Section 6B: Part-II Power Supply System 1

MUMBAI METROPOLITAN REGION DEVELOPMENT AUTHORITY

“DESIGN, MANUFACTURE, SUPPLY, INSTALLATION, INTEGRATION, TESTING AND

COMMISSIONING OF 220 kV RECEIVING SUBSTATION INCLUDING 220 kV, 33kV & 25kV
CABLING WORK, COMPLETE 25kV OVERHEAD CATENARY SYSTEM ALONGWITH
SWITCHING STATION, 33kV AUXILIARY POWER DISTRIBUTION SYSTEM INCLUDING
33/0.415 kV AUXILIARY SUB-STATION (ASS) AND COMPLETE SCADA SYSTEM,
ELECTRICAL & MECHANICAL WORKS AND LIFT & ESCALATOR WORKS FOR PART OF
MAIN LINE, STATIONS & KASHELI DEPOT OF MUMBAI METRO RAIL LINE 5 PROJECT OF
MMRDA INCLUDING 15 YEARS OF COMPREHENSIVE MAINTAINENCE AFTER 2 YEARS OF
DEFECT LIABILITY AND MAINTAINENCE PERIOD.”

IOCT NO: MMRDA/ML-5/MMRP/PST-E&M-L&E/CA-239

TENDER DOCUMENTS

PART - II

SECTION – 6B

CHAPTER 3

POWER SUPPLY SYSTEM

February - 2024

MUMBAI METROPOLITAN REGION DEVELOPMENT AUTHORITY

Metro PIU, 1ST Floor, A-Wing Old Administrative Building Bandra-Kurla Complex, Bandra (East)
Mumbai 400 051, India

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 2

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Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
 Section 6B: Part-II Power Supply System 3

Contents

3.0 POWER SUPPLY SYSTEM.......................................................................................................... 4

3.1 Receiving Sub Station (RSS) ................................................................................................... 4
3.2 Technical Parameters for Major RSS equipment.................................................................... 10
3.3 33kV Cabling ......................................................................................................................... 21
3.4 Specifications of 33kV Cable.................................................................................................. 22
3.5 Standards .............................................................................................................................. 22
3.6 Abbreviations ......................................................................................................................... 23
3.7 Method of laying cables ......................................................................................................... 23
3.8 Cable Trays / Hangers ........................................................................................................... 26
3.9 33kV GIS Switchgear ............................................................................................................. 27
3.10 33KV/433V Auxiliary Main Sub-Stations (AMSS) at RSS and ASS at Kasheli Depot and
Stations .................................................................................................................................. 28
3.11 33kV/415V Auxiliary Transformers ......................................................................................... 29
3.12 Earthing and Bonding ............................................................................................................ 30
3.13 33kV Voltage Transformer & Current Transformer ................................................................. 30
3.14 Protection Systems ................................................................................................................ 30
3.15 Lighting .................................................................................................................................. 33
3.16 25kV AC GIS Switchgear ....................................................................................................... 34
3.17 25kV Control and Relay Panel ............................................................................................... 36
3.18 Uninterruptible Power Supply (UPS) at RSS .......................................................................... 36
3.19 Low Voltage Switchboards at RSS ......................................................................................... 43
3.20 Low Voltage Cables for RSS and station / Depot ................................................................... 54
3.21 110V DC & AC Control Voltage .............................................................................................. 61
3.22 110 V DC Battery ................................................................................................................... 62
3.23 110 V DC Battery Charger ..................................................................................................... 62
3.24 Fire Protection ....................................................................................................................... 62
3.25 25kV Traction and return Cables. ........................................................................................... 69
3.26 Specifications for Metal Clad Indoor SF6 Gas Insulated Switchgear (GIS) for 220 kV ............ 73
3.27 EOT Crane............................................................................................................................. 97
3.28 SCADA System...................................................................................................................... 97
3.29 RSS and ASS Metering........................................................................................................ 113
3.30 Distributed Temperature Sensing ......................................................................................... 114
3.31 RSS & Simulation Study ...................................................................................................... 114
3.32 Embedded Transformer Operating System .......................................................................... 115

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 4

3.0 POWER SUPPLY SYSTEM

3.1 Receiving Sub Station (RSS)

3.1.1 Traction & Auxiliary power supply for Mumbai Metro Line-5 shall be provided from
Receiving Substations (RSS) located at Kasheli. 220 kV EHV power supply for the RSS
shall be obtained from the Temghar-Colorchem/Kalwa 220kV Line as given in Table-1.
220 kV supply form MSETCL Tower No.6 shall be routed through 220kV conductors and
Copper Cables of appropriate size and specification to suit the technical requirements of
MSETCL. Indicative cable sizes for RSS’s are given in Chapter-14 (Annexure- 9) of
Particular Specifications. However, the contractor shall ensure that the sizes are
adequate based on the simulation studies.

Sr. From To
No.

1 MSETCL Temghar- MSETCL Kasheli Depot LILO

Colorchem/Kalwa 220kV Line Tower Substation
No. 6
(By means of 220kV Conductors and EHV Towers)
2 MSETCL Kasheli Depot LILO MMRDA –
Substation Kasheli Depot RSS

(By means of 220kV cables as per MSETCL Specifications)

 The 220kV EHV supply at the MMRDA - Kasheli Depot RSS will be
obtained from MSETCL LILO Substation located within the RSS premises.
Tapping of 220kV Power Supply from 1 line of MSETCL at Tower No. 6 by
means of LILO arrangement and its extension upto the Gantry of LILO
Substation shall be done by PST Contractor. From the Gantry upto the
Incomer of 220kV GIS inside LILO Substation shall be connected by means
of copper cables (as per MSETCL specifications).
 MSETCL LILO Substation is a part of MMRDA - Kasheli Deport RSS.
Table-1
3.1.2 All equipment of the LILO GIS must be supplied in accordance with MSETCL
requirement and Particular Specification. (It includes 5 Nos. GIS Bay, EHV/LV Power
cables, Protection panel, Metering Panel, SCADA system, Communication System,
ACDB, DCDB, Battery Bank with Battery charger, Emergency panel, fire protection
system, EOT crane, LV equipment’s etc.)

3.1.3 The technical specification of 220kV GIS equipment including cable mentioned in point-
b are provided by MSETCL for MSETCL LILO GIS and attached for Contractor
reference as Annexure- 12 of Chapter 14.

3.1.4 The contractor shall quote all-inclusive per km or meter rate of cabling of 220 kV cables
to cater for any subsequent change in the cable length due to the shifting of RSS
location.

3.1.5 RSS will be consisting of two nos. 220/33kV, 15/20 MVA Auxiliary Main Transformers.
Out of these two one will be in service and other will be standby, but in charged
condition. Auxiliary main transformers at RSS are meant for momentary parallel
operation for changeover for maintenance.

3.1.6 Similarly, two 220/27.5kV, 40/50 MVA Traction Transformers will be provided, out of
which one will be in service and other will be standby, but in charged condition.
Momentary parallel operation for changeover to be provided.

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 5

3.1.7 220kV GIS

220kV GIS shall be indoor type switchgears comprising two incoming, four outgoing and
one coupling bays including the PT, CT, disconnectors, switches, LAs and other
associated equipment as per contract specification.
GIS to be used inside LILO Substation shall confirm to the specifications of MSETCL.
End cover for Bus Duct: - One Set of three phase enclosure GIS end Covers for bus
with double configuration (both ends of both bus-bars) with additional gas compartment
to facilitate future extension of the GIS with all bays remaining in service, shall be in
contractors scope of work. This additional gas compartment shall be provided with SF6
gas density monitor and annunciation shall be provided on LCP.

3.1.8 33kV GIS,

 At Kasheli Depot RSS, 33kV AMSS will be GIS type Indoor switchgear comprising
two incoming, eight outgoing and one coupling bays including the PT, CT,
disconnectors, LA's, Switches and other associated equipment and protection
systems as per contract specification.

3.1.9 25kV GIS.

 At Kasheli Depot RSS, 25kV TSS will be GIS type Indoor switchgear comprising
two incoming, five outgoing and one coupling bays including the PT, CT,
disconnectors, LA's, Switches and other associated equipment and protection
systems as per contract specification.

3.1.10 Two nos. 33kV/433V Dry type Auxiliary Transformers shall be provided at the
following locations.

[Link] Locatio Capacity

. n
1 Kasheli RSS 200kVA, AN
2 Kasheli Depot (ASS-1) 2000kVA, AN
3 Kasheli Depot (ASS-2) 2000kVA, AN
3.1.11 Emergency load at RSS shall be provided by 415V three phase Back up DG set located
at nearest ASS. DG set shall be covered in the scope of E&M Contractor.

3.1.12 LV cable laying and installation (includes pre-installation tests and post installation
tests) of suitable size from 415V three phase Back up DG to RSS LT panel for required
emergency load shall be done by RSS contractor and RSS contractor will interface with
the E&M Contractor for this.
3.1.13 Supplying and laying of pilot cable/OFC for monitoring and control of power supply from
MSETCL to Receiving Substation also forms integral part of power supply including
remote temperature monitoring of 220kV cable.

3.1.14 Indicative cable sizes are given in Chapter-14 (Annexure-9). However, the contractor
shall ensure that the sizes are adequate based on the simulation studies.

3.1.15 Harmonic Filters with associated equipment to be provided, to maintain the individual
and total harmonic limits at the point of common coupling with the utility system as per
IEEE 519 Standard OR EXISTING rdso STANDARD WHICH IS LATEST, if required.

3.1.16 The contractor shall quote all-inclusive per km rate of cabling of 220kV cables to cater
for any subsequent change in the cable length due to the shifting of RSS location (if
any).

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 6

3.1.17 220kV Cables:

3.1.18 The 220kV cabling work from MSETCL LILO Tower to Kasheli Depot MSETCL LILO
GIS, from Kasheli Depot MSETCL LILO GIS to Kasheli Depot Metro RSS shall
conform to the technical requirements specified by M/s MSETCL. All 220kV Cables
and its accessories to be supplied shall conform in all respects to high standards of
engineering, design and workmanship and be capable of performing in continuous
commercial operation in a manner acceptable to the Employer who will interpret the
meaning of drawings and specification and shall have the power to reject any work or
material which in his judgment is not in full accordance therewith.
 As a proof of satisfactory performance of 220kV cable during last five years
from the bidder/JV partner /sub-contractor from whom Bidder intends to
supply,the bidder shall furnish the necessary information in respect of 220kV
cable and its accessories. The information will be used to finalize the sub-
contractor/ vender for the particular equipment for this work. Also, the bidder
shall furnish Type Test report of same size cable used for this contract which
is not more than five years old.
 The cable should be designed for maintenance free best service life, best in
the industry and not less than 30 Years for all types of installation & under
prescribed environmental conditions.
3.1.19 Technical Specification of 220kV Cable & Accessories:
The following standard specifications of latest version updated to as on date of opening
of this bid document will govern supply, laying testing and commissioning of cables
and their accessories However, the cables and accessories (such as termination kit,
straight through joints, bonding cable, link box, etc.) shall also confirm to the technical
requirement and specification of MSETCL. In the event of mismatch between the
specifications and technical requirements, the requirement of M/s MSETCL shall
prevail. GTP of 220kV EHV cable has been furnished in Chapter-15 of Particular
Specification.

Sr. Title of Specification Specification No.

No

Cross linked polyethylene insulated

1 Thermoplastic sheathed cables for
working voltages from 66kV up to BIS:7098 (Part 3) latest or relevant
and RDSO specification
including 220kV
2 Conductors for insulated cables IEC:60228 – latest
3 Test on extruded over Sheath with IEC:60229 – latest
a
special protective function applied by
4 HDPE pipes BIS:4984 latest
5 Power cables with extruded IEC:62067
insulation and their accessories for
rated voltages
above 150 kV (Um = 170 kV) up to
500 kV (Um = 550 kV) – Test
methods and
requirements

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 7

6 Impulse test on cables and IEC 60230 or Latest

their accessories
7 Electric test methods for
partial discharge mean IEC 60885-Part 3 or latest
lengths for extruded power cables.

8 Specification for optic fiber cable (Pilot RDSO Specification No.

cable) TI/SPC/PSI/ OFC/0050
9 Test methods of fiber optic cable ITU-T-G- 652 latest IEC-793-1
latest

3.1.20 Technical Requirements of 800 [Link]. 220kV Cable

[Link] The cables shall be suitable for laying below the ground and in underground
trenches with chances of flooding by water, in ducts & in pipes. The cable shall be
220kV (E), EHV grade, single core, stranded circular Aluminium conductor, XLPE
insulated, Copper screen with copper tape binder, lead alloy sheathed, Double
nonmagnetic steel tape Armored, HDPE sheathed, and overall graphite coated.
Method statement for laying EHV cable shall be approved by MSETCL. The cable
specification is applicable for the cable between MSETCL LILO GIS to Metro Kasheli
RSS and cables required with in the RSS.
[Link] XLPE insulation shall be suitable for following conditions.
 continuous conductor temperature of 90 deg C
 overload condition 105 deg C
 and short circuit conductor temperature of 250 ℃
[Link] The eccentricity of the core insulation shall not exceed 15% and ovality not to
exceed 5%. The eccentricity of the insulation shall be calculated as:

and the ovality shall be calculated as:

where tmax / tmin is the maximum / minimum thickness of the

insulation and dmax / dmin is the maximum / minimum diameter of
the core.
[Link] On plant repairs to the cable shall not be accepted. Pimples, Fisheye, blow holes
etc. are not acceptable. There shall be No water penetration. The outer sheath shall
be HDPE and black in colour.
[Link] Dielectric Power Factor (tan δ): The Dielectric Power Factor at rated voltage shall not
exceed 0.001 i.e., 0.1%.
[Link] Expected fault level of the power supply system shall be 40 kA for duration of 3
second at 220kV. The cable shall be suitable for withstanding without damage, the
thermal and mechanical stress due to 3-phase symmetrical short circuit of 57.2/63 kA
as per application duty requirement and earth fault withstand current of 40 kA for 3
second. Actual fault level will be indicated based on the requirement of MSETCL.
[Link] Additional acceptance tests (on offered lot) shall be carried out for ovality &
eccentricity.
[Link] The actual cable details received from MSETCL will be provided.

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 8

3.1.21 The cable laid in the ground for each phase shall be able to carry a continuous current
to meet the requirements of traction and Aux. Power loads. The size of the conductor
shall be sufficient to carry this current continuously followed by a 10% overload for two
hours under site conditions without deterioration of the insulation. The Contractor
should submit design calculations for cable size and the required size to be provided
which shall not be less than 800 [Link]. The Contractor shall take into account factors
like characteristics of soil such as ground temperature, thermal resistivity of the soil,
depth of laying of cables in the ground, group rating factor for single core cables laid
in flat formation, hot spot temperature, presence of other power cables, type of
sheathed bonding adopted etc. to ensure continuous current carrying capacity of the
cable as required. To comply with the requirement, the Contractor is advised to obtain
the values of the required parameters from statutory authorities or measure the same
wherever necessary.
Normally cable will be laid in concrete trench constructed as per specifications
of MSETCL.

3.1.22 The Employer may decide to visit the works of cable manufacturer to verify the
manufacturing process mentioned. The Bidder shall submit the details regarding cable
construction, bill of material and the manufacturing process proposed to be adopted for
the manufacturing of cables to be used in the project, along with Quality control
measures adopted by the Manufacturer, to ensure:
 The values and tolerances are strictly as per latest IEC or relevant applicable
specifications.
 The cable manufacturer exercises strict quality control measures, including
stage inspections, routine inspections etc. to ensure conformity to standards.
 Periodical inspections of the Manufacturer work, manufacturing processes,
Internal Quality control records of the manufacturer etc. shall be carried out by
MMRDA/GC to ensure compliance to Quality standards.

3.1.23 220kV cable Constructional Features

[Link] Conductor
The conductor shall be formed from plain Aluminum complied with IEC latest
publications 60228. The conductor shall be compact circular stranded. The
conductor shall be made watertight by providing Non conducting water swellable
tape yarns followed by semiconducting water swellable tape(s) over the conductor.
The conductor shall be watertight.
[Link] Conductor Screen
The conductor screen shall be provided over the conductor by extrusion of semi-
conducting compound. A semi conducting tape(s) shall be provided below the
extruded semi-conducting conductor screen to prevent penetration of compound into
the underlying conductor. The minimum thickness of extruded conductor screen shall
be 1.0 mm. The pulling eye should have the same strength as the permissible
conductor strength.
[Link] Insulation
The conductor with screening shall be provided with cross linked polyethylene XLPE
(insulation compound ultra-super clean of Borealis/DOW make)) insulation applied
by extrusion. The minimum thickness of insulation shall be 18 mm. The insulation
compound shall be of high quality, heat, moisture, ozone, and corona resistant. The
insulation shall be suitable for operation in wet or dry locations at conductor
temperature not exceeding 90°C for normal operation, and 250°C for short circuit
conditions.
[Link] The insulation shall be applied by extrusion and vulcanized using dry curing process
to form a compact homogenous body free from micro voids and contaminants.
[Link] Insulation Screen
The Insulation screening shall be applied directly upon the insulation and shall be of

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 9

a layer of extruded semi conducting thermosetting compound firmly and totally

bonded to the insulation. The conductor screen, insulation & insulation screen shall
be extruded in a single process (triple extrusion). The minimum thickness of
insulation screen shall be 1.0 mm.
[Link] Moisture Barrier
The water barrier shall be semi-conducting water swellable tape to be applied over
the extruded insulation screen to block and prevent moisture propagation in a
longitudinal direction and radial water tightness. The semi-conducting tape shall be
suitable for the operating temperature of the cable and compatible with the
insulation.
[Link] Concentric Copper wire screen
Plain copper wires shall be applied helically with gap. Copper wire screen alone shall
be designed for 40 kA for 3 second. Actual fault level will be indicated based on
requirement of MSETCL.
[Link] Binder tape
Open helix of copper tape binder shall be applied helically with suitable overlap.
[Link] Longitudinal water Barrier
Semi conducting water swellable tape shall be applied helically with suitable overlap.
[Link] Metal Sheath
Lead alloy sheath of type kb-PbTe 0.04 as per DIN 17640 or type 1/2 C as per
BS801. Bidder to provide details of sheath.
[Link] Bedding
The bedding over metallic sheath shall be of layer of extruded PVC.
[Link] Armour
Double Non-magnetic stainless-steel tapes designed to provide adequate
mechanical protection during installation and in-service conditions. Thickness shall
be 0.8 mm nominal.
[Link] Bedding
A suitable binder tape or bedding shall be applied over armour tapes and under the
over sheath.
[Link] Over sheath
Extruded Black HDPE jacket over the armour. The jacket shall protect the cable
sheath and armour from electrolysis caused by stray currents from galvanic action,
corrosion, and microbiological attack. Suitable additives harmless to operating
personnel/ environment shall be included in the HDPE jacket to prevent attack by
rodents and termites.
[Link] Coating
A hard baked one layer of graphite shall be applied over the over sheath as outer
electrode for testing the sheath.

3.1.24 Technical Requirements Cable joints & Terminations

 The joints & Termination offered should have been type tested and
passed all the tests as per IEC 60840 and IEEE 404 and the Type Test
reports from KEMA/CPRI shall be submitted along with offer.
 Type tests to be conducted as per IEC 62067, IEC 60840, ASTM &ASTM
& another relevant IEC. Type Test reports shall not be older than 5 years.
 The design of joints & Terminations should be mechanically robust for
which the manufacturer must have a minimum of 10 years’ experience in
design and manufacturing usage.
 The stress control of Joints & Termination shall be by means of stress
cone made up of Silicon rubber. EPDM rubber is not allowed for stress
cones.
 Ease of Installation: The joint body should be a three-piece assembly to
allow for easy installation without the use of special tools and to kefirmirm
control on the positioning of the stress control cone etc.

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 10

 The composite insulator used in the Oil filled Outdoor termination

should be manufactured by the cable accessory manufacturer only.
 Oil used in Oil filled Outdoor termination should be Silicon Oil. It should not
be heated at site before filling inside the termination.
3.1.25 RSS equipment numbering to be done in such a way that equipment numbers should
not be repeated. However, numbering scheme of RSS equipment will be as decided
by MMRDA.
3.1.26 In Switch yard of RSS, Busbar Gantry Height should be same to avoid bending of
busbar for connection of PT, LA etc
3.1.27 For removal of big size equipment like Dry Type Transformer, 33/25KV GIS panel,
sufficient space should be provided without obstruction in floor and upside by façade
during emergency from ASS/RSS. Also, Anchor support (winch) should be provided in
beam to pull the DTT/GIS panel by chain pully.
3.1.28 RSS layout of equipment and arrangement:
Regarding the design, layout of equipment and arrangement, the contractor shall
respect the following rules:
[Link] The apparatuses shall be installed according to the group phase layout, whereby the
three phases of each circuit are installed side-by-side and advance function-by-
function.
[Link] The architectural configuration of the station shall make it as compact as possible with
clear and logical layout of the bus-bars, facilitating, in addition, accessibility to all
actuating devices and possible extensions to accommodate equipment to be installed
subsequently.
[Link] The means of access to the various equipment for the maintenance staff shall be safe.
[Link] The maintenance personnel shall have access to and shall be capable of moving
freely around each element in the cubicles.
[Link] The equipment may be supported on metal frames provided by the contractor when
required. These frames shall not hinder access to any part of the station, nor handling,
overhauling, and assembly operations.

3.2 Technical Parameters for Major RSS equipment

3.2.1 220kV/27.5kV Traction Transformers

The Traction transformer shall be of minimum 40/50 MVA, ONAN/ONAF capacity with
On Load Tap Changer conforming to latest RDSO Specification and IEC-60076.
Capacity of transformers shall be verified by the contractor by carrying out the
simulation studies. The Traction Transformer shall be complete with all Parts,
Fittings, and oil for the first filling, and accessories necessary for its efficient
operation, including mounting framework of steel. All such Parts, Fittings and
Accessories shall be deemed to be within the scope of this Specification, whether
specifically mentioned or not. Indicative technical detail of 220/27.5kV Traction
Transformer has been given in Chapter-15 of Particular Specification.
After constant operation at continuous full load, the transformer shall have a
guaranteed minimum overload capacity of:
 50% for a duration of 15 minutes
 100% for a duration of 5 minutes
After overload the temperature rise shall not be more than:
 65°C above ambient temperature for oil.
 75°C above ambient temperature for windings
Losses: The transformer shall be designed for minimum losses. Full load
transformer losses shall not exceed 0.5% of rated power (Percent of
Transformer’s ONAN rating).
When comparing different tenders the present value of the capitalized cost of
losses in the transformers shall be added to their financial bid by the following
formula refer part-I section-2 ITB.

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 11

In case the transformer losses during tests are found greater than the values
guaranteed in the offer, a consolidated penalty shall be paid by the contractor,
according to the following formula (for the tolerance permissible according to
IEC standard):

PWa = 1.5*K*365*24* C (Wir + b² Wcu)/1000

PWa = 1.5*10.675*365*24* 7.53 (dWir + b² dWcu)/1000 Where
PWa : Penalty value based on measured losses during testing.
K (present worth factor (8% interest, 25 years) = {(1+0.08)25– 1}/{0.08*(1+0.08)25}
= 10.675
C = cost of the kWh (in Indian Rupees (considered as per latest Power Supply
Authority prevailing rate at the time of penalty calculation.
Wir = iron losses in Watts at normal voltage and main tapping
Wcu = full load copper losses in Watts at normal voltage and main tapping at 95°C b
= load factor of transformer = 50 %
Where:
d Wir and d Wcu are the differences between the test values of iron losses
at full voltage and copper losses at full load on one transformer at main
tapping and the values guaranteed in the offer.

3.2.2 Standards

[Link]. Specification No. Title of Specification

1. IEC:60076-1,2,3,4,5 Power Transformer or relevant RDSO

&7 specification

2. IEC: 60214 Tap changer for power transformer

3 IEC 60296 Insulating oil for Transformer
IS 12463:1988 Insulating oil for Transformer (revise for Ester
3A along. Oil)
With additional
requirements of RDSO
3B IEC 61099 Synthetic Oil (SEO) for power
Este
r transformers
3C IS16081 Synthetic Oil (SEO) for power
Este
r transformers
4 IS335 Insulating oil for Transformer
5 IEC 60028 Conductor for Insulated cable
6 IEC 60137 Insulating Bushing for rated Voltage
above 1KV
7 IEC 617-2 Earthing terminal
8 IEC 60 721-2-5 Specification for painting: Environmental
condition
9 ISO12944-5 Protective Paint system

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Section 6B: Part-II Power Supply System 12

3.2.3 On-load tap changer

 Voltage shall be substantially constant at the untapped windings (secondary

windings) and variable at the tapped winding (primary winding).
 The OLTC shall be fully type tested (type tests reports shall not be more than 05
years old at the time of vendor approval or the type tests shall be conducted at no
extra cost to employer.)
 The on-load tap changer shall be single-phase enclosure type, installed in a
separate oil tank, offering 15 steps (+6step, normal and -9step), each representing
1.667% of the nominal voltage.
 The tap changer shall have the following characteristics:
- 50000 operations without any attention
- Motor and hand-driven possibility
- Tap position indicators.
- Commutation current compatible with the short duration transformer over-
current.
- Diverter switches shall be designed for high-speed operation and shall be
interlocked to ensure that there is no possibility of an operation stopping in
mid- position. Arcing contacts shall be of tungsten alloy material.
- Devices for ease of extraction for maintenance purpose
- Manual/Automatic, Local/Remote, Control & Monitor of OLTC from
RSS control room and OCC/BCC.
a. The oil volume of the on-load tap changer unit must be separated from the
tank for core and winding oil.
b. The power circuit of the on-load tap changers shall be connected to the
primary windings and shall enable the required voltage variations as
mentioned in the annexed technical sheet.
c. periodicity for checking and overhauling the power circuit shall be indicated in
the transformer maintenance Manual. The servomechanism settings shall be
designed and executed to avoid too many actuations.
d. The manufacturer shall provide mechanical and electrical diagrams. A suitable
protection relay shall be connected to the oil pipe between the on-load tap
changer and the expansion vessel. The voltage ratio shall be checked
according to the guaranteed figures and the tolerances stipulated in the
standards.

3.2.4 Short-circuit withstand capability.

i. HV SIDE:
The transformer shall be designed and constructed to withstand without
damage, or impairment in its performances, any external short-circuit.
 The primary winding of the transformer shall be designed for
carrying the full symmetrical short circuit current, for 3 sec. The full
symmetrical short circuit current shall be calculated in accordance
with IEC after considering the system impedance on the primary
voltage of the transformer.
 The design of the primary side bushings of the Transformers shall
withstand the symmetrical current for 3 seconds during short-circuit
on primary voltage as specified in IEC 60076-5.
 To limit the short-circuit symmetrical current to an allowable value;
the percentage impedance voltage shall never be less than 12%. At
rated power and frequency on the main tapping, the impedance
voltage shall be equal to about 12.5 %.
ii. LV SIDE:
The maximum short circuit current at the output of feeder station must be
limited at 16 kA to comply with the rolling stock on board circuit breakers

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 13

breaking capacity, (Compared to distribution network) only limited by the

internal transformer leakage impedance.
The contractor shall specify a guaranteed value and tolerances according to
the standards and requirements.
iii. Windings
 The winding conductors shall be made of the best quality high
conductivity electrolytic copper, in compliance with the standard (IEC
60028) requirements.
 Both windings, primary and secondary, shall be designed to withstand
over- voltages and over-currents in case of direct short-circuit across the
medium voltage terminals with the primary winding line for three
seconds.
 The insulation material used for the transformer windings and
connections shall be of class A.
iv. Control and protection
The transformer shall be delivered with "Buchholz", thermal (Oil
Temperature Indicator, Winding Temperature Indicators and Fiber Optic Hot
Spot Temperature Monitor) and earth fault protections, all connected to the
control and monitoring cabinet.
v. Thermostat
The thermostat itself shall be installed in the monitoring box, while the
indicator on its facade and the thermal probe shall be installed into the tank with
appropriate pocket.
vi. Metal work and Paintwork
All metal surfaces shall receive anti-corrosion process (as per IEC 60721-2-5
standard):
a. Natural stainless for Bolts & screws
b. Hot dip galvanization for radiators
c. Rust-proofing and anti-corrosion paint for tank, oil expansion vessel
and other metal surfaces
d. All the external surfaces of the Transformer including radiators &
accessories shall be given first coat of epoxy zinc rich (having
minimum 83% metallic zinc) primer (50-micron thickness),
intermediate coat of epoxy chemical and corrosion resistant High
Build Epoxy Intermediate paint (100 micron thickness) and final coat
of Glossy Aliphatic Acrylic Polyurethane Coating paint (50 micron
thickness). The total dry film thickness of the paints shall be minimum
200 micron.
e. For panels like marshalling Box, OCTC/OLTC drive mechanism box
and RTCC panels Powder Coating painting of minimum 80-micron
thickness is to be done
f. For all exposed metal parts of the bushing, Powder Coating painting
of minimum 80 micron thickness is to be done.
vii. Fire Protection and Suppression System: -
Transformer shall be provided with “Nitrogen Injection Fire Protection
System” or any other requirements as per the latest regulation.
viii. Installation
The Transformers are to be installed in Substation on two running rails, and
consequently must be delivered with a set of swiveling rollers. These rollers
shall be mounted, electrically insulated from the tank and with locking
devices. Electrical insulation of 2.5-5kV must be ensured between the rollers
and the tank. Material layout and volume shall be such that it shall be
possible to remove parts without dismounting other parts. The Traction
Transformer shall be complete with all Parts, Fittings, and oil for the first filling,
and accessories necessary for its efficient operation, including mounting

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 14

framework of steel. All such Parts, Fittings and Accessories shall be deemed
to be within the scope of this Specification, whether specifically mentioned or
not.
NOTE- 1. Employer may go for primary and secondary connections through Dry type plug-
in termination in place of conventional OIP bushing on the transformer as
applicable. The vendor may quote the unit price separately in the items given in
Appendix-E Section – 4C (Part 1) for the change.
1. Employer may go for transformers filled with proven design K3 Class
Biodegradable synthetic Organic Ester oil instead of conventional type mineral
oil. The vendor may quote the unit price separately in the items given in
Appendix-E Section – 4C (Part 1) for the change.
ix. Test Sheet & GTP Sheets:
All type tests and routine tests of Transformer, ON load tap Changer and
Bushings as per relevant RDSO & IEC Specifications specified in technical
specifications shall be carried out and submitted. Short circuit withstand test
shall be conducted on one each type and rating of transformer to validate
the design and quality unless such test has been conducted within the last
five years on the transformer of same specification. In case there is
change in
specification before five years, the new transformer design shall be validated
by carrying out short circuit withstand test. All the type test reports shoud be
valid at the time of vendor approval.
The contractor shall submit fully filled technical data along with other relevant data
during technical approval. All the type tests on Transformer & its accessories shall
be conducted as per RDSO specifications only.

3.2.5 220kV Current Transformer

The Values/Information are to be furnished by the Contractor and values declared are to
be established by conducting actual tests/scrutiny of test reports.
3.2.6 Lightning Arrestor
The Values/Information are to be furnished by the Contractor and values declared are to
be established by conducting actual tests/scrutiny of test reports.
3.2.7 220kV Solid Core Post Insulators
The Values/Information are to be furnished by the Contractor and values declared are to
be established by conducting actual tests/scrutiny of test reports.
3.2.8 Clearances:
 Creepage distance for all equipment’s shall be 31mm/kV suitable for very
heavy pollution as per IEC 60815 and CEA regulation rule-43. Clearance
between equipment’s live part to earth shall be as per IE rules.
 Minimum Clearance of any earthed part or enclosure from any live terminal of
transformer should be as per IEC 60076-3.
 The bottom most portion of any insulator or bushing in service is at an
absolute minimum height of 2500 mm above ground level.
3.2.9 220kV/33kV Auxiliary Main Transformer
The Main Outdoor 220kV/33kV, Oil filled Auxiliary Main Transformer Shall Conform
to IEC:60076. The transformer should be of minimum 15/20 MVA, ONAN/ONAF
capacity with On Load Tap Changer, However the contractor should verify the
capacity by conducting the simulation studies. Indicative technical detail of
220kV/33kV Auxiliary Main Transformer has been given in Chapter-15 of Particular
Specification
The transformers shall be able to withstand an overload of 25% for duration of 2
hours, following continuous running at maximum continuous rated load without

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 15

exceeding the limits of temperature rise stipulated in the standards as specified

below.
The supplier shall indicate the precise overload capacities of the equipment for 30
minutes, 1 hour, 2 hours and 4 hours rating, on the basis of the thermal balance
resulting from extensive initial operation at load of 1/4, 2/4, 3/4 and 4/4 across the
secondary winding.
After overload temperature remaining within 65°C above ambient temperature for oil
and 75°C above ambient temperature for windings.
The primary windings shall be star connected with neutral brought out and earth
connected through insulated cable of appropriate rating. The neutral point shall be
earthed via an isolator.
The secondary windings shall be star connected with neutral brought out and earth
connected. The rated voltage shall be 33 kV rms. The insulation level shall be of a
36 kV rms highest system voltage and the neutral end shall be fully insulated and
earthed through a neutral grounding resistor (NGR) to limit the current to a maximum
of 1000 A into the 33 kV cable screen. The 33 kV neutral point shall be earthed via an
isolator (20 kV) and surge arrester (24 kV, 10 kA). The surge arrester shall be
located as close as possible to this [Link] should be provided on 33 kV side of
Power Transformer installed at RSS. The calculations shall be submitted during the
design of the transformer.
Losses: The transformer shall be designed for minimum losses. Full load
transformer losses shall not exceed 0.5% of rated power (Percent of Transformer’s
ONAN rating).
When comparing between different tenders the present value of the capitalized cost of
losses in the transformers shall be added to their financial bid by the following formula
PW = 1.5*K*365*24* C (Wir + b² Wcu)/1000 Where
K (present worth factor (8% interest, 25 years) = {(1+0.08) ^25– 1}/{0.08*(1+0.08) ^25}
= 10.675
C = cost of the kWh (in Indian Rupees) considered as per latest Power Supply Authority
prevailing rate at the time of penalty calculation.
Wir = iron losses in Watts at normal voltage and main tapping
Wcu = full load copper losses in Watts at normal voltage and main tapping at
95°C
b = load factor of transformer = 50 %
d Wir and d Wcu are the differences between the test values of iron losses at full
voltage and copper losses at full load on one transformer at main tapping and the
values guaranteed in the offer.

x. Standards:

S. Specification No. Title of Specification

No.
1. IEC:60076-1,2,3,4,5 Power Transformer & RDSO specification
&7
2. IEC: 60214 Tap changer for power transformer
3 IEC 60296 Insulating oil for Transformer
4 IS335 Insulating oil for Transformer
5 IEC 60028 Conductor for Insulated cable
6 IEC 60137 Insulating Bushing for rated Voltage above 1KV
7 IEC 617-2 Earthing terminal

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 16

8 IEC 60 721-2-5 Specification for painting: Environmental condition

9 ISO12944-5 Protective Paint system
10 IEC61099 Synthetic ester Oil (SEO) for Power Transformer
11 IS16081 Synthetic ester Oil (SEO) for Power Transformer

xi. On-load tap changer

Voltage shall be substantially constant at the untapped windings (secondary
windings) and variable at the tapped winding (primary winding).
The OLTC shall be fully type tested (type tests reports shall not be more than
05 years old at the time of vendor approval or the type tests shall be
conducted at no extra cost to employer.) The on-load tap changer shall be
suitable capacity, design, and enclosure type, installed in a separated oil tank,
offering 15 steps (+6step, normal and -9step), each representing 1.667% of
the nominal voltage.
It shall have the following characteristics:
- Enabling 50000 operations without attention
- Motor and / hand-driven
- Manual, Automatic, Local, Remote, Raise, Lower control & monitoring OLTC
from RSS control room and OCC/BCC
- Tap position indicators with transducers.
- Commutation current compatible with the short duration transformer over-current.
- Diverter switches shall be designed for high-speed operation and shall be
interlocked to ensure that there is no possibility of an operation stopping in
mid- position. Arcing contacts shall be of tungsten alloy material.
- Between positions disabled
- Devices to ease extraction for maintenance purposes.
- Automatic / Manual and Local /Remote selector switch operation, Control &
Monitor of OLTC from RSS control room and OCC/BCC
- The oil volume of the on-load tap changer unit must be separated from the
tank for core and winding oil.
- The power circuit of the on-load tap changers shall be connected to the
neutral of the primary windings and shall enable voltage variations.
- The full technical description shall be given as regards power and auxiliary
circuits; periodicity for checking and overhauling the power circuit shall be
indicated in the transformer maintenance Manual. The servomechanism
settings shall be designed and executed to avoid too many actuations.
- As the transformer is deemed to run in parallel during power transfer, OLTC
shall be fitted with a servo-mechanism suitable for such a purpose. The
manufacturer shall provide mechanical and electrical diagrams. A suitable
protection relay shall be connected to the oil pipe between the on-load tap
changer and the expansion vessel.
- The voltage ratio shall be checked according to the guaranteed figures and
the tolerances stipulated in the standards.
- UPS should be provided for Un-interrupted AC supply to Transformer OLTC
as at present when ACDB trips, OLTC does not work
xii. Short-circuit withstand.
The transformer shall be designed and constructed to withstand without
damage, whatever may result, from an external short-circuit. The primary
winding of the transformer shall be designed for carrying the full symmetrical
short circuit current, for 3 sec. The full symmetrical short circuit current shall
be calculated in accordance with IEC after considering the system impedance

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 17

on the primary voltage of the transformer.

