-1-

TECHNICAL SPECIFICATION
Supply, installing , testing and Commissioning of 80 W LED lamps along with
fixtures for switchyard lighting in Substations.
-1 - -1 -

3.1 SCOPE:

This Specification covers design, manufacture, assembly, shop testing,

forwarding and delivery F.O.R. destination including unloading at stores /
site free installation and commissioning of LED out door light fittings as per
the schedule .

3.2 STANDARDS:

Except otherwise specified or implied herein the LED Luminaries/ Light

fittings shall comply in all respects with the applicable latest International/
Indian standards for the technical specifications specified here in..

3.3 TYPE AND RATING:

The LED luminaries should be suitable for yard lighting in substation

switch yard application and should provide lumen output .

The Bidder shall furnish all valid type test reports along with the bid
including the following as applicable as per the standards.

i. Total Luminous flux

ii. Luminous Intensity distribution
iii. Electrical power
iv. Luminous efficacy
v. Color characteristics
- Chromaticity
- CCT
- CRI
vi. Degree of Protection IP-65
 -2-
GUARANTEED TECHNICAL PARTICULARS REQUIREMENTS OF LED
LIGHT FITTINGS/ LUMANAIRS FOR OUTDOOR YARD LIGHTING AT
SUBSTATIONS

Supply Source 85-264 volt. However, conditions for voltage

fluctuations should be considered and the system
should be robust enough to withstand such variation in
supply source.
Frequency 47 to 63 Hz
Luminaire Efficacy The luminaries should have a system efficacy of
greater than 90 lm/W
LED requirement High power LED with correlated color temperature of
4000K to 6500K+/-500K.
Luminaire technical requirement The LED luminaire should be suitable for substation
outdoor yard lighting application and should provide
similar lumen output to that of the existing light and
uniformity.
Usage Hours 12 hrs per day
Power Consumption Optimum for the efficacy and Lux equivalent to 250 W
HPSV Luminaires.
Power Factor Greater than 0.95
Life Expectancy About 50,000 burning hours at a 350 C ambient
temperature with 70% lumen maintenance.
Colour Rendering Index Minimum CRI of 75
Control Circuit Compatible with LED
Construction Cast Aluminium with Toughened Glass sealed to IP 65
with SS Toggles.
Required illumination level At main equipment 50 lux and at other locations
20 lux.
Warranty 3 years on entire luminary, illumination levels and on
LEDs for 100% replacement.

l
 -3-

GENERAL REQUIREMENTS FOR LED YARD LIGHTING

i. LED lamps of CREE/ NICHIA/OSRAM/SEOUL/PHILIPS LUMILEDS/

LEDNIUM shall be used for the purpose.

ii. The luminary casing/housing shall be of stainless sheet steel SS304 grade or
aluminum having high conductivity preferably to grade 5000 or LM9 or similar to
high conductivity heat sink material.

iii. The electronic components used shall be as follows:-

a. IC (Integrated Circuit) shall be of industrial grade or above.

b. Metallic film or paper or polyester capacitor shall be rated for a sustained

operating temperature of 1050 C.

c. The resistors shall be preferably made of metal film of adequate rating.

The actual rating versus loading shall be by a factor of 3.

d. The junction temperature of the switching devices such as transistors or

MOSFETs etc. shall not exceed 1250 C (allowing thermal margin of
25 0C).

e. The protective cum adhesive coating used on PCBs should be cleared and
transparent and should not affect color code of electronic components or
the product code of the company.

f. The construction PCBs and the assembly for the components for the PCBs
should be as per IS/IEC standards.

g. The electronics covered for this equipment shall pass all the tests called
for in the above specification. The tenderer shall indicate the deviation or
compliance otherwise the offer shall not be considered for evaluation.

h. The infrastructure of Quality Assurance facilities as called for in the above

specification must be available at the manufacturing facility. In-house
testing facility for Quality Assurance should be present. The compliance
shall be indicated clearly in the tender itself.

