PLATE: Size 300x300x8mm: To be made out of G.S. Plate of8mm thickness. The anchor
plate to have at its centre 22mm dia hole.
c) TURN BUCKLE, EYE BOLT WITH 2 NUTS: To be made of 20mm dia G.S. Rod having an overall
length of 450 mm. One end of the rod to be threaded upto 300mm length with a pitch of 4 threads per
cm. The 20mm dia bolt so made shall be provided with two G.S. Hexagonal nuts of suitable size
conforming to IS:1637/1967 & IS:1363/1967.
The other end of the rod shall be rounded into a circular eye of 40mm inner dia with proper and good
quality of welding. Welding details are to be indicated by the bidder separately for approval.
d) BOW WITH WELDED CHANNEL: To be made out of 16mm dia G.S. Rod. The finished bow shall
have and overall length of 995 mm ad height of 450 mm. The apex or top of the bow shall be bent at
an angle of 10R. The other end shall be welded with proper and good quality welding to a G.S. Channel
200mm long having a dimension of 100x50x4.7 mm. The Channel shall have 2 holes of 18 mm dia and
22 dia hole at its centre.
e) THIMBLE 2 Nos.: To be made of 1.5mm thick G.S. sheet into a size of 75x22x40mm and shape as per
standard.
f) GALVANISING: The complete assembly shall be hot dip galvanised.
g) WELDING: The minimum strength of welding provided on various components of 20mm dia stay sets
shall be 4900 kg. Minimum 6mm filet weld or its equivalent weld area should be deposited in all positions
of the job i.e. at any point of the weld length. The welding shall be conforming to relevant IS: 823/1964
or its latest amendment.
h) THREADING: The threads on the Anchor Rods, Eye Bolts and Nuts shall be as per specification IS:
4218:1967 (ISO Metric Screw Threads). The Nuts shall be conforming to the requirements of IS:
1367:1967 and have dimension as per IS 1363:1967. The mechanical property requirement of fasteners
shall confirm to the properly clause 4.6 each for anchor rods and Eye bolt and property clause 4 for
nuts as per IS: 1367:1967.
AVERAGE WEIGHT OF FINISHED 20MM STAYS SET: 14.523 KG. (MIN.) (EXCLUDING NUTS THIMBLE &
WASHER): 15.569 KG. (MAX.)
AQ
3. TEST CERTIFICATE: The contractor shall be required to conduct testing of materials at Govt./Recognized
testing laboratory during pre – dispatch inspection for Tensile Load of 3100 Kg/4900 Kg. applied for one
minute on the welding & maintained for one minute for 16 mm and 20 mm dia stay sets respectively.
4. IDENTIFICATION MARK: All stay sets should carry the identification mark of word RGGVY XII Plan and
size of the stay set. This should be engraved on the stay plate and on stay rods to ensure proper
identification of the materials.
The nuts should be of a size compatible with threaded portion of rods and there should be no play or
slippage of nuts.
Welding wherever required should be perfect and should not give way after erection.
5. TOLERANCES: The tolerances for various components of the stay sets are indicated below subject to the
condition that the average weight of finished stay sets of 16mm dia excluding nuts, thimbles and washers
shall not be less than the weight specified above :-
No. Item Section Tolerances Fabrication Tolerances Material

1 Anchor Plate 6mm thick + 12.5% 200x200mm + 1% GS plate 6mm thick
- 5%
8mm thick + 12.5% 300x300mm + 1% GS plate 8mm thick
- 5%
2 Anchor Rod 16mm dia + 5% Length 1800mm + 0.5% GS Round 16mm dia
- 3%
Rounded Eye 40 mm inside dia + 3%. GS Round 16mm dia
Threading 40mm+11% - 5
20mm dia + 3% Length 1800mm + 0.5% GS Round 20mm dia
- 2%
Round Eye 40mm inside dia + 3%. GS Found 20mm dia
Threading 40mm +11% -5%
3 Turn Buckle 16 mm dia + 5% Length 995mm + 1% 16mm dia GS Round 16mm dia
Bow - 3%
Length 180mm + 1% 50x50x6mm GS Angle
Channel length 200mm + 1% GS Channel
100x50x4.7mm
4 Eye Bolt Rod 16mm dia + 5% Length 450mm + 1% GS Round 16mm dia
- 3% Threading 300mm + 1%
Round Eye 40mm inside dia + 3%
20mm dia + 3% Length 450mm + 1% GS Round 20mm dia
- 2% Threading 300mm + 1%
Round Eye 40mm inside dia + 3%
AQ
G I WIRES
1. SCOPE
This specification covers details of solid G.I. Wires for use in rural distribution system.
Except when they conflict with the specific requirements of this specification, the G.I. wires shall
comply with the provisions of IS:280-1978 and IS:7887-1975 or the latest version thereof.
3. APPLICATION & SIZES

G.I. wires covered in this Specification are intended for the following applications :
Application Sizes (nominal dia)

3.15mm (for single phase cables services )
Bearer wire for service
4 mm ( for three phase services)
Earthing of Transformers, poles & Fittings. 4 mm
Continuous Earthwire for. 11 KV lines 4 mm
Protective guarding at the crossing of

over-head power lines with roads, railway 3.15, 4 and 5 mm
tracts and telecommunication lines
4. MATERIAL
4.1 The wires shall be drawn from the wire rods conforming to IS:7887-1975 or the latest version
thereof.
4.2 The requirements for chemical composition for the wires shall conform to IS:7887.
4.3 The wires shall be sound, free from split surface flaws, rough jagged and imperfect edges and
other detrimental defects on the surface of the wires.
5. GALVANISING
The wires shall be galvanised with ‘Heavy Coating’ as per IS:4826-1979 or the latest version
thereof.
6. GRADES
GI wires shall be classified into two grades based on their tensile strength :
Tensile Strength
Grade
(MPa)
Annealed 300-550
Hard 550-900
7. TOLERANCE IN DIAMETER
The tolerance on nominal diameter at any section of wire shall not exceed (±)2.5%. Further,
the maximum difference between the diameters at any two cross-sections of wires shall not
exceed 2.5%.
AR
8. TESTS
The following tests shall be carried out in accordance with IS:280-1978 or the latest version
thereof as per sampling criteria stipulated therein :
i) Dimensional check (dia) - refer clause 7 above.
ii) Visual inspection regarding freedom from defects refer clause
4.3 above.
iii) Tensile test
iv) Wrapping test (for wire diameters smaller than 5mm)
v) Bend test (for wire diameters 5mm only)
vi) Coating test - refer clause 5 above
vii) Chemical composition
9. PACKING
The wires shall be supplied in 50-70 kg. coils, each coil having single continuous length. Each
coil of wire shall be suitably bound and fastened compactly and shall be protected by suitable
wrapping.
10. MARKING
Each coil shall be provided with a label fixed firmly on the inner part of the coil bearing the
following information :
a) Manufacturer’s name or trade mark
b) Lot number and coil number
c) Size
d) Grade (Annealed or Hard)
e) Mass
f) Length
g) ISI Certification mark, if any
AR
HOT DIP GALVANISED GS SOLID WIRE
The hot dip galvanized MS Solid wire of sizes 5 mm, 4 mm and 3.15 mm diameters shall conform to the
relevant ISS specification, briefed here below: -
1) MATERIAL
The Mild Steel wire shall have the chemical composition maximum sulfur - .055%, Phosphorus – 0.055%,
Carbon 0.25%.
Zinc shall conform to grade Zen 98 specified in IS 209-1966 & IS: 4826-1979 with up to date amendments.
2) ZINC COATING
Zinc coating shall be in accordance with IS: 4826-1979 (Col.4.2.1) for heavily coated hard quality.
3) GALVANISING
Galvanizing shall be as per IS 2629-1966, IS: 4826-1979 with up to date amendments.
4) UNIFORMITY OF ZINC COATING
Uniformity of Zinc coating shall be as per IS 2633-1972 (Col.4.2.1 to 4.2.3) with up to date amendments.
5) TENSILE PROPERTIES
The tensile strength of the wire after, galvanizing shall be between 55-95 Kg/Sq.mm (heavily coated Hard
as per IS: 4826-1979 Tables-1) ensuring MS wire Mechanical properties as per IS-28-1972 8.1 to 8.3.
6) FREEDOM FROM DEFECTS
As per IS 2629-1966 (Cl.6.1) & 4826-1979 (Col.4.3) & with up to date amendments, be ensured.
7) TESTS
During the process of manufacture/ fabrication and finish all tests for chemical, mechanical, galvanizing as
per IS-280-1979, IS: 1521-1972, IS1755-1961, IS: 6745-1972 & 4826-1979 be carried out. Test certificate
towards, chemical composition (as per above) shall be submitted for each lot offered for inspection.
The following tests shall be conducted in presence of owner’s representative.
1. Visual Physical inspection and measurement of specified dimensions.

2. Coating test as per IS-1755-1961, IS: 2629-1966, IS: 2633-1972, IS: 4826-1969 & 1979 – IS: 6745-
1972.
3. Adhesion test as per IS: 1755-1961, IS: 2629-1966, IS: 2633-1972, IS: 4826-1969 & 1979 – IS:
6745-1972.
4. Tensile strength and breaking load and elongation determined as per IS 1521-1972 with up to date
amendments.
AS
8) PACKING
Packing shall be as per IS 280-1979 (Col.3.1) and each coil shall be between 50-100 Kg.
9) MARKING
As per IS: 280-1972 (Col.14.1 & 14.1.1) is required.
AS
LT LINE SPACERS
1. SCOPE
This specification covers details of LT line Spacers to overcome the problem of mid-span clashing
of conductors. The specification covers two types of spacers:
i) Spiral type spacers (Fig.1)
ii) Composite spacers (Fig.2)
2. WORKING CONDITIONS
LT Line Spacers shall be suitable for tropical climate with a maximum ambient air temp. of 50o C,
humidity of 100% and wind pressure upto 150 Kg/M2.
3 MATERIAL
3.1 Spiral type spacers shall be made of high quality PVC.
3.2 The composite spacers shall be made poly-propylene and shall be made of single mould except the
clamping pieces. The fly nuts and studs shall be made of Engineering Grade Nylon. The studs shall be
properly fixed in position at the moulding stage.
4. SHAPE AND DIMENSIONS
4.1 The shape and dimensions of spiral type and composite spacers are shown in Figures 1 & 2 respectively.
4.2 Unless otherwise specified by the purchaser, the spacer shall be suitable for holding conductors having
diameters ranging from 6mm to 11mm.
5. APPLICATION
5.1 Normally only one set of spiral type spacers (number of spacers will depend upon the number of
conductors) or one single composite spacer in the middle
of span should be adequate. However, where necessary, additional spacer(s) may be used in each
span.
5.2 The spiral type spacer shall be fixed between two adjacent conductors by twisting the spiral
ends around the conductors manually. The spacers shall automatically grip the conductors
and remain in position.
5.3 One spiral type spacer shall hold two line conductors and two spacers shall hold three conductors and
so on (Fig.1).
5.4 The composite spacer is fixed by sliding the line conductors in the grooves and tightening the flynuts
manually. Only one composite spacer is required to hold a number of conductors depending upon
its design. In the enclosed Figure-2, a typical spacer suitable for holding 4 conductors (3-phase, 4-
wire - vertical formation) is shown.
5.5 Both spiral type and composite spacers are suitable for vertical and horizontal configuration of
conductors. However, the purchaser should clearly indicate the spacing between
the adjacent conductors to enable the manufacturer to supply right type of spacers.
AT
6. TESTS
LT spacers shall comply with the following test requirement:
6.1 Type Tests
(a) Dry power frequency withstand voltage test: Spacer shall withstand dry power frequency test
voltage of 23KV when tested in accordance with IS : 1445-1977 with suitable modifications to
simulate the actual method of application in the field.
(b) Wet Power frequency withstand voltage test : The spacers shall withstand a wet power
frequency test voltage of 10 KV when tested in accordance with IS : 1445-1977 with
suitable modifications to simulate actual method of application in field.
(c) Ageing/Tensile test: Three specimens of LT Spacers shall be maintained at a temp 70o (±) 2o C for
a period of 24 hours. After this treatment, the specimens shall not show any deformity and after
cooling, shall have a minimum tensile strength of 500 Kg.
(d) Dimensional verification:

i) The dimensions given in Figure 1 shall have the following
Tolerances/range of variation :
i) Length : 3mm of specified conductor spacing
ii) Spacer rod dia : 3 to 14 mm
iii) Spiral hole dia : 5 to 6 mm
iv) Length of each spiral : Indicated dimensions (±) 5mm
and overall spiral length
Indicated dimensions : (±) 5 mm
ii) The dimensions given in Fig.2 shall have the following tolerance :
i) Overall length : (±) 5mm
ii) Each conductor spacing : (±) 3mm
iii) Other dimensions : (+) 1mm
Note : The purchaser has the option to either accept type test certificate for the tests done earlier
on spacers or get fresh tests done particularly when the ordered quantity is large, say, over 10000
Nos. for spiral type and 3000 Nos. for composite spacers.
6.2 Acceptance tests:

a) Visual examination : The spacer shall have fine and uniform finish.
b) Ageing/Tensile test : As per 6.1 (c) above
c) Dimensional verification : As per 6.1 (d) above
Note : The manufacturer shall make necessary arrangement for carrying out the above tests in
his works and the purchaser will have the option to carry out these tests at the time of inspection
by selecting at random 3 specimens out of a lot of every 5000 spiral
type spacers or 1000 composite spacers or part thereof depending upon the total
quantity ordered. The visual and dimensional examination can be made on as many numbers as
desired.
7. INSPECTION
All tests and inspection shall be made at the place of manufacturer unless otherwise especially
agreed upon by manufacturer and the purchaser. The manufacturer shall afford the inspector all
AT
reasonable facilities, without charge, to satisfy him that the material is being supplied in accordance
with this specification.
8. PACKING
The spacers shall be suitably packed in wooden boxes suitable for easy but rough handling and
acceptable by rail/ road transport. Each box shall contain not more than 500 pieces.
9. MARKING
Each spacer shall be embossed with the following information :
a) Manufacturer`s name or trade mark and
b) Year of manufacture.
AT
AT
AT
VARIOUS SIZES OF HOT ROLLED STEEL BEAMS (JOISTS)
1. SCOPE :-
Specification covers the manufacture, testing at works and supply of various sizes of Hot rolled steel beams.
2. APPLICABLE STANDARDS:
The Mild shall be conforming to IS:2062 – 1992 GRADE ‘ A ‘ modified upto date or its equivalent international
standard for steel materials, document for which shall be made available at the time of inspection to the Employer’s
representative. The dimensions of Hot Rolled Steel Beams shall be conforming to IS: 808 / 1989 amended upto date
and tolerance as per IS : 1852 modified upto date.
3. GENERAL REQUIREMENTS :
Material shall be supplied as per the sizes and technical details as per following requirements and drawing.
ANNEXURE-I
AU
Sr.No Requirement as per Specification

Particulars
.
MB SC
1 Designation (DxB) ( mm x mm ) 175X85 152X152
2 Length of joist-Meter with +100 mm tolerance 9m 11m / 13m
3 Weight (kg/M) 19.6 37.1

4 Sectional area (A) (Sq.cm. ) 25.0 47.4
5 Depth of section ( D ) (mm) 175 152
6 Width of flance ( B ) (mm) 85 152
7 Thickness of flance (Tf) (mm) 9 11.9
8 Thickness of Web (Tw) (mm) 5.8 7.9
9 Radius of fillet or root (R1) (mm) 10 11.7
10 Radius of tow (R2) (mm) 5 3

11 Moment of Inertia
(i) I xx ( cm⁴) 1260 1970
(ii) I yy ( cm⁴) 76.7 700
12 Radius of Gyration GR xx (cm) 7.13 6.45

13 Modulus of Section
(i)Z xx (cm³ ) 144 259
(ii)Z yy(cm³ ) 18 91.9
14 Tolerance in dimensions plus/minus ---------As per IS: 1852---------
AU
ISI MARK HOT DIP GALVANISED MILD STEEL HEXAGONAL HEAD BOLTS AND NUTS
All bolts and nuts shall conform to IS: 6639 and shall be galvanized as per IS: 1367 – Part 13)/IS-2629. All bolts and
nuts shall have hexagonal heads, the heads being forged out of solid truly concentric, and square with the shank,
which must be perfectly straight.
Bolts upto M16 and having length upto 10 times the diameter of the bolt should be manufactured by cold forging and
thread rolling process to obtain good and reliable mechanical properties and effective dimensional control. The shear
strength of bolt for 5.6 grade should be 310 MPA minimum as per IS – 12427. Bolts should be provided with washer
face in accordance with IS: 1363 Part – I to ensure proper bearing.
Nuts should be double chamfered as per the requirement of IS: 1363 Part – III 1984. The manufacturer should
ensure that nuts should not be over tapped beyond 0.4 mm oversize on effective diameter for size upto M16.
Fully threaded bolts shall not be used. The length of the bolt shall be such that the threaded portion shall not extend
into the place of contact of the component parts.
All bolts shall be threaded to take the full depth of the nuts and threaded enough to permit the firm gripping of the
component parts but no further. It shall be ensured that the threaded portion of the bolt protruded not less than 3
mm and not more than 8 mm when fully tightened.
All nuts shall fit and tight to the point where shank of the bolt connects to the head. Flat washers and spring washers
shall be provided wherever necessary and shall be of positive lock type. Spring washers shall be electro-galvanised.
The thickness of washers shall conform to IS: 2016.
The Bidder shall furnish bolt schedules giving thickness of components connected the nut and the washer and the
length of shank and the threaded portion of bolts and size of holes and any other special details of this nature.
To obviate bending stress in bolt, it shall not connect aggregate thickness more than three time its diameter. Bolts at
the joints shall be so staggered that nuts may be tightened with spanners without fouling.
To ensure effective in-process Quality control it is essential that the manufacturer should have all the testing facilities
for tests like weight of zinc coating, shear strength, other testing facilities etc, in-house. The agency should also have
proper Quality Assurance system which should be in line with the requirement of this specification and IS –14000
services Quality System standard.
Fasteners of grade higher than 8.8 are not to be used.
RAW MATERIALS
MS round 16mm / 12mm used shall be tested for quality as per IS: 2062 Gr. “A”.
GALVANISATION
The bolts & Nuts shall be ISI Marked Mild Steel of Black Grade “B” and shall be round with hexagonal head. The
finished product shall be hot dip galvanized. The mass of zinc coating on pins shall be as per Clause-4 of IS: 4759-
1979 and in case of Nuts shall be as per Clause No.”4” of IS: 1367 (Part-XIII)-1983 having zinc coating not be less
than 610 gm/sq meter.
AV
OTHER
The Bolts and Nuts shall be manufactured by Hot/Cold forging process neatly and cleanly finished and shall have
metric threads as per IS: 4218/1967 with its latest amendments.
The dimensions of the bolts & nuts and tolerances should conform to IS: 1363 with their latest amendments in all
respect. The eccentricity and angular errors of various elements shall be within specified limits as per IS: 1367/1967
with its latest amendments. The bolts & nuts shall be free from forging and threading defects such as cuts, splits,
burns, bulging, taper, eccentricity, loose fill etc. which may affect their serviceability.
The bolt heads and nuts shall be chamfered on one face only and other face shall be machined made.
Mechanical property requirement of tester shall conform to IS: 1367 (Part-III) 1979 property class 4.6 for bolts &
property class-5 for nuts as per IS: 1367 (Part VI) – 1980.
The bolts & nuts shall be supplied in well-cleaned conditions and suitably protected against corrosion in individual
bags of 50 kgs.
ACCEPTANCE TESTS
The tenderer should furnish test certificate from his own/recognized Govt. Laboratory giving the results of tests as
per IS: 1367 (Part-III) –1979 & IS: 1367 (Part-VI) 1980 witnessed by Board’s inspecting officer for each lot under
inspection. The test certificate shall be in respect of the following for all sizes of both bolts & nuts as applicable given
below:-
a) Galvanizing Test: The uniformity of zinc coating and Wt. of zinc coating for pins and nuts shall be
verified as per requirements of IS: 2633/1972.
b) Dimensional particulars (Sampling in accordance with IS: 2614 for both bolts & nuts (tolerance as per
drawing).
c) Tensile strength test on full size (for bolts min. 400 N/ Sq.mm and for Nuts. Proof Stress (Min 610
N/Sq. mm).
d) Power load test on full size bolts and M-12-51400 N for 15 Sec.
e) (with Head soundness tests for bolts (no fracture).
f) Brinell hardness tests or Rockwell Hardness or Vicker’s Hardness tests for bolts min-114 & max. 209 or
min. 67 & max. 95 or min. 120 & max. 220 respectively. For nuts Vicker’s Hardness min. 130 & max.
302.
PRE-DESPATCH INSPECTION AND TEST
The contactor shall arrange to carryout acceptance tests in presence of Board’s inspecting officer in his own
laboratory. In case testing facilities are not available at his works he will make necessary arrangements for carrying
out these tests at a Govt. recognized lab at his own expense(s) and will provide all testing arrangement for Board’s
representative to witness the tests.
MARKINGS
AV
On the bolt head, there shall be identification marking of the manufacturer as well as property class “4.6”. If possible
property class “5” shall be marked on Nuts also. Further “ISI Mark” shall be marked on Sunny Bags for proper
identifications.
AV
11 KV DROP OUT FUSE CUT OUTS
1. SCOPE
This specification covers outdoor, open, drop-out expulsion type Fuse Cutouts suitable for
installation in 50 Hz, 11 KV distribution system.
2. APPLICATION
The distribution fuse cutouts are intended for use in distribution transformers and have no inherent
load break capacity.
3. APPLICABLE STANDARD
Unless otherwise modified in this specification, the cutout shall conform to IS:9385 (Part-I to III) as
amended from time to time.
4. RATED VOLTAGE
The rated voltage shall be 12 KV.
5. RATED CURRENT
The rated current shall be 100 A.
6. RATED LIGHTNING IMPULSE WITHSTAND VOLTAGE VALUES FOR THE FUSE BASE
The rated lightning impulse withstand voltages both for positive and negative polarities shall be as
given below:
a) To earth and between poles 75 KV (Peak)

b) Across the isolating distance of fuse base 85 KV (Peak)
7. RATED ONE MINUTE POWER FREQUENCY WITHSTAND VOLTAGE (DRY &

WET) VALUES FOR THE FUSE BASE
a) To earth and between poles 28 KV (rms)

b) Across the isolating distance 32 KV (rms)
8. TEMPERATURE RISE LIMIT (In Air)
a) Copper contacts silver faced 65oC

o
b) Terminals 50 C
c) Metal parts acting as springs. The temp. shall not reach such a value
that elasticity of the metal is changed.
9. RATED BREAKING CAPACITY
The rated breaking capacity shall be 8 KA (Asymmetrical).
10. GENERAL REQUIREMENTS/CONSTRUCTIONAL DETAILS
10.1 The cutouts shall be of single vent type (downward) having a front connected fuse carrier suitable for
angle mounting.
AW
10.2 All ferrous parts shall be hot dip galvanised in accordance with the latest version of IS:2633. Nuts
and bolts shall conform to IS:1364. Spring washers shall be electro-galvanised.
10.3 Typical constructional details of the fuse cutout are shown in Fig. 1
11. FUSE BASE TOP ASSEMBLY
11.1 The top current carrying parts shall be made of a highly conductive copper alloy and the contact
portion shall be silver plated for corrosion resistance and efficient current flow. The
contact shall have a socket cavity for latching and holding firmly the fuse carrier until the fault
interruption is completed within the fuse.
11.2 The top contact shall be actuated by a strong steel spring which keeps it under sufficient pressure
to maintain a firm contact with the fuse carrier during all operating conditions. The spring shall
also provide flexibility and absorbs most of the stresses when the fuse carrier is pushed into the
closing position.
11.3 The current carrying parts of the assembly shall be protected from water and dust formation by a
stainless steel top cover.
11.4 The top contact assembly shall have a robust galvanised steel hook to align and guide the fuse
carrier into the socket latch even when the fuse carrier is closed at an off-centre angle.
11.5 The top assembly shall have an aluminum alloy terminal connector (refer clause 19).
11.6 The top assembly shall be robust enough to absorb bulk of the forces during the fuse carrier
closing and opening operations and shall not over-stress the spring contact. It shall also prohibit
accidental opening of the fuse carrier due to vibrations or impact.
12. FUSE BASE BOTTOM ASSEMBLY
12.1 The conducting parts shall be made of high strength highly conductive copper alloy and the contact
portion shall be silver plated for corrosion resistance and shall provide a low resistance current
path from the bottom fuse carrier contacts to the bottom terminal connector.
12.2 The bottom assembly shall have hinge contacts made from highly conductive, anti-corrosive
copper alloy and shall accommodate and make a firm contact with the fuse carrier
bottom assembly. The fuse carrier shall be placed easily in or lifted from The hinges without any
maneuvering. In addition, the bottom assembly shall perform the following functions :-
i) When opened manually or after fault interruption the fuse carrier shall swing through 180 o to
the vertical and its further travel shall be prevented by the fuse base bottom assembly.
ii) The fuse carrier shall be prevented from slipping out of the self locking hinges during all
operating conditions and only when the fuse carrier has reached its fully open position can it
be removed from the hinge support.
12.3 The assembly shall have an aluminium alloy terminal connector (refer clause 19).
13. FUSE CARRIER TOP ASSEMBLY
13.1 The fuse carrier top contact shall have a solid replaceable cap made from highly conductive, anti-
corrosive copper alloy and the contact portion shall be silver plated to provide a low
resistance current path from the Fuse Base Top Contact to the Fuse Link. It shall make a firm
contact with the button head of the fuse link and shall provide a protective enclosure to the fuse
link to check spreading of arc during fault interruptions.
AW
13.2 The fuse carrier shall be provided with a cast bronze opening eye (pull ring) suitable for operation
with a hook stick from the ground level to pull-out or close-in the fuse carrier by manual
operation.
14. FUSE CARRIER BOTTOM ASSEMBLY
14.1 The fuse carrier bottom assembly shall be made of bronze castings with silver plating at the contact
points to efficiently transfer current to fuse base. It shall make smooth contact with the fuse base
bottom assembly during closing operation.
14.2 The bottom assembly shall have a lifting eye for the hook stick for removing or replacing the fuse
carrier.
14.3 The bottom assembly shall have a suitable ejector which shall perform the following functions :
i) It shall keep the fuse link in the centre of fuse tube and keep it tensioned under all operating
conditions.
ii) It shall be capable of absorbing the shock when the fuse carrier is pushed into the closed
position and shall not allow the fuse link to be damaged. This is specially important when the
fuse link is of low-ampere rating.
iii) The ejector at the instant of interruption shall retain the fuse carrier in the closed position long
enough to ensure that the arc is extinguished within the fuse tube thereby excluding the
possibility of arcing and subsequent damage at the contact surfaces.
iv) The ejector shall help the fuse link separation after fault interruption, allowing the fuse carrier to
drop out and clearing the pigtail of the blown fuse link through the bore of fuse tube.
15. FUSE BASE (PORCELAIN)
The fuse base shall be a bird-proof, single unit porcelain insulator with a creepage distance (to
earth) not less than 320mm. The top and bottom assemblies as also the middle clamping
hardwares shall be either embedded in the porcelain insulator with sulphur cement or suitably
clamped in position. For embedded components, the pull out strength should be such as to result
in breaking of the porcelain before pull out occurs in a test. For porcelain insulators, the beam
strength shall not be less than 1000 Kg.
16. FUSE TUBE
The fuse tube shall be made of fibre glass coated with ultraviolet inhibitor on the outer surface
and having arc quenching bone fibre liner inside. The tube shall have high bursting strength to
sustain high pressure of the gases during fault interruption. The inside diameter of the fuse tube
shall be 17.5mm. The
solid cap of the fuse carrier shall clamp the button head of the fuse link, closing the top end of
the fuse tube and allowing only the downward venting during fault interruption.
17. TYPE TESTS
The cutout shall be subjected to the following type tests :

i) Dielectric tests (rated impulse withstands and rated one minute power frequency with stand test
voltages)
ii) Temperature rise test
The above tests shall be carried out in accordance with IS:9385 Part I & II.
AW
For Porcelain Fuse Base only.
iii) Pull out test for embedded components of the fuse base
iv) Beam strength of porcelain base
18. MOUNTING ARRANGEMENT
18.1 The cutouts shall be provided with a suitable arrangement for mounting these on 75x40mm or
100x50mm channel cross arm in such a way that the centre line of the fuse base is at an angle
of 15o to 20o from the vertical and shall provide the necessary clearances from the
support. Mounting arrangement shall be made of high strength galvanised steel flat and shall be
robust enough to sustain the various stresses encountered during all operating conditions of the
cutout. For more details see enclosed figure 2.
18.2 Strength of the component marked 1 (see figure) shall be determined by clamping the member
with the shorter leg at the top to a rigid support by M-10 carriage bolts. A downward force shall be
applied along the axis of M-14
carriage bolt parallel to the longer leg and in the direction of longer leg of the member
under test. A load of 50 Kg. shall be applied and then removed to take up any slack in the
mounting arrangement before the measurement of position is taken, the permanent set
measured at the axis of the M-14 carriage bolt shall not exceed 1.6mm when a load of 425 Kg. is
applied and removed.
18.3 The strength of the M-14 bolt shall in no case be less than1900 Kg. and the strength of M-10 bolts
not less than 3500 Kg.
19. TERMINAL CONNECTIONS
The cut-out shall be provided with two aluminium alloy (alloy designation 2280 (A-11) as per IS :
617-1975) terminal connectors at top and bottom of fuse base assemblies to receive aluminium
conductors of diameters between 6.3mm to 10.05mm. These terminals shall be easily accessible
irrespective of the cut-out location with respect to the pole. The terminals shall meet the test
requirements of REC Construction Standard.
20. INSPECTION
All tests and inspection shall be made at the place of manufacture unless otherwise especially
agreed upon by the manufacturer and the purchaser at the time to purchase. The
manufacturer shall afford the inspector representing the purchaser all reasonable facilities without
charge, to satisfy him that the material is being furnished in accordance with this specification.
The purchaser has the right to have the tests carried out at his own cost by an independent agency
AW
AW
AW
11KV AUTOMATICALLY SWITCHED CAPACITOR BANKS AT SUB-STATIONS
1. SCOPE
This specification covers 3-phase, 50 Hz, out-door type Automatically Switched Shunt Capacitor
Banks intended for installation at 33/11 KV and 66/11KV sub-stations. The equipment covered in
this specification comprises (i) Capacitor Bank, (ii) Automatic Control Unit, (iii) Capacitor Switches and
(iv) Auxiliary Equipment.
Unless otherwise modified in this specification, the capacitors shall comply with latest version of
IS:2834. The other components such as Capacitor Switches, Auxiliary Equipment shall comply with the
latest version of relevant Indian Standards.
A. CAPACITOR BANKS
3. TEMPERATURE CATEGORY
The capacitor shall be suitable for upper limit of temperature category 500C as per IS:2834.
4. RATED VOLTAGE
4.1 The rated voltage of the 3-phase capacitor banks shall be12KV(phase-to-phase) and the individual
capacitor units shall be rated for 12/3 KV.
4.2 Supplier shall make extra allowance for voltage rise due to use of 6% reactors wherever provided, for
which necessary details will be provided by the purchaser.
5. RATED OUTPUT
5.1 The ratedout put of 3-phase capacitor banks shall be 600 KVAR and 1200 KVAR at the rated voltage
of 12 KV intended for use on power transformers of 3.15 MVA and 5 MVA (see Clause 14.3).
5.2 The standard basic unit rating of capacitors (single phase) shall be 200 KVAR. The units shall be
connected in star formation with floating neutral.
6. PERMISSIBLE OVER LOADS

For capacitors covered in this specification, the maximum permissible overloads with regard to
voltage, current and reactive output shall not exceed the limits specified in IS:2834.
7. POWER LOSS
The power loss in capacitors shall not exceed 0.2 watt/KVAR (subject to a tolerance of +10%).
8. DISCHARGE DEVICE
Suitable discharge device shall be connected across the capacitor unit in accordance with the provision
of IS:2834.
The discharge device shall reduce the residual voltage from the crest value of the rated voltage to 50V
or less within 5 minutes after the capacitor is disconnected from the source of supply.
9. EARTHING CONNECTIONS
The container of each capacitor unit shall be provided with suitable earthing terminal clearly marked
with "Earth" Symbol.
AX
10. PROTECTIVE FUSES

The capacitor units shall be provided with either internal or external fuses, as per standard practice of
the manufacturer. In the later case, the manufacturer shall supply the external HRC fuses together
with fixing accessories; a set of six spare fuse links shall be supplied along with each capacitor bank.

11.1 The capacitors shall be of non-PCB type, using polypropylene film as the dielectric.
11.2 Complete mounting brackets supporting insulators and all other components for formation of capacitor
bank racks shall be supplied along with the capacitor units. Necessary foundation bolts/nuts shall
also be supplied.
11.3 The outside of the capacitor container and other structures should have smooth and tidy look and
should be coated with the weather-proof, corrosion-resistant paint of white or light grey shade.
12. MARKING
The capacitor units shall be provided with a rating plate and terminal markings as stipulated in
IS:2834.
13. TESTS
The switched capacitors shall be subjected to all the type, routine and acceptance tests in
accordance with IS:2834. In addition, Endurance Test as per IEC 871-2, 1981 shall be carried out
as a type test. (This test is under consideration for adoption by BIS).
B. AUTOMATIC CONTROL UNIT (ACU)
14. SWITCHING ARRANGEMENT
14.1 The Automatic Control Unit shall be provided inside the control room to continuously monitor total load
KVAR on secondary side of the transformer and shall automatically switch ON or switch OFF the
capacitor banks through the operation of 11KV Capacitor Switch in accordance with
the parameters given in clause 14.3. Overriding provision shall also be made for electrical switching
ON or OFF of the capacitor switch by the operator from the ACU panel.
14.2 In the case of 3.15 MVA transformer, the capacitor banks will be controlled by two 11KV automatic
capacitor switches each controlling a 600 KVAR bank. For 5 MVA transformer, the capacitor banks will
be controlled by two 11KV automatic switches; the 1st switch controlling 600 KVAR bank and the 2nd
switch controlling 1200 KVAR bank.
AX
14.3 The following scheme shall be adopted for automatic operation of 11KV capacitor switches/capacitor
banks:
S.No Transformer Capacitor Capacity Status of Status of
Capacity Bank Size to be capacitor Capacitor
Switched switches when Switches when
on load KVAR on load KVAR drops
transformer to
reaches
1 2 3 4 5 6
1 1x3.15MVA 1200 KVAR 600 KVAR 700 KVAR (Switch-I 600 KVAR (Switches
split into ON, Switch-II OFF) I & II OFF)
600 KVAR
+
600 KVAR 1200 KVAR 1300KVAR 1200 KVAR (Switch-
(Switches-I&II ON) II OFF, Switch-I
ON).
2 1x5 MVA 1800 KVAR 600 KVAR 700 KVAR(Switch-I
split into ON, Switch-II OFF) 600 KVAR (Switches-
600 KVAR I & II OFF)
+
1200 KVAR 1200 KVAR 1300 KVAR(Switch-I
OFF, Switch-II ON) 1200 KVAR (Switch-
II OFF, Switch-I ON)
1800 KVAR 1900 KVAR
(Switches-I & II ON) 1800 KVAR (Switch-I
OFF, Switch-II ON)
NOTE :
1. For more than one transformer, a separate capacitor bank for each transformer shall be provided.
2. The required 11KV CTs and PTs for measurement of Load KVAR are normally available at the Sub-station
and will not form part of the equipment to be supplied against this Specification.
15. TIME DELAY

The switching ON operation will take place only if the KVAR value indicated in column 5 of the table in
clause No.14.3 persists (or is more) for a period of 5 minutes. The switching OFF operation will take
place if the KVAR value indicated in column 6 of the table persists (or is less) for a period
of 5 minutes. However, if the load drops to less than 80% of value specified in column 6, the
switching off operation of the relevant step will be instantaneous. In no case switching
ON operation will take place within a period of less than 5 minutes after the capacitor is switched
OFF due to any reason.
16. CONTROLS
The automatic control unit shall instantly switch OFF the capacitor switch in the following
contingencies occurring in any of the phases :
i) Voltage increases by 7% above the rated voltage of 12KV.
ii) Power Transformer current imbalance (due to single phasing and for any other reasons) between any
of the two phases exceeding 20% of the lowest current of the 3-phases.
iii) Current increases in any Capacitor unit by 30% above the rated current (only the relevant capacitor
switch will open).
AX
iv) Current between any of the two phases of the capacitor bank differs more than 15% of the lowest
current of the 3-phases (only the relevant capacitor switch will open).
NOTE: Normal automatic functioning of the Capacitor Bank will resume :

In the case of (i) above, after the excessive voltage hasdropped to 3.5% above the rated 12 KV.
and
In the case of (ii) above, the power transformer current imbalance between any two phases
reduces to 15%.
In case of (iii) & (iv) above, a suitable indication for the type of fault i.e. whether (iii) or (iv) above
will be provided on ACU Panel and the capacitor bank will not get automatically switched ON again
till the faulty condition is attended to and ACU is reset for its normal operation.
17. MONITORING FACILITY

A suitable ammeter with a selector switch to indicate the capacitor current in each phases of the
capacitor bank shall be provided on the ACU panel inside the control room. Indicating lamps will
also be provided to indicate ON & OFF status of each capacitor switch.
18. CONTROL POWER

The D.C. control voltage for operation of the ACU shall be taken from sub-
station battery. The standard D.C. control voltages at the 33/11KV Sub-station and 66/11KV Sub-
stations are 24 Volts and 110V respectively.
Note: The purchaser will clearly specify the battery voltage if voltage other than that specified
above is to be adopted.
19. TEMPERATURE VARIATION

The control equipment and associated circuitry shall be suitable for operation in a temperature range
of 00 C to (+) 550C.
20. PROTECTION OF ACU

Besides in-built protection against line surges and transient over voltages, suitable fuses shall
be provided for protection against over current. The ACU shall remain fully functional during and
after line surges and transient over voltage.
21. CONTROL UNIT CASING

Except for the terminals, the Automatic Control Unit shall be enclosed in a suitable casing so as to
avoid ingress of dust.
AX
C. 11 KV AUTOMATIC CAPACITOR SWITCH
22. SCOPE
This specification covers 11KV, 50Hz, out-door type automatic capacitor switches suitable for
switching capacitor banks of 600 KVAR and 1200 KVAR ratings or any other higher rating
specified.

Unless otherwise stipulated in this specification the capacitor switch shall comply with the latest
version of IS:9920 (AC Switches for voltages above 1000V).
24. RATED VOLTAGE

The rated voltage for the capacitor switch shall be 12KV. This represents the highest system
voltage corresponding to the nominal system voltage of 11KV.
25. RATED CURRENT

The standard rated normal current shall be 200A.
26. RATED CAPACITIVE SWITCHING CURRENT

The rated capacitive switching current shall not be less than 100 A.
Note : The capability of the switch shall also take into account the parallel switching of capacitor
bank steps.
27. RATED SHORT TIME CURRENT

The rated short time symmetrical current for 1 second shall be 10KA (rms A.C. component).
28. RATED MAKING CURRENT

The rated making current shall be 2.5 times the rms value of the a.c. component of rated short time
capacity.
29. BASIC IMPULSE LEVEL (BIL)

The rated basic impulse level of switch to earth as also across the open terminals shall be 75 KV.
30. CONTROL SUPPLY

The control power for closing the switch shall be 230V single phase AC supply. The closing
mechanism shall be suitable for a voltage variation of (+) 10% to (-) 20%.
31. DESIGN & CONSTRUCTION REQUIREMENTS
31.1 Type
The switches shall be of either vacuum or SF6 type.
31.2 The capacitor switches shall be of three phase construction and shall be suitable for remote
operation.
31.3 The capacitor switch shall be suitable for outdoor installation and shall have sealed weather proof type
construction.
AX
31.4 The capacitor switch shall be provided with a mechanical indicator to show whether the contact is in
open/closed position, locally, as also through indication on the ACU panel. Provision shall also be
made for manual closing and opening.
31.5 The metallic enclosure of the capacitor switch shall be provided with two earthing terminals
marked with the earth symbol.
31.6 The bushings provided on the switch shall have clamp type of terminals to directly receive aluminium
conductors up to 10mm diameter in both horizontal and vertical
directions. The terminal arrangement shall be such as to avoid bimetallic corrosion.
32. OPERATING MECHANISM

The operating mechanism shall be either solenoid or motor charged spring for which the control
supply shall be as per clause 30.
33. MECHANICAL AND ELECTRICAL ENDURANCE

The switch shall be capable of performing not less than 10,000 mechanical operations and 10,000
electrical operations at 100A capacitive current without getting damaged.
34. MARKING
The capacitor switch shall be provided with a legible and indelibly marked name plate with the
following :
a) Name of the manufacturer,
b) Type, designation and serial number.
c) Rated voltage and current.
d) Rated frequency.
e) Number of poles.
f) Rated short time current (symmetrical).
g) Rated making current.
h) Rated capacitive switching current.
35. TESTS
The switch shall be subjected to the following tests in accordance with the IS:9920 (Part-IV).
35.1 Type Tests

a) Tests to verify the insulation level, including withstand tests at power frequency voltages
on auxiliary equipment.
b) Tests to prove that the temperature rise of any part does not exceed the specified values.
c) Making and breaking tests including tests for the rated capacitive current
d) Tests to prove the capability of the switch to carry the rated short time current.
e) Tests to prove satisfactory operation and mechanical/electrical endurance.
f) Tests to provide satisfactory operation under ice conditions.
35.2 Routine Tests
a) Power frequency voltage dry tests.
b) Voltage tests for auxiliary circuits.
c) Measurement of the resistance of the main circuits.
d) Tests to prove satisfactory operation.
AX
D. AUXILIARY EQUIPMENT
36. CURRENT TRANSFORMER

The current transformers of suitable current ratio and burden for measuring the capacitor current
shall form part of the equipment to be supplied. These CTs shall form either an integral part of
capacitor switches or may be of separate outdoor type.
The accuracy class for the purpose of measuring the current shall be 1.0.
37. HRC FUSES

Suitable outdoor type 11KV HRC fuses along with the mounting insulators etc. to provide proper
protection for the entire installation (and also HRC fuses for protection of individual capacitor
bank step where internal fuses for capacitors are not provided) shall form part of the equipment to
be supplied. The rupturing capacity of the fuses shall be 12.5 KA.
38. SURGE ARRESTERS

5 KA, 9 KV metal oxide surge arrestor, conforming to REC Specification of 11KV and 33 KV Metal
Oxide Lighting Arrester shall be used for the entire capacitor bank for each transformer and will form
part of the equipment to be supplied.
39. INRUSH SUPRESSION SERIES REACTOR (I SSR)

Suitable Inrush Suppression Series Reactors shall be provided on each capacitor Bank steps to limit
the inrush current due to parallel switching within a safe limits.
40. SCHEMATIC DIAGRAM

A Schematic diagram showing typical arrangement of 11KV automatically switched capacitor
bank for a 5 MVA transformer at 33/11 KV sub-station is given in the Annexure.
41. INSTALLATION OPERATION & MAINTENANCE

The supplier shall provide :
i) Necessary manual on installation, operation and maintenance as also the schedule for routine testing
or check ups of all the equipment covered by the installation.
ii) List of recommended spares indicating prices and specialised test equipments required for routine
testing of the system.
42. GUIDANCE FOR PROCUREMENT

The entire equipment covered in this specification shall be covered as a single package to avoid the
problem of mismatching and responsibility for maintenance etc.
43. WARRANTY
The supplier shall guarantee satisfactory performance of the complete capacitor bank installation for
a period of 18 months from the date of supply or 12 months from the date of commissioning,
whichever is earlier. During the warranty period, all repairs/replacements shall be carried out free of
cost.
AX
44. INSPECTION
All tests and inspection shall be made at the place of manufacture unless otherwise especially
agreed upon by the manufacturer and the purchaser at the time of purchase. The manufacturer shall
afford the inspector representing the purchaser, all reasonable facilities, without charge, to satisfy
him that the material being supplied is in accordance with the specification.
The purchaser has the right to get the tests carried out at his own cost by an independent agency,
whenever there is a dispute regarding the quality of supply.
AX
AX
33 KV AND 11 KV POST INSULATOR
1 GENERAL REQUIREMENTS
I. The porcelain shall be sound and free from defects, thoroughly vitrified and smoothly glazed.
II. Unless otherwise specified the glaze shall be brown in colour. The glaze shall cover all the expose
porcelain part of the insulator except those area which serve as support or required to be left un-glazed.
III. Precaution shall be taken during design and manufacture to avoid the following:
a) Stress due to expansion and contraction which may lead to deterioration .
b) Stress concentration due to direct engagement of the porcelain with the metal fittings.
c) Retention of water in the recesses of metal fitting and
d) Shapes which do not facilitate easy cleaning by normal methods.
IV. Cement used in the construction of the post insulator shall not cause fracture by expansion or
loosening by contraction and proper care shall be taken to locate the individual parts correctly during
cementing. Further, the cement shall not give rise to chemical reaction with metal fittings and its
thickness shall be as uniform as possible.
V. All ferrous metal parts except those of stainless steel, shall be hot dip galvanized and the
uniformity of zinc coating shall satisfy the requirements of IS : 2633. The parts shall be galvanized
after mechanising . The finished galvanized surface shall be smooth.
VI. The threads of the tapped holes in the post insulators metal fittings shall be cut after giving anti-
corrosion protection and shall be protected against rest by greasing or by other similar means. All
other threads shall be cut before giving anti-corrosion protection. The tapped holes shall be suitable
for bolts with threads having anti - corrosion protection and shall confirm to IS : 4218(Part-I to VI).
The effective length of thread shall not be less than the nominal diameter of the bolt.
VII. The post insulator unit shall be assembled in a suitable jig to ensure the correct positioning of the
top and bottom metal fitting relative to one another. The faces of the metal fittings shall be parallel
and at right angles to the axis of the insulator and the corresponding holes in the top and bottom
metal fittings shall be in a vertical plan containing the axis of insulator.
2 CLASSIFICATION
The post insulators shall be of type ’B’ according to their construction, which is defined here under :
A post insulator or a post insulator unit in which the length of the shortest puncture path through
solid insulating material is less than half the length of the shortest flash over path through air outside
the insulator.
AY
3 Standard insulation levels :
I. The standard insulator levels of the post insulator or post insulator unit shall be as under :
Highest Visible Dry one minute Wet one Power frequency Impulse voltage
system discharge power frequency minute power puncture withstand test.
voltage test withstand test. frequency withstand test.
withstand test.
1.3 times the

12 KV actual dry flash
9 KV(rms) 35 KV(rms) 35 KV(rms) 75 KV peak
(rms) over voltage of
the unit(KVrms)
1.3 times the
36 KV actual dry flash
27 KV(rms) 75 KV(rms) 75 KV(rms) 170 KV peak
(rms) over voltage of
the unit(KVrms)
II. In this standard, power frequency voltage are expressed as peak values divided by 2. The impulse
voltages are expressed as peak values.
III. The withstand and flashover voltage are referred to the atmospheric condition.
4 TESTS
I. The insulators shall comply with the following constitute the type tests :
a) Visual examination.
b) Verification of dimensions.
c) Visible discharge test.
d) Impulse voltage withstand test.
e) Dry power frequency voltage withstand test.
f) Wet power frequency voltage withstand test.
g) Temperature cycle tests.
h) Mechanical strength tests.
i) Puncture test.
j) Porosity test.
k) Galvanising test.
Type test certificates for the tests carried out on prototype of same specifications shall be enclosed
with the tender and shall be subjected to the following acceptance test in the order indicated below.
AY
II. Acceptance test:
The test samples after having withstood routine test shall be subjected to the at least following
acceptance test in the order indicated below :
a) Verification of dimensions.
b) Temperature cycle tests.
c) Mechanical strength tests.
d) Puncture test.
e) Porosity test.
f) Galvanising test.
III. Routine tests:

The following shall must be covered under routine tests on each post insulator or post insulator unit.
a) Visual examination as per Cl. No.- 9.12 of IS : 2544/1973

b) Mechanical routine test as per Cl. No.- 9.14 of IS : 2544/1973
c) Electrical routine test as per Cl. No.- 9.13 of IS : 2544/1973
5 MARKING
I. Each post insulator shall be legibly and indelibly marked to show the following.
a) Name or trade mark of the manufacturer.

b) Month & year of manufacture.
c) Country of manufacture.
II. Marking on porcelain shall be printed and shall be applied before firing.
III. Post insulator or post insulator units may also be mark with I.S.I. certification mark.
6 PACKING
All post insulators shall be pack in wooden crates suitable for easy but rough handling and acceptable
for rail, transport. Where more than one insulator is packed in a crate wooden separators shall be
fixed between the insulators to keep individual insulator in position without movement within the
crate.
AY
Table-I
Highest System Voltage Minimum Creepage distance in mm

in kV
Post insulator
12 320
36 900
AY
ANNEXURE – A
1 Hydraulic Internal Pressure Test on Shells (if applicable)
The test shall be carried out on 100% disc strain insulator shells before assembly. The details regarding test
will be as discussed and mutually agreed to by the Contractor and Owner in Quality Assurance Programme.
2 Thermal Mechanical Performance Test
Thermal Mechanical Performance Test shall be performed in accordance with IEC-383-1-1993 Clause 20
with the following modifications:
value.
(a) X greater than or equal to R+ 3S.

