SECTION – C - npcil. · PDF fileNUCLEAR POWER CORPORATION OF INDIA LIMITED ... P.BARIK,...

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SECTION – C

TECHNICAL SPECIFICATIONS OF STORES

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NUCLEAR POWER CORPORATION OF INDIA LIMITED (A Govt. of India Enterprise)

KAKRAPAR ATOMIC POWER STATION -1&2

Specification No: KAPS-1&2 / EMU/ 52420/ 2016/SPEC/ 001

REVISION NO. 0

DATE OF ISSUE (MONTH/YEAR) SEP/2016

TOTAL NO. OF PAGES (INCLUDING COVER SHEET) 80

TECHNICAL SPECIFICATION

FOR

415 VOLTS SWITCHGEAR USI NO: 52420

Prepared by: SHADAB AHMAD,SO/D

U.PETKAR, SE (EM)

Checked by: P.BARIK, SME (E)

Reviewed by: S.K DESHMUKH, MS

Concurred by: B.G.BALIGA , ACE(ED) , HQ

Approved by: V.K.SHARMA, CS, KAPS-1&2

(Refer Revision Control Sheet for details of revisions)

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Control of Revision Sheet

Document Type: Specification No. : KAPS-1&2 / EMU/ 52420/2016/ SPEC/ 001

Title: 415 Volts switchgear for KAPS-2

Rev No Date Description of

change Prepared by Checked by Reviewed by Concurred

by Approved by

0 01/09/2016

New specifications

1.SHADAB AHMAD

SO/D

2. U.PETKAR,

SE( EM)

P.BARIK, SME(E)

S.K.DESHMUKH MS

B.G BALIGA

ACE-HQ

V.K SHARMA CS, KAPS-

1&2

NUCLEAR POWER CORPORATION OF INDIA LIMITED

SPECIFICATION OF 415 V SWITCHGEAR FOR KAPS-2 KAPS-1&2 / EMU/ 52420/2016/ SPEC/ 001, R 0

CONTENTS

S. No. Description Page No.

1. Scope 4

2. Project Data 5

3. Codes and Standards 5

4. Technical Requirements 24

5. Drawings, documents & data 24-36

6. Tests and test reports 37-38

7. Inspection and Testing 38

8. Quality Control Plan 43 9. Erection and commissioning 43-46

10. Training 46

Annexure

1 Project Data 46

2 Applicable Standards 47-48

3 Data Sheet for Switchgear 49-63

4 List of Drawings 63-65

5 Quality control plan 66-80

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1. SCOPE OF SUPPLY / WORK / SERVICES

The scope of this specification covers the technical requirements of Replacement of existing 415 volt switchgear by new switchgear for Unit No.2 at Kakrapar Atomic power station (KAPS # 2)

Replacement of existing switchgear panels by new switchgear

The scope covers design, manufacture, assembly, testing at manufacturer’s works, inspection, packing, and transportation/ delivery to site well as erection and commissioning of 415 volts switchgear at site for Unit No.2 at Kakrapar Atomic Power Station (KAPS-1&2).The scope also includes carrying out exercise of seismic qualification of representative switchgear panel (of each rating) by test/analysis/combination of test and analysis.

The scope also includes decommissioning of existing 415 volt switchgear by disconnection of existing cables/ bus-ducts, removal of panels and installation of new switchgear panels at the location of removed panels & termination of earlier disconnected cables/ bus ducts by properly matching the existing available cable/ bus duct slacks.

The scope also includes supply of extra four no. circuit breakers as spare along with necessary auxiliary contacts, draw out mechanism with complete assembly having similar technical specifications as described in detailed technical specifications for equivalent (rating) of ME-3205 CBs which shall be installed and commissioned air circuit breakers for bus incomer & tie circuit breakers (equivalent of existing ME-3205 CBs) .The location for these CBs shall be decided mutually by purchaser and contractor depending upon space constraint and requirement of purchaser.

The scope also includes performance guarantee of 12 months from the date of commissioning.

The bidder is also required to include his confirmation to buy back the existing switchgear to be replaced and accordingly include the same in price part of the bid.

1.1. Unless otherwise specified, all accessories required for normal operation of equipment are deemed to be considered as a part of the bidder’s scope of supply.

1.2. Spares parts required for five years of trouble free operation of the system shall be listed & supplied by the bidder.

1.3. Special tools and tackles required for completing the work either at supplier’s premises or at purchaser’s site or at third party place like testing laboratory are deemed to be included in the scope of supplier only

1.4. It is not the intent to specify completely herein all the details of design, engineering, manufacture & construction of the equipment; however the equipment shall confirm in all respects to high standards of engineering, design & workmanship & be capable of performing continuously up to the vendors guarantees in a manner acceptable to the purchaser, who will interpret the meaning of drawing & specification and shall be entitled to reject any work or material which, in his judgment, is not in full accordance herewith.

1.5. Details of work involved & scope of material to be supplied by bidder has been included in this specification to the maximum extent possible. However, it is advised that bidder shall visit site and shall do the complete measurement & do feasibility study with respect to their standard designs before submission of quotation.

1.6. Detailed technical requirements are mentioned in following clauses of this specification.



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2. PROJECT DATA:

Details are as indicated in annexure-1

3. CODES AND STANDARDS:

1. The design, material, construction, manufacture, inspection, testing and performance of 415V switchgear and bus ducts supplied shall comply with the latest editions (including amendments thereto) of all currently applicable standards, statutes, regulations and safety codes in the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve the CONTRACTOR of this responsibility. Any supply items which are bought out by the CONTRACTOR shall be procured from manufacturers approved by the PURCHASER.

2. In case of conflict between the standards, stringent specifications out of these standards shall govern, whereas in case of conflict between the standards and this specification, requirements of this specification shall govern.

3. Other National Standards are acceptable if they are established to be equal to or superior to the listed standards. In all such cases, however, copies of English translation of such National Standards shall be attached to the Tender. The tenders not complying with this requirement are liable for rejection. Some of applicable standards are listed below.

The list of applicable standards are indicated in annexure-2.

4. TECHNICAL REQUIREMENTS:

4.1 BRIEF DETAILS OF EXISTING SWITCHGEAR The brief details of existing 415 switchgear at KAPS # 2 is given below for general information of bidder, however bidders are advised to visit the location of installation to get acquainted with site conditions, contingencies, work involvement, drawings to be referred & technical clarifications if any before arriving at their offer. It would be deemed that bidder has acquired all required information & understood the scope completely prior to submitting his offer. Breaker ratings given are enclosed rating. TABLE -1: Specifications of 415 Volt buses & breakers

Sl No BUS NAME BUS SPECIFICATION

1 2-52310-BUS-J Buses:

M/S. NGEF, Bangalore make, Sheet steel metal enclosed, single front, rigid floor mounted, air insulated cubicle type, double tier construction, Continuous rating : 3200 Amps for all buses except bus- S & Bus-T which are rated for 1600 Amps, short time rating: 50 KA for 1 sec., dynamic rating: 105 KA (peak), Min clearances : 25 mm between phase to phase & phase to earth., degree of protection: IP-54 for switchgear panels & IP-52 for relay panels

2 2-52420-BUS-K

3 2-52420-BUS-L

4 2-52420-BUS-M



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5 2-52310-BUS-P The Bus Bar chambers are mounted on the top portion. The main horizontal bus bars are made of Aluminum. The circuit breakers are arranged in single tier for incoming and double tier for outgoing feeders. The switch boards are provided with one common earth bus bar of 40 x 10mm tinned copper flat.

Breakers:

M/S. NGEF, Bangalore make, Type: M.E., Triple pole, Air break, Horizontal draw out air circuit breaker, Service voltage: 415 Volts, rated operating duty (P2): B-3m-MB-3m-MB, Minimum continuous current rating in switchgear panel with an ambient temp. of 45 0 C outside the panel for (a) Type- ME-1000 breaker: 1000 Amps (b) Type- ME-1600 breaker: 1250 Amps (c) Type: ME-3205 breaker: 3200 Amps .

Symmetrical breaking current: 50 KA (rms), Rated peak making current: 105 KA (peak), Rated short time current: 50 KA for 1 sec, Operating mechanism: Electrically operated breakers have motor wound Spring charged closing mechanism, Trip free, 250 V DC auxiliary supply for closing, tripping, and spring charging .Limits of operating voltages as percentage of normal voltage for satisfactory operation of (a) Operating mechanism: 85 to 110 % (b) Closing coil: 85 to 110 % (c) Trip coil: 50 to 110 % , Power required for closing at normal voltage & 80 % of normal voltage: 400 W, Power required for tripping at normal voltage & 50 % of normal voltage: 220 W. No. of trip coils: One

6 2-52310-BUS-P1

7 2-52310-BUS-Q

8 2-52310-BUS-Q1

9 2-52310-BUS-S

10 2-52310-BUS-T

TABLE -2: Details of breakers (Bus wise)

Sl No

Bus Name No of Vertical sections

No of

cubicles

Population of breakers

ME-1000 ME-1600 ME-3205

1 2-52310-BUS-J 3 02 -- -- 01

2 2-52310-BUS-K 10 11 03 + 03* 02* 02

3 2-52310-BUS-L 10 11 03 + 04* 01* 02

4 2-52310-BUS-M 11 11 03 + 02* 03* 02

5 2-52310-BUS-P 14 14 06 + 02* 02 03

6 2-52310-BUS-P1 10 12 10 -- 01

7 2-52310-BUS-Q 14 14 06 + 02* 02 03

8 2-52310-BUS-Q1 10 12 10 -- 01

9 2-52310-BUS-S 6 08 02 + 02* 03 --

10 2-52310-BUS-T 6 08 01 + 03* 03 --



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a) ‘*’ - indicate number of breakers with only manual closing provision

b) No of vertical sections includes breaker cubicles, dummy cubicles, PT cubicles and sections for bus interconnections.

c) Total Breakers; 93 No.

The main bus bars are located horizontally at top of each panel & vertical droppers are provided for fixed isolating main contacts for breaker. For further details like dimensions, orientation, interconnections etc. the tender drawing may be referred.

All protective and auxiliary relay are mounted on separate relay panels located nearby switchgear panels. Marshalling panels as part of relay panels are provided for marshalling all the external connections. Combined duplex type relay panels are provided for Bus –J , K, L and M. Separate simplex type relay panels are provided for Bus P-P1( combined) , Q-Q1( Combined), S & T.

4.2.0 Scope for replacement of existing switchgear with new switchgear:

4.2.1 Supply of material:

As a part of replacement of existing switchgear with new switchgear; bidder shall replace/provide following brand new equipments /parts as specified in the specifications.

a) Switchgear panels required for complete replacement of existing switchgear buses consisting of bus bars, enclosures, cubicles, air circuit breakers, rack-in/rack out trolleys, mechanisms, all components like auxiliary switches, fuses, fuse bases & carriers, MCB’s, CT’s, PT’s, auxiliary relays, indicating & pilot instruments/devices, panel meters, various switches, push buttons, space heaters & lighting components, limit & snap switches, sliding contacts / Plug In type arrangement for extending control circuit to CB , terminal blocks, transducers etc. wired up completely ready for installation with all features similar to the existing switchgear

b) Extra four no. circuit breakers as spare for bus incomer & tie CB ( existing ME-3205 type ) along with switchgear panels consisting of all components as per point no. a) above.

c) Relay panels (relay board) for five location of switchgear (Bus-P-P1,Q-Q1,S,T,J-K-L-M) required to be replaced with new panels consisting of associated auxiliary relays, protective relays and auxiliary equipments etc. All the protective relays shall be numerical protection relays which shall be replacing the existing electromechanical / static relays / releases.

d) Supply of base frames along with spacers, packings, shims etc. for mounting the new equipments at purchaser’s site

e) All consumable like wires, ferrules, lugs, TB’s, markers, ties, nomenclature labels, cable glands, instruction & danger sign boards, hardware, sealing gaskets etc



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f) Rubber bellows/ expansion joints, bus duct accessories etc. along with necessary supports required to match with existing bus ducts & new switchgear

g) All air circuit breakers shall have minimum rating equivalent to the existing rating or with nearest next higher rating of concerned manufacturer’s standard rating. The ME-1000 & ME-1600 breakers may be replaced with single rating CB’s subject to fulfillment of other design requirements

h) Computer/ software based systems if used for monitoring / control / protection of the systems covered in this specification, shall be subjected to Independent Verification and Validation (IV&V) at factory and also at site. IV&V at factory will be carried out after completion of inspection/tests by NPCIL and at site after completion of site commissioning tests. Detailed scope of IV&V shall be as described in Annexure 3.

4.2.2 Erection & Commissioning:

Following works shall be performed by supplier at KAPS site

a) Disconnection of existing power & control connections/ cables/ bus ducts at switchgear end with record of disconnection & tagging of identification marks for ease during reconnection.

b) Removal of cables from switchgear panels, sealing of bare ends & storage of removed ends in dressed manner.

c) Removal of existing switchgear & shifting to storage place within KAPS-1&2 premises. d) Removal of existing mounting frames if required, by means of drilling / grinding/ any

other necessary operation e) Mounting of new base frames made of ISMC according to approved layout for new

switchgear f) Shifting the new material from place of storage to place of installation g) Interior & exterior painting of base frames structures with approved procedure & shades h) Installation of new switchgear i) Re glanding of earlier removed control/ power cables & laying the cable ends in side the

switchgear after installation of glanded cable ends through gland holes & connections thereof.

j) Matching bus duct connections, modifications as necessary to match bus ducts & Bus duct connections

k) Installation of gaskets, sealing of openings, alignment, lubrication of mechanism l) Removal of necessary components from protective relay cum marshaling panel &

installation of new components along with associated rewiring work. m) Partition in top and bottom of two-tier switchgear shall be provided for safe working. n) Removal of existing insulating mat and refixing of new mat of suitable rating shall be

provided by supplier. o) Trolleys for removal of breaker for maintenance work shall be provided by supplier. p) Cable and cable trays housekeeping including proper clamping and support shall be under

scope of supplier. q) Internal & external painting of protective relay cum marshaling panel along with

nomenclature tag. r) Installation and commissioning of four no. spare circuit breakers for bus incomer & tie

circuit breakers (equivalent of existing ME-3200 CBs) .The location for these CBs shall



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be decided mutually by purchaser and contractor depending upon space constraint and requirement of purchaser

s) Through inspection, operability & functional checks, integrity checks/ testing/ inspection etc.

t) Charging of the switchgear & commissioning of individual breakers u) Rectification of all the deficiencies observed during re-commissioning of switchgear v) Preparation & obtaining the approvals of work & test procedures, plans, inspection &

quality control programs w) Documentation like maintaining log books, testing/ inspection records, man & material

history, measurements, procedures, trainings, safety, security & administrative aspects with respect to switchgear erection & commissioning work

4.3 INTERCHANGEABILITY

a) All identical equipment and corresponding parts including chassis of draw out modules of the same size shall be fully interchangeable without having to carryout any modifications for trouble free interchangeability. The draw out arrangements shall be designed such that normal dimensional variations are taken care of by self-aligning feature of the modules.

b) Components and equipment that are not fully interchangeable are liable for rejection. Supplier shall replace all such equipment by fully interchangeable equipment at his cost.

c) Typical control schematics indicating the control requirements together with the list of components equipment required are detailed in the enclosed drawing list in annexure-4. Same may be referred at site.

d) Physical size of compartment for each type of control and current rating shall be so chosen that all equipment can be housed in the compartment. No equipment/devices associated with any particular circuit shall be permitted to be mounted in any other circuit module.

e) Individual circuit breakers and its controlling cubicle should be aligned symmetrically.

4.4 SHEET METAL WORK AND FRAMEWORK

a) The switchgear panels structural frame shall be fabricated using suitable mild steel structural sections or pressed and shaped cold rolled sheet of thickness not less than 2.5 mm.

b) Frames shall be enclosed by sheet steel of thickness not less than 2 mm. cold rolled, smoothly finished, leveled and free from flaws. Doors, partitions and covers shall be made of sheet steel of thickness not less than 2 mm cold rolled. Stiffeners shall be provided wherever necessary. Gland plates shall be made of 2.5mm CRCA or 4mm aluminum for single core cables.

c) All panel edges and door edges shall be reinforced against distortion by rolling, bending or by the addition of welded reinforcement members.

d) Cutouts shall be true in shape and devoid of sharp edges.

e) Complete structure shall be rigid, self-supporting free from vibration, twists and bends.

f) Perimeter of all doors and removable covers shall be gasketted all around with neoprene gaskets.



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g) Base frames of floor mounted boards/panels shall be welded to the embedded parts provided on the floor. In case the embedded parts provided are not suitable for welding of the base frames, equipment may be fixed to the floor using approved make of anchor fasteners.