The design of the primary side bushings of the Transformers shall withstand
the symmetrical current for three seconds during short-circuit on primary
voltage, as specified in IEC 60076-5.
To limit the short-circuit symmetrical current to an allowable value, the
impedance voltage shall never be less than 12%. At rated power and
frequency on the main tapping, the impedance voltage shall be equal to about
12.5%.
xiii. Windings
 The winding conductors shall be made of the best quality high conductivity
electrolytic copper, in compliance with the standard (IEC 60028)
requirements.
 Both windings, primary and secondary, shall be designed to withstand over-
voltage and over-current in case of direct short-circuit across the medium
voltage terminals with the primary winding line for three seconds.
 The adjustment windings shall be designed specifically to withstand direct
short-circuit of all part of the adjustment turns that may occur at the contact
plates of the on-load tap changer switches. The winding, connections and
terminal links shall be properly brazed so as to withstand the shocks and
vibrations which may occur during transport or short- circuit time. Testing of
samples must be carried out and submitted for approval during in-plant
inspection before starting assembly of the transformer windings.
 The insulation material used for the transformer windings and connections
shall be of class A.
Calculations for selecting the insulation class shall be submitted for approval,
however, in no case the insulation class shall be lower than class A.
xiv. Control and protection
The transformer shall be delivered with "Buchholz", thermal (Oil Temperature
Indicator, Winding Temperature Indicators and Fiber Optic Hot Spot
Temperature Monitor) and earth fault protections, all connected to the control
and monitoring cabinet.
xv. Thermostat
The thermostat itself shall be installed in the monitoring box, while the
indicator on its facade and the thermal probe shall be installed into the tank
with appropriate pocket.
xvi. Metal work and Paintwork
All metal surfaces shall receive anti-corrosion process (as per IEC 60721-2-5
standard):
a. Natural stainless for Bolts & screws
b. Hot dip galvanization for radiators
c. Rust-proofing and anti-corrosion paint for tank, oil expansion vessel and
other metal surfaces
d. All the external surfaces of the Transformer including radiators &
accessories shall be given first coat of epoxy zinc rich (having minimum
83% metallic zinc) primer (50-micron thickness), intermediate coat of
epoxy chemical and corrosion resistant High Build Epoxy Intermediate
paint (100-micron thickness) and final coat of Glossy Aliphatic Acrylic
Polyurethane Coating paint (50 micron thickness). The total dry film
thickness of the paints shall be minimum 200 micron.
e. For panels like marshalling Box, OCTC/OLTC drive mechanism box and
RTCC panels Powder Coating painting of minimum 80-micron thickness is
to be done.
f. For all exposed metal parts of the bushing, Powder Coating painting of
minimum 80 micron thickness is to be done.
xvii. Fire Protection and Suppression System: -

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 18

Transformers shall be provided with “Nitrogen Injection Fire Protection System”

or any other requirements as per the latest regulation.
xviii. Transportation and Installation
 Use the shock indicator during transformer transport, installation and storage
and detect critical core displacement.
 The transformers are to be installed at the RSS on two running rails, and
consequently must be delivered with a set of swiveling rollers. These rollers
shall be mounted electrically insulated from the tank and with locking devices.
Electrical insulation of 2.5-5kV must be ensured between the rollers and the
tank.
 Material layout and volume shall be such that it shall be possible to remove
parts without dismounting other parts. The Traction Transformer shall be
complete with all Parts, Fittings, and oil for the first filling, and accessories
necessary for its efficient operation, including mounting framework of steel. All
such Parts, Fittings and Accessories shall be deemed to be within the scope of
this Specification, whether specifically mentioned or not.
NOTE- 1. Employer may go for primary and secondary connections through Dry type
plug- in termination in place of conventional OIP bushing on the transformer
as applicable. The vendor may quote the price separately in the
addition/deletion items given in Appendix E of Section – 4 (Part 1) for the
change.
In case of Space constraints Employer may ask for transformers filled with
proven design K3 Class Bio degradable synthetic Organic Ester oil instead of
conventional type mineral oil.
Employer may go transformers filled with proven design synthetic Ester oil
instead of conventional type mineral oil. The vendor may quote the price
separately in the addition/deletion items given in Appendix E of Section – 4C
(Part 1) for the change.

xix. Test Sheet & GTP Sheets:

All type tests and routine tests of Transformer, ON load tap Changer and
Bushings as per RDSO/relevant IEC standards specified in technical
specifications shall be carried out and submitted. Short circuit withstand test
shall be conducted on one each type and rating of transformer to validate the
design and quality unless such test has been conducted within the last five
years on the transformer of same specification. In case there is change in
specification before five years, the new transformer design shall be validated by
carrying out short circuit withstand test. All the type test reports shall be valid at
the time of vendor approval.
The contractor shall submit fully filled technical data along with other relevant
data during technical approval.
3.2.10 Expansion Type flexible connectors to be provided in HV & LV side bushings
connecting with busbar for both Power (Aux.) & Traction Transformers to avoid
excessive load bushings. Also rain cap to be provided in every bushing of power
transformer.
3.2.11 RSS Earthing
The Receiving Sub Substation installation is subject to various faults such as operating
over voltages, short circuits, or lightning. *To ensure protection to people and
equipment, an Earth mesh, sized to limit the step and touch voltages below the
dangerous values, shall be provided. The Earth Mesh design and installation shall be
done in accordance with relevant provisions in standards such as IEEE 80-2013 or
latest and IEEE 837-2014.

Earth network should be designed considering conductors' temperature rise as regard

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 19

to the faulty current levels. The Contractor will have to provide a buried earth mesh in
the Substation site. As far as the area over which the SWGR & Control Room are
situated, a separate earth mat suitably designed shall be provided under the building
housing the SWGR and Control room, apart from the Main Earth Mesh (alternatively
common earth mat design can be proposed by the Contractor for Engineer’s approval).
The design of the Main Earth Mesh shall be done by the Contractor, considering the
site conditions (soil resistivity etc.). The Main Earth mesh must be exothermically
welded as per IEEE 837-2014 for the purpose of maintaining equipotential bonding to:

a. the earth mat under the SWGR room

b. the return current arrangement/connecting Copper Bonded Steel Conductor
for traction return current.
c. Main Transformer 220kV/33kV, with NGR.
d. All equipment structures supporting 220kV, 33kV,25 kV equipment.
e. Baffle walls between transformers
f. Substation fencing
g. Lighting protection Earthing

Earthing drawing & design shall be submitted in coordination with civil design &
drawings so that during execution minimum infringement of earth mat occurs
with cable trenches & other civil structures like pile caps, cable pull pits etc.

i. Earth network should be designed considering conductors' temperature rise

as regard to the faulty current levels. Separate clean earth to be provided for
RTU, UPS, and electronic equipment with less than 0.5-ohm resistance value.
ii. The Contractor will have to provide a buried (min.100X10mm Cu Flat) earth
mesh in the Substation site. As far as the area over which the AMSS (Auxiliary
Main Substation) & Control Room are situated, earth mat suitably designed
shall be provided under the building housing the AMSS and Control room,
apart from the Main Earth Mesh. The material to be used for earthing should
be copper. The design of the Main Earth Mesh shall be done by the
Contractor, considering the site conditions (soil resistivity etc.). The soil
resistivity of sites in dry conditions is to be measured by the contractor.
Maintenance free earthing to be provided.
iii. In areas where the soil resistivity is rather high and where it may not be
possible to obtain a low impedance grounding system by spreading the grid
electrodes over a large area, as is done in more favorable conditions, the
various measures given in latest IEEE 80 shall be used for reducing the soil
resistivity to meet the site constraints. The Main Earth mesh has to be linked
(by exothermic welding), by means of two copper cables / flats of appropriate
size as following:
- the earth mat under the AMSS room
- the buried rail (min.100X10mm Cu Flat) /connecting strip for traction return
current.
- Auxiliary Main Transformer neutrals
- All equipment structures supporting equipments.
- Baffle walls between transformers.
- Lightning Protection Earthing
The connections which are prone to bi-metallic action shall always be made
through bimetallic strips and washers.
iv. Parameters affecting the design of earth mat.
Several variable factors are involved in the design of an Earth Mat at
Substations. The following are some of the parameters which affect the design
of Earth mat.
- Magnitude of fault current

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 20

- Duration of fault
- Soil resistivity– two layers method Resistivity of surface material Earthing mat
geometry
- Resistivity of surface material
- Earthing mat geometry
- Material of earth mat conductor
- Shock duration etc.
Earth mat for Receiving Sub substation must be designed individually. The
Earth mat must be designed for the site conditions and shall ensure a low
over all impedance (not more than 0.5 ohms) and a current carrying capacity
consistent with the fault current magnitude.
v. Exothermic Welding
Suitable sample moulds for each type of joints / connections shall be
submitted to employer for approval. All Joints shall be tested as per UL 467 &
RDSO / SPN/ 197 Ver. 1.0-2016 and IEEE 837 2014. The resistance of the
joint shall be tested on a random sample preferably 20% of the joints & 100%
of critical joints. Method statement clearly indicating various procedures and
precautions required for an effective welding shall be submitted by the
contractor for approval.

[Link] Maintenance free Earth Electrodes to be used for earth pits in RSS.
[Link] GROUNDING SYSTEM MATERIAL SPECIFICATION: -
 Earth Mat and Earth Electrodes:

The earth electrode is the main component of the earthing system. The
electrode shall be of, high tensile steel rod, The outer surface of the steel
electrode shall be coated with copper having a thickness of 250 micron
(average) as per IEC 60364 / 62561. Ground rods shall have minimum dia. of
17.8mm copper coated steel rods and the size shall be selected based on
current density. The standard length of the ground rod shall be “3.0 Meter” for
use both in the earth mat as well as earth pits. However, space-limited
installations and at locations where relatively low resistivity is experienced at
depths “below 3 meters”, extra-long rods may be considered. For two layer
and multi-layer soil models, where the upper layer has high soil resistivity,
deep driven rods shall be considered so that the rod is in contact with low
resistivity lower soil layer. Copper bonded earth electrode shall be tested as
per the requirements of IEC: 62561-2.
Rods installed in bored holes may be used to reach lower resistivity ground
strata at depths beyond the reach of driven rods or where rock is
encountered, and it is not possible to drive rods. After installing the rod, the
bored hole shall be backfilled with Highly conductive and Environment
friendly corrosion free backfill material. The compound used shall not pollute
the Ground water.

 HIGHLY CONDUCTIVE AND ENVIRONMENT FRIENDLY CORROSION

FREE BACKFILL MATERIAL:
Environment friendly Carbon based backfill compound or Mineral Compound
shall be suitable to be installed in either slurry or dry form and shall not be
mixed with any soil while pouring in the bore hole. The back-fill material shall
conform to Clause 14.5d of IEEE80-2013 Standard and Cl No.13.8 of IS
3043: 2018 with resistivity below 0.12 Ohm-meter.
Tested as per IEC: 62561-7 and the test certificates (Corrosion Test, Leach
Test, Sulphur Test & Resistivity Test) shall be submitted.

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 21

[Link] Lightning Protection

The entire Substation shall be protected against lightning by providing either earth
screen conductors on tower peaks, or by means of Lightning Protection Masts,
suitably spaced to cover the entire area.
The height and locations of Lightning Masts shall be designed appropriately, with
due consideration to the equipment layout in the RSS, to ensure that all the
equipment meant to be protected against lightning are within protective zone
provided by the Lightning conductor.
The Lightning conductor generally consists of:
h. the lightning receiver projecting above the object to be protected.
i. the earthing grid, and
j. The conductor which connects the receiver with the earthing grid and is meant
to carry the lightning current away safely to ground.
The Contractor shall indicate the heights and locations of the Lightning Masts, on
the Substation Layout Drawing, and shall also submit supporting design
calculations to prove the adequacy of the arrangement to cover all equipment for
protection against lightning.

The contractor shall install a Passive sensor designed system to balance and
deionize the effects of atmospheric electric charge in a protected region at all
times. The technology should not allow a lightning strike to occur within a protected
region and provide 24 x 7 protection monitoring. The material for High rise
Lightning Arrestor shall be Aluminium and Polyacetal (POM), does not contain
electronic components or heavy or radioactive metals which should adopt the
RoHS compliance. The design and installation of high-rise Lightning Arrestor shall
be done in accordance with CE, UKCA, NATO, ISO, ITE test Standards.

3.3 33kV Cabling

3.3.1 Scope of Work:
The scope of work includes, but not limited to:
a. 33kV incoming cables from Auxiliary Main Transformer to 33kV incomer
panel on 33kV GIS switchboard within RSS.
b. 33kV outgoing cable
Sizes given below for 33kV cables are Indicative.

Description Minimum Location

Conducting
Core
From 220/33kV Transformer to 33kV 400 sq. mm Copper
GIS incomer
From 33kV feeder CB at 33kV GIS to 95 sq mm Copper
Dry type Transformer (33kV/415 V)
From 33kV feeder CB at 33kV GIS to 400 sq. mm Copper Kasheli
Station GIS Depot
RSS
From 33kV feeder CB at 33kV GIS of
Kasheli Depot RSS to Dry type
Transformer (33kV/415 V) in 300 sq mm
ASS1 & ASS2 Aluminium

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 22

From 33kV feeder CB at 33kV GIS in

one station to 33kV feeder CB at 300 sq mm
33kV GIS in other station Aluminum
From 33kV feeder CB at 33kV GIS in Station
ASS to Dry typeTransformer 95 sq mm Copper to
(33kV/415 V) Station
c. 33kV auxiliary substation comprising 33kV Switchgear(GIS), auxiliary dry
type transformers and 415V cables.
d. Protection arrangements
e. Earthing and bonding system
f. Control voltage source and associated switchgear
g. Other miscellaneous works
3.3.2 Single core armoured copper / aluminum conductor cable of minimum cross
section as per the above table shall be used for laying. Protective Earthing shall
be ensured as per IE Rules. The Contractor shall submit design calculations for
cable size. Indicative 33kV cables sizes are given in Chapter-15 of Particular
Specification.
3.3.3 Straight through joints and end termination shall be done with proper shrinking
type polyethylene box kits. These cables shall be laid through the cable supporting
arrangements to be designed by the Contractor in consultation with Employer.
3.3.4 Supplying and laying of 24 core pilot cable/OFC for monitoring and control of
power supply also forms integral part of 33kV cabling.
3.3.5 The Employer may decide to visit the works of cable manufacturer to verify the
manufacturing process mentioned.
3.3.6 The Bidder shall submit the details regarding cable construction, bill of material
the manufacturing process proposed to be adopted for the manufacturing of 33kV
cables to be used in the project, along with Quality control measures adopted by
the Manufacturer.

3.4 Specifications of 33kV Cable

For Detailed specification refer clause no: 5.2,5.3 and 5.4 in Chapter 5 (25kV,33kV
LT and Control Cables ) below.

3.5 Standards
The 33kV Cables shall satisfy the following requirements along with relevant
RDSO specification and shall also comply with standards in force when the
cables are manufactured, particularly which are in the following table (Unless
otherwise stipulated in the specifications, the latest version of the following
Standards shall be applicable):

Standard Description

Power cables with extruded insulation and their accessories for rated
voltages from 1kV (Um = 1,2kV) up to 30kV (Um = 36kV) –
IEC 60502 Part 2: Cables for rated voltages from 6kV (Um = 7,2kV) up to 30kV
(Um
= 36kV)"
IEC 60228 Conductors of insulated cables

Power cables with extruded insulation and their accessories for rated
IEC 60840 voltages above 30kV (Um = 36kV) up to 150kV (Um = 170kV) - Test
methods and requirements

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 23

Part 1: Tests on electric and optical fiber cables under fire

IEC 60332 conditions Part 3: Tests on electric cables under fire conditions

IEC 60811 Electric and optical fibre cables - Test methods for non-metallic
materials
Test on gases evolved during combustion of materials from
IEC 60754 cables – Part 1: Determination of the halogen acid gas content

ASTM D 2843 Standard Test Method for Density of Smoke from the Burning or
Decomposition of Plastics

ASTM D Standard Test Method for Measuring the Minimum Oxygen

2863 Concentration to Support Candle- Like Combustion of Plastics
(Oxygen Index)
IS 7098 Part Cross linked polyethylene insulated thermoplastic sheathed cables,
2 Part 2: for working voltages from 3.3kV up to & Including 33kV.

3.6 Abbreviations
 IEC – International Electro technical Council
 ASTM - American Society for Testing and Materials
 XLPE – Cross Linked Polyethylene
 FRLS – Fire Retardant Low Smoke
 FRLSZH – Fire Retardant Low Smoke Zero Halogen
 PD – Property Development
 IS – Indian Standard

3.7 Method of laying cables

3.7.1 The cable shall be laid in ground / trench within as per the requirement of this contract
confirming to code of practice of cable laying.
3.7.2 Cable laying shall conform to the requirements of IS 1255 and to the code of practice
of cable laying.
3.7.3 Laying of Cables in Ground
i. This method shall be adopted where the cable route is through open ground,
along roads / lanes, etc. and where no frequent excavations are likely to be
encountered and where re-excavation is easily possible without affecting other
services.
ii. The width of the trench shall be determined on the following basis:
a. The minimum width of the trench for laying a single circuit shall be 400 mm.
b. Where more than one cable is to be laid in the same trench in horizontal
formation, the width of the trench shall be increased such that the inter-
axial spacing between the cables, except where otherwise specified, shall
be at least 2D (where D is diameter of cable).
c. There shall be a clearance of at least 100 mm between the axis of the
end cables and the sides of the trench.
iii. Depth of trench
a. The depth of the trench shall be determined on the following basis.
b. Where the cables are laid in the single tier formation, the total depth of
trench shall not be less than 1050 mm.
c. When more than one tier of cables is unavoidable and vertical formation
of laying is adopted, the depth of the trench shall be increased by 2D for
each additional tier to be formed.
iv. Excavation of trenches

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Section 6B: Part-II Power Supply System 24

1. The trenches shall be excavated in reasonably straight lines. Wherever

there is a change in direction, a suitable curvature shall be adopted.
2. Where gradients and changes in depth are unavoidable, these shall be gradual.
3. The bottom of the trench shall be level and free from stones, brick bats etc.
4. The excavation should be done by suitable means, manual or mechanical.
The excavated soil shall be stacked firmly by the side of the trench such
that it may not fall back into the trench.
5. Adequate precautions should be taken not to damage any existing cable
(s), pipes or any other such installation on the route during excavation.
Wherever bricks, tiles or protective covers or bare cables are encountered,
further excavation shall not be carried out without the approval of the
Employer.
6. Existing property, if any, exposed during trenching shall be temporarily
supported adequately as directed by the Employer. The trenching in such
cases shall be done in short length, necessary pipes laid for passing
cables therein and the trench refilled back.
7. If there is any danger of a trench collapsing or endangering adjacent
structures, the sides should be well shored up with sheeting as the
excavation proceeds. Where necessary, these may even be left in place
when back filling the trench.
8. The Contractor shall use a live cable detector along the route of the
excavation and identify existing live cables along the route and exercise
precaution during excavation.
3.7.4 Laying of cables in trench
1. Adequate sand cushioning shall be provided before laying the cables in the
trench.
2. The cable drum shall be properly mounted on jacks, or on a cable wheel at
the suitable location, making sure that the spindle, jack etc. are strong
enough to carry the weight of the drum without failure, and that the spindle
is horizontal in the bearings to prevent the drum creeping to one side while
rotating.
3. The cable shall be pulled over on rollers in the trench steadily and
uniformly without jerks and strain. The entire cable length shall be as far
as possible be laid off in one stretch.
4. After the cable has been uncoiled, it shall be lifted slightly over the rollers
beginning from one end by helpers. The cables shall then be lifted off the
rollers and laid in a reasonably straight line.
5. The cables shall be tested for continuity of cores and insulation resistance
and the cable length shall be measured, before closing the trench. The
cable end shall be sealed and covered to avoid ingress of moisture.
6. Cable laid in trenches in a single tier formation shall have adequate
cushion of sand before the protective cover is laid.
7. At the time of original installation, approximately 3 m of surplus cable shall
be left on each terminal end of the cable and on each side of the
underground joints. The surplus cable shall be left in the form of a loop.
Where there are long runs of cables, such loose cables may be left at
suitable intervals as specified by the Employer.
8. RCC protective covers of minimum 50 mm thickness shall be provided.
3.7.5 Back filling
1. The trenches shall be then back filled with excavated earth, free from
stones or other sharp-edged debris and shall be rammed, compacted, and
watered.
2. Trenches cut through roadways or other paved areas shall be restored to
the same density and materials as the surrounding area and repaved to
the satisfaction of Employer.

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Section 6B: Part-II Power Supply System 25

3. Where road or lawns have been cut out of necessity, or kerb stone displaced,
the
same shall be repaired and made good to the original condition to the
satisfaction of the Employer and all the surplus earth or rock shall be
removed.
3.7.6 Warning Tape
A warning tape of minimum 200 mm width shall be laid 200 mm below the
ground to give warning signal during excavation at a future date. This tape shall
be of yellow colour made of synthetic anticorrosive material and “Danger,
MMRDA Metro Line 5 33kV cables” shall be printed on this tape.
3.7.7 Route Markers
Route markers shall be provided along the run of cables at locations approved
by the Employer and generally at intervals not exceeding 100 m. Markers shall
also be provided to identify change in the direction of the cable route and at
locations of underground joints. The marker shall be approved by Employer.
The words MMRDA Metro Line 5 33kV Cables shall be inscribed on the
marker.
3.7.8 Cable Laying in HDPE Pipes / Closed Ducts
In locations such as road crossings, entry into buildings, paved areas etc.
Cables shall be laid in multi-conduit made of HDPE pipes of PN4 type as per
relevant Indian Standard.
Each cable shall be laid in one pipe. Pipes shall be continuous and clear of
debris or concrete before cables are drawn. Sharp edges, if any, at ends shall
be smoothened to prevent damage to cable sheathing.
Pipe for each cable shall be not less than two times in cable diameter. One
spare pipe shall also be provided for each type of pipe.
i. Road crossings
a. All road crossings shall be by trenchless drilling method.
b. The top surface of pipes shall be at a minimum depth of 1 m from the
pavement level when laid under roads, pavement etc.
c. The pipes shall be laid preferably in skew condition to reduce the angle
of bend as the cable enters and leaves the crossing.
3.7.9 Cables Identification Tags
Whenever cable is laid / run, marker tags as approved, inscribed with cable
identification details shall be permanently attached to all the cables in the
manholes / pull pits / joint pits / entry points in buildings/ open ducts etc.
These shall also be attached to cables laid directly in ground at specified
intervals before the trenches are backfilled. Cable identification tags shall be
made of Al/ galvanized steel.
3.7.10 End Capping of Cables
After the cable has been laid in the trench, the cable ends should be checked
for any damage. The ends must always be sealed to avoid ingress of moisture
with suitable seals, which could either be of plastic, heat shrinkable or
plumbed type.
3.7.11 Protective Cable Covers
Protective covers must be installed immediately after the cable is placed in the
trench. The cable should never be left uncovered after it is laid. After a cable
has been laid and until the whole of cable to be laid in the trench has been
covered with protective covers, no sharp metal tools, such as spades,
crowbars etc. should be used in the trench or placed in such a position that
they may fall into the trench.
3.7.12 Straight through Joints and End Termination
The Contractor shall supply and carry out jointing and terminations of cables
at both ends. The cable joints and terminations shall be heat shrinkable type
conforming to IS 13573. The jointing and terminations shall be carried out as

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Section 6B: Part-II Power Supply System 26

per manufacturer ‘s instructions, duly ensuring all precautions & all required
tests including Continuity Test, Insulation Resistance Test & HI-POT Test at
Low frequency method as specified in IS/IEC Standards.
3.7.13 Earthing of Metallic Sheath
Earthing of metallic sheath / armour shall be carried out at both ends and
single end as in accordance to approved design and the requirements of
power utility.
3.7.14 Testing
i. Testing before laying
All cables before laying, shall be tested with a 2500/5000V megger. The
cable cores shall be tested for continuity, absence of cross phasing,
insulation resistance from conductors to earth / armour and between
conductors.
ii. Testing before backfilling
All cables shall be subjected to the above-mentioned tests, before covering
the cables with protective covers and back fillandalso before taking up any
jointing operation.
iii. Testing after Laying
All tests are to be performed as per IS/IEC Codes, which shall include Continuity
Test, Insulation Resistance Test & Hi-POT test.
To prevent human interference during the Hi-POT test, the contractor must
take the necessary precautionary measures at the test area and the opposite
end.
3.7.15 Miscellaneous Items
i. The Contractor shall be fully responsible for barricading the trenches, putting
off sign boards with LED paint, lettering for day and red lamps for the night,
employing security staff and taking any other precautions as per traffic rules.
Typical arrangement of barricades to be employed is indicated in the Drawing
No. SYSTRA-L5-SYS-PST-1S5- X10011 & SYSTRA-L5-SYS-PST-1S5-
X10012.
ii. The work shall be carried out in co-ordination with road owning agency and
traffic police.
iii. The sealing of the cable cut-outs will be done by Contractor in receiving
substation area and in ASS rooms of Depot and Stations for cut outs utilized
by the contractor using an approved fire sealing technique.
iv. Provision of submersible pump to be made in depot cable trench and RSS
cable trench to avoid accumulation of rain water in the trench with auto
ON/OFF mode provision.

3.8 Cable Trays / Hangers

3.8.1 The Contractor shall supply and install metallic cable trays, hangers along the cable
route (excluding those on the viaducts) for supporting the various cables related to
Works. The cable trays, hangers and all accessories, metal works shall be
fabricated and galvanized as per the Technical Specifications IEC 61357 and ISO
1461 and shall have a minimum factor of safety of 3 (three).
3.8.2 The scheme for anchor fastening systems shall be subject to the approval by
Employer‘s representative.
3.8.3 For installation of cable containment system, the Contractor shall submit drawings
and obtain Employers approval.
3.8.4 While erecting cables, contractor to ensure there is no damage to the cable
insulation and if there is slight damage at some location special precaution need
to be done during preventive and schedule maintenance. Incase of any damage
cable found during regular execution contractor will have to replace full cable
connection to connection.

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Section 6B: Part-II Power Supply System 27

3.9 33kV GIS Switchgear

3.9.1 The 33kV switchgear shall be installed inside RSS and Station ASS. The
Switchgear shall permit the entry of 33kV cable at the bottom in RSS and top
cable entry in ASS. However it may be bottom entry at the ASS in the Depot.
3.9.2 The Switchgear will also be fitted with protection and synchronizing relays,
standard accessories such as bushings, cable clamps, padlocking facilities, phase
comparators, Capacitive voltage indicating lamps, Cable flashover tripping device
etc. in accordance with relevant standards and the requirements of this
specification. The applicable Codes and standards are also specified in Chapter-
14 (Annexure -1). The GIS shall be designd with single busbar system. The
switchgear and bus bar shall be contained in an enclosure made of stainless steel,
aluminum alloy or equivalent material and fitted with SF6 gas at appropriate
pressure to ensure the insulation and breaking functions. All the live parts
including the VCB, Disconnector, and main busbar shall be encapsulated in an
enclosure filled with SF6 gas. The enclosure shall meet the sealed pressure
system‖ criterion in accordance with relevant standards. No handling of gas shall
be required throughout the 35 years of service life of the equipment. 33 kV GIS
shall be modular in design & compatible for future extension. The Vacuum Circuit
Breaker, Vacuum Interrupter and GIS Panels shall be of the same make.
3.9.3 Operating environment: The switchgear shall be capable of operating in a class B
environment stipulated in the Specification.
3.9.4 Interlocking Arrangement- Interlock arrangements shall be as per clause 5.11 of
IEC 62271 - [Link] Contractor shall develop the interlocking scheme and
provide after Employers approval.
a. The circuit breakers shall be fully interlocked to ensure the correct sequence
of operation. Simultaneous closing of the main switch and earth switch should
not be possible. Mandatory interlocks shall be mechanical. Mechanical safety
interlock shall be provided in accordance with relevant standards.
b. To prevent the earthing of energized cable, status of live cable shall be
provided on the panel. It shall be ensured to have the live/dead status of
cable on SAS workstations or through same panel under voltage relay.
c. The circuit breaker and its enclosure door shall comply with electrical
interlocking described in the relevant drawing to be supplied by the
Contractor.
3.9.5 Earthing of 33kV Breakers - There shall be continuity between the metallic parts of
the switchboard and cable sheath so that there is no electric field pattern in the
surrounding air, thereby ensuring the safety of people. The frames of all the
equipment of the substation shall be connected to the main earth bus bars.
3.9.6 All operating mechanisms should be motorized. Manual emergency operation and
mechanical position indicators shall also be provided.
3.9.7 All operating devices, operating relay and selector switches shall be located at
man height.
3.9.8 All parts shall withstand at least 10,000 operations without any signs of detriment.
3.9.9 Internal arc classification of the switchgear shall be in accordance with IEC 62271-
200
3.9.10 SAS Compatibility - The switchgear unit should be SAS compatible. Switchgear
shall have sufficient auxiliary contacts for each isolator and breaker. Protection
relays shall be mounted on the switchgear panels and provided an additional 20%
spare relay contacts with terminal blocks.
3.9.11 All Alarm & tripping features of GIS as recommended by OEM should be
implemented
3.9.12 All PTs should be plug in/out type and should be provided with disconnector
switch. The provision should be available to manually disconnect the PTs from the

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Section 6B: Part-II Power Supply System 28

circuit without the need to take associated circuit breaker or busbar out of service.

3.10 33KV/433V Auxiliary Main Sub-Stations (AMSS) at RSS and ASS at Kasheli Depot
and Stations
3.10.1 At each RSS, an Auxiliary Main substation (AMSS) shall be provided for
transformation of electrical power from 33kV to 415V by means of Dry Type
Transformer. The kVA rating of the transformers mentioned in below Table is
minimum and contractor should verify the capacity by conducting the simulation
studies.

Sr. no. Location Minimum capacity

1. Kasheli RSS 200 kVA
2. Station 500 kVA
3. Kasheli Depot ASS 1 & 2 2000 kVA

Losses: The transformer shall be designed for minimum losses. Full load
transformer losses shall not exceed 1% of rated power (Percent of Transformer’s
rating).
3.10.2 Technical Specifications:
a. AMSS Kasheli RSS shall mainly comprise of:
b. 33kV Switchgear Board
c. Two 33kV/433V Auxiliary Transformers
d. Associated measuring and protection devices.
e. Associated control and monitoring devices
f. Control voltage source (AC and DC) with associated DBs
g. Power and Control wiring and cabling / bus duct from transformer to main
LV switch board
h. Interfaced with Substation automation system (SAS) at RSS and
SCADA at OCC/BCC.
i. Closing interlocking between breakers (2 of 3 method) and doors.
3.10.3 The cable connection from transformer to MDB shall be of suitable size copper
conductor of specified quality. If necessary suitable bus ducts can be adopted
based on the situation.
3.10.4 The scope for Auxiliary Substation-1& 2 at Kasheli depot shall include following
but not limited to:
v. 33kV/415V Dry Type Transformers: Installation and Testing (includes pre-
installation tests and post installation tests) and energization of 2 nos. of
2000kVA Dry type transformers at Kasheli Depot ASS-1 & 2 including 33kV
Cables laying.
vi. Supply, Installation and Testing (includes pre-installation tests and post
installation tests) and energization of 33kV, 1Cx120 [Link] power cable from
Auxiliary Main Substation at Kasheli Depot RSS to Transformer at Kasheli
Depot ASS sheath voltage limiters.
vii. Supply, Installation and Testing (includes pre-installation tests and post
installation tests) of battery charger and maintenance free VRPP battery bank.
viii. Supply, Installation and Testing (includes pre-installation tests and post
installation tests) of all other equipment ACDB, DCDB and other associated
required works.
ix. Provision of Earth Bus inside ASS and earthing connection of all the installed
equipment as per contract specification.
x. Laying of Cable with different kind of arrangements and restoration works
wherever necessary.

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Section 6B: Part-II Power Supply System 29

xi. Supply of safety equipment. (Like Voltage indicator, HV detection kit, HV hand
gloves, fire extinguishers, Temporary earthing kit, Eye protection goggles,
rubber mats, foot path reflector, Safety & exit sign boards etc.)
xii. Supply of Low Voltage cables & connections as per requirement.

3.11 33kV/415V Auxiliary Transformers

3.11.1 This specification defines the technical characteristics required for the 33/0.415kV
transformers to be used in Auxiliary substations (ASS). These shall comply with
IEC 60076 and IS: 11171 standards.
3.11.2 The transformer shall be of cast resin (Dry) type. The voltage shall be adjusted by
using off- load taps (-5%, - 2.5%, 0, + 2.5%, and + 5% settings). The transformer
short circuit impedance voltage (minimum) shall be 4% up to 630 kVA, 5% above
630 kVA transformers (up to 1250 kVA) & 6% above 1250 kVA transformers (up to
2500 kVA). The no load voltage on the secondary side shall be 433V.
3.11.3 The primary and the secondary windings shall be capable of withstanding
symmetrical three- phase short-circuit regardless of the tapping selected. The
secondary neurtal of transformers shall be solidly earthed.
a) The Contractor shall confirm the following characteristics for each
distribution transformer:
 Short-circuit voltage,
 No-load losses,
 Full-load copper losses
 Efficiency at different load conditions (efficiency shall be maximum at 50%
load).
3.11.4 The 33kV/415V Cast Resin Transformers shall be manufactured and guaranteed to
deliver following power satisfactorily, measured across the secondary winding,
under load with natural air cooling.
xiii. Transformer Cubicle
a. Transformers shall be installed in a cubicle with enclosure having a degree of
protection of not less than IP 21 and without any HV portions exposed.
Suitable arrangement shall be provided to allow observation of the
transformer accessories from the front face. The doors shall be closed and
locked to prevent access to the transformer while either the HV or the LV
side is live. The transformer door shall be interlocked with a circuit breaker
to ensure that accidental opening of door trips the circuit breaker. Similarly,
it shall not be possible to close the circuit breaker when transformer door is
open.
b. An indicator shall be installed on the front door to indicate the winding
temperature. This shall be installed on the middle low voltage winding.
c. Consequently, ventilation louvers shall be installed at the bottom of the front
doors and in the bay rear panel and roof. A metal sheet shall be installed at
10 to 15 cm from the top grating to provide protection against any falling
water.
d. Cable arrangement shall facilitate the exchange of either of the two
transformers without any difficulty. The cables shall be laid along each side
and connected to the transformer in such a way that it will not block the
passage for removal of any of the transformer during service. Painting
should be suitable for corrosive, humid and polluted atmosphere and shall
comply with IEC 60 721 -2-5 standard.
e. The secondary neutral of transformers shall be solidly earthed. The
transformer and its cubicle shall be connected to earth by two separate
earth strips.
f. Surge Arrestor of suitable rating shall be provided on the HV side.
g. Transformer castle key interlock with Up-stream and Down-stream HV & LV

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Section 6B: Part-II Power Supply System 30

switchgears.
h. The complete earthing system shall be linked to the earth terminals provided
by Transformer supplier / SBS contractor.
3.11.5 Short-circuit withstand capability.
a. The transformer shall be designed and constructed to withstand without
damage or impairment in its performances, any external short-circuit.
b. The primary winding of the transformer shall be designed for carrying the
full symmetrical short circuit current, for 3 sec. The full symmetrical short
circuit current shall be calculated in accordance with IEC after considering
the system impedance on the 33KV system.
c. The winding conductors shall be made of the best quality, high conductivity
electrolytic copper, in compliance with the standard (IEC 60228)
requirements.
d. Tests on samples shall be carried out and results submitted for approval
before starting assembly of the transformer windings. Current density for
each winding shall be not more than 2.5 A/mm2.
e. The insulation material used for the transformer windings and connections
shall be of minimum class F.
3.11.6 Protection
Selectivity of the protection arrangements shall be provided to avoid all
unwanted tripping. The time delay of the various circuit breakers shall be set
to ensure chronological selectivity of the tripping. The Contractor shall define
precisely the minimum intervals between the various protection stages,
accounting for the timings and for the actuation times of each one of the
equipment involved. To avoid unwanted tripping, it shall be necessary to
account for transient phenomenon such as energizing of transformers, cables
etc.
Gas Suppression system to be provided along with the Transformer and
further integration with SCADA & SAS system.

3.12 Earthing and Bonding

The earth network may be subjected to various faults such as operating over
voltages, short circuits, or lightning. Suitable earthing and bonding arrangements
shall be designed and installed to keep the step and touch potential within
permissible limits in accordance with standard IEEE 80. The Contractor shall
interface with Station civil contractor, design and install the earthing system at
stations.
3.12.1 All panel and access covers or doors, rotating about hinges etc. shall be earthed
to the adjacent main frames by copper flexible protective bonding conductors.
3.12.2 The frame of each switch shall be provided with reliable earthing terminal having a
clamping screw of not less than 12 mm in diameter.
3.12.3 All the earthing terminals shall be inter-bonded for equal potential and brought to
main earthing terminals.
3.12.4 The earthing conductor or strap mainly of copper shall be mechanically protected
as well as against corrosion and shall be of adequate size. The substation
equipment frames shall be connected to the main earth bus bar.
3.12.5 All switchgear shall be connected to the earth by two connections, one at each
extremity of the switchgear. The panels themselves will be connected. The cables
shall be earthed by an earthing switch with suitable short-circuit making capacity
as per IEC 62271-102. Any additional earthing as required for the GIS Switchgear
shall be provided accordingly.
3.13 33kV Voltage Transformer & Current Transformer
The Values/Information are to be furnished by the Contractor and values declared
are to be established by conducting actual tests/scrutiny of test reports.
3.14 Protection Systems

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Section 6B: Part-II Power Supply System 31

a. The basic protection schemes envisaged at the 220kV, 33kV & 25kV levels
shall be as per below, however detailed protection scheme shall be worked out
during design phase:
b. All relays shall be IEC-61850 based numerical relays.

