TECHINCAL SPECIFICATION

SECTION: Outdoor Switchyard

TABLE OF CONTENTS
Clause No Description
Page No
1 Scope 2
2 Codes, Standards and Specifications 2
3 Design Requirements 3
4 Equipment Specifications 8
5 Cabling System 13
6 Lightning System 14
7 Earthing System 15
8 Shop Inspection and Testing 19
9 Packing and Dispatch 19
10 Field Testing and Commissioning 19
11 Approved makes of equipment/components 19
12 Bidder Data Requirement 19
TECHINCAL SPECIFICATION
SECTION: Outdoor Switchyard
1 Scope
1.1 The scope of this specification is to define the minimum technical requi
rements for the design & detail engineering, supply, transportation to site, ins
tallation, testing and commissioning of electrical equipment and associated mate
rial as required for outdoor switchyard.
1.2 Work shall be performed in accordance with terms, conditions and approve
d drawings wherever applicable, as set forth in this document and instructions i
ssued by the site in-charge or his authorized representative from time to time.
1.3 It is not the intent to specify completely herein the details of design
and construction of switchyard. However the switchyard layout, equipment and ass
ociated accessories shall conform in all respects to high standards of engineeri
ng, design and workmanship. The switchyard, when commissioned, shall be capable
of operating continuously in a manner acceptable to the purchaser, who will inte
rpret the meaning of drawings and specifications. The purchaser reserves the rig
ht to reject any work or materials; which in his judgment, are not in full accor
dance therewith.
1.4 It is not the intent to specify completely herein the details of design
and construction of switchyard. However the switchyard layout, equipment and ass
ociated accessories shall conform in all respects to high standards of engineeri
ng, design and workmanship. The switchyard, when commissioned, shall be capable
of operating continuously in a manner acceptable to the purchaser, who will inte
rpret the meaning of drawings and specifications. The purchaser reserves the rig
ht to reject any work or materials; which in his judgment, are not in full accor
dance therewith.
2 Codes, Standards and Specifications
2.1 The equipment shall comply with the requirements of latest revision of f
ollowing standards issued by BIS (Bureau of Indian Standards), unless otherwise
specified.
IS: 398 Aluminium conductors for overhead transmission purpose
IS: 802 Code of practice for use of structural steel in overhead transmission li
ne
IS: 2121 Conductors and earth wire accessories for overhead power lines
IS: 2165 Insulation coordination
IS: 2309 Code of practice for the protection of buildings & allied struct
ures against lightning.
IS: 2486 Insulator fittings for overhead power lines with a nominal volta
ge greater than 1000 Volts.
IS: 2544 Porcelain post insulators for system with nominal voltage greate
r than 1000 Volts
IS: 3043 Code of practice for earthing
IS: 3716 Application guide for insulation coordination
IS: 5561 Electrical power connectors
IS: 10118 Code of practice for Selection, Installation and m
aintenance of Switchgear and Control gear
IS: 13235 Calculations of the effects of short-circuit currents
2.2 In case of imported equipment, standards of the country of origin can be
accepted if these standards are equivalent or stringent than the applicable Ind
ian standards.
2.3 The equipment shall also conform to the provisions of Indian Electricity
rules and other statutory regulations currently in force in the country.
2.4 In case Indian Standards are not available for any equipment - standards
issued by IEC/BS/IEEE/NEMA or equivalent agency shall be applicable.
2.5 In case of any contradiction between various referred standards/specific
ations/data sheet and statutory regulations the following order of priority shal
l govern:
• Statutory regulations
• Data sheets
• Specifications
• Codes and standards
3 Design Requirements
3.1 General
3.1.1 The offered equipment shall be brand new with state of art technology an
d proven field track record. No prototype equipment shall be offered.
3.1.2 Bidder shall ensure availability of spare parts and maintenance support
services for the offered equipment for at least for 15 years from the date of su
pply.
3.1.3 Bidder shall give a notice for at least one year to the purchaser before
phasing out the product/spares to enable the end user for placement of order fo
r spares and services.
3.1.4 All similar materials and removable parts shall be uniform and interchan
geable with one another. The installation of all equipment shall conform to the
requirements of purchaser’s specification for electrical equipment installation.
3.2 Switchyard Design
3.2.1 This specification, together with the applicable equipment specification
shall govern the design and engineering of electrical facilities - The design s
hall be based on the following:

• Safety to personnel and equipment during operation and maintenance.