iv. The connecting wires used inside the luminaire, shall be low smoke halogen free,
fire radiant e-beam cable and use protection shall be provided in input side.

v. Care shall be taken in the design that there is no water stagnation anywhere. The
entire housing shall be dust and water proof having IP65 protection as per IEC
60529.

vi. The LED module(s), Driver gear, etc. shall be designed in such a way so that
temperature of heat sink shall not exceed 15 0C above the ambient temperature.
 -4-
vii. All the materials used in the luminaire shall be halogen free and fire retardant
confirming to safety standard UL94.

viii. Lumen maintenance of 70% for at least 50000 hours for Interior and exterior
applications. Data sheet showing lumen maintenance in the LED shall also be
submitted.

ix. The LED should have following qualities:

a. A unique, patented system of positioning LEDs in order to achieve optimal even

light distribution.
b. An embedded intelligent driver allowing a configuration which serves the needs
of a particular installation.
c. A built in thermal protection from overheating of the source of light.
d. The source of light safe for the environment.
e. High mechanical and vibration resistance of LEDs

Qualities of the intelligent controller:

a. Soft Start function – smooth increase of brightness from 0% to 100% in
programmable time.
b. Electronic compensation of environment temperature influence on luminous flux
value.
c. Optional Aging Compensation function – Electronic compensation of source of
light ageing influence on luminous flux value through increasing the luminaire
power in time.
LED should have the following Features:

1. Intelligent Current control

2. No Adverse Glare
3. No light pollution
4. No High-voltage non dust absorption
5. No High-temperature, No aging Yellow lampshade
6. Start without delay
7. No strobe
8. Impact Resistance, Shock-proof, without ultraviolet (UV) and infrared
(IR) Radiation
9. High color index,
10. High luminous efficiency
POWER ELECTRONICS:

1. The components used in the electronics circuit should be RoHS compliant

and the certificates for the same should be made available.

2. The connecting wires used in the circuit should be of UL grade and the
certificate of the same shall be made available on request.
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3. constant current out put for wide input voltage range.
4. MCPCB should possess thermal conductivity of up to 3W/m-0 K
5. MCPCB thermal resistance should be less than 0.350 C-cm2/watt.
Protection
1. over current
2. over voltage
3. over temperature
4. under voltage protection
5. out put short circuit protection
Testing procedures and certificates

1. Luminaire Photometry reports by NABL/DOE certified laboratories.

2. RoHS compliance certificate for all electronics components used.
3. The IES files of the Luminaires should be made available on request.
4. Life expectancy test of LEDs.

In- House Manufacturing, Assembly, Testing and Demonstration of

product.

1. Surface Temperatures Measurements

2. Over voltage protection
3. over current protection
4. over temperature protection
5. Humidity test
6. Insulation resistance, electrical strength and leakage current
7. Creepage distance and clearance
8. LED Mounting on PCBs
9. Electrical circuit assembly
10. Pre dispatch tests conducted as per IEC/IS
3.19 DRAWINGS:
3.19.1 The manufacturer shall supply four copies of the drawings which will
describe the equipment in detail for approval. After approval six complete
sets of final drawings for each substation shall be sent. The reproducible
drawings may also be supplied.

3.19.2 The following drawings for each item are to be supplied as a part of the
contract.

a) Outline dimensional drawings of LED Luminaries / Fittings and

accessories.
a) Assembly drawings and weight of main components.
c) Test reports (for both type and routine tests).

3.19.3 Six copies of instruction booklets/operation and maintenance manuals shall

be supplied for each substation. Descriptive literature and data on LED
Luminaries / Fittings, construction, shall be supplied for each LED
Luminaries / Fittings.
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3.20 GUARANTEED TECHNICAL AND OTHER PARTICULARS:

The Guaranteed technical and other particulars of the LED

Luminaries/Fittings shall be furnished in the proforma given in Annexure-I.

