DNIT Vol 2 Part 4 Specs Elec Instru SCADA WWT Budha Nallah Ludhiana

Annexure-3 : Revised “ Volume-2(R1)”
In continuation of Volume-2 (Part-3)
Volume -2 (Part - 4) (R1)

Specifications of Electrical, Instrumentation, PLC and
SCADA Works
February, 2020
1
Specifications for Electrical, Instrumentation, PLC and

SCADA Works
Contents
Sr. No. Description Page No.

Specifications For Electrical, Instrumentation, PLC And
1 3-79
SCADA Works For STPS, MPS And IPS
2
14. SPECIFICATIONS FOR ELECTRICAL, INSTRUMENTATION, PLC AND

SCADA WORKS FOR STPs, IPS and MPS
Specifications described here are in general for various works. However
specifications for only those Materials /Equipments/ Instruments shall be
applicable which are required or provided at site. If the specification of any items
are not described here then specifications as per the relevant IS code or prevalent
as per the department practice will be applicable as approved by Engineer-in-
charge.
14.1. General Conditions
14.1.1. General Condition of Electrical, Instrumentation, PLC & SCADA Work

a) The scope covers design, manufacture, inspection, supply, storage at site till the
installation/commissioning works starts and erection, testing, commissioning of all the
electrical, instrumentation, PLC, SCADA and accessories required to run the STP, IPS
and MPS safely and efficiently.
b) All equipment and accessories shall conform to the latest applicable IS, BS, IEEE,
IEC, IE rules, codes, other applicable standards.
c) Specification of items not covered in this section shall follow specification given
elsewhere in the DNIT. Specification of items not covered in DNIT shall be as per
relevant IS or other applicable standards and codes with amendments. In case of
conflict, specifications as per decision of Engineer-in-Charge will be followed.
d) All equipment and accessories shall be suitable for continuous operation at rated load
at maximum ambient temperature and humidity applicable as per location and site
condition.
e) The equipment offered shall be new, of proven design & quality, reputed makes.
Contractor shall ensure availability of spare parts and maintenance support services
for the offered equipment.
f) The contractor shall submit all required calculations, drawing, document, data sheet
including manufacturer drawings with bill of material, specification and catalogues to
client/client’s representative for approval/ review. Procurement and thereafter
execution shall be done only after approval/ review by client.
g) Contractor shall submit QAP of all major equipment before manufacturing/fabrication
for client/ client’s representative review/approval. Inspection shall be carried out by
client/ client’s representative as per approved drawing & document, relevant IS/BS/IEC
or other standards. Acceptance and routine test shall be carried out on all equipment
as per their relevant standard. These test reports and manufacturer type test report
shall be submitted before dispatch of the equipment. Required performance test shall
be conducted at site as per relevant standard. Cost of inspection and all test carried
out at manufacturer works, site shall be borne by the contractor.
h) All the electrical equipment proposed by the bidder shall be energy efficient as per
applicable standards.
i) Bidders shall visit the site to study existing system and its condition and proposed site
to assess extent of work required under this contract.
j) Following starter selection chart to be adopted; DOL Starter – Up to 7.5 KW, Star-
Delta Starter - Above 7.5 KW & up to 22 KW, Soft Starter – Above 22 KW, VFD – As
per process requirement and as specified.
k) All the PCBs (Printed Circuit Boards) in VFD, Soft starters etc. shall be coated with
anti- corrosive epoxy coating.
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14.1.2. General Specification of Instrumentation

a) Proposed instrumentation & installation shall be as per BOQ/scope of work,
specification and as required at site for the complete system.
b) Proposed Instruments shall ensure high standards of operational reliability &
sustainability. Instruments mounted in field and on panels shall be suitable for
continuous operation. All electronic components shall be adequately rated and circuits
shall be designed so that change of component characteristics shall not affect plant
operation.
c) All equipment shall be new, of proven design, reputed make and shall be suitable for
continuous operation. Unless otherwise specified, all instruments shall be tropicalized.
The outdoor equipment’s shall be designed to withstand tropical rain. Wherever
necessary space heaters, dust and waterproof cabinets shall be provided. Instruments
offered shall be complete with all the necessary mounting accessories.
d) The instruments shall be designed to permit maximum interchange ability of parts and
ease of access during inspection and maintenance.
e) The field instruments mounted outside the control panel shall be mounted at a
convenient eye level height. All field instruments and cabinets/panel mounted
instruments shall have tag plates/name plates permanently attached to them.
f) All instruments cables (signal/control/special cables) between field instruments/JBs/LT
panel/RTU/PLC etc. including glands, lugs, ferrules, markers are in bidder scope.
g) All instruments of submersible type shall be protected to IP-68. Field mounted
electrical and electronic instruments shall be IP-55 gasket with multi-point latching
door.
h) All electrical accessories for instrumentation system including instrumentation power
supply equipment are in bidder scope.
i) Instruments, supports etc. shall be of material resistant to or protected from the
temperature and humidity to be encountered in the atmosphere present in the tropical
climate.
j) Overall accuracy of all measurement system shall be +/- 1% of measured value and
repeatability shall be +/- 0.5%. Individual instruments accuracy and other details as per
specifications.
k) Instruments shall be provided with all mounting hardware and floor stands, wall
brackets or instrument racks and all necessary accessories as per site requirement.
l) Cable tray, GI/HDPE conduit, steel support, copper earthing pit, strip, wire etc. are in
bidder scope.
m) Lockable enclosures shall be provided for the field mounted instruments.
n) The cabinets shall be upright floor mounted front open type with removable door and
shall have ventilation with steel mesh. The outside colour of all
instrumentation cabinets, control desks, consoles, local cabinets, marshalling
cabinets, system cabinets etc. shall be of Siemens grey RAL 7032 or equivalent
international code. The inside colour of all these cabinets shall be brilliant white. This
shall hold good for instrumentation cabinets of all auxiliary units also.
o) The cabinets / transmitters & enclosures shall be ensured of dust proof
confirming to IP65 standard.
p) Equipment inside the cabinets shall be so located that their terminals and adjustments
are readily accessible for inspection and maintenance.
q) The power supply equipment shall be installed inside the instrument cabinet.
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r) Wires shall run in suitable plastic wiring sleeves between terminal ends. Wherever
screened cables are used for signal transmission, these shall be of cross-twisted pair
type; shield shall be earthed at one end only inside the control room.
s) The various flexible cores within the cables shall be PVC insulated and numbered and
/ or identified by a colour code. All cables shall be in accordance with applicable
standards and codes.
t) Cables shall be clamped at appropriately and at the ends and bends without over
lapping.
u) Signal cables shall not be run in the same conduits as power cables. Installation in
rigid GI pipe/HDPE conduit or steel trunking shall be provided wherever required in
view of site conditions.
v) All cables running from the field instruments to PLC/RTU panel shall be a single,
continuous length without joints except at marshalling boxes. The boxes shall have
terminal blocks with 20% spares.
w) Instrumentation and necessary equipment shall be installed in accordance with the
manufacturer’s instructions.
14.2. 11 KV ABS, DO FUSE & LA ON DP STRUCTURE

The Scope includes supply, installation, testing and commissioning of 11 KV Air Break
Switch, DO Fuse and Lightning Arrestor on Double Pole structure as per relevant IS and
having following specifications:
(a) DP: Double pole structure made of two nos. 9 meter long PCC poles (400 Kg) & 7 nos.
MS channel each of size 100 mmx50mmx2500mm complete with earthing of the
structure as per REC standards in all respect with nuts, springs washers, clamps as
required.
(b) GO: Off load type gang operated 3-pole vertical flute type switch suitable for 11 KV;
400A, 3 phase, central post rotating double break isolator complete with MS hardware,
copper moving & fixed contact, assembly of 9 Nos pin insulator, GI pipe of suitable
length for operation.
(c) DO: 3 No’s Vertical / Horizontal mounted 11 KV horn gap fuse set / drop out 11 KV
barrel fuses mounted on 6 No. pin insulators.
(d) LA: 3 piece non-linear resistor type, lightning arrestor of approved make suitable for 3
wire, 11 KV overhead line with rated voltage of 9 KV rms & nominal discharge current
rating of 5 KA & complete with galvanized clamping arrangement GI bolts, nuts,
washer etc. as required.
(e) Jumpers: 3 No. 11 KV ACSR conductors mounted on pin type insulators as required.
(f) General: The GO shall be operated by hand operated liver properly earthed with
provision for locking mounted at 3’.
14.3. 11 KV HT Panel/11 KV SWITCHGEAR
14.3.1. Applicable Standards

The 11 KV HT Panel and its components shall conform to the latest applicable
standards specified below:
Sr. Code No. Title

No.
1. IS 13118 / BS 5311 / IEC 56, 694 Specification for High Voltage AC
Circuit Breakers
5
Sr. Code No. Title

No.
2. IS 3427 / BSEN60298 / IEC298 AC Metal enclosed switchgear
and control gear for rated
voltages above 1 KV and up to
and including 52 KV
3. IS 2705 / BS 7626 Current Transformers
4. IS 3156/BS 7625/IEC 186 Voltage Transformers
5. IS 5578 Guide for marking of insulated
conductors
6. IS 2544 / BS 3297 / IEC 273 Busbar Support insulators
7. IS 3231, 3842 / BS 142 / IEC 255 Electrical Relays for Power
system protection
8. IS 1248 / BS 89 / IEC 51 Direct Acting Indicating Analogue
Electrical Measuring Instruments
and their Accessories
9. IS 9385 / BS 2692 / IEC 282 High Voltage Fuses
10. IS 722, 8530 / BS 5685 / IEC 145, Specification for AC Electricity
211 Meters
11. IS 6005 / BS 3189 Code of practice for phosphating
of iron and steel
12. IS 9920 / IEC 129, 265 & 298 High Voltage Switches
13. IS 13703 / BS 1362 / IEC 269 Low voltage fuses
14. IS 10118 Code of practice for selection,
installation and maintenance of
switchgear and control gear
15. IS 6875 / BSEN 60947 / IEC 947 Control Switches
14.3.2. Constructional Features

The 11 KV HT Panel shall have separate compartments, according to definition in the
Standards, for the following components:
Each set of bus bars, Current transformers, Voltage transformers on incomer side, Each
main switching device, Cable chambers suitable for heat shrinkable type cable
termination, Metering, control, indications, annunciations and relaying devices.
Switchgear shall comprise indoor, metal-clad, draw out type Vacuum circuit breaker. The
circuit breaker shall be fully horizontally draw out type. The circuit breaker shall have
distinct ‘service’ and ‘test’ positions. In the ‘test’ position, the circuit breakers shall be
capable of being tested for operation without energizing the power circuits. Adequate
number of auxiliary contacts shall be provided for each of the ‘service’ and ‘test’ limit
position switches.
The ‘test’ position should preferably be obtained without the need to disconnect normal
control connections and use of extension cords for testing. The switchgear shall fully
house the breaker both in the ‘service’ position as well as in the ‘test’ position. The
current transformers shall be mounted on the fixed portion of the switchgear and not on
the breaker truck.
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Instruments, relays and control devices shall be mounted flush on hinged door of the
metering compartment located in the front portion of cubicle. All auxiliary relays not
requiring manual resetting will be mounted inside the Low Voltage compartment.
14.3.3. Safety Interlocks

Switchgear shall be provided with following interlocks:
 Operation of an isolator shall not be possible unless the associated circuit
breaker is in the ‘open’ position.
 Compartment door of a breaker or an isolator shall not open unless the
associated breaker or an isolator is in ‘open’ position.
 Circuit breaker cubicles shall be provided with safety shutters operated
automatically by the movement of the circuit breaker carriage to cover the
exposed live parts when the breaker is withdrawn.
 It shall not be possible to rack-out/withdraw a ‘Closed’ breaker from ‘Service’
position to ‘Test’ position or rack-in a ‘Closed’ breaker from ‘Test’ position to
‘Service’ position.
 The breaker trolley/cassette shall be earthed firmly before the same gets into
‘Service’ position.
14.3.4. Fabrication
Metal enclosure shall comprise rigid welded structural frame enclosed completely by
metal sheets, minimum 2.5 mm thick, hot rolled (HR) or 2.0 mm thick, cold rolled, cold
annealed (CRCA), smooth finished, levelled and free from flaws.
All sheet steelwork shall be phosphated in accordance with the following procedure
and in accordance with relevant standards for phosphating iron and steel.
 Oil, grease and dirt shall be thoroughly removed by emulsion cleaning.
 Rust and scale shall be removed by pickling with dilute acid followed by washing
with running water, rinsing with slightly alkaline hot water and drying.
 After phosphating, thorough rinsing shall be carried out with clean water,
followed by final rinsing with dilute dichromate solution and oven drying.
 The phosphate coating shall be sealed by application of two coats of primer
suitable for finishing by powder coating.
 After application of the primer, the fabricated sheet steelwork shall be subject to
epoxy based powder coating. Shade of powder coating is subject to approval by
the Employer’s Representative.
The final finished thickness of the coating on steel shall not be less than 100 microns and
shall not be more than 150 microns.
Each floor-mounted, free-standing panel shall be provided with its own base channel of at
least 50 mm height, providing rigidity to the entire assembly. The base channel may be
painted matt black. Panel door shall be supported by strong hinges and braced in such a
manner as to ensure freedom from sagging, bending and general distortion of panel or
hinged parts. All the hardware such as nuts and bolts shall be of stainless steel.
All doors, panels, removable covers shall be gasketted all around with neoprene gaskets.
All louvers shall have screens and filters. Vent openings shall be covered by fine mesh on
the vertical face. The screens and grills shall be made of either brass or galvanized iron
wire mesh.
Separate removable gland plates with minimum thickness of 3 mm shall be provided for
power and control cables. The gland plate for the power cables shall be of non-magnetic
material. Structure, buses and control wiring troughs shall be so designed and arranged
7
as to make future extensions readily feasible. Lifting lugs shall be provided for installation
purposes.
14.3.5. Bus bars

Main bus bars shall be of electrical grade aluminium of high conductivity and non-
segregated type. Bus bars shall be located in air insulated enclosures and segregated
from all other compartments of the cubicle. Direct access or accidental contact with bus
bars and primary connections shall not be possible. To provide a seal between adjacent
cubicles, bus bars shall be taken through FRP seal-off barriers.
All bus bars joints shall be thoroughly cleaned and anti-oxide grease shall be applied.
Plain and spring washers shall be provided to ensure good contacts at the joints and
taps. Wherever aluminium to copper connections is required, suitable bimetallic
connectors or clamps shall be used or copper shall be tinned to prevent electrolytic
corrosion. Bus bars shall be rated in accordance with the service conditions and the rated
continuous and short time current ratings as specified. Maximum temperature of the bus
bars and bus bar connections, under operating conditions, when carrying rated normal
current at rated frequency shall not exceed 85 deg. C.
Bus bars shall be adequately supported on insulators, to withstand dynamic stresses due
to short circuit current. Bus bar support insulators shall conform to relevant standards.
Supports shall be of porcelain, cast resin, DMC or SMC. Hylam or similar hygroscopic
material shall not be used for bus bar supports or shrouds. The bus bar clearances in air
shall be suitable for the Basic Insulation Level (BIL) of the equipment and the bracing
shall be suitable for electrodynamics forces during short circuit.
Bus bars shall not be normally painted and all performance characteristics specified shall
be obtained with unpainted bus bars. Bus bars shall be insulated by heat shrinkable type
sleeving providing full insulation, with mould caps protecting all joints. ‘Raychem’ or
equivalent make sleeving providing full insulation shall be provided.
14.3.6. Circuit Breakers
14.3.6.1. General
Circuit breakers shall be VCB type. These shall conform to relevant standards specified
and shall be of draw out type. Circuit breakers shall comprise three separate identical
single pole units operated through a common shaft by the operating mechanism. Circuit
breakers shall be suitable for switching duty of transformers.
Isolating plugs and sockets for power as well as control circuits shall be of robust design
and fully self-aligning. Plugs and sockets for power circuits shall be silver faced and
shall be insulated with PVC or other insulating material shrouds.
The vacuum circuit breakers controlling motors shall be complete with surge arrestors
to provide protection against switching surges. Breaker internal wiring up to the plug
shall be similar for all breakers.
14.3.6.2. Operating Mechanism

Circuit breaker shall be power operated, by a motor charged spring operated
mechanism. Main poles of the breakers shall be such that the maximum difference
between instants of contacts touching during closing shall not exceed half cycle of
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rated frequency. Operating mechanism shall be provided with anti-pumping feature,

electrically and mechanically. Electrical anti-pumping feature shall be obtained by
means of an auxiliary relay.
Mechanism shall be such that failure of any auxiliary spring shall not prevent tripping
and will not cause tripping or closing operation of the power operated closing devices.
When the circuit breaker is already closed, failure of any auxiliary spring shall not cause
damage to the circuit breaker or endanger the operator. A mechanical indicator shall be
provided to show ‘open’, ‘closed’, ‘service’ and ‘test’ positions of breaker. It shall be
located in a position where it will be visible to the operator standing on the front of the
switchgear with cubicle door closed.
The closing coil shall operate correctly at all values of voltage between 80 % and 110 %
of the rated voltage. A shunt trip shall operate correctly under all operating conditions of
the circuit breaker up to the rated breaking capacity of the circuit breaker and all values
of supply voltage between 50 % and 110 % of rated voltage.
Mechanical trip and close devices shall be provided for manual operation of the
breaker. Access to mechanical closing device shall be secured by suitable shrouding or
shall be accessible only after opening the cubicle door. However, the mechanical trip
device shall be brought out to the front of the cubicle door.
Auxiliary switches mounted on the fixed portion of the cubicles and directly operated
from the breaker operating mechanism on each breaker having 2 'NO' and 2 'NC'
potential-free contacts rated for 10 amps. 240V AC and 1.0 amp (inductive breaking)
110 V DC shall be provided. These contacts shall be in addition to those utilised in the
control circuit of each breaker and shall be exclusively meant for the Purchaser's use in
external interlocks and controls, indications/SCADA system.
14.3.6.3. Spring Operated Mechanism

Spring operated mechanism, shall be complete with motor, opening spring, closing
spring with limit switch for automatic charging and all necessary accessories to make
the mechanism a complete operating unit. As long as power is available to the motor, a
continuous sequence of closing and opening operations shall be possible. After failure
of power supply to the motor, at least one open-close-open operation of the circuit
breaker shall be possible.
Breaker operation shall be independent of the motor which shall be used solely for
compressing the closing spring. Closing action of the circuit breaker shall compress the
opening spring ready for tripping. When closing springs are discharged, after closing a
breaker, closing springs shall automatically be charged for the next operation. Motor
shall be such that it requires less than 30 sec. for fully charging the closing spring.
Motors shall be rated for 240V AC and shall operate satisfactorily at all values of
voltage between 80 % and 110 % of rated voltage.
Mechanical indicators to indicate ‘charged’ and ‘discharged’ condition of spring shall be

provided. It shall be possible to charge the spring manually in the event of non-
availability of the spring charging motor. Suitable spring charging handle shall be
9
provided for this purpose. A mechanical operation counter shall be provided for the
circuit breaker which shall indicate number of closing-opening operations the breaker
has performed.
14.3.6.4. Operating Mechanism Control

The local electrical closing and tripping control shall be by a control switch mounted on
the cubicle door. The mechanical trip and close devices shall be provided on the
breakers in addition to above.
14.3.7. Safety Earthing Switches/ Earthing Trucks or cassettes

Suitable in-built earthing switches or earthing trucks/ cassettes shall be provided for
safety during maintenance and for discharge of the cables.
The earthing devices shall have same short time rating as the main switchgear.
Incoming line side earthing switches shall be provided with cautionary warning to
prevent earthing of live incoming circuit. In case of earthing trucks/ cassettes, these
shall provide pre-earthing audio-visual warning prior to earthing of live cable. Cable
earthing switches shall be interlocked with the corresponding circuit breaker so that the
earthing switch can be closed only when the circuit breaker is Off and vice versa.
14.3.8. Inspection and Testing

All Routine Tests according to IS or IEC shall be carried out on completely assembled
switchgear assembly at the manufacturer’s Works and the same shall be witnessed by
Employer’s Representative. The Employer’s Representative shall also witness all the
Routine and performance tests on the circuit breaker. In addition to these tests, the
manufacturer of the equipment shall also carry out primary injection test for all current
operated relays and meters.
Routine Test Certificates of all major items such as circuit breakers, CTs, VTs,
protective relays and meters shall also be furnished to the client.
14.3.9. Typical Bill of Materials
14.3.9.1. Incoming to the Switchboard:

Sr.
Items Qty.
No.
630A, 11 kV, 500 MVA Vacuum circuit breaker, horizontal draw-out,
motorised spring charged, spring charging motor voltage 240V AC,
1 1
closing and tripping coils rated for *V DC, complete with at least 4
NO (open) + 4 NC (closed) auxiliary contacts
Auxiliary relay/contactor for electrical anti-pumping, if not already
2 1
built into the circuit breaker
3 Breaker control switch, Trip – Neutral – Close, spring return type 1
Indicating lamps R, G, A, W for CB ‘On’, ‘Off’, ‘Tripped’ & ‘Trip
4 4
Circuit Healthy’ indications
CTs, */1-1A, 7.5 VA, Cl. 1.0 for metering & 7.5VA, Cl. 5P10 for
5 3
protection
10
Sr.
Items Qty.
No.
6 Electronic multi-function meter for metering 1
VTs, (11000/ √3)/(110/ √3)V/(110/√3)V, 25VA, Cl. 1.0 & 25VA, Cl.
7 3P for metering complete with HRC fuses on HV side and 3
MCB/fuses on LV side.
Trip Circuit Supervision relay for both ‘On’ and ‘Off’ positions of the
8 1
circuit breaker
Triple pole IDMT Over-current relay for ‘51’ function and single pole
9 1
IDMT Earth-fault relay for ‘51N’ function, numerical type.
10 High speed tripping relay, hand reset type, for lock-out function. 1
Facia annunciator, 4 windows type, complete with ‘Accept’, ‘Reset’

11 1
& ‘Test’ facilities
Set of MCBs/ fuses for isolation and protection of auxiliary supplies

12 1
to the panel.
14.3.9.2. Outgoing Transformer Feeder:

Sr.
Items Qty.
No.
630A, 11 kV, 500 MVA Vacuum circuit breaker, horizontal draw-out,
motorised spring charged, spring charging motor voltage 240V AC,
1 1
closing and tripping coils rated for *V DC, complete with at least 4
NO (open) + 4 NC (closed) auxiliary contacts
Auxiliary relay/contactor for electrical anti-pumping, if not already
2 1
built into the circuit breaker
3 Breaker control switch, Trip – Neutral – Close, spring return type 1
Indicating lamps R, G, A, W for CB ‘On’, ‘Off’, ‘Tripped’ & ‘Trip
4 4
Circuit Healthy’ indications
CTs, */1-1A, 7.5 VA, Cl. 1.0 for metering & 7.5VA, Cl. 5P10 for
5 3
protection
6 Electronic multi-function meter for metering 1
Trip Circuit Supervision relay for both ‘On’ and ‘Off’ positions of the
7 1
circuit breaker
Triple pole IDMT Over-current relay for ‘51’ function, Triple pole
high set instantaneous overcurrent relay for ‘50’ function and
8 1
single pole instantaneous Earth-fault relay for ‘50N’ function,
numerical type.
9 High speed tripping relay, hand reset type, for lock-out function. 1
Auxiliary relays for contact multiplication of transformer ‘fault trip’
10 6
contacts
11 Facia annunciator,12 windows type, complete with ‘Accept’, ‘Reset’ 1
11
Sr.
Items Qty.
No.
& ‘Test’ facilities
Set of MCBs/ fuses for isolation and protection of auxiliary supplies
12 1
to the panel.
Note: (*) To be decided by the contractor.

