CONTROL EQUIPMENT ENGINEERING DIVISION

BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

The specification is for the requirement of 1) COMPLETE DISTRIBUTION TRANSFORMER

MONITORING SYSTEM and its associated Control room Server and 2) REMOTE
MONITORING SYSTEM FOR TRANSFORMERS and its associated control room
peripherals. These system are a combination of various Electronics cards assembly,
communication protocol gateways, application logic and precession mechanical structure
which shall be responsible for monitoring distribution transformers, sub-station transformers
and its peripherals and communicate with the control room and cloud (internet) for parameter
monitoring and report generation, etc.

1. GENERAL

This specification covers the requirements of infrastructure, quality of manpower

considered essential for quality and reliability of design ,development , manufacturing
testing & supply of various high tech Electronics cards/modules involving multilayer
PCBs , ASICs , SMT components and digital electronics components like FPGA,
DSP , Micro controllers , Micro-processors etc. The requirement also involves rigorous
software development on various platforms and technologies.

The supplier should confirm availability of the required infrastructure and manpower in
technical bid as given in this specification.

a INFRASTRUCTURE FACILITIES

The supplier should have the following manufacturing facilities:

1. Dust Free environment for card assembly.

2. Stencil Printer .
3. Automatic Glue Dispenser
4. High speed component placement machine
Following features would be preferred :
 Board size capability - 400 mm x 300 mm min.
 Placement Range - 0603 to SOIC’s , 0402 compatible

5. Dual wave Soldering machine

6. 4 zone Reflow oven
7. Digital / Analog Temperature controlled solder stations .
8. Component lead forming machines.
9. Details of Electrostatic discharge protection
& ESD procedure adopted to be submitted with offer .
10. Semi-Automatic component insertion machines.

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

b. TESTING FACILITIES :

The supplier should have the following test facilities :

(a) Digital oscilloscope Dual channel Min.100 MHZ Band width with following
advance features would be preferred. .
 Advanced signal processing
 TDR measurement
 Eye pattern analyzer
 Cross talk and ringing analysis

(b) Spectrum analyzer with following features preferably :-

 Electromagnetic Interference Analysis.
 High frequency analysis.
 Harmonic Distortion Measurement.
 AM / FM Measurement

(c) Multi channels / 100 MHZ band width logic analyzer

(d) Multi channels Digital Pattern Generator.
(e) Computer added Functional Testing facilities for electronic card.

c. Skilled Manpower requirement

The development shall require at least two engineering graduate (electronics) who
would be responsible for execution of the order . Experience in multilayer PCB
manufacturing using latest state of art technology components like SMT ,
digital electronics components, ASICS & microcontrollers and software application
on .NET platform, Database Management System like ORACLE would be
preferred. Technical persons responsible for the execution of the contract should
be competent enough to substitute / suggest suitable alternatives for the
components which are getting obsolete / not available in the market .

e. Willingness for Confidentiality Agreement

Supplier to confirm their willingness for unconditional confidentiality agreement on

stamp paper as per the attached annexure A to qualify for their consideration in
technical scrutiny of tender.

2. SCOPE OF WORK & Technical requirement

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL
A. SCOPE OF WORK:

The Scope of this specification is divided into development of a common hardware and
software platform which can be scaled up and down to realize two different monitoring
systems architectures to meet different technical requirements.

The scope shall cover:

1. Distribution Transformer Monitoring System (BH-BPL-DTMS)
2. Remote Monitoring System For Transformers (BHEL-REMOTRANS)

COMMON HARDWARE PLATFORM FOR MONITORING SYSTEM (SAN-trans)

The common hardware platform shall be developed as per following architecture which
shall be modular in nature to scale up or scale down the system based on the technical
requirement.

a. Section-1 and Section-2 should be enclosed in a single EMI/EMC enclosure with

provision for LED / Local character Display.
b. An external DIN rail mounted SMPS for powering section-1 & section-2 should be
present with battery back-up of atleast 10000mAH. Suitable connectors to be
provided on the section-1 for external power supply input. Following topology is
required to be adapeted for power supply:

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

Two separate SMPS provision to be kept for a. Section-1 only and b. Section-1 and
Section-2 combined.

c. The 4G module for wireless connectivity shall be part of Section-1.

ITEM no. 1 Distribution Transformer Monitoring System (BH-BPL-DTMS)

The project scope is for development of Gerber, PCB, complete card assembly,
firmware, software, testing and integration of the developed system with BHEL existing
server. Bidder to Design & develop PCB manufacturing documents / PCB Gerber files &
test jig and take approval on the same from BHEL before arranging the PCBs and
testing of the card .