220kV In-coming feeder from grid sub-station to RSS

- Line differential protection
- Backup over current protection both instantaneous and time delayed
earth fault protection
- Under Voltage & Over Voltage protection
- Reverse current blocking Scheme.
- Any other protection as required by MSETCL

220kV Bus-bar protection in RSS

- Reverse current blocking Scheme.
- Bus bar differential protection
*Note: Bus bar protection for each bus bar shall incorporate a main protection
and check feature. It shall be low impedance. Any Stabilizing resistance shall
not be used.
- Built-in backup with breaker failure protection
220kV Bus-coupler in RSS
- Over current and earth fault protection instantaneous and with time delay

220/33kV and 220/25kV Transformer Feeder

- Differential protection
- Restricted earth fault protection
- Over Voltage
- Over flux
- Backup over current protection, instantaneous and with time delay
- Transformer Tank Earth fault protection
- Standby Earth fault protection (only for 220/33 kV 3 phase transformer )
- Other transformer protections like
- Buchholz alarm and trip
- Oil temperature alarm
- Oil temperature trip
- Winding temperature alarm and trip
- Fan supply fail
- MCB trip indication
- OLR operated.
- Low oil level alarm
- Wrong Phase coupling

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Section 6B: Part-II Power Supply System 32

25kV Traction network protection

25kV Incoming from traction transformer
- Over current, both instantaneous and with time delay
- Directional power
25kV Traction feeder protection
- impedance protection with RX values and
- Over current and earth fault protection, both instantaneous and with time
delay
- WPC,
- Delta -I relay.
- Auto recloser
- PT fuse failure

25kV Traction Bus-Coupler Protection

- Under Voltage
- Master Trip Relay
- LBB (Local Breaker Backup) Protection

Incoming Feeder of 33kV GIS Switchgear at AMSS

- Over current and earth fault, sensitive earth fault protection instantaneous
and with time delay
- LBB (Local Breaker Backup) Protection
- Over Voltage & Under Voltage
- Pilot wire protection

Incoming Feeder of 33kV GIS Switchgear at ASS

- Over current and earth fault, sensitive earth fault protection instantaneous
and with time delay
- LBB (Local Breaker Backup) Protection
- Over Voltage & Under Voltage Protection
- Pilot wire Protection

33kV Auxiliary Bus-Coupler Protection ,Over Voltage & Under Voltage Protection
- Over Current
- Earth Fault
- LBB (Local Breaker Backup) Protection
- Pilot Wire Protection

33kV Outgoing feeders in AMSS

- Busbar protection shall be provided with zone selective tripping, bus differential
as Main and with directional O/C, E/F, LBB as Backup
(as applicable for single and double busbar arrangement)

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Section 6B: Part-II Power Supply System 33

33/0.415kV Auxiliary Transformer protection through Numerical relays

- Restricted earth fault protection
- Backup over current protection, instantaneous and with time delay
- Winding temperature alarm & trip, Stand-by Earth fault protection
- Door open interlock with tripping

415V LT PCC
- Inbuilt Breaker Protection Microprocessor based with Over current, Earth
Fault & Short Circuit

c. 220kV Bus Bar protection scheme shall

 Have maximum operating time up to trip impulse to trip relay for all types of
faults of 25 milli seconds at 2 times setting value.
 Operate selectively for each bus bar
 Shall ensure hundred percent security up to 40 KA fault level for 220KV.
 Not result in false operation during normal load flow in bus bars.
 Incorporate clear zone indication.
 have Separate Tripping relay (MTR) for busbar tripping command for each bay.
 Be of phase segregated and triple pole type
 Provide independent zones of protection.
 Include individual high speed electrically reset tripping relays for each feeder
 Be transient free in operation.
 Shall include continuous D.C. supplies supervision.

d. Incorporate continuous supervision for CT secondary and shall render the

relevant zones of protection in operative against possible open circuit and
protection transferred to check zone only.
e. Isolator status of all connecting bays and Breaker status of Bus coupler shall
be incorporated in Busbar differential protection.
f. Each IED/BPC/BCU should confirm to environment factor 3C3 as per IEC
60721-3-3 for highly polluted area. Relay cards must have conformal coating.
The relays shall be type tested as per IEC 61850-10.
Note: No additional cost shall be paid for any additional protection adopted at the
Designing stage. As it is a design build contract and same shall be decided after
finalization of design.

3.15 Lighting
3.15.1 Indoor internal LED type lighting, external LED type lighting with high mast shall be
provided in RSS. Energy efficient and aesthetic appearance IP 65 lighting fixtures of
suitable capacity of reputed make shall be provided to give illumination of 35 Lux in the
entire switch yard.
i. General lighting within the Control building shall be through energy efficient
LED modern lamps/fittings.
ii. and task lighting through low power compact LED lamps. Large area spaces
with high ceilings may have general lighting by LED lamps along with LED
fixtures.
iii. Temperature correction factor shall be considered for LED luminaries.
Maintenance factor to be used for illumination design in different areas are.
a) Dust prone indoor area and outdoor areas : 0.7
b) General indoor areas : 0.8
iv. The steady state voltage drop to the last light fitting in a lighting circuit shall not
exceed 5%.
v. For the lighting of various areas and services the following lux levels
shall be considered:

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 34

a) Ramps, Stairways, Toilets – 150 lux

b) Corridor, Circulation spaces, Lobby, Stores – 200 lux
c) Meeting room, Conference room – 300 lux
d) Electrical S/s, – 250 lux
e) Cable Cellars – 200 lux
f) Roads – 50 lux
3.16 25kV AC GIS Switchgear

3.16.1 The 25kV switchgear shall be installed at RSS. The Control Building at RSS shall
house 25kV GIS Switchgear. 25kV Circuit breaker shall be provided for the
incoming/outgoing feeders and Bus coupler. The Switchgear shall be installed on an
elevated base to permit the entry of 25kV cable at the bottom or alternatively top cable
entry may be used.
3.16.2 The Switchgear will also be fitted with protection relays, standard accessories such as
bushings, cable clamps, padlocking facilities, phase comparators, voltage indicating
lamps etc. in accordance with relevant standards and the requirements of this
specification. The applicable Codes and standards are also specified in Chapter-14
(Annexure -1). The GIS shall be designed with single busbar system. The switchgear
and bus bar shall be contained in an enclosure made of stainless steel, aluminum alloy
or equivalent material and fitted with SF6 gas at appropriate pressure to ensure the
insulation and breaking functions. All the live parts including the VCB, Disconnector,
and main busbar shall be encapsulated in an enclosure filled with SF6 gas. For future
upgrading or repair, it must be possible to add panels on the side of switchgear without
gas work. All operating mechanisms should be motorized. Manual emergency
operation and mechanical position indicators shall also be provided. The enclosure shall
meet the sealed pressure system‖ criterion in accordance with relevant standards. No
handling of gas shall be required throughout the 35 years of service life of the
equipment. 25 kV GIS shall be compatible for future extension. The Vacuum Circuit
Breaker, Vacuum Interrupter and GIS Panels shall be of same make.
3.16.3 Operating environment: The switchgear shall be capable of operating in class B
environment stipulated in the Specification.
3.16.4 Interlocking Arrangement- Interlock arrangements shall be as per clause 5.11 of IEC
62271- [Link] Contractor shall develop the interlocking scheme and provide after
Employers approval.
a. The circuit breakers shall be fully interlocked to ensure the correct sequence of
operation. Simultaneous closing of the main switch and earth switch should not
be possible. Mandatory interlocks shall be mechanical. Mechanical safety
interlock shall be provided in accordance with relevant standards

b. To prevent the earthing of energized cable, status of live cable shall be provided
on the panel. It shall be ensured to have the live/dead status of cable on SAS
workstations.
c. The circuit breaker and its enclosure door shall comply with electrical
interlocking described in the relevant drawing to be supplied by the Contractor.
3.16.5 Earthing of 25KV Breakers - There shall be continuity between the metallic parts of the
switchboard and cable sheath so that there is no electric field pattern in the
surrounding air, thereby ensuring the safety of people. The frames of all the equipment
of the substation shall be connected to the main earth bus bars.
3.16.6 All operating devices, operating relay and selector switches shall be located at man
height.

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 35

3.16.7 All parts shall withstand at least 10,000 operations without any signs of detriment.
3.16.8 Internal arc classification of the switchgear shall be in accordance with IEC 62271-200
3.16.9 SAS Compatibility-The switchgear unit should be SAS compatible. Switchgear shall
have sufficient auxiliary contacts for each isolator and breaker. Protection relays shall
be mounted on the switchgear panels and provide an additional 20% spare relay
contacts with terminal blocks.
3.16.10 All Alarm & tripping features of GIS as recommended by OEM should be implemented
3.16.11 Main features required:
i. The 27.5kV equipment shall be built according to the relevant rdso/IEC/EN
standards.
ii. Unless indicated otherwise herein, all equipment supplied and installed shall
comply with the IEC/EN standards.
iii. Bus zone wise busbar segregation should be provided with gas monitoring
system for each bus zone.
iv. Individual Pressure gauge to be provided for each circuit breaker compartment
installed at the front of the panel to supervise the SF6 Gas Pressure. The
protection devices for SF6 pressure protection devices shall ensure
permanent monitoring with analog display of gas pressure inside each
compartment.
v. Internal insulation level between live part and earth when the pressure of gas
goes to the atmospheric pressure should not be less than 1.2*27.5kV.
vi. The metal enclosures for SF6 gas insulated equipment/module shall be made
from material which does not require protective painting either internal or
external switchgear.
vii. GIS supplier should have supplied similar GIS for any Rail/Metro system. The
tenderer will be required to explain availability of spares and services from
technically trained manpower in India to support the ultimate customer in
future.
viii. The incoming (single core) cable feeder shall be of suitable size as per
Traction Transformer capacity. The termination arrangement shall be
designed for such cables. The outgoing connections from GIS shall also be
cable.
ix. The disconnectors and earthing switches shall be mechanically interlocked
against maloperation. Feeder earthing switch shall be isolated from earthed
enclosures and shall permit testing of switchgear. It shall also be possible to
carry out high pot DC testing of Cable core without disconnecting the cables.
x. The conductors/bus bars shall be of copper and enclosure shall be made of
corrosion resistant metal.
xi. The gas barrier insulation between compartments shall withstand 1.5 times
maximum rated pressure on one side and vacuum on the other side, if
applicable in the design. The panel shall not require any gas handling at site.
xii. All gas sampling shall be possible during normal operation and without loss of
gas.
xiii. Loss of gas per annum shall not exceed 0.5% by weight in each compartment.
xiv. Adequate burden/capacity shall be available in instrument transformers to
permit provision of protection/measuring equipment. The instrument
transformers shall have separate metering cores to permit measurement of
values of energy, power, current and voltage as per required accuracy.
xv. VTs should be pluggable type and provision should be available to manually
disconnect the VTs from the circuit without the need to take associated circuit
breaker or busbar out of service.
xvi. Clear visual indication of Isolator and earthing switch, whether open or closed
shall be provided.
xvii. The Switchgear panel should be of modular design with external busbar
plugs to be used for connecting two switchgear modules.

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 36

xviii. Interrupting Medium for Circuit breaker shall be Vacuum/ SF6. The
actuating drive should be Spring drive. To give the highest reliability of the
system, following loss of supply voltage the operating mechanism shall have
local stored energy sufficient for duty cycle of O-CO without the need of
recharging. The circuit breaker shall be provided with an anti-pumping coil for
all the commands going to the switchgear. All interlock and auxiliary system
within the actuation system shall be designed so that the circuit breaker
execute operation only when it is in a position enabling to do so completely
and reliably.
xix. The isolator shall be fitted with a suitable power actuation system backed up
by an emergency manual actuation in case of mal function of the former. The
isolator shall not change position under the effect of electro dynamic loads.
xx. In case of any replacement or extension of switchgear panels at site it should
be possible to replace or add a fully assembled circuit breaker without
interfering with the operation of the adjacent feeder as well as without any bus
zone degassing. All circuit breakers of same rating should be interchangeable.
3.16.12 Monitoring of Gas in the enclosure:
Each gas compartment and bus zone should have its own temperature
compensated density indicator featuring 3 auxiliary contacts for alarm. The
protection devices for the equipment shall ensure permanent monitoring of gas
pressure inside each compartment by means of temperature compensated
monitoring devices triggering a dual alarm threshold annunciation system in
the event of gas pressure drops.
3.16.13 The design of the cable termination shall allow plugging and unplugging the HV cable
without need of opening the GIS and without any gas filling.
3.16.14 The complete GIS equipment shall meet the requirements of the IEC/EN standard.
 The modules individually as well as assembly subject to various routine test
including type test.
 Site test shall include leakage test, moisture contents in dielectric medium and
power frequency test.
3.16.15 The internal arc classification shall be IAC AFLR for 1 sec upto Full Short Circuit Level.
3.16.16 Earthing: Entire metallic enclosure shall be bonded and effectively earthed
3.16.17 The switchgear is used for controlling 25kV OHE feeder and 25kV cable. Contractor
to confirm suitability of equipment for this application and also confirm maximum
over voltage during switching operation.
3.16.18 The contractor is responsible for the selection of proper relays, CT/PT application
check, all assistance during integrated testing for the protections.
3.16.19 Panel Gas Flooding system to be provided inside the Control Panel of 25 kV GIS. This
will detect and suppress fire in case any fire is detected in the Control Panel. Any such
event shall cause an Alarm and will be displayed in OCC and BCC through SCADA
25kV Control and Relay Panel
3.16.20 All Alarm & tripping features of GIS as recommended by OEM should be implemented

3.17 25kV Control and Relay Panel

3.17.1 RDSO Specification No. TI/SPC/PSI/PROTCT/4050 with latest A&C slip for Control
and Relay Panel.

3.18 Uninterruptible Power Supply (UPS) at RSS

3.18.1 General
The Contractor shall supply and install the complete Uninterruptible Power Supply
(UPS) System at RSS of Kasheli Depot, batteries and its necessary components as
per capacity rating indicated on the Drawings and/or specified herein in the
Technical Specification.
3.18.2 Standards and Reference.

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 37

The UPS shall comply with the following codes and standards.

Sr. Standard No. Description

Semiconductor Converters – General requirement

1 IEC 60146 and line commutated converters – Part 1-1:
Specification of basic requirements.
Information technology equipment Safety Part 1:
2 IEC 60950
General requirements.
Uninterruptible power systems (UPS) – Part 3:
3 IEC 62040-3
Performance requirements
International Electrotechnical Vocabulary (IEV) -
4 IEC 60050-195 Part 195: Earthing and protection against electric
shock
Direct acting indicating analogue electrical
5 IEC 60051
measuring instruments and their accessories
Semiconductor converters - General requirements
6 IEC 60146
and line commutated converters
Standard for Harmonic Control in Electric Power
8 IEEE 519
Systems
Specification for cartridge fuses for voltages up to
9 BS 88
660 volts
Safety of transformers, reactors, power supply
10 BS 61558
units and combinations thereof
Secondary cells & batteries containing Alkaline or
11 IEC 61951 other non-acid electrolytes - secondary sealed
cells and batteries for portable applications.
12 BS 6290 Lead-acid stationary cells and batteries
13 BS EN 60146 Semiconductor converters
EN 500091-1 USA/Canada: UL1778 - Standards
14 Safety Europe:
for Uninterruptible Power Supply Equipment.
Emission & Immunity:
15 Europe: EN 500091-2 USA/Canada: FCC Class A
CE-Marked
The tenderer shall be ISO 9001 certified. Copy of
16 ISO 9001 Certification:
certificate shall be enclosed along with the tender.

3.18.3 Submittal
i. The Contractor shall submit material lists and technical data including
schematic diagram for approval including name of suppliers before
purchasing.
ii. The Contractor shall submit the following technical data for approval before
installation.
a. Installation detail drawings of the UPS and Stationary Batteries
(Dimension plan, section view, required clearances and location of all
associated equipment).
b. Installation detail drawings of Cables & Raceways and its accessories

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 38

connected with the UPS and Stationary Batteries.

c. Installation and operation manuals
iii. The Contractor shall submit calculation sheets for batteries capacity based on
ambient operating temperature.
iv. The Contractor shall submit the battery de-rating curve and the life
expectancy decreasing data due to room temperature variation.
v. The Contractor shall submit the necessary list of spare parts and
special tools.
3.18.4 Material Description
i. The equipment and/or components shall be fully tropicalized and designed to
operate 24 hours a day, 365 days a year.
ii. The UPS system shall be True Online Double Conversion System consisting
of rectifier/charger, inverter, static bypass transfer switch, manual bypass
switch, battery bank, Nickel Cadmium batteries and other equipment
necessary for completion of the system.
iii. The UPS shall be a dual unit parallel-redundant type (for charger and inverter
section only but with one set of batteries only) suitable for continuous
operation.
iv. All materials and parts comprising the UPS system shall be new, of current
manufacture and shall not have been in prior service except as required
during factory testing.
v. The Contractor shall ensure that the harmonics generated by each UPS unit
will not affect the performance of other UPS units and the entire electrical
distribution system.
vi. Environmental Conditions
vii. UPS system shall operate generally in Class “A” environment. However, the
UPS shall operate satisfactorily under the Class “B” environment for a duration
of 1 hour (based on the requirement) in case of failure of air conditioning
system. The UPS Battery shall be located in Air- Conditioned Room. Aging
factor & Design Factor shall be taken as 25% & 10%.
viii. Operation Mode
1. Normal Mode
a. During normal mode operation, the AC supply line from substation auxiliary
supply shall supply power to the rectifier/charger which converts AC power
to the regulated DC power. Simultaneously, the regulated DC power shall be
used to float-charging the batteries while it supplies the inverter.
b. The inverter shall invert DC power into AC power for supplying critical loads
within specified parameters.
2. Emergency Mode
a. Upon failure or loss of the main AC supply line, the critical loads shall be still
continuously supplied, without any switching, interruption, or excessive
disturbance, by the batteries through the inverter.
b. Upon restoration of the m
c. ain AC supply line, the rectifier/charger shall recharge the batteries in
preparation for future station auxiliary supply line failure and still supply full
rated power through the inverter to the loads without interruption.
d. The UPS shall shut down itself if the batteries are discharged to their
minimum discharge voltage. These batteries shall be able to supply rated
output power for the time specified hereafter.
3. Bypass Mode
a. Automatic Bypass
1. The static bypass switch shall automatically transfer the load synchronously
and without interruption, to the reserve supply in the event of any UPS
malfunction (system overload, heavy in-rush current, etc. or inverter
shutdown) which could cause the load to deviate beyond the specified

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 39

tolerance. Upon restoration of the UPS function, the output of the UPS shall
be synchronized with the reserve supply and then the load shall be allowed
to transfer from the static bypass switch to the inverter without interruption.
b. Manual Bypass
1. If the UPS must be taken out of service for maintenance or repair, a manually
operated mechanical bypass system shall be provided to avoid the danger of
working on live part; this system shall be designed to isolate the inverter and
static switch while maintaining the critical loads via the reserve supply.
2. Transfer by manual bypass or re-transfer back to the UPS system shall take
place synchronized with the reserve supply (or main supply in case of re-
transfer) and with no disturbance to the loads.
ix. Physical Requirement
1. The UPS equipment shall be housed in a free-standing, floor mounted with
protection degree at least IP41 or more cubicle, designed for heavy-duty
applications and constructed of steel, or equivalent. All components and
materials shall be a new version of the current state-of-the-art.
2. All equipment in the system shall form a match and line-up configuration.
3. Equipment shall be designed for front access.
4. Enclosures shall be coated with several coats of anti-sulphuric or anti-
alkaline enamel inside and outside. All equipment doors shall be hinged and
provided with lockable handles (all keyed alike), or pad-lockable handles.
5. All status, alarm and instrumentation display and all normal operator
controls shall be visible and accessible to a person standing on the floor.
6. All power circuit sub-assemblies except major magnetic shall have the
capability of insertion or removal by one person without the use of
mechanical means except to remove screws/bolts. Sub-assemblies
performing similar functions shall be interchangeable. All power connections
shall be bolted and readily accessible.
7. Control sub-assemblies shall be in racks or trays. Printed circuit boards shall
be grouped according to function in a single location/rack in the module.
x. Protective Devices Requirement
The following protective devices and system shall be equipped within the UPS
system:
1. Switches with Fuse for main AC input protection
2. Circuit Breakers for DC input protection
3. Switches with Fuse for AC output protection
4. Alarm warning system for the Rectifier, Charger, Inverter and Bypass Switch
5. Phase sequence, Earth fault, Low battery voltage, Self-diagnostic annunciation
system.
xi. Performance Requirement
(1) Overload : ≥150% for 1 minute
: ≥125% for 10 minutes
(2) Overall efficiency : > 95% for all loads and a power factor near
Unity
(3) Back-up time : 2 hours as per requirements mentioned in
scope.
for 100% load, near to unity
(4) Noise generation level: : < 70dB (A) @1.5 m from the UPS cabinet
The UPS system shall be suitable for continuous operation allowing for
achieving highest system availability and reliability.
3.18.5 Components
i. Current Limiting
The rectifier/charger provides for input current limiting whereby the UPS
modules will draw only sufficient power to drive the critical load with an
additional pre-set maximum power lever to recharge the battery. Thus, the

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 40

input kVA drawn by the system is the sum of two components due to the
critical load and due to battery charging. The input current is limited to 115%
of the total rectifier rating.
ii. Input Power Walk-In
When the mains are restored following an outage, the UPS modules shall
initially draw no power over a period of approximately 15 seconds (known as
walk-in time). The input power requirements will rise to a level dictated by the
power required to drive the critical load and the additional pre-set power to
recharge the batteries as described above.
iii. Rectifier/Battery Charger Unit
1. The rectifier/charger shall be solid state type with relevant electronic control circuit.
2. The rectifier/charger shall have sufficient capacity to support a fully loaded
inverter and at the same time maintain the battery at fully charged condition.
If the battery is fully discharged, the rectifier/charger shall recharge the
battery to 75% of its fully charged condition within 5 hours and 100% of its
fully charged condition within 10 hours at the same time supplying full load
current to the UPS system.
3. The unit shall be a complete set manufacturing from the factory.
4. Electrical characteristic of the unit shall be as listed below:
(a) Rated input voltage: 415 Volts ac +20%
(b) Input frequency : 50 Hz ± 5%
(c) Input power factor: > 0.95 lagging when the system is operating at
full load and nominal voltage.
(d) Input THDI : < 3% at rated load
(e) Input Current limiting: adjustable from 100% to 125%
(f) DC output voltage regulation: ± 1%
5. Rectifier shall provide a smooth output with filters to remove harmonics.
Harmonic voltage distortion presented to the mains supply shall not exceed
5%.
6. The rectifier shall have both constant current and constant voltage
charging characteristics dependent on the state of charge of the batteries.
7. The rectifier shall cease operating when the mains supply falls below the
minimum viable input voltage.
8. Each rectifier shall be rated to meet the full load of charging the batteries
together with powering the inverter while operating at rated output.
9. It is required to maintain THDI as less than 3% & Power Factor at input side
should read as 0.95. The battery Charger (12-Pulse) shall be as per ma
nufacturer ‘s Data.
iv. Inverter Unit
1. The unit shall be a transistorized solid-state type, IGBT, which is designed
for Pulse Width Modulation technology interconnected with 3 phase isolation
transformer and filter capacitor. The Transformers can be either inbuilt or
External part of UPS System as per the Manufacturer.
2. Output terminal of the unit shall be bus bars type with a neutral bus size not less
than
1.4 times of the rated current.
3. Electrical characteristic of the unit shall be as listed below:
(a) Rated output power (kVA) : Rated output capacity @ 0.8 power factor
(b) Output voltage, Transient and recovering
(i) Steady state : 415 Volts ac ± 1%, 3Ø, 4W with Earth
(ii) Transient 0% - 100% step load : + 5% of rated voltage
(iii) Transient recovery time : < 50 ms for non-linear load and <
20ms
for linear load
(iv) Voltage imbalance : < 1.5% at 50% unbalance load

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 41

(v) Phase Displacement : < ± 2.0°

(c) Output frequency
(i) Steady state : 50 Hz ± 1%
(ii) Free running : 50 Hz ± 0.1%
(iii) Slew rate (df/dt) : < 1 Hz/sec
(d) Output harmonic distortion
(i) 100% linear load : < 1%
(ii) 100% non-linear load : < 5%
4. The output of the inverters shall be a sine wave having less than 1% total
harmonic voltage distortion content for linear loads, and less than 5% for
100% non-linear loads with a crest factor up to 3:1.
5. Each unit shall have a dynamic response such that application or removal of
a 100% step load causes an output voltage transient of less than + 2% with
a recovery time of less than 4 ms.
6. The inverters shall be capable of delivering its rated power into a load with a
power factor near unity.
v. Indications and Controls
1. A front panel mimic display shall be provided showing the UPS and bypass
mode of operation.
2. The monitoring and diagnostic system shall provide an audible alarm to
provide warning and fault indication.
3. Battery voltage measurement points shall be provided such that faulty
groups of batteries can be detected.
4. Volt-free contacts shall be provided from the UPS systems to provide key
status information remotely to the SAS.
vi. Static Bypass Switch
1. The static bypass switch shall be designed to bypass the critical load from
the inverter to the main power source in the event of UPS malfunctions
without interrupting the critical load operation.
2. The static bypass switch shall be rated at least to carry full load continuously
and shall be able to withstand any internal and external fault current not less
than ten (10) times of full load within 100 milliseconds.
3. The following static bypasses shall be provided:
a. Changeover to reserve - this shall operate in the event of inverter failure (or
manual operation) to transfer the UPS output to the reserve inverter.
b. Changeover to mains - this shall operate in the event of UPS failure, inverter
overload (or manual operation) when the mains supply is live, to transfer the
UPS output to the mains.
c. Maintenance bypass - this shall be a manually operated switch to take the
entire UPS out of service, whilst the UPS loads continue to be supplied
directly from the mains supply.
vii. Maintenance Bypass Transfer Switch
a. A manually operated maintenance bypass switch shall allow the critical load
to be fed from the normal power source while providing isolation of the
inverter and static bypass switch for safety during maintenance.
b. Testing of the maintenance switch may be performed while the load is being
fed from the normal power source.
c. The bypass switch shall permit the transfer of critical loads to the normal
power mains during the electrical disconnection of the UPS module for
maintenance purposes.
viii. Battery Bank
The battery bank shall at least consist of the following.
1. Set of Maintenance free VRPP (Nickel Cadmium) batteries
2. Battery racks, which shall be coated by acid resistant material from the factory.
3. Associated equipment of the battery, panel board and isolators.

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Section 6B: Part-II Power Supply System 42

4. Grounding system
ix. Battery
1. The battery selected shall consider, as a minimum, the following criteria: -
2. Autonomy.
3. Battery recharging period, following a complete discharge.
4. Service life.
5. The UPS Batteries shall be sealed maintenance free type VRPP.
Tenderer shall indicate calculated figure for Service Life of 8 years as
required based on the manufacturer data. The selection of the battery
type shall take into consideration the Local Environmental , Health and
Safety Regulations.
6. A fully discharged battery shall be charged to 75% of its rated capacity in 4
hours under float charge conditions.
7. A fully discharged battery shall be charged to 100% of its rated capacity
in 8 hours under boost charge conditions.
g. Not Used.
8. The battery shall have capability to deliver the output power rating as
specified on the drawings at the output terminal of the UPS for the
required back up time.
9. The maximum and minimum voltage of the battery shall be matched with
the operating input voltage of the inverter. The minimum final discharge
voltage of the battery shall be limited to 1.1 V or at the recommendation
value from the manufacturer.
10. Low Battery Voltage Protection: To prevent total discharge or damage to the
battery, the UPS shall transfer to standby operation when the battery voltage
reaches a set minimum voltage level (programmable). If AC input source
has not returned within 10 minutes after low battery‖ shutdown, the UPS
shall electronically disconnect DC Power from the battery to avoid deep
discharge.
x. Associated Equipment of the Battery
1. The battery cell inter-connectors shall be copper bar and fully insulated. All
bolts and nuts shall be of the acid resistant type.
2. All battery terminal posts shall be covered with soft rubber pole caps to
prevent external short circuit.
xi. Control and Annunciation System
1. The UPS shall incorporate the necessary control, instruments and
annunciation to perform the completed function and to allow the operator to
monitor the system status and performance as well as to take any
appropriate action.
2. The control and annunciation system shall be micro-processor-based control
complete with LCD display for monitoring of events and measured values.
3. The visible and audible alarm for the UPS shall be provided.
4. The minimum requirement of the measuring values for monitoring shall be as
listed:
(a) Input : Voltage, Frequency, Power,
(b) Output : Voltage, Current, Frequency, Power,
(c) Battery Output : Voltage, Current, Temperature, Autonomy time
5. The minimum requirement of the status and alarm for monitoring shall be as listed:
(a) Rectifier : Off, Over Temperature, Failure
(b) Inverter : Off, Over Temperature, Failure
(c) Battery : On Load, Over Temperature
(d) Bypass On Load
(e) Overload
xii. Network Interfacing
1. The Network/Communication Port (RS485 or 10/100 Base-T or etc.) shall be

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Section 6B: Part-II Power Supply System 43

provided within the UPS for remote monitoring and management.

2. The interface units shall be provided to interface with SAS for remote
monitoring and management in Station Control Room and/or OCC and/or
BCC room respectively.
3. The UPS and Battery management software with license number shall be
provided.
4. AI & DI Signals of SCADA UPS to be integrated with SCADA System.
xiii. Enclosure
The UPS shall be housed in a free-standing enclosure. The enclosure shall be
designed to blend into a computer room environment. The cabinet shall be
equipped for fork truck lifting. The UPS cabinet shall be painted in
thmanufacturer ‘r‘s standard colour. All service access shall be from the
front and top. Details of forced ventilation if required shall be furnished along
with the tender. Overall dimensions of the UPS systems as also the battery
banks shall be furnished. The weight of the UPS units and battery banks shall
also be furnished for checking structural floor loading.

3.18.6 Installation
[Link] The UPS and Battery Bank including associate equipment shall be
installed on the location as indicated on the Drawings.
[Link] The installation, size of cables and conduits shall follow the instruction
from manufacturer.
3.18.7 Testing and Commissioning
Upon completion of installation, the UPS and associate equipment shall be
tested within the minimum requirement as follows:
i. The system shall be tested involving electrical characteristics as specified
above for load condition in a period of not less than 8 hours.
a. No Load
b. 50% Load (Dummy Load)
c. Full Load (Dummy Load)
ii. Record Input and output voltage/current wave form, which are measured in
each load condition of 0%, 25%, 50%, 75% and 100%.
iii. Measure and record overall efficiency at 100% load in each condition of main
power supply from utility line and from batteries.
iv. Test grounding of the system.
3.19 Low Voltage Switchboards at RSS
3.19.1 General
i. This specification describes low voltage switchboard complete with bus
connections, incoming circuit breaker, tie and feeder circuit breakers, and bus
bars for distributing power to a 415 V, 3-phase, 50Hz, 4-wires, solidly
grounded neutral system, interconnections, metering, protection, earthing etc.
LV switch Boards at Kasheli Depot ASS is not in the scope of this Contract.
ii. The Contractor shall furnish and install low voltage switchboards, as
described, or indicated on the Drawings and specified herein.
iii. The LV switchboard & assemblies manufactured should have been type
tested according to the IEC 60439-1(1999-09)/IS 6623 (I) with acceptance by
independent agency (e.g. CPRI, ERDA, KEMA VDE, ASTA etc.). All the
switchb o a r d s shall be assembled within the Manufacturer‘s premises.
3.19.2 Standards and Reference
i. The Main low voltage switchboard, distribution boards, and accessories shall
comply with the following codes and standards.

(1) IEC 60439- : Low voltage switchgear and control gear assemblies Part 1:
1/1999 Type-

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Section 6B: Part-II Power Supply System 44

tested assemblies
(2) IEC 60269 : Low voltage fuse
(3) IEC 60529/1989 : Degree of protection provided by enclosures (IP Code)
(4) IEC 60947-1/1988 Low-voltage switchgear and control gear – Part 1:
:
General Rules
(5) IEC 60947-2/1995 Low-voltage switchgear and control gear – Part 2: Circuit-
: breakers
(6) IEC 60947-7/1999 Low-voltage switchgear and control gear – Part 7: Ancillary
:
equipment
(7) IEC 60439-2/1999 Low-Voltage switchgear and control gear – Part 2:
: assemblies
Particular requirements for Bus bar trunking system (Bus
ways)
(8) IEC 60296 : Mineral Insulating oils for transformers & switchgear
(9) IEC 60050 : International Electro Technical Vocabulary
(10) IEC 60439 : Low voltage switchgear and control gear assemblies
(11) IEC 60947 : Standards for low-voltage switchgear and control gear
(12) NFPA 70 : National Electrical Code
(13) BS 88 : HRC Fuses
(14) BS 5486 : Low-voltage switchgear and control gear assemblies.
Requirements
for type-tested and partially type- tested assemblies.
(15) BS EN 60898 : Electrical accessories — Circuit breakers for over- current
protection
for household and similar installations
(16) EN 60255 : Measuring relays and Protection Equipment
(17) EN 60298 : A.C. metal-enclosed switchgear and control gear for
rated voltages above 1kV and up to and including 52kV
(18) IS 13947 : Low Voltage switchgear & control gear
(19) IS 8828 : Low Voltage switchgear & control gear - Part V Control circuit
devices and switching elements MCBs
(20) IS 11353 : Marking of Switchgear bus bar
(21) IS 3231 : Electrical relays for power system protection
(22) IS 10118 : Code of Practice for selection, installation and Maintenance of
switchgear & control gear
(23) IS 8623 : Low Voltage switchgear & control gear assemblies
(24) IS 2147: 1962 : Degree of protection enclosures for low voltage Switchgears
(25) IS 3231: 1986 : Electrical relays for power protection
(26) IS 2551: 1982 : Danger notice plate

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Section 6B: Part-II Power Supply System 45

(27) IS 4201 : Application guide for current transformers

(28) IS 4140 : Application guide for voltage transformers
(29) IS 3842 : Application guide for relays
(30) IS 5051 : Electro-magnetic relays
3.19.3 LV system Description
i. The LV Switchboard shall be designed and fabricated for use on a 415V AC, 3
phase, 4 wires, 50 Hz, grounded neutral system and the construction shall be
of Form 4B type.
ii. There shall be two Auxiliary dry type Transformers in ASS & each capable of
supplying the full station service load.
iii. The rating and quantity of outgoing feeders for each MDB (for the
corresponding Transformer rating) shall be coordinated with E&M Contractor
during detailed engineering stage. The incomer and tie breakers shall be
adequately sized by the PST Contractor as required. For RSS switchboards
PST Contractor shall decide. All the assemblies shall be modular and
expandable.
iv. The switchgear shall contain all necessary relays, meters, control switches,
and other equipment necessary for protection and control of the main breakers
and feeder breakers.
v. The switchover of supply from one source to other sources shall be automatic
and such a system shall evolve an automatic efficient control logic system to
ensure 100% reliable supply.
vi. The protection scheme selected shall be such that the offered panel complies
with total discrimination w.r.t. all incoming and outgoing breakers and
upstream HT breakers.
vii. All Circuit breakers should comply with the IEC and IS standard and the main
ACB shall be equipped with Ground Fault protection.
viii. 20% Spare outgoing breakers at least 1 of each rating shall be provided.
Spare panel space on top of the 20% spare breaker capacity shall be provided
for future expansion.
ix. All cable terminations and component circuit references shall be properly
labelled & tagged to facilitate easy identification and fault diagnostics.
x. The low voltage switchgear shall have the electrical characteristic as follows:
(1) System Wiring 3-phase, 4-wires solidly grounded neutral.
(2) Rated Voltage 415V
(3) Rated Frequency 50 Hz.
(4) Insulation Class 660-750V (Minimum)
(5) Degree of protection IP 43
3.19.4 Components
i. LV Switchboards
I. Panel Construction
a. The main LV switchboards shall be of sturdy and robust, metal enclosed,
moisture, dust, termite and vermin proof with ventilation louvers, indoor
purpose, free- standing, front accessible, and should be fabricated in
modularized design system, fully extensible, self-supporting on steel
frame construction in 2 mm thick. Enclosures shall be fabricated with
2mm for load bearing members and 1.6mm for non-load bearing
members. The CRCA sheets shall be used. The panel shall be Epoxy
powder coated to a minimum thickness of 80 microns.
b. The Switchboard shall be completely self-supporting structure of the
required number of vertical sections bolted together to form a single
metal switchboard and can be easily separated from another; The
switchboard design shall be compact and is subject to Employer ‘s

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Section 6B: Part-II Power Supply System 46

approval.
c. Metal barriers shall divide the switchgear unit into compartments to
provide t
d. Totally separated 4 basic compartments from front to rear in form 4B as
follow:
 Circuit breaker compartment for installation of switching equipment.
 Bus bars Compartment is the chamber for bus bar installation both
horizontal and vertical.
 Cable compartment which will be provided for power cable
incoming and outgoing from the switchboard.
 Cable termination compartment which will be provided for
power cable termination for incoming and outgoing cables.
e. Each compartment as mentioned above shall have sheet metal safety
partition with minimum thickness not less than 2mm.
f. The top, sides and rear cover plates shall be removable and attached to
the frame with rustproof screws. The front doors shall be attached to the
frame with the hidden hinged and approved keys providing easy opening
to the doors.
g. All front plates used for mounting meters, selector switches or other front
mounted devices shall be hinged with all wiring installed and laced with
flexibility at the hinged side. The back-closure plate shall also be hinged
type and other closure plates shall be screw removable and small
enough for easy handling by one man.
h. Bus bar supports shall be formed of high-dielectric strength and low
moisture absorption moulded compound with the high impact strength
and low creepage surface and shall be designed for thermo dynamic
stresses to sustain ducting short circuit.
i. All current carrying parts shall be copper.
j. All steel parts of the panel shall be completely dry and chemically clean,
preventing corrosion, before being painted with the non-rusting primer
and not less than two stove- enamel-coating finished on top both inside
and outside. The finish shall be light grey with RAL standard colour,
unless otherwise directed by the Employer.
k. Ventilating louvers where required shall be provided on the sides and
backs of panels and shall be of approved design. All louvers shall be
screened.
l. Mimic diagram shall be plastic strip adhered on the front of the panel
showing single line diagram of the system. Mimic bus shall be 3 mm.
thick and 10 mm. wide.
m. A flexible ground strap shall connect all removable doors to the frame.
n. All the feeder cubicles shall be designed for feeder cables entry from the
top. Removable cover plates for all cable entrances shall be provided.
o. Suitable supports for cables and wiring shall be provided within the
cubicles to prevent undue stress on terminal connections.
p. The switchboards shall be provided with adequate lifting means and be
capable of being rolled or moved into position and bolted directly to the
floor without the use of floor sills.
q. Automatic Gas flooding of electrical panel, using linear heat sensing
tubes Fire trace or equivalent to be provided.
II. Bus bars and Supports.
a. The Main Bus bar shall be arranged throughout the switchboard in the
sequence of R- Y-B from left to right, top to bottom and front to back as
viewed from the front and to permit future additions. Bus bars shall be
bare copper and permanently labelled by phase for identification of each
phase, neutral and protective conductor as following:

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Section 6B: Part-II Power Supply System 47

 Phase R of three-phase ac. Circuit with Red coloured

 Phase Y of three-phase ac. Circuit with Yellow coloured
 Phase B of three-phase ac. Circuit with Blue coloured
 Neutral of three-phase ac. Circuit with Black coloured
 Earthing conductors with Green or Green-and-Yellow strip coloured.
 Horizontal and vertical bus bars should be insulated by heat shrink
HR PVC sleeve of 1.1kV grade.
 Insulation at joints and tap offs – FP shrouds.
b. The main Bus shall have a continuous current rating not less than the
main Incomer breaker, and the individual unit buses shall have a current
rating not less than that of the feeders. Buses shall be braced and
supported for the maximum allowable fault current of the incoming
breakers.
c. The Bus bar shall be 99.9% copper and shall be mechanically braced to
withstand the maximum symmetrical short-circuit current rating of the
main breaker in each assembly. The bus bar shall have sufficient cross-
sectional area to continuously conduct rated full fault current, for
operation in Mumbai environment ambient temperature and for limit
temperature rise within the requirements of IEC 60439-1. The current
carrying capacity of the bus bar shall be of the bare bus bar rating,
conforming to IEC 60439-1. The bus bar shall be designed to limit the
temperature rise to 30Deg C above ambient.
d. The neutral bus shall be furnished through the entire length of the
switchgear, and it shall be connected to the transformer neutral. Neutral
bus size shall not be less than full size of phase bus and shall have the
same bracing. All switchgear equipment requiring neutral shall be
connected to this bus. Bolted type terminal lugs shall be furnished for
connecting the neutral bus to the incoming and outgoing cables.
e. A ground bus, 50% size of phase bus, shall be furnished to the entire
length of the switchgear. All switchgear equipment requiring grounding
shall be connected to this bus.
f. All bolted bus joints shall be silver plated or tin plated, and all joints shall
be securely tightened to Manufacturer ‘s standards for each size of
hardware. Bolted, Nut and Washer for buses connection shall be high
tension class and the contact point between buses and terminal pad
shall be electrical compound painted.
g. Bus bar holder shall be of fiberglass reinforced polyester (FRP) type or
Epoxy-resin or manufacturer ‘s recommendation. The calculation sheet
and technical data showing the minimum spacing between the bus bar
holder to withstand the maximum force caused by short circuit current
from the bus bar holder ‘s manufacturer shall be submitted for approval.
The horizontal main bus bar supports, connections, and joints shall be
bolted to be free of required periodic maintenance.
h. Anti-Condensation Space Heaters
1 No. 100 W, 240 volts, single phase, 50 Hz AC Anti Condensation
space heaters controlled by thermostat and protected by 6 amps SP
MCB‘s shall be provided in each vertical section of main LT panel and 1
No. 60 watt Anti Condensation space heater shall be provided in each
cable alley of main distribution boards and sub distribution boards.
Supply and control equipment for the above shall be provided by the
Contractor.
III. Circuit Breakers
a. All circuit breakers installed in the switchboard shall comply with IEC
60947-1, IEC 60947-2, IEC 890, IEC 947, EN 60947 standard and IS
13947.

