Professional Documents
Culture Documents
Amendments To REC Specifications and Construction Standards
Amendments To REC Specifications and Construction Standards
to
REC Specifications
and
Construction Standards
CONTENTS
I.
Attachment A
Attachment B
Attachment C
Attachment D
Attachment E
Attachment F
Attachment G
II.
i)
III.
Attachment H
New Specifications
i)
Attachment I
ii)
Attachment J
iii)
Attachment K
iv)
Attachment L
v)
Attachment M
% Composition
Carbon
0.50 to 0.85
Manganese
0.50 to 1.10
Phosphorous
Sulphur
Silicon
0.10 to 0.35
Page 1 of 5
Type Tests
The following tests shall be conducted once on a sample/samples of conductor
(ACSR/AAAC) for every 1500 Kms. of production from each manufacturing
facility:
(a)
UTS test on stranded conductor
(b)
DC resistance test on stranded conductor
2
Acceptance Tests
(a)
Visual and dimensional check on drum
(b)
Visual check for joints scratches etc. and length measurement of
conductor by rewinding
(c)
Dimensional check on steel and aluminium/Al-alloy strands
(d)
Check for lay-ratio
(e)
Galvanising test on steel strands
(f)
Torsion and Elongation tests on steel strands
(g)
Breaking load test on steel and Aluminium strands
(h)
Wrap test on steel & Aluminium strands
(i)
DC resistance test on Aluminium strands
(j)
Procedure qualification test on welded joint of Aluminium strands
Note: All the above tests except (j) shall be carried out on aluminium and steel
strands after stranding only.
3
(a)
(b)
(c)
(d)
Routine Test
Check to ensure that the joints are as per Specification.
Check that there are no cuts, fins etc. on the strands.
Check that drums are as per Specification.
All acceptance test as mentioned above to be carried out on each coil.
(a)
(b)
(c)
Page 3 of 5
Page 5 of 5
ATTACHMENT - B
REC specification No. 33/1984 (R-1993)
Aluminium Alloy Conductors for Overhead Power Lines.
(a) Following para shall be inserted in the beginning of Clause 4
(PROPERTIES OF WIRES):
The wire shall be of heat-treated aluminium, magnesium silicon alloy having a
composition appropriate to the mechanical & electrical properties as specified in
IS : 398(Part-4).
The Aluminum Alloy strands drawn from heat-treated aluminium alloy redraw
rods conforming to Type B as per IEC: 104-1987. The chemical composition of
redraw rods shall confirm to IS : 9997 1991 as given below:Elements
Percent
Si
0.50-0.90
Mg
0.60-0.90
Fe
0.50 max
Cu
0.10 max
Mn
0.03 max
Cr
0.03 max
Zn
0.10 max
0.06 max
0.03 max
0.10 max
Al
Remainder
Page 1 of 4
2
Acceptance Tests
(a)
Visual check for joints scratches etc. and length measurement of
conductor by rewinding
(b)
Dimensional check on Al-alloy strands
(c)
Check for lay-ratio
(d)
Elongation test
(e)
Breaking load/tensile test on Aluminum alloy strands
(f)
DC resistance test on Aluminum alloy strands
(g)
Wrap test on Aluminum alloy strands
(h)
Visual and dimensional check on drum
3
(a)
(b)
(c)
(d)
Routine Test
Check to ensure that there are no joints.
Check that there are no cuts, fins etc. on the strands.
Check that drums are as per Specification.
All acceptance test as mentioned above to be carried out on each coil.
4
(a)
Page 2 of 4
4
Visual and Dimensional Check on Drums
The drums shall be visually and dimensionally checked to ensure that they
conform to the requirements of this Specification.
5
Visual Check for Joints, Scratches etc.
Conductor drums shall be rewound in the presence of the Owner or his
representative. The Owner/his representative shall visually check for scratches,
joints etc. and that the conductor generally conforms to the requirements of
this Specification. Ten percent (10%) drums from each lot shall be rewound in
the presence of the Owner's representative.
6
Dimensional Check on Aluminum alloy Strands
The individual strands shall be dimensionally checked to ensure that they
conform to the requirement of this Specification.