4.5 CONSTRUCTIONAL FEATURES

415V AC switchgear shall be 1) Of the metal enclosed, indoor, floor mounted modular type. 2) Made-up of the vertical sections. Protective relays associated with the feeder shall be housed

in same vertical section, if applicable. 3) Vermin proof construction and construction should be of dust proof except wherever

ventilation louvers are required for effective cooling. However, louvers should be provided with wire mesh of brass (or) stainless steel with holes not greater than 1 mm, such louvers are permitted in places like cable alley.

4) Easily extendable on both sides by the addition of vertical sections after removing the end covers.

5) Circuit breakers shall be of fully withdraw able type. 6) Panels shall be provided with cable or bus bar entry at top/ bottom as applicable, with 3 mm

thick removable gland plates on breaker panels and 2 mm thick removable gland plates on other panels. For single core cables aluminium gland plates shall be provided.

7) Of uniform height of not more than existing panels. 8) Having single front and two tier execution (as in existing panels), the switchgear shall

incorporate operating devices only in the front of the cubicles

9) Operating devices shall be placed in front of the switchgear. No equipment shall be located at less than 250 mm from floor level.

10) Provided with CT and PT which shall be located in such a way that they can be easily accessible for maintenance.

11) Provided with indelibly marked labels on the front and rare indicating the switchgear designation.

12) Each vertical section shall be equipped with thermostatically controlled space heaters, which may be located in the cable alley.

13) Provided with sheet metal partition between two adjacent vertical sections running along entire height of the switchgear except for the horizontal bus-bar compartment

14) Equipment associated with different circuits shall be housed in different 15) Design shall be such that all live connections remain shrouded at all times & Insulating sheet

with slots shall be provided wherever bus bar or breaker power connector extrusion is needed. These slots also shall be suitably shrouded with automatic shutter of insulating plate to prevent access to any part of live circuit when breaker trolley is in test & isolated position or breaker trolley is completely removed from compartment.

16) The individual compartment doors shall be provided with suitable cutouts as necessary to permit operation of circuit breakers and circuit isolating switches from the front without having to open the door. Such cutouts shall be provided with spring-loaded gaskets for the purpose of dust and vermin proofing.



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17) Suitable barriers shall be placed between circuit breakers and all control, protective and indication circuit equipment including instrument transformer. External cable connections shall be carried out in a separate cable compartment.

18) After fully withdrawn condition, the power and control connections of a circuit , it shall be possible to safely carry out maintenance in a compartment with the bus bars and adjacent circuits live.

19) Rear of single front switchgear shall be provided with concealed type hinged doors with lockable handles. All doors shall be provided with concealed type hinges and captive screws

20) The protection for 250 V DC circuits in existing switchgear is provided by fuses on both positive and negative sides. However for new switchgear these protections shall be provided by suitable MCBs.

21) The design of switchgear shall be such that the accessibility to sliding contacts shall be easy. However instead of sliding contact arrangement; plug in type arrangement shall be preferred.

22) For 250 V DC circuits the arrangement of main terminations shall be such that while disconnection of wire of a particular circuit, no other circuit shall get affected by any means and it should be possible to isolate & do maintenance work on individual circuits without affecting the other ones by any means.

23) One metal sheet shall be provided between two adjacent vertical sections running to the full height of the panel except for the horizontal bus bar compartment.

24) Panel construction shall be either welded type or bolted type. In case of bolted type member shall be joined using standard bolt, nut, plain washer and spring washer. Use of tapped screws for jointing members is not preferred. Rare side of panel shall have bolted cover.

25) Double compression type tinned brass cable glands suitable for the type and size of cables as finalized during the drawing approval stage shall be supplied.

4.6 MAIN POWER BUS All PANELS shall be provided with high conductivity Aluminium alloy bus bars as specified in DATASHEET.

1) Bus bars shall be of uniform cross section throughout length of the panel extending up to the outgoing/ incoming terminals and shall be capable of carrying continuously the specified rated current without exceeding the maximum allowable temperature as specified in DATASHEET. Tap-off bus bar connections to potential transformer up to primary fuse should be designed to meet the specified short circuit conditions.

2) Bus bars shall be insulated and provided with at least minimum clearances in air as specified in Data Sheets.

3) Main bus bars shall be located in separate independent air insulated enclosure and segregated from all other compartments of the cubicle. Direct access or accidental contact bus bars and primary connections shall not be possible.

4) Clearances in air between live pars and live parts and earth shall not be less than those specified in Data Sheets.



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5) The bus bar support insulators, bushings shall be of Class-B materials. Separate supports shall be provided for each phase of bus bars.

6) Bus bars (both horizontal as well as vertical droppers) shall be adequately supported and braced to the stresses due to the specified short currents conditions. Bus bar supports shall be made of insulated sheet glass reinforced moulded plastic material or cast resin. The supports shall be of high dielectric strength, non-tracking protection, impervious to water, tropicalised condition and resistant to fungi, non-inflammable and self-extinguishing.

7) The neutral bus of the 3 phase, 4 wire panels/boards shall be rated to be not less than 50% of the phase bus bars. The neutral bus bar shall have same capacity to withstand fault current as specified in DATASHEET for phase bus bar.

8) Separate supports shall be provided for positive and negative bus bars of DC system. Suitable insulated barriers shall be provided over the entire length of horizontal and vertical bus bars.

9) Copper Bus bar joints shall be tinned and complete with high tensile, bolts, washers and nuts. Bus bars shall be thoroughly cleaned at the joint locations and suitable contact grease shall be applied just before making a joint.

10) Bus bar joints shall be shrouded. All bus-bar joints shall be silver-plated.

11) All joints should be easily accessible for inspection whenever necessary

12) Bus bars (horizontal and vertical) shall be provided with black matt epoxy coating. However, no credit shall be taken for extra current carrying capacity due to black matt painting.

4.7 AIR BREAK CIRCUIT BREAKERS

1) Circuit breakers shall be three-pole air break horizontal draw out type and shall have fault making and breaking capacities as specified with out any additional devices. The circuit breakers, which meet specified parameter only after provision of releases or any other devices, are not be acceptable.

2) Circuit breakers shall be mounted along with its operating mechanism on a wheeled carriage. Suitable guides shall be provided to minimize misalignment of the breaker.

3) There shall be `Service', `Test' and ‘Fully withdrawn’ positions for the breakers. In `Test' position the circuit breaker shall be capable of being tested for operation without energizing the power circuits i.e. the power Contacts shall be disconnected while the Control circuits shall remain undisturbed. Locking facilities shall be provided so as to prevent movement of the circuit breaker from the `SERVICE', `TEST' OR FULLY WITHDRAWN' position. It shall be possible to close the door in TEST position.

4) All circuit breakers shall be provided with 6 NO and 6 NC potentially free auxiliary contacts. These contacts shall be in addition to those required for internal mechanism of the breaker.

5) Separate limit switches each having required number of contacts shall be provided in both `SERVICE' & `TEST' position of the breaker. (3 No.s for service & 1 no. for test minimum)

6) All contacts shall be rated for making continuously carrying and breaking 10 Amps at 240V AC and 1 Amp (Inductive) at 250V DC. Suitable mechanical indications shall be provided on all circuit breakers to show `OPEN'. `CLOSE', `SERVICE', `TEST' and `SPRING CHARGED' positions.



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7) All circuit breaker shall be provided with shunt and/ or series trip coil as specified in section CC-3.

8) Provided with mechanically operated red trip push button, shrouded to prevent accidental operation.

9) Provided with two trip coils.

10) Provided with control switches as per enclosed schematic drawings to perform opening/ closing operation of breaker in test position.

11) All circuit breakers shall be provided with the interlocks as explained in further clauses.

12) Movement of a circuit breaker between SERVICE AND TEST positions shall not be possible unless it is in OPEN position.

13) Attempted with drawl of a closed circuit breaker shall not trip the circuit breaker.

14) Closing of a circuit breaker shall not be possible unless it is in SERVICE, TEST POSITION or in FULLY WITHDRAWN POSITION.

15) Incomer and tie circuit breakers shall be mechanically and electrically inter locked so that only one at a time can be closed.

16) Circuit breaker cubicles shall be provided with safety shutters operated automatically by the movement of the circuit breaker carriage to cover the stationary isolated contacts when the breaker is withdrawn. It shall however, be possible to open the shutters intentionally, against spring pressure for testing purpose.

17) A breaker of particular rating shall be prevented from insertion in a cubicle of a different rating.

18) Circuit breakers shall be provided with electrical anti-pumping and trip free feature, even if mechanical anti pumping feature is provided.

19) Mechanical tripping shall be possible by means of front mounted RED `Trip' push-button. In case of electrically operated breakers these push buttons shall be shrouded to prevent accidental operation.

20) Means shall be provided to slowly close the circuit breaker in withdrawn position. If required for inspection and setting of Contacts, in service position slow closing shall not be possible.

21) The Circuit breakers shall be provided with power operated/ manual spring charge mechanism as specified in section CC-3.

22) The closing action of circuit breaker shall charge tripping spring ready for tripping.

23) Closing of circuit breaker shall automatically initiate recharging of spring ready for next closing stroke.

24) The circuit breaker shall not close until spring is fully charged.

25) Shocks, vibration or failure of spring shall not operate the breaker or prevent intended tripping.



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26) Power operated spring charging mechanism shall be provided with universal motor suitable for operation on AC or DC voltage with voltage variation between 85% and 110%. The motor shall be totally enclosed easily accessible. Suitable inspection covers to be provided for brush gear for adjustment of brushes.

27) Designed to enable a continuous sequence of closing and opening operation as long as power is available and at least one operation on power supply failure.

28) Provided with emergency manual charging facility.

29) Spring charging time for power operated mechanism should not exceed 20 seconds.

30) The circuit breaker shall make one complete closing operation once the control switch is operated and the first device in the control scheme has responded even though the control switch is released before the closing operation is complete provided there is no counter trip pulse.

31) The trip coil shall operate satisfactorily under all values of supply voltage between 70% to 110% of rated control voltage. Close coil shall operate satisfactory under all values of supply voltage between 80% to 110% of rated control voltage

32) Provision for mechanical closing of the breaker only in `TEST' and `WITHDRAWN' positions shall be made.

33) Preferably mechanical inter locks shall be provided between incomer(s) and incomers and bus tie breakers so that only one in feed can be switched on at any time.

34) For routine works like measurement of Loads parameters (IR,PI etc) ,breakers back compartment should be easily and safely approachable.

35) Latching relay features shall be provided to retain its existing position on failure of controlling supply of breakers (for 52a & b multiplication relays)

4.8 AUXILARY COMPONENTS & FUNCTIONAL REQUIREMENTS 4.8.1 Fuse

a. All fuses shall be of the HRC cartridge type. Control circuit fuses shall be of the plug-in type. Fuses shall be provided with visible indication to show that they have operated.

b. Fuse ratings chosen by Bidder for application in various circuits shall be subject to Purchaser’s approval.

c. Fuses shall preferably be mounted on moulded plastic carriers, which are mounted on the fuse bases. It shall be possible to mount fuses on carriers.

d. Wherever it is not possible to mount fuses on carriers, fuses shall be directly mounted on plug-in type of bases covered with insulated shroud. In such cases an insulated fuse-pulling handle shall be provided for each size of fuse for each switchboard.

e. It shall be possible to change fuses with the control circuit alive, without danger of contact with live metal.



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f. Current Vs time characteristics of fuses shall be furnished after placement of order. 4.8.2 Miniature Circuit Breakers:

a) MCBs shall be hand operated, air break, quick make, quick break confirming to applicable standards.

b) MCB shall be provided with overload and short circuit protective device for protection under overload and short circuit conditions. The minimum breaking capacity of MCB shall be 10 kA r.m.s at 415VAC/250V D.C. All MCBs shall have current limiting features. The let through I2t shall be limited to a value less than I2t of one-half cycle wave of the symmetrical prospective current without any fusible elements when operating within its current range. All MCBs shall have potential free auxiliary contact as per section CC-3/ schematic drawing.

c) Bus incoming control supply fuses shall have proper protection coordination with downstream distribution circuits.

d) The MCB’s shall be provided with an inscription window. The vendor shall provide removable labels (indelible) on the same. MCB’s on VT secondary circuit shall be provided with 1 No + 1 NC auxiliary contact.

4.8.3 Current Transformers:

1. Current transformer shall be of resin cast dry type with class- B insulation.

2. Current transformer shall have short time rating equal to the short time rating of the associated switchgear panel.

3. VA burden, current rating and accuracy class etc shall be as per section SLD. However it is contractor’s responsibility to co ordinate the current transformer burden with the requirement of relay/ instruments and lead associated with particular transformer, maintaining minimum burden as specified in single line diagram.

4. All current transformers shall be earthed through a separate link on the terminal block to permit easy measurement of the current transformer insulation measurement.

4.8.4 Voltage Trasformers

1. Voltage transformer shall be of resin cast dry type with class- B insulation.

2. Dual purpose VT and dual accuracy class for metering and protection as per section CC-3 shall be provided.

3. All secondary winding phase voltage of VT shall be rated for 110/√3 V.

4. Voltage transformer shall have continuous over voltage factor of 1.2 and short time over voltage factor 1.5 for 30 seconds in case of effectively earth system.

5. Voltage transformer shall be fixed type complete with suitable rated primary and secondary fuses. Primary fuses shall have rupturing capacity equal to the 80kA at 440V. Fuses shall be provided in all sub circuit.

6. It shall be possible to replace transformer without de energize the main bus bar.



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7. Terminals of VT which are required to be earthed shall be done with an isolating device without fuse.

4.8.5 Indicating instruments and meters

1. Unless otherwise specified, all electrical indicating shall be with 96 mm square and 240 degree scale, taut-band type. They shall be suitable for semi-flush mounting with only flanges projecting on front of the cubicle.

2. Instrument dials shall be white with black numerals and lettering. Knife edge pointers and parallax free dials shall be provided. Instruments shall be provided with non reflecting glass.

3. Instruments shall have accuracy class of 1.5 or better. The design of the scales shall be such that it can read a resolution corresponding to 50% of the accuracy class index.

4. Indicating instruments shall have provision for zero adjustment outside the cover.

5. Ammeter shall l continuously withstand 120% of rated current and 10 times the rated current for 0.5 seconds without loss of accuracy. Voltmeter shall withstand 120% of rated voltage continuously and twice the rated voltage for 0.5 seconds. All voltage circuits of meters shall be provided with fuses. Indicating instrument shall be provided as per the single line diagrams & data sheets enclosed.

4.8.6 Indicating Lamps/modules:

1. Indicating lamps shall be of the cluster LED type. Lamps shall be provided with series resistors, lamp holders and covers. These shall give red and green indications as per control schematics in DB wiring diagrams enclosed.

4.8.7 Push Buttons

1) Unless otherwise specified, push buttons shall be of momentary contact type with rear terminal connections. Push button contacts to be provided with enclosures. They shall be provided with integral inscription plates engraved with their functions. The push button knob shall be suitably shrouded to prevent inadvertent operation.

2) All push buttons shall have potential free two normally open and two normally closed contacts. The contact faces shall be of silver/silver alloy. The contacts shall be able to make and carry 10A at 220V DC and shall be capable of breaking inductive load of 1A at 220V DC.

4.8.8 Space heaters

1) Strip type space heaters of adequate capacity shall be provided on floor mounted panels to prevent moisture condensation on the wiring and panel-mounted equipment. Space heaters shall be rated for 240V, single phase, 50 Hz. supply. Heaters inside the panel shall not be mounted close to the wiring or any panel mounted equipment. Also accidental contact with heaters by operators shall not be possible. Heaters shall be complete with MCB on phase and link on the neutral of the heater supply. A thermostat shall control the switching of the heater.

4.8.9 Relays



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1) Protection relays as mentioned below shall be of numerical type with following general specification.

2) The sampling rate of CT/PT inputs shall be adequate to process the inputs with required accuracy. The system shall use non volatile memory unit and shall not require any loading of soft ware after it is inspected at factory. The response time for instantaneous type protection shall be less than 30 m second. Time delayed and IDMT protection shall be suitable for coordinating with down stream protection system.

3) Necessary provision shall be made in the relay so that the configuration can be changed at site, if required.

4) Relay facia shall have LED displays with functional keys to program the relay for relay setting and configuration.

5) The contractor shall specifically indicate the various protection for which multi function numerical relays are offered. Contractor shall also confirm the arrangement and specification of CT as specified in section CC-3/ schematic drawing.

6) All numerical relays shall have self diagnostic facilities to indicate the failure or unhealthiness of various module. Display shall be provided for above function.

