Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 1 of 13

Common Equipments

Project Document No: G3IR-1050-65-SP-9045

Unit: Discipline: Document Type:

General Electrical Specification

Document Title:

SPECIFICATION FOR COMMON EQUIPMENTS

ISSUED FOR DESIGN

08 Aug 2012

1 0 Revision

30-Jul-12 19-Jul-12 Date

Issued for Design Issued for RFQ Purpose

HS HS Prepared By

NG NG Checked By

VP VP Fluor BASF

Approved By

G3IR-1050-65-SP-9045

Page 1 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 2 of 13

Common Equipments Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. 0 1 Date Description

19-Jul-12 30-Jul-12

Issued for Design (RFQ) Issued for Design

G3IR-1050-65-SP-9045

Page 2 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 3 of 13

Common Equipments

TABLE OF CONTENTS

1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9

GENERAL .................................................................................................................................................. 4 SCOPE ....................................................................................................................................................... 4 REFERENCES........................................................................................................................................... 4 SERVICE CONDITION .............................................................................................................................. 5 TECHNICAL REQUIREMENTS ................................................................................................................ 5 ALUMINIUM TUBULAR CONDUCTOR.................................................................................................... 5 ACSR CONDUCTOR................................................................................................................................. 5 CLAMPS AND CONNECTORS................................................................................................................. 6 DISC INSULATOR..................................................................................................................................... 7 POST INSULATOR STACK ...................................................................................................................... 8 GALVANIZED STEEL SHIELD WIRE....................................................................................................... 8 BUNDLE SPACERS .................................................................................................................................. 9 CONTROL CABINETS, JUNCTION BOXES, TERMINAL BOXES & MARSHALLING BOXES FOR OUTDOOR EQUIPMENT .......................................................................................................................... 9 CABLE RACKS INCLUDING SUPPORTS, TRAYS AND ACCESSORIES .......................................... 10

2.10 SPACERS ................................................................................................................................................ 11 2.11 TERMINAL BLOCKS............................................................................................................................... 11 2.12 WIRING .................................................................................................................................................... 12 2.13 CONDUITS, PIPES AND ACCESSORIES.............................................................................................. 12 2.14 DISTRIBUTION BOARDS (415 V AC & DC) .......................................................................................... 12

G3IR-1050-65-SP-9045

Page 3 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 4 of 13

Common Equipments

1.0

GENERAL 1.1 SCOPE 1.1.1 This specification is intended to cover design, engineering, procurement, manufacture, inspection and testing at manufacturers works, packing, loading, forwarding, transport and delivery to site, erection / installation, testing and commissioning at site of all common equipments and accessories associated with MEV package. 1.1.2 The make of all accessories and hardware shall be subject to purchasers approval. 1.1.3 It is not the intent to specify completely herein all details of design and construction of the equipment. However, all components shall conform in all respects to high standards of design engineering, materials of construction, workmanship and shall also be in line with the current practice for reliable and efficient functioning of the equipment and be capable of performing in continuous commercial operation in a manner acceptable to the Owner. 1.1.4 Supplier is required to carefully examine and understand the specifications and seek clarifications, if required, to ensure that he has understood the specifications as intended by the Owner. In the absence of any specific clarifications made by the Owner during bidding stage, the interpretation of Owner shall be final. The Suppliers offer should not carry any sections like clarifications, interpretations and/or assumptions. All such points are required to be clarified during bidding stage. 1.2 REFERENCES 1.2.1 Common equipment shall conform to the latest editions of respective standards issued by BIS (Bureau of Indian Standards) and IEC unless otherwise specified. Each publication shall be the latest revision and addendum in effect on the date this specification is issued for Purchase, unless noted otherwise. 1.2.2 In case of any contradiction between various referred standards/specification/data sheets and statutory regulations, it shall be brought to the notice of Client for resolution. Generally the following order of priority shall govern,

G3IR-1050-65-SP-9045

Page 4 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 5 of 13

Common Equipments 1.3 Statutory regulations BASF Guidlines Data Sheets This specification Codes and standards

SERVICE CONDITION 1.3.1 The equipment shall, in all respects, be suitable for operation under the service conditions stated in the RFQ. 1.3.2 The isolator shall have life expectancy of twenty five (25) years under site conditions with periodic maintenance interval shall be greater than 5 years.

