AdditionalTechnicalSpecifications (RDSS MVVNL) Compressed

REVAMP DISTRIBUTION SECTOR SCHME-MVVNL
Additional Technical Specifications
Index
S. No. Technical Specification of following items Page
number
1 Single and Three Phase Oil Immersed Distribution Transformers (Outdoor Type) 1
2 LT Aerial Bunched Cables (APPLICABLE FOR LT AB CABLE WITH XLPE INSULATION ONLY) 66
3 LT PVC Armoured Service Cable (2 Core 4 sqmm, 2 Core 6 sqmm, 4 Core 10 sqmm & 4 78
Core 16 sqmm)
4 LT (upto 1100v) single/two/three/three and half core, XLPE insulated, PVC sheathed, 82
armoured power cables
5 8.5 M. LONG 180 KG. WORKING LOAD PCC POLES 96
6 9.0 M LONG 400 KG. WORKING LOAD PCC POLES 104
7 9, 11 & 13 METER STEEL TUBULAR POLES WITH WELDED BASE PLATE 115
8 1.98 & 3.96 MVAR, 11 KV, OUTDOOR TYPE AUTOMATICALLY SWITCHED H.T. SHUNT 120
CAPACTIOR BANK ALONG WITH 11 KV CAPACITOR CONTROL PANEL
9 (MEDIUM VOLTAGE) AL59 ACS COVERED CONDUCTOR & ACCESORIES 149
10 Earthing Coil 178
11 GAS FILLED CYLINDRICAL LT CAPACITORS UNIT 180
12 RESIN FILLED CYLINDRICAL LT CAPACITORS UNIT 185
13 DWC HDPE PIPES 195
14 LT SHACKLE INSULATORS 207
15 3 PHASE L.T. DISTRIBUTION BOX FOR AERIAL BUNCHED CABLE 212
16 1 PHASE L.T. DISTRIBUTION BOX FOR AERIAL BUNCHED CABLE 216
17 PUSH FIT TYPE MOULDED METER BOX SUITABLE FOR THREE PHASE STATIC ENERGY
METERS 220
18 PUSH FIT TYPE MOULDED METER BOX SUITABLE FOR SINGLE PHASE STATIC ENERGY
METERS 229
19 CT operated alternating current Smart Meter of Accuracy Class 0.5S (DT Meter, LT-CT
Meter, etc.) 237
20 SHEET MOULDED COMPOUND (SMC) LT Distribution boxes of 63,100 & 250 kVA
Distribution Transformers 240
21 SHEET MOULDED COMPOUND (SMC) LT Distribution boxes of 10 kVA (1-Phase), 16 KVA
(1 Phase) & 25 KVA (3- Phase) Distribution Transformers 252
22 1.1 KV GRADE SINGLE CORE 70, 120, 400, 630 SQ. MM L.T. XLPE CABLE 265
23 LT OUTDOOR PANELS FOR UNDERGROUNDING WORKS 274
24 STREET LIGHT POLE JUNCTION BOX 327
25 Armour rod and Aluminium leg long barrel 337
26 TUSKER Terminal connector on HT and LT bushings of Distribution Transformers 339
27 Bimetallic Lugs 342
28 Signboard 344
1
Single Phase Oil Immersed Distribution Transformers (Outdoor Type)
1 SCOPE:
1.1 This specification covers design, engineering, manufacture, assembly, stage testing, inspection
and testing before supply and delivery at site of oil immersed naturally cooled with completely
self-protected feature, outdoor type 11 kV/240 V, 11/√3 kV/240 V single phase distribution
transformers for outdoor use.
1.2 The equipment shall conform in all respects to high standards of engineering, design and
workmanship and shall be capable of performing in continuous commercial operation in a manner
acceptable to the purchaser, who will interpret the meanings of drawings and specification and
shall have the power to reject any work or material which, in his judgment is not in accordance
therewith. The offered equipment shall be complete with all components necessary for their
effective and trouble-free operation. Such components shall be deemed to be within the scope of
bidder’s supply irrespective of whether those are specifically brought out in this specification
and/or the commercial order or not.
1.3 The transformer and accessories shall be designed to facilitate operation, inspection,
maintenance and repairs. The design shall incorporate every precaution and provision for the
safety of equipment as well as staff engaged in the operation and maintenance of equipment.
1.4 All outdoor apparatus, including bushing insulators with their mountings, shall be designed so as
to avoid any accumulation of water.
1.5 STANDARD RATINGS
1.5.1 Standard ratings of single-phase transformers shall be 16 kVA.
2 STANDARDS:
2.1 The materials shall conform in all respects to the relevant Indian Standard, with latest
amendments thereof unless otherwise specified herein; som e of them are listed below.
2.2 Material conforming to other internationally accepted standards, which ensure equal or
better quality than the standards mentioned above would also be acceptable. In case the
bidder who wishes to offer material conforming to the other standards, salient points of
difference between the standards adopted and the specific standards shall be clearly brought
out in relevant schedule. Four copies of such standards with authentic English translations
shall be furnished along with the offer.
3 SERVICE CONDITIONS:
Indian Title International

Standards Standards
IS -2026 Specification for Power Transformers IEC 76
2
IS 1180 (Part-I): Outdoor Type Oil Immersed Distribution

2014 Transformers up to and including
2500kVA, 33kV- Specification
IS 12444 Specification for Copper wire rod ASTM B-49
IS-335 Specification for Transformer/Mineral Oil IEC Pub 296
IS-5 Specification for colors for ready mixed paints
IS -104 Ready mixed paint, brushing zinc chromate,
priming
IS-2099 Specification for high voltage porcelain
bushing
IS-649 Testing for steel sheets and strips and magnetic
circuits
IS- 3024 Cold rolled grain oriented electrical sheets and
strips
IS - 4257 Dimensions for clamping arrangements for
bushings
IS - 7421 Specification for Low Voltage bushings
IS - 3347 Specification for Outdoor Bushings DIN 42531 to 33
IS - 5484 Specification for Al Wire rods ASTM B – 233
IS - 9335 Specification for Insulating Kraft Paper IEC 554
IS - 1576 Specification for Insulating Press Board IEC 641
IS - 6600 Guide for loading of oil Immersed IEC 76
Transformers
IS - 2362 Determination of water content in oil for
porcelain
bushing of transformer
IS - 6162 Paper covered Aluminum conductor
IS - 6160 Rectangular Electrical conductor for
electrical machines
IS - 5561 Electrical power connector
IS - 6103 Testing of specific resistance of electrical
insulating liquids
IS - 6262 Method of test for power factor and dielectric
constant of electrical insulating liquids
IS - 6792 Determination of electrical strength of
insulating
oil
IS - 10028 Installation and maintenance of transformers.
3.1 The distribution transformers to be supplied against this specification shall be suitable
for satisfactory continuous operation under the following climatic conditions as per IS 2026
(Part-I).
i) Location: At various locations in the country

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ii) Max ambient air temperature (0C): 50
iii) -5
Minimum ambient air temperature (0C):
iv) Maximum Average daily ambient air 40
temperature (0C):
v) Maximum Yearly weighted average ambient 32
temperature (0C):
vi) Maximum altitude above 5000 meters mean
sea level (metres):
vii) For HP, J&K, Uttrakhand, Sikkim, Assam,
Meghalaya,
Manipur, Nagaland, Tripura,Arunachal Pradesh
and Mizoram
Note:
1. The climatic conditions specified above are indicative and can be changed by the user as
per requirements.
2. The equipment shall generally be for use in moderately hot and humid tropical
climate, conducive to rust and fungus growth unless otherwise specified.
4 PRINCIPAL PARAMETERS:
4.1 The Transformer shall be suitable for outdoor installation with single phase, 50 Hz, 11 kV systems
in which the neutral is effectively earthed and they should be suitable for service under fluctuations
in supply voltage up to + 12.5% to - 12.5%.
4.2 The transformer shall conform to the following specific parameters. Rated HV side value
(11 kV or 11/√3 kV) shall be specified in the detailed bill of quantity by purchaser.
Sl.No ITEM SPECIFICATION
1. System voltage(max) 7/ 12 kV
2. Rated voltage HV Rated 11/√3 or 11 kV
voltage LV
240 V*
3. Frequency 50 Hz +/- 5%
4. No. of Phases Single
4
5. Type of cooling ONAN
4.3 INSULATION LEVELS
Voltage Impulse Voltage Power Frequency (kV)

(Volts) (kV Peak)
433 - 3
11000 75 28
11000/√3 60 20
5 TECHNICAL REQUIREMENTS:
5.1 CORE MATERIAL:
5.1.1 Transformer core shall be wound core type construction using new and high quality cold
rolled grain oriented (CRGO) steel with heat resistant insulating coating.
5.1.2 The bidder should offer the core for inspection and approval by the purchaser during
manufacturing stage. CRGO steel for core shall be purchased only from the approved
vendors, list of which is available at
http://apps.powergridindia.com/ims/ComponentList/Power-
former%20upto%20420%20kV-CM%20List.pdf
5.1.3 The transformer shall be suitable for over fluxing (due to combined effect of voltage
and frequency) up to 12.5% without injurious heating. The operating flux density shall
be such that there is a clear safe margin over the over fluxing limit of 12.5%.
5.1.4 No-load current shall not exceed 3% of full load current and will be measured by energizing
the transformer at rated voltage and frequency. Increase of 12.5% of rated voltage shall not
increase the no-load current by 6% of full load current.
5.1.5 Please refer to “Check-list for Inspection of Prime quality CRGO for Transformers”
attached at Annexure-A. It is mandatory to follow the procedure given in this Annexure.
5.2 WINDINGS MATERIALS:
5.2.1 HV and LV windings shall be wound from Aluminium covered with double paper. The
inter layer insulation shall be of nomex/epoxy resin dotted kraft paper.
5.2.2 Proper bonding of inter layer insulation with the conductor shall be ensured. Test for
bonding strength to be conducted.
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5.2.3 The core coil assembly shall be dried in an oven. The type of winding shall be indicated
in the tender. Whether LV windings are of conventional type or foil wound shall be
indicated.
5.2.4 Dimensions of winding coils are very critical. Dimensional tolerances for winding coils
shall be within limits as specified in guaranteed technical particulars (GTP).
5.2.5 The core coil assembly shall be securely held in position to avoid any movement under
short circuit conditions.
5.2.6 Joints in the winding shall be avoided. However, if jointing is necessary the joints shall
be properly brazed and the resistance of the joints shall be less than that of parent
conductor. In case of foil windings, welding of leads to foil can be done within the winding.
5.3 WINDING CONNECTION AND TERMINAL ARRANGEMENTS:
5.3.1 For 11 kV transformers both ends of primary winding shall be brought out through HV bushings.
For 11/√3 kV transformers, neutral end of the primary HV winding shall be brought out for
connecting to ‘Neutral’ supply wire through 1 kV bushings. There shall be provision for
connecting ‘Neutral’ terminal, to local ‘Earth’ by way of a tinned Copper strip of adequate
size and dimension. The secondary winding shall be connected to two LV bushings.
5.4 OIL:
5.4.1 The insulating oil shall comply with the requirements of IS 335.Use of recycled oil
is not acceptable. The specific resistance of the oil shall not be less than 2.5x1012 ohm-
cm at 27 0C when tested as per IS 6103.
5.4.2 Oil shall be filtered and tested for break down voltage (BDV) and moisture content before filling
5.4.3 The design and all materials and processes used in the manufacture of the transformer, shall
be such as to reduce to a minimum the risk of the development of acidity in the oil.
6 LOSSES:
6.1 The bidder shall guarantee individually the no-load loss and load loss without any
positive tolerance. The bidder shall also guarantee the total losses (no load + load losses
at 75 0C) at the 50% of rated load and total losses at 100% of rated shall not exceed
the maximum total loss values given in Table-9 of IS 1180(Part-1):2014.
6.2 The maximum allowable losses at rated voltage and rated frequency permitted at 75 0C
for 11/0.433 kV transformers can be chosen by the utility as per Table-9 for ratings 10,
a n d 16 kva as per Energy Efficiency Level-1 specified in IS 1180 (Part-1): 2014 as per
latest amendment 4 March 2021 for single phase distribution transformers.
Table 9 Maximum Total Losses upto 11 kv Class Transformers

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(Clauses 8.8.1.1, 8.8.1.2 and 8.8.1.3)

Energy Energy Energy Energy Energy
Efficiency Efficiency Efficiency Efficiency Efficiency
S.No Rating Impedenc Level 1 Level 2 Level 3 Level 4 Level 5
. (KVA) e (%) 50% 100 50% 100 50% 100 50% 100 50% 100
Loa % Loa % Loa % Loa % Loa %
d Load d Load d Load d Load d Load
1 5 2.5 35 95 30 75 27 68 24 62 21 57
2 10 4 60 170 55 150 50 135 45 122 40 112
3 16 4 82 224 63 190 58 175 54 164 50 145
4 25 4 110 300 95 260 88 240 80 225 74 210
5 50 4 210 590 190 520 177 480 160 451 148 420
6 75 4 310 880 285 780 265 720 242 670 223 625
7 100 4 410 1140 375 1030 350 964 320 900 299 842
6.2 The above losses are maximum allowable and there would not be any positive tolerance.
Bids with higher losses than the above specified values would be treated as non-responsive.
However, the manufacturer can offer losses less than above stated values. The utility can
evaluate offers with losses lower than the maximum allowable losses on total owning
cost basis in accordance with methodology given in Annex-I.
7 PERCENTAGE IMPEDANCE:
7.1 The percentage impedance of single-phase transformers at 75 0C for different ratings

upto 16 kVA shall be as per Table 9 of IS 1180(Part-1):2014.
8 TEMPERATURE RISE:
8.1 The permissible temperature rise shall be as per IS: 1180
8.2 Bids not conforming to the above limits of temperature rise will be treated as non-responsive.
9 PENALTY FOR NON PERFORMANCE
9.1 During testing at supplier’s works if it is found that the actual measured losses are more
than the values quoted by the bidder, the purchaser shall reject the transformer and he
shall also have the right to reject the complete lot.
9.2 Purchaser shall reject the entire lot during the test at supplier’s works, if the temperature rise
exceeds the specified values.
9.3 Purchaser shall reject any transformer during the test at supplier’s works, if the
impedance values differ from the guaranteed values including tolerance and if they
do not meet the requirements of clause 7.1
10 BUSHINGS:
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10.1 The bushings shall be either porcelain or epoxy type and shall conform to the relevant
standards specified. Polymer insulator bushings conforming with relevant IEC can also be
used.
10.2 For HV, 12 kV class bushings shall be used and for LV, 1 kV class bushings shall be used.
10.3 The terminal arrangement shall not require a separate oil chamber not connected to oil in
the main tank.
10.4 The HV bushings shall be fixed to the top cover of the transformer and the LV bushings
shall be fixed to transformer on sides and in the same plane.
10.5 The bushing rods and nuts shall be of brass/stainless steel.
10.6 Arcing horns will be provided on HV bushings and 1 clamp for LA shall also be provided for each
HT bushing. Supply of LA is not included in DT supplier’s scope.
10.7 Bushings shall be marked with manufacturer’s name, month and year of manufacture.
11 BUSHING TERMINALS:
11.1 HV terminal shall be designed to directly receive ACSR conductor upto 7/2.59 mm
(without requiring the use of lug) and the LV terminals shall be suitable for directly
receiving LT cables (aluminium) ranging from 10 Sq mm to 25 Sq mm both in vertical
and horizontal position and the arrangements should be such as to avoid bimetallic
corrosion. Terminal connectors must be type tested as per IS 5561.
12 TANK:
12.1 The oil volume inside the tank shall be such that even under the extreme operating
conditions, the pressure generated inside the tank does not exceed 0.4 kg/sq. cm positive or
negative. There must be sufficient space from the core to the top cover to take care of oil
expansion.
12.2 The tank cover shall have plasticized surface at the top to guard against bird faults.
Alternately, suitable insulating shrouds shall be provided on the bushing terminals.
12.3 The Transformer tank shall be of robust construction round/rectangular in shape and shall
be built up of tested CRCA/Mild Steel Sheet.
12.4 The tank shall be capable of withstanding a pressure of 1 kg/cm2 (g) and a vacuum of 760
mm of Hg for 30 minutes without any permanent deflection ( Air pressure test shall be
conducted as per IS -1180(Part-I):2014.
12.5 The L - seam joint, C - seam joint and all fittings and accessories shall be oil tight
and no deflection / bulging should occur during service.
12.6 Manufacturer should carry out the all the welding operations as per the relevant
ASME standards and submit a copy of the welding procedure and welder
performance qualification certificates to the Purchaser.
12.7 The circular bottom plate edges of the tank should be folded upward, for at least 25 mm,
to have sufficient overlap with vertical sidewall of the transformer.
12.8 The Transformer tank and the top cover shall be designed in such a manner as to leave
no external pockets in which water can lodge.
12.9 Tank shall have permanent lugs for lifting the transformer bodily and there shall be facilities
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for lifting the core coil assembly separately.

12.10 The transformer shall be provided with two mounting lugs suitable for fixing the transformer
to a single pole by means of 2 bolts of 20 mm diameter as per ANSI C 57.12.20-1988.
12.11 Both mounting lugs are made with steel of minimum 5 mm thickness.
12.12 Jump proof lips shall be provided for upper mounting lug.
12.13 Mounting lug faces shall be in one plane.
12.14 Minimum Oil level mark shall be embossed inside the tank (at 250 C).
12.15 The top cover shall be fixed to the tank through clamping only.
12.16 HV bushing pocket shall be embossed to top side of the top cover so as to eliminate
ingress of moisture and water.
12.17 The edges of the top cover shall be formed, so as to cover the top end of the tank and gasket.
12.18 Nitrile/ polyurethane /neoprene rubber gaskets’ conforming to latest IS 4253 part-II shall
be provided between tank and top cover.
12.19 The gaskets shall be continuous i.e. without any joint.
13 TANK SEALING:
13.1 The space on the top of the oil shall be filled with dry air or nitrogen. The nitrogen plus
oil volume inside the tank shall be such that even under extreme operating conditions, the
pressure generated inside the tank does not exceed 0.4 kg/sq. cm positive or negative. The
nitrogen shall conform to commercial grade of the relevant standards.
14 SURFACE PREPARATION AND PAINTING:

14.1 GENERAL
14.1.1 All paints, when applied in a normal full coat, shall be free from runs, sags, wrinkles,
patchiness, brush marks or other defects.
14.1.2 All primers shall be well marked into the surface, particularly in areas where painting is
evident, and the first priming coat shall be applied as soon as possible after cleaning. The
paint shall be applied by airless spray according to manufacturer’s recommendations.
14.1.3 Protection: The transformer shall have the following additional fittings as its integral part:
The transformers shall have the following CSP features: a) Internal HV Fuses on the HT
side of transformers: Specification for HT Fuses: Expulsion /any other suitable fuse placed
in series with primary winding. This fuse is mounted normally inside of the primary bushing
and is disconnected to high voltage winding through a terminal block. This has to protect
that part of electrical distribution system, which is ahead of the distribution transformers
from faults, which occurs inside the distribution transformers i.e. either the winding or some
other part of the transformer. It shall be ensured that this fuse does not blow for faults on
the secondary side (LT side) of the transformer i.e. the blowing characteristics of the fuse
and LT beaker shall be coordinated that the fuse shall not blow for any faults on the
secondary side of the transformer and these faults shall be cleared by the LT breaker only.
The time current characteristics and co-ordination with HV fuses shall be submitted along
with the offer.
b) Internally mounted oil immersed LT Breaker on the LV side of the transformer: LT
Circuit Breaker: The LT Circuit breaker shall clear all LT faults. As such, it shall be
9
designed for perfect coordination with the HT fuse link. The supplier shall furnish the time
/current characteristics of LT Circuit breaker and 11/√3 kV fuses for various current
multiples. The two characteristics shall be drawn on the same sheet to indicate coordination
between the circuit breaker and fuse. This shall be based on the type test carried out on one
of the transformers. In addition, the supplier shall carry out coordination test as indicated
above, and this forms one of the testes for acceptance. The breaker is to be mounted on the
secondary side of the transformer under oil to minimize premature operations from primary
surges. Two single pole elements is preferred. The Breaker shall be coordinated thermally
with the transformer rating to follow closely the variations of coil temperature due to
fluctuations in loads and ambient temperature. This is to be accomplished by connecting
the breaker in series between the secondary winding and load. The breaker shall be located
in the same oil as the core and coil assembly so that the bimetal strips are sensitive to the
temperature of oil as well as the load current. The circuit breaker may be an electro-
mechanical device with three elements viz. (a) temperature sensing (b) latching and tripping
and (c) current interrupting. The temperature sensing function might be accomplished
through the use of bimetallic strips which would be built into breaker, such that load current
of the transformer flows through them. In addition to this, a magnetic tripping device is to
be provided for increasing the opening speed of the breaker under high fault conditions.
The circuit breaker shall be mounted inside of the transformer so that these bimetallic strips
are within the top oil layer of the transformer. The latching and tripping functions of the
circuit breaker may be carried out within assembly similar to those used in industrial type
air circuit breaker. The circuit breaker shall also be closed and opened manually standing
on ground and with a magnetic trip device also. The current interruption element shall
consist of copper current carrying parts plus a set of copper tungsten current interrupting
contacts the magnetic element increase the opening speed of the circuit breaker under high
fault current conditions. The response of circuit breaker to the activity shall remain
unchanged by the addition of the magnetic trip element. The specification to which the
breakers conform shall be indicated. The Type tests shall be carried out on Circuit breaker
as per IS: 13947 (Part-2)/1993 amended up to date at any NABL Laboratory and shall be
submitted along with the offer.
Note: Mechanical operation test on LV Circuit Breaker shall be carried out in OIL
medium as per IS: 13947 (Part-2)/1993 amended up to date.
c) Load Management Signal Light: A signal light, controlled by a metal in the breaker shall
switch on when the transformer load reaches a predetermined level indicating that the
transformer has been over-loaded. The load management signal light shall perform two
functions. It shall show visually when the particulars transformers has been operating in an
overload condition and shall provide knowledge that for good system management, the
economic change out point for the transformer is fast approaching. The signal light need
not indicate temporary overloads and shall turn on only when the overload condition has
existed at a given level for a certain length of time. The LT circuit breaker shall be have a
set of auxiliary contacts builtin for signal light operation. These, normally open contacts,
shall form part of the signal light circuit. The signal light circuit shall consist of an auxiliary
transformer winding one or two turns) which generates about 4V, for the signal light contact
set within the circuit breaker, and the signal light is mounted on the transformer tank. The
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signal light contact set is mechanically connected to the main circuit breaker latching and
bimetal system. The signal light mechanism is adjusted so that the signal light contacts will
close at a pre-set thermal condition, which occurs before the main latching system opens
the main contact. The net result is a visual external indication that a pre-set load conditions
has reached by the transformer. The signal light mechanism does not reset itself when the
load drops off, the signal light remains lighted once the signal light contact closes and can
only be turned off by manually operating the external circuit breaker handle.
ALTERNATIVE FOR a) Externally mounted MCCB for LV side: Single pole MCCB is to
be provided on LV side with thermal trip release with inverse time current characteristics
for overload protection and magnetic trip release for instantaneous tripping in the wake of
short circuits. The time current characteristics and co-ordination with HV fuse shall be
submitted along with the offer. MCCB is to be fixed in an enclosure (IP 55) in ready to be
used condition and to be mounted on the transformer before installation on the pole. The
enclosure shall be made with sheet steel of thickness not less than 1.6 mm. It shall be painted
both inside and outside with powder coating. Enclosure shall have providing for pad locking
arrangement. Detachable gland plate shall be provided for taking connections from MCCB
and transformer bushing terminal. Signal light (LED Indicating lamp): The MCCB
enclosure shall be provided with LED indicating lamp to indicate tripping of MCCB. An
auxiliary relay with changeover contacts can be used to connect LED indicating lamp to the
transformer secondary terminals if MCCB is not having auxiliary contacts. In case the
MCCB trips or switched OFF, the relay contacts are closed which turns ON the LED
indicating lamp. When the MCB is reset and switched ON, the indicating lamp switches
OFF. Signal light shall be arranged to avoid damages while handling the MCCB enclosure
at site.
14.2 CLEANING AND SURFACE PREPARATION:
14.2.1 After all machining, forming and welding has been completed, all steel work surfaces
shall be thoroughly cleaned of rust, scale, welding slag or spatter and other contamination
prior to any painting. Steel surfaces shall be prepared by Shot blast cleaning (IS 9954) to
grade Sa. 2.5 of ISO 8501-1 or chemical cleaning including phosphating (IS 3618).
14.2.2 The pressure and volume of the compressed air supply for blast cleaning shall meet the
work requirements and shall be sufficiently free from all water contamination to ensure
that the cleaning process is not impaired.
14.2.3 Chipping, scraping and steel wire brushing using manual or power driven tools cannot
remove firmly adherent mill-scale and shall only be used where shot blast cleaning is
impractical. Manufacturer shall indicate such location, for purchaser’s information, in his
offer.
14.3 PROTECTIVE COATING:

As soon as all items have been cleaned and within four hours of the subsequent drying, they
shall be given suitable anti-corrosion protection.
14.4 PAINT MATERIAL:

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Following are the types of paint that may be suitably used for the items to be painted at
shop and supply of matching paint to site:
14.4.1 The painting shall be as per Annexure-Paint which is attached herewith.
14.4.2 For external surfaces one coat of Thermo Setting paint or 1 coat of epoxy primer followed
by 2 coats of polyurethene base paint. These paints can be either air-drying or stoving.
14.4.3 In case of highly polluted area, chemical atmosphere or at a place very near the sea coast,
paint as above with one intermediate coat of high build MIO (Micaceous iron oxide) as an
intermediate coat may be used to give a total dry film thickness of 150 to 180 microns.
14.5 PAINTING PROCEDURE:

14.5.1 All prepared steel surfaces should be primed before visible re-rusting occurs or within 4
hours, whichever is sooner. Chemical treated steel surfaces shall be primed as soon as the
surface is dry and while the surface is still warm.
14.5.2 Where the quality of film is impaired by excess film thickness (wrinkling, mud cracking or
general softness) the supplier shall remove the unsatisfactory paint coating and apply
another. In all instances where two or more coats of the same paint are specified, such
coatings may or may not be of contrasting colours.
14.5.3 DAMAGED PAINTWORK:
14.5.4 Any damage occurring to any part of a painting scheme shall be made good to the same
standard of corrosion protection and appearance as that was originally employed.
14.5.5 Any damaged paint work shall be made good as follows:
14.5.6 The damaged area, together with an area extending 25 mm around its boundary, shall be
cleaned down to bare metal.
14.5.7 A priming coat shall be immediately applied, followed by a full paint finish equal to
that originally applied and extending 50 mm around the perimeter of the original damage.
14.5.8 The repainted surface shall present a smooth surface. This shall be obtained by carefully
chamfering the paint edges before and after priming.
14.6 DRY FILM THICKNESS:
14.6.1 To the maximum extent practicable the coats shall be applied as a continuous film of
uniform thickness and free of pores. Over spray, skips, runs, sags and drips should be
avoided. The different coats may or may not be of the same colour.
14.6.2 Each coat of paint shall be allowed to harden before the next is applied as per manufacturer’s
recommendation.
14.6.3 Particular attention must be paid to full film thickness at edges.
14.7 TESTS:
 The painted surface shall be tested for paint thickness.
 The painted surface shall pass the cross hatch adhesion test and impact test as routine
test, Salt spray and Hardness test as type test as per the relevant ASTM standards.
14.8 The paint shade shall be as per Annexure-Paint which is attached herewith.
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Note: Supplier shall guarantee the painting performance requirement for a period of not less
than 5 years.
15 RATING AND TERMINAL PLATES:
15.1 Each transformer shall be provided with rating plate made of anodized
aluminium/stainless steel material securely fixed on the outer body, easily accessible,
showing the information given in Fig.2 of IS 1180(Part-1):2014 for single phase
transformers. The entries on the rating plates shall be indelibly marked by engraving.
15.2 Each transformer shall be provided with a terminal marking plate in accordance with Fig.5
of IS 1180(Part-1):2014. The rating and terminal marking plates may be combined into
one plate at the option of manufacturer.
15.3 The distribution transformer be marked with the Standard Mark and the use of Standard
Mark is governed by the provisions of Bureau of Indian Standards Act, 1986 and the Rules
and regulations made thereunder. As per Quality Control Order for Electrical Transformers-
2015, issued by Dept. of Heavy Industries, the Standard / ISI marking on Distribution
Transformers is mandatory and the product should be manufactured in compliance with IS
1180 Part-1: (2014).
16 PRESSURE AND VACCUM REQUIREMENTS:

16.1 Single phase transformers up to 25kVA, the transformer tank shall be of roboust
construction, round in shape shall be capable of withstanding a pressure of 100kPa and a
vacuum of 760 mm of mercury.
17 FITTINGS:
17.1 The following standard fittings shall be provided :
17.1.1 Two earthing terminals with earthing symbol.
17.1.2 Lifting lugs for the complete transformer as well as for core and winding assembly.
17.1.3 HV side neutral grounding strip(where one of the bushing terminal is connected to earth).
17.1.4 Rating and terminal marking plates.( Non detachable type)
17.1.5 Pressure relief device or self-ventilating cover
17.1.6 HV bushings.
17.1.7 LV bushings.
17.1.8 HV and LV terminal connectors.
17.1.9 Top cover fixing clamps.
17.1.10 Mounting lugs - 2 Nos.
17.1.11 Bird guard.
17.1.12 LV earthing arrangement.
17.1.13 Any other fitting required as per IS: 1180 (Part 1)
18 FASTENERS:
18.1 All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with
the appropriate Indian Standards for metric threads, or the technical equivalent.
18.2 Bolts or studs shall not be less than 6 mm in diameter except when used for small
13
wiring terminals.
18.3 All nuts and pins shall be adequately locked.
18.4 Wherever possible bolts shall be fitted in such a manner that in the event of failure of
locking resulting in the nuts working loose and falling off, the bolt will remain in position.
18.5 All All bolts/nuts/washers exposed to atmosphere should be as follows.
a) Size 12 mm or below – Stainless steel
b) Above 12 mm- steel with suitable finish like electro galvanized with passivation or hot
dip galvanized.
18.6 Each bolt or stud shall project at least one thread but not more than three threads through
the nut, except when otherwise approved for terminal board studs or relay stems. If bolts
and nuts are placed so that they are inaccessible by means of ordinary spanners, special
spanners shall be provided.
18.7 The length of the screwed portion of the bolts shall be such that no screw thread may form
part of a shear plane between members.
18.8 Taper washers shall be provided where necessary. Protective washers of suitable material
shall be provided front and back or the securing screws.
19 OVER LOAD CAPACITY:

19.1 The transformer shall be suitable for loading as per latest IS 6600.
20 TESTS:
All the equipment offered shall be fully type tested by the bidder as per the relevant
standards including the additional type tests mentioned at clause 23.The type test must
have been conducted on a transformer of same design during the last five years at the time
of bidding. The bidder shall furnish four sets of type test reports along with the offer. In
case, the offered transformer is not type tested, the bidder will conduct the type test
as per the relevant standards including the additional type tests at his own cost in
CPRI/ NABL accredited laboratory in the presence of employer’s representative(s)
without any financial liability to employer in the event of order placed on him.
20.1 Special tests other than type and routine tests, as agreed between purchaser and bidder shall
also be carried out as per the relevant standards
20.2 The test certificates for all routine and type tests for the transformers and also for the
bushings and transformer oil shall be submitted with the bid. However, if the same are not
available at the time of bidding, the same may be submitted after order but before
commencement of supply.
20.3 The procedure for testing shall be in accordance with IS 1180(Part-1): 2014/2026 as the case
may be except for temperature rise.
20.4 Before dispatch each of the completely assembled transformer shall be subjected to the
routine tests at the manufacturers works.
21 ROUTINE TESTS:
21.1 Ratio, polarity tests.
21.2 No load current and losses at service voltage and normal frequency.
14
21.3 Load losses at rated current and normal frequency.

21.4 Impedance Voltage test.
21.5 Resistance of windings cold (at or near the test bed temperature).
21.6 Insulation resistance.
21.7 Induced over voltage withstand test.
21.8 Separate source voltage withstand test. This test will not be applicable for single phase DTs with
11/√3 kV as primary voltage.
21.9 Oil sample test (one sample per lot) to comply with IS 1866.
21.10 Air pressure test on empty tank as per IS 1180
22 TYPE TESTS TO BE CONDUCTED ON ONE UNIT:
In addition to the tests mentioned above following tests shall be conducted:

22.1 Temperature rise test for determining the maximum temperature rise after continuous full
load run. The ambient temperature and time of test should be stated in the test certificate.
22.2 Impulse voltage withstand test: As per IS 2026 part-III. Basic insulation
level (BIL) for 11 kV shall be 75 kV peak while for 11/√3 kV, it will be
60KVp
22.3 Air pressure test: As per IS 1180 (Part-I):2014.
22.4 Short circuit withstand test: Thermal and dynamic ability.
22.5 Oil samples (Post short circuit and temperature rise test) - Only DGA & BDV test shall be
conducted.
22.6 Noise level measurement.
22.7 Permissible flux density and over fluxing withstand test.
22.8 Type test certificates for the tests carried out on prototype of same specifications shall be
Submitted along with the bid.
22.9 The purchaser may select the transformer for type tests randomly.
23.10 Short Circuit Test and Impulse Voltage Withstand Test: The purchaser intends to
procure transformers designed and successfully tested for short circuit and impulse test.
In case the transformers proposed for supply against the order are not exactly as per the
tested design, the supplier shall be required to carry out the short circuit test and impulse
voltage withstand test at their own cost in the presence of the representative of the
purchaser.
23.11 The supply shall be accepted only after such test is done successfully, as it confirms
on successful withstand of short circuit and healthiness of the active parts thereafter
on un- tanking after a short circuit test.
23.12 Apart from dynamic ability test, the transformers shall also be required to withstand
thermal ability test or thermal withstand ability will have to be established by way of
calculations.
23.13 It may also be noted that the purchaser reserved the right to conduct short circuit test
and impulse voltage test in accordance with the IS, afresh on each ordered rating at
purchaser’s cost, even if the transformers of the same rating and similar design are
already tested. This test shall be carried out on a transformer to be selected by the
15
purchaser either at their works when they are offered in a lot for supply or randomly
from the supplies already made to purchaser’s Stores. The findings and conclusions of
these tests shall be binding on the supplier.
24 TESTS AT SITE:
24.1 The purchaser reserves the right to conduct all tests on transformer after arrival
at site and the manufacturer shall guarantee test certificate figures under actual
service conditions.
25 ACCEPTANCE TESTS:
25.1 The transformers shall be subjected to the following routine/ acceptance test in the
presence of purchaser’s representative at the place of manufacture before despatch
without any extra charges. The testing shall be carried out in accordance with IS 1180,
Part-1 (2014) and IS 2026. Checking of mass, dimensions, fitting and accessories, tank
sheet thickness, oil quality, material, finish and workmanship as per GTP/QA plan and
contract drawings.
25.2 Physical verification of core coil assembly and measurement of flux density of one unit
of each rating, in every inspection with reference to short circuit test report.
25.3 All tests as specified in clause 22.
26 INSPECTION:
26.1 In respect of raw material such as core stampings, winding conductors, insulating paper
and oil, supplier shall use materials manufactured/supplied by standard manufacturers
and furnish the manufacturers’ test certificate as well as the proof of purchase from the
manufacturers (excise gate pass) for information of the purchaser. The bidder shall furnish
following documents along with their offer in respect to the raw materials :
26.1.1 Invoice of supplier.
26.1.2 Mill’s certificate.
26.1.3 Packing List.
26.1.4 Bill of landing.
26.1.5 Bill of entry certificate by custom.
Please refer to “Check-list for Inspection of Prime quality CRGO for Transformers”
26.2 To ensure about the quality of transformers, the inspection shall be carried out by the
purchaser’s representative at following stages:
26.2.1 Online anytime during receipt of raw material and manufacture/ assembly whenever
the purchaser desires.
26.2.2 When the raw material is received, and the assembly is in process in the shop floor.
26.2.3 At finished stage i.e. transformers are fully assembled and are ready for despatch.
26.3 After the main raw-materials i.e. core and coil materials and tanks are arranged and
transformers are taken for production on shop floor and a few assembly have been
completed, the firm shall intimate the purchaser in this regard, so that an officer for
carrying out such inspection could be deputed, as far as possible within seven days from
16
the date of intimation. During the stage inspection a few assembled core shall be
dismantled (only in case of CRGO material) to ensure that the CRGO laminations used
are of good quality. Further, as and when the transformers are ready for despatch, an
offer intimating about the readiness of transformers, for final inspection for carrying
out tests as per relevant IS and as in clauses above, shall be sent by the firm along
with routine test certificates. The inspection shall normally be arranged by the
purchaser at the earliest after receipt of offer for pre-delivery inspection.
26.4 In case of any defect/defective workmanship observed at any stage by the purchaser’s
inspecting officer; the same shall be pointed out to the firm in writing for taking
remedial measures. Further processing should only be done after clearance from the
Inspecting officer/purchaser.
26.5 All tests and inspection shall be carried out at the place of manufacture unless
otherwise specifically agreed upon by the manufacturer and purchaser at the time of
purchase. The manufacturer shall offer the inspector representing the purchaser all
reasonable facilities, without charges, to satisfy him that the material is being supplied
in accordance with this specification. This will include stage inspection during
manufacturing stage as well as active part inspection during acceptance tests.
26.6 The manufacturer shall provide all services to establish and maintain quality of
workmanship in his works and that of his sub-contractors to ensure the
mechanical/electrical performance of components, compliance with drawings,
identification and acceptability of all materials, parts and equipment as per latest quality
standards of ISO 9000.
26.7 Along with the bid the manufacturer shall prepare Quality Assurance Plan (QAP)
identifying the various stages of manufacture, quality checks performed at each stage
and the customer hold points. The document shall also furnish details of method
of checking, inspection and acceptance standards/values and get the approval of
purchaser or his representative before proceeding with manufacturing. However,
purchaser or his representative shall have the right to review the inspection reports,
quality checks and results of manufacturer’s in house inspection department which
are not customer hold points and the manufacturer shall comply with the remarks made
by purchaser or his representative on such reviews with regards to further testing,
rectification or rejection etc. Manufacturer should submit the list of equipment for testing
along with latest calibration certificates to the purchaser.
26.8 Purchaser shall have every right to appoint a third party inspection to carry out the inspection
process. The purchaser has the right to have the test carried out at his own cost by
an independent agency wherever there is a dispute regarding the quality of supply.
Purchaser has right to test 1% of the supply selected either from the stores or field to check
the quality of the product. In case of any deviation purchaser has every right to reject the
entire lot or penalise the manufacturer, which may lead to blacklisting among other things.
27 QUALITY ASSURANCE PLAN:

27.1 The bidder shall invariably furnish following information along with his bid, failing which
his bid shall be liable for rejection. Information shall be separately given for individual
type of material offered.
27.2 Statement giving list of important raw materials, names of sub-suppliers for the raw
17
materials, list of standards according to which the raw materials are tested, list of test
normally carried out on raw materials in presence of bidder’s representative and copies of
test certificates.
27.3 Information and copies of test certificates as above in respect of bought out accessories.
27.4 List of manufacturing facilities available.
27.5 Level of automation achieved and list of areas where manual processing exists.
27.6 List of areas in manufacturing process, where stage inspections are normally carried out
for quality control and details of such tests and inspections.
27.7 List of testing equipment available with the bidder for final testing of equipment along
with valid calibration reports shall be furnished with the bid. Manufacturer shall possess
0.1 accuracy class instruments for measurement of losses.
27.8 Quality assurance plan with hold points for purchaser’s inspection.
27.9 The successful bidder shall within 30 days of placement of order, submit following
information to the purchaser.
27.9.1 List of raw materials as well as bought out accessories and the names of sub-suppliers
selected from those furnished along with offer.
27.9.2 Type test certificates of the raw materials and bought out accessories.
27.10 The successful bidder shall submit the routine test certificates of bought out accessories
and central excise passes for raw material at the time of routine testing.
27.11 ISI marking on the transformer is mandatory. As per Quality Control Order for Electrical
Transformers- 2015, issued by Dept. of Heavy Industries, the Standard / ISI marking on
Distribution Transformers is mandatory and the product should be manufactured in
compliance with IS 1180 Part-1:(2014).
28 DOCUMENTATION:
28.1 Completely dimensioned drawings indicating general arrangement and details of fittings,
clearances and winding details shall accompany the tender.
28.2 Drawings of internal constructional details and fixing details of coils should also be
indicated. Tank dimensions, position of fittings, clearances between leads within the
transformer, core grade of laminations, distance of core centers, area of conductor bare
and with insulation. No. of coils, No. of turns per coil material of bushing metal parts
etc., shall also be furnished with tender.
29 PACKING and FORWARDING:

29.1 The packing shall be done as per the manufacturer’s standard practice.
However, he should ensure the packing is such that, the material should not get
damaged during transit by rail/road.
29.2 The marking on each package shall be as per the relevant IS.
30 GUARANTEE:
31.1 The manufacturers of the transformer shall provide a guarantee of 60 months from the
date of commissioning. In case the transformer fails within the guarantee period, the
supplier will depute his representative within 15 days from date of intimation by utility
18
for joint inspection. In case, the failure is due to the reasons attributed to supplier, the
transformer will be replaced/repaired by the supplier within 2 months from date of joint
inspection.
31.2 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.
31.3 In the event of the supplier’s inability to adhere to the aforesaid provisions, suitable
penal action will be taken against the supplier, which may inter alia include blacklisting
of the firm for future business with the purchaser for a certain period.
(i) Methodology for computing total owning cost*

Annex-I
TOC = IC + (A xWi) + (B xWc) ; Losses in KW

Where,
TOC = Total Owning Cost
IC = Initial cost including taxes of transformer as quoted by the manufacturer
A factor = Cost of no load losses in Rs/KW (A = 288239)
B factor = Cost of load losses in Rs/KW (B = 93678)
Wi = No load losses quoted by the manufacturer in KW
Wc = Load losses quoted by the manufacturer in KW
Note:
No (+) ve tolerance shall be allowed at any point of time on the quoted losses after the award. In case,
the losses during type testing, routine testing etc. are found above the quoted losses, the award shall stand
cancelled. In such a case, the CPG money shall also be forfeited.
* Amendment issued vide letter No. REC/DDUGJY/SBD/DTR-TS/969 Dated 29.09.2016
Annexure-Paint
Painting-Transformer Main tank, pipes, Conservator Tank, Radiator etc.
19
Surface primer intermediate finish total Colour

Preparation coat under coat coat DFT shade
Main tank, Blast Epoxy Epoxy base Aliphatic Min 541
pipes, conservator cleaning base Zinc primer Polyuret 110 shade
tank,etc. (External Sa2½ 30-40 micron hane (PU micron of IS:5
surfaces) Zinc primer Paint)
30-40 micron (min 50
micron
Main tank, Blast Hot oil -- -- Min 30 Glossy
pipes (above 80 cleaning resistant, non- micron white
NB), Sa2½ corrosive for
conservator varnish or paint
tank,etc (Internal paint
surfaces)
Radiator Chemical / Epoxy base Epoxy base Aliphatic Min 541
(Externalsur blast cleaning zinc primer Zinc primer Polyureth 110 shade
faces) (Sa2½) 30-40 micron Min 30-40 ane(PU micron of IS:5
micron Paint)
(min)50
micron
Radiator and Chemical Hot oil -- -- -- Glossy
pipes up to 80 cleaning if proof low white
NB (Internal required viscosity for
surfaces) varnish or hot paint
oil resistant
non
corrosive paint
GUARANTEED TECHNICAL PARTICULARS FOR COMPLETELY SELF PROTECTED
DISTRIBUTION TRANSFORMERS
Sl.No. Description 10 kVA 16kVA
1. Name of the manufacturer and place of manufacture

2. Continuous maximum rating as per this specification.
3. Normal ratio of transformer
4. Method of connection HV/LV
5. Maximum current density in Windings :
1. HV (A/sq mm)
20
2. LV (A/sq mm)
6. Maximum hot spot temperature 0C(Ambient air temperature on which
above is based) 0C.
7. Maximum temperature : 0C (a)Maximum observable oil temperature (ambient air
temperature on which above is based)
b)Maximum winding temperature at an ambient temperature of
8. No-load losses at rated voltage (watt)
9. Full load losses at 75 0C (watt)

10. Total losses at 100% load (watt)
11. Total losses at 50% load (watt)
12. Efficiency at normal voltage :
(i) Unity Power Factor
(a) At 50% load
(b) At 75% load
(c) At full load
(ii) 0.8 Power Factor

(a) At 50% load
(b) At 75% load
(c) At full load
13. Regulation as percentage of
normal voltage :
(a) At unity power factor

(b) At 0.8 power factor lagging
14. Percentage impedance voltage at normal ratio between HV and LV windings
15. Type of transformers, CRGO type
16. Type of Insulation used in
HV
Winding s LV
Winding s
17. Type of insulation used in
Core bolts
Core bolt
washers End plates
Core lamination
18. Impulse withstand test voltage level (kV)
HV Windings LV Windings
21
19. Characteristics of transformer oil

20. Total content of oil in litres
21. Whether transformer will be transported with oil?
22. Type of transformer tank
23. Approximate overall dimensions
a) Height mm
b) Length mm
c) Width mm
Tank dimensions
a) Diameter mm
b) Height mm
24. Mass of insulated conductor
HV(minimum) kg
LV(minimum) kg
25. Mass of core (minimum) kg (CRGO)
26. Mass of complete transformer arranged for transport
22
ADDITIONAL DETAILS
Sl. No. Description Unit
1. Core grade
2. Core dimensions mm
3. Gross core area cm2
4. Net Core area cm2
5. Flux density Tesla
6. Mass of Core kg
7. Loss per kg of core at the specified flux density watt
8. Core window height mm
9. Center to center distance of the core mm
10. No. of LV Turns
11. No. of HV turns
12. Size of LV Conductor bare/ covered (dia) mm
13. Size of HV conductor bare/covered (dia) mm
14. No. of parallels
15. Current density of LV winding A/sq mm
16. Current density of HV winding A/sq mm
17. Mass of the LV winding for Transformer kg
18. Mass of the HV winding for Transformer kg
19. No. of of LV Coils/phase
20. No. of HV coils . phase
21. Height of LV Windings mm
22. Height of HV winding mm
23. ID/OD of LV winding HV mm
24. ID/OD of LV winding mm
25. Size of the duct in LV winding mm
26. Size of the duct in HV winding mm
27. Size of the duct between HV and LV mm
28. HV winding to LV clearance mm
29. HV winding to tank clearance mm
30. Calculated impedance %
31. HV to earth creepage distance mm
32. LV to earth creepage distance mm
23
SOURCE OF MATERIALS/PLACES OF MANUFACTURE, TESTING AND INSPECTION
Source of Place of Place of

Sl. No. Item
Material Manufacture
testing and
inspection
1. Laminations
Aluminium/Copper (As per Discom

Practice aluminium windings are to be
2. used up to 100 kVA and copper
windings are to be used above 100
kVA)
3. Insulated winding wires
4. Oil
5. Press boards
6. Kraft paper
7. MS plates/Angles/Channels
8. Gaskets
9. Bushing HV/LV
10. Paints
24
3-Phase Distribution Transformers 11 kV/433-250V (Outdoor Type)
1. SCOPE:
i) This specification covers design, engineering, manufacture, assembly, stage testing,
inspection and testing before supply and delivery at site of oil immersed, naturally
cooled 3-phase 11 kV/433 - 250 V distribution transformers for outdoor use.
ii) The equipment shall conform in all respects to high standards of engineering, design
and workmanship and shall be capable of performing in continuous commercial
operation, in a manner acceptable to the purchaser, who will interpret the meanings of
drawings and specification and shall have the power to reject any work or material
which, in his judgment is not in accordance therewith. The offered equipment shall be
complete with all components necessary for their effective and trouble free operation.
Such components shall be deemed to be within the scope of bidder’s supply irrespective
of whether those are specifically brought out in this specification and / or the commercial
order or not.
iii) The transformer and accessories shall be designed to facilitate operation, inspection,
maintenance and repairs. The design shall incorporate every precaution and provision
for the safety of equipment as well as staff engaged in operation and maintenance of
equipment.
iv) All outdoor apparatus, including bushing insulators with their mountings, shall be
designed so as to avoid any accumulation of water.
2 STANDARDS:
2.1 The major materials used in the transformer shall conform in all respects to the
relevant/specified Indian Standards and international Standards with latest amendments
thereof as on bid opening date, unless otherwise specified herein. Some of the applicable
Indian Standards are listed as hereunder:
3.2
Indian Title International
Standards Standards
IS -2026 Specification for Power Transformers IEC 76
IS 1180 (Part- Outdoor Type Oil Immersed Distribution Transformers
I): upto and including 2500kVA, 11kV-Specification
2014
IS 12444 Specification for Copper wire rod ASTM B-49
IS-335 Specification for Transformer/Mineral Oil IEC Pub 296
IS-5 Specification for colors for ready mixed paints
IS -104 Ready mixed paint, brushing zinc chromate, priming
25
IS-2099 Specification for high voltage porcelain bushing

IS-649 Testing for steel sheets and strips and magnetic circuits
IS- 3024 Cold rolled grain oriented electrical sheets and strips
IS - 4257 Dimensions for clamping arrangements for bushings
IS - 7421 Specification for Low Voltage bushings
IS - 3347 Specification for Outdoor Bushings DIN 42531 to
33
IS - 5484 Specification for Al Wire rods ASTM B - 233
IS - 9335 Specification for Insulating Kraft Paper IEC 554
IS - 1576 Specification for Insulating Press Board IEC 641
IS - 6600 Guide for loading of oil Immersed Transformers IEC 76
IS - 2362 Determination of water content in oil for porcelain
bushing of transformer
IS - 6162 Paper covered Aluminium conductor
IS - 6160 Rectangular Electrical conductor for electrical machines
IS - 5561 Electrical power connector
IS - 6103 Testing of specific resistance of electrical insulating
liquids
IS - 6262 Method of test for power factor and dielectric constant of
electrical insulating liquids
IS - 6792 Determination of electrical strength of insulating oil
IS - 10028 Installation and maintenance of transformers.
3 STANDARD RATINGS:
The standard ratings shall be 16, 25, 63, 100,160, 200, 250, 315, 400, 500, 630, 1000, 1250, 1600,
2000 and 2500 kVA for 11 kV distribution transformers.
4 SERVICE CONDITIONS:
4.1 The Distribution Transformers to be supplied against this Specification shall be
suitable for satisfactory continuous operation under the following climatic conditions as
per IS 2026 (Part - I).
i) Location : At various locations in the country
ii) Maximum ambient air temperature (0C) : 50
iii) Minimum ambient air temperature (0C) : -5
iv) Maximum average daily ambient air temperature (0C):40

26
v) Maximum yearly weighted average : 32

ambient temperature(0C)
vi) Maximum altitude above Altitude of 5000 meters mean sea level (meters) :
for HP, J&K, Uttrakhand, Sikkim , Assam, Meghalaya, Manipur, Nagaland, Tripura, Arunachal
Pradesh and Mizoram
(ii) Note:
1. The climatic conditions specified above are indicative and can be changed by the user as per
requirements.
2. The equipment shall generally be for use in moderately hot and humid tropical climate,
conducive to rust and fungus growth unless otherwise specified.
5 PRINCIPAL PARAMETERS:
5.1 The transformers shall be suitable for outdoor installation with three phase, 50 Hz, 11
kV system in which the neutral is effectively earthed and they should be suitable for service
with fluctuations in supply voltage upto plus 12.5% to minus 12.5%.
(i) The transformers shall conform to the following specific parameters :
Item 11 kV Distribution Transformers

Sl.No.
1 System voltage (Max.) 12 kV
2 Rated Voltage (HV) 11 kV
3 Rated Voltage (LV) 433 - 250 V*
4 Frequency 50 Hz +/- 5%*
5 No. of Phases Three
6 Connection HV Delta
7 Connection LV Star (Neutral brought out)
8 Vector group Dyn-11
9 Type of cooling ONAN
Audible sound levels (decibels) at rated voltage and frequency for liquid immersed
distribution transformers shall be as below (NEMA Standards):
27
kVA rating Audible sound levels (decibels)

0-50 48
51-100 51
101-300 55
301-500 56
750 57
1000 58
1500 60
2000 61
2500 62
(iii) TECHNICAL REQUIREMENTS: Minimum Guaranteed weight or core, conductor, transformer
oil & minimum thickness of tank sheet shall be as following
6.1.1 CORE MATERIAL

6.1.2.1 The core shall be stack / wound type of high grade Cold Rolled Grain Oriented having
low loss and good grain properties, coated with hot oil proof insulation, bolted together
and to the frames firmly to prevent vibration or noise. The core shall be stress relieved
by annealing under inert atmosphere if required. The complete design of core must ensure
permanency of the core loss with continuous working of the transformers. The value of
the maximum flux density allowed in the design and grade of lamination used shall be
clearly stated in the offer.
6.1.2.2 The bidder should offer the core for inspection and approval by the purchaser during
manufacturing stage. CRGO steel for core shall be purchased only from the approved vendors,
list of which is available at http://apps.powergridindia.com/ims/ComponentList/Power-
6.1.2.3 The transformers core shall be suitable for over fluxing (due to combined effect of voltage
and frequency) up to 12.5% without injurious heating at full load conditions and
shall not get saturated. The bidder shall furnish necessary design data in support of this
situation.
28
6.1.2.4 No-load current up to 200kVA shall not exceed 3% of full load current and will be
measured by energising the transformer at rated voltage and frequency. Increase of
12.5% of rated voltage shall not increase the no-load current by 6% of full load current.
or
No-load current above 200kVA and upto 2500kVA shall not exceed 2% of full load current
and will be measured by energising the transformer at rated voltage and frequency.
Increase of 12.5% of rated voltage shall not increase the no-load current by 5% of full load
current.
6.1.2.5 Please refer to “Check-list for Inspection of Prime quality CRGO for Transformers”
7 WINDINGS:
(i) Material:
7.1.1 HV and LV windings shall be wound from Double Paper covered Aluminium (upto 100 kVA) /
Electrolytic Copper conductor (Above 100 kVA).
7.1.2 LV winding shall be such that neutral formation will be at top.
7.1.3 The winding construction of single HV coil wound over LV coil is preferable.
7.1.4 Inter layer insulation shall be Nomex /Epoxy dotted Kraft Paper.
7.1.5 Proper bonding of inter layer insulation with the conductor shall be
ensured. Test for bonding strength shall be conducted.
7.1.6 Dimensions of winding coils are very critical. Dimensional tolerances for winding coils
shall be within limits as specified in Guaranteed Technical Particulars (GTP Schedule I).
7.1.7 The core/coil assembly shall be securely held in position to avoid any movement under
short circuit conditions.
7.1.8 Joints in the winding shall be avoided. However, if jointing is necessary the joints
shall be properly brazed and the resistance of the joints shall be less than that of parent
conductor. In case of foil windings, welding of leads to foil can be done within the
winding.
8 TAPPING RANGES AND METHODS:

8.1.1 No tapping shall be provided for distribution transformers up to 100 kVA rating.
8.1.2 The tapping shall be as per provisions of IS: 1180 Part-I (2014).
8.1.3 Tap changing shall be carried out by means of an externally operated self-position
switch and when the transformer is in de-energised condition. Switch position No.1 shall
correspond to the maximum plus tapping. Each tap change shall result in variation of
2.5% in voltage. Arrangement for pad locking shall be provided. Suitable aluminium
anodized plate shall be fixed for tap changing switch to know the position number of
tap.
9 OIL:
9.1 The insulating oil shall comply with the requirements of IS 335. Use of recycled oil is not
acceptable. The specific resistance of the oil shall be as per IS 335.
29
9.2 Oil shall be filtered and tested for break down voltage (BDV) and moisture content before filling.
9.3 The oil shall be filled under vacuum.
9.4 The design and all materials and processes used in the manufacture of the transformer,
shall be such as to reduce to a minimum the risk of the development of acidity in the oil.
10 INSULATION LEVELS:
Sl. Power Frequency
Voltage (kV) Impulse Voltage (kV Peak)
No. Voltage (kV)
1 0.433 - 3
2 11 75 28
3 33 170 70
11 LOSSES:
11.1 The transformer of HV voltage up to 11kV,the total losses(no-load + load losses at 75
0C) at 50% of rated load and total losses at 100% of rated load shall not exceed the
maximum total loss values given in Table-3 upto 200kVA & Table-6 for ratings above
200kVA of IS 1180(Part-1):2014.
11.2 The maximum allowable losses at rated voltage and rated frequency permitted at 75
0C for 11/0.433 kV transformers can be chosen by the utility as per Table-3 upto
200kVA and Table-6 for ratings above 200kVA as per Energy Efficiency Level-1
specified in IS 1180 (Part-1):2014 as per latest amendment 4 March 2021 for all kVA
ratings of distribution transformers.
(Clause 6.8.1.1,6.8.1.2,6.8.1.3 and 6.8.2)
Efficiency Efficiency Efficiency Efficiency Efficiency
Rating Impedence Level 1 Level 2 Level 3 Level 4 Level 5
S.No.
(KVA) (%)
50% 100% 50% 100% 50% 100% 50% 100% 50% 100%
Load Load Load Load Load Load Load Load Load Load
1 16 4.5 135 440 120 400 108 364 97 331 87 301
2 25 4.5 190 635 175 595 158 541 142 493 128 448
3 63 4.5 340 1140 300 1050 270 956 243 870 219 791
4 100 4.5 475 1650 435 1500 392 1365 352 1242 317 1130
5 160 4.5 670 1950 570 1700 513 1547 462 1408 416 1281
6 200 4.5 780 2300 670 2100 603 1911 543 1739 488 1582
(Clause 7.8.1.1)
S.No Rating Impeden Efficiency Efficiency Efficiency Efficiency Efficiency
. (KVA) ce (%)
Level 1 Level 2 Level 3 Level 4 Level 5
30
50% 100% 50% 100% 50% 100% 50% 100% 50% 100%
Load Load Load Load Load Load Load Load Load Load
1 250 4.5 980 2930 920 2700 864 2488 811 2293 761 2113
2 315 4.5 1025 3100 955 2750 890 2440 829 2164 772 1920
3 400 4.5 1225 3450 1150 3330 1080 3214 1013 3102 951 2994
4 500 4.5 1510 4300 1430 4100 1354 3909 1282 3727 1215 3554
5 630 4.5 1860 5300 1745 4850 1637 4438 1536 4061 1441 3717
6 800 5 2287 6403 2147 5838 2015 5323 1892 4853 1776 4425
7 1000 5 2790 7700 2620 7000 2460 6364 2310 5785 2170 5259
8 1250 5 3300 9200 3220 8400 3142 7670 3066 7003 2991 6394
9 1600 6.25 4200 11800 3970 11300 3753 10821 3547 10363 3353 9924
10 2000 6.25 5050 15000 4790 14100 4543 13254 4309 12459 4088 11711
11 2500 6.25 6150 18500 5900 17500 5660 16554 5430 15659 5209 14813
11.3 The above losses are maximum allowable and there would not be any positive tolerance.
Bids with higher losses than the above specified values would be treated as non-
responsive. However, the manufacturer can offer losses less than above stated values.
The utility can evaluate offers with losses lower than the maximum allowable losses on
total owning cost basis in accordance with methodology given in Annex-I.
12 TOLERANCES:
12.1 No positive tolerance shall be allowed on the maximum losses displayed on the label for
both 50% and 100% loading values.
13 PERCENTAGE IMPEDANCE:
The percentage impedance of transformers at 75 0C for different ratings upto 200 kVA
shall be as per Table 3 and for ratings beyond 200 kVA shall be as per Table 6 of IS
1180(Part-1):2014.
14 Temperature rise: The temperature rise over ambient shall not exceed the limits given below:
14.1 The permissible temperature rise shall be as per IS: 1180 (Part-I):2014.
14.2 The transformer shall be capable of giving continuous rated output without exceeding
the specified temperature rise. Bidder shall submit the calculation sheet in this regard.
14.3 Protection: The transformer shall have the following additional fittings as its integral
part: The transformers shall have the following CSP features: a) Internal HV Fuses on the
HT side of transformers: Specification for HT Fuses: Expulsion /any other suitable fuse
placed in series with primary winding. This fuse is mounted normally inside of the
primary bushing and is disconnected to high voltage winding through a terminal block.
This has to protect that part of electrical distribution system, which is ahead of the
distribution transformers from faults, which occurs inside the distribution transformers
i.e. either the winding or some other part of the transformer. It shall be ensured that this
fuse does not blow for faults on the secondary side (LT side) of the transformer i.e. the
31
blowing characteristics of the fuse and LT beaker shall be coordinated that the fuse shall
not blow for any faults on the secondary side of the transformer and these faults shall be
cleared by the LT breaker only. The time current characteristics and co-ordination with
HV fuses shall be submitted alongwith the offer.
b) Internally mounted oil immersed LT Breaker on the LV side of the transformer: LT
Circuit Breaker: The LT Circuit breaker shall clear all LT faults. As such, it shall be
designed for perfect coordination with the HT fuse link. The supplier shall furnish the
time /current characteristics of LT Circuit breaker and 11/√3 kV fuses for various current
multiples. The two characteristics shall be drawn on the same sheet to indicate
coordination between the circuit breaker and fuse. This shall be based on the type test
carried out on one of the transformers. In addition, the supplier shall carry out coordination
test as indicated above, and this forms one of the testes for acceptance. The breaker is to
be mounted on the secondary side of the transformer under oil to minimize premature
operations from primary surges. Two single pole elements is preferred. The Breaker shall
be coordinated thermally with the transformer rating to follow closely the variations of
coil temperature due to fluctuations in loads and ambient temperature. This is to be
accomplished by connecting the breaker in series between the secondary winding and
load. The breaker shall be located in the same oil as the core and coil assembly so that the
bimetal strips are sensitive to the temperature of oil as well as the load current. The circuit
breaker may be an electro-mechanical device with three elements viz. (1) temperature
sensing (2) latching and tripping and (3) current interrupting. The temperature sensing
function might be accomplished through the use of bimetallic strips which would be built
into breaker, such that load current of the transformer flows through them. In addition to
this, a magnetic tripping device is to be provided for increasing the opening speed of the
breaker under high fault conditions. The circuit breaker shall be mounted inside of the
transformer so that these bimetallic strips are within the top oil layer of the transformer.
The latching and tripping functions of the circuit breaker may be carried out within
assembly similar to those used in industrial type air circuit breaker. The circuit breaker
shall also be closed and opened manually standing on ground and with a magnetic trip
device also. The current interruption element shall consist of copper current carrying parts
plus a set of copper tungsten current interrupting contacts the magnetic element increase
the opening speed of the circuit breaker under high fault current conditions. The response
of circuit breaker to the activity shall remain unchanged by the addition of the magnetic
trip element. The specification to which the breakers conform shall be indicated. The Type
tests shall be carried out on Circuit breaker as per IS: 13947 (Part-2)/1993 amended up to
date at any NABL Laboratory and shall be submitted along with the offer.
Note: Mechanical operation test on LV Circuit Breaker shall be carried out in OIL
medium as per IS: 13947 (Part-2)/1993 amended up to date.
c) Load Management Signal Light : A signal light, controlled by a metal in the breaker
shall switch on when the transformer load reaches a predetermined level indicating that
the transformer has been over-loaded. The load management signal light shall perform
two functions. It shall show visually when the particulars transformers has been operating
32
in an overload condition and shall provided knowledge that for good system management,
the economical change out point for the transformer is fast approaching. The signal light
need not indicate temporary overloads and shall turn on only when the overload condition
has existed at a given level for a certain length of time. The LT circuit breaker shall be
have a set of auxiliary contacts builtin for signal light operation. These, normally open
contacts, shall form part of the signal light circuit. The signal light circuit shall consist of
an auxiliary transformer winding one or two turns) which generates about 4V, for the
signal light contact set within the circuit breaker, and the signal light is mounted on the
transformer tank. The signal light contact set is mechanically connected to the main circuit
breaker latching and bimetal system. The signal light mechanism is adjusted so that the
signal light contacts will close at a pre-set thermal condition, which occurs before the main
latching system opens the main contact. The net result is a visual external indication that
a pre-set load conditions has reached by the transformer. The signal light mechanism does
not reset itself when the load drops off, the signal light remains lighted once the signal
light contact closes and can only be turned off by manually operating the external circuit
breaker handle.
ALTERNATIVE FOR a) Externally mounted MCCB for LV side: Single pole MCCB is
to be provided on LV side with thermal trip release within verse time current
characteristics for overload protection and magnetic trip release for instantaneous tripping
in the wake of short circuits. The time current characteristics and co-ordination with HV
fuse shall be submitted along with the offer. MCCB is to be fixed in an enclosure (IP 55)
in ready to be used condition and to be mounted on the transformer before installation on
the pole. The enclosure shall be made with sheet steel of thickness not less than 1.6 mm.
It shall be painted both inside and outside with powder coating. Enclosure shall have
providing for pad locking arrangement. Detachable gland plate shall be provided for
taking connections from MCCB and transformer bushing terminal. Signal light (LED
Indicating lamp): The MCCB enclosure shall be provided with LED indicating lamp to
indicate tripping of MCCB. An auxiliary relay with changeover contacts can be used to
connect LED indicating lamp to the transformer secondary terminals if MCCB is not
having auxiliary contacts. In case the MCCB trips or switched OFF, the relay contacts are
closed which turns ON the LED indicating lamp. When the MCB is reset and switched
ON, the indicating lamp switches OFF. Signal light shall be arranged to avoid damages
while handling the MCCB enclosure at site.
15 PENALTY FOR NON PERFORMANCE:

15.1 During testing at supplier’s works if it is found that the actual measured losses are more
than the values quoted by the bidder, the purchaser shall reject the transformer and he
shall also have the right to reject the complete lot.
15.2 Purchaser shall reject the entire lot during the test at supplier’s works, if the temperature rise
exceeds the specified values.
15.3 Purchaser shall reject any transformer during the test at supplier’s works, if the impedance
values differ from the guaranteed values including tolerance.
33
16 INSULATION MATERIAL:
16.1 Electrical grade insulation epoxy dotted Kraft Paper/Nomex and pressboard of standard
make or any other superior material subject to approval of the purchaser shall be used.
16.2 All spacers, axial wedges / runners used in windings shall be made of pre-compressed
Pressboard-solid, conforming to type B 3.1 of IEC 641-3-2. In case of cross-over coil
winding of HV all spacers shall be properly sheared and dovetail punched to ensure
proper locking. All axial wedges / runners shall be properly milled to dovetail shape
so that they pass through the designed spacers freely. Insulation shearing, cutting,
milling and punching operations shall be carried out in such a way, that there should not
be any burr and dimensional variations.
17.1 TANK:
 Transformer tank construction shall conform in all respect to clause 15 of IS 1180(Part-1):2014.
 The internal clearance of tank shall be such, that it shall facilitate easy lifting of core with
coils from the tank without dismantling LV bushings.
 All joints of tank and fittings shall be oil tight and no bulging should occur during service.
 Inside of tank shall be painted with varnish/hot oil resistant paint.
 The top cover of the tank shall be slightly sloping to drain rain water.
 The tank plate and the lifting lugs shall be of such strength that the complete
transformer filled with oil may be lifted by means of lifting shackle/Hook Type.
 Manufacturer should carry out all welding operations as per the relevant ASME
standards and submit a copy of the welding procedure and welder performance
qualification certificates to the customer.
i) PLAIN TANK:
17.2.1 The transformer tank shall be of robust construction rectangular/octagonal/round/
elliptical in shape and shall be built up of electrically tested welded mild steel plates of
thickness of 3.15 mm for the bottom and top and not less than 2.5 mm for the sides for
distribution transformers upto and including 25 kVA, 5.0 mm and 3.15 mm respectively
for transformers of more than 25 kVA and up to and including 100 kVA and 6 mm and
4 mm respectively above 100 kVA. Tolerances as per IS1852 shall be applicable.
17.2.2 In case of rectangular tanks above 100 kVA the corners shall be fully welded at the corners
from inside and outside of the tank to withstand a pressure of 0.8 kg/cm2 for 30 minutes.
In case of transformers of 100 kVA and below, there shall be no joints at corners and
there shall not be more than 2 joints in total.
17.2.3 Under operating conditions the pressure generated inside the tank should not exceed 0.4
kg/ sq. cm positive or negative. There must be sufficient space from the core to the top
cover to take care of oil expansion. The space above oil level in the tank shall be filled with
dry air or nitrogen conforming to commercial grade of IS 1747 for DT up to 63 KVA. For
DT of 63 KVA and above rating, conservator shall be provided.
(i) The tank shall be reinforced by welded flats on all the outside walls on the edge of the tank.
(ii) Permanent deflection: The permanent deflection, when the tank without oil is subjected
to a vacuum of 525 mm of mercury for rectangular tank and 760 mm of mercury for
34
round tank, shall not be more than the values as given below:
(All figures are in mm)
Horizontal length of flat plate Permanent deflection
Up to and including 750 5.0
751 to 1250 6.5

1251 to 1750 8.0
1751 to 2000 9.0

17.2.4 The tank shall further be capable of withstanding a pressure of 0.8kg/sq.cm and a vacuum
of 0.7 kg/sq.cm (g) without any deformation.
17.2.5 The radiators can be tube type or fin type or pressed steel type to achieve the desired
cooling to limit the specified temperature rise.
17.3 CORRUGATED TANK:

17.3.1 The bidder may offer corrugated tanks for transformers of all ratings.
17.3.2 The transformer tank shall be of robust construction corrugated in shape and shall be built
up of tested sheets.
17.3.3 Corrugation panel shall be used for cooling. The transformer shall be capable of giving
continuous rated output without exceeding the specified temperature rise. Bidder shall
submit the calculation sheet in this regard.
17.3.4 Tanks with corrugations shall be tested for leakage test at a pressure of 0.25kg/ sq cm
measured at the top of the tank.
17.3.5 The transformers with corrugation should be provided with a pallet for transportation,
the dimensions of which should be more than the length and width of the transformer
tank with corrugations.
18 CONSERVATOR:
(i) Transformers of rating 63 kVA and above with plain tank construction, the provision of
conservator is mandatory. For corrugated tank and sealed type transformers with or
without inert gas cushion, conservator is not required.
(ii) When a conservator is provided, oil gauge and the plain or dehydrating breathing device
shall be fitted to the conservator which shall also be provided with a drain plug and a
filling hole [32 mm (1¼”)] normal size thread with cover. In addition, the cover of the
main tank shall be provided with an air release plug.
(iii) The dehydrating agent shall be silica gel. The moisture absorption shall be indicated by a
change in the colour of the silica gel crystals which should be easily visible from a
distance. Volume of breather shall be suitable for 500g of silica gel conforming to IS
3401 for transformers upto 200 kVA and 1 kg for transformers above 200 kVA .
(iv) The capacity of a conservator tank shall be designed keeping in view the total quantity of
35
oil and its contraction and expansion due to temperature variations. The total volume
of conservator shall be such as to contain10% quantity of the oil. Normally 3% quantity
the oil shall be contained in the conservator.
(v) The cover of main tank shall be provided with an air release plug to enable air trapped
within to be released, unless the conservator is so located as to eliminate the possibility
of air being trapped within the main tank.
(vi) The inside diameter of the pipe connecting the conservator to the main tank should be
within 20 to 50 mm and it should be projected into the conservator so that its end is
approximately 20 mm above the bottom of the conservator so as to create a sump for
collection of impurities. The minimum oil level (corresponding to -5 0C) should be above
the sump level.
19 SURFACE PREPARATION AND PAINTING:
(i) GENERAL
19.1.1 All paints, when applied in a normal full coat, shall be free from runs, sags, wrinkles,
patchiness, brush marks or other defects.
19.1.2 All primers shall be well marked into the surface, particularly in areas where painting is
evident and the first priming coat shall be applied as soon as possible after cleaning. The
paint shall be applied by airless spray according to manufacturer’s recommendations.
However, where ever airless spray is not possible, conventional spray be used with prior
approval of purchaser.
19.2 CLEANING AND SURFACE PREPARATION:

a) After all machining, forming and welding has been completed, all steel work surfaces
shall be thoroughly cleaned of rust, scale, welding slag or spatter and other
contamination prior to any painting.
b) Steel surfaces shall be prepared by shot blast cleaning (IS9954) to grade Sq.
2.5 of ISO 8501-1 or chemical cleaning including phosphating of the appropriate quality (IS
3618).
c) Chipping, scraping and steel wire brushing using manual or power driven tools cannot
remove firmly adherent mill-scale. These methods shall only be used where blast cleaning
is impractical. Manufacturer to clearly explain such areas in his technical offer.
19.3 PROTECTIVE COATING:

19.3.1 A s soon as all items have been cleaned and within four hours of the subsequent drying,
they shall be given suitable anti-corrosion protection.
19.4 PAINT MATERIAL:

i) Following are the types of paint which may be suitably used for the items to be painted
at shop and supply of matching paint to site: Heat resistant paint (Hot oil proof) for inside
surface
ii) For external surfaces one coat of thermo setting powder paint or one coat of epoxy
36
primer followed by two coats of synthetic enamel/polyurethene base paint. These paints
can be either air drying or stoving.
iii) For highly polluted areas, chemical atmosphere or for places very near to the sea coast,
paint as above with one coat of high build Micaceous iron oxide (MIO) as an
intermediate coat may be used.
19.5 PAINTING PROCEDURE:

i) All prepared steel surfaces should be primed before visible re-rusting occurs or within 4
hours, whichever is sooner. Chemical treated steel surfaces shall be primed as soon as the
surface is dry and while the surface is still warm.
ii) Where the quality of film is impaired by excess film thickness (wrinkling, mud cracking
or general softness) the supplier shall remove the unsatisfactory paint coating and apply
another coating. As a general rule, dry film thickness should not exceed the specified
minimum dry film thickens by more than 25%.
19.6 DAMAGED PAINTWORK:
(i) Any damage occurring to any part of a painting scheme shall be made good to the same
standard of corrosion protection and appearance as that was originally applied.
(ii) Any damaged paint work shall be made good as follows:
19.6.2.1 The damaged area, together with an area extending 25 mm around its boundary, shall be
cleaned down to bare metal.
19.6.2.2 A priming coat shall be immediately applied, followed by a full paint finish equal
to that originally applied and extending 50 mm around the perimeter of the original
damage.
19.6.2.3 The repainted surface shall present a smooth surface. This shall be obtained by carefully
chamfering the paint edges before and after priming.
19.6.2.4 The paint shade shall be as per Annexure-Paint which is attached herewith.
19.7 DRY FILM THICKNESS:

19.7.1 To the maximum extent practicable the coats shall be applied as a continuous film of
uniform thickness and free of pores. Overspray, skips, runs, sags and drips should
be avoided. The different coats may or may not be of the same colour.
19.7.2 Each coat of paint shall be allowed to harden before the next is applied as per manufacturer’s
recommendation.
19.7.3 Particular attention must be paid to full film thickness at the edges.
19.7.4 The requirements for the dry film thickness (DFT) of paint and the materials to be used
shall be as given below:
Sl. Paint type Area to be painted No. of Total dry film

37
No. coats thickness

(min.) (microns)
1. Thermo setting powder paint inside 01 30

outside 01 60
2. Liquid paint
a) Epoxy (primer) outside 01 30
b) P.U. Paint (Finish coat) outside 02 25 each
c) Hot oil paint/ Varnish inside

01 35/10
19.8 TESTS FOR PAINTED SURFACE:

19.8.1 The painted surface shall be tested for paint thickness.
19.8.2 The painted surface shall pass the cross hatch adhesion test and impact test as acceptance
tests and Salt spray test and Hardness test as type test as per the relevant ASTM standards.
Note: Supplier shall guarantee the painting performance requirement for a period of not
less than 5 years.
20 BUSHINGS:
20.1 The bushings arrangement shall be decided by utility during detailed engineering.
20.2 For 33 kV voltage level-36 kV class bushings shall be used for transformers of ratings
500 kVA and above. And for transformers below 500 KVA, 33 kV class bushings shall
be used, for 11 kV voltage level -12 kV class bushings and for 0.433 kV voltage level- 1
kV class bushings shall be used.
20.3 Bushing can be of porcelain/epoxy material. Polymer insulator bushings conforming
with relevant IEC can also be used.
20.4 Dimensions of the bushings of the voltage class shall conform to the Standards
specified and dimension of clamping arrangement shall be as per IS 4257
20.5 Minimum external phase to phase and phase to earth clearances of bushing terminals shall
be as follows:
Voltage Clearance
Phase to phase Phase to earth
33 Kv 350mm 320mm
11 kV 255mm 140mm
LV 75mm 40mm
For DTs of 200 KVA and above, the clearances of cable box shall be as below:
Voltage Clearance
38
Phase to phase Phase to earth

33 kV 350mm 220mm
11 kV 130mm 80mm
LV 25mm 20mm
20.6 Arcing horns shall be provided on HV bushings.

20.7 Brazing of all inter connections, jumpers from winding to bushing shall have cross section
larger than the winding conductor. All the Brazes shall be qualified as per ASME, section
– IX.
20.8 The bushings shall be of reputed make supplied by those manufacturers who are having
manufacturing and testing facilities for insulators.
20.9 The terminal arrangement shall not require a separate oil chamber not connected to oil
in the main tank.
21 TERMINAL CONNECTORS:
21.1 The LV and HV bushing stems shall be provided with suitable terminal connectors as per
IS 5082 so as to connect the jumper without disturbing the bushing stem. Connectors
shall be with eye bolts so as to receive conductor for HV. Terminal connectors shall be
type tested as per IS 5561.
22 LIGHTNING ARRESTORS:
22.1 9 kV, 5 kA metal oxide lightning arrestors of reputed make conforming to IS 3070 Part-
III, one number per phase shall be provided.( To be mounted on pole or to be fitted under
the HV bushing with GI earth strip 25x4 mm connected to the body of the transformer
with necessary clamping arrangement as per requirement of purchaser.) Lightening
arrestors with polymer insulators in conformance with relevant IEC can also be used. 1
clamp for LA shall also be provided for each HT bushing. Supply of LA is not included
in DT supplier’s scope.
23 CABLE BOXES:
No cable box shall be provided in transformer below 200 kVA. Above 200kVA, Cable
Boxes shall be provided on both HV & LV side.
23.1 In case HV/LV terminations are to be made through cables the transformer shall be fitted
with suitable cable box on 11 kV side to terminate one 11kV/ 3 core aluminium conductor
cable up to 240 sq. mm. (Size as per requirement).
The bidder shall ensure the arrangement of HT Cable box so as to prevent the
ingress of moisture into the box due to rain water directly falling on the box. The cable
box on HT side shall be of the split type with faces plain and machined and fitted with
Neo-k-Tex or similar quality gasket and complete with brass wiping gland to be mounted
on separate split type gland plate with nut-bolt arrangement and MS earthing clamp. The
bushings of the cable box shall be fitted with nuts and stem to take the cable cores
39
without bending them. The stem shall be of copper with copper nuts. The cross section
of the connecting rods shall be stated and shall be adequate for carrying the rated
currents. On the HV side the terminal rod shall have a diameter of not less than 12 mm.
The material of connecting rod shall be copper. HT Cable support clamp should be
provided to avoid tension due to cable weight.
23.2 The transformer shall be fitted with suitable LV cable box having non-magnetic material
gland plate with appropriate sized single compression brass glands on LV side to
terminate 1.1 kV/single core XLPE armoured cable (Size as per requirement).
24 TERMINAL MARKINGS:
High voltage phase windings shall be marked both in the terminal boards inside the tank
and on the outside with capital letter 1U, 1V, 1W and low voltage winding for the same
phase marked by corresponding small letter 2U, 2V, 2W. The neutral point terminal shall
be indicated by the letter 2N. Neutral terminal is to be brought out and connected to local
grounding terminal by an earthing strip.
26.1 The following standard fittings shall be provided :

i. Rating and terminal marking plates, non-detachable.
ii. Earthing terminals with lugs - 2 Nos.
iii. Lifting lugs for main tank and top cover
iv. Terminal connectors on the HV/LV bushings (For bare terminations only).
v. Thermometer pocket with cap - 1 No.
vi. Air release device (for non-sealed transformer)
vii. HV bushings - 3 Nos.
viii. LV bushings - 4 Nos.
ix. Pulling lugs
x. Stiffener
xi. Radiators - No. and length may be mentioned (as per heat dissipation
calculations)/ corrugations.
xii. Arcing horns on HT side - 3 No . Only clamps for lightning arrestor shall be provided.
xiii. Prismatic oil level gauge.
xiv. Drain cum sampling valve.
xv. One filter valve on upper side of the transformer (For transformers above 200 kVA)
xvi. Oil filling hole having p. 1- ¼ ‘’ thread with plug and drain plug on the conservator.
xvii. Silica gel breather (for non-sealed type transformer)
xviii. Base channel 75x40 mm for up to 100 kVA and 100 mmx50 mm above 100
kVA, 460 mm long with holes to make them suitable for fixing on a platform or plinth.
xix. 4 No. rollers for transformers of 200 kVA and above.
xx. Pressure relief device or explosion vent (above 200 kVA)
xxi. Oil level gauge
40
A. -5 ˚C and 90˚C marking for non-sealed type

Transformers
B.- 30˚C marking for sealed type transformers
xxii. Nitrogen / air filling device/ pipe with welded cover
Capable of reuse (for sealed type transformers)
xxiii. Inspection hole for transformers above 200 kVA
xxiii. Pressure gauge for sealed type transformers above 200 kVA.
xxiv. Buchholz relay for transformers above 1000 KVA.
27 FASTENERS:
27.1 All bolts, studs, screw threads, pipe threads, bolt heads and nuts shall comply with the
appropriate Indian Standards for metric threads, or the technical equivalent.
27.2 Bolts or studs shall not be less than 6 mm in diameter except when used for small
wiring terminals.
27.3 All nuts and pins shall be adequately locked.
27.4 Wherever possible bolts shall be fitted in such a manner that in the event of failure of
locking resulting in the nuts working loose and falling off, the bolt will remain in position.
27.5 All bolts/nuts/washers exposed to atmosphere should be as follows.

a) Size 12 mm or below – Stainless steel
b) Above 12 mm- steel with suitable finish like electro galvanized with passivation or hot
dip galvanized.
27.6 Each bolt or stud shall project at least one thread but not more than three threads through
the nut, except when otherwise approved for terminal board studs or relay stems. If bolts
and nuts are placed so that they are inaccessible by means of ordinary spanners, special
spanners shall be provided.
27.7 The length of the screwed portion of the bolts shall be such that no screw thread may form
part of a shear plane between members.
27.8 Taper washers shall be provided where necessary.
27.9 Protective washers of suitable material shall be provided front and back of the securing screws.
28 OVERLOAD CAPACITY:
28.1 The transformers shall be suitable for loading as per IS 6600.
29 TESTS:
29.1 All the equipment offered shall be fully type tested by the bidder or his collaborator as per
the relevant standards including the additional type tests. The type test must have been
conducted on a transformer of same design during the last five years at the time of bidding.
The bidder shall furnish four sets of type test reports along with the offer. In case, the
offered transformer is not type tested, the bidder will conduct the type test as per the
relevant standards including the additional type tests at his own cost in CPRI/ NABL
accredited laboratory in the presence of employers representative(s) without any financial
liability to employer in the event of order placed on him.
29.2 Special tests other than type and routine tests, as agreed between purchaser and bidder
41
shall also be carried out as per the relevant standards.

29.3 The requirements of site tests are also given in this clause.
29.4 The test certificates for all routine and type tests for the transformers and also for the
bushings and transformer oil shall be submitted with the bid.
29.5 The procedure for testing shall be in accordance with IS1180 (Part-1) :2014 /2026 as the
case may be except for temperature rise test.
29.6 Before dispatch each of the completely assembled transformers shall be subjected to the routine
tests at the manufacturer’s works.
30 ROUTINE TESTS:
30.1 Ratio, polarity, phase sequence and vector group.

30.2 No Load current and losses at service voltage and normal frequency.
30.3 Load losses at rated current and normal frequency.
30.4 The test certificates for all routine and type tests for the transformers and also for the bushings
and transformer oil shall be submitted after the receipt of order.
30.5 Impedance voltage test.
30.6 Resistance of windings at each tap, cold (at or near the test bed temperature).
30.7 Insulation resistance.
30.8 Induced over voltage withstand test.
30.9 Separate source voltage withstand test.
30.10 Neutral current measurement-The value of zero sequence current in the neutral of the
star winding shall not be more than 2% of the full load current.
30.11 Oil samples (one sample per lot) to comply with IS 1866.
30.12 Measurement of no load losses and magnetizing current at rated frequency and 90%,
100% and 110% rated voltage.
30.13 Pressure and vacuum test for checking the deflection on one transformer of each type in
every inspection.
31 TYPE TESTS TO BE CONDUCTED ON ONE UNIT:
In addition to the tests mentioned in clause 30 and 31 following tests shall be conducted:
31.1 Temperature rise test for determining the maximum temperature rise after continuous full
load run. The ambient temperature and time of test should be stated in the test certificate.
31.2 Impulse voltage test: with chopped wave of IS 2026 part-III. BIL for 11 kV shall be 75
kV peak.
31.3 Short circuit withstand test: Thermal and dynamic ability.
31.4 Air Pressure Test: As per IS – 1180 (Part-1):2014.
31.5 Magnetic Balance Test.
31.6 Un-balanced current test: The value of unbalanced current indicated by the ammeter shall
not be more than 2% of the full load current.
31.7 Noise-level measurement.
31.8 Measurement of zero-phase sequence impedance.
42
31.9 Measurement of Harmonics of no-load current.

31.10 “Vacuum Type Test on Transformer Tank” shall be carried out as per IS 1180 (Part-1):
2014 i.e. The transformer tank shall be subjected to air pressure 80 kPa for 30 minutes
and vacuum of 250 mm of mercury for 30 minutes. * The permanent deflection of flat
plates after the vacuum has been released shall not exceed the values specified below:
*Amendment issued vide letter No. REC/DDUGJY/SBD/TS/2017-18/D.No. 3091 dated
25.08.2017
Horizontal length of flat plate (in mm) Permanent deflection (in mm)
Upto and including 750 5.0
751 to 1250 6.5
1251 to 1750 8.0
1751 to 2000 9.0
31.11 Transformer tank together with its radiator and other fittings shall be subjected to pressure
Corresponding to twice the normal pressure or 0.35 kg / sq.cm whichever is lower,
measured at the base of the tank and maintained for an hour. The permanent deflection
of the flat plates after the excess pressure has been released, shall not exceed the figures
for vacuum test.
31.12 Pressure relief device test: The pressure relief device shall be subject to increasing fluid
pressure. It shall operate before reaching the test pressure as specified in the above class.
The operating pressure shall be recorded. The device shall seal-off after the excess pressure
has been released.
31.13 Short Circuit Test and Impulse Voltage Withstand Tests: The purchaser intends to
procure transformers designed and successfully tested for short circuit and impulse test.
In case the transformers proposed for supply against the order are not exactly as per the
tested design, the supplier shall be required to carry out the short circuit test and impulse
voltage withstand test at their own cost in the presence of the representative of the purchaser.
31.13.1 The supply shall be accepted only after such test is done successfully, as it confirms on
successful withstand of short circuit and healthiness of the active parts thereafter on un-
tanking after a short circuit test.
31.13.2 Apart from dynamic ability test, the transformers shall also be required to withstand
thermal ability test or thermal withstand ability will have to be established by way of
calculations.
31.13.3 It may also be noted that the purchaser reserves the right to conduct short circuit test
and impulse voltage withstand test in accordance with the IS, afresh on each ordered
rating at purchaser cost, even if the transformers of the same rating and similar design are
already tested. This test shall be carried out on a transformer to be selected by the
purchaser either at the manufacturer’s works when they are offered in a lot for supply
or randomly from the supplies already made to purchaser’s stores. The findings and
conclusions of these tests shall be binding on the supplier.
43
32.1 At least 10% transformers of the offered lot (minimum of one) shall be subjected
to the following routine/ acceptance test in presence of purchaser’s representative at
the place of manufacture before dispatch without any extra charges. The testing shall
be carried out in accordance with IS:1180 (Part-1): 2014 and IS:2026.
32.2 Checking of weights, dimensions, fitting and accessories, tank sheet thickness, oil quality,
material, finish and workmanship as per GTP and contract drawings on one transformer of
each type in every inspection.
32.3 Physical verification of core coil assembly and measurement of flux density of one unit
of each rating, in every inspection with reference to short circuit test report.
32.4 Temperature rise test on one unit of the total ordered quantity.
33 TESTS AT SITE:
The purchaser will conduct the following test on receipt of transformers in their store. The
utility shall arrange all equipment, tools & tackle and manpower for the testing. The bidder
will depute his representative to witness the same. All such test shall be conducted by utility
not later than 10 days from receipt of transformers.
i) Megger Test
ii) Ratio test
34 INSPECTION:
34.1 In respect of raw material such as core stampings, winding conductors, insulating paper
and oil, supplier shall use materials manufactured/supplied by standard manufacturers
and furnish the manufacturers’ test certificate as well as the proof of purchase from
these manufacturers (excise gate pass) for information of the purchaser. The bidder shall
furnish following documents along with their offer in respect of the raw materials:
i. Invoice of supplier.
ii. Mill’s certificate.

iii. Packing list.
iv. Bill of landing.
v. Bill of entry certificate by custom.
Please refer to “Check-list for Inspection of Prime quality CRGO for

Transformers” attached at Annexure-A. It is mandatory to follow the procedure
given in this Annexure.
35 INSPECTION AND TESTING OF TRANSFORMER OIL:
35.1 To ascertain the quality of the transformer oil, the original manufacturer’s tests report should
be submitted at the time of inspection. Arrangements should also be made for testing of
transformer oil as per IS: 335 , after taking out the sample from the manufactured transformers
and tested in the presence of purchaser’s representative.
35.2 To ensure about the quality of transformers, the inspection shall be carried out by the
purchaser’s representative at following two stages:-
44
35.2.1 Anytime during receipt of raw material and manufacture/ assembly whenever the
purchaser desires.
35.2.2 At finished stage i.e. transformers are fully assembled and are ready for dispatch.
35.3 The stage inspection shall be carried out in accordance with Annexure-II.
35.4 After the main raw-material i.e. core and coil material and tanks are arranged and
transformers are taken for production on shop floor and a few assembly have been
completed, the firm shall intimate the purchaser in this regard, so that an officer for
carrying out such inspection could be deputed, as far as possible within seven days
from the date of intimation. During the stage inspection a few assembled core shall
be dismantled to ensure that the laminations used are of good quality. Further, as
and when the transformers are ready for dispatch, an offer intimating about the
readiness of transformers, for final inspection for carrying out tests as per relevant IS
shall be sent by the firm along with Routine Test Certificates. The inspection shall
normally be arranged by the purchaser at the earliest after receipt of offer for pre-
delivery inspection. The proforma for pre delivery inspection of Distribution
transformers is placed at Annex- III.
35.5 In case of any defect/defective workmanship observed at any stage by the
purchaser’s Inspecting Officer, the same shall be pointed out to the firm in writing
for taking remedial measures. Further processing should only be done after clearance
from the Inspecting Officer/ purchaser.
35.6 All tests and inspection shall be carried out at the place of manufacture unless
otherwise specifically agreed upon by the manufacturer and purchaser at the time
of purchase. The manufacturer shall offer the Inspector representing the Purchaser
all reasonable facilities, without charges, to satisfy him that the material is being
supplied in accordance with this specification. This will include Stage Inspection
during manufacturing stage as well as Active Part Inspection during Acceptance Tests.
35.7 The manufacturer shall provide all services to establish and maintain quality of
workman ship in his works and that of his sub-contractors to ensure the mechanical
/electrical performance of components, compliance with drawings, identification and
acceptability of all materials, parts and equipment as per latest quality standards of ISO
9000.
35.8 Purchaser shall have every right to appoint a third party inspection to carry out the
inspection process.
35.9 The purchaser has the right to have the test carried out at his own cost by an
independent agency wherever there is a dispute regarding the quality supplied.
Purchaser has right to test 1% of the supply selected either from the stores or field to
check the quality of the product. In case of any deviation purchaser have every right
to reject the entire lot or penalize the manufacturer, which may lead to blacklisting,
among other things.
36.1 The bidder shall invariably furnish following information along with his bid, failing
45
which his bid shall be liable for rejection. Information shall be separately given for
individual type of equipment offered.
36.2 Statement giving list of important raw materials, names of sub-suppliers for the raw
materials, list of standards according to which the raw materials are tested, list of
tests normally carried out on raw materials in the presence of bidder’s representative,
copies of test certificates.
36.3 Information and copies of test certificates as above in respect of bought out accessories.
36.4 List of manufacturing facilities available.
36.5 Level of automation achieved and list of areas where manual processing exists.
36.6 List of areas in manufacturing process, where stage inspections are normally carried
out for quality control and details of such tests and inspection.
36.7 List of testing equipment available with the bidder for final testing of equipment along
with valid calibration reports. These shall be furnished with the bid. Manufacturer shall
posses 0.1 accuracy class instruments for measurement of losses.
36.8 Quality Assurance Plan (QAP) withhold points for purchaser’s inspection.
36.9 The successful bidder shall within 30 days of placement of order, submit
following information to the purchaser :
36.9.1 List of raw materials as well as bought out accessories and the names of sub-
suppliers selected from those furnished along with offer.
36.9.2 Type test certificates of the raw materials and bought out accessories.
36.9.3 The successful bidder shall submit the routine test certificates of bought out accessories
and central excise passes for raw material at the time of routine testing.
36.9.4 ISI marking on the transformer is mandatory. As per Quality Control Order for
Electrical Transformers- 2015, issued by Department of Heavy Industries,
Government of India, the Standard / ISI marking on Distribution Transformers is
mandatory and the product should be manufactured in compliance with IS 1180 Part-
1: (2014).
37 DOCUMENTATION:
37.1 The bidder shall furnish along with the bid the dimensional drawings of the items
offered indicating all the fittings.
37.2 Dimensional tolerances.
37.3 Weight of individual components and total weight.
37.4 An outline drawing front (both primary and secondary sides) and end-elevation and
plan of the tank and terminal gear, wherein the principal dimensions shall be given.
37.5 Typical general arrangement drawings of the windings with the details of the insulation at
each point and core construction of transformer.
37.6 Typical general arrangement drawing showing both primary and secondary sides
and end- elevation and plan of the transformer.
38 PACKING AND FORWARDING:

38.1 The packing shall be done as per the manufacturer’s standard practice.
46
However, it should be ensured that the packing is such that, the material would not get
damaged during transit by Rail / Road / Sea.
38.2 The marking on each package shall be as per the relevant IS.
39 GUARANTEE
41.1 The manufacturers of the transformer shall provide a guarantee of 60 months from the
date of receipt of transformer at the stores of the Utility. In case the transformer fails
within the guarantee period, the supplier will depute his representative within 15 days
from date of intimation by utility for joint inspection. In case, the failure is due to the
reasons attributed to supplier, the transformer will be replaced/repaired by the supplier
within 2 months from date of joint inspection.
41.2 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.
41.3 In the event of the supplier’s inability to adhere to the aforesaid provisions, suitable
penal action will be taken against the supplier which may inter alia include blacklisting
of the firm for future business with the purchaser for a certain period.
40 SCHEDULES:
42.1 The bidder shall fill in the following schedule which will be part of the offer. If the
schedule are not submitted duly filled in with the offer, the offer shall be liable for
rejection.
Schedule-A : Guaranteed Technical Particulars
Schedule-B : Schedule of Deviations
41 DEVIATIONS :
43.1 The bidders are not allowed to deviate from the principal requirements of the
Specifications. However, the bidder is required to submit with his bid in the relevant
schedule a detailed list of all deviations without any ambiguity. In the absence of a
deviation list in the deviation schedules, it is understood that such bid conforms to
the bid specifications and no post-bid negotiations shall take place in this regard.
43.2 The discrepancies, if any, between the specification and the catalogues and / or
literatures submitted as part of the offer by the bidders, shall not be considered and
representations in this regard shall not be entertained.
43.3 If it is observed that there are deviations in the offer in guaranteed technical
particulars other than those specified in the deviation schedules then such deviations
shall be treated as deviations.
43.4 All the schedules shall be prepared by vendor and are to be enclosed with the bid.
(iv)
(v) Annex-I
METHODOLOGY FOR COMPUTING TOTAL OWNING COST*
TOC = IC + (A xWi) + (B xWc) ; Losses in KW
47
Where,
TOC = Total Owning Cost
IC = Initial cost including taxes of transformer as quoted by the manufacturer
A factor = Cost of no load losses in Rs/KW (A = 288239)
B factor = Cost of load losses in Rs/KW (B = 93678)
Wi = No load losses quoted by the manufacturer in KW
Wc = Load losses quoted by the manufacturer in KW
Note: No (+) ve tolerance shall be allowed at any point of time on the quoted losses after the award. In
case, the losses during type testing, routine testing etc are found above the quoted losses, the award shall
stand cancelled. In such a case, the CPG money shall also be forfeited.
* Amendment issued vide letter No. REC/DDUGJY/SBD/DTR-TS/969 Dated 29.09.2016

48
Annexure-Paint
Painting-Transformer Main tank, pipes, Conservator Tank, Radiator etc.-
(vi) Annexure – II
Surface primer intermedi finish total Colour
Preparatio coat ate under coat DFT shade
n coat
Main tank, Blast Epoxy Epoxy Aliphatic Min 541 shade
pipes, conservator cleaning base base Polyuret 110 of IS:5
tank,etc. (External Sa2½ Zinc hane (PU micron
surfaces) Zinc primer primer Paint)
30-40 micron 30-40 (min 50
micron micron
Main tank, Blast Hot oil -- -- Min 30 Glossy
pipes (above 80 cleaning resistant, non- micron white for
NB), Sa2½ corrosive paint
conservator varnish or
tank,etc (Internal paint
surfaces)
Radiator Chemical / Epoxy base Epoxy Aliphatic Min 541 shade
(External blast zinc primer base Polyuret 110 of IS:5
surfaces) cleanin 30-40 micron Zinc h ane(PU micron
g primer Paint)
(Sa2½) Min 30- (min)50
40 micron micron
Radiator and Chemical Hot oil -- -- -- Glossy
pipes up to 80 cleaning proof low white for
NB (Internal if required viscosity paint
surfaces) varnish or hot
oil resistant
non
corrosive paint
PROFORMA FOR STAGE INSPECTION OF DISTRIBUTION TRANSFORMERS
(A) GENERAL INFORMATION:

1. Name of firm : M/s.
2. Order No. and Date :
3. Rating-wise quantity offered :
4. Details of offer
49
a) Rating
b) Quantity
c) Serial Numbers
5. Details of last stage inspected lot:
a) Total quantity inspected
b) Serial Numbers
c) Date of stage inspection
d) Quantity offered for final
inspection of
(a) above with date
(B) Availability of material for offered quantity :

Details to be filled in
(C) Position of manufacturing stage of the offered quantity :
a) Complete tanked assembly

b) Core and coil assembly ready
c) Core assembled
d) Coils ready for assembly
(i) HV Coils
(ii) LV Coils
Note: (i) A quantity of less than 100 Nos. shall not be entertained for stage inspection. If the awarded
quantity is less than 100 Nos., then whole lot shall be offered in single lot.
(ii) The stage inspection shall be carried out in case :-
(a) At least 25% quantity offered has been tanked and
(b) core coil assembly of further at least 30% of the quantity offered has been
completed.
(iii) Quantity offered for stage inspection should be offered for final Inspection within
15 days from the date of issuance of clearance for stage inspection, otherwise
stage inspection already cleared shall be liable for cancellation.
Sl. Particulars As offered As observed Deviation

No and
Remarks
(D) Inspection of Core:
(I) Core Material
(1) Manufacturer’s
Characteristic Certificate in
50
respect of grade of lamination

used. (Please
furnish test certificate)
(2) Remarks regarding Rusting
and smoothness of core.
(3) Whether laminations used
for top and bottom yoke are
in one piece.
(II) Core Construction :
(1) No. of Steps
(2) Dimension of Steps
Step No. 1 2 3 4 5 6 7 8 9 10 11 12
As offered:
W mm
T mm
As found:
W mm
T mm
(3) Core Dia (mm)
(4) Total cross Section area of core
(5) Effective cross Sectional area of core
(6) Clamping arrangement
(i) Channel Size
(ii) Bolt size and No.
(iii) Tie Rods size and No.
(iv) Painting
(a) Channels
(b) Tie Rods
(c) Bolts
(7) Whether top yoke is cut

for LV connection.
(8) If yes, at 7 above, whether
Reinforcement is done.
(9) Size of Support Channels provided
for Core base and bottom yoke
(Single piece of channels are only
acceptable).
51
(10) Thickness of insulation

provided between core base
and support channel.
(11) core length (leg center
to leg center)
(12) Window height
(13) Core height
(14) Core weight only
(without channels etc.)
(E) INSPECTION OF WINDING
(I) Winding material
(1) Material used for
(a) HV winding
(b) LV winding
(2) Grade of material for
(a) HV winding
(b) LV winding
3) Test certificate of
manufacturer (enclose copy)
for winding material of:
(a) HV
(b) LV
(II) CONSTRUCTIONAL DETAILS
(1) Size of Cross Sectional
area of conductor for :
(a) HV winding
(b) LV winding
(2) Type of insulation for
conductor of :
a) HV winding
(b) LV winding
(3) Diameter of wire used
for delta formation (mm)
(4) Diameter of coils in:
a) LV winding
i) Internal dia (mm)
ii) Outer dia (mm)
52
b) HV winding
i) Internal dia (mm)
ii) Outer dia (mm)
(5) Current Density of
winding material used
for :
(a) HV
(b) LV
(6) Whether neutral formation on top.
(7) HV Coils/ Phase
a) Number
b) Turns / coil
c) Total turns
(8) LV Coils/ Phase
a) Number
b) Turns / coil
c) Total turns
(9) Method of HV Coil Joints
(10) Total weight of coils of
a) LV winding (kg)
b) HV winding (kg)
(F) INSULATION MATERIALS :
(I) MATERIAL :
1) Craft paper
a) Make
b) Thickness (mm)
c) Test Certificate of
manufacturer (enclose copy).
2) Press Board
a) Make
b) Thickness (mm)
c) Test Certificate of
manufacturer (enclose copy).
3) Material used for top and
bottom yoke and
insulation
53
(II) Type and thickness of

material used : (mm)
a) Between core and LV
b) Spacers
c) Inter layer
d) Between HV and LV winding
e) Between phases
f) End insulation
(G) CLEARANCES : (mm)
(I) Related to core and
windings
1) LV to Core (Radial)
2) Between HV and LV
(Radial)
3) (i) Phase to phase

between HV Conductor
(ii) Whether two Nos. Press Board
each of minimum 1 mm thick
provided to cover the tie rods.
4) Thickness of locking spacers
between LV coils (mm)
5) Axial wedges between HV and
LV coils / phase (Nos.)
6) No. of radial spacers per phase
between HV coils
7) Size of duct between
LV and HV winding (mm)
(II) Between core - coil assembly
and tank : (mm)
1) Between winding and body:
a) Tank lengthwise
b) Tank Breadth wise
2) Clearance between top cover and
top yoke upto 100 kVA and between
top cover and top most live part of tap
54
changing switch for 200 kVA and

above.
(H) TANK :
(I) Constructional details :
1) Rectangular shape
2) Thickness of side wall (mm)
3) Thickness of top and
bottom plate (mm)
4) Provision of slopping top cover
towards HV bushing.
55
GUARANTEED TECHNICAL PARTICULARS of Completely Self Protected 3-ph

Transformer
Sr. Particulars Unit / Type As per Firm's
No. Offer
1 Name of manufacturer
2 Place of Manufacturing
3 Transformer capacity KVA
4 Voltage 11/0.433-0.250 KV
5 No. of Phases 3 No./1 No.
6 Vector Group Dyn11
7 Type of Cooling ONAN
8 Type of Transformer Sealed/Unsealed
9 For 200 KVA/500 KVA transformers
a) No. of tap positions in HV winding
b) Voltage variation
10 Energy Efficiency Level Level-1 (As per BIS
ammendement no-04)
11 Losses
I Core loss Watts
a) at Normal Voltage Watts
b) at Maximum Voltage Watts
Ii Full Load losses at 75 deg.C. Watts
Iii Total losses at 50 % loading at 75 deg.C. Watts
Iv Total losses at 100 % loading at 75 deg.C. Watts
12 Percentage Impedance at 75 deg.C. %
13 Maximum temperature rise of
a) Windings by resistance method 40 deg C
(35 deg C for 5KVA)
b) Oil by Thermometer 35 deg C
(30 deg C for 5KVA)
14 Clearances
a) Core & LV mm
b) LV & HV mm
c) HV Phase to Phase mm
d) End insulation clearance to Earth mm
e) Any point of winding to tank mm
f) HV to earth creepage distance mm
g) LV to earth creepage distance mm

15 Efficiency at 75 deg.C.
56
a) Unity P.F.
1) 2) 125% load %
3) 4) 100% load %
5) 6) 75% load %
7) 8) 50% load %
9) 10) 25% load %
b) 0.8 P.F.
1) 2) 125% load %
3) 4) 100% load %
5) 6) 75% load %
7) 8) 50% load %
9) 10) 25% load %
16 Regulation at
a) b) Unity P.F.
c) d) 0.8 P.F. at 75 deg.C.
17 CORE CRGO
i Core Grade
ii Core diameter mm
iii Gross Core area Mtr2
iv Net Core area Mtr2
v Flux density Wb/Mtr2
vii Wt. of Core Kg
viii Loss per kg. of Core at the specified Flux Watts
Density
ix Core window height mm
x Centre to centre distance of the core mm
xi The nominal flux density at
a) b) 100% rated voltage ≤ 1.69 Wb/Mtr2
c) d) 110% of rated voltage ≤1.9 Wb/Mtr2
xii % No load current of full load current at rated voltage and
frequency on the secondary and Increase of voltage by 112.5%
(i) CRGO Core: at 100% and 112.5% of rated
Voltage
a) Up to 200 KVA Transformer ≤ 3% and ≤ 6 %
57
b) Above 200 KVA ≤ 2% and ≤ 5 %

18 Transformer
WINDINGS Aluminium / Copper
(As per Discom Practice
aluminium windings are
to be used up to 100
kVA and copper
windings are to be used
above 100 kVA)
i No. of L.V. Turns No.

ii No. of H V turns No.
iii Size of LV Conductor bare/ covered mm
iv Size of HV conductor bare/covered mm
v No. of parallels No.
vii Resistance of HV winding at 20 deg.C Ohm
viii Resistance of LV winding at 20 deg.C Ohm
ix Current density of LV winding Amps/sq.mm.
x Current density of HV winding Amps/sq.mm.
xi Wt. of the LV winding for Transformer kg.
xii Wt. of the HV winding for Transformer kg.
xiii No. of LV Coils/phase No.
xiv No. of HV coils / phase No.
xv Height of LV Windings mm
xvi Height of HV winding mm
xvii ID/OD of LV winding mm
xviii ID/OD of HV winding mm
xix Size of the duct in LV winding mm
xx Size of the duct in HV winding mm
xxi Size of the duct between HV & LV mm
xxii Inter layer insulation provided in design for
1) Top & bottom layer
2) In between all layer
3) Details of end insulation
4) Whether wedges are provided at 50% turns
of the HV coil
xxiii Insulation materials provided
a) For Conductors
58
(1) HV
(2) LV
B) For Core
xxiv Material and Size of the wire used
1) HV a) SWG No.
b) Dia mm
2) LV a) Strip size mm X mm
b) No. of Conductors in parallel No
c) Total area of cross section sq.mm.
19 Weight content of
a) Core lamination (min) KG
b) Windings (min) Aluminium/Copper KG
c) Tank & Fittings KG
d) Oil KG
e) Oil qty (min) Litre
f) Total Weight KG
20 Oil Data
1. Qty for first filling (min) Litre
2. Grade of oil used
3. Maker’s name
4. BDV at the time of filling KV
21 Transformer
1) Overall length x breadth x height mm X mm X mm
2) Shape of Tank
2) Tank length x breadth x height mm X mm X mm
3) Thickness of plates for
a) Side plate (min) mm
b) Top & Bottom plate (min) mm
4) Conservator Dimensions mm X mm
5) Tank base channel dimensions mm X mm X mm
22 HV Bushings & Terminals
1) Make of HV bushing
2) Rating in KV KV
3) Turret Height mm
4) Material of HV terminal Brass/Copper
5) Current Density of HV terminal Amps/sq.mm.
23 LV Bushings & Terminals
59
1) Make of LV bushing
2) Rating in KV KV
3) Turret Height mm
4) Material of LV terminal Brass/Copper
5) Current Density of LV terminal Amps/sq.mm.
24 Details of MCCB
(for transformers having rating upto 25
Make
KVA)
Rated thermal current Amp.
Current setting Amp.
Minimum short circuit breaking current KA
25 Radiation
1) Heat dissipation by tank walls exclusive top
& bottom
2) Heat dissipation by cooling tube
3) Dia & thickness of cooling tube
4) Whether calculation sheet for selecting Yes/No
cooling area to ensure that the transformer is
capable of giving continuous rated output
without exceeding temperature rise is enclosed.
26 Whether the name plate gives all particulars Yes/No

as required in Tender
27 Whether the transformer offered is already type Yes/No
tested for the design and test reports enclosed
60
Name Plate Details

Digit/letter Details TIN Remark
No.
Name of
1 M First letter of DISCOM name
Company
for 5/10/16/25/63/100/200/500 KVA
2 KVA rating 5 ratings digits will be respectively
1/2/3/4/5/6/7/8
Type of Core
3 1 CRGO
Material
Core
4 1 Stack-1, Wound-2
construction
5 1
Supplier Name each supplier will be given 2 digit code
6 Code 5 no.
e.g. M/s XYZ given code no.15
7 Month of 0 2 digits for Month of
8 manufacturing 2 manufacturing
9 Year of 1 2 digits for Year of
10 manufacturing 7 manufacturing
11 9
12 CPP Tender 0
4 digits for CPP tender no.
13 No. 3
14 2
15 0 5 digits for transformer sr. no. given by
16 0 supplier
Sr. No. of
17 0 (e.g. M/s XYZ will give transformer sr.
transformer
18 0 no. from 00001 to 00260 for P.O. of 260
given by
no.
Supplier
19 1 transformers issued to them vide CPP tender
no.9032 )
61
Annexure-A
Check-list for Inspection of prime quality CRGO for Transformers
During inspection of PRIME CRGO, the following points needs to be checked by the Transformer
manufacturer. Utility’s inspection shall verify all these points during inspection:-
A) In case PRIME cutting is at works of Transformer Manufacturer:
1 Review of documents:
 Purch
 Manufacturer’s test certificate
 Invoice of the Supplier
 Packing list
 Bill of Lading
 Bill of Entry Certificate by Customs Deptt.
 Reconciliation Statement as per format below
 Certificate of Origin
 BIS Certificate
Format for Reconciliation/Traceability records

Packing List No. / Date /Quantity of PRIME CRGO received
Name of Manufacturer
Manufacturer test certificate No. / date
Serial no. Details of Drawing Quantity Cumulative Balance in

package / job Reference involved quantity stock
consumed
2.1 Inspection of PRIME CRGO Coils:
a) PRIME CRGO-Manufacturer’s identification Slip on PRIME CRGO Coils

b) Visual Inspection of PRIME CRGO Coils offered as per packing list (for verification of coil
details as per Test certificate & healthiness of packaging).
c) Unique numbering inside of each sample of PRIME CRGO coil and verification of records to
be maintained in the register for consumption of CRGO coil.
d) ISI logo Sticker on packed mother coil and ISI logo in Material TC.
62
2.2 During inspection of PRIME CRGO, surveillance testing of sample shall be carried out for
Stacking Factor, Permeability, Specific watt loss at 1.5 Tesla and/or 1.7 Tesla depending on the
grade of PRIME CRGO and aging test etc. applicable as per relevant IS/ IEC standard, Tech.
pec., MQP and Transformer manufacturer plant standard.
Inspection Clearance Report Would Be issued after this inspection
3 Inspection of PRIME CRGO laminations: Transformer manufacturer will maintain records for
traceability of lamination to PRIME CRGO coils and burr/bow on lamination shall be measured.
4. Inspection at the time of core building:
Visual Inspection of PRIME CRGO lamination. In case of suspected mix-up/ rusting/ decoloration,
Samples may be taken for testing on surveillance basis mentioned in A.2.2 above.
Above tests shall be witnessed by utility. In case testing facilities are not available at
Manufacturer‘s work, the sample(s) sealed by utility to be sent to approved labs for testing.
Inspection Clearance Report would be issued after this inspection
B) In case PRIME CRGO cutting is at Sub-vendor of Transformer Manufacturer:
1 Review of documents:
 Purchase Order (unpriced) to PRIME CRGO supplier/ Authorized Agency
 Purchase Order (unpriced) to Core Cutter
 Manufacturer test certificate
 Invoice of the Supplier
 Packing List
 Bill of Lading
 Bill Of Entry Certificate by Customs Deptt.
 Reconciliation Statement as per format below
 Certificate of Origin
 BIS Certificate
Format for Traceability records as below:-
Packing List No./date/quantity of PRIME CRGO received

Name of Manufacturer
Manufacturer test certificate No. / date
Serial Name of Details of Drawing Quantity Cumulative Balance Dispatch

no. customer package / Reference involved quantity in stock details
job consumed
63
2.1 Inspection of PRIME CRGO Coils:
a) PRIME CRGO-Manufacturer’s identification Slip on PRIME CRGO Coils

b) Visual Inspection of PRIME CRGO Coils offered as per packing list (for verification of coil
details as per Test certificate & healthiness of packaging).
c) Unique numbering inside of each sample of PRIME CRGO coil and verification of records to
be maintained in the register for consumption of CRGO coil.
d) ISI logo Sticker on packed mother coil and ISI logo in Material TC.
2.2 During inspection of PRIME CRGO, surveillance testing of sample shall be carried out for
Stacking Factor, Permeability, Specific watt loss at 1.5 Tesla, Thickness depending on the grade
of PRIME CRGO and aging test etc. applicable as per relevant IS/IEC standard, Tech.Spec., MQP
and Transformer manufacturer plant standard.
3 Inspection of PRIME CRGO laminations:
Transformer manufacturer representative will inspect laminations and issue their internal
Inspection Clearance Report. Inspection will comprise of review of traceability to prime CRGO
coils, visual Inspection of PRIME CRGO laminations and record of burr/bow. After clearance
given by the transformer manufacturer, utility will issue an Inspection Clearance Report after
record review. If so desired by Utility, their representative may also join transformer manufacturer
representative during this inspection.
4 Inspection at the time of core building

Visual inspection of PRIME CRGO laminations. In case of suspected mix-up/rusting/decoloration,
samples may be taken for testing on surveillance basis for tests mentioned in B.2.2.
NOTE:-
a) Transformer Manufacturer to ensure that PRIME CRGO is procured from POWERGRID

approved vendors and CRGO manufacturer should have valid BIS Certificate for respective
offered Grade.
64
b) Transformer Manufacturer should also involve themselves for ensuring the quality of CRGO
laminations at their Core Cutter’s works. They should visit the works of their Core cutter and carry
out necessary checks.
C) General
If a surveillance sample is drawn and sent to TPL ( if testing facility not available with the
manufacturer), the transformer manufacturer can continue manufacturing at their own risk and
cost pending TPL test report on PRIME CRGO sample drawn. Decision for acceptance of PRIME
CRGO shall be based upon report of sample drawn.
These checks shall be read in –conjunction with approved quality plan, specification as a
whole and conditions of contract.
Sampling Plan (PRIME CRGO)
33/11 kV - 1st transformer and subsequently at random 10% of

Transformers (min.1) offered for inspection.
DTs and other ratings - 1st transformer and subsequently at random 10% of
Transformers (min.1) offered for inspection.
NOTE:- One sample for each lot of CRGO shall be drawn on surveillance basis.
CRGO has to be procured only from POWERGRID approved vendors. List of such vendors is
available at the following website. Since the list is dynamic in nature, the site may be checked
from time to time to see the list of approved vendors.
http://apps.powergridindia.com/ims/ComponentList/Power-
SL. NO ITEM VENDOR NAME

1 CRGO STEEL M/S NIPPON STEEL & SUMITOMO METAL CORP,
JAPAN
2 CRGO STEEL M/S KAWASAKI CORPORATION/JFE,JAPAN
3 CRGO STEEL M/S A.K.STEEL, USA
4 CRGO STEEL M/S POSCO KOREA

5 CRGO STEEL M/S AST ITALY
6 CRGO STEEL M/S TKES GERMANY
7 CRGO STEEL M/S UGINE DIVISION DUSINOR SACLAR, S.A.,
FRANCE
8 CRGO STEEL M/S ORB ELECTRICALS STEELS, UK
9 CRGO STEEL M/S PREUSSAG HANDEL, GERMANY
10 CRGO STEEL M/S ACESITA, BRAZIL
11 CRGO STEEL M/S VIZ STEEL, RUSSIA valid upto 05.02.2018
65
12 CRGO STEEL WITH M/S TKES INDIA PVT. LTD. NASIK, (approval valid
FINAL PROCESS OF upto 20.08.2016) and subject to condition
COATING &
ANNEALING OF
SEMIPROCESSED
CRGO MOTHER COIL
(SOURCED FROM
TKES, Germany
66
LT Aerial Bunched Cables

(APPLICABLE FOR LT AB CABLE WITH XLPE INSULATION ONLY)
1. SCOPE:
This specification covers XLPE insulated Aluminium cable twisted over a central bare
Aluminium Alloy messenger wire for use of L.T. Over-Headlines in Rural Electrification
System. The Aerial Bunched cable and messenger wire should be confirming to IS (as
per latest amendment if any).
(Sizes: of the cable)

1X16 (Ph) + 1X25 (bare messenger cum neutral) SQ. MM.
1X16 (Ph) + 1X25 (bare messenger cum neutral) + 1x16 (insulated Street lighting)SQ. MM.
3X16(Ph)+1X25 (bare messenger cum neutral) SQ. MM.
3 X 16(Ph) +1x25 (bare messenger cum neutral) + 1x16 (insulated Street lighting) SQ.MM.
1X25(Ph)+1x25 (bare messenger cum neutral) SQ. MM.
1X25(Ph) + 1X25 (bare messenger cum neutral) + 1x16 (insulated Street lighting) SQ. MM.
1x35(Ph) + 1X25 (bare messenger cum neutral) + 1x16 (insulated Street lighting) SQ.MM.
3X35 (Ph) + 1x25 (bare messenger cum neutral)+ 1x16 (insulated Street lighting) SQ.MM.
3X50 (Ph)+1x35 (bare messenger cum neutral) +1x16 (insulated Street lighting) SQ. MM.
3X95(Ph)+1X70 (bare messenger cum neutral) SQ. MM.+1x16 (insulated Street lighting)SQ.
MM
MM
3X150(Ph)+1X120 (bare messenger cum neutral) SQ. MM.+1x16 (insulated Street
lighting)SQ. MM
2. RATED VOLTAGE:
The rated voltage of the AB cables shall be 1100 volts
3. APPLICABLE STANDARDS:
Unless otherwise stipulated in this specification the following Standards shall be applicable.
i) IS – 14255/1995 : ABC cables 1100 volts.
ii) IS – 8130/1984 : Conductors for insulated cables.
iii) IS – 398/Pt.IV/1994: Aluminium alloy conductor.

67
iv) IS – 10418/1982 : Drums for electric cables
4. GENERAL:
The AB cable covered under this specification should be suitable for use on three phase, 4
wire earthed system for working voltage up to 1100 V. It should confirm the relevant
standards stated above and others if applicable.
The phase conductor shall be 150 sqmm, 120 mm², 95 mm² and 50 mm², 35 mm, 25 mm²
and 16 mm² XLPE insulated and the messenger-cum-neutral conductor of sizes 120 sqmm,
95 mm², 70 mm², 35 mm² and 25 mm² shall be bare heat treated aluminium-magnesium-
silicon alloy wires containing 0.5% magnesium and approximately 0.5% silicon confirming
to IS: 398 (Part-IV):1979 and its latest amendment, if any.
5. PHASE CONDUCTORS:
5.1 The phase & street lighting conductor shall be provided cross linked poly ethylene
insulation applied byextrusion. The thickness of insulation shall not be less than 1.2 mm up
to 35mm² and shall not be less than 1.5 mm for above 35mm² at any point and insulation
shall be so applied that it fits closely on the conductor and it shall be possible to remove it
without damaging the conductor. The insulated conductors shall generally conform to the
standards IS-14255:1995.
5.2 The phase conductors shall be provided with one, two & three ‘ridges’ for easy
identification.
5.3 The tensile strength of the aluminium wire used in the conductor shall not be less 90
N/mm².
5.4 The standard size and technical characteristics of the phase conductors shall be as
shown in the Table-1.
TABLE-I
Nominal Diameter of Max. DC

No. of Strands Compacted Insulation
Sectional area Résistance at
inmm² conductor in mm 20ºc(Ohm/km) Thickness inmm
1 2 3 5 6
16 7 4.4 1.91 1.2
25 7 5.6 1.20 1.2
35 7 6.7 0.868 1.2
50 7 8.0 0.641 1.5
95 19 11.0 0.320 1.5
120 19 12.9 0.253 1.5
150 19 14.2 0.196 2.1
NOTE: 1) The resistance values given in col.5 are the max. permissible.
68
Tolerance of + 5% is allowable on dimension.
6. MESSENGER-CUM-NEUTRAL WIRE:
6.1 Thebare messenger wire shall be of aluminium alloy generally confirming to IS–
398/Pt.IV/94 composed of 7 strands and shall be suitable compacted or stranded to have
smooth round surface to avoid damages to the overall insulation of phase & neutral
conductor twisted around the messenger. There shall be no joint in any wire of the
stranded messenger Conductor except these made in thebase rod or wires before final
drawing.
6.2 Thesizes and other technical characteristics of the messenger wire shall be as given in
the Table No.2.
TABLE –2
Diameter of
Nominal Diameter of
Stranded Max .DC
Sectional area No. of Strands Compacted
conductor
conductor in mm Resistance
inmm² in mm
1 2 3 4 6
25 7 5.6 6.42 1.380
35 7 6.7 7.56 0.986
70 7 9.4 10.65 0.492
7. XLPE INSULATION:
The insulation shall generally conform to IS-14255
Sr.No. Property Requirement
1 Tensile Strength 12.5 N / mm² Min

2 Elongation at break 200 % Min.
3 Ageing in air over
a Treatment: Temperature & duration 135 ± 3ºC & 7 days
b Tensile strength variation ± 25% Max.

c4 Elongation variation ± 25% Max.
Hot Set
Treatment 200 ± 3ºC,
a
temperature,Time Under load, mechanical stresses 15 minutes
20 N /cm².
b Elongation under load 175 % max.
c Permanent elongation (set) after cooling 15 % Max
69
5 Shrinkage
130 ± 3ºC
a Treatment temperature duration
For 1
hour
b Shrinkage 4% Max
6 Water absorption (Gravimetric)
Treatment– Temp. 85 ± 2ºC
a
Duration 14 days
b Water absorbed 1 mg. / cm² max.
8. TYPE TEST:
A. Test for Phase/Street Light Conductors
(iv) Tensile Test (IS-8130)
(v) Wrapping Test (IS-8130)
(vi) Conductor Resistance Test (IS-8130)
B. Test for Messenger:
(i) Breaking load test (to be made on finished conductor) -(IS-398/

Pt.IV/ 1994 with latest revision)
(ii) Elongation test (IS - 398 / Pt.IV/1994)
(iii) Resistance test (IS - 398 / Pt. IV /1994)
(iv) If insulated , the test of insulation as per relevant IS will be applicable
C. Physical test for XLPE insulation
(v) Tensile strength and Elongation at break
(vi) Ageing in air oven
(vii) Hot set test
(viii) Shrinkage test
(ix) Water absorption (Gravimetric)
(x) Carbon black 1. Content & 2. Dispersion
D. Test for thickness of insulation

70
E. Insulation Resistance (Volume Resistivity ) Test
F. High Voltage Test
Note: The Manufacturer should submit the entire above type test of Govt. of India’s
approved Laboratory along with their offer.
Optional Test:
Bending test on the completed cable:

Bending test shall be performed on a sample of complete cable. The sample
shall be bent around a test mandrel at room temperature for at least one
complete turn. It shall then be unwound and the process shall be repeated
after turning the sample around its axis 1800. The cycle of this operation
shall be then repeated twice.
The diameter of mandrel shall be 10 (D+d). Where D = Actual diameter of cable (i.e. the
min. circumscribing diameter in mm) d = Actual diameter of the phase conductor in mm
No cracks visible to the naked eye are allowed.
9. ACCEPTANCE TESTS:
Tests for Phase / Street Light Conductors:
a. Tensile test (for Phase / Street light conductor)
b. Wrapping test (for Phase / Street light conductor)
c. Breaking load test for messenger conductor

d. Elongation test for messenger conductor
e. Conductor Resistance test
f. Test for thickness of insulation
g. Tensile strength and elongation at break test
h. Hot set test ( For XLPE insulation)
i. Insulation Resistance test
j. High voltage test
10.PACKING MARKING:
10.1 The LT AB cable shall be wound in nonreturnable drums conforming to

IS-10418/1982 “Specificationfor Reels and Drums for bare wire” of the latest
version thereof. The drums shall be marked with the following:
a) Manufacturers name
71
b) Trade mark if any
c) Drum number
d) Size of Conductor
e) Size of Messenger
f) Voltage grade
g) Number of lengths of pieces of Cable in each drum
h) Gross mass of the packing
i) Net mass of Cable
j) ISI mark
10.2 The drums shall be of such a construction as to assure delivery of conductor in field
free from displacement and damage and should be able to withstand all stresses due to
handling and the stringing operation so that cable surface not dented, scratched or damaged
in any way during transport and erection. The cable shall be properly lugged on the drums
10.3 The cable drums should be suitable for wheel mounting.
11.Designation and parameters of the Finished Cables:

The designation and parameters of the finished cables shall be as given in the Table 5
below. The first part of the designation refers to the Number & size (cross sectional
area in sq.mm)of the Phase Conductor, the second part refers to the (cross sectional area
in sq.mm) of the Messenger.
Sizes:
Complete Cable
Description of Sizes
Approx. Overall dia. (mm)
3x16+1x16+1x25 19
3x25+1x16+1x25 22
3x35+1x16+1x25 24
3x50+1x16+1x35 32
3x70+1x16+1x50 34
3x95+1x16+1x70 39
3x120+1x16+1x95 44
3x150+1x16+1x120 49
12.STANDARD LENGTH:
The standard length of drum will be 500 meter with + 5%
Non-standard Length:
Nonstandard length not less than 50% of the standard length shall be accepted to the extent
of 10%of the ordered quantity.
72
13.INSPECTION:
All tests and inspections shall be made at the place of manufacturer unless otherwise
especially agreed upon by the manufacturer and purchaser at the time of purchase. The
manufacturer shall afford the inspector representing the purchaser all reasonable facilities,
without charge, to satisfy him that the material is being furnished in accordance with this
specification.
14. SAMPLING OF CABLES:

In any consignment the cables of the same size manufactured under essentially similar
conditions of production shall be grouped together to constitute a lot. Samples shall be
taken and tested from each lot for ascertaining the conformity of the lot to the
requirement of the specification. The number of drums (n) to be selected from the lot
of drums(N) of consignment of cables shall be in accordance with column 2 and 1 of
following table:
Table: Number of Drums to be selected Sampling and permissible Number of Defectives.

