NAGPUR METRO RAIL PROJECT

Transcription

1 NMRCL TENDER NO. N1Tr-02/2016 PART-II NAGPUR METRO RAIL PROJECT BID DOCUMENT FOR DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF 25 KV SINGLE PHASE, 50HZ AC, REGULATED, CONVENTIONAL AND TRAMWAY TYPE OHE IN AT GRADE SECTION AND MIHAN DEPOT, 33/25 KV TRACTION SUB STATION & SSP INCLUDING 33 KV CABLING WORK OVER NORTH SOUTH CORRIDOR OF NAGPUR METRO RAIL CORPORATION LIMITED TENDER NO. N1Tr-02/2016 PART II MARCH 2016 Nagpur Metro Rail Corporation Limited Metro House, Bungalow No: 28/2, Anand Nagar, CK Naidu Road, Civil Lines, Nagpur Maharashtra, INDIA Website: NMRCL MARCH

2 NMRCL TENDER NO. N1Tr-02/2016 PART-II Contents of Part-II PART II: Works Requirements Section VII-A. Works Requirement - General Specifications Section VII-B. Works Requirement - Technical Specifications Section VII-C: Reference Documents / Drawings (SOD, GADs etc.) NMRCL MARCH

3 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification NAGPUR METRO RAIL PROJECT BID DOCUMENTS FOR DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF 25 KV SINGLE PHASE, 50HZ AC, REGULATED, CONVENTIONAL AND TRAMWAY TYPE OHE IN AT GRADE SECTION AND MIHAN DEPOT, 33/25 KV TRACTION SUB STATION & SSP INCLUDING 33 KV CABLING WORK OVER NORTH SOUTH CORRIDOR OF NAGPUR METRO RAIL CORPORATION LIMITED TENDER NO. N1Tr-02/2016 PART II: WORKS REQUIREMENTS SECTION VII-A: WORKS REQUIREMENT GENERAL SPECIFICATION Nagpur Metro Rail Corporation Limited Metro House, Bungalow No: 28/2, Anand Nagar, CK Naidu Road, Civil Lines, Nagpur Maharashtra, INDIA Website: NMRCL MARCH

4 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section- VII-A General Specification CONTENTS 1. GENERAL Application of the General Specification (GS) Abbreviations Definitions Glossary of Terms Submission for Review Standards, Codes of Practice Employer s Drawings Specifications in Metric and Imperial Units System Safety Availability (Reliability and Maintainability) Suitability for Purpose Climatic Condition / Operating Environment Survey and Site Investigations PLANNING, PROGRAMME AND PROGRESS MONITORING 2.1 Planning. 2.2 Programming General Requirements. 2.3 Progress Monitoring Works Programme Design Submission Programme Design, Procurement and Manufacturing Programme. 2.7 Installation Programme Testing and Commissioning Programme. 2.9 Training and Transfer of Technology Programme Not Used 2.11 Not Used 2.12 Time Chainage Programme (T/C). NMRCL MARCH

5 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section- VII-A General Specification 2.13 Track Related Installation Programme (TRIP) Programme Submissions Programme Review Works Programme Revisions Monthly Progress Report Programme Analysis Report Key Date and Milestone Report Physical Progress (Earned Value) Report Progress Meetings 2.22Quarterly Review Meetings. 3.MANAGEMENT PLANS AND SUBMISSIONS 3.1 General General Organisation Project Management Plan Systems Assurance Plans Design, Procurement and Manufacturing Plan Construction and Installation Management Completion Management Plan DOCUMENTS SUBMISSION AND REVIEW Documents, Submissions and Correspondence Submissions to the Employer s Engineer Records and Reports Records QUALITY MANAGEMENT Introduction General Requirements Management Quality Plan... NMRCL MARCH

6 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section- 5.4 Design Quality Plan... VII-A General Specification 5.5 Manufacturing Quality Plan Site Quality Plan Inspection and Test Plans, Records and Report Review, Verification & Audit Quality Control Register Summaries of Inspection and/or Test Notification of Non-conformities SOFTWARE MANAGEMENT AND CONTROL Prescriptive Framework Software Framework Software Management Control Status Reporting Auditing Software Acceptance Not used Re-Use of Existing Software Application of Commercial Off The Shelf Software (COTS) Millennium Bug Test Software Global Positioning System Week-counter Rollover MATERIALS AND EQUIPMENT Materials and Equipment Provided by the Employer Materials Equipment Electronic Control Racks &Cabinets PACKAGING, STORAGE, SHIPPING AND DELIVERY... NMRCL MARCH

7 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section- 8.1 Storage of Equipment... VII-A General Specification 8.2 Crating General Precautions Packaging Procedures Shipping Delivery TESTING AND COMMISSIONING General Manufacturing Test Plan Commissioning Plan On-Site Testing and Commissioning Plan Activity of the Employer and the Employer s Engineer Records and Reports Test Equipment and Facilities Witnessing by the Employer and the Employer s Engineer Failures Repeat Tests Fault Categories Fault Log Hardware Failure Reports Software Failure Reports TRAINING AND TRANSFER OF TECHNOLOGY Training Requirements Training Method Employer s Instructor Training Training Plant &Equipment Testing and Assessment Training Records... NMRCL MARCH

8 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section Transfer of Technology... VII-A General Specification 11. OPERATION AND MAINTENANCE DOCUMENTATION General Arrangement and Format of Manuals Drawings Submissions Operation and Maintenance Manuals SUPERVISION AND PLANNING OF MAINTENANCE Scope Maintenance Planning & Management Staff Supervisory Staff SUPPLY OF SPARE PARTS, SPECIAL TOOLS AND TEST EQUIPMENT Details of supply Manufacture and delivery of Spare Parts Contract Spares Commissioning Spares Defects Liability Spares Special Tools and Test Equipment Coding and Tagging of Spare Parts and Special Tools and Test Equipment 14. THE WORKS AND CARE OF THE WORKS Methods of Construction Temporary Works Normal Working Hours Drawings and Schedules Notification and Inspection of Works Construction Restraints Protection from Water... NMRCL MARCH

9 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section Protection from Weather... VII-A General Specification 14.9 Protection of Work SITE ESTABLISHMENT AND ATTENDANCE Use of the Site Survey of the Site Fences and Signs on the Site The Contractor s Site Accommodation Site Utilities and Access Not used Clearance of the Site Attendance Contractor s Equipment Security LIAISON WITH OTHERS Liaison with Others Work by Other Contractors Interface Management THE SITE Access to Site Site Restrictions Site Services Site Cleanliness Prevention of Mosquito Breeding Prevention of Dust Engineering Conditions for Temporary Land Allocation Attendance by Civil Works Project Contractor Access to the Site by Other Contractors... NMRCL MARCH

10 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section Transportation to Site... VII-A General Specification Contractor s Own Rolling Stock Defined Area Working and Works Train Operations Work in Vicinity of Operating Tracks Rodent Control HEALTH AND SAFETY DAMAGE AND INTERFERENCE Damage and Interference Watercourses and Drainage Systems Utilities Structures, Roads and Other Property Access Trees and Other Similar Obstructions Noise Control on Works Site Spoil Disposal ENVIRONMENTAL PROTECTION REQUIREMENTS NOT USED TEMPORARY ELECTRICITY SUPPLY Not Used Applicability Work on Site Electrical General Materials, Appliances and Components Design Considerations Mains Voltage Types of Distribution Supply Protection of Circuits... NMRCL MARCH

11 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section Earthing... VII-A General Specification Plugs, Socket Outlets and Couplers Cables Lighting Installation Electrical Motors Inspection and Testing Identification Maintenance Maintenance Record Metering Power Supply for Installation MOCK-UPS, PROTOTYPES AND SAMPLES Requirements Purpose Review MONTHLY PROGRESS REPORT Topics Progress Reports Copies CONTRACT SYSTEMS SAFETY MANAGEMENT Safety Assurance Programme Hazard Analysis Results SUBMISSION FOR REVIEW REQUEST FORM SCHEDULE OF ITEMS TO BE SUBMITTED BY CONTRACTOR TYPICAL TYPE TEST REQUIREMENTS... NMRCL MARCH

12 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section- 5.1 Electronic and Electrical Equipment... VII-A General Specification 5.2 Mechanical Tests Environmental Tests Electrical Tests REQUEST FOR INSPECTION OF WORKS FORM NOISE MONITORING INSTRUMENT FIRST AID REQUIREMENTS Provisions by others Provisions by the Contractor WORKS AREAS Works Areas Schedule of Works Area Availability:... End of Table of Contents NMRCL MARCH

13 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification 1. GENERAL CHAPTER Application of the General Specification (GS) The provisions contained in the Technical Specification (TS) and the Employer s Drawings shall prevail over the provisions contained in this GS This GS shall be read in conjunction with the other documents constituting the Contract Abbreviations Common abbreviations used in the GS and in the PSs shall have the following meanings: ACB BCC BS CADD CAR CNP COTS CPM CV DLP LMRC DVT E&M EMC EMIP EMP EMSD EMU EN EPD : Air Circuit Breaker : Backup Control Centre : British Standard : Computer Aided Design and Drafting : Corrective Action Request : Construction Noise Permits : Commercial Off the Shelf : Critical Path Method : Curriculum Vitae : Defects Liability Period : Lucknow Metro Rail Corporation : Design Verification Table : Electrical & Mechanical : Electromagnetic Compatibility : Environmental Mitigation Implementation Plan : Environmental Management Plan : Electrical and Mechanical Services Department : Electric Multiple Unit : Euro-Norm (European Standards) : Environmental Protection Department NMRCL MARCH

14 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification ETI : Employer's Training Instructors FAI : First Article Inspection FAT : Factory Acceptance Test(s) FMEACA : Failure Mode Effect and Criticality Analysis GCC : General Conditions of Contract GIF : Graphic Information Format GS : General Specification (this document) HV : High Voltage IEC : International Electro-technical Commission IEE : The Institution of Electrical Engineers IP : Ingress Protection IS : Indian Standards ISO : International Standards Organisation ITT : Instructions To Tenderers ITU : International Telecommunications Union LV : Low Voltage MC : Metro Corridor MCB : Miniature Circuit Breaker MMI : Man-Machine Interface MTR : Mass Transit Railway NSR : Noise Sensitive Receivers OCC : Operations Control Centre OCS : Overhead Contact System (Rigid Conductor) OSR : Operational Safety Report OSR(S) : Operational Safety Report (Software) OHE : Overhead Equipment (Flexible Catenary) P3 : Primavera Project Planner PLC : Programmable Logic Controller PPE : Personal Protective Equipment PS : PVC : Polyvinyl Chloride QA : Quality Assurance RAMS : Reliability, Availability, Maintainability and Safety RC : Rail Corridor RTU : Remote Terminal Unit NMRCL MARCH

15 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification SAR SAT SCC SIL SQAP SRR SWA T/C TRIP : Special Administrative Region : Systems Acceptance Test(s) : Special Conditions of Contract : Safety Integrity Level : Software Quality Assurance Plan : Submission Review Request : Steel Wire Armoured : Time Chainage : Track Related Installation Programme Further abbreviations may be defined within the body of the GS or PS where there is only local applicability. Where such abbreviations exist the Contractor shall exercise great care that the abbreviation is not used out of context when communicating with the Employer, the Employer s Engineer or any Third Party Abbreviations of units of measurement used in the GS shall have the meanings as defined under the SI system of units. 1.3 Definitions Words and phrases defined in the GC or PC shall retain the same meaning within the GS and PS unless specifically redefined within this GS or under the provisions of clause above for the purpose of a particular clause or group of clauses. (1) Access Dates are dates that are to be achieved by other than the Contractor and which are considered to be essential to the successful completion of the Contract to the original planned schedule. Lists of the activities completion of which are considered to give rise to an Access Date are included in the PS. (2) Commissioning means the process of setting to work the complete transportation system through a series of integrated tests that demonstrate the installation and performance in accordance with the specified criteria. (3) Day means calendar day unless expressly stated otherwise. (4) Defined Area means an area within which Works Trains will be operated and the Employer s defined area working safety rules will apply. (5) Factory Acceptance Tests means the tests to be performed at the Contractor s factories prior to delivery to the Site to verify compliance with the Specification and quality standards (6) Installation Tests means the tests to be performed to verify the conformity of completion of an installation/assembly to the design documents previously reviewed NMRCL MARCH

16 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification without objection by the Employers Engineer prior to the start of Commissioning. Installation Tests do not form part of the Tests on Completion to be performed by the Contractor in order to achieve Employer s Taking Over of the Works or any Section however they must be successfully completed before the Tests on Completion can commence. (7) Key Dates are dates which are to be achieved by the Contractor and which are considered to be essential to the successful completion of the project to the original planned schedule. A list of the activities, completion of which gives rise to a Key Date, is included in the PS. (8) Partial Acceptance Tests means the functional tests to be performed on components and parts of systems to meet the specified criteria. Partial Acceptance Tests form part of the Tests on Completion to be performed under the Contract in order to achieve Employer s Taking Over of the Works or any Section. (9) Service Trial means the phase after completion of the System Acceptance Tests where the training and operating procedures are validated through the running of the trains to the published timetable. Service Trial form part of the Tests on Completion to be performed under the Contract in order to achieve Employer s Taking Over of the Works or any Section. (10) Quality Control Point means a point in time when a notice or other document is to be submitted to the Employer s Engineer in accordance with the Contract before the Contractor can commence, proceed with or terminate an activity (11) Quality Hold Point means a point in time when a notice of no objection by the Employer s Engineer is required. (12) S curve means the graphical relationship between the planned (and actual where appropriate) quantity of completed work (or resources) and time. The curve produced is to be illustrated on an accumulative basis where the slope of the line indicates the rate of undertaking the work or rate of expenditure of the resources. (13) Specification (the) means the aggregate sum of the documents and any amendments thereto, issued to Tenderers by NMRC as part of the Tender process before the final date for submission of Tenders. This shall include but not be limited to; Design Criteria, Employer s Requirements, Employer s Tender Drawings, Preliminary Operating Plan and Clarification of Tender Documents issued in accordance with the ITT but shall not include the ITT itself nor any minutes of meetings. (14) Specification (this) means the particular document within which the reference is made. (15) System Acceptance Tests means those tests that demonstrate the performance of the installation/equipment to the specified requirements as detailed in the PS. SATs form part of the Tests on Completion to be performed under the Contract in order to achieve Employer s Taking Over of the Works or any Section. (16) Integrated Testing and Commissioning means those tests that demonstrate the integration of the complete transport system meeting the requirements of the NMRCL MARCH

17 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Specification in an operating environment. Integrated Testing and Commissioning form part of the Tests on Completion to be performed by the Contractor in order to achieve Employer s Taking Over of the Works or any Section. (17) Validation means the process of confirmation by examination and provision of objective evidence that the application produced achieves the particular requirements specified. (18) Verification means the process of confirmation by examination and provision of objective evidence that the specified requirements have been incorporated within design. 1.4 Glossary of Terms Words and expressions to which meanings are assigned in any paragraph of the GS shall have the same meanings in other paragraphs of the GS except when the context otherwise requires Utilities are electricity, lighting, traffic control, telephone and other communication cables, gas, water, sewage and drainage pipes and ducts, including all associated protection, supports, ancillary structures, fittings and equipment. 1.5 Submission for Review Reference in the GS and PS to any submission made by the Contractor to the Employer s Engineer having been reviewed without objection by the Employer s Engineer shall mean the issue of a notice of no objection by the Employer s Engineer issued in response to a submission made by the Contractor. Documents, drawings, specifications, calculations, technical papers, material samples, methods of construction and any other matters which have been reviewed without objection by the Employer s Engineer shall not be changed without further submission for review to the Employer s Engineer of the proposed changes Clause 4.2 below prescribes the process to be adopted for submissions of documents, material samples and any other items to the Employer s Engineer. Schedules of items that are to be submitted to the Employer s Engineer for review are contained within this GS and/or the PS Submissions for review shall be made in accordance with the dates (relative to the Works Programme) stated in the GS and/or the PS. For items not specifically given a submission date in the Specification submissions shall be strictly in accordance with the agreed Submissions Programme or as directed by the Employer s Engineer. 1.6 Standards, Codes of Practice Permanent Works, Temporary Works, Contractor s Equipment, hardware, firmware, software, apparatus of all kinds, and, where appropriate, materials and workmanship shall be in accordance with the Standards quoted in the Specification and the requirements identified in the PS or, where no Standard is identified, the Contractor shall make a proposal which shall be subject to review by the Employer s Engineer. NMRCL MARCH

18 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification 1.7 Employer s Drawings The Employer s Drawings assist in describing the scope of the Works in general and clarify constraints, interface arrangements and the conceptual nature of the finished structures/system outline The Contractor shall carefully check all Employer s Drawings and advise the Employer s Engineer of discrepancies, omissions, errors or ambiguities should any be found The Contractor shall note that any drawings included but marked For information only do not form part of the Contract Dimensions shall not be obtained by scaling from the Employer s Drawings. Dimensions that are not shown or are not calculable from dimensions shown on Employer s Drawings shall be obtained from the Employer s Engineer. 1.8 Specifications in Metric and Imperial Units Specifications in imperial units shall not be substituted for specifications in metric units stated in the Contract without the prior consent of the Employer s Engineer Conversion of metric units to imperial units and of imperial units to metric units shall be in accordance with the Standard International Practice. 1.9 System Safety Safety philosophy Safety of passengers, staff and the general public is paramount for railway operation. Prime consideration shall be given to all design issues that can have an effect on safety During the construction phase the safety of all staff involved in the Works and any members of the general public affected by the Works shall be the prime feature of all working methods, including storage and transport to site as well as all temporary works not incorporated into the final construction Safety Management The Contractor shall implement the Contract Systems Safety Management Requirements, as referenced in the Project Safety Manual and elsewhere in the Specification, in consultation with the Employer s Engineer Prescriptive Safety Criteria The Contractor shall identify and list all applicable statutory and regulatory requirements and codes of practice relevant to the design of the Works undertaken and to work within the constraints and limitations imposed by the requirements and codes The safety of the Contractor s supplied systems and equipment shall be developed by the Contractor in accordance with the requirements contained in clause below and the PS Availability (Reliability and Maintainability) NMRCL MARCH

19 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The reliability and maintainability of the Permanent Works shall be developed by the Contractor in accordance with the requirements contained in clause 3.4 below and the PS The Contractor shall prepare Availability and Maintainability plans as detailed in European standard EN The first draft of these plans shall be submitted to the Employer s Engineer for review within 6 months of the Commencement Date of the Works Suitability for Purpose Nagpur Metro Rail Limited (NMRC) shall be operating high-density passenger trains with high volume of traffic in the proposed corridors commensurate with the stage opening of the sections Interference and Compatibility The Contractor shall ensure that all Works and Contractor s Equipment operate in a satisfactory manner without causing interference to other equipment and services including parties external to the Employer. The Contractor shall also ensure that the Permanent Works are physically and technically compatible with associated plant and in particular with that of other Contractors Design for introduction to service The Permanent Works shall be designed in such a manner that they can be installed, tested and commissioned without adversely affecting the operation or safety of the Project. The Permanent Works shall be designed so that, where appropriate, considering the operating procedures adopted by the Employer, they can be brought into operational use during non-traffic hours and if necessary during a single night following maintenance, repair or overhaul during the life of the Permanent Works, equipment and systems Climatic Condition / Operating Environment General The following information on climatic conditions in Nagpur shall be taken into account by the Contractor when designing any part of the Permanent Works. The Contractor shall ensure that due allowance is made for more severe local conditions when Permanent Works are required to operate, for example, with restricted ventilation that may lead to higher local ambient temperatures, and any other factors that may affect the operating environment in any way. (1) Unless specific figures are provided elsewhere, the Permanent Works will generally be required to function at its rated value with the values of ambient temperature and relative humidity appropriate to the location of the equipment within the classifications shown in Table 1-2. Certain parts of the Permanent Works may need to be rated for more or less onerous conditions as required by the PS. (2) Clause below gives the different classifications of environment to be encountered. For any type of item, examples of which are installed in more NMRCL MARCH

20 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification than one environmental class, all examples of the type shall be suitable for installation in the most severe environmental class conditions encountered by any example of the type. (3) The Contractor s attention is drawn to the more severe environmental conditions that may exist during the construction period and shall take adequate measures to protect the Permanent Works against any deleterious effects of such conditions during the time between installation and final completion of the Project. (4) Air throughout the Project will contain considerable moisture content and the atmosphere will be corrosive. The Permanent Works shall be tropicalised and vermin proof Classification of Equipment Environment The locations at which equipment may be installed have been divided into four environmental classes as shown in Table 1-2. The classes of environment are considered to become more extreme from A to D. CLASS A B C D LOCATION of EQUIPMENT Air Conditioned Offices, Computer and Equipment Rooms Ventilated Equipment Rooms in buildings at the surface or at the underground structures. Deleted Outdoors Table 1-2 Classes of Environment The following are the minimum design requirements for equipment to be installed in each class of environment. Where any class does not have a value for a parameter the most extreme value quoted for the lesser class environments should be used Requirements for Class A Minimum Temperature - Ambient Temperature - Maximum Temperature - NMRCL MARCH o C 25 o C 35 o C Relative Humidity - Minimum 0%, Nominal 65%, Maximum 95% (Non Condensing) Electrical Noise - High Frequency to 1MHz, 1kV damped to 50% after 6 cycles. Radio Frequency field strength 10 V/m, UHF & VHF bands Requirements for Class B

21 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Ambient Temperature - Maximum Temperature - Relative Humidity - 30 o C 45 o C Nominal 70%, Maximum 100% (Non Condensing) Air Quality - Polluted and dusty - SO 2 : mg/m 3 Suspended Particulate Matter: mg/ m 3 Electrical Noise - Impulse 1kV, 1.2/50 rise/decay, 500 source impedance, 0.5 J source energy. Radio & High frequency as Class A Requirements for Class C Deleted Requirements for Class D Temperature All equipment shall be designed and tested in accordance with the given figured allowing a margin of at least 10% greater and 2 o C less than the limits recorded. All designs for equipment shall work within the enclosures proposed with the specified environment outside the enclosure; particular attention shall be paid to the possibility of solar gain as referred to in clause below. Daily maximum and minimum temperature during winter, summer and rainy season (ever recorded): Max Min Winter (November to January) 38 o C -1.0 o C Summer (February to June) 48.2 o C 5.4 o C Rainy (June to October) 47.7 o C 17.2 o C Monthly average maximum and minimum temperature during winter, summer and rainy season: Winter Nov Dec Jan o C o C o C Max: Min: Summer Feb Mar Apr May o C o C o C o C Max: Min: NMRCL MARCH

22 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Rainy Jun July Aug Sep Oct o C o C o C o C Max: Min: Rain Fall Maximum recorded daily total rainfall per 24 hrs : average total rain fall (during rainy season) 47 mm Monthly June July August Sept Oct mm 277 mm 284 mm 201mm 49 mm Wind Pressure The system is to be designed to give satisfactory service for a wind pressure up to 178 kgf/m Sunshine Monthly average sunshine hours can be obtained by placing a specific request to Meteorological Department Relative Humidity Daily maximum and minimum average values during winter, summer and rainy season. Max Min Winter 94.5% 42% Summer 62% 15.5% Rainy 92% 62% Electromagnetic Compatibility (EMC) Electronic equipment in a railway environment shall be immunised against the usual electromagnetic influences to be expected from the rail operations. For this, the following EMC classification in accordance to IEC 801 or similar, for the equipment rooms shall be achieved: Electrostatic discharge The electronic equipment rooms shall be designed in accordance to class 2 of IEC or similar. NMRCL MARCH

23 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Electromagnetic fields The electronic equipment rooms shall be designed in accordance to class 2 of IEC or similar Fast transient interference (Burst) The electronic equipment rooms shall be designed in accordance to class 2 of IEC or similar High energy transient interference The electronic equipment rooms shall be designed in accordance to class 2 of IEC or similar Switching processes in high-voltage installations Magnetic fields The location of computer systems in the neighbourhood < 1m of high-voltage installations, such as medium voltage or transformer stations as well as direct parallel exposure of power and data cables should be avoided. The following magnetic field strengths at the place of installation of cathode ray tube (CRT) based visual display units (VDU) should not be exceeded: DC fields: 10 A/m or 12 µt AC fields: 1 A/m or 1,2 µt If the image quality is impaired by values exceeding the above the Contractor shall provide any necessary shielding or alternative corrective measures to restore the picture quality. Note flat screen VDU using LED technology or similar may be acceptable if a sufficiently high resolution and image size can be obtained Survey and Site Investigations For reference to surveys external to the Contract, the Contractor shall refer all Levels to Mean Sea Level (MSL) Datum, which is that generally used throughout Nagpur The datum used for the Contract shall be Mean Sea Level Datum The Contractor shall carry out all further site investigations necessary for the design of the Permanent Works and to enable the determination of the methods of construction and the nature, extent and design of Temporary Works The Contractor shall investigate environmental factors also to determine suitable methods of manufacture and installation, both for Temporary and Permanent Works. In particular the Contractor shall ensure that the dusty environment of Nagpur.has no detrimental effect to the functionality, reliability or long term maintainability of the Permanent Works. NMRCL MARCH

24 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification End of Chapter NMRCL MARCH

25 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER PLANNING, PROGRAMME AND PROGRESS MONITORING Planning The Contractor shall develop in detail, a logical method of executing the Works taking into account their complex nature and different phases and shall provide programmes which reflect the detailed planning undertaken The programmes shall start with the Commencement Date of the Works as day one, are to be realistic, achievable and shall be accompanied by the detailed supporting Plans referred to in Chapter 3 below Programming General Requirements Programme activities shall be discrete items of work, which when combined, produce definable elements, components, Milestones, Stages and Sections of the Works and clearly identify the completion obligations of the Contractor. Design programmes shall be organised by Design Stages and Plans as described in clause below Key Dates and Milestones shall be an integral part of all programmes and all activities, and sequencing and interrelationships required to achieve each completion obligation shall be shown The critical path shall be clearly identified in the programme and fully described in the accompanying programme narrative Activity descriptions shall clearly convey the nature and scope of the Works. Programmes shall take into account the activities of precursor, concurrent, adjacent and follow on Project Contractors as well as utility service diversions, new utilities and connections and any other activity that may affect the progress of the Works The Contractor shall also incorporate the Employer s Engineer s requirements for additional activities, to further explain or subdivide complex or long duration tasks, without affecting completion dates Progress Monitoring The Contractor shall monitor its and its subcontractors performance and against programmes to ensure its compliance with its obligations under the Contract. Monitoring of the Works shall include direct, daily monitoring of the progress of the Works and the preparation of written and computerised reports to be submitted to the Employer s Engineer. The reports shall include all necessary supporting data to apprise the Employer s Engineer of the status of the completion of the Works as described in clause 2.17 below. NMRCL MARCH

26 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Works Programme The Works Programme to be submitted under the Contract shall be developed from the Outline Works Programme submitted and developed during the Tender period. Similarly the Design Submission Programme shall be developed from the Outline Design Submission Programme submitted and developed during the Tender period Submission Dates Deleted Content The Works Programme shall demonstrate by reference to its Sub-Programmes, Supplementary Programmes and associated Management Plans, the sequence and duration of activities and any restraints thereto, that the Contractor shall adopt to achieve Key Dates and to fulfil all Contract obligations. The Works Programme shall become the Employer s Engineer s basis of administration of the time-related aspects of the Contract The Contractor shall provide the Employer s Engineer with substantiation for each constraint whether target start, target finish or mandatory constraint entered by the Contractor into the Works Programme. The number of constraints shall be kept to an absolute minimum in order that the CPM networks developed can be freely analysed The Works Programme shall include activities for all the phases and stages of the Works, clearly showing all logical interdependencies and stages in the development of the Contractor s design, procurement, installation, commissioning and setting to work. As a minimum, it shall include: (1) all work comprising the Permanent Works; (2) preparation, submission and review of Design Documents showing all items where review by the Employer s Engineer is required; (3) procurement of all major materials and items of Contractor s Equipment for the Works, including the dates orders are to be placed, manufacture period and the expected delivery date to the Site for each item; (4) all manufacture or prefabrication of materials or components; (5) all design and installation of major Temporary Works; (6) all activities associated with the securing of necessary permits and other statutory approvals for the Works; (7) access and availability dates for all Project Contractors; (8) all interfaces related to the Project that may affect the progress of the Works; (9) testing and commissioning activities which demonstrate an understanding of the interfaces. NMRCL MARCH

27 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Works Programme shall be divided into Sub-Programmes of manageable sizes addressing in more specific detail, the content of the Management Plans as stated in Chapter 3 below. The Sub-Programmes shall be as follows: (1) Design Submission Programme; (2) Design, Procurement and Manufacturing Programme; (3) Installation Programme; and (4) Testing and Commissioning Programme; and 2.5 Design Submission Programme The Contractor shall, within 30 days of the Commencement Date of the Works, submit a Design Submission Programme covering all proposed submissions to the Employer s Engineer The Submissions Programme shall include the requirements of the Design Submissions as described in clause below, including the procurement activities of all subcontractors and suppliers The Submissions Programme shall include each submission for every item listed in the Specification as being required to be submitted The Submissions Programme shall ensure that all submissions are properly coordinated with the Contractor s overall Works Programme, particularly in respect of the following:- (i) progress of design, manufacture, installation and testing work; (ii) co-ordination with other Contractors; and (iii) including due allowance for the Employer s Engineer s review process to be undertaken, including the time needed for any re-submissions The Final Design shall include at least but not limited to; details showing all of the proposed equipment, interconnections, physical layout, installation locations and interfaces to other suppliers. 2.6 The Contractor shall continuously maintain this schedule and report upon the status of each item as part of the Contractor s regular progress reporting The Contractor shall submit, as part of the Design, Procurement and Manufacturing Programme, a Factory Testing Programme that shall support all aspects of the Factory Testing Plan. This Programme shall clearly demonstrate the logic and include the topics listed in clause below The Factory Testing Programme shall be fully detailed, with activities individually identifying all tests for which a certificate will be issued, and shall include activities for preparation, submittal and review of the test procedures. NMRCL MARCH

28 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Factory Testing Programme shall demonstrate the logical dependencies between the individual tests of the Works, and shall also show the interfaces and dependencies with the Contractor s delivery programme The Factory Testing Programme shall include details of inspection, testing and witnessing of the Contractor s and subcontractor s procurement and manufacturing activities. As a minimum, it shall include: (1) First Article Inspection; (2) Quality Hold Points; (3) Quality Control Points; (4) Type Tests; and (5) Routine tests Installation Programme The Installation Programme shall be submitted as stated in the PS or as directed by the Employer s Engineer The Installation Programme shall include detailed activities describing all aspects of the installation of the Works. It shall be clearly linked to the Design, Procurement and Manufacturing Programme and Testing and Commissioning Programme to form an integrated part of the Works Programme The Installation Programme shall be fully supported by the Construction and Installation Management Plan as specified in clause 3.6 below The Installation Programme shall indicate the physical areas to which the Contractor requires access, access date, duration required and the required degree of completion for civil or architectural finishes prior to the access date Installation Tests shall be clearly shown in the Installation Programme and shall include those interface tests required to be carried out by others to establish a timetable for these tests In preparing the Installation Programme, the Contractor should note that the following conditions shall apply: (1) the Contractor shall not have exclusive access to any part of the Site except by the specific consent of the Employer s Engineer; (2) the Contractor shall take note that concurrent time allocations for certain areas may be given to more than one contractor. The Contractor shall coordinate the Contractor s work in such areas with that of Project Contractors through the Employer s Engineer; (3) the absence of a programme date or installation period for the Contractor in a specific area shall not prejudice the right of the Employer s Engineer to establish a reasonable programme date or installation period for that area; NMRCL MARCH

29 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (4) the Contractor shall deliver all Contractor s Equipment and Permanent Works for stations and ventilation shafts by road and via temporary access openings unless otherwise reviewed by the Employer s Engineer Testing and Commissioning Programme The Testing and Commissioning Programme shall be submitted as stated in the PS or as directed by the Employer s Engineer The Contractor shall submit the Testing and Commissioning Programme that shall fulfil all the on-site testing and commissioning requirements of clause below. The Testing and Commissioning Programme shall clearly demonstrate the logic and highlight the topics listed in the On-Site Testing and Commissioning Plan in clause below The Testing and Commissioning Programme shall be fully detailed, with activities individually identifying all tests for which a certificate will be issued, and shall include activities for preparation, submittal and review of the test procedures The Testing and Commissioning Programme shall demonstrate the logical dependencies between the individual tests of the Works, and shall also show the interfaces and dependencies with all of the Project Contractors tests required to commission the Works and support the Commissioning Plan. 2.9 Not Used 2.10 Not Used 2.11 Not Used 2.12 Time Chainage Programme (T/C) For installation to be carried out in sections of the railway (whether in tunnels, in car depot or in RSS/TSS areas), the Contractor shall submit a T/C Programme well before the start of Site works. The format and content of the T/C Programme shall be submitted for review by the Employer s Engineer prior to submission of the substantive T/C programme itself The T/C Programme shall be compatible in all respects with the Works Programme and shall include, but not be limited to, details of the planning of the Works in a linear time/location manner. The T/C Programme shall demonstrate how linear tasks interrelate with time, access points, access/handover dates, planned production outputs, construction material call-off rates, etc Track Related Installation Programme (TRIP) The Employer and the Employer s Engineer shall, upon taking over the Permanent Works for works train running, maintain a co-ordination between the various contractors wishing to work in the train tunnels The Contractor and each other contractor will submit his requirements in a form similar to that required in the T/C in clause 2.12 above. The Site Co-ordination Team referred NMRCL MARCH

30 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification to in clause 9.5 below will maintain the TRIP and resolve conflicts between contractors by discussion at the weekly Works Train meeting to which the Contractor may send a representative The TRIP and associated safe working documentation issued by the Site Coordination Team shall be accepted by all contractors as limiting their areas of working. Any work carried out in contradiction to that allowed by the TRIP will be considered to be a breach of the site safety arrangements Programme Submissions The Contractor shall submit all programmes described in this Chapter in conjunction with the Management Plans described in Chapter 3 below to the Employer s Engineer for review Programme Review The Employer s Engineer shall, within 28 days of receipt of the initial submission of any programme for review, either give a notice of no objection or provide specific details as to why a notice of no objection is not given. If the Contractor is advised that the programme is not given a notice of no objection, the Contractor shall amend the programme taking into account the Employer s Engineer s comments and/or requirements and resubmit the programme within 14 days In the case of further re-submittals, the resubmission time shall also be 14 days Works Programme Revisions The Contractor shall immediately notify the Employer s Engineer in writing of the need for any change in the Works Programme, whether due to a change of intention or circumstances or for any other reason. Where such a proposed change affects the timely completion of the Works or any Section or Stage; the Contractor shall within 14 days of the date of notifying the Employer s Engineer submit for the Employer s Engineer s review his proposed revised Works Programme and accompanying Programme Analysis Report If at any time the Employer s Engineer considers the actual or anticipated progress of the work reflects a significant deviation from the Works Programme, he may request the Contractor to submit a proposed revised Works Programme. Upon receipt of such a request the Contractor shall submit within 14 days a revised Works Programme, together with an accompanying Programme Analysis Report and Narrative Statement, that shall demonstrate the means by which the Contractor intends to eliminate the deviation Monthly Progress Report The Contractor shall prepare Monthly Progress Reports covering all aspects of the execution of the Works. Such Monthly Progress Reports shall be in writing and shall be delivered to the Employer s Engineer by the 5th day of the month following the month of the Monthly Progress Report. The Monthly Progress Report shall take account of NMRCL MARCH

31 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification work performed up to and including the last day of the month to which the Monthly Progress Report relates. The Monthly Progress Report shall include an executive summary and contain clear and concise statements in respect of every significant aspect of the Works including, without limitation, the requirements specified in CHAPTER Appendix 1 of this Specification The Monthly Progress Report shall contain evidence that documents and supports the progress of the Works, as stated in the Interim Payment Certificates, to the satisfaction of the Employer s Engineer The reports, documents and data provided shall be an accurate representation of the current status of the Works and of the work to be accomplished and shall provide the Employer s Engineer with a sound basis for identifying problems and deviations from planned work and for making decisions Physical Progress (Earned Value) Report General The Contractor shall prepare and submit, a monthly Physical Progress Report in accordance with the procedure described below. The proposal for the Physical Progress Report and basis for measuring progress shall be prepared in accordance with the requirements listed below and shall be submitted within 30 days of the Commencement Date of the Works Selection of work activities Contractor s work activities be broken down into discrete measurable units that are time phased (0% to 100% complete) in accordance with the Contractor s programme and maximum limit Key work activities for reporting progress shall be determined by the Employer s Engineer in consultation with the Contractor To the maximum extent possible, activities shall be chosen which can be measured quantitatively rather than subjectively as the work progresses. In the event it is necessary to use activities that can only be measured subjectively, intermediate activities or milestones shall be identified on the programme which will establish a predetermined intermediate percent complete for the activity at attainment of each intermediate milestone. Such milestones shall be no more than one month apart Revisions to Physical Progress Report Once the weightings have been established they shall not be changed unless there is a variation that significantly impacts on the programme and the weightings. If, after review, it is decided by the Employer s Engineer to incorporate a major variation, the weightings shall be adjusted for the impact of the variation and both the plan and actual curves revised. The curves shall be recalculated by inserting the variation activity NMRCL MARCH

32 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification percent complete plan (0 to 100%) in the time frame it will occur and applying the revised weightings. This recalculation shall be submitted to the Employer s Engineer for consideration and review prior to its use in the Monthly Progress Reports. The other time-phased planned activities shall remain unchanged during this process in order to maintain the integrity of the baseline plan Key Dates- Described in APPENDIX- Eof Section-VII-B, Part Physical Progress (earned Value) report Measurement of activity progress The actual percentage of the Works completed shall be calculated on a monthly basis as required to support the preparation of the Physical Progress Report and the Project status reviews. The Contractor shall ensure that sufficient reliable quantitative backup documentation exists to support these calculations for each activity within the Physical Progress Report Periodic detailed reviews may be made by the Employer s Engineer to assess the Contractor s calculations Progress Meetings The Employer will chair progress meetings every month with the Contractor. These meetings will be held at dates and times to be advised by the Employer s Engineer. Progress meetings shall not be later than 10 days after the issue of the Contractor s Monthly Progress Report The Employer s Engineer may convene at his discretion, at any time upon reasonable notice to the Contractor, any meeting, either on or off the Site, to discuss and address any aspect of the Works or the Contract. The Contractor shall attend any such meetings convened by the Employer s Engineer All meetings shall be convened in Nagpur unless directed otherwise by the Employer s Engineer. Meetings shall be attended by senior personnel from the Contractor who shall arrive properly briefed for all aspects of the meeting and shall be empowered to make executive decisions in respect of the execution of the Works Quarterly Review Meetings The Employer s Engineer may convene Quarterly Review Meetings in Nagpur at approximately three monthly intervals. The Employer s Engineer will notify the Contractor the date of such Quarterly Review Meetings not less than 28 days before they are to be held Quarterly Review Meetings shall be held over a period of up to 3 days in order to review the overall progress of the Works in the context of the Project as a whole and to address and resolve any issues relevant to the execution and progress of the Works. Such Quarterly Review Meetings will be chaired by the Senior Director, Capital Projects of the Employer or his delegate. The Contractor shall have in attendance one senior NMRCL MARCH

33 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification representative of Director level from each of the companies comprising the Contractor (together with the Managing Director of the company acting as leader or sponsor of the Contractor if it is a joint venture, consortium or partnership whenever necessary and required by the Employer s Engineer) The Contractor shall submit names of the persons whom the Contractor proposes to attend each Quarterly Review Meeting to the Employer s Engineer for review not less than 7 days prior to each Quarterly Review Meeting. * End of Chapter * NMRCL MARCH

34 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER 3 3. MANAGEMENT PLANS AND SUBMISSIONS 3.1 General In order to organise the various submissions required by the Employer s Engineer, and to ensure the Contractor s understanding and compliance with the requirements of the Contract, a series of Management Plans shall be developed. These Management Plans will serve to structure the submittals in a manner that the Contractor can develop and prepare the submittals and the Employer s Engineer can review and comment on a prescribed programme The Management Plans shall be configured as a family of stand-alone plans and associated documents each covering one of the subjects listed below. The plans and documents shall be co-ordinated with each other and shall collectively define, describe and encompass the Contractor s proposed methods, procedures, processes, organisation, sequencing of activities, etc. and shall show how these combine together to assure that the Works truly meet the requirements of the Specification in respect of the subjects listed. Unless otherwise stated in the PS, all plans and documents shall be submitted in preliminary form within 60 days of the Commencement Date of the Works followed by detailed plans within 60 days of the preliminary submission. Further submissions shall be made: (1) when required in accordance with the Works Programme; (2) whenever the development of the Contractor s designs or planning allows the plan to be developed further; (3) in response to comments made by the Employer s Engineer in accordance with clause below; (4) whenever any change occurs that invalidates the information contained in the previously submitted and reviewed document, within 14 days of the occurrence of such change; and (5) when requested by the Employer s Engineer from time to time. 3.2 General Organisation The Plans listed below shall be developed and submitted by the Contractor for the Employer s Engineer's review: Project Management Plan - Contractor s Project Plan - Interface Management Plan Systems Assurance Plans - Quality Plans NMRCL MARCH

35 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification - Safety Plans - Electromagnetic Compatibility Management Plan - Software Quality Assurance Plan Design, Procurement and Manufacturing Plan - Design Plan - Design Verification and Validation Plan - Factory Testing Plan - Procurement, Manufacturing and Delivery Plan Construction and Installation Management Plan - Construction and Installation Plan - Health and Safety Documentation - Environmental Qualities Management Plan - Environmental Mitigation Implementation Schedule - Traffic Management Submissions (if required) Completion Management Plan - Commissioning Plan - Operation and Maintenance Manuals Plan - Training and Transfer of Technology Plan - Spares Management Plan - Defects Liability Management Plan 3.3.Project Management Plan The overall management of the Works shall be the Contractor s responsibility. The organisation of the resources for the design, procurement, manufacture, delivery, installation, testing and commissioning, and setting to work is to be developed into a Project Management Plan. Each section of this plan shall fully describe the NMRCL MARCH

36 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Contractor s understanding of the Works and management skills and structure required to achieve the same Contractor s Project Plan The Contractor s Project Plan shall provide a clear overview of the Contractor s organisation, management systems and methods to be used for the complete execution of the Works The Contractor s Project Plan shall include a summary description of each and every stage of implementation of the Works, clearly showing the principal organisational interfaces both within the Contractor s own organisation (including sub-contractors of every tier) and with Other Contractors and Relevant Authorities, defining how each of these interfaces is to be managed and controlled. An organisation chart shall be produced to illustrate the subdivision of the work into elements for effective technical and managerial control, the reporting structure and the interface relationship among all parties involved. Names, addresses, telephone and fax numbers of all principal contacts shall be listed The Contractor s Project Plan shall contain structured organisation charts showing the hierarchical relationship of the Contractor s organisation (including subcontractors of every tier). The organisation charts shall be produced as a family such that the basic chart shows the overall organisation structure supported by subsidiary charts detailing the internal structure of the various departments or sections of the overall organisation The Contractor s Project Plan shall include full details of the qualifications, experience, authority and responsibility of the personnel assigned to all key positions of the Contractor s organisation (including sub-contractors of every tier). As a minimum, this shall include all levels down to senior managers and shall include the personnel responsible for each individual department and functional group. A clear reference shall be given as to the location of staff (e.g. Site resident or factory based, etc.). Names, addresses, telephone and fax numbers of all principal contacts shall be listed The Contractor s Project Plan shall define the Contractor's management structure for the execution of the Works and for the control of the quality of the Works and shall, without limitation, identify and set out: (1) the procedure for audit; (2) the procedures for the control of receipt and issue of all Works related correspondence so as to ensure traceability; (3) the procedures for filing system to be implemented to maintain the Contractor s records during the course of the work. The filing systems used NMRCL MARCH

37 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification by the Contractor and sub-contractors of any tier shall be compatible as far as is necessary; (4) the procedures for the identification, production, verification, internal approval, review (when required) by the Employer s Engineer, distribution, implementation and recording of changes to all drawings, reports and specifications; (5) the procedures for the evaluation, selection, engagement and monitoring of sub-contractors / suppliers together with the means of application of quality assurance to their work including audit and acceptance; (6) the procedure for the regular review and revision of each type of quality plan and its supplemental individual specific quality plans to ensure their continuing suitability and effectiveness, in addition to the method to be used for revision and issue of revised documentation; (7) the procedures for the control, calibration and maintenance of inspection, testing and measuring equipment; (8) the procedures for the selection, indexing, disposition and maintenance of project records for storage in the archives. A list of items to be archived including their periods of retention shall be submitted for review by the Employer s Engineer; (9) the procedures for identifying training needs and for the provision of Particulars of agent training of all personnel performing activities affecting quality; and (10) the procedures for the control of non-conformity. (1) The Contractor shall give and provide all necessary supervision during the execution of the Works as long as the Employer s Engineer considers necessary for the proper fulfilment of the Contractor s obligations under the Contract. (2) The Contractor shall ensure that he is at all times represented on the Site by a competent and authorised English/Hindi speaking agent who shall be deemed to have been reviewed without objection by the Employer s Engineer provided such agent is not expressly objected to by the Employer s Engineer in writing within 14 days from the service of a notice upon the Employer s Engineer by the Contractor of the appointment of such agent. Such agent shall be constantly on the Site and shall give his full time to the superintendence of the Works. (3) The Employer s Engineer shall have the authority to withdraw his notice of no objection to the agent at any time. If such notice of no objection is withdrawn the Contractor shall remove the agent from the Site forthwith and shall not thereafter employ him again on the Site in any capacity and shall NMRCL MARCH

38 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification forthwith replace him by another competent English/Hindi speaking agent reviewed without objection by the Employer s Engineer. (4) Such authorised agent shall receive on behalf of the Contractor directions and instructions from the Employer s Engineer. (5) The following particulars of the proposed agent shall be submitted to the Employer s Engineer for review:- (i) (ii) (iii) (iv) name; copy of Identity Card; details of qualifications, including copies of certificates; and details of previous experience. (6) The particulars of the agent shall be submitted 30 days before the agreed scheduled start of that part of the Works. Except in the case of a replacement agent (as provided for in clause (3) above), in which case the said particulars shall be submitted forthwith. (7) The agent shall possess relevant academic or professional qualification and have at least 10 years experience in relevant engineering works. The Employer s Engineer reserves the right to call upon the Contractor to prove such qualifications/experience to the satisfaction of the Employer s Engineer Interface Management Plan a) The Contractor shall interface and liase with other Contractors in accordance with the requirements of clause 16.3 below. b) Within 60 days of notification from the Employer s Engineer of the identity of each Other Contractor, the Contractor shall develop and submit to the Employer s Engineer an Interface Management Plan that is mutually acceptable to both the Contractor and the other Contractors. The Interface Management Plan shall: (1) identify the sub-systems as well as the civil works and facilities with interfacing requirements; (2) define the authority and responsibility of the Contractor s and other Contractors (and any relevant sub-contractors ) staff involved in interface management and development; (3) identify the information to be exchanged, together with the management and technical skills required for the associated development work, at each phase of the Contractor s and other Contractors (and any relevant sub-contractors ) project life-cycles; (4) include considerations of the Interface Hazard Analysis; NMRCL MARCH

39 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (5) specify the configuration and version control procedures in accordance with the Contractor s and other Contractors (and any relevant subcontractors ) quality management system; and (6) address the design, supply, installation, testing and commissioning programme of the contracts to meet the key dates of each contract, and highlight any programme risks requiring management attention. c) Once the Interface Management Plan has been reviewed without objection by the Employer s Engineer, the Contractor shall execute the Works in accordance with the Interface Management Plan. The Contractor shall advise the Employer s Engineer immediately of any difficulty in developing a mutually acceptable Interface Management Plan. d) Within 90 days of notification from the Employer s Engineer of the identity of each Other Contractor, the Contractor shall develop and submit to the Employer s Engineer for review a Detailed Interface Document for each Other Contractor that is mutually acceptable to both contractors. The Detailed Interface Document shall address in detail how the dates identified in the Interface Management Plan shall be achieved and shall identify the data required by the interfacing other Contractors to meet the requirements of the PS. e) The Detailed Interface Document shall specify the proposed method and schedule for verifying the interface integrity, the individual equipment/system performance and the combined system performance. The Detailed Interface Document shall include a programme of tests to demonstrate the performance and integrity of the integrated systems. The Interface Specification appended to the PS shall form the basis of the Detailed Interface Document, but does not relieve the Contractor s obligation to identify any new interface to meet the Contract requirements. Any revision to the Detailed Interface Document shall be mutually acceptable by contractors and submitted to the Employer s Engineer for review. 3.4 Systems Assurance Plans The Systems Assurance Plans shall submitted for review to the Employer s Engineer in Preliminary and Final forms The various plans shall be co-ordinated with each other and shall collectively define, describe and encompass the Contractor s proposed methods, procedures, processes, organisation, sequencing of activities, etc. and shall show how these combine together to assure that the Works truly meet the requirements of the Specification in respect of the subjects listed Configuration management of all hardware and software shall be in accordance with ISO Quality Plans The Contractor shall submit for review by the Employer s Engineer quality plans in accordance with the requirements of clause 5.2 below. NMRCL MARCH

40 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Safety Plans Site Safety Plan The Contractor shall prepare a Site Safety Plan incorporating the requirements of the Project Safety for the various sites (including storage and overseas sites) on which work under the Contract is carried out The Site Safety Plan shall form a part of the Health and Safety Documentation referred to in Chapter 18 below RAMS Plan The Contractor shall implement a formal Reliability Plan and a formal Maintainability Plan in accordance with the PS and EN (Railway applications - The specification and demonstration of dependability, reliability, availability, maintainability and safety (RAMS)) The System Safety plan shall address all the factors referenced in Appendix 2 of this Specification and as required by the PS Electromagnetic Compatibility Management Plan a. The Contractor shall prepare and submit for review by the Employer s Engineer an EMC Management Plan which shall, based upon a top-down approach, define the EMC philosophy, activities, means of control for the design processes and EMC submissions to be supplied to demonstrate compliance with the PS and GS. b. The EMC Management Plan shall identify a comprehensive list of specifications, standards, method statements and procedures to be submitted to the Employer s Engineer for review. The EMC Management Plan shall also include a programme that shall identify the dates for EMC submissions. c. The EMC Management Plan shall include an initial list of design documentation, test specifications and test reports with a single paragraph description of each document to indicate compliance with the Specification. d. The EMC Management Plan shall include a definition and description of the process and methods used for Verification and Validation that the Works will achieve the required EMC parameters in all respects. e. The Contractor shall co-ordinate the levels of interference emissions and susceptibility of all equipment which are to be designed, manufactured, supplied and installed by the Contractor and its sub-contractors and suppliers. The Contractor shall designate a person as point of contact to deal with EMC matters. Details of the nominated person and any subsequent change of the nominated person shall be subject to review by the Employer s Engineer. f. The Contractor shall liase and co-ordinate with all Other Contractors in the exchange of EMC data and related equipment performance characteristics and NMRCL MARCH

41 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification advise the Employer s Engineer when any such information is requested from any Other Contractor. A copy of all EMC related information exchange shall be sent to the Employer s Engineer for review. g. The Contractor shall comply with the following EMC requirements: (i) (ii) (iii) (iv) (v) (vi) (vii) The Contractor shall ensure that all electrical and electronic apparatus is designed and constructed to operate without degradation of quality, performance or loss of function in the electromagnetic environment of the Project. The Contractor shall meet the requirements of the BS ENV50121 series of standards (Railway applications Electromagnetic compatibility), 1996 edition, the UK s Electromagnetic Compatibility Regulation, the IEC 61000: Electromagnetic Compatibility or equivalent and other standards mentioned in the PS to be reviewed by the Employer s Engineer. EMC considerations shall be incorporated in the Contractor s procedures for product safety and design Verification. Detailed requirements in respect of electromagnetic compatibility characteristics are contained in the PS. The design shall ensure that any electromagnetic interference emissions introduced into the environment do not exceed those detailed in the PS and GS. The Contractor shall ensure that the specified electromagnetic compatibility (EMC) requirements are adequate. Any shortcomings shall be made known to the Employer s Engineer immediately and recommendations for corrective action formulated. In respect of the design documentation, the Contractor shall demonstrate by theoretical analysis that the design of the electrical and electronic systems is fully compliant with the EMC requirements identified. The Contractor shall state clearly in the documentation all the assumptions made and parameters used in the analysis. The Contractor shall detail the methodology, verify and validate any simulation models used in support of the analysis. The Contractor shall prepare and submit to the Employer s Engineer for review reports of the Verification and Validation of the models. In the circuit analysis, calculations shall be made for all component tolerance effects due to manufacture, environment, ageing, and all possible component Failure Modes. If any component can exist in a Dormant Failure Mode, the analysis must assume that the component has failed. The Contractor shall identify all component Failure Modes considered and produce evidence to the Employer s Engineer for review. (viii) The Contractor shall identify all components to be tested, specify the interval between routine tests, define the test procedure and provide NMRCL MARCH

42 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Verification levels and pass marks, which must be achieved. Contractor shall carry out proof testing of circuit components. The (ix) (x) (xi) (xii) The Contractor shall supply documentation showing how system safety and reliability is ensured. It shall include Failure Modes, system failures, the effect of human intervention and how equipment thresholds have been set in order to keep them above worst case interference levels, and how equipment tolerances and other characteristics in the Specification have been allowed for in designing the system. The Employer s Engineer may conduct an independent EMC audit for both the system and its component parts and shall therefore require access to all the relevant design and production information. The Contractor shall supply sufficient documentation and analysis in a form reviewed by the Employer s Engineer. EMC type testing shall be carried out on all equipment identified in the design stage which require attention regarding EMC. The Employer s Engineer may request at his discretion, attendance at the manufacturing factory prior to delivery to assist in providing confidence that the EMC requirements will be met. However, this will not give design acceptance that can only be given after successful completion of the System Acceptance Tests. (xiii) The Employer s Engineer may request that tests be carried out to simulate the Failure Mode of any critical hardware/software component that is considered to have a significantly detrimental effect. (xiv) The Contractor shall implement corrective actions to rectify any EMC problems identified during design, on-site testing and when the whole system is in operational service. (xv) The Contractor must be fully aware of the EMC requirements and any modifications to systems and equipment carried out by the Contractor during the Defects Liability Period shall not cause the immunity or emission levels of the installed system and equipment to exceed such values. Detailed EMC documentation on all modifications carried out shall be submitted to the Employer s Engineer for review. Modification work shall not commence until the respective submission has been reviewed without objection by the Employer s Engineer. 3.5 Design, Procurement and Manufacturing Plan The Design, Procurement and Manufacturing Plan shall be configured as a family of stand-alone plans and associated documents each covering one of the subjects listed below. The plans shall be co-ordinated with each other and shall collectively define, describe and encompass the Contractor s proposed methods, procedures, processes, organisation, sequencing of activities, etc. and shall show how these NMRCL MARCH

43 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Design Plan combine together to assure that the Works fully meet the requirements of the Specification in respect of the subjects listed Design shall be undertaken to ensure a smooth flow of information for review by the Employer s Engineer. Submissions shall be strictly in accordance with the Design Submissions Programme prepared in accordance with clause 2.5 above The Contractor shall perform his designs for the Works and prepare a design plan for his design work in accordance with the following design stages. The Contractor shall submit to the Employer s Engineer for his review, relevant design information as identified under each stage: (2) Conceptual Design Stage Design of the overall system and elaborating on the proposed system configuration with emphasis on how the interface requirements are to be achieved. a. The Contractor shall prepare and submit to the Employer s Engineer for his review a System Requirement Specification (SRS) which includes, as a minimum, operational, functional, performance and design requirements of the proposed system. b. The System Requirement Specification, serving as a means of system requirement management and the Contractor s top level design document, shall state all the requirements completely and unambiguously and how each requirement can be verified and validated. c. The System Requirement Specification shall include a compliance matrix that includes cross-references to the requirements stated in the PS, the System Requirement Specification and the Design Verification Table (DVT). d. The conceptual design stage, as a minimum, shall identify the function of each system, sub-system, equipment or other element within the overall SRS and specify the relationships and interfaces between each element of the system, including the systems of the interfacing elements of other Contractors. (3) Design Review a. A series of Baseline Design Reviews shall be arranged prior to the conclusion of the Conceptual Design Stage. Within 30 days after completion of each critical design submission during preliminary design, the Contractor shall arrange a Design Baseline Review meeting to baseline the design for the next stage of activity. b. Upon completion of the Conceptual Design Stage the Contractor shall submit for review by the Employer s Engineer a homogenous Preliminary System Design. (4) Preliminary Design Stage NMRCL MARCH

44 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The preliminary design stage shall address each element of the SRS as developed in the Preliminary Design. Equipment and interconnection specifications, with supporting calculation, shall be developed at this stage. Manufacturing of production units will only be allowed to commence after receiving a notice of no objection for the relevant design elements. a. Preliminary electrical and control schematics shall be developed to illustrate how the various operational and functional requirements can be achieved. Software design and development shall also be carried out during this stage. b. The submission shall clarify and confirm as necessary all technical aspects of all interfaces with other elements of the Contractor's overall design and of any interfaces with works being supplied by other Contractors. c. Ergonomic design, followed by the production of mock-ups and prototypes shall be developed as part of the preliminary design. d. If at any time in the development of the preliminary design, the Contractor wishes to modify the conceptual design by dividing any system or subsystem into a number of smaller systems or by reconfiguring the interfaces or for any other reason, the Contractor shall resubmit the SRS and/or the Preliminary Design for the Employer s Engineer s review. e. A detailed submission list for the preliminary design shall be submitted to the Employer s Engineer for review 30 days prior to the start of the preliminary design. The submission shall be in sufficient detail to evaluate the progress and technical adequacy of the selected design approach. f. Upon completion of the Preliminary Design Stage the Contractor shall submit for review by the Employer s Engineer a homogenous Final Design. (5) Site Design Stage Installation detail and method statements for various areas and sections shall be released progressively during this stage. Installation works on Site will only be allowed to commence following the Employer s Engineer s review of the relevant design information with no objection raised Separate parts of the design plan shall be prepared for Contractor and subcontractor design activities. The design plans shall define the Contractor's policy for the design of the Works and shall, without limitation, define: (1) the organisation of the Contractor's design staff with particular reference to the design interfaces; (2) the specific allocations of responsibility and authority given to identified design staff with particular reference to the review and Verification of design specification, drawings and calculations by the Contractor; NMRCL MARCH

45 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (3) the specific methods of design necessary to identify any relevant method statements and develop those method statements to a sufficient degree of detail reviewed by the Employer s Engineer; and (4) the list of procedures and work instructions to be applied to manage and control the quality of the design work, including without limitation: a) the design and performance requirements which shall be defined in terms of basic data and design assumptions made; relevant codes, standards and regulatory requirements; safety, reliability, security and environmental requirements; and commissioning requirements; b) the design methods. Software applications to be used in the design, both proprietary and public domain, including any requirements for physical and mathematical model testing; c) the preparation, checking, issue, distribution, indexing and filing of reports, calculations, drawings and specifications together with the means for their revisions; d) the formal design review, authorisation and approval of design documentation; and e) the independent design Verification and Validation Design Verification and Validation Plan The Design Verification and Validation Plan, supplementary to the Design Plan, shall be prepared by the Contractor in order that design Verification and Validation activities are properly directed. The plan shall address, but not be limited to, the following:- (1) the objectives of each Verification phase and each Validation phase; (2) defined input and output criteria for each development phase; (3) identification of types and detailed methods of test, Verification and Validation activities to be carried out; (4) detailed planning of Verification and Validation activities to be carried out, including schedules, resources and approval authorities; (5) selection and utilisation of the test equipment, and their test environmental conditions; and (6) criteria on which the Verification or Validation is judged to be acceptable. These criteria shall be traceable to the design and performance requirements as referred to in Clause (4).a) above. NMRCL MARCH

46 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Contractor shall, by means of a design Verification and Validation process, demonstrate that all requirements within the Specification have been met The DVT Design Verification Table shall be supplied to the Employer s Engineer for his review and shall be monitored throughout the design and construction of the Works. Any changes to the DVT must be submitted to the Employer s Engineer for review before implementation The DVT shall identify the proposed Verification and Validation process(es) for each specification requirement and the acceptance criteria for achieving the requirement. The DVT does not relieve the Contractor of any other requirements of the Specification in relation to design review, Verification, Validation, conformance or planning For each item in the DVT, the Verification and Validation methods to be used shall be listed by the Contractor. The methods used shall be reviewed by the Employer s Engineer. At least one stage of Verification and Validation shall be performed prior to production of an item Subject to review without objection by the Employer s Engineer for each application, the Verification and Validation methods listed below are acceptable if implemented (whether singly or in combination): (1) Similarity - equipment and requirement are identical to those successfully applied on other projects. (2) Historical - requirement has been met by numerous previous design. (3) Calculations and Drawings - for review. (4) Design Review - either scheduled or specifically targeted. (5) Mock-Up - actual size representation of design. (6) Development Test - performance testing on equipment or material under development. (7) Type Test - performance testing of the as-built component, assembly or system. (8) Routine Test - test every component, assembly or system. (9) First Article Inspection (FAI) - acceptances of the exact look and fit of equipment. (10) Inspection - formal inspection of the finished item. (11) In Service - for service demonstration requirements only After each Verification or Validation activity, a Verification Report shall be produced including, as a minimum, the following: NMRCL MARCH

47 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (1) the Verification or Validation results stating whether the objectives and criteria of the Design Verification and Validation Plan have been met; and (2) the reasons for failure if there is a failure, and proposal for remedial actions Factory Testing Plan The Contractor shall prepare and submit for review by the Employer s Engineer the Contractor s Factory Testing Plan detailing and explaining how the Contractor will plan, perform, and document all inspections and tests that will be conducted to verify and validate the Works prior to delivery to the Site. The plan shall consist of a narrative description supported by graphics, diagrams and tabulations as required. The plan shall contain but not be limited to the following topics: (1) the Contractor s strategy for inspection and Factory Acceptance Tests of all constituent parts of the Works and how this relates to the sequence of delivery; (2) the sequencing and interrelationships of the inspections and tests including: (a) all Quality Hold Points; and (b) all Quality Control Points; (3) the type and extent of inspection and Factory Acceptance Tests to be undertaken and the parts of the Works to be proven by that testing; (4) the objective of each inspection or test, what particular design and operating criteria the test or inspection will prove and how the success of the test or inspection will be demonstrated or measured; (5) organisation chart and CV of key personnel in inspection and test team; the plan for the production and submission of the inspection and test procedures to the Employer s Engineer for review including the submission of the inspection and test reports and records; and (6) Type Tests, Routine Tests, First Article Inspections and any other tests constituting the Factory Acceptance Tests The Contractor shall arrange for all equipment and systems manufactured for incorporation into the Permanent Works to undergo a Factory Acceptance Test (FAT) before shipment from the place of manufacture. Any particular requirements for inspection and testing at the place of manufacture are prescribed in the PS The Contractor shall be responsible for re-inspecting and re-testing any failed inspection and Factory Acceptance Test including regression testing on previously passed items Inspections and tests that are to be witnessed by the Employer or the Employer s Engineer shall be sensibly grouped and scheduled so that as many inspections and tests as possible may be witnessed during a single visit Type Tests as detailed in clause below shall be performed on all items of equipment to be installed as part of the Permanent Works under the Contract.. The NMRCL MARCH

48 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Type testing shall be based on the environmental class of the sites into which the equipment will be installed. Refer to clause above for the different environmental classifications or otherwise as required in the PS For all production items a First Article Inspection shall be undertaken as detailed in clause below. Routine production testing methods shall be detailed for review by the Employer s Engineer. Routine testing shall ensure that all samples of a production item are within the tolerances required for complete interchangeability The Contractor shall prepare two copies of an inspection or test report immediately after the completion of each inspection or test whether or not witnessed by the Employer or the Employer s Engineer. If the Employer or the Employer s Engineer has witnessed the inspection or test, he will countersign the inspection or test report to indicate his review of the information and conclusions (i.e. whether or not the equipment being inspected or tested has passed satisfactorily) contained therein. If the Employer or the Employer s Engineer has not witnessed the inspection or test (i.e. if a waiver has been granted, or the Employer or the Employer s Engineer has not witnessed the inspection or test for some other reason in accordance with the Contract), the Contractor shall forward two copies of the inspection or test report without delay to the Employer s Engineer. The Employer s Engineer will countersign the report to indicate his review of the information and conclusions (i.e. whether or not the equipment being inspected or tested has passed satisfactorily) and return one copy to the Contractor. Where the results of the inspection or test do not meet the requirements of the Specification, the Employer or the Employer s Engineer may call for a re-inspection or re-test For standard equipment which is serial or bulk manufactured, manufacturer s type test certificates (or equivalent) may, subject to review by the Employer s Engineer, be accepted Test equipment and instrumentation shall be subject to approved calibration tests within a properly controlled calibration scheme, and signed calibration certificates shall be supplied to the Employer s Engineer in duplicate. Such calibration checks shall be undertaken prior to testing and, if required by the Employer s Engineer, shall be repeated afterwards Materials and equipment shall not be released for shipment until all applicable inspections and tests including Factory Acceptance Tests have been satisfactorily completed Procurement, Manufacturing and Delivery Plan The Contractor shall prepare procurement, manufacturing and delivery plans in respect of all items and goods. Separate parts of the plan shall be prepared for Contractor or sub-contractor off-site activities. Each plan shall identify the scope of work to be applied. In relation to such scope of work, it shall, without limitation, define: NMRCL MARCH

49 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (1) the organisation of the Contractor's staff directly responsible for the day to-day management of the manufacturing activity on or off the Site; (2) the specific allocations of responsibility and authority given to identified personnel for the day-to-day management of the work with particular reference to the supervision, inspection and testing of the work; (3) the interfacing or co-ordination required with the Contractor's other related plans; (4) the specific methods of manufacture to identify any relevant method statements and develop those method statements to a degree of sufficient detail reviewed by the Employer s Engineer; and (5) the list of procedures and work instructions to manage and control the quality of work during purchasing, manufacturing and delivery, including without limitation: a) the purchasing of items and goods and ensuring they comply with the requirements of the Specification, including (without limit) purchasing documentation and specific Verification arrangements for Contractor/Employer s Engineer inspection of material or manufactured product prior to release for use; b) the manufacturing process so as to ensure compliance with the design; c) the manufacturing process so as to ensure clear identification and traceability of material and manufactured parts; d) the inspection and testing of incoming materials, in process and final product so as to ensure specified requirements for the material and/or manufactured product are met; e) the identification of the inspection and test status of all material and manufactured products during all stages of the manufacturing process to ensure that only products that have passed the required inspections and tests are dispatched for use and/or installation; f) review and disposal of non-conforming material or product so as to avoid unintended use; g) the assessment and disposal of non-conforming material and manufactured product and approval for reworking or rejection as scrap; h) the identification of preventive action so as to prevent recurrence of similar non-conformance; and i) the handling, storage, packaging, preservation and delivery of manufactured product. NMRCL MARCH

50 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Contractor shall prepare and submit the inspection and testing plans to manage and control any test and inspection activities in accordance with clau7se above; The Contractor shall propose a structured set of inspection hold points. The hold points shall be structured such that a formal hold point is allowed for each significant element of the manufacturing process. At each hold point, the Employer s Engineer shall hold a formal inspection or advise that the inspection has been waived Once the inspection and any required remedial actions are completed to the satisfaction of the Employer s Engineer, the Employer s Engineer shall give a notice of no objection for unit shipment. The Employer s Engineer will not withhold his notice of no objection for shipping unreasonably, provided all pre-delivery assembly and testing has been successfully completed Any unit delivered without the Employer s Engineer s notice of no objection shall be rejected at the Site and all expenses thereby incurred shall be borne by the Contractor. 3.6.Construction and Installation Management Plan The Construction and Installation Management Plan shall be configured as a family of stand-alone plans and associated documents each covering one of the subjects listed below. The plans shall be co-ordinated with each other and shall collectively define, describe and encompass the Contractor s proposed methods, procedures, processes, organisation, sequencing of activities, etc. and shall show how these combine together to assure that the Works truly meet the requirements of the Specification in respect of the subjects listed Construction and Installation Plan The Contractor shall prepare plans for the construction and installation activities on and off the site, as referenced in clause below, and shall ensure that these are properly related to the subsequent testing and commissioning activity Separate parts of the plan shall be prepared for other contractor(s) or subcontractor(s) off-site activities Each construction plan shall identify the scope of activity to be controlled. In relation to such scope of activity, it shall, without limitation, define: (1) the organisation of the Contractor's staff directly responsible for the day-today management of the activity on or off the Site; (2) the specific allocations of responsibility and authority given to identified personnel for the day-to-day management of the Works with particular reference to the supervision, inspection and testing of the Works; (3) the interfacing or co-ordination required with the Contractor's other related plans; NMRCL MARCH

51 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (4) the specific methods of construction and installation to identify any relevant method statements and develop those method statements to a sufficient degree of detail reviewed by the Employer s Engineer; (5) a detailed method statement which shall include but not be limited to: a) description of main operations and sub-operations; b) sequence of sub-operations; c) quantities of the work and production rates to be achieved; d) resources to be employed; and e) quality checks to be carried out, supervision being exercised and safety precautions to be employed; (6) the list of procedures and work instructions to manage and control the quality of construction and installation works, including without limitation: a) the inspection and testing activities of incoming materials, in process and final product so as to ensure specified requirements for the material and/or product are met; b) the purchasing of materials and ensuring they comply with the requirements of the Specification, including purchasing documentation and specific Verification arrangements for Contractor/Employer s Engineer inspection of material or manufactured product prior to release for use/installation; c) the construction processes including Temporary Works so as to ensure compliance with drawings and Specification. In addition, any software to be used in the construction, installation and commissioning process shall be identified and details of the Verification and Validation processes for the software application shall be given; d) the construction and installation process so as to ensure clear identification and traceability of material and manufactured product; e) the identification of the inspection and test status of all material and manufactured products during all stages of the construction and installation process to ensure that only products that have passed the required inspections and tests are despatched for use and/or installation; f) review and disposition of non-conforming material or product so as to avoid unintended use/installation; g) the assessment and disposition of non-conforming material and product and approval for reworking or rejection as scrap; h) the identification of preventive action so as to prevent recurrence of similar non-conformance; and i) the handling, storage, packaging, preservation and delivery of product; and (7) the security control of the Site and the works area for Contractor s accommodation, storage, car park and other works facilities, etc. in accordance with clause below. NMRCL MARCH

52 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Contractor shall prepare and submit the inspection and test plans to manage and control any test and inspection activities in accordance with clause below Where all or part of the Works is within the NagpurProtection Zone, the Contractor shall follow the guidelines issued by the Employer s appropriate authority. The Contractor shall submit to the Employer s Engineer for review his construction method statement and detailed design of any Temporary Works proposed to be erected within this zone adjacent to Nagpur.properties The following particulars shall be submitted to the Employer s Engineer for review within 14 days of the Commencement Date of the Works: (i) (ii) (iii) drawings showing the layout within the Site of the Employer s Engineer s and Contractor s accommodation, Project signboards, access roads and major facilities required early in the Contract; drawings showing the layout and the construction details of the Employer s Engineer s accommodation; and drawings showing the details to be included on Project signboards Drawings showing the location of stores, storage areas, work areas and other major facilities shall be submitted to the Employer s Engineer for review as early as possible, but in any case not later than 28 days before construction of the facilities Health and Safety Documentation The Contractor shall submit Health and Safety Documentation to fully comply with the requirements of the Project conditions and proposed work activities in accordance with Chapter 18 below The Contractor shall submit to the Employer s Engineer the Health and Safety Documentation for review within 30 days of the Commencement Date of the Works Environmental Qualities Management Plan The Contractor shall within 112 days of the Notice to Proceed submit an Environmental Plan based the Outline Environmental Plan submitted and adapted during the Tender period. The Environmental Plan shall comprise a set of Environmental Plans as detailed below: - Environmental Management Plan; - Environmental Mitigation Implementation Schedule (if required); and - Traffic Management Submissions Environmental Plans shall include the Contractor s proposed means of complying with his obligations detailed in Chapter 0 below and in the PS in regard to: a) The Site Environment as found; and b) System Environment as described in the Specification. The Environmental Plan shall include as required detailed policies, procedures and applicable regulations. NMRCL MARCH

53 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Environmental Management Plan The Contractor shall submit for review by the Employer s Engineer, an Environmental Management Plan (EMP) which will set out in detail the approach for dealing with each of the potential environmental impacts arising from the various different construction activities The EMP shall address all the potential impacts outlined in the Employer s Final Assessment Report and shall follow the EMP Outline contained in Chapter 0 below The Contractor shall submit the final EMP, for review by the Employer s Engineer, 30 days prior to the commencement of construction activities Environmental Mitigation Implementation Schedule The Contractor shall submit for review an Environmental Mitigation Implementation Schedule (EMIS) which is a plan for the provision of the mitigation measures identified in the EMP The Contractor shall submit the EMIS, for review by the Employer s Engineer in conjunction with the EMP, 30 days prior to the commencement of construction activities Traffic Management Submissions Where the Contractor is required to become involved with traffic or footpath management activities, submissions shall be made by the Contractor for the Employer s Engineer's review 60 days before implementation proving all relevant details and implications. 3.7 Completion Management Plan The Contractor shall organise the services required under the Contract to bring the Works into service under one plan. This co-ordinated approach shall allow the Employer s Engineer the ability to review all aspects of the Works and services in an integrated manner. The Completion Management Plan shall be configured as a family of stand-alone plans and associated documents each covering one of the subjects listed below. The plans shall be co-ordinated with each other and shall collectively define, describe and encompass the Contractor s proposed methods, procedures, processes, organisation, sequencing of activities, etc. and shall show how these combine together to assure that the Works truly meet the requirements of the Specification in respect of the subjects listed. Unless otherwise stated, all plans and documents shall be submitted in preliminary form within 60 days of the Commencement Date of the Works followed by detailed plans within 60 days of submission. Further submissions shall be made: (1) when required in accordance with the Contractor s Works Programme; NMRCL MARCH

54 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (2) whenever the development of the Contractor s designs or planning requires the plan to be developed further; (3) in response to comments made by the Employer s Engineer in accordance with clause below; (4) whenever any change occurs that invalidates the information contained in the previously submitted and reviewed document, within 14 days of the occurrence of such change; and (5) when requested by the Employer s Engineer from time to time Commissioning Plan The Contractor shall ensure the timely preparation of the Commissioning Plan in a format and to a level of detail in accordance with clause 9.3 below. The Contractor shall submit the first draft of the Commissioning Plan to the Employer s Engineer within 180 days of the Commencement Date of the Works The Commissioning Plan shall consist of the following: a. Factory Testing Plan (see clause above) b. On-Site Testing and Commissioning Plan (i) Installation Tests Schedule The Contractor shall submit to the Employer s Engineer a comprehensive schedule of Installation Tests as required by clause below and the PS and in accordance with the Installation Programme as stated in clause 2.7 above. The schedule shall be submitted within the period of time laid down in the PS, or, if none is given, not later than two months in advance of the date for the commencement of the Installation Tests. (ii) Partial Acceptance Tests Plan The Contractor shall submit to the Employer s Engineer a comprehensive Partial Acceptance Tests Plan including all requirements detailed in clause below and the PS. The plan shall be submitted within the period of time laid down in the PS, or, if none is given, not later than four months in advance of the date for the commencement of the Partial Acceptance Tests. (iii) System Acceptance Tests Plan The Contractor shall submit to the Employer s Engineer a comprehensive System Acceptance Tests Plan including all requirements detailed in clause below and the PS. The plan shall be submitted within the period of time laid down in the PS, or, if none is given, not later than four months in advance of the date for the commencement of the System Acceptance Tests. (iv)integration Testing & Commissioning Plan The Contractor shall submit to the Employer s Engineer a comprehensive Integrated Testing & Commissioning Plan including NMRCL MARCH

55 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification all requirements detailed in clause below and the PS. The plan shall be submitted within the period of time laid down in the PS, or, if none is given, not later than four months in advance of the date for the commencement of the Integrated Testing & Commissioning Operation and Maintenance Manuals Plan The Contractor shall develop an Operation and Maintenance Manuals Plan to suit staged commissioning of the system and to ensure the timely preparation of the Contractor s Operation and Maintenance Manuals and the As-Built drawings in a format and to a level of detail reviewed without objection by the Employer s Engineer and in accordance with Chapter 11 below The Contractor shall submit the Operation and Maintenance Manuals Plan by the date stated in the PS, or, if none is given, not later than nine (9) months prior to the issue of the Taking Over Certificate for the Works and according to staged commissioning of the proposed systems Training and Transfer of Technology Plan The Contractor shall ensure the timely preparation of the Contractor s Training and Transfer of Technology Plan in a format and to a level of detail reviewed without objection by the Employer s Engineer and fulfilling the requirements of clause 10.1 below The Contractor shall submit the Training and Transfer of Technology Plan by the date stated in the PS, or, if none is given, not less than six (6) months prior to the issue of the Taking Over Certificate for the Works and also to suit the staged commissioning of the relevant systems Spares Management Plan The Contractor shall submit for review by the Employer s Engineer a Spares Management Plan to furnish a priced, manufacturer-recommended list of spare parts necessary to support continuous operation of all such equipment for a minimum period of 24 months after the commencement of Revenue Operations, in accordance with Chapter 13 below The Contractor shall submit the Spares Management Plan by the date stated in the PS, or, if none is given, not less than six (6) months prior to the issue of the Taking Over Certificate for the Works Defects Liability Management Plan The Contractor shall submit for review by the Employer s Engineer a Defects Liability Management Plan to repair, replace and perform any remedial item upon the Works identified by the Employer s Engineer during the Defects Liability Period (DLP). The first submission of this plan is required upon issuance of the Taking Over Certificate for the Works. The Contractor shall: (a) endeavour to complete all necessary work in a timely responsible manner; NMRCL MARCH

56 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (b) (c) (d) not proceed with any remedial work without the consent of the Employer s Engineer; submit a plan that details the methods and timing of any proposed work; and update the plan monthly, showing progress of the work and the time to completion Supervision of Maintenance Plan The Contractor shall prepare outline plans for the management of the maintenance function in accordance with the requirements of clause below and submit them for review by the Employer s Engineer at least 3 months prior to the scheduled commencement of Service Trial. End of Chapter NMRCL MARCH

57 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER 4 4. DOCUMENTS SUBMISSION AND REVIEW 4.1 Documents, Submissions and Correspondence Copies of correspondence relevant to the execution of the Works and not of a confidential nature received from or despatched to Government departments, utility undertakings and Project Contractors employed by the Employer shall be submitted to the Employer s Engineer for information as soon as possible but in any case not later than 7 days after receipt Submissions to the Employer s Engineer General requirements All submissions shall be made to the Employer s Engineer in a format reviewed without objection by the Employer s Engineer and in accordance with the requirements in: (1) the Contract; (2) the Computer Aided Design & Drafting (CADD) Manual; and (3) the Document Submittal Instructions to Consultants and contractors Paper and drawing sizes shall be A series sheets as specified in BS The following software (versions quoted or higher) compatible for use with Intel Windows based computers shall be used, unless otherwise stated, for the various electronic submissions required: Document Type Electronic Document Format Text Documents MS Word, Ver. 7.0 Spread Sheets MS Excel, Ver. 7.0 Data Base Files MS Access, Ver. 7.0 Presentation Files MS PowerPoint, Ver. 7.0 Programmes Primavera for Windows, Ver. 2.0b AutoCAD Graphics CorelDraw,Ver. 7.0/ AutoCAD ver.14 Photographic Adobe Photoshop, Ver.4.0 Desktop Publishing QuarkXPress, Ver.3.32 CADD Drawings Micro Station SE/95 Media for Electronic File Submission One copy shall be submitted unless otherwise stated. Internet File Formats/Standards NMRCL MARCH

58 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The following guidelines shall be followed when the Contractor uses the Internet browser as the communication media to share information with the Employer. All the data formats or standards must be supported by Microsoft Internet Explorer version 3 or above running on Windows NT and Windows 95. The following lists the file types and the corresponding data formats to be used on Internet. The Contractor shall comply with them unless the Employer s Engineer has previously reviewed without objection the Contractors proposal to adopt an alternative: File Type Photo Image Image other than Photo Computer Aid Design files (CAD) Data Format Joint Photographic Experts Group (JPEG) GIF or JPEG Computer Graphics Metafile (CGM) Project documents refer to the document type in clause above Video Sound The following states the standards to be used on Internet when connecting to database(s). The Contractor shall comply with them unless the Employer s Engineer has previously reviewed without objection the Contractors proposal to adopt an alternative: Function to be Implemented Database connectivity Publishing hypertext language on the World Wide Web Window video (.avi) Wave file (.wav) Standard to be Complied With Open Database Connectivity (ODBC) Hypertext Mark-up Language (HTML) The hard copy of all documents shall be the contractual copy If required, two copies of all internal and external orders placed by the Contractor for equipment or materials required for the Works shall be forwarded to the Employer s Engineer at the time of issue. All orders shall state the Employer s Engineer s requirements for inspection and testing, shall bear the Contract reference, Contractor s name and address and shall indicate, where applicable, the sub-section of the Works for which the equipment or material is required Distribution of copies of the orders shall be in accordance with the Employer s Engineer s instructions The Contractor shall have the obligation to upgrade, at his own cost, all the relevant software to the latest version upon instruction by the Employer s Engineer, after the new version of the relevant software has been launched for more than six months in Nagpur. NMRCL MARCH

59 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Contractor shall submit a drawing register to the Employer s Engineer in electronic copy and hard copy with each submission of drawings and at an interval agreed by the Employer s Engineer. The drawing register shall be in a format submitted for review and agreed without objection by the Employer s Engineer and shall include each document reference number, version, date, title and data-file name Specific additional requirements in respect of the numbering scheme shall be as defined in the PS Content Unless otherwise specified or permitted by the Employer s Engineer, each submission shall comprise: (1) for drawings - one A1 master on vellum (signed by the contractor), one A1 copy on vellum, one paper A1 copy, six paper A3 copies and an electronic data copy of all drawings; and (2) for documents - the unbound original, one bound copy and an electronic copy when applicable The A3 copies of drawings shall be produced as reduced versions of the A1 original. 4.3.Records and Reports Reports and records that are to be submitted to the Employer s Engineer shall be in a format reviewed by the Employer s Engineer. Reports and records shall be signed by the Contractor s agent or by a representative authorised by the Contractor Within 28 days of the Commencement Date of the Works, the Contractor shall submit a Project document control procedure to the Employer s Engineer for review, which shall include but not be limited to the following: (1) a document approval system which shall specify the level of authority for approval of all documents and material before submission to the Employer s Engineer; (2) a system of issuing documents to ensure that pertinent documents are issued to all appropriate locations; (3) a document change or re-issue system to ensure that only the latest revision of a document can be used; and (4) a submission identification system which identifies each submission uniquely by the following: (a) (b) (c) contract number; discipline; submission number; and NMRCL MARCH

60 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (d) revision indicator Project records will eventually be used by the Employer to manage, operate and maintain the Works after the completion of the Project under construction and for future reference The Contractor shall submit the documents as required by the Employer s Engineer as Project records in full and on time. The Employer s Engineer shall determine the adequacy of the Project record Submission and review procedure Except where specific procedures are given for certain items, all submissions shall be submitted and reviewed according to the procedure laid down in the following clauses Each submission shall be accompanied by a brief introduction to explain which subsystem, part or Section of the Works to which the submission refers, listing the documents enclosed with the submission, and describing in outline how all relevant requirements of the Specification are achieved by the proposals For each stage of submittal, the Contractor shall prepare a Submission Review Request (SRR) carrying the date of submission, the submission reference number as defined in clause (4) above, the submission title, the stage of submission (e.g. preliminary design, final design, etc.), and the authorised signature of the Contractor s responsible engineer in the format shown in Appendix 3 of this Specification, to confirm that, in the opinion of the Contractor, the submission: (1) complies with all relevant requirements of the Specification; (2) conforms to all interface requirements; (3) contains, or is based on auditable and proven or verified calculations or design criteria; (4) has been properly reviewed by the Contractor, according to the Contractor s QA system, to confirm its completeness, accuracy, adequacy and validity; and (5) has taken account of all requirements for approval by statutory bodies or similar organisations, and that where required, such approvals have been granted The Employer s Engineer s response to the submission will normally be made within 30 calendar days of receipt of the submission, provided that the submission is made no later than the date shown on the Submissions Programme described in clause 2.5 above. The Employer s Engineer may extend the review period depending on the amount of documentation accompanying the submission Throughout the design period, the Contractor shall attend monthly design review meetings with the Employer s Engineer. At these Employer s Engineer s review meetings, the Contractor shall present information, drawings and other documents to the Employer s Engineer in respect of all submissions programmed to occur during the NMRCL MARCH

61 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification following five week period. The Contractor s presentations shall be in sufficient depth to enable the Employer s Engineer to obtain a clear understanding of the Contractor s proposals and to discuss the methodology and process used in reaching the proposed design solutions. Unless directed otherwise by the Employer s Engineer, all meetings shall be convened in Nagpur The Contractor shall record all of the Employer s Engineer s observations and any agreed actions resulting from the Employer s Engineer s review meeting and shall address each of these fully before submission of the respective documents for formal review If, in the Employer s Engineer s opinion, following receipt of a submission there is benefit to be gained from a meeting with the Contractor to clarify or discuss any of the contents of the submission, he will notify the Contractor accordingly with not less than 5 days advance notice, and the Contractor shall attend at the time and place appointed by the Employer s Engineer No submission may be made by the Contractor in respect of the Works or any subsystem, part or Section thereof unless a notice of no objection has been received for the previous stage of the same Works or any sub-system, part or Section thereof Employer s Engineer s Response The Employer s Engineer will respond in one of the following three ways: (1) Reviewed without Objection (2) Reviewed without Objection, Subject to (3) Rejected If the Employer s Engineer, having reviewed the submission, has not discovered any noncompliance with the Contract, the SRR will be returned endorsed with the Employer s Engineer s signature and the words Reviewed without Objection. Receipt of such notice of no objection does not in any way imply the Employer s Engineer s approval of the submission, nor does it remove any responsibility from the Contractor for complying with the Contract. Issue of a Notice of No Objection entitles the Contractor to proceed to the next stage of the programme of work If the Employer s Engineer discovers minor non-compliance, discrepancies, omissions, etc. that, in his opinion, are not of a fundamental nature, he may return the SRR endorsed with the Employer s Engineer s signature and the words Reviewed without Objection Subject to, and including a list of the features that are required to be amended, included or improved to comply with the Contract. Issue of a Notice of No Objection Subject to entitles the Contractor to proceed to the next stage of the programme of work provided that all of the Employer s Engineer s comments are taken into account fully and implemented exactly If the Employer s Engineer issues a Notice of No Objection Subject to, the Contractor shall resubmit the affected parts of the submission, clearly demonstrating how the Employer s Engineer s comments have been taken into account and resubmit amended NMRCL MARCH