7) The programming of relays shall be easily implement able at site and shall not required special programming knowledge for the operator.

8) Relay shall be suitable for accepting minute or hour pulse from station master clock.

9) Pass word protection shall be provided for implementing changes in the relay setting and configuration.

10) For all transformer feeder, protection relay shall have cold load pick up function to prevent unwanted tripping of transformer when started after long outage or initial charging.

11) Three phase over current and earth fault protection shall be provided for transformer and tie feeder. Event recording, disturbance recording and fault recording function shall be provided. Each phase over current protection function shall generate two pair of programmable potential free contact and earth fault function shall generate two pair of programmable potential free contact as per the requirement of 220 V DC scheme. The contact rating of potential free contact shall be as per section CC-3.

12) Motor protection relay shall be programmable to adjust characteristics in hot and cold conditions and also the staring duty specified for motor. The relay shall not prevent two successive hot and a third start after 20 minutes. All protection as specified in section CC-3 shall be provided. Event recording, disturbance recording and fault recording function shall be provided. Facility to display motor starting current shall be made. Three pair of programmable potential free output contact shall be provided as per the requirement of 220V DC scheme. Contact rating shall be as per section CC-3.

13) Operating principle indicating alogorithim, formulae used, block logic diagram in order to understand function of numerical relay for various protection shall be furnished.

14) All relays shall conform to the requirements of IS-3231 or equivalent. All numerical relays shall be draw out type flush mounted and relays with flag indication and manual resetting



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shall be suitable for semi-flush mounting with only flanges, projecting on the front with connections from the rear. Relays shall be dust tight and have transparent covers removable from the front.

15) Auxiliary relays may be of fixed type mounted inside the cabinet. Auxiliary relays shall be rated to operate satisfactorily between 70% and 110% of the rated voltage. Auxiliary relays like 3C, 3T and 43MX shall be provided with free wheeling diods.

16) All relays shall be self reset type except protection lock out relay unless otherwise stated in specification / scheme drawings. PLA relays shall not be accepted as failure rate of existing PLA relay is very high.

17) Numerical relays offered for CL-III & CL-II switchgear systems, independent verification and validation (IV&V) shall be performed. The scope includes preparation and submission of all necessary documentation and performance of tests at factory after the relays are inspected and cleared by quality surveillance and also at site. Details of the scope of work are indicated in Annexure-3.

4.8.10 Control Switches:

1) Switches shall be of rotary type, heavy duty, double break hand operated, air break, quick make, quick break type conforming to applicable standards. Switch ratings and number of poles shall be as per applicable scheme drawing.

2) The switches shall be capable of withstanding the mechanical stresses caused by the peak short circuit current of value equal to the cut off current of the associated fuse/ MCB. The utilization category for switches shall be selected in commensuration with its application.

3) Lockable type switches which can be locked in local or remote position shall be provided for local/ remote switches.

4) The connections between switch and fuse shall be insulated and all live connections shall be shrouded.

5) The circuit breaker test control switches shall be 3 position, spring return to neutral position. The control spring shall be strong and robust enough to prevent inadvertent operation due to light touch.

6) Instrument selector switches shall be stay put type. Ammeter selector switch shall be make before break type contact so as to prevent open circuit of CT secondary.

7) Contact of the switches shall be spring assisted and contact faces shall be of silver/ silver alloy. Spring shall not be used as current carrying part. The contact combination shall be as indicated in enclosed drawings. The contact rating shall meet the requirement of the circuit for which it is used.

4.8.11 Trasducer:

1) Voltage/ current transducers as indicated in schematic drawings shall be provided in the panels. Transducer output shall be as per Data Sheets / scheme drawings and capable of loading a burden of 750 Ohms.

2) The transducers shall be electronics based and shall have two galvanically isolated outputs.



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3) Galvanic isolation shall be provided between the input and output.

4) Auxiliary power supply requirement shall be compatible with 48V DC derived from the separate source.

5) Transducers shall comply with the IEC-60688, Class-III requirements.

4.8.12 Power & Control Supplies

1) The switchgear boards, if specified, shall be provided with necessary arrangement for receiving, distributing, isolating and fusing of D.C. and A.C. supplies as applicable for various control, signaling, lighting and space heater circuits. The incoming and sub-circuits shall be separately provided with switch & fuse. Selection of the main and sub-circuit fuse rating shall be such as to ensure selective clearance of sub-circuit faults. Fuses shall protect potential circuits for relaying and metering.

4.8.13 Equipment Mounting

1) All equipment on front of cubicle shall be mounted or flush/ semi-flush. In case of semi-flush mounting, only flange or bezel shall be visible from the front.

2) Equipment shall be mounted such that removal and replacement can be accomplished individually without interruption of service to adjacent equipment. Equipment mounted inside the cubicles shall be so located that fuses, terminals and adjacent devices are readily accessible without the use of special tools. Terminal markings shall be clearly

3) Cutouts if any, provided for future mounting of equipment shall be properly blanked off.

4) Indicating instruments and meters shall be at a suitable height so that the lettering on the dials can be easily read.

5) Control switches, push buttons and relay resetting knobs shall be conveniently located for ease of operation. The complete layout shall give a neat and uniform appearance.

4.8.14 Panel Wiring

1) Each panel shall be supplied completely wired internally to equipment and terminal blocks and ready for PURCHASER's external cable connections at the control terminal blocks. In case the boards are supplied in shipping sections the entire inter board wiring between shipping sections at site will be done by the CONTRACTOR by deputing his personnel with the required material for this purpose.

2) Internal control wiring diagram and external cable connection diagram for each board shall be furnished by CONTRACTOR.

3) All control wiring shall be carried out with 650V grade, self-extinguishing, flame retardant, non-propagating, PVC insulated, single core, stranded copper conductor wires, and shall be vermin and rodent repellent. The minimum size of the stranded copper conductor used for board wiring shall be as follows :

All control circuits except CT circuits

1.5 mm2 per lead

CT circuits 2.5 mm2 per lead Main controls supply(

close, trip and protection 10 mm2



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supply bus) Space heater main supply

and lighting supply 4 mm² copper

The minimum number of strands per conductor for 2.5 mm2 shall be seven (7) and for 1.5 mm2 shall be (3). Extra flexible wires shall be used for of devices mounted on moving parts such as swinging panels or doors.

4) Panel wiring shall be securely supported, neatly arranged, readily accessible and connected to equipment terminals and terminal blocks. Wiring gutters, troughs shall be used for this purpose. Wiring between terminals shall be point to point (without any splicing or 'T' connections).

5) Wire terminations shall be made with solder less crimping type of tinned copper lugs, which firmly grip conductor and preferably employ insulated compression sleeves to grip the wire insulation. Insulated sleeves shall be provided at all the wire terminations. Engraved core identification plastic ferrules, marked to correspond with CONTRACTOR'S board wiring diagram shall be fitted at both ends of each wire. Ferrules shall fit tightly on the wires and shall not fall off when the wire is disconnected from terminal blocks. All ferrules shall be yellow coloured with black lettering.

6) Wherever required longitudinal troughs extending throughout the full length of the boards shall be provided for inter-vertical section wiring. Wire troughs shall be made of self-extinguishing material.

7) If accidental short circuiting of certain wires is likely to result in malfunction of equipment or shorting of positive and negative wires, then these wires shall not be terminated on terminals with suitable barriers and provided with shrouds.

8) The unused instrument space on the front of the shall be kept clear of wiring to facilitate addition of devices as may be required in future without rewiring associated portion of boards.

9) Following colour coding scheme shall be adopted for: (i) 220V DC - Grey (ii) 240V AC & spare white (iii) all neutrals - Black (iv) all earthing - Green (v) 24V DC - Brown (vi) CT/PT connection: Red, Yellow and blue for R,Y&B phase respectively 4.8.15 Terminations

1) Terminal blocks for control wiring shall be 650 V grade "ELMEX" type or equivalent, 10 amps rated, one piece moulded complete with insulated barriers. Stud type terminals, washer, nuts and lock nuts of copper and identification strips and rated terminal block shall be provided. Markings on the terminal strips shall correspond to wire numbers on the wiring diagrams.

2) Moulding materials shall be self-extinguishing and resistant to flame propagations, substantially non hygroscopic and shall not carbonize when tested for tracking. The insulation between any terminal and framework or between adjacent terminals shall withstand a test of 2 KV rms, for one minute. The mouldings shall be mechanically robust to withstand handling while making termination.



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3) At least 20% spare terminals shall be provided in each cubicle and these spare terminals shall be uniformly distributed on all terminal blocks.

4) All control contacts and terminals of the board mounted equipment and devices shall be wired to terminal blocks for external use by PURCHASER.

5) Each terminal of terminal block shall have not more than one incoming and one outgoing wire termination.

6) There shall be a minimum clearance of 250 mm between first row of terminal blocks and the associated cable gland plate. Also the clearance between two rows of terminal blocks shall be minimum 150 mm.

7) Terminal block for CT and VT secondary leads shall be provided with test link and isolating facilities. CT secondary leads shall be provided with shorting links and earthing facilities.

4.8.16 Cable Termination 1) PURCHASER's external control cables will be terminated on the terminal blocks provided

in the marshalling panel wherever marshalling is done and the rest on the switchgear cubicle. The number and sizes of the PURCHASER's cables will be furnished to the CONTRACTOR after placement of order. All necessary cable terminating accessories such as gland plates, supporting clamps and brackets, wiring troughs and gutters, etc. for the PURCHASER's cables shall be included in the CONTRACTOR's scope of supply.

2) Terminals for power cables in the switchgear panel shall be suitable for stranded copper conductor, fire survival, armored / Aluminium conductor, XLPE, FRLS armored cables with sizes as specified in the single line diagram.

3) All cables shall be adequately supported at regular intervals, by means of suitable rubber or PVC lined clamps up to the respective terminals.

4.8.17 Interior Lighting and Receptacle 1) A 240V, 1 phase, 50 Hz. A.C. 5 Amps, 3-pin receptacle with switch shall be provided at a

convenient location in the interior of each vertical Section of floor-mounted panels. 2) Each vertical section of floor-mounted panels shall be provided with CFL lighting fixtures

rated for 240V, 1 phase, 50 Hz. supply for interior illumination of the panel during maintenance. The fittings shall be complete with MCB. The door switch shall control the switching of the fittings.

4.8.18 Name plates & Labeling

1) All labels shall comprise white letters on a black background. Labels shall be made of non-rusting metal. Labels shall be properly fixed at front and back, with provision to prevent distortion due to expansion. Danger plates shall also be provided as per IS.

2) Sizes of labels and lettering are subject to Purchaser’s approval.

4.8.19 Earthing 1) An earthing bus of GI shall be provided and extended the length of the panel and in each

vertical section. It shall be bolted to the framework of each unit. 2) The earth bus of GI, shall have sufficient cross section to carry the momentary short circuit

and short time fault current for 1 second as specified in Data Sheets, without exceeding minimum allowed temperature rise shall be provided for all switchgear panels. Earth bus shall extend the length of the panels and in each vertical section. This shall have provision for connecting to PURCHASER’s external earthing connection.



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3) Suitable clamp type terminals at each end of the earth shall be provided to suit the size of the PURCHASER’s earthing conductor.

4) All non current carrying metal work of the switchgear shall be effectively bonded to the earth bus.

5) Bolted joints, splices, taps, etc. to the earth bus shall be made with at least two bolts. 6) Hinged doors shall be earthed through extra flexible wire. 7) All metallic cases of relays, instruments and other cubicle mounted equipment shall be

connected to the earth bus by independent copper wire of size not less shall than 2.5 sq. mm. The colour coding of earth wire shall be as per applicable standards. Earthing wires shall connect on terminals with suitable clamp connectors. Soldering shall not be permitted of earth connection to other devices when the loop is shall not be permitted.

8) Looping of earth connections that would result in loss of earth connection to other devices when the loop is broken shall not be permitted. However, looping of connections between equipment to provide alternate paths to earth bus shall be provided.

4.8.20 Protection co-ordination 1) It shall be the responsibility of the CONTRACTOR to fully co-ordinate the over current,

earth fault and short circuit tripping of the devices with the upstream and down stream fuse/MCCB/Circuit breaker built-in releases/fuses/motor starters and capability of the connected loads to provide satisfactory discrimination. In order to achieve complete discrimination in protection coordination if ratings and type of fuse/MCCBs etc are required to be changed, it shall be carried out with out any extra cost to PURCHASER. Details shall be subjected to the approval of PURCHASER

4.8.21 Seismic requirement Seismic qualification of CL-III & CL-II switchboard assembly generally as per IEEE- 344 and as per approved test procedures for specified seismic acceleration shall be performed. This may involve performance of seismic tests on representative components and panels of PURCHASER's choice with all components mounted & wired on the cubicle and qualification of test switchboard of each rating.

1) Class-III, Class-II switchgear (of each rating) shall be qualified for seismic requirement by

carrying out actual test in the shake table facilities located at CPRI Bangalore. Typical assembly consisting of suitable number of vertical section, representing Class-III and Class-II 415V AC switchgear panel shall be subjected to seismic qualification along with all other component mounted inside panel. Further these switch boards shall be qualified by analysis.

2) The seismic testing procedure shall be prepared by contractor in consultation with purchaser and testing agency. The procedure is subject to purchaser approval. Procedure shall include the list of parameter to be monitor during, before and after seismic testing. As a minimum following electrical tests shall be included for acceptance of equipment.

3) Monitoring of breaker contact, draw out contact, protective relay contact and circuit breaker auxiliary contact for chattering during the test

a) Closing and opening operation of breaker. b) HV and IR value measurement before and after seismic test c) Visual inspection to assess damage of equipment & loosening of busbar joints, support

insulators etc.



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Switchgear and components subjected to seismic shall not be used for Cl-III and Cl-II panels. If switchgear and components which are practically in the same condition as before seismic test may be used for Cl-IV panels after obtaining purchaser’s approval.

4.9 Surface Treatment

All sheet steel work shall be phosphated in accordance with the following procedure and in accordance with IS: 6005 “Code of Practice for phosphating Iron and Steel”. Oil, grease & dirt shall be thoroughly removed by emulsion cleaning. Rust and scale shall be removed by pickling with dilute acid clean water followed by final rinsing with dilute dichromate solution and oven drying. The phosphate coating shall be sealed by the application of two coats of ready mixed, stoving type zinc chromate primer. The first coat may be “Flash dried” while the second coat shall be stoved. After application of the primer, two coats of finishing synthetic enamel paint shall be applied, each coat followed by stoving. Each coat of primer and finishing paint shall be of a slightly different shade to enable inspection of the painting. Switchgear panels shall be powder coated. The final finished thickness of paint film on steel shall not be less than 50 microns and shall not be more than 80 microns. Finished painted surface of panels shall present an aesthetically pleasing appearance free from dents and uneven surface. Panels not complying with the foregoing requirements are liable to be rejected. A small quantity of finishing paint as required shall be supplied for minor touching up required at site after the installation of the panels. The color of the finish paint shall be aircraft grey to shade 631 of IS-5 on exterior of the panel and semi-gloss white on interior of the panel.

4.10 General layout of Switchgear

For replacement of existing Switchgear with new switchgear, new switchgear along with relay panels and its associated components shall be provided as per existing layout. While performing above in Relay Panels (protective relay cum marshalling panel), removal of existing panels and necessary existing components including wiring, terminals, mounting of new components in panel & carrying out wiring within panel shall be in the scope of supplier. The modifications within panels that may be necessary for mounting of new components due to orientation/ size/ type variations & sealing of extra holes/ openings that may create during new component installation shall be carried out by supplier with no extra cost. The additional holes,



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openings created during new component installation shall be closed by welding of equivalent sized sheet steel by gas welding method, followed by finishing of deformities caused by welding with power tool grinding, filing etc. Suitable hardener-resin base filler & metal putty shall be applied to get plain finish surface & be painted initially with two coats of rust preventive primer followed by two coats of specified finished paint shade. All works that may affect the finish of panel shall be completed before applying finished paint coat.

4.11 Spare parts & tools

The bidder shall quote for adequate spare parts of switchgear for five years of trouble free operations with unit rates. The bidder may quote for all components require for switchgear as well as for tools and associated equipments required for the maintenance of breakers and relays and recommend the quantities required for five years of trouble free operation.

5.0 Specification of Equipments and accessories This section covers data sheets for 415 V switchgear. The data sheets in this section shall be read in conjunction with the single line diagram and

layout drawings for proper understanding of the devices required in the switchgear. Tag nos. of equipment supplied for shall be as per the enclosed single line diagrams and

scheme drawings.