7
Check for Lay-ratios of Various Layers
The lay-ratios of various layers shall be checked to ensure that they conform to
the requirements of this Specification.
8
Torsion and Elongation Tests on Aluminum alloy Strands
The test procedures shall be as per clause No. 10.3 of IEC : 888. In torsion test,
the number of complete twists before fracture shall not be less than 18 on a
length equal to 100 times the standard diameter of the strand. In case test
sample length is less or more than 100 times the stranded diameter of the
strand, the minimum number of twists will be proportioned to the length and if
number comes in the fraction then it will be rounded off to next higher whole
number. In elongation test, the elongation of the strand shall not be less than
4% for a gauge length of 250 mm.
9
Check on Barrel Batten strength of Drums
The details regarding barrel batten strength test will be discussed and mutually
agreed to by the Contractor & Owner in the Quality Assurance Programme.
10
Breaking Load Test on Individual Aluminium Alloy Wires
The test shall be conducted on Aluminum alloy wires. The breaking load of
one specimen cut from each of the samples taken shall be determined by
means of suitable tensile testing machine. The load shall be applied gradually
Si the jaws of the testing machine shall be not less than 25 mm/min. and not
greater than 100 mm./ min. The ultimate breaking load of the specimens shall
be not less than the values specified in the Specification.
11
Resistance test on Aluminum alloy wire
The test shall be conducted on aluminium alloy wires only, conforming
to procedure as per IEC: 889. The electrical resistance of one specimen of
aluminium wire cut from each of the samples taken shall be measured at
ambient temperature. The measured resistance shall be corrected to the
value corresponding to 20 degree C. by means of following formula.
1
R20 =
RT ------------------1+alpha x (T-20)
Where
Page 3 of 4
Page 4 of 4
The test shall be carried out on 100% shells before assembly. The detail and
methodology for conducting this test has been illustrated at attached Annexure 1.
Page 1 of 2
2.0
Thermal Mechanical Performance Test shall be performed in accordance with IEC383-1-1993 Clause 20 with the following modifications:
(1) The applied mechanical load during this test shall be 70% of the rated
electromechanical or mechanical value.
(2)
Where
X
Standard deviation.
(b)
(c)
units.
3.0
This test shall be performed in accordance with clause 18 and 19 of IEC 383 with the
following acceptance
(i)
Standard deviation.
(ii)
(iii)
Page 2 of 2
Annexure - 1
ATTACHMENT D
REC specification No. 13/1979
Porcelain Insulators and Insulator Fittings for 33 kV Overhead Power Lines
(a) Sub-clause 3.6.1 (g) of Clause 3.6 (TESTS) shall be replaced by the
following:
(g) Electro-mechanical failing load test to be carried out as per procedure
described at Sub-clause 3.6.4.
(b) Sub-clause 3.6.1 (h) of Clause 3.6 (TESTS) shall be replaced by the
following:
(h) Mechanical failing load test (for those of Type B string insulator units to
which electro mechanical failing load test (g) is not applicable) to be carried
out as per procedure described at Sub-clause 3.6.4.
(c) A new Sub-clause 3.6.1 (m) (Thermal Mechanical Performance Test) shall
be inserted to Clause 3.6 (TESTS) as follows:
(m) Thermal Mechanical Performance Test (for Strain insulators only) to be
carried out as per procedure described at Sub-clause 3.6.4.
(d) Sub-clause 3.6.2 (d) of Clause 3.6 (TESTS) shall be replaced by the
following:
(d) Electro-mechanical failing load test to be carried out as per procedure
described at Sub-clause 3.6.4.
(e) A new Sub-clause 3.6.3 (d) (Hydraulic Internal Pressure test) shall be
inserted to Clause 3.6 (TESTS) as follows:
(d) Hydraulic Internal Pressure test on shells for strain insulators to be carried out
as per procedure described at Sub-clause 3.6.4.
(f) A new Sub-clause 3.6.4 shall be inserted to Clause 3.6 (TESTS) as follows:
3.6.4 Following procedure shall be used for conducting tests on insulators:
1.0
The test shall be carried out on 100% shells before assembly. The detail and
methodology for conducting this test has been illustrated at attached Annexure 1.
