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400kV XLPE Cable Specs for Arun-3

This document outlines the technical specifications for 400kV XLPE cable and accessories for a hydropower project in Nepal. It covers the scope, codes and standards, specific technical requirements, bill of quantities, technical qualifying requirements, functional guarantee requirements, general requirements, testing requirements, drawings and documentation requirements, quality plans, defect liability, packing requirements, definitions, abbreviations and list of documents. The electrical scope of work includes engineering, manufacturing, supply, installation, testing and commissioning of the cable and accessories along with necessary equipment, spares and tools.

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0% found this document useful (0 votes)

239 views136 pages

400kV XLPE Cable Specs for Arun-3

Uploaded by

Veera Bramham

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Download as PDF, TXT or read online on Scribd

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SHARAT HEAVY ELECTRICALS LIMITED

Ii•
DOCUMENT
TRANSMISSION BUSINESS ENGINEERING MANAGEMENT

TB-405-316-002
NOIDA
Rev 00 Prepared Checked Approved
NO. 1
TYPE OF
DOC. TECHNICAL SPECFICATION NAME Vyom JK ~ SKS
SIGN X-l(
?"
~.!f..
TITLE DATE 05.01 .2020 05 .01 .2020 a /'/I'l4 .
GROUP TBEM
400kV XLPE Cable
WONo.

CUSTOMER SJVN Arun-3 Power Development Company (P) Ltd. (SAP DC)
Consultant SJVN Ltd
PROJECT 4x225MW Arun-3 (HEP),Nepal
Contents
No of
0>- Section No. Description
W
....
iii0. Pages
- E Scope, Technical Requirements and Quantities
~ Section-1 15
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(f) " Annexure BOQ 15+4
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«;;: Section-2 Equipment Specification under scope of supplies 19+11
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Section-3 Project details and general technical requirements 41
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Annexure B Compliance Certificate to Technical Specification 01
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'" Anne xure_ Relevant Drawings of the Project
c: .,
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cUi Remarks: Bidder to note that data and details of Guaranteed Techn ical Particulars &
.s
-
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.t:: .- '" Design documents shall not be reviewed during Technical Evaluationl Review, hence
compliance of Guaranteed Technical Particulars in line with Technical Specification shall
....
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be bidder's responsibility .

1
Rev Date Altered Checked Approved Annexure BOQ & Annexure_TQR revised

No.
Distribution To
Co ies
Bharat Heavy Electricals Limited SECTION‐1
Project: 4x225MW Arun‐3 (HEP), Nepal
Technical Specification: 400kV XLPE Cable & its Accessories
Doc No. TB‐405‐316‐002 Rev 00
-------------------------------------------------------------------------------------------------------------------

Contents

1. Scope

2. Codes & Standards

3. Specific Technical Requirements

4. Bill of Quantities

5. Technical Qualifying Requirements

6. Functional Guarantee Requirement

7. Other General Requirements

8. Type, Routine, Acceptance & Field test:

9. Drawings & Documentation

10. Quality plan

11. Defect liability and latent defect

12. Packing and Dispatch

13. Definitions Used

14. Abbreviations Used

15. List of Documents/ Drawings

________________________________________________________________________________
Section 1:  Scope, Project specific technical requirements & Bill of Quantities         Page 4 of 15
Bharat Heavy Electricals Limited SECTION‐1
Project: 4x225MW Arun‐3 (HEP), Nepal
Technical Specification:  400kV XLPE Cable & its Accessories
Doc No. TB‐405‐316‐002 Rev 00
-------------------------------------------------------------------------------------------------------------------
The bidder has to consider the functional guaranteed value for the 400kV EHV XLPE Cable as
per following: ‐

a) Min accepted Guarantee for the Total Losses (Copper Losses + Dielectric Losses etc. ):

GUARANTEED LOSS – 113kW FOR 4550 Meter (AT RATED CURRENT 450A)
b) Evaluation, Penalty and Rejection Criteria
i. Penalty on Guarantee (INR) :  2,50,000 per kW@@
ii. Rejection :  >10% of guaranteed losses quoted by the bidder

Location to demonstrate Guarantee: At Works
Rectification to Meet Guarantee: At Works**

Liquidated Damages shall be levied for short fall @ Rs.2,50,000/‐ per KW.
Penalty shall be imposed on Total losses which shall be calculated as Total measured length of
400kV EHV XLPE Cable laid multiplied by per kW loss per meter length respectively.

** The Contractor shall have to make good and meet the guarantees in case of shortfall in test
values vis‐à‐vis guaranteed values. Two month, will be given to the Contractor for the same for
rectification and re‐demonstration.

@@ Penalty shall be imposed on Total losses which shall be calculated as Total measured length
of XLPE Cable laid multiplied by per kW loss per meter length respectively.

7. OTHER GENERAL REQUIREMENTS
The other general requirements for the equipment (400KV XLPE Cable & its Accessories) shall be
as follows,
1. Schedule
a. Bidder shall submit detailed bar chart indicating all the milestones from engineering till
manufacturing/ testing, dispatch to site, installation, testing and commissioning.
b. Bidder to submit list of consumables with shelf life of less than two years. It shall be
supplied before erection after clearance from BHEL/ Customer/ Consultant.
2. Store
a. Open store area shall be provided by BHEL, however, bidder shall provide their
requirement of space in open & closed store during tender stage only. In addition to
this, bidder shall also provide their standard recommendations for precautions to be
taken during unloading and storage etc for approval of BHEL/ Customer/ Consultant.
Bidder to submit requirement of closed store during technical bid.
b. Office facilities & accommodation for bidder’s staff along with conveyance,
transportation of all special tools & plants, testing kits etc. shall be in bidder’s scope.
3. Installation of cable trays, cable rack assembly along with Earthing
a. The cables shall be laid in cable trays fixed on cable racks assembly in cable tunnel
(underground / surface as applicable) / trestle / trench, as per site requirement. Cable
________________________________________________________________________________
Section 1:  Scope, Project specific technical requirements & Bill of Quantities         Page 5 of 15
Bharat Heavy Electricals Limited SECTION‐1
Project: 4x225MW Arun‐3 (HEP), Nepal
Technical Specification:  400kV XLPE Cable & its Accessories
Doc No. TB‐405‐316‐002 Rev 00
-------------------------------------------------------------------------------------------------------------------
racks assembly in cable trench/ trestle shall be supplied and fixed by BHEL based on
detailed input design and drawing provided by bidder. These details shall be furnished
during tender stage. Installation and fixing of earthing grid with suitable size of GI flats
shall be done by BHEL, however, earthing of cable system including earthing cable shall
be in bidder’s scope.
b. It may also be noted that earth grid connection shall not be available at all points in
route and, hence provisions of independent earthing etc. shall be deemed to be
included in bidder’s scope.
c. The required drilling, fabrication and minor civil works required for completion of
cable laying work shall be in bidder’s scope.
4. Termination and Jointing
a. Tools & tackles, testing instruments/ kits required for carrying out termination/
jointing works shall be bidder’s scope.
b. Any cable or accessories damaged during installation, testing & commissioning shall be
made good/ repaired/ replaced by bidder to the satisfaction of BHEL/ Customer.
5. Site Testing & Commissioning
a. Bidder shall depute its qualified testing & commissioning engineer including supply of
all testing instruments/ kits (DC test for outer sheath and HV test).
b. Bidder shall submit complete methodology for conduction of site tests for further
approval of BHEL/ Customer/ Consultant.
6. Construction supply
For construction purpose, the necessary power supply at site shall be provided by
BHEL at one point only, however supply requirements for testing etc. shall be arranged
by bidder only.
7. Site Supervisor and Jointer
a. Termination/ jointing of cables shall be done by skilled and experienced jointer
certified by OEM of the joints/ end terminations and duly approved by Engineer‐in
charge.
b. Provision of site supervisor and skilled technician, qualified jointer etc. along with tools
& tackles, testing instruments/ kits etc. shall be deemed to be included in bidder’s
scope.
8.   Manuals – Required receipt, storage, installation, testing, commissioning manuals
covering all equipment of EM works shall be supplied by bidder as per project
requirement.
c. Storage and preservation manual
d. Safety manual
e. Erection Manual
f. Testing and commissioning manual
g. Operation & Maintenance manual
h. Long term storage manual for Generator Transformer
i. Long term storage manual for boxed up component / equipment.
j. Repair process / procedure manual for equipment / system

9. Additional Inputs to be furnished by bidder
Bidder to submit special tools, tackles, slings, testing instrument etc. required for handling,
pulling, laying, installation, testing and commissioning of 400 kV cables, accessories and
________________________________________________________________________________
Section 1:  Scope, Project specific technical requirements & Bill of Quantities         Page 6 of 15
Bharat Heavy Electricals Limited SECTION‐1
Project: 4x225MW Arun‐3 (HEP), Nepal
Technical Specification:  400kV XLPE Cable & its Accessories
Doc No. TB‐405‐316‐002 Rev 00
-------------------------------------------------------------------------------------------------------------------
cable support systems, shall be arranged by the Contractor.
Erection, testing and commissioning tools/tackles and testing instruments, to be arranged
by the Contractor, shall include but not limited to the following:
a) Special tools required for laying, installation and dismantling of the 400kV cables,
accessories and cable support systems.
b) The HVAC testing kit and partial discharge measurement equipment for field tests.
c) Any additional requirement of erection tools, testing instrument etc. for erection,
testing and commissioning shall be met by the Contractor without any extra cost to the
Employer.

10. Bidder to note that different bays may be commissioned different point of time, and
hence bidder shall be required to deploy the resources multiple times at site in line with
site requirement.
11. Bidder shall dispatch the consumables just before the start of the work at site and
only after specific clearance from BHEL/ Customer.
12. Any special tools and tackles required to complete the cable installation/ laying,
termination, testing and commissioning etc. shall be included in the offer. However,
general tools and tackles for laying of cables shall be provided by BHEL.
13. The bidder must fill up all the details required for offered item/s. Instead of indicating
“refer drawing, or as per IS/IEC”, the exact value/s must be filled in.
14. Availability of Spare Parts And Maintenance Supports ‐ Bidder shall ensure the
availability of spare parts and maintenance support services for the equipment (400KV
XLPE Cable & its Accessories) at least for 15 years from the date of supply. Bidder/ OEM
shall give a notice of at least one year to the BHEL/ Customer before phasing out the
products/spares to enable the owner for placement of order for spares and services.



8. TYPE, ROUTINE, ACCEPTANCE & FIELD TEST:

8.1. TYPE TESTING FOR 400KV XLPE CABLE

The contractor shall carry out type tests for the respective Equipment (400KV XLPE Cable & its
Accessories). The charges for each of these type tests shall be indicated separately in the
respective price schedules and the same shall be considered for the evaluation of the bids. The
owner reserves the right to waive conducting of any or all of the specified type tests on
submission of type test certificates from Govt. approved labs/ accredited laboratories conducted
on similar equipment during last five (5) years from the date of bid opening (dated 09 February
2018), in which case the type test charges shall not be payable for the type tests which are
waived. The type test charges shall be paid only for the test(s) actually conducted successfully
under this contract.

The contractor shall only submit the certificates from Govt. approved labs/ accredited laboratories
of the type tests for the respective equipment (400KV XLPE cable Accessories) which should have
been carried out within last five (5) years from the date of bid opening i.e. dated 09 February
2018. These reports should be for the tests conducted on the equipment similar to those
proposed to be supplied under this contract and the test(s) should have been either conducted at
an independent laboratory or should have been witnessed by a client. In case the contractor is not
able to submit report of the type test(s) conducted within last five years from the date of bid
opening i.e. dated 09 February 2018, or in case the type test report(s) are not found to be meeting
the specification requirements, the contractor shall conduct the test without any financial
implication to BHEL / Customer.

8.3. REPETITION OF TYPE TEST

Type tests shall be carried out to prove the general qualities and design of the 400kV XLPE cable.
The charges for each of these type tests shall be indicated separately in the respective price
schedules and the same shall be considered for the evaluation of the bids.
The BHEL / Owner reserves the right to waive conducting of any or all of the specified type tests
on submission of type test certificates from Govt. approved labs/ accredited laboratories
conducted on similar equipment during last five (5) years from the date of bid opening (dated 09
February 2018) , in which case the type test charges shall not be payable for the type tests which
are waived.

The type test charges shall be paid only for the test(s) actually conducted successfully under this
contract.

Sr.No.   Description of Test

1 Check on insulation thickness as per IEC 60811 (check of cable construction)
2 Tan δ measurement.
3 Partial discharge test after complete assembly of end terminations
‐ At ambient temperature
‐ At high temperature (90°C)
4 Cable bending test followed by partial discharge test at ambient temperature.
5 Switching impulse voltage withstand test as per IEC 60230/62067
Lightning Impulse voltage withstand tests followed by power frequency voltage
6
test as per IEC 62067/6023
7 Ageing treatment as per IEC 60811
8 Tests for determining the mechanical properties of XLPE insulation and outer
sheath (PE) before and after ageing.
9 Heat cycle voltage test as per IEC 62067
________________________________________________________________________________
Section 1:  Scope, Project specific technical requirements & Bill of Quantities         Page 8 of 15
Bharat Heavy Electricals Limited SECTION‐1
Project: 4x225MW Arun‐3 (HEP), Nepal
Technical Specification:  400kV XLPE Cable & its Accessories
Doc No. TB‐405‐316‐002 Rev 00
-------------------------------------------------------------------------------------------------------------------
10 Flame retardant test on outer sheath (Test under fire condition)
11 Insulation shrinkage test
12 Measurement of resistivity of semi‐conducting screens as per IEC 62067.
13 Conditioning & mechanical test as per IEC 60811
14 Pressure test at high temperatures on over sheaths
15 Hot set test for XLPE insulation.
16 Measurement of carbon black contents in PE outer sheath.
17 Water penetration test. hardness of outer sheath
18 Measurement of hardness of outer sheath
19 Abrasion test on outer sheath.
20 Heat shock test on outer sheath.
21 Oil resistant test for outer sheath.

8.4. Field Testing & Commissioning
1. Bidder shall carry out the installation, field testing and commissioning of the equipment
(400KV XLPE Cable & its Accessories). Further appropriate test and commissioning reports and
as‐built documentation as necessary be submitted.
2. Field testing and commissioning of the equipment (400KV XLPE Cable & its Accessories) shall
be done by Bidder/OEM only.
3. Bidder shall also submit site acceptance testing (SAT) procedures and get them approved from
BHEL/ Customer before carrying out the site testing at site.
4. Bidder/ OEM shall coordinate with manufacturers of other equipment wherever required and
shall freely and readily supply all technical information for this purpose as and when called for.
5. Testing instruments required for field testing is in the scope of bidder.  Special tools & tackles
for site testing kits for testing & commissioning shall be in bidder's scope, however, it shall be
brought at site on returnable basis only.
6. All the general and special tools & tackles, testing instruments/ kits required for carrying out
termination/ jointing works shall be bidder’s scope. it shall be brought at site on returnable
basis only.

8.5. PERFORMANCE TESTING
If nothing unusual has been observed in load run and load rejection tests, the test service period
of 72 hours shall follow. During this test service period, the unit must operate continuously at
rated condition without any interruption except of those beyond the control of the Contractor.
However, such interrupted period shall not be counted for in the test service period. There should
be one‐month reliability run of the complete unit reckoned from the date of taking over by
employer. During reliability run, machine shall be operated by employer and any problem
observed during this run shall be attended by the contractor including replacement of
components and providing requisite manpower.

8.6. General Note for type, routine, acceptance & field tests

 Type, Routine and acceptance tests as listed in relevant standard and equipment

9. DRAWINGS & DOCUMENTATION

9.1. Documents to be submitted along technical bid
1. Bidder shall furnish following document / calculations of cable for following during tendering
stage itself for information purpose. The same shall be reviewed and commented during
contract stage only. (Bidder to note, deviations if any needs to be submitted in schedule of
technical deviation only. Deviations submitted elsewhere in bid document / in any calculations
shall not be considered.)

Sr Name of Documents
1 SCHEDULE OF GUARANTEED TECHNICAL
PARTICULAR (as per attached format)
2 Detailed Cross Section Drawing of Cable.
3 List of Type Test Report Details of Test object, test
name, Test Lab, Report number
& report date.
4 Requirement of Earthing & Bonding
5 Calculation for Rated short circuit capacity for
metallic sheath.
6 Calculation for Rated short circuit capacity for
Conductor.
7 Calculation for Maximum & Average Electrical
Stress on Conductor, Conductor screen
________________________________________________________________________________
Section 1:  Scope, Project specific technical requirements & Bill of Quantities         Page 10 of 15
Bharat Heavy Electricals Limited SECTION‐1
Project: 4x225MW Arun‐3 (HEP), Nepal
Technical Specification:  400kV XLPE Cable & its Accessories
Doc No. TB‐405‐316‐002 Rev 00
-------------------------------------------------------------------------------------------------------------------
semiconductor layer, Insulation screen semi‐
conductor layer & Insulation
8 Calculation for Screen/ sheath voltage under full
load condition
9 Calculation for Screen/ sheath voltage during an
external three phase symmetrical through‐fault.

10 Details of System being offered for (section‐2
clause 17.1.1.2) “Control, monitoring and
related items and services Co‐ordination and
provision of necessary contacts and/or ports
for integration with plant SCADA system.”
11 Suggested Cable Trench arrangement for 400kV
XLPE Cable.
12 Any other calculation / design document as
applicable in line with technical specification and
/ or relevant section of IEEE / IS etc

2. Bidder shall furnish calculations for screen/ sheath voltage/ current and the recommended
method for metallic screen bonding and screen sizing shall be designed in such a manner so
that it can carry the earth fault current level of the system, considering 400KV system is solidly
grounded.

9.2. Drawings / documents required for engineering manufacturing clearance

The drawings/ documents, as follows shall be used for providing engineering manufacturing
clearance of the equipment (400KV XLPE Cable & its Accessories) and furthermore, it shall be used
for delay analysis, if any from bidder. The schedule for submission and resubmission shall be in
line with details provided in section‐3. The successful bidder is required to submit drawings and
documents that shall cover but not limited to the following:

LOT‐1

Sl. Description of Drawing
1 Cable Cross Section Drawings with Guaranteed Technical particulars
2 Type Test Report of Cable
Bonding / Earthing Cable Cross Section Drawings with Guaranteed Technical
3
particulars
4 Design Calculations including cable sizing
5 Earthing / sheath voltage limitation study (Voltage Gradient)
6 Temperature rise calculations & Heat Losses
7 Sizing calculation & short circuit withstand capabilities of metallic sheath.
8 Cable Cutting & Cable Drum Schedule
9 OGA Drawing with Guaranteed Technical Particulars of Cable Drum
10 Quality Assurance Plan & Inspection Test Schedule of HV Cable
________________________________________________________________________________
Section 1:  Scope, Project specific technical requirements & Bill of Quantities         Page 11 of 15
Bharat Heavy Electricals Limited SECTION‐1
Project: 4x225MW Arun‐3 (HEP), Nepal
Technical Specification:  400kV XLPE Cable & its Accessories
Doc No. TB‐405‐316‐002 Rev 00
-------------------------------------------------------------------------------------------------------------------

LOT‐2

Sl. Description of Drawing
1 OGA Drawing with Guaranteed Technical particulars of Termination Kits
2 OGA Drawing with Guaranteed Technical particulars of Straight Through Joints
3 OGA Drawing with Guaranteed Technical particulars of Link Box
4 Type Test Report of Cable Termination, Jointing Kit & Link Box
5 Quality Assurance Plan & Inspection Test Schedule of HV cable accessories

In addition to above, following documents are to be submitted during detailed engineering stage
as per project requirement.

1 Cable Laying Technique criteria (Flat / Trefoil)
2 Loading Distribution on Foundation / Bracket
3 OGA / Cable Layout (Plan & Section) for Cable installation
4 Foundation / Clamp / Brackets drawings for cable laying
5 Arrangement of XLPE Cable Trench in Cable Tunnel
6 Cable Termination Arrangement
7 Sheath Earthing / Cable Earthing Arrangement including accessories
8 Cable Laying & handling Procedure document
9 XLPE Testing Procedure document
10 Component wise weight schedule, lifting arrangement & safety arrangement
All Electrical & Control Drawings such as Electrical Panels OGA, Cable Block &
11 Termination Diagram, Schematic Diagram, JB/MB/Kiosk Diagram etc. in respect of XLPE

12 Erection Procedure documents along with all the drawings pertaining to this section

13 Technical Datasheet & Catalogue of every component used under this chapter.
Any other document required to meet technical requirement in line with relevant IS/
14
IEC code / technical specification.