415V AC SWITCHGEAR DATA SHEETS 5.1.0 415V SWITCHGEAR AND BUSBAR RATINGS 5.1.1 Type of switchgear : Metal Clad and Indoor 5.1.2 Rated Voltage : 415 V 5.1.3 Number of phases : TPN 5.1.4 Rated frequency : 50 Hz 5.1.5 System neutral earthing : Solidly earthed 5.1.6 Maximum system voltage : 457 V 5.1.7 One minute power frequency voltage For power circuits : 2500 V For control circuits : 2000 V



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For circuits connected to CT Secondary : 2000 V 5.1.8 Reference design ambient temp. : 45°C 5.1.9 Rated impulse withstand voltage For power circuit : 8kV For control circuit : 4kV 5.1.9 Max. Temperature at continuous current rating under design reference ambient Al Cu for bus bars : 85°C 85°C for droppers : 85°C 85°C for contacts (both sides with silver facing): 105°C 105°C for bolted joints : : 85°C Accessible cubicle outer surface : 70°C Operating handle : 55°C Inside relay/ transducer cubicle : 55°C Cable alley : 65°C Breaker contact ( silver plated) : 105°C Inside breaker cubicle where : 55°C

electronic release is housed 5.1.10 Short circuit withstand for bus bars and droppers One second rating : 50 kA (rms) Dynamic rating : 105 kA (peak) 5.1.11 a) Cable entry : As per the GA layout arrangement : Refer annexure-4 5.1.12 Bus bar material : Aluminium of grade 63401 WP 5.1.13 Single front / double front : Single front 5.1.14 Fully draw out/semi-draw out : Fully draw out for all panels

except bus VT. Fixed type for bus VT panel



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5.1.15 Degree of protection : IP 42 5.1.16 Number of tiers : Single & double tire for breaker (as

applicable) 5.2.0 SWITCHGEAR CONSTRUCTIONAL REQUIREMENTS 5.2.1 Colour finish shade Interior : Semi-glossy white/ RAL 7032 Exterior : Aircraft grey Shade 631of

IS:5/RAL 7032 5.2.2 Earth bus bar material and size : GI, suitable to carry 50 kA for 1

second 5.2.3 Purchaser’s earthing conductor : copper of 126.7 sq mm material and size OR 2 no's 50x6 GI flat 5.2.4 Clearance in air of live parts Phase to phase : 25.0 mm Phase to earth : 19.0 mm 5.3.0 BREAKER PARTICULARS 5.3.1 Type : Air circuit breakers 5.3.2 Voltage, frequency, no. of phases : 415 V, 50 Hz, 3-phase with

neutral link 5.3.3 Utilization category : B 5.3.4 Rated breaking capacity

Service short circuit breaking : 50 kA (rms) Capacity Ultimate short circuit braking : 50 kA (rms) capacity

5.3.5 Rated making current : 105 kA (peak) 5.3.6 Short time withstand current for one second duration : 50 kA (rms)



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5.3.7 Rated current at enclosed : As per applicable SLD ambient temperature 5.3.8 Type of operating mechanism : Electrical (power) operated store

energy type / Independent Manual spring charged as indicated in data sheets

5.3.9 Protection required relays : As per applicable SLD and

scheme drawings 5.3.10 Min. no. of auxiliary contacts required : 6 NO - 6 NC 5.3.11 Control voltage (a) For spring charging motor : 250 V DC with +10% to -20%

variation (b) For closing coil : 250 V DC with +10% to -30%

variation (c) For protection and trip coil : 250 V DC with +10% to -30%

variation 5.3.12 Emergency manual operations required in addition to electrically operated devices (a) For spring charging : Yes (b) For tripping : Yes (c) For closing : Yes 5.3.13 Rated impulse withstand voltage : 8 kV

for power circuit

5.3.14 Rated impulse withstand voltage : 4 kV For control circuit 5.3.15 EMC compatibility for releases : Required for environment category

A 5.4.0 CURRENT TRANSFORMERS 5.4.1 Type : Cast resin



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5.4.2 System voltage & frequency : 415 V, 50 Hz 5.4.3 Power frequency withstand voltage : 3 kV 5.4.4 Class of insulation : Class-B or better 5.4.5 Winding material : Copper 5.4.6 Rated primary current and ratio : As per applicable one line

diagrams 5.4.7 Accuracy class & burden : As per applicable one line metering & protection diagrams

5.4.8 Short time (1 sec.) current rating

and dynamic rating

:

As seen by CT primary & secondary when 50 kA (rms); 105 kA (peak) is applied to main power circuit to which CT belongs

5.4.9 Core balance CTs : Suitable for the respective cable

sizes as per one line diagrams & control schematics

5.5.0 VOLTAGE TRANSFORMERS . 5.5.1 Type : Cast resin, single phase 5.5.2 Rated voltage Primary : 415 V / √3 volts Secondary : 110 V / √3 volts 5.5.3 Method of connection Primary : Star-earthed Secondary : Star-earthed 5.5.4 Burden : 100 VA 5.5.5 Accuracy class : 0.5 / 3.0 (dual accuracy) 5.5.6 Rated voltage factor : 1.2 continuous; 1.5 for 30 sec. 5.5.7 Class of insulation : Class-B



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5.5.8 Withstand test voltage (one minute : 3 kV (rms) power frequency) 5.6.0 METERS 5.6.1 Type : Taut Band 5.6.2 Accuracy class : 1.5 5.6.3 Current/ Voltage rating : 5 A 5.7.0 TRANSDUCERS 5.7.1 Type : Dual output type 5.7.2 Output range : 4-20 mA DC 5.7.3 Load resistance / capability : 750 Ohms 5.7.4 Accuracy : 0.5% of full scale 5.7.5 Overload : (a) Current transducers shall

continuously withstand 120% of rated current and 10 times the rated current for 0.5 sec., without loss of accuracy.

(b) Voltage transducers shall

continuously withstand 120% of rated voltage and twice the rated voltage for 0.5 sec., without loss of accuracy.

5.7.6 Input parameters (a) Ampere transducer : 5 A (b) Voltage transducer : 110 V 5.7.7 Power frequency withstand voltage : 2 kV RMS for 1 minute between

wires and case 5.7.8 Application : For remote metering and indication



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5.7.9 No. of outputs : Two (2) 5.7.10 Auxiliary supply : 250 V DC 5.7.11 Applicable standard : IEC 60 688 5.8.0 CONTROL / SELECTOR SWITCHES 5.8.1 Type : Pistol grip handle switch, black, 3-

position spring return to normal type for breaker control switches and Oval handle, black stay-put type for selector switches

5.8.2 Applicable standard : As per Annexure - 2 5.9.0 INDICATING LAMPS 5.9.1 Type : Multichip LED type lamps, screw

type replaceable for each indication 5.9.2 Applicable standards : As per Annexure - 2 5.10.0 MCBs 5.10.1 Rated current : 16 A 5.10.2 Rated breaking capacity : 10 kA 5.10.3 No. of poles & auxiliary contacts : As per control schematics 5.10.4 Applicable standards : As per Annexure - 2 5.11.0 FUSES (For VTs and Control Circuits) 5.11.1 Type : HRC cartridge type 5.11.2 Rating : As per one line diagram / schematics 5.11.3 Rupturing capacity : Min. 80 kA 5.11.4 Applicable standards : As per Annexure - 2 5.12.0 SPACE HEATERS 5.12.1 Type : Strip type



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5.12.2 Voltage : Single phase, 240 V AC, 50 Hz 5.12.3 KW rating : TENDERER to indicate 5.13.0 LIGHTING / RECEPTACLE 5.13.1 Lighting 5.13.1.1 Type : Fluorescent / Incandescent 5.13.1.2 Voltage : 240 V, single phase, 50 Hz 5.13.2 Receptacle 5.13.2.1 Type : Industrial 5.13.2.2 Rating : 240 V AC, single phase, 50 Hz, 5A, 3- Pin 5.13.3 Isolating Switches : As per control schematics 5.14.0 Relays and Timers : As per single line diagrams, control schematics and data-sheets.

Feeder schedules / single line diagram shall be as given in Annexure-3. DATA SHEET - PROTECTIVE RELAYS 5.14.1 Under Voltage Relay (27) 5.14.1.1 Type : Under voltage relay 5.14.1.2 Number of poles : 1 5.14.1.3 Voltage rating : 110 V 5.14.1.4 Setting range : 40% to 80% 5.14.1.5 Auxiliary supply : 250 V DC 5.14.1.6 Number of contacts : 2 pairs of self reset make contacts



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5.14.1.7 Insulation : 2 kV for 1 minute. Relay shall meet req. of IS:3231 / IEC:60255

5.14.1.8 Operation indicator : Required 5.14.1.9 Type of mounting : Semi-Flush

5.14.2 Data Sheet – Protective Relays

5.14.2.1 Common Requirements for all Numerical Relays 5.14.2.1.1 Functional requirements (a) Protection functions, (b) Metering

function, (c) Fast transient recording function, (d) Capability to communicate with remote computer based system, (e) logical functions, (f) supervision of CT leads and trip circuit, (g) communication capability with programming /diagnostic tools.

5.14.2.1.2 Inputs 5A from CT secondary or 110V AC as required. Incase of CBCTs, CONTRACTOR to decide.

5.14.2.1.3 Outputs Potential free contacts having: 1. Making current capability: 30A

for 3 seconds. 2. Breaking current capability:

1A inductive at 250V DC (L/R=40ms)

3. Continuous current capability: 5A

4. Mechanical durability: >10000 operations.

5. Contact performance: According to IS-12083

5.14.2.1.4 Accuracy ± 0.2% at In. v? power? Timers: ±2% or 10ms whichever is lower.

5.14.2.1.5 Over Current capability a) 100In for 1 second b) 40In for 2 seconds c) 4In continuous.

5.14.2.1.6 Over Voltage capability a) 2.6 Vn- 10 sec b) 2 Vn- continuous

5.14.2.1.7 Type of mounting Flush Mounting 5.14.2.1.8 Auxiliary supply voltage 250V DC, +10% and –30% variation.



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5.14.2.1.9 Self testing and diagnostic features a) Hard-wired watchdog timer feature shall be provided with contacts for external alarm.

b) Internal Auxiliary power supply monitoring with contacts for external alarm.

5.14.2.1.10

Password Protection Multi level password protection required.

5.14.2.1.11

Local Display LCD/LED Display required for indicating

a) Relay status b) Measured quantities. c) Set values. d) Quantities at the instant of

relay operation. 5.14.2.1.12

EMC Levels To comply with IEC 61000-6-5 Immunity for Power Stations and Substation environment.

Enclosure Port (a) Power frequency magnetic field 30A/m as per IEC 61000-4-8,

Performance criteria-A (b) Radio-frequency electromagnetic field.

AM modulated 80-1000MHz: 10V/m 1.4GHz-2.0GHz: 3V/m 2.0-2.7 GHz: 1V/m as per IEC 61000-4-3 Performance criteria-A

(c) Electrostatic discharge ±8kV as per IEC 61000-4-2, Performance Criteria-B

Signal Ports (a) Radio-frequency Common mode 10V/m as per IEC 61000-4-6.

Performance Criteria-A (b) Fast transient disturbance 4kV auxiliary voltage class4 as per IEC

61000-4-4, Performance Criteria-B (c) Surges, Line to earth ±1kV as per IEC 61000-4-5,

Performance Criteria- B Input and output DC Ports (a) Radiated Radio frequency

electromagnetic field 10V/m as per IEC 61000-4-6, Performance Criteria-A

(b) Surges, (i) Line to earth (ii) Lin-Line

±0.5kV ±0.5kV as per IEC 61000-4-5, Performance Criteria-B

(c) Fast transients ±2kV as per IEC 61000-4-4, Performance Criteria-B

Input and Output AC power ports (a) Radiated Radio frequency

electromagnetic field 10V/m as per IEC 61000-4-6, Performance Criteria-A



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(b) Surges, (i) Line to earth (ii) Lin-Line

±2kV ±1kV as per IEC 61000-4-5, Performance Criteria-B

(c) Fast transients ±2kV as per IEC 61000-4-4, Performance Criteria-B

(d) Voltage dips i) 0% for 1 cycle as per IEC 61000-4-11, Performance Criteria-B

ii) 40% for 10 Cycles as per IEC 61000-4-11, Performance Criteria-C.

iii) 70% for 25 Cycles as per IEC 61000-4-11, Performance Criteria-C.

Insulation Resistance ≥ 1000MΩ 5.14.2.1.13

Climatic conditions a) Operating temperature: 50C to 550C

b) Storage temperature: 500C to 700C

c) Humidity: 93% RH at 400C d) Vibration:

5.14.2.1.14

Degree of Protection provided by relay enclosure

IP 52 and IP20 for rear connections

5.14.2.1.15

Power off withstand 50ms

5.14.3 Numerical relay for Motor protection (99) 5.14.3.1 Type of protections i) 49-Thermal overload ii) 50- Instantaneous over current iii) 37-Under current protection* iv) 48/50 LR- Locked rotor vi) 50N- Instantaneous ground over

current 5.14.3.2 Thermal over load protection (49) settings

comprising of

i) Thermal current setting range 0.2-1.5 In in linear steps of 0.1 or better. Relay characteristics shall match with the motor thermal withstand characteristics. Motor thermal withstand characteristics will be given during detailed engineering.

ii) Thermal alarm setting range 20 to 120 % of thermal current in linear steps

iii) Start-up inhibition Required 5.14.3.3 Short circuit protection (50) settings

comprising of

i) Current setting range 100 to 1200% In in linear steps



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ii) Time delay setting range 0-100s in linear steps 5.14.3.4 Under current protection (37) settings

comprising of *

i) Current setting range 0.1 to 1 In in linear steps ii) Time delay setting range 0.2 to 100s in linear steps iii) Inhibition time at start-up 0.05 to 300s in linear steps 5.14.3.5 Too-long start-up protection (48) settings

comprising of

i) Start-up detection criteria Closing 52 + current threshold ii) Current setting 1 to 6 times thermal current threshold in

linear steps iii) Time delay setting 1 to 20 s in linear steps 5.14.3.6 Locked rotor protection (50LR) protection

settings comprising of

i) Current settings 1 to 6 times thermal current threshold in linear steps

ii) Time delay 1 to 60 s in linear steps 5.14.3.7 Unbalance current protection (46) settings

comprising of Selectable Inverse and Definite time characteristics. Inverse curves shall match with the motor characteristics.

i) Negative sequence current setting 0.05 to 0.8 In in linear steps ii) Time delay 0.04 to 200 s in linear steps 5.14.3.8 Earth fault protection (50N) settings

comprising of

i) Current setting 0.002 to 1 Ion in linear steps ii) Time delay 0.2 to 100 s in linear steps iii) Inhibition time at start-up 0.05 to 300 s in linear steps iv) Provision for connection of external

CBCT Required as per SLD

5.14.3.9 Latching of trip output relays on Short-circuit, earth fault, unbalance, negative sequence, locked rotor as per logic schemes

5.14.3.10 Number of Output relays Minimum 5 5.14.3.11 Number of Poles 3 phase and earth fault elements 5.14.4 Numerical relay for Over current and earth fault protection of (a) Transformer

feeders and (b) Tie feeders- 50, 51, 50N and 51N. 5.14.4.1 Phase over current & short circuit protection

settings comprising of

i) Instantaneous current setting range 0.1 to 40 In continuously adjustable ii) IDMT current setting range 0.1 to 2 In continuously adjustable iv) Time delay for instantaneous 0 ms to 150 s in linear steps v) TMS range for IDMT 0.025 to 1.5 in linear steps. IDMT

curves as per IEC/ IEEEE/ANSI with variable TMS in order to provide time discrimination between upstream and downstream feeders over full range of



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current setting. In addition to above definite time delay setting shall be made available.

5.14.4.2 Instantaneous Earth fault protection i) Current threshold 0.01 to 40 Ion in linear steps ii) Time delay 0 to 150 s in linear steps iii) Provision for connection of external CBCT Required if specified 5.14.4.3 Latching of trip output relays on Separately for Phase over current,

short-circuit and earth fault 5.14.4.4 Number of output relays Minimum 6 5.14.4.5 Number of Poles 3 phase i) Current setting range 0.002 to 40 Ion in linear steps ii) Time delay 0-150 s in linear steps iii) Provision for connection of external CBCT Required as per SLD 5.14.4.6 Directional Earth fault protection (67/50N/2) i) Current setting range 0.002 to 40Ion in linear steps ii) Voltage range 0.01 to 0.5 Vn iii) Time delay 0-150 s in linear steps iv) Provision for connection of external CBCT Required as per SLD 5.14.4.7 Latching of trip output relays on Earth fault (Directional/Non-

directional), phase over current (Directional/non-directional)

5.14.4.8 Number of output relays Minimum 6 5.14.4.9 Number of poles 3 phase 5.15.0 Requirement of Auxilliary Relays & Timers As per bill of material enclosed with specification. NOTE: 1. Protection schemes / relays mentioned above shall be complete in all

respects. Auxiliary relays, timers etc., required to make the scheme complete shall be included in the scope.