62 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification or corrected material within 10 working days of issue of the Employer s Engineer s comments, using the process described in clause above If the Employer s Engineer discovers major non-compliance, discrepancies, omissions, etc. that, in his opinion, are of a fundamental nature, he may return the SRR endorsed with the Employer s Engineer s signature and the word Rejected, and including a list of the features that are required to be amended, included or improved to comply with the Contract. Issue of a Notice of Rejection does not entitle the Contractor to proceed to the next stage of the programme of work until all of the Employer s Engineer s comments are fully taken into account and a satisfactory resubmission has been made (i.e. one which results in a Notice of No Objection or Notice of No Objection Subject to ) If the Employer s Engineer issues a Notice of Rejection, the Contractor shall resubmit the complete submission, clearly demonstrating how the Employer s Engineer s comments have been taken into account and resubmit amended or corrected material within 10 working days of issue of the Employer s Engineer s comments, using the process described in clause above. 4.4 Records The Contractor shall establish and maintain a place for the storage and archiving of all the documents relating to the Works and not required to be submitted to the Employer s Engineer under clause 4.1 above which shall be: (1) the same place or office where the Contractor is performing the work and storing documents reviewed by the Employer s Engineer, or; (2) at the Site or elsewhere in Nagpur.a records office, which contains all other, documents that the Contractor is required to maintain in accordance with the Contract All documents shall be filed, indexed and suitably stored to permit easy identification and necessary audits The Contractor shall maintain in Nagpurhis archive of all documents in connection with and arising out of the Contract, until 28 days after the issue of the Final Certificate or until final settlement of all Disputes, whichever is later. End of Chapter CHAPTER 5 5. QUALITY MANAGEMENT 5.1 Introduction The Contractor shall maintain and implement a Quality Management System that shall remain in effect during the execution of the Works. The Contractor s Quality Management System shall be based on the International Standard ISO 9001:1994 Model for quality NMRCL MARCH

63 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification assurance in design, development, production, installation and servicing. The Contractor shall submit its Quality Management System documentation for the Employer s Engineer s review as specified in this Chapter. The Quality Management System documentation shall include, but shall not be limited to the following: (1) quality manual; (2) quality procedures and work instructions; (3) quality plans; and (4) inspection and test plans The Contractor shall plan, perform and record all quality control activities to ensure that all work is performed in accordance with the requirements of the Contract and is detailed in the quality plans which are required under this Chapter. Such activities shall include, without limitation, the inspections and/or tests expressly or implicitly required by the Contract Without prejudice to such requirements, the Employer s Engineer may from time to time instruct the Contractor in relation to such further or other inspections and/or tests as are in his opinion appropriate Quality audits will be conducted by the Employer s Engineer to verify the Contractor s implementation and compliance with the quality management system as specified herein. 5.2 General Requirements All quality system documents and plans to be submitted shall embrace all activities of the Contractor and sub-contractors of any tier, including its suppliers and any design consultants Quality Plans The quality plans to be submitted by the Contractor shall comprise of: (1) a Management Quality Plan, for the control of all management related activities; (2) a Design Quality Plan, for the control of all design related activities for the Works, including Temporary Works; and (3) Manufacturing Quality Plan and Site Quality Plan, for the control of activities within each category of work or discrete element of procurement, manufacturing, delivery, construction and installation of the Works, including Temporary Works Within 30 days of the Commencement Date of the Works, the Contractor shall submit for review by the Employer s Engineer: (1) the quality system procedures and any associated system instructions and/or forms which he proposes to use for the Works; and NMRCL MARCH

64 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (2) the initial submission of quality plans shall be a development of that submitted at Tender stage and shall contain as a minimum, the Contractor s proposed Management Quality Plan and a Design Quality Plan as detailed further in this Chapter The Contractor shall submit separate Manufacturing Quality Plan and Site Quality Plan covering all elements of the Works. These shall be in accordance with the specific requirements of this Chapter and shall be submitted to the Employer s Engineer for review 60 days prior to the commencement of the manufacturing and construction works covered by the quality plans. In addition, the Contractor shall prepare inspection and test plans for the management and control of the inspection and/or testing by the Contractor of the Works identified in each quality plan The Contractor shall promptly supply the Employer s Engineer with two (2) controlled copies of his quality manual, quality plans, inspection and test plans and related procedures/instructions/forms upon such documents being reviewed without objection by the Employer s Engineer. The Contractor shall maintain such controlled documents throughout the duration of the Contract. For any amendment to quality system documentation, the Contractor shall as soon as reasonably practicable prepare and submit the proposed amendment for review by the Employer s Engineer. In addition, the Employer s Engineer may request further copies of the quality system documents and these documents shall reach the Employer s Engineer s office within fourteen (14) days of notification The Contractor shall appoint (a) suitably qualified and experienced person(s) as Quality Manager(s), who shall be directly responsible to senior management level and is able to discharge his duties without hindrance or constraint, and provide such other resources as may be required to ensure effective implementation of the Quality Management System and all quality plans. Details of the qualifications, experience, authority and responsibility of the proposed Quality Manager(s) shall be submitted for review by the Employer s Engineer within 30 days of the Commencement Date of the Works During the Contract period, upon receipt of a Corrective Action Request (CAR) or similar document issued by the Employer s Engineer as a result of quality audits, the Contractor shall submit a proposed corrective and preventive action plan within 14 days to the Employer s Engineer for review. 5.3 Management Quality Plan The Management Quality Plan shall define the Contractor's management structure for the execution of the Works and for the control of the quality of the Works and shall, without limitation, define: (1) the appointment of a Quality Manager in accordance with clause above; (2) the organisation of the Contractor s managerial staff with particular reference to any joint venture partners and main subcontractors. An organisation chart shall be produced to illustrate the sub-division of the Works into elements for effective technical and managerial control, the reporting structure and the interface relationship between all parties involved; NMRCL MARCH

65 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (3) the hierarchy of the overall quality management system documentation to be applied to the Works; (4) the quality management system of the Contractor in monitoring and controlling sub-contractors and suppliers; and (5) the list of quality system procedures and work instructions to be applied to manage the quality of the Works. 5.4 Design Quality Plan The Contractor shall prepare a Design Quality Plan for its design works. The Design Quality Plan shall define the Contractor s policy for the design works and shall, without limitation, define: (1) the organisation of the Contractor s design staff; (2) the specific allocations of responsibilities and authorities given to identified design staff or sub-contractors for particular design work; (3) the hierarchy of quality management system documentation for managing and controlling design works, including design works of subcontractors of any tier; and the list of procedures and instructions to be applied to manage and control the quality of the design works. 5.5 Manufacturing Quality Plan The Contractor shall prepare a Manufacturing Quality Plan for his manufacturing works. The Manufacturing Quality Plan shall, without limitation, define: (1) the organisation of the Contractor s staff directly responsible for the dayto-day management of the manufacturing activities on or off the Site; (2) the specific allocations of responsibilities and authorities given to identified personnel or sub-contractors for particular manufacturing work; (3) the hierarchy of quality management system documentation for managing and controlling manufacturing works, including manufacturing works of sub-contractors of any tier; and (4) the list of procedures and instructions to be applied to manage and control the manufacturing works, together with the procedures and instructions which have not been previously submitted for review The Contractor shall also prepare inspection and test plans to manage and control any test and inspection activities in accordance with clause above. 5.6 Site Quality Plan The Contractor shall prepare a Site Quality Plan for its construction and installation works. The Site Quality Plan shall, without limitation, define: (1) the organisation of the Contractor s staff directly responsible for the dayto-day management of the construction and installation activities on or off the Site; NMRCL MARCH

66 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (2) the specific allocations of responsibilities and authorities given to identified personnel or sub-contractors for particular construction and installation work; (3) the hierarchy of quality management system documentation for managing and controlling construction and installation works, including construction and installation works of sub-contractors of any tier; and (4) the list of procedures and instructions to be applied to manage and control the construction and installation works together with the procedures and instructions that have not been previously submitted for review The Contractor shall also prepare inspection and test plans to manage and control any test and inspection activities in accordance with clause below. 5.7 Inspection and Test Plans, Records and Reports Inspection and test plans shall be produced for every activity requiring test and/or inspection. Each inspection and test plan shall identify the quality objectives and include, without limitation: (1) the personnel responsible for undertaking and certifying the inspection and/or test; (2) the procedure or instructions for the inspection and/or test; (3) the test method or a reference to the relevant standard of testing; (4) the inspection and/or test required prior to commencement of an activity; (5) the inspection and/or test during an activity and its frequency; (6) the inspection and/or test required to complete an activity; (7) all Quality Control Points, Quality Hold Points and any notices or other documents to be given to the Employer s Engineer in relation to Quality Control Points and Quality Hold Points; (8) the compliance criteria; (9) the method of analysis of test data; (10) the procedure for correction or disposal of any work which fails the compliance criteria; (11) examples of the documentation to be used for reporting the results of inspections, tests and analysis of test data; (12) examples of the documentation to be used for recording the status of inspections and tests in accordance with clause below; and (13) the procedure for the distribution, filing and storage of inspection reports, test reports and reports on analysis of test data. NMRCL MARCH

67 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Each report of the inspection and/or test shall be prepared in accordance with clause below The Contractor shall ensure that a signed copy of each report of inspection and test is filed in his filing system within 3 (three) working days of the date of inspection and test In relation to all Quality Control Points and Quality Hold Points involving inspection and/or test by the Contractor, the Contractor shall give the Employer s Engineer notice of when the relevant work will be inspected and/or tested in accordance with clause9.8.1 below. 5.8 Review, Verification & Audit The Contractor shall continuously monitor the performance of each quality plan related to the execution of the Works and shall include in each Monthly Progress Report the status of all quality system documentation, an up-to-date audit schedule and status and an up-to-date non-conformity register providing the status of all nonconformities identified by the Employer s Engineer and the Contractor. The Contractor shall make an appraisal of such performance and identify in particular any non-conformities or other shortcomings in the quality management system, the actions being taken to dispose of these non-conformities, any necessary corrective action taken or proposed to be taken to prevent the re-occurrence of these nonconformities or shortcomings and, any other items as instructed by the Employer s Engineer The Contractor shall ensure that audits of all the activities in each quality plan are carried out at quarterly intervals, or at such other intervals as the Employer s Engineer may require, to ensure the continuing suitability and effectiveness of the quality management system. Reports of each such audit shall be submitted promptly for review by the Employer s Engineer The Contractor shall ensure that the requirements for supervision and verification of work by the Contractor and/or his sub-contractors of any tiers are identified in the quality plans and adequate resources and trained personnel are provided for these activities The Contractor shall submit for review by the Employer s Engineer details of the authority, qualifications and experience of personnel assigned to design verification and to audit activities The Employer s Engineer may by notice to the Contractor, require external audits of the Contractor's quality management system to be carried out either by the Employer's staff or by his representative. In such case, the Contractor shall afford to such auditors all necessary facilities and access to the records to permit this function to be performed. 5.9 Quality Control Register NMRCL MARCH

68 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Contractor shall provide and maintain at all stages of the Works a quality control register or registers to identify the status of inspections, sampling and testing of the work and all certificates. Such registers shall be updated by the Contractor to show all activities in previous months and shall reach the Employer s Engineer s office before the 7 th working day of each month. Each register shall: (1) list the certificates received for each batch of goods and materials incorporated in the Works and compare this against the certification required by the Contract and the Contractor s quality plans; (2) list the inspection and testing activities undertaken by the Contractor on each element of the Works and compare these activities against the amount of inspection and testing required by the Contract and the Contractor s quality plans; (3) show the results of each report of inspection and/or test and any required analysis of these results and compare these results against the pass/fail criteria; and (4) summarise any actions proposed by the Contractor to overcome any non-conformity identified in clauses (1),(2)&(3) above Summaries of Inspection and/or Test The Contractor shall submit to the Employer s Engineer for his information summaries based on quality control register in accordance with the Summaries of Inspection and/or Test described in clause below Notification of Non-conformities If, prior to the issue of the Taking Over Certificate for the Works or the relevant Section, the Contractor has used or proposes to use or repair any item of the Works which does not conform to the requirements of the Contract, he shall immediately submit to the Employer s Engineer such proposal, supplying full particulars of the nonconformity and, if appropriate, of the proposed means of repair which shall include any calculation analysis or other documentation to support the repair or acceptability of the nonconformity If the Employer s Engineer issues non-conformity reports or similar documents to notify the Contractor of any item of the Works which he considers to constitute a nonconformity and which has not been reported in accordance with clause above, the Contractor shall promptly investigate the matter and, within 14 days of notification by the Employer s Engineer, submit to the Employer s Engineer for review the remedial measures to be taken and stating the reasons for such measures. End of Chapter NMRCL MARCH

69 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER 6 6. SOFTWARE MANAGEMENT AND CONTROL 6.1 Prescriptive Framework All software to be developed or modified (re-engineered software) shall follow the normative requirements of EN50128 (Railway Applications: Software for Railway Control and Protection Systems). The Software shall be designed, developed and tested according to the Software Quality assurance Plan, Software Integrity Level (SIL) and the Software Lifecycle. The Contractor shall define within the Software Quality Assurance Plan what techniques and measures are to be applied for software development. In addition to the requirements of the Software Quality Assurance Plan, justification, which shall be reviewed without objection by the Employer s Engineer, shall be required in respect of any highly recommended EN50128 Annex A normative clauses which are not to be applied to software development and supply. 6.2 Software Framework As defined in EN50128, all software produced or supplied for the project shall be subject to a defined quality framework. The Contractor shall use a Quality Assurance System which is compliant with CENELEC specifications, with EN29000 series and others and meet the requirements as stipulated in the PS. ISO is considered appropriate for Safety Integrity Level 0 or 1 software. 6.3 All Control & Monitoring Software has to be provided to the Employer in the following formats i) Source Code II) Detailed Programme With explanation of key functions, protection schemes and safety requirement. III) System description and layout module wise. IV) Troubleshooting of hardware & software including that in communication with SCADA. 6.4 System should generate non- conformity statements with classification of severity of the non-conformity. The daily reports should be updated. 6.5 This will form part of the submittals. * End of Chapter * NMRCL MARCH

70 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER 7 7. MATERIALS AND EQUIPMENT 7.1 Materials and Equipment Provided by the Employer Materials and equipment which are to be provided by the Employer will be as stated in the Contract Materials and equipment provided by the Employer shall be collected by the Contractor from the locations stated in the Contract and delivered by the Contractor to the Site. The Contractor shall inspect the materials and equipment before taking receipt and shall immediately inform the Employer s Engineer of any shortage or damage Materials or equipment provided by the Employer which are damaged after collection shall be repaired by the Contractor and submitted to the Employer s Engineer for review. Materials or equipment which are lost or which in the opinion of the Employer s Engineer are not capable of being or have not been repaired satisfactorily shall be replaced by the Contractor The Contractor shall dispose of crates and containers for materials or equipment provided by the Employer Equipment / materials provided by the Employer, surplus to the requirements of the Works shall be returned to the locations stated in the Contract The Contractor shall protect and maintain equipment provided by the Employer while it is on the Site and shall provide operatives, fuel and other consumables required to operate the equipment. 7.2 Materials General Materials for inclusion in the Permanent Works shall be new unless otherwise stated in the Contract or having been reviewed without objection by the Employer s Engineer Certificates of tests by manufacturers, which are submitted to the Employer s Engineer, shall relate to the material delivered to the Site. Certified true copies of certificates may be submitted if the original certificates cannot be obtained from the manufacturer. A letter from the supplier stating that the certificates relate to the material delivered to the Site shall be submitted with the certificates Materials, which are specified by means of trade or proprietary names, may be substituted by materials from a different manufacturer, provided that the materials are of the same or better quality and comply with the specified requirements and have been reviewed without objection by the Employer s Engineer In addition to any special provisions in the Contract for the sampling and testing of materials, the Contractor shall submit samples of all materials and goods which it propose to use or employ in or for the Works. Such samples, if having been reviewed without objection, shall be retained by the Employer s Engineer and shall not be returned to the NMRCL MARCH

71 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Contractor or used in the Permanent Works unless reviewed by the Employer s Engineer. No materials or goods of which samples have been submitted shall be used in the Works unless and until the Employer s Engineer shall have reviewed such samples without objection The Employer s Engineer may reject any materials and goods which in his opinion are inferior to the samples previously reviewedand the Contractor shall promptly remove such materials and goods from the Site If any material required for this Contract is not available in metric specifications from any known sources, at the time the material is required for the Contract, the Employer s Engineer may, upon application from the Contractor, give permission to the use of an equivalent material in imperial specifications as a substitute, provided that: (1) no statutory specification shall be altered except in accordance with relevant legal provision, if any; (2) the Employer s Engineer is satisfied that the Contractor has made every reasonable effort to obtain the material in metric specifications; (3) in the opinion of the Employer s Engineer, the substitute material is suitable for the Works in all respects; (4) in the opinion of the Employer s Engineer, the substitute material complies with all the specifications for the material substituted, allowing minor discrepancies between the specified metric measurements and the corresponding imperial measurements of the substitute, provided that such discrepancies can be effectively and satisfactorily compensated for by the provision of extra quantity of the material; and (5) the Contractor shall be responsible for all extra quantities of the material required for meeting design and specification requirements of the Works due to the use of the substitute Hardwood shall not be used for Site hoardings, shoring of trenches and pits, falsework or formwork Notice of place of manufacture and/or source of supply The Contractor shall notify the Employer s Engineer of the places of manufacture and/or the source of supply of all goods and materials previously reviewed without objection by the Employer s Engineer to be incorporated into the Permanent Works. The Contractor shall give reasonable notice (which shall not in any event be less than 56 days) to the Employer s Engineer before the start of any manufacturing and/or the supply of goods and materials Certificates for Manufactured Goods or Materials The Contractor shall obtain certificates for each batch of goods and materials incorporated into the Permanent Works. Each certificate shall certify that the materials comply with the requirements of the Contract and shall include all reports of inspections and/or tests carried out at the place of manufacture. 7.3 Equipment Identification labels Each and every individual item of equipment forming part of the Permanent Works shall be fitted with permanent identification labels in accordance with a system based on the NMRCL MARCH

72 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification contract identification. In this respect, the term individual item of equipment refers to a complete assembly of components and to each removable sub-module within the complete assembly The proposed labelling system shall be submitted for review by the Employer s Engineer at least 3 months before the scheduled date for the shipment of the first item of equipment to site The identification label shall be permanently attached in such a way that it shall not become detached or illegible during the lifetime of the system from any cause including wear and tear, environmental effects (such as rain, direct sunlight, etc.) or any other influence. Preference shall be given to embossed or engraved metallic labels mechanically fastened by riveting or similar means to the item to which they refer All labels shall be easily cleaned to remove dirt and debris (including grease and oil) without disturbing the legibility properties All labels shall incorporate the inscription Property of NMRC. 7.4.Electronic Control Racks & Cabinets Racks & Cabinets Electronic control equipment shall be housed in 19" racking suitably enclosed in metal cabinets of a type acceptable to the Employer s Engineer. A sample of each type of rack or enclosure proposed shall be submitted to the Employer s Engineer for inspection The equipment shall be of modular construction to facilitate maintenance, repair and replacement of parts. Standard commercial parts shall be utilised to the maximum extent possible Cubicles, Equipment Racks, cable and wiring Termination Racks shall not be filled to greater than 80% of their capacity at the completion of the works There shall be a minimum walkway of 1000mm between equipment racks The equipment shall be suitable for the environment in which it is to be used and it shall be designed to prevent ingress of all vermin and to minimise the ingress of moisture, dust and dirt Outdoor equipment shall be sealed against the ingress of dust, moisture and vermin No item of equipment which is removable as part of routine maintenance procedures shall be mounted at more than 2.0m above floor level Cables No joints or splices shall be permitted in cables or wires except at recognised termination points All multi-core cables shall allow 20% or 2 cores, whichever is the greater, as spares All cable cores shall be terminated including all spare conductors. NMRCL MARCH

73 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Each cable core shall be uniquely numbered and identified with a label giving details of the circuit carried Terminals carrying voltages exceeding 50 volts shall be uniquely identified and protected against accidental contact by persons, test equipment or other unintended physical contact. Similarly all bus bars shall be suitably identified and protected. End of Chapter NMRCL MARCH

74 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER 8 8. PACKAGING, STORAGE, SHIPPING AND DELIVERY 8.1.Storage of Equipment The Contractor shall provide and maintain acceptable storage facilities for the Permanent Works, equipment and materials of all kinds intended for use in carrying out the Works or for incorporation into the Works The Contractor shall prepare, protect and store in an agreed manner all Permanent Works, Contractor s Equipment, equipment and materials so as to safeguard them against loss or damage from repeated handling, from climatic influences and from all other hazards arising during shipment or storage on or off the Site Secure and covered storage shall be provided by the Contractor for all Permanent Works, Contractor s Equipment, equipment and materials which are other than those having been reviewed without objection by the Employer s Engineer as suitable for open storage. 8.2.Crating The Contractor shall provide all packing, crates and markings. In doing so, it shall comply with the following requirements:- (1) Each case, crate or package shall be waterproof, rot-proof and insect/rodent-proof, of robust construction and suitable for the intended purposes. The Contractor shall, in determining the package materials to be used, take cognisance of the climatic conditions likely to occur during the period of transport, shipment and storage. (2) Each case, crate or package shall be legibly and indelibly marked in large letters with the Site address, Contract number, "right way up", opening points and other markings as necessary to permit materials to be readily identified and handled during transit and when received at the Site. (3) Each case, crate or package shall contain a comprehensive packing list showing the number, mark, size, weight and contents together with any relevant drawings. A second copy of the packing list shall be enclosed in a watertight enclosure on the outside of each case or package. Distribution of additional copies of each packing list shall be in accordance with the Employer s Engineer's instructions. (4) All items heavier than 100 kg shall be marked on the outside of the case to show the gross and net weights, the points for slinging, and where the weight is bearing. (5) Care shall be taken to prevent movement of items within cases, crates or packages by the provision of bracing, straps and securing bolts as necessary. Bags of loose items shall be packed in cases, and shall be clearly identified by well-secured metal labels on which the quantity and name of the part and its index or catalogue number have been stamped. NMRCL MARCH

75 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (6) Plug connected electronic circuit boards shall be removed from their racks, packed and shipped separately. (7) All packing shall be free from sharp edges to prevent injury to persons or other objects. (8) Each bulky/heavy case, crate or package shall include (a) wedge(s) for easy loading and unloading by mechanical handling equipment such as forklift truck. (9) Electronic circuit boards, integrated circuits (IC) and the like shall be well protected by using appropriate packing, e.g. anti-static bubble bag or similar. (10) Rubber products and the like shall be suitably packed to avoid damage including but not limited to hardening, deformation and peel-off. 8.3 General Precautions Spare parts shall be tropicalised in their packing for prolonged storage in accordance with BS 1133 or other equivalent International /Indian standard and shall be suitably and individually labelled to indicate: (1) shelf life and date of manufacture; (2) type or condition(s) of storage and special handling information; (3) description of item and relevant part number; (4) serial number, if applicable; (5) inspection/test certificate number and batch number; and (6) Contract number, variation order number and item number Tubes, cable, conductor and other similar openings shall be properly sealed and blanked off to prevent ingress of dirt or moisture. Flanged ends shall be protected by adhesive tape or jointing material covered by a properly secured wooden blank not smaller than the flange itself. Plain tube ends shall be closed off with bungs or plugs or suitable materials firmly fixed in position Particular care shall be taken to prevent mechanical transport related damage or corrosion of shafts and journals where they rest on timber or other supports which may contain moisture. At such points, wrappings impregnated with anti-rusting composition and of sufficient strength to resist chafing under the pressures and movements during transit shall be used Spare ball and roller bearings and similarly protected items shall not be removed from the manufacturer s wrappings or packing Fragile materials shall be packed in such a way that they shall not be damaged during transit and when they are properly unpacked for quality inspection. Glass items shall be capable of NMRCL MARCH

76 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification being easily re-packed without removing the original wrappings or packing for long-term storage within the same packing case Appropriate precautions in accordance with the Contractor s safety regulations, the regulations of the Employer, and statutory regulations shall be taken in respect of all hazardous, toxic, inflammable, etc. materials. 8.4 Packaging Procedures All required inspection/test certificates shall be supplied and packed together with individual material. All packaging materials and procedures shall be subject to review by the Employer s Engineer All empty cases, crates or packages, whether or not returnable, shall be removed from the Site by the Contractor or stored by the Contractor in such a way that they do not interfere with the progress of the works of Project Contractors. 8.5 Shipping The Contractor shall notify the Employer s Engineer ten days in advance of any expected shipment date and give further notification of the actual shipment date and routing when such information is subsequently established. This shall complement the inspection requirements prior to delivery as specified herein Two copies of packing lists and quality certificates shall be attached to each case or package to be shipped. One copy shall be placed inside the package and the second copy shall be enclosed in a watertight enclosure on the outside of each case or package. A copy of packing lists and quality certificates shall be sent to the Employer s Engineer after each package of the Works, the equipment, spare parts and other items to be shipped have been shipped Without prejudice to any other provisions of the Contract, the Contractor shall be responsible for all legal requirements, duties, dues, taxes and other such requirements and expenditures required for the importation of the Works, the equipment, spare parts and other items to be supplied under the Contract into Nagpur The Contractor shall clear the Works, the equipment, spare parts and other items to be supplied under the Contract through Nagpur customs/indian sea port in accordance with all Government of India Enactments. 8.6 Delivery The Contractor shall deliver the Works and all items to be supplied under the Contract to the Site The Contractor shall unload the Works and all items to be supplied under the Contract at the designated delivery point and positioning or storing them. NMRCL MARCH

77 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Any part of the Works or any item to be supplied under the Contract that is damaged in transit shall not be considered as delivered until repairs or replacements have been made and all necessary spare parts or items have been delivered to the Site All documents, manuals, drawings and other deliverables shall be delivered to an address in Nagpurto be designated by the Employer s Engineer in writing The Contractor shall store and secure the Works, equipment, spare parts and other items until the same have been inspected and are considered delivered at the designated point by the Employer s Engineer The Contractor shall remove temporary fittings required for shipment and re-assembly of equipment and shall complete this prior to the equipment or parts thereof being inspected and before they are considered delivered An item shall be considered delivered when all damage have been repaired and all documentation and post delivery preparation have been completed to the satisfaction of the Employer s Engineer. End of Chapter NMRCL MARCH

78 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER 9 9. TESTING AND COMMISSIONING Testing and Commissioning shall comply with all the requirements of the GCC supplemented, amplified, modified or superseded as applicable by this Specification and the PS. 9.1 General The Contractor shall perform all testing and commissioning activities to satisfactorily demonstrate the performance of the Works within the framework of the Completion Management Plan The Contractor s activities shall include but are not limited to the following: (1) provision of all labour and experienced supervision to perform all inspections and tests required to demonstrate the performance of the Works; (2) preparation of that portion of the Commissioning Plan that applies to the Works to a level of detail acceptable to the Employer s Engineer; (3) performance of all duties and responsibilities, as specified in the Commissioning Plan; (4) participation in the Commissioning Team that shall develop, review and implement the Commissioning Plan. As a participant of the Commissioning Team, the Contractor shall provide personnel and technical support to the Employer and the Employer s Engineer in the Commissioning of the Project; (5) performance of the testing and commissioning for all systems forming part of the Works in a manner which is fully co-ordinated with other Contractors, the Employer and the Employer s Engineer; (6) provision of all required testing and specialised equipment and materials including consumables required to support the testing and commissioning preoperations activities; and (7) removal and appropriate disposal of any toxic or other spoils (e.g. cable drums, depleted filters, oils, and fluids) created as a result of the Contractor s construction, testing and commissioning activities The Contractor shall provide full access for the Employer and Employer s Engineer to witness any test or inspection The Employer and the Employer s Engineer will bear their own costs for attendance at witnessed inspections or tests (other than re-tests) scheduled in accordance with the agreed Works Programme and subject to notice in accordance with the Specification. NMRCL MARCH

79 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification 9.2 Manufacturing Test Plan The Manufacturing Test Plan is the Contractor s plan for carrying out the necessary procedures to ensure that the items presented for acceptance by the Employer and the Employer s Engineer are in compliance with the requirements of the Specification During the process of procurement and manufacture of the system components the Contractor shall undertake such testing and inspection as is required by the Quality Plan referred to in clause 5.5 above The Employer and the Employer s Engineer will not become involved in the Contractor s Manufacturing Tests except in respect of the following: Type Tests; and First Article Inspection Before shipment of any items to Site the Contractor shall present the items for the first stage of Acceptance according to the Commissioning Plan as detailed in clause 9.3 below Inspection The Contractor shall be wholly responsible for all inward inspection of items to be incorporated into the system as a whole Equipment issued by the Employer shall not be subject to Type Tests or First Article Inspection however the Contractor shall undertake Inspection as referenced in clause 7.1 above. Should the Employer s issued equipment be subsequently incorporated into another manufactured item then the whole item shall be subject to both Type Tests and First Article Inspection Type Tests Type tests will not be required in those cases where the Contractor can produce certified evidence that the required type tests have been performed successfully on identical equipment or equipment which is, for practical test purposes, similar and produced in the factory where the equipment offered is to be manufactured Evidence to this effect submitted during the Tender period shall be resubmitted, this and any further submissions for waiver of Type Testing shall be submitted for review by the Engineer s Representative no later than two months before the scheduled date for shipment of the item to site Unless specified to the contrary, equipment type testing shall consist of performing the tests listed below on at least one sample of the design: a) Mechanical Tests - Based on the function to be performed as laid down in the PS; b) Environmental Tests - Based on the class of environment into which the item is to be installed; c) Functional Tests - To comply with the requirements of the PS; NMRCL MARCH

80 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification d) Electrical Tests - (where appropriate) To demonstrate compliance with electrical characteristics under conditions of interference and power supply disruption; and e) Fatigue (Soak) Tests - To demonstrate the reliability or longevity of the item Type tests are not required if previously independently witnessed tests have been successfully carried out. Where only some of the required tests have been carried out, the Employer s Engineer may agree to selected type tests being carried out individually rather than as part of a sequence The Contractor shall conduct the tests in accordance with the reviewed test procedures, and shall enter the results in the result sheets. Full use shall be made during the tests of operator manuals and other documentation provided by the Contractor, to provide a series of tests of their accuracy Various requirements for typical Type Tests are included in Appendix 5 of this Specification For each test, the Employer s Engineer will determine whether the item under test has passed or failed. In general, the test will be considered to have failed if either: The result of the test is not in accordance with the expected result described in the test procedure, or The result of the test is in accordance with the expected result described in the test procedure, but some other unexpected or unexplained event occurred which the Employer s Engineer considers to be a fault If during Type Tests, any failure occurs or the equipment design is changed, it shall be reported to the Employer s Engineer who may, at his discretion, require repetition of the previous tests at the Contractor's cost First Article Inspection FAI shall be performed jointly by the Employer and the Employer s Engineer and the Contractor on all major equipment items or sub-systems identified by the Employer s Engineer Equipment shall be shipped from the point of manufacture only after a FAI has been completed or the requirement waived in writing by the Employer s Engineer The Contractor shall provide a minimum of 15 working days notice to the Employer s Engineer before any FAI. Other than the FAI, the Contractor shall give the Employer s Engineer notice of all Quality Control Points and Quality Hold Points involving inspections and/or tests by the Contractor in accordance with clause below At least 15 days prior to each FAI, the latest drawings, inspection and test procedures, specifications and quality documentation required for adequate inspection of the equipment under inspection shall be submitted to the Employer s Engineer. The drawings shall be complete to the lowest level replaceable unit. NMRCL MARCH

81 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Contractor shall ensure that he and his subcontractors are prepared for all FAIs. The Contractor shall not schedule more than one FAI on the same day without prior notice of No Objection by the Employer s Engineer The FAI shall evaluate component and system maintainability. The FAI shall enable the Employer and the Employer s Engineer and the Contractor to jointly establish the quality of workmanship for the balance of like components The FAI shall not be conducted until the design drawings of the equipment have been reviewed. If drawings with outstanding comments are used, the Employer s Engineer s comments shall be satisfied at the FAI and represented by the inspected equipment FAI shall be performed on a component built using reviewed without objection production processes, tooling and manpower. All test fixtures, programs and instruments used in FAI shall be those to be used in the routine production testing of subsequent identical items The Contractor shall be responsible for the cost and scheduling, to the Employer and the Employer s Engineer's convenience, of any repeat testing of items which fail FAI Factory Acceptance Test Before shipment all manufactured items or systems shall undergo FAT in accordance with the requirements of the PS. 9.3 Commissioning Plan The Commissioning Plan is the Employer and the Employer s Engineer s tool for managing and co-ordinating the Testing, Commissioning, Training and Service Trial activities. The Commissioning Plan will be divided into the following sub-plans: (1) Factory Testing Plan ( see clause above and PS) (2) On-Site Testing and Commissioning Plan Testing and Commissioning Phases Testing and Commissioning activities shall be undertaken in the following phases: (1) Factory Acceptance Test (which requirements are specified in clause above); (2) Installation Tests; (3) Partial Acceptance Tests; (4) System Acceptance Tests; (5) Integration Testing & Commissioning; and (6) Service Trial. NMRCL MARCH

82 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Items (3), (4), (5) and (6) as required by the PS constitute the Tests on Completion referred to in the GCC. 9.4 On-Site Testing and Commissioning Plan The Contractor shall prepare and submit for review by the Employer s Engineer the Contractor s On-Site Testing and Commissioning Plan detailing and explaining how the Contractor will plan, perform and document all tests and inspections that will be conducted to verify and validate the Works on Site. The On-Site Testing and Commissioning Plan shall consist of a narrative description supported by graphics, diagrams and tabulations as required The On-Site Testing and Commissioning Plan shall contain, but not be limited to, the following topics: (1) the Contractor s strategy for testing and commissioning all constituent parts of the Works and how this relates to the sequence of construction and installation; (2) the sequencing and interrelationships of the inspections and tests including: (a) (b) all Quality Hold Points; and all Quality Control Points; (3) the interdependency and interaction with other Contractors and their commissioning programmes; (4) the type and extent of testing and commissioning to be undertaken and the parts of the Works to be proven by that testing; (5) the objective of each test, what particular design and operating criteria the test or inspection will prove and how the success of the test will be demonstrated or measured; (6) organisation chart and CV of key personnel in testing and commissioning team; (7) the plan for the production and submission of the testing and commissioning procedures to the Employer s Engineer for review including the submission of the testing and commissioning reports and records; and (8) the On-Site Testing and Commissioning Plan shall be organised and submitted in the stages described in clauses above, below&9.4.7 below Installation Tests The Installation Tests phase is defined as being the final stage of assembly/installation before the start of commissioning itself. The Installation Tests are to be performed by the Contractor under the Contract and may be NMRCL MARCH

83 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification witnessed by the Employer or the Employer s Engineer. During this phase, the Contractor shall perform static testing of components and/or systems in preparation for Partial Acceptance Testing The particular requirements for Installation Tests are prescribed in the PS. Where performance across interfaces to other Contractors or to other parties is required to be verified, the Contractor shall liase with the interfacing party to co-ordinate the test procedures and programme in the manner prescribed in clause above The Contractor shall prepare three copies of a test report immediately after the completion of each test whether or not witnessed by the Employer or the Employer s Engineer. If the Employer or the Employer s Engineer has witnessed the test, he will countersign the report to indicate his agreement to the information and conclusions (i.e. whether or not the equipment being tested has passed satisfactorily) contained therein. If the Employer or the Employer s Engineer has not witnessed the test (i.e. if a written waiver has been granted), the Contractor shall forward three copies of the test report without delay to the Employer s Engineer The Employer s Engineer will countersign the report to indicate his agreement to the information and conclusions (i.e. whether or not the equipment being tested has passed satisfactorily) and return one copy to the Contractor. Where the results of the test do not meet the requirements of the Specification, the Employer or the Employer s Engineer may call for a re-test Test equipment and instrumentation shall be subject to calibration test within a properly controlled calibration scheme, and signed calibration certificates shall be supplied to the Employer s Engineer in duplicate. Such calibration checks shall be undertaken prior to testing and, if required by the Employer or the Employer s Engineer, shall be repeated afterwards The Contractor shall submit to the Employer s Engineer a comprehensive schedule of tests as required by the PS giving full details and procedures for each test to be carried out under the Contract and including the pass / fail criteria (i.e. the standards or limits to be achieved) Partial Acceptance Tests Partial Acceptance Tests are defined as the performance of functional tests of sections, areas, or stages of a system. The Partial Acceptance Tests are part of the Tests on Completion to be performed by the Contractor under the Contract in order to achieve Employer s Taking Over of the Works. During this phase, an energy source shall be introduced to enable functional testing to be performed. On satisfactory completion of the Partial Acceptance Tests, the tested items will be considered available for Systems Acceptance Testing The particular requirements for Partial Acceptance Tests are prescribed in the PS The Contractor shall submit to the Employer s Engineer a comprehensive Partial Acceptance Tests Plan including all requirements detailed in the PS. The plan shall be submitted on a logical section-by-section basis, using a top-down approach describing the testing and commissioning strategies and processes clearly showing how these serve to provide the full verification of the systems and equipment. NMRCL MARCH

84 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Partial Acceptance Tests Plan shall identify a comprehensive list of specifications, standards, method statements, procedures, pass/fail criteria, sample records, resources to be made available, drawings and records to be submitted to the Employer s Engineer, and a programme showing the dates for testing and for submission of each test procedure Test procedures shall be carefully planned to ensure that the work can be executed in the time available. If the available time is restricted, this planning shall include contingency plans to be implemented if testing proceeds slower than anticipated or if defects are discovered that necessitate rectification and subsequent repeat testing, etc If any working equipment is relocated or altered by the Contractor during the execution of the Works, thorough re-testing shall be performed to verify that the equipment remains fully functional and operates safely according to its specification. The testing to be performed shall be no less rigorous than the procedures used for the original testing and commissioning of the equipment The Contractor shall submit to the Employer s Engineer by the date laid down in the PS (or if none is given, no later than two months before the commencement of the commissioning work whichever is earlier), 3 copies of its proposed Partial Acceptance Tests records. The records shall be appropriately sub-divided to make provision for the various parts of the systems and equipment covered by the Contract and shall cover all tests (mechanical, electrical or otherwise), positive identification of equipment, assemblies and sub-assemblies by serial number, drawing and specification reference numbers (and issue reference) and any other data to be certified by the Employer or the Employer s Engineer during the course of commissioning The Contractor shall during the execution of the Works prepare such reports and records of design, manufacture, installation, erection and testing as may be required in order that any relevant licences or approvals (including any statutory approvals) may be issued or granted. Such records shall be adequate to enable the system or its respective part to be commissioned and to meet the requirements of the licensing authority or statutory body Immediately following the successful Partial Acceptance Testing of the system or any constituent part, the Contractor shall complete the appropriate Partial Acceptance Tests records in the agreed format and submit 3 signed copies to the Employer s Engineer The Contractor shall include a complete schedule of all Partial Acceptance Tests records and their current status within the Monthly Progress Report System Acceptance Tests System Acceptance Tests are defined as the tests undertaken to demonstrate that the Works in its entirety is capable of functioning in accordance with the specified requirements in the Contract in all respects. The System Acceptance Tests are part of the Tests on Completion to be performed by the Contractor under the Contract in order to achieve Employer s Taking Over of the Works. The System Acceptance Tests may commence before remote operations capability (if any) is fully functional, however, the system must be satisfactorily tested remotely (if specified to have such capability) before the System Acceptance Tests can be considered to be completed. NMRCL MARCH

85 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification On satisfactory completion of the System Acceptance Tests, the tested items will be considered available for Integrated Testing & Commissioning The particular requirements for System Acceptance Tests are prescribed in the PS The Contractor shall submit to the Employer s Engineer a comprehensive System Acceptance Tests Plan including all requirements detailed in the PS. The plan shall be submitted on a section by section basis to demonstrate how the System Acceptance Tests are to be carried out. The plan shall adopt a top down approach and describe the system completion strategy and process System Acceptance Tests shall comprise comprehensive testing of the assembled installation to ensure that it operates in accordance with the requirements of the PS The tests shall include, but not be limited to, the following: (1) tests of all functional and performance requirements for the system; (2) tests of behaviour under failure conditions, e.g. changeover to redundant hardware; initiation of re-configuration functions or reverse modes of operation; and recovery of the equipment and system from failure The System Acceptance Test Plan shall identify a comprehensive list of specifications, standards, method statements, procedures, pass / fail criteria, sample records, resources to be made available, drawings and records to be submitted to the Employer s Engineer, and programme showing the dates for testing and for submission of each test procedure Test procedures shall be carefully planned to ensure that the work can be executed in the time available. If the available time is restricted, this planning shall include contingency plans to be implemented if testing proceeds slower than anticipated or if defects are discovered that necessitate rectification and subsequent repeat testing, etc Immediately following the successful acceptance testing of the system, the Contractor shall complete the appropriate commissioning records in the agreed format and submit 3 signed copies to the Employer s Engineer The Contractor shall include a complete schedule of all System Acceptance Test records and their current status within the Monthly Progress Report Integration Testing & Commissioning Integrated Testing & Commissioning are defined as the final tests to be undertaken before the commencement of Service Trial. The Integrated Testing & Commissioning are part of the Tests on Completion to be performed by the Contractor under the Contract in order to achieve Employer s Taking Over of the Works. The Integrated Testing & Commissioning shall demonstrate the full compatibility between all interfacing systems. On satisfactory completion of the Integrated Testing & Commissioning, the tested items will be considered available for Service Trial The particular requirements for Integrated Testing & Commissioning are prescribed in the PS. NMRCL MARCH

86 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Contractor shall submit to the Employer s Engineer a comprehensive Integrated Testing & Commissioning Plan as required by the PS. The plan shall be submitted on a logical section-by-section basis, using a top-down approach describing the testing and commissioning strategies and processes clearly showing how these serve to provide the full verification of the systems and equipment in context of the complete railway system The Contractor shall co-ordinate with the Employer and the Employer s Engineer and with all interfacing parties to ensure that the proposed test programme and schedule truly demonstrate that the full specified performance requirements are achieved The tests shall include, but shall not be limited to the following:- (1) test of all functional and performance requirements for the system; (2) test to demonstrate compliance with all interface specifications; and (3) test of behaviour under failure conditions (e.g. changeover to redundant hardware, initiation of re-configuration functions or reversionary modes of operation, recovery of systems and equipment from failure, demonstrations of planned emergency procedures, etc.) The Integrated Testing & Commissioning Plan shall identify a comprehensive list of specifications, standards, method statements, procedures, pass/fail criteria, sample records, resources to be made available, drawings and records to be submitted to the Employer s Engineer, and a programme showing the dates for testing and for submission of each test procedure Test procedures shall be carefully planned to ensure that the work can be executed in the time available. If the available time is restricted, this planning shall include contingency plans to be implemented if testing proceeds slower than anticipated or if defects are discovered that necessitate rectification and subsequent repeat testing, etc Immediately following the successful Integrated Testing & Commissioning of the system or any constituent part, the Contractor shall complete the appropriate commissioning records in the agreed format and submit 3 signed copies to the Employer s Engineer The Contractor shall include a complete schedule of all Integrated Testing & Commissioning records and their current status within the Monthly Progress Report Service Trial Service Trial is defined as the final test of the fixed equipment, the rolling stock, and the operational procedures including the final elements of the Tests on Completion to demonstrate that the system in its entirety can operate satisfactorily. The Service Trial is performed by the Employer with attendance by the Contractor under the Contract in order to achieve Employer s Taking Over of the Works. During this phase, the system will be run to the published timetable but without fare-paying passengers. This phase also allows for Validation of the training procedures in a real time environment. NMRCL MARCH

87 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Commissioning Team in conjunction with the Employer will develop the Service Trial Plan. Operations Department and will serve to organise and co-ordinate all onsite activities The particular requirements for tests to be undertaken during the Service Trial are prescribed in the PS The Contractor shall provide special and general attendance to the Employer and the Employer s Engineer during the Service Trial period as required by the PS The Contractor shall co-operate with the Employer and the Employer s Engineer and with all interfacing parties to ensure that the proposed Service Trial programme and schedule truly demonstrates that the full, specified performance requirements and operating parameters are achieved The Contractor shall review and comment on the Employer s Engineer s Service Trial Plan and shall identify specifications, standards, method statements, procedures, pass / fail criteria, to the Employer s Engineer for inclusion in the Plan The Contractor shall not interfere with the Service Trial tests and Validations in any manner. Any need for remedial works required to be performed by the Contractor shall be co-ordinated with the Employer and the Employer s Engineer in advance Immediately following the successful tests of the system or any constituent part during Service Trial the Contractor shall complete the appropriate commissioning records in the agreed format, submit 3 signed copies to the Employer s Engineer and may then apply for the Taking Over Certificate in accordance with the requirements of the GCC The Contractor shall include a complete schedule of all Service Trial records and their current status within the Monthly Progress Report. 9.5 Activity of the Employer and the Employer s Engineer The Employer and the Employer s Engineer will establish a Commissioning Team and a Site Co-ordination Team at appropriate stages of the Project. These teams will comprise representatives of all interested parties including not more than two representatives of the Contractor, subject to review by the Employer and the Employer s Engineer. In accordance with the Commissioning Plan, the Commissioning Team shall advise and plan to co-ordinate the activities of the Contractor to ensure the Employer and the Employer s requirements are met The Contractor shall participate in the activities of the Commissioning Team and Site Coordination Team in addition to its own testing and commissioning or as directed by the Employer or the Employer s Engineer. 9.6 Records and Reports The Contractor shall submit to the Employer s Engineer for review not less than six (6) months before commissioning activities commence his proposed format for the NMRCL MARCH

88 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification commissioning records. The records shall be appropriately sub-divided to make provision for the various parts of the Permanent Works covered by the Contract The format of the records shall cover all mechanical and electrical tests, provide positive identification by serial number for assemblies and sub-assemblies of the Permanent Works and show modifications to Employer s Drawings and diagrams or "as built" data to be certified by the Employer or the Employer s Engineer in the course of installation, testing and setting to work of the Works The Contractor shall, during the execution of the Works, prepare such reports and records of design, manufacture, installation and testing as may be required in order that a licence may be issued or statutory requirements may be met or approval given. Such reports or records shall be adequate to enable each part of the Permanent Works to be commissioned and to meet the requirements of the licensing authority or any standing statutory regulations, and shall be reviewed by the Employer and the Employer s Engineer The Contractor shall obtain reports of each inspection and/or test. Such reports shall show the results of all the inspections and/or tests carried out and shall certify that the work has been inspected and/or tested in accordance with the requirements of the Contract and that the work complies with the requirements of the Contract Any analysis of the results required to confirm that the work complies with the requirements of the Contract shall be compiled and reported to the Employer s Engineer in accordance with Chapter A representative of the Contractor who has been allocated the required authority under the relevant quality plans shall sign each report of inspection and/or test Each report of inspection and/or test shall include the appropriate details of:- (1) the description of the item or goods subjected to the test or Inspection; (2) if applicable, the batch from which the samples were taken for test, the size and description of samples and the method of sampling; (3) the place of testing; (4) the date and time of tests; (5) the environmental conditions; (6) the technical personnel supervising or carrying out the test or inspection; (7) the properties tested or inspected; (8) the method of testing or inspection; NMRCL MARCH

89 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (9) all relevant checklists and work sheets used during the inspection and/or test, including the readings and measurements taken during the tests; and (10) the test results, including any calculations and graphs After Commissioning of a part of the Works, the Contractor shall complete each commissioning record in the agreed format and shall forward copies of the record to the Employer s Engineer for review The Contractor shall submit within its Monthly Progress Report a complete schedule of his commissioning records showing completion dates, target completion dates and status Timing for Reports of Inspection and/or Test The Contractor shall ensure that a signed copy of each report of inspection and test is filed in his filing system within 3 (three) working days of the date of inspection and test Quality Control Register The Contractor shall provide and maintain at all stages of the work a quality control register or registers to identify the status of inspections, sampling and testing of the work and all certificates in accordance with Quality Control Register in Chapter Summaries of Inspection and/or Test The Contractor shall submit to the Employer s Engineer for his information summaries based on each quality control register showing the type and amount of certification received and the inspection and/or testing undertaken on each element of the Works. Such summaries shall reach the Employer s Engineer s office before the 7 th working day of the month. The summaries shall identify and demonstrate the compliance of such certification, inspection and/or testing with the requirements of the Contract and shall identify any item which does not conform to the requirements of the Contract. 9.7 Test Equipment and Facilities The Contractor shall provide all equipment and services required for testing, including, but not limited to: i. Laboratory test instruments. ii. Special test equipment, emulators, simulators and test software, to permit full testing of System functions and performance. iii. iv. Other items of the System, specified elsewhere as being part of the Contractor's supply, even if not part of the Subsystem under test. Consumables. NMRCL MARCH

90 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification All test instruments shall be subject to routine inspection, testing and calibration by the Contractor Details of all test instruments shall be submitted for review by the Employer s Engineer and, if required by the Employer or the Employer s Engineer, shall be calibrated at the expense of the Contractor by an independent standards laboratory All test equipment must be capable of operating from the mains supply (230V AC 50Hz) All test software shall be subject to formal quality assurance requirements stipulated elsewhere in the Specification The Contractor shall ensure that all inspection and test equipment is calibrated in accordance with the specified standards or, if such standards are not applicable to certain test and inspection equipment, with systems and programmes of calibration which have been reviewed without objection by the Employer s Engineer The Contractor shall ensure that documented evidence of instrument calibration is maintained and made available to the Employer or the Employer s Engineer on request. 9.8 Witnessing by the Employer and the Employer s Engineer Notice for Trial, Inspection and/or Test to the Employer s Engineer In relation to all Quality Control Points and Quality Hold Points involving inspection and/or testing by the Contractor, the Contractor shall give the Employer s Engineer notice of when the relevant work will be inspected and/or tested using the form in Appendix 6 of this Specification. The period of notice shall be as stated in the PS or such period as in the opinion of the Employer s Engineer is reasonable and notified to the Contractor. In the absence of any such statement or notice, a reasonable period of notice shall be given by the Contractor provided that: (1) in the case of on-site work, such notice shall be given not less than 72 hours of normal working time before the work is to be inspected and/or tested; (2) in the case of work carried out off-site in Nagpur such notice shall be given not less than 5 days before the work is to be inspected and/or tested; and (3) in the case of work carried out outside Nagpur such notice shall be given not less than 14 working days before the work is to be inspected and/or tested In relation to all inspection and/or testing notified by the Contractor, the Employer and the Employer s Engineer may elect to witness such inspections and/or tests but the Contractor may proceed with the inspections and/or tests notwithstanding the absence of the Employer or the Employer s Engineer or of any response to the said notice If the Contractor is in any doubt whether inspection and/or testing by the Employer s Engineer is required as a Quality Hold Point, the Contractor shall request that the NMRCL MARCH

91 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Employer s Engineer clarifies his requirements prior to submitting the relevant inspection and testing plan for review, and in any event not later than 30 days Timing for Inspection and/or Test by the Employer and the Employer s Engineer The Contractor shall allow the Employer and the Employer s Engineer a reasonable time to carry out any inspection and/or testing and to assess the result of any inspection and/or test before proceeding with the Works Unless the Employer s Engineer s prior review without objection has been obtained, all inspections and/or tests to be carried out or witnessed by the Employer and the Employer s Engineer shall be carried out between 0800 and 1800 hours Failure to Notify the Employer s Engineer 9.9 Failures The Employer or the Employer s Engineer may reject the test and test results in question, and require the test to be repeated in the event of any failure by the Contractor to notify the Employer s Engineer in accordance with clause above The Contractor shall correct all faults found during testing, and shall arrange for the relevant tests to be repeated. The relevant tests shall only be repeated when the fault has been remedied and the equipment demonstrated to function correctly Where remedial measures involve significant modifications that might, in the Employer s Engineer's opinion, affect the validity of earlier tests, the Contractor shall repeat the earlier tests and obtain results satisfactory to the Employer and the Employer s Engineer before repeating the test in which the fault was first identified The Employer or the Employer s Engineer shall have the right to order the repeat or abandonment of any test in the event that results demonstrate that the equipment is significantly non-compliant with the Contract The Employer or the Employer s Engineer shall have the right to suspend any test in the event that errors or failures have become unacceptable. The Employer or the Employer s Engineer shall also have the right to suspend any test if a fault was detected by the Contractor but not reported to the Employer s Engineer within 24 hours of the detection. In this event, the suspension shall remain in effect until reporting has been brought up to date to the satisfaction of the Employer and the Employer s Engineer Repeat Tests The Contractor shall correct and re-test every fault detected during the tests If the test results in a failure of the item under test the provisions of GCC shall apply Fault Categories NMRCL MARCH

92 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Employer s Engineer will allocate a category to each fault, which shall determine the future conduct of tests. Test categories shall be as defined in Table 9.1 Category Description 0 An item recorded as a fault during testing, and subsequently considered as being a normal acceptable occurrence. Testing may continue. 1 Minor fault. An event not affecting the functionality being tested in that session. Testing may continue. Category Table 9.1 Fault Categories Description 2 Repeatable fault not affecting the functionality being tested in the session. Testing may continue at the discretion of the Employer s Engineer. 3 Repeatable fault affecting the functionality being tested in the session. The fault must be rectified before retest of the affected test session or sessions. Testing may proceed on other sessions if permitted by the Employer s Engineer. 4 Major fault affecting the functionality being tested in the session. The fault must be rectified before recommencing testing. 5 Non repetitive fault affecting functionality being tested in the session. The action taken will depend on the severity of the fault. Discussion is needed to establish the most appropriate course of action. 6 Documentation error or deficiency. The error will usually be amended during the test and the test will continue. The documentation shall be corrected before the tests are considered complete. 7 Deficiency in the ability of the test or test equipment to demonstrate the functionality being tested in the session. Discussion is needed to establish the most appropriate action. 8 Other fault not covered above, but requiring explanation and, in some cases, correction Fault Log The Contractor shall maintain a fault log throughout each series of tests. Every fault detected during the tests will be entered in the log, together with the actions taken to clear and re-test the fault. NMRCL MARCH

93 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The fault log will be retained as part of the permanent quality assurance record for the system and be subject to regular inspection by the Employer s Engineer Hardware Failure Reports For each hardware failure that occurs at any stage of testing, the Contractor shall investigate the failure and prepare a report on its cause(s) and design implications, if any, resulting from such failure. The report shall clearly show: (1) the observed symptoms; (2) the most likely cause of the failure; (3) the fault category (from Table 9.1 ); (4) an analysis of any stress that may have been caused to other components of the equipment being tested as a result of the failure; (5) whether the failure is a result of any component operating outside its design range; and (6) whether any design changes should be made to avoid further failures All such reports will be retained as part of the permanent quality assurance record for the system, which shall be subject to inspection by the Employer s Engineer Software Failure Reports For each software failure that occurs, once the software has been reviewed without objection for inclusion into the system and is subject to configuration control, the Contractor shall generate a software failure report All such reports will be retained as part of the permanent quality assurance record for the system, which shall be subject to inspection by the Employer s Engineer The report shall clearly show: (1) the observed symptoms; (2) the likely cause; (3) the fault category (from Table 9.1); (4) the operator input The report shall also clearly show the following information which shall be entered when the failure has been investigated: (1) the actual cause of the failure; (2) the corrective action taken; and (3) all software modules affected. * End of Chapter * NMRCL MARCH

94 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER TRAINING AND TRANSFER OF TECHNOLOGY 10.1 Training Requirements The Contractor shall provide comprehensive training to the Employer s staff to enable all of the systems and equipment supplied, installed or modified as part of the Works to be operated and maintained in the designed manner safely and efficiently so as to achieve the maximum reliability and economy, and to meet the requirements of the Employer s programme The recommendation shall include details of training equipment necessary and appropriate to achieve the training objectives The Training Plan shall provide a structured training programme to educate and train the personnel of the Employer in all aspects of the system operation and maintenance and shall include, but not be limited to, the following: (1) Objective, syllabus, format, class size and duration of each training course; (2) training facilities to be provided by the Employer; (3) list of training materials and documentation to be included with the training course; (4) method of pre- and post- testing to be utilised; Courses offered shall be suitable for operations and maintenance staff classified below as distinct from engineering design staff: (1) first line and second line maintenance staff undertaking recovery/corrective and routine/preventive maintenance; (2) third line (high skill level) maintenance staff specialised in workshop repair and overhaul of equipment; and (3) technical support staff specialising in fault analysis and investigation techniques associated with the particular type of equipment Training shall, as a minimum, impart the following techniques to the Employer s staff of the appropriate grades: (1) all planned maintenance and overhaul of the systems and equipment supplied, installed or modified under the Contract; (2) fault finding and rectification techniques for the systems and equipment supplied, installed or modified under the Contract. These shall be developed from the Contractor s previous experience with similar equipment and also from the fault tree NMRCL MARCH

95 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification analysis and other analyses carried out as part of the reliability engineering studies undertaken by the Contractor; (3) normal and degraded modes of operation of the systems and equipment supplied, installed or modified under the Contract; (4) all rules, regulations, practices and procedures necessary for the safe and efficient operation of the systems and equipment supplied, installed or modified under the Contract; and (5) all contingency plans necessary to recover speedily and safely from any mishaps or emergencies that may arise with the systems and equipment supplied, installed or modified under the Contract Training shall be carried out in the medium of the English language and supplemented, if necessary, in the Hindi language During the Defects Liability Period, when the Contractor is responsible for fault-finding and repair, he shall provide practical hands on training to the Employer s maintenance staff to facilitate the successful handover of this function Training Plant & Equipment With the prior review of the Employer s Engineer, the Contractor may use the Permanent Works being erected, tested or commissioned for the training of the Employer s staff. In general, the Contractor shall not use Contract Spare parts for this purpose Training course notes shall be entirely compatible, and, where appropriate, crossreferenced to the manuals supplied by the Contractor as part of the Operation and Maintenance documentation The Contractor shall provide such written or printed matter, functional equipment, samples, models, cutaway equipment, slides, films and other instructional materials as may be necessary for training. Such equipment and material shall remain the property of the Employer and shall be sufficient both for the persons trained by the Contractor and for those to be subsequently trained by the ETI All training course notes and instructor s guides shall be in a form that allows for easy reproduction All training course notes and instructor s guides shall be in a standard format as set out by the Employer If the Employer s Engineer considers that the course has not achieved the required objectives, he will advise the Contractor who shall then organise and implement appropriate re-training The Contractor shall, at the completion of each training course: (1) provide the Employer s Engineer with a consolidated training record listing the training course title, date of training, name of all trainees, training result and other relevant information; and NMRCL MARCH

96 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (2) issue an appropriate certificate to each trainee who has successfully completed the course Transfer of Technology Deleted End of Chapter NMRCL MARCH

97 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER OPERATION AND MAINTENANCE DOCUMENTATION 11.1 General The Contractor shall supply Operation and Maintenance documentation in respect of the systems and equipment supplied or installed or modified under the Contract in accordance with the requirements of the following clauses, except where expressly specified otherwise in the Contract All Operation and Maintenance Manuals produced by the Contractor shall conform to the requirements of the Employer. The Contractor shall interface with the Employer for the requisite format The Contractor shall supply all documentation, including Operation and Maintenance Manuals and as-built drawings, necessary for operating, maintaining, repairing and modifying the systems and equipment supplied, installed or modified under the Contract Except where otherwise stated, the Contractor shall provide one electronic copy, eight bound copies and one unbound copy of all documentation. The unbound copy will be used by the Employer for reproduction purposes. All documentation shall be in the English language The Operation and Maintenance Manuals shall be provided in the English language The Contractor shall fully co-ordinate and cross-reference interfaces and areas associated with interconnecting equipment and systems within the Contract. The Operation and Maintenance Manuals shall fully describe the overall operation of all systems incorporating all equipment The Operation and Maintenance Manuals shall contain no irrelevant or ambiguous information and shall relate specifically to this Contract The Contractor may use manufacturer s data and handbooks for individual items of E&M equipment that are a sub-component of the overall system, including printed circuit boards, providing they meet the intent of the Specification, and are integrated by the Contractor into the description of his equipment, and are indexed accordingly in his own general index. All such documentation shall be contained in similar binders Where a sub-assembly item is of such a nature that local repairs in Nagpur/India cannot be made and it is necessary to be returned to the manufacturer as a unit for overhaul, NMRCL MARCH

98 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification the specific information concerning its repair and breakdown into component parts shall be provided Arrangement and Format of Manuals The Contractor shall arrange all documentation in accordance with the Employer requirements The Contractor shall provide documentation for all hardware and software for computer systems and other associated electronic equipment to meet the following requirements. Such documents shall include but not be limited to: (1) manufacturers documentation supplied as standard with the equipment; (2) hardware configuration with details of expansion capabilities and options; (3) Not Used (4) Not Used; Not Used. (5) flow charts, data flow diagrams and state diagrams as appropriate; 11.3 Drawings The Contractor shall submit such drawings as may be required for the operation and maintenance and repair of the Permanent Works by the Employer Information contained on the drawings shall include but not be limited to: (1) arrangement drawings for all sub-systems and individual items of equipment; (2) installation and fixing drawings for all sub-systems and individual items of equipment; (3) interface drawings for all sub-systems and individual items of equipment; (4) schematic drawings for all electrical, pneumatic, hydraulic, water and drainage systems; (5) sizes, material and finish of all fixtures and threads; (6) manufacturer's code, drawing and reference numbers; (7) wiring diagrams to BS EN 60617, BS 3939 and BS 376 including internal wiring of sealed unit items; (8) setting dimensions and tolerances; and (9) bill of materials. NMRCL MARCH

99 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Where instructed by the Employer s Engineer, drawings shall be supplied with Hindi language notation in addition to English. The Employer s Engineer will supply such Hindi notation to the Contractor Submissions The Contractor shall deliver all documentation to the Employer s Engineer by the date stated in the PS, or, if none is given, not later than six (6) months prior to the issue of the Taking Over Certificate for the Works (for the final draft version), and one (1) month prior to the issue of the Taking Over Certificate for the Works (for the final version). The delivery shall include a copy of the software and licence to operate the software to modify the manuals together with one set of CADD drawing files. The final manuals shall incorporate comments made by the Employer s Engineer on the draft manual Drawings shall be submitted to the Employer s Engineer as stated in the PS. The submission shall be in accordance with stage commissioning requirements specified in the Works Programme and shall include two 35mm microfilms and/or Compact Discs (CD) for each drawing Following the Employer s Engineer s review, the Contractor shall make a final submission of the complete Operation and Maintenance Manuals and as-built drawings in a form and in a quantity specified in the PS. The final submission shall be made not later than the date set by the Employer s Engineer. The type of binder used to bind the Operation and Maintenance documentation shall be of a design which will permit all changes and additions to the said documentation to be readily collated therein. The Contractor shall make such amendments to his submissions as may prove necessary during commissioning of the Permanent Works and the Defects Liability Period. Amendments found necessary during commissioning shall be completed within two months after the issue of the Taking Over Certificate for the Works. Subsequent amendments shall be completed two months prior to the issue of the Defects Liability Certificate Operation and Maintenance Manuals The Employer shall have the right to reproduce any part or the whole of any Operation and Maintenance Manual as he wishes for his O and M requirements. End of Chapter NMRCL MARCH

100 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER SUPERVISION AND PLANNING OF MAINTENANCE 12.1 Scope The Contractor shall be responsible for the supervision of maintenance of the equipment supplied under the Contract after the Employer s Taking Over of the Works or Part of the Works till DLP. The maintenance personnel shall be provided by the Employer The scope of maintenance activities shall include all scheduled and unscheduled maintenance required including all routine inspections and service overhauls at trackside, on trains and in workshops. Maintenance work shall include fault-finding following report of incidents and repair of items of equipment changed out in the course of fault rectification but excluding any Contractor s liability for work to be carried out under the requirements of the Defects Liability Period Maintenance Planning & Management Staff The Contractor shall undertake the necessary tasks in planning the maintenance activities to ensure that the reliability of the operating railway is upheld including but not limited to: (i) (ii) Provide recommendations in respect of procedures for repairs of electronic systems, including PCBs, and the scale of facilities required to be set up in the Depot and Workshops for this purpose. Efficient supervision of the maintenance, overhaul and repair activities of maintenance staff to ensure high quality work and productivity Supervisory Staff The Contractor shall provide supervisory maintenance staff who are experts in the first and third line faultfinding, maintenance and repair of the various systems supplied under the Contract The experts provided for supervision of maintenance shall have adequate qualifications and experience in the relevant discipline in the maintenance depots / workshops of existing metro type undertakings The deployment of the experts may not be continuous and they may be required to supervise the maintenance in short periods at the discretion of the Employer The experts shall be available in Nagpur at short notice to supervise the Employer s staff at any time during the Normal Operating hours and by arrangement to undertake extended investigations during Non-Revenue hours. End of Chapter NMRCL MARCH-16272

101 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER SUPPLY OF SPARE PARTS, SPECIAL TOOLS AND TEST EQUIPMENT 13.1 Details of supply The Contractor shall supply to the Employer for the Permanent Works, in accordance with the provisions of this Chapter, as part of the Works: (a) spare parts including (but not limited) sub-assemblies and those to be supplied by its subcontractors of any tier ("Spare Parts"); (b) special tools, jigs, fixtures and gauges and test equipment, including those to be supplied by it s subcontractors of any tier ("Special Tools and Test Equipment"), 13.2 Commissioning Spares In addition the Contractor shall keep on the Site throughout the installation, erection and commissioning periods, sufficient stocks of Spare Parts to enable immediate replacement of any item in the Permanent Works found to be defective or in any way in non-conformance with the Specification during the installation, erection and commissioning period ("Commissioning Spares") The Contractor shall supply and deliver the Commissioning Spares on or before the commencement of any Partial Acceptance Tests (PAT) or as defined in the PS The Contractor shall submit to the Employer s Engineer for review a list of all Commissioning Spares that shall be made available during the installation, erection and commissioning period The Contractor shall not be entitled to use any of the Contract Spares to replace any item in the Permanent Works during the installation, erection and commissioning periods Defects Liability Spares The Contractor shall keep sufficient stocks of Spare Parts in an off-site location in Nagpur throughout the Defects Liability Periods to enable rapid replacement of any item in the Permanent Works found to require replacement as part of the Contractor's obligations during the Defects Liability Periods ('Defects Liability Spares") Special Tools and Test Equipment The Special Tools and Test Equipment (together with the relevant calibration certificates) required to carry out all the functions described in the Operation and Maintenance Manual or as required by the PS shall be suitably packed and identified in accordance with Chapter 8 above, consigned to the Employer by the Contractor and delivered to the Employer in accordance with the Employer s Engineer's instructions not later than the date scheduled for stage commissioning. The extent of supply shall include protective carrying cases as may be appropriate for the storage and use of each item. NMRCL MARCH

102 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification All Special Tools and Test Equipment shall be supplied with Operation and Maintenance Manuals, complete diagrams, schematics, assembly and connection drawings, calibration instructions and circuit diagrams/descriptions for future maintenance Where the Contractor has used the Special Tools and Test Equipment for installation and commissioning of the Permanent Works, he shall refurbish and re-calibrate each item to the satisfaction of the Employer s Engineer prior to handover to the Employer, accompanied by the Certificate of Calibration traceable to a recognised International or National standard Where any item of Special Tools and Test Equipment is provided by the Contractor, it shall be accompanied by drawings, manuals and full operating instructions to enable them to be used by suitably skilled (but not necessarily specially trained) personnel in a non-hazardous manner and to achieve the desired result in terms of accuracy and quality The Contractor shall provide the means and instructions which describe the parameters of each item of Special Tools and Test Equipment that are critical to their proper methods of use and which enable the Employer's staff using the Special Tools and Test Equipment to achieve the proper performance and operation. Such means and instructions shall include, but not be limited to, any routine checking or recalibration needs for the Special Tool and Test Equipment itself Coding and Tagging of Spare Parts and Special Tools and Test Equipment All Spare Parts and Special Tools and Test Equipment to be delivered to the Employer shall each carry a tag suitably marked, bar-coded (as directed by the Employer s Engineer) and numbered The numbers on the tags shall correspond with those on the coding system developed by the Contractor for all E&M components, parts and equipment's. See also clause above. End of Chapter NMRCL MARCH

103 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER THE WORKS AND CARE OF THE WORKS 14.1 Methods of Construction The Contractor shall, as stated in the PS and in any case not less than 12 weeks before starting the construction of the Works on Site, submit to the Employer s Engineer the Construction and Installation Plan as specified in Chapter 3 above Temporary Works Upon receiving a written application from the Contractor, the Employer s Engineer may at his absolute discretion consent to certain Temporary Works of a minor nature being exempted from the requirements of this Chapter. Such exemption shall not relieve the Contractor of any of his obligations under the Contract Normal Working Hours Normal working hours shall be defined as the period between 0700 hours and 1900 hours on all days excluding General Holidays. Work outside normal working hours shall not be carried out unless reviewed without objection by the Employer s Engineer and unless the Contractor has obtained any necessary permission or approval from Relevant Authorities The Contractor shall inform the Employer s Engineer 24 hours, or such shorter period reviewed without objection by the Employer s Engineer, in advance of any occasion when work outside normal working hours is proposed Work in the vicinity of existing Indian Railway tracks shall only be possible in nontraffic hours. Non-traffic hours are from the time of passage of the last train at the close of traffic, to the commencement time of running of the next first train Drawings and Schedules Detailed manufacturing drawings for the Permanent Works will not normally be required to be submitted to the Employer s Engineer for review but shall be available on the Contractor s or his sub-contractor s premises if required. The Contractor shall also maintain at the Site a comprehensive and up-to-date set of drawings properly indexed and catalogued, which shall include complete sets of detailed working and, where applicable, manufacturing drawings and shall permit free access to such drawings by the Employer s Engineer at any reasonable time Notification and Inspection of Works The Works will be the subject of a formalised system of written applications for inspection. NMRCL MARCH

104 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Work that is carried out without being appropriately sanctioned by the Employer s Engineer could be classified as defective work Construction Restraints The Contractor shall design and implement Temporary Traffic Management (TTM) in accordance with the provisions of the Enactments The Contractor shall ensure that the design, construction and performance of all Temporary Works and the design and construction of all Permanent Works shall be such that any ground movements in and around the Site will not result in settlement and/or subsidence of the ground that will cause damage to any buildings, structures, rail, roads, footpaths, slopes or utilities The Contractor shall ensure that the method of installation of any part of the Permanent Works (prior to dewatering and excavation) minimises settlements in the adjacent ground or buildings. Dewatering of an excavation will not be permitted unless a closed perimeter of impermeable wall is complete The Contractor s design of dewatering methods shall as far as possible avoid lowering of the water table outside the excavations. The reduction in piezometric pressure shall in no case be greater than 2 metres in adjacent ground, unless the Contractor can clearly demonstrate that buildings, structures, roads, footpaths and utilities within the influence of the dewatering will not be damaged by the proposed dewatering. Pumping shall be confined within the boundaries of the excavation and the water level within the excavation shall not be lowered by more than two metres below the formation level Protection from Water Unless otherwise reviewed by the Employer s Engineer, all work shall be carried out, as near as may be practicable in the circumstances, in dry conditions, except where the work is required to be carried out in or with water or other fluids The Permanent Works, including materials for use in the Permanent Works, shall, where necessary and as near as may be practicable, be kept free of water and protected from damage due to water. Water on the Site and water entering the Site shall be disposed of by temporary drainage or pumping systems or by other methods capable of keeping the Works free of water and protected from damage due to water. Traps shall be provided by the Contractor to intercept silt and debris before water is discharged from the Site The discharge points of the temporary drainage and pumping systems shall be as those having been reviewed without objection by the Employer s Engineer. The Contractor shall make all arrangements with and obtain the necessary approvals and inspections from the Relevant Authorities for discharging water to drains, watercourses etc. The NMRCL MARCH

105 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification relevant work shall not start until the arrangements for disposal of the water previously reviewed without objection by the Employer s Engineer have been implemented Measures shall be taken to prevent flotation of new and existing structures Protection from Weather Work shall not be carried out in weather conditions that may adversely affect the work unless protection by methods reviewed without objection by the Employer s Engineer is provided The Permanent Works, including materials for the Permanent Works, shall be protected by methods reviewed without objection by the Employer s Engineer from exposure to weather conditions which may adversely affect the Permanent Works Protection of Work Finished work shall be protected by methods reviewed without objection by the Employer s Engineer from damage that could arise from the execution of adjacent work. Work shall be carried out in such a manner that work carried out by others, including Government departments, utility undertakings, Relevant Authorities and Project Contractors, is not damaged. End of Chapter NMRCL MARCH

106 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER SITE ESTABLISHMENT AND ATTENDANCE 15.1 Use of the Site The Site shall not be used by the Contractor for any purpose other than for executing the Works or carrying out other work which is associated with the Works and having been reviewed without objection by the Employer s Engineer Entry to and exit from the Site shall be obtained only at the locations stated in the Contract or other locations having been reviewed without objection by the Employer s Engineer All materials and equipment stored on Site shall be adequately protected against loss or damage due to any cause such as climatic effects, vandalism, shock and vibration, etc. according to the nature of the articles stored and the local Site condition The particular use to which the Site is put shall be submitted to the Employer s Engineer for review with the following particulars: (1) drawings showing the layout within the Site of the Employer s Engineer s and Contractor s accommodation, access roads and major facilities required early in the Contract; 15.2 Survey of the Site On or before the Contractor is granted access to a certain portion of the Site, the Contractor shall carry out a survey jointly with the Other Contractors executing works on that portion of the Site. The Contractor shall advise the Employer s Engineer of the date of the joint survey at least 1 week in advance of the date Fences and Signs on the Site Hoardings, fences, gates and signs on and at the Site shall be maintained in a clean, stable and secure condition Project signboards stated in the Contract shall be erected not more than 28 days, or such other period reviewed without objection by the Employer s Engineer, after the Commencement Date of the Works. Other advertising signs shall not be erected on the Site unless reviewed by the Employer s Engineer The permission of the Employer s Engineer shall be obtained before hoardings, fences, gates or signs are removed. Hoardings, fences, gates and signs which are to be left in position after Employer s Taking Over of the Works shall be repaired and repainted as instructed by the Employer s Engineer The Contractor s Site Accommodation NMRCL MARCH

107 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Contractor s offices, sheds, stores, mess rooms, latrines and other accommodation on the Site shall be maintained in a clean, stable and secure condition. Living accommodation shall not be provided on the Site unless stated in the Contract or having been reviewed without objection by the Employer s Engineer. The Contractor's personnel shall not be allowed to live on the Site The Contractor shall provide and maintain all necessary offices, sheds, stores, mess rooms, latrines and other accommodation and remove the same from the Site on the Employer s Taking Over of the Works. These shall be to the satisfaction of the Employer s Engineer and shall be kept in a clean and sanitary condition. No structure shall be erected by the Contractor within the Site without the written consent of the Employer s Engineer and such consent will not relieve the Contractor of the responsibility of sitting temporary structures clear of the Works A copy of the plan showing the extent and position of all offices, stores, sheds, etc.shall be prepared by the Contractor and retained for inspection in the Site office The works area for Contractor s accommodation will be available to the Contractor on dates set out in the PS, Employer s Drawings or Appendix 9 of this Specification The Contractor shall not erect or operate canteen and kitchen facilities on the Site except with the consent of the Employer s Engineer and, where appropriate, the Relevant Authorities. Any such facilities shall, in particular but without limitation, conform to all regulations and standards to the extent required by the concerned city authorities of GCDA Site Utilities and Access Not used If, under the Contract, the Contractor is provided with Site utilities and access by any Other Contractor under the attendance of the same or another Other Contractor, the Contractor shall ensure that all requirements in terms of use of such facilities, their upkeep and maintenance, etc. are properly observed. If the facilities provided under such attendance are insufficient for the Contractor s bona fide needs, the Contractor shall be solely responsible for providing such additional facilities he may require for the execution of the Works Access roads and parking areas shall be provided within the Site as required and shall be maintained in a clean, passable and stable condition Not used 15.7 Clearance of the Site Temporary Works, which are not to remain on the Site after the Employer s Taking Over of the Works, shall be removed on the Employer s Taking Over of the Works or at such other time(s) as instructed by the Employer s Engineer. The Site shall be cleared and NMRCL MARCH

108 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification reinstated to the lines and levels and to the same condition as existed before the Works started except as otherwise stated in the Contract Attendance Offices for the Employer or the Employer s Engineer Unless otherwise stated in the Contract, the Employer or the Employer s Engineer may supply his own temporary accommodation on the Site at locations indicated in the Contract or in writing. The Contractor shall afford, provide and maintain free and unhindered access to such Employer or the Employer s Engineer s Site offices and parking areas and for the Employer or the Employer s Engineer s Site officers, contractors and workmen as may be necessary for installation, inspection, maintenance, repair and removal of the aforesaid Employer or the Employer s Engineer s Site offices and the services thereto Attendance on the Employer or the Employer s Engineer The Contractor shall provide all necessary assistance to the Employer or the Employer s Engineer, including adequate and safe means of access to all parts of the Site to assist him in carrying out his duties and responsibilities under the Contract. Such assistance shall not include the provision of full-time attendance upon the Employer or the Employer s Engineer Attendance on the Commissioner of Rail Safety or other inspecting authorities The Contractor shall afford all necessary attendance upon the Commissioner of Rail Safety or other inspecting authorities Inspectorate during their inspections including adequate and safe means of access to appropriate parts of the Site The Contractor shall provide all documents necessary for inspection as are requested by the above authorities Attendance on the Fire Services Department The Contractor shall afford all necessary attendance upon the Fire Services Department to enable them to carry out such tests and inspections as are required by the Nagpur fire service of Practice for Inspection and Testing of Installations and Equipment and the requirements of any Other Contractors. Such attendance shall include adequate and safe means of access to all parts of the Site Attendance on Other Contractors The Contractor shall provide general and special attendance on Other Contractors who will be carrying out the execution of electrical and mechanical and other works on the Site. Reference shall be made to the PS to determine the full extent of such attendance General attendance shall include but not be limited to providing for accepting deliveries, unloading and storing materials for the Other Contractors on the Site and allowing the NMRCL MARCH

109 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Other Contractors space for their site offices, and all reasonable access and facilities for the proper execution of their work including the free use of access roads, craneage, scaffolding, ladders, stores, messrooms, sanitary and welfare facilities provided that these facilities are normally available on the Site at the time The Contractor shall allow the use of his Site services including ventilation, temporary water supply, temporary electricity supply, background lighting, pumping, watchmen, etc. by the Other Contractors. The Contractor shall ensure that his Site services referred to above shall be available for use by the Other Contractors until the commissioning of the relevant permanent installations or until the issue of the Taking Over Certificate for the Works, whichever is the later Special attendance shall include but not be limited to cutting of holes and other openings, forming chases, providing built-in sleeves, grouting in bolts, anchors, brackets, base plates, frames and the like, including making good to the disturbed work and cleaning after completion of the disturbed work Attendance by Other Contractors Where provided for under the Contract, the Contractor shall receive attendance from Other Contractors. The Contractor shall ensure that by receiving such attendance, it does not hinder, obstruct or otherwise frustrate the Other Contractor that is providing the attendance in any way Contractor s Equipment Security The Employer s Engineer reserves the right to order the immediate removal and replacement of any Contractor s Equipment that, in his opinion, is unsatisfactory for its purpose The Contractor shall be responsible for the security of the works area for Contractor s accommodation and shall provide and maintain fencing The Contractor shall provide adequate training to its security staff to ensure that they are able to discharge their security duties properly The Contractor shall establish and maintain contingency plans to cope with emergencies such as fire, flooding, serious damage to the Works, etc The Employer s security staff will conduct inspections and security audits on the Site and the works area for Contractor s accommodation from time to time. The Employer s Engineer will give recommendations for improvement arising from the inspections and security audits to the Contractor. However, managing the security of the Site and the works area for Contractor s accommodation remain the Contractor s responsibility. End of Chapter CHAPTER 16 NMRCL MARCH

110 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification 16. LIAISON WITH OTHERS 16.1 Liaison with Others The Contractor shall make all necessary arrangements with and obtain the necessary approvals from Government departments, utility undertakings and other duly constituted authorities for the execution of the Works The Contractor shall maintain close liaison with Other Contractors and other contractors employed by the Employer, utility undertakings or other authorities who are carrying out work on or adjacent to the Site. The Contractor shall ensure as far as possible that the progress of the Works is not adversely affected by the activities of such other entities Work by Other Contractors The contractor shall keep note of the works which may be proceeding on various adjacent areas by others include, but is not limited to, those listed in the PS. The Employer s Engineer will keep the Contractor informed of forthcoming work by Other Contractors in the proximity of the Site The Contractor shall provide reasonable access to such contractors and any other adjacent contractors and shall where necessary liase with the appropriate contractors, utility undertakings and other duly constituted authorities on details of interdependent phasing. The Contractor shall notify the Employer s Engineer and other concerned entities at least 14 days in advance should he wish to alter these access arrangements during the course of the Works Interface Management The Contractor shall co-ordinate with Relevant Authorities and Other Contractors in the execution of the Works The Contractor shall interface and liase with Other Contractors to ensure the effective and compatible co-ordination of all aspects of the design, installation and testing of the Works. The Employer s Engineer shall be kept fully informed at all stages of the Works The Contractor shall assign a person as the interface contact for each Other Contractor to actively manage the progress of each interface to ensure adherence to the jointly developed Interface Management Plan Throughout the design process, the Contractor shall liase with Other Contractors to develop interface designs in conjunction and co-operation with the designers of interfacing systems. Interfacing systems include, but are not limited to, those listed in the PS. These interface designs will be monitored and reviewed by the Employer s Engineer but the Contractor shall work directly with the Other interfacing Contractors to develop designs which are mutually acceptable to all parties. The Employer s Engineer will provide details of the Other Contractors as contracts are awarded. NMRCL MARCH

111 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Employer s Engineer may, at his discretion, attend the Contractor s meetings with Other interfacing Contractors. The Contractor shall give the Employer s Engineer a minimum of 7 days notice of all meetings to be held with any Other interfacing Contractors, or 14 days notice if the meeting is to be outside Nagpur. If insufficient notice is given to the Employer s Engineer, he may require the meeting to be postponed to a later date to enable him to attend The Contractor shall provide the Employer s Engineer with two copies of the minutes of all meetings within 14 days of each meeting and also two copies of all correspondence with any Other Contractor The Contractor shall attend co-ordination/design meetings chaired by the Employer s Engineer at no greater than monthly intervals to discuss and ensure that designs are correct and that conflicts in E&M services requirements between the Contractor and Other Contractors are identified and resolved The Contractor shall co-ordinate his installation activities with the Other Contractors. The Contractor shall ensure that there is no interference to the work of the Other Contractors and shall maintain close co-ordination with Other Contractors working on or adjacent to the Works to ensure that their work can progress in a smooth and orderly manner The Contractor shall be given access to the various parts of the Site by the dates relative to the Works Programme defined in the ITT and the PS as Access Dates. The ITT and the PS specify certain Key Dates by which the Contractor shall complete certain parts of his Works to enable work to be undertaken by the Other Contractors. These dates may be subject to adjustment by the Employer s Engineer in consultation with the Contractor and the Other Contractors to ensure the progress of the Project The Contractor's responsibility shall include provision of and receipt from Other Contractors or the Employer s Engineer of information required for construction of the Works and the installation of the Works and Contractor's Equipment, insofar as that requirement is specified in or can reasonably be inferred from the Contract. Where the execution of work by a Other Contractor depends upon the Contractor s Site management or upon information to be given by the Contractor, the Contractor shall provide the Other Contractor with either the required services or the correct and accurate information required to enable the Other Contractor to meet his programme for the construction or installation of his works In the event of any disagreement as to the extent of services or information required to be exchanged between the Contractor and a Other Contractor, the Employer s Engineer shall determine the requirements and this determination shall be final and binding on the Contractor and the Other Contractor The Contractor shall co-ordinate his testing and commissioning activities with the Other Contractors. The Contractor shall ensure that there is no interference to the work of the NMRCL MARCH

112 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Other Contractors and shall maintain close co-ordination with Other Contractors working on or adjacent to the Works to ensure that their testing and commissioning work can progress in a smooth and orderly manner. End of Chapter NMRCL MARCH

113 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER THE SITE 17.1 Access to Site The Contractor will be given access to the Site in accordance with following conditions Site Restrictions The particular use to which the Site is put shall be submitted to the Employer s Engineer for review within 14 days of the Commencement Date of the Works and the Contractor shall: (1) confine his use of the areas of the Site to purposes having been reviewed without objection by the Employer s Engineer who reserves the right to extend, amend or restrict the uses to which areas of the Site will be put; (2) where required under the Contract, provide and maintain fencing and lighting around and within the areas of the Site when or where necessary for the safety and convenience of the public or others or as directed; (3) refrain from depositing rubbish or causing nuisance or permitting nuisance to be caused and, except where reviewed without objection by the Employer s Engineer, depositing earth on or removing earth from areas of the Site; (4) on the Employer s Taking Over of the Works, or earlier if so instructed by the Employer s Engineer, remove all Temporary Works except where permitted and reinstate the areas of the Site to the extent, standards and details indicated in the Contract or as directed by the Employer s Engineer; (5) refrain from obstructing manholes, utility access points and the like; and (6) refrain from felling trees, other than those specifically identified in the Contract to be felled, and refrain from depositing earth around the trunks of trees and protect all trees remaining on Site to the satisfaction of the Employer s Engineer Work other than that necessary for completion of the Works shall not be carried out on the Site While the Contractor is being given access to the Site, he shall provide means of distributing loads imposed by Contractor s Equipment and prevent damage to utility services Except where otherwise provided, the Contractor shall not permit any person to reside on the Site. NMRCL MARCH

114 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Unless otherwise stated, the Contractor shall pay all rates and charges of any nature whatsoever arising out of his use of the Site and all work areas provided therein under the Contract The location and size of stockpile material, including excavated material within the Site, shall be submitted to the Employer s Engineer for review. All stockpiles shall be maintained at all times in a stable condition The Contractor shall not allow animals to be brought onto or kept on the Site The Contractor s attention is drawn to the Waste Disposal Regulation currently prevalent in Nagpurregarding storage, transportation and disposal of chemical waste. The Contractor s proposed methods and chemicals to be used in cleaning shall be submitted for review by the Employer s Engineer No rock crushing or screening facilities shall be set up on Site unless reviewed by the Relevant Authorities and reviewed without objection by the Employer s Engineer Site Services Where required under the Contract, the Contractor shall provide all Site services as necessary and appropriate for the construction of the Works, which shall include, but not necessarily be limited to: (1) electricity; (see Chapter 22 below) (2) water; (3) compressed air; (4) Site communication facilities; and (5) temporary drainage and sewage disposal The Contractor shall provide such services for use solely in connection with the proper execution of the Works. The Contractor shall comply with all regulations of the utility companies and Government departments concerned. The Contractor shall provide and maintain installations associated with such services and in relation thereto and shall take all reasonable precautions to safeguard the safety and health of all persons and the security of the Site. The Employer s Engineer may demand the immediate disconnection or alteration of such installations or portions thereof he considers as being prejudicial to safety, health or security. As soon as any or all of the Contractor s installations are no longer required for the execution of the Works, they shall be entirely removed to the satisfaction of the Employer s Engineer All installations shall comply fully with all appropriate statutory requirements. Pipes, tubes, ducts or cables crossing highways, footpaths or rights of way shall be ramped over or recessed below the surface. Specific services shall comply with the following:- (1) Electricity (2) Water The electricity supply shall comply with the requirements of Chapter 22 below. NMRCL MARCH