10. QUALITY PLAN
The successful bidder shall submit Quality Assurance Plan in line with reference QAP attached in
Section‐2 for the equipment (400KV XLPE Cable & its Accessories) etc. with in‐process inspection
methods, tests, records, etc. for BHEL/ Customer approval. Customer hold points will also be
included in the plan, which shall be mutually agreed by the BHEL/ Customer. In case bidder has
reference Quality Assurance Plan agreed with BHEL/ Customer, same shall be submitted for
specific project to BHEL/ Customer approval. There shall be no commercial implication to BHEL/
Customer on account of Quality Plan approval.

Superior quality control system shall be adopted to assure high product quality. Raw materials of

________________________________________________________________________________
Section 1: Scope, Project specific technical requirements & Bill of Quantities Page 15 of 15
Section-2 ARUN-III HEP

SECTION – 17

400kV XLPE CABLES

17.1 SCOPE OF WORK

Scope of work under this section covers the provision of labour, tools, plants,
materials and performance of work necessary for the design, engineering, manufacture,
quality assurance, quality control, shop assembly, shop testing, packaging & delivery
at site including insurance, unloading, site storage and preservation, in plant
transportation at site, erection / installation, testing supervision, pre commissioning,
successful commissioning, performance and acceptance testing, handing over to
Employer and warrantee for two years of 400kV XLPE Cables as per the
specifications hereunder, complete with all auxiliaries, accessories, spare parts and
warranting a trouble free safe operation of the installation. The scope of work covered
under this section shall be read in conjunction with General Technical specifications,
Section-3
Chapter-1.

17.1.1 Detail scope of work

The scope of work shall be a comprehensive functional system complete in every
respect including but not be limited to following:

17.1.1.1 400 kV XLPE cable

i. Thirteen (13) nos. - single-phase, 400-kV, copper conductor, XLPE cables

(including one spare cable of the longest length) for the interconnection of
400kV GIS Adaptor in transformer Hall to 400kV GIS in Pot Head Yard,
each complete with all necessary auxiliary equipment and hardware. The
tentative length of cable will be 4550 Meter.

ii. Twenty (24) nos. – cable sealing end (SF6 to XLPE ) suitable for
terminating the cable for interconnection with GIS complete with all
necessary fittings, accessories and hardware.

iii. One (1) set of sealing arrangement for sealing the one (1) spare cable at both
ends.

Remark - 1. Unloading of material at Store shall be provided by BHEL.

Chapter 17: 420kV XLPE Cables ED/TS/ARUN/01.06.17 Page 1 of 19
2. Closed & Open store shall be provided by BHEL including security of material.
ARUN-III HEP

iv. One (1) set of bonding arrangement for the connection of the cable sheath to
the grounding system.

v. One (1) Lot of cable support system including cable trays / hangers, fixtures,
hardware etc. for supporting all the cables along the entire length of cable.

The payment of cable length will be as per actual measurement at site jointly.
The length mentioned is for evaluation of bid purpose only. The final length
shall be decided after jointly with successful bidder as per the latest layout
arrangement of power project.

17.1.1.2 Control, monitoring and related items and services

Co-ordination and provision of necessary contacts and/or ports for integration
with plant SCADA system.

17.1.1.3 Common Supplies and services

i. Drawings, documents and design calculations as per clause 17.6.
ii. Shop, assembly, inspection & tests as per clause no. 17.7.
iii. Packaging, handling and site storage as per clause no. 17.8.
iv. Delivery, installation and commissioning as per clause no. 17.9.
v. Tools and instruments as per clause no. 17.10.
vi. Spare parts as per clause no. 17.11
vii. Field/touch-up painting including all painting materials.

17.1.1.4 Completeness of System

Any other item (s) not mentioned specifically but necessary for the satisfactory
completion of scope of work defined above, as per accepted standard (s)/best
international practice.

17.2 STANDARDS & REGULATIONS

The design, manufacture and testing of the various equipment covered under this
specification shall comply with the requirements of the latest edition of the relevant
IEC/IS/IEEE/ISO standards only. Preference for latest IEC standards for particular
equipment / system shall be governed over IEEE/ IS/ ISO standards. Further rules, guide
lines and standard laid down by international/ national agency shall be applicable in this
specification.

Chapter 17: 420kV XLPE Cables ED/TS/ARUN/01.06.17 Page 2 of 19

ARUN-III HEP

The relevant abstract (in soft / hard copy) of all referred standards shall be provided free
of cost during engineering stage for facilitating review/ approval of submitted
drawing/documents.

17.3 PARAMETERS& GUARANTEES

17.3.1 Layout and General Arrangement

For the interconnection between 400kV GIS adaptor in Transformer Hall and the 400 kV
GIS in Pot Head Yard, Twelve (12) nos. of single-phase 400 kV XLPE cables shall be
provided. The laying of cable shall be in cable cum ventilation tunnel in flat/trefoil
formation. The preliminary layout Tender drawing of Transformer Hall, Pot Head yard
and cable cum ventilation tunnel are covered in section- 35.
In addition, one single-phase 400 kV XLPE cable shall be provided and shall be laid with
sufficient slack as spare cable with a total length equal to that of the longest cable used
for connection. The spare cable will be laid in such a way that it can be pulled to any
termination position without disturbing the other Twelve [12] cable lengths.

The spare cable length will be laid without termination, with suitable sealing at both ends.

The spare end terminations will be stored separately and will be used whenever spare
length is required to be put into service depending on shelf life. The laying of spare cable
shall be designed so as be used in any equipment without cutting and without exceeding
the specified bending radius.

17.3.2 Type and Rating

Sr.No. Particulars Unit Value/Remarks

1 Rated System Voltage kV 400

2 Highest System Voltage kV 420

3 Number of Phases Nos 3

4 System Frequency Hz 50±5%

5 System Earthing Solidly Grounded

6 Rated normal current at nominal voltage A (rms) 630A

450 A
(400kV)

Chapter 17: 420kV XLPE Cables ED/TS/ARUN/01.06.17 Page 3 of 19

ARUN-III HEP

7 Rated Peak withstand current kA 125

8 System fault current for one second kA 50

9 Rated withstand voltage to earth of cable

and cable sealing s

- One
60 minute power frequency kV 630
440

- Lighting impulse kVp 1425 (1.2/50 )

- Switching impulse kVp 1050 (250/2500)

10 Nominal Cross section area of conductor mm2 500

11 Type of Conductor Copper

12 Internal Semiconductor XLPE semi-conductor

shield

13 Insulation XLPE

14 External Semiconductor XLPE semi-conductor

shield

15 Metallic Sheath Corrugated/Aluminum/

Corrugated copper/

Welded
aluminum/laminated
aluminum

16 Outer sheath PE with HFFR Layer

17 Creepage distance for termination Mm/kV 31

18 Max permissible operating temperature of ºC 90

the conductor at rated continuous current

19 Short Circuit Temperature ºC 250

20 Daily Load Hours 24

21 Sheath voltage under full load condition to V 180 (Max)

Chapter 17: 420kV XLPE Cables ED/TS/ARUN/01.06.17 Page 4 of 19

ARUN-III HEP

ground

22 Laying Method Flat/trefoil formation

in cable tunnel

23 Design Ambient Temp ºC 40

24 Min ambient Temp ºC -4

17.3.3 Operating conditions

Normal operation shall be defined as operation with operating parameters within the
following ranges:

Grid parameter Normal range

Voltage 90 % to 110 % of rated value

Frequency 47.5 Hz to 52.5 Hz

17.3.4 Performance Guarantee

17.3.5.1 The bidder shall guarantee the following parameters of 400kV cables and the same
shall be supported by calculations submitted along with the bid. The values of these
parameters shall be indicated in the Guaranteed and other Technical Particulars.
i) Power loss in conductor and in metallic sheath from GIS adapter bushing
termination upto GIS termination in Pot Head Yard per length of 400kV
single core 500mm2 cables while carrying continuous rated current.
ii) Dielectric power loss from GIS adapter bushing termination upto GIS
termination in Pot Head Yard per length of 400kV single core 500mm 2
cables, while carrying continuous rated current.
iii) The temperature rise for conductor and insulation/sheath while carrying
continuously rated current
a) For conductor
b) For cable insulation / sheath
iv) DC resistance of conductor at 20 0 C (Firm value without tolerance).
v) Skin Effect Factor.

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17.3.5.2 The total losses listed in the Guaranteed and other Technical Particulars by the bidder
shall be the losses in KW basis of 420 kV cables by considering cumulative length of
4550 meter.. The calculation in support of stated value of guaranteed total power
losses for conductor, sheath and dielectric shall be submitted along with the bid.

17.3.5.3 The losses indicated in the Guaranteed and other Technical Particulars shall be firm.
To verify the actual losses, the actual DC resistance shall be measured to calculate the
AC resistance of the cable, using factors as given in IEC 60287. Further, the actual
loss angle (dielectric loss) and other parameters shall also be measured during testing.
The actual losses may then be determined based on these measured/ calculated values.
If the actual calculated losses are found to be more than the values guaranteed, penalty
will be imposed on the Contractor at the rate of Rs. 250000 for each kW and its
fraction of excess in losses for actual length of cable.

17.3.5.4 The Employer reserves the right to reject the cable if the actual calculated losses
exceed >10%of the guaranteed losses quoted by the bidder

Minimum
17.3.5.5 For accepted
purpose
Deleted Guarantee for
of comparison of the
bid,Total
theLosses (Copper
quoted pricesLosses
shall+ Dielectric
be enhancedLossesby
etc.): 113 kW for 4550
capitalization meter
the cable (at rated
losses at thecurrent
rate of450A)
Rs. 125000 per kW (corresponding to
lowest quoted losses amongst the bidders). Loading for all the 13 lengths including
one spare length of XLPE Insulated Power Cables shall be considered for equalization.
No change in the values of Losses Quoted in guaranteed & technical particulars shall
be permitted after opening of bids & evaluation will be carried out on the basis of
information furnished by the bidder in the bid.

17.3.5.6 The Contractor shall have to make good and meet the guarantees in case of shortfall in
test values vis-à-vis guaranteed values. One month, will be given to the Contractor for
the same for rectification and re-demonstration at works. Delay on account of
Rectification process shall not affect the overall project schedule. Imposition of
penalty on account delay due to rectification shall be governed by respective clauses of
SCC/GCC.
Contract.

17.4 DESIGN AND CONSTRUCTION

17.4.1 Design considerations

The cables shall be capable of carrying the specified rated current continuously
without exceeding the specified temperature limitations. Sheath voltage under full
load condition shall not exceed 180V to ground at termination. Sheath shall be solidly
grounded at the switchgear end. The charging current of the cable shall be as low as

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possible.

The 400 kV systems will be solidly grounded. Cables will be protected from over
voltages caused by lightning strikes or switching surges by means of station type
lightning arresters located in the pot yard.

The manufactured length of each cable shall be the responsibility of the contractor
who shall determine exact requirements to enable installation of the cables from
terminal to terminal without resorting to cable splices and other corrective measures in
order to ensure a satisfactory installation.

Contractor shall satisfy itself before commencing manufacture as to the exact lengths
of cables required.

Additional cable lengths required for test samples shall be provided by the contractor

17.4.1.1 Mechanical Aspects

Design of 400 kV XLPE Insulated Power Cable systems shall be such that a life
expectancy minimum of 35 years is achievable.

The 400kV XLPE Insulated Power cables for all the circuits shall be installed in the
same tunnel, which is naturally ventilated and/or forced ventilation cooling is
envisaged.

Each 400kV XLPE Insulated Power Cable of single core 500 mm 2 size shall be
supplied in single length. The exact length of each cable shall be finalized during
detailed design stage. The cable joints between end terminals shall not be permitted at
initial stage.

Laying arrangement of 400 kV XLPE Insulated Power cables shall be such as to

achieve optimum space saving, neat and logical arrangement when laid in horizontal
snaking formation. The routine inspections and possible repairs for all elements shall
be accessible without removing support structures.

The 400kV cables shall be securely supported for the entire length with suitable cable
cleats to maintain continuous equal space between the cables laid in horizontal snaking
formation.

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Cables shall be supported on suitable cable supporting arrangement of galvanized steel

in such a way so as to avoid development of any type of stress in the cable. The laying
of cables shall be in a horizontal snaking formation to absorb the thermal expansion
and contraction of the cables. Necessary calculations in this regard shall be furnished
during design stage.

The ambient temperature at project site varies between (+) 4ºC to (+) 35 oC. The
relative humidity varies between 35% to about 100%. These conditions along with
the other climatic and high altitude parameters, as specified in other

All the accessories shall be identical allowing for interchangeability within and
between the accessories.

The cable system shall withstand the electro mechanical forces due to short circuit and
earth fault currents including superimposed seismic forces.
All accessories of power cables shall be capable of withstanding the specified seismic
forces along with short circuit forces.

17.4.1.2 Electrical Aspects

The 400kV cables and accessories shall be suitable for bi-directional flow of power,
under isolated/parallel operation with other circuits of the system and connected to
grid system according to loading cycle of Arun-3 H.E. Project, Nepal.
All lengths of 400kV cables and accessories shall be capable of continuous operation
at the maximum rated current without exceeding the maximum conductor temperature
as specified in Clause 17.3.2 of this specification.

Thermal rating for all current carrying parts of the cable system shall be suitable for
the normal rated current and for the rated symmetrical short circuit current of 50 kA
for duration of 1second. If the maximum short circuit time be extended, the I* I* t
value shall remain constant where I =Short circuit current in Ampere and t=duration of
short circuit in seconds.

The contours of energized metal parts of the 400 kV cable end terminations shall be
such as to eliminate areas/points of high electrostatic flux concentrations. Surfaces
shall be smooth with no projection or irregularities, which may cause visible corona.
No corona shall be visible in complete darkness when the accessories are subjected to
the specified tests.

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Metal cleats and spacers/saddles for the 400 kV cables and other metal parts, which
are subject to eddy currents induced by the cable current, shall be appropriately
earthed and shall be of non-magnetic material.

17.4.1.3 Seismic Design criteria

The cable end terminals and supporting structures shall be designed for operation in
seismic zone four for earthquake resistance. The seismic forces due to the horizontal
and vertical accelerations may be assumed to act non-concurrently. The coefficients
for horizontal acceleration as 0.24 g and vertical acceleration as 0.16 g shall be used
for design purposes. The seismic forces shall be equal to static loads corresponding to
the weight of the parts / accessories multiplied by the acceleration coefficients.

The supporting structures for 400 kV cables and accessories shall be strong enough to
withstand all the forces in normal operation and in abnormal conditions with forces
superimposed due to occurrence of earthquake. The design calculations for cable
accessories and support structures by simulating the site parameters shall be furnished
by the Contractor during detailed design stage.

To prevent the movement of cable accessories during earthquake, suitable devices

shall be provided for fixing the assemblies to the foundations. The bidder shall include
necessary bolts and fittings for embedding in the concrete foundations in the scope of
supply.

17.4.2 General Requirements #

The cable shall confirm to IEC-62067. The cable shall consists of 400kV Grade single
core 500sq.mm Compacted Circular copper conductor, XLPE dry cured insulation,
extruded semi conducting compound insulation screen, bedding of swellable type
water blocking semi conducting tape(s), copper wire screen with copper binder tape(as
per requirement), laminated or extruded aluminium metallic sheath and extruded
flame retardant Polyethylene (P E) outer sheath.

The conductor screen, insulation and insulation screen shall be extruded in one
operation of triple extrusion process, so as to obtain continuously smooth interfaces
between the insulation and screens.

The copper wire/tape screen and laminated/extruded aluminum metallic sheath shall be
capable of withstanding the short circuit current of 50 kA for one second.

The cable shall be suitable for use in solidly earthed system.

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# Technical specification provides flexibility for bidder to choose the type of metallic sheets (corrugated aluminium sheets or flat
aluminium / Copper / Lead alloy sheets with or without copper wired scheme, wire shield cable or Cu laminated cable etc) for
XLPE cable fulfilling following conditions:- (1.) Metallic sheet shall be designed for fault level of 50kA for 1 Sec. (2.) Act as /
Provide for Radial water barrier.
ARUN-III HEP

The cable shall be suitable for installation in underground tunnels and in concrete
trenches in surface pothead yard, with restricted air circulation. The cable shall be
capable to withstand all mechanical and thermal stresses under steady state and
transient operating conditions.

Repair to the new cables shall not be accepted. Pimples, fish eye, blow holes etc. are
also not acceptable.

Cable ends shall be sealed by heat shrinkable PVC/metal caps with pulling eye to
prevent damage and ingress of moisture.

The Eccentricity of the core shall not exceed 10% and Ovality of the core shall not
exceed 5%.
The Eccentricity shall be calculated as (tmax -t min)/tmax ≤ 0.10

The Ovality shall be calculated as (dmax– dmin)/dmax ≤ 0.05

wheretmax/tmin are the maximum/minimum thickness of insulation and

dmax/dmin are the maximum/minimum diameter of the core.

17.4.3 Conductor

The conductor shall consist of plain annealed copper stranded wires in accordance
with IEC-60228 or equivalent and the shape shall be circular, round and very well
compacted to facilitate a smooth interface between conductor screen (shield) and the
insulation. For segmented conductor, each segment shall be isolated with a separator
tape & cabled together with a semi-conducting binder tape. The total cross-sectional
area of copper conductor shall be 500mm2 . The conductor strand shall have smooth
surface with no intermediate joint.

17.4.3.1 Conductor Screen(Shield)

Conductor screen shall consist of extruded cross-linked semi-conducting compound

applied over the conductor, which shall be firmly bonded to the inner surface of the
insulation layer. The semi-conducting compound shall be free from any void and
protrusion which may deteriorate the cable’s electrical performance for the specified
voltage class. The material of conductor screen shall have the maximum resistivity of
1000 ohm-m.

17.4.4 Insulation

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Insulation material shall be of extruded Cross Linked Polyethylene (XLPE). The

insulation shall be free from any harmful void and contaminant which may
deteriorate the cable electrical performance for the specified voltage class. The
average thickness of insulation shall not be less than the nominal value guaranteed in
the technical particulars. The minimum thickness of insulation at any point shall not
be less than 95% of the guaranteed value.

17.4.4.1 Insulation Screen(Shield)

Insulation screen shall consist of extruded cross-linked semi-conducting compound

and shall firmly be bonded to the insulation. The semi-conducting compound shall
be free from any void and protrusion.

17.4.5 Bedding ##

Bedding shall consist of layer(s) of semi conducting tape(s) to absorb the thermal
expansion and contraction of the extruded layers during operation with swelling
compound to form water protection barrier to be applied over the extruded semi-
conducting insulation screen with suitable overlap. Semiconducting swelling tape(s)
shall also be provided over copper wire screen.

17.4.6 Metallic Sheath

The metallic inner sheath shall consist of extruded or laminated aluminium tape/lead
in accordance with relevant IEC or equivalent standards. The inner sheath shall be
suitable to carry short circuit current of 50kA for one second. The calculations for
sizing and short circuit withstand capability of the metallic sheath, along with copper
wire screen & copper binder tape, shall be submitted during detailed design stage.
The average thickness of sheath shall not be less than the nominal value specified in
guaranteed technical particulars. However, the minimum thickness at any point shall
not fall below 95% of the nominal value

17.4.7 Outer Sheath

Outer sheath shall consist of extruded black and flame retardant PE compound, in
accordance with relevant IEC/IS. The average thickness shall not be less than the
nominal value specified in the guaranteed technical particulars. However, the
minimum thickness at any point shall not be less than 95% of the specified value.

17.5 AUXILIARY SYSTEMS AND MISCELLANEOUS COMPONENTS

17.5.1 Cable Identification/ Marking

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## Swellable tape(s) shall be provided for longitudnal water barrier to prevent penetration of water along the cable
between core and metallic sheet, for the provision of Cu wire screen please refer comments marked in Clause 17.4.2
ARUN-III HEP

At least the following clear markings shall be provided over outer sheath of the cable
at an interval of one meter throughout the length of the cable by embossing:

i. Rated voltage
ii. Conductor size
iii. Type of insulation
iv. Manufacturer’s name
v. Year of manufacture
vi. Employer’s name
vii. Sequential marking of length of cable in meters by embossing/printing.

The embossing/printing shall be progressive, automatic, in line and marking shall be

legible and indelible.

17.5.2 Cable Identification Tags

In order to identify the phases and circuits, the identification tags shall be provided at
each end of the cable as well as at an interval of 100m in the cable length for each
phase and circuit number.

17.5.3 Cable Lengths And Cable Drums

The Cables shall be supplied in steel drums of heavy construction. The Cable drums
shall be supplied with definite cable lengths to be decided during detailed
engineering. Cable drums with shorter/longer lengths shall not be accepted.

17.5.4 Cable Accessories

17.5.4.1 Cable Terminations / Sealing Ends

The termination/sealing ends shall be located inside the underground transformer in

one end to GIS adapter and other end to GIS at Pot Head Yard. The Bidder shall co-
ordinate with the GIS Contractor in this regard, so that there shall be no mis match
during installation/erection of the cables.

Each termination/sealing end shall be complete with all fittings, supporting

structures, earthing, accessories, consumables etc. as required for erection, testing
and commissioning.