Number of Drums in the Number of Drums to be Permissible Number of
Lot (1) N Taken as Sample Defectives(3)a
(2) n
Upto 50 2 0
51 to 100 5 0
101 to 300 13 0
301 to 500 20 1
501 and above 32 2
14.EXPERIENCE:
The manufacturer must have some experience of manufacturing and supply of this cable to
any Electricity Board. Copy of order executed and performance report may be submitted
along with the offer.
15.TYPE TEST CERTIFICATES:
The duly attested copy of Type Test Certificate of the offered sizes of AB cable, as per IS:
14255/1995 with latest amendment/revision be submitted from any Govt. laboratory or from
a NABL accredited laboratory along with the offer. Type Test Certificate shall not be more
than Five Years Old from Date of supply.
However, if the same are not available at the time of bidding, the same may be submitted
after order but before commencement of supply.
In case, the bidder is not able to submit the Type Test Certificate from any Govt. laboratory
or from a NABL accredited laboratory for any size of cable, the same shall be conducted
by the bidder free of cost without any additional financial liability on utility. For this
purpose, Type test Report of a phase wire or messenger wire once tested shall be accepted
73
for all other combination. For example, if 1x16+ 25 sq mm and 3x35 + 25 sq mm already
tested then this will be valid for 3x16+25 sq mm (as phase wire of 16 sq mm and messenger
wire of 25 sq mm are already tested) and for 3x35 + 25 sq mm + 16 sq mm (as phase wire
of 35 & 16 sq mm and messenger wire of 25 sq mm are already tested.
16. SUBMISSION OF ISI LICENSE FOR IS14255:1995
The Manufacturer are required to submit duly attested photo copy of the valid ISI License
up to the date of delivery for supply of these AB cables/wires and they should also submit
GTP failing which, the offer would be ignored.
17.IMPORTANT:
In absence of valid ISI License/GTP duly filled in/and copy of type test certificate of Govt.
approved Laboratory, duly attested by authorized person, offer will be liable to be ignored
without any further correspondence.
18.ISI MARKING:
The material supplied shall be conforming to Indian Standard Specification and also with ISI
marking as applicable and even after inspection of the lot, if the materials received at site is
found without ISI marking, the lot shall be rejected and no further correspondence shall be
entertained in this regard.
Exact details of marking/embossing, color of outer sheath etc. will be as per the detailed
purchase order.
GUARANTEED TECHNICAL PARTICULARS (G.T.P.)
Technical information and Guaranteed Technical Particulars (G.T.P.) for

LT Aerial Bunched Cable (XLPEinsulated only) of sizes:
1X16 (Ph) + 1X25 (bare messenger cum neutral) SQ. MM.
1X16 (Ph) + 1X25 (bare messenger cum neutral) + 1x16 (insulated Street lighting)SQ. MM.
1X25(Ph)+1x25 (bare messenger cum neutral) SQ. MM.
1X25(Ph) + 1X25 (bare messenger cum neutral) + 1x16 (insulated Street lighting) SQ. MM.
3 X 25(Ph) +1x25 (bare messenger cum neutral) + 1x16 (insulated Street lighting) SQ. MM.
1x35(Ph) + 1X25 (bare messenger cum neutral) + 1x16 (insulated Street lighting) SQ.MM.
3X35 (Ph) + 1x25 (bare messenger cum neutral)+ 1x16 (insulated Street lighting) SQ.MM.
3X50 (Ph)+1x35 (bare messenger cum neutral) +1x16 (insulated Street lighting) SQ. MM.
74
MM
MM
3X150(Ph)+1X120 (bare messenger cum neutral) SQ. MM.+1x16 (insulated Street
lighting)SQ. MM
PART – A
Manufacturer has to confirm following important requirements:
confirmation
Sr.No. Particulars
AB Cable shall be manufactured and supplied Confirming to IS: 14255/1995
1 Yes
with latest Amendment if any
2 Cable drums/label shall bear ISI Mark Yes
3 ISI License shall remain valid till order is Completed Yes
4 Colour of XLPE Insulation – Black
4a 1X16 + 1X25 SQ. MM. Yes
4b 1X16 + 1X25 + 1x16 SQ. MM. Yes
4c 3X16+1X25 SQ. MM. Yes
4d 3 X 16 +1x25 + 1x16 SQ. MM. Yes
4e 1X25+1x25 SQ. MM. Yes
4f 1X25 + 1X25 + 1x16 SQ. MM. Yes
4g 3X25+1X25 SQ. MM. Yes
4h 3 X 25 +1x25 + 1x16 SQ. MM. Yes
4i 1X35+1X25 SQ. MM. Yes
4j 1x35 + 1X25 + 1x16 SQ. MM. Yes
4k 3X35+1X25 SQ. MM. Yes
4l 3X35 + 1x25 + 1x16 SQ. MM. Yes
4m 3X50+1X35 SQ. MM. Yes
4n 3X50 +1x35 +1x16 SQ. MM. Yes
4o 3X95+1X70 SQ. MM. Yes
4p 3X95+1X70 +1x16 SQ. MM. Yes
4q 3X120+1X95 SQ. MM. Yes
4r 3X120+1X95 +1x16 SQ. MM. Yes
4s 3X150+1X120 SQ. MM. Yes
4t 3X150+1X120+1x16 SQ. MM. Yes
5 Shape – compacted Yes
Standard length in case 500 mtrs+ 5 % tolerance longer length acceptable Yes
6
Non-Standard length 50% of Std. length up to 10%of ordered quantity Yes

7
8 Packing shall contain only one Length. Yes
9 Packing material: Wooden drums as per IS: 10418/1982 duly painted

75
Yes
9a 1X16 + 1X25 SQ. MM. Yes
9b 1X16 + 1X25 + 1x16 SQ. MM. Yes
9c 3X16+1X25 SQ. MM. Yes
9d 3 X 16 +1x25 + 1x16 SQ. MM. Yes
9e 1X25+1x25 SQ. MM. Yes
9f 1X25 + 1X25 + 1x16 SQ. MM. Yes
9g 3X25+1X25 SQ. MM. Yes
9h 3 X 25 +1x25 + 1x16 SQ. MM. Yes
9i 1X35+1X25 SQ. MM. Yes
9j 1x35 + 1X25 + 1x16 SQ. MM. Yes
9k 3X35+1X25 SQ. MM. Yes
9l 3X35 + 1x25 + 1x16 SQ. MM. Yes
9m 3X50+1X35 SQ. MM. Yes
9n 3X50 +1x35 +1x16 SQ. MM. Yes
9o 3X95+1X70 SQ. MM. Yes
9p 3X95+1X70 +1x16 SQ. MM. Yes
9q 3X120+1X95 SQ. MM. Yes
9r 3X120+1X95 +1x16 SQ. MM. Yes
9s 3X150+1X120 SQ. MM. Yes
9t 3X150+1X120+1x16 SQ. MM. Yes
10 Following shall be embossed on cable & Marking on drum shall be as per IS: Yes
14255/1995
10a Purchaser (Employee) Yes
10b 1100 Volts Yes
10c IS:14255/1995 Yes
10d Year of manufacture Yes
10e Trade Mark Yes
11 Conductor –
11a For Phase 16 mm² ,25 mm², 35 mm², 50 mm², 95 mm² & 120 mm² 150 mm2 Yes
Aluminium as per
IS 8130/1984
11b For Messenger wire 25 mm², 35 mm², 70 mm² & 95 mm² Aluminium Alloy as per IS Yes
398/Pt.IV/1994
12 Maximum Conductor resistance at 20ºC For Phase Conductor
12a 16 mm² Conductor – 1.91 Ohm/KM Yes
12b 25 mm² Conductor – 1.20 Ohm/KM Yes
12c 35 mm² Conductor – 0.868 Ohm/KM Yes
12d 50 mm² Conductor – 0.641 Ohm/KM Yes
12e 95 mm² Conductor – 0.320 Ohm/KM Yes
12f 120 mm² Conductor – 0.253 Ohm/KM Yes
12g 150 mm2 conductor- 0.180 ohm/KM Yes

76
For messenger conductor
12e 25 mm² Conductor – 1.380 Ohm/KM Yes
12f 35 mm² Conductor – 0.986 Ohm/KM Yes
12g 70 mm² Conductor – 0.492 Ohm/KM Yes
12h 95 mm² Conductor – 0.331 Ohm/KM Yes
12i 120 mm² Conductor – 0.274 Ohm/KM Yes
13 Minimum average XLPE Insulation thickness for AB Cable
13a 16 mm² - 1.0 mm Yes
13b 25 mm² - 1.0 mm Yes
13c 35 mm² - 1.0 mm Yes
13d 50 mm² - 1.2 mm Yes
13f 95 mm² - 1.4 mm Yes
13g 120 mm² - 1.6 mm Yes
13h 150 mm² - 2.1 mm Yes
14 Volume resistivity of insulation
14a At 27ºC – 1 x 10^13 Ohm-cm. Min Yes
14b At 70°C – 1 x 10^11 Ohm-cm. Min Yes
15 Tensile strength of Insulation & sheath -12.5 N/mm² Min. Yes
16 Elongation at break of Insulation and Sheath –200% Min. Yes
17 Overall tolerance in supply of ordered total quantity shall be + 2 %( Plus and Yes
minus two %)
PART- B
Manufacturer has to furnish below details about material for information:
Sr.
Particulars confirmation
No.
1 ISI License for IS:14255/1995 Yes

1a Number
1b Date of expiry
Approximate weight of 1000 meters length (Weightin Kgs.)

2
Size of cable Alum. Alu. Alloy XLPE Total
1X16 + 1X25 SQ. MM.
1X16 + 1X25 + 1x16 SQ. MM.
3X16+1X25 SQ. MM.
3 X 16 +1x25 + 1x16 SQ. MM.
1X25+1x25 SQ. MM.
1X25 + 1X25 + 1x16 SQ. MM.
3X25+1X25 SQ. MM.
77
3 X 25 +1x25 + 1x16 SQ. MM.

2a
1X35+1X25 SQ. MM.
1x35 + 1X25 + 1x16 SQ. MM.
3X35+1X25 SQ. MM.
3X35 + 1x25 + 1x16 SQ. MM.
3X50+1X35 SQ. MM.
3X50 +1x35 +1x16 SQ. MM.
3X95+1X70 SQ. MM.
3X95+1X70 +1x16 SQ. MM.
3X120+1X95 SQ. MM.
3X120+1X95 +1x16 SQ. MM.
3X150+1X95 SQ. MM.
3X150+1X95 +1x16 SQ. MM.
3 Cable Conductor, Circular Compacted? Yes
PART – C (ENCLOSURES)
Manufacturers have to enclose following documents and has to confirm for the same
S
Particulars confirmation
r
.
N
o
.
ISI1 License Yes
Proof
2 if applied for renewal of ISI License Yes
TYPE TEST CERTIFICATE:Type test certificate from Govt. of India

Yes
approvedLaboratory
3 Size of AB Cable
Name of Lab. &
a
City Name
b
T.R. No.
Date c
List of plant and machinery Yes

4
List
5 of testing facility available Yes
List
6 of orders pending/executed Yes
with
6 Employer Yes
a
with
6 agencies other than Sr. no. 6(a) Yes
b
78
L.T. PVC Armoured Service Cable 2 Core 4 sqmm, 2 Core 6 sqmm, 4 Core 10
sqmm & 4 Core 16 sqmm.
1. GENERAL INSTRUCTIONS:
The LT PVC Insulated armoured cables shall be suitable for use on AC Single Phase or
Three Phase (earthed or non-earthed) system for rated voltage up to and including 1100 volts.
These cables may be used on DC system for rated voltage up to and including 1500 volts.
The cable shall be suitable for use where the combination of ambient temperature and
temperature rise due to load, results in a continuous temperature not exceeding 700C.
2. ITEM:
Circular 2 Core 4 Sq.mm., 2 Core 6 Sq.mm., 4 Core 10 Sq.mm. & 4 Core 16 Sq.mm.
armoured cable with aluminium Conductor insulated with PVC & PVC sheathed cover
conforming to IS: 1554 (Part-1):1988 with amendment, if any.
DESCRIPTION:
3.1 Conductor:
For all above items, H2 or H4 Grade Aluminium shall be used, minimum guaranteed weight
of Al. / Km shall be 173 Kg. The conductor shall be solid circular in section, smooth, uniform
in quality, free from scale inequalities, spills, splices and any other harmful defects. The
conductor shall be compressed of Aluminium wires complying with IS: 8130/1984 with
amendment thereof.
The Aluminium used shall be standard make e.g. Hindalco, NALCO, BALCO.
2.2 Insulation:
The insulation shall consist of one of the material of standard make such as Reliance, Sri
Ram, Finolex, NOCIL, this should have been suitably compounded and processed.
Polyvinyl Chloride (PVC).
Suitable co-polymers of major constituent shall be vinyl chloride.
Mixtures of (a) & (b) above.
The PVC insulation of core shall be conforming to requirement of Type-A Compound as per
IS: 5831/1984 with amendment, if any. The conductor shall be provided with PVC insulation
applied by extrusion.
The insulation shall be so applied that it fits closely on the conductor and it shall be easily
possible to remove it without any damage to the conductor.
Colour Scheme for identification of core:
Individual cores of cables shall be red, yellow, blue and Black as per IS: 1554 (Part-1).
79
2.3 ARMOUR
Galvanized steel wire armouring shall be provided. The dimensions of steel wire shall be as
per IS: 1554 (Part-1):1988 and its latest amendment and strip shall conform to latest
provisions of IS: 3975 – 1988 and amendment thereof.
2.4 SHEATH:
The composition of PVC compound of sheath shall be same as mentioned at Sl. 3.2
above. The compound shall be designed to have adequate mechanical strength. The
colour of PVC Compound used for sheath shall be black. The sheath shall be of PVC
conforming to requirement Type ST-I compound of IS: 5831/1981 by extrusion. It
shall be applied over the laid up cores and it shall be possible to remove it without any
damage to the insulation.
2.5 LENGTH:
The cables shall be supplied in 1000+5% meters length. Short length shall be allowed
for maximum 5% of the ordered quantity but short length cables shall not be less than
100 meters in any case. However sub-standard length up to a maximum of 5% shall be
acceptable in a particular lot offered for inspection.
3. PACKING AND MARKING:
4.1 The cable shall be either wound on reels or supplied in coils packed and labeled.
4.2 The cables which shall be securely attached to the reels or coils shall have the
following information:
(a) Property of MVVNL-RDSS
(b) Designation of consignee & destination railway station.
(c) Reference of the ISS.
(d) Name of manufacturers, Brand name or Trademark.
(e) Cable code as per clause 13.2 of IS: 694/1977.
(f) Nominal Cross sectional area of the conductor of the cable.
(g) Type of cable and voltage grade.
(h) Number of cores.
(i) Approximate Gross weight.
(j) Year of manufacture.
(k) Length of the cable, contained in the coil/reel.
(l) The cable may also be marked with ISI certificate mark.
4. EMBOSSING:
On the outermost sheathing of cable, following should be embossed at the regular interval
of one-meter length of cable.
(i) PROPERTY OF MVVNL.
(ii) NAME OF MANUFACTURER.
(iii) VOLTAGE GRADE AND SIZE.
(iv) YEAR OF MANUFACTURER.
80
(v) SPECIFICATION NO.

(vi) LENGTH MARKING IN METRES.
The cables so embossed shall not be utilized or sold anywhere else by the supplier
6. TOLERANCE OF QUANTITIES:
The total permissible variation for the entire quantity ordered shall be subject to limit + 1%
of ordered quantity. However, the permissible variation in case of individual consignees may
be + 5%.
7. INSPECTION, TESTING AND TEST CERTIFICATES:
7.1 The contractor shall furnish an authenticated electrostat copy of type test results as
carried out on the same design to prove that the design has successfully passed through
required tests. The type test up to a maximum of 5 years prior to date of tender opening
by recognized test house of repute shall be acceptable.
7.2 If successful type test have been carried out on the offered design during last five years
(counted from the date of tender opening), repetition of type tests is not required.
On the other hand, if the offered design is not type tested during last five years, the
cable shall be subjected to all type tests in accordance with IS: 694/1977 and
amendment thereof, at recognized test house of repute. All charges/fee/transportation
etc, to conduct these tests shall be borne by contractor.
Regular supply of the material shall commence only after successful type testing &
dispatch authorization from competent authority.
However the purchaser reserves the right to get cable type tested at any stage during
the currency of contract at his own expenses in any reputed test house. The
transportation and arrangement of testing of sample to test laboratory shall be the
responsibility of the contractor.
7.3 The following tests shall be carried out by the inspecting officers of the MVVNL on
samples selected at random as per IS: 694/1977 with latest amendments.
1. Tests on conductor
a) Tensile test (For aluminium) IS: 8130-1984
b) Wrapping test (For aluminium) IS: 8130-1984
c) Conductor resistance test IS: 8130-1984
2. Test for thickness of Insulation & Sheath IS: 5831-1970
3. Physical test for insulation & sheath IS: 5831-1970
4. Insulation resistance test IS: 8130-1984
5. High voltage test (water immersion test) IS: 694 -1977
Length/weight check shall also be carried out on minimum 5%, reels/coils subject to
minimum one reel/coil by the inspecting Officers as per their decision along with above
81
acceptance test. The contractor will make all necessary arrangements & provide all necessary
facilities at his own cost for the above tests/checks.
8. Raw material:-
The supplier shall themselves be responsible for timely arrangement / procurement of all the
raw-materials required for the manufacturing of all ordered items and shall furnish their test
certificates to the purchaser if so required.
9. The cables offered by the supplier shall conform to the requirement of IS: 694:1977 or latest
amendment if any, and as per technical particulars enclosed herewith (Annexure-III), No
other technical particulars or Deviations from technical specification shall be accepted.
Further, these specifications are subject to the technical terms and conditions mentioned in
instructions to tender general requirement of specification and form 'B'. In case of any ambiguity
of technical specification/Technical particulars shall prevail
82
LT (upto 1100v) single/two/three/three and half core, XLPE insulated, PVC

sheathed, armoured powercables.
1. Scope:
The specification covers design, manufacturing, testing, packing, supply & delivery
on FOR destination basis of 1100 volts grade,LT Cable, multiple core, Cross linked
Polyethylene (XLPE) insulated, PVC sheathed, armoured power cables for effectively
earthed systems.
2. Standards:
Unless otherwise specified, the cable shall conform in all respects to IS 7098-Part-
1(1988), IS 8130-1984,IEC: 60502 ,IS 5831-1984,IS 10810-1984,IS 3975-1999 and
IS 10418-1982 standards with latest amendments thereof.
3. Climatic conditions:
1 Location UTTAR PRADESH

2 Maximum ambient air temperature 49 deg C
3 Minimum ambient air temperature 3 deg C
4 Average daily maximum ambient 40 deg C
temperature
5 Max yearly weighted average ambient 32 deg C
temperature
6 Isoceraunic level 163 AQI
7 Maximum altitude above mean sea 123 meters
level
8 Minimum relative humidity 26%
9 Max. relative humidity 100%
10 Average no of rainy days/ year 85
11 Basic Wind Speed 13 kmph
12 Avg. Annual rainfall 260 mm
13 Pollution Extreme
14 Maximum wind pressure 998 mb
15 Sesimic Zone Zone-III
Note: Moderately hot & humid tropical climate is conducive to rust & fungus
growth. The climatic conditions are also prone to wide variations in ambient
conditions. Smoke is also present in the atmosphere. Heavy lightning also occurs
during June to October.
Design, construction and technical parameters:-

4. Conductor:
The conductor of the cable shall be made from high conductivity, Electrolytic, H4
Grade, stranded aluminium to form compacted and circular /shaped conductor having
resistance withinlimits as specified in IS 8130/ 1984 with latest amendments. The
aluminium conductor shall be of class-2 as per IS 8130.
83
5. Insulation:
The insulation shall be suitable for LT system voltage and the insulating material shall
be cross linked Poly Ethylene (XLPE), and applied by extrusion process as per IS 7098
Part-1 and its latest amendments. The insulation shall be an extrusion of thermosetting
cross linked poly ethylene rated for 90ºC continuous operation. The insulating material
shall have excellent electrical properties with regard to resistivity,dielectric constant and
loss factor and shall have high tensile strength and resistance to abrasion. This shall not
deteriorate at elevated temperatures or when immersed in water. The insulation shall be
preferably fire resistant and resistant to chemicals like acids, alkalis, oils andozone. The
insulation properties shall be stable under thermal conditions arising out of continuous
operation at conductor temperature of 90ºC rising momentarily to 250ºC under short
circuit conditions. It shall be free from any foreign material or porosity visible to the
unaided eye. The insulation shall be so applied that it fits closely on the conductor and
it shall be possible to remove it without damaging the conductor. The average thickness
of insulation shall not be less than the nominal value as specified in IS: 7098 (Part I)
with latest amendments. Tolerance on insulation thickness shall be as per IS-7098 Part-
1.The insulation shall withstand mechanical and thermal stress under both steady state
and transient operating conditions.
6. Core identification (for multiple core cables):

Individual core of multi-core cables shall be colour coded and/or numbered for
properidentification in accordance with clause 10.1 of IS: 7098 (Part – I).
7. Fillers and Laying up of cores (for multiple core cables):

In multi core cables, the cores shall be laid together with a suitable right hand lay.
The interstices shall be filled with non-hygroscopic material. Further, the
compounds used withfillers shall be such as to have no deleterious effect on other
components of the cable and to bestable at cable temperatures.
8. Inner sheath (common covering):

The laid up cores shall be provided with inner sheath applied by extrusion process.
It shall be ensured that the shape is as circular as possible. It shall be applied to fit
closely on to the laid up cores and shall be possible to remove easily without
causing any damage to the underlying insulated cores. The thickness of the inner
sheath shall be as per (12.3) IS: 7098 (Part - I). No tolerance on the negative side
shall be acceptable.
9. Armouring:
The armour of cables shall consist of either galvanized round steel wires or
galvanized steel strips as per clause 13.2 of IS: 7098 (Part I). The armouring shall
be applied such that the minimum area of coverage shall be 90% and the gap
between any two armour strips/ wire shall not be more than the width of strip/
diameter of armour wire. The galvanized steel strips/wire shall comply with the
requirements of IS: 3975- with latest amendments. In case of Single core cable
84
armouring shall be of Non-magnetic material conforming to IS: 3975 – 1999

(amended upto date). The dimensions of the galvanized steel strip/wire shall be as
per IS: 7098 (Part-I) (Table 6, Clause 13.3, armouring size and dimension shall
be as per method (b), method (a) is not acceptable). with latest amendments.
No tolerance on the negative side shall be acceptable. Tolerance onsize of armour
shall be as per IS:7098 Part-1 &IS:3975.
10. Outer sheath:

The outer sheath shall consist of extruded tough outer sheath of PVC compound
insulation over the armouring. The PVC compound for the outer sheath shall
conform to type ST-2 of IS: 5831 - 1984 (amended up to date) with suitable
additives (to prevent attacks by rodents and termites) shall be provided. The
colour of the outer sheath shall be black. The cable must meet all the requirements
of the IS: 7098 (Part 1) amended up to date and shall bear ISI mark.
11. General:
All materials used in manufacturing of cable shall be new, unused and of finest
quality. All materials should comply with the requirements / tests as per
applicable IS / IEC specification, Indian Electricity Rules and any other
statutory provision of rules & regulations. The purchaser reserves the right to
ask for documentary evidence of the purchase of various materials, (to be used
for the manufacture of cable) as a part of quality control. Quality Assurance
plan shall be submitted. Each of cable type and size shall be ISI certified. The
manufacturer shall submit self-certified Xerox copy of valid ISI license with
the offer.
12. Continuous Current rating:

As per Appendix -1
13. Short circuit Current rating:

As per Appendix -1
14. Operation:
i) Cable shall be suitable for operation under voltage and
frequency variation as perLatest Indian Electricity rule.
ii) Cable shall be suitable for laying in air, in duct or buried
underground directly orthrough trenchless boring.
iii) Cable shall have heat & moisture resistance properties. These
shall be of type &design with proven record on distribution
network service.
15. Tests:
A. Type tests:
All the cable types and sizes i.e. items offered should have been fully type
tested as per IS 7098 (Part-1) with amendments upto date at any NABL
accredited Laboratory/ Test house. If the manufacturer’s lab is accredited by
NABL then it shall be acceptable for type testing. The bidder shall furnish
one set of authenticated copy of type test reports along with the offer.
85
These type tests must have been conducted within last five years prior to date
of Bid opening. For any change between design/type of already type tested
and the design / type offered against this specification, the purchaser reserves
the right to demand repetition of type tests without any extra cost. For each
type and size the type test shall be got carried out independently.
The purchaser also reserves the right to have tests carried out at his own cost
from an independent agency, whenever there is a dispute regarding the quality
of supply.
The type test certificates type tests as per IS7098 part-1 shall be furnished
invariably with the offer:
(a)
Tests on conductor:
(i) Tensile test
(ii) Wrapping test
(iii) Resistance test
(b) Tests for armouring strips / wires. :
(c) Tests for thickness of insulation (eccentricity) and sheath.
(d) Physical tests for insulation. :
(i) Tensile strength and elongation at break.
(ii) Ageing in air oven
(iii) Hot set
(iv) Shrinkage test
(v) Water absorption test (gravimetric)
(e) Physical tests for outer seath :
(i) Tensile strength and elongation at break.
(ii) Ageing in air oven
(iii) Shrinkage test
(iv) Hot deformation
(v) Loss of mass in air oven
(vi) Heat shock
(vii) Thermal stability
(viii) Carbon black content of polythene sheath.
(f) Insulation resistance test (volume resistivity)
(g) High voltage test
(h) Flammability test
(i) FRLS Tests-
The following FRLS tests are to be conducted as per the referred standard
• HCL gas evolution test (IEC - 754.1)
• Oxygen Index (ASTM-D-2863)
• Temperature Index (ASTM-D-2863)
• Smoke density test (ASTM-D-2863)
• Flammability test (IEC-332.1)
• Swedish Chimney test (SS-424 14 75)
• Ladder Test (IEEE-383)
XLPE cables shall be tested as per IS 7098 / IEC.
The LT XLPE cables shall be routine tested as per relevant IEC/IS
B. The first lot offered shall not be less than 10% of ordered quantity of
each size of LT XLPE ARMORED CABLE. One sample from the 1st
Lot of LT XLPE ARMORED Cable of each size as received in
86
purchaser’s store shall be selected and sealed by the inspecting officer

nominated by purchaser’s for getting it type tested at any NABL
accredited testing laboratory. The charges incurred towards type test of
the material received in our stores shall be borne by Supplier.
In case sample from first lot fails then:
a. Supplier shall have to replace the full quantity of the

respective inspected lot supplied to various stores and lying
unused at stores.
b. For the quantity already utilized against the order in field a

deduction @ 15% (Fifteen Percent) of F.O.R. Destination
prices of the material supplied shall be made.
(iv) Sample from next lot shall be selected again for type test. All test charges
incurred towards type test of the material for second time shall be borne by the
Supplier. In case sample again fails in the type test then further supplies shall
not be accepted.
C. Acceptance test:
The selection of sample pieces for acceptance test shall be as per Appendix
A of IS 7098(Part-I), of each lot offered for inspection or part thereof. The
minimum shall be one drum.
The g acceptance tests shall be carried as per IS: 7098 (Part-I) out on the selected
samples.
(a) Tensile test (for aluminium)
(b) Wrapping test (for aluminium)
(c) Conductor resistance test.
(d) Test for thickness of insulation and sheath
(e) Hot set test for insulation
(f) Tensile strength and elongation at break test for insulation and sheath.
(g) High voltage test.
(h) Insulation resistance (volume resistivity) test
All the acceptance tests shall be carried out by the firm, in the presence of
purchaser’s representative at their works. The firm shall give atleast 15 days
advance notice to the purchaser to enable him to depute the engineer for
witnessing the tests. The test certificates for acceptance tests witnessed by
inspecting officer/ engineer shall be submitted for approval before dispatch of
material.
D. Routine Tests:
The following shall constitute the routine tests. The Inspector may also inspect
the routine testsat the time of inspection.
(a) Conductor resistance test
(b) High-voltage test for 5 minutes [as per Clause 16.2 of IS: 7098 (Part-I).
87
16. Quality Assurance Plan:

A detailed list of bought out items which got into the manufacture of cables
should be furnished indicating the name of the firms from whom these items
are procured. The bidder shall enclose the quality assurance plan invariably
along with offer followed by him in respect of the bought out items, items
manufactured by him & raw materials in process as well as final inspection,
packing & marking. The Company may at its option order the verification of
these plans at manufacturer's works as a pre-qualification for technically
accepting the bid
17. Identification mark:

The outer sheath of the cable shall bear following identification parameters
embossed atintervals of length of one meter of cable, throughout the cable:-
i) Name of manufacturer
ii) Year of manufacture
iii) Voltage grade
iv) Size of cable
v) Cable code
vi) Name of purchaser “ MVVNL”
vii) ISI certification mark.
viii) Successive length
ix) Marking for FRLS cable
18. Packing and forwarding:

18.1 The cable shall be wound on non-returnable wooden drums as per
IS: 10418 – 1972 and packed in drums suitable for vertical /
horizontal transport, as the case may be and shall be suitable to
withstand rough handling during transport and outer storage.The
outer surface of the drum shall be painted with white aluminium
paint. Similarly, the inside surface of drum shall have the
protective layer of varnish / paint.
18.2 The wooden drums shall be reinforced with steel bends and
strips for betterprotection.
18.3 Length: The cable shall be supplied in standard drum length as per
detail below:-
Size(sq.mm) 1C(meter) 2C(meter) 3C(meter) 3.5C&
4C(meter)
0-up to16 2000 1500 1000 1000
Above 16-up 1500 1000 1000 1000
to50
Above 50-up 1000 750 750 750
to150
Above 150-up 750 500 500 500
to300
Above 300 500 300 300 300
18.4 The ends of the cable shall be sealed by means of non- hygro
scopicheat shrinkable
88
sealing material.
18.5 The following information be stenciled on the drum with either

water proof ink or oilpaint:
i. Reference of IS / IEC standard.
ii. Manufacturer’s name or trademark.
iii. Type of cable and voltage grade.
iv. No. of cores.
v. Nominal cross-sectional area of conductor
vi. Cable code.
vii. Length of cable on the drum
viii. Gross weight
ix. Direction of rotation of drum (by means of an arrow)
x. Position of outer end of cable
xi. Nigam’s technical specification number.
xii. Year of manufacture
xiii Reference of Tender No. / P.O. No. date xiv Property of
“MVVNL”.
xv. Name of consignee and the destination. Xvi ISI Certification
Mark.
18.6 The firm shall be responsible for any damage to the cables during
transit due to improper and inadequate packing. Wherever
necessary, proper arrangement for lifting, such as lifting hooks,
shall be provided. Any cable found short inside the packing cases
shall be supplied by the supplier, without any extra cost.
18.7 Each consignment shall be accompanied by a detailed packing list,
containing the following information:
(a) Name of consignee
(b) Details of consignment
(c) Destination
(d) Total weight of consignment
(e) Handling and unpacking instruction
(f) Bill of materials, indicating contents of each package.
19. Inspection:
The inspection may be carried out by the purchaser at any stage of
manufacture. The successful bidder shall grant free access to the purchaser’s
representative at reasonable time, when the work is in progress. Inspection
and acceptance, of any cables under this specification by the purchaser, shall
not relieve the supplier of his obligation of supplying cable in accordance
with the specification and shall not prevent subsequent rejection, if the
cables are not found as per the technicalspecifications.
19.1 The supplier shall keep the purchaser informed in advance about
the programme of manufacturing of cables so that arrangement can
be made for inspection.
19.2 The purchaser reserves the right to insist for witnessing the
acceptance / routine tests of the bought out items.
89
19.3 The manufacturer shall be responsible to pay penalty of Rs

20,000/- for eachoccasion at which the fake inspection call has
been made or the material is rejected during testing/inspection by
the authorized agency/representative of the Nigam. This penalty
would be in addition to the expenses incurred by the Nigam in
deputing the Inspecting Officer, carrying out such inspection.
19.4 At least 5% of total numbers of drums subject to minimum of 2 in

each lot put up for inspection shall be selected at random to
ascertain the length/workmanship of cable by the following
method:
19.5 At the work of the manufacture, the cable shall be transferred from
one drum to another for checking any manufacturing defects in the
cable drum selected for conducting acceptance tests, at the same
time measuring its length with the help of pulley & cyclometer
graduated in presence of inspector. The difference in themeasured
length thus obtained from the declared length by the supplier in the
packing list shall be applied to all the drums if the cable is found
short during checking the sample lot (s).
19.6 The supplier shall present the latest Calibration Certificate(s) of

testing instruments/equipments to be used for the testing of the
material covered in the Purchase Order to the authorized
inspecting officer /inspecting agency of the purchaser. The testing
instruments / meters /apparatus etc. should be got calibratedby the
supplier from time to time from an independent testing laboratory
/ house having valid accreditation from National Accreditation
Board for testing and calibrating laboratories for the testing
equipment or from original manufacturers having traceability to
NABL /NPL. The calibration certificate(s) should not in any case
be older than one year at the time of presenting the same to the
inspecting officer / inspecting agency of the purchaser. The testing
instruments / equipment should be duly sealed by the Calibrating
Agency and mention thereof shallbe indicated in the calibration
certificate(s).
20. Documentation:
20.1 The bidder shall furnish following documents along with his offer
- Sectional view, showing the General constructional feature with
conductor / conductor screen / insulation / armouring / inner and
outer sheath etc.
20.2 Drawing of cable drums with details of material dimension and paint
etc.
20.3 All the required type test reports.
20.4 Literature, pamphlets for the supplied items.

90
21. Technical and guaranteed particulars:

The bidder shall furnish all Guaranteed Technical Particulars, as called for, in
Appendix -2 of this Specification. Particulars, which are subject to guarantee,
shall be clearly identified. Offer not containing these information will not be
considered for acceptance.
22. Challenge Clause:-

The material offered/received after the inspection by the authorized inspecting
officer may again be subjected to test for any parameter from any testing
house/in-house technique of the Nigam & the results if found deviating/ un-
acceptable or not complying to Technical specification, the bidder shall
arrange to supply the replacement within thirty (30) days of such detection at
his cost including to & fro transportation. In addition, penalty @10% of cost
of the inspected lot of material shall be imposed.
23. Warranty Period:-

The supplier shall be responsible to replace, free of cost, with no
transportation or insurance cost to the purchaser, up to destination, the whole
or any part to the material which in normal and proper use proved as defective
in quality or workmanship, subject to the condition that the defect is noticed
within 72 months from the date of commissioning. The consignee or any other
officer of Nigam actually using the material will give prompt notice of each
such defect to the supplier. The replacement shall be effected by the supplier
within a reasonable time, but not, in any case, exceeding 45 days/ The supplier
shall, also, arrange to remove the defective materialwithin a reasonable period,
but not exceeding 45 days from the date of issue of notice in respect thereof,
failing which, the purchaser reserve the right to dispose of defective material
in any manner considered fit by him (purchaser), at the sole risk and cost of
the supplier. Any sale proceeds of the defective material after meeting the
expenses incurred on its custody, disposal handling etc., shall however be
credited to the supplier’s account and set off against any outstanding dues of
the purchaser against the supplier. The warranty shall be for the entire duration
of the warranty period.
24. Nigam’s Quality Assurance Plan:-
The Nigam’s Quality assurance plan for the inspection of material at

manufacturer’s factory, post receipt inspection at Nigam’s stores/ turnkey
contractor’s site stores , dispatch of material, supply lots, counter checking etc is
in force for the procurement and turnkey works which shall be applicable, as the
case may be, alongwith uptodate amendments, if any
Appendix-1
1100V Single Core, XLPE insulated Armoured Power Cables with aluminium conductor for
earthed systems:-
1. Continuous current rating-
91
Nominal cross Continuous current Continuous currentrating Continuous current

sectional area rating for Three for single rating for two core
of conductor Core cables (Amps) core cables (amps) cables (amps)
(sq mm) In In air In ground In air In ground In air
ground
6 - - - - -
10 57 53 59 57 57 53
16 78 70 76 73 78 70
25 - - 99 115 90 78
35 116 117 117 140 116 117
50 140 140 138 170 140 140
95 200 221 204 255 200 221
120 225 258 230 300 225 258
150 255 294 265 342 255 294
185 285 339 295 385 285 339
240 325 402 340 450 325 402
300 370 460 390 519 370 461
400 435 542 450 605 435 542
500 481 624 500 700 481 624
630 537 723 555 809 537 723
Nominal cross Continuous currentrating for Continuous currentrating for 4C core

sectional area 3.5C core cables (amps) cables (amps)
of conductor In ground In air In ground In air
(sq mm)
6 - - - -
10 - - - -
16 - - 78 70
25 95 99 95 99
35 116 117 116 117
50 140 140 140 140
95 200 221 200 221
120 225 258 225 258
150 255 294 255 294
185 285 339 285 339
240 325 402 325 402
300 370 461 370 460
400 435 542 435 542
500 481 624 481 624
630 537 723 537 723
 Depth of laying: 900 mm; Ambient Air temp: 40 deg C; Ground Temp: 30 deg C;Thermal
resistivity of soil: 150 deg C cm/w.
 While designing over all system suitable derating factor shall be take in to account as
perthe site condition.
92
Single core armoured cables - dimensional details as per IS 7098 (Part-1)
Nominal area of conductor Nominal thicknessof Minimum thicknessof outer

(sq insulation (mm) sheath
mm) (mm)
25 1.2 1.24 (round wire)
35 1.2 1.24
50 1.3 1.24
95 1.4 1.40
120 1.5 1.40
150 1.7 1.40
185 1.9 1.40
240 2.0 1.40
300 2.2 1.56
400 2.4 1.56
500 2.6 1.56
630 2.8 1.72
Conductor resistance and Short Circuit Current Carrying Capacity (commonfor 1C and 3C&
3.5C):
Nominal area of Maximum DC Short Circuit current
conductor (sqmm) resistance at 20 deg C(Ohms/ for conductor (KA/sec)
km)
25 1.20 2.35
35 .8680 3.29
50 .6410 4.70
95 .3200 8.93
120 .2530 11.28
150 .2060 14.10
185 .1640 17.39
240 .1250 22.56
300 .1000 28.20
400 .0778 37.60
500 .0605 47.00
630 .0469 59.22
Appendix-II
GUARANTEED TECHNICAL AND OTHER PARTICULARS FOR THE SUPPLY OF MULTIPLE
CORE LT XLPE ARMOURED CABLES.
MULTIPLE CORE XLPE
S. PARTICULARS ARMOURNDCABLES IN
No SIZE
1 Manufacturer’s name and works address.
2 Standard specification to which the
material shall
3 VOLTAGE GRADE.
4 NO. OF CORES.
5 CONDUCTOR DETAILS:
93
A Normal cross section area of :

1 Phase Conductor (Sq.mm)
2 Neutral Conductor (Sq.mm)
B No. and size of strands (in mm)of:
1 Phase Conductor (Sq.mm)
2 Neutral Conductor(Sq.mm)
C SHAPE OF CONDUCTOR
D Whether compacted or non-compacted
E Resistance at 27 0c
1 Phase Conductor ohm/km
2 Neutral Conductor ohm/km
6 INSULATION
1 Type
2 Colour
3 Thickness
A Phase Conductor (sq.mm)
1 Nominal (mm)
2 Minimum (mm)
B Neutral Conductor (Sq.mm)
1 Nominal (mm)
2 Minimum (mm)
7 Type of inner sheathing and colour
8 Whether Binder Tape provided
9 Armouring
A Type
B Dimension (mm)
10 Outer Sheath
A Material
B Thickness
1 Nominal (mm)
2 Minimum (mm)
C Standard to which it Confirm
11 A Type and size of filler used
B MIN. WT. OF FILLER IN KG./KM
12 MAX. OVERALL DIAMETER OF THE CABLE
IN
MM.
13 Nature of Packing.
14 DRUM
A TARE WEIGHT OF DRUM
B WHETHER DRUM IS WHELL
C STANDARD SPECIFICATION TO
WHICH
D DRUM DETAILS & DIMENSIONS
E Whether 2-Full Ply Flange Construction
or 2-Full Ply plus 1 Segmental layer
Flange Construction.
1 Drum size
A Flange Diameter (d1) (mm)
B Barrel Diameter (d2) (mm)
C Centre hole Diameter (d3) (mm)
D Overall with (L1) (mm)
F Travers (L2) (mm)
94
G Thickness of Flange
H Barrel End (Supporting disc or
1 Diameter (mm)
2 Thickness (mm)
I Stretchers (core carrier Planks )
1 Number (Min)
2 Thickness
x width
(mm)
J Barrel Battens thickness
(core
K Barrel Middle Supports (Middle
L Thickness of External Lagging.
2 DETAILS OF METAL
A Clamping Studs with
1 Numbers
2 Diameter
(mm)
B Square or Round Washers
1 Number
2 Thickness
x width
(mm)
C M.S. Bushes
1 Numbers
2 Thickness
of Sleeve
(mm)
3 Dimension
of Sleeve
(mm
4 Number of
Bolts
5 Diameters
of Bolts
D M.S. /C.I. Centre Plate

1 Numbers
2 Diameter of
Bolts (mm)
3 Centre
Plate Bolts.
4 A Numbers
B Diameter of Bolts (mm)
E Centre Hole Diameter (mm)
F Minimum Weight in Kg/km

1 Aluminium
2 XLPE
3 PVC
G Standard Length of cable in metre & its

Tolerance
H Whether material bears BIS Certification

I BIS License no.& validity.
J Embossing.
K Any other particulars.
95
MEDCO/2649/2022
TECHNICAL SPECIFICATION FOR 8.5 M. LONG 180 KG.

WORKING LOAD PCC POLES.
1.0 SCOPE:
This specification covers pre-stressed concrete poles suitable for use in 11KV/L.T.
Overhead Power lines and conforming to IS: 1678:1998 (read with its amendments
thereof).
2.0 GENERAL:
2.1 Solid sections pre-stressed cement concrete poles shall be suitable for use in overhead
11KV/L.T. Distribution lines and suitable for a working load of 180 KG. applied in
transverse direction at a distance of 300 mm. below top. The Overall length of the pole
shall be 8.5 M. having depth of plantation as 1.52 mtr. suitable for plantation direct into
ground, when used in straight-line position. The structural strength of pole in longitudinal
direction shall be at least one fourth of the strength in transverse direction. The average
permanent load is 40% of working load.
For earthing G.I wire No. 8 SWG shall be embedded with projecting length of 150 mm.
at 300 mm. from top and 150 mm. at 1350 mm. from bottom as per enclosed drawing.
The pole shall conform to IS: 1678-1998, IS: 1343-1980 and IS: 456-2003. (read with
their latest editions/revisions thereof)
Two numbers through holes of 18-mm. dia. on the broader longitudinal side of the poles
in the direction of conductor to be laid normal to and shall be provided such that the
centers of these holes are at a distance of 100 mm. and 200 mm. from the top of poles.
Apart from above, necessary lifting hooks may also be provided.
2.2 The bidders shall quote only for following cross sections of 8.5 M long PCC Poles.
Category-I: 90 mm × 145 to 300 mm. Tolerance

Category-II: 100 mm × 125 to 280 mm. ± 5 mm
Note:- Poles having cross section mentioned in category -I shall be preferred.

3.0 MATERIAL:
3.1 CEMENT:
The cement used in the manufacture of prestressed concrete poles shall be any of the
following: -
a) Portland slag cement conforming to IS: 455 (read with its latest amendments) but
with not more than 50% slag content.
b) Rapid hardening Portland cement conforming to IS: 8041 (read with its latest
amendments).
c) 43 Grade ordinary Portland conforming to IS: 8112 (read with its latest
amendments) and
d) 53 Grade ordinary Portland cement conforming to IS: 12269 (read with its latest
amendments).
96
3.2 AGGREGATES:
Aggregates used for manufacture of prestressed concrete pole shall conform to IS:
383:1970(latest amendments thereof). If required a sample of the aggregates shall be
submitted by the manufacturer to the purchaser for approval. The maximum size of the
aggregate shall in no case exceed 20 mm.
3.3 WATER:
The water used for concrete mixing and curing shall be clean and free from organic and
inorganic matter harmful to concrete.
3.4 ADMIXTURE:
The use of admixture is not generally recommended. These may be used only with the
approval of the purchaser based on evidence that with the passage of time neither the
compressive strength of concrete is reduced by more than 10% nor are other requisite
qualities of concrete and/or steel impaired by the use of such admixtures .The admixture
shall conform to IS: 9103.
3.5 PRESTRESSING STEEL (High Tensile Steel):
High tensile steel used for manufacture of prestressed concrete poles shall conform to IS:
1785 or IS: 2090 or IS 6003-1983 (latest amendments thereof). The Pre-stressing steel
shall be free from splits, harmful scratches surface flaws, rough rust, scale and other
similar deleterious matter liable to affect adversely proper tensioning or its bond with
concrete. The diameter of smooth wire used for prestressing of poles shall be 4 mm. or 5-
mm. dia. or a combination of two sizes and its ultimate tensile strength shall not be less
than 175 Kg/mm2 for 4 mm wire & 160 Kg/mm2 for 5 mm dia wire.
3.6 OTHER REINFORCEMENT:
Apart from the high tensile steel provided for prestressing the poles, 6mm. dia plain
round M.S Bar or 4mm.dia. H.T. Wire stirrups (as per IS: 432 or IS: 1786) shall be
provided 4 Nos. at each end and 4 Nos. in the mid portion uniformly distributed.
The surface of reinforcement shall be free from loose scale, oil, grease, clay or other
material that may have degenerating affect on the bond between the reinforcement and
concrete.
4.0 CONCRETE:
Design Mix. Concrete as defined in para 9.0 of IS: 456: 2003 (read with its latest
amendments) and para 8 of IS: 1343: 1980 (read with its latest amendments) will be used
in the manufacture of the poles. The design of concrete mix shall conform to the
requirements laid down for controlled concrete under Para 9.2 of IS: 456:2003 (read with
its latest amendments) subject to following further conditions.
a) Minimum cube strength at 28 days shall not be less than 450 Kg/cm2 in
accordance with acceptability criteria given in clause 16 of IS: 456:2003 (read
with its latest amendments).
b) The mix shall contain as low as possible water cement ratio as is consistent with
adequate workability.
c) The concrete shall be compacted thoroughly by vibration, pressure, shock, or
other means and shall have a density of not less than 2.4 MT/cm3.
d) The cube strength of concrete at transfer of prestress shall not be less than 245
Kg/cm2.
97
e) The supplier shall be required to maintain a register showing the test results of
cubes at the age of 3 and 28 days and at the transfer of prestress. For strength test
the cubes shall be taken for each days casting. The register will show the serial
number and the pole cast that day for which the test will apply. The acceptability
criteria will be as per Para 16.3 to 17.5 of IS: 456:2003 (read with its latest
amendments). The register shall be opened for inspection with the authorized
representative of the Corporation.
e) The tenderer shall give a proper mix design of the grade M 45 of design mix
concrete proposed to be used for casting of pole and such mix design may be
supported by the test certificate of some Govt. Lab, or other Recognized Lab. Mix
design done earlier not prior to one year may be considered adequate for later
work, provided there is no change in source and quality of material.
5.0 DESIGN:
5.1 The poles shall be so designed that they do not fail owing to failure initiated by
compression in concrete. Maximum wind pressure to be assumed may be determined as
specified in IS: 875 Part-3 (read with its latest amendments).
5.2 The pole shall be 8.5 M. long and should be designed for an ultimate load of 450 Kg.
acting at 300 mm. below top. The dimensions, reinforcement etc. required to be provided
may be shown in the drawing supplied by the tenderer.
5.3 The ultimate moment capacity in longitudinal direction should be atleast one fourth of
that in transverse direction. The PCC Pole be designed so that it should be safe against
bending, shear, torsion and axial load at various stages of loading under most unfavorable
condition of loading.
5.4 The G.I Wire, no.8 SWG, which be in one continuous length, shall be embedded in the
pole for earthing purpose. No joint of any kind in this wire shall be permitted. The
position and details of connection to be provided at the end of earth wire have been
shown in the enclosed drawing. 2 nos. Galvanized bolts with two nuts and 3 washers with
each bolt are to be supplied by the manufacturer. The details of bolts, nut and washers are
shown in the drawing.
5.5 The position and diameter of the holes to be provided in the poles are also shown in the
enclosed drawing and shall be centrally located and will be perpendicular to the face of
the pole.
5.6 Factor of safety against ultimate failure is 2.5. While it is 1.0 for first crack moment.
Designer should mention basis for adopting various design constants e.g. permissible
tensile, compressive stress, modulus of rupture etc.
5.7 The poles shall be designed to be suitable for fitting stays and clamps.
5.8 Eye hooks shall be provided for lifting of poles. Designer should specify the points from
which PCC Poles can be safely lifted or slung for erection. The poles should be strong
enough for lifting and erection in any direction during handling and transport. During
erection poles are laid on the ground and lifted at some point near the end, similarly while
loading and unloading the poles from carriers they are lifted at one end resting on the
ground and pushed on to the trucks/trailers. The poles should be able to withstand all
such manual handling.
5.9 TRANSVERSE STRENGTH AT FAILURE:
The poles shall be so designed that its strength in transverse direction shall be sufficient
to take the load due to wind on wires and poles, multiplied by load factor.
98
6.0 MANUFACTURE:
The tensioning of pre-stressing tendons shall be carried out in a manner that will induce a
smooth and even rate of increase of stress in the tendons.
6.1 The force induced in the pre-stressing tendon shall be determined by suitable means
attached to the tensioning apparatus. It is essential that the method used to determine the
initial pre-stress in the wire give accurate result. Each wire shall be anchored positively
during casting. Pre-stress in each wire shall be uniform. Care must be taken to ensure that
anchorage do not yield before concrete attains the desired strength.
6.2 The cover of concrete measured from the outside of the pre-stressing tendon shall be at
least 30 mm. or the size of the cable or bar whichever is bigger.
6.3 When measuring the pre-stressing force, any slip which may occur in the gripping device
shall be taken into consideration.
6.4 The transfer of pre-stressed shall be carried out gradually by a proper device, so that the
entire set of wires are released simultaneously.
6.5 In long line method, where the transfer is made on several moulds at a time, care shall be
taken to ensure that pre-stressing force is evenly applied on all moulds and that the
transfer of pre-stress to concrete is uniform along with entire length of tension line by
ensuring correct alignment of moulds on guide plates.
6.6 The high tensile wire shall be continuous over the entire length of the tendon. Welding
shall not be allowed in any case.
6.7 COMPACTING:
Concrete shall be compacted by vibrating, Shocking or other suitable mechanical means.
Hand compaction shall not be permitted
6.8 CURING:
To be done as specified in IS: 1678-1998 (read with its latest amendments). Curing of
PCC Pole be preferably done in tanks filled with water.
7.0 INSPECTION / TESTING:
7.1 The minimum offered number of poles for inspection/ testing should not be less than 500.
7.2 The MVVNL authorized representative shall be entitled for periodical checking and
inspecting of the raw material to be used in entire production scheme and finished poles.
The supplier’s shall be bound to follow all written instructions found necessary to ensure
quality control and conformity of the product to the relevant standards.
7.3 The transverse strength test on the poles shall be performed in accordance with IS: 2905-
1989 (read with its latest amendments thereof).
7.4 A pole shall be deemed not to have passed the test if hair cracks appear at a stage prior to
application of 50% of the ultimate Transverse load or the hair cracks if any, produced on
application of 60% of the minimum ultimate Transverse load of 450 Kg. at 300 mm. from
top do not close upon the removal or reduction of test load.
7.5 For the purpose of test, a lot shall consist of maximum of 200 Nos. of poles. Out of which
15 Nos. of poles shall be tested for over all length, cross section and uprightness, and 1%
of the poles of the lot shall be tested till breakage amongst those 15 Nos. for transverse
strength. Lot with lesser number of poles will also be tested as per above criteria.
7.6 The poles for test shall be selected at random out of a lot.
99
7.7 A lot shall be considered as conforming to these specifications if it satisfied the following
conditions:
(A) The number of poles which do not satisfy the requirement of overall length, cross
section and uprightness shall not exceed one no. out of the 15 Nos. poles tested. If
the number of such poles exceeds one then all the poles in a lot shall be tested for
these requirements and those not satisfying the requirement shall be rejected.
(B) All the poles tested for transverse strength test shall satisfy the requirement of the
test. If one or more poles fail, twice the number of poles originally tested shall be
taken from those already selected, and subjected to the test. If there is no failure
among these poles, the lot shall be considered to have satisfied the requirements
of this test.
(C) A pole should be deemed to have passed the transverse load test if there is no
permanent set observed 10 minutes after the release of applied load 180 Kg.
7.8 No payment shall be made for broken pole to the extent of 1% or more during
inspection/testing out of the lot offered for the inspection.
8.0 TOLERANCE:
(i) The tolerance on overall length of the pole shall be ± 15 mm.
(ii) The tolerance on cross sectional dimensions shall be ± 5 mm.
(iii) The tolerance on the uprightness or straightness of the pole shall be 0.5%
(Measurement of uprightness or straightness of pole shall be done as per clause No.
4.2.1.1 of IS: 1678:1998).
(iv) A tolerance of ± 15 mm is also allowed in the position of G.I Wire.
9.0 MARKING:
The pole shall be clearly and indelibly engraved with the following particulars during
manufacture so as to easily read after erection in position.
(a) Tender Spec. No. MEDCO/ /
At two positions (i) 400 mm, below top (ii) 3.0 meters from the bottom.
(b) MVVNL, Date, month and year of manufacturing at a place in between code
numbers as given in (a).
10.0 SPECIAL AND IMPORTANT CONDITIONS OF THE TENDER:
I. The price of 8.5 m long pcc pole shall be firm and firm in all respect and the
Tenderer must quote accordingly.
II Tenderer must quote for a minimum of 20% of the Tendered Qty of 8.5 M
LONG PCC POLES, otherwise their tender shall not be considered.
III For loading/unloading /transport and insurance against all risks including
insurance charges for 30 days storage after recept of poles at destination stores
/substation has to be quoted for Lucknow/LESA Zone.
NOTES: Firm situated outside the geographical limit of Madhyanchal Vidyut Vitran Nigam
Ltd., Lucknow, shall transport the PCC Poles from their works to the nearest border
of Madhyanchal Vidyut Vitran Nigam Ltd., Lucknow free of cost. This can be further
understood as if the nearest border of Madhyanchal Vidyut Vitran Nigam Ltd.,
Lucknow from the firm's work is ‘X’ Km. & the poles have been transported for total
100
‘Y’ Km. distance, the firm shall be given transportation charges Corresponding to (Y-
X) Km. only.
Incase of any ambiguity in quoting the above rates, the tender is liable to be
rejected.
IV ‘Proven design’ as mentioned in clause No.1.2.6 of Instruction to Tenderers
implies that the drawing & design calculation of 8.5 M Long PCC Pole should be
got approved by a govt. approved Institution of national repute.
V Date of R/R shall be deemed to be date of delivery for dispatch by rail, the data of
receipt of material in purchaser’s store shall be deemed to be the date of delivery
for dispatch by Road.
VI No payment shall be made for broken pole to the extent of 1% or more during
inspection/testing out of the lot offered for inspection.
VII THE BIDDER SHOULD SIGN AND STAMP EACH PAGE OF THE BIDS ITS
ANNEXURE/DOCUMENTS NECESSARILY.
VIII Incase of any Inconsistency the provisions contained above shall prevail.
IX The tender part II (price part) of bidders who quote poles of cross-sections
different form that mentioned in the tender specification shall not be opened.
X Tenderers are required to give their cost analysis of one 8.5 M Long PCC Pole
along with part-II (Price Part) of the bid i.e. quantity of various inputs like
cement, sand, aggregate, H.T. Wire G.I. Wire etc., and their rates/prices, labour
charges Bank interest on capital borrowed, profit etc.
XI The tender part-II (Price Part) of bidders who quote poles of cross-sections
different from that mentioned in the tender specification shall not be opened.
XII Tenderers are required to give their cost analysis of one 8.5 M Long PCC Pole
charges Bank interest on capital borrowed, profit etc., in enclosed proforma.
Tenderers may offer for either type of poles 8.5 M
11.0 QUALITY ASSURANCE PLAN :
11.1 The Bidder shall invariably furnish the following information along with his bid, failing
which his bid shall be liable for rejection. Information shall be separately given for
individual type of material offered.
i. Statement giving list of important raw materials/accessories, names of sub-
suppliers for the raw materials, list of standards according to which the raw
materials are tested, list of test normally carried out on raw materials in presence
of Bidder’s representative, copies of test certificates. (Note:- The list of
suppliers/accessories out of the list provided by the bidder shall be approved by
the purchaser, but in case of any deviations the same should be got approved.
Submitting a request to the purchase along with reasons for such deviations)
ii. Information and copies of test certificates as in (i) above in respect of bought out
accessories.
iii. List of manufacturing facilities available.
iv. Level of automation achieved and list of areas where manual processing exists.
101
v. List of areas in manufacturing process, where stage inspections are normally
carried out for quality control and details of such tests and inspections.
vi. Lists of testing equipment available with the bidder for final testing of equipment
specified and test plant limitation, if any, vis-à-vis the type, special acceptance
and routine tests specified in the relevant standards. These limitations shall be
very clearly brought out in schedule of deviations from specified test
requirements.
i. List of raw materials as well as bought out accessories and the names of sub-
suppliers selected from those furnished along with offers.
ii. Type test certificates of the raw materials and bought out accessories if required
by the purchaser.
iii. Quality assurance plan (QAP) with hold points for purchaser’s inspection. The
quality assurance plan and purchasers hold points shall be discussed between the
purchaser and bidder before the QAP is finalized.
11.3 The contractor shall operate systems which implement the following
i. Hold Point : A stage in the material procurement or workmanship process beyond
which work shall not proceed without the documental approval of designated
individuals or organizations. The purchaser’s written approval is required to
authorize work to progress beyond the hold points indicated in quality assurance
plans.
ii. Notification Point : A stage in the material procurement or workmanship process
for which advance notice of the activity is required to facilitate witness. If the
purchaser does not attend after receiving documented notification in accordance
with the agreed procedures and with the correct period of notice then work may
proceed.
11.4 The successful bidder shall submit the routine test certificate of bought out accessories
and central excise passes for raw material at the time of routine testing if required by the
purchaser and ensure that Quality Assurance requirements of this specification are
followed by the sub-contractors. The Quality Assurance program of the contractor shall
consist of the quality systems and quality plans with the following details.
i. Quality System :
The structure of the organization.
The duties and responsibilities assigned to staff ensuring quality of work.
The system for purchasing, taking delivery and verification of materials
The system for ensuring quality workmanship.
The system for retention of records.
The arrangements for contractor’s internal auditing.
A list of administration and work procedures required to achieve and verify
contracts quality requirements. These procedures shall be made readily available
to the project manager for inspection on request.
ii. Quality Plans :
102
An outline of the proposed work and program sequence.
The structure of the contractors organization for the contract.
The duties and responsibilities assigned to staff ensuring quality of work
Hold and Notification points.
Submission of Engineering documents required by the specification.
The inspection of materials and components on receipt.
Reference to the contractor’s work procedures appropriate to each activity.
Inspection during fabrication/construction.
Final Inspection and test.
103
104
MEDCO/2302/2018
TECHNICAL SPECIFICATION FOR 9.0 M LONG PCC POLES

(FOR BAREILLY AND FAIZABAD ZONE/GONDA ZONE) OF 400 KG. W/L
1. SCOPE:
This specification covers the design and manufacture of 9 Meter long, rectangular
shaped, solid prestressed cement concrete poles as per the reference at clause No. 2
required for creation of 11/33 KV urban distribution system.
2. STANDARD:
The poles shall conform in all respect IS as detailed below. Poles meeting any other
authoritative standard which ensure an equal or better quality than the standard
mentioned below will also be acceptable. In such cases the copy of standards
(English version) adopted should be enclosed with the tender.
i) IS: 1678/1998 Specification for prestressed
(Latest amended) concrete poles for overhead power
traction and telecommunication lines.
ii) IS: 2905/1989
(Latest amended) Method of test for concrete poles for
overhead power and telecommunication
lines.
iii) IS: 7321/1974
(Latest amended) Code of practice for selection, handling
and erection of concrete poles for
overhead power and telecommunication
lines.
3. CLIMATIC CONDITIONS:
Peak ambient temperature in 50 Degree C.
Shade.
i) Maximum average ambient 40 Degree C.
temperature in 24 hours period in
shade.
ii) Maximum temperature attainable 60 Degree C.
By an object exposed to sun.
iv) Maximum relative humidity 100%
v) Average number of thunder storm 40
days per annum
vi) Average number of rainy days 70
per annum
vii) Average annual rainfall 10-100 cm 105
viii) No. of months of tropical monsoon 4 months

Conditions.
xi) Maximum wind pressure 100 kg/ m2.
x) Altitudes not exceeding 1000 Mtrs.
4.0 PRINCIPAL PARAMETERS:
4.1 TYPE AND RATING:
9 meter long rectangular shaped, solid prestressed cement concrete poles for working
load 400 kg with factor of safety as 2 with following dimensions:
Bottom : 395 mm
Top : 225 mm
Breadth : 100 mm
No. of tensioned wires of 4 mm. (Indented) : 20 Nos.
Configuration type : As per REC manual No. 24/1983/
(Revised 1987)
5.0 MATERIALS:
The following quality of material should be used for manufacturing of PCC poles.
5.1 CEMENT:
The cement used in manufacture of prestressed concrete poles shall be 43 grade
ordinary Portland cement conforming to IS: 8112/1976 or IS: 8041- 1978
(Specification for rapid hardening Portland cement) or Portland slag cement
conforming to IS: 455 but with not more than 50% slag cement or 53 grade ordinary
Portland Cement conforming to IS 12269.
5.2 AGGREGATES:
Aggregates used for the manufacture of prestressed concrete poles shall conform to
IS 383/1970 (specification for coarse and fine aggregates from natural sources for
concrete). The nominal maximum size of coarse aggregates shall not exceed 12 mm.
Only coarse sand of FM not less than 2.5 is permissible.
5.3 WATER:
Water should be free from chlorides other salts and organic matter. Potable water is
generally suitable.
5.4 ADMIXTURES:
These admixtures should not contain calcium chloride or other chlorides and salts
which are to likely to promote corrosion of prestressing steel. The admixtures shall
conform to IS 9103
5.5. PRESTRESSING STEEL:
The pre stressing steel wires including those used as un-tensioned wires should
conform to IS: 1785 (Part. I) 1966 (Specification for plain hard drawn steel wire) or
IS: “6003/1983 (Specification for indented wire for pre stressed concrete)”. The type
design for Indented wires of 4 mm diameter are with a guaranteed ultimate Tensile
strength of 175 kg./sq. mm.
5.6. CONCRETE MIX: 106
The concrete mix. M45 grade shall be designed to the requirements laid down for
controlled concrete (also called design concrete requirement laid down / mix
concrete) in IS: 1343/1980 (Code of practice for pre stressed concrete) and IS:
456/2000 (code of practice for plain and reinforced concrete) subject to the following
special conditions:
a) Min. working cube strength at 28 days should be at least 450 kg./Sq. cm.
b) The mix. Should contain at least 380 kg. cement per cubic meter of concrete.
c) The concrete strength at transfer should be at least 245 kg. /Sq. cm.
d) The mix. Should contain as low water content as is consistent with adequate
workability. If it becomes necessary to add water to increase the workability
the cement content should also be raised in such a way that the original value
of water cement ratio is maintained.
e) Weigh Batcher should be used for mixing aggregates and coarse sand by
weight.
5.7. REINFORCEMENT:
The reinforcing bars and wires used for manufacturing of prestressed cement
concrete poles shall conform to the following Indian standards.
i) Mild steel bars conforming to IS: 432 Part-I & Part II.
ii) High tensile steel wires conforming to IS: 1786.
6.0 TECHNICAL REQUIREMENTS:
6.1 DESIGN REQUIREMENTS:
The poles shall be designed for the following requirements.
a) The poles shall be planted directly in the ground with a planting depth of 1.5
meters.
b) The working load on the poles shall be 400 kg. applied at 0.6 M from top.
c) The factor of safety shall not be less then 2.
d) The average permanent load should be 40% of the working load.
e) The factor of safety against first crack load shall be 1.0.
f) At the design value of first crack load the modulus of rupture shall not exceed
53 kg. / cm2.
g) The ultimate moment capacity in the longitudinal direction should be at least
one fourth of that in the transverse direction.
h) The max. compressive stress in concrete at the time of transfer of prestress
should not exceed 0.8 times the cube strength.
i) The concrete strength at transfer shall not be less then half of the 28 days
strength ensured in the design.
6.2 OTHER TECHNICAL REQUIREMENTS: 107
A EARTHING: Earthing shall be provided, by having continuous length of 4 mm dia

G.I. wire left projected from the transverse face of the poles to a length of 100 mm at
250 mm from top and 150 mm below ground level (Planting depth to be 1.5 M). The
tolerance of 25 mm shall be allowed in position of earth wire. The earth wire shall
not be allowed to entangle with prestressing wires. G.I. wire coatings should be
heavy as per IS 4826: 1979
MARKING: The poles shall be clearly marked by embossing during manufacture, the
following particulars at a height of 3 meters from the bottom end which should be
clearly visible/readable/legible.
1 Date, month and year of manufacture.
2 Sl. No. of pole
3 Name of manufacturer mark. It should be distinct and should not resemble with mark
of other manufacturers and if it is found that it resembles with marking of other
manufacturers then you should change your marking.
4 Wire “MVVNL”
6.3 GUARANTEED TECHNICAL PARTICULARS:
The tenderer must furnish the guaranteed technical particulars of the PCC poles as
required in the Volume-2 (B) by mentioning specific figures therein. Any item of the
GTP left unfilled or simply written as per ISS etc. shall be considered as incomplete
GTP and such tender is liable to be rejected.
6.4 SUPPLY OF RAW MATERIAL:
No assistance shall be provided by the purchaser for arranging, procuring the part /
full required quantity of any raw materials like cement, aggregates. HT steel wires,
MS rounds, etc. While quoting the delivery viz. commencement time and monthly
rate of supplies, this point should be kept in view.
7 INSPECTION:
Inspection shall comprise of:
a) Visual inspection for shape, workmanship and finish of the PCC poles.
b) Checking of dimensions/quantity as per the GTP.
c) Witness of tests:
i) On PCC poles for its transverse load strength, and
ii) Testing arrangement shall be preferably as specified in the relevant
specification i.e. IS: 1678/1998 and IS: 2905/ 1989 (both latest
amended). As per provision of clause No. 6.2.3 of IS: 2905/ 1989, the
load shall be applied at a point stipulated in the relevant IS by means of
a suitable device such as a wire rope and which placed in a direction
normal to the relevant IS by means of a suitable device such as a wire
rope and which placed in a direction normal to the direction of the
length of the pole so that the minimum length of the pole under pull is
not less than the length of the pole.
As per provision of clause No. 6.2.5 of IS-2905/1989 (latest amended)” load
measurement”, the dynamometer or any other satisfactory method of load
measurement shall be calibrated at regular intervals and capable of measuring load to 108
the accuracy of 50 N may be adopted.