2. The above data sheet indicates only the main items. All items like switches,

fuses, indicating lamps, push buttons, control switches etc. are to be provided as per the requirements finalized during approval of drawings.

3. The details of protective relays indicated above are indicative, Bidder shall

offer suitable relays details of which will be reviewed during tender/drawing approval. It is the responsibility of bidder to provide suitable protective relays approved by the purchaser without any price increase after placement of order.

4. The contact rating of auxiliary and protective relays shall be properly selected

by the bidder. In particular those wired in breaker close/trip coil circuits. Provisions such as contacts with blow- out magnets etc. shall be considered to ensure trouble free service.



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6.0 Schedule for Documents, drawings & other reports.

A. Following drawings/documents shall be submitted by vendor after award of contract as per schedule.

a) Complete assembly drawings of the switchgear showing plan, elevation typical sectional views and location of terminal blocks for external wiring connections, cable entry slots, gland plates etc.

b) Foundation plan showing location of channels, welding of channels to floor embedded parts etc.

c) General arrangement drawing showing the equipment mounted on each module.

d) Complete wiring diagrams indicating terminal wiring designations of each module including all spare terminals and inter modular and inter-panel wiring.

e) Schematic control diagrams, for each type of module and space heaters etc f) Fuse characteristic curves for each type and rating of fuse. Characteristic of

overload relay at air temperature inside the module. g) Item-wise bill of material listing all devices mounted or otherwise furnished,

indicating manufacturer’s type rating etc for different types of cubicles. h) Quality Assurance Plan & test schedule and test procedure (6 copies). A

sample QAP is given in tender document. i) Operation and maintenance manual for individual equipment and complete

switchgear. j) Test certificates in respect of major components equipment and complete

switchgear k) Reproducible tracing films of all finally approved general arrangement,

schematic and wiring diagram. l) Manufacturing of panels shall be started only after approval of all the

abovementioned drawings and documents. m) Bound volumes of end document containing copies of PO, approved QAP,

Test certificates, O&M manual, drawings in miniaturized form etc.(six nos.) shall be furnished.

n) Supplier shall prepare and submit bill of material for switchgear and associated components based on requirements outlined in Engineering Drawings.

o) IV&V requirement: Where ever numerical relay is provided, if any, supplier has to get and submit desired details to KAPS-1&2, as needed for IV&V.

The CONTRACTOR shall submit the schedule of activity after the issue of letter of intent covering submission of drawings, approval of drawings, submission and approval of QAP, procurement of material, manufacture, type testing, submission of test reports, O&M manuals, end documentation, transportation, erection, testing and commissioning. The schedule shall be submitted in two weeks and whole activity of replacement of switchgear will have to be completed in six months from the issue of the letter of intent. However this is indicative only and shall be suitably modified according to Shutdown schedule of KAPS-1&2.

B. Schedule to be given for drawing/documents: Submission of following drawings



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a) GA drawings: General arrangement including plan, front elevation, rear and side elevation

inside view showing mounting arrangement of various equipment, location of terminal blocks for external wiring connections, details of bus duct connections, cable entry, slots, gland plates, Foundation plan showing location of channels, welding of channels to floor embedded parts .etc. for 415 V switchgear and marshalling panels : ___

b) Schematic drawings: Schematic wiring diagrams to cover controls, protection interlocks, instruments, etc. for each cubicle of switchgear : ___

c) Internal wiring diagram: Detailed internal wiring diagram of each cubicle of switchgear and marshalling panels including terminal block number, ferrule numbers, inter-cubicle and inter-panel wiring designations and the Purchaser’s external cable connection designations & Itemized Bill of material for each cubicle of switchgear, inter-cubicle and inter panel wiring designations and the Purchaser’s external cable connection designations (These drawings shall be submitted only for information and records and shall be based on approved schematic drawing. The correctness of this drawing shall be the responsibility of the CONTRACTOR). 1) Interconnecting wiring diagram : ___ 2) Cable Schedule : ___ 3) Bill of materials : ___

d) Approval of drawings by Purchaser : ___ e) Submission of Quality Plan : ___ f) Approval of Quality Plan by Purchaser : ___ g) Procurement of material and sub-orders : ___ h) Manufacturer of Pro-type and type testing : ___ i) Submission of test reports, O&M manuals, etc. : ___ j) Manufacturing and routine tests : ___ k) Delivery to KAPS-1&2 : ___ l) Site erection, testing and commissioning : ___

Note: The above schedule is indicative. This shall be suitably modified according to Shutdown schedule of KAPS-1&2 7.0 Inspection & testing 7.1.0 General 7.1.1 The overall requirements for stage inspection and testing, material tests etc. in respect of equipment covered in this contract. The routine tests, acceptance tests, special tests and type tests are covered in this section. Inspections and tests at raw material stage, semi finished or module level are detailed in the typical QAP given in section annexure-5. 7.1.2 All the equipments offered should have been successfully type tested as per the relevant standards, amended up to date. In case the equipment of the type and design offered has already been typed tested, bidder shall furnish type test reports before proceeding with manufacture. Type tests must not have been conducted earlier than five years from the date of opening of bids. In case the type tests were conducted earlier than five years, such type tests shall be repeated by carried out by the successful bidder free of cost before commencement of supply. The undertaking to this effect shall be furnished along with the offer without which the offer shall be liable for rejection. As a part of technical offer, bidder shall include a tabulation detailing various type tests on each type of equipment along with applicable type test certificate number, details of the equipment subjected to type test, place of testing and final results. 7.1.3 The purchaser reserves the right to demand repetition of some or all the type tests in the presence of his representative. For this purpose the bidder shall quote unit rates for carrying out each



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type test. 7.1.4 If there are changes in the components or in the design/type already type tested and the design/type offered against this specification, the purchaser reserves the right to demand repetition of tests without any extra cost before commencement of supply. The bidder shall bring out in his offer all such changes made in components, materials, design etc. as the case may be and likely affects of such changes on type qualification. 7.1.4.1 Routine Tests:

All routine tests as per applicable Indian Standards on 415V AC switchgear Panels shall be performed in the presence of PURCHASER’s representative and reports issued. These tests shall include the following:

a. Visual inspection, dimensional checks, verification of bill of material and wiring as per approved schematics for all feeders and continuity and polarity tests on all coils and circuits.

b. Mechanical operation tests on circuit breakers, switches, auxiliary electrical and manual devices etc.

c. Interchangeability of removable elements i.e. circuit breakers etc. d. Electrical control, interlock and sequential operation tests. e. Power frequency voltage dry tests and insulation resistance tests using 500V

megger on the main circuit, control and auxiliary circuits. The values of test voltages to be applied shall be as specified in data sheets in of the specification.

f. All the functional tests & checks on all equipment. 7.1.4.1.2 The following tests shall be carried out on marshalling panels.

a) Verification of bill of material and wiring as per approved drawings. b) High voltage test. c) Insulation resistance test.

7.1.4.2 Type tests:

a. Mechanical operation and performance tests on breaker. Test sequence I and combine test sequence as per IEC-60947 part-2.

b. Short circuit withstand capacity test. c. Impulse voltage withstand test. d. One minute power frequency voltage withstand test and insulation resistance

test on the main bus bars. e. Verification of degree of protection.

7.1.4.3 Special type tests:

a. Temperature rise test on each type of 415V AC switchgear panel b. Seismic test on switchgear panels (each rating of swgr panel). c. Independent verification and validation (each type of relay).

All major components used in the equipment should have been type qualified in accordance with the applicable standards and applicable valid type test reports shall be submitted by the PURCHASER. All the routine and type test reports including test records, performance curves, GA drawings etc. shall be supplied according to the distribution schedule. All the tests shall be carried out in accordance with the provision of this contract.



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SEISMIC QUALIFICATION OF SWITCHGEAR:

A. Seismic Qualification of switchgear by analytical analysis

The complete switchgear along with all accessories, base frames & interconnections shall be designed for specified seismic requirement. The applicable floor response spectra shall be given to successful bidder. The seismic qualification shall be carried out either by combination of analysis and testing of active components or by full fledged shake table test as the case may be. The modifications in design that may emerge from analysis or test shall be carried out by supplier at no extra cost to purchaser.

B. Seismic Qualification of switchgear by testing: One randomly selected representative vertical section of switchgear in ‘completely ready to use form’ (i.e. assembled fully with all accessories like breakers, trolleys, base frame, bus bar, vertical droppers, meters, indications, shutters, selector switches & other associated components which shall supposed to be part of subject vertical section) shall be tested as per procedure approved by NPC. The test shall be carried out either at CPRI,Banglore or any other test facility approved by NPC. The test procedure shall be submitted by vendor for the approval of purchaser. The format of test procedure shall be given to successful bidder. The engineering of seismic qualification by analytical analysis & qualification of switchgear by testing at approved laboratory, to & fro transportation of associated specimens & accessories to test laboratory from suppliers premises or from KAPS site as the case may be, coordination of seismic test, preparation of test procedure & obtaining the purchasers approvals, loading/unloading, octroi & taxations, insurance, submission of bank guarantee & other incidental expanses shall be in the scope of supplier.

C. INDICATIVE POCEDURE FOR SEISMIC QUALIFICATION TEST:

a. The test specimen (i.e. vertical section of switchgear to be seismically tested) shall be subjected to IR measurement, HV test & physical inspection prior to keep on shake table for seismic test.

b. The test specimen shall be fixed on shake table along with base frame in similar way in which it shall be erected at site

c. During the seismic tests, the circuit breaker shall be kept closed & placed on a fixed load of the value of approximately 2 % of the rated load at 415 V, 3 phase, 50 Hz power supply. All auxiliary supplies like 250 V DC, 240 V AC, 48 V DC etc. shall be kept extended & terminated at appropriate TB’s of specimen. Monitoring of current and voltage shall be done through out the testing. No fluctuations & circuit interruptions in voltage or current should occur during testing.

d. The test specimen shall be subjected to the specified test response spectrum (TRS) considering a margin of 10% over FRS (Floor response Spectra). There shall be 5 OBE tests followed by 1 SSE test. The number of tests in each direction shall be such that all conditions as per IEEE 344 are satisfied.

e. Specimen then shall be subjected to all the tests as specified in 6.1.3.a.



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f. The specimen shall be considered qualified if there is no degradation of the test result parameters, no deformity or breakage or damage is observed together with the condition at point No. c above is satisfied.

g. The detailed test procedure including proper write up, sketches, FRS, TPS, drawings(GA, scheme drawing, panel fixing drawing, bill of material), tabulated format for verification of parameters and acceptance criteria, shall be prepared by Contactor for purchaser’s review & approval

The suppliers having already seismically qualified design for their switchgear may produce documentary evidences & certification from expertise agency that the switchgear being supplied is tested for the seismic response spectra’s higher than the response spectra’s of KAPS & that no repeat testing is necessary & switchgear is fully seismically qualified for using at KAPS. 7.1.4.4 Tests at Purchaser’s site The following tests shall be conducted at site on 415 V switchgears, Bus ducts and accessories per standards specified. These are however not intended to form a comprehensive commissioning check list as it shall be the CONTRACTOR’S responsibility to draw up and carry out such a program duly approved by the PURCHASER. Typical checks to be carried out at site are listed below & CONTRACTOR shall arrange for necessary equipment for carry out these tests at site. i) Switchgear:

a) Preliminary checks: 1. Check nameplate details of every associated equipment according to specification. 2. Check for physical damage. 3. Check tightness of all bolts, clamps and connecting terminals. 4. Check cleanliness. 5. Check cleanliness of insulators & bushings. 6. Check earthing. 7. Check heaters provided.

b) Commissioning checks:

1. Switch developments. 2. Each wire shall be traced by continuity tests and it should be made sure that the

wiring is as per relevant drawings. All interconnections between panels/equipment shall be similarly checked.

3. All the wires should be meggered to earth. 4. Megger between bus bars and bus bars to earth. HV test on high voltage circuits at

80% voltage. 5. Checks on relays 6. Checks on meters 7. Checks on CTs 8. Checks on VTs 9. Settings of relay, other alarm, tripping devices and interlocks as per scheme.



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10. Functional checking of all control circuit – e.g. closing, tripping, control, interlock, supervision and alarm circuits including proper functioning of the component equipment.

ii) Circuit Breakers: a) Preliminary checks

1. Check name plate details according to specification. 2. Check for physical damage. 3. Check tightness of all bolts, clamps and connecting terminals. 4. Check earth connections. 5. Check cleanliness of insulators and bushings. 6. Check all moving parts are properly lubricated. 7. Specific checks recommended by the contractor.

b) Commissioning checks

1. Check alignment of breaker trucks for free movement inside the cubicle, check correct operation of shutters. Check for interchangeability of CB trucks and PT trucks.

2. Slow-closing/opening operation. 3. Check control wiring for correctness of connections, continuity and IR values. 4. Manual operation of breakers. 5. Proper closing/opening operation manually and electrically. 6. Breaker closing and tripping time measurement. 7. Trip free and anti-pumping operation. 8. IR values, resistance and minimum pick up voltage of coils. 9. Contact resistance. 10. Check electrical and mechanical interlocks provided. 11. Checks on spring charging motor correct operation of limit switches and time of

charging. 12. All functional checks. 13. Simultaneous closing of 3 poles, duty cycles test, Any other recommended by

CONTRACTOR. 14. HV Test at 80% voltage. 15. IR value check for power circuit.

iii) Current transformers: a) Preliminary checks

1. Check nameplate details according to specification. 2. Check for physical damage. 3. Check tightness of all bolts, clamps and connecting terminals. 4. Check earth connections.




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1. Megger between windings and winding terminals to body. 2. HV test. 3. Polarity test. 4. Spare CT cores, if any, to be shorted and earthed. 5. Ratio test. 6. Magnetization characteristics. 7. Secondary winding resistance.

iv) Meters: a) Preliminary checks

1. Check name plate details according to specification. 2. Check for physical damage.


1. Check calibration by comparing it with a standard meter. 2. Megger all insulated portions. 3. Check CT and VT connections with particular reference to their polarities for power type

meters. v) Relays: a) Preliminary checks

1. Check name plate details according to specification. 2. Check for physical damage.


1. Check internal wiring. 2. Megger all terminals to body. 3. Megger AC to DC terminals. 4. Check operating characteristics by secondary injection. 5. Check minimum pick up voltage on DC coils. 6. Check operation of electrical/mechanical targets. 7. Relay settings. 8. Check CT and VT connection with particular reference to their polarities for directional relays.

8.0 QUALITY CONTROL PLAN Refer Annexure – 5 9.0 Erection & Commissioning 9.1 General Requirements



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a. The erection and commissioning shall comply with all applicable statutes, regulations, Indian Electricity Rules, Safety Codes and applicable standards in the locality where the equipment will be installed. Nothing in the specification shall be considered to relieve the contactor of the responsibility.

b. Contactor shall provide insurance coverage for all the material for the time required for transportation, storage, erection and commissioning of the equipment against damages, theft, fire etc. Repair or replacement of items which are damaged during transportation and storage shall be arranged immediately by the contactor so that installation and commissioning schedule is not affected. All claims insurance shall be processed by the contactor under intimation to the purchaser.

c. Contactor shall submit following documents for approval before commencing erection of the equipment

1. Detailed procedure for erection of various equipment and foundation details. 2. Erection schedule. 3. Details of proposed manpower to be deployed. 4. List of commissioning checks, tests and procedure 5. Procedure for qualification of welder and welding procedure.

d. Contactor shall arrange to transport the equipment from the place of storage to the place of

installation. Handling facilities if available at site will be provided by the purchaser on chargeable basis at the rates prevailing at that time. Cubicles shall be laid in accordance with the approved drawings.

e. Erection shall also include leveling, alignment and mounting of the Switchgear panels, mechanical interconnections between different sections, inter-panel wiring if required, connection between existing Switchgear buses and the panels supplied and any modifications required to ensure satisfactory installation and operation.

f. Before commencement of commissioning, a list of commissioning check and procedures to be followed shall be submitted for approval. Commissioning checks shall be carried out in accordance with the list of commissioning checks and procedures approved by the purchaser.

g. Termination of purchaser’s external power and control-cables is also included in the Contractor’s scope of erection and commissioning.

h. Purchaser’s site engineers shall have access to inspect erection, commissioning procedure being followed by contractor and contractor shall provide all necessary instrument required for inspection when informed by the purchaser’s inspector about non-conformance of erection/commissioning procedure, standards, tolerances etc. as the case may be, due to contractor’s mistakes during erection/ commissioning, the contractor shall rectify the same to the full satisfaction of the purchaser

i. Contractor shall touch-up the cubicles by painting after erection/commissioning of the equipment.

j. Space for storage of equipment will be provided by the purchaser k. Electric power supply of 415 V, 3 phase, 4 wire, 50 z for the purpose of erection and

commissioning will be made available by the purchaser free of cost. l. Cranes, trucks and other handling facilities if made available by the purchaser may be on

chargeable basis, as per the utility practice. m. All tools, tackles, testing equipment etc shall be in contactor’s scope. n. Purchaser shall be at all times have an access to check the progress of work. Contactor shall

proceed to the next stage only after obtaining clearance from the purchaser.