115 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification An adequate supply of potable water shall be provided at the Site, including provision to the satisfaction of the Water Authority of any storage tanks so that sufficient potable water is always available for the execution of the Works. Suitable provision shall be made where the Water Authority requires the use of salt water for flushing purposes. (3) Compressed Air Except in pressurised workings, the compressed air supply for pneumatic tools and equipment shall be at a pressure of not more than 0.9MN/m 2. The Contractor shall submit for review by the Employer s Engineer details of proposed air supply for use in pressurised workings. (4) Site Communication Facilities Where required under the Contract, the Contractor shall install efficient means of Site communications including messenger, telephone and, where appropriate, two-way radio to the satisfaction of the Employer s Engineer. (5) Temporary Drainage & Sewage Disposal Where required under the Contract, adequate provision shall be made for the discharge or disposal from the Site of all water, surplus fluid sewage and waste products and the method of disposal shall be submitted to the Employer s Engineer for review. The Site shall be kept well drained and free from standing water. Where existing channels and gullies cannot be maintained, temporary drainage arrangements shall be provided The Employer s Engineer will instruct the Contractor as to the requirements for Site services to be connected to the Employer s Engineer s portable Site accommodation at any given location and the Contractor shall provide and maintain these services during his use of the Site Site Cleanliness The Site shall be maintained in a clean and tidy condition. Materials, including materials required for Temporary Works shall be stored in an orderly manner. Rubbish, debris, cement bags, disused formwork and the like shall be disposed of at least once a day and the work area cleaned by flushing with water as necessary so that the Site is kept constantly clean and tidy. Notwithstanding the above, the Contractor shall place rubbish bins at strategic locations about the Site. The Contractor shall throughout the period of the Contract provide a central collection point on Site, as reviewed without objection by the Employer s Engineer, for collecting all empty cans, drums, packing and other receptacles capable of holding water. The Contractor shall procure the regular collection and removal of such debris from the Site. After every shift of works, all work areas shall be cleaned and made tidy to the satisfaction of the Employer s Engineer. NMRCL MARCH

116 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Contractor shall ensure that no earth, debris, rock or empty cable drums are deposited on public or private rights of way as a result of the Works, including any deposits arising from the movement of Contractor s Equipment. All roads, both within and external to the Site which are affected by the Works shall be kept in a clean condition by the Contractor. All haul roads shall be regularly graded and watered, as necessary to minimise dust nuisance Where required under the Contract, the Contractor shall provide and maintain a patrol unit for the duration of the Contract. The unit shall comprise 1 foreman and 2 labourers whose services shall be allocated full-time to the unit. The main duties of the patrol unit shall include the upkeep of lighting, signage and security as well as other related duties as instructed from time to time by the Employer s Engineer The patrol unit shall be required to work outside the Contractor s normal working hours if so required by the Employer s Engineer The Contractor shall provide all necessary protective clothing, safety equipment, hand tools, ladders, trestles, power supply, replacement equipment and the like for the exclusive use of the patrol unit Prevention of Mosquito Breeding Measures shall be taken to prevent mosquito breeding on the Site. The measures to be taken shall include the following: (1) empty cans, oil drums, packing and other receptacles which may retain water shall be deposited at a central collection point and those not required for future use shall be removed from the Site regularly; (2) standing water shall be treated at least once every week with an environmental acceptable oil which will prevent mosquito breeding; and (3) Contractor s Equipment and other items on the Site that may retain water shall be stored, covered or treated in such a manner that water will not be retained Posters in both English, Marathi and Hindi drawing attention to the dangers of permitting mosquito breeding shall be obtained from the Nagpur Government and displayed prominently on the Site, to the requirement of the Enactments. These posters shall be removed on Employer s Taking Over of the Works Prevention of Dust Work shall be carried out in such a manner that avoidable dust is not generated. Areas of the Site in which dust is likely to be generated shall be sprayed with water regularly. Screens, dust sheets, tarpaulins or other methods reviewed by the Employer s Engineer shall be used to prevent generation of dust. Materials, including earthworks material, from which dust may be generated when being transported to or from the Site shall be sprayed with water or covered. The location and size of material stockpiles, including NMRCL MARCH

117 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification excavated materials within the Site, shall be subject to review by the Employer s Engineer. All stockpiles shall be maintained at all times in a safe manner Engineering Conditions for Temporary Land Allocation The Contractor shall comply with the obligations, requirements and restrictions described in the PS in respect of the Contractor s work areas if any Attendance by Civil Works Project Contractor Where supplies of electricity, water, compressed air, temporary ventilation, temporary lighting, etc. are installed by the Civil Works Project Contractor for use during construction of the structural components of the Project, these services may be made available to the Contractor for his own use during erection, installation and testing of the Works in accordance with Chapter 22 below The Contractor shall supply the Employer s Engineer with its requirements (if any) for such services within 90 days of the Commencement Date of the Works. Upon receipt of the Contractor s declaration, the Employer s Engineer will ascertain whether any of these requirements can be satisfied by the installations installed by the Civil Works Project Contractor. The Employer s Engineer will subsequently notify the Contractor of the result of these investigations Where services are required and are not available from the Civil Works Project Contractor, the Contractor shall provide, test, maintain and subsequently remove the services Background lighting to an average level of 50 lux at the walkway level will be provided in the tunnels by the Civil Works Project Contractor. The Contractor shall provide any additional lighting he may require to facilitate his own work or for reasons of safety Access to the Site by Other Contractors Due to the multi-discipline nature of the Project, several different parties may require access to the same portion of the Site during the construction phase for the installation, erection and testing of the Works. To facilitate the organisation and coordination of access and occupation requirements, including the use of Works Trains, if any, the Employer s Engineer will issue and maintain a TRIP as referred to in clause 2.13 above The TRIP will be developed from the declared requirements of all Project Contractors and others having need of access and occupancy, at the weekly Works Train Meeting. The TRIP will be subject to revision and updating to reflect changing circumstances during the progress of the Project The Contractor shall work in accordance with the arrangements prescribed by the TRIP The Contractor shall ensure that his working arrangements on the Site conform to the agreements made with the Employer s Engineer during establishment of the TRIP requirements. In particular, the Contractor shall ensure that his occupancy does not extend either physically or chronologically beyond the agreed boundaries. NMRCL MARCH

118 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Transportation to Site The Contractor shall use such routes and rights of entry to the Site as may be decided by the Employer s Engineer from time to time. Routes for very large or very heavy loads shall be discussed with the Employer s Engineer in advance of the need arising and all arrangements therefore shall be submitted for review by the Employer s Engineer In this context, the definition of the terms very large and very heavy refer to articles that cannot be transported by normal road vehicles or be handled by readily available methods. Where doubt exists, it shall be the responsibility of the Contractor to notify and discuss the nature of the load in question with the Employer s Engineer in accordance with clause above The Contractor shall comply with the requirements of the Commissioner of Transport and /or the Commissioner of Police and / or any other Relevant Authority regarding any special traffic arrangements that may be necessary. The Contractor s attention is drawn to the Road Traffic (Regulation and Licensing of Vehicles) Regulations and the Road Traffic (Construction and Use) Regulations currently in use at Nagpur Extraordinary traffic may be moved from docks and between areas of the Site over public highways only by police escort and on a route and at a time determined by the Relevant Authority. The Contractor shall be responsible for obtaining permission from the Relevant Authorities to move extraordinary loads and traffic and for arranging police escorts as necessary The Contractor shall make all arrangements and assume full responsibility for transportation to the Site of all Contractor s Equipment, materials and supplies needed for the proper execution of the Works While travelling to and from the Site, the Contractor shall observe all posted speed limits, traffic regulations, stop signs, etc., and adherence to the access route indicated on the Employer s Drawings or as instructed by the Employer s Engineer. No employee of the Contractor shall trespass into any part of the Employer's premises other than the Site or the designated route of access The Contractor shall ensure that all roads and pavements, etc. leading to and around the Site are kept free from obstructions and shall not cause inconvenience or hindrance to traffic or persons either by its vehicles or by its workmen, scaffolding, plant, materials, equipment, etc The Contractor shall repair damage to existing roads, footpaths, steps, cables, sewers, live drains, etc. and shall reinstate any damage caused by the Contractor s actions Contractor s Own Rolling Stock Where the Contractor is to provide rolling stock (either self-propelled or trailing) for use during the installation and testing of the Works, the requirements of clause below shall apply. All the Contractor s own rolling stock shall not exceed the Construction NMRCL MARCH

119 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Vehicle Load Gauge as shown in the Specification Drawings except with the Employer s Engineer s written consent The Contractor shall submit full details of any rolling stock that is to be used during the installation and testing of the Works to the Employer s Engineer for review within 90 days of the Commencement Date of the Works. Such details shall include a full description and drawings of the rolling stock, details of axle load, stopping distance, failsafe braking system, kinematic envelope, and operating and maintenance instructions The Contractor shall maintain its own rolling stock during the installation and testing of the Works. The maintenance work shall be carried out by qualified and experienced personnel, whose qualifications have been reviewed without objection by the Employer s Engineer, in accordance with the maintenance procedures that shall have been reviewed without objection by the Employer s Engineer Prior to use, and following each maintenance examination, the Contractor s qualified engineer shall certify the Contractor s own rolling stock as fit-to-run. Thereafter, the Contractor s qualified engineer shall issue a registration tag. The expiry date, i.e. the date of the next inspection, shall be shown on the registration tag. The Contractor s own rolling stock shall not be used without a valid registration tag The Contractor shall establish a maintenance programme for his own rolling stock and shall submit the maintenance programme for review by the Employer s Engineer prior to the delivery of his own rolling stock to the Site. The Employer s Engineer will periodically inspect the Contractor s own rolling stock to ensure it is properly maintained to the standards set out in the maintenance programme If the Contractor s own rolling stock is found to be operating in an unsatisfactory or unsafe condition, it shall be immediately removed until it has been restored to an acceptable condition to the satisfaction of the Employer s Engineer Defined Area Working and Works Train Operations When the Project under construction has been made available for track related electrical and mechanical installation works, the area will be classified as a Defined Area within which Works Trains will be operated All persons whose duties require them to work within a Defined Area must observe safety rules and procedures to be provided by the contractor and reviewed without objection by the Employer s Engineer. It shall provide procedures and guidance for the safety of all persons in the Defined Area The Contractor shall establish communicate the rules and procedures, which shall be published from time to time, to their workers and/or agents on Site, and to ensure all such rules and procedures are being observed in the course of all works and construction activities. NMRCL MARCH

120 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Persons working on or near tracks in a Defined Area, either by themselves or supervising a working party, must be suitably trained and qualified by the Employer or his delegates in the safety provisions of the Works Train Manual. Persons who are not qualified shall not attempt to gain access to the railway tracks unless accompanied by a qualified person When overhead lines are energised, EMUs may be running at high speed for testing. No work may be undertaken on either the Up or Down tracks when test trains are running. Procedures for gaining access to the energised track will be detailed in the Works Train Manual. The Contractor shall make requests for gaining access to the energised track at the weekly Works Train Meetings Work in Vicinity of Operating Tracks T This Paragraph shall apply to works in the vicinity of the existing Metro Railway tracks after the commencement of revenue operations and all ancillary areas which form a part of the operating system, including all depots and sidings The following words and expressions shall have the meaning hereby assigned to them in this Paragraph: (1) Railway means the existing rail tracks of the Nagpur and Southern Railway after the commencement of revenue operations and any ancillary areas such as the depots, sidings, stations, terminus and traction power stations. (2) Railway Representative means a person, or persons, nominated by the Employer s Engineer to liase with the Contractor and the Employer s Engineer on matters affecting the operation of the Railway. (3) Restriction means speed restriction, which is a limitation of the normal permitted speed of rail traffic over a specified length of the Railway. (4) Possession means possession of the Railway, which is the closing of a specified length of the Railway to rail traffic. (5) Isolation means isolation and earthing of the electrical equipment, which is the disconnection of a section of such equipment from all sources of electricity supply and the connection of it to the Railway The Contractor shall have regard to the Specification for work within the vicinity of the Railway and shall comply strictly with the requirements as set out therein. The Contractor shall comply with any instructions given by the Employer or the Railway Representative through the Employer s Engineer with regard to planning, methods of working, safety requirements and on any other matters which may affect the operation of the Railway, and also shall comply with all rules, regulations, procedures, manuals and notices which may be published from time to time by the Employer or the Railway Representative. Provided that if a situation occurs which in the opinion of either the Contractor or the Employer or the Railway Representative may give rise to or actually constitute an emergency and either the Contractor or the Employer or the Railway Representative considers that it is not practicable to communicate through the NMRCL MARCH

121 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Employer s Engineer then the Contractor and the Employer or the Railway Representative may communicate directly and the Employer or the Railway Representative may give a direct instruction to the Contractor and such instruction shall be regarded for the purposes of this Contract as an instruction from the Employer s Engineer Should the Contractor be unwilling or unable at once to conform with a direct instruction from the Employer or the Railway Representative under the provisions of the paragraph above or to carry out any remedial or other work or repair, the Employer or the Employer s Engineer may by written order to the Contractor suspend the execution of the Works or of any part thereof or authorise the carrying out of such remedial work or other work or repair by a person other than the Contractor The Contractor shall notify the Employer s Engineer as soon as possible of any direct instruction received from the Employer under the provisions of this Paragraph Where any part of the Works has to be carried out during the period of a Restriction and/or Possession and/or Isolation and the period of such Restriction and/or Possession and/or Isolation is prescribed in the Contract, the Contractor shall plan and execute that part of the Works so that such period is not exceeded and so that no further periods are required If no such period is prescribed, the Contractor shall before commencing any work hold discussions through the Employer s Engineer with the Employer who will decide whether any part of the Works is to be carried out during a period of a Restriction and/or Possession and/or Isolation and the Employer s Engineer will notify the Contractor accordingly After the method of carrying out the work has been agreed with the Employer (and taking into account any provisional arrangements which have been made) the Contractor shall in all cases other than for emergency works submit written notice of his programme of work, which shall include details of any Restriction and/or Possession and/or Isolation previously notified by the Employer as being necessary, to the Employer at least 10 (ten) weeks in advance of the proposed commencement of work on or near the Railway and shall at the same time submit a copy thereof to the Employer s Engineer Where a Restriction and/or Possession and/or Isolation is necessary, the Contractor shall initiate the necessary action to obtain the requisite approval for such Restriction and/or Possession and/or Isolation from the Employer. The Contractor shall be solely responsible for all delays caused through failure to submit the necessary application for approval, late submission of any such application or submission of inadequate information The Contractor shall so organise the execution of the work during any period of Restriction and/or Possession and/or Isolation that he will be able to give up such Restriction and/or Possession and/or Isolation at the time prescribed in the Contract or agreed by the Employer. Should the Contractor in the opinion of the Employer or the NMRCL MARCH

122 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Employer s Engineer not make sufficient or adequate arrangements (including the provision of standby plant) for completing the whole or any stage of the work within the time allowed in the programme or agreed with the Employer, the Employer may in his discretion cancel the Restriction and/or Possession and/or Isolation, or the Employer may employ labour, plant and materials to assist the Contractor to finish the work or to carry out such work as is necessary, or may himself carry out such work as is necessary, to enable the Restriction and/or Possession and/or Isolation to end at the earliest possible moment A period of Restriction and/or Possession and/or Isolation cannot normally be extended. If the Contractor fails to carry out the work during any such period, then Contractor shall be required to re-apply to the Employer for a further period of Restriction and/or Possession and/or Isolation All expenses which in the opinion of the Employer s Engineer are properly incurred by the Employer as a result of the Employer making necessary arrangements to assist the Contractor or carrying out any necessary work in accordance with clause above shall be a debt due from the Contractor to the Employer The Contractor shall on demand pay to the Employer any loss of revenue and additional expenditure which in the opinion of the Employer s Engineer has been incurred by the Employer by reason of the rescheduling of services by the Employer due to the Contractor obstructing the Railway or interfering with the control or signalling system or electrical equipment other than for a period for which a Restriction and/or Possession and/or Isolation has been given In the event that damage is caused by the Contractor to the Railway such that rescheduling/suspension of services by the Employer has to be made, then the Contractor shall on demand pay to the Employer any loss of revenue and additional expenditure which in the opinion of the Employer s Engineer has been incurred by the Employer in making good the damage and in rescheduling/suspending the services The Employer shall have the right to cancel or alter the date and the timing of any agreed period of Restriction and/or Possession and/or Isolation if this proves necessary for the safety or uninterrupted running of rail traffic by notice to the Contractor which shall be deemed to be an instruction issued by the Employer s Engineer, but in such an event the Employer s Engineer shall make alternative arrangements as soon as practicable Not Used Rodent Control The Contractor shall at all times take effective measures to prevent damage by rodents to the Permanent Works and constituent parts thereof, such as cables, electronic cards, etc., during the execution of the Works and shall advise the Employer s Engineer of such measures taken accordingly. NMRCL MARCH

123 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER HEALTH AND SAFETY See Conditions of Contract on Health, Safety and Environment in PS End of Chapter NMRCL MARCH

124 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER DAMAGE AND INTERFERENCE 19.1 Damage and Interference Work shall be carried out in such a manner that, as far as is practicable, there is no damage to or interference with the following, other than such damage as is necessitated to enable the execution of the Works: (1) watercourses or drainage systems; (2) utilities; (3) structures, roads including street furniture, or other property; (4) public or private vehicular or pedestrian accesses; (5) trees, graves or burial urns; and (6) existing railways and railway systems. The Contractor shall obtain prior approval of the concerned authority or party, if so required, for any work near properties under their ownership or management. The Contractor shall inform the Employer s Engineer as soon as practicable of any item, utility or thing which is not stated in the Contract as requiring diversion, removal or relocation but which the Contractor considers as requiring diversion, removal or relocation to enable the Works to be executed. The Contractor shall not divert, remove or relocate any such item, utility or thing without such diversion, removal or relocation having been reviewed without objection by the Employer s Engineer Items which are damaged or interfered with as a result of the Works being carried out and items which are diverted, removed or relocated to enable the Works to be carried out, shall be reinstated to the same condition as existed before the Works started or to such condition as may be reviewed without objection or instructed by the Employer s Engineer The Contractor shall excavate by hand where damage may be caused by the operation of mechanical plant adjacent to any utilities Except with the prior approval of the NagpurFire Services, no damage or interference with existing fire hydrants and valves shall be caused Prior to trench excavation, the Contractor shall carry out investigations to locate utilities by means of hand-dug inspection pits. The locations and number of inspection pits required in meeting the Contractor s obligations to establish the location of existing NMRCL MARCH

125 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification utilities and underground features shall be determined by the Contractor. The Contractor shall note that many existing pipes/ducts/cables may not be shown in the records kept by the utility undertakings, and may only be exposed as the excavation proceeds. The trench excavation shall be carried out by hand where there are utilities adjacent to or within the excavation works and the Contractor shall have allowed in his programme the time required for the exposing, temporary support and diversion of these recorded or unrecorded utilities. Should any pipes/ducts/cables or cover tiles be exposed, the respective utility undertaking shall be contacted to determine if all the utilities have been located. Cover tiles and utilities shall only be removed by the utility undertakings concerned Where the Employer s Engineer has conducted utility and ground investigation on behalf of the Employer, the Contractor may obtain the data obtained from the investigations from the Employer s Engineer in accordance with clause above and subject to the condition of clause 19.3 below Watercourses and Drainage Systems Existing watercourses and drainage systems shall be temporarily diverted as required to enable the Works to be carried out. Particulars of the proposed diversions shall be submitted to the Employer s Engineer for review at least 14 days before the relevant work starts. Diversions shall be constructed to the satisfaction of the Employer s Engineer with such alignment and in such manner that the flow is discharged adequately and effectively without causing flooding or erosion to the adjacent area. The diversions shall be maintained while the work is being carried out and shall be reinstated, including the removal of any obstructions to flow, as soon as practicable after the work is complete Measures shall be taken to prevent excavated material, silt or debris from being deposited in existing drainage systems, watercourses or the river Under no circumstances shall foul sewage flow be diverted into existing storm-water drains and vice versa The Contractor shall adequately maintain the existing drainage and sewerage systems at all times including removal of solids in sand traps, manholes, gullies and streambeds The Contractor shall discharge water surface run-off from the Site into storm drains via adequately designed sand/silt removal facilities such as sand traps, silt traps and sediment basins. Channels or sandbag barriers shall be provided on Site to properly direct the storm water to such silt removal facilities. The Contractor shall remove all silt, which may have accumulated in the drainage or sewerage systems whether within the Site, or not. If at any time such provisions prove to be ineffective, the Contractor shall take such additional measures as the Employer s Engineer deems necessary Water pumped out of the trenches under construction shall be discharged into storm drains after the removal of silt in silt removal facilities. NMRCL MARCH

126 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Contractor shall maintain the silt removal facilities, channels and manholes and remove the deposited silt and grit regularly, at the onset and after each rainstorm to ensure that these facilities are functioning properly at all times No obstruction to flow is to be left in position longer than is necessary for carrying out the Works. The Contractor shall ensure that adequate provisions are made for dealing with increased flow of water during the wet season The Contractor shall keep interruption or disturbance to the public due to the diversion works to a minimum If any mechanical equipment is required for the foul sewage diversion work, the Contractor shall suggest and provide precautionary measures to mitigate against consequences of breakdown of the equipment The Contractor shall at all times ensure that all existing stream courses and drains within and adjacent to the Site are kept safe and free from any debris and any excavated materials arising from the Works. The Contractor shall ensure that chemicals and concrete agitator washings are not deposited in watercourses The Contractor shall be responsible for the Temporary Works involved in training, diverting, or conducting of open streams or drains intercepted by the Works and the Site, for the maintenance of the Temporary Works and waterways as required by the Employer s Engineer, and for reinstating these to their original courses on Employer s Taking Over of the Works, when and where in the opinion of the Employer s Engineer such action is desirable The Contractor shall take all necessary precautions to prevent water entering upon or being discharged from the Site, from entering upon the works of adjacent contractors or adjacent properties The Contractor shall provide where necessary temporary water courses, floodwalls, flood gates, ditches, drains, pumping or other means of maintaining the Works and the Site free of water Utilities The details of existing utilities are given by the employer for information only and the accuracy of the details is not guaranteed. The Contractor shall make his own enquiries and shall carefully excavate trial holes to locate accurately the utilities indicated to him by the utility undertakings Temporary supports and protection to utilities shall be provided by methods reviewed without objection by the Employer s Engineer. Permanent supports and protection shall be provided if instructed by the Employer s Engineer The Contractor shall inform the Employer s Engineer and the utility undertakings without delay of the following: NMRCL MARCH

127 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (1) damage to utilities; (2) leakage of utilities; (3) discovery of utilities not shown on any drawings; and (4) diversion, removal, repositioning or re-erection of utilities which is required to enable the execution of the Works The Contractor shall take all steps necessary to enable the utility undertakings to proceed in accordance with the programme agreed between the Contractor and the utility undertakings under clause above. The Contractor shall maintain close liaison with the utility undertakings and shall inform the Employer s Engineer of any delays in works by the utility undertakings The Contractor shall keep records of existing utilities encountered on the Site and a copy provided for the Employer s Engineer. The records shall be submitted for review by the Employer s Engineer and shall contain the following details: (1) location of utility; (2) date on which utility was encountered; (3) nature and size of utility; (4) condition of utility; and (5) temporary or permanent supports provided The Contractor shall co-ordinate the activities of the utility undertakings in connection with the diversion of utility services necessary for the execution of the Works The Contractor shall set up and manage a Utilities Liaison Group for the duration of the Contract. The Group shall meet at a frequency to be as instructed by the Employer s Engineer but at least once a month, and shall discuss and resolve matters associated with utility undertakings on programming, co-ordination and action. The Contractor shall ensure that all relevant utility undertakings and the Employer s Engineer are represented at the meetings The Contractor shall inform the Employer s Engineer of the date, time and place of every meeting with utility undertakings and he shall copy all correspondence and minutes of meetings to the Employer s Engineer The programme for any section of work to be carried out by a utility undertaking shall be confirmed in writing by the Contractor to the utility undertaking no more than four weeks and no less than one week before the agreed scheduled start date for that section of Works, such confirmation to be notified to the Employer s Engineer The Contractor shall monitor the progress of utility undertakings against the agreed programmes and shall notify the Employer s Engineer of any slippage to these programmes. The agreed programmes shall mean those programmes agreed in writing by the Contractor and the various utility undertakings described in above. NMRCL MARCH

128 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification In the event of any such slippage, the Contractor shall prepare and execute a plan of action with the relevant utility undertaking to redress the slippage. Such a plan may, if necessary, include provision of Contractor s labour resources, materials and/or plant to the utility undertaking The Contractor shall ensure that the peak particle velocity and amplitude of ground movement due to temporary sheet pile driving for trench excavation or any other construction activities, as measured by a vibrograph at all water mains within or adjacent to the Site shall not exceed the values specified in Table 19-1 Table 19-1 of this GS. Type of structure or Peak particle velocity installation (mm/s) Water retaining structures Water tunnels Water mains Other structures and pipes Vibration (mm) amplitude Table 19-1 Peak Particle Velocity & Vibration Amplitude Hand digging method shall always be employed where there are utilities adjacent to or within the trench excavation works. Portable mechanical tools may be used but shall be restricted to the breaking of the pavement surface. Due care shall be exercised to prevent damage to the underground cables, water pipes, gas pipes or other utility installations Exposed utility installations shall be adequately supported and protected from accidental damage Smoking and use of naked flames shall be prohibited if gas pipes are present, or pipes the use of which are not identified are present Structures, Roads and Other Property The Contractor shall immediately inform the Employer s Engineer of any damage to structures, roads or other property that is not required for the execution of the Works The Contractor shall use every reasonable means to prevent any of the highways or bridges connecting with, or on the routes to, the Site from being damaged by any traffic of the Contractor or any of his sub-contractors of any tier and the Contractor shall, in particular, select routes, choose and use vehicles and restrict and distribute loads so that the moving of Temporary Works, Permanent Works and Contractor's Equipment from and to the Site shall be organised as far as reasonably possible so that no unnecessary damage or injury may be occasioned to such highways and bridges. The Contractor shall in selecting such routes take advice from and follow the instructions of the Commissioner for Transport and other Relevant Authorities of GNCTD and GOI Not Used. NMRCL MARCH

129 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Not Used Where the nature of the Works is such as to require the use by the Contractor of waterborne transport, the foregoing provisions of this Clause shall be construed as though "highway" includes any river or other structure related to, on or beneath a waterway, and "vehicle" includes craft, vessels or platforms and shall be read and construed accordingly. If in the course of or for the purposes of the execution of the Works or any part thereof any highway or road or way shall have been damaged, broken or broken into then notwithstanding anything herein contained: (a) If the permanent reinstatement of such highway or road or way is to be carried out by the appropriate Relevant Authority or by some person other than the Contractor or any sub-contractor of any tier to him, the Contractor shall: (i) at his own cost and independently of any requirement of or notice from the Employer s Engineer be responsible for the temporary reinstatement of such highway, road or way and the making good of any subsidence or shrinkage or other defect, imperfection, settlement or fault in the temporary reinstatement of such highway, road or way and for the execution of any necessary repair or amendment thereof from whatever cause the necessity arises until the end of the Defects Liability Period in respect of the part of the Permanent Works beneath or over such highway, road or way or until the Relevant Authority or such other person as aforesaid shall have taken possession of the highway, road or way for the purpose of carrying out permanent reinstatement, whichever is the earlier; and (ii) indemnify and save harmless the Employer against and from any damage or injury to the Employer or claims by third parties arising out of or in consequence of any neglect or failure of the Contractor to comply with the foregoing obligations or any of them, and against and from all claims, demands, proceedings, damages, costs, charges and expenses whatsoever in respect thereof or in relation thereto; and (b) as from the end of such Defects Liability Period or the taking of possession of such highway, road or way referred to in clause 0(a)(i) above whichever shall first happen, the Employer shall indemnify and save harmless the Contractor against and from any damage or injury to the Contractor arising out of or in consequence of or in connection with the said permanent reinstatement or any defect, imperfection or failure of or in such permanent reinstatement and against and from all claims, demands, proceedings, damages, costs, charges and expenses whatsoever in respect thereof or in relation thereto. NMRCL MARCH

130 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Where the Relevant Authority or other person referred to in clause 0 above shall take possession of the highway, road or way as aforesaid in sections or lengths, the responsibility of the Contractor under clause 0 above shall cease in regard to any such section or length at the time at which possession thereof is so taken. But shall during the continuance of the said Defects Liability Period continue to be responsible for any section or length of which possession has not been taken and the indemnities given by the Contractor and Employer respectively under clause 0 above shall be construed and have effect accordingly Access Alternative access shall be provided if interference with existing public or private vehicular or pedestrian access is necessary to enable the execution of the Works. The arrangements for the alternative access shall be as reviewed without objection by the Employer s Engineer. The permanent access shall be reinstated as soon as practicable after the work is complete and the alternative access shall be removed as soon as practicable after it is no longer required Trees and Other Similar Obstructions Trees which are to be retained or which are not required to be removed in order to carry out the Works, shall be protected from damage at all times by methods reviewed without objection by the Employer s Engineer. Materials, including excavated materials, shall not be banked around such trees and they shall not be trimmed or cut without having been reviewed without objection by the Employer s Engineer If any trees or other obstructions are required to be removed during the execution of the Works which are not specifically required to be removed or otherwise catered for, the Contractor shall draw the attention of the Employer s Engineer to them and shall not remove them without having received a notice of no objection from the Employer s Engineer Noise Control on Works Site All Contractor s Equipment shall be effectively sound-reduced by means of silencers, mufflers, acoustics linings or shields or acoustic sheds or screens to levels prescribed in the relevant Noise Control Ordinance and measured outside the nearest occupied property or to the satisfaction of the Employer s Engineer. The Contractor shall provide details of proposed noise control measures to the Employer s Engineer for review prior to the use of any Contractor s Equipment on the Site Provided that the provisions of this Paragraph shall not be applicable in the case of emergency work necessary to save life or property or for the safety of the Works or in the case of blasting operations necessitated by urgency and reviewed by the Employer s Engineer. NMRCL MARCH

131 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification The Contractor shall provide a sound level meter (as specified in Appendix 7 of this Specification), reviewed without objection by the Employer s Engineer, for the exclusive use of the Employer s Engineer at all times during the continuance of the Contract Spoil Disposal The Contractor shall make his own enquiries and arrangements regarding the location and the availability of spoil disposal areas and reclamation and shall pay all costs of complying with all regulations and requirements of Relevant Authorities in connection with the use of such areas. These areas are not within the control of the Employer and no claims will be entertained in respect of non-availability of a particular areas or changes in the costs of arrangements for the use thereof The Contractor shall be responsible for all necessary liaisons to ensure compliance with the requirements of unproductive disposal of any surplus excavated rock or soft material, which is suitable for filling The Contractor shall conform to all pertinent Environmental Protection Ordinances and be liable for any breach of such Ordinances committed by himself and/or his subcontractors during the disposal of surplus excavated material and water from the Site. End of Chapter NMRCL MARCH

132 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER ENVIRONMENTAL PROTECTION REQUIREMENTS See Conditions of Contract on Health, Safety and Environment in PS End of Chapter NMRCL MARCH-16304

133 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER PHOTOGRAPHS 21.1 Photographs On demand of Employer s Representative, Colour progress photographs showing the progress of the Works and the quality of the materials and workmanship shall be taken by the Contractor. End of Chapter NMRCL MARCH-16305

134 NMRCL CHAPTER 22 Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification 22. TEMPORARY ELECTRICITY SUPPLY 22.1 Not Used 22.2 Applicability Where the Contractor is required to provide temporary electrical supplies, or to use, extend or expand on temporary supplies installed by others, all such activity shall be executed in accordance with clauses 22.3 to inclusive When the Contractor makes use of temporary electrical supplies provided by other, viz. Project (Civil) Contractors, he will observe and comply with the requirements of this Chapter Work on Site The Contractor shall nominate a representative whose name and qualifications shall be submitted in writing to the Employer s Engineer for review not later than 4 weeks before the appointment and who shall be solely responsible for ensuring the safety of all temporary electrical equipment on Site. The Contractor shall not install or operate any temporary Site electrical systems until this representative is appointed and has commenced duties The name and contact telephone number of the representative having been reviewed without objection by the Employer s Engineer shall be displayed at the main distribution board for the temporary electrical supply so that he can be contacted in case of an emergency The Contractor shall submit schematic diagrams and the details of the equipment for all temporary electrical installations, and these diagrams together with the temporary electrical equipment shall be submitted to the Employer s Engineer for review All electrical installation work on Site shall be carried out in accordance with the requirements laid down in BS 7375 and the Specification. All work shall be supervised or executed by qualified and suitably categorised electricians, who are registered as such under the Electricity Ordinance 1990/Electricity (Registration) Regulations Electrical General Temporary electrical Site installations and distribution systems shall be in accordance with:- (1) Indian Electrical Regulations; (2) The Power Companies Supply Rules; (3) Electricity and its subsidiary Regulations; (4) IEE Wiring Regulations (16th Edition); (5) BS 7375 Distribution of Electricity on Construction and Building Sites; (6) BS 4363 Distribution Assemblies for Electricity Supplies for Construction and Building Sites; and (7) BS 6164 Safety in Tunnelling in the Construction Industry. (8) Any other applicable national& state standards NMRCL MARCH

135 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification 22.5 Materials, Appliances and Components All materials, appliances and components used within the distribution system shall comply with BS 4363 and BS 7375 Appendix A Design Considerations Distribution equipment utilised within the temporary electrical distribution system shall incorporate the following features:- (1) flexibility in application for repeated use; (2) suitability for transport and storage; (3) robust construction to resist moisture and damage; and (4) safety in use All cabling shall be run at high level whenever possible and firmly secured to ensure they do not present a hazard or obstruction to people and equipment The installation on Site shall allow convenient access to authorised and competent operatives to work on the apparatus contained within Mains Voltage The Site mains voltage shall be as the Electricity Companies Utility supplies, 415V 3-phase 4 wire system Single-phase voltage shall be as the Electricity Companies' Utility supplies, 230V supply Reduced voltages shall conform to BS Types of Distribution Supply The following voltages shall be adhered to for typical applications throughout the distribution systems: (1) fixed plant - 415V 3 phase; (2) movable plant fed by trailing cable - 415V 3 phase; (3) installations in Site buildings - 230V 1 phase; (4) fixed flood lighting - 230V 1 phase; (5) portable and hand held tools - 115V 1 phase; (6) Site lighting (other than flood lighting) - 115V 1 phase; and (7) portable hand-lamps (general use) - 115V 1 phase When the low voltage supply is energised via the Employer's transformer, any power utilised from that source shall be either 415V 3 phase or / 230V single phase as appropriate. The Contractor shall carry out any conversion that may be necessary to enable him to use power from that source Protection of Circuits Protection shall be provided for all main and sub-circuits against excess current, residual current and earth faults. The protective devices shall be capable of interrupting (without NMRCL MARCH

136 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification damage to any equipment or the mains or sub-circuits) any short circuit current that may occur Discrimination between circuit breakers, circuit breakers and fuses shall be in accordance with: Earthing (1) BS 88; (2) BS EN 60898; and (3) BS 7375; (4) Any other appropriate Indian Standards Earthing and bonding shall be provided for all electrical installations and equipment to prevent the possibility of dangerous voltage rises and to ensure that faults are rapidly cleared by installed circuit protection Earthing systems shall conform to the following standards:- (1) IEE Wiring Regulations (16th Edition); (2) BS 7430; (3) BS 7375; and (4) IEEE Standard 80 Guide for Safety in AC Substation Grounding Plugs, Socket Outlets and Couplers Low voltage plugs, sockets and couplers shall be colour coded in accordance with BS 7375, and constructed to conform to BS EN High voltage couplers and 'T' connections shall be in accordance with BS Cables Cables shall be selected after full consideration of the conditions to which they will be exposed and the duties for which they are required. Supply cables up to 3.3KV shall be in accordance with BS The cable armouring shall be used as the earth return in conditions where the cable is continuously extended and not subject to continuous movement after installation For supplies to mobile or transportable equipment where operation of the equipment subjects the cable to flexing, the cable shall conform to one of the following standards appropriate to the duties imposed on it: (1) BS 6708 flexible cables for use at mines and quarries; (2) BS 6007 rubber insulated cables for electric power and lighting; and (3) BS 6500 insulated flexible cords and cables Where low voltage cables are to be used, reference shall be made to BS The following standards shall also be referred to particularly for underground cables:- (1) BS 6346 for armoured PVC insulated cables; and (2) BS 6708 Flexible cables for use at mines and quarries All cables which have a voltage to earth exceeding 65 V (except for supplies from welding transformers to weldingelectrodes) shall be of a type having a metal sheath and/or armour which shall be continuous and effectively earthed. In the case of flexible or trailing cables, NMRCL MARCH

137 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification such earthed metal sheath and/or armour shall be in addition to the earth core in the cable and shall not be used as the sole earth conductor Armoured cables having an over-sheath of polyvinyl chloride (PVC) or an oil resisting and flame retardant compound shall be used whenever there is a risk of mechanical damage occurring For resistance to the effects of sunlight, overall non-metallic covering of cables shall be black in colour Cables which have applied to them a voltage to earth exceeding 12 V but not normally exceeding 65 V shall be either one of the type as described in clause above or alternatively of a type insulated and sheathed with a general purpose or heat resisting elastomer All cables that are likely to be frequently moved in normal use shall be flexible cables Flexible cables shall be in accordance with BS 6500 and BS Lighting Installation Lighting circuits shall be run separate from other sub-circuits and shall be in accordance with BS 7375 and BS Voltage shall not exceed 55 V to earth except when the supply is to a fixed point and where the lighting fixture is fixed in position Luminaries shall have a degree of protection not less than IP 54. In particularly bad environments where the luminaries are exposed to excesses of dust and water, a degree of protection to IP 65 shall be employed Where the Employer s Engineer requires Site inspection of the Works, the Contractor shall upgrade the lighting level to a minimum of 200 lux by localised lighting in all areas Use of wire guards or other such devices shall provide mechanical protection of luminaries against damage by impact whenever risk of damage occurs Electrical Motors Totally enclosed fan cooled motors to BS 4999:Part 105 shall be used Motor control and protection circuits shall be as stipulated in BS Emergency stops for machinery shall be provided Inspection and Testing Electrical installations on Site shall be inspected and tested in accordance with the requirements of the IEE Wiring Regulations (16th Edition) Identification NMRCL MARCH

138 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Identification labels of a type reviewed without objection by the Employer s Engineer shall be affixed to all electrical switches, circuit breakers and motors to specify their purpose Maintenance Strict maintenance and regular checks of control apparatus and wiring distribution systems shall be carried out by an electrician (duly qualified to carry out the said checks) to ensure safe and efficient operation of the systems. The Contractor shall submit for review by the Employer s Engineer details of his maintenance schedule and maintenance works record Maintenance Record All portable electrical appliances shall be permanently numbered (scarf tag labels or similar) and a record kept of the date of issue, date of the last inspection carried out and the recommended inspection period Metering For the purposes of the clause above, construction works shall mean the Works excluding both the Contractor's on and off Site, fabrication facilities, workshops, workyards, offices and stores The Contractor shall install a separately metered and invoiced supply or supplies of electricity for:- (1) Site fabrication facilities; (2) Site workshops and work-yards; and (3) Site offices and stores Power Supply for Installation The system wide Contractor shall arrange for his own separate power and water supply for his installation works. End of Chapter NMRCL MARCH

139 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER MOCK-UPS, PROTOTYPES AND SAMPLES 23.1 Deleted End of Chapter NMRCL MARCH

140 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification CHAPTER 24 FACILITIES FOR THE EMPLOYER'S REPRESENTATIVE The following type of land transport shall be provided for the assembly, testing and commissioning phases of the Works : One round the clock AC Four-Wheeler vehicles, (Scorpio or similar MUV) to be provided at the commencement of the Works or as agreed by the Employer s Representative) with high and low gear ranges for round the clock service. It shall have an engine capacity of not less than 2000cc (nominal) and a seating capacity of no fewer than 5 persons. This cost should be inclusive in the overall offer. NMRCL MARCH

141 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Appendix 1 1. PROGRESS REPORT 1.1 Topics The Progress Report required under clause 2.17 of the GS shall include as a minimum the following sections and topics: (1) Executive Summary, highlighting any matters of concern and explaining corrective action to be taken (2) Safety and Quality issues (including any necessary corrective action taken or proposed to prevent the re-occurrence of the non-conformities) (3) Programme and overall progress (4) Physical progress report (see Paragraph 2.19 of the General Specification) (5) Achievement of Key Dates and Milestone Dates (6) Design status (7) Design and design co-ordination progress (8) Design submission and Employer s Engineer s response status (list of all design submissions showing current status to be appended) (9) Manufacturing status (10) Materials ordered / in process (11) Equipment manufactured / procured (12) Factory acceptance test status report (13) Delivery status (14) Shipping / transportation activity (15) Deliveries to Nagpur (including release certificate reference) (16) Free issue items (where applicable) (17) Installation / erection on Site (18) Site surveys (where applicable) (19) Equipment installation and erection (20) Completion of remedial works / Site acceptance (21) Safety audit and safety report (22) Test and Commissioning (23) Commissioning activity (24) Planned vs. Actual Table (25) Remedial works (26) System integration tests NMRCL MARCH

142 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (27) Documentation (28) Functional design (29) Maintenance manuals (30) As-built drawings (31) Spares / special tools / test equipment (32) Training 1.2 Copies (33) Employer s Taking Over of Works (part or whole of Works) (34) Taking Over Certificate (35) Maintenance issues (36) Defects Liability (37) Contractual / Commercial (38) Payments / invoices (39) Employer s Engineer s instructions and variation orders (40) Claims / potential claims (41) Contractor s resources (details of all staff and sub-contractors engaged on the Works) (42) Progress photographs The Contractor shall submit 1 unbound original and 9 bound hard copies of all Monthly Progress Reports and of the accompanying documents plus one copy in electronic format on pendrive compatible with Microsoft Office. End of Appendix 1 NMRCL MARCH

143 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Appendix 2 2. CONTRACT SYSTEMS SAFETY MANAGEMENT To follow explicit provision in PS and GS End of Appendix 2 NMRCL MARCH-16315

144 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Appendix 3 3. SUBMISSION FOR REVIEW REQUEST FORM Reference No. (see Paragraph 4.3.2) Date Programme reference and scheduled date: Submission Stage (see Paragraph ) Title We hereby submit for review by the Employer s Engineer the documents or articles listed below: (Introduction and list of items submitted see Paragraph continue on separate sheet if necessary) I confirm that the material submitted is in full compliance with the Contract. Signed (Contractor s responsible engineer) Employer s Engineer s Response Dated The material submitted has been reviewed and the following decision is given: No Objection / No Objection Subject To (see below) / Rejected (see below) The following comments are made and a re-submission is to be made by the Contractor within 10 working days demonstrating fully how all of these are taken into account: (Employer s Engineer s comments) Signed (Employer s Engineer) End of Appendix 3 NMRCL MARCH

145 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Appendix 4 4. SCHEDULE OF DOCUMENTS TO BE SUBMITTED BY CONTRACTOR To follow explicit provision in PS and GS End of Appendix 4 NMRCL MARCH

146 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Appendix 5 5. TYPICAL TYPE TEST REQUIREMENTS 5.1 Electronic and Electrical Equipment The initial visual inspection shall be carried out to ensure that the equipment is of sound construction and, so far as can be ascertained, meets the requirements of the Specification Initial Performance Test i. The initial performance tests shall consist of a comprehensive series of measurements of the characteristics of the equipment to demonstrate that its performance is in accordance with its functional requirements, including detailed requirements of the Specification. ii. This test shall normally be performed at an ambient temperature of 40 C +5 C while supplied at its normal voltage and frequency, if relevant. iii. This test shall extend to demonstrating compliance with any limitation on self generated vibration or interference as stated in the Specification Modes of Testing i. Electrical tests will generally be applied to the 'external terminals' of the item of equipment to be tested which are normally used to interface the subject equipment to other equipment or external circuits, e.g. power supply terminals, signal input/output terminals, frame (safety) earth terminals, etc. Tests may be applied in Common Mode and/or Series Mode, as described below. ii. Common mode tests generally involve testing circuits with respect to the equipment's frame earth. All accessible metal parts (intended to be connected to earth) are to be connected to the frame earth. iii. All the terminals of the circuit to be tested shall be connected together, where practicable. All terminals of circuits not involved in the test shall preferably be connected to earth. iv. For example, a common mode test on the AC power supply circuit of an item of equipment would involve connecting all the supply circuit terminals together (e.g. phase (s) and neutral) and applying the test between those connected terminals and the equipment's frame earth terminal. The terminals of all other circuits, e.g. signal input/output terminals, shall preferably be connected to earth. NMRCL MARCH

147 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification v. Series mode tests generally involve testing circuit connections with respect to each other. vi. Where an item of equipment to be tested has a large number of identical interfaces circuits series mode testing may be restricted to a representative sample of those interfaces, the proportion being to the agreement of the Employer s Engineer. vii. viii. ix. The test is applied between terminals (other than the earth terminal) either associated with the same circuit (e.g. between power supply terminals) or associated with different circuits (e.g. between input signal terminals and output signal terminals). All terminals of circuits not involved in the test shall preferably be connected to earth. For example, a series mode test on an RTU analogue input circuit would involve applying the test between the positive and negative analogue signal input terminals, preferably with all other terminals connected to earth. For each item of equipment to be tested, there may be many combinations of terminals to which series mode testing could be applied. Not all combinations may be relevant or subject to the conditions against which a particular test is to be performed. However, the Contractor shall test all combinations unless specifically agreed otherwise by the Employer s Engineer. 5.2 Mechanical Tests Drop Test i. The drop test is intended to be carried out on units and sub-assemblies that are portable. It is not intended that it be carried out on complete racks of equipment. ii. Casings or dust covers, which have to be removed for servicing, shall be removed after subjecting equipment to this test to inspect for damage. The test is designed to reveal any weakness of assembly and to ensure that the component mountings are of adequate strength. It is not designed to check whether doors or windows made of glass will fracture and to this end meters, glass windows, etc., may be removed. iii. The equipment shall not be deemed to have failed the drop test if externally accessible components such as control knobs or connectors are damaged. The Employer s Engineer however reserves the right to ask for some form of guard, to prevent such damage, to be fitted at the Contractor's cost. iv. Test conditions shall be in accordance with IEC Information required for paragraph 4.2 of that test: NMRCL MARCH

148 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification a. Visual inspection and function test to specification. b. Assembled ready for installation. c. Connectorised cables removed, casings or covers in place. d. Not applicable. e. All. f. 25mm, 6 times. g. 25mm, 6 times. v. Visual inspection and function test to specification. vi. Topple (or push over) test is not required Vibration Test i. The vibration test is designed to reveal any parts or components of the equipment that may be prone to any resonance severe enough to cause possible damage or malfunctioning. ii. The test shall be in accordance with IEC Information required for Chapter 12 of that standard: a. Measuring Points: If four or less fixing points are used for the specimen, these shall also be used as checkpoints. If more than four fixing points are used then those nearest the corners shall be used as checkpoints. The checkpoints shall be located as close as possible to the fixing points. b. Transverse Motion: Any transverse motion in excess of that specified in the above standard clause shall be noted and recorded in the test results. c. Distortion: As defined in clause 3 in excess of the limits in clause of the above standard shall be noted as defined in clause paragraph 4 of the same standard. d. Derivation of Control Signal Single point. e. Tolerances at check points shall be as clause of the above standard. Where these cannot be achieved, the actual values shall be recorded. f. Monitoring of Specimen(s): The equipment shall be rigidly mounted in a jig so designed as to transmit the input vibration with minimum modification Vibration Test 1 i. Equipment intended for use with vibration isolators shall normally be tested with its isolator. When this is not possible, the equipment shall be rigidly secured to the vibrator and the input vibration levels modified to include transmissibility of the isolators. ii. Equipment under test is to be mounted in its normal operational attitude. NMRCL MARCH

149 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification iii. Frequency Range: See Chapter 6, Paragraph 5.5 (Equipment Requirements). iv. Vibration Amplitude: See Chapter 6, Paragraph 5.5 (Equipment Requirements). v. Special crossover frequency: See Chapter 6, Paragraph 5.5 (Equipment Requirements). vi. vii. Type and duration of endurance: a. Endurance by sweeping 6 hours, i.e. 2 hours per axis b. Endurance at critical frequencies (as defined in the above standard clause 8.1): 1 minute at each frequency providing not more than four such frequencies exist per axis. Pre-conditioning: None. viii. Initial measurements Functional test to the appropriate test procedure. ix. Axes of vibration: Three mutually perpendicular axes in turn. x. Force Limitation: Not required. xi. Test stages to be performed in the sequence below: xii. xiii. xiv. xv. xvi. xvii. xviii. a. Vibration response investigation. b. Endurance at fixed frequencies derived from vibration response investigation. c. Endurance by sweeping. The equipment functionality shall be verified throughout the sweep test to the appropriate test procedure. Action to be taken after vibration response investigation. If less than four critical frequencies are found in each axis, then endurance testing for the prescribed duration shall be performed at each frequency. Final response test not required. Predetermined frequencies shall be derived from the vibration response investigation. Conditioning at the resonance frequencies of the specimen on its isolators (where fitted) shall be included. Final measurements Functional test to the appropriate test procedure. Any resonance liable to affect the performance or reliability of the equipment shall be reduced to an acceptable level by suitable modifications and the complete test repeated. 5.3 Environmental Tests Dry Heat Test i. The dry heat test shall be carried out on each complete piece of equipment or assembly, with all doors and covers being in place and closed as in normal operation. NMRCL MARCH

150 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification ii. Test conditions shall be in accordance with IEC Information required for paragraph 44 of that test: a. Laboratory ambient. b. Visual inspection. c. Assembled and mounted in rack, enclosure or cabinet ready for operation or installation. d. On. e. Maximum class temperature (see Chapter 6, Chapter 5.2, Equipment Requirements) for 16 hours. f. At maximum class temperature after 16 hours, switch on and function test to specification. g. Recovery at laboratory ambient. h. Visual inspection and function test to specification. i. None Low Temperature Test (in case applicable for Nagpur ambient temperature range) i. The low temperature test shall be carried out on each complete piece of equipment or assembly, with all doors and covers being in place and closed as in normal operation. ii. Test conditions shall be in accordance with IEC Information required for paragraph 33 of that test: a. Laboratory ambient. b. Visual inspection and function test to specification. c. Assembled and mounted in rack, enclosure or cabinet ready for operation or installation. d. Off. e. Minimum class temperature (see Chapter 6, Paragraph 5.2, Equipment Requirements) for 16 hours. f. At minimum class temperature after 16 hours, switch on and function test to specification. g. Recovery at laboratory ambient. h. Visual inspection and function test to specification. i. None Change of Temperature Test i. If both Dry Heat and Low Temperature Tests are required (as decided by the Employer s Engineer) they may be replaced by a single test in accordance with IEC NMRCL MARCH

151 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification ii. Information required for paragraph 2.9 of that test: a Assembled and mounted in rack, enclosure or cabinet ready for operation or installation. b Minimum class temperature. iii. iv. Maximum class temperature. Per Minute. v. One. vi. Visual inspection. vii. On. viii. ix. Hours. None. x. Recovery at laboratory ambient. xi. Visual inspection and function test to specification Damp Heat Test i. The damp heat test shall be carried out on each complete piece of equipment or assembly, with all doors and covers being in place and closed as in normal operation. ii. Test conditions shall be in accordance with IEC Information required for paragraph 10 of that test: a Maximum class temperature, two cycles. b Visual inspection and function test to specification. i. Switched on, ready to use. ii. None. v. Variant 2. vi. At maximum class temperature after 12 hours, function test to Specification. At 6 hours after the temperature starts to fall a further function test to specification. Tests to be repeated during second cycle. vii. Laboratory ambient conditions. viii. None. ix. Visual inspection and function test to specification within 4 hours Driving Rain Test i. The test conditions shall be in accordance with IEC Method Rb 2.2. NMRCL MARCH

152 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification ii. iii. iv. Information required for paragraph of that document: a. Minutes/m2 for a minimum of 15 minutes. b. No preconditioning of seals. c. Visual inspection and function test to specification. d. Table V1: a = 60. B = 60 C. duration = 10 minutes. e. Table V2: diameter = 0.40mm. water flow = dm3/min. supply pressure = 80 kpa. Equipment functioning throughout the test to be verified by testing. Any ingress of water shall be reported to the Employer s Engineer, the equipment shall be visually inspected and function tested to Specification. 5.4 Electrical Tests Supply Variations Measurements of equipment performance and maximum VA consumption shall be made, for supply voltage and frequency variations in all possible combinations of upper limit, normal and lower limit as detailed in the Specification. Throughout these tests, the equipment shall function in accordance with the Specification Supply Interruptions i. The supply input to the equipment under test shall be interrupted for periods of 10 ms. ii. iii. The tests shall be performed ten times at random for ac supplies and three times at random for dc supplies. The equipment shall be capable of withstanding these interruptions of supply input without damage, interruption or resetting by the operator and shall continue to function and operate correctly in accordance with the Specification High Frequency Disturbance Test i. The High Frequency Disturbance test is required to determine whether an item of equipment will continue to operate correctly when specified high frequency transients, representative of practical system conditions, are applied to the fully operating equipment. ii. The test to be applied is based on IEC 255-4, Appendix E. iii. This test shall be performed for all equipment required to operate in environments subject to Electrical Interference Class 2 or 3 (refer to Table 8-3) and shall be applied to the AC power supply terminals of that equipment. NMRCL MARCH

153 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification iv. Waveform: a damped oscillatory wave with the envelope decaying to 50% of peak value at the end of three to six cycles. a. Frequency: 1 MHz tolerance + 10%. b. Source impedance: 200 ohm tolerance + 10%. c. Repetition rate: the test wave is applied to the equipment under test at a repetition rate of 400 per second. d. Duration of test: 2 s tolerance + 10% 0% (see Sub-clause E5.2.7 of IEC 255-4, Appendix E). e. Standard value of test voltage: Refer to Table 8-3. f. Test voltage tolerance: +0-10%. v. The test voltage levels are the voltages at the output of the test circuit before the equipment to be tested is connected to the test circuit terminals. vi. The test leads shall not be longer than 2 m. vii. viii. The disturbance test shall be applied to the AC supply terminals of the equipment under test in series mode (refer to Sub clause 2.1.3). The tests shall be carried out with the equipment operating under nominal supply conditions. ix. The equipment shall function in accordance with the Specification throughout the test Radio Frequency Interference i. Portable radio communication transmitters are a common source of radio frequency interference when they are operated in close proximity to equipment. A field strength of 10 V/m shall be assumed to be present in the VHF and UHF bands. ii. These field strengths are approximately those expected at a distance of 35 cm from a 5 iii. watt hand portable radiotelephone. These fields can induce currents of the order of 100 ma into cables, screens and metalwork. Other possible sources are low level radiation from adjacent equipment including fluorescent lamps and signals from powerful but more distant radio, television and radar transmitters. iv. The test to be applied is based on IEC over a frequency range of 27 MHz to 500 MHz. The Severity Level (Chapter 5) to be applied shall be as follows: v. The Contractor shall state to what field strength the equipment is immune, and include as an option the cost of testing to 10 V/m. The equipment functionality and performance shall not be degraded during or after the RFI test. NMRCL MARCH

154 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification vi. With regard to RTUs and tele-protection equipment, the command outputs shall be immune to mal-operation with the cubicle doors open when the equipment is subjected to the radiated field strengths mentioned above Electrical Stress Impulse Voltage Withstand i. The Impulse Voltage Withstand test is designed to demonstrate that the equipment has been correctly designed to withstand, without damage, the electrical stresses to which it might be subjected in practice. ii. The test to be applied is based upon IEC 255-4, Appendix E. iii. This test shall be performed for all equipment required to operate in environments subject to Electrical Interference Class 2 or 3 (refer to Table 8-3) and shall be applied as follows: a. To all AC power supply input and output terminals of all equipment. b. To all signal input/output, communication interface and DC power supply terminals of RTU and tele-protection equipment. c. For the withstand test, the impulse voltage is a periodic transient voltage without appreciable oscillations (see IEC Publication 60, High-voltage Test Techniques). iv. Impulse waveform: This shall be the standard 1.2/50 impulse specified in IEC Publication 60 and having the following tolerances: a. Voltage rise time: + 30%. b. Voltage falls time: + 20%. c. Source impedance: 500 ohm tolerance + 10%. d. Source energy: 0.5 J tolerance + 10%. e. Standard value of test voltage: Refer to Table 3. f. Test voltage tolerance: +0-10%. v. The test voltage levels are the voltages at the output of the test circuit before the equipment to be tested is connected to the test circuit terminals. vi. The test leads shall not be longer than 2m. vii. Three positive and three negative impulses shall be applied at intervals of not less than 5s. Both common mode and series mode tests shall be performed (refer to Sub-clause 2.1.3). viii. After the above tests, the equipment shall be visually inspected and function tested to check compliance with the Specification Insulation Resistance (Across Isolating Barrier) Test NMRCL MARCH

155 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification i. Where a barrier is used to provide isolation from external circuits, its insulation ii. iii. iv. resistance shall be measured. If the barrier is required to withstand high voltage stresses, then it shall be stressed at the specified voltage to demonstrate its withstand capability and a further insulation resistance test shall be made to ascertain that it has not been significantly degraded as a result of the stress being applied. The insulation of all circuits that include contacts of switches, relays or contractors for isolation functions shall be tested for insulation resistance, R1. R1 shall not be less than 20 megohm when measured at 500 V dc. For switches, relays and contractors, 500 V is to be applied between: a. The opposite ends of each circuit with contacts in open position. b. Both ends of each circuit to earth with contacts in closed position. v. For circuits intended for connection to 100 V ac or dc and above, 2 kv RMS shall be vi. vii. viii. applied for one minute and this shall be followed by a further test for insulation resistance, R2. Stress to be applied between: a. The individual circuits of this type. b. Each circuit of this type and all other circuits including earth. These other circuits can be strapped together electrically for the purpose of this test. Final insulation resistance shall be such that either: a. R2 > 20 megohm, or b. R2/R1 > 0.7. For circuits intended to provide isolation against large differences in earth potential, the barrier shall, after the initial resistance measurement, be stressed to the design voltage and this shall be followed by a further insulation resistance test. End of Appendix 5 NMRCL MARCH

156 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Appendix 6 6. REQUEST FOR INSPECTION OF WORKS FORM REQUEST FOR INSPECTION OF WORKS To the Date Employer s Engineer * Location (Will be ready for your inspection) on * Description of Works ) at prior to ) ) on at hrs * Labour and plant to be used Signed for Contractor. Received by for Employer s Engineer date time Filled in by Engineer Filled in by Inspector Mr Mr Signed Please arrange inspection Please check setting out The above work was inspected and permission was given / not given to proceed with next operation. * The following remedial works were required * Contractor informed verbally (to MR by Mr on at hrs) * Remedial works inspected and permission given to proceed with next operation on at hrs) as supervised by Signed Date Time Verbal or written permission by the Employer s Engineer or his staff shall in no way relieve the Contractor of his responsibilities under the Contract. * To be completed if applicable. End of Appendix 6 NMRCL MARCH

157 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Appendix 7 7. NOISE MONITORING INSTRUMENT (1) Not Used * End of Appendix 7 * NMRCL MARCH

158 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Appendix 8 8. FIRST AID REQUIREMENTS 8.1 Provisions by others (1) First aid bases will be located at the main Civil works Contractor's principal Works Areas. The bases will consist of a treatment room fitted with two treatment couches, a hand wash basin, sterilising equipment and lockable cupboards to contain sufficient medical supplies for the Contractor's workforce, the Employer s Engineer's site supervisory staff, the Designated Contractors working in the area and any visitors to the Site. The first aid post will be airconditioned, with cooling capability sufficient to maintain the temperature of the inside of the building at 20 o C. (2) A qualified doctor, nurse and assistant nurse will be in attendance at the first aid base during all times when work is being undertaken on the Site, including work by the Designated Contractors and periods when only emergency activities are being undertaken, such as during periods of inclement weather. (3) A fully equipped ambulance and driver will be provided at the first aid base during all working hours. The ambulance will be equipped with emergency life support equipment suitable for application in construction site accidents. 8.2 Provisions by the Contractor The Contractor shall supply portable first aid boxes maintained fully equipped at each local site offices and any work locations where 20 or more persons work at a time In each site office and work location at least one of the Contractor s employees shall be trained in first aid and should be available at all working hours for purpose of attending to emergencies The Contractor shall be responsible for making his employees aware of the location and access route to the nearest first aid base and if necessary shall provide facilities for evacuating a workman by stretcher from the worksite The Contractor shall keep the first aid base personnel informed of the number and identity of staff working within the area of responsibility of each first aid base. End of Appendix 8 NMRCL MARCH

159 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification Appendix 9 9. WORKS AREAS 9.1 Works Areas (a) (b) (c) (d) (e) Temporary occupation of land is governed by Part VI of land acquisition Act 1894 which limits occupation to 3 years. The Site is divided into a series of principal Works Areas that will be made available to the Contractor at different times and for various durations. These Works Areas are illustrated in the Drawings. In order to avoid doubt, should any discrepancies be found in the definition of the extent of these Works Areas between the Figures in this Appendix and the Drawings, the Drawings shall prevail. The descriptions of the principal Works Areas given below are indicative and the Contractor shall satisfy its self as to the exact nature of the various Works Areas and the extent of works to be carried out prior to the execution of the Permanent Works or making use of the area as working space and/or for temporary site facilities. In addition to these principal Works Areas, the Contractor will be required to establish secondary Works Areas at, for example, station locations. The Contractor shall submit to the Employer s Engineer proposals for the use and occupation of these secondary Works Areas, such submissions being at least sixty (60) days prior to the programmed use of the specific Works Area. Prior to the Key Dates or the Works Area Handover Dates for returning any Works Area, the Contractor shall carry out the following works: (i) construct all Permanent Works within the area, to the extent defined in this Appendix, in accordance with the requirements of the Contract, (ii) reinstate the area to the condition as close as possible to its condition when it was taken over, (iii) form the area to the approved lines and levels and carry out such other works as may be required by the Employer s Engineer, (iv) remove all rubbish, debris and other materials. 9.2 Schedule of Works Area Availability: (a) Temporary occupation of land is governed by Part VI of land acquisition Act 1894 which limits occupation to 3 years. (b) Deleted. (c) Deleted. (d) Deleted. NMRCL MARCH

160 NMRCL Tender No. N1 Tr-02/2016 Part-II: Work Requirement, Section-VII-A General Specification (e) Prior to the Works Area Handover Dates for returning any Works Area, the Contractor shall carry out the following works: (i) construct all Permanent Works within the area, to the extent defined in this Appendix, in accordance with the requirements of the Contract, (ii) reinstate the area to the condition as close as possible to its condition when it was taken over, (iii) form the area to the approved lines and levels and carry out such other works as may be required by the Employer's Representative, (iv) remove all rubbish, debris and other materials... End of Appendix 9 NMRCL MARCH

161 NAGPUR METRO RAIL PROJECT BID DOCUMENTS FOR DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF 25 KV SINGLE PHASE, 50HZ AC, REGULATED, CONVENTIONAL AND TRAMWAY TYPE OHE IN AT GRADE SECTION AND MIHAN DEPOT, 33/25 KV TRACTION SUB STATION & SSP INCLUDING 33 KV CABLING WORK OVER NORTH SOUTH CORRIDOR OF NAGPUR METRO RAIL CORPORATION LIMITED TENDER NO. N1Tr-02/2016 PART II: WORKS REQUIREMENTS SECTION VII-B: WORKS REQUIREMENT PARTICULAR SPECIFICATION Nagpur Metro Rail Corporation Limited Metro House, Bungalow No: 28/2, Anand Nagar, CK Naidu Road, Civil Lines, Nagpur Maharashtra, INDIA Website: NMRCL MARCH

162 TABLE OF CONTENTS PARTICULAR SPECIFICATIONS 1 GENERAL... 2 OVERVIEW OF THE PROJECT... 3 SCOPE OF WORK... 4 PERFORMANCE REQUIREMENTS... 5 FUNCTIONAL REQUIREMENTS... 6 DESIGN REQUIREMENTS... 7 TECHNICAL REQUIREMENTS... 8 INSTALLATION, INSPECTION, TESTING AND COMMISSIONING... 9 MAINTENANCE AND TRAINING SPARE PARTS, SPECIAL TOOLS AND TEST EQUIPMENT... NMRCL MARCH

163 List of Appendices Appendix A Interface specifications Appendix B Technical sheets Appendix C Test sheets Appendix D Safety Requirements Appendix E Key and Access Dates Appendix F Preliminary list of deliverables Appendix G Control and monitoring signals (I/O list for SCADA) NMRCL MARCH

164 1 GENERAL 1.1 Scope and purpose This Technical Specification specifies the objectives, guidelines and requirements for Detailed DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF 25 KV SINGLE PHASE, 50HZ AC, REGULATED, CONVENTIONAL AND TRAMWAY TYPE OHE IN AT GRADE SECTION AND MIHAN DEPOT, 33/25 KV TRACTION SUB STATION & SSP OVER NORTH SOUTH CORRIDOR OF NAGPUR METROcollectively referred to as NS Corridor: Sections Reach Route Km (App.) Track Km (App.) No. of Stations No. of Depot Expected Date of Completion PS Mihan Depot to New Airport Station June, 2017 The Works to be executed under the Contract include the Design, Manufacture, Delivery, Installation, Testing and Commissioning and technical / maintenance support defect Liability Period. 1.2 Definition In this and its appendices, the following list defines terms shall have the meanings ascribed to them below: S.No. TERMS DEFINITION 1 2 ACCEPTANCE MEASUREMENT OVERHEAD PROTECTION CONDUCTOR 3 AIR SECTION 4 AUTO-TENSIONING EQUIPMENT 5 AUXILIAIRY SUBSTATION 6 BALANCE WEIGHT ASSEMBLY 7 BLOW-OFF 8 BOND Final definitive records of the measurement of the installed contact wire heights and staggers at OCS support and registrations and at midspan. A conductor on traction masts / structures / supports and bonded to their metallic parts / supports and connected to earth. Electrical sectioning of OCS for separating feeding network. OCS Conductors terminated with balance weighs, Springs or hydraulic tensioning devices to maintain constant tension over a specified range of conductor temperatures by compensating for conductor thermal expansion and contraction. Power received at 33 kv and transformed to 415 V by means of 33 kv/415 V transformers and then distribute to Auxiliary equipment in the passenger stations The tensioning gear with weighs that are installed at each end of a tension section of an auto-tensioned OCS. Lateral displacement of the overhead contact system due to wind. Electrical connection between two or more conductors or non-current carrying metallic parts of traction masts or structures or supports and rails. NMRCL MARCH

165 9 BRACKET TUBE 10 BRIDDLE WIRE 11 BRIDGING INTERRUPTOR 12 CANTILEVER ASSEMBLY 13 CATENARY or CATENARY SYSTEM 14 CLEARANCE TO EARTH 15 CONTACT WIRE 16 CROSS SPAN 17 CURRENT COLLECTION 18 DROPPER 19 ELECTRICAL CLEARANCE 20 ENCUMBRANCE 21 END APPROACH 22 EXPANSION JOINT 23 FEEDER CABLES 24 FEEDING POST 25 FLEXIBLE OVERHEAD CONTACT SYTEM 26 HEAD SPAN It comprises of standard bracket tube and insulated by bracket insulator. Messenger wire is supported from this member by catenary suspension bracket and catenary suspension clamp. A Short loop of wire that supports a single contact wire from horizontal. An interrupter which is provided at the neutral section to extend the feed from one substation to the overhead equipment normally fed by the other substation in emergencies or when the latter is out of use. This normally remains in the open position. An OCS support frame typically for mounting a messenger and a contact wire with register and steady arm assembly that is mounted on a pole or portal beam drop arm. The structure of conductor above the track which carries the electric supply for electric locomotives and is used for overhead electricity collection. It may be rigid or flexible overhead contact system. The clearance between any conducting parts and any parts which are earthed or intended to be earthed. The wire with which the pantograph or trolley pole makes for current collection. A Single wire fastened between two supports that crosses the tracks just above contact wire level and supports one or more contact wires. The act of picking up electrical power from Overhead contact wire by pantograph. A fitting used in overhead equipment construction for supporting the contact wire from the messenger wire. The distance in air between live equipment and the nearest earthed part. Encumbrance is defines as the axial distance on vertical plane between messenger and contact wire at OHE support in flexible overhead contact system. The Sloping end portion of Rigid Conductor rail so as to maintain smooth pantograph passage Mechanical joint for absorbing expansion of rigid contact wire due to temperature changes. 25 kv Feeding cables from 25 kv switchgear to rigid conductor rail/ flexible OCS for supplying traction power. It is a power supply post where the incoming 25 kv feeder lines from substation are connected to the overhead equipment. It is a conventional type of overhead contact system. It is defined in this section at s no. 36 An OCS support structure with two or more wires over the multi- tracks and supports several cantilevers, or NMRCL MARCH

166 27 IMPEDANCE -BOND 28 INTERRUPTER 29 JUMPER 30 LIGHTNING ARRESTOR MAST MAIN CABLE TRAY/TRENCH/DUCT 33 MESSENGER WIRE 34 NEUTRAL SECTION 35 OVERHEAD CONTACT SYTEM (OCS) 36 PANTOGRAPH 37 PARALLELING INTERRUPTOR 38 PORTAL 39 PULL OFF / PUSH OFF CANTILEVER 40 PUSH UP (UPLIFT) 41 RECEIVING SUBSTATION Several single contact wires in multi -track area. A bond installed by the signal and telecommunication department which provides a low impedance path for traction return current and a relatively high impedance path for track circuit current. It is a single phase Vacuum load break switch to close/open the circuit on load. It is operated either by remote control or manually at site. A conductor or an arrangement of conductors for electrical continuity not under tension, which forms electrical connection between two conductors or equipment. A device typically mounted on OCS poles and connected to the OCS, designed to protect the OCS and adjacent equipment due to lightning. Cable tray/ trench/duct which will be used to run the cables along with the viaduct and underground tunnel other than the equipment room. A single vertical post embedded in the foundation or otherwise rigidly fixed in vertical position to support the overhead equipment with cantilever. The conductor from which the contact wire is suspended by means of droppers. This is the dead zone of the OHE located approximately mid way between the adjacent substations, which are connected to different phases. The part of the traction power system comprising the overhead conductors, OCS supports, Foundations, balance weighs and other equipment and assemblies, that delivers the electrical power to non-self powered electric vehicles. A current collection device fitted on top of an electrically powered rail vehicle, hinged to allow it to vary in height as it rubs along the contact wire. An interrupter which connects overhead equipment of two different tracks. A frame support structure, typically of galvanized steel, consisting of vertical columns supporting each end of a horizontal beam carrying multiple OHE for two or more tracks.. A cantilever that provides registration of the contact wire towards the pole in relation to the centreline of track. It is defined as a vertical displacement of a contact wire or the conductors of the overhead equipment due to pressure exerted by the pantograph either in static or in dynamic condition. Power received at 220kV /132 /33 kv from authority grid sub-station and transformed to 25/27 kv by NMRCL MARCH

167 42 REGISTER ARM 43 REGULATING EQUIPMENT RETURN CIRCUIT CURRENT RIGID OVERHEAD CONTACT SYSTEM 46 SAG 47 SCISORS CROSSOVERS 48 SECTION INSULATOR SECTIONING INTERRUPTOR SECTIONING AND PARALLELING POST (SP) 51 SETTING DISTANCE 52 SHORT NEUTRAL SECTION 53 SPAN 54 SPAN WIDTH 55 STAGGER 56 STAY TUBE 33/25 kv transformers for auxiliary loads of stations, depots etc. and 25 kv for Traction loads. It comprises of tube to register the contact wire in the desired position with the help of steady arm. A device for maintaining the tension of OHE conductors constant under all ambient temperature conditions. Note: Such OHE is called regulated OHE. Running track rails and conductors forming part of traction return current circuit. The overhead conducting composite aluminium rail with copper contact wire including support fittings and insulators for distribution of electric power to the train. The difference between the average height of a conductor at its adjacent support and its height at the lowest point in the span. A pair of parallel or nearly parallel tracks with crossovers provided in both directions between the two lines (i.e., trains can be routed from either line to either line, in both directions). Often, scissors crossovers are provided from a running line to a dead-end siding to allow for one train to be passed by another. Also referred loosely, as scissors crossing A device installed in the contact wire for insulating two elementary electrical sections from each other while providing a continuous path for the pantograph without break of current. An interrupter which connects adjacent subsectors together to maintain continuity of supply. This normally remains in closed position. It is a supply control post situated mid-way between two feeding posts at the neutral section and provided with bridging and paralleling interrupters. The horizontal distance from the nearest face of traction mast to the center line of the track. In heavily graded and suburban sections where adoption of overlap type neutral section is not feasible, short neutral section of 5m length comprising of PTFE insulator. The distance between the centre line of the adjacent supporting structures for the overhead equipment / lines is known as span. The distance across track or roadway between the columns of a portal, head span or crossspan. Stagger is the horizontal distance of the contact wire from the vertical plane through the centre of pantograph pan at the contact surface. It comprises of Small tube and an adjuster at the end to keep the bracket tube in position NMRCL MARCH

168 57 STEADY ARM 58 STRUCTURE BOND SUB-SECTIOINING AND PARALLELING POST ( SSP ) SUB-SECTIONING POST (SS) It holds the contact wire and prevents it from lateral displacement. A bond connecting the non-current carrying metallic parts of a traction mast or structure or support to a traction rail. It is a supply control post where sectioning and paralleling interrupters are provided. It is a supply control post where a sectioning interrupter / isolator is provided. 61 SUPPORT INSULATOR Insulator for supporting rigid conductor rail. 62 SUPPORTING FIXTURE 63 TENSION LENGTH 64 TRACTION SUBSTATION 65 TURNOUT 66 TWO - TRACK CANTILEVER Adjustable supporting fitting for conductor rail so as to maintain the geometry of height and stagger of contact wire with respect to the track. Length of conductor which is stretched between the two anchor points. A traction substation is an electrical substation that derives power from RSS and feeds power to the catenary system A section of track branching off from another. Sometimes spelled 'turn-out' or 'T/out'. A single OCS Cantilever frame serving two adjacent to one side of its supporting pole, and catering to the independent movement of the catenaries in AT systems. NMRCL MARCH

169 1.3 List of abbreviations Sl.No. ABBREVIATION DEFINITION 1 AC Alternating Current 2 ACOCB Alternating current outgoing circuit breaker 3 ACB Air Circuit Breaker 4 ACRC Alternating current rectifier contactor 5 ACRCB Alternating current rectifier circuit breaker 6 AED As Erected Drawing 7 AFNOR Association francaise de normalisation 8 AMS Auxiliary main sub Station 9 ANSI American National Standards Institute 10 ASTM American Society for Testing and Materials 11 ASS Auxiliary Sub Station 12 AT Auxiliary transformer 13 ATCB Auxiliary Transformer Circuit Breaker 14 ATIS Auxiliary Transformer Isolator 15 AVO Amperes-Voltage-Ohms (meter) 16 B Traction bus bar 17 BA Batteries 18 BAIT Batteries interrupter 19 BFB Broad Flange Beam 20 BS British Standards 21 BW Balance Weight 22 BWA Balance Weight Assembly 23 CAMS Computer Aided Maintenance System 24 CB Circuit Breaker 25 C&C Control & Communication 26 CCB Coupling circuit breaker 27 CIS Coupling Isolator 28 CSD Cross Section Drawing 29 CT Current Transformer 30 CTATP Current Transformer for protection of Auxiliary Transformer 31 CTC Current transformer for coupling NMRCL MARCH

170 32 CTD Capacitor Tripping Device 33 CTIM Incoming Current Transformer for Measures 34 CTT Current transformer for traction transformer 35 CTTTP Current Transformer for Protection of Traction Transformer 36 dan Deca - Newton 37 DC Direct Current 38 DCAC Direct current auxiliary contactor 39 DCACB Direct current charging Air Circuit Breaker 40 DCACC Direct current auxiliary coupling contactor 41 DCOCB Direct current outgoing circuit breaker 42 DCRC Direct current rectifier contactor 43 DP Double Pole Insulator 44 DTN Data Transmission Network 45 EIS Earthing Isolator 46 EMIS Energy Management and Information System 47 FP Feeding Post 48 FRLS Flame Retardant Low Smoke 49 GRC General Remote Control 50 HMI Human Machine Interface 51 ICB Incoming Circuit Breaker 52 IEC International Electro technical Commission 53 IEIS Incoming Earthing Isolator 54 ISO International Organization for Standardization 55 IRS Indian Railway Specification 56 IR Indian Railways 57 IS Indian Standard 58 IS Isolator 59 IT Interrupter 60 ITC Coupling interrupter 61 ITL Integral Transverse Link 62 L Hand operated traction isolator 63 LAAT Lightening arrester for Auxiliary Transformer 64 LAN Local Area Network NMRCL MARCH

171 65 LATT Lightening arrester for Traction Transformer 66 LBCB Lighting bridge circuit breaker 67 LBCCB Lighting bridge coupling circuit breaker 68 LBCCT Lighting bridge coupling current transformer 69 LBCT Lighting bridge current transformer 70 LBCVT Lighting bridge coupling voltage transformer 71 LBEIS Lighting bridge earthing isolator 72 LBVT Lighting bridge voltage transformer 73 LCB Line Circuit Breaker 74 LEIS Line Earthing Isolator 75 LFCB Lighting feeder circuit breaker (spare) 76 LFEIS Lighting feeder earthing isolator 77 LIS Line Isolator 78 LV Low Voltage 79 LVACB Low voltage auxiliary circuit breaker 80 LVACCB Low voltage auxiliary coupling circuit breaker 81 LVAT Low voltage auxiliary transformer 82 LVATCB Low voltage auxiliary transformer circuit breaker 83 LVATEIS Low voltage auxiliary transformer earthing isolator 84 LVCB Low voltage circuit breaker 85 LVCCB Low voltage coupling circuit breaker 86 MVCB Medium Voltage Circuit Breaker 87 NCT Neutral Current Transformer 88 NMS Network Management System 89 NGR Neutral Grounding Resistor 90 OCC Operation Control Centre 91 OCR Over Current Relay 92 OCS Overhead Contact System 93 ODC Over Dimensional Consignment 94 OHE Overhead Equipment 95 OLTC On Load Tap Changer 96 PCW Power Control Workstation 97 PICOP Person In Charge Of Possession NMRCL MARCH

172 98 PLC Programmable Logic Controller 99 PNCT Primary neutral current transformer 100 PNEIS Primary neutral earthing isolator 101 PSU Power Supply Unit 102 PT Potential Transformer 103 PTFE Polytetrafluroethylene 104 RDSO Research Design & Specification organisation 105 ROCS Rigid Overhead Contact System 106 RSJ Rolled Steel Joist 107 RSS Receiving Sub Station 108 RTF Reproducible Tracing Film 109 RTCC Remote Tap Changer Control 110 SCADA Supervisory Control And Data Acquisition System 111 SED Structure Erection Drawing 112 SF-6 Sulphur Hexa Fluoride 113 SNCT Secondary neutral current transformer 114 SNEIS Secondary neutral earthing isolator 115 SNLA Secondary neutral Lightening arrester 116 SP Single Pole Insulator 117 SP Sectioning Post 118 SSP Sub Sectioning and Paralleling Post 119 T/out Turnout 120 TEIS Transformer Earthing Isolator 121 TPC Traction Power Control. 122 TNEB Tamil Nadu Electricity Board 123 TR Power Transformer 124 TSS Traction Sub - Station 125 TT Traction transformer 126 TTCB Traction Transformer Circuit Breaker 127 TTCCB Traction Transformer coupling Circuit Breaker 128 TTIS Traction Transformer Isolator 129 UPF Unity Power Factor 130 UIC International union of railway 131 UPS Uninterrupted Power Supply 132 VCB Vacuum Circuit Breaker 133 VDU Video Display Unit 134 VT Voltage Transformer NMRCL MARCH

173 135 VTB Voltage Transformer for traction bus bar 136 VTBB Bus Bar Voltage Transformer 137 WPC Wrong Phase Coupling 138 WTI Winding Temperature Indicator 139 XLPE Crosslink polyethylene 1.4 Standards This following list is provided solely for the convenience of the bidder. Standards referenced within this document that are not identified in this list must still be compliant with. Reference to any specifications shall be taken as reference to the latest version of that specification. IEC PUBLICATION S.No. STANDARD NO. DESCRIPTION 1 IEC Insulator for overhead lines. 2 IEC IEC Common specifications for high voltage switchgear and control gear standards. High-voltage switchgear and control gear - Part 100: Alternating current circuit-breakers (Electrical & Mechanical characteristics - Circuit Breakers). 4 IEC AC disconnector and earthing switches. 5 IEC IEC A.C. metal-enclosed switchgear and controlgear for rated voltages above 1 kv and up to and including 52 kv Gas insulated metal enclosed switchgear for rated voltage of 52 kv and above. 7 IEC Insulated bushings for alternating voltage above 1000 volts. 8 IEC Instrument transformers - Current transformers 9 IEC Instrument transformer - Inductive voltage transformer 10 IEC Instrument transformers - Combined transformers 11 IEC IEC / IEC IEC Surge Arrestor. Instrument transformers - Requirements for protective current transformers for transient performance High voltage alternating current circuit breaker. 14 IEC Electric traction overhead lines 15 IEC Power cables with extruded insulation and their accessories for rated voltages from 1 kv (Um = 1,2 kv) up to 30 kv (Um = 36 kv) 16 IEC Conductors of insulated cables NMRCL MARCH

174 17 IEC Power transformers 18 IEC Power transformers Temperature Rise IEC IEC Power transformers Insulation levels, dielectric tests and external clearances in air Power transformers Guide to the lightning impulse and switching impulse testing - Power transformers and reactors 21 IEC Power transformers - Ability to withstand short circuit 22 IEC IEC IEC High-voltage switches Switches for rated voltage above 1kV & less than 52kV Insulators for overhead lines with a nominal voltage above 1000 V - Part 1: Ceramic or glass insulator units for a.c. systems - Definitions, test methods and acceptance criteria Insulators for overhead lines with a nominal voltage above 1000 V - Part 2: Insulator strings and insulator sets for a.c. systems - Definitions, test methods and acceptance criteria 25 IEC Electric traction overhead lines 26 IEC IEC standard voltage 27 IEC IEC standard current ratings 28 IEC IEC standard frequencies 29 IEC Surge arresters - Part 4: Metal-oxide surge arresters without gaps for a.c. systems 30 IEC Degrees of protection provided by enclosures (IP code) 31 IEC IEC IEC IEC Graphical symbols for diagrams. Part 2: symbol elements, qualifying symbols and other symbols having general application. Classification of environmental conditions - Part 3: Classification of groups of environmental parameters and their severities - Section 4: Stationary use at non-weather protected locations Power cables with extruded insulation and their accessories for rated voltage above 30kV (Um = 36 kv) up to 150 kv. Test methods and requirements. Short-circuit currents - Calculation of effects - Part 1: Definitions and calculation methods 35 IEC Hard-drawn Aluminium wire for overhead line conductor 36 IEC IEC Electromagnetic compatibility Insulation co-ordination - Part 1: Definitions, principles and rules 38 IEC ICE Functional safety of electrical/electronic/programmable safety-related systems. Part 3: software requirements Industrial electro heating installations - General test methods 40 IEC Programmable controllers 41 IEC Insulated Bushing for rated Voltage above 1 kv NMRCL MARCH

175 42 IEC IEC Conductor of Insulated Cables Tests on Indoor and Outdoor Post Insulators of Ceramic Material or Glass for Systems with Nominal Voltages greater than 1000 V 44 IEC IEC IEC Characteristic of indoor and outdoor post insulators for systems with nominal voltages greater than 1000 V Fluids for Electro-technical applications - Unused mineral insulating oils for transformers and switchgear Mechanical structures for electronic equipment - Dimensions of mechanical structures of the 482,6 mm (19 in) series. 47 IEC IEC IEC Locking Devices for Ball and Socket Couplings of String Insulator Units Dimensions and Tests Specification of technical grade sulphur hexafluoride (SF6) for use in electrical equipment Secondary cells and batteries containing alkaline or other non-acid electrolytes - Sealed nickel-cadmium prismatic rechargeable single cells 50 IEC International standard of resistance for copper 51 IEC IEC IEC IEC IEC IEC IEC Surge arresters - Part 1: Non-linear resistor type gapped surge arresters for a.c. systems Semiconductor converters, general requirements and line commutated converters. Specifications of basic requirements. Semiconductor converters, general requirements and line commutated converters. Application guide Semiconductor converters, general requirements and line commutated converters. Transformers and reactors Classification of environmental conditions- Classification of groups of environmental parameters and their severity- Stationary use at non weather protected locations. Classification of environmental conditions- Classification of groups of environmental parameters and their severity- Stationary use at weather protected locations. Power cables with extruded insulation and their accessories for rated voltages above 30 kv (Um = 36 kv) up to 150 kv (Um = 170 kv) - Test methods and requirements 58 IEC Electronic equipment used on rail vehicles 59 IEC IEC GRAFCET specification language for sequential function charts Tele-control equipment and systems. Part 1: General considerations. Section One: General principles NMRCL MARCH

176 61 IEC IEC IEC IEC Tele-control equipment and systems - Part 2: Operating conditions - Section 1: Power supply and electromagnetic compatibility Tele-control equipment and systems. Part 3: Interfaces (electrical characteristics) Tele-control equipment and systems. Part 4: Performance requirements Tele-control equipment and systems - Part 5: Transmission protocols - ALL PARTS 65 IEC Communication networks and systems in substations 66 IEC Low Voltage Switchgear Circuit Breakers 67 IEC IEC Common specifications for high voltage switchgear and control gear standards. Classification of environmental conditions - Part 2: Environmental conditions appearing in nature - Section 5: Dust, sand, salt mist S.No. STANDARD NO. BS PUBLICATION DESCRIPTION 1 EN Maintenance/Maintenance Key performance indicators 2 EN Fixed installations - Part 1: Protective provisions relating to electrical safety and earthing 3 EN EN EN ISO EN ISO EN ISO EN EN Conductors for overhead lines. Round wire concentric lay stranded conductors Current collection systems - Requirements for and validation of measurements of the dynamic interaction between pantograph and overhead contact line Hot dip galvanized coatings on fabricated iron and steel articles. Specifications and test methods Protection against corrosion of iron and steel in structures. Zinc and aluminium coatings. Guidelines Non-magnetic coatings on magnetic substrates. Measurement of coating thickness. Magnetic method Current collection systems. Validation of simulation of the dynamic interaction between pantograph and overhead contact line Environmental conditions for equipment. Fixed electrical installations 10 EN Fixed installations. Electric traction overhead contact lines NMRCL MARCH