• Reliability of service.
• Ease of maintenance and convenience of operation.
• Ease of future extension
• Automatic protection of all electrical equipment through selective relaying
system
• Suitability for applicable environmental factors.
• Minimal fire risk.
3.2.2 Layout of the switchyard is decided keeping in view the following:
a) Convenience of terminating HV transmission line. The sequence of bays sh
all be so arranged that the maximum horizontal angle of deviation of the incomin
g line and shielding conductor does not exceed 30° from Horizontal plane.
b) Movement of equipment in live switchyard, access roads etc.
c) Taking out of the transformers.
d) Provision of future bays for transformer and incoming line.
e) Roads within the switchyard to access the main road to facilitate transp
ortation of various equipments.
f) Sufficient ground clearance to-ensure safety of the personnel moving abo
ut within the switchyard.
g) Unless otherwise specified Highest system voltage (kV) and basic insulat
ion level (kVp) shall be as follows:

System Voltage (kV) Highest System Voltage (kV) Basic Insulation level (
kVp)
66 72.5 325
h) Minimum practiced clearances i.e. P-P, P-E, sectional clearance/ isolati
ng distance, based on system voltage/BIL, as per following Table:
Highest System Voltage (kVp) Basic Insulation Level (kVp) Minimum Clearanc
e Between Sectional Clearance
P-P(mm) P-E(mm) (mm)
72.5 325 630 630 3500
i) Minimum creepage distance based on heavily polluted (31mm/kV) environmen
tal conditions.
j) Approach to waste oil pit.
3.2.3 The approximate area for the switchyard as per the Switchyard layout dra
wing no. 3UIN080126E2001-Rev-A.
3.2.4 The amount of galvanizing shall be minimum 900 gm/m2 as per IS: 802.
3.2.5 Wherever cables cross rail track, cables shall be taken in ERC/concrete
blocks.
3.2.6 Lightning masts shall be provided for lightning protection. However, the
incoming shield wire shall be terminated at the incoming gantry and the same sh
all be included suitably in the protective zone. Bidder shall submit calculation
s for the adequacy of lightning protection (zone of protection). For outdoor lig
hting of switchyard, flood lighting system may be installed on these masts.
3.2.7 Operating handles for isolator main box, earth switch and discharge coun
ter of LA shall be at a height of 1500 mm (maximum) from FGL.
3.2.8 VA rating of all CTs/ PTs shall be calculated by Bidder. Ratio/ burden/
specifications/ accuracy class/ make, etc., of CT/PT required for Gujarat energy
transmission corporation (GETCO) shall be as per GETCO requirements. In line PT
s, GETCO metering core shall be terminated in a separate junction/ terminal box,
which shall be taken separately to the GETCO panel for metering purpose. If sep
arate PT with double break isolators is required by GETCO same shall be provided
by Bidder.
3.2.9 For power transformers, which are being given as free issue item, erecti
on and commissioning shall be done by the bidder.
3.2.10 Suitably supported G.l. rating shall be provided on the top of oil soak
pit provided for the transformers to facilitate movement.
3.2.11 All control cabinets, junction boxes etc. located in outdoor switchyard
area shall have enclosure protection of IP-55 and shall be provided with additio
nal canopy.
3.2.12 Solid core insulators shall be provided for supporting the tubular bus b
ars (if required).
3.2.13 Cadmium plated bolts, nuts, plain washers and spring washers shall only
be used for the equipment, marshalling boxes, junction boxes etc. MS G.I. fasten
ers shall not be used.
3.2.14 LED based alarm annunciations shall only be provided.
3.2.15 Double earthing shall be provided to all the distribution boards, juncti
on boxes of outdoor lighting fixtures, flood light fixtures/ towers etc. whereve
r 415V will be available even if 3-Phase power supply is distributed in that par
ticular junction box to utilize for the single phase equipment.
3.2.16 Details of the cable (size, no. of cores etc.), details to which equipme
nt (tag no.) it is going or from which equipment (tag no.) it is coming etc. as
per cable schedule shall be painted on the cable terminal boxes of the various e
quipments.
3.3 Bus bars
Bus bars shall be either strain type or rigid type (tubular conductors).
3.3.1 Strain Type Bus bar
a) Unless otherwise specified, ACSR shall be used for strain type bus bar,
strung between two supporting structures and supported by strain type insulators
.
b) The size of the conductor shall not be less than incoming O/H line condu
ctor and shall be based on the maximum power to be handled within the switchyard
.
c) The size of the conductor chosen shall be checked for suitability under
following conditions:
• Temperature rise during steady state operation while carrying full load current
at max. ambient and considering the effect of solar radiation, emissivity and ab
sorptivity of conductor, solar absorption co-efficient and still air condition.
The maximum temperature in case of steady state shall be limited to 75°C.
• Temperature rise during short circuit operation considering steady state operati
on prior to fault. The maximum conductor temperature in case of bare conductors,
solid or stranded, Aluminium shall be limited to 200°C, while in case of aluminiu