Where,
X Mean value of the individual mechanical failing load.
R Rated electro-mechanical / mechanical failing load.
S Standard deviation.
(c) The individual electromechanical failing load shall be at least equal to the rated value. Also puncture
shall not occur before the ultimate fracture.
3 Electromechanical/Mechanical Failing Load Test.
This test shall be performed in accordance with clause 18 and 19 of IEC 383 with the following acceptance
(i) X greater than or equal to R + 3S

Where,
X Mean value of the electro-mechanical/mechanical/ failing load.
R Rated electro-mechanical / mechanical failing load.
S Standard deviation.
4 Chemical Analysis of Zinc used for Galvanizing
Samples taken from the zinc ingot shall be chemically analysed as per IS:209. The purity of zinc shall not
be less than 99.95%.
AY
5 Tests for Forgings
The chemical analysis, hardness tests and magnetic particle inclusion test for forgings, will be as per the
internationally recognised 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 Contractor
and Owner in Quality Assurance Programme.
6 Tests on Castings
The chemical analysis, mechanical and metallographic tests and magnetic particle inclusion for castings will
be as per the internationally recognised procedures for these tests. The samplings will be based on heat
number and heat treatment batch. The details regarding test will be as discussed and mutually agreed to
by the Contractor and Owner in Quality Assurance Programme.
AY
CLAMPS & CONNECTORS
CLAMPS & CONNECTORS: Clamps & connectors shall conform to IS: 5561. The clamps and connectors shall be made
of materials listed below:
For connecting ACSR conductors Aluminium alloy casting, conforming to designation A6 of IS: 617 and
shall be tested for all tests as per IS: 617
For connecting equipment terminals made Bimetallic connectors made from aluminium alloy casting conforming
of copper with ACSR conductor to designation A6 of IS:617 with 2mm thick Bimetallic liner and shall
be tested as per IS:617
For connecting GS shield wire Galvanised mild steel
Bolts, Nuts & plain washers Hot dip galvanised mild steel for sizes M12 and above, and electro-
galvanised for sizes below M12
Spring washers for items ‘a’ to ‘c’ Electro-galvanised mild steel suitable for at
least service condition 4 as per IS:1573
All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and corners shall be
blurred and rounded off.
No current carrying part of a clamp or connector shall be less than 10 mm thick. They shall be designed and
manufactured to have minimum contact resistance.
For Bimetallic clamps or connectors, copper alloy liner of minimum 2 mm thickness shall be provided.
Flexible connectors, braids or laminated strips made up of copper/ aluminium for the terminal clamps for equipment
shall be suitable for both expansion or through (fixed/ sliding) type connection of IPS Aluminium tube as required. In
both the cases the clamp height (top of the mounting pad to center line of the tube) should be same.
Size of the terminal/conductor for which the clamp/connector is suitable shall be embossed/punched (i.e. indelibly
marked) on each components of the clamp/ connector, except on the hardware.
Clamp shall be designed to carry the same current as the conductor and the temperature rise shall be equal or less
than that of the conductor at the specified ambient temperature. The rated current for which the clamp/ connector is
designed with respect to the specified reference ambient temperature, shall also be indelibly marked on each
component of the clamp/connector, except on the hardware.
Clamps and connector shall be designed corona controlled.
Clamps & connectors shall conform to type tests and shall be subjected to routine and acceptance tests on minimum 3
samples per lot as per IS: 5561. Type tests report for all clamps and connectors for temperature rise test, tensile test,
shall be furnished by the Contractor.
AZ
EPOXY BASED PROTECTIVE PAINT

1. SCOPE
This specification covers the requirement of self-priming epoxy-based protective paint both for new and
old steel structures such as poles, sub-station structures etc.
2. COMPOSITION
The paint shall be epoxy-based with metallic zinc as an essential component. The paint shall be
supplied in two components and shall be suitable for a single coat application. It shall have such
composition as to satisfy the requirements of this standard. The mixing ratio (base-to-
accelerator) shall be specified by the manufacturer.
3. REQUIREMENTS
3.1 Volume Solids 85% (±)3%

3.2 Theoretical covering Capacity 6.5 sq. mtrs. per litre at 125 microns dry film
thickness
3.3 Weight per 10 litres of mixed paint 14 to 15 Kg. (±) 0.3 kg
3.4 Drying time (at 30 OC) dry Surface : Not more than 4 hours
Hard Dry : 16-18 hours
Recoating Time: 16-18 hours
Curing time : 7 days
3.5 Scratch hardness (with 1.5 kg.load) No such scratch as to show the base metal
3.6 Finish Smooth and semi-glossy

3.7 Colour Ash Grey or Aluminium (as required)
3.8 Dry Film Thickness The paint shall develop a dry film of minimum 100-
125 microns in a single coat(measured by Elcometer)
3.9 Flash point Not below 40 OC

3.10 Flexibility and adhesion The paint shall not show damage, detachment
or cracking.
3.11 Resistance to humidity Shall pass 1000 hours (minimum) at 125 microns D.F.T
3.12 Resistance to lubricating Shall show no sign of permanent injury

oil petroleum, hydrocarbon
solvent,petrol and heat
4. STORAGE LIFE & POT LIFE
Minimum 6 months from the date of manufacture in original sealed

4.1 Storage life
container under normal covered storage conditions
O
4.2 Pot life (at 30 C) Not less than 4 hours
5. DURABILITY
Under severe surface conditions, paint shall protect the substrate at least for 5 years, if it is wire-
brushed/power tool cleaned and 7 years for commercially grit-blasted steel sub-strate.
6. SURFACE PREPARATION
If possible, the surface on which the paint has to be applied shall be cleaned by grit blasting,
otherwise manual wire brushing or power tool cleaning process may be used as convenient.
BA
7. METHOD OF APPLICATION
Brushing, rollers or spraying.
8. TESTS
The following tests shall be carried out in accordance with the procedure given in the Indian Standard
quoted against each, except requirements stipulated in clauses 3.1 and 3.2 which shall be tested in
accordance with the procedure indicated in Annexure-II; preparation of painted panels for conducting
different tests shall be done as given in Annexure-I.
8.1 Requirement stipulated in clauses 3.3 to 3.12 - IS:101
8.2 Resistance to Salt Spray
Shall pass 1000 hours (minimum with 200 microns D.F.T.) - IS:2074
8.3 Chemical Resistance
Shall be resistant to acid/alkaline chemicals or solvents - IS:8662
9. PACKAGE
Unless otherwise specified by the purchaser, the paint shall be normally supplied in 2 litre packs.
BA
Annexure – I
DETAILS OF PREPARATION OF PAINTED PANELS FOR TESTING EPOXY BASED
PROTECTIVE PAINT ( TWO PACKS)
S. Test Type Size in mm Painting Dry Film Method of Duration of Special

N. of Details Thickness Application air drying Instructio
Metal before ns
commencem
ent of test
1 2 3 4 5 6 7 8 9
1 Drying Time Mild 150x100x1.25 One coat of 100 Brush /Spray - -
Steel Epoxy based
protective paint
2 Finish -do– -do – -do – -do – 48 hours

-do -
3 Colour -do – -do – -do- -do – 24 hours

-do –
-
4 Dry Film -do – -do- -do – -do – 24 hours
-do –
Thickness
-
5 150x150x0.31 -do – -do- -do- 7 days -

Flexibility Tinne
and adhesion 5
d
-
Scratch
6 -do – -do- -do – -do – -do –
Hardness -do –
7 Resistance to 150x150x1.25 -do – 200 -do – 7 days Apply a

Mild
Salt Spray load of 1.5
Steel
Kgs.
Instead of
1 kg. As
8 Protection - do - -do- 125 - do - - do - specified in
- do -
against Col.15.1 of
corrosion IS: 101 –
under 64
conditions of -
condensation
BA
ANNEXURE-II
Procedure for determining volume solids
1. Scope :
This method is applicable to the determination of the volume non-volatile matter of paint coatings.
2. Significance :
This method is intended to provide a measure of the volume of dry coating obtainable from a
given volume of liquid coating. This volume is considered to be the most equitable means of comparing
the coverage (square metre of surface covered at a specific film thickness per unit volume) and also
for calculating the wet film thickness of the given paint.
3. Apparatus
i) Analytical Balance
ii) Steel disc : Preferably stainless steel, 60mm dia, and 0.70mm thickness with a small hole 2 to
3mm from the edge. A fine wire such as chromel is attached through the hole and made of the
appropriate length for suspending the disc in a liquid.
iii) Weight Box
iv) Beaker : 1 litre for weighing the disc in liquid.
v) Weight per litre cup for determining the specific gravity of the paint material and of the suspending
liquid if not known.
vi) Oven
4. Procedure
i) Dry the disk in an oven at 1050C for 10 minutes and cool.
ii) Weigh the disk in air, let it be W1 grams.
iii) Suspend the disk in water and weigh again. Let it be W2 grams.
iv) Calculate the volume of disk ‘V’ as follows:
V = W1-W2/d where ‘d’ is the density of the water at room temperature
v) Determine the weight of non-volatile content per gram of the liquid coating material by drying a
known amount of paint at 1050C for 3 hours. Let it be ‘W’ grams.
vi) Determine the specific gravity of the paint to the nearest 0.001 g/ml. by using weight per liter
cup. Let it be ‘p’.
vii) Dip the disk in the paint sample for 10 minutes, and take out the disc and allow the excess coating
material to drain off. Blot the coating material off the bottom edge of the disc so that beads or drops
do not dry on the bottom edge of the disc.
viii) Dry the disc in oven for 3 hours at 1050 C and cool.
ix) Weigh the coated disc in air. Let it be W3 grams.
x) Suspend the coated disc in water and weigh it. Let it be W4 grams.
xi) Calculate the volume of the coated disc as follows:
V1 = W3-W4/d, where ‘d’ is the density of the water at room temperature.
BA
xii) Calculate the volume of the dried coating as follows:
Volume of dried coating (Vd) = V1-V
xiii) Calculate the volume of the wet coating as follows:
Vw = W3-W1/WxP, where W = grams of non volatile matter in one gram of wet coating
P= Specific gravity of the paint.
xiv) Calculate the percentage volume solids of the paints as follows:
= V1 – Vx100 or Vdx100
Vw Vw
The volume of non volatile matter or the percentage volume solids of a paint is related to the covering
capacity and film thickness in the following manner:
a) Theoretical Coverage (m2/1) = % volume solids x 10
Dry film thickness (in microns)
b) Wet film thickness (in microns) = Dry Film thickness x 100 (in microns)
% volume solids.
BA
FIRE FIGHTING EQUIPMENTS
DRY CHEMICAL POWDER TYPE FIRE-EXTINGUISHERS:
Capacity 5 Kgs. Complete in all respects conforming to IS 2171/1976. Fitted with adequate length of high
pressure discharge house with control nozzle. Body of welded construction and specially treated to withstand
internal and external corrosion with easily detachable specially designed CO 2. Charged, mounted on trolley
with rubber-solid wheels as per suitability of size of equipment. Complete with first charge. The extinguisher
should be refillable on the spot.
CO2 GAS TYPE FIRE-EXTINGUISHERS
Capacity 2 Kg. complete in all respects conforming to IS:2878/1976. Fitted with adequate length of high
pressure discharge hose and horn with control nozzle. Complete with first charge.
BB
HIGH TENSILE STEEL WIRES FOR PCC POLES

1. SCOPE
This specification covers the requirements of indented type High Tensile Steel Wires for manufacturer of
PCC Poles.
Except when it conflicts with the specific requirements of this Specification, the wires shall comply
with the provisions made in IS:6003/1983 (Specification for Indented Wires for pre-stressed Concrete).
3. NOMINAL SIZES
The nominal diameter of the finished wires shall be 4mm and 5mm, as required.
4. TOLERANCE
4.1 The tolerance on the nominal diameter shall be (+) 2% to (-) 1%.
4.2 The diameter shall be determined with a micro-meter by taking two measurements at right angles to
each other at three places along a length of not less than 250mm and the average of
these six measurements shall be taken as the diameter of the wire.
4.3 As indenting is done after drawing, there are chances of the material being compressed at the points of
indenting. In taking the measurement of diameter, such points shall be avoided to enable correct
measurement.
5. MANUFACTURE AND CHEMICAL COMPOSITION
5.1 The wires shall be cold drawn from steel made by the open hearth, electric duplex, acid Bessemer,
basic oxygen or a combination of these processes.
5.2 The chemical composition and manufacturing details shall conform to IS:6003.
6. MECHANICAL PROPERTIES
6.1 Tensile Strength
Unless otherwise agreed to between the purchaser and the supplier, the minimum specified tensile
strength of wires shall be as given below :
Nominal Dia (mm) Tensile strength (Min) (N/mm2)
4 1715
5 1570
6.2 Proof Stress
The proof stress of the wires shall be not less than 85% of its minimum specified tensile strength.
6.3 Ductility
The wires shall withstand the reverse bend test specified in IS:6003.
6.4 Elongation after fracture
Elongation after fracture over a gauge length of 200mm shall be as follows :

Nominal Dia (mm) Elongation % (Min.) (Gauge length 200mm)
4 3
5 4
BC
6.5 Relaxation Stress
The relaxation stress in the wires shall not exceed the provision of IS:6003-1983. Alternatively, the
manufacturer shall provide proof that the quality of wires supplied is such as to comply with this
requirement.
6.6 Stress Corrosion
The manufacturer shall provide proof that the quality of wires supplied is such that it is
not susceptible to stress corrosion.
7. SELECTION OF TEST PIECES

7.1 All test pieces of wires of sufficient length for specified tests shall be selected either from.
a) the cuttings of length of wires or ends of coils of wires;
or
b) from the coil or a length of wire, after it has been cut to the required or specified length and the test
pieces taken from any part of it.
7.2 A test piece shall be detached from the coil or length or wires only in the presence of the purchaser
or his authorised representative.
7.3 Before the test pieces are selected, the manufacturer shall furnish the purchaser with copies of the mill
record giving the number of coils or bundles in each cast with sizes as well as identification marks
whereby each coil or bundle of wire can be identified.
7.4 Test samples shall not be subjected to any form of heat treatment. Any straightening which the test
sample may require shall be done cold.
8. TESTS
The following tests shall be carried out in accordance with IS:6003.
i) Tensile test
ii) Test for proof stress
iii) Reverse bend test
iv) Test for elongation after fracture
v) Test for relaxation stress
9. SAMPLING AND CRITERIA FOR CONFORMITY

The details for sampling and criteria for conformity shall be as per IS:6003.
10. MARKING
The following information shall be tagged to each coil :
i) Manufacturer’s name
ii) Purchaser’s name
iii) Trade Mark, if any
iv) Year of manufacturing
v) Coil identification number
vi) Sizes of wire
vii) Length of wire
BC
MID SPAN COMPRESSION JOINT AND REPAIR SLEEVE
1.0 Mid Span Compression Joint
1.1 Mid Span Compression Joint shall be used for joining two lengths of conductor. The joint shall have a
resistivity less than 75% of the resistivity of equivalent length of conductor. The joint shall not permit slipping off,
damage to or failure of the complete conductor or any part thereof at a load less than 95% of the ultimate tensile
strength of the conductor.
1.2 In ACSR conductors, the joint shall be made of steel and Aluminium for jointing the steel core and Aluminium
respectively. The steel sleeve should not crack or fail during compression. The Brinnel Hardness of steel sleeve shall
not exceed 200. The steel sleeve shall be hot dip galvanised. The Aluminium shall have Aluminium/alloy. Aluminium
plugs shall also be provided on the line of demarcation between compression and non compression zone.
2.0 Repair Sleeve
Repair Sleeve of compression type shall be used to repair conductor with not more than two strands broken
in the outer layer. The sleeve shall be manufactured from Aluminium and shall have a smooth surface. The repair
sleeve shall comprise of two pieces with a provision of seat for sliding of the keeper piece. The edges of the seat as
well as the keeper piece shall be so rounded that the conductor strands are not damaged during installation.
3.0 Material and Workmanship
3.1 All the equipment shall be of the latest proven design and conform to the best modern practices adopted in
the power line field. The Bidder shall offer only such equipment as guaranteed by him to be satisfactory and suitable
for 11/33 kV transmission line application and will give continued good performance.
3.2 The design, manufacturing process and quality control of all the materials shall be such as to achieve
requisite factor of safety for maximum working load, highest mobility, elimination of sharp edges and corners, best
resistance to corrosion and a good finish.
3.3 All ferrous parts shall be hot dip galvanised, after all machining has been completed. Nuts may, however, be
tapped (threaded) after galvanising and the threads oiled. Spring washers shall be electro galvanized as per grade 4
of IS-1573-1970. The bolt threads shall be undercut to take care of increase in diameter due to galvanising.
Galvanising shall be done in accordance with IS:2629-1985 / IS-1367 (Part-13) and satisfy the tests mentioned in IS-
2633-1986. Fasteners shall withstand four dips while spring washers shall withstand three dips. Other galvanised
materials shall have a minimum over range coating of Zinc equivalent to 600 gm/sq.m and shall be guaranteed to
withstand at least six dips each lasting one minute under the standard Peerce test for galvanising unless otherwise
specified.
3.4 The zinc coating shall be perfectly adherent, of uniform thickness, smooth, reasonably bright, continuous and
free from imperfections such as flux, ash, rust stains, bulky white deposits and blisters. The zinc used for galvanising
shall be of grade Zn.99.95 as per IS:209.
BD
3.5 In case of castings, the same shall be free from all internal defects like shrinkage, inclusion, blow holes.
cracks etc.
3.6 All current carrying parts shall be so designed and manufactured that contact resistance is reduced to
minimum and localised heating phenomenon is averted.
3.7 No equipment shall have sharp ends or edges, abrasions or projections and shall not cause any damage to
the conductor in any way during erection or during continuous operation which would produce high electrical and
mechanical stresses in normal working. The design of adjacent metal parts and mating surfaces shall be such as to
prevent corrosion of the contact surface and to maintain good electrical contact under all service conditions.
3.8 Particular care shall be taken during manufacture and subsequent handling to ensure smooth surface free
from abrasion or cuts.
3.9 The fasteners shall conform to the requirements of IS:6639-1972. All fasteners and clamps shall have corona
free locking arrangement to guard against vibration loosening.
4.0 Compression Markings
Die compression areas shall be clearly marked on each equipment designed for continuous die
compressions and shall bear the words ‘COMPRESS FIRST’ ‘suitably inscribed on each equipment where the
compression begins. If the equipment is designed for intermittent die compressions, it shall bear the identification
marks ‘COMPRESSION ZONE’ and ‘NON-COMPRESSION ZONE’ distinctly with arrow marks showing the direction of
compression and knurling marks showing the end of the zones. The letters, number and other markings on finished
equipment shall be distinct and legible.
5.0 Bid Drawings
5.1 The Bidder shall furnish detailed dimensioned drawings of the equipments and all component parts. Each
drawing shall be identified by a drawing number and Contract number. All drawings shall be neatly arranged. All
drafting and lettering shall be legible. The minimum size of lettering shall be 3 mm. All dimensions and dimensional
tolerances shall be mentioned in mm.
5.2 The drawings shall include
(i) Dimensions and dimensional tolerances
(ii) Material. Fabrication details including any weld details and any specified finishes and coatings.
Regarding material, designations and reference of standards are to be indicated.
(iii) Catalogue No.
(iv) Marking
(v) Weight of assembly
(vi) Installation instructions
(vii) Design installation torque for the bolt or cap screw
BD
(viii) Withstand torque that may be applied to the bolt or cap screw without failure of component parts
(ix) The compression die number with recommended compression pressure.
(x) All other relevant technical details
5.3 The above drawings shall be submitted in five copies with all the
details as stated above along with the bid document. After the placement of award. The Contractor shall again
submit the drawings in four copies to the Owner for approval. After Owner’s approval and successful completion of
all type tests, 20 (twenty) more sets of drawings shall be submitted to Owner for further distribution and field use at
Owner’s end.
6.0 Tests
6.1 Type Tests
6.1.1 Mid Span Compression Joint for Conductor
(a) Chemical analysis of materials ( as per Annexure – A)
(b) Electrical resistance test
(c) Heating cycle test
(d) Slip strength test
6.1.2 Repair Sleeve for Conductor
(a) Chemical analysis of materials
6.1.3 Flexible Copper Bond
(a) Slip Strength Test ( as per Annexure – A)
6.2 Acceptance Tests
6.2.1 Mid Span Comprression Joint for Conductor and Earthwire
(a) Visual examination and dimensional verification
(b) Galvanising test

(c) Hardness test
6.2.2 Repair Sleeve for Conductor
6.2.3 Flexible Copper Bond
(b) Slip strength test
BD
6.3 Routine Tests
6.4 Tests During Manufacture
On all components as applicable
(a) Chemical analysis of Zinc used for )

galvanising )
(b) Chemical analysis mechanical metallo- )

graphic test and magnetic particle ) As per Annexure-A
inspection for malleable castings )
(c) Chemical analysis, hardness tests and )

magnetic particle inspection for forgings )
7.0 Tests and Standards
7.1 Testing Expenses
7.1.1 Testing charges for all type tests shall be included in the quoted ex-works price.
7.1.2 In case of failure in any type test. the Bidder whose material has failed is either required to modify the
design of the material & successfully carryout all the type tests as has been detailed out in this specification or to
repeat that particular type test at least three times successfully at his own expenses.
7.1.3 Bidder shall indicate the laboratories in which they proposes to conduct the type tests. They shall ensure
that adequate facilities for conducting the tests are available in the laboratory and the tests can be completed in
these laboratories within the time schedule guaranteed by them in the appropriate schedule.
7.1.4 The entire cost of testing for acceptance and routine tests and tests during manufacture specified herein
shall be treated as included in the quoted Ex-works Price.
7.1.5 In case of failure in any type test, repeat type tests are required to be conducted, then, all the expenses for
deputation of Inspector/Owner's representative shall be deducted from the contract price. Also if on receipt of the
Contractor's notice of testing, the Owner's representative/Inspector does not find 'plant' to be ready for testing the
expenses incurred by the Owner for redeputation shall be deducted from contract price.
7.1.6 The Contractor shall intimate the Owner about carrying out of the type tests alongwith detailed testing
programme at least 3 weeks in advance of the scheduled date of testing during which the Owner will arrange to
depute his representative to be present at the time of carrying out the tests.
BD
8.0 Sample Batch For Type Testing
8.1 The Contractor shall offer material for sample selection for type testing only after getting Quality Assurance
Programme approved by the Owner. The Contractor shall offer at least three times the quantity of materials
required for conducting all the type tests for sample selection. The sample for type testing will be manufactured
strictly in accordance with the Quality Assurance Programme approved by the Owner.
8.2 Before sample selection for type testing the Contractor shall be required to conduct all the acceptance tests
successfully in presence of Owner’s representative.
9.0 Schedule of Testing and Additional Tests
9.1 The Bidder has to indicate the schedule of following activities in their bids
(a) Submission of drawing for approval.
(b) Submission of Quality Assurance programme for approval.
(c) Offering of material for sample selection for type tests.
(d) Type testing.
9.2 The Owner reserves the right of having at his own expense 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.
9.3 The Owner also reserves the right to conduct all the tests mentioned in this specification at his own expense
on the samples drawn from the site at Contractor’s premises or at any other test centre. In case of evidence of non
compliance, it shall be binding on the part of Contractor to prove the compliance of the items to the technical
specifications by repeat tests, or correction of deficiencies, or replacement of defective items, all without any extra
cost to the Owner.
10 Test Reports
10.1 Copies of type test reports shall be furnished in atleast six copies alongwith one original. One copy shall
be returned duly certified by the Owner, only after which the commercial production of the concerned material shall
start.
10.2 Copies of acceptance test report shall be furnished in atleast six copies. One copy shall be returned, duly
certified by the Owner, only after which the materials will be despatched.
10.3 Record of routine test report shall be maintained by the Contractor at his works for periodic inspection by
the Owner’s representative.
10.4 Test certificates of tests during manufacture shall be maintained by the Contractor. These shall be
produced for verification as and when desired by the Owner.
BD
11.0 Inspection
11.1 The Owner’s representative shall at all times be entitled to have access to the works and all places of
manufacture, where the material and/or its component parts shall be manufactured and the representatives shall
have full facilities for unrestricted inspection of the Contractor’s, sub-Contractor’s works raw materials.
manufacturer’s of all the material and for conducting necessary tests as detailed herein.
11.2 The material for final inspection shall be offered by the Contractor only under packed condition. The
engineer shall select samples at random from the packed lot for carrying out acceptance tests.
11.3 The Contractor shall keep the Owner informed in advance of the time of starting and of the progress of
manufacture of material in its various stages so that arrangements could be made for inspection.
11.4 Material shall not be despatched from its point of manufacture before it has been satisfactorily inspected and
tested unless the inspection is waived off by the Owner in writing. In the latter case also the material shall be
despatched only after all tests specified herein have been satisfactorily completed.
11.5 The acceptance of any quantity of material shall in no way relieve the Contractor of his responsibility for
meeting all the requirements of the Specification, and shall not prevent subsequent rejection, if such material are
later found to be defective.
12.0 Packing and Marking
12.1 All material shall be packed in strong and weather resistant wooden cases/crates. The gross weight of the
packing shall not normally exceed 50 Kg to avoid handling problems.
12.2 The packing shall be of sufficient strength to withstand rough handling during transit, storage at site and
subsequent handling in the field.
12.3 Suitable cushioning, protective padding, dunnage or spacers shall be provided to prevent damage or
deformation during transit and handling.
12.4 Bolts, nuts, washers, cotter pins, security clips and split pins etc. shall be packed duly installed and
assembled with the respective parts and suitable measures shall be used to prevent their loss.
12.5 Each component part shall be legibly and indelibly marked with trade mark of the manufacturer and year of
manufacture.
12.6 All the packing cases shall be marked legibly and correctly so as to ensure safe arrival at their destination
and to avoid the possibility of goods being lost or wrongly despatched on account of faulty packing and faulty or
illegible markings. Each wooden case/crate shall have all the markings stencilled on it in indelible ink.
13.0 Standards
13.1 The Hardware fittings, conductor and earthwire accessories shall conform to the following
Indian/International Standards which shall mean latest revisions, with amendments/changes adopted and published,
unless specifically stated otherwise in the Specification.
BD
13.2 In The Event Of The Supply Of Hardware Fittings; Conductor And Earth wire Accessories Conforming To
Standards Other Than Specified, The Bidder Shall Confirm In His Bid That These Standards Are Equivalent To Those
Specified. In Case Of Award, Salient Features Of Comparison Between The Standards Proposed By The Contractor
And Those Specified In This Document Will Be Provided By The Contractor To Establish Their Equivalence.
——————————————————————————————————————————
Sl. Indian Title International
No. Standard Standards
——————————————————————————————————————————
1. IS : 209-1992 Specification for Zinc BS:3436-1986
2. IS 1573-1991 Electroplated Coating of
Zinc on iron and steel
3. IS : 2121-1981 Specification for Conductor
and Earthwire Accessories for
Overhead Power lines
Part-I Mid-span Joints and Repair
Sleeves for Conductors
4. IS:2486 Specification for Insulator
Fittings for Overhead power
Lines with Nominal Voltage
greater than 1000 V
Part-I.1993 General Requirements
and Tests
5. IS:2629-1990 Recommended Practice
for Hot Dip Galvanising
of Iron and Steel
6. IS:2633-1990 Method of Testing
Uniformity of Coating on
Zinc Coated Articles
———————————————————————————————
BD
ANNEXURE – A
1.0 TESTS ON HARDWARE FITTINGS
1.1 Galvanising/Electroplating Test
The test shall be carried out as per Clause no. 5.9 of IS:2486-(Part-1) - 1972 except that both uniformity of
zinc coating and standard preecee test shall be carried out and the results obtained shall satisfy the
requirements of this specification.
1.2 Mechanical Strength Test of Each Component
Each component shall be subjected to a load equal to the specified minimum ultimate tensile strength (UTS)
which shall be increased at a steady rate to 67% of the minimum UTS specified. The load shall be held for
five minutes and then removed. The component shall then again be loaded to 50% of UTS and the load shall
be further increased at a steady rate till the specified UTS and held for one minute. No fracture should occur.
The applied load shall then be increased until the failing load is reached and the value recorded.
1.3 Mechanical Strength Test of Welded Joint
The welded portion of the component shall be subjected to a Load of 2000 kgs for one minute. Thereafter, it
shall be subjected to die-penetration/ ultrasonic test. There shall not be any crack at the welded portion.
1.4 Clamp Slip Strength Vs Torque Test for Suspension Clamp
The suspension assembly shall be vertically suspended by means of a flexible attachment. A suitable length
of Conductor shall be fixed in the clamp. The clamp slip strength at various tightening torques shall be
obtained by gradually applying the load at one end of the conductor. The Clamp slip strength vs torque curve
shall be drawn. The clamp slip strength at the recommended tightening torque shall be more than 12.5%
but less than 20% of conductor rated strength.
2.0 TESTS ON CONDUCTOR AND EARTHWIRE ACCESSORIES
2.1 Mid Span Compression Joint for Conductor and Earthwire
(a) Slip Strength Test
The fitting compressed on conductor/earthwire shall not be less than one metre in length. The test shall be
carried out as per IS:2121 (Part-II)- clause 6.4 except that the load shall be steadily increased to 95% of
minimum ultimate tensile strength of conductor/earthwire and retained for one minute at this load. There
shall be no movement of the conductor/ earthwire relative to the fittings and no failure of the fittings during
this one minute period.
(b) Hardness Test
The Brinnel hardness at various points on the steel sleeve of conductor core and of the earthwire
compression joint and tension clamp shall be measured.
BD
2.2 Flexible Copper Bond
a) Slip Strength Test
On applying a load of 3 kN between the two ends, stranded flexible copper cable shall not come out of the
connecting lugs and none of its strands shall be damaged. After the test, the lugs shall be cut open to
ascertain that the gripping of cable has not been affected.
2.3 Chemical Analysis Test
Chemical analysis of the material used for manufacture of items shall be conducted to check the
conformity of the same with Technical Specification and approved drawing.
3.0 TESTS ON ALL COMPONENTS (AS APPLICABLE)
3.1 Chemical Analysis of Zinc used for Galvanizing
Samples taken from the zinc ingot shall be chemically analysed as per IS-209. The purity of zinc shall not
be less than 99.95%.
3.2 Tests for Forgings
The chemical analysis hardness tests and magnetic particle inspection for forgings, will be as per the
internationally recognised 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
Contractor and Owner in Quality Assurance Programme.
3.3 Tests on Castings
The chemical analysis, mechanical and metallographic tests and magnetic particle inspection for castings
will be as per the internationally recognised procedures for these tests. The samplings will be based on
heat number and heat treatment batch. The details regarding test will be as discussed and mutually
agreed to by the Contractor and Owner in Quality Assurance Programme.
BD
MILD STEEL CHANNEL, ANGLE AND FLAT
1) APPLICABLE STANDARDS:
The mild steel shall conform to IS: 2062 grade ‘a’ modified upto date or equivalent international standard for
steel materials, documents for which shall be made available at the time of inspection to the owner’s
representative.
2) GENERAL REQUIREMENTS:
Material shall be supplied as per the following sizes:
100x50 ISMC channel conforming to IS: 2062 grade ‘a’ modified upto date or its equivalent International
Standard having length ranging from 5.5 to 13.5 meters. 75x40 ISMC channel conforming to IS: 2062 grade ‘a’
modified upto date or its equivalent International Standard having length ranging from 5.5 to 135 meters.
50x50x8 mm or 6 mm ISA angles conforming to IS: 2062 grade ‘a’ modified upto date or its equivalent
international standard having length ranging from 5.5 to 13.5 meters.
45X45X5 mm ISA angles conforming to IS: 2062 grade ‘a’ modified upto date or its equivalent international
standard having length ranging from 5.5 to 13.5 meters.
60x65x6 mm ISA angles conforming to IS: 2062 grade ‘a’ modified upto date or its equivalent international
standard having length ranging from 5.5 to 13.5 meters.
50x8 flats conforming to IS: 2062 grade ‘a’ modified upto date or its equivalent international standard having
length ranging from 5.5 to 9.5 meters.
3) GALVANISATION:
All above steel members shall be fabricated as per approved drawing having smooth edge, drilled
circular/elliptical holes of suitable measurements.
All structural steel members and bolts shall be galvanized as per IS:4759 and zinc coating shall not be less than
610gm/sq. meter for all structural steel members. All weld shall be 6mm filled weld unless specified otherwise.
All nuts and bolt shall be of property class 5.6 of IS 1367. Plain washers shall be as per IS 2016 and spring
washers shall be IS:3063
4) INSPECTION:
All inspection/test will be carried out by representative of owner.
All tests and inspection shall be made at the place of manufacturer unless otherwise specially agreed upon by
the manufacturer and the owner. The manufacturer shall provide all reasonable facilities, without charge to
satisfy him that the material is being supplied in accordance with the specification.
BE
REWIREABLE TYPE PORCELAIN FUSE UNITS FOR RATINGS FROM 32 AMP 415 VOLT
UPTO AND 300 AMP 415 VOLTS AND HRC FUSE LINK WITH DMC/BAKELITE BASE
1. P.F. UNITS:
This specification provides for manufacturing and testing at works before dispatch and supply of rewireable type
Porcelain Fuses without sheet metal cover consisting of fuse carriers and fuse bases.
2. TECHNICAL PARTICULARS: The porcelain rewireable type electric fuses having fuse carriers and fuse
passes of specified ratings must conform to IS 2086-1993 or with latest amendments.
The material to be used for various current carrying/non-ferrous parts shall be as tabulated below:-
Particulars Ratings
32 A / 415V 63 A / 415V 100 A / 415V 200 A / 415V 300 A / 415V
Terminal Block Tin plated cast brass metal
U Contacts Tin Platted copper strips
Extension strips Not to be provided Tin platted electrolytic copper strips
for fixing lugs
Side leaves Tin platted phospher bronze
Iron and steel shall not be used for current carrying part including screws provided in base terminal block.
The insulating resin used to protect accidental contact of screws should be of good quality so that it should not
melt off at full load. For rating 100 Amp & above EPOXY compound may be used.
The screws used on terminal block for fixing of incoming and outgoing wires to the terminal should be of brass
and of adequate dimension.
The dimensions of terminal holes of the fuse units must be adequate for the suitable cable entry as under: -
For fuse units upto 32 Amp rating the terminal hole should be suitable for 6 sq. mm aluminium cables. For 63
Amp. Fuse units the terminal holes should be suitable for 25 sq.mm. Aluminium cables.
For 100 Amp. 200 Amp and 300 Amp ratings the terminal holes should be as shown in respective drawings. The
fuse units shall be provided with extension strips with following sizes of aluminium lugs for 3 Core Aluminium
Cable of the sizes indicated below :-
Sl. Ratings of PF Cable sizes Minimum thickness of Minimum / total Diameter of lugs
Units lugs Flat / Rounded Length of lugs Internal Outer (mm)
(mm) / (mm) (mm)
1 100 Amp 95 sq.mm. 4.2 / 2.1 64 12.9 17.1
2 200 Amp 120 sq.mm. 4.68 / 2.4 73 15.0 19.6
3 300 Amp 300 sq.mm. 7.0 / 3.5 115 25.0 32.0
Asbestos sheet (and not asbestos cloth) shall be used in the case of the porcelain fuse units to avoid short circuit
between earth and fuse wire. Where fuse wire is made to pass through the hole provided in the porcelain carrier
an asbestos tube must be inserted in the hole to avoid direct heating of the porcelain.
BF
The contacts used shall be of excellent quality and alignment should be perfect so as to provide easy but perfect
contact. ‘U’ contact should penetrate full depth of base contacts. The dimension of ‘U’ contacts and terminal block
used in various ratings should be as under:-
Sl Ratings ‘U’ contact Dimension (in mm) Terminal Block Dimension (in mm)
Length Width Thick Height Width Length Dia of hole
i 32 Amp/415V 24 + 1 10 + .5 1.4 +.5 15+.5 10+.5 12+.5 6+.5
ii 63 Amp/415V 35 + 1 16 + .5 1.6 +.5 18+.5 14+.5 20+.5 8.5+.5
iii 100 Amp/415V 45 + 1 19 + .5 2 + .1 22+ 1 17+.5 27+ 1 13+.5
iv 200 Amp/415V 55 + 1 25 + 1 3 + .1 25+1 25+1 28+ 1 18+.5
v 300 Amp/415V 57 + 1 32 + 1 3 + .1 30+ 1 27+ 1 33+ 1 18+.5
The fuse units of the ratings 100, 200 and 300 Amp should be provided with electrolytic copper extension strips
of the size as mentioned below with suitable size of bolt nuts for cable termination.
Sl. Rating Width Thickness Total length Length outside Hole dia.
porcelain
a 100A/415V 25mm+1 3.00mm+.1 76.5+1 40mm+1 6.0mm+.5
b 200A/415V 25mm+1 5.00mm+.1 92.0+1 40mm+1 10.0mm+.5
c 300A/415V 32mm+1 6.00mm+.1 94.0+1 40mm+1 10.0mm+.5
The minimum weight of current carrying parts shall not be less than as indicated below:-
i) 16A/415V 18 Gms
ii) 32A/415V 32 Gms
iii) 63A/415V 100 Gms
iv) 100A/415V 240 Gms
v) 200A/415V 610 Gms
vi) 300A/415V 855 Gms
The side leaves on the base should be sufficiently thick and stiff, to ensure tight fittings of ‘U’ contacts with base
block.
Care has to be taken to ensure that no corrosion takes place between aluminium and copper/brass of the fuse
terminal being of different types of materials.
The H.R.C. Fuse link of 300 A ratings to be fixed with ISI marked conforming to IS:9224 Part-II-1979 latest
amendment if any.
The P.F. units should be supplied complete with all accessories, which might have not indicated in the order, but
form an integral part of the PF Units.
3. Marking: Clear and indelibly embossing should be done on every fuse carrier for Rated current, Rated
voltage, Name of the manufacturer/Trade mark of manufacturer, Word “EMPLOYERRGGVY works” and size of
fuse wire.
The P.F. units to be supplied by the firm should be conform to the following type test as per IS:2086 – 1993 :-
BF
Mechanical Test Sequence
1. Visual Examination
2. Test for dimensions
3. Test for mechanical endurance
4. Test for mechanical strength
5. Test for withdrawal force
Electrical Test Sequence
1. Test for temperature rise

3. High Voltage test
4. Test for breaking capacity
Test for proving Material Properties
1. Test for water absorption

2. Test on ceramic material
3. Ignition test
Acceptance Test
1. Test for dimensions

2. Test for mechanical endurance
3. Test for withdrawal force
4. Test for temperature rise
6. High voltage test
7. Test for water absorption (non ceramic)
8. Temperature cycle test (for Ceramic material)
The lugs to be supplied with each P.F. units should conform to following specification:
1. The material is electrolytic aluminium tubes conforming to IS-5082 as per IS:8309

2. The grade of aluminium for manufacturing aluminium lugs is Gr.T-1F as per IS:8309.
The weight of the lugs for each categories are as under:
Size Weight (in Grams)

95 sq.mm. 17.00
120 sq.mm. 26.00
300 sqmm. 94.00
BF
TERMINAL BLOCK
All internal wiring to be connected to the external equipment shall terminate on terminal blocks, preferably
vertically mounted on the side of cabinet, junction box, terminal box and marshalling box.
The terminal blocks shall be made of moulded, non-inflammable thermosetting plastic. The material of terminal
block moulding shall not deteriorate because of varied conditions of heat, cold humidity, dryness etc. that would be
anticipated at the location where the equipment is proposed to be installed.
The terminal shall be such that maximum contact area is achieved when a cable is terminated. The terminal shall
have a locking characteristic to prevent cable from escaping from the terminal clamp unless it is done intentionally.
The terminal blocks shall be non-disconnecting stud type equivalent to Elmex type CAT-M4.
The conducting part in contact with cable shall be tinned or silver plated. The terminal blocks shall be of extensible
design.The terminal blocks shall be of 1100 V grade and shall be rated to carry continuously the maximum current
that is expected to be carried by the terminals.
The terminal blocks shall be fully enclosed with removable covers of transparent, non-deterioration type plastic
material. Insulating barriers shall be provided between the terminal blocks. These barriers shall not hinder the
operator from carrying out the wiring without removing the barriers.
The terminals shall be provided with the marking tags for wiring identification.
The blocks shall be provided with 20% spare terminals unless otherwise specified. Unless otherwise specified,
terminal blocks shall be suitable for connecting the following conductors on each side.
All circuits except CT/VT Minimum of two 2.5 sq.mm copper flexible
All CT/VT circuits Minimum of 4 nos. of 2.5 sq.mm copper flexible
AC/DC Power supply circuits One of 16 sq. mm. Aluminium.
There shall be a minimum clearance of 250 mm between the first row of terminal block and the cable gland plate
or side of the box. Also the clearance between two rows of terminal blocks shall be a minimum of 150 mm.
The arrangements shall be in such a manner so that it is possible to safely connect or disconnect terminals on live
circuits and replace fuse links when the cabinet is live. Cabinet wiring should be suitable for 60ºC as the space
heaters will keep the temperature 10º.C higher than the ambient.
For the Control and Relay Panels the terminal blocks for current transformer and voltage transformer secondary
lead shall be provided with test links and isolating facilities. Also current transformer secondary leads shall be
provided with short circuiting and earthing facilities.
BG
Wiring
All wiring shall be carried out with 1100 V grade stranded copper wires. The minimum size of the stranded
conductor used for internal wiring shall be as follows:
1. All circuits except CT circuits 2.5 sq.mm

2. CT circuits 2.5 sq. mm (minimum number of strands shall be 3 per conductor).
All internal wiring shall be securely supported, neatly arranged readily accessible and connected to equipment
terminals and terminal blocks.
Wire terminations shall be made with solderless crimping type of tinned copper lugs which firmly grip the conductor
and insulation. Insulated sleeves shall be provided at all the wire terminations. Engraved core identification plastic
ferrules marked to correspond with the wiring diagram shall be fitted at both ends of each wire. Ferrules shall fit
tightly on the wires shall not fall off when the wires and shall not fall off when the wire is disconnected from
terminal blocks.
All wires directly connected to trip circuit breaker shall be distinguished by the addition of a red coloured unlettered
ferrule. Number 6 & 9 shall not be included for ferrules purposes.
All terminals including spare terminals of auxiliary equipment shall be wired upto terminal blocks. Each equipment
shall have its own central control cabinet in which all contacts including spare contacts from all poles shall be wired
out. Inter-pole cabling for all equipment’s shall be carried out by the Contractor.
BH
EQUIPMENT ERECTION NOTES
All support insulators, circuit breaker and other fragile equipment shall preferably be handled with cranes with
suitable booms and handling capacity.
The slings shall be of sufficient length to avoid any damage to insulator due to excessive swing, scratching by
sling ropes etc.
For cleaning the inside and outside of Hollow insulators only muslin of leather cloth shall be used.
Handling equipment, sling ropes etc. should be tested before erection and periodically for strength.
Bending of compressed air piping should be done by a bending machine and through clod bending only.
Bending shall be such that inner diameter of pipe is not reduced.
Cutting of the pipes wherever required shall be such as to avoid flaring of the ends, and only a proper pipe
cutting tool shall be used. Hack-saw shall not be used.
The Contractor shall arrange at site all the equipments, instruments and auxiliaries required for testing and
commissioning of equipment.
STORAGE OF EQUIPMENTS
The Contractor shall provide and construct adequate storage shed for proper storage of equipments. Weather
sensitive equipment shall be stored indoor. All equipments during storage shall be protected against damage
due to acts of nature or accidents. The storage instruction of the equipment manufacturer/Owner shall be
strictly adhered to.
BI
TECHNICAL SPECIFICATION FOR LAYING AND COMMISSIONING OF 11 KV XLPE

U.G. CABLE.
1) GENERAL:
This part of the specification deals with the supply and or installation of 11 KV U.G. cables, supply of the
materials associated with the installation, testing and commissioning. As already stated the scope includes
supply of materials like sand, cable covering tiles/bricks, G.I.pipes, cable route marker, cable joints/termination,
etc., required for installation of the U.G. cable.
2) STANDARDS:
Except as modified by this specification all materials to be supplied including materials needed for cable laying
shall conform to the requirements of the latest editions of relevant standards of
IS: 1255 Installation of cables.