4.0 TESTS

a) All the offered equipment shall be fully type tested by the bidder as
per the relevant standard. The type tests must have been conducted
on the same rating of LED Luminaries/Fittings not earlier than ten
years as on the date of bid opening. The bidder shall furnish two sets
of the following type test reports as per relevant standards for each
type of equipment offered along with the bid. The offers received
without these test reports shall be treated as NON-RESPONSIVE .

b) Special tests other than type and routine tests, Bidder shall also be carry
out any tests that are required to establish the performance of the Light
fittings offered as per the technical specification at any stage at the bidder’s
cost.
c) The pre-shipment checks to be carried out by the Bidder are given under
clause 6.0, "Inspection".

d) The bidder shall offer the LED Luminaries / Fittings type tested. The type
tests should have been conducted not earlier than 10 years as on date of bid
opening. In the absence of not having valid type test reports as above, the
successful bidder shall conduct the type tests on the offered equipment
before supply.

5.1 Routine tests :

All standard routine tests in accordance with applicable International

/Indian Standards and latest amendments shall be carried out on the LED
Luminaries / Fittings.
Terminals connectors shall be tested as per IS: 5561. In addition, the
Bidder shall carry out an additional test to demonstrate withstand capacity
of wind load. The test procedure and acceptance norms shall be furnished
for Purchaser's approval.

2.1 Test reports

a) Four (4) sets of certified test reports and oscillograms shall be submitted for
approval prior to despatch of the equipment. The equipment shall be
dispatched only when all the required type and routine tests have been
carried out and test reports have been approved by the Purchaser.

b) Four (4) copies of the test reports for the tests carried out on the ancillary
apparatus shall be furnished to the Purchaser for approval prior to despatch.
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c) All auxiliary equipment shall be tested as per the relevant standard. Test
certificate shall be submitted for bought out items.

6.0 INSPECTION

6.1 General

i) The owner shall have access at all times to the works and all other places
of manufacture where the LED Luminaries/Fittings are being
manufactured and the Bidder shall provide all facilities for unrestricted
inspection of the Bidder's works, raw materials, manufacture of all the
accessories and for conducting necessary tests as detailed herein.

ii) The successful Bidder shall keep the Purchaser informed in advance of the
time of starting and of the progress of manufacture of equipment in its
various stages so that arrangements could be made for inspection.

iii) No material shall be dispatched from its point of manufacture unless

the material has been satisfactorily inspected and tested.

iv) The acceptance of any quantity of equipment shall in no way relieve the
successful Bidder of his responsibility for meeting all the requirement of
this specification and shall not prevent subsequent rejection if such
equipment are later found to be defective.

6.2 Inspection programme

a) The Bidder shall chalk out a detailed inspection and testing programme for
manufacturing activities for the various components. An indicative
programme of inspection as envisaged by the Purchaser. This is not
however intended to form a comprehensive programme as it is Bidder's
responsibility to draw up and carry out such a programme duly
approved by the Purchaser. The owner reserves the right to carryout
any tests by a third party.

b) Cost of inspection/tests and third party inspection if any shall be borne by

the Bidder.

c) Additional tests, if required, are deemed to be included in the scope of

work.

d) Stages of inspection and Purchaser's participation would be

defined and tied up at the time of award of contract.

7.0 QUALITY ASSURANCE PLAN :

7.1 The bidder shall invariably furnish the following information along with his offer
failing which the offer shall be liable for rejection. Information shall be
separately given for individual type of equipment offered.
a) The Structure of organization
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b) The duties and responsibilities assigned to staff ensuring quality of work

c) The system of purchasing, taking delivery and verification of materials

d) The system for ensuring quality of workmanship

e) The quality assurance arrangements shall confirm to the relevant

requirement of ISO-9001 on ISO 9002 as applicable.

f) Statement giving list of important raw materials, names of sub-supplies for

the raw materials, list of standards according to which the raw material are
tested, list of tests normally carried out on raw material in the presence of
suppliers representative, copies of test certificates.

g) Information and copies of test certificates as on (i) above in respect of

bought out items.

h) List of manufacturing facilities available

i) Level of automation achieved and list of areas where manual processing

exists.

j) List of areas in manufacturing process, where stage inspections are normally

carried out for quality control and details of such tests and inspections.

k) List of testing equipment available with the bidder for final testing of
equipment specified and test plant limitation, if any vis-a-vis the type.
Special acceptance and routine tests specified in the relevant standards.
These limitations shall be very clearly brought out in "Schedule of
Deviations" from the specified test requirements.