Page 1 of 2
2.0
Thermal Mechanical Performance Test shall be performed in accordance with IEC383-1-1993 Clause 20 with the following modifications:
(1) The applied mechanical load during this test shall be 70% of the rated
electromechanical or mechanical value.
(2)
Where
X
Standard deviation.
(b)
(c)
units.
3.0
This test shall be performed in accordance with clause 18 and 19 of IEC 383 with the
following acceptance
(i)
Standard deviation.
(ii)
(iii)
Page 2 of 2
ATTACHMENT - E
REC specification No. 7/1974 (R-1993)
Three-phase, 33/11 kV Step-Down Power Transformers.
(a) The heading of Clause 3 shall be read as GENERAL in place of
STANDARD RATINGS:
(b) The first para of the Clause 3 (GENERAL) shall be deleted and a new Subclause 3.1 (STANDARD RATINGS) shall be inserted to Clause 3
(GENERAL) as follows:
3.1 STANDARD RATINGS
The standard ratings shall be 630 KVA, 1600 KVA, 3150 KVA and 5000 KVA
for transformers with off-circuit taps.
(c) A new Sub-clause 3.2 (WINDING MATERIAL) shall be inserted to Clause
3 (GENERAL) as follows:
3.2 WINDING MATERIAL
Winding shall be made of Electrolytic Copper only.
(d) A new Sub-clause 3.3 (CORE) shall be inserted to Clause 3 (GENERAL) as
follows:
3.3 CORE
The Core of the power transformer shall be as per details given below:
i)
ii)
iii)
iv)
The core shall be constructed either from high grade, non-aging Cold Rolled
Grain Oriented (CRGO) silicon steel laminations conforming to grade M4 or
better or of amorphous metal. The amorphous core shall be of high quality
amorphous ribbons having very low loss formed into wound cores of
rectangular shape and clamped together by frames firmly to prevent
vibration or noise. The maximum flux density in any part of the cores and
yoke at normal voltage and frequency shall be such that the flux density with
+ 12.5 % voltage variation from rated voltage and frequency variation of 5% shall not exceed 1.9 Tesla. The bidder shall provide saturation curve of
the core material proposed to be used.
v)
The bidder should offer the core for inspection and approval by the
purchaser during the manufacturing stage. Bidders call notice for the
Page 1 of 6
xvi)
Page 2 of 6
The laminations shall be free of all burrs and sharp projections. Each sheet
shall have an insulating coating resistant to the action of hot oil.
The insulation structure for the core to clamp plates, shall be such as to
withstand 2000 V DC voltage for one minute.
The completed core and coil shall be so assembled that the axis and the plane
of the outer surface of the core assembly shall not deviate from the vertical
plane by more than 25 mm.
All steel sections used for supporting the core shall be thoroughly shot or
sand blasted, after cutting, drilling and welding.
The finally assembled core with all the clamping structures shall be free
from deformation and shall not vibrate during operation.
The core clamping structure shall be designed to minimize eddy current loss.
The framework and clamping arrangements shall be securely earthed.
The core shall be carefully assembled and rigidly clamped to ensure
adequate mechanical strength.
Oil ducts shall be provided, where necessary, to ensure adequate cooling
inside the core. The welding structure and major insulation shall not obstruct
the free flow of oil through such ducts.
The design of magnetic circuit shall be such as to avoid static discharges,
development of short circuit paths within itself or to the earthed clamping
structure and production of flux component at right angle to the plane of the
lamination, which may cause local heating. The supporting framework of the
cores shall be so designed as to avoid the presence of pockets, which would
prevent complete emptying of the tank through the drain valve or cause
trapping of air during filling.
The construction is to be of `core type. The core shall be provided with lugs
suitable for lifting the complete core and coil assembly. The core and coil
assembly shall be so fixed in the tank that shifting will not occur during
transport or short circuits.
vii)
The Transformer tank and cover shall be fabricated from high grade low
carbon plate steel of tested quality. The tank and the cover shall be of
welded construction.