The housing of the indoor termination/ sealing end shall be of epoxy/porcelain

insulator type suitable for use with 400 kV GIS and shall have sufficient strength
against mechanical, electrical and thermal stresses.

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The 400kV cable Contractor shall supply all the required fittings, supporting
structures, accessories and consumables in order to connect the termination assembly
of cables to GIS.

The design and manufacturing of the termination assembly shall be done in latest
standards. The Contractor shall coordinate with the Contractor of GIS to complete
the termination work.

The cable termination sealing ends shall be suitably double earthed with the earth
mat risers, provided by the Employer, in the vicinity of the equipment.

17.5.5 DISCONNECTING LINK BOX (Cable Covering Protective Unit -CCPU)

The cable screen/metallic sheath connections with grounding system shall be bolted
type. The connecting bar and disconnecting link shall be of copper. The arrangement
shall be installed in a watertight box having degree of protection of IP 55.
Disconnecting links shall be provided to sealing ends to facilitate periodical checking
of the integrity of the outer sheath.

The terminal end shall have suitable type of disconnecting link box known as Cable
Covering Protective Unit (CCPU) to disconnect the earthing circuit during testing
with sheath voltage limiter. The GIS adapter side terminal end shall have
disconnecting link box (CCPU) for direct earthing.

The disconnecting link box shall be mounted on galvanized supporting steel structure
and provided for each circuit individually. The protective device (sheath voltage
limiter) shall be of non-liner resistor type and shall be made of zinc oxide compound.

17.5.6 Bonding Cable

Bonding cable shall be used for earthing the metallic sheath of 400kV Cable and as
an earth continuity wire, equalizing earth level between disconnecting links.
Construction and materials of bonding cable shall comply with relevant IEC or
equivalent standards and the cross-sectional area shall be chosen so as to withstand
the short circuit rating of the cable system. The calculations for selecting the size of
bonding cable shall be furnished by the Contractor during detailed design stage.

17.5.7 Termination/ Sealing End Supporting Structure

. Supporting structure for indoor termination/sealing end shall consist of galvanized

steel members. The supporting structure shall be designed and supplied, complete in
all respects, with all necessary embedments, hardware, earthing materials etc. The
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zinc coating shall be uniform, clean, smooth and free from spangle as possible. All
galvanizing shall comply with the requirements of the relevant IEC / IS Standards.

17.5.7 Cable Racks Supports and Accessories

The 400 kV cables from the Transformer Hall to 400KV GIS shall be supported on
supports of galvanized steel. The cable supports shall be designed and supplied
complete in all respects with necessary embedments, hardware, Cable spacers,
stainless steel blocks/ saddles to snaking the cable, cable earthing materials etc. The
Cable support system shall be designed to withstand the static and dynamic loads of
required no. of cables laid on each rack. All galvanizing shall comply with the
requirements of the relevant IEC/IS standards. The provision for one cable rack for
future requirement shall be made in the cable support system to be supplied under
this package.
Design of support structure at both side of termination end of 400kV XLPE cable are also in bidders scope.
17.3.1 400 KV Cable Cleats

Each cable shall be clamped with single way aluminum cleats at each support. The
material of cleats shall be aluminum alloy in accordance with relevant IEC / IS or
equivalent standards and the cable cleat shall be designed for the type, rating and
diameter of cable to be cleated, as required.

17.5.9 Foundations & Fixtures

If required, foundations of the equipment shall be prepared by the Employer on the

basis of data supplied by the Contractor. All bracket supports, fixtures / inserts etc.
necessary for proper erection of embedded parts shall be supplied by the Contractor.
The Contractor shall depute to project site his authorized person (s) for supervision of
work of providing of embedments etc. wherever required & shall ensure the
correctness of the same. Employer shall not be responsible for correctness of
embedments. If during erection, any change is required in the embedments, the same
shall be done by Contractor at his cost.

17.5.10 Painting

Before dispatch, the surface of all material, to be painted, shall be cleaned, filed, if
necessary, and painted with suitable priming coat. The cable supporting system
members, which shall be inaccessible after installation, shall be finally painted at
works before dispatch. All other cable supporting members shall be finally painted at
site by the Contractor after installation. Necessary quantity of paint for this purpose
shall be supplied by the Contractor.

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Painting shall be applied to clean surface free from dust, oil, moisture and other
foreign materials. The details of equipments/members to be painted shall be supplied
by the Contractor.

The Contractor shall apply one (1) coat of finish paint to the metal surface of &
associated equipment at site, which is already painted with one (1) coat of finish paint
and rust preventive paints at the manufacture’s works. The suppler shall also perform
repair and finish coating on parts of shop-coated equipment which get damaged during
transportation or installation work.

17.6 DRAWINGS, DOCUMENTS AND DESIGN CALCULATIONS

17.6.1 Drawings and documents
After award of contract, the contractor shall furnish all drawings, documents,
design calculations, data, manuals & other necessary literature, pertaining to
equipment offered by them & so specified under various clauses, in accordance
with requirements stipulated
Technical Specification in “clause
and relevant 1.19 of Section
IEC & International codes. – 1 i.e. General Technical
Specification (GTS)”. A comprehensive list of all such drawings/documents
planned to be submitted for reference/approval shall be provided beforehand for
approval of. the purchaser as already explained in clause no. 1.19.6 of Section Chapter –1 1
(GTS). The list of drawings & documents to be furnished for approval / reference
shall not be limited to the following:-

i) Drawings, documents, design calculations literatures, manuals etc. as per

clause no. 1.19 of Section-1
Chapter 1 (GTS)

ii) Drawings, documents, design calculations, literatures, manuals as listed in

Annexure – D of Section
Chapter -1
1 (GTS) referred under clause no. 1.19.6

iii) Detailed quality assurance plan, giving complete specifications of the

materials and specifications relating to inspection and testing of materials
and finished components.
iv) All drawings having bearing on civil foundations, equipments foundation
details and loads
v) Arrangement, installation, foundation, plan, section, detailing of main
equipment and sub-assemblies including control & instrumentation
system.

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vi) All Electrical, Hydraulic & Control Drawings such as Electrical Panels
OGA, Cable Block & Termination Diagram, Schematic Diagram,
JB/MB/Kiosk Diagram etc. in respect of this section.

vii) All manufacturing drawings not specifically covered under

approval/reference category shall be submitted for record and facilitate
inspection of the component in the shop and assembly at site.

viii) Detailed drawing of cable drum, disconnecting link boxes with and
without SVL.
ix) Any other drawings, documents, design calculations, literatures, manuals
etc. not covered anywhere in the specification, but required to be furnished
for approval / reference of employer for suitability of design to fulfill the
scope of work.

17.7 SHOP ASSEMBLY, INSPECTION AND TESTS

All Type, Acceptance and Routine tests on Cables, Accessories and support systems
shall be carried out as per specification and relevant standards. The Type tests,
Routine tests and Acceptance tests on 400 kV Cables and Accessories shall be
carried out as per IEC 62067, Technical specifications and other relevant standards.

17.7.1 Type Test

The Type tests as listed in Schedule VI shall fall under Category –I. These are to be
conducted to demonstrate that the cables and accessories offered meet the
requirement of specifications.

17.7.2 Routine Tests

The following Routine tests shall be conducted on samples of manufactured cables
and on components of accessories in order to verify that the finished products meet
the requirements of specifications.
a) Conductor examination
b) Measurement of electrical resistance of conductor
c) Measurement of thickness of XLPE insulation and over sheath
d) Measurement of thickness of metallic sheath
e) Measurement of diameter
f) Hot set test for XLPE insulation
g) Measurement of capacitance
h) Lightning impulse voltage test followed by a power frequency Voltage test

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i) Water penetration test

j) Determination of losses .

The following Routine tests shall be carried out on all finished cables and associated
accessories before dispatch at the manufacture’s works:
a) Check of dimensions
b) Conductor resistance and capacitance test
c) AC high voltage test as per relevant IEC/IS
d) Partial discharge test as per relevant IEC/IS
e) Electrical Tests on outer sheath as per relevant IEC/IS

Seaworthy / Export worthy

packing is included in
17.8 PACKAGING, HANDLING AND SITE STORAGE bidder's scope.
Immediately after the completion of tests at works cable ends shall be sealed by heat
shrinkable PVC/metal caps with pulling eye both ends of the cables to prevent the
ingress of moisture, dirt and insects. Each length of cable shall be supplied on a
seaworthy robust steel drum.

Drums or parts of drums made from ferrous metals shall be treated with suitable rust
preventive finish or coating to avoid rusting, during transit or storage.

Cable accessories, cable support systems and other associated items shall be packed in
robust wooden or suitable cases. Hydrophobic materials shall be duly protected from
sea water or rain during transportation and storage.
The bonding cable shall be supplied on wooden/steel drum.

Shipping dimensions of cable drums shall be as large as practicable but within

transport limitations as specified elsewhere in the Bidding Document.

The construction of cable drums shall be suitable for convenient handling of drums
during loading/unloading, in transit and storage & laying at site. The cable drums shall
be suitable for wheel mounting.

The Contractor shall indicate the methods of storage of cable drums and accessories at
site during the detailed design stage.

A label shall be attached to each reel, giving the Employer's order number, length of
cable, size of conductor, thickness of insulation, cable designation in accordance with
these specifications, shipping weight dimensions as well as project particulars.

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The Contractor shall indicate the methods of storage of cable drums and accessories at
site during the detailed design stage.

17.9 SITE INSTALLATION AND COMMISSIONING

17.9.1 Installation procedure
The Contractor shall follow the construction methodology and installation procedure
recommended by the cable manufacturer and shall arrange all the necessary erection
tools/devices required for installation of cables such as cable rollers, cable pullers,
motorized winches, power packs, two-way communications and safety devices etc., as
per manufacturer’s standard practices for installation of the cables.

17.9.2 Field Tests

Following tests shall be conducted after laying of cables and installation of accessories
in accordance with relevant IEC or equivalent standards:
a) High voltage
voltage AC
AC resonant
withstand tests
type Test / UOo voltage for 24 hours.
b) Partial discharge measurement test
c) DC Voltage test of the oversheath.
17.9.3 Performance Testing
If nothing unusual has been observed in load run and load rejection tests, the test
service period of 72 hours shall follow. During this test service period, the unit must
operate continuously at rated condition without any interruption except of those beyond
the control of the Contractor. However, such interrupted period shall not be counted for
in the test service period. There should be one month reliability run of the complete unit
reckoned from the date of taking over by employer. During reliability run, machine
shall be operated by employer and any problem observed during this run shall be
attended by the contractor including replacement of components and providing requisite
manpower.

17.10 TOOLS AND INSTRUMENTS

All special tools, tackles, slings, testing instrument etc. required for handling, pulling,
laying, installation, testing and commissioning of 400 kV cables, accessories and cable
support systems, shall be arranged by the Contractor. Erection, testing and
commissioning tools/tackles and testing instruments, to be arranged by the Contractor,
shall include but not limited to the following:

a) Special tools required for laying, installation and dismantling of the

400kV cables, accessories and cable support systems.
b) The HVAC testing kit and partial discharge measurement equipment for
field tests.

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c) Any additional requirement of erection tools, testing instrument etc. for

erection, testing and commissioning shall be met by the Contractor
without any extra cost to the Employer.
17.11 SPARE PARTS
The spare parts mentioned here under are meant for use by the Employer during
operation and maintenance stage and shall not be used as erection spares required
during installation.

17.11.1 Mandatory Spare Parts

The Contractor shall supply the mandatory spare parts as per Schedule-III.
Bid Price Schedule

17.11.2 Recommended Spare Parts

The Contractor shall furnish the list of recommended spare parts at Schedule-IV.

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420kV XLPE Cables: Schedule of documents

INDEX

Sr. No. Schedules for 400kV cables Page.

No.
i. Schedule
deleted of Requirement 2

ii. Schedule of Guaranteed Technical Particulars 3

iii. Schedule
deleted of Mandatory Spares 10

iv. Schedule of Recommended Spares 11

v. Schedule
deleted of Tools 12

vi. Schedule of Type Test 13

vii. Schedule
deleted of Technical Deviation 15

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SCHEDULE-II

SCHEDULE OF GUARANTEED TECHNICAL PARTICULAR

Description Bidder to
Sr. No. Unit
Specify
A. 400 kV Cables
1 Manufacturer’s name & Country of origin
Standards according to which cable is
2 manufactured and tested
3 Type
4 No. of phases per circuit
5 No. of cables per phase
6 No. of cores per cable
7 Rated Voltage* kV
8 Highest system voltage* kV
9 Rated continuous current* A
Rated short-time current withstand capacity for 1
10 second
a) For conductor* kA
b) For metallic sheath kA
Electrical stresses (AC Voltage) Short circuit
11
forces*
a) On conductor
i) Average kV/mm
ii) maximum kV/mm
b) On conductor screen semi-conductor layer
i) Average kV/mm
ii) Maximum kV/mm
c) On insulation screen semi-conductor layer
i) Average kV/mm
ii) Maximum kV/mm
d) Insulation
i) Average kV/mm
ii) Maximum kV/mm
12 Rated frequency Hz
13 Insulation level*
a) One minute Power Frequency withstand voltage kV (rms)
1.2/50 micro-second lightning impulse withstand
b) voltage kV (peak)

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ARUN-III HEP

250/2500 micro-second Switching impulse

c) withstand voltage kV (peak)

14 Temperature*
Max. temperature rise over ambient temperature
a) of the conductor at rated load °C

c) Heating time constant when cable is switched on

Maximum permissible operating conductor temp.
d) at 10% continuous over load
From zero load (cold condition) to a load of
i) continuous current and corresponding conductor Seconds
temperature
From zero load (cold condition) to a load of
ii) maximum continuous current to attain 90°C Seconds
temperature, keeping the load constant
15 Power losses*
Guaranteed Power loss in conductor in each
a) cable length of 350m at rated voltage and current W
Guaranteed Dielectric power loss in each cable
b) length of 350m at rated voltage and current W
Guaranteed power loss in metallic sheath in each
c) cable length of 350m at rated voltage and current W
Guaranteed total power loss in each cable length
d) of 350mat rated voltage and current (a+b+c) W
Maximum permissible iron losses in supporting
e) structures W

16 Maximum total power losses per meter* W

17 Conductor details
a) Type
b) Material and shape

c) Cross-sectional area mm2

d) No. of strands/Diameter of each strand No./mm
e) Weight of copper in cable Kg/m
f) Current density in conductor A/mm2
g) Conductivity of conductor Mho/m
h) Ultimate tensile strength of conductor N/mm2
i) Maximum short-circuit current rating & duration kA/sec.
j) Impedance of conductor per meter Ω
k) Resistance per meter Ω

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ARUN-III HEP

DC at 20°C
i)

ii) AC at 20°C Ω
18 Conductor screening
a) Material
b) Thickness mm
c) Maximum size of protrusion µm
d) Electric stress level
i) Maximum kV/mm
ii) Average kV/mm
e) Maximum resistivity*
Ω-m

19 Insulation details
a) Material
b) Thickness mm
c) Relative permittivity
Dielectric loss angle (at rated voltages at 20°C &
d) 90°C)
e) Insulation resistance constant Ω-cm
f) Elongation %
g) Tensile strength N/mm2
h) Thermal resistance between conductor and sheath km/W
i) Thermal resistance of outer sheath km/W
20 Insulation screening
a) Material
b) Thickness mm
c) Maximum size of protrusion µm
Electric stress level
d)

i) Maximum kV/mm
ii) Average kV/mm
e) Maximum resistivity* Ω-m
21 Bedding (cushion layer)
a) Material
b) Total Thickness mm
22 Metallic sheath
a) Material
b) Type
c) Thickness mm

420kV XLPE Cables: Schedules ED/TS/ARUN/01.06.17 Page 5 of 15

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d) Maximum short circuit current rating & duration kA/sec.

e) Sheath induced voltage V
f) Type of earthing
g) Diameter of cable over Metallic sheath mm
h) Mutual inductance between conductor and sheath mH/km
i) Resistance per meter
a) DC at 20° C Ω/m
b) AC at 20° C Ω/km
23 Outer sheath
a) Material
b) Type
c) Thickness mm
d) Colour
e) Oxygen index
f) Carbon black contents for PE %
24 Overall diameter of cable mm
25 Cable weight Kg/m
26 Inductive reactance per phase per meter at 20°C Ω
27 Capacitance per phase per meter at 20°C & 50Hz µF
28 Effective AC resistance per phase per meter Ω
29 Surge impedance Ω
30 DC resistance at 20°C Ω/km
Maximum safe continuous current at ambient
31 temperatures varying from (+)4°C to(+) 35° C A

32 Charging current & power

a) Maximum charging current per phase A/km
b) Maximum charging current per circuit A/km
c) Maximum charging power per circuit
kVA/km
Cable burn through time at rated short circuit
34 Sec.
current
35 Corona Extinction voltage kV
36 Radio interference at 266 kV (rms) µV
37 Skin effect factor*
B. 400 kV Cable Accessories
1 Indoor Termination
a) Name and country of manufacture
b) Type
c) Insulation medium
d) Type of interface

420kV XLPE Cables: Schedules ED/TS/ARUN/01.06.17 Page 6 of 15

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e) Is terminal type tested, if yes, to which standard?

f) Overall dimensions (LxBxH) mm
g) Overall weight Kg
h) Current rating
i) Normal A
ii) Short circuit kA
2. a) Disconnecting Link (CCPU)
i) Material and size
ii) Continuous current rating A
iii) Momentary current rating kA
b) Earthing Devices
i) Earthing conductor
- Material & size
- Continuous current rating A
- Momentary current rating kA
ii) CCPU Cable link Box
- Material
- Size & weight
- Protection code
iii) Technical particulars of LA (SVL)
- Type
- Rated voltage kV
- Voltage limiting range
- Fault current rating for 1 second kA
Lightning impulse voltage withstand capacity kV
-
(peak)
- Power frequency withstand voltage kV(rms)
- Momentary current rating kA
- Continuous current rating A
- Residual voltage V
3 Cable drums
a) Flange diameter mm
b) Drum diameter & width mm
c) Drum weight Kg
d) Drum material
e) Spindle hole diameter mm
5 Supporting Structures
a) Cable Supporting Arrangement
i) Manufacturer’s name

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ii) Material
iii) Whether magnetic or non-magnetic
iv) Minimum yield point
v) Maximum span between the supports M
Maximum temperature rise under steady state
vi) °C
condition at maximum continuous rated current
Maximum potential rise in the event of short-
vii) V
circuit
b) Terminal End Supporting Structure
i) Material/ Composition of material
ii) Reference standard
iii) Minimum guaranteed yield point
iv) Ultimate tensile strength
v) Base dimensions
Weight & size of each member of supporting
vi) structures Kg

c) Saddles, cleats, clamps, bolts and nuts

i) Material/composition of material
ii) Minimum tensile strength of bolts kg/sq.cm
iii) Proof load at nuts
Minimum creepage distance of porcelain
iv) mm /kV
bushing
Maximum permissible pressure of Oil gas in
v) outdoor termination
Designed pressure of Oil gas for outdoor
vi) termination
Max. permissible pressure of SF6 gas in indoor
vii) termination
Designed pressure of SF6 gas in indoor
viii)
termination
ix) Permissible tension for outdoor termination Kg/mm2
x) Permissible tension for indoor termination Kg/mm2

6 Bonding Cable
i) Material
ii) Size mm2
iii) Type of bonding
iv) Current carrying capacity A
C. Other Information
1 Details of interface

420kV XLPE Cables: Schedules ED/TS/ARUN/01.06.17 Page 8 of 15

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a) Max. force at interface

- Tensile
- Compressive
b) Tolerance on positioning of flanges
c) Earthing arrangement
2 Minimum recommended clearance
a) Between the cable mm
b) Between the racks mm
Details of cable end sealing, cable clamping
3 arrangement etc.
Details of cable handling, laying and pulling
4
device
5 Weight and dimensions of shipping packages
Name and shipping weight of the heaviest
a) package of cable drums etc. kg
Name and dimensions (LxBxH) of the largest
b) package m
Shipping weight of all special cable laying,
c) handling devices, wrenches and tools etc.
Shipping weight and dimensions of each XLPE
d) cable end termination
Maximum length of 400kV, single phase, single m
core of 1200mm2 copper conductor XLPE
e)
insulated power cable which can be supplied in
single length
f) Standard length m
6 Designed life of cable Years
7 Cable loading
i) Continuous over loading at one go
Total hours of emergency to which cable can be
ii) loaded during its life
8 Any other item/information not covered above
Date: Signature of Bidder
Place: Name:
Status
Whether authorized attorney
Of tendering company
Name of Tendering Company

420kV XLPE Cables: Schedules ED/TS/ARUN/01.06.17 Page 9 of 15

ARUN-III HEP

SCHEDULE-IV

SCHEDULE OF RECOMMENDED SPARES

Sr.No. Description Unit Quantity

Date: Signature of Bidder

Place: Name:
Status
Whether authorized attorney
Of tendering company
Name of Tendering Company

420kV XLPE Cables: Schedules ED/TS/ARUN/01.06.17 Page 11 of 15

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SCHEDULE-VI

SCHEDULE OF TYPE TEST

Sr.No. Description of Test

Check on insulation thickness as per IEC 60811 (check of cable construction)
1
2 Tan δ measurement.

