Page|1 ANNEXURE-IV DAMODAR VALLEY CORPORATION TRANSMISSION SYSTEM CONSTRUCTION DVC, MAITHON ‘soe TECHNICAL SPECIFICATION 36 KV HEAVY DUTY STATION CLASS ZINC OXIDE GAPLESS LIGHTNING ARRESTERS TRANSMISSION SYSTEM CONSTRUCTION DVC, MAITHON10. 2. M4 Page|2 tem Page Number Scope Standards, System Data Construction of Lightning Arrester.. Construction of Connect0rS snnmsnnnnannnennn Climatic Condition at Site 5 Inspection and Testing 8 Post Award Submi 9 sion of Documents and Approval. Specific Requirements. Delivery 12 Qualifying Requirements (Technical Parameters) snemmnonnonnsnesnnnnnansnnnel Instruction to the Participating Bidders... Schedule for Guaranteed Technical Particulars.Page| 1. Scope This specification cover the design, manufacture, testing at manufactures works, packing for road transportation and delivery F.O.R destination by Road Transport at DVC Store(s) of 36 KV, MCOV 30 KY, heavy duty, station class, long duration discharge class : 3, 2 inc Oxide, gapless Lightning Arresters for 33 KV AC ungrounded system complete with insulating base, surge monitors, surge ‘counters, current meters and other connecting accessories including terminal connectors. 2. Standards The equipment covered by this specification shall conform in all respect to the latest edition/revision of the following standards: Lightning Arrester : Specification for Metal-oxide surge arresters without gaps for A. 1 IEC 6009-4 systems Specification for Metal-oxide surge arresters without gaps for A. 2) 18:3070, Part-3 Ps * es systems Hollow Insulator : 1) Is:s621 Specification of Hollow Insulators for Use in Electrical Equipment Connector + D 1s-$561 Electrical Power Connectors 2) 18-2629 Recommended practice for Hot Dip Galvanising of Iron and Steel 3) 18-2633 Method of testing uniformity of coating on Zine coated articles Wherever the stipulations in this specification are at variance with the indicated standards, the stipulations made herein shall be binding, 3. System Data Normal System Voltage Class (KV rms) = 33KV Highest System voltage (KVems) = 36KV No, of Phases - 3 Operating frequency (He) - 90 System neutral connestion = 33KVearthed though Grounding Transformera 5 ° % 8 Page |4 Specification of Grounding Transformer — 2) Voltage +33 KV /415 Volts b) Rating - 250KVA ©) Ylmpedance—4.0% 4) Maximum permissible neutral current for single phase to ground fault (amps) for one minute - 400 A. ) Zero sequence impedance -143 Ohms + Tolerance as per IS-2026 and IS-3151 Isokeraunic level - 0 Shielding ground wires provided = Overhead Shield angle = 30 BLL. ofthe equipment tobe protected (KV eres) = 170 KVp Construction of Lightning Arrester Construction requirements shall conform to Section S of IEC 60099-4, Each dismountable unit of the single pole arrester assembly shall have its characteristic clements hermetically sealed under dry insert gas and fully protected against ingress of moisture. The seal shall be very stable, designed and tested to last for the equitable service length of the arrester under the ‘tropical weather conditions viz, large variations in day temperature and humidity in air. The Zine Oxide blocks shall be made of materials which even when subjected to extreme weather conditions encountered in tropics will have non-ageing characteristics and stable thermal properties. ‘The block shall be metalised on the flat surfaces for proper interfacial electrical contact and insulated ‘on the cylindrical side to prevent surface flashover. Each section of the arrester shall be fitted with pressure relief devices to prevent shuttering of the porcelain in case excessive interna ‘gas pressure builds up. This should be so designed as to vent the ionized gases caused by surge current are, to the atmosphere. The leakage distance shall be Large to ensure that the resulting surface contamination in the specified ‘weather conditions do not adversely affect the arester gap voltage grading and reduces the SOcps. gap break down voltage. ‘The radio interference level for the arresters shall be negligible. ‘All cemented and detachable ferrous hardware shall be hot dip galvanised. Galvanisation shall ‘conform to IS: 2629,hy » 9 a 8 6. use and mounted upright on Stee! Structure. The porcelain shall be made by wet process, and shall be homogeneous thoroughly vitrified and impervious to moisture. The glazing shall be uniform brown color, free from blisters, burns and other similar defects. The oil filled bushing shall have ample insulation and mechanical strength for the duty involved and shall be designed to prevent