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9.2 SAFETY & SECURITY

a. Contactor shall be responsible for safety of the equipment at all time during the period of contract.

b. Contactor shall ensure safety of crew employed for erection/ commissioning by providing workmen with adequate protective gear as required, by employing skilled and trained labor for this kind of jobs, by enforcing safety norms to the followed by his workmen.

c. The contractor shall abide by all safety rules and regulations stipulated by the project safety officer.

d. All Security measures as advised by the Plant authority shall be followed strictly. Entry Permit, Token Pass etc. shall be obtained by the contractor from concerned Plant Authority as per the rules.

9.3 House keeping

The contractor, upon completion of the job shall clean and dispose of all surplus materials, rubbish and temporary works of whatsoever nature and kind as directed by the purchaser and leave the work site clean and tidy.

9.4 Inspection of Site

The contractor or his representative shall be deemed to have inspected the site and surroundings before submitting his tender. The contractor shall follow at site all security rules in force. The contractor shall follow all the central and state government Rules/Acts applicable for the work and also maintain necessary records stipulated in these Rules/Acts. Before commencement of the job, contractor shall provide detailed schedule for the completion of the jobs indicating target for the completion of major events, manpower requirements during various stages of erection, commissioning.

9.5 Accommodation & medical facilities

The Contactor shall arrange for accommodations, medical and other requirements on his own. However, subject to availability hostel accommodation may be provided to contactor’s personnel of supervisor grade or above on chargeable basis.

9.6 Installation of Switchgear

Erection and commissioning work for Switchgear will be done one by one in phase manner. Unless first switchgear is not commissioned in full; work on second switchgear may not be allowed. Supplier shall co-ordinate his erection & commissioning work according to site schedule & requirement in consultation with engineer in charge of work. The supplier in his bid shall indicate tentative time required/ schedule of work for erection & commissioning of one switchgear bus in all respect.

9.7 Free Issue Item

No free issue items will be issued to supplier either during manufacturer or erection & commissioning. However necessitated switchgear assemblies from existing switchgear may be issued to bidder & permitted to take out from station premises against submission of following documents for conducting engineering of seismic test by bidder. • Bank guarantee of appropriate value having suitable validity



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• Analytical seismic qualification of retrofitted switchgear • The consent of test laboratory for conducting seismic testing along with schedule of test • Transit insurance for the material being taken out • Approved seismic test procedure from SA & S department, NPCIL, Mumbai

10.0 TRAINING: Bidder shall provide the training for at least Two engineer, two supervisor & eight technicians of purchaser on operation & maintenance aspects of new circuit breakers / switchgear at manufacturing works of bidder. The duration, contents of training shall be subject to approval of purchaser.

ANNEXURE-1

PROJECT DATA FOR KAPS-1&2

1.1 PURCHASER : NUCLEAR POWER CORPORATION (A Govt. of India Enterprise)

1.2 PROJECT : Kakrapar Atomic Power Station-1&2 1.3 LOCATION : Kakrapar (approx. 87 KM from Surat) 1.4 ELEVATION : 51 Meters above MSL 1.5 CLIMATIC CONDITION AT SITE:

RELATIVE HUMIDITY: The climate is tropical with high

humidity and heavy Rainfall

1.6 AMBIENT AIR TEMPERATURE: Minimum : 4 degree C Maximum: 45 degree C

1.8 STATION POWER SUPPLY : a) 415V, 3 phase, 50 HZ A.C. Solid grounded b) 240 V, single phase, 50 Hz A.C. c) 250V, D.C. ungrounded (voltage from 187 V to 250 V) d) 50 V, D.C. ungrounded (Voltage from 39 V to 53 V)



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ANNEXURE-2

APPLICABLE STANDARDS BUREAU OF INDIAN STANDARDS

1) IS: 5 Colours for ready mixed paints and enamels. 2) IS: 694 PVC insulated cables for working voltages upto a nd including 3) IS: 2062 Structural steel 4) IS: 513 Cold rolled low carbon steel sheet and strip 5) IS: 613 Copper rods and bars for electrical purpose 6) IS: 2629 Recommended practice for hot dip galvanizing on iron and steel 7) IS: 1248 Direct acting indicating analogue electrical measuring instrument and their

accessories 8) IS: 732 Code of practice for electrical wiring installation 9) IS: 1897 Copper strip for electrical purpose 10) IS: 1293 Three pin plugs and socket outlets 11) IS: 60947 Degrees of protection provided by enclosures for low voltage 12) IS: 9537 Rigid no-metallic conduits for electrical installations 13) IS: 2551 Danger notice plates 14) IS: 2675 Enclosed distribution fuse boards and cutouts for voltages not exceeding 1000V

A.C. and 1200V D.C. 15) IS: 3043 Code of practice for earthing. 16) IS: 2705 Current transformer 17) IS: 3156 Voltage transformers 18) IS: 3231 Electrical relays for power system protection 19) IS: 8686 Static protective relays 20) IS: 8714 Electric protective relays for use in seismic area 21) IS: 5082 Wrought aluminium & aluminium alloy bars, rods, tubes and sections for

electrical purposes. 22) IS: 1477 Boxes for enclosure of electrical accessories. 23) IS: 5216 Recommendations on safety procedures and practices in electrical work. 24) IS: 5578 Guide for marking of insulated conductors. 25) IS: 6005 Code of practice for phosphating iron and steel.

26) IS: 8623 Low voltage switchgear and control gear assemblies. 27) IS: 60898 Electrical accessories - circuit breakers for over current protection for household

and similar installation. 28) IS: 10118 Code of practice for selection, installation and maintenance of switchgear and

control gear. 29) IS: 11353 Guide for uniform system of marking and identification of conductors and

apparatus terminals. 30) IS: 12021 Control transformers for switchgear and control gear for voltages not exceeding

1000V A.C. 31) IS: 13703 Low voltage fuses for voltage exceeding 1000 V AC or 1500V DC.



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32) IS: 60947 Specification for low voltage switchgear and control gear. INTERNATIONAL STANDARDS

1) IEEE: 344 Recommended practices for seismic qualification of Class 1E equipment for nuclear power generating stations.

2) ASME B&PVC SEC: IX

Codes for welding.

3) IEC; 60688 Electrical measuring transducer for converting AC electrical quantities to analogue or digital signal

INDIAN ELECTRICITY RULES NATIONAL ELECTRICAL CODE PB-P-541: Seismic qualification procedure.



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ANNEXURE – 3

Details of activities for Independent Verification & Validation (IV & V) of computer/PLC based system of Completely Of the Shelf Type (COTS)

1 Independent verification & validation (IV & V) activity shall cover the review, verification and validation of computer/PLC based system in phase of procurement, development, manufacturing, testing at factory (after completion of the PURCHASER’s inspection but before issuing the shipping release), testing at plant site (after fully integrated and commissioned at plant site) and change/modification stages of the hardware & software of the computer/PLC based system.

2 The IV & V activity shall ensure the proposed system is build as per the system requirements, functionally tested at factory, functionally tested at plant site after fully integration with plant systems, fail-safe operation of the system for safety of the equipment and the safety of the plant and finally fulfill all the regulatory requirements.

3 On placement of Purchase Order, PURCHASER’S IV & V Task Force (IV&V-TF) shall carry out the verification and validation tests at VENDOR’S factory and at PURCHASER’S site as per the approved system validation procedure at factory (SVP-F) and system validation procedure at site (SVP-S). VENDOR shall ensure all the tools and resources while conducting the validation tests at factory as well as at plant site. The cost for factory test shall be included in package.

4 VENDOR shall prepare and submit the minimum five copies of each of the following documents for IV & V requirement:

4.1 System Specification Compliance (SSC)

4.2 Fitness For the Purpose (FFP)

4.3 System Build (SB)

4.4 Application Programming Requirements & application program (APR)

4.5 User Documentations (UD)

4.6 System Validation Procedure at Factory (SVP-F)

4.7 System Validation Procedure at Plant site (SVP-S)

4.8 Hardware Reliability Analysis (HRA)

4.9 System Safety Analysis Report (SSAR)

5 The required formats for the documents are attached here for reference and guideline for preparation of the documents. These are the sample formats and may vary depending on the latest revision of the document. Therefore VENDOR shall clarify from the PURCHASER before finalization of each document.

6 VENDOR shall ensure that the entire document shall be correct, consistence and complete with required information about the system.

7 Typical examples indicating formats and contents of different types of documents under IV&V.

7.1 Format for System Specification Compliance (SSC)



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7.1.1 Introduction 7.1.1.1 Purpose

To establish that (a) one to one compliance between the technical specifications given by the PURCHASER and the technical specifications given by the CONTRACTOR/supplier and (b) to record any deviation (addition/deletion) from the original technical specifications

7.1.1.2 Scope Describe the scope of this document

7.1.1.3 Definitions, Abbreviations and Notions Describe various definitions, abbreviations and notations as applicable to this document.

7.1.1.4 References Provide reference to applicable documents, standards, codes, and guidelines etc. that need to be referred to for information.

7.1.1.5 Overview Provide a brief overview of the contents of the document.

7.1.2 Technical Specifications given by NPCIL in TSD (here the extract/copy of the Technical Specifications shall be used)

7.1.2.1 System hardware configuration 7.1.2.2 System software requirements 7.1.2.3 Other requirements as per SR 7.1.2.4 Data Sheets/checklist/compliance list requirements 7.1.3 Technical Specifications offered by Vendor

(here copy of the Technical Specifications offered by the vendor shall be pasted)

7.1.3.1 Description of the system hardware configuration 7.1.3.2 Description of the system software configuration/packages 7.1.3.3 Other requirements as per SR 7.1.3.4 Data Sheets/checklist and any additional feature of the proposed

system

7.1.4 Compliance report as submitted by vendor 7.1.5 Approved deviation reports, if any (Copy shall be enclosed) 7.1.6 List of Annexures 7.1.6.1 Guaranteed technical particulars for the offered system by Vendor 7.1.6.2 Bill of the material to be delivered 7.1.6.3 Simplified /block/context diagram of the proposed system. 7.1.6.4 Copy of the purchase order (un-priced) 7.1.7 Conclusion 7.2 Format for Fitness For Purpose document (FFP) 7.2.1 Introduction 7.2.2 Purpose

To establish that (a) The COTS product/system has been developed, inspected and tested in accordance with the governing standards and (b) The product is suitable for the kind of application envisaged

7.2.3 Scope Describe the scope of this document

7.2.4 Definitions, Abbreviations and Notations Describe various definitions, abbreviations and notations as applicable to this document.



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7.2.5 References and Applicable Documents Provide reference to applicable documents, standards, codes, and guidelines etc. that need to be referred to for information.

7.2.6 Overview Provide a brief overview of the contents of the document. 7.2.7 Manufacturer

Experience in the field ISO 9000 (or other) quality system certification Hardware Process Description of design process Description of manufacturing process Standards followed Certification Software Process SEI CMM level qualification? Standards followed in design/coding/testing of software (IEEE?) Software Quality Assurance standard (IEEE 730.1/ IEC 60880 /ISO 9000-3) Configuration Management standard (IEEE etc.)

7.2.9 Product Model / Version no. Compliance to standards (IEC etc.) Certifications available (UL, CE etc.) Test/Verification/Validation reports available Years in manufacture and field operation Same model, same version no. Same model, earlier version Earlier model Number of installations Total number of installations In similar applications (area/criticality) (give sample list) Field experience (Errors reported, versions released, known faults) Reliability Documentation available

7.2.10 Maintenance support from the manufacturer (after sale) 7.2.11 Conclusion 7.3 Format for the Application Programming Requirements

(Typical for the PLC software) 7.3.1 Introduction 7.3.2 Purpose: 7.3.3 Scope 7.3.4 Definitions, Abbreviations and Notions 7.3.5 References 7.3.6 Overview 7.3.7 Brief overview of PLC hardware 7.3.8 Application Programming Requirements 7.3.9 Description of logic scheme (as described in the SR) 7.3.10 Block Logic Diagram (BLD) (it shall be enclosed) 7.3.11 List of Man Machine Interfaces/operator interfaces 7.3.12 List of Field Input and output



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7.3.13 Software Variable 7.3.14 List of the event/messages printout through ASCII module 7.3.15 Brief description of the Software programming Tool to be deployed 7.3.16 Steps for running Software programming Tools 7.3.17 Brief description of the Application Software to be deployed

I/O map and Software Variable for Application Software 7.3.18 Memory allocation for Application Software 7.3.19 Description of Sections in a Segment of application software 7.3.20 Effect PLC hardware and software failure 7.3.21 Logging of Alarms 7.3.22 Miscellaneous Terminology 7.3.23 Scan Time / Response Time 7.3.24 Accuracy 7.3.25 Resolution 7.3.26 Segment Scheduler 7.3.27 Traceability requirements between SR and APR 7.3.28 List of the Annexure 7.3.29 Block Logic Diagram 7.3.30 Ladder Logic/Functional Block Logic Diagram 7.3.31 List of field Input and Output 7.3.32 PLC block/context diagram 7.3.33 Conclusion 7.4 Format for System Build document (SB) 7.4.1. Introduction 7.4.1.1 Purpose

To provide the information about the hardware package, software package and integration of the hardware & software components to build the final system as per the system requirements.

7.4.1.2 Scope Describe the scope of this document

7.4.1.3 Definitions, Abbreviations and Notations Describe various definitions, abbreviations and notations as applicable to this document.

7.4.1.4 References and Applicable Documents Provide reference to applicable documents, standards, codes, and guidelines etc. that need to be referred to for information.

7.4.1.5 Overview Provide a brief overview of the contents of the document. 7.4.2. System Decomposition

List all the Subsystems that the system is composed of, enclosed the diagram. 7.4.3. Subsystem n 3.n.1 Hardware Package Build 3.n.1.1 List of items this package is composed of 3.n.1.2 Unique Ids 3.n.1.3 Hardware Environment Description Provide embedded software version, Jumper

settings, switch settings, software settings, and cable connectivity 3.n.1.4 Integration Procedures / drawings 3.n.2 Software Package Build 3.n.2.1 List of sub-packages



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3.n.2.2 Unique Ids/Version Nos. 3.n.2.3 Media Details (Floppies/CDs/Tapes/EPROM's) 3.n.2.4 Relevant Disk / Memory maps 3.n.2.5 Hardware Environment Description Describe the Processor type, Memory ports, hard

disk space, etc. 3.n.2.6 Software Environment Description Describe OS version and services settings,

Compiler version; compile time options, library versions, and environment variables. 3.n.2.7 Integration Procedures 7.4.4 System hardware and software integration for System Build

Integration drawings Integration procedure

System Start up and Shutdown Procedure Bill of the material List of the Annexure Conclusion

7.5 Document Format for User Documentation (UD) 7.5.1. Introduction 7.5.1.1 Purpose Provide the purpose of preparing this document 7.5.1.2 Scope

Describe the scope of this document 7.5.1.3 Definitions, Abbreviations and Notations

Describe various definitions, abbreviations and notations as applicable to this document.


7.5.1.5 Overview Provide a brief overview of the contents of the document. 7.5.1.6 Description of the manuals with ID details

Describe the list of system manuals with ID (List of End documents) and the contents of the document. This should include the GA drawings, Configuration drawings etc. The list of the documents shall be attached here with for completeness of the UD documents. This document shall cover the followings Information

7.5.2 Information for Installation of the system.

This shall include the installation drawing, and detail for the system. 7.5.3 Information for Commissioning of the system.

Refer WDs, SB configuration drawing BOM. Write the procedure for sequence of steps to be followed. Set up environment such as IP addresses, switch settings etc.