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Section 6B: Part-II Power Supply System 48

b. All circuit breakers shall be selected to perform in coordination

pattern along the protective lines.
c. Terminals of all circuit breakers rating < 225 AF shall be cable lugs
and the others shall be bus bar terminals.
d. Air Circuit Breaker (ACB)
The breakers above 630A shall be of Air Circuit Breakers and shall
comply with IEC 408 with the following characteristic:
1. Number of poles 4 poles
2. Continuous rated current As indicated.
3. Icu 50 kA (otherwise as
indicated in the drawing)
4. Ics 100% of Icu
5. Short circuit withstand Icu at 3 Sec.
6. Electrical Draw out type (EDO)
7. Spring shall be operated manually and motorized.
8. 2-steps operating mechanism
 Step 1: Charge closing spring.
 Step 2: After the spring is fully charged, press the button at the
front of circuit breaker to close the circuit breaker contacts.
The draw out mechanism shall hold the breaker rigidly in the
CONNECTED, TEST, and DISCONNECTED position (for draw out type).
Interlocks shall be provided which will prevent connecting the breaker to or
removing it from; the bus stabs unless the breaker is OPEN (tripped). All
spare contacts on breaker position switches and auxiliary relays shall be
wired to accessible terminal blocks. Each breaker shall be provided with
6 N.O and 6 N.C auxiliary contacts for the Employer ‘s use.
Each Air circuit breaker shall have an independent manual CLOSE push
button and a “TRIP” push button with stored energy or spring assisted
mechanism, and shall be provided with “CLOSED”, “OPEN” indicator
whether the mechanism is fully” Charged” and “Discharged” indicator
shall be provided.
A geared motor for automatic charging of closing spring shall be provided.
The motor charges the closing springs again immediately after the circuit
breaker has closed.
The closing springs can, however, be charged manually (using the relative
operating mechanism lever) in the event of a power supply failure or during
maintenance work.
Control contacts shall be made when the breaker is in the “CONNECTED”
position and break when in the “DISCONNECTED” position. The auxiliary
contacts shall make when the breaker is in the “CONNECTED” position
and break when in the “TE

ST.”
and “DISCONNECTED” position.
The circuit breaker shall be completed with accessories or devices as listed
below:
I. Auxiliary Switches
II. Time Delay Under-Voltage Trip
III. Shunt Trip
IV. Motor Operate
V. Alarm Switch
VI. Microprocessor adjustable Trip Unit as followings;
 Long-time protection (LT) can be continuously adjusted from 0.4–
1 time of ampere rated current (In) and can be continuously
adjusted time delay from 15–480 seconds at 5.5 times of ampere

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Section 6B: Part-II Power Supply System 49

rated.
 Short time protection (ST) can be continuously adjusted from
1.5–12 time of ampere rated current (In).
 Short time delay / Long time delay
 Instantaneous trip (INST)
 Thermal Memory up to 180 minutes.
 Ground fault protection, current pick- up adjustment and time delay
type.
VII. LCD display for current value, trip history, type of fault, pre-trip alarm
and main contact maintenance shall be built-in the circuit breaker.
VIII. Healthy unit LED for self-inspection.
IX. ACBs shall be provided with RS 485 ports for BMS (Building
Management System) connectivity through MODBUS protocol.
e. Moulded Case Circuit Breaker (MCCB)
The MCCB shall have the following characteristic:
i. All moulded case circuit breakers shall be 4 Pole, rated 415V AC, 50Hz
and shall be manual operated, draw out type, except MCCB for UPS
shall complete with motor operated, trip free from the handle and shall
be continuous adjustable microprocessor-based overload and
instantaneous short-circuit protective elements.
ii. Quick–make, quick–break and trip-free for over-current and short
circuit current and have a common trip on all multi-pole breakers with
internal tie mechanism.
iii. Drives shall be toggle operating mechanism, operated by trip-free
system and shall have clear indication whether the circuit breaker is
“ON”, “OFF” or “TRIP”. All breakers shall be provided with terminal
connectors for connecting to the outgoing feeders.
iv. De-rating factors shall be considered where applicable to compensate
for ambient temperature, enclosure, loading duty cycle, frequency, and
altitude.
v. All MCCB shall be installed the additional devices such as shunt trip,
under- voltage relay, auxiliary switch, alarm switch, rotary handle, pad
locking device, etc. to increase performance of the protection control.
vi. All MCCB shall have a 50 KA rupturing capacity. When necessary,
feeder circuit breaker shall incorporate reverse current tripping.
IV. Measuring Devices
a. Digital Multifunction Meter (MFM)
1. The MFM shall be panel mounted type, complete with LED display unit.
2. The display unit shall have a minimum of 3 rows with 16 characters per
row for value monitoring.
3. The MFM meter shall be able to measure true RMS values as follows
(minimum):
- Current : per phase
- Voltage : VL-L and VL-N
- Power : kW, kVAR, kVA per phase and total at 3 phases
- Power Factor : per phase and average at 3 phases
- Frequency : incoming electrical source (Hz.)
- Energy : kWh,kVARh,kVAh
- Harmonic : THDI and harmonic order from 3rd Up to 11th
4. The MFM shall be complete with built-in RS-485, Mod bus communication
port or RS- 232 communication ports (2 ports) to interface with SAS.
5. The MFM shall be operated at rated voltage does not exceed 600 VL-L and
current rating
< 5 A (from secondary of current transformer)
6. The accuracy of meter shall be:

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Section 6B: Part-II Power Supply System 50

- Current/Voltage : 0.5 %
- Power/Energy : 1.0 %
- Power Factor : 1.0%
b. Ammeter, Voltmeter
1. Each indicating instrument shall be semi-flush mounted, back connected,
dustproof, fully tropicalized, switchboard type with a dull black case for
mounting on a steel panel. Each shall be suitable for operation with
instrument transformers.
2. not used
3. not used
4. The ammeters for which the upper limit of the effective range does not
exceed 20 amps may be direct (series) connected. For higher range,
current transformer operated ammeter shall be used, and shall be
designed for a secondary current of 5 amps.
5. Accuracy Class of the meters shall be 1.0 or better.
6. Voltmeters shall be the direct connection type with the accuracy class 1.0
and scale range 0-500V.
c. Instrument Transformers
1. The current transformers shall be suitable for use with meters and tropical
proof type with a 5 A secondary and a primary rating equal to the breaker
continuous current rating. All current transformers shall have thermal and
mechanical limits coordinated with the short-time rating of the circuit breakers
with which they are used.
2. All current transformer secondary leads shall be brought out to shorting type
terminal blocks located in the instrument compartments and shall be
arranged to provide any combination of connections or polarity.
3. The current transformer shall not be used in dual-purpose role serving both
instrument and protective device.
4. Accuracy Class of the current transformers shall be in accordance with the
following function:

- Tariff metering : 0.2

- Non-tariff metering : 1.0
- Switchboard indicating : 1.0
instrument
- Protection : 5P20
5. The voltage transformer (if applied) shall be of the air-insulated type, with the
windings encapsulated in epoxy resin or other suitable synthetic material. All
voltage transformer secondary leads shall be brought out and connected,
through secondary fuses, to terminal blocks for external connections or
connection to other devices integral to the switchgear. These fuses and
terminal blocks shall be mounted in the instrument compartments.
6. On 3-phase, 4-wire systems, ammeter switches shall have four operating
positions, marked 'R', 'Y', 'B', 'N', and 'OFF' position, and shall enable the
single ammeter to read, in sequence, the currents in each of the three
phases and the neutral wire. Ammeter switches shall have 'make-before-
break' contacts and shall be connected so that the associated current
transformers are short-circuit when they are not connected to the ammeter.
7. On 3-phase, 4-wire systems, voltmeter switches shall have six operating
positions, marked 'R-Y', 'Y-B', 'B-R', 'R-N', 'Y-N', 'B-N', and 'OFF' position,
and shall enable the single voltmeter to read, in sequence, each of the three-
line voltages and each of the three phase-to-neutral voltages. Voltmeter
switches shall have 'break-before-make' contacts.
8. Under voltage relay shall be provided to turn off the main circuit breaker when

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Section 6B: Part-II Power Supply System 51

the voltage falls below premeditated level. Under voltage relay shall be 3-
phase, 4-wire, 415V, 50Hz unit. The under-voltage setting shall be adjustable
to 10% with time delay setting 0-10s. The under-voltage relay shall include
phase sequence and phase failure to trip the breaker when one phase falls
symmetrically.
d. Control wiring and terminal blocks
1. All control wiring shall be with flexible, stranded copper conductors,
switchboard wire and shall not be less than 1.5mm2 except for current
transformer circuits which shall not be less than 2.5mm2. All hinged wiring
shall be extra flexible. The wiring shall be neatly and carefully installed in
suitable wiring ducts with removable covers and shall be terminated at
suitable terminal blocks. Splices shall not be permitted in control wiring or
instrument leads.
2. The switchgear shall be provided with terminal blocks for termination of all
wiring devices and each terminal block shall be clearly identified to show
wiring which will be installed by the Contractor. Extra terminals, in a quantity
of not less than 25% of the active terminals, shall be provided on each
terminal block for circuit modifications and for future use. The terminal blocks
shall be located so that the accessibility to them will not be lessened by
interference from structural members or panel instruments. Ample space
shall be provided at terminal blocks for termination of external circuits.
3. Terminal blocks shall be of the rail-mounted type and shall be of screw less
type terminals 600V A.C. moulded block type with moulded insulating barrier
between terminals. Terminal connections shall be such that the conductors
shall be connected with the necessary maintained contact pressure.
Terminals shall be so constructed that the conductors can be clamped
between suitable su
4. rfaces without any significant damage either to conductors or terminals.
5. Terminal blocks for final connections for indication, instrumentation and
metering circuitry shall have test probe facilities for connections of test leads
and an integral disconnecting device to facilitate testing. Terminal blocks
utilized in the secondary circuits of current transformers and electrical
measuring transducers shall be of short- circuiting elements type.
6. Wiring shall be identified at each end with a legible printed black marking
sleeve. Sleeves shall be white tubing, sized to fit the insulation. Sleeves shall
be able to rotate on the wire so not to inadvertently hide the wire number.
7. Nameplates shall be furnished and mounted by the Contractor. Each
assembly, each piece of equipment mounted on an assembly, and each
power and control circuit shall be provided with a nameplate. All nameplates
shall be made of laminate plastic. Characters shall be black on a white
background.
8. All indicating, and pilot lamp assemblies shall be of cluster LED. The colour
caps shall be Red, Yellow, Blue, White, or as required.
3.19.5 Relays, CTS, PTS, Meters, Indicating Lamps Etc.
i. General
ii. This section covers specifications for Protection and Control Relays for
breakers, Instrument Transformers, Measuring Instruments, Push Buttons,
Indicating Lamps etc. required in LT and HT switchboards.
iii. Standards and Codes
iv. Updated and current Indian Standard Specifications and Codes of Practice will
apply to the equipment and the work covered by the scope of this contract. In
addition, the relevant clauses of the Indian Electricity Act 2003, Indian
Electricity Rules 1956, National Building Code 1994, National Electric Code
1985, Code of Practice for Fire Safety of Building (general): General Principal
and Fire Grading – IS 1641 as amended up to date shall also apply. Wherever

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Section 6B: Part-II Power Supply System 52

appropriate Indian Standards are not available, relevant British and/or IEC
Standards shall be applicable.
a. Application guide for Current Transformers IS 4201
b. Application guide for Voltage Transformers IS 4140
c. Application guide for Relays IS 3842
d. Electromagnetic Relays IS 5051
v. Protection and Control Relays
I. The Circuit Breaker shall have protection and control relays. Relays shall be
approved types complying with relevant IS and having approved
characteristic. Relays shall be flush mounted in dustproof cases. Relays
shall be arranged so that adjustments, testing and replacement can be
affected with minimum time and manpower.
II. In the case of C.T. operated thermal overload and magnetic instantaneous
short circuit relays, the overload relays shall be such that each phase can
be individually set depending on the phase unbalanced currents. The
relays shall have inverse time current characteristics and the magnetic
relays shall be time delayed with a minimum setting of 25 msec. varying up
to 300 msec. for discrimination without effecting the breaking current
capacity of the ACB.
vi. Current Transformers
I. Separate sets of CTs shall be provided for metering and protection. C/Ts
shall conform to IS 2705 (Part-I, II and III) in all respects. All C/Ts used for
medium voltage application shall be rated for 1kV. C/Ts shall have rated
primary current, rated burden and class of accuracy as specified. Rated
secondary current shall be 5A unless otherwise stated. The minimum
acceptable class for measurement shall be class 0.2s to 1 and for
protection class 5P20. C/Ts shall be capable of withstanding magnetic and
thermal stresses due to short circuit faults as applicable. Terminals of C/Ts
shall be paired permanently for easy identification of poles. C/Ts shall be
provided with earthing terminals for earthing chassis, framework, and fixed
part of metal casing (if any). Each C/T shall be provided with rating plate
indicating:
a. Name and make.
b. Serial number
c. Transformation ratio
d. Rated burden.
e. Rated voltage.
f. Accuracy class
II. CTs shall be mounted such that they are easily accessible for inspection,
maintenance, and replacement. Wiring for CT shall be with copper
conductor LSZH PVC insulated wires with proper termination works and
wiring shall be bunched with cable straps and fixed to the panel structure
in a neat manner. Facilities for a shorting terminal shall be provided.
III. Separate CT core for incomer 220kV/ 110kV for connection of Tri-vector meter of
CRP panel for employer metering and separate core for utility metering to be
provided at RSS.
vii. Potential Transformer
viii. PT ‘s shall conform to IS 3156 (Part I, II and III) in all respects. Primary and
secondary circuit wiring star - Star connected and voltage ratio shall be
33kV/√3/ 110/3or 415/√3/ 110/√3. Class of accuracy shall be 0.2 to 1. Over
voltage factor shall be 1.2
ix. Measuring Instruments
Direct reading electrical instruments shall conform to IS 1248 in all respects.
Accuracy of direct reading shall be 0.2s to 1.0. Meters shall be suitable for
continuous operation between 0 deg C and 50 deg C. Meters shall be flush

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Section 6B: Part-II Power Supply System 53

mounting and shall be enclosed in dust tight housing. The housing shall be of
steel or phenolic mould. Design and manufacture of meters shall ensure
prevention of fogging of instrument glass. Display shall be 0.5 inches, 7
segment bright LED’s. Suitable selector switches shall be provided for
ammeters and volt meters used in three phase system unless otherwise
stipulated; 96 mm x 96 mm instrument shall be used. The meter shall have a
built-in selector switch. The rating type and quantity of meters, instruments
and protective device shall be as required. The ammeter on motor circuit shall
be provided with suppressed scales to take care of shorting surges.
I. Ammeters
Ammeters shall be of digital type. Ammeter shall be with the latest Micro
controller-based technology, built-in selector switch for phase selection,
ultra-bright LED display, CT ratio programmable through front keypad and
auto ranging.
II. Voltmeters
Voltmeters shall be digital type range of 3 phase 415 Volt voltmeters shall
be 0-500. Volt meters shall be provided with protection MCB.
III. Watt meter
The wattmeter shall be of 3 phase digital type and shall be provided with a
maximum demand indicator if required.
IV. Power factor meters
Phase power factor meters shall be of digital type with current and potential
coils suitable for operation with current and potential transformers provided
in the panel. Scale shall be calibrated for 50% lag - 100% - 50% readings.
Phase angle accuracy shall be +40.
V. Energy and reactive power meters
Tri-vector meters shall be two elements, integrating type, kWH, kVA,
kVARH meters. Meters shall conform to IEC 170 in all respects. Energy
meters, kVA, and kVARH meters shall be provided with integrating registers.
The registers shall be able to record energy consumption of 500 hours
corresponding to maximum current at rated voltage and unity power factor.
Meters shall be suitable for operation with current and potential transformers
available on the panel.
Tri-vector meters installed in RSS for monitoring Traction & Auxiliary
Energy Consumption separately, should communicate with SCADA system
& should generate daily report
x. Indicating Lamps
Cluster LED type indicating lamps shall be provided for indication of phases
and Breaker positions for all circuits as required. Lamps shall be provided
with a fuse andd also shall be easily removed and replaced from the front of
the panel by manual means not requiring the use of extractors.
xi. Push Buttons
Push buttons shall be of non-hygroscopic material, non-swelling and fitted to
avoid any possibility of sticking. Contacts shall be of adequate strength and
have a positive whipping action when in operation.
3.19.6 Installation
[Link] All low voltage switchgears shall be installed on the location as indicated.
[Link] The main low voltage switchboard shall be installed on the concrete base at least
150mm. height.
[Link] All equipment shall be installed as recommended and certified by the
manufacturers.
3.19.7 Testing and Commissioning
i. Field Testing
I. Field inspection and testing for Switchboards shall occur after
installation is complete, feeders are terminated, and the room is

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Section 6B: Part-II Power Supply System 54

secure. Testing shall be conducted not more than 4 weeks before the
equipment is energized.
II. Testing scope:
a. Visual and physical inspection of equipment.
b. Check control wiring and metering.
c. Meter calibration
d. Ground fault protection.
e. Insulation testing for equipment.
f. Adjust circuit breaker setting based on recommendations in the
short circuit and co-ordination study.
g. Primary current injection testing of circuit breakers.
h. System grounding.
i. Function & operation testing for equipments inclusive of
interlocking scheme.
III. Certified test report:
a. Verify that the installation is in accordance with Standards and
regulations.
b. Verify that the equipment has been fully tested and is operational.
ii. Factory Testing
I. The Low Voltage Switchboard shall conform to IEC 60439-1 with type
test certificates issued by an independent and approved test authority
and type test shall include:
a. Temperature-rise limit
b. Dielectric properties
c. Short-circuit withstand strength.
d. Effectiveness of the protective circuit
e. Clearance and creepage distances
f. Mechanical operation
g. Degree of protection
II. The Low Voltage Switchboards shall be type tested and shall have
certificates tested for all ranges of Ampere rating, Degree of Protection
(IP), Short-circuit current, Temperature-rise limits as indicated on
above item.
III. The routine testing for the Switchboard at factory shall follow IEC
60439-1 and cover below lists.
a. Wiring and Operation testing
b. Protective measures
c. Insulation resistance.
3.20 Low Voltage Cables for RSS and station / Depot
3.20.1 General
i. The Contractor shall furnish and install the low voltage cables and
accessories as described and specified herein.
ii. This cable specification provides for use under present scope of works.
3.20.2 Standard and Reference
The power cable shall comply with the following codes and standards but not
limited:
1. IEC 60228/1978: Conductors of Insulated cables
2. IEC 60502-1/2004: Power cables with extruded insulation and their
accessories for rated voltage from 1kV – Part 1: Cables for rated voltage
of 1kV
3. IEC 60332: Tests on electric cables under fire conditions
4. IEC 61034-2/1997: Measurement of smoke density of cables burning
under defined conditions – Part 2: Test Procedure and Requirements
5. IEC 60754: Tests on gases evolved during combustion of electric Cables.
6. IEC 60287

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Section 6B: Part-II Power Supply System 55

7. IEC 60332
8. IEC 60502
9. IEC 61034
10. IEC 331
11. IEC 332
12. IEEE 48
13. IEEE 338
14. IEEE 404
15. SS 299
16. ASTM D 2863
17. ASTM B 173-64
18. BS 6007
19. BS 6347
20. BS 7655
21. BS 6469, BS 8491
22. BS 6387: Specification for performance requirements for cables
required to maintain circuit integrity under fire conditions.
23. IS 694: PVC insulated cables for working voltages up to and including 1100 V.
24. IS 1554: PVC insulated (heavy duty) electric cables.
25. IS 7098: Cross-linked polyethylene insulated PVC sheathed Cables.
26. IS 5578: Guide for marking of insulated conductors.
27. IS 732: Code of Practice for Electric Wiring Installations
28. IS 1255 - 1983: Code of practice for installation and maintenance of power
cables.
29. IS 8130 -1984: Conductors for insulated electrical cables.
30. IS 10418- 1982: Drums for electrical cable.
31. IS 10810- 1988: Methods of test for cables.
32. IS 3961- 1987: Recommended current rating.
33. IS 5891- 1970: Recommended short circuit rating of high voltage PVC cables.
34. IEC-332: Flammability Characteristics of cables
35. SS4241475class (F3) Flammability Characteristics of cables
36. ASTM-D-2843: Determination of smoke generation of outer sheath under fire.
3.20.3 Submittal
i. The Contractor shall submit the technical data, catalogues, cable installation
drawings, cable routes, cable connection and other necessaries of the low
voltage cables for approval before purchasing and installation.
ii. Routine test reports and Type test reports as necessary for each type of cable
in accordance with the standards as mentioned above or submittal of
certificated testing report for standard manufactured.
3.20.4 Material Description
i. Power cables shall be single, two, three or four conductors, rated for 1100V,
and shall be used in a 3-phase, 4-wire, 50 Hz, solidly grounded system.
ii. All cables shall be suitable for indoor and outdoor installations, wet and dry
locations, exposed to sunlight, in conduit, in cable tray as appropriate.
iii. The conductors shall be unbroken for the full length of the reels.
iv. Type of the low voltage cables shall be specified by the category of service as
follows:
a. Power Cables shall be FRLS /FRLSZH, XLPE insulated cable as
per the requirement.
b. Cables for life safety equipment shall be fire survival type cables.
c. Control cables 1100V FRLS, PVC/XLPE insulated cables, with/or
without shields. The control wiring within the switchboards shall be rated
for 105 deg C.
v. All wires, cables and control cables shall be FRLS type. The minimum cross-
section of conductors shall be not less than 2.5 sq. mm.

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Section 6B: Part-II Power Supply System 56

3.20.5 Component
i. PVC insulated cable.
1. Low voltage cables shall be copper conductors, PVC insulated, PVC
sheathed with flame retardant low smokeflame-retardante retardant low
smoke zero halogen (FRLSZH) compound and armoured conforming to
IS:1554 Part-I. Cables shall be rated for 1100 Volts. (2) All cables of size
6 mm 2 or larger shall be stranded.
2. Cables wiring inside the luminaries shall not be smaller than 1.0 mm2.
3. Control wires size shall not be smaller than 1.5mm2.
4. Cable wiring to the convenience outlets shall not be smaller than 2.5 mm 2.
ii. XLPE Cable
1. The cables shall be 1100 Volt grade XLPE insulated with PVC inner
sheath steel armouring and with an outer protective sheath of flame-
retardant low smoke (FRLS)
/ Flame Retardant Low Smoke Zero Halogen (FRLSZH) compound,
conforming to IS: 7098 (Part I). Cables shall have high conductivity
stranded copper conductors and cores colour coded to the Indian
Standards.
2. Fillers shall be used in the interstice of the multi-core conductor cable
where necessary to give the complete cable a substantially circular
cross section. Fillers shall be of polypropylene, non-hygroscopic
materials.
iii. Fire Survival Cable
1. The outer and inner sheath shall be of polyethylene or other material
that have low smoke and zero halogen (LSF or LSFOH). For multi-core
cable spacing between conductors shall be filled with filler.
2. Rated voltage of cable shall be 0.6/1kV.
3. The cables shall confirm to BS 8491 & BS 7629.
4. Cable shall not generate corrosive gases when burnt.
5. The Standard for Testing of Flame Retardant shall be conforming to IEC
60332-1.
6. Standard for Testing of Low Smoke shall be conforming to IEC 601034-3.
7. The Contractor shall submit the test report for approval.
iv. Control Cable
1. The minimum cross-section of conductors shall not be less than 2.5 sq. mm.
2. All control cables shall be suitable for installation in wet and dry
locations. The conductor shall be of soft or annealed strand uncoated
copper wire.
3. The cables shall be FRLS, PVC/XLPE, insulated suitable for use on
a copper conductor with a maximum operating temperature of 70 deg.
C.
4. Fillers shall be used in the interstice of the multi-conductor cable where
necessary.
to give the complete cable a substantially circular cross section. Fillers
shall be Polyvinyl chloride (PVC) rod or Polyethylene (PE) materials.
5. All the control cabling from DG set to AMF panel shall be of FS type
as per BS 8491.
3.20.6 Installation
i. In general, the Power cables shall be run in conduits, in cable tray and shall
be run concealed in ceiling, floor, and wall.
ii. No wire shall be pulled into the conduit system until it is complete in all details.
iii. Lubricant shall be used to facilitate wire pulling. Lubricants shall be approved
for use with the insulation specified.
iv. The splicing of large wires and cables shall be by compression type, solder
less wire connectors indented by special hydraulic tool. The splice shall be

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Section 6B: Part-II Power Supply System 57

insulated with plastic insulation tape such as Scotch Brand No.35. The
thickness of the tape shall not be less than three layers or at least the same
thickness as the wire insulation.
v. Compression type, solder less lugs indented by proper tool shall be used at the
end of all wires and cables and shall be connected to the screw type terminals
of the equipment and to the bus bars.
vi. The cut end of cables shall be treated to prevent seepage of water into the
cable. When unreeling cable from the cable drums, special care shall be taken
to prevent damage to the cables. When removing the cover of the drum, care
shall be taken to prevent damage to the cable sheath.
vii. The contractor shall provide all necessary materials for installation of the
cables, such as grounding lead wires, compression type terminals, metal
fitting, bolts and nuts including cable identification and felt packing to be
inserted between cable and cleats.
viii. The unoccupied space in cable knockouts and conduits after cable insertion
shall be filled, with duct seal to prevent insects and small animals from
entering the equipment housing.
ix. Where cables are buried in the ground the minimum depth of burial shall be
0.75 m. Cables shall be laid on 0.15 m and covered by a 7.5 cm. layer of clean
sand or indicated in Bureau of Indian Standards. Cables shall be covered with
tiles and or marking tape and the trenches backfilled to grade level.
x. Cables under roads shall be enclosed in ducts supplied and installed by the
electrical work.
xi. All cables shall be identified by means of cable tags fitted to each termination
point and at 30-meter intervals along the cable route.
xii. Cable route markers shall be installed above ground along underground cable
routes. These shall be located at 30-meter inter- intervals, at changes of
direction and at entries to buildings.
xiii. The Contractor shall be responsible for the supervision of the cable trench
excavation, sanding and backfilling, supply, and instaloftion to warning tape,
cable tiles and cable marker posts as detailed in these Specifications.
xiv. Cables shall be laid in one continuous length without joint.
xv. Cable Loops
1. At the time of the installation approximately 3 meters of surplus cable
shall be left at each end of the cable on each side of underground
straight through/tee/termination joints. At entries to buildings and such
other places as may
be decided by the Employer.
2. This cable shall be left in the form of a loop. Wherever long runs of cable
length are installed cable loops shall be left at suitable intervals as
specified by the Engineer- in- Charge.
xvi. Conductors with compression type terminals and insulation cover shall be
arranged in a neat manner on terminal box or equivalent terminals. The
contractor shall install plastic cable tie-wraps as required to neatly group
cables and to keep the weight of the cable from damaging terminations with
suitable identification.
xvii. Cable Entry into Buildings
Cable entry into buildings shall be made through Hume pipes recessed in
the floor. Hume pipes shall be provided well in advance for service cable
entries. The pipe shall be filled with sand and sealed at both ends with
bitumen mastic to avoid entry of water. Suitable size manholes shall be
provided wherever required to facilitate drawing of cables as per
requirements.
xviii. Laying and Drawing of Wires
I. Bunching of Wires

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Section 6B: Part-II Power Supply System 58

Wires carrying current shall be so bunched in conduits that the outgoing

and return wires are drawn into the same conduit. Wires originating from
two different phases shall not be run in the same conduit.
II. Drawing of Wire
The drawing of wires shall be done with due regard to the following
precautions.
a. No wire shall be drawn into any conduit, until all work of any nature, that
may cause injury to wire is completed. The burs in cut conduits shall be
smoothened before installation of conduits. Care shall be taken in pulling
the wires so that no damage occurs to the insulation of the wire.
Approved type bushes shall be provided at conduit terminations.
b. Before the wires are drawn into the conduits, conduits shall be
thoroughly cleaned of moisture, dust, dirt, or any other obstruction by
forcing compressed air through the conduits if necessary.
c. While drawing insulated wires into the conduits, care shall be taken to
avoid scratches and kinks which cause breakage of conductors.
d. The Contractor shall, after wiring is completed, provide a blank metal/
sun mica plate on all switch / outlet / junction boxes for security and to
ensure that wires are not stolen till switches / outlets etc. are fixed at no
extra cost. The contractor shall be responsible for ensuring that wires
and loop earthing conductors are not broken and stolen. In the event of
the wire being partly / fully stolen, the contractor shall replace the entire
wiring along with loop earthing at no extra cost. No joint of any nature
whatsoever shall be permitted in wiring and loop earthing.
III. Termination /Jointing of Wires
a. Sub-circuit wiring shall be carried out in a looping system. Joints shall be
made only at distribution board terminals, switches/buzzers and at
ceiling roses/connectors/lamp holder terminals for lights/fans/socket
outlets. No joints shall be made inside conduits or
junction/draw/inspection boxes.
b. Switches controlling lights, fans or socket outlets shall be connected to
the phase wire of the final sub circuit only. Switches shall never be
connected to the neutral wire.
c. Conductors having nominal cross-sectional area exceeding 1.5 Sq. mm
shall
always be provided with crimping sockets. Tinning of the strands shall
be done wherever crimping sockets are not available as per instructions
of the Engineer-in-
Charge
d. All wiring shall be labelled with appropriate plastic ferrules for identification.
e. Brass nuts and bolts shall be used for all connections.
f. Only certified valid license holder wiremen shall be employed to do
wiring/jointing work.
IV. Load Balancing
The Contractor shall plan the load balancing of circuits in 3 phase
installations and get the same approved by the Employer before
commencement of the work.
xix. Colour coding for the low voltage cables shall be as follow:
(1) Phase R : Red
(2) Phase Y : Yellow
(3) Phase B : Blue
(4) Neutral : Black
(5) Ground : Green or Yellow Strip Green
xx. Wiring Requirements and Measurement
Wiring for lights, fans and socket outlets shall be measured on Point Basis

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Section 6B: Part-II Power Supply System 59

as given in schedule of quantities and as elaborated below unless

otherwise specified.
xxi. Average wiring Length:
The point wiring basis for wiring for lights, fans and socket outlets shall
assume average wiring length and average conduit length per point based
on parameters stipulated herein. The average wiring length and average
conduit length forming the basis of point wiring measurement shall take the
electrical layouts of the entire Works into consideration.
xxii. Point wiring for Lights – Primary and Secondary Light Points.
a. In case of group control of lights (more than one light controlled by one
switch or MCB), wiring up to the first light in the group shall be measured as
a primary light point. Wiring for other lights looped in one group for switch
controlled as also MCB controlled lights shall be measured as secondary
light points. Primary light points for switch-controlled lights shall include the
cost of control switch.
b. Wherever primary light points are controlled by MCBs, switch shall not be
included in this measurement. Since the MCB shall be included in the item
of DB. Primary light points shall include the cost of circuit wiring (wiring from
DB terminal to the first switch in the sub circuit)
xxiii. Design Parameters: Wiring shall be carried out as per following design
parameters in recessed/ surface conduit/conduit cum raceway system.
a. Only looping system of wiring shall be adopted throughout. No joints
shall be permitted except at wiring terminals.
b. All accessories shall be flush type unless otherwise specified.
c. For estimation of load, following loads per point shall be assumed.
 Light points 60/100 watts or considering LED fittings.
 6 Amps socket outlet points 100 watts.
 Fan points 60 watts.
 Exhaust fan points 100 watts unless otherwise specified.
 16 Amp socket outlet points 500/1000 watts unless otherwise
specified.
d. Light and fan points shall be wired on a common final sub-circuit. Each
sub circuit shall not have more than a total of 10 nos. lights and fans or
load of 800 watts whichever is less unless otherwise specified. Load
calculations shall always be with energy efficient fittings.
xxiv. Scope of Point Wiring
I. Wiring for Lights
a. Primary Light Points:
Wiring for Primary light points shall commence at the DB terminals and
shall terminate at the ceiling rose/connector in ceiling box/lamp holder
via the control switch (for switch-controlled lights). Rates for Primary
light point wiring shall be inclusive of entire material and labour require
for completion of Primary light point including:
i. Recessed/surface conducting system with all accessories,
junction/draw/inspection boxes, bushes, check nuts etc. complete
as required,
ii. Wiring with stranded copper conductor FRLS PVC insulated
660/1100-volt grade wires including terminations etc. complete as
required.
iii. Control switch with switch box and cover plate of specified type
including fixing screws, earth terminal etc. complete as required.
The switch shall be applicable only for switch-controlled points.
This shall not be applicable for DB controlled Primary light points.
iv. Loop earthling with insulated copper wires.
b. Secondary Light points:

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Section 6B: Part-II Power Supply System 60

Secondary light points shall cover the interconnection wiring between

group controlled light fittings and shall be inclusive of entire materials
and labour required for completion of the secondary light point
including:
i. Recessed / surface conducting system with all accessories,
junction/draw/inspection boxes, bushes, check nuts etc. complete
as required,
ii. Wiring with stranded copper conductor FRLS PVC insulated
660/1100-volt grade wires including terminations complete as
required.
iii. Loop earthing with insulated copper wires.
II. Wiring for Ceiling Fans
Wiring for ceiling fan points shall be same as for Primary light points
and shall, in addition, include ceiling outlet box with recessed fan hooks
and installation of fan regulator.
III. Wiring for Exhaust Fans
Wiring for exhaust fan points shall be same as for Primary light points
and shall in addition include 3/5 pin 6 Amp socket outlet near the fan
along with plug top and a separate 6 Amp control switch.
IV. Wiring for Convenience Socket Outlets
a. Point wiring for 3 pin 6 Amp convenience socket outlets.
b. Point wiring for 3 pin 6 Amp socket outlets on point wiring basis shall be
the same as Primary light points and shall in addition include 3 pin 6
amp socket outlet with 6 amp control switch in Zinc Chromate MS box
with moulded cover plate including loop earthing of the third pin
complete as required and as detailed in scheduled of quantities.
c. Point wiring for 3 pin 16 Amp socket outlets.
d. Point wiring for 3 pin 16 Amp socket outlets on point wiring basis shall
be the same as Primary light point and shall in addition include 3 pin
16 amp socket outlet with 16 amp control switch in Zinc Chromate MS
box with moulded cover plate including loop earthing of the third pin
complete as required and as detailed in scheduled of quantities.
V. Sub mains wiring
Sub mains wiring shall be measured on a linear basis as per the length
of installed between terminations. This shall include a conduit system
with all accessories, wires and insulated loop earthing conductors as
detailed in schedule of quantities. This shall include termination of
wiring at either end. Wires only without conduits at either end required
for end terminations or taken inside switchboards shall be deemed
included in the linear running meter rate of sub main wiring in conduit.
3.20.7 Testing and Commissioning
i. Power cables, 1100/600 volts rated, shall be meagered phase-to-phase and
phase-to- ground before the equipment is connected and phase-to-ground
after the equipment is connected and all connections are tapped.
ii. Insulation resistance tests shall be performed by using a 500 V dc megger on
the 400 volts system. Insulation resistance shall be not less than 50 mega-
ohms per 1000 volts rating.
iii. Testing of Polarity of Non-Linked Single Pole Switches
iv. In a two-wire installation, a test shall be made to verify that all non-linked
single pole switches have been connected to the same conductor throughout,
and such conductor shall be labelled or marked for connection to an outer or
phase conductor or to the non- earthed conductor of the supply. In the three of
four-wire installation, a test shall be made to verify that every non-linked single
pole switch is fitted to one of the outer or phase conductor of the supply. The
entire electrical installation shall be subject to the final acceptance of the

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Section 6B: Part-II Power Supply System 61

Employer as well as the local authorities.

v. Wiring Continuity Test
All wiring systems shall be tested for continuity of circuits, short circuits, and
earthing after wiring is completed and before installation is energized.
vi. Performance
Should the above tests not comply with the limits and requirements as
above the contractor shall rectify the faults until the required results are
obtained. The contractor shall be responsible for providing the necessary
instruments and subsidiary earths for carrying out the tests. The above
tests are to be carried out by the contractor without any extra charge.
vii. Tests and Test Reports
The Contractor shall furnish test reports and preliminary drawings for the
equipment to the Employer for approval before commencing supply of the
equipment. The Contractor should indicate with the tender the equipment
intended to be supplied with its technical particulars. Any test certificates
etc., required by the local Inspectors or any other Authorities would be
supplied by the Contractor without any extra charge. All test reports shall be
approved by the Employer prior to energizing of installation.