m alloy it shall be limited to 170°C, as per IS 13235, Table V.
• Allowable maximum tension in strung bus depending on the economics of structure
and allowable sag of the conductor so as to maintain the required electrical cle
arances, as per CI. 3.2.2.
3.3.2 Tubular Bus bar
a) In the case of rigid bus arrangement, aluminium pipes confirming to IS:
5082 shall be used.
b) In case of long spans, expansion joints shall be provided to avoid strai
n on the supporting insulators due to thermal expansion or contraction of pipe.
c) The bus bar sizes shall meet the electrical and mechanical requirement o
f the Specific application. Following checks shall be made for deciding suitabil
ity of Al tube.
• Calculation of total stress in the tube as per IS: 13235.
• Deflection of bus bars shall be limited to either 1/150th of the span length, or
half the diameter of the tube, whichever is less.
• Capacity of the bus bars to withstand the electro dynamic forces under three pha
se short circuit conditions shall be calculated as per IS 13235. The coincidence
of short circuit and particular climatic conditions need not to be taken in to
account.
Lowest of the spans from the above consideration shall be used.
d) The size of the tubular bus chosen shall be checked for suitability unde
r following conditions:
• Temperature rise during continuous current operation considering the effect of s
olar radiation at max. ambient. The maximum temperature shall be limited to 75°C.
• Temperature rise during short-circuit current operation, considering steady stat
e operation prior to fault. The maximum temperature shall be limited to 200°C.
3.4 Bus Post Insulators (BPI)
• Unless otherwise specified, BPI shall be of solid core type.
• Bus Post Insulator shall be selected on the basis of system voltage, insulation
level, mechanical strength and pollution level.
• For selecting cantilever strength of the insulator, the factor of safety for bus
post insulator shall be as under:
o Under static condition 2.0
o Under dynamic condition 1.5
• Corona free insulators shall be provided.
• The spacing of the insulators shall be decided based on the availability of insu
lators with the cantilever strength as required and the limitation of span from
viewpoint of the deflection, as specified above.
3.5 Oil soak pit and Waste oil pit
Civil work for oil soak pit and waste oil pit is not in bidder scope.
Power transformers shall be provided with a RCC oil soak pit below the transform
er. Following guidelines shall be followed in this regard:
• The RCC oil soak pit shall be dimensioned such that the clearance between the pi
t extension and the transformer body shall be 20% of the height of the transform
er (highest point) or minimum 800 mm beyond transformer body (Tank and Radiator)
all around.
• For the transformers, which are having their soak pits connected to a common was
te oil pit, the individual soak pit shall be sized to hold one third of the oil
content of the particular transformer (Tank, Cooler, Conservator and OLTC) plus
a margin of app. 5-7% for rain water. However, the transformers with oil capacit
y exceeding 2000 litres, but not connected to waste oil pit, soak pit shall be s
ized to take the whole of the oil of the transformer plus 10% design margin.
• The pit shall be filled with 40 or 60 mm size gravel and a porosity factor of 40
% may be considered for sizing of the pit.
• Total pit volume shall also account for the transformer foundation or any other
foundation in the pit.
• Pit internal edge shall be raised at least 150mm above the external level.
In addition, provision shall also be made to drain away the oil from individual
soak pit to a separate waste oil tank/pit, where use of more than 9,000 litres o
f oil in any oil tank or chamber is involved. This pit shall be connected by a s
uitable hume / HDPE drain pipe of no less than 200 mm diameter to each soak pit.
Waste oil pit shall be located away from the transformer, in the lowest part of
 the switchyard to assist drainage. The tank shall be of sufficient capacity to
receive, without overflowing, the contents of the specified transformer plus the
water of any fixed fire fighting system and a certain quantity of rain water co
llected form all pits. No other drain shall lead to the pit.
This pit shall be provided with an air vent large enough to avoid over pressure
during operation. The whole internal surface shall be impermeable. This pit shal
l not have stone filling.
Suitable manhole with ladder shall be provided for the waste oil pit. For taking
out the oil from the waste oil pit, a pump of suitable rating shall be provided
and discharge shall be connected to oil waste sewer (OWS), which will be availa
ble at the switchyard battery limit.
3.6 Interlocks
i. Isolator and the controlling circuit breaker shall be interlocked, so th
at the isolator cannot be operated unless the corresponding breaker is not opera
ted.
ii. Isolator and the corresponding earthing switches shall be interlocked so
that no earthing switch can be closed unless and until the-corresponding isolat
or is in open position.
iii. Between various breakers, isolators, earthing switches as per approved i
nterlock schemes.