177 11 EN Electromagnetic compatibility 12 EN EN Insulation coordination. Basic requirements. Clearances and creepage distances for all electrical and electronic equipment Insulation coordination. Overvoltage and related protection 14 EN Supply voltages of traction systems 15 EN CENELEC EN Current collection systems. Technical criteria for the interaction between pantograph and overhead line. Cast aluminium alloy enclosures for gas-filled high-voltage switchgear and control gear; 17 EN Copper and copper alloy grooved contact wires 18 EN EN EN Hot Rolled Products of Non-Alloy Structural Steels: Delivery Conditions Structural Steel I and H Sections Tolerances on Shape and Dimensions Hot Rolled Steel Equal Flange Tees with Root and Toes Dimensions and Tolerances on Shape and Dimensions 21 EN Structural Steel Equal and Unequal Leg Angles 22 EN Quenched and Tempered Steels 23 EN Stainless Steels 24 EN 1301 Aluminium and Aluminium Alloys 25 EN Supply Voltage of Traction System 26 EN Insulating and Sheathing Materials of Electric Cables 27 EN EN EURONORM EN EN EN Railway application electromagnetic compatibility : Part 5 : Standard for emission and immunity of fixed power supply installations & apparatus Structural steel I & H sections Tolerances on shape & dimensions IPE Beams; I-Beams with Parallel Flange Facings and Steel Products IPN Beams Dimensions The specification and demonstration of reliability, availability, maintainability and safety (RAMS) Communications, signalling and processing systems. Software for railway control and protection systems Communication, signalling and processing systems. Safety related electronic systems for signalling NMRCL MARCH

178 RDSO PUBLICATION S. No. STANDARD NO. DESCRIPTION 1 TI/SPC/OHE/SNS/0000 Specification for Short Neutral Section Assembly (Phase Break) 2 TI/SPC/OHE/INSCOM/1 070 Composite 9 tonne insulator (polluted zone (1050mm)) 3 ETI/OHE/13 latest version Hot dip zinc galvanization of steel masts, tubes and fittings for 25kV ac OHE 4 ETI/OHE/76 latest version Hard drawn grooved contact wire 5 ETI/OHE/50 latest version 65mm² Cadmium Copper Messenger wire 6 ETI/OHE/3 latest version Stranded annealed copper jumper wire (50 sq mm) 7 ETI/OHE/13 latest version Galvanised Steel tubes (Large Bracket) 8 ETI/OHE/27 9 ETI/PSI/ ETI/PSI/116 Specification for section insulator assembly with / without core insulator Specification for 245/145/123/72.5 kv triple pole isolators. double pole and 220 KV/132 KV/66 KV AC double pole and triple pole outdoor SF-6 gas circuit breakers for Railway 11 ETI/PSI/ /132kV current Transformer 12 ETI/PSI/31 Standards for drawings for power supply installation 13 RE/OHE /25 Standard drawings for Traction overhead Equipment IS PUBLICATION S.No. STANDARD NO. DESCRIPTION 1 IS 209 Zinc Ingot - Specification 2 IS 398 (Part II) 3 IS 398 (Part I) Aluminium conductors for overhead transmission purposes: Part 2 Aluminium conductors, galvanized steel reinforced Aluminium conductors for overhead transmission purposes: Part 1 Aluminium stranded conductors 4 IS 2062 Steel for General Structural Purposes - Specification 5 IS 3043 Code of practice for earthing 6 IS 9968 (Part II) Specification for Elastomeric-insulated Cables - Part 2 : For Working Voltages from 3.3 kv up to and Including 3 3kV 7 IS 1893 Criteria for Earthquake Resistant Design of Structures NMRCL MARCH

179 UIC PUBLICATION S.No. STANDARD NO. DESCRIPTION 1 UIC Resistance to spread of flame 2 UIC 600 Electric Traction with aerial contact line 3 UIC Maintenance guidelines for overhead contact line 4 UIC 870 Technical specification for grooved contact wires 5 UIC UIC UIC OR 8 UIC OR 9 UIC 608 OR Railway Transport Stock Rolling Stock Construction Gauge Effects on the Application of the Kinematic Gauges defined in the 505 Series of Leaflets on the Positioning of Structures in relation to the Tracks and of the Tracks in relation to each other Consequences of the Application of the Kinematic Gauges defined by UIC Leaflets in the 505 Series on the Design of the Contact Lines Installation of 25 kv and 50 or 60 Hz Overhead Contact Lines Conditions to be complied with for the Pantographs of Tractive Units used on International Services 10 UIC 791 R Quality Assurance of Overhead Line Equipment AFNOR PUBLICATION S.No. STANDARD NO. DESCRIPTION 1 X Industrial maintenance Maintenance function 2 X Maintenance - Technical documentations associated with an item throughout its life cycle ISO PUBLICATION S.No. STANDARD NO. DESCRIPTION 1 ISO 1190 Copper and Copper alloys 2 ISO 1035 Hot Rolled Steel Bars 3 ISO 1190 Copper and Copper Alloys 4 ISO 1234 Split Pins 5 ISO 1337 Wrought Coppers (having Minimum Copper Contents of 99,85%) Chemical Composition and Forms of Wrought Products 6 ISO 1460 Metallic Coatings Hot Dip Galvanised Coatings on NMRCL MARCH

180 7 ISO ISO 2092 Ferrous Materials Gravimetric Determination of the Mass per Unit Area Metallic Coatings Hot Dip Galvanised Coatings on Fabricated Ferrous Products Requirements Light Metals and their Alloys Code of Designation based on Chemical Symbols 9 ISO 2340 Clevis Pins without Head 10 ISO 2341 Clevis Pins with Head 11 ISO ISO ISO 2859/1 ISO General Purpose Metric Screw Threads General Plan ISO General Purpose Metric Screw Threads Selected Sizes for Screws, Bolts and Nuts Sampling Procedures for Inspection by Attributes Sampling Plans Indexed by Acceptable Quality Level (AQL) for Lot-by-lot Inspection 14 ISO 3768 Metallic Coatings Neutral Salt Spray Test (NSS Test) 15 ISO 4014 Hexagon Head Bolts Product Grades A and B 16 ISO 4017 Hexagon Head Screw Bolts Product Grades A and B 17 ISO 4032 Hexagon Nuts, Style 1 Product Grades A and B 18 ISO ISO 657 Hot Rolled Steel Sections Steel and Steel Products General Technical Delivery Requirements 20 ISO 68 ISO General Purpose Screw Threads Basic Profile 21 ISO 8402 Quality Management and Quality Assurance Vocabulary 22 ISO 898 Mechanical Properties of Fasteners 23 ISO 9000 Quality Management and Quality Assurance Standards 24 ISO ISO ISO 9003 Quality Systems Model for Quality Assurance in Design / Development, Production, Installation and Servicing Quality Systems Model for Quality Assurance in Production and Installation Quality Systems Model for Quality Assurance in Final Inspection and Test 27 ISO 9004 Quality Management and Quality System Elements 28 ISO 965 ISO General Purpose Metric Screw Threads 1.5 Relevant Documents This s should be read in conjunction with the General Conditions of Contract (GC), the Particular Conditions of Contract (PC), the Employers RequirementGeneral NMRCL MARCH

181 Specifications (GS), the Employer's Drawings and any other document including stand alone specifications of various sub-systems forming part of the Contract. In the event of a conflict between the GS and this Specification, this Specification shall prevail. In the event of a conflict between this Specification and any other standards or specifications quoted herein, the requirement of this Specification shall prevail In case of any discrepancy between main document and appendices, the appendices shall prevail. Notwithstanding the precedence specified in 1.5.2, 1.5.3, and the Contractor shall always immediately seek advice from the Employer s Representative in the event of conflicts between Specifications. The priority order of documents is as indicated (sorted from highest to lowest priority): a. including appendices b. General Specification c. Indian Railway (IR) AC traction manual d. Indian Railway (IR) book of treatise on electric traction distribution of Indian Railway institute of electrical engineer e. Other IR Standards f. International Standards referenced herein g. Other International Standards NMRCL MARCH

182 2 OVERVIEW OF THE PROJECT 2.1 General This Chapter gives an overview of the Project and the information provided in this Chapter is for reference only. The General features of the above Lines are mentioned here in below: Trains are electric multiple unit (EMU). Modern rolling stock with stainless steel body and VVVF 3-phase drive with regenerative braking has been utilised. The cars are air-conditioned. NMRC has planned to adopt Commmunication Based Train Control (CBTC) System i.e., driverless train where Electric Train will run on 25 kv Traction System. Rolling stock maintenance Depot for North South Corridor will be at MIHAN. 25kV single phase AC traction has been utilized with regulated flexible Overhead Equipment (OHE) on priority section. 2.2 Key Challenges The Power Supply, Distribution and Traction systems shall be adequate, safe and reliable. The Power Supply system and Overhead Equipment and shall be guaranteed at each stage of the contractor works. The following are the Key Challenges presented to the Contractor. ; a) The specified level of reliability, availability, maintainability and safety requirements of the System shall be achieved as required in this Specification. b) The space requirement given in the tentative layouts of Rooms, etc. shall be critically reviewed by the Contractor to economise on space and also to provide a layout amenable to good maintenance and operation practices, to achieve an overall economic design. c) Various interfacing issues with other Contractors are required to be resolved to ensure timely completion of the Works. Whilst most of the interface issues have already been addressed, some of them are yet to be identified or finalised during the progress of the work. It is the Contractors responsibility to ensure that all interfacing issues are clearly defined and agreements sought from all concerned Contractors in accordance with the GS and the interface requirements. d) The System Design shall meet the specified performance and operational requirements stipulated in this. e) The Contractor shall assess the work to be done to suppress the effect due to 25kV ac traction (EMI/EMC) on Civil Engineering RCC construction, power, telecom, control, ETS and signalling circuits etc. for safety of public, personnel and equipment. f) 25kV AC & 415 V AC and control cables will require laying at different levels within Receiving Substations, Cable Galleries, Stations. Liaison with the Civil Contractor & other Electrical System Contractors shall be undertaken to ensure that workable solutions for cable installation are established well in advance keeping in view the maintenance requirements. NMRCL MARCH

183 g) The cable feeders, overhead current collection system, other system components shall be designed to withstand the atmospheric pollution and ambient conditions furnished in GS (clause 1.12) relevant to the location where installed. However, the equipment installed in open at the ground level or inside buildings at ground level shall be designed for working in the tropical conditions existing in the area and under the maximum ambient temperature and relative humidity levels prevalent in the area. h) The entire Scope of Works shall generally meet design requirements of fire safety in accordance with Standards. i) The entire installation shall meet the protective provisions relating to electrical safety and immunity, including those required against induced emf caused by 25 kv ac traction. Civil Constraints a) Due to advanced programme of the civil works of Priority Section i.e. MIHAN to New Airport Station, the locations of OHE mast location shall be fixed according to site conditions & requirements. b) However, the N1Tr-02/2016 contractor will be required to interface with the working contractors. END OF CHAPTER NMRCL MARCH

184 3 SCOPE OF WORK 3.1 General The Power supply and Overhead Equipment for Priority Section is to Design, Manufacture, Supply, Install, Testing and Commissioning by the Contractor under this Contract and shall meet all performance, functional, design and technical requirements as defined in this Specification. The scope of work also includes transportation, storage, loading / unloading, insurance and safe custody till handing over of the Facilities The scope of work includes the quality checking and quality management for all the works listed in section 5. The scope of work includes the training to operation and maintenance personnel for the project. The scope of work includes the supply of spares and maintenance tools and maintenance manuals of OEMs. The scope of work includes the design of an Electrical Work Permits plan and the management of the Electrical Work Permits on site, including: - organizing meeting on a weekly basis with other contractors to list the needs of electrical work permits issuance - issuing and collecting back electrical works permits from contractors - de-energizing and locking out of the power supply and OHE contractor s equipment and fixing of earthing pole on the catenaries where required in accordance to the local safety rules and to the electrical work permits. - keeping a record of all the work permits and providing a copy the SHE manager of the Employer representative. Two kinds of electrical permit shall be issued by the contractor: - Electrical Work Permit ensuring that works are allowed and that all equipment have been de-energized and no electrical hazard can be introduced - Testing, Troubleshooting, and Voltage Measuring (TTVM) Electrical Work Permit, for works that needs to be done with the system energized. 3.2 Detailed Description Receiving Substation The scope of work comprises of Design, Manufacture, Shop testing, Supply, Delivery at site, installation, inspection, testing and commissioning of Single phase, 33 kv, 5MVA, Air insulated outdoor type) receiving sub-stations at Mihan Depot. The supply will include control buildings, supporting structures, auxiliary equipment, mechanical linkages, auxiliary circuits wiring, interlocking devices, current and voltage transformers, 33 KV HV cables including accessories from Grid Substation (of MSETCL at Khapri) to RSS, cable end boxes. Necessary sub-assemblies must be assembled in the supplier s plan, accounting for the transportation condition The RSS includes the various facilities inside the RSS premises, bound by a fencing or boundary wall. The works include, but not limited to NMRCL MARCH

185 a. High Voltage bays b. Civil Works including the Control Room Building, c. Equipment inside the Control room d. Cabling. e. HV (33 kv) cable laying works from MSETCL Sub station to RSS f. Two 33/25 kv 3MVA, Single phase Traction Power Transformers In general the Contractor is responsible for all works within the RSS premises and related to HV cable laying from MSETCL Substations to NMRC RSS, Civil Works includes the following: a. Geotechnical investigations to determine the safe bearing capacity of the soil and other design parameters, including Soil conductivity, b. All Civil Works in the RSS, including but not limited to land preparation, drainage, access roads, design and construction of the Control room building complete in all respects and cable paths and cable trenches in the Transformers yard, as well as inside the Switchgear room and control room. Contractor shall also execute all utility works like fire detection, fire alarm, fire fighting, water supply, sanitary & sewage, storm water drainage works, etc,. c. Yard lighting d. Lightning protection masts e. Transformer Oil sump f. Baffle walls g. Boundary wall along with gates h. Design and installation of Earth Mesh i. Earthing arrangements in Switchgear room and Control Room building j. Earthing of fencing/boundary walls High Voltage Bays Incoming Bays Supply and erection of all Switchgear, Measurement transformers, lightning arresters, bus bars, jumpers, steel structures along with their foundations to support the various equipment / bus bars Supply and erection of any other component or material required to make the installation complete and operable Traction Power Transformer outgoing bays Supply and erection of Power Transformers Supply and erection of all Switchgear, Measurement transformers, lightning arresters, bus bars, jumpers, steel structures along with their foundations to support the various equipment / bus bars Supply and erection of any other component or material required to make the installation complete and operable. NMRCL MARCH

186 Coupling bays Supply and erection of all Switchgear, Measurement transformers, bus bars, jumpers, steel structures along with their foundations to support the various equipments / bus bars 3.2.5Equipment inside the Control Room Supply, installation and putting into operation of Digital Protection Equipment/ Bay Controllers for 33/27kV, and linking with the HV equipment in the yard Supply, installation and putting into operation of all 33 kv & 25 kv control equipment and relay & Control panels Providing a Gateway for SCADA to be provided in future to support control and monitoring of all 33 kv and 25 kv system from the Operations Control Centre (OCC) proposed to be located at Sitabuldi and Backup Control Centre (BCC) proposed to be coming up in Metro HQ of Metro Bhawan. The gateway shall be Ethernet compliant Supply and erection of all other equipment in the Control room as necessary, to enable the protection, control and monitoring of all 33 kv and 25 kv equipment, from Bay level and Control room level (and in future through SCADA from Operations Control Centre) Cabling The Contractor shall be responsible for Supply, Laying, Testing and Commissioning (including integrated testing and Commissioning) of HV Cables for Receiving Substations at above mentioned locations. This includes all works such as excavation of ground, provision of HDPE pipes, restoration of ground and all other works required to make it fully functional Cable in all respects. The concerned work would comprise of: Supply of 33 KV HV cables as per requirement specified in PS and in accordance with the International Standards. Final location survey and confirmation of utilities, preparation of final construction /cable layout drawings indicating cable pull boxes, joint locations, any uncharted utilities, utility/route diversions if any and co-coordinating with the various State and Central Government Departments & utilities whenever and wherever necessary on the behalf of NMRC. The coordination with city agencies shall also be done for the purpose of crossing over/under or minor shifting of utilities for cable laying etc. in case of major problems NMRC may also assist. This includes taking permission, depositing fees, if any & taking clearance after restoring back the works & handing over. This will also include depositing cost of restoration works, penalties on any account levied, security deposits or compensation for any damage or loss during the course of work. Fees deposited by the contractor to Government Agencies for obtaining permission for laying of HV cables shall be reimbursed by NMRC on submission of documentary evidence of payment. Only road restoration charges paid by the contractor to the civic agencies will not be reimbursed by NMRC and therefore the price of Road restoration shall be included in the price schedule. NMRCL MARCH

187 Barricading, excavation along the cable routes, preparation of trenches, sand cushioning, coverings, reconstruction as per site conditions and as per drawing. The works will be secured by adopting adequate safety measures. Laying of the HV cables & protection as per [IS: ], international standards and manufacturer s recommendations. Supply of complete kits with accessories for Jointing, Cross-bonding, mid-point bonding, single point bonding, termination of cables, cable termination structure and jumpering at GSS of PSA, its installation and commissioning using appropriate techniques as specified with the approval of employer. The joints to be located and secured in a joint box as per approved drawing with adequate looping length. Provision of required number of sheath voltage limiters (SVL s) and earthing electrodes as necessary and commensurate with soil resistivity and bonding. Provision of multi-conduit HDPE pipes of adequate mechanical impact strength embedded in concretes as laid in ground with proper separation for road crossing or abutment (in the case of Cable crossing the rail/road) and making a bridge to cross the cables over nallah or drains. Restoration of the routes excavated for the cable laying and other concerned purposes to the original position within given time span. Provision of chamber boxes etc. if required for locating/housing the cable joints, cross bonding and earthing etc. Providing necessary (RCC) protection covers, route markers & sand cushions for the cables. Testing and commissioning of EHV cables. Providing barricades for protection of work, deployment of traffic marshals, watch & ward and traffic diversion works to the satisfaction/approval of the Traffic Police department. Interface with TRANSCO and DISCOMs for obtaining power supply at receiving substations including necessary protection and insulation co-ordination. Employer/Employer s Representative will assist. Evaluation & checking of proposed design/ layouts as specified in tender, preparation of final or modified layout & construction drawings, protection schemes for approval of employer and final construction drawings. Preparation of drawings, OEM maintenance manuals Items of Works The following items of work are within the Scope of this Tender. - Final location survey of the Route for HV cables between the Grid Substation of Power Supply Authority Khapri TSS and the proposed NMRCL RSS at Mihan Depot. - Submission of details of possible alternative routes, together with their implications on Work Methodology, Execution time, cost, utilities affected to be diverted and acceptable to civic bodies. NMRCL MARCH

188 - Preparation of cable paths as per the route accepted by the Employer and in accordance with approved designs. - Laying of cables in accordance with the Methodology (pulling, running out or ploughing in) accepted by the Employer. - Straight through joints - Cable terminations at either end. - Cable termination structure and jumpering at GSS of PSA connecting cable to the supply point. - Single bonding or Cross-bonding as necessary with SVLs and earthing as per approved design - Laying of Control and Monitoring cables (copper-core or optic fibre) for protection and communication between the Receiving Substation of Power Supply Authority and the NMRC RSS - Testing and Commissioning of the Cables - Supply of Special Tools and plant and spare parts as specified in the Bid Documents - Supply of Operation and Maintenance Manuals for EHV cables - Deal and resolve in co-ordination with the Employer the interface with Local Authorities like NMC, NIT, BSNL, MSETCL and other state government authorities etc to ensure progressing of the field works as per schedule - Deal and resolve in co-ordination with the Employer the interface with MSETCL/MSEDCL and other Power Supply Authorities, to ensure completion of works in their premises, as per schedule. - Interfacing with other Contractor as required RSS HT Cabling a. Supply, Laying, Testing and Commissioning of HV (33kV) cables from Grid Substation (GSS) of Power supply Authorities to NMRCL Receiving Cum Traction Sub Station. b. Termination of the 33 KV HVcables in the Cable end boxes/ cable end termination structure at GSS end of Power supply Authorities &NMRCL RSS. c. Supply, Laying, Testing and Commissioning of Control, protection & communication (related to above work) d. All HV 33kV and 25 KV cables inside the RSS premises e. All LV cables and control cables f. All necessary termination and jointing for the various cables. 3.3 Traction Network The scope of work comprises of Design, Manufacture, Testing, Supply, Delivery at site, Installation, Inspection and Commissioning of 33kV/25kV AC 50 Hz Single Phase traction substation, feeding post, sub sectioning post, sub sectioning and paralleling post, sectioning and paralleling post and overhead contact system. NMRCL MARCH

189 3.3.2The scope of work broadly includes Design, Supply, Installation, Testing and Commissioning of: 3.4 SCADA a. Feeding arrangements to the overhead contact system with suitable protection at feeding post. b. Sectioning and paralleling feeding arrangement with suitable protection. c. Sub-sectioning and paralleling feeding arrangement with suitable protection. d. Sub-sectioning arrangement with suitable protection. e. Supply of traction power through overhead contact system with suitable earthing and protection arrangements. f. Associated galvanized steel structures, buildings, foundations, ancillary equipment, feeders, jumpers and connections to overhead contact system, etc. g. Interlocking and protection coordination of various equipment at TSS, FP, SS, SP & SSPs. h. Providing earthing arrangement for all equipment and structures in the TSS, FP, SS, and SP& SSPs. i. Structures and foundations to support the equipment. j. Supply of spare parts and maintenance tools and maintenance manuals. k. Other associated items of work. l. The contractor shall submit six hard copies and two soft copies of drawings including completion drawings Deleted, However while supplying equipment it should be kept in account that the employer may in future provide SCADA through another contract and therefore the list of input output variables are provided in Appendix G and equipment must be amenable for monitoring and control through SCADA then. 3.5 Overhead Equipment The scope of work comprises of Design, Manufacture, Shop testing, Supply, Delivery at site, Installation, Testing and Commissioning of the Overhead Equipment for NMRCL metro project In the main lines on at grade sections, the Overhead Equipment shall consist of simple catenary system for approximately 4.5 Km Route length Deleted InMihan Depot, The Overhead Equipment shall beof tramway type for stabling, workshops, Washing/Pit Lines etc. for approximately 8 Km track length, The overhead line of the test track (approximately 1Km) shall be as main line type The following items of work are within the scope of work of this tender but not limited to: a. All survey on site necessary to do in order to design OHE. b. The design of the OHE. c. Supply and Erection of 25 kv Traction Overhead Equipment for Main line in Priority Section, Depots and Test Line. d. OHE masts with base plate for bridge and without base plate at grade area. e. Design of Tubular Portals with drop arms without base plate at grade. f. Drop arms attached to roof trusses in stations and in depot. g. Cantilever assemblies with silicon insulators for main line and depot. NMRCL MARCH

190 h. Overhead equipment conductors like messenger wire, contact wire, bridle wire for tramway OHE, jumpers, and dropper wires etc. i. Overhead Protection Conductor (OPC). j. Termination assemblies for conductors with silicon composite insulators. k. Anti-creep assemblies. l. Guy rod assemblies with base plate connection for viaduct and U bolts embedded in concrete blocks for depot. m. Regulated OHE with BWA type ATD. n. Cut in insulators and section insulators. o. PTFE Neutral sections at feeding posts. p. Adequate measures to be taken to minimize the EMI impacts on the neighbourhood of Airport by provision of RC BT etc. q. Bonding and earthing including earth mats or electrodes in depot area and Track sides. r. All inspection, testing, integrated testing, and Commissioning of all erected equipment s. Mast foundations including foundation design and calculation and geotechnical investigations shall also be done in order to decide the foundation type. t. Other miscellaneous works. 3.6 Auxiliary Network and Auxiliary Sub-Stations Deleted 3.7 Civil Works and ancillary installations General The Contractor will be required to execute civil, finish & utility works at the RSS locations. The specific nature of civil works, required to be done at various locations, will be different and will be location specific. Broadly, at RSS locations, where no other civil contractor is working, the Contractor will be required to arrange for land preparation, erection of boundary wall, entrance gate, baffle walls between transformers, transformer support anchor blocks, provide architectural services, civil and structural design services and other auxiliary services like water supply, lighting, ventilation, air-conditioning, fire detection and alarm etc, for the Control Room Building. The contractor shall interface with other contractors to design, schedule and execute Receiving Sub Station works. The services to be provided by the Contractor are broadly described in the subsequent paragraphs Land preparation The contractor shall inspect the sites for various RSS locations and gather for good completion of the civil works various details such as topography and land levels, soil condition including the safe bearing capacity, soil resistivity etc, MFL (maximum flood level) at the Substation site, drainage requirements etc.. The site will have to be cleared of all existing encumbrances, levelled and compacted. The finished ground level of the Substation site shall be above the Maximum Flood Level (MFL) in the Region, to be ascertained by the Contractor and confirmed by the Local Authorities. During land preparation, if it becomes necessary to cut or transplant trees, it shall be done by the Contractor with the notice of no objection of NMRC, strictly in accordance with the Local laws Access roads NMRCL MARCH

191 The Contractor will be required to provide suitable access road to the Substation site, from the nearest main road, which shall have necessary width and strength to carry the Power Supply equipment Plumbing & Drainage Plumbing & Drainage of the Substation site shall be provided as per the best engineering practices, so as to prevent surface flooding and pooling of water. For this purpose, suitably designed drains and sumps shall be provided and if the water level inside the sump rises above a predetermined level, the sump water shall be arranged to be pumped out by means of suitable electric/ diesel pumps fixed in the sump. Water supply will be provided to the contractor within 5m from boundary wall of the substation RSS/TSS building civil works The Contractor will have to study the General Layout of the RSS Building. The structure shall be designed and constructed as RCC framed structure as per BIS codes. Based on this, the Contractor will be required to prepare and submit detailed design of civil, structural, architectural and electrical works. All applicable building regulations must be observed, and also the rules for good building practice. After e the Employer s/employer s representative s notice of no objection, the Contractor will construct the building along with auxiliary works, in accordance with approved drawings and designs. Contractor shall submit a detailed safety policy and execute the work as per policy. Contractor shall also carry out all finishing works for the RSS buildings as per notice of no objection issued by Employer / Employer s Representative for finish materials. All operation, maintenance, store and office rooms shall be suitably designed and furnished Cable Routing The Contractor shall provide all cable routing in the transformer yard and inside the RSS/TSS Building Boundary Walls Signage 3.8 Design Along the periphery of the Substation site, contractor will provide a boundary wall matching with the finish of the RSS building and furnish with appropriate suitable MS gates of approved design. Boundary wall shall be Precast RCC Panels. The entire RSS (-cum-tss-cum CR) premises shall be provided with suitable Signage s. All the basic designs, drawings of the power supply and overhead contact system (Flexible and Rigid) shall be arranged by the contractor himself. All designs, legends, notes on drawings and schedules of materials shall be in English and shall be prepared in the metric system and all design and drawings shall conform to specification of Indian Railway RE/OHE/25, ETI/PSI/ Interface The purpose of the Interface Specifications is to provide Project Contractors involved in the interface with a clear overview of the purpose and functionality of each interface. It provides a framework such that Project Contractors can set to work in a co-operative way to produce the interfacing standard. NMRCL MARCH

192 Details of the interfaces of Power supply system and OHE Contractor with the other contractors are in the Interface Specifications in Appendix A. NMRCL MARCH

193 3.10 Documents and Manuals List of deliverables The Contractor shall supply to the Employer s representative s a list of deliverables for the procurement, design, manufacture, Inspection, testing, installation, training, maintenance and operation of the Works. The contractor list of deliverables shall list all documents required in General Specification and list the document drawings etc that the contractor intend to produce and submit. All subjects listed in Appendix F List of deliverables shall be dealt in the contractor list of deliverables. The contractor shall duly indicate in the list of deliverables the documents he intends to submit for information only and documents he intends to submit for notice of no objection and the related time schedule. The contractor list of deliverable shall be submitted to employer/employer s representative within 2 months of the date of signing the contract Maintenance and training For the equipment of different stages, the contractor shall be responsible for the maintenance of the equipment supplied under the contract till the Employer s Taking Over of the whole works related to that stage. The contractor shall be responsible for the supervision of maintenance of the equipment supplied under the contract during the DLP. The Contractor, upon noticing any defects, deficiency in quality and quantity of spares and materials shall without delay, arrange for alternative source of supply and submit his proposal to the Employer s Representative for review. During the Defects Liability Period (DLP) maintenance of all Works will be conducted by the Employer under the supervision of the Contractor. The Contractor shall ensure that in order to supervise maintenance during the DLP, personnel are always available with the relevant skills and level of competence. During the Defects Liability Period (DLP), in the event of a failure, the Contractor shall undertake the management and investigation necessary to identify and rectify the cause. The Contractor shall provide staffs who are expert in all the different levels of fault finding, maintenance and repair of the various systems supplied under the Contract covering the following: a. Cabling system (33 kv ac, 25 kv ac) b. Receiving Traction substation (33 kv / 25 kv) c. 25 kv OHE (Flexible) Stipulations of section 12.3 of the General Specification shall apply here. The contractor shall provide training that enable all the installations, to be operated and maintained in the most efficient and safe manner, so as to achieve the maximum reliability and economy required by Metro System. NMRCL MARCH

194 4 PERFORMANCE REQUIREMENTS 4.1 General The Power Supply system and Overhead Equipment shall achieve all performance requirements as specified in the Specification when operating in the Priority Section. All subsystems, equipment to be used for the Power Supply system and Overhead Equipment shall be of proven design and in use in other passenger carrying metro/railway systems. The system shall meet or exceed the requirements of CENELEC Standards EN50126 or equivalent international standards for Reliability, Availability, Maintainability and Safety of electronic equipment. The latest versions of the specifications should be followed in respect of all standards. In case of loss of one traction transformer supply in the RSS, there should not be any impact on the normal Train operation. In such case Train operation shall be possible with two three cars trains in Priority section. For all transformers, the transformers losses (iron/copper/load) shall not exceed the expected values specified in Volume 4 Appendix B Technical Sheets. 4.2 RAM Specifications 4.3 RAM (Reliability Availability Maintenance) Plan a. The contractor shall provide a maintenance plan of the system and equipment. b. The maintenance plan shall provide a complete list of preventive maintenance procedures for each type of equipment supplied under the contract. c. The Contractor shall define and present in the maintenance plan: i) The technical means and procedures necessary for the operator to perform his maintenance operations ii) The maintenance time and workforce for every procedure iii) For corrective maintenance, the minimum information necessary for the operator to define, when an alarm occurs, the exact nature of the failure, as well as the precautions to be taken (by the operator) to perform efficient maintenance tasks. iv) For corrective maintenance, the tests and controls to perform in order to identify the exact nature of the failures, and after repair, to ensure the compliance of the equipments and their proper and safe operating condition. 4.4 RAM Requirements Verification i) The achievement of the RAM requirements is measured during the whole performance checking period. If the System does not prove during performance checking period its ability to satisfy to the RAM requirements, performance checking period can be extended by the Employer. In that case, the Contractor shall improve the System until the System reaches the specified RAM requirements. NMRCL MARCH

195 ii) During all the warranty period, should one or several RAM requirements not being achieved for reasons under the responsibility of the Contractor, the Contractor shall improve the System by modifications of material, or procedures until the System met all the requirements. In this case, extension of warranties shall be implemented at no additional cost for the Employer. 4.5 Reliability Requirement The Reliability measure for the Power Supply system shall be the Mean Time between Maintenance Action (MTBMA) The Power Supply system shall achieve a MTBMA of no less than 7 days for the RSS Maintenance actions shall include investigations where no fault or failure is identified. 4.6 Availability Requirements The Contractor shall be responsible for providing a System design, maintenance procedures, and defining the recommended spares holdings to ensure that the Availability requirements of the Power Supply system and Overhead Equipment shall be achieved The availability of the Power Supply and Overhead equipment system shall be 99.99% For the purposes of availability calculations, the Contractor shall assume that the service operating hours are 19 hours per day (05:00 hrs to 00:00 hrs), for 365 days a year The availability of the Power Supply system and Overhead Equipment shall be demonstrated by the Contractor in accordance with the processes defined in the Specification. 4.7 Maintainability Requirements System and Equipment design a. The System shall be designed to maximize Availability during traffic hours, to minimize the amount of maintenance required to maintain the System and to ensure that any maintenance can be carried out with the minimum amount of time, the minimum amount of skill and at a minimum cost. b. The contractor shall provide details of corrective and preventive maintenance activities. c. The Contractor shall design the system in order to allow easy cleaning operations. d. Accessibility to test and diagnosis interfaces, to event recorders shall be effortless. Their access shall be designed and located in that way. e. The Contractor shall design the System in order to allow most of the maintenance workload to take place during Business Hours. f. The System shall inform the operator of any failure, dysfunction or disrupting event that could occurs on the System. The understanding of diagnosis data by maintainers shall be easy and shall not require any specific expertise of the system. g. The Contractor shall identify with tags: cables, connectors, relay, switches, fuses, circuit breakers, test spots as well as any devices that the maintainer should have to manipulate Service Life a. All components, materials, software and other support required to repair and service all Power Supply system and Overhead Equipment shall be available for at least 30 years from the Employer s taking over of the Works or Section. NMRCL MARCH

196 b. All updated components shall be fully backward compatible with the originally installed component. 4.9 Safety Requirements The contractor shall provide a Power Supply system and Overhead Equipment for the safe routing, spacing, movement and control of trains and protection of the passengers in platforms. The Contractor shall establish and assume complete responsibility of the system safety through the application of engineering and management principles, criteria and techniques to optimize all aspects of safety throughout all phases of the system life cycle. This shall apply to all systems supplied under this contract. The Power Supply system and Overhead Equipment shall not lead to an unsafe condition when the plug-in module/card/equipment is taken out. The safety performance requirement shall be achieved with a calibration/inspection interval of not less than 1 year. The safety of the Power Supply system shall be demonstrated by the Contractor in accordance with the process defined in the GS. All Power Supply system and Overhead equipment shall be protected from damage or reliability degradation due to vibration, shock and other atmospheric conditions SCADA, control and monitoring Deleted NMRCL MARCH

197 5. FUNCTIONAL REQUIREMENTS 5.1 General Contractor shall issue during its preliminary design a functional preliminary specification for the whole Power Supply system and overhead equipment, rehearsing all the function achieved by the system and their taking in account in the different Power Supply system and overhead equipment sub-systems. For each Power Supply system and overhead equipment sub-systems, the contractor shall issue during its preliminary design a functional preliminary specification in respect with the requirements of this section 5. Content of those preliminary functional specifications shall be detailed by contractor during detail design stage in detailed design functional specifications. 5.2 Receiving Substation 5.3 High Voltage protection Incomer Line Protection Following section details the specifications for the Incomer feeder (Applicable to 33kV Incoming feeder circuits) to RSS from MSETCL. Incomer from MSETCL shall have the following main Protections: Line Distance Protection for 33 kv feeders having feeder cables length more than 3 km. Backup O/C protection (Both time delayed and Instantaneous) The Contractor has to liaise with MSETCL during detailed design stage for the integrated protection scheme Line Distance Protection A high speed full scheme distance protection with at least three zones should be possible to include in order to get fault clearance in case of communication failure, it shall be possible to have the distance protection continuously in operation or only released for operation at communication failure. The distance Protection shall have characteristics that will give load encroachment discrimination and load current compensation of the reactance line in the first zone to avoid over reach. It should be possible to set the distance Protection zone in forward, reverse or non directional mode. Each zone should have individual resistive and reactive reach settings. Separate phase selection logic and automatic switch onto fault logic should be included Backup O/C Protection (both time delayed and instantaneous) Shall have three over current Elements Shall be of Numerical type with full compliance to IEC standards Shall have facility to select any type inverse characteristics as per IEC to suit requirement Shall have separate High set element for instantaneous function Shall be built in configuration logic to assign inputs/outputs to any functions IED shall have LED for relay healthiness & unhealthiness Integration of Backup O/C Protection within the Bay Control Unit (IED) will be acceptable. NMRCL MARCH

198 5.3.4 Bus bar protection Receiving Substations (33kV) shall be equipped with a full fledged Bus bar protection system with following specifications: Numerical bus bar differential protection scheme with full compliance to IEC standards shall be provided for each main bus at the receiving substation Bus bar protection for each bus bar shall incorporate a main protection and check feature Each Bus Bar protection scheme shall a. Have maximum operating time up to trip impulse to trip relay for all types of faults of 25 milli seconds at 5 times setting value. b. Operate selectively for each bus bar c. Give hundred percent security up to 40 KA fault level for 220KV and 31.5 ka fault level for 33kV. d. Incorporate continuous supervision for CT secondary against any possible open circuit and if it occurs, shall render the relevant zone of protection inoperative and initiate an alarm e. Not give false operation during normal load flow in bus bars. f. Incorporate clear zone indication. g. Be of phase segregated and triple pole type h. Provide independent zones of protection. i. Include individual high speed electrically reset tripping relays for each feeder j. Be transient free in operation k. Include continuous D.C. supplies supervision. l. Not cause tripping for the differential current below the load current of heaviest loaded feeder. m. Shall include trip relays, CT switching relays (if applicable), auxiliary CT s (if applicable) as well as additional power supply modules, input modules etc. as may be required to provide a Bus-bar protection scheme for the complete bus arrangement i.e. for all the bay or breakers under this specification as well as for the future bays as per the Single line diagram for new substations. n. Shall incorporate continuous supervision for CT secondary and shall render the relevant zones of protection in operative against possible open circuit and protection transferred to check zone only CT switching and External Zone formation is not acceptable Built-in Local Breaker Backup protection feature as a part of bus bar protection scheme shall also be acceptable The Bus Bar protection relays shall be equipped with built-in DR and Event recorder IED shall have LED for relay healthiness & unhealthiness Transformer protection Main Protections Following sections detail the technical specifications for transformers for different voltage levels. Each Transformer will be provided with the following Main Protections: a. Differential Protection b. Restricted earth fault Protection c. Standby earth fault Protection d. Backup O/C protection (Both time delayed and Instantaneous) Transformer Differential Protection Transformer Differential Protection shall be based on Numerical relay technology, conforming to IEC standard and shall be suitable for protection and monitoring of 3- phase SWR Transformers and single phase traction transformers. It shall have the following features: a. Be triple pole type, with faulty phase identification/ indication NMRCL MARCH

199 b. One IED shall be designed to operate correctly over a wide range of frequency range in order to cope with Power system frequency variations during disturbances. c. IED shall be based on advanced and proven algorithms to handle multitude of application and shall support user friendly Engineering tool and disturbance handling tool. d. It shall be possible to integrate the Protections functions for Transformer into one IED. e. The IED shall have extensive self supervision including analogue channels. The configuration of the IED shall be such that it will suit most applications and if needed the same shall be modified easily. f. Transformer differential Protection with short operate time shall be included and shall have automatic ratio matching the vector group compensation. Use of Interposing CT s for ratio correction will not be acceptable. g. In order to ensure through-fault stability is external summation of currents not recommended. h. The differential Protection shall have a settable restrain characteristics and a high set unrestrained function shall also be included. i. Second harmonic restraint features shall be included in order to avoid tripping at inrush currents. j. Fifth harmonic restraint feature shall be included to avoid tripping at over excitation condition. k. Adaptive stabilization for system recovery inrush and Ct saturation at external faults shall be included. The IED should utilize a measuring principle that gives high sensitivity for turn to turn faults. l. High and low impedance based restricted earth fault protection with short operate time and high sensitivity shall be available within the IED. m. It shall be possible to include Backup Protection functions such as instantaneous over current functions for phase and earth faults and time delayed directional/non directional over current functions with inverse and definite time characteristic with at least three two steps for phase and earth faults. n. Other current functions such as thermal overload alarm based on thermal model and trip steps shall be possible to include within the IED. o. The IED shall be provided with programmable logic for tripping and indications as well as high number of logic blocks and timers for adaptation. p. IED should have built in disturbance recorder and event recorder. q. IED shall have LED for relay healthiness & unhealthiness Restricted Earth Fault Protection Restricted earth fault Protection will be based on Numerical technology and shall have following features: a. Be single pole type b. Be of current/voltage operated high impedance type c. Have a current setting range of 10-40% of 1 Amp./ have a suitable voltage setting range. d. Be tuned to the system frequency e. Be used for HV and LV winding wherever applicable Standby Earth Protection (only for station transformers) a. Have Non directional earth fault protection with IDMT characteristic with a definite minimum time of 3.0 seconds at 10 times setting and have a variable setting range of 20-80% of rated current. b. Shall be numerical type NOTE: Integration of following Protections of Transformers into one Protection unit IED is acceptable: NMRCL MARCH

200 - Transformer Differential protection - Restricted earth fault Protection - Standby earth fault Protection Backup O/C Protection (both time delayed and Instantaneous) a. Shall have three over current Elements b. Shall be of Numerical type with full compliance to IEC standards c. Shall have facility to select any type inverse characteristics as per IEC to suit requirement. d. Shall have separate High set element for instantaneous function. e. Shall be built in configuration logic to assign inputs/outputs to any functions. NOTE: Integration of Backup O/C Protection within the Bay Control Unit (IED) will be acceptable BUS COUPLER Following sections detail the technical specifications for both Bus coupler circuit at the Receiving substation. Backup O/C protection (Both time delayed and Instantaneous) Shall have three over current Elements Shall be of Numerical type with full compliance to IEC standards Have facility to select any type inverse characteristics as per IEC to suit requirement. Shall have separate High set element for instantaneous function. Built in configuration logic to assign inputs/outputs to any functions. Integration of Backup O/C Protection within the Bay Control Unit (IED) will be acceptable. Under Voltage Protection 33kV line shall be with Under Voltage Protection Interlocking The contractor shall submit interlocking plan for approval of employer. 5.4 Traction Network 5.5 Traction Substation Receiving Traction Substation performs the task of converting the 33 kv incoming power to 27.5 kv single phase power and of supplying this power to the traction overhead equipment through appropriate switchgear and protection arrangements. Traction feeder stations are fitted with 25 kv circuit breakers for ensuring the isolation of the faulty sections. The purpose of the protection equipment is to ensure isolation or de-energizing of a system or equipment whose operating conditions have become faulty and/or abnormal to avoid: - any major repercussions on the traffic - any damages or dangerous effects to person and equipment The protection relays required for protection of Traction Feeders (Overcurrent, Distance) and for protection against Panto flash over, DELTA I relay for pure;y resistive fault and Wrong phase coupling at Neutral Sections, shall be provided by the Contractor. In addition, the protection relays required for protection of feeders to Depot/s (Line differential, if required and Overcurrent) shall also be provided by the Contractor. All the instantaneous relays should be capable of operating the circuit breaker within a duration of 120 ms from the occurrence of the fault. This time duration should include the dead time of the relays and this feature should be demonstrated during testing of the relays. NMRCL MARCH

201 5.5.1 Traction Protections The purpose of the protections installed in traction feeder stations is to isolate all or part of the dependent equipment from the network, in case of phase-to-phase or phase-to-earth /rail fault. The Traction Protection system can be broadly divided into two main groups: - Traction set protection, which will essentially include all equipments starting from the HV busbar to which the Traction Transformers are connected, upto the 25kV busbars from which the 25kV Traction Feeders take off kv Traction Feeder Protection, including OHE protection Traction set protection Each HV circuit-breaker located upstream the power transformers ensures the protection of : - the bus bars for connection to transformers on the HV side. - the transformer, - the 25 kv bus bars located downstream, These protections include: - phase-phase and homopolar over-current protections on the HV side (fn 5051 and fn 50N- 51N)., - the differential current protection of power transformers (fn 87), - the over-current protection located on the secondary winding side of the transformer(fn 50-51), - the over current tank relay protection installed on the main transformer (fn64), - The buchholz relay, installed on main tank and tap changer tank, as well (fn 80), - the temperature relay (fn 49) including : - oil temperature, - winding temperature Directional power protection The function of directional protection (fn32) is to check the power transit direction in the catenary system, mainly due to regenerative braking, which could flow back to the HV grid through the transformers. Two stages are involved: - a slow one, - a quick one. When the first stage is activated, a signal is emitted and a time-out 1 is started. When timeout 1 ends, a second signal is emitted. If, after 3 minutes, the fault still persists, a tripping command is sent to the concerned traction set circuit-breaker. When the second stage is activated, at the end of time-out 2, a tripping command and signal are emitted by the protection device; the 1st stage and 2nd stage current thresholds can be parameterized as well as time-outs, and angle of straight line D can be adjusted. - F 50: Instantaneous over current protection - F 51: Time delayed over current protection - F50 N: Instantaneous earth fault protection (homopolar) - F51 N: Time delayed earth fault protection (homopolar) NMRCL MARCH

202 Track feeder Functional description From a feeder station, and for the same direction, each track is fed and protected through an assigned circuit breaker. Each portion of OHE fed by a circuit breaker is called "sector". Each sector is sub-sectioned into elementary sections (catenary section between two breaking apparatus). The sectors of same direction are put in parallel at the level of the paralleling station through interrupters. All the fault on: - the catenary network, together with the switchgear directly connected thereto, - the rolling stock (upstream the circuit breakers), - the paralleling stations (bus-bars, switchgear), are detected and protected by the circuit breakers of the feeder station according to the following sequence: - a fault is detected by the two protection devices (minimum Z or Over current) of the same direction through the paralleling, - the related two circuit breakers are switched off, - the fault localisation system is put into service (operation is described later), - the paralleling interrupters open due to the lack of power on the two tracks after a temporisation of about 500 ms, - The re-closing order is given to circuit breaker within about 7 seconds, If the fault remains (10% of the cases): - the circuit breaker of the faulty sector trips and this is blocked open for 3 mn, - the fault locator determines the faulty elementary section - the circuit breaker for the healthy sector switches on. If the fault is transient (90% of the cases): - the 2 circuits breakers re-close, the paralleling interrupters close following the energising of the two sectors, after a temporisation of approximately 1 mn Track feeder protection Each track feeder circuit-breaker is actuated by :-Minimum impedance protection,(fn 21) -Over current protection (fn 50-51). - F87: Differential Current Protection for TSS feeder CB s which are directly connected to switching posts in underground section. All other necessary provisions, space, CT cores, wiring etc. to be provided by the RSS contractor. Relay shall be provided by Traction contractor Differential protection Differential protection is designed to detect faults in the area set to be protected. This protection shall be provided where the supply is extended to the main line having separate feeder breakers at the feeding post of underground station. This will work as replacement to impedance protection relay and the RSS contractor shall interface with the Traction contractor for provision of impedance relay at feeding post. NMRCL MARCH

203 Minimum impedance protection This module is a single-phase impedance measuring (in R-X co-ordinates) relay, which operates when the impedance value falls below a selected adjustment threshold. The minimum impedance module defines the quadrilateral characteristic by fixing the straight lines D1, D2, D3 and D4. The possibilities of adjusting the various elements of the parallelogram enable it to be adapted to various network conditions. This protection is directional and selective; it makes a distinction between a high load and a distant fault of small intensity. The minimum impedance protection is self-supervised and an internal fault in the protection entails the tripping of the associated circuit-breaker Over current protection An over-current protection is designed to detect faults occurring very close to the feeder station. This protection causes the tripping of the circuit breaker when the current reaches a value exceeding the highest load on the network. NMRCL MARCH

204 Two stages of operation are foreseen: - an instant one, - a time-delayed one. The tripping curves can be of two types: constant over time, if necessary, dependent over time, following an inverse, highly inverse or extremely inverse characteristic. It should be noted that protections with thermal images, which are widely used in distribution networks, are not suitable for a 50 Hz catenary system Differential protection Differential protection is designed to detect faults in the area set to be protected. This protection shall be provided where the supply is extended to the main line having separate feeder breakers at the feeding post of underground station. This will work as replacement to impedance protection relay and the RSS contractor shall interface with the Traction contractor for provision of impedance relay at feeding post Selectivity of protections Selectivity calculation is based on the second-stage time-outs of over-current protections. As a rule, for a 25 kv fault, it is admitted that the time-out must be minimum but not nil to avoid tripping on a transient current or a load transfer. Therefore, HV protections are calculated with a longer timing, which remains below the power supplier line protection set values Other Protections These protections are mainly concerned with the monitoring of the state and operation of: - SF6 gas pressures of 33kV and 25 kv circuit breakers if any, - transformer temperature (oil), - non availability of auxiliary supply (d.c.). Two stages are involved: - the first one is an alarm, - the second one causes tripping (except for the SF6 gas pressure which entails blocking) of the equipment concerned Voltage protection As a rule, there is no tripping following 33kV or 25 kv under-voltage except for: - cancelling paralleling of two tracks, - loss of voltage in auxiliaries which causes tripping of 33kV and 25 kv circuitbreakers. Only the monitoring and alarm of the upper voltage (25 kv) entail a rapid regression of the transformer on-load tap changer Fault locator This function is activated following a circuit breaker tripping due to: - Minimum impedance detection, - Over current, allowing an auto reclosure sequence. The fault locator measures the catenary/ rail loop fault impedance and compare with the minimum impedance relay and determine the kilometre point from the feeder station Switching Stations Traction power at 25 kv is fed to the main line or depot from the Traction Transformers located in the premises of Receiving Traction Substations (RSS), as explained below. For NMRCL MARCH

205 purposes of operation and maintenance, the Traction Overhead Equipment between 2 Traction Substations is subdivided into several smaller sections by introducing switching stations as per Volume 5 drawings. - Traction feeding and sectioning diagram- corridor Switching posts fall mainly under 3 Categories: a. Sectioning Post (SP) It is a supply control post situated mid-way between two feeding posts at the neutral section and provided with bridging and paralleling interrupters. The function of Sectioning Post is to segregate the power supply feeds from adjacent substations, since the 2 feeds will have a phase difference between them and cannot be coupled together. The Sectioning Post SP will have a Neutral Section in front of it and the OHE on either side of the Neutral Section will not be bridged. In present case there is no SP in the scope of contract. b. Sub Sectioning and Paralleling Posts (SSP) At strategic intervals the OHE is Sub Sectioned by means of an insulated overlap, which is normally bridged by an interrupter. In addition, the Up and Dn track OHE s are paralleled at these SSP s by means of Interrupter. The SSP provides a Sectioning facility and also helps to improve the voltage regulation because of paralleling. In present case there shall be two SSP within the scope of contract, one at Khapri station and other inside Mihan depot. c. Sub Sectioning Station (SS) With a view to limiting the length of any section of OHE, which can be affected by a fault or an electrical isolation for maintenance, the OHE is further Sub Sectioned, so that generally not more than 3 or 4 Metro Stations fall in one Sub-section. No paralleling facility is provided at these SubSectioning Stations. In present case there is no SS in the scope of contract The protective provisions for overhead contact line systems serve the basic purpose of sensing and evaluating the occurrence of any electric faults and overloads, in order to: - Prevent or keep to a minimum any damage to the contact line installations and equipment, - Minimise the hazards to persons being directly or indirectly exposed to impressible voltages, - Maintain the best possible availability of the traction power supply and - Provide and process information which assists fault analysis Isolator Under Voltage Protection - 25kV line shall be with Under Voltage ProtectionLocking and interlocking arrangements: an interlocking device which makes the operation of the isolator or earthing switch dependent upon the position or operation of one or more other pieces of equipment The operating mechanism box shall have provision for a padlock for locking its door The isolator shall have provision for locking its main rotating shaft with the help of padlock, both in Open as well as in Closed positions The pad locking in any intermediate position shall not be possible. Besides the above, the isolators shall have two locking mechanisms, for the purpose of interlocking with the associated circuit breaker(s) However, mounting arrangement for these locks shall be provided by the manufacturer in such a way that it is possible to insert the key(s) from outside for operation of lock(s) and the successful bidder shall coordinate with manufacturer of circuit breaker and the employer for this purpose. NMRCL MARCH

206 Earthing switch The operating mechanism box shall have provision for a padlock for locking its lid A mechanical interlock shall be provided in the operating mechanism of isolator and earthing switch, so that operation of earthing switch is possible only when the isolator is locked in open position This interlock shall also prevent closing of isolator unless earthing switch is locked in open position An integral lock shall be fitted in the operating mechanism box of the earthing switch for locking the operating mechanism both in Open as well as Closed positions The design of the earthing switch shall be such as to permit use of a padlock for locking the operating handle of the earthing switch both in Open as well as Closed positions Interlocking arrangements for 25 KV Circuit Breaker: The CB shall be provided with a suitable interlocking device for electrical and mechanical interlocking with its associated isolator(s), such that: - the isolator(s) can be operated only when the CB is locked in open condition, and - the CB cannot be operated both manually and electrically either on LOCAL or on REMOTE unless the isolator(s) is locked in the CLOSE or OPEN condition Three types of isolator interlocking schemes shall be utilized. The details of these schemes are indicated below: Single isolator interlocking (SI) a. Under this scheme, the circuit breaker shall be interlocked with its single associated isolator. This interlocking scheme shall be provided on the circuit breaker to be installed as transformer breakers and circuit breaker for controlling feed to the shunt capacitor. b. In this scheme the key shall be trapped in the lock mounted on the circuit breaker mechanism when the circuit breaker is in closed position. c. The key can be released from the operating mechanism when the circuit breaker is in the open position only. d. Any attempt to forcibly withdraw the key when the circuit breaker is in the closed position shall result in tripping of the circuit breaker. e. The key thus released from circuit breaker shall be utilized to operate the lock mounted on the isolator. f. It shall be possible to release this key from the isolator lock only when the isolator is locked in open or closed position. g. Once the key has been removed from the circuit breaker operating mechanism, it shall not be possible to operate the circuit breaker either manually or electrically by local / remote control Double isolator interlocking (DI) a. The scheme is identical to the SI scheme but in this the circuit breaker shall be interlocked with its two numbers associated isolators. b. The interlocking shall be provided on circuit breaker to be installed as feeder breakers Bus coupler isolator interlocking (BCI) a. Under this scheme the circuit breakers of adjacent bay shall be interlocked with the bus coupler isolator / interrupter. b. The operation of the bus coupler isolator/interrupter shall not be possible unless both the circuit breakers of adjacent circuit are locked in open position. c. In this scheme the two keys so released from the circuit breakers shall be inserted in a key exchange box (which shall be supplied loose) for releasing a third key which shall be used for operating the bus coupler isolator NMRCL MARCH

207 /interrupter The interlocks provided on the circuit breakers installed at a traction sub-station a. shall have non-interchangeable key codes to safeguard against any misoperation. a. The lock meant for mounting on the associated isolator(s) and bus coupler isolator shall be bolt type lock of approved design. b. The internal mechanism of the lock shall be made of non-ferrous metal and the outer housing shall be of steel hot dip galvanized One spare duplicate key shall be supplied with each of the three types of interlocking schemes. 5.6 Auxiliary Network Deleted 5.7 SCADA, control and monitoring Deleted NMRCL MARCH

208 6. DESIGN REQUIREMENTS 6.1 General This section is dealing with Power Supply system and overhead equipment design requirement. Regarding all transformer supply for this contract, power losses are a real concern. Contractor shall design and size the transformer so that performance requirement is fulfilled and so that transformer losses are as low as possible. The contractor shall ensure that the designs proposed are of most modern and latest available technology internationally. The contractor shall propose the designs, supported with references of designs adopted in other similar metros in India and worldwide most recently with improvements in the designs based on the Aesthetics, working experience or financial savings. 6.2 Receiving Substation RSS metering General The following metering arrangements shall be provided at the Receiving Substations On the Incoming Feeders from the Power Supply Authority a. Ammeters (to read the value of current in each phase of each of the Incoming Feeders) b. Voltmeter (to read the value of line voltages R-Y, Y-B, B-R, in each of the Incoming Feeders) c. Energy meter (Electronic energy meter, Accuracy class 0.2, to enable measurement of Active energy (kwh), Reactive energy (kvarh), Apparent energy (kvah), phase angle, frequency, power factor, instantaneous maximum demand, integrated maximum demand, total harmonic distortion etc. The meters should have recording and memory facilities. One Energy meter is required to be provided, which shall be able to indicate/record/store the total energy of the incoming feeder, through suitable connections). Covered space, if required by Power Supply Authority, shall be provided by Contractor in RSS On the Transformer Output side a. Ammeters (to read the value of current delivered by each Transformer) b. Voltmeter (to read the value of secondary voltage of each Transformer, whether onload or as hot standby) c. Energy meter (Electronic energy meter, Accuracy class 0.2, to enable measurement of kwh, KVAh, KVARh, and instantaneous maximum demand kva. Only one energy meter is required to be provided, which shall be able to indicate/record/store the values of energy (kwh) and max demand (kva), delivered in total by both the Traction Transformers, through suitable summation CT and connections) Communication to RSS and OCC Deleted Testing of Energy Meters. NMRCL MARCH

209 All the energy meters should be tested by the third party agency authorized by Indian Government for testing and calibration of meters. RSS - general electrical works Yard lighting The lighting of the RSS shall be provided to permit circulation in the external area comprising the RSS. A lighting coverage of 30 lux at 1 metre from ground level shall be ensured for the entire RSScumTSS compound. This lighting shall be installed on the main masts, over the conductors, with adequate electrical clearance. This distance shall be at least 3 meters from the conductors. When the mast is inside the area, each face of the mast shall be fitted with one lamp. When the mast is at one border, only the 3 or the two sides of the mast, facing into the area, need to be fitted with one lamp each. The complete lighting fixture shall have an IP code of 55 to ensure a good protection against dust and water (raining). The lamps, low High pressure vapour sodium type, shall have a suitable power to ensure the required level of illumination specified above. Colour temperature will be between 2000 and 2200 K The life duration shall be at least hours Lightning protection The entire Substation shall be protected against lightning by providing either earth screen conductors on tower peaks, or by means of Lightning Protection Masts, suitably spaced to cover the entire area. The height and locations of Lightning Masts shall be designed appropriately, with due consideration to the equipment layout in the RSS, to ensure that all the equipments meant to be protected against lightning are within protective zone provided by the Lightning conductor. The Lightning conductor generally consists of - the lightning receiver projecting above the object to be protected - the earthing grid, and - the conductor which connects the receiver with the earthing grid and is meant to carry the lightning current away safely to ground. The Contractor shall indicate the heights and locations of the Lightning Masts, on the Substation Layout Drawing, and shall also submit supporting design calculations to prove the adequacy of the arrangement to cover all equipments for protection against lightning. RSS layout of equipment and arrangement: Regarding the design, layout of equipment and arrangement, the contractor shall respect the following rules: a. The apparatuses shall be installed according to the group phase layout, whereby the three phases of each circuit are installed side-by-side and advance function-byfunction. b. The architectural configuration of the station shall make it as compact as possible with clear and logical layout of the bus-bars, facilitating, in addition, accessibility to all actuating devices and possible extensions to accommodate equipment to be installed subsequently. c. The means of access to the various equipment for the maintenance staff shall be safe. d. The maintenance personnel shall have access to and shall be capable of moving freely around each element in the cubicles. The equipment may be supported on metal frames provided by the contractor when required. These frames shall not hinder access to any part of the station, nor handling, overhauling, and assembly operations. NMRCL MARCH

210 6.3 Traction Network The Traction Substation mainly comprises of: - 33 kv/27.5kv Traction Transformer (02 nos.) - 33 kv Incoming Circuit Breakers (02 nos.) - One 25kV Bus Coupler Interrupter, along with its 1 isolator with earth switch on cable side of it - 3 outgoing 25kV feeders for Khapri Up /Khapri Down and 1 for Depot SSP, consisting of two circuit breaker with associated Interruptors and its 1 isolators with earth switch on cable side of it - Instrument transformers, as necessary for protection and measurement - Protection relays, measurement meters and associated devices, as necessary - All interconnecting power cables, including 25kV cables from TSS exit point upto the point for feeding the OHE - All return cables from the track-side Impedance bonds to the buried rail at TSS and onwards to the traction transformer - All control and monitoring cables for necessary connection of equipments - Other associated equipments, such a battery, battery chargers, AC and DC Distribution boards, control and relay panels, etc to make the traction substation fully fit to perform its task. 6.4 Traction Transformers The traction transformers shall comply with the standards of the International Electro technical commission (IEC 76) or equivalent Indian standards Characteristics:- The Traction Transformers at TSS shall meet the following characteristics: - 2-phase Primary winding of 33kV - 1-phase secondary winding of 27.5KV - Entirely submerged in mineral oil tank - Outdoor type, suitable for tropical conditions, satisfying the climatic conditions of Nagpur - On load tap changer on primary windings - Possibility of various overload conditions - Separated oil conservator - Cooling by natural oil circulation and banks of radiators mounted on the tank - Both transformers shall be identical - Transformer noise level should not exceed 75dB measured at a distance of 1.5 m - The Vector group shall be I. i. - Should have symphonic filter. Transformer noise level should not exceed 75dB measured at a distance of 1.5 m, The two transformers at any Traction Substation are not meant to work in parallel. NMRCL MARCH

211 6.5 Rated power The Transformers shall be manufactured and guaranteed so as to perform satisfactorily with a power rating, measured across the secondary winding, of 5 MVA under load without forced cooling system in operation (ONAN mode). Cooling System Rating (MVA) ONAN Overload capacity After constant operation at continuous full load, the transformer shall have a guaranteed minimum overload capacity of: - 50% for a duration of 15 minutes, i.e. 7.5 MVA - 100% for a duration of 5 minutes, i.e. 10 MVA After overload the temperature rise shall not be more than: 65 C above ambient temperature for oil. 75 C above ambient temperature for windings 6.7 Rated voltages The primary winding voltage shall be 33 kv, as applicable at a power frequency of 50 Hz, on the main tapping. Operating voltage may increase to + 10% or drop to -15% for the traction transformers. The primary winding shall be fitted with on-load tap changer offering 6 steps ensuring the primary voltage compensation from -15% to +10% of primary voltage. The secondary winding voltage shall be 27.5 kv at a power frequency of 50 Hz, one end being connected to the rails and the earth. 6.8 On-load tap changer Voltage shall be substantially constant at the untapped windings (secondary windings) and variable at the tapped winding (primary winding). The category of regulation applied shall be constant-flux variable voltage type (CFVV) The on-load tap changer shall be single-phase enclosure type, installed in a separate oil tank, offering 6 steps ( +2 step, normal and -3step). The tap changer shall have the following characteristics: operations without any attention - Motor and hand-driven possibility - Tap position indicators - Commutation current compatible with the short duration transformer over-current. - Diverter switches shall be designed for high speed operation and shall be interlocked to ensure that there is no possibility of an operation stopping in mid-position. Arcing contacts shall be of tungsten alloy material. - Devices for ease of extraction for maintenance purpose NMRCL MARCH

212 - Manual/Automatic, Local/Remote, Control & Monitor of OLTC from RSS control room and OCC The oil volume of the on-load tap changer unit must be separated from the tank for core and winding oil. The power circuit of the on-load tap changers shall be connected to the primary windings and shall enable the required voltage variations as mentioned in the annexed technical sheet. The full technical description shall be given as regards power and auxiliary circuits; periodicity for checking and over hauling the power circuit shall be indicated in the transformer maintenance Manual. The servomechanism settings shall be designed and executed to avoid too many actuations The manufacturer shall provide mechanical and electrical diagrams. A suitable protection relay shall be connected on the oil pipe between the on-load tap changer and the expansion vessel. The voltage ratio shall be checked according to the guaranteed figures and the tolerances stipulated in the standards. 6.9 Cooling system The Traction Transformer shall be designed to operate in ONAN/ONAF mode (mineral oil natural / air natural/air forced) The oil along with inhibitor to be used for the transformer must be in conformity with the IEC 296 standard, or IS 335 (with latest amendments) and of the highest inflammability degree. Spare oil for at least 10% of each transformer shall be provided. The maximum temperature allowable at nominal rating shall never exceed: - 50 C above ambient temperature for mineral oil - 55 C above ambient temperature for the copper winding and the iron core. Dielectric strength of the oil during test should be more than 55 kv /2.5 mm; the contractor shall mention the method and the referenced standard employed. The transformer shall be rejected in case the temperature rise exceeds the guaranteed values by more than five degrees centigrade s. The contractor shall give full description of the design, operation and maintenance of the proposed air cooling system for ONAN and indicate the air flows needed for ventilating the cubicle and the air cooling units. In case of fire detection into the transformer cubicle, the air cooling system shall be immediately and automatically switched off 6.10 Short-circuit withstand capability Short-circuit on H.V. side The transformer shall be designed and constructed so as to withstand without damage, or impairment in its performances, any external short-circuit. NMRCL MARCH

213 The primary winding of the transformer shall be designed for carrying the full symmetrical short circuit current, for 3 sec. The full symmetrical short circuit current shall be calculated in accordance with IEC after taking into account the system impedance on the primary voltage of the transformer. The design of the primary side bushings of the Transformers shall withstand the symmetrical current for three seconds during short-circuit on primary voltage as specified in IEC To limit the short-circuit symmetrical current to an allowable value, the impedance voltage shall never be less than twelve percent (12%). At rated power and frequency on the main tapping, the impedance voltage shall be equal to about twelve point five percent (12.5%). Short-circuit on L.V. side The maximum short circuit current at the output of feeder station has to be limited at 16 ka to comply with the rolling stock on board circuit breakers breaking capacity, (compared to distribution network) only limited by the internal transformer leakage impedance. Consequently transformers must be designed taking into account this current short circuit limit, as well as electrodynamics and thermal constraints. The contractor shall specify a guaranteed value and tolerances according to the standards and requirements Iron core The magnetic core, frame assembly, clamping and general structure of the transformer shall be mechanically sturdy so as to be capable of withstanding shocks which may happen during transport or during short-circuits and over-voltages. Cores and magnetic circuit shall consist of cold-rolled grain-oriented silicon steel sheets of the best quality, offering every guarantee of durability, heat and oil resistance The core tightening bolts shall be suitably insulated and the grounding of the magnetic circuit shall employ generously sized copper connections and links. The keying and compression of the laminations, together with the induction value, shall be designed so as to keep vibrations to a minimum and to reduce, in particular, the third and fifth harmonics influences. Calculation sheets to establish maximum flux density (i.e Tesla) shall also be submitted with Design to employer. The contractor shall submit complete technical data of the system to the employer Transformer losses The transformers shall be designed for minimum losses. (No load losses within 2% & Full load losses within 5%) NMRCL MARCH

214 6.13 Windings The winding conductors shall be made of best quality high conductivity electrolytic copper, in compliance with the standard (IEC 60028) requirements. Both windings, primary and secondary, shall be designed to withstand over-voltages and overcurrents in case of direct short-circuit across the medium voltage terminals with the primary winding line for three seconds. Construction shall take into account electrodynamics and thermal constraints specific to railway traction duty The adjustment windings shall be designed specifically to withstand direct short-circuit of all part of the adjustment turns that may occur at the contact plates of the on-load tap changer. The windings, connections and terminal links shall be properly brazed so as to withstand the shocks and vibrations that may occur during transport or short-circuit. Tests on samples shall be carried out and results submitted for approval before starting assembly of the transformer windings. Current density for each winding shall be not more than 2.5 A/mm². The insulation material used for the transformer windings and connections shall be of class A Terminals and connections The primary and secondary connections shall be realized through porcelain/polymeric bushings insulators as applicable. The porcelain shall be brown glazed. It shall be unaffected by atmospheric conditions like fumes, ozone acids, alkaline, dust, sand storms or rapid change in temperature between 0 C and 75 C under working conditions and the prevailing environmental conditions/changes in Lucknow. In order to avoid damages to tank in case of disruptive discharge, bushing base should be connected to the earth. Creepage distance for one bushing should be 3.1 cm/kv. Bushings shall be realized in conformity with the IEC 137 standard. Special care shall be taken against transmission of vibrations by employing a damping system and suitable fittings. The design shall take into account the ease of overhaul. It should be possible to withdraw and to remove the transformer at ease. Interchangeability between transformers shall be achieved through the use of identical elements. The link between secondary terminals of the transformer and the 25 kv switchgear shall be made by cables connected directly at the outside of the secondary bushing. Bushings shall be realized in conformity with the IEC 137 standard. NMRCL MARCH

215 6.15 Tank and radiators The transformer tank shall be made of high quality boiler plate steel with stiffening frame and girders. The thickness of sections shall be suitably sized so that it is possible to dismantle by grinding and redo welding at least three times, before it becomes necessary to condemn the sections and refabricate. The thickness of the tank should not be less than 10 mm, with reinforcement in order to withstand full vacuum, and mineral oil pressure Tank shall only be connected to the earth through current transformer In case of separated radiators, they shall be earthed separately and consequently pipes network shall be mounted with insulating joints. The tank itself, the pipe work, valves, joints and gaskets shall be airtight, watertight and oil-tight. The junction shall be capable of withstanding the temperature of a fire without causing any leak as per IEC standards. The tank shall be fitted with hooking points to enable it being lifted in balance by means of an overhead travelling crane, either as the main package or in form of the complete unit, fully equipped and filled with mineral oil. The frame shall enable the transformer being laid normally on a slab or foundation block, without rollers. Each dismountable tank and radiators element shall be equipped with the following auxiliary devices: - flanged oil drainage valves, - oil sampling cocks at top and bottom of the tank, - flanged valves suitable to connect the oil filtering unit, - hooking points and overall shall be equipped with: - special pockets for checking by thermometers, - earthing terminals according to IEC standard - Frame to ease the transportation - swivelling removable rollers with locking devices. - overpressure relief device provided with electrical contacts - manholes on the tank cover so as to obtain access to the core winding assembly, tap changer mechanism, terminal, the lower ends of all bushings etc. for purpose of repair without lifting the core winding assembly NMRCL MARCH

216 6.16 Oil expansion vessel The transformer shall be equipped with an oil expansion vessel placed above the transformer on a specific support. It shall be partitioned so as to avoid mixing between the on-load tap changer oil and the core and winding oil. Each partition shall: - be connected to the transformer through all the necessary pipe-works, fitted with flexible metal joints and gaskets; the connecting pipe shall over-extend vertically inside the vessel (at least 8 cm) - be provided with, easy to reach, drainage valves, oil sampling devices and relief valve. - be equipped with a dehydrating breather filled with Silicagel or equivalent, permitting easy maintenance during transformer normal operation. - be provided with an oil level indicator having auxiliary contacts and easily observable from ground level. - The oil volume should be above the minimum level, when the ambient temperature is 0 C or below. Similarly the oil volume should be below the maximum level when the ambient temperature is 55 C or above 6.17 Control and protection The transformer shall be delivered with "buchholz", thermal and earth fault protections, all connected to the control and monitoring cabinet "Buchholz" The term "buchholz" protection denote the gas-sampling device and relay for gas fault detection and storage for analysis The relay shall comprise of two thresholds as follow: - alarm in case of minor fault such as local overheating of windings or core (small gas discharge), - tripping-out in case of major fault (violent gas discharge) and excessive oil leakage. Both transformer and load-tap changer oil circuits shall be equipped with "buchholz" protection. They shall be connected to the oil pipe between the tank and the expansion vessel, without any flat part and any less than 50mm bend. It shall be free for access and maintenance; a by-pass system shall be provided to enable oil flow without interrupting operation during maintenance checks. In order to ease gases chemical analysis, the gas-sampling device shall be accessible during transformer operation, at man s working level. Thermostat The thermostat itself shall be installed in the monitoring box, while the indicator on it facade and the thermal probe shall be installed into the tank with appropriate pocket. NMRCL MARCH

217 Earth fault The insulated tank shall only be connected to the earth through a current transformer, which shall be linked to the control system via monitoring cabinet terminal block. Control and monitoring cabinets Made of stainless steel-sheets, grade-304 totally enclosed dust-proof and watertight type (IP55) suitable for outdoor applications it shall be equipped with: a) For transformer - Access doors with padlocks /230 V protection and power circuits V dc control and monitoring relays - Internal lighting monitored by the door position. - Heating thermostat. with indicators and contacts - Information terminal block - Remote control and monitoring multi-pin connector b) For On-load tap changer - Access doors with padlocks /230 V protection and power circuits V DC or 415 V AC (3 ph) or 220 V AC (1ph) motor, control and monitoring relays - Internal lighting monitored by the door position. - On-load tap changer operating equipment and control - Counter - Information terminal block - Remote control and monitoring multi-pin connector - RTCC indoor Panel with AVR relay and remote indication. AVR relay to have adjustabletime voltage settings for OLTC tap operation feature, for auto and only manual operation ofoltc. AVR should operate based on voltage level of primary side of transformers All control and monitoring cabinets used in indoor shall conform to the following minimum specifications Material : Steel Minimum thickness of Steel sheets : 3 mm for front cover & base frame 2 mm f0r rear door 1.6 mm for roof plate, bottom plate & side covers NMRCL MARCH

218 Powder Coating : Exterior Interior Base frame Thickness : : RAL 7032, Texture finish RAL 7032, Texture finish Black Min. 80 microns of Power coating The Contractor shall submit to the Employer, the complete details of the Control & Monitoring Cabinets, including details of the structure, process of finish and painting, wiring, terminal blocks, cubicle illumination heating etc, for Employer s approval. The details adopted for Control and Relay panels, Bay Control and Protection units, Transformer and On-load tap changer cubicles and all other Control and Monitoring Cabinets, located inside the RSS Control Room shall be identical to project an aesthetically good appearance 6.18 Metal work and Paint-work Painting should be suitable for salty seaside atmosphere and has to comply with IEC standard The entire surface (Internal as well as External) to be painted shall be prepared by Shot blasting to cleanliness level, SA21/2 as per ISO 8501/SIS Ensure that the cleaned surface is free of oil or grease, scales rust and other residue. Surface profile of the blasted surface should be approximately microns. All the external surface of the transformer shall be given first coat of Epoxy zinc rich (having minimum 83% metallic zinc) primer (Min.50 microns thickness), first intermediate coat of epoxy zinc phosphate paint (Min.60 microns thickness), intermediate coat of Epoxy high build MIO (Min.80 microns thickness), and final coat of glossy Aliphatic Acrylic polyurethane (Min.50 microns thickness). The total dry film thickness (DFT) of the paints shall be minimum 240 microns and should withstand 120 C. The shade of paint shall be gray shade 631 as per IS: 5. All steel surfaces which are in contact with insulating oil shall be painted with heat resistant oil- insoluble insulating varnish. After baring, all metal surfaces shall receive anti-corrosion process: - natural stainless for Bolts & screws - hot dip galvanization for radiators - rust-proofing and anti-corrosion paint for tank, oil expansion vessel and other metal surfaces. The transformer and its accessories shall be completely painted in plant. The necessary touch-ups shall be executed on-site after erection. This protection shall be fully guaranteed for five years starting from provisional taking over. Should any noticeable deterioration by rust or corrosion appear before this time elapses, the contractor shall be responsible for repainting at his own expense and for renewing his guarantee for the work performed. NMRCL MARCH

219 The painting and preserving of panels for transformer protection should be similar match with that of other control and relay panels provided in the control room Particular dispositions, Installation Transport For transport either by road, ship or rail, the transformer shall be filled with oil up to windings top and then with Nitrogen at recommended pressure up to the tank top or alternatively the transformer may be filled with Nitrogen, in full, during transportation. The bushing, breather, wheels and all other external parts shall be removed on condition that they can be mounted at site. Installation The Transformers are to be installed in Substation on two running rails, and consequently must be delivered with a set of swiveling rollers. These rollers shall be mounted, electrically insulated from tank and with locking devices. Material layout and volume shall be such that it shall be possible to remove parts without dismounting other parts kv Switchgear 6.20 The 27.5 kv switchgear shall consist of structure mounted Circuit breakers, interrupter and isolators electrically linked This switchgear shall comprise: a. incoming circuit breakers and interrupter with associated Isolators b. Bridging and paralleling interrupter c. isolators d. associated measuring, controlling, monitoring, and protecting devices e. These apparatuses shall be structure mounted with the switching apparatus at pole top level and control equipment at hand level along with transmitting mechanism Circuit breaker/interrupter All circuit-breakers shall follow the same electrical and mechanical characteristics and must be in accordance with IEC standards or RDSO s standard ETS/PSI/116(4/88) with latest modifications 6.21 Isolators All isolators shall follow the same electrical and mechanical characteristics and must be in accordance with IEC standards 129 or RDSO s specification ETI/PSI/ Monitoring Box NMRCL MARCH

220 Connections Mounted on the pole at hand level (1.2m), it shall be made of steel-sheets, totally enclosed, dustproof and water tight type (IP55), equipped with: a. Access doors with padlocks b. 415/240 V heating device. c. 110 V DC control and monitoring relays and motors d. Remote control and monitoring multi-pin connector. e. Internal lighting controlled by door position f. 240 V AC plug g. 3 positions switch (Remote / local / manual ) h. Handle (Facade or beside) i. Label (Facade) Note: - Any handle operation shall disable motor supply. - All equipment shall withstand power frequency test at 2000 V 50Hz / 1mn. - The earthing connector shall be located externally Cable path shall be needed between: a. The incoming circuit-breaker and its corresponding transformer, b. The outgoing circuit-breaker and the OHE via an opening on the Viaduct, c. The transformer and the return current connecting strip, d. The return current outside man hole and the rail via an opening on the Viaduct. The position and alignments of cable paths shall firstly be such as to facilitate pulling, laying and securing of the cables and, secondly, shall not hinder access to the bus-bar box-section. Metallic cable paths shall be linked to a ground collector Transformer to the 27.5 kv switchgear Each connection between transformer secondary windings and the 27.5 kv switchgear incoming circuit breakers shall be realised with 4 x 240 mm² copper cables by phase or Al busbar as per RDSO Specification Overhead Contact System (Regulated) Each connection between 27.5 kv switchgear outgoing circuit breaker and the corresponding OHE pole mounted isolator shall be realised with 2 x 240mm² copper cables Return current From the tracks (impedance bonds), the return current flows back to each transformer with 4x240mm² copper insulated cables connected to intermediate connecting strip (CS) which allows to isolate, under particular safety procedure, the track side from the feeder station side in case of intervention on equipment (i.e. earth measurement, works) Electrical connections The connecting strip shall permit to connect all the elements (so as to realise an integral transversal link), such as: a. Return current cables to transformers b. Track impedance bonds c. Overhead Protection Conductor (OPC) NMRCL MARCH

221 d. Earth Cable (EC) e. RSS-cum-TSS earth mesh f. OHE masts g. Metallic fences Electrical connection between messenger wire and contact wire and with various equipments: the following types of jumpers are used to electrically connect between various conductors and equipment of OCS: a. Copper jumper (hard drawn bare conductor) is used for connection from cross feeder to OHE. b. Stranded annealed copper conductor (known as G jumper) is used to connect electrically between one OHE with another, as in the case un-insulated overlap, turn outs, diamond crossings, crossovers to carry the full OHE current. c. Potential equalising stranded annealed copper conductor jumpers (known as F jumpers). d. In-span jumpers (known as H jumpers) used to connect messenger wire and contact wire every 350 m. e. Aluminium large jumpers is used to connect all aluminium cross feeders wherever needed to connect aluminium bus terminal of FP, SSP, SP etc. f. Stranded annealed copper conductor (large size) used to connect cross feeders to OHE, isolators to OHE etc. Short-circuit withstand capability of Traction Transformer Short-circuit on H.V. side a. The transformer shall be designed and constructed so as to withstand without damage, or impairment in its performances, due to any external short-circuit. b. The primary winding of the transformer shall be designed for carrying the full symmetrical short circuit current, for 3 sec. The full symmetrical short circuit current shall be calculated in accordance with IEC after taking into account the system impedance on the 220kV/132/33kV system. c. The design of the 33kV side bushings of the traction transformers shall withstand the symmetrical current for three seconds during short-circuit on 33kV as specified in IEC Short-circuit on L.V. side a. The maximum short circuit current at the output of feeder station has to be limited to comply with the rolling stock on board circuit breakers breaking capacity, (compared to distribution network) only limited by the internal transformer leakage impedance. b. Consequently transformers must be designed taking into account the current short circuit limit, as well as electrodynamics and thermal constraints. c. The contractor shall specify a guaranteed value of short circuit current on L.V. side and tolerances according to the standards and requirements Auxiliary Network Deleted 6.23 Overhead Equipment design The project design of overhead contact line system process primarily consists of the following phases: a. Preliminary design study, NMRCL MARCH

222 b. Design planning, c. Project implementation planning, d. Preparation of review document The contractor shall carry out preliminary design study which examines the various options for the overhead line system and also identifies any additional infrastructure works required on track layout bridges, etc. This study produces technical solutions, including the design of the OHE, adaptation of track lay out, structural alterations to tunnels and bridges, and an estimate of the implementation period etc. Thereafter the contractor shall submit the summary report of the design study for appreciation of the employer s representative The design planning commences with the preparation of an OHE circuit diagram based on data provided in the preliminary design study. The process of design planning is described in the figure given below: The design study carried out by the contractor, including all planning documents, pole locations and OHE layout diagrams, shall be distributed with an explanatory report to all concerned A site inspection of the line by all project participants is the first phase of the project implementation planning which has to be organised by the contractor. The project implementation planning process is given in the following figure: NMRCL MARCH

223 A review process of intermediate and final results during project implementation planning avoids errors, and thus additional costs and time delays In order to resolve obstacles, the contractor shall implement deviations after obtaining notice of no objection from the employer s representative After completion of the work, the revised documents will give an accurate picture of the installed OHE which is needed for operation and maintenance. The following basic demands must be made on the design of a contact line installation: NMRCL MARCH

224 Persons and equipment must not be placed in any danger from the operation of contact lines At all speeds, the dynamic interaction of the current collector and the contact line has to ensure that interruptions to power transmission do not occur under normal condition and for design speed 80km/h+10% All components of the system should have a longer life. For this, the following specific requirements are important: a. Adequate mechanical and electrical strength, b. Resistance to loads imposed by wind and aggressive substances in the air, c. Corrosion resistance of all component, d. Uniform, low contact wear of the contact wire During the design of overhead contact line installations in built-up areas, aesthetic and city planning aspects have to be observed Nature and environment protection have to be taken into account The investments for the installation and the costs for operation and maintenance should be as low as possible during the life cycle of the equipment. It is essential that each installation is designed to allow faults to be quickly and precisely localized. The system shall be designed in accordance with the design requirements of EN 50119, and book on treatise on Electric Traction Distribution issued by Indian Railways institute of electrical engineering including the following items contained in it: a. Volume- II-part III-the layout and layout plans, wiring of points and crossing, structural design of overhead equipment supports, arrangement of masts, cantilever arrangement, tramway type overhead equipment, bonding and earthing, OHE sectioning etc. b. Volume-II-part-IV-selection of span, dropper schedule, determination of dimensions of cantilever assemblies, design of overlaps, automatic tensioning of overhead equipment, clearance study, jumpers, switching stations etc. The contractor shall carry out Computer simulations to demonstrate the anticipated current collection performance. The adopted computer simulation programs should be validated against physical testing results, in accordance with EN The contractor shall submit cross section drawing OHE installation indicating all the details in the drawing, so as to ensure installation of OHE properly during inspection by the employer s representative. Contact line systems have to be designed to function in a defined range of ambient temperature of Nagpur area to be obtained from meteorological department at Nagpur. The standard EN specifies environmental conditions of ambient temperature and wind pressure/wind velocity to be considered for design of overhead contact line by the contractor. Climatic conditions found in Nagpur are given in volume 3 The design of contact lines with respect to wind loads involves two main aspects: Verification of serviceability, avoidance of pantograph de-wiring caused by wind deflected contact wire, Reliable design of structural elements to withstand the wind loads which probably will occur during the life time of the installation. NMRCL MARCH

225 The maximum mast deflection under maximum load at the height of messenger wire shall be maximum 1.5%. When masts are used between tracks in station, the mast width shall not exceed 30 cm. At this level of preliminary design, this applies to OTA station. The contractor should design the contact line system in such a way so that the period of line closure, for planned maintenance work or to repair contact lines and tracks, are kept as low as possible. The contractor should ensure that hazards due to electricity must be limited to acceptable values by adequate design of installations. Those hazards could arise from: a. The overhead contact line to rail voltage, b. The operating current and short circuit current, c. The electric field, d. The Heating effect, e. The magnetic field, f. Rail to earth potential, g. Induced longitudinal voltages, h. Capacitive charges etc. The governing important standards but not limited for reliability and safety to be followed by the contractor are EN 50119, EN 50121, EN , EN , EN , EN 50163, and EN The contractor shall adopt the correct choice of design insulation level which should ensure that the equipment will withstand the necessary voltages. Depot design requirement: a. The overhead contact system of test track shall be of main line type. b. The OHE inside the stabling lines and the inspection bay shall be provided on drop arms. c. The shunting necks provided near approach to depot shall be at grade and therefore independent mast at grade shall be provided. d. The wiring of full tension length at stabling lines, inspection bay, workshop siding etc. shall start from their dead ends. Rigid Overhead Contact System (ROCS): NOT APPLICABLE Design Parameters Type of overhead contact system The Rigid Overhead Contact system shall include 25kV ac overhead rigid conductor rail with contact wire, associated jumpers, support structures and ancillary equipment Clearances - Minimum Electrical and Mechanical Clearance NMRCL MARCH

226 The minimum electrical and mechanical clearances shown in Table shall not be infringed under the worst operating conditions of the overhead line equipment, the rolling stock and pantograph. Table Minimum Electrical and Mechanical Clearance (mm) Item Normal inside Tunnel 25kV Live metal to earth Static Dynamic (passing) kV Live Metal to Vehicles -Static - Dynamic (passing) Phase Difference (47.6kV) Static Dynamic (passing) Gap at Insulated Overlap or air- gap on rigid OCS between conductors of different electrical sections Gap at Uninsulated Overlap or expansion joint on rigid OCS The minimum clearances inside the tunnel for 25 kv traction are those specified in IEC (1988). The values shown in the Table above shall be used as a minimum. In the event of additional space being available, the space shall be used to enhance the electrical clearances above the stated values, before consideration is given to increase the system height. The Contractor shall interface with designated civil Contractors to verify bored tunnel, box tunnel and station box cross-sections and also in respect of moving dimensions Mechanical Clearance Mechanical clearance to any point from the OCS with power off shall be adequate to provide for manoeuvring of working tools while carrying out maintenance work on the OCS. During detailed designing, the contractor shall ensure that the minimum clearance between pantograph and insulator is 100mm Rolling stock NMRCL MARCH