The major implementation features of the Distribution monitoring system shall be:
1. Development, Supply, customization, installation, deployment and maintenance of
necessary hardware, software and communication equipment at distribution
transformer site to facilitate monitoring of Distribution Transformer for the purpose
of centralized DT monitoring, data logging and data analysis.
2. Integrating the proposed DTMS system with BHEL Bhopal server.
3. DTMS Software should be scalable in nature, DTMS Software and associated
equipment’s should be capable of handling at-least 2000 connections, without any
additional infrastructure and cost implication.
4. DTMS system should have complete interoperability for accommodating all types
of FRTU/MFM and communication H/W and vice-versa should also be there for
any future up gradation of hardware / software.
5. The proposed solution must efficiently enable all required interfaces and
integration, including integration with the existing software infrastructure of BHEL
server.
6. The supplier shall be responsible for providing all material, equipment and
services specified or otherwise, which are required to fulfill the intent of ensuring
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operability, maintainability and the reliability of the complete work covered under
this specification.

i. SYSTEM ARCHIETECTURE:

The proposed system will meet following requirements:

1. Monitor and transmit distribution transformer instantaneous and energy
parameters at set periodical time intervals.
2. Monitor and transmit following parameters from distribution transformer.
a. Electrical analogue (V, I, KW, KVAR, pF, Freq. etc.) and energy
parameters.
b. Transformer oil temperature via thermostat (with required high temperature
set point).
c. Transformer oil low level via digital input.
3. Monitor abnormal conditions and send alarm messages.
4. Generate alarms and events on following conditions:
a. Transformer overload
b. Load unbalance in the transformer.
c. Low transformer oil level
d. High transformer oil temperature.
e. High harmonics
f. Phase failure
5. Communication shall be via cellular modem.
6. Parameters received from all distribution transformers will be saved in SQL or
other equivalent database in Control Centre.
7. Provide on-line parameters, trends and alarms.
8. Required reports and log sheets shall be provided.
9. Provide feature for SMS/Email alerts
10. All standard protocol supported i.e. Modbus/IEC 104
11. Secure M2M connectivity with IPsec/L2TP/VPN & 3 DES.
12. All the Electrical and Non-Electrical data from the DTMU shall be integrate with
Control Centre SCADA system

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

Block Schematic for the Distribution Transformer Monitoring System

Smart Energy Monitoring unit with cellular modem will be installed at each distribution
transformer site. DTMU will monitor all transformer parameters and transmit the same to
Server at the control center.

DT Monitoring Unit at Distribution Transformer Site:

Smart Energy Monitoring Unit with cellular modem will be installed at each distribution
transformer site. It should have following functions:
1. Monitor electrical parameters (instantaneous and energy) from distribution
transformer.
2. Monitor harmonics (voltage and current) & Total Demand Distortion (TDD)
3. Monitor transformer parameters for limit conditions (alarm conditions):
a. Over load
b. Load unbalance
c. High harmonics etc. (up-to total sixteen set points can be set)
d. Low transformer oil level
e. High transformer oil temperature
f. Phase failure detection
4. Monitor transformer oil level via digital input.
5. Monitor transformer oil temperature via analog input.
6. Send all parameters to control centre periodically as well as report by exception.
7. Send instant messages to control centre on alarm events mentioned above).
8. Communicate with control centre via cellular modem (3G/4G).
9. Multiple set point minimum 12, so that required alarm set point can be configured
and transmitted to control centre.\
10. The scope also includes supply of following compatible sensors with cabling and
installation to transformer unit:
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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL
a. Current sensor
b. Voltage monitoring arrangement
c. Oil level sensor
d. Temperature sensor