Qty. of Outgoing Transformer Feeder as per Transformer Qty.
14.4. CABLING SYSTEM
14.4.1. General
The cabling system covers laying of all types of cables in tray, trench, direct buried
in ground, conduit, duct as required at site. Scope also includes supply of cable
trays, racks, supports and associated accessories, hardware and their installation. It
shall be the responsibility of the contractor to complete the cabling system in all
respects.
The following points shall be considered while planning cabling system:

(i) Inside the building: Cable shall be laid on overhead trays fixed to wall or hanged
to the ceiling. Cable may also be laid on trays inside cable trench covered with
MS chequered plate but in this case, the bottom of cable trench shall be at least
100 mm above flood level in that area to avoid any water seepage/logging
problem in future.
(ii) Outside the building/outdoor plant area: Cable shall be laid on overhead tray
mounted on suitable support. Removable cover allowing adequate ventilation
shall be provided on top most overhead cable tray in horizontal tier formation.
Direct buried cable can be adopted in case of laying of HT power cable.
At road crossing overhead trays shall be installed at 5000 mm (minimum) above
ground level.
(iii) Required clearances as per IS 1255 shall be maintained between power, control,
instrument, PLC/data cables.
(iv) Entry/exit of cables to building shall be through sloped pipe sleeves only which
shall be sealed after installation of cables to avoid seepage of water inside
building.
(v) Cable shall be arranged in the trays/trenches in such a manner that criss-
crossing of cable is avoided.
(vi) Cable routing between cable trench and equipment/motors shall be taken through
GI pipe sleeves of adequate size.
(vii) Cable routing shall be coordinated to avoid interference with structure, drains,
piping etc.
(viii) Cable marker shall be placed at every change in direction of cable routing and
every 30 metre interval.
(ix) Flexible metallic conduits shall be used for termination of connection to
equipment such as motors, limit switches and other apparatus.
(x) All cables shall be identified close to their termination point by cable tag numbers
as per cable schedule.
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(xi) Cables shall be clamped to the cable tray at regular intervals.

(xii) All cable trays (Ladder/Perforated type) shall be minimum 2mm thick and hot dip
galvanized (with Zinc coating of 610 gm. /sqm or 85 micron thickness) while
supports shall be painted.
(xiii) All support shall be structurally designed to take weight of cable, tray & support
and wind force.
(xiv) All steel sections such as angles, channels, and brackets etc., required for
supporting the cable trays shall be provided by the contractor.
(a) Installation of Cables

The Contractor shall install, test and commission the cables in accordance with above
guidelines, approved drawings and IS-1255. The Contractor shall also supply the
necessary materials and equipment required for jointing and termination or the cables.
Wherever cables pass through floor or wall openings or other partitions, suitable
bushes of an approved type shall be supplied and put into position by the Contractor.
The Contractor shall seal the cables into the bushes using fire resisting materials to
prevent the spreading of fire through each partition. Sharp bends and kinks in cables
shall be avoided. The bending radii for various types of cables shall not be less than 15
times the overall diameter of the cable. Power, control and instrumentation cables shall
be laid in separate cable trays.
Where cables cross roads or water/sewage pipes, the cables shall be laid in reinforced
spun concrete or steel pipes. For road crossings, the pipe for the cables shall be buried
at not less than one metre depth. Care shall be taken to avoid sharp bending or kinking
cables, damaging insulation or stressing cable beyond manufacture's
recommendations in pulling. Cable shall be protected at all times from mechanical
injury and from absorption of moisture at unprotected ends.
Control cable termination shall be made in accordance with wiring diagrams, using
proper colour codes for the various control circuit, by code marked wiring diagram.
Metal sheath and armour of the cable shall be bonded to the earthing system. The size
of conductor for bonding shall be appropriate with the system fault current.
All cables shall be tested for insulation resistance before jointing. After jointing is
completed, all cables shall be tested again by a 1000 volt megger. Cable core shall be
tested for;
(i) Continuity;
(ii) Absence of cross phasing;
(iii) Insulation resistance to earth; and
(iv) Insulation resistance between conductors.
Contractor shall provide testing kits and instruments required for field testing.
14.4.2. 11 KV XLPE CABLE
14.4.3. Scope of Work

The specification covers design, engineering, manufacture, stage testing,
inspection and testing before supply, delivery at site, installation, testing &
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commissioning of 11 KV, XLPE cables for use with effectively earthed distribution
system.
14.4.3.1. Standard to be Followed

The materials shall conform in all respects to the relevant Indian Standards
Specification with latest amendments thereto.
Indian
Description
Standard No.
IS-7098 Cross Linked Polyethylene Insulated PVC Sheathed

Cables for working Voltages from 3.3 KV up to and
Part-II/1985 including 33 KV
IS-5831/1984 PVC insulation and sheath of Electric cables
IS-8130/1984 Conductors for insulated electric Cables and Flexible cords
IS-10418/1982 Drums for electric cables
14.4.3.2. Technical Requirement

(a) Main Features
The Power Cable shall be 11 KV Grade, high conductivity, stranded compacted circular
Aluminium Conductor, XLPE insulated, extruded inner PVC sheathed, galvanized steel strip
armoured with overall separate extruded PVC outer sheathed, conforming to relevant
standards suitable for 11 KV three phase 50 cycle second earthed system.
14.4.3.3. Materials and Construction

(a) Conductor
The cable conductor shall be made from stranded aluminium to form compacted circular
conductor having resistance within the specified limits as per relevant standards.
(b) Conductor Shield

The conductor shall have a non-magnetic semi-conducting screen, which will ensure
perfectly smooth profile and avoid concentration. The Conductor screen shall be extruded
in the same operation, as the insulation.
(c) Insulation
The XLPE insulation shall be suitable for specified system voltage. The manufacturing
process shall ensure that insulation is free from voids. The insulation shall withstand
mechanical thermal stresses under steady state and transient operating condition. The
extrusion method shall give smooth interface between semi-conducting screen and
insulation.
14
(d) Insulation Shield

To confine electrical field to the insulation, insulation screening consisting of two parts,
namely metallic (non-magnetic) and non-metallic (semi-conducting) shall be provided over
the insulation of each core. The non-metallic insulation shield shall be extruded in the same
operation as the conductor shield and the insulation by the triple extrusion process. The
insulation shield shall be of bonded type and strippable on adequate heating. Metallic
screening of copper tape shall be provided over non-metallic shield as per relevant ISS.
(e) Inner Sheath

An extruded PVC inner sheath shall be provided over laid up cores. The sheath shall be
suitable to withstand the site conditions and the desired temperature. It shall be of thickness
as per the relevant standards, consistent quality and free from all defects. The binding tape
used over the laid up cores shall not be constructed as a part of the inner sheath.
(f) Armour
Armouring shall be applied over inner sheath with galvanized steel strip complying with the
requirements of relevant standards. The armour strips shall be applied as closely as
possible. The joints in armour strip shall be made by brazing or welding and the surface
irregularities shall be removed. A joint in any strip shall be at least 300 mm from the nearest
joint in any other armour strip in the completed cable.
(g) Outer Sheath

Extrude PVC outer sheath shall be applied over armouring with suitable additives to prevent
attack by rodents and termites. Outer sheathing shall be designed to offer high degree of
mechanical protection and shall also be heat, oils, chemicals, abrasion and weather
relevant. Common acids, alkalies, saline solutions etc., shall not have adverse effects on
the PVC sheathing material used.
(h) Construction
The cable shall have suitable PVC fillers laid up with insulation cores to provide
substantially circular cross section before the inner sheath is applied. The fillers shall be
suitable for the operating temperature of the cable and compatible with the insulating
material. All materials used in the manufacture of cable shall be new, unused and of finest
quality. All materials shall comply with the applicable provisions of the tests of the relevant
standards. The PVC material used in the manufacture of cable shall be of reputed make.
No recycling of the PVC is permissible. The purchaser reserves the right to ask for
documentary proof of the purchase of various materials to be used for the manufacture of
cable and to check that the conductor is complying with quality control. The cable shall be
suitable for laying in covered trenches and/or buried underground to meet the outdoor
application purposes.
(i) Current Rating

The cables shall have current ratings and derating factors as per relevant Indian Standards.
The current ratings shall be based on maximum conductor temperature of 90 deg. C with
ambient site condition specified for continuous operation at the rated current. The one-
15
second short circuit current rating shall be as per table given below at maximum
temperature of 250 oC.
(j) Operation
Cables shall be capable of satisfactory operation, under a power supply system frequency
variation of +/- 5 c/s. voltage variation of +10% to –15%. Cable shall be suitable for laying in
ducts or underground. Cables shall have heat and moisture resistance properties. These
shall be of type and design with proven record on Distribution Network service.
(k) Identification
For identification of individual cores, coloured strips of red, yellow and blue colours
respectively shall be used on the cores to identify phase conductors as per relevant ISS.
(l) Embossing
The cable shall be embossed throughout the length with the name of the manufacturer or
trade mark. Voltage grade with cable size and the year of manufacture. The embossing
shall be done only on the outer sheath, the distance between any two consecutive
embossing shall not be more than 1 Meter. The cable shall be embossed for the verification
of its length at intervals of 1 Meter say 1, 2, 3, up to full length.
(m) Test
Type Test: The material offered shall be fully type tested at recognized test laboratories by
the Bidder as per the relevant standards but test reports shall not be more than five year old
from the date of opening of bid.
Acceptance and routine test: All acceptance and routine tests as stipulated in the relevant
standards shall be carried out by the supplier.
14.4.4. LT XLPE CABLE
14.4.4.1. Scope
The specifications cover requirement of 650 / 1100 Volts grade solid/stranded,
Copper/Aluminum conductors, XLPE insulated and sheathed galvanised round/flat
steel wire armoured and PVC overall sheathed cables.
14.4.4.2. Code and Standards

The cables shall comply with all currently applicable IS / IEC Standards, Electricity
Rules, approval of Fire Insurance Association and Electrical Inspector.
Unless otherwise specified, cable shall conform to the following latest applicable
Standards.
PVC insulated (heavy duty) electric cables for working

IS 1554,Part -I 1988
voltages up to and including 1100 V
Cross linked polyethylene insulated PVC sheathed

IS 7098,Part-I 1988
cables for working voltage up to and including 1100 V
16
Conductors for insulated electric cables and flexible

IS 8130 1984
cords
IS 5831 1984 PVC insulation and sheath of electric cables
Mild steel wires, formed wires and tapes for armouring

IS 3975 1999
of cables
Methods of test for cables : Mass of zinc coating on

IS 10810,Part 41 1984
steel armour
IS 209 1992 Zinc Ingot
Recommended current ratings for cables: Part – 2 PVC

IS 3961 Part-2 1967
insulated and PVC sheathed heavy duty cables
IS 10418 1982 Drums for electric cables
IS 10810 Part 58 1998 Method of test for cables : Part 58 Oxygen Index test
IS 10810 Part 61 1988 Method of test for cables : Part 61 Flame Retardant test
Method of test for cables : Part 62 Fire resistance test

IS 10810 Part 62 1993
for bunched cables
694 2010 PVC insulated unsheathed and sheathed cables for

IS
rated voltage up to and including 450/750 V
The cables and accessories shall also conform to the provisions of Indian Electricity
Rules and relevant statutory regulations.
14.4.4.3. Climatic Conditions

Cables shall be installed in air / ground, in atmosphere having maximum ambient
temperature and relative humidity as per prevailing site condition.
14.4.4.4. Constructional Requirement

(a) Conductor
The material of conductor shall be Electrical grade high conductivity, compacted,
aluminium / copper. Conductor shall be solid for conductor of nominal area up to and
including 4 sq.mm and stranded beyond 4 sq.mm. Conductors of nominal area less
than 25sq.mm shall be circular or sector shaped. Cables with reduced neutral
conductor shall have sizes as per table 1 of IS 1554 (part-1). Cables up to and
including 4 sq. mm shall be of Cu and above 6 sq. mm shall be of Al unless specified
otherwise. Strand details shall be preferably as below:
6 to 10 sq mm [CU/AL] - 7 strands
17
(b) Insulation
The material of insulation shall be Cross Linked Polyethylene applied over the
conductor by extrusion. Insulation shall be free from contamination and water voids
and shall withstand all mechanical and thermal stresses under steady state and
transient operating conditions. The thickness of the insulation shall be as per IS: 7098
(part I).
(c) Inner Sheath

The inner sheath shall be applied over the cores by a method of extrusion and shall be
of PVC conforming to the requirements of Type ST-1 PVC compound as IS: 5831. The
thickness of inner sheath shall be as per relevant standards. There will be no sheath
for single core cables, in case of single core when there are both metallic screening
and armouring there shall be extruded inner sheath between them.
(d) Armouring
If armouring is specified for multicore cables, the same shall be single round
galvanised steel wires / galvanised steel strips as per the requirement. If armouring is
specified for single core cables, the same shall be with H4 grade hard drawn
aluminium round wire of 2.5 sq.mm diameter.
Requirement and methods of tests for armour material, galvanising uniformity and
dimensions of armour shall be as per relevant standards.
(e) Outer Sheath

This shall consist of extruded ST-1, PVC compound having oxygen index value of
minimum 28 % at 27 ± 2 deg. C, is resistant to termite and rodent attack. Outer sheath
shall be of black colour, external surface of which shall be embossed with voltage
designation and manufacturer’s name at regular interval. The thickness of outer sheath
shall be as per IS: 1554 – part 1.
Sequential marking of the length of the cable in metre shall be provided on the outer
sheath at every one metre. The embossing / engraving shall be legible and indelible.
PVC / Rubber end caps shall be supplied free of cost for each drum with a minimum of
twenty per thousand metre length.
Outer sheath with FRLS compound shall be provided for better fire resistance.
(f) General Requirements

The cables shall be suitable for laying in trays, trenches, ducts, conduits and for
underground buried installation with uncontrolled backfill and possibility of flooding by
water and chemicals. Cables shall be suitable for keeping in a proper looped position
for longer period without occurring of any damage to the insulations and armour.
The material of conductors shall be from annealed high conductivity Copper /
Aluminum. The maximum conductor temperature in deg.0C shall be limited to data as
specified in data sheets. Conductor shall be of either circular or sector shaped
stranded conductor or circular solid construction as specified in data sheet.
18
Cables shall be supplied wound on non-returnable wooden drums of heavy duty

construction and of suitable barrel diameter and shall be covered fully with wooden
battens. Wooden drums shall be properly seasoned and treated with anti-rodent
material and painted with good quality paint to increase the life of the drum. Ferrous
parts used shall be treated with a suitable rust preventive finish or coating to avoid
rusting during transit or storage.
Drums shall be suitably marked with manufacturer’s name, customer’s name, project
title, cable type, size, voltage grade of cable, length of cable in metres, drum number,
IS certification mark, gross weight, rolling direction etc. as per BIS/BS.
Packing should be sturdy and adequate to protect the cables from any injury due to
mishandling or other conditions encountered during transportation, handling and
storage. Both cable ends shall be sealed with PVC / heat shrinkable end caps so as to
eliminate the ingress of water during transportation, storage and erection.
The cable of one size shall be in one length only, if the requirement is less than full
standard drum length. Cables shall be suitable for earthed system. Negative tolerance
on cable drum length is not acceptable.
(g) Test
Type Test: The material offered shall be fully type tested at recognized test
laboratories by the Bidder as per the relevant standards but test reports shall not be
more than five year old from the date of opening of bid.
Acceptance and routine test: All acceptance and routine tests as stipulated in the
relevant standards shall be carried out by the supplier.
14.4.5. 415 V SOFT STARTERS

The Scope includes supply, installation, testing and commissioning of 415 V Soft
Starters as per applicable standard and having following specifications:
14.4.5.1. Construction
The construction features of this Panel shall be governed by the technical specification
of LT Panel as described in previous section.
14.4.5.2. Design
Soft starters for 415 V application shall be electronic type or FCMA or HFSR type. The
soft starters shall enable smooth acceleration of motor and shall be universal in
design. It shall be compatible with any make of the motor and its performance shall not
be dependent on the design of the motor. The soft starters shall be provided with
bypass facility, either built into the soft starter or with the help of an external contactor
adequately rated. Bypass shall be effected once the motor has successfully picked up.
Bypass of the soft starters, however, shall not make the inherent motor protections
built into it. In case, bypass contactor bypasses the soft starter completely, external
protections by way of electronic motor protection relays shall be provided. Control
circuit shall ensure that the motor is not switched ‘On’ with the bypass contactor ‘On’.
The soft starter shall have communication facility with PLC/SCADA. The soft starter
shall have self-diagnostic feature and shall annunciate failure/ trouble with the soft
starter.
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14.4.5.3. Performance
14.4.5.3.1. Rated current

The Soft Starter shall have nominal current rating of 1.3 times the full load current of
the controlled motor for standard duty applications. (Standard duty applications are
those which do not exceed 240 seconds at 3 times the motor nominal current per hour
including starting, stopping or braking.)
For severe duty applications such as centrifugal blowers, the Soft Starter should be
de-rated to suit the requirements of the application. The manufacturer shall state the
nominal current ratings of the Soft Starter in such cases. In the case of the ambient
temperature exceeding design temperature around the soft starter, the soft starter
should be de-rated suitably.
14.4.5.3.2. Current Limit Range

The Manufacturer shall specify the current limit range of his proposed Soft Starter.
14.4.5.3.3. Operating Characteristics

The Soft Starter shall comply to the following operating characteristics:
Allow the output limit current to be adjusted from 150 to 600% of the nominal current
rating of the Soft Starter. Allow adjustable acceleration times up to 60 seconds.
14.4.5.3.4. Soft Starter Protections

Protections should be provided as specified below:
Thermal replica types overload protection, Protection against single phasing,
excessive negative phase sequence currents, reverse phase sequence in supply,
Earth faults and stalled rotor protection
Fuses should be supplied for type 2 co-ordination. These should be of the fast acting
‘semiconductor grade’ for protection of the Thyristors.
14.4.5.3.5. Motor Thermal Protection

Thermal overload protection should be integrated in the Soft Starter and should be
adjustable according to thermal class of the application.
14.4.5.3.6. Start time too long

The Soft Starter should supply protection against start times exceeding the
programmed start time in the case of overloads at starting.
14.4.5.4. Indications and Alarms

A fault history for soft starter protection functions shall be provided for fault indication
and fault tracing. Fault indication shall be displayed in plain text on an alphanumeric
display.
14.4.5.5. Operator Controls

The Soft Starter should be provided with local and remote control functions.
20
14.4.5.5.1. Local Control

A control panel shall be mounted on the front of the enclosure provided with operation
functions.
14.4.5.5.2. Remote Control

Provisions shall be included for the Soft Starter to be controlled remotely. Necessary
terminals for the input and output functions shall be provided. When the control
function is changed from local to remote or the reverse the adjustments of the Soft
Starter shall be maintained.
The following functions shall be provided:

Uploading and downloading of pre-set parameters to the PC, Locking and unlocking
parameter settings to prevent unauthorized access.
14.4.5.6. Instruments and Meters

All required instruments and meters, control and selector switches, push buttons and
indicating lamps shall be provided.
14.4.5.7. Analogue and Digital I/O

Digital and Analogue inputs and outputs shall be fully programmable and shall be
galvanically isolated. The function for scaling of analogue output shall be fully
programmable. Facilities for selection of signal range from 0 to 20mA, 4 to 20mA, 0 to
10V or 2 to 10V shall be provided.
14.4.5.8. Cable Connections

Terminal blocks provided shall be segregated according to circuit voltage and field
destination.
14.4.5.9. Wiring
All wires for electronics and signals should be shielded and should be at least 0.5mm2.
14.4.5.10. Earthing
Earthing shall be provided as per manufacturer standard.
14.4.5.11. Rating Plates and Labels

The Soft Starter shall have a rating plate permanently fixed to the front of the
equipment giving relevant information as per Standards and as per Manufacturer’s
standard.
14.4.6. TRANSFORMER – OIL COOLED TYPE
14.4.6.1. Scope
The scope of this specification covers the design, manufacture, supply, testing and
delivery to site the Distribution transformers required.
The transformers up to 2500 kVA, 33 kV class shall conform to IS 1180-2014 revision.
The transformers shall be Energy Efficient Level 3 with maximum losses at 50% load
and at 100% load as defined in IS 1180.
21
14.4.6.2. Codes and Standards