3.7 Structural Steel

3.7.1 This shall include all steel structures required for the switchyard gant
ries and for mounting of equipment such as circuit breakers, isolators, CT’s, PT’s,
lightning arrestors, post-insulators etc. The structures shall be complete with
the necessary footings for equipment, attachment for insulators, bolts, nuts etc
.
3.7.2 The Steel structures shall conform to enclosed specifications.
3.7.3 The amount of galvanizing shall be as per structural specification.
4 Equipment Specifications
4.1 General
4.1.1 The equipment shall conform to the enclosed specifications. In case spec
ifications are not attached for particular equipment, same shall be supplied as
per Indian/IEC Standards. Equipment shall be suitable for installation and satis
factory operation in the specified service conditions.
4.1.2 The equipment offered shall be designed to operate satisfactorily and me
et all the requirements of site and system conditions, enclosed standard specifi
cation, job specifications and data sheets.
4.1.3 The equipment shall be designed and manufactured in accordance with the
best engineering practice and shall be suitable for the intended purpose.
4.1.4 The equipment specified under this specification shall be designed as pe
r BIS specification for heavily polluted atmosphere.
4.1.5 All equipment shall have tropical and fungical treatment.
4.1.6 Any material used shall be standard and easily replaceable. All accessor
ies like bolts, nuts, pins etc. shall be of standard size and rating and shall b
e easily interchangeable.
4.1.7 The equipment and accessories covered under this specification shall be
so designed that no special tools are necessary for installation and maintenance
. However if special tools are required, same shall be supplied.
4.1.8 The consumable required for installation like topping of oil, grease, jo
inting compound, parts etc shall be supplied along with equipment at no extra co
st.
4.1.9 The equipment painting shade shall be RAL 7035 for outdoor equipments an
d RAL 7032 for indoor equipments as per IS: 5, unless otherwise specified.
4.2 Circuit Breaker
4.2.1 Circuit breaker shall be SF6 type unless otherwise specified and shall m
eet the requirement of IEC standards, enclosed specification for outdoor HV circ
uit breaker and data sheet.
4.2.2 Circuit breaker shall have motor operated spring/spring charging mechani
sm, as specified in the data sheet.
4.2.3 In case of individual pole operated breaker; coupling between the poles
shall be by electrical and pneumatic means. Pole discrepancy feature shall be pr
ovided to ensure proper closing of the individual poles.
4.3 Isolators & Earthing Switch
4.3.1 Isolators shall meet the requirements of enclosed specification for outd
oor HV isolator & earthing switches and data sheet.
4.3.2 The isolators shall be three phase, manual & motorized gang operated, do
uble break type, as specified in data sheet. The earthing switches shall be manu
al gang operated, vertical break type.
4.4 Lightning Arrestor
4.4.1 Lightning arrestor shall be gapless, metal oxide type and shall meet the
requirement of enclosed specification for lightning arresters, insulation coord
ination and data sheet.
4.5 Instrument Transformer
4.5.1 The current transformers shall be multi core, single pole, oil filled ty
pe and shall meet the requirements of enclosed specification for outdoor HV curr
ent and voltage transformers and data sheet.
4.5.2 The voltage transformer shall be electro magnetic type.
4.5.3 The voltage transformer shall meet the requirement of enclosed specifica
tion for outdoor HV current and voltage transformers and data sheets.
4.5.4 For the purpose of grid metering, the voltage transformer shall be elect
ro magnetic type. Ratio, burden, accuracy class and the specifications of curren
t and voltage transformer for tariff metering purpose shall be as per the requir
ement of State Grid Authority.
4.5.5 Bidder shall note that rating of CT ratio, burden, class specified are t
entative. Application check for CTs i.e. final rating, knee point voltage etc. s
hall be decided by the Bidder for Purchaser s review.
4.6 Power transformer
4.6.1 Power transformer shall be a free issue item.
4.7 Neutral Grounding Resistor
The NGR shall meet the requirement of enclosed specification for neutral groundi
ng resistor and data sheet. Tubular bus bar /single core insulated cable of adeq
uate voltage and current rating shall be used for connection between transformer
neutral and NGR and GI strip between NGR and earth electrode.
4.8 Relay and Control Panel
4.8.1 Relay and control panel shall be as per enclosed specification for Relay
and control panels/desks, single line diagram and data sheets.
4.8.2 The relay/control panel shall be Simplex type unless otherwise specified
.
4.8.3 Relay and Control panel shall have a separate dedicated 415V AC supply f
eeders.
4.8.4 Closing and tripping coil of each breaker shall have a dedicated DC feed
er.
4.8.5 The captions to be engraved for various feeders/ annunciators shall be f
inalized during detail engineering.
4.8.6 Testing facility for meters and relays shall be provided. For this purp
ose, necessary test blocks and test plugs shall be provided.
4.8.7 Requirement of ICTs, stablizing resistance and metrosil shall be decided
by the Bidder.

4.9 AC Distribution Boards

4.9.1 Distribution Board shall be as per enclosed specification.
4.9.2 The switchboard shall be free standing, metal enclosed, fully compartmen
talized, modular type. The switchboard shall be of single front, fixed execution
or double front, draw out execution as specified in data sheet, suitable for in
door installation.
4.9.3 Switchboard shall comprise of two incoming power supply load break switc
hes / circuit breakers, bus coupler circuit breaker/load break switch and requir
ed number of outgoing switch fuse and motor starter feeders with 10% spare feede
rs of each rating.
4.9.4 The incomers of distribution boards shall be provided with kWh meter and
Voltmeter, ammeter with selector switches.