2.0

TECHNICAL REQUIREMENTS 2.1 ALUMINIUM TUBULAR CONDUCTOR 2.1.1 2.1.2 The aluminium tube shall be grade 63401 WP (range2) as per IS 5082. There shall be no negative tolerance on OD and thickness of the tube. Other tolerances shall be as per IS: 2678 and 2673. 2.1.3 Tests: In accordance with the IS standards, type test certificates shall be submitted. 2.2 ACSR CONDUCTOR 2.2.1 The Aluminium Standard conductor and steel reinforced shall have the technical parameters matching with the requirements given in Annexure. ACSR conductors shall conform to the latest revision of IS-398. 2.2.2 The material for ACSR conductor shall conform to the following: a) Aluminium The aluminium strands shall be hard drawn from electrolytic aluminium rods having purity not less than 99.5% and a copper content not exceeding 0.04%. b) Steel

G3IR-1050-65-SP-9045

Page 5 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 6 of 13

Common Equipments The steel wire strands shall be drawn from high carbon steel wire rods and shall conform to the following chemical composition: Element Carbon Manganese Phosphorous Sulphur Silicon c) Zinc The zinc used for galvanizing shall be electrolytic High Grade Zinc of 99.95% purity. It shall conform to and satisfy all the requirements of IS: 209-1979. 2.2.3 Tests: In accordance with the IS standards, type test certificates shall be submitted. 2.3 CLAMPS AND CONNECTORS 2.3.1 The material of clamps and connectors shall be Aluminium alloy casting conforming to designation A6 of IS: 617 for connecting to equipment terminals and conductors of aluminium. In case the terminals are of copper, the same clamps/connectors shall be used with 2mm thick bimetallic liner. 2.3.2 The material of clamps and connectors shall be Galvanized mild steel for connecting to shield wire. 2.3.3 Bolts, nuts and plain washers shall be hot dip galvanized mild steel for sizes M12 and above. For sizes below M12, they shall be electro-galvanized mild steel. The spring washers shall be electro-galvanized mild steel. 2.3.4 All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and corners shall be rounded off to meet specified corona and radio interference requirements % Composition 0.50 to 0.85 0.50 to 1.10 not more than 0.035 not more than 0.045 0.10 to 0.35

G3IR-1050-65-SP-9045

Page 6 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 7 of 13

Common Equipments 2.3.5 Current rating and size of terminal/conductor for which connector is suitable shall be embossed/punched on each component 2.3.6 No current carrying part of any clamp shall be less than 10 mm thick. All ferrous parts shall be hot dip galvanised. Copper alloy liner of minimum 2 mm thickness shall be cast integral with aluminum body for Bi-metallic clamps. 2.3.7 Tests: In accordance with the IS standards, type test certificates shall be submitted. 2.4 DISC INSULATOR 2.4.1 All disc insulators shall be dimensioned appropriately so as to have the required Electro- Mechanical strength for EHV outdoor duties. 2.4.2 When operating at normal rated voltage there shall be no electric discharge between conductor and insulator which would cause corrosion or injury to conductors or insulators by the formation of substances due to chemical action. No radio interference shall be caused when operating at normal rated voltage. 2.4.3 Insulating shall be co-ordinated with basis impulse level of the system. The creepage distance shall correspond to very heavily polluted atmosphere (31mm/KV) 2.4.4 Porcelain used in insulator manufacture shall be homogeneous, free from lamination, cavities and other flaws or imperfection that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture. 2.4.5 Bidder shall make available data on the essential features of design including the method of assembly of discs and metal parts, number of discs per insulators, the manner in which mechanical stresses are transmitted through discs to adjacent parts, provision for meeting expansion stresses, results of corona and thermal shock tests, recommended working strength and any special design or arrangement employed to increase life under service conditions. 2.4.6 Insulator hardware shall be of forged steel. Malleable cast iron shall not be accepted except for insulator disc cap. The surface of hardware must be clean, smooth, without cuts, abrasion or projections. No part shall be subjected to

G3IR-1050-65-SP-9045

Page 7 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 8 of 13

Common Equipments excessive localized pressure. The metal parts shall not produce any noise generating corona under operating conditions. 2.4.7 2.4.8 It shall be anti-fog type and Electro mechanical strength shall be 120 KN. Tests: In accordance with the IS standards, type test certificates shall be submitted. 2.5 POST INSULATOR STACK 2.5.1 Post type insulators shall consist of a porcelain part permanently secured in a mental base to be mounted upright. They shall be designed to withstand any shocks to which they may be subjected to by the operation of the associated equipment. Only solid core insulators will be acceptable. 2.5.2 Porcelain used shall be homogeneous, free from lamination, cavities and other flaws or imperfection that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture. 2.5.3 Glazing of the Porcelain shall be of uniform brown in colour, free from blisters, burrs and other similar defects. 2.5.4 The insulator shall have alternate long and short sheds with aerodynamic profile. The shed profile shall also meet the requirements of IEC-815 for the specified pollution level. 2.5.5 When operating at normal rated voltage there shall be no electric discharge between conductor and insulators, which would cause corrosion or injury to conductors or insulators by the formation of substances produced by chemical action. 2.5.6 The design if the insulators shall be such that stress due to expansion and contraction in any part of the insulator shall not lead to deterioration. 2.5.7 Post insulator shall be complete with necessary fixing clamp at top for clamping of Aluminium tube, as required. The insulators shall be provided with necessary nuts, bolts and washers. 2.5.8 Cantilever strength requirement shall be specified by the vendor based on the calculations subject to Owners approval.