accumulation of explosive gases and to provide adequate oil circulation to remove internal heat. There shall be no undue stressing due to temperature changes and adequate means shall be provided to accommodate conductor expansion. Each Lightning Arrestor shall be complete with all fittings and accessories like grading rings, discharge sakage current detector, connecting conductor, clamp type terminal connectors, porcelain base, two (2) clamp type ground terminal connectors suitable for G1. Strip (50mm x 6mm) and necessary hardware such as nuts, bolts, spring washers ete. with 20% spare hardware. The connector for Lightning Arrester to Surge Monitor shal be of 1.5 meter, at least 50 sq. mm PVC. insulated stranded copper cable with suitable lugs. Construction of Connectors ‘The connectors shall be of best quality and workmanship and in line with all the requirements laid out in the adopted standards. All bolts, nuts and washers should have a bright finish. The holes of plain washers shall be reasonably concentric with the outer periphery. All sharp edges should be rounded off. Spring washers shall be supplied in natural finish and conforming to relevant IS specification and shall be Electro galvanised, Bolts, nuts , plain washers shall be Hot dip galvanised mild steel for size M12 and above and Electro galvanised mild stee! for size below M12. The current carrying parts shall be so designed, manufactured that contact resistance is reduced to the All connectors should be so designed and manufactured so as to offer ease of installation as these are to be used in overhead installations, Design should be such that full tightening of nuts and bolts is possible with the ordinary tools, The connectors shall be designed so as to avoid local corona, sound and visible discharge. The connectors shall be suitable for conductor size of 19/2.89 AAAC Dog (Overall Diameter : 14.45 mm) and 37/3.15 AAC Panther(Overall Diameter : 22.05 mm) Conductors with horizontal and vertical take off arrangement. Climatic Condition at Site ‘The Lightning Arresters shall be suitable for installation in heavily polluted atmosphere at site, Detailed climatic conditions at site are stated below.» 2a 3) 4) 3) 9 0 8) %» Atmosphere Altitude Ambient air temperature (summer) Ambient air temperature (winter) ‘Maximum humidity Rainfall Number of rainy days per year on which rainfall, exceeds 12.5 mm Average number of thunder stormy days per Average number of dust storm days per annum 10) Number of months of tropical monsoon conditions per annum 11) Lightning, 12) Maximum wind pressure 13) Seismic Loads 1. Tests 7A Type Tests Page ls Industral, foggy, smoky and acidic Not exceeding 1000 Meters above MSL 50°C (Peak) "Cc 96% Tropical in character, Average 1270 mm, t0 2000 mm per annum 41 (average) 0 1510.20 5 (June to October) Heavy during monsoon 200 Kg/Sq, Meter Seismic Zone-3,as per Seismic Zone ‘map of India, The following constitutes the Type Tests on Lightning Arrester: 1 yy On Lightning Amester Housing Insulation Withstand Tess onthe 2) Lighting Impulse Voltage Test 2) Power Frequency Voltage Test (Dry) ©) Power Frequency Voltage Test (Wet)Page|? Residual Voltage Test on offered ZnO Block ) Stoop Current Impulse Residual Voltage Test ») Lightning Impulse Residual Voltage Test ©) Switching Impulse Residual Voltage Test 3. Long Duration Current Impulse Withstand Test 4. Operating Duty Test a) Switching Surge Operating Duty Test 5. Power Frequeney Voltage vs, Time Curve 6. Pressure Relief Test, 7. Test on Arrester Disconnectors (when fitted) 8. Short Circuit Test a) High Current Test ») Low Current Test 9. Partial Discharge Test 10, Seal Leakage Test 11, Artificial Pollution Test 2, Test on Lightning Arrester Housing a) ‘Temperature Cycle Test b) Porosity Test 13. Galvanising Test on exposed ferrous Metal Parts 14, Seal Leakage Test and Operation Test on Surge Monitor 7.2 Routine Tests Routine Tests must be carried out on all the manufactured units. ‘The Bidder shall have the facilities at his work to conduct all the Routine Tests as per indicated ISIEC at his cost The following constitutes the routine tests |. Reference Voltage TestLightning Impulse Residual Voltage Test Partial Discharge Test 4. Visual Examination 5. Insulation Withstand Test of Insulating Base and arester housing. 