4.10 String Bus Conductor

4.10.1 Material
For ACSR conductor, Aluminium strands shall be hard drawn from 99.5% pure electr
olytic aluminium rods with 61%, IACS conductivity. The bidder shall specify the
guaranteed minimum and average values of conductivity. The steel wires strands o
f ACSR conductor shall be hot dip galvanized. Zinc coating shall be evenly and u
niformly coated.
4.10.2 Chemical composition of the material shall comply with the requirements
of relevant Indian standards.
4.10.3 The surface of conductor shall be clean and dry and free from any excess
grease that may be used in its fabrication. The surface strands shall be smooth
and free from burrs and other projections which may be, the cause for increasin
g corona losses when die conductor is used on extra high voltage lines.
4.11 Clamps and Connectors
4.11.1 Materials
Clamps and connectors shall be made of materials listed below:
For connection AAAC/ACSR conductors / aluminium tubes. Aluminium alloy casting
For connecting equipment terminals made of copper or brass to AAAC/ACSR Conducto
r/ Aluminium Tubes Bimetallic connectors made from Aluminium with cast co
pper alloy liner alloy casting
For connecting GI shield wire Malleable iron casting
Bolts, Nuts, Plain washers and spring washers. Hot dip galvanized mild steel
4.11.2 All castings shall be free from blow holes, surface blisters, cracks and
cavities. All sharp edges and corners shall be burred and rounded off. Clamps s
hall be corona free.
4.11.3 No part of a clamp or connector shall be less than 10 mm thick.
4.11.4 For bimetallic clamps or connectors, copper alloy liner shall be cast in
tegral with aluminium alloy body.
4.11.5 Flexible connectors, braids or laminated straps shall be made from tinne
d copper sheets or aluminium laminates depending on the clamp.
4.11.6 Clamp shall be designed to carry the same current as the conductor and t
he operating temperature shall be equal or less than that of conductor at the sp
ecified ambient temperature.
4.11.7 Clamps and connectors shall be designed to withstand stresses due to win
d, vibrations, fluctuations in temperature and short circuit forces without suff
ering permanent deformation or breakages. Tubes in flexible connector shall net
rattle.
4.11.8 Clamps and connectors design shall be such that tensile, bending and wre
nching stresses transmitted to the equipment terminals are minimum possible.
4.11.9 Tubes in flexible connectors shall be prevented from falling out of the
tubular connector.
4.11.10 Flexible and sliding connector shall allow axial movement of tubular con
ductor.
4.11.11 Any tapping from the conductor with single PG/T clamps shall be avoided
and a single conductor shall be provided.

4.12 Insulators & hardware

4.12.1 All insulators shall be suitable for site and system as specified.
4.12.2 The porcelain shall be sound, free form defects, thoroughly verified and
smoothly glazed. Insulators shall have good luster and of uniform brown color.
The glaze shall be unaffected by sudden changes in temperature and by atmospheri
c pollution of ozone, acids, alkali, dust etc.
4.12.3 Under surfaces and grooves shall be shaped for easy cleaning. Shells sha
ll be substantially symmetrical] in shape without any warping.
4.12.4 Insulators shall be designed to avoid excessive concentration of electri
cal stresses in any section or across leakage surfaces.
4.12.5 Strain and suspension strings shall comprise of the conventional ball an
d socket type disc insulators. Individual insulators as well as strings of the s
ame type shall be interchangeable with one another and it shall be possible to f
orm either suspension or strain string using the same disc. The locking clips sh
all be made of Phosphor Bronze and shall provide positive locking of coupling.
4.12.6 Bus post insulators shall be of solid core type. The minimum cantilever
strength of the BPI shall be calculated, to withstand the wind and short circuit
forces.
4.12.7 All ferrous parts shall be hot dip galvanized conforming to relevant Ind
ian standards. All castings shall be free from blow holes, cracks and other cast
ing defects.
4.12.8 Bolts shall be of sufficient strength to withstand without bending the s
tresses introduced in them, when they are stressed to their rated strength. The
bolts shall be readily removable after the fittings have been so stressed.
4.12.9 All current carrying parts shall be designed and manufactured to have mi
nimum contact resistance.
4.12.10 The items of hardware and fittings shall make complete assemblies and sh
all include all bolts, nuts, washers, locknuts, celter pins and other misc. Piec
es which are necessary or usual for their satisfactory performance and efficient
maintenance, are deemed to be within the scope of this specification whether sp
ecifically mentioned or not.
4.12.11 Where parallel insulators are used, base places at the top and bottom sh
all be of sufficient strength.