3.21 110V DC & AC Control Voltage

3.21.1 The power supply for operating various equipment for control and monitoring will
be at 110V DC. This power shall be obtained through redundant battery chargers
and a set of 2 maintenance free Nickel Cadmium (VRPP) batteries sized for a
minimum of 8-hour backup. DCDB are to be provided at ASS also.
3.21.2 The low voltage supply of 415V shall be provided from AC Distribution Board
(ACDB), which in turn will be fed from essential load bus of low voltage switchgear
in the RSS. The supply from ACDB shall be fed to all the control circuits and the
battery charger. ACDB are to be provided at ASS also.
3.21.3 AC distribution board of 415V AC, 50Hz shall be fed from the essential load bus of
low voltage switchgear in the RSS. ACDB shall be equipped with annunciation for
all the phases. Protection for all inputs and outputs shall be provided with MCBs of
appropriate rating. ELCB shall be provided for protection against earth leakage.
The ACDB box shall be of steel sheet and shall support a chassis to carry the
equipment. It shall provide protection of IP 43 and shall be closed by a door with a
casement bolt and a key-operated lock. ACDB shall meet all the requirements as
per standard IS-13032
3.21.4 The cables used for the low voltage power supply and control shall have the
following characteristics.
a. All cables shall have copper conductor.
i. Semi flexible conductor shall be used.
ii. The minimum cross section of the conductor shall not be less than 2.5
mm2.
b. The minimum cross-section of current transformers secondary circuits
shall not be less than 6 mm2.
c. The minimum cross-section of voltage transformers secondary circuits
shall not be less than 4 mm2.
d. The voltage rating of distribution cables shall be 1100 Volts and 110
V dc for control supply.
e. Power and control cables shall have sheath earthing on both sides.
f. Power cables shall not have a voltage drop of more than 5%.
g. The cables shall have a minimum of 25% extra cores.
h. Different colour coding as per relevant IS shall be used for multicore cables.
i. Power and control cables shall have armouring.
 Power cables shall have 3 phase 4 wires with equal cross section for neutral

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Section 6B: Part-II Power Supply System 62

wire.
 FRLS cables up to 6 sq mm shall have PVC insulation and more than
6 sq mm cables shall have XLPE insulation.
 Cables and wires shall be treated to withstand flame propagation.
 All cables shall be suitable for indoor and outdoor installation, wet and dry
locations, exposed to sunlight, in conduit, in cable tray as appropriate.
 All cables shall have anti-termite and anti-rodent properties

3.22 110 V DC Battery

The Values/Information are to be furnished by the Contractor and values

declared are to be established by conducting actual tests/scrutiny of test
reports.

3.23 110 V DC Battery Charger

The Values/Information are to be furnished by the Contractor and values

declared are to be established by conducting actual tests/scrutiny of test
reports. Dual FCBC (Float -Cum-Boost) with redundancy (hot & standby) to be
provided.

3.24 Fire Protection

3.24.1 Fire protection system

Scope: The Fire protection system shall be designed to cater for protection of
Transformer and Switch yard and the control room building in the RSS.
3.24.2 Standards and codes

a. RDSO, NBC
b. NFPA 10 : Standard for portable fire extinguishers
c. NFPA 70 : National Electrical Code
d. NFPA 72 : National Fire Alarm Code
e. NFPA 101: ―Life Safety Code.
f. Relevant BIS codes.
EMC Directive 89/336/EEC Electromagnetic Compatibility
Requirement or any other latest code applicable.
3.24.3 Fire extinguishers
Portable fire extinguishers shall be distributed all over the area as per NFPA-10.
The types and uses of fire extinguishers shall be as follows:
a. 5 Kg, multipurpose ABC Chemical type fire extinguishers: All areas
except electrical rooms, generator rooms and fuel pump room.
b. 5 Litres, stored pressure water type fire extinguishers: All areas except
electrical rooms, generator rooms and fuel pump room.
c. 2 Kg CO2 fire extinguisher: Electrical rooms.
d. 9 Litres Aqueous film forming foam (AFFF) stored pressure type
fire extinguisher for Generator room and fuel pump room.
e. 10 Kg automatic ceiling mounted dry powder fire extinguisher for Sub-
stations and plant room.
f. 2 Kg Clean Agent Extinguishers for Server room, control room, data storage
area
3.24.4 Gas Based Fire Protection System Description:
a. Shall be provided for all the HT & LT Switchgear including UPS panels

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Section 6B: Part-II Power Supply System 63

within the present scope of work.

b. Designing, installation, testing and commissioning of UL listed, FM
approved total environment friendly gas based modular fire protection
system for Electrical Panels.
c. Scope of work includes but not limited to, providing all engineering,
drawings, and calculations necessary for installation and commissioning of
system.
d. Submit shop drawing of each panel showing exact location of cylinder,
trace tube inside the panel, mounting brackets for tubes and other
associated components.
e. Submit all necessary calculations for quantity of gas required for each
panel and capacity of cylinder needed for the system.
f. When the temperature of tube installed inside the panel increases to above
120 degC or the detection tube comes in the direct contact of flame, the
tube shall burst and initiates the diffusion of extinguishing medium which is
CO2 gas.
g. The system shall be meant for direct discharge of extinguishant through
the tube when rupture occurs. The diameter of tube for direct discharge
shall be as per calculations and Manufacturer recommendations but shall
not be less than 6mm under any condition.
h. All the necessary accessories required for operation of systems shall be
part of supply from single Manufacturer for UL listing of system. This shall
include but not limited to:
i. Non-return valve with removable gauze.
ii. Pressure switch used for system monitoring and transfer of signal to
fire alarm panel.
iii. Weight monitoring unit of cylinder.
iv. Isolation valve.
v. Self-contained alarm sounder.
vi. Trace tube fittings like Male / Female elbows, two way/four-way tee,
male stud, Straight connector, bulkhead etc.
vii. Auxiliary alarms contact for connection to fire alarm and BMS system.
 Shall be designed so that not affecting the IP ratings of Electrical
panels. The Contractor must coordinate with manufacturer of
electrical panels for provision of holes to run the tube and brackets
for mounting the tube. The entry of tube inside the panel shall be
though suitable size of connector.
 The tubing shall be manufactured from specially processed polymer
material to achieve the desired heat detection and delivery
characteristics. Provide minimum two runs of fire trace tube along
with any two sides of every compartment of the panel.
 The tube shall be capable of working even when contaminated with
oil, dust, and debris if the contamination will allow the heat to pass
through the tube.
3.24.5 Nitrogen injection fire prevention and extinguishing system for oil filled transformers
as per RDSO Spec. TI/SPC/PSI/TRNPWR/3201 of July 2010 or Latest:.
i. General Description
a. Nitrogen injection fire protection system designed for oil filled
transformers shall prevent tank explosion and the fire during internal
faults resulting in an arc, where tank explosion will normally take few
seconds after arc generation and extinguish the external oil fires on
transformer top cover due to tank explosion and
/or external failures like bushing fires, OLTC fires and fire from
surrounding equipment.
b. The system shall work on the principle of DRAIN AND STIR and on

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activation, it shall drain a pre determined quantity of oil from the tank
top through outlet valve to reduce the tank pressure and inject nitrogen
gas at high pressure from the lower side of the tank through inlet valves
to create stirring action and reduce the temperature of top oil surface
below flash point to extinguish the fire.
c. Conservator tank oil shall be isolated during bushing bursting, tank
explosion and oil fire to prevent aggravation of fire.
d. Transformer isolation shall be an essential pre condition for activating
the system. The system shall be designed to operate automatically.
However, it shall be designed for manual operation, in case of failure of
power supply.
e. The system shall consist of the following equipment:
1. Fire extinguishing cubicle placed on a plinth at about 5 10 meter
away from the transformer.
2. Control box placed in the control room.
3. Conservator Isolation Valve/Pre stressed non-return valve in the
conservator pipe.
4. Required number of fire detectors on the tank top cover.
5. Signal box fitted on the tank top or tank side wall.
ii. Scope
a. The scope of this specification covers design, engineering, supply,
testing at works before dispatch; installation, testing and commissioning
and performance demonstration of fire protection and extinguishing
system by nitrogen injection method. The necessary civil work which will
be required for construction of supports for pipe, soak
– pit for the storage of oil coming out from the transformer and plinth for
extinguishing cubicle is outside the scope of this specification & will be
done by PST contractor.
b. However, laying of oil pipe, nitrogen pipe, electrical cables, control
boxes, extinguishing cubicle, nitrogen cylinder, PRV, fire detectors and
other equipment & accessories required for installation, testing,
commissioning, and performance demonstration of the complete fire
protection system is in the scope of the tenderer. It will be the
responsibility of the tenderer to coordinate with the supplier of the Fire
Protection System for all the arrangements for the complete installation,
testing, commissioning, and performance tests. Notwithstanding the
technical specifications and requirements mentioned herewith, any
modification can be incorporated for correct operation of nitrogen
injection fire protection system without extra cost. The full details of the
same are required to be submitted to RDSO for approval.
iii. Operational controls:
The system shall be provided with automatic control for fire prevention and
fire extinction. Besides automatic control remote electrical push
button/Switch control on control box and local manual control in the fire
extinguishing cubicle shall be provided. Spare potential free contact for
interlocks are to be provided for ensuring that it should not be possible to
close HV or LV circuit breakers to energize the transformer after the
activation of the fire prevention and fire extinction system.
There shall also be provision for isolating the system by electrical and
mechanical during maintenance and/or testing of the transformer.
iv. System activating signals:
Transformer isolation shall be an essential pre condition for activating the
system. Transformer isolation through Master trip relay or circuit breaker
(HV and LV side in series) must be incorporated. Besides, two electrical
signals to be provided in series, for activating the system as under:

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Section 6B: Part-II Power Supply System 65

a. For Prevention:
i. Differential relay.
ii. Buchholz relay paralleled with pressure relief valve.
b. For Extinction:
i. Fire detector.
ii. Buchholz relay paralleled with pressure relief valve.
v. System equipment:
Fire Extinguishing Cubicle (FEC), placed on plinth at about minimum 5 meter
away from the transformer shall consist of:
a. Nitrogen gas cylinder of sufficient capacity with pressure regulator having
excess pressure relief device, pressure adjusting knob at bottom and falling
pressure electrical contact manometer with sufficient number of adjustable
NO contact Soil drainpipe with mechanical quick drain valve.
b. Electromechanical control equipment for oil drain and pre determined
regulated nitrogen release.
c. Pressure monitoring switch for backup protection for nitrogen release.
d. Limit switches for monitoring of the system.
e. Flanges on top panel for connecting oil drain and nitrogen injection
pipes for transformer.
f. Panel lighting
g. Oil drainpipe extension of suitable sizes for connecting pipes to oil pit.
h. Control box with activating, monitoring devices and line faults
indicators. (To be placed in the control room). It should have audio
visual alarm indication and push button switches.
i. Flow sensitive conservator Isolation valve / Pre stressed non-return
valve (PNRV) to be fitted in the conservator pipeline, between
conservator and Buchholz relay operating mechanically on transformer
oil flow rate with electrical signal for monitoring.
j. Fire detectors to be fixed on transformer tank top cover and detectors
shall have minimum IP55 class degree of protection.
k. Signal box to be fixed on transformer side wall for terminating cable
connections from fire detectors and PNRV.
l. All other consumables necessary for complete system.
vi. Other requirements for system installation:
a. Oil drain and nitrogen injection openings with gate valves on
transformer tank at suitable locations.
b. Flanges with dummy piece in conservator pipe between Buchholz
relay and conservator tank for fixing PNRV.
c. Fire detector brackets on transformer top cover.
d. Spare potential free contacts for system activating signals i.e.
differential relay, Buchholz relay, pressure relief valve, Circuit breaker
operation/transformer isolation (master trip relay).
e. Pipe connections between transformer to fire extinguishing cubicle and
fire extinguishing cubicle to oil pit.
f. Cabling on transformer top covers all fire detector to be connected in
parallel and inter cabling between signal box to control box and control
box to fire extinguishing cubicle.
g. Plinth for fire extinguishing cubicle. Oil pit with capacity as 10 % of total
oil quantity of transformer.
vii. Technical details:
a. Fire Extinction period
1. On commencement of Nitrogen injection: Maximum 30 seconds.
2. On system activation up to post cooling: Maximum 3 minutes.
3. Fire detectors heat sensing temperature: 130 deg C (+/- 2 deg C/ As
perRDSO)

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Section 6B: Part-II Power Supply System 66

4. Heat sensing area: 800 mm radius

5. Conservator Isolation Valve/Pre stressed non-return valve setting for
operation: min. 60 ltr. per minute
b. Power Source:
1. Control Box: 110 V DC
2. Fire extinguishing cubicle for lighting: 240 V AC
c. Facility shall be provided to test the system when the transformer is in
service,without actually draining the oil and injecting Nitrogen.
d. The nitrogen gas leakage to ensure the escape of leaking gas in to
theatmosphere and leaked nitrogen gas should not entered into the
energized transformer.
e. OEM to submit the drawings and design calculations for the number of fire
detectors, pipe sizing of drainpipe and Nitrogen injection pipe, Nitrogen
cylinder capacity, number of injection points, etc.
viii. Cabling:
a. Fire survival cables, able to withstand 750°C, 4 core x 1.5 mm2 for
connection of fire detectors in parallel shall be used. The test certificates
for the cables shall be submitted.
b. Fire retardant low smoke (FRLS) cable 12 core x 1.5 mm 2. for connection
between transformer signal box/marshalling box to control box and
control box to fire extinguishing cubicle shall be used.
c. Fire retardant low smoke (FRLS) cable 4 core x 1.5 mm2. for connection
between control box to DC supply source and fire extinguishing cubicle to
AC supply source, signal box/ marshalling box to pre stressed non-
return valve connection on transformer shall be used.
ix. Previous experience for qualifying supplier:
The supplier shall have a minimum experience of two years in the design,
manufacturing, installation, testing and commissioning of nitrogen injection
fire protection system on power transformers of similar or higher rating. At
least 2 sets of the system shall be in successful operation for a minimum
period of 2 years. The supplier shall furnish the details of nitrogen injection
fire protection systems supplied by them so far, giving order reference,
name, and address of the customer, indicating the dates of commissioning
as well as performance certificate of successful and satisfactory operation
for minimum two years from the customers. The supplier / vendor shall be
RDSO approved. System shall only be supplied after factory acceptance
test is completed in presence of employer/engineer.
x. Tests
a. Type tests
Type test reports including that for detectors along with declared
response time as per TAC ‘s letter shall be submitted along with the
tender.
The system shall be tested by UL, FM, LPC or a national testing body
(BIS or equivalent recognized laboratory. TAC ‘s approval, if any, shall be
submitted with the tender.
b. Factory test
Tests will be carried out on individual equipment of the system and
the total system in the supplier’s workshop in the presence of
purchaser’s representative.
c. Performance test
Performance test of the complete system shall be carried out after
complete installation at site by the supplier ‘s representative. These
tests shall include simulation and verification of the response time of
the complete system without actual draining of the oil and injection of

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Section 6B: Part-II Power Supply System 67

the nitrogen gas.

In addition to the above, additional tests as required necessary shall be
conducted.
d. Drawings and manuals
Detailed layout drawing along with the equipment drawing to be given in
the
tender along with complete bill of materials. After awarding of contract,
detailed dimensional drawing of the system complete bill of materials
including location and size of plinth for cubicle and recommended
capacity of oil soak pit shall be submitted for purchaser ‘s approval.
After approval 10 (ten) sets of all above drawings and 5 (five) sets of
operation and maintenance instruction manual (bound) shall be
submitted for purchaser ‘s use.
e. Spares:
One full set of spare nitrogen gas filled cylinder, 50% of the installed
no. of fire detectors (heat sensing element) shall be provided in
addition to additional other recommended spares. The list of
recommended spares is to be submitted along with the tender.
3.24.6 Fire alarm system design
a. The Fire alarm system including fire detection, a one-way voice
communication system, and a two-way fire department communication
system shall be provided. The system shall comprise of:
i. Automatic fire detection - overall operating characteristics & where
specific types of fire detection devices are required including
smoke detectors, heat detectors & pull stations (call points).
ii. Emergency voice/ alarm communication- Pre-recorded and live
voice announcements as per fire zones.
Fire department communications system - location of
communication devices and overall operating characteristics.
b. Initiating devices, notification appliances and interfacing devices shall
be provided throughout the area as per codes. A detector shall be
provided for above false ceiling area and below false ceiling as per
code/site requirements.
c. All the notification appliances, initiating devices and interfacing devices
provided shall be monitored and controlled by a control panel located at
suitable place in fire control room.
d. The fire alarm system shall be a fully addressable system with
automatic transmission of alarm events to Fire control room. The main
fire alarm control panel, including annunciation of devices and the one
and two-way voice communication system master controls, shall be in
the Fire Control Room.
e. The system includes smoke and Heat detection in areas required by
code. Detectors provided in the building are connected to the fire alarm
system. These detectors are analogy addressable devices capable of
providing at least two sensitivity settings. Activation of the first
sensitivity setting initiates a local alarm within the unit and sends a
supervisory signal to the fire control room. Activation of the second
sensitivity setting initiates the building fire alarm system and the
building alarm notification procedure. The purpose of this procedure is
to minimize the activation of the building fire alarm and notification
system from a false alarm in a unit.
f. The system also includes a manually operated two-way voice
communication system for fire department use. The system provides,
the fire department, a means of communicating between the master
handset in the fire control room and other handsets at strategic

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 68

locations throughout the building. Telephone handsets are provided on

every floor inside all exit stairway enclosures.
g. The power system for the detection system shall be designed for the
operation of DC power supply, where the input supply is AC.

*Note: In addition to the specifications mentioned above, Contractor shall follow

RDSO Specification TI/SPC/PSI/TRNPWR/3201 Annexure-1 for Nitrogen Injection
Fire Prevention and Extinguishing System to be used for Traction Transformers. In
case of any ambiguity between specifications mentioned above and specifications
given in RDSO Specification TI/SPC/PSI/TRNPWR/3201 Annexure-1, RDSO
Specification TI/SPC/PSI/TRNPWR/3201 Annexure-1 for Traction Transformers shall
be followed.
h. Linear Heat Detection System
i. Linear Heat Detection cable shall be supplied and installed at following locations-
 On the ceiling above top of cable tray at RSS.
 In the RCC cable trench, cable cellar inside RSS.
ii. The Linear Heat Detection System shall use Raman based OTDR technology that includes
the Optical Fiber Linear Heat Sensing Cable and Linear Heat Detection Control unit that
Houses the electronics.
iii. The Optical Fiber shall be connected to the control unit on either end to a single control unit
to ensure redundancy and full coverage of the protected fire zones even if the cable is
broken / cut / damaged at one point. FRNC (Flame retardant non corrosive) coated
thermoplastic fiber optic cable should be supplied.
iv. The thermoplastic sensor cables shall be tested and approved for functional integrity for 2
hours at temperature up to 750⁰C according to IEC 60331-25.
v. A cable break or fire / alarm condition shall be initiated, located / identified by the system
itself.
vi. The system shall be fully programmable with respect to zone lengths and alarm thresholds.
Alarm set-points may be set to fixed temperature, deviation from average and/or rate-of-rise
temperature, which should further be adjustable false alarms.
vii. The control unit shall have a min. 44-volt free non-latching, certified relay outputs. (1 contact
is for signals and remaining 43 contacts are programmable zonal relay contacts).
viii. The control unit shall have the capability to be interfaced via an Ethernet link or USB port for
interface to a PC and Modbus over Ethernet (Modbus TCP) for a site control system. The
PC shall include program / licensed software for displaying real time zone temperature.
ix. A real time temperature trace of the sensor cable shall be displayed on the BMS - PC and
alarm messages highlighted and acknowledged, including identification of the actual position
of a cable break / fire condition.
x. All accessories such as Control Units, fittings, fastenings, sleeves, straps, staples, clips
(mountings), rings, test terminals, junction boxes, etc. which are required for interconnection
with the fire annunciation system shall be provided as per manufacturer recommendation.
xi. The control unit should be able to operate in temperatures between -10 and +60 deg C on a
continual basis without loss of performance.
xii. The system should be internationally approved for fire detection by UL according to US
standards.
xiii. Typical power consumption shall be less than 20 W (room temperature / 25 deg C)
xiv. Laser Source shall be based on a Laser Diode according Class 1 M, as specified by
EN60825-1 (2000). The Laser output power shall be less than 20mW.
xv. The LHD Cable should be installed above the cable trays at RSS and at top in the RCC
cable trenches of RSS. It will be preference to install at the highest practical point. All the
installation shall be done under the guidance of manufacturer.
xvi. The LHD manufacturer should be able to provide local support.

DATA SHEET- Linear Heat Detector & Sensing Cable

Type : OTDR based Fiber Optic Linear Heat Detection
Certified Range : UL 521 (1ch x max.10 km, 2ch x max.8km,4ch x
max.6km)

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 69

Operating Voltage/Power : 10 to 30 V DC/ 23W

Controller Operating Temp : -10 dep. C to 60 dep. C
Spatial Resolution : flexible setting 1.0 - 8.0 meters
sampling resolution : 0.5 or 1.0 meter
Response Time :10/20 seconds
Laser Safety : CIass 1M, as specified by EN60823-1 (2000)
Laser Power :<20mW
Detector / Control Unit : LEDs or LCD for power on / fault/ alarm
condition: Shall consist of 43 +1 integrated
programmable volt free relay contacts
PC Interface : Via Ethernet/ USB (Integration with BMS &FACP)
SCADA Interface : Modbus over Ethernet (Modbus TCP)
Enclosure Rating : IP 66 (wall-mount)
Mounting : Wall mounted or 19" Rack Mounted
Fire / Break Detection : Unit should detect the exact location of an abnormal &
Redundancy hot spot in a range of 1- 8 meter. System
shall be capable of automatic measurement from both
ends of the fibre even in the event of break for ensuring
continued fire protection over the entire length.
Plastic Sensor Cable
Nominal Cable Diameter : 4mm
Max. Bending Radius : 80mm
Max. Crush resistance : 100 N/cm
Max. tensile strength : 1000 N (short term)
Cable Operating Temp. : -40 deg. C to +85 deg. C (short term<
one hour +150 deg.C)
Cable Integrity (Functional} : 750°C / 2 hours
Cable Optical Parameter : 50/125pm graded index, Multimode
Fiber
EMI/RFI Limitations : None, totally immune (Sensor cable)
Approvals : UL521 / ATEX

3.25 25kV Traction and return Cables.

25 kV, 240 sq. mm Single Core Copper Cables shall be provided from traction
transformer to 25kV GIS incomer, from 25 kV GIS Outgoing to 25 kV Over
Head Equipment. Similarly, 240 sq. mm 3.3kV cables from traction
transformer to buried rail (min.100 X 10 mm Cu Flat) shall be provided for
return path conforming to IEC 60840 with specified voltage as 26/45kV (52kV)
grade.
3.25.1 Standards:
The 25kV Cables shall satisfy the requirements given below and shall also
comply with standards in force when the cables are manufactured, particularly
those which are in the following table. (Unless otherwise stipulated in the
specifications, the latest version of the following Standards shall be

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 70

applicable). In the case of available RDSO spcifications, same shall be

followed.

Standards Description

Power cables with extruded insulation and their accessories

for rated voltages from 1kV (Um = 1,2kV) up to 30kV (Um =
IEC 60502 36kV) - Part 2: Cables for rated voltages from 6kV (Um =
7,2kV) up to 30kV (Um
=36kV)"
IEC 60228 Conductors of insulated cables

Power cables with extruded insulation and their accessories for

IEC 60840 rated voltages above 30kV (Um = 36kV) up to 150kV (Um =
170kV) -
Standard Test Method for Density of Smoke from the Burning or
ASTM D 2843 Decomposition of Plastics

Standard Test Method for Measuring the Minimum Oxygen

ASTM D 2863 Concentration to Support Candle-Like Combustion of Plastics
(Oxygen

Cross linked polyethylene insulated thermoplastic sheathed

IS 7098 Part 2 cables, Part 2: for working voltages from 3.3kV up to &
Including 33kV.

The Contractor shall calculate cross section area of the cable as per the
required current carrying capacity of transformer with overloading condition and
other load requirement and to verify cross-sectional area of these cables as
regard to the actual laying arrangement. Same shall be verified in simulation
studies also.
The various Constructional features required for the 25kV cables are as under:
i. Conductor
The conductor shall be formed from annealed copper conductor with required
size according to class 2 (Stranded compact circular) complied with IEC 60228
latest publication.
ii. Insulation
The Insulation shall be XLPE. The insulation shall have a higher degree of
Cross- Linking, free from contaminants and air voids, heat resistant and
shall be applied by the extrusion process.
The XLPE insulation shall be suitable for use on power cable in wet and dry
locations at conductor temperature as per IEC 60840. For this purpose, short
circuit current in conductor is to be considered as 16 kA for 3 seconds.
The conductor with screening shall be provided with XLPE insulation
applied by extrusion. The nominal thickness of insulation shall not be less
than 10 mm subject to tolerance as per IEC – 60840, clause 10.6.2.
The insulation compound shall be of high quality, and shall be heat,
moisture, ozone, and corona resistant. XLPE compound should be from a
reputable manufacturer with satisfactory service experience of more than 5
years. The Insulation shall be applied by triple extrusion and vulcanized

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Section 6B: Part-II Power Supply System 71

using dry curing process to form a compact homogenous body free from
micro voids and contaminants.
iii. Insulation Screen
The insulation screening shall be applied direct upon the insulation and shall
be of a layer of extruded semiconducting thermosetting compound firmly
and totally bonded to the insulation. Semiconducting compound should be
from a reputed manufacturer e.g. Borealis, Sweden or NUC Japan or
equivalent with satisfactory service experience of more than 5 years.
The conductor screen, insulation & insulation screen shall be extruded in a
single process (triple extrusion).
The screen placed over the insulating envelope shall consist of a non-
metallic semi- conducting part, associated with a metallic part. The non-
metallic part, consisting of a semi- conducting material, will be easily
separable from the insulant to facilitate cleaning of the latter. This semi-
conducting material will have to constitute a mat which protects the
insulation from expansion strains. The metallic part applied over the semi-
conducting part will consist of stranded wire with copper tape.
iv. Water Barrier:
The water barrier shall be semi-conducting water swellable tape to be
applied over the extruded insulation screening to block and prevent
moisture propagation in a longitudinal direction. The semi-conducting tape
shall be suitable for the operating temperature of the cable and compatible
with the insulation. Semiconducting Tape The semiconducting tape(s) should
be applied over the insulation screen.
v. Metallic Screen
The metallic screen shall be plain copper round wires applied helically over
the semi- conductor bedding tape(s). The Area of copper wire shall be able
to withstand specified earth fault current. Bidder must submit the
calculations giving details of the area of copper wire screen.
An annealed plain copper binder tape shall be applied in the form of an open
helix, over the copper wire screen.
vi. Inner Sheath: The Inner sheath shall be provided with extruded PVC
compound.
vii. Armouring: Double Tape Aluminium armouring should be applied over the inner
sheath and the thickness of the same should be as per IEC 60502 as
applicable.
viii. Outer Protective Sheath: The anti-corrosion outer protective sheath, applied
directly over the metallic screen, whose grade is compatible with the operating
temperature of the cables; it must ensure protection against corrosion. The
nominal thickness of this sheath will be determined according to the
requirements set forth in standard IEC 60502.
ix. The cable shall be insulated with XLPE, with semiconducting screen over a
copper conducting core and insulating envelope and FRLSZH type PVC
protective sheath for the cables to be laid outside.
x. Short Circuit Rating of Metallic Sheath/Screen The area of plain copper round
wire screen
xi. shall be designed to meet the requirement of the system short circuit rating of
16 kA for 3 [Link] and Climatic Conditions:
xii. The entire equipment will be designed for operation in hot weather, according to
the climatic conditions defined in General Specifications.
xiii. The equipment will be sturdy and properly protected against corrosion. This
protection shall be suited to the various environmental conditions encountered
in the various parts of the network.
xiv. It must be noted that environmental conditions will be very severe during
construction; these conditions shall not be the cause of any alteration of

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Section 6B: Part-II Power Supply System 72

equipment or material whether already installed or simply stored.

xv. MAINTENANCE & LIFE
The cable should be designed for maintenance free, the best service life best
in the industry and not less than 30 years for all types of installation & under
prescribed environmental conditions.

3.25.2 Characteristics
i. Conducting Core
The conducting core shall be made of bare annealed copper, according to
clause 2 as per publication IEC 228.
ii. Core Screen
The screen placed over the core shall consist of extruded covering of semi-
conducting material.
iii. Insulating Envelope
The insulating envelope shall consist of extruded solid dielectric, made of
chemically cross- linked polyethylene. Its nominal thickness and tolerances
comply with the requirements set forth in standard IEC 502-1.
iv. Insulating Envelope Screen
a. The screen placed over the insulating envelope shall consist of a non-
metallic semi- conducting part, associated with a metallic part.
b. The non-metallic part, consisting of a semi-conducting `material, shall
be easily separable from the insulant to facilitate cleaning of the
latter.
c. This semi-conducting material shall constitute mats which protect the
insulant from expansion strains.
d. The metallic part applied over the semi-conducting part shall consist of
stranded wire with copper tape for 10kA fault current.
v. Outer Protective Sheath
I. The anti-corrosive outer protective sheath, applied directly over the
metallic screen, consists of a heat-setting mix of Fire-retardant polyvinyl
chloride, whose grade is compatible with the operating temperature of
the cables. It must ensure protection against corrosion.
II. The nominal thickness of this sheath shall be determined according to
the requirements set forth in standard IEC 502-1
III. The protective sheath shall carry the indications listed below, in letters
and digits at least 6 mm high:
a. MMRDA
b. cross-sectional area of conductors,
c. specified cable voltage,
d. Manufacturer ‘s name.
e. Line no.
vi. Straight through Joints and End Terminations
I. 25kV straight through joints & end terminations of heat shrinkable type
conforming to IS 13573 Standards shall be used after taking approvals
from the Employer. The jointing and terminations shall be carried out as
per manufacturer's instructions duly ensuring all precautions & all
required tests including continuity test, insulation resistance test and Hi-
Pot test as specified in IS/IEC standards.
II. Due to less time availability for maintenance and repair, due
consideration shall be given to connection processes & shall be having
the following characteristics:
a. Quickness of execution,
b. Possibility of replacement without having to disturb the cable.
vii. Cable Laying
The 25kV traction cable from traction transformer to 25kV GIS incomer and

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Section 6B: Part-II Power Supply System 73

return cables from transformer to buried rail (min.100 X 10 mm Cu Flat)

shall be laid in the ground / air as per IS:1255 after taking route approvals.
The cables shall pass all the tests stipulated in RDSO/IEC 840. The sleeves
and the insulating materials used shall meet the requirements mentioned in
this specification.
viii. Installation, Testing and Commissioning
1. The installation, testing and commissioning of all the equipment shall be
carried out by the Contractor as per relevant standards.
2. The Contractor shall carry out all the tests and checks required to
guarantee the Employer of the good construction and the satisfactory
operation of the entire installation. Also, the Contractor shall co-ordinate
and arrange testing equipment etc. required for testing different
equipment as and when needed. The equipment shall be subjected to all
the tests required as per the relevant IEC or other standards mentioned in
the Technical Specification. The test reports shall be submitted to the
Employer for his approval. After getting the approval, integrated testing
and commissioning shall be carried out duly coordinating with
Designated Contractors during which different operating conditions
(putting into service, normal actuation, failure/ tripping) will be
demonstrated to Employer for his satisfaction.