7.5.4 Information for Operation of the system.

Write the details on start-up, normal operation procedure, shutdown procedure, and various modes of operation, usage details to cover. Various functions, test utilities, tools available



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7.5.5 Information for Maintenance of the system.

Describe possible failures and its symptoms, possible known cause of the failures, describe the fault tree analysis and trouble-shooting procedure for the above. This shall include the procedure to bring up the system after troubleshooting. Cover test programme, diagnostics for checking healthiness, etc

7.5.6 List of the Annexure 7.5.7 Conclusion 7.6 Format for System Validation Procedure at Factory (SVP-F)

7.6.1. Introduction 7.6.1.1 Purpose Provide the purpose of preparing this document 7.6.1.2 Scope Describe the scope of this document 7.6.1.3 Definitions, Abbreviations and Notations



7.6.1.5 Overview Provide a brief overview of the contents of the document. 7.6.2. Test Team Details

Give the requirement of the test team members, their roles and responsibilities for carrying out the System Validation test at factory and specified the expected test duration under following heads Test Team Members Test team members Role and Responsibilities Test Duration

7.6.3. Infrastructure and resource requirements Give the infrastructure and resources requirements for the system validation under the following heads.

Infrastructure requirement Resources requirements QA inspection test procedure and test reports Vendor’s QA test reports Copy of the purchase orders with bill of the material Test certificates by third party/principal suppliers Standard Test Setup with diagram Manpower Requirement

7.6.4 System Validation Test Plan

The system validation tests should be carried out as per following plan

7.6.4.1 Confirmation of System Build (SB) 7.6.4.2 Confirmation of the User Documentation



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7.6.4.3 Hardware validation Test on AC-PLC Panel 7.6.4.4 Verification of QA and vender test reports 7.6.4.5 Simulation and testing of all the inputs and outputs 7.6.4.6 Off line verification of the software logics 7.6.4.7 Software validation test on the software logics 7.6.5 System Validation Test Procedure 7.6.5.1 Confirmation of System under test for System Build

Confirm that the system H/W and S/W is built according to the System Build document under the following heads.

7.6.5.2 Confirmation of System Hardware All the hardware modules shall be listed out with type number, ID number, make etc General hardware at panel level Panel wise hardware Modules

7.6.5.3 Confirmation of the System Software

All the software modules shall be listed out with the name, version, license (if applicable), location and size etc. Operating System software with service packs System software with services packs. Application software development tools/software manager (complete sets). Application software. List of the firmware deployed Anti-virus software, if any Any other relevant software

7.6.5.4 Confirmation of the system Integration with hardware and software 7.6.5.5 Confirmation for User Documentation for system under test

Verify the list of the documents and content of each document as per the UD. This shall include the descriptions in the user documents as implemented in the system. Ex: Operating procedures, modes, command options, error messages, help, utilities, etc.

7.6.5.6 Verification of QA and vender test reports

Verify all the QA test reports and type test reports on the system. Also verify the vendors internal test reports and test reports on the bought out items.

7.6.5.7 System Hardware Validation Test (Hardware performance test)

Activity shall cover system hardware test cases by simulating the failure of the hardware. This shall include the test cases, its procedure and expected test results. This shall be prepared in line of system requirement and its expected performance in case of the failure (Including the single component failure for fail safe mode operation)

7.6.5.8 System Software Validation Tests

This shall cover the system software test cases by simulating the input for open loops as well as closed loops using the test tools like automatic functional testers, simulators, TDR etc. The



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software access control and self-diagnostics shall also be tested. This included the following heads:

Verification of application s/w with software logic requirements (BLD) Offline validation of the application s/w on workstation (simulation mode) Verification of all the inputs and outputs by simulation on screen Validation of the software database Validation of the software timers/counters for its setting & its accuracy Validation of the software security access control Validation of the system self-diagnostics features in case of faults. Validation of the memory allocation for application s/w and available free memory. Validation of the critical parameters (System dependent) Validation of Application Software by simulation for open & close loops Validation of Application Software by simulation in test/fail safe modes Validation of Application Software by simulation for interfaces (COIS, Printers, SCADA etc)

7.6.5.9 List of Annexure

This shall includes the test set up diagram, system context diagram, procedure for testing of system software logics (for all inputs and outputs), List of Inputs and corresponding variable name used in s/w, List of Outputs and corresponding variable name used in s/w etc.

7.6.5.10 Traceability requirements 7.6.5.10.1 Forward Traceability

Generate a cross-reference of all requirements mentioned in System Requirements to various packages to confirm that all system requirements have been included Requirements cross-reference matrix is preferable.

7.6.5.10.2Backward Traceability Generate a cross-reference of all requirement mentioned in this document to those listed in System Requirements. If some requirements have been added to facilitate system architectural design these should be also listed. Requirements cross-reference matrix is preferable.

7.6.5.11Conclusion 7.7 Format for System Validation Procedure at Site (SVP-S) 7.7.1. Introduction 7.7.1.1 Purpose Provide the purpose of preparing this document 7.7.1.2 Scope Describe the scope of this document 7.7.1.3 Definitions, Abbreviations and Notations



7.7.1.5 Overview Provide a brief overview of the contents of the document. 7.7.2. Test Team Details



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Give the requirement of the test team members, their roles and responsibilities for carrying out the System Validation test at plant site and specified the expected test duration under following heads Test Team Members Test team members Role and Responsibilities Test Duration

7.7.3. Infrastructure and resource requirements Give the infrastructure and resources requirements for the system validation under the following heads. Infrastructure requirement Resources requirements Commissioning test procedure Commissioning test reports Standard Test Setup Manpower Requirement Necessary clearances from Shift Charge Engineer/Control room

7.7.4. System Validation Test Plan The system validation test shall be carried out as per the following plan:

7.7.4.1 Verification of the approved Commissioning Procedure and Commissioning Report.

Verification of remedial action for deficiency, if any, noted during system validation tests at factory Confirmation for System Build for system under test Confirmation of the system Integration with plant systems. Confirmation Hardware validation test on integrated panel Software Validation tests on integrated penal Functional testing of man machine interfaces and other computer base subsystem Functional testing of logic schemes for all possible test cases.

7.7.5.0 System Validation Test Procedure

This shall cover the system hardware and software test cases by actuating the actual field inputs and observe the field outputs this includes the performance of the hardware, execution the software logics/programme, signal processing, response time audio-visual alarms at LCP and in MCR, event recording, Interface with other computer base systems, synchronization with master clock, testing of the self diagnostic features, software access control, etc. This included the following heads:

7.7.5.1 Verification of the approved Commissioning Procedure and Commissioning Report

The approved commissioning procedure and commissioning report shall be verified for the under test

7.7.5.2 Verification of remedial action for deficiency, if any, noted during system validation tests at

factory Verify that all the deficiencies are rectified as per the recommendation of the SVTR at factory. Any modification in hardware/software is to be revalidated at plant site.

7.7.5.3 Confirmation for System Build for the system under test



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Confirm that the system H/W and S/W is built according to the System Build document and it is installed, integrated with the plant systems under the following heads.

7.7.5.3.1 Confirmation of System Hardware

Panel wise hardware Modules General hardware at panel level Plant Interface with panel/hardware modules

7.7.5.3.2 Confirmation of the System Software

Operating System software with service pack, licensing System software with services packs. Application software development tools/software manager. Application software. System firmware, if any Antivirus software, if any Any other related software loaded in the system

7.7.5.3.3 Confirmation of the system Integration with plant systems 7.7.5.3.4 Confirmation hardware validation test on integrated panel

Hardware performance tests (sample test) System self-diagnostics features in case of faults. Redundancy/failure test

7.7.6 Software Validation tests on integrated penal Validation of the software logics (sample basis) Validation of the software security access control and creation of the users based on the site requirements Verification of allocated memory and available free memory for software

7.7.7 Functional testing of man machine interfaces and other computer base subsystem

Testing of all the Field Inputs by actuating from the field and observing in the software program on the screen of the programming unit. Testing of all the Field outputs by actuating from the software of the programming unit and observing in the field Functional testing of window annunciation provided on LCP and MCR panel. Functional testing of Hand Switches and lamp indications provided on LCP and MCR Panel. Functional testing of window annunciation, meters, switches provided on LCP and MCR Panel. Functional testing of MCC interface. Functional testing of SCADA interface. Functional testing of event message printing with time and date stamping Functional testing of system synchronization with Master Clock

7.7.8 Functional testing of logic schemes for all possible test cases.

The functional testing of the logic scheme shall be carried out as per the test cases given in the Annexure-….

7.7.9 Validation of the software timers/counters for its setting based on the field response time.



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Based on the field requirements the setting of software timer may be changed .the same shall be recoded during validation test at site.

Transfer of the application software from RAM to UV-EPROM after final testing After final testing of all the test case and satisfactorily operation of the system under test the application software shall be transferred from RAM to UV-EPROM using EPROM programmer and associated software. Also take the back up on HDD as well as on the CD for the future reloading /reference.

7.7.10 List of Annexure

This shall includes the following: Test set up diagram, System context diagram with plant interfaces, List of the test cases for the functional testing of the logic scheme, List of field inputs & outputs with its types (Digital/Analogue) and state (NO/NC),

7.7.11 Traceability Requirement 7.7.11.1 Forward Traceability

Generate a cross-reference of all requirements mentioned in System Requirements to various packages to confirm that all system requirements have been included Requirements cross-reference matrix is preferable.

7.7.11.2 Backward Traceability Generate a cross-reference of all requirement mentioned in this document to those listed in System Requirements. If some requirements have been added to facilitate system architectural design these should be also listed. Requirements cross-reference matrix is preferable

7.8 Hardware Reliability Analysis (HRA) 7.8.1 Introduction 7.8.1.1 Purpose

Provide the purpose of preparing this document 7.8.1.2 Scope

Describe the scope of this document

7.8.1.3Definitions, Abbreviations and Notations Describe various definitions, abbreviations and notations as applicable to this document.

7.8.1.4 References and Applicable Documents

Provide reference to applicable documents, standards, codes, and guidelines etc. that need to be referred to for information.

7.8.1.5 Overview of the system

Describe the context of the system vis-à-vis the plant and its architecture to the level of modules/subsystems whose failures are being considered subsequently



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7.8.2 System Description Provide the description of the system, hardware details of its modules/subsystems, interfaces, functionality of each module, series & redundancy relationships as well as functional interdependence between modules along with necessary context diagrams under following heads

7.8.2.1 Introduction

7.8.2.2 System Functional description

7.8.2.3 System hardware configuration

7.8.2.4 System input & output details

7.8.2.5 System schematics

Article I. 7.8.3 System Analysis Provide the details of the modules considered/not considered for analysis and logic/rationale for the same. Also provide the details of methods and tools, types of failure with justifications, values of the failure rates with the source details under the following minimum heads

7.8.3.1 Scope/coverage

7.8.3.2 Boundary conditions & Assumptions

7.8.3.3 Values MTBF & MTTR for hardware modules

7.8.3.4 Values of failure rates

7.8.3.5 Failure criteria

7.8.4 Results of Analysis Provide the Fault Tree diagram & derived failure frequencies

7.8.4.1 Domain cut set

7.8.4.2 Fault tree diagram

Article II. 7.8.5 Traceability 7.8.5.1 Forward traceability

7.8.5.2 Backward traceability

Article III. 7.8.6 List of the Annexure Enclosed the Annexure as required in the document

Article IV. 7.8.7 Conclusion 7.9 System Safety Analysis Report (SSAR) 7.9.1. Introduction 7.9.1.1 Purpose Provide the purpose of preparing this document 7.9.1.2 Scope

Describe the scope of this document 7.9.1.3 Definitions, Abbreviations and Notations



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Describe various definitions, abbreviations and notations as applicable to this document. 7..9.1.4References and Applicable Documents

Provide reference to applicable documents, standards, codes, and guidelines etc. that need to be referred to for information.

7.9.1.5 Overview of the system

Describe the context of the system vis-à-vis the plant and its architecture to the level of modules/subsystems whose failures are being considered subsequently

7.9.2 System Architecture

Describe the system architecture in terms of decomposition into sub-systems (if any) with connectivity and the inputs and outputs connected to each sub-system

7.9.3 System Interfaces Describe the interfaces of each subsystem with the plant as well as with other sub-systems

9.n.1. Interface of subsystem n with Plant 9.n.1.1. Inputs This section should list the description of the inputs 9.n.1.2. Outputs This section should list the description of the outputs 9.n.2. Interface with other subsystems This section should list the connectivity of the sub-system with other sub-systems 9.n.3. Interface with other systems

This section should list the connectivity of the sub-system with other systems 9.n.4 Interfaces with power supplies This section should list the connectivity of the sub-system with power supplies and power sources.

7.9.4 Effect of System Failures on Plant Safety

Consequence of a Single module / subsystem failure including power supplies and power sources and connectivity with other subsystems on the plant safety Module / subsystem n Failure This section should identify the various failure modes of the module/subsystem (cover both partial as well as total failures) and their affects on system outputs and plant safety in the following format Subsystem n failure Mode m Effects on System Outputs This section should identify the affected outputs, mention about their state during the failure and the maximum time to reach that state Effect on Plant Safety This section should analyze the impact on plant safety as a consequence of the system outputs behavior discussed in the preceding section Effect of System Failures on equipment Safety Describe the effect of the failure of system module on the safety of the equipment.

7.9.5 List of the Annexure Enclosed the table describing the Mode of the failure, Cause of the failure, detection mechanism, Effect of the failure on the safety of the system equipment and on plant equipment



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7.9.6 Conclusion 7. 10 SAMPLE FORMAT FOR THE FORWARD TRACEABILITY MATRIX FOR AC-PLC

FOR ABC 1. Name of the System: AC-PLC 2. USI Number: 67510 3. Name of the CBS deployed: Programmable Logic controller (PLC) for Air Compressor

System 4. System Category: Commercially Off the Shelf (COTS) 5. Safety Category: EA 6. Forward Traceability Matrix from. SR To. APR

Sl. No

SOP Requirements Document-SOP SR Requirements Document-SR Clauses Referred

Page No. Clauses Referred

Page No.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10 7.11 SAMPLE FORMAT FOR THE BACKWARD TRACEABILITY MATRIX FOR AC-

PLC FOR ABC 1. Name of the System: AC-PLC 2. USI Number: 67510 3. Name of the CBS deployed: Programmable Logic controller (PLC) for Air Compressor System 4. System Category: Commercially Off the Shelf (COTS) 5. Safety Category: EA 6. Backward Traceability Matrix from. To.

Sl. No

SR Requirements Document-SR SOP Requirements

Document-SOP Clauses Referred

Page No.

Clauses Referred

Page No.

1. 2. 3. 4. 5. 6. 7. 8. 9.



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Sl. No

SR Requirements Document-SR SOP Requirements

Document-SOP Clauses Referred

Page No.

Clauses Referred

Page No.

10. 7.12 SAMPLE FORMAT FOR TEST CASES FOR THE TESTING OF THE LOGIC

SCHEME AT FACTORY DURING VALIDATION TESTS (PART OF SVP-F)

Sr. NO.

Input Side Details

Test case simulation procedure

Expected Output side Expected Observation

Remark, If any

Input contactor/relay

Input address

Output Control relay

Output Power contactor (If present)

Alarms/indications on LCP

Alarms/indications on MCR

Log/print the output

1 Test case#1: 2 Test case#2: 3 Test case#3: 4 Test case#4: 7.13 SAMPLE FORMAT FOR TEST CASES FOR THE FUNCTIONAL TESTING OF

THE LOGIC SCHEME AT PLANT SITE DURING VALIDATION TESTS (PART OF SVP-S)

Sr. No.

Name of the functional tests as per SVP-S

Input Conditions

Expected output

Log/printout Observation Remarks, if any



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ANNEXURE - 4 LIST OF DRAWINGS

Sr. No.

Description Drawing No.