7.2 The Contractor shall within 30 days of placement of order, submit the following
information to the purchaser.

i) List of the raw material as well as bought out accessories and the names of
sub-suppliers selected from those furnished along with the offer.

ii) Type test certificates of the raw material and bought out accessories if
required by the purchaser.

iii) Quality Assurance Plan (QAP) with hold points for purchasers inspection.
QAP and purchasers hold points shall be discussed between the purchaser
and contractor before the QAP is finalised.

The contractor shall submit the routine test certificates of bought out accessories and
central excise invoice for raw material at the time of routine testing if required by the
purchaser and ensure that the quality assurance requirements of specification are
followed by the sub-contractor.
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7.3.1 The Quality Assurance Programme shall give a description of the Quality System
and Quality Plans with the following details.

a) Quality System:

* The Structure of the Organisation

* The duties and responsibilities assigned to staff ensuring quality of work.
* The system of purchasing, taking delivery of verification of materials.
* The system of ensuring of quality workmanship.
* The system of control of documentation.
* The system of retention of records.
* The arrangement of contractor internal auditing.
* A list of Administrator and work procedures required to achieve contractors
quality requirements. These procedures shall be made readily available to the
purchaser for inspection on request.

b) Quality Plans:
a. An outline of the proposed work and program sequence.
b. The structure of contractors organizations for the contract.
c. The duties and responsibilities ensuring quality of work
d. Hold and notification points.
e. Submission of engineering documents required by this specification.
f. The Inspection of the materials and components on request.
g. Reference to contractors work procedures appropriate to each activity.
h. Inspection during fabrication/construction.
i. Final inspection and test.

8.0 DOCUMENTATION:

8.1 i) The Bidder shall furnish along with the bid the dimensional drawings
of LED Luminaries / Fittings, GA and all other accessories.
ii) These drawings shall include the following information.
a) Detailed internal drawings of LED Luminaries / Fittings clearly
indicating all the details of assembly incorporating all important
dimensions, ratings etc.
b) Tolerances on dimensions.
c) Material designation used for different components with
reference to standards.

d) Fabrication details such as welds, finishes and coatings.

e) Catalogue or part numbers for each component and the total
assembly with bill of materials.
f) Identification marking.

g) Weight of individual components and total assembled weight.

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8.2 Test Reports

i) Four copies of type test reports shall be furnished to the Purchaser within
one month of conducting the tests. one copy will be returned duly
certified by Purchaser to the Bidder within three weeks thereafter and
on receipt of the same Bidder shall commence with the commercial
production of the concerned material.

ii) Four copies of acceptance test reports shall be furnished to the

Purchaser. One copy will be returned duly certified by the Purchaser and
only thereafter shall the materials be dispatched.

iii) All records of routine test reports shall be maintained by the Bidder at
his works for periodic inspection by the Purchaser.

iv) All test reports for tests conducted during manufacture shall be maintained
by the Bidder. These shall be produced for verification as and when
requested for by the Purchaser.

8.3 All drawings shall conform to International Standards Organization (ISO)

'A' series of drawing sheet/Indian Standards Specification. All drawings shall
be in ink and suitable for micro filming. All dimensions and data shall be in S.I.
Units only.

The Bidder shall within 2 weeks of placement of order, submit four sets of final
versions of all the above drawings for Purchaser's approval. The Purchaser shall
communicate his comments/approval on the drawings to the Bidder within
reasonable time. The Bidder shall, if necessary, modify the drawings and resubmit
four copies of the modified drawings for Purchaser's approval within two weeks
from the date of Purchaser's comments.

After receipt of Purchaser's approval, the Bidder shall within three weeks, submit
6 prints and two good quality reproducible of the approved drawings for
Purchaser's use.