The supply, installation, testing and commissioning of transformers and accessories
shall comply with the latest applicable standards and codes of practices.
The list of some of the applicable Indian Standards is as given below:
IS 1180- Outdoor Type Oil Immersed Distribution Transformers
2014 up
to and including 2500 kVA, 33 kV - Specification
IS 335 New Insulating Oils
IS 2026 Power Transformers
IS 2099 Bushings for Alternating Voltages above 1000 V
IS 3639 Fittings and Accessories for Power Transformers
IS 6600 Guide for Loading of Oil Immersed Transformers
14.4.6.3. General
Transformers shall comply with IS 1180-2014 & IS 2026. They shall be oil immersed,
naturally cooled type classified ONAN.
The transformer shall be sized for continuous operation at its maximum rating under
the climatic conditions defined in the Employer’s Requirements. The rating shall allow
for open, un-shaded operation.
14.4.6.4. Constructional Features
14.4.6.4.1. Tank
Tank shall be made from good commercial grade low carbon steel and shall be of
welded construction. Tank shall be designed to permit lifting, by crane or jacks, of the
complete transformer assembly filled with oil.
Tank shall be braced to withstand full vacuum and pressure test as specified by CBIP's
(Central Board of Irrigation & Power) latest specification. Suitable guides shall be
provided in the tank for positioning the core and coil assembly. The core and coil
assembly shall not be cover mounted.
Adequate space shall be provided at the bottom of the tank for collection of sediment.
The transformer base shall be designed to permit skidding of the complete transformer
unit in any direction, when using plates or rails. The under-base shall be detachable
unless transport facilities permit a fixed base.
The transformer top shall be provided with a detachable cover with a bolted flanged
gasket joint. Lifting lugs shall be provided for removing the cover. The surface of the
cover shall be suitably sloped so that it does not retain rain water. The material used
for gaskets shall be rubberised cork.
14.4.6.4.2. Core
The magnetic circuit shall be of "core type" construction. The core shall be built out of
high grade, non-ageing, low loss and high permeability, cold rolled grain oriented
silicon steel laminations adequately insulated and joints mitred and interleaved to
provide continuity of the magnetic circuit.
22
After being sheared the laminations shall be treated to remove all burrs. Both sides of
the laminations and the cut edges shall be treated with appropriate insulation. The
finally assembled core shall be free from distortion. It shall be rigidly clamped to
ensure adequate mechanical strength and to prevent vibrations during operation.
The core clamping structure shall be designed to minimise eddy current loss. The core
shall be provided with lugs suitable for lifting the complete core and coil assembly. The
core and coils assembly shall be so fixed in the tank that shifting will not occur during
transport or short circuits.
All steel sections used for supporting the core shall be thoroughly sand-blasted, after
cutting drilling and welding. The operating flux density ‘B’ shall be so chosen that the
core does not get into saturation at 110% of the rated voltage. The operating flux
density shall be of the order of 1.65 to 1.7 Tesla. Cross-sectional area for this purpose
shall be adequate.
14.4.6.4.3. Windings
Windings shall be of copper. Windings shall be subjected to a shrinking and seasoning
process, so that no further shrinkage occurs during service. Adjustable devices shall
be provided for taking up possible shrinkage in service.
Coils shall be supported at frequent intervals by means of wedge type insulation
spacers permanently secured in place and arranged to ensure proper oil circulation.
To ensure permanent tightness of winding assembly, the insulation spacers shall be
dried and compressed at high pressure before use.
Windings shall not contain sharp bends which might damage the insulation or produce
high dielectric stresses. No strip conductor wound on edge shall have width exceeding
six times the thickness. Materials used in the insulation and assembly of the windings
shall be insoluble, non-catalytic and chemically inactive in the hot transformer oil and
shall not soften or be otherwise affected under the operating conditions.
All threaded connections shall be locked. Leads from the winding to the terminal board
and bushings shall be rigidly supported to prevent it from vibration. Guide tubes shall
be used where practicable. Windings and connections shall be braced to withstand
shocks during transport or short circuits.
Coil clamping rings shall be of steel or of a suitable insulating material built from flat
laminations. Permanent current carrying joints in the windings and lead shall be brazed
or soldered. Clamping bolts for current carrying parts inside oil shall be made of oil
resistant material which shall not be affected by acidity in the oil. Terminals of all
windings including unloaded stabilising windings shall be brought out of the tank
through bushings for external connection.
14.4.6.4.4. Bushings
a) All bushings shall conform to the requirements of latest revision of IS: 2099.
The bushing ratings shall be commensurate with the transformer rating and
shall not pose any limitations on transformer overload capacity. Impulse
withstand levels shall be in accordance with the Standards mentioned and
creepage distance shall be suitable for severely polluted atmosphere
(minimum 31 mm/ kV).
b) All porcelain shall be sound, free from defects and thoroughly vitrified. The
glaze shall not depend upon insulation, shall be smooth, hard, of uniform
shade of brown and shall cover completely all exposed parts of insulator.
23
Porcelain shall not engage directly with the hard metal and, where necessary,
approved gasket shall be interposed between porcelain and fittings. All
porcelain clamping surfaces in contact with gaskets shall be accurately ground
and free from glaze.
c) Connection from the main winding to the bushing shall be flexible.
d) Clamps and fittings made of steel and malleable iron shall be galvanised.
e) Bolt threads shall be greased before erection
f) Each porcelain bushing shall have the manufacturer’s identification marks.
g) Bushing insulators are to be mounted on the tank in a manner such that the
external connection can be taken away clear of all obstacles. Neutral bushing
shall be mounted in a position from which a connection may be taken.
h) The bushing shall be so located as to provide minimum electrical clearances
between phase and also between phase and ground as per the IS 2099.
14.4.6.4.5. Oil
Transformer and associated oil filled equipment shall be supplied with first filling of
oil plus 10% extra in non-returnable drums. The oil shall conform to IS: 335. No
inhibitors shall be used in the oil. In all cases, oil will not contain any polychlorinated
biphenyl (PCB).
14.4.6.4.6. Cable Terminations

Cable termination boxes for ground-mounted transformers shall be suitable for dry
termination of HV cables and LV cables / bus duct. Non-magnetic gland plates shall be
provided for the termination of single core cables.
LV neutral shall be brought out through 1.1 kV rated bushing for forming 3 ph., 4 wire
system. An extra LV Neutral bushing shall be provided and shall be directly connected
to earth by means of two nos. earthing conductors. Bushings rated above 1000 VAC
shall comply with IS 2099.
It shall be possible to remove the cable boxes without dismantling the cable glanding
or draining the oil.
14.4.6.4.7. Cable Box with Disconnecting Chambers

Air insulated cable box shall be provided on provided on H.V. side. The disconnecting
chamber shall be air insulated. Phase to phase and phase to ground clearances with
the cable box shall be as per CBIP.
14.4.6.4.8. Bus Duct Termination

Distribution transformers with secondary voltage as 433 V and rated above 1000 kVA
shall be provided with a flanged throat or equivalent connection for termination of bus
ducts. The bus duct throat arrangement shall be suitable for vertical and horizontal
take off. The bus duct throat shall be on the side wall of a tank. Transformers rated
below 1000 kVA shall be provided with cable termination box.
14.4.6.4.9. Transformer Cooling Equipment

Transformers of rating below 500 kVA shall be equipped with fixed type radiators and
transformers of rating 500 kVA and above shall be provided with detachable or
separately mounted radiator banks. Tank mounted radiators shall be of the detachable
24
type with bolted flanged connections. Sheet steel thickness for the radiators shall not
be less than 1.2 mm. The following accessories shall be provided for each radiator:
Shut off valves and blanking plates on transformer tank at each point of connection,
Top and bottom shut off valves and blanking plates on each radiator, Lifting lugs, Top
oil filling hole with cap, Air release plug at top, Oil drain plug at bottom.
14.4.6.5. Fittings and Accessories (R – Required, NR – Not Required)

Sr. Description Rating of Transformer to which
No. fitted
Up to 500 to 1000 2500
400 800 to KVA
KVA KVA 2000 &
KVA above
1 Rating & diagram plate R R R R
2 Dial type magnetic oil level gauge with low level NR NR R R

alarm contacts
3 Silica Gel breather with a seal & connecting pipe, R R R R
in a transparent enclosure
4 Explosion Vent with diaphragm, Equalising pipe R R R R
5 Conservator with filling hole, cap and drain valve R R R R

and isolating valve for conservator.
6 Double float buchholz relay with alarm and trip NR R R R
contacts and a test lever for simulating operation
of buchholz relay and shut off valve on both sides.
7 Dial thermometer for oil temperature marked in R R R R
o C with alarm and trip contacts (adjustable) with a
maximum reading pointer
8 Image coil with C.T. test terminals, calibrating NR NR R R
resistors etc. for winding temperature with dial
type thermometer having alarm & trip contacts
(adjustable) with a maximum reading pointer
Weather-proof marshalling box with terminal
blocks complete with PVC armoured cables
9 terminated with glands, for alarm/trip contacts of R R R R
buchholz relay, OTI & WTI etc.
10 Thermometer pocket (for top oil temp.) R R R R
11 Lifting lugs R R R R
12 Jacking pads – 4 Nos. NR NR R R
13 Draw eyes NR NR R R
25
14 Top Filter valve R R R R
15 Bottom filter valve R R R R
16 Drain valve with plug R R R R
17 Oil sampling valve R R R R
18 Inspection cover R R R R
19 Air release vent R R R R
20 Bi-directional rollers R R R R
21 Two earthing terminals R R R R
22 Plain oil level indicator with minimum marking R R R R
23 Extra LV Neutral bushing for direct earthing, in R R R R

addition to one for power system
14.4.6.6. Noise Level

The noise level when energised at normal voltage and frequency shall not exceed 78
dB when measured one meter from edge of transformer.
14.4.6.7. Painting
The interior of all transformer tanks and other oil filled chambers and internal structural
steel work shall be cleaned of all scale and dust and surfaces shall be painted with not
less than two coats of heat resistant, oil insoluble and insulating varnish. Steel
surfaces exposed to the weather shall be thoroughly cleaned and applied a priming
coat of zinc chromate. The second coat shall be of an oil and weather resistant nature,
preferably of different colour from the prime and finish coats. The final coat shall be of
glossy oil and weather resisting non fading epoxy paint of specified shade. All exposed
bolts, nuts and washers shall be of stainless steel.
Metal parts not accessible for painting shall be made of corrosion-resistant material.
Machine finished and bright surfaces shall be coated with a suitable compound and
wrapped. Interior surfaces of mechanism chambers and knocks shall receive three
coats of paint after proper cleaning. The final coat shall be of a light coloured anti-
condensation paint.
14.4.6.8. Operational Requirements

Voltage and Frequency Variations
Transformers shall operate without injurious heating, on any tap, under the following
conditions, provided increase in voltage is not accompanied by reduction in frequency:
At rated kVA, with voltage variation of (+) or (-) 10% of the voltage corresponding to a
particular tap.
26
At rated current, with 105% rated voltage.

Transformer shall accept, without injurious heating, combined voltage and frequency
fluctuations which produce 110% over fluxing conditions.
Operating Under Overloads
It shall be possible to operate the transformer as per loading guide IS: 6600 up to
overloads of 150%. There shall be no limitations imposed by bushings, tap changers,
auxiliary equipment, etc. to meet this requirement.
14.4.6.9. Tests
The following tests shall be conducted in presence of the Employer’s Representative;
All routine tests, Heat run test (on mutually agreeable basis) Oil Pressure Test
Vendor shall submit the S.C. test withstand certificate for similar transformer.
14.4.6.10. Losses
The total maximum losses at 50% load and 100% load shall be within the limits
specified in IS 1180 – 2014.
14.4.6.11. Specification of O.L.T.C & A.V.R
14.4.6.11.1. On Load Tap Changer

On load Tap changer suitable for application at all locations of 11 kV, 3 phase, Star
or Delta connected transformers. It is a linear gear, requiring a potentiometric
tapping arrangement with a Wander lead. The Tap Changer has a max. of 9
positions so that it can be applied to a winding of 8 steps, to give 9 different
voltages. The functions of the tap selector and diverter Switch are combined in a
selector switch. The Selector Switch and its integrally mounted stored energy type
Driving Mechanism, are housed in a sheet steel tank, with a Flange suitable for
mounting on a port on the Transformer tank. Leads can be brought out of the
transformer through a Port Flange mounted, oil tight, Terminal Barrier Board, which
is part of the Tap changer supply. The Tap changer must be connected to a
conservator, through an Oil Surge Protective Relay. The Oil Surge Protective Relay
forms part of Tap changer Supply. The Transformer Manufacturer must fill the Tap
changer with oil. The Tap changer must conform to Type tests and Routine tests as
per IS: 8468.
14.4.6.11.2. Technical Data:

Rated Voltage : 11KV
Maximum System Voltage : 12 KV
No. of positions : 9
No. of Phases : 3
Maximum Continuous current : 200 A
Maximum Operating step voltage : 300 V
Maximum Operating voltage over
Tapping range : 6000V
Maximum Continuous voltage to ground : 12,000V
Maximum Continuous voltage
Between phases : 12,000V
27
Peak emergency current : 450 A

Time per tap change : 4-6 Sec.
Weight of Tap changer without oil : 370 Kgs.
Weight of Tap changer with oil : 610 Kgs.
Oil content : 230 Lts.
Transition switching time : 50 milli.secs.
14.4.6.11.3. Automatic Voltage Regulating Relay

Automatic Voltage Regulating Relay designed for maximum Operational simplicity
for regulating the secondary voltage of power transformers with On Load Tap
Changer. The dead band (band width) can be set by setting the nominal value
adjustment (NVA) to the required value (110V+10%) & then setting the L & R Limits
around the NVA within 0.5v to 5v.
The desired time delay can be set up on the front panel and the control action will
take place only if the voltage continues to remain outside the dead band after the
time delay has elapsed. For voltage corrections requiring more than one tap
change, time delay is initiated again before further tap change. The relay is reset
automatically after the voltage is brought within the selected dead band, the time
delays is effectively reduced to provide a voltage time integral response of the
regulator.
Operation of the Raise Control Relay is automatically inhibited when the voltage
falls below the specified under voltage limit or it falls. One pair of normally open
relay contacts is provided to affect the tap changer during Raise and Lower
operation and to trigger an alarm in case of under voltage/ P.T fail conditions.
14.4.6.11.4. SPECIFICATIONS
Auxiliary supply : 110 V/ 230V AC + 15% 50Hz, 15 VA
PT Supply (Regulating Voltage) : 110V + 10%, 50Hz., 1.5VA
Sensitivity (Dead Band) : 1) Nominal value adjustable (NVA) between
And Nominal value Range +10% of 110V and readable on DPM.
: 2) L setting adjustable between 0.5v to 5v
above the NVA and readable on DPM.
: 3) R` Setting adjustable between 0.5v to 5v
below the NVA and readable on DPM.
: 4) Actual PT voltage also readable on DPM.
Time delay setting : Fixed (voltage independent) time delay
continuously adjustable from 10 to 120
seconds.
Time delay Resetting : Instantaneous resetting with voltage
deviation occurring in opposite direction.
Under voltage blocking : Internal blocking at 80% of NVA
Restoration at 85% of NVA (other values
available on request)
Controls Relays : One pair of normally open potential free
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contacts of rating 5A at 220V AC of 24V

DC resistive load for each lower, raise
and under voltage control relays.
Control Operation : Single Pulse operation with 5 seconds
(approx.) on time.
Operating Temperature : 0 – 500C.
Size : Panel cutout dimensions 330 x 135mm
Depth 260mm approx. Mounting Hole
Dimensions 360mm + 2mm x 100mm +
2mm (¼” Ø x 4).
14.4.7. DG SYNCHRONIZATION PANEL
14.4.7.1. SCOPE
This section covers design, manufacture, inspection, transportation to site, installation,
testing and commissioning of DG Synchronization Panel for running of DG Set in
parallel i.e. their synchronization on common bus bar, auto load sharing and auto load
management.
The construction features of this Panel and their component shall be governed by the
technical specification of LT Panel as described in previous section.
14.4.7.2. GENERAL
The operation of DG Set shall be monitored and controlled by this PLC based logic
Panel. In case of mains failure, this logic panel shall control auto changeover from
mains to DG Sets supply and interlocking of MCCB/ACB, auto synchronizing and auto
load management functions.
The panel shall be provided with a total manual over ride facility. The panel shall be
complete with all Auxiliary relays, timers, contactor, PLC, control wiring,
interconnections etc.
14.4.7.3. CONTROL PHILOSOPHY
14.4.7.3.1. Automatic Start & Stop of Engine

The system should come in operation after sensing of grid failure and automatically
control the start & stop of engines, depending on the predefined load setting in the
PLC.
14.4.7.3.2. Automatic Synchronization

The facility of synchronization will be available in both Auto & Manual mode. In normal
circumstances the auto synchronization will work, however if due to any reason auto
synchronization fails repeatedly the facility for closure of MCCB/ACB must be available
automatically. In manual mode MCCB/ACB will be closed by panel push button.
14.4.7.3.3. Automatic Load Sharing

The load sharing will also be automatic by sensing both active & reactive power.
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14.4.7.3.4. Back Up Protection

The system should also have following in built protection other than external relays in
synchronization panel:
Reverse power, reverse KVAR, over current, under current, over voltage, under
frequency, over frequency, synchro check & earth fault relay except differential relay.
Due to any electrical fault PLC shall trigger the master trip relay.
14.4.7.4. SEQUENCE OF OPERATION

The following sequence of operation shall be achieved through PLC based logic panel
in addition to hardware interlocks as well as software interlocks:
(a) Selection of any generator as a lead generator to achieve the uniform running
hours of all generators.
(b) Three attempts to start the engine of lead generator. In case the engine fails to
start or does not achieve the requisite speed within the predetermined time, PLC
system declares engine of generator faulty. In this event PLC automatically
selects next generator as the lead generator.
(c) The PLC system automatically selects starting sequence of other generators on
the basis of the lead generator being selected by the operator.
(d) Before issuing close command to lead generator ACB/MCCB, PLC checks that
ACB/MCCB of any generator is not in close position. Then PLC system gives
close command to lead generator ACB/MCCB. The PLC system tries two times
with interval of 5 secs to close the ACB/MCCB. Simultaneously, it also gives
starting command to next generator engine in queue depending upon load.
(e) The speed, excitation, frequency and voltage of incoming generator are controlled
identically as per the lead generator starting sequence described above, except
closing of ACB/MCCB.
(f) When the lead generator KW crosses more than the 85% of rated capacity of DG
set, the PLC system performs synchronization sequence for paralleling of
generator prior to switching on the ACB/MCCB of 2nd generator.
(g) The last incoming generator ACB/MCCB is tripped when PLC system senses that
the total load on the system is less than the specified load and stops the engine
after 5 minutes of idle running.
(h) DG sets will start and stop automatically depending on the pre-defined load setting
in the PLC & also all DG sets will operate in load sharing mode.
14.4.8. EARTHING SYSTEM
14.4.8.1. Scope
The scope includes supply of earth electrode pits and earthing conductors and their
installation including associated civil work as per the specifications and drawings, to
the satisfaction of the Employer’s representative and the Electrical Inspector. Proper
earthing shall be provided to ensure adequate system neutral earthing and for
equipment and personnel safety.
All work such as cutting, bending, supporting, painting/coating, drilling, welding,

clamping, bolting and connection to structures, equipment frames, terminals, etc. shall
be in the Contractor’s scope of work. All incidental hardware and consumables such as
fixing cleats/clamps, anchor fasteners, lugs, bolts, nuts, washers, bituminous
compound, welding rods, anti-corrosive paint as required for the complete work shall
be deemed to be included by the Contractor as part of the installation work.
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14.4.8.2. Earthing System Installation

Earthing system shall conform to the latest edition of IS: 3043 and Indian Electricity
Rules, 1956. All materials and fittings used in the earthing installation shall conform to
the relevant Indian Standards and as approved by the Employer’s Representative.
Installation work shall be in accordance with approved earthing layout drawings and
any change in routing, size of conductors etc. shall be subject to the prior approval of
the Employer's Representative.
Metallic frames of all electrical equipment shall be earthed by two separate and distinct
leads and then connected with earthing system in line with IE rules and IS-3043.
Neutral points of transformers and DG set shall be earthed by two separate and
distinct connections to two treated electrode pits. Crane rails shall also be connected
to the earthing system. Cable sheaths and armour shall be bonded to the earthing
system. Metal pipes and cable conduits shall be effectively bonded and earthed.
Neutral connection shall never be used for equipment earthing.
The scope of installation of earthing leads to the equipment and risers on steel
structures/walls shall include laying the conductors, welding/cleating at specified
intervals, welding to the main earth grids, risers, bolting at equipment terminals and
coating welded joints by bituminous paint. Galvanized conductors shall be touched up
with zinc-rich paint, when holes have to be drilled in them at site for bolting to
equipment/structure.
The substation consisting of structure, transformer, fence and gate shall be properly
earthed. Wherever earthing conductor crosses underground service duct and pipes, it
shall be laid 300 mm below them. If the distance is less than 300 mm, the earthing
conductor shall be bonded to such service ducts/pipes.
14.4.8.3. Earth Electrode Pits

Electrodes shall, as far as practicable, be embedded below permanent moisture level.
Test pits with covers shall be provided for periodic testing of earth resistance.
Installation of pipe electrodes in test pits shall be suitable for watering. The necessary
materials required for installation of test pits shall be supplied and installed by
Contractor. The installation work shall also include civil works such as
excavation/drilling and connection to main earth grid.
Treated earth pits shall be treated with salt and charcoal. Soil, salt and charcoal placed
around the electrode shall be finely graded, free from stones and other harmful
mixtures. Backfill shall be placed in layers of 250 mm thick uniformly spread and
compacted. If excavated soil is found unsuitable for backfilling, the Contractor shall
arrange for a suitable soil from outside.
14.4.8.4. Earthing Conductors

Earthing conductors shall have the following minimum sizes:
Transformers, LT Panel and standby DG Set 50 x 6 mm flat GI

Interconnection to building comprising the Works
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and to the Main Earth grid 50 x 6 mm flat MS

Interconnection to PCC/MCC/PMCC 50 x 6 mm flat GI
Power factor correction capacitor panel 25 x 3 mm flat GI
Local push buttons station 14 SWG GI wire
4 SWG GI wire / Equivalent
copper flexible wire
12 SWG GI wire/Equivalent
copper flexible wire
Outdoor Street lighting 8 SWG GI wire
Ladder rack and cable tray at suitable points 25 x 3 mm flat GI
Hand rails and metallic structures, crane rails, 25 x 3 mm flat GI
air handling ductwork etc.
14.4.8.5. LV Motors
Up to 10 kW 8 SWG GI wire
10 to 20 kW 4 SWG GI wire
Above 20 kW 25 x 3 mm flat GI
Notes:
1. Definitions: GI is galvanized Iron; MS is mild steel.
2. Equipotential conductors shall interconnect between the device to be bonded and the
main equipotential conductor.
3. Connections to building structural steelwork or concrete reinforcement shall be made
by a bolted connection to a tag welded to the steelwork or reinforcement bars. Unless
otherwise specified at least two connections shall be made to the steelwork and
reinforcement bars at the perimeter of each building at diagonally opposite locations.
4. Location of earth electrode/ earth conductor shall be decided at site to suit actual
location of trays, trenched electrical equipment’s and pipe sleeves.
5. All instruments and PLC/SCADA shall be earthed by copper wires/strip connected to
independent copper earthing pit as per manufacturer recommendation.
14.4.9. LIGHTING SYSTEM
14.4.9.1. General
The contractor shall execute all works related to lighting system of all STP buildings,
plant area and roads. The contractor shall provide all indoor & outdoor LED lighting
fixtures complete with driver, high mast for plant area lighting, ceiling fans complete
with speed controlling device, exhaust fan, receptacles, MCB, main lighting panel,
lighting panels for each building, earthing, ACs for control room & office and all other
miscellaneous works required to fulfil the lighting system as per site requirement and
as decided by Engineer-in-charge.
Illumination levels shall be maintained as per IS 3646 (Part-1)- 1992 and as below:
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Sr. Intensity required

Description
No. ( Lux)
Pump House/ Blower House/ MCC Room/ Guard

1. 200 lux
Room/ Meter Room/ Bedroom/ Pantry & Kitchen
Workshop/ Store Room/ Centrifuge Building/

2. 150 lux
Chlorine Room/ Tonner Room/
3. Office/ PLC Room/ Laboratory 300 lux
4. All other indoor areas 150 lux
5. switch yard 50 lux
6. outdoor plant/Street lighting 20 lux
All indoor & outdoor lighting fixtures shall be LED type suitable for operation on a
nominal supply of 240 V, single phase, 50 Hz, AC with a voltage variation of +/- 10 %.
Outdoor lighting fixture shall be weather-proof and rain proof type. All lighting fixtures
shall be designed for continuous trouble free operation and supplied with driver and all
necessary accessories for their satisfactory operation. The fixtures shall be designed
so as to facilitate easy maintenance including cleaning, replacement of component.
14.4.9.2. Lighting System of Buildings