IS: 7098 Cross linked Polyethylene PVC sheathed cables.
IEC : 332 Tests on erected cables.
IEC: 1329 Alied steel, tubes tubular and other wrought iron fittings.
IS: 2629 recommended practice for hot dip galvanising of iron & steel.
ASTM-D: 2671 Standard method of testing heat shrinkable tubing for electrical use.
ASTM-D: 3111 Flexibility determination of hot melt adhesives by mandrel bend test method.
IEC: 60 High voltage test
IS : 3043 Grounding practices.
3) LOCAL CONDITIONS
It will be imperative on each bidder to fully inform himself of the local conditions and factors which may have
any effect on the execution of the supply and services covered under these documents and specification.
It shall be understood and agreed that such factors will have been properly investigated and considered in any
bid that is submitted. No claim for financial adjustments to the contract awarded under these specifications
and documents will be entertained by the Employer, neither change in the time schedule of the contract nor
any financial adjustments arising thereof shall be permitted by the Employer, which are based on incorrect
information or its effect on the cost of the contract to the bidder.
Bidders are advised to visit the various areas where the U.G. cables are going to be installed and assess the
problems due to restrictions in access, road/drain/footpath crossings to enable them to make proper costing
and then quote accordingly.
4) DETAILS OF WORK
The scope of work involves supply and or installation, testing and commissioning of 11 KV 3 Core 185 sq. mm
XLPE UG cable and Sundry materials like sand, cable covering tiles, jointing / termination kits etc.
5) SERVICE CONDITIONS :
The climatic conditions are prone to wide variations in ambient temperature, humidity, etc, and the accessories
offered shall be suitable for installation under the above tropical conditions, where moderately hot and humid
conditions conducive to dust, rust and fungi growth, prevail at site.
BJ
Generally the underground cables are to be laid in busy and congested localities of the city, where other utility
services like telephone and telegraph water supply, sewerage, L.T. and H.T. power cables, open and close
drains are encountered.
6) COMPLIANCE WITH REGULATIONS:
All services carried out by the bidder / sub contractor shall be as per the requirements of the Indian electricity
Rules, the Indian electricity Act 2003, and any other applicable statutory laws governing the services in the
state.
Particular attention is drawn to the necessity of consulting the local authorities and the administrative heads
concerned with the operation and maintenance of roads, railways, telegraph and telephone services, water
supply and sewerage and other public utilities.
The EMPLOYER will arrange for permission from civil authorities for cutting roads, however the necessary
charges shall be paid by the bidder sufficiently in advance. EMPLOYER will also co-ordinate with the traffic
police authorities for regulation of traffic during cutting of roads.
7) INSPECTION BY ELECTRICAL INSPECTOR:
All Electrical installations and equipments are to be inspected and approved by the Chief Electrical Inspector to
the government, before commissioning.
The Contractor will arrange for the payment of the necessary fees for inspection which shall be re-imbursed to
him at actual on submission of documentary evidence to that effect.
Any defects pointed out by the Electrical Inspector, shall be corrected or attended by the bidder / subcontractor
at his own cost and he shall pay, for subsequent inspection charges to the Electrical Inspector, for obtaining
approval.
8) INSTALLATIOIN OF U.G. CABLES:
System particulars
Nominal system voltage 11KV
Highest system voltage 12KV
Number of phases 3
Frequency 50 Hz
Method of grounding solid
Basic impulse level 75KV
Total relay and breaker operation time 15 to 20 cycles
9) METHOD OF LAYING:
The cables shall be laid directly in ground on bedding free from large stones, pieces of rocks, etc., and drawn in
pipes or ducts wherever necessary. 200 mm bed of fine coarse sand as shown in the drawing enclosed with the
BJ
bid is to be provided. Cable shall be covered with 2nd class CPWD specification bricks, (8 bricks per meter
length) and laid at a depth of 1000mm from ground level. Excavated soil shall require to filled back by ramming
and extra earth resulted out of such excavation shall be removed from the site.
10) ROUTE PLANS:
Tentative cable route plans will be furnished to the successful bidders, indicating the roads and road crossings.
The exact route survey and alignment will be decided on evaluating the findings by excavating trial holes by the
successful bidder / subcontractor. The work should be taken upon only after the final route is approved by
EMPLOYER Engineers. The EMPLOYER reserves the right to change, alter deviate the route on technical
reasons.
11) TRIAL HOLES:
The Bidder shall excavate trial holes, for alignment purpose at appropriate distance apart as warranted by the
local conditions, keep a record of the findings and close the trial holes properly to avoid hindrance / accidents
to pedestrian traffic. The final route / alignment of the cable shall be decided based on the finding of the trial
holes.
It is the responsibility of the bidder / subcontractor to maintain, as far as possible the required statutory
clearances from other utility services.
Any damage caused, inadvertently to any utility services shall be the sole responsibility of the successful bidder
/ subcontractor.
12) STATUTORY NOTICES AND WAY LEAVES:
The EMPLOYER will arrange the necessary way leaves from the concerned public utility authorities and shall
give the required assistance to the successful bidder in completing the project.
13) LAYING OF CABLES:
The successful bidder shall excavate the cable trench using manual and mechanical modes. Most main road is
of cement concrete, bitumen road or of deep macadam surface. An air compressor pneumatic drill or
equivalent mechanical excavating tool will be essential if the crossing is to be made with minimum delay,
where paved footpaths are to be dug to excavate the cable trench, care must be taken to carefully remove the
pavement slabs and store them properly and relay them properly after the work is completed.
The successful bidder shall take all precautions while excavating the trench to protect the public / private
property and to avoid any accidental damage. Any accidental damage should immediately be reported to the
concerned utility.
The successful bidder is liable to pay for all damages caused by his work man.
The sides of the excavated trench shall, wherever necessary be well shored up with timber and sheeting.
The excavated material shall be properly stored to avoid obstruction.
The bottom of the excavated trench should be carefully levelled and freed from pebbles / stones. Any gradient
encountered shall be gradual.
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There is a likely hood of a situation demanding that more than one cable is required to be run in the same
trench the successful bidders shall agree to increase the width of the trench to accommodate more than one
cable.
14) PAYING OUT THE CABLE:
The excavated cable trench shall be drained of all water and bed surface shall be smooth, uniform and fairly
hard before laying out the cable. The cable shall be pulled in the trench only on cable rollers spaced out at
uniform intervals to prevent damage to cable. The laying out process shall be smooth and steady, without
subjecting the cable to abnormal tension. The cable laid out shall be smoothly and evenly transferred to the
ground after providing sand and shall never be dropped. All snake bends in the cable shall be straightened out.
15) PACKING:
Wherever it is not possible to lay off the entire cable drum length, the cable should be cut and properly sealed
and if it is necessary to remove the cable from the drum, it should be properly flaked. Such cable lengths
should be properly stored at site.
16) SAND CUSHION:
When the cable has been properly straightened the trench shall be covered with 75mm thick layer of good
quality clean sand cushion. Then the cable shall be lifted and placed over the sand cushion. Again, another
layer of sand 100mm thick should be laid and gently pulled on to the top of the cable to form a depth of
100mm from the top of the cable. The minimum envelop cushion around the cable shall not less than 200mm.
The pulling shall be done by hand and in such a manner as to provide good bedding for the protective cable
covers like bricks.
17) PREVENTION OF DAMAGE DUE TO SHARP EDGES:
After the cable has been laid in the trench and until the cable is covered with its protective covering, no sharp
metal tool shall be used in the trench or placed in such a position that may fall into the trench.
Rollers used during laying of the cables shall have no sharp projecting parts liable to damage the cables.
While pulling cable through hume pipes/stoneware pipes/G.I. pipes/M.S. pipes, the cable shall be protected to
avoid damage due to sharp edges.
18) CABLES OVER BRIDGES:
Wherever the cable route crosses bridges the cable shall be laid in the ducts, if provided, by removing and
replacing the R.C.C. covers and filled with sand cushion.
In the absence of the cable ducts over bridges, the cable shall be laid in suitable size steel/G.I. pipes or as
directed by the engineer in-charge and the pipe covered by cement concrete if necessary to protect from direct
sun rays.
19) CABLE CROSSING OPEN DRAINS WITH LONG SPAN:
Wherever the cable has to cross open drains, with a long span, the cable shall be laid in suitable size G.I./street
pipe, properly jointed with suitable collars. The steel / G.I. pipe shall be firmly supported on pillars, columns,
or suitable support of R.C.C. foundation with stone masonary in cement mortar 1:4.
BJ
Wherever the U.G. cable has to cross the sewerage or water supply line the U.G. cable has to be taken below
them maintaining adequate clearance. Further wherever the U.G. cable runs parallel to the telephone cable a
separation distance of at east 300 mm shall be maintained.
The cables shall be laid in stone-ware pipe wherever the cable and trench crosses private roads, gates, etc. In
order to avoid inconvenience the stone - ware pipe should be laid first after excavation and excavated trench
shall be back filled, compacted and surface properly redone to restore that original condition.
20) ROAD CROSSINGS :
The road cutting whether cement concrete, asphalt or macadam road shall be taken after obtaining approval
from civic authorities, Police, Telecom authorities and work should be planned to be completed in shortest
possible time. Where necessary the work shall be planned during night time or light traffic time. . In the
excavated trench across the road the G.I. pipe of appropriate size shall be laid, excavation backfilled compacted
and surface shall be redone in shortest time to allow the traffic on the road.
21) FOOTPATH CUTTING :
The pavement slabs shall be removed, neatly stacked on side before starting excavation.
22) REINSTATMENT :
After the cables and /or pipes have been laid and before the trench is filled in all joints and cable positions
should be carefully plotted and preserved till such time the cable is energised and taken over by the engineer in
charge. The requisite protective covering will then be provided, the excavated soil replaced after removing
large stones and well rammed in successive layers of not more than 20cms in depth, where necessary the
trench being watered to improve consolidation. It is advisable to leave a crown of earth not less than 50 mm
and not more than 100 mm in the centre and tapering towards the sides of the trench.
The temporary reinstatement of road ways should be inspected at regular intervals, more frequently during
the wet weather and immediately after overnight rain, if trench is closed overnight and settlement should be
made good by further filling to the extent required such temporary reinstatement should then be left for a time
so that soil thoroughly settles down.
After the subsistence has ceased the trench may be permanently reinstated and the surface restored to the
best possible condition.
If the surface is of special material like cement concrete, asphalt, or tarred macadam, resurfacing will be done
by the civic authorities.
23) CABLE AND JOINT MARKERS :
Permanent means of indicating the positions of joints on site should be provided as per CPWD specifications.
During the course of permanent reinstatement cable and joint markers, should be laid directly above the route
of the cable and the position of the joint respectively.
Wherever it is not possible to place the marker directly over the cable route or joint the marker should be
suitably placed near the cable route or joint on which the distance of the cable route or joint at right angles to
and parallel to the marker should be clearly indicated.
BJ
The position of fixing the markers will be at the discretion of the Engineer incharge.
JOINTING OF CABLES :
1) GENERAL :
It shall be noted that the U.G. cables are of XLPE insulation and needs special care in jointing. The cable
jointer and his assistant shall have experience in making joints/terminations. Jointing work should commence
as soon as two or three lengths of cables have been laid. All care should be taken to protect the factory
plumbed cap/seal by laying the end solid in bitumen untill such time as the jointing is commenced.
Jointing of cables in carriageways, drives, under costly paving, under concrete or asphalt surfaces and in
proximaty to telephone cables and water mains, should be avoided whenever possible.
2) JOINT HOLES:
The joint holes should be of sufficient dimensions as to allow jointers to work with as much freedom of
movement and comfort as possible. The depth of the hole should be at least 0.3mtrs. below the cables
proposed to be jointed. The sides of the hole should be draped with tarpaulin sheet to prevent loose earth
from falling on the joint during the course of making. The hole should be well shored with timber, if necessary.
An overlap of about 1.0mtrs. may be kept, of the cables to be jointed for allowance to adjust the position of the
joint. When two or more cables are laid together the joints shall be arranged to be staggered by 2 to 2.5 mtrs.
3) SUMP HOLES:
When jointing cables in water logged ground or under monsoon conditions, a sump hole should be excavated
at one end of the joint hole in such a position so that the accumulating water can be pumped or baled out by
buckets without causing interference to the jointing operation.
4) TENTS:
A tent should be used in all circumstances wherever jointing work is carried out in the open irrespective of the
weather conditions. The tent should be so covered as to have only one entrance and the back facing the
direction of the wind. The tent cover should be properly weighted or tied down on the sides.
5) PRECAUTIONS BEFORE MAKING A JOINT OR CUTTING A CABLE:
The lead sheath or cable end seals should not be opened until all necessary precautions have been taken to
prevent circumstances arising out of rainy/inclement weather conditions, which might become uncontrollable.
The cable seals should be examined to ascertain if they are intact and also that the cable ends are not
damaged.
If the seals are found broken or the lead sheath punctured, the cable ends should not be jointed until after due
examination and testing by the engineer in charge of the work.
BJ
6) MEASUREMENT OF INSULATION RESISTANCE:
Before jointing is commenced the insulation resistance of both sections of the cable to be jointed should be
checked by insulation resistance testing instrument. A insulation resistance testing instrument of 2.5/5 kV shall
be used. The insulation resistance values, between phases and phase to earth shall be recorded.
The actual jointing operation shall start only after the approval of the engineer in charge of works.
7) PRECAUTIONS TO BE TAKEN ON LIVE CABLES IN SERVICE:
Sometimes it becomes necessary that a H.V. cable which is in service is cut for making a straight joint with a
new cable. In such cases work on joint should start only after the in service cable is properly identified,
isolated, discharged, tested and effectively earthed.
Search coils, interupters or cable identifying instruments should be used for this purpose.
8) IDENTIFICATION NUMBERS / COLOURS AND PHASING:
The cables should be laid and jointed number to number or colour to colour shown on the core/paper/core
identifying marks and prevent cross jointing. In all cases, the cables should be tested and phased out, and
more particularly so when the cable terminates at Ring Main Unit/Sub-Station.
9) MAKING A JOINT:
For XLPE cable, screened typed the joint boxes/kits used shall invariably of Heat shrinkable type. EPOXY based
joints are not permitted. Comprehensive jointing instructions should obtained from the manufacturer of joint
kits and meticulously followed. The connection of the earth wires should be done using flexible bonds
connected to cable sheath using clips or soldering. Aluminium conductor strands shall be joined by mechanical
compression method, using suitable die and sleeve with a good quality tool. The joints shall conform to
specification as per IS 13573-1992.
10) CABLE TERMINATIONS:
Cable terminations required are both indoor and outdoor type and invariably be of heat shrinkable type with
appropriate sheds for rain water in case of outdoor terminations.
The terminations shall conform to specifications as per IS 13573 - 1992.
The instructions furnished by the manufacturer of termination boxes/kits should strictly be followed.
Wherever a cable rises from the trench to end in a termination, to be finally connected to an overhead line or a
transformer, the following instructions should be complied with –
i) One coil to made and left in the ground for future needs.
ii) The rise of cable, immediately from the ground level should be enclosed in suitable diameter G.I. pipe to
height of 2 mtrs.
BJ
iii) The balance portion of the cable should be neatly curved, in ‘S’ shape. The cable and pipe should be
properly fastened by using appropriate clamps/support. The hard ware of clamps shall be painted with red
oxide and enamel paint or galvanized.
iv) Lugs on the termination shall be compressed with a suitable compression tool.
11) EARTHING AND BONDING:
The metal sheath and armour should be efficiently bonded and earthed at all terminals to earth electrodes
provided.
The cross sectional area of the bond shall be such that the resistance of each bond connection shall not exceed
the combined resistance of an equal length of the metal sheath and armour of the cable.
12) TESTING AFTER LAYING AND JOINTING:
All cables, after laying and jointing works are completed should be tested systematically and insulation and
pressure tests should be made on all underground cables.
All test results should be recorded in tabular form in log books kept for the purpose.
The cable cores should be tested for:-
i) Continuity;
ii) Absence of cross phasing;
iii) Insulation resistance to earth;
iv) Insulation resistance between conductors.
13) H.V. TESTS:
After the laying and jointing work in completed, a high voltage test should be applied to the cable to ensure
that the cable has not been damaged during or after the laying operations and there is no defect in the
jointing.
The high voltage tests should be as per I.S. 1255 or latest version or as per international standards. The H.V.
testing instruments shall be brought by the bidder. The Employer may in special case hire out the testing
equipments available with him at prevailing rates.
14) TESTING AND RECORD OF CABLE CONSTANTS:
When the cable is ready, just before commissioning, the cable constants, viz., the resistance, capacitance and
inductance of each conductor should be determined and recorded, along with frequency at which the values of
capacitance and inductance are determined.
15) GUARANTEE:
All cable joints/termination done by the contractor shall be guaranteed for 12 months from the date of
energisation of the complete cable. In the event of failure during the guarantee period, the restoration work
shall be done free of cost by the contractor within 24 hours of giving notice or else the expenditure incurred by
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EMPLOYER to re-do the joint/termination will be recovered from the performance guarantee amount with the
EMPLOYER .
16) CABLE RECORDS:
Accurate neat plans/sketches, drawn to suitable (1 cm = 10M) scale should be prepared and furnished by the
successful bidder after the completion of each work.
All relevant information should be collected at site, during the progress of work and preserved for preparation
of drawings.
The following essential data should be incorporated on all drawings.
a) Size, type of cable or cables.
b) Location of the cable in relation to prominent land mark property. kerb-line, etc., with depths.
c) The cross section showing where cables are laid in pipes or ducts, giving their sizes, type and depths
together with an indication of any spare ways are available.
d) Position and type of all joints.
e) Location of other cables which run along side or across the cable route.
f) Position and depths of all pipes, ducts, etc., which are met as obstruction to the cable route.
g) Accurate lengths from joint to joint and
h) Manufacturers name and drum number of the cable, between sections/joint to joint.
Two transparencies and six blue print copies of the cable records prepared as above shall be given to the
EMPLOYER engineer as a part of the contract as soon as the cable is charged.
BJ
DANGER NOTICE PLATES

1. SCOPE
This Specification covers Danger Notice Plates to be displayed in accordance with rule No. 35 of Indian
Electricity Rules, 2003.
Unless otherwise modified in this specification, the Danger Notice Plates shall comply with IS:2551-1982 or
the latest version thereof.
3. DIMENSIONS
3.1 Two sizes of Danger Notice Plates as follows are recommended:
a) For display at 415 V installations - 200x150mm
b) For display at 11 KV (or higher voltages) installations - 250x200mm
3.2 The corners of the plate shall be rounded off.
3.3 The location of fixing holes as shown in Figs. 1 to 4 is provisional and can be modified to suit
the requirements of the purchaser.
4. LETTERINGS
All letterings shall be centrally spaced. The dimensions of the letters, figures and their respective position
shall be as shown in figs. 1 to 4. The size of letters in the words in each language and spacing between them
shall be so chosen that these are uniformly written in the space earmarked for them.
5. LANGUAGES
5.1 Under Rule No. 35 of Indian Electricity Rules, 2003, the owner of every medium, high and extra high
voltage installation is required to affix permanently in a conspicuous position a danger notice in Hindi or English
and, in addition, in the local language, with the sign of skull and bones.
5.2 The type and size of lettering to be done in Hindi is indicated in the specimen danger notice plates shown
in Fig. 2 and 4 and those in English are shown in Figs. 1 and 3.
5.3 Adequate space has been provided in the specimen danger notice plates for having the letterings in local
language for the equivalent of' Danger',' 415' '11000' and 'Volts'.
6. MATERIAL AND FINISH
The plate shall be made from mild steel sheet of at least 1.6mm thick and vitreous enameled white, with
letters, figures and the conventional skull and cross-bones in signal red colour (refer IS:5-1978) on the
front side. The rear side of the plate shall also be enamelled.
BK
7. TESTS
The following tests shall be carried out :
i) Visual examination as per IS:2551-1982
ii) Dimensional check as per IS:2551-1982
iii) Test for weather proofness as per IS:8709-1977 (or its latest version)
8. MARKING
Maker's name and trade mark and the purchaser's name shall be marked in such a manner and position on
the plates that it does not interfere with the other information.
9. PACKING
The plates shall be packed in wooden crates suitable for rough handling and acceptable for rail/road
transport.
BK
BK
BK
METER BOARD FOR SERVICE CONNECTIONS

1.0 SCOPE:
1.1 This specification covers manufacture and supply of meter board with excellent weather-ability so as to
offer protection against harsh weather. The Board shall be anti-corrosive, shock, vermin & moisture
resistant, fire resistant and UV stabilized.
2.0 MATERIAL OF METER BOARD:

2.1 The meter board shall be made out of :
2.1.1 Thermosetting plastic e.g. glassfibre reinforced polyester SMC (Sheet Moulding Compound) as per
S1 grade of IS: 13410, or Glass Reinforced Polyester Dough Moulding Compounds as per Grade D1 of
IS 13411, with flame retardant properties and corrosion resistant properties.
OR
2.1.2 Polycarbonate with UV stabilized & fire resistant properties.
2.2 All accessories of MS, like nuts, bolts, washers etc., shall be galvanized.
2.3 The overall dimensions of meter board shall be as per Annexure or as specified by the owner.
3.0 CONSTRUCTION
3.1 The meter board shall be single piece moulded.

3.2 Fixing arrangement:
The meter board shall have 4 nos. 6 mm dia holes for mounting the meter board on a wall with suitable
screws. The mounting arrangement shall be designed in such a way that the board is securely held on to
the wall.
3.3 Inlet and Outlet:
Suitable number of holes shall be provided in the meter board for cable/wire entry as required. The size
of the holes shall be suitably modified depending on the size of the cable used for connections.
Thickness of the meter board shall not be less than 2.5 mm.
3.4 The meter board shall generally comply with the provisions of IS14772 or IEC 695. The meter board
shall be suitable for outdoor/indoor application. The meter board shall be with good workmanship.
3.5 The color of meter board shall be off white/admiral grey/Black or as specified by the owner.
3.6 Wherever required ribs of adequate thickness shall be provided beneath the face of the board.
3.7 While moulding the meter boards, upto 20 %( max) resin regrind may be used with virgin material.
The manufacturer shall declare the permissible regrind to be mixed with virgin material & all type tests
shall be conducted on items moulded with the maximum permissible regrind.
3.8 It shall be possible to replace the switches/holders etc. without the need to remove the meter
board from the wall. Wherever required metallic inserts shall be provided for fixing of fittings with screws.
Screws fixing means shall be so designed that they withstand the mechanical stresses during installation
and normal use. Test for this shall be carried out in line with clause 11.8 of IS:14772
3.9 Marking:
The name of the manufacturer along with month & year of manufacture shall be engraved/moulded on
the meter board.
4.0 Sample Meter Board:
4.1 The manufacturer shall submit a sample meter board before commencement of bulk production. The
bulk production and supplies shall commence only after approval of sample & type test reports by the
owner.
BL
5.0 Quality Control:
5.1 Type test report for UV stabilization test as per ASTMG 53/26/23 on the material used for making the
board shall be submitted for approval. Type test reports from NABL accredited laboratory in accordance
with clause 5 of IS: 14772 for the following tests shall be submitted for approval. The type test reports
shall not be older than 5 years.
a) Marking
b) Dimensions
c) Construction - Test for screw fixing means as per clause 11.8 of IS: 14772
d) Resistance to ageing & to climatic condition as per clause 12.1.1 of IS: 14772
e) Resistance to humid condition as per clause 12.2 of IS: 14772
f) Mechanical strength as per clause 13.2 of IS: 14772
g) Resistance to heat as per clause 14.2 of IS: 14772
h) Resistance to abnormal heat and fire (Glow wire test) as per clause 15 of IS: 14772 at a temperature
of 650 deg.C
i) Drop test- The meter board shall not get damaged or deformed when dropped from a height of 2
meters on to concrete floor.
5.2 The owner may witness acceptance tests as per IS 14772 or any other applicable standard. All tests
shall be carried out on every batch of manufacturing. All test records shall be maintained with proper
correlation. IS 13360 ‘Plastics – Methods of Testing’ shall be referred wherever required.
Following Acceptance tests shall be carried out in every lot:
a) Marking
b) Dimensions including thickness of material
c) Test for screw fixing means as per clause 11.8 of IS: 14772
d) Resistance to ageing to climatic condition as per clause 12.1.1 of IS: 14772
e) Resistance to humid condition as per clause 12.2 of IS: 14772
f) Mechanical strength as per clause 13.2 of IS: 14772
g) Resistance to heat as per clause 14.2 of IS: 14772
h) Resistance to abnormal heat and fire (Glow wire test) as per clause 15 of IS: 14772 at a temperature
of 650 deg. C.
i) Drop test- The meter board shall not get damaged or deformed when dropped from a height of 2
meters on to concrete floor
BL
BL
NUMBER PLATE (Support)
Weather proof number plate shall have unique name are to be installed on the pole support. The plate shall be made
from mild steel sheet of at least 1.6mm thick and vitreous enameled white, with letters in signal red color (refer IS:
5-1978) on the front side. The rear side of the plate shall also be enameled. The digits shall be as under:
110121
000001
226
Digits shall be displayed as detailed above having at-least 25mm height. The over all size of the plate shall be
200x250mmx1.6mm. The corners of the plate shall be rounded off. All lettering shall be centrally spaced. The
dimensions of the letters, figures and their respective position shall be as shown above. The size of digits and
spacing between them shall be so chosen that these are uniformly written in the space earmarked for them. The type
and size of digits to be written in English as indicated above. The plate should be provided with 6mm dia holes in
horizontal alignment for fixing to the pole by means of Galvanized MS flat clamp of 25x3 mm size. The nut & bolts
used for fixing of plate should be of galvanized and washers of electro-plated. The bolt should be used of at-least
6mm diameter.
TESTS: The following tests shall be carried out:
i) Visual examination as per IS:2551-1982

ii) Dimensional check as per IS:2551-1982
iii) Test for weather proof-ness as per IS 8709-1977 (or its latest version).
Numbering Transformer/ Feeders/ Equipments ( in Grid Sub-Station ):
All augmented/ new power transformer, Breakers, Outgoing feeders, respective control panels, Kiosks are to be
named. Base should be painted with yellow paint and black digits should be displayed of at-least 25mm height.
Experienced painter should be used to provide this work. LT and HT bushing should be colour coded, CT and PT
panels are to be named. The Yellow base plate should be encircled by a black strip. Naming shall be in the local as
well as English language.
Numbering of control panel:

Name of Feeder should be displayed on front end and at rear end along with serial number of the panel. Yellow base
paint and 25mm high black digits are to be used for this purpose. The base paint should be encircled by a black strip.
Naming shall be in the local as well as English language.
Strip
25mm Height
BM
11 KV CIRCUIT BREAKERS FOR CONTROLLING CAPACITORS
1. SCOPE
This Specification covers three-pole 50 Hz 11 KV Vacuum/SF 6 circuit breakers for controlling
capacitor banks of 1200 KVAR, 2400 KVAR and 3600 KVAR at 33/11 KV sub-stations. The circuit
breakers shall be of indoor or outdoor type, as required by the purchaser.
Unless otherwise modified in this specification, the circuit breakers shall comply with the
following Indian Standards as amended from time to time.
IS-13118: Circuit Breakers

IS-3156 : Voltage Transformers
IS-2705 : Current Transformers
3. RATED VOLTAGE
The rated voltage for the circuit breaker shall be 12 KV. This represents the highest system voltage
corresponding to the nominal system voltage of 11 KV.
4. RATED CURRENT
4.1 The standard rated normal current shall be 400 A.
4.2 The bus-bar rating of the indoor type circuit breaker shall be 800 A.
4.3 The standard rating for capacitive breaking current shall not be less than 300 A.
5. RATED SHORT-CIRCUIT BREAKING CURRENT

5.1 The rms value of the AC component of the rated short circuit breaking current shall be
12.5 KA.
5.2 The value of dc component shall be calculated in accordance with the recommendations
contained in IS: 13118-1991.
5.3 The circuit breakers shall be restriking-free.
6. RATED SHORT-CIRCUIT MAKING CURRENT

The rated short-circuit making current of the circuit breakers shall be taken as 2.5 times the rms
value of the ac component of the rated short-circuit breaking current.
7. RATED VOLTAGE OF OPERATING DEVICES

The standard DC Voltage for the operating devices shall be 24 V.
8. METERING
The control panel shall be provided with an ammeter of suitable rating with a selector switch.
9. PROTECTION SCHEME
The following relays shall be provided for protection of the capacitor banks:
i) Triple-pole over-current relay with a setting range of 50% to 200%.
BN
ii) Instantaneous single pole earth fault relay with a setting range of 10% to 40%.
iii) Over-voltage relay with a setting range of 100% to 170% in conjunction with an auxiliary
transformer having a ratio of 121:121 with taps on the secondary side from 115 to 127
volts for finer adjustment.
iv) Instantaneous under-voltage relay with cut off at 30% voltage.
v) 5-minutes time delay relay
vi) Neutral voltage displacement relay in conjunction with RVT

OR
Unbalance current relay in conjunction with split neutral CT of double-star arrangement.
(The supplier may adopt the alternative arrangement as per his standard practice).
10. RESIDUAL VOLTAGE TRANSFORMER

The residual voltage transformer (RVT) for the neutral voltage displacement relay shall be of
out-door type naturally cooled, with a ratio of 11000/190 V with VA burden of 50 per phase and
accuracy class 5.0 as per IS:3156 (Part-III). It shall have primary connected in star and
secondary in open delta with ungrounded neutral to energise neutral voltage displacement relay and
to discharge capacitor bank to voltage not exceeding 50 V in less than 5 minutes.
11. CURRENT TRANSFORMER
11.1 The current transformer for metering and protection shall have transformation ratio of
300-150/5A (for 2400 KVAR & 3600 KVAR capacitor banks).
11.2 The rated output (burden) of the current transformer shall be in conformity with the
relays and meters provided.
11.3 Accuracy class for the purpose of metering shall be 1.0 and for the purpose of protection
shall be 5 P with an accuracy limit factor of 10.
12. CONSTRUCTIONAL FEATURES
12.1 Indoor Application
12.1.1 The circuit breakers shall have fixed or draw out type of construction and shall be of
extendible type.
12.1.2 In the case of fixed type of construction, an isolator shall be provided between the
breaker and bus-bar. The isolator shall have an integral facility for earthling of the feeder. An
inter-locking arrangement shall be provided to ensure that the isolator cannot be operated with
breaker in closed position.
BN
12.2 Outdoor Application
12.2.1 The circuit breakers for outdoor application shall have fixed type of construction and
vacuum/SF6 interrupters with HV connections shall be totally
enclosed in hermetically sealed housing having inert atmosphere inside. In the
case of vacuum circuit breakers, porcelain housing shall be preferred. The
operating mechanism, links etc. shall be housed in a separate cubicle and should be
accessible for maintenance. The relays, meters , indicators, operating handle etc. shall be
provided on the front side with a hinged door and locking device. The door shall open
upwards, with hinge at the top, for protection against rain (when in open position).
Alternatively, the door opening sideways shall be acceptable, if provided with
automatic closing springs and a hood on the top for protection against rain.
12.2.2 No isolator shall be provided in outdoor breakers.
13. CLOSING/TRIPPING MECHANISM

13.1 The circuit breakers shall be provided with hand-operated spring-closing mechanism.
Note: The hand-operated spring mechanism is quite light in the case of vacuum /SF6
circuit breakers as compared to the conventional oil circuit breakers and is ideal for rural
sub-stations due to its simplicity and economy.
13.2 If power-operated mechanism is desired, 230 V single-phase motor-

operated spring closing mechanism shall be used both for vacuum and SF6 circuit breakers.
For vacuum circuit breakers, an additional option for solenoid mechanism suitable
for operation with 24 DC battery is also available; this arrangement is particularly suitable and
reliable for indoor type circuit breakers, where 24 V station. battery is provided.
Note: In the case of outdoor circuit breakers, it would be preferable to house the station battery
in an outdoor kiosk instead of the control room to avoid excessive voltage drop in the long leads.
Alternatively, use of self-contained, sealed-for-life, 1.8 AH, NICAD Battery in each breaker
complete with automatic charging arrangement suitable for 230 V AC supply may be stipulated.
14. TESTS
The circuit breakers, residual voltage transformers and current transformers shall be subjected
to all the type and routine tests in accordance with the details specified in the relevant Indian
Standards (See Clause 2), as amended from time to time.
15. INSPECTION
15.1 All tests and inspection shall be made at the place of manufacture unless
otherwise especially agreed upon by the manufacturer and purchaser at the time of purchase.
The manufacturer shall afford the inspector representing the purchaser all reasonable facilities,
without charge, to satisfy him that the material is being furnished in accordance with this
specification.
BN
15.2 The purchaser has the right to have the tests carried out at his own cost by an
independent agency whenever there is dispute regarding quality of supply.
BN
TECHNICAL SPECIFICATION FOR 33/0.4KV,100 KVA STATION SERVICE TRANSFORMER
1. SCOPE :
1.1. This specification covers design, manufacture, assembly, testing at manufacturer‟s works,
supply and delivery of 100 KVA, 33/0.4 KV, Station Service Transformer for efficient and trouble
free operation.
1.2. The transformer covered by this specification shall be complete in all respect. Any material or
accessories which may not here specifically mentioned but which is usual and necessary for
satisfactory and trouble free operation and maintenance of the transformer, shall be supplied
without any extra charge.
2. LOCATION:
The transformer may be installed outdoor by Employer anywhere in the project as per site
requirement.
3. SYSTEM DETAILS :
The 33 kV systems are non effectively earthed through grounding transformer & 0.4 KV systems
are effectively earthed at the neutral points of the star connected secondary winding of the
transformer.
4. .SERVICE CONDITIONS

average number of thunderstorm days per annum (isokeraunic 70 70
level)
BO
Environmentally, the region where the equipment will be installed includes coastal areas, subject to high
relative humidity, which can give rise to condensation. On shore winds will frequently be salt laden. On
occasions, the combination of salt and condensation may create pollution conditions for outdoor insulators.
Therefore, outdoor material and equipment shall be designed and protected for use in exposed, heavily
polluted, salty, corrosive, tropical and humid coastal atmosphere
5. STANDARDS :
01. Transformers covered by this specification shall, unless otherwise specified be built to
conform to the latest Indian Electricity Rules, wherever applicable and the requirements of
latest issue of ISS:1180 and ISS 2026, CBIP Standards and other ISS(all as per latest issues)
02. In the event of a conflict between the above standard and the specification the latter shall
govern.
6. RATING AND GENERAL DATA FOR DISTRIBUTION TRANSFORMERS :
01. Core Type, three phase oil immersed step down two winding distribution transformers for
outdoor installation with weather condition as stated above.
02. Rating: 100 KVA
03. Number of phase : three
04. Frequency : Transformer shall be suitable for continuous operation at the rated output and also
with voltage variation of ±10% of rated voltage and a frequency variation of +3% from
normal 50 c/s without exceeding the specified temperature rise.
05. Type of cooling : ONAN
06. Voltage Ratio : 33/0.4 KV at normal tap
07. Vector group reference : Dyn.11.
7. CONNECTIONS :
The primary (HV) winding shall be connected in delta and the secondary (L.V) winding in star
with vector group Dyn,11.The neutral of the secondary (LV) winding shall be brought out to a
separate insulated terminal.
The size (Cross section) of the neutral connection conductors and jumpers must be of same size
as that of the phase connecting conductors and jumpers which shall be properly supported and
insulated.
8. TEMPERATURE RISE :
For winding 55 0 C (measured by resistance) and for top oil 450 C (measured by thermometer)
when tested in accordance with clause 4.0 of I.S.2026-1977 (latest) Pt-II.
9. Short Circuit Impedance :

4% at 750 C, 50HZ with IS tolerance
Temp. rise will be c0nducted corresponding to loss figure at lowest tap position
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10. TERMINAL ARRANGEMENT :
Bare on outdoor porcelain bushings for outdoor type transformers as per ISS/CBIP specification
and other relevant specification. The top of the bushing shall be immersed in the oil when the oil
level is at the minimum marking of the oil level gauge. The bushings rods should be locked in
position so that twisting of leads is avoided during tightening of nuts of bushing rods. H.T. & L.T.
studs are to be made of brass for terminal connections as per IS 1180 (Part-I) of 1989.
33 KV SIDE The terminals shall be through outdoor type bushings conforming to IS-2009
and provided with Bi-metallic terminal connectors (rigid type) suitable for “Panther” ACSR
conductor. Terminal connectors are to be supplied as per Technical specification of Clamps &
Connectors. L.V. SIDE Connection from transformer L.V. terminal to the respective 400 V
switchgears shall be made through three phase 4 core cable. L.T. terminals of transformers shall
be brought out through LV bushing mounted on side wall mounted bushings. The neutral
terminal shall be brought out along with the L.V. terminals through a separate bushing for
connection to the respective switchgears neutral bus.
11. LEADS :
All leads of the windings, connection of the windings or their wires to one another to terminal
bushing shall be properly insulated and covered with insulation sleeves. The soldering materials
shall have higher melting temperature above 300 0 C and preferably above 400 0 C for better
thermal endurance and mechanical strength. The tenderer shall specifically mention the method
and materials to be used by them for lead connection.
12. CONDUCTORS : Copper
13. Tank :
01. Tank wall must be fabricated from tested quality of mild steel sheets of adequate thickness.It
should be shaped so as to make welding to a minimum . All welding shall be done electrically
and relieved of welding stresses. All seams shall be double welded for absolute oil tightness.
The tank wall shall be formed by stiffner of structural steel for general rigidity and to dampen
transformer noise. It shall also withstand partial vacuum as per latest CBIP manual against
standard atmospheric pressure. Maximum tolerance on the negative side of the steel sheets
shall be 0.35 mm as per cl.8.22. of IS-1852- 1985 (Specification for Rolling and cutting
tolerances for hot rolled steel products.).
Tank design shall be such that the core and winding assembly can be tanked or de-tanked freely
and easily.
Inside wall of the tank and the M.S.Channel shall be painted with varnish or with hot oil
resistance paint. Horizontal&Vertical Stiffner shall be continuously welded on the tank wall.
02. The tank cover shall be bolted on to flanged rim of the tank with a weather proof, hot,/cold oil
resistance, resilient gasket in between for oil tightness. If the gasket is compressible, metallic
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strips shall be provided to prevent over compression of the gasket. Bushing turrets, covers for
pockets of thermometers and other devices shall be designed to prevent any ingress of rain
water into the tank and the tank cover as a whole shall shed of all rain water. The tank cover
should have downward bent edges on all sides so that the gasket under the top cover is
protected from direct exposure to weather.
Gasket used between top cover and tank flange shall be of neoprene rubberised cork sheet and
shall be provided with water tight compound between the tank flange and the gasket. G.I. nuts,
bolts, flat washers, spring washers shall be used and suitably space to press the tank cover.
03. Bushing turrets, access hole covers, pockets of thermometers shall be so designed to prevent
any ingress or collection of water.
04. Conservators along with Silicagel breathers are to be provided inthe transformers. The
conservator shall be liberally dimensioned such that with the lowest ambient temperature and
no load on the transformer, the oil level shall not recede too low and with the highest ambient
temperature and permissible overload on the transformer, the oil will not spill into the breather
pipe or to the exterior to waste. The conservator shall be provided with oil level indicator with
Minimum, Normal & Maximum temperature Markings. The inside diameter of the pipe
connecting the conservator to the main tank shall be < 25 to 50 mm and it should be projected
into the conservator in such a way that its end is approximately 20 mm above the bottom of the
conservator.
Conservators shall not be provided with drain plug. Filling hole with cover shall be provided as
usual. The conservator pipe hole fitted to the tank cover should be provided with a suitable
slanted plate, if required so that while pouring oil into the transformer through the conservator,
oil does not fall directly on the winding. Care should be taken so that free oil flow is not
impeded. Explosion vents for transformers shall also be welded on the cover. Air release plug
should be provided in the explosion vent, and in tank cover to release any entrapped air. One
suitable inspection hole with cover of adequate size should be provided on the tank top cover
sothat bushing ends and tap changer assembly may be easily accessible through that hole.The
inspection cover should be placed on turret and should be provided with lifting handle and air
release plug. All the fitting on the top cover should be placed on the turret. An air release plug
should also be provided at the topmost point of the H.V.Bushing turrets so that any
accumulated air bubble therein may be released through Air release Plug. Conservator tank
shall be provided with plain oil gauge with maximum and normal marking visible from the G.L.
Conservator tank shall be provided with dehydrating breathers. Drain valve shall be provided on
conservator.
The Buchholz relay shall have two contacts for alarm and for tripping. The relay shall also
comprise drain cock, air vent, and facility of testing with air injection/mechanical testing facility.
05. OTI pocket is to be Provided.