The supplier should have transverse load testing arrangements of its own.
d) TOLERANCE:
The following tolerances shall be allowed.
i) Over all length of PCC poles. + 15 mm
ii) Top and bottom dimension. + 5 mm
iii) Clear concrete cover over HT steel + 1 mm
Wires (Average of measurements at three
Sections)
iv) Uprightness of the PCC poles. 0.5%
v) Diameter of HT wires as per IS: 6003/1983 + 0.05mm
vi) Diameter of GT wires as per IS: 280/1978 + 2.5%
vii) Diameter of M.S. Rod for Eye hook as per IS: 1786/1966 + 4%.
The material used with negative tolerance more than above tolerance in the pole will not
be acceptable.
All the tests (as mentioned above) and Inspection shall be made at the place of
manufacture unless otherwise especially agreed upon by the bidder and purchaser at the time
of purchase. The bidder shall afford the inspection officer (s) representing the purchaser all
reasonable facilities without charges, to satisfy him that the material is being furnished in
accordance with this specification. The purchaser has the right to have the tests carried out at
this own cost by an independent agency whenever there is a dispute regarding the quality of
supply.
The Inspection may be carried out by the purchaser at any stage of manufacture/ before
dispatch as per relevant standard.
Inspection and acceptance of any material under the specification by the purchaser,
shall not relieve the bidder of his obligation of furnishing material in accordance with the
specification and shall not prevent subsequent rejection if the material is found to be
substandard. The Bidder shall keep the purchaser informed in advance, about manufacturing
programme so that arrangements can be made for inspection.
The purchaser reserves the right to insist for witnessing the acceptance/ routine testing
of the bought out items.
The bidder shall give 15 days (for local supplies) /30 days (in case of foreign bidder) 109
advance intimation to enable the purchaser to depute his representative for witnessing the
acceptance and routine tests. The inspection charges (inspectors traveling, boarding/
lodging) would be to the purchaser’s account.
NOTE FOR FOREIGN BIDDER:
The Bidder shall indicate the name(s) of reputed inspection agencies and their
inspection charges clearly for each lot. The Inspection charges will be borne by the
purchaser. However, the purchaser reserves the right to appoint at its cost any inspection
agency to carry out the inspection.
8 SAMPLING:
a) Randomness is the pre requisite for sample checking and testing. Starting from any
random serial number or PCC poles in the offered lot (arranged serial number wise
and sub-divided sub-lots each not exceeding 500 Nos. of poles) every pole shall be
included in the sample “r” being the next higher integral part of N/n where N is the
size of the lot or sub-lot and “n” is the sample size as per the table below: -
Sample size and criterion for conformity:
Size of lot or sub- Dimensional requirement No of sample poles
lot (N) for transverse
Sample size (n) Permissible No. of strength test (r)
defective samples (Till breakage)
Upto 100 10 1 1
101 to 200 15 1 3
201 to 300 20 2 4
301 to 500 30 3 5
The minimum size of lot which can be offered for inspection is 500 Nos.
except in case of last lot which will be balance quantity left. Lots size once offered
for inspection cannot be reduced subsequently under the re-inspection if required
unless re inspection charges for each sub lots out of the original lot are deposited.
b) Deviation in selection of samples may be effected by the inspecting officer only if he
thinks that the purpose of checking/testing will be better served by such deviation.
c) The number of poles, in every lot/sub lot, which does not satisfy, the requirement of
overall length, cross section and uprightness shall not exceed the corresponding
number given in col.3 of the above Table. If the number of such poles exceeds the
corresponding number, supplier shall segregate the pole not conforming to the
requirement of specification and shall submit the remaining poles for checking. Fresh
poles as per sample size indicating in col.2 will be drawn from the remaining poles
also exceeds the permissible number indicated in Col.3 then the subject lot or sub lot
under inspection will be rejected without further checking. Result of all such
checking shall be recorded.
d) PCC poles, in every lot/sub lot sampled for transverse load strength test shall satisfy
the requirement of the test. If one or more poles fail, twice the number of poles
originally tested shall be selected as before and subjected to the test. If there is no
failure among these poles the lot or sub lot under inspection shall be considered to
have satisfied the requirements of this test. All result shall be recorded.
All of the poles subjected to transverse load strength test shall be reserved for 110
at least 7 days from the date of inspection for any subsequent checking by any other
representative of the purchaser, if required. These poles shall not be
dispatched/supplied to the purchaser.
e) The pole out of these already subjected to transverse load strength test, from every
lot/sub lot, shall be destructed to:
i) Measure clear thickness of concrete cover at three points one within 1 metre
from the butt end of the pole, the second within 0.6 metre from the top end of
the pole and the third at an inter mediate point and the mean value compared
with the specified value.
ii) Check size, quantity and configuration of steel reinforcement and GI earth
wire.
iii) The destructed poles shall also be preserved for at least seven days from the
date of inspection for subsequent checking by any other representative of the
purchaser if required. In case of foreign bidders, this period shall be fifteen
days.
The tenderer shall invariably furnish the following information along with his offer,
failing which his offer shall be liable for rejection. Information shall be separately
given for individual type of equipment offered.
i) Statement giving list of important raw materials, name of sub-suppliers for the
raw materials, list of standards according to which the raw materials are
tested. List of tests normally carried out on raw materials in presence of
tenderer’s representative, copies of tests certificates.
ii) Information and copies of test certification as in (i) above in respect of bought
out accessories.
iii) List of manufacturing facilities available.
iv) Level of automation achieved and list of areas where manual processing
exists.
v) List of areas in manufacturing process, where stage inspections are normally
carried out for quality control and details of such tests and inspections.
vi) Special features provided in the equipments to make it maintenance free.
vii) List of testing equipments and apparatus along with their date of calibration,
available with the tenderer for testing of pole specified and test plant
limitation, if any, vis-à-vis the type, special acceptance and routine tests as
specified in the relevant standards. These limitations shall be very clearly
brought out in schedule of deviations from specified tests requirements.
9.1 The successful tenderer shall within 30 days of placement of order, submit following
i) List of raw material as well as bought out accessories and the name of sub-
suppliers selected from those furnished along with offer.
ii) Quality assurance plan (QAP) with hold points for purchaser’s inspection. The
quality assurance plan and purchasers hold points shall be discussed between the
purchaser and the supplier, before the QAP is finalized.
9.2 The successful tenderers shall submit the routine tests certificates of bought out
accessories and central excise passes for raw materials at the time of routine test.
10.0 DOCUMENTATION
All drawings based on the drawing (as enclosed) of REC specification No. 111
24/1983 (amended upto 1987). All drawings shall be in ink and suitable for
microfilming. All dimensions and data shall be in SI units.
10.1 LIST OF DRAWINGS AND DOCUMENTS:
a) Detailed dimensional drawing of pole
b) Sectional view showing –
i) Configuration of HT wires size and No. of HT wires eye hooks positions and
projection of earth wire marking and reinforcement.
ii) Test reports, literature, pamphlets of the bought out items, and raw material.
10.2 The successful tenderer shall, within two weeks of placement of order, submit three sets
of final versions of all the above said drawings for purchaser’s approval.
10.3 The manufacturing of the poles shall be strictly in accordance with the approved drawing
and no deviation shall be permitted without the written approval of the purchaser. All
manufacturing and fabrication in connection with the pole prior to the approval of the
drawing shall be at the suppliers risk.
11.0 SPECIAL AND IMPORTANT CONDITIONS OF THE TENDER:
I. The price of 9 m long pcc pole shall be firm and firm in all respect and the
Tenderer must quote accordingly.
II Tenderer must quote for a minimum of 650 nos. 9 m long pcc poles,
otherwise their tender shall not be considered.
Incase of any ambiguity in quoting the above rates, the tender is liable to be
rejected.
III ‘Proven design’ as mentioned in clause No.1.2.6 of Instruction to Tenderers
implies that the drawing & design calculation of 9.0 M Long PCC Pole should be
got approved by a govt. approved Institution of national repute.
IV Date of R/R shall be deemed to be date of delivery for dispatch by rail, the data of
receipt of material in purchaser’s store shall be deemed to be the date of delivery
for dispatch by Road.
V No payment shall be made for broken pole to the extent of 1% or more during
inspection/testing out of the lot offered for inspection.
VI THE BIDDER SHOULD SIGN AND STAMP EACH PAGE OF THE BIDS ITS
ANNEXURE/DOCUMENTS NECESSARILY.
VII Incase of any Inconsistency the provisions contained above shall prevail.
VIII The tender part II (price part) of bidders who quote poles of cross-sections
different form that mentioned in the tender specification shall not be opened.
IX Tenderers are required to give their cost analysis of one 9.0 M Long PCC Pole
charges Bank interest on capital borrowed, profit etc.
X The tender part-II (Price Part) of bidders who quote poles of cross-sections
different from that mentioned in the tender specification shall not be opened.
XI Tenderers are required to give their cost analysis of one 9.0 M Long PCC Pole
charges Bank interest on capital borrowed, profit etc., in enclosed proforma.
Tenderers may offer for either type of poles 9.0 M
112
11.0 QUALITY ASSURANCE PLAN :

11.1 The Bidder shall invariably furnish the following information along with his bid, failing which
his bid shall be liable for rejection. Information shall be separately given for individual type of
material offered.
i. Statement giving list of important raw materials/accessories, names of sub- suppliers
for the raw materials, list of standards according to which the raw materials are tested,
list of test normally carried out on raw materials in presence of Bidder’s representative,
copies of test certificates. (Note:- The list of suppliers/accessories out of the list
provided by the bidder shall be approved by the purchaser, but in case of any
deviations the same should be got approved. Submitting a request to the purchase along
with reasons for such deviations)
ii. Information and copies of test certificates as in (i) above in respect of bought out
accessories.
iii. List of manufacturing facilities available.
iv. Level of automation achieved and list of areas where manual processing exists.
v. List of areas in manufacturing process, where stage inspections are normally carried
out for quality control and details of such tests and inspections.
vi. Lists of testing equipment available with the bidder for final testing of equipment
specified and test plant limitation, if any, vis-à-vis the type, special acceptance and
routine tests specified in the relevant standards. These limitations shall be very clearly
brought out in schedule of deviations from specified test requirements.
i. List of raw materials as well as bought out accessories and the names of sub-suppliers
selected from those furnished along with offers.
ii. Type test certificates of the raw materials and bought out accessories if required by the
purchaser.
iii. Quality assurance plan (QAP) with hold points for purchaser’s inspection. The quality
assurance plan and purchasers hold points shall be discussed between the purchaser
and bidder before the QAP is finalized.
11.3 The contractor shall operate systems which implement the following
i. Hold Point : A stage in the material procurement or workmanship process beyond
which work shall not proceed without the documental approval of designated
individuals or organizations. The purchaser’s written approval is required to authorize
work to progress beyond the hold points indicated in quality assurance plans.
ii. Notification Point : A stage in the material procurement or workmanship process for
which advance notice of the activity is required to facilitate witness. If the purchaser
does not attend after receiving documented notification in accordance with the agreed
procedures and with the correct period of notice then work may proceed.
11.4 The successful bidder shall submit the routine test certificate of bought out accessories and
central excise passes for raw material at the time of routine testing if required by the purchaser
and ensure that Quality Assurance requirements of this specification are followed by the sub-
contractors. The Quality Assurance program of the contractor shall consist of the quality
systems and quality plans with the following details.
i. Quality System :
The structure of the organization.
The duties and responsibilities assigned to staff ensuring quality of work.
The system for purchasing, taking delivery and verification of materials 113
The system for ensuring quality workmanship.

The system for retention of records.
The arrangements for contractor’s internal auditing.
A list of administration and work procedures required to achieve and verify contracts
quality requirements. These procedures shall be made readily available to the project
manager for inspection on request.
ii. Quality Plans :
An outline of the proposed work and program sequence.
The structure of the contractors organization for the contract.
The duties and responsibilities assigned to staff ensuring quality of work
Hold and Notification points.
Submission of Engineering documents required by the specification.
The inspection of materials and components on receipt.
Reference to the contractor’s work procedures appropriate to each activity.
Inspection during fabrication/construction.
Final Inspection and test.
GURANTEED 114
115
Steel Tubular Poles for Overhead Lines
1 SCOPE:
This specification covers the general requirements towards design, manufacture,
testing at manufacturers works, supply and delivery for tubular steel poles of circular
cross section ( swaged type ) for overhead lines.
2 STANDARD:
The tubular steel poles shall conform to the latest edition of Indian Standard
specification IS: 2713 (Part – I, III): 1980 or any other authoritative standards (as
amended up-to- date) except where specified otherwise in this specification.
3 Topography and Climatic Condition:

The materials offered, shall be suitable for operation in tropical climate and will be
subjected to the sun and inclement weather and shall be able to withstand wide range of
temperature variation. For the purpose of design, average atmospheric temperature may
be considered to be 50ºC with humidity nearing saturation.
4 Materials:
4.1 The materials used in construction of tubular steel poles shall be of the tested
quality of steels of minimum tensile strength 410 MPa (42 Kgf/mm2).
4.2 The materials, when analysed in accordance with IS: 228 (Part-III: 1972) and IS :
228 ( Part-IX) shall not show sulpher and phosphorous contents of more than 0.060
percent each.
5 Types, Size and construction:
5.1 Tubular Steel Poles shall be swaged type.

The poles required under this specification are as below: -
1. Steel Tubular Poles (410 SP-31) 9.00 Meter Length.
5.2 Swaged poles shall be made of seamless or welded tubes of suitable lengths swaged
and jointed together. No circumferential joints shall be permitted in the individual tube
lengths of the poles. If welded tubes are used they shall have one longitudinal weld seam
only: and the longitudinal welds shall be staggered at each swaged joint.
5.3 Swaging may be done by any mechanical process. The upper edge of each joint
shall be chamfered if at an angle of about 45o. The upper edge need not be chamfered if
116
a circumferential weld is to be deposited in accordance with clause No. 5.3 2 of IS: 2713
( Part-I):1980.
5.4 The length of joints on swaged poles shall be in accordance with clause No. 5.4 of
IS: 2713 (Par-I): 1980.
5.5. Poles shall be well-finished, clean and free from harmful surface defects. Ends of
the poles shall be cut square. Poles shall be straight, smooth and culindrical. The weld
joints, if any, shall be of good quality, free from scale, surface defects, cracks, etc.
5.6. Tolerances for outside diameter, thickness, length, weight and straightness shall be
in accordance with IS: 2713 (Part-I) : 1980.
5.7. The poles shall be coated with black bituminous paint conforming to IS: 158-1968
throughout, internally and externally, upto the level which goes inside the earth. The
remaining portion of the exterior shall be painted with one coat of red oxide primer as
specified in IS: 2074-1979.
6 Earthing Arrangements:
For earthing arrangement a through hole of 14mm diameter shall be provided in each
pole at a height of 300mm above the planting depth.
7 Tests and Test Certificates:
7.1 The following tests shall be conducted on finished poles:
A. Tensile test and chemical analysis for sulpher and phosphorous,

B. Deflocation test,
C. Permanent set test, and
D. Drop test.
7.2 In addition to above verification of dimensions as per IS: 2713 (Part-III) : 1980
shall be carried out during acceptance lots.
7.3 Number of poles selected for conducting different tests shall be in accordance to
clause No. 10.1.1 and No. 10.1.12: of IS: 2713 (Part-I) 1980.
7.4 Tests shall be carried out before supply of each consignment at the manufacturers
woks and test certificates should be submitted to the purchaser for approval prior to
delivery.
117
7.5 Re-tests, if any, shall be made in accordance with IS: 2713 (Part-I) 1980.
7.6 Purchaser reserves the right to inspect during manufacturing and depute his
representative to inspect/test at the works.
7.7 If any extra cost is required for carrying out the above specified tests, the same
shall be borne by the manufacturer.
8 Marking:
8.1 The poles shall be marked with designation, manufacturer’s identification, year of
manufacture and name of the purchaser: Employer Name; RDSS:
Respective DISCOM/Manufacturer’s name/ Year of Manufacturing/RDSS
8.2 The poles may also be marked with the ISI certification mark.
9 Guaranteed technical particulars:
9.1 The manufacturer shall furnish all necessary guaranteed technical particulars in the
prescribed Performa enclosed hereinafter.
10 Performance:-
10.1The manufacturer shall furnish a list of the major supplies effected during the last
3 (three) years indicating the volume of supply and actual delivery dates.
10.2Manufacturer may not be considered if the past manufacturing experience is found

to be less that 3 (three) years.
11 Deviation:-
Any deviation in technical specification shall be clearly indicated with sufficient
reasons thereof. Purchaser shall however reserve the right to accept and/or reject the
same without assigning any reasons what-so-ever.
118
ANNEXURE –‘A’
SPECIFIC TECHNICAL REQUIREMENTS FOR TUBULAR STEEL POLES :

SWAGED TYPE
9 meters long 11 meters long 13 meters long

1) Standard IS: 2713 ( Pat-I and III): 1980 as amended upto date
2) Type of Pole Swaged Type
3) Designation 410 SP 31 410 SP 55 410 SP 72
4) Overall Length 9 meters 11 meters 13 meters
5) Planting depth 1.5 meters 1.8 meters 2.0 meters
6) Height above ground 7.5 meters 9.2 meters 11.0 meters
7) Effective length of
Each section.
a) Bottom 5 meters 5.6 meters 5.80 meters
b) Middle 2 meters 2.7 meters 3.60 meters
c) Top 2 meters 2.7 meters 3.60 meters
8) Outside diameter and
Thickness of each
Section.
a) Bottom 165.1 X 4.50 mm 193.7x4.85 mm 219.1x5.90 mm
b) Middle 139.7 X 4.50 mm 165.1x4.50 mm 193.7x4.85 mm
c) Top 114.3 X 3.65 mm 139.7.x4.50 mm 165.1x4.50 mm
9) Joint Length ( in cm.):
a) Bottom (J2) 35 cm 40 cm. 45 cm.
b) Top (J1) 30 cm 35 cm. 40 cm.
10) Approximate weight 147 kg
227 Kg. 343 Kg.
of Pole
11)Point of application
0.3 mtr (from top) 0.6 mtr.(from top) 0.6 mtr (from top)
of load below/top (mtr.)
12)Breaking load (inKgf
517 650 828
)
13) Working load with
factor of Safety : 2.5 ( in 207 308 331
Kgf )
14) Crippling load (
367 462 588
inKgf )
15) Load for permanent
set Not exceeding 251 316 527
13mm (in Kgf)
16) Load for Temporary
Deflection of 157.5 mm 139 130 121
(in Kgf)
119
17)Minimum tensile
strength of steel used in
42 42 42
manufacturingof
poles(kg.f mm2
18) Tolerance As per IS : 2713 ( Part-I & Part-III): 1980
19) Finish -do-
20) Manufacturing -do-
clause
120
TECHNICAL SPECIFICATION FOR 1.98 & 3.96 MVAR, 11 KV,

OUTDOOR TYPE AUTOMATICALLY SWITCHED H.T. SHUNT
CAPACTIOR BANK ALONG WITH
11 KV CAPACITOR CONTROL PANEL
1.0 SCOPE
This specification cover design, engineering, manufacture, assembly, stage testing,
inspection and testing before supply and delivery at various Store/Center/destination, of
1.98 & 3.96 MVAR, 11KV rates and designed for 12.65 KV, outdoor, type shunt
Capacitor Banks automatically switched in steps along with associated equipments and
accessories that may be required for proper functioning of the capacitor Banks & to be
installed on 5 MVA and 10 MVA, 33/11 KV Power Transformers. Circuit Breaker Control
& Relay panels are also covered in the scope of supply.
1.1 It is not be the intent to specify completely here in all the details of design and
construction of material. However the material shall conform in all respects to high
standards of Engineering, design and workmanship operation in manner acceptable to
the purchaser, who will interpret the meanings of drawings and specification and shall
have the power to reject any work or material which in his judgment is not in
accordance therewith. The offered material shall be complete with all components
necessary for their effective and trouble free operation. Such components shall be
deemed to be within the scope of bidders supply irrespective of whether these are
specifically brought out in this specification and/or Purchase order or not.
1.2 In order to ascertain the highest reliability of system offered Capacitor Banks, Automatic
Power Factor Controller and Vacuum Contactors shall be from manufactured by single
company.
1.3
2.0 STANDARDS
The equipment shall conform (for performance and testing thereof) in all respects to the
relevant Indian/International Standards specifications with latest amendments thereto.
2.1 INDIAN STANDARDS

ISS NO. Title
13925:1998 Specification for H.T. shunt Capacitor
IS 9920-2002 Vacuum Contactors/ Capacitor Switch
IS 9921 -1985 Isolator
IS 2705 Current Transformer
IS 3070 Lighting Arrestor
IS 3156 Residual Voltage Transformer.
IS 5553 Series Reactor
IEC 61000 Automatic Power Factor Controller
The other components such as VCB panel & other auxiliary equipments shall comply
with the latest version of latest Indian/International standards.
2.3 Equipment conforming to other internationally accepted standards which ensure equal or
higher quality than the above mentioned standards would also be acceptable. In such
case bidders, who wish to offer material conforming to standards other than listed above,
shall clearly bring the salient points of difference between the standards forward/adopted
and specified hereinabove. Four copies of such standards with authentic English
Translation shall be furnished along with the offer. In case of conflict order of preference
121
shall be (1) ISS (2) IEC (3) other standards. In case of any difference between
provisions of these standards and provision of this specification the provision contained
in this specification shall prevail.
30 SERVICE CONDITIONS
The capacitor Bank to be supplied against this specification shall be required to operate
satisfactorily and continually under the following moderately hot and humid tropical
climate conducive to rust and fungus growth
 Location: - At various location in Uttar Pradesh
 Maximum ambient air temperature (deg. C) 50
 Minimum ambient temperature (deg. C) (-)5
 Average daily ambient air temperature (deg/C) 40
 Maximum relative Humidity (%) 100
 Maximum altitude above sea level (M) 1000
 Average annual rainfall (MM) 1200
 Isoceraunic level (days per year) 50
 Sciemic level (Horigental accn.) 0.30 g
 Maximum wind pressure 0kg/sqm) 195
40 PRINCIPAL PARAMETER
The equipment covered under this specification shall conform to specific parameters
given below:
4.1 CAPCITOR BANKS
Sl. No. Item Specification
1. Nominal system voltage 11 KV

2. Rated voltage of capacitor bank 12.65 KV
Output of capacitor bank at 12.65 KV 1980 & 3960 KVAR
4. Rated line current 90.36 & 180.73Amp.
5. Connection of capacitor bank Single star
6. No. of phases 3
7. Rated voltage of individual capacitor unit 7.3
8. Capacity of individual capacitor unit 132 , 264 & 396 KVAR
9. Insulation level RMS-28 KV
Peak -75 KV
10. Maximum temp. rise over 10 C
ambient on container
measured
11. Type of discharge Internally though resistor provided
within the Unit
12. Type of fuse Internal fuse
13. Type of installation Outdoors
14. Power loss (Tan delta) Not to exceed 0.2 watt/KVAR
subject to tolerance as per
standard.
122
Capacitor Bank Rating:
Sl.No. Transformer Rating of Capacitor Steps configuration

Capacity (MVA) Bank (MVAr) kVAr X No. of Steps
(Switched)
1 5 1.98 396+792+792
2 10 3.96 792+792+1188+1188
Note: The stages may be changed during detailed engineering Residual Voltage Transformer
4.3
Sl. Item Specification
No.
1. Nominal system voltage 11KV
2. Voltage ratio 11KV/110 V-190V
3. Mode of connection Star/Star /Open delta
4. Rated Burden 100 VA
5. Type Oil cooled, out door
6. Accuracy class 1/ 3P
7. Type of core 5 limb Construction
8. Terminal arrangements H.V. side 4 Nos. 11 KV
bushing
L.V. side Terminal Box
9. Insulation level RMS-28 KV Peak-75 KV
5.0 TECHICAL REQUIREMENT
5.1 CAPACITOR UNITS
The capacitor shall be of unit type construction suitable for outdoor installation having
high dielectric strength. No sun protection will be provided. The capacitor bank shall be
complete with mounting frames, insulators and all other components for formation of
capacitor bank. The bank shall be open type complete with inter connecting aluminum
bus bars and adequate clearance shall be provided between phases and phase to earth.
An elevating structure shall be provided for each bank so as to get minimum ground
clearance of 2.5 meters to lowest live part to bank. Necessary foundation bolts & nuts
shall also be supplied. The outside of the capacitor container and other structures
should have smooth and tidy look and should hot dip galvanized.
The capacitor should be able to withstand 10% overvoltage and 30% over current
(r.m.s. value) arising due to over voltage and harmonics
5.2 ASSEMBLY
Capacitor units of 132, 264 & 396 KVAR, 7.3 single phase shall be connected in
parallel in each phase to form a three phase star connected capacitor bank. The
bank shall be mounted on a steel frame work in suitable one/two tier formation and shall
be so arranged that an individual unit of 132, 264 & 396 KVAR can be removed easily
without disturbing the complete assembly/ other units.
123
5.3 CONTRUCTION OF CAPACITOR UNIT
A. CONTAINER
The container shall be built from CRCA of sufficient thickness (not less than 1.6 mm) to
avoid damages to the tank in case of internal fault. It shall be of fabricated construction
with all joints properly welded and designed to withstand rough handing and should be
hydraulically tested before assembling the internal elements. It shall be adequately
epoxy pointed. The lid of container shall be properly welded to the container.
The capacitor unit shall be hermetically sealed after the entire assembly has been
dried and impregnated with suitable liquid (Dielectric.) The capacitor elements shall
be thoroughly dried and impregnated with an impregnant which has been completely
refined and degasified so as not to have any impurities or gas which may cause
deterioration of the dielectric. The impregnant used shall have low viscosity and high
chemical stability and should be non-PCB. The steel container shall be adequately
insulated from capacitor elements. Sufficient 'Wall' insulation shall be provided so that
the capacitor units meant for use of 11 KV nominal system can be place directly on
grounded steel structures. The metallic surface of capacitor units shall be epoxy painted
making capacitor units suitable for installing outdoor under moist tropical climatic
conditions.
B. CAPACITOR UNIT
The capacitor unit shall have aluminum foil as conducting layer. The dielectric used shall
be polypropylene film by using layers of polypropylene film shall have the following
compatibility criterion: -
(i) Polypropylene film shall conform to standard specification with latest amendments,
for plastic film for new generation.
(ii) Compatibility between oil film (after thermal aging at 115 C for 96 Hrs.)
The impregnant used shall be non PCB liquid with low be accumulating, rapid bio
degradation and low toxicity. Adequate number of such elements shall be assembled and
enclosed in the enclosure to form a single phase unit with terminal bushings. The air in
the enclosure and moisture absorbed by the paper shall be removed under high vacuum
at elevated temperature and replaced by suitable impregnating medium having high
permeability, high dielectric strength and non-inflammable properties.
C. DISCHARGE DEVICE:
Suitable discharge device shall be connected across the capacitor unit in accordance
with IS: 13925. The discharge device shall reduce the residual voltage from the crest
value of the rated voltage to 50 V the or less within 10 Minutes after the capacitor
is disconnected from the source supply.
D. EARTHING CONNECTIONS:
The container of each capacitor unit shall be provided with suitable earthing terminal
clearly marked with Earth symbol.
E. MARKING:
The capacitor unit shall be provided with a rating plate and terminal markings as
stipulated in IS: 13925. The bidder shall submit the type test report along with the bid.
F. FUSES
Each capacitor element shall be protected by external expulsion fuse of
124
suitable rating and interruption capacity so that a faulty capacitor element shall be
disconnected by fuse. The fuse shall satisfactorily operate under ambient conditions.
The following requirements shall be considered while selecting the right size of fuse.
a. Ability to withstand the maximum discharge current from healthy capacitor
element.
b. Capability of handing fault current so as to Blow off before the in case rupture
takes place thereby avoiding damage to adjoining capacitor
elements/capacitor
units.
G. BUSHINGS
Bushing shall be of porcelain or polycrete and shall be jointed to the case by welding
method (Weldable type bushing) to ensure adequate and permanent seal. Leads shall
be brought out through one-piece bushing and welded to the terminal stud to make a
strong and positive electrical contract. Bushing terminal shall be of stainless steel.
5.4 PHYSICAL ARANGEMENT OF BANK

Star point of the capacitor bank shall be ungrounded. The mounting rack arrangement
shall be such that one no. additional unit in each phase can be installed in future for
increasing capacity.
5.5 AUTOMATIC CONTROL UNIT
(a) Switching Arrangement:

The Automatic control unit shall be provided inside the control; room to
continuously monitor total load KVAR on secondary side of the transformer and
shall automatically switch ON or switch OFF the capacitor banks through the operation
of 12 KV Capacitor Switch in accordance with the parameter given in table no. 4.2
Overriding provision shall also be made for electrical switching ON or OFF of the
capacitor switch by the operator from the ACU control box.
(b) Time Delay:

The switching ON operation will take place after period of 10 minutes. The
switching OFF operation of relevant steps will be instantaneous.
(c) Controls:
The Automatic control unit shall instantly switch OFF the capacitor bank in the following
Contingencies occurring in any of the phases.
i) Voltage increased by 10% above the rated voltage of 11 KV.
ii) Power transformer current impedance (due to single phasing and for any
other reasons) between any of the two phases exceeding 20% of the lowest, iii) Current
increases in any capacitor unit by 30% above the rated current (only the relevant
capacitor switch will open).Current between any of the two phases of the capacitor bank
differs more than 15% of the lowest current of the 3 phases (only the relevant capacitor
switch will open).
(d) Monitoring Facility:

A suitable display should be provided to indicate the capacitor current in each phases
of the complete capacitor bank on the ACU panel inside the control room. Indications
shall also be provided to indicate ON & OFF status of each capacitor bank. Along with
125
audio alarm indicating tripping of capacitor bank and ON /OFF, visual display window be
provided on control panel. Automatic Control unit shall have
GSM(4G/3G/2G/GPRS)/CDMA connectivity; suitable modem shall be connected along with
control unit to transfer the data to remote locations. Provision of SIM will be under the scope
of bidder. Bidder has to provide online Dashboard to the PUVVNL, VARANASI users as per
their requirements, Capable to show real time data and capable to generate MIS as per
requirement .Bidder has to establish secure head end system on cloud which will be under
the scope of bidder. Data transferred from Modem to Head end system through secure APN
SIM, for the entire agreemented period.
GSM / GPRS MODEM Specifications:
• Quad-band 850/900/1800/1900MHz
• GPRS multi-slot class 12/10
• GPRS mobile station class B
• Compliant to GSM phase 2/2+
– Class 4 (2 W @ 850/900MHz)
– Class 1 (1 W @ 1800/1900MHz)
• Control via AT Commands (3GPP TS 27.007, 27.005 and enhanced AT Commands)
(e) Control Power:

The AC control voltage for operation of the ACU shall be taken from substation
battery. The required control voltage shall be 230 VAC supply.
(f) Temperature Variation:

The control equipment and associate circuitry shall be suitable for operation at an
ambient temperature in the range of + 5 deg C to (+) 50 deg C.
(g) Protection of ACU:

Besides in-built protection against lines surges and transient over voltages, suitable
fuses/MCB shall be provided for protection against over current. The ACU shall remain
fully functional during and after line surges and transient over voltages.
(h) Control Unit Casing:

Except for the terminals, the ACU shall be enclosed in a suitable casing so as to avoid
ingress of dust.
ACU should be installed at inside of substation on Floor mounting arrangement.
56 CAPACITOR SWITCHES
This specification covers 11 KV, 50 Hz, Outdoor type automatic Capacitor Switch
suitable for switching capacitor in steps.
(a) Applicable Standards:

Unless otherwise stipulated in this specification the Capacitor Switch shall comply with
the latest version of IS:9920 (AC Switches for voltages above 1000 V).
(b) Rated Voltage:

The rated voltage for the Capacitor Switch shall be 12 KV. This represents the highest
system voltage corresponding to the nominal system voltage of 11 KV.
126
(c) Rated Current:

The standard rated normal current shall be 200A
(d) Rated Capacitive Switching Current:

The rated capacitive switching current shall not be less than 200 A Note: The
capability of the Capacitor Switch shall also take into account the parallel switching of
capacitor bank steps.
(e) Rated Short Time Current:

The rated short time symmetrical current for 1 second shall be 10KA (rms AC.
component).
(f) Rated Making Current:

The rated making current shall be 2.5 times the rms value of the a.c. component of rated
short time capacity.
(g) Basic Impulse Level (BIL):

The rated basic impulse level of Capacitor Switch to earth as also across the open
terminals shall be 75 KV.
(h) Control Supply:

The control power for closing the Capacitor Switch shall be 230 V single phase AC
supply. The closing mechanism shall be suitable for a voltage variation of (+) 10% to (-)
20%.
(i) Design & Construction Requirement:

Type:
a. The Capacitor Switch shall be of vacuum type.
b. The Capacitor Switch shall be of three phase construction and shall be suitable
for remote operation.
c. The Capacitor Switch shall be suitable for outdoor installation and shall have
sealed weather proof type construction.
d. The Capacitor Switch shall be provided with a mechanical indicator to
show whether the switch is in open/closed position, locally, as also through
indication on the ACU panel.
e. The metallic enclosure of the Capacitor Switch shall be provided with two earthing
terminals marked with the earth symbol.
f. The bushings provided on the switch shall have clamp type of terminals to directly
receive aluminium conductors up to 10mm dia in both horizontal
and vertical directions. The terminal arrangement shall be such as to avoid
bimetallic corrosion.
(j) Operating Mechanism:

The operating mechanism shall be either solenoid or motor charged spring for which the
control supply shall be as per clause 31.
(k) Mechanical and Electrical Endurance:

The Capacitor Switch shall be capable of performing not less than 10,000
mechanical operations and 10,000 electrical operations at 50A capacitive current
without getting damaged.
(l) Marking:
127
The Capacitor Switch shall be provided with a legible and indelibly marked name
plate with the following:
a) Name of the manufacturer.
b) Type, designation and serial number.
c) Rated voltage and current.
d) Rated frequency.
e) Number of poles.
f) Rated short time current (symmetrical).
g) Rated making current.
h) Rated capacitive switching current.
i) Date of manufacturing.
j) Property of respective DISCOM
(m) Testes: The Capacitor Switch shall be subjected to the following tests in accordance with
the IS:9920 (Part-IV),
(i) Type Tests

a) Tests to verify the insulation level, including withstand tests at power
frequency voltages on auxiliary equipment.
b) Tests to prove that the temperature rise of any part does not exceed the
specified values.
c) Making and breaking tests including tests for the rated capacitive current.
d) Tests to prove the capability of the switch to carry the rated short time current.
e) Tests to prove satisfactory operation and mechanical/electrical
endurance.
(ii) Routine Tests

a) Power frequency voltage dry tests.
b) Voltage tests for auxiliary circuits.
c) Measurement of the resistance of the main circuits.
d) Tests to prove satisfactory operation.
5.7 AUXILARY EQUIPMENTS

(a) Isolator:
(i) The Isolator shall be Outdoor type, 11 KV, 400Amp, Single throw, Double break,
off load type, triple pole, Horizontal gang operated with earth switch.
(ii) Tests: The Isolator shall be type tested and shall be subjected to routine
and acceptance test in accordance with IS: 1818-1972.
(iii) The bidder shall submit guaranteed technical particulars along with their bid.
5.8. LIGHTNING ARRESTOR

(i) The specification covers the supply, delivery, erection, testing &
commissioning of 9
(ii) KV, 10 KA, Station class heavy duty, gapless, metal (zinc) oxide
surge arrestors complete along with clamps, complete fitting and
accessories for installation on outdoor type 11 KV switchgear, transmission
lines, transformers etc.
a. Tests: The Lightning Arrestors shall be type tested and shall be
subjected to routine and acceptance test in accordance with IS: 3070.
(iii) The bidder shall submit guaranteed technical particulars along with their bid.
5.9 RESIDUAL VOLTAGE TRANSFORMERS

128
The residual voltage transformers shall be out door type, oil cooled with primary in star
and secondary in star & tertiary in open delta formation. The neutral of the primary
winding shall kept fully insulated and would be isolated from ground. The tertiary
winding in open delta shall be used to energise the neutral unbalanced voltage withstand
relay. The RVT should be suitable to discharge the capacitor bank to voltage not
exceeding as per standards with latest amendments thereof. The RVT should be
designed to with stand the temperature rise due to energy discharge in to it capacitors in
case of tripping. All the type test as per IS including temperature rise test should be
furnished.
5.10 EXPULSION FUSES

Suitable outdoor type 11 KV expulsion fuses along with the mounting insulators etc.
to provide proper protection for the capacitor unit shall form part of the equipment to be
supplied.
5.11 SERIES REACTORS

0.2 % Series reactor per phase per step of capacitor rating for inrush current
restriction to be connected on neutral end as per IS: 5553. The rated voltage shall be
12 KV. The reactor shall be dry type single phase reactors mounted on post insulators
and designed to carry 130 % of rated current continuously without exceeding the
temperature rise & shall be applicable for thermal class of insulation used. The reactor
shall be mounted on structure.
i. Tests: The series reactor shall be type tested and shall be subjected to
routine and acceptance test in accordance with IS: 5553.
ii. The bidder shall submit guaranteed technical particulars along with their bid.
5.12 MOUNTING RACK AND ELEVATING

The mounting rack shall be hot dip galvanised (HDG) and should be suitable for out door
installation under moist climatic conditions, as per relevant standards and latest
amendments thereof. Mounting racks shall be complete with rack insulators and
interstack insulators, wherever required, shall have basic insulation level. The mounting
rack shall be of robust design and shall have two earthing terminals. Capacitors,
Capacitor Switches, Series Reactor, LA, Isolators, RVT shall also be mounted on
structure.
5.13 BUSSBARS AND INTERCONNECTION MATERIALS

Suitable bus bar arrangement shall be provided by the supplier and requisite quantity of
bus bar material shall be provided for the Bank. All bus bars shall be aluminum flats
with minimum with minimum cross section of 120 sq. mm. Bus bar connections between
Bank and RVT. Shall also be provided.
5.14 ACCESSIORIES
Each capacitor bank shall be provided with the following accessories:-
1. Galvanised supports
2. 2 Nos. earthing terminals
3. Clamps and connectors
4. Aluminum bus bar
6. Series reactor
7. APFC Relay Panel
8. Isolator
9. Lightening Arrestor
129
10. One no. residual voltage transformer

11. Rating plate
12. All other accessories required for erection, assembly and commissioning of
the
capacitor bank.
13. One capacitance meter with each unit.
5.15 RATING PLATE

Each unit shall be fitted with a rating plate giving clearly the particulars specified of
marking as per standards:
5.16 CLEARNCESINSTALLATION AND MAINTENCACE INSTRUCTIONS:

The supplier shall provide 3 sets of detailed instruction manuals and drawings
covering all aspects of installation and maintenance of the capacitor bank and the
associated equipments. Installation shall be carried out by the purchaser/consignee.
5.18 OPERATION OF CAPACITOR BANK

a. The capacitors are proposed to be connected in 3 phase, 11 KV, 50 Hz
system.
The maximum symmetrical short circuit level on 11 KV systems is 26.2 kA for 1
seconds.
b. It is to be specifically noted that 1.5 & 3 MVAR capacitors banks are intended for
use at our 33/11 KV receiving substations within our distribution network.
c. Maximum permissible over voltage shall be as per standards and latest
amendments thereof.
d. Permissible increase in current loading due to any or all of the following shall not
exceed 30% of the rated current.
1. Increased voltage
2. Increased frequency
3. Non sinusoidal voltage
e. The capacitors shall be suitable for operating in temperature category 50° C as
per standards.
6.0 TESTS
6.1 TYPES TESTS

All the offered equipment shall be fully type tested by the bidder as per relevant
standards including the type tests mentioned below. Type test should have been
conducted on the similar or higher capacity of equipments for 11 KV or 33 KV class of
capacitor bank from recognized NABL test laboratory preferably CPRI or other Govt. test
labs within 10 years prior to date of opening of bid. The bidder shall furnish four sets of
test reports as per relevant standards for each type of equipment offered. along with the
bid. The offers received without type tests shall be tested as non responsive and
rejected.
a. Thermal stability
b. Capacitor less tangent measurement at elevated temperature.
c. A.C. voltage test between terminal & container.
d. Lightening impulse voltage test between terminal and container.
e. Short circuit discharge test.
6.2 ACCEPTING TEST

All acceptance tests stipulated in relevant standards and including those as
130
mentioned below shall be carried out by the Supplier in presence of Purchaser's

representative.
a. Capacitance measurement test
b. Capacitor loss tangent measurement test.
c. Voltage test between terminals.
d. A.C. voltage test between terminal and container.
e. Tests of internal discharges device.
f. Sealing test
.
The method shall be subject to agreement between the Supplier and Purchaser where
it is not specified in the relevant standards. The Purchaser reserves the right to carry
out any other test (s) of reasonable nature, in addition to above mentioned tests, at
works/test house of the Supplier or any other recognized laboratory/Research Institute
to satisfy that the material compiles with the intent of this specification
7.0 INSPECTION
The inspection shall be carried out by the Purchaser at two stages of manufacture i.e.
inspection during manufacturing and final inspection and testing. The Supplier shall keep
the Purchaser informed in advance of the manufacturing programmer so that the
arrangement can be made for inspection. The Manufacturer shall grant free access to
works, for Purchaser's representative at a reasonable time. Inspection and acceptance
of any equipment under this specification by the Purchaser shall not relieve the Supplier
of his obligation of furnishing the equipment in accordance with this specification and
shall not prevent subsequent rejection if the equipment is found to be defeat/not as per
this specification.
All acceptance tests and inspection shall be carried out at the place of
manufacture unless otherwise specifically agreed upon by the contractor and Purchase.
The contractor shall offer to the inspecting official (s) representing the Purchase, all
reasonable facilities without charge, to satisfy that the material is being furnished in
accordance with this specification. The Purchase has the rights to have the tests
carried out at his own cost by an independent agency wherever there is a dispute
regarding the quality of the supply.
The contractor shall give not less than 15 days advance intimation to enable the
purchase to depute his representative for witnessing the state/acceptance tests.
8.0 QUALITY ASSURANCE PLAN
8.1 The bidder shall have ISO-9001/9002 or any latest, certification'. The bidder shall
invariably furnish the following information alongwith his bid part-I falling which his bid
shall be liable for rejection. Separate information should be given be individual type of
material offered.
(I) Statement giving list of important raw materials, name of Suppliers for raw
material, list of standards according to which the raw materials are tested
and
list of tests normally carried out on raw materials in presence of bidder's
representative, copies of tests certificates
(II) Information and copies of test certificates as in (1) above in respect of bought
out items,
131
(III) List of manufacturing facilities available
(IV) Level of automation and list of areas where manual processing exists.
(V) List of areas in manufacturing process where stage inspections are
normally
carried out for quality control and details of such test.
(VI) List of testing equipment available with the bidder for stage and final testing of
equipment offered and test plant limitations if ay, vis-a vis the type test, special
acceptance and routine test specified in the relevant standards. These
limitations shall be very clearly brought out in the relevant schedule of
deviations as deviations from specified tests requirements.
8.2 The successful bidder(s) shall within 30 days of placement of order submit the following
Information: -
i. List of raw material and bought out items and names of the Suppliers
selected
from those furnished along with the bid.
ii. Type test certificates or the raw material and bought out items.
iii. Quality assurance plan (QAP) with hold points for purchase's inspection (to
be finalized after mutual discussions between the bidder and the purchaser,
at latter's office.)
HOLD POINT
A stage in the material procurement of manufacturing process beyond which work
shall not proceed without the documental approval of the purchase.
NOTIFICATION POINT:
A stage in the material procurements, or manufacturing process for which advance
notice of the activity is required to facilitate witness by the purchasers
representatives.
8.3 The QAP of the contractor shall consist of the following details.
♦ An outline of the proposed work and program sequence.
♦ The structure of contractor organisation for the contract.
♦ The duties and responsibilities assigned to the staff ensuring quality of work
♦ Hold and Notifications points.
♦ Submission of engineering documents required by this specification.
♦ The inspection of material and components on receipt
♦ Stage Inspection.
♦ Final Inspection.
90 DOCUMENTATION
All drawing shall conform to International standards organisation (ISO), 'A' series of
drawing sheets/Indian standards specification IS: 656. All dimensions shall be in SI
units.
LIST OF DRAWINGS
The bidder shall furnish the following alongwith the bid: -
i. Two sets of drawing showing clearly the general arrangement, fitting
details, electrical connections etc. required for erection & commissioning
ii. Technical leaflets (users manual) giving operating instructions.

132
iii. Three copies of dimensional drawings.

9.2 The manufacturing of the equipment shall be strictly in accordance with drawings
approved by purchaser and no deviation shall be permitted without the written approval
of the purchase. Any manufacturing and fabrication prior to approval of the purchaser
shall be at supplier risks.
9.3 Approval of drawing/work by the purchase shall not relieve at supplier
of his responsibility and liability for ensuring the correctness and correct
9.4 Interpretation of the drawing for meeting the requirements of latest revisions of
applicable standards, rules and code 6f practices. The purchase shall have power to
reject any work or material which in his judgment is no in all accordance therewith.
9.5 Three sets of drawings for purchaser's approval shall be furnished within two weeks
of
placement of order. The purchaser shall communicate his comments/ approval within
reasonable. The supplier, shall, if necessary modify the drawings and resubmit
three
copies of modified drawings for a approval.
9.6 Three sets of separating manual, drawing, technical leaflets, inspection manual etc
shall
be supplied to each consignee in the first instance.
9.7 One set of routine test certificate shall accompany such dispatch consignment.
10 0 PACKING & FORWARDING

The equipment shall be packed in creates suitable for vertical, horizontal transport as the
case may be and suitable to withstand handling during transport and outdoor storage
during transit. The supplier shall be responsible for any damage to the equipment during
transit, due to improper and to the equipment during transit, due to improper and
inadequate packing. The easily damageable material shall be carefully-packed and
marked with the appropriate caution symbol. Wherever necessary proper arrangement
for lifting such as fitting hooks shall be provided. Any material found short within the
packing case(s) shall be supplied immediately by the supplier without any extra cost to
purchaser.
Each consignment shall be accompanied with a detailed packing list containing
the following information and shall be marked "PROPERTY OF respective DISCOM".
a) Name of the consignee
b) Details of consignment
c) Destination
d) Total weight
e) Handling and packing instructions
f) Bill of material indicating contents of each package.
In addition to the above the marking on each package shall per relevant standards.
10.1 The packing shall be done an per manufacture's standards practice ensuring that no
material is damaged during transit by Rail/Road.
11.0 SUPERVISION SERVICES:

The bidders shall provide free of services of their engineers, If required during erection &
commissioning of capacitor bank at various places.
Advance notice of 15 days shall be given to the contractor to depute his engineer to
various substation in state of Uttar Pradesh.
12. MANDOTRY SPARES AND TOOLS

133
The bidder shall supply free of cost 1 set of special tools/kit required for erection and
maintenance with each capacitor bank. One no. capacitance meter shall also be provided
with each capacitor bank.
Schematic Diagram for 1.98 & 3.96 Mvar, 11 KV Automatic Capacitor Bank
134
135
GUARANTEED TECHNICAL PARTICULARS
Technical Particulars of HT - APFC Capacitor Bank For 1.98 MVAr at 11 KV at 5 MVA

S Particulars Specifications
r
… Nominal System Voltage
.
Maximum Operational Voltage
N Frequency
o
. Rating of APFC Capacitor bank
Step configuration
No. of Banks
CAPACITOR SUB-BANK RATINGS
■ Capacitor Sub Bank
Sub-Bank Unit
Rated Voltage, KV
Rated output, KVAr
■ Rated Current, Amps.
■ No. of phases
■ Insulation Level(KV rms / KV peak)
■ No. of Banks / Units
BANKING DETAILS
■ Type of Banks
■ Connection
■ Terminal Arrangement
■ Series Group per phase
■ Units in parallel per Series group per
phase
■ Bus bar Material
■ Overall Dimensions
UNIT DETAILS
■ Dielectric and Impregnant
■ No. of Bushings ;
■ Discharge device to Discharge to 50 '•
Volts in less than 600 Sec.
136
■ Unit Protection
■ Allowable Overloads ■
■ Losses
■ Finish
■ Dimensions
Technical Particulars of HT - APFC Capacitor Bank For 3.96 MVAr at 11 KV at 8 & 10 MVA
Sl. Particulars Specifications
Nominal System Voltage

Maximum Operational Voltage
Frequency
Rating of APFC Capacitor bank
Step configuration
No. of Banks
CAPACITOR SUB-BANK RATINGS
Particulars ■ Capacitor Sub Bank
Sub-Bank Unit
Rated Voltage, KV
Rated output, KVAr
■ Rated Current, Amps.
■ No. of phases
■ Insulation Level(KV rms / KV peak)
■ No. of Banks / Units
BANKING DETAILS
■ Type of Banks
■ Connection
■ Terminal Arrangement
■ Series Group per phase
■ Units in parallel per Series group per
phase
137
■ Bus bar Material

■ Overall Dimensions
UNIT DETAILS
■ Dielectric and Impregnant
■ No. of Bushings
■ Discharge device to Discharge to 50
Volts in less than 600 Sec.
■ Unit Protection
■ Allowable Overloads ■
■ Losses
■ Finish
■ Dimensions
138
General Technical Particulars of Series Reactors

Reactor shall be suitable to be connected in Series with Capacitor Bank on the Neutral side for
suppressing switching inrush currents. The reactor shall be dry type and shall be suitable for Outdoor
installation and shall have other particulars as mentioned below.
A Reference standard :
B Type of Reactor :
C Rated Voltage & Frequency :
D No. Of phase :
Capacitor Sub-Bank rating :
E Per phase reactance, Ohms :
F Per phase voltage drop, volts :
G Rated output, KVAr :
H Rated current, Amp :
I Max. Continuous current :
J Temperature rise :
K Basic insulation Level :
L Terminal arrangement :
M Accessories for Reactors :
N Testing :
O Other details
i) Class of insulation :
ii) Rated short time symmetrical RMS Current:
iii) Winding materials :
iv) Type of Installation :
139
GENERAL TECHNICAL PARTICULARS FOR RESIDUAL VOLTAGE TRANSFORMER:
Sr. Particulars Specifications

No.
Reference Standard
Type
Rated primary voltage
Frequency
No. of secondary windings
Ratio
Rated burden per phase & Accuracy class
a) Metering Winding ( Star)
b) Protection Winding ( Open Delta)
Method of connection
Insulation level a) One minute power
frequency withstand voltage b) Impulse with stand
voltage (1.2x50 micro sec. wave, crest)
Voltage Factor
Terminal Arrangement 1) HV Side 2) LV

Side
Make Creepage distance of bushing

140
GENERAL TECHNICAL PARTICULARS FOR ISOLATOR WITH EARTH SWITCH

No.
Type: Outdoor, Off load, isolator, Double Break, with ON/OFF Indicator,
mechanical interlock & padlocking
Reference Standard
Nominal System Voltage
Maximum permissible continuous service voltage
Distance between Centre of outer stack of insulator
Power frequency withstand test voltage for completely
assembled switches
a) Against Ground
b) Across open contacts
c) Between Phases
Impulse withstand test voltage of completely assembled
switches without arcing horn & with 1.2/50 micro second
impulse wave
a) Against ground (KV Peak)
b) Across the open ends of the phase (KV)
c) Between phases (KV Peak)
100% impulse flash over voltage of completely
assembled switch with arcing horns with 1.2/50 micro
second impulse wave against ground (KV Peak)
Particulars of the main contacts i.e. fixed contacts &
moving contacts
a) Type I) Fixed contacts
II) Moving contacts
b) Material I) Fixed contacts
II) Moving contacts
Continuous current rating (Amps)
Short time current rating
141

No.
a) For 1 second
b) For 3 second
Rated peak short circuit current (KA peak)
Type of interlocking between isolator switch & earth
switch
Number of operations which the isolator can withstand without
deterioration of contacts
Phase to phase distance
Type of mounting
142
TECHNICAL PARTICULARS OF CAPACITOR SWITCH
1 Applicable standard
2 Type & Make
3 Number of poles, nos of break/pole
4 Model
5 Maximum capacity
7 Rated Voltage
8 Rated maximum voltage
9 Rated normal current
10 Rated single capacitor banks current
11 Frequency
12 Rated short time current for one sec
13 Rated short circuit making current
14 Impulse with stand voltage (1.2x50 micro sec.
wave, crest)
15 One minute power frequency withstand
voltage
16 One minute power frequency withstand
voltage on auxiliary circuit to earth
19 Mechanical endurance
20 Electrical endurance
21 Max. Required current of Solenoid
i Closing solenoid
ii Opening solenoid
22 Closing time
24 Operating Mechanism
i Stored energy
ii Release
iii Rated voltage
26 Inherent delay between two switching
operations
27 IP protection
143
GENERAL TECHNICAL PARTICULARS FOR 9 KV METAL OXIDE (GAPLESS)

LIGHTNING ARRESTERS

No.
Name of the manufacturer
Type
Applicable standard
Rated voltage (KV rsm)
Rated frequency (HZ)
No.of unit per arrester
Nominal discharge current (8x20 micro
second wave) (KA)
Maximum continuous operating voltage KV
(rms)
Insulation withstand voltage
a) Dry power frequency
c) Impulse (1.2x50 micro second)
Lightning impulse residual voltage (8/20 micro
second wave)
a) 5000 A
b) 10000 A
c) 20000 A
Minimum clearance
a) Between arresters
b) Arrester & adjoining earthed object
144
Guaranteed Technical Particulars for Power factor Controller
Sl. No. Particulars Proposed Offered

3ph, 3wire, 110Volt
1. Feed-back Voltage:
(+10%/-20%).
Selectable 1A or 5A for
2. Current input:
both load & capacitor.
3. Auxiliary Supply: 1Ph 415V (+10% to -20%).
(Isolated 'NO' contacts of
4. Output banks control for 8 banks.
rating 5Amp ac / 250Vac).
5. RS-232 baud rate selectable upto 38.4kBPS.
6. Dedicated RS232 port on front
fascia.
Facility for separate
7.
temperature probe (PT100)
8. provided. temperature:
Operating 0 to 50oC.
9. Storage temperature: -10 to +75oC.
10. Humidity: 0 to 98%.
11. Supply frequency: 45Hz to 55Hz.
Automatic synchronization
capable of giving correct results
12.
even for wrong connections at
CT terminals (& also wrong
Load
polarityV,I and Cap. current
of CTs).
13. THD measurement with odd
harmonic coeff. upto 15 th
14. Mode of switching
harmonic. user defined.
Standard 144 X 144 cabinet for
15.
panel door flush mounting.
Serial communication
16.
through standard
Dedicated protocols. MODBUS RS485 or RS232,
17. Selectable communication port
on rear side.
Logging of data in the form of
recording all electrical
18. Hourly Records, Fault Records &
values.
Daily Records
19. Protections provided
20. Over/under Voltage
21. Cap. Over/under current / THD.
22. Over/Under frequency
23. Over / Under load.
24. Load unbalance.
25. Over temperature.
26. Out of steps (only for indication).
27. NV-RAM battery down.
145
Guaranteed Technical Particulars for Controller Control Panel
1. Product Control Panel

2. Application Automatic Switching of 11 kV Capacitor banks
3. Installation Indoor
4. Ambient Temperature
5. No. of steps
6. Power Frequency Voltage
7. Control Mode
8. Control Parameter
9. Protection
10. Ingress Protection
11. Inputs
12. Output
146
GUARANTEED TECHNICAL PARTICULARS OF 11KV VACUUM SWITCH GEAR
FOR CAPACITOR BANKS

1.0 Switchgear
1.1 Type
1.2 Nominal system voltage
1.3 Highest system voltage
1.4 Frequency
1.5 Normal current rating
(a) At designed ambient temp.

(b) At site conditions
1.6 Making capacity

(a) Symmetrical Breaking
capacity
(b) Asymmetrical breaking capacity
1.7 Short time current rating for 3 sec.
1.8 Number of break per pole
1.9 Total length of break per pole
1.10 Arc Duration

(a) With "No Load"
(b) With 100% SC current
1.11 a. Type and material of main contact,

b. Material & Thickness of plating of contacts.
1.12 Break Time
1.13 Make Time
1.14 Type of Arcing contacts/ or Arc control device

1.15 a. Whether the circuit breaker fixed trip or Trip free,
b. Whether it is lock out prevent closing.
1.16 Number pf contacts of Auxiliary switch
a. Normally open
b. Normally closed.
1.17 Details of operating mechanism

1.18 Power required to close
147
the circuit breaker at nominal voltage

1.19 Nominal voltage
of closing mechanism
1.20 Impulse withstand
(1/50 micro sec wave)
Test voltage KV
1.21 One minute power frequency with
stand test voltage
KV rms.
1.22 Minimum clearance in air

a. Between phases
b. Between the live
part & earth.
1.23 Minimum clearance in vacuum

a. Between phases
b. Between the live part & earth.
1.24 Total weight of complete Breaker.
1.25 Dimension and mounting details Applicable standard
1.27 Details of ref. Drawing attached
2.0 BUS BAR
2.1 Bus bar material
2.2 Cross sectional area.

2.3 Insulation
2.4 Minimum Electrical clearance

a. Phase to earth
b. Between phases
148
TECHNICAL SPECIFICATION (MEDIUM VOLTAGE) AL59 ACS COVERED

CONDUCTOR & ACCESORIES.
TECHNICAL SPECIFICATION
FOR
(MEDIUM VOLTAGE) AL59 ACS COVERED CONDUCTOR & ACCESORIES
TECH. SPEC NO.

…………………………………………………………….
Date :
149
1. SCOPE :
This specification covers details of AL59 ACS Covered Conductors for use on 33KV &
11KV Distribution system. The covered conductor insulation shall be as per EN
50397-1: 2006.
2. SERVICE CONDITIONS :
The conductor to be supplied against this specification shall be suitable for satisfactory
continuous operation under the following tropical conditions.
a) Maximum ambient temperature (Degree C) ------ 50

b) Minimum temperature of air in shade (Degree C ------ 3.5
c) Relative Humidity (%) ------ 10 to 100
d) Maximum Annual Rainfall (mm) ------ 1450
e) Maximum Wind Pressure (kg/sq.m.) ------ 150
f) Maximum altitude above mean sea level (meter) ------ 1000
g) Isoceraunic level (days/ year) ------ 50
h) Seismic level ( Horizontal acceleration) ------ 0.3g
3. CONDUCTOR SIZES :
Actual
Stranding wire & Dia
Area
ALU. ACS.
sq.mm.
No./mm. No./mm.
20.98 6/2.11 1/2.11
31.6 6/2.59 1/2.59
52.88 6/3.35 1/3.35
78.82 6/4.09 1/4.09
104.98 6/4.72 1/4.72
158 30/2.59 7/2.59
212 30/3.0 7/3.0
150
TECHNICAL SPECIFICATION (MEDIUM VOLTAGE) AAA COVERED

4. APPLICABLE STANDARDS :
Unless otherwise stipulated in this specification, the conductor shall conform

to the following Indian/International Standards (amended upto date ).
Sr. Indian / International

No. Standard Title
Specification for aluminium conductors for
1 IS : 398 ( Part II) / 1996
overhead transmission purpose
Covered Conductor Specification for voltage
2 EN 50397-1:2006
1KV to 33KV.
3 IS : 10418 Reels and drums for bare conductors.
4 SS 424 08 13 & SS 424 08 14 Aluminium alloy wire for stranded conductors

for overhead lines –Al 59 wire
Aluminium Clad steel wire for Electrical
5
IEC - 1232 : 1993-06 purpose
6 SS EN - 50182 Conductor for Overhead lines – Round wire
concentric Lay stranded Conductors
5. PROPERTIES OF CONDUCTOR :
The properties of stranded AL59 ACS conductor of various sizes shall be as in Table 1
TABLE - I
AL59 ACS CONDUCTOR DETAIL

Calculated Approx.
Approx.
Actual Approx. Resistance Calculated Reactance Current
Stranding wire & Dia Overall
Area Mass at 20⁰C Breaking per km. Rating
dia
(Max.) Load
ALU. ACS.
sq.mm. mm. Kg/km Ohm/km kN. Ohms. Amps.
No./mm. No./mm.
20.98 6/2.11 1/2.11 6.33 80.54 1.390 9.44 0.2991 120
31.6 6/2.59 1/2.59 7.77 121.35 0.923 14.23 0.2862 155
52.88 6/3.35 1/3.35 10.05 203 0.551 23.62 0.27 215
78.82 6/4.09 1/4.09 12.27 302.62 0.370 32.58 0.2575 278
104.98 6/4.72 1/4.72 14.16 403 0.278 41.64 0.2485 335
158 30/2.59 7/2.59 18.13 681.18 0.184 83.77 0.233 445
212 30/3.0 7/3.0 21 913.9 0.137 112.39 0.2237 540
151

6 (a)
PROPERTIES OF WIRES :
ALUMINIUM WIRE USED IN CONSTRUCTION OF ALUMINUM CONDUCTOR WITH

ALUMINIUM CLAD STEEL
Diameter of Wire Minimum

Crossectional area of DC resistance
Mass breaking load
nom. Wire dia at 20⁰C
Nom. Min. Max after stranding
mm. mm. mm. Sq.mm. Kg./Km. kN Ohm/Km.