6. Teston Surge Counter 7. Porosity Test on Arrester Housing 73 Acceptance Tests 731 Lightning Arrester All tests indicated in IEC 60099-4 shall constitute Acceptance Tests Tests shall be carried out on minimum of next highest inte cr of CVof offered quantity) or on the quantity desired by the Purchaser's representative during Acceptance Tests, Acceptance Tests shall be carried out in the presence of Purchaser's representative ifso desired by ‘the Purchaser and the Bidder shall provide all necessary facilities to them, Al the testing equipments must have valid calibration on the date of testing, otherwise the bidder ‘must carry out calibration of such equipments at his cost before commencement of testing. 732, Connector ‘The Bidder shall have the facilities at his work to conduct the Acceptance T at his cost, The following constitutes the acceptance tests: sts as per indicated IS 1. Visual inspection 2. Verification of dimensions. 3. Galvanising Test (i applicable) 8. Inspection and Testing ‘The purchaser and / or his authorised representative(s) shall be given access to the Manufacturer's, ‘Works for the purpose of inspecting the manufacture and testing ofthe materials and equipments The purchaser and / or his authorised representative(s) shall be present at the time of Acceptance Tests and the Bidder must provide all necessary facilities to them. ‘The Bidder shall give the Purchaser at least fifteen (15) days advance intimation in writing along with the routine test reports for inspection and acceptance test of the equipment. ‘Transport to and from nearest Airport/Railway Station (Lo be indicated by the Purchaser atthe time of inspection) for inspection to be provided by the Bidder.9. Post Award Submis on of Documents and Approval Successfull Bidder shall submit the following documents within fifteen (15) days from the date of issuance of Supply Order for Purchaser's approval of drawing and documents for Type Testing and manufacturing clearance. 1. Guaranteed ‘Technical Particulars as enclosed withthe Supplv Onder. 2. Drawings 28) Dimensioned drawing of complete arrester and Fixing details 1) Sectional view ofthe aster 6) Diagram of minimum clearances in relation o adjacent grounded metallic structures 4) Dimensioned drawing of terminal and ground connestr giving details of materials used 6) Dimensioned drawing ofthe surge monitor and counter and eurent meter 1) Dimensioned drawing ofthe insulating base 2) Drawing of Zn0 block 1) Drawing of Terminal Connector i) Name Plate Details Diagram comprising the following deals i) Name of Equipment/Device ii) Name of Purchaser iil) Name of Manufacturer iv) Type designation of Equipment/Device ¥) Year of manufacturing vi) Rated Voltage vil) Rated Frequency vill) Nominal Discharge Current ix) MCOV (Maximum Continuous Operating Voltage in KV), x) Discharge class xi) Energy Discharge Capability (KJ/KV rating) xii) Supply Order reference xiii) Reference StandardPage [10 xiv) Pressure Relief Rated Current in KA rms xv) Serial Number 3. List of Testing Equipments with serial number, make and other technical particulars having valid calibration. 4, Manuals containing erection, assembly, operation and maintenance instruction before issuance of dispatch clearance. Five (05) sets of approved drawings shall be supplied to the Purchaser as contract drawings before dispatch of the equipment.10. Specific Requirements Page|" Si Parameter Value Lightning Arrester| 1, | Type ofiinstalation Outdoor, pedestal mounted 2, [Arrester ype and class Metal oxide, heavy duty, gapless, single column, single phase, station class 3._ [Rated arrester voltage 36KV 4, [Maximum continuous operating voltage at 50 «C (MCOV) 30KV '5._ [Nominal discharge current in KA with 8720 ysee wave 10 6, |[nsulation withstand voltage (Dry, Wet and Impulse) To be tested in accordance with IEC 6009-4 ‘Steep current impulse residual voltage at 10 KA of | ysee front time To be tested in accordance with IEC 6099-4 8. | Lightning Impulse residual Voltage (KVp) (820 usec wave) i) 50004 i) 10000 A iit) 20000 A ‘To be tested in accordance with IEC 60099-4 9. [Long duration discharge class Class 3 10, [Switching impulse withstand voltage of arrester housing To be tested in accordance with TEC 60099-4 11, | High current impulse withstand value (4x10 psec) 100 KA peak 12, | Pressure relief rated current To be tested in accordance with 3) High Current TEC 6099-4 i) Low Current 13. [BIL (KVp) 170 14, | Minimum creepage distance (mm) 900 15, | Partial Discharge Level (pO) Less than 10Page| 11.Delivery Time of completion of delivery shall be as follows; Description ‘Quantity | Completion of Delivery 36 KV, MCOV : 30 KV, heavy duty, station class, ‘Nos. | Within Six (06) Jong duration discharge class : 3, Zine Oxide, months from the date gapless Lightning