8.4 Adequate copies of contract drawings, acceptance and routine test certificates, duly
approved by the Purchaser shall accompany each of the dispatched consignment.

8.5 The manufacturing of the equipment shall be strictly in accordance with the
approved drawings and no deviation shall be permitted without the written
approval of the Purchaser. All manufacturing and fabrication work in connection
with the equipment prior to the approval of the drawing shall be at the Bidder's
risk only.

8.6 Six copies of nicely printed and bound volumes of operation, maintenance and
erection manuals in English language shall be supplied by the Bidder along
with each LED Luminaries / Fittings to destination. The manual shall contain all
the drawings and information required for erection, operation and maintenance of
 - 11 -
theLED Luminaries/Fittings. The manual shall also contain a set of all the
approved drawings, type, routine & acceptance Test reports etc.

8.6 Approval of drawings by the Purchaser shall not relieve the Bidder of his
responsibility and liability for ensuring correctness and correct interpretation of
the latest revision of applicable standards, rules and codes of practices. The
equipment shall conform in all respects to high standards of engineering, design,
workmanship and latest revisions of relevant standards at the time of ordering
and the Purchaser shall have the power to reject any material which in his
judgment is not in full accordance therewith.

9 PACKING AND FORWARDING:

9.1 The equipment shall be packed in crates suitable for vertical/horizontal

transport as the case may be and suitable to withstand handling during transport
and outdoor storage during transit. The Bidder shall be responsible for any
damage to the equipment during transit, due to improper and inadequate packing.
The easily damageable material shall be carefully packed and marked with the
appropriate caution symbol. Wherever necessary, proper arrangement for lifting,
such as lifting hooks etc. shall be provided. Any material found short inside the
packing cases shall be supplied by Bidder without any extra cost.
9.2 Each consignment shall be accompanied by a detailed packing list containing the
following information:

a) Name of the consignee

b) Details of consignment
c) Destination
d) Total weight of consignment
e) Handling and unpacking instructions.
f) Bill of material indicating contents of each package.

The Bidder shall ensure that the packing and bill of material are approved by the
Purchaser before despatch.

9.3 Weight of the LED Luminaries / Fittings shall be designed, so that the LED
Luminaries / Fittings, can be transported by road. Heaviest single packet that can
be transported by owner's trailor is about 60 MTs.

10.0 QUANTITY AND DELIVERY REQUIREMENTS :

i) This is set out in Schedule.

ii) The scope of supply shall include a supply of 2.5% extra quantity of bolts,
nuts, washers, split pins, cotter pins and such other small loose items free of
cost.
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ANNEXURE-1
ANNEXURE -1
GUARANTEED TECHNICAL PARAMETERS FOR 80 W LED LIGHT FIXTURE
S.No Parameters Details/Guaranteed value
1 Output luminous Flux of luminaire 10200 lumens
2 Average Lux Level of luminaire ~ 15 Lux
0 0 0
3 Beam angle of Luminaire 120 ; horizontal: 110 , Vertical: 50
4 Uniformity <0.5
5 Photometric Curve Enclosed
6 Material of luminaire & Diffuser LM6/9 Aluminum & poly carbonate for lenses
7 Operating temperature -200C to 550C
8 Luminaire finishing colours Metal silver colour
9 Body and & Lamp shade material Aluminum LM6/9
10 Working temperature -200C - +550C
11 Working humidity 10% to 90% Relative Humidity
12 Working Life >50,000 burning hours at 35 0C ambient
temperature with 70% lumen maintenance.
13 Lamp’s efficiency > 95%
14 Fixture efficiency > 87%
15 Light distribution curve/beam pattern Symmetric
0 0 0
16 The highest light intensity angle 120 ; horizontal: 110 , Vertical: 50
17 Electrical insulation class Class F
18 Conformity with IP65 features IP 65
19 Conformity with UL 94 All the major components used in the
luminaire conforms to UL 94
LED: UL 746C
MCPCB : UL94 V0
0
20 Surface temperature of the luminaire < 15 C above ambient temperature
21 Power consumption of the luminaire 87W
22 IEC/IS applicable IEC 60529
LED
23 Make CREE/PHILIPSLUMILEDS/OSRAM/NICHIA
24 Family XLamp-XTE
25 LED operating current LEDs should not be driven more than 50% of
its maximum operating current.
26 LED life 60,000 burning hours with 70% lumen
maintenance.
27 LED power consumption 76 – 81W (only LEDs put together)
28 CCT (Correlated Color Temperature) 6000 – 6500K
29 Color rendering index (CRI) 75
0
30 LED junction temperature 150 C Max.
0
31 LED Thermal Resistance, Junction to < 6 C/W
Solder point
0
32 LED beam angle 125
MCPCB
33 Make Laird Tech
0
34 Operating temperature 110 C Max.
35 Junction temperature of electronic 70 C ±10% (Ta = 25 0C)
0