4.13 Tubular Bus Bars

4.13.1 Tube material shall be aluminium. Aluminium tubes shall comprise of hard
drawn aluminium with minimum 61 % IACS conductivity at 20° C.
4.13.2 The tube sizes offered shall be as per standard matericated Iron Pipe Si
zes (IPS) and extra Heavy Pipe Sizes.
4.13.3 For the inside diameter (ID) of the rube there shall be no plus toleranc
e and for the outside diameter there shall be no minus tolerance.
4.13.4 Jointing sleeves shall be six times the nominal size of the rube and out
er diameter of sleeve shall be suitable to fit snugly in the main rube.
5 Cabling System
5.1 All control cables and auxiliary power cables shall conform to enclosed
specification.
5.2 The cabling work shall conform to enclosed specification for cable insta
llation.
5.3 All cable trays shall be prefabricated GI type. At point of entry into i
ndoor areas, waterproof sealing arrangement shall be provided. Cabling shall be
undertaken as per following:
a. Cables shall be laid on cable racks in RCC trenches with removable type
RCC covers in switchyard.
b. Cables shall be laid in cable trays in multi/single tier arrangement in
cable cellar.
c. In case of raised switchyard control building, RCC trenches with cable r
acks shall be used.
5.4 The trenches shall be sloped in their run to drain freely and necessary
arrangement shall be provided to drain accumulated water to the plant drainage a
t the nearest point.
5.5 GI pipe sleeves of required size shall be provided from cable trench to
all equipment to pull and protect the cables. Pull boxes to facilitate cable pul
ling shall be provided at suitable locations. Conduits shall be sloped and drain
ed at low points. Care shall be taken to ensure the water does not accumulate wi
thin the conduit or drain into the equipment at the end.
5.6 Power and control cables shall be segregated by running on separate rack
s. Separate cables shall be considered for AC and DC signals. Segregation of AC
and DC control cables shall also be done. Separate control cable shall be used f
or each CT and PT.
5.7 All medium voltage cables shall be XLPE insulated, armoured and PVC over
all sheathed, copper/aluminium conductor cables. 1.1 KV grade power cables shall
be PVC insulated, PVC sheathed, armoured cable with copper/aluminium conductor.
The control cable shall be 1100V grade, PVC insulated, PVC sheathed armoured ca
ble with copper conductor.
5.8 The power and control cables shall have the following minimum cross sect
ional areas:
Control cable 2.5 mm2 copper
Lightning/convenience receptacles 2.5 mm2 copper
Solid conductor shall be used for 2.5mm2 copper conductor control cables.
5.9 All control cables shall have at least 10% spare cores subject to minimu
m of 1 core up to 10 core cable and 20% spare cores subject to minimum of 2 core
s above 10 core cable.
5.10 Cables shall be connected directly between switchyard equipments (Breake
r, isolator, CT/PT, Transformer etc.) and Relay & Control Panel without any join
t or Marshalling box

5.11 The cables shall be sized based on the maximum continuous load current,
the voltage drop, system voltage and short circuit withstand criteria. Besides t
he derating due to ambient air temperature, ground temperature grouping and prox
imity cables with each other, thermal resistivity of soil (for buried cables) et
c. shall be taken in to account while sizing the cables.
5.12 The maximum voltage drops in various sections of the electrical system s
hall be within the limits stated in the following table:-

Sr. No. System Element Maximum Permissible Voltage Drop

a) Cable between-Transformer Secondary and AC Distribution Board 0.50%
b) LV Cable between AC Distribution Board / Lighting Board and Lighting P
anel 1-1.5%
c) Cable between lighting panel and lighting points. 4%
d) DC supply circuit 5%
For medium voltage motor, the voltage available at the motor terminals must not
be less than 80% of the rated value during start-up.
5.13 Industrial type, heavy duty, 415V, 63V, 3 phase welding receptacle with
earthing facility, necessary interlocks and associated plugs shall be provided.
Min. one no. shall be provided in cellar, however adequate no, of welding recept
acles shall be provided at Suitable location in the switchyard to ensure accessi
bility with a 50 metres length of trailing cable to any point within the battery
limit.

5.14 Cable trays and its supports shall be galvanized.

6 Lightning System
6.1 The work shall conform to enclosed specification for lighting installati
on.
6.2 Lighting shall be designed to meet illumination levels as mentioned in t
he specification. Lighting design shall ensure uniform illumination and dark spo
ts shall be avoided.
6.3 Fluorescent lighting shall be limited to Substation/control room buildin
g, while HPSV lights shall be used for switchyard. Post top lantern type fining
shall be used for gate lighting. GLS type finings shall be provided for DC criti
cal lighting.

6.4 Following minimum illumination levels shall be maintained for various ar

eas:-
Area Description Average Illumination Level "Lux"
Switchyard Equipments 50
Remaining area of switchyard 20
Pathways 20

6.5 Maintenance factor of 0.7 and. 0.8 shall be considered for outdoor and i
ndoor areas respectively.
6.6 Lightning Mast structure and separate lighting poles shall be used for i
nstalling the lighting fixtures. Lighting fixtures shall not be installed on the
switchyard structures.

6.7 Lighting system shall include normal and critical lighting. Normal light
ing shall operate on 240V AC and critical lighting on DC supply.
6.8 Critical lighting shall be located at strategic locations including the
exit points, switchyard passage, stair case, control and switchgear room etc. an
d shall be switched on automatically in the event of total AC supply failure.
6.9 All outdoor lighting shall be controlled by means of synchronous tuner w
ith manual overriding. All indoor lighting shall be manually switched ON and OFF
by local switches.
6.10 The lighting system shall comprise of lighting distribution board, light
ing and power panels, fixtures, switches, junction boxes, 3 pin 5A/15A convenien
ce socket outlet etc.
6.11 Lighting distribution system shall be 415V, 50Hz, 3 phase and neutral fr
om lighting distribution board. Lighting fittings shall be fed across any one of
phases and neutral i.e. 240 volts to balance the load on three phases as far as
possible. Each branch circuit shall not carry a load of max. 10 light points wi
th a limit of 800W. Not more than two power sockets shall be wired on any single
circuit.
6.12 Wiring between lighting panel and lighting fixtures shall be with 3 core
PVC insulated 2.5mm2 copper conductor, armoured cable for switchyard and with P
VC insulated 2.5 mm2 copper wire within conduit for substation/control room buil
ding.