227 The locked down height of the pantograph is 4048 mm, the minimum OCS height is 4318 mm Supporting structure Safety of supporting structure Supporting steel structure for overhead contact system shall have a safety factor not less than 3 times yield point strength of steel against dynamic operational loads. Grouting shall be designed with a factor of safety as 4 and shall be load tested individually Anchor plug and anchor bolt/ Chemical fasteners of supporting fixture. Anchor bolt shall be installed for the supporting fixtures of rigid conductor rail at intervals finalised on basis of detailed design. The type of bolts shall be similar to existing Line No. 2 or chemical fasteners of adequate design. The supporting fixtures shall have facility of adjustment so as to install the rigid OCS at the designed height with the requisite stagger of the conductor rail. Yielding point strength of the fixtures and fitments shall have adequate factor of safety, considering worst loading/torsion conditions and dynamic loading on account of pantograph thrust and movement. The Contractor shall furnish the supporting design details Supporting steel fixture The supporting steel fixtures shall be provided at suitable intervals based on design consideration. The interval between successive fixtures shall not permit undue sag and vibrations. The contractor shall furnish the supporting data of similar systems, which may have been provided by him on other metro systems with 25kV ac rigid conductor OCS. The steel work shall be hot dip galvanized and the nuts, bolts and washers shall be stainless steel of suitable grade for moist and polluted tunnel atmosphere Support Insulator Type of OCS support insulator to be provided shall be a proven one. The electrical and mechanical properties of support insulator for the 25 kv ac rigid conductor shall be in accordance with the recommendations of IEC 383 / The minimum creepage distance of the insulator shall be 1100 mm, wet power frequency withstand voltage shall be 132kV and dry lightning impulse withstand voltage shall be 250 kv in accordance with the recommendations of IEC The mechanical design should be proven to take the fluxul stress to support the design train headway of 90 seconds. Supporting insulator fixture shall permit free sliding of Rigid conductor to allow for expansion on account of temperature changes Preventing loosening of nuts and bolts Adequate measures shall be taken for preventing all bolts and nuts from becoming loose, through use of lock nuts/ spring washers Expansion Joint Typical arrangement and Interval between expansion joints. NMRCL MARCH

228 Expansion joints shall be provided at suitable intervals but the maximum interval may be allowed up to 250m depending upon the site condition Parallel contact wires at expansion joint Parallel contact wires shall be of adequate length to provide for suitable expansion joint assembly with provision for adequate number of flexible continuity jumpers. Separation distance between two OCS sections at expansion joint shall not be less than 200mm to ensure smooth passage of pantograph. No expansion joint shall be provided in the station area. Suitable gradient will be provided to ensure smooth change over. The expansion joint may be erected at site or prefabricated from the manufacturing works Sectioning equipment Air-gap section The structure of air-gap section shall be same as that of an expansion joint. At insulated airgaps, separation distance between two OCS sections at the overlap shall not be less than 400 mm, with two OCS sections aligned such that pantograph passes satisfactorily. No airgap section shall be provided in the station platform area. Airgap sections shall be provided at the crossovers to segregate two sections. In case air-gaps are not found practicable, only in exceptional circumstances the section insulators may be permitted Jumper wire for rigid conductor Anchors Jumper wires for rigid conductor shall be of stranded annealed copper with adequate current carrying capacity. Connection of jumper wire to rigid conductor rail shall be through suitable bimetallic terminals each having at least two fixing bolts. Bolts shall not conduct any current. Jumper wire shall be flexible to allow creeping of rigid conductor. The design shall ensure that the jumper loops remain at least 75 mm above the contact plane. Anchors shall be provided for prevention of unidirectional creeping of rigid conductor rail Location of anchoring Anchoring shall be provided in the middle of one conductor run length between two expansion joints Anchoring Insulators and Hardware The design shall be such that the Insulator and hardware used at anchoring location shall be least affected by passing pantographs. Materials for anchors shall be corrosion resistant such as hot dip galvanized or of stainless steel. Suitable bimetallic fitment shall be integral with the hardware to prevent electrolytic corrosion to aluminium Rigid conductor rail and contact wire Conductor rail shall be of Aluminium alloy section with wearing copper contact wire. The conductor rail shall have anti-corrosion treatment on its surface. Sections of transportable lengths will be joined together to form lengths up to 250m between expansion joints. The contractor shall furnish the merits of the conductor rail system offered indicating the life, speed potential of installation, strength and conductivity of joints, maintainability and the supporting details including performance of similar rigid conductor systems if provided by him on any other metros system. In regard of the wearing copper contact wire size, clauses may be referred to. Contact Wire shall be Round Bottom, 150 sq mm area and shall comply with EN Contact wire shall be made from Continuous Cast Copper (CCC) rod NMRCL MARCH

229 of minimum 21 mm diameter as per RDSO Specification. Also, Contact wire shall be hard Drawn Grooved Copper contact Wire complying to RDSO standard ETI/OHE/76 (6/97) Standard length of conductor rail system Standard length of conductor rail offered shall not be generally less than 10 metres. However, the length offered shall be supported by the data of various metro systems using similar/same size rigid conductor OCS and the site condition Protection cover for rigid conductor rail Protection cover with Warning Boards of material and design to be approved by the Employer for rigid conductor rail shall be provided at station area, below the ventilation ducts and where there is a possibility of maintenance personnel inadvertently coming close to the rail. In case of continuous provision of protection covers, Warning Boards shall be provided on the protection cover at 5m intervals. The waterproof cover shall be provided on the conductor rail where water leakage will occur in the tunnel. The material should be Fire Retardant Low Smoke, Zero-Halogen (FRLSOH) Height of rigid conductor rail and contact wire Minimum Height of the contact wire plane shall not be less than 4318 mm from the safety distance criterion as per EN and keeping safety clearance and electrical clearance as per IEC Stagger of rigid conductor and contact wire Stagger of rigid conductor contact wire shall be limited to 200 mm, nominal, from rail centre on tangent track and on the curves, however, the value of stagger shall be finalised based on pantograph profile obtained from the rolling stock Contractor. Stagger of rigid conductor and contact wire (200mm) shall beachieved over a suitable length to avoid grooving on the pantograph current collection strips The design of OCS shall permit a displacement of track by 50 mm horizontally without need for changing any component Permissible gradient of contact wire Gradient of contact wire shall be not more than 1/1000 on main tracks and not more than 2/1000 on stabling line tracks at terminal stations. Deviation from these limiting values shall only be with specific permission of the Engineer. The junction with level contact surface shall be joined by a transition gradient half that adopted for the main gradient. NMRCL MARCH

230 Cross Over The separation of contact wire at centre of the turn out shall be not less than 250 mm and not more than 300mm from the track, which it serves at any point after the take off Transition from Rigid to Flexible Catenary System The transition from Rigid overhead conductor system in the tunnels to flexible overhead catenary system in the ramp portion shall be so designed that passage of the trains (electrical multiple units) is as smooth as possible without resulting in any pantograph jerk, sparking and wear of components. The X-sectional area of copper (current carrying capacity) to remain the same throughout the installation. The design should be a proven one Indicators Boards a) OCS section indicator Boards shall be provided at approach to each electrical section of OCS, which shall be visible to Train Operators (Drivers) from an adequate distance.. b) Number plates shall be provided at support locations, the numbering scheme to be adopted shall be submitted for review of Engineer. c) Warning indicator Board shall be provided at approach to termination of contact wire. d) Warning: 25kV ac Boards shall be provided at locations and intervals decided upon by the Employer. These boards shall be prominently displayed at the platform at frequent intervals Contractor s Design Responsibility Design Environment This is furnished in clause 1.12 of GS and clause 4.2 of this Specification Traction Power Supply Performance Requirement These are addressed in clause 4.9 of this Specification Detailed Design of the OCS Based on the survey of entire route, the Contractor shall offer the most suitable OCS profile including OCS sectioning and work out in detail the OCS construction plan including return current longitudinal (continuity) and transverse (equalizer) bonding plan The above application designs shall be based on standard arrangement Design principles and specially for: OCS supports and spans, adequate common parallel run at expansion joint Arrangement of jumper connections at expansion joints and at feeder connections. NMRCL MARCH

231 As far as possible section insulators shall not be used on the main line. The X-overs, turnout etc shall be designed through over laps Transition arrangement with flexible OHE to be such that area of X-section remains the same throughout this section The insulator and OCS fittings must be able to take the fluxul stresses to accommodate train headway of 90 seconds The components and fittings shall be of type and metallurgy, which are rust and corrosion proof. Steel components shall be hot dip galvanised. Nuts, bolts and spring washers shall be suitable grade stainless steel. The fittings, jumpers etc shall need minimum maintenance and to the extent possible shall be of fit and forget type. Insulators suitable for humid and urban polluted atmosphere of Lucknow shall be used. The insulator shall be oil resistant and the surface finish should be such that least amount of dust is able to accumulate on the insulator surface. The design shall be coordinated fully with the requirements of the signalling and train control system, final track work, tunnel work and any specified design requirements that those systems or facilities may dictate for the operation and management of the services Submittals Basic Design Based on the basic designs worked out and route survey, the Contractor shall prepare and submit a detailed OCS final design, together with hardware applications design appropriate for the whole Project. The design of the support and anchor assemblies shall ensure adequate clearance from the pantographs under dynamic conditions. The submittal shall include a tabulated allocation of all parts for the OCS. The Contractor shall select a full range of proven OCS components, and shall demonstrate by means of engineering calculations that all elements of the selected system are capable of meeting the Design Criteria, Safety, and Operational requirements as stated in these Specifications. When computer programs are proposed for use, the Contractor shall submit typical hand calculations, together with comparable computer data input and output, for verification of the program, together with a description of the software Drawings for review Construction drawings shall be prepared and verified at site. The site verified plans shall be submitted to the Employer for review. These shall include but not be limited to: General Traction Power supply diagram Schematic sectioning Diagrams OCS construction Plans. NMRCL MARCH

232 These shall include chainage of all support anchors and air gaps, height over rail level and other general particulars. On- site verification of the plans shall be carried out and based on final construction plan. OCS layout shall be finalized for construction OCS layout plan: Based on the finalised construction plan, OCS layout plan shall be developed and submitted for review by Engineer. The OCS layout plan incorporating following information shall be submitted: The alignment of the conductor Chainage of each support structure location Exact chainage of all expansion joints, anchors and air gaps Direction and value of stagger at each location Clearance of live conductors to fixed structures with respect to reference chainage Alignment and layout of feeders Jumper connections to switches and feeder tails List of infringements, if any Numbering of each support structure with respect to reference chainage Location and serial number of isolator switches Final Sectioning diagram drawn to a convenient scale showing identification number of section insulators and elementary sections Transition Element drawing (from Rigid OCS to Flexible OHE) General arrangement of OCS at SSP, SP and SS OCS profile drawings In case the height of contact wire is changed, an OCS profile drawing showing the actual height of the contact wire at each location and the gradient adopted until normal height of contact wire is achieved Return current and Earthing and Bonding plan Return current circuit Earthing and bonding plan in interface with Track construction Contractor, Signalling and Train Control Contractor Proceed to construction Based on finalized plans field construction work may proceed Construction Requirement Track route and layout inspection and preparation of installation work NMRCL MARCH

233 As preparatory work prior to installation, the location and position of supporting fittings, rigid conductor rail and anchoring shall be verified and marked at site. Height of the tunnel from top of rail at various locations shall be confirmed Installation of supporting structure Supporting structure Supporting anchor bolts shall be supplied and installed by the Contractor Supporting Insulator and accessories Supporting insulator and accessories for rigid conductor rail shall be mounted on supporting structure to enable adjustment of the conductor to required stagger as per the final design drawings Installation of rigid conductor and contact wire Transporting material Care shall be taken that no breakage, dent, crack or bending of any component takes place during transportation. Adequate care shall be taken to prevent any damage due to rust by applying rust prevention paint. Painting schedule to be submitted for review by Engineer. Materials delivered at work site shall be laid up neatly at nominated locations so that interference does not occur from other works going on nearby Installation of rigid conductor rail and contact wire Due care shall be taken while handling the rigid conductor rail that no twisting or bending or development of any crack takes place. Temporarily supporting the rail with one end cantilevering should be prohibited. While installing the rigid conductor rail, safe practices shall be adopted. The erection of conductor rail shall be commenced from the anchor structure and continued on to the expansion joint. Before installation of the end approach of expansion joint, adjustment of final length shall be in accordance with the measured temperature in the tunnel. On curved track, the conductor rail lengths appropriately bent to requisite curvature taking into account track conditions and deviations of contact wire shall be provided. On turnouts the level of the crossover contact wire shall be raised so that it does not come in contact with train pantographs running on the main track, and for the trains negotiating the turnout, the passage and current collection by pantograph is smooth. Adequate tensile force shall be maintained in the contact wire. The contractor shall interface with Tunnel and Station Civil Contractor and shall be responsible for Centre line Marking of Track (even without its laying) on the roof of the tunnel. The Contractor shall submit the OCS installation plan to Employer for approval Jointing the rail NMRCL MARCH

234 If the rail lengths are bolted together, the bolting process shall be of proven design with use of proven components Installation of Feeding System Design requirement of traction power cables 25 kv feeder cables shall conform to the specifications of these cables given in clause 8.2. The number of cables constituting a feeder shall take in account the whole current requirement of a single source of feed. The feeder cables and the jumper cables shall be sized to provide for environmental derating corresponding to the laying method and maximum overload and short-circuit currents. The cable terminations shall be suitably designed for adequate insulation, mechanical strength, low resistance and against fraying of strands, developing cracks or getting loosened with vibrations, wear and tear. The interrupters and isolators meant for sectioning shall be located in the station area in a room close to the sections required to reduce length of cables. Connection of feeder cables to OCS conductor rail shall be through flexible jumper and terminal connectors and shall be of bolt fixing type. Details shall be submitted for review of Engineer. The feeder cable jumpers shall be flexible to accommodate rigid conductor rail movement due to temperature variations. Due care should be taken to lay and connect the cables to switchgear and to OCS to ensure that the current carrying capacity of the system is not de-rated. All connectors shall be robust and of proven types Return conductor and earth conductors Return Conductor. Return conductor shall be aluminium conductor conforming to Bureau of Indian Standards, specification IS: 398 (Part I)-Latest Revision OR Copper conductor of adequate size to be finalised by EMC simulation study. The Conductor shall conform to Indian Railway s RDSO specification for Annealed stranded copper conduct ors (ETI / OHE/ 3, Latest version) and IS:9968 (Part 2) Earth Conductor Earth Conductors shall be made of flexible copper conductors of adequate size to be finalised by EMC simulation study. The Earth Conductor shall conform to Indian Railway s RDSO specification for Annealed stranded copper conductors (ETI/OHE/3, Latest version) and IS: 9968(Part 2) Submittals of Designs and drawings for review NMRCL MARCH

235 The designs and drawings for the cable runs, connection and jumpering arrangement of the 25 kv feeder cables to the OCS and Earthing and return current conductors shall be submitted to Engineer for review. The drawings shall include but not be limited to the following: a) General arrangement drawings for each type of joint and connection b) Individual Site location drawings over the entire route. c) Bonding and Earthing plans over the entire route Cable Installation Requirements General As preparation work prior to cable installation, the location and position of cable supporting fittings shall be ascertained and actually at site in coordination with other civil works so as to avoid any error in installation. Provision of adequate clearance for running cables across tracks and at location of jumpers to OCS should be ensured through interface with Civil Contractors who may have to provide niches to obtain such extra clearance Cable laying Cable protection At any location where any damage or rubbing to cables or touching with walls is expected, fibre glass or equivalent cable protection cover shall be provided Bending of cables Bending of cable shall be executed gradually and bending radius of the cable shall be not less than allowable bending radius of cable. Bending of cables shall not be executed repeatedly. Special precaution shall be taken for bending at cable ends where shrinkable sleeves and petticoats are fitted Final Adjustment and Measurement of OCS After the equipment has been finally adjusted, the equipment shall be subject to final measurements jointly with the Employer. The checks shall include but not be limited to: a) Support location member, its height above rails level and stagger, gradients in OCS. b) Contact wire height at mid span between successive support members. c) Anchors, expansion joints and air gap separations. d) Clearance checks to ensure pantograph passing clearances, both electrical and mechanical clearance Pantograph test to ensure smooth shock free passage especially at section insulators at air gaps, at turnouts, crossovers and change of height of the contact system. e) Fittings or jumpers and cable connection to Overhead conductor rail NMRCL MARCH

236 Return current circuit connected to running rails 6.39 Site Testing and Inspection In accordance with Chapter 14 of this Specification and the GS a detailed protocol for inspection and testing of complete OCS shall be prepared and the tests and complete methodology for testing shall be submitted for review by the Engineer Installation checks and tests a) Visual inspection of overhead contact system installation, random check of components; electrical and mechanical clearances, air gaps and general alignment. b) Continuity test of each joint in traction and return current circuit. c) Insulation resistance of 25 kv ac overhead contact system shall be as per international standards. d) Physical examination of rail bonds. e) Checking of construction gauge f) Return current continuity test, testing of joints. g) Earth resistance test Partial Acceptance Tests 6.42 Tests After physical verification and measurements, tests as indicated below but not limited to these, shall be carried out Circuit continuity, loop resistance test The purpose of this test is to obtain the OCS section. These test checks both the OCS and the rail return system for electrical continuity. The test entails shortcircuiting a discrete section of the OCS by connecting the OCS to the rails at one end and applying a variable ac voltage at the other end. The length of section under test should be approximately km (i.e. in the station to station zones). An ac source with variac to provide requisite testing current High voltage ac test. Meggering of OCS sections at 2.5 kv and record results Pantograph tests will be performed using a self-powered transit vehicle in order to identify any locations where arcing may occur. NMRCL MARCH

237 The Contractor shall be responsible for all adjustments required as a result of these tests System Acceptance Tests 6.46 Energisation Successive Energisation Each electrical section shall be energised successively at 25kV ac from for one minute with adjacent sections isolated and connected to traction earth. Finally entire section shall be energized for at least 24 hrs Short circuit tests shall be carried out as per a detailed test protocol, which shall be submitted for review by Engineer Integrated Testing and Commissioning All the items of supply and required for completion of the work in all respects, testing and commissioning of the overhead equipment system as well as associated work for facilitating trial run of the rolling stock and Integrated Testing and Commissioning shall form part of the work covered by the contract whether specifically stated or not. During train trial contractor shall be responsible for providing and fixing discharge rods during power block permission/cancellation before ROD High speed tests shall be carried out by means of running the trains initially at slow speed, then increasing the speed in stages up to full speed permitted for the section. On successful completion of the high speed tests, the OCS shall be declared fit for pre-revenue system tests The Contractor shall be required to operate and maintain the OCS until Taking Over by the Employer Proceed to construction: Based on finalized plans field construction work may proceed Civil Works and ancillary installations General Unless stated otherwise in the Contract Documents the whole of the civil, structural, services and finishing works shall be constructed to comply with relevant laws and regulations of the Indian Government and of MaharastraState government as well as complying with the requirements of the public utility authorities of Nagpur, fire regulations and such additional requirements as may be stated in the documents. The design requirements relating to fire safety and escape shall be generally in accordance with NFPA, BS 476 and other applicable standards. RSS civil works Land preparation In any case, the finished ground level shall be at least 60 cm above the main rail/ road level, near to the site. The compaction of soil shall be done in accordance with Standard Engineering NMRCL MARCH

238 practices and the site, after compaction shall be fit, without any detriment to support the heavy equipments, including transformers whose weight may be in the region of tonnes, supported on 4 wheels which are spaced approximately 2.4 metres, running on a Broad Gauge (1.676m) track Access Roads The access road shall be black topped and transformer area shall be either cement concrete or RCC. For this purpose, the Contractor shall prepare the necessary design & calculations and submit them to the Employer/Employer s Representative, for notice of no objection. On notice of no objection of designs and calculations, the Contractor shall construct the approach roads as per approved designs. The approach roads should, at the minimum, be 7.0m wide and shall be able to support equipment loaded trailers Plumbing & Drainage Plumbing & Drainage of the Substation site shall be provided as per the best engineering practices, so as to prevent surface flooding and pooling of water. For this purpose, suitably designed drains and sumps shall be provided and if the water level inside the sump rises above a predetermined level, the sump water shall be arranged to be evacuated by means of suitable electric pumps fixed in the sump. In addition, suitable precautions shall also be taken to prevent transformer insulating oil from being discharged into the environment in the event of a ruptured transformer tank. This shall be realised by a retention tank for each transformer a. dimensioned in order to be able to contain the whole transformer oil; b. laid below the transformer; c. covered by a net to maintain a 5 cm width stone bed on which the oil might fall; d. fitted with a beside extraction pit to be used for oil or raining water pumping. The pumping shall be realised with a portable manual or electrical pump, which is to be stored in the maintenance room. Contractor shall provide with water supply system fully functional for toilets and maintenance room, wherever required he may construct sump, Over Head tank, pump rooms, supply of pump, etc to make system fully operational. Contract shall design the water supply and drainage system as per applicable standards; he may submit the same for notice of no objection from employer / employer s representative, before start of work. Contractor will have to identify the suitable source for supply of water. Drain shall be RCC type Control Room building Detailed Design The Contractor will have to study the General Layout of the Control Room Building. The structure shall be of RCC framed structure based on BIS codes. Based on this, the Contractor will be required to prepare and submit detailed design of civil, structural, architectural and electrical works. All applicable building regulations must be observed, and also the rules for good building practice. After obtaining the Employer s/employer s representative s notice of no objection, the Contractor will construct the building along with auxiliary works, in accordance with approved drawings and designs. Proposed RSS at Transport Nagar is to be built on the filled earth; contractor shall survey the area, conduct geotechnical survey to identify safe bearing capacity and shall design the building with suitable foundation and structure. The contractor shall obtain notice of no objection from the employer or employer s representative, before start of construction Civil and Structural Design NMRCL MARCH

239 The Contractor shall perform the civil and structural design, including the preparation of calculations, drawings, specifications, cost estimates and other documents, for but not limited to: i. General arrangement (layout and elevation); ii. Structures and sub-structures; iii. Foundations; iv. Drainage (Covered type); v. Networks (Water, sewage, etc.) vi. Baffle walls vii. Boundary walls Architectural services The Contractor shall perform the Architectural services design, including the preparation of calculations, drawings, specifications, cost estimates and other documents, for but not limited to: General arrangement (layout and elevation); Section and details i. Walls, floors, ceiling finishing ii. Doors, frames and windows iii. Toilet rooms, and partitions including equipments iv. Concrete (types and treatments) v. Thermal and moisture protection vi. Electrical and mechanical fittings vii. Building surrounding environmental arrangement The internal finishes and facade finish of the RSS building shall be similar to Depot building. All structure and finishing work shall confirm to Indian Standards, wherever Indian standards are not available the work shall comply to relevant international standard or as per manufacturer s instructions. Following suggested finishes and materials are options, the contractor shall study in detail the proposed options and station building finishes, he may also come with other alternatives, provided employer or employer s representative issue notice of no objection. a) Deleted b) Deleted. c) Deleted. d) LVSGR shall also be finished with plastering and acrylic emulsion paint, over and above suitable wall putty. Floor of this room to be with Hard granolithic cement concrete, with vacuum de-water finish. e) Office room, Store room and Maintenance room shall be plastered and painted with acrylic emulsion paint, floor shall be vitrified / ceramic tile laid to standards. f) Toilets shall be designed for adequate urinals, counter type washbasins, mirror, etc, Room shall be finished with anti-skid ceramic tile on floor, walls shall be dado for 2.5m height with glazed ceramic tile, remaining area shall be finished with acrylic emulsion paint over plastered surface. g) Battery room shall be finished with hard floor acid resistant, walls to be with glazed ceramic tile for 2.5m (minimum), above it shall be finished with acrylic emulsion paint. This room to be air-conditioned to maintain the room temperature as per design requirement. h) Control room in the RSS shall be finished with vitrified tile on floor and acrylic emulsion paint on the walls. As temperature is to be maintained in this room, it shall be air conditioned Auxiliary services NMRCL MARCH

240 The Contractor shall perform the Auxiliary service design, including the preparation of calculations, drawings, specifications, cost estimates and other documents, for but not limited to: i. Lighting, fans and sockets ii. Fire detection, fire alarm and fire fighting iii. Cables routing (cable trenches, trough, trays etc ) iv. Earthing v. Water pumps vi. Water supply and sanitary vii. Storm water drainage viii. Door s & Ironmongeries The contractor shall design and furnish the building with tables, chairs, etc, Design of furniture requirement shall be submitted for notice of no objection from employer/ employer s representative. A master key, with all required ironmongeries shall be provided. Toilet doors can be FRP doors to the standards Control room Building requirements General While planning and constructing the buildings and rooms for electrical equipment, care must be taken to ensure that i. all operational requirements are satisfied ii. the rooms are free from groundwater and flooding iii. adequate accesses are provided for operation, transport and fire-fighting services iv. all applicable building regulations are respected v. the building is structurally and functionally adequate in all respects and aesthetically presents a good look. Materials used for the construction of the building shall be new and of good quality Materials shall be so chosen that the buildings when erected shall have good heat and sound insulation properties in normal conditions, as well as when combined with the heating or air-conditioning equipment installed by the Contractor. Height of the control room and SWR room shall be at least 4.8 m Walls, ceiling & floors Walls, ceiling and floors must be dry. The inside surfaces of the walls should be as smooth as possible to prevent dust deposits. The ceiling shall be finished in such a way that the equipments are not endangered by falling plaster. The floor surface must be easy to clean, pressure-resistant, non-slip and wear-resistant. Concrete floor with adequate strength to withstand movement of equipment/panels wear-resistant protective coating with ceramic/ vitrified tiles is recommended for the control room. Attention must be paid to floor loadings when taking the equipment in and out. In front of control panels and Switchgear panels, insulated mats of approved design, shall be provided. The internal walls & ceiling shall be finished with acrylic plastic emulsion paint Doors and Windows Windows to each room shall be of an area, not less than 20% of the floor area or as per Indian standard, whichever is maximum. Windows must be so arranged that they can be opened and closed without any personnel coming dangerously close to any live parts. All windows of the ground floor building shall be fitted with burglar bars firmly attached to the structure of the building. The window shall be aluminium of appropriate section. NMRCL MARCH

241 All opening windows shall be fitted with locks. Internal doors shall be 2 hours fire rated and shall be fitted with door closers, lever latches, mortise lock and keys. External doors shall have barrel bolts both at top and bottom of one leaf and a Yale lock on the other leaf, they shall be equipped with an Anti-Panic system permitting urgent door opening by mean of a bar located at 0.7 m high from floor level. External doors shall be of solid external quality and hung with heavy-duty hinges Ventilation The rooms must be sufficiently ventilated. In the control room, where people are likely to be present Battery Rooms In battery rooms, the following additional precautions have to be taken. i. the walls & floor must be resistant to electrolyte action and provided with acid resistant tiles. ii. ceilings should be painted with acid-resistant paint which does not give off harmful vapour. iii. Ventilation by means of induced draught is preferred. An air change rate of 5 times the room volume per hour is recommended Water supply, electricity, sanitation and fire fighting Building shall be supplied with continuous (24 hour) running potable cold water to the pantry and wash rooms. The toilets may use raw water for flushing, shall be equipped with water closets and sitting type stools and urinal and shall be adequately ventilated through the ceiling. The Contractor shall also design and provide necessary arrangements for the constant and hygienic disposal of all effluent, sewage and rubbish from the buildings to the nearest sewer line or septic tank. Storage and septic tanks shall be required due to restricted hours of water supply in the Nagpur. All buildings shall be supplied with electricity at 230 volts, at 50 Hz through 25kV/230V Aux Transformer. Fire extinguisher shall be provided as per norms Exterior finish External finish of the Control Room Building shall be attractive and pleasing to the eye preferably of stable and durable cladding of granite or equivalent of approved shade and design. Considering that the RSS locations and SWR and Control Room Buildings are prestigious installations and should blend smoothly and aesthetically with the surroundings, the SWR and Control Room Building shall have a good exterior finish. Use of an indigenous combination of stone cladding and grit finish, or suitable combination of glass and stone or any other arrangement of exterior finish shall be adopted, subject to Employer s notice of no objection Internal equipment The SWR and control room building shall be designed and constructed to accommodate the following equipment and facilities: 1) Power equipment room: i. Low voltage distribution cubicles (AC and DC) ii. iii. iv. HV equipment Control & Relay Panels (Traction equipment cubicle panel) Battery chargers 2) Battery room: Batteries 3) Control rooms i. Control and Relay panels ii. SCADA equipment, including work stations if any NMRCL MARCH

242 iii. SCADA system, if any. 4) Rest room and toilets 5) Maintenance room The building shall have only ground floor cellar with all partition walls, openings, and all facilities, designed to receive power supply installations. Facilities should include but not restricted to : - Water; network and equipment (supply, sanitary, sewage ) - Cables trenches and conduits - Low voltage installation (lighting socket, fans, ventilation, fire protection ) - Doors and locks - Painting Low voltage installation Lighting & power: Normal lighting and power supplies The lighting and power auxiliary outgoings located in AC auxiliary cubicles, forming the exit point for all the normal lighting supplies and power connections, shall be supplied from both LT auxiliary transformers. The lighting and power supplies shall be distributed as follow: A) AC auxiliary cubicle 1: i. The first half lighting of the SWR power equipment room ii. The first half lighting of the external RSS (e.g. yard/equipment lighting etc.) iii. The lighting of rest room and toilets iv. The lighting of control room v. The supply of sockets in the SWR vi. The supply of sockets in control room B) AC auxiliary cubicle 2: i. The second half lighting of the SWR power equipment room ii. The second half lighting of the external RSS (e.g. yard/equipment lighting etc.) iii. The lighting of battery room iv. The lighting of maintenance room v. The supply of sockets in RSS vi. vii. The supply of sockets in battery room The supply of sockets in maintenance room The circuits shall always be cut off on all poles. For instance, in the case of three-phase distribution, the three conductors shall be cut-off by a four poles circuit breaker. In the case of 2-wire supply, this shall be cut-off by a two-pole switch and shall again take place on all poles. Supply of Power socket circuits shall be made through 5 conductor cables (3 phases, neutral and ground) Stand-By lighting This lighting shall automatically come into service as soon as a voltage deficiency is detected on either of the two auxiliary cabinets and shall not go through any intervening switch. The power source for this lighting shall come from two supplies of 110 V DC battery/battery charger sets together with the AC and DC protection systems and the corresponding remote annunciation systems, associated to the 110 V DC distribution cabinet described above, which will include a changeover device between the two 110 V DC supplies. NMRCL MARCH

243 As soon as the normal half station 415/240 V AC auxiliary sources fail and in order to prevent untimely operation when the cut-off period is too short, automated closure of the contactor shall be provided so as to energise the standby lighting system which shall take over until normal power supply is restored. This installation shall ensure minimum lighting in the SWR building guaranteeing personnel safety and permitting, at the points where necessary, all isolation or re-supply operations following total cut-off of the medium voltage sources. Emergency lighting An emergency lighting system will be provided evenly by means of self contained units in the various accesses and ways to indicate the way to exit Ventilation: The Control Room shall be air-conditioned. The High Voltage rooms shall be suitably ventilated by air circulation as follows: i. Air inlet louvre at the 33 kv switchgear base, ii. Air inlet at the base of each transformer cell iii. Air exit at the top of each transformer cell 1st case: Ambient air is less than 35 C, the equipment does not need any forced ventilation; The transformer room is at least equal or higher than the 33 kv switchgear room temperature due to the fact that there is no energy spent into the switchgear. When the transformer room temperature is higher than the switchgear room temperature, a natural air convection is made through the both air inlets and air exit; 2nd case: Ambient air is more than 35 C, the equipment needs forced ventilation: in that case, the transformer air fans reinforce the natural air cooling Technical conditions: The technical conditions for carrying out the works and providing the supplies are as follow: lighting equipment This shall be of fluorescent tube type. Average lighting intensity will be 300 lux in the control rooms, and in technical rooms lux in the low voltage auxiliary transformer rooms - 80 lux in all other levels and in the stairway. The fluorescent tubes shall be mounted beneath cover glasses (as shall also be the case for the standby lighting). In the battery rooms, they shall also be mounted with glands to keep out acid vapours and hydrogen. The sealed fluorescent light fittings shall be capable of withstanding impacts and shall be explosion-proof (as for those in the transformer cubicles). The light fittings proposed by the contractor are subject to notice of no objection by the Employer Power sockets : They shall be of sealed, wall mounted type, with four poles plus central ground, rated for 16 A and 500 V AC and with a cover flap fitted with a plug holding pin. The external sockets shall be mounted on mast, at the level of each circuit breaker Fire protection: Auxiliary supply of each fire detection system shall be 110 V DC Fire detection system: In case of fire in any transformer, the fire detection system shall instantaneously come into action isolating the transformer by tripping the upstream and the downstream transformer circuit-breakers and put the fire extinction system into action. Coming into action, it shall also stop the fan working NMRCL MARCH

244 and close all apertures (air inlet and air exit) to avoid or minimise any fire propagation. The thermo element detectors shall be mounted at the cover level of the transformer. The detectors shall detect at any moment an abnormal temperature rise generated by a fire on the tank, the terminals or even on the transformer bed. The detectors shall be designed and equalised such that they do not operate at slow temperature rise, which may occur due to a variation of ventilation, variation load, solar beam, etc. The design of the detectors shall ensure complete security, such that it will not operate due to any reason except for fire, and complete dependability in case of fire. If more than one detector is necessary, they shall be series mounted by a fire resistant electric cable, which is connected to a detection unit. The detectors shall be of simple, study inspect vibration proof, moisture acid resistant construction. Provision shall be made for a guard current flowing through the detectors. Interruption of the guard current due to break of the elements series connecting cable or loose terminal shall activate an audible and visible alarm signal at the detection unit of the equipment indicating interruption of guard current. This signal must not activate the extinction system and the signal can be used for blocking of the extinction system on request. The detection shall be completed with a smoke detector mounted in series with thermos detector System Voltage: Auxiliary Supply shall be 110 V, DC Fire fighting equipment: The contractor shall supply atleast 4 nos. of 5 kg CO2 portable fire extinguishers distributed throughout the power equipment room Safety equipment: The contractor shall supply one safety tool board comprising at least : i. Insulated gloves ii. Insulating stools iii. iv. Protecting glasses Body lifting pole v. Single pole voltage detection pole vi. Movable earthing and short circuit equipment vii. Insulated cable cutting pliers vii. Notice about care to electrified peoples ix. Salt to avoid kidney blocking The battery rooms shall be fitted with eye washer equipment Cable paths In Open Yard The cable path in the open yard shall be in the form of suitable RCC cable trenches with appropriate RCC covers with angle iron edges or in the form of Heavy Duty PVC pipes of suitable diameter, subject to Employer s notice of no objection Inside Rooms The cable paths inside the rooms shall be in the form of cable trenches with necessary cable supports and covered by steel/aluminium checker plates of good and aesthetic quality Separation of different voltage families As the cable routes are dealing with different voltage family, they have to be physically separated Cable Route Plan The Contractor shall submit cable route plan, cable trench cover drawings, to the Employer, for notice of no objection, well in time Boundary Walls NMRCL MARCH

245 The gate shall be designed in such a way to permit the movement of personnel and goods. The Boundary wall shall be provided with a gate with sliding barrier which shall be motoroperated. Gate also shall be motor operated with a control switch in guard room Guard room The Guard Room shall be provided with near the main gate. Suitable communication link between the Guard and the Substation operator located in the Control Room, shall be provided. The Guard shall be able to open the gate only when he is authorized by the Substation Operator to do so and a suitable interlocking arrangement to achieve this Security arrangement, shall be provided. The specification shall be similar or matching to main building Signages Depending upon the layout and construction finally adopted, the various installations (eg. TSS, SWR, HV and MV Bay, Transformers, Control Room etc) shall be provided with Sign boards, both in Marathi, Hindi and English. These Sign boards are in addition to Equipment labelling, which shall be provided as per approved drawing. The Contractor shall submit drawings for the proposed Signage s, for Employer s notice of no objection and the Signage s shall be provided in accordance with approved drawings. Traction network equipments Equipment pedestals: Pedestals for Control and Monitoring panels at grade, where required, shall be of mass concrete M-15 in accordance with IS: OHE Foundations General 'At-grade', concrete foundations shall be used for supporting the OHE masts, portals and head span which shall be in stabling yards and depots. The contractor shall carry out the geotechnical investigations for foundation design Switching stations (SSP, SP, SS) gantries including VCB shall be provided mostly on the gantries of the viaduct with bolted base plate with anchor U bolts grouted in the parapet Deleted The equipment for the switching stations and VCB shall be in panel and the panel foundation or steel frame works should be designed by the contractor in such a way so as to have minimum noise and vibration The contractor shall ensure effective proper interface with the concerned civil contractor for proper design and execution of all the foundations and steel frame works mentioned above Design Principles The concrete foundations shall be designed to withstand safely, the vertical loads and the bending moments arising parallel and perpendicular to the track and the principal loads which are required to the reckoned while arriving at the vertical loads and bending moments are: - Weight of the OHE, weight of cantilevers including insulators etc., weight of any equipment such as OCS and any conductor, isolator, interrupter etc. on the structure, weight of structure itself. - Radial forces arising out of the pull on contact wire, messenger wire, anticreep wire, feeder, return conductor, aerial earth wire etc. and the bending moments occurring on the top of foundation due to such radial forces. - Wind forces, due to wind blowing parallel or perpendicular to the track, on conductors, cantilevers, pole-mounted equipments and on the structure itself. NMRCL MARCH

246 - In addition, weight of a man with equipment standing on the cantilever shall also be considered for calculating the bending moments and direct load However, when the effect of full wind is taken in the calculations, for any particular case of load combination, the effect of the weight of a man standing on the cantilever need not be considered, as an addition. In other words, the more severe case between the two alternatives viz: i. without man and with wind, ii. with man and with reduced (20%) wind load, shall be considered The foundations designed shall be checked for safety against Seismic forces (Zone II) in accordance with IS: Types of foundations The following types of foundations are used: i. Side Bearing: This type is generally used in level grounds, cutting and good consolidated embankments with sufficient shoulder width. ii. Side gravity: This type is used in good consolidated embankments, where the shoulder with is insufficient. iii. Pure gravity: This type is used in unconsolidated banks and in ash filled areas. iv. In those areas, where black cotton soil is encountered, special Black Cotton soil foundations may be used Soil pressure Soils are classified in accordance with their capability to withstand the mechanical forces to which they are subjected They are generally defined in terms of maximum permissible pressure which could be withstood by them Three types of soil are taken into account i. Normal Soil: Maximum permissible pressure is 0.11 Mpa to 0.22 MPa. ii. Rocky Soil: Maximum permissible pressure is 0.5 MPa to 1.0 Mpa, for soft rock and 2.4Mpa for hard rocks. iii. Loose Soil: Maximum permissible pressure is 0.06 MPa The contractor shall ensure these design criteria mentioned for foundation and associated requirements to the satisfaction of the employer s representative Concrete Mix: i. Concrete for foundations shall be of nominal mix of grade M-15 obtained by mixing cement, coarse aggregate, fine aggregate and water in accordance with proportions given in Table 9 of IS:456. ii. For grouting, muffing and embedding of structures, in foundations and for cable trenches at switching stations, nominal mix concrete M-20 shall be used, in accordance with IS:456. iii. Concrete Poles shall be grouted with dry sand and the core hole after sand grouting shall be sealed with a 10cm layer of Bitumen before Muffing is provided to prevent any ingress of water in to the Core hole Bolted base masts / portals/gantries: Base plates: i. As already stated, the OHE structures, portal and gantries uprights to be located on the viaduct parapet, are required to be provided with steel base plates, welded to the structure/upright. ii. The typical arrangement of base plates for structures/uprights and for anchor on viaduct, shall be provided to the successful bidder. iii. The contractor should ensure that the steel used for base plates shall be of wieldable quality as per national/ international standards. NMRCL MARCH

247 Anchor bolts shall be suitably designed by the contractor, to transmit the mechanical forces from the structure to parapet; shall be provided by the viaduct contractor (see interfacing document) at the time of casting and installation of parapets The contractor should ensure by interfacing with the viaduct contractor that these anchor bolts are provided, strictly in accordance with design (bolt diameter, spacing etc.), failing which it could lead to problems in installation of structure / uprights on viaducts Fencing post: Foundation for fencing posts shall rest on consolidated soil. In case of feeding posts and in the depot, if the depth of unconsolidated soil is less than 1.5 m below the datum level, the fencing shall be with rectangular parallel piped in shape. If the depth of unconsolidated soil is more than 1.5 m, the foundation block shall rest on reinforced concrete piles cast-in-site or reinforced concrete foundation may be adopted as desired by the employer s representative Permissible gradient of contact wire Gradient of contact wire shall be not more than 1/1000 on main tracks and not more than 2/1000 on stabling line tracks at terminal stations. Deviation from these limiting values shall only be with specific permission of the Engineer. The junction with level contact surface shall be joined by a transition gradient half that adopted for the main gradient. NMRCL MARCH

248 7 TECHNICAL REQUIREMENTS 7.1 Receiving Substation High voltage equipment Unless indicated otherwise herein, all equipment supplied and installed shall comply with the International Electro-technical Commission (IEC) standards, or equivalent Indian standards The supply shall include all supporting structures, embedded parts, auxiliary equipment, mechanical linkages, hydraulic piping for control devices with pumps, auxiliary circuits wiring, interlocking devices, current and voltage transformers, cable end-boxes The necessary sub-assemblies must be assembled in the contractor's plant, taking into account the transportation conditions Complete safety to personnel during operation and ease of maintenance shall be ensured The equipment characteristics are given in the technical data sheets The High Voltage bays shall comply with the outdoor type requirement The manufacturer shall check and certify that the equipment characteristics are suited for the MSETCL/MSEDCL network characteristics, if necessary in consultation with the Power Supply Authorities viz MSETCL The plots layouts are shown on the enclosed drawings: The Contractor shall optimize the layout without compromising on the electrical clearance,accessibility to equipments inside the RSS, safety requirements and provisions for future. The layouts shall be subject to notice of no objection by the Employer and shall not have any functional implications Creepage distance for all equipments shall be 25mm/kV, except LA (31mm/kV) Maximum fault duration for all equipments shall be taken as 3 sec The 33 kv Circuit Breakers shall conform to IEC and IEC (C2-M2 class compliant/rdso approved). The electro-technical characteristics required to be guaranteed for circuit breakers of different voltage levels, are shown in the Technical sheets (see Chapter 3.1.1) The circuit breaker must be SF-6 puffer type and single pressure type with only one breaker NMRCL MARCH

249 per pole, mounted on one insulated support column. The operating mechanism shall be spring-spring type The Circuit Breakers shall be fitted with an electrical actuation system operating simultaneously on all three poles, backed-up by an emergency manual actuation in case of malfunction of the former The moving contact shall be equipped with different compartment allowing a rise of pressure which shall be used to extinguish the arc and assist the opening movement, in order to avoid poles deterioration and to reduce the actuation energy required to operate the CB It shall be possible to lock the manual actuating device in open position by means of key and lock system An anti-hunting coil is required on all commands going to the switchgear. This function prevents execution of two successive closing if the first one is immediately followed by a tripout that is to say if the first closing is not successful. This prevents the circuit breaker from re-closing and from hunting until any opening order is given to confirm the tripping. Then a new closing order could operate A 110 V DC auxiliary under-voltage trip-out coil is required in all circuit breaker with approved means All interlocks and automatic systems within the actuation system shall be designed so that the circuit breaker executes operations only when it is in a position enabling to do so completely and reliably. That mean, for example, when an apparatus is in remote control, the local control does not operate The contractor shall provide a detailed description of the pneumatic or hydraulic or spring system used to operate the circuit-breaker, their rated supply pressure, lower and higher acceptable pressure limits and thresholds together with the maximum number of consecutive actuation possible while still enabling correct operation Each pole shall be mechanically connected by means of a link and a transmission assembly to the operating mechanism The energy needed for the opening and the closing operations shall be supplied by different springs located in the control cubicle It shall be possible to reload the springs manually by mean of handle The control cubicle shall include a remote/local changeover switch and opening and closing push buttons These Push buttons shall be active in local mode and inactive in remote mode. NMRCL MARCH

250 The control cubicle shall be dust and water proof (IP 55) and shall include an anti condensation heating An optical indicator shall indicate: a. the position of the circuit breaker (Closed or open) b. the position of the closing spring (Loaded or unloaded) c. the position of the closing spring (Loaded or unloaded) The operating cut-off, opening and closing duration shall comply with the standards in force (IEC 60694, ). All three poles shall open and close simultaneously. In case of any mechanical out of synchronization in the operation of the three poles it shall none the less fall within the tolerances stipulated in the standards in force The rated lightning impulse withstand voltage when interrupter gap open should be as per IEC for breakers The protection devices for SF6 pressure protection devices shall ensure permanent monitoring of gas pressure inside each compartment by mean of temperature compensated monitoring devices triggering a dual alarm threshold annunciation system in the event of gas pressure drops Contractor shall provide following initial alarm threshold: a. Performance of the CB is unaffected; in particular breaking capabilities remain intact. b. Immediate intervention by specialist is not necessary Contractor shall provide following Second alarm threshold: a. CB tripping and locked until SF6 refilling b. Isolating capabilities of the CB remain intact. c. Control orders are inactive. d. Immediate intervention by specialist is necessary The devices used must provide full reliability and operating safety and not represent a weak spot for the tightness of equipment. At no time shall these devices indicate any wrong data, not lose their accuracy regardless of ambient temperature or of the operating incident concerned. This is why monitoring devices with temperature compensation are specified Each gas compartment should have its own SF6 pressure monitoring facilities as well as its static filters Pressure relief devices should be designed to limit maximum pressure rise below the bursting level of the enclosure and barrier insulation but not designed to retain the fragment of bursting disk All gas compartments shall be equipped with rupture diaphragms to prevent the enclosure from uncontrolled bursting. NMRCL MARCH

251 Testing and inspection devices Each compartment will be equipped with valves and connections enabling gas to be added or direct readout pressure measuring equipment to be fitted while the equipment is energized The various joints and gaskets shall ensure full tightness and be protected so as towithstand the effects of the various corrosive agents present in the atmosphere (pollution, temperature, humidity, etc.). The corresponding flanges shall be fitted with an effective system for testing sealing all leaks even very slight ones that may occur around or because of these joints The apparatuses shall be fitted with pressure release valves with deflectors to ensure protection against overpressure. Test certificates of this device shall be supplied Each circuit breaker shall be equipped with an earthing connecting device, on upstream and downstream side, to earth the isolated circuit All isolators shall conform to IEC 517, 694, 129. The electro-technical characteristics required to be guaranteed for isolators of different voltage levels are shown in the technical sheets (see Chapter 3.2.1) The isolators shall be fitted with an electrical actuation system operating simultaneously onall three poles, backed-up by an emergency manual actuation in case of malfunction of the former. The actuating device shall be capable to be operated electrically or manually through a changeover switch with three positions (off / manual / electrical) provided on the motor box The isolators shall not change of position under the effects of electrodynamics loads, whichmay occur during operation, in particular those caused by short-circuits The isolators shall be of two-column rotary centre break type, with two moving parts (tworotating columns). They shall be protected against corona discharge by providing metallic ring The line isolator (LIS-x) shall be equipped with earthing isolator (LEIS-x) to earth the cable from MSETCL. This earthing isolator shall be mechanically interlocked with the line isolator LIS to lock the open apparatus when the other one is closed. The operation of the both apparatuses shall be simultaneous with the same control The electrical operation of LIS-x - LEIS-x, remotely or locally, shall be interlocked with the voltage lack on the cable or with the open position of up and downstream circuit breakers. That mean it shall be impossible to operate the both apparatuses, LIS-x LEIS-x, when the cable is under voltage The manual operation shall be subject to the local locking by padlock. Nevertheless, in order to ensure the safety of the operator, it could be possible to send a tripping order to NMRCL MARCH

252 the relevant circuit breaker at MSETCL side, when putting in manual mode the threeposition changeover switch Each isolator shall be equipped with an earthing connecting device, on upstream and downstream side, to earth the isolated circuit by mean of a device interconnecting and earthing the three phases. The line isolators (LIS-x), being equipped with an upstream earthing isolator, shall have only a downstream earthing connecting device To unify the equipment, the current transformers shall be SF6 insulated. That means the active part of the CT, primary and secondary are enclosed into a chamber full of SF6 to ensure isolation between the both winding and to reduce the dimension of the active part. In this system the tank is at the primary potential, contrary to the general case of current transformer oil insulated where the tank is insulated For the SF6 pressure protection device, refer to the relevant chapter of circuit breaker Each incoming section shall be equipped with measuring and protection current transformer on each phase Each transformer section shall be equipped with protecting current transformer on each phase, that is to say 3 current transformers for the 3-Phase transformer section The coupling section shall be equipped with a set of three protection current transformers, one on each phase The voltage transformers shall be of capacitive type Each incoming section shall be equipped with voltage transformer on each phase The coupling section shall be equipped with a set of three voltage transformers on eachhalf-bus bar The high voltage capacitor and intermediate capacitor shall consist of series connected capacitors. Each element shall be made of high purity cellulose paper or paperpolypropylene and aluminium sheets or foils forming electrodes. The oil seal shall be ensured by rubber gasket unaffected by oil or ambient pollution Extension of oil, due to temperature variations, shall be ensure by an elastic diaphragm also unaffected by oil. Alternatively, stainless steel bellows are acceptable The electromagnetic element, MV transformer and series inductances, shall be located in an hermetically sealed tank filled with oil The electromagnetic part shall be equipped with a protection against over-voltage and iron resonance phenomenon The low voltage terminals, mounted on the tank, shall be made on an insulated epoxy resin containing the secondary terminals and the fuse-holders. The ground terminals can be provided outside the secondary terminal box. NMRCL MARCH

253 Anti-condensation heating arrangement shall be provided inside the Low Voltage terminal box. If anti-condensation heating is not provided, suitable breathers have to be provided to remove moisture, if any Each phase of the Incoming feeders shall also be provided with Lightning arresters as per the following specifications: a. Each phase of the primary side of each transformer shall be equipped with a lightning arrester. b. These are made to protect the transformers against operating over-voltage and, eventually, against lightning impulses. For this reason they shall be installed immediately upstream the transformer primary connection. c. They shall be zinc-oxide types and they shall contain a single of resistor, which active part shall be composed of perfectly homogenous resistors. d. The Composite enclosure shall be long creepage distance to ensure good insulation with a high level pollution. e. They shall correspond to the class discharge 4 of the IEC (20 long duration current impulse of 1200 A-2ms 9.5 kj/kv) f. A surge counter shall be installed on each lightning arrester to indicate the number of functioning of each device. They shall also indicate the value of the leakage current. g. They shall be well insulated and shall be suitable for outdoor use Transformer Power Transformers (33kV / 25 kv) Execution rules The power transformers shall be manufactured in accordance with the standards of the International Electro-technical Commission (IEC 76) Characteristics The Auxiliary power transformers if any shall meet the following characteristics: i. 3-phases type in mineral oil tank, ii. Entirely submerged in mineral oil tank, iii. Outdoor type, suitable for tropical conditions, iv. On load tap changer on primary windings, v. Possibility of various load conditions vi. Separated oil conservator vii. Cooling mode: ON AN/ ON AF viii. Both transformers shall not work permanently in parallel (only during a transfer without breaking), ix. Transformers shall be exactly similar and replicas of each other. x. Transformer plus ventilation system noise level should not exceed 70dB, at a distance of 1.5m xi. The Vector group shall be: YN yn Rated power NMRCL MARCH

254 The transformer shall be manufactured and guaranteed so as to provide a continuous power rating, measured across the secondary winding, of the following value at a voltage of 25kV under load. The nominal ratings thus defined shall not result in temperature rises exceeding those stipulated in the standards as specified below Overload capacity The transformers shall be able to withstand an overload of 25% for duration of 2 hours, following continuous running at maximum continuous rated load without exceeding the limits of temperature rise stipulated in the standards as specified below. In his bid, the supplier shall indicate the precise overload capacities of the equipment for 30 minutes, 1 hour, 2 hours and 4 hours rating, on the basis of the thermal balance resulting from extensive initial operation at load of 1/4, 2/4, 3/4 and 4/4 across the secondary winding. After overload the temperature shall remain within the following limits, 65 C above ambient temperature for oil. 75 C above ambient temperature for windings Rated voltages Primary winding: The primary winding neutral brought out and earth connected. The rated voltage shall be 33 kv rms as applicable at a power frequency of 50 Hz on the main tapping. Operating voltage may increase to + 10% and drop to - 15%. The insulation level of the Transformers shall correspond to the following values proposed in Volume 4 Appendix B Technical Sheets. Secondary winding: The secondary windings shall be neutral brought out and earth connected. The rated voltage shall be 33 kv rms. The insulation level shall be 36 kv rms highest system voltage and the neutral end shall be fully insulated and earthed through a 20 ohm resistor in order to limit the current to a maximum of 1000 A admissible into the 33 kv cable screen. The 33 kv neutral point shall be earthed via an suitable capacity and rating isolator. Current transformers for earth protection and standby earth protection and surge arrester. The surge arrester shall be located as close as possible to this terminal. The calculations shall be submitted in the definition file of transformers On-load tap changer Voltage shall be substantially constant at the untapped windings (secondary windings) and variable at the tapped winding (primary winding). The category of regulation applied shall be constant-flux regulation (CFR). The on-load tap changer shall be single-phase enclosure type, installed in a separated oil tank, offering 16 steps, each representing 1.667% of the nominal voltage as follows: For 33 kv It shall have the following characteristics: i. Enabling 50,000 operations ii. Motor and / hand-driven iii. iv. Manual, automatic, local and remote control & monitoring Tap position indicators v. Commutation current compatible with the short duration transformer over-current. vi. Diverter switches shall be designed for high speed operation and shall be interlocked to ensure that there is no possibility of an operation stopping in midposition. Arcing contacts shall be of tungsten alloy material. vii. Between positions disabled viii. Devices to ease extraction for maintenance purpose. NMRCL MARCH

255 ix. Manual/Automatic, Local/Remote, Control & Monitor of OLTC from RSS control room and OCC The oil volume of the on-load tap changer unit must be separated from the tank for core and winding oil. The power circuit of the on-load tap changers shall be connected to the neutral of the primary windings and shall enable the voltage variations. The full technical description shall be given as regards power and auxiliary circuits; periodicity for checking and over hauling the power circuit shall be indicated in the transformer maintenance Manual. As the transformer are deemed to run in parallel during power transfer, OLTC shall be fitted with a servo-mechanism suitable for such a purpose. The manufacturer shall provide mechanical and electrical diagrams. A suitable protection relay shall be connected on the oil pipe between the on-load tap changer and the expansion vessel. The voltage ratio shall be checked according to the guaranteed figures and the tolerances stipulated in the standards Cooling system The power transformer shall be designed to operate in ONAN/ ONAF mode (oil natural air natural / oil natural, air force). The oil to be used for the transformer must be in conformity with the IEC 60296/ IS standard, and of the highest non-inflammability degree. The maximum temperature allowable at nominal rating for each cooling condition (natural and forced air) shall never exceed: i. 50 C above ambient temperature for mineral oil ii. 55 C above ambient temperature for the copper winding and the iron core. Oil breakdown strength during test should be more than 55/2.5 kv / mm. The transformer will be rejected in case the temperature rise exceeds the guaranteed values by more than five degrees. The contractor shall give full description of the design, operation and maintenance of the proposed air cooling system and indicate the air flows needed for ventilating the cubicle and the air cooling units Short-circuit withstand The transformer shall be designed and constructed so as to withstand without damage, whatever may result, from an external short-circuit. To limit the short-circuit symmetrical current to an allowable value, the impedance voltage shall never be less than twelve percent (12%). At rated power and frequency on the main tapping, the impedance voltage shall be equal to about twelve point five percent (12.5%). It shall withstand the symmetrical current for 3 second during short-circuit for 220/132/33 kv network Iron core The magnetic core, frame assembly, clamping and general structure of the transformer shall be mechanically sturdy so as to be capable of withstanding shocks which may happen during transport or during short-circuit and over-voltage times. Cores and magnetic circuit shall consist of cold-rolled grain-oriented silicon steel sheets. They shall offer guarantee of durability in time, heat resistance and oil resistance. The tightening bolts shall be suitably insulated and the ground of the magnetic circuit shall employ generously sized copper connections and links. The keying and compression of the laminations, together with the induction value, shall be designed so as to keep vibrations to a minimum and to reduce, in particular, the third and fifth harmonics influences. NMRCL MARCH

256 Calculation sheets to establish maximum flux density (i.e Tesla) shall also be submitted with Design to employer. The contractor shall submit complete technical data of the system to the employer. During testing, noise shall be measured according to the standard and the guaranteed minimum noise level shall be as low as possible for transformer of this power Transformer losses The transformers shall be designed for minimum losses.(refer 6.12) The transformer losses shall not exceed specified maximum values as per Volume 4 Appendix B Technical Sheets (Expected Values) Windings The winding conductors shall be made of best quality high conductivity electrolytic copper, in compliance with the standard (IEC 28) requirements. The both windings, primary and secondary, shall be designed to withstand over-voltage and over-current in case of direct short-circuit across the medium voltage terminals with the primary winding line for three seconds. The adjustment windings shall be designed specifically to withstand direct shortcircuit of all part of the adjustment turns that may occur at the contact plates of the on-load tap changer switches. The winding, connections and terminal links shall be properly brazed so as to withstand the shocks and vibrations which may occur during transport or short-circuit time. Testing of samples must be carried out and submitted for notice of no objection during in-plant inspection before starting assembly of the transformer windings. Current density for each winding should be not more than 2.5 A/mm². The insulation material used for the transformer windings and connections shall be of class A Terminals and connections The primary and secondary bushing insulators shall be plain porcelain. The porcelain shall be brown glazed, it shall be unaffected by atmospheric conditions due to fumes, ozone acids, alkaline, dust, sand storms or rapid change in temperature between 0 C and 75 C under working conditions and the prevailing environmental conditions/changes in Nagpur. n order to avoid damages to tank in case of disruptive discharge, bushing base should be connected to the earth. Creepage distance for one bushing should be 3.1 cm/kv. Full particulars of the offered bushings shall be given in the bid. Bushings shall be realized in conformity with the IEC 137 standard. Special care shall be taken against transmission of vibrations by employing a damping system and suitable fittings. The design shall take into account the ease of overhaul. It should be possible to withdraw and to remove the transformer at ease. Interchangeability between transformers shall be achieved through the use of identical elements. The link between secondary terminals of the transformer and the 33 kv switchgear shall be made by cables connected directly at the outside of the secondary bushing Tank The transformer tank shall be made of high quality boilerplate steel with stiffening frame and girders. The width of the welding sections shall be sized so as to permit three dismantling operations by grinding before having to completely reform them. The thickness of the tank should not be less than 10 mm. and the tank should withstand full vacuum. The NMRCL MARCH

257 contractor shall provide all necessary guides for mounting and removing of the tank. Tank shall only be connected to the earth through current transformer. In case of separated radiators, they shall be earthed and consequently pipes network shall be mounted with insulating joints. The tank, valves, joints and gaskets shall be air-tight, water-tight and oil-tight. The junction shall be capable of withstanding the temperature of a fire without causing any major leak as per IEC 76 standard. For this purpose, the flanges connecting the tank to the pipe-work and the flanges between parts of the pipe-work shall be designed with particular care. The tank shall be reinforced in order to render it capable of withstanding the pressure caused by the various mineral oil treatments. The tank shall be fitted with hooking points to enable it being lifted in balance by means of an overhead travelling crane, as the main package on a road trailer or in form of the complete unit, fully equipped and filled with mineral oil. The tank shall be secured to a frame equipped with bi-directional and removable rollers made of cast iron and fitted with locking devices. The frame shall enable the transformer being laid normally on a slab or foundation block, without rollers. The tank shall be equipped with the following auxiliary devices: i. manholes on the tank cover, if necessary, ii. iii. iv. flanged oil drainage valves, oil sampling cocks at top and bottom of the tank, flanged valves suitable to connect the oil filtering unit, v. special pockets for checking by thermometers, vi. earthing terminals Transformers shall be fitted with overpressure relief device provided with electrical contacts. Name plate to be provided with all technical particulars Oil expansion vessel The transformer shall be equipped with an oil expansion vessel placed above the transformer. The oil expansion vessel shall be partitioned so as to avoid mixing between the on-load tap changer oil and the core and winding oil. It shall be connected to the transformer through all the necessary pipe-works, fitted with flexible metal joints and gaskets; the connecting pipe shall over-extend vertically inside the vessel (at least 8 cm) The various drainage valves, oil sampling devices and relief valve shall be provided and easy to reach for each partitioned volume. The dehydrating breather with Silica gel or equivalent fitting and checking glass shall be accessible easily to change the dehydrating product during operation of the transformer. The oil level indicator with auxiliary contacts shall be easily observable from ground level. The oil volume should not reach: i. the minimum level by 0 C (Ambient temp.) ii. the maximum level by 50 C (Ambient temp.) Control and protection The transformer shall be delivered with "buchholz", thermal and earth fault protections, all connected to the control and monitoring cabinet Buchholz: The term "buchholz" protection denotes the gas-sampling device and relay for gas fault detection and storage for analysis. The relay shall comprise two thresholds as follow: NMRCL MARCH

258 i. alarm in case of minor fault such as local overheating of windings or core (small gas discharge), ii. Tripping-out in case of major fault (violent gas discharge) or important oil leakage. Both transformer and on load-tap changer oil circuits shall be equipped with "buccholz" protection. They shall be connected to the oil pipe between the tank and the expansion vessel, without any flat part and any less than 50mm band. It shall be free for access and maintenance; a by-pass system shall be provided to enable oil flow without interrupting operation during maintenance checks. In order to ease gases chemical analysis, the gassampling device shall be accessible during transformer operation, at man level Thermostat The thermostat itself shall be installed in the monitoring box, while the indicator on its facade and the thermal probe shall be installed into the tank with appropriate pocket Earth fault The insulated tank shall only be connected to the earth through a current transformer, which shall be linked to the control system via monitoring cabinet terminal block Control and monitoring cabinets Made of steel-sheets, grade 304 totally enclosed, dust-proof and waterproof type (IP55) it shall be equipped with: a) For transformer i. Access doors with padlocks ii. 415 /240 V protection and power circuits. iii. 110 V DC control and monitoring relays iv. Internal lighting monitored by the door position. v. Heating thermostat with indicators and contacts vi. vii. Information terminal block Remote control and monitoring multi-pin connector b) For On-load tap changer i. Access doors with padlocks ii. 415 /240 V protection and power circuits. iii. 110 V DC control and monitoring relays iv. Internal lighting monitored by the door position. v. On-load tap changer operating equipment and control vi. Counter vii. Information terminal block viii. ix. Remote control and monitoring multi-pin connector RTCC Panel with AVR relay and remote indication. AVR relay to have adjustable time voltage settings for OLTC tap operation, feature for auto and only manual operation of OLTC. AVR should operate based on voltage level of primary side of transformers. All control and monitoring cabinets used in indoor shall conform to the following minimum specifications Material : Steel Minimum thickness of Steel sheets : 3mm for front cover & base frame 2 mm for rear door 1.6 mm for roof plate, bottom plate & side covers NMRCL MARCH

259 Powder Coating : Exterior Interior Base frame Thickness : : RAL 7032, Texture finish RAL 7032, Texture finish Black Min. 80 microns of Power coating The Contractor shall submit to the Employer, the complete details of the Control & Monitoring Cabinets, including details of the structure, process of finish and painting, wiring, terminal blocks, cubicle illumination heating etc, for Employer s approval. The details adopted for Control and Relay panels, Bay Control and Protection units, Transformer and On-load tap changer cubicles and all other Control and Monitoring Cabinets, located inside the RSS Control Room shall be identical to project an aesthetically good appearance Metal work and Paint-work Painting should be suitable for salty seaside atmosphere and has to comply with IEC standard The entire surface (Internal as well as External) to be painted shall be prepared by Shot blasting to cleanliness level, SA21/2 as per ISO 8501/SIS Ensure that the cleaned surface is free of oil or grease, scales rust and other residue. Surface profile of the blasted surface should be approximately microns. All the external surface of the transformer shall be given first coat of Epoxy zinc rich (having minimum 83% metallic zinc) primer (Min.50 microns thickness), first intermediate coat of epoxy zinc phosphate paint (Min.60 microns thickness), intermediate coat of Epoxy high build MIO (Min.80 microns thickness), and final coat of glossy Aliphatic Acrylic polyurethane (Min.50 microns thickness). The total dry film thickness (DFT) of the paints shall be minimum 240 microns and should withstand 120 C. The shade of paint shall be gray shade 631 as per IS: 5. All steel surfaces which are in contact with insulating oil shall be painted with heat resistant oil- insoluble insulating varnish. After baring, all metal surfaces shall receive anti-corrosion process (as per IEC standard): i. Natural stainless for Bolts & screws ii. Hot dip galvanization with paint or Elastomeric paint or Epoxy paint for radiator. iii. Rust-proofing and anti-corrosion paint for tank, oil expansion vessel and other metal surfaces The transformer and its accessories shall be completely painted in plant. The necessary touch-ups shall be executed on-site after erection. This protection shall be fully guaranteed for five years starting from provisional taking over. Should any noticeable deterioration by rust or corrosion appear before this time elapses, the contractor should be responsible for repainting at his own expense and for renewing his guarantee for the work performed. The painting and preserving of panels for transformer protection should be similar match with that of other control and relay panels provided in the control room Particular dispositions, Installation NMRCL MARCH

260 Transport For transport either by road, ship or rail, the transformer shall be filled with oil up to windings top and then with Nitrogen at recommended pressure up to the tank top or alternatively, the transformer may be filled with Nitrogen, in full, during transportation. The bushing, breather, wheels and all other external parts shall be removed on condition that they can be mounted at site. Installation The transformers are to be installed at the RSS-cum-AMS on two running rails, and consequently must be delivered with a set of swiveling rollers. These rollers shall be mounted electrically insulated from tank and with locking devices. Material layout and volume shall permit an easy access to every part of the equipment, in particular those requiring maintenance. The contractor shall indicate the method of handling all the parts from the main access of the RSS Grounding of 132kV / 33 kv power transformer neutrals Grounding of the high voltage neutral: The high voltage neutral shall be solidly earthed through an isolator whose open or closed position shall be according to the general operating condition of the distribution network. Switches shall be of single phase, air insulated and manually controlled. Their insulation level shall be suitable as per primary voltage of transformers. The actuation level shall be at man level. Locks and keys shall be provided to achieve the safety interlocking conditions. Flexible braids to a copper bar insulated shall connect the primary neutral terminal and whose crosssection shall enable the current flowing to earth in case of failure. This link shall be fitted with a current transformer and a surge arrester, situated as close as possible to the neutral terminal Grounding of medium voltage neutral Grounding of each neutral of the secondary windings of the power transformers shall be made through a resistor and an Isolator. Temperature rise according to the duty class shall be reduced to the minimum possible and never exceed the values stipulated by the IEC standards. Each resistor shall be installed next to the transformer and shall be surrounded by a frame to avoid any access when the transformer is working. The frame door shall be interlocked according to this condition. The NGR body shall be painted with three coats of non-metallic paint of the same quality, description and method as that used for outdoor transformers, total thickness should not be less than 240 µm and should withstand 120 C. The contractor shall be responsible for the following, for each of these resistors: i. installation and securing, ii. Connection from the resistor input terminal to the neutral terminal of the transformer via suitable size of a copper cable with suitable insulation fixed on wood clamping blocks and with a cross-section suited to the operating rating of the resistor. iii. setting and erection of a single-phase, manually controlled, air insulted, isolator provided to isolate the resistor from the transformer side iv. Connection from the resistor output terminal to the underground earthing circuit of the station via copper bus-bar. v. Erection and connection of various current transformers NMRCL MARCH

261 vi. vii. viii. Installation and connection of a current transformer after the output terminal of the resistor. grounding of the various main metal sections Surge arrester situated as close as possible to the transformer neutral terminal. The isolator shall be of single phase, air-insulated and manually controlled. Isolators, surge arresters and current transformers shall be installed on a portal located respectively over the neutral resistors. 7.2 Fire Protection & Suppression system:- In terms of CEA (safety regulations), 2010 transformers of 10 MVA and above rating or in case of oil filled transformers with oil-capacity of more than 2000 litters are provided with fire fighting system as per IS : 1993 or with Nitrogen Injection Fire Protection system ; In view of above, transformer shall be provided with Nitrogen Injection Fire Protection System. 7.3 Fiber Optic Winding Hot Spot Temperature Monitor: Fiber optical winding hot spot temperature monitor to be provided with transformer windings connected in parallel of the winding temperature indicator to measure transformer winding hot spots in real time and activate control of the cooling system. The Fiber to be given high strength casing through rugged jacketing and fiber to be securely routed till the tank wall plate. Specification for Fiber Optic Temperature Measurement System. Fiber optic based temperature measurement of Oil and windings shall be done using Fiber Optic sensors kv / 230 V Auxiliary transformers The Auxiliary Transformers, also referred to as Auxiliary Station Transformers are required to supply the power requirement at 230 V of various electrical equipments, systems and appliances in the RSS. Mainly these comprise of power required for lighting, fans, airconditioning, control and monitoring circuits, battery chargers, space heaters in the switchgear / panels etc General This specification defines the main technical characteristics required for the 25kV/230V transformers to be used in Auxiliary of Main Substations. (As per RDSO specification) The transformers shall have a min power rating of 100 kva. They shall satisfy the following requirements and shall also comply with standards in force when the transformers are manufactured, particularly IEC standards or equivalent UTE standards. The transformer shall be cast resin type Characteristics i. - Climatic conditions: indoor operation ii. - Operation: continuous iii. - Windings: copper iv. - Primary line voltage (across phases): 33 kv v. - Secondary voltage, off-load : 415 V vi. - Secondary voltage at full load and power factor 0,8: 400 V vii. - Insulation rated voltage: 36 kv viii. - Frequency: 50 Hz ix. - Withstand at industrial frequency: 70 kv x. - Voltage surge withstands: 170 kv xi. - Impedance voltage: 4% xii. - Coupling: Dyn11 xiii. - Cooling: natural xiv. - Off load tap changer: ± 2.5% and ± 5% NMRCL MARCH

262 The voltage shall be adjusted by a 5 positions switch which can be used dead and provides -5%, - 2,5%, 0, + 2,5%, and + 5% settings. The magnetic circuit shall be in low-loss oriented-grain silicon steel sheet. The primary and the secondary windings shall be capable of withstanding a symmetrical three-phases short-circuit regardless of the tapping selected, that is to say a short-circuit current, at secondary side, of 7000 A. The terminals shall be of the 36 kv type. The secondary neutral shall be solidly earthed The medium and low voltage connections shall be made using braids whose cross-section is suited for the current level to be transmitted and which are very easy to disconnect so as to enable very quick replacement of the transformer in the event of breakdown. This equipment shall satisfy all the requirements for interchangeability, interlockability and functional servo-control applicable to this type of equipment. It shall use a technology and components identical to those of the equipment to be installed in the Auxiliary stations Temperature Protection Transformers shall be fitted with a temperature protection system that allows winding temperatures to be monitored. This shall consist of two sensors placed on each lowvoltage winding, i.e. three alarm sensors and three trip out sensors. An indicator shall be installed on the front door of the bay to indicate continuously the winding temperature. This shall be installed on the middle low voltage winding Transformer Values The contractor shall confirm the following characteristics for each power distribution transformer: - Short-circuit voltage, - No-load losses, - Full-load copper losses - Efficiency at different load conditions: - 1/4 - load: power factor = 1 (Minimum: 98,25%) Power factor = 0,8 (Minimum: 97,85%) - 1/2 - load: power factor = 1 (Minimum: 98,1%) power factor = 0,8 (Minimum: 97,65%) - 3/4 - load: power factor = 1 (Minimum: 97,8%) power factor = 0,8 (Minimum:97,25%) - Full load: power factor = 1 (Minimum: 97,35%) - power factor = 0,8 (Minimum: 96,7%) Switchgear Room equipments General Description Switchgear room (SWGR) located within the premises of the Receiving Substation (RSS) performs the task of supplying 33 kv, 3-phase power supply to the 33 kv distribution network, through appropriate switchgear and protection arrangements. The SWGR mainly comprises of: i. 33 kv, Indoor type, with drawable switchgear cubicles including 33 kv Circuit Breakers / interrupters 33 kv bus bars, 33 kv potential and current transformers as required, earth switches, protection relays, meters and all other components required for satisfactory operation of the switchgear. ii. 33 kv / 415 V 100 to 200 kva Auxiliary dry type transformers iii. 415 V AC Distribution Board NMRCL MARCH

263 iv. DC-UPS including Battery, Battery chargers v. 110 V DC Distribution Board vi. Interface cubicle to act as a link between SWGR equipments and GATEWAY To SCADA vii. Interconnecting power and control cables SWGR Room All SWGR Equipments are installed in a room, which is part of the SWGR & Control Room building SWGR & CONTROL ROOM As part of the SWGR & Control Room Building, the Contractor is required to build the SWGR Room complete with cable gallery, cable paths and covers and other general electrical facilities such as lighting, ventilation, fire detection and alarm system, SWGR Room earthing system etc. The Contractor shall comply with the SWGR & Control Room Building requirements., KV SWITCHGEAR 33KV Switchgear will be SF6 / Vacuum Indoor type. For underground, the 33kV Switchgear shall be metal-enclosed gas insulated switchgear and the circuit interrupting device shall be vacuum type. The switchgear offered shall have a basic insulation level (BIL) of not less than 170kV peak. The switchgear shall be capable of operating in class B environment stipulated in clause 1.13 of General Specification. This 33kV configuration shall be in line with our proposal for Auxiliary network A circuit breaker complying with all necessary safety conditions and interlocks shall be capable of being mounted inside each circuit-breaker cubicle. 33kV switchgear breaker should be type tested for internal arc test for 1s as per latest IEC under the most stringent condition Switch gear cubicles General data All circuit breaker cubicles shall be of the same type. All non-welded assemblies shall be assembled by means of bolts and nuts with mandatory use of lock-washers. All panels, separating partitions and accessories shall be mounted similarly, in such a way so as to withstand indefinitely the vibrations transmitted, in particular by the resetting mechanism of the circuit-breakers and their actuation Electrical characteristics The service voltage is 33 kv The insulation level is 36 kv minimum Compliant to latest IEC. All parts of the cubicle (bus-bars, sliding connector, partition passages) shall be capable of permanently withstanding the temperature rise caused by the currents and shall match the nominal rating of the circuit-breaker provided. The cubicles shall be capable of withstanding without any damage the loads generated by 1500 MVA peak short-circuits. The number and frequency of those are not limited in time Cubicles common part It must be of metal-clad switchgear type, closed by a door forming the facade, equipped with riveted marking plates and single-wire diagram also fitted with the display lamps indicating the presence of 33 kv voltage Bar set compartment: NMRCL MARCH

264 i. 33 kv, 2000A bar set mounted on insulators, suited to withstand 1500 MVA peak shortcircuit. ii. Inter-cubicles high-voltage connectors. In principle, the bus bar shall be of copper and shall be a rectangular cross-section. Alternatively hollow tubular bus bars are acceptable, provided they meet the current requirement of 2000A Paint-work Painting should be suitable for polluted atmosphere and has to comply with IEC standard After baring of all metal surfaces, an initial coat of rust-proofing and anti-corrosion paint will be applied; then they will be covered with two coats of paint and one finishing coat, colour to be defined Protection level Cubicle enclosures and medium voltage sheaths shall provide an insulation protection level, IP 3X minimum Apparatuses Circuit breakers Make-up & equipment: Each Circuit Breaker will be bipolar three pole type and Vacuum/SF6 type and will include: i. Up & down stream plug-in connectors ii. Life insulated poles iii. Energy accumulation type actuation system (electromechanical springs) iv. Electric and manual arming capability (Tripping and closing coils motor...) v. Under-voltage tripping coil (Auxiliary voltage off) vi. Locking and interlocking devices vii. Open / Closed auxiliary contacts viii. Low voltage multi-pin connector and flexible cable Self Interlock requirements: Circuit-breaker can be plugged-in or out only if tripped-out. All access to the fixed plug-in parts is prevented when the circuit breaker is withdrawn. The interlock shall fulfill the following conditions: i. When unplugged and withdrawn from the cubicle, the circuit breaker shall inhibit opening of the flaps covering the receptacles and shall enable the key to be turned. ii. By turning the lock and withdrawing the key, it shall not be possible to plug-in the circuit breaker. iii. In addition for the outgoing 33 kv cable cubicles, it shall be possible to actuate the earth isolator only after first unplugging the circuit breaker and withdrawing the first key. iv. Conversely, the earth isolator being closed, it shall not be possible to unlock the cubicle in order to plug a circuit breaker in. v. The type of lock shall be selected among equipment considered as being safety equipment. vi. A general diagram of the key interlocks for the station, indicating all the locks provided for the present equipment shall be prepared. NOTE: It shall invariably be possible to padlock the interlocks Current transformers Each Current transformer will be installed in the cable end compartment between the downstream pole and the cable connector. Cable end compartment volume will allow current transformer easy access and removal. Current transformers shall be cast resin type. Current transformer performances shall be as per technical sheets included into the relevant Chapter. NMRCL MARCH

265 Voltage transformers Each Voltage transformer shall be installed in the cable end compartment, connected between the downstream pole and the cable connector through HRC fuses. Cable end compartment volume will allow voltage transformer easy access and removal. Voltage transformers shall be cast resin type. Voltage transformer performances shall be as per technical sheets included in the relevant Chapter Motion and plug-in mode Special devices All complete sets of plug-in accessories shall be provided for each type of circuit-breaker, together with four sets of auxiliary plug-in actuating devices, where the circuit-breaker has such devices. In addition two hoisting devices (pulley fastened to the ceiling or any other solution) shall be provided if necessary for the storage position and the maintenance depot Specific Requirement for 33 kv GIS NOT APPLICABLE i) GIS supplier should have minimum experience of 05 years for manufacturing of similar GIS substations. The type of GIS offered should have been in satisfactory operation for atleast three years. Contractor should submit performance certificate from the employer. ii) The 33kV equipment shall be built according to the SF6 gas insulation technology. iii) 33kV GIS as offered should be fully type tested as per latest IEC standards at the time of submitting the bid. iv) The equipment installed shall offer all necessary facilities for equipping and connecting the equipments sections to follow, without entailing any shut down of equipment already in service. v) In the event of arching in a compartment, the arches should not extend to the neighbouring compartment. Any failure to the enclosure of the compartment shall not lead to damages in the neighbouring compartments. vi) Suitable means of expansions should be provided in the metal enclosure and pipelines to absorb the actual thermal expansion and contraction of the SF6 equipment and to facilitate the alignment of the switchgear assembly. vii) The metal enclosure for the SF6 gas insulated equipment modules shall be made from aluminium alloy/ stainless steel. viii) GIS should be of modular design, and it should be possible to add feeder panels if required. ix) Inter-panel auxiliary and control wiring shall have terminals in each relevant cubicle so placed for the bus wiring to be readily run from unit to unit. Auxiliary and control wiring to be connected to other equipment shall be wired to terminals at the rear of individual cubicles, suitably located for the wiring to be extended via multicore cabling run in floor ducts. All auxiliary and control wiring shall be separated from high-voltage conductors, even though the latter are insulated by earthed metal enclosures. NMRCL MARCH

266 x) All auxiliary and control cables and wirings shall have suitable marking, such as ferrule markers, which shall clearly identify their function and shall match the control schematic drawings and wiring diagrams. The markers shall fit firmly over the outer diameter of individual cable and each wire core. Marks shall be printed and legible. For easy identification, colour coding shall be used to differentiate various functions of the cable and wires. All auxiliary and control wirings shall also be complete with cable lugs for termination. xi) A relay and instrument compartment shall be located at the front of each switchgear unit and shall be provided with a hinged door for access to the internal wiring and terminals. Gaskets shall be used to provide close sealing. The height of the instrument panel above floor level shall not exceed 2,000mm unless otherwise reviewed without objection by the Engineer who may require the Contractor to provide, at its own cost, suitable means for easy access to the instrument panel. xii) Anti-condensation heaters with humidity control function shall be installed for each switchgear panel. xiii) The switchboard shall be designed to cater for future extension Low voltage AC distribution board General Both the auxiliary transformers, with a unit power of 200 kva are intended to supply the auxiliaries needed for operation of RSS, and SWGR equipment, as well as for the supply of the Auxiliary installation of these equipment. The low voltage AC Distribution Board has 2 incoming feeders from the 33 kv / 415 V Auxiliary Transformers, together with a Coupling Circuit Breaker. There are several 415 V or 240 V outgoing feeders for feeding the power required for lighting, fans, air-conditioning, control and monitoring of switchgear etc in the RSS. The Specifications for the Board shall be broadly as given below Other Components The LVSB1 and LVSB2 cabinets shall include the following (list is only indicative and not restrictive). i. A master protection Circuit Breaker, plug-out type, lockable by lock and key ii. A set of four poles copper bus bar 1000A (short Circuit current 7 ka for 1 sec) for supply iii. A set of output circuit-breakers iv. The signaling contact on each apparatus v. A specific outgoing for a battery charger vi. An interlocking device prohibiting paralleling. Similarly, the coupling LVCSB cabinet shall include the following. i. A master protection Circuit Breaker, plug-out type, lockable by lock and key ii. A set of four poles copper bus bar (short Circuit current 7 ka for 1 sec) for supply iii. The both protection circuit breakers for protection of the stand by rectifier set iv. The automatic change over for the supply of the stand by rectifier set The supply of the stand by rectifier set shall be realized though the medium of an automatic changeover contactor set Main low voltage circuit breakers NMRCL MARCH

267 The moving part of incoming circuit breaker shall consist of a metal chassis fitted with an extraction system. This chassis shall carry a manually controlled four-pole circuit breaker with a current rating of 630 A The circuit breakers shall have sufficient breaking capacity to cut any short-circuit which could occur without suffering damage. They shall be fitted with: - A four pole, magnetic-thermal, trip out relay and a differential module. These shall ensure a good selectivity with the downstream protections, i. Eight power connectors split down into two groups of four (inlet and outlet connectors), ii. A mechanical "closed" and "open" indicator (red and green) iii. An interlocking system which prevents any movement of the chassis if the circuitbreaker is closed, iv. A lock which only releases the key when the moving section is unplugged and which engages in the fixed part, v. A manual control system consisting of a lever that can be operated from outside, vi. A grounding system, which keeps the chassis ground during plugging-in until the power and monitoring connectors are engaged and which still ensures the chassis is grounded in the unplugged position Voltage Monitoring A voltage monitoring system shall be mounted upstream of the miniature circuit breaker on each main inlet. This system shall comprise: i. A moving-iron voltmeter and a selector switch to select voltages across phases and between each phase and the neutral, ii. A 415 V indicator light protected by HRC fuses, iii. An On/Off voltage relay with a permanent power supply Current Monitoring There shall be a current monitoring system mounted downstream of the main circuit breaker protected by HRC fuses. This monitoring system shall comprise three 5 A, 15 VA, class 2 current transformers each feeding a moving-iron ammeter Protections These shall be installed in, or on the front panel of the upper compartment together with the monitoring systems. They shall comprise: i. auxiliary relays (alarms, voltage,..., etc.), ii. test point boxes, iii. indicator lights and a "lamp test" push button, iv. selector switches and push button, v. The fuses required to protect this equipment and the monitoring systems. However, in general, all accessory equipment which contributes to the operation of a power switching component shall be mounted in the same cabinet as the component Auxiliary Power Supply This shall be provided by a 110 V DC battery and charger system The protective systems shall provide optimum selectivity to ensure maximum continuity of the electrical power supply and to restrict any failures to their immediate area (in practice, this means that the values, curves and responses times of upstream protective systems shall always exceed those of downstream protective systems) Electrical Characteristics Inlet Current Rating NMRCL MARCH

268 These shall be, at least, equal to the rated secondary current of the / 415 V transformer, i.e. 280 A Main Bus-bar of LVSB 1 & LVSB 2 These bus bars shall have a current rating of 1000 A Short-circuits The three-phase short-circuit current shall match the transformer currents when Vsc = 4%. The values used shall be as follows: kva transformer Isc = 7 ka This value correspond to a "locked" short-circuit and shall be used to select the dimensions of the main bus bar sets, the characteristics of the main low voltage circuit breakers and those of the protection equipment Manufacturing & Operating Principles Connection to Transformer LVSB1 and LVSB2 shall be connected to the respective transformers, by the station Contractor Wiring Only copper cable, multi-wire or single-wire cables, with a core cross section area of 1.5 mm² or more, shall be used for control and signaling wiring. All power connections shall be made at the bottom/ Top of the board. The terminal strips shall be designed to accept cables one gauge higher in cross-section than the cable used. Separators shall protect the strip against the danger represented by falling conductive objects Grounding Frames shall be made electrically continuous by connection with copper bar, at least 30 x 3 mm size or 50x6 mm GI strip may be, provided for the grounding of the outlets Equipment specification The following 110 V DC source equipment shall be provided in the auxiliary room and in the battery rooms of the substation Battery Each battery shall be of stationary compact, nickel-cadmium type. They shall be maintenance free. The capacity of the battery shall be decided by the Contractor taking into account the permitted voltage tolerance of the individual loads, the power consumption of various loads, the length of time they are in operation and the manner in which they draw power. The precise capacity of battery shall be determined to ensure total autonomy of the station for 8 hours as required to retain the power supply of the standby lighting and of the control/monitoring auxiliaries in case of total failure of the AC sources. The battery protection shall be as close as possible to the battery and shall be contained in separate enclosure for negative and positive pole respectively. The enclosure shall be made of insulating material. The connection between the battery and its protection shall consist of single conductor and shall be run in such a manner so that they are protected from physical damage. Each battery half shall be connected through its own battery distribution board to the main board, and each battery half section shall have its own supervisory equipment to indicate and alarm for the maximum and minimum voltage levels on float-charge and earth fault Battery charger NMRCL MARCH

269 The battery charger shall be Float cum Boost type suitable for charging Ni-Cd cells and duly certified, accepted by the battery manufacturer. AC Power Supply: i. - Voltage: 230V/415V ± 10% ii. - Frequency: 50 Hz ± 3% iii. - Maximum short-circuit current: 4000 A rms. iv. - Recharge to 80% of the battery capacity: 8 hours DC Output: i. - Power supply voltage: suitable for a battery of : 110 V ii. - Operating period after AC supply failure: 8 hours iii. - Constant power drain: shall be decided by the Contractor, to deliver the full duty. The minimum capacity of the Battery shall not be less than 300AH. The AC and DC terminal strips shall be separated from each other. Each battery charger shall be: i. designed to ensure operation according to the battery ratings as described below, ii. installed in a sheet cabinet with feet, closed by panels. iii. Ventilation shall be natural. Characteristics: Major characteristics are described in the annexed technical sheet. The chargers shall be diode and thyristors regulated type, wired as Graetz Bridge. Operating and floating rates: The voltage at the charger current output terminals shall be automatically kept within +1% for variations of +10% / -15% of the AC voltage and of +5% of the frequency, whatever may be the output required. The residual ripple ratio shall be as low as possible (less than 3.5%) so as not to disturb the various operating circuits. Equalization charge operation: This charge shall be able to take place up to the floating voltage within +1% under the same conditions as above. Automatic change-over from floating to equalization charge and conversely Following any failure of more than five minutes of the AC supply network, the charger shall automatically revert to the charge position right upon return of the voltage and shall remain on this position throughout the time set by an adjustable timer (from 1 hour to 20 hours). After this time, the charger shall return to floating operation. The charger shall remain in floating operation if the network failure is shorter than five minutes. Direct operation: The charger shall be capable of operating directly, without the battery, under the same conditions of accuracy as for the floating and charge modes. Manually controlled operation: Operation in manual control shall be possible, i.e. it shall be possible to execute manual adjustment of the voltage in case of malfunction of the regulator. Alarms: The status of all battery chargers shall be indicated at the SWGR, as well as at the OCC (through SCADA), as per the following convention: Green Healthy and in-service, Yellow Healthy and standby, Red Defective. The change of status from Healthy to Defective shall be accompanied by an audible alarm/hooter, both at the control room of RSS and in the OCC. However, if the SWGR is unmanned, it shall be possible to annul the audible alarm function at the unmanned RSS. NMRCL MARCH