DT Monitoring unit should have following unique features which are essentials for this
project.
a. All the required electrical parameters are available on display and communication.
b. PT input up to 690VAC (Line to line)
c. CT input 1A or 5A
d. PT Burden < 0.15VA. CT Burden: For 5A CT Sec. <0.1 VA, for 1A CT Sec.
<0.02VA
e. CT primary and PT ratio are site configurable.
f. All type of wiring is configurable at site.
g. Four quadrant measurement.
h. All parameters updated on cycle to cycle basis and sampling rate 128 sample per
cycle.
i. Accuracy class 0.2S as per IEC-62053-22:2003.
j. Input frequency: 45-65 Hz.
k. Individual Harmonics for voltage and current till 39th harmonic.
l. Internal RTC.
m. Energy display of nine digits.
n. Data log memory >= 135KB.
o. Front panel LED for calibration check and communication status.
p. Communication protocol: MODBUS RTU, ASCII, DNP 3.0., IEC 104 Required
communication protocol is selectable at site.
q. User defined registers. Minimum 100 user defined registers should be available in
the device.
r. Standard IoT’s of IEC 104 for configuration mapping with SCADA FEP (Front End
Protocol) server.
s. All the parameters should be available as direct reading 32 bit registers.
t. Power Supply: (Self powered)
u. Ambient operating temperature: -10 to 60ºC.
v. Ambient operating humidity: 0 to 95% non-condensing.
w. Standard DIN Rail mounted.
x. Input/output Signals:
a. 4 Digital inputs and 2 digital relay outputs for digital signal monitoring.
b. 3 Analog inputs
y. Cellular Modem with antenna along with SIM card and monthly usage charges for
entire project duration i.e. 24 Months
z. The system shall be mounted on wall or pole, outdoor ABS/Polycarbonate plastic
cabinet.
aa. Required MCB

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

Distribution Transformer Monitoring Control Room:

Software implementation in control room server should provide following unique features:

a. Collects, archives and analyses collected parameter from all sites.

b. Can handle 2000 of remote sites.
c. Multiple users are able to view the data in required formats for graphs, trends, tables and reports.
This enables better monitoring and control of transformers.
d. Can be customised based on number of DTMU installed and number of user clients.
e. Each user can be assigned individual passwords and rights.
f. Graphic user interface.
g. View location of transformers on map
h. Real time instantaneous parameters.
i. Log energy parameters for energy reports.
j. View all parameters and reports via web clients.
k. Trends.
l. Alarms and events
m. required log sheets
n. Required reports can be configured by the user.

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL
o. Send alarm messages via e-mails to pre-defined users in case on events.
p. Send reports to pre-defined user at set intervals.
q. Results in saving capital equipment by early detection of expected faults.
r. Based on alarm messages received from remote DT sites.
s. Detect location of transformer faults.
t. Detect energy loss based on energy through DT and actual energy billed.

INSTALLATION & IMPLEMENTATION

a. The successful bidder shall be responsible for installation and configuration of software, hardware and other
equipment supplied to the satisfaction of the owner.
b. Post Go-Live, the software vendor shall provide support to fix any bug related to implementation. The entire
system would be considered as successfully installed when the software will run with actual live data at site
without any bugs (Bug is lacunae in the system that prevents/ delays an operation or performs a function
within the system at suboptimal level/ at performance level lesser than that specified in this specification or
provides incorrect operational data or provides incorrect results in any data format in the reports generated by
the users).
c. Demonstration of all the features of latest version of software; Acceptance testing of the system thus
implemented to the owner’s satisfaction.

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

ii. Sub-Station Transformer Monitoring System (BH-BPL-REMOTRANS)

The Hardware architecture of BH-BPL-REMOTRANS shall contain two parts:

a. Outdoor REMOTRANS unit
b. Indoor REMOTRANS unit

ITEM no. 2 OUTDOOR REMOTRANS UNIT: The unit shall comprise of

complete redundant set of SAN-trans along with accessories as mentioned in the
following block schematic. The outdoor REMOTRANS unit shall reside in an IP
rated enclosure.

NOTE:
1. The redundancy logic for all the channels and processor shall be finalized after taking BHEL’s approval.
2. Any other Accessories, ethernet cable etc not mentioned here but required for complete implementation
of the unit shall be under supplier’s scope.

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL
ITEM no. 3 INDOOR REMOTRANS UNIT:

Server Details:
Processor: i7
RAM: 8GB minimum
Hard-disk: 1TB
Operating System: Windows 10
Port: 2 no. HDMI port, 2 no. USB3.0, ETHERNET
Software: MSOFFICE latest version

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL
COMPLETE SYSTEM ARCHEITECTURE:

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

NOTE: Stage-2 shall be implemented on the BHEL central servers made available to the supplier.

Software implementation in control room server should provide following unique features:

a. Collects, archives and analyses collected parameter from all sites.

b. Can handle 20 of Sub-stations.
c. Multiple users are able to view the data in required formats for graphs, trends, tables and reports.
This enables better monitoring and control of transformers.
d. Can be customised based on number of Sub-stations installed and number of user clients.
e. Each user can be assigned individual passwords and rights.
f. Graphic user interface.
g. View location of transformers on map
h. Real time instantaneous parameters.
i. Log energy parameters for energy reports.
j. View all parameters and reports via web clients.
k. Trends.
l. Alarms and events
m. required log sheets
n. Required reports can be configured by the user.
o. Send alarm messages via e-mails to pre-defined users in case on events.
p. Send reports to pre-defined user at set intervals.
q. Results in saving capital equipment by early detection of expected faults.
r. Based on alarm messages received from remote DT sites.
s. Detect location of transformer faults.