2.11 2.09 2.13 3.50 9.45 0.874 8.451
2.59 2.56 2.62 5.27 14.24 1.317 5.609
3.35 3.32 3.38 8.81 23.82 2.204 3.353
4.09 4.05 4.13 13.14 35.51 3.022 2.249
4.72 4.67 4.77 17.50 47.30 4.024 1.689
2.59 2.56 2.62 5.27 14.24 1.317 5.609
3 2.97 3.03 7.07 19.11 1.767 4.180
ALUMINIUM CLAD STEEL WIRE USED IN CONSTRUCTION OF ALUMINUM CONDUCTOR

WITH ALUMINIUM CLAD STEEL
Diameter of Wire Minimum
Crossectional area of DC resistance
Mass breaking load
Nom. Min. Max nom. Wire dia at 20⁰C
after stranding
mm. mm. mm. Sq.mm. Kg./Km. kN Ohm/Km.
2.11 2.09 2.13 3.50 23.04 4.196 24.252
2.59 2.56 2.62 5.27 34.72 6.322 16.096
3.35 3.32 3.38 8.81 58.09 10.401 9.621
4.09 4.05 4.13 13.14 86.58 14.452 6.454
4.72 4.67 4.77 17.50 115.31 17.497 4.846
2.59 2.56 2.62 5.27 34.72 6.322 16.096
3 2.97 3.03 7.07 46.58 8.482 11.997
6 (b) TOLERANCE ON NOMINAL SIZES :
The tolerance shall be permitted on the nominal diameter aluminium

wire used in the manufacture of AL59ACS COVERED CONDUCTOR. However,
positive & negative tolerance in this respect shall be as provided in IS: 398 (Part
IV)/1994 (amended up to date).
7. FREEDOM FROM DEFECTS:
The wire shall be smooth and free from all imperfections such as spills , splits,
slag inclusion , dia. marks scratches, fittings, blow holes, projections, looseness,
overlapping of strands, chipping of aluminium layers etc. and all such other
defects which may hamper the mechanical and electrical properties of the
conductor. Special care should be taken to keep away dirt, grit etc. during
stranding.
152

8. JOINTS. IN WIRES:
8.1 Conductors containing seven wires :-
There shall be no joint in any wire of a stranded conductor containing seven

wires , except those made in the base rod or wire before final drawing.
8.2 Conductors containing more than seven wires :-
In conductors containing more than seven wires, joints in individual wires are
permitted in any layer except the outermost layer ( in addition to those made in
the brass rod or wire before final drawing) but no two such joints shall be less
than 15 m apart in the complete stranded conductor, such joint shall be made
by resistance or cold pressure butt welding. They are not required to fulfill the
mechanical requirement of unjointed wires. Joints made by resistance butt
welding shall, subsequent to welding , be annealed over a distance of at least
200 on each side of the joint.
9. STRANDING:-
9.1 The wires used in the construction of a stranded conductor shall, before
Stranding satisfy all the relevant requirements of this standard.
9.2 The lay ratio of the different layers shall be within the limits given in the
Table-III .
TABLE - III : LAY RATIOS FOR AL59 ACS CONDUCTORS
LAY RATIO OF ALUMINIUM CONDUCTORS , WITH ALUMINIUM CLAD STEEL REINFORMCED

Lay ratio for Aluminium wire
Layer
Ratio of Aluminium Lay ratio of steel immediately
Number of wires Outer most
wire diameter to steel core beneath
layer
wire diameter Outermost
Layer
Aluminium Steel Min. Max. Min. Max Min. Max
6 1 1 ----- ----- 10 14 ----- -----
9 30 7 1 13 28 10 14 10 16
.
9. 3
In all constructions, the successive layers shall have opposite directions of lay,
the outer most layer being right handed . The wires in each layer shall be evenly
and closely stranded .
.
Page 6
153

9.4 In aluminium alloy stranded conductors having multiple layers of wires, the lay
ratio of any layer shall not be greater than the lay ratio of the layer immediately
beneath it.
10 FILLING (WATER BLOCKING):
The Stranded Conductor shall be longitudinally water tight by means of water blocking
material incorporated during the extrusion process. The use of grease /water swellable
tape / water swellable powder inside or over the surface of conductor is not permitted.
The water blocking material shall be stable at maximum operating conductor
temperature of 90 Deg. Cent. The water blocking compound shall be compatible with the
conductor material as well as the semi conducting polymer screen layer above it and not
adversely affect its electrical or mechanical properties.
11 INSULATION:
The Insulation should be dual layered with the Inner Layer being XLPE with a nominal
thickness of 1.2 mm for Voltages up to 11 KV and 2.43 mm for 33 KV and the Outer
Layer of XLPE which is UV Resistant, Anti Tracking and Erosion Resistant with a
nominal wall thickness of 1.1 mm for Voltages up to 11 KV and 1.2 mm for 33 KV. The
minimum combined Insulation Thickness of both Layers should be 2.0 mm for Voltages
up to 11 KV and 3.0 mm for Voltages up to 33 KV minimum.
The conductor manufacturing and stranding process shall incorporate the longitudinal
water blocking also.
The Semi Conducting Screen, Inner Insulation and Outer Insulation should be extruded
in one step i.e. triple extrusion to ensure a good, permanent bond between the three
layers and also with the conductor.
It shall be possible to remove the Semi Conducting Screen, Inner and Outer Insulation
Layers without damage to the conductor.
.
Page 7
154

Figure 1 shows the Cross Section of a AL59 ACS COVERED Conductor.
.
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TECHNICAL SPECIFICATION OF (MEDIUM VOLTAGE) AL59 ACS COVEREDC COVERED CONDUCTOR &
ITS ACCESORIES.
155
12 TYPE TEST:
All the following type tests certified in CPRI/ERDA in accordance with EN 50397-1 : 2006
shall be performed on MVCC samples drawn by purchaser..
12.1 Electrical tests

12.1.1 Conductor resistance
12.1.2 High voltage test

12.1.2.1 For CC without conductor screen:
Test voltage (a.c.) 1U
Number of specimen 1
Length of specimen (minimum) 5m
Duration of immersion in water (minimum) 1h
Temperature of water (20 ± 5) deg C
Test duration 15 min (S)
1 h (T)
12.1.2.2 For CC with conductor screen or upon agreement between customer and
Producer :
Test voltage (a.c.) 1U
Length of specimen (minimum) 5m
Duration of immersion in water (minimum) 1h
Temperature of water (20 ± 5) deg C
Test duration 4 h (S)
48 h (T)
12.1.3 Spark test on the covering (R)

Test voltage: a.c. 0,7 U or dc 1 U
12.1.4 Leakage current (S)

Test voltage: a.c. 0,7 U
12.1.5 Tracking resistance (S)
12.2 Construction and dimensions (T,S,R)

12.2.1 Compliance with the designs requirements
12.2.2 Thickness of the covering
12.3 Construction and mechanical properties of the conductor (T,S)

12.3.1 Rated tensile strength
12.3.2 Construction and dimensions
.
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TECHNICAL SPECIFICATION OF (MEDIUM VOLTAGE) AAA COVEREDC COVERED CONDUCTOR &
ITS ACCESORIES.
156
12.4 Non-electrical tests on the covering (T)

12.4.1 Mechanical properties
a) before ageing of sample
b) after ageing of sample
12.4.2 If Carbon black used for UV Stabilization - Carbon black content (T)
12.3.2 Resistance to UV rays (T)
12.5 Tests of compatibility (T)

Ageing of complete product sample
12.6 Thermal properties of the covering

12.6.1 Shrinkage test (T)
Distance “L” between marks: (200± 5) mm
12.6.2 Hot-set-test (T,S)
12.6.3 Pressure test at high temperature (For Thermo plastic Cable))
12.7 Further tests on the covering

12.7.1 Water absorption (T)
12.7.2 Shore D hardness (For Thermo plastic Cable)
12.8 Test of the longitudinal water tightness

12.8.1 With heat cycle (T)
Length of specimen 3m
Test duration 24 h
Bending radius 20 D
12.8.2 Without heat cycle (S)

Length of specimen 1m
Test duration 1h
12.9 Marking
12.9.1 Content, legibility (T , S , R)
12.9.2 Durability (T)
Note : T – Type Test S – Acceptance Test R – Routine Test
13 ROUTINE TESTS:
All the Routine tests as per EN 50397-1 : 2006 amended upto date shall be carried
out on each and every delivery length of MVCC . The result should be given in test
report.
Page 10
TECHNICAL SPECIFICATION OF (MEDIUM VOLTAGE) AL59 ACS COVERED CONDUCTOR &
ITS ACCESORIES.
157
The details of facility available in the manufacturer's works in this connection

should be given in the bid.
All Acceptance tests as per EN 50397-1 : 2006 as amended upto date including the
Optional and should offered Anti tracking testing on selective samples in
Manufacturer’s work during acceptance test.
15 TESTING FACILITIES AND DETAILS OF EQUIPMENTS :
The supplier / tenderer shall clearly state as to what testing facilities are available in
the works of manufacturer and whether the facilities are adequate to carry out type,
routine and acceptance tests And Anti Tracking as mentioned in EN 50397-1 :
2006 on the MVCC. The facilities shall be provided by the bidder to purchaser’s
representative for witnessing the tests in the manufacturer’s works. If any test
can not be carried out at manufacturer’s works reason should be clearly stated in
the tender.
END SEALING :-
16
Heat Shrinkable end caps with sealant shall be used for effectively sealing the end
terminals of the covered conductor. The inner diameter range of cap shall be such
that it shall tightly fit to the covered conductors to prevent moisture ingress.
17 PACKING AND MARKING :
The conductors shall be wound in reels or drums conforming to the latest

versions of IS : 10418 ( amended upto date ), ' Specification for Drums for cables .
18.1 PACKING :
18.1.1 The gross mass of packing for various conductors shall not exceed by more than
10% of the values given in the following table .
Conductor Size in sq.mm. Gross Mass in kg
20.98 sq.mm. (ALU 6/2.11 + ACS 1/2.11 ) 1100

31.60 sq.mm (ALU 6/2.59 + ACS 1/2.59) 1100
52.88 sq.mm. (ALU 6/3.35 + ACS 1/3.35) 1500
78.82 sq.mm. (ALU 6/4.09 + ACS 1/4.09) 1600
104.98 sq.mm. (ALU 6/4.72 + ACS 1/4.72) 2000
158 sq.mm. (ALU 30/2.59 + ACS 7/2.59) 2000
212 sq.mm. (ALU 30/3.0 + ACS 7/3.0) 2400
.
Page 11
ITS ACCESORIES.
158
18.1.2 The normal length of various conductors shall be as given in the following
table:
Conductor Size in sq.mm. Normal Length

in km
20.98 sq.mm. (ALU 6/2.11 + ACS 1/2.11 ) 2.0
31.60 sq.mm (ALU 6/2.59 + ACS 1/2.59) 2.0
52.88 sq.mm. (ALU 6/3.35 + ACS 1/3.35) 2.0
78.82 sq.mm. (ALU 6/4.09 + ACS 1/4.09) 1.0
104.98 sq.mm. (ALU 6/4.72 + ACS 1/4.72) 1.0
158 sq.mm. (ALU 30/2.59 + ACS 7/2.59) 1.0
212 sq.mm. (ALU 30/3.0 + ACS 7/3.0) 1.0
18.1.2.1 LENGTHS AND VARIATION IN LENGTHS :
The standard length of AL59 ACS Covered Conductor shall be as per mentioned in
clause. No 18.1.2 Tolerance of +/- 5%( plus or minus five percent ) shall be
permitted in this standard length. All the lengths outside these limits of tolerances
shall be treated as random length.
Random length shall not be less than 80%( eighty percent ) of the standard length
specified as above and the total acceptable quantity of such random lengths shall
be within 7%( seven percent ) quantity of the allotted quantity to each consignee of
the respective size of the conductor.
18.2 MARKING :
IDENTIFICATION MARKS ON COVERED CONDUCTOR:
The following particulars shall be properly legible embossed/Printing on the

Covered conductor at the intervals of not exceeding one meter throughout length
of the cable. The covered conductor with poor and illegible embossing or printing
shall be liable for rejection
a) Manufactures name and/or Trade name.

egible
b) Voltage grade.
c) Year of manufacture.
d) KSEBL
e) Successive Length.
f) Size of cable
g) EN 50397-1 : 2006
.
Page 12
ITS ACCESORIES.
159
Also The following information be marked on each package:
a) Manufacturer's name
b) Trade mark, if any
c) Drum or identification number
d) Size of conductor Number and lengths of conductors
e) Gross mass of the package
g) Net mass of conductor
h) EN 50397-1 : 2006.
19. INSPECTION:
All tests and inspection shall be made at the place of manufacturer unless
otherwise especially agreed upon by the manufacturer and purchaser at the
time of purchase. The manufacturer shall afford the inspector representing
the purchaser all reasonable facilities without charges , to satisfy him that
the material is being furnished in accordance with this specification.
20 . VERIFICATION OF LENGTH OF CONDUCTOR :
i ) The Company shall ascertain the length of AL59 ACS COVERED Conductor at
supplier's works and at the receiving store centres by measuring the actual
length by length measuring machine used for the purpose. The supplier
should ensure that length measuring machine is available for measurement
of the length by our inspecting officer.
ii ) Both ends of the AL59 ACS COVERED Conductor will be sealed by the supplier
and seals will be contained in the drum and not exposed out of drum.
iii ) The declared length will be measured between manufacturer's seals at both
ends of AL59 ACS COVERED Conductor.
iv ) The weight of AL59 ACS COVERED Conductor will also be checked for ensuring
correct lay and length of AL59 ACS Covered Conductor.
v) For the verification of the length of the conductor, 10 %of total lot (in Drums)
should be selected at the works. The physical verification of the length of the
conductor should be carried out for maximum up to 5 (five) drums. If there
are anymore drums left for verification, then weight of each verified drum
should be carried out and average weight may be calculated.
Then the weight of each of all the remaining selected drums may be taken
and if these weights are matching with the average weight, then that
particular lot may be accepted otherwise rejected.
.
Page 13
ITS ACCESORIES.
160
vi) Verification of length of conductor will also be carried out at each stores center
for two drums out of each lot. If the average length is found correct or more, the
lot will be accepted. If the average length is found to be less than the declared,
the percentage of such short length will be applied for reduction for the entire
quantity supplied in the lot at respective stores for acceptance.
vii) In case of dispute, joint inspection along with the representative of the supplier
shall be carried out after giving 10 (ten) days’ notice to the supplier to remain
present at stores centre for the purpose. If the representative fails to attend on
Stipulated date for joint inspection, the decision of the consignee shall be final
and binding.
21 REJECTION :
i) While measuring the length, the sample piece from each length shall be taken
for carrying out the test as per EN 50397-1 : 2006 . All the values of each sample
should not exceed the value as per the relevant specification. In case of deviation,
whole lot will be rejected at works.
22 EN CERTIFICATION MARK:
The AL59ACS COVERED Conductor with EN marking only is required by the KSEBL
Against this tender specification
23 SCHEDULES:
The tenderer shall fill in the following schedules which form part of the
tender specification and offer.
.
Page 14
ITS ACCESORIES.
161
Schedule ' C '----- Schedule of Tenderer's Experience.
SCHEDULE 'C '
SCHEDULE OF TENDERER'S EXPERIENCE
Tenderer shall furnish here a list of similar orders executed/under execution by him to
whom a reference may be made by Purchaser in case he considers such a reference
necessary. -----------------------------------------------------------------------------------------------
--------------------------
Sr. Name of Client Value Period of supply Name & Address to No. & Description.
of order and commissioning whom reference may be made
------------------------------------------------------------------------------------------------------------
------------
1 2 3 4 5
------------------------------------------------------------------------------------------------------------
------------
NAME OF FIRM __________________________________
NAME & SIGNATURE OF TENDERER_________________
DESIGNATION ____________________________________
DATE___________________________________________
SEAL &SIGNATURE OF THE TENDERER
. Page 15
ITS ACCESORIES.
162
GUARANTEED TECHNICAL PARTICULARS AAA Covered Conductor ……Sqmm
Description Unit
SR. To be filled by
No Bidder
1 Name & Address of Manufacturer
2 Reference Standared
3.0 Material of Covered Conductor
3.1 Aluminium / Alloy Rods

a) sI %
b) mg %
c) fe %
d) cu %
e) mn %
f) cr %
g) zn %
h) b %
i) other elements (each) %
j) other elements (total) %
k) al %
3.2 Aluminium Alloy strands (Individual) Nos

3.3 Diameter
a) Nominal mm
b) Maximum mm
3.4 Minimum Breaking load of strand
a) Before stranding
2) After stranding
Maximum Resistance of strand at 20

3.5 deg. C Ohm/km
Minimum elongation of strand (200
3.6 mm gauge )
Before and After Stranding
.
Page 16
ITS ACCESORIES.
163
4 Complete conductor
Calculated breaking load of complete
4.1 conductor KN
Lay ration conductor (lay length/overall
4.2 diameter)
a) 6+1 wire aluminium alloy layer
Maximum DC Resistance of complete
4.3 conductor at 20 deg. C ohms/km
4.4 Working tension of conductor
4.5 Modulus of elasticity of
a) Conductor kg/cm2
Co-efficient of linear expansion per deg
4.6 c of
a) Conductor per deg c
4.7 a) Overall diameter of conductor mm
b) Actual area Sq.mm
c) Cross setional area of individual
aluminium alloy wire Sq.mm
5 Filling
6 Insulation
6.1 Material
6.2 Nominal Thicknes of insulation
6.3 outer layer of insulation
6.4 Colour
Length & other details of Covered
7 conductor
7.1 Strandard length of covered conductor mtr
7.3 Direction of lay for outetmost layer
Linear mass of the covered conductor (
7.4 approx) kg/km
a) Approx mass of individual
aluminium / alloy wire kg/km
7.5 Embossing / printing on cable
7.6 Approximate Standard drum length mtrs
7.7 Drum dimention in MM mm
8 Contineus AC current capacity Amp
9 Short current rating of covered
conductor KA for 1 Sec kA
.
Page 17
ITS ACCESORIES.
164
TECHNICAL SPECIFICATIONS FOR 11/22/33 KV MEDIUM VOLTAGE

COVERED CONDUCTOR (MCCC) ACCESSORIES
INDEX
Clause No. Clause
1 SCOPE
2 SERVICE CONDITIONS
APPLICABLE STANDARDS
3
4 TYPE OF ACCESSORIES for (MVCC)
5 MARKING
Annexure-I
Annexure-II
.
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ITS ACCESORIES.
165
1 SCOPE:
This specification covers design, manufacture, assembly, testing and supply of

Accessories for AL59 ACS Covered Conductors for use on 33 kV & 11 kV distribution systems.
2 SERVICE CONDITIONS :
The Accessories to be supplied against this specifications shall be suitable for

satisfactory continuous operation under the following tropical conditions.
i) Maximum ambient temperature (Degree C) ------ 50

j) Minimum temperature of air in shade (Degree C ------ 3.5
k) Relative Humidity (%) ------ 10 to 100
l) Maximum Annual Rainfall (mm) ------ 1450
m) Maximum Wind Pressure (kg/sq.m.) ------ 150
n) Maximum altitude above mean sea level (meter) ------ 1000
o) Isoceraunic level (days/ year) ------ 50
p) Seismic level ( Horizontal acceleration) ------ 0.3g
3 APPLICABLE STANDARDS :
Unless otherwise stipulated in this specification , the accessories of conductor

shall conform to the following Standards (amended upto date ).
1 EN 50397-1:2006 Covered Conductor Specification- Up to 33 KV
2 EN 50397-2:2006 Covered Conductor Accessories Specification- up to

33 KV
3 NFC 33-041 Insulated cables and their accessories for power
(SEPTEMBER 2013) systems – Anchoring devices for overhead
distribution with bundle assembled cores, of rated
voltage 0.6/1 kV.
4 EN 50483-4 Test requirements for low voltage aerial bundled
(MARCH 2009) cable joints
5 EN 50397-2 Covered conductors for overhead lines and the
(MARCH 2010) related accessories for rated voltages above 1kV a.c.
and not exceeding 36kV a.c. PART 2 : Accessories
for covered conductors : tests and acceptance
criteria
6 EN 50182 Conductors for overhead lines- Round wire
concentric lay conductors
. Page 19
ITS ACCESORIES.
166
4 TYPE OF MEDIUM VOLTAGE COVERED CONDUCTOR ACCESSORIES:
The Accessories of Medium Voltage Covered Conductor (MVCC) are specified below
and shall consist of the following:
Sl.No Description Application

For fitting onto a pole for tensioning at the
beginning or end of a length of MVCC, or for
1 Tension Assembly (TA) anchoring while a major change in direction.
The Tension assembly consists of one wedge
type Tension / anchoring clamp and one
Tracking protection IPC.
For supporting and aligning MVCC at an
intermediate pole in a length, with small angle
of deviation.
Insulator Clamp / Tie
2 The Insulator Clamp hold the MVCC in its
(IC) position on top of the pin or post insulator.
Insulator Tie consists of either an “Insulated
Plastic” or “Metallic helical” Type for Line
Alignment.
For supporting a length of MVCC at an
intermediate pole in a length, with large angle of
Suspension Clamp
3 deviation with a disc insulator.
(SC) The suspension clamp consists of an “Assembly
with one locking type Suspension clamp with
provision to fix in Insulators.
For main (Bare) to main (MVCC) networking
Insulation Piercing connection.
Connector for “Bare to This connector is to ensure the electrical
4
Covered characteristics with in the required limits, while
interconnection” ensuring necessary insulation protection
(IPC – Type 1) against tracking and water penetration on
MVCC.
For main (MVCC) to main (MVCC) networking or
branching of MVCC to another MVCC Or
Insulation Piercing
Branch Cable or Looping for transformer
5 Connector for junctions.
Networking / This connector is to ensure the electrical
Branching /Looping characteristics with in the required limits, while
(IPC – Type 2) ensuring necessary insulation protection
against tracking and water penetration on
MVCC.
Insulation Piercing For Temporary Earthing Provision from MVCC
6
Connector with Cable for maintenance purpose.
. Page 20
TECHNICAL SPECIFICATION OF (MEDIUM VOLTAGE) AAAC COVEREDC COVERED CONDUCTOR &
ITS ACCESORIES.
167
Aluminum Bail for This connector is to ensure the electrical

earthing characteristics within the required limits, while
(IPC – Type 3) ensuring necessary insulation protection
against tracking and water penetration on
MVCC.
Mid-span tension joints for jointing MVCC over
7 Tension Joints (TJ)
a span
4.1 Tension / Anchoring Clamp:

Anchoring assemblies are used to firmly hold the MVCC to a concrete or steel pole
and transmit the mechanical tension.
at the end of a run
at a major change in direction of over 20 degrees.
The clamp should consists of an Aluminum alloy corrosion resistant casted body,
Rigid sling (“bail”) of stainless steel with Tracking IPC and self-adjusting plastic
wedges which shall anchor/hold the cable. The following key criterion to be followed
for the design of the same
There shall be no losable part (except Tracking IPC and bail) in the process of
clamping arrangement
Locking mechanism should be wedge type self-locking. Wedges are to be made of high
strength, climatic resistance Engineering Plastic with glass fibre.
The fittings shall be able to withstand the specific minimum failure load (SMFL) and
shall not damage the covering. SMFL is the minimum load specified by the purchaser
or declared by the supplier at which mechanical failure will not take place.
4.1.1 Rigid Sling (Bail) of Anchor Assembly
The Anchoring assembly shall be supplied with a Galvanized steel rod to connect the
Tension Clamp to the Insulator clamp on the pole.
The Rigid Bail forming part of clamp should have sufficient distance between bracket
and body of clamp and shall have sufficient mechanical strength to withstand the
mechanical test for the complete assembly tests in this specification.
Flexible bail is not acceptable due to the reason to withstand the load.
Rigid Bail should be fitted with provision to remove from the clamp to have easy
installation.
4.1.2 Wedge Type Tension Clamp for Anchoring Assembly
Wedge type clamps shall be used for clamping the MVCC without damaging the
insulation and shall be capable of clamping an uncut MVCC so that it can continue
without break to the connecting point or next span.
The clamp shall be of aluminum with fully insulating type of mechanical and weather
resisting thermoplastic wedges.
No tools shall be needed for fitting the MVCC into the clamp.
. Page 21
TECHNICAL SPECIFICATION OF (MEDIUM VOLTAGE) Al59 ACS COVERED CONDUCTOR &
ITS ACCESORIES.
168
Type tests as per IEC and specification shall be conducted from NABL accredited
independent Lab of India/the International Laboratory Accreditation corporation,
Mutual Recognitions Arrangement (ILAC, MRA) signatory Laboratory like COFRAC.
4.1.3 Testing Requirements for an Anchoring Assembly.
The following tests are intended to establish design characteristics as per EN 50397 –
2 and NFC 33-041.
# Test Type Acceptance Routine
test Test test
1 Visual examination x x x
2 Dimensional verification x x x
3 x
Mechanical tests
3.1 x x
Tensile test at ambient temperature
3.2 Tensile test at low temperature x
3.3 Tensile test at high temperature x
Slippage test at ambient temperature
3.4 x x
4 Environmental tests
4.1 Corrosion test x
Climate ageing test
4.2 x
Resistance against tracking in heavy
4.3 polluted areas x
5 Check for permanent marking x x
4.2. Insulator Clamps / Ties

The Clamps / ties shall be designed suitably to hold the MVCC in its position on top
of the insulator. The Clamps is preferred to be made of Insulating Plastic materials or
protected with Insulating Plastic material to ensure tracking resistance and to avoid
any insulation damage to covered conductor due abrasion while mechanical or wind
induce vibration.
4.2.1 Testing Requirements for an Insulator Clamps / Tie.
Tests shall meet the requirement of EN Standard 50397 - 2
Sl. No. Test Type Acceptance Routine
test Test test
3 Check for Marking x x x
4 Mechanical tests x x x
4.1 Failure Load Tests x x x
4.2 Slip Load Tests x x x
4.3 Lift / Side Load Tests x x x
4.4 Thermal Tests under load x
4 Environmental tests
4.1 Corrosion test x
. Page 22
ITS ACCESORIES.
169
4.2 Climate ageing test x

4.3 Resistance against tracking x
in heavy polluted areas
4.3. Suspension Clamps
The Suspension Clamps shall be made of Insulating Plastic to ensure tracking

resistance and to avoid any insulation damage to covered conductor due abrasion
while mechanical or wind induce vibration.
4.3.1 Testing Requirements for Suspension Clamps

Tests shall meet the requirement of EN Standard 50397 - 2
Sl. No. Test Type Acceptance Routine
Test Test test
4.1 Failure Load Tests x x x
4.2 Slip Load Tests x x x
4.3 Lift / Side Load Tests x x x
4.4 Thermal Tests under load x
4.4 Insulation Piercing Connectors for MVCC .

Insulation Piercing Connectors (IPC) are used for making Tee / Tap-off/ connections
to an MVCC / Bare Overhead Line.
Insulation Piercing Connectors are designed to make a connection between the uncut
main conductor and a branch cable conductor without having to strip either cable to
expose the conductor. Instead, the tightening action of the IPC will first pierce the
Insulation, then make good electrical contact between the main and branch
conductor while simultaneously insulating and sealing the connection.
The insulation piercing connectors shall be of the following type(s) depending on the
applications.
4.4.1 Insulation Piercing Connectors
The connector bodies shall be made entirely of mechanical and weather resistant
plastic insulation material made of weather & UV resistant reinforced polymer and no
metallic part outside the housing is acceptable except for the tightening bolt or nuts.
Any metallic part that is exposed must be free from potential during or after
connector installation.
Screws or nuts assigned for fitting with IPC (Insulating Piercing connector), must be
fitted with torque limiting shear heads to prevent over tightening or under tightening.
While the min & max torque values are to be specified by Manufacturer, these should
not exceed 27 N mtr for IPC for main conductor < 95 sq mm, and 42 Nmtr for main
conductor >95, but < 240 sq mm.
. Page 23
ITS ACCESORIES.
170
The IPC must perform piercing and connection on Main and Branch cable
simultaneously using single bolt for tightening as multiple bolts do not ensure even
tightening. The shear bolt/nut shall be suitable for tightening with a hexagonal socket
of 13 mm or 17mm.
The contact teeth or blade of the connector is made of tinned copper with equivalent
cross
Section with respect to %IACS to suit the max branch cable size declared.
The IPCs shall be water proof and the water tightness shall be ensured by appropriate
elastomeric materials and not by grease, gel or paste alone. Grease can be applied to
protect the contact blade alone and shall not be visible on the outer surface of the
connector. Connector should not be dipped in grease.
Each IPC should be provided with a cap to seal the cut end of the Branch cable. It
should be of a design that once the connector is installed, it shall not be possible to
remove the cap without dismantling the connector.
All the metallic parts of the connector should be corrosion resistant and there should
not be any appreciable change in contact resistance & temperature after overloads &
load cycling and should conform to the long duration tests specified in this standard.
4.4.2 Testing Requirements for Suspension Clamps

The following tests are intended to establish design characteristics as per NFC 33-
003, 004, 020 and EN 600068 - 1
Sl. Test Type Acceptance Routine
No. test Test test
1 Visual examination x x
2 Dimensional verification x x
4 Voltage and Water Tightness test x x x
5 Climatic Ageing Test x
6 Corrosion Test x
7 Electrical Ageing Test x
8 Check for marking x x
4.5 Mid Span Insulated Jointing Sleeves

The sleeves should be Pre-Insulated type. Sleeve should be made of Aluminum,
insulated with an Anti-UV black thermoplastic tube hermetically sealed two ends with 2
flexible rings. Strip length, Hexagonal crimping die reference and size to be marked on the
outer surface of plastic sleeve.
Reference standard, type test and design requirements as per NFC 33 021
Sl. Test Type Acceptance Routine

No. Test Test test
. Page 24
ITS ACCESORIES.
171
4 Voltage and Water Tightness test x x x
5 Climatic Ageing Test x
6 Corrosion Test x
7 Electrical Ageing Test x
4.5.1 Heat Shrinkable End Cap

The Insulated End Cap with sealant shall be suitable for effectively sealing the end
terminal of the covered conductors. The inner diameter range of the Cap shall be such
that it shall tightly fit to the covered conductors to prevent entry of moisture.
5.0 MARKING:
5.1 On Covered Conductor
The covered conductors shall carry the following marking as per 50397-1
5.2. On Accessories
Manufacturer’s name with designation if any.
Batch code and Manufacturing period (MM/YY) is to be marked.
. Page 25
ITS ACCESORIES.
172
ANNEXURE I : - TYPICAL GENERAL ARRANGEMENT DIAGRAM AND DRAWINGS

Tension Assembly (TA) with Anchoring clamp and one Tracking protection IPC
2. Insulator Clamp / Tie (IC)
. Page 26
TECHNICAL SPECIFICATION OF (MEDIUM VOLTAGE) AAAC COVEREDC COVERED CONDUCTOR &
ITS ACCESORIES.
173
3. TYPE-1 : Insulation Piercing Connector for Networking / Branching /Looping, TYPE -

3: Insulation Piercing Connector with Aluminum Bail for earthing and Tension Joints
(TJ)
T
E
C
H
N
I
C
A
L
S
P
E
C
I
F
I
C
A
T
I
O
N OF (MEDIUM VOLTAGE) AL59 ACS COVERED CONDUCTOR & ITS ACCESORIES.
174
ANNEXURE-II - Guaranteed technical particular format
1. GTP for Dead-End / Anchoring Assembly (Dead-End Clamp with Bracket)
Sl. No. Description Particulars
1 Name of the Supplier
2 Type of Design
3 Weight
Range to in line with this

4 Cable Range
specification
5 Material
For conductor range of 50 - 70
sqmm = 20 KN
6 Ultimate Tensile Strength For conductor range of 70 - 120
sqmm = 30 KN
For conductor range of 120 - 200
sqmm = 30 KN
Installation(With/Without Ready- to-use ( Without
7
disassembly) disassembling )
8 Marking
9 Dimensions
2. GTP for Insulator Clamp / Tie (IC)
2 Length
3 Weight
4 Cable Range
specification
5 Material
7
8 Marking
.
Page
TECHNICAL SPECIFICATION OF (MEDIUM VOLTAGE) Al59 ACS COVERED CONDUCTOR &
ITS ACCESORIES.
175
3. GTP for Suspension Clamp


2 Cable Range
specification
3 Material
4 Minimum Breaking Load - Vertical
5
6 Marking
7 Dimensions
8 Weight
4. GTP for INSULATION PIERCING CONNECTOR

Sl No Particulars
1 Name of supplier
Bare to Covered conductor
2 Type of connection required Covered conductor to Covered
conductor
Tapping connector
Are torque limiting shear heads provided
3
to tightening bolts
Range of cable sizes Range to in line with this
4
accommodated for Main & Branch specification
5 Tightening Torque
Torque for establishing
6 70% of min torque specified
connection between main and Tap (Nm)
Marking and embossing on the
7
connector
. Page 37
ITS ACCESORIES.
176
5. GTP for INSULATED TENSION / MIDPSAN JOINTS

Sl.
PARTICULARS
No
1 Name of Supplier.
IS manufacturer of Accessories an ISO

2
9001-2000 Company?

3 Type No & Size Range
specification
Is any metallic part carrying potential

4
in operation exposed during installation
Crimping by Hexagonal
5 Installation
Compression
. Page 38
177
10."TECHNICAL PARAMETERS
11kV AL59 ACS Covered conductor
AL59-ACS AL59-ACS AL59-ACS
RABBIT RACCOON DOG
Sr.
PARTICULARS Unit COVERED COVERED COVERED
No.
CONDUCTOR CONDUCTOR CONDUCTOR
(50 mm2) (80 mm2) (100 mm2)
1.0 Name of ľhe Manufcľuíeí
2.0 Applicable sľandaíd
3.0 Type of cable AL59-ACS CC AL59-ACS CC AL59-ACS CC
4.0 Volľage gíade kV 11 11 11
5.0 Cíoss-secľional aíea of conducľoí mm2 52.88 78.8 105
6.0 Conducľoí
AL59 ALLOY AL59 ALLOY AL59 ALLOY
CONDUCTOR CONDUCTOR CONDUCTOR
ALUMINIUM ALUMINIUM ALUMINIUM
a Maľeíial
CLAD STEEL CLAD STEEL CLAD STEEL
REINFORCED REINFORCED REINFORCED
(AL59-ACS) (AL59-ACS) (AL59-ACS)
b Shape
No. / diameľeí of wiíes befoíe No. / 6 / 3.35 + 1 / 6 / 4.09 + 1 / 6/ 4.72 + 1/
c
sľíanding mm 3.35 4.09 4.72
d Nominal conducľoí diameľeí mm 10.05 12.27 14.16
e Max. D.C. íesisľance aľ 20°C Ω/km 0.5272 0.365 0.274
f Appíox. bíeaking load KN 22.55 33.45 39.56
7.0 Thickness and dimensions
7.1 Conducľoí scíeen
a Maľeíial
b Nominal ľhickness mm 0.3 0.3 0.3
7.2 Insulaľion - Inneí layeí
a Maľeíial XLPE XLPE XLPE
7.3 Insulaľion - ouľeí layeí
a Maľeíial
c Appíox. oveíall diameľeí mm 17.0 19.5 21.5
d Appíox. weighľ Kg/km 345 485 620
Conľinuous cuííenľ caííying
8.0 capaciľy in aií aľ 40°C ambienľ & Amp --- --- ---
75 ᵒC opeíaľing ľemp.*
9.0 capaciľy in aií aľ 40°C ambienľ & °C --- --- ---
10.0 capaciľy in aií aľ 40°C ambienľ & 220 280 335
11.0 Sag and span
a Span mľí 59 61 61
b Sag (Wiľh No Wind aľ 32⁰C) mm 260 260 270
c Pole heighľ above gíound mľí 8 8 8
c Peícenľage Sag %
Noľe * Cuííenľ íaľings of Coveíed conducľoís menľioned above aíe aľ wind speed 0.5 m/S, Inľensiľy of
* Cuííenľ íaľings of Baíe conducľoís menľioned above aíe aľ wind speed 0.5 m/S, Inľensiľy of
178
Earthing Coil
Earthing Coils shall be fabricated from soft GI Wire Hot Dip Galvanized. The Hot
Dip galvanized wire shall have clean surface and shall be free from paint enamel or
any other poor conducting material. The coil shall be made as per REC constructions
standard (Refer tender drawing No. REC-XI Plan-Gen-005). The Hot Dip galvanizing
shall conform to IS:2629/1966, 2633/1972 and 4826/1969 with latest amendments.
Galvanizing should be heavily coated and should stand for the following tests.
Galvanizing Tests
i) Minimum Mass of Zinc
a) ON GI Wire used 280 cm/m2

b) After Coiling – 266 gm/m2. The certificate from recognized laboratory shall
be submitted towards mass of zinc.
ii) Dip TestShall stand 3 dips of 1 minute and one dip of ½ minute before coiling
and 43 dips of 1 minute after coiling as per IS : 4826/1979.
THE DIMENSIONAL REQUIREMENT SHALL BE AS FOLLOWS

a) Nominal dia of GI Wire 4 mm (Tolerance + 2.5%)
b) Minimum no. of turns – 115 Nos.
c) External dia of Coil (Min) – 50 mm
d) Length of Coil (Min) – 460 mm
e) Free length of GI Wire at one end coil (Min.) – 2500 mm
The turns should be closely bound. Weight of one finished Earthing Coils (min.) –
1.850 Kg.
Adhesion test – As per ISS 4826 – 1979

179
180
TECHNICAL SPECIFICATIONS FOR GAS FILLED

CYLINDRICAL LT CAPACITORS UNIT
1. SCOPE:
This specification covers supply, testing, installation and commissioning of three phase 440V, delta
connected, 50Hz, self healing or explosion proof, metalized polypropylene design, Gas Filled LT Capacitors
Units, Cylindrical type, suitable for outdoor use, intended for power factor improvement and to be
installed on secondary side of the distribution transformers on LT lines poles of various ratings by way of
suitable clamp.
Gas filled capacitor unit shall be ISI Marked along with IP54 degree protection level.
Unless otherwise stipulated in the specification, the capacitor units shall comply all testing parameters as
per IS: 13340 (Part-1 & Part -2): 2012 with latest amendment for routine and type tests including
IP54 and Wave Cut design type tests and also comply IS: 12672: 1989 for internal fuses and internal
over pressure disconnectors.
Only ISI marked capacitor units shall be accepted. Further the equipment, from the
manufacturer having ISO 14000 & above certification in addition to ISO 9000 &
above certification, shall be preferred.
3. CLIMATIC CONDITIONS:
Max. Ambient Temperature

55o C
Min. Ambient Temperature -5o C
Max. Relative Humidity 100%

Min. Relative Humidity 26%
Altitude Below 1000 meters above mean sea level.
The capacitor units shall be, suitably designed & treated for normal life and satisfactory operation under
hot and hazardous tropical climatic conditions and shall be dust and vermin proof. All the parts and surface,
subjected to corrosion, shall either be made of such material or provided with such protective finish so as
to provide suitable protection against any injurious effect of excessive humidity.
4. SYSTEM DETAILS / PARTICULARS
The distribution transformers are connected to the 11 KV network on its HT side while LT side is connected
to the 440 volts LT network.
1) Nominal Voltage: 440 V AC/+10% Volts
2) Over Voltages (excluding transients): As per IS: 13340 (Part 1 & 2):2012
3) Rated Frequency: 50Hz
4) No. of Phases: Three

181
5) Harmonics contents: Harmonic generating leads should be less than 15% of the total load at the trial
load Intended for P.F correction.
6) System Operation hours: Continuous
5. RATING
The stated output of capacitor units in KVAr at frequency of 50 Hz for upper limit of temperature category of
550 C, shall be as per relevant annexure of IS.
6. RATED VOLTAGE
The rated voltage of capacitor units shall be 440 Volts. The fluctuation in supply voltage as specified in IS:
13340 (Part 1 & 2):2012 (with latest amendments) shall not affect normal working of the equipment.
7. GENERAL TECHNICAL REQUIREMENT:
1) The capacitor element used in unit shall have multilayer metalized polypropylene film (MPP)
having low loss dielectric and: impregnated with such impregnant which shall have high dielectric
constant and high chemical stability.
2) The impregnant should be inert gas to avoid risk of fire in case of failure of capacitor. Concentric
winding shall be adopted to form three phases in order to facilitate the better heat dissipation,
reduce interconnections between windings and no heat concentration in the winding cores.
3) The PP film should be in wave cut design, so that higher current carrying capabilities can be
achieved. Active binding element shall be properly heated and then vacuum dried prior to
encapsulation in gas impregnation. The contact area must be carefully prepared so as to achieve
high in rush current and long life. Film thickness minimum 7 micron ( +/- manufacturer tolerance )
4) Discharge resistance shall reduce the residual voltages to less than 75 volts within three minute as
required by latest IS: 13340 (Part 1 & 2):2012. For easy identification of damaged units with naked
eye, Visual Fault Indicator shall be provided.
8. CONSTRUCTION
1. The capacitors should have 3 phases, cylindrical unit housed in cylindrical aluminium container. The
height and diameter of the capacitor shall be as per relevant standard. At the base of capacitor
unit suitable arrangement for earthing preferably in form of M-12 size stud bolt having 16 mm
outer (projected) length with toothed washer hexagonal nut & two numbers spring washer shall be
provided in such a way that it should also serve facility for clamping capacitor unit on LT poles. The
outgoing terminals of capacitor unit should be covered by a UV resistant cap and cable gland with
multi hole rubber. The capacitor & unit with the cap and cable gland should conform to IP 54 degree
of protection.
2. The gas filled in capacitor units must be inert and absolutely harmless to
environment: The operation and disposal of capacitor units must be
environment friendly. The construction features necessary to prevent leakage
and to ensure safety during operation must be adopted.
3. There should be in built protection devices / pressure sensitive in the event of any fault/ abnormal
condition inside the capacitor unit. Occurrence of such condition must be indicated by display of red
182
colour (red UV tape) indication (tape wrapped on capacitor below terminal cover) by upward movement
of terminal cover cap in case of capacitor failure and should be visible from the ground to facilitate
identification and replacement of the faulty unit.
4. The cable connection to terminals shall be encapsulated by resin to avoid loose connection and
climatic effect (corrosion) on terminal contact area.
5. The features necessary for outdoor installation/ operation on L.T lines, without enclosures, must be
incorporated
9. INSTALLATION
LT Capacitors are to be installed on LT Line Poles one span ahead of common Pole (DTR) through
suitable clamping arrangement. A suitable size of ISI marked with UV protection wire of reputed
makes, per phase should be used for connecting the capacitors with DTR.
10. PERMISSIBLE OVER LOADS
For capacitors specified in this specification, the maximum permissible over loads shall not exceed anyone
of the limits given in (i) and (ii) below as conforming to IS: 13340 (Part 1 & 2):2012.
1. Voltage: The permissible overloads shall not exceed limits-set by IS: 13340 (Part 1 & 2):2012
for self healing type capacitors. Capacitors -shall, be suitable for prolonged operation at RMS
voltage between terminals not exceeding 1.1 times the rated voltage. Current: Capacitor units shall
be suitable for continuous operation at RMS
Line current 1.3 times the current occurs at rated sinusoidal voltage and rated frequency
excluding transients. As per IS:13340 (Part 1 & 2):2012 for self healing type, capacitors.
2. Inrush Current: Should be 300 times the I nominal current.
11. CAPACITOR LOSS
The dielectric loss shall not be more than 0.20 W/KVAR. This should be indicated in the bid. The total
capacitor loss excluding discharge resistor and cable should not be more than 0.6 W/KVAR for self
healing type capacitors using metalized polypropylene.
12. CAPACITOR LIFE
The life of capacitor units shall not be less than 1,30,000 hours. The bidder as per the performance
guarantee clause of the specification shall guarantee the capacitor units. The failure rate should be within
3% (including the capacitors failed due to drift in accuracy).
13. SAFETY REQUIREMENT
1. Capacitor unit shall be provided with directly connected discharge device metal oxide varistors
(MOV) or resistors of suitable energy handling capacity and as per IS: 13340 (Part 1 & 2):2012
for self healing capacitors. It should be ensured that there must be no switch, fuse or any other
isolating .device between the capacitor unit and the discharge device.
2. Capacitor shall comply with the relevant general safety regulations for power installation as per
Indian Electricity Rules 1956. The capacitor units shall be provided with a suitable earth terminal
clearly marked so that it will be connected by the worker to the system earth.
3. The protective cap and terminal block should entirely eliminate hazards increase of accidental
contact.
183
14. MONITORING FACILITY

For easy identification of damaged units with naked eye, Visual fault indicators shall be provided.
15. TESTS
a. TYPE TESTS & TEST CERTIFICATES:

The type test is mandatory and pre-requisite. Capacitor Units shall be fully type, tested, as per
latest version of IS. The type test certificates shall be submitted along with the bid of similar orn
higher ratings. Bids, without type test certificates are liable for rejection. The type test certificates
shall not be more than 10 years old.
b. IP 54 TEST
Bidder should furnish IP 54 type test as per IEC 60529 for Similar or higher ratings than required
capacitor.
c. CONCENTRIC WINDING/WAVE CUT DESIGN TEST

Bidder should also furnish type test for wave cut design as a proof that bidder is offering capacitor
banks having wave cut PP (polypropylene) film. Type test of higher or lower rating than that required
here would be acceptable for Wave cut criteria.
d. ROUTINE TESTS
The Acceptance and Routine tests shall be carried out, as per latest version of IS13340 (Part 1 &
Part 2):2012 with its latest amendment.
19. DRAWINGS AND DOCUMENTATION

Tender must accompany relevant catalogues and sectional drawing showing necessary details
of the equipment offered and installation arrangements. One copy of the dimensional drawing and
internal constructional drawing shall be furnished with the tender.
20. GUARANTEE
The capacitor units shall be guaranteed for satisfactory operation for a period of 24 months from
the date of supply or 18 months from the date of commissioning, whichever is later.
21. RATING PLATE

The name plate, containing the information as specified in IS: 13340 Part-1 & Part-2: 2012 shall
be provided on each capacitor unit.
22. BILL OF QUANTITY
Quantity
S. No. Item Description (Nos.)
LT Shunt Capacitors 440V ___ KVAr 3 Phase 50 Hz, IP54 with fault
1 indication. __
2 indication. __
3 indication. __
184
Guaranteed Technical Particulars for Gas filled LT Shunt Capacitor

Sr. No. Particular of Item Required parameters Offered by manufacturer
1. Name of the manufacturer
Address of Manufacturer
2. No. of Phase 3 Phase, delta connected
3. Type of impregnation Gas impregnated
4. Ingress Protection IP 54
5. Type of Winding Concentric Winding
6. Film Cutting technology Wave Cut
7. Dielectric Polypropylene film
8. Thickness of film 7 Micron ±5%.
Highest insulation strength for
9. outdoor applications 15 KV
10. Harmonics 15%
11. Inrush current 300* In
12. Overloads ( voltage and current ) As per IS: 13340 (Part 1):2012
13. Dielectric loss <= 0.2 watts/kvar

Discharge to 75 volts in 180
Discharge IS 13340 ( as per latest seconds as per IS 13340 Part-1
14. edition 2012) 2012.
15. Rating (Output KVAr)
16. Rated Voltage 440 V
17. IR (A)
18. CR (mF)
19. Dimensions (Æ × L) mm
20. Approx Weight (Kg)
21. Capacitor Lifecycle 1,30,000 Hrs
Cable (Cross Section) mm and
22. length
185
TECHNICAL SPECIFICATIONS FOR RESIN FILLED CYLINDRICAL LT

CAPACITORS UNIT
1. SCOPE:
This specification covers design, manufacturing, testing, insurance, transportation and

supply of 440 V Three Phase, Delta connected 50 Hz., outdoor, self healing, Metalised
Poly- Propylene (MPP) design type cylindrical LT fixed shunt capacitor unit intended for
power factor improvement and to be installed near to starter of motor of Agriculture.
Consumers. The capacitance meter of standard make (for measurement of capacitance
at site) equal to 0.1% (1 No. for each 1000 Nos.) of the ordered quantity shall be supplied
free of cost.
2. STANDARDS:
Unless otherwise stipulated in the specification the capacitor units shall generally
comply with IS:13340/1993 (Reaffirmed 1998) for self healing type, S:12672/1989 for
"Internal fuses and internal overpressure disconnectors for shunt capacitors" and
IS:13341/1992 for "Requirements for ageing test, self-healing test and destruction test on
shunt capacitors of the self-healing type for AC power systems having a rated voltage
uptoand including 650 V" (With latest version/amendments).
The capacitor units shall be ISI marked.
The capacitor element used shall be self healing metallised polypropylene (MPP) type.
The cell shall be topped up with Non-PCB, non- hazardous, flexible polyurethane resin. The
capacitor unit shall be hermetically sealed.
This specification supersedes requirements in IS wherever applicable.
LT shunt capacitor meeting any other authoritative standard which ensure equal or
better quality than standard mentioned above will also be acceptable but in such cases, a
copyof standard (English version) adopted, should be enclosed with the tender.
3 CLIMITIC CONDITIONS:
The equipment to be supplied against this specification shall be installed near to

starter of motor of Agriculture. Consumers and therefore shall be suitable for satisfactory
continuous operation at site under the following tropical climatic conditions:
(i) Max. temperature of air in shade : 40 deg. C.

(ii) Min. temperature of air in shade : 5 deg. C.
(iii) Max. relative humidity : 95%
(iv) Min. relative humidity : 10%
(v) Height above mean sea level : Upto 1000 Mt.
(vi) Average No. of thunder storm days per : 40 days
annum
(vii) Dust storms likely to occur : March to May
186
(viii) Average rainfall : 80-180 Cm

(ix) No. of months during which tropical : 4 months June,July,
monsoon condition prevail Aug. & Sept.
4 SYSTEM DETAILS/ PARTICULARS:
The distribution transformers are connected to the 11 KV network on its HT side while
the LT side is connected to the 440 Volts for Three Phase LT network.
i) Nominal Voltage 440 V ± 10% Volts

ii) Rated Frequency 50 ± 3 % Hz
iii) No. of phases 3
5 RATING:
The rated output of capacitor units in KVAR at frequency of 50 Hz for upper limits
of temperature category of 55 Deg.C. shall be as per relevant Annexure-A of the IS.
6 RATED VOLTAGE:
The rated voltage of the capacitor unit shall be 440 Volt for Three Phase
Capacitors.The fluctuation in supply voltage as specified in IS: 585/1962 and IS: 12360/1985
(with latest amendments) shall not affect the normal working of the equipment.
7 GENERAL TECHNICAL REQUIREMENT:
The capacitor elements used in unit shall have multilayer metallised polypropylene
film (MPP) having low losses dielectric and impregnated with a impregnant which has been
completely refinished and degasified so as not to have any deterioration of the dielectric
material. The impregnant used shall have high dielectric constant, low viscosity and high
chemical stability. The impregnant should be NPCB (Non-polychlorinated biphenyl) and
should be non oxidizing and specially suitable for capacitor. Alternatively, capacitor -
elements used in the units shall be MPP thoroughly dried (without NPCB), casted in high
quality epoxy resin of very high dielectric constant. The PP film should be a product
manufactured by a company of international repute. Active binding element shall be properly
heated and then vaccumed dried prior to encapsulation in soft resin. The contact area must
be carefully prepared so as to achieve high inrush current withstand and long life. The
capacitor unit shall have over pressure disconnector protection. The over voltage limiter shall
reduce the residual voltage to less than 50 volts within one minute as required by
IS:13340/1993 with latest ammendment.
8 CONSTRUCTION:
The capacitors should be a compact single unit having following KVAR rating cylindrical unit
housed in cylindrical Aluminium container. The height and diameter of the capacitor unit shall be as
per relevant standards. At the base of capacitor unit suitable arrangement for earthing preferably in
the form of M-12 size stud bolt having 16 mm outer (projected) length with toothed washer and
hexagonal Nut and 2 No. spring washer shall be provided in such a way that it should also serve a
facility for clamping the capacitor unit in the container. A 500 mm length three single core copper
strand wire, flexible cable (ISI mark) of size as indicated in the table given below for various rating
capacitors against each shall also be provided with
187
lugs whose one end shall be connected with three outgoing terminals of the capacitor
unit by soldering and other end having suitable lugs for providing connection at the starter
of Ag Consumers. The outgoing terminals of the capacitor unit should be covered by a cap. The
capacitor unit along with the cap should confirm to IP-54 degree of protection. A fixing clamp with
two nut and bolts spring washer shall be provided duly fitted with capacitor unit two mount
the capacitor on bakelite sheet.
9 PERMISSIBLE OVER LOADS:
For capacitors specified in this specification, the max. permissible over loads shall not
exceed anyone of the limits given in (i) and (ii) below as confirming to IS:13340/1993 (Re-
affirmed 1998).
i) VOLTAGE: The permissible over loads shall not exceed the limits set byIS:13340 for self
healing type capacitors.
ii) CURRENT: Capacitor units shall be suitable for continuous operation at R.M.S. line
current of 1.30 times the current that occurs at rated sinusoidal voltage and
rated frequency, excluding transients (as per IS:13340 for self healing type
capacitors).
10 CAPACITOR LOSS:
The dielectric loss shall not be more than 0.20 W/KVAR. This should be indicated in
the bid. The total capacitor loss excluding discharge resistor and cable should not be more
than 0.6 W/KVAR for self-healing type capacitors using metalized polypropylene.
11 RATING PLATE:
A rating plate shall be provided on each unit with complete information marked
indeliblyin accordance with Clause 10 "Marking" of IS:13340 (With latest amendments).
12 SAFETY REQUIREMENT:
i) Capacitor unit shall be provided with directly connected discharge device metal oxide
varistors (MOV) or resistors of suitable energy handling capacity and as per IS:13340/1993
(With latest amendment) for self-healing type capacitors. It should be ensured that there
must be no switch, fuse or any other isolating device between the capacitor unit and the
dischargedevice.
188
ii) The discharge device shall reduce the residual voltage from the crest value of the rated
voltage to 50V or less within one minute after the capacitor is disconnected from the source
ofsupply.
iii) Capacitor shall comply with the relevant general safety regulations for power installation
as per Indian Electricity Rules 1956.
iv) The capacitor should have Pressure Sensitive disconnector so that in case of capacitor
failure, it is visible from the ground. The pressure sensitive disconnector should be lifted
upto a height of 12 mm so that it may give clear indication of fault occurrence. The colour
marking should also be provided for this purpose.
13 MARKING:
The words "PROPERTY OF MVVNL" shall be marked conspicuously on capacitor

unit with indeable marking along with details of TN No., P.O. No. & Date, rating, Sr. No. etc.
The firm will dispatch the material in continuous ascending Sr. No.
14 TESTS:
14.1 ROUTINE TESTS:
All individual capacitor units shall be subjected to the routine tests at the
manufacturer's works (at the cost of the manufacturer) for the tests specified in Clause
12.1.1 of IS:13340/1993. A certificate detailing the results of such tests shall be furnished by
the supplier alongwith inspection call to the purchaser.
14.2 TYPE TESTS:
All the tests indicated at Clause 12.2.2 of IS:13340/1993 with latest amendments,
if any, shall constitute the type tests. All the type tests shall be carried out at the laboratories
accredited by National Accreditation Board of Testing and Calibration Laboratories (NABL) in
accordance with the IS:13340/1993.
Further the following special tests shall also be covered under type test:
i) Ageing test.
ii) Self-healing test.
iii) Destruction test.
14.3 The tenderer shall furnish copies of type test reports as per relevant IS for the
equipments/ material offered along with the tender. The tenderer should note that the offers
received without type test reports shall stand rejected.
The equipment offered shall be fully type tested as per the relevant standards for all
the type tests specified in the IS at the testing laboratories accredited by National
Accreditation Board of Testing and Calibration Laboratories (NABL). The tenderer shall also
furnish a copy of accreditation certificate issued by NABL to the testing laboratory.
189
Price bids of the firms be opened who have furnished the valid Type Test Reports
which has been conducted at NABL Accredited Lab / Govt. approved Laboratory of offered
type & design as per Clause No. 12.2.2 of IS:13340/1993 with latest amendments, if any,
and not older than five years from the date of opening of Technical Bid.
OR
Price bid of the firms may be opened if the bidder furnishes an undertaking stating that
valid type test certificate of offered type and design as per clause no. 12.2.2 of
IS:13340/1993 with latest amendments, if any from a Govt./Govt. approved /Govt.
recognized /NABL accredited/ ILAC accredited laboratory shall be furnish before
commencement of supply or from first lot (Without asking any delivery
extension) along with the type test bank guarantee of Rs. 5.0 lacs with the
technical bid.
In respect of the successful tenderers, the purchaser reserves the right to demand
repetition of some or all the type tests in the presence of the purchaser's representative. In
case the capacitor unit fails in the type test complete supply shall be rejected.
14.4 ACCEPTANCE TESTS:
The inspecting officer will carry out the Acceptance Tests specified as under as per
IS:13340/1993 (latest amendments) for self healing type capacitors.
i) Visual Examination
ii) Sealing Test
iii) Measurement for capacitance and output
iv) Insulation Resistance Test between terminals & capacitor container.
v) Capacitor loss tangent (tan delta) measurement at elevated temperature.
vi) A.C. Voltage Test between terminals
vii) A.C. Voltage test between terminals & container (for capacitor units &capacitor
bank).
viii) Test for efficiency of discharge device
ix) Any other test as per relevant IS.
14.5 TEST AT SITE:
The purchaser reserves the right to conduct all or any of the tests on LT shunt
capacitors after arrival at stores/ site and the contractor shall guarantee test certificate
figures under actual service conditions.
The supplier should furnish detailed write up for the procedure to be adopted for error
testing of the meters in the laboratory and at site/field.
190
15.0 INSPECTION:
15.1 All the tests (as mentioned at Clause 14.4) shall be made at the place of manufacturer
unless otherwise specially agreed upon by the bidder and purchaser at the time of purchase.
The bidder shall afford the inspecting officer(s) representing the purchaser all reasonable
facilities without charges, to satisfy him that the material is being furnished in accordance
with this specification. The purchaser has the right to have the tests carried out at his own
cost by an independent agency whenever there is a dispute regarding the quality of supply.
The Inspection may be carried out by the purchaser at any stage of manufacture/before
despatch as per relavant standard. The sampling shall be made as per Sampling Plan
Annexure `F' clause No. 12.3 of IS: 13340:1993.
15.2 Inspection and acceptance of any material under the specification by the purchaser,
shall not relieve the bidder of his obligation of furnishing material in accordance with the
specification and shall not prevent subsequent rejection if the material is found to be
defective. The Bidder shall keep the purchaser informed in advance, about manufacturing
programme so that arrangements can be made for inspection. The purchaser reserves
theright to insist for witnessing the acceptance/ routine testings of the bought out items.
15.3 The Bidder shall give 15 days advance intimation to enable the purchaser to depute his
representative for witnessing the acceptance and routine tests. The inspection charges would
be to the purchaser's account.
16 TEST CHECKING OF MATERIAL RECEIVED IN STORE:
a) Test checking of material received in store shall be carried out. On receipt of material
in stores one sample shall be taken from sub-lot/ lot of every 4000 capacitors units or
part thereof for 10 KVAR, 25 KVAR, & 40 KVAR rating. The samples shall be selected
by the purchaser in presence of representative of firm if desired by them. The
following tests shall be carried out:
i) KVAR Capacity.
ii) Capacitor loss in watt per KVAR.
b) For witnessing of the testing, 7 days notice shall be given by the purchaser to the
supplier stating clearly the date, time and place where the tests are to be conducted.
The authorised representative of the supplier and the officer nominated by the
purchaser for witnessing the test shall be present at the time of testing.
c) The results of the test checking shall be applicable to sub-lot/ lot of the capacitor
units of which the samples have been selected at any store of the Nigam. If the
measured KVAR & capacitor loss in watt per KVAR of the samples does not confirm to
guaranteed values as per contract considering tolerance as per ISS, the material shall
be rejected and the rejected material shall have to be replaced by the supplier and in
case of rejection, the testing charges will be recovered.
d) The testing of the samples shall be conducted at the test facilities of the Nigam. In
case facilities are not available in the Nigam, the tests shall be got conducted at any
government test house/ NABL approved test house. All the tests charges
incurred
191
towards test checking of the material in our stores shall be borne by the Nigam
except that of personal expenses of the representative of the supplier for witnessing
the tests.
17 PACKING & FORWARDING:
i) The equipments shall be suitably packed in order to avoid damages/ losses or

breakage during transit or handling. Each capacitor unit may be suitably packed in the
first instance to prevent ingress of dust and moisture and then placed in a cushioned
carton of a suitable material to prevent damage due to shocks during transit. The lid
of the carton may be suitably sealed. A suitable number of sealed carton may be
packed in a case of adequate strength with extra cushioning, if considered necessary.
The cases may then be properly sealed against accidental opening in transit. The
packing cases may be marked to indicate the fragile nature of the contents.
ii) The following information shall be furnished with the consignment:
- Name of the consignee

- Details of consignment.
- Destination.
- Total weight of consignment
- Sign showing upper/lower side of the cartoon
- Sign showing fragility of the material
- Handling and unpacking instructions.
- Bill of Materials indicating contents of each package and spare materials.
iii) The supplier shall be responsible for all the damages/ losses due to improper packing.
Replacement shall be made free of cost regarding material pointed out defective by
theconsignees.
18 DRAWINGS AND CATALOGUES:
Tender must accompany relevant catalogues and sectional drawing showing

necessary details of the equipment offered alongwith bill of material.
One copy of the dimensional drawing and internal constructional drawing shall be
submitted with the tender. These drawings should be in standard size of 12"x18".
19. GUARANTEE:
The supplied capacitors shall be guaranteed against premature failure for a

period of five years from the date of receipt of the material in Nigam's Store.
In case of premature failure, the capacitors shall be replaced free of cost within a
period of sixty days from the date of intimation and guarantee for the new capacitors shall
be started from the date of fresh supplies.
After replacement of defective capacitors with new ones, the defective capacitors
would be returned to the manufacturers.
192
20. GUARANTEED TECHNICAL PARTICULARS:
The guaranteed technical particulars proforma as enclosed at Schedule-I with the

specification, shall be furnished duly filled along with the tender.
21. DELIVERY SCHEDULE:
The bidders are required to indicate the delivery period in the schedule attached
herewith. The commencement period shall include the time taken for conducting the type
test and approval of drawings etc. The maximum commencement period should not be more
than 45 days from the date of receipt of P.O. Further the monthly delivery quoted shall be
such that the entire offered quantity shall be completed within a period of 10 months from
date of issue of P.O. including commencement period. The offers deviating in deliveries as
per above schedule given, shall be considered as non-responsive. The monthly delivery shall
be quoted irrespective of the offered / ordered quantity and offers with any conditional
deliveries shall beconsidered as non-responsive.
22. PRICE:
The price shall be quoted on FOR destination basis in the manner detailed in
schedule of price (BOQ) indicating details of Ex-works price, excise duty, freight and
insurance charges, sales tax/VAT and entry tax (for outside Rajasthan firms) for delivery at
our stores.
The quoted price shall be FIRM. The price shall be quoted after considering
MODVAT benefit and benefit of VAT available to the supplier. The offers where the price
have not been quoted in prescribed manner are liable for rejection.
193
Schedule -I
GUARANTEED TECHNICAL PARTICULARS OF THREE PHASE LT SHUNT CAPACITORS
Sr.
Particular of Item 10 KVAR 25 KVAR 40 KVAR
No.
1 Type / Rating
2 Manufacturer’s name and Trade mark
3 Country of origin
(a) Whether ISI marked
(b) ISI mark license No.
4
(c) Valid upto
(d) Rating covered in license (Enclosed copy of license)
(a) Shape of basic element
(b) Type of dielectric film used
(c) Thickness of film (Microns)
(d) No. of film layers between aluminium foils
5
(e) Voltage stress (Volts / Microns)
(f) Voltage rating of each pack
(i) Without thickness of impregnent
(ii) With thickness of impregnent.
Dielectric used
6 (a) Inflamable or non inflammable
(b) Type of dielectric used.
7 Type of impregnent used
8 Rated capacity of each capacitor unit
9 (a) Rated voltage
(b) Permanent Over Voltage
8 hours/day
30 min/day
5 min/day
1 min/day
(c) Mfd. per phase
(d) Life Expectancy in hours
(e) Capacitor losses in W per KVAR (Max.)
(a) Max. temperature rise
10
(b) Hot Spot temperature rise
11 Voltage proof test
(a) Test Voltage between terminals
(b) Test voltage between terminals and container
Is the cells offered fitted with 3 phase pressure
(a) interrupter with visible indication of failure
12
(b) Is the indication visible from a distance? Give details.
How does the interrupter disconnect phase by
(c) phase, or simultaneously?
13 Weight of each capacitor unit
Material and dimensions of container
(a) Material of container (Whether CRCA sheet or not)
(b) Dimensions:
14
194
14
(i) Length (mm)
(ii) Diameter (mm)
(iii) Height (mm)
15 Details of testing facilities
(i) Details of testing facilities available
(ii) Test on raw material
(a)
(b)
(c)
(d)
(ii) Routine tests:
(a)
(b)
(c)
(d)
(iii) Acceptance tests:
(a)
(b)
(c)
(d)
(iv) Type Test:
(a)
(b)
(c)
(d)
Note:- In case testing facilities are not available for certain test,indicate in the remark column that from
which testing house(s)/ Institution(s) these test will be got carried out.
(Signature)
Name & Designation
with seal of the bidder
195
TECHNICAL SPECIFICATION FOR DWC HDPE PIPES

This Specification covers design, manufacturing, testing, packing, supply of DWC HDPEPipe.
1 Service Conditions:
Equipment to be supplied against this specification shall be suitable for satisfactorycontinuous
operation under the following tropical conditions.
a)
b)
c)
d)
e) Relative Humidity: up to 95%
f) Average number of thunder storm days per annum: 15
g) Maximum annual Rainfall: 150cm
h) Maximum Altitude above mean sea level: 1000Meter
i) Maximum Wind Pressure: 150 Kg/cm2 (As per IS 802 latest code)
j) Maximum soil temperature at cable dk)
2 Technical Parameters:
(a) DWC high density Polyethylene pipe shall have corrugation on outer wall but innerwall
shall be plain conforming to IS 14930 Part I and II amended from time to time.
(b) Terminology as defined in IS: 14930shallbefollowed
(c)
(d)
to make the joints water / damp proof.
3 Code & Standards:

All standards, specifications and codes of practice referred to herein shall be the latest editions
including all applicable official amendments and revisions as on date of opening ofbid. In case of
conflict between this specification and those (IS: Codes, standards, etc.) referred to herein, the
former shall prevail.
a) IS:14930Pt.-I:General requirements of Conduit System for Electrical and
Communication installation
b) IS:14930Pt.-II: Particular requirements of Conduit system for Electrical and
Communication installation
c) IS: 2530: Method for test for Polyethylene moulding material Sand polyethylene
compounds.
d) IS:7328: HDPE materials for moulding and extrusion
e) IS:12063 : Classification of degrees of protection provided by Enclosures of
electrical equipment
f) ASTMD 1693: Test method for environmental stress Cracking of ethylene plastics
g) ASTMD638:Standard test method for tensile properties of plastic
h) ASTMD790: Test method for flexural properties of Un-reinforced and Reinforced
Plastics and Electrical Insulating Materials.
i) ASTMD 2240: Standard Test method for Rubber property.
j) ASTMD648: Standard Test method for deflection temperature of Plastic under
flexure load in the Edge Wise Position.
196
k) IS:11000(Pt-2):Glow-wire Test and guidance test methods for fire /Sec-1) Hazard
Testing.
4 General Requirement:
General:
i. The DWC HDPE pipe shall consist of two layers, the outer layer will be corrugated andthe
inner layer shall be plain and smooth.
ii. DWC HDPE pipe shall be so designed and constructed that in normal use their
performance is reliable and without danger to the user or surroundings.
iii.
therein.
iv. Within the conduit system there shall be nos hardedge, burrs or surface projections which
are likely to damage insulated conductors or cables or inflict impure it to the installer or
user.
v. The protective properties of the joint between conduit and conduit fittings shall be not
less than that declared for the conduit system.
vi. The DWC HDPE pipe and fittings hall withstand and the stresses likely to occur during
transport, storage, recommended installed on practice and application.
vii. The DWC HDPE pipe shall be supplied in continuous length in coil for more straight length,
suitable for shipping and handling purpose.
viii. For conduit systems that areas assembled by means other than threads, the manufacturer
shall indicate whether the system can be disassembled and if, so, how this can be
achieved.
REQUIREMENTS OF RAW MATERIALS USED FOR THE DWC HDPE PIPE

i. The base HDPE resin used for the outer and inner layer of the DWCHDPE Pipe shall
conform to any designation of IS: 7328or to any equivalent standard meeting the
requirements given inTableNo.1, when tested as per the standards given their in.
However, the manufacturers shall furnish the designation for the HDPE resin as per IS:
7328 as applicable.
ii. The anti-oxidants used shall be physiologically harmless.
iii. None of the additives shall be used separately or together in quantities as to impair long
term physical and chemical properties of the duct.
iv. Single pass rework material of the same composition produced from the
ny case.
v. The raw material used for extrusion shall be dried to bring the moisture content to less
than 0.1%.
vi. Suitable UV stabilizers shall be used only for manufacture of the nonblack colored HDPE
duct to protect against UV degradation, when stored in open for minimum 8
Content test by FTIR method from any recognized laboratory shall be accepted and the
Hindered Amine Light Stabilizer shall be minimum 0.15 %. UV Content test need not to be
conducted in case of UV Stabilized raw material is used.
REQUIREMENT OF DWC HDPE PIPE
i. Visual Requirement: The Pipe shall be checked visually for ensuring good workmanship
that the ducts shall be free from holes, breaks and other defects. The ends shall be
cleanly cut and shall be square with axis of the ducts.
ii. Colour: The colour of the pipe viz. Green, Orange, Blue, Yellow, Brown, Violet, Grey and
Red. The purchaser shall specify the colour of the duct at the time of ordering.
197
iii. Dimensions: The dimensions of the DWC HDPE pipe shall be as per requirement / BOQ.
iv. Standards Length: Duct up to 50 mm OD nominal size shall be supplied in standard length
of 100 mtr. ± 1% or 6 mtr ± 1 % and all other sizes will be supplied in standardlength of 6
mtr. ± 1%
v. Compression Strength: The conduit system shall have adequate mechanical strength.
Conduits when bent or compressed either during, or after, installation according to
extent that introduction of the insulated conductors or cables becomes difficult or that
the installed insulated conductors, or cables are likely to be damaged while being drawn
in. Compliance may be checked with the application of force which shallbe at least 450 N,
when reaching the deflection of 5%.
vi. Impact Strength: The conduit system shall have adequate mechanical strength.
vii. Conduits when exposed to impact either during, or after, installation according to
extent that introduction of the insulated conductors or cables becomes difficult or that
the installed insulated conductors, or cables are likely to be damaged while being drawn
in. Compliance may be checked by ensuring there shall be no crack allowing the ingress of
light or water between the inside and outside after the test.
viii. Bending Strength: The conduit system shall have adequate mechanical strength.
instructions, shall not crack and shall not be deformed to such an extent that introduction
of the insulated conductors or cables becomes difficult or that the installed insulated
conductors, or cables are likely to be damaged while being drawn in. During the test
sample shall not flatten Compliance shall be checked by passing a ball having a diameter
equal to 95% minimum inner diameter of the sample declared by the manufacturer,
through the sample whilst it is bent around the test apparatus.
ix. Oxidation Induction Test (OIT): The OIT in a qualitative assessment of the level (or
degree) of stabilization of material.
x. Resistance to Flame Propagation: Non flame propagating ducts shall have adequate
resistance to flame propagation. Samples of DWC HDPE Ducts shall be checked by applying
a 1KW flame.
xi. Anti-Rodent Properties: Safety of ducts from the direct attack of subterranean organism
anti rodent material is of utmost importance. These ducts shall be evaluated for their
safety against rodents before laying them in the fields.
xii. Resistance to External Influences on DWC HDPE Duct Accessories: The accessories in
Clause 11.5.4 shall be tested for external influences as per IS-12063 for ingress of dust &
ingress of water. DWC Duct systems when assembled in accordance with the
according to the classification declared by the manufacturer with a requirement of IP67.