06. Marshalling box is to be provided for housing OTI. OTI shall be DIAL Type Thermometer with
mercury contacts.
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07. PRESSURE TEST : The tank shall be fixed with a dummy cover with all fittings including
bushings in position and shall be subject to air pressure of 35 Kpa above atmosphere for 30
minutes. The permanent deflection of flat plate after pressure has been released shall not
exceed the values given below :-
Length of plate Deflection
Upto 750 mm 5 mm
751 to 1250 mm 6 mm
08. The manufacturers should submit pressure test certificate for the transformers tanks at least for
each batch either conducted by them or by their fabricators, for which order is placed with
them and the edges (both inside and outside) of the transformer tanks should be double
welded electrically and scrupulously as per the specification.
14. CORE :
01 The magnetic core shall be built of low loss Silicon steel, cold rolled grain oriented steel core
may be of stack type or wound type.
02 The materials used for insulating the sheets, shall have high inter-lamination resistance and
rust inhibiting property. It shall not be deteriorated by ageing from hottest operating
temperature and clamped pressure of the core dis-integrated due to mechanical modes of
core vibration. It shall not have the least tendency to absorb moisture or to react with the
dissolved particles in the insulting oil thus accelerating sludge formation.
03 The assembled core shall be securely clamped in the lines and in the uniform pressure so as
to minimize the noise from the core.
04 The core-clamping frame shall be provided with lifting eyes for the purposes of tanking and
untacking the active part of the transformers. The whole core shall be electrically connected
by copper strip of adequate section to the core frame at two separate points for being
eventually earthed through the tank to drain off electrostatic potential that may be built up.
Core base and top and bottom of yoke shall be supported with M.S. Channel of proper size
and properly bolted together for stack type core. For wound type cores suitable M.S. clamping
device should be used to hold together core laminations firmly to prevent vibration or noise.
05 The supporting framework of the cores shall be so designed so as to avoid the presence of
pockets which would prevent complete emptying of tank through the drain valve or cause
trapping of air during filling.
06 Adequate provision shall be made to prevent movement of the core and winding relative to
the tank during transport and installation or while in service.
07 The cores shall conform to :
IS : 3024 - 1965 Electrical sheet steel & IS : 649 - 1983 method of test steel sheet.
08 Successful bidder will offer for care for inspection and/or approval by the purchaser during
the manufacturing stage. The manufacturer‟s call notice for the purpose should be
accompanied with the following documents as proof towards the use of prime core material:
(i) Invoice of the supplier

(ii) Mill‟s Test certificate
(iii) Packing List
(iv) Bill of Ladding
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(v) Bill of entry certificate to customs

Core material shall be procured either from core manufacturer or through their accredited
marketing organization of repute.
Voltage Impulse Voltage(KV Peak) Short duration Power
15. frequency voltage (KV)
W 400V - 3
I
33000V 170 70
N
DING :
01. The winding shall be made of paper insulated continuous and smooth electrolytic copper
conductor & shall be provided with the requisite number of windings and shall be designed to
withstand the electromechanical stress exerted under short circuit conditions as per ISS:2026
– 1977.
Class „A‟ insulation shall be used. Paper insulation shall be dry and free from punctures and
other defects. Solid insulation shall be best quality. Wooden supports, if used, shall be well
seasoned and compatible with hot transformer oil. The test certificate of the raw materials
shall be made available by the Transformer manufacturer on request during Inspection &
Testing.
02. The insulation level of the windings shall be as follows as per Part-III of IS-2026)
03. The winding shall be so designed to reduce to a minimum the out of balance forces in the
transformer (at all voltage ratings).
04. The winding shall also be designed such that all coil assembles of identical voltage rating shall be
interchangeable and repairing of the winding can be made readily without special equipment’s.
05. BRACING OF WINDINGS:

(1) The windings and connections of all transformers shall be braced to withstand shocks which
may occur during transport or due to switching/ short circuit and other transient
conditions during service.
(2) Coil clamping rings, if provided, shall be of steel or of suitable insulating material. Axially
laminated material other than bakelised paper shall not be used.
06. WINDING AND CONSTRUCTION:

The winding shall be assembled on the core co-axially for magnetic balance and symmetrically
for electrical balance. Liberal ducts shall be provided for oil circulation and lowering hot spot
temperature in the winding. Spacers, wedges shall be robust & hard insulations are so fitted in
the winding that they will neither move, nor permit any relative movement of any part of the
winding during normal service and under a terminal short circuit, with out causing mechanical
injury to any insulation in the windings.
07. (i) The stacks of windings shall receive adequate shrinkage treatment before final assembly.
Adjustable devices shall be provided for taking up any possible shrinkage of coils in service.
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(ii) The coil clamping arrangement and the finished dimensions of any oil duct shall be such
as will not impede free-circulation of oil through the ducts.
08. Conformation to IS standards relating of conductors and insulation. The following Indian
standards specification shall govern the quality of conductor, covering insulation such as
enamel, paper and insulating boards.
1) IS: 2067-1975: Wrought Aluminium Wire for electrical purposes
2) IS:7404(Pt.I & II)1974:Paper covered copper conductor.
3) IS: 1397-1967: Kraft paper
4) IS: 335-1983 : New insulating oil.
5) IS: 1576-1967
IEC: B-2.1
IEC: B-3.1 Solid Press Board for electrical purposes.
IEC: B-4.3
6) IS: 4800-1968: For enamelled round winding wire.
16. Bushings :
All bushing shall confirm to the requirements of latest revision of IS:3347. Bushings must be
well processed, homogeneous and free from cavities and other flaws. Glazing must be uniform
in colour and free from blisters, burns and other defects. The clearances in air between live
and conductive parts and live conductive part to earthed structures shall be as follows:
Nominal System Clearances

Voltage KV Test Voltage Phase to Phase Phase to Earth Arcing Horn gap
rms Inpulse KVP (mm) (mm)
0.400 - 85 40 -
33 170 350 320 86*
The minimum creepage distance of 33 KV bushings should be 900 mm.
17. TAP CHANGER/TAPPINGS :-
The OFF load tap changing shall be effected by an external 3 phase gang operated tap changing
switch. The operation shaft shall be brought out of the tank and provided with hand wheel so that it
can be operated at standing height from plinth level and be easily accessible. The tap position
should correspond to the voltage variation of (+)5% to ( -)7½% in step of 2.5% at HV side with its
normal position at 3.
A visual tap position indicator shall be provided near the operating handle and provision shall
be made to pad lock the handle in each tap position. The locking arrangement shall be such
that pad lock can not be inserted unless required contacts corresponding to the tap position
are correctly connected with full contact pressure. All contacts of the tapping shall be silver
plated and held in position under strong contact pressure. Taps shall be provided on high
voltage windings. At each tap position, rated output shall be available within allowable range of
voltage variation.
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The tap position marking should increase in clockwise direction and there should be a stopper
in between maximum position i.e. 1 and minimum position i.e. 6. The tap position marking
should be such that they are easily visible and permanent.
18. COOLING ARRANGEMENT:
1. The transformer shall be suitable for loading of 100% continuous maximum rating with
“ONAN” cooling without exceeding the thermal limit.
2. The transformer shall be fitted with round or elliptical cooling tubes bent and welded to tank
or radiators consisting of a series of separate circular or elliptical tubes, or a pressed steel
plate assembly formed into elliptical oil channels, welded at their top and bottom to the tank.
3. The round cooling tubes shall be made of mild steel(ERW) having a minimum wall thickness
of/ 1.50 mm and a clean bright internal surface free from rust and scale. They shall be
suitably branched to protect them from mechanical shocks normally met in transportation and
to damp the modes of vibration transmitted by the active part of the transformer in service.
The elliptical tubes or elliptical oil channels of pressed steel plate at least of 18 SWG (or
1.25mm Thickness).
4. The manufacturer will have to provide information regarding wall surface area of tank radiator
cooling tubes separately as part of the guaranteed technical particulars.
19. PAINTING:
1. The surface to be painted shall be completely cleaned & made free from all rust, scale or
foreign adhering matter on grease. The cleaning & derusting can be done by sand blasting or
other approved method.
2. All steel surface in contact with insulating oil as far as accessible shall be painted with heat
resistant, oil insulable, insulating varnish or paint.
3. All steel surface exposed to wheather, shall be given a primary coat of Zinc chromate and two
coats of dark admiral gray paints. (IS 104 & IS 2932) OR Powder coating painting as specified
by CEA/REC
4. All paints shall be carefully selected to withstand tropical heat and extremities of weather. The
paint shall not scale off or winkle or be removed by abrasion due to normal handling.
5. All nuts and bolts used in the transformer for external fittings shall be galvanished or zinc
passivated and painted with body paint.
20. TEST & INSPECTION (AS PER I.S.S)
01. ROUTINE TEST.
All transformers shall be subject to routine tests at the manufacturers Works. The following
tests are to be carried out.
a) Measurement of winding resistance at all taps.
b) Ratio, polarity and phase relationships .
c) Impedances voltage.
d) Load losses.
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e) No load less and no load current.

f) Insulation resistance.
g) Induce over voltage withstand.
(h) Separate source voltage withstand.
(i) Characteristic requirement of oil sample will be as per IS-1866, 1983 amended up to 1987.
(j) Unbalance current: The maximum value of unbalance current in transformer shall not exceed
2% of full load current as per CBIP manual for transformer.
(k) Magnetising current at rated voltage & frequency and 112.5% of rated voltage & frequency
should not exceed the limit as per IS 1180(part-I) 1989
(l) Insulation resistance between windings & wings to earth at 75 0C
m) To facilitate testing, arrangement should be made for Carrying out Heat Run tests for one
transformer.
02 TYPE TESTS :
In addition to the routine tests, the following type tests,if required, are to be made by the
manufacture, who does not have type tests Report of identical transformers.
a) Dynamic short circuit withstand test to be conducted as per Cl.16.11 & 16.11.4.4 of IS:2026
(Part-I) 1977
b) Impulse voltage withstand test to be conducted as per Cl.13 of relevant IS
c) Temperature rise test –will be conducted on one transformer for every lot offered for inspection.
If records of type tests (a) & (b) above on a transformer which in essential details, is
representative of the one being purchased, are furnished the purchaser may accept these as
evidence test instead of actual test.
d) Pressure test mentioned in the at 13.04 & 13.05
Employer or its appointed authorised agency may witness the said tests at the manufacturers
premises.
03 The manufacture will have to submit thermal calculation of short circuit withstand ability for 2
seconds and 3 seconds.
04 Performance under external short Circuit condition and limit of temperature rise.
All transformers shall be capable of withstanding, without damage the thermal and mechanical
effects of a short circuit at the terminals of any of windings for 2 secs. The temperature in the
windings after 2 secs. of over current must not exceed 200 0C for Al and 250 0C for Cu
windings After the above tests, the transformer shall be subjected to all or a part of the
routine test. The criteria for evaluation of test results shall be the same as that for the test to
determine the dynamic ability to withstand short circuit in accordance with ISS 2026.
Employer may also make a testing arrangement for carrying out short circuit tests with
duration not exceeding 2 secs. in a suitable place. The transformer Subjected to such test
shall be examined for temperature rise within specified limit for any damage or displacement
of any parts within the transformer.
The transformer so tested shall not exhibit more than 2 percent variation in percentage
reactance after the short circuit test form the original measured value before testing according
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to clause 16.11.5.4 of IS 2026 (Part-I), 1977. The selection of transformer for such test shall
be carried out at the discretion of the Company from any lot of transformers of same
capacities offered for inspection and testing before delivery. The cost of to and fro
transportation to the test premises for the above testing shall be borne by the
Suppliers/Manufactures of the Transformers.
05. 1. The bidder should submit Type Test Report from CPRI/ NABL/Govt. approved
laboratories along with their offer having identical technical parameters as that of the
tendered item failing which their offer may not be technically accepted.
2. However, if it is found that the bidder has submitted Tests Report but those have not been
conducted on identical design of equipment/material as per specification of Employer, the same may
be accepted subject to the following condition :- Employer at his discretion request the successful
bidders to conduct Type Tests/special tests on identical design as per specification of Employer .
Such Type Tests/special tests if required to be carried out at NABL/Govt. approvedLaboratories for
which no extra cost will be charged to Employer
06. Transformers shall have to be tested for Dynamic Short Circuit withstand Test and Impulse
voltage withstand test at CPRI/ NABL Accredited Laboratory or any other Govt. recognized
Test House. Transformers for such tests are to be manufactured as per relevant technical
specification and approved drawing and should be offered for preliminary testing like routine
and temperature rise test prior to type tests, by Employer ‟s testing wing. After successful
completion of preliminary tests, transformers may be sent for type tests. Type tested passed
transformers, duly witnessed and sealed by Employer ‟s Testing Wing are to be retained at
the manufacture‟s premises with Employer seals for comparison of the transformers to be
offered. The transformers to be manufactured and supplied should have identical design,
dimension and drawings as that of approved design, dimensions and drawings of the type
tested transformers.
07. INSPECTION : The transformer may be stage inspected at the factory of the manufacture.
The manufacture shall intimate in advance in writing to the purchaser about the stages of
manufacture & subsequent readiness of the transformers to enable him to carry out stage
inspection & final inspection and testing of the finished transformers. The stage inspection
will be carried out at the discretion of the purchaser during the process of manufacturing of
the transformers. The manufacturer need not stop the process of production because of
programme of stage inspection of the Purchaser. While offer for final inspection the
following point should invariably betaken care of.
i) Name plates should be welded/rivetted on the tanks of the transformer.
ii) The bolts connecting the top cover of the transformer with the tank at the two opposite
comers are to be provided with holes at their lower portions which would go beyond nuts so
that the transformers may be sealed by inserting sealing wire in these holes.
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21. Over Load Capacity :
Each transformer shall be capable of carrying sustained overload as stated in IS: 6600.
22. Over Fluxing:
Over fluxing in the core shall be limited to 10% so that the flux density in the core does
not exceed 1.9. Tesla (19000 lines/ sq.cm) The maximum flux density in any part of the core
under such condition shall not exceed 19000 lines/Sq.cm. on the basis of M4, M5 & M6 grades
as per BS 601: Part-2: 1973 (Specification for sheet and for magnetic circuits of electrical
apparatus oriented Steel)
23. Transformer Oil:-
The oil shall be as specified in IS:335-1980 and it shall be free from moisture and have
uniform quality throughout.
24. a. The outdoor apparatus including bushing insulators shall be designed so as to avoid
pocket in which water can collect.
b. All mechanism shall be so as to prevent sticking of “dew” to avoid rust and corrosion.
c. All apparatus shall be designed to minimise the risk or accidental short circuit caused
by animals, birds or verurin.
25. Internal Earthing Arrangement :
All metal parts of the transformer with the exception of the individual core laminations,
core bolts and associated clamping plates shall be maintained at some fixed potential and core
should be earthed att two points.
26. Anything not covered by this specification will be as per relevant I.S.S./IEC Specificiation.
27. MAXIMUM ALLOWABLE LOSS VALUES AND % IMPEDANCE.
KVA Ratting Voltage Ratio No. load loss. Load loss at Percentage
In watts 750C in watts Impedance
100 KVA 33/0.400 KV 260 1760 4%
No load loss and load loss figures as mentioned above are without any positive tolerance.
Tolerance i.r.o. percentage impedance will be as per ISS-2026-1977.
28. CAPITALIZATION OF LOSSES

The Capitalization of guaranteed losses of the transformer shall be calculated and considered while
evaluating the bids.
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29. LIQUIDATED DAMAGES FOR EXCESSIVE LOSSES

There is no positive tolerance on the guaranteed losses offered by the bidder. However, the
transformer(s) shall be rejected out rightly, if any of the losses i.e. no load loss or load loss or both
exceed (s) the guaranteed maximum permissible loss figures quoted by the bidder in the Technical Data
Schedule with the bid.
30. Asset Codification no. – Asset codification no. for the ordered quantity shall be
communicated to the supplier after placement of order. Necessary Engrave/Embossing (cold
punch) shall be done on the main tank with 28 no font size and DTR name and diagram plate
with font size not less than that used for marking KVA rating of the DTR.
If cold punch on the tank is not possible then separate property plate(details marking of the
plate shall be submitted with the transformer drawing for approval) shall be welded to the tank
with the following details:-
1. Ratings :
2. Manufacturer’s Sl.No. :
3. Manufacturer’s Name :
4. P.O. No. :
5. Year of Manufacturing:
6. Property of : Employer (RGGVY-XII Plan Projects)
7. Asset Code Number : ( 10 digit alpha numeric numbers as allotted by the purchaser)
Again the following points shall have to be noted

a) Front Size of letter shall be 28 i.e. 7 mm x 5.5 mm
b) Letters shall be distinctly engraved by cold Punch
c) Plate size shall be minm 125mm X 170mm and shall be electrical run Welded be
throughout its perimeter
d) Material of Plate shall be Mild Steel and not less than 3mm thick.
e) Plate shall be welded on the transformer tank at visible position and height.
31. TESTING EQUIPMENTS
i) KV Meter for 33KV system

ii) Volt Meter (0- 1000V)
iii) Milliammeter for leakage current (0 -100ma)
iv) Power Analyzer of reputed Make( should display 3-Ph current, voltage,watt andΣ3ΦPower
v) Megger – 2.5KV
vi) Thermometer (preferably Digital)-0 -100°C
vii) TTR Meter
viii) Winding Resistance measurement (Preferably ELTEL or reputed make)
ix) Digital Multimeter to measure magnetizing current & core balance of 11KV system.
x) Clamp on Ammeter ( 0- 300A)
32. INSPECTIONS AND TESTING
32.1.1 The Employer shall have free entry at all times, while work on the contract is being
performed, to all parts of the manufacturer’s works which concern the processing of the
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equipment ordered. The manufacturer shall afford the Employer without charge, all
reasonable facilities to assure that the equipment being furnished is in accordance with this
specification. After approval of Drawings by the Employer, the manufacture shall manufacture
a Prototype Model as per the Approved Drawing and offer the same for inspection.
The Supplier shall offer the core, windings and tanks of each transformer for inspection
by the Employer’s representative(s). During stage inspection of the Prototype Model, all the
measurements like diameter, window, height, leg centre, stack width, stack thickness,
thickness of laminations etc for core assembly, conductor size, insulation thickness, I.D.,
O.D., Winding height, major and minor insulations for both HV and LV windings, length,
breadth, height and thickness of plates of transformer tanks, the quality of fittings and
accessories will be taken/ determined.
The Inspection Report for the Tests conducted by our Authorized Inspectors in presence
of the manufacturer’s representative, for the Prototype Model offered for inspection with
suggested modifications, if any shall be submitted to the undersigned for approval.
After Inspection, the Prototype Model shall be kept sealed, in the premises of the
manufacturer till the completion of delivery of final consignment, for future reference during
subsequent Inspections.
The Supplier can offer for final inspection of the transformers subject to
clearance of the stage inspection report by the Employer.
32.2 The Employer reserves the right to reject an item of equipment if the test results do not comply
with the values specified or with the data given in the technical data schedule.
32.3 Routine tests shall be carried out by the Supplier at no extra charge at their works.
Adequate facility with calibrated testing equipment must be provided by the manufacturer free of
cost to carry out the tests. Type test certificates must be furnished along with the tender for
reference of the Employer.
32.4 The Employer will witness all required tests. In order to facilitate this, the Supplier shall give the
Employer a minimum of 10 days notice that the materials are ready for testing.
32.5 The supplier shall submit to the Employer five signed copies of the test certificates, giving the
results of the tests as required. No materials shall be dispatched until material dispatch clearance
is not issued by employer.
The test certificates must show the actual values obtained from the tests, in the units used in
this specification, and not merely confirm that the requirements have been met.
32.6 The Employer at his discretion may re-confirm the Routine Test Results, particularly no load
losses, load losses and percentage impedance in his own laboratory or laboratory of his choice.
No inspection or lack of inspection or passing by the Employer’s Representative of equipment or materials

whether supplied by the Supplier or sub-supplier, shall relieve the Supplier from his liability to complete the
contract works in accordance with the contract or exonerate him from any of his guarantees.
However in case of future discrepancy, if any, after acceptance of equipments, observed at any stage
during guarantee period, the matter may be referred to Bureau of Energy Efficiency (B.E.E) for random
testing of equipments supplied. In such cases the observation of B.E.E shall be binding to both parties.
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33. GUARANTEE
The supplier shall guarantee the following:

 Satisfactory operation during the guarantee period from the date of commissioning, as per
general terms of condition of the contract.
 Performance figures as supplied by the tendered in the schedule of guaranteed particulars;
 The offered surface treatment shall protect the treated metal from corrosion for a period of not less
than five years from the date of delivery.
34. PACKING AND SHIPPING
34.1 Packing
The equipment and any supporting structures are to be transported adequately sealed against water
ingress. All accessories and spares shall be packed and securely clamped against movement in robust,
wooden, non returnable packing cases to ensure safe transit in rough terrain, cross country road
conditions and in heavy rains from the manufacturer’s works to the work sites/ earmarked destinations.
34.1.1 All accessories shall be carefully packed so that they are fully protected during transport and
handling operations and in storage. Internal surfaces of loose accessories shall be sealed by means of
gaskets and blanking off plates. All parts liable to rust shall receive an anti-rusting coat and shall be
suitably protected. It shall be the responsibility of the Supplier to make good any damage caused
through insufficient packing. Each packing case shall be indelibly marked, on two adjacent sides and on
the top, with the following:

 Destination;
 Supplier’s name;
34.1.2 Each crate or container shall be marked clearly on the outside of the case to show TOP and
BOTTOM positions with appropriate signs to indicate where the mass is bearing and the correct
positions for slings. All component parts which are separately transported shall have permanent
identification marks to facilitate correct matching and assembly at site. Welded parts shall be marked
before welding. Six copies of each packing list shall be sent to the Employer prior to dispatching the
equipment.
34.2 Transportation
The contractor shall be responsible for the transport of all plant and equipment supplied by them and for
the transport of all goods to the various specified destinations including all road clearance, offloading,
warehousing and insurance. The Supplier shall inform himself fully as to all relevant transport facilities
and requirements and loading gauges and ensure that the equipment as packed for transport conform
to these limitations. The Supplier shall also be responsible for verifying the access facilities specified.
The contractor shall be responsible for the transportation of all loads associated with the contract works
and shall take all reasonable steps to prevent any highways or bridges from being damaged by his
traffic and shall select routes, choose and use vehicles and restrict and distribute loads so that the risk
of damage shall be avoided. The Supplier shall immediately report to the Employer any claims made
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against the Supplier arising out of alleged damage to a highway or bridge. All transport accessories,
such as riding lugs, jacking pads or blanking off plates shall become the property of the Employer.
All items of equipment shall be securely clamped against movement to ensure safe transit from the
manufacturer’s facilities to the specified destinations.
The Supplier shall advice the storage requirements for any plant and equipment that may be delivered
to the Employer’s stores. The Supplier shall be required to accept responsibility for the advice given in
so far as these arrangements may have a bearing on the behavior of the equipment in subsequent
service.
35. Hazardous substances
35.1 The Supplier shall submit safety data sheets for all hazardous substances used with the equipment.
The Supplier shall give an assurance that there are no other substances classified as hazardous in the
equipment supplied. No oil shall be supplied or used at any stage of manufacture or test without a
certificate acceptable to the Employer that it has a PCB content of less than 2 mg/ kg. The Supplier
shall accept responsibility for the disposal of such hazardous substances, should any be found. The
Supplier shall also be responsible for any injuries resulting from hazardous substances due to non
compliance with these requirements.
35.2.1 Programme
A copy of installation and commissioning instructions and of the operation and maintenance instructions
and troubleshooting charts shall be supplied with each transformer.
35.3 Drawings
35.3.1 Within 15 days of award of contract, the Supplier shall submit 4 complete sets of drawings as
detailed below describing equipment in details. These drawings would be duly approved by the
Employer after due securitization and approval will be communicated within 15 days of receipt of these
drawings. After the drawings are approved and communicated to the supplier, he would supply ten
complete sets of final drawings.
35.3.2 All detail drawings submitted for approval shall be to scale not less than 1:20. All important
dimensions shall be given and the material of which each part is to be constructed shall be indicated on
the drawings. All documents and drawings shall be submitted in accordance with the provisions of this
specification and shall become the property of the Employer.
35.3.3 All drawings and calculations, submitted to the Employer, shall be on international standard
size paper, either A0, A1, A2, A3 or A4. All such drawings and calculations shall be provided with a
contract title block, which shall include the name of the Employer and shall be assigned an unique
project drawing number; the contract title block and project numbering system shall be agreed with
the Employer.
35.3.4 Script sizes and thickness of scripts and lines be selected so that if reduced by two stages the
alphanumeric characters and lines are still perfectly legible so as to facilitate microfilming.
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35.3.5 For presentation of design drawings and circuit documents IEC Publication 617 or equivalent
standards for graphical symbols are to be followed. The drawing approval will be communicated within
15 days from the receipt of drawings from the Bidder and for any delay in furnishing the drawings, if
delivery period will be delayed, no extension of delivery time will be granted due to this.

e. Drawing showing details such as clamping arrangements of core, core assembly showing oil duct
section of HT and LT coils with conductor size showing insulation arrangements of windings and their
reinforcement to withstand short circuit stresses, in side tank dimensions showing core assembly.
f. Schematic diagram showing the flow of oil in the cooling system as well as each limb and winding.
Longitudinal and cross- sectional views showing the duct sizes, cooling pipe etc. for transformer/ heat
exchanger, drawn to scale shall be furnished.
h. Test Reports
36. FASTENERS
36.1 All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the appropriate
Indian Standards for metric threads, or the technical equivalent.
36.2 Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring terminals.
All nuts and pins shall be adequately locked.
36.3 Wherever possible, bolts shall be fitted in such a manner that in the event of failure of locking
resulting in the nuts working loose and falling off, the bolt will remain in position.
36.4 All ferrous bolts, nuts and washers placed in outdoor positions shall be of anti-corrosive materials
except high tensile steel bolts and spring washers which shall be electro galvanized to service condition
stated elsewhere in the Specification. Appropriate precautions shall be taken to prevent electrolytic
action between dissimilar metals where bolts are used on external horizontal surfaces and where water
can collect, methods of preventing the ingress of moisture to the threads shall be provided. Each bolt
or stud shall project at least one thread but not more than three threads through the nut, except when
otherwise approved for terminal board studs or relay stems. If bolts nuts are placed so that they are
inaccessible by means of ordinary spanners, special spanners shall be provided. The length of the
screwed portion of the bolts shall be such that no screw thread may form part of a shear place
between members. Taper washers shall be provided where necessary. Protective washers of suitable
material shall be provided front and back on the securing screws.
37. LABELS
37.1 All apparatus shall be clearly labelled indicating, where necessary, its purpose and service positions.
The material of all labels and plates, their dimensions, legend and the method of printing shall be
subject to approval of the Employer. The surfaces of all labels and plates shall have a mat or satin
finish to avoid dazzle from reflected light. Colours shall be permanent and free from fading. Labels
mounted on black surfaces shall have white lettering. Danger plates shall have white lettering on a red
background. All labels and plates for outdoor use shall be of in-corrodible material. Where the use of
enameled iron plates is approved, the whole surface including the back and edges, shall be properly
covered and resistant to corrosion. They shall be engraved in English. Name plates shall be white with
black engraved lettering and shall carry all the applicable information specified in the applicable items
of the Standards. No scratching, corrections or changes will be allowed on name plates.
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37.2 Name plates shall be provided of white background with black engraved lettering carrying all the
applicable information specified in the standards and other details as required by the Employer. The
name plate inscription and the size and lettering shall be submitted to the Employer for approval.
38. ROFORMA FOR STAGE INSPECTION OF DISTRIBUTION TRANSFORMERS
1. Name of Firm :
4. Details of offer
(a) Rating
(b) Quantity
(c) Serial Numbers

(b) Serial Numbers
6.
(a) Inspection of BEE 3 Star Level/ Embossing / Punching requirement: whether satisfies the
Specification: deviation if any to be mentioned
(b) Availability of material for offered quantity
(c) Position of manufacturing stage of the offered
QUANTITY :

(c) Core assembled
(i) HV Coils
(ii) LV Coils
NOTE:
(iii) Quantity offered for stage inspection should be offered for final inspection within 15 days from the
date of issuance of clearance for stage inspection, otherwise stage inspection already cleared shall be
liable for cancellation.
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11 KV 350MVA 1250 AMP VCB SWITCHGEAR PANELS (MC VCB) - Indoor
1.1. INTRODUCTION
1.1.1. The section covers the specification of metal clad indoor vacuum type switchgear unit
with horizontal draw out circuit breaker as per IS 13118 [1991] / IEC 62271-100 or
latest amendment thereof.
1.1.2. All the equipments shall be suitable for satisfactory operation in tropical climates and
dry dust laden atmosphere prevailing in the location where it shall be used against
the Contract. The equipment shall be able to with stand a wide range of
temperature variation in the required location.
1.1.3. All the plant/apparatus/equipment supplied shall comply in all respect with the
requirement of Indian Electricity Act 2003 and Indian Electricity Rule 2003/IS and
latest amendment thereof during the execution of contract where-ever applicable.
1.2. STANDARDS.
The circuit Breaker shall confirm to the latest revision with amendment available of
relevant standards, rules, and code. Some of which are listed herein for ready
reference.
Sl. Standard Item

No.
1. IEC- 62271-100 /IS- Switchgear
13118(1991)
2. IS-2705 (1992) Current Transformer
3. IS-3156 (1992) Voltage Transformer
4. IS-3231 (1987) Relays
5. IS-1248 Ammeter & Voltmeter
6. IS-375 Arrangement of Breakers Bus Bars main
connection and auxiliary wiring.
7. IEC-60687/CBIP REPORT Tri vector meter
NO-88 (JULY) 1996)
1.3. CONSTRUCTION
1.3.1. The switchgear shall be of CRCA steel construction with sheet not less than 3mm
thickness for load bearing section and not less than 2 mm thickness for non-load
bearing and shall totally dust and vermin proof. However, if vendor has standardized
the thickness of enclosure other than above mentioned and it meets the performance
requirements and the design has been established through type test, the same shall
be accepted. The panels shall be rigid without using any external bracings. The
switchboard panels should comply with relevant IS/IEC and revision thereof and shall
be designed for easy operation maintenance and further extension. Bus bar,
metering circuit breaker chamber, cables and cable box chamber should have proper
access for maintenance, proper interlocks should be provided. All instruments shall
be non-draw out type and safe guard in every respect from damages and provided
with mechanical indicator of connection and disconnection position. The switchgear
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shall be completed with all necessary wiring fuses, auxiliary contacts terminal boards
etc.
1.3.2. The arcing contacts and bus bar should be rated for 350 MVA for 3 seconds. Bus
bars shall be capable of connecting one switchgear panel to other through proper
insulated arrangement, which does not decrease the insulation strength of the bus
bar at the point of connection between two panels. The panels shall be modular in
design.
1.3.3. The breakers should be able to be drawn out in horizontal position at ground level
[with vertical/horizontal isolation] when breaker is drawn out in horizontal position
none of the live components inside the 11 KV switchgear panel should be accessible.
The safety shutters shall be robust and shall automatically cover the live components
when the breaker is drawn out. The switchgear shall have complete interlocking
arrangements at the fully inserted and fully drawn out and test positions.
Withdrawal of the breaker should not be possible in ON position, it should not be
possible to close the circuit breaker in service unless the entire auxiliary and control
circuit are connected.
1.3.4. Breaker should have three distinct positions inside the cubical; i.e. service, test and
isolated.
1.3.5. Built-in/separate trolley mounted earthing switches for incomer and outgoing shall be
provided.
1.3.6. All the high voltage compartments must have pressure discharge flap for the exit of
gas due to internal are to insure operator safety. All the HV compartment design
ensures conformity to IEC-60298 and must be type tasted for Internal Arc Test.
1.4. BUS BARS AND CONNECTORS
1.4.1. Bus bars and all other electrical connection between various components shall be
made of electrolytic copper of rectangular cross sections. The bus bars section shall
be ample capacity to carry the rated current of minimum 1250 Amp continuously
without excessive heating and for adequately meeting the thermal and dynamic
stresses in the case of short circuit in the system up to full MVA rating specified in
Para 3.2 above.
1.4.2. All bus bars connections shall be firmly and rigidly mounted on suitable insulators to
withstand short circuit stresses and vibrations.
1.4.3. Adequate clearance between 11 KV point and earth and between phase shall be
provided to ensure safety as per provision in Indian Electricity Rule 2003 and its
amendment thereof and also in accordance with the relevant Indian standard
specification and the same shall be capable of withstanding the specified high
voltage tests as per IS-13118/ IEC 62271-100 and amendment thereof.
1.4.4. Sharp edges and bends either in the bus bars or bus bar connections shall be
avoided as far as possible. Wherever such bends or edges are un-avoidable, suitable
compound or any other insulation shall be supplied to prevent local ionization and
consequent flashover.
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1.5. CIRCUIT BREAKER
1.5.1. The vacuum circuit breaker shall be draw out type suitable for installation in the
switchgear cubicles (indoor). The breaker shall comply with IS-13118 (1991)/ IEC
62271-100 and latest amendment thereof. Construction of breaker shall be such
that the points, which require frequent maintenance, shall be easily accessible.
1.5.2. The circuit breakers shall be spring operated, motor/manually charging of the spring
feature, manually released. VCB shall have spring closing mechanism for 3 pole
simultaneous operation. The speed of closing operation shall be independent of the
speed of hand operating level. The indication device shall show the OPEN and
CLOSE position of breaker visible from the front of cubical.
1.5.3. The breakers shall be capable of making and breaking the short time current in
accordance with the requirement of IS 13118(1991)/ IEC 62271-100 and latest
amendment thereof and shall have three phase rupturing capacity of 350MVA for 3
second at 11 KV. The continuous current rating of breaker shall not be less than
1250 Amp for all items. The total break/make time shall be not more than 4 cycles
for break and 6 cycles for make time for all breakers.
1.5.4. The vacuum circuit breakers shall ensure high speed extinction and adequate control
of pressure during breaking of current and also designed to limit excessive over
voltages.
1.5.5. Comprehensive interlocking system to prevent any dangerous or inadvertent

operation shall be provided. Isolation of circuit breaker from bus bar or insertion into
bus bar shall only be possible when the breaker is in the open position.
1.5.6. Vacuum Circuit Breaker shall have completely sealed interrupting units for
interruption of arc inside the vacuum. The vacuum bottle sealed for life shall be
provided with contact wear indicator.
1.5.7. Vacuum interrupter should have an expected life of 10000 operations at rated
current and should be capable for operating more than 100 times at rated short
circuit current.
1.5.8. Vacuum interrupter technical data particularly provided by the manufacturer should
also be provided with Bid.
1.6. PROTECTION RELAYS
1.6.1. All relays shall conform to the requirements of IS:3231/IEC-60255 or other applicable
standards. Relays shall be suitable for flush or semi-flush mounting on the front with
connections from the rear. The relay for entire project shall be of same type. The
protective relay shall be numerical type. Composite relay unit having O/C, E/F &
directional element etc shall be preferred.
1.6.2. The protective relays mounted on the panels shall be of the draw out type. The
relays must be capable of resetting with out necessity of opening the case. The
relays shall be provided with flag indicators. Each functional element of a relay shall
be provided with its own flag indicator to enable the type of fault condition to the
identified.
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1.6.3. Each of the incomer/outgoing switchgear units shall be provided with 3 elements of 5
Amp Non-directional, over current relays and 1 element non-directional, earth fault
relay with self/hand reset contacts. The O/C element shall have setting of 30 to
120% in seven steps and E/F element shall have setting of 10 to 40% in seven
steps. However, final decision regarding selection of steps and setting of relay shall
be decided during detail Engg. for proper co-ordination of protection system.
1.6.4. High set instantaneous element of low transient over reach not exceeding 5%
should be incorporated in the O/C and Earth Fault relays for all the outgoing feeder
panels capable of adjusting the setting from about 5 to 20 times normal rating in the
O/C relays and 2 to 8 times in Earth Fault relays.
1.6.5. During detail engineering provision for shunt trip or series trip relays shall be decided
by POWERGRID for which contractor should not have any objection. Further, in this
case, the series trip relays auxiliary unit contracts in the tripping circuit should be
designed to handle current up to 150 Amp. and like wise trip coil voltage which
appears across open contact of the series-tripping unit, be limited to 150 volts.
1.6.6. With CTs used as per Para 7.1 and taking into account the trip coil impedance of
breaker with the plunger DOWN and with plunger UP position, the VA burden of
relays offered etc. should be duly coordinated, so that the protection operates
without errors at fault current corresponding to the fault MVA of 350 for all the tap
position of the relays and the values of the impedance of the choke and resistance
which may be required should also be determined and incorporated.
1.6.7. The protective relays shall withstand 20 times the maximum current for 3 second on
any tap setting. The over shoot time on removal of current setting shall not be
greater than 0.05 seconds.
1.7. CURRENT TRANSFORMERS:

1.7.1. The requirement of ratio, VA capacity, class or accuracy, limit factor etc. for resin
cast CTs installed in different type of units are tabulated below:
Item Core/CT Ratio VA Knee ALF Class of

Burden Point accuracy
(min) Voltage
Incoming Protection 600- 15 300 at 10 PS
Panel 300/1A 600/1A
tap
Protection 600- 15 …….. 10 5P
300/5A
Metering 600- 2.5 …….. 0.5
300/5A
Outgoing Protection 600- 15 ……… 10 5P
Panel 300/5A
Metering 600- 2.5 …….. 0.5
300/5A
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1.7.2. Short time rating of CTs shall be 18.4 KA for 3 second. CTs shall be double core and
dual ratio. Saturation factor for metering core shall not exceed 2.5.
1.7.3. The designed accuracy should be available even at the lowest ratios and all CTs shall
withstand fault current corresponding to 350 MVA for 3 sec.
1.7.4. The secondary terminal of the current transformers shall be such that effective and
firm wire terminations are possible. Shorting links of adequate capacity shall be
provided at the terminal blocks for sorting of the leads from secondary terminals of
current transformers. The secondary terminal of the CTs shall be earthed at one
point.
1.7.5. The secondary winding resistance of CTs shall be as low as possible but not greater
than 0.2 ohms per 100 turns.
1.7.6. CTs shall confirm to IS 2705 with latest amendment, if any in all respect and will be
subjected to all routine and type test specified in the IS.
1.8. CABLE GLANDS AND CLAMPING ARRANGMENT FOR HOLDING SUITABLE

CABLE BOXES
1.8.1. Two nos, brass-wiping glands for each incomer and one no. Brass wiping gland for
each outgoing panel of adequate dimension for XLPE cable of 3 crores up to 400 sq.
mm size shall be supplied along with panels. For bus coupler no cable glands should
be provided.
1.8.2. Suitable cable boxes as per requirement of cable shall be arranged by the purchaser
at his end. The panel shall however provide a flat of size 50X6 mm 2 with suitable
clamp made of 50X6 mm2 flat along with Nuts Bolts and Washers for holding the
cable boxes. The flat should be fitted at a suitable height with allotted arrangement
for adjustment of height from 300mm to 500mm at site. The clamp and flat shall
have suitable stud type arrangement for earthing cable and cable box.
1.8.3. All control cable/wire entries shall be by means of suitable cable glands, such glands
shall be of brass and tinned.
1.9. AUXILIARY/CONTROL WIRING
All the secondary wiring in the panel shall have high quality PVC insulation and the
same shall have conductor size of not less than 2.5 mm 2 of copper Colours of the
secondary/auxiliary wiring should confirm to IS 375/1963 and latest amendment
thereof if any. All wiring shall be neatly run and group of wiring shall be securely
fixed by clips so that wiring can be checked without necessity of removing the
clamps. Wiring between fixed and moving portion of the panel shall be run in
flexible tubes and the same shall be so mounted to avoid any damage to them due
to mechanical movements. Ferrules with number shall be provided on both end of
the wiring.
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1.10. MARKING OF PARTS
For facilitating the erection, the several parts of the plant and equipment shall be
suitably marked.
1.11. NAME PLATE AND DIAGRAM PLATES
All equipment shall have weather proof and non corrosive metal plates fixed in
suitable position with full particulars engraved thereon with white letters against
black background.
The firm shall affix a name plate on each Switchgear panel having following
information:
1. Manufacturer’s name and trade mark.