3 Partial discharge test after complete assembly of end terminations

- At ambient temperature
- At high temperature (90°C)
-
4 Cable bending test followed by partial discharge test at ambient temperature.

5 Switching impulse voltage withstand test as per IEC 60230/62067

6 Lightning Impulse voltage withstand tests followed by power frequency voltage test as
per IEC 62067/6023

7 Ageing treatment as per IEC 60811

8 Tests for determining the mechanical properties of XLPE insulation and outer sheath
(PE) before and after ageing

9 Heat cycle voltage test as per IEC 62067

10 Flame retardant test on outer sheath (Test under fire condition)

11 Insulation shrinkage test

12 Measurement of resistivity of semi-conducting screens as per IEC 62067.

13 Conditioning & mechanical test as per IEC 60811

14 Pressure test at high temperatures on over sheaths

15 Hot set test for XLPE insulation.

16 Measurement of carbon black contents in PE outer sheath.

17 Water penetration test. hardness of outer sheath

18 Measurement of hardness of outer sheath

420kV XLPE Cables: Schedules ED/TS/ARUN/01.06.17 Page 13 of 15

ARUN-III HEP

19 Abrasion test on outer sheath.

20 Heat shock test on outer sheath.

21 Oil resistant test for outer sheath.

Date: Signature of Bidder

Place: Name:
Status
Whether authorized attorney
Of tendering company
Name of Tendering Company

420kV XLPE Cables: Schedules ED/TS/ARUN/01.06.17 Page 14 of 15

Bill of Quantity of Supply and Spare Items for 400kV XLPE Cable of Arun 3 HEP Project - Rev 1 Date 19 July 2021

Sno Short Description Detailed BOQ Long Description Unit Qty Remark
CABLE

XLPE, Copper conductor cable shall be complete in all respects and comprising of following but not limited to,
1. The cable construction shall as per technical specification.
2. The exact cable length shall be decided after visiting site & making precise measurements at contract stage.
Manufacturing lengths and drum length shall be determined with consultation & approval with BHEL/ Customer/
SUPPLY- HIGH VOLTAGE POWER CABLE : XLPE Consultant.
INSULATED, COPPER (PLAIN) CONDUCTOR, PE WITH 3. Bidder shall furnish calculations of cable for following during tendering stage only, Estimated qty for 12+1 (Spare) circuit length. The interconnection of "400kV GIS Adaptor" in transformer Hall
1.01
HFFR LAYER OUTER SHEATH 230/400KV SINGLE CORE,
400 kV, 1Cx500sqmm, Copper Conductor, XLPE cables Meter 6000
(a) Screen/ sheath voltage under full load condition, to "400kV GIS" in Pot Head Yard
500 SQMM SIZE (b) Screen/ sheath voltage during an external three phase symmetrical through-fault.
4. Bidder shall furnish calculations for screen/ sheath voltage/ current and the recommended method for metallic screen
bonding and screen sizing shall be designed in such a manner so that it can carry the earth fault current level of the system,
considering system is solidly grounded.
5. Any other item/(s) required to complete the supply in all respects but not limited to above shall be in bidder's scope.

Earthing arrangement between Cable to Link box will be covered in this scope. (ref. Section-2 Clause 17.5.6).
1. Bidder shall submit the calculations for sizing of earthing/ bonding cable in such a manner that it can carry the earth
SUPPLY- HIGH VOLTAGE POWER CABLE : BONDING Construction and materials of bonding cable shall comply with relevant IEC or equivalent standards and the
Bonding cable suitable for earthing/ bonding of metallic sheath of 400kV fault current level of the system.
1.02 CABLE FOR EARTHING THE METALLIC SHEATH OF THE Meter 100 cross-sectional area shall be chosen so as to withstand the short circuit rating of the cable system. The
EHV CABLE XLPE Cable. 2. Any other item/(s) lugs/ connectors and other accessories required to complete the supply
calculations for selecting the size of bonding cable shall be furnished by the Bidder during detailed design
stage.

This shall be used as an earth continuity wire / equalizing earth level between disconnecting links / Link Box.
1. Bidder shall submit the calculations for sizing of earthing/ bonding cable in such a manner that it can carry the earth
(ref. Section-2 Clause 17.5.6). Earthing arrangement after Link box will be covered in this scope. Construction
SUPPLY- HIGH VOLTAGE POWER CABLE : EARTH fault current level of the system. 1850
1.03
CONTINUITY CONDUCTOR
Earth continuity conductor between end terminations Meter 2000 and materials of bonding cable shall comply with relevant IEC or equivalent standards and the cross-sectional
2. Any other item/(s) lugs/ connectors and other accessories required to complete the supply
area shall be chosen so as to withstand the short circuit rating of the cable system. The calculations for selecting
the size of bonding cable shall be furnished by the Bidder during detailed design stage.

CABLE ACCESSORIES

Cable sealing end shall be complete in all respects and comprising of following but not limited to,
Cable Sealing end (SF6 to XLPE ) - Suitable for termination of 400 kV, 1. It shall be suitable for the size of conductor, insulation and voltage/ current ratings of the cable.
SUPPLY- HIGH VOLTAGE POWER CABLE : INDOOR/ 1Cx500sqmm, Copper Conductor, XLPE cables for interconnection with GIS 2. It shall also be complete with all necessary fittings, accessories, hardware, Bonding & grounding system (excluding
The interfaces between 400kV XLPE Cable to SF6 Bushing Module shall conform to IEC standards. Cable to SF6 Bushing Module
2.01 OUTDOOR TERMINATION KIT FOR GIS END SUITABLE module, complete with all necessary fittings, accessories, hardware, Bonding bonding cable and other items already covered in BOQ). Nos 24 shall be of the plug-in type with dry-type or fluid-filled terminations.
FOR 230/400KV, 500 SQMM SIZE & grounding system (excluding bonding cable and other items already 3. Any other item/(s) such as weather shields/ sealing ends, Cu lugs/ connector suitable for size of conductor, Non-
covered in BOQ). magnetic glands/ dummy glands, hardware and other accessories required to complete the supply in all respects but not
limited to above shall be in bidder's scope.

Cable sealing end shall be complete in all respects and comprising of following but not limited to,
1. It shall be suitable for the size of conductor, insulation and voltage/ current ratings of the cable.
Cable Sealing arrangement (SF6 to XLPE) - for sealing one spare 400 kV,
SUPPLY- HIGH VOLTAGE POWER CABLE : INDOOR/ 2. It shall also be complete with all necessary fittings, accessories, hardware, Bonding & grounding system (excluding
1Cx500sqmm, Copper Conductor, XLPE cables, complete with all necessary
2.02 OUTDOOR TERMINATION KIT FOR SPARE EHV CABLE bonding cable and other items already covered in BOQ). Nos 2 Necessary provision to protect installed spare termination / sealing is to be provided.
FOR 230/400KV, 500 SQMM SIZE fittings, accessories, hardware, Bonding & grounding system (excluding
3. Any other item/(s) such as weather shields/ sealing ends, Cu lugs/ connector suitable for size of conductor, Non-
bonding cable and other items already covered in BOQ).
magnetic glands/ dummy glands, hardware and other accessories required to complete the supply in all respects but not
limited to above shall be in bidder's scope.

SUPPLY- HIGH VOLTAGE POWER CABLE : 1 X 3 PHASE - 1x3- PHASE DISCONNECTING LINK BOX WITH SVL - (Cable Covering
DISCONNECTING LINK BOX WITH SVL(SHEATH Protective Unit -CCPU) with Sheath Voltage Limiter suitable for 400 kV, Any other item/(s) such as mounting structure and other accessories required to complete the supply in all respects but not
2.03 VOLTAGE LIMITER SUITABLE/ COMPATIBLE FOR EHV 3Rx1Cx500sqmm, Copper Conductor, XLPE cables along with installation of limited to above shall be in bidder's scope. Nos 4 Please refer clause 17.5.5 of Section-2.
CABLE SYSTEM WITH NECESSARY FITTINGS AND metallic screen bonding/ earthing cable along with accessories (excluding (1Set= 3Phase)
ACCESSORIES bonding cable and other items already covered in BOQ).

SUPPLY- HIGH VOLTAGE POWER CABLE : 1 X 3PHASE 1x3- PHASE DISCONNECTING LINK BOX WITHOUT SVL - (Cable
DISCONNECTING LINK BOX WITHOUT SVL(SHEATH Covering Protective Unit -CCPU) without Sheath Voltage Limiter suitable for Any other item/(s) such as mounting structure and other accessories required to complete the supply in all respects but not
2.04 VOLTAGE LIMITER) SUITABLE/ COMPATIBLE FOR FOR 400 kV, 3Rx1Cx500sqmm, Copper Conductor, XLPE cables along with limited to above shall be in bidder's scope. Nos 4
EHV CABLE SYSTEM WITH NECESSARY FITTINGS AND installation of metallic screen bonding/ earthing cable along with accessories (1Set= 3Phase)
ACCESSORIES (excluding bonding cable and other items already covered in BOQ).

SUPPLY- HIGH VOLTAGE POWER CABLE : 1 PHASE - 1- PHASE LINK BOX WITH SVL - DISCONNECTING LINK BOX (Cable
DISCONNECTING LINK BOX WITH SVL(SHEATH Covering Protective Unit -CCPU) with Sheath Voltage Limiter suitable for Any other item/(s) such as mounting structure and other accessories required to complete the supply in all respects but not
2.05 VOLTAGE LIMITER SUITABLE/ COMPATIBLE FOR EHV 400 kV, 1Cx500sqmm, Copper Conductor, XLPE cables, along with limited to above shall be in bidder's scope. Nos 1
CABLE SYSTEM WITH NECESSARY FITTINGS AND installation of metallic screen bonding/ earthing cable along with accessories (1Set= 1Phase)
ACCESSORIES (excluding bonding cable and other items already covered in BOQ).

SUPPLY- HIGH VOLTAGE POWER CABLE : 1 X 3 PHASE - 1x3- PHASE CROSS BONDING LINK BOX WITH SVL - Link Box with
CROSS BONDING LINK BOX WITH SVL(SHEATH Any other item/(s) such as mounting structure and other accessories required to complete the supply in all respects but not
Sheath Voltage Limiter suitable for Cross Bonding arrangement of 400 kV,
2.06 VOLTAGE LIMITER SUITABLE/ COMPATIBLE FOR EHV limited to above shall be in bidder's scope. Nos 1
CABLE SYSTEM WITH NECESSARY FITTINGS AND 3Rx1Cx500sqmm, Copper Conductor, XLPE cables, complete with all
(1Set= 3Phase)
ACCESSORIES necessary fittings, accessories, hardware, Bonding & grounding system.

Page 1 of 2
Bill of Quantity of Supply and Spare Items for 400kV XLPE Cable of Arun 3 HEP Project - Rev 1 Date 19 July 2021

Sno Short Description Detailed BOQ Long Description Unit Qty Remark

SUPPLY- HIGH VOLTAGE POWER CABLE : CABLE Supporting Structure for cable termination end / cable sealing End etc
Supply of all structural materials including hardware for both ends required to complete the work in all respects shall be in
2.07 SUPPORT STRUCTURE FOR CABLE SEALING END ,including necessory cable trays / hangers, fixtures, hardware etc as MT 5
SUITABLE/ COMPATIBLE FOR FOR CABLE SYSTEM bidder's scope.
applicable.

SUPPLY- HIGH VOLTAGE POWER CABLE : SINGLE Non-magnetic Clamps suitable for installation of 400 kV, 1Cx500sqmm, 1. Clamps shall be fixed at the distance of 1.5 meters on circuit cables.
2.08 CLAMPS, NON-MAGNETIC SUITABLE/ COMPATIBLE FOR Copper Conductor, XLPE cables, in flat formation, complete with necessary 2. Any other item/(s) such as mounting/ fixing hardware and other accessories required to complete the supply in all Nos 4000 Suitable for spacing upto 1.5 meter between clamp to clamp
FOR CABLE SYSTEM fittings / accessories & mounting hardware. respects but not limited to above shall be in bidder's scope.

SUPPLY- HIGH VOLTAGE POWER CABLE : TREFOIL Non-magnetic Trefoil Clamps suitable for installation of 400 kV, 1. Clamps shall be fixed at the distance of 1.5 meters on circuit cables.
2.09 CLAMPS, NON-MAGNETIC SUITABLE/ COMPATIBLE FOR 3Rx1Cx500sqmm, Copper Conductor, XLPE cables, in Trefoil formation, 2. Any other item/(s) such as mounting/ fixing hardware and other accessories required to complete the supply in all Nos 100 Optional Item. Suitable for spacing upto 1.5 meter between clamp to clamp
CABLE SYSTEM complete with necessary fittings / accessories & mounting hardware. respects but not limited to above shall be in bidder's scope.

Control, monitoring and related items shall be complete in all respects and comprising of following but not limited to,
SUPPLY- HIGH VOLTAGE POWER CABLE : SUPERVISION 1. Control, monitoring and related items as per clause no. 17.1.1.2, Co-ordination and provision of necessary contacts
2.1
, CONTROL, MONITORING AND RELATED ITEMS
Control, monitoring and related items Lot 1
and/or ports for integration with plant SCADA system.
2. Any other item required for completion of work shall be included in biider's scope.

SUPPLY- HIGH VOLTAGE POWER CABLE : CABLE This shall includes all items required for commisioning of cable system inclduing cable marker, cable identification tags Cable Identification Tags, route marker. Other miscellaneous items and accessories are deemed included in the
2.11
IDENTIFICATION TAGS
Miscellaneous item including cable Identification Tags/ route marker etc. Lot 1
and other items. scope.

MANDATORY SPARES

SPARES- HIGH VOLTAGE POWER CABLE : XLPE

INSULATED, COPPER (PLAIN) CONDUCTOR, PE WITH
3.01
HFFR LAYER OUTER SHEATH 230/400KV SINGLE CORE,
SPARES - 400 kV, 1Cx500sqmm, Copper Conductor, XLPE cables meter 350
500 SQMM SIZE

SPARES - Cable Sealing end (SF6 to XLPE ) - Suitable for termination of

SPARES- HIGH VOLTAGE POWER CABLE : INDOOR/
400 kV, 1Cx500sqmm, Copper Conductor, XLPE cables for interconnection Suitable for terminating the 400kV XLPE, single phase cable for interconnection with GIS module. complete
3.02 OUTDOOR TERMINATION KIT FOR GIS END SUITABLE Nos 2
FOR 230/400KV, 500 SQMM SIZE with GIS module, complete with all necessary fittings, accessories, hardware, with all necessary fittings, accessories, hardware, Bonding & grounding system (excluding bonding cable).
Bonding & grounding system.

SPARES - Straight through Joint Kit, suitable for 400 kV, 1Cx500sqmm,
SPARES- HIGH VOLTAGE POWER CABLE : COPPER
Copper Conductor, XLPE cables complete with all necessary fittings,
3.03 (PLAIN) CONDUCTOR, STRAIGHT THROUGH JOINT Nos 2
SUITABLE FOR 230/400KV, 500 SQMM SIZE accessories, hardware & Bonding arrangement for the connection of the cable
sheath & armour.

SPARES- HIGH VOLTAGE POWER CABLE : SURGE

3.04 ARRESTOR (SHEATH VOLTAGE LIMITER) FOR 400KV SPARES - Sheath Voltage Limiter Nos 4 (3 Mandatory spare + 1 construction spare)
XLPE CABLE

SPARE - 1x3- PHASE DISCONNECTING LINK BOX WITH SVL - (Cable

SPARES- HIGH VOLTAGE POWER CABLE :
3.05
DISCONECTING LINK BOX, Three Phase PHASE
Covering Protective Unit -CCPU) with Sheath Voltage Limiter suitable for No 2
400 kV, 3Rx1Cx500sqmm, Copper Conductor, XLPE cable.

SPARE - 1- PHASE LINK BOX WITH SVL - DISCONNECTING LINK

SPARES- HIGH VOLTAGE POWER CABLE :
3.06
DISCONECTING LINK BOX, SINGLE PHASE
BOX (Cable Covering Protective Unit -CCPU) with Sheath Voltage Limiter No 2
suitable for 400 kV, 1Cx500sqmm, Copper Conductor, XLPE cable

SPARES- HIGH VOLTAGE POWER CABLE : BONDING

3.07 CABLE FOR EARTHING THE METALLIC SHEATH OF THE SPARES - Bonding Cable / Earth Continuity Cable meter 350
EHV CABLE

Page 2 of 2
Bill of Quantity of Services for 400kV XLPE Cable of Arun 3 HEP Project - Rev 1
Sno Description of Item Quantity Unit
4 SERVICES

Site survey for route & length finalization of 400 kV, 1Cx500sqmm, Copper Conductor, XLPE cables The exact
cable length shall be decided after visiting site & making precise measurements at contract stage. Manufacturing
lengths and drum length shall be determined with consultation & approval with BHEL/ Customer/ Consultant. 1.
The payment of cables lengths for supply shall be as per approved quantities after survey. 2. The Payment of
4.01 1 Lot
cables length for installation shall be as per actual measurement at site which shall also include cable
terminations. 3. The length may vary by -20% to +20% at contract stage based on actual measurement at site and
calculations submitted by the bidder.
( 1 Lot = Complete requirement for package )

Installation of 400 kV, 1Cx500sqmm, Copper Conductor, XLPE cables complete in all respect including earthing
, bonding arrangements and Earth Continuity Conductor. Scope includes installation of installation of clamp,
route marker, cable marker & other miscellaneous cable accessories. Installation of XLPE, Cu conductor cable
shall be completed in all respects and comprising of following but not limited to, 1. Laying of cables in flat /
trefoil form with proper dressing by fixing trefoil clamps and/ or single form as required on support structure
4.02 6000 Meter
using trefoil/ single clamps on cable trays of cable trench/ rack assembly/ other structure assembly. The scope
shall include includes snaking, dressing of cable etc. also. 2. Arrangement of special tools & tackles for smooth
laying & installation on returnable basis. 3. Al cable tags shall be supplied and fixed at the distance of 30m and in
all bends/ as applicable in technical specification. 4. Any other service/(s) required to complete the work in all
respects but not limited to above shall be in bidder's scope.

Installation of Cable Accessories: Cable sealing end (SF6 to XLPE ) suitable for termination of 400 kV,
1Cx500sqmm, Copper Conductor, XLPE cables for interconnection with GIS complete with all necessary
fittings, accessories, hardware & Bonding arrangement for the connection of the cable sheath to the grounding
system Termination of Cable Sealing End shall be completed in all respects and comprising of following but not
4.03 limited to, 1. Termination suitable with Copper Cable in all respects. 2. Fixing of structure for support of 26 Nos
termination including other fixing arrangements. 3. Termination/ jointing of cables shall be done by skilled and
experienced jointer certified by OEM of the joints/ end terminations and duly approved by Engineer-in charge. 4.
Any other service/(s) required to complete the work in all respects but not limited to above shall be in bidder's
scope.

Installation of Cable Accessories: 1x3-PHASE DISCONNECTING LINK BOX WITH & WITHOUT SVL -
(Cable Covering Protective Unit -CCPU) with Sheath Voltage Limiter suitable for 400 kV, 3Rx1Cx500sqmm,
Copper Conductor, XLPE cables, along with installation of metallic screen bonding/ earthing cable along with
accessories. Installation of link box shall be completed in all respects and comprising of following but not limited
4.04 8 Nos
to, 1. Installation of link box along with installation of metallic screen bonding/ earthing cable along with
accessories. 2. Installtion of rod electrode/ pipe electrode or any other accessories for earthing shall also be in
bidder's scope. 3. Any other service/(s) required to complete the work in all respects but not limited to above shall
be in bidder's scope.

Installation of Cable Accessories: 1- PHASE LINK BOX WITH SLV - DISCONNECTING LINK BOX (Cable
Covering Protective Unit -CCPU) with Sheath Voltage Limiter suitable for 400 kV, 1Cx500sqmm, Copper
Conductor, XLPE cables, along with installation of metallic screen bonding/ earthing cable along with
accessories. Installation of link box shall be completed in all respects and comprising of following but not limited
4.05 1 Nos
to, 1. Installation of link box along with installation of metallic screen bonding/ earthing cable along with
accessories. 2. Installtion of rod electrode/ pipe electrode or any other accessories for earthing shall also be in
bidder's scope. 3. Any other service/(s) required to complete the work in all respects but not limited to above shall
be in bidder's scope.