G3IR-1050-65-SP-9045

Page 8 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 9 of 13

Common Equipments

2.6

GALVANIZED STEEL SHIELD WIRE 2.6.1 Galvanized steel shield wire shall generally conform to IS 398 (Part-ll) except as specified herein and in annexure. The steel strands shall be drawn from high carbon steel rods produced by either acid or basic open health process, the electric furnace process or basic oxygen process. The wire shall be hot dip galvanized. 2.6.2 Zinc used for galvanizing shall be electrotype high-grade zinc of 99.5% purity and shall conform to IS: 209 -1966. The hot dip galvanizing shall be done as per IS: 4826 for heavy coating. 2.6.3 There shall be no joint of any kind in the finished strand wire entering into the construction of earth wire.

2.7

BUNDLE SPACERS 2.7.1 Bundle spacers shall have enough strength so as to restore normal spacing of conductors after displacement by winds, short circuits etc. without damages or permanent deformation. The spacers shall have long life without fatigue or wear and shall have gentle but firm grip on conductor. They shall be able to withstand all the electromagnetic and electrostatic forces under different operating conditions including dead short circuit 2.7.2 They shall be one-piece construction and shall not have separate small components. 2.7.3 The spacers shall be flexible enough so as to avoid distortion or damages to the conductor or themselves. Rigid spacers are not acceptable.

2.8

CONTROL CABINETS, JUNCTION BOXES, TERMINAL BOXES & MARSHALLING BOXES FOR OUTDOOR EQUIPMENT 2.8.1 All types of boxes, cabinets etc. shall generally conform to & be tested in accordance with IS-5039/IS-8623, IEC-60439, as applicable, and the clauses given in fellow clause. 2.8.2 Control cabinets, junction boxes, Marshalling boxes & terminal boxes shall be made of sheet steel or aluminium enclosure and shall be dust, water and vermin

G3IR-1050-65-SP-9045

Page 9 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 10 of 13

Common Equipments proof. Sheet steel used shall be atleast 2.0 mm thick cold rolled or 2.5 mm hot rolled or alternately 1.6 mm thick stainless steel can also be used. The box shall be properly braced to prevent wobbling. There shall be sufficient reinforcement to provide level surfaces, resistance to vibrations and rigidity during transportation and installation. In case of aluminum enclosed box the thickness of aluminum shall be such that it provides adequate rigidity and long life as comparable with sheetsteel of specified thickness. 2.8.3 A canopy and sealing arrangements for operating rods shall be provided in marshalling boxes / Control cabinets to prevent ingress of rain water. 2.8.4 Cabinet/boxes shall be provided with double hinged doors with padlocking arrangements. The distance between two hinges shall be adequate to ensure uniform sealing pressure against atmosphere. The quality of the gasket shall be such that it does not get damaged/cracked during the operation of the equipment. 2.8.5 All boxes/cabinets shall be designed for the entry of cables from bottom by means of weather proof and dust-proof connections. Boxes and cabinets shall be designed with generous clearances to avoid interference between the wiring entering from below and any terminal blocks or accessories mounted within the box or cabinet. Suitable cable gland plate above the base of the marshalling kiosk/box shall be provided for this purpose along with the proper blanking plates. Necessary number of cable glands shall be supplied and fitted on this gland plate. Gland plate shall have provision for some future glands to be provided later, if required. The Nickel plated glands shall be dust proof, screw on & double compression type and made of brass. The gland shall have provision for securing armour of the cable separately and shall be provided with earthing tag. The glands shall conform to BS:6121. 2.8.6 A 240V, single phase, 50 Hz, 15 amp AC plug and socket shall be provided in the cabinet with ON-OFF switch for connection of hand lamps. Plug and socket shall be of industrial grade. 2.8.7 For illumination, a fluorescent tube or CFL of approximately 9 to 15 watts shall be provided. The switching of the fittings shall be controlled by the door switch. 2.8.8 Positive earthing of the cabinet shall be ensured by providing two separate earthing pads. The earth wire shall be terminated on to the earthing pad and