Arresters for 33 KV AC of issuance of Supply ungrounded system complete with insulating base, Order surge monitors, surge counters, current meters and ‘other connecting accessories including terminal ‘connectors as per specification 12. Qualifying Requirements (Technical Parameters) ra 123 14 The Bidder is required to furnish the following documents in support of their eligibility for Qualification (Technical) Manufacturer Documentary evidence for being Original Manufacturer of offered Lightning Arrester as per technical specification. ‘Manufacturing and Past Supply Record Documentary evidence for manufacturing and supplying of “36 KV, MCOV : 30 KV, heavy duty, station class, long duration discharge class : 3, Zine Oxide, gapless Lightning Arresters” to Government/Government UndertakingyPublic Sector Undertaking/ Private Power Utilities within seven (07) years as on the date of NIT. ‘Type Test All the Type Test Reports indicated under Section 7.1 of this specification shall be submitted with the offer. Type Test Reports must be from an Accredited Laboratory. Accreditation shall be from the National Accreditation Body of the Country in which the Laboratory is located, ‘The date of report shall not exceed 5 years ending last day of the month, previous to one in which offers are invited Performance Certificate1s 2B. Page| Performance Certificate indicating satisfactory performance for two (02) years as on date of opening of bid issued by Government Power Utilities /Government Undertaking Power Utilities ‘Public Sector Undertaking Power llities / Private Power Utilities supplied within seven (07) years as on the date of NIT of : “36 KV, MCOV : 30 KV, heavy duty, station class, long duration discharge class: 3, Zine Oxide, gapless Lightning Arresters” ‘Manufacturing Capacity, QAP and Testing Facilities Documentary evidence in support of 8) Installed Manufacturing Capacity b) Complete Quality Assurance Plans ©) Testing Facilities at Bidder’s Works to carry out Routine and Acceptance Tests as per specification Instruction to the Participating Bidders Participating Bidders must submit/upload the following documents related to Technical Parameters with the offer as per the stipulations indicated in the NIT. ’) All documents duly signed and sealed by the participating Bidder related to Qualifying Requirements indicated in the NIT. i) Duly filled Guaranteed Technicel Panicularsas per prescribed schedule i) Drawings 2) Dimensioned drawing of complete aster and fixing deta b)_ Sectional view ofthe arrester ¢) Diagram of minimum clearances in relation to adjacent grounded metalic structures, 4) Dimensioned drawing of terminal and ground connector giving details of materials used. Dimensioned drawing of the surge monitor and counter and current meter. Dimensioned drawing of the insulating base. 8) Drawing of Zn0 block 1h) Drawing of Terminal ConnectorM4. Schedule for Guaranteed Technical Particulars Name of Bidder/Manufacturer Offer No. and date Address and contact details of manufacturer a) Office by Works ©) Contact Number (Mobile/l-and Line) ) e-mail Reference Standard of Lightning Arrester ‘Type designation No. units per arrester Rated voltage (KV) Maximum continuous operating voltage (KV) Nominal discharge current (KA) (8x20 microsecond wave) Reference current (mA) Insulation withstand voltage (KV) a) One Minute Power Frequency withstand voltage (Dry) b) One Minute Power Frequency withstand voltage (Wet) ©) Lightning Impulse withstand voltage Maximum residual voltage for discharge current of (8x20 micro second wave) a) 5000 Amps Page|20, 2. Page [15 » 10000 Amps 3 20000 Amps Maximum Steep current impulse residual voltage at 10KA of | micro second front time Maximum Switching impulse residual voltage at 1000 Amps (30x60 mito second) Long Duration Discharge Class Long duration current impulse a) Current peak ) Virtual duration in microsecond B.LL of the equipment (KVp) Protective Ratio (minimum distance to achieve sullicient protective margin) High current impulse withstand value (KA) (4x10 micro seconds) Pressure relief class a) High current (KA) b) Lowcurrent (A) Currents at M.C.ON. a) Resistance current (IR) b) Capacitate current (1C) Partial Discharge (pC) Minimum Creepage Distance Total (eam) 8) Protected (mm)24. 25, 26. 2. 28, 29, 30. Temporary Over voltage capability Overall dimension (mm) a) Height b) Diameter Cantilever Sterngth (KGM) Minimum clearance (mm) a) Between Arresters by Amresters & adjoining earthed objects Energy capability of Dises (KK) Dise size Net weight of Arrester (KG) Page [16