6.13 Lighting and power panels shall be provided with miniature circuit break
ers for the control and protection of circuits and ELCB for incomer. A minimum o
f 20% of miniature circuit breakers of each panel shall be left as spares. MCB s
hall not be loaded more than 80 percent of rated capacity. Cables feeding distri
bution board shall be sized taking into consideration future loads on spare feed
ers.

6.14 Switches shall be provided outside the battery room.

7 Earthing System
7.1 Earthing system shall conform to following standards:
a. IEEE-80 Guide for safety in AC substation grounding.
b. IS-3043, Code of practice for earthing.
c. CBIP Tech. report for Earthing System for HV, EHV and UHV Substations.
d. IS-2309 Protections of buildings and allied structures against lightning
strokes.
e. Indian Electricity Rules 1956, as amended from time to time and the rele
vant regulations of the Electricity Supply Authority concerned.
The earthing work shall also conform to enclosed specification for Installation
of earthing system.
7.2 Earth Electrode
The earth electrodes shall be made from 65 mm dia., 3 meter long GI pipe for tra
nsformer only in accordance with enclosed Standard.
7.3 Earthing conductor
Cross-section of earthing conductor shall be designed to prevent fusing of condu
ctor and deterioration of joint under most adverse conditions of fault. The same
shall be determined by consideration of potential difference and temperature ri
se and as per IS: 3043, and to meet the regulations of Indian Electricity Regula
tions. Preferably, M.S. rod shall be used for the burried earth grid, however fo
r equipment earthing equivalent GI earth strip shall be used.
For earthing conductor sizing, duration of earth fault current duration to be co
nsidered, shall be minimum one second.
7.4 System requirement
7.4.1 The entire installation shall be done in accordance with standards menti
oned herein. The Bidder shall carry out any changes desired by the electrical in
spector or the Purchaser, in order to make the installation conform to Indian El
ectricity rules at no extra cost.
7.4.2 Earthing system shall be designed to have low impedance to ground and a
current carrying capacity consistent with the fault current. The earth loop impe
dance to ground shall not be in excess of 1.0.
7.4.3 The main earth loop shall be laid at a depth of minimum 500 mm below gra
de level. Wherever cable trenches are available, the earth lead shall be laid in
the trenches and shall be firmly cleated to the walls when run in concrete line
d trenches. The earthing strip shall be protected against mechanical damage.
7.4.4 Joints and tapping in the main earth loop shall be made in such a way th
at reliable and good electrical connections are permanently ensured. All joints
below ground shall be welded and shall be suitably protected. All joints above g
round shall be by means of connections/lugs, and shall be suitable to resist cor
rosion.
7.4.5 Test disconnect facilities shall be provided for the earth pits to check
their earth resistance periodically.
7.4.6 The switchyard earthing shall be made up of a lattice grid. Earthing mat
of a finer mesh shall be provided just below the operating handles or mechanism
s. For junction boxes and other operator accessible areas, the above mentioned m
esh should be buried 225 mm to 300 mm below the grade level.
7.4.7 Average rate of corrosion of steel shall be considered as 61mils for fir
st 12 years and 30.5 mils for the next 12 years. After this period, it is assume
d that no corrosion taker place.
7.4.8 The method of earthing switchyard fence has to be considered from the vi
ew point of touch and step potentials in the area outside the fence. The earth m
ay be extended (500mm, min.) beyond the fence, so as to ensure that the area in
the vicinity of the substation fence is safe from the viewpoint of touch potenti
al under fault conditions.
7.4.9 Switchyard area shall be covered with about 100 mm of gravels or crushed
rock (25-50mm) (Not in bidder scope).
7.4.10 The attainable and permissible values of the step and touch potential in
the design of the grounding grid in substation shall be calculated as per IEEE
80, and it shall be ensured that the attainable step and touch potential are les
s than permissible step and touch potential.
7.4.11 All electrical equipment are to be double earthed by connecting two eart
h strips conductor from the frame of the equipment to the main earth grid. There
shall be provision for earthing the following:
a) The neutral point of the transformer shall be earthed using 2 ohm NER by
not less than two separate and distinct connections with earth, each having its
own electrodes, which in turn shall be interconnected with station earthing mat
.
b) Equipment frame work and other non-current carrying metallic parts.
c) All extraneous metallic frame work not associated with equipment.
d) Each lightning arrestor and lightning mast shall have independent earth
electrode, which should in rum be connected to the station earthing grid.
e) All switchgear and their earth buses.
f) Motor, frames.
g) Non-current carrying metallic parts of electrical equipment such as swit
chgear, switch-rack, panels boards, motor control centers, lighting panels, inst
rument panels, push button stations etc.
h) All fences/fence gates/enclosures housing electrical equipment.
i) All steel structures, rails, cable trays etc. including bonding between
sections.
j) Shield wire, lighting/lightning mast.
k) Current Transformer - secondary neutral
l) VT neutral
m) Structural steel
7.4.12 The electrodes and earth conductor shall have a clean surface not covere
d by paint, enamel, grease or other materials of poor conductivity. All hardware
used for earthing installation shall be hot dip galvanized or zinc passivated.
Spring washers shall be used for all earth connections of equipment having movin
g parts or vibrations.
7.4.13 Lighting fixtures shall be earthed through the extra core provided in th
e lighting cable for this purpose.
7.4.14 Provision shall be made to connect the switchyard earth grid to the plan
t grid at minimum two places.
7.5 Lightning Protection
7.5.1 The switchyard shall be shielded against direct lightning strokes by rod
s, masts and overhead ground wires.
7.5.2 The lightning protection shall be provided as per the details given in a
book titled, “High Voltage Engineering by Rezvig”.
7.5.3 The masts or overhead ground wires shall be grounded and interconnected
with the grounding system of the structure to be protected.