2. Unique No.
3. Type of Panel.
4. CT Ratio.
5. Rated Voltage.
6. Rated Insulation Level
7. Rated Frequency
8. Rated Normal Current
9. Rated Short Circuit Breaking Current.
10. Weight
11. Specification No.
12. Order No. and Date
13. Year of supply.
14. Property of SEBs
1.12. PAINTING
All metallic surface [except enameled and bright parts] exposed to weather shall be
given suitable primer coat and two coats of first quality paint of approved colour. The
supplier shall also supply adequate quantities of paints, Varnish etc. for use of finished
cost and for use of patching up any scratches received during transport, handling
erection testing and commissioning.
Instead of above proper powder coating after proper pre treatment is acceptable and
in that case earlier condition will not applicable.
1.13. DETAILED FITTING AND MOUNTING
Detailed fittings and mountings of equipments in various switchgear panel shall be as

follows
1.13.1. ITEM NO. 1 – INCOMING PANELS RATING; 1250 AMP WITH CT RATIO 600-
300/5A or 600-300/1A
Each unit shall have the fittings and equipments as follows:
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 1 No steel totally enclosed, fully interlocked, indoor industrial pattern, metal clad,
horizontal draw out, vertical/horizontal isolation floor mounting switch unit complete with
transportation truck having integral mechanism and all necessary supports each
equipped as under:
 1 No Fabricated sheet steel housing.
 1 No. Complete set of mechanical interlocks.
 1 No. Set of isolating plugs and sockets [6 nos. rated for 1250 Amp. With
automatic safety shutters and pad locking arrangements. Facilities shall be
provided for proper opening of the safety shutter for cleaning, inspection and
testing.
 1 No. 1250 Amp triple pole VCB fitted with isolating sockets, spring operated,
manually as well motor charged, manually/ electrically released spring closing
mechanism with mechanical ON/OFF indicators suitable for a rupturing capacity
of not less than 350 MVA at 11 kV for 3 seconds and fitted with one set of direct
acting trip coils suitable for operation with AC series trip relays.
 1 No. Auxiliary switch with minimum four normally closed and four normally
opened contacts. The contact terminals shall be brought out and terminated at
Terminal Board irrespective of whether terminals are used or not.
 3 Nos. 600-300/5-5 A ratio double core resin cast current transformer of required
Accuracy, for protection and metering as per Para 4.7.1 of specification. Alternatively
single core dual ratio 5 nos., CTs [3 nos. for protection and 2 nos. for metering] shall
also be acceptable.
 1 No. Ammeter digital static ammeter suitably scaled and must suit CT ratio.
 1 No. 3 phase resin cast, draw out type bus bar connected potential transformers of
Ratio 11000/110 volts class 0.5 accuracy having minimum 50 VA output per phase to
operate the A.C. static H.T. Tri-vector meter, voltmeter etc. and complete with HT fuse
and LT MCB with monitoring contacts.
 1 No. Voltmeter round flush pattern digital static suitably scaled to suit the PT ratio.
 1 No. 3 way and off voltmeter selector switch for reading the voltage between any two
phases on the voltmeter.
1 No. static digital Tri vector energy meter suitable for three phase 3 wire un-
balanced load and CT, PT, ratio mentioned above, 0.5 accuracy class with load,
survey and TOD/Tariff and MRI facility. TVM shall be as specification attached
with this specification.
 1 No. Non directional adjustable IDMT series trip O/C relay with definite minimum 3
seconds at 10 times plug setting. The relay shall be arranged for over current protection
with setting from 50 to 200% of 5A on all three over current elements mounted in draw
out case tropicalised with flag indicator.
BP
 1 No. set of indicating lamps operating at 230V AC single phase one coloured RED and
other GREEN to show the closed or open position of circuit breaker.
 1 No. 80 watts continuously rated tubular/strip type heater with manual ON/OFF switch
working on 230 VAC single phase supply.
 1 No. set of copper bus bars of not less than 1250 Amp. Continuous rating.
 1 No. multi way plug box for secondary wiring between the fix and moving glands.
 1 No. set of independently operated automatic shutters for bus bar cable and voltage
transformers orifices, which shall be clearly leveled and individually pad-locked.
 1 No. Sheet instruments panel mounted on the front of the unit with hinged access
doors and totally enclosed wiring terminals mounted there.
 1 No. Complete set of self contained inter connectors, foundation bolts, fine Wiring,
wiring terminals board, sundries to complete the unit.
1.13.2. ADDITIONAL FEATURE IN 600-300/ 1A INCOMERS FOR 10 MVA AND

HIGHER TRANSFORMERS (Applicable in case of installing 10MVA or above
transformer).
This switchgear shall be used with 10MVA, 33/11 KV Transformer having delta in
primary and grounded star in secondary, conventionally differential protections is
essential for the transformer. For 11 kV side 3 nos. CTs of 600-300/1 A [Class PS
and appropriate knee point voltage] and matching inter posting CTs (if required)
shall be provided in this switchgear panel. The mounting inter connection and
termination etc. for these additional devices/relays shall be covered in scope of
supply.
1.13.3. CLARIFICATION
The total requirement of CTs for incomer of ratio 600-300/5A is as follows:
 3 CTs one for each phase of ratio 600-300/5A to connect to 3 nos., O/C relays.
 2 nos. CTs one on R phase and other on B phase of ratio 600-300/5 A for
metering.
1.13.4. ITEM NO. 2 OUTGOING FEEDER PANEL WITH CT RATIO 600-300 /5A
The fittings and mountings shall be similar to item no. 1 above except the following:
 The CT ratio will be 600-300/5A.
 The voltage transformers voltmeter and voltmeter selector switch shall be deleted.
 3 nos, CT operated overload releases are to be provided.
BP
 1 no. non directional triple pole adjustable IDMT, combined O/C and E/F [3 no. O/C and
1 no. E/F] AC series trip relay with instantaneous high set trip feature of low transient
over reach not exceeding 5% with definite minimum 3 seconds at 10 times plug setting.
The relay shall be arranged for over current protection with setting 30-120 % of 5 Amp.
And for earth fault protection with setting 10-40 % mounted on a draw out case
tropicalised with flag indicators. High set element of O/C shall have setting range of 5 to
20 times the rated current and the E/F elements shall be 2 to 8 times of rated current.
1.13.5. BUS COUPLER PANEL
Each unit shall have the fittings and equipment as follows:
 1 No. All steel totally enclosed fully interlocked indoor industrial pattern, metal clad
horizontal draw out, horizontal/vertical isolation, floor mounting switch unit complete
with transportation truck having integral circuit breaker mechanism and all necessary
supports each equipped as under:
 1 No. Fabricated sheet steel mounting.
 1 No. Complete set of mechanical interlocks.
 1 No. Set of isolating plug and sockets [6 nos. Rated for 1250 Amp.] with automatic
safety shutters and pad locking arrangement. Facilities shall be provided for proper
opening of the safety shutter for cleaning inspection and testing.
 1 No. 1250 Amp. Triple pole VCB fitted with isolating sockets, spring operated, manually
charged, and manually released spring closing mechanism with mechanical ON/OFF
indicators suitable for a rupturing capacity of not less than 350 MVA at 11 kV for 3
second.
 1 No. A set of Red and Green pigmy lamps for indicating opened and closed position of
breaker.
 1 No. 3 way auxiliary switch with 4 normally closed and eight normally open contacts.
 1 No. 80 watt. 230 VAC heaters with 6 Amp. Rotary cam switch.
 1 No. Bus bar chamber with 1250 A rated copper Bus Bars.
 1 No. A set of self aligning horizontal/vertical isolation type auxiliary plug and sockets.
 1 No. Sheet steel instrument panel mounted on the front of the unit with hinged across
doors and totally enclosed wiring terminals mounted there.
 The panel shall be without any metering protection CTs, cable box, series trip coils, and
relays.
The HT chambers [adopter chamber] will be gasketed to make it vermin proof. The gasket
shall be as specified in Section-I(Introduction and general technical requirements).
BP
NOTE Separate spring charging handle shall be provided and supplied with each set of the VCB.
1.14. ANNUNCIATION SYSTEM

Alarm annunciation system shall be provided in the control board by means of visual
and audible alarm in order to draw the attention of the operator to the abnormal
operating conditions or the operation of some protective devices. The annunciation
equipment shall be suitable for operation on the voltages specified in this specification
i.e. 30 Volt DC for new substation or as existing DC supply system of the utility (This
shall be verified by the successful bidder before submission of the drawing for
approval).
Audible annunciation for the failure of DC supply to the annunciation system shall be
provided and this annunciation shall operate on 240 Volts AC supply. On failure of the
DC to the annunciation system for more than 2 or 3 seconds. (adjustable setting), a
bell shall sound. A separate push button shall be provided for the cancellation of this
audible alarm alone but the facia window shall remain steadily lighted till the supply to
annunciation system is restored.
A separate voltage check relay shall be provided to monitor the failure of supply (240V
AC) to the scheme mentioned in Clause above. If the failure of supply exists for more
than 2 to 3 seconds. this relay shall initiate visual and audible annunciation. This
annunciation shall operate on Annunciation DC and buzzer shall sound.
1.15. TESTS
The design of circuit breaker shall be proven through all the routine and in accordance
with IS 13118: 1991/IEC 56 and any amendment thereof. Photocopy of all the test
reports must be enclosed with the tender. Type test report earlier than 7 year from
the date of tender opening shall not be acceptable.
TYPE TESTS:
Each circuit breaker shall comply with requirements of type tests prescribed in IEC
publication No.56.
i. Short time and peak withstand current test.

ii. Short circuit breaking capacity and making capacity.
iii. Capacitive current switching test: Cable charging current breaking test (Ur less than
or equal to 52 kV).
iv. Dielectric test i.e., power frequency withstand and impulse withstand test
v. Temperature rise test.
vi. Mechanical Endurance Test at ambient temperature.
vii. Measurement of resistance of the main circuit.
viii. Internal arc test.
1.16. COMMISSIONING CHECKS/TESTS
BP
After installation of panels, power and Control wiring and connect Contractor shall
perform commissioning checks. as listed below to proper operation of switchgear/panels
and correctness of all respects.
In addition the Contractor shall carry out all other checks and tests recommended by the
manufacturers.
1.16.1. GENERAL
i) Check name plate details according to specification.
ii) Check for physical damage
iii) Check tightens of all bolts, clamps and connecting terminal
iv) Check earth connections.
v) Check cleanliness of insulators and bushings.
vi) Check heaters are provided.
vii) H.V. test on complete switchboard with CT & breaker/ contractor lubricated
in position.
viii) Check all moving Parts are properly lubricated.
ix) Check for alignment of busbars with the insulators to ensure alignment and
fitness of insulators.
x) Check for inter changeability of breakers.
xi) Check continuity and IR value of space heater.
xii) Check earth continuity of the complete switchgear board.
1.16.2. CIRCUIT BREAKER
i) Check alignment of trucks for free movement.
ii) Check correct operation of shutters.
iii) Check slow closing operation (if provided).
iv) Check control wiring for correctness of connections, continuity and IR

values.
v) Manual operation of breakers completely assembled.
BP
vi) Power closing/opening operation, manually and electrically at extreme

condition of control supply voltage.
vii) Closing and tripping time.

viii) Trip free and anti-pumping operation.
ix) IR values, resistance and minimum pick up voltage of coils.
x) Simultaneous closing of all the three phases.
xi) Check electrical and mechanical inter locks provided.
xii) Checks on spring charging motor, correct operation of limit switches and
time of charging.
xiii) Check vacuum (as applicable).
xiv) All functional checks.
1.16.3. Current Transformers
i) Megger between windings and winding terminals to body.
ii) Polarity tests.
a. Ratio identification checking of all ratios on all cores by primary injection of current.
b. Magnetization characteristics & secondary winding resistance.
iii) Spare CT cores, if any to be shorted and earthed.
1.16.4. VOLTAGE TRANSFORMERS
i) Insulation resistance
ii) Ratio test on all cores.
iii) Polarity test
iv) Line connections as per connection diagram.
1.16.5. CUBICLE WIRING
i) Check all switch developments.
ii) It should be ensured that the wiring is as per relevant drawings. All
interconnections between panels shall similarly be checked.
BP
iii) All the wires shall be meggered to earth.
iv) Functional checking of all control circuit e.g. closing, tripping, interlock,
supervision and alarm circuit including proper functioning of component/
equipment .
v) Check terminations and connections. To check wiring related to CT and PT

circuits, carryout primary injection and then check for secondary value at
relay and metering instrument terminals.
vi) Wire ducting.
vii) Gap sealing and cable bunching.
1.16.6. RELAYS
i) Check internal wiring.
ii) Megger all terminal body.
iii) Megger AC to DC terminals
iv) Check operating characteristics by secondary injection.
v) Check minimum pick up voltage of DC coils.
vi) Check operation of electrical/ mechanical targets.
vii) Check CT connections with particular reference to their polarities for

differential type relays.
viii) Relay settings.
1.16.7. METERS
i) Megger all insulated portion.
Check CT & VT connections with particular reference to their polarities for power type
meter.
BP
SPECIFICATIONS FOR LED Self BALLASTED LAMPS (Retrofit LED Lamp )

1. Lamp Terminology : Self Ballasted LED Lamp retrofits for GLS lamp, cap size E27.
2. Technical Requirement: The lamps shall conform to 16102 (Part 1) for safety requirements. The test method for
performance requirement shall be as per IS 16102(Part 2). The performance of lamps shall be as specified in the
following table.
3. LED Chip conformity should mandatory be as per LM80.
4. Lamp Specifications:
Sr. Referred Standard
Test Parameters Requirements
No. IS/IEC
1 Rated Wattage Minimum 7 Watts - Upto 9 W IS 16102 (Part 2)
IS 16102 (Part 1)
2 Cap Type E27
3 Efficacy (lm/w) Minimum 80 lumen/watt IS 16102 (Part 2)

Minimum operating input
4 AC 144 V to 288 V
voltage
Shall be able to operate satisfactorily
Up to and including 250 V AC; in case of
5 Rated Voltage
voltage range - 220 V to 240 V, AC
6 Rated frequency 50 Hz IS 16102(Part 1)
Light Source (LED LM 80 Compliant (Certified by the
7 COB/SMD LED
chips/Die) supplier)
Cool White (Cool daylight)
5700K (5665 ± 270) to
8 CCT 6500K(6432±340) IS 16102 (Part 2)
Colour variation category, initial and
maintained-B
9 Beam angle Minimum 140° IS 16102 (Part 2)
10 Power factor Minimum 0.9° IS 16102 (Part 2)
11 Life Average life 25,000 hrs IS 16102 (Part 2)
12 CRI Minimum 70 IS 16102 (Part 2)
Maximum 10% at 25% of rated lamp
13 Lumen Maintenance life(with a maximum duration of IS 16102 (Part 2)
6000hrs).
14 Rated Luminous flux Minimum 710 lm IS 16102 (Part 2)
Lamp shall meet all the safety
15 Safety requirement IS 16102 (Part 1)
requirements
16 Guarantee Minimum 3 years
On the product of packaging

1. This lamp is specially made for
Marking shall be on the carton and
distribution under RGGVY scheme
Making the product as specified in IS 16102
2. Year of Mfr/Batch No./Serial no.
(Part 1) and (Part 2)
3. Name/ Address of Manufacturer
4. "Not for SALE or retail market"
For life, immediately self-certification to

Certification endurance and
deter from sub-standard supply.
switching immediately
Later final life test after 9 months
BQ
16 KVA 11/0.433 KV DISTRIBUTION TRANSFORMERS
1. SCOPE: -
The specification covers design and manufacturing of oil immersed, naturally air cooled (type ONAN),
outdoor type, three phase, 50 Hz, 11/.433 KV step down distribution transformers of capacities 16 KVA to
be supplied at the Area Stores after testing and inspection.
The current rating of transformer shall be as under: -

Rarting in KVA RATED FULL LOAD CURRENT IN AMPS
HIGH VOLTAGE SIDE LOW VOLTAGE SIDE
16 0.84 A 21.34 A
2. APPLICABLE STANDARDS: -
Although smaller rating of distribution transformers are not covered in any Indian/International
Standards, the transformers shall comply with the requirement of ISS: 1180 (latest issue) 2026 (latest
issue) . The bushings used shall conform to ISS: 2099 & 3347 (latest issue) except as modified herein.
3. TYPE: -
I. The transformers shall be double wound, three phase oil immersed, oil natural air natural
cooled (type ONAN), core type suitable for outdoor installation in tropical climate and shall be
insulated with DPC insulation on HV & LV windings. Insulation should be of temperature class
as per the temperature rise stipulated in this specification.
II. The neutral point of the secondary (LV winding) is intended for solidly earthed system
andshould be brought out to 4 separate insulated terminal, enabling external insertion of
&current transformer in the earth load to be connected wherever required.
4. CLIMATIC CONDITIONS: -
average number of thunderstorm days per annum (isokeraunic 70 70
level)
BR
5. RATINGS: -
Primary voltage : 11 KV
Secondary voltage : 0.433 KV
The windings of the transformers shall be connected in delta on primary side and star on thesecondary
side. The neutral of the LT winding shall be brought out to a separate terminal.The vector group shall be
DyN-11.
6. TEMPERATURE RISE: -
Temperature rise for top oil over an ambient of 50 °C should be 45 °C max (measured by thermometer
as per IS: 2026).
Temperature rise for windings over an ambient of 50 °C should be 50 °C max (measured by resistance in
accordance with IS: 2026)
7. NO LOAD VOLTAGE RATING: -

The no load voltage ratio shall be 11000/433-250 volts.
8. TAPS: -
No tapings shall be provided on transformer.
9. DESIGN AND CONSTRUCTION:-

(a) Core Material: - CRGO Sheet.
(b) The core shall be of high grade cold rolled grain oriented annealed steel laminations having low loss
and good grain properties, coated with hot oil proof insulation, bolted together and to the frame firmly to
prevent vibration or noise. All core clamping bolts shall be effectively insulated by zinc chromate and
paper. The completer design of core must ensure permanency of the core losses with continuous working
of the transformers. The value of the flux density allowed in the design and grade of lamination used
shall be clearly stated.
(c) The transformer core shall not be saturated for any value of V/f ratio to the extent of 112.5%
of the rated value of V/f ratio (i.e. 11 KV /50 due to combined effect of voltage and frequency) up to
12.5% without injurious heating at full load condition and core should not get saturated. The supplier
shall furnish necessary design data in support of this situation.
(d) Flux Density: - Flux density at rated voltage and frequency shall not exceed 1.55 Webbers per Sq,
meter. No load current at rated voltage and at 112.5% of rated voltage shall not exceed the values given
below: -
Rarting in KVA Percentage of rated full load current

At 100 % Rated voltage At 112.5 % Rated voltage
16 3.5 7
BR
(e) Details of Core:-
S. Particulars Rating in KVA 16

No.
1 Core Clamping
a MS Channel or MS Angle of suitable size
b Bolt dia mm/Nos. (High tensile bolts shall be used) 12 mm / 2 Nos. (at each end)
c Tie bolts 4 Nos. of 12 mm dia MS rod
d Rods to be painted with zinc chromate and affectively insulated
e Top & bottom yoke should be constructed in single place of CRGO laminations.
(f) The top yoke channels to be reinforced by MS Flat of 50x6 mm at equal distance, if holes cutting are
done for LT Lead so as to avoid bending of channel.
(g) Core Base and bottom yoke shall be supported with 75mm x 40mm MS channel properly bolted
together. In no case, Flat or cut channels shall be accepted.
(h) All channels, top and bottom yoke Nut Bolts; Tie rods shall be painted with oil and corrosion
resistant paint before use.
(i) Core should be properly earthed through copper strip. One end of copper strip should be inserted
deeply into core laminations and other end bolted with the core clamping channel.
(j) To prevent any possibility of movement of core assembly in transit, following provision shall
be made: -
(k) 4 No. core guides shall be provided at the bottom of the tank. Alternatively, bottom foot channels of
core channels shall be extended to serve this purpose.
(l) The core shall be securely fastened to side of tank with minimum 4 fixing bolts.
10. WINDINGS: -
a) Materials: - Double paper cover Aluminum Conductor for 16 KVA rating should be used.
b) Current Density for HV &LV shall not be more than 1.25 Ampere per Sqmmfor Aluminum
Conductor.
Accordingly, HT & LT conductor size shall be chosen from the relevant ISS and shall be of standard size.
c) LV winding shall be in even layers so that the neutral formation will be at top.
11. LOSSES AND IMPEDENCE: -

The losses and impedance for both the ratings of transformers should be as shown below and shall have
no positive tolerance as per IS: 1180/2026 and shall be calculated at 75°C.
S. Rating in KVA No load loss (watts) Load loss at 75°C (watts) Impedance(%)
No.
1 16 KVA 90 325 4
BR
(i). During testing if it is found that the actual measured losses are more than the values specified in
tender, the entire lot of the transformer offered for testing will be rejected.
(ii) If the transformer are not found as per specification of tender/order while testing at company area
stores/lab, in that case the entire lot will be rejected & firm has to collect the transformer within 15 days
of receipt of intimation given by respective Area Stores at his own cost. The firm has to offer fresh
material for the quantity rejected.
12. Insulation Material and Clearances: -
(a) Materials: - Electrical grade insulating craft paper of Triveni Ballarpur or equivalent make subject
to approval of the Employer. Press board of Senapaty, Whitelay or Raman make or equivalent
subject to approval of Employer. Permawood or Haldiwood blocks shall be used for top and
bottom yoke insulation.
(b) Radial clearance of LV coil to core (bare conductor) shall not be less then: -
(i) 16 KVA - 3.25 mm
(c) Radial clearance between HV & LV shall not be less then 11mm for 16 KVA rating.
(d) Phase to Phase clearances between HV conductor shall not be less than 10 mm with the
minimum of 2x1mm press board to cover the rods.
(e) The minimum electrical clearance between the winding and body of the tank(between inside
surface of the tank and outside edge of the windings) should be30mm.
(f) Minimum end insulation to earth shall be 25mm.
(g) No. of coils HV/phase (minimum).
(i) For 16 KVA – 3 Nos.
(h) Thickness of locking spacers between HV coils- 10mm (minimum).

(i) No. of axial wedges between LV and HV winding equispaced around LV-6 Nos.
(j) Minimum external clearances of Bushing terminals: -
Phase to Phase Phase to Earth
HV 255 mm 140 mm
LV 75 mm 40 mm
13. TANK: -
The transformers tank shall be of robust construction and shall be built of electrically welded MS plates.
All joints of tank and fittings shall be oil tight and no bulging shall occur during service. The tank design
shall be such that the core and windings can be lifted freely. The tank plate shall be of such strength that
the complete transformer when filled with oil may be lifted easily by means of the lifting lugs provided.
Tank inside shall be painted by varnish/zinc chromate. Top cover shall be slightly sloping (difference of
height should be 20mm ± 10%) towards HV bushing and cover the top with end walls. Shape of the tank
shall be rectangular only. No other shape will be accepted. The tank shall be fabricated by welding at
corners. No horizontal or vertical joints in tank side and its bottom or top cover will be allowed.
a) (i) Side wall plate thickness : 2.00 mm.

(ii) Top and bottom plate thickness. : 3.15 mm
BR
b) Reinforced by welded angle of size 40x40x5mm on all the outside walls on the edge of tank to form
two equal compartments. The permanent deflection is not more than 5mm up to 750mm length and
6mm up to 1250mm. Length, when transformers tank without oil is subjected to a vacuum of 760 mm of
mercury.
c) Lifting lugs: - 2 Nos. welded heavy duty lifting lugs of MS plate 8mm thick suitably reinforced by
vertical supporting flat welded edgewise below the lug on the side wall, up to the reinforcing angle.
d) Pulling lug: - 4 Nos. of welded heavy duty pulling lugs of MS plates of 8mm thick shall be provided on
width side to pull the transformers horizontally.
e) Top cover Gasket & Bolts: -

(i) The Gasket provided in between top cover plate and tank shall be of 5mm thick neoprene rubberized
cork sheets confirming to IS: 4352 (Pt-II).
(ii) G.I. Nut Bolts shall be of size 3/8’’x1.5’’ with one plain and one spring washer suitably spaced to press
the cover.
(iii) The height of the tank shall be such that the minimum clear height up to the top cover plate of
120mm is achieved from top yoke.
14. RADIATORS: -
(a) No radiators shall be provided.
(b) Heat dissipation by tank walls excluding top and bottom should be- 500 Watts persquiremeter.
15. CONSERAVATOR: -
Transformers shall have no conservator.
16. TERMINALS: -
(a) Brass rods 12mm dia for HT and LT with necessary Nuts check nuts and plain thick tinned washers.
(b) HT & LT bimetallic connectors shall be provided with transformer for all ratings.
(i) Normal Current Rating: -
(a) HV - 50 Amps.
(b) LV - 200 Amps.
(ii) Short Time current - 3000 Amps. for 1 sec.
Rating for HV & LV
(iii) Tensile strength for HV & LV- 110 Kg.
17. BUSHINGS: -
(i) For HV side (11KV), 12 KV Bushings will be used and for LV side (433 volts), 11KV terminal bushings
will be used. Bushings of the same voltage class shall be interchangeable. 11 KV Bushings shall be either
solid core type or porcelain bushing filled with epoxy compound. These bushings shall be mounted on
turrets and gasket should be covered by a cup. LT (0.433KV) bushing shall be of solid core or Epoxy
bushings. Bushings with plain sheds as per IS: 3347 shall be mounted on side of the tank and not on the
top cover. Only continuous sheet metal pocket shall be provided for mounting of all HV & LV bushings
and the same shall not be fixed on pipes. Sheet metal pocket shall be designed in such a way that all HV
& LV bushings shall remain parallel and equidistance all through and inside connections of windings to
bushings shall remain within the pocket. Bushings having type tested as per IS: 3347 shall only be
BR
acceptable. Arrangements for studs provided for fixing of HV bushings should be diamond shape so that
the arcing horns are positioned vertically. Alternatively, oil filled bushings may be
provided.
The LV bushings shall be housed within the metallic enclosure with sealing arrangement so as to avoid
any possibility of tapping of supply from the bushing terminal.
ii) INTERNAL CONNECTIONS: - In case of HV winding, all jumpers from windings to bushing shall
have cross section larger than the winding conductor (normally, 1.5 times). For copper winding, joints will
be made by using silver brazing alloy. For aluminum winding, L&T alkapeealuminium brazing rods with
suitable flux will be used alternatively crimped at three spots. Aluminium brazing rods to be used ring
formed on other end and not bolting on HV bushing stud.
LT star connection will be made by using aluminium/copper flat and properly brazed or bolted with the
crimped lugs on windings by means of plain or spring washers and lock nuts to the flat. Other end of the
conductor is brazed on ‘L’ Shape aluminium/copper flat and flat not bolted with neutral bushing stud. The
star connection should be wrapped with cotton/paper tape. Firm connection for LV winding to bushings
shall be made by adequate size of ‘L’ shape flats nut bolted with LV bushing stud. For delta formation on
HV side, copper wire having cross sectional area 1.5 times the winding area should be used. SRBP
tube/insulation paper should be used on delta connection and on the portion of HV winding joining to HV
bushing.
18. NITROGEN FILLING: -

Distribution transformers shall be filled with nitrogen confirming to commercial grade of IS: 1747-1972
(with latest amendments). The top cover of these transformers shall have bolted arrangement with
suitable gasket between tank and top cover.
19. PERFORMANCE OF TRANFORMERS: -

The performance of transformers to be guaranteed for current unbalanced up to order of 50% of current
in other phases. Performance to be guaranteed for any phased current not exceeding the rated value.
20. TANK BASE CHANNEL: -

Two channels of 75x40mm to be fitted across the length of the transformer at a distant of 415mm apart
(as per ISS: 1180/2026) with hole at each end on bottom flange of the channels.
21. TERMINAL MARKING PLATE AND RATING PLATE: -

The transformers shall be provided with a plate showing the relative physical position of the terminal and
their markings engraved on it. The transformers shall be provided with non detachable rating plate of
Aluminium anodized material fitted in a visible position, furnishing the information as specified in IS: 2026
and no load and load losses of the transformer. The rating plate shall be embossed/ engraved type but
not such as painting.
Further, MS plate of size 125x125mm be got welded on width side of the transformer on stiffener angle.
On this plate name of firm, order No. & Date, Rating, Serial Number and Date of Dispatch should be
engraved.
BR
22. FITTINGS: -
The fittings on the transformers shall be as under: -
(i) Rating and diagram plate - 1 No.
(ii) Earthing terminals with lugs - 2 Nos.
(iii) Lifting lugs 8 mm thick - 2 Nos.
(iv) Transformer shall have no drain valve -
(v) Thermometer Pocket -
(vi) Platform mounting channels - 2 Nos.
(With hole at each end)
(vii) Bushings: - HT - 3 Nos.
LT - 4 Nos.
Each bushing should be provided with.
3 Nos. of brass nuts and 2 plain brass
washers for connecting terminal
(viii) Pulling Lugs - 4 Nos.
(ix) Pressure relief value - 1 Nos.
(x) Top cover lifting lugs - 2 Nos.
(xi) Bimetallic connectors for all ratings to
be fitted on the studs: - HV - 3 Nos.
LV - Instead of bimetallic terminal connectors suitable
cable glands with lugs should be provided.
23. TRANSFORMER OIL: -
The transformer shall be supplied complete with first filling of oil and the same shall comply with IS: 335-
1983 with latest version thereof and ageing characteristics specified.
24. FINISHING: -
The exterior of the transformer and other ferrous fittings shall be thoroughly cleaned, scraped and given
primary coat and the two finishing coats of durable oil and weather resistant paint of enamel. The colour
of the finishing coats shall be DARK GREEN conforming to IS: 5 of 1961 (colours for ready mixed paints).
25. TYPE & TEST CERTIFICATES: -

(A) TYPE TESTS: -
i. All the equipments offered shall be fully type tested from NABL Accredited Laboratory as per relevant
ISS & technical specification. The following type tests shall be carried out on the transformers in
accordance with ISS: 2026/1977 as amended from time to time: -
(i) Short Circuit Test.

(ii) Lightening Impulse Voltage withstand test.
(iii) Temperature rise test.
ii. Transformers offered as per technical specifications shall be type tested in an independent test
laboratory, the Contractorshall furnish one set of test reports along with the offer. These tests must not
have been conducted earlier than five years from the date of opening of bids. The Employer reserves the
right to demand repetition of some or all the type tests in the presence of owner’s representative. For
this purpose the bidder may quote unit rates for carrying out each type test.
BR
iii. In case the offered transformers are not type tested or any change in design alreadytype tested from
the technical specification, the type tests shall have to beconducted afresh by the manufacturer at their
cost in accordance with the specification. In both the above cases, the tests shall be carried out
immediately anddetailed type test reports submitted within one month from the date of issue of letterof
intent. Please note that no separate time shall be permitted for this purpose. The transformer possessing
type test certificate shall only be permitted in the project.
(B) ROUTINE TESTS: -

Before dispatch each of completely assembled transformers shall be subjected to the following routine
tests at the manufacturers work in accordance with the details specified in IS: 1180/2026 and as detailed
below: These test certificates shall be submitted along with inspection offer given for transformers.
a) Measurement of winding resistance.
b) Ratio, polarity and phase relationship.
c) Impedance voltage.
d) No load loss and No load current.
e) Load loss.
f) Insulation resistance.
g) Separate Source voltages withstand.
h) Induced over voltage withstand.
(C) ACCEPTANCE TEST: -

The following tests shall be witnessed by the Employer’s representative at the work of the supplier: -
(a) All the routine tests as mentioned above shall be performed on minimum 10 % quantity of
offered lot.
Following tests are to be performed on one unit of each rating wise lot offered for inspection.
(b) Verification of active parts alongwithweighment of unit.
(c) Spill current measurement test.
(d) Test for magnetic balance. This shall be conducted by connecting the LV phase by phase to
rated phase voltage and measurement of an, bn, cn, voltage will be carried out.
(e) Test for over fluxing of core.
(f) Pressure test performed on one tank.
(g) Breakdown voltage test of transformer oil.
(h) Heat run test- One unit of the ordered quantity of each rating.
Heat run test shall have to be conducted at suppliers cost on one transformer of each
rating,generally from first offered lot, during the course of supplies. In case of transformers with
tap,]
temperature rise test shall be conducted on lowest tap feeding corresponding losses at 75°C
and the measured losses at lowest tap at ambient temperature shall be specifically indicated
in the inspection report.
To facilitate conduction of heat run test on any unit in any lot at any point of time during the supply, the
manufacturer will provide a thermometer pocket which gets immersed in oil on the side of the
transformer in all the transformers. This pocket shall also be used for connecting thermal sensing device
to monitor the variations in temperature, whenever required and to operate the protective devices. The
sensor pocket shall be of 12mm diameter with blanking screwed cap, removable at site. The depth of the
BR
projecting stem of this pocket inside the transformer will be below oil level. It shall not fringe with
electrical clearance nor obstruct the un tanking of the active part.
26. TESTING FACILITES: -

The tenderer should have adequate testing facilities for all routine and acceptance tests as described and
also arrangement for measurement of losses, resistance etc.
27. INSPECTION: -
To ensure about the quality of transformers, the inspection shall be carried out by the Company’s
representative at following two stages: -
a. When the raw material is received, and the assembly is in process in the shop floor. After the main raw
materials i.e. core and coil materials and tanks are arranged and transformers are taken for production
on shop floor and a few assembly have been completed, the firm shall intimate the O/o Addl. Chief
Engineer (Purchase) in this regard, so that an officer of the utility and or officials of any agency
appointed by the utility in this regard for carrying out such inspection could be deputed, as far as possible
within seven days from the date of intimation. During the stage inspection.
(i) A few assembled cores shall be dismantled to ensure that the CRGO laminations used are of good
quality.
(ii) The dimensional details of construction of transformers as per the guaranteed technical particulars
offered by the manufacturer and approved by the Employer shall be verified.
(iii) Pressure and vacuum test: - The tank shall be fixed with a dummy cover with all fittings including
bushings in positions and shall be subjected to following pressure/vacuum created inside the tank: -
a) 0.8 Kg. /cm. sq. above atmospheric pressure for 30 minutes.
b) A vacuum corresponding to (-) 0.7 Kg. /cm sq. for 30 minutes.
Permanent deflection of tank plate, after pressure has been released, shall not exceed the values given
below: -
Length of plate Deflection

Up to 750 mm 5 mm
751 to 1250 mm 6 mm
251 to 1750 mm 8 mm
In case of any defect/defective workmanship observation at any stage during stage inspection by the
Company’s Inspecting Officer, the same shall be pointed out to the firm in writing for taking remedial
measures. Further, processing should only be done after clearance from the inspecting officer O/o Addl.
Chief Engineer (Purchase).
b. At finished stage i.e. transformers are fully assembled and are ready for dispatch. As and when the
transformers are ready for dispatch, an offer intimating about the readiness of transformers, for final
inspection for carrying out acceptance tests as per relevant ISS, shall be sent by the firm along with
routine test certificates. The inspection shall normally be arranged by the Company at the earliest after
receipt of offer for pre-delivery inspection.
All tests and inspection shall be carried out at the place of manufacture unless otherwise specifically
agreed upon by the manufacturer and Employer at the time of placing of purchase order. The
BR
manufacturer shall offer the inspector representing the Employer, all reasonable facilities, without
charges, to satisfy him that the material is being supplied in accordance with this specification. This will
include stage inspection during manufacturing stage as well as active part inspection during acceptance
tests.
Random sample checking and testing of the transformer selected at random from the lot offered for pre-
dispatch inspection shall be done for verification of technical details, design and losses as per approved
GTP, drawings and technical specification of the order. In case of variations, the lot shall be rejected.
The Employer has all the rights to conduct the test including type tests, at its own cost by an
independent agency whenever there is a dispute regarding the quality of supply or interpretation of test
results.
28. INSPECTION & TESTING OF TRANSFORMER OIL: -

To ascertain the quality of the transformer oil, the original manufacturer’s test report should be submitted
at the time of inspection. Also, arrangements should be made for testing of transformer oil, after taking
out the sample from the manufactured transformers and tested in the presence of Employers’
representative.
29. Drawings
29.1 Within 15 days of award of contract, the Supplier shall submit 4 complete sets of drawings as
detailed below describing equipment in details. These drawings would be duly approved by the Employer
after due securitization and approval will be communicated within 15 days of receipt of these drawings.
After the drawings are approved and communicated to the supplier, he would supply ten complete sets of
final drawings.
29.2 All detail drawings submitted for approval shall be to scale not less than 1:20. All important
dimensions shall be given and the material of which each part is to be constructed shall be indicated on
the drawings. All documents and drawings shall be submitted in accordance with the provisions of this
specification and shall become the property of the Employer.
29.3 All drawings and calculations, submitted to the Employer, shall be on international standard size
paper, either A0, A1, A2, A3 or A4. All such drawings and calculations shall be provided with a contract
title block, which shall include the name of the Employer and shall be assigned an unique project drawing
number; the contract title block and project numbering system shall be agreed with the Employer.
29.4 Script sizes and thickness of scripts and lines be selected so that if reduced by two stages the
alphanumeric characters and lines are still perfectly legible so as to facilitate microfilming.
29.5 For presentation of design drawings and circuit documents IEC Publication 617 or equivalent
standards for graphical symbols are to be followed. The drawing approval will be communicated within 15
days from the receipt of drawings from the Bidder and for any delay in furnishing the drawings, if
delivery period will be delayed, no extension of delivery time will be granted due to this.
BR
29.6 The following drawings for each item are to be submitted as part of this Contract.
e. Drawing showing details such as clamping arrangements of core, core assembly showing oil duct
section of HT and LT coils with conductor size showing insulation arrangements of windings and their
reinforcement to withstand short circuit stresses, in side tank dimensions showing core assembly.
f. Schematic diagram showing the flow of oil in the cooling system as well as each limb and winding.
Longitudinal and cross- sectional views showing the duct sizes, cooling pipe etc. for transformer/ heat
exchanger, drawn to scale shall be furnished.
h. Test Reports
30 FASTENERS
30.1 All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the appropriate
Indian Standards for metric threads, or the technical equivalent.
30.2 Bolts or studs shall not be less than 6 mm in diameter except when used for small wiring terminals.
All nuts and pins shall be adequately locked.
30.3 Wherever possible, bolts shall be fitted in such a manner that in the event of failure of locking
resulting in the nuts working loose and falling off, the bolt will remain in position.
30.4 All ferrous bolts, nuts and washers placed in outdoor positions shall be of anti-corrosive materials
except high tensile steel bolts and spring washers which shall be electro galvanized to service condition
stated elsewhere in the Specification. Appropriate precautions shall be taken to prevent electrolytic action
between dissimilar metals where bolts are used on external horizontal surfaces and where water can
collect, methods of preventing the ingress of moisture to the threads shall be provided. Each bolt or stud
shall project at least one thread but not more than three threads through the nut, except when otherwise
approved for terminal board studs or relay stems. If bolts nuts are placed so that they are inaccessible by
means of ordinary spanners, special spanners shall be provided. The length of the screwed portion of the
bolts shall be such that no screw thread may form part of a shear place between members. Taper
washers shall be provided where necessary. Protective washers of suitable material shall be provided
front and back on the securing screws.
31. LABELS
31.1 All apparatus shall be clearly labelled indicating, where necessary, its purpose and service positions.
The material of all labels and plates, their dimensions, legend and the method of printing shall be subject
to approval of the Employer. The surfaces of all labels and plates shall have a mat or satin finish to avoid
dazzle from reflected light. Colours shall be permanent and free from fading. Labels mounted on black
surfaces shall have white lettering. Danger plates shall have white lettering on a red background. All
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labels and plates for outdoor use shall be of in-corrodible material. Where the use of enameled iron
plates is approved, the whole surface including the back and edges, shall be properly covered and
resistant to corrosion. They shall be engraved in English. Name plates shall be white with black engraved
lettering and shall carry all the applicable information specified in the applicable items of the Standards.
No scratching, corrections or changes will be allowed on name plates.
31.2 Name plates shall be provided of white background with black engraved lettering carrying all the
applicable information specified in the standards and other details as required by the Employer. The
name plate inscription and the size and lettering shall be submitted to the Employer for approval.
32 .PROFORMA FOR STAGE INSPECTION OF DISTRIBUTION TRANSFORMERS
1. Name of Firm :
4. Details of offer
(a) Rating
(b) Quantity
(c) Serial Numbers

(b) Serial Numbers
6.
(A) Inspection of BEE 3 Star Level/ Embossing / Punching requirement: whether satisfies the
Specification: deviation if any to be mentioned
(C) Position of manufacturing stage of the offered
QUANTITY :

(c) Core assembled
(i) HV Coils
(ii) LV Coils
NOTE:
(iii) Quantity offered for stage inspection should be offered for final inspection within 15 days from the
date of issuance of clearance for stage inspection, otherwise stage inspection already cleared shall be
liable for cancellation.
BR
Vol-II : Section-III
RGGVY Works
XII Plan
Standard Construction Drawings

Index
HT Drawing
S.No. Title Drawing no.
1 11 KV line Conductors formation and Clearance with earth wire REC-XII Plan-11KV-A3
2 11 KV line Pole Top Bracket REC-XII Plan-11KV-A7
3 33 KV line Pole Top Bracket REC-XII Plan-11KV-A7A
4 11 KV line ACSR condcutor voltage regulation table REC-XII Plan-11KV-A9
5 11 KV line tapping arrangement first strucuture of lengthy SPUR line REC-XII Plan-11KV-A12
11 KV line conductors formation and Clearances of 11 KV 3-phase/single phase composite system (
6 REC-XII Plan-11KV-A16
Phase to Neutral)
11 KV lines conductor formation and arrangement of guys for 10 to 60 angle locations (single pole
7 REC-XII Plan-11KV-A24
support)
8 11 KV lines conductor formation and arrangement of guys for dead locations (Double pole support) REC-XII Plan-11KV-A27
9 415/240 V lines conductor formation and clearances horizontal formation REC-XII Plan-11KV-B3
10 415/240 V lines protective guarding across the road vertical formation REC-XII Plan-11KV-B4
11 415/240V line supports Vertical formation REC-XII Plan-11KV-B6
12 415 volts lines AAC and ASCR Conductor voltage Regulation table REC-XII Plan-11KV-B9
13 Arrangement of conductors at angle location 415/ 240 volts lines (cross country) horizontal formation REC-XII Plan-11KV-B10
14 415/240 V Lines conductor formation and clearance, 3 Ø, 4 W(horizontal formation) REC-XII Plan-11KV-B12
15 415/240 V Lines conductor formation and clearance, 3 Ø, 4 W(Vertical formation) REC-XII Plan-11KV-B13
16 415/240 V Lines conductor formation and clearance, 3 Ø, 4 W(vertical formation) REC-XII Plan-11KV-B15
17 LT lines PVC spacer REC-XII Plan-11KV-B16
18 Earth Knob for L.T line REC-XII Plan-11KV-B17

415/240 V Lines conductor formation and arrangement of guys for 0 ˚ To 10 ˚ angle locations, (3 Ø, 4
19 REC-XII Plan-11KV-B20
W, Horizontal formation)
415/240 V Lines conductor formation and arrangement of guys for dead end locations, (3 Ø, 4 W,
Horizontal formation)
Vertical formation)
Vertical formation)
Vertical formation)
30 Pin insulator REC-XII Plan-11KV-C1
31 Clevis & tongue type strain insulator set REC-XII Plan-11KV-C2
32 Holding of conductor on 11 KV Pin insulator strain run( using hellically formed fittings) REC-XII Plan-11KV-C3
33 Holding of conductor on 11 KV Pin insulator angle location( using hellically formed fittings) REC-XII Plan-11KV-C4
34 11 KV conductor dead-end arrangement(using hellically formed fittings) REC-XII Plan-11KV-C5

35 415/240 V shackle insulator REC-XII Plan-11KV-D3
36 415/240 V insulator and hardware fittings for type-2 shackle insulators REC-XII Plan-11KV-D4
37 415/240 V insulator and hardware fittings for type-1 shackle insulators REC-XII Plan-11KV-D5
38 Finished joint using service connector REC-XII Plan-11KV-E28
39 Application of Epoxy compound on T-joint for L.T service connections REC-XII Plan-11KV-E29
40 Bimetallic connector (H.T) for 11 KV Distribution transformer REC-XII Plan-11KV-E30
41 Hellical formed fittings lashing rods REC-XII Plan-11KV-E31
42 Hellical formed fittings T-connector REC-XII Plan-11KV-E32
43 Hellical formed fittings splice for ACSR joint REC-XII Plan-11KV-E33
44 Crimp joint for L.T service connection REC-XII Plan-11KV-E39
45 Distribution sub-station for drop-out fuse REC-XII Plan-11KV-F1
46 Distribution sub-station with AB switch & HG fusefor drop-out fuse REC-XII Plan-11KV-F2
47 11-0.4 KV Distribution sub-station for online location-Along Line REC-XII Plan-11KV-F3
48 11 KV Horn Gape fuses REC-XII Plan-11KV-F6
49 11 KV Horn Gape fuses mounting details REC-XII Plan-11KV-F7
50 Earthing arrangement for distribution sub-station REC-XII Plan-11KV-F10

Installation of Automatic Transformer Disconnection Switch on 11KV/433-250 Dist. Sub-Stat. with Do
51 REC-XII Plan-11KV-F11
fuse
52 Single phase distribution sub-station arrangement REC-XII Plan-11KV-F13
53 Single phase Transformer Mounting details REC-XII Plan-11KV-F14
54 3-Phase Distribution Transformer using two 11KV Single Phase Transformer REC-XII Plan-11KV-F15
55 Single phase distribution sub-station arrangement REC-XII Plan-11KV-F19
56 Distribution sub-station mounting arrangement of 25 KVA transformer on single pole REC-XII Plan-11KV-F20
57 Guy end assembly (using Helically formed Fitting) REC-XII Plan-11KV-G2
58 Guying arragement of single and double guy REC-XII Plan-11KV-G3
59 33-11 KV sub-station metering arrangement REC-XII Plan-11KV-L3
60 11 KV Bridling "V" cross-arm REC-XII Plan-11KV-Q3
61 11 KV "V" cross-arm REC-XII Plan-11KV-Q4
62 33/11 KV Substation Single line diagram-SLD REC-XII Plan-11KV-Q7
63 Layout Diagram od Additional 33KV bay at 33/11KV Substation REC-XII Plan-11KV-S2
64 Layout Diagram od Additional 11KV bay at 33/11KV Substation REC-XII Plan-11KV-S3
65 REC-XII Plan-11KV-RLC-DRG-001 -Sht1
67 GA of 11 KV Line Crossing of Railway on DP Structure, 8 Mtr, 200Kg PSC Poles REC-XII Plan-11KV-RLC-DRG-001 -Sht3

70 GA & Component Drawing of 11kV Line Support on Single 8m-200KG PSC Pole REC-XII Plan-11KV-001S
Components for 11kV Line Formation at DP on 8M-200kG Pole
71 REC-XII Plan-11KV-002S (Sheet1)
(In Line Arrangement)
Components for 11kV Line Formation at DP on 8M-200kG Pole
72 REC-XII Plan-11KV-002S (Sheet2)
(In Line Arrangement)
73 GA of 11kV Lines Formation on Single 8M-200KG PSC Pole REC-XII Plan-11KV-003
74 REC-XII Plan-11KV-004-Sht1
GA of 11kV Lines Formation at DP on 8M-200KG PCC Pole
(Angular Location 10°-60°)
76 REC-XII Plan-11Kv-005-Sht1
GA of 11kV Lines Formation at Four 8M-200KG PCC Pole
(Angular Location 60-90)
GA of 11kV Lines Formation at DP on 8M-200KG PCC Pole
(At Dead End Location)
80 GA of 11kV Line Tapping from Existing Line on Single 8M-200 kG PSC Pole REC-XII Plan-11KV-008
81 REC-XII Plan-11KV-008ASht1
GA of 11kV Line Tapping Arrangement With 8M-200 KG DOUBLE POLE
82 REC-XII Plan-11KV-008ASht2
83 REC-XII Plan-11KV-010- Sht1

GA of 11kV Pole Extension for Single 8M-200 kG PSC Pole
85 11kV Line Protective Guarding Across Minor Crossing REC-XII Plan-11KV-011

GA of 11kV and LT AB Cable Composite Line Formation
87 REC-XII Plan-11KV-015S- Sht2
88 11 kV Danger Board REC-XII Plan-11KV-022
GA of 11KV Line Sectionalizer on 8m-200Kg PSC Pole
91 11KV AB Cable to Cable End Termination Arrangement REC-XII Plan-11KV-023S
92 General Arrangement of DC Cross Arm & Bracing with Back Cleat for 150m DP on 600 IBS PCC Pole REC-XII Plan-11KV-S
LT Drawing
93 GA of LT Line Formation on Single 8M/200Kg PSC Pole 3Ph, 4Wire (Line Arrangement) REC-XII Plan-LT-001
GA of LT ine Horizontal Formation on Single 8M/200Kg PSC Pole 3Ph, 4WIRE (Angular
94 REC-XII Plan-LT-002
Arrangement)
GA of LT Line Horizontal Formation on Single at Dead End Location
3Ph, 4Wire
96 REC-XII Plan-LT-004-SH 1
GA of LT Line Horizontal Formation on Single (In Line Arrangement)
1Ph, 2Wire
97 REC-XII Plan-LT-004-SH 2
GA of LT Line Horizontal Formation on Single (In Angular Arrangement)
1Ph, 2WIire
99 REC-XII Plan-LT-007- Sht1
GA of LT Line Vertical Formation on Single (In Line Arrangement) 3Ph, 4Wire
100 REC-XII Plan-LT-007- Sht2
GA of LT Line Vertical Formation on Single (In Angular Arangement)
3Ph, 4Wire
102 GA of LT Line Vertical Formation on Single 8M/200Kg PSC Pole(At Dead End) 3Ph, 4Wire REC-XII Plan-LT-009
103 REC-XII Plan-LT-010-SH1
GA of LT Line Vertical Formation on Single (In Line Arrangement)
1Ph, 2Wire
104 REC-XII Plan-LT-010-SH2
GA of LT Line Vertical Formation on Single (In Angular Arrangement)
1Ph, 2Wire
106 GA of LT Line Vertical Formation on Single (At Dead End) 1Ph, 2Wire REC-XII Plan-LT-012
107 GA of LT Line Formation on Single (In Line Arrangement) With LT AB Cable REC-XII Plan-LT-013
108 GA of LT Line Formation on Single (Dead End Arrangement) With LT AB Cable REC-XII Plan-LT-014
109 REC-XII Plan-LT-015(SHT-1)

GA & Component Details of AB Cable Connections And Tappimng Arrangement
110 REC-XII Plan-LT-015(SHT-2)
111 433V Danger Board REC-XII Plan-LT-016
General Drawing
112 Service Connection Single Phase REC-XII Plan-Gen-002
113 Cable Trench Layout REC-XII Plan-Gen-003
114 RCC Base PAD For PCC Pole REC-XII Plan-GEN-004
115 Spiral Earthing Details REC-XII Plan-Gen-005
116 Pipe Type Earthing REC-XII Plan-GEN-006
117 Pipe Type Earthing (As per IS 3043) REC-XII Plan-GEN-006A
118 Stay Set Arrangement for 11KVLT Line REC-XII Plan-GEN-007
119 Foundation Details of 8.0 9.0MTR. PSC Pole REC-XII Plan-Gen-008
120 Concrete (PCC) Foundation Details for PSC Poles REC-XII Plan-Gen-009
121 Strut Arrangement REC-XII Plan-Gen-010
122 Spike Type Earthing for Normal Soil REC-XII Plan-Gen-012
123 Details Of Cable Trenches (Inside Control Room) REC-XII Plan-GEN-013
124 Detail Of Bondary Wall For Switchyard With Entrance Gate REC-XII Plan-GEN-014
125 Detail Of Fencing For Switchyard With Gate Arrangement REC-XII Plan-GEN-015
126 G.A. of Control Building REC-XII Plan-GEN-016
127 Details of RCC Road and Drain REC-XII Plan-GEN-017
128 Septic Tank & Soak Pit Details REC-XII Plan-GEN-018
129 33 KV Tower Structure Marked T1 REC-XII Plan-GEN-019
130 11 KV Beam Structure REC-XII Plan-GEN-020
131 33 KV Beam Structure REC-XII Plan-GEN-020A
132 Structure Detail of 11KV PI REC-XII Plan-GEN-021
133 Structure Detail of 11KV Isolator REC-XII Plan-GEN-022
134 Structure Detail of 11KV LA REC-XII Plan-GEN-023
135 Structure Detail of 33KV HG Fuse REC-XII Plan-GEN-024
136 Structure Detail of 33KV Isolator REC-XII Plan-GEN-025
137 Structure Detail of 33KV LA REC-XII Plan-GEN-026
138 Structure Detail of 33KV PI REC-XII Plan-GEN-027

139 Foundation Detail of 11KV VCB & CT REC-XII Plan-GEN-028
140 Foundation Detail of 33KV VCB & CT REC-XII Plan-GEN-029
141 Foundation Detail of 33KV ISO, HG Fuse and 11KV ISO REC-XII Plan-GEN-030
142 Details of Girder Type"G2" REC-XII Plan-GEN-031
146 Structure Details of Tower Type-"T1" REC-XII Plan-GEN-035
148 Structure Details of Tower Type-"T2A" REC-XII Plan-GEN-037
150 Structure Details of Tower Type-"T3A" REC-XII Plan-GEN-039
151 General Arrangement of 33/11KV Sub-Station REC-XII Plan-GEN-040
152 Layout of 33/11KV Sub-Station REC-XII Plan-GEN-041

Single Line Diagram of 1x3.15MVA (Type-A)
153 REC-XII Plan-GEN-042A
33/11KV Substation with Indoor 11kV Switchgear
Single Line Diagram of 1x5MVA (Type-B)
154 REC-XII Plan-GEN-042B
Single Line Diagram of 2x5MVA (Type-C)
155 REC-XII Plan-GEN-042C
156 Layout Section of 33/11 KV Substation REC-XII Plan-GEN-043
33 KV Drawing
157 33 KV line conductor formation & clearances REC-XII Plan-33KV-M3
158 33 KV line pole bracket REC-XII Plan-33KV-M4
159 33 KV Lines ACSR conductors voltage regualtion table REC-XII Plan-33KV-M5
160 33 kV line arrangement of conductor at Single Pole Support (0˚ to 10˚ Deviation) REC-XII Plan-33KV-M7
161 33 KV Bridling "V" cross arm (road crossing) REC-XII Plan-33KV-Q1
162 33 KV "V" cross arm REC-XII Plan-33KV-Q2

12 11 10 9 8 7 6 5 4 3 2 1
H REC H
CONSTRUCTION STANDARD
160 190
A-3
A-7
650
G G
Note: V-Cross Arm of type, detailed out at Drawing No. Q-3 shall be used.
300
1070
F F
800
E E
D D
Earth Wire
Pole
C C
FOR TENDER PURPOSE ONLY

ALL DIMENSIONS ARE IN MM.
ELEVATION END VIEW
B Rural Electrification Corporation Ltd. B
All Dimensions are in mm.