xiii. Marking Identification: The conduit shall be prominently marked at regular intervals along
their length of preferably 1m but not longer than 3m using indelible ink with following.
Manufacturers name
Specification No.
Name of the duct with sizeLot
No. of the Product Date of
manufacture Product Length
198
DWC HDPE PIPE ACCESSORIES
i. The following accessories are required for jointing the ducts and shall be supplied along
with the ducts against specific orders. The manufacturers shall provide complete
procedure and method for installation of the accessories. The required quantities of
accessories are to be mentioned by the purchasing authority in the purchase order.
a. Plastic Coupler:
The coupler shall be of Push-fit type with O-ring. It is used for jointing woor more ducts.
The design of this shall be simple easy to install and shall provide air tight andwater tight
joint between the two ducts. The coupler shall insure that the two ducts are butted
smoothly without any step formation in the inner surface. The coupler may be straight,
bands, T-joints type as per requirements of purchaser.
b. End Cap:
This cap made of suitable plastic material shall be fitted on the both ends of duct, coil
after manufacturing the duct. This shall avoid entry of dust, mudandra in water in to the
duct during the transit &storage.
Selection of pipe for different sizes Cables
Following guide of the pipe fill shall be used for sizing the pipe Size:
a. 1 cable in pipe - 53% full
b. 2 cable in pipe - 31% full
c. 3 or more cables - 43% full
d. 4 Multiple cables - 40% full
5 Tests
The following tests shall be carried out in accordance with IS or the latest versionthereof:
a. TYPE TESTS
i) Visual.
ii) Requirement of Colour.
iii) Dimension
iv) Standard Length
v) Compression Strength
vi) Impact Strength
vii) Bending Strength
viii) Oxidation Induction Test
ix) Resistance to Flame Propagation
x) Anti-Rodent
xi) Resistance to External influence on DWC HDPE Pipe
b. ACCEPTANCE TESTS
The following tests be carried out by the manufacturer after 240 hrs of manufacture: -
i) Visual Requirement
iii) Dimension
iv) Standard Length
vi) Impact Strength
viii) Resistance to Flame Propagation
199
c. ROUTINETESTS
The following tests be carried out by the manufacturer after 240 hrs of manufacture: -
i) Visual Requirement
iii) Dimension
iv) Standard Length
vi) Impact Strength
viii) Resistance to Flame Propagation
6 Tests Procedure
a) COMPRESSION TEST
i. Conduits are subjected to a compression test as per IS: 14930 (Pt-II). The tests for conduits
shall not best rated until 240 hrs after manufacture.
ii. Samples shall be200 ±5mm long.
iii. Before the test the outside and inside diameters of the samples shall be measures described
in clause above.
iv. The samples shall be compressed between two flat steel plates having minimum dimensions
(100x200x15mm), the length 200mm being along the length of the sample.The sample shall
be compressed data rate of 15±0.5mm/min and the load recorded atthe vertical deflection
equivalent to 5%of the average value of the original inside diameter of the sample.
v. When reaching the deflection of 5 %, the applied force shall be at least 450N
vi. After the test there shall be no crack allowing the ingress of light or water between the
inside and the outside.
vii. The deflection is calculated with the inner dia meter but the measurement of the outside
diameter may be sufficient. In case of doubt, itwill be necessary to measure the inner
diameter.
b) IMPACT TEST
i. Twelve samples of the duct each 200±5mm in length or fittings are subjected to an impact
test as per IS: 14930(Pt-II) by means of the apparatus shown Figure-1.
ii. The test apparatus shall be placed on a firm flat surface. The samples shall be conditioned
in a cold chamber at a temperature of 5±1°C for 2h. The samples shall beremoved from the
cold chamber and placed on the vee block holder of the impact tester as shown in figure 1.
iii. The striker shall fall once on each sample. The time between removal of the sample from
the cold chamber and completion of impact shall not exceed 10seconds.The impact height
and mass shall be as follows.
Nominal Size of Mass of Striker Fall Height Energy Joules
Conduit (+1%/-0%)kg (+0%/-1%)(mm)
Upto60 mm 5 300 15
61to90 mm 5 400 20
91to140 mm 5 570 28
Above140mm 5 800 40
iv. The test sample shall be made on the weakest part of the Duct fittings except that it shall
not be applied within 5mm of any sample entry. Samples of ducts are tested on
the center of their length
200
v. After the test, at least in nine of the samples, there shall be no crack allowing the in gress
of light or water between the inside and the outside.
c) BENDING TEST
i. This test shall be carried out on pliable conduits.
ii. The test is made on six samples having an appropriate length as per IS: 14930 (Pt II). Three
samples shall be tested at room temperature; the other three shall be tested at- 5±1°C.For
the test at -5°C, the sample shall be conditioned in a cold chamber for 2 hours. The test
apparatus as shown in Figure-2 shall allow being the duct with a bending radius equal to the
minimum bending radius values specified by the manufacturer. One of the ends soft he
samples shall be fixed. The sample is then bent to approximately 90 degrees (right angle)
and hold.
iii. During the test, the sample shall not flatten. Compliance shall be checked by passing a ball
having diameter equal to 95%minimum inner diameter of the sample declared by the
manufacturer, through the sample whilst it is bent around the test apparatus.
d) OXIDATION INDUCTION TEST PROCEDURE
i. A short length of completed duct (approximately 30cm) shall be sealed at the end sand
placed in an oven at temperature of 68±1°C for 8 hours. The sample shall then beallowed to
cool at room temperature for at least16hrs.The samples shall be clean anddry. The sample
shall then be tested by means of a Differential Canning Calorimeter (DSC) or by Differential
Thermal Analyzer (DTA).
ii. Instrument Test Procedure:
Cell Cleaning: The cell shall be held at approximately 400°C for 10minutes in Nitrogen.
The cell shall be cleaned after standing over night and between testing of different
formulations.
Temperature Calibration: This has to be done according to the instrument manual. The
temperature scale should be adjusted until the determined melting point of pure
Indiummetalis 156.6°C at a heat rate of 5°Cper minute or any other heat rate as indicated
in the manual of the equipment is permitted.
Aluminum Pan Preparation: Standard aluminum DSC pans as per ASTMD 4565 are required
to hold specimens during testing. A fresh pan shall be used for each test.
Sample preparation: Take the sample weighing about 5mg from the duct conditioned as
indicated above. Position the sample in the center of the pan.
Nitrogen Purge: Place the sample pan and reference pan in instrument cell. Flush for 5
minutes with cylinder of nitrogen (99.6%extradrygrade) at 60±10 cc per minute.
Oxidation Test: Rapidly increase the temperature of the sample (20°C/minor greater)
from 100°C or lower initial temperatureto 199±1°C. After
thermal equilibrium is obtained (steady recorder signal) switch to 80±20cc per minute
oxygen flow and simultaneously start time-base recording. The oxygen used for the test
should be equivalent to or betterthan99.6% extra dry grade.
Induction Period: The oxygen induction point shall be recorded as time zero, and thechart
speed shall be sufficient to provide a clearly discernible lop eat the start of theexothermic
reaction. The test in the pure dry oxygen atmosphere shall continue until the exothermic
peak is produced. The inter section of the tangent of the exothermic sloped line with the
extended base line will be drawn. The time from time zero to isinter section point is read
from the base line and recorded as the oxidative inductiontime.
201
e) RESISTANCET OF LAME PROPAGATION TEST PROCEDURE

i. Samples of DWC HDPE Ducts shall be checked by applying 1KW flame.
ii. As ample of length 675+10 mm is mounted vertically in a rectangular metal enclosure with
one open face, as shown in Figure-3-2 in an area substantially free from draughts. The
general arrangements is shown in Figure-3 Mounting is by means of two metal clamps
approximately 25mm wide spaced 550 +10mm apart and approximately equal distance from
the ends of the sample. A steel rod of 16+ 0.1 mm is passed through thesample. It is rigidly
and independently mounted and clamped at upper end to maintain the sample in a straight
and vertical position. The means of mounting is such as not toobstruct drops from falling on
to the tissue paper. A suitable piece of white pine woodboard, approximately 10 mm thick,
covered with single layer of white is sue paper is positioned on the lower surface of the
enclosure.
iii. The assembly of sample, rod and clamping apparatus is mounted vertically in the center of
the enclosure, the upper extremity of the lower clampbeing500+10mmabovetheintern
allowed surface of the enclosure.
iv. The burner is supported so that its axis is 45+20to the vertical. The flame is applied tothe
samples that the distance from the top of the burner tube to the sample measuredalong the
axis of the flame is 100+10mm and the axis of the flame intersects with the surface of the
samples at a point 100+5 mm from the upper extremity of the lower clamp, and so that the
axis of the flame intersects with the axis of the sample.
v. The test is carried out on three samples. During the application of the flame, it shall not be
moved except to remove it at the conclusion of the period of the test. After the conclusion
of the test and after any burning of the sample has ceased, the surface of the sample is
wiped clean by rubbing with a piece of cloth soaked with water.
vi. All three samples shall pass the test. If the sample is not ignited by the flame, it shall be
deemed to have passed the test.
If the sample burns, or is consumed without burning, the sample shall be deemed to have
passed the test if after burning has ceased, and after the sample has been wiped in
accordance with1.3 there is no evidence of burning of charring within 50mm of the lower
extremity of the upper and also with in50mm of the upper extremity of the lower clamp.
If the sample burns, it shall be deemed to have failed the test if combustion is still in
progress 30seconds after removal of the flame.
If the tissue paper ignites, the sample shall be deemed to have failed the test. For theparts
of the same below the burner, the presence of molten material on the internal or external
surfaces shall not entail failure if the sample itself is not burned or charred.
vii. Compliance of DWC HDPE Duct fittings is checked by using the glow wire test IS: 11000
(Part2/Sec1). The glow wire shall be applied once to each sample in the most unfavorable
position of its intended use, with the surface tested in vertical position, at a temperature
of 750oC. The sample is deemed to have passed this test if there is no visible flame or
sustained glowing or inflames or glowing extinguishes within 30 soft here moval of the glow
wire.
f) ANTI RODENT TEST PROCEDURE:
The test against rodent may be conducted as per following procedures:
The ducts are to be laid underground in fields and also near urban or rural settlements.
Therefore, they should be exposed to 3-4 most predominant rodent species in habiting
these locations. The test rodent species may include the lesser bandi cootrat, Bandi
cotabengalensis, The Indian gerbils, tatera indica, the soft furred field rats, Millar diamelt
ada and the house rats, Rattusrattus.
202
The test ducts should be exposed to the serodent species housed individually in iron mesh
cages under laboratory conditions. Only freshly capture rodent are to be utilized for the
study. The rodent sare first acclimatized in laboratory cages for7-10 days and then the
tests be initiated. For each trial, 3-4 rodents of uniform body weight are to be used for the
trial. Two different types of testes may be under takenfor all the ducts.
Choice Tests: In this trial the ducts of 15-30 cm length (ones ample each of treated and
untreated/ control sample) are exposed to the test rodents along with food, thusthe roden
thada choice between the food and the test duct. This test may be run forlonger periods
(30-45days). Tap water should be provided adlibitum to the rodents.
NO Choice Test: The rodents are exposed to the test ducts only and no food is given to the
rodents during the period of trial. The test ducts (one sample each of treated and
untreated/control sample) are to the exposed to the test rodents. This trail maybe run for
5-7 days depending upon the health status of starved test rodents. Tap water should be
providing dad labium other rodents.
Observation on tooth marks, rodent behavior toward exposed ducts, and relative extent of
damage in treated and untreated samples should be computed for both types of ducts.
Health status of test animals in choice and no choice test must also bemonitored for their
cordanyill effect of exposure of treated/ control ducts on these animals. Number of cases
and the extent of rodent bites/scratch marks in control andanti-rodent treated ducts may
indicate the relative deterrent/repellent properties ofthe test ducts.
203
FIGURE- 1
IMPACT APPRATUS
204
TENDER NOTICE No:-
FIGURE- 2
BENDINGTESTAPPARATUS
205
RESISTANCETOFLAMEPROPAGATIONTESTAPPARATUS
206
GTP OF HDPE PIPES
SR. DESCRIPTION / PARAMETERS OFFERED BY THE BIDDER

1 Make
2 Applicable Standard
3 Grade
4 Pressure rating (Kg/Sqcm.)
5 Outside Diameter (mm)
6 Inside Diameter (mm)
Recommended For (Mention Maximum
7
Armoured cable Type and Size)
207
TECHNICAL SPECIFICATION FOR LT SHACKLE

INSULATORS
1. SCOPE:
This specification covers the details of the LT Shackle White glazed/brown glazed
insulators for use on 230/440V overhead lines and to supply to any of our Regional
Stores/Divisional Stores/Destinations in Uttar Pradesh as intimated by the DISCOM
time to time.
IS-1445/1977 (Second revision Including Amendment Nos. 1,2,3,4 &5) and its latest
amendment if any.
3. GENERAL REQUIREMENT:
3.1 The porcelain shall be sound, free from defects, thoroughly vitrified and
smoothly glazed.
3.2 The glaze, unless otherwise specified shall be brown in colour. Except the
parts on which the porcelain is supported during firing, which may please be left
unglazed, all other surface of the insulators shall be effectively glazed.
3.3 The design of the insulators shall be such that stresses due to expansion and
contraction in any part of the insulator shall not lead to deterioration.
3.4 The insulator shall be in one piece.
4. INSULATOR CHARACTERISTICS:
The insulators shall have the electrical and mechanical characteristics given in Table-I
of IS-1445/1977 as under:
Dry P.F. Wet P.F. Min.

P.F. Puncture
Sr. Type of Withstand Withstand Failing
withstand voltage
No Insulator voltage KV voltage load
KV (rms)
(rms) KV (rms) KN
1.3 x the actual dry 11.5
1 Shackle 23 10
flash over voltage. (Type-1)
N.B.: Size of shackle 90 x 75 mm as per Fig. 3 Type-I of IS: 1445/1977.
5. TESTS:
The Insulator shall comply with the following tests as per IS: 1445/1977
(Second revision Including Amendment Nos. 1,2,3,4 &5)
5.1 ROUTINE TEST:
The following test shall be carried out as routine test.
Visual Examination:- This test shall apply to all insulators.
5.2 TYPE TESTS: (IS: Cl no. 8.1)

The firm shall submit the type test report from Govt. approved laboratory not
more than Seven (07) years old along with offer .The following type tests are to
208
be carried out on Two (02) nos. of samples in the order mentioned below as per
IS: 1445/1977.
a) Tests on the Both Insulators:
i) Visual examination (8.4)
ii) Verification of dimensions (8.5)
iii) Dry power frequency Voltage withstand test (8.6)
iv) Wet power frequency voltage withstand test (8.7)
v) Temperature Cycle test (8.8)
b) Tests on First Insulator:
i) Mechanical failing load test (8.9)
ii) Porosity test (8.11)
c) Test on Second Insulator:
i) Power frequency puncture withstand test (8.10)
NOTE: - The identification marks of Firm provided on the insulator should be

invariably mentioned in the Type Test Certificate.
5.3 ACCEPTANCE TESTS:

The test samples after having withstood the routine test shall be subjected to the
following Acceptance Tests in the order indicated below:
a) Visual examination (8.4)
b) Verification of dimensions (8.5)
c) Temperature Cycle test (8.8)
d) Mechanical failing load test (8.9)
SAMPLE SIZE- ACCEPTANCE AND REJECTION NUMBERS
Lot Size First Second Acceptance First Second

Sample Sample Number Rejection Rejection
Size Size Number Number
(1) (2) (3) (4) (5) (6)
Up to 500 8 8 0 2 2
501 to 1000 13 13 0 3 4
1001 to 3000 20 20 1 4 5
3001 to 10000 32 32 2 5 7
10001 to 35000 50 50 3 7 9
35001 and above 80 80 5 9 13
As per IS 1445:1977 Ammendment-5 January 1993 (Table-3, Clause-B-1.1)
The criteria for conformity should be as per IS 1445:1977 Ammendment-5, B-2
6. MARKING:
Each Insulator shall be legibly and indelibly marked to show the following.
a) Name and Trade Mark of the manufacturer.
b) Year of manufacturing.
c) Word 'Name of DISCOM'.
209
d) Minimum failing load in KN.
Marking on porcelain shall be printed and shall be applied before firing.
7. PACKING:
Each Insulator should be wrapped with dry grass. This shall be then packed in either
crates/boxes/polythene or double gunny bags suitable for rough handling. No. of
insulator should not be more than 50 in one bag.
8. TENDER SAMPLES:
The Tenderer has to submit Two (02) nos. of samples along with offer. The offer
without samples will be straight-way rejected.
Manufacturer's Name
and Address:
210
GUARANTEED TECHNICAL PARTICULARS (G.T.P.)
Technical information and Guaranteed Technical Information for supply of LT Shackle

Insulators
PART-‘A’
Bidder has to confirm following important requirements.
Sr.
Particulars Confirmation
No
Insulator shall be manufactured as per IS: 1445/1977 (Second
1 Yes
revision Including Amendment Nos. 1,2,3,4 &5)
2 Size of Insulator 90 x 75 mm. Type-I, Fig-3 of IS: 1445/1977 Yes
3 Dry power frequency withstand voltage 23 KV rms Yes
4 Wet power frequency withstand voltage 10 KV rms Yes
Power frequency puncture withstand voltage KV rms i.e. 1.3 x the

5 Yes
actual dry flashover voltage
6 Mechanical failing load 11.5 KN (Min) Yes
Tolerance in dimension as per relevant IS-1445/1977 (Second

7 Yes
revision Including Amendment Nos. 1,2,3,4 &5)
8 Marking on insulator as per Clause No.6 Yes
9 Packing of insulators as per Clause No.7 Yes
PART-‘B’
Bidder has to furnish below details about material.
1. Colour of glaze of LT Shackle Insulator

2. Type of firing the insulator
3. Details of test conducted on raw material
4. Quality assurance plan which are being implemented
211
PART-‘C’
ENCLOSURES:
Bidder has to enclose following documents and has to confirm for the same.
Sr.N
Particulars Confirmation
o.
2 nos. (Two) of samples for LT Shackle Insulators to be sent
1 Yes
with tender
Type test certificate covering all the tests as per Cl. No. 5.2 of
2 Tender specification from NABL accredited/ Govt. approved Yes
laboratory
3 List of Plant and Machinery Yes
4 List of Testing Equipment Yes
List of Orders pending / executed at least for past Three (03)
years for the item offered:
5
(a) With MVVNL and their subsidiary companies Yes
(b) With the purchase other then MVVNL and their Yes
subsidiaryCompanies
PART-‘D’
Bidder has to mention below deviation if any, quoting relevant clause of Technical
Specification.
Signature & seal of Tenderer

212
TECHNICAL SPECIFICATIONS FOR 3 PHASE L.T. DISTRIBUTION BOX FOR

AERIAL BUNCHED CABLE
1 SCOPE:-
a) The Specification covers the design, manufacture and testing of Moulded

Distribution Box to provide service connection to LT Line Consumers through over head ABC
line.
b) The LT Distribution Box should be suitable for Outdoor use and will be installed at the
poles.
c) The Distribution box should be anti corrosive, dust proof , rust proof, shock proof,
vermin proof, U.V. stabilized and flame retardant property. Base door or other joint should not
bend or soften on heating so as to ensure tamper proof construction.
d) The Distribution box should not melt at high temperature. .
e) The body of box should be single piece moulded without any construction joint.
Door will also single piece moulded in one door or double door construction as per specific
requirement.
2 MATERIAL OF DISTRIBUTION BOX:
a) Material of construction of distribution Box shall be THERMOSETTING PLASTIC i.e.

Glass Fiber Reinforced Polyester Sheet Moulding Compound (SMC) as per IS: 13410 -1992
and confirming to the requirements of this specification/GTP.
b) Material of box should withstand temperature rise, hot spot temperature and
occasional arcing bas box.
c) All other MS part should be anti corrosive treated.
3 CONSTRUCTION:
a) Distribution box shall comprise of SMC moulded base and SMC moulded door of
in single piece moulded construction without fabrication joints.
b) Concealed hinges should fix the base and cover, with hardware from inside in such a
manner that it can’t be manipulated from outside.
c) The door in closed position should be overlapped on base such that direct entry of
screwdriver, tool or rod is not possible.
d) Wall mounting holes should be made.
e) Provision of wire seal should be made.

213
f) Cable entry holes should be provided PVC Plug.
g) Earthing bolt shall be provided as shown in drawing.
h) All the corners of the meter box should be round.
i) The box should have sealing as well as pad locking arrangement.
4 DESIGN:
a) The Distribution Box shall have 3 Phase Bus bars of EC grade Aluminium of size
25x6x300 mm long and natural bus bar shall be of size 40x6x300 mm. The Bus bars shall be
provided with colour coding for identification. Each Bus bar shall be provided with facility of
cable termination as under:-
i) Incoming : 1 No lead per phase, thus 4 polymeric gland of 25 mm dia at bottom.
ii) Outgoing : Twelve leads per phase, thus 12 nos. 10 mm dia holes with
rubber gromets i.e. 6 holes on each Side wall with rubber covers.
b) To facilitate easy working on termination on bus bar, the arrangement for termination
of each lead should be have 6 mm dia holes duly fitted with M 6 x 20 screw, 1 custom
designed Aluminum palm washer, 1 washer, 1 spring washer and 1fly nut as shown in drawing.
c) In order to restrict entry of tool from unused (cable entry) holes, partition plate
should be provided between wall of the box and bus bar system. The service wire/cables
will be taken from entry hole, suitably bent and taken to bus bar and finally the wire/cable
shall be terminated and lightened using fly nut.
d) The assembly of four nos. Al. Busbars shall be mounted on one SMC Step mounting
arrangement. The mounting arrangement of Bus bars shall be such that minimum
clearance of 50 adequate space for working as well as bending of wires . Also there should
be minimum clearance of 40 mm between each bus bar so as take care of clearance and
creepage distance requirements in line with IS 13947.
e) The dimension of box shall be 450x375x200 mm. Thickness of box shall be 3 mm.
5 COLOUR :
The colour of box shall be Off White such that it does not absorbe heat of solar
radiation. Reprocessible plastics and of dark colour will not asseptable.
6 MAKING:
Each Box shall be legible marked as under “MVVNL PROPERTY”
1. Manufacturer’s name
2. Danger Logo
7 DRAWING: Refer to enclosed drawing (Annex-I)
8 GUARANTEED TECHNICAL PARTICULARS: Given in the enclosed Annex-II.

214
9 TESTING
One sample selected from first lot should be tested at Govt. approved
independent test house for compliance of performance parameters as given in GTP
including Material identification to be carried out by CIPET/IR Spectrometry. The test
report should be submitted to purchaser before completion or order. Inspection of
each lot, sampling plans for test: 1 nos. selected randomly from Lot for testing at
works.
Sl. No. Test Requirement of Meter Box. Reference Standards
a Marking IS: 14772
b Dimensions and construction -D0-
c Heat Deflection Temperature (Min. 1500 C) IS:13411
d Spirit Burner Test (Self Extinguishing) IS:4249 IS:13360 part 6 Sec 10, 1992
Section 1 method „A‟ Capillary
e Melting Point (Does Not Melt Test up to 2500C) Tube Method
10 SPECIFIC REQUIREMENT:
Thickness of SMC Box - 3 mm (Min)
Dimension - 450 (H)x375(W)x200(D) mm.
No. of doors - Single door hinged type

215
216
217
218
219
220
TECHNICAL SPECIFICATION FOR PUSH FIT TYPE MOULDED

METER BOX SUITABLE FOR THREE PHASE STATIC ENERGY
METERS
1.0 SCOPE:
This specification covers the moulding and supply of moulded Meter Box suitable to
house the Energy Meters. The Meter Box shall be suitable for wall mounting.
2.0 TECHNICAL REQUIREMENT & STANDARDS
2.1 MATERIAL AND STANDARDS

The Meter Box i.e. base and cover shall be made of injection moulded, unbreakable, high
grade flame retardant polycarbonate with minimum thickness of 2.0 mm having good
dielectric and mechanical strength however, due to manufacturing process, the negative
tolerance of 0.2 mm may be allowed.
The top cover of the Meter Box must be totally transparent without any provision of the
separate window arrangement. The material must be „UV‟ stabilized to ensure that the
moulded Meter Box should not change in colour shape, size and dimension when
subjected to 200 hrs. on U-V ageing test.
The Meter Box should have tapered surface / corners to prevent stay of rain water at
the top of the meter cup board.
The Meter Box should be capable of withstanding the mechanical, electrical and
thermal stresses as well as the affects of humidity which are likely to be encountered in
service, at the same time ensuring desired degree of safety. The plastic material
should be adequately stabilized against detrimental effects of light and weather. The
surface appearance of moulded part must be smooth, non-porous and homogenous, free of
ripples, defects and marks. No fillers of fibers should be visible at any place. The
Meter Box shall comply in all respect with the requirement of latest amended
IS:14772/2000 “General requirements for enclosures for accessories for household and
similar fixed electrical installations”. Applicable degree of protection shall be IP 42
or better.
2.2 PROPERTIES OF PLASTIC MATERIAL

The plastic material which is to be used by the bidder for these moulded Meter Box,
must have the following properties:
221
S.No Property Units Value

1. Physical Max. 0.35
Water Absorption %
2. Thermal HDT Deg. C Min. 125.
3. Flammability
a) Rating FV 2
b) Glow wire test @ 650 Deg.C Passes
4. Mechanical
a) Tensile Strength MPa Min. 50
b) Flexural strength Mpa Min. 90
c) Modulus of Elasticity Mpa Min. 2000
d) Izod impact strength KJ/Sq.m. Min 8
notched 23 deg. C.
2.3 SERVICE CONDITIONS

a) Maximum ambient air temperature : 50 deg.C
b) Maximum ambient air temperature in shade : 45 deg.C
c) Maximum temperature attainable by the meter : 60 deg. C
exposed to sun.
d) Minimum ambient temperature (-) 5 deg.C
e) Average daily ambient air temperature : 40deg.C
f) Maximum relative humidity : 95 %
g) Number of months of tropical monsoon condition : 4 months
h) Maximum altitude above mean sea level : 1000 meters
i) Average annual rain fall : 10-100 cms
j) Maximum annual rain fall : 1450 mm
k) Maximum wind pressure : 200 kg /sq.m
l) Isoceraunic level (days per year) 40
m) Seismic level (horizontal accn.) : 0.30 g
n) Permitted noise level : 45. Db
2.4 GENERAL & CONSTRUCTIONAL REQUIREMENTS

2.4.1 DIMENSIONS
The size of Meter Box (length, breadth and height) shall be such that there should
be a minimum of 20 mm clearance between outer most part of meter casing and inner most
part of inside of meter box base on all sides from the meter sides except the bottom side
of meter box base which should be minimum 75 mm from the plane surface of
terminal block and 15 mm clearance on front and 10 mm clearance from back of
the meter. However in
222
case sufficient space is available for sealing then, above mentioned
requirement of 20 mm space may be relaxed.
2.4.2 BASE & COVER DETAILS
1. The cover shall be made overlapping type having collars on all four sides. The cover of the
Meter Box shall be provided with semicircular / circular gasket of suitable size to
completely fit in the grooves of the base. The gasket should be made of neoprene
rubber. The base of the Meter Box must have a groove to hold the gasket and the
overlap of the top cover with the base must be minimum 6 mm (with gasket).
2. The meter box cover or base shall have a barrier so positioned that any possibility of
fiddling the meter terminal from outside of the meter box through cable entry holes is
not possible. The barrier shall have reinforce / located at both sides to restrict its
movement up and down even by applying external pressure through any tools.
3. DATA DOWNLOADING THROUGH OPTICAL PORT:
An opening (with the arrangement of collar) shall be provided of suitable size on box
cover in front of optical port of the meter for assessing CMRI to download the meter
data. Suitable arrangement to cover the said opening by rubber/plastic cap attached with
Box shall be provided. The rubber/plastic cap shall be hanging type connected with the
collar.
4. Push Button :
The push button on meter box cover should be designed such that it is not possible to
remove/take out the push button by any means and there should not be any gap
between push button and cover. It should be access the push button of the meter without
opening the main meter box cover and suitable arrangement for access to meter push
button shall be provided.
2.4.3 METER BOX SEALING AND SELF LOCKING ARRANGEMENT
A) SELF LOCKING ARRANGEMENT
The cover should be fitted with base by non-detachable push fit type arrangement. It
should have knobs provided with the cover such that if pushed once inside the
arrangement in the main body of the base and fitted in the arrangement, it becomes
integral part of Meter Box and cannot be detached from the base without breakage.
The cover shall rest on the base of Meter Box in such a way that any access from
outside to the meter is not possible. The cover in closed position should
223
be overlapped on collar of base such that direct entry of screw driver or any other tool/
wire is not possible.
A protective lock device shall be provided so that during transportation or before

installing the Meter Box at site the lock should not operate. The device shall be disabled
before the Meter Box is locked.
The snap fit lock (male part) must be inserted in groove (female part) by at least 5
mm to ensure proper locking of the meter cup board.
The top cover when opened after installation must have visible cracks/damages to
make visible that the meter cup board has been forciblyopened up.
Both male and female portions shall be an integral part of the meter box base and
cover mould and not affixed separately by any method.
B) SEALING ARRANGEMENT
In order to make the above self locking arrangements of meter box fool prooffrom
tampering, two numbers of push-fit moulded seals shall be provided on the meter case-
cover boundary as below:
The meter box shall be sealed with two specially designed and moulded coloured
polycarbonate tamper proof seals (lash wire seals are not allowed), to be inserted on
each side of meter box case, with internal locking arrangement embossed or laser
etched with serial number and manufacturer‟s logo visible from the front and matching
with the serial number of the meter.
The provision of sealing shall be integral part of the meter box. The seal inserting
arrangement shall also be integral part of moulded meter box. The push fit seals should
have adequate barriers around the sealing arrangement such that any attempt to reach
the sealing arrangement through wire etc. is not possible.
The seals shall become unserviceable and shall be irreplaceable in case of any attempt to
tamper the meter box.
These seals shall be placed in the meter box at specified place (not in loose condition) for
inserting them at site after installation.
The meter and terminals shall be rendered inaccessible after the meter box is self locked
and sealed with such seals.
The serial number on seals shall be same as the serial number of the meter and
meter box. Provision for all the seals should be made on front side of the meter box.
The serial number of meter shall be embossed or laser etched on the base as well as the
cover of the meter box which can be easily viewed.
3 Phase Meter with Bo x 224
2.4.4 METER MOUNTING INSIDE THE METER BOX
The meter base support inside the box is raised by about 10mm in the box for ease of
wiring. Fixing arrangement of meter to the base of meter box should be as per clause
7.8 of specification of Energy Meter.
2.4.5 INCOMING AND OUTGOING CABLE ARRANGEMENT
Suitable circular holes shall be provided at the bottom of the Meter Box for inlet & outlet
cables with suitable gland size to accommodate three & half core armoured aluminum
cable(s) up to 25 Sq.mm made of engineering plastic for the cable securely fixed to the
bottom of the Meter Box on both sides by chucknuts. A suitable arrangement like clamping
nut may be provided with the gland so that opening dia can be reduced to the size of cable.
2.4.6 FIXING ARRANGEMENT OF METER BOX
For fixing the Meter Box to wall or wooden board, 4 nos. holes (two top side holes to be
keyholes) of minimum 6 mm dia, shall be provided at the four corners of Meter Box.
The meter is to be installed in the Meter Box and the Meter Box in assembled
condition shall have provision to fix it to a pole or on wall. The 4 nos. self threaded
screws of min. size of 4mmdia and 25 mm longshall be provided with each Meter Box.
2.4.7 MARKING
The following information shall be clearly & indelibly embossed/engraved (not
printed) on the cover and base of the Meter Box (except Sr. No. of the meter -
which may be indelibly printed inside the base of meter box and also on the meter
box cover with laser marking). The meter box Sr. No. shall be same as of meter Sr.
No. housed inside the particular meter box:
i) Model No.
ii) Name/ Brand name of Manufacturer.
iii) Meter Sr. No. (printed on both the base & cover of meter box)
iv) Sign of danger
2.5 DRAWING
Detailed dimensional drawing & detailed leaflets showing clearly the dimensions &
material for meter cup boards and its constructional features should be furnished with
the tender offer.
3 Phase Meter with Bo x 225
2.6 TESTS
A) Type Tests
The meter Box offered shall be fully type tested as per relevant standards and this
technical specification (table 2). The bidder must furnish one set of type test reports
along with the technical bid. The type test report should be from independent recognized
testing laboratory / house whose calibration of testing instruments should have
traceability to NABL/NPL/ or equivalent. The type tests mentioned below must not have
been conducted earlier than three years from the date of opening of techno commercial
bid.
TABLE-2
LIST OF TESTS TO BE CARRIED OUT ON MOULDED METER BOX
S. Name of Indian Clause Test requirement Test particulars
No. Standard/ Ref.
Type Routine Accept-
Equivalent
ance
International
1. IS:14772 Clause 7 Marking T A

2. As per Bidder‟s Dimensions T A
drawing
3. IS:14772 Clause 9 Protection against T R A
electric shock
4 IS:14772 Clause11 Construction T
5. IS 14772 Clause12 Resistance to ageing, T

to humid condition,
to ingress of solid
object and to
harmful ingress of
water.
6. IS : 14772 Clause13 Mechanicalstrength T
7. IS :14772 Clause14 Resistance to heat T
8. IS:14772 Clause16 Resistance torusting T

3 Phase Meter with Box 226
9. IS:14772 Clause17 Resistance to

tracking
10. IS:8620/1996 Test for resistance to T
heat & fire.
Glow w/ire test at
650 deg. C as per cl.
4 to 10 of IEC
695-2-1
11. IS:13411 Annexure Heat deflection T

H temperature (Min.
125 degC.)
12. IS : 4249 Self Extinguishing T

property of spirit
burner test.
13. IS:8623/1993 (Part-1) Verification of die T
18.2.2.2 electric properties,
insulation test with
500V DC magger
14. CIPET/IR Material T

Spectrometry identification.
15. IS:13411/1992 Annexure Test for water T
D absorption (Max.
0.35)
Note : Applicable degree of protection shall be IP 42 or better.Legend :-
T = Type Test, R = Routine Test, A = Acceptance Test
B) Routine test
The routine tests as stipulated in the table 2 shall be carried out and routine test
certificates / reports shall be submitted to the purchaser‟s inspecting officer at the time
of inspection of the offered material.
ANNEXURE-B
Guaranteed Technical and other Particulars of Moulded Meter Box
suitable for Three Phase Energy Meters with Box.
S. Particulars
No
1. Material used for moulded meter box
a) Base
b) Cover
2. Thickness of moulded sheet in mm
a) Base
b) Cover
3. Properties of material for moulded meter box. (Indicate complianceYes/No)
S.No Property Units Value

i) Physical: % Max.0.35
Water Absorption
ii) Thermal HDT Deg. C Min. 125
iii) Flammability
a) Rating FV2
b) Glow wire test Passes
@ 650 Deg. C
iv) Mechanical
a) Tensile strength MPa Min. 50
b) Flexural strength MPa Min. 90
c) Modulus of MPa Min.

elasticity 2000
d) Izod impact KJ/Sq Min. 8
strength, Notched, M
23
Deg. C
4. Dimension of box in mm
a) Minimum clearance from meter on all 4sides
b) Minimum clearance from meter on front

c) Minimum clearance from back of meter
5. Weight of complete box in Kg, with ± %tolerance
6. Whether details of marking are as perspecification?
7. Is the cover overlapping type having collars onall

four sides?
8. Is the cover/base provided with semi-circular /
circular gasket of sufficient size to completely fitin
the groove of the base?
8(a) Is the meter box having push button for accessto the
meter without opening of meter box cover.
9. Material of the gasket

10. Sealing and self locking arrangement
i) No. of transparent polycarbonate securityseals
provided and its colour.
ii) The Sr No on these seals is same as

meter Sr No?
iii) Is the Sr No. on seals is laser hatched?
iv) Does the sealing holes provided on both sides of
box, have min 2 mm dia and are in alignment
at two places each in top andbottom pieces of
meter box?
v) Whether sealing arrangement is integralpart of
mould case. of meter box.
vi) Are the seals kept in un-sealed condition,to be
sealed after installation of meter and box, in
the field?
viii) Is the cover fitted with base by non-detachable
push fit arrangement?
viii) No. of snap lock fitting arrangement in thebox?
11. Dimensions of holes and screw for mountingmeter box
i) Dimensions of holes for box fixing screw(in

mm)
ii) Dimensions of box fixing screws (in mm)
iii) Total No. of fixing screws
iv) The top side two fixing holes are Key-holes?
12. Colour of base of the box

13. Details of Cable glands
a) Material
b) Whether Size of gland is as per
specification ?
c) Whether a suitable arrangement like clamping
nut has been provided with the gland so that
opening dia can be reduced
to the size of cable?
229
TECHNICAL SPECIFICATION FOR PILFER PROOF METER

BOX SUITABLE FOR SINGLE PHASE STATIC ENERGY METER
1.0 SCOPE:
1.1 This specification covers manufacture and supply of Pilfer Proof Meter Box (PPMB) suitable to house
Single Phase Static Energy Meter. The Meter Box shall be wall mounted type. ability so as to offer
protection of electrical equipment against harsh weather. The box shall be anti-corrosive, dust proof, shock,
vermin & waterproof, pilfer proof, fire proof and UV stabilized. The enclosures shall not deform or melt
when exposed to fire.
2.0 TECHNICAL REQUIREMENT :

2.1 The Meter Box i.e base and cover shall be made of hot press/injection moulded, unbreakable, high grade
fire retardant Engineering Plastic (Acrylonitrile Butadiene Styrene)/Polycarbonate, with minimum thickness
2.0 mm having good di-electric and mechanical strength. The material must be such that the Meter Box
should not change in colour, shape. size, dimensions when subjected to Ageing Test. The Meter Box
should have top tapered surface and round corners to prevent any water logging on the top of meter cover.
The overall dimensions of the enclosure shall be suitable for housing single phase meter as offered by the
bidder and there should be a clearance of 30 + 2 mm from top & both sides of the meter. Bottom side
clearance should be 75 + 5 mm from the lower edge of terminal block of the meter. Clearance from front
side and back side of the meter should be 15 + 2 mm and 10 + 2 mm respectively. Meter Box with higher
dimensions may be considered if found suitable.
2.2 The Meter Box should be capable of withstanding the mechanical, electrical and thermal stresses well as
the effects of humidity which are likely to be encountered in service. At the same time the box should
ensure desired degree of safety. The material used should be adequately stabilized against detrimental
effect of light and weather. The surface appearance of the moulded parts must be smooth, non-porous and
homogeneous, free of ripples, defects and marks. No fillers of fibers should be visible at any place.
2.3 The box should comply in all respect with the requirement of latest amendments of IS /ASTM. Applicable
degree of protection shall be IP 42 or better.
2.4 All accessories like nuts, bolts, washers etc. shall be galvanized.
3.0 CONSTRUCTION :
3.1 The enclosure shall be single piece moulded with hot process compression moulding or injection moulding.
3.2 Dimension : To be specified by the bidder.
3.2 Hinges :
A minimum of 2 nos. brass/stainless steel hinges in left side of the door and 1 no. brass/stainless steel
hinge/stainless steel U type latch with locking arrangement in right side of the door shall be provided inside
the enclosure. The hinges of the door shall be concealed and they shall be fixed to the flanges provided on
the body and cover of the enclosure in such a manner that the door opens by a minimum of 120 degrees.
3.3 Suitable grove with locking arrangement shall be provided for opening of the enclosure door.
3.4 Earthing Bolt :

8mm dia. G.I. bolt with 2 nos. washers for earthing all metal parts shall be provided.
3.5 Fixing arrangement :
The meter box shall have 4 nos. of mounting brackets made out of same material as meter box with
provision for 6 mm dia hole for mounting the box on the wall or wooden board with suitable screws. The
meter box shall have provision to fix it on the wall or wooden board with the meter in assembled condition.
Four (4) nos. self threaded screws of minimum size of 4 mm dia and 25 mm long shall be provided with
each meter box.
Any other suitable arrangement for fixing the box may be accepted after verification.
230
3.6 Sealing arrangement :

The Box should have provision for padlocking and also for sealing arrangement of the base with cover
providing holes for 1 no. seal to make it fully tamper proof.
3.7 Incoming and outgoing cable arrangement :

Suitable 2 (two) Nos. of holes at bottom (12 mm. dia) shall be provided in the box for cable/wire entry.
2 (two) holes must be totally covered with neoprene rubber gasket (NRG). NRG will be punched for entry of
incoming and outgoing cable/wire.
3.8 Base and Cover details :

Thickness of the meter box shall not be less than 2.0 mm on all sides including door. The meter box shall
have 4 mm thickness of the tongue and groove area. The meter box cover shall be made overlapping type
having collars on all four (4) sides and shall be provided with Neoprene rubber gasket of minimum 2.5 mm
dia to completely fit in the grooves of the base. The base of the meter box must have a groove to hold the
gasket and the overlap of the top cover with base should be sufficient. The tongue of the base shall ensure
proper sealing arrangement against ingress of rainwater and dust inside the box.
3.9 The Enclosures shall generally comply with the provision of IS 14772 or IEC 695. The enclosures shall be
suitable for outdoor application. The enclosure shall be with good workmanship.
3.10 Soft neoprene/nitride rubber gaskets shall be provided all round wherever required for protection against
entry of dust and water. The gasket shall confirm to Type-III as per IS-11149. The enclosure shall comply
with IP-42 or better degree of protection.
3.11 The Enclosures shall be off white/admiral gray / ivory/ transparent polycarbonate.
3.12 Marking/Embossing:
The following information shall be clearly & indelibly embossed/laser printed on the cover and base of the
Meter Box. The top & bottom corner of Meter Box Sl. No. shall be same for the particular Meter Box.
i) Property of WBSEDCL
ii) Name/Brand name of Manufacturer
iii) Meter Box Sl. No. (Embossed / laser printing on both the base and covers of Meter Box)
iv) Sign of Danger
4.0 Submission of Sample :

4.1 The bidder shall submit a sample Meter Box as per our specification along with the sample meter to the
office of the Chief Engineer, (DTD), Abhikshan Bhavan, Sector-V, Salt Lake, Kolkata-91 before the last day
of submission of bid.
4.2 Submission of sample meter box as per size available with the bidder but conforming to our specification
towards its quality is acceptable . Type testing including material identification (IR Spectrometry test) of one
meter box manufactured as per specification is to be conducted at any NABL accredited laboratory/CIPET by
the supplier at their own cost after placement of order. For type testing the meter box will be selected from
the first offered lot of meter with meter box. If the type test results are not found satisfactory, the offered lot of
meter along with meter box will be rejected.
5.0 Quality Control:

5.1 Type test reports from CIPET/NABL accredited laboratory as per Standard IS/ASTM shall be submitted. The
type test reports shall not be more than 5 (five) years old. Acceptance tests as per IS/ASTM are to be carried
out by the supplier in presence of WBSEDCL‟s representative. Material of meter enclosure shall be tested for
Heat Deflection Temperature, Exposure to Flame (Self-extinguishing) and Resistance to Heat & Fire (Glow
wire) as per specification and Ref. Standard IS/ASTM.
6.0 General Construction Requirement:

6.1 Viewing Window:
A viewing window as per drawing made up of scratch and break resistant, UV resistant, transparent
Polycarbonate material shall be provided on the door for reading the meter without inconvenience. The
minimum thickness of the viewing window shall be 2.0 mm.(flashing with top). The viewing window shall be
provided with fixed rain hood. The window shall be securely fixed with meter enclosure from inside. Suitable
neoprene gasket shall be provided so that there shall not be any ingress of moisture through this window into
the enclosure.
No viewing window is required for transparent polycarbonate meter box.
231
6.2 Construction of louver:

Louver must be provided in one side of the pilfer proof box inside of which must be covered with the mesh
(plastic) in such a way that from outside that mesh can not be approached.
No louver is required for transparent polycarbonate meter box.
6.3 One push button is to be provided on the front side of the top cover of meter box for taking meter reading
during power off condition without opening of meter box cover.
7.0 Guarantee:
The Pilfer Proof Meter Box should be guaranteed against any manufacturing defects arising out of faulty
design or bad workmanship or component failure for a period of 5 ½ years from the date of supply.
The meter box found defective within the above guarantee period shall be replaced by the supplier free of
cost within one month of the receipt of intimation of failure/defect. Defective meter box are to be replaced by
new one with new sl. nos. as allotted by C.E (DTD).
8.0 Replacement of defective Meter Box :

The Meter Box declared defective by the WBSEDCL shall be replaced by the supplier up to the full
satisfaction of the WBSEDCL at the cost of supplier. Failure to do so within the time limit prescribed shall
lead to imposition of penalty of twice the cost of meter box. The same may lead to black listing even, as
decided by WBSEDCL. In this connection the decision of WBSEDCL shall be final.
9.0 Testing:
a) Type Test:
The bidder must furnish type test report including material verification of the offered/sample meter box
from any NABL/Govt. approved laboratory as available with them along with technical bid without which
the offer will not be considered. Type test report should not be more than 5 (five) years old.
Type testing at any recognized NABL accredited laboratory/CIPET in respect of one meter box as per
the specified size, selected from any one of the offered lot during supply is to be conducted by the
supplier at their own cost after placement of order for verification of material and quality of the box. If
the type test results are not found satisfactory, the offered lot of meter along with the meter box will be
rejected.
b) Acceptance Test:
The acceptance test as stipulated in Annexure-VI shall be carried out at the time of inspection of the
offered material.
c) Routine Test:
The routine tests as stipulated in the Annexure-VI shall be carried out and routine test certificate
/reports shall be submitted to Chief Engineer (DTD), WBSEDCL,Abhikshan,Sector-V, Salt Lake City,
Kolkata-700091 while offering inspection & testing of the meter with meter box.
Notes: 1) Where facilities do not exist at supplier‟s works for carrying out one or more of the Acceptance
Tests as per Annexure-VI, such tests may be carried out at any of the approved laboratories
such as CIPET/IIT/National Test House/Govt. approved laboratory etc. in presence of
WBSEDCL‟s representative.
2) The sampling plan for carrying out the acceptance tests shall be as per IS.
10.0 Submission of Drawing:

Three (3) copies of drawing complete in all respect should be submitted to the C.E (DTD) under intimation to
the Material Controller for accordance of approval immediately after placement of order. 25 copies of
approved drawing are to be submitted for distribution to sites.
11.0 Inspection:
The inspection will be carried out as per inspection & testing clause of General Conditions of Contract (GCC).
12.0 Guaranteed Technical Particulars:

The bidder shall furnish all the necessary information as per Annexure-VII - Guaranteed
Technical Particulars. If the bidder desire to furnish any other information in addition to the details as asked
for, the same may be furnished.
232
ANNEXURE-V
LIST OF TESTS TO BE CARRIED OUT ON SINGLE PHASE METER BOX
Name of Indian
Sl. standard/equivalent
Test requirement Test particulars
No. international
standard
Type test Routine Acceptance
Test Test
1. IS : 14772 Marking T A
2. As per Drawing Dimensions T R A
3. IS / ASTM Protection against T R A
electric shock
4. IS / ASTM Construction T R A
5. IS / ASTM Resistance to ageing, to T
humid conditions, to
ingress of solid object
and to harmful ingress of
water
6. IS / ASTM Mechanical strength T
7. IS / ASTM Resistance to heat T
8. IS / ASTM Resistance to rusting T
9. IS / ASTM Resistance to tracking T
10. IS / ASTM Test for resistance to T
heat & fire (Glow wire
test at 6500 C)
11. IS / ASTM Heat deflection temp. @ T R
1.8 MPa-1000 C (Minm.
for Engg. Plastic)/1400 C
(Minim. for
Polycarbonate
12. IS / ASTM Self Extinguishing T R A
property of spirit burner
test.
13. IS / ASTM Melting point-1800 C T
(Minimum for Engg.
Plastic)/2100 C
(Minimum for
Polycarbonate)
14. IS / ASTM Verification of di-electric T
properties, insulation test
with 500V DC magger
15. CIPET/IR Material identification T
Spectrometry
16. IS / ASTM Physical water T
absorption (Max. 0.35%)
Note : Applicable degree of protection shall be IP42 or better.
Legend : T- Type Test, R- Routine Test, A- Acceptance Test
233
ANNEXURE-VI
GUARANTEED TECHNICAL PARTICULARS OF PILFER PROOF METER BOX

FOR SINGLE PHASE METER
Sl. Offered by
No. Description Detailed requirement
the bidder
Material used for moulded meter Engineering Plastic (Acrylonitrile
1.
box Butadiene Styrene)/Polycarbonate
2. Grade of Material Fire Retardant, Self Extinguishing
Properties of material for meter
3.
box
Heat Deflection Temperature
1000 C (Minimum for Engg. Plastic) /
(a) (Min. 1400 C @ 1.8 MPa)
1400 C (Minimum for Polycarbonate)
(Ref. Std. IS/ASTM)
Exposure to flame
(b) Self-extinguishing
(Ref. Std..IS/ASTM)
Melting Point 1800 C (Minimum for Engg. Plastic) /
(c) (Ref. Std. IS/ASTM) 2100 C (Minimum for Polycarbonate)
(d) Resistance to heat & fire Glow wire test at 6500 C
(e) Mechanical Property
i) Tensile Strength (MPa) To be specified by the bidder
ii) Flexural Strength (MPa) - Do -
iii) Modulus of Elasticity (MPa) - Do -
Constructional features of the
4.
box
Clear inside dimensions of Meter
(a) Refer Drawing
Box
i) Height To be specified by the bidder
ii) Width - Do -
iii) Depth - Do -
iv) Rust & Vermin proofing Neoprene Rubber Gasket NRG
Clearance from all sides of the meter
should be 30+2 mm except the
Minimum clearance from meter
(b) bottom side which should be 75+5
on all 4 sides
mm from the lower edge of terminal
block.
Minimum clearance from meter
(c) 15+2 mm
on front
Minimum clearance from back of
(d) meter 10 + 2 mm
(e) Viewing Window :
Material of transparent Glass/Polycarbonate with Rubber
i)
cover Gasket
ii) Size of opening (Min.) 90mm x 75 mm
234
Thickness of moulded
iii) 2.0 mm (Minimum)
sheet
iv) Fixing method Fixed from inside with rubber gasket
(f) Earthing arrangement 1 No. Earthing Bolt as prescribed
(g) Sealing Arrangement Holes for wire seal (One No.)
Colour of Meter Box (base &
(h) Grey / Off-White / Ivory
cover)
(i) Box mounting arrangement
No. of holes for fixing of
i) 4 Nos. Holes
meter box
ii) Dimension of holes 6 mm
Dimension of box fixing
iii) 4X25 mm self threaded
screw
Total no. of fixing screws
iv) 4 nos.
to be provided
(j) Hinges Concealed hinges
2 Nos. 12 mm. dia. Holes at bottom
(k) Incoming & outgoing cable holes totally covered with Neoprene Rubber
Gasket (NRG)
Whether the cover is overlapping
(m) type having collars on all four Yes
sides
Whether the cover/base provided
with semicircular/circular
(n) neoprene rubber gasket of 2.5 Yes
mm dia (Minm.) to completely fit
in the grove of the base
Whether the meter box having
push button to access to the
(o) meter for taking reading during To be provided
power off condition without
opening of meter box cover
Weight of complete box in Kg
(p) To be specified by the bidder
with +/- tolerance
Type test report as per Technical
5. To be submitted by the bidder
Specification
6. Degree of protection IP 42 or better
7. Any other information
235
ANNEXURE - VII
TESTING
1. Sample selected from first lot should be type tested at any NABL accredited laboratory for
compliance of performance parameters as given in GTP including material identification to
be carried out by CIPET (IR Spectrometry test).
2. The test report should be submitted to WBSEDCL before delivery of
3. Inspection of each lot & sampling plans for acceptance test : 1 no. selected randomly
from lot for testing at works.
Sl.
Test Requirement for moulded meter box Reference Standards
No.
a) Marking IS /ASTM
b) Dimensions & construction IS /ASTM
Heat Deflection Temperature - 1450 C at no pressure

c) IS /ASTM
(Minimum)
d) Spirit Burner Test (Self Extinguishing) IS /ASTM
e) Melting point - 1300 C at no pressure (Minimum) IS /ASTM

236
237
Three phase CT operated alternating current Smart Meter of Accuracy Class 0.5S ( DT Meter,
LT-CT Meter, etc.)
C.1 General Standards Applicable for Meter
Unless otherwise specified elsewhere in this specification, the performance and testing of
the meters shall conform to the following standards and amendments/revisions thereof.
Sl. No. Standard No. Title

AC Static Transformer Operated Watt-hour
IS 16444: Part 2 with latest and VAR-Hour Smart Meters, class 0.2S,
1
amendments
0.5S and 1S
CBIP- Publication 325 with Standardization of AC Static Electrical
2
latest amendments Energy Meters
CBIP Technical report no. 111 Specification for Common Meter Reading
3
with latest amendments Instrument
Basic Environmental Testing Procedures
4 IS:9000 with latest amendments
for Electronic & Electrical Items.
IS 12063 with latest Degrees of protection provided by

5
amendments enclosures of electrical equipment.
Telemetering for consumption and
IS 14451, Part-2: 1999 with demand. Direct digital transfer of meter
6
latest amendments
values.
IS 4905: 1999 with latest
7 Methods for Random sampling.
amendments
IS 12346 with latest Specifications for Testing Equipment for
8
amendments AC Energy meter.
Data exchange for electricity meter
IS 15959 Part 3 (as applicable) reading, tariff and load control: Companion
9
with latest amendments
specification
C.2 Communication
Meter shall have ability to communicate with HES on any one of the technologies mentioned
in IS 16444 (RF/Cellular/PLC) in a secure manner. The selection of communication
technology should be as per the site conditions and as per design requirement of the AMISP
to meet the Service Level Agreements (SLAs). In case of cellular based meter, the meter
shall accommodate SIM Card / e-SIM of any service provider. The meter shall log the
removal of the plug-in type communication module removal /nonresponsive event with
snapshot.
238
C.3 Other Specifications
Particulars Specifications
The meters shall comply with IS 16444: Part2 for all
requirements except for those parameters which have
Applicable Standards
been specifically mentioned to be otherwise in this
specification.
Reference Voltage [As per relevant IS]
Current Rating Ib 5A
Starting Current As per IS 16444: Part2
Accuracy Class 0.5S as per IS 16444: Part 2
Limits of error As per IS 16444: Part 2
Operating Temperature
As per IS 16444: Part 2
range
Humidity As per IS 16444: Part 2
Frequency As per IS 16444: Part 2
Influence Quantities As per IS 16444: Part 2
Power Consumption of
meter excluding As per I S 16444: Part 2
communication module
Current and Voltage circuit As per IS 16444: Part 2
Running at No Load As per IS 16444: Part 2
Test output device As per IS 16444: Part 2
Meter Display As per IS 16444: Part 2
Time of Use
(In case of net-meter both As per IS 15959: Part 3 (as applicable)
export & import parameters
to be measured)
Parameters to be measured As per IS 16444: Part 2 / IS 15959: Part 3 (as applicable)
Power Quality Information As per IS 15959: Part 3 (as applicable)
Maximum Demand As per IS 15959: Part 3 (as applicable)
Load Survey/Interval Data As per IS 15959: Part 3 (as applicable)
LED/LCD
As per IS 16444: Part 2
Indicators
Tamper/Event recording As per IS 15959: Part 3 (as applicable)
Alarm As per IS 16444 / IS 15959: Part 3 (as applicable)
Measuring Elements As per IS 16444: Part 2
239
Particulars Specifications
The meter shall continue working under tamper conditions as

defined in IS 15959 Part 3 and would log the event and send
Anti-Tamper features
alarm at HES after logging of the defined tamper features as
per IS 15959 Part 3.
Programmability As per IS 16444: Part 2

Communication As per IS 16444: Part 2
Communication Protocol As per IS 15959: Part 3 (as applicable)
Real time clock (RTC) As per IS 16444: Part 2 / IS 15959: Part 3 (as applicable)
Data Retention As per IS 16444: Part 2
Meter shall be supplied with separate battery backup for
Battery Backup
RTC.
As per IS 16444: Part 2 (as applicable)
However minimum requirement should include the following:
Data Display shall have following features:
 High Resolution (Shall display energy values with
Data display facility resolution of 2 digits before decimal and 3 digits after
(manual/Auto) decimal.
 The Push button for manual scrolling in addition
to auto scrolling with a persistence time of 10
seconds for each parameter shall be provided.
Display of data as per IS 16444 (Part 2)
Remote Firmware Upgrade As per IS 15959: Part 3 (as applicable)
240
Technical specifications of LT Distribution boxes of 63,100 & 250

kVA Distribution Transformers
1. SCOPE:
Specification covers the design, manufacture, testing at works and supply of Distribution Boxes
made out of thermosetting plastic i.e. Glass Reinforced Polyester Sheet Moulding compound (S1
grade) conforming IS : 13410-1992 for controlling the L.T. feeders from the L.T. side of
Distribution Transformers. The system shall be A.C. 3 phase, 4 wire, 433V, 50HZ. The
Distribution Box shall comprise of (1) suitable enclosure (factory built assembly) SMC confirming
to IS 13410 (2) Porcelain Fuse units as per IS: 2086/1993 with latest Amendment/ Revision if any
on the date of inviting tender and as per our specification. (3) Incoming Switch disconnector as
per IS: 13947/1993 with latest Amendment/Revision if any on the date of inviting tender. L. T.
Distribution Box should be designed to have maximum utilization of transformer capacity and
shall be well equipped with adequate protection to transformer and feeder against overload and
short circuit and minimum interruption in power supply.
2. SERVICE CONDITIONS:
The equipment to be supplied against this specification shall be suitable for satisfactory
continuous operation under the tropical conditions as specified by employer which is as
hereunder;
2.1 Maximum ambient temperature (Degree C) 50
2.2 Maximum temperature in shade (Degree C) 45
2.3 Minimum Temperature (Degree C) 3.5
2.4 Relative Humidity (percent) 10 to 95
2.5 Maximum Annual rain fall (mm) 1450
2.6 Maximum wind pressure (kg/sq.m) 150
2.7 Maximum altitude above mean sea level ( Meter) 1000
2.8 Isoceranic level (days per year) 50
2.9 Siesmic level (Horizontal Acceleration) 0.3g
Moderately hot and humid tropical climate conductive to rust and fungus growth.
3. SYSTEM DETAILS:
Distribution Boxes are meant for control and protection of Distribution Transformers with
relevant parameters as under:-
S.N. Particulars Details

1. KVA rating 63 KVA 100 KVA 250 KVA 400 KVA
2. Voltage 433 V, 3 Ph, ( 3x 250 V)
3. Frequency 50 HZ
4. Phases 3 phase, solidly grounded neutral
Approximate full load current of
5. 84 A 133 A 333 A 534 A
transformer
6. No. of Outgoing circuits 2 nos 3 nos 4 nos
241
3.4 Applicable Standards:

IS :13947/ (Part 3) (amended upto date) for Isolator (Switch Disconnector)
IS: 13947/ (Part2)(amended upto date) for L.T. MCCBs.
IS: 8623 (amended upto date) for enclosure Box & for degree of protection provided by
enclosures of electrical equipments.
IS: 4237, IS:8623 (amended upto date) – for general requirement of L.T. switchgears.
IS 13703 ( Part I & II amended upto date) for HRC Fuse Base and HRC Fuse Link.
IS: 5 /2007 - Colours of Ready Mixed paints and Enamels.
IS: 13871/1993 (amended upto date) – Powder coatings – specifications
IS : 6005/1998 (amended upto date) – Code of Practice for phosphating of iron and steel.
IS:13410 / 1992 for SMC (Sheet Moulding Compound) MoC of Enclosure.
3.5 MANUFACTURE/CONSTRUCTION OF BOXES:

Distribution Boxes shall have Isolator (Switch Disconnector) and HRC fuse base with links
on incoming circuit and single pole MCCBs & Link Disconnector on outgoing circuits with
necessary interconnecting Bus Bars/ Links. Standard General Arrangement of Isolators,
HRC fuse base with links, MCCBs, Link Disconnector, Neutral Links, Bus Bars,
connecting links, Cable termination arrangement etc inside the Box is shown in the
enclosed drawings.
3.6 INCOMING CIRCUIT –
6.1 Isolator (Switch Disconnector) -

Each distribution box shall have one triple pole Isolator (Switch Disconnector), conforming
to relevant latest IS. The supplier shall indicate makes and types of offered isolator in GTP.
4.2 The boxes shall be made by Hot Press Compression Moulding Process.The supplier
shall submit Type Test Report of the Isolator as specified in Cl. No. 12.3 (II) for approval
of Employer before commencement of supply. The Switch disconnector to be provided in
the Distribution Box will be as per Employer specification. The Isolator should be front
operated triple pole type. The casing of Isolator shall be of non-tracking, heat resistant
insulating material of Dough Moulding Compound (DMC) of D3 Grade as per IS:13411
(amended upto date), no separate enclosure is required. Isolator Base should withstand the
breaking capacity of 80 kA. To extinguish the arc immediately in isolators, in each phase
arc-chutes with minimum 12 strips shall be provided.
The isolator should be front operated triple pole type. The isolator shall be robust in
construction and easy for operation. The handle of the isolator should be detachable easily
for security purpose while working on L.T. circuits. 4.3 The dimensions of the LT
Distribution box shall be as under.
For 63KVA & 100KVA : 1000 X 1000 X 325 mm for Incoming & Outgoing Circuit as
shown in drawing For 250KVA : 900 X 450 X 250 mm for incoming circuit & 1000 X
1000 X 325 mm for Outgoing Circuit as shown in drawing.
For 400KVA : Two Nos 1000 X 1000 X 325 mm enclosure for Incoming & Outgoing
Circuit as shown in drawing. The wall thickness of the Distribution Box shall be 3 mm
min.on load bearing side and 2 mm min. on other side in Base & 2 mm min.thick For Lid.
The characteristics of Isolator shall be as follows:
242
Rating
S.N. Characteristics 400
63 KVA 100 KVA 250 KVA
KVA
1. Basic uninterrupted duty 200 A 600A
2. Mechanism Manual quick make quick break
3. Standard applicable IS : 13947 amended upto date
4. Utilization category AC –23 A
5. Mechanical Endurance As per IS 13497 amended upto date
6. Electrical Endurance As per IS: 13947 amended upto date
7. Rated Duty Uninterrupted
8 Making /Breaking capacity Not less than requirement of AC –23 A category
9. Two seconds rating 4 KA 8 KA
10. Rated insulation voltage 660 V
The terminal connector strips of the isolator shall be projecting out of isolator of 80 mm
(minimum) in length on cable connection side and 60mm (minimum) on HRC fuse base side as
shown in the drawings. In 63 /100/250 KVA distribution box, the cross section of the strips on
outside of the isolator shall be provided as below:
63/100 KVA - 25X5 mm.
250 KVA- 50X 6 mm
400 KVA- 50X 6 mm
The material of isolator strips shall be EC grade tin-plated copper. The terminal strips shall be
continuous from the point of contact separation inside the Isolator with cross section as mentioned
above throughout the length. Gap of 50mm shall be maintained between each terminal throughout
the length.
6.2 HRC FUSE

HRC Fuse of suitable capacity shall be provided between outgoing terminal of Switch
Disconnector (Isolator) and incoming Busbar to facilitate electrical breaking of the circuit.
Each Distribution Box shall have 3 Nos. of HRC Fuse Base with HRC Fuse Links (Blade
type Contacts).
The supplier shall indicate in GTP, the make, type and capacity of HRC Fuse Base and Fuse
Links offered.
(i) HRC FUSE BASE

The base of the HRC Fuse shall be of non-tracking, heat resistant insulating material of
Dough Moulding Compound (DMC) of D3 Grade as per IS:13411/1992. The Fuse Base
shall be sturdy in construction.
The extension terminal connector strips of the Fuse Base shall be projecting out on both
sides, made with two pieces ( half portion of the terminal contact and extension strip should
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be continuous in one piece), as shown in the drawing. The dimensions shall be as shown in
the drawing. The material for both strips shall be tin plated EC Grade copper. HRC Fuse
Base & fuse link should have withstand the breaking capacity of 80 kA.
HRC Fuse base shall be suitable for fuse of 200A for 63/100 KVA distribution box and 400
A for 250 KVA and 630A for 400 kVA distribution box.
(ii) HRC FUSE LINK

The HRC Fuse Links shall be sturdy in construction of “Din Type”. Breaking Capacity shall
be 80 kA. For fault indication red pop up indicator should come out instantly on fusing.
Manufacturer’s name, current rating, breaking capacity and type shall be marked on HRC
fuse link.
HRC Fuse link Current rating for 63/100 /250/400 KVA distribution box shall be as follows:
63 KVA - 100 A
100 KVA - 160 A
250 KVA - 315 A.
400 KVA - 500 A
The supplier shall submit Type Test Report of the HRC fuse base and HRC fuse link as
specified in Cl. No. 12.3 (III) for approval of Employer before commencement of supply.
The HRC fuse base with links to be provided in the Distribution Box will be as per
Employer approval given in the detailed purchase order.
3.7 OUTGOING CIRCUITS:
(i) MCCBs
Each distribution box shall have 6 nos. of single-pole MCCBs in 63 KVA /100 KVA Box,
9 nos of single-pole MCCBs in 250 KVA box and 12 nos of single-pole MCCBs in 400
KVA box to protect outgoing circuits. MCCB shall be of reputed make and shall confirm
to latest IS. The supplier shall indicate the makes and types of MCCBs offered in GTP.
The supplier shall submit Type Test Report of the MCCB as specified in Cl. No. 12.3 (IV)
for approval of Employer before commencement of supply. The MCCBs to be provided
in the Distribution Box will be as per Employer approval as given in the detailed purchase
order.
MCCB shall have quick make quick break mechanism. Making of MCCB shall only be
manual but breaking of MCCBs shall be electrical as well as manual.
The detailed specification for MCCBs shall be as under.
S.No. Particulars Details

1. KVA rating 63 KVA 100 KVA 250 KVA 400 KVA
2. Rated current 150 A 200 A
Fixed overload release
60 A 90 A 120 A 120 A
3. setting ( A)
4. No. of poles Single pole
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Rated service short circuit

breaking capacity ( kA)
which is equal to ultimate
5. 10 KA at 0.4 p.f . ( lag)
breaking capacity as per
IS 13947 (amended upto
date)
The sequence of operation for this test shall be, O - t - CO - t - CO, and t = 3 min.). The
test shall be done at 250V at 0.4 p.f. (lag). Voltage rating phase to phase 433 V and phase
to earth 250V.
Power factor for short
6. 0.4 lag
circuit (Max.)
7. Utilization category A
8. Rated Insulation Voltage 660 V
The Busbar dropper and Terminal connection strip of Link Disconnector shall be placed
in contact terminal of MCCB as shown in the drawing.
The rated service short circuit breaking capacity as specified above, shall be based on
the rated service short circuit test carried out at specified power factors.
To extinguish the arc immediately in MCCBs, arc-chutes with minimum 8 strips shall
be provided.
While the above stipulation regarding the test power factor and the sequence of operation
shall be binding, the other procedure for making the short circuit test and circuit etc. shall
generally be in accordance with the Indian Standard applicable to the type of circuit
breakers under test.
7.2 TIME CURRENT CHARACTERISTICS of MCCBs:

The L.T. MCCBs shall have time current characteristics as follows:
Multiple of normal Current
Tripping time
setting
1.05 More than 2.5 hrs.
1.2 More than 10 minutes and less than 2 hrs.
1.3 Less than 30 minutes
2.5 Less than 1 minute
4.0 Not less than 2 seconds
6.0 Less than 5 seconds
12.0 Instantaneous (less than 40 milli seconds.)
For above time/current characteristic, the reference calibration temperature of the breaker shall be
50°C. Deration, if any, up to 60°C. Ambient temperature shall not exceed 10% of the current
setting indicated above.
c. LINK DISCONNECTOR :
Link Disconnector of 200 A capacity shall be provided between outgoing terminal of
MCCB & cable connection to facilitate mechanical breaking (manual isolation) of the
circuit. 63 /100 kVA Distribution Box shall have 6 Nos. of link Disconnectors, 250 kVA
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distribution box shall have 9 nos of link Disconnectors and 400 kVA distribution box shall
have 12 nos of link Disconnectors.
The supplier has to indicate the makes and types of Link Disconnector offered in GTP.
The supplier shall submit Type Test Report of Link Disconnector as specified in Cl. No.
12.3 (V) for approval of Employer before commencement of supply. The link
Disconnectors to be provided in the Distribution Box will be as per EMPLOYER’s
approval as given in the detailed purchase order.
The base of the Link Disconnector shall be of non-tracking, heat resistant insulating
material of Dough Moulding Compound (DMC) of D3 Grade as per IS:13411 (amended
upto date). The Link Disconnector shall be sturdy in construction and easy in operation.
The link of Link Disconnector shall be of Tin-plated E.C. grade copper. The construction
of the Link Disconnector shall be such that it shall be hinged type on cable connection end
and disconnectable at the MCCB end. The disconnection will be with the help of special
handle/puller. One handle/puller shall be supplied alongwith each Distribution Box. The
terminal connector strips of the Link Disconnector of 25 x 3 mm cross section, shall be
projecting out of Link disconnector for minimum length of 80 mm. on cable connection
side and 40 mm on MCCB outgoing side. The cross section of knife edge link shall be 20
x 5 mm. The material for both the strips and links shall be tin-plated E.C. grade copper.
The size of bimetallic lugs hole & the hole on the disconnectors strip on cable side should
be same.
3.8 BUSBARS AND CONNECTIONS:

The Incomer feeder should be on right side of the distribution box and all outgoing feeders
will be on left side of the distribution box, with phase sequence RYB to be maintained. The
phase busbars, incoming droppers and feeder droppers from busbars shall be of EC Grade
Aluminium. The phase busbar strips shall be of size 25X8 mm for 63 KVA/100 KVA and
40X10 mm for 200 and 40X15 for 400 KVA box. Feeder droppers shall be 25X8 mm.
Incomer dropper of 25 x 8 mm cross section for 63 /100 KVA box and 40 x 10 mm cross
section for 250KVA box and 40X15 for 400 KVA box be provided. All busbars and
droppers shall be properly drilled and de-burred. Each bus bar shall be of one single strip
without any joint.
Busbars shall be provided with durable PVC insulating sleeves of standard colour code for
different phases. Corrugated/Spring & Plain washers shall be used for Nut-Bolt
connections.
Busbars shall be mounted on suitable size support insulators which should be tightened
from inside. i.e. once fitted, should not be able to removed.
Minimum clearances, wherever shown, shall be as per General Arrangement Drawing
enclosed with this specification. Other clearances shall be as per requirement of IS: 4237
amended upto date.
3.9 ENCLOSURE:
9.1 The Box & Doors shall be made up of thermosetting plastic i.e. Glass Reinforced Polyester
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Sheet Moulding Compound (S1 grade) conforming IS : 13410-1992 of 2mm thickness.