G3IR-1050-65-SP-9045

Page 10 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 11 of 13

Common Equipments secured by the use of self etching washer. Earthing of hinged door shall be done by using a separate earth wire. 2.9 CABLE RACKS INCLUDING SUPPORTS, TRAYS AND ACCESSORIES 2.9.1 The Contractor shall fabricate and install mounting arrangements for the support and installation of all the cables on trays in the RCC trenches. These mounting structures/ cable racks shall be fabricated from structural steel members (channels, angles and flats) of the required size. 2.9.2 Cable racks and supports shall be painted after installation. The painting shall be in conformity with stipulated elsewhere in the specification. All welding works inclusive of the consumables required for fabrication and installation shall be in the scope of the Contractor. 2.9.3 Cable Trays: Hot dip galvanized ladder type cable trays of adequate width are to be provided as required for laying of cables in the control room building/Cable Trench. Aux. power cables are to be laid on the top tray and AC and DC control cables at bottom trays. Cable trays shall be designed to carry cables load without bending and proper tray supports shall be provided at every 2 m interval. All nuts, bolts, washers etc. to be supplied by the Contractor shall be hot dip galvanized after fabrication 2.10 SPACERS 2.10.1 Spacers shall conform to IS: 10162. They shall be of non-magnetic material except nuts and bolts, which shall be of hot dip galvanized mild steel. 2.10.2 Spacers shall generally meet the requirements of clamps and connectors as specified above. Its design shall take care of fixing and removing during installation and maintenance. 2.10.3 In addition to the type tests as per IS: 10162, clamp slip test should have been conducted. This test should have been performed on all other clamps of the sample. The test shall be conducted as per relevant standards.
G3IR-1050-65-SP-9045 Page 11 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 12 of 13

Common Equipments 2.11 TERMINAL BLOCKS 2.11.1 The terminal blocks shall be of 650V grade, and rated to continuously carry maximum expected current. The conducting part shall be tinned or silver plated. 2.11.2 They shall be of moulded, non-inflammable thermosetting plastic. The material shall not deteriorate with varied conditions of temperature and humidity. The terminal blocks shall be fully enclosed with removable covers of transparent, nondeteriorating plastic material. Insulating barriers shall be provided between the terminal blocks so that the barriers do not hinder the wiring operation without removing the barriers. 2.11.3 The terminal blocks for CT and VT secondary leads shall be provided with test links and isolating facilities. CT secondary leads shall also be provided with short circuiting and earthing facilities. 2.12 WIRING 2.12.1 All wiring shall be carried out with 1100 V grade stranded copper wires. The minimum size of the stranded conductor used for internal wiring shall be as follows: All circuits except CT circuits 2.5 sq.mm CT circuits 4 sq. mm (minimum number of strands shall be 3 per conductor).

2.12.2 All internal wiring shall be securely supported, neatly arranged readily accessible and connected to equipment terminals and terminal blocks. 2.12.3 All wires directly connected to trip circuit breaker shall be distinguished by the addition of a red coloured unlettered ferrule. Number 6 & 9 shall not be included for ferrules purposes. 2.12.4 All terminals including spare terminals of auxiliary equipment shall be wired up to terminal blocks. Each equipment shall has its own central control cabinet in which all contacts including spare contacts from all poles shall be wired out. 2.13 CONDUITS, PIPES AND ACCESSORIES The Contractor shall supply and install all rigid conduits, mild steel pipes, flexible conduits, hume pipes, etc. including all necessary sundry materials, such as tees, elbows, check nuts, bushing reduces, enlargers, wooden plugs, coupling caps, nipples, gland sealing fittings, pull boxes, etc.
G3IR-1050-65-SP-9045 Page 12 of 13

Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9045 Date 19-Jul-12 Page 13 of 13

Common Equipments 2.14 DISTRIBUTION BOARDS (415 V AC & DC) 2.14.1 The AC distribution boards (3 nos-normal & emergency lighting and auxiliary power) and one DC distribution board shall be located in the Substation 1 building. 2.14.2 Each AC board except auxiliary board shall receive single phase power from Owner provided cables. For auxiliary board, there shall be 3 phase incomer from owner provided power cables. For DC distribution, vendor shall provide incomer from Battery Charger. 2.14.3 For Substation 2, there shall be one AC distribution board (3 phase incomer) from Owner provided cables and DC distribution board. For DC distribution, vendor shall provide incomer from Battery Charger 2.14.4 The Boards shall be made out of at least 2.0 mm thick cold rolled steel sheet, suitably reinforced to provide flat level surfaces. 2.14.5 All cables shall enter and leave from bottom. Suitable cable terminal blocks with cable lugs shall be provided inside each cabinet for the incoming and outgoing cables. The terminals shall be serially numbered to facilitate installation and maintenance. 2.14.6 Each board shall have minimum 20% spare feeders. 2.14.7 Distribution board sub-circuit loading shall not exceed 80% of the protective device rating.

G3IR-1050-65-SP-9045

Page 13 of 13