3.26 Specifications for Metal Clad Indoor SF6 Gas Insulated Switchgear (GIS) for 220 kV

3.26.1 Scope
This specification covers requirements of Gas Insulated Switchgear (GIS) rated for
220kV indoor use on 50 Hz Power systems as applicable.
3.26.2 Codes and standards
The applicable Codes and standards are specified in Chapter-14 (Annexure -1).
3.26.3 Components of GIS assembly
The components of switchgear assembly shall essentially consist of the
following items and their accessories specified in subsequent clauses.
a. Circuit breaker
b. Disconnect Switches
c. Ground switches (Maintenance and High-Speed types), in each feeder
(Incoming & outgoing)
d. Potential transformers
e. Current transformers
f. SF6 Surge Arrestor (where applicable)
g. SF6 to air bushing for circuit terminations (where applicable)
h. Terminations - overhead line, overhead line via power cable and
transformer (SF6 to Oil bushing) terminations
i. Bus enclosures and accessories with different bus arrangements.
j. Local control panels and operating mechanism cabinets.
k. SF6 GIS Bus duct Indoor/outdoor (where applicable)

3.26.4 Design and constructional features

i. General
a. The switchgear assembly shall be suitable for indoor or outdoor installation.
Constructional features shall be selected not only to withstand satisfactorily
the specified atmospheric conditions but allow for thermal expansion during its
normal use, without any damage. Normally, GIS switchgear shall be installed
indoor.
b. One Set of three phase enclosure GIS end Covers for bus with double
configuration (both ends of both bus-bars) with additional gas compartment to
facilitate future extension of the GIS with all bays remaining in service, shall be

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Section 6B: Part-II Power Supply System 74

in contractor’s scope of work. This additional gas compartment shall be

provided with SF6 gas density monitor and annunciation shall be provided on
LCP.
c. The three phases of components of each bay shall be arranged in compact
and modular design with individual equipment modules connected together to
form a complete assembly for the intended GIS Bus configuration. The GIS
shall be design with double busbar system
d. The equipment and connections within each compartment shall be arranged to
allow removal and replacement of any section both during normal and abnormal
(fault) working conditions with minimum disturbance to adjacent, in service,
pressurized sections.
e. The GIS Equipment shall be complete with all necessary supports, platforms,
ladders, galleries, staircases, catwalks, mechanism cabinets, internal cable
raceways etc. for each bay and it shall be of modular construction and
extendable design. All structures, galleries, staircases, and walkways shall
conform to the relevant Occupational Safety and Health Administration
(OSHA) standards. To access the LCC panel above the man height,
permanent platform to be provided in front of the LCC Panel. Further,
Maintenance Platform Trolley to be provided in each RSS / GIS.
f. Minimum assembly work shall be envisaged during installation. The GIS shall
be supplied as completely factory assembled switchgear bays, within
shipping/transportation limits.
g. The GIS shall be installed on suitable mounting pads or supporting
frames/structures with provision for levelling, including fasteners to foundation,
which shall also be included in the supply. Support structures shall be
designed and fabricated to withstand the short circuit forces of the ground fault
current as well as prevent excessive vibration during switching operation or
faults.
h. The GIS shall be provided with expansion joints and flexible connections,
where several enclosures are connected in the longitudinal direction, such as
the main bus. Expansion joints provided for installation alignment shall be
locked in place when alignment is complete. Expansion joints for
compensation of thermal expansion and installation tolerances shall have the
means to preserve mechanical integrity of the enclosure and the plug-in
contacts for the conductor

i. All modules of the GIS switchgear and components of the same rating and
construction, which may need to be replaced, shall be completely
modular/interchangeable.
j. The GIS interface points shall be carefully coordinated with other equipment
such as cables, transformers, reactors, capacitor banks, etc., supplied by other
manufacturers to ensure full compatibility.
k. The switchgear and all its components and accessories shall be designed for
minimum maintenance during service. The manufacturer shall state the
minimum interval between minor inspections (which will be restricted to visual
checking and adjustments of external parts only) and major
inspection/overhaul, including refilling or replenishment of gas and cleaning of
the contaminant or filter in the circuit breaker chamber(s). Suitable openings
shall be provided in the circuit breaker, disconnect and grounding switch
modules for major inspection/adjustments. The bearings and other such parts
shall be permanently lubricated for the entire service life.
l. To facilitate transport and handling, lifting eyes or other suitable attachments
shall be provided with each GIS module.
m. Each module of switchgear, consisting of individual elements intended to be
directly connected together, shall be constructed as a transportable assembly
suitable for shipping and transportation without being dismantled.
n. All new gaskets, sealants, and desiccants for permanent sealing of all field
joints and all access covers, removed during assembly, shall also be provided.
o. The Bus and all current carrying parts shall be made of copper. In certain
specific requirements, electrolytic copper may be provided. All interconnecting

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Section 6B: Part-II Power Supply System 75

sections of current transferring parts shall be silver-plated. Joints and

couplings between dissimilar metals should be avoided to prevent galvanic
corrosion.
p. All steel structures above grade level required for supporting the switchgear,
including SF6/Air Bushing supports and feeder bus duct supports, etc., shall
be hot dip galvanized and shall be supplied as a part of switchgear package.
The supporting steel work shall have a minimum thickness of 0.13 mm
equivalent to 130 microns (915gms/m2). All welding in GIS shall conform to
Section IX of ASME code or equivalent.
q. A partition separating a compartment filled with insulating gas from a
neighboring compartment such as a cable box, filled with liquid, shall not show
any leakage affecting the dielectric properties of the two media.
r. All piping for SF6 gas, hydraulic and pneumatic operating mechanism
including their fittings shall be made of copper, brass or stainless steel and
shall be of welded construction.
s. All external connectors and terminal pads shall be made of aluminum or
copper with tin- plating.
t. By design, there should be no need for gas works during the whole time on
site, not even for exchanging a center panel or extending the switchgear at
later stage, e.g. no gas handling shall be necessary during the anticipated
service life of the switchgear, under normal operating conditions. (The gas-
filled clad compartments are to be designed to be maintenance-free and
hermetically sealed pressure systems in accordance with IEC 62271-200).
The switchgear panels shall be filled with gas and checked for leakage in
the factory. For a proper recycling / emergency replacement, a gas valve in
gas compartment must be provided. In addition, the standard tools for filling
the SF6 Gas also must be provided.
u. It shall also be possible to carry out high voltage testing (AC and DC) of the
cable cores without having to open the breaker assembly or SF6 chamber
without disconnecting the cable. A suitable adapter for such testing should be
provided.
v. The GIS switchgear design shall complfull-serviceull service continuity as per
IEC 62271- 203 Annexure F.
w. All Alarm & tripping features of GIS as recommended by OEM should be
implemented
x. Separate control and relay protection panel shall be provided for 220 kV bays
in the Scope of this contract.
ii. Ratings
a. The specific ratings of the GIS equipment shall be as specified in the
Technical Sheets.
b. The switchgear shall be capable of carrying the specified rated current
continuously at the specified ambient conditions as per Technical Sheets,
without temperature rise of various parts exceeding the limits stated in IEC
60694, or equivalent ANSI standards. The maximum temperature of the
external surfaces, normally handled by an operator, shall be 70°C for the
outdoor portion of enclosure and 40°C for indoor enclosure.
c. The switchgear and its associated apparatus shall produce minimum noise
during service. The maximum noise level shall be indicated by the
manufacturer and be subject to approval by the Employer.
d. All equipment and components of the switchgear including bus support
insulators shall be free of partial discharges when operated at the rated
voltage. The partial discharge intensity at 110% rated voltage shall not exceed
10 pC over a maximum background level of 5 pC.
e. The insulation level requirements shall be as specified in Technical Sheets
and in conformity with IEC 60694 and IEC 60071.
iii. GIS Enclosure
 The GIS shall be of either single-phase encapsulated type or three-phase
encapsulated type for voltage levels specified in Technical Sheets.
 The enclosure shall be capable of sustaining without damage all mechanical,

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Section 6B: Part-II Power Supply System 76

electrical, and thermal shocks that may occur in service during normal and
fault conditions, including pressure effects of internal fault arc current of
specified short circuit level and time. The enclosure assembly, material and
design shall be such as to minimize induced electrical losses and heating
effects which could occur in service under normal and faulty conditions.
 The creation of a single gas zone for single-phase type GIS enclosures by
external piping connection between the phases is not acceptable. Also,
external piping connection (with normally open valve) to create common gas
zone (between same phase) in single-phase type GIS is not acceptable.
 The GIS enclosure shall be safe to touch and fully ensure operational security
and personnel safety under all normal and fault conditions with the maximum
allowed induced voltage in the enclosure of 65 volts.
 The enclosure shall be designed to withstand internal fault at the rated short
circuit current level and consequent pressure for a period specified in
Technical Sheets
 The GIS enclosures shall have a minimum burn-through time in accordance
with IEC 62271-203.
 Gas enclosures and flange joints shall be designed to withstand 1.5 times the
operating pressures by provision of suitable reinforcement(s) at all the required
locations.
 The construction and thickness of the GIS enclosure shall conform to
ANSI/ASME Boiler and Pressure Vessel Code and ANSI/ASME B31.1,
CENELEC EN 50052 & EN 50064 or equivalent.
 Interior finishing material of the enclosure shall not contain any substances
which could contaminate the enclosed SF6 gas or affect its insulating
properties. The GIS enclosures may be provided with suitable devices like
particle traps to eliminate conducting particles which shall be based on the
design of the manufacturer but is not mandatory if the manufacturer does not
practice the use of Particle trap as a standard design requirement.
 The exterior surface finish of the enclosure shall be finalized in agreement with
the Employer. The actual colour shade shall be based on the end user‘s
requirement. The protective finish shall prevent deterioration due to corrosion,
humidity, temperature, ageing due to weather, attack from fungus or rodents
for minimum of five years.
 SF6 Gas monitoring and service piping including all fittings and accessories
shall be of copper, brass or stainless steel.
 The GIS enclosure shall have an enclosure protection Class of IP 54. All
components of the GIS shall be able to withstand the environmental conditions
for outdoor application including temperature variation during the various
seasons.
 The degree of protection for all terminal boxes, operating mechanism
enclosure, control cabinets, auxiliary equipment enclosures and all
accessories except LCC (IP 41) shall be IP 33 for Indoor application and shall
be IP 54 for Outdoor application.
iv. GIS Gas Sections
 The GIS shall be divided into compartments separated by gas barriers. The
gas barriers shall be suitably identified on the outside of the GIS.
 Long bus runs shall be sectionalized into several gas compartments such that
failure in any gas section does not affect the adjacent gas sections.
 The sections shall be so designed as to minimize the extent of plant rendered
inoperative when gas pressure is reduced, because of excessive leakage or
for maintenance purposes. The design shall be such as to minimize the
quantity of gas that has to be evacuated and then recharged before and after
carrying out maintenance of equipment. The cable box where cable-sealing
end is installed shall have its own independent gas compartment, with gas
monitoring.
 Gas compartments shall be designed in such a way that voltage transformers
can be easily removed without degassing any of the bus bar compartments.
 The gas section barriers shall be capable of withstanding the differential

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Section 6B: Part-II Power Supply System 77

pressure due to full vacuum on one side and 1.5 times rated gas absolute
pressure on the other side.
v. Gas Seals
 All gas seals shall be designed to ensure that leakage rates are kept to a
specified minimum under all normal pressure, temperature, electrical load, and
fault conditions. Single gas seals with provision to monitor the failure of the first
seal shall be provided. Gas leakage should be less than 0.5% / year.
 The material for the seals shall be non-deteriorating.
vi. Support Insulators
f. The support insulators and Gas section barriers/ insulators will be of solid
moulded composite, epoxy resin and shall be manufactured from the highest
quality material.
g. All insulators shall be free of partial discharge at a voltage, which is at least
10% greater than the maximum service voltage. A test certificate in this
regard, as proof, shall be furnished.
h. The solid insulators shall be non-hygroscopic, track resistant and free from
voids and contaminants. The design shall be such as to reduce the electrical
stresses in the insulators to a minimum.
vii. Pressure Relief Device / Rupture Discs
 Pressure relief devices or Rupture Discs may be provided in each gas section
where it is considered necessary to protect the main gas enclosure from
damage or distortion during the occurrence of abnormal pressure increase or
shock waves generated by internal electrical fault arcs.
 The effect of an arc shall be confined to the compartment in which it has been
initiated and under no circumstances shall be allowed to spread out to
adjacent compartments/Gas Sections or other parts of the GIS.
 The pressure relief device or rupture discs shall be located away from gauges,
meters, gas filling ports and gas density device calibrating point.
 Deflectors shall be provided to direct all escaping gases, arcing products and
fragments of the bursting rupture discs away from operating personnel and
nearby devices. The direction of the escaping gas shall be so oriented as to
cause no damage to the GIS equipment.
viii. Expansion or Flexible Connections for Enclosure
 The number and position of expansion joints and flexible connections are to be
determined by the GIS Manufacturer to ensure that the complete installation
will not be subjected to any expansion stresses which could lead to distortion
or premature failure of any component of the GIS equipment, support
structures or foundations.
 The arrangement of assembly offered shall provide adequate access for
operation, testing and maintenance of each bay and shall be subjected to
approval of Employer.
ix. SF6 Gas Monitoring Devices
 All gas compartments must have their own independent and reliable gas
supervision alarm system with annunciations.
 The devices shall be temperature compensated electrically isolated and
independently adjustable, dust proof and vibration resistant.
 Two potential free electrical contacts shall be provided exclusively for each of
the above alarm/ trip conditions for wiring to supervisory control system. These
contacts shall be in addition to those required for local indication and trip and
shall be wired to the cable termination blocks in the local control panels.
x. Layout of GIS
a. The layout shall be such that future alterations and extensions for 2 bays can
be undertaken in either direction without requiring major shutdown or Bus
b. Outage or adjacent bay outage. Manufacturers shall include in their Drawing &
documents detailed plans to describe the process of expansion.
c. The layout shall also ensure maintenance or removal of a circuit breaker or
disconnect switch from a particular bay will not involve removal from service of
adjacent bay disconnect switch or main bus sections.
d. The layout shall ensure that GIS bus link section is provided for future

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 78

extension of the GIS buses to avoid de-gassing and modification of the

existing bus.
e. The physical layout shall ensure free movement of the SF6 Gas Cart and easy
access
f. to all components of the GIS for maintenance purposes. Provision of
walkway/platforms/ladders for ease of access to control cubicles/operating
handles provided on individual equipment.
3.26.5 GIS Switchgear
i. Circuit Breakers
g. The circuit breakers shall meet the following requirements:
a. Rated normal current of the Bus bars and Feeders at the rated Voltage as
stated in the single line diagram.
b. Duration of short circuit withstand current as stated in Technical Sheets.
c. Capability for three pole auto-reclosing without replenishment of stored
Energy as a minimum. The rated operating duty cycle sequence shall be
as below.
O - 0.3 secs. - CO - 3 min – CO
d. The maximum interrupting time at the minimum operating SF6 pressure
of the mechanism shall not exceed 3 cycles (60 ms-50 Hz systems and
50 ms-60 Hz systems) for Circuit Breakers up to 245kV class and not
more than 2 cycles (40 ms50 Hz systems and 33 ms-60 Hz systems) for Circuit
Breakers above 420kV class or as specified in Technical Sheets.
e. The Circuit Breakers shall have a First Pole to Clear factor of 1.5 for Circuit
Breakers up to 245kV class.
f. The total interrupting time at all currents less than the rated short circuit
interrupting current shall not exceed the rated maximum interrupting
time. Restrikes shall not occur under any mode of interruption.
g. Rated small inductive current breaking. The value shall be assigned by
the GIS Manufacturer having regard to the ratings and characteristics of
the associated transformers/reactors and shall be supported by test
reports, which shall be submitted with the Tender.
h. The circuit breakers shall be of double interrupter design (2 breaks in
series per pole) or alternatively can be of single interrupter design for 40
kA IC subject to satisfactory operation of the Circuit Breaker for Short
Line Faults and Terminal Faults. Test duties without the need of external
devices like Line to Ground capacitor devices to mitigate the TRV which
is supported by type tests for evidence.
i. External Line to ground capacitors or grading capacitors shall not be
used to mitigate the TRV for Short Line Faults test duty. External Line to
ground capacitors or grading capacitors, if used to mitigate the TRV for
Short Line Faults, will have to be indicated separately and can only be
accepted if specifically approved.
j. However, Voltage grading capacitors may be used across contacts for
double interrupter designs for 40 kA IC Circuit Breakers to control the
voltage gradient.
k. Single pole type circuit breakers with individual operating mechanism
shall be provided with pole-discrepancy protection with time delay for
tripping both trip coils (1st stage) and adjacent breakers (2nd stage) in
case of discrepancy.
l. Single pole type circuit breakers with individual operating mechanism
shall have capability for 1-Phase and/or 3-phase auto-reclosing facility to
meet the operating duty cycle.
m. In addition, the circuit breaker shall comply with the following
requirements as specified in IEC 62271-203, IEC 62271-100, and IEC
60694.

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Section 6B: Part-II Power Supply System 79

i. Rated LIWL and SIWL (applicable for Voltages 400kV and above).
ii. Rated Frequency
iii. Rated Transient Recovery Voltage (TRV) for terminal faults and
short line faults.
iv. Rated short circuit making current (at 50 Hz & 60 Hz as applicable)
v. Rated characteristics for short line faults.
vi. Rated out-of-phase breaking current.
vii. Rated capacitive current switching.
viii. Rated Power Frequency withstand Voltage.
ii. Switching Performance Requirements, the breakers shall be capable of:
a. Circuit breakers installed close to large generating plant or controlling
very long transmission Lines will be subjected to fault currents which may
have delayed or no zero crossing for a considerable number of cycles
due to a high X/R ratio of the system. The GIS Manufacturer shall
propose a suitable Circuit Breaker which can mitigate the high reactive
component to achieve the opening of the Circuit Breaker at current zero
within the normal operating time of the breaker. The methods of
demonstrating satisfactory conformance to this requirement shall be
mutually agreed between the Employer and the Contractor.
b. Employer shall furnish the Network parameters for the delayed zero
passage condition, if applicable to the GIS Manufacturer after award of
Contract. The GIS manufacturer shall prove by calculations and by
factory tests that the Circuit Breaker can safely interrupt the fault without
restrikes.
c. Switching off unloaded overhead lines.
d. Switching unloaded transformers without exceeding specified over voltages.
e. Cable Switching
There shall be no restrike across the main contacts when breaking
capacitive or cable charging currents up to a value specified in IEC 62271-
203 and IEC 60694 or as specified in Technical Sheets.
iii. Closing/Opening Resistors/Reactors (where applicable)
a. Closing Resistors/Reactors may be provided in special cases where
applicable to limit the Inrush charging current of the breakers within its
capability. Closing and/or opening resistors/Reactors shall also be
provided in special cases to limit switching surges and to mitigate the
TRV within the Circuit Breaker capability. The closing/Opening
Resistors/Reactors shall be provided with a bypass switch arrangement
to cut in/out the Resistor/Reactor for the intended purpose only.
b. Closing Resistors/Reactors shall have adequate thermal capacity for
the auto reclose duty cycle.
iv. SF6 Gas System and associated Devices
a. The SF6 gas shall conform to IEC 60376 and IEC 60480.
b. The SF6 gas manufacturer shall provide the data regarding gas
characteristics corresponding to the degree of deterioration beyond
which treatment or replacement of gas would become necessary along
with procedural instructions for gas treatment to restore original quality.
c. The GIS shall be fully gas tight. The sealing system shall effectively
ensure against the ingress of moisture, dust, and other contaminants
into gas compartments. All gas compartments shall contain suitable
agent to absorb moisture and any other decomposition products of SF6
gas.
d. SF6 gas leakage rate of each gas compartment shall not exceed 1%
per year.
e. The GIS enclosure shall be sectionalized for each equipment into
modular units or compartments, each separated by gas barriers with an

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 80

effective sealing system. Each compartment shall be provided with the

necessary piping and valves to allow isolation, evacuation, and refilling
of SF6 gas without evacuating any other section.
f. Gas barriers and sealing systems shall have adequate mechanical
strength to withstand the dynamic forces caused by short circuits, and
effects of internal arc faults as well as maximum pressure differential
that could exist between adjoining compartments,
g. SF6 gas in each individual compartment shall be monitored by suitable
temperature- compensated pressure gauges and two stage
temperature compensated pressure (gas-density continuous
monitoring) switches/ relays to monitor the loss of SF6 gas. The dial of
the pressure gauges shall be graduated to read pressures and
coloured green, yellow and red to indicate normal, Alarm Stage I and
Alarm Stage II pressure conditions.
h. The gas-density monitors shall be capable of being calibrated with the
monitored equipment in service. If the gas-density monitor has a visual
indicator, it shall be readable from the ground. Each relay shall be
provided with two convertible (NO and NC) potential-free auxiliary
contacts for two-stage alarm initiation as mentioned below. These
alarm contacts shall be wired to the annunciator in the respective GIS
bay control panel and in OCC.
i. Stage I: Alarm at 10% above minimum safe operating gas density (and
block breaker closing) (Refill stage).
j. Stage II: Alarm in the event of gas density falling below the minimum
safe operating limit (and block breaker Closing + Tripping.
k. All gas compartments shall have their own coupling valve, so that all
maintenance jobs, like drawing gas samples or conditioning and
replenishing the SF6 gas can be carried out during normal operation of
the switchgear without difficulty or loss of gas.
l. In the event of gas leakage, all parts of the switchgear in the affected
compartment shall be able to withstand continuously the maximum
rated voltage with SF6 gas at atmospheric pressure.
m. It shall be possible to test and replace each pressure gauge and the
density switch/relay with the GIS in service.
n. The gasket shall be synthetic elastomeric type. The gasket shall resist
oil and waste by-products of the SF6 gas decomposition. The gasket
shall have minimum deformation in service life of GIS and low gas and
moisture permeability.
o. Gas leakage detectors of an approved/OEM Make shall be provided.
p. Permanently fixed gas pipework shall be installed. The design, material,
specification and associated fittings for all gas pipe work shall be rated
for operation under normal and fault conditions and shall form part of
the switchgear assembly during all testing carried at the manufacturer's
works and at site. The gas piping system, valves etc. shall minimize the
possibility of accidental third- party damage and eliminate the need to
dismantle the pipe work during maintenance and/or removal of
modules, other than the pipe work associated with
the maintenance item.
q. At each gas compartment, provisions shall be made for connecting
online moisture measurement instrumentation and the gas service cart.
The moisture content in the gas shall not exceed 150 ppmv (parts per
million per volume) in circuit breakers, and 250 ppmv in other
equipment. Provision for disconnection of gas pipelines shall be
incorporated. 100 m or smaller sintered stainless-steel particle filter
disk, suitable for pressure involved, shall be installed at the gas service

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Section 6B: Part-II Power Supply System 81

connection.
r. Filters shall be inserted in all the gas compartments in addition to the
circuit breaker compartment. Filters for gaseous arc by-products shall
be installed before the bursting disc/pressure relief device, so that
arcing by-products will be removed in a controlled and filtered way. SF6
gas filters shall be as follows:
I. For moisture (H2O): Desiccant material such as Al2O3, also
called drying agent. The recommended particle size is 2-5 mm.
II. For gaseous arc by-products: Molecular sieve with a pore
size of 4Å Materials used for this purpose should not be
regenerated.
III. For particles (generally dust residues) or solid arc by-
products: filter to remove particles with a size larger than 1 m.
s. A coloured diagram showing various gas compartments, piping,
interconnections, valves, orifices and isolations to prevent current
circulation, necessary controls and monitoring systems etc. together
with normal and alarm ranges shall be provided in the drawing holder
on the inside of each control cubicle for ease of supervision.
t. The location of gas barrier insulators shall be clearly and permanently
marked on the finished external surface of the GIS enclosures.
u. The switchgear assembly supply shall include the initial complete filling
of SF6 gas for the assembly, and in addition, any gas lost during
installation and commissioning procedures.
v. The switchgear assembly supply shall include an additional 10% supply
of gas complete with containers and monitoring equipment for use
during the warranty period.
w. The total design shall incorporate facilities for SF6 storage adjacent to
the installed switchgear assembly.
v. Interrupting Contacts
a. Main contacts shall have ample area and contact pressure for carrying
the rated current and the short time rated current of the breaker without
exceeding guaranteed temperature rise.
b. Positive mechanism interconnection shall be provided between
interrupting contacts, resistor switches (when used), blast valve
mechanism, if any, to ensure maximum operating reliability.
c. Where Two breaks per pole interrupters are used, these shall be so
designed that a uniform voltage distribution is developed across them.
Grading capacitors across contacts may be used only to have a
uniform voltage gradient across the contacts.
vi. Operating Mechanism
Operating mechanism shall have following features:
a. Circuit breakers shall be operated by Spring or Hydraulic-Spring or
hydraulic or pneumatic mechanism. Each mechanism shall be provided
with its own monitoring gauges and accessories. In addition, provision
for manual operation shall also be made.
b. The operating mechanism shall normally be operated by remote
electrical control. Electrical tripping shall be performed by shunt trip coils.
Provision shall be made for local electrical control.
c. A local manual closing device shall also be provided for maintenance
purposes. The direction of motion of handle shall be clearly and indelibly
marked.
d. Circuit breakers shall have high repeatability of closing time over a wide
range of parameters (ambient, temperature, hydraulic/pneumatic
pressure, control voltages etc.). The time difference between first and last
pole, for opening or closing shall be as follows:

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Section 6B: Part-II Power Supply System 82

1. Closing: Less than 4 [Link] (60Hz) and 5 [Link](50Hz)

2. Opening: Less than 2.5 [Link](60Hz) and 3 [Link] (50Hz)
e. Operating mechanism shall be suitable for Auto reclosing. It shall be
non-pumping electrically and mechanically under every method of
closing (except during manual closing of a breaker for maintenance). A
latch checking switch shall be provided on mechanically trip free
mechanisms to prevent re-closure before the breaker latches have reset.
f. Have two electrically independent trip coils and one close coil. The
tripping mechanism shall function correctly when either one or both the
trip coils are energised. The close and trip coils shall be rated for the DC
voltage indicated in Technical Sheets and shall operate satisfactorily at
the designed temperature for voltage ranges between 85% to 110%
rated voltage for closing coil and 70% to 110% for tripping coils.
However, in some specific cases the trip coil may be required to operate
with a different voltage range, which will be as specified in Data Sheet
A1.
g. A mechanical indicator shall be provided to indicate open and closed
positions at a location from where it will be visible to a person standing
on the floor. An operation counter shall also be provided. Separate
counter shall be provided on each phase for a segregated system.
h. The circuit breaker mechanism shall be mechanically trip free. The
Circuit Breaker shall also be provided with an Anti-pumping feature.
i. Working parts of the mechanism shall be of corrosion resisting material.
Bearings which require grease shall be equipped with pressure type
grease fitting. Bearing pin, bolts, nuts, and other parts shall be
adequately pinned or locked to prevent loosening or changing of
adjustment with repeated operation of the breaker.
j. Provision shall be made for attaching an operation analyser to perform
CB timing tests after installation of the [Link] operation analyzer
shall also be supplied for maintenance staff for free of cost.
k. Interlocks and/or blocking devices shall be provided to prevent hunting
and dangerous or undesirable operations of the circuit breaker. The
interlock arrangements shall include but not be limited to the following:
1. Minimum Pressure/stored energy detection (1st Threshold)
A low pressure/stored energy sensor shall initiate a first stage alarm
both locally at the substation and remotely at the system control
centre. This alarm shall be initiated after a time delay sufficient to
allow normal recharging following a 'close- open' operation.
2. Minimum Pressure/stored energy detection (2nd Threshold)
 Under the condition that the first stage alarm has been initiated.
 Immediately initiate the second stage remote alarm both locally at
substation and remotely at the system control centre.
 Automatic blocking of tripping of circuit breaker
 At the same time, block closing of circuit breaker.
vii. Spring and Hydraulic-Spring Operated Mechanism
a. The operating mechanism shall be motor-compressed spring-
operated, or hydraulic/hydraulic-spring or pneumatic charged. Single
pole circuit breaker employing single-pole operating mechanism shall
be electrically coupled for synchronous three-pole operation.
b. Motor-compressed spring-operated mechanism shall employ a motor
for the rated DC Voltage for spring charging. The energy storage of a
motor compressed spring- operated circuit breaker shall be sufficient
for an open-close-open operation without replenishing the stored
energy. Means shall be provided to prevent overcharging of spring.
Mechanical indication of spring(s) for both "charged" and "discharged"

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 83

states shall be provided. Provision for manual spring charging shall be

provided, which shall automatically cut off the power supply to the
motor during manual charging.
c. The capacity of energy storage facilities that are integral part of the
hydraulic/hydraulic-spring operating mechanism shall be sufficient to
permit at least full rated duty cycle of the breaker without replenishing
the stored energy. A hydraulic pressure gauge shall also be provided.
Oil used in the hydraulic/hydraulic-spring mechanism shall be free of
PCB.
viii. Hydraulic Operated Mechanism
a. The hydraulic operated mechanism shall comprise of self- contained
operating unit with power cylinder, control valves, high and low-
pressure reservoir, motor etc. In case of Auxiliary Power failure,
provision for manual charging shall also be provided for emergency
operation. The manual operation shall be interlocked with auto-
operation by blocking it to ensure safety for the operator.
b. The Design shall be such that it shall be possible to perform at least
two close- open operations after failure of AC supply to the motor.
ix. Pneumatic Operated Mechanism
a. A pneumatic system with centralised air compressor utilising
compressed air to drive the operating mechanisms of the Disconnect
Switches, Grounding switches, etc. will not be accepted.
b. Where pneumatic drive is employed for the circuit breaker operating
mechanism, each circuit breaker shall have its own local air receiver
for stored energy and own compressor for a minimum of three O-C-O
operation.
c. The GIS Manufacturer is required to provide a dual piping system for all
main lines with suitable change over (by-pass) valves.
d. Each air receiver shall be provided with a safety valve with a suitable
range of setting. Pressure tests on the air receivers shall be based on
the pressure at which the safety valve operates. Safety valves shall
reset fully after operation with minimum drop in air pressure.
e. The internal surface of the air receiver shall be given a suitable
finish to prevent corrosion.
f. The construction and thickness of the air storage tank of the pneumatic
operating mechanism shall conform to ANSI/ASME Boiler and
Pressure Vessel Code, and ANSI/ASME B31.1 or CENELEC EN
50052 and EN 50064 or equivalent Japanese Pressure vessels
standards whichever is most stringent..
x. Disconnect switches and Ground switches.
General
a. The disconnect and grounding switch shall be Motorized, three (3) pole gang
operated, no-load break, single stroke type, and shall generally comply with the
requirements of IEC-62271-102.
b. The disconnect switch shall fully comply with the specified requirements of
insulation level for the isolating distance as stated in IEC 60694.
h. The disconnect switch shall be capable of interrupting rated capacitivecurrents
originating from switching bus bars, bus ducts and very short lengths of cable
and inductive currents as specified in the data schedule per IEC 60129.
c. The bus bar side disconnect switches shall be capable of switching rated Bus-
Transfer switching currents (Bus side Disconnects of each bay for Double Bus
schemes) as per IEC 62271-102
d. The disconnect switches shall be equipped with adjustable, self-aligning, high
pressure type silver-faced copper contacts. The contacts shall be capable of
carrying full rated and short circuit currents without over heating or welding.
Contact design shall be such that no shunt current shall flow through the

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Section 6B: Part-II Power Supply System 84

contact springs.
e. Grounding switches shall be high-speed type for all feeders and maintenance
type for bay grounding. Maintenance type Bus Grounding switches shall be
provided for each bus of the GIS.
f. The grounding switches shall be equipped with snap spring-operated high
speed operating mechanism with provision for manual operation.
g. Termination point grounding switches shall be capable of closing against the
rated short circuit making current of the switchgear. All grounding switches
shall have the same short time current rating as that of the switchgear.
h. In all grounding switches, the ground connection of each phase shall be
isolated from the ground connection of the other phases and from the
switchgear enclosure, and brought out through an insulated bushing, rated
10kV minimum. Direct connection to ground shall be via a removable grounding
strap. The current rating of the removable grounding strap shall be equal to that
of the grounding switch.
i. The line grounding switches installed at each termination point of GIS shall be
capable of breaking the induced capacitive and inductive currents per
IEC62271- 102 (Class B) considering the transient recovery switching duty
imposed on the ground switch.
j. All disconnect and grounding switches shall be equipped with local as well as
remote-controlled power-operated mechanism. An emergency manual operating
device shall also be provided. DC power supply to the mechanism shall be
automatically disconnected and local/remote electrical operation shall be
prevented when manual operating device is engaged. The power to the
disconnect and grounding switch in the enclosure shall be transmitted via gas-
sealed pressure-resistant shaft glands. Once initiated, the motor mechanism
shall complete an open or close operation without requiring the initiating contact
to be
k. held closed.
l. The disconnect and grounding switches shall be provided with pad- locking
facilities to permit locking both in open and closed positions. Possibility of
providing interlocking facility may be explored & provided.
m. All disconnect and grounding switches shall have mechanical position
indicators for the main contact movements, directly coupled to the driving shaft
and clearly visible from outside.
n. Inspection windows/endoscopy ports shall be provided in the housing of each
disconnect and grounding switch to ensure isolating distance or gap by
observing the position of each movable contact. The inspection viewports shall
have removable covers to prevent damage of the actual viewport due to
external elements. Access to viewports/endoscopy ports shall be convenient. A
warning plate (green or white background with black lettering) shall be installed
near each viewport/endoscopy port to warn of possible danger when viewing
the interior during switching operation (with words: WARNING —DO NOT
LOOK INTO THE VIEWPORT DURING SWITCHING OPERATION. ARCING
MAY DAMAGE YOUR EYES)
o. The area around the viewport/endoscopy port shall be painted a distinctive
colour as a warning (orange or yellow).
p. Anti-condensation heaters shall be provided within the housing of each motor
driven operating mechanism.
xi. Interlocks
a. Electrical and Mechanical interlocks shall be provided for absolute and
positive protection against potentially harmful mal operations of the
switchgear. Electrical interlocking shall be fail-safe type.
b. Disconnect Switch and Grounding switch shall be mechanically
interlocked such that it will not be possible to close the Grounding
switch when the Disconnect Switch is closed or vice-versa.
c. Disconnect Switch shall be provided with electrical interlocking feature.
This shall be in the form of bolt interlock comprising an interlock coil of
latch-in type to lock the Disconnect Switch driving shaft and hence

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 85

prevent Disconnect Switch operation in the latch-in condition. It shall

be possible to release the latch by energizing the interlock coil only
when all the conditions of safe operations are satisfied. Facilities shall
be provided for wiring external interlocks in Disconnect Switch opening
and closing circuits for this purpose.
xii. Short Circuit Withstand Capacity
a. The rated peak short-circuits current or the rated short time current
carried by a Disconnect Switch or Grounding switch for the rated
maximum duration of short circuit shall not cause:
i. Mechanical damage to any part of the Disconnect Switch or
Grounding switch.
ii. Separation of the contacts or contact welding.
iii. Excessive temperature rise which is likely to damage insulation.
b. After the passage of these currents, the Disconnect Switch shall be
able to carry its rated current under specified conditions and the
operation of the operating device shall not be impaired.
c. Where a Grounding switch is combined with a Disconnect Switch as a
single unit, the rated peak short circuit current and the rated short
time current of the
Grounding switch shall be at least equal to those specified for the
Disconnect Switch.
xiii. Auxiliary Switches
a. Each circuit breaker, disconnect and grounding switch shall be provided
with mechanically direct driven auxiliary switches. These auxiliary
switches shall be provided with minimum six (6) normally open (NO) and
six (6) normally closed (NC) Directly driven spare auxiliary potential-free
contacts and six (6) normally open (NO) and six (6) normally closed
(NC) multiplied spare potential free contacts in addition to those required
for the operating mechanism control and indications, protection and
interlocks with other equipment.
b. Auxiliary switches shall be rated for 10A D.C 600 volts. Adequate
number of Auxiliary switch contacts (Directly driven and multiplied)
shall be provided.
c. Directly operated, electrically separate, reversible and adjustable type
auxiliary switches shall be provided on breakers, disconnect switches
and ground switches in quantities as required for the Project.
d. All tripping and interlocking schemes shall use directly driven contacts
of the Circuit Breaker, Disconnect and ground switches.
e. Alarm, trip and spare contacts from operating mechanism shall be
wired to the local control panels. Alarm and trip contacts to be used for
Remote Control panel should be connected to terminal blocks.
f. 10 % Spare Auxiliary contacts completely wired up to the Terminal
blocks in the Local Control Panel shall be provided.
xiv. Instrument Transformers
General Requirement
a. Terminal and polarity marks shall be indelibly marked on each PT & CT
on the associated terminals and these marks shall be in accordance with
relevant standards.
b. Secondary terminals of each potential and current transformer shall be
brought out in a weather-proof terminal box. Facility shall be provided
for shorting and grounding the CT secondary at the terminal box. The
star point, whenever required, shall be formed at the terminal box only.
c. Potential and current transformers shall be provided with the
following accessories:

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Section 6B: Part-II Power Supply System 86

i. Two Grounding terminals for connecting the specified size of

Grounding conductor.
ii. Terminals for Tan Delta measurement. These terminals
under service conditions shall be connected to Grounding by
means of links.
xv. Potential Transformers
a. All Potential Transformers shall conform to IEC 61869 in general, Potential
transformers shall be of single core type the metal enclosed gas insulated
electro- magnetic mounted directly on the high voltage enclosure with plug in
contacts that allow easy removal. The PTs shall be 5 limb type or 3-Single
phase units in case of a common 3 phase enclosure.
b. Minimum accuracy, burden and transient response characteristics shall be as
specified in the single line diagram.
c. In case of ungrounded potential transformers both the terminals of the primary
winding
d. shall be brought out through bushings rated for full line voltage. In the case of
Grounded potential transformers, the end of the primary winding intended to
be Grounded shall be brought out through a bushing and Grounding
connection shall be made outside.
e. The secondary terminal box for the potential transformers shall also include
necessary HRC fuses/ MCBs for protecting the secondary circuit. Further, for
the purpose of fuse supervision both terminals of fuse shall be brought out to
the terminal box. MCBs shall be provided with auxiliary contacts for
interlocking, Trip and alarm purposes.
f. Whenever a PT secondary winding is used for both measurement and
protection application it shall have dual accuracy class of 0.5/3P, unless
otherwise specified. However, for revenue class metering applications the
accuracy class shall be 0.2/3P for that core.
g. PT secondaries shall have extended Voltage tap wherever required for the
purposes of synchronizing. The rating shall be as indicated in the Technical
Sheets.
h. The Potential Transformer shall be so designed to avoid ferro resonance
effects and shall be provided with adequate ferro resonance-suppressor (if
required) on the secondary windings. An electrostatic shield shall be employed
between the windings of PT to prevent coupling of the transients generated in
the GIS high voltage conductors with the control wires.
i. Potential Transformers shall not be mounted on the same compartment/Gas
section as the Cable Feeder termination compartment to test the Cable feeder
independent of the Potential Transformer.
xvi. Current Transformers
a. Number and location of CTs.
i. The ratio, burden, accuracy class, knee point voltage etc. shall be
provided as specified in the single line diagram.
ii. The physical relative location of core in the CTs should be in
accordance with the locations shown in single line diagrams which
were enclosed with the Tender enquiry to ensure over lapping of
protective zones.
iii. Separate CT core for incomer 220kV for connection of Tri-vector
meter of CRP panel for employer metering and separate core for
utility metering to be provided at RSS.

b. Minimum Accuracy for Relaying Core

All Current Transformer cores shall conform to IEC 60044-1 in general
and IEC 60044- 6 for Transient Protection Class CTs.
1. Accuracy Class 5P20, Class PX, Class TPS as required shall be
provided as specified in the single line diagram.
2. Current Transformers may be single/dual/Multi Ratio type (MRCT)
as specified in the Relaying and Metering Single Line diagram.

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Section 6B: Part-II Power Supply System 87

3. For polarity checking, the position of each primary terminal in the

current transformer SF6 gas section shall be clearly marked.
4. In the case of multi core CTs, it shall be possible to adjust the
ratio taps on any core independent of the setting on the other
cores, for which purpose these tappings shall have to be provided
on the secondary windings only.
5. All CT cores shall be of low reactance type.
6. No turns compensation shall be used in the case of Class TPS or
Class PX CTs. Turns compensation, if any, shall be clearly
brought out in the Data Sheet
7. In the case of multi ratio CTs, the minimum specified requirements
in respect of VA, accuracy and Knee Point Voltage (Vkp) and
maximum secondary resistance shall be applicable at all the taps
as per relevant drawings enclosed with the Tender.
8. Magnetizing characteristics (extending well beyond Vkp) and
secondary impedance values shall be furnished in Data
Sheet for all protection cores.
xvii. GIS Surge Arresters (if applicable)
i. SF6 Insulated GIS Surge arresters shall be provided in the switchgear
equipment for limiting any system transient voltages during switching and/or
fault conditions in the system, if deemed necessary as per calculations. The
location of the surge arrester shall be in accordance with the single line
diagram. The surge arresters shall fully comply with IEC-60099-4 as
applicable and as noted in this specification.
j. The surge arresters shall be housed in enclosures mechanically separated
from the other GIS parts by means of a gas barrier insulator. Each single-
phase surge arrester and enclosure shall be treated as a single gas-monitoring
zone.
k. The base plate of the enclosure shall be provided with a bushing type facility to
permit leakage current measurements and the addition of discharge counters
for the purpose of monitoring the frequency of discharges.
3.26.6 GIS Terminations
The following type of terminations shall be made, as applicable where SF6
Gas Bus duct directly connects the feeders provided in the GIS with the
external Cables/Overhead Lines, Power Transformers, Shunt Reactors,
Shunt Capacitors etc.
i. Sealing end box for GIS to XLPE Cable Termination
 Suitable SF6 gas-filled cable sealing end boxes shall be provided, where
required, for accommodating XLPE single core copper cable terminations. The
boxes shall be designed to accept the cable along with its terminations cone
from below. The scope shall also include necessary cable supports and cable
grounding facilities.
 Necessary data about the power cables required for designing/supplying
suitable cable terminations are as specified in Technical Sheets.
 The cable connections shall generally comply with IEC 60859.
 The SF6-to-XLPE Cable at the power cable pothead termination shall allow for
power cable disconnection from the gas-insulated bus through a removable link
and provide means to permit High Voltage AC field testing of the cable.
 Effective and long life gas-tight seals shall be provided between the cable
sealing end and the cable termination enclosure. It shall be possible to
accommodate high voltage cables of all types up to 2000 mm2 conductor cross-
section at the cable end terminations.
 All the GIS apertures intended for future cable terminations shall be sealed with
effective cover plates to safeguard against SF6 leakage.
 Wherever necessary the cable enclosure and support structure shall be
equipped with means for isolating the cable sheath to provide cathodic
protection of the cable system as per IEC 60859.