9.2 The manufacturing process of Box shall be Sheet Moulding compound (S1 grade)
conforming IS : 13410-1992.
9.3 In case of distribution boxes, the rounding of corners and slope on top shall be as shown in
the drawing.
9.4 The welding process of distribution boxes shall be done by MIG (Metal Inert Gas) welding
and workmanship/finishing should be good enough.
9.5 For Sheet Moulding Compound Process

9.6 Box: the general clear dimensions of 63 / 100 KVA Distribution Box shall be 1000 x 1010
x 325 (LXHXW)mm. The center height of distribution box on front side shall be 1000 mm
The general clear dimensions of 250 kVA distribution box shall be 900 X 450 X 250 mm
for incoming circuit and 1000 X 1000 X 325 mm for Outgoing Circuit (LXHXW) mm. The
center height of the distribution box on front side shall be 1050 mm.
9.7 The Base and doors of enclosure shall be individually in one piece without any welding,
except for fixing of the accessories like hinges, clamps, mounting clamps, bolts etc.
A. 63/100 kVA boxes shall have two doors as shown in the drawing fixed on right & left
side of the box with four hinges provided from inside of box. On closing of doors, right
door shall rest on the left door. Hinges shall not be visible and approachable after
closing the box.
B. 250/400 kVA boxes shall have two doors as shown in drawing fixed on right side &
left side of the box with four hinges on both sides shall be provided from inside of box.
On closing of doors, right door shall rest on the left door. Hinges shall not be visible
and approachable after closing the box.
Base and doors shall have flange / collars as shown in drawing. Collar of Base and doors
shall overlap by 10mm. Rubber gasket of suitable size shall be provided in between base
and doors, such that it provides proper sealing between the door and base of box to avoid
penetration of dust & ingress of water. Degree of protection shall be IP- 54 as per IS-
8623 ( amended up to date ). Rubber Gasket shall be fixed with suitable adhesive. Four
hinges on each side shall be provided from inside of the box to fix the doors. Hinges shall
be minimum 50 mm in length & made from 2mm thick sheet. Hinge stainless steel pin
diameter shall be 4mm. The hinges shall not be visible from outside.
9.8 The MCCBs, Link Disconnector, Isolator and HRC fuse base with link shall be housed
inside the enclosure. Isolator operating handle shall be accessible only after opening of the
doors.
9.9 Four set of Louvers (two sets on each side) of suitable size shall be provided as shown in
drawing. The louvers shall be provided such that heat dissipation is proper. The perforated
sheet of 20 SWG with 2.5 mm holes shall be welded from inside of the louvers.
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9.10 Mounting of components inside the enclosure shall allow free air circulation keeping the
clearances as per drawings attached with specification.
9.11 Locking Arrangement to the Box:
The doors shall be closed with a push fit locking arrangement such that on pressing/pushing
the right door, the distribution box gets locked from inside from top & bottom. This
arrangement shall be operational for opening of the door with a handle provided outside
the door. Handle shall be removable type only. A Nylon washer shall be provided between
the handle and door to avoid penetration of water. One central lock with brass levers shall
be provided inside the door. Key way shall be provided on the door for operating the central
lock from outside. Key way shall be provided with cover.
9.12 A suitable cable termination arrangement with support insulators shall be provided on
Isolators and Link Disconnectors. The bimetallic lugs of adequate size, as per enclosed
specification & drawing, shall be provided. Clearances, Creepages and convenience in
making connections shall be ensured.
9.13 EC grade Aluminium Neutral Busbar of 300 x 25 x 8 mm for 63/100 KVA box and 525 x
40 x 10 mm for 250 KVA and 40 x 15mm for 400 KVA Box capable of carrying for full
load current. Neutral Busbar shall be isolated with respect to body. The bimetallic lugs of
adequate size, as per enclosed specification & drawing, shall be provided. Neutral Busbar
shall be as shown in the drawing attached with the specifications.
9.14 Bolts of M10 mm and 35 mm length with 2 Nos. plain washer and two Nos. nut are to be
provided on both the sides for earthing of the distribution box. Earthing bolt is to be fixed
on U-structure (Earth Clamp) welded on both sides of the distribution box. Thickness of
earth clamp shall be 2mm. The top surface of the earth clamp shall be properly Zinc plated.
Earthing nut bolt and washer should be zinc plated. There should be no powder coating on
top surface of the earthing clamps.
9.15 Three bottom plates for 63/100 KVA and 4 bottom plates for 250 KVA and 5 bottom Plates
for 400 KVA shall be provided for incoming and outgoing cables as shown in the drawing.
Bottom plate of size 125mm x 125mm fixed with four screws from inside shall be provided
for incoming and outgoing cables. Bottom plates shall be provided with suitable holes and
rubber glands for the cables. Rubber glands shall be made such that internal diameter of
glands provided for cables should be closed with the rubber film of minimum 1mm
thickness. Cable will go through the glands by cutting the film of the glands. Bottom plates
shall also be provided with cable clamps as shown in drawing.
9.16 Necessary fixing arrangement shall be provided at the back of the enclosure to ensure
proper fixing on double pole structure by means of suitable clamps at 4 places.
9.17 Danger marking shall be provided in red colour on the right door of the distribution box.
Marking shall be scratch proof and properly readable.
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9.18 All the components inside the Box shall be mounted on Polymer and glass strips of 2mm
thickness. The mounting strips shall be provided with required bends or ribs to give the
extra strength and shall be powder coated or zinc plated.
9.19 All joints of current carrying parts shall be bolted with 8.8 grade High Tensile MS Nuts &
Bolts, Corrugated/spring & Plain Washers. The nuts & bolts should be of hexagonal type.
All the nuts, bolts & washers should be properly zinc plated.
9.20 Each distribution box shall be supplied with proper packing in five ply - corrugated box.
9.21 Name plate having details such as Month & year of manufacturing, , Sr.No, and rating of
Distribution box, DVVNL”Name of Employer” shall be riveted on the Distribution box
door. Name of Manufacturer shall be duly embossed on the door of the distribution box.
The name plate should be of stainless steel of thickness 1 mm.
9.22 Incoming and outgoing circuit should be duly highlighted with paint by stencil printing.
9.23 Adequate slope on the top of box shall be provided to drain out rainwater from the top.
9.24 3 Nos. MCCBs and 3 Nos. HRC fuse links in spare should be invariably provided with
each box.
9.25 Good-quality plastic sticker leaflet should be pasted inside of distribution box door. The
matter of instruction leaflet shall be provided by the employer. All the instructions in leaflet
should be in Hindi/English/Local language.
3.10 CABLE TERMINATION:

Adequate size of Bimetallic lugs shall be provided for 3½ core, LT XLPE cable on
incoming side and out going side for 63/100/250/400 KVA boxes as below :
Incoming side Outgoing Side

63 KVA 70 sq.mm 50/ 70 sq.mm
100 KVA 150 sq.mm 50/70 sq.mm
250 KVA 300 sq.mm 150 sq.mm.
400 KVA 300 sq.mm 150 sq.mm.
3.11 LUG : Bimetallic lug should be made for electrolytic grade aluminium. Each lug should
be copper coated by electrolytic process and rich layer of tin should be mounted through
out the lug to protect from Galvanic Corrosion. The lugs shall be such that the rich layer
of tin should not peel of during operation. Individual lot should be pre filled with
conductive inhibition compound and lug should be duly capped to prevent oozing of
compound. The ductility of material should be such that flow ability of material be
adequate to flow in to the strand of the conductor and withstand on crimping pressure of
8500 PSI. The cut cross section of the joints
shall be homogeneous.
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3.12 FINISHING OF DISTRIBUTION BOX:

The outer side and inside surface of the box shall be properly Pre-treated
/Phosphated in seven tank process as per IS: 6005 and shall be applied powder coating
of minimum 40 micron thickness. The Colour shade of light Admiralty gray (as per
employer requirement) for 63, 100, 250 and 400 KVA box as per IS: 5/2007 (Colours of
Ready Mixed paints and Enamels) shall be applied inside & outside surface of the box or
as per state practice. Powder coating shall be suitable for outdoor use, conforming IS:
13871 (amended upto date) – Powder coatings. The process facility shall be in-house to
ensure proper quality for outdoor application.
3.13 TESTS & TEST CERTIFICATES:
In case of bought out items, routine and acceptance tests as per relevant IS and this
specification shall be carried out at the original manufacturers' works.
a) Routine Test (Carried out on all boxes):
Overall Dimensions Checking.
Insulation Resistance Tests.
High Voltage Test at 2500 V, 50 Hz AC for one minute.

12.1.4. Operation Test on MCCB/Isolator/Link Disconnector / HRC fuse base and fuse links.
b) Acceptance Tests (on complete Distribution Box):

Following tests shall be carried out as per acceptance tests in addition to routine tests on
one random sample of each rating out of the lot offered for inspection:
i) Temperature rise test on one sample of each rating.
Temperature rise test will be carried out as per the procedure given below:
For temperature rise test, a distribution box with all assembly of MCCBs / Link
Disconnectors / Isolator / HRC fuse base with link shall be kept in an enclosure such that
the temperature outside the box shall be maintained at 50 ° C.
20% more current than transformer secondary capacity i.e. for 63 KVA Distribution
Transformers full load current 84A, 20 % more is 100 A shall be kept in incoming circuit
keeping outgoing circuits short, till the temperature stabilizes and maximum temperature
rise should be recorded.
ii) Time-Current Characteristics
The MCCB should be tested for time current characteristics at 1.05 & 1.2 times of overload
release setting current and should pass the requirement given in clause- 7.2.
c) TYPE TESTS :
1 ON COMPLETE BOX:
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a. Temperature rise test:- The temperature rise test should be carried out as per IS: 8623
High voltage test shall be carried out as per IS:8623 amended upto date.
Short Time Withstand Current Test on Distribution Box shall be carried out as per IS
8623 or latest version.
The Distribution Box should be subjected to Short Time Withstand Current Test for 4KA
for 2 seconds for 63/100 KVA Box and 8 KA for 2 second for 200/315 KVA box) all the
circuits independently. The test should be carried out after by-passing MCCBs.
Degree of protection for IP- 54 on complete box shall be carried out as per IS: 13947/1993
or the latest version thereof.
Time /current characteristic test on MCCBs shall be carried out as per clause 7.2 of this
specification as stated above.
2 ON ISOLATOR (SWITCH DISCONNECTOR):

All type tests on Isolator (Switch Disconnector) as per IS: 13947 (Part III) amended up to
date shall be carried out.
3 ON HRC fuses base and HRC fuse links :
All type tests on HRC fuses and HRC fuse links IS 13703 ( Part I & II amended upto date)
for HRC Fuse Base and HRC fuse link shall be carried out.
4 ON MCCB:
All type tests on MCCB as per IS-13947 amended upto date shall be carried out.
5 ON Link Disconnector:
Following tests shall be carried out on link disconnector as per IS:
Short Circuit Withstand Strength
Temperature rise Limits
Mechanical Operations
12.4 TYPE - TEST CERTIFICATES:
The Distribution Box, Isolator (Switch Disconnector), HRC fuse, HRC Fuse Link and
MCCB offered shall be fully type tested as per relevant IS and this specification. The
Supplier shall furnish detailed type test reports before commencement of supply. The
detailed Type Test Reports shall be furnished with relevant oscillogram and certified
Drawings of the equipment tested. The purchaser reserves the right to demand repetition
of some or all the Type Tests in presence of purchaser’s representative at purchaser’s cost.
All the type tests shall be carried out from laboratories accredited by National
Accreditation Board of Testing And Calibration Laboratories (NABL), Department of
science & technology , Govt. of India to prove that the complete Box, Isolator, HRC fuse,
Link Disconnector & MCCB meet the requirements of the specification. The Manufacturer
should also furnish certificate from laboratories that laboratories are having all the
requisite test facility available in house. The type test Reports conducted in manufacturers
own laboratory and certified by testing institute shall not be acceptable.
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The Supplier should furnish the particulars giving specific required details of Distribution
Boxes, MCCBs, Isolator and Link Disconnector.
3.14 TESTING & MANUFACTURING FACILITIES :

Supplier must be an indigenous manufacturer. The Supplier must clearly indicate what
testing facilities are available in the works of manufacturer and whether the facilities are
adequate to carry out all Routine & Acceptance Tests. These facilities should be available
to Employer’s Engineers, if deputed to carry out or witness the tests in the manufacturer's
works. The supplier must have all the in-house testing facilities to carry out the acceptance
tests on the Box.
The supplier shall furnish detailed process of manufacturing & Powder coating.
3.15 PROTOTYPE & DRAWINGS:-

The manufacturer has to manufacturer the prototype Unit for each rating as per this
specification before bulk manufacturing. The manufacturer should intimate the readiness
of prototype to employer. The Project Manager will inspect the prototype for approval. The
manufacturer should submit the final drawings in line with this specification and prototype
to employer for approval before bulk manufacturing. The approval of prototype &
drawings shall be a responsibility of manufacturer/Contractor. Tentative drawing of box is
enclosed herewith.
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10 kVA 1-Phase, 16 KVA (1 Phase) & 25 KVA 3-Phase L.T.

Distribution Box (with MCCBs)
1. SCOPE:
This specification covers the design, manufacture, inspection, testing at manufacturer place
and supply of L.T. Distribution Box with energy meter. Distribution Boxes shall be used
for controlling the L.T. feeders from the L.T. side of Distribution Transformers. The system
shall be A.C. 3phase, 4 wires, 433V or AC single phase 2 wire, 230V, 50 Hz with
effectively grounded neutral.
2. SERVICE CONDITIONS:
The equipment to be supplied against this specification shall be suitable for satisfactory
continuous operation under the climatic conditions of the State.
3. SYSTEM DETAILS:
Distribution Boxes are meant for metering, control and protection of Distribution
Transformers with relevant parameters as under:
Transformer Full Current Incoming Circuit Outgoing Circuits

S.No.
Capacity kVA Amps Configuration Configuration
1 10 KVA (1-Phase) 43 Amp 45 A SPN MCCB 2 x 32A SP MCCB
2 16 KVA (1-Phase) 70 Amp 80 A SPN MCCB 2 x 50 A SP MCCB
3 25 KVA (3-Phase) 34 Amp 40 A TPN MCCB 6 x 25A SP MCCB
Each Distribution box shall have provision for fixing of three phase tri-vector energy
meter/single phase meter for DT metering depending upon capacity and type of
transformer, 1No. single pole Neutral (SPN)/Three Pole Neutral (TPN) MCCB at incoming
and 2 & 6 Nos. single pole MCCB at outgoing circuit as per above table. Incoming and
Outgoing MCCB shall be connected through insulated connectors. Cable from the
Distribution Transformer shall be connected to the incoming MCCB through energy meter.
Cables from the outgoing terminals of the incoming MCCB shall be connected respectively
to the R-Y-B Phase and Neutral terminals of the insulated bus bars or insulated Multiple
Outgoing Connectors. Cables from insulated bus bars or insulated Multiple Outgoing
Connectors shall be connected to the outgoing MCCBs. Aluminium cable of 16mm2 for 10
KVA / 16KVA and 35mm2 for 25KVA transformer shall be used. Cable shall be fixed with
bus bar or connectors with minimum two screws of size not less than M6. Insulation
provided shall be such that no live part including the screws for holding the cable shall be
accessible by hand/finger.
4. MCCB:
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MCCB shall be of reputed make and shall confirm to latest IS. MCCB shall be of fixed
rating type. MCCB shall have rated service short circuit breaking capacity of 10 KA at 0.4
P.F. (lag) with rated insulation voltage of 660 V. The time current characteristics of MCCB
shall be as per the following details:
Multiple of normal Current Setting Tripping Time
1.05 More than 2.5 hrs.
1.2 More than 10 minutes and less than 2 hrs.
Multiple of normal Current Setting Tripping Time
2.5 Less than 1 minute
6.0 Less than 5 Seconds
For above test, the reference calibration temperature of the MCCB shall be 500C.
5. ENCLOSURE:
(i) The enclosure shall be made up of Moulded Distribution Box of Glass Reinforced Polyester
Sheet Moulding compound (S1 grade) conforming IS : 13410-1992. The Distribution Box shall
comprise of (1) suitable enclosure (factory built assembly) SMC confirming to IS 13410 (2)
Porcelain Fuse units as per IS: 2086/1993 with latest Amendment/ Revision if any on the date
of inviting tender and as per our specification. (3) Incoming Switch disconnector as per IS:
13947/1993 with latest Amendment/Revision if any on the date of inviting tender. The wall
thickness of the Distribution Box shall be 3 mm min.on load bearing side and 2 mm min. on
other side in Base & 2 mm min.thick For Lid.
(ii) The inside dimensions of Distribution Box shall be 300 x 500 x 160mm for 10 &16 kVA
single phase transformer and 700 X 480 X 210 mm for 16 & 25 kVA three phase
Transformer. However, the dimensions of the box is for reference only, internal clearance
as per our requirement shall be strictly maintained. Overall dimensions of the box shall be
such that the box will withstand temperature rise limits as per IS and Company’s
Specification and to have sufficient space for working during maintenance. The size of the
box will depend on the size of Electrical components and other relevant provision made in
IS:13947/(P1,2&3), IS 2086and IS:4237 with latest amendment if any. Adequate slope on
the top of box (as shown in the drawing) shall be provided to drain out rainwater from the
top. The body and door of enclosure shall be individually in one piece without any welding,
except for fixing of the accessories like hinges, clamps, mounting clamps, bolts etc. which
shall be spot welded or MIG welded only. The door of Distribution box shall be fixed on
three tamper proof inside hinges not visible from outside. Hinges shall be welded from
inside of the box and door shall be fixed with the two screws in each hinge. Hinges shall
be made from 1.6mm MS sheet with hinge pin of diameter 3mm. The hinge pin shall have
head on top so that it does not fall down during the normal usage. Base and door shall have
flange / collars as shown in drawing. Collar of Base and door shall overlap by minimum
8mm. Rubber gasket shall be provided in between base and doors, such that it provides
proper sealing between the door and base of box to avoid ingress of water. Degree of
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protection shall be IP- 54 as per IS-13947 (amended up to date). Rubber Gasket shall be
fixed with suitable adhesive. Two numbers ‘U’ shaped latch arrangement shall be provided
to Seal the door with body for 10/16KVA single phase and three numbers ‘U’ shaped latch
arrangement shall be provided for 16/25KVA three phase. 2.5mm & 8mm diameter hole
shall be provided in U-shaped latch for sealing wires & padlock. Holes provided for sealing
& padlock should be aligned when latch is in closed position. ‘U’ shaped latch arrangement
shall be made from 1.6 mm thick MS sheet and shall be welded from inner side of the box.
U-latch shall be joined with stainless steel rivet.
(iii) Viewing window opening of 80mm x 90mm shall be provided with toughened glass of
5mm thickness as shown in drawing. Size of glass shall be 100mm x 110mm. Glass shall
be provided with a wraparound single piece rubber gasket (without joint) having minimum
depth of 8mm made from good quality rubber so that it can withstand weather effect. Glass
along with rubber gasket shall be fixed from inside of the door of distribution box with
powder coated glass holder made of 20 SWG MS sheet without any welding joint and by
draw process. Glass holder shall be fixed with minimum four welded screws & nuts from
inside and not visible from outside.
(iv) Mounting arrangement of the meter shall be as shown in the drawing. It should be raised
from the base of box by 15mm (minimum). It should be suitable for different makes of
meters. Galvanized/Zinc Plated adjustable strip shall be provided on meter mounting
arrangement for fixing of the meter. Three mounting MS screws, one for upper hanger (M4
threads x length 12mm) & two (M4 threads x 25 or 35mm length) in moving slotted flat
shall be provided for fixing of the meter.
(v) Two sets of Louvers (One set on each side) shall be provided. The perforated sheet of Glass
Reinforced Polyester Sheet shall be moulded from inside of the louvers.
(vi) The surface of the enclosure shall be properly Pre-treated / Phosphated in a 7-Tank process
and shall be applied with a powder coating of about 40 micron thickness. The powder
coating shall be of Light Admiralty Grey colour shade (IS-5:1993 Colour No. 697). Powder
coating shall be suitable for outdoor use. Rating and Type of distribution box shall be
printed or embossed on the door of the distribution box.
(vii) EC grade Aluminium Bus bars of 100mm2 (minimum) for Phase and Neutral, capable of
carrying full load current shall be provided. Bus bar shall be completely insulated such that
no live part including screws are accessible by hand/finger after fixing of cables. Insulation
shall be Fire retardant. Bus bars shall be isolated with respect to body.
(viii) Two earthing bolts of diameter 10mm and 25mm long shall be welded from inside of the
box and shall be provided with 2 nuts & washer. Earth marking shall be duly embossed
near the earth bolts. There shall be no powder coating on the earthing bolts.
255
(ix) One No. Incoming & 2 Nos. outgoing cable holes shall be provided as shown in drawing.
Cable holes shall be provided with superior quality rubber cable glands of internal diameter
30mm. Rubber glands shall be made such that internal diameter of glands provided for
cables should be closed with the rubber film of minimum 1mm thickness. Cable will go
through the glands by piercing the film of the glands.
(x) For mounting of box on pole, four holes shall be provided the back side of the box as shown
in drawing.
(xi) Danger marking shall be provided on the box in red color.

(xii) Name of Utility and name of scheme i.e. RDSS shall be embossed on the distribution box.
(xiii) Each distribution box shall be supplied with proper packing in 3 ply corrugated box.
(xiv) Tolerance permissible on the overall dimensions of box shall be ±3%.
6. FINISHING OF DISTRIBUTION BOX:

The surface of the box shall be properly pretreated / phosphated in 7-tank process and shall be
applied with powder coating. The process facility shall be in house of the manufacturer to
ensure proper quality for outdoor application.
7. ACCEPTANCE TESTS :
Following acceptance tests shall be carried out while inspecting lot of material offered.
1) Visual Examination:
The Distribution box shall be inspected visually, externally and internally for proper
Powder Coating layer, fitting of all the components in accordance with technical
Specification.
2) Verification of dimensions:
Verification of dimensions, external / internal clearances will be carried out as per
technical specifications.
3) Verification of fittings:
Components like insulated bus bars, MCCBs, Hinges, Rubber Glands etc will be
verified as per technical specification.
4) High voltage withstand test at 2.5KV:
The A.C. voltage of 2.5KV, 50HZ shall be applied for one minute as follows:
i) Between Live Parts of each insulated bus bar
ii) Between each insulated bus bar and earthing Screw/bolts
iii) On bus bar insulation.
iv) On PVC coating of PVC cables.
There shall not be any puncture or flash over during this test.
5) MCCB:
Time current characteristics of each rating of MCCB shall be checked as per the
requirement of the specifications.
6) Current Carrying Capacity:
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The current of 200 Amp shall be applied for 30 minutes through high current source on
each insulated bus bar. There shall not be overheating of the insulated bus bars during
this test.
8. TESTING & MANUFACTURING FACILITIES:
The Tenderer must clearly indicate what testing and manufacturing facilities are available
in the works of manufacturer and whether the facilities are adequate to carry out all Routine
& Acceptance Tests. These facilities should be available to inspection Engineers, if
deputed to carry out or witness the tests in the manufacturer's works. The tenderer must
have all the in-house testing facilities to carry out the acceptance tests on the Box.
9. TESTS:
The Distribution box shall comply with the requirement of IP54. Each type of LV
Switchboard shall be completely assembled, wired, adjusted and tested at the factory as per
the relevant standards and during manufacture and on completion.
i) Routine Test
The tests shall be carried out in accordance with IS 13947 and 8623 include including
but not necessarily limited to the following:
(a) Visual Check
(b) Verification of Component Rating
(c) Other Checks
i) Easy Accessibility and Maintenance
ii) Color Coding provided by colored tapes.
iii) Bus bar dimensions
iv) Degree of Protection check by paper.
(d) Dimension check
(e) Insulation Resistance Tests
(f) Mechanical Operation Tests
(g) Bus bar support and clearances
(h) Continuity of circuits and Function
(i) Powder Coating
(j) Overload Release setting of the Circuit Breakers
ii) Type Test
The box shall be fully type tested as per the requirement of IS 13947 (Part-1):1993
with latest amendment. The type test shall be carried out from the Govt. approved
laboratories duly accredited by National Board of Testing & Calibration Laboratories
(NABL) of Govt. of India.
10. Prototype & Drawings:-

The manufacturer has to manufacturer the prototype Unit for each rating as per this
specification before bulk manufacturing. The manufacturer should intimate the readiness
of prototype to employer. The Project Manager will inspect the prototype for approval. The
257
manufacturer should submit the final drawings in line with this specification and prototype
to employer for approval before bulk manufacturing. The approval of prototype &
drawings shall be a responsibility of manufacturer/Contractor. Tentative drawing of box is
enclosed herewith.
258
TECHNICAL SPECIFICATION FOR LT

UNDER GROUND WORK
Sl.
Particular Detail
No.
“Conversion of Overhead LT Electrical Power Distribution System of

1. Introduction various 33/11 KV Sub-stations into Underground Electrical Power
Distribution System in MVVNL, UP” under RDSS scheme.
Brief description of works:
 Undergrounding the existing overhead LT line of various 33/11 KV S/S

of MVVNL.
 Dismantling of existing overhead lines and cartage it to nearest store.
 Installation of LT Distribution boxes (Type A, Type B & Type C).
2. Scope of work  Laying of service cable from C-Type box to consumer premises, meter
shifting/meter connections.
 It will be whole responsibility of bidder, to get road cutting and

restoration permission from Govt. of UP, and it is must to submit the
NOC/permission to MVVNL before starting the work/agreement.
MVVNL will not be responsible for any delay in work due to above said
permission. Road cutting/restoration charges will be paid by contractor
to Nagar Nigam Kanpur or who so ever be owner of land/area.
All the works indicated above are to be carried out complete in all respect on
Turnkey basis within the specified time and as per guidelines and specification of
3. Execution
REVAMPED REFORMS-BASED AND RESULTS-LINKED, DISTRIBUTION
SECTOR SCHEME.
1. The quantity of material required for these works has been described separately
in the Bill of Quantity (BOQ) annexed with the tenderdocument.
5. Quantities indicated in the BOQ are tentative. The actual quantities shall
depend on the actual site conditions. Therefore, the contractor shall procure
the material only after ascertaining the revised bill of quantity, approved by
the CEO. The payment shall be made accordingly.
Bill of Quantity
4.
(BOQ) 6. The additional quantity of items which are mentioned in BOQ shall be
arranged by the contractor at unit rates given in price schedule.
4. However, some items which are not mentioned in BOQ, may be required
essentially to complete the works. These items shall also be arranged by the
contractor and no extra amount shall be made on thisaccount.
259
7. It will be mandatory of the bidders to conduct pre-tender survey of the sites and
for that they should visit every proposed 33/11 KV Substation and other
Pre Tender Survey & works site & also see the tentative line routes to assess the quantum of work.
5.
Site Visit
2. To access the quantum of work before quoting the price bid, tenderer
260
Sl.
Particular Detail
No.
may contact Executive Engineer (Construction).
8. The contractor has to make his own arrangements for procurement, supply
and use of materials as per requirement.
9. In procurement of these items the contractor shall follows all regulations of

the UPPCL/UP govt. / Government of India in respect of import license etc.,
if he chooses to procure these from imports.
Procurement of
6. Material and Further, the contractor shall be responsible for the payment ofapplicable
Equipment duties and taxes, port clearance, inland transportation etc.
10. Manufacturers test certificate for these materials shall be submitted and got
approved by Engineer of the contract, before utilization. The materials so
supplied by the contractor shall be guaranteed as per addenda/corrigenda of
Form „A‟.
11. This being a Turnkey contract, successful installation, commissioning &

integration with existing system, of those equipment/accessories/material not
specifically mentioned in the specifications, shall be the responsibility of
contractor. No extra payment shall be made for these inherent works.
12. He shall also supply all other associated equipment/ material/accessories not
specifically mentioned in this tender specification but are required for
successful and trouble-free operation of the executed work as a whole. For
that no extra payment shall be made to the contractor.
7. Accessories 13. This also includes insulators, cross arms, hardware, jumpers, cable racks, GI
strips, junction boxes, lugs, clamps, connectors, earthing rods, hardware
fittings, angles and channels and all other unforeseen items whose prices are
not indicated in the price schedule.
4. Contractor shall be supplying suitable size jumpers/ droppers/any other item,

needed for connecting equipments with existing equipments.
14. The electrical equipments and materials required during erection should be of
high standard. Technical features of these equipments and materials must
conform to the technical specification given in this bidding document.
Wherever the same is not specified, it must conform to the relevant I.S for
that material.
15. Materials conforming to other international standards, which ensure equal or

higher quality than the standards mentioned above, shall alsobe acceptable. In
case the bidders who wish to offer materials conforming to other standards,
salient points of difference between standards adopted and specific standards
8. Technical Standards
shall be clearly brought out in the respective schedule. Four copies of such
standards with authentic English version shall be furnished along with the
offer.
16. Whenever a material or an article is specified or described by the name of a

particular brand, manufacturer or trade mark, the specific item shall be
understood as establishing type, function and quality desired. Products of
other manufacturers may also be considered, provided sufficient information
is furnished, so as to enable the owner to determine that the products are
equivalent to those mentioned.
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Sl.
Particular Detail
No.
4. Materials supplied/used shall conform in all respects to the relevantIndian

Standard Specification with latest amendments there to.
Title IS No.
1. Cement IS 269
2. Steel IS 6003/1970
3. Fasteners IS 6639/1972
4. Concrete mix IS 1343
5. RCC IS 456
6. Cable laying and jointing IS 1255
5. Installation work pertaining to equipment, cabling etc should be in

accordance with the applicable standards, safety codes etc.
The major equipments/material supplied by the contractor or its sub vendor has
to be got inspected and tested by the Engineers of the Corporation for its quality
and quantity before dispatch to the work site.
The contractor shall have to follow the procedures laid down with this tender
specification or any other procedure intimated later on.
Rest of the equipments/ materials shall be checked at site for dimensions, weights,
finish and quality. For this purpose, the contractor shall have to provide general
measuring equipments like steel tape, Vernier calipers, screw gauge, tong tester,
Quality Assurance, earth resistance tester, 2.5 KV meggar etc.
9. Inspection & Testing
(QA&I) The following items shall be inspected/tested at the manufacturer‟spremises
before dispatch:
1) All types of power cables
2) Distribution Pillar Box
3) Meters
4) LT XLPE cable
5) ST Poles
6) GI & GSS wire
7) LT Distribution Box
8) All other items required for completion of work
The approaches to site of work, if necessary, shall have to be made by the
contractor at his own cost so as to get easy access for both personnel and
10. Approaches
equipments.
The Contractor has to make use of the water supply if available at any of the
substation site for construction purpose transport of water from the source to the
working area will be contractor‟s responsibility.
It is essential that the contractor shall prevent misuse of wastage of water at all
Water and Power time, failing which necessary charges will be collected from the contractor. In
11.
Supply case, water is not available at site, the contractor has to make his own
arrangement and any extra claim on account of this will not be entertained.
Power required for construction will be made available on demand at one
point for which payment shall be made by the contractor.
17. The contractor shall himself arrange all men & material, all constructional T
& P and any other material required for successful and speedy execution of
12. Men, Material & T&P
the job within the prescribed time
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18. All tools, welding equipment, crane, scaffolding, rigging materials, ladders,
consumables, hardware etc. required for installation shall be arranged by the
contractor.
19. The contractor shall provide experienced, technically qualified, and

supervising Engineers for supervision. The contractor shall engage only
competent skilled workers.
4. The contractor shall observe strict adherence to the existing labour laws.
20. It shall be the responsibility of the contractor to store, move/transport from

stores/storage yard etc., relevant items and accessories to the place of
installation wherever necessary he will assemble all parts of equipment. In
accordance with the specific installation instructions as directed by Site
Site Storage/
13. Engineer.
Transportation
21. The stores should be dismantled, and site cleared after the work is completed
22. The contractor shall be responsible for overall co-ordination with

internal/external agencies, project management, training of owner‟s
manpower etc. as required.
14. Co-ordination
23. The supplier/ contractor shall open his office in that town and shall co-
ordinate with concerned authorities of respective DISCOM for all the matters
pertaining to the works.
24. All the works covered under the scope of the tender shall be done in
accordance with the norms defined in urban construction manual of UPPCL,
unless the same is not specifically defined in the specification or with the
provisions of Indian Electricity Rules/Acts/Other Government
Rules/Regulations as prevalent at the time of executionof the job/work.
25. Installation shall be carried out strictly in accordance with the approved
drawings Modifications, if any, required to suit site conditions, shall be
carried out only with the prior approval of the Site Engineer. All such
changes shall be incorporated in “As built” drawings to be furnished by the
contractor.
26. Responsibility for successful installation of other equipment accessories,

purchased but not mentioned specifically above, and their commissioning
Erection, Testing and shall be on contractor. For all such items the contractor shall be supplying all
15.
Commissioning material and equipment required to accomplish the job complete in all
respect.
4. Installation work pertaining to equipment, cabling etc should be in

accordance with the applicable standards, safety codes etc.
5. The contractors shall themselves be responsible for timely arrangement/

procurement of all the raw materials required for the manufacture of all
tendered items by them/ their and / or by their vendors.
27. While Repairing & Replacing the equipment, if any other equipment gets
damaged due to negligent handling of the contractor the same shall be
replaced by the contractor at his cost to the owner
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Sl.
Particular Detail
No.
satisfaction.
He shall be responsible for dismantling of defective equipments, thereproper

handling and shifting.
Also, he shall hand over the old & dismantled equipments/ material to the
purchaser‟s local stores or other sites as per instructions of the Chief
Engineer, MVVNL, for which no extra payment shall be made.
28. All charges on account of damages/losses/claims/thefts etc. involved under

the conditions laid down above shall be borne by the contractor. Its cost shall
be recovered from his bills /security deposits /other assets.
29. In order to avoid hazards to personnel moving around, the equipment such as
Transformer, Capacitor Banks, Switchgears etc. if required to be kept
charged after installation till their commissioning, shall be cordoned off by
suitable barriers to prevent accidental injury to personnel moving around.
9. Where the equipments/ assemblies are supplied in more than one part, the
contractor shall make all necessary mechanical and electrical connections
between the sections. The contractor shall also do necessary adjustment in
the alignments required for its proper operation.
30. Care shall be taken in handling instruments relays and other delicate devices
where instruments and relays are supplied separately they shall be mounted
only after the associated switch gear/control panels are erected and aligned.
31. Precaution: The contractor shall exercise all possible care to avoid damage
to public utilities e.g. water/ sewage pipes telephone and power lines/cable
already existing. In case of any accidental damage during the work, the
contractor shall be responsible to repair/replace the same at his own cost and
shall ensure that the purchaser is not put to any loss.
32. The contractor shall have to provide proper lighting, barricading, signboards
etc. at the work site as a necessary precautionary arrangement to avoid
accident/ damage/ losses to the public
/utilities/properties.
33. Site Solution: It may be possible due to some reasons or others that it would
not be possible to work as per the procedure. In such case/cases, the solution
to the problem shall be achieved by the CEO with the consultation of
contractor, and the contractor shall work asper procedure proposed by the
CEO. Such cases shall in variably be informed to the engineer of the contract
for which no extra payments shall be made.
34. Space Constraints: While executing the job it is quite possible that some of
the specified work may not be carried out due to space/land/ other technical
constraints etc. In such case if required MD MVVNL may divert this work at
some other site or cancel the left-over portions of
work.
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Particular Detail
No.
35. The contractor shall ensure that the equipment under erection as well as the
work area and the site are kept clean to the satisfaction of the Engineer. In
case, the Engineer is not satisfied about the cleanliness he will have the right
to carry out the cleaning operations and expenditure incurred in this regard
will be to contractor‟s account. Packing cases and packing materials shall be
promptly cleared from sites.
36. The complete work mentioned in the specification shall be completed within
completion period mentioned in Special Condition of Contract from the date
of awarding the contract.
The survey of each and every site of the work shall be completed within a
week by the contractor.
37. The contractor shall estimate the actual quantities of equipments / material
required to complete the work to the full satisfaction of respective DISCOM
and as per Urban Construction manual of UPPCL and get it approved from
the CEO.
38. The contractor shall submit the „PERT‟ chart for complete execution ofwork
at the time of signing the contract agreement as per completion schedule of
contract.
Schedule of work
16. completion/ PERT
Chart/Bar Chart This PERT chart shall include all the activities such as design, engineering,
approval of drawings and vendors, procurement, manufacturing, erection,
testing and commissioning.
39. After placements of the orders with the manufacturer, the delivery of
equipments should be so regulated that it is received at the site nearly 7 days
prior to its erection.
40. The delivery of material/equipments being received at site should be strictly
regulated with the schedule of its erection.
41. The payment of material shall be justified by the CEO with the physical
progress of the corresponding work.
42. Precaution should be taken, not to increase the inventory of the ownerwithout
actually utilizing it at the site for a long time.
For other specifications not mentioned in the RDSS guidelines, MVVNL

17. Other specifications given here and established practices for same work, shall
prevail accordingly.
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TECHNICAL SPECIFICATION FOR 1.1 KV GRADE SINGLE CORE 70, 120, 400,
630 SQ. MM L.T. XLPE CABLE
1 .0. SCOPE:
This specification covers design, engineering, manufacture, stage testing, inspection and
testing before supply and delivery at site of 1.1 kV grade single core 70, 120, 400, 630
Sq. mm. XLPE Cables for use with effectively earthed distribution system.
1.2. It is not the intent to specify completely herein all the details of the design and construction
of material. However, the material shall confirm in all respects to high standards of
engineering, design and workmanship and shall be capable of performing in continuous
commercial operation in a manner acceptable to the purchaser, who will interpret the
meanings of drawings and specification and shall have the power to reject any work or
material which, in his judgment is not in accordance therewith. The offered material
shall be complete with all components necessary for their effective and trouble-free
operation. Such, components shall be deemed to be within the scope of Bidder‟s supply
irrespective of whether those are specifically brought out in this specification and/or the
commercial order or not.
2.0. STANDARDS:
2.1. The materials shall conform in all respects to the relevant Indian StandardSpecifications
with latest amendments thereto.
Indian Standard Title Internationally

No. Recognized
standard
IS-7098 Part- Specification for Cross Linked IEC 502 (1983)
I/1988 Polyethylene Insulated PVC Sheathed
Cables for working Voltages Up to and
including 1100V
IS-5831/1984 PVC insulation and sheath of IEC 502 (1983)
electric cables
IS-8130/1984 Conductors for insulated electric IEC 228 (1978)
cables and Flexible cords
IS 3975/1979 Specification for armoring
IS-10418/1982 Specification for cable drum
Material conforming to other internationally accepted standards, which ensure

equal or higher quality than the standards mentioned above, would also be acceptable.
In case the Bidders who wish to offer material conforming to the other standards, salient
points of difference between the standards adopted and the specific standards shall be
clearly brought out in relevant schedule. Four copies of such standards with authentic
English Translations shall be furnished along with the offer. . In case of conflict the
order of precedence shall be (i) IS,
(ii) IEC, (iii) Other standards. In case of any difference between provisions of these
standards and provisions of this specification, the provisions contained in this
specification shall prevail.
Moderately hot and humid tropical climate, conducive to rust and fungus
growth.
266
3.0. PRINCIPAL PARAMETERS :

The material shall conform to the following specific parameters:
Sl. Item Specification

No.
1. Type of Installation Outdoor
2. System Voltage 440 V (+/-15% )
3. System Frequency 50 Hz +/- 5%
4. No. of Phases Three
5. System of earthing Solidly grounded
4.0 TECHNICAL REQUIREMENTS:
4.1 MAIN FEATURES:

The power cables shall be of LT 1.1 kV Grade, stranded compacted, high conductivity,
aluminum conductor, XLPE insulated, ST-1 type extruded PVC outer sheathed,
conforming to relevant standards suitable for LT AC three phase, 50 c/s, effectively
earthed distribution system.
4.2 MATERIALS AND CONSTRUCTION:
4.2.1 CONDUCTOR:
The cable conductor shall be made from stranded aluminum to form compacted shaped
conductor having resistance within the limits specified in IS-8130/1984
4.2.2 INSULATION:
The XLPE insulation shall be suitable for the specified system voltage. The
manufacturing process shall ensure that the insulation is free from voids. The insulation
shall withstand mechanical and thermal stresses under steady state as well as transient
operating conditions. The extrusion method shall give smooth surface of insulation. The
insulation shall be so applied that it fits closely on the conductor and it shall be easily
possible to remove it without damaging the conductor.
4.2.3 OUTER SHEATH:
Extruded PVC outer sheath of GREEN colour shall he applied with suitable additives to
prevent attack by rodents and termites. Outer sheathing shall be designed to offer high
degree of mechanical protection and shall also be heat, oil, chemical, abrasion and
weather resistant. Common acids, alkalies, saline solutions etc., shall not have adverse
effects on the PVC sheathing material used.
4.2.4 CONSTRUCTION:
1) All materials used in the manufacture of cable shall be new, unused and of
finest quality. All materials shall comply with the applicable provisionsof the
tests of the relevant Standards.
2) The PVC material used in the manufacture of cable shall be of reputed make.No
recycled PVC is permissible. The purchaser reserves the right to ask for
documentary proof of the purchase of various materials to be used for the
manufacture of cable and to check that the conductoris complying with quality
control.
267
3) The cable shall be suitable for laying in covered trenches and/or buried
underground to meet the out door application purposes.
4) Cables shall have suitable fillers laid up with the conductors to provide a
substantially circular cores section before the sheath is applied. Fillers shall be
suitable for the operating temperature of the insulation & compatible with the
insulation material
5) Minimum guaranteed weight of Al. Conductor used in the cable Kg./KM.
1x 70 - 189
1x120 - 324
1x 400 - 1080
1x 630 - 1701
No negative tolerance is acceptable in Kg/Km weight.
4.2.5 CURRENT RATING:
The cables shall have current ratings and derating factors as per relevant Indian
Standards. The current ratings shall be based on maximum conductor Temperature of
90 deg 0C with ambient site condition specified for continuous operating at the rated
current.
4.2.6 OPERATION:
Cables shall be capable of satisfactory operation, under a power supply system
frequency variation of +/- 5 c/s, voltage variation of +10% or-15%. Cables shall have
heat and moisture resistance properties; these shall be of type and design with proven
record on Distribution Network service.
4.2.7 LENGTH:
The cable shall be supplied in wooden drums and the standard drum lengthshall be as
follows-
1x 70 Sq. mm - 1000 meters +/- 5%
1x 120 Sq. mm - 500 meters +/- 5%
1x 400 Sq. mm - 500 meters +/- 5%
1x 630 Sq. mm - 500 meters +/- 5%
Substandard drum length of not less than 100 meters upto a maximum of 5% of the
quantities ordered shall be accepted. However substandard drum length upto a
maximum of 5% shall be acceptable only in a particular lot offered for inspection
4.2.8 IDENTIFICATION:
For identification of individual cores, coloured strips of red, yellow and blue colours
respectively shall be used on the cores to identify phase conductors as per relevant ISS.
4.2.7 EMBOSSING:
The cable shall be embossed throughout the length with the name of the manufacturer
and the letters “Property of MVVNL., Specification No., voltage grade with cable size
and the year of manufacture”. The embossing shall be done only on the outer sheath, the
distance between any two consecutive embossing‟s shall not be more than 2 Meter. The
cable shall also be embossed
268
(clearly visible) for the verification of its length at intervals of 1 Meter say 1,2,3up to
full length.
4.2.8 GUARANTEED TECHNICAL PARTICULARS:

The guaranteed technical particulars as detailed in the specification annexure-I shall be
guaranteed and a statement of guaranteed technical particulars shall be furnished in
the format along with the bid without which the Bid shall be treated as Non –
Responsive.
Immediately after completion of the electrical tests (during routine/acceptance
tests), the ends of the cable shall be enclosed by rubber/PVC caps of wall thickness not
less than 2.5 mm and then sealed by non-hygroscopic material (the cores being suitably
insulated from the cap). The cap shall be of robust construction and tight fit, and it
shall have the trademarkof the manufacturer embossed thereon
5.0. TESTS:
5.1 Type Test:
The material offered shall be fully type tested at independent test laboratoriesby the
Bidder as per the relevant standards, but test reports shall not be more than five years
old from the date of opening of bid. The bidder shall furnish complete set of following
type test reports along with the bid. The bids received without these type test
reports shall be treated as Non- responsive.
7. Tests on conductors
8. Test for thickness of insulation and sheath
9. Physical tests for insulation
10. Physical tests for outer sheath
11. Insulation resistance test
12. High voltage test
43.2. Acceptance and Routine test: All acceptance and routine tests as stipulated in the relevant
standards shall be carried out by the supplier in presence of purchaser‟s representative.
6.0 INSPECTION:
6.1 The inspection shall be carried out by the purchaser‟s representative during manufacture
and before dispatch. The supplier shall keep the purchaser informedin advance, about the
manufacturing programmed so that arrangement can be made for inspection.
The manufacturer shall grant free access to the purchaser‟s representative, at a
reasonable time, when the work is in progress. Inspection and acceptance of any equipment
under this specification by the purchaser, shall not relieve the supplierof his obligation
of furnishing the equipment in accordance with the specification and shall not prevent
subsequent rejection if the equipment is found to be defective.
6.2 All Acceptance tests and inspection shall be made at the place of manufacturer unless
otherwise especially agreed upon by the Bidder and purchaser at the timeof purchase.
The purchaser reserves the right to insist for witnessing the acceptance/routine
testing of the bought-out items. The supplier shall give 15
269
days (for local supply)/ 30 days (incase of foreign supply) advance intimation to enable
the purchaser to depute his representative for witnessing the acceptance and routine
tests. Material shall be dispatched only after getting the dispatch authorization from
Inspectors representing purchaser, after successful testing.
6.3 If successful type tests have been carried out on the offered design during last five years
(counted from the date of tender opening), repetition of type tests is not required.
On the other hand, if the offered design is not type tested during last five years,
the cable shall be subjected to all type test in accordance with IS: 1554 (Part-I)/1988
and amendment thereof at recognized test house of repute. All
charges/fee/transportation etc. to conduct these tests shall be borne by Contractor.
Regular supply of the material shall commence only after successful type testing and
dispatch authorization from the competent authority.
However, the purchaser reserves the right to get cable type tested at any stage
during the currency of contract at his own expenses in any reputed test house. The
transportation and arrangement of testing of sample to test laboratory shall be the
responsibility of the contractor.
6.4 Routine tests report shall be sent by the manufacturers with their offer for
inspection, the following acceptance tests as laid down in the referred ISS (with latest
amendments) shall be carried out by the inspecting officer of the MVVNL on Samples
selected at random as per Appendix `A „ in IS-1554 (Part-I) 1988.
1. Tests on conductor Reference to I.S.S.

a) Tensile test IS: 8130-1984
b) Conductor resistance test IS: 8130-1984
2. Test on armoring strips:

a) Measurement of dimension IS: 3975 – 1979
b) Tensile test IS: 3975 – 1979
c) Elongation test & winding test IS: 3975 – 1979
d) Zinc coating IS: 2633 – 1984
3. Test for thickness of insulation and sheath IS: 5831 – 1984
4. Tensile strength and elongation

at break of insulation and sheath IS:5831 – 1984
5. Insulation Resistance Test IS: 5831 – 1984
6. High voltage test at room temperature IS: 1554 (Part-I) – 1988 In
addition to above, length/weight check and bending test on one drum

per inspection shall also be carried out by the inspecting officers for which contractor
will make all necessary arrangements and provide all necessary facilities at his own
cost.
270
7.0 CALBE DRUMS:

The cables shall be supplied in non-returnable substantially lagged wooden drums of
heavy construction suitable for transportation by goods train or truck and for storage at
site. The wood used for construction of the drum shall be properly seasoned and sound
and wood preservative shall be applied to the entire drum. All ferrous parts shall be
treated with a suitable rust preventivefinish or coating to avoid rusting during transit
or storage. The drum shall also conform to specn. No. IS: 10418-1982 with latest
amendment thereof.
Each drum shall have the following information marked on it with indelible ink
alongwith other important information including technical data: -
1. Name of Project:RDSS
2. Property of MVVNL.
3. Designation of consignee:
4. Drum Number.
5. Aluminum Core Cable.
6. Cable rating eg. Voltage grade, No. of cores, sizes etc.
7. Height of empty drum.
8. Length of Cable.
9. Gross weight of drum with cable.
10. Year of manufacture.
8.0 PACKING AND TRANSPORT:
All the material covered under this specification shall be adequately packed for
transportation by Rail/Road. A layer of waterproof paper shall be applied to the surface
of the drums and over the outer cable layer. A clear space of at least 40 mm shall be left
between the cable and the laggings. The packing shall be adequate to protect the cable
from damage, in transit and contractor shall be responsible for it and make good at his
own expense any and all damages due to improper packing etc.
44. VARIATION OF QUANTITY:

The supplied quantity can vary within Plus/Minus 20% of the ordered quantity.
271
General Technical Particular of 1x400sqmm and 1x630sqmm, LT XLPEarmoured cable against tender
Sl.
Particulars Unit 1x400sqmm 1x630sqmm
No.
Manufacturer‟s name and
1
address
2 Location of Factory
IS-7098 Part- IS-7098 Part-
Standard to which cable 1/1988 1/1988
3
conform
4 CONDUCTOR DETAILS
Material compositions class asper
a) H4 Grade H4 Grade
IS:8130
b) Shape of stranded conductor Compacted Compacted
Number of strands in each core(Min)
c) No 58
58
d) Diameter of each strand mm 2.97 3.72
Nominal cross section area ofeach
e) sq. mm 630
core 400
Guaranteed weight of
f) aluminum per Core per KM(min) kg/km 1080 1701
5 CONDUCTOR SCREEN
a) Material as per IS as per IS
b) Thickness (min) mm as per IS as per IS
6 INSULATION
a) Material with ref. of ISS IS:7098 IS:7098
Thickness of insulation (mm)(min.)
b) mm
Normal 2.00 2.40

Minimum 1.70 2.06
7 INSULATION SCREEN
a) Material
1) Semi conducting part as per IS as per IS
2) Metallic part as per IS as per IS
b) Thickness for
1) Semi conducting part (min) mm as per IS as per IS
2) Metallic part (min) mm as per IS as per IS
8 INNER SHEATH
a) Material as per IS as per IS
b) Thickness (Min) mm as per IS as per IS
9 Filler material
10 ADMOURING
a) Material
Dimension of Flat armoringstrip
b) mm x mm
11 OUTER SHEATH ST2 ST2

a) Material 2.20 2.40
272
b) Thickness of sheath (Min) mm 1.56 1.72
12 Weight of Finished cable kg/km 1525 2395

(Approx)
13 Standard delivery length meter 500 250
Tolerance in standard drumlength
14 % ±5% ±5%
of the cable
Gross weight of drum includingcable (
15 kg 1625 2495
imensi)
16 Recommended depth of laying mm As per IS As per IS
Short circuit current for duration of
17 short circuit of 1 kA As per IS As per IS
Sec.
Voltage drop per thousand- meter
18 As per IS As per IS
length at rated current.
a) When laid directly in ground. Volt/km As per IS As per IS
b) When laid directly in covered volt/km As per IS As per IS

Trenches
c) When laid directly in air volt/km As per IS As per IS
19 Impulse voltage withstands kV As per IS As per IS
Derating factors under various
20
conditions of installation
D.C. resistance per core at200C
a) ohm/km
(Max.)
A.C. resistance per core at200C 0.078 0.047
b) ohm/km
(Max.)
c) Reactance per core ohm/km
d) Capacitance per core microf/km
Insulation resistance at 27 C
0 As per IS As per IS
e) M.oh/km
(Min)
Volume resistivity of insulationat
f) ohm/km 1x1014 1x1014
270C (Min)
Maximum partial discharge
21 pC As per IS As per IS
magnitude at 1.5 Uo
Maximum cable charging current
22 at normal operatingvoltage amp/km As per IS As per IS
Recommended minimum
23 Mm As per IS As per IS
bending radius.
size, size,
Manufacturers Manufacturers
Embossing on cable name, voltage name, voltage
level & Property level & Property
of of
24 MVVNL MVVNL
Dated For M/s
Place Signature
(By its constituted attorney)
Note : The tenderers should clearly note that above guaranteed technical particulars are to be givenonly in the proforma given
above and not in random form. Technical particulars given in any other form shall not be considered. Any extra information
can be given separately in the form of annexure to above technical particulars.
273
274
TECHNICAL SPECIFICATION OF L.T. AIR CIRCUIT BREAKER

1. SCOPE
This specification covers the technical requirements of design, engineering, manufacturing, testing at manufacturer's works, packing,
forwarding, supply and unloading at store/site, of LT ACB (630A, 800A, 1250A) complete with all accessories for efficient and
trouble free operation.
2. APPLICABLE STANDARDS
The equipment covered by this specification shall confirm to the requirements stated in latest editions of
relevant Indian/ IEC Standards and shall conform to the regulations of local statutory authorities.
a) IS 60947-1-2004/ : Low voltage switchgear and control gear – Part1: General rules
IEC 60947-1-Edition 5.1b
2009-05
b) IS 60947-2-2003/ : Specification for Low voltage switchgear and control gear – Circuit
IEC 60947-2-Edition 4.1b Breakers
c) IS 12063-1987 : Degree of Protection provided by enclosures
IEC 60529-1989
d) IS 8623-2-1993 : Specification for LV Switchgear and Control gear assemblies-
IEC 60439-2-1987 particular requirements for bus bar trunking system (bus ways)
e) IS 14772-2000 : General requirements for enclosures for accessories for
Household and similar fixed electrical installation
f) IEC 60664 : Insulation co-ordination within low voltage system including
clearances and creepage distance for equipment.
g) IS 2551- 1982 : danger notice plates
3. CLIMATIC CONDITIONS OF THE INSTALLATION

a) Max. Ambient Temperature : 50 deg.C
b) Max. Daily average ambient temp. : 40 deg.C
c) Min Ambient Temp : 4 deg C
d) Maximum Humidity : 100%
e) Minimum Humidity : 10%
f) Average No. of thunderstorm days per Annum : 50
g) Average Annual Rainfall : 750 mm
h) Average No. of rainy days per annum : 60
i) Rainy months : June to Oct.
j) Altitude above MSL not exceeding : 300 meters
k) Wind Pressure : 126 kg/sq m up to an elevation of 10M.
The atmosphere is generally laden with mild acid and dust in suspension during the dry months and is subjected to fog in cold
months. The design of equipment and accessories shall be suitable to withstand seismic forces corresponding to an
acceleration of 0.1 g.
4. GENERAL TECHNICAL REQUIREMENTS
S No.
DESCRIPTION REQUIREMENT
4.1 Rating 630A, 800A,1250A (AC)
4.2 Type of ACB Drawout type, manually operated
4.3 Type of Release Microprocessor based release
4.4 ACB O/L Release setting 40% to 100%
4.5 Utilization Category B
4.6 No. of Poles Three
4.7 Rated operational Voltage 415V
4.8 Rated Impulse withstand voltage (Uimp) 8kVP
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4.9 Rated ultimate short circuit breaking capacity (Icu) 50kA rms
4.10 Rated service short circuit breaking capacity (Ics) 100% of Icu
4.11 Rated Insulation voltage (Ui) 1000V
4.12 Rated Short time withstand Capacity (Icw) 50kAP for 1 sec.
4.13 Rated Making Capacity (Icm) 105 kAP
4.14 Material of Busbar Aluminium
4.15 Current Density of busbar 1.0 A/mm².
800C at terminals with an ambient temperature
4.16 Max. permissible temperature rise
not exceeding 400C
4.17 Min. Clearance b/w phases 25.4 mm
4.18 Min. Clearance b/w phase & earth 19.4 mm
4.19 Isolation Shall be suitable
4.20 Degree of Protection IP 65
5. GENERAL CONSTRUCTION
5.1 ENCLOSURE
The ACB shall be housed in an enclosure made of 2mm thick sheet steel. Enclosure of the ACB shall be weather proof and
vermin proof. The enclosure shall be provided with taper type construction & an overall canopy to prevent accumulation of
water. The enclosure shall be suitable for outdoor application with Degree of protection as IP65. The enclosure shall be
provided with extended insulated Aluminium links outside & designed for use of 415V, 3-Phase 4 Wire, 50Hz supply system.
The pockets of Aluminium links shall be sealed properly to avoid ingress of moisture.
The enclosure shall have single door arrangement with hinges so that it is not possible to remove the door. However a
separate lifting window type arrangement should be provided on the door for operation of ACB. It shall be so designed that
when the front cover is opened, there should be no accessible space. The access should only be such that the maintenance of
the ACB and its protective parts can be easily carried out. The relay push trip mechanism shall be provided on the front door
of the ACB so as to ensure that the tripping mechanism is accessible from outside. All parts shall be manufactured in
accordance with relevant IS/IEC. In case of equipment with conductive enclosures, means shall be provided if necessary to
ensure electrical continuity between exposed conductive parts of the equipment and the metal sheathing of connecting
conductors. The removable parts of the enclosure shall be firmly secured to the fixed parts by a device such that they cannot be
accidently loosened or detached owing to the effects of operation of the equipment or vibrations. When an enclosure is so
designed as to allow the covers to be opened without the use of tools, means shall be provided to prevent loss of the fastening
devices. The circuit breaker shall have the provision to lock the operating mechanism in OFF position. One padlock at the
front side shall be provided with common master key for all the circuit breakers. All the hardware used shall be hot dipped
Galvanized or electro-zinc plated. ACB shall have anti-pumping, line load reversibility and shall be of Pollution degree 3. It
should have micro processor based tripping mechanism having an in-built feature of thermal memory and sensing true RMS
giving a stable, inverse time current characteristic which cannot be inadvertently adjusted. The operating characteristic shall be
such that:
5.2 AIR CIRCUIT BREAKERS

The ACB shall be of drawout type, manually operated stored energy design. Switching ON & OFF of the ACBs shall be
independent of speed of the operator. For safety of operator, the ACB shall be totally front shielded with an escutcheon cover,
while maintaining the required IP65 it shall also prevent contact with live parts when the enclosure door is opened.
The ACB shall be fitted with microprocessor based release only. Overload releases shall have minimum adjustability from
40% to 100%. However the same shall be preset at 80% of the rated current while calibrating during manufacturing at 433V
AC. The CTs mounted for thermal overload release shall have secondary terminals inaccessible from front including tripping
mechanism of O/L to avoid tampering of CTs. Separate indications Mechanical / Electrical for overload trip and short circuit
trip shall be provided. Besides this, temp. at cable terminals should not exceed 800C at 400C ambient on full rated current.
The time-current characteristics shall be of IDMT, normal inverse type with a pick up between 1.05 to 1.3 times the rated
current settings. Magnetic short circuit release shall be of instantaneous pick-up design. The Short circuit release shall be of
instantaneous pick-up design. The Short Circuit release shall have field adjustable pick-up of range 6-8 times the rated current
with accuracy of +20% maximum. The arc chutes shall be of arc resistant material and ensure that the arc is positively
extinguished within the arc chutes while clearing the rated breaking current.
The actuator of the equipment shall be insulated from the live parts of the ACB. If it is made of metal, it shall be capable of
being satisfactorily connected to a protective conductor unless it is provided with additional reliable insulation. If it is made of
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or covered by insulating material, any internal metal part, which might become accessible in the event of insulation failure,
shall also be insulated from live parts for the rated insulation voltage. The direction of movement of the actuator shall comply
with the requirements of IEC-447. The open and closed positions shall be ambiguously indicated by means of position
indicating devices. For equipment operated by means of two push buttons, only the push button designated for the opening
operation shall RED or marked with symbol “O”. Red color shall not be used for any other push-button. The colours of other
push-buttons shall be in accordance with IEC-73.
› Circuit breakers shall be microprocessor based release 3 pole, air break, moulded case, draw out type as specified and designed to
deliver performances without periodical maintenance.
› Air circuit breakers (ACB) shall comply with standards IS/IEC 60947-1 & 2. The breakers shall be tested & certified at
CPRI/ERDA.
› Air circuit breakers shall have a rated operational voltage of 440V AC (50/60Hz).
› The rated insulation voltage shall be 1000V AC (50/60Hz) & impulse voltage of 12 kV.
› Circuit breakers shall be capable of carrying the full load current defined for 50 0C without any derating.
› Circuit breaker main contacts shall be silver plated high grade copper with each pole encased in a reinforced polyester casing
completely insulated from each other internally and offer double insulation for the operators on the breaker front face.
› Circuit breakers from 630-1250A shall be of single frame having uniform “height x width x depth” with common door cut-outs.
› All accessories & auxiliaries should be common for entire range of circuit breakers.
› The operating mechanism shall be of fast opening type with opening time of breaker should be <40ms
› ACB should be with microprocessor based release. It should give protection against over load, short ckt & earth fault. Individual
fault trip LED indications shall be available on the trip unit for easy & faster identifying the cause of fault.
› It should be possible to change the protection settings on line and the circuit breaker need not be switched off while adjusting the
setting.
› ACB should be equipped with standard safety shutters with locking provision & ready to close contact to ensure all safety
parameters are full filled.
› Modbus communication & GPRS modem :
 All ACB should have in built two way Modbus communication.
 ACB release should be suitable to integrate 3rd party GPRS modem with SIM card for remote monitoring.
 Circuit breaker trip unit shall have a display for measurement of current parameters. It shall be possible to view last 20 trip
history with date and time and magnitude of fault. The release shall also store and display 100 events with date and time.
All trip units provided shall have thermal memory as standard which shall be switchable.
 The ACB display shall provide details like no. of operations, trip history, etc. the same shall be possible to be downloaded
from the front of the ACB.
 ACB should have SCADA compliant for on/off status.
Performances:
› The ACB breaking capacity performance certificates shall be available for category B according to IEC 60947-2 standard.
› The tests shall be carried out with a breaking performance during operation (Ics) and admissible short time withstand (Icw) equal to
the ultimate breaking capacity (Icu). i.e. Icu = Ics = Icw = 50KA for 1 Sec.
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› All Air circuit breakers can be reverse fed without reduction in performance.
› The Circuit Breaker shall have minimum Mechanical life of 15000 operations up to 1600A without maintenance.
› The breakers shall have minimum electrical life of 6000 operations up to 1600A without maintenance.
› The operating mechanism shall be of the Open/Closed/Open stored-energy spring type and preferably having a ready to close
mechanical indication on front of ACB. The closing time shall be less than or equal to 50 milliseconds to ensure faster closing.
› The operating mechanism shall be of fast opening type with opening time of breaker should be <30ms.
› All 4 Pole ACBs shall have fully rated neutral equal to rating of the breaker & shall be protected against over-load & short-circuit
with provisions for settings at :
 4P 3d - neutral unprotected,
 4P 3d + N/2 - neutral protection at 0.5In,
 4P 4d - neutral protection at In to ensure precise neutral protection.
Accessories & Auxiliaries:

› Electrical operated Circuit Breakers shall be operated with remote operation function combined , closing
coil & shunt trip coil having control voltage of . The electrical operated breaker shall also be provided with operating
handle for manual closing, mechanical ON/OFF indicator, spring charged indicator, etc.,
› Shunt trip and closing coil shall be of typical design and both should be accessible from the front of ACB after opening the cover,
without disturbing any other part/release.
› Circuit breaker shall be provided with under-voltage trip release which shall automatically trip the breaker for voltages in the range
of 35% to 70% of the system voltage.
› The ACB design shall be modular in construction that is it shall be possible to mount the coils from the front without removing the
breaker from Cradle.
› All electrical auxiliaries including the shall be field adaptable and should not require any
calibration at site or the necessity for any tool (except a screwdriver).
› The Circuit Breaker shall have minimum 4 changeover auxiliary contacts rated at 10 A 240/380V volts 50 Hz. There should exist
facility to add one more set of 4 contacts as required.
› Option for fixing Ready-to-close contact shall exist for indicating that all safety parameters are checked & enabling closure of
breaker, ensuring at-most safety for the user.
› All accessories & auxiliaries should be common for entire range of circuit breakers.
Safety:
› It shall be possible to connect all auxiliary wiring from the front face of the air circuit breaker. This wiring shall be taken through a set of
disconnecting contacts, so that all auxiliary wiring is automatically disconnected in the isolated position.
› There exists clear indication of the following parameters in the front panel of the circuit breakers:
 ON - Circuit breaker closed
 OFF - Circuit breaker open
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› Mechanical and electrical anti-pumping devices shall be incorporated in the circuit breakers as required.
› The circuit breaker shall be fitted with arc chutes on each pole designed to permit rapid dispersion, cooling and extinction of the arc. Arc Chute
cover should be integral part of breaker to safeguard persons from arc during extinction & it shall be removable on site.
› The automatic shutters should be integral part of breaker & locking arrangement should be provided as per standards.
› The with-drawable circuit breaker shall have the following three distinct and separate positions, which shall be indicated on the face of the panel.
 "Service" -- Both main and auxiliary circuits are connected
 "Test" – All auxiliary circuits are connected & main circuits are disconnected
 "Isolated" -- Both main and auxiliary circuits are disconnected
› There should be a positive locking at these positions while racking out or racking in for clear & confirmative indications as the position is reached.
A push button shall be available to release the lock.
› The circuit breaker shall be suitable for moving out to Maintenance Position with the telescopic rails extended and with the cubicle door opened.
The routine maintenance shall be capable of being carried out in this position.
Interlocks:
› It shall not be possible to with-draw the breaker from the cubicle in "ON" condition. To achieve this, suitable mechanism shall be provided to trip
the breaker before the Breaker is isolated.
› It shall not be possible to switch “ON” the breaker until it is either in the fully inserted position or for testing purposes it is in the fully isolated
position.
› It shall not be possible for the Circuit Breaker to be plugged in unless it is in the OFF position.
› A safety catch shall be provided to ensure that the movement of the breaker, as it is withdrawn, is checked before it is completely out of the
cubicle, thus preventing its accidental fall due to its weight.
› A door interlock shall be provided so that it shall not be possible to open the door until the air circuit breaker moving part is in the disconnected
position.
› A mis-match interlocking shall be provided to prevent insertion of a draw-out type circuit breaker having a rating higher than the current rating of
the fixed part.
› The racking handle shall be stored on the air circuit breaker in such a manner as to be accessible without defeating the door interlocking.
› Provision should exist for fixing key lock to have secured interlocking with the other circuit breakers.
› The breaker shall be locked in disconnected position using key lock or padlock to avoid accidental charging of the breaker during maintenance
phase.
Terminations:
› All circuit breakers shall be fully tropicalized as standard & suitable for terminating copper or aluminium bus bars.
› Both fixed & draw-out circuit breakers shall have single pole-pitch to ensure sufficient & safer clearances between phases.
› Provision shall exist to change the orientation of rear terminations from to horizontal to vertical connection or vice-versa at installation to enable
ease of bus bar/cable terminations.
Protections:
› The Circuit breaker protection shall be through microprocessor based trip units.
› The microprocessor release should be self powered type without any auxiliary power supply during normal operation of the breaker.
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› The circuit breaker control unit shall measure the true r.m.s value of the current.
› The protection release shall have following protections as standard.