Tank shall be designed to permit lifting by crane or jacks of the complete
transformer assembly filled with oil. Suitable lugs and bosses shall be
provided for this purpose.
All beams, flanges, lifting lugs, braces and permanent parts attached to the
tank, shall be welded and where practicable, they shall be double welded.
The main tank body of the transformer, excluding tap changing
compartments and radiators, shall be capable of withstanding pressure of
760 mm of Hg.
Inspection hole(s) with welded flange(s) and bolted cover(s) shall be
provided on the tank cover. The inspection hole(s) shall be of sufficient size
to afford easy access to the lower ends of the bushings, terminals etc.
All bolted connections to the tank shall be fitted with suitable oil-tight
gaskets which shall give satisfactory service under the operating conditions
for complete life of the transformer. Special attention shall be given to the
methods of making the hot oil-tight joints between the tank and the cover as
also between the tank cover and the bushings and all outlets to ensure that
the joint can be remade satisfactorily and with ease, with the help of semiskilled labour. Where compressible gaskets are used, steps shall be provided
to prevent over-compression.
Suitable guides shall be provided for positioning the various parts during
assembly or dismantling. Adequate space shall be provided between the
cores and windings and the bottom of the tank for collection of any
sediment.
The transformer top shall be provided with a detachable tank cover with bolted
flanged gasket joint. Lifting lugs shall be provided for removing the cover. The
surface of the cover shall be suitably sloped so that it does not retain rainwater.
(f) A new Sub-clause 3.5 (PAINT) shall be inserted to Clause 3 (GENERAL) as
follows:
3.5 PAINT
The paint material and procedure for the power transformer shall be as per details
given below:
Page 3 of 6
ii)
Surface Preparation for radiatorAll internal and external surfaces of radiator shall be thoroughly cleaned
either by chemical cleaning or by blast with sand or shot or grit in
accordance with ISO 8501 Part 1 to make the surface free from visible oil,
grease & dirt, mill scale, rust, paint coatings and foreign matter. Suitable
chemical should be used for chemical cleaning, if required. The air that is
used for blasting should be dry and free from oil. After adequate surface
cleaning, the first coat of primer paint/varnish should be applied not later
than 3-4 hours after preparation of surface to avoid oxidation.
iii)
Painting- external & internal surfacesPainting shall be carried out in closed and dust free area. The external
surface shall be coated with suitable layers of paint and to form an
impermeable layer so that air and water cannot reach the substrate. The paint
selected shall be stable in outdoor condition such as rain, sunlight, pollution
etc. Paint used for primer, under coat and top or finish coat should be from
the same manufacturer and compatible to each other. In case in the rare
event, paint used for primer, under coat and finish coat are not from the
same manufacturer the compatibility test of the paint from different source
shall be carried out. Painting shall be applied as per the recommendation of
the paint manufacturer. The number of coats shall be such that the minimum
dry film thickness (DFT) specified is achieved. The DFT of painted surface
shall be checked with a measuring gauge to ensure specified DFT. Complete
painting scheme for the transformer is tabulated below:
Page 4 of 6
PRIMER
COAT
INTERMEDIATE
UNDERCOAT
FINISH
COAT
TOTAL
DFT
COLOUR
SHADE
Blast
cleaning
Sa2
Epoxy base
Zinc primer
(30-40 m)
Epoxy HB MIO
(30-40 m)
Aliphatic
Polyurethane
(min 50 m)
Min 155 m
697 shade as
per IS 5
Tank
(Internal
surfaces)
Blast
cleaning
Sa2
Hot
oil
resistant,
noncorrosive
varnish
or
paint
or
epoxy
--
--
Min 30 m
Glossy white
for paint
Radiator (External
surfaces)
Chemical /
blast
cleaning
(Sa2)
Epoxy base
zinc primer
(30-40m)
PU
paint
(min 50m)
Min 110m
Matching
shade of tank/
different
shade
aesthetically
matching to
tank
Chemical
cleaning if
required
--
--
--
--
v)
Surface Preparation for Control cabinets/Marshalling Boxesa. Surface Preparation for all Transformer Control cabinets/Marshalling Boxes
shall be carried out confirming to following Indian standard in dust free area:
01)
IS: 3618: Degreasing by solvent wiping: Phosphate Treatment
of Iron &Steel for Protection against corrosion.