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Section 6B: Part-II Power Supply System 88

ii. SF6-to-Air Overhead Line Termination

 For connecting overhead lines with the GIS, SF6-to-Air outdoor bushings,
mounted on suitable steel structures shall be installed. The bushings shall be
wet processed porcelain or Composite (SIR) Insulator bushing and shall
generally conform to IEC 60137. The bushings shall have adequate Mechanical
strength to withstand the Short circuit forces, Wind force and loading for the
type connection
 The SF6-to-Air terminations shall include all necessary materials such as SF6
bus duct, gas monitoring devices, bus bar extensions, and removable links to
ensure complete termination.
 The SF6-to-Air termination shall be provided with bursting/rupture disc. To
obtain the necessary air clearance at the outdoor terminals, the bushings shall
be splayed using suitable shaped enclosure section.
iii. SF6-to-Oil Transformer Termination
 Gas tight seals shall be provided between the duct enclosure and the SF6-to-
Oil bushing.
 All such GIS apertures intended for future use shall be provided with gas tight
cover plates.
 The termination apertures shall be matched with the transformer dimensions.
SF6-to- Oil transformer terminations shall include all necessary materials such
as SF6 bus duct, gas monitoring devices, bus bar extensions, removable links,
bellow assembly, flexible interconnecting copper straps to minimize vibration
transfer from the transformer, and supporting structures, etc., to ensure
complete termination. The bellows shall be self- compensated or compensated
in compression by tie-rods, springs.
 The SF6-to-oil bushing at the power Transformer termination shall allow for
disconnection from the gas-insulated bus through a removable link and provide
means to permit field testing of the Transformer at the point of connection.
3.26.7 Local Control Panels and Mechanism Cabinets
i. General
l. Control panel shall be dead back type, sheet steel enclosed with degree of
protection of IP 41 suitable for mounting close to the wall. Sheet steel used
shall be cold rolled and at least 2.0 mm thick. Door shall have key locking
facility or provision for padlocking.
m. Control equipment shall not be mounted on the hinged doors. All control
equipment shall be suitable for operating in an ambient temperature varying
between 0 deg C and+ 40 deg C. For Outdoor installations, the ambient
temperature variation shall be between –5 deg C to + 60 deg C with a Relative
Humidity of 100%.
n. A Ground bar for terminating the Ground wires of shielded control cables shall
be located near the cable entry location.
o. All control Panels and Marshalling Cabinets shall be provided with Ant-
Condensation heaters which are thermostatically controlled. These Heaters
shall operate on 1- phase, 240 V AC. The thermostat-controlled heaters, shall
be provided complete with rotary type ON/OFF switch, HRC fuses or single
pole MCB with overload and short circuit protection, link on neutral Provision
for monitoring of heater failure shall be provided for all heaters.
p. A compact LED lighting fixture with door switch and one 6 pin 240V AC, 5/15 A
Duplex receptacle shall be provided in each cabinet.
q. The accessories and auxiliary equipment required for the correct functioning of
each circuit element shall be installed in conveniently located mechanism
cabinet (s).
r. The interior shall be painted glossy white and exterior paint shade shall be 693
as per IS- 5, unless specified otherwise.
s. Terminal blocks of approved type shall be provided. The terminal blocks shall
be of Phoenix make, Type OTTA-6 or Weidmuller make or equivalent. Terminal
wiring shall be accessible from the front side of the panel.
ii. Local Control Panel
t. Individual local control panels for each circuit shall be supplied to facilitate

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope
Section 6B: Part-II Power Supply System 89

local control
u. of circuit breakers, disconnects and Ground switches. These panels shall also
house the various relays, timers etc. to realize specified interlock requirement
among circuit breakers, disconnects and Ground switches. The contacts,
signals and conditions originating from/ going to the switchgear, associated
auxiliary, monitoring equipment and CT/PT wiring from the terminal boxes
shall be wired up to the local control panels.
v. Separate and isolated circuit shall be used for operating mechanism control,
tripping alarms and auxiliary devices. CLOSE and TRIP circuits shall be kept
isolated to their final mechanical or electrical actuators. Trip circuits shall have
individual monitoring facilities.
w. Low Voltage AC/DC Switches/ MCBs
a. Switches/MCBs shall be hand operated, air break, heavy duty, quick
make, quick break type conforming to applicable clauses of IEC 60947-1
& 2. and IEC 60439.
b. It shall be the responsibility of the Manufacturer to fully coordinate the
overload and short circuit tripping of the MCBs with the sub- circuit
MCBs/fuses to provide satisfactory discrimination.
c. The switch handle shall have provision for locking in both fully open
and fully closed positions. MCBs shall preferably be provided with
suitable locking facility.
d. Single throw isolating switches for complete isolation of the DC control
circuits shall be provided.
e. Control and selector switches shall be of the rotary type provided with
properly designated escutcheon plates clearly marked to show the
operating positions. Control switches shall have momentary contacts,
spring return to normal, with pistol grip handle. Selector switches shall
have stay put contacts with oval handles. The local/remote selector
switch shall be lockable in both positions. The number of contacts and
their operation in each switch position shall be as per the requirements
of the connected circuit. The switches shall be rated for minimum 10 A
at 240 AC and 1 A inductive break at specified DC voltage.
iii. Control & Auxiliary Power Supply
a. For alarm, auxiliary devices, annunciation and indication, separate control
supply feeder shall be provided to each Local Control Panel.
b. All control equipment shall be suitable for operation on specified DC system.
c. Duplicate power supply shall be provided to each local control panel.
The GIS Manufacturer shall supply all necessary equipment and
control for automatic change over from one source to another in the
event of failure of one source/ contactor drop out.
d. Separate circuits with switches, fuses, etc. of adequate rating shall be
provided for control of space heater, lighting and power receptacle.
These shall be on 240 V, single phase AC supply, unless specified
otherwise.
e. AC and DC power supply shall be such that isolation of individual
equipment is possible.
iv. Relays
a. Relays for various controls, monitoring and blocking functions of circuit
element shall be of Numerical type design installed in associated local
control panel.
b. Necessary auxiliary relays for alarm, time-delay relays, voltage relays
as required for control and protection shall be mounted inside the local
control panel. Voltage operated relays shall have sufficient thermal
capacity for continuous energisation,
c. Auxiliary relays shall be rated to operate satisfactorily between 80%
and 110% of the specified rated voltage.

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Section 6B: Part-II Power Supply System 90

d. Each relay shall be provided with at least 2 NO and 2 NC potential free

contacts, wired up to terminals for Customer‘s use.
e. Coils of all the relays shall be adequately rated to avoid spurious
operation of relays on D.C. system ground or induced surges.
f. All relays shall be tropicalised and shall be suitable for design
ambient temperature of 40°C.
g. Make and type of relay shall be subject to approval of the Employer.
v. Push Buttons
All push buttons shall be of push to actuate type, having 2 NO and 2 NC
self-reset contacts. They shall be provided with integral escutcheon plates,
engraved with functions. Push button contacts shall be rated for 10 A at 240
V AC and 1 A inductive breaking at specified DC voltage.
vi. Indicating Lamps
Cluster LED type indicating lamps shall be provided.
vii. Internal Wiring
a. Cabinets/Panels shall be supplied completely wired ready for external
connections at the terminal blocks. All wiring shall be carried out with
wires of 1100 V grade, stranded copper conductors. The insulation shall
be halogen free and flame retardant. Power circuits shall be wired with
stranded copper conductors of adequate sizes to suit the rated current.
Unless otherwise specified, control alarm and indication circuits shall be
wired with stranded, tinned copper conductors of sizes not smaller than
1.5 [Link]. CT and PT circuits shall be wired with stranded copper
conductor of size, not smaller than 2.5 [Link].
b. Engraved identification ferrules, marked to correspond with the wiring
diagram shall be fitted at both ends of each wire. All wiring shall be
terminated on terminal blocks. Terminals shall be adequately rated for
the circuit current; minimum rating shall be 10A. Control wiring shall be
protected against mechanical damage.
c. CT/PT terminals shall be of disconnecting links types and all other
terminals shall be of stud type. CT terminals shall have a Grounding
facility.
d. The wire terminations shall be made with solder less crimping type of
tinned copper lugs.
e. Wiring shall be colour coded and be firmly supported, neatly installed
by lacing and taping, readily accessible and connected to equipment
terminals and terminal blocks. Halogen free, flame-retardant plastic
wiring channels/troughs with strap on covers shall be used for this
purpose.
viii. Mimic Diagrams
Mimic diagrams shall be provided on local control panels. The mimic strips
shall be made of anodised aluminium and shall be screwed onto the
panel. Colours of the various voltages of the mimic bus comply with
relevant IEC standard. The width of mimic strip shall not be less than 5
mm. Discrepancy switches and semaphore indicator shall be provided on
the mimic diagram as applicable.
ix. Local Alarm/Annunciation
Window type Alarm/Annunciation shall be provided on local control panels
of each bay for annunciating the specified abnormal conditions related to
the bay covering
SF6 gas pressure conditions, control supply fail as well as the pneumatic/
hydraulic operating mechanism. The alarm windows shall have provision
for differentiating cleared and un- cleared faults and flashing for new
faults. The Alarm/Annunciator system shall be provided with a First out
feature.

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Section 6B: Part-II Power Supply System 91

x. Mechanism Cabinets
The Circuit breaker mechanism cabinet shall consist of the following:
a. Circuit breaker position indicator
b. Operation counter
c. Provision for connection of time travel recorder
d. Operating and monitoring device associated with circuit breaker
operating mechanism shall be wired to terminal blocks in circuit breaker
mechanism cabinet and further to terminal blocks in local control
cabinet.
e. Monitoring and indication devices for the status of the stored energy of
the circuit breaker or other status of the operating mechanism.
xi. Disconnect Switch and Grounding switch mechanism cabinet.
The mechanism cabinet, in addition to other components or accessories
the GIS Manufacturer considers necessary for safe and reliable operation,
shall incorporate the following.
a. Disconnect /Grounding switch position indicator.
b. Auxiliary switches
c. Terminal blocks
d. Operating and monitoring device associated with Disconnect
/Grounding switch operating mechanism shall be wired to terminal
blocks in isolator mechanism cabinet and further to terminal blocks in
local control cabinet.
e. Monitoring and indication devices for the status of the operating mechanism.
xii. Labels and Diagram Plate
 Every GIS equipment and device mounted in the cabinet/ control panel shall be
provided with individual labels with equipment designation/ rating. Also, the
cabinet/ control panel shall be provided on the front with a non-rusting label
engraved with the designation of the cabinet/control panel.
 As built copy of a circuit diagram shall be fixed inside the door.
3.26.8 Miscellaneous Requirements
i. Grounding
a. The GIS shall be bonded to the “Main Ground Bus” for the specified short circuit
current magnitude and duration to which all intentionally Grounded parts of the
assembly.
b. It shall be the responsibility of the GIS manufacturer to provide enough Ground
connection points on the GIS which shall be suitable for interconnection.
c. Provision shall be made for future extension and/or bonding to ground bus(es) of
other switchgear.
d. Every section of the SF6 switchgear equipment including all panels, cubicles,
kiosks, and boxes shall be solidly bonded to the Grounding system, by at least
two independent leads. Two Grounding pads shall be provided at each
equipment for the connection to Grounding system.
ii. Grounding Tester
As an additional measure for the safety of personnel it shall be possible to
ascertain that the section of the plant is de-energised before a Ground
switch is closed onto the conductor. A capacitive tap shall be provided on
each gas section. One loose instrument common to the complete plant,
shall be supplied for connection to a capacitive tap to indicate whether the
circuit is “live” or “dead”. Provision of taps to indicate status – live or dead,
capacitive taps and the instrument shall be optional and quoted for
separately.
iii. Welding/Casting Nuts and Bolts
a. All welding/casting shall conform to the requirements of relevant IEC
standards.
b. At least 10% of all welds/casting shall be subjected to non-destructive testing
by X rays or ultrasound and all records there of shall be made available upon

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Section 6B: Part-II Power Supply System 92

request. 5% welds shall be tested by inspecting officer in FAT.

c. All welding shall be performed with suitable submerged-arc welding machines
or by fully certified welders.
d. Drawings submitted for approval shall indicate following information in respect
of welds:
• Type of weld
• Procedure employed.
• Inspection applied.
• Applicable standard

e. Details of bolt sizes and threading shall be clearly shown on the appropriate
drawings. Where self-locking type of nuts are used, they shall be of the re-
usable type. Pressed type nuts are not acceptable.
f. Fasteners used for current carrying parts shall be of Stainless Steel - 304.
g. GIS Manufacturer shall indicate the type of protection needed and precautions
to be taken during GIS installation to prevent moisture or dirt entering the
enclosures.
iv. Seismic Qualification
a. The GIS shall be designed to safely withstand the seismic forces
as per the codal design wherever applicable.
b. The GIS Manufacturer shall submit type test certificates; if
applicable to prove seismic withstand capability. If identical GIS is
not tested in the past, successful GIS Manufacturers shall furnish
design calculation or carry out testing to prove seismic withstand
capacities.
3.26.9 Special Tools
i. The GIS manufacturer shall include the supply of all the SF6 gas necessary
for initial filling (including usual losses during commissioning.) and putting into
commercial operation of the complete switchgear. In addition, ten percent of
the total SF6 gas required for the complete GIS shall also be supplied as
spare in non-returnable containers in ready to use condition and shall be
included in the scope of supply.
ii. If specified, a mobile SF6 gas treatment plant, which shall be suitable for
draining, filtration/purification and refilling equipment shall be provided. The
plant shall have storage capacity for at least two of the largest switchgear
compartments and shall be supplied with complete accessories such as
vacuum pump, pressure gauge, valves, hoses, couplings, adaptors, etc.,
necessary for evacuating and filling, together with storage facilities for these
items.
iii. A two-wheel gas maintenance cart fitted with a cylinder of SF6 gas, a vacuum
pump, a vacuum and pressure gauge and all necessary valves, hoses and
couplings for evacuating and filling the switchgear shall be supplied alongwith
GIS.
iv. A SF6 Gas maintenance cart, which shall be easily moved by One person,
shall be provided with enclosed storage facilities for proper storage of
cylinders and other accessories including power leads. The enclosed storage
shall have facilities for padlocking.
v. SF6 gas leakage test equipment shall be suitable for testing SF6 gas as per
recommendations of IEC 60376.
a. Instruments for automatic and continuous monitoring for the presence of
SF6 gas in the atmosphere of the switchgear room shall be provided if
required as per Data Sheet. The recommended positions, exact number
of detectors, type of mounting, facilities for alarm etc. shall be indicated
in the datasheet.

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Section 6B: Part-II Power Supply System 93

b. Each set of analysers shall comprise of:

i.SO2 content in SF6 gas
Purity of SF6 gas
ii.
SF6 gas moisture content
iii.
vi. All special tools required for the purpose of installation, maintenance,
overhauling and testing of GIS and for the measurement of moisture in SF6
shall be supplied with GIS.
3.26.10 Testing
All the tests including type tests, routine tests and FAT should be carried out as
specified in chapter 10 of particular specifications.
3.26.11 GAS INSULATED SWITCHGEAR APPLICABLE CODES, STANDARDS AND
SPECIFICATIONS
i. APPLICABLE CODES, STANDARDS AND SPECIFICATIONS
 The design, material, construction, manufacturer, inspection, installation, testing and
commissioning of switchgears and accessories shall comply with all currently applicable
statutes, regulations and safety codes in the locality where these will be installed. The
material shall also conform to the latest applicable RDSO standards. Nothing in this
specification shall be construed to relieve the contractor of this responsibility.
 Except as noted, all the equipment offered shall conform to the requirements of the
latest editions of relevant standards published by the international electro-technical
commission (IEC).
 National standards will be acceptable only if they are established to be equal to or
superior to IEC standards. In all such cases, copies of English translation of all such
standards shall be enclosed with the drawing & documents.
 In the event of any conflicts between the codes and standards referred to in this
specification and the requirement of this specification, the latter shall govern.

STANDARD
S.N. TITLE REFERENCE

1. INTERNATIONAL ELECTRO- IEC-60050

TECHNICAL VOCABULARY
2. HIGH VOLTAGE ALTERNATING CURRENT IEC-62271-100
CIRCUIT BREAKERS
3. GAS-INSULATED METAL-ENCLOSED SWITCHGEAR IEC-62271-203
FOR RATED VOLTAGES 52kV & ABOVE
4. HIGH VOLTAGE TEST TECHNIQUES IEC-60060
5. RECOMMENDATION FOR HEAT TREATED IEC-60114
ALUMINIUM ALLOY BUSBAR MATERIAL OF
THE ALUMINIUM-MAGNESIUM-SILICON
TYPE
6. ALTERNATING CURRENT DISCONNECT IEC-62271-102
SWITCHES AND GROUNDING SWITCHES
7. BUSHING FOR ALTERNATING VOLTAGES IEC-60137
ABOVE 1000 VOLTS
8. INSTRUMENT TRANSFORMERS PART 1: IEC-60044-1
CURRENT TRANSFORMERS
9. REQUIREMENTS FOR PROTECTIVE CURRENT IEC-60044-6
TRANSFORMERS FOR TRANSIENT PERFORMANCE

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STANDARD
S.N. TITLE REFERENCE

10. INSTRUMENT TRANSFORMERS PART 2: IEC-60044-2

INDUCTIVE VOLTAGE TRANSFORMERS
11. ELECTRICAL RELAYS IEC-60255
12. LOW VOLTAGE FUSES IEC-60269
13. LOW VOLTAGE MOTOR STARTERS IEC-60292
14. SPECIFICATION AND ACCEPTANCE OF NEW IEC-60376
SULPHUR HEXAFLORIDE.
15. FIRST AND SECOND SUPPLEMENT TO IEC PUB- IEC-60376 A&B
376 (1971)
16. SYNTHETIC TESTING OF HIGH VOLTAGE IEC-60427
ALTERNATING CURRENT CIRCUIT
BREAKERS
17 GUIDE FOR CHECKING SF-6 GAS TAKEN IEC-60480
FROM ELECTRICAL EQUIPMENT
18. ARTIFICIAL POLUTION TEST ON HV IEC-60507
INSULATORS TO BE USED ON AC SYSTEM
19. DIRECT CONNECTIONS BETWEEN POWER IEC 61639
TRANSFORMERS AND GAS INSULATED METAL-
ENCLOSED SWITCHGEAR FOR RATED VOLTAGES
72.5KV AND ABOVE

20. CLASSIFICATION OF DEGREE OF PROTECTION IEC-60529

PROVIDED BY ENCLOSURES

21. COMMON CLAUSES FOR HV SWITCHGEAR AND IEC-60694

CONTROLGEAR STANDARDS

22 ADDITIONAL REQUIREMENT FOR ENCLOSED IEC-60932

SWITCHGEAR AND CONTROL GEAR FROM 1kV TO
72.5kV FOR USE IN SEVERE CLIMATE
23. GUIDE FOR SELECTION OF INSULATORS IN IEC-60815
RESPECT OF POLLUTED CONDITIONS

24. GAS INSULATED METAL – ENCLOSED IEC-61259

SWITCHGEAR FOR RATED VOLTAGES 72.5kV
AND ABOVE – REQUIREMENTS FOR SWITCHING
OF BUS CHARGING CIRCUIT BY DISCONNECT
SWITCHES
25. SPECIFICATION FOR TRANSPORTABLE GAS BS-5045-1
CONTAINERS. SEAMLESS STEEL CONTAINERS.
26. IEEE GUIDE FOR SAFETY IN AC IEEE STD. 80
SUBSTATION GROUNDING
27 STANDARD FOR GAS INSULATED ANSI/IEEE
SUBSTATIONS C37.122

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STANDARD
S.N. TITLE REFERENCE

28. QUALITY SYSTEMS – MODEL FOR QUALITY ISO-9003

ASSURANCE IN FINAL INSPECTION AND TEST

29. EUROPEAN STANDARD – CAST ALUMINIUM ALLOY EN-50052

ENCLOSURES FOR GAS FILLED HIGH
30 WROUGHT ALUMINIUM AND ALUMINIUM ALLOY EN-50064
ENCLOSURE FOR GAS FILLED HIGH VOLTAGE
SWITCHGEAR AND CONTROL GEAR
31 WELDED COMPOSITE ENCLOSURES OF CAST EN-50069
AND WROUGHT ALUMINIUM ALLOYS FOR GAS
FILLED HIGH VOLTAGE SWITCHGEAR AND
32 SURGE ARRESTERS-PART4: METAL-OXIDE SURGE IEC-60099-4
ARRESTERS WITHOUT GAPS FOR AC SYSTEMS
33 SURGE ARRESTERS-PART5: SELECTION IEC-60099-5
AND APPLICATION RECOMMENDATIONS
34 GUIDE FOR PARTIAL DISCHARGE ANSI/IEEE 1291
MEASUREMENTS IN POWER SWITCHGEAR

3.26.12 Drawings/Documents
i. The Contractor shall furnish the following drawings/documents for the GIS and
accessories.
ii. Engineering Schedule indicating list of drawings, documents, data,
performance curves, test certificates, manuals, etc. to be submitted by the
Contractor together with dates of submissions and category of approval i.e.,
for approval or for reference.
iii. Circuit parameters for the delayed zero passage condition.
iv. General Arrangement drawings for approval-
a. Overall layout of GIS (indoor/outdoor) bays and routing of bus ducts l
b. Bay cross sections for-
i. Incoming bay
ii. Feeder Bay
iii. Transformer Bay
iv. Outgoing Cable circuit bay
v. Outgoing overhead line bay
vi. Bus coupler bay
vii. Bus section Bay
c. Local Control Panels
d. Partial Discharge Monitoring System (if required) Including all
dimensional details, layout and maintenance requirements, details of
supports required for piping and other accessories, cable entry details,
Grounding requirements, etc.
v. Foundation drawings for all equipment/accessories indicating the grouting
details, static and dynamic loading data and any insert details for supporting
structures and other equipment being supplied by the Contractor.
vi. Bill of materials including make, technical specification, etc. for all
equipment/accessories.
vii. Detailed cross-sectional drawings showing all relevant internal details of all

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Section 6B: Part-II Power Supply System 96

equipment/ accessories.
viii. Gas Section diagram
ix. Arrangement of bus, insulators, etc. within the bus duct.
x. Drawing showing the terminal connection between bus duct and SF6 to Air
bushing.
xi. Data/ drawings to be submitted
xii. Block interlock diagrams indicating the control and interlock logic
for all equipment/accessories.
xiii. Detailed schematic drawings for all equipment/accessories.
xiv. Manufacturing Plan.
xv. Assurance plan.
xvi. Final test procedures (at shop as well as at site).and Test Set-Up
xvii. Design calculations (wherever necessary) to prove the adequacy of the
equipment offered.
xviii. Any other drawings/documents considered necessary.
xix. Following drawings shall be for reference and will not be approved
a. Interconnection schedules (ICS) with terminal numbers indicating the
details of cable connections to be made between all equipment being
supplied under this CONTRACT and for interconnections between
equipment supplied under this CONTRACT and equipment covered by
other CONTRACTS. The format of the ICS shall be subject to
EMPLOYER ‘S/ Engineer ’s approval.
b. Detailed wiring diagrams indicating terminal numbers, ferrule numbers,
etc. for all equipment/accessories.
c. Details of bus duct bending arrangement.
d. Details showing typical bus duct joint between sections.
e. Details of seal off bushings and gas seals.
f. Details of typical rigid and expansion connections.
g. Data to be submitted
h. All final technical details, parameters, characteristic and performance
curves as specified, and any other data required.
i. CT characteristic curves with excitation current Vs. secondary voltage
for each core as measured in the case of protection CTs.
j. CT secondary resistance values in ohms.
k. Maximum dimensions and weights of various packages for shipment
under this CONTRACT.
l. Details of pedestals to be provided outside the GIS building (by the
Employer) for the purpose of bus duct support, SF6/Air bushings, piping
supports, etc.
m. Suggested layout of trenches for control and power cabling within
the GIS building.
n. GA drawings for SF6 gas maintenance plant and SF6 gas leak detectors

3.26.13 TEST CERTIFICATES

a. Type test certificates of all the major equipments for this project shall
be as per CEA guidelines. Type test report of all those items which
are not covered in CEA guidelines shall not be more than 5 years old
from the date of Letter of Acceptance (LOA) of the Contract.
b. Routine test certificates for all equipment/plants/accessories being
supplied under this contract.
c. Specified number of copies of the compiled and approved test certificates.
d. Records of radiography tests and NDT as specified.

3.26.14 INSTRUCTION MANUALS

a. The contractor shall furnish the specified number. of copies of the

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instruction manual contains detailed instructions for all installation,

testing, operation and maintenance requirements. The manual shall be
furnished at the time of despatch of the equipment and shall include the
following aspects before start of commissioning
b. Outline dimension drawings showing relevant cross-sectional views,
Grounding details and constructional features.
c. Catalogue numbers of all the components which need to be replaced
during the life of the equipment.
d. Instructions for unpacking and handling at site.
e. Storage for prolonged duration.
f. Installation drawings with written assembly instructions that would
enable the Employer to carry out installation with his own
personnel.
g. Detailed instructions for the installation, operation and maintenance of
GIS and accessories.
h. Pre-commissioning tests.
i. Maintenance procedures including precautions to be taken during
operation and maintenance work.
j. All detailed catalogues and literature of equipment supplied.

3.27 EOT Crane

RSS at Kasheli depot (at both RSS & MSETCL LILO GIS Room), shall be
equipped with the EOT crane of suitable capacity for handling of GIS cubicles
and other plants/equipment inside the RSS. Layout and travel particulars for
the EOT crane shall be designed by the contractor duly considering the layout
of GIS and other equipment required to be handled with the EOT crane.

3.28 SCADA System

3.28.1 The SCADA system shall be provided for the control and monitoring of RSS
equipment, TSS equipment, AMSS equipment, Traction SWS equipment, ASS
equipment, and OCS disconnect switches at-grade section and the Depot. The
scope of work shall comprise but not be limited to the following:
i. OCC SCADA equipment
a) Two Database/application Servers in Hot Standby configuration
along with associated monitors & keyboards.
b) Two Front-end/communication Servers in Hot Standby configuration
along with associated monitors & keyboards.
c) Three Workstations with dual monitors (Two for controller and
one for maintenance.)
d) Two all in one laser colour printers
e) Associated redundant communication and dual LAN equipment.
f) Modular furniture, etc.
g) Other equipment as necessary to fulfil the specified requirements.
ii. BCC SCADA equipment
h) Two Database/application Servers in Hot Standby configuration
along with associated monitors & keyboards.
i) Two Front-end/communication Servers in Hot Standby configuration
along with associated monitors &keyboards.
j) Three Workstations with dual monitors (Two for controller and
one for maintenance.).
k) Two all in one laser colour printer and one A3 size printer.
l) Associated redundant communication and dual LAN equipment.
m) Modern furniture, etc.
n) Other equipment as necessary to fulfil the specified requirements.
iii. DCC SCADA equipment

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o) One Workstation with dual monitors.

p) Associated communication and LAN equipment.
q) Other equipment as necessary to fulfil the specified requirements.
iv. Field equipment
r) RTUs and associated communications equipment for each Station, for
each Depot ASS, and for Depot SSP & main line SSPs.
s) All types of Cables, connectors, converters, and accessories necessary
for the works at each RSS/TSS/AMSS, Traction SWS, ASS, and OCS
disconnect switch location.
t) Other equipment as necessary to fulfil the specified requirements.
v. Special design provisions:
u) The SCADA system shall have design provision for remote temperature
monitoring of 220 kV, 33 kV and 25 kV cables.
v) The SCADA system shall have design provision for remote temperature
monitoring of traction transformers and auxiliary main transformers in
the RSS and auxiliary transformers in the ASS.
w) The SCADA system shall have interface provision with STPT to provide
the energization status of individual OCS sections.
x) Disturbance record access of all the relays in ASS / RSS from OCC and BCC
y) All electronic equipment shall be with Conformal Coating
z) The SCADA system shall have interface provision with other corridors to
monitor and control the RSSs. Necessary Interlocking arrangements to be
done in the RTU & SCADA System to avoid the mis operation.

3.28.2 The performance of the system must enable the operators to operate the line
under satisfactory conditions. More precisely, the following targets must be
reached:
a. Transfer time: - The display of each Safety Critical system shall require
rapid updates of the workstation displays of the status and event data,
together with a rapid response by the SCADA system to control inputs.
The status of any circuit breaker trip, protecting any Safety Critical
equipment, shall also be identified on the workstations and recorded in
the event record, within 1 second of its occurrence. The time required
between the supervised or controlled equipment event and the
operator’s display must be less than 1 second under any circumstances.
Similarly, activation of a control command shall reach any Safety Critical
systems in no more than 1 second.
b. It shall be possible to carry out “Housekeeping” actions such as
changes to the database or that of the display format or colour scheme
philosophy online by the SCADA platform.
c. Integrity check of all the remote terminal units shall be verified by the
SCADA system at intervals not exceeding 30 seconds. In the event of
any failure or malfunction of a remote terminal unit, a corresponding
message shall be displayed on the appropriate workstations as a
SCADA system alarm.
d. System Capacity: - the processing power of servers, workstations,
remote terminal units, and all the relevant peripherals of the system
should be designed to guarantee that SCADA system will cope with all
situations and allow the operator to manage all the events he oversees
supervising. In other words, it shall be able to deal with all the events to
which the system may be subjected. Transient occurrences that do not
represent a status change are not included.
e. Chronological analysis: - To analyse a sequence of events with an
acceptable accuracy the number of data samples must be sufficient.
Therefore, every alarm or event is dated with a time stamp of one

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millisecond (day and time: hours, minutes, seconds, milliseconds) by

the RTU that receives it from an equipment, or by the computer that
generates it if no RTU is involved in this alarm or event: this date is
called the “origin date” of the alarm or event. Each alarm or event
potentially existing in the whole system is designed to be sent to the
OCC and the BCC.
f. Transmission errors: - The number of undetected errors shall not be greater
than
10. This means that the number of wrong Remote Monitoring or Control
recognised by the system as correct shall not be higher than 10.
g. Expandability: - The size of the system must be sufficient to allow the
addition of new equipment to be supervised. The system provided will
incorporate the relevant expandability requirements. The various phases
of line extension will be as much
as possible performed by simple addition of racks, or cards on a modular
basis.
h. Analysis: The system shall be capable to analyse normal operation
features like power consumption as well as events. The analysis shall be
possible based on on- line data as well as on archives.

3.28.3 The proposed SCADA system shall be equipped with following functions:
i. Intelligent Remote Monitoring:
 The system shall collect and transmit remote monitoring information from field
supervised equipment and SAS system to workstations in the OCC/BCC.
 The Power controller shall be able to control and monitor the status of the HV,
traction and auxiliary power supply equipment. The operator shall receive
alarms related to different events from field devices.
 The SCADA software shall be designed with necessary process display screen
to provide a graphical depiction of the power supply and distribution system for
MML-5. This shall include Receiving Substations, Auxiliary Main Substations,
Traction Substations, Traction Switching Stations, and Auxiliary Substations for
Mainline and Depot. Other than these two separate views for the complete
Traction and Auxiliary Power networks should be included.
 The event logging system of SCADA System shall support the following
features:
- Historical storage of events with a facility to retrieve them later.
- Configurable layout: columns, fonts, toolbars, colouring, etc.
- Configurable scrolling behaviour.
- Configurable presentation modes: log mode /event mode, top/bottom listing.
- Updating/Frozen presentation modes.
- Easy navigation through scrolling, go to date, time filters.
- Filtering (By Station, Device, Period, etc.)
- Find, Sorting by column.
- Exporting data to other Windows applications like MS Excel, etc.
- Printing
- Commenting on events by operator

 The SCADA System shall be able to handle various types of alarms, typically:
- Alarm generated due to change in field information.
- Alarm generated due to fault in SCADA system equipment and communication
link. The important functions in remote monitoring are:

Event management: - The system shall collect the operator’s requests and
field information changes. Any change on the field or any operator request
shall be processed as an event. The SCADA system may generate additional

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events resulting from the processing of field information and / or operator

requests.
a) The SCADA system shall record any events caused by faults, malfunctions,
warnings or alarm information generated automatically by the selected
equipment. A central recording system shall be provided to record events
including but not limited to the following:
 Change of state of remote terminal unit input parameters.
 Events designated as alarms.
 Faults.
 Control actions.
 Text entered by operators.
 System generated messages.
b) Events shall be given an order of priority to allow events to be classified,
sorted and filtered. Subject to the requirements of the approved operations
plan, events shall be classified as:
 Emergency: this type of event shall require instant attention in order to
minimize interruption to normal operation or risk of injury to personnel
or passengers and shall be classified as an Alarm.
 Urgent: this type of event shall require reasonably prompt, but not
instant attention to minimize interruption to normal operation and shall
be classified as an Alarm; and
 Non urgent: this type of event does not directly result in any degradation
to normal operation and shall be dealt with on a non-priority basis. Such
events do not need to be configured as alarms. These are to be
stamped in the event log only.
c) The event records shall be available as a text table, with each event
classified by its priority level and shall be tagged with details of the date
and time at which the event occurred. Additionally, the operator’s
identification code shall be recorded for each event that is initiated directly
by him. An event shall continue to be displayed until it has been
acknowledged and cancelled in the event log provided that the condition
that generated the event no longer exists.
d) All data messages transmitted through the SCADA system shall be
tagged with the time at origin to an accuracy of one millisecond and shall
be sorted and logged in time tagged order on the central database.
e) Each SCADA workstation shall be capable, at any moment in time, of
sorting and filtering events in accordance with their priority level. A facility
shall also be provided to enable a summary of event records to be
generated, listing not only the current active events, but also any events,
including alarms reported and/or cleared during the period since the
previous summary report. The event record shall also be able to be
interrogated in a structured manner to determine the trends and
associations between different events based on association by location,
time, or equipment type. All data records associated with the daily event
record, once stored in the central database, shall be collated, sorted and
be accessible within one minute of a request being issued by any
workstation in the SCADA system.
f) The event log shall have various filter facilities to enable the operator to
display different formats of events. The filter keys shall typically include:
 Location
 Equipment group
 Time period
 Event category
 Other options
Any combination of the filter keys shall be possible. When a filter is

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applied to the event list, a specific display should be presented to the

operator.
If a particular incident gives rise to numerous SCADA events, then the
SCADA workstations shall be capable of displaying either all such events or
only the most all-encompassing event.
The SCADA system shall be capable of producing regular reports of the
overall power system reliability with faults categorized by subsystem and
location.
All databases established within the SCADA system shall be accessible for
maintenance and exporting of data as required by the operator. This
requirement should also include any database used to configure the
graphics on the workstation VDUs. The Contractor shall supply the
necessary database tools, manuals, documentation and training required
to enable the maintenance and exporting of such data to be performed.
g) Alarm Management: Alarms shall be generated in case of any change
from “normal” to “abnormal” value of a monitored state. The processed
alarm shall be considered as an alarm appearance event and shall
generate an alarm.
Similarly, alarm shall be generated in case of changes from “abnormal” to
“normal” value of a monitored or processed alarm. This shall happen
whenever a reconfiguration action is required from the operator to restore
normal operation.
The SCADA system shall be able to handle various types of alarms, typically:
 Monitored alarm: - Shall be directly linked with the value of a field-
monitored alarm.
 Complex alarm: - Shall be the result of processing the values of one or
more field events. This shall be derived (computed) alarms to be
defined during engineering.
 Conflicting alarm: - Shall apply to a processed status resulting from
several distinct field monitored states, when the sources give
inconsistent information e.g. inconsistent inputs resulting from
chattering of breakers or non-zero voltage/current appearing on SLD
when corresponding breaker is in open state.
 Control failure alarm: - When performing such remote control, the
SCADA system shall check the correct monitored or processed status
change. If this event does not occur after a predefined time, the
SCADA system shall generate a Control failure alarm.
 Uncontrolled state change alarm: - If a monitored or processed status
associated with remote-control changes without previous control
action from the operator or the system, an uncontrolled state change
alarm shall be generated.
h) Alarm Classification: The classification shall be programmed in the OCC,
BCC and the local equipment, but can be easily modified and reloaded
from OCC and BCC.
All alarms shall be classified into priority levels. Each level of priority shall
be segregated and characterized by a distinguishable colour and a display
attribute (flashing) that are the same on all the Workstations of the
system.
The alarms and events shall appear in a display window and are displayed
on a priority basis. When there are several alarms or events of the same
priority, the system will establish another priority between them; the older
they are, the lower their priority.
i) Audio Visual Alarm: Generation of alarm shall lead to an audio-visual signal
for the operator. The signals shall be generated in such a manner that they
immediately draw the attention of the operator.