270 Protections and monitoring: Miscellaneous: The battery charger equipment shall also include: i. a signalling light denoting the opening of the make-break switch on the AC side, controlled by the tripping of one of the Miniature Circuit Breaker protecting the various circuits of the apparatuses, ii. a signalling light denoting the opening of the make-break switch on the DC side through actuation of the magneto-thermal relay, iii. a voltmeter indicating the voltage on the AC side iv. a voltmeter indicating the voltage on the DC side v. A centre-zero ammeters which shall indicate whether the battery is under charge or the battery is only delivering the load. vi. the position of the various circuit-breakers and of the protection and fault relays shall be monitored through two flip-flop stages. vii. An inspection light shall be fixed inside the charger compartment, which will automatically come on when the charger compartment is opened for inspection. This shall be independent of the on/off position of battery changer and shall be operative when the 415 V supply is available to the charger V DC DISTRIBUTION BOARD Description Distribution of the 110 V DC sources shall be gathered inside two specific cabinets, one for each half station, called DC auxiliary. These cabinets shall be equipped with doors, fitted with flexible seals, close via lock-bars and on which shall be installed a mimic diagram with signalling lights denoting the position of the main apparatuses KV PROTECTIONS SWGR Equipment protection 33/25kV main transformer protection: The protection of the 33/25 KV main transformers shall include: i. High speed percentage differential protection to trip both upstream and downstream transformer circuit-breakers, including the connection from the transformer to the 33 kv bus bar. ii. Restricted earth fault protection of 33 kv side of power transformer. The relay shall be of approved design and protects 100% of the windings. iii. Two steps three phases over-current protection on HV and LV sides, one directional and the other non-directional. iv. 3 phases directional over-current protection on HV side, as applicable. v. Protection against the gas: The relay shall be sensitive to all types of faults inside the transformer tank. The relay shall be of the buchholz type or the rate of pressure rise type. vi. Protection against excessive heating. The transformer shall be equipped with thermal image and dial thermometer with contacts that sound an alarm at excessive temperatures, and giving tripping order above the permissible temperatures. vii. Protection against heating of transformers. The protection includes detectors coils embedded in the transformer cover to indicate oil and winding temperature at the control board. An automatic device shall sound an alarm at failure of the cooling medium. viii. Protection against low oil level. The transformer shall be equipped with devices, which sound an alarm when the oil level drops below permissible limit kv cables protection and fault localization NMRCL MARCH

271 33 kv cables are protected at the SWGR side by 33 kv circuit breakers and their associated protection relays. This means in case of a fault on 33 kv cables, it will be cleared by the circuit breaker but the fault cannot be located and it will not be possible to segregate the faulty section. To locate the fault a detection relay installed on each outgoing 25 kv board, of each ASS will send to the ECC an indication that it detects a fault. This will be seen on the screen of the ECC equipment and the fault could be located between the last relay detecting the fault and the first relay not detecting the fault. With these indications the operator will be able to take the necessary measure to isolate the faulty section and to reenergize the healthy part of the network kv Equipment protections Zero sequence protections: A master earthing protection shall be provided through measurement of the zero sequence current going through the earthing resistor of the 110/33 KV transformer A current transformer installed on the earthing connection of the neutral, shall supply the current measuring relays of this protection, which shall be with adjustable threshold. Lighting bridge circuit breaker (LBCB) The protection of this circuit shall consist of : i. F 50: Instantaneous over current protection ii. F 51: Time delayed over current protection iii. F50 N: Instantaneous earth fault protection (zero sequence) iv. F51 N: Time delayed earth fault protection (zero sequence) Lighting bridge coupling circuit breaker (LBCCB) The protection of this circuit shall consist of: i. F 50: Instantaneous over current protection ii. F 51: Time delayed over current protection iii. F50 N: Instantaneous earth fault protection (zero sequence) iv. F51 N: Time delayed earth fault protection (zero sequence) This circuit shall include also a synchronism check device, which shall measure: i. The voltage difference between the both sources ii. The phase unbalance between the both sources iii. The phase correspondence between the both sources Moreover, in case of lack of voltage on one source, the device shall authorize the coupling circuit breaker closing without any comparison. Lighting 33 kv cable circuit breaker (LFCB, RCCB) The protection of this circuit shall consist of : i. F 50: Instantaneous over current protection ii. F 51: Time delayed over current protection iii. F50 N: Instantaneous earth fault protection (zero sequence) iv. F51 N: Time delayed earth fault protection (zero sequence) Auxiliary transformer circuit breaker (LVATCB) The protection of this circuit shall consist of : i. F 50: Instantaneous over current protection ii. F 51: Time delayed over current protection iii. F50 N: Instantaneous earth fault protection (zero sequence) iv. F51 N: Time delayed earth fault protection (zero sequence) v. Temperature Alarm, first threshold vi. Temperature tripping, second threshold NMRCL MARCH

272 The thresholds shall be set according to the maximum of temperature the auxiliary transformer can withstand without damage. Low voltage protection The low voltage circuit breaker shall be equipped with magneto-thermal protection to protect the main circuit against short-circuit, over-current and earth fault. This protection shall be thermal compensated to take into account the ambient temperature. This protection shall be equipped on the LVCB and LVCCB. The selectivity shall take into account the time delay and the current level of the downstream protections Protection General: The purpose of the protection equipment is to ensure isolation or de-energising of a system or equipment whose operating conditions have become faulty and/or abnormal to avoid: - any major repercussions on the traffic - any damages or dangerous effects to person and equipment Electromagnetic compatibility Due to the consequent interference level in the environment, protection equipment has to present sufficient level of immunity defined by the following standards: - IEC Class 3, - IEC Class 4, - IEC Class 3. Such criteria shall be obtained by using either numerical type relays or specifics PLC cards Protection descriptions A distinction shall be made between the following cases Hydraulic or thermal protections These protections, such as lack of pressure or abnormal temperature, shall include measuring elements situated on the protected apparatus, actuating a contact (mandatory of flip-flop type) which represents the start of the protection line Electrical protections Protections through lack of monitoring voltage Each cut-out apparatus shall include a device controlling its opening and preventing it from any re-closing in case of lack of monitoring voltage Protections through lack of AC voltage Ensured by means of phase - phase voltage measurements with adjustable threshold, possibly associated to time delay, adjustable as well. The measurement shall be supplied from the secondary of the voltage transformers Protection against phase-phase short-circuits Ensured by means of current relays (primary current measurement relays with adjustable threshold, associated to time delay also with adjustable threshold). The current relay shall be supplied from the secondary of the current transformers Over current protections NMRCL MARCH

273 This function ensures the tripping of concerned circuit breaker when the current value exceeds the highest allowable load on the network in instantaneous or delayed time conditions. Following the network configuration, pre-set tripping thresholds could be commuted via automatic interlocking or voluntary action. Tripping curves characteristics could be: i. At constant time, ii. At dependant time following a characteristic: iii. Inverse, iv. Very inverse, v. Extremely inverse Protection against zero sequence faults At the output level, these shall be ensured by means of zero sequence current measuring relays (obtained through associating of the currents from the current transformers). These relays shall not be affected by the capacitive currents in the cables during unbalanced operating times which occur on the power supply (such as earthing fault of the other cables, etc.) Synchro-coupler relay This relay shall ensure authorization of closing a coupling apparatus. Its own functioning shall come into service, only in the case of voltage presence on the both parts of the coupling apparatus. When into service, it shall compare the phase, the frequency and the voltage of the both sources to be coupled. Phase difference, frequency difference and voltage difference shall be settable SF6 pressure protection This protection system shall ensure constant monitoring of gas (SF6) pressure inside each compartment and shall trigger a dual alarm threshold communication system when the gas pressure drops Presence of voltage: Voltage relay shall be used to authorize the operation of the incoming isolators and earthing isolators on no load, wherever required Staging of the protections Selectivity of the protection arrangements shall be provided so as to avoid all unwanted tripping. The time delay of the various circuit breakers shall be suitably set so as to ensure chronological selectivity of the tripping. The supplier shall define precisely the minimum intervals between the various protection stages, accounting for the timings and for the actuation times of each one of the apparatus involved. A logic selectivity system shall be incorporated wherever required. To avoid unwanted tripping, it shall be necessary, in particular, to take into account transient phenomena such as energizing of transformers and engagement of cables, etc Protection back up Protections have a direct action on the tripping gear of circuit breakers and inform the local RSS automation protection system. NMRCL MARCH

274 Earthing In case a protection is inoperative, a tripping order is sent to the higher-level circuit breaker via the local supervision after time delay (except for the power supplier HV circuit breakers) Earth mesh General The Substation installation is subject to various faults such as operating over voltages, short circuits or lightning. In order to ensure protection to people and equipment, an Earth mesh, sized to limit the step and touch voltages below the dangerous values, shall be provided. The Earth Mesh design and installation shall be done in accordance with relevant provisions in IEEE Earth network should be designed taking into account conductors' temperature rise as regard to the faulty current levels. The Contractor will have to provide a buried earth mesh in the Substation site. As far as the area over which the SWGR & Control Room are situated, a separate earth mat suitably designed shall be provided under the building housing the SWGR and Control room, apart from the Main Earth Mesh. The design of the Main Earth Mesh shall be done by the Contractor, taking into account the site conditions (soil resistivity etc). The Main Earth mesh has to be linked, by means of two 120 sq mm copper equivalent cables to - the earth mat under the SWGR room - the buried rail/connecting strip for traction return current - Main Transformer (33/25kV ) neutrals - All equipment structures supporting 33kV - Baffle walls between transformers. - Substation fencing - Lighting protection Earthing Parameters affecting the design of earth mat Several variable factors are involved in the design of an Earth Mat at Substations. The following are some of the parameters which affect the design of earthing mat. - Magnitude of fault current - Duration of fault - Soil resistivity - Resistively of surface material - Earthing mat geometry - Material of earth mat conductor - Shock duration Earth mat for each substation has to be designed individually. The earthing mat has to be designed for the site conditions and shall ensure a low over all impedance (not more than 0.5 ohms) and a current carrying capacity consistent with the fault current magnitude Short Circuit Level The maximum short circuit power (Isc), considered for the whole substation area, for different voltage levels, are as follow: For 33 kv 5000 MVA Short circuit Current Accordingly, the short circuit current to be taken into consideration, for the Earth mesh design at Substations, shall be as follows : NMRCL MARCH

275 For 33 kv 22kA Duration of fault current In India, the short term rating of most of the equipment is based on 1.0 second duration of fault. Therefore, 1 second may be adopted on the duration of fault in the calculations to determine the size of conductor for the earth mat. For the purpose of determining the safe step and mesh potentials, a duration of 0.5 second may be adopted. However, it has to be ensured that, on the basis of the protective gear and protective scheme provided, the fault is cleared within a period not exceeding 0.5 seconds. Corrosion factor of 2 is to be considered for MS Determining the max Grid current (IG) The design value of the maximum grid current IG is given by the following formula IG = CP. Df. Ig Where, IG = Maximum grid current in Amperes CP= Corrective projection factor Df= Decrement factor Ig= Symmetrical grid current (RMS) in A Ig= Sf (3IO) Where, IO= Zero Sequence fault current Sf= Current division factor (which relates to the magnitude of the portion of fault current to that of its portion flowing between the earth mat and surrounding earth, to the total fault current) The calculation of Sf is done by deriving an equivalent representation of the overheard ground wires, neutrals etc, connected to the earthing mat and then solving the equivalent circuits to determine the fraction of the total fault currents which flow between the mat and the earth and through the ground wire or neutrals. In practice, at the design stage, it will be fairly accurate to adopt a value of 0.5 for Sf to determine the fault current that flows through the grid to earth. Hence, the values of maximum grid current IG to be considered for design of Earth mat for Substations of different voltage levels, may be taken as follows : For 33 kv 0.5 x 22 = 11kA Important Note: The above values of max grid current are applicable only for determining the estimated values of Step and Mesh potentials. For determining the cross-sectional area of the earthing mat conductor, full fault current should be considered Earth Mesh Characteristics General Design A mesh made of bare cables forms the protection earth circuit. Earth conductors should be buried as deep as possible to keep a significant cylindrical equi-potential area ensuring the earth resistance decreasing The common practice consists to bury the mesh at 1m depth, to avoid soil conductivity variation as regard to the variation of dryness or humidity conditions. The connection on power equipment should be made by conductors in loop mode avoiding the power equipment insulation from the earth mesh in case of conductor breaking. The earth connection to equipment in antenna mode is strictly prohibited. Earth conductors are linked by fixed NMRCL MARCH

276 connection. Earth conductors should preferably be cylindrical copper cables. Alternatively Mild Steel flats of appropriate size are acceptable. Similarly, earthing connections between equipment and earth mesh may be realized either by means of copper (min. 25 sq mm) or galvanized MS Flats. The earth mesh implementation should avoid any permanent or occasional contact of earth conductors with other different metals Particular Arrangement to minimize voltage rise The ground is considered as a pure resistance regarding electrical phenomenon. Only very bad resistivity conjugated with very high frequencies involve the ground capacitive parameter. To minimize electromagnetic coupling between Low voltage cables and HV equipment, the cables shall be annealed types earthed at each end. In the aim to: i. Decrease the loop length given by cable shielding and the earth, ii. Limit the current in these shields in case of short circuit, iii. Minimize the works, The earth conductors may be buried as far as possible under the LV cable routing. The distance between LV cables and earth conductors shall be 0.30 m. at minimum to avoid any impact on LV cables in case of earth conductor overheating. The earth mesh density shall be increased around circuit breaker and power transformer cells Equipment connecting mode to Earth mesh i. Principles: Main gantries, frames, equipment bodies or tank and all metallic structures are at minimum connected on an uninterruptible loop of the earth mesh. A clamp makes the connection point with bi-metallic sheet plate located close to the soil from which aerial earth cables linking the equipment will be connected and crimped on earth mesh. When one clamp is not enough, it could be provided a copper connecting strip on which several clamps could be installed. All of conductors linking an equipment to the earth and liable to support the short circuit current shall have the same cross section as the earth mesh conductors. When the equipment connection is only made for equi-potential purpose, the cable cross section could be less than earth mesh conductor with a minimum of 25 mm². ii. Earth cable fixations along the structures All cables should be fixed all along the masts and beams as follows: - Bare cables should keep distance from the metallic supporting structure to avoid any electrolytic corrosion and should be fixed via metallic (i.e. bronze or copper alloy) bolted clamp with bi-metallic sheet plate. - Insulated cables shall be fixed to the structure in the same manner as above when earth connection with the structure is necessary, or by collars mainly used on catenary masts Equipment connection i. Measuring transformers Voltage transformers: To reduce high frequency interference transmission at the secondary side; the P2 terminal (cold point) of primary winding, located inside the transformer connection box is connected to the earth mesh at the general earth connection level. Current transformers The S2 terminal of secondary winding should be connected to the earth mesh, with a connection as short as possible. NMRCL MARCH

277 Circuit breakers CBs earthing could be ensured through the supporting frame, itself connected to the earth, except when one part of the equipment is painted. In this case it is necessary to install an earth cable. In the first case a copper cable shall jump the mechanical connection between the CB and the frame. For 33kV circuit breakers two earth clamps on each side of the frame base and linked to the earth mesh should be implemented Power transformers Each file of running rails (if any) and rollers shall be earthed directly. The tank insulated from the rails is earthed using a low insulated cable via the protection current transformer. The S2 current transformer terminal and metallic base shall be earthed via a separated connection. The power transformers earth cable should be as shorter as possible Isolators Incoming isolators earth blades should be linked to the isolator base by copper braid, the base being directly connected to the mesh Electrical control boxes should be earthed directly. On hand operated isolators a copper braid should link the control box with the transmission axle, the control box being directly connected to the mesh. In both control modes; a metallic duck board should be installed in front of the control device, linked to the control boxes and the mesh via a direct connection fixed on the frame Lightning arresters The lightning arrester earth terminal shall be directly connected to an earth electrode and also to the earth mesh through separate bare cables fixed on the frame Earth gantry arrangement In the case of frame in π configuration one mesh connection is installed at each base of masts. A bare cable fixed by bolted clamp runs along the masts and the beam of the structure Traction return current earthing Traction return current connecting strip shall be earthed through 120mm² loop Lightning guard line earthing Lightning guard line if provided shall be earthed through 93.3mm² steel bare cable to a specific earth rod located at the bottom of each guard line supporting structure, these earth rods being connected to the general earth mesh at the RSS-cum-TSS Lightning Protection The entire Substation are a shall be protected against lighting by providing either earth screen conductors on tower peaks, or by means of Lightning Protection masts suitably spaced to cover the entire area CONTROL ROOM BUILDING EARTHING Before laying the foundations of the C&M building, a well interconnected earthing mesh using flexible copper cable of 120 mm² cross section will be laid (buried conductors under the foundation raft). This mesh will enter into the C&M via several rising links, with at least 2 links on each face of the building, at the building basement level. This mesh will be connected to the general one by at least two connecting points using crimped connections. Mild steel network of concrete structures shall be equipped with rising links with at least two links per face of the building. 7.4 Traction Network NMRCL MARCH

278 The Traction Power Supply Network transforms the High voltage 33 kv into 25 kv by means of transformers and distributes the 25 kv through adequate protecting and sectioning equipment to the Over Head Catenary system (OHE) which feeds the Electric Multiple Units It is mainly composed of Feeding Posts (FP), Sectioning Post (SP), Sub-Sectioning Post (SS) and Sub-Sectioning & Paralleling Post (SSP), collectively referred to as Switching Stations The traction network uses single phase load fed from a balanced three phase system which introduces a current and voltage unbalance in the system. The contractor should examine the effect of unbalancing and ensure permissible level of current, voltage and harmonics generated in the traction network system to minimize the ill effect on unbalancing The contractor shall examine the voltage drop and ensure permissible level of voltage drop of the catenary system of traction network for varying load current drawn by the metro car The technical features of various equipments and components associated with the traction network are given below: kv Switchgear a. The 27.5 kv switchgear consists of structure mounted Circuit breakers, interrupter and isolators electrically linked. b. The steel structure for mounting shall be in accordance with IEC standards c. All circuit-breakers shall follow the electrical and mechanical characteristics in accordance with IEC standards or RDSO s standard ETS/PSI/116(4/88) with latest modifications. d. These equipments shall be pole mounted with the switching part at pole top level, separated from the control equipment located at hand level and base pole mounted, both connected together with a transmitting mechanism. e. These equipments shall follow the electrical and mechanical characteristics and must be in accordance with IEC standards IEC and IEC 694. f. All parts shall withstand at least operations without any signs of detriment. g. 27.5kV switchgears of TSS and of underground SSP, SP & SS shall be indoor GIS type with SF6/Vacuum circuit breaker/interrupter. 27.5kV switchgears of outdoor SSP, SP & SS shall be outdoor type with SF6/Vacuum circuit breaker/interrupter Circuit Breakers / Interrupters a. SF6 type Circuit breaker The current rupturing part consists of a couple of moving and fix contacts embedded in a body fastened on cast resin material or hard porcelain brown glazed insulated at 52 kv (according to the IEC 273), and the moving contact is connected by mean of slipping contact. b. Vacuum type Circuit breaker and interrupter The current rupturing part consists of a vacuum bottle embedded in silicon rubber to prevent water condensation. Bottle is fastened on hard porcelain brown glazed insulated at 52 kv (according to the IEC 273), and the moving contact is connected by mean of flexible copper braid. c. All apparatuses up and down stream connectors shall be made of pre-drilled copper plates in order to receive 2 x 240mm² copper cable each. NMRCL MARCH

279 Characteristics of breaker a. Power frequency withstand one minute in Kv(rms): 95 kv for 33/25 kv. b. Impulse withstand (1.2/50 microsecond) in Kv(peak): 250 kv for 33/25 kv Isolators - The Isolator shall be air insulated type and shall include: - Up & down stream connectors - Vertical break - Motor operated where required and manually operated capability - Locking and interlocking devices - Open / Closed auxiliary contacts - Low voltage multi-pin connector and flexible cable a. All Isolators shall follow the same electrical and mechanical characteristics and must be in accordance with IEC standards 129 b. All interrupters and isolators shall have provision for pre-drilled copper plates in order to receive 2 x 240 mm² cable Measuring Transformers All measuring transformers shall follow the same electrical and mechanical characteristics and must be in accordance with IEC 44-1(CT) and IEC 44-2 (VT) or RDSO s specifications ETI/PSI/117(7/88), PSI 3156 of Voltage transformers a. Primary connectors:25kv connectors shall be made of bronze pipe 20, length 60mm. b. Secondary connecting box: Secondary winding connection will be realized through a dust-proof and water tight type (IP55) connecting box fitted with a 6.3 A fuse and able to receive 2x10mm² screen-cable. c. Voltage transformer 25000/110 V shall be dry resin, and shall ensure that self-heating shall be less than 1 C per hour. d. The self-heating has to comply with the climatic conditions defined in General Conditions e. The maximum temperature rises should be in accordance with the insulation medium, as defined in the IEC standard Current transformers a. Primary connectors: Consist of up & down stream connectors, made of pre-drilled copper plates in order to receive connector fittings rated at 1250 Amps for 2 x 240mm² cables or bus bar connection. The connectors shall be able to handle at least 2500A for 5 min without overheating. b. Secondary connecting box: Secondary winding connection will be realized through a dust-proof and water tight type (IP55) connecting box and able to receive 2x10mm² copper screen-cables. c. Current transformers shall be dry resin, and shall ensure that self-heating shall be less than 1 C per hour. d. The self heating has to comply with the climatic conditions. e. The maximum temperature rises should be in accordance with the insulation medium, as defined in the IEC standard Indoor 25kV Gas Insulated Switchgear (GIS) Scope of Work The scope of work comprises of design, manufacture, shop testing, supply, delivery at site, installation, testing and commissioning supervision of 1-phase, 27.5kV (Rated Voltage NMRCL MARCH

280 52kV), 3000A, 16kA Gas Insulated Indoor type Switchgear. The supply will include all supporting structures, auxiliary equipments, mechanical linkage, spring drive, SF6 gas piping, auxiliary circuit wiring, interlocking devices, current and voltage transformers, cable End boxes, meters and other accessories. The scope of work includes the following: Incomer Bay (2 Nos.) each consisting of: Circuit Breaker 1 No. Current Transformer 1 No. Disconnector with Earth Switch 1 No. Voltage Transformer 1 No. Lightning Arrestor 1 No Other items as required for connection to the Bus bars, Incoming cables through lightning arrestor and for completing the intent of work Outgoing Feeder Bay (5 Nos. for Transport Nagar RSS and 4 Nos. for Munshi Pulia RSS): Bus Coupler (1 No.) Bus bars for Single Bus arrangement Main features required: The 27.5kV equipment shall be built according to the relevant IEC/EN standards Unless indicated otherwise herein, all equipment supplied and installed shall comply with the IEC/EN standards Bus zone wise busbar segregation should be provided with gas monitoring system for each bus zone Individual Pressure gauge to be provided for each circuit breaker compartment installed at the front of the panel inorder to supervise the SF6 Gas Pressure Internal insulation level between live part and earth when the pressure of gas goes to the atmospheric pressure should not be less than 1.2*27.5kV The metal enclosures for SF6 gas insulated equipment/module shall be made from material which does not require protective painting either internal or external switchgear GIS supplier should have supplied similar GIS for any metro/rail system. This shall be explained in tender s technical proposal. The tender will be required to explain availability of spares and services from technically trained manpower in India to support the ultimate customer NMRCL in future. NMRCL MARCH

281 The incoming (single core) cable feeder shall be of suitable size as per Traction Transformer capacity. The termination arrangement shall be designed for such cables. The outgoing connections from GIS shall also be cable The disconnectors and earthing switches shall be mechanically interlocked against maloperation. Feeder earthing switch shall be isolated from earthed enclosures and shall permit testing of switchgear. It shall also be possible to carry out high pot DC testing of Cable core without disconnecting the cables The conductors/bus bars shall be of copper and enclosure shall be made of corrosion resistant metal The gas barrier insulation between compartment shall withstand 1.5 times maximum rated pressure on one side and vacuum on the other side All gas sampling shall be possible during normal operation and without loss of gas Loss of gas per annum shall not exceed 1% by weight in each compartment Adequate burden/capacity shall be available in instrument transformers to permit provision of protection/measuring equipment. The instrument transformers shall have separate metering cores to permit measurement of values of energy, power, current and voltage as per required accuracy VTs should be pluggable type and provision should be available to manually disconnect the VTs from the circuit without the need to take associated circuit breaker or busbar out of service Clear visual indication of Isolator and earthing switch, whether open or closed shall be provided The Switchgear panel should be of modular design with a flanged connection between circuit breaker and busbar compartment Interrupting Medium for Circuit breaker shall be Vacuum/ SF6. The actuating drive should be Spring drive. To give the highest reliability of the system, following loss of supply voltage the operating mechanism shall have local stored energy sufficient for duty cycle of O-CO without the need of recharging. The circuit breaker shall be provided with an anti pumping coil for all the command going to the switchgear. All interlock and auxiliary system within the actuation system shall be designed so that the circuit breaker execute operation only when it is in a position enabling to do so completely and reliably The isolator shall be fitted with a suitable power actuation system backed up by an emergency manual actuation in case of mal function of the former. The isolator shall not change position under the effect of electro dynamic loads. NMRCL MARCH

282 In case of any replacement or extension of switchgear panels at site it should be possible to replace or add a fully assembled circuit breaker without interfering the operation of the adjacent feeder as well as without any bus zone degassing. All circuit breaker of same rating should be interchangeable Monitoring of Gas in the enclosure: Each gas compartment and each bus zone should have its own temperature compensated density indicator featuring 3 auxiliary contacts for alarm The protection devices for the equipment shall ensure permanent monitoring of gas pressure inside each compartment by means of temperature compensated monitoring devices triggering a dual alarm threshold annunciation system in the event of gas pressure drops The design of the cable termination shall allow plugging and unplugging the HV cable without need of opening the GIS and without any gas filling The complete GIS equipment shall meet the requirements of IEC/EN standard The modules individually as well as assembly subject to various routine test including type test Site test shall include leakage test, moisture contents in dielectric medium and power frequency test Earthing: Entire metallic enclosure shall be bonded and effectively earthed Technical Specification 1) Enclosure Type Single Phase Enclosure 2) System Voltage 27.5kV 3) Rated Voltage 52kV 4) Rated frequency 50Hz 5) Rated Current 40 Deg C 3000 A for 5 minutes 6) Power Frequency withstand voltage 95kV rms 7) Lightning Impulse withstand voltage 250kV rms 8) Rated short time current 16kA for 3sec 9) Peak withstand current 40kA peak 10) Guaranteed SF6 gas loss per year < 1% The switchgear is used for controlling 25kV OHE feeder and 25kV cable. Vender to confirm suitability of equipment for this application and also confirm maximum over voltage during switching operation. NMRCL MARCH

283 In case protection is included in the scope, vendor is responsible for selection of proper relays, CT/PT application check, co-ordination of relay setting and all assistance during integrated testing. The CTs shall be located above the HV cable termination socket Cable Termination kit: Confirmation of incomer cable size would be made available to the vendor at the time of manufacturing clearance. underneath the panel. The cable entry shall be vertically from Outgoing feeders are two runs of 240sq.mm copper cable Along with bid vendor to submit SLD and the GA drawing indicating the space requirement (length x depth) and the minimum clearance required in front of the cubicle and back side from the operation/maintenance consideration Traction Protections The purpose of the protections installed in traction feeder stations is to isolate all or part of the dependent equipment from the network, in case of phase-to-phase or phase-to-earth /rail fault The Traction Protection system can be broadly divided into two main groups: Traction set protection, which will essentially include all equipments starting from the HV bus bar to which the Traction Transformers are connected, up to the 25kV bus bars from which the 25kV Traction Feeders take off Traction set protection: Each HV circuit-breaker located upstream the power transformers ensures the protection of: - the bus bars for connection to transformers on the HV side. - the transformer, - the 25 kv bus bars located upstream, Directional power protection a. The function of directional protection is to check the power transit direction in the catenary system, mainly due to regenerative braking, which could flow back to the HV grid through the transformers. Two stages are involved: - a slow one, - a quick one. b. When the first stage is activated, a signal is emitted and a time-out 1 is started. When time-out 1 ends, a second signal is emitted. c. If, after 3 minutes, the fault still persists, a tripping command is sent to the concerned traction set circuit-breaker. d. When the second stage is activated, at the end of time-out 2, a tripping command and signal are emitted by the protection device; the 1st stage and 2nd stage current thresholds can be parameterized as well as time-outs, and angle * of straight line D can be adjusted Minimum impedance protection a. This module is a single-phase impedance measuring (in R-X co-ordinates) relay, which operates when the impedance value falls below a selected adjustment threshold. b. This protection is directional and selective; it makes a distinction between a high load and a distant fault of small intensity. NMRCL MARCH

284 c. The minimum impedance protection is self-supervised and an internal fault in the protection entails the tripping of the associated circuit-breaker Over current protection An over-current protection is designed to detect faults occurring very close to the feeder station. This protection causes the tripping of the circuit breaker when the current reaches a value exceeding the highest load on the network Fault locator is activated following a circuit breaker tripping due to: - Minimum impedance detection, - Over current, This allows an auto re-closure sequence The fault locator measures the catenary/ rail loop fault impedance and compare with the minimum impedance relay and determine the kilometre point from the feeder station Power factor improvement: Deleted Between TSS and OHE each connection between the 25 kv Outgoing Circuit Breaker / Isolator at TSS and the OHE pole mounted Isolator shall be realised by means of 2x240 sq.mm copper cables Between running track and the Buried Rail in RSS a connecting strip, as per specifications shall be provided on the Viaduct / near the track The mid-point of the Impedance Bond (or the Earthing rail, if no impedance bond is provided) of each track shall be connected to the above Connecting Strip, by means of 4x240 sq mm copper cables. The connection between the Connecting strip on the Viaduct and the buried earthing rail in the TSS/RSS shall be realized by means of 8x240 sq mm copper cables. 7.5 Traction Overhead Equipment Hot dip galvanized steel structures of overhead equipment support: the contractor shall ensure zinc coatings of various type of mast, tubes and fittings including fabricated mast as per IS 209, ETI/OHE/13 latest version and shall not be less than 85 microns locally and 100 microns for area The contractor shall adopt the following types of mast of various sizes of H type mast for main line: - Normal mast-single, - Overlap anchor mast, - Overlap intermediate mast-holding two OHE, - Overlap central mast-holding two OHE, - Anticreep central mast, - Anticreep anchor mast, - Gantry, head span and portal mast The contractor shall select proper type of portal and head span arrangement which shall be used in depot depending on number of tracks and the clear span of the portal The contractor shall adopt H type drop arm only to get rid off the menace of bird nesting. Contact wire: The contact wire shall be of 150 sq mm hard drawn grooved, flattened copper conductor, as per EN configuration similar to BF-150. NMRCL MARCH

285 The contact wire should be drawn out of continuous cast rods of minimum diameter of 21 mm. Contact wire shall conform to latest RDSO specification ETI/OHE/ The contractor should ensure the following minimum values of the contact wire: - Linear weigh : kg/meter, - Breaking load : 5265 dan, - Coefficient of linear expansion (α) : 17 x 10-6degree C, - Elongation factor (λ ) : 91 x Conductivity : 98%, - Resistivity : 1, ohmmeter Messenger wire The Messenger wire shall be of Cadmium copper, diameter 10.5 mm, consisting of 19 strands, each of 2.1 mm diameter. The nominal cross section of the Messenger wire is 65 sq. mm. The messenger wire shall conform to Indian Railways' RDSO specification No. ETI/OHE/50 (Latest Revision). The contractor should ensure the following minimum values of the messenger wire: - Linear weight : kg/meter, - Breaking load : 3844 dan, - Coefficient of linear expansion (α) : 17 x 10-6degree C, - Elongation factor (λ ) : 118 x Conductivity : 81%, - Resistivity : 2.93 microhm.cm Feeder - Raw material : Aluminium / Steel - Cross Section (sq.mm) : Diameter(mm) : Composition Aluminium : 30 wires Ø 3.15 Steel : 7 wires Ø Weight per meter (kg) : Breaking load (dan) : Dilatation (calf.ά) : 18 x Elongation (calf. ʎ) : 132 x Conductivity (in % of copper) : 61 % - Resistivity (µ ῼ/sq,cm/cm) : Overhead Protection Conductor: An ACSR conductor, consisting of 7 steel wires each of 2.5 mm diameter and 12 aluminium wires also of 2.5 mm diameter each, with a nominal cross section of 93.3 sq.mm. The overall diameter of the conductor is 12.5 mm. The ACSR conductor shall conform to Bureau of Indian Standard specification IS: 398(Part II)-Latest Revision. The contractor should ensure the following minimum values of the aerial earth wire: - Linear weight: kg/meter, - Breaking load: 4610 kgf (4520 dan), - Coefficient of linear expansion (α): 17 x 10-6degree C, - Elongation factor (λ ): 132 x 10-6 NMRCL MARCH

286 - Conductivity: 61%, - Resistivity: microhm.cm Earth Conductor (BEC): An ACSR Conductor, consisting of 7 steel wires each of 2.5 mm diameter and 12 aluminium wires also of 2.5 mm diameter each, with a nominal cross section of 93.3 sq.mm is used as OPC. The overall diameter of the conductor is 12.5 mm.the ACSR conductor shall generally confirm to Bureau of Indian Standard specification IS:398(part-II) latest version or as per design. Bridle wire shall be of cadmium copper, consisting of 37 strands each of 1.1 mm diameter with a nominal cross section of 35 sq. mm and overall diameter of 7.7 mm. The Bridle Wire shall conform to Indian Railway's RDSO specification ETI/OHE/50, Latest version, for cadmium copper conductor. Droppers: Flexible droppers, made of bronze, consisting of 1 wire of 7 strands each of 0.65 mm diameter and 6 wires of 7 strands each of 0.54 mm diameter, with crimped endings with eye on either end and reinforced automatic clamps (copper alloy made) on messenger wire and contact wire, are used as in-span droppers. The nominal cross sectional area of the droppers is 12 sq.mm and the diameter is 5 mm Flexible stainless steel wire, 5 mm diameter and 19.6 sq.mm cross section with crimped ending eyes and fixing parts on either end will be used as Register arm dropper.jumpers: the contractor should adopt proper sizes of jumpers to be used in the OHE at various locations: - 26 sq mm 2 jumper of annealed copper, consisting of 19 strands, each strand containing 7 wires each of 0.5 mm diameter, with a nominal Cross Section of 26 sq mm and diameter of 7.5mm. This is used as In-span jumper sq mm jumper of annealed copper, consisting of 37 strands each containing 7 wires each of 0.6 mm diameter, with a nominal cross section of 75 sq mm and diameter of 12.70mm. This is used as Continuity Jumper sq mm jumper of annealed copper, consisting of 37 strands each strand containing 7 wires each of 0.9 mm diameter, with a nominal cross section of 164 sq mm and diameter of 18.1 mm. This is used as Continuity Jumper and Feeding Jumper. Insulators: all OHE insulators shall be silicon composit insulators, conforming to IEC 61109, and the latest RDSO specification. Section Insulators are deployed when it is necessary to electrically separate one section of the OHE from another. The arrangement provides the necessary insulation between adjacent sections of the OHE The contractor shall ensure to select the Section Insulators which should meet the following requirements, - Light weight - Better current collection at maximum commercial speed - Long Life permitting a large number of panto-passages per day. - Less maintenance: the skids should not require frequent checks and adjustments thereby permitting the Section Insulators to be left unattended for long periods Section insulators should be equipped of proper supporting arms allowing the smooth passage of pantograph by accurate tuning of the skids Such Section Insulators shall be used on Main lines. NMRCL MARCH

287 In stabling and depot lines, Section Insulators of conventional design to Indian Railway's RDSO specifications ETI/OHE27/ Latest version shall be used. All neutral section shall be automatically switched short neutral sections. Earthing and Bonding The contractor shall design earthing and bonding as per the standards and submit for approval of employer. The contractor shall take adequate steps to the following aspects: - a safe low resistance path for the return current from the rail to earth and back to traction substation. - avoidance of dangerously high 'touch potentials' The European Norms EN and and Bureau of Indian Standards specification IS:3043, shall be followed. The expenditure for construction, operation and maintenance of overhead contact line installation should be as low as possible through the entire service life. Therefore, the contractor has to select the components and elements in such a way so as to get maximum reliability and which require very little or no maintenance. This does not absolve the responsibility of the contractor for using the national/ international standards. The contractor should sincerely use the corrosion protection measure including the menace of bimetallic effect so as to derive longer service life of various equipment, fittings and components. Various equipments, fittings, insulators and components shall be chosen in such a way by the contractor so as to have easy installability and interchangeability. The contractor shall ensure selection of suitable material of collector strip of the pantograph duly interfacing with rolling stock contractor so as to minimize the wear on contact wire. The contractor shall ensure the electrical separation of the overhead contact lines of the adjacent tracks and, wherever possible, the use of separate poles for each track should be considered. The overhead contact line should be such that the period of line closure for planned maintenance work or repair of OHE and track are kept as low as possible: it should not exceed 3 hours for normal maintenance. The contractor shall collect all the relevant regional and national directives and laws with regard to nature and bird protection and ensure installation of bird protection devices so as to reduce the potential hazards significantly. Conductors Mechanical Tensions: For main lines, the mechanical tension of the messenger wire and of the contact wire 150 sq mm (tensioned at 1200 dan each) are kept constant within the temperature range of +20º C to +60º C (by sun and electric heating effects) by means of a pulleys-block tensioning device Depot: in entire depot except test track, unregulated tramway type OHE shall be used with 150 sq mm contact wire. Isolation arrangement in the depot: NMRCL MARCH

288 There will be isolation of OHE in inspection lines, stabling lines and washing lines The isolation will be done with double pole isolators with earthing heel and the earthing heel on each isolator shall be earthed individually by providing earth pits The contractor will provide, whenever it is necessary, interlocking system with depot equipment. It will be a mechanical key based system. 7.6 Auxiliary Network Deleted 7.7 Cabling General All cables including HV (33 kv, 25 kv and LV cables, required for works in the RSS, except where otherwise stated specifically in this Bid Documents, shall be supplied and installed by the Contractor. All cables including HV and LV, required for works in the RSS shall be FRLS (Fire Retardant Low Smoke) Type. All power and control cables shall be armored. 33 KV cables Governing Specifications The 33 kv Cables shall conform to IEC 502/1 and shall be of 19/33(36) kv.. The cables shall be of dry-insulated, radial-field cable, unearthed type based on proven technology. They shall be constituted by assembly of three single core cables in twisted or cloverleaf pattern Technical Particulars Insulation The cables shall be insulated with chemically cross-linked polyethylene, with semi-conducting screen over a copper conducting core, and insulating envelope and polyvinyl chloride protective sheath. Operating voltage : 33 kv rms between phases, Specified voltage : 18 kv rms (according to IEC 502/1) Fire Retardant, Low Smoke (FRLS) All cables shall be non-fire propagating, non-toxic and low-smoke producing and conform with the UTE standard , test No 2, IEC or equivalent. Cables used in Underground Corridors and in Underground ASS s shall, in addition, be of Zero Halogen Conducting Core The conducting core shall be made of bare annealed copper, according to class 2 as per publication IEC 228, or aluminium. The cross section of the conducting core shall be as follows for various connections: a. From SWGR Transformer Secondary to the 33 kv Switchgear in the SWGR Room 400 sq mm copper b. From 33 kv Switchgear in the SWGR Room to the 33 kv / 415 V Auxiliary Station Transformer in the SWGR Room Aluminium of appropriate size The Contractor shall confirm the section of these cables as regard to: a. the route installation, NMRCL MARCH

289 b. the thermal conditions in service, c. the climatic conditions, d. the energy and currents flowing through this cables, taking into account the worst electrical conditions: e. operation under permissible overload conditions, f. operation when all 33 kv distribution are supplied by only one transformer, and on only one 33 kv cable Core Screen The screen placed over the core shall consist of extruded covering of semi-conducting material Insulating Envelope The insulating envelope shall consist of extruded solid dielectric, made of chemically crosslinked polyethylene. Its nominal thickness and tolerances shall comply with the requirements set forth in standard IEC Insulating Envelope Screen The screen placed over the insulating envelope shall consist of a non-metallic semiconducting part, associated to a metallic part. The non-metallic part, consisting of a semiconducting material, shall be easily separable from the insulant in order to facilitate cleaning of the latter. This semi-conducting material shall have to constitute a mat which protect the insulant from expansion strains. The metallic part applied over the semiconducting part shall consist of stranded wire with copper tape. This metallic screen shall be capable of routing the network zero sequence short-circuit current, in the event of parallel operation of two HV/MV transformers Outer Protective Sheath The anti-corrosion outer protective sheath, applied directly over the metallic screen shall consist of a heat-setting mix of polyvinyl chloride, whose grade is compatible with the operating temperature of the cables; it must ensure protection against corrosion. The nominal thickness of this sheath shall be determined according to the requirements set forth in standard IEC The protective sheath shall carry the indications listed below, in letters and digits at least 6 mm high: a. designation of ownership, b. nature and cross-sectional area of conductors, c. specified cable voltage, d. phase numbering, e. manufacturer s name Connecting Junctions - MV Ends Connecting Junctions Connecting junctions shall reconstitute perfectly all elements of the MV cables, so as to obtain electrical and mechanical characteristics at least equal to those of the cable. The Contractor shall submit to the client, for notice of no objection, a detailed description of the technique foreseen for execution of connections in MV lines. However, maintenance and repair being able to be carried out only during a short period of time, at night, due consideration shall be given to connection processes having the following characteristics, quality being otherwise equal: a. quickness of execution, b. possibility of replacement without having to disturb the cable, c. small bulk. NMRCL MARCH

290 The Straight through joints shall be Heat Shrink Type Cable Heads MV cable heads shall be connected to cable junction boxes with the MV apparatus. The Sealing Ends shall be Heat Shrink Type 7.8 Execution Rules The entire supply shall be executed according to all Rules of the Art pertaining to professional-grade equipment, and in compliance with the technical specifications and specifications of the International Electro-technical Commission relative to power supply cables (IEC 55-1, 55-2 and 502-1). The sleeves and the insulating materials used shall meet the guarantee requirements imposed. The equipment shall be capable of withstanding intensive use without alteration, and of performing its duty even after extended idle period. 7.9 Atmospheric and Climatic Conditions The entire equipment shall be designed for operation in hot weather, according to the climatic conditions. The equipment shall be sturdy and properly treated against corrosion. This protection shall be suited to the various environmental conditions encountered in the various parts of the network. It must be noted that environmental conditions shall be very severe during construction; these conditions shall not be the cause of any alteration of equipment or material whether already installed or simply stored Low voltage cables and wiring This specification is made to define the characteristics of low voltage cables used for distribution, control and monitoring. They shall be supplied either in A.C. or in D.C. They shall be used for electrical connection between apparatuses of RSS, TSS, SSP, SWGR, ASS and all other technical rooms General Conductors supplied for low voltage or remote control lines shall have a bare or tinned copper core. Semi flexible conductors shall be used; rigid conductors shall be prohibited. The minimum cross-section of conductors shall not be less than 2.5 sq mm. The minimum cross-section of current transformers secondary circuits shall not be less than 6 mm2. The minimum cross-section of voltage transformers secondary circuits shall not be less than 4 mm². The voltage rating of distribution cables shall be 1100 Volts. Grounding conductors shall have green/yellow-stripped insulation. Neutral conductors are to be deemed as being active conductors. All LV Cables and wires shall be of FRLS type with XLPE insulation Cable Cross Section Determination Determining the technical core section of a cable implies determining the smallest standard cross-section in the type of cable selected which, under the applicable environmental conditions, could satisfy the following criteria: a. Normal temperature rise b. Maximum voltage drop NMRCL MARCH

291 i) 3% for main distribution lines (between primary and secondary cabinets) ii) 3% for lighting circuits iii) 5% for power circuits iv) 12% for motor circuits during start-up c. Overload and short-circuit d. Protection against indirect contact e. If heavy currents are to be carried, the economic section must also be taken into f. account Standards All cables shall comply with the IEC standards (IEC 288 and IEC 227) in force and shall, at least, have satisfied the following tests: a. Dielectric strength, b. Insulation resistance, c. Core resistance, d. Flash-over voltage, e. Insulation stability in a conductive environment, f. Capacitance and differential capacitance, g. Smoke opacity: NBS chamber test, h. Combustion gas analysis, i. Calculation of conventional pollution index, j. Calculation of the conventional toxicity index, k. Measurement of insulation and cladding thickness l. Measurement of diameters, m. Composition and dimensions of the conductive cores, n. Cable construction and identification of cores, o. Tensile properties of insulating and protective cladding mixtures, p. Thermal aging of insulation and protective cladding mixtures, q. Resistance of insulation and cladding materials to pressure at high temperature, r. Resistance of cladding to mineral oils, s. Resistance of cladding to acids and alkalis, t. Resistance of protective cladding to tearing, u. Core bending, v. Coiling at low temperature. And for the corresponding cables: Identification a. Category C 2 cables (non-flame propagating), b. Category C 1 cables (non-fire propagating), c. Category CR1 cables (Fire-resistant cables). All conductors, cables, wiring, terminals and apparatuses shall be identified according to the indications of the diagrams. This identification shall be placed so as to be easily read from the accessible face of the cable or wiring. In all structures, cables shall be marked both at their ends and approximately every 20 meters over their full length, particularly when they change of direction, enter conduits, etc. Along the track, cables shall be identified in the pulling chambers and at their ends. The identification shall be realized with Tag-Holder providing the following guarantees: a. Easy fastening, NMRCL MARCH

292 b. Non flammable, c. Permanence of the marking d. Easy reading. The tag-holder and its bi-directional marking type shall be submitted to the employers notice of no objection Connections All connections, whether made by end-fittings, sleeves or terminals, shall comply with good trade practice. The connection terminal blocks supplied by the contractor shall be identified and includes space enabling precise referencing of all terminals, also possessing all guarantees of permanence and fastening. The crimped section of cables shall be insulated by heat-retractable sleeve. The screen of screened cables shall be connected to ground and continuity shall be ensured Fire-resistant Cables The cables used for the supply to safety systems or other such area/equipment shall be capable of continuing to feed these systems during a fire. To this end, they shall satisfy the electrical and mechanical integrity when exposed to heat and vibration test defined by UTE standards and , test No 3 (CR1 type) or equivalent. In addition, the Contractor shall ensure that the insulation and cladding used minimizes the toxicity and opacity of the gasses evolved during combustion. All insulation materials shall be non-hygroscopic Spare: Systematically, for control and monitoring cables, all the links of a section shall include 15% spare conductors with at least one spare conductor per cable SCADA, control and monitoring Deleted, however the Equipments to be so selected that have provision for interface with RTU which the employer may provide in future. NMRCL MARCH

293 8 INSTALLATION, INSPECTION, TESTING AND COMMISSIONING 8.1 General The Contractor shall operate a robust system for the control of effective working on the site. The contractor shall follow the underlying principles of construction, management and maintenance which are depicted in the following figure: Management Operate Working Monitoring Setting Commissioning Maintenance Altering Switching Adjusting Controlling Preventive Corrective Maintenance Maintenance Servicing Inspection Scheduled Unscheduled Repai r Repai r Requirement of team managers The contractor shall keep the following minimum set of team to manage installation, inspection, testing and commissioning: One site manager per team: a. He shall be available at site during prescribed duty hours. b. He shall be responsible for all technical and organizational matters, general planning and supervision, and man power planning connected with the efficient installation, inspection, testing and commissioning of OHE, power supply and SCADA etc. in accordance with prevailing prescribed schedules and regulation. c. Study of the day-to-day technical, stores and organizational problems so as to effectively assess and monitor the progress and completion of assigned work within NMRCL MARCH

294 prescribed key/access dates and he shall initiate appropriate measures to deal with these. d. Watch on the availability of equipment and material required for the work and initiate necessary action well in advance for procurement of items involving prolonged delivery and effective follow-up action to ensure progress and completion on prescribed key/access dates. e. Coordinate with the concerned contractor for interface requirements and maintain close liaison with power supply authorities. f. Provide adequate skilled man power and keep watch on adequacy and alertness of the team so as to avoid failures, break downs and accidents One site execution assistant manager per team: a. He shall be available at site during prescribed duty hours and execution of work. b. He shall be responsible for efficient execution of work so as to maintain the key/access date. c. He should possess adequate knowledge of rules and regulations. d. He shall be responsible for any type of accidents/emergency. e. He should account and verify periodically the stores and tools so as to offer for checking by Employer or his representative. He shall be responsible for security of the equipment and materials. f. He shall keep updated compiled detailed progress report and submit it to the Employer or his representative periodically or when ever required by checking authority Quality manager: a. He shall be responsible for quality assurance plan including detailed inspection, testing, and commissioning including prescribed acceptance test of OHE, power supply, SCADA etc. for its equipments and materials. b. He shall be accountable for any accident/mishap for lack of inspection, testing etc. c. He shall keep updated compiled detailed inspection, testing etc. report and submit it to the Employer or his representative, at least once a month, or when ever required by checking authority. d. He should coordinate with the concerned contractors along with his site team for quality interface. e. Detailed visual inspection of the OHE in his OHE Inspection Car periodically. f. Detailed inspection of receiving substation, auxiliary substation, traction sub-stations, switching stations and other power supply installations, in particular, protective gear. g. Frequent surprise checks of working gangs at work. h. Check of the procedure followed for installation/erection to verify that all prescribed safety rules are being rigidly followed. i. Periodic inspection of subordinate offices, including stores, for following quality assurance plan. j. Current Collection Test over his entire jurisdiction during commissioning/ warranty period. Installation The Contractor shall comply with all Enactment's in executing the Works, including but not limited to all statutory provisions on occupational health and safety. The Contractor shall coordinate with Other Contractors in the execution of the Works. The Contractor shall also cooperate with all Relevant Authorities in the execution of the Works. The installation of all equipment shall be undertaken at all times by suitably trained and competent employees of the Contractor, to the satisfaction of the Employer s Representative. Only appropriate tools, plant, equipment and vehicles shall be used. Installation of all equipment shall be in accordance with the Construction and Installation Plan described in the GS. Installation of all equipment shall conform to the best industry practices. Precautions shall be undertaken to ensure the safety of personnel and equipment for all installation works. The Contractor shall, prior to starting any NMRCL MARCH

295 installation and construction work, identify any possible hazards, and implement measures of eliminating and/or controlling such potential hazards, in line with safe working practices. The Contractor shall ensure that all areas of work are sufficiently illuminated for the works to be undertaken and that a safe system of work is employed for all activities. The Contractor shall operate a robust system for the control of persons entering or working upon the site. The system shall include as a minimum: a. register of all employees; b. personal identification, with photograph; c. levels of competency; d. date of expiry; e. date of issue; f. signature; and g. register of all visitors. The Contractor shall co-operate, at all times, with the Employer s Representative and Other Contractors to ensure that the Site is protected from unauthorised admission, either wilfully or otherwise. The Contractor shall make due provision for the safe access and egress to the Site of Works for its staff and subcontractors. This access shall be maintained such that it is free of all hazards and is in a safe condition throughout the duration of the Works Specific requirements The installation and construction work pertaining to this Contract shall include, but not be limited to the following: a. Finalisation of the Construction and Installation Programme; b. Survey on Site and review the technical requirements shown in this Specification and the Employer s Drawings; c. Production of the calculation sheets and installation drawings for Site installation; d. Production of specific site designs and drawings based on typical designs and drawings supplied; e. Installation in accordance with the finalised installation drawings; f. Co-ordination with Other Contractors; g. Submission of the installation reports and records; h. Testing and commissioning, as per finalised protocol and programme. i. Production of as built drawings, documents, calculation sheets, and records Installation plan The Contractor shall undertake installation work in stages as shown in the detailed installation programme. Installation, testing and commissioning of later stages shall not impact revenue operation of earlier stages. As a minimum, the detailed Construction and Installation Plan shall include but not be limited to all the activities described. The contractor shall submit installation details and methods of all activities, equipment and tools to be used for installation, safety issues, supervision, temporary land occupation needed and the vehicles to be used for installation Works area The Contractor will be given temporary work sites as stipulated in this Specification. The Contractor shall comply with the requirements specified in Volume 3 General Specifications in relation to the use of works sites allocated to the Contractor Temporary works The design of the Temporary Works shall be submitted to the Employer s Representative for review. All Temporary Works shall be removed on completion of the Section, or as directed by the Employer s Representative. All Temporary Works shall be clearly distinguishable from the Permanent Works Construction plant and equipment The Contractor shall provide for himself the required number of sets Construction Plant & Equipment, for Construction. Areas will be available to NMRCL MARCH

296 contractor as per details given in volume 3 and volume 8, for his office and godown and part of other needs. In addition the Contractor will be permitted to use the Substation sites for storage of materials, equipments etc, and also for a small site office, till the Substations are ready for commissioning Site supervision and safety issues The Contractor shall set up a Site supervision system, which shall be part of the overall safety, system assurance and quality management system. Details of Health and Safety requirements at Site are described in Volume 3 General Specifications. The Contractor shall adopt an appropriate quality management system throughout the entire Site installation period to ensure that the System performance requirements as specified in this PS are achieved. The Contractor shall provide sufficient number of suitably experienced supervisors and skilled workers to ensure that the progress and quality of the work, both on Site and in the Contractor s workshops, are maintained to the satisfaction of the Employer s Representative. Supervisors shall have a minimum of five years previous experience in a supervisory capacity on similar projects and all the skilled workers including linesmen electricians fitters and craftsmen, shall have a minimum of two years previous experience in installation of similar systems. The Contractor s supervision system shall be responsible not only for the supervision of the concerned system installation but also for the supervision of the installation of the primary fixing system (mast foundation), the earth mats and systems, etc. The supervisors shall work on a full-time basis during the entire installation process. The Contractor shall maintain a set of drawings at each project site which accurately reflect the current status of field changes. The Contractor shall obtain letter of no objection from the Employer s Representative for any such changes. The Contractor shall prepare final drawings showing the as built configuration. These drawings shall be developed in a logical format to facilitate routine system maintenance and troubleshooting. All drawings and details shall be endorsed by the Contractor. The Employer s Representative reserves the right to undertake, at any time, checks on the proficiency of the Contractors staff, licensing and all associated documentation. Should any of the Contractors staff be found incompetent or unlicensed he shall be removed from the site until their Competency has been established Workmanship All the installation shall be carried out according to the instructions shown in this Specification and Employer s Drawings. All assemblies of equipment and their components and parts shall be completely interchangeable if they are of similar type The style and procedure of the workmanship shall be consistent throughout the Works. Unless otherwise specified, the Employer s Representative shall decide the final colours for all paint work and other finishes to be applied to any part of the Works. All parts, which are subject to, wear or damage by dust shall be completely enclosed in dust proof housings Inspection All installation work will be subjected to the inspection by the contractor to the entire satisfaction of the employer s representative to ensure that the work is done in accordance with the specifications and approved drawings, designs and employer s prescribed Quality Assurance Standards The inspection programme of the Contractor shall generally cover the following but not limited to: NMRCL MARCH

297 The Contractor shall implement the provisions of the Quality Assurance Manuals and Quality Assurance Programmes as specified by the employer s representatives The Contractor shall adopt Procedure for: a. Source Inspection. b. Incoming raw material inspection. c. Verification of materials purchased. d. Fabrication controls. e. Site erection controls. f. Safety inspection and audit The contractor shall adopt Inspection procedure for: a. Manufacturer and quality control procedure b. Field / site activities All section 0 requirements are with sole objective of achieving the high standards of reliability and availability for operation of suburban traffic. 8.2 Receiving Substation Installation Manual Handling To facilitate handling of equipment during installation and maintenance thereafter, the Contractor shall closely co-ordinate and interface with station contractor, Via-ducts contractor, track contractor, depot Contract and Signalling & Telecommunications Contractor for installation of the material handling equipment as below: a. Travelling hoists and unloading jib cranes for traction substations. b. Any other handling arrangement in order to ensure smooth handling of Substation equipment, from point of receipt at site to the final point of installation The work of installation of the hoists and jib cranes shall be closely co-ordinated with Viaduct and Station Building and track contractors who will have to design the structures, install the beams at appropriate locations and provide the hoists and jib cranes. The entire material handling plan for receiving substation for movement of bulky item such as transformers, 33kV switchgear shall be carefully planned Installation of cables The Contractor shall co-ordinate with the Civil Contractors wherever necessary, for the installation of cables in cable galleries, trenches, ducts, troughs, risers and other locations. The cable system shall, during installation, be fully protected from mechanical damage and be generally accessible at all points for inspection along its entire route. Suitable cable markers shall be provided for covered cables upon completion of installation. Should it prove necessary to cut any cable during installation, all cut ends shall be properly sealed. The maximum pulling force of any cable during installation shall not exceed the design force of cables. All cables shall be installed in the formed cable trenches, shafts, hangers, trays and brackets. The minimum recommended bending radius of the cables shall be adhered to during installation. All materials used for termination, jointing and installation of cables in confined spaces shall have flame retardant, low smoke, halogen free characteristics Programme requirement Deleted Testing NMRCL MARCH

298 This section describes the testing & commissioning relating to the Power supply equipment, in conformity with the requirements of international standards and Railway practices. Testing constitutes an essential obligation to satisfy the Railway System Testing conditions and equipment acceptance The contractor will have to carry out all the tests and checks required guaranteeing the Employer of the good construction and the satisfactory operation of all power supply installation. Also the contractor shall co-ordinate and arrange testing equipment etc required for testing facilities. The various high, medium and low voltage equipment will be subjected to all the tests required under equipment test sheets, (lists are not exhaustive) as per the relevant IEC or other standards mentioned in the technical & performance specification of each equipment or otherwise. It is reminded that the contractor will be totally entrusted with full assembly and installation of all pieces of equipment mentioned in this specification, with supplying the maintenance equipment and the special tooling which shall be delivered as soon as equipment installation will be completed and with the various duties he is bound to regarding witnessing of tests at commissioning and supervision after energizing Documents related to the tests The contractor shall draft and submit to the Employer notice of no objection of "the testing lists", which he will have to supply in their final form one month before in-plant acceptance of the equipment. These lists shall be extremely detailed and include for each piece of equipment: a. The list of the in-plant tests, b. The operating mode (testing procedure) describing how to proceed to perform properlythe test, c. The testing book indicating the expected result of the various tests and provision to indicate the obtained result during the test and to record all observations. For the on-site tests, the contractor will have to draft a bilingual testing lists which will include, for each testing stage and for each piece of equipment the list of all the operations to be carried out and the precise mentions, for each of these, of the interventions to be executed, of the references required for proper identification of the equipment (testing procedure) and of the results which can be expected from these tests with provision to indicate the obtained result during the test and to record all observations (testing book). The contractor will have to supply the various certificates and the relevant computation sheets, at the latest one month after the tests Testing conditions The Employer will appoint representative who will be in charge of supervising the design, the manufacturing and the assembling of the equipment in the contractor s workshops. They will be empowered to halt the proceeding of any assembly work, which would not be in accordance with the stipulations, and to have replaced every part damaged during assembly or transportation. They will witness the in-plant tests. All delays which could arise from additional tests from modifications required due to a defects will not be able to be used by the contractor to justify price increase or time extensions. Each piece of equipment will be subjected to two successive tests: in the plant and on the site after assembly. These tests will be carried out by the contractor, under his responsibility and in the presence of the Employer and of the consulting engineer. NMRCL MARCH

299 Each of these tests will be subjected to a certificate. Provisional acceptance will be granted only after execution of the both sets of tests. NOTE: For type tests, the contractor can provide test reports performed according to the corresponding IEC standard, on similar equipment of same capacity and design In-plant testing In plant testing concern type and routine tests a. Type tests are tests performed on one or two of a equipment series b. Routine test are tests performed on each equipment These tests will enable checking the quality of the equipment and its compliance with the specifications. Once the equipment will have passed the in-plant acceptance tests, it shall be delivered and installed under the contractor responsibility. Concerning some type tests, test certificates issued by recognized agencies will be able to supplied if the contractor cannot carry out these tests himself and if the test certificates are related to a similar equipment of same capacity and design. However, the tests of checking the operation of isolators and earth isolators will have to be performed as routine test. The final factory tests will be carried out on the fully assembled equipment as specified. Thereafter, if required and permitted by the technical features of the equipment, the equipment may be dis-assembled for transportation purposes. The dis-assembly should not, however, cause any deterioration of the technical performance of the equipment. In respect of certain routine tests, it may be necessary to repeat the tests at more than one stage, and the Contractor should ensure that this is done, as required by the Employer s representative. The fact that certain tests had to be carried out on the equipment and/or any part, at more than one stage, cannot be claimed by the Contractor, as reason for any failure/sub-standard technical performances of the equipment After shipment and Preliminary tests After shipment It should be performed at this stage the tests verifying that any damage have taken place during transportation. They should include, at least, the tests listed in the column after shipment of each concerned equipment test sheet Preliminary tests It should be performed at this stage the tests verifying that equipment have been installed and assembled correctly. They should include, at least, the following: a. All test listed in the column on site of each equipment test sheet b. Conformity of the assembly and wiring with the contractor s drawings and instructions c. Sealing of all pipe junctions, and the tightness of bolts and connections; d. Proper function of each part of equipment, of each equipment and of sections e. Cleanliness of installations Commissioning General The Commissioning description, based on the following frame, will have to be defined by the contractor and submitted to the Employer. NMRCL MARCH

300 Once the contractor will have completed the after shipment tests, and the various pieces of equipment installation, the assignment should include: a. Station tests b. Putting into service tests c. After energizing The Employer and the consulting engineer will be empowered to ask for any additional testing they may deem necessary. The contractor will have to supply the testing installations and measuring apparatuses required to this effect. In accordance with the stipulations, provisional acceptance will then take place, followed by final acceptance at the end of the guarantee time Station tests The testing period shall mandatorily be included in the period of the works stated in the contract project. All putting into tests will be carried out in co-operation with the Employer or its representative. It should be performed at this stage the tests verifying that the different sections are electrically and mechanically compatible. They should include, at least, the following: a. Tests requiring several sections to operate at once, b. Internal and between sections operational and safety Interlocking tests, Putting into service tests It should be performed at this stage the tests verifying that the different equipment are acting correctly when energized Integrated testing and commissioning The general testing having shown proper operation, it should be performed, after the first 15 days of operation, an overall integrated test of the installations, during which the various actuation and operation situation (putting into service, normal actuation, failure tripping) will be simulated Specific tests Once the installation of the various pieces of equipment will have been completed, and the common test performed, some equipment will require specific tests. The list of this tests shall be included in the "On site testing" document, which the contractor will have to supply. 8.4 Traction network and Overhead Equipment This section describes the installation, inspection, testing & commissioning relating to the Traction network and Traction Overhead Equipment in conformity with the requirements of international standards and Railway practices. Installation: general This section deals with the installation of overhead equipment and switching stations The contractor shall furnish the design and drawing of complete formwork (i.e.) the form as well as their supports for the notice of no objection from Employer s representative before starting of any installation work is taken up. NMRCL MARCH

301 The Contractor shall provide sufficient number of suitably experienced supervisors and skilled workers to ensure that the progress and quality of the work, both on Site and in the Contractor s workshops, are maintained to the satisfaction of the Employer s Representative The Contractor shall provide for himself the required number of Work Trains/trucks for Construction and considering the necessity. The Contractor is advised to carefully consider the works trains/trucks design so that the working platforms have the flexibility to enable this train/truck to pass the height restriction and yet be of sufficient height for safe and efficient installation of OHE when on site Contractor shall provide following handling equipment for installation of the material as mentioned below: a. Travelling hoists and unloading jib cranes for switching substations. b. Any other handling arrangement in order to ensure smooth handling of Overhead equipment, from point of receipt at site to the final point of installation Contractor will be required to interface with the civil contractor for various civil works related with traction network installation at the following locations: a. Installation of OHE Masts / Portals on the Viaduct/Depot/underground. b. Traction Switching Stations on the Viaduct/Depot/tunnel section. c. Cable path and earthing and bonding arrangements along Viaduct, depot and tunnel section. d. Any other items not included in this section Anchor bolts on the parapet, shall be provided by the civil contractor at the time of casting and installation of parapets Erection of gantries / portals, mast and supporting structures shall cover following items, but not limited to: a. Structures and gantries may consist of the following types but not limited to: - Broad flanged beams - Rolled steel joists - Fabricated structures - Two track cantilever / Multi cantilever structure b. The method of erection of structures, gantries and other supporting frames shall be subject to the notice of no objection from Employer s representative. c. Supply of all necessary galvanized steel bolts, nuts, lock-nuts, washers etc. wherever required as per approved designs and drawings and fastening the same for making a complete assembly of the steel work at site. d. Erection of anti climbing, if required and anti - bird nesting device on the structures Erection of overhead equipment (flexible and rigid) shall cover following items, but not limited to: NMRCL MARCH

302 a. All work shall be done in accordance with methods of erection and installation of overhead equipment and the contractor shall obtain notice of no objections from the employer s representatives. b. The entire equipment shall be erected in accordance with the finally adopted sectioning diagrams. c. The bracket assemblies shall be erected in such a way that the free length of the bracket tube beyond the catenary suspension bracket is at least 200 mm to facilitate adjustment during maintenance. d. The choice of stay arms shall be such that their adjusters are capable of adjusting minimum of 90 mm in either direction except as otherwise relaxed. e. No chipped or cracked insulators shall be installed mm creepage path type silicon composit insulators shall be used. f. The messenger wire shall be suspended from pulley blocks hung from the suspension clamp eye of bracket assemblies. g. The contact wire shall be suspended from pulleys hung from droppers fitted to the messenger wire in their final position. In curves, the contact wire shall be run in pulley located at traction masts or supports, corresponding to the approximate final position of the wire. h. Droppers shall be correctly positioned in each span to ensure correct level of contact wire as per dropper chart applicable to the span. i. The auto-tensioning device shall be erected initially with 70% of the require counterweight for 72 hours and the temperature and contraction /expansion of the conductors recorded. Thereafter the maximum and minimum positions of movement of counter weight arrived and marked on the mast. j. All insulators shall be so positioned that they are away from the swept zone of the pantographs. The live parts of these insulators shall also be so located that they are at least 2m away from structures other than those supporting traction overhead equipment. k. All jumper connections including anti-theft jumpers shall be made properly with parallel clamps and finished neatly without any loose wire or cables. The length of flexible jumpers shall be adequate to avoid any disturbance to overhead equipment or restraint in the relative movement of conductors, but the jumpers should not be excessively long. The ends of jumpers shall be tinned, including the portion inside the first parallel clamp. l. The physical separation required between overhead equipments and bracket assemblies on the same Structure at insulated overlaps shall be ensured. m. Installation of Rigid Overhead Contact System (ROCS) in the Underground Sections shall include design of the first tension length of flexible OHE, immediately after the Rigid Overhead Contact System and junction of Contact wire between the two systems. n. Transition from Rigid Overhead Contact System to Flexible Overhead Contact System and Vice- versa should be installed properly so as to pass the pantograph smoothly Erection of all Switching Stations in the elevated and at-grade corridors shall cover following items, but not limited to: a. 25 kv Switchgear b. Jumpers and connecting cables c. LT and Control Cables from the Switching Station to the Station control room in the nearest station d. Structures and foundations (if necessary) to support the equipments and all other related works to make the Switching Station complete and for its successful and satisfactory working Erection of 25 kv Switch Gear and associated equipment at Switching Stations shall cover NMRCL MARCH

303 following items, but not limited to: a. Erection of 25 kv Single Pole Vacuum Circuit Breaker: b. 25 kv Circuit Breaker shall be erected complete with operating mechanism, all fittings and accessories including terminal connections and necessary jumpers. c. Grouting shall be done for the supporting frame and mechanism box on foundation block and mounting of other accessories in their respective places. d. The contractor shall supply and erect enamelled number plate Erection of 25 kv Pole Isolators: a. 25 kv pole isolator shall be erected and alignment of complete with mounting base, operating rod, operating mechanism, and all accessories required for its smooth and trouble free operation including terminal connections and necessary jumpers. b. Mounting shall be done for support insulators. c. Padlock shall be provided for each isolator. d. Isolator switches shall normally be so mounted that when the switches are operated, the operator faces the directions of the motion of trains. The operating handles and contact blades shall be correctly aligned for easy operation Erection of 25 kv Potential Transformers: a. Mounting arrangement for the transformer shall be fixed. b. 25 kv / 132 V Potential Transformer shall be erected complete with all fittings and accessories including its terminal connections and jumper wires Erection of 25 kv Current Transformers a. Mounting arrangement for the transformer shall be fixed. b. 1500/750/5 A Current Transformer shall be erected complete with all fittings and accessories including its terminal connections and jumper wires Erection of Lightning Arrestors of 42 kv for 25 kv system: a. Mounting arrangement for the Lightning Arrestor shall be fixed in position. b. 42 kv class Lightning Arrestor for 25 kv system shall be erected complete with all fittings and accessories including its terminal connections and jumper wires The contractor shall provide suitable bonding and earthing arrangements at the grade as adopted on the Indian Railway and on viaduct, suitable arrangements will have to be made to ensure. a. A safe low resistance path for the return current from the rail to earth and back to traction substation. b. Avoidance of dangerously high 'touch potentials' along the viaduct portion The following earth conductors shall be provided by the contractor as part of the OHE. a. Aerial Earth Cable (AEC) shall be installed as per approved drawing and connection between AEC and all metallic structures like the platform canopy, foot bridges etc, shall be established. b. Buried Earth Cable (BEC) shall be installed as per approved drawing and connected to various parts by means of flexible copper cables. c. Interconnection of the earthing systems in the Underground and ramp portions Contractor will have to provide the necessary pipe conduits to carry such cables along the NMRCL MARCH

304 viaduct and tunnel from the main duct provided by the civil contractor to the Equipment to connect. The size and arrangement of such pipe conduits will be decided depending upon the actual site conditions obtaining. Installation requirements of flexible overhead contact system The contractor shall adopt the best industry practices for installation and assembly work for an overhead contact line system During commencement of the installation the contractor shall keep ready in advance and submit to the Employer s representative a site management plan for review The contractor shall assure the Employer s representative for review of its site management and submit the site management for notice of no objection while starting the work For any violation of site management rules/procedures, the contractor shall be held responsible and the work shall be suspended without any consequence on delays till all the corrections are made The contractor shall respect the implementation documents such as pole and foundation tables, material lists, contact lines lay outs etc. with reference to approved design drawing submitted by him form the basis of work The contractor shall have to produce the compiled detailed implementation document to the quality team of the Employer s representative, including the relative quality Checking reports, as a matter of checking proof as and when required The contractor shall subdivide the installation documentation into two parts and these are documents for individual stations and inter-station sections The contractor shall follow in general primary characteristics of selected methods that have proven themselves in practice are described below: Tasks Foundation Set Poles Preparation of cantilevers Working Steps Survey of Locations, Search for cables and pipelines, Secure ballast, excavating, scaffolding, drilling, ramming, anchor bolts, installing foundations earthing, pouring and compacting concrete. Check viaduct anchor bolts and their locations. Attach brackets, Clean excavation or hole, mount or insert pole and align, pour concrete or underfill poles. Prepare the mounting arrangement of portal beam and/or head span wire, mount portal beam and/or head span wire. Calibrate poles, calculate cantilever dimensions, saw tubes and drill, cut threads, mount fittings and insulators Cantilever Assembly Bolt cantilever to pole and secure against turning, remove transport protection for insulator NMRCL MARCH

305 Mount Device tensioning Insert midpoint anchor, attach ropes for messenger wire mid point anchor and tension to the specified force. Midpoint anchor installation Preparation of Droppers and stitch wires Install contact line Adjustment Work Electrical Connectors Install overhead line Disconnectors Install traction power supply Plates and labels Railway Earthing Revision of Plans Install midpoint anchor, attach ropes for messenger midpoint anchor and tension to the specified force. Measure the contact wire support clamp, calculate and manufacture droppers, cut stitch wire to length. String messenger and contact wire singly or together, connect with the tensioning device at the start of the tensioning section, string under tension, clamp into the cantilever and terminate at the midpoint anchor and the tensioning device at the end with specified tensile force, release the tensioning device. Install the stitch wires and droppers during the stringing work, install the contact wire midpoint anchor, tension the stitch wire. Unwiring of cable should not be done by hand. The contractor shall submit similar installation method for rigid overhead contact system. Check the contact wire height and stagger and adjust if necessary by altering the cantilever and dropper. Install electrical connectors at connected overlaps, isolated overlaps, fix points, bridges, switches between contact line and positive feeder line. Install and adjust drive mechanism; linkage and disconnector parts, connect remote control cable and power feeder or switching lines. Verify all elementary electrical OHE section. Fix insulators, string traction supply power line, tension and clamp in Attach pole, disconnector and traction power line number, attention and warning plate at the prescribed positions. Provide anticlimbing device if required. Connect metal parts in the contact line range and poles with the selected rails; lay and connect earthing connections. Verify earth resistance values. Revision of the documents to comply with the installation Installation and adjustment of the overhead line supports and contact lines a. The contractor shall plan and install the cantilevers and contact lines as soon as track laying, the foundation in the depot and U bolt on the viaduct, pole erection and it s setting are completed. The cantilever dimensions can be calculated on the basis of the pole positions. b. The cantilever supports and the contact lines within a tensioning length shall have to be installed using during one technological sequence (integrated overhead line installation) so as to complete the work quickly to comply the commissioning as per key/access dates. NMRCL MARCH

306 c. The contractor should plan and preassemble the cantilever assembly in advance so that it can be installed along with stringing of contact line which will reduce the time of installation of OHE. d. The contractor shall interface with track contractor to get marking of rail head height on the pole so that fabrication of droppers shall be taken in advance before stringing of contact lines. Such practice will further reduce the time of installation Installation of section insulators, cross-over contact lines, railway earthing: a. The contractor should ensure proper installation practice for erection of section insulator and highly skilled staff of the team. He should install it on tensioned contact wire only. Since section insulators provide abnormality in the overhead contact line as a result of their mass and importance of location, the contractor shall exercise utmost care in height adjustment of the entry and exit sections and of the gliding skid as it has significant influence on the pantograph dynamics and avoidance of premature wear. b. The contractor shall also take extra precaution during the installation of the contact lines over crossovers to ensure that both contact wires in the pantograph entry area are located on one half of the collector head, since collector head traps could otherwise arise. The contractor shall carefully install and adjust the droppers in contact lines above the switches to achieve better results. c. Earthing lines in 25 KV AC systems are attached to the poles and the metallic equipment located in the area of the overhead lines and to the provided connection points on the rail through signaling impedance bond and OHE integrated transverse link, with the inclusion of return current and earthing conductors. Since these works rarely require track closures, this work contractor shall have to plan and execute before track closure and therefore the installation time can be reduced further. d. The contractor is required to draw out the various activities in the form of steps to ultimately erect the section insulators and the crossovers. This is necessary for complicated work for better understanding of work team Equipment for installation and maintenance: a. The contractor has to arrange specialized equipment and specialized vehicles in addition to usual tools and vehicles to comply with the requirement for qualified installation and maintenance of overhead contact line systems. It will be necessary for correct, rapid, and safe working of installation, inspection, maintenance, and repair activities. b. The contractor has to ensure that these equipment are user friendly, simple in handling and ensure continuous operational availability even during rough railway operation under any abnormal situation/condition, which is essential for high availability. c. The contractor shall ensure to keep voltage tester at working site to ensure that the line is de energized which is necessary if the line is charged during installation for antitheft measures or otherwise charged with 25 KV. d. The contractor shall arrange adequate number of safety belts and protective helmets for accident free working on the overhead contact line system. e. The contractor shall produce the list of minimum tools and equipments, specialist vehicles and normal vehicles require for installation, inspection, testing, and commissioning for notice of no objection of the Employer before planning for starting the work The interrupters and isolators meant for sectioning shall be located in the station area in a room close to the sections required to reduce length of cables Connection of feeder cables to ROCS conductor rail shall be through flexible jumper and NMRCL MARCH

307 terminal connectors and shall be of bolt fixing type and the details shall be submitted for review by the contractor to the employer s representative The feeder cable jumpers shall be flexible to accommodate rigid conductor rail movement due to temperature variations Due care should be taken to lay and connect the cables to switchgear and to ROCS to ensure that the current carrying capacity of the system is not de-rated and all connectors shall be robust and of proven types The Contractor shall provide and maintain documentation at all stages of the works in the formats prepared by him (contractor) duly obtaining notice of no objection from employer s representatives The contractor shall maintain the documentation so as to identify the status of inspections. Such documentation shall contain: a. list of certificates received for each batch of goods and materials incorporated in the works and compare this against the certification required by the Contract. b. list the inspection activities undertaken by the Contractor on each element of the works and compare these activities against the amount of inspection and testing required by the contract. c. Summaries of any actions proposed by the Contractor to overcome any deficiencies so identified during various inspections including the inspection by his (Contractor) quality manager The contractor shall also inform the employer s representatives in writing, when anyportion is ready for inspection giving him at least 24 hours advance intimation to enable him to inspect the same, without retarding progress of the work Employer s representatives shall have free access at any time to every part of the works and to all places where materials for the works are stored or being prepared The Contractor shall furnish with reasonable facilities and assistance to the employer s representatives during inspection The Contractor shall conduct formal, documented Safety Inspections, at least in a month and report of each safety inspection shall include the actions taken to resolve any problems or shortcoming discovered during the inspection. The report shall be made available for audit purposes and be discussed at the relevant meetings The contractor shall submit the basis of inspection to be carried out in advance to the Employer which should be based on international standards and the various specification adopted by Indian Railway Research design and standard organization etc. the The quality manager of the contractor shall conduct 100 percent inspection and keep a record The employer s representative may inspect 10 percent of ordered quantity on supply itemsin manufacturer s premises in presence of contractor and the manufacturer percent inspection on supply items shall be inspected by the quality manager of the contractor in the manufacturer s premises on supply items and shall keep records The employer s representative may inspect 10 percent of ordered quantity on supply items at site in presence of contractor. NMRCL MARCH

308 percent inspection on supply items shall be inspected by the quality manager of the contractor at site on supply items and shall keep records Such inspections shall include quality procedure checks and during inspection qualified staff shall be provided by the contractor Demonstration of conformity of overhead contact system: Testing a. The contractor has to compile a complete detail inspection (on installed OHE and on supply of equipment and materials) carried out by his quality manager and contractor shall submit a report to the Employer once in a month. b. Monthly, the employer s representative may conduct inspections of progress activities of the contractor at least one km for every 10 km. c. The contractor shall arrange inspection by Employer s at least one kilometer of installed OHE stage wise, on every 10 kilometers and random check on supply of equipment and materials. d. The contractor shall conduct current collection test as per EN50317 to demonstrate that a newly installed overhead contact line satisfies the quality requirement for a given running speed. e. The contractor shall check the electrical and mechanical line parameters to fulfill the electrical requirements, both the static (validation of static dimensions) and the dynamic (validation of dynamic behavior) design requirements within the design tolerances as per schedule of dimensions standard gauge of Nagpur Metro Rail Project. f. As erected drawing shall be submitted by the contractor so as to ensure that defects, modifications, corrections pointed out during inspection have been carried out The contractor shall co-ordinate & arranges testing equipment etc required for testing facilities Factory Inspection and testing of supply items of equipment and components of Overhead contact line: a. 1 month before factory acceptance test, contractor shall submit to the Employer s representative the test content. This test content shall refer to appropriate standards. b. The contractor quality manager will assist to all factory acceptance test on equipment and components of Overhead contact line in the manufacturer s workshops. After each test, a test report shall be made, giving a pass or fail status, and shall be submitted to the Employer s representative. c. The contractor design and quality team shall conduct the factory acceptance test on equipment and components of Overhead contact line in the manufacturer s workshops. This will be performed on 10% of the quantity ordered based on random selection of the product offered for inspection. The Employer s representative may take part to inspection. d. Such material immediately after completion of inspection and testing shall be sealed before shipping in presence of witnessing by Employer s representative, manufacturer s representative and the contractor. NMRCL MARCH

309 e. Type test shall have to be performed as per specification if it has not been done earlier by an national /international accredited reputed agency. f. More over the employer reserves the right to order type test irrespective of whether the type test conducted earlier or not. g. Concerning type tests, test certificates issued by national/international recognized agencies may be asked to issue, if the contractor cannot carry out these tests himself and if the test certificates are related to a similar equipment of same capacity and design The following major equipment and components shall be inspected and tested in the manufacturer s workshops: a. Hard drawn grooved copper contact wire for electric traction (150 sq mm): the material shall be inspected and tested as per EN50149 specification, UIC 870 specifications and as per Indian Railway RDSO specification ETI/OHE/76-latest revision. The quantity to be inspected shall be in number of drums and be to 10% which will include the requirement of tunnel section also subject to minimum one drum per shipment. b. Hot dip zinc galvanization of steel mast with plates, tubes and fittings: the material shall be inspected and tested as per EN ISO 2178 specification and as per Indian Railway RDSO specification ETI/OHE/13-latest revision. c. The contractor shall carry out testing on weldings done on the mast and rigid portal beam. d. The contractor shall carry out load carrying capacity test on each type of mast on first batch of production e. The contractor shall carry out load carrying capacity test on 10 % of each type of cantilever tubes and fittings. f. The contractor shall ensure that the galvanization shall only be done after required plates are welded properly and holes of proper size are made. g. Messenger wire Cadmium copper stranded conductors: the material shall be inspected and tested as per EN specification and as per Indian Railway RDSO specification ETI/OHE/50-latest revision. The quantity to be inspected shall be in number of drums and be to 10% subject to minimum one drum per shipment. h. Short Neutral Section: the set of 25KV PTFE type short neutral section shall be inspected and tested as per Indian Railway RDSO specification TI/SPC/OHE/SNS/0000-latest revision. The complete set of automatic switched short neutral section as per latest design including VCB and its circuitry shall be type tested (if already not done) and performance witnessed. i. Aerial Earth Wire: the material shall be inspected and tested as per IS-398(part II)latest revision. j. Buried earth cable: the material shall be inspected and tested as per Indian Railway RDSO specification ETI/OHE/3-latest revision and IS:9968(part II)- latest revision. k. Silicone Composite Insulators 1600mm creepage distance: the silicon composite insulators for stay, bracket and 9 ton insulators shall be inspected and tested as per Indian Railway RDSO specification TI/SPC/OHE/INSCOM/1070-latest revision and as per IEC61109 specification. l. The contractor shall ensure that the tests of checking the operation of isolators and earth isolators will have to be performed as routine test Final factory tests a. The final factory tests will be carried out on the fully assembled equipment as specified. Thereafter, if required and permitted by the technical features of the NMRCL MARCH

310 equipment, the equipment may be dis-assembled for transportation purposes. The dis-assembly should not, however, cause any deterioration of the technical performance of the equipment. In respect of certain routine tests, it may be necessary to repeat the tests at more than one stage, and the Contractor should ensure that this is done, as required by the Employer s representative. The fact that certain tests had to be carried out on the equipment and/or any part, at more than one stage, cannot be claimed by the Contractor, as reason for any failure/substandard technical performances of the equipment. b. The Employer reserves the right to halt the proceeding of any assembly work, which would not be in accordance with the stipulations of this section. c. All delays which could arise from additional tests, from modifications required due to a defects will not be able to be used by the contractor to justify price increase or time extensions. d. Each piece of equipment will be subjected to two successive tests: in the factory and on the site after assembly. e. Tests of ) d. will be carried out by the contractor s responsibility and in the presence of the Employer s representative. f. Tests of ) d. will be subjected to a certificate. Provisional acceptance will be granted only after execution of ) d. of tests After shipment and Preliminary tests a. After shipment - The contractor should perform at this stage the tests verifying that any damage has taken place during transportation. - The contractor should ensure to carry out, at least, the tests listed in the column after shipment of each concerned equipment test sheet (test sheet in Appendix C) b. Preliminary tests: the contractor should ensure at this stage the tests verifying that equipment have been installed and assembled correctly On site test of flexible OCS The contractor has to compile detail complete test of installed OHE carried out by contractor s quality manager and report submitted to the Employer s representative once in a month The contractor shall arrange test by Employer s representative also at least one KM of installed OHE on every 10 KM: a. The strength of the insulation of the entire equipment as installed shall be tested with a 2500 V Megger and desirable value is 25 mega ohm as per para of Indian Railway AC traction manual. b. The electrical continuity of the line and the existence of bad contacts, if any, will be tested with a Megger. c. electrical independence of individual elementary sections in relation to one another shall also be tested with a Megger. d. All isolators shall be tested for smooth and trouble free operation. e. All automatic tensioning devices installed shall be tested for sensitive functioning adjustment including x-y settings and marking on poles. f. The stager and height of contact wire (at mid point and at support) over the entire section of completed over head equipment and the clearances available shall be measured and the measurement shall be checked against approved drawings. These NMRCL MARCH

311 measurements shall be carried out at low speed with a vehicle or device to be arranged by the contractor, the movement of which will follow the track levels as closely as possible. Tolerance that will be permitted on the dimensions indicated in the approved drawings. g. The actual position of the two contact wires, relative to each other, at overlaps and turnouts shall also be checked. Special attention shall be paid to a smooth movement of Pantographs over section insulators, particularly those which are likely to be frequently traversed. h. The mechanical behavior of the entire equipment shall be tested at various speeds under normal pantographs pressure without energizing the over head equipment. Tightening of bolts must be checked before and after such check. i. If the over head equipment, after being subjected to the above tests in an unenergized condition, is found to be satisfactory, it will be energized with the normal 25 KV A.C. supply. j. Testing of OHE Tests shall then be conducted to check if the current collection performance (as per EN50317) of the over head equipment is satisfactory after ensuring that the contact wire is adequately smooth. For this purpose, an observation vehicle shall be attached next to the electric locomotive. The behavior of the over head equipment will be watched at the various speeds. Current collection shall be considered unsatisfactory, if long blue flash is observed, indicating that the contact between the contact wire and the pantograph is not smooth Inspection and testing of switching stations a. As soon as a switching station is ready for inspection and testing, the contractor shall advise the Employer s representative in writing and should submit jointly the internal checking testing report with the passed status without any observation. b. Testing will be carried out on contractor s cost. c. Those shall include the test which the Employer s representative may like to conduct with a view to assure himself of the soundness of these equipments and their erection in compliance with these specifications. d. Testing equipment such as 2500 and 5000 V Muggers, Earth megger and accessories, Continuity test apparatus, Avometer and staff required for the tests shall be provided by the contractor free of charge. e. The Contractor shall take full responsibility and submit the report to the Employer s representative. f. The contractor shall carry out Visual inspection which shall include check for satisfactory workmanship, shall cover all connections, painting, plastering, cleanliness of all insulators etc. and compliance with Indian Electricity Rules. g. The contractor shall carry out by operating every individual items of equipment such as vacuum interrupters, vacuum circuit breaker, isolators etc. to ensure that the equipment as a whole is functioning properly and is mechanically sound. h. Continuity test of high tension connections after setting such interrupter, circuit breaker and isolator in their respective positions shall also be conducted by the contractor as part of the operation test. i. The Employer s representative shall carry out random test equipment wise/component wise. j. The strength of insulation of the various items of equipment shall be tested by the contractor with a 2500 V/ 5000 V megger as required. k. All isolators will be tested for smooth and trouble free operation. l. Vacuum interrupter and circuit breaker: Operation of trip and close coils for interrupters and circuit breaker shall be tested for satisfactory performance Earthing: NMRCL MARCH