Installation of Cable Accessories: 1x3-Phase CROSS BONDING LINK BOX WITH SVL - Link Box with
Sheath Voltage Limiter suitable for Cross Bonding arrangement of 400 kV, 3Rx1Cx500sqmm, Copper
Conductor, XLPE cables, complete with all necessary fittings, accessories, hardware, Bonding & grounding
system. Installation of link box shall be completed in all respects and comprising of following but not limited to,
4.06 1 Nos
1. Installation of link box along with installation of metallic screen bonding/ earthing cable along with
accessories. 2. Installtion of rod electrode/ pipe electrode or any other accessories for earthing shall also be in
bidder's scope. 3. Any other service/(s) required to complete the work in all respects but not limited to above shall
be in bidder's scope.

Installation of Support structure: Support structure for Cable Termination/ Sealing End, including cable trays /
hangers, fixtures, hardware etc as applicable. All structural works required to support and fix the end terminations
4.07 5 MT
including supply of mounting hardware, fixing hardware, grouting and other civil works required to complete the
work shall be in bidder's scope.

1 of 2
Bill of Quantity of Services for 400kV XLPE Cable of Arun 3 HEP Project - Rev 1
Sno Description of Item Quantity Unit

Installation and services for Control, monitoring and related items Installation of Control, monitoring and related
items shall be complete in all respects and comprising of following but not limited to, 1. Control, monitoring and
4.08 related items as per clause no. 17.1.1.2, Co-ordination and provision of necessary contacts and/or ports for 1 Lot
integration with plant SCADA system. 2. Any other service required for completion of work shall be included in
biider's scope.

5 FIELD TESTING

Field testing & commissioning 400kV XLPE, Cu conductor cable along with accessories - a) High voltage AC
5.01 resonant type Test / Uo voltage for 24 hours as per clause no 16.3 of IEC 62067 (AC voltage test of the 1 Lot
insulation)

Field testing & commissioning 400kV XLPE, Cu conductor cable along with accessories - b) Partial discharge
5.02 1 Lot
measurement test
Field testing & commissioning 400kV XLPE, Cu conductor cable along with accessories - c) "DC Voltage test of
5.03 1 Lot
the oversheath
6 TYPE TESTING
6.01 Repetition of Type Test: Check on insulation thickness as per IEC 60811 (check of cable construction) 1 Lot

6.02 Repetition of Type Test: Tan δ measurement. 1 Lot

Repetition of Type Test: Partial discharge test after complete assembly of end terminations - At ambient
6.03 1 Lot
temperature - At high temperature (90°C) -
6.04 Repetition of Type Test: Cable bending test followed by partial discharge test at ambient temperature. 1 Lot

6.05 Repetition of Type Test: Switching impulse voltage withstand test as per IEC 60230/62067 1 Lot
Repetition of Type Test: Lightning Impulse voltage withstand tests followed by power frequency voltage test
6.06 1 Lot
asper IEC 62067/6023
6.07 Repetition of Type Test: Ageing treatment as per IEC 60811 1 Lot

Repetition of Type Test: Tests for determining the mechanical properties of XLPE insulation and outer
6.08 1 Lot
sheath(PE) before and after ageing

6.09 Repetition of Type Test: Heat cycle voltage test as per IEC 62067. 1 Lot

6.1 Repetition of Type Test: Flame retardant test on outer sheath (Test under fire condition) . 1 Lot

6.11 Repetition of Type Test: Insulation shrinkage test . 1 Lot

6.12 Repetition of Type Test: Measurement of resistivity of semi-conducting screens as per IEC 62067. 1 Lot

6.13 Repetition of Type Test: Conditioning & mechanical test as per IEC 60811 . 1 Lot

6.14 Repetition of Type Test: Pressure test at high temperatures on over sheaths . 1 Lot

6.15 Repetition of Type Test: Hot set test for XLPE insulation. 1 Lot

6.16 Repetition of Type Test: Measurement of carbon black contents in PE outer sheath. 1 Lot

6.17 Repetition of Type Test: Water penetration test. hardness of outer sheath . 1 Lot

6.18 Repetition of Type Test: Measurement of hardness of outer sheath . 1 Lot

6.19 Repetition of Type Test: Abrasion test on outer sheath. 1 Lot

6.2 Repetition of Type Test: Heat shock test on outer sheath. 1 Lot

6.21 Repetition of Type Test: Oil resistant test for outer sheath. 1 Lot

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SECTION‐ 3

PROJECT DETAILS AND GENERAL SPECIFICATIONS

3.0 GENERAL

This section stipulates the General Technical Requirements under the Contract and will form
an integral part of the Technical Specification.

The provisions under this section are intended to supplement general requirements for the
materials, equipment and services covered under other sections of tender documents and are
not exclusive.  However in case of conflict between the requirements specified in this section
and requirements specified under other sections, the requirements specified under respective
sections shall prevail.

3.1 PROJECT DETAILS

Name of the Project: 4x225MW , Arun‐3 HEP ,Nepal
Name of the Customer: SAPDC
Name of Consultant : SJVN

SJVN Arun‐3 Power Development Company (P) Ltd. (SAPDC), a company promoted by SJVN
Ltd., as a single shareholder company in Nepal having its registered office at Lokanthali,
Kathmandu, Nepal has signed Project Development Agreement with Government of Nepal to
plan, promote, organize & execute Arun‐3 Hydroelectric Project (900 MW) in Sankhwasabha
District. of Nepal.

The bid prepared by the Bidder and all correspondence and documents related to the bid
exchanged by the Bidder and the consultant/owner shall be written in the English, provided
that any printed literature furnished by the Bidder may be written in another language, as
long as such literature is accompanied by a translation in English, in which case, for purposes
of interpretation of the bid, the translation shall govern.

3.2 Location & Land Availability:

The proposed project site is located at a distance of 50 km from Khandbari, the headquarters
of Sankhuwa sabha District of Nepal. It is at about 240 km from Biratnagar and about 740 km
from Kathmandu. The location details of the proposed project site are as indicated below:
• Latitude …………………………………………………. .27o30’N – 27o ‐35’N
• Longitude ……………………………………………….. ...87o ‐12’E – 88o‐20’E
• Distance from Tumlingtar (domestic airport) town is……………….About 68 km
• Distance of Kathmandu (international airport) from Tumlingtar…..About 660.km

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3.3 Climatic Condition

A Meteorological data
0
1.1 Maximum ambient temperature C 35
0
1.2 Minimum ambient temperature C 4
0
1.3 Design ambient temperature C 40
0
1.4 Design minimum ambient temperature C ‐4
1.5 Maximum Relative humidity % 100
1.6 Maximum Relative humidity % 35

3.4 Seismic Zone
The equipment shall be designed for operation in seismic zone IV for earthquake resistance.
The equipment and each part of it shall be strong enough and sufficiently well connected to
resist total operating stresses resulting from forces in normal operation, abnormal condition
and forces superimposed due to occurrence of earthquakes of intensity which cause a ground
acceleration of 0.16 g in vertical direction and 0.24 g in the other horizontal directions.

3.5 Transportation
Unless otherwise specified in the Specification, responsibility for arranging transportation of
plant and equipment lies with the Contractor. The Contractor shall at its own risk and expense
transport all plant and equipment to a destination specified in bid document. The contractor
shall transport the contracted plant and equipment/ supplies through registered common
carriers only.

The nearest major airport is at Kathmandu which is at a distance of 740km from Project
Site. Biratnagar is connected to Kathmandu by Road.

The major nearest seaport for the trans‐shipment of heavy equipment to Nepal is Kolkata.
Other sea ports for imported equipment would be Mumbai or Chennai as convenient. The
two sea ports Mumbai & Chennai are connected to Kolkata and Jogbani by rail as well as
roads.

Railway transport is available from Kolkata and other locations of Indian Cities to the
Nepal‐India border only. The broad gauge line from Kolkata ends at Jogbani, Bihar. All
rail freight for Nepal has to be unloaded there. The distance of Kolkata by rail route is
about 800 km. From Jogbani, the road distance to the projects sites via Biratnagar is about
300km.

Road access to Arun‐3 project from Kolkata to Jogbani is 600km; from Biratnagar to Project
Area via Hile is 300km. Total distance to project area from Kolkata is 900km. Alternative route
could be from Kolkata to Raxaul which is 800km, further from Birganj to Dhalkebar to Hile to
Project Area which is 450km. Total distance Kolkata to Project Area is 1250km.

Local transportation, insurance and other services incidental to the delivery of facilities to be
supplied from Employer’s country (Schedule‐ 2 Items) shall be quoted separately.

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3.6 Transport Limitation

The transport limitation by road from Jogbani to the project site is the governing factor
for determining permissible package size and weight.
The existing roads allow the transport of the packages of the following size and weight.
Size (in mm) (l x b x h) ‐ 9700 x 6000 x 6000*
Weight (Tonnes) ‐ 70R
Heaviest package to be transported with suitable number of axle for safe transportation of
consignment for 70R bridge capacity.

* Height from the ground.

3.7 Salient features of Project

The salient features of Arun‐3 HEP are as follows:

A. POWER HOUSE COMPLEX
i. Power House Cavern    Underground on Left bank
ii. Installed capacity   900 MW
iii. No. of units   4
iv. Unit Capacity   225 MW
v. Size of Power House Cavern   179.50m (L) x 22.5m (W) x49.5m(H)

B. UNDERGROUND TRANSFORMER CAVERN

i. Size   146.14m (L) x 16 m(W)x 23m(H)
ii. Transformer Type   Single Phase
iii. Number and rating   13 nos. (including 1 spare),
15.75/420/√3kV, 50Hz, 92MVA
iv.Transformer Hall level   El. 552 m

C. Switchyard & Transmission

i.Type of Switching   Gas Insulated Substation and
                                                                                             Pothead Yard

ii. Size   207m (L) x 106m (W)

iii. Switchyard level   El. 557 m

iv. Transmission System   400kV Arun III HEP – Muzzafarpur
                                                                                                 via Dhalkebar D/c Quad Moose
                                                                                                 Lines with LILO of both circuits at
                                                                                                 Dhalkebar 400/220kV substation

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3.7.1 SYSTEM PARAMETERS

Continuous current carrying capacity
1 2000A (min)
(rms) at 40° C ambient temperature.

2 Short time current carrying Capacity 50kA for 1sec

400KV/420kV (rms)
3 Voltage
(Nom/Max)
4 Frequency 50Hz
5 System neutral earthing Effectively earthed
6 Insulation Level
One minute Dry Power frequency
a Withstand 630
Voltage (kV rms)
One minute Wet power frequency
b 630
Withstand Voltage (rms)
Switching Impulse withstand(250/2500
7 microsec.) voltage (kV peak) 1050
Impulse Withstand Voltage of arrester
1425 kVp
8 housing with 1.2/50 micro sec wave.
9 Creepage distance 25 (mm/kV)
10 Radio Interference voltage at 320kV   As per CEA guidelines

3.7.2 AUXILIARY POWER SUPPLY

3.7.2.1 AC power
Three‐phase system with grounded neutral for feeding three‐phase and one‐phase consumers
(connected between phase and neutral), 415/240V ± 10% and 50Hz , ‐5% to +3 %. All motors
and other electrical apparatus should be designed to work continuously under,‐5% to +3 %
frequency variation and ±10% voltage variation.

3.7.2.2 DC power
DC Systems, ungrounded, with earth fault detection 220V plus (+) 10% and minus (‐) 20% for
the supply of main control circuits for high and medium voltage switchgear, protection circuits
and to other larger essentials loads. Other voltage systems eventually needed, shall be
generated from the above systems by means of dc/dc converters, inverters etc.

3.7.2.3 Deleted

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3.7.2.4 Cabling & wiring
Wiring within cubicles and equipment enclosures shall conform to requirements of this
section unless otherwise specified. Control wiring shall be single / stranded copper subjected
to prior approval by purchaser during detailed engineering and shall not be smaller than 2.5
Sq. mm, except as otherwise agreed by the purchaser.

All Distribution Boards, Control & Protection panels, Motor Control control panels etc.
shall be supplied completely wired internally up to the terminal blocks ready to receive
purchaser control cable.

All inter cubicle and inter panel wiring and connections between panels of same
Distribution Board, Control & Protection panels, Motor Control panels including all bus
wiring for AC and DC supplies shall be provided by the tenderer.
Larger size wiring shall be used where needed for the current carrying capacity
requirements.

Cables shall have at least 1000 V PVC insulation except for 220V DC and telemetering or
communication system equipment for which 650V and 300 V ratings respectively are
acceptable.

For current and potential transformer secondary circuits the minimum cross section of the
conductors shall not be less than 4.0 Sq. mm.

Wiring shall terminate at terminal blocks at one side only. Where tap connections are
required, they shall be made on terminal blocks. Wiring shall be neatly arranged and laid
in wire ways accessible from the front door.

Engraved core identification ferrules marked to correspond with panel wiring diagram shall be
fitted at both ends of each wire.

Each cubical shall be provided with an earthing bar (PE) of sufficient cross section carrying any
possible fault current without undue heating. All metallic parts of the cubicle not forming part
of the live circuits, all instrument transformer terminals to be earthed and other earthing
terminals as well as all cable screens and PE‐wires shall be connected to the earthing bar.

3.7.2.5 Power outlets
Power outlet for utilities such as electric drills, welding equipment etc., shall be provided in all
floors of the powerhouse to enable repair and maintenance works to be done locally/ in‐situ.

3.7.2.6 Terminal blocks
The terminal blocks shall be located to allow a neat and easy connection work and shall be
safely accessible while the equipment is in service. Control circuits and power circuits shall be
completely separated by use of divided or separate terminal blocks. Power terminal blocks
shall be rated in accordance with applicable standards, and shall be provided with covers.
Terminal blocks shall be 1100V grade and have continuous rating to carry the maximum
expected current on the terminals.

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Terminal blocks for current transformer and voltage transformer secondary leads shall be
provided with test links and isolating facilities. The current transformer secondary leads shall
also be provided with short circuiting and earthing facilities.
The terminal shall be such that maximum contact area is achieved when a cable is terminated.
The terminal shall have a locking characteristic to prevent cable from escaping from the
terminal clamp unless it is done intentionally.
The conducting part in contact with cable shall preferably be tinned or silver plated.
The terminal blocks shall be of extensible design. The terminal blocks shall have locking
arrangement to prevent its escape from the mounting rails.

The terminal blocks shall be fully enclosed with removable covers of transparent, non‐
deteriorating type plastic material. Insulating barriers shall be provided between the terminal
blocks. These barriers shall not hinder the operator from carrying out the wiring without
removing the barriers.

Unless otherwise specified terminal blocks shall be suitable for connecting the following
conductors on each side.

All circuits except CT/ Minimum of two of 2.5 sq. mm
PT flexible circuits copper

All CT/ PT Minimum of 2 nos. of 6 sq. mm
Circuits flexible copper

The arrangements shall be made in such a manner so that it is possible to safely connect or
disconnect terminals on live circuits and replace fuse links when the cabinet is live.
Wherever duplication of a terminal block is necessary it shall be achieved by solid bonding
links.

At least 20% spare terminals shall be provided on ach panel / cubicle / box and these spare
terminals shall be uniformly distributed on all terminals rows.
There shall be minimum clearance of 250 mm between the first / bottom row of terminal
block and the associated cable gland plate. Also, the clearance between two rows of terminal
blocks shall be a minimum of 150 mm.

3.7.2.7 Protection requirement
For short circuit and overload protection of power and control circuits, air circuit breakers,
moulded case circuit breakers or MCBs shall be used. Outlets from AC (and DC) distribution
panels are protected in their respective panels.

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3.7.2.8 Switches, Lamps & Instruments
General
Control switches, indicating lamps and instruments shall be arranged so that all parts are
readily accessible for servicing without the necessity to remove other devices, terminal blocks
or excessive amount of wiring.

All control switches and indicating devices mounted in cabinets and enclosures shall be visible
with the doors closed.

Identification nameplates shall be provided for all control switches, indicating instruments and
lamps, in accordance with clause “Nameplates”.
Instruments and controls shall be located so that their dials, indicators and nameplates are
clearly readable. Data for all instruments to be provided, including type, size, scale range,
electrical ratings, nameplate and name of manufacturer, shall be furnished. Steel panels shall
be provided for group mounting of the instruments.

All instruments shall be of an approved type and shall match, insofar as practicable, the other
instruments with which they are associated; their dial type, scaled markings and units, type of
connection and mounting, shall be co‐coordinated. All piping and tubing required for
instruments shall be furnished and installed. All instruments and control switches shall be
furnished with necessary auxiliaries,i.e. resistors, shunts etc.

3.7.2.9 Control and Selector switches
The switches and push buttons shall be provided with ample contact ratings, suitable cam or
block arrangements necessary for the control functions on 230 V AC or 220V DC circuits. The
control switches used in mimic diagrams shall be of discrepancy type with built in lamp
indication.
Control and Selector switches shall be rotary type with escutcheon plates clearly marked to
show the function and positions. The switches shall be of sturdy construction suitable for
mounting on panel front.
Switches with shrouding of live parts and sealing of contacts against dust ingress shall be
provided.
Circuit breaker control switches shall have three positions and shall be spring return to
"NEUTRAL” from "CLOSE" and "TRIP" positions and shall have pistol grip handles. They shall
have at least two (2) contacts closing in close position, and two (2) contacts closing in trip
position unless specified otherwise.
Ammeter and voltmeter selector switches shall have four stay out position with adequate
number of contacts for three phase 4 wire system. These shall have oval handles. Ammeter
selector switches shall have make before break type contacts to prevent open circuiting of CT
secondaries. Contacts of the switches shall be spring assisted and shall be of suitable material
to give a long trouble free service.

3.7.2.10 Push buttons

Push‐buttons shall be of spring return, push to actuate type. Their contacts shall be rated to
make, continuously carry and break 10A at 230V AC and 0.5A at 220V DC.

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All push buttons shall have one normally open and one normally closed contact, unless
specified otherwise. The contact faces shall be of silver or silver alloy.

All push buttons shall be provided with integral escutcheon plates marked with its
function. The colour of the button shall be as follows:

Green :  Breaker Close
Red :   Breaker Open
Black :   For overload reset

3.7.2.11 Indicating and signaling lamps
Each indicating and signaling lamp shall have a removable cap, which can be inscribed with
wording and shall not be affected with the heat of the lamp.
Indicating lamps are preferably of LED type & low watt consumption and shall be replaceable
from the front of the panel. The indicating and signaling lamps shall be of the same size and
type.
Lamps shall be provided with series resistors, preferably built‐in the lamps assembly.
The lamps shall have escutcheon plates marked with its function, wherever necessary.

Lamps shall have translucent lamp‐covers of the following colours, as warranted by the
application.

Red :   ACB's/MCCB's close
Green :   ACB's/MCCB's open
White :   Auto trip
Amber :  For all healthy conditions e.g. control supply
Voilet :   Circuit breaker spring charged
Blue : For all alarm conditions (e.g. overload) Also for "SERVICE" & "TEST" positions
indicators

Indication lamps should be located just above the associated push buttons/control switches.
All indicating lamps shall be suitable for continuous operation at 90% to 110% of their rated
voltage.

3.7.2.12 HRC Fuses
HRC‐Fuses shall have visible operation indicators.

HRC‐Fuses shall be mounted on fuses carriers, which are mounted on fuse bases. Wherever it
is not possible to mount fuses on carriers, fuses shall be directly mounted on plug‐in type of
bases. In such cases one set of insulated fuse pulling handles shall be supplied with each
switchgear.

HRC‐Fuse rating shall be chosen by the tenderer depending upon the circuit requirements.

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3.7.2.13 Indicating instruments and Meters
Instruments mounted on panels, shall be of the semi flush type back connected, matching
pattern, shape, and of approved finish to present neat and fitting appearance consistent with
functional requirements Mechanical quantity measuring instruments which are directly
mounted on equipment shall have circular dials and shall be properly supported and guarded
against accidental injury/breakage. These shall be placed in convenient locations.
The instruments shall accurately measure and indicate the quantity under all conditions of
operation with minimum instrument errors. Changes in ambient temperature within the
range prevailing at site shall not affect the accuracy Contact making instruments shall have
contacts suitable for 240 V AC or 220 V DC circuits.
The reading scales on the dials shall be in metric units only and range shall be such that the
normal operating values of the quantities are indicated in the middle 3rd of the scale. The
dials pointer etc. shall be designed to facilitate accurate reading by minimizing parallax and
glare from instrument window and by providing clear bold dial markings. The size of dial and
length of the scales of the indicating instruments shall be large enough to suit the
requirements. The scale plates of panel mounted indicating instruments shall have a
permanent white mat finish with black graduations and the pointer shall also be of the black
colour. Instruments mounted on panels shall be of flush type and shall be back connected. All
instruments on a switchgear panel shall be of matching pattern, shape and finish so as to
present a pleasing appearance consistent with the functional requirements.
All instruments shall conform to relevant International or national applicable standards. These
shall be subjected to tests prior to dispatch. The instruments shall be shock, vibration and
moisture proof. The electrical instruments shall withstand dielectric test of 2000 V RMS to
ground for one (1) minute as per standards.
The coils of electrical instruments shall be designed for continuous operation at 110% of the
full load current at instrument potential. The coil rating of the measuring instruments shall be
coordinated with those of the associated instrument transformers (i.e. CTs, PTs, etc.) by the
supplier. The VA burden of the instruments shall be as low as possible. The meters shall be of
the first grade in respect of accuracy classification.
Energy meter shall be suitable for 3‐phase, 4‐wire unbalanced system and shall comply
generally with the relevant standard. All instruments shall be tested in accordance with the
requirements of relevant standards.