8 Shop Inspection and Testing

8.1 Shop inspection and testing shall be as per individual equipment specifi
cation / standards.
8.2 For the items bought by equipment supplier from their sub-suppliers, cer
tified test reports of the tests carried out at the manufacturer s works shall b
e submitted. Normally, all routine tests as specified in the relevant standards
shall be conducted by the sub-supplier at his works.
9 Packing and Dispatch
The equipment shall be divided in to several shipping sections for protection an
d ease of handling during transportation. The equipment shall be properly packed
for transportation by ship/rail or trailer. The panels shall be wrapped in poly
ethylene sheets before being placed in wooden crates/cases to prevent damage to
the finish. Crates/cases shall have skid bottoms for handling. Special notations
such as Fragile , This side up , Weight , Purchaser s particulars , PO nos
. etc., shall be clearly marked on the package together with other details as p
er purchase order.
The equipment may be stored outdoors for long periods before installation. The p
acking should also be suitable for outdoor storage areas with heavy rains/high a
mbient temperature unless otherwise agreed.
10 Field Testing and Commissioning
The electrical equipments and the installation as a whole shall be subjected to
elaborate tests and inspection as per the procedures agreed with engineer-in-cha
rge or his authorized representative. The equipment and/or the installation shal
l be inspected and tested as soon as they are available for this purpose and a s
chedule shall be prepared by the Bidder for carrying out the inspections and tes
ting within the time available before the target date so that the overall comple
tion is reached.
11 Approved makes of equipment/components
Bidder shall procure and supply major equipment/ components from makes indicated
in Annexure-1 of this specification.
12 Bidder Data Requirement
S.No. Description With Bids After award of contract
For review For reference & records No. of weeks aft
er award of contract
1. List of deviations to bid package (If Any) *
2. Switchyard single line diagram (as build) * *
3. Switchyard layout- plan & section (as build) * *
4. Equipment data sheets (as per enclosed formats) * *
5. Bus bar/ bus post insulator sizing calculation * *
6. Switchyard earthing & lightning
protection calculations *
7. Switchyard lighting calculations * *
8. DC Load profile calculation for Battery & Battery Charger sizing
*
9. Switchyard cable layout *
10. Switchyard lighting layout *
11. Switchyard earthing & lightning protection layout
*
12. Switchyard equipment GA drawings & control schematic drawings.
*
13. Switchyard clamps & connector
Details. *
14. Relay, metering & control panel GA and schematic drawings.
*
15. SLD, GA & schematic drawing of PDB. *
16. Soak pit layout and sizing calculations *
17. Cable schedule *
18. Interconnection drawings *
19. Equipment & schematic drawings, calculations etc.
*
20. Complete literature/ leaflets of all equipments *
*
21. Final drawings/ documents *
22. Operation & maintenance manual *

Notes:
1. Switchyard SLD & Electrical layout drawings shall be prepared in A1/ A0
size. Layout drawings shall be in scale 1:100. Other documents/ Bidder drawings
may be in A3/A4 size/ per bidder s standard.
2. No. of prints of drawings/ documents required with the bid shall be same
as no. of copies the bid. For review/ records Bidder shall submit 6 prints of d
rawings/ documents. Final/ As-Built documents shall include 6 nos. prints of dra
wings/ documents, along with electronic files on two CD.
3. Each drawing shall show the following data as a minimum for identificati
on purpose.
Project Detailed Design & Engineering of Power Distribution for Sanand Grinding
Unit.
Client Ambuja-Sanand
Contract No. Drawing No.(with proper revision): Job No.:

4. Review of bidder drawings shall be done by ABB, as applicable, under fol

lowing codes.
Review code 1 No Comments
Review code 2 Proceed with manufacture/fabrication as per commented drawing. R
evised drawing required.
Review code 3 Document does not conform to basic requirements as marked. Resub
mit for review.
Review code R Document retained for records
Review code V Document submission stands void.