02)
IS: 6005: Code of Practice for phosphating of Iron & Steel.
b. Chemicals: Suitable chemicals should be used and concentration of chemicals
/weight of Phosphate coating should be checked regularly as per
recommendation of the chemical manufacturer and applicable IS.
c. Inspection: The surface for application of paint should be dry, free from oil,
dirt, acid & loose adhering powder and reasonably smooth in finish without
uncovered areas, rusty surfaces and roughness.
vi)
Enamel paint shall be used with total paint thickness as minimum 80 microns.
Page 5 of 6
Page 6 of 6
ATTACHMENT - F
REC specification No. 2/1971 (R-1997)
Out-door type three phase, 11 kV/433-250 V Distribution Transformers upto and
including 100 KVA.
(a) A new Clause 8A (PAINT)
(CONSERVATOR) as follows:
shall
be
inserted
after
Clause
8A. PAINT
The paint material and procedure for the distribution transformer shall be as per
details given below:
1 All paints shall be applied in accordance with the paint manufacturers
recommendations. Particular attention shall be paid to the following :
a.
b.
c.
d.
Page 1 of 4
2.4 Chipping, scraping and steel wire brushing using manual or power
driven tools cannot remove firmly adherent mill-scale and shall only be
used where blast cleaning is impractical.
3
Protective Coating
3.1 As soon as all items have been cleaned and within four hours of the
subsequent drying, they shall be given suitable anticorrosion
protection.
Paint Material
Followings are the type of paints that may be suitably used for the
items to be painted at shop and supply of matching paint to site:
i)
ii)
Painting Procedure
5.1 All painting shall be carried out in conformity with both specifications
and with the paint manufacturers recommendations. All paints in any
one particular system, whether shop or site applied, shall originate
from one paint manufacturer.
5.2 Particular attention shall be paid to the manufacturers instructions on
storage, mixing, thinning and pot life. The paint shall only be applied
in the manner detailed by the manufacturer e.g. brush, roller,
conventional or airless spray and shall be applied under the
manufacturers recommended conditions. Minimum and maximum
time intervals between coats shall be closely followed.
5.3 All prepared steel surfaces should be primed before visible re-rusting
occurs or within 4 hours whichever is sooner. Chemical treated steel
surfaces shall be primed a s soon as the surface is dry and while the
surface is warm.
5.4 Where the quality of film is impaired by excess film thickness
(wrinkling, mud cracking or general softness) the supplier shall remove
the unsatisfactory paint coatings and apply another. As a general rule,
dry film thickness should not exceed the specified minimum dry film
thickness by more than 25 %. In all instances, where two or more coats
of the same paints are specifies, such coatings may or may not be of
contrasting colors.
5.5 Paint applied to items that are not be painted, shall be removed at
suppliers expense, leaving the surface clean, un-stained and
undamaged.
Page 2 of 4
Paint Type
Powder Paint
(a) Thermo setting
powder
Liquid paint
a) Zinc Chromate
(Primer)
b) Synthetic Enamel
(Finish Coat)
c) Hot Oil paint
Area to be
painted
Inside
outside
Out side
02
45 micron
Outside
02
35 micron
Inside
01
35 micron
Page 3 of 4
The core shall be wound or cut type. The stack type core is not permitted.
ii)
iii)
Stage level inspection for core construction shall be carried out by the
owner.
iv)
Each lamination shall be insulated such that it will not deteriorate due to
mechanical pressure and the action of hot transformer oil.
v)
The core shall be constructed either from high grade, non-aging Cold Rolled
Grain Oriented (CRGO) silicon steel laminations conforming to grade M4 or
better. The maximum flux density in any part of the cores and yoke at
normal voltage and frequency shall be such that the flux density with + 12.5
% voltage variation from rated voltage and frequency variation of -5% shall
not exceed 1.9 Tesla. The bidder shall provide saturation curve of the core
material proposed to be used.
vi)
The bidder should offer the core for inspection and approval by the
purchaser during the manufacturing stage. Bidders call notice for the
purpose should be accompanied with the following documents as applicable
as a proof towards use of prime core material:
a)
b)
c)
d)
e)
Page 4 of 4
ATTACHMENT - G
REC specification No. 70/1993(R-1997)
Out-door type 3-phase 11 kV/433-250V Conventional and Sealed distribution
transformers with Amorphous Metal Core upto and including 100 KVA.