Lighting system of Buildings includes the following work:
(i) Cabling, conduiting, internal wiring, lighting fixtures (LED decorative type),
receptacles, ceiling & exhaust fan, lighting panels, other associated
components and support material.
(ii) LED decorative light fixture shall be ceiling/ recess/ suspended mounted type
made from CRCA sheet steel housing, high purity/ transmisivity diffuser for
uniform light distribution. High efficiency driver electronics having efficiency
>85% and in compliance to IEC standards (integral driver). Life time of 50000
burning hours with 70% initial lumens maintained. CCT 3000 K, 4000 K and
6000 K. Fixture shall be CE compliance.
(iii) Earthing.
14.4.9.3. Plant Area Lighting

Plant area lighting shall be done by 16/20 M high mast (in 2 section) lighting system.
High mast shall be hot dipped galvanized and consisting of lantern carriage for up to
12 nos. luminaries, mast head assembly, 2 nos. aviation obstruction lights, double
drum type self-sustaining winch, integral power tool (winch motor with control circuit),
lightening finial, suitable ropes and CC foundation of M-15 grade complete with Panel,
internal cables, high power LED flood lights as required. The mast shall be constructed
from mild steel plates (as per BS-EN 10025) cut and folded to form a polygonal
section, telescopic jointed and welding as per BS 5135. Number of high mast and its
luminaries shall be worked out considering 20 lux levels throughout outdoor plant area.
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LED flood light shall be IP-66 protected with extruded aluminum housing, toughened
glass diffuser with suitable lenses on LED to achieve various beam angles, 240 volts,
50 Hz of high power LED lamps supplied with pre wired cable of 1 mtr. Integrated
driver shall be high efficiency (>85%) and in compliance to IEC standards. System life
of 50000 burning hours with 70% of initial lumen be maintained. Fixtures shall be CE
compliance.
14.4.9.4. Street Lighting and Building Exterior Illumination

Street lighting LED luminaire shall be used for illumination of secondary roads,
walkways, peripheral lighting of the premises, building exterior.
Poles for street lighting shall of heavy gauge MS, stepped solid drawn seamless pipe
in section 139.7 x 114.3 x 88.9mm dia (5mt + 2 mt + 2mt) with base plate 300 x 300 x
6mm. The total length of pole shall be 9mts. The pole shall be fitted with bend arm of
40mm dia centrally reverted angle of tilt 15 degrees and over hang 2000mm with
weather proof junction box, connector, MCB, cover and cable entry and leaving holes.
Pole shall be erected truly vertical. 25mm dia light class GI pipe 1.5 mt long shall be
provided for cable entry into water tight terminal boxes. The junction box of CI/MS shall
be adequate size so as to accommodate MCB, connector etc. at suitable operating
level.
Building exterior illumination shall be done by LED street light fixture on single arm
bracket mounted on building exterior wall.
Street light luminaries shall be IP-66 protected made from powder coated single piece
pressure die cast aluminium housing with heat dissipation fins on housing with high
power LEDs. Diffuser/glass cover for ensuring IP-65 protection for lamp and control
gear compartment, system lumen output of 100 lum/watt high power LED. Integrated
driver shall be high efficiency (>85%) and in compliance to IEC standards. System life
of 50000 burning hours with 70% of initial lumen be maintained. Fixtures shall be CE
compliance.
Each lighting fixture shall be provided with an earthing terminal. All metal or metal
enclosed parts of the housing shall be bonded and connected to the earth terminal to
ensure satisfactory earthing continuity throughout the fixture.
14.4.9.5. General Lighting Requirements

(i) Provide a lighting fixture for each lighting outlet as per the Lighting Schedule
(ii) Provide complete fixtures including glassware, diffusers, lenses, canopies,
sockets, reflectors, ballast, wiring, hangers and any other auxiliaries necessary to
complete such fixture installation.
(iii) Verify ceiling materials employed and co-ordinate fixtures to mount to the ceiling
system used.
(iv) All lighting fixtures and fittings shall be ISI marked.
(v) Provide support materials of all types necessary to secure lighting fixtures to the
building structure. Such support shall include all material required to support
lighting fixtures to the basic building structural members. Method of support shall
comply with local codes and ordinances effecting each type of installation.
(vi) Submit an initial sample of each fixture and obtain an approval from ENGINEER-
IN-CHARGE before manufacturing total quantities required.
(vii) The actual location of fixtures shall be as per the site condition and shall be
finalized with the Engineer-in-charge before starting the work.
34
(viii) All products shall be as per Indian Standards

(ix) The decision of the Engineer-in-charge regarding the acceptability of any fixture
shall be final.
14.4.9.6. Lighting Panels for Different Units of Building

(i) Lighting/power panels shall be manufactured with 1.6 mm cold rolled sheet and
shall be dust and vermin proof. All accessible live connections/metals shall be
shrouded and it shall be possible to change individual MCBs from the front of the
board panels without danger of contact with live metal. Indoor type panel shall have
IP42 degree of protection and shall be suitable for surface or flush mounting on wall
surface. Outdoor panel shall be IP55 weather protected with integral canopy.
(ii) Lighting/power panels shall have TPN incoming feeder and single phase outgoing
feeders. Lighting circuit feeders shall be rated for 10A and power circuit feeder for
16A. AC unit power circuit feeder shall be rated for 20A or more as per AC ratings.
The incomer shall be with MCB and ELCB unit.
(iii) Each circuit phase & neutral shall be given ferrule numbers. Complete wiring inside
the panel shall be neatly bunched with PVC tape and button. The panel shall have
knock out holes or removable gland plate for the entry of incoming and outgoing
conduit or cables.
(iv) The Main Distribution Board (MDB) shall be made of 2 mm thick sheet steel panel,
dust and vermin proof similar in construction to lighting/power panel but with TPN
MCCB and TPN outgoing (MCB with ELCB) of required number. All MCB shall be of
M9 category and sensitivity of ELCBs shall be 100-300 mA.
14.4.9.7. Fixture Location

(i) Prior to installing fixture outlets, approval from ENGINEER-IN-CHARGE is
necessary.
(ii) Locate fixtures to suit site condition and as directed by the Engineer-in-charge.
(iii) Locate fixtures symmetrical with patterns and room dimensions.
(iv) Fixture outlets shall be accessible and fixtures shall hang clear of ducts and piping.
(v) Verify exposed duct and piping locations prior to final location of electrical outlets.
(vi) Adjust outlet locations to co-ordinate with ducts and piping.
(vii) Follow standard mounting heights.
14.4.9.8. Fixture Support and Installation Conditions

General
(i) Lighting installation shall be carried out strictly in accordance with relevant Indian
Electricity Rules, I.S. codes of practice, Fire Insurance and other applicable codes
and regulation.
(ii) Lighting fixtures, receptacles and junction boxes shall be properly earthed along
with the Lighting Wires/Cables.
(iii) All junction boxes shall be fabricated from galvanized iron sheet steel as per I.S.
2667.
(iv) Lighting wiring from lighting panel to junction box shall be carried out with 2.5 mm2
PVC insulated FRLS flexible copper conductor and from junction box to lighting
fixture with 1.5 mm2 PVC insulated FRLS flexible copper conductor.
(v) A separate neutral shall be provided for each circuit.
35
(vi) Red/Yellow/Blue wires for phases, black wire for neutral and green wire for earth
shall be used (size of earth wire shall be same as for phase and neutral size).
14.4.9.9. Fixture
(i) Provide material required for complying with code requirement. Install in perfect
vertical and horizontal alignment.
(ii) Support surface fixtures with a minimum of 2 fastenings per fixture, located near
each end of fixture.
(iii) Locate fastening for all surface-mounted fixtures to provide maximum fixture
support and optimum fixture alignment.
(iv) Individually mounted, suspended fixtures shall have a minimum of two supports per
fixture.
(v) Fastening for suspended fixture supports attached to concrete slab shall consist of
a minimum of 10mm screws fastened to concrete inserts for each individual fixture
support.
(vi) Provide canopies on stems fitting to and concerning outlet boxes and support
devices.
(vii) Cable entries shall be sealed with cable compound.
14.4.9.10. Expansion Shield Anchors

Expansion shields may be used for supporting lighting fixtures instead of concrete
inserts under the following conditions:
(i) Fastening and expansion shield anchors shall be one trade size larger than
specification requirements for fastening used with concrete inserts.
(ii) Holes for expansion shield anchors, clinch anchors, etc. shall be self-drilled with
carbide tipped rotary type concrete drills.
(iii) Drill holes for expansion shields carefully in a workmanlike manner. Drill to the
depth of the expansion shield anchor and in a manner that will develop the full
strength of the fastening.
14.4.9.11. Receptacles
The Contractor/ bidder shall provide suitable number of indoor receptacles as per
requirement of site conditions.
General
(i) Protective metallic plug and deeply recessed contacts in the sockets shall be
provided such that it gives very high degree of safety for operating personnel
against risk of accidental exposure of live contacts.
(ii) Earthing connection of plug while inserting and removing shall be made first and
broken after the main circuit connections.
(iii) Plug shall be provided with compression gland to grip the cable firmly.
(iv) Casting of plug, sockets and conduit boxes shall be of non-corroding Die-cast
Aluminium alloy.
(v) Guide pin shall ensure the non-reversibility.
(vi) Receptacle Type Z-2
Receptacle Z-2 shall be 15 or 20-Ampere single phase metal clad totally enclosed
wall-mounting type, interlocked switch, socket and plug unit shall conform to the
relevant Indian Standards. Switch shall be interlocked with plug such that plug
36
cannot be inserted or removed while the switch is in `ON' position. Plug and sockets
shall be Crompton make ASSP 20 type.
(vii) Office Receptacles Type Z1
Receptacle shall be single phase 15 Ampere multi-pin, plus ground plastic moulded
with switch, fuse and plug mounted in common enclosure. Receptacle shall conform
to IS 1293 and switch shall conform to IS 3854.
14.4.9.12. Exhaust Fans

Sufficient Nos. & required size of heavy duty Exhaust fans (Industrial type) of approved
make shall be provided in Blower house, MCC room, workshop/store room, sludge
sump house, chlorine room, laboratory, meter room etc. Suitable exhaust fan shall also
be provided in toilets, pantry, kitchen etc. Noise free, wall cowl acoustic lining shall be
provided and fixed as per direction of Engineer-In-Charge.
14.4.10. LT PANEL WITH CAPACITOR BANK
14.4.10.1. GENERAL
The offered Panel shall be brand new with state of the art technology and proven field
track record. Vendor shall ensure availability of spare parts and maintenance support
services for the offered equipment at least for 10 years from the date of supply.
The panel shall be free standing floor mounted with complete front access for
operation and maintenance. The panel shall be fixed type (draw out type for ACB
feeder) in single front execution, assembled in single line up, metal enclosed, fully
compartmentalised, totally segregated compartments for feeders, cables and bus bar,
dust and vermin proof suitable for indoor installation.
All hardware shall be corrosion resistant. All joints and connections of the panel
members shall be made of galvanised or zinc passivated cadmium plated high quality
steel bolts, nuts and washers secured against loosening. All openings, covers and
doors shall be provided with gaskets around the perimeter to make the switchboard
dust and vermin proof. Suitable lifting hooks shall be provided for each shipping
section for ease of lifting of panel.
The panel shall comprise of incoming ACB and Bus-coupler ACB with required
protection, digital multi-function meter, surge protection device, indication lamps.
Outgoing shall consist of Soft Starters/ Automatic Star-delta Starters, DOL Starters,
MCCBs, digital multi-function meter, L/R selector switch, start-stop push button,
indication lamps, suitable rated heavy duty MD/APP bank of capacitors with MCCB,
capacitor duty contactor, APFC relay etc. complete with required protections. Panel
shall also comprise control supply transformer, both power and auxiliary/control bus
bars, cable termination compartments etc. The incomer of the panel shall be
electrically & mechanically interlocked so that only one incomer (main or DG supply) is
On at a time.
All feeders shall be of modular design with height in multiples of standard unit size. All
auxiliary devices for control, indication, measurement and protection except the
37
bimetallic relays shall be mounted on the front side of the respective compartment.
Components requiring frequent inspection during operation shall be easily accessible.
Panel shall be SCADA compatible.
14.4.10.2. CONSTRUCTIONAL FEATURES

The Panel shall be sheet steel clad with the frame fabricated out of 2 mm CRCA sheet
steel and doors/cover out of at least 1.6 mm CRCA sheet steel.
All doors shall be supported by strong hinges of the disappearing or internal type and
braced in such a manner as to ensure freedom from sagging, bending and general
distortion of panel or hinged parts. All floor mounted panels shall be provided with a
channel base frame. Total height of all floor mounted panels shall not be greater than
2300 mm. Panel shall be dust and vermin proof. Degree of protection of the enclosure
shall be IP 42 for indoor installations and IP 55 with rain canopy for outdoor
installations.
Metal clad cubicles/modules shall be provided with hinged doors in the front, with
facility for padlocking door handles. More than one module may be arranged in the
same vertical section. Circuits shall be of the fixed type. The switchboard enclosure
shall conform to “Form - 4” as per IS-8623. It shall be possible to extend the
switchboard on both sides.
The fixed type module shall have all the circuit components mounted in the
compartment, with bolted type power and control connections. It shall be possible to
remove all circuit components after removing the connections and the component
fixing bolts. Instruments, relays and control devices shall be mounted flush on hinged
door of the cubicles. Switchboard shall be complete with inter-panel wiring.
Panel shall also be fitted with a label indicating its title. Each cubicle shall be fitted with
a label on the front and rear of the cubicle. Each relay, instrument, switch, contactor
and MCCB/MCB shall be provided with a separate label. One metal sheet shall be
provided between two adjacent vertical sections running to the full height of the
switchboard except for the horizontal bus bar compartment. However, each shipping
sections shall have metal sheets at both ends. After isolation of the power and control
connections of a circuit, it shall be possible to carry out maintenance in a compartment
safely, with the bus bars and adjacent circuits alive.
14.4.10.3. BUS-BAR
The bus bars shall be suitable for 4 wire, 415 volts, 50 Hz system and shall be made of
high conductivity electricity conductor grade electrolytic AL 91E. In case of copper bus
bar it shall be electrically conductor grade electrolytic copper and at the time of joining
of two copper buses tinning will be done on the copper strips ends to a length equal to
the lap length of the joint plus one each. The phase and neutral bus bars shall be of
rating indicated in the corresponding BOQ/one line diagram. The bus bars shall have
uniform cross section throughout and shall be provided with minimum clearances as
specified in relevant IS.
38
The bus bars shall be capable of carrying the rated current at 415 volts continuously
and will run in a separate bus bar chamber All bus bars and bus taps shall be insulated
with close fitting sleeve of hard, smooth, dust and dirt free, heat shrunk PVC insulation
of high dielectric strength, to provide a permanent non-ageing and non-tracking
protection, impervious to water, tropical conditions and fungi. The insulation shall be
non-inflammable and self-extinguishing type and in fast colors to indicate phases. The
dielectric strength and properties shall hold good for the temperature range of 0 to 95
degree centigrade. If the insulating sleeve is not coloured, bus bars shall be colour
coded with coloured PVC tape at suitable intervals.
Bus bar joints shall be of the bolted type. Spring washers shall be provided to ensure
good contact at the joints. Bus bars shall be thoroughly cleaned at the joints and
suitable contact grease shall be applied just before making a joint. Direct access to, or
accidental contact with bus bars and primary connections shall not be possible. All
apertures and slots shall be protected by baffles to prevent accidental shorting of bus
bars due to insertion of maintenance tools. Sequence of red, yellow and blue phases
and neutral for four-pole equipment shall be left to right and top to bottom, for
horizontal and vertical layouts respectively.
14.4.10.4. AIR CIRCUIT BREAKER
14.4.10.4.1. GENERAL
Air circuit Breaker shall comply with latest IEC/IS standards. All four pole Breaker shall
be capable of setting Neutral Protection to N or N/2 to ensure precise neutral
Protection. Breaking Capacity of Breaker in Panel shall be Ics = Icu at 440V & Ics = Icu
= Icw (for 1sec). All ACB shall have Fault indication LEDs on release.
ACB shall have indication of Mechanical wear of Contacts, enabling visible indication
of Contact life. All ACBs should have the moulded case design with class 2 front facia.
The accessories like shunt trip, closing trip coils should be continuously rated to avoid
the Burning due to sustained command.
14.4.10.4.2. OPERATING MECHANISM

ACB shall be EDO type. The operating mechanism shall be of the Open/Closed/Open
stored-energy type. The closing springs shall be able to be manually charged by
operating the front lever. The circuit breaker shall be of trip free type and shall be
provided with built-in mechanical Anti Pumping device. Closing coil & other auxiliary
devices shall be available in sufficient number for the purpose of indication, alarms,
annunciations on switch boards as well as on respective remote control panel in
control room & for the purpose of interlocking scheme shall be provided
There shall be four distinct & separate position of the circuit breakers on the cradle as
– Service / Test / Isolated / Maintenance. The first three positions shall be positively
achieved only through the racking motion of draw out mechanism & not by trail & error.
There shall be indicator clearly showing the above 3 conditions.
14.4.10.4.3. PROTECTION & MEASUREMENT FUNCTION

All ACBs shall have microprocessor based releases capable of sensing true rms value
of current based on digital technology. Protection unit shall offer following as standard
in all breakers excluding bus couplers: Long-time protection with adjustable time delay.
39
Instantaneous or Short circuit protection with time delay. The short circuit setting (Isd)
should necessarily be the function of the set current (Ir) of the ACB. The instantaneous
protection shall have the option of OFF position in case of certain conditions of
discrimination. Earth fault protection with adjustable current and time setting along with
separate adjustable setting for instantaneous short circuit protection.
All the adjustments should be on line & the circuit breaker need not be switched off
while adjusting the settings.
The control unit shall have thermal memory for repetitive over current faults for
protecting the cables & loads. Breaker shall have facility of Zone selective interlocking
without needing any external control supply.
14.4.10.5. MOULDED CASE CIRCUIT BREAKER (MCCB)

MCCBs shall be of the air break, quick make, quick break and trip free type and shall
be totally enclosed in a heat resistant, moulded, insulating material housing. MCCBs
shall have an ultimate short circuit capacity not less than the prospective short circuit
current at the point of installation.
MCCBs shall have a service short circuit breaking capacity equal to the ultimate short-
circuits capacity. Each pole of MCCB shall be fitted with a bi-metallic thermal element
for inverse time delay protection and a magnetic element for short circuit protection.
Alternatively, they shall be fitted with a solid state protection system. Such a protection
system shall be fully self-contained, needing no separate power supply to operate the
circuit breaker tripping mechanism. Thermal element shall be adjustable (70-100%).
Adjustments shall be made simultaneously on all poles from a common facility.
Thermal elements shall be ambient temperature compensated. The MCCBs shall be
provided with the following features:
(i) Common trip bar for simultaneous tripping of all poles.
(ii) Shrouded terminals
(iii) Time for clearing short circuit current of 20 msec.
(iv) 2 NO + 2 NC auxiliary contacts
14.4.10.6. MINIATURE CIRCUIT BREAKER (MCB)

MCB shall be hand operated, air break, quick make, quick break type. Operating
mechanisms shall be mechanically trip-free from the operating knob to prevent the
contacts being held closed under overload or short-circuit conditions.
Each pole shall be fitted with a bi-metallic element for overload protection and a
magnetic element for short-circuit protection. Multiple pole MCBs shall be mechanically
linked such that tripping of one pole simultaneously trips all the other poles. The
magnetic element tripping current classification shall be of the type suitable for the
connected load. Where this is not specified, it shall be Type C. The short circuit rating
shall be not less than that of the system to which they are connected.
14.4.10.7. CONTACTOR
The power contactors used in the panel shall be of, air break, single throw, triple pole,
electromagnetic type. Contactors shall be suitable for uninterrupted duty and rated for
Class AC3 duty in accordance with the latest edition of IS 13947. Operating coils of all
contactors shall be suitable for operation on 240 V, single phase, 50 Hz supply.
Contactors shall be provided with at least two pairs of NO and NC auxiliary contacts.
Contactors shall not drop out at voltages down to 70 % of coil rated voltage.
40
Contactors shall be provided with a two element, positive acting, ambient temperature
compensated, time lagged, hand reset type thermal overload relay with adjustable
settings. The hand reset button shall be flush with the front door of the control module,
and shall be suitable for resetting the overload relay with the module door closed.
Relays shall be either direct connected or CT operated. Overload relay and reset
button shall be independent of the "Start" and "Stop" push buttons. All contactor shall
all be provided with single phasing preventer (SPP). Motor starters shall be complete
with auxiliary relays, timers and necessary indications.
14.4.10.8. INSTRUMENT TRANSFORMER

Current transformer (CT) shall have polarity markings indelibly marked on each
transformer and at the lead terminations at the associated terminal block. CT shall be
able to withstand the thermal and mechanical stresses resulting from the maximum
short circuit current. CT core laminations shall be of high grade silicon steel.
Secondary winding of voltage transformer (VT) shall be rated for a two phase line to
line voltage of 110 V. Identification labels giving type, ratio, output and serial numbers
shall be provided.
14.4.10.9. RELAY
Main protective relays shall be Numerical / Static type. All relays shall be enclosed in
rectangular shaped, dustproof cases and shall be suitable for flush mounting. All relays
shall be accessible from the front for setting and resetting. Access to setting devices
shall be possible only after the front covers of the relays are removed. Resetting
facilities shall however be accessible external to the relay case. All protective relays
shall be of the draw-out type and shall be provided with operation indicators visible
from the front. Auxiliary relays and timers shall be rated to operate satisfactorily
between 70 % and 110 % of the rated voltage.
14.4.10.10. SOFT STARTER & VFD

Soft Starter and VFD may or may not be integral part of LT Panel as required.
Specification of Soft Starter & VFD is given separately.
14.4.10.11. AUTO TRANSFORMER STARTER

Auto Transformer Starter shall be air cooled type suitable for reduced voltage starting
of raw sewage pump motor of required rating and duty condition. It shall consist of all
required components including but not limited to the following:
Incomer MCCB, power contactors, Auto Transformer 50/65/80% taps suitable for 6
starts/hour, overload relay, timer, control relays, CT, Ammeter & Voltmeter with
selector switch, multi-function meter, required protections (earth fault, phase failure,
under and over voltage, under current, current unbalance, phase unbalance, phase
reversal, lock rotor, single phase preventer), LED indication lamps for R/Y/B, on/off/trip,
add on block for contactor, contact block for push button, MCB, enclosure.
14.4.10.12. CAPACITOR BANK

Capacitor bank shall be part of the LT Panel and shall consist of heavy duty MD/APP
bank of capacitors (combination of individual capacitors as per motor loads) with APFC
relay, MCCB, capacitor duty contactor, de-tuner, indication lamps, selector switch,
push button, auxiliary contactor, MCB etc. complete with all accessories.
41
Total and individual rating of capacitors to be put in bank shall be confirmed prior to
fabrication of capacitor bank.
14.4.10.13. CONTROL AND SELECTOR SWITCH