312 a. Each wires will be checked for continuity and electrical isolation for every 1000 m approx. including at integral transverse bond by the contractor. b. Clearance between earth wires and out-of-run wires of overhead equipments and signals shall be checked by the contractor. c. Earth resistance shall be measured separately for each pit and inter-connected earth pit at every switching station by the contractor and meet the requirement of the Earthing and bonding policy note (Volume 3 Appendix 16). d Detailed procedure for test: a. The detailed procedure for inspection and testing will be organized by the contractor. b. The contractor shall submit the proforma to the Employer s representative for notice of no objection in advance for indicating the results of tests for switching stations. c. The contractor shall submit the results of tests for switching stations in the approved proforma to the Employer s representative Acceptance test: a. The contractor should ensure the requirement for acceptance as set out in EN 50119, clause 8.15 so as to conduct the test on technical/functional aspect and safety aspect. b. Thereafter the contractor along with Employer s representative (Inspector) shall list out all the defects. c. After all the defects are rectified the contractor along with the Inspector confirms that the inspected section is free from safety aspect and recommends energizing of the line. d. After energization of the OHE, test runs are conducted to know the interaction between contact line and the pantograph. Thereafter defects are listed and rectified All the items of supply and required for completion of the work in all respects, testing and commissioning of the rigid overhead contact equipment system as well as associated work for facilitating trial run of the rolling stock and Integrated Testing and Commissioning shall form part of the work covered by the contract During train trial contractor shall be responsible for providing and fixing discharge rods during power block permission/cancellation The contractor will have to supply the testing and measuring apparatuses and testing cars required for the commissioning Till the end of the contract, contractor shall provide and fix discharge rod when required and requested by any other contractor or by Employer s representative Maximum design speed tests shall be carried out by means of running the trains initially at slow speed, then increasing the speed in stages up to full speed permitted for the section and on successful completion of the high speed tests, the ROCS shall be declared fit for system acceptance tests. The contractor shall have to provide all the documents including drawings and reports required for inspection of nominated electrical inspector to government of India before commissioning. NMRCL MARCH

313 The contractor has to accompany employer s representative during such inspections if required before submission of the reports to the Electrical Inspector to government of India. 8.5 Auxiliary Network Deleted NMRCL MARCH

314 9 MAINTENANCE AND TRAINING 9.1 Introduction This section describes the maintenance philosophy and training of operation and maintenance staff for power supply, OHE, SCADA and control & monitoring installations taking into account international standards and Railway practices. This training shall enable all the installations, to be operated and maintained in the most efficient and safe manner, so as to achieve the maximum reliability and economy required by such Metro Rail System. 9.2 General principles of an effective maintenance system The contractor shall develop a maintenance philosophy and management plan which shall comply with the state of the art and with the general prevailing standards with regard to the maintenance of durable goods, in particular, standards X and EN The management of the maintenance process entails defining various levels of responsibility and enabling them to implement the strategic orientations defined by the directing authority: a. by defining their respective missions, b. by setting objectives for each person, c. by translating these objectives into action plans, d. by implementing the means required to carry out action plans, e. by diagnosing the causes of any deviation from the set objectives, f. by taking corrective measures concerning the action plans or the objectives. This management process requires a global approach and helps to improve the performance of the maintenance work of different components with quality, on time and at low cost. The contractor will implement the management and management procedures of the maintenance process described in section 0 at three levels: a. at the level of human resources and management in the context of the scheduling of work, the allocation of human resources and the training of personnel, b. at the skills level to ensure quality, safety and suitable working conditions, c. at an economic and financial level to ensure responsible management of production, spare parts, purchasing and miscellaneous costs. Within the context of this approach, the management control function ensures timely advice to be given to those with operational and maintenance responsibility: a. by placing at their disposal the tools and information required for piloting and diagnosis, b. by participating in carrying out this diagnosis, c. by participating in the task of defining the objectives to be achieved. The process of maintenance management must incorporate two major components: the management of human resources and the study of the most suitable means of achieving the set objectives. This is one of the first guidelines of maintenance organisation. 9.3 Implementation of maintenance In accordance with section contractor will provide the facilities and tools so that the set objectives can be achieved. 9.4 Assistance for maintenance NMRCL MARCH

315 Deleted 9.6 Comprehensive maintenance 9.7 Deleted. 9.8 Training The Contractor shall provide comprehensive training to the Employer s staff, in accordance with the requirements which shall include: i) Operations Staff; iii) Maintenance Staff; iii) Staff who are to become Trainers within the Employer s organisation. The final requirements for training will be decided by the Employer s representative in consultation with the Contractor, during the course of Detailed Design, taking into account the trainees skill and background, the maintenance strategy to be employed, the staging of the project for revenue service and any other Employer constraints. 9.9 MANNINGOF SUBSTATION / SWITCHINGSTATION: TheContractor shall deploystaff for manning and operation attssasdirectedbyemployer's Engineer.Manningshall bedoneroundtheclockinthreeshiftsof8hourseach.thestaff,holdingminimumitiqualification, shallbedeployedineachshift.theyshallbefullyconversantwithoperationofvariousequipmenti nstalled inthe substation / switchingstation.thestaffshallbedeployedaftertestandtrialbyemployer/engineerandonissu eofcompetencycertificate.thestaffdeployedshallactinaccordancewithinstructions/direction sgivenbytractionpowercontroller(tpc)/representativeofemployer.thestaffshallnotleaveth eworkingplace(substation / switchingstation)inanycasewithoutpermissionofemployer'srepresentative. NMRCL MARCH

316 10 SPARE PARTS, SPECIAL TOOLS AND TEST EQUIPMENT 10.1 General Contractor shall provide spare parts in accordance with the requirements of section 13 of the Volume 3 and this section 10 of the Volume 4. All spare parts for which the Contractor has been authorised to provide through a written instruction by the Employer s Representative shall be provided 6 weeks before commencement of revenue service. The quantity of contract spares associated with stage 1 & 1a equipment, shall be sufficient for the period between the issuance of the completion certificate for stage 1 & 1a until the end of the DLP for the stage 1 works. The quantity of contract spares associated with stage 2 equipment, shall be sufficient for the period between the issuance of the completion certificate for stage 2 until the end of the DLP for the stage 2 works Spares List The Contractor shall submit to the Employer s Representative a list and provide spares as required. The spares shall be distinctly grouped as follows: a. Contract spares shall be as the agreed final list of spare parts to be procured by the Employer the maximum of using the formula as indicated in the Volume 3. b. Commissioning spares the Contractor shall keep on the Site throughout the installation, erection and commissioning periods, sufficient stocks of Spare Parts to enable immediate replacement of any item to be used during the contract period at no charge to the Employer; and c. DLP spares In addition to the Contract Spares, the Contractor shall keep sufficient stocks of Spare Parts in an off-site location in Nagpur throughout the Defects Liability Periods to enable rapid replacement of any item during the Defect Liability Period at no charge to the Employer. The Contractor shall submit to the Employer s Representative for review the calculations and spares list. The spares list shall be grouped by subsystem, test equipment and special tools as applicable for stocking identification. The spares list shall have detailed description with drawing references and correlation with the maintenance manuals. The spares list shall distinctly group spares covering stage 1 & 1a and spares covering stage Second Sourcing The Contractor shall identify principal and second-source suppliers that can supply the systems and sub-system spares listed. The Contractor shall ensure that second-source supplier information is maintained up to date throughout the service life of the System. The Contractor shall make the second-source supplier information available to the Employer s Representative at the time of submission of the final design Long Lead Times NMRCL MARCH

317 The Contractor shall identify the lead times for all spare parts. Parts with long lead times shall be identified as such to the Employer s Representative in the spares list Routine Change In the event that any item of the supply requires be routinely changing or calibrating regardless of whether it appears in the spares list or not, it shall be identified to the Employer s Representative together with the routine change interval Shelf Life In the event that any of the spares identified have a particular shelf life or storage requirement, this shall be made known to the Employer s Representative with the submission of the spares list, including the necessary action for disposal or storage Testing of Spares The Contractor shall ensure that all spares are correctly calibrated, tested and labeled prior to their delivery. Test certificates for each piece or set of equipment shall be submitted to the Employer s Representative Special Tools and Test Set up The Contractor shall provide the necessary tools and test & measuring equipment to meet the testing, commissioning and maintenance requirements of the Contract. The Contractor shall submit a schedule of all tools and equipment with details of calibration and supplier. The Contractor shall set up an offline-testing platform at a suitable place provided by the Employer. NMRCL MARCH

318 APPENDIX -A Interfaces TABLE OF CONTENTS Nagpur Metro Rail Corporation Limited Metro House, Bungalow No: 28/2, Anand Nagar, CK Naidu Road, Civil Lines, Nagpur Maharashtra, INDIA OBJECTIVE INTERFACING REQUIREMENTS INTERFACE WITH ROLLING STOCK CONTRACTOR INTERFACE WITH TRACK CONTRACTOR INTERFACE WITH SIGNALLING CONTRACTOR (SIG) INTERFACE WITH TELECOM CONTRACTOR (TEL) INTERFACING WITH E&M CONTRACTORS IN STATIONS AND DEPOTS (E&M) INTERFACE WITH POWER SUPPLY AUTHORITIES (PSA)... E 11. INTERFACING REQUIREMENTS FOR HT CABLING WORKS... NMRCL MARCH

319 12. INRODUCTION 1.1 OBJECTIVE The design and construction of the Nagpur Metro Railway, is a complex multidisciplinary project, requiring close interaction and co-ordination between the various designers and builders. The objective of the Interfacing document is to define as clearly as possible, the Scope of Work of different Agencies, so that the problems which could arise during the Execution Stage are greatly minimized, if not eliminated. Notwithstanding the above, it is imperative that the N1TR02/2016 Contractor shall maintain a close Interface with the other concerned Contractors and Design Consultants, so that the problems faced at site, if any, are communicated through Interface documents and discussed in periodical Interface meetings, to arrive at logical and expeditious solutions, to ensure smooth progress of physical works and realization of the scheduled dates of completion of works. 1.2 INTERFACING REQUIREMENTS The major interfacing requirements are with the following Agencies / Designers / Contractors Rolling Stock (RS) & Signalling Contractors (SIG) Contractor, Design and Build Contractors of Tunnel / Box-Section / Ramp linking elevated and underground Sections (RAMP), Viaduct Contractors of different Corridors (VDC), Station Building Contractors in different Corridors (SBC), Track Contractors (TRACK), Telecom Contractors (TEL), E & M Contractor for Station Buildings of different Corridors (E&M and Depot), 2. INTERFACE WITH ROLLING STOCK CONTRACTOR 2.1 Deleted 3. INTERFACE WITH STAITON BUILDING CONTRACTOR (SBC) STATIONS IN PRIORITY SECTION 3.1 ITEMS OF INTERFACE Different Consultants/Contractors are assigned for design and construction of the various stations, collectively referred to as SBC. The Contractor shall interface with the various Consultants/Contractors, mainly for the following works: - Support of OHE from Platform shed roof trusses - Providing OHE masts/portal /Anchors along the track. - Providing electrical and mechanical clearances for OHE - Providing earthing connections NMRCL MARCH

320 - Provision of openings in slabs etc. for cable entry and cable exit. - Sealing of cable cut outs Table 3.1 Interfacing Requirement with Station Building Contractor (SBC) Item No. Item Description N1TR02/2016 Contractor Station Building contractor (SBC) Remarks 1. Supportof OHE from Platform shed roof trusses 2. Providing OHE masts/anchors along the track stations. 3. Providing electrical and mechanical clearances for OHE 4. Providing earthing connections 5. Auxiliary Substations 6. Provision of openings in slabs etc. for cable entry N1TR02/2016 will provide general arrangementshowing suspension members from station ceiling, from which OHE can be supported. N1TR02/2016 will also indicate typical bending moment and direct load arising from OHE, at suspension points. N1TR02/2016 will prepare detailed drawings for support of OHE from suspension members. N1TR02/2016 will indicate the locations where masts/anchors are required to be provided (in the pegging plans) N1TR02/2016 will provide bolted base OHE masts/anchors etc. N1TR02/2016 will provide the necessary clearance diagrams showing minimum clearances required from OHE. N1TR02/2016 will provide Earthing connection drawings, showing locations of earth terminals, earth mesh etc required at stations. N1TR02/2016 will provide necessary interconnections between earth terminals/riser terminals and earth conductors (OPC, EC) as shown in the Earthing connection drawings. Deleted N1TR02/2016 will provide drawings showing the locations and sizes of openings to be provided in slabs etc. to allow SBC will provide the necessary steelwork and boltholes etc. to enable the suspension members to be supported from the platform shed roof trusses. Will provide holding down bolts as per approved drawings (used on viaduct to take the base-plate). Will ensure that the clearance diagrams are respected and there are no infringements. Will provide necessary earth terminals, earth mesh etc. and risers and respect the schematic earthing drawing, will ensure provision of minimum of 50mm dia pipe5nos. on each platform under the floor for continuity of earthing platform shelter/canopy. Will prepare cable route drawing. Will provide openings as NMRCL MARCH

321 and cable exit. passage of cables. per drawing. N1TR02/2016 will supply and install cable supports inside the ASS Room and from viaduct to ASS. N1TR02/2016 will interface with Station Building Contractor to ensure correct and adequate cable routings, openings etc. N1TR02/2016 will supply, install and connect cables. 4. INTERFACE WITH TRACK CONTRACTOR Supply and installation of cable supports along the cable route, outside the ASS room, in accordance with cable route drawing. The construction should take into consideration cable bending radius (specified in the drawing), cable fastening arrangements and suitable provision to cover the cables in public places. 4.1 ITEMS OF INTERFACE Interfacing with Track contractor will be required for - Information regarding track alignment, cant of track, versine of track, rail levels, curve details along with transition curve details. - Providing continuity in Plinth Reinforcement bars of segments in one girder and earth terminals at either ends on end plinth sections. - Providing pipes for track-crossing, for cables. - Providing continuity bonds in track, particularly at points and crossings. 4.2 INTERFACE REQUIREMENTS The Interface requirements are described in Table 4.1. Table 4.1 Interfacing Requirement with Track Contractor Item No. Item Description N1TR02/2016 Contractor Track Contractor Remarks 1. Information regarding track alignment, curves, levels etc. Wil information provide to NMRCL MARCH

322 N1TR02/ Viaduct and bridges, earthing through tracks plinth and plates welded to plinth reinforcement steel. 3. Providing pipes for track crossing, for cables. 4. Providing continuity bonds in tracks. 5. Electrical and Physical clearance N1TR02/2016 will supply and connect the connection cable to the EC and plinth connecting plates at the end of consecutive spans. N1TR02/2016 will provide drawings showing requirement of pipes at specific locations. N1TR02/2016 shall supply and provide the pipes over viaduct and pipes over parapet walls and interface with TRACK for correct location of pipes and verify before plinth casting N1TR02/2016 will provide bonding details. N1TR02/2016 will provide the continuity bonds Shall necessary drawings provide Supply and install GI plates on every deck end. Ensure the electric plinth continuity on every span by providing earth terminals at each end of the plinth duly connected with cable. The material details and specifications of connecting cables shall be interfaced with N1TR02/2016 contractor. Track contractor shall interface with N1TR02/2016 for finalizing location of pipe crossings. Will check the details and acceptability. confirm Respect the given clearance. Will require interfacing with Signaling Contractor also. NMRCL MARCH

323 5. INTERFACE WITH SIGNALLING CONTRACTOR (SIG) North South Corridor will have CBTC (Communication Based Train Control) based signaling which is based on radio communication between trackside equipment and cab. A backup train detection system based on AFTC or axle counter may be provided. N1TR02/2016 Contractor shall interface for all the requisite details. It is likely that the antennae for CBTC system will be mounted on OHE masts also in addition to independent antennae mast. Both contractors will interface for appropriate arrangement so that installation and maintenance can be done safely. 5.1 ITEMS OF INTERFACE Interfacing with the Signalling Contractor will be required for - Signal locations along the track - CBTC (Communication Based Train Control) based signaling - Track-circuiting details - Signaling cable details - Providing impedance Bonds 5.2 INTERFACE REQUIREMENTS The Interface requirements are described in Table 8.2. Table 5.2 Interfacing Requirement with Signaling Contractor (SIG) Item No. Item Description N1TR02/2016 Contractor Signalling Contractor Remarks 1. Signals for N1TR02/2016 will give Will install a signal to insulated overlaps, to SIG locations of protect the insulated Booster insulated overlaps. overlap to avoid entry of a Transformer locations BT overlap shall not be provided before a signal. train into the subsector ahead, when under shutdown. Will avoid Signal ahead ofbooster Transformer. NMRCL MARCH

324 2. Signals for Neutral Section 3. Track circuiting details 4. Connection of Conductor to rail, through impedance Bonds or direct to rail. N1TR02/2016 will give to SIG location plan of Neutral Section N1TR02/2016 will design Bonding and earthing plan to suit the track circuiting details furnished by SIG. N1TR02/2016 will provide earthing and bonding. N1TR02/2016 prepare connection showing will typical drawings connection between RC and Rail through Bond. NGP Impedance 1&2 will supply and install cables and connect them to RC side. Will adjust the positioning of stop signals in such a way that a train starting from stop at a stop signal is able to achieve necessary speed to negotiate the neutral section, with power off, under its own momentum Will furnish to N1TR02/2016 details of track circuits along the track. Will supply and install impedance bonds and make connection of the cable to Impedance Bond if provided. 5. Signaling cable details 6 Normal and short circuit currents levels in the OHE 7 Location of Track Circuits 8 Bonding and Earthing Plan In case direct connection to rail is required, N1TR02/2016 shall provide the connection to rail with exothermic welding. N1TR02/2016 will 'model' the signaling cables suitably for EMC study. N1TR02/2016 will advise to SIG N1TR02/2016 will Design Bonding and Will furnish to N1TR02/2016 specifications of signaling cables and their locations. SIG will give details to N1TR02/2016 NMRCL MARCH

325 9 Rail Continuity Bonds 10 Impedance Bonds & TCPMM Earthing Plan to suit track- circuiting details furnished by SIG N1TR02/2016 will provide Rail continuity bonds, according to finalised bonding plan and in co-ordination with SIG N1TR02/2016 will provide TCPMM for earth continuity. 11 Cross Bonds N1TR02/2016 will provide cross bonds, according to finalised bonding plan and in coordination with SIG 12 Insulated Rail Joints SIG will supply and install Impedance bonds at finalised locations. SIG will provide details regarding locations of insulated rail joints on the main line and in the Depot/yard. 13 Signal Locations SIG will provide chainages of signal posts, to N1TR02/ OHE mast/struct ure locations 15 Electrical Clearances 16 Power Supply Protection System and trip settings N1TR02/2016 will provide Layout Plans of OHE showing mast locations, wire staggers etc, to SIG. N1TR02/2016 will provide Layout Plans of OHE to SIG. N1TR02/2016 will advise to SIG the protection relay settings. 17 EMI/EMC Study N1TR02/2016 will provide inputs to SIG. 18 Cable support on viaduct N1TR02/2016 shall provide cable support on viaduct for signaling & telecom cables SIG will ensure that signals are mounted in locations where they are not hidden by OHE masts or other hardware SIG shall coordinate with N1TR02/2016 to ensure minimum safe clearances between any signalling field installation and the live OHE part. SIG will ensure Train Control and Signalling systems are designed suitably. Signal & Telecom contractor to co-ordinate. NMRCL MARCH

326 6. INTERFACE WITH TELECOM CONTRACTOR (TEL) 6.1 ITEMS OF INTERFACE Interfacing with Telecom contractor will be required for - Telecom cables and Exchange locations - Control & Monitoring data exchange. - Telephone connections to the Rail corridor internal telecom network. - Laying of C&M cables. - Telephone connection to RSS. 6.2 INTERFACE REQUIREMENTS The Interface requirements are described in Table 9.2. Table 6.2 Interfacing Requirement with Telecom Contractor (TEL) Item No. Item Description N1TR02/2016 Contractor Telecom Contractor (TEL) Remarks 1. Telecom Cables and exchange locations 2. Control & Monitoring data exchange N1TR02/2016 will perform the EMC simulation study Will supply and install suitable redundant OFC cables for connection from RTU to optical ethernet ports at. - each station telecom equipment room (from ASS, Traction Switching Will furnish to N1TR02/2016 the locations of telecom cables and Telephone exchanges, of Rail corridor in sufficient details for enabling 'modelling' of cables and for performing simulation study on Electro-magnetic compatibility. Will supply and install optic fibre cables, including the channels required for C&M data exchange and for interlinking the OCC s. Will also supply and install optic fibre ports at - each station NMRCL MARCH

327 Stations - the station nearest to RSS, for connection from the RSS Equipment Room - the Depot TER 3. Telephone connections to the Rail corridor internal telecom network Provide a connected telephone at - each ASS Room - TSS Control Rooms - ECC desks at SP and MB - OHE depot - TRANSCO Substations. 4. Laying of C cables Supply and install C&M cables in the S&T cable trough between each traction switching station and the nearest Station Control Room/TER Provide space (approx 10cm 2 ) in the S&T cable trough NMRCL MARCH

328 6 INTERFACING WITH E&M CONTRACTORS IN STATIONS AND DEPOTS (E&M) 7.1 GENERAL Different Consultants / Contractors are assigned for the design and construction of various E&M facilities, including lighting, pumps, escalators, elevators, D.G. sets etc in the stations and in the Depots. These Consultants / Contractors are collectively referred to as E&M. The N1TR02/2016 Contractor is responsible for supply and erection of various equipments in the Auxiliary Substations at the stations and Depots to step down the 33 kv Auxiliary power to 415 V AC and supply to the Station Auxiliaries. N1TR02/2016 shall interface with E&M for various items of work. 7.2 ITEMS OF INTERFACE The mains items of Interface are V AC Distribution Board Connection from Transformer to MDB kv / 415 V Auxiliary Transformer protection Low voltage protection Transformer door interlock Intertripping Lighting and Ventilation in ASS Rooms Earthing in ASS s SCADA integration of 415 V breakers main incomers and coupler in MDB 7.3 INTERFACE REQUIREMENTS The Interface requirements are described in Table NMRCL MARCH

329 Table 7.3 Interfacing with E & M Contractors in Stations Depot (E&M) Item No. Item Description N1TR02/2016 Contractor E&M Contractors (E&M) Remarks 1 a) SCADA integration of main incomers and coupling breaker of 415V AC Distribution Board (for Station) 2 a) Connection from Transformer to MDB (cables) 7 Connection from Transformer to MDB (Bus trunking) 3 33 kv / 415 Auxiliary Transformer protection 4 Transformer door interlock N1TR02/2016 will provide RTU and designated terminal board for connection of C&M cables from 415 V CBs to RTU N1TR02/2016 contractor will provide LT terminals for connection of multiple runs of 3.5 core LT cables and openings in enclosure for cable entry so that no modification on or inside the transformer enclosure is required to be done by E&M. Facilitate connections Transformers to LT Breakers, provide necessary opening in enclosure suitable reinforced to strengthen and prevent sagging of enclsure N1TR02/2016 will coordinate relay settings on transformer primary side with those of secondary side provided by E&M Wiring and interlock for transformer enclosure door will be provided by N1TR02/2016. E&M will provide C&M cable connection from MDB to RTU in the designated terminal board. E&M will provide cable paths and will connect the Transformer to thelv Distribution Board by means ofsuitable cables, as per specifications, for each connection Depot E&M contractor will do Supply and Installation of LT Switch board in the ASS Room and Realize connections Transformer to 415 V Switch Board by means of Bus Duct (Sandwich Type) or cables as required E&M will do the same at secondary end. Will install interlock supplied by NGP 1&2 on MDB 5 Supply and commissioning of cable to be laid to charge the ACDB This activity is in scope of N1TR02/2016 Contractor. E&M contractor shall connect the cable at EPP Panel. NMRCL MARCH

330 inside the ASS 6 Intertripping between main LV Circuit Breakers and the 33 kv MV Circuit Breakers of the The intertripping circuits, as per requirements shown in specifications, will be provided by N1TR02/2016, for stations. - Auxiliary Transformers 7 Lighting and Ventilation in ASS Rooms N1TR02/2016 will advise to the E&M any special requirements or preferred locations of lights, fans and exhaust fans. 8 Earthing in ASS s N1TR02/2016 will provide 9 Earthing of depot sheds, track support structure in IBL an Earth bus inside the ASS, to which various metallic objects will be connected through suitable G.I. flats, by the N1TR02/2016. Connection from the Earth bus / transformer neutral to the METs (Main Earthing Terminals) in ASS will be provided by N1TR02/2016. N1TR02/2016 will provide earthing drawing E&M will provide Lighting and ventilation arrangements. Earth mesh in the Station or Depot will be provided by E&M. Interconnection between the ASS MET and Station or Depot earth will be provided by E & M Contractor on ground. METs as required by N1TR02/2016will be provided by E&M. Will provide earthing as per drawing under the floor or as required and connection to earthing stations NMRCL MARCH

331 8 INTERFACES WITH DEPOT CONTRACTOR (Depot ) 8.1 Mihan depot is being constructed in North South Corridor and is connected to Priority Section. 8.2 The N1TR02/2016 contractor shall interface with the Depot Civil woks consultant and the Civil contractor on the following issues Support of OHE in Workshop, Inspection Bays and Stabling Lines Provision of facilities in ASS Room and Depot Control Room Provision of Cable routes for HT Cables and control cables Provision of OHE Maintenance depot and Storage facilities Provision of OHE foundations inside the DEPOT. 8.3 The interface requirements are described in Table 8.3 NMRCL MARCH

332 Table 8.3 Interfaces with Depot Contractor Item No Item Description N1TR02/2016 Depot Contractor (Depot) Remarks 1 Feeding Post Install equipments in the Feeding Post Prepare a space as per the drawing.. 2 Installation of OHE in Workshop (Inspection Bay), Stabling shed, Interior cleaning Plant Realize supporting structure preparation for OHE suspension / bracket assemblies on the columns and Emergency Equipment and drop arms fixed on Building. trusses as per specific detailed drawings. The overall weight to be taken in to account is 500 kg at each suspension. 3 ASS room preparation according to drawing and the following criteria: ASS room layout principle - Preparation of ASS Room as per drawings and specification - Possibility of concrete refilling 0.3m depth. - Floor and walls prepared with antidust paint. - 2 doors 2x3 m with anti-panic system (bar across the door facilitating its opening) - Low voltage installations (Lighting, Socket, fans, ventilation, fire protection) - Transformers access from the nearest suitable road) Supply of Interface drawings including requirements of mounting plates on columns and drop arms fixed to the trusses, supports for termination arrangements on beams/ slabs etc., for various buildings. Supply and install bracket assemblies with fastening devices on the columns and drop arms. Supply Interfacing drawings Prepare the ASS room as per the drawing and criteria. NMRCL MARCH

333 4 OHE Power supply and SCADA to Depot according to drawing and the following criteria : - Preparation of Room as per drawings - Floor and walls prepared with antidust paint. - Each room equipped with a door 2.5 m with anti-panic system(bar across the door facilitating its opening) - Low voltage installations (lighting, socket, fans, ventilation, fire protection ) - Open access to the tower wagon depot 3m high fence around the depot open storage with 3x3m double gate. 5 Earthing in ASS s Supply Interfacing drawings. Install spares and Parts and Maintenance tools N1TR02/2016will provide an Earth bus inside the ASS, to which various metallic objects will be connected through suitable G.I. flats, by the N1TR02/2016. Connection from the Earth bus / transformer neutral to the METs (Main Earthing Terminals) in ASS will be provided by N1TR02/2016 Prepare the rooms and spaces as per the drawings and criteria. Earth mesh in the Station or Depot will be provided by depot E&M contractor. Interconnection between the ASS MET and Station or Depot earth will be provided by depot E& M Contractor on ground. METs as required by N1TR02/2016 will be provided by E&M. 6 Cable route from ASS Room to: - DCC for telecommunication cables - Viaduct S&T cable trough for FP C&M Cables, RTU communication cables. Cable support supply and installation inside the ASS rooms. Coordinate with civil contractors to ensure cable routing continuity; Cable supply, installation and connection. Cable support supply and installation all the route outside ASS, according to the cable routing principle and the following criteria: - Cable bending radius - Possibility to fasten cables - Cable route hidden in public areas. NMRCL MARCH

334 7 8 9 Masonary Cable ducts inside ASS Earthing of depot sheds, track support structure in IBL OHE foundations in the Depot N1TR02/2016 will prov drawings and cable brackets Will provide cable ducts /trays inside ducts. Will provide earthing as per drawing under the N1TR02/2016 will floor or as required and earthing drawing connection to earthing stations N1TR02/2016 contractor shall provide the design for the OHE foundation. N1TR02/2016 Contractor shall provide the requisite details to the civil contractor and supervise the work, Depot Civil contractor shall cast the foundations as per the design provided by N1TR02/ INTERFACE WITH POWER SUPPLY AUTHORITIES (PSA) 9.1 ITEMS OF INTERFACE Power Supply required for Traction and Auxiliary purposes will be obtained from MSETCL / MSEDCL or other Power supply agencies as the case may be. These Agencies are collectively referred to as Power Supply Authority (PSA) and the N1TR02/2016 Contractor is required to interface with the PSA for the following items - Take-off points at PSA Substations - Protection Co-ordination - Metering Equipment - Data exchange. 9.2 INTERFACE REQUIREMENTS The Interface requirements are described in Table 9.2 & Table 9.3. Table 9.2 Interfacing Requirements with PSA Item Item Description N1TR02/2016 Contractor PSA Remarks No. 1. Take-off points at PSA Substations N1TR02/2016contractor will ordinate with PSA to ensure PSA will indicate at site as well as schematically the that the necessary CB s and arrangements for the instrument transformers are outgoing feeders to the provided by PSA in their LMRC Substations from switchyard for necessary PSA Substations. protection and measurement. N1TR02/2016 contractor will provide cable terminations, cable paths, cable support structure inside PSA NMRCL MARCH

335 substation for LMRC HT feeder cables. 2. Protection Coordination N1TR02/2016 contractor will prepare a self-explanatory document, describing the various protective devices, relays etc and submit to PSA. 3. Metering equipment N1TR02/2016 Contractor will provide necessary check meters for measurement of voltage, current, p.f, kva, kvarh, kwh, at the LMRC RSS. 4. Data exchange N1TR02/2016 contractor will indicate to the PSA the list of data/information which, LMRC would like to send to and receive from PSA. For exchange of data, N1TR02/2016 contractor will deploy digital relays and communication cables and. Permanent phoneswill be provided by LMRC Telecom Contractor. 5. Cable protection N1TR02/2016 contractor will provide the necessary protection arrangements (Line differential, distance, overcurrent etc), as per design, for the Incoming HV Cables. The Relays required to be provided at the PSA end, if any, will be supplied and installed at the PSA premises, by the N1TR02/2016 contractor. PSA will verify and approve the final scheme of protection. PSA will provide necessary metering equipment on their panels at their Substations to measure kwh, kvarh, kva, p.f, current and voltage at the feeders outgoing to LMRC Substations PSA will approve the final list of data/information identified for exchange between PSA & LMRC. If any pilot wire is required to be provided, for protectionandscada, the same shall be supplied by the N1TR02/2016 contractor. The pilot wire shall be armored type. NMRCL MARCH

336 Table 9.3 Interfacing Requirements with PSA Item No. Item Description N1TR02/2016 Contractor Remarks 1. Supply and N1TR02/2016 contractor will provide cable Installation of HV trenches & cable supports inside the RSS Underground cables and proper planning for cable entry into the from PSA Substation to LMRC Substation RSS. N1TR02/2016 Contractor will supply and install the underground cables from PSA substation to LMRC RSS. 2. Cable termination structure (CTS) in the PSA Substation. 3. Cable termination box at the LMRC RSS and cable termination N1TR02/2016 contractor will provide the necessary Cable Termination Structure, supports inside the GSS/GIS of PSA substation at the appropriate designated location. For GIS, all cable termination at LMRC GIS end and PSA end will be supplied and installed by N1TR02/2016 contractor.n1tr02/2016 Contractor: 1. will supply and install the necessary cable termination boxes on the CTS. 2. will bring the HV cables up to the termination boxes and terminate them suitably. 4. Cable paths N1TR02/2016 contractor will provide the necessary cable paths, as per design, inside the RSS & PSA Substation premises i.e. from the RSS Boundary wall till the CTS. 5. Jumper connection N1TR02/2016 contractor will provide jumper connection from termination box bushing to the HV Busbar. NMRCL MARCH

337 10. INTERFACING REQUIREMENTS FOR HT CABLING WORKS The major interfacing requirements are with the following Agencies / Designers / Contractors. Power Supply Authorities RSS Contractor (N1TR02/2016) Telecom Contractor NMC, NIT and other state government authorities. MTNL / IGL/BSNL and other Utilities Interface with Power Supply Authorities (PSA) Item Item Description N1TR02/2016 Contractor PSA No. 1 Termination of cable N1TR02/2016 contractor will terminate the cables PSA will provide the at the Grid at the appropriate EHV necessary assistance to Substation of Switchgear in the PSA premises. the N1TR02/2016 PSA N1TR02/2016 contractor shall provide the contractor and approve necessary Cable Termination the arrangement and Structures along with foundations etc. in the layout. PSA will accord PSA s premises, provide Termination boxes, permission to work. connectors if any required, Electrical connections to the cable tip and their fastening, sealing between cable box enclosures and cable end parts, provide earth connections and jumpers for connecting cable end termination to the power supply take off point. 2 Cable Path inside GSS of PSA 3 Cable sheath, calculation of fault level 4 Cable Termination Structure (CTS) in the DMRC s RSS N1TR02/2016 contractor will construct cable trench as per approved design including covers for laying cables in case no spare trench or spare capacity in available trench of PSA is available. N1TR02/2016 contractor will undertake this exercise for identification and interaction. N1TR02/2016 contractor will obtain fault level from the PSA and check the rating of the cable and design of sheath N1TR02/2016 contractor will provide the necessary cable termination structure, inside the RSS 5 Cable Termination 1. N1TR02/2016 contractor will supply and box at the DMRC s RSS and cable termination install the necessary cable termination boxes on the CTS. 2. N1TR02/2016 contractor will bring the EHV cables up to the termination boxes and terminate them suitably 6 Cable Paths N1TR02/2016 contractor will provide cable paths from the PSA Substation up to the RSS Boundary wall. N1TR02/2016 contractor will provide the necessary cable paths, as per design, inside the PSA will permit laying of cables in existing trench or separable trench if available in the GSS. PSA will permit and approve construction and design of new trench for laying cables if no trench is available. PSA will provide fault level and short circuit power. NMRCL MARCH

338 7 Cable for SCADA and Protection RSS premises i.e., from the RSS Boundary wall till the CTS. Pilot wire required, if any, will be supplied and installed by the N1TR02/2016 contractor, as per design. Copper-core and/or Optic fibre cable, if any supplied will also be installed by N1TR02/2016 contractor. N1TR02/2016 contractor will provide the necessary protection arrangements (Line differential, distance, overcurrent etc), as per design, for the Incoming HV Cables. The Relays required to be provided at the PSA end, if any, will be supplied and installed at the PSA premises, by the N1TR02/2016 contractor. If any pilot wire and terminations for OFC/CAT5 is required to be provided, for protection, the same shall be supplied by the N1TR02/2016contractor. 8 Terminations N1TR02/2016 contractor will provide all cable end terminations and erect these in consultation with PSA for Air insulated switchgear. NMRCL MARCH

339 Interface with NIT, NMC /CIVIC AUTHORITIES AUTHORITIES The N1TR02/2016 Contractor, in the course of survey, execution, testing and commissioning shall maintain constant interface with NIT, NMC & CIVIC AUTHORITIES to obtain All permissions and approvals including payment of fees/ restoration charges/ penalties/ demurrages. Clearances for digging along pavements / roads, as necessary Restoration of the sites, as required under terms of agreement with LDA/ Muncipal Corporation /Lucknow CIVIC AUTHORITIES and final clearance to be obtained Interface with IGL /BSNL and other Utilities authorities The N1TR02/2016 Contractor, in the course of survey, execution and testing and commissioning shall maintain constant interface with IGL/ BSNL and other utilities authorities to ensure that The functioning of the utilities is not jeopardized by the actions of the N1TR02/2016 Contractor No damage is caused to the utilities And, if any, work is carried out in the vicinity or on the utilities; the status-quo-ante is restored to the satisfaction of the Utilities. Obtaining No objection and final clearance as required including payment of fees/restoration Charges/penalties/demurrages. NMRCL MARCH

340 APPENDIX B TECHNICAL SHEETS Expected values given in this appendix are tentative and shall be updated as per contractor detail design with notice of no objection from employer representative. 1. MAIN TRACTION TRANSFORMER General Spec RDSO TI/SPC/PSI/30TRN/ / 25 kv Traction Main Transformer INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Manufacturer drawing reference Standards IEC 60076, IEC 60137, IEC 60296, 1) ELECTRICAL CHARACTERISTICS Type Coupling Outdoor I.i Rated frequency Hz 50 Rated power MVA 3 Cooling mode ONAN Primary rated insulation voltage kv 52 Primary operating voltage kv 33 Rated short duration power frequency withstand voltage for primary winding kv RMS 275 Rated lightning impulse withstand voltage for primary winding kv peak 650 Primary line ends Secondary rated insulation voltage kv 29 Secondary rated operation voltage under load kv 27.5 Rated short duration power frequency withstand voltage for secondary winding kv 95 NMRCL MARCH

341 Rated lightning impulse withstand voltage for secondary winding kv 250 Maximum Iron losses kw 8 Magnetic Loading Tesla <1.55 Short-circuit voltage - On load tap changer on tap 1 - On load tap changer on median tap - On load tap changer on tap 16 % % % Voltage drop at secondary winding 4/4 of secondary load V Permissible overload duration with: - 10% overload starting from 4/4, 3/4, 2/4, ¼ rated output - 25 % overload - 50 % overload starting from 4/4, 3/4, 2/4, ¼ rated output - 100% overload staring from 4/4, 3/4, 2/4, ¼ rated output h h h h Maximum Copper losses - 4/4 of secondary load kw 12 Short circuit current at secondary - On load tap changer on tap 1 - On load tap changer on median tap (Normal Tap) - On load tap changer on tap 16 ka ka ka Transformation ratio - On load tap changer on tap 1 - On load tap changer on median tap - On load tap changer on tap / / / 27.5 Power at primary winding - 4/4 of secondary load, power factor 0,95 MVA Impedance voltage % 13.8(Max) Duration of admissible short-circuit seconds 3 Efficiency (not accounting for the power drawn by the secondary) - 4/4 of secondary load, power factor 0,95 NMRCL MARCH

342 Temperature rise at thermal stabilization at secondary at 4/4 load - for copper - for magnetic sheets - for oil Temperatures allowable occasionally and temporarily without limitation of the unit service life - for copper - for magnetic sheets - for oil Allowable overload on secondary in permanent duty, power factor 0,9, ambient temperature 45 C C C C C C C MVA ) CONSTRUCTION CHARACTERISTICS Winding type On load tap changer type - Rating - Number of taps - Voltage corresponding to each tap 3) DIMENSIONAL CHARACTERISTICS Transformer Overall dimension * - Length - Width - Height Weight * - of transformer in operating condition - of oil - detanked weight Rolling tracks (between inner faces of the rails) spacing - large axis - small axis - rail profile Preserver - Oil weight * - Installation height mm mm mm kg kg kg m m kg mm NMRCL MARCH

343 Main parcel : - Length/Width/Height - weight - with oil - with insert gas mm kg kg Handling, i.e. under hooks height required for travelling crane to enable handling - complete transformer - main parcel placed on the trailer mm mm Overall dimension drawing number 4) NOISE LEVEL Transformer alone (per testing mode stipulated in IEC standards) dba - Overall noise level - at rated voltage and no load - at 110% of rated voltage and no load - at maximum over-induction - Fans running 5) MISCELLANEOUS INFORMATION dba dba dba dba dba 70 Thermal time constant - of oil - of transformer h h Maximum value of energizing current at no load Value of direct and reverse impedance - as seen from primary terminals - as seen from secondary terminals Value of zero sequence impedance - as seen from primary terminals - as seen from secondary terminals A peak Degree of protection for auxiliary circuit IP55 (* Approximate only) NMRCL MARCH

344 1.2 On Load Tap Changer for 33 / 25 kv Transformer INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Manufacturer drawing reference Standards IEC ) ELECTRICAL CHARACTERISTICS Rated frequency Hz 50 Cooling mode ONAN Rated insulation voltage kv 52 Operating voltage kv 33 Rated short duration power frequency withstand voltage kv RMS 275 Rated lightning impulse withstand voltage kv peak 650 Rated current Short-circuit withstand current - Thermal (2 seconds) - Dynamic A ka RMS ka peak Tap voltage V 2200 Number of taps 15 (+6, -9) Mechanical and electrical contact reliability Operatio ns 50,000 Motor drive Technical data - Rated voltage - Rated current V DC or AC 110 V DC/ 230 V (1 Ph)/ 415 V (3Ph) NMRCL MARCH

345 Protection system - Over current protection device - Other protections Degree of protection for Auxiliary cubicle RS 1000 IP55 2. HIGH VOLTAGE EQUIPMENTS 42 kv Surge Arresters INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Manufacturer drawing reference Standard IEC 99-4 Type of substation Type Surge arrester type Open Outdoor ZnO Rated system voltage kv 33 Rated voltage for surge arrester kv 42 Permanent voltage kv 33 Nominal discharge current ka 22 Discharge class 4 Energy absorbs in 2 shocks kj/kv 9,5 Maximum residual voltage (wave impulse 8/20 s) 10 ka 20 ka kv kv Pressure relief withstand Current time ka ms Minimum admissible static flexion moment m.dan 350 NMRCL MARCH

346 3 33kV Cables DESCRIPTION UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Cable Size Sq.mm Cable type CU/XLPE/PVC Voltage Grade (U 0 /U (U 2 ) kv 19/33 (36) Reference Standard IEC No. and cross sectional area of conductor Conductor Material Copper Shape Circular compact stranded Class/Standard Class 2/ IEC 228 Nominal Diameter of Conductor Conductor Screen materials Nominal thickness of conductor screen Insulation material Nominal thickness of insulation Nominal diameter over insulation Insulation screen material (Non-metallic) Nominal thickness of insulation screen Insulation screen material (metallic) Nominal thickness of tape mm mm mm mm mm mm Extruded semiconducting compound XLPE Extruded semiconducting com'd Copper wires No. and Diameter of wires No. /mm - Cross sectional area Outer sheath material Sq mm Flame retardant polyvinyl chloride Nominal thickness of outer sheath Nominal overall diameter (± 2mm) Minimum bending radius Max. DC Conductor resistance at 20 o C Max. AC Conductor resistance at 65 o C Star reactance per phase at 50 Hz Capacitance per phase mm mm mm Ω/km Ω/km Ω/km µf/km NMRCL MARCH

347 Charging current per phase at U 0, 50 Hz A/km DESCRIPTION UNIT EXPECTED VALUES VALUES SUBMITTED Max. Current rating in air A Max. Current rating in Ground A Max. Conductor temperature on continuous Max. conductor temperature in short Circuit Max. short Circuit current rating t = 0.1 sec o C o C KA 89.7 t = 0.2 sec KA 63.4 t = 0.5 sec KA 40.1 t = 1.0 sec KA 28.4 Length marking: Length shall be marked with number at one meter intervals on the sheath. NMRCL MARCH

348 425kV Cables INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Reference Standard IEC Voltage Grade kv 26/45 (52) Operating Voltage kv 27.5 Cable type Copper / XLPE / PVC Cable size Sq mm 400 / 240 Conducting Core Conductor diameter Core Screen Thickness of Core Screen Insulation Thickness of Insulation Insulating Envelope Screen Thickness of insulation screen Outer Sheath Thickness of outer sheath Nominal Overall diameter of cable Approximate weight of cable Minimum Bending Radius mm mm mm mm mm Kg/km m Annealed copper, Class 2 / IEC 228 Extruded Semiconducting Extruded solid dielectric made of XLPE with tolerance as per IEC Non-metallic part of semiconducting material plus metallic part consisting of standard wire and copper tape, rated to carry a short circuit current of 14 ka. PVC NMRCL MARCH

349 5. 33 KV SWITCHGEAR KV Circuit-Breaker cubicles INDICATIONS UNIT Manufacturer Place of manufacture Standards 1) CUBICLE (FIXED PART) EXPECTED VALUES IEC 298, IEC VALUES SUBMITTED - Class Indoor - Rated insulation voltage kv 36 - Rated operating voltage kv 33 - Rated frequency Hz 50 - Rated short time duration power frequency withstand voltage kv RMS 70 - Rated lightning impulse withstand voltage kv peak Rated short time duration power frequency withstand voltage across isolating distance kv RMS 80 - Rated lightning impulse withstand voltage across isolating distance kv peak Cubicle rated current A Bar set rated current A Allowable over current for 1 second ka RMS 25 - Instantaneous over current ka peak Number of flip-flop contacts for circuit-breaker plugging-in and plugging-out monitoring - Number of flip-flop contact for earthing isolator open/closed position monitoring - Number of flip-flop contacts for isolator open/closed position monitoring minimum minimum minimum - Maximum dimensions of the cubicle - Width - Depth - Height - Depth with circuit-breaker plugged-out mm mm mm mm - Protection degree IP 3X NMRCL MARCH

350 - Overall dimension drawing number 2) CIRCUIT-BREAKER (MOVABLE PART) Three pole type Yes - Rated insulation voltage kv 36 - Rated operating voltage kv 33 - Rated frequency Hz 50 - Rated short time duration power frequency withstand voltage kv RMS 70 - Rated lightning impulse withstand voltage kv peak Rated short time duration power frequency withstand voltage across isolating distance kv RMS 80 - Rated lightning impulse withstand voltage across isolating distance kv peak Rated current A Allowable over current for 1 second ka RMS 25 - Instantaneous over current ka peak Breaking capacity ka RMS 25 - Making capacity ka peak 62.5 Breaking mode: - Opening time - Breaking time - Closing time ms ms ms Rated operating cycle O-CO-3 -CO - Breaking capacity of cable at no load A - Number of auxiliary contact for open/closed position of the circuit-breaker O/O O/C - Auxiliary supply voltage V DC Supply voltage for motor drive circuits V DC Allowable variation range of supply voltage +10%, -15% - Power consumption of auxiliary VA Coils consumption: - engagement coil - release coil - Consumption of arming motor A A A NMRCL MARCH

351 - Maximum noise level during opening and closing actuation db Degree of protection for auxiliary circuit IP3X NMRCL MARCH

352 kv Current Transformer (Incomer, Coupler) INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Standards IEC Rated insulation voltage kv 36 - Operating voltage kv 33 - Rated frequency Hz 50 - Rated power frequency short duration withstand voltage kv 70 - Rated lightning impulse withstand voltage kv 170 Actual transformation ratio Protection secondary - Accuracy class - Rated output A VA /5/5 5P15 20 Measuring secondary - Accuracy class - Rated output VA 0,5 15 Short-circuit current allowable for 1 seconds ka 25 Permanent operation without danger In Overheating In Over current class kv Current Transformer for Line Outgoing Feeders, Spare Feeders INDICATIONS Manufacturer Place of manufacture UNIT EXPECTED VALUES Standards IEC 44-1 VALUES SUBMITTED NMRCL MARCH

353 - Rated insulation voltage kv 36 - Operating voltage kv 33 - Rated power frequency short duration withstand voltage kv 70 - Rated lightning impulse withstand voltage kv Rated frequency Hz 50 Actual transformation ratio A /5 Protection secondary - Accuracy class - Rated output Measuring secondary - Accuracy class - Rated output VA 5P15 20 VA 0,5 15 Short-circuit current allowable for 1 seconds ka 25 Permanent operation without danger Overheating Over current class kv Current Transformer for Station Auxiliary Transformer Feeder INDICATIONS Manufacturer Place of manufacture In In UNIT EXPECTED VALUES Standards IEC Rated insulation voltage kv 36 - Operating voltage kv 33 - Rated power frequency short duration withstand voltage kv 70 - Rated lightning impulse withstand voltage kv Rated frequency Hz 50 Actual transformation ratio A 20-10/5/5 Protection secondary - Accuracy class - Rated output Measuring secondary - Accuracy class - Rated output VA 5P15 20 VA 0,5 15 Short-circuit current allowable for 1 seconds ka 25 Permanent operation without danger Overheating Over current class In In VALUES SUBMITTED NMRCL MARCH

354 INDICATIONS kv Voltage Transformers (Incomers) UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Standards IEC Primary insulation voltage kv 36 - Operating voltage kv 33 - Rated frequency Hz 50 - Rated short-time duration power frequency withstand voltage kv 70 - Rated lightning impulse withstand voltage kv 170 Actual transformation ratio - Primary winding - 1st secondary winding - 2nd secondary winding kv V V 33/ 110/ 110/ Accuracy class - 1st secondary winding - 2nd secondary winding 0,5 3P Rated output - 1st secondary winding - 2nd secondary winding VA VA NMRCL MARCH

355 kv Voltage Transformers (Coupling Bay) INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Standards IEC Primary insulation voltage kv 36 - Operating voltage kv 33 - Rated frequency Hz 50 - Rated short-time duration power frequency withstand voltage kv 70 - Rated lightning impulse withstand voltage kv 170 Actual transformation ratio - Primary winding - secondary winding kv V 33/ 110/ 3 3 Accuracy class 3P Rated output VA 60 NMRCL MARCH

356 5.7 Tank Protection Current Transformers INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Standards IEC 44-1 Voltage / earth insulation kv 1.2 Frequency Hz 50 CT insulation type Erection Impulse Cast resin Outdoor Rated Impulse withstand (1.2/50 micro second) kv peak Rated Power frequency withstand voltage-one minute kv RMS 5 Insulation withstand voltage (permanent) kv 3 Transformation Ratio /1 Precision Power VA 5 Precision Class 3 Withstand Over-current(1s /peaks) ka 1 / 5 Degree of protection for auxiliary circuit IP55 NMRCL MARCH

357 5.7 Circuit-Breaker Cubicles MVCB 2) CIRCUIT-BREAKER (MOVABLE PART) INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Standards IEC 298, 56 1) CUBICLE (FIXED PART) - Class Indoor - Rated insulation voltage kv 36 - Rated operating voltage kv 33 - Rated frequency Hz 50 - Rated short time duration power frequency withstand voltage kv RMS 70 - Rated lightning impulse withstand voltage kv peak Cubicle rated current A Bar set rated current A Allowable over current for 3 second ka RMS 12,5 - Instantaneous over current ka peak 31,5 - Number of flip-flop contacts for circuit-breaker plugging-in and plugging-out monitoring - Number of flip-flop contact for earthing isolator open/closed position monitoring - Number of flip-flop contacts for isolator open/closed position monitoring - Maximum dimensions of the cubicle - Width - Depth - Height - Depth with circuit-breaker plugged-out minimum minimum minimum mm mm mm mm - Protection degree IP 3X - Earthing isolator making capacity ka 5 NMRCL MARCH

358 - Overall dimension drawing number Three pole type Yes - Rated insulation voltage kv 36 - Rated operating voltage kv 33 - Rated frequency Hz 50 - Rated short time duration power frequency withstand voltage kv RMS 70 - Rated lightning impulse withstand voltage kv peak Rated short time duration power frequency withstand voltage across isolating distance kv RMS 80 - Rated lightning impulse withstand voltage across isolating distance kv peak Rated current A Allowable over current for 3 second ka RMS 12,5 - Instantaneous over current ka peak 31,5 - Breaking capacity ka RMS 12,5 - Making capacity ka peak 31,5 Breaking mode: - Opening time - Breaking time - Closing time ms ms ms Rated operating cycle O-CO-3 -CO - Breaking capacity of cable at no load A - Number of auxiliary contact for open/closed position of the circuit-breaker O/O O/C - Auxiliary supply voltage V DC 110 Supply voltage for motor drive circuits V DC Allowable variation range of supply voltage +10%, -15% - Power consumption of auxiliary VA - Coils consumption: - engagement coil - release coil - Consumption of arming motor A A A NMRCL MARCH

359 - Maximum noise level during opening and closing actuation db Degree of protection for auxiliary circuit IP3X INDICATIONS Manufacturer 5.8 Interrupter Cubicles, Interrupter and Coupling Interrupter Place of manufacture UNIT EXPECTED VALUES Standards IEC 298, ) CUBICLE - Class Indoor - Rated insulation voltage kv 36 - Rated operating voltage kv 33 - Rated frequency Hz 50 VALUES SUBMITTED - Rated short time duration power frequency withstand voltage kv RMS 70 - Rated lightning impulse withstand voltage kv peak Cubicle rated current A Bar set rated current A Allowable over current for 3 second ka RMS 12,5 - Instantaneous over current ka peak 31,5 - Number of flip-flop contacts for circuit-breaker plugging-in and plugging-out monitoring - Number of flip-flop contact for earthling isolator open/closed position monitoring - Number of flip-flop contacts for isolator open/closed position monitoring minimum minimum minimum NMRCL MARCH

360 - Maximum dimensions of the cubicle - Width - Depth - Height - Depth with circuit-breaker plugged-out mm mm mm mm - Protection degree IP 3X - Earthing isolator making capacity ka 5 - Overall dimension drawing number 2) INTERRUPTER Three pole type Yes - Rated insulation voltage kv 36 - Rated operating voltage kv 33 - Rated frequency Hz 50 - Rated short time duration power frequency withstand voltage kv RMS 70 - Rated lightning impulse withstand voltage kv peak Rated short time duration power frequency withstand voltage across isolating distance kv RMS 80 - Rated lightning impulse withstand voltage across isolating distance kv peak Rated current A Allowable overcurrent for 3 second ka RMS 12,5 - Instantaneous overcurrent ka peak 31,5 - Breaking capacity A RMS Making capacity ka peak 31,5 - Breaking mode: - Opening time ms 70 - Breaking time ms 80 - Closing time ms Number of auxiliary contact for open/closed position of the circuit-breaker O/O O/C NMRCL MARCH

361 - Auxiliary supply voltage V DC 110 Supply voltage for motor drive circuits V DC Allowable variation range of supply voltage +10%, -15% - Power consumption of auxiliary VA - Consumption of arming motor A - Maximum noise level during opening and closing actuation db Degree of protection for auxiliary circuit IP3X NMRCL MARCH

362 INDICATIONS kv Current Transformer for MVCB Cell UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Standards IEC Rated insulation voltage kv 36 - Operating voltage kv 33 - Rated frequency Hz 50 - Rated power frequency short duration withstand voltage kv 70 - Rated lightning impulse withstand voltage kv 170 Actual transformation ratio A 25/5 Protection secondary - Accuracy class - Rated output VA 5P15 10 Measuring secondary - Accuracy class - Rated output VA 0,5 15 Short-circuit current allowable for 3 seconds ka 12,5 Permanent operation without danger Overheating In In Overcurrent class NMRCL MARCH

363 INDICATIONS 5.10 Current Transformer for interrupter Cell UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Standards IEC 44_1 - Type toroidal Actual transformation ratio A 25/5 Protection secondary - Accuracy class - Rated output VA 5P15 10 Short-circuit current allowable for 3 seconds ka 12,5 Permanent operation without danger Overheating In In Overcurrent class NMRCL MARCH

364 INDICATIONS kv Voltage Transformers UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Standards IEC Primary insulation voltage kv 36 - Operating voltage kv 33 - Rated frequency Hz 50 - Rated short-time duration power frequency withstand voltage kv 70 - Rated lightning impulse withstand voltage kv 170 Actual transformation ratio - Primary winding - secondary winding kv V 3 3/ 11 0/ 3 3 Accuracy class 3P Rated output VA 30 NMRCL MARCH

365 6. 25 KV SWITCHGEAR kV Circuit Breaker INDICATIONS UNIT EXPECTED VALUES Manufacturer Manufacturer drawing reference Standards IEC 60694& Type Indoor/Outdoor Rated voltage kv 25 VALUES SUBMITTED Rated frequency Hz 50 Number of phases 1 Type of mechanism Spring Maximum service voltage (permanent) kv 27.5 Rated insulation voltage level kv 40 Rated current A 1250 Rated power frequency withstand voltage for one minute Rated impulse withstand (1.2 / 50 microsecond) voltage for primary winding kv RMS 95 kv peak 250 Rated short circuit making capacity ka 40 Rated Short circuit current breaking capacity ka 16-3 sec Rated operating sequence CO-15 sec-co Maximum closing time ms 100 Maximum opening time ms 70 Insulation material composite Motor power W 250 Motor service voltage V DC 110 Auxiliaries contacts 8 NO + 8 NC Maximum starting current at 110 V DC Mechanical life time A Cycles Temperature range C Maximum weight kg Degree of protection IP55 NMRCL MARCH

366 6.2 25kV Interrupters INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Manufacturer drawing reference Standards IEC 60694& Type Indoor/Outdoor Rated voltage kv 25 Rated frequency Hz 50 Number of phases 1 Maximum service voltage (permanent) kv 27.5 Rated insulation voltage level kv 40 Rated current A 1250 Rated short circuit making capacity ka 40 Rated Short circuit current breaking capacity ka 16-3 sec Rated power frequency withstand voltage for one minute Rated impulse withstand (1.2 / 50 microsecond) voltage for primary winding Rated operating sequence kv rms 95 kv peak 250 CO-15 sec-co Maximum closing time ms 100 Maximum opening time ms 70 Insulation material composite Motor power W Motor service voltage V DC 110 Maximum starting current at 110 V DC A Mechanical life time Cycles 50,000 Aux.contacts 8 NO + 8 NC Temperature range C Max.weight Kgf 160 Degree of protection IP55 NMRCL MARCH

367 6.3 25kV Isolator INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Manufacturer drawing reference Standards IEC 60694& Electrical characteristics: Type Indoor/Outdoor Rated voltage kv 25 Rated frequency Hz 50 Number of phases 1 Maximum service voltage (permanent) kv 27.5 Rated insulation voltage level kv 40 Rated Operating current A 1250 Rated Bus bar current A 1250 Rated short circuit making capacity ka 40 Rated power frequency withstand voltage for one minute kv rms 95 Rated impulse withstand (1.2 / 50 microsecond) voltage for primary winding Opening / Closing mode kv peak 250 Motorised/Manual Aux.contacts 8 NO + 8 NC Aux.supply control voltage V DC 110 Mechanical life time Cycles Temperature range C Degree of protection IP55 NMRCL MARCH

368 INDICATIONS kV Current Transformer Manufacturer Manufacturer drawing reference UNIT EXPECTED VALUES Standards IEC 44-1 Type Indoor/Outdoor Rated voltage kv 25 Rated frequency Hz 50 Transformer type Cast resin Number of phases 2 Maximum service voltage (permanent) kv 27.5 Rated insulation voltage kv 40 Rated power frequency withstand voltage one minute for primary winding kv rms 95 Rated impulse withstand (1.2 / 50 microsecond) voltage for primary winding kv peak 250 Rated secondary current A 1 Creepage distance mm/kv 31 VALUES SUBMITTED Secondary core, CT between Transformer and 25 kv Breaker side Core1 (Protection) Core2 (Protection) /1, 30VA, 5P /1, 30VA, 5P15 Core3 (Metering) /1, 20VA, 0.5CL Secondary core, CT between 25 kv breaker and 25 kv Bus bar side Core1 (Protection) /1, 30VA, 5P15 Core2 (Metering) /1, 20VA, 0.5CL Withstand Over current ( Is / peaks ) ka 20/40 Temperature range C Degree of protection IP55 NMRCL MARCH

369 INDICATIONS Manufacturer kV Potential Transformer Manufacturer drawing reference UNIT EXPECTED VALUES Standards IEC 44-2 Type Indoor/Outdoor Rated voltage kv 25 Rated frequency Hz 50 Number of phases 1 Maximum service voltage (permanent) kv 27.5 Rated insulation voltage kv 40 Rated power frequency withstand voltage one minute for primary winding Rated impulse withstand (1.2 / 50 microsecond) voltage for primary winding kv RMS 95 kv peak 250 Rated Primary/Secondary voltage V 25kV/ 3/110/ 3 Creepage distance mm/kv 31 Resistance of Primary winding Secondary core winding Ω Core-1 Core-2 Temperature range C Degree of protection Not <27000 Ω at 10 C 25kV/ 3/110/ 3, 30VA,Cl-1 25kV/ 3/110/ 3, 30VA,Cl-1 IP55 VALUES SUBMITTED NMRCL MARCH

370 INDICATIONS Manufacturer kV Lightning Arresters Place of Manufacture Manufacturer Drawing reference UNIT EXPECTED VALUES Standard IEC 99-4 Type of Substation Type Lightning Arrester type Open Outdoor Non-linear Metal Oxide Resistor type, gapless Nominal System Voltage Phase to Earth kv 27 Nominal System Voltage Phase to Phase Rated Voltage for lightning Arrester kv 42 Line discharge class 3 Nominal discharge current ka 10 Max. discharge Voltage at nominal discharge current Power frequency withstand voltage for arrester housing Pressure Relief Class kv kv 125 kv 105 A VALUES SUBMITTED NMRCL MARCH

371 6.7 25kV isolator (opening or closing manual or motorized, pole mounted) INDICATIONS Manufacturer Manufacturer drawing reference Standards Type UNIT EXPECTED VALUES IEC 60694& Outdoor Rated voltage kv 25 Rated frequency Hz 50 Number of phases 1 Maximum service voltage (permanent) kv 27.5 Rated insulation voltage level kv 40 Rated Operating current A 1250 Rated Bus bar current A 1250 Rated short circuit making capacity ka 40 Rated power frequency withstand voltage for one minute Rated impulse withstand (1.2 / 50 microsecond) voltage for primary winding Aux.contacts kv RMS 95 kv peak NO + 8 NC Aux.supply control voltage V DC 110 Mechanical life time Cycles Temperature range C Degree of protection IP55 VALUES SUBMITTED NMRCL MARCH

372 6.8 25kV motorized circuit breaker (pole mounted) INDICATIONS UNIT EXPECTED VALUES Manufacturer Manufacturer drawing reference Standards IEC 60694& Type Outdoor Rated voltage kv 25 VALUES SUBMITTED Rated frequency Hz 50 Number of phases 1 Type of mechanism Spring Maximum service voltage (permanent) kv 27.5 Rated insulation voltage level kv 40 Rated current A 1250 Rated power frequency withstand voltage for one minute kv RMS 95 Rated impulse withstand (1.2 / 50 microsecond) voltage for primary winding kv peak 250 Rated short circuit making capacity ka 40 Rated Short circuit current breaking capacity ka 16-3 sec Rated operating sequence CO-15 sec-co Maximum closing time ms 100 Maximum opening time ms 70 Insulation material ceramic Motor power W 250 Motor service voltage V DC 110 Aux.contacts 8 NO + 8 NC Starting current A 7 A max at 110 V dc Mechanical life time Cycles 50,000 Temperature range C Maximum weight Kg 140 Degree of protection IP55 NMRCL MARCH

373 7. LOW VOLTAGE EQUIPMENTS 7.1 Station Auxiliary Transformer 400 kva INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Manufacturer drawing reference Standards IEC 76 Insulation type Cast resin Rated power kva 400 Cooling mode AN Primary rated insulation voltage kv 36 Primary operating voltage kv 33 Secondary rated operating voltage V 415/240 Rated short duration power frequency withstand voltage for primary winding Rated lightning impulse withstand voltage for primary winding kv 70 kv 170 Short-circuit voltage % 4 Voltage setting (off load tap changer) % 0, 2.5, 5 Vector group Dyn11 Maximum noise level dba 68 Maximum Iron losses W % Maximum load losses W % Dimensions (maximum) - Length - Width - Height mm mm mm Weight (maximum) kg 2100 NMRCL MARCH

374 V DC Battery INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Standards IEC 622 Type Stationary compact Maintenance free Ni-Cd yes Capacity offered for 10 hours discharge duration Voltage per cell Ah V Number of cells Rated operating voltage V DC 110 Maximum output current Dimensions - Length - width Total weight A mm mm kg NMRCL MARCH

375 V DC Battery Charger INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of manufacture Standards IEC Phases power supply V AC 415 Frequency Hz 50 Rated direct voltage V DC 110 Allowable output voltage variation - for +10% variation of supply voltage - for +5% variation of frequency +1% +1% Maximum output current in permanent duty A Residual ripple ratio Dimensions - length - depth - height Total weight mm mm mm kg NMRCL MARCH

376 8. OVERHEAD CONTACT SYSTEM 8.1 Contact wire INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of Manufacture Manufacturer Drawing reference Standard Material EN 50149, UIC 870 Copper Cross section type BF-150 Maximum linear weight Minimum linear weight kg/m kg/m Coefficient of linear expansion 1/ C 17x 10-6 Minimum breaking load dan 5265 Elongation factor 91x 10-6 Equivalent copper Conductivity 98% Maximum Resistivity at 20 C µω.cm Minimum diameter of contact wire drawn out of continuous cast rod Length of wire per drum Weight of drum with contact wire Drum type mm 21 m kg Wood with mild steel frame Drum tested as per EN NMRCL MARCH

377 8.2 Messenger wire INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of Manufacture Manufacturer Drawing reference Standard RDSO SPECIFICATIO N:ETI/OHE/ 50 Material Cadmium copper Nominal cross section mm2 65 Diameter mm 10.5 Composition 19 strands, each of 2.1 mm diameter Maximum Linear weight kg/m Coefficient of linear expansion 1/ C 17x 10-6 Minimum breaking load dan 3844 Elongation factor 118x 10-6 Equivalent copper Conductivity 81% Maximum Resistivity µω.cm 2.93 Length of wire in the Drum Weight of drum with messenger wire m kg Drum type Wood with mild steel frame NMRCL MARCH

378 INDICATIONS 8.3 Overhead Protection Conductor (OPC) UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of Manufacture Manufacturer Drawing reference Standard Material IS:398(part II) Aluminium core steel reinforced (ACSR) Nominal cross section mm Diameter mm 12.5 Composition if Aluminium Composition if steel 12 wires each 2.5mm diameter 7 wires each 2.5mm diameter Maximum Linear weight kg/m Coefficient of linear expansion 1/ C 17x 10-6 Minimum breaking load dan 4610 Elongation factor 132x 10-6 Maximum Resistivity µω.cm Length of wire in the Drum Weight of drum with messenger wire m kg Drum type Wood with mild steel frame NMRCL MARCH

379 INDICATIONS Manufacturer 8.4 Burried earth cable (BEC) Place of Manufacture Manufacturer Drawing reference UNIT EXPECTED VALUES Standard IEC Voltage Grade kv 26/45 (52) Operating Voltage kv 27.5 Cable type Copper / XLPE / PVC Cable size Sq.mm 400 / 240 Conducting Core Annealed copper, Class 2 / IEC 228 Conductor diameter Core Screen Thickness of Core Screen Insulation mm mm Extruded Semi-conducting Extruded solid dielectric made of XLPE with tolerance as per IEC VALUES SUBMITTED Thickness of Insulation mm Insulating Envelope Screen Non-metallic part of semiconducting material plus metallic part consisting of standard wire and copper tape, rated to carry a short circuit current of 14 ka. Thickness of insulation screen mm Outer Sheath mm PVC Thickness of outer sheath Nominal Overall dia of cable Approx weight of cable Minimum Bending Radius mm mm kg/km m NMRCL MARCH

380 8.5 Jumper wire INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of Manufacture Manufacturer Drawing reference Material Annealed copper In span jumper - Nominal cross section - Diameter - Type mm2 mm strands, each containing 7 wires each of 0.5 mm diameter - Linear weight - Coefficient of linear expansion kg/m 1/ C x 10-6 Continuity jumper - Nominal cross section - Diameter - Type mm2 mm strands, each containing 7 wires each of 0.6 mm diameter - Linear weight - Coefficient of expansion linear kg/m 1/ C x 10-6 Feeding jumper - Nominal cross section - Diameter - Type mm2 mm strands, containing 7 wires each of 0.9 mm diameter - Linear weight - Coefficient of expansion linear kg/m 1/ C x 10-6 NMRCL MARCH

381 INDICATIONS 8.6 Dropper wire UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of Manufacture Manufacturer Drawing reference Material Bronze Nominal Cross Section mm2 12 Diameter mm 5 1 wire type one wire of 7strands, each of 0.65 mm diameter 6 wire type 6 wire of 7strands, each of 0.65 mm diameter Linear weight kg/m Coefficient of linear expansion 1/ C 17x 10-6 Minimum breaking load dan 695 Equivalent copper Conductivity 72% NMRCL MARCH

382 8.7 Mast INDICATIONS UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Manufacture place Manufacturer drawing reference Standard IS:2062, IS: 800, IS:808, RDSO SPECIFICATION:E TI/OHE/13 Galvanization Standard IS:209 Zinc coating size of galvanization Microns 85 to 100 H type mast BFB-152x152mm RSJ-203x153mm BFB-206x204mm Length m 8.5 Plate welding standard Portal - Galvanization Standard ISO-TC-44 IS Zinc coating - Welding standard Microns 85 to 100 ISO-TC-44 NMRCL MARCH

383 INDICATIONS 8.8 Insulators (for bracket, stay arm, conductor anchor) UNIT EXPECTED VALUES VALUES SUBMITTED Manufacturer Place of Manufacture Manufacturer Drawing reference Standard Type Nominal Voltage at 50 Hz ( line to earth) RDSO SPECIFICATION:TI /SPC/OHE/INSCO M/1070 Silicone composite Insulator kv 25 System voltage can go up to kv 30 Creepage distance of insulator mm 1600 Creepage value of insulator mm/kv 31 Shed and sheath material of Insulator Core material of the Insulator Made of HTV type silicone rubber having silicon content between 40-50% and preferably Alumina Tri hydrate as filler Boron free, electrically corrosion resistant grade glass fibre reinforced epoxy resin rod having at least 70% fibres by weight NMRCL MARCH

384 8.9 Short Neutral Section INDICATIONS UNIT Manufacturer EXPECTED VALUES VALUES SUBMITTED Place of Manufacture Manufacturer Drawing reference Standard Type IEC61109 EN Automatic Switched Neutral Section Current carrying capacity A 1000 Maximum short circuit current capacity ka 40 Maximum short circuit current time ms 80 Insulator Application Spark Extinguishing Insulation Resistance (Insulator without skids) Ω Fibre coated with self cleaning PTFE Outdoor/Tunnel 100%, When locomotive is not switched off while passing neutral section 1000million Creepage Distance (Insulator without skids) mm 2500 Power frequency dry withstand voltage (Insulator without skids) Power frequency dry withstand voltage (Insulator without skids) kv kv kv, 50 HZ, Vacuum switch - Manufacturer - Manufacturer location - Manufacturer Drawing reference - Application - Power frequency wet withstand voltage - Short time current rating - - Current - Time kv ka Outdoor/Tunnel 90 3 ms 500 Locomotive current NMRCL MARCH

385 Actuation of the system INDICATIONS Manufacturer 8.10 Section Insulator (conventional type) Place of Manufacture Manufacturer Drawing reference Standard Type Nominal Voltage at 50 Hz ( line to earth) UNIT EXPECTED VALUES RDSO SPECIFICATION: ETI/OHE/27 Composite Insulator kv 25 Creepage distance of insulator mm 1200 VALUES SUBMITTED NMRCL MARCH

386 INDICATIONS Manufacturer 8.11 Light weight section insulator Place of Manufacture Manufacturer Drawing reference Standard Type Nominal Voltage at 50 Hz ( line to earth) UNIT EXPECTED VALUES PROTOTYPE RDSO SPECIFICATION:TI/S PC/OHE/LWTSI/0060 Silicone composite Insulator kv 25 System voltage can go up to kv 30 Creepage distance of insulator mm 1600 Creepage value of insulator mm/kv 31 Shed and sheath material of Insulator Core material of the Insulator Made of HTV type silicone rubber having silicon content between 40-50% and preferably Alumina Tri hydrate as filler Boron free, electrically corrosion resistant grade glass fibre reinforced epoxy resin rod having at least 70% fibres by weight VALUES SUBMITTED Breaking load kn 80 Dry condition flash over kv 78.3 Wet condition flash over kv 64.5 NMRCL MARCH

387 APPENDIX C TEST SHEETS TABLE OF CONTENTS 1. AUXILIARY NETWORK /33 kv Power Transformer /33 kv On-Load Tap Changer kv Circuit Breaker Fixed Part kv Circuit Breaker Movable Part Transformer Neutral Surge Arrester Transformer Neutral Isolator Voltage Transformer Current Transformer Auxiliary Transformer Battery Charger Battery AC And DC Auxiliary Cabinets kv Interrupter Cell kv Interrupter RECEIVING SUB STATION kv Isolator (Incoming and Earthing) kv Isolator (Aux Transformer, Traction Transformer and Coupling) kV Circuit Breaker kv Current Transformer kv Voltage Transformer kv Surge Arrester TRACTION SUB STATION: /25 kv Power Transformer /25 kv On-Load Tap Changer kv Circuit Breaker kv interrupters kv Isolators kv Current Transformers kv Voltage Transformer Overhead Equipment: Contact wire Messenger wire Aerial Earth cable (AEC) Buried earth cable (BEC) Jumper wire Dropper wire...4.7mast and portal: Insulators (for bracket, stay arm, conductor anchor and section insulator) KV Short Neutral Section Rigid Overhead Contact System... NMRCL MARCH

388 1. AUXILIARY NETWORK 33 kv Circuit Breaker Fixed Part INDICATIONS TYPE of TEST Type Routine On site After Shipment Temperature rise X Lightning impulse withstand voltage test X Short circuit withstand for main & earthing circuits X Protection of persons against live parts X Internal faults arcing effects X Aux. circuits power frequency withstand voltage test X Main circuits resistance value X Power frequency withstand voltage test X All devices operation checking X Wiring X X Function X X Interlocking X X Painting & external visual inspection X * X X Exchangeability of similar devices X X X Aux. circuits insulation X Instrumentation & relays calibration X * Tests to be performed just prior shipment. NMRCL MARCH

389 kv Circuit Breaker Movable Part INDICATIONS TYPE of TEST Type Routine On site Temperature rise Lightning impulse withstand voltage test Partial discharge Over-voltage Short circuit Current making & breaking capacity Magnetizing & small inductive current switching Peaks & short time current withstand Aux. circuits dielectric withstand Main circuits resistance value Withstand voltage at 50 Hz X X X X X X X X X X Mechanical operations at rated, max. & min voltage Functioning times X X X Interlocking X X Visual inspection X X NMRCL MARCH

390 1.2 Transformer Neutral Surge Arrester INDICATIONS T YPE of TEST Type Routine On site Measurement of power-frequency sparkover voltage X Standard lighting impulse sparkover test Measurement of front-of-wave impulse sparkover-voltage X X Measurement of residual voltage Current impulse withstand test Operating duty test X X X Dry power frequency voltage spark-over test Standard lightning impulse spark-over test X X NMRCL MARCH

391 1.3 Transformer Neutral Isolator INDICATIONS TYPE of TEST Type Routine On site Temperature rise Over-voltage Peaks & short time current withstand X X X Aux. circuits dielectric withstand Main circuits resistance value Power frequency withstand voltage test X X X Mechanical operations X X Visual inspection X X 1.4 Voltage Transformer INDICATIONS TYPE of TEST Type Routine On site Temperature rise Lightning impulse withstand voltage Short circuit withstand X X X Primary windings power withstand voltage test Secondary windings power withstand voltage test Between section power withstand voltage test Transformer ratio frequency frequency frequency X X X X Terminal marking X X NMRCL MARCH

392 Visual inspection X X Exchangeability of similar devices 1.5 Current Transformer INDICATIONS X TYPE of TEST Type Routine On site Temperature rise Lightning impulse withstand voltage Short circuit withstand X X X Primary windings power frequency withstand voltage test Secondary windings power frequency withstand voltage test Between section power frequency withstand voltage test Transformer ratio X X X X Terminal marking X X Visual inspection X X Exchangeability of similar devices X 1.6 Auxiliary Transformer INDICATIONS TYPE of TEST Type Routine On site Specia ls Temperature rise* Lightning impulse withstand voltage test* X X Separate-source voltage withstand test X X Measurement of winding resistance Measurement of voltage ration and check of phase displacement Measurement of no load loss and current X X X NMRCL MARCH

393 Visual inspection X X * For this type test, the Contractor could provide a report of less than 5 years on similar equipment 1.10 Battery Charger INDICATIONS TYPE of TEST Type Routine On site Specials Temperature rise* X Power frequency withstand voltage test Floating operation mode test Equalization operation mode test Direct operation mode test Protection devices operation Setting test X X X X X X Visual inspection X X * For this type test, the Contractor could provide a report of less than 5 years on similar equipment 1.11 Battery INDICATIONS TYPE of TEST Type Routine On site Specials Electrical specifications checking (on one cell) X Visual inspection X X Capacity measurement Endurance test Overload aptitude test X X X 1.12 AC And DC Auxiliary Cabinets INDICATIONS TYPE of TEST Type Routine On site Specials Rated short duration power frequency withstand voltage test X X NMRCL MARCH

394 Operation checking Visual inspection X X X NMRCL MARCH

395 kv Interrupter Cell INDICATIONS TYPE of TEST Type Routine On site After Shipment Temperature rise Lightning impulse withstand voltage test Short circuit withstand for main & earthing circuits Protection of persons against live parts Internal faults arcing effects X X X X X Aux. circuits power frequency withstand voltage test Main circuits resistance value Power frequency withstand voltage All devices operation checking X X X X Wiring X X Function X X Interlocking X X Painting & external visual inspection X * X X Exchangeability of similar devices X X X Aux. circuits insulation Instrumentation & relays calibration X X * Tests to be performed just prior shipment. NMRCL MARCH

396 kv Interrupter INDICATIONS TYPE of TEST Type Routine On site Temperature rise X Lightning impulse withstand voltage test X Partial discharge X Over-voltage X Short circuit Current making capacity X Peaks & short time current withstand X Aux. circuits power frequency withstand voltage test X Main circuits resistance value X Power frequency withstand voltage test X Mechanical operations at rated, max. & min voltage X X Functioning times X Interlocking X X Visual inspection X X NMRCL MARCH

397 2. RECEIVING Cum Traction SUB STATION /27kV Circuit Breaker INDICATIONS TYPE of TEST Type Routine On site After Shipment Temperature rise Lightning impulse withstand voltage Short circuit withstand Protection of persons against live parts Peak and short time current withstand X X X X X Magnetizing and small inductive current switching Short circuit making and breaking capacity Aux. circuits dielectric withstand Main circuits resistance value Withstand voltage at 50 Hz All devices operation checking Wiring X X Function X X Interlocking X X Painting & external visual inspection X * X X Exchangeability of similar devices X X X Aux. circuits insulation X * Tests to be performed just prior to shipment X X X X X X NMRCL MARCH

398 3. TRACTION SUB STATION: /25kV Power Transformer INDICATIONS TYPE of TEST Measurement of zero sequence impedance Temperature rise Type Routine On site X X After Shipment Lightning impulse withstand voltage test X Measurement of noise level X Short circuit withstand test X Tank, Expansion vessel & Radiator Water tight X X Piping welds & joints Water tight X X Measurement of windings resistance X Measurement of voltage ratio and check of phase displacement X Measurement of short circuit impedance and load loss X Measurement of no-load loss & current X Power frequency withstand voltage test X X Short and long duration Induced AC withstand voltage test, with partial X discharge measurement On load tap changer functioning X X On load tap changer Aux. Circuits insulation X Painting & external visual inspection X * X X Core Insulation resistance X * X X Insulation oil breakdown strength X Aux. Circuits insulation X Aux. Circuits operation X Instrumentation & relays calibration X * Tests to be performed just prior to shipment KV On-Load Tap Changer INDICATIONS Mechanical operation Oil tank tightness Selector operation TYPE of TEST Type Routine On site X X X After Shipment NMRCL MARCH

399 These tests will be performed prior to On-load tap changer insertion into the transformer kv Circuit Breaker INDICATIONS TYPE of TEST Temperature rise Type Routine On site Mechanical operation X X Lightning impulse withstand voltage Short circuit Current making & breaking capacity Magnetizing & small inductive current switching Peaks & short time current withstand Aux. circuits dielectric withstand Main circuits resistance value Withstand voltage at 50 Hz Mechanical operations at rated, max. & min voltage Functioning times Interlocking X X Visual inspection X X X X X X X X X X X X X NMRCL MARCH

400 kv interrupters INDICATIONS TYPE of TEST Temperature rise Mechanical operation X X Lightning impulse withstand voltage Short circuit Current making & breaking capacity Magnetizing & small inductive current switching Peaks & short time current withstand Aux. circuits dielectric withstand Main circuits resistance value Withstand voltage at 50Hz Lightning withstand voltage All devices operation checking Functioning times Type Routine On site Wiring X X Interlocking X X Painting & external visual inspection X X Exchangeability of similar devices Aux. Circuits insulation X The Mechanical operation test to be done as a Routine test and shall comprise of five opening and five closing operations at each of the rated, maximum and minimum control voltages. The contact travel characteristics shall be recorded for each closing and tripping operation. X X X X X X X X X X X X kv Isolators INDICATIONS TYPE of TEST Type Routine On site Temperature rise Lightning impulse withstand voltage Peaks & short time current withstand X X X NMRCL MARCH

401 Aux. circuits dielectric withstand X Main circuits resistance value X Withstand voltage at 50Hz X All devices operation checking X Operation times X Wiring X X Interlocking X X Painting & external visual inspection X X Exchangeability of similar devices X Aux. circuits insulation X kv Current Transformers INDICATIONS TYPE of TEST Type Routine On site Temperature rise X Lightning impulse withstand voltage X Short circuit withstand X Primary windings Voltage withstand at 50 Hz X Secondary windings Voltage withstand at 50 Hz X Between section Voltage withstand at 50 Hz X Transformer ratio X Terminal marking X X Visual inspection X X Exchangeability of similar devices X kv Voltage Transformer INDICATIONS TYPE of TEST Type Routine On site Temperature rise X lightning impulse withstand voltage X Short circuit withstand X Primary windings Voltage withstand at 50 Hz X Secondary windings Voltage withstand at 50 Hz X Between section Voltage withstand at 50 Hz X Transformer ratio X Terminal marking X X Visual inspection X X Exchangeability of similar devices X NMRCL MARCH

402 4. Overhead Equipment: 4.1 Contact wire INDICATIONS Type test Routine test On line test After shipment test Test Standard as per EN 50149, UIC 870, RDSO specification ETI/ OHE/ 76 X X Determination of copper and other elements of raw material X Electrolytic Analysis for chemical X X X composition of copper. Tensile Testing X X X X Hardness Test X X X X Compression Test X X Bend Test X X Metallurgical test on conductor X Profile measuring device X X Breaking load X Elongation and contraction X Resistivity X X Flaw detection in contact wire drawn out X of continuous cast rod Visual examination of drum and contact wire X X X Visual checking of packaging including drum X X X 4.2 Messenger wire INDICATIONS Test Standard as per EN 50182, RDSO specification ETI/ OHE/ 76 Determination of copper and other elements of raw material of copper and cadmium Type test X X Routine test X X On line test After shipment test Electrolytic Analysis for chemical composition of copper and cadmium. X X X Tensile Testing X X X Compression Test X X Breaking load X Elongation and contraction X Resistivity X X Wrapping test of wire X Visual examination of drum and messenger wire X X X Visual checking of packaging including drum X X X NMRCL MARCH

403 4.3 Aerial Earth cable (AEC) INDICATIONS Type test Routine test On line test After shipment test Test Standard as per IS: 398 (Part II) X X Determination of composition of aluminium And steel X Tensile Testing X X X X Compression Test X X Breaking load X X Resistivity X X Wrapping test of wire Visual examination of drum and Aluminium core steel reinforced (ACSR) wire Visual checking of packaging including drum X X X X X X X 4.4 Buried earth cable (BEC) INDICATIONS Type test Routine test On line test After shipment test Test as per product standard ( IEC 60840) X X Current carrying capacity test X Maximum short circuit current capacity X Visual examination X X X Packaging visual examination X X X Leakage current Insulation Resistance X X Power frequency dry withstand voltage X NMRCL MARCH

404 Power frequency wet withstand voltage X Dielectric strength X X 4.5 Jumper wire INDICATIONS Test Standard as per, RDSO specification ETI/ OHE/ 3 Type test X Routine test X On line test After shipment test Determination of copper and other elements of raw material of copper X and composition of number of strands Electrolytic Analysis for chemical composition of copper. X X X Tensile Testing X X X X Compression Test X X Breaking load X Elongation and contraction X Resistivity X X Wrapping test of wire X Visual examination of drum and jumper wire X X X Visual checking of packaging including drum X X X 4.6 Dropper wire INDICATIONS Type test Routine test On line test After shipment test Test Standard as per, RDSO specification ETI/ OHE/ 3 X X Determination of bronze and other elements of raw material of bronze and composition of number of strands X Electrolytic Analysis for chemical composition of bronze. X X X Tensile Testing X X X X Compression Test X X Breaking load Elongation and contraction X X NMRCL MARCH

405 Resistivity X Wrapping test of wire Visual examination of drum and dropper wire X X X X Visual checking of packaging including drum X X X 4.7 Mast and portal: INDICATIONS Type test Routine test On line test After shipment test Standards as per IS:2062, IS: 800, IS:808, RDSO SPECIFICATION:ETI/OHE/13 Hot dip galvanization ( EN ISO 1461, IS 209) Zinc coating size of galvanization X X X Plate welding standard ( ISO-TC-44) Loading test (IEC 60652, IEC60826) Bending test Mast dimension tolerances (EN 10034) X X X X X X X Visual examination X X X 4.8 Insulators (for bracket, stay arm, conductor anchor and section insulator) INDICATIONS Type test After Routine On line shipment test test test Test standard: RDSO X X SPECIFICATION:TI/SPC/OHE/INS COM/1070 Mechanical failing load test X Mechanical load time test (clause X 6.4 of IEC 61109) Analysis of material properties (housing X material-silicone compound, core material) Visible discharge test X Dry lightning impulse withstand X X X X X NMRCL MARCH