(a) A new Clause 8A (PAINT)
(CONSERVATOR) as follows:
shall
be
inserted
after
Clause
8A. PAINT
The paint material and procedure for the distribution transformer shall be as per
details given below:
1 All paints shall be applied in accordance with the paint manufacturers
recommendations. Particular attention shall be paid to the following :
a.
b.
c.
d.
e.
Page 1 of 4
2.4 Chipping, scraping and steel wire brushing using manual or power
driven tools cannot remove firmly adherent mill-scale and shall only be
used where blast cleaning is impractical.
3
Protective Coating
3.1 As soon as all items have been cleaned and within four hours of the
subsequent drying, they shall be given suitable anticorrosion
protection.
Paint Material
Followings are the type of paints that may be suitably used for the
items to be painted at shop and supply of matching paint to site:
i)
ii)
Painting Procedure
5.1 All painting shall be carried out in conformity with both specifications
and with the paint manufacturers recommendations. All paints in any
one particular system, whether shop or site applied, shall originate
from one paint manufacturer.
5.2 Particular attention shall be paid to the manufacturers instructions on
storage, mixing, thinning and pot life. The paint shall only be applied
in the manner detailed by the manufacturer e.g. brush, roller,
conventional or airless spray and shall be applied under the
manufacturers recommended conditions. Minimum and maximum
time intervals between coats shall be closely followed.
5.3 All prepared steel surfaces should be primed before visible re-rusting
occurs or within 4 hours whichever is sooner. Chemical treated steel
surfaces shall be primed a s soon as the surface is dry and while the
surface is warm.
5.4 Where the quality of film is impaired by excess film thickness
(wrinkling, mud cracking or general softness) the supplier shall remove
the unsatisfactory paint coatings and apply another. As a general rule,
dry film thickness should not exceed the specified minimum dry film
thickness by more than 25 %. In all instances, where two or more coats
of the same paints are specifies, such coatings may or may not be of
contrasting colors.
5.5 Paint applied to items that are not be painted, shall be removed at
suppliers expense, leaving the surface clean, un-stained and
undamaged.
Page 2 of 4
Paint Type
Powder Paint
(a) Thermo setting
powder
Liquid paint
a) Zinc Chromate
(Primer)
b) Synthetic Enamel
(Finish Coat)
c) Hot Oil paint
Area to be
painted
Inside
outside
Out side
02
45 micron
Outside
02
35 micron
Inside
01
35 micron
Page 3 of 4
i)
ii)
iii)
iv)
v)
vi)
The core shall be wound or cut type. The stack type core is not permitted.
The design of magnetic circuit shall be such as to avoid static discharges
development of short circuit paths within itself or in the earthed clamping
structure.
Stage level inspection for core construction shall be carried out by the
owner.
Each lamination shall be insulated such that it will not deteriorate due to
mechanical pressure and the action of hot transformer oil.
The core shall be constructed of amorphous metal. The amorphous core
shall be of high quality amorphous ribbons having very low loss formed into
wound cores of rectangular shape and clamped together by frames firmly to
prevent vibration or noise. The maximum flux density in any part of the
cores and yoke at normal voltage and frequency shall be such that the flux
density with + 12.5 % voltage variation from rated voltage and frequency
variation of -5% shall not exceed 1.9 Tesla. The bidder shall provide
saturation curve of the core material proposed to be used.
The bidder should offer the core for inspection and approval by the
purchaser during the manufacturing stage. Bidders call notice for the
purpose should be accompanied with the following documents as applicable
as a proof towards use of prime core material:
a)
b)
c)
d)
e)
Page 4 of 4