Control and selector switches shall be of the rotary type, having enclosed contacts,
which are accessible by the removal of the cover. Control and selector switches for
instruments shall be flush mounted on the front of the panels and desks. All control
switches shall be of the spring return to normal type and shall have momentary
contacts. Selector switches shall be of the stay-put, maintained contact type.
14.4.10.14. INDICATING INSTRUMENT & METER

All indicating Instruments shall be flush mounting 96x96 mm digital type with
accuracy class 1.0 and RS 485 communicable port for direct connection to SCADA
using the Modbus protocol. Digital multi-function meter shall indicate following
parameters; V, A, F, PF, KW, KVA, KVAR, KWh, KVAh, KVARh, run hours, on hours,
Phase angle, interrupts, THD, events, neutral current.
14.4.10.15. INDICATING LAMP

Indicating lamps shall be of the cluster LED type, with low watt consumption.
Indicating lamp shall be of the double contact, bayonet cap type rated for operation at
either 240 V AC or at the specified DC system voltage as applicable. Lamps shall be
provided with translucent lamp covers. Bulbs and lenses shall be interchangeable
and easily replaceable from the front.
14.4.10.16. PUSH BUTTON

"Start" and "Stop" push buttons shall be coloured green and red respectively. Stop
Push Button shall be lockable stay-put type with Mushroom head. Colours of push
buttons shall generally comply with IS6875, BSEN 60947, 60 0 37 or IEC 60073.
14.4.10.17. SPACE HEATER

Adequately rated anti-condensation space heaters shall be provided, one for each
control panel, for each switchboard and for each marshalling kiosk. Space heater shall
be of the industrial strip continuous duty type, rated for operation on a 240 V, 1 phase,
50 Hz, AC system. Each space heater shall be provided with a single pole MCB with
overload and short circuit release, a neutral link and a control thermostat to cut off the
heaters at 45° C.
14.4.10.18. CUBICLE LIGHTING/RECEPTACLE

Each control panel, control cabinet, marshalling box, etc. shall be provided with interior
lighting by means of a CFL/LED lighting fixture. A Miniature Circuit Breaker (MCB)
shall be provided for the lighting circuit. The lighting fixture shall be suitable for
operation from a 240 V, 1 ph, 50 Hz, AC supply. A 240 V, 1 phase, AC receptacle
(socket) plug point shall be provided in the interior of each panel with a MCB for
connection of hand lamp.
42
14.4.10.19. SAFETY ARRANGEMENT

All terminals, connections and other components, which may be “live” when front
access door is open, shall be adequately screened. It shall not be possible to obtain
access to an adjacent cubicle or module when any door is opened. Components within
the cubicles shall be labelled to facilitate testing.
14.4.10.20. POWER AND CONTROL CABLE TERMINATION

Equipment terminal blocks for power connections shall be complete with adequate
phase segregating insulating barriers, shrouds and suitable crimping type of lugs for
terminating the cables. Double compression type cable glands shall be provided for all
power and control cables. Earthing connectors between cable armour and earth shall
be routed outside the cable gland in an approved manner. Gland insulation shall be
capable of withstanding a high voltage test of 3000 V for one minute.
14.4.10.21. WIRING FOR CONTROL AND PROTECTIVE CIRCUIT

All wiring for control, protection and indication circuits shall be carried out with 650 V
grade, FRLS PVC insulated cable with stranded, tinned copper conductor of minimum
1.5 sq. mm size. The size of conductor for CT circuits shall be minimum 2.5 sq. mm.
All wiring shall be run on the sides of panels and shall be neatly bunched and cleated
without affecting access to equipment mounted in the panel. All wiring shall be taken to
terminal blocks without joints or tees in their runs. All wiring shall be colour coded as
given below:
(a) Instrument Transformer : Red, Yellow or Blue determined by the
Circuit phase with which the wire is associated
(b) A C phase wire : White
(c) A C neutral : Black
(d) D C circuits : Grey
(e) Earth connections : Green
Engraved core identification ferrules, marked to correspond with the wiring diagram,
shall be fitted to each wire and each core of multicore cables terminated on the panels.
Ferrules shall fit tightly on wires, without falling off when the wire is removed. Ferrules
shall be of yellow colour with black lettering.
All wires forming part of a tripping circuit shall be provided with an additional red ferrule
marked 'T'. Each wire shall be identified by a letter to denote its function followed by a
number to denote its identity, at both ends. Unused core of multicore cables shall be
ferruled U1, U2 etc., at both ends, and connected to spare terminals. Spare auxiliary
contacts of electrical equipment shall be wired to terminal blocks.
14.4.10.22. CONTROL WIRING TERMINAL BLOCK

Terminal blocks shall be of the 650 V grade and stud type. Brass stud of at least 6 mm
dia. with fine threads shall be used and securely locked within the mounting base to
prevent turning. Each terminal shall comprise two threaded studs, with a link between
them, washers, and matching nuts and locknuts for each stud. Connections to the
terminals shall be at the front.
Terminals shall be numbered for identification, grouped according to function.
Engraved ‘black on-white’ labels shall be provided on the terminal blocks describing
the function of the circuit. Terminals for circuits with voltage exceeding 110 V shall be
43
shrouded. Terminal blocks at different voltages shall be segregated into groups and
distinctively labelled.
Terminals used for connecting current transformer secondary leads shall be
‘disconnecting and shorting’ type with a facility grounding the secondary.
Terminal blocks shall be arranged with 100 mm clearance, between any two sets.
Separate terminal stems shall be provided for internal and external wiring relatively.
All wiring shall be terminated on terminal blocks, using crimping type lugs or claw
type of terminations.
Test terminal blocks, if any, shall be provided for secondary injection and testing of
relays. A suitable metering block shall be provided where specified for the connection
of a portable precision instrument to be operated when required for specific plant
testing purposes.
14.4.10.23. EARTHING OF PANEL

Each panel shall be provided with an earth bus bar running along its entire length.
The earth bus bar shall be located at the bottom of the panel. Earth bus bar shall be
properly supported to withstand stresses induced by the momentary short circuit
current of value equal to the momentary short circuit rating of the associated panel.
Positive connection of the frames of all the equipment mounted in the panel to the
earth bus bar shall be maintained through insulated conductor of size equal to the
earth bus bar or the load current carrying conductor, whichever is smaller.
All instrument and relay cases shall be connected to earth bus bar by means of 650
V grade, green coloured, PVC insulated, stranded, tinned copper, 2.5 sq. mm
conductor looped through the case earth terminals.
14.4.10.24. TECHNICAL PARTICULARS

The specific technical particulars of the panel shall be as given below:
Ser
Description Particulars
No
1. Rated voltage, Phases and Frequency 433 V, 3 Ph, 50 Hz
2. Type of Construction Single front, fixed type
(except for ACB)
3. Maximum system voltage 476 V
4. One minute Power Frequency
withstand voltage
a) Power circuit 3000 V (rms)
b) Control Circuit 2000 V (rms)
5. Auxiliary circuit connection to 2000 V (rms)
secondary of CTs
6. Current rating of busbars over design (*)
ambient temperature of 45oC
7. Short circuit withstand for main and (*)
auxiliary busbars (1 sec.)
8. Maximum temperature of main and 85 degree C
auxiliary busbars at continuous rated
current rating under site design
ambient temperature of 45degree C
44
Ser
Description Particulars
No
9. Colour finish shade as per IS:5
10. Interior Glossy white
11. Exterior Light grey, semi-glossy,
shade 631 of IS 5
12. Earthing bus material and size Copper, 25 x 6 mm
13. Clearances in air of live parts 25.4 mm
14. Power contactors
a) Contactor rated duty AC3
b) Utilisation category Uninterrupted
15. Motor Starters Auto Transformer, Star-
Delta, DOL Starters
18. Type of Mounting Floor
19. Cable Entry (*)
(*) To be worked out by the contractor based on approved calculations submitted by
the contractor.
14.4.11. L.T. BUS DUCT
14.4.11.1. SCOPE
This section covers design, manufacture, inspection, transportation to site, installation,
testing and commissioning of Low voltage bus duct for connection between
Transformer secondary and LT panel.
14.4.11.2. GENERAL
The layout of the bus ducts shall be prepared in line with the site conditions and shall
be got approved by Engineer-in-charge. All parts and accessories shall have
appropriate match mark and part numbers for easy identification and installation at
site.
14.4.11.3. STANDARDS
The bus duct works shall conform to up-to date amendments and relevant
standards/code as applicable.
14.4.11.4. DESIGN
Bus duct shall be Non-segregated phase suitable for 415 volts, 3 Phase & Neutral, 50
Hz, AC supply both indoor and outdoor installation as per site requirement. Bus duct
shall be designed to withstand the fault level of 50KA for 1 second. Bus duct shall be
designed for continuous current rating as given in the BOQ.
14.4.11.5. CONSTRUCTION
14.4.11.5.1. ENCLOSURE
All the three phases shall be enclosed in a weather proof, dust tight enclosure,
Outdoor section of the bus duct shall be completely rain proof. Weather resistant type
circumferential gaskets shall be provided for making the joints with adjacent
45
enclosures dust – proof and impervious to moisture suitable inspection opening with
gaskets shall be provided for access to support insulator, lugs joints etc. Bus duct
enclosure shall be made of 14 swg. (2mm) CRCA sheet steel, for bus rating below
3000A. The degree of enclosure protection shall be IP 52 for indoor application and
IPW-55 with canopy for outdoor section of the bus duct. All ventilation openings shall
be screened and drains shall be filtered to prevent entrance of dust and vermin.
Suitable means shall be provided to isolate the transformer vibration from rest of the
bus duct. For continuous operation at specified ratings, temperature rise of the bus
duct and auxiliary equipment shall be limited to the site permissible values stipulated in
relevant standards and/or this specification. Bus duct and auxiliary equipment shall be
capable of withstanding the mechanical forces and thermal stresses of the short-circuit
currents without any damage or deterioration of material. The L.T. bus ducts shall be
self-cooled and shall not be equipped with blower or any other type of forced
ventilation.
14.4.11.6. DETAILED SPECIFICATIONS
14.4.11.6.1. BUS-BARS
(a) Material
Bus bars shall be made up of high conductivity electrolytic quality aluminum as
specified in BOQ with maximum temperature limited to 85 deg. C (i.e. 35 deg. C rise
over 50 deg. C ambient).
(b) Current density

The Aluminum bus bars shall be of sufficient cross section. The design current density
of 1Amp/Sq. mm for aluminum bus bars shall be maintained. However, the design
shall be suitable for the 50 KA fault level.
(c) Neutral bar rating

The rating of the neutral bar shall be minimum 50% of the phase bar.
(d) Joints
Adequate contact pressure shall be ensured by means of two bolt connection with
plain & spring washers and locknuts. All bus joints shall be silver plated. Bimetallic
connectors shall be provided for connections between dissimilar metals. The bus
conductor shall be designed for bolted connections throughout the run. Joints for the
bus bar shall be bolted but joints of construction with double cover fish plates and with
adequate contact area.
(e) Insulation & supports

Bus bars and connections shall be fully insulated for working voltage with heat shrink
colour coded PVC insulating sleeves. Bus insulators shall be flame-retardant, non-
hygroscopic, track resistant type with high creepage surface materials like fiber glass
reinforced thermosetting plastic/ epoxy/ FRP. The supports shall be made of single
piece. They shall withstand without any damage or deformation the thermal and
dynamic stresses due to short circuit currents.
46
(f) Color coding

Bus bars shall be colour coded for easy identification (Red, Yellow, Blue for three
phases and Black colour for neutral for A.C 3 phase system). Heat shrinkable, colour
coded PVC insulation sleeve shall be used for this purpose.
(g) Lay out sequence

Sequence shall match both transformer and LT Panel end.
(h) Clearances & creepage distances

As far as possible, large phase and ground clearances and creepage distances shall
be provided on the bus bar system to minimize possibilities of fault. The clearance
mentioned below shall be minimum and maintained even at the connection point. 1
Phase to Phase – 35 mm 2 Phase to Neutral – 28 mm 3 Phase to Earth – 28 mm.
14.4.11.6.2. Hard Ware

Zinc passivated or any other superior quality standard size hard ware to be used for all
joints/ connections/ terminations at switchgear & control gear, bus bars, ground bus,
interconnections/ wiring etc.
14.4.11.6.3. Convenience of maintenance

The system shall be maintenance friendly. i.e. it should be possible to easily
connect/tighten/disconnect etc.
14.4.11.6.4. Inspection Covers

Inspection covers shall be provided at suitable intervals as required.
14.4.11.6.5. Disconnect Link

Removable bolted disconnect link shall be provided in the bus for the purpose of
isolation. Disconnect link shall consist of a removable section of conductor and shall
be so constructed as to permit easy removal or reinsertion without alignment
difficulties. The bus on both sides of the link shall be rigidly supported so that the
disconnect link is equal in mechanical strength to any other section of the bus. A
minimum clearance of 300 mm (12”) shall be provided between the disconnected bus
sections with the link removed.
14.4.11.6.6. Ventilation
The bus duct shall be natural cooled.
14.4.11.6.7. Joints, Expansion/Flexible joints

The bus bar shall be supported in such a way that the expansion/contraction does not
have undue strain on the bus and at the terminals at both ends. Circumferential
neoprene gaskets shall be provided for dust tight joints with adjacent enclosure
section. The bus enclosure shall have extended bellows or equivalent means to allow
for temperature changes and vibrations. 28 Flexible joints shall be provided in
enclosures at all points where the bus duct terminates at equipment to withstand
vibration, expansion/contraction and at suitable intervals in any straight run of the bus
duct where expansion and contraction would otherwise result in stresses in the
supporting structures. Flexible connections shall be provided between bus sections to
47
allow for expansion and contraction of the conductor. Flexible connection shall also be
provided at all equipment terminations. All contact surfaces shall be silver plated to
ensure an efficient and trouble free connection.
14.4.11.6.8. Other points

Shipping length of the bus duct shall be not more than three (3) meters in length.
Filtered drains for drainage of condensate shall be provided at the lowest points and at
such locations where accumulation of condensate can be expected.
14.4.11.6.9. Ground Bus

Two numbers of Earth bars shall run along the full length of bus duct made up of size
50 mm X 5 mm Aluminium, strip. This ground bus shall be fixed to the bus duct on the
external side. It shall have provision to connect main earth/loop earth conductors with
bolts, nuts, washers & spring washers. Metallic parts of the bus duct & associated
structures etc. shall be bonded to the ground bus for effective earthing. One end of the
earth bus shall be joined to the LT Panel side body earth lead and the other end shall
be joined to the transformer body earth.
14.4.11.6.10. Installation
All supporting structures required for hanging and/or supporting the complete bus duct
shall be provided including related civil works. These include all types of supports,
brackets, beams, channels, rods, clamps, hardware, etc. to support with wall, roof,
truss etc. Bus ducts running along the wall should be supported at intervals not
exceeding 1.5m. In case of branching, there should be a support on all branches at a
distance of 30 cms from the point of branching. Support should not be less than 40mm
X 40mm X6mm MS angle secured in an approved manner. Supports may also be
formed as brackets fixed to walls where runs are along with walls. Supports shall be
grouted on the walls. In case of ceiling suspended bus ducts, supports made of 40mm
X 40mm X6mm MS angle iron shall be provided. The horizontal interval between two
such supports should not be more than 1200mm. However, additional supports to be
given at the bends and termination points. These duct supports shall be suspended
from the C.I/MS. boxes or suitable approved suspension device provided in the ceiling
by means of 12 mm diameter MS rods. Where fish plates are available, the same can
be used for bus duct support works. Where there is no such provision, good quality
anchor fasteners of size not less than 8mm shall be used in the ceiling. 29 Seal-off
bushings complete with wall frame and support plates shall be provided where the bus
duct penetrates the building wall. The seal is to prevent free exchange of air between
two portions of the bus duct part of which is indoor while the other is outdoor. Silica-gel
breather shall be provided on both portions of the bus duct between the seal of
bushings.
14.4.11.6.11. Connections & Terminations

All matching flanges, seal-off bushings, gaskets, fittings, hardware and supports
required for termination of the bus duct at the switchgears, transformers and other
equipment shall be provided. Flexible connections both for conductor and enclosure
shall be provided. a) At all equipment termination to provide for misalignment up to 25
mm (1”) in all directions. b) Between bus duct supported from building steel to prevent
transmission of vibration. The equipment terminal connections shall be readily
48
accessible and shall provide sufficient air gap for safe isolation of equipment during
testing. If the material of bus conductor and that of the equipment terminal connectors
are different then suitable bi-metallic connectors shall be furnished.
14.4.11.6.12. Painting
Unless otherwise specified, the painting process shall be as follows:-
All steel surfaces shall be thoroughly cleaned by sand blasting or chemical agents,
as required, to produce a smooth surface free of scales, grease and rust etc. The
steel surfaces after cleaning shall be given on all sides proper coat of anti-corrosive
primer followed by two coats of powder coating painting. The bus duct shall be
finished with two coats of grey (IS 5 shade # 632) powder coated paint. Earth strip
shall be painted with green colour enamel paint. Where the painting is damaged
during transit, installation etc., and touch up painting shall be done at site. All
metallic parts involved in the installation like supports, beams, channels, brackets,
clamps, poles, hardware etc. shall be enamel painted.
14.4.11.6.13. Tests
(a) Factory Test
The routine/acceptance tests as per relevant IS may be witnessed at the
manufacturer’s works by client/ representative.
(b) Type Tests

Bus duct shall be got manufactured by only reputed bus duct manufacturers having
type tested as per IS by CPRI or other government testing laboratory on similar bus
duct (s) with minimum 50KA short circuit current with stand capacity and the type
test certificate shall be produced to the client/representative at the time of factory
test.
(c) Site Tests

In addition to the tests at manufacturer’s premises, all relevant pre-commissioning
checks and tests shall be done at site before energizing the bus duct. The following
tests are to be particularly done before connecting the bus duct.
i) Physical inspection for breakages/damages/orderliness.
ii) Insulation resistance test with 500 V Megger. The insulation resistance shall
not be less than 100 mega ohms.
iii) Earth continuity test. All test results are to be recorded and reports should be
submitted to the department.
14.4.12. VARIABLE FREQUENCY DRIVE
14.4.12.1. General
The Scope includes supply, installation, testing and commissioning of VFD as per
IEC 1800-2 or EN 61800-2 which is the “General Requirement for Variable Speed
Electrical Power Drives – Product Standard” and other applicable standard.
49
14.4.12.2. Assemblies
14.4.12.2.1. Incoming Isolation and VFD Safety Devices
The frequency controller, when mounted in an enclosure, shall be provided with an
incoming isolating device such as Moulded Case Circuit Breaker or Air Circuit
Breaker depending upon rating of the VFD. Local isolation as above is essential for
safety of operating personnel.
In addition, appropriately rated semiconductor grade fuses shall be provided for

protection of the semiconductors in the VFD. The power supply facility will not have
this protection built into it.
14.4.12.2.2. Cooling
The VFD itself shall be provided with its own cooling fan integral to the heat sink of
the unit. In addition, the enclosure of the VFD shall be provided with a cooling fan of
adequate capacity for maintaining temperature of the enclosure within the
permissible limits. Louvers meant for fresh air intake shall be covered with fine wire
mesh or foam filter to prevent ingress of dust.
Effective operation of enclosure cooling fan shall be monitored by any one of the
following methods;
Using undercurrent relay sensing failure of the cooling fan, using an air flow switch
mounted on the cooling fan ensuring proper operation of the fan.
Failure of enclosure cooling fan shall be annunciate on SCADA/ remote control

system. Failure of integral cooling fan, which results into over-temperature of the
heat sink shall trip the VFD with an appropriate annunciation in the operator
interface module.
14.4.12.2.3. Enclosure
The degree of protection shall be IP42 minimum. The controller must have
adequate free space around it to permit good air flow for cooling purposes.
14.4.12.3. Type of Converter

The type of Inverter shall be suitable for controlling the speed of standard AC
squirrel cage induction motors. This shall be of latest technology, IGBT based, with
high frequency switching (switching frequency less than 4 kHz), based on PWM
principle, producing a near-sinusoidal waveform in the output.
The Inverter shall include power conversion components, power control logic
devices and regulator circuitry. The VFD panel is likely to be installed in an AC
environment. However, under site operating conditions, the electronics (PCBs) may
still be subject to highly corrosive gases such as H2S. For this purpose, the PCBs
shall be provided with special anti-corrosive coating
50
The regulator shall be fully digital with a microprocessor controlling the output
frequency, voltage and current. The Power Rectifier should be 6 or 12 pulse
operation.
14.4.12.4. Performance
14.4.12.4.1. Rated current

The converter shall have a current rating that is at least equal to the full load current
of the controlled motor with a margin of 10%. In case of low inertia loads such as
pumps etc. ‘Normal duty’ rating of the VFD shall be applicable while for high inertial
loads ‘Heavy duty’ rating shall be applicable. The supplier of VFD shall declare both
‘normal duty’ as well as ‘heavy duty’ ratings of VFDs offered by him and select
appropriate rating for the VFD.
14.4.12.4.2. Input Filter/ Harmonic mitigation

The converter should be equipped with an Input and/or DC choke or low EMC filter
to reduce the harmonics on the supply side. The overall design shall be “Low
Harmonic” type. Refer to IEC1800-3 or (EN61800-3) which states the Variable
Speed Drive product standard relating to electromagnetic compatibility.
14.4.12.4.3. Output Overvoltage Control

As required by the application and based on VFD manufacturer’s standard, an
output side choke shall be provided for protection of motors from overvoltage in
case the output cable length exceeds the acceptable value.
14.4.12.4.4. Current Limit Range

The Variable Speed Drive current limit should be variable to a maximum value of at
least 150% of the drive rated current.
14.4.12.4.5. Speed Control Range

The drive shall have sufficient capacity to provide speed control of the motor
throughout the applications’ operating range.
14.4.12.4.6. Operating Characteristics

The VFD shall comply with the following operating characteristics:
 Allow a maximum current of 1.5 x the rated current for a maximum of 60 seconds
at rated motor frequency.
 Frequency resolution of 0.1%
 Electronic bi-directional operation
 Greater than 95% efficiency at full load and speed
 A minimum incoming line power factor throughout the load and speed range of
0.95
14.4.12.5. Protections
The VFD shall provide following protections to the drive motor:
 Motor Thermal Protection (49) should take the speed and cooling (forced or self-
cooled motor) into account and shall provide thermal protection under both “Hot”
and “Cold” condition.
 Motor Locked Rotor Protection (50 LR)
51
 Motor Negative Phase Sequence Overcurrent (which includes single phasing)

protection (46)
 Motor circuit Earth Fault Protection (50N or 50G)
 Motor Short Circuit Protection (50) should be provided on the output of the drive
against short circuits between phases and between phases and earth.
 Where thermistor probes/ RTDs are integrated into the motor, they shall be fed
back as an input to the drive.
In addition, the VFD itself shall be provided with following protections:

Supply under voltage/ failure, Supply voltage unbalance/ single phasing, VFD (heat
sink) over-temperature.
14.4.12.6. Operator Interface Module

An operator interface module (key pad) shall be provided for each VFD. This shall
provide setting and programming facility for the VFD. The interface module shall
also provide display of important operating parameters of the VFD as well as alarm
functions. The key pad portion and the display shall be available on the enclosure
door for easy access.
Indications and Alarms on Operator Interface Module:

A fault history for drive protection functions shall be provided for fault indication and
fault tracing. Fault indication shall be displayed in plain text on an alphanumeric
display.
In addition to the above fault indications, the following parameters shall be indicated
on the display in the normal operating mode:
Frequency Set point (Hz), Output Frequency (Hz), Motor Speed (RPM), Motor
Current (Amps), Calculated Motor Power (kW), Mains Voltage.
14.4.12.7. Operator Controls

The frequency converter should be provided with local and remote control functions.
Local Control: As mentioned above, a local operator interface panel shall be

mounted on the front of the enclosure provided with required operation functions.
Remote Control: Provisions shall be included for the VFD to be controlled remotely.
This may be via DIs & DOs and AIs & AOs. Necessary terminals for the input and
output functions shall be provided. The remote control may also be obtained via a
soft link over RS 485 or suitable protocol, for direct communication with the SCADA
system.
When the control function is changed from local to remote or the reverse, the
adjustments of the frequency converter shall be maintained.
The following functions shall be provided:

Uploading and downloading of pre-set parameters to a PC, Locking and unlocking
parameter settings to prevent unauthorised access.
52
14.4.12.8. Instruments and Meters

All required instruments and meters, control and selector switches, push buttons
and indicating lamps shall be provided.
14.4.12.9. Analogue and Digital I/O

Digital inputs and outputs shall be fully programmable and shall be galvanically
isolated.
The function for scaling of analogue inputs and outputs shall be fully programmable.
Facilities for selection of signal range from 0 to 20mA or 4 to 20mA or 0 to 10V or 2
to 10V shall be provided.
As a general requirement, following DIs is envisaged:

VFD ‘On’, VFD Trouble/Tripped, VFD in Remote Select
Following DOs are envisaged:
VFD Run (Single contact for On/Off control for ‘maintained’ type output and two
contacts for momentary ‘On’, ‘Off’ output)
Following AIs are envisaged:
Proportional to Speed, Proportional to Current
Following AOs are envisaged; Proportional to Speed reference
14.4.12.10. Cable Connections

Provisions for required cabling and cable connections shall be made.
14.4.12.11. Wiring
All wires for electronics and low level signals should be shielded and should be at
least 0.5mm.
14.4.12.12. Earthing
Grounds between the VFD, the motor and the cable shielding must have “high
frequency” equi-potentiality. Cables, for this purpose, shall be either shielded type
or 3 ½ core or 4 core as per VFD manufacturer’s recommendation.
Panel mounted units shall contain an earth bar to which internal earthing
conductors shall be terminated.
The normal protective conductors PE (green and yellow) should be connected to

the PE terminals on each controller.
14.4.12.13. Rating Plates and Labels

Rating plates, nameplates and labels shall have the following minimum information.
Rated voltage and frequency, Rated output capacity, Standard to which equipment
conforms, Month and year of manufacture, Manufacturers name and address, Type
and serial number, Degree of ingress protection.
53
14.4.13. SILENT DIESEL GENERATING (DG) SET
14.4.13.1. General
Scope includes supply, installation, testing and commissioning of water cooled turbo
charged silent Diesel Generating set (CPCB norms compliance) mounted and aligned
on a common M.S. base frame complete with M.S. fuel tank, Engine control panel,
AMF Panel, residential exhaust Silencer, AVM pads fitted on base frame, battery &
battery leads, 1st fill of lube oil and all housed in sound proof acoustic enclosure with 4
no’s earthing complete in all respects and as required at site.
14.4.13.2. Engine
The water cooled engine shall conform to IS-10002/BS-5514/DIN-6271/ISO-3046 at
1500 RPM capable of running the coupled alternator under conditions specified
therein. The Engine shall be fitted with following accessories subject to the design of
the manufacturer:
a) Dynamically balanced Flywheel.
b) Necessary flexible coupling and guard for alternator and engine (applicable only
for double bearing alternator).
c) Air cleaner (dry/oil bath type) as per manufacturer standard.
d) A mechanical/electronic governor to maintain engine speed at all conditions of
load.
e) Daily fuel service tank of suitable capacity fabricated from MS sheet with inlet,
outlet connections air vent tap, drain plug and level indicator (gauge), MS fuel
piping from tank to engine with valves, unions, reducers, flexible hose connection
and floor mounted pedestals, twin fuel filters and fuel injectors.
f) Dry exhaust manifold with suitable exhaust residential grade silencer to reduce
the noise level.
g) Suitable self-starter for 12 V/ 24 V DC
h) Battery charging alternator unit and voltage regulator, suitable for starting
batteries, battery racks with interconnecting leads and terminals.
i) Necessary gear driven oil pump for lubricating oil, priming of engine bearing as
well as fuel systems as per manufacturer recommendation.
j) Naturally aspirated/turbo charger (as per manufacturer standard)
k) Lubrication oil cooler
l) Lubrication oil filters with replaceable elements
m) Crank case heater as per manufacturer recommendations
n) Fuel injection, Fuel control solenoid, Fuel pump with engine speed adjustment
o) Engine Control Panel: fitted and having digital display for following;
i) Start/Stop key switch ii) Lube oil pressure indication
iii) Water temp. Indication iv) RPM indication
v) Engine hours indications vi) Battery charging indication
vii) Low lube. Oil trip indication viii) High water temp. Indication
ix) Over speed indication
p) All moving parts of the engine shall be mechanically guarded in such a manner
that a human finger cannot touch any moving part.
q) Radiator/Heat Exchanger System / Remote Radiator
r) Any other item not included / specified but is a standard design of the
manufacturer
54
s) Engine Operation/ Maintenance & Spare Parts Manual

t) Loading permitted 110% for 1 Hr. once in every 12 hrs.
u) Engine Warranty Certificate
v) Engine test certificate
w) The engine should be of as per list of approved make.
14.4.13.3. Alternator
Self-excited, screen protected, self-regulated, brushless alternator, horizontal foot
mounted in single/double bearing construction suitable for the following;
a) Rated PF : 0.8
b) Rated Voltage : 415 V
c) Rated Frequency : 50 Hz
d) No. of Phases : 3
e) Enclosure : SPDP
f) Degree of Protection : IP-23
g) Ventilation : Self ventilated air cooled
h) Insulation Class : F/H
i) Temperature Rise : within class F/H limits at rated load
j) Voltage Regulation : +/- 1 %
k) Voltage Variation : +/- 5 %
l) Overload duration/Capacity: 10% for 1 hr. in every 12 hrs. of continuous use
m) Frequency Variation : As defined by the Engine Governor (+/- 1%)
n) Excitation : Self (up to 750 KVA/ separately excited (>750)
o) Type of AVR : Electronic
p) Type of bearing & lubrication: Anti-friction bearings with grease lubrication
q) Standard : IS 4722 & IEC: 34 as amended up to date
Alternator should be able to deliver output rating at actual site conditions. The
alternator above 500 KVA shall be fitted with suitable No’s Resistance Temperature
Device (RTD) & Bearing Temperature Device (BTD) along with space heaters. The
terminal of space heaters will be wired to terminal box and the temperature scanner
shall be provided in control panel for scaling the winding and bearing temperature.
14.4.13.4. Essential Accessories

One set of the following essential accessories shall be supplied with DG set. This set
of accessories shall be housed inside the enclosure;
a) One No. M.S. base frame suitable for mounting of the offered engine and
alternator.
b) One No. inbuilt Daily fuel tank of suitable capacity complete with fuel gauge,
inlet/ outlet connections, drain plug etc.
c) Suitable Dry type Batteries of Approved Makes with leads and terminals shall be
part of the equipment. The pack shall be suitably positioned and modular
withdraw able for ease of servicing. The Battery pack shall be minimum 180 AH.
d) 1 Set of AVM Pads fitted on Base Frame.
55
14.4.13.5. BASE PLATE

Sturdy, fabricated / welded construction, made out of high quality steel section suitable
for mounting the engine and alternator. The base frame shall be suitably designed to
simplify transportation, handling, slinging, erection and commissioning. Shall have
provision for levelling adjustments, as required during installation. Engine and
alternator should be directly coupled through a set of flexible couplings and mounted
on a common fabricated base plate.
14.4.13.6. Auto Mains Failure (AMF) Panel

The AMF Panel shall be fabricated from 2mm thick sheet steel, powder coated, totally
enclosed, dust, damp and vermin proof, free standing, floor mounted type & front
operated. The degree of protection will be IP-42 conforming to IS 2147. Panel shall
include the following:-
a) Control system equipment’s and components such as relays, contactor, timer
etc. both for automatic operation on main failure and as well as for manual
operation.
b) Necessary instruments and accessories such as voltmeter, Ammeter, PF meter,
KW & KWH meter, frequency meter etc. in one energy analyser unit with selector
switch.
c) Necessary indicating lamps, fuses, terminal blocks, push button, control switch
etc. as required.
d) Electronic hooter, Visual & Alarm indication for faults, UPS.
e) ACB/MCCB, Battery charger etc.
14.4.13.7. Acoustic Enclosure

a) The acoustic enclosure shall be designed and manufactured confirming to
relevant standards suitable for outdoor installation exposed to weather conditions
and to limit overall noise level to 75 dB (A) at a distance of 1 mtr. from the
enclosure as per CPCB norms under free field conditions.
b) The construction should be such that it prevents entry of rain water splashing
into the enclosure.
c) The enclosure shall be fabricated out of the CRCA sheet of thickness not less
than 1.6 mm on the outside cover with inside cover having not less than 0.6 mm
thick perforated powder coated CRCA sheet.
d) The hinged door shall be made from not less than 16 SWG thick CRCA sheet
and will be made air tight with neoprene rubber gasket and heavy duty locks.
e) All sheet metals parts should be processed through 7 tank process.
f) The enclosure should be powder coated.
g) The enclosure should accommodate the daily service fuel tank with provision of
fuel gauge. The fuel tank should be filled from the outside as in automobiles and
should be with a lockable cap.
h) The batteries should be with accommodated in the enclosure in battery rack.
i) The canopy should be provided with high enclosure temperature safety device.
j) The acoustic lining should be made up of high quality insulation material i.e. rock
wool /glass/mineral wool/PU foam of appropriate thickness & density for sound
absorption to reduce the sound level as per CPCB norms. The insulation shall be
56
covered with fine glass fibre cloth and would be supplied by perforated MS sheet
duly powder coated / GI sheet / aluminium sheet.
k) The enclosure shall be provided with suitable size & No. of hinged type doors
along the length of the enclosure on each side for easy access inside the
acoustic enclosure for inspection, operation and maintenance purpose. Sufficient
space will be provided inside the enclosure on all sides of the DG set for
inspection, easy maintenance & repairs.
l) The canopy should be as compact as possible with good aesthetic look.
m) The complete enclosure shall be of modular construction.
n) The forced ventilation shall be as per manufacturer design using either engine
radiator fan or additional blower fans.
o) The acoustic enclosure should be suitable for cable connection / connection
through bus-trunking. Such arrangements on acoustic enclosure should be water
proof & dust-proof conforming to IP-65 protection.
p) The inside of enclosure should be provided with at least 2 No’s 28W T5
fluorescent tube light luminaire.
14.4.14. FLOW MEASURING SYSTEM
14.4.14.1. General
i. Flow measuring system shall consist of flow sensor/ transducers, flow
transmitter, digital flow indicator and integrator and any other item required to
complete the system.
ii. Flow transducers shall be rugged in construction and shall be suitable for
continuous operation. Flow transducers shall have waterproof construction and
shall be suitable for installation on underground /above ground pipelines/open
channel.
iii. To avoid the effects of disturbances in the velocity profile, a straight and
uninterrupted run, upstream as well as downstream from the location of the flow
sensor shall be provided, as required by the flow meter manufacturer and in line
with applicable standards. Contractor shall finalize the exact location of flow
transducers in consultation with Employer’s Representative.
iv. The flow transmitter shall be suitable for field mounting and shall accept input
from the flow transducer. It shall process the input signal and provide 4-20 mA
DC output proportional to flow rate. Flow transmitters shall have LCD display to
indicate instantaneous flow rate. The flow range shall be adjustable.
v. For ultrasonic flow meters, an insertion / retraction tool assembly shall be
provided so that the flow transducers can be removed or inserted without de -
pressurizing the pipeline. The same shall be made of anti-corrosive material.
vi. The flow computer shall be microprocessor based and shall have self-diagnosis
facilities.
vii. The following standards shall be followed:
- BS EN 24185 - Measurement of fluid flow in closed conduits - Weighing
Method.
- BS ISO 12765 - Measurement of fluid flow in closed conduits - Methods using
transit-time ultrasonic flow meters.
- ISO 8316 - Measurement of fluid flow in closed conduits - Method by
57
collection of the liquid in a volumetric tank.

- BS EN ISO 6817 - Measurement of conductive liquid flow in closed conduits -
Method using electromagnetic flow meters.
- BS EN 29104 (ISO 9104) – Measurement of fluid flow in closed conduit -
Method of evaluating the performance of electromagnetic flow measuring
system for liquid
- ISO 9826: Measurement of liquid flow in open channel - Parshall Flume.
14.4.14.2. Ultrasonic Flow Measuring System for Open Channels

a) Open channel type flow measuring system shall consist of Parshall flume/
Venturiflume/ weir, ultrasonic level measuring transducer, flow computer and
flow transmitter, flow indicator and flow integrator and any other item required to
complete the flow measuring system.
b) The level of the fluid in the flume/ weir shall be measured by the ultrasonic level
transducer. The level measured shall be used along with the physical
characteristics of the flume/ weir to compute the flow rate.
c) The design and application of ultrasonic level transducers shall take into account
the channel construction, the material, size, shape, environment, process fluid or
material, the presence of foam, granules, size etc.
d) The installation shall avoid any degradation of performance from spurious
reflections, absorption, sound velocity variations, sensor detection area,
temperature fluctuations, specific gravity changes and condensation. For
application where spurious reflections are unavoidable the control unit shall be
provided with facilities for spurious reflection rejection.
e) The structure required for supporting the level sensor, platform, railings etc. shall
be in the Contractor’s scope.
f) The flow computer shall be microprocessor based and shall have facilities for on-
line diagnosis, entering data like the type of channel, channel dimensions,
engineering units, measuring span, etc.
Type of channel Parshall flume

3 % of full scale with facility for range
Overall accuracy of measurement loop
selection
II)Level Measuring Unit:
1. Type Ultrasonic
2. Mounting On flow channel
3. Output 4-20 mA or pulsed
4. Enclosure Material Die Cast Aluminium
5. Enclosure Protection IP 66 of IS 13947 Part-I
6. Integral cable with sensor Required
III)Flow Computer and Transmitter
1. Type Microprocessor based
2. Mounting Field
3. Input From level measuring unit
4. Output 4-20 mA DC (Isolated)
5. Enclosure Protection IP 66 of IS 13947 Part-I
58
Programming facility with

6. Required
programmer
Digital, Seven segment back-lit
7. Display
LCD/LCD display
8. Unit of display Flow rate -m3 / hr Totalized flow –ML
Facility to feed data like the type of
9. channel, channel dimensions, engg. Required
unit, dead band etc.
10. Enclosure Material Die Cast Aluminium
IV) Flow indicator and integrator
Specifications shall be as given under ‘Flow Indicator and Integrator’.
14.4.14.2.1. Ultrasonic Flow Measuring System for Pipes

a) Ultrasonic Transducers shall work on transit (time of flight) time principle.
b) The transducer probe shall be of the wet insertion type with facility for online
insertion and retraction.
c) The flow computer shall be microprocessor based and shall have facilities for on-
line diagnosis, entering pipe size, engineering units, measuring span etc.
d) The Contractor shall provide a section of pipe having uniform diameter, for
installation of flow probes so as to configure a flow meter. The section of pipe
shall be installed in the pipeline at site. The exact inside diameter of the pipe at
the location of flow transducer shall be used for flow computation.
e) Contractor shall construct a suitable concrete chamber for enclosing flow
transducers to be mounted on underground pipe lines. A concrete enclosure
shall be constructed above the chamber for housing the flow transmitter. For
surface pipelines, a concrete cabin shall be constructed around the pipeline for
housing the flow transducer and the flow transmitter. A lockable enclosure shall
be provided for the flow transmitter cum computing unit.
f) In order to facilitate the removal / reinsertion of the flow transducers when the
pipeline is pressurized, the Contractor shall provide an insertion-retraction tool
assembly which shall be leak proof at 1.5 times the working pressure.
Accuracy of flow sensor and transmitter

±1% of full scale
during FAT
Overall accuracy of measurement loop ±1.5% of full scale
Material of pipe MS
Raw water and Clear water
Application
pumping mains
II) Flow Sensor/Transducer:
Multipath, Insertion type (Clamp-
Type
on type not acceptable)
Four paths (8 trans receiver
No. of paths
transducers).
Measuring principle Transit time (Time off light)
Weather Protection Class IP 68 as per IS 13947 Part-I
Surge protection devices (SPD) between Required for protection from
59
each flow sensor and flow computing lightning surges

unit/ flow transmitter
Flow probe material SS 316
Other wetted parts SS 316
Provision for online removal/ insertion of
flow sensors without depressurization of Required
the line
i) Prefabricated integral cables
for connecting sensors and flow
computer/transmitter
ii) Insertion / Retraction assembly
Accessories
and isolation valve.
iii) Sensor mounting nozzles
/couplings
iv) Mounting bracket
Name plate/ Metal tag
III) Flow computer and transmitter
Type Indicating type
i) 4 digit, backlit LCD/ LCD , 12 mm
height for flow rate in m3/hr.
2 Type of display
ii) 8 digit, backlit LCD/ LCD, for
totalized flow in ML.
3 Input From ultrasonic flow sensors
4 Output 4-20 mA DC(isolated)
5 Zero and Span Adjustment Required
6 Weather Protection Class IP 65 as per IS 13947 Part I
7 Battery backup for totalized flow Required
Facility shall be provided that when any
one sensor / path fail the flow meter
8 shall continue to function by Required
automatically discarding the faulty
sensor/ path from averaging function.
Facility to display flow measured
9 Required
by each path
IV) Flow indicator and integrator
Specifications shall be as given under ‘Flow Indicator and Integrator’.
g) Calibration
The ultrasonic flow meter shall be calibrated for the accuracy of velocity
measurement wherein the velocities shall correspond to the flow range of the
flow meter covered in the tender. The calibration shall be carried out for the
ultrasonic flow meter under test consisting of multipath flow sensors, flow
transmitter cum computation unit and flow indicator cum integrator unit.
The calibration method shall be either gravimetric method or volumetric method.
The ‘test bed’ shall be accredited by National /International certifying authority as
per ISO 8316 (Calibration by Volumetric Method) or ISO 4185 (Measurement of
fluid flow in closed conduits – weighing method). The Contractor shall produce
60
accreditation certificates for the test facility and the calibration certificate for the
flow meter for review by Employer’s representative and shall also demonstrate
complete calibration on the test bed in the flow meter laboratory during
witnessing of the Factory Acceptance Test. The flow meter shall be acceptable if
the accuracy and repeatability is equal to or better than those specified.
14.4.14.3. FLOW INDICATOR AND INTEGRATOR

Flow indicator and integrators shall be modular in design. It shall consist of two
separate dedicated displays for flow rate indication and total flow indication. It shall
accept 4-20 mA DC isolated input. The flow integration shall be carried out in the
Programmable Logic Controller (PLC). The flow indicator cum flow integrator shall
provide 4-20 mA retransmission output proportional to flow rate.
Details Description
Type Microprocessor based
Mounting Front facia of Control Panel
Display Digital, seven segment back lit LCD / LED
display
Digit Height 14 mm or Higher
No. of Digits for Flow indicator 4 Digits
Flow integrator 6 Digits
Input 4-20 mA DC (Isolated) from flow transmitter
through analogue signal multiplier (Refer
Note2)
Zero and span Required
adjustment
Manual Reset Facility Required (shall be password protected)
for flow integrator
Engineering units:
-Flow rate indicator Cum/hr ML
-Flow integrator
Battery backup for integrator Required
Retransmitted output 4-20 mA proportional to flow rate
Alarm outputs 1 NO + 1 NC for high and low alarms
(adjustable)
Communication port RS-485 (With Modbus protocol) for
interfacing with PLC
Weather Protection Class IP-52 of IS 13947 Part-I
Accuracy ± 0.25% of span or better.
Notes: Digital flow indicator and flow integrator shall be a combined unit. Facility shall
be available in the analog signal multipliers and in the flow indicator and
integrator for providing excitation voltage for the flow transmitter in case of 2-
wire flow transmitters.
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14.4.14.4. ELECTROMAGNETIC FLOW METER