components
0
36 System Resistance 0.35 C/W
37 Heat dissipation and cooling process Natural convection
38 Thermal Conductivity >3.0Watt/mK.
39 Thermal resistance 0.340 C –cm 2/watt
40 IEC applicable IEC 62321
ELECTRICAL
41 Input voltage 100V – 300V
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S.No Parameters Details/Guaranteed value
42 Power factor >0.96
43 Input frequency 47 – 53 Hz
44 Driver Efficiency 96%
45 THD (Total Harmonic Distortion) <2.4%
46 Adjusting of the Luminaire The luminaire should have adjustable
inclination adopter for inclinations from 00 to 90 0.in order
to meet field requirements like effective
illumination can be achieved at various
heights by changing the inclination of the
luminaire.
47 Logo on the Luminaire Manufactures logo should be integrated in
the heat sink of the luminaire

GUARANTEED TECHNICAL PARTICULARS

(TO BE SUBMITTED BY THE BIDDER)

Sl.
No. Parameters Details/Guaranteed value
1. Name of the manufacturer of the Light fitting offered
Complete Postal address with Fax And Phone numbers.
2. Name of the manufacturer of the LEDs that go in to the
light fitting offered with Complete Postal address with
Fax And Phone numbers
3. Names of the manufacturers of all the other components
that go in to the light fitting offered with Complete
Postal addresses with Fax And Phone numbers of all
these manufacturers.
LUMINAIRE
4. Output Luminous Flux of luminaire
5. Average Lux Level of luminaire
6. Beam Angle of luminaire
7. Uniformity
8. Photometric Curve
9. Material of Luminaire & Diffuser
10. Dimensions
11. Weight of the luminaire
12. Operating temperature
13. Adjusting of the luminaire inclination
14. Luminaire finishing colours
15. Body & lamp shade material
Working temperature.
17. Working humidity
 - 14 -
18. Working life
19. Lamp’s efficiency
20. Fixture efficiency
21. Light Distribution curve /beam pattern
22. Lamp base
23. The highest light intensity angle
24. Electrical insulation class
25. Conformity with IP-65 fixtures

Sl.
No. Parameters Details/Guaranteed value

26. Conformity with UL94

27. Surface temperature of Luminaire
28. Power Consumption of Luminaire
29. IEC/IS applicable
30. Illumination (E) of LED luminaire equal to
HPSV lamps for the heights 6m, 8m, 10m &
12m.
31. Effective Illuminated area from the height of
6m, 8m, 10m & 12m.
LED
32. LED Operating Current
33. LED Life
34. LED power consumption
35. CCT (Correlated Colour Temperature)
36. Color Rendering Index (CRI)
37. LED Junction temperature.
38. LED Beam angle

MCPCB
39. Operating temperature
40. Junction temperature of Electronic components
41. System resistance
42. Heat dissipation & cooling process
43. Thermal conductivity
44. Thermal resistance
45. IEC applicable
Electrical
 - 15 -
46. Input voltage
47. Power Factor
48. Input frequency
49. Driver efficiency
50. THD (Total Harmonic Distortion)