3.7.2.14 Integrating instruments
The Wh and VArh meters shall be of the semi‐flush‐mounted type. Each meter shall be
connected to terminal blocks suitable for opening and short‐circuiting for testing purposes.
The meter cases shall be dust‐tight and with removable covers. The meters shall be three‐
phase, three element, equipped with an impulse contact mechanism, potential free for
remote metering purposes, and shall be suitable for continuous operation from secondary of
potential transformers and from secondary of current transformers, with transformer ratios
and connections indicated on the contract drawings.
The meters shall be provided with primary‐rated, direct reading registers, with five or more
digits and a suitable multiplier. The meters for the outgoing lines shall be of the two‐way type
and all meters shall have mechanism to prevent negative registration.

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The meters shall have built in over‐voltage protection and isolation according to IEC
Publication 60521. The tolerance ambient temperature range of the meters shall be 0 to 45
degrees C.
The protection class of the Wh meters shall be 0.2 and the VArh meters 0.2 according to IEC
Publication 60687.

3.7.2.15 Measuring converters
The converters shall be suitable for direct connection to the secondary circuits of the potential
and current transformers used, or other sensors, each as they apply. The converters shall be
static type, having all accessories to provide an output signal of 4‐20 mA, filtered DC.
For the measuring converters the following minimum requirements shall be fulfilled:
Current transducers shall be single‐phase, of accuracy class 0.5 or better. Voltage transducers
shall be single‐phase of accuracy class 0.5 or better. W and VAR transducers shall be two
elements, three‐phase. Accuracy class of the transducers shall be 0.5 or better.
3.7.2.16 Measuring transformers
All current and voltage transformers shall be completely encapsulated cast resin insulated
type suitable for continuous operation at the temperature prevailing inside the switchgear
enclosure, when the distribution board is operating at its rated condition and the outside
ambient temperature is 40 deg.C.
All instrument transformers shall be able to withstand the thermal and mechanical stresses
resulting from the maximum short circuit and momentary current ratings of the associated
switchgear.
All instrument transformer shall have clear indelible polarity markings. All secondary terminals
shall be wired to a separate terminal on an accessible terminal block where star‐point
formation and earthing shall be done.

All VTs shall have readily accessible HRC current limiting fuses on both primary and secondary
sides.The class of insulation should be E or better.

The parameter & rating of CTs & PTs are minimum requirement & tentative only. Contactor
shall submit the calculations for selection of CT/PT for approval to purchaser. Potential
transformer secondary windings shall be rated 110 / V3 V Current transformer secondary
windings shall have a rated current of 1A / 5A.

3.7.2.17 Nameplates and Labels
Each major and auxiliary item of equipment shall have a nameplate permanently affixed
thereto, or as directed, showing in a legible and durable manner the serial number, name and
address of the manufacture, rated capacity, speed, electrical characteristics, and other
significant information, as applicable.
The module identification plate shall clearly give the feeder number and feeder designation
wherever applicable. For single front switchboards, similar panel and board identification
labels shall be provided at the rear also.
All name plates shall be of non rusting metal or 3‐ply lamicoid with white engraved lettering
on black back‐ground, inscriptions and lettering sizes shall be as per their standard practice.
Suitable plastic sticker labels shall be provided for easy identification of all equipment, located

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inside the panel/module. These labels shall be positioned so as to be clearly visible and shall
give the device number, as mentioned in the module wiring drawings.

3.7.2.18 Motors
All electric motors for driving various equipment shall conform to relevant standards viz. IEC,
BS or IS as applicable. The motor rating, torque characteristics, speed etc. shall be selected to
suit the duty requirements.
Type of starter for motors shall be duly approved by the purchaser during detailed
engineering. The detailed design calculation for selection of type of starters is to be submitted
for approval. The priority for type of starters shall be in the following order:
1. Variable frequency drive
2. Soft starter
3. Star delta/ auto –transformer
4. Direct on‐line starter
The enclosure of each motor shall be of the type best suited for the service conditions of the
motor. The motor insulation shall be resistant to moisture, oil or oil vapor and the motors in
general shall be so designed as to suit the tropical climate. Varnished cambric or glass
insulation class F shall be used for connection from the windings to the terminals.
The terminal box shall be closed conduit box type conveniently located, and shall have means
for terminating the external wiring for outdoor use. The motor terminals shall be of the stud
type totally enclosed. Eye bolts or lugs shall be provided for lifting.
Space heaters to avoid condensation shall also be provided. Special type of motors, not
adequately covered by these specifications, shall be offered for any special application, but
these shall be subject to the approval of purchaser.

3.7.2.19 Space heaters
Space heater shall be provided in the Distribution Boards, Control & Protection panels, Motor
Control panels etc. The space heaters shall be suitable for continuous operation on 240V AC,
50 HZ single phase supply, and shall be automatically controlled by thermostats. Necessary
isolating switches and fuses shall also be provided.

3.7.2.20 Auxiliary relay, contacts and devices
All relays and timers in protective circuits shall be flush mounted on panel front with
connections from the inside. They shall have transparent dust tight covers removable from
the front. All protective relays shall have a draw out construction for easy replacement from
the front. They shall either have built‐in test facilities, or shall be provided with necessary test
blocks and test switches located immediately below each relay. The auxiliary relays and timers
may be furnished in non‐draw out cases.
All AC auxiliary relays shall be suitable for operation with VTs and CTs secondaries.
DC auxiliary relays shall be designed for 220V DC unless otherwise specified and shall operate
satisfactorily between 80% and 110% of the rated voltage. Relays shall have adequate thermal
capacity for continuous operation in circuits in which they are used.
All protective relays and timers shall have at least two potentially free output contacts. Relays
shall have contacts as required for protection schemes. Contacts of relays and timers shall be
silver faced and shall have a spring action. Adequate number of terminals shall be available on
the relay cases for applicable relaying schemes.

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Suitable number of auxiliary contacts or auxiliary relays shall be provided with each VCB's /
ACB’s for indication, remote indication, annunciation and automatic changeover and
interlocking scheme.
All protective relays, auxiliary relays and timers shall be provided with hand reset operation
indicators (flag) for analysing the cause of operation.

3.7.2.21 Welding & NDT
Preparation of base material
Members to be joined by welding may be cut to shape and size by mechanical means such as
shearing, machining, grinding, or by gas or arc cutting, to suit the conditions. Edges shall be
shaped according to ASME requirements. Design of welded joints and selection of weld filler
metal shall be in accordance with approved standards and shall allow thorough penetration
and good fusion of the weld with the base metal. The edges of surfaces to be welded shall be
sound metal free of visible defects such as laminations or defects caused by cutting operation
at least 30 mm back from the edge of the weld, and free from rust, oil, grease, and other
foreign matter.

The establishment of welding procedures, welder’s qualifications shall conform to the
requirements of the ASME Boiler and Pressure Vessel Code Section VIII and IX. The approved
copy of the WPS & WPQR in accordance with the ASME requirements shall be submitted to
the purchaser for review and record.

3.7.2.22 Field welding
Filler material required for field‐welded joints shall be furnished by the Contractor. The
Contractor shall perform all welding work at site in accordance with the applicable WPS. Only
qualified welders shall be used for undertaking welding as per the applicable WPS.NDT shall
be performed as per the approved drawings.
Preparation for field welding
All cutting, chamfering, and other shaping of metals necessary for the field connection shall be
done as far as possible in the shop. Adequate temporary bolted field connections shall be
provided to hold the assemblies rigidly and in proper alignment during shop and field
assembly.
To ensure proper alignment during field erection, a minimum of two dowels shall be provided
for each field connection between subassemblies. The holes shall be drilled and the dowels
fitted at shop assembly after the subassemblies have been satisfactorily aligned. All
stipulations for welding, structural work and other, shall be applied to fieldwork as well as to
shop work, except where otherwise stated.

3.7.2.23 Painting
All the equipment furnished and installed by the Contractor shall be completely painted for
final use, with the exception of those parts or surfaces that are expressly designated as
unpainted. Surfaces to be painted shall receive the preparatory treatment and required
number of coats. The Contractor shall perform all painting work in the shop, before shipment,
followed by a final coat of paint at site after installation as per the standard procedure.

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All materials, supplies, and articles furnished shall be the standard products of recognized
reputable manufacturers. Colour schedule of equipment supplied shall be finalized during
detailed design stage.

3.7.2.24 Galvanization
All materials to be galvanized shall be of the full dimensions shown or specified and all
punching, cutting, drilling, screw tapping and the removal of burrs shall be completed before
the galvanizing process commences. All galvanizing shall be done by the hot dip process with
smelter, not less than ninety eight percent (98%) of which must be pure zinc. No alternative
process shall be used without the approval of the purchaser. No components shall be
galvanized which are likely to come into subsequent contact with oil. Bolts shall be completely
galvanized including the threads, but the threads shall be left uncoated in the case of nuts.
The zinc coating shall be uniform, clean, smooth and as free from spangle as possible. In the
case of component parts the zinc coating shall weigh not less than 0.6 kg/m2 over the area
covered and be not less than 0.09mm in thickness. All galvanizing shall comply with the
requirements of the relevant ASTM standards/Indian Standards. All galvanized parts shall be
protected from injury to the zinc coating due to differential aeration and abrasion during the
period of transit, storage and erection. Damaged areas of the coating shall be touched up with
an approved zinc dust paint or other approved flake metallic compound.

3.7.2.25 Pumps
All pumps forming part of the generating units and other plant and equipment shall be of high
performance requisite type (viz. centrifugal, rotary etc.) and rating, of reputed make, and shall
be directly coupled to their driving motors. The pumps shall be of self‐priming type and with
proper sealing systems and protection.
The materials of construction of pumps in general shall suit the service conditions. The
materials of construction of the pumps handling water, such as drainage & dewatering pumps,
turbine top cover drainage pumps etc. shall be resistant to abrasive effects of silt in such
water. The pumps shall operate quietly without undue noise and vibration in their full
operating range of head and flow. They shall be easy to maintain.

3.7.2.26 Embedded parts, Anchor Bolts and Fasteners
All embedded anchor bolts, rods, pipes, welding plates and support plates shall be provided
by contractor. Anchor bolts shall consist of a threaded steel rod installed inside a pipe sleeve
to provide lateral adjustment after the sleeve is embedded. The threaded end of the rod shall
be provided with two steel nuts and two steel washers to permit leveling and anchoring the
equipment prior to grouting.
Approved types of expansion or chemical anchors shall be used where practicable for small
equipment.

3.7.2.27 Rust Prevention and Protection during Transit:‐
Bright steel parts including all machined surfaces shall be given a thick coat of tar or tallow or
any other approved rust resisting paint in plain colour to prevent rusting during shipment and
transport.

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3.7.2.28 Civil Works
Civil foundations for equipment of the generating units and other plant and equipment will be
prepared by the Purchaser in accordance with the basic design data to be supplied by the
Contractor.
The Contractor shall provide design for foundations and install the concrete
inserts/embedment; support steels and/or components for foundation /supports purpose,
shall do any chipping / levelling works, denting / painting etc.

3.7.3 Erection, Testing, Commissioning and performance of Guarantee Tests

3.7.3.1 Testing and inspection
Materials used for construction of major & important sub‐assemblies shall be thoroughly Lab /
shop tested and inspected by the Contractor at his own expense prior to dispatch. Lab / Shop
test shall comprise of routine test & type tests.
The shop tests and inspections shall be as spelt out in individual equipment specifications as
dealt in succeeding sections but shall not be limited to the same. Any other tests and
inspection not specifically listed but are otherwise considered essential and advisable shall
also be conducted.
The Bidders shall furnish schedule of the lab / shop tests and inspections on materials and
equipment. Important tests/inspections shall be subject to witness by the purchaser for which
the Contractor shall give sufficient advance notice. In case purchaser is unable to witness shop
tests/inspections, the Contractor shall be so intimated and the tests/inspections may then be
carried out in the absence of the Purchaser.

Equipment on which tests and inspections have been duly witnessed and approved by the
Purchaser may be dispatched by the Contractor. Equipment on which tests and inspections
have not been witnessed by the purchaser shall be dispatched only after the shop tests and
inspection Certificates have been approved by the Purchaser.

3.7.3.2 Dimensional Checks and Visual Inspection
Dimensional checks shall be performed on all major parts, components and partial
assemblies, especially when close tolerances and fits are involved (tolerance of shafts,
between stationary and moving parts, connecting dimensions for the assembly with other
supplies, etc.). If the dimensional checks show discrepancies in measurement, which may
affect the fit, assembly or dismantling of the respective part or component, the same have to
be corrected correspondingly. Such correction or modification shall, however, in no way lead
to sacrifices with respect to reliability of operation or inter‐changeability, and shall be
performed only after the agreement of the Owner has been obtained. If the correction or
modification cannot be carried out in accordance with the terms mentioned above, the part
or component concerned may be subject to rejection. Faulty machine parts or equipment
shall by no means be delivered.

3.7.3.3 Functional Tests
Functional tests on partial assemblies and/or complete assemblies shall be carried out as
much as possible already in the manufacturer's workshops. Such tests shall be performed as
far as possible under operation‐like conditions.

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When requested by the Owner, the functional tests shall be repeated until full proof has been
obtained that the functioning of the assemblies will comply with the requirements of the
Contract Documents.

3.7.3.4 Erection, commissioning & field tests
The Contractor has to do all the work related to assembly, erection, testing and
commissioning complete in all respects. All necessary tools, plants, labour, materials including
consumables for performing installation, testing and pre‐commissioning shall be provided by
the Contractor.
The Contractor shall submit the necessary data/information, layout and foundation/support
drawings well in advance. The Contractor shall provide and install the concrete
inserts/embedment, support steels and/or components for foundation/supports purpose as
per approved erection drawings and coordinate the activities with civil contractors to keep his
activities in synchronism with civil work. All installation for foundation shall be verified and
accepted by the Engineer.
The Contractor shall use anchor fasteners for installation of piping, fixtures, mountings,
conduits, cabling, panels etc. Minor Chipping of concrete is permitted. However, taking
support from reinforcement bars shall not be allowed.

3.7.3.5 Installation procedure
The Contractor shall submit six copies of all detailed programs and the procedures to be
adopted for erection / installation, testing and commissioning well in advance, before start of
erection activities/ installation.
The installation procedure shall also have a section “site quality assurance plan” containing
erection data sheets / site protocols for various components. These sheets should specify site
measurements/ inspections required to be made for ensuring proper installation.

3.7.3.6 Cable laying
Wiring between equipment enclosures shall be made with cables, laid in trenches and/or
cable trays and in cable conduits. The Contractor shall submit for review to the Engineer a
cable route layout‐showing location of trenches, conduits and trays. All material for cable
laying such as cable trays supports and fastening material shall be furnished and placed by the
Contractor. Cables shall be properly fastened and marked where they enter enclosures by
either cable clamps or nipples.
Cables in horizontal cable trays shall be fastened properly with clamps or plastic strips. Power
and control cables shall be placed in separate trays or conduits. Cables shall be clearly marked
at each terminal point and appropriate intermediate locations as per Standard.

Conduits shall be of heavy gauge rigid steel, hot‐dip galvanized, cut square reamed, threaded
and screwed tight at all joints.

Conduit entrances to pull boxes and switches shall have double lock nuts & insulating
bushings. No running thread shall be used.

Flexible metallic conduit shall be used for connection to equipment, which are subject to
vibration, and also for connection to level/limit/pressure switches.

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3.7.3.7 Field inspection
The Contractor shall permit Engineer to perform inspections of the assembly which will
include a complete verification of the assembly of all parts as to their levels, clearances,
pertinent fits, alignments and quality of workmanship. The field supervisor of the Contractor
shall provide Engineer with three (3) copies of all the clearances, tolerances and data of all
pertinent fits, alignments and levels, so that the latter may repeat the Contractor’s
measurement, if desired.
Unless otherwise specified, any rejection based on the inspection will be reported to
Contractor within fifteen (15) days.

3.7.3.8 Field tests
All field tests including tests during installation, pre‐commissioning, commissioning,
performance and field acceptance tests shall be conducted by the Contractor, in the presence
of representative of the Employer. Procedure to be adopted for conducting these tests shall
be submitted well in advance, before start of relevant testing, for approval of the Employer.
The equipment / system shall be deemed to be commissioned and ready for trial run only
after successful operation for a test service period specified in sub clause “Performance
Testing”. In the event of any failure this period shall be repeated for any number of times till
the successful operation as described above is achieved.
All test equipment and instruments shall be furnished by the Contractor and will remain the
Contractor’s property after the fulfillment of all field tests.
Any defects or leaks disclosed in the tests shall be duly mended/ repaired to meet the desired
function and retested. All necessary materials and labour for performing all the above tests
shall be provided by the Contractor.
The Contractor shall prepare written test certificates in a form agreed upon by the Contractor
and Employer of all tests results and hand them over to the Employer in due time.
The design, location and approval tests of anchoring rings for the fixing of lifting apparatus
necessary for assembly and dismantling of equipment and plant accessories shall be the
responsibility of the Contractor.

3.7.3.9 Taking over of facilities
Taking over” means that the Facilities (or a specific part thereof where specified) have been
completed operationally and structurally and put in a tight and clean condition, and that all
work in respect of pre‐commissioning of the Facilities or such specific part thereof has been
completed and commissioning has been attained as per Technical Specifications. The
contractor shall make formal request for taking over the facility to the EIC.

3.7.3.10 Operation acceptance
The operational acceptance by the Employer of the Facilities (or any part of the Facilities
where the Contract provides for acceptance of the Facilities in parts), which certifies the
Contractor’s fulfillment of the Contract in respect of Functional Guarantees of the Facilities (or
the relevant part thereof) in accordance with the provisions of Specification.

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3.7.3.11 Consumables, oils and Lubricant
The Contractor shall deliver to the Owner all equipment complete with initial fill of fluids,
grease or lubricants, transformer oil, Nitrogen, SF6 gas and other used gases in non returnable
drums / containers and replace any quantity used up or lost during installation and testing.
The oil used for the lubrication and oil pressure systems for the turbine, governor, shutoff
valve and generator shall be preferably of the same type.

Supply
The Contractor shall furnish the following:
(i) All oil for initial filling of all equipment supplied, plus additional oil equivalent to the first
filling requirement of one unit.
(ii) Grease if required for initial filling of all of the equipment, plus 10% additional.
(iii) Gases for initial filling of all equipment supplied, plus 10 % additional quantity.
(iv) Flushing fluids to flush and clean all systems.

3.7.3.12 Deleted:

3.7.3.13 Submission of Drawings, Documents, Manual, software, Calculations, Safety

Margin Details etc.

All drawings and documents shall be submitted to purchaser in hard form as well as in
editable soft form. Bidder shall submit Ten (10) number hard copies of the documents &
drawings to purchaser for reference / review / approval. A comprehensive list of all such
drawings/documents planned to be submitted for reference/approval shall be provided
beforehand to the purchaser.

Loading drawings
For all larger pieces of Works which, due to their dimensions and/or weight and transport
limitations, will require special means for their transportation, the Contractor shall submit
binding loading drawings indicating dimensions, weights, etc., of the respective pieces of
Works and the necessary trailer for its transportation to the site.
Foundation drawings
If a piece of works requires its own foundation or needs a special area for installation, the
contractor shall submit drawings indicating all pertinent dimensions, static and dynamic loads,
etc. They shall include all essential details required for proper design and construction of the
foundations and/or buildings.
In addition, they shall include openings, sleeves, slopes and the arrangement of any
supporting structure, i.e. base‐frames or other steel constructions for permanent fixing or
erection purposes.
If conduits are to be installed in the foundations, the relevant information such as diameter,
length, and purpose shall be indicated on the drawings.

Arrangement drawings
All arrangement drawings shall be drawn to scale. The General Arrangement Drawings shall
show the physical arrangement of Works (constructions, machines, complete switchgears,
control panels, instrument cubicles, etc.), civil constructions (buildings, rooms, foundations,
ducts, etc.) and reserved areas (for pipes, cables, lines, etc.) in relation to each other and to

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agreed co‐ordinates and boundaries. Such drawings shall be prepared for the whole plot, for
separate plots and for each building (building, hall, room, ducts and trenches, etc.).