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Section 6B: Part-II Power Supply System 102

 There shall be three categories of audible alarms easily

distinguishable by separate tones or sounds for events classified as
emergency, urgent and non- urgent. A mute facility shall be provided
to silence the alarm. Once the event
causing the alarm has been acknowledged, the alarm shall be muted.
It shall be possible to acknowledge alarms individually or in groups
from the alarm display page. When the status of an alarm returns to
normal condition, a return-to-normal message to this effect shall be
generated.
 The nature of all audible alarms shall be accompanied with a
corresponding message providing details of the alarm, which is
presented on the workstation display. When an alarm is initially
received a corresponding visual flashing indicator shall appear on the
display. Once the alarm has been acknowledged the flashing indicator
shall transfer to a permanent illumination.
 In the event of multiple events initiating audible alarms, only one alarm
shall be broadcast at any any given time. The highest category of
alarm shall always take priority, even a lower priority alarm is already
being broadcast. Once the higher category has been acknowledged
and muted, the next lowest category of alarm shall initiate the alarm
broadcast.
 To avoid unnecessary and nuisance alarms or alarms generated by
testing, a facility shall be provided to enable alarm blocking/filtering to
inhibit particular or global alarms, from any workstation. Inhibited
alarms shall activate an appropriate message, detailing the non-
alarmed parameters and the remote terminal units affected.
ii. Web Enabled Operator Consoles: All operator consoles shall be web-enabled.
It shall work through the web browser and be able to host a full graphic user
interface only for remote viewing of data with limited rights. The web clients
can connect to the SCADA services at the OCC or BCC through LAN, WAN,
or through the internet or even wireless.
iii. Data Exchange: The SCADA systems shall be able to exchange various types
of data with the other application software.
iv. Calculated Data: It shall be possible to define the calculations on real-time
data and historical data, periodically but on request. The results shall be
incorporated into the database as calculated data available for display & report
generation.
v. The user shall be able to define calculated analog values using database
points as the arguments and mathematical functions as the operations.
Functions such as addition, subtraction, multiplication, division, maximum
value, minimum value, average, count, square root, etc. shall be provided.
vi. Trending: Trend displays shall enable the user to select real-time and
historical data for trending on graphical displays and for tabular displays. In
graphical trending it shall be possible to assign any number of tags to a single
window for trending.
vii. Programmed Controls: The SCADA System shall be capable of executing
predefined/predetermined commands from the work stations to field devices.
Controls may be generated by operator or the system and executed by the
SCADA system. Operator should be able to take actions wherever and
whenever required. In case of an emergency or abnormal situation, the
Operator shall be able to control the various items of equipment, typically:
isolation of the faulty sections, restoration of the normal configuration after the
fault is remedied.
Three levels of control management are possible, namely:
 Centralized from OCC control room: In that mode, all the actions are

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Section 6B: Part-II Power Supply System 103

carried out from the OCC provided that the appropriate configuration is in
place from the equipment and local control room.
 Local mode from RSS control room: The equipment can be operated from
the local control room through the workstation connected to the local area
network. An authorization is proposed to the operator to take over the
management from the OCC. Operation of the equipment from this
workstation is possible when the access rights
are granted by the OCC operator. The local workstation can carry out
operation of equipment either by logging into the server at OCC or BCC or
be capable of independent operation when the communication with OCC
or BCC is temporarily unavailable.
 Local mode from the equipment: The equipment is associated with a
changeover switch with two positions “local” and “remote”. Its actuation
sets the working mode in remote (from OCC) or in local (from equipment).
The actuation of the switch in manual mode has the highest priority over the
other actions from the local control or the OCC.
The following control functions shall be available in the SCADA system:
 The SCADA system shall provide facility to open /close circuit breakers
and motorized disconnect switches. It shall be guided by a Remote/Local
selector switch at the equipment. In case of remote selection, operation
can be done from SCADA at OCC. In case of local selection, operation
from SCADA shall be inhibited from RSS control room.
 It shall be possible to control the breakers and motorized disconnect
switches via Operator request or via automatic control procedures.
 Control command logging: The SCADA system shall log the control
operations by the operators in the event list so that any closing or opening
of circuit breakers or disconnect switches other than those issued by the
operator from SCADA can be distinguished in the Event log.
 Permissive for Local Operation: In order to facilitate local maintenance of
the equipment and to prevent unauthorised local operations, Permissive
for Local operation shall be provided by way of Access Control Rights so
that the field operator can carry out operation of the power equipment only
after the above permission is granted from the Control Centre. SCADA
system should ensure that no operation is performed without permission
from Operator. Further, even after granting the permission of local
operation, the events and parameters shall continue to be monitored.
 Remote control inhibition: The operator shall be able to inhibit/block the
equipment control from SCADA system. This blocking action shall be
available in the blocking list. The control inhibition/control blocking shall be
possible individually for each equipment being processed. The operator
shall be able to cancel the blocking as well.
The SCADA System shall handle, for each controllable item of equipment, a
control status, which is a combination of:
 local/remote operation,
 remote control inhibition.
The SCADA System controller shall have access to a list showing all remote
control inhibitions currently active.
 The blocking actions shall be available in the SCADA system in the form of
a blocking list for identification of the blocked equipment, status of
equipment when it was blocked, and time of blocking
 Traction Sectioning: This feature applies mainly to Traction installations.
For the protection of engineering works, the Operator may set (or cancel)
the isolation of any subsection of the line. Such action shall involve setting
(or cancelling) a grouped inhibition on the remote control of all the traction
supply equipment of the relevant section. An identification number shall be

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requested to the operator. All Sections of the OCS shall be identified by a

unique number and relevant switches shall automatically open or close for
setting or cancelling the isolation of that particular section. In scheduled
or unscheduled maintenance periods, the Operator, in co-
ordination with the relevant staff, shall be able to protect the areas of work
by isolation of the relevant section or circuit. Setting a section or circuit
isolation shall involve the following steps on the equipment:
 Open the relevant switching devices.
 Setting remote control inhibition on each device
 Prove and confirm correct operation to Operator.
If all the steps have been performed successfully, the system shall give
authorisation to proceed with the maintenance work. A unique identification,
given by the SCADA system or controller, will identify the particular isolation.
The Operator will then give this identification and authorisation to proceed to
the person in charge of maintenance. After the work has been completed, the
Operator will cancel the corresponding isolation using the relevant
identification.
viii. Interlocking: To improve the overall power availability, a common practice is to
supply the system via two separate incoming feeds connected to different
sources. In case of loss of one source, automatic transfer switching could be
executed to transfer the supply to the other healthy source.
In case of power failures, transfer schemes may be initiated to restore power
to the effected equipment/subsystems. There shall be a provision to operate
these schemes through automatic mode or manual mode.
ix. Tele Measuring: In the power system, some of the data needs to be measured
and monitored like voltage, current, power factor, power demand, energy for
traction and auxiliary services. Dedicated equipment picks up the relevant
information and sends it to the RTU for transmission to the OCC.
The RTU shall be provided with necessary analogue input modules to receive
input from the transducers, which are in the scope of this contract.
This information is recorded and used for several purposes, among which is
energy consumption and maximum demand statistics for often desired.
The measured values shall allow the power consumption of various equipment
(such as RSS, TSS, and ASS), current values, and voltage values for several
parts of the network.
The energy (i.e. kWh, kVARH, pf) shall be measured for each equipment
supplying the network, mainly:
 220 kV incoming feeder
 220 kV outgoing feeder
 33 kV outgoing feeder
The measuring of Maximum demand will be made at an interval of 30
minutes. The measurement will be done through the latest digital signal
processing-based multifunction meters. Voltage & Current shall be measured
at the following points.
 Each 220 kV feeder
 Each 33 kV feeder at RSS and ASS(including ASSs in Depot)
 Each 25 kV feeder at TSS
These indications will be updated every 5 seconds. They will be displayed on
the Operator Workstation.
x. IS&R and Report Generation: A data and software storage system (archives)
with removable storage media facilities shall be provided at the OCC for the
historical storage of database records and software.
IS&R function shall provide for periodic archiving of analog and status data.
Archiving shall take place in standard RDBMS packages like MS SQL Server,
Oracle etc. IS&R shall support archival of history data in external mass

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storage media. The archived data shall be retrievable on demand for analysis.
These reports shall be available on shift/daily/monthly and yearly basis on
query. It shall be possible to export the generated reports into excel.
 The storage system shall utilise optical disc technology, which shall allow
the data to be indexed and shall allow random and sequential searches.
Each data storage facility shall have a capacity adequate to hold all
operational and user programmable software as well as data records
generated over the previous minimum period of 60 days without the
replacement of storage media. All data records generated within the
minimum 60 days period shall be available for recovery from any OCC
workstation within 1 minute of completion of any request procedure.
Retrieval of such data shall not degrade the performance of the SCADA
system.
 An automatic alarm shall be triggered in the OCC Workstation in the event
that the accumulated data and software is stored for more than a pre-
defined period (maximum seven days) without being backed up. The bulk
data storage system shall have sufficient capacity to provide a master
historical data storage of all software and recorded data for the entire
SCADA system. All software files contained within the SCADA
workstations shall be able to be uploaded to the OCC for historical data
storage.
 The historical data storage system shall index the storage media to enable
rapid retrieval of data by date and time and be capable of event searches
based on selectable criteria.
xi. Operational Aids: - Various functions shall be provided in the SCADA system
to assist the operator in the operation. Some of the features are the following:
 Log on.
 Log off.
 Filing
 Reports as described above.
 Trends
 Find, Sorting by column, Copy/Paste of events to other windows application.
 Printing
 Commenting on events by operator
 Search with a provision of easy sorting through several criteria
 Inhibits and tags.

3.28.4 SCADA Technical Requirements

The SCADA system shall be constructed with modern techniques in
accordance with internationally recognised standards and designed for safe
and efficient operation. All materials and equipment to be supplied shall be
of a proven design and the major components of the SCADA system shall
have a Service Life of at least ten years.
The Contractor shall ensure that the SCADA system is designed to
accommodate the ambient conditions under which the SCADA is required to
operate as stipulated in the Contract, the Employer’s Requirements, and
other documents forming part of the Contract. In addition , the Contractor
shall ensure that condensation does not form in a manner detrimental to the
durability or operability of any part of the SCADA system.
The SCADA system shall be designed to achieve high system availability and
to ensure that any single point failure of SCADA equipment shall not cause a
reduction in SCADA system performance. Redundancy shall be
incorporated, where failures cannot be tolerated, particularly when
associated with Safety Critical systems.
The SCADA system shall be based upon a multiplexed communication

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network with distributed processing capability. Data shall be capable of being

transferred to and from any point in the SCADA network. Failure of any
equipment element or node on the SCADA network shall not affect the
operation of any selected equipment. The Contractor shall ensure that the
security and vitality of the SCADA system is not compromised by links to the
selected equipment.
The remote terminal units shall be configured to enable logical and sequential
functions to be carried out locally, without reference to any master stations
and/or workstations. The SCADA system shall be capable of transmitting the
results of such operations to the master station for data storage.
The SCADA system shall be designed to accommodate future expansions,
and to incorporate additional functions and facilities, such as additional data
storage, interface input/output ports, condition monitoring etc., which may
also be necessary in the future.
SCADA equipment that is not desk-mounted or otherwise free-standing shall
be housed in line-replaceable plug-in modules, rack mounted in accordance
with DIN standards.
The racking shall be enclosed within suitable cabinets to suit the climatic
conditions of the installation. The arrangement of the SCADA equipment
within the cabinets shall be such that all routine maintenance can be carried
out through hinged access doors or removable covers, and where possible
from the front.
The design of the cabinets shall ensure adequate ventilation and air
circulation without permitting the entry of vermin. Cable entries shall be
closed , sealed and made vermin proof, by means of non-magnetic, fire-
barrier plates. All SCADA equipment shall be identified with permanently
affixed labels, written in English.
All SCADA equipment shall operate satisfactorily in the very high "electrical
noise" environment normally associated with electrified mass transit railways
due to electrical and magnetic fields created by traction supplies.
Equipment shall be immune to the effects of conducted and radiated
electrical and magnetic interference.
All SCADA equipment shall be fully protected against the effects of power
supply surges and transients.
The SCADA equipment shall be fully protected against the effects due to
lightning strikes in accordance with the requirements of an internationally
recognised standard and the Contractor’s Earthing Policy.
All surge suppression equipment shall be self-contained and self-resetting.
The suppression equipment shall be selected to ensure that the let-through
voltage does not exceed the absolute maximum voltage specified for the
particular equipment being protected. Signal cables from external sensors at
risk from the effects of lightning shall have surge suppressers fitted at both
ends of each cable and shall be installed and connected in accordance with
the manufacturer's recommendations.
The Contractor shall provide portable programming devices, including all the
associated software, to enable the maintenance personnel to test or
interrogate items of the SCADA equipment locally, i.e. without using the
SCADA communication network.
The system architecture for SCADA system shall be as below.
The SCADA equipments at Main and BCC shall control the entire Traction
and Auxiliary Supply network and RSS.

3.28.5 Communication Philosophy

i. Data Transmission network
The SCADA system acquires data from the RTU installed at various

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Section 6B: Part-II Power Supply System 107

locations and SAS system via Data Transmission network:

It picks up data also called the Remote Monitoring on site, i.e. RSS’s
SAS system and entire Auxiliary and Traction power system and brings
them to OCC Data Processing system. On the other direction, all the
operator’s instructions are sent to the remote terminal units by means of
Remote Controls.
ii. Data Processing system:
The RTU’s will act as the data processing equipments. These RTUs acquire
the process information and transmit the same to the Control Centers.
iii. Communication Protocol:
The SCADA system installed at Main(Mandale) and Backup OCC´s shall support
the following communication protocols:
• IEC 60870-5-104 for communication with the RTU´s and RSS´s SAS
system gateways.
iv. Synchronisation Process
The SCADA servers will be synchronised with Central Master Clock which in
turn will synchronise the RTU´s with the required periodicity.
The accuracy and resolution of the time stamping is very critical for analysing
the events that occur across various stations. To achieve this RTU should be
provided with clock which shall support time synchronisation from master
station via periodically initiated synchronisation messages of communication
protocol.
Apart from periodically synchronising the RTUs, the SCADA servers will
synchronise the RTU during start-up or after recovering from communication
failure. The SCADA system shall also initiate Time Synchronisation
messages when the communication with the RTU is restored after a
communication failure.
The SCADA servers will acquire the time synch messages from the LAN via
NTP protocol.
RTU shall be provided with dedicated back-up power for clock, so that in the
event of RTU getting off due to power failure, the clock shall be updating the
time. When communication with an RTU is interrupted, all data from that
RTU shall be marked with invalid time till the time synchronisation with the
RTU is established again.
v. Fiber Optical Communication network
The SCADA at Main and Backup OCC´s will communicate with the RTUs
and SAS system via Fiber Optic Link. This communication network from
RTU’s and SAS system to OCC and BCC TER shall be provided by
Communication Contractor.
vi. Performance requirements
The performance of the system must enable the operators to operate the line
under satisfactory conditions. More precisely, the following targets must be
reached:
a. Transfer time
The time required to transmit the status information and alarms to the
SCADA system is no more than 1 second in avalanche conditions.
b. System Capacity
The installed hardware will have capacity to handle the SCADA system load
for entire MML5 and an additional 100% of this capacity.
vii. Communication Medium
Operation and Control Center (OCC)
• The SCADA Servers shall communicate with the RTU´s and RSS gateways
through communication Front Ends, which shall use IEC 60870-5-104
protocol to communicate with the RTU´s.
• The Front End Processors shall be connected to the OFC transmission

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Section 6B: Part-II Power Supply System 108

system equipment installed at Main and Backup OCC´s via Ethernet

interface. Necessary STP cables or OFC and Ethernet to OF converters are
considered in the scope.
• The Front End Processor shall include necessary software with licenses
(operating system, specific software, data base softwares, graphics, etc.).

3.28.6 Remote Terminal Units (RTU)

• The RTU proposed shall be modular in nature and scalable up to
maximum of 2000 data points. The RTU shall support distributed
processing intelligence with decentralised structuring with the task of pre-
processing of inputs distributed to the IO modules.
• The RTU shall support the following technical features which are very
critical for ensuring the functional requirements for a critical application
like Metro Railway Traction Power Control.
• RTU´s will monitor and control both ASS and Switching Post Equipment.
• RTUS’s shall have 20% spare IO points in each type.
• RTU’s shall be type tested as per IEC 61850-10
i. Central Processing Unit (CPU):
The Central processing unit shall have at least 32 bit microprocessor and a
dedicated peripheral bus controller for handling the IO functions. The CPU
module shall have non-volatile memory. The CPU module shall support the
following serial port requirements in two CPU modules. It shall have
necessary communication ports for communication with at least 3 control
centers i.e. 2 control centers on IEC 870-5-104 protocol. It shall support data
acquisition from Energy meters on MODBUS protocol on one port. The RTU
shall have one MMI port which can be used for configuration purposes.
ii. RTU Internal Clock:
RTU shall be provided with dedicated back-up power for clock, so that in the
event of RTU getting off due to power failure, the clock shall be updating the
time. When communication with an RTU is interrupted, all data from that
RTU shall be marked with invalid time till the time synchronisation with the
RTU is established again.
iii. Remote Programming Facility:
The RTU shall support remote programming facility using RTU programming
utility software from the Master Control center. The MMI port on the RTU
shall be terminated to the Master Control center via the same Ethernet
channel.
iv. I/O Module Specification \\[Link]. DigitaI Input Module:
The Digital input module shall have 16 optically isolated channels per
modules and shall support time stamping with time resolution of 1 ms.
The digital input module shall support configuration of inputs for the
following options:

• Single Indications
• Double Indications
• Digital Measurands
The digital input module shall support the following features: Programmable
parameters like
• Bounce Filter (Suppression Time)
• Settling time for reliable digital measured value
• Chatter suppression (for avoiding constant changes in the digital input)
• Suppression of intermediate position
• With / Without time tagging shall be a configurable feature
• Configurability of message transmission priority
• Indication processing of

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• Group or Common alarms shall be configurable from Individual

alarms by Boolean operations.
• Acquisition of events in chronological order with a time resolution of 1 ms.
• Buffering up to 3 changes per input
v. Analogue Input Module:
The Analogue inputs module shall have 8 channels per module and shall
support Dual Slope integration A/D conversion. The Analogue module shall
support the following features:
• Unipolar Measured values
• Bipolar measured Values
• Programmable parameters like
• Live zero conversion coefficients
• Cyclic Transmission or threshold value
• Forced zero- point conversion coefficient.
• Limit Values
• Smoothing factor
• Threshold values
• Cyclic duration
• Priority of Transmission
• Other parameters:
• Inputs shall be configurable for 4 to 20 mA / bipolar or live zero
• Accuracy - </= 0.1 %
• Common Mode Voltage: +/-8 V DC
• Line Interference suppression: > 100 d for fn 50
or 60 Hz [Link].3.
• Digital Output Module:

The Digital Output module shall support 16 digital output channels per module.
The output module shall support the following features . Programmable
Parameters shall include

• Duration of Output Pulse

• Release disconnection delay time at response indications
• Select before execute.
• Cyclic duration
• Priority of Transmission
vi. Redundancy:
The RTU offered shall have duplicated CPU and communication unit and
duplicate power supply system (power inverters). Both communications
cards shall have two ethernet ports to communicate with the two Master
Control center. Only one set of I/O cards will be provided.
vii. PLC Programming Facility:
The RTU has to program several logic functions which are required for the
metro power supply distribution application. Hence the RTUs offered shall
support PLC programming facility as per IEC 61131-3 standards. Necessary
programming tools shall be offered & supplied.
viii. Transducers for Analogue Measurements:
The RTUs will acquire analogue signals like voltages and currents from the
transducers via 4 to 20 mA analogue inputs. The transducers shall be
supplied by the contractor.
ix. RTU Panels
The RTU panel which houses RTU hardware mainly consists of the CPU &
IO racks and power supplies, interface converters etc. All panels shall
provide enough space to house main and redundant components and shall
be of IP54 protection class or higher for indoor panels and of IP55 protection

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Section 6B: Part-II Power Supply System 110

class or higher for outdoor ones.

MEP Contractor will provide a separate Clean Earth terminal for the RTU´s,
with less than 0.5 ohm. RTU´s shall be connected to the earth terminal
using galvanized iron conductor of at least 75 sq. mm by the contractor.
x. Environment Conditions:
The RTU hardware shall meet the following environmental
requirements: EMC Immunity: As per IEC 60870-2-1 Level 3 or 4
EMC Emission: As per IEC 60870-2-1 Class A
Temperature: -10 to 55 deg C as per IEC 80870-2-2
Humidity: 5 to 100% as per IEC 80870-2-2
The hardware adopted shall have protective features to withstand saline /
industrial pollution prevalent in Mumbai.

3.28.7 Hardware of the SCADA System

a) The OCC configuration shall consist of server hardware in dual redundant in
hot standby mode. The function of communicating with SAS gateway shall
be carried out through dual Front-end processors (FEP) in hot standby
mode. The hardware specification of Application Servers shall meet the
requirements of the SCADA system decided during detail design stage.
b) Operator workstations and Engineering workstations at OCC shall consist of
22 inch LCD dual monitor based workstation. The Contractor shall ensure
that the monitors provided shall be of the same manufacturer, size and
model as provided by other System suppliers in the OCC and BCC control
centers operator positions.
c) A high speed dual redundant LAN shall be created for communication of all
equipment inside the OCC. A minimum of 16 port Ethernet switch shall be
provided for each LAN. The incoming data connection from automation
network WAN / Fiber optic shall be terminated on to the 2 LAN switches. All
the SAS gateways shall communicate with FEP using the same LAN switch.
d) The SCADA master shall be synchronized using a time master using IRIG-
B/ NTP/ Precision Time Protocol (IEEE1588) using a GPS clock at OCC and
BCC. This time master shall act as a backup time master for all the SAS
gateways at each substations.
e) The workstations shall be placed in control room area of OCC. The Servers,
FEP and switch panel shall be placed in Technical Equipment rooms (TER).
The contractor shall lay the necessary LAN cabling from TER to control
rooms and Video wall.
f) Physically, the network shall be built with a physical topology which will
optimize the transfer capacity, the availability, and the cost. All the OCC
equipment shall operate on Single Phase, 240V, 50Hz UPS supply.
g) The facilities and configuration at BCC shall be similar to the one provided
at OCC.

3.28.8 SCADA Software:

The technical features of the SCADA software shall meet the following
minimum technical features.
i. Process Display:
The SCADA software shall support flexible process displays for continuous
& effective monitoring at OCC for the Receiving Traction & Auxiliary Power
equipment on the power supply network of the Metro Railway.
The process display feature shall facilitate depiction of Single Line Diagrams
with flexible choice of colours for the process objects and backgrounds. The
Process Displays shall support zooming & panning facility. The process
display features shall be flexible enough to build the complete Traction
network and the auxiliary network as a single Mimic Display with facility to

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Section 6B: Part-II Power Supply System 111

navigate using mouse from one end of the network to the other. It shall also
be possible to zoom portions for picture for getting a magnified view of the
Single Line Diagram
ii. Alarm Management:
Alarm Management System to alert operator & maintenance staff during
equipment malfunctions or any other system alarms likely to cause
disruption to operation of the services. The alarm management function
shall support.
• Two types of Alarm List templates
• User-friendly filters, Alarm List setting tool for Colours and text layout
• Updating/Frozen presentation modes
• Alarm acknowledgement, Alarm reset function.
• Authorization support
• Help in all dialogs.
• Visible Alarm Class
• Locate Object
• Column sort, Find, Fields indicating the number of active and
unacknowledged alarms
• Field indicating the use of filters.
• Field indicating the current presentation mode.
• Current/total page number indication on both lists
iii. Event Logging System:
Event Logging System for displaying and logging sequence of event
recording with 1 millisecond resolution for the various field inputs configured
at the RTU. The Event List contains the following features and options:
• Historical Storage of events with facility to retrieve the same later .
• Configurable layout: columns, fonts, toolbars, Colouring, and so on.
• Configurable Colouring of events
• Configurable scrolling behaviour
• Configurable presentation modes: log/event order, latest at top/bottom
• Updating/Frozen presentation modes
• Easy navigation through scrolling, go to date, time filters, and so on.
• Extensive filtering that can be stored and easily called up later.
• Find, Sorting by column, Copy/Paste of events to other windows applications.
• Printouts
• Commenting of events by operator
iv. Measurement Reports
The SCADA software shall support configuration of time related
measurement reports. Measurement Report is used within SCADA’s library
applications for various types of time related reports, such as hourly, daily,
weekly, monthly and yearly reports. The reports shall be based on time-
related follow-ups of process, metered, entered or calculated data. The data
for the reports shall be stored in real time. Report data is collected and
calculated cyclically or triggered by events. The most common method is to
fetch raw data from the process, and thereafter to scale and store it in the
report database. All the events/reports shall be automatically written in text
files and stored on hard disk in the reports folder of the application. Periodic
backups of reports shall be possible:
The Measurement Reports supports the following time related reports:
• Hourly report (time resolution: 3 minutes)
• Daily report (time resolution: 15 and 30 minutes)
• Weekly report (time resolution: 1 day)
• Monthly report (time resolution: 1 day)
• Yearly report (time resolution: 1 month)
Printers that are connected to the Master Stations are used for printing of reports.

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Automatic periodic printing of reports can be configured for the Master.

Printing of reports is also possible.
v. Trends:
The SCADA shall support trends for performing time related follow up of
process data. The trends shall be possible for both digital as well as
analogue parameters. The trend
shall support a maximum of 10 trend parameters. The trends shall be
possible in both graphical and tabular forms which share the same
database. The x- axis and y- axis of the graphs shall be configurable in
scale. It shall be possible to have different scan time variables in single
display. The trend display shall support the following features:
• Support of Graphical or tabular view modes with zooming facility
• Shall support Scrolling with scroll bars and panning.
• Configurable axes, line properties and legend
• Update interval options from 30 seconds to 10 minutes
• Trends for Calculation formulas; direct, mean, sum and difference shall be
possible.
• Shall have Printout option.
• Depiction of Update/Frozen modes
• Facility to Copy to clipboard and export to CSV File
vi. Control Functions:
The SCADA system shall support control function based on automatic &
manual control of power and traction equipment. The manual control of
equipments shall be possible using select- check- execute sequence. The
open/close function for the operator control action shall be possible to be
passed through protective interlock functions.
vii. Safety Tagging:
The SCADA software shall support the feature of safety tagging up to at
least 2 levels by the addition of note marker. The note marker shall be
inserted into any of the pictures and shall be saved even on the condition of
change over. The operator shall be able to give some specific instructions to
the shift operator using this functionality.
viii. Blocking List:
The SCADA software shall support feature of Blocking List which shall
depict the blocking status of update, Control, Alarm and event for the
various data base points along with the name of the Signal text used in the
SCADA system.
ix. Bus Bar Colouring:
The SCADA software proposed shall support necessary bus bar colouring
feature by which the dynamic status of the bus bar can be depicted during
charged and uncharged condition. The bus bar colouring shall be provided
for the ASS overview diagram, Traction over view diagram and Traction
individual screens. The colours will be as existing ones.
x. Connectivity to Receiving Substation:
The SCADA system installed at the Main and Backup OCC´s will integrate
with the Substation Automation system installed at the Receiving
Substations via IEC 870-5- 101 gateway.
xi. Visual Display Panels
The large screen graphics wall in OCC is used for the display of important
data, graphics from the PC, workstation, and video. It has the functionality to
preconfigure and save various display layouts to be accessed at any given
point of time with a simple mouse click.
Visual display panel will be composed by display modules. The display
modules will be connected to the graphical controller where the graphical
software will run.

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Section 6B: Part-II Power Supply System 113

3.29 RSS and ASS Metering

Energy meter (Electronic energy meter, Accuracy class 0.2s, to enable
measurement of import & export of Active energy (kWh), Reactive energy
(KVARh), Apparent energy (kVAh), phase angle, frequency, power factor,
instantaneous maximum demand, integrated maximum demand, total
harmonic distortion etc. Energy meter shall be ABT with TOD and power
quality measurement feature. The meters should have recording and
memory facilities for at least 45 Days.
The following smart metering arrangements shall be provided at the
Receiving Substations.

3.29.1 On the 220 kV Incoming & Outgoing Feeders from the Power Supply Authority
a. Ammeters (to read the value of current in each phase of each of the
Incoming Feeders)
b. Voltmeter (to read the value of line voltages in each of the Incoming Feeders)
c. Meters shall be provided as per the requirement of the Power Supply
Utility i.e. MSETCL for incommers. Apart from these meters, separate
Meter/s (Tri-vector energy meter, Accuracy class – same as MSETCL, to
enable measurement of Active energy (kWh), Reactive energy (kVARh),
Apparent energy (kVAh), frequency, power factor, instantaneous
maximum demand, etc.) shall be provided on each incoming and
outgoing feeder for Metro purpose.

3.29.2 On Traction and Auxiliary Main Transformer Output Side

a. Ammeters (to read the value of current delivered by each Transformer)
b. Voltmeter (to read the value of secondary voltage of each Transformer,
whether On-Load or Hot stand-by)
c. Energy meter (Electronic energy meter, Accuracy class 0.2, to enable
measurement of kWh, kVAh, kVARh, total harmonic distortion and
instantaneous maximum demand kVA. Only one energy meter is
required to be provided, which shall be able to indicate/record/store the
values of energy (kWh) and max demand (kVA), delivered in total by
both the Auxiliary Main/Traction Transformers, through suitable
summation CT and connections).
d. Energy meter for 25kV Depot feeders (Electronic energy meter,
Accuracy class 0.2, to enable measurement of kWh, kVAh, kVARh
instantaneous maximum demand kVA and total harmonic distortion)

3.29.3 25 KV & 33 kV GIS Outgoing Feeder in RSS and 33 kV GIS Outgoing

Transformer Feeder at ASS
a. Ammeters
b. Voltmeter
c. Energy meter (Electronic energy meter, Accuracy class 0.2, to enable
measurement of kWh, kVAh, kVARh instantaneous maximum demand
kVA and total harmonic distortion). Energy meter on each outgoing
feeder shall be provided, which shall be able to indicate/record/store the
values of energy (kWh) and max demand (kVA).
d. Communication to RSS, OCC & SLDC.

All the metering data inclusive of above parameters shall be transmitted/

communicated to SAS in RSS on IEC61850, SCADA in OCC through
Gateway and SLDC on IEC104 for trends and reports.
Laptop along with the accessories and communication software for fetching
the meter reading and configuring the meters to be provided.

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3.29.4 Testing of Energy Meters

All the energy meters should be tested by the third-party agency authorized
by Indian Government for testing and calibration of meters.

3.30 Distributed Temperature Sensing

Distributed Temperature Sensing shall monitor and analyse the temperature of

220kV cable on a real time basis and shall provide the graphical as well as digital
representation of temperature of the cable versus distance in a monitor.
The real time temperature monitoring will be done by a 4 core optical fiber cable
(OFC) with distributed temperature sensor. The OFC can be built into the cable
during manufacturing or attached externally at the time of laying. The OFC may be
laid coaxially in the center of the trefoil or by any appropriate method in consultation
with the employer. At the grid substation end, the OFC is to be terminated at DTS
monitoring unit. Optical fiber cable shall conform to the relevant IEC standards and
necessary Type Tests as per relevant standard shall be provided.
The software for DTS should offer digital as well as graphical display of the thermal
profile of the power cable, alarms for absolute and rate of rise of temperature and
data storage facilities. The DTS system shall also have a HMI interface and it shall
be compatible with the SCADA systems.

3.31 RSS & Simulation Study

Simulation is to be done for Normal as well as Abnormal Scenarios.

All Traction equipment in service & N-1 condition is to be considered as Normal and
N-2 condition is to be considered as abnormal.
Single Failure Condition (N-1): For Single failure of
RSS/TSS/SWS/AMSS/ASS/SCADA designed head way train services shall be
maintained without any loss of performance.
Two failure condition (N-2): For double failure of RSS/TSS/SWS/AMSS/ASS/SCADA
the traction power supply system shall allow for a reduced train services/may
consider extended headway/reduced speed of trains to operate the affected section
supported by traction Simulation study.
For minimum Voltage for Guaranteed performance please follow bid conditions.
Contractor shall provide the software (ETAP or equivalent) with valid licence (one
user- Standalone & lifetime validity) of latest version which to be used for Load Flow
Study, Short Circuit Study, Contingency Study and Protection Coordination Study
before the design submission so that employer’s engineer can verify the results of
simulation and studies. Software shall be capable to support the following simulation
–
a) Support for graphical creation and editing of network topology and data. The
software has compatibility with Windows 10 or above with 64-bit Operating
System.
b) The software shall be without an artificial size limitation. (Number of
busses/nodes should be minimum 1000 Bus).
c) ISO 9001 Certification Software
d) General Design & Drafting for making Single Line Diagram of electrical system.
e) Power system studies
f) Load Flow/Voltage drop (Balance & Unbalance)
g) Short Circuit/ Fault study
h) Protective Device Coordination & Auto Evaluation

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i) Star Automated Protection and Coordination Evaluation

j) Panel Systems and Single-Phase Load Flow Analysis
k) Power quality studies
l) Energy management studies
m) Power factor analysis and correction
n) Network reliability
o) Overall network behaviour.
p) Software product should comply with quality assurance standards.
q) Provide online support and technical tutorials.
r) System to be provided with free software updates. Training to cover manual,
practical training on how to model a network.

3.32 Embedded Transformer Operating System

Transformers should be equipped with an on-line health monitoring system which will
enable the user to operate a transformer close to its thermal, current, voltage limits,
while considering thermal aging and avoiding critical hot spot temperature. It should
support advanced management of possible overload conditions to avoid an outage of
the transformer by early detection of faults. It should enable the user to perform
condition-based maintenance of the transformer.
All monitoring sensors for the transformer are to be connected to Embedded
Transformer Operating System (IED) which shall be installed at the transformer. Each
transformer tank shall have a separate system installed. This system should be an
open modular and upgradable system. It should be able to accept inputs from
additional sensors of any make, if required, in future.
The system installed on each transformer tank should be independently capable of
measuring, calculating, and recording the below parameters:
a. Load current, Ambient temperature, Winding Temperature & Top oil
temperature over analog input card. The single Analog input card with
minimum 8 inputs should have flexibility to take different forms of Analog
inputs such as RTD: 100 ohm platinum (Pt100); simulated winding
temperature; Current: Clamp-on CT, 0 - 5A, - 10A, - 20A, -100A; DC Current
Loops: 0 - 1 and 4 - 20 mA DC; DC voltage: 0 - 100 mV DC and 0 - 10 VDC;
AC Voltage: 0 - 140 VAC and 0 - 320 VAC; 50/60 Hz; Potentiometer: 1500 -
15,000 ohms; Dry Contact: Open/Closed; Switch contact: >80 V or >130 V
open, jumper selectable; optically isolated; Tap Position: 0 - 1, 0 - 5, 0 - 10, -5
- +5, -10 - +10, 0 - 125 VDC or non-powered; Resistor Bridges of 40 - 2500
ohm(1% acc, 100 ppm); or 0 - 1 mADC or 4 - 20 mADC over one single card
without any external hardware for conversion of the signals. One FO card for
winding temperature should be included in the same

b. Operating voltages along with power calculations etc.

c. Tap position of on-load tap changer, measure the number of switching

operations of OLTC duration per tap, monitoring of OLTC oil temperature,
indicate the number of OLTC operations until service & provision of alarm after
fixed number of operations.

d. OLTC health should be monitored online by inputs from Vibroacoustic

Monitoring sensor for the On Load Tap Changer. It will provide Warnings
regarding the mechanical deterioration, contact problems or synchronization
problems between the drive and the OLTC.

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e. The transformer monitor shall include the following communication ports:

10/100 Ethernet TX; RJ45 port; Serial Fiber Optic Port, ST connector; Serial
Fiber Optic Port, ST connector; Ethernet FX, ST connector; RS485, 4-wire
communications port; USB-A port; Display port for optional remote display.
The transformer monitor system shall support all industry standard
communication protocols DNP3.0, IEC 61850, and Modbus.

f. Circuit states of Buchholz Relay, Oil level indicator, Pressure Relief Device,
etc. through Digital input channels on Digital Input card with minimum 14
inputs on each card.

g. The online DGA instrument should measure directly in the vessel (in tank) with
two nos. ball valve installation and SS tubes to ensure TRUE sampling. The
equipment should be Gas Chromatography based equipment capable of
extracting the seven Fault gases and the two Atmospheric gases and
measuring them individually without interference of other gases and reporting
the concentrations from transformer oil. It shall measure all seven transformer
fault indication gases i.e., Acetylene (C2H2), Methane (CH4), Ethane (C2H6),
Hydrogen (H2), Ethylene (C2H4), Carbon Dioxide (CO2), Carbon monoxide
(CO) and moisture (H2O). and the two atmospheric gases i.e. Oxygen (O2) &
Nitrogen (N2). Instrument must be provided with on-board automated
Calibration verification facility to ensure performance to specifications
throughout the service life of the equipment. The Monitor MUST be calibrated
with a Reference Calibration Gas Standard that has a NIST Traceability
Certificate. The offered DGA should be IP 66.

h. Bushing health should be monitored online with bushing monitoring sensors

based on the Double-Reference Method (2/3-reference method) for accurate
analysis which monitors the condition of the bushing insulation regarding
changes in capacitance (C1) and dissipation factor (tanδ) in a three-phase
system. The system should consist of Bushing Adaptors, Coupling Units and
Evaluation Unit (within the Embedded Transformer Operating System).

i. The following displays shall be at least provided: -

1. Tan δ trend
2. Capacitance trend
3. Tan δ/ temperature gradient trend.

j. Circuit state of fans and pumps and control.

i. On the basis of received on-line measurements from various available
sensors, the transformer monitoring system should calculate/analyze:-
the Apparent Power, Load Factor, Hot spot temperature in accordance
with IEC 60076-7, Top oil temperature according to thermal model as per
IEC, Cumulative Ageing rate in accordance with IEC 60076-7, Moisture
of insulation paper, Bubbling temperature, Overload capacity,
Emergency overloading time when overloading, Running hours of fans
and pumps, Cooling efficiency (thermal resistance Rth).
ii. The software should be in IED (inside box of Embedded Transformer
Operating System) to enable system to act as a black box. It should have
a robust operating system as the basis for all the system and application
functions. It should have the Database of current and historical operating
data as well as status and log information. Customization with flexible
digital and Analog inputs and outputs, which can be programmed by the

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Section 6B: Part-II Power Supply System 117

user. Web based Visualization in accordance with HTML 5 standard with

SVG (scalable vector Graphics) with no loss of quality.

k. The system should have a Cyber Secure design with:

 Pre-configured integrated firewall in accordance with IEC 62443.
 SSL/TLS (HTTPS) encryption (256-bit) in accordance with BSI TR
02102
 "Role-Based Access Control (RBAC)" role-based user management in
accordance with IEC 62351
 Password management in accordance with NERC-CIP
 Integrity of firmware, software and data.

Bidding Document for CA-239 Design Build and Maintain Single-Stage: Two-Envelope