The Electromagnetic Flow Meters shall be installed in RCC chambers/open pits or
buried for indication of flow rate and total consumption of water in a transmission or
distribution pipe network of city’s water supply system. The flow meter should
minimum have the stainless steel housing and should minimum show Velocity,
Instantaneous Flow, Total flow and conductivity on its Display. Flanges must be
welded to the flow tube thus sandwich design or lap joint will not be accepted.
The Electromagnetic Flow meters shall withstand maximum working temperature of
about 600 C and working pressure of 10 kg/cm2 (1.0 Mpa), unless specified
otherwise.
Full bore electromagnetic flow meters should be designed, manufactured and
calibrated according to ISO standard. The flow meter shall be capable of measuring
bi-directional flow.
Electromagnetic Flow Meter shall be a velocity sensing electromagnetic type,
microprocessor based signal converter, sealed housing, flanged tube meter for 1.0
Mpa working pressure. The meter shall be manufactured to highest standard
available for mag-meters. The meter shall be equipped with minimum six digit digital
totalizers, reading in units of kiloliters and shall be accurate within 0.5% of true flow.
The accuracy should be inclusive of linearity, hysterisis and repeatability,
temperature and pressure effects. The meter assembly shall operate within a range
of 0.3 m/sec to 4 m/sec and be constructed as follows: Flowmeter display should at
least show Flow rate, Totalized flow, and velocity.
Meter Tube (Sensor) shall be fabricated from stainless steel tube and use class
PN10 flat face carbon steel flanges in accordance with IS 1538. The internal and
external of the meter tube shall be blasted to near white and lined with hard rubber
preferably by SBR or EPDM. Meter tube shall have a constant nominal inside
diameter offering no obstruction to the flow.
Coil Housing shall be fabricated from stainless steel for corrosion resistance and
welded to the tube providing a completely sealed environment for all coils, electrode
connections and wiring harness capable of submerged or buried operation.
Signal Converter shall be pulsed DC coil excitation type with auto zeroing. The
signal converter shall be remotely mounted away from the meter. The converter
shall indicate direction of flow and provide a flow rate indication and a total of flow
volume for both forward and revere directions.
The converter shall provide an isolated 4-20 mA output into minimum 500-ohm load
and a frequency output of a maximum of 0-10 KHZ and a scaled pulse output. The
microprocessor based signal converter shall have a backlit display that must
continuously display ‘Rate of Flow’ ‘Total Volume, velocity & Conductivity.
The converter shall be compatible with Microsoft Windows and other software
programs with suitable communication capabilities. The converter shall have the
feature to remotely mount up to 200 m from the sensor, however the exact distance
shall be found as per locations.
The signal converter housing should be die-cast aluminum with glass window. The
converter cum transmitter should be fully programmable from the front facia. The
programming should be user friendly, self-prompting menu driven.
Volumetric Testing: All flow meters from DN 150 Size and above shall be
calibrated using volumetric method only. The complete meter assembly and signal
62
converter must be wet accuracy tested and calibrated as a unit near minimum,
intermediate, and maximum specified flow ranges of the meter (full range of flow).
The volume of water used to conduct the test must be shown on a shipping tag
attached to the meter.
The overall uncertainty of the calibration rig should be at least three times better
than the uncertainty of the full bore electromagnetic flow meter. The competent
authority NABL must certify the test facility. All the meters shall be calibrated for a
minimum of 3 point.
Supplier must have test facilities, spare parts, and personnel to maintain, instruct,
train or whatever is necessary to assure that meters shall be maintained throughout
the guarantee/maintenance contract period.
Technical Specification
A) Process Liquid
a. Liquid Type : Potable water/raw water
b. Type of solid : Silt particles
B) Operating Condition
a. Operating pressure : Max. up to 1.0 Mpa
b. Operating temperature : 0o C to 50o C.
C) Flow Sensor
a. Type : Pulsed DC excitation
b. System : Separate with cable output
c. Power supply : 240 V AC, 50 Hz
d. End Connections : Flanges of Carbon Steel
e. Flange Rating : PN10 – Up to size 1200mm
PN 6 -from 1300mm to 2000mm
f. Electrode material : SS 316 (Stainless steel) /Platinum /Tantalum
g. Meter tube : SS 304 (Stainless steel)
h. Electrode type : Round head electrodes (Bullet nose)
i. Lining material : Hard Rubber (SBR or EPDM)/ Neoprene
j. Protection category : IP 68
k. Measuring accuracy : Measuring accuracy
+/-0.5% of Measured Value inclusive of Linearity,
repeatability, Pressure Effect and Hysterics
between 0.5 - 4 m/s velocity.
l. Coil Housing : SS 304 with fully welded construction
m.Connection / Junction Box : SS 304
n. Earthing : Grounding Rings in SS 304, or earthing electrodes
o. Fluid conductivity : > 20  Siemens/cm
p. Marking : Direction of flow with arrow, size, Sr. no, make
D) Flow Transmitter/Converter
a. Type : Microprocessor based, Modular Design, remote
mounting
b. Display language : English
c. Ambient temperature : -20 C to +600 C
d. Display : Min. 2 line back lit LCD for indication of actual flow
rate, forward, reverse, sum totalizer, velocity&
conductivity.
63
e. Outputs : One Current output (4 – 20 mA)

One saleable pulse output
One Status output
f. Protection Category : IP 65
g. Enclosure : Die Cast Aluminum with polyurethane finish
with glass window
h. Programming : Through Key /keypad on front facia /optical touch
key
i. Power Supply : 240 V AC, 50 Hz
j. Cable Gland : ½” NPT (4 glands of double compression type)
k. Mounting : Wall mounted
l. Interface : Needed For Data Transmission
m.Power failure mode : Provision of RAM/PROM to store parameter
entered and measured flow data during power
failure
n. Max. Separation possible : Up to 200mtrs. between sensor & transmitter
without any signal boosters
o. Terminals : Shock – Hazard – protected push lock terminals
p. Error Identification : 0/3.6/22 m Amp
q. Interchangeability : Fully interchangeable with all sizes of flow sensors
r. Safety classification : General purpose certification
14.4.15. LEVEL MEASURING SYSTEM
14.4.15.1. Ultrasonic Level Meters

Ultrasonic level measuring devices applied for liquid level measurement shall comprise
a transducer, control unit and remote indicator. The transducer shall be suitable for
flange or bracket mounting as required and shall be environmentally protected to IP
65.
The design and application of ultrasonic level meters shall take into account the vessel
or channel construction, the material, size, shape, environment, process fluid or
material, the presence of foam granules, size etc.
The installation shall avoid any degradation of performance from spurious reflections,
absorption, sound velocity variations, sensor detection area, temperature fluctuations,
specific gravity changes and condensation. For applications where spurious
reflections are unavoidable the control unit shall be provided with facilities for
spurious reflection rejection. If turbulence exists, shielding, stilling tubes or other
measures shall be provided to avoid effects on the measurement.
14.4.15.2. Conductivity Level Switches

The electrodes used for conductivity level switches shall be stainless steel. Single
electrode systems (one electrode per holder) shall be used (except where their use is
impractical) with insulated electrodes such that only the tip of each electrode is
exposed to the liquid at the operating level.
Relay or control units operating with level electrodes shall have adjustable
sensitivity. Electrodes for use in fluids of low or variable conductivity shall be fitted with
conductivity discs. Where relay or control units are not mounted in control panel,
64
they shall be provided with surface mounting enclosures with a degree of protection
to IP-54 for indoor locations or IP 65 for outdoor location.
14.4.15.3. Ultrasonic Differential Level Measuring System

The ultrasonic type differential level measuring system shall consist of ultrasonic type
level sensors on upstream and downstream of screens, differential level computer /
transmitter and indicator. The flow computer / transmitter shall be microprocessor
based and shall have facility for programming (i.e. adjustment of set points).
The ultrasonic transducer shall be suitable for flange or bracket mounting as
required and shall be environmentally protected as per IP-65. It shall have
ambient temperature compensation and adjustable datum setting facilities.
14.4.16. PRESSURE GAUGE

Pressure gauges shall be glycerin filled with isolation valve and tap off pipe and shall
comply with BS 1780. Snubber shall be provided where the gauge is subjected to
pressure pulsations and / or vibrations. The internal parts of pressure gauge shall be of
stainless steel material. In chlorine applications the diaphragm shall be silver or
tantalum for other fluids an appropriate diaphragm material shall be used. The
pressure gauges shall be provided with diaphragm seal arrangement.
The minimum diameter for round pressure gauges shall be 150mm unless specified
otherwise or where the gauge forms part of a standard item of equipment. The
accuracy of pressure gauges shall be ±1% over the operating range. The zero and
span of pressure gauges shall not change by more than ±0.1% of the span per °C
changes in ambient temperature.
14.4.17. ONLINE SEWAGE WATER QUALITY MONITORING STATION
14.4.17.1. General Requirement

 The station will collect the following parameters;
pH, COD, BOD, TSS, Temperature, Ammonical Nitrogen, TKN, Electrical
Conductivity.
 Analyser should be in compliance with latest guidelines for Online Continuous
Effluent Monitoring Systems (OCEMS) issued by CPCB.
 Analyzer should be able to produce analytical valid results and flag sensor fault.
 Sensors should be robust and rugged and is capable of operating in
variable and extreme measurement condition, and still maintaining its calibrated
status.
 The life of sensors should be at least 10 years & source lamp should not be
replaced during the period.
 The manufacturer’s guarantee of the whole system shall be at least 5 years at no
extra cost.
 The entire monitoring station including the sensors and hardware should
be tamper proof.
 The analyser should record all operation information in log files.
 Should have non-volatile data logger for recording at least one year continuous
data.
 Should have facility of plant level data viewing and retrieval with selection of
Ethernet, wireless, Modbus and USB.
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 Records of calibration and validation should be automatically uploaded on web

server to PWSSB/ PPCB/CPCB/Dept. of Science & Tech.
 Online diagnostic features should be available.
 System should have expandable program to calculate parameter load daily,
weekly or monthly basis for future evaluation with flow rate signal input.
 BOD/COD measurement should be based on the Total organic
Carbon (TOC) measurement / UV Visible spectroscopy double beam
complying to US EPA 415.1 / 415.2 or equivalent standard for
effluent/sewage/waste water.
 The seamless data to be transferred to PWSSB/ PPCB/CPCB/Dept. of Science
& Tech. server through 2G – GSM on continuous basis for seamless data
transmission.
 The Server and software should be as per CPCB protocol C 12011/33/2015
Tech dated 11.06.2015.
 The equipment should be TUV, MCERT, USEPA certified.
 Certificate from Original Equipment Manufacturer (OEM) for authorization of data
management.
 Every system supplier will comply with testing/calibration protocol as per
international standards of the CPCB.
14.4.17.2. The major prerequisites of efficient online analyzers are:

 Should be capable of operating unattended over prolonged period of time.
 Should produce analytically valid results with precision and repeatability.
 The instrument/analyzer should be robust and rugged, for optimal
operation under extreme environmental conditions, while maintaining its
calibrated status.
 The analyzer should have inbuilt features for automatic water matrix change
adaption.
 The instrument / analyzer should have onboard library of calibration
spectras for different industrial matrices with provision of accumulating further
calibration matrices.
 Should have provision for Multi-server data transmission from each station
without intermediate PC or plant server.
 Should have provision to send system alarm to central server in case any
changes made in configuration or calibration.
 Should have provision to record all operation information in log file.
 For each parameter there should be provision for independent analysis,
validation, calibration & data transmission.
 For TOC analyzer, the empirical relationship between TOC to COD or
BOD must be authenticated for all industrial applications and the correlation
calculation (for factor) provided.
 Record of calibration and validation should be available on real time basis
on central server from each location/parameter.
 Record of online diagnostic features including sensor status should be
available in database for user friendly maintenance.
 Must have low operation and maintenance requirements with low
chemical consumption and recurring cost of consumables and spares.
 Should have data validation facility with features to transmit raw and validated
data to central server.
 Should have remote system access from central server provisioning log file
access.
 Must have provision of a system memory (non-volatile) to record data for at least
one year of continuous operation.
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 The correlation/interpretation factor for estimating COD and BOD using UV-
Visible Absorption Technique shall be regularly authenticated/ validated and
details should be transmitted online.
14.4.17.3. Quantification:
 Instrument Calibration: The following frequency has to be used for
calibration of analyzer. This calibration can be done in the laboratory of the
industry and data should be submitted online to CPCB.
 pH – once every week or as specified by manufacturer whichever is earlier
 COD – once every week or as specified by manufacturer whichever is earlier
 BOD – once every week or as specified by manufacturer whichever is earlier
 TSS – once every week or as specified by manufacturer whichever is earlier
 Others – once every week or as specified by manufacturer whichever is earlier
The software must keep all calibration data points in memory for interpretation
of matrix change adaption.
14.4.17.4. System Validation:

Online instrument operation will be evaluated using the known buffers,
traceable standards and laboratory techniques. By validating sensors and
probes with known standards such as KHP (potassium hydrogen phthalate)
for COD & TOC, Formazin equivalent standard for TSS & pH buffers have to be
used to calculate a running variance of the measurements. When the variance
is outside of the set points, this can be an indication the monitor requires
calibration. Frequency of the validation should be once in three months or as
specified by manufacturer, whichever is earlier.
14.4.17.5. Parameter validation:

Each parameter is validated with reference to standard laboratory analysis and known
standards.
14.4.17.6. Parameter Accuracy: Allowed Variability:

The relative difference between online and laboratory measurements has
to be between
 COD Accuracy ±10% or better.
 BOD Accuracy ±10% or better.
 pH Accuracy ±0.2 pH or better.
 TSS Accuracy +/-10 % or better.
 Others Accuracy +/-10 % or better.
14.4.17.7. Operation & maintenance:

 Daily Check – GPS Transmission, System Diagnostic alarms.
 Monthly Check – Sensors & system cleaning, data backup, Parameter
Calibration as specified in calibration schedule.
 Periodic Check – System validation with known standards,
Laboratory & Online parameters Comparative
14.4.17.8. Reporting:
The suppliers have to provide central server at cloud operational on 24x7 basis and to
provide online data connectivity with CPCB and SPCBs servers. Beside data
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connectivity they need to provide login credential to respective SPCBs/PCCs and

CPCB to view the data in graphical/ tabular format and also to compare the data
features.
One minute data average must be transmitted /retrieved to servers every 30 minutes.
In the event of transmission loss the time stamped data in the data logger memory
must be transmitted to fill from the last transmission break with a stamp of time
delay. The software should have two way communication, so that data from the
system can be seen whenever desired and remote of controller/data logger can be
taken to visualize the immediate status of the system. The data along with diagnostics
and calibration details should be transmitted to CPCB and SPCBs servers.
14.4.17.9. Data Management:

Considering the heterogeneity of real time monitoring systems, it is required to
submit real time data through their respective instrument suppliers. This
mechanism will help in consolidating the data avoiding the complexity of different
technologies and availability of monitored data in different data formats and at the
same time involving the instrument suppliers in data transferring mechanism. The
system enables two ways communication required to manage such real time systems.
The basic functional capabilities of such software systems shall include:-

 The system should be capable of collecting data on real time basis without any
human intervention.
 The data generation, data pick up, data transmission; data integration at
server end should be automatic.
 The submitted data shall be available to the Boards, SPCBs and CPCB
for immediate corrective action.
 Raw data should be transmitted simultaneously to SPCBs and CPCB.
 Configurations of the systems once set up (through remote procedure)
and verified, should not be changed. In case any setting change is required it
should be notified and recorded through the authorized representatives only.
 The data submitted electronically shall be available to the data generator
through internet, so that corrective action if any required due to submission of
erroneous data can be initiated by the industry.
 The software should be capable to verify the data correctness which means at
any given point of time the regulatory authorities/data generator should be able
to visualize the current data of any location’s specific parameter.
 A system for data validation shall be incorporated in the software with two
stage/three stage validation and fixed responsibilities of stakeholders as below;
a. Data Generator
b. SPCBs
c. CPCB
 Change Request Management: window for requesting data changes due to
actual field conditions shall be provided in line to SPCB to consider the request
or not.
 The site surrounding environmental conditions shall also be recorded along with
other environmental parameters, as these have the potential to affect the
system adversely and corrupt the data generated.
 System should have capability to depict data at the actual location of industry
over the map. CPCB and or SPCBs shall develop a map based system
for data integration at a single location.
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The software should be capable of analyzing the data with statistical tools and
shall have the following capabilities:
i) Statistical data analysis (customizable) for average, minimum,
maximum, diurnal variation.
ii) Capability of comparison of data with respect to standards/
threshold values.
iv) Auto report and auto mail generation etc.
iv) Providing calibration database for further validation/correction of data.
v) Providing data in export format on continuous basis through central/station
computer system to other system.
 Data Storage for next five years.

 System should be connected to a backup power source with adequate capacity
(min. 2 hrs.) to avoid any power disruption.
14.4.17.10. Technical Specification

Analyser Cabinet Type & Multi-parameter
BOD
COD
TSS
Parameter to be pH
measured Temperature
Ammonical Nitrogen
TKN
Electrical Conductivity
UV-Vis Spectrophotometry (double beam with
COD/BOD
entire spectrum scanning) (200-750 mm)
Principle of
TSS Light scattering/ reflection principle
measurement
pH Electrode/Potentiometric method
Conductivity Electrode direct contact
0 to 1000 mg. /lit. Accuracy ±
COD
5%, resolution 1 mg/l or better
0 to 500 mg. /lit. or higher
Accuracy with
BOD Accuracy ± 5%, resolution 1
reference to
mg/l or better
Measuring laboratory
0 to 1000 mg. /lit. Accuracy ±
Range TSS analysis.
10%
0 to 14 Accuracy ± 0.2,
pH
resolution 0.01 of pH or better
0-5000µS/cm, Accuracy ± 10%,
Conductivity
resolution 0.01 µS/cm
Operating
4 kg/CM2
Pressure
Operating Sample temperature: 0 to 50 deg. C / Ambient temperature - 50
Temperature deg. C
Operating
5 to 95 % non-condensing
Humidity
Material of
construction of SS 316, Optional Titanium
sensor
Enclosure
IP65 or better
protection
Signal output Compatible with Data Acquisition System
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RS 232 required (Sub-D 9 ways female connector) with 2 meters

cable for PC
Communication
RS 485 required for the connection of external probes
USB port required for USB key connection
5000 records (up to 16 measurement channels) with date and
Memory
time
Colour TFT LCD/LED (alpha numeric display of parameter in
Display
engineering unit)
Measuring
time/Response 60 sec or better
time
Measuring
Continuous
Cycle
Power 12 V DC Nominal
Cleaning
Automatic self-cleaning facility
method
Calibration Zero Calibration Facility should be there.
requirement Span adjustment either not required or should be adjustable.
Reagent if any Not required
Analyser should be cabinet type for easy operation, maintenance
& troubleshooting.
USB port is required for recorded measurement download,
screen copy function (easy troubleshooting) & software update.
Wi-Fi & Ethernet module should be available for remote data
transfer.
Reagent-free measurement.
Maintenance Free.
Additional
Operating cost should be low.
Features
Data Transmission from Analyser to PC, CPCB & PPCB server.
Supplier to make available all the measurement data to PPCB
server so that on-line data is available at PPCB and CPCB
server.
Auto calibration facility.
All the accessories required for mounting the sensor are to be
provided.
Self-cleaning (automatic).
Compliance of statutory guidelines issued time to time and issued by PPCB/CPCB

are applicable for compliance up to the date of tendering.
14.4.18. PLC/SCADA SYSTEM

The complete Plant shall be designed for automatic operation through Programmable
Logic Control (PLC) and Supervisory Control and Data Acquisition (SCADA). This shall
be achieved by either individual equipment PLCs with SCADA/HMI or single PLC and
SCADA for entire Sewage Treatment including pumping stations. These shall be
located at control room of the STP.
The plant shall have provision for operations in following modes –
1. Automatic – Auto operation through PLC/digital controller.
2. Manual – Operator intervention through SCADA/HMI.
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3. Local – Local operation through local control panel located near equipment.
Audio Visual Alarms –
Audio visual alarms shall be initiated under emergency or equipment trip conditions, other
than usual service alarms. Salient features of the proposed control system shall be as
follows:
 Dynamic display of all Units, equipment and drives shall be available on SCADA
screen.
 It shall Acquire, process and manage the processed data.
 It shall safeguard the process by means of interlocks and alarms.
 Auto/Manual operation of each drive shall be made by selecting a soft switch on
SCADA/HMI screen.
 In Auto mode, each drive shall operate based on pre-set sequence and
interlock. Also automatic change over from working to standby drive shall
happen after a drive reaches pre-set hours of operation.
 In Manual mode, each drive shall be operated in Local/Remote mode by
selecting a soft switch on SCADA/HMI screen. In Local mode, each drive shall
be operated from the Local Push Button Station (LPBS) located nearby. In
Remote mode, operation from LPBS shall be disabled and each drive shall be
operated manually from PLC. Also provision for working/standby selection of
drives by selecting a soft switch on SCADA screen shall be provided.
 Run/Trip indication of all drives shall be displayed on SCADA/HMI screen.
 Open/Close indication of all Auto Sluice Gates and Auto Valves shall be
displayed on SCADA/HMI screen.
 Annunciation & Alarm facility shall be available in PLC/HMI/SCADA. In the event
of a Fault, the symbol representing the equipment/drive shall continue flashing
on SCADA/HMI screen with equipment/drive description appearing at bottom of
the SCADA/HMI screen and electric Hooter shall continue blowing until the Fault
Alarm is acknowledged.
 Data logging of Running Hours of each drive, Alarms, Historical Trends of
monitored Parameters, etc. shall be envisaged in SCADA.
 Report generation for plant performance.
The process system must have pre-configured software packages which can be adapted
to the process by parameterization.
The monitor images must be designed to be user-friendly by hierarchical breakdown with
the possibility of selective display and optimum selection possibilities. Changing of
parameters and other software units must be possible "online", i.e. with the system
running. Different alarms colours provide information on their priorities.
For the system engineering offered, the Contractor must take measures, e.g. by the
installation of surge voltage arresters or surge voltage filters, to ensure that internal and
external surge voltages do not impair the function of his parts of the system.
The programs and data entered must be backed up in a non-volatile read-only memory.
A limit value and plausibility check must be provided in the software of the process station
for the measured values and messages. Exceeding of limit values or deviations detected
by the above checks must trigger an event and cause a message to be sent.
Further demanded features of the process system:
 Integrated, detailed error message and fault detection concept with display on the
HMI/SCADA for quick localization of faults. The system operator must be able to
identify the fault from the error.
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 Essentially maintenance-free
 Robust against external interferences of all kinds
 Proven design and solder-free connection technique
 Protection of the equipment against surge voltages
 Automatic fault detection and quick troubleshooting in the PLC system by
integrated, hierarchically structured diagnostic devices
 Power supply in wide admissible voltage range
 Simple function-oriented operation
The process system (PLC, HMI/SCADA) shall be protected against power failure by
an uninterruptible power supply (UPS) for minimum 60 minutes.
Mode selector switch

A mode selector switch is to be installed on the MCC or distribution board. It serves
for pre-selection between Automatic mode and Manual/Local mode.
The following switching functions must be provided:

Automatic – Manual/Local
 Automatic: In this position, only automatic operation is possible; the local
switches have no function (Except emergency stop).
 Local: Automatic mode cannot be started. The drives can be operated
individually without interlock with the local switches.
Local switches (LPBS)

Each drive must be equipped with a local switch positioned in such a location that
the corresponding machine or conveyor can be switched on in Manual/Local mode
and can be monitored visually at all times.
The local switch must have the following switching functions:

START – STOP (for drives with one direction of rotation) or
FORWARD – STOP - REVERSE (for reversible drives)
 If a unit has several drives (e.g. conveyor belt drive and travel drive), the local
switches should be installed if possible in one switch box or at least installed
next to one another.
 Each local switch must be adequately labeled in plain text so that no operator
errors can occur.
PLC
The automatic start-up of the whole system, sequential operations and the
automatic shutdown, allowing for external control influences, e.g. EMERGENCY
STOP, etc., is performed by programmable logic controller (PLC).
This performs not only the control of the system, but also the display of the
operating state in the HMI/SCADA.
The interlocks of the individual process groups and their signaling must be
performed by the PLC.
A system must be selected which is sufficiently protected against external
interference in the supply, control and signaling lines. The aim is that the program
can continue to run without fault signals in the event of transient earth faults in the
supply grid. In the event of prolonged power failures, on the other hand, a controlled
restart must be triggered (under-voltage trip of the non-automatic circuit breaker).
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PLC Specifications: Technical