TENGENT LOCATION
RGGVY-XII Plan Projects
MAXIMUM SPAN-107 METERS
11 KV LINES CONDUCTOR FORMATION AND
NOTE:- 11 KV -CONSTRUCTION WITHOUT CONTINUOUS CLEARANCE WITH EARTH WIRE
A
EARTH WIRE VIDE A-2 IS PREFERRED. A
R0
PROJECT
REC-XII Plan-11KV-A-3 1 OF 1 0
REV. NO. PREPARED CHECKED APPROVED DATE
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H REC H
A-9
G
KW-KM FOR 11 KV 3-PHASE LINES FOR 1% VOLTAGE DROP G
CONFIGURATION :
650 mm
F F
E 1070 mm E
D KW-KM FOR 1% VOLTAGE DROP * D
CONDUCTOR 1.0 0.9 0.8 0.7

p.f p.f p.f p.f
7/2.11mm ACSR 727 652 617 585
C 7/2.59mm ACSR 1048 902 838 782 C
7/3.35mm ACSR 1703 1356 1219 1106

*FOR A CONDUCTOR TEMPERATURE 60C FOR A CONDUCTOR TEMPERATURE OF 50C.THE ABOVE
FIGRES WOULD BE 3% HIGHER,AND FOR A TEMPERATURE OF 70C, ,ABOUT 3% LOWER.
11 KV LINES A.C.S.R CONDUCTOR VOLTAGE

REGULATION TABLE
A A
R0
PROJECT
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H REC H
A-12
G G
BILL OF MATERIAL
P.C.C SUPPORTS 8 MTR LONG 1 Nos.
CHANNELS (FOR V-CROSS ARM) REFER REC CONST. STD A-6 1 Nos.
CHANNELS (FOR HORIZONTAL CROSS ARM) 75X40-1150(APPROX.) 1 Nos.

F F
11 KV STRAIN INSULATORS WIOTH HARDWARE 3 Nos.
11 KV PIN INSULATORS WITH PINS 4 Nos.
POLE TOP BRACKET REFER REC CONST. STD A-7 1 No.
GUY SETS REFER REC CONST. STD G-2 1 No.
BUS PLATE REFER REC CONST. STD K-1 1 Nos.
PIPE/ROD EARTHING REFER REC CONST. STD J-2 1 Nos.

E E
BLACK CLAMP(FOR V-CROSS ARM) REFER REC CONST. STD K-2 1 No.
EARTHING MATERIAL,NUTS,BOLTS,CLAMPS ETC. AS REQUIRED
NOTE:-MAXIMUM SPAN BETWEEN THE TAPPING POLE AND

ADJACENT POLE OF THE BRANCH LINE - 50 MTR.
D D
C GL GL GL C

Elevation Side
11 KV LINES TAPPING ARRANGEMENT
A
FIRST STRUCTURE OF LENGTHY SPUR LINE A
R0
ALL DIMENSIONS ARE IN MM. REC-XII Plan-11KV-A-12
PROJECT 1 OF 1 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H REC H
A-16
BILL OF MATERIAL
F.C.C SUPPORTS 8 M 1 Nos.
G G
POLE TOP BRACKET 1 Nos.
V- CROSS ARM 1 Nos.
11 KV PIN INSULATORS WITH PINS 3 Nos.
SHACKLE INSULATORS 4 Nos.
U-CLAMP WITH BOLT 1 No.
EARTHING MATERIAL 1 No.

F F
BOLTS,NUTS,CLAMPS ETC. AS REQUIRED
BOLTS 16 O 1 Nos.
BASE PLATE 1 No.
NOTES:-
1. IF THROUGH BOLT ARRANGEMENT FOR FIXING

THE SHACKLE INSULATOR TO THE POLE IS
E E
NOT POSSIBLE SUITBALE POLE CLAMP MAY
BE USED.
2. THE EARTH-CUM-NETRUAL WIRE SHALL BE

RUN ON LT SHACKLE INSULATOR.
D D
GL GL
C C
ALL DIMENSIONS ARE IN MM. 11 KV LINES CONDUCTORFORMATION AND CLEARANCES

3-PHASE//SINGLE PHASE COMPOSITESYSTEM
OF 11 KV 3-PHASE LINE IN
A (PHASE - TO-NEUTRAL) A
R0
PROJECT
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H REC H
A-24
G G
F
NOTE:- F
1. REFER REC CONSTRUCTION STANDARD

A-22 FOR TYPE OF POLE TO BE USED.
2. THE DRAWING INDICATES THE POSITION

OF GUY CLAMP ON THE POLE. THE
DIRECTION OF GUY WIRE SHALL BE
E
SUCH AS TO COUNTERACT .THE E
RESULTANT TENSION OF THE CONDUCTORS.
3. GUY ANGLE SHALL BE 30 TO 45.
D D
ELEVATION
C C

PLAN 11 KV LINES CONDUCTOR FORMATION AND
ARRANGEMENT OF GUYS FOR 10 TO 60 ANGLE LOCATIONS
A
AT A-A' (SINGLE POLE SUPPORT) A
R0 SUPPORT)
PROJECT
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H REC H
A-27
G G
NOTE:-
1. REFER REC CONSTRUCTION STANDARD
A-22 FOR TYPE OF POLE TO BE USED.
2. THE DRAWING INDICATES THE POSITION

F
OF GUY CLAMP ON THE POLE. THE F
DIRECTION OF GUY WIRE SHALL BE

SUCH AS TO COUNTERACT .THE
3. GUY ANGLE SHALL BE 30 TO 45.
E E
D D
ELEVATION
C C
PLAN 11 KV LINES CONDUCTOR FORMATION AND

ARRANGEMENT OF GUYS FOR DEAD
A LOCATIONS (DOUBLE POLE SUPPORT) A
R0
PROJECT
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
REC Construction Standard H
B-3
EARTH
KNOB
275
275
G G
30 X Y X 30 30 450
F F
75 X 40
WEIGHT 5.7 Kg/m
E E
D D
C C
3 PHASE
5 WIRE
1 PHASE
3 WIRE
END VIEW
ELEVATION ELEVATION
TANGENT LOCATION
SAGS HORIZONTAL MAXIMUM SPAN-57 MTRS. RGGVY-XII Plan Projects
SPACING
X Y
UP TO 750 300 450
750 TO 1200 450 450 415/240V Conductor Formation and Clearance Horizontal Formation
A A
R0

PROJECT REC-XII Plan-11KV-B-3 1 OF 1 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
75
300
300
300
300
NETURAL CUM
EARTH EARTH WIRE
KNOB
ELEVATION END VIEW

415 240V LINES CONDUCTOR FORMATION AND
CLEARANCES Vertical Formation
1 OF 1 0
12 11 10 9 8 7 6 5 4 3 2 1
H REC Construction Standard H
B-6
Bill of Material
Earth Knob Supports 7.5 M 1 No.
V-Cross Arm 1 No.
G
Black Clamp 1 No.
G
Pole Top Bracket 1 No.

L.T Pin Insulators 4 Nos.
L.T Pin 4 No.
Earth Knob 1 No.
Bolt 10 O 4 No.
F F
Horizontal
Sags Spacing Tangent Location
X Y Maximum Span-67 Mtr.
UP TO 750 300 450
E
750 TO 1200 450 450 E
Note:- All Dimension are in mm.
D D
GL GL GL
C C

ELEVATION END VIEW
415/240V Line Supports Horizontal Formation

A A
R0

BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
B-9
KW-KM For 415 Volts 3-Phase Lines For 1%% Voltage Drop
Configuration For AAC P
300 mm 300 mm 300 mm

G G
F
P F
N
Configuration For ACSR
E P P P N E
300 mm 300 mm 300 mm
D D
KW-KM for 1%% Voltage Drop *
CONDUCTOR 1.0 0.9 0.8 0.7

p.f p.f p.f p.f
C C
7//2.21mm ACC 1.37 1.21 1.14 1.08
7//3.10mm AAC 2.69 2.18 1.98 1.81 FOR TENDER PURPOSE ONLY
7//2.11mm ACSR 1.04 0.94 0.90 0.85
7//2.50 mm ACSR 1.49 1.31 1.22 1.15
7//3.35 mm ACSR 2.42 1.98 1.80 1.65

For A Conductor Temperature of 60 Degree Celsius. For Conductor Temperature of 50 Degree Celsius. The Above Figures Would be About
3% Higher, And for a Temperature of 70 Degree Celsius, About 3% Lower.
415 Volts Lines AAC and ASCR Conductors Voltage Regulation Table
A A
R0

BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
REC Construction Standard

H
B-10 H
EARTH
KNOB
30 X Y X 30
G G
30 X Y X 30
F F
E E
A
Figure-1
UP TO 10 for 7/2-11 mm & 7/2.59 ACSR
UP TO 5 for 7/23.35 mm ACSR Pole Shall be of
Special Strength
D D
B C
Figure-2 Figure-3
( 10 TO 30) ( 30 TO 60)
D
C Figure-4 C
( 60 TO 90)
Horizontal Spacing
x y
300 450
All Dimension are in mm.

Arrangement of Conductors at Angle Location 415/240 Volts Lines

(Cross Country) Horizontal Formation
A A
R0

BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
B-12
Cross Arm 75x40-5.7 kg/m
Bill of Material
Earth Knob Supports 7.5 M 1 No.
Cross Arm 1 No.
G
Black Clamp 1 No.
G
L.T Pin Insulators 3 Nos.

L.T Pin 3 Nos.
Earth Knob 1 No.
Bolt 16 O with Nuts 2 No.
F F
Horizontal
Sags Spacing
X Y
UP TO 750 300 450
750 TO 1200 450 450
E Note:- All Dimension are in mm. E
Pole
D D
GL GL GL
C C
ELEVATION END VIEW

415/240V Line Conuctor Formation And Clearances

3O,4W (Horizontal Formation)
A A
R0

BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H H

B-13
G G
Bill of Material
8 M Supports 1 No.
U- Clamp 3 Nos.
Shackle Insulators 3 Nos.
Earth Knob 1 No.
F Netural Cum Bolt 16 O with Nuts 4 No.
F
Earth Wire
Earth Knob
E E
Pole
D D
C C
GL GL GL
415/240V Line Conuctor Formation And Clearances

ELEVATION END VIEW 3O,4W (Vertical Formation)
A A
Note:- All Dimension are in mm. R0

BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
B-15
Bill of Material
8 M Supports 1 No.
U- Clamp 2 Nos.
G
Shackle Insulators 2 Nos. G
Netural Cum
Earth Knob 1 No.
Earth Wire
Bolt 16 O with Nuts 3 No.
F F
Earth Knob
E E
Pole
Pole
D D
C GL GL GL C

ELEVATION END VIEW
415//240V Line Conuctor Formation And Clearances
1O,3W (Vertical Formation)
A A
Note:- All Dimension are in mm. R0

BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
B-16
Tests:-
The Spaces shall comply with the
G
following Test Requirements:- G
1. Dry Power Frequency Withstand Voltage 23KV.
2 Wet Power Frequency Withstand Voltage 10KV.
3.Three Specification Shall be Maintained At A

F
Temp. of 70_2C For Period of 24 Hours.After F
This Treatment,The Speciments shall Not Show

Any Deformity,And After Cooling ,shall Have A
Minimum Tensile Strength of 375 Kg/Cm(500 Kg
For 13mm Dia Spacer)
E E
6mm. Dia Sprial Hole

( To Grip AAC/ACSR NOTE:-
Conductor From While 1 And 2 Will Be Treated AS Type Tests.
7/ 2.11 To 7/ 3.35 mm) The Third Test Will Be Carried Out On Each
Batch of 5000 Nos.
D D
C C
A View of the PVC Spacers FOR TENDER PURPOSE ONLY

on the L.T Line
L.T Lines PVC Spacer

A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
B-17
G G
F F
E E
D D
C C

R6
Earth Knob For L.T Line

A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
B-20
C1 C2 C3 C4
1. FOR 7/ 2.11 mm AND 7/ 2.59 mm ACSR THE ANGLE OF

G DEVIATION MAY BE TAKEN UP TO 10. G
NOTES:-
2. FOR 7/ 3.35 mm ACSR THE ANGLE OF DEVIATION MAY
BE TAKEN UP TO 5.
3. REFER REC CONSTRUCTION STANDARD B-19 .FOR

TYPE OF POLE TO BE USED.
F
Guy F
4.THE DRAWING INDICATES THE POSITION OF GUY

WIRE SHALL BE SUCH AS TO COUNTERACT.THE
5.GUY ANGLE SHALL BE 30 TO 45.
E E
NOTATIONS:-
C1,C2,C3 PHASE CONDUCTORS
C4 EARTH CUM NEUTRAL
D D
C C

Elevation
Guy
Plan 415V/240V Lines Conductor Formation And Arrangement of

Guys For 0 TO 10 Angle Locations(3-Phase,4Wire,Horizontal Formation)
A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
C1 C2 C3 C4
B-22
G G

TYPENOTES:-
OF POLE TO BE USED.

Guy RESULTANT TENSION OF THE CONDUCTORS.
F F
E E
NOTATIONS:-
D D
C
Elevation C
B Guy Rural Electrification Corporation Ltd. B

Plan
415V/240V Lines Conductor Formation And Arrangement of
A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
B-23
C1,2,3,4
C1 C2 C3 C4
G G

NOTES:-

F F
Guy
E E
NOTATIONS:-
D D
Elevation
Guy
C C

Guy

A
Plan Guys For 60 TO 90 Angle Locations(3-Phase,4Wire,Horizontal Formation)
A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
B-24
C1 C2 C3 C4
G G

NOTES:-

F F
Guy 3.GUY ANGLE SHALL BE 30 TO 45.
E E
NOTATIONS:-
D D
ELEVATION
C C
Guy

PLAN
Guys For Dead End Locations(3-Phase,4Wire,Horizontal Formation)
A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
B-25
C1 C2 C3 C4
G G

TYPENOTES:-
OF POLE TO BE USED.

F F

Guy
E E
NOTATIONS:-
D D
C C

Elevation
Guy

A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
C5
B-26
G
C1 C2 C3 C4 G

NOTES:-

F F

Guy
E E
NOTATIONS:-
C1,C2,C3,C5 PHASE CONDUCTORS
D D
C C

Elevation
Guy

Plan Guys For 10 TO 30 Angle Locations(3-Phase,5Wire,Horizontal Formation)
A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
C5 REC Construction Standard H
B-27
C1 C2 C3 C4
G G

TYPENOTES:-
OF POLE TO BE USED.
Guy 2.THE DRAWING INDICATES THE POSITION OF GUY

F F
E E
NOTATIONS:-
D D
C
Elevation C
B
Guy
Rural Electrification Corporation Ltd. B

Plan
A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
C5 C5
B-28
C1 C2 C3 C4
G G

NOTES:-

F F
Guy
E E
NOTATIONS:-
D D
Elevation
Guy
C C

Guy

A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
C5 B-29
G C1 C2 C3 C4 G

NOTES:-

F F
Guy
E E
NOTATIONS:-
D D
ELEVATION
C C

Guy
PLAN 415V/240V Lines Conductor Formation And Arrangement of

Guys For Dead End Locations(3-Phase,5Wire,Horizontal Formation)
A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
75
H H
B-30
C0
G G
300
TYPENOTES:-
OF POLE TO BE USED.
725

650
C1 WIRE SHALL BE SUCH AS TO COUNTERACT.THE

300
350
F F
50 3.GUY ANGLE SHALL BE 30 TO 45.
C2
300
250
E E
NOTATIONS:-
550
C3 C0,C1,C2,C3
C4
PHASE CONDUCTORS
EARTH CUM NEUTRAL
300
D
C4 D
C
Guy C

Elevation
Guys For Dead End Locations(3-Phase,5Wire, Vertical Formation)
A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
B-31
75
G G

C1 TYPE OF POLE TO BE USED.
NOTES:-
300
475
400

C2
200 350
F F

300
C3
500
300
E E
NOTATIONS:-
C1,C2,C3, PHASE CONDUCTORS
C4
Guy
D D
C C

Elevation
Guys For Dead End Locations(3-Phase,4Wire, Vertical Formation)
A A
R0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H H
18.2
REC
C-1
G G
44
165
F
240/ SMALL STEEL HEAD
F
1. PIN AS SHOWN SUITABLE FOR METAL CROSS

ARM.
40 INSULATOR PIN 2. FOR WOOD CROSS ARM INSTEAD OF SPRINGS

WASHER USE TWO SQUARE WASHERS 50x50x5mm
25 ON THE TOP AND THE OTHER BOTTOM
12 R
5
E
NOTES E
20O /
D D
150
SPRING WASHER
HEXAGONAL NUT
100

B
Rural Electrification Corporation Ltd.

TYPE S 165
IS:2488 (PART-II)
PROJECT:
PIN INSULATOR
RGGVY XII Plan Projects
TITLE
11 KV INSULATOR & FITTINGS INSULATOR PIN

A
SIZE SCALE DRG. NO. SHT. NO. REV. NO.

R0
REV. NO. PREPARED CHECKED APPROVED DATE PROJECT

A3 NTS REC-XII Plan-11KV-C-1 1 OF 1 0
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
REC Construction Standord H
C-3
Chloroprene Pad
G G
F
DISTRIBUTION TIE F
E E
D D
DISTRIBUTION TIE IN POSITION ON 11KV PIN INSULATOR FOR TENDER PURPOSE ONLY
B
2
PROJECT:
NOTE:- FOR DETAILS OF HELICALLY FORMED FITTING. REFER REC SPECIFICATION NO. 25/1983.
TITLE
Holding of Conductor on 11 kv. Pin Insulator
A
-Run (Using Helically Formed Fitting)
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H REC Construction Standord H
C-5
G G
F F
E E
D D
11kV CONDUCTOR DEAD-END FITTING IN POSITION CONDUCTOR DEAD-END FITTING
11 kv STRAIN INSULATOR HARDWRAE CONSIST OF:

1. HELICALLY FORMED DEAD -END FITTING.
2. CLEVIS THIMBLE AND
3. CROSS-ARM STRAP WITH BOLT

NOTE :- FOR DETAILS OF HELICALLY FORMED FITTING REFER
B REC SPECIFICATION NO 25/1983
2
PROJECT:

TITLE
11 KV Conductor Dead -End Arrangement
A
(Using Helically Formed Fitting)
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
REC
H
CONSTRUCTION STANDARD H
E-29
G G
STEP: I. MIX THE ' RESIN' AND 'HARDNER' AS PER INSTRUCTIONS OF
THE MANUFACTURER TO PREPARE PUTTY.
F F
I
E E
CLIP
STEP: II. MIX T-JOINT BY TWISTING OF STANDS OR BY USING

BINDING WIRE AS PER NORMAL PRACTICE.
D D
II
3
STEP: lII. APPLY PUTTY OVER THE JOINT TO COMPLETELY
CLIP ENCAPSULATE THE JOINT.
B
2
PROJECT:
III TITLE
Application of Epoxy Compound on T-Joint
A
for L. T. Service Connections
1
1
R0

A3 NTS REC-XII Plan-11KV-E-29 1 OF 1 0
D
H
12 11 10 9 8 7 6 5 4 3 2 1
E
F
A
H
B
F
E-30
12
12
17
32 4
11 20
2 13 3 4 5
1
11
11
27
20 15O
35
10 45
10
10
THREADS TO SUIT M-12
MIG BOLT
20 85 TYPE"A"
30
9
9
30
8
8
M S RIVET ELECTRO GALVANISED M-6 BOLT,NUT( IS:1367)
WITH PLAIN AND SPRING WASHER
17
32 4
7
7
11
2 3 4 5
3 1
2
6
6
20 15O
35
10
MIG BOLT TYPE"B"

5
5
20
115
30
43 12
12 18
4
30 24
NOTES:-
M S RIVET HOLE DIA TO SUIT M G BOLTS
3
1. ALUMINIUM ALLOY 'A-11' CONNECTOR GRIP WITH ELECTRIC

GALVANIZED MIO BOLT ,NUT WITH PLAIN AND SPRING ALL DIMENSIONS ARE IN MM.
WASHERS TO GRIP THE CONDUCTOR IN HORIZONTAL AND
VERTICAL DIRECTIONS.
2. ALUMINIUM ALLOY 'A-11'(IS:617-1975)BODY. FOR TENDER PURPOSE ONLY
3. EPOXY SEAL TO GUARD AGAINST ATMOSPHERIC EFFECTS.
4. HIGH PRESSURE FIT JOINT BETWEEN ALUMINIUM ALLOY AND
BRONZE COMPONENTS OF THE CONNECTOR.
5. HIGH STRENGTH CORROSION RESISTANT BRONZE BODY.
2
PROJECT:

TITLE
Bimettalic Connector (H. T.) for
11kV Distribution Transformer
1

R0

A3 NTS REC-XII Plan-11KV-E-30 1 OF 1 0
D
H
E
F
A
H
B
F
REC Construction Standord
12
E-33
12
A
11
11
B
10
10
C
9
9
8
8
7
7
FIGURE-1
6
6
5
5
FIGURE-2
4
FIGURE-3
3
A. SHOWS THE CORE SPLICE

B. SHOWS THE FILLER RODS
C. SHOWS THE OUTER SPLICE.
FIG.1 SHOWS THE CORE SPLICE - IN POSITION FOR TENDER PURPOSE ONLY
FIG.2 SHOWS THE CORE SPLICE AND FILLER
RODS IN POSITION.
FIG.3 SHOWS THE COMLETE JOINT AND THE
2
OUTER SPLICE IN POSITION.

PROJECT:

TITLE
Helically Formed Fittings Splice For ACSR Joints

1

R0

A3 NTS REC-XII Plan-11KV- E-33 1 OF 1 0
D
H
E
F
A
H
B
F
E-39
12
12
11
11
10
10
9
9
SERVICE CONNECTOR
APPLICATION OF CRIMPING TOOL

8
8
UNCRIMPED PORTION
7
7
6
6
CONDUCTOR
5
5
4
SERVICE CABLE 4
3
A VIEW OF CRIMPED SERVICE CONNECTOR (PARTLY CRIMPED)

2
PROJECT:

TITLE
CRIMPED JOINT FOR L.T. SERVICE CONNECTION
1

R0

A3 NTS REC-XII Plan-LT- E-39 1 OF 1 0
D
H
E
F
12 11 10 9 8 7 6 5 4 3 2 1
H
x REC H
F-1
Double 100 X 50
Clamp
G G
SUPPORTS - 9 M 2
L.T Line CHANNELS 100X50-2800(APPOX.) 4
75 x 40 75 x 40
CHANNELS 75X40-2800(APPOX.) 1
75 x 40
L 35X35X5 CHANNELS 75X40-X ARM FOR SUPPORTING
L.T Cable 2
Bracing DROP OUT FUSE UNIT
F
ANGLES 50X50X6-2800(APPROX.) 2 F
ANGLES 35X35X5- 460(APPROX.) 2

ANGLES 35X35X5- BRACING FOR 2
SUPPORTING
H.G.FUSE FOR
SUPPORTING
7500
DISTRIBUTION BOX 1
L 50X50X6 For
Transformer Belting DISTRIBUTION TRANSFORMER 1
Transformer
L 50x50x6
E L 35X35X5 Double DROP OUT FUSE UNIT -3 PHASE 1 SET E
TRANSF
75 x 40
5490
( UP TO 100 KVA)
3
5440
11 KV LIGHTNING ARRESTERS
DISTRIBUTION BOX 1
EARTHING SET AS REQD.

Double 100 X 50
DANGER BOARD 1
3660
Additional Clamp CLAMPS,NUTS,BOLTS,BARBED WIRE ETC AS REQD.
For Rails,Beams,Tublar
2440( APPROX.)
Poles Danger Board L.T CABLE AS REQD.

D D
L.T Distribution
Box
2000
2440
G.L G.L G.L
C Earthing
Pipe
x
J-2
K-1
B
ELEVATION VIEW XX Rural Electrification Corporation Ltd.
PROJECT:

TITLE
11 KV/433-250V Distribution Sub-Station With Drop Out Fuses
A

R0

A3 NTS REC-XII Plan-11KV- F-1 1 OF 1 0
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
REC
H
AB SWITCH H
F-2
DOUBLE 75X40
G
SUPPORTS - 9 M 2 G
CLAMP
SINGLE
75x40 CHANNELS 100X50-2800(APPOX.) 4
800
LA
CHANNELS 75X40-2800(APPOX.) 2+1
CHANNELS 75X40-X ARM FOR SUPPORTING 2+2
H.G FUSE & L.A
460 760 760 460 ANGLES 50X50X6-2800(APPROX.) 2
LT LINE
F LT CABLE ANGLES 35X35X5- 460(APPROX.) 2 F
ANGLES 35X35X5- BRACING FOR 2

SUPPORTING
L 75X40 H.G.FUSE FOR
DOUBLE 75X40
L 35X35X5 SUPPORTING
L50X50X6 FOR DISTRIBUTION 1BOX
TRANSFORMER DISTRIBUTION TRANSFORMER 1
BELTING
7500
E AIR BREAK SWITCH(HORIZONTAL TYPE) 1 E
H.G FUSE UNIT -3 PHASE 1 SET

L35X35X5 TRANSFORMER L35X35X5
UP TO
100 KVA BRACING 11 KV LIGHTNING ARRESTERS 3
5490
DISTRIBUTION BOX 1
DOUBLE 100X50
4900
15 EARTHING SET AS REQD.
ADDITIONAL CLAMP 20 DOUBLE 75X40
1
3660
D
FOR RAILS BEAMS DANGER BOARD D
TUBULAR POLES L.T. DISTRIBUTION

BOX CLAMPS,NUTS,BOLTS,BARBED WIRE ETC AS REQD.
2440 APP
OPERATING L.T CABLE AS REQD.

HANDLE
2000
Operating
handle
1250
2440
C

1500

J-2 PROJECT:
K-1 VIEW AT X-X
J-2 RGGVY XII Plan Projects
ELEVATION TITLE
11 KV 433-250 V Distribution Sub-Station With A.B Switch
A
& Horn Gap Fuses
R0

12 11 10 9 8 7 6 5 4 3 2 1
1350 REC
X
F-3
2 2
600
5
1500
1200
3
3
BILL OF MATERIAL
460 760 760 460 7
L.T. LINE BRACING
11 KV
H.G
S.No
FUSE
1 SUPPORT - 9m 2
1200
2 CHANNEL 100X50 - 2800 (APP.) 2
4 3 CHANNEL 75X40 - 1500 (APP.) 2
4 CHANNEL 75X40 - 2800(APP.) 4
5 5 ANGLE 50X50X6 - 2800 (APP.) 3
6 ANGLE 35X35X5 - BREACHING FOR SUPPORTING
A - B SWITCH - 1000 ( APP.) 2
5
7500
7 ANGLE 35X35X5 - FOR TRANSFORMER BELTING 2
8 ANGLE 75X40 - X. ARM FOR SUPPORTING
6 A - B SWITCH - 1000 (APP.) 4
6 TRANSFORMER BRACING
UP TO 9 DISTRIBUTION TRANSFORMER 1
100 KVA 9 10 AIR BREAK SWITCH (HORIZONTAL TYPE) 1 SET
5490
4 11 H. G. FUSE UNIT - 3 PHASE 1 SET
2
12 11 KV LIGHTING ARREST'S 3
4500
15 13 13 DISTRIBUTION BOX 1
ADDITIONAL CLAMP
14 BASE PLATE (REFER K-1) 2
3660
FOR RAILS BEAMS
20 15 DANGER BOARD 1
TUBULAR POLES
16 CLAMPS, NUTS, BOLTS, BARBED WIRE ETC AS REQD
2440 APP
17 L. T. CABLE AS REQD
OPERATING 18 PIPE/ROD EAR THING (REFER J-2) AS REQD
HANDLE
2000
19 EAR THING SET AS REQD

20 BOARD 1
1250
2440
1500
J2 J2
K-2
POLE
X' K-1 VIEW AT X-X DETAIL 'A'
K-2
ELEVATION
R
Y
B
760 760
TAPPING ARRANGEMENT
REC-XII Plan-11KV- F-3
12 11 10 9 8 7 6 5 4 3 2 1

H
F-7 H
460
460
G G
760
760
2440
2440
F F
760
760
415
E E
460
460
REFER REC CONSTRUCTION
STANDARD F-2 REFER REC CONSTRUCTION
STANDARD F-4
310
PLAN
D
PLAN OF PIN INSULATORS
D
400 500 OF PIN INSULATORS

OF PIN INSULATOR
205 75x40
75x40
ALL DIMENSION ARE IN MM
C
415
4000 FROM GL
460 760 760 460
35X35X35
ELEVATION
2440
B
ELEVATION SIDE Rural Electrification Corporation Ltd.

PROJECT:

TITLE
11KV HORN GAP FUSES MOUNTING DETAILS
A

R0

12 11 10 9 8 7 6 5 4 3 2 1
A
H
E
F
F-10
12
12
Lightining Arrester
11
A.B Switch
11
L.A Earthing Lead
10
10
Pole
H.G Fuse
9
9
Embedded Pole Earth
Transformer
8
8
7
7
LT Circuit Breaker Box
6
6
AB Switch Handle
5
5
G.L G.L
Earthing Electrode
4

3

2
PROJECT:

TITLE
Earthing Arrangement for Distribution Substation
1

R0

A3 NTS REC-XII Plan-11KV-F-10 1 OF 1 0
D
H
E
F
F-11
12 11 10 9 8 7 6 5 4 3 2 1
H H

350 F-13
1100 HOT LINE

G
1100 CLAMP
G
BILL OF MATERIAL
350 P.C.C SUPPORTS 8 M 1 No.
400 POLE WITH BRACKET 1 No.

FUSE CUT OUT
11 KV PIN INSULATOR WITH PIN 1 No.
F
SHACKLE INSULATOR 1 No.
F
A.B.C U-CLAMP WITH BOLT

800 1 No.
L.A WITH FIXTURE 1 No.
FUSE CUT OUT WITH FIXTURE 1 No.
SINGLE PHASE TRANSFORMER WITH 1 No.

400 L.A LT M.C.C.B AND FIXTURE
E A.B.C AS REQD. E
OPERATING POLE CLAMP 1 No.

HANDLE FOR
EARTHING MATERIAL,NUTS,BOLTS,CLAMPS,ETC. AS REQD.
L.T,M.C.C.B
HOTLINE CLAMP 1 No.
BASE PLATS 1 No.

5050
D D
SINGLE PHASE NOTE:-

THE TRANSFORMER MOUNTING DETAILS ARE GIVEN
TRANSFORMER IN R.E.C CONSTRUCTION STANDARD 'F-14'.
3800 ALL DIMENSIONS ARE IN MM.

G L G L
B

1500
PROJECT:

TITLE
Single Phase (Phase to Neutral)
ELEVATION SIDE
A
Distribution Sub-Station Arrangement
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

H
F-14 H
/
20 O-200 LONG BOLT
NUT WITH SPRING & 75 X 40 - 520 LONG
SEE DATAILS M.S. CHANNEL
FLAT WASHERS
AT "B"
G G
TRANSFORMER
TRANSFORMER
440 450 440 450 300
A A
F F
/
20 O-200 LONG BOLT
NUT WITH SPRING AND
FLAT WASHERS
ALTERNATIVE-I
E
ALTERNATIVE-II E
/ POLE MOUNTING LUG

20 O FLAT WASHER
2-JUMP PROOF LIPS
D D
75
32
TRANSFORMER
100
/ /
22
POLE BOLT SPACING
SLOT SPACING
20 O 100 Long 20 O SPRING POLE CLAMP WITH
BOLT WITH NUT WASHER EXTENDED ARM 50X6 FLAT
440
450
DETAIL AT 'AA'
C
75
NOTE:- DETAIL AT "B"
1.ALTERNATIVE-I WILL BE USED WHEN SUITABLE HOLES ARE FOR TENDER PURPOSE ONLY
AVAILABLE IN THE FOR THROUGH BOLTS.
2.ALTERNATIVE-I WILL BE USED WITH POLE CLAMPS.
B

PROJECT:

TITLE
Single Phase TransformerMounting Details
A

R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
B B
H Y
Y
Y
F-15 H
350
300
R R
R
B BILL OF MATERIAL
1100 P.C.C POLE 8 M 1 No.
V-CROSS ARM 1 No.

G
X G
POLE WITH BRACKET 1 No.
H G FUSE 11 KV PIN INSULATOR WITH FIXTURE 1 No.
11 KV N.G FUSEOR FUSE CUT-OUT 1 No.

Z L A'S
1600 11 KV L.A'S WITH FIXTURE 1 No.
SINGLE PHASE TRANSFORMER 1 No.

A B LT M.C.C.B 1 No.
F
M.S CHANNEL 75 X40X800 F
TO L T EARTHING MATERIAL,NUTS,BOLTS,CLAMPS AS REQD.

TO L T BUSHING POLE CLAMP,ETC.
BUSHING OF TRANS.
1 OF TRANS. 8000 1 2 NO.2 1
NO.2 INTERCONNECTED
CABLE
NOTE:-
SINGLE PHASE L.V NETURAL TERMINAL OF ONLY ONE OF THE TRANSFORMER WILL
E TRANS. BE EARTHED AS SHOWN IN THIS SCHEMATIC DIAGRAM. E
11KV/440-220V
3800 LT CABLE
TO MCCB
MCCB MCCB
Y B
D D
G L G L L G
SECTION
1500 AT 'XX'
Y R
VIEW AT 'A' ELEVATION VIEW AT 'A'
C
R R
Y Y
B B B
TR-1 TR-2
TR-1 TR-2 TR-2 LA ALL DIMENSIONS ARE IN MM.
X LIGHT
XX MOTOR MCCB Y B
R
N
Y LA R FOR TENDER PURPOSE ONLY
B TR-1
LA
B L L M MCCB
SCHEMATIC X X XX
CONNECTION SECTION Rural Electrification Corporation Ltd.
DIAGRAM WITH LT OF AT 'ZZ'
PROJECT:
TRANSFORMERS
NO 1 & 2
TITLE
3-Phase Distribution Sub-Station
using Two 11kV (Phase to Phase)
A
Single Phase Transformers
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
1070 REC Construction Standord

H
300
F-19 H
HOT LINE BILL OF MATERIAL

CLAMP P.C.C POLE 7.5 M 1 No.
650 A.B.C
V-CROSS ARM 75X40 1 No.
G
HORIZONTAL CROSS ARM 75X40X1150 1 No.
G
11 KV PIN INSULATOR WITH PINS 2 No.
11 KV N.G FUSEOR FUSE CUT-OUT 2 No.
FUSE CUTOUT 11 KV L.A 2 No.
11 KV SINGLE PHASE TRANSFORMER 1 No.

M.S 50X50X6-600 FOR L.S'S FITTING 1 No.
F 1250 L.A. BASE PLATE 1 No. F
EARTHING MATERIAL,NUTS,BOLTS,CLAMPS AS REQD.

HOT LINE CLAMPS 2 NOS.
ABC AS REQD.
NOTE:-
1. TRANSFORMER MOUNTING DETAILS ARE AS PER REC
E OPERATING CONSTRUCTION STANDARAD F-14. E
2.AS AN ALTERNATIVE ARRANGEMENT TO ABC L.T LINE

HANDLE FOR SHOWN IN THE DRAWING,CABLE CONNECTION CAN BE
7500 MCCB USED TO THE FIRST POLE OF CONVENTIONAL L.T LINE
L.V. BUSHING
D D
SINGLE PHASE
3800 TRANSFORMER
G L G L
B

1500
PROJECT:
TITLE
Single Phase (Phase to Phase)
ELEVATION SIDE VIEW Distribution Sub-Station Arrangement
A

R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
L.A. REC Construction Standard

A
700 700 F-20
1000
1000
1000
U
Y BILL OF MATERIALS
G
SUPPORTS(8 M/200 KG)

B
HORIZONTAL CROSS ARM

400 400
100X50X6-150
L.T CABLE 100X50X6-150
FUSE CUTOUT L.A WITH FITTINGS
C
D.O FUSE WITH FITTINGS
25 KVA TRANSFORMER
L.T. BUSHING L.T.M.C.C.B
DISC INSULATOR WITH FITTINGS
25 KVA 3 PHASE STRUCTURE FOR TRANSMOUNTING:-
TRANSFORMER
100X50X6-1000
D
50X50X6-600 D
8000 EARTHING MATERIAL

GUY SET
BASE PLATE
5400 NUTS, BOLTS,POLE TOP CLAMPS
E
STRUCTURE FOR D.O FUSE MOUNTING:- E
L.T. CABLE
100X50X6-600
50X50X6-400
2440 L.T.MCCB
F
1500 F

L G G L

1500
2
G G
PROJECT:
ELEVATION SIDE VIEW
TITLE
Distribution Sub-Station Mounting
Arrangement on Single Pole
1
H SIZE SCALE DRG. NO. SHT. NO. REV. NO. H
R0

12 11 10 9 8 7 6 5 4 3 2 1
D
H
E
F
12 11 10 9 8 7 6 5 4 3 2 1
H
G-2
G. I. Stay Wire
G
Hellically Formed End Fitting G
F F
Thimble
E E
Stay Rod
D D
NOTE: FOR DETAILS OF HELLICALLY FORMED GUY GRIPS REFER REC SPECIFICATION NO. 25/1983

B

PROJECT:

TITLE
Guy -End Assembly
(Using Hellically Formed Fitting)
A

R0

A3 NTS REC-XII Plan-11KV-G-2 1 OF 1 0
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H
G-3
350
300 300 300

875
30
TO
G 30 45 G
TO 30
45 TO
45
NOTES :-
1. SINGLE GUY ARRANGEMENT AS PER

FIGURE 1, 2 & 3 CAN BE USED WHEN
TOTAL TENSION TO BE TAKEN ON THE
F
GUY DOES NOT EMCEED THE FOLLOWING F
LIMITS
SIZE OF GUY WIRE MAXIMUM TENSION

2
70 Kgf/mm QUALITY ON THE GUY
7/2.50 mm 920 Kg.

E
7/3.15 mm 1450 Kg. E
2. IN THE DURABLE GUY ARRANGEMENT THE

FOUNDATION OF THE GUYS SHOULD BE
FIG :- 1 FIG :- 2 FIG :- 3 SO PLACED THAT ONE DOES NOT REDUCE
SINGLE GUY THE STRENGTH OF THE OTHER . IN OTHER
250
WORDS, THE SOIL WHICH RESISTS THE

UP - LIFT SHOULD NOT BE DISTURBED
D
WHILE DIGGING THE FOUNDATION FOR D
THE OTHER STAY.

3. FOR DETAILS OF COMPONENTS OF GUY
ASSEMBLY, REFER, G - 1.
C
.
1500

B
DOUBLE GUY 1500 Rural Electrification Corporation Ltd.