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL

iii. SCOPE OF SUPPLY:

The supply against this specification shall include:

Item no. Description quantity
1 Distribution Transformer Monitoring System (BH- 4 nos.
BPL-DTMS)
Distribution Transformer Monitoring Unit as described
in this specification with Various Software required for
execution of the projects for DTMS and SERVER
application
2 Sub-station Transformer Monitoring System (BH- 4 no.
BPL-REMOTRANS)
OUTDOOR UNIT with Various Software required
3 Sub-station Transformer Monitoring System (BH- 2 no.
BPL-REMOTRANS)
INDOOR UNIT with Various Software required and
centralized server application / implementation

In addition to the above, any hardware/software required to complete the scope of

work mentioned in this specification shall be in the supply scope of the supplier.
The supplier to hand-over complete source code to BHEL for maintainability and
future modifications.
Comprehensive training to be conducted by the supplier on the source for BHEL to
ensure working/operation knowledge of the source code to BHEL.

iv. Application software

The application software of the system shall be based on an interactive platform for easy
implementation and understanding and shall be finalized after placement of order and
supplier is responsible to fully implement and prove the same.
The application software shall also have option for self-test of the system.
Application preferably to be developed in JAVA/.NET Database to be developed
preferably on ORACLE 11G
Supplier to ensure Penetration testing to be conducted by CERT-IN empaneled agency
on the application

a) Programming software for controller/FPGA/processor/DSP/DSC used in SAN-trans.

b) Application source code and its programming software for server application.

v. Test jigs/tools

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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL
Complete test jigs/tools for complete system to be developed and supply along
with clear test instructions for comprehensive testing on test.

Supplier to provide Programmable tools (supplier’s own or /and third party

instruments, software/GUI) for downloading and modifying software for
controller and server free of cost.

B. QUALITY OF ELECTRONIC CARD ASSEMBLY:

The module shall be used in power plant application, the quality of the assembly ,
soldering, handling of the components & assembled cards(EMI/EMC), sourcing of
semiconductor components are of vital importance. Therefore, each of the above should
be carefully monitored and sources of the components must be from OEM/reputed
international farms who adhere to strict quality norm.
To improve, maintain Quality, and highest level of reliability, it is essential to generate
statistical data of any failure during testing and also after burn in, rework done. So, that
improvement in the assembly and process can be analyzed. Supplier should provide the
statistical report to BHEL.

C. FITTINGS OF CARDS & MECHANICAL ASSEMBLY:

As quality of soldering is predominant in performance of the individual electronics card,
final assembly like fixing heat sinks with MOSFETS, fixing of vertically mounted cards,
electrolytic capacitors, fiber optic connectors are crucial for reliable functioning of the
modules in traction application. Supplier must ensure use of proper size of hardware and
insulating fixing material. All hardware are of stainless steel. Each fixing screw must
contain proper plain washer & spring washer.

D. CONFORMAL COATING OF THE PCB’S:

Conformal coating is very essential for long life and trouble free operation in dusty and
hazardous environment. The conformal coating should be in line with ABB document, It is
recommended multiple layers of coating is applied on each PCB’s and proper time delay
between two layers of coating is followed.

CAUTION:
1. Before applying coating, the PCB’s should be tested in all respect.
2. All contacts for connectors and test points & fiber optic ports must be
protected thoroughly by providing suitable cover on it. This cover only be
opened after the coating is dried up.

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3. Standard EMI/EMC protective norms must be followed during the entire
process.

F. TESTING & TEST REPORTS:

The test schedule calls for testing of individual cards and complete assembly. Each
module should comply 100% with the test parameters as per the test schedule. Each
module has to be burn-in at 60 Degree C for minimum 2Hour. Test result shall be
generated and complied for every module with each cards.

Type Test compliance:

The complete electronics rack should be complied with following type tests and certificate
for the same to be provided by the supplier.