 The PLC shall be non-redundant.
 PLC of individual equipment shall be selected to carry out necessary operations
without overloading the PLC memory.
 The PLC shall have adequate I/O per card.
 There shall be 15% spare I/O of each type.
 The CPU shall not be loaded more than 60% of its capacity.
 Retentivity shall be 100% to save the recorded data and saving the
programmed logic, other attributes connected with system for power & system
failure.
 Change in programme / modifications to programme shall be possible by a
portable laptop.
 It is preferred to have all PLC’s in the plant from same manufacturer.
HMI/SCADA system
The HMI system shall be designed as a minimum 6”, color, touch-screen on the
panel. Whereas SCADA system must be computer based. All displays must be
designed by the Contractor with graphic sophistication and all texts in the
visualization system must be displayed in English.
A sub-menu for each operating mode and further menus for editing the system
parameters, fault archive, etc., must be developed. It must be as simple as possible
to switch between the various menus and to edit the system parameters.
When designing the user interface or the assignment of the function keys, attention
must be paid that the function key assignment remains the same in all sub-menus
so that it is possible to jump to another menu without first having to jump back to the
main menu.
It must be possible to edit the following parameters at the touch-panel and SCADA:
 Operating mode
 Changes in the speeds of frequency converter-controlled equipment
 Start-up times
 Shutdown times
 Duration of the operation of warning devices
 Limit values for sensors, etc.
Faults, level messages, pressed EMERGENCY STOP buttons, etc., must also be
clearly displayed at the bottom of the screen, irrespective of the selected screen
page or sub-menu.
It must be possible to output all important menu items to the printer. The
corresponding interfaces must be provided.
The display of the function plans, images, etc. is affected in direct dialog with the
system by means of the mouse and keyboard. The central SCADA shall generate
various reports to analyze plant performance. The process is documented via the
laser printer.
Computer hardware and software

All programs required for operation of the system must be correspondingly
compatible. The corresponding licenses must be supplied for the standard
programs. The operating systems and minimum system configuration requirement
must be agreed upon with the Client.
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Complete Project shall operate in auto mode. As a minimum, following controls

must be considered in Bidder’s Control Philosophy:
1. Coarse screens
Each mechanical coarse screen shall be installed with ultrasonic differential level
transmitter / level switch, across it; the same shall be operated on the basis of set
differential level in SCADA. Also if differential level is not reached for certain time
period, the screen shall be operated on the basis of set time in SCADA.
The selection of Auto/Manual and Working/Stand-by shall be made available in
SCADA. In manual mode the screen operation will be done from SCADA screen.
Physical switch over of screens in plant will be done by operator using manual
gates.
Necessary interlocks, controls, alarms, report generation, etc. shall be considered in
PLC for auto operation of coarse screen.
2. Raw Sewage Sump and Pumps

The sump will employ Ultrasonic level transmitter to measure level. The combined
operation of Raw Sewage Pumps will be dependent on rate of change of level with
reference to time and VFD operation. The selection of Auto/Manual and
Working/Stand-by shall be made available in SCADA. In manual mode the pump
Start/Stop will be done through SCADA screen.
PLC for auto operation of Raw Sewage Pumps.
3. Inlet chamber
Ultrasonic flow transmitter shall be provided on rising main of Sewage Treatment
Plant. PLC shall calculate instantaneous flow as well as cumulative flow, both shall
be displayed on SCADA.
4. Fine screens
Each mechanical fine screen shall be installed with ultrasonic differential level
transmitter / level switch, across it; the same shall be operated on the basis of set
level in SCADA. Also if level is not reached for certain time period, the screen shall
be operated on the basis set time in SCADA.
SCADA. In manual mode the screen operation will be done from SCADA screen.
Physical switch over of screens in plant will be done by operator using manual
gates.
PLC for auto operation of fine screen.
5. Grit Chambers
Each grit chamber will consist of Detroiter (1No.), Organic Return Pump (1No.) and
Screw Conveyor for grit removal (1No.). As such Detroiter, Organic Return Pump
and Screw Conveyor will not have auto operation; these will be started and stopped
from SCADA screen as required.
Necessary interlocks, alarms, report generation, etc. shall be considered in PLC for
operation of Grit chamber equipment.
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6. Biological Reactor/Basins
Complete operation and control of plant will be done through a separate PLC and
SCADA. However it shall have necessary inputs and generate required outputs to
operate in co-ordination upstream and downstream units of balance plant.
Alternatively contractor may provide single PLC and SCADA for entire Sewage
Treatment Plant.
Necessary interlocks, controls, alarms, report generation, etc. shall be considered.
Each reactor/basin shall be equipped with Level Transmitter, DO Transmitter etc.
for monitoring and recording of critical operation parameters through SCADA.
7. Sludge sump and pump

An ultrasonic type level transmitter shall be used for measurement of level in sludge
sump. Screw pumps will be used to feed sludge to Centrifuge. These will operate as
per level in sludge sump.
SCADA for sludge pumps. In manual mode the Start/Stop of pump will be done
from SCADA screen.
operation of chlorination system.
8. Chlorination tank
SCADA for booster pumps. In manual mode the Start/Stop of pump will be done
from SCADA screen. Though chlorinator will have standalone operation, feedback
for the equipment shall be taken to PLC and displayed SCADA for monitoring
purpose.
operation of chlorination system.
9. Centrifuge
The drives and instruments of centrifuge shall be connected to PLC for its auto
operation. Starting of dewatering system will be a manual process.
auto operation of centrifuges.
14.4.19. UNINTERRUPTIBLE POWER SUPPLY (UPS)

The UPS shall be floor mounted, self-contained, metal clad and shall be
suitable for operating on a nonlinear load. It shall be front door accessible.
The UPS system shall be true On-Line. The ON LINE UPS shall be incorporating
a six-pulse rectifier and pulse width modulation inverter technology with 100%
microprocessor control with built in static and manual bypass switch.
The UPS shall incorporate a DC under voltage trip circuit to electrically trip the UPS in
order to protect the battery. The noise level of the unit shall not exceed 60dB (A) at 1m
from the UPS cabinet. The output of the inverter shall be a sine wave having less than
5% THD for linear loads and less than 4% to 50% nonlinear load. It shall be suitable
for load power factor 0.8 lag.
The unit shall have dynamic response such that a 100% step load causes an
output voltage transient of less than ±4% with a recovery time of less than 4 ms. For
three phase output units the output voltage shall not vary by more than ±1%
for an unbalance for 10%. The load crest factor shall not be less than 3:1.
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The efficiency at full load and 0.8 power factor shall be greater than 88%. Indicators
to indicate; UPS status & UPS alarm conditions
The UPS shall provide a volt free contact output to indicate:
• Warning i.e. low battery capacity, Fault, Static bypass in use
The UPS shall have an overload capacity of 150% for 30 seconds and shall be
protected in the event of a short circuit of the output. The batteries shall be housed,
either within the UPS enclosure or within a separate matching battery cubicle
suitable for location adjacent to the UPS. The batteries shall be maintenance free
lead acid type sealed for life. Terminals shall be shrouded to prevent accidental
contact. The battery enclosure shall be corrosion resistant and ventilated to prevent
the buildup of gases.
Warning notices shall be provided for wall mounting to warn of the presence of
charge gases. The battery supply of the UPS shall be via a fused load break
switch dis-connecter circuit breaker. The battery recharge time to 90% of full
charge shall be approximately ten times the discharge time at full load. The
UPS battery shall have a backup of 30 minutes at full load and supported with
inverter of suitable capacity.
14.4.20. CCTV SYSTEM
14.4.20.1. General
Proposed CCTV system shall be an open standard based integrated system with IP
network centric functional and management architecture aimed at providing high-
speed manual/automatic operation for best performance.
System shall use video signals from various types of indoor/outdoor CCD colour
cameras installed at different locations, process them for viewing on work
stations/monitors at Central Control Room/local control rooms and simultaneously
record all the cameras after compression using MPEG 4 or better standard. Joystick or
Mouse-Keyboard controllers shall be used for Pan, Tilt, Zoom, and other functions of
desired cameras.
System shall have combination of Digital CCD Colour video Cameras with individual IP
address, analog CCD Colour Video Cameras with Fixed or P/T/Z Lens, encoders/
decoders, Network Video recorders (NVR/CAMERA SERVER), Network attached
storage (NAS) / Raid backup device for recording, Application software, Colour Video
Monitors, Keyboards with Joystick controllers / Mouse-Keyboard, software based
Video Matrix Switcher, work station for System Administration / Management /
Maintenance etc.
The NVR / CAMERA SERVER can be embedded type or server based. However the
NVR / CAMERA SERVER software shall run on common off the shelf available
servers (Camera server & Database server). Each NVR / Camera Server shall be able
to handle 12 or more cameras.
Network Video Recorder shall offer both video stream management and video stream
storage management. Recording frame rate & resolution in respect of individual
channel shall be programmable.
System should ensure that once recorded, the video cannot be altered, ensuring the
audit trail is intact for evidential purposes. System shall provide sufficient storage of all
the camera recordings for a period of 30 days or more@ 25 FPS, at 4 CIF or better
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quality using necessary compression techniques for all cameras (extended capacity of
cameras i.e. present capacity + 25%).
System shall use a combination of IP enabled cameras & analog CCD cameras with
external encoder. The video shall be compressed using MPEG-4 or better standard
and streamed over the IP network.
Encoders shall digitize analog video, compress the digital video using various
compression algorithms for outdoor installations, shall be suitable to work from (-) 10o
C to (+) 50° C with RH up to 90% non-condensing.
14.4.20.2. System requirements

Camera with external encoder or IP Camera shall be used for image capture. Indoor
cameras shall be either with fixed focal length lens or with Pan/Tilt & Zoom lens as per site
requirement. All outdoor Cameras shall be Day/Night cameras.
Housing of cameras meant for indoor use shall be of IP 42 rating whereas outdoor camera
housing shall be of IP 66 or better rating. These must be integrated by the camera
manufacturer. System must provide built-in facility of water marking or Digital certificate to
ensure tamper proof recording so that these can be used as evidence at a later date, if so
desired. The recording shall support audit trail feature.
All camera recordings shall have Camera ID & location/area of recording as well as
date/time stamp. Camera ID, Location/Area of recording & date/time shall be
programmable by the system administrator with user ID & Password.
Facility of camera recording in real-time mode (25 FPS)/15/12.5/10 or lower FPS as well
as in any desired combination must be available in the system. Facility of Camera
recording in CIF, 2CIF, 4 CIF as well as in any combination i.e. any camera can be
recorded in any quality. Selective or Group of cameras must be available in the system.
System shall have facility of additional camera installation beyond the originally planned
capacity. In order to optimize the memory, while recording, video shall be compressed
using MPEG-4 or better standard and streamed over the IP network. Once on the
network, video can be viewed on a Control room work station or on analogue monitor
using a hardware decoder (MPEG-4/compatible standard receiver) and shall be recorded
on NVR/CAMERA SERVER and shall be backed up on NAS/RAID backup device.
System shall be triplex i.e. it should provide facility of viewing, recording & replay
simultaneously. The offered system shall have facility to export the desired portion of
clipping (from a desired date/time to another desired date/time) on CD or DVD. Viewing of
this recording shall be possible on standard PC using standard software like windows
media player etc.
PTZ Cameras shall have 64 or more pre-defined positions, to be selected through suitable
input alarm. System shall have provision of WAN connectivity for remote monitoring.
14.4.20.3. System design

Each camera should be connected to a Hardware Encoder, through cable, which shall
support minimum dual streams. Alternatively, the camera shall be IP based, UTP ready.
The encoders should be capable of producing streams @ 25 fps for each camera for
viewing on LAN and on monitors and also recording into the NVR/CAMERA
SERVER/Camera servers and NAS box/Raid backup device @ 25 fps or lower frame rate,
user selectable as per requirement, for each individual camera.
Encoders shall be Power Over Ethernet (POE) compliant and connected to Layer 2 or
Layer 3 switch as per system design using UTP CAT 6 Cable or fiber optic cable and the
77
required connectors as per standards. For monitoring purposes, Video monitors/Plasma

monitors/Video wall shall be set up with suitable mounting arrangements, as per user
requirements. Facility for viewing and controlling all the cameras at various other locations,
as required, shall be provided.
Monitoring at Local control rooms may be restricted to operation of certain cameras only &
system administrator should be able to configure the system, accordingly. There shall be a
Control System with Video Control Software to manage all the video surveillance devices.
14.4.20.4. Video Surveillance Application Software

The software shall operate on open architecture for integration with perimeter safety,
access control, PA and fire / safety systems based on open standards. Digital video
surveillance control software should be capable to display and manage the entire
surveillance system. It should be capable of supporting variety of devices such as cameras,
video encoders, video decoders, PTZ controller, NVR, NAS boxes/Raid backup device etc.
The software should have inbuilt facility to store configuration of encoders / decoders and
cameras. The software should support flexible 1/2/4 Windows split screen display mode or
scroll mode on the PC monitor or on preview monitor as per site requirement. The software
should be able to control all cameras i.e. PTZ control, Iris control, auto / manual focus, and
color balance of camera, selection of presets, Video tour selection etc.
The software should have user access authority configurable on per device or per device
group basis. The user shall have the facility to request the access of any camera and can
control the camera for a reservation period. Control of camera is released after the
reservation period.
The system shall provide User activity log (audit trail) with user ID, time stamp, and action
performed etc. The administrator should be able to add, edit & delete users with rights. It
shall be possible to view ability / rights of each user or the cameras which can be viewed &
controlled as per the permission assigned by the administrator.
It should have recording modes viz. continuous, manual, or programmed modes on date,
time and camera-wise. All modes should be disabled and enabled using scheduled
configuration. It should also be possible to search and replay the recorded images on date,
time and camera-wise. It should provide onscreen controls for remote operation of PTZ
cameras. It should have the facility for scheduled recording. Different recording speeds
(fps) and resolution for each recording mode for each camera should be possible.
14.4.20.5. Retrieval
The CCTV application should allow retrieval of data instantaneously or any date / time
interval chosen through search functionality of the application software. In case data is
older than 30 days and available, the retrieval should be possible. The system should also
allow for backup of specific data on any drives like CD/DVD/ Blu ray Recorders or any
other device in a format which can be replayed through a standard PC based software.
Log of any such activity should be maintained by the system which can be audited at a
later date.
78
14.4.20.6. Detailed Technical Specifications
14.4.20.6.1. Colour video Dome Camera with PTZ

Inter line transfer 1/4"or better format CCD
Image Device
sensor
Focal length 4mm to72 mm or better
Optical zoom (For Indoor Camera) 18X or better
Optical zoom(For Outdoor Camera) 26X or better
Number of Pixels 720X576
Scanning System PAL
Resolution 480 TVL or better
Illumination (For Indoor camera) 1.0 Lux (Color),0.1Lux(B/W) or better
Illumination (For Outdoor camera) 1.0 Lux(Color),0.05Lux(B/W) or better
Pan Travel 3600Continuous
Tilt Travel 0-900
Manual Tilt Speed 0.5°/SEC to 90°/SEC
Manual pan speed 0.5°/SECto90°/SEC
Preset Tilt speed 0.5°/SEC to90°/SEC
Preset Pan speed 0.5°/SEC to 300°/SEC
Preset positions Min.64
Iris Control Auto
Focus Auto
Required with black masking or other suitable
Back Light compensation
technology
White balance Auto
Electronic shutter Auto
S/N ratio >=48 dB
As per OEM's design, however generally AC
Power supply 230V@50Hz/12Vor 24 VAC Rectifier and
SMPS if DC supply
14.4.20.6.2. Bullet Camera

Signal System NTSC/PAL
Image Sensor 1/3" Sony Super HAD
Scanning System 2:1 Interlace
Horizontal Resolution 600 TV Lines
Synchronization Internal
Luminance S/N More than 50dB (AGC
Min. Illumination 0 Lux (IR LED On)
Gamma Adjustable / User
Video Output Level 1.0 Vp-p Composite
Day and night True Day and Night
IR LED 850nm, 20ea, Up to 30m
IR LED Operation On: 1Lux, Off: 3Lux
79
IP Rating IP66 (Water Repellent)

OSD Display Built-in
Sense-Up Auto Adjustable
3DDNR 0~100 Level Adjustable
D-WDR Off/Indoor/Outdoor
BLC Off/BLC/HSBLC
Image Freeze / Mirror /D-zoom / Sharpness
/NEG Image
Gain Control Off/Low/Middle/High
White Balance ATW/ PUSH/PUSH-
LOCK/MANUAL/INDOOR
Motion Zone 4ea (Mask On/
Privacy Masking Zone 8ea (Mask On/
Function Language Standard :English
Operating Temperature -10°C~50°C (14°F~122°F)
Storage Temperature -20°C~60°C (-4°F~140°F)
Power Supply Dual: DC12V±10% /AC 24V±10%
14.4.20.6.3. Fixed Colour Dome Camera Varifocal

Image Device 1/3”or ¼”CCD Sensor
Number of Pixels Minimum 720x576
Scanning System PAL
Resolution 480 TV Lines or better
Min Illumination 1 Lux at F1.2
S/NRatio >=48 dB
Electronic Shutter AUTO
Lens Built-in Varifocal lens. Auto Iris,
lens f=4–9mm. (approx.)
Back light compensation Required
Power supply As per OEM's design
14.4.20.6.4. MPEG4 Encoder (Hardware Based)

The encoder shall be built on embedded processor and real time operating system. The
Encoder should convert Analog Composite/S-Video input into good quality digital stream
on real time basis and shall be able to transmit as Unicast /Multicast IP packet with low
latency (less than 200 msec.) for live viewing as well as for recording.
The video resolution should be configurable at either of 4 CIF, 2 CIF, CIF @ 25 fps or at
lower frame rate per camera, user selectable.
The encoder should generate MPEG4 video stream Compliant with ISO/IEC 14496
standard. The encoder should be interchangeable with any standard encoder of any
other make, which generates MPEG4 video stream Compliant with ISO/IEC 14496
standard.
Encoder should have the following specifications or should match with the requirement.
Format PAL color, B/W,composite,25fps,2:1interlaced
80
Resolution (HxV pixels) 4CIF704x576,2CIF,CIF,QCIF

Frame Rate 25fps(PAL)and lower
Encoding MPEG-4 Compliant with ISO/IEC 14496 Standard
Video Parameters Brightness, contrast, hue, sharpness and sizings
electable
Video Latency Less than200 msec.
Connectors BNC for Composite Video for input, suitable connectors
for Power, Alarm in, and Alarm out, RJ-45
forEthernet10/100 Base-T output.
IP Address Static IP Address or as per System requirement.
MPEG4 standard Compliant with ISO/IEC 14496
IP Packets Unicast and Multicast
POE Compliant
Power supply As per OEM's design
14.4.20.6.5. Network Attached Storage

NAS box/RAID backup device shall be used to record video streams based on the
configuration assigned by administrator. Work stations & Servers within the LAN should
be able to access the recorded video streams. The NAS/RAID backup device should
support simultaneous play back and recording at full duplex operation.
It shall provide a high quality recording storage and play back of images. It should
support integration with LAN to provide Centralized Management and shall operate on
Windows / Linux OS. Support of user management for security level control and
authentication required.
The minimum capacity of storage device shall not be less than 2TB.
14.4.20.6.6. Camera Housing & mount

The camera mount should be:
i. Of the same make as that of camera and suitable for the model number offered
as specified by the manufacturer and should be an integrated unit.
ii. Should be compact and indoor / outdoor type as required.
iii. Should support the weight of camera and accessories such as housing, pan & tilt
head in any vertical or horizontal position etc.
14.4.20.6.7. Speed dome controller/PTZ controller

Speed Dome Controller should have variable speed joystick, LCD display for
Programming and it should be able to control the speed dome for PAN / TILT / Zoom.
14.4.20.6.8. Cables
Sr. No. Connectivity Cable Type
1 Camera to Video Encoder CoaxialRG6/U/CAT6/Fibre Optic
2 Video Encoder to Switch in control room UTPCAT6/Fibre Optic
3 Switch to Video Wall Switches UTPCAT6/Fibre Optic
4 From switches to NAS Box Fibre Optic
5 Hardware Decoder to monitor Composite signal cable
81

DNIT Vol 2 Part 4 Specs Elec Instru SCADA WWT Budha Nallah Ludhiana

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DNIT Vol 2 Part 4 Specs Elec Instru SCADA WWT Budha Nallah Ludhiana

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Annexure-3 : Revised “ Volume-2(R1)”

In continuation of Volume-2 (Part-3)

Volume -2 (Part - 4) (R1)

Specifications for Electrical, Instrumentation, PLC and

Sr. No. Description Page No.

14. SPECIFICATIONS FOR ELECTRICAL, INSTRUMENTATION, PLC AND

14.1. General Conditions

14.1.1. General Condition of Electrical, Instrumentation, PLC & SCADA Work

14.1.2. General Specification of Instrumentation

14.2. 11 KV ABS, DO FUSE & LA ON DP STRUCTURE

14.3. 11 KV HT Panel/11 KV SWITCHGEAR

14.3.1. Applicable Standards

Sr. Code No. Title

Sr. Code No. Title

14.3.2. Constructional Features

14.3.3. Safety Interlocks

14.3.5. Bus bars

14.3.6. Circuit Breakers

14.3.6.2. Operating Mechanism

rated frequency. Operating mechanism shall be provided with anti-pumping feature,

14.3.6.3. Spring Operated Mechanism

Mechanical indicators to indicate ‘charged’ and ‘discharged’ condition of spring shall be

14.3.6.4. Operating Mechanism Control

14.3.7. Safety Earthing Switches/ Earthing Trucks or cassettes

14.3.8. Inspection and Testing

14.3.9. Typical Bill of Materials

14.3.9.1. Incoming to the Switchboard:

Facia annunciator, 4 windows type, complete with ‘Accept’, ‘Reset’

Set of MCBs/ fuses for isolation and protection of auxiliary supplies

14.3.9.2. Outgoing Transformer Feeder:

Note: (*) To be decided by the contractor.

14.4. CABLING SYSTEM

The following points shall be considered while planning cabling system:

(xi) Cables shall be clamped to the cable tray at regular intervals.

(a) Installation of Cables

14.4.2. 11 KV XLPE CABLE

14.4.3. Scope of Work

14.4.3.1. Standard to be Followed

IS-7098 Cross Linked Polyethylene Insulated PVC Sheathed

IS-5831/1984 PVC insulation and sheath of Electric cables

IS-8130/1984 Conductors for insulated electric Cables and Flexible cords

IS-10418/1982 Drums for electric cables

14.4.3.2. Technical Requirement

14.4.3.3. Materials and Construction

(b) Conductor Shield

(d) Insulation Shield

(e) Inner Sheath

(g) Outer Sheath

(i) Current Rating

14.4.4. LT XLPE CABLE

14.4.4.2. Code and Standards

PVC insulated (heavy duty) electric cables for working

Cross linked polyethylene insulated PVC sheathed

Conductors for insulated electric cables and flexible

IS 5831 1984 PVC insulation and sheath of electric cables

Mild steel wires, formed wires and tapes for armouring

Methods of test for cables : Mass of zinc coating on

IS 209 1992 Zinc Ingot

Recommended current ratings for cables: Part – 2 PVC

IS 10418 1982 Drums for electric cables

Method of test for cables : Part 62 Fire resistance test

694 2010 PVC insulated unsheathed and sheathed cables for

14.4.4.3. Climatic Conditions