Outline drawings
The Outline Drawing shall show all elements and the main dimensions of individual
components where necessary in plan view, cross‐section, side and top views. If reasonably
possible such dimensions can be shown on Arrangement Drawings.

Design drawings
The Design Drawings shall include the shop drawings, assembly drawings, erection drawings,
piping diagrams and piping arrangement drawings, etc., showing the dimensions, design and
data of all constructions, apparatus and Works to be furnished under this Contract. The
drawings shall ‐ where applicable ‐ substantially conform to the Contract Drawings and shall
show:
• 3‐D Assembly drawings for major components in hard and soft form.
• Details of manufacturing and treatment of major single work pieces specially manufactured
for this Contract
• Assembly of the Works in plan and elevation with main dimensions Sub‐assembly of the
principal components of the Works with overall dimensions, adjustment and clearance
tolerances, numbers of corresponding detail drawings
• Sub‐assemblies in which the Contractor proposes to ship the Works
• All necessary details of the parts connecting to the Works supplied by others
• Location and sizes of auxiliary connections for oil, grease, water, air, electrical power etc.
• Location and size of the instruments and accessories provided
• Methods of lubrication and sealing
• Instructions for heat treatment, pressure tests, surface preparation and anticorrosive
protection
• Full details of parts for which adjustment is provided or which are subject to wear
• Method and sequence of installation, field joints, erection and lifting devices, jacks, grout
plugs, anchoring details, etc., if not shown on foundation drawings.

Installation drawings
The construction, mechanical, electrical and I & C Installation Drawings shall provide detailed
information on the disposition of the various items of a system (e.g. lighting fixtures, socket
outlets, connection boxes, transmitters, actuators, loudspeakers, telephones, pipes, valves,
pumps, compressors, etc.) and of the piping and wiring respectively included in the
installation or assembly. They shall be based on dimension drawings of cubicles, rooms,
buildings or areas containing the Works.

Diagrams

Single‐line diagrams
This is a simplified diagram of the essential electrical Works and their interconnections. Each
circuit shall be represented by a single line only. It shall contain all required technical
information of the Works represented, e.g. voltage, current, capacity, shortcircuit level, ratios,

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voltage variations, positive and zero sequence impedances, measuring transformer and
protection relay indices, interlocking, kind of switch drive, code designation, etc. as applicable.

Circuit diagrams
The Circuit Diagrams shall show the power circuits in all the phases with the main apparatus
as well as the pilot circuits (measuring and control circuits). It shall show in full the functioning
of part or all installations, Works or circuits with all required technical details.

Block diagrams
The Block Diagrams shall be used to show in a simplified manner the main inter ‐ relationships
between the elements of a system by means of symbols, block symbols and pictures without
necessarily showing all the connections. The symbols used for the individual kinds of
components, e.g. servomotors, computing modules, etc., shall clearly be explained on the
diagram or on an attached legend.

Logic diagrams
The Logic or Functional Diagrams shall be used for representation of logic and sequence
controls and interlocking by showing only binary logic elements and their effect on the various
process equipment disregarding their electrical realisation. Logic function elements (AND, OR,
NOR, NAND, STORAGE, etc.) shall be used for processing and combining binary signals.

Terminal diagrams
Such diagrams shall be prepared for any type of terminal box, marshalling rack, control
cubicle, switchboard, etc., and shall show the terminals (properly numbered) and the internal
and/or external conductors (wires or cables) connected to them.
The terminal diagram of each individual switchboard, terminal box, panel, etc., shall contain,
but not be limited to the following information:

Protection co‐ordination diagrams
These diagrams shall show in a graphical manner separately for each power supply circuit:
• A simplified single‐line diagram of the circuit with technical data of all instrument
transformers and relays
• Co‐ordinated tripping curves of related protection devices
• Setting of the protection devices.

Emergency shutdown diagram
This diagram shall show the sequential steps and interdependencies during emergency
closure.

Flow Charts
Flow charts shall be used for representing sequence of events for start / stop / shut down of
the machine including associated equipment and auxiliaries.

Manuals
The following manuals covering all equipment of EM works shall be supplied as per the
time schedule in both editable soft and hard form:‐

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Sr.No.      Manual Description
1.      Storage and preservation manual
2.      Safety manual
3.      Erection Manual
4.      Testing and commissioning manual
5.      Operation manual
6.      Maintenance manual
7.      Long term storage manual for Generator Transformer
8.      Long term storage manual for boxed up component / equipment.
9.      Repair process / procedure manual for equipment / system

As built drawing to be provided incorporating changes made during erection, testing and
commissioning.

Drawing & Document Submission Schedule
Drawings & documents submission schedule of the EM package with the categorization (i.e.
Approval / reference) & tentative submission date shall be submitted to purchaser.

Preliminary list of drawings under various categories have been prepared and appended at
Section 1 of the Technical Specification.

3.8 DRAWINGS & DOCUMENTS TO BE SUBMITTED BY THE SUCCESSFUL BIDDER AFTER
AWARD OF CONTRACT

One set of soft copies of all the approved drawings, documents including as built drawings
shall be furnished by the Bidder to the Owner / Consultant in compact discs.

White prints or other non‐reproducible drawings can be mailed folded. Blue prints shall
generally not be used.
All drawings, prepared by the Bidder shall be as per IS: 696. Supplier's standard drawings
are exempted from the above size limitation, unless his "standard" includes drawings of
very large size or length. There shall be sufficient reference notes on the drawings to permit
identification of all the drawings which are required for a proper understanding.

Bills of material and drawings shall be cross‐referenced for easy identification.

All drawings shall be dimensioned in the metric system. Where drawings are usually made in
the British (or other) system, they shall also have metric system dimensions in parentheses
or below dimension line. Titles and written notations shall be in English. If the original is in
another language it shall carry English translation. The translations will appear immediately
on the drawings. Attached lists of translated words shall not be accepted.

Drawings and bills of material shall be identified by a numbering system to be mutually
agreed later on. Any additional identification numbers or symbols that the Bidder selects to

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use for his own purposes are permissible so long as Owner's number is the prime means of
identification.

The scale of the drawing shall be shown clearly in the title block of the drawing. Wherever
possible, scales of drawings shall be:‐

1:1 1 :  2.5 1 :  5 1 : 10 1 : 20 1  :  25
1:50 1 :  100 1 :  200 1 : 300 1 : 500
1: 1000 1 :  2000 1 :  5000

All reproducible must be made from original drawings.

All revised drawing shall clearly indicate the number, date and subject to each revision. All
the revisions carried out in the drawings shall be clearly identified and marked.

Drawing list shall be kept up‐to‐date, incorporating all new additions, cancellations and
changes, and will be reissued periodically with Progress Report.

General arrangement drawings shall be submitted for approval to the Owner/ Consultant
prior to the commencement of detail engineering by the Bidder. These drawings shall show
to scale all major equipment including electrical equipment and building outlines and overall
dimensions as well as tie‐in dimensions and clearances shall be clearly indicated. Approved
arrangement drawings shall be used as basis for design and preparation of detail drawing to
be prepared by the Bidder. The Bidder shall furnish all the necessary drawings, data etc., of
the plant/equipment with appropriate "Status" stamp in adequate no. of copies as indicated
below:

CONTRACT
TENDER FINAL
S. No. DESCRIPTION STAGE FOR
STAGE DOCUMENTATION
APPROVAL

Prints Prints CDs

1 Drawings and Data Sheets 1 6 10 -
2 Drawings “As Built “ - - 10 -
3 Type Test Reports 1 6 10 02
4 Erection Manuals - 6 10 -
10
5 Operation and Maintenance Manuals - 6 -

6 Manufacturing Quality Plan 1 6 10 -

7 Field Quality Plan 1 6 10 -
8 Inspection Test Reports - - 10 -

All instruction manuals / O&M Manual/”as built drawing”: 10 copies each

3.8.1.1 QUALITY ASSURANCE PROGRAMME

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The Bidder shall follow Quality Assurance Programme to ensure that the equipment and
services under the scope of contract whether manufactured or performed at the Bidder’s
works or at his sub‐vendor’s premises or at the SAPDC’s site or at any other place of work are
in accordance with the technical specifications. Such programme shall be outlined by the
Bidder and be submitted along with the bid. The QA programme shall be generally in line with
IS/ISO‐ 9001 and generally cover the following:

 ORGANISATION STRUCTURE FOR THE MANAGEMENT AND IMPLEMENTATION OF THE
 PROPOSED QUALITY ASSURANCE PROGRAMME
 QUALITY SYSTEM MANUAL
 DESIGN CONTROL SYSTEMS
 DOCUMENTATION AND DATA CONTROL SYSTEMS
 QUALIFICATION/EXPERIENCE OF BIDDER’S KEY PERSONNEL.
 PROCEDURE FOR PURCHASE OF MATERIAL, PARTS, COMPONENTS AND SELECTION OF
SUB‐VENDOR’S SERVICES INCLUDING VENDOR ANALYSIS, SOURCE INSPECTION,
INCOMING RAW‐MATERIAL INSPECTION, VERIFICATION OF MATERIALS PURCHASED, ETC.
 SYSTEM FOR SHOP MANUFACTURING AND SITE ERECTION CONTROLS INCLUDING
PROCESS, FABRICATION AND ASSEMBLY.
 CONTROL OF NON‐CONFORMING ITEMS AND SYSTEM FOR CORRECTIVE ACTIONS AND
 RESOLUTION OF DEVIATIONS.
 CONTROL OF CALIBRATION AND TESTING OF MEASURING / TESTING EQUIPMENT.
 SYSTEM FOR QUALITY AUDITS.
 SYSTEM FOR IDENTIFICATION AND APPRAISAL OF INSPECTION STATUS.
 SYSTEM FOR AUTHORISING RELEASE OF MANUFACTURED PRODUCT TO THE PURCHASER.
 SYSTEM FOR TRANSPORTATION /DELIVERY, HANDLING, STORAGE AND PRESERVATION.
 SYSTEM FOR MAINTENANCE OF RECORDS.

GENERAL REQUIREMENTS ‐ QUALITY ASSURANCE

All materials, components and equipment covered under scope and its technical specifications
shall be procured, manufactured, erected, commissioned and tested at all the stages, as per a
comprehensive Quality Assurance Programme agreed mutually.

Minimum Quality Assurance Test Requirement (QATR) to be followed during Manufacturing
and Field erection indicating requirement of various tests / inspections, on major equipment /
items, to be carried out as stipulated in technical specification and standards mentioned
therein, are attached hereto and are part of bidding documents.

Clarification, if any, on these quality assurance test requirement, raised by bidder shall be
discussed and resolved during pre‐bid meeting.

After the award of contract, the contractor shall submit the detailed Manufacturing & Field
Quality Assurance Plans for complete equipment / material during detailed engineering in the
format attached hereto (format of quality plan F‐060‐02 issue 2.0 rev. 01, Total 1 Page) for

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approval and acceptance by SAPDC/Consultant in line with technical specification, Quality
Assurance – General & Test Requirements and detailed engineering.

Manufacturing Quality Assurance Plans shall detail out for all the components and equipment
& various tests/inspection, to be carried out in conformity with relevant latest IEC/IS/ISO etc,
quality practices and procedures to be followed by Contractor’s / Subvendor’s Quality Control
Organization, the relevant reference documents, standards and acceptance norms etc. during
all stages of material procurement, manufacture, assembly and final testing / factory
acceptance tests.

The Field Quality Assurance Plans shall detail out the various tests/inspection to be carried out
in conformity with relevant latest IEC/IS/ISO, quality practices and procedures etc. to be
followed by the contractor’s / sub‐contractor’s site Quality Control Organisation during
various stages of site activities from receipt of material/equipment at site till final
commissioning/ acceptance/handover.

All major items/ equipment/ components to be manufactured in house as well as procured
from sub‐vendors (Bought out Items, BOI) to be listed in the bid. Bidder shall submit Quality
Assurance Plan submission schedule in the bid for above listed items in attached Format (duly
filled in the format F‐060‐05 Issue 2.0 Rev. 00, Total 1 Page) in line with L2 Schedule.

For components / equipment / Bought out Items procured by the contractor for the purpose
of the contract, the Contractor’s purchase specifications and inquiries shall call for quality
plans to be submitted by the sub‐vendors.
The quality plans called for from the sub‐vendors shall detail out, during the various stages of
manufacture and installation, the quality practices and procedures followed by the sub‐
vendor’s quality control organisation, the relevant reference documents/standards used,
acceptance level, inspection of documentation raised, etc.

Such quality plans of the successful sub‐vendors shall be finalized with the SAPDC/Consultant
in line with requirement mentioned above and such approved Quality Plans shall form a part
of the purchase order/contract between the contractor and his sub‐vendor.

Within three weeks of the release of the purchase orders /contracts for such bought out items
/components, a copy of the same without price details but together with the detailed
purchase specifications and other related documents such as data sheet, drawings, quality
plans and delivery conditions shall be furnished to the SAPDC/Consultant by contractor along
with a report of the Purchase Orders placed, on the monthly basis, so far for the contract.

The Quality Plans shall be submitted on electronic media e.g. CD or E‐mail in addition to hard
copy, for review and approval of SAPDC/Consultant. After approval, the same shall be
submitted in compiled form on CD‐ROM by contractor.

For all spares, replacement items and additional similar items, the quality
requirements/Quality Plans as agreed for the main equipment supply shall be applicable.

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All material of construction shall be as per technical specification / approved drawings / GTP.

Contractor’s Plant internal standards must be traceable to acceptable International / National
standards & salient points of difference (if any) shall be clearly stated with submission of plant
standards. The contractor shall furnish copies of reference documents, plant standards,
acceptance norms, test and inspection procedure etc. as referred in Quality Plans along with
Quality Plan to SAPDC/Consultant. These Quality Plans and reference documents/standards
etc. will be subject to approval of SAPDC without which manufacturer shall not proceed.
These documents shall form a part of the contract.

Tests on components and sub‐assemblies shall be carried out at various stages of
manufacturing, till the product undergoes the final tests in conformity with the relevant
standards.

The Customer Hold Points (CHPs), identified in approved quality plan, i.e. testing checks which
shall be carried out in the presence of the SAPDC, beyond which the work will not proceed
without written consent of SAPDC’s authorized representative.
The contractor / sub‐vendor shall carry out routine test on 100% items at his works. The
quantum of check / test for routine and acceptance test by SAPDC/Consultant shall be
generally as per criteria / sampling plan defined in referred standards. Wherever standards
have not been mentioned, quantum of check / test for routine / acceptance test shall be as
agreed during detailed engineering.
The quantum of check when specified in percentage (%) / sampling basis shall be treated as
per lot per sub‐vendor. When the quantum of check is indicated to in whole no., then same
quantum of check shall be applicable to each sub‐vendor supplying the same equipment.

For sub‐vendors identified during pre‐award stage for submission of vendor details/
credentials (category “DR”), contractor shall submit documents in format F‐060‐01 after
placement of award in the manner as specified as under prior to any procurement and within
a month after placement of award or a period as agreed at the time of pre‐award discussions.

The proposed sub‐vendors should be registered vendors of the bidder and must have proven
experience for successful operation for similar equipment / items / processes as mentioned
elsewhere in technical specification.

Before assigning any portion of work to the sub‐vendor, other than one specified and duly
accepted in the contract, the contractor will take prior approval of BHEL/SAPDC.

Normally no request for change of sub‐vendors or inclusion shall be entertained by SAPDC.
But in exceptional circumstances, if the request for change of sub‐vendors or inclusion is
found reasonable and justified, then the same shall be entertained and the decision of SAPDC
in this respect shall be final and binding. The time consumed for the change / inclusion of sub‐
vendors shall not be excluded from the stipulated time of the completion of the contract. This
change shall not relieve the contractor from the responsibility to complete the work within
stipulated time in any manner.

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The contractor’s proposal shall include sub‐vendor’s facilities established at the respective
works, the process capability, process stabilization, Q.C. system followed, experience list etc.
along with his own technical evaluation of sub‐vendor. (Format F‐ 060‐01 issue 2.0 rev. 01,
Supplier / Sub‐vendor Assessment Sheet, Total 14 pages).
However, whenever felt necessary, sub‐vendor assessment will also be carried out by
SAPDC/Consultant in accordance with the above procedure and by factory visits; for
existing/proposed vendors/sub‐vendors. This approval shall not relieve the contractor from
any obligation, duty or responsibility under the contract & SAPDC shall not be responsible for
any complications arising between the contractor and his subcontractor(s) / sub‐vendor (s)
and / or any other liabilities.

SAPDC/Consultant reserves the right to carry out quality audit and quality surveillance of the
system and procedures of the contractor / or their sub‐vendor. The contractor shall provide all
necessary assistance to enable SAPDC/Consultant to carry out such details & surveillance
including Quality Manuals, if required by SAPDC/Consultant.

All welding and brazing shall be carried out as per procedure drawn and qualified in
accordance with requirement of ASME section‐VIII/IX or other International equivalent
standard acceptable to SAPDC/Consultant. All welding/brazing procedures shall be submitted
to SAPDC/Consultant/BHEL for review / verification prior to carrying out the welding/brazing.
However, wherever required by the SAPDC/Consultant, tests shall be conducted in presence
of SAPDC’s authorized representative.

All Brazers, Welders and welding operators employed on any part of the contract either in
Contractor/his sub‐vendor’s works or at site or elsewhere shall be qualified as per ASME
section‐VIII/IX or other equivalent International Standards acceptable to SAPDC/Consultant.

Unless otherwise proven and specifically agreed with SAPDC/Consultant, welding of dissimilar
material and high alloy materials shall be carried out at shop only.

All non‐destructive examination shall be performed in accordance with written procedures as
per International Standards. The NDT operator shall be qualified as per SNT‐TC‐IA (of the
American or Indian Society of non‐destructive examination). NDT shall be recorded in a
report, which include detail of methods and equipment used, result/evaluation, job data and
identification of personnel employed and details of correlation of the test report with the job.

All material used for equipment manufacture including castings and forgings, etc. shall be of
tested quality as per relevant codes/standards. Details of results of the tests conducted to
determine the mechanical properties; chemical analysis and details of heat treatment
procedure recommended and actually followed shall be recorded on certificates and time
temperature chart. Tests shall be carried out as per applicable material standards and/or
agreed details.

Contractor shall submit Field Welding Schedule for field welding activities like field welding
location, numbers, welding procedure to be used, requirements, codes and NDT requirement
along with all supporting documents, like welding procedures, heat treatment procedures,

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NDT procedures, etc. to SAPDC/Consultant for review at least ninety days before schedule
start of erection work at site.
Any other statutory requirements as applicable for the equipment / systems shall also be
complied with.

The inspection calls (duly filled in the format F‐060‐06 Issue 2.0 Rev. 00, total 1 Page) shall be
placed at least 06 weeks in advance for overseas inspections excluding India and 15 days in
advance for inspections within India and Nepal.
Before submitting the inspection call to SAPDC for witnessing the Customer Hold Points
(CHP’s) and/or requesting SAPDC for issuance of Material Dispatch Clearance Certificate
(MDCC) based on Test Certificate (TC) review / Certificate of Conformance (COC), the
contractor shall ensure that all Drawings / documents / GTP / technical data sheet, relevant to
respective CHP / MDCC requirement, has been duly approved /accepted / noted by SAPDC.
Contractor shall ensure readiness of offered equipment by all means, before raising such call
to SAPDC to attend CHP inspections. In case, SAPDC engineer (s) on reaching at a place of
inspection found that material is not ready for inspection due to whatsoever reason, the
complete inspection expenditure of SAPDC engineer(s) as per actual shall be chargeable to the
contractor.

Only calibrated testing & measuring instruments shall be used while performing tests during
manufacturing and erection, testing & commissioning at site by the contractor. Copy of the
calibration certificates will be submitted to SAPDC/Consultant by the contractor during
inspection as an evidence.

Non‐conformities observed during manufacturing, shop testing, handling, packaging,
transportation, storage, preservation, erection, testing & commissioning are required to be
intimated by the contractor (Format for reporting, F‐060‐04 issue 2.0 rev 01, Total 5 pages).
The acceptance/rejection of the non‐conformities will be at the discretion of SAPDC.

Repair/rectification procedures to be adopted to make the job acceptable shall be subject to
the acceptance of SAPDC. Action taken in accordance with decision of disposal of non‐
conformity for repair / rework / modification of the item / equipment and to prevent re‐
occurrence. The corrective and preventive action may involve modification of item /
equipment, change in procedure and system etc. to achieve quality improvement at all stages
and levels.

Quality audit/surveillance/approval of the results of the tests and inspection will not,
however, prejudice the right of the SAPDC to reject the equipment if it does not comply with
the specification when erected or does not give complete satisfaction in service and the above
shall in no way limit the liabilities and responsibilities of the Contractor in ensuring complete
conformance of the materials/equipment supplied to relevant specification, standard, data
sheets, drawings etc.