1. Single Line diagram KAPP-1,2/52420/6002/ED KAPP-1,2/52310/6001/ED KAPP-1,2/52420/6000/ED

2. Schematic wiring diagram of control Circuits For load center bus breaker

KAPP-1,2/52421/2730/ED

3. Schematic wiring diagram of control Circuits For Incomer breaker

KAPP-2/52421/2608/ED

4. Schematic wiring diagram of control circuit For motor pump breaker

KAPP-2/52421/2600/ED

5. Schematic wiring diagram of control Circuits For MCC breaker

KAPP-2/52421/2596/ED KAPP-2/52421/2614/ED

6. Control scheme for tie breakers KAPP-2/52421/2595/ED KAPP-2/52421/2596/ED KAPP-1,2/52421/2750/ED KAPP-2/52421/2541/ED KAPP-2/52421/2535/ED

Control scheme for special feeder 7. CB-302 KAPP-2/52421/2586/ED

8. CB-303 KAPP-2/52421/2587/ED 9. CB-306 KAPP-2/52421/2590/ED 10. CB-315 KAPP-2/52421/2599/ED 11. CB-323 KAPP-2/52421/2607/ED 12. CB-326 KAPP-2/52421/2610/ED 13. CB-336 KAPP-2/52421/2620/ED 14. CB-343 KAPP-2/52421/2627/ED 15. CB-344 KAPP-2/52421/2628/ED 16. CB-345 KAPP-2/52421/2629/ED 17. CB-204 KAPP-2/52421/2538/ED 18. CB-206 KAPP-2/52421/2540/ED 19. CB-209 KAPP-2/52421/2543/ED 20. CB-210 KAPP-2/52421/2544/ED

General Arrangement Drawings 21. GA Drawings of BUS-K KAPP/52421/2669/GA 22. GA Drawings of BUS-L KAPP/52421/2686/GA 23. GA Drawings of BUS-M KAPP/52421/2703/GA 24. GA Drawings of BUS-J KAPP/52421/2652/GA 25. GA Drawings of BUS-P-P1 KAPP/52421/2552/GA 26. GA Drawings of BUS-Q-Q1 KAPP/52421/2569/GA 27. GA Drawings of BUS-S KAPP/52421/2502/GA 28. GA Drawings of BUS-T KAPP/52421/2519/GA 29. GA Drawings of Relay Panels J,K,L,M KAPP/52421/2657/GA 30. GA Drawings of Relay Panels P,P1 KAPP/52421/2557/GA



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31. GA Drawings of Relay Panels Q,Q1 KAPP/52421/2574/GA 32. GA Drawings of Relay Panels S KAPP/52421/2507/GA 33. GA Drawings of Relay Panels T KAPP/52421/2524/GA

Layout of switchgear and relay panels 34. Floor layout of Bus S & T switchgear and relay

panel KAPP1-2/52421/2504/GA

35. Floor layout of Bus P-P1 and Q-Q1 switchgear and relay panel

KAPP1-2/52421/2554/GA

36. Floor layout of Bus K, L, M and J switchgear and relay panel

KAPP1-2/52421/2654/GA

37. Lay Out of 415 V Bus ducts 38. Layout of 3200 A Bus Duct From Bus J to Bus

K,L,M and Bus P-P1 and Bus Q-q1 switchgear KAPP1-2/52421/2801/GA

39. Layout of 1000 A Bus Duct between Bus S and T and between Bus P-P1 / Bus Q-q1 and Bus S /T switchgear

KAPP1-2/52421/2802/GA

40. Details of sectional view -CC KAPP1-2/52421/2817/GA 41. Details of sectional view –AA & BB KAPP1-2/52421/2811/GA 42. Lay out of 415 V Bus P-P1, Q-Q1 switchgear &

relay panel KAPP1-2/52310/6070/GA

43. Sectional view of Incomer panel from bottom ( ME-1600 ACB ) suitable for Cl- II Bus- S & T switchgear

KAPP-2/52421/2765/GA



Page 66 of 80

ANNEXURE - 5 Quality control plan

This document indicates the requirements expected from the contractor/manufacturer of the above equipments. Subsequent to the placement of Purchase Order contractor/manufacturer shall submit” for purchaser’s approval a quality assurance plan in line with this document incorporating specific document numbers for “format of records”, “acceptance norms” and “reference documents Abbreviations: V - Verified by TR - Test Report 1. NPCIL QS P - Performed by PS - Plant Standard 2. Prime Supplier W - Witnessed by TC - Test Certificate 3. Sub-vendor of 2 H - Hold by NPCIL IR - Inspection Report AD- NPC Approved document.(PO/Drgs./Test procedures) Notes:

Wherever V& W are both indicated, NPC QS to witness test or review TRs. TRs not more than five-year-old from date of purchase order shall be reviewed for acceptance. Otherwise test shall be carried out. Minor: The characteristic of a component, process or operation whose failure neither materially reduce the usability of the product in operation, nor

does it affect the aesthetic aspects. Major: The characteristics of a component, process or operation whose failure may cause operation failure which cannot be readily corrected at site or

cause substandard performance, increased erection and maintenance cost, reduced life or seriously affect aesthetics or ergonomics. Critical: The characteristics of a component, process or operation failure of which will surely cause operating failure or intermittent troubles which is

difficult to rectify at site or render the unit unfit for use or safety hazards. ‘‘Failure ‘’ of a characteristic means failure to meet the ‘acceptance norms ‘. Sampling: Generally in accordance with IS: 2500. Sampling will be used as under:-

If 100% “Witness” of tests is carried out by Vendor QC,, NPC QS will witness on sample basis or if 100% “ Witness" of test is carried out by “Sub Vendor”, “Vendor QC” will witness on sample basis. Any deviation to this QAP shall be brought by the vender in his offer,, failing which, this QAP shall be complied fully.

Sl. No.

Components Characteristics checked.

Category Method check

Extent check Reference document

Acceptance norms

Format of record

Agency Remarks



Page 67 of 80

V P W H 1.0 Raw Material/

Bought out items.

1.1 Sheets CRCA/HRCA & structural members.

Chemical composition.

Major Chemical Sampling 1 No. per lot.

IS IS TC 1,2 3

Bending tests. Major Mechanical

Sampling 1 No. per lot

IS IS TC 2 3

Dimension/Thickness

Major Measurement

100% IS IS TC 1 3 2

Hardness Major Physical Sampling 1 No. per lot.

IS IS TC 2 3

Surface finish Major Visual 100% IS IS TC 2 3 1.2 Bus bars Chemical

composition. Major Chemical Sampling 1

No. per lot. IS IS TC 1 3 2

Electrical conductivity.

Major Electrical Sampling 1 No. per lot.

IS IS TC 1 3 2

Dimension check.

Major Measurement

Sampling 1 No. per lot.

IS IS TR 1 3 2

Check for mechanical property

Major Mechanical

Sampling 1 No. per lot.

IS IS TR 1 3 2

Visual check. Major Visual 100% IS IS TC 1 3 2 1.3 Control wires Routine tests. Major Electrical 100% IS IS Mfr’TC 1,2 3



Page 68 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H Acceptance tests.

Major Electrical 1 No. per lot IS IS TC 3 1,2

Type tests. Major Electrical 1 No. of per lot.

IS IS TC 1 3 2

1.4 Indicating Meters. Routine tests Major Electrical 100% IS IS Mfr’TC 1 3 2 Review of type test reports.

Major Electrical 100% IS IS Mfr’TC 1,2 3

1.5 Fuses Routine tests Major Electrical 100% IS IS Mfr’TC 1,2 3 Review of type test reports.


1.6 Switches Routine tests Major Mechanical

100% IS IS Mfr’TC 1,2 3

Review of type test reports.


1.7 Push buttons Routine tests Major Mechanical

sample IS IS Mfr’TC 1,2 3

Review of type test reports.


1.8 1. Indicating lamps assembly.

Current voltage rating/type

Major Visual 100% As per approved drgs QC record

1,2 3



Page 69 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H Operational test

Major Electrical 100% As per com drgs. QC record

1,2 3

1.9 Lugs & Terminal block.

Appearance Major Visual sample As per Com drg/Mfg drg

As per Com drg/Mfg drg

QC record

1,2 3

Dimension Major Measurement

sample As per Com drg/Mfg drg

As per Com drg/Mfg drg

QC record

1,2 3

1.10 ACBs Routine tests Major Electrical 100% IS IS Mfr’TC 3 2 1 Mechanical operation.

Major Mechanical

100% IS IS TC 3 1,2

Calibration of releases.

Major Electrical 100% IS IS TC 3 1,2

Dielectric withstand

Major Electrical 100% IS IS TC 3 1,2

Type test as per sequence I & VI and EMC compatibility for electronic releases

Major Electrical Sample IS- 60947 IS Mfr’TC 3 2 1 Verification by purchaser under hold



Page 70 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H 1.11

MCBs Routine tests Major Electrical 100% IS IS Mfr’TC 1,2 3 Review of type test reports.

Major Electrical 100% IS IS Mfr’TC 1 3 2

1.12

Protection & auxiliary relays

Routine tests Major Electrical 100% IS IS Mfr’TC 3 2 1 Review of type test reports.

Major Electrical 100% IS IS Mfr’TC 1,2 3 1

1.13

Transducers Routine tests Major Electrical 100% IS IS Mfr’TC 3 2 1 Review of type test reports.

Major Electrical 100% IS IS Mfr’TC 1,2 3 1

1.14

Shunts Dimensions Major Electrical 100% IS IS TC 1 3 2 Accuracy Major Electrical One of each

type IS IS TC 1 3 2

1.15

Control transformers & instrument transformers.

Routine test Major Electrical 100% IS IS TC 3 2 1 Type tests Major Electrical One of each

type IS IS TC 3 2 1

1.16

Support insulators (SMC)

Appearance Major Visual Com. drg Com. drg TC 1 3 2

Dimensional Major M Com. drg Com. drg TC 1,2 3

Creepage distance

Major Com. drg Com. drg TC 1,2 3



Page 71 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H Tensile strength/compressive strength

Major BS BS QC Record

1,2 3

Comp. Tracking index

Major BS BS QC record

1,2 3

1.17

Thermostat Appearance Major Visual 100% PS PS TC 1,2 3 IR, HV tests Major Electrical 100% PS PS TC 1,2 3 Functional test critical Electrical 100% IS IS TC 1,2 3

1.18

Space heater, cubicle lamp & other accessories.

HV & IR test Major Electrical 100% IS IS QC Record

1,2 3

Functional test Major Electrical 100% App Drg/Mfrs. Drg

App Drg/Mfrs. Drg

QC Record

1,2 3

Dimensional check

Major Measurement

100% App Drg/Mfrs. Drg

App Drg/Mfrs. Drg

QC Record

1,2 3

1.19

Gaskets Surface finish Major Visual 100% PS PS TC 1 3 2 Dimension Major Measure

ment 1 no per lot PS PS TC 1,2 3

Hardness Major Physical 1 no per lot %

PS PS QC Record

1,2 3

Elongation and compression test

Major Verification

1 no per lot %

IS IS QC Record

1,2 3



Page 72 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H Burning test Major Physical 1 no per lot

% IS IS QC

record 1 3 2

1.20

Bus bar sleeve Visual dimension

Major Visual/mechanical

1 no per lot PS/Com. Drg

PS/Com. Drg

TC 1 3 2 Applicable in case sleeves are provided

Post shrinkage test

Major mechanical

1 no per lot PS/Com. Drg

PS/Com. Drg

TC 1 3 2

1.21

Fastners, Washers, spring washers

Appearance Major Visual 100% As per com. Drg.

As per com. Drg.

QS Record

1,2 3

Coating Major Visual Sample As per com. Drg.

As per com. Drg.

QS Record

1,2 3


Sample As per com. Drg.

As per com. Drg.

QS Record

1,2 3

Interchangeability

Major Physical Sample As per com. Drg.

As per com. Drg.

QS Record

1,2 3

Mechanical properties

Major Mechanical

sample As per PS As per PS QS Record

1,2 3



Page 73 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H 2.0 Panel fabrication Appearance Major Visual Sample Com. drg Com. drg Shop

record 1,2 3


Sample Com. drg Com. drg Shop record

1,2 3

Verticality Major Measurement

Sample Com. drg Com. drg Shop record

1 3 2

Interchangeability

Major Physical Random Com. drg Com. drg Shop record

1 3 2

2.1 Panel pretreatment Seven tank phosphating process.

Critical Visual/Measurement

Sample PS IS Shop record

3 1,2

Visual or poor coating & patches.

Major Visual Each lot PS PS Shop record

3 1,2

Coating weight for category ‘C’.

Major Measurement

Once in Quarter

PS PS Shop record

3 1,2

2.2 Panel power coating Surface finish Major Visual 100% PS PS Shop record

3 1,2

Paint shade Major Visual Sample/day RAL RAL Shop record

3 1,2

Paint thickness Major Measurement

Sample/day PS 50 micron Min

Shop record

3 1,2



Page 74 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H Adhesion & peel of test.

Major Physical Once in a qutr

PS PS Shop record

3 1,2

Flexibility test-14” mandrel (bending test)


PS PS Shop record

3 1,2

Scratch hardness


PS PS Shop record

3 1,2

Salt spray Major Chemical Once in 6 month

PS PS QC record

3 1,2

3.0 Assembly of panels Visual Major Visual 100% IS/PO IS/PO TR 1,2 3 Dimensional check

Major Measurement

100% IS/PO IS/PO TR

3.1 Interconnecting wiring

Correctness Major Visual 100% App drg App drg QC record

1,2 3

Pull test Major Mechanical

sample Physical test

Physical test

QC record

1,2 3

Continuity Major Electrical 100% App drg App drg QC record

1,2 3

3.2 2. Bus bars Finish and joint surface

Critical Visual Sample PS PS Shop record

1 3 2



Page 75 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H Visual inspection of sleeved bus bar

Major Visual Sample PS PS Shop record

1 3 2 Applicable if bus bars are sleeved

Electrical test on bus bar sleeving.

Major Electrical sample PS PS Shop record

1 3 2 Applicable if bus bars are sleeved

4.0 Assembled panel with all accessories mounted and wired.

Appearance Major Visual 100% IS IS QC Record

1,2 3

Verticality Major Measurement

100% IS IS QC Record

1,2 3

Verification Major Physical 100% IS IS QC Record

1,2 3

Dimension check

Major Measurement

100% IS IS QC Record

1,2 3

Interchangeability of similar modules.

Crticial Physical Random IS IS QC Record

1,2 3

Tightness of busbar joints

Critical Physical random IS IS QC Record

1,2 3

5.0 Final test Routine test on swgr panel



Page 76 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H Appearance Major Visual 100% IS IS Test

Report 3 2 1

Bill of material

Major Visual 100% IS IS Test Report

3 2 1


100% IS IS Test Report

3 2 1

Surface finish Major Visual Random IS IS Test Report

3 2 1

Provision of partitions/compartments.

Major Visual 100% IS IS Test Report

3 2 1

Interchangeability

critical Physical Random IS IS Test Report

3 2 1

Mechanical operation

Major Electrical 100% IS IS Test Report

3 2 1

Electrical control, interlock and sequential operation


3 2 1



Page 77 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H Wiring check neatness of wiring and accessibility & adequacy of space for external wiring termination.

Major Electrical/Visual

100% IS IS Test Report

3 2 1

One minute power freq. Voltage withstand & insulation resistance test.


3 2 1

Functional test on all equipment

Major Electrical 100% IS/PS IS/PS Test Report

3 2 1

Closing and tripping time of circuit breaker

Major Electrical 100% IS/PS IS/PS Test Report

3 2 1

Routine test on marshalling panel



Page 78 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H Bill of material and wiring check

Major Electrical 100% AD AD Test Report

3 2 1

HV test Major Electrical 100% IS/PS IS/PS Test Report

3 2 1

IR test Major Electrical 100% IS/PS IS/PS Test Report

3 2 1

Type test For all type tests, verification under hold

Temp. rise test Major Electrical One of each rating and type

IS IS Test report

3 2 1

One min HV and IR test on the main bus bar

Major Electrical One of each rating and type

IS IS Test report

3 2 1

Degree of protection.

Major Electrical Sample IS IS Test report

1 3 2

Short circuit withstand test

Major Electrical Sample IS IS Test report

1 3 2 1



Page 79 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H Mechanical

operation and performance test on breaker

Major Electrical Sample IS/PS IS/PS Test report

3 2 1

Clearance and creepage distance

Major Measurement

Sample IS IS Test report

3 2 1

Special type tests

Temp. rise test Major Electrical One of each rating and type

IS and AD

IS and AD

Test report

3 2 1

Seismic test (on panel specified in NPCIL spec.)

Major Testing Sample IEEE-344/PB-P-541

IEEE-344/PB-P-541

Test report

3 2 1

IV&V test Verifiction part

Major Electrical 100% AD AD Test report

3 2 1

Validation part Major Electrical Sample AD AD Test report

3 2 1

6.0 End documents Type test reports*

Major Visual 100% QAP/spec.

QAP/spec.

Test report

3 2 1

Routine test reports*


QAP/spec.

1,2 3



Page 80 of 80

Sl. No.




Acceptance norms

Format of record

Agency Remarks

V P W H Stage inspection reports*


QAP/spec.

1,2 3

Final Report Major Visual 100% QAP/spec.

QAP/spec.

1,2 3

O&M Manuals/Catalogues of all bought out items.


QAP/spec.

1,2 3

Date post:	07-Feb-2018
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