 Adjustable over load current (Ir) settings from 40% to 100% of rating of ACB (In).
 Over load time setting (tr) from 0.5s, 1s, 2s, 4s…….24s as field selectable curves.
 Short circuit setting (Isd) from 1.5 to 10 times of Ir setting
 Short circuit time delay adjustable from 0 to 400 msec.
 Instantaneous (Ii) protection with an adjustable pick-up and an OFF position.
 Earth fault setting adjustable in absolute Ampere with time delay settings from 0 to 800 ms.
› Individual fault trip LED indications shall be available on the trip unit for easy & faster identifying the cause of fault.
› I2t ON / I2t OFF options shall be available for short-circuit & earth fault protections to enhance discrimination with downstream devices.
› The trip unit shall have integral test facility to verify the healthiness and to avoid external calibration.
› The release shall be self diagnostic with separate indication in case of mal functioning.
› It shall be possible to change the protection settings on line and the circuit breaker need not be switched of while adjusting the setting.
› Circuit breakers shall conform to Electromagnetic compatibility tests (EMC) as specified in IEC60947-2, Appendix- F.
› The Circuit breaker control unit shall be interchangeable on site for adaptation to changes in the installation.
› The control unit shall have thermal memory throughout the range to store temperature rise data in case of repetitive overload or earth fault for
protecting the cables and loads.
› Circuit breakers in the outgoing feeders shall be provided with micro processor based trip units offering protection against over load (Long time)
& Instantaneous protection (Ii) ensuring total discrimination.
› ACBs shall have fully rated neutral equal to rating of the breaker and shall be protected against over-load faults with provisions for
settings 0%, 25%, 50%, 75%, 100%, 150% & 200% of In to ensure precise neutral protection having arrangement to connect
external Neutral CT to avail neutral protection in 4P ACBs.
Environmental requirements
› Circuit breakers shall conform to environmental directives like ROHS & WEEE.
› The manufacturer shall implement non polluting production processes that do not make use of chlorofluorocarbons, chlorinated hydrocarbons, ink
for cardboard markings, etc…
› The manufacturer shall provide instructions on the removal, dismantling and processing of Air circuit-breaker materials at the end of service life
(material composition, weight, toxicity).
5.3 TERMINALS & CONNECTIONS

Current carrying parts shall have the necessary mechanical strength and current carrying capacity for their intended used. All
parts of terminals which maintain contact and carry current shall be of metal having adequate mechanical strength. Standard
sizes of bolts, screws, pipe and other fittings shall be used and number of sizes to be kept minimum. Terminals shall be so
constructed that the conductors can be clamped between suitable surfaces without any significant damage either to conductors
or terminals. Terminals shall not allow the conductors to be displaced or be displaced themselves in a manner detrimental to
the operation of equipment and the insulation voltage shall not be reduced below the rated values. Terminals for connection to
external conductors shall be readily accessible during installation. Phase barriers between phase bus bars shall be provided to
avoid short circuit. Clamping screws and nuts shall not serve to fix any other component although they may hold the terminals
in place or prevent them from turning.
All mechanism shall be made of such material as to prevent corrosion due to sticking of dust. The bolts, nuts and washers shall
be of Stainless steel only to avoid corrosion and trouble free operation at the time of maintenance. 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. The manufacturer shall state the type (rigid/stranded/flexible), the minimum and the
maximum cross-section of conductors for which the terminal is suitable and, if applicable, the number of conductors
simultaneously connectable to the terminal.
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The enclosure shall incorporate neutral link. The neutral bus bar shall be of same size as phase bus bar. Cable lugs shall be of
crimping type of Aluminum suitable for Aluminum cable of size 300 sq. mm. These shall be symmetrically arranged to
facilitate easy cable connections. The cable lugs shall be of long barrel type with two hole arrangement. Aluminum lugs with
the provision of both wire sizes as mentioned in the below table are required to be supplied with each ACB. Sizes of incoming
and outgoing cables for phases and neutral shall be as given below. The cables shall be 1100V, single core and XLPE
insulated. Single core cables shall be unarmored, whereas multi core cables shall be armored.
The provision control wiring where ever shall be including spiral PVC conduits.
Rated Phase Size of I/C cable (sq Size of O/G cable

S No.
Current (A) mm) / phase (sq mm)
1 630 1RX1CX 630 300/630 sq.mm
2 800 1RX1CX 630 300/630 sq.mm
3 1250 2RX1CX 630 300/630 sq.mm
4 Neutral Busbar Same as of Phase size
5.4 INSULATION SUPPORT

The bidder shall use fire retardant material (not bakelite) for insulation and seal the gap near the bus-bars with sealing agent, to
prevent the inrush of dust and moisture from the back side of enclosure. Phase barrier of same material shall also be provided.
If, in order to prevent accidental contact between a metallic enclosure and live parts, the enclosure is partly or completely lined
with insulating material, then this lining shall be securely fixed to the enclosure.
5.5 PROTECTIVE MEASURES

The design shall incorporate every reasonable precaution and provision for the safety of all those concerned in the operation
and maintenance so that there is no possibility of the operator experiencing a shock during normal operation. 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. Bakelite impregnated / non impregnated should not be used internally or externally. All apparatus shall be so designed
and constructed as to obviate the risks or short circuits of the live parts by lizards / rodents.
When the operating person is opening the door, at any circumstances he should not be able to access the live bus directly,
Insulated barriers shall be provided wherever necessary so as to ensure that no accidental contact with any live parts inside is
possible.
5.6 PROTECTIVE EARTHING

The fixed parts of a metal enclosure shall be electrically connected to the other exposed conductive parts of the equipment and
connected to a terminal which enables them to be earthed or connected to a protective conductor. The exposed conductive
parts (e.g. chassis, framework and fixed parts of metal enclosures) other than those which cannot constitute a danger shall be
electrically interconnected and connected to a protective earth terminal for connection to an earth electrode or to an external
protective conductor. Under no circumstances shall a removable metal part of the enclosure be insulated from the part carrying
the earth terminal when the removable part is in place. The ACB shall be provided with an Aluminium Earth bus suitable for
the rated short circuit current of the breaker. Two nos. body earthing studs shall be provided on side of boxes for body
earthing. One other stud shall be provided for neutral earthing. The earth terminal /stud shall be of suitable size to
accommodate the earth conductor and shall be corrosion protected. The earth terminal shall be identified by means of earthing
sign marked in legible and indelible manner on or adjacent terminals. The earthing stud shall be welded from inside so as to
prevent access to theft. The protective earth terminal shall be readily accessible and so placed that the connection of the
equipment to the earth electrode or to the protective conductor is maintained when the cover or any other removable part is
removed.
5.7 PAINTING
The paint shall be applied on clean, dry surface under suitable atmospheric conditions by seven tank process followed by
powder coating. The paint shall be RAL 7032 with thickness of powder coating not less than 70 to 80 microns.
6 NAMEPLATE & MARKING

All the components and operating devices of the ACB shall be provided with durable and legible nameplates containing all
technical parameters. The name plate on enclosure of the ACB shall be embossed with P.O no. with date, “PROPERTY OF
KESCO Kanpur “& “CODE NUMBER” along with the following parameters:-
i) Manufacturer‟s Name or trade mark

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ii) Type designation or serial no.

iii) Reference to IEC 947-2
iv) Utilization category
v) Rated Operational Voltage(s) (Ue)
vi) Value/ Range of rated frequency
vii) Rated service short circuit breaking capacity (Ics)
viii) Rated ultimate short circuit breaking capacity (Icu)
ix) Line and load terminals
x) Neutral pole terminals
xi) Protective earth terminal
xii) Danger Plate
xiii) No. of the relevant standard
xiv) Terminal Marking
7 TESTS
All routine, acceptance & type tests shall be carried out in accordance with the relevant IS/IEC standards. All routine/acceptance
tests shall be witnessed by the Purchaser/his authorized representative. All the components should also be type tested as per
relevant standards. Following tests shall be necessarily conducted on the equipment in addition to the others specified in IS/IEC.
7.1 Type Tests -

a) Temperature Rise Test
b) Tripping Limits & Characteristics
c) Dielectric Properties
d) Operational Performance Capability
e) Overload Performance (where applicable)
f) Short Circuit breaking capacities
g) Short Time withstand current (where applicable)
h) Degree of Protection of enclosed equipments
7.2 Routine/ Sampling Tests -

a) Mechanical Operation
b) Calibration of Releases
c) Dielectric withstand
d) Verification of clearances
e) Dimensional check
8 TYPE TESTS CERTIFICATES

The bidder shall furnish the type test certificates of the circuit breaker for the tests as mentioned above as per the corresponding
standards. All the tests shall be conducted at CPRI / ERDA as per the relevant standards. Type test should have been conducted
in certified Test Laboratories during the period not exceeding 5 years from the date of opening the bid . In the event of any
discrepancy in the test reports i.e. any test report not acceptable or any/all type tests (including additional type tests, if any) not
carried out, same shall be carried out without any cost implication to Purchaser.
9 PRE-DISPATCH INSPECTION
Equipment shall be subject to inspection by a duly authorized representative of the Purchaser. Inspection may be made at any
stage of manufacturing at the discretion of the purchaser and the equipment, if found unsatisfactory as to workmanship or
material is liable to rejection. Supplier shall grant free access to the places of manufacture to 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 Purchaser.
Following documents shall be sent along with material:
a) Test reports
b) MDCC issued by Purchaser
c) GR/LR copy
d) Invoice in duplicate
e) Packing list
f) Drawings & catalogue
g) Guarantee / Warrantee card
h) Delivery Challan
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i) Other Documents (as applicable)
10 INSPECTION AFTER RECEIPT AT STORE

The material received at Purchaser store will 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 Project Engineering department
11 GUARANTEE
Bidder shall stand guarantee towards design, materials, workmanship & quality of process / manufacturing of items under this
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 Company up to a period of at least 36 months from the date of commissioning or 42 months from the
date of last supplies made under the contract whichever is later, (the time scale of 36/42 months could be enhanced subject to
mutual agreements) Bidder shall be liable to undertake to replace/rectify such defects at its own costs, within mutually agreed
time frame, and to the entire satisfaction of the Company, failing which the Company will be at liberty to get it
replaced/rectified at Bidder‟s risks and costs and recover all such expenses plus the Company‟s own charges (@ 20% of
expenses incurred), from the Bidder or from the “ Security cum Performance Deposit” as the case may be.
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 Company.
12 PACKING
Bidder shall ensure that all equipment covered under this specification shall be prepared for rail/road transport (local
equipment) and be packed in such a manner as to protect it from damage in transit.
13 TENDER SAMPLE
Not applicable.
14 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/ Consultant‟s engineer shall have free access to the
manufacturer‟s/sub-supplier's works to carry out inspections.
15 MINIMUM TESTING FACILITIES

Bidder / Manufacturer shall have adequate in house testing facilities for carrying out all routine tests & acceptance tests as per
relevant International / Indian standards.
16 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
17 SPARES, ACCESSORIES & TOOLS

Bidder shall provide a list of recommended spares with quantity and unit prices for 3 years of operation after commissioning. The
bidder shall provide a list of accessories and tools required for erection & maintenance along with the installation procedure.
18 DRAWINGS
Following drawings & Documents shall be prepared based on Purchaser specifications and statutory requirements and shall
be submitted with the bid:
a) Completely filled-in Technical Parameters.
b) General description of the equipment and all components including brochures
c) General arrangement drawings
d) Single Line Diagram
e) Bill of material
f) Type Test Certificates
g) Experience List
h) Foundation fixing drawings.
i) Manufacturing schedule and test schedule
After the after of the contract, four (4) copies of the drawings, drawn to scale, describing the equipment in detail shall be
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forwarded for approval and 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 the purchaser.
Drawings/documents to be submitted after the award of the contract:
S.No Description For For Review Final
Approval Information Submission
1 Technical Parameters  
2 General Arrangement drawings  
3 Dimensional drawings  
4 Bill of Material √
5 Foundation Plan/ Mounting details  
6 Manual/Catalogues/drawings for ACB  
7 Installation Instructions  
8 Instruction for Use  
9 Transport/ Shipping dimension drawing  
10 QA &QC Plan   
11 Test Certificates   
All the documents & drawings shall be in English language.

Instruction Manuals: Supplier 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.
Type test: Bidder must have type test report of offered items as per relevant IS/IEC and copies of test reports to be
enclosed.
Preferred Make : Schneider, Siemens, L&T, ABB.
19 GUARANTEED TECHNICAL PARTICULARS:
To be furnished by
S.No Description Units
Bidder
1 Type of ACB
2 No of Phase Nos.
3 No of poles Nos.
4 Rated Current A
5 Type of release
6 ACB Release setting
7 Rated Operational Voltage V
8 Rated Impulse withstand voltage (Uimp) kV
9 Rated Insulation Voltage (Ui) V
10 Rated Ultimate short Ckt Breaking capacity Icu (rms) kA
11 Rated service short Ckt breaking capacity Ics (rms) kA
12 Rated short circuit making capacity Icm (peak) kA
13 Short time withstand Capacity (Icw)
14 Utilization Category
15 Typical Opening Time m sec
16 Typical Closing time m sec
17 No. of Operating Cycles
18 Material of Bus Bar
19 Max. current Density of Bus Bar A/mm2
20 Max. Permissible Temp. rise
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21 Min. Clearance b/w phases mm

22 Min. Clearance b/w phase & earth mm
23 Phase Barriers
24 Degree of Protection for Enclosure
25 Overall Dimensions
SCHEDULES OF DEVIATIONS:
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.
SCHEDULE OF DEVIATIONS:
(TO BE ENCLOSED WITH TECHNICAL 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
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SPECIFICATION FOR MOULDED CAGE CIRCUIT BREAKER
1.0 MOULDED CASE CIRCUIT BREAKER:
1.1 Each distribution box shall have MCCB‟s to control & protect outgoing circuits. The
MCCB‟s should comply with the following specifications:
1.2 MCCB shall be triple pole complete with over current tripping device, and suitable for
direct mounting inside a cubicle switchboard. MCCB shall be provided with detachable,
fully rated, front accessible neutral copper link mounted inside the enclosure.
1.3 MCCB‟s shall be manually independent and operating mechanism shall be quick make,
quick break and facility of having adjustment for overload.
1.4 MCCB shall comply with international standards IEC 60947- 2 and EN 60947- 2 and
should be certified at independent & approved test authorities.
1.5 MCCB shall be current limiting type having trip test button facility for testinghealthiness of
the mechanism. There should be clear indication of ON, OFF & TRIP position on the
MCCB.
1.6 MCCB shall have thermal magnetic/microprocessor-based tripping mechanism having an

in-built feature of thermal memory and sensing true RMS giving a stable, inverse time
current characteristic which cannot be inadvertently adjusted. The operating characteristic
shall be such that:
 The time delay on overload tripping shall be inversely proportional to the over current up
to a threshold value of approximately 7 times the rated current or as otherwise specified
 There shall be no international time-delay on over current tripping due to short circuit or
heavy over current exceeding the threshold value.
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45. MCCB shall be suitable for disconnection function.
ii. The operating characteristic shall be calibrated at 40 deg. C.
iii. MCCB shall be type tested to IEC 60947-2 and EN 60947- 2.-
iv. All plastic material must comply to glow wire tests Rated Operation Voltage690 volts.
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v. MCCB should have no load line bias & have low let through energy i.e. MCCB can be
feeded either from line side of from load side without effecting the electrical features.
vi. The temperature rise at the terminals at the rated current should not exceed 50-degree
0
C and all current carrying parts should be silver plated copper.
vii. Rated impulse with stand voltage 8 KV.
viii. Minimum Electrical Endurance should be 15000 operations up to 160 Amp.Rating
and 10000 operation above 160 amps MCCBs.
ix. Mechanical Endurance shall be 25000 operations up to 160 Amp. And 15000
operation above 160 Amps. MCCBs.
x. Rated insulation voltage for MCCBs should be 800 V.
xi. Utilization category of MCCB shall be "A" for all MCCB .
xii. All the breaking capacities shall be Ics 100% of Icu

xiii. MCCB's should have in built locking facility in off position.
xiv. MCCB's should also have higher fault life i.e. at 600% rated current min 100
operations.
xv. Ics shall be as based on the following test sequence followed and the test tobe
carried out at the specific power factor open-3 minutes- co-03 minutes- co‟.
xvi. While the test power factor and the sequence shall be a binding but the other
procedure for making the circuit etc shall be as per IS applicable.
xvii. All MCCB should be with double insulation at front face and there should bea total
segregation (insulation) between phases inside the MCCB.
xviii. The detailed specification for MCCB‟s shall be as follows:
Specification
Details
Rated current of MCCB (Amp) 63 100 160 250 300 400 630 800
Adjustable between 70-100%

Thermal release settings/O.L. protection
Magnetic/short circuit release 6 times in
(Fixed)
Stand. Applicable IEC 60947-II
25 25 KA 50 50 50 KA 50 KA
Breaking capacity to IEC 9478 ICS at 415V KA KA KA
Fault Clearing time < 10 ms
0.4 lag
Power factor for short circuit (max)
Making Capacity KA 52.5 52.5 105 105 105 105 105 105
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GUARANTEED AND OTHER TECHNICAL PARTICULTARS FOR

MCCB
S.N GAURANTED VALUES PARAMETERS

O
1 Name/Trade name of the manufacturer :
2 Full Address :
3 Rating :
4 Rated Current :
5 Overload release setting :
6 Magnetic over load/short circuit value setting :
7 No. of Pole :
8 Electrical Life :
9 Fault clearing life :
10 Max Power factor on short circuit :
11 Utilization Category :
12 Max. terminal rated temperature at rates current :
13 Mechanical Life :
14 Insulation Voltage :
15 Making Capacity :
16 Percentage overload carrying capacity :
17 i. Backup guarantee certificate from :
ii. Principal/imensio manufacturer :
18 Have enclosed the type test certificate :
19 Have your enclosed performance certificate :
20 Over all imension of the equipment in detail :
21 Total weight of the equipment :
22 Rated Operation Voltage :
23 Breaking Capacity ICU at 415 :
24 Breaking Capacity ICS (% of ICU) :
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TECHNICAL SPECIFICATION OF LT PANEL (Revised)

1. General :
This section covers the detailed requirements of low voltage switchboard, shall be as under Supply
voltage : 415V± 10%, 3Ph
b). Frequency : 50 Hz ± 5%,
c). Combined voltage/frequency variation : ±10%d.
System earthing : Solidly Earthed (TNS)
2. SWITCH BOARDS
This specification covers the design, manufacture and testing of industrial type metal enclosed factory assembled LV
Panels, used in electrical systems of up to 1000V. In general, the LV panels are referred to as LV switchboard panels
in this specification. Throughout this specification reference is made to "specified elsewhere or as specified". Details for
requirements of this type are to be found in the one-line diagram.
3. CODES AND STANDARDS

The LV Switchgear shall be designed manufactured and tested in accordance with the latest applicable sections of the
IEC codes. The latest edition shall always be used. LV Switchgear manufactured in India shall be designed,
manufactured and tested in accordance with either IEC or IS codes and standards.
Conflicts between referenced documents shall be identified to the CLIENT in writing for resolution. In general the order
of precedence is:
• Single-Line Diagram (When reference to the Single-line diagram is made in the following part of this
specification, it shall be deemed to include reference to the associated schedules)
• Approved Drawings & Datasheets
• Specification
• BOQ
• IS/ International Standards
IEC /IS STANDARDS
IEC 60269(2009) Low-Voltage Fuses
IS 8623 Low-voltage Switchgear and Control gear assemblies
IEC 60044(2003) Instrument Transformers
IEC 60051(1997) Direct acting indicating analogue electrical measuring instruments andtheir
accessories
IEC 60073(2002) Basic and Safety Principles for Man-Machine Interface, Marking and
Identification - Coding Principles for Indicators and Actuators
IEC 60255(2009) Electrical relays
IEC60417DB(2005)0 Graphical symbols for use on equipment
IEC 62052-11(2003) Electricity metering equipment (AC) General requirements, tests andtest
conditions Part 11: Metering equipment-First Edition
IEC 62052-21(2004) Electricity metering equipment (A.C.) General requirements, tests andtest
conditions Part 21: Tariff and load control equipment-First Edition
IEC 60715(1995) Dimensions of low-voltage switchgear and Control gear. Standardized
mounting on rails for mechanical support of electrical devices inswitchgear
and Control gear installations
IEC 61641 Internal ARC
IEC 62208(2002) Empty enclosures for low-voltage switchgear and Control gear assemblies
General requirements and Control gear assemblies Generalrequirements-First
Edition
IEC 60228(2004) Conductors of Insulated Cables
IEC 60947-4-1 & IS 13947-1 Contactors and motor starters
4. GENERAL
(i) The LT panel shall in all respects, be suitable for operations in service conditions and withstanding
thestresses to the seismic conditions. The panel must have access from back and front end both with
bar lock arrangement( Godrej type).
(ii) The Vendor shall furnish the Single Line Diagram for DISCOM‟s approval.
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(iii) All Components shall be rated as per the electrical system. For circuit breakers, special reference shall
be made in respect of enhanced circuit making requirements.
(iv) The Short circuit current with minimum duration of 1sec. for LV switchgear panels shall be as
indicated in SLD.
(v) The design temperature for the equipment provided in the main low voltage switchboards shall be
+50°C. The relative humidity shall be 95% at a temperature rise as per mentioned in IEC standards.
(vi) Where armoured multi-core cables terminate inside the switchboard enclosure, glanding plates or
glanding brackets shall be provided for securing the cables to the switchboard. Glanding plates,
glanding brackets and extension boxes shall be removable and shall be of adequate size for the
particular cables to be terminated. Separate current transformers shall be provided for each protection
device and for instrumentation.
(vii) Switchboards shall have a short circuit level withstand as per Schedule of Quantities and drawings.
(viii) The enclosures shall be designed to take care of normal stress as well as abnormal electro- mechanical
stress due to short circuit conditions. All covers and doors provided shall offer adequate safety to
operating persons and provide ingress protection of IP-65 as per BOQ and IP unless otherwise stated.
(ix) Ventilating openings and vent outlets, if provided, shall be arranged such that same ingress protection
of IP-65 is retained.
(x) The switchboard along with ACBs and connections should have been tested at
CPRI/ERDA/Independent international test house for short circuit, temperature rise, protective earth
short circuit test and dielectric tests of the ratings required .
(xi) For operator safety IP2X (touch proof) protection to be available even after opening the feeder
compartment door. The compartmentalization to be achieved by using metal separators, use of PVC
sheet/Hylem sheets shall not be allowed.
(xii) For form of separation only metallic covers shall be used. Hylem/PVC sheets shall not be allowed.
4.1 Switchboard Configuration

(i) The Switchboard shall be configured with Air Circuit Breakers, MCCB's, MCB‟s and other
equipment as called for in the schedule of quantities/SLD.
(ii) The MCCBs shall be arranged in multi-tier formation whereas the Air Circuit Breakers shall be
arranged in multitier formation as per manufacturing standard only to facilitate operation and
maintenance.
(iii) The Switchboards shall be of adequate size with a provision of spare space to accommodate
possible future additional switch gear.
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4.2 Constructional Features
(i) The equipment shall be arranged within each compartment such that all normal maintenance can be
carried out through hinged access doors or removable covers, and where possible from the front.
The switchboard shall have a rated short time withstand current as per SLD and a fault withstand
for a supply voltage of 415V AC between phases at 50Hz as per BOQ.
(ii) Protection against shock in normal service shall be achieved by the provision of barriers or
enclosures both vertical and horizontal and between adjacent units to ensure segregation and
prevent accidental contact with live parts, or by complete insulation of all live parts. Control cables
shall be segregated from primary conductors.
(iii) The Switchboards shall be metal clad totally enclosed, floor mounted free standing type ofmodular
extensible design suitable for indoor mounting.
(iv) Switchboards construction shall employ the principle of compartmentalized and segregation for
each circuit.
(v) The LVSB shall be provided with front and back access and the maximum height shall not exceed
2.60m. All relays and indicating instruments shall be at least 500mm and not higher than 1.8m
above floor level. The clearances (required) in front, back and side of all assemblies of switchgear
and control gear shall be generally not less than 1.5 meters. The switchgear shall be considered in
the fully drawn out condition for this purpose.
(vi) Incomer and bus section panels or sections shall be separate and independent and shall not be wired
with sections required for feeder. The incomer panel shall be suitable for receiving bus trunking or
LV cable of size specified.
(vii) Switchboards shall be made up of requisite vertical sections, which when coupled together, shall
form continuous dead front switchboards.
(viii) Switchboard shall be readily extensible on both sides by addition of vertical sections after removal
of the end covers.
(ix) The switchboards shall be designed for use in high ambient temperature and humid tropical
conditions as specified. Ease of inspections, cleaning and repairs while maintaining continuity of
operation shall be provided in the design.
(x) Metal based gaskets between all adjacent units and beneath all covers shall be providedto render
the joints dust and vermin proof to provide a degree of protection of IP-54 upto 2500A above & IP-
43 above 2500A or as stipulated in schedule of quantities. The unused openings within the
switchboards shall be closed using suitable grommets.
(xi) Special care to be taken to ensure effective earthing of the frame and doors of the switchboard.
(xii) Each vertical section shall be provided with a rear chamber housing the cable end connections and
power/control cable terminations. There should be generous availability of space for ease of
installation and maintenance with adequate safety for working in one vertical section without
coming into contract with any live parts. The design of the switchboard shall allow standard
extension chambers if required to accommodate cables.
(xiii) Switchboard shall have all structural members made of galvanized steel of thickness 2.0 mm and all
other members like door, covers etc. of CRCA Sheet of 2.0mm. While gland plate shall be 3mm
CRCA Sheet and load bearing plates shall be of 2mm thickness. All above components shall be
made of continuously hot dip zinc coated low carbon sheet steel with zinc coating of 140mm i.e.
Z140 category
(xiv) Each door shall be kept closed by 2 Nos. of threaded knobs provided on the right sides of the door
(one at top and one at bottom). Suitable circlips are to be provided on each knob to avoid loss of the
knob in the field. Further, each door shall have one handle at the center both front and back side. It
shall have a hole to match with the hole provided on angular bracket on fixed frame of the hole in
the handle. Padlocks are included in the scope of supply of Distribution Boxes. One universal type
lock arrangement (as in OCB/Control Panel) on each door is required to be provided on each
compartment in addition to this.
(xv) All panels and covers shall be properly fitted and square with the frame. The holes in the panel
shall be correctly positioned.
(xvi) Switchboard shall be provided with “Danger Notice Plate” conforming to relevant Indian
Standards.
(xvii) The LVSB shall be mounted on a robust base frame made up of steel channels with a minimum
height of 75/100mm. The base frame shall be able to withstand the static and dynamic loads of the
LVSB. The steel channels shall be painted with epoxy Polyster paint.
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(xviii) Gland plates of not less than 3.0mm thick shall be provided at the top and bottom of the LV main
switchboard for the termination of incoming and outgoing power cables or bus- ways.
(xix) Surface Treatments:

(A) All metal work shall undergo chemical/mechanical cleaning process before receiving two coats
of primer (red oxide) and two coats of final paint.
(B) Electrostatic painting and oven drying will be preferred.
(C) Final paint shade from inside and outside shall be dark admiralty gray as per Code No.632 of
IS-5/78.
(D) All other metal parts used in the distribution box shall be treated as under: Bus bar and
connections: Coat of insulating materials
4.3 Switchboard Compartmentalization
(i) For compartmentalized switchboards, separate totally enclosed compartments shall be provided for
horizontal busbars, vertical busbars, ACBs, MCCBs, and cable alleys.
(ii) Earthed metal or insulated shutters shall be provided between draw-out and fixed portion of the
switchgear such that no lives parts are accessible with equipment drawn-out.Degree of protection
within compartments shall be at least IP-2X.
(iii) Sheet steel hinged lockable doors for each separate compartment shall be provided and duly
interlocked with the breaker in "ON" and "OFF" position.
(iv) For all Circuit Breakers separate and adequate compartments shall be provided for accommodating
instruments, indicating lamps, control contactors and control MCB etc. These shall be accessible
for testing and maintenance without any danger of accidental contact with live parts of the circuit
breaker, busbars and connections.
(v) Each switchgear cubicles shall be fitted with label in front and back identifying the circuit,
switchgear type, rating and duty. All operating device shall be located in front of switchgear only.
(vi) A horizontal auxiliary bus with screwed cover shall be provided at the top to take interconnecting
control wiring between vertical sections.
(vii) Separate cable compartments running the height of the switchboard in the case of front access
boards shall be provided for incoming and outgoing cables.
(viii) Cable compartments shall be of adequate size for easy termination of all incoming and outgoing
cables entering from bottom or top. The construction shall include necessary and adequate and
proper support shall be provided in cable compartments to suppor tand clamping the cable in the
cable alley / cable chamber.
4.4 Switchboard Bus Bars

(i) Busbars and busbar connections shall be constructed in accordance with the requirements of IS-
8623.
(ii) The short-time withstand current rating shall be at least 50kA for 1Sec. at 415V.
(iii) Busbars shall be of rectangular section hard drawn high conductivity Aluminium
adequately rated and supported by non-tracking moulded insulators spaced at suitable intervals.
The complete assembly shall be capable of withstanding the maximum mechanical stresses to
which it may be subjected to under fault conditions.
(iv) Busbar, busbar connection and conductors forming part of the equipment of the switchboard shall
comply with IS 8623 on current carrying capacity and limits of temperature rise.
(v) All conductors between the busbars and the switchgear shall be of high conductivity Copper bar,
having a current rating of not less than that of the frame size of the switchgear to which they are
connected. The conductors shall be insulated and colour coded for phase identification.
(vi) The busbars shall be extendible from both ends.
(vii) Temperature rise of panels shall be in line with latest IEC standards of IS 8623.
(viii) The bus bar system may comprise of a system of main horizontal bus bars and auxiliary vertical
bus bars run in bus bar alley on either side in which the circuit could be arranged with front access
for cable entrances.
(ix) Auxiliary buses for control power supply, space heater power supply or any other specifiedservice
shall be provided. These buses shall be insulated, adequately supported and sized to suit specific
requirement.
(x) Clearances between phase-phase, phase –Earth/ neutral should be in line with IEC.
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4.5 Switchboard Interconnection

(i) All connection and tap offs shall be through adequately sized connectors appropriate for fault level at
location. This shall include tap-off to feeders and instrument/control transformers.
(ii) For unit ratings upto 100A, PVC insulated 105°C withstand, copper conductor wires of adequate size to
carry full load current shall be used. The terminations of such interconnections shall be crimped. Solid
connections shall be used for all rating of above 100A.
(iii) All connections, tappings, clamping, shall be made in an approved manner to ensure minimum contact
resistance. All connections shall be firmly bolted and clamp with even tension. Before assembly, joint
surfaces shall be filed or finished to remove burrs, dentsand oxides and silvered to maintain good
continuity at all joints. All screws, bolts, washers shall be zinc plated/blackodised. High Tensile grade
nuts and bolts shall be used for busbar connections.
4.6 Instrument Accommodation

(i) All voltmeter and ammeter and other instruments shall be flushed mounted type of size 96mm2
conforming to class 1.0 to IS-1248 for accuracy. All voltmeter/instruments shall be protected with
MCB‟s.
(ii) Instruments and indicating lamps shall not be mounted on the Circuit Breaker Compartment door for
which a separate and adequate compartment shall be provided and the instrumentation shall be
accessible for testing and maintenance without danger of accidental contact with live parts of the
Switchboard.
(iii) For MCCBs, instruments and indicating lamps can be provided on the compartment doors.
(iv) The current transformers for metering and for protection shall be mounted on the solid copper busbars
with proper supports.
(v) On all the incomers of switch boards ON/OFF indicators lamps shall be provided suitable for operation
on AC 230 volts supply. All lamps shall be protected by MCBs.
4.7 Wiring
All wiring for relays and meters shall be with FRLS copper conductor wires. The wiring shall be coded and labelled with
approved ferrules for identification. The minimum size of copperconductor control wires shall be 2.0 mm2. Runs of wires
shall be neatly bunched and suitably supported and clamped. Current circuit shall be 2.5mm2. Means shall be provided
for easy identification of wires. Identification ferrules shall used at both end of wires. All control wires meant for external
connections are to be brought out on a terminal board. The cables and control wires shall be suitable for withstanding
105°C.
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TECHNICAL SPECIFICATION
OF
STREET LIGHT POLE JUNCTION BOX

328
1.0 SCOPE:
This specification covers the design, manufacture, testing of tamper proof, shock proof
and rust proof Street Light Pole Junction Boxes duly fitted with aluminium Bus Bar. The
Box is intended to be used for Street Light consumers. It should be suitable for out door
use for mounting on pole as well as for mounting in meter cabinet of multistoried
buildings. It is not the intent to specify herein complete details of design and construction.
The Street Light Pole Junction Boxes offered shall conform to relevant standard and high
quality and workmanship capable to perform continuous and satisfactory operations in
the actual service conditions at site. Bidder shall have proven experience of 3 years of
manufacturing of similar products and supplying to electrical utilities
2.0 SERVICE CONDITION:

The Meter Box to be supplied against this specification shall be suitable for satisfactory
continuous operation under the following service conditions.
Max. & ambient air temperature 50 degree C

Max. relative humidity 100%
Max. annual rainfall 1450 mm
Max. wind pressure 150 Kg/Sq.m
Max. altitude above mean sea level 1000 mtrs
Isoceraunic level 50 days/year
Seismic level (Horizontal acceleration) 0.3 g
Climatic condition Moderately hot and humid Tropical
climate conducive to rust and fungus
growth
Ambient temperature for temperature 50 deg.C
rise
3.0 APPLICABLE STANDARDS:

All components used in the manufacture of the materials shall conform to the relevant
Indian standards and especially to the followings
3.1 IS:14772/2000 General Requirements for Enclosures for Accessories for
Household and Similar Fixed Electrical Installations
–Specification
3.2 IS:13947/1993 Specification for Low-voltage Switchgear and Controlgear –
(Part 1) Part 1 : General Rules& Annex ‘C’ for Degrees of Protection
provided by enclosures of electrical Equipments
3.3 IS: 13410/ 1992 Glass reinforced polyester sheet moulding compounds (SMC)
3.4 IS: 13411/1992 Glass reinforced polyester dough moulding compounds (DMC)
3.5 IS: 732/1989 Code of Practice for Electrical Wiring Installations
3.6 IS: 4249/1967 Classification and methods of tests for non-ignitable and self-
extinguishing properties of solid electrical insulating materials
329
4.0 DESIGN & CONSTRUCTION:
4.1 The Street Light Pole Junction box shall be made out of thermosetting plastic i.e. glass
reinforced polyester sheet moulding compound (SMC) conforming IS: 13410-1992
grade and also conform to self extinguishing properties as per IS-4249 & requirements
of this specification.
4.2 The enclosures shall be made of high grade virgin material with anti- corrosive, rust
proof, shock proof, dust and vermin proof, U.V. stabilized with flame retardant
property
4.3 The Street Light Pole Junction box shall comply with the requirement of IP- 44 type as
per the IS – 13947 or the latest version thereof
4.4 The wall thickness of the box shall be minimum 2mm. The Street Light Pole Junction
box should have minimum 40 mm clearance on all three sides and bottom clearance of
minimum 60 mm for pole mounted boxes & 100 mm for boxes used in the metering
cabinet.
4.5 The enclosures should be suitable for outdoor use, Pole mounting and should not
soften, bend or melt at high temperature. It should have flame retardant properties and
material of it should not generate burning droplets in the event of fire.
4.6 The Street Light Pole Junction Box shall be suitable for housing Bus Bar system with
adequate clearances. The General arrangement drawing shall be as per the attached
drawing.
4.7 The base and door should be single piece moulded individually with rounded corners
without any construction/ fabrication joint.
4.8 The door in closed position should overlap on base such that direct entry of screw
driver, tool or rod is not possible.
4.9 Concealed hinges should be provided to the Street Light Pole Junction boxes
4.10 The Box should have positive locking system by way of bolt and nuts in addition to “U”
Clamp as shown in the Drawing. “U” clamp should have matching Holes on base and
door to facilitate wire sealing.
4.11 Holes for in-coming and out-going Cables should be provided at bottom as shown in
the G.A. Drawing. Suitable number of holes with rubber grommets of suitable size shall
be provided at the bottom of Street Light Pole Junction box for incoming and outgoing
cables
4.12 The box should have holes on the back-side as shown in Drawing for fixing it on Pole
with suitable clamping arrangement or in metering cabinet in the buildings.
4.13 The Bus Bar mounting system should be angled and stepped so as to facilitate easy
connection and disconnection of cable without twisting and sharp bending of
wire/cable. The mounting steps shall be made out of Thermosetting Plastic insulating
330
material as given above.
4.14 Fixing of accessories like clamp, handles etc and all metal part excluding hardware shall
be of stainless steel only.
4.15 The surface appearance or part of Street Light Pole Junction box must be smooth, non
porous and homogeneous, free from ripples, defects and marks. No fillers or fibres
should be visible at any place.
4.16 One no Earthing Bolt of size M6 having length of min 25mm with two washers & nuts
shall be provided on the connection box for necessary earthing
5.0 ALUMINIUM BUSBAR:

5.1 The Bus Bars shall be made out of Aluminium bus bar. The size of Bus Bars shall be
adequate as per rating
5.2 The Bus bar shall be made of aluminium with cross section & length as per the
requirement
5.3 Provision for one incoming circuit of single/three phase with neutral of cable size 16 Sq mm
cable & outgoing connections of cable size 6 to 10 sq mm. size as per requirement on each
phase bus bar & neutral shall be provided
5.4 Street Light Pole Junction Boxes shall have one incoming and one outgoing combination.
6.0 TESTS & TEST CERTIFICATES

6.1 TYPE TESTS
Type tests as mentioned in annexure A shall be carried out on SMC material as per IS
13410/13411. In addition to above following type tests shall be carried out on complete
box
1. High Voltage test on Bus bar as per IS 8623 (A.C. voltage 2.5KV applied for one
minute.
2. Temperature Rise Test at 100% rated current as per IS 8623.
3. Degree of protection Test for IP44 as per IS 13947/1993 (Part 1).
4. Mechanical Strength Test as per IS 14772
6.2 ACCEPTANCE TESTS

Following acceptance tests shall be carried out.
1) Acceptance tests as mentioned in annexure A shall be carried out on SMC material
as per IS 13410/13411.
2) Verification of dimensions & construction as per IS 14772.
3) High Voltage test
6.3 TEST CERTIFICATES

The material offered shall be fully type tested as per relevant IS and this specification.
The successful Bidder shall furnish detailed type test reports before commencement of
supply for necessary approval.
331
The purchaser reserves the right to demand repetition of some or all the Type tests in presence
of purchaser’s representative at purchaser’s cost.
The type test report of meter box having identical constructional and other features
carried out during last five years prior to due date of opening of offer shall be valid
All the Type Tests shall be carried out from laboratories which are accredited by the
National Board of Testing and Calibration Laboratories (NABL) of Government of India
such as CPRI Bangalore/ Bhopal, ERDA Baroda, to prove that the material offered meet
requirements of the specification. The tenderer should also furnish certificate from
laboratories that laboratories are having all the requisite test facility available in house.
The type tests reports conducted in manufacturers own laboratory and certified by
testing institute shall not be acceptable.
6.4 TESTING AND MANUFACTURING FACILITIES

The manufacturers must have necessary machinery for production of SMC Street Light
Pole Junction Box. The manufacturer should have in house testing facilities for carrying
out acceptance test as per mentioned above
7.0 GUARANTEE
The material supplied shall be guaranteed for the period of 60 months from the date of
commissioning or 66 months from the date of dispatch whichever is earlier.
8.0 MARKING
The following information shall be legibly and indelibly marked to show the following
a) Purchase order number and date

b) Year and month of manufacture
c) Name of Purchaser: KESCo
d) Guarantee: 3 years
e) Name and trademark of manufacturer
f) Danger logo (Screen Printed)
9.0 SCHEDULES
The tenderer shall fill in the following schedules and submit along with the offer. If the
schedules are not submitted duly filled in with the offer, the offer shall be rejected.
Schedule – A : Guaranteed Technical Particulars
10.0 DRAWINGS:
The successful bidder shall submit set of all above drawings of the distribution box and
its components shall be submitted in triplicate to Nodal,RDSS (KESCo) office and get
approved before commencement of supply.
332
Annexure ‘A’
Specifications for Fiberglass Reinforced Plastic Sheet moulding compound
1) FRP Sheet Moulding Compound shall conform to IS:13410-1992

2) The Surface appearance of the door must be smooth, non porous, and
homogeneous, free of ripples, defects, and marks. No filler or fiber shall be visible at
any place.
3) Other properties of SMC material shall be as follows & shall pass the test
mentioned against the same.
Sr. Characteristic Requirement Type of test Method of test

No. Ref. to
1. Material. Thermosetting
Plastic
2. Grade of material SMC Electrical IS:13410-1992
grade S3
Material requirement for Sheet Moulding Compound
4. Glass content, percent 20 Type Annexure A of
by mass (Min.) IS:13411-1992
5. Mould shrinkage, linear 0.25 Acceptance Annexure B of
% Max IS:13411-1992
6. Flow, mm, Minimum 170 Acceptance Annexure C of
IS:13411-1992
Requirement for Moulded Sheet Moulding Compound
7. Water Absorption, % 0.20 Type Annexure D of
Max IS:13411-1992
8 Izod impact strength 55 Type Annexure E of
(Notched), KJ/m 2 IS:13411-1992
9 Flexible Strength ,MPa , 170 Type Annexure F of
Min IS:13411-1992
10 Power Arc Resistance 180 Type Annexure G of
Sec. Min. IS:13411-1992
11 Modulus of Elasticity, 12 to 15 Type IS: 8543 Part-4
10 , MPa
3 (Sec-1)/1984
12 Tracking Resistance 1000 Type IS: 2824/1975
CTI, Min
13 Dielectric Strength at 11 Type IS:6262/1971
90 C in Oil KV/mm
o
14 Dissipation factor (4 0.01 Type IS: 4486/1967

days at 80 % RH & 1
KHz)
15 Heat Distortion 150 Type Annexure H of
Temperature, oC ,Min IS:13411-1992
333
16 Oxygen Index,% Min 24 Type IS: 13360 Part-

6 (Sec-6)/1992
17 Post shrinkage, % Max 0.01 Acceptance Annexure B of
IS:13411-1992
18 Tensile Strength ,MPa , 70 Acceptance IS: 8543 Part-4
Min (Sec-1)/1984
19 Density of Moulding, 1.8 to 2.1 Routine IS: 8543 Part-I
g/ml /Sec 2/1979
20 Surface resistivity (24 H 1 x 10 13 Routine IS: 3396/1979
in water), Ohm,Min
21 Volume resistivity, 1 x 10 14 Routine IS: 3396/1979
Ohm-cm, Min
22 Exposure to flame Self- IS:4249
Extinguishing
23 Melting Point test up to 400ºC IS:13360 Part6
: Sec 10 : 1992
24 Cross Breaking Strength (1723 Kg/sq.cm) As per ASTM
D790
25 Shear Strength (879 Kg/sq.cm) As per ASTM
D732
26 Flammability ( V2) UL 94 or IS : IS : 11731
11731 (Pt.II) (Part- II)
27 Marking, Dimensions and IS : 14772
construction
334
SCHEDULE – A
GUARANTEED TECHNICAL PATRICULARS
For Street Light Pole Junction Box for L.T. Lines / Consumer Mains
Sr. Parameter Name Parameter

No. type
1. Name or Trademark of Manufacturer. Text
2. Type of Street Light Pole Junction Box (Type & total No. of Text
Outgoing connections ) provided
3. Rated normal voltage Text
4. Material of construction Text
5. Thickness of SMC sheet for enclosure Text
6. Dimensions of Street Light Pole Junction Box Text
Width x Depth x Height (in mm)
7. Degree of protection of the Box Text
8. Sealing U clamps details Text
{2 Nos. S.S.”U” Clamp of minimum thickness (0.8 ± 0.1 mm)}
9. No. of Holes provided for cables Text
A) Incoming Cable
B) For Outgoing Cables
10. Minimum side clearances from spring loaded Bus Bar module in Text
the box ( in mm)
11. Marking on the box is as per the specifications Text
12. Fiberglass Reinforced Plastic Sheet Moulding Compound Text
12.1 Material (Thermosetting Plastic) Text
12.2 Grade of material (SMC as per IS:13410-1992) Text
12.3 Heat deflection Temperature (As per IS:13411)(min 150ºC) Text
12.4 Exposure to flame (Ref. Std. IS:4249) (Self-Extinguishing) Text
12.5 Melting Point (Ref. Std. IS:13360) (Does not melt) Text
12.6 Door material (U.V. resistant & resistant to salty & humid Text
atmosphere)
12.7 Specific Gravity as per IS:10192 of SMC material (1.8) Text
12.8 Dielectric Strength as per IS:1998 Text
12.9 Tensile Strength as per IS:867-1963 (1058 Kg/sq.cm) Text
12.10 Cross Breaking Strength as per ASTM D790 (1723 Kg/sq.cm) Text
12.11 Insulation Resistance (As per ASTM D257) Text

12.12 Water Absorption as per IS:14772 Text
12.13 Mechanical Strength as per IS:14772 Text
13. Type of clamping/fixing Arrangement for box Text
14. Type of hinges for door ( Clause no. 4.1.9) Text
15. Number of hinges provided. Text
16. Earthing bolt as per specification with earthing logo provided Boolean
335
Sr. Parameter Name Paramet

No. er
type
17. Spring Loaded bus bar system
17.1 Mounting Material of spring loaded Bus Bar & mounting Bus bar Text
Supports (Thermosetting Plastic (SMC) as per IS-13410-
1992)
17.2 Material of Bus Bar (Aluminium) Text
17.3 Cross Section area and length of Bus Bar (Total 100 Sq. mm) Text
17.4 Length of bus bar (mm) Text
17.5 No. of Bus Bar module complete with fitting Text
17.6 Pressure Plate thick & MoC (Thickness 2.0 mm stainless) Text
17.7 Distance between Bus Bars module (Center to Centre distance 35 Text
mm (Min.)
18 Details of Type Tests Carried out Text
19 Other detail if any Text
336
Al
Bus
bar
337
Technical Specifications of Armour rod and Aluminium leg

long barrel
1. Prefomed Armour Rod
Scope:
This specification is for full tension splice for ACSR and is designed as a three component
assembly for ACSR splice. It is used for restorative repair for the core damaged conductor
of ACSR. The holding strength is not less than 95% of the rated breaking strength of the
conductor and provide better conductance than an equal length of unspliced conductor.
Kindly follow the following technical particulars:

Conductor PA Rod
No. Of Rods/Set
Code Name Dia L ΦD
Squirrel 06.33 1016 3.71 07
Weasel 07.77 1067 3.71 08
Rabbit 10.05 1320 4.24 09
Raccoon 12.27 1370 4.24 10
Dog 14.15 1524 4.62 11
2. Aluminium Leg Long Barrel

Scope:
This standard specifies the requirements of Aluminium Leg long barrel which is a type
of aluminium lugs as per IS standard 8309: 1993 and covers Compression Type
Tubular Terminal Ends for Aluminium Conductors of Insulated Cables for rated
voltages up to and including 11 kV.
Area E A C D B J
mm
25 8.2 7.2 9.6 14.0 41 69
35 8.2 8.3 11.1 16.0 50 79
50 10.2 10.1 13.5 19.5 49 81
70 10.2 10.2 14.5 20.5 62 96
95 12.7 12.0 16.9 23.5 73 109
338
120 12.7 13.7 19.0 26.5 73 114

150 12.7 15.1 21.1 29.5 83 128
185 12.7 16.6 23.9 33.0 83 131
225 12.7 18.6 26.1 36.0 86 140
240 12.7 19.3 27.2 37.5 86 144
300 20.3 21.8 30.2 42.0 89 157
400 20.3 25.0 34.8 48.0 113 187
500 20.3 28.2 39.1 54.0 125 205
339
22) Technical Specification:
High Ampacity & Low Loss - Smart Equipment Connections
1. SCOPE
This specification covers the design, manufacture, testing & supply of equipment
connectors which are to be used for making connection to the equipment like Power
Transformers & Distribution Transformers, Current Transformers…… It shall be used to
connect conductors to equipment or any other suitable application.
2. STANDARDS
The rating as well as performance and testing of the HT & LT connectors shall conform to
the latest revisions of IS 5561.
3. EQUIPMENT CONNECTOR
3.1 It consists of suitable Al Alloy with corrosion resistance surface treatment and shall
be “factory coated oxide inhibitor” to eliminate oxidation of contact points.
3.2 They shall be suitable for connecting “Copper or Copper Alloy (Brass) terminal
studs” of M12/M20/M30/M42 and “Al Cables or AAC, ACSR, AAAC conductors”
3.3 These connectors shall provide a non-corrosive connection and that is protected
against temperature variation and overloading. Also, connector shall provide a reliable
electrical as well as mechanical connection for solid, stranded, rounded, or compacted
conductor combinations including AAC, AAAC and ACSR.
3.4 All the Conductors/Cables shall be removed without damaging the conductor such
that conductor as well as the connector can be used again, if feasible.
3.5 An oxidation inhibitor shall be applied to the surface there by elimination of
oxidation of metallic surface. This inhibitor shall ensure repeatability and reliability of the
electrical contact made in every connection.
3.6 Connector design shall be proven for disrupting surface oxide film to generate large
number of contact spot in the electrical surfaces. When connected, this it shall provide a
reliable electrical and mechanical connection for stranded or compressed conductor
combinations including AAC, AAAC and ACSR.
3.7 Connectors shall be supplied with proper quality screws/bolts which shall ensure
right force applied on connection points. It shall use simple tools for installation, to
ensure installation quality and repeatability which will eliminate operator dependency.
3.8 It should be user, O&M Friendly design which should accommodate stud diameter
range variation and act like spring-back during installation and after. This spring acting
force shall be proven practically. It should be user, O&M Friendly design which should
accommodate stud diameter range variation and act like spring-back during installation
and after. This spring acting force shall be proven practically.
3.9 High Ampacity Smart Terminal Lugs shall be Torque Controlled Type and to be used
to terminate cables on busbars and flat palms. It should be with Removable & Reusable
features.
4. FREEDOM FROM DEFECTS
4.1 The connectors shall be smooth and free from cavities, blowholes, and such other
defects, which would likely cause them to be unsatisfactory in service.
4.2 The connectors shall be so designed and proportioned that they are capable of
safely withstanding stresses to which they may be subjected (including those due
to short circuit and climatic conditions)
4.3 They shall be designed, manufactured to avoid sharp edges, which might lead to,
340
localized pressure on or damage to the conductor in service.
Guaranteed Technical Particulars (GTP)

Sr.
TECHNICAL DETAILS REQUIREMENT
No
1 Suitable for Transformer Rating 25/63/100/160 KVA – M12 STUD
200/250/315/400 KVA – M20 STUD
500/630/750 KVA – M30 STUD
990/1000/1200 KVA – M42 STUD
2 Product Description High Ampacity Low Loss Transformer Terminal for
DTR/PTR
3 Rated Voltage LV & MV Upto 66KV
4 Rated Current As per Max Rating of Transformer
5 PART 1: Connector outer Main body Al Alloy
6 PART 2: Ring Type - Connecting Part Al Alloy as per Design with Bimetallic Plating
9 PART 3: Shearing Bolts Al Alloy
7 PART 4: Bolts, Nuts, Screws, Washers… Suitable sizes as per design
8 Cable or Conductor Range As per customer requirements
10 In-House Qualification Tests 1. Temperature Rise (TR) Test as per IS-5561
2. Contact Resistance Test as per IS-5561
3. Tensile Test - as per IS-5561
4. IACS% Electrical Conductivity Test
5. Torque Assurance Test as per design
11 Is removable feature Yes, by using Allen keys
12 Is reusable feature Yes, based on connector parts condition after
removal
13 Oxide Inhibitor Yes, factory applied
14 Installation Instruction Yes
15 Is it feasible for RETROFIT purpose Yes, Use Manufacturer's recommendations.
16 Description of offered connector 1. M12_1Run-95/185mm2 or 2 Runs-25/95mm2
with Current Rating. for 25-160 KVA Transformer (for all MV Bushings)
2. M20_1Run-240/400mm2 or 2 Runs-185/400mm2
Attached drawings, only for for 200-400 KVA Transformer
reference and can be further 3. M30_1 Run-6300mm2 or 2 Runs-400/630mm2
customized as per application & for 500-630 KVA Transformer
customer requirements 4. M42_1 Run-1000mm2 or 2 Runs-400/630mm2
for 990/1000 KVA Transformer
17 Type Test Report as per IS5561 Latest All tests including Short Circuit Test for at-least any
Standard one connector of similar design
18 Performance Track Record Proven with at-least 3 Distribution Utilities for its high
ampacity & loss reduction objectives in long term.
Also it should be proven for O&M perspectives.
341
Guaranteed Technical Particulars (GTP)

Low Loss Terminal & Joint Connectors
Sr.
TECHNICAL DETAILS REQUIREMENT
No
1 Description High Ampacity Low Loss Terminal Connector for
Aluminium Cable to Equipment Terminal or Busbar
2 Type Torque Controlled
3 Rated Voltage Upto 66KV
4 Rated Current as per conductor size and its rating
5 Shear Bolts per connector 1/2/3/4 Nos per cable as per design
6 Connector outer body Al Alloy
7 Shear Bolts Al Alloy
95-185, 240-400 or 630 or 1000 Aluminium or
8 Conductor Range in mm2
customized range
9 Busbar Range as per equipment or switchgear
10 Surface finish Cu + Tin Plating
11 In-House Qualification Tests 1. Temperature Rise (TR) Test as per IS-5561
2. Contact Resistance Test as per IS-5561
3. Tensile Test - as per IS-5561
4. IACS% Electrical Conductivity Test
5. Torque Assurance Test as per design
12 Is removable feature Yes
13 Is reusable feature Yes (require New Shear Heads)
14 Oxide Inhibitor Yes, factory applied
15 Installation Instruction Yes
16 Is it feasible for RETROFIT purpose Yes, Use Manufacturer's recommended practice.
17 Drawing attached
Proven with at-least 3 Distribution Utilities for its high
18 Performance Track Record ampacity & loss reduction objectives in long term.
Also it should be proven for O&M perspectives.
342
TECHNICAL SPECIFICATION OF BIMETALLIC LUGS
1) SCOPE:
Bimetallic terminal lugs are for use in Distribution Boxes/Distribution Transformer and other O&M
application for Crimping Copper and Aluminum Cables and termination on surface namely
Aluminum/Brass/Copper Plated terminals without the use of Bimetallic washers.
2) STANDARD:
Bimetallic lug crimped joint should conform to all tests laid down in IS-8337 e.g. clause 4.1.1 (6.2) for
initial resistance and clause 4.1.3 (6.4) for Electrical Load Cycle test for 1000 Cycles and Tensile Test
clause 4.2 (6.5). Type Test certificate to this effect giving numerical values obtained must be provided.
3) SERVICE CONDITION:
The Lugs to be supplied against this specification shall be suitable for satisfactory continuous operation
under the following tropical conditions.
3.1 Maximum ambient temperature ( Degree C) 50
3.2 Maximum temperature in shade (Degree C) 45
3.3 Minimum Temperature (Degree C) 3.5
3.4 Relative Humidity ( percent) 10 to 95
3.5 Maximum Annual rain fall (mm) 1450
3.6 Maximum wind pressure ( kg/sq.m) 150
3.7 Maximum altitude above mean sea level ( Meter) 1000
3.8 Isoceranic level ( days per year ) 50
3.9 Siesmic level ( Horizontal Acceleration ) 0.3 g
3.10 Moderately hot and humid tropical climate conductive to rust and fungus growth.
4) MATERIAL SPECIFICATION:
343
Bimetallic lug should be made for electrolytic grade aluminum. Each lug should be copper coated by
electrolytic process and rich layer of tin should be mounted through out the lug to protect from Galvanic
Corrosion. The lugs shall be such that the rich layer of tin should not peel of during operation. Individual
lot should be pre filled with conductive inhibition compound and lug should be duly capped to prevent
oozing of compound. The ductility of material should be such that flow ability of material be adequate to
flow in to the strand of the conductor and withstand on crimping pressure of 8500 PSI. The cut cross
section of the joints shall be homogeneous.
5) GENERAL REQUIREMENTS:
The minimum dimensions of the bimetallic lug in respect of barrel thickness and holes diameter should
conform to enclosed Drawing No. DIST/DB/SMC/URBAN/2010/10
6) TESTS:
i) Initial resistance test of bimetallic crimped joint as per IS 8337.
ii) Heating cycle test for 1000 cycles of crimped joint of bimetallic lugs as per IS 8337.
iii) Tensile strength test of the crimped joint of bimetallic lug as per IS: 8337.
iv) Dimensional test as per drawing/offer.
7 TEST CERTIFICATES:
At present the following makes and types of bimetallic lugs are accepted by the MSEDCL.
Usha Martin Industries, Ismail, Chetna , Klippon, SRI, Alcon, NES , Hames and HB
In case any other equivalent make of bimetallic lugs, if bidder offer, they should indicate makes and
types of bimetallic lugs in E-tendering GTP. The bidders should submit complete test reports of the
bimetallic lugs as per this specification, clause No. 6 to CE (STORES) for approval before commencement
of supply. The Tests on lugs should be done in any reputed independent laboratory.
344
Technical Specification of Sign board

Major infrastructures like new primary substation, new Distribution Transformer, new lines
etc developed under RDSS needs to be clearly denoted by a signboard that should
represent
1.7.1. About the Work

1.7.2. Date of Commissioning
1.7.3. Estimated cost
1.7.4. Scheme
1.7.5. Employer’s details
1.7.6. For Transformers, rating in kVA
S.No Components Desired specifications

1 Iron sheet MS sheet 14 guage (1.6 mm thickness)
2 Size of iron sheet 6 feet x 4 feet (Length x Breadth)
3 Painting of board Enamel paint with red oxide coat
4 Printing on board Colour printing by screen printing method
5 Height of board from ground 6 feet
level (Between ground level and
bottom part of board)
6 Support L type angle 3” x 3”, 6 mm thickness
7 Length of angle to be buried in 1.50 feet with 1 feet hole pass inside
ground

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REVAMP DISTRIBUTION SECTOR SCHME-MVVNL

Additional Technical Specifications

Single Phase Oil Immersed Distribution Transformers (Outdoor Type)

1.5 STANDARD RATINGS

1.5.1 Standard ratings of single-phase transformers shall be 16 kVA.

Indian Title International

IS 1180 (Part-I): Outdoor Type Oil Immersed Distribution

i) Location: At various locations in the country

ii) Max ambient air temperature (0C): 50

Sl.No ITEM SPECIFICATION

5. Type of cooling ONAN

4.3 INSULATION LEVELS

Voltage Impulse Voltage Power Frequency (kV)

5.1 CORE MATERIAL:

5.2 WINDINGS MATERIALS:

5.3 WINDING CONNECTION AND TERMINAL ARRANGEMENTS:

Table 9 Maximum Total Losses upto 11 kv Class Transformers

(Clauses 8.8.1.1, 8.8.1.2 and 8.8.1.3)

7.1 The percentage impedance of single-phase transformers at 75 0C for different ratings

8.1 The permissible temperature rise shall be as per IS: 1180

9 PENALTY FOR NON PERFORMANCE

for lifting the core coil assembly separately.

14 SURFACE PREPARATION AND PAINTING:

14.3 PROTECTIVE COATING:

14.4 PAINT MATERIAL:

14.5 PAINTING PROCEDURE:

14.6 DRY FILM THICKNESS:

15 RATING AND TERMINAL PLATES:

16 PRESSURE AND VACCUM REQUIREMENTS:

19 OVER LOAD CAPACITY:

21.3 Load losses at rated current and normal frequency.

22 TYPE TESTS TO BE CONDUCTED ON ONE UNIT:

In addition to the tests mentioned above following tests shall be conducted:

27 QUALITY ASSURANCE PLAN:

29 PACKING and FORWARDING:

(i) Methodology for computing total owning cost*

TOC = IC + (A xWi) + (B xWc) ; Losses in KW

* Amendment issued vide letter No. REC/DDUGJY/SBD/DTR-TS/969 Dated 29.09.2016

Surface primer intermediate finish total Colour

Sl.No. Description 10 kVA 16kVA

1. Name of the manufacturer and place of manufacture

9. Full load losses at 75 0C (watt)

(ii) 0.8 Power Factor

(a) At unity power factor

19. Characteristics of transformer oil

Sl. No. Description Unit

SOURCE OF MATERIALS/PLACES OF MANUFACTURE, TESTING AND INSPECTION

Source of Place of Place of

Aluminium/Copper (As per Discom

3. Insulated winding wires

3-Phase Distribution Transformers 11 kV/433-250V (Outdoor Type)

IS-2099 Specification for high voltage porcelain bushing

ii) Maximum ambient air temperature (0C) : 50

iii) Minimum ambient air temperature (0C) : -5

iv) Maximum average daily ambient air temperature (0C):40

v) Maximum yearly weighted average : 32

(i) The transformers shall conform to the following specific parameters :

Item 11 kV Distribution Transformers

kVA rating Audible sound levels (decibels)

6.1.1 CORE MATERIAL

8 TAPPING RANGES AND METHODS:

15 PENALTY FOR NON PERFORMANCE: