Specification No.CSC-129/R-1/DH/UH/P&D/ TECHNICAL SPECIFICATION FOR. 400,500,630 & 1000 KVA,11KV / 0.4KV Compact Sub Station

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1 Specification No.CSC-129/R-1/DH/UH/P&D/ TECHNICAL SPECIFICATION FOR 400,500,630 & 1000 KVA,11KV / 0.4KV Compact Sub Station Issue Month:June-2016 Amendment date Common Specification Committee UHBVN & DHBVN Page 1 of 11

2 1.0 SCOPE: This specification covers the technical requirements of design, manufacture, testing at manufacturer's works, packing, forwarding, supply and unloading at store/site and performance of Package type substation comprising an enclosure containing high voltage switchgear, transformer and low voltage switchgear with LT Metering. The transformer shall be of400,500,630 &1000 KVA, The HV compartment shall comprise 3 Way Indoor type Ring Main Unit The LV compartment shall comprise - 1 LT ACBs along with MCCBs 2.0 APPLICABLE STANDARDS The equipment covered by this specification shall unless otherwise stated, be designed, manufactured and tested in accordance with the latest editions of the following Indian/International standards and shall conform to the regulations of the local statutory authorities. Sr. No. Applicable standards 1 IEC HV switchgear and control gear- HV/LV Pre-fabricated sub-station IEC IEC IEC HV switchgear and control gear-ac Metal Enclosed switchgear and control gear for voltages above 1kV and upto and including 52kV. Common specifications for high voltage switchgear and control gear standards HV switchgear and control gear-alternating current disconnections and earthing switches IEC High voltage switches Part 1: Switches for rated voltages 5 above 1 kv and less than 52 kv 6 IEC Degrees of protection provided by enclosures (IP Code) 7 IEC IEC High-voltage test techniques Degrees of protection provided by enclosures for electrical equipment against mechanical impacts (IK Code) IEC / IS (Reaffirmed- 2004) IEC IEC / : IS IEC IEC / : IS (Reaffirmed- 2002) Low voltage switchgear and control gear Low-voltage switchgear and control gear assemblies- Type tested and partially type tested assemblies Power Transformers Electrical relays - Part 3: Single input energizing quantity measuring relays with dependent or independent time. Current Transformers Page 2 of 11

3 IEC / : IS Voltage Transformers 1992(Reaffirmed- 2002) IEC High-voltage prefabricated switchgear and control gear assemblies - Voltage presence indicating systems IS : IS (Reaffirmed-2006) Recommended practice for Hot Dip Galvanizing of Iron & Steel. (Reaffirmed-2006) Tests for uniformity of zinc coating CEA Guidelines dt August 2008 for Energy Efficient Distribution Transformers 3.0 CLIMATIC CONDITIONS OF THE INSTALLATIONS 1 Location Haryana 2 Maximum ambient air temperature 50 deg C 3 Minimum ambient air temperature (-)5 deg C 4 Average daily maximum ambient 40 deg C temperature 5 Max yearly weighted average ambient 32 deg C temperature 6 Isoceraunic level 45 days/year 7 Maximum altitude above mean sea level 1000 meters 8 Minimum relative humidity 26% 9 Max. relative humidity 100% 10 Average no of rainy days/ year Basic Wind Speed 47m/s 12 Avg. Annual rainfall 900 mm 13 Pollution Moderate 14 Maximum wind pressure 195 kg/ m sq 15 Sesimic Zone Zone-IV,III,II The atmosphere is generally laden with mild acid and dust suspended during dry months and subjected to fog in cold months. 4.0 GENERAL TECHNICAL REQUIREMENTS: S.No. Description Requirement A. FOR ENCLOSURE 1 Application Outdoor 2 Rated voltage 12kV 3 Service voltage 11kV Page 3 of 11

4 4 System frequency 50 Hz 5 Rated Impulse withstand voltage 75 kvp Rated power frequency withstand 6 voltage 28 kvrms 7 Rated LT voltage Degree of protection Transformer Compartment:- IP23 HV Compartment:- IP54 LV Compartment:-IP54 9 Internal arc test IAC-AB as per IEC Maximum permissible temp. for any accessible part of the enclosure As per IEC : Minimum thickness of sheet a) Sides 2mm b) Base 4mm 12 Control wiring a) Type and insulation PVC and 1.1 KV (max) b) Conductor material and size Copper and 1.5 & 2.5 sq mm 13 Ventilation Aperture Class K10 14 Locking arrangement The doors shall be padlocked as well as lock protected 15 Paint PANTONE 2727C B. RMU: Please refer technical specification of 11kV RMU C. Transformer: Please refer technical specification of oil filled distribution transformers D. LV Compartment: Please refer specification of LT feeder pillar of type -A 5.0 GENERAL CONSTRUCTION Package type substation is designed to comprise the following main components: a) Enclosure b) HV compartment consisting of 11kV Ring Main Unit. c) Distribution transformer. d) LV compartment consisting, LT ACB, MCCBs with Interconnections. 5.1 OUTDOOR ENCLOSURE The enclosure shall be made of minimum 2mm thick MS sheet steel with a base of 4 mm (min.), tropical zed to meet Indian weather conditions. The base of the enclosure shall ensure rigidity for easy transport and installation. The structure of the substation should be provided with additional supporting beams capable of supporting the gross weight of all the equipments. The roof of the sub-station compartments shall be designed to support adequate loads with sufficient clearance for removal/installation of components inside the package sub-station. There shall be Page 4 of 11

5 provision of proper ventilation through louver apertures so as to allow circulation of hot air inside enclosure naturally. The complete design shall be compartmentalized The HV compartment shall comprise of one no. 3 Way, non-extensible indoor type, 11kV RMU with 2 nos. LSB and one no. circuit breaker as outgoing. Termination kits and Boots for RMU shall be supplied by the bidder as per DHBVN approved make. The transformer shall be of 11/0.433 kv, 400,500,630& 1000kVA, hermetically sealed with corrugated tank construction. The LV compartment shall comprise of one no. 800 A ACB with 3 nos., 400A each MCCB for 400 kva transformer, 800 A ACB with 3 nos., 400A each MCCB for 500 kva, one no A ACB with 4nos., 400A each MCCB for 630kVA transformer &1600 A ACB with 5 nos. 400A each MCCB for 1000kVA other auxiliary components with interconnections required for the complete operation of the sub-station Degree of Protection for the HV compartment, Transformer compartment and LV compartment shall be IP54, IP23 and IP54 in accordance with IEC recommendation. There shall be no bolting arrangement on the doors and sides (periphery) so as to avoid access of dust and water inside. This would also ensure that the unit is well protected from outside public nuisance owing to its being located in crowded and outdoor areas HV and LV compartments shall be accessible on the sides of the substation through double doors equipped with key lock and nit rile/neoprene rubber seal. The doors shall be Pad locked and/or lock protected to ensure theft prone locking arrangement. Heavy duty hinges shall be provided for each door such that they are not visible from outside and hence not removable. The outgoing of the distribution transformer shall be connected directly to Incomer of LV distribution through bus bars. Transformer chamber door can be opened by accessing from the door arrangement from LT compartment. HV, LV and Transformer compartment should be isolated from each other internally. Also, the locking arrangement shall be such that the transformer chamber door cannot be opened when HT is energized. Two No. lifting arrangements shall be provided on both sides of transformer chamber There shall be an arrangement for internal lighting activated by associated switch on doors for HV, Transformer and LV compartments separately. Heater with thermostat shall be provided in LV compartment along with Hooter. Suitable arrangement for lifting of Package type substation should be provided Ventilation aperture shall be as per Class K10 and the sub-station shall be Type tested for Internal Arc Withstand test as per IEC. The Bidder shall provide provision for remote monitoring of the status of RMU, Fault passage indicator, LT ACB & MCCB s, Transformer OTI EARTHING: All non-current carrying parts of the sub-station shall be earthed to a common earth conductor at two points with 50X6 sq mm GI strip running all long the periphery of the Package sub-station. Four nos. earthing terminals/studs shall be provided on the enclosure at each corner positions which shall be internally connected to the common earth conductor/strip provided for the entire sub-station. The diameter of the stud shall be at least 12mm and shall be able to connect and terminate the external earth conductor. The connecting point shall be marked with the Protective earth symbol as per IEC. Separate earthing conductor/strip shall be provided for transformer Neutral and the same shall be insulated from the body earth and suitably brought out from the enclosure for connecting to external system earth. All hinge doors shall be earthed to the enclosure with green color copper flexible wire of size 2.5 sq mm (min). Page 5 of 11

6 5.1.8 Paint: All paint shall be applied on clean, dry surfaces under suitable atmospheric conditions by seven tank process and powder coating. The paint shall not scale off or crinkle or be removed by abrasion during normal handling. The enclosure for the sub-station shall be painted with shade as above.. Sufficient quantity of touch-up paint shall be furnished for application at site Galvanizing: The galvanizing shall be carried out by the hot dip process in accordance with IS 2629/ ISO 1460 amended to date. However, high tensile steel nuts, bolts & spring washers shall be electrogalvanized to service condition four. The zinc coating shall be smooth, continuous and uniform. It shall be free from acid spots and shall not scale, blister or removable by handling or packing. There shall be no impurity in the zinc or additives to galvanic bath, which could have a detrimental effect on the durability of the zinc coating After galvanizing no drilling or welding shall be performed on the galvanized parts of the equipment except that nuts may be threaded after galvanizing To avoid the formation of white rust, galvanized material shall be stacked during transport and stored in such a manner as to permit adequate ventilation. Sodium dichromate treatment shall be provided to avoid formation of white rust after hot dip galvanization. The galvanized steel shall be subject to tests as per IS 2633/ BS 729 amended to date 5.2 HV COMPARTMENT: kv RING MAIN UNIT- As per Nigam Specification All the technical specifications of RMU shall be same except the Auxiliary power transformer that shall be supplied with RMU shall be rated for V/230V, 2KVA(minimum), 50 Hz allowing for possible variation from 190 V to 300 V. The auxiliary power transformer shall provide all the auxiliary power supply requirement for CSS DISTRIBUTION TRANSFORMER: As per Nigam Specifications LV COMPARTMENT: The complete arrangement of ACB and MCCBs shall be provided on a framework of channels with adequate strength to support the weight of the ACB and MCCB s. The Framework shall be covered from the front with GI sheet of thickness not less than 2 mm. such that no live part is accessible at any time during the operation or testing period. All mechanism shall be made of such material as to prevent corrosion due to sticking of dust. Cast iron shall not be used for any part of the equipment which may be subjected to mechanical stresses. All connections and contacts shall be of ample section and surfaces for carrying continuously the specified current without undue heating and shall be secured rigidly & locked in position. All apparatus shall be so designed and constructed as to obviate the risks or short circuits of the live parts by lizards / rodents. Corresponding parts of similar apparatus shall be mutually interchangeable. All apparatus, connections and cabling shall be designed / arranged to minimize risks of fire and any damage which might cause in the event of fire ACB and MCCBs with Bus-bars: As per Nigam Specification 6.0 NAME PLATE & MARKING: - Page 6 of 11

7 All the Components of the Package sub-station shall be provided with durable and legible name plates containing all technical parameters. Name plates shall be suitably embossed with PO no. with date, PROPERTY OF DHBVN & CODE NUMBER along with the following information for different components. A Danger plate of appropriate size shall also be provided on the enclosure ENCLOSURE: a) Manufacturer s Name b) Rated Voltage c) System Frequency d) Rated Short time withstand current for 1 sec e) Rated Impulse withstand Voltage f) Degree of Protection g) Rated class of enclosure 6.2. RMU: 6.3. TRANSORMER: 6.4. LV ACB, MCCBS, and PANELS: 7.0 TESTS: As per Nigam Specification As per Nigam Specification As per Nigam Specification. As per Nigam Specification 8.0 PRE- DESPATCH INSPECTION: Equipment shall be subject to inspection by a duly authorized representative of the Purchaser. Inspection may be made at any stage of manufacture at the option of the purchaser and the equipment if found unsatisfactory as to workmanship or material, the same is liable to rejection. Bidder shall grant free access to the places of manufacture to the Purchaser s representatives at all times when the work is in progress. Inspection by the Purchaser or its authorized representatives shall not relieve the supplier of his obligation of furnishing equipment in accordance with the specifications. Material shall be dispatched after specific MDCC (Material Dispatch Clearance Certificate) is issued by the Purchaser. Following documents shall be sent along with material: a) Test reports b) MDCC issued by Purchaser c) Invoice in duplicate d) Packing list e) Drawings & catalogue f) Guarantee / Warrantee card g) Delivery Challan h) Other Documents (as applicable) 9. INSPECTION AFTER RECEIPT AT STORE: The material received at the Purchaser store shall be inspected for acceptance and shall be liable for rejection, if found different from the reports of the pre-dispatch inspection and one copy of the report shall be sent to PD department. 10. GUARANTEE: Bidder shall stand guarantee towards design, materials, workmanship & quality of process/ manufacturing of items under the contract for due and intended performance of the same, as an integrated product delivered under this contract. In the event any defect is found by the Purchaser up to a period of 72 months from the date of commissioning. Bidder shall be liable to undertake to replace/rectify such defects at his own costs. within mutually agreed timeframe, and to the entire satisfaction of the Purchaser, failing which the Purchaser will be at liberty to get it replaced/rectified at Bidder s risks and costs and recover all such expenses plus the Purchaser s own charges (@ 20% of expenses incurred), from the Bidder or from the Security cum Performance Deposit as the case Page 7 of 11

8 may be. In case of PSS fails within the guarantee period the purchaser will immediately inform the bidder who shall take back the failed PSS within 15 days from the date of intimation at his own cost and replace / repair the box within forty five days of date of intimation with a roll over guarantee. The outage period i.e. period from the date of failure till unit is repaired / replaced shall not be counted for arriving at the guarantee period. Bidder shall further be responsible for free replacement for another period of THREE years from the end of the guarantee period for any Latent Defects if noticed and reported by the Purchaser. 11. PACKING: Bidder shall ensure that all the equipment covered under this specification shall be prepared for rail/road transport in a manner so as to protect the equipment from damage in transit. The material used for packing shall be environmentally friendly. 12. TENDER SAMPLE: Not applicable. 13. QUALITY CONTROL: The bidder shall submit with the offer Quality assurance plan indicating the various stages of inspection, the tests and checks which will be carried out on the material of construction, components during manufacture and bought out items and fully assembled component and equipment after finishing. As part of the plan, a schedule for stage and final inspection within the parameters of the delivery schedule shall be furnished. The Purchaser's engineer or its nominated representative shall have free access to the manufacturer s/sub-supplier's works to carry out inspections. 14. MINIMUM TESTING FACILITIES: Bidder shall have adequate in house testing facilities for carrying out all routine tests, acceptance tests as per Indian /International standards. 15. MANUFACTURING ACTIVITIES: The successful bidder will have to submit the bar chart for various manufacturing activities clearly elaborating each stage, with quantity. This bar chart should be in line with the Quality assurance plan submitted with the offer. This bar chart will have to be submitted within 15 days from the release of the order. 16. SPARES, ACCESSORIES AND TOOLS(As per Nigam Specifications) Bidder shall provide a list of recommended spares with quantity and unit prices for 5 years of operation after Commissioning. The Purchaser may order all or any of the spare parts listed at the time of contract award and the spare parts so ordered shall be supplied as part of the definite works. The Purchaser may order additional spares at any time during the contract period at the rates stated in the Contract Document. The bidder shall provide one no. SF6 gas leak indicator & one no. phase comparator. The bidder shall also provide the required quantity of 11kV cable whenever the same is asked for by the Purchaser. A list of complete set of special tools and gauges required for erection & maintenance and installation procedure should be submitted. Bidder shall give an assurance that spare parts and consumable items will continue to be available through the life of the equipment which shall be 25 years minimum. However, the Purchaser shall give a minimum of 12 months notice in the event that the Bidder or any sub-vendor plans to discontinue manufacture of any component used in this equipment. Any spare apparatus, parts or tools shall be subject to the same specification, tests and conditions as similar material supplied under the Contract. They shall be strictly interchangeable and suitable Page 8 of 11

9 for use in place of the corresponding parts supplied with the plant and must be suitably marked and numbered for identification. 17. DRAWING AND DOCUMENTS: Following drawings and documents shall be prepared based on Purchaser specifications and statutory requirements and shall be submitted with the bid: a) Completely filled in Technical Particulars b) General description of the equipment and all components including brochures. c) General arrangement for meter box d) Experience List e) Type test certificates After the award of the contract, four (4) copies of following drawings, drawn to scale, describing the equipment in detail shall be forwarded for approval. Sr. No. Description For Approval For Review Final Information Submission 1 Technical Parameters 2 General Arrangement drawings 3 Power Flow Diagram 4 HV and LV Compartment layout 5 Schematic diagrams 6 Earthing plan 7 Bill of Material 8 Foundation Plan & Loading details 9 Installation Instructions 10 Instruction for Use & Maintenance 11 Transport/ Shipping dimension drawing 12 QA & QC Plan 13 Test Certificates Bidder shall subsequently provide Four (4) complete sets of final drawings, one of which shall be auto positive suitable for reproduction, before the dispatch of the equipment. Soft copy (Compact Disk CD) of all the drawing, GTP, Test certificates shall be submitted after the final approval of the same to purchaser. Page 9 of 11

10 All the documents & drawings shall be in English language. Instruction Manuals: Bidder shall furnish two softcopies (CD) and four (4) hard copies of nicely bound manuals (In English language) covering erection and maintenance instructions and all relevant information and drawings pertaining to the main equipment as well as auxiliary devices. 18. GUARANTEED TECHNICAL PARTICULARS: A. ENCLOSURE FOR PSS S.No. Description Units As furnished by Bidder 1. Application 2. Rated Voltage kv 3. Service Voltage kv 4. System Frequency Hz Hz 5. Rated Impulse withstand Voltage kvp 6. Rated Power Frequency withstand voltage kv rms 7. Rated LT voltage V 8. Degree of Protection for Enclosure 9. Internal Arc test 10. Maximum Permissible Temperature for any ºC accessible part of the enclosure 11. Dimensions of Enclosure (LxWxH) mm x mm x mm 12. Thickness of sheet for side and base 13. Control wiring a) Insulation type and Voltage grade b) conductor material and size c) wiring identification mark & accessories as per specification 14. Ventilation Aperture 15. Locking Arrangement 16. Earthing to be provided for -PSS -RMU &11kV Metering cubicle -Trf body and neutral -LV ACB & MCCB 17. Accessories like Heater, lamps, hooter, door switch,etc 18. Paint 19. No. of accessories furnished a) Earthing equipment b) Test plug Page 10 of 11

11 20. Guarantee- From date of taking over by DHBVN 21. Availability of spares 22. Dimensions mm mm xmm 23. Total weight Kg 19. SCHEDULE OF DEVIATION: The bidders shall set out all deviations from this specification, Clause by Clause in this schedule. Unless specifically mentioned in this schedule, the tender shall be deemed to confirm the purchaser s specifications. (TO BE ENCLOSED WITH THE BID) All deviations from this specification shall be set out by the bidders, clause by Clause in this schedule. Unless specifically mentioned in this Schedule, the tender shall be deemed to confirm the purchaser's specifications: S.No. Clause No. Details of deviation with justifications We confirm that there are no deviations apart from those detailed above. Seal of the Company: Signature: Designation: sd- S.E./P&D, DHBVN Cum-member Secretary CSC, UHBVN/DHBVN Page 11 of 11

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