PROJECT:

TITLE
Guying Arrangement Single & Double Guy
A

R0

A3 NTS REC-XII Plan-11KV-G-3 1 OF 1 0
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
R 11KV BUSBAR
H
Y L-3 H
G G
11000//110V
P.T.
F R F
Y
B
KWH KWH
CosO
/
E E
NOTE:-
D
A V A 1.EACH OF THE IN COMING AND OUTGOING 11 KV PANELS SHOULD
D
BE PROVIDED WITH A kWh. METER AND AN AMMETER FOR PROPER
ASSESSMENT OF LOSSES.IN ADDITION , EACH INCOMING PANEL
SHOULD HAVE A VOLTMETER. IN CASE THERE ARE NO INCOMING
RELAY SELECTOR SELECTOR PANELS,A VOLTAMETER SHOULD BE PROVIDED ON ONE OF THE
SWITCH SWITCH RELAY SELECTOR OUTGOING PANELS.
SWITCH
(i) PROTECTION
C
& INSTRUMENT 2.ONLY ONE P.T AND ONE POWER FACTOR METER NEED BE PROVIDED
C.T. AT EACH SUB-STATION.
(i) METERING
C.T.
B

FROM PROJECT:
TRANSFORMER OUTGOING
FEEDER
INCOMING PANEL OUTING PANEL TITLE

33-11kV Sub-Stn. Metering Arrangement.
A

R0

A3 NTS REC-XII Plan-11KV- L-3 1 OF 1 0
12 11 10 9 8 7 6 5 4 3 2 1
1525
12 11 10 9 8 7 6 5 4 3 2 1
H
M-4
50
G G
300
3
M. S. ANGLE 65X65X6(5.8 Kg-m)
F Pin Insulator M. S. CHANNEL F
100x50x6.4 - 65
530 LONG WELDED
590
WITH ANGLE
67 65 67
25
100
100
100
100
75
E E
8
240
50
50
/ HOLES
20O
140
380
380
30
60 30
D D
60
65 / HOLES
16O
100
100
100
/ HOLES
16O
40
40
25
40
65
ELEVATION END VIEW

Pole
END VIEW
ELEVATION FOR TENDER PURPOSE ONLY
B

PROJECT:

TITLE
33 kv Line Pole Bracket
A

R0

A3 NTS REC-XII Plan-11KV-M-4 1 OF 1 0
12 11 10 9 8 7 6 5 4 3 2 1
400 1530 400
Hole O25
/ Hole O25
/
5 Welded
2 1
4
3
Welded
a
/
Hole O18
450 400
170
170
50
ELEVATION END VIEW
/
Hole O18
7
a
35 35
100
PLAN
BACK CLEAT
33KV Bridling 'V" Cross Arm (Road Crossing)
BILL OF MATERIAL
PART STORE CODE
DESCRIPTION QTY.
NO. NO.
1 M. S. CHANNEL 100x50x6 = 1040 LONG 1 No. F-002308
3 M. S. ANGLE 65x65x6 = 710 LONG 1 No. F-000324
4 M. S. ANGLE 65x65x6 = 510 LONG 2 Nos. F-000324
7 M. S. CHANNEL 50x50x6 = 300 LONG 2 Nos. F-002308
Note: For P. C. C. PLOT = 230mm

b = 230mm

4
1530 5 8
/
Hole O25 Welded
1
8 /
Hole O18
3
2
230
/
Hole O18
6 450 400
170
130
50
ELEVATION END VIEW
/
Hole O18
75 75
75 710 75
7
PLAN 230
35 35
300
33KV 'V" Cross-Arm
ISMC BACK CLEAT (2 Nos.)
BILL OF MATERIAL
PART NO. DESCRIPTION QTY.
1. ISMC CHANNEL 100x50x6 = 1040 LONG 1 No.
2 ISMC CHANNEL 100x50x6 = 940 LONG 1 No.
3 ISMC ANGLE 65x65x6 = 710 LONG 1 No.
4 ISMC ANGLE 65x65x6 = 150 LONG 2 Nos.
5 ISMC ANGLE 65x65x6 = 75 LONG 2 Nos.
6 ISMC ANGLE 50x50x6 = 50 LONG 1 No.
7 ISMC CHANNEL 75x40x6 = 300 LONG 2 Nos.
8 ISMC PLATE 50x50x6 2 Nos.(Welded)
NOTE:- (1) a & b shown area for P.C.C. Poles

4 /
Hole O18
1070 5 Welded
/
Hole O18
3 2
Welded 150 Welded

180
ELEVATION END VIEW
6 Hole O18
/
150
75 75 50 50
50 300 50
250
PLAN
BACK CLEAT
11KV 'V" Cross-Arm
BILL OF MATERIAL
PART
DESCRIPTION QTY.
NO.
1 M. S. CHANNEL 75x40x6 = 710 LONG 1 No.
3 M. S. ANGLE 50x50x6 = 300 LONG 1 No.
4 M. S. ANGLE 65x65x6 = 125 LONG 2 Nos.
5 M. S. ANGLE 65x65x6 = 50 LONG 2 Nos.

/ /
Hole O20 Hole O20 Welded
1070
300 300
1
4 5
3 2
Welded /
Hole O18
ELEVATION END VIEW
6 /
Hole O18
300 1070 300
25 275 300 300 50 50

150
50 50 25
250
75 PLAN 75
BACK CLEAT
BILL OF MATERIAL
PART STORE CODE
DESCRIPTION QTY.
NO. NO.
6 M. S. CHANNEL 75x40x6 = 250 LONG 2 Nos. F-002255

33 KV Incomer Q7
33KV LA
33 KV Isolator
33KV CT
33KV VCB
33 KV Isolator
Bus Isolator
33KV Bus Bar
33 KV Isolator
33KV VCB 33KV VCB
33KV CT
33KV LA
33//11KV Transformer
5 MVA
11KV LA
CT CT
VCB
VCB
Bus Coupler
11 KV Isolator
VCB VCB VCB VCB VCB VCB

11//0.433 KV
100KVA Station
Transformer
Capacitor Feeder 1 Feeder 2 Feeder 3 Feeder 4 Feeder 5 Feeder 6
Bank
12 11 10 9 8 7 6 5 4 3 2 1
H H
G
BILL OF MATERIAL G
Part No. Description Qty.
1. M.S Channel 100 X50X6 = 3240 Long 2 Nos.
2. M.S Angle 65X65X6 = 1800 Long 2 Nos.

Details of 2
3. M.S Angle 50x50x6 = 2700 Long 2 Nos.
4. Strain Plate 3 Nos.

F F
5. M.S Angle 65X65X6 = 280 Long 4 Nos.
6. M.S Clamp 50x8 4 Nos.
7. Nut Bolts As reqd.

Details of 3
Details of 5 Details of 4
E E
Holes O 25
Back Cleat
Strain Plate
D D
M.S Flat
1. FLANGE OF ANGLE SHOULD BE WRAPPED ON OTHER SIDE OF

FLANGED AND THEN DRILLED.
2. ONE SIDE FLANGE SHOULD NOT BE CUT.
All dimensions are in mm.

C C
All holes are 18mm dim.

From Ground
level
General Arrangement of DC Crosss-Arm and Bracing With

Back Cleat for 150 m DP on 600 IBS PCC Poles
A A
R0
PROJECT
REC-XII Plan-11KV- s 1 OF 1 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H H
LAYOUT DAIGRAM OF ADDITIONAL 33 K V BAY AT 33/11 K.V. SUBSTATION MATERIAL IN 33 KV BAY AT 33/11 KV GRID SUBSTATION(RS JOISTS SUPPORTS)
No. Description UNIT QTY.
1. 9m. LONG REINFORCED 2 X175X85 mm R.S JOISTS NO. 2
2. 4.8 M D.C CROSS ARM SETS OF 100X50 MM M.S CHANNELS FOR BUS-BAR STRUCTURES SET 6
3. 33 KV ISOLATOR STRUCTURE AND METERING EQUIPMENT STRUCTURES SET 4

(DOUBLE POLE SHAPE)OF 9 M LONG REINFORCED 2X175X85 mm R.S JOISTS
G G
4. 4.8 M D.C CROSS ARM SETS OF 100X50 MM M.S CHANNELS FOR BUS-BAR STRUCTURES NO. 4
5. 33 KV STRAIN SETS WITH 4 DISCS AND H.W/H.T CONDUCTOR DEAD END TO HOLD ONE NO. SET 18
6. ACSR 100 mm. SQ AT EQ. CONDUCTOR KM. 0.05
7. 33 KV PIN INSULATOR WITH G.I PINS NO. 3
8. T CLAMPS FOR JUMPERS NO. 12
9. 33 KV LIGHTING ARRESTORS NO. 3

VCB
10. 33 KV AB SWITCH NO. 1
F F
STAY 11. MOUNTING STRUCTURE SET 1
12. CONCRETING OF STRUCTURE @0.5 CMT PER STRUCTURE CMT 1
13. PAINTING OF POST SET 1
14. NUTS,BOLTS AND OTHER MINOR ITEMS SET 1
ELEVATION 15. SPIKE EARTHING SET 4
16. G.I PIPE EARTHING SET 2
17. LABELLING LS
E 18. G.I STANDERD WIRE FOR EARTHING 7/3.15 MM DIA KGS. 31 E
D D
M.E Mounting
D.P
PLAN
C C
Lay Out Daigram of Additional 33 Kv Bay at 33/11 Kv

Substation
A A
R0
PROJECT
REC-XII Plan-11KV- S2 1 OF 1 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H H
LAYOUT DAIGRAM OF ADDITIONAL 11 K V BAY AT 33/11 K.V. SUBSTATION MATERIAL IN 33 KV BAY AT 33/11 KV GRID SUBSTATION(RS JOISTS SUPPORTS)
1. 9m. LONG REINFORCED 2 X175X85 mm R.S JOISTS NO. 2
3. 33 KV ISOLATOR STRUCTURE AND METERING EQUIPMENT STRUCTURES SET 4

(DOUBLE POLE SHAPE)OF 9 M LONG REINFORCED 2X175X85 mm R.S JOISTS
G G
4. 4.8 M D.C CROSS ARM SETS OF 100X50 MM M.S CHANNELS FOR BUS-BAR STRUCTURES NO. 4
5. 11 KV STRAIN SETS WITH 4 DISCS AND H.W/H.T CONDUCTOR DEAD END TO HOLD ONE NO. SET 18
7. 11KV PIN INSULATOR WITH G.I PINS NO. 3

VCB
9. 11KV LIGHTING ARRESTORS NO. 3

F F
11. MOUNTING STRUCTURE SET 1
12. CONCRETING OF STRUCTURE @0.5 CMT PER STRUCTURE CMT 1

ELEVATION 13. PAINTING OF POST SET 1
14. NUTS,BOLTS AND OTHER MINOR ITEMS SET 1
15. COIL EARTHING SET 4
16. G.I PIPE EARTHING SET 2
17. LABELLING LS
E 18. G.I STANDERD WIRE FOR EARTHING 7/3.15 MM DIA KGS. 31 E
M.E Mounting
D.P
D D
PLAN
MATERIAL IN 33 KV BAY AT 33/11 KV GRID SUBSTATION( PCC POLE SUPPORTS)

1. BUS BAR SUPPORTS 9.1 M LONG PCC POLE 272 kgs. NO. 2
C C
3. ISOLATOR STRUCTURE AND METERING EQUIPMENT STRUCTURES SET 4
(DOUBLE POLE SHAPE)OF 9 .1M LONG PCC POLE
4. 4.8 M D.C CROSS ARM SETS OF 100X50 MM M.S CHANNELS FOR BUS-BAR STRUCTURES NO. 4 FOR TENDER PURPOSE ONLY
5. 11KV STRAIN SETS WITH 4 DISCS AND H.W/H.T CONDUCTOR DEAD END TO HOLD ONE NO. SET 18
ACSR 100 mm. SQ AT EQ. CONDUCTOR
7. 11 KV PIN INSULATOR WITH G.I PINS NO. 3

B
9. 11 KV LIGHTING ARRESTORS NO. 3
Rural Electrification Corporation Ltd. B
11. MOUNTING STRUCTURE SET 1
CONCRETING OF STRUCTURE @0.5 CMT PER STRUCTURE CMT 1

12.
13. PAINTING OF POST SET 1
14. NUTS,BOLTS AND OTHER MINOR ITEMS SET 1 Lay Out Daigram of Additional 11 Kv Bay at 33/11 Kv
15. COIL EARTHING SET 4 Substation
A 16. G.I PIPE EARTHING SET 2 A
17. LABELLING LS
G.I STANDERD WIRE FOR EARTHING 7/3.15 MM DIA KGS. 31 R0

18.
PROJECT
REC-XII Plan-11KV- S3 1 OF 1 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
REC
H
CONSTRUCTION STANDARD H
Gen-3
G G
F F
E E
D D
C C
Cable Trench Layout

A A
R0
PROJECT
REC-XII Plan-11KV-Gen-3 1 OF 1 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
1635
H H
50 650 235 650 50
DOG CONDUCTOR
CONDUCTOR
150
WITH CRIMPED LUG
11 /
11 4NOS. M16x65
TWO LUGS
4NOS.O12 HOLE
HT CABLE
TERMINATION KIT CONNECTED
3 2
TOGETHER
CABLE
40
1000
TOP CHANNEL (75x40)
G G
/
MASSENGER WIRE 70 4NOS. O12 HOLE 70
6
4NOS. M16x65
CONDUCTOR TO CABLE CONNECTION
M10x60
30 162 180 1315 180 163 30
4
13 12 5
150
175 865 175 /
50x8 MS FLAT 50 50 4NOS.HOLE O18x36
/ HOLE
4NOS. O18
2200
70
35 35
.
F
(MIN) 30 30 (MIN) AB CABLE SUPPORTING ANGLE(50x50x6) F
11KV, 3CX35X70 AB CABLE PLAN

/
O 18 HOLE
50
BILL OF MATERIAL
ERE SECTION MATERIAL LENGTH kG.//mtr. TOTAL Wt.
235 CODE
DESCRIPTION
MM
QTY.
KG.
295
1 8M//200kG PSC POLE M.S. 8000 2 NOS.
1000
7
CLAMP FOR 2 TOP CHANNEL C 75X40 M.S. 1635 7.90 2 NOS. 25.28
TOP CHANNEL (ISMC75) BACK CLAMP FOR TOP CHANNEL
3 50X8 M.S. 441 3.14 2 NOS. 2.769
95
E 4 AB CABLE SUPPORTING ANGLE 50x50x6 M.S. 2200 4.50 1 NOS. 9.900 E
DANGER
11000 VOLTS
2NOS, M10x60 11000 N 2NOS, M10x60 5 BC FOR AB CABLE SUPPORTING ANGLE 50X8 M.S. 551 3.14 2 NOS. 13.360
[[kRkjk
9 50x8 MS FLAT
5500
U CLAMP FOR AB CABLE SUPPORTING CHANNEL
190
8 6 M.S. 3 NOS.
35 35 7 BARBED WIRE M.S. AS REQ.
8 DANGER BOARD M.S. 3 NOS.

(MIN) 30 30 (MIN) 9 BACK CLAMP FOR BARBED WIRE 50X8 M.S. 661 3.14 3 NOS.
2 2.075
PLAN 10 ALUMINIUM BINDING WIRE AS REQ.

/
O 18 HOLE
11 HT AB CABLE TERMINATION KIT 2 NOS.
50
12 EYE HOOK 2 NOS.
D
1 180 13 HT TENSION CLAMP 2 NOS.
D
240
3000
TOTAL 53.384
SR.
NO. DESCRIPTION SECTION MATERIAL LENGTH kG.//mtr. QTY. TOTAL Wt.
95 MM KG.
1500 14 NUTS & BOLTS M16 65 0.164KG//NO. 8 NOS. 1.132
50x8 MS FLAT 15 NUTS & BOLTS M10 60 0.055KG//NO. 6 NOS. 0.330
143
16 SPRING WASHERS M16 3.5 THK. 0.009KG//NO. 8 NOS. 0.072
35 35
PIPE EARTHING 17 SPRING WASHERS M10 3.5 THK. 0.003KG//NO. 4 NOS. 0.012
C 005
18 PLAIN WASHER M16 3 THK. 0.015KG//NO. 16 NOS. 0.240
(MIN) 30 30 (MIN) PLAIN WASHER M10 3 THK. 0.005KG//NO. 4 NOS. 0.020
19
GL GL GL GL
PLAN TOTAL
/
O 18 HOLE 1.706

300
50
0
180
240
CLAMP FOR
1500
CONCRETE GRADE
AB CABLE SUPPORTING ANGLE
B
1 : 2 : 4
50
THREADS FOR
CLAMPING
100
90 90 290 PROJECT:
TITLE
FRONT VIEW SIDE VIEW U CLAMP FOR HT CABLE 11KV AB CABLE TO CABLE END TERMINATION ARRANGMENT
A
DATE SCALE DRG. NO. REV. NO.
R0 NTS R0
SIZE
REC-XII Plan-11KV-023
SHT. NO.
A3 1 ON 1
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H H
1070 1070
90 002
808
145
006
2-M16x200
75
650
008 2-M16x70
3Cx185sq mm XLPE
End Termination kit
G 812 007 G
4-M16x65 813a
2000 3-M16x65
1500
001
005 3Cx185 sq mm XLPE
Cable 30~o 45 o
813
812 2-M16x35
4-M16x65
3-M16x65
F F
815
2000
1000
1-M16x35 004
814
815 DANGER
11000
11000
VOLTS
003
E
2-M16x35 E
2-M16x65
8000
3-M16x65
812
2-M8x50 814B
3000
2500
D D
0
0
GL GL GL GL
C C
GENERAL NOTES:
1) ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE MENTIONED
CONCRETE GRADE
1500
2) FOR EARTHING REF. DRG.No NESCL-RE-GEN-006

1 : 2 : 4 3) FOR FOUNDATION DETAILS REF. DRG. No. NESCL-RE-GEN-009
4) ALL CHANNELS & ANGELS SHALL CONFORM TO IS: SP6 PART 1

DOUBLE RUN 5) ALL MS PARTS SHALL CONFORM TO IS: 2062
6) ALL MS PARTS SALL BE HOT DIP GALVANISED AS PER IS: 2629 & IS: 4759
90 FRONT VIEW 90 290

B B
PROJECT: RGGVY XII Plan Projects

TITLE GA OF 11 KV LINE CROSSING OF RAILWAY
USING 3c X 185 SQMM XLPE CABLE ON
A
DP STRUCTURE 8 MTR. 200 KG PSC POLES A
DATE SCALE DRG. NO. REV. NO.

R0 GRB RWG NTS R0
SIZE
REC-XII-PLAN-11KV-RLC-DRG-001
PROJECT SHT. NO.
BY BY BY A3 1 OF 4
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
GUY GUY
90
BILL OF MATERIAL
H 90 ERE DESCRIPTION QTY. REF. DRG. NO.
H
CODE
GUY GUY
PLAN
60 1 8M//200kG PSC POLE 2 NOS. REC-XII Plan-GEN-001A
B 2 11kV PIN INSULATOR WITH GI PINS 3 NOS.
1070 1070
2 3 BARBED WIRE 7000MM
90
808
6 145 4 11kV DANGER BOARD 1 NO. REC-XII Plan-11KV-022
18
36 5 PIPE EARTHING 1 SET REC-XII Plan-GEN-006
2NOS. M16x200 6 11kV DISK INSULATORS WITH H//W 6 NOS.
G 2NOS. M16x70 G
1500 o
7 STAY SET ARRANGEMENT 4SET
31 808 TOP CHANNELS (100x50) 2 NOS.
REC-XII Plan-GEN-007
7
812 BELTING ANGLES(50x50x6) 2 NOS.
2000
DETAIL A 815 BRACING ANGLES(50x50x6) 2 NOS. REC-XII Plan-11KV-002
1
809 FISH PLATE 6 NOS. REC-XII Plan-11KV-002
Angle should not be cut on its one 816 TOP CLAMPS FOR ANTI CLIMBING DEVICE 1 SET REC-XII Plan-11KV-002
of the sides. Instead, both the 817 BOTTOM CLAMPS FOR ANTI CLIMBING DEVICE 1 SET REC-XII Plan-11KV-002
F M16x35 2NOS. M16x65 F
A
812
813 sides should be bent and then 813 CLAMP A FOR BELTING ANGLE 2 NOS. REC-XII Plan-11KV-002
drilled. 814B CLAMP B FOR BELTING ANGLE 2 NOS. REC-XII Plan-11KV-002
810 CLAMP FOR STAY SET 4 NOS. REC-XII Plan-11KV-002
816
M10x65
BOLTS AND NUTS AS REQD,.
815
M16x35
2000
1000
E
3
NOTES:- E
817 145 1) ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE MENTIONED.

2) MANUFACTURING TOLERANCE
815
UPTO 50mm= _+5%
2NOS. M16x65 _
51 TO 100mm = +4%
BOLT 101 TO 300mm = _
8000
DANGER
11000
11000 N VOLTS +3%
812
M8x30
4
814B
ABOVE 300mm = _
+2%
3) ALL MS PARTS SHALL CONFIRM TO IS :2062
4) ALL M.S. FABRICATED ITEMS SHALL BE HOT DIP GALVANISED.AS PER IS 2629&4759
D D
5) ALL THE ITEMS SHALL BE MARKED WITH ERECTION CODE

100x50 CHANNEL
6) WEIGHT MENTIONED IS FOR PACKING & FORWARDING PURPOSE.
PSCC POLE
3000
809 FISH PLATE

7) ALL CHANNELS & ANGLES SHALL CONFORM AS PER IS:SP6 PART-1
DETAIL B
2500
ALL CHANNELS SHALL BE ISLC CHANNELS

8) THIS DRAWING SHALL BE USED AT TENSION LOCATION FOR SECTIONALISING
AT AN INTERVAL OF 1.6KM.
PIPE EARTHING 005

0
GL GL GL GL
PIPE EARTHING
300
12
00
1500
CONCRETE GRADE
00
12
B
1 : 2 : 4

90 90 290
FRONT VIEW SIDE VIEW 1500 GA OF 11kV LINE FORMATION AT DP ON 8M//200kG
POLE WITH COMPONENTS (IN LINE ARRANGEMENT)
A
R0

PROJECT REC-XII Plan-11KV-002S 1 OF 2 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
ARRANGEMENT OF GUYS
GUY GUY 90 ERE DESCRIPTION QTY. REF. DRG. NO.
CODE
H
GUY GUY
90 1 8M//200kG PSC POLE 2 NOS. REC-XII Plan-GEN-001A H
2 11kV PIN INSULATOR WITH GI PINS 3 NOS.
PLAN
60 3 BARBED WIRE 7000MM
GUY GUY
B
1070 1070 4 11kV DANGER BOARD 1 NO. REC-XII Plan-11KV-022
62.5
90
808
6 145 6 11kV DISK INSULATORS WITH H//W 6 NOS.
18
100
36
600
810 7 STAY SET ARRANGEMENT 6 SET REC-XII Plan-GEN-007

811 808 TOP CHANNELS (100x50) 2 NOS.
G 2NOS. M16x200 REC-XII Plan-11KV-002 G
1500 0
31
2NOS. M16x70
812 BELTING ANGLES(50x50x6) 2 NOS. REC-XII Plan-11KV-002
815 BRACING ANGLES(50x50x6) 2 NOS. REC-XII Plan-11KV-002
GU
7
Y
2000
GU
809 FISH PLATE 6 NOS. REC-XII Plan-11KV-002
DETAIL A
Y
816 TOP CLAMPS FOR ANTI CLIMBING DEVICE 2 SET REC-XII Plan-11KV-002
1
817 BOTTOM CLAMPS FOR ANTI CLIMBING DEVICE 2 SET REC-XII Plan-11KV-002
Angle should not be cut on its one of the 813 CLAMP A FOR BELTING ANGLE 2 NOS. REC-XII Plan-11KV-002
sides. Instead, both the sides should be
bent and then drilled. 814B CLAMP B FOR BELTING ANGLE 2 NOS. REC-XII Plan-11KV-002
F M16x35 2NOS. M16x65 F
A 813
812 810 CLAMP FOR STAY SET 4 NOS. REC-XII Plan-11KV-002
816 BOLTS AND NUTS AS REQD,.

M10x65
815
145
2000
M16x35
1000
E
3
NOTES:- E
817 1) ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE MENTIONED.

815 BOLT
_
UPTO 50mm - +5%
2NOS. M16x65 51 TO 100mm - +4%
_
_
8000
DANGER
11000
11000 N VOLTS 101 TO 300mm - +3%
812
M8x30
4
814B
Above 300mm - _+2%
100x50 CHANNEL 3) ALL MS PARTS SHALL CONFORM TO IS :2062
D PSCC POLE D
809 FISH PLATE 5) ALL THE ITEMS SHALL BE MARKED WITH ERECTION CODE
DETAIL B 6) WEIGHT MENTIONED IS FOR PACKING & FORWARDING PURPOSE.
3000

2500
PIPE EARTHING 005

0
GL GL GL GL
PIPE EARTHING
300
12
00
1500
CONCRETE GRADE
00 Rural Electrification Corporation Ltd.
12
B
1 : 2 : 4

90 90 290
FRONT VIEW SIDE VIEW 1500 GA OF 11kV LINES FORMATION AT DP ON 0
0
8M/200KG PCC POLE(ANGULAR LOCATION 10-60)
A
R0

PROJECT REC-XII Plan-11KV-004 1 OF 2 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
1070 1070 2140 Angle should not be cut on its one of the sides. Instead,
100
90 60
200
X X 145 145 both the sides should be bent and then drilled.
H H
007
002 819 36 GUY GUY
825 825
200
0
18
820 31
350
350
824 824
GUY
M16x65-4+4NOS
M16x65-4+4NOS DETAIL A
811 2140 M16x65-4+4NOS 810
1070
2000
820
PIPE EARTHING
1850
0 0
G G
001 30-45 0 120 002
007
2 NOS. M16x35
120 0 821
001
1070
A M16x65-4+4NOS
813A 813A
822 M16x65-4+4NOS 822A 2140
1070
M16x35-2+2NOS
826 826
816
2140
F F
823 M10x65
823
GUY
823
2140 819
2000
003
1000
2000
817 1070 1070
120 0
M10x65 0 120 VIEW `X-X'
E
PLAN VIEW E
M16x65-4+4NOS PIPE EARTHING

M16x65-4+4NOS 814A 814A
8000
DANGER
11000
11000 N VOLTS
M16x35-2+2NOS NOTES:-
822
827 004
M10x25-2NOS 822A
UPTO 50mm - +5% _
51 TO 100mm - +4%_
D 101 TO 300mm - _+3% D
3000
ABOVE 300mm - +2% _

3) ALL MS PARTS SHALL CONFIRM TO IS :2062
2500
5) ALL THE ITEMS SHALL BE MARKED WITH ERECTION CODE
PIPE EARTHING 005 7) ALL CHANNELS & ANGLES SHALL CONFORM AS PER IS:SP6 PART-1
C
2140
0
0
GL GL GL GL GL GL
200
300
500
CONCRETE
1500
GRADE
B
1 : 2 : 6 Rural Electrification Corporation Ltd.
2500

90 90 290 290
600 600 GA OF 11kV LINE FORMATION AT FOUR
0 0
8M/200KG PCC POLE (ANGULAR LOCATION 60-90)
A FRONT VIEW SIDE VIEW
R0

PROJECT REC-XII-11KV-005 1 OF 2 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
GUY GUY
90
H O/ 18 HOLES 90 BILL OF MATERIAL H
ERE
60 CODE
DESCRIPTION QTY. REF. DRG. NO.
PLAN B 1 8M//200kG PSC POLE 2 NOS. REC-XII Plan-GEN-001A
1070 1070
3 BARBED WIRE 7000MM
90 4 11kV DANGER BOARD 1 NO. REC-XII Plan-11KV-022
6 145
18
62.5 808
2NOS. M16x200 6 11kV DISK INSULATORS WITH H//W 6 NOS.

G G
2NOS. M16x70 0
1500 7 STAY SET ARRANGEMENT 2 SET REC-XII Plan-GEN-007
31 808 TOP CHANNELS (100x50) 2 NOS. REC-XII Plan-11KV-002
7
812 BELTING ANGLES(50x50x6) 2 NOS. REC-XII Plan-11KV-002
DETAIL A
2000
815 BRACING ANGLES(50x50x6) 2 NOS. REC-XII Plan-11KV-002

1 816 TOP CLAMPS FOR ANTI CLIMBING DEVICE 2 SET REC-XII Plan-11KV-002
Angle should not be cut on its one of the 817 BOTTOM CLAMPS FOR ANTI CLIMBING DEVICE 2 SET REC-XII Plan-11KV-002
sides. Instead, both the sides should be 813 CLAMP A FOR BELTING ANGLE 2 NOS. REC-XII Plan-11KV-002
F
M16x35 2NOS. M16x65
bent and then drilled. F
A 813 814B CLAMP B FOR BELTING ANGLE 2 NOS. REC-XII Plan-11KV-002

812
BOLTS AND NUTS AS REQD,.
816
M10x65
815
145
2000
M16x35
1000
E
3 NOTES:- E

815 BOLT _
UPTO 50mm - +5%
2NOS. M16x65 51 TO 100mm - _+4%
DANGER
_
101 TO 300mm - +3%
8000
11000 VOLTS
N
11000
812 ABOVE 300mm - +2%_

4
M8x30 814B
100x50 CHANNEL 3) ALL MS PARTS SHALL CONFIRM TO IS :2062
D D
PSC POLE 5) ALL THE ITEMS SHALL BE MARKED WITH ERECTION CODE
DETAIL B 6) WEIGHT MENTIONED IS FOR PACKING & FORWARDING PURPOSE.

3000

2500
8) GUY ANGLE SHALL BE 30 TO 45.
PIPE EARTHING 005

0
GL GL GL GL
PIPE EARTHING
300
12
00

1500
00
CONCRETE GRADE
12
B
1 : 2 : 4

90 90 290
1500
GA OF 11kV LINES FORMATION AT DP ON
FRONT VIEW SIDE VIEW
8M//200KG PCC POLE (AT DEAD END LOCATION)
A
R0

BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
40 1070 40 176
50x50x6 PLATE / FLAT 50x8mm
145 900 O22 HOLE
TO BE WELDED
100
H H
250 350
002
70
801
90
310
2NOS, M16x140
/
O18x40 HOLES
80 29 29
PLAN
100
3NOS, M16x65 818
900 [[75x40x5.7Kg//m
1505
1070 250
30 250 30
310 370 310
ELEVATION
600
600
G
ELEVATION G
803
FLAT 50x8mm PSC POLE
802
2NOS, M16x65
M16x65 BOLT
900 1070
20
805
29
2NOS, M16x65
2NOS, M16x65 804
PLAN
6500
008 X-ARM
5000
810
V- CROSS ARM 8O2
REC CONSTRUCTION STANDARD
Y
SR.
GU
NO. DESCRIPTION SECTION MATERIAL LENGTH kG.//mtr. QTY. TOTAL Wt.

A-6 MM KG.
PLAN 12 NUTS & BOLTS M16 140 0.283KG//NO. 2 NOS. 0.566
75
816 13 NUTS & BOLTS M16 65 0.164KG//NO. 9 NOS. 1.476
2NOS, M10x60
CLAMPS & X-ARM ASSEMBLY 14 NUTS & BOLTS M10 60 0.055KG//NO. 4 NOS. 0.220
40 490 170
/ 40
O18x36 HOLES BACK CLAMP FOR X-ARM 803D 15 NUTS & BOLTS M8 50 0.05KG//NO. 2 NOS. 0.100
F F
1150 REC CONSTRUCTION STANDARD 16 SPRING WASHERS M16 3.5 THK. 0.009KG//NO. 11 NOS. 0.099
ELEVATION K-2 17 SPRING WASHERS M10 3.5 THK. 0.003KG//NO. 4 NOS. 0.012
1000
20
40
/
003 2NOS. 6mm ROD SPIKE
O22 HOLES / / HOLES
2NOS. O22
/ 18 SPRING WASHERS M8 3.5 THK. 0.002KG//NO. 2 NOS. 0.004
2NOS. O18 HOLES 2NOS. O18 HOLES 19 PLAIN WASHER M16 3 THK. 0.015KG//NO. 11 NOS. 0.165
20 PLAIN WASHER M10 3 THK. 0.005KG//NO. 4 NOS. 0.020
817 21 PLAIN WASHER M8 3 THK. 0.004KG//NO. 2 NOS. 0.008

40 60 60 40
2NOS, M10x60 1150 TOTAL 2.670
30 30 213 30 30
PLAN FLAT 40x5mm / 30 30 195 30 30
814
004 HORIZONTAL CROSS ARM 804 O12 HOLE
FLAT 40x5mm /
95 O12 HOLE
35
001
FLAT 50x8
20
35
178
E
A E
35
FLAT 50x8mm
20
M10x60
35
155
2 NOS.
35
/
FLAT 50x8 O6mm MS ROD
150
M10x60
SPIKES (14 NOS.)A PLAN 2 NOS.
BOTTOM CLAMP 817 /
O6mm MS ROD
35
2N SPIKES (14 NOS.)
PLAN
35
2N
20
ANTI CLIMBING DEVICE
3000
30 OS 30 TOP CLAMP 816
3N
RGGVY
NESCL O 30 30
S. PLAN .O ANTI CLIMBING DEVICE
OS
30 O/ 30
/
18 /
.O
18 GENERAL NOTES:
18
30 171 30 30 254 30 30 231 70 30 2) MANUFACTURING TOLERANCE
D D
CLAMP FOR 805 ELEVATION CLAMP FOR 818

CLAMP FOR STAY SET 810M UPTO 50mm - +5% _
HOR. CROSS ARM STRAIN INSULATOR
0 51 TO 100mm - +4%
1500
10
/
O18 HOLE _
1200 101 TO 300mm - +3%
300
50
_
300
DETAIL `A'
GL GL GL GL GL
ABOVE 300mm - +2%
_
78
25 25
25 25
128 3) ALL M.S. PARTS SHALL CONF0RM TO IS:2062
300
FLAT (50x8) 4) ALL M.S. FABRICATED ITEMS SHALL BE HOT DIP GALVANISED
/ SPIKE EARTHING
CONCRETE 10 AS PER IS:2629 & 4759

GRADE 0 5) ALL THE ITEMS SHALL BE MARKED WITH ERECTION CODE.
1500
C 1 : 2 : 4 C
SECTION A-A
7) ALL CHANNELS AND ANGLES SHALL CONFORM TO IS: SP6 PART-1.
SPAN (<<20m) 6mm ROD SPIKE
O20
EXISTING LINE
RCC BASE
290
450x450x75
005 90
GUY
GUY
500 600
ELEVATION SIDE VIEW
GUY
THIS DP STRUCTURE SHALL BE
NORMAL IN LINE DP.
FOR LENGHTY SPUR LINE (>>2mtr.) THE DP
SHALL BE PROVIDED WITH A.B. SWITCH
GUY
GUY
PLAN
GA OF 11kV LINE TAPPING FROM EXISTING LINE ON
A
SINGLE 8M//200 kG PSC POLE A
R0

BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
A A 1350
H H
882
1500
100
1200
881
150 1070 1070 150

M16x65-4 NOS.
M16x220-4 NOS.
M16x65-4 NOS. M16x150-6 NOS. 838 847 PG CLAMPS
G G
GU
Y
GU
Y
847
M16x65-7 NOS.
842
F F
1300
843
848
M16x65-6 NOS. 852
11000
11000
M10x65-4 NOS. 004 842
M8x85-2 NOS. 8
1000
1300
E E
853 RGGVY
NESCL
M10x65-4 NOS.
1500
1400
1200
2440 GENERAL NOTES:

1200
300
D D
GL GL GL GL GL GL
200
300
UPTO 50mm - +5%

500
_
51 TO 100mm - +4%
_
101 TO 300mm - +3%
_
ABOVE 300mm - _+2%
1500
1500
3) ALL M.S. PARTS SHALL CONF0RM TO IS:2062

4) ALL M.S. FABRICATED ITEMS SHALL BE HOT DIP GALVANISED
AS PER IS:2629 & 4759
C C
5) ALL THE ITEMS SHALL BE MARKED WITH ERECTION CODE.
90 90 90 6) WEIGHT MENTIONED IS FOR PACKING & FORWARDING PURPOSE.
600 600 500 7) ALL CHANNELS AND ANGLES SHALL CONFORM TO IS SP6 PART-1.
SIDE VIEW ELEVATION ALL CHANNELS SHALL BE ISLC CHANNELS

8O2
1400 1400
B 180
1070 1070
809 838
219
163
163
105 95
838
VIEW "A-A" GA OF 11kV LINE TAPPING ARRANGEMENT

A
WITH 8M//200 KG DOUBLE POLE.
R0

PROJECT REC-XII Plan-11KV-008A 1 OF 2 0
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H H
NOTES:-
G G
1) THE CONCRETE MIX SHALL BE OF M15 GRADE

2) BASE PLATE IS NOT NECESSARY FOR CONCRETE LOCATIONS
3) EQUIVALENT SIZE OF STONE PAD CAN BE USED AS BASE PLATE
WHEREVER AVAILABLE ECONOMICALLY.
4) ALL DIMENSIONS ARE IN MM UNLESS OTHERWISE MENTIONED.
F F
E E
D D

C

PROJECT:
TITLE
RCC BASE PAD FOR PCC POLE

A

R0 COMMON FOR ALL
A3 NTS REC-XII Plan-GEN-004 1 OF 1 0
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H H
G G
F F
E E
D D

B
RGGVY XII Plan Project
PIPE TYPE EARTHING (As per IS 3043)

A
R0

PROJECT REC-XII Plan-GEN-006A 1 OF 1 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
1:3:6
12 11 10 9 8 7 6 5 4 3 2 1
H H
S.NO. Description 3
Vol. in m
G
1 /
Excavation (0.5Ox0.6x1.5M) 0.45 G
/
2 Concreting (O0.5x0.05x1/6th length in mm)
+0.014 Cut for muffing
F
All Dimensions are in mm unless otherwise mentioned F
All Dimensions
500 are in mm unless otherwise mentioned
E
Line E
Direction
600
GL.
Foundation With
D
Concreting (1:3:6) D
Section A-A
1500
A A NOTES:-
1.UNLESS OTHERWISE SPECIFIED, ALL DIMENSIONS ARE IN MM.
C Concreting (1:3:6) 2.THIS ARRANGEMENT SHALL BE USED
FOR ALL TAPPING POLES ,DEAD END POLES , DTC
ANGULAR POLES, CROSSING, 2//4 POLE STRUCTURES AND FOR
ALL 33 KV POLES.
B
500 RGGVY XII Plan Project
CONCRETE (PCC) FOUNDATION DETAILS FOR PSC POLES

A
Fig. 8.5 : Concrete Foundation For PSC Poles
R0

PROJECT REC-XII Plan-GEN-009 1 OF 1 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H H
G G
8 S.W.G. G.I. Wire

F F
/
40 O G.I Rod
E
NOTES:- E
1. ALL DIMENSIONS ARE IN MM.
2500
2. EARTH TERMINAL SHOULD BE MADE OF G.I
12O/ STRIP 40x3 WITH 1NO. 12O/ STUD.
3. MANUFACTURING TOLERANCE.
UPTO 50mm - +5%
_
51 TO 100mm - _+4%
Welding
D D
101 TO 300mm - +3%
_
ABOVE 300mm - +2%
_
4. CLAMP IS TO BE WELDED TO SPIKE.
5. THE WHOLE ASSEMBLY IS TO BE HOT DIP GALVANISED(IS:2629&4759)
6. ALL MS PARTS SHALL CONFIRM TO IS :2062
7. WEIGHT MENTIONED IS FOR PACKING AND FORWARDING PURPOSE ONLY.
B
RGGVY XII Plan Project
SPIKE TYPE EARTHING FOR NORMAL SOIL

A
R0

PROJECT REC-XII Plan-GEN-012 1 OF 1 0
BY BY BY
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
7.5000 570 7.5000

7.5000 7.500090.0000 90.0000 90.0000 150
90.0000 820
H H
150.0000
150.0000 112.5000
150
375.0000
225.0000 30 40 30
674.8220
562.8816
592.5000 795.0000 375.0000 150.0000 50
405.0000 345.0000
862.5000
232.1184
G
270.0000 270.2500 100 G
187.5000
187.5000 112.5000
112.5000 75
75
112.5000
100 749.2875 100
112.5000
100 1124.2875 100
F F
112.5000 112.5000
149.6459
150.9728
149.6250
299.7500
E E
1000 50
149.6250
1000
55 149.8125
60
50
50
25
D
25 75 D
570
820 100 100
187.5000
100
C 300
300
112.5000 112.5000
820 930.0000

B
2
PROJECT:

TITLE
REC Construction Standard DETAILS OF CABLE TRENCHES
SWITCHYARD AREA
A
Gen-013
1
R0

A3 NTS REC-XII Plan-Gen-013 1 OF 1 0
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

H H
Gen-013A
40
G 60 G
600.0300 300.0150 39.9600

44.9550
39.9600 60
50
49.9500
25
200.0100 114.8850
850.0425
25 75
200.0100 124.8750
F F
25.0013 150.1742
125.0063
75.0038
100.0050
E E
999.5750
75.0038
125.0063 125.0063
75.0038
49.8321
50.2739
49.8251
D D
99.8168
50
400 49.8251
49.8876
1000.0500
50
100
200
C
100
560.0280 455.0228
400
25.0013 25.0013 FOR TENDER PURPOSE ONLY

75.0038
B
2
PROJECT:

TITLE
DETAILS OF CABLE TRENCHES
A
(INSIDE CONTROL ROOM)
1
R0

A3 NTS REC-XII Plan-Gen-013A 1 OF 1 0
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

H
Gen-014 H
20MM SQ. ROD (TYP)
500.1261
20MM SQ. ROD @ 150MM DISTANCE (TYP)
PCC 1:2:4
COPING
90.0000
20MM SQ. ROD
500
100 SQ. 300 DEEP

1800
G 2000 1710 POCKET WITH PCC G
1:2:4
2000 1875
200
230.0000
125
1000
50.0000
(TYP.)
200.0000
WHEEL & FLAT
75.0000
100 800
300 300
1400 1600 1400 1600 1400 1600 1400
F F
700 3000.0000 3000.0000 3000.0000 700
200
100
75
750 1480 5230 750
A
(TYP)
100x50x6 THK. MS. FLAT
WELDED TO BAR FRAME
230.0000
B 300.0000
(TYP) 260
E E
650 3000.0000 3000.0000 3000.0000 650 A A A

50
499.8953 B B
EQ
250
EQ
300.0000 50.1904
10
90.0000
0
10
D 50 230 80 230 50 50 230 50 D
1250 5000
1800 1800
2000 1710
300 TOP OF ROAD/CONCRETE IN

230
OPENING PROFILE 50x6 THK. MS FLAT
200
50x6 THK. MS FLAT CURVED
230
300
200 125 50x6 THK. FLAT
50x6 THK. FLAT LUG

300 200 LONG @ 300C/C
125
1000 1000 PCC 1:2:4 (TYP)
200.0000
10MM SQUARE ROD
200.0000 50x6 THK. FLAT-100 LG.
75.0000
200 WELD WITH GATE
225.0000 10MM SQUARE ROD
100
C
50.0000 B B
50.0000 50.0000 50.0000

B
2
PROJECT:

TITLE
DETAIL OF BOUNDARY WALL FOR
A
SWITCHYARD WITH ENTRRANCE GATE
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
0
00
.0
500.0000 499.7049
50
H 500.0000 H
50.0000 20MM SQ. ROD (TYP)
0
10
10MM SQ. ROD @ 230MM DISTANCE (TYP)
600.0000
PCC 1:2:4
500 20MM SQ. ROD
COPING
2000.0000 2000.0000
30 100 SQ. 300 DEEP

POCKET WITH PCC
1400.0000 1:2:4
50.0000
50.0000
50.0000
200.0000 200.0000
G 2000 G
200.0000 200.0000 1875
200.0000
800.0000 800.0000
800.0000
400.0000
400.0000
2500 400.0000 WHEEL & FLAT
(TYP)
Y8 @ 200C/C BOTHWAYS 800
Y10 @ 200C/C BOTHWAYS 300 300
75 THK. PCC 1:4:8

2-Y16
200
50x6 THK. MS FLAT 150 THK. SAND FILLING
F 230 F
150
75
125 700 3500 700
300
Y8 @ 200C/C
2-Y16
500.0000
100 10MM SQUARE ROD 100x50x6 THK. MS. FLAT
WELDED TO BAR FRAME
(ENLARGED)
600.0000 100
E E
30
1400.0000
1300
50.0000 50 TOP OF ROAD/CONCRETE IN

OPENING PROFILE
200.0000
50x6 THK. FLAT 50x6 THK. MS FLAT CURVED
500
200.0000 300 300
230 1300
D 800.0000 50x6 THK. FLAT LUG
300 200 LONG @ 300C/C
10
50x6 THK. FLAT-100 LG. 10MM SQUARE ROD 500 PCC 1:2:4 (TYP)
WELD WITH GATE
400.0000
500 300 500 500 300 500 200

50 50 50 50
3270
REC Construction Standard FOR TENDER PURPOSE ONLY

Gen-015
B
2
PROJECT:

TITLE
DETAIL OF FENCING FOR SWITCHYARD WITH
GATE ARRANGEMENT
A
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
12000.0000 12000.0000
450.0000
150.0000 150.0000
2500.0000 2500.0000
600.0000
300.0000
7000.0000
450.0000
150.0000 150.0000
2500.0000 2500.0000
600.0000
300.0000
7000.0000

H 150.0000
115.0000
150.0000
115.0000
Gen-016 H
5000.0000 5000.0000 5000.0000 5000.0000
230.0000 230.0000
10000.0000 10000.0000
G G
3800.0000
750.0000 750.0000
4850.0000
5000.0000 5000.0000
600.0000 600.0000
500.0000 500.0000
F F
300
750.0000
E E
450.0000
500.0000
D D

B
2
PROJECT:

TITLE
G.A. OF CONTROL BUILDING
A
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

H
Gen-017 H
G G
F F
3250
E E
D D

50 50
B
2
100
PROJECT:

TITLE
DETAILS OF RCC ROAD AND DRAIN
A
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

H
Gen-018 H
G
A G
B
F F
E E
D D

B
2
PROJECT:

TITLE
SEPTIC TANK & SOAK PIT DETAILS
A
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
TOWER
MKD
ANGLE SIZE
& NOS OF BOLTS
PA PB PC PD PE PF GA GB GC GD GE GF
H
T1 ANGLE SIZE L50X50X6 L50X50X6 L65X65X6 L65X65X6 L65X65X6 L75X75X6 L45X45X5 L45X45X5 L45X45X5 L45X45X5 L45X45X5 L45X45X5
Gen-019 H
NOS OF BOLTS 02 02 3DS-6 TH. PLT 3DS-6 TH. PLT 3DS-6 TH. PLT 3DS-6 TH. PLT 02 02 02 02 02 02
TOWER ANGLE SIZE

JA JB JC JD JE JF AA AB AE DA DB DC
MKD & NOS OF BOLTS
T1 ANGLE SIZE L45X45X5 L45X45X5 L45X45X5 L45X45X5 L45X45X5 L45X45X5 L65X65X6 L65X65X6 L45X45X5 L45X45X5 L45X45X5 L45X45X5
NOS OF BOLTS 02 02 02 02 02 02 02 02 02 02 02 02
G G
AE
C
MIN. 525MM EMBEDED
D
COLUMN MARKED 'T1' IS A CORNER TOWER WITH PEAK
GA
AE
JA
BASE PLATE
SUPPORTING ONE BEAM OF SPAN 3.5M (C//C)
300X300X16 THK.
CONNECTED AT 6.5M.
GA
JA
F F
150X8 THK. SPAN OF BEAM=3.5M (C//C)

RIB PLATE HEIGHT OF BEAMS=6.5M
GB
GB
JB
JB
HEIGHT OF COLUMN=6.5M & 2.0M (PEAK)
A
D
AA
J G 6 THK. FILLET WELD
JC C GC C
CL BEAM G2B
AA
1. ALL DIMENSIONS ARE IN MM U.N.O.
E E
2. ALL UN-NOTED MEMBER ARE ISA L45X45X5
3. ALL ANGLE SECTIONS USED ARE EQUAL ANGLES.
GD
GD
JD
JD
4. ALL DIMENSIONS ARE CENTER LINE DIMENSIONS U.N.O.