406 Voltage test (clause 6.1 of IEC 61109) Wet power frequency test (clause X 6.2 of IEC 61109) Wet power frequency maximum withstand X voltage test Visual examination (clause 8.2 of IEC X X X 61109) Mechanical load test X X Visual examination of packaging X X Recording of standard atmospheric condition X X X Verification of dimension X X X Bending load test X X Hardness (Shore A) X (As per ASTM D 2240) Specific gravity (As per ASTM D 792) X X Sudden load release test X Water immersion test X 1000 hours, 5000 hours-tracking and X erosion test X KV Short Neutral Section INDICATIONS Type test Routine test On line test Test as per product standard (IEC 61109, EN 50119) X X Current carrying capacity test X Maximum short circuit current capacity with duration test X Pollution index test (As per DIN 50022) X X Vibration intensity (maximum horizontal acceleration) X X Static withstand contact pressure (80N ± 10N) X After shipment test Insulator (As per RDSO SPECIFICATION:TI/SPC/OHE/INSCO M/1070) X Spark Extinguishing X Visual examination X X X Packaging visual examination X X X Leakage current X Insulation Resistance (Insulator without skids) X Creepage Distance (Insulator without skids) X Power frequency dry withstand voltage X Power frequency dry withstand voltage X Lightning impulse withstand voltage X NMRCL MARCH

407 Power frequency pollution withstand voltage (As per IEC 61109) 25kv, 50 HZ, Vacuum switch - Current working range - Power frequency wet withstand voltage - Short time current rating - Maximum short circuit current with duration - Maximum opening and closing time X X X X X X X NMRCL MARCH

408 APPENDIX D Deleted NMRCL MARCH

409 APPENDIX E KEY AND ACCESS DATES Sr. No. A Pre Execution Work Name of the Work Completion deadline from the date of LOA (In Weeks) 1 Design/Drawing Submission for TSS & SSP 6 th Week 2 Design/Drawing Submission for OHE 6 th Week B Work Execution 3 All Civil Work of SSP & TSS 25 th Week 4 All Civil Work (Foundation) of OHE 35 th Week 5 Installation work of SSP &TSS 44 th Week 6 Installation work of OHE 47 th Week 7 Testing & Commissioning 50 th Week 8 Charging of system 52 nd Week NMRCL MARCH

410 APPENDIX F LIST OF DELIVERABLES NMRCL MARCH

411 DOCUMENTS SUBMISSION The Contractor shall supply to the Employer s representative s duly indicating the documents required for information and the documents required for notice of no objection for the procurement, design, manufacture, Inspection, testing, installation, training, maintenance and operation of the Works. The contractor list of deliverables shall at list cover all documents required in Volume 3 - General Specification and cover the following items: 1. Preliminary list of design documentation: a. Full dimensioned General Arrangement drawings indicating clearances, fixing arrangement of the mounting structure on the foundation. b. Schematic drawings. c. List of essential plant, machinery and testing facilities. d. Type test report for various equipment of relevant rating. e. Construction drawings of indoor and outdoor installations, equipments and facilities. f. As built drawings. g. List of Sub-Contractors / Suppliers / Vendors for all the items. h. The proposed planning and programming of manufacturing and execution of the work suiting to the procurement / availability of the equipment, and achieving the completion of the work as per technical specifications within the stipulated period of completion. i. List of supplies and performance report for the tendered equipment from user railway /other customer. j. Pert, CPM and Bar chart for the sequence of activities to complete the project as per Time Schedule. k. Weekly/ Monthly Progress Reports. l. Progress monitoring, monthly report including earned value report. m. Electromagnetic compatibility report n. Work programme. o. Design, procurement, manufacturer and manufacturing tests programme. p. Procurement of material, Installation, Quality procedures and test programs. 2. Design documentation The successful tenderer shall submit following details / dimensioned drawings as per Indian Railways standard in sizes of Scale 1:200 thereof for getting notice of no objection from employer s representative. a. General assembly showing mounting arrangement and overall dimensions. b. Technical solution including design of the both type of the contact system. c. Plain mass concrete foundation drawing and design calculations. d. Design calculation for structural safety along with details of supporting structure. e. Estimation of implementation period. f. Summary report of the design of the project. g. Schematic and wiring diagram with explanation sheet. NMRCL MARCH

412 h. Details of main parts / sub-assembly. i. Name / Rating plate of the equipment. j. Characteristics of the adopted design of overhead contact system. k. Explanation report covering overhead line and civil engineering aspects. l. Overhead contact line layout plans. m. Transverse profile for inter station lines and stations and depot. n. Longitudinal profile for overhead contact line height reductions. o. Project specific structures with drawings and calculations. p. Cantilever and dropper length calculation. q. Polygon calculation for head span structures. r. Earthing plans. s. Cable layout plans for the cables of disconnector and remote control. t. Complete parts lists consisting of pole and foundation tables, overhead contact line tables and list of materials. u. Details of main, fixed and moving contacts and arcing contacts of CBs. v. Operating and coupling mechanism of complete CB along with schematic diagram showing the mechanical linkages with explanation sheet. w. Details of insulators for support of Overhead equipment (Flexible and Rigid). x. Identification of constraints such as points, sub sectioning, structures, railway crossings etc., y. Preparation of wiring design with pole locations at consultant such as crossings, turn out etc., z. Preparation of wiring design with pole locations other than constraints locations. 3. Manuals Any other drawing considered necessary by the successful tenderer / manufacturer and / or Purchaser. a. Operations manual b. Maintenance manual c. Test Data Manual d. Trouble shooting Manual e. Testing & Commissioning NMRCL MARCH

413 APPENDIX G CONTROL AND MONITORING SIGNALS (I/O LIST FOR SCADA) TRACTION SWITCHING STATIONS (ELEVATED): (SPS, SSPS, SS AND FP) S.No Device Event Description Digital Input Event Type Dig Ou ital tp ut An alo Inp g ut Cla ss Ala rm Normal State Event Text Alarm State 1 Interrupt ers 2 Permission for Local Control Local/Remote in Local DI P1 Remote Local DI P1 Banned Permitted 3 110V DC Control Voltage Fail DI P2 Normal Fail 4 Open Indication DI P0 Open 5 Close Indication DI P0 Close 6 Vacuum or SF6 Gas Pressure Low Alarm DI P2 Normal Alarm 7 IT in Test/Service DI P2 Normal Alarm 8 IT Trip Circuit Unhealthy DI P3 Normal Alarm 9 Spring Discharged DI P1 Charged Discharged 10 CB Close Command DO NMRCL MARCH

414 11 CB Open Command DO 12 SCADA Permissive For Local Control DO 13 Voltage Transfor mer Voltage AI 14 ISOL Local/Remote in Local DI P1 Remote Local 15 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 17 Open Indication DI P0 18 Close Indication DI P0 19 Open Command DO 20 Close Command DO 21 SCADA Permissive For Local Control DO 22 Battery Charger Status DI P1 Normal Standby Charger 23 Float/Boost Mode DI P2 Float Boost 24 Input MCB Trip DI P2 Normal Trip 25 AC Supply Fail DI P2 Normal Fail 26 Charger Unhealthy DI P2 Normal Unhealthy 27 DC Under Voltage DI P2 Normal Alarm 28 DC Over Voltage DI P2 Normal Alarm 29 Output MCB Trip DI P2 Normal Trip 30 RTU Power Supply ON/OFF DI ON OFF 31 SCADA Permissive switch Remote/Local DO NMRCL MARCH

415 RECEIVING cum Traction SUB-STATION S.No Device Event Description Event Type Di git In al pu t Di Ou gittp al ut An aloin g pu t Cla ss Ala rm Device Event Description Normal State Alarm State 1 Under Voltage Alarm DI P2 Normal Alarm 2 R-Y Voltage AI 3 Incomer#1 VT Y-B Voltage AI 4 R-B Voltage AI 5 R Current AI 6 Incomer1 CT Y Current AI 7 B Current AI NMRCL MARCH

416 8 Under Voltage Alarm DI P2 Normal Alarm 9 R-Y Voltage AI 10 Incomer#2 VT Y-B Voltage AI 11 R-B Voltage AI 12 R Current AI 13 Incomer2 CT Y Current AI 14 B Current AI 15 Earth Close Indication DI P0 Close 16 LEIS1-1 Earth Open Indication DI P0 Open 17 Earth Close Indication DI P0 Close 18 LEIS 2-1 Earth Open Indication DI P0 Open 19 Local/Remote in Local DI P1 Remote Local 20 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 22 Close Indication DI P0 Close 23 LIS 1-1 Open Indication DI P0 Open 24 Close Command DO 25 Open Command DO 26 SCADA Permissive Command For Local Control DO 27 Local/Remote in Local DI P1 Remote Local 28 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 30 Close Indication DI P0 Close 31 LIS 2-1 Open Indication DI P0 Open 32 Close Command DO 33 Open Command DO 34 SCADA Permissive Command For Local Control 35 LCB1 Local/Remote in Local DI P1 Remote Local 36 Permission for Local Control DI P1 Banned Permitted DO V DC Control Voltage Fail DI P2 Normal Fail 38 Close Indication DI P0 Close 39 Open Indication DI P0 Open 40 Spring Discharged DI P1 Charged Discharged 41 SF6 Gas Pressure Low Alarm DI P2 Normal Low NMRCL MARCH

417 42 SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 43 CB Stuck Alarm DI P2 Normal Alarm 44 CB Trouble Close Block DI P2 Normal Alarm 45 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 46 Close Command DO 47 Open Command DO 48 SCADA Permissive Command For Local Control DO 49 Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy 50 Master Trip Relay Operated DI P2 Normal Operated 51 MTR Reset Command DO 52 O/C & E/F Relay Faulty DI P3 Normal Faulty Over Current Protection Operated DI P2 Normal Operated Earth Fault Protection Operated DI P2 Normal Operated Local/Remote in Local DI P1 Remote Local 56 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 58 Close Indication DI P0 Close 59 Open Indication DI P0 Open 60 Spring Discharged DI P1 Charged Discharged LCB2 SF6 Gas Pressure Low Alarm DI P2 Normal Low SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 63 CB Stuck Alarm DI P2 Normal Alarm 64 CB Trouble Close Block DI P2 Normal Alarm 65 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 66 Close Command DO 67 Open Command DO SCADA Permissive Command For Local Control DO Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy 70 Master Trip Relay Operated DI P2 Normal Operated 71 MTR Reset Command DO 72 O/C & E/F Relay Faulty DI P3 Normal Faulty Over Current Protection DI P2 Normal Operated NMRCL MARCH

418 73 Operated 74 Earth Fault Protection Operated DI P2 Normal Operated 75 Bus#1 Under Voltage Alarm DI P2 Normal Alarm 76 Bus#2 Under Voltage Alarm DI P2 Normal Alarm 77 Local/Remote in Local DI P1 Remote Local 78 Permission for Local Control 110V DC Control Voltage DI P1 Banned Permitted 79 Fail DI P2 Normal Fail 80 LIS1-2 Close Indication DI P0 Close 81 Open Indication DI P0 Open 82 Close Command DO 83 Open Command DO Permissive Command For Local Control 88 LIS2-2 Close Indication DI P0 Close DO Local/Remote in Local DI P1 Remote Local 86 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 89 Open Indication DI P0 Open 90 Close Command DO 91 Open Command DO Permissive Command For Local Control DO Local/Remote in Local DI P1 Remote Local 94 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 96 Close Indication DI P0 Close 97 CIS-1 Open Indication DI P0 Open 98 Close Command DO 99 Open Command DO 100 SCADA Permissive Command For Local Control 101 CIS-2 Local/Remote in Local DI P1 Remote Local 102 Permission for Local Control DI P1 Banned Permitted DO V DC Control Voltage Fail DI P2 Normal Fail 104 Close Indication DI P0 Close 105 Open Indication DI P0 Open 106 Close Command DO NMRCL MARCH

419 107 Open Command DO SCADA Permissive Command For Local DO Control Local/Remote in Local DI P1 Remote Local 110 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 112 Close Indication DI P0 Close 113 Open Indication DI P0 Open SF6 Gas Pressure Low Alarm DI P2 Normal Low SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 116 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 117 Spring Discharged DI Charged Discharged 118 Close Command DO 119 Open Command DO 120 CCB SCADA Permissive Command For Local Control DO 121 Master Trip Relay Operated DI P2 Normal Operated 122 MTR Reset Command DO 123 Master Trip Relay Circuit Unhealthy DI P3 Normal Alarm 124 CB Stuck Alarm DI P2 Normal Alarm 125 CB Trouble Close Block DI P2 Normal Alarm 126 O/C & E/F Relay faulty DI P3 Normal Faulty Over Current protection Operated DI P2 Normal Operated Earth Fault protection Operated DI P2 Normal Operated Synchronization Relay Faulty DI P3 Normal Faulty 130 Synchronization Not In limit DI P2 In Limit Not in Limit 131 Local/Remote in Local DI P1 Remote Local 132 Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage 133 ATIS1 Fail DI P2 Normal Fail 134 Close Indication DI P0 Close 135 Open Indication DI P0 Open 136 Close Command DO 137 Open Command DO NMRCL MARCH

420 SCADA Permissive For Local Control DO Local/Remote in Local DI P1 Remote Local 140 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 142 Close Indication DI P0 Close 143 Open Indication DI P0 Open SF6 Gas Pressure Low Alarm DI P2 Normal Low SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 146 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 147 Spring Discharged DI P1 Charged Discharged 148 Close Command DO 149 Open Command DO 150 SCADA Permissive Command For Local Control DO 151 Master Trip Relay Operated DI P2 Normal Operated ATCB1 152 Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy 153 CB Stuck Alarm DI P2 Normal Alarm 154 CB Trouble Close Block DI P2 Normal Alarm 155 MTR Reset Command DO 156 Differential Relay Faulty DI P3 Normal Faulty Differential Protection Operated DI P2 Normal Operated Primary Neutral Earth Protection Operated DI P2 Normal Operated Secondary Neutral Earth Relay Faulty DI P3 Normal Faulty Secondary Neutral Earth Protection Operated DI P2 Normal Operated 161 O/C & E/F Relay Faulty DI P3 Normal Faulty Over current Protection operated DI P2 Normal Operated Earth Fault Protection operated DI P2 Normal Operated Oil Temp High Alarm DI P3 Normal High 165 Oil Temp High Auto trip Alarm DI P3 Normal Trip 166 AT1 Winding Temp High Alarm DI P3 Normal High 167 Winding Temp High Auto Trip Alarm DI P3 Normal Trip NMRCL MARCH

421 Buccholz protection 1st Threshold alarm DI P2 Normal Alarm Buccholz protection 2nd Threshold alarm DI P2 Normal Alarm Transformer Oil level "Low" Alarm DI P2 Normal Low Pressure Relief Valve Auto Trip Alarm DI P2 Normal Alarm 172 Tank Earth fault relay Faulty DI P3 Normal Faulty 173 Tank Earth fault protection operated DI P2 Normal Operated 174 Tap changer Local Remote Mode in Local DI P1 Remote Local Tap Changer 11o V DC 175 Control Voltage Fail DI P2 Normal Fail Tap changer Buchholz protection Alarm DI P2 Normal Alarm Tap Changer Auto/Manual in Manual DI P1 Auto Manual 178 Tap changer stuck Alarm DI P2 Normal Alarm 179 Tap Changer in Lower limit DI P2 Normal Alarm 180 Tap Changer in Upper limit DI P2 Normal Alarm 181 Tap Changer Fault DI P2 Normal Alarm 182 Raise Command DO 183 Lower Command DO 184 Tap changer Indication AI 185 Local/Remote in Local DI P1 Remote Local 186 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 188 Close Indication DI P0 Close 189 ATIS-2 Open Indication DI P0 Open 190 Close Command DO 191 Open Command DO 192 SCADA Permissive Command For Local Control DO 193 Local/Remote in Local DI P1 Remote Local 194 Permission for Local Control DI P1 Banned Permitted 195 ATCB2 110V DC Control Voltage Fail DI P2 Normal Fail 196 Close Indication DI P0 Close 197 Open Indication DI P0 Open NMRCL MARCH

422 SF6 Gas Pressure Low Alarm DI P2 Normal Low SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 200 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 201 Spring Discharged DI P1 Charged Discharged 202 Close Command DO 203 Open Command DO 204 SCADA Permissive Command For Local Control DO 205 Master Trip Relay Operated DI P2 Normal Operated 206 Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy 207 CB Stuck Alarm DI P2 Normal Alarm 208 CB Trouble Close Block DI P2 Normal Alarm 209 MTR Reset Command DO 210 Differential Relay Faulty DI P3 Normal Faulty Differential Protection Operated DI P2 Normal Operated Primary Neutral Earth Protection Operated DI P2 Normal Operated Secondary Neutral Earth Relay Faulty DI P3 Normal Faulty Secondary Neutral Earth Protection Operated DI P2 Normal Operated 215 O/C & E/F Relay Faulty DI P3 Normal Faulty AT2 Over current Protection operated DI P2 Normal Operated Earth Fault Protection operated DI P2 Normal Operated Oil Temp High Alarm DI P3 Normal High Oil Temp High Auto trip Alarm DI P3 Normal Trip 220 Winding Temp High Alarm DI P3 Normal High Winding Temp High Auto Trip Alarm DI P3 Normal Trip Buccholz protection 1st Threshold alarm DI P2 Normal Alarm Buccholz protection 2nd Threshold alarm DI P2 Normal Alarm Transformer Oil level "Low" Alarm DI P2 Normal Low Pressure Relief Valve Auto Trip Alarm DI P2 Normal Alarm 226 Tank Earth fault relay Faulty DI P3 Normal Faulty NMRCL MARCH

423 Tank Earth fault protection operated DI P2 Normal Operated Tap changer Local Remote Mode in Local DI P1 Remote Local Tap Changer 11o V DC Control Voltage Fail DI P2 Normal Fail Tap changer Buchholz protection Alarm DI P2 Normal Alarm Tap Changer Auto/Manual in Manual DI P1 Auto Manual 232 Tap changer stuck Alarm DI P2 Normal Alarm 233 Tap Changer in Lower limit DI P2 Normal Alarm 234 Tap Changer in Upper limit DI P2 Normal Alarm 235 Tap Changer Fault DI P2 Normal Alarm 236 Raise Command DO 237 Lower Command DO 238 Tap changer Indication AI 239 Local/Remote in Local DI P1 Remote Local 240 Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage 241 Fail DI P2 Normal Fail 242 Close Indication DI P0 Close 243 TTIS-1 Open Indication DI P0 Open 244 Close Command DO 245 Open Command DO 246 SCADA Permissive Command For Local Control DO 247 Local/Remote in Local DI P1 Remote Local 248 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 250 Close Indication DI P0 Close 251 Open Indication DI P0 Open TTCB-1 SF6 Gas Pressure Low Alarm DI P2 Normal Low SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 254 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 255 Spring Discharged DI P1 Charged Discharged 256 Close Command DO 257 Open Command DO NMRCL MARCH

424 258 SCADA Permissive Command For Local Control DO 259 Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy 260 Master Trip Relay Operated DI P2 Normal Operated 261 CB Stuck Alarm DI P2 Normal Alarm 262 CB Trouble Close Block DI P2 Normal Alarm 263 MTR Reset Command DO 264 Differential Relay Faulty DI P3 Normal Faulty 265 Transformer Differential Protection Operated DI P2 Normal Operated 266 O/C & E/F Relay Faulty DI P3 Normal Faulty TT1 Over current Protection operated DI P2 Normal Operated Tank Earth fault protection operated DI P2 Normal Operated Earth Fault Protection operated DI P2 Normal Operated Oil Temp High Alarm DI P3 Normal High Oil Temp High Auto trip Alarm DI P3 Normal Trip 272 Winding Temp High Alarm DI P3 Normal High Winding Temp High Auto Trip Alarm DI P3 Normal Trip Buccholz protection 1st Threshold alarm DI P2 Normal Alarm Buccholz protection 2nd Threshold alarm DI P2 Normal Alarm Transformer Oil level "Low" Alarm Pressure Relief Valve Auto Trip Alarm DI P2 Normal Low DI P2 Normal Alarm Tap changer Local Remote Mode in Local DI P1 Remote Local Tap Changer 11o V DC Control Voltage Fail DI P2 Normal Fail Tap changer Buchholz protection Alarm DI P2 Normal Alarm Tap Changer Auto/Manual in Manual DI P1 Auto Manual 282 Tap changer stuck Alarm DI P2 Normal Alarm 283 Tap Changer in Lower limit DI P2 Normal Alarm 284 Tap Changer in Upper limit DI P2 Normal Alarm 285 Tap Changer Fault DI P2 Normal Alarm NMRCL MARCH

425 286 Raise Command DO 287 Lower Command DO 288 Tap changer Indication AI 289 Local/Remote in Local DI P1 Remote Local 290 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 292 Close Indication DI P0 Close 293 TTIS-2 Open Indication DI P0 Open 294 Close Command DO 295 Open Command DO 296 SCADA Permissive Command For Local Control DO 297 Local/Remote in Local DI P1 Remote Local 298 Permission for Local Control DI P1 Banned Permitted 299 TTCB-2 110V DC Control Voltage Fail DI P2 Normal Fail 300 Close Indication DI P0 Close 301 Open Indication DI P0 Open SF6 Gas Pressure Low Alarm DI P2 Normal Low SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 304 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 305 Spring Discharged DI P1 Charged Discharged 306 Close Command DO 307 Open Command DO 308 SCADA Permissive Command For Local Control DO 309 Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy 310 Master Trip Relay Operated DI P2 Normal Operated 311 CB Stuck Alarm DI P2 Normal Alarm 312 CB Trouble Close Block DI P2 Normal Alarm 313 MTR Reset Command DO 314 Differential Relay Faulty DI P3 Normal Faulty 315 Transformer Differential Protection Operated DI P2 Normal Operated 316 O/C & E/F Relay Faulty DI P3 Normal Faulty 317 Over current Protection operated DI P2 Normal Operated NMRCL MARCH

426 TT2 Tank Earth fault protection operated DI P2 Normal Operated Earth Fault Protection operated DI P2 Normal Operated Oil Temp High Alarm DI P3 Normal High Oil Temp High Auto trip Alarm DI P3 Normal Trip 322 Winding Temp High Alarm DI P3 Normal High Winding Temp High Auto Trip Alarm DI P3 Normal Trip Buccholz protection 1st Threshold alarm Buccholz protection 2nd Threshold alarm DI P2 Normal Alarm DI P2 Normal Alarm Transformer Oil level "Low" Alarm DI P2 Normal Low Pressure Relief Valve Auto Trip Alarm DI P2 Normal Alarm Tap changer Local Remote Mode in Local DI P1 Remote Local Tap Changer 11o V DC Control Voltage Fail DI P2 Normal Fail Tap changer Buchholz protection Alarm DI P2 Normal Alarm Tap Changer Auto/Manual in Manual DI P1 Auto Manual 332 Tap changer stuck Alarm DI P2 Normal Alarm 333 Tap Changer in Lower limit DI P2 Normal Alarm 334 Tap Changer in Upper limit DI P2 Normal Alarm 335 Tap Changer Fault DI P2 Normal Alarm 336 Raise Command DO 337 Lower Command DO 338 Tap changer Indication AI 339 Incoming AC MCB Trip Alarm DI Normal Trip 340 DC to Protection Circuit Fail DI Normal Fail 341 Bus PT MCB Trip Alarm DI Normal Trip 342 Protection Line PT Protection Core Panel MCB Trip alarm DI Normal Trip Line PT Metering Core MCB Trip Alarm DI Normal Trip Metering Aux. Supply Fail Alarm DI Normal Fail NMRCL MARCH

427 AC-DC LOCAL DISTRIBUTION IN RSS/TSS S.No Device Event Description Event Type Di git In al pu t Di Ou gittp al ut An aloin g pu t Cla ss Ala rm Device Event Description Normal State Alarm State Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 4 Close Indication DI P0 Close 5 Open Indication DI P0 Open 6 CB in Test/Service DI P2 Service Test 7 CB Trip Relay Operated DI P2 Normal Operated 8 9 LVCB1 Thermal O/L Protection Operated DI P2 Normal Operated Under Voltage Trip Operated DI P2 Normal Operated 10 Spring Discharged DI P1 Charged Discharged 11 Change Over in SCADA mode DO 12 Close Command DO 13 Open Command DO 14 SCADA Permissive For Local Control DO Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage 17 Fail DI P2 Normal Fail LVCB2 18 Close Indication DI P0 Close 19 Open Indication DI P0 Open 20 CB in Test/Service DI P2 Service Test 21 CB Trip Relay Operated DI P2 Normal Operated 22 Thermal O/L Protection Operated DI P2 Normal Operated 23 Under Voltage Trip Operated DI P2 Normal Operated 24 Spring Discharged DI P1 Charged Discharged NMRCL MARCH

428 25 Change Over in SCADA mode DO 26 Close Command DO 27 Open Command DO 28 SCADA Permissive For Local Control DO Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 32 Close Indication DI P0 Close 33 Open Indication DI P0 Open 34 CB in Test/Service DI P2 Service Test 35 CB Trip Relay Operated DI P2 Normal Operated LVCCB Thermal O/L Protection 36 Operated DI P2 Normal Operated 37 Spring Discharged DI P1 Charged Discharged 38 Change Over in SCADA mode DO 39 Close Command DO 40 Open Command DO SCADA Permissive For Local Control 45 DCACB Close Indication DI P0 Close 1 46 Open Indication DI P0 Open DO Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 47 Close Command DO 48 Open Command DO DCACB 2 SCADA Permissive For Local Control DO Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage 52 Fail DI P2 Normal Fail 53 Close Indication DI P0 Close 54 Open Indication DI P0 Open 55 Close Command DO 56 Open Command DO NMRCL MARCH

429 57 SCADA Permissive For Local Control DO Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 61 DCACC Close Indication DI P0 Close 62 Open Indication DI P0 Open 63 Close Command DO 64 Open Command DO V Bus #1 110V Bus #2 Input #1 to Charger Input #2 to Charger Output #1 to charger Output #2 to charger SCADA Permissive For Local Control DO Lack of 110 V DI Normal Alarm Lack of 110 V DI Normal Alarm Input MCB Trip DI Normal Trip Input MCB Trip DI Normal Trip Output MCB Trip DI Normal Trip Output MCB Trip DI Normal Trip Float/Boost DI P2 Float Boost 73 AC Fail DI P2 Normal Fail 74 Battery Charger Fail DI P2 Normal Unhealthy 75 Charger 1 DC Under Voltage DI P2 Normal Alarm 76 DC Over Voltage DI P2 Normal Alarm 77 Charger Status DI P1 Normal Standby 78 Float/Boost DI P2 Float Boost 79 AC Fail DI P2 Normal Fail 80 Battery Charger Fail DI P2 Normal Unhealthy 81 Charger 2 DC Under Voltage DI P2 Normal Alarm 82 DC Over Voltage DI P2 Normal Alarm 83 Charger Status DI P1 Normal Standby 84 Float/Boost DI P2 Float Boost 85 AC Fail DI P2 Normal Fail 86 Battery Charger Fail DI P2 Normal Unhealthy 87 Charger 3 DC Under Voltage DI P2 Normal Alarm 88 DC Over Voltage DI P2 Normal Alarm 89 Charger Status DI P1 Normal Standby NMRCL MARCH

430 8.9 TRACTION SUB-STATION S.No Device Event Description Event Type Di git In al pu t Di Ou gittp al ut An aloin g pu t Cla ss Ala rm Device Event Description Normal State Alarm State Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 4 Close Indication DI P0 Close 5 Open Indication DI P0 Open 6 SF6 Gas Pressure Low Alarm DI P2 Normal Low 7 SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 8 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 9 Spring Discharged DI P1 Charged Discharged 10 CB Stuck Alarm DI P2 Normal Alarm 11 CB Trouble Close Block DI P2 Normal Alarm 12 Close Command DO 13 Open Command DO 14 TCB1 SCADA Permissive For Local Control DO 15 Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy Master Trip Relay Operated DI P2 Normal MT Relay Reset Command DO Operated 18 O/C & E/F Relay Faulty DI P3 Normal Faulty 19 O/C Protection Operated DI P2 Normal Operated 20 E/F Protection Operated DI P2 Normal Operated 21 Directional Power Protection Relay Faulty DI P3 Normal Faulty 22 Dir. Power Operated DI P2 Normal Operated Dir. Power Stage- 1Operated DI P2 Normal Operated Dir. Power Stage-2 Operated DI P2 Normal Operated 25 TCT1 Current AI NMRCL MARCH

431 26 VT1 Voltage AI Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 30 ISOL-1 Close Indication DI P0 Close 31 Open Indication DI P0 Open 32 Close Command DO 33 Open Command DO 34 SCADA Permissive For Local Control 35 TCB2 Local/Remote in Local DI P1 Remote Local DO Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 38 Close Indication DI P0 Close 39 Open Indication DI P0 Open SF6 Gas Pressure Low Alarm DI P2 Normal Low SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 42 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 43 Spring Discharged DI P1 Charged Discharged 44 CB Stuck Alarm DI P2 Normal Alarm 45 CB Trouble Close Block DI P2 Normal Alarm 46 Close Command DO 47 Open Command DO 48 SCADA Permissive For Local Control DO Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy Master Trip Relay Operated DI P2 Normal Operated 51 MT Relay Reset Command DO 52 O/C & E/F Relay Faulty DI P3 Normal Faulty 53 O/C Protection Operated DI P2 Normal Operated 54 E/F Protection Operated DI P2 Normal Operated 55 Directional Power Protection Relay Faulty DI P3 Normal Faulty 56 Dir. Power Operated DI P2 Normal Operated NMRCL MARCH

432 57 58 Dir. Power Stage- 1Operated DI P2 Normal Operated Dir. Power Stage-2 Operated DI P2 Normal Operated 59 TCT2 Current AI 60 VT2 Voltage AI Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 64 ISOL-2 Close Indication DI P0 Close 65 Open Indication DI P0 Open 66 Close Command DO 67 Open Command DO 68 SCADA Permissive For Local Control 69 Close Indication DI 70 CIS-1 Open Indication DI Spring Discharged DI P1 Charged Discharged BM1-2 SF6 Gas Pressure Low 77 Alarm DI P2 Normal Low DO Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 74 Close Indication DI P0 Close 75 Open Indication DI P0 Open 78 SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 79 Close Command DO 80 Open Command DO 81 SCADA Permissive For Local Control 82 Close Indication DI P0 Close 83 CIS-2 Open Indication DI P0 Open 84 Bus #1 PT Under Voltage Alarm DI Normal Alarm 85 Bus#2 PT Under Voltage Alarm DI Normal Alarm 86 ISOL11A Close Indication DI Close 87 Open Indication DI Open CB11 DO Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted NMRCL MARCH

433 90 110V DC Control Voltage Fail DI P2 Normal Fail 91 Close Indication DI P0 Close 92 Open Indication DI P0 Open SF6 Gas Pressure Low Alarm DI P2 Normal Low SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 95 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 96 Spring Discharged DI P1 Charged Discharged 97 CB Stuck Alarm DI P2 Normal Alarm 98 CB Trouble Close Block DI P2 Normal Alarm 99 Close Command DO 100 Open Command DO SCADA Permissive For Local Control DO Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy Master Trip Relay Operated DI P2 Normal Operated MT Relay Reset Command 105 O/C & E/F Relay Faulty DI P3 Normal Faulty 106 O/C protection Operated DI P2 Normal Operated 107 E/F protection Operated DI P2 Normal Operated 108 Impedance Relay faulty DI P3 Normal Faulty 109 DO Impedance protection operated DI P2 Normal Operated 110 auto reclose operated DI P2 Normal Operated 111 auto reclose lockout DI P2 Normal Operated 112 Panto Flashover Protection Operated DI P2 Normal Operated 113 ISOL11B Close Indication DI P0 Close 114 Open Indication DI P0 Open 115 ISOL12A Close Indication DI P0 Close 116 Open Indication DI P0 Open 117 CB12 Local/Remote in Local DI P1 Remote Local 118 Permission for Local Control DI P1 Banned Permitted V DC Control Voltage Fail DI P2 Normal Fail 120 Close Indication DI P0 Close 121 Open Indication DI P0 Open 122 SF6 Gas Pressure Low Alarm DI P2 Normal Low NMRCL MARCH

434 123 SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 124 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 125 Spring Discharged DI P1 Charged Discharged 126 CB Stuck Alarm DI P2 Normal Alarm 127 CB Trouble Close Block DI P2 Normal Alarm 128 Close Command DO 129 Open Command DO 130 SCADA Permissive For Local Control DO Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy Master Trip Relay Operated DI P2 Normal Operated 133 MT Relay Reset Command DO 134 O/C & E/F Relay Faulty DI P3 Normal Faulty 135 O/C protection Operated DI P2 Normal Operated 136 E/F protection Operated DI P2 Normal Operated 137 Impedance Relay faulty DI P3 Normal Faulty 138 Impedance protection operated DI P2 Normal Operated 139 auto re close operated DI P2 Normal Operated 140 auto re close lockout DI P2 Normal Operated 141 Panto Flashover Protection Operated DI P2 Normal Operated 142 ISOL12B Close Indication DI P0 Close 143 Open Indication DI P0 Open 144 ISOL21A Close Indication DI P0 Close 145 Open Indication DI P0 Open Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 149 Close Indication DI P0 Close 150 CB21 Open Indication DI P0 Open 151 SF6 Gas Pressure Low Alarm DI P2 Normal Low 152 SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip 153 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 154 Spring Discharged DI P1 Charged Discharged NMRCL MARCH

435 155 CB Stuck Alarm DI P2 Normal Alarm 156 CB Trouble Close Block DI P2 Normal Alarm 157 Close Command DO 158 Open Command DO 159 SCADA Permissive For Local Control DO Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy Master Trip Relay Operated DI P2 Normal Operated 162 MT Relay Reset Command DO 163 O/C & E/F Relay Faulty DI P3 Normal Faulty 164 O/C protection Operated DI P2 Normal Operated 165 E/F protection Operated DI P2 Normal Operated 166 Impedance Relay faulty DI P3 Normal Faulty 167 Impedance protection operated DI P2 Normal Operated 168 auto reclose operated DI P2 Normal Operated 169 auto reclose lockout DI P2 Normal Operated 170 Panto Flashover Protection Operated DI P2 Normal Operated 171 ISOL21B Close Indication DI P0 Close 172 Open Indication DI P0 Open 173 ISOL22A Close Indication DI P0 Close 174 Open Indication DI P0 Open Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 178 CB22 Close Indication DI P0 Close 179 Open Indication DI P0 Open 180 SF6 Gas Pressure Low Alarm DI P2 Normal Low 181 SF6 Gas Low Pressure Auto Trip Alarm DI P2 Normal Trip NMRCL MARCH

436 S.No Device Event Description Event Type Di git In al pu t Di Ou gittp al ut An aloin g pu t Cla ss Ala rm Device Event Description Normal State Alarm State 182 CB Trip Circuit Unhealthy DI P3 Normal Unhealthy 183 Spring Discharged DI P1 Charged Discharged 184 CB Stuck Alarm DI P2 Normal Alarm 185 CB Trouble Close Block DI P2 Normal Alarm 186 Close Command DO 187 Open Command DO 188 SCADA Permissive For Local Control DO Master Trip Relay Circuit Unhealthy DI P3 Normal Unhealthy Master Trip Relay Operated DI P2 Normal Operated 191 MT Relay Reset Command DO 192 O/C & E/F Relay Faulty DI P3 Normal Faulty 193 O/C protection Operated DI P2 Normal Operated 194 E/F protection Operated DI P2 Normal Operated 195 Impedance Relay faulty DI P3 Normal Faulty 196 Impedance protection operated DI P2 Normal Operated 197 auto reclose operated DI P2 Normal Operated 198 auto reclose lockout DI P2 Normal Operated 199 Panto Flashover Protection Operated DI P2 Normal Operated 200 ISOL22B Close Indication DI P0 Close 201 Open Indication DI P0 Open Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 205 ISOL Close Indication DI P0 Close (IDdu) 206 Open Indication DI P0 Open 207 Close Command DO 208 Open Command DO 209 SCADA Permissive For Local Control DO NMRCL MARCH

437 Local/Remote in Local DI P1 Remote Local Permission for Local Control DI P1 Banned Permitted 110V DC Control Voltage Fail DI P2 Normal Fail 213 ISOL. Close Indication DI P0 Close (Ibdu) 214 Open Indication DI P0 Open 215 Close Command DO 216 Open Command DO 217 SCADA Permissive For Local Control DO Incoming AC MCB Trip Alarm DI Normal Trip DC to Protection Circuit Fail DI Normal Fail 220 Bus PT MCB Trip Alarm DI Normal Trip Protecti Line PT Protection Core 221 on Panel MCB Trip alarm DI Normal Trip Line PT Metering Core MCB Trip Alarm DI Normal Trip Metering Aux. Supply Fail Alarm DI Normal Fail NMRCL MARCH

438 PART II: WORKS REQUIREMENTS NMRCL Tender No. N1 Tr-02/2016 SECTION VIII-C: Reference Document NAGPUR METRO RAIL PROJECT BID DOCUMENTS FOR DESIGN, SUPPLY, INSTALLATION, TESTING & COMMISSIONING OF 25 KV SINGLE PHASE, 50HZ AC, REGULATED, CONVENTIONAL AND TRAMWAY TYPE OHE IN AT GRADE SECTION AND MIHAN DEPOT, 33/25 KV TRACTION SUB STATION & SSP INCLUDING 33 KV CABLING WORK OVER NORTH SOUTH CORRIDOR OF NAGPUR METRO RAIL CORPORATION LIMITED TENDER NO. N1Tr-02/2016 PART II: WORKS REQUIREMENTS SECTION VII-C: Reference Document Nagpur Metro Rail Corporation Limited Metro House, Bungalow No: 28/2, Anand Nagar, CK Naidu Road, Civil Lines, Nagpur Maharashtra, INDIA Website: NMRCL MARCH

439 PART II: WORKS REQUIREMENTS NMRCL Tender No. N1 Tr-02/2016 SECTION VIII-C: Reference Document 1. Mihan Depot Layout 2. GAD- Reach-1 3. Priority Section Plan 4. SOD Table of Contents NMRCL MARCH

440

441 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT AIRPORT LAND EDP 01 TOWARDS DR.AMBEDKAR AIRPORT AIRPORT LAND TOWARDS INGOLE NAGAR PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT TOWARDS CARGO TERMINAL SEPTIC TANK SEPTIC TANK DRAIN ROAD SEPTIC TANK KM STONE NO.: PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

442 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT ROAD SEPTIC TANK KM STONE NO.: MH MH EDP W MH 02 OTTA TOWARDS SHIVANGAON OTTA SHED SHED MH PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT SEPTIC TANK HOUSE W PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT TOWARDS NAGPUR RLY. STATION TOWARDS FIELD W MH W KM MH PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

443 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT W W MH MH MH EDP KM W RLY MH 03 RLY PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT W PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT RLY EX. RL MAIN LINE = m HFL = m NALA BED LVL = m 2x9.14M-(G) RAILWAY BRIDGE RLY RLY PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

444 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT W EDP RLY RLY 04 RLY PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT RLY EX. RL MAIN LINE = 300.5m NALA BED LVL = m HFL = m 1x3.05M-ARCH RAILWAY BRIDGE PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT RLY MH RLY W W RLY PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

445 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT W W RLY RLY 05 RLY PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT MH RLY RLY PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT RLY TOWARDS FIELD RLY RLY RLY PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

446 PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT FM Y FM Y Y RL RL Y RL Y RL RL Y RL Y RL RL Y -3 ON LOOP LINE M M O C D E S O P RIDGE ) PRO C/L OF WEIGH B TO FM ( 6M 31 CAL: m S RD WA ARI O T AP KH OAD R MH S RD WA R O U T GP NA PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 4.95m TENTATIVE LOCATION OF END OF VIADUCT AT CHAINAGE 17/715

447 WT W TOW A KHA RDS PA ROA RI D S RD EZ A W /S TOIHAN M WT Y RL Y RL W KHAPARI CH:18/291 Y MH RL Y Y RL MH 5.3M WT WT WT Y RL -CHANGE TER MIHAN IN RL PLATFORM FLYOVER FM MIHAN INTER-CHANGE FLYOVER GROUND LVEL: m SOFFIET LEVEL: m PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT S RD WA ARI O T AP KH OAD R S RD I WA TO APAR KH OAD R 99 PLATFORM S RD WA H A O T RD W A OAD R S RD HA A D W TO /WAR R PU G NA FM TENTATIVE LOCATION OF END OF AT GRADE SECTION CHAINAGE 18/700 S RD I WA TO APAR KH OAD R TRACK CENTERS AT SCISSOR CROSS OVER TO BE KEPT AS 4.95M 4.95m C/L OF KHAPRI STATION BUILDING (KM:824/ AT CH: MH Y RL FM 3.9m 4.95m PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 4.95m PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT 07 FM FM

448

449 NAGPUR METRO RAIL CORPORATION LIMITED (A JOINT VENTURE OF GOVT. OF INDIA & GOVT. OF MAHARASHTRA) SCHEDULE OF DIMENSIONS FOR STANDARD GAUGE (1435 mm) (25 kv AC OHE TRACTION) NOVEMBER 2015 NAGPUR METRO RAIL CORPORATION LIMITED 28/2, Anand Nagar, C.K Naidu Road, Civil Lines Nagpur INDIA

450 Nagpur Metro Rail Corporation Limited Table of Contents Approval Letter Preamble 1 Introduction 2 CHAPTER I GENERAL 1.1 Spacing of Tracks Curves Gradients Buildings and Structures Kinematic Envelope Structure Gauge Extra Clearance on Curves Minimum Track Spacing on Curves Derailment Guard Special Operating Condition Additional Operating Condition for Elevated and At-Grade Section 10 CHAPTER - II STATIONS 2.1 Spacing of Track at Stations Platforms Gradients Interlocking and Signal Gear Points and Crossings Super elevation and Speed at Stations on Curve with Turnouts of 14 Contrary and Similar Flexure 2.7 Additional Clearance for Platforms on Curves 15 i Oct 2015

451 Nagpur Metro Rail Corporation Limited CHAPTER - III ROLLING STOCK 3.1 Passenger Electric Multiple Units Locomotives and Engineering Service Vehicles 17 CHAPTER - IV OVERHEAD ELECTRIC TRACTION-25 kv AC 50 Hz 4.1 Electrical Clearances for At-Grade and Elevated Section 18 CHAPTER V PLATFORM SCREEN DOOR 5.1 Platform Screen Door Setting Out Dimensions 20 ii Oct 2015

452 Nagpur Metro Rail Corporation Limited LIST OF APPENDICES APPENDIX NO. DESCRIPTION PAGE NO. Appendix 1 Permissible Speed, Cant and Minimum 21 Track Spacing on Curves Appendix 2 Extra Horizontal Clearance on Curves 22 (Curvature effect) Appendix 3 Cant Effect on Kinematic Envelope Horizontal 24 (Vehicle Speed 90 kmph) At-Grade and Elevated sections Appendix 3i Cant Effect on Kinematic Envelope Horizontal 25 (Vehicle Speed 40 kmph) At-Grade and Elevated sections Appendix 3A Cant Effect on Structure Gauge (Corresponding to kmph KE) Horizontal At-Grade and Elevated Sections Appendix 3A Cant Effect on Structure Gauge (Corresponding to kmph KE) Horizontal At-Grade and Elevated Sections Appendix 4 Additional Clearance for platforms on curves 28 iii Oct 2015

453 Nagpur Metro Rail Corporation Limited LIST OF FIGURES FIGURE DESCRIPTION PAGE NO Figure No. NMSG-1 Figure No. NMSG 1A Figure No. NMSG 2 Kinematic Envelope for 90 kmph (At- Grade and Elevated Sections) Kinematic Envelope for 40 kmph (At- Grade and Elevated Sections) at platform Structure Gauge At-Grade and Elevated Sections on level or Constant Grade Tangent Track Figure No. NMSG 3 Effect of cant on Kinematic Envelope 32 Figure No. NMSG 3A Effect of cant on Structure Gauge 33 Figure No. NMSG- 4 Figure No. NMSG-5 Figure No.NMSG-6 Figure No.NMSG-7 Effect of vertical curve on Structure Gauge Structure Gauge at Elevated/ At-Grade station with side platforms on level or Constant Grade Tangent Track Structure gauge at Elevated / At-Grade station with island platform on level or constant grade tangent track Platform Gate Elevated/ At-Grade (Platform) on level or constant grade tangent track iv Oct 2015

454 COPY OF APPROVAL LETTER

455 Nagpur Metro Rail Corporation Limited SCHEDULE OF DIMENSIONS STANDARD GAUGE (1435 mm) PREAMBLE Nagpur Metro rail has adopted Standard Gauge with 25 kv AC OHE Traction System. The Schedule of Dimensions has been prepared based on following factors: - 1. The Kinematic Envelope and other infringements have been calculated for the 2900 mm wide and 4200 mm high Rolling Stock, based on the Kinematic Envelope calculations. The track and vehicle maintenance shall conform to the clearances indicated therein during the period that these Rolling Stocks are in operation. 2. Track shall be maintained to the tolerances taken for calculation of Kinematic Envelope. 3. The clearances are based on assumption that windows are sealed and doors are closed during movement / operation. 4. The Structure Gauge indicated in the SoD shall not be violated under any circumstances except for platform coping. 5. The Kinematic Envelope(s) indicated in the SoD shall not be violated under any circumstances. 6. The Vehicle Kinematic Envelope for 40 kmph shall be applied only within the confines of stations. At all other locations, the Kinematic Envelope corresponding to 90 kmph vehicle speed with 100 kmph side wind speed shall be used for determining the Structure Gauge and Electrical clearances. The maximum speed for passenger operation shall be 80 kmph. 7. Maximum operating speed at platform shall be 40 kmph and Kinematic Envelope will not be infringed under any circumstances. 8. This SoD is applicable for Ballastless track on mainline and ballasted/ballastless track in Depots. 9. For evacuation of passengers, in case of emergency, including in cases of derailment of the end coaches, emergency doors provided at both ends (front & rear) of the train shall be used for evacuation. The emergency doors will open and rest between or onto the track plinth and the space available between the track plinths shall be used as walkway. The evacuation will be done under the supervision of train operator and/or station staff. Page 1 of 37 Nov 2015

456 Nagpur Metro Rail Corporation Limited INTRODUCTION The dimensions given in this Schedule of Dimensions are to be observed in all works on 1435 mm gauge (STANDARD GAUGE), unless prior sanction has been obtained from the Railway Board through the Commissioner of Metro Railway Safety to execute works, which infringe this Schedule of Dimensions. This Schedule of Dimensions is applicable to Elevated and At-Grade sections of Nagpur Metro Rail, which shall be with 25 kv AC Traction system and Over Head current collection. The Rolling Stock shall be 2900 mm wide and 4200 mm high (maximum with pantograph in locked down condition or without pantograph) with sealed windows and doors closed while in motion. Elevated Systems shall be on Viaduct. Elevated section shall have suitably designed Ballastless (DFF) Track. At-Grade system and the Depot area may have either Ballasted Track or Ballastless Track. The Schedule of Dimensions (SoD) has been divided into five chapters as under Chapter-I General Chapter-II Stations Chapter-III Rolling Stock Chapter-IV Electric Traction Chapter-V Platform Screen Door Page 2 of 37 Nov 2015

457 Nagpur Metro Rail Corporation Limited CHAPTER-I GENERAL 1.1 SPACING OF TRACKS Minimum distance, centre to centre of tracks without any structure between tracks for tangent (straight) track: a) Elevated Sections 3650 mm b) At-Grade sections 3650 mm Note: See Para-1.8 and Appendix-1 for minimum track centers on curves. 1.2 CURVES Minimum radius of curves (horizontal) i) On main running lines Elevated and At-Grade Sections 120 m ii) Depot and other non-passenger Lines 100 m iii) At passenger platforms 1000 m Check Rail / Restraining Rail Check Rail / Restraining Rail shall be provided on curves on main line with a radius of 190 m or less. Check rail/restraining rail shall not be mandatory for curves in depots, yards and non-passenger lines like pocket track, depot entry lines, etc., where speed is less than 25 kmph. The clearance between check rail/restraining rail and running rail shall be suitably decided by metro Minimum radius of vertical curve 1500 m Cant and Cant Deficiency a) Maximum Cant on curves 125 mm b) Maximum Cant Deficiency 100 mm 1.3 GRADIENTS The maximum grade (compensated) shall be 4%. Note: (i) There will be no change of gradient in transition portion of curves. (ii) The gradient will be compensated for curvature at the rate of 0.04% per degree of curve. Page 3 of 37 Nov 2015

458 Nagpur Metro Rail Corporation Limited Maximum permissible gradient on turnouts Note: (i) On Ballasted Track 0.25% (ii) On Blallastless Track 2.5% (i) There shall be no change of grade on and within 15 m of any turnout on ballastless track. Similarly, there shall be no change of grade on and within 30 m of any turnout on ballasted track. (ii) In case of turnouts on gradient, there shall be no horizontal curve on and within 15 m of any turnout on ballastless track and 30 m of any turnout on ballasted track. 1.4 BUILDINGS AND STRUCTURES Minimum horizontal distance from centre of track to any structure (except at Note: passenger platform) for heights above rail level on level/constant grade tangent track shall be as under: - Elevated and At-Grade Sections Height from rail level i. Up to 65 mm 1465 mm ii. 65 mm to 200 mm iii. 200 mm to 305 mm iv. 305 mm to 930 mm Horizontal distance from C.L. of track 1465 mm increasing to 1640 mm 1640 mm 1640 mm increasing to 1735 mm v. 930 mm to 1095 mm 1735 mm increasing to1740 mm vi mm to 3310 mm vii mm to 3860 mm viii mm to 6200 mm Also refer to Figure No. NMSG mm increasing to 1825 mm 1825 mm decreasing to 1495 mm 1495 mm i) Extra allowance shall be provided for curves as laid down at Para-1.7. ii) The term structure covers any item including light ones like ladders, isolated posts, cables etc. erected alongside the track except for passenger platform. iii) Minimum lateral clearance for OHE masts for tangent track on the viaduct shall be 2150 mm from centre line of nearest track. iv) Minimum lateral clearance for OHE masts for tangent track at-grade and depot shall be 1950 mm from centre line of nearest track. iv) For passenger platform, refer to Para to of Chapter-II. Page 4 of 37 Nov 2015

459 Nagpur Metro Rail Corporation Limited 1.5 KINEMATIC ENVELOPE For the Kinematic Envelope for level or constant grade tangent track, refer to: a) Figure No. NMSG-1 for At-Grade and Elevated Sections. b) Figure No. NMSG-1A for At-Grade and Elevated sections at passenger platform. Note: Extra Allowance shall be provided for curves as laid down at Para STRUCTURE GAUGE Note: Elevated and At-Grade Sections The Structure Gauge (Fixed Structure Line) has been arrived at by allowing minimum clearance of 150 mm to Kinematic Envelope and minimum electrical clearance of 270 mm from 25 kv live parts conforming to the stipulations in chapter-iv of this SoD. Refer to Figure No. NMSG-2 for Structure Gauge for outside stations on level or constant grade tangent track. Extra allowance shall be provided for curves as laid down at Para EXTRA CLEARANCES ON CURVES Following are the extra allowances considered for curves. Abbreviations used in Para-1.7: C is the distance between centres of bogies in metres, C1 is the coach (vehicle) length in metres, R is the radius of curve in metres, Ca is the Cant applied in mm, h is the height from rail level in mm and g is the distance between centres of rails in mm INSIDE OF CURVE Note: A. Curvature effect i) Mid throw at the center of the vehicle = V (in mm) =125xC 2 /R ii) Allowance due to gauge widening on curves For values of items (i) and (ii) above, refer to Appendix-2 Lateral shift of 26 mm due to nosing is included in Kinematic Envelope for tangent track (and as a result, included in Structure Gauge also) shall be subtracted from the total extra allowance worked out as at Para-1.7.1(A)-i &ii Page 5 of 37 Nov 2015

460 Nagpur Metro Rail Corporation Limited above for inside of a curve in case the value of mid throw (V) is equal to or greater than 26 mm. In case the value of mid throw (V) is less than 26 mm, the curvature effect shall be due to widening of the gauge only. (The Mid throw minus 26 mm shall be taken as zero). B. Clearance for Cant Elevated and At-Grade Sections The lean L due to Cant at any point at height h above rail level is given by: L = Ca x h/g (all in mm) For values of Structure Gauge (E1) for inside of a curve with cant effect only, (as shown in Figure No. NMSG-3A), refer to Appendix-3A for At- Grade and Elevated Sections. C. Clearance for vertical curve (vertical throw) Vertical Throw V1 and V2 (in mm) for vertical curve shall be calculated as under: V1 (with vehicle centre in sag or vehicle end on summit) = 125xC 2 /R V2 (with vehicle centre on summit or vehicle end in sag) = (125xC1 2 /R)-(125xC 2 /R) For values of vertical throw V1 & V2 due to vertical curves of different radii, refer to NMSG OUTSIDE OF CURVE A. Curvature effect i) End throw at the end of vehicle = Vo (in mm) ii) Allowance due to gauge widening on curves iii) Additional nosing due to gauge widening on curves The values of items (i) to (iii) are shown in Appendix-2 B. Clearance for Cant Elevated, and At-Grade sections = [125xC1 2 /R]-[125xC 2 /R] The lean L due to Cant at any point at height h above rail level is given by: L = (-) Ca x h/g (all in mm) -ve sign indicates relief due to cant or reduction in clearance required. Page 6 of 37 Nov 2015

461 Nagpur Metro Rail Corporation Limited Note: Full relief for lean due to cant (Ca) is to be taken into account only for calculation of track spacing without any structure between tracks. In case there is a structure adjacent to track, relief for lean is to be taken into account only if the cant provided is greater than 50 mm and shall be limited to a value = (Ca - 50) x h/g. For values of Structure Gauge (F1) on outside of curve with Cant effect only (as shown in Figure No. NMSG-3A), refer to Appendix-3A for Elevated and At- Grade Sections. C. Clearance for vertical curve (Vertical throw) The provisions at Para (C) above shall be applicable in this case also. For values of vertical throws V1 & V2 due to vertical curves of different radii, refer to NMSG MINIMUM TRACK SPACING ON CURVES Elevated and At-Grade Sections The worst case will be when the end of a bogie carriage on the inner track is opposite the centre of a similar carriage on the outer track Without any structure between tracks Notes: The minimum track spacing on curves without any structure between tracks shall be the sum of the following: i) (E + F), ii) T1 (Extra lateral allowance due to curvature on inside of curve iii) T2 (Extra lateral allowance due to curvature on outside of curve iv) Minimum clearance between adjacent Kinematic Envelopes stipulated is as under:- 300 mm for Elevated and At-Grade Sections. Where, E is the distance from vertical axis of centre line of canted track to canted Kinematic Envelope on inside of curve at a height h (from rail level) for a given cant (Figure No. NMSG-3) and F is the distance from vertical axis of centre line of canted track to canted Kinematic Envelope on outside of curve at a height h (from rail level) for a given cant (Figure No. NMSG-3). i) The value of F, calculated from the formula at Figure No. NMSG-3 includes full relief due to Cant. Page 7 of 37 Nov 2015

462 Nagpur Metro Rail Corporation Limited ii) The sum of 'E' and 'F' for same height (which are with Cant effect only) shall be the maximum of values calculated for various heights from rail level. For values of E, F, T1 and T2, refer to the Appendices as shown below: SECTIONS For E & F For T1 &T2 Elevated and At-Grade 1. 3 for 90 kmph KE 2. 3i for 40 kmph KE With a structure between adjacent tracks Notes: The minimum track spacing on curves with a structure between tracks shall be the sum of the following: Where, i) (E1 +T1) Minimum clearance to the structure from centre line of track on inside of curve (for outer track) ii) (F1 +T2) Minimum clearance to the structure from centre line of track on outside of curve (for inner track) iii) Width of structure between adjacent tracks (measured across the tracks). E1 is the horizontal distance from vertical axis of centre line of track to canted Structure Gauge on inside of curve for a given cant, (Ref Fig no: NMSG-3A) F1 is the horizontal distance from vertical axis of centre line of track to canted Structure Gauge on outside of curve for a given cant, (Ref Fig no: NMSG-3A) T1 is extra lateral allowance due to curvature on inside of curve and T2 is extra lateral allowance due to curvature on outside of curve. (i) The values of E1 and F1 for a given cant Ca, shall each be the maximum of values at different heights of structure from rail level. In case the cant provided is greater than 50 mm on inner track, the value of F1 shall be for the cant of (Ca-50) mm. In case the cant provided is 50 mm or less on inner track, the value of F1 shall be for ZERO cant. Page 8 of 37 Nov 2015

463 Nagpur Metro Rail Corporation Limited (ii) Minimum track spacing, so worked out with a structure between the adjacent tracks shall not be less than that calculated as per Para for tracks without any structure between adjacent tracks. For values of E1, F1, T1 and T2, refer to the Appendices as shown below: SECTIONS For E1 & F1 For T1 &T2 Elevated and At-Grade 1. 3A for Structure Gauge corresponding to 90 kmph KE. 2. 3Ai for Structure Gauge corresponding to 40 kmph KE DERAILMENT GUARD (a) Derailment Guard shall be provided on inside/outside of running rail on viaduct and At-Grade section at locations specified by Metro Railway. (b) Lateral Clearance between the running rail and the derailment guard shall be 250 ± 40 mm. It shall not be lower than 25 mm below the top of running rail and shall be clear of the rail fastenings to permit installation, replacement and maintenance SPECIAL OPERATING CONDITIONS: (COMMON FOR ELEVATED AND AT- GRADE SECTIONS) Scheduled maintenance of permanent way will be performed outside service hours only All the passenger coaches will be provided with sealed windows including the cab, to prevent limbs and heads of passengers projecting outside the train. The passenger coaches will be provided with automatic remote controlled double leaf doors with their control from drivers cab. Until all doors are proved closed, it should not be possible to start the train. Likewise until the train has come to the stop, it should not be possible to energize the door opening circuits Since minimum clearance with fully worn wheel and under fully loaded condition from rail level for bogie mounted equipment is 75 mm, the coaches with the clearance less than 75 mm will not run on Metro Railway network. Page 9 of 37 Nov 2015

464 Nagpur Metro Rail Corporation Limited The way side signaling, wherever provided, in addition to ATP, on temporary or permanent basis, will be so located that proper visibility to the driver is ensured. No workmen / Equipment are allowed between vehicle and structure gauge during operation of trains The corridor when fully functional will not have way side signaling as train protection will be by ATP. However in the initial period, till cab signaling system is fully commissioned, there will be way-side signaling which should be so located near the masts so that the proper visibility to the driver is ensured considering the alignment The evacuation of passengers in case of emergency in mid-section shall be done from front & rear emergency doors of the train. Space available between the track plinths shall be used as the walkway. The evacuation will be done under the supervision of train operator and/or station staff Additional Operating Condition for Elevated and At-Grade Sections In case of At-Grade sections, the track may be passing through populated areas and there are chances of trespass. Considering this fact, to prevent the people s and animals access to the track, the sections will be robustly fenced The speed of trains shall be restricted to 30 kmph on platform when wind speed is more than 70 kmph but less than 100 kmph. When wind speed exceeds 100 kmph, the train movement shall be halted, preferably at platforms. Stationary trains shall not be started till wind speed reduces below 100 kmph As the track will be open to the climate, temperature variation will take place in the track, frequent cab inspection will be done during extreme winter and summer. Page 10 of 37 Nov 2015

465 Nagpur Metro Rail Corporation Limited CHAPTER - II STATIONS 2.1 SPACING OF TRACKS AT STATIONS Minimum spacing of tracks at station on straight and on curve of radius of 1000 m and flatter, without any structure between tracks Elevated & At-Grade stations 3650 mm 2.2 PLATFORMS Maximum horizontal distance from centre of track to face of passenger platform coping (i) For Elevated/At-Grade section 1525 mm Minimum horizontal distance from centre of track to face of passenger platform coping (i) For Elevated/At-Grade section 1520 mm Notes: a) Platform faces shall be flared away smoothly from the centre line of the track at either end for a distance of 1500 mm beyond passenger area so as to give from centre of track a dimension: for At grade and Elevated Stations b) For additional clearance for platforms on curves, refer to Para-2.7 c) The track access gates at the end of platform up to a height of one meter from top of platform shall not infringe the Kinematic Envelope Height above rail level for passenger platform: Maximum Minimum (a) Ballasted Track 1085 mm 1075 mm (b) Ballastless Track (DFF) 1095 mm 1085 mm (i) Minimum horizontal distance of any isolated structure on 2500 mm a passenger platform from the edge of coping. ii) Minimum horizontal distance of any continuous structure on a passenger platform from the edge of coping mm Page 11 of 37 Nov 2015

466 Nagpur Metro Rail Corporation Limited Notes: a) The structure on the platform is treated as isolated if the length along the platform length is 2000 mm or less. Any structure having a length exceeding 2000 mm is treated as continuous structure. The clocks/mirrors/cctv screens etc shall not be considered structures and shall be located at a minimum horizontal distance of 1000 mm from platform edge/coping with minimum height of 2000 mm from top of platform. b) There shall be no cant in passenger platform lines For Structure Gauge at stations at Elevated Stations and At-Grade, refer to figure no NMSG-5 & NMSG GRADIENTS Track gradient in Stations Gradient of track in station platform length shall be as under: (a) Maximum gradient 1 in 400 (b) Desirable Level Note: i) There shall be no change of grade/vertical curve within station platform track. ii) There shall be no change of gradient within 30 m of any points or crossings on Ballasted track. In the case of Ballastless track, there shall be no change of grade/ vertical curve on the turnout. 2.4 INTERLOCKING AND SIGNAL GEAR Note: Maximum height above rail level of any part of interlocking or signal gear on either side of centre of track subject to the restrictions embodied in Note below shall be as under: At-Grade and Elevated Stations From C.L. of track to 1330 mm 25 mm From 1330 mm to 1465 mm 25 mm increasing to 65 mm From 1465 mm to 1640 mm 65 mm increasing to 200 mm Except for check rails on curves, ordinary and diamond crossings or wing rails and point rails of crossings leading to snag dead ends, or such parts of signalling gear as are required to be actuated by the wheels, no gear or track fittings shall project above rail level for a distance of 229 mm outside and 140 mm inside the gauge face of the rails. Page 12 of 37 Nov 2015

467 Nagpur Metro Rail Corporation Limited 2.5 POINTS & CROSSINGS Maximum clearance of check rail opposite nose of crossing 44 mm Minimum clearance of check rail opposite nose of crossing 41 mm Minimum clearance between switch rail and stock rail at heel 52 mm of switch Maximum clearance of wing rail at nose of crossing 44 mm Minimum clearance of wing rail at nose of crossing. 41 mm Minimum clearance between toe of open switch and stock rail. 160 mm Minimum radius of curvature for slip points, turnouts and 140 m crossovers On main lines, the turnouts and diamond Crossings shall be of the following types a) 1 in 9 type turnout 190 m radius b) 1 in 7 type turnout 190 m radius (Desirable) 140 m radius (Exceptional circumstances) c) Scissors cross-over of 1 in 9 type consisting of 4 acute turnouts of 1 in 9 and 1 diamond crossing. d) Scissors cross-over of 1 in 7 type consisting of 4 acute turnouts of 1 in 7 and 1 diamond crossing On depot lines, non-passenger lines like pocket track, depot entry lines etc, the turnouts and diamond Crossings shall be of the following types: a) 1 in 7 type turnout 140 m radius b) Scissors cross-over of 1 in 7 type consisting of 4 acute turnouts of 1 in 7 and 1 diamond crossing. c) 1 in 7 derailing switches/ 1 in 7 type symmetrical split turnout Diamond crossings not to be flatter than 1 in 6. Page 13 of 37 Nov 2015

468 Nagpur Metro Rail Corporation Limited Note: a) The above restrictions shall not apply to moveable diamond crossings. b) Switches and crossings shall not be located on transition curves & vertical curves. b) There must be no change of super elevation (of outer over inner rail) between points 18 m outside toe of switch rail and nose of crossings respectively, except in the case of special crossing leading to snag deadends or under circumstances as provided for in item 2.6 below Minimum length of tongue rail 9000 mm Minimum track spacing for 1 in 7 scissors crossover 4500 mm Minimum track spacing for 1 in 9 scissors crossover 4500 mm 2.6 SUPER-ELEVATIONS AND SPEED AT STATIONS ON CURVES WITH TURNOUTS OF CONTRARY AND SIMILAR FLEXURE Main Line: Subject to the permissible run through speed based on the standard of interlocking, the equilibrium super-elevation, calculated for the speed of the fastest train may be reduced by a maximum amount of 100 mm without reducing speed on the main line Turnouts: i) Curves of contrary flexure The equilibrium super-elevation (s) in mm should be = (1510/127)*(V 2 / R) Where, R = Radius of turnout in meters and V is speed on turnout in Kmph. The permissible negative super-elevation on the turnout (which is also the actual super-elevation of the main line) may then be = (100 s) mm. ii) Curves of similar flexure The question of reduction or otherwise of super-elevation on the main line must necessarily be determined by the administration concerned. In the case of a reverse curve close behind the crossing of a turnout, the super-elevation may be run out at the maximum of 1 mm in 400 mm. Page 14 of 37 Nov 2015

469 Nagpur Metro Rail Corporation Limited 2.7 ADDITIONAL CLEARANCE FOR PLATFORMS ON CURVES The additional clearance for platforms on curves shall be provided as shown at Appendix-4 Note: As the minimum radius of curve for stations is 1000 m, there will be no super elevation and gauge widening on passenger platform lines. Page 15 of 37 Nov 2015

470 Nagpur Metro Rail Corporation Limited CHAPTER-III ROLLING STOCK 3.1 PASSENGER ELECTRIC MULTIPLE UNITS (a) Maximum Length of the coach body (including end fairings) (b) Maximum width of the vehicle (c) Height of the coach body (maximum with pantograph in locked down condition) mm 2900 mm 4200 mm Distance between bogie centres mm Kinematic Envelope for level tangent track a. For At-Grade and Elevated Sections except for passenger platform. b. For At-Grade and Elevated Sections at passenger platform Minimum clearance above rail level under dynamic condition of fully loaded vehicle under worst condition** for bogie and axle mounted equipment Minimum clearance above rail level under dynamic condition of fully loaded vehicle under worst condition*** for body mounted equipment. Figure No. NMSG-1 Figure No. NMSG-1A 75 mm 102 mm Wheel **The worst condition means it is with deflection of primary suspension and maximum tread wear. ***The worst condition means it is with deflection of primary suspension and, deflated air spring and maximum tread wear. a) Maximum wheel gauge back to back distance b) Minimum wheel gauge back to back distance a) Maximum diameter on the tread (measured at 70 mm from wheel gauge face) 1360 mm 1358 mm 860 mm Page 16 of 37 Nov 2015

471 Nagpur Metro Rail Corporation Limited b) Minimum diameter on the tread (measured at 70 mm from wheel gauge face) a) Minimum projection for flange of new wheel (measured at 70 mm from wheel gauge face) b) Maximum projection for flange of worn wheel (measured at 70 mm from wheel gauge face) a) Maximum thickness of flange of wheel measured from wheel gauge face at 18 mm from outer edge of flange. b) Minimum thickness of flange of wheel measured from wheel gauge face at 18 mm from outer edge of flange. 780 mm 28 mm 36 mm 32.5 mm 22 mm Minimum width of wheel 127 mm Incline of tread 1 in Floor Height a) Maximum height above rail level for floor of any unloaded vehicle b) Minimum height above rail level for floor of fully loaded normal vehicle a) Maximum height of centre coupler above rail level for unloaded vehicle b) Minimum height of centre coupler above rail level for fully loaded vehicle 1130 mm 1100 mm 815 mm 740 mm Maximum length over couplers mm Length of rigid wheel base for single bogie 2200 to 2600 mm Maximum distance between any two adjacent axles mm 3.2 LOCOMOTIVES AND ENGINEERING SERVICE VEHICLES Other items of rolling stock, viz shunting locomotives, OHE maintenance and inspection cars, emergency re-railing vans, track machines, etc., used on Nagpur Metro System (where these cars would be plying) will conform with the Kinematic Envelope of the Passenger Electric Multiple Units as shown in Figure No NMSG - 1 for Elevated & At-Grade sections and Figure No NMSG-1A for Elevated & At-Grade sections at platforms. Page 17 of 37 Nov 2015

472 Nagpur Metro Rail Corporation Limited CHAPTER-IV OVERHEAD ELECTRIC TRACTION 25 kv/ac 50 CYCLES PER SECOND Note: Special precautions must be taken to maintain following clearances: 4.1 ELECTRICAL CLEARANCES FOR AT-GRADE AND ELEVATED SECTIONS Minimum vertical distance between any live bare conductor (overhead equipment or pantograph) and any earthed structure or other bodies (rolling stock, over bridges, signal gantries etc.) Note: Condition For Flexible OHE (i) Long duration (Static) 250 mm (ii) Short Duration (Dynamic ) 200 mm A minimum vertical distance of 270 mm shall normally be provided between rolling stock and contact wire to allow for a 20 mm temporary raising of the tracks during maintenance. Wherever the allowance required for track maintenance exceeds 20 mm, the vertical distance between rolling stock and contact wire shall correspondingly be increased Minimum lateral distance between any bare live conductor (overhead equipment or pantograph) and any earthed structure or other bodies (rolling stock, over bridges, signal gantries etc.) Condition (i) Long duration (Static) 250 mm (ii) Short Duration (Dynamic) 200 mm For Flexible OHE Height of contact wire: Minimum height from rail level to the underside of live Conductor wire i) In the open, Under bridges and other special locations mm ii) At level crossings mm Note: iii) In running and carriage sheds where staff may be expected to work on the roof of rolling stock mm a) The normal height from rail level to the underside of contact wire is 5000 mm b) On curves, all vertical distances specified in items above, shall be measured above level of the inner rail, increased by half the superelevation. Page 18 of 37 Nov 2015

473 Nagpur Metro Rail Corporation Limited Maximum variation of the live conductor wire on either side of the centre line of the track under static conditions: Note: i) On straight mm ii) On Curves mm These limits would not apply to special locations like insulated overlaps and out of run wires Maximum width of pantograph collector: The Kinematic Envelope with the size of Pantograph adopted shall be within the Kinematic Envelope shown at Figure No. NMSG-1. Page 19 of 37 Nov 2015

474 Nagpur Metro Rail Corporation Limited CHAPTER-V PLATFORM SCREEN DOOR 5.1 PLATFORM SCREEN DOOR SETTING OUT DIMENSIONS Minimum Platform screen door width Minimum Platform screen door height Maximum Platform screen door threshold offset from track centerline straight track Minimum Platform screen door panel offset from track centerline straight track Minimum Platform screen door header offset from track centerline Station Platform height finished architectural level Minimum horizontal distance of any structure on a passenger platform from the edge of coping 2000 mm 2150 mm 1520 mm 1525 mm 1520 mm 1090±5mm 2500 mm Note: (a) Assumed plus/minus 300 mm stopping accuracy. (b) Platform screen door at stations on curves shall be considered separately taking into account the additional clearance as per Appendix-4. (c) Platform screen doors are designated as railway operational structures. Therefore, platform screen doors may infringe the Structure Gauge, but does not infringe the kinematic envelope and having minimum clearance of 10 mm from kinematic envelope to platform screen door (refer NMSG-7) (d) The deflector attached to the bottom of the sliding door shall be designed in order not to protrude beyond the door threshold. Page 20 of 37 Nov 2015

475 Nagpur Metro Rail Corporation Limited Appendix-1 PERMISSIBLE SPEED, CANT AND MINIMUM TRACK SPACING ON CURVES. ELEVATED AND AT-GRADE SECTIONS Notes: (a) RADIUS OF CURVE CANT MAXIMUM PERMISSIBLE SPEED MINIMUM DISTANCE BETWEEN ADJACENT TRACKS See note (a) (m) mm kmph mm 3000 or more * * The track spacing shown in the table above is without any column/structure between two tracks and is with equal cant for both outer and inner tracks. b) Track spacing shown in Table above is not applicable to stations which should be calculated depending on specific requirement. c) Figures for any intermediate radius of curvature may be obtained by adopting the value for sharper curve. d) Cant provided is limited to desirable value of 125 mm. e) Maximum cant deficiency is 100 mm f) Maximum permissible speed shown in above is calculated with maximum super-elevation of 110 mm and maximum cant deficiency of 85 mm. g) The above table gives the max permissible speed for different curvatures. However, the cant to be provided depends on the speed attainable on any speed restrictions etc. The speed attainable should be determined through speed simulation. h) Spacing between tracks = E+F+T1+T2+300 mm (clearance between adjacent Kinematic Envelopes). Where, E& F refers to Fig. NMSG-3, T1 & T2 refers to Appendix-2 T1 = Extra lateral allowance due to curvature inside of curve. T2 = Extra lateral allowance due to curvature outside of curve. * Curves to be provided in depots Page 21 of 37 Nov 2015

476 Nagpur Metro Rail Corporation Limited RADIUS OF CURVE MID- THROW (28500/R) Appendix-2 EXTRA HORIZONTAL CLEARANCE ON CURVES NOSING INCLUDED IN K.E/ STRUCTURE GAUGE FOR TANGENT TRACK (CURVATURE EFFECT) INSIDE OF CURVE EXTRA GAUGE TOLERANCE ON CURVES REFERENCE: PARA EXTRA HORIZONTAL CLEARANCE ON CURVE (m) (mm) (mm) (mm) (mm) (R) (V) ( N ) (G) (T1) or more REMARKS (G) EXTRA GAUGE TOLERANCE ON CURVES SHARPER THAN 1000 m RADIUS: 9 mm FOR CURVES WITH RADII SHARPER THAN 500 m AND 5 mm FOR CURVES WITH RADII OF 500 m TO LESS THAN 1000 m. T 1=V-N+G for V EQUAL TO OR GREATER THAN (N) AND T1= G for V < (N) Note: Mid throw ( in mm ) V = (125 x C 2 ) /R= 28500/R Where 'C' is the distance between bogie centers= =15.100m OR = m The worst case will be with C= m R is the radius of curve in metres. Mid throw (in mm) V = (125 x C 2 ) /R= 28500/R Page 22 of 37 Nov 2015

477 Nagpur Metro Rail Corporation Limited RADIUS OF CURVE END- THROW (33525/R) EXTRA GAUGE TOLERANCE ON CURVES OUTSIDE OF CURVE EXTRA NOSING DUE TO EXTRA GAUGE TOLERANCE REFERENCE: PARA EXTRA HORIZONTAL CLEARANCE ON CURVE (m) (mm) (mm) (mm) (mm) (R) (Vo) (G) (EN) (T2) or more REMARKS (G) EXTRA GAUGE TOLERANCE ON CURVES SHARPER THAN 1000 m RADIUS: 9 mm FOR CURVES WITH RADII SHARPER THAN 500 m AND 5 mm FOR CURVES WITH RADII OF 500 m TO LESS THAN 1000 m. T2=Vo+G+EN EN=Gx Note: End Throw ( in mm ) Vo= (125 x C1 2 ) /R - (125xC 2 )/R = 33525/R Where 'C' is the distance between bogie centers = =15.100m OR = m Worst case will be with C= m 'C1' is length of coach in meters = m and 'R' is radius of curve in meters. Page 23 of 37 Nov 2015

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482 Nagpur Metro Rail Corporation Limited Appendix-4 Additional Clearance for Platforms on Curve Elevated and At-Grade stations Radius (metre) Cant (mm) Extra Clearance (mm) Remarks Inside of curve Outside of curve 1. Extra Clearance for curves: a) Inside of curve = Midthrow = 125C 2 /R = 28500/R and C, Distance between bogie centres = 15.10m for the worst case and R is radius of curvature in metre. b) Outside of curve = Endthrow = (125C 12 /R) - (125C 2 /R) = 33525/R where C 1, Length of the vehicle = 21.94m (including end fairings) and C, Distance between bogie centres = 14.60m for the worst case and R is radius of curvature in metre. 2. Additional Sway has not been taken to reduce the extra clearance on curved platforms. Page 28 of 37 Nov 2015

483 Nagpur Metro Rail Corporation Limited COACH PROFILE C/C OF RAILS KINEMATIC ENVELOPE FOR 90 kmph AT-GRADE AND ELEVATED SECTIONS ON LEVEL OR CONSTANT GRADE TANGENT TRACK EXCEPT FOR PASSENGER PLATFORM STANDARD GAUGE NAGPUR METRO RAIL CORPORATION LTD ( 1435 mm ) 25 kv A.C.TRACTION SCALE: NOT TO SCALE FIGURE No. NMSG-1 REF: PARA 1.5, 3.1 & 3.2 Page 29 of 37 Nov 2015

484 Nagpur Metro Rail Corporation Limited KE HEIGHT OF PANTOGRAPH IN WORKING POSITION Y' NOTES: 1. ALL DIMENSIONS ARE IN mm. 2. HORIZONTAL AND VERTICAL ALLOWANCES DUE TO CURVES, INCLUDING VERTICAL CURVES AND CANT SHALL BE EXTRA. 3. KINEMATIC ENVELOPE IS VALID FOR VEHICLES WITH SEALED WINDOWS AND DOORS CLOSED WHEN IN MOTION. 4. KINEMATIC ENVELOPE IS VALID FOR 40 KMPH VEHICLE SPEED STATIC HEIGHT OF PANTO IN LOCKED DOWN POSITION CO-ORDINATES X' Y' COACH PROFILE C.L. OF TRACK PLATFORM COPING 1525 (Maximum) 1520 (Minimum) KINEMATIC ENVELOPE AT PLATFORM FOR OPERATING SPEED OF 40 KMPH AND WIND SPEED OF 80KMPH PLATFORM RAIL LEVEL X' NAGPUR METRO RAIL CORPORATION LTD STANDARD GAUGE ( 1435 mm ) 25 kv A.C.TRACTION KINEMATIC ENVELOPE FOR 40 KMPH AT GRADE AND ELEVATED SECTIONS ON LEVEL OR CONSTANT GRADE TANGENT TRACK AT PASSENGER PLATFORM SCALE: NOT TO SCALE FIGURE NO. NMSG-1A REF: PARA 1.5, 3.1 & 3.2 Page 30 of 37 Nov 2015

485 Nagpur Metro Rail Corporation Limited 1546 KE HEIGHT OF IN PANTOGRAPH WORKING POSITION STATIC HEIGHT OF IN PANTOGRAPH IN LOCKED DOWN POSITION 4200 FROM RAIL LEVEL STRUCTURE GAUGE TANGENT TRACK NOTES MIN ALL DIMENSIONS ARE IN mm. 2. THIS STRUCTURE GAUGE WILL ALSO BE APPLICABLE FOR ROBs/FOBs AT STATIONS WITHOUT THE MAST UNDER THE STRUCTURES. IN CASE THE CONTACT WIRE IS HIGHER, THE HEIGHT OF THE ROB/FOB SHALL BE INCREASED ACCORDINGLY. 3. MINIMUM CLERANCE BETWEEN KINEMATIC ENVELOPE AND STRUCTURE GAUGE WILL BE 150 mm. MINIMUM ELECTRICAL CLEARANCE OF 270 mm SHALL BE MAINTAINED BETWEEN 25 KV LIVE PARTS AND THE EARTHED STRUCTURES. 4. MINIMUM LATERAL CLEARANCE FOR OHE MAST WILL BE 2150 mm FROM THE CENTRE OF TRACK. 5. MINIMUM LATERAL CLEARANCE FOR OHE MAST WILL BE 1950 mm FROM THE CENTRE OF TRACK FOR AT GRADE AND DEPOT. 6. THE KINEMATIC ENVELOPE AND STRUCTURE GAUGE ARE VALID FOR ROLLING STOCK WITH SEALED WINDOWS AND DOORS CLOSED WHILE IN MOTION HORIZONTAL AND VERTICAL ALLOWANCE DUE TO CURVES INCLUDING VERTICAL CURVE AND CANT SHALL BE EXTRA. 8. FOR KINEMATIC ENVELOPE, REFER TO FIGURE:NMSG-1 9. THIS STRUCTURE GAUGE IS VALID FOR 90 kmph VEHICLE SPEED MINIMUM REFER TO PARA C/C OF RAILS 229 STRUCTURE GAUGE AT-GRADE AND ELEVATED SECTIONS (OUTSIDE STATION) ON LEVEL OR CONSTANT GRADE TANGENT TRACK NAGPUR METRO RAIL CORPORATION LTD STANDARD GAUGE ( 1435 mm ) 25 kv A.C.TRACTION SCALE: NOT TO SCALE FIGURE No. NMSG-2 REF: PARA 1.4 & 1.6 Page 31 of 37 Nov 2015

486 Nagpur Metro Rail Corporation Limited KINEMATIC ENVELOPE ab=ab= Distance from centerline of track to Kinematic Envelope for Tangent Track at height 'h' sin = cant/g g= 1510 mm Ca = Cant applied E =[ab+( h x tan )] x cos F =[Ab- (h x tan )] x cos a E b c d B F A H 1=(Ca/2)+(h/cos )+(Ab-h x tan ) x sin H 2=(Ca/2)+(h/cos ) - (ab+h x tan ) x sin For values of E, F, H 1and H 2, refer to Appendix 3 for 90 kmph Kinematic Envelope and Appendix 3a for 40 kmph Kinematic Envelope. NOTES: KINEMATIC ENVELOPE FOR AT-GRADE/ELEVATED SECTIONS HAS BEEN SHOWN AS A TYPICAL FIGURE. H 2 h H1 g C/C OF RAILS Ca=Cant EFFECT OF CANT ON KINEMATIC ENVELOPE STANDARD GAUGE NAGPUR METRO RAIL CORPORATION LTD. ( 1435 mm ) 25 kv A.C.TRACTION SCALE: NOT TO SCALE FIGURE No. NMSG-3 REF: PARA Page 32 of 37 Nov 2015

487 Nagpur Metro Rail Corporation Limited ab=ab= Distance from centerline of track to Structure Gauge for Tangent Track at height 'h' sin = cant/g g= 1510 mm Ca = Cant applied E 1=[ab+( h x tan )] x cos F 1 =[Ab- (h x tan )] x cos H 1=(Ca/2)+(h/cos )+(Ab-h x tan ) x sin H 2=(Ca/2)+(h/cos ) - (ab+h x tan ) x sin CENTRE LINE OF TRACK For values of E 1, F 1, H 1and H 2, refer to Appendix 3A. INSIDE OF CURVE STRUCTURE GAUGE OUTSIDE OF CURVE NOTES: STRUCTURE GAUGE FOR AT-GRADE/ELEVATED SECTION HAS BEEN SHOWN AS A TYPICAL FIGURE. H2 a E B b c 1 d 1 C/C OF RAILS=g F h A H1 Cant = Ca EFFECT OF CANT ON STRUCTURE GAUGE NAGPUR METRO RAIL CORPORATION LTD. STANDARD GAUGE ( 1435 mm ) 25 kv A.C.TRACTION SCALE: NOT TO SCALE FIGURE No. NMSG-3A REF: PARA 1.7.1, &1.8.2 Page 33 of 37 Nov 2015

488 2 1 V V V V 2 1 Nagpur Metro Rail Corporation Limited VERTICAL THROW RADIUS OF VERTICAL CURVE metres V mm V 2 mm NOTE: THE FIGURE IS TYPICAL AND WILL APPLY TO ELEVATED AND AT-GRADE SECTIONS. EFFECT OF VETRTICAL CURVE ON STRUCTURE GAUGE NAGPUR METRO RAIL CORPORATION LTD. STANDARD GAUGE ( 1435 mm ) 25 kv A.C.TRACTION SCALE: NOT TO SCALE FIGURE No. NMSG-4 REF: PARA 1.7.1(C) & 1.7.2(C) Page 34 of 37 Nov 2015

489 Nagpur Metro Rail Corporation Limited FIXED STRUCTURE LINE (STRUCTURE GAUGE) RADIUS= mm. (THIS WILL VARY WITH TRACK SPACING AND OHE STRUCTURE) R PLATFORM 3275 (WITH BALLASTLESS TRACK) KINEMATIC ENVELOPE TANGENT TRACK PLATFORM COPING (MAXIMUM) 1525 (MINIMUM) 1520 KINEMATIC ENVELOPE AT 40 kmph SPEED 1435 C.L. OF TRACK 1510 C/C OF RAILS (MIN) (MAXIMUM) 1525 (MINIMUM) MINIMUM C/C OF TRACKS =3650 (WITHOUT ANY STRUCTURE) C.L. OF TRACK C/C OF RAILS PLATFORM COPING MINIMUM FIXED STRUCTURE LINE (STRUCTURE GAUGE) ISOLATED STRUCTURE PLATFORM 1520 CONTINUOUS STRUCTURE (WITH BALLASTED TRACK) RAIL LEVEL NOTES: 1. ALL DIMENSIONS ARE IN mm. 2. ALLOWANCE FOR CURVE/CANT SHALL BE EXTRA. HOWEVER THE TRACK CENTRES AT STATION WILL NOT INCREASE WITH CURVES OF RADIUS OF 1000 M AND ABOVE. 3. STRUCTURE GAUGE IS VALID FOR VEHICLES WITH SEALED WINDOWS AND DOORS CLOSED WHILE IN MOTION 4. OHE IS SUSPENDED FROM CEILING BY DROP ARM. 5. IN THE STATION AREAS A REDUCED KE AS SHOWN IN THIS FIGURE SHALL BE APPLICABLE SUCH THAT THE KE IS CLEAR OF THE PLATFORM COPING AND ACCORDINGLY THE MAXIMUM SPEED THAT CAN BE PERMITTED IN THE STATION AREAS SHALL BE DETERMINED NAGPUR METRO RAIL CORPORATION LTD STANDARD GAUGE ( 1435 mm ) 25 kv A.C.TRACTION STRUCTURE GAUGE AT ELEVATED/AT-GRADE STATION WITH SIDE PLATFORMS LEVEL OR CONSTANT GRADE TANGENT TRACK SCALE: NOT TO SCALE FIGURE NO. NMSG-5 REF: PARA Page 35 of 37 Nov 2015

490 25 kv A.C. TRACTION (1435mm) Minimum Min 6200 OHE MAST OHE MAST Minimum Minimum TYPICAL FOR 8.0 m WIDE ISLAND PLATFORM. STRUCTURE GAUGE AT ELEVATED STATION WITH ISLAND PLATFORM STANDARD GAUGE FIGURE NO NMSG - 6 b) Allowance for curve shall be extra. c) Structure gauge is valid for vehicles with sealed windows and doors closed while in motion. d) Distance of platform coping from center of track as per the Para ± 5 mm FOR BALLASTLESS TRACK 1080 ± 5 mm FOR BALLASTED TRACK NOTES : ON LEVEL OR CONSTANT GRADE TANGENT TRACK NAGPUR METRO RAIL CORPORATION LTD SCALE: NOT TO SCALE REFER PARA a) All Dimensions are in mm. Nagpur Metro Rail Corporation Limited 2150 Min ISOLATED STRUCTURE Minimum 2150 Page 36 of 37 Nov CONTINUOUS STRUCTURE 1520 CONTINUOUS STRUCTURE ISOLATED STRUCTURE