Type Testing / Environment Testing For electronics RACK

Sr.No Test
EMI / EMC Test
1 Conducted Emission
2 Radiated Emission
3 Radiated susceptibility
4 Conducted RF Immunity
5 Power Frequency
Magnetic field
6 waveform
Ring Wave immunity
Environment Test
7 Damp Heat Test –
Steady State
8 Cold Test - Operating
Standard Specification
CISPR 11 Class A Quasi peak: 150kHz-500kHz, 79
dBµV,500kHz-30 MHz, 73 dBµV Average:
150kHz-500kHz, 66 dBµV500kHz-30 MHz,
60 dBµV
CISPR 11 Class A Quasi peak:30-230MHz, 40dBµV at 10m
measurement distance230-1000 MHz, 47
dBµV at 10m measurement distance
IEC 61000-4-3 80 MHz-1000MHz, 30V/m
IEC 61000-4-6 Power port:0.15-80MHz :10Vrms 1kHZ,
80% AM Signal port:0.15-80MHz :10Vrms
1kHZ, 80% AM
100 A/m for continuous 1min1000 A/m for 3
IEC 61000-4-8
sec
Power Port: non-repetitive damped oscillatory
transients (ring waves) with 2 kV line to ground as
voltage of the first peak (maximum or minimum) in
the test waveform & 1kV line to line as voltage of the
first peak (maximum or minimum) in the test
IEC 61000-4-12
Signal port: non-repetitive damped oscillatory
transients (ring waves) with 1 kV line to ground as
voltage of the first peak (maximum or minimum) in
the test waveform & 0.5kV line to line as voltage of
the first peak (maximum or minimum) in the test
waveform
IEC 60068-2-78 +40°C / 4 days / 93% RH
IEC 60068-2-1 - 40°c / 16 H
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BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL
9 Dry Heat Test –
Operating
10 Damp Heat Test Cyclic
Mechanical Stress Test
11 Vibration (during
operation and
Transportation)
Dielectric Test
12
Dielectric Test
IEC 60068-2-2 +70°c / 16 H
IEC 60068-2-30 +55°C,95% RH / 6 Days
IEC 60255-21-1
Acceleration: 1g from 10 to 150Hz, 1
Vibration Response –
sweep in each axis total 3 axes
Powered ON, Class 1
Acceleration: 1g from 10 to 150 Hz 20
IEC 60068-2-6
sweep
IEC60255-27 For Power Supply, Ct & PT – AC test voltage
Cl no. 10.6.4.3; cl 2 kV
no. 10.6.4.3.3 table For digital I/O, analog I/O & 4 to 20 mA I/O
no. 14 – AC test voltage 0.5 kV

3. DOCUMENTS TO BE SUBMITTED TO BHEL FOR APPROVAL .

While executing the PO, supplier shall submit to BHEL and take approval for the
following documents for each of the modules mentioned in the enquiry.
1. Test Certificate
2. Burn-in test report
3. Warranty certificate
4. Card Schematics
5. BOM
6. User Manuals
7. System Administrator Manuals
8. Technical Manuals
9. Installation Guides
10. Business Process Guides
11. Program Flow Descriptions
12. Sample Reports
13. Screen Formats
14. Toolkit Guides
15. Troubleshooting Guides
16. Frequently Asked Question (FAQ) Guides

4. WARRANTY.

System along with all the components mounted thereon shall be guaranteed for 24
months from the date of supply or 18 months from date of commissioning whichever is
earlier.

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5. SERIAL NUMBERING / INDENTIFICATION .

All the individual cards and complete rack to be numbered as per following convention:

CARD NAME or RACK NAME/WORK ORDER NO./MMYY-Serial no.

Work Order no. shall be provided by BHEL

5. Document to be submitted with technical Bid

Following document duly filled must be submitted by the bidder party as annexure to
their technical bid (to be kept in separate sealed envelope) . Otherwise bid will be
technically rejected.

A. Infrastructure details

SNo. Description/Equipment Make / details #

1 Dust Free environment for card assembly Area to be specified with
temperature& humidity
information.
2 Automatic Glue Dispenser
3 High speed component placement machine
4 Dual wave Soldering machine
5 4 zone Reflow oven
6 Digital / Analog Temperature controlled solder
stations
7 Component lead forming machine
8 Details of Electrostatic discharge protection &
ESD procedure adopted .

9 Semi Automatic component insertion machines

10 Digital sampling oscilloscope Dual channel
Min.100 MHZ Band width .
11 Digitizing oscilloscope with Min.100MHz band
width
12 Multi channel Spectrum analyzer -
13 Multi channels , 100 MHZ band width logic
analyzer
14 Multi channels Digital Pattern Generator.
15 Multi channel temperature scanner.
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16 Computer aided Functional Testing facilities for

electronic card.
# Machine details like model / Type No. make ,features ,capacity etc to be given.

B. Confirmation for Confidentiality agreement

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