5. ALL CONNECTION BOLT SHALL BE 16MM DIA. BOLT OF
CLASS 5.6
6. ALL STEEL ITEMS, BOLTS, NUTS & WASHERS SHALL BE
HOT DIP GALVANISED.
7. THE WT. OF THE ZINC COATING SHALL BE AT LEAST
B
D
AB
GE
GE
JE
JE
8. COMPATIBLE FOR MOUNTING SPIKE ON PEAK OF TOWER.
D D
AB
GE
GE
JE
JE
C
GF
GF
JF
JF

B

GF
GF
JF
JF
2
PL PL PL PL PROJECT:
GL GL GL GL RGGVY XII Plan Projects

TITLE
33kV TOWER STRUCTURE MARKED "T1"
A
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
BEAM ANGLE SIZE

ECL CCL EBL EBC VDIAM PBL PBC PDIAM DIAMOND
H
MKD & NOS OF BOLTS H
G2 ANGLE SIZE L50X50X6 L50X50X6 L45X45X5 L45X45X5 2L45X45X5 B/B L45X45X5 L45X45X5 L50X50X6 L45X45X5
NOS OF BOLTS 2DS-6 TH. PLT 2DS-6 TH. PLT 02 02 02 02 02 02 02
G G
F F
HIGHLIGHT:-
SPAN OF GIRDER=5.5M (C/C)
SPAN OF GIRDER=5.0M (CLEAR)
CROSS SECTION OF GIRDER=0.5MX0.5M
E E

2. ALL UN-NOTED MEMBER ARE ISA
L45X45X5
3. ALL ANGLE SECTIONS USED ARE
EQUAL ANGLES.
4. ALL DIMENSIONS ARE CENTER LINE
DIMENSIONS U.N.O.
5. ALL CONNECTION BOLT SHALL BE
D
16MM DIA. BOLT OF CLASS 5.6 D
6. ALL STEEL ITEMS, BOLTS, NUTS &

WASHERS SHALL BE HOT DIP
GALVANISED.
7. THE WT. OF THE ZINC COATING

Gen-020
B
2
PROJECT:

TITLE
11kV BEAM STRUCTURE
A
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
BEAM ANGLE SIZE

ECL CCL EBL EBC VDIAM PBL PBC PDIAM DIAMOND 1250 1250
H MKD & NOS OF BOLTS H
G2 ANGLE SIZE L60X60X6 L60X60X6 L45X45X5 L45X45X5 2L45X45X5 B//B L45X45X5 L45X45X5 L60X60X6 L45X45X5
NOS OF BOLTS 2DS-6 TH. PLT 2DS-6 TH. PLT 02 02 02 02 02 02 02
G G
HIGHLIGHT:-
SPAN OF GIRDER=5.5M (C//C)
SPAN OF GIRDER=5.0M (CLEAR)
CROSS SECTION OF GIRDER=0.5MX0.5M

F F
2. ALL UN-NOTED MEMBER ARE ISA
L45X45X5
3. ALL ANGLE SECTIONS USED ARE
EQUAL ANGLES.
4. ALL DIMENSIONS ARE CENTER LINE
DIMENSIONS U.N.O.
5. ALL CONNECTION BOLT SHALL BE
16MM DIA. BOLT OF CLASS 5.6
6. ALL STEEL ITEMS, BOLTS, NUTS &
E E
WASHERS SHALL BE HOT DIP
GALVANISED.
7. THE WT. OF THE ZINC COATING
D D

Gen-020A
B
2
PROJECT:

TITLE
33kV BEAM STRUCTURE
A
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
NOTES
NOTES
NOTES
NOTES
NOTES
NOTES
12 11 10 9 8 7 6 5 4 3 2 1
H H
G G
F F
E E
D D

B
2
PROJECT:

TITLE
GENERAL ARRANGEMENT OF
A
33//11kV SUB STATION
1
REC Construction Standard R0
Gen-40 REV. NO. PREPARED CHECKED APPROVED DATE PROJECT

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1
H H
G G
F F
E E
D D

B
2
PROJECT:
REC Construction Standard TITLE

Layout of 33//11 KV Substation
A Gen-41
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

H
Gen-42A H
G G
F F
E E
D D

B
2
PROJECT:

TITLE
Single Line Diagram of 1x3.15MVA (Type-A)
A
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

H
Gen-42B H
G G
F F
E E
D D

B
2
PROJECT:

TITLE
Single Line Diagram of 1x5MVA (Type-B)
A
1
R0

A3 NTS REC-XII Plan-Gen-42B 1 OF 1 0
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

H Gen-42C H
G G
F F
E E
D D

B
2
PROJECT:

TITLE
Single Line Diagram of 2x5MVA (Type-C)
A
1
SCALE DRG. NO. SHT. NO. REV. NO.
R0 SIZE

NTS REC-XII Plan-Gen-42C 1 OF 1 0
A3
12 11 10 9 8 7 6 5 4 3 2 1
12 11 10 9 8 7 6 5 4 3 2 1

H
Gen-43 H
G G
F F
E E

B
2
PROJECT:

TITLE
Layout Section of 33/11 KV Substation
A
1
R0

12 11 10 9 8 7 6 5 4 3 2 1
VOLUME-II: SECTION – IV
PROJECT MANAGEMENT SYSTEM (PMS),
QUALITY ASSURANCE MECHANISM (QAM)
& DOCUMENTATION
Volume-II : Section IV 1
PMS, QAM & Documentation
PROJECT MANAGEMENT SYSTEM, QUALITY ASSURANCE AND DOCUMENTATION
This section describes the project management system, quality assurance and
documentation requirements for the project.
1. Project Management System
1.1. General
The Contractor shall assign a project manager with the authority to make commitments and
decisions that are binding on the Contractor. Employer will designate a project manager to
coordinate all employer project related activities. All communications between employer and
the Contractor shall be coordinated through the project managers. The project managers
shall also be assisting employer in communicating project related information to other stake
holders.
Bidder shall submit the manpower deployment plan along with the bids, describing the key
roles of each person.
The role and responsibilities of contractor shall be as follows:
a) To prepare, maintain and update project detailed Work Execution Plan for
successful implementation of project like approval of GTP, approval of sub-
contractor, approval of drawings, supply of materials, mobilization of men, material
and equipment etc. at site for successful completion of works, Compile and up-load
physical as well as financial progresses, compile the progress of works at Employer
level and to assist in forwarding it to all stake holders.
b) To actively participate with employer in resolving all issues relating to project

implementation including ROW, Forest Clearances, Railway Crossings, and Payments
to contractors/vendors and policy matters.
c) To actively participate in monitoring, reviewing and analysing the physical, financial

and quality assurances works’ progress of RGGVY works and also to take suitable
measures on compliance of observations being raised during monitoring/review
meetings with employer.
d) To implement and maintain a dedicated centralized bank account for the project,
upload and up-date project wise physical progress in RGGVY web portal. Physical as
well as financial progresses shall be uploaded in standard Bill of Material format of
the contract. Also, to submit claims as per release RGGVY guidelines to Employer for
release of payments/funds.
e) To oversee the progress and compliance of the Three Tier Quality Assurance
Mechanism as per RGGVY guidelines.
RGGVY/XII-Plan/R1
1.2. Project Schedule
As per the schedule the bidder shall submit a preliminary implementation plan along with the
bid. The detailed project implementation schedule shall be submitted by the contractor after
the award for employer’s approval, which shall include at least the following activities:
(a) Surveying of site.

(b) Documents submission and approval schedule
(c) Type Testing Schedule
(d) Despatch Schedule
(e) Installation & commissioning schedule
(f)Training schedule, if any.
The project schedule shall include the estimated period for completion of project and its
linkage with other activities.
1.3. Progress Report
A progress report shall be prepared by the Contractor each month against the activities listed
in the project schedule. The report shall be made available to employer on a monthly basis,
e.g., the 10th of each month. The progress report shall include all the completed, ongoing
and scheduled activities.
1.4. Transmittals
Every document, letter, progress report, change order, and any other written transmissions
exchanged between the Contractor and employer shall be assigned a unique transmittal
number. The Contractor shall maintain a correspondence index and assign transmittal
numbers consecutively for all Contractor documents. Employer will maintain a similar
correspondence numbering scheme identifying documents and correspondence that
employer initiates.
2. QUALITY ASSURANCE MECHANISM (QAM)
The contractor shall be solely responsible & accountable for assuring quality in RGGVY
works. Accordingly, contractor shall formulate a comprehensive Quality Assurance (QA) Plan
with an objective to build a zero defect infrastructure under RGGVY works. The QA Plan shall
be integral part of the contract agreement with contractor. Documentation with regard to
Manufacturing Quality Plan (MQP) & Field Quality Plan (FQP) shall be maintained by
bidder/Employer and kept in proper order for scrutiny during the course of project execution
by Quality Monitors.
RGGVY/XII-Plan/R1
The internal quality assurance mechanism followed by EMPLOYER and the turnkey contractor
shall be termed as level-zero of overall quality assurance plan of the XII plan RGGVY
works.
Quality checks under Level-Zero of QAM: Level-zero is of utmost importance. Under this
level, the turnkey contractor & EMPLOYER shall strictly perform following QA checks during
the course of project execution:
a. 100% pre-dispatch inspections of all material as per MQP/ Drawings/ Technical

Specifications & applicable national & international standards
b. 100% villages with all infrastructure are to be verified for quality as per MQP/
Drawings/Technical Specifications and FQP
c. 100% of all 33/11 kV sub stations (New & Augmented) for quality of material as per
MQP/Drawings/Technical Specifications and erection works in the field as per FQP
d. 100% verification of BPL connections
Vendor approval: EMPLOYER shall allow procurement of materials for RGGVY works only
from the vendors approved by their Quality Assurance Departments. A manufacturer's facility
may be visited and the capability assessed suitably before accepting it as approved vendor.
Material Inspection: All materials of REDB (33/11kV or 66/11kV substation) as well as that
of VEI (Village Electricity Infrastructure) shall both be inspected at manufacturer premises
before dispatch.
FQP for construction works: EMPLOYER shall approve a separate FQP prepared by
contractor for construction works. The turnkey contractor shall adhere to this FQP while
carrying out physical works.
FQP for testing & commissioning: Contractor shall prepare and Employer shall approve a
comprehensive FQP for testing & commissioning of S/s (REDB) as well as VEI. The electrical
system shall be energized only after performing all tests as described in the FQP. Proper
records in this regard, including tests on earth resistance, insulation resistance of 11 KV line
& Distribution Transformer etc shall be maintained.
QA documentation: All QA checks conducted in the field as per FQP shall be properly
documented & signed by the quality engineer of the turnkey contractor & countersigned by
EMPLOYER's representative. These documents shall be maintained in proper order & easily
available at site for verification by Quality Monitors.
RGGVY/XII-Plan/R1
Three tier Quality Assurance Mechanism
XII Plan RGGVY Projects shall have a 3-tier Quality Assurance Mechanism (QAM). The 3-tier
QAM shall exclude level-zero, the in-process quality assurance plan followed by the Project
Implementation Agency (PIA) during the physical execution of the project.
TIER – I
1. Under Tier-I of Quality Assurance Mechanism, QA checks shall be performed by a Third Party
Inspection Agency (TPIA) to be deployed by EMPLOYER through outsourcing by tendering
process. EMPLOYER shall designate a Senior Executive Engineer/Assistant Engineer level
officer as Project Implementing Agency’s Quality Assurance Coordinator (PQCC) at district
level and for State Level Quality Assurance responsibility, EMPLOYER shall designate a senior
officer to the level of Superintending Engineer /Dy. GM (for CPSU) office as its State Quality
Assurance Coordinator(SQAC).
The TPIA shall perform test inspections & checks and shall ensure conformity on part of
system procedural and policy implementation.
Upon award of the contract and start of the works, EMPLOYER through its State Level Officer
or in case of CPSU through its Regional office, shall ensure quality of materials procured and
workmanship of executed works.
EMPLOYER is required to engage a Third Party Inspecting Agency (TPIA), who will verify the
quality of RGGVY works in 50% of the villages covered in a project.
1.1. Material Inspection: Important materials of REDB (33/11kV or 66/11kV) substation

as well as that of VEI (Village Electricity Infrastructure) shall both be inspected at
manufacturer premises before dispatch.
1.1.1. Inspection of S/S (REDB) materials: Following materials have been

identified as important materials for s/s:
1. Power Transformer, 7. Energy meter

2. Circuit Breaker, 8. Insulators,
3. Current Transformer 9. Battery Chargers,
4. Potential Transformers, 10. ACDB/DCDB Board,
5. Isolators, 11. 11 kV XLPE Cables
6. Control & Relay Panel, 12. Cables other than 11kV
Ten percent (10%) of aforesaid REDB materials shall be inspected by the TPIA as
per MQP. The inspection/testing/ witnessing of acceptance tests shall be as per
Drawings/Technical Specifications & applicable national & international standard.
RGGVY/XII-Plan/R1
1.1.2. Inspection of VEI Materials: Following materials have been identified as

important material for VEI:
1. Distribution Transformer, 8. AB switch( GO switch),

2. Overhead Conductor, 9. HG fuse,
3. Energy Meter, 10. Earthing materials
4. Pole, 11. Hardware: channels, PG
5. Insulators, Clamp connector,
6. Cables, suspension clamp, tension
7. Lightening Arrester clamp, nut & bolts
Ten percent (10%) of aforesaid VEI materials shall be inspected by the TPIA as per
MQP. The inspection/testing/ witnessing of acceptance tests shall be as per
1.1.3. Sampling from field: Any material, including following important materials,
may be picked from site for testing at test laboratory chosen by
TPIA/RQM/NQM/REC/MoP:
1. Distribution Transformer, 8. AB switch( GO switch),

2. Overhead Conductor, 9. HG fuse,
3. Energy Meter, 10. Earthing materials
4. Pole, 11. Hardware: channels, PG Clamp
5. Insulators, connector, suspension clamp,
6. Cables, tension clamp, nuts & bolts
7. Lightening Arrester
All expenditures towards packing, transport, inspection, testing charges etc shall be
borne by the EMPLOYER.
1.2. 50% villages as per MQP/ Drawings/ Technical Specifications and FQP
1.2.1. 50% villages are to be inspected in 2 (two) stages. Stage-I inspection shall
cover 10% and Stage-II inspection shall cover 50% villages including revisit
of the villages inspected during stage-I inspection.
1.2.2. Stage-I inspection shall begin and end when the physical progress in the
project is completed in 10% and 30 % of villages respectively. Five (5) nos.
of villages in a project are to be thoroughly inspected at the very beginning
when the same is completed in the project. These villages after rectification
of defects will become modal quality village. The findings of inspection of
these five villages shall be used as training resource and necessary
improvement in Quality Assurance.
Page 5 of 21
1.2.3. Stage-II inspection shall begin and end when the physical progress in the
project is completed in 50% and 90 % of villages respectively.
1.3. 100% New and 100% Augmented 33/11 kV or higher capacity substation for
quality of material as per MQP/Drawings/Technical Specifications and works in the
field as per FQP.
1.4. 100% verification of BPL connections, 100% Distribution Transformer Substations,

100% LT Lines, 50% of 33kv Lines and 100% of the 11KV lines attributed to the
village (emanating from cut-point/grid substation) as well as the 11 KV line laid
within the village, verification of energisation of village & BPL beneficiaries,
installation of service connections in public places, hours of supply in the village, time
taken by DISCOM to raise first energy bill in favor of beneficiaries are to be inspected
in 50% villages of the project.
1.5. State Quality Assurance Coordinator(SQAC) shall also oversee the Contract
Management Part of contractor like contractual provisions of identifying defects and
their communication, timely rectification of defects, time line for Assurance
mechanism of EMPLOYER for rectification of defects, resolution of project related
issues and action on delayed project. In their visit, they would give thrust on
adherence on systems and procedures of RGGVY schemes by EMPLOYER and
turnkey contractors. They would also ensure availability and awareness of project
specific drawings, documents, quality assurance plans among all stakeholders in
EMPLOYER, contractor staff/workers.
1.6. State Quality Assurance Coordinator(SQAC) shall also see the progress of up-loading
of monitoring observations and its compliance details including site photographs in
RGGVY web portal.
Tier– II
2. Rural Electrification Corporation (REC), the nodal agency for RGGVY works, shall operate
Tier-II of Quality Assurance Mechanism. REC shall designate a senior officer (ZM/CPM of the
state) as REC State Quality Assurance Coordinator (RSQAC) at its State level project office.
Under this mechanism, adherence to system procedures and guidelines shall also be verified
by inspection agency though RSQAC.
REC shall outsource independent agencies to verify the quality of RGGVY works in 20% of
the villages covered under the Project in addition to conducting pre-dispatch quality checks
of all important materials at the vendor’s outlet. These independent agencies are designated
as REC Quality Monitors (RQM). RQM will review the inspections carried out by TPIA for 2%
of villages.
Page 6 of 21
2.1. Material Inspection: Important materials of REDB (33/11kV or 66/11kV

substation) as well as that of VEI (Village Electricity Infrastructure) shall both be
inspected at manufacturer premises before dispatch by RQM.
2.1.1. Inspection of S/S (REDB) materials: Following materials have been

identified for inspection by RQM under Grid Substation works:
1. Power Transformer, 9. Earthing materials,

2. Circuit Breaker, 10. Battery Chargers,
3. Current Transformer 11. ACDB/DCDB Board,
4. Potential Transformers, 12. 11 kV XLPE Cables
5. Isolators, 13. Cables other than 11kV
6. Control & Relay Panel,
7. Energy meter
8. Insulators,
At least one type from each of aforesaid 13 materials shall be inspected by the RQM
as per MQP. The inspection/testing/ witnessing of acceptance tests shall be as per
2.1.2. Inspection of VEI materials: Following materials have been identified for
inspection by RQM under Village Electrification works (VEI works):
1. Distribution Transformer,
2. Overhead Conductor,
3. Energy Meter,
4. Pole,
5. Insulators,
6. Cables,
7. Lightening Arrester
8. AB switch( GO switch),
9. HG fuse,
10. Earthing materials
11. Hardware: channels, PG Clamps connectors, suspension clamp, tension
clamp, nuts & bolts
Page 7 of 21
At least one type from each of aforesaid materials shall be inspected by the RQM as
per MQP. For item no. 11, at least one type of each of listed hardware materials shall
be inspected. The inspection/testing/ witnessing of acceptance tests shall be as per
2.1.3. Sampling from field: Any material, including following materials, may
be picked from site for testing at test laboratory chosen by
TPIA/RQM/NQM/REC/MoP
1. Distribution Transformer, 9. HG fuse,

2. Overhead Conductor, 10. Earthing materials
3. Energy Meter, 11. Hardware: channels, PG
4. Pole, Clamp connector,
5. Insulators, suspension clamp,
6. Cables, tension clamp, nuts &
7. Lightening Arrester bolts
8. AB switch( GO switch),
All expenditures towards packing, transport, inspection, testing charges etc

shall be borne by the EMPLOYER.
2.2. 20% villages as per MQP/ Drawings/ Technical Specifications and FQP shall be
inspected by RQM as under:
2.2.1. 20% villages are to be inspected in 2 (two) stages. Stage-I inspection

shall cover 5% and Stage-II inspection shall cover 20% villages including
the villages inspected during stage-I inspection.
2.2.2. Stage-I inspection shall begin and end when the physical progress in the
project is completed in 10% and 30 % of villages respectively. Five (5)
nos. of villages in a project are to be thoroughly inspected at the very
beginning when the same is completed in the project. These villages
after rectification of defects will become modal quality village. The
findings of inspection of these five villages shall be used as training
resource and necessary improvement in Quality Assurance.
2.2.3. Stage-II inspection shall begin and end when the physical progress in
the project is completed in 70% and 90 % of villages respectively.
RGGVY/XII Plan/SBD-R1
2.3. 100% New and 100% Augmented 33/11 kV or higher capacity substation for
quality of execution of works at site as per FQP shall be inspected by RQM.
2.4. In 20% villages of the project, 100% verification of BPL connections, 100%
Distribution Transformer Substations, 500 m(for hilly areas)/1KM (for plain
areas) of 33kV Lines, 100% LT Lines and 100% of the 11KV lines attributed to
the village (emanating from cut-point/grid substation) as well as the 11 KV line
laid within the village, verification of energisation of village & BPL beneficiaries,
installation of service connections in public places, hours of supply in the
village, time taken by DISCOM to raise first energy bill in favor of beneficiaries.
2.5. RQM shall also oversee the Contract Management Part of contractor like
contractual provisions of identifying defects and their communication to
working teams, timely rectification of defects, resolution of project related
issues and action on delayed project. In their visit, they would give thrust on
adherence on systems and procedures of RGGVY schemes by turnkey
contractors. They would also ensure availability and awareness of project
specific drawings, documents, quality assurance plans among all stake holders
including contractor staff/workers.
2.6. RQM shall also see the progress of up-loading of monitoring observations and
its compliance details including site photographs in RGGVY web portal by
contractor through Employer.
Tier – III
3. Ministry of Power, Govt. of India shall enforce Tier-III of Quality Assurance Mechanism.
Ministry of Power shall outsource independent agencies to verify the quality of RGGVY
works in 1% of the villages covered under the Project. These independent agencies
would be designated as National Quality Monitors (NQM). NQM will review the
inspections carried out by TPIA for 0.1% of villages.
3.1. Under this mechanism, adherence to system procedures and guidelines shall
also be verified by inspection agency though Quality Assurance Coordinator.
Following checks shall be conducted by NQM:
3.1.1. 1% randomly selected villages as per approved drawings/ Technical

Specifications and FQP
3.1.2. At-least one 33/11 kV or higher capacity new substation for quality of
execution of works at site as per FQP/approved drawings/technical
specifications
3.1.3. At-least one 33/11KV or higher capacity augmented substation for

quality of execution of works at site as per FQP/approved
drawings/technical specifications.
3.1.4. Review of material test records (MQP & FQP) of important items as
described at section 2.1.1 & 2.1.2
3.1.5. In 1% villages of the project, 100% verification of BPL connections,

100% Distribution Transformer Substations, 100% of LT Lines and
100% of the 11KV lines attributed to the village (emanating from cut-
point/grid substation) as well as the 11 KV line laid within the village,
verification of energisation of village & BPL beneficiaries, installation of
service connections in public places, hours of supply in the village, time
taken by DISCOM to raise first energy bill in favor of beneficiaries.
3.1.6. NQM shall also oversee the Contract Management Part of contractor like
contractual provisions of identifying defects and their communication to
working teams, timely rectification of defects, resolution of project
related issues and action on delayed project. In their visit, they would
give thrust on adherence on systems and procedures of RGGVY schemes
by EMPLOYER and turnkey contractors. They would also ensure
availability and awareness of project specific drawings, documents,
quality assurance plans among all stake holders including contractor
staff/workers.
3.1.7. NQM shall also see the progress of up-loading of monitoring

observations and its compliance details including site photographs in
RGGVY web portal by turnkey contractor through Employer.
4. GENERAL
4.1. To ensure that the equipment and services under the scope of this Contract
whether manufactured or performed within the Contractor’s Works or at his
Sub-contractor’s premises or at the Employer’s site or at any other place of
Work are in accordance with the specifications, the Contractor shall adopt
suitable quality assurance programme to control such activities at all points
necessary. Such programme shall be broadly outlined by the contractor and
finalized after discussions before the award of contract. The detailed

programme shall be submitted by contractor after the award of contract and
finally accepted by the Employer after discussions. A quality assurance
programme of the contractor shall generally cover the following:
a) His organization structure for the management and implementation of the

proposed quality assurance programme :
b) Documentation control system;
c) Qualification data for bidder’s key personnel;
d) The procedure for purchases of materials, parts components and selection of
sub-Contractor’s services including vendor analysis, source inspection, incoming
raw material inspection, verification of material purchases etc.
e) System for shop manufacturing and site erection controls including process
controls and fabrication and assembly control;
f) Control of non-conforming items and system for corrective actions;
g) Inspection and test procedure both for manufacture and field activities.
h) Control of calibration and testing of measuring instruments and field activities;
i) System for indication and appraisal of inspection status;
j) System for quality audits;
k) System for authorizing release of manufactured product to the Employer.
l) System for maintenance of records;
m) System for handling storage and delivery; and
n) A manufacturing quality plan detailing out the specific quality control measures
and procedures adopted for controlling the quality characteristics relevant to
each item of equipment furnished and/or services rendered.
o) A Field quality Plan covering field activities
4.2. The manufacturing & Field quality Plans shall be mutually discussed and
approved by the Employer after incorporating necessary corrections by the
Contractor as may be required.
4.3. The Employer or his duly authorized representative reserves the right to carry
out quality audit and quality surveillance of the system and procedure of the
Contractor/his vendor’s quality management and control activities.
4.4. The Contractor would be required to submit all the Quality Assurance
documents as stipulated in the Quality Plan at the time of Employer’s
Inspection of equipment/material.
5. TYPE & ACCEPTANCE TESTS
The following type, acceptance and routine tests and tests during manufacture shall be
carried-out on the material. For the purpose of this clause:
5.1. 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. Contractor shall
provide copy of such tests at site in support of type-tested materials supplied
under the contract.
5.2. Acceptance Tests shall mean those tests which are to be carried out on samples
taken from each lot offered for pre-despatch inspection, for the purposes of
acceptance of that lot.
5.3. Routine Tests shall mean those tests, which are to be carried out on the
material/equipment to check requirements which are likely to vary during
production.
5.4. 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.
5.5. The norms and procedure of sampling for these tests will be as per the Quality
Assurance Programme to be mutually agreed to by the Contractor and the
Owner.
5.6. 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 procedure of the tests shall be as per
IS/IES/Standard this specification or as mutually agreed to between the
Contractor and the Owner in the Quality Assurance Programme.
5.7. For all type test and acceptance tests, the acceptance values shall be the values
specified in this Specification, Approved Quality Plan or guaranteed by the
Bidder, as applicable.
6. TYPE TESTING, INSPECTION, TESTING & INSPECTION CERTIFICATE
6.1. All equipment being supplied shall conform to type tests including additional
type tests, if any as per technical specification and shall be subject to routine
tests in accordance with requirements stipulated under respective sections.
Employer reserves the right to witness any or all the type tests. The Contractor
shall intimate the Employer the detailed program about the tests at least three
(3) weeks in advance in case of domestic supplies & six (6) weeks in advance in
case of foreign supplies.
6.2. The reports for all type tests and additional type tests as per technical
specification shall be furnished by the Contractor alongwith equipment/material
drawings. The type tests conducted earlier should have either been conducted
in accredited laboratory (accredited based on ISO/IEC Guide 25/17025 or EN
45001 by the national accredition body of the country where laboratory is
located) or witnessed by the representative(s) of Employer or Utility. The test-
reports submitted shall be of the tests conducted within last 10 (ten) years prior
to the date of bid opening. In case the test reports are of the test conducted
earlier than 10 (ten) years prior to the date of bid opening, the contractor shall
repeat these test(s) at no extra cost to the Employer
6.3. In the event of any discrepancy in the test reports i.e. any test report not
acceptable due to any design/manufacturing changes (including substitution of
components) or due to non-compliance with the requirement stipulated in the
Technical Specification or any/all additional type tests not carried out, same
shall be carried out without any additional cost implication to the Employer.
6.4. The Employer, his duly authorized representative and/or outside inspection
agency acting on behalf of the Employer shall have at all reasonable times free
access to the Contractor’s/sub-vendors premises or Works and shall have the
power at all reasonable times to inspect and examine the materials and
workmanship of the Works during its manufacture or erection if part of the
Works is being manufactured or assembled at other premises or works, the
Contractor shall obtain for the Engineer and for his duly authorized
representative permission to inspect as if the works were manufactured or
assembled on the Contractor’s own premises or works. Inspection may be made
at any stage of manufacture, dispatch or at site at the option of the Employer
and the equipment if found unsatisfactory due to bad workmanship or quality,

material is liable to be rejected.
6.5. The Contractor shall give the Employer/Inspector thirty (30) days written notice
of any material being ready for joint testing including contractor and Employer.
Such tests shall be to the Contractor’s account except for the expenses of the
Inspector. The Employer/Inspector, unless witnessing of the tests is virtually
waived, will attend such tests within thirty (30) days of the date of which the
equipment is notified as being ready for test /inspection, failing which the
Contractor may proceed alone with the test which shall be deemed to have
been made in the Inspector’s presence and he shall forthwith forward to the
Inspector duly certified copies of tests in triplicate.
6.6. The Employer or Inspector shall, within fifteen (15) days from the date of
inspection as defined herein give notice in writing to the Contractor, of any
objection to any drawings and all or any equipment and workmanship which in
his opinion is not in accordance with the Contract. The Contractor shall give due
consideration to such objections and shall either make the modifications that
may be necessary to meet the said objections or shall confirm in writing to the
Employer/Inspector giving reasons therein, that no modifications are necessary
to comply with the Contract. If any modification is made on the equipment on
the basis of test results not in conformity with the contract, the modified
equipment shall be subject to same sequence of test again without any
additional cost to Employer.
6.7. When the factory tests have been completed at the Contractor’s or Sub-
Contractor’s works, the Employer/Inspector shall issue a certificate to this effect
within fifteen (15) days after completion of tests but if the tests are not
witnessed by the Employer/Inspector, the certificate shall be issued within
fifteen (15) days of receipt of the Contractor’s Test certificate by the
Engineer/Inspector. Failure of the Employer/Inspector to issue such a certificate
shall not prevent the Contractor from proceeding with the Works. The
completion of these tests or the issue of the certificate shall not bind the
Employer to accept the equipment should, it, on further tests after erection, be
found not to comply with the Contract. The equipment shall be dispatched to
site only after approval of test reports and issuance of CIP by the Employer.
6.8. In all cases where the Contract provides for tests whether at the premises or at
the works of the Contractor or of any Sub-Contractor, the Contractor except
where otherwise specified shall provide free of charge such items as labour,
materials, electricity, fuel, water, stores, apparatus and instruments as may be

reasonably demanded by the Employer/Inspector or his authorized
representative to carry out effectively such tests of the equipment in accordance
with the Contract and shall give facilities to the Employer/Inspector or to his
authorized representative to accomplish testing.
6.9. The inspection by Employer and issue of Inspection Certificate thereon shall in
no way limit the liabilities and responsibilities of the Contractor in respect of the
agreed quality assurance programme forming a part of the Contract.
6.10. The Employer will have the right of having at his own expenses any other
test(s) of reasonable nature carried out at Contractor’s premises or at site or in
any other place in addition of aforesaid type and routine tests, to satisfy that
the material comply with the specification.
6.11. The Employer reserves the right for getting any field tests not specified in
respective sections of the technical specification conducted on the completely
assembled equipment at site. The testing equipments for these tests shall be
provided by the Employer.
6.12. The Purchaser intends that type tests and additional type tests are conducted
on Transformers, Pin & Disc Insulators, AB cable, Conductor, Battery Charger
and consumer energy meter. The price of conducting type tests and additional
type tests shall be included in Bid price.
6.13. In case the contractor opts to procure these items from more than one
manufacturer, the type test shall be conducted in respect of all the
manufactures. No repeat type test charges shall be paid by owner.
6.14. Purchaser reserves the right to witness any or all the type tests.
7. PRE-COMMISSIONING TESTS
On completion of erection of the equipment and before charging, each item of the
equipment shall be thoroughly cleaned and then inspected jointly by the Employer and
the contractor for correctness and completeness of installation and acceptability for
charging, leading to initial pre-commissioning tests at Site. The list of pre-
commissioning tests to be performed is given in respective chapters or as included in
the Contractor’s quality assurance programme.
8. COMMISSIONING TESTS
All required instrumentation and control equipment will be used during such tests and
the contractor will use all such measuring equipment and devices duly calibrated as far
as practicable. However, the Contractor, for the requirement of these tests, shall take
immeasurable parameters into account in a reasonable manner. The tests will be
conducted at the specified load points and as near the specified cycle condition as
practicable. The contractor will apply proper corrections in calculation, to take into
account conditions, which do not correspond to the specified conditions.
9. Any special equipment, tools and tackles required for the successful completion of the
Commissioning tests shall be provided by the contractor, free of cost.
10. The specific tests to be conducted on equipment have been brought out in the
respective chapters of the technical specification. However where the pre-
commissioning tests have not been specified specifically they shall be as per relevant IS
code of practice or as mutually agreed.
11. The Contractor shall be responsible for obtaining statutory clearances from the
concerned authorities for commissioning and operation of the equipment including the
Electrical Inspector.
3. Documentation
3.1. GENERAL
3.1.1. To ensure that the proposed systems conform to the specific provisions and
general intent of the Specification, the Contractor shall submit documentation
describing the systems to employer for review and approval. The contractor
shall obtain approval of employer for the relevant document at each stage
before proceeding for manufacturing, system development, factory testing,
site testing, training etc. The schedule for submission/approval of each
document shall be finalised during the discussions before placement of the
contract, this schedule shall be in line to overall project schedule.
3.1.2. Each document shall be identified by a Contractor document number, the

employer document number, and the employer purchase order number.
Where a document is revised for any reason, each revision shall be indicated
by a number, date, and description in a revision block along with an indication
of official approval by the Contractor's project manager. Each revision of a
document shall highlight all changes made since the previous revision.
3.1.3. All technical description, specifications, literature, correspondence, prints,

drawings, instruction manuals, test reports( both factory and at site), progress
photographs, booklets, schedules and all supplementary data or documents
furnished in compliance with the requirements of the Contract, shall become
the property of the Employer and the costs shall be considered as included in
the Contract price.
3.1.4. The Contractor shall be responsible for any time delay, misinterpretation, error
and conflict during design, manufacturing, testing and erection of the Works
resulting from non-compliance with the requirements of this Specification.
3.1.5. The Employer shall have the right to make copies of any documents, data,
reports, information etc. supplied by the Contractor in connection with the
Works. The Employer shall not impart the information of these documents to
any other manufacturer or competitor but he shall be free to use these for
preparation of technical papers, reports etc.
3.1.6. All documentation shall be in English language.
3.2. REQUIREMENTS FOR SUBMISSION OF DOCUMENTS, INFORMATION AND DATA BY

THE CONTRACTOR
3.2.1. The Contractor shall submit to the Employer all documents in accordance with
an approved schedule of submissions and shall submit any further information
(in the form of drawings, documents, manuals, literature, reports etc.) when
asked by the Employer while commenting/approving any drawings/documents
etc. All applicable documents shall be provided for each converter station
separately.
3.2.2. The documents which are subject to the approval of the Employer shall be
identified by the Contractor with the stamp "FOR APPROVAL". All other
documents shall be submitted to the Employer for information and shall be
identified by the Contractor with the stamp "FOR INFORMATION".
3.2.3. The sequence of submission of the documents shall be subject to the approval
of the Employer. The sequence of submissions of all documents shall be such
that the necessary information is available to enable the Employer to approve
or comment the document.
3.2.4. The Contractor shall supply 4 hard copies of all drawings and documents.
3.2.5. In case a "SUBSEQUENT" revision of any document is made due to any reason
whatsoever, a revision of the same, highlighting the changes shall be
resubmitted for the Employer's specific approval/ information.
3.3. DOCUMENTS FOR APPROVAL
3.3.1. The Employer shall be allowed fifteen (15) calendar days to approve the
Contractor's submissions. The submissions for approval, shall be returned to
the Contractor marked in one of the following ways :
Category I: Approved
Category II: Approved with Comments.
Category III: Returned for correction.
Category IV : For information
3.3.2. The first notations "I" or "II" shall be deemed to permit the Contractor to
proceed with the work shown on the document, except in the case of notation
"II" the work shall be done subject to the corrections indicated thereon and/or
described in the letter of transmittal. The Contractor shall bear the full
responsibility for proceeding with the Works prior to receipt of the release in
notation "I" from the Employer.
3.3.3. In case of notation "II", the Contractor shall include the alterations required &
resubmit the document within fifteen (15) days from date of Employer's letter
of transmittal.
3.3.4. In case of notation "III", the Contractor shall include the alterations required
and resubmit the document to the Employer, within fifteen (15) days, from
date of letter of transmittal, so that such document can be returned with the
notation "I" or "II".
3.3.5. It may also be noted that the approval/commenting by the Employer does not
relieve the Contractor of any of his contractual obligations and his
responsibilities for correctness of dimensions, materials, weights quantities or
any other information contained therein, as well as the conformity of designs
with Indian Statutory Laws and the Technical Specifications as may be
applicable. The approval also does not limit the Employer's rights under the
Contract.
3.3.6. The approved documents shall be considered as the working documents.

However the Technical Specification and connected documents shall prevail
over these documents in case a decision is required on interpretation.
3.4. DOCUMENTS FOR INFORMATION
The Contractor shall not delay the Works pending the receipt by the Contractor of the
comments on documents submitted to the Employer for information. However, the
Employer shall have the right to comment on all the documents submitted by the
Contractor, when, in the opinion of the Employer the document does not comply with
the Contract or otherwise. The Contractor shall satisfactorily demonstrate that the
information contained in the aforesaid document does meet the requirements of the
Contract or revise the document in order that the information shall comply with the re-
quirements of the Contract.
3.5. BASIC REFERENCE DRAWINGS
3.5.1. The reference drawings are enclosed with the bid document, which forms a part
of the specification. The contractor shall develop a new layout in line with the
specification and take the approval of the EMPLOYER. The contractor shall
maintain the overall dimensions of the substation, buildings, bay length, bay
width, phase to earth clearance, phase to phase clearance and sectional
clearances, clearances between buses, bus heights but may alter the locations
of equipment to obtain the statutory electrical clearances as required for the
substation.
3.5.2. All drawings submitted by the Contractor including those submitted at the time
of bid shall be in sufficient detail to indicate the type, size, arrangement,
material description, Bill of Materials, weight of each component, break-up for
packing and shipment, dimensions, internal & the external connections, fixing
arrangement required and any other information specifically requested in the
specifications.
3.5.3. Each drawing submitted by the Contractor shall be clearly marked with the
name of the Employer, the unit designation, the specifications title, the
specification number and the name of the Project. If standard catalogue
pages are submitted, the applicable items shall be indicated therein. All titles,
noting, markings and writings on the drawing shall be in English. All the
dimensions should be in metric units.
3.5.4. Further work by the Contractor shall be in strict accordance with these drawings
and no deviation shall be permitted without the written approval of the
Employer, if so required.
3.5.5. The review of these data by the Employer will cover only general conformance
of the data to the specifications and documents interfaces with the equipment
provided under the specifications. This review by the Employer may not
indicate a thorough review of all dimensions, quantities and details of the
equipment, materials, any devices or items indicated or the accuracy of the
information submitted. This review and/or approval by the Employer shall not
be considered by the Contractor, as limiting any of his responsibilities and
liabilities for mistakes and deviations from the requirements, specified under
these specifications and documents.
3.5.6. All manufacturing and fabrication work in connection with the equipment prior
to the approval of the drawings shall be at the Contractor’s risk. The
Contractor may make any changes in the design which are necessary to make
the equipment conform to the provisions and intent of the Contract and such
changes will again be subject to approval by the Employer. Approval of
Contractor’s drawing or work by the Employer shall not relieve the contractor
of any of his responsibilities and liabilities under the Contract.
3.5.7. All engineering data submitted by the Contractor after final process including
review and approval by the Employer shall form part of the Contract
Document and the entire works performed under these specifications shall be
performed in strict conformity, unless otherwise expressly requested by the
Employer in Writing.
3.6. PRE-DISPATCH INSPECTION:

Pre-dispatch inspection shall be performed on various materials at manufacturer’s work
place for which contractor shall be required to raise requisition giving at least 7-day
time. Depending on requirement, inspection shall be witnessed by representatives of
Employer, TPIA and/or RQM/REC/MoP.
The turnkey contractor shall ensure that pre-dispatch inspection for materials are
intimated only when the material is completely ready for inspection. On due date of
inspection, if it is found that materials are not ready in required quantities, all
expenditures incurred on deployment of various inspecting officials along with a fine of
Rs 50,000/- shall be recovered from the bills of the agency. 2 nd such situation at same
manufacturer/supplier shall result in rejection of name of manufacturer from list of
approved vendors/sub-vendors.

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STANDARD BIDDING DOCUMENT

RURAL ELECTRIFICATION WORKS OF XXXX (NAME

CIVIL WORKS AND SOIL INVESTIGATION

However, the Contractor shall quote according to the complete requirements.

3.1. Bore Holes

Performing Standard Penetration Tests at approximately 1.5 m interval in the borehole

The depth of Water table shall be recorded in each borehole.

3.2. Electrical Resistivity Test

3.3. Water Sample

3.4. Back Filling of Bore Holes

3.5. Laboratory Test

2. All samples brought from field, whether disturbed or undisturbed shall be

The following laboratory tests shall be carried out

a) Visual and Engineering Classification

b) Liquid limit, plastic limit and shrinkage limit for C-

c) Natural moisture content, bulk density and specific gravity.

d) Grain size distribution.

f) Consolidated un-drained test with pore pressure measurement.

g) Chemical tests on soil and water to determine the carbonates,

i) Rock quality designation (RQD), RMR in case of rock is

3.6. Test Results and Reports

a) Geological formation of the area, past observations or historical data, if available,

b) Recommended type of foundations for various structures. If piles are

d) Recommendations regarding slope of excavations and dewatering schemes, if

f) If expansive soil is met with, recommendations on removal or retaining the same

g) Recommendations for additional investigations beyond the scope of the present

3) Material unsuitable for founding of foundations shall be removed and replaced by

5.2. Excavation and backfill

3. When embankments are to be constructed on slopes of 15% or greater, benches

4. Embankments adjacent to abutments, culverts, retaining walls and similar

5. Earth embankments of roadways and site areas adjacent to buildings shall be

2. At all times unfinished construction shall have adequate drainage. Upon

3. Each layer of earth embankment when compacted shall be as close to optimum

5.4. Requirement for fill material under foundation

6. STONE FILLING & ANTIWEED TREATMENT

6.1. Scope of Works

(a) Sieve analysis limits/Gradation

(c) Flakiness Index

7.3 A base layer of uncrushed/crushed/broken stone of 20 mm nominal size (single sized)

9. ROADS AND CULVERTS

2. All substation roads shall be constructed so as to permit transportation of all

3. Road construction shall be as per IRC standards.

10. TRANSFORMER FOUNDATION

If existing/failed transformer is required to be replaced by new one in augmentation/bay

11. CABLE & PIPE TRENCHES

5. Trenches shall be drained. Necessary sumps be constructed and sump pumps if

8. Cables from trench to equipments shall run in hard conduit pipes.

13. Cable trench shall be constructed as per enclosed tender drawing.

12. FOUNDATION /RCC CONSTRUCTION

However, for the augmentation/bay extension works of existing substation, type

8. If pile foundations are adopted, the same shall be cast-in-situ driven/bored or

7. Necessary protection to the foundation work, if required shall be provided to take

12.3. Admixtures & additives

4. The water-reducing set-retarding admixture shall be an approved brand of Ligno-

5. The waterproofing cement additives shall be used as required / advised by the

12.4. GATES AND BOUNDARY WALL

13. BUILDINGS - GENERAL REQUIREMENTS

If any extension of the Control Room building is required in augmentation / bay

13.2. Control room Building

Minimum headroom of 3 M below soffit of beams/false ceiling shall be considered for

a) The buildings shall be designed:

1. To the requirements of the National Building Code of India, and the

2. For the specified climatic & loading conditions.