No material shall be dispatched from the manufacturer’s works before the same is duly
accepted, subsequent to pre dispatch/final inspection including verification of records of all

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previous tests/inspection by SAPDC and duly authorised for Dispatch by issuance of Material
Dispatch Clearance Certificate (MDCC).

The test reports of type tests conducted as per contract, in line with requirement stipulated in
the technical specification / quality plan should be got accepted from SAPDC/Consultant
before final inspection / issuance of MDCC.

All materials used or supplied shall be accompanied by valid and approved material
certificates and tests and inspection reports. These certificates and reports shall indicate the
heat numbers or other such acceptable identification numbers of the material. The material
certified shall also have the identification details stamped on it to ensure physical correlation
and traceability of material vis‐a‐vis test certificate. Such identification no. shall remain same
and verifiable for all stages of manufacturing and installation.

3.8.1.2 QA DOCUMENTATION
The contractor shall be required to submit the QA Documentation in two hard copies and two
CD ROMs, as identified in respective quality plan.

Each QA Documentation shall have a project specific Cover Sheet bearing name and
identification number of equipment including index of its contents with page control on each
document. The QA Documentation file shall be progressively completed by the
Contractor/sub‐vendor to allow regular reviews by all parties during the manufacturing.

The final quality document will be compiled and issued at the final assembly place of
equipment before despatch. However CD‐ROM may be issued not later than three weeks.

Before dispatch / commissioning of any equipment, the Contractor shall make sure that the
corresponding quality document or in the case of protracted phased deliveries, the applicable
section of the quality document file is completed. The Contractor will then notify the
Inspector regarding the readiness of the quality document (or applicable section) for review.

The contractor shall be required to submit copies of the following quality assurance
documents in original duly reviewed and accepted by contractor along with the request letter
for issuance of MDCC (Material Dispatch Clearance Certificate):

 QUALITY PLAN CHECK LIST.
 MATERIAL MILL TEST REPORTS ON COMPONENTS AS SPECIFIED IN QUALITY PLAN.
 SKETCHES AND DRAWINGS USED FOR INDICATING THE METHOD OF TRACEABILITY OF THE
 RADIOGRAPHS TO THE LOCATION ON THE EQUIPMENT.
 NON‐DESTRUCTIVE EXAMINATION RESULTS REPORTS INCLUDING INTERPRETATION
REPORTS.
 CALIBRATION CERTIFICATE OF ALL METERS & MEASURING INSTRUMENTS PROPOSED TO
 BE SUPPLIED AS PART OF RELEVANT BILLING BREAKUP ITEM.
 ROUTINE TEST REPORTS FOR TESTING REQUIRED AS PER APPLICABLE CODES AND
 STANDARDS REFERRED IN THE SPECIFICATIONS.
 INSPECTION REPORTS DULY SIGNED BY AUTHORIZED REPRESENTATIVE OF SAPDC AND

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 CONTRACTOR FOR THE AGREED CUSTOMER HOLD POINTS.
 ALL THE ACCEPTED DEVIATIONS SHALL BE INCLUDED WITH COMPLETE TECHNICAL DETAILS.
 LIST OF BALANCE POINTS IF ANY.
 CERTIFICATES IN RESPECT OF CALIBRATION, WELDERS & BRAZERS QUALIFICATION ETC.
 COPY OF ALL REFERENCE DRAWINGS AND REFERENCE TECHNICAL DOCUMENTS
 ACCEPTANCE OF TYPE TEST REPORTS BY SAPDC/CONSULTANT.

Similarly, the Contractor shall be required to submit two sets (two hard copies and two CD
ROMs), containing QA Documentation pertaining to field activities as per Approved Field
Quality Plans and other agreed manuals/procedures, within 2 weeks after commissioning of
individual system.

On release of QA Documentation by Inspector, one set of quality document shall be
forwarded to Consultant and other set to SAPDC. For the particular case of phased deliveries,
the complete quality document to the SAPDC/Consultant shall be issued not later than 3
weeks after the date of the last delivery of equipment.

ASSOCIATED DOCUMENTS / FORMATS
• F‐060‐01 VENDOR / SUB‐VENDOR ASSESSMENT SHEET
• F‐060‐02 QUALITY PLAN SUBMISSION BY CONTRACTOR.
• F‐060‐04 NON‐CONFORMANCE REPORT (NCR)
• F‐060‐06 INSPECTION CALL REQUEST.

3.8.1.3 Safety
Safety of personnel
All equipment and services provided under this contract shall abide by international standards
commonly accepted in the hydroelectric utility industry for safety of personnel whether
involved with operation or maintenance.

Safety of operation
All equipment and services provided under this contract shall abide by commonly accepted
standards for safety of operation.
The various system and sub‐systems supplied under this contract shall be designed to follow
and operate under a clear hierarchical structure:
• Plant control level,
• Unit control level,
• Functional control level, functional drive group level,
• Local drive level.

Each hierarchical control level shall perform its specific tasks and always depend on the
subordinate lower control levels. In general, should a higher control level failure occur, the
lower control level shall not be affected and shall be able to control the power plant with full
safety.

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The Contractor shall accordingly build into the "Electrical & Mechanical System" adequate
levels of autonomy, independence, redundancy and functional distribution to insure that
safety is maintained at all times.

3.8.1.4 Earthing
Earthing terminals for equipment of these specifications shall form part of equipment
supplies. The contractor shall connect the earthing conductors to these terminals as required.

Risers from earthing bus shall be in the scope of purchaser. However, extension from these
risers to the equipment shall be in the scope of supplier in the Power House, Transformer Hall,
Switchyard and Butterfly Valve House.

However, overall earthing arrangement required for HT panel, LT panel, DG set, motor &
motor control panels etc. at isolated location such as Dam Site, TRT Outfall area and Surge
Shaft either by pit earthing or counter poise etc. shall be in the scope of supplier including civil
works, design, material supply (for main earthing risers, interconnection, charcoal, salt,
Bentonite etc.), erection, testing & commissioning etc.

A copper ground bus, sized to carry maximum short circuit current, shall run along the entire
length of panel structure and shall have terminal connector at each end for connection to
station ground grid (50 X 6 mm G.I. flat).

Tests
Each panel shall be completely assembled, wired, adjusted and tested at the factory prior to
shipment. The test shall include wiring continuity tests, insulation tests and functional tests
to ensure satisfactory operation and control of individual equipment.

Special Cables
Special cables for specific purpose, as required, shall be supplied and installed by the Bidder.

3.8.1.5 Completeness of the specification
Any fittings, accessories, equipment or any other things required for successful commissioning
of Arun‐III Hydro Electric Project, though may not have been specifically mentioned in the
specification but are usually necessary for the completeness of the equipment shall be
deemed to be included in the specification and shall be supplied by the contractor without
any extra cost to the Employer.

3.8.1.6 Packaging and Shipment
The Contractor shall provide such packing of the Goods as it is required to prevent their
damage or deterioration during transit to their final destination as indicated in the Contract.
The packing shall be sufficient to withstand, without limitation, rough handling during transit
and exposure to extreme temperatures, salt and precipitation during transit and open
storage. Packing case size and weights shall take into consideration, where appropriate, the
remoteness of the final destination of Goods and the absence of heavy handling facilities at all
points in transit.

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The packing, marking and documentation within and outside the packages shall comply
strictly with such special requirements as shall be expressly provided for in the Contract and,
subject to any subsequent instruction ordered by the Employer consistent with the
requirements of the Contract.
After unpacking of Goods the packing material shall become the property of Employer

The contractor shall wrap, pack and crate all plant included in the work or part thereof,
suitable for shipment to a tropical location, facilitating proper handling and protection from
damage in rail, truck, ocean or air shipment as applicable. An approved drying agent, such as
Silica Gel, shall be packed in containers or packages holding plant which may be adversely
affected by moisture or excessive humidity.

All packing crates shall be clearly marked before shipping to indicate the contract number,
shipping address, volume, weight, name, number and unit number of the contents, slinging
and weight bearing points.

All plant parts shall be marked to facilitate erection. Each packing crate shall contain a packing
list in a waterproof envelope. Parts shall be described and also identified by their numbered
marking in the packing list.

Three copies of the packing list shall be forwarded to the purchaser prior to dispatch. The
ownership of packaging materials shall be of Employer. All wooden packaging crates and steel
support structures shall be dumped to the designated area within 5kms of the power house as
per the direction of Engineer in charge.

The supplier shall be entirely responsible for the insurance, shipment, handling and
transportation.

The equipment shall not be dispatched by the Bidder from the place of manufacture to the
site until the dispatch instructions are issued by the Owner.

3.8.1.7 PACKAGING, HANDLING AND SITE STORAGE

The Contractor shall pack all the consignment in sea worthy packaging strong enough to
withstand rough handling during transit. Machine surface shall be suitably protected against
scratches, corrosion, shocks, impact etc. Packages shall be suitably and distinctly identified for
type of handling and kind of storage.

Electronic equipment shall be packaged, shipped and stored in anti‐static packing. All
packages shall be stored indoor. Packages containing electronic equipment shall be stored in
humidity controlled environment.
The Bidder shall indicate the number of packages of consignment together with the size
(L x W x H) and weight for transporting the equipment in the Bidding Document.

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3.9 SPECIAL INSTRUCTIONS TO BIDDERS

General

The Bidder shall base the equipment design on the information given in this specification. The
equipment shall be complete in all respects. Any item which is not specifically mentioned
herein but found essential for safe and efficient operation and maintenance and satisfactory
performance of the system shall be deemed to have been included in the scope of the Bidder.
It shall be presumed that the Bidder has studied the site, all the drawings, tender documents
and is fully aware of the scope of work involved and the site conditions prevailing.

3.10 Codes and Standards

a) All equipment, systems and works covered under this specification shall comply, in all
respect, with requirements of applicable latest statutes and that of latest editions of
codes and standards. Latest regulations and safety & environmental requirements as
applicable in India / state of installation shall also be complied with.

b) All codes and standards mentioned shall mean as relevant and applicable to a particular
equipment / system.

c) All other codes/standards not covered in Section 1 / Section 2  but required for the plant
and system offered shall also be referred / followed by the Bidder. The Bidder, along with
the bid, shall submit a comprehensive list of codes and standards to be followed for
various equipment / system.

d) In all cases where IBR does not govern, German, American, British, ISO or other
international standards established to be equivalent or superior to the codes specified
are also acceptable. In the event of any conflict between the requirements of equivalent
codes and standards and the requirements of Indian standards / regulations, the latter
will govern unless specified otherwise in the specifications.

e) The Bidder shall be responsible to be in possession of all the specified Codes / Standards
and ensure reference to the same before submitting the offer/ bid.

f) Mandatory codes / local regulations to be followed for safety, design, fabrication and
operation of the switchyard shall be, followed:

g) If the equipment supplied does not conform to the codes and standards mentioned in
this specification, but is manufactured to the Bidder's own standard, developed as a
result of his experience, is also acceptable provided the same is found to be superior to
the above mentioned codes and standards. The Bidder shall identify such equipment and
shall also present sufficient data to the Owner / Consultant to support his design and to
establish the superiority. The design may be accepted by Owner/ his Consultants only if
the Purchase / his consultant is satisfied that sufficient experience exists with the design
proposed.

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h) Design not meeting the stipulations of the codes and standards will not be acceptable.

i)      Apart from various codes and standards mentioned in Section 1/2, the Manufacturer
shall comply with other requirements of codes and standards mentioned in this
Specification for detailed design, manufacture, testing, erection, construction etc.

Control System IEEE – 122 , 1992
API  675  –  1987  (Positive  displacement
pumps – controlled volume)
Metering / Dosing pumps API  676  –  1987  (Positive  displacement
pumps – Rotary).
Centrifugal pumps API 610 – 1990, ASME PTC 8.2 – 1965
Gear Box API 613 – 1993 & AGMA 420 & 421
Coupling API 671 – 1993
IS 1893 – 1991, IS 875‐1992 & IS 800 –
Structural
1991
Pressure Vessel ASME Sec. VIII, Div. 1 – 1995
Piping ANSI B 31.1‐1995 / 31.3 – 1993, IBR
Valve API
Instrument ISA, API
Electrical As  per  specification  attached  &  relevant
IS/IEC
Tanks API 650‐ 1993
Electrodes AWS, IS
Painting IS Standards
Performances Tests
Overload test of crane and hoists IS 3177

3.11 Deviations and Assumptions

Bidders requested to carefully examine and understand the specifications and seek
clarifications, if required, to ensure that they have understood the specifications. The Bidder's
offer should not carry any sections like clarifications, interpretations and/or assumptions. In
the event of conflict between the Technical Specifications and the condition of contract, the
requirements as indicated in the technical specification shall govern, unless confirmed
otherwise by the Owner in writing before the award of contract, based on written request
from the bidder for such a clarification.
In the event of conflict between requirements of any two clauses of the specification
documents, the more stringent requirements shall apply, unless otherwise confirmed by the
Owner in writing before the award of this contract, based on a written request from the
Bidder for such clarification.

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The Bidders are advised that while making their Bid Proposals and quoting prices, all terms
and conditions of bidding documents may appropriately be taken into consideration. Bidders
are required to furnish a certificate indicating their full compliance to the terms and
conditions of the bidding documents.

3.12 Limit of Contract

Equipment furnished shall be complete in all respect with all mountings, fittings, fixtures and
standard accessories normally provided with such equipment and/ or needed for erection,
completion and safe operation of the equipment as required by applicable codes though they
may not have been specifically detailed in the respective specifications, unless included in the
list of exclusions. All similar standard components/ parts of similar standard equipment
provided shall be interchangeable with one another.

This review by the Owner’s Engineer / Consultant may not indicate a thorough review of all
dimensions, quantities and details of the equipment, materials, any devices or items
indicative of the accuracy of the information submitted. This review and/ or approval by the
Engineer shall not be construed by the Bidder, as limiting any of his responsibilities and
liabilities for mistakes and deviations from the requirements specified under these
specifications and documents.

3.13 Latent Defects
Notwithstanding the issue of the Take Over Certificate, the Contractor shall be responsible for
making good with all possible speed any Latent Defect in any Works /equipment of the plant
which appears at any time before the expiry of defect liability period. And shall remedy such
defect at its own cost and expense. The latent defect liability period shall be a minimum of 5
years from the end of defect liability period. The defects to which this applies are defects in
design, materials or workmanship or defects arising from any act or omission of the
Contractor done or omitted prior to Take‐over of the portion of the Plant affected by the
defects or during the Warranty Period which a reasonable examination at the end of the
Warranty Period would not have disclosed.

3.14 Defect Liability

a) Defect Liability Period” means the period of validity of the warranties given by the
Contractor commencing at Completion of the Facilities or a part thereof, during which the
Contractor is responsible for defects with respect to the Facilities (or the relevant part thereof
as provided here.
b) The Contractor warrants that all the facilities or any part thereof are new, unused,
and of the most recent or current models, and that they incorporate all recent improvements
in design and materials, unless provided otherwise in the Contract.
c) The Contractor further warrants that the Plant and equipment shall be free from
defects arising from any act or omission of the Contractor or arising from design, materials,
and workmanship, under normal use in the conditions prevailing in the country of final
destination.
d) The defect liability period shall be Twenty Four months (24) months from the date
of completion of the facilities (or any part thereof) or eighteen (18) months from the date of

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operational acceptance/taking over of the facilities (or any part thereof), of respective unit/
common auxiliary whichever period concludes earlier.
e) If during the Defect Liability Period any defect should be found in the design,
engineering, materials and workmanship of the Plant and equipment supplied or part thereof,
the Contractor shall promptly, in consultation and agreement with the Employer regarding
appropriate remedying of the defects, and at its cost, repair, replace or otherwise make good
(as the Contractor shall, at its discretion, determine) such defect as well as any damage to the
Facilities caused by such defect. The Contractor shall not be responsible for the repair,
replacement or making good of any defect or of any damage to the Facilities arising out of or
resulting from any of the following causes:
(a) improper operation or maintenance of the Plant and equipment by the Employer
(b) operation of the Facilities outside specifications provided in the Contract
(c) normal wear and tear.
f)   Upon receipt of notice the contractor shall within one week start the repair work.
g) The Employer shall give notice to the Contractor stating the nature of any such
defects together with all available evidence thereof, promptly following the discovery thereof.
The Employer shall afford all reasonable opportunity for the Contractor to inspect such
defects.
h) Upon receipt of such notice, the Contractor shall, within the period specified in the
specification, expeditiously repair or replace the defective Plant and equipment or parts
thereof, at no cost to the Employer.
i)   If the Contractor fails to commence the work necessary to remedy such defect or any
damage to the Facilities caused by such defect within a reasonable time (which shall in no
event be considered to be less than fifteen (15) days), the Employer may, following notice to
the Contractor, proceed to do such work, and the reasonable costs incurred by the Employer
in connection therewith shall be paid to the Employer by the Contractor or may be deducted
by the Employer from any monies due the Contractor or claimed under the Performance
Security.
j)   If the repair, replacement or making good is of such a character that it may affect the
efficiency of the Plant and equipment or any part thereof, the Employer may give to the
Contractor a notice requiring that tests of the defective part of the Facilities shall be made by
the Contractor immediately upon completion of such remedial work, whereupon the
Contractor shall carry out such tests.
k) If such part fails the tests, the Contractor shall carry out further repair, replacement
or making good (as the case may be) until that part of the Facilities passes such tests. The
tests in Character shall in any case be not less than what has already been agreed by the
Employer and the Contractor for the original equipment / part of the Facilities.
l)   If the Plant and equipment or any part thereof cannot be used by reason of such
defect and/or making good of such defect, the Defect Liability Period of the Facilities or such
part, as the case may be, shall be extended by a period equal to the period during which the
Facilities or such part cannot be used by the Employer because of any of the aforesaid
reasons.
m) Upon correction of the defects in the Facilities or any part thereof by
repair/replacement, such repair/replacement shall have the Defect Liability Period
extended by a period of twelve (12) months from the time such replacement/repair of the

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facilities or any part thereof subject to maximum time period of thirty six (36) months from
the date of putting plant and equipment into use.
n) The Contractor’s obligations under this Clause shall not apply to
(i.) any materials that are supplied by the Employer are normally consumed in
operation, or have a normal life shorter than the Defect Liability Period stated herein
(ii.) any designs, specifications or other data designed, supplied or specified by or on
behalf of the Employer or any matters for which the Contractor has disclaimed
responsibility herein .
(iii.) any other materials supplied or any other work executed by or on behalf of the
Employer, except for the work executed by the Employer for remedy of defects in the
work executed by the contractor as per provisions mentioned below.
o) The Employer shall afford the Contractor all necessary access to the Facilities and the
Site to enable the Contractor to perform its obligations under this Clause .The Contractor may,
with the consent of the Employer, remove from the Site any Plant and Equipment or any part
of the Facilities that are defective if the nature of the defect, and/or any damage to the
Facilities caused by the defect, is such that repairs cannot be expeditiously carried out at the
Site.
p) Except as provided in (Defect Liability) and (Loss or Damage to property), the
Contractor shall be under no liability whatsoever and howsoever arising, and whether under
the Contract or at law, in respect of defects in the Facilities or any part thereof, the Plant and
Equipment, design or engineering or work executed that appear after Operational acceptance
or any part thereof, except where such defects are the result of the gross negligence, fraud,
criminal or wilful action of the Contractor.
q) The contractor shall provide an extended warranty for a period of 36 months from
the date of taking over of Facilities for the part repaired (as envisaged in POINT NO (k)).

21. Loss of or Damage to property:
a) The Contractor shall indemnify and hold harmless the Employer and its employees
and officers from and against any and all suits, actions or administrative proceedings, claims,
demands, losses, damages, costs, and
b) expenses of whatsoever nature, including attorney’s fees and expenses, in respect of
the death or injury of any person or loss of or damage to any property (other than the
Facilities whether accepted or not), arising in connection with the supply and installation of
the Facilities and by reason of the negligence of the Contractor or its Subcontractors, or their
employees, officers or agents, except any injury, death or property damage caused by the
negligence of the Employer, its contractors, employees, officers or agents.
c) If any proceedings are brought or any claim is made against the Employer that might
subject the Contractor to liability the Employer shall promptly give the Contractor a notice
thereof and the Contractor may at its own expense and in the Employer’s name conduct such
proceedings or claim and any negotiations for the settlement of any such proceedings or
claim.
d) If the Contractor fails to notify the Employer within twenty‐eight (28) days after
receipt of such notice that it intends to conduct any such proceedings or claim, then the
Employer shall be free to conduct the same on its own behalf. Unless the Contractor has so

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failed to notify the Employer within the twenty‐eight (28) day period, the Employer shall make
no admission that may be prejudicial to the defense of any such proceedings or claim.
e) The Employer shall, at the Contractor’s request, afford all available assistance to the
Contractor in conducting such proceedings or claim, and shall be reimbursed by the
Contractor for all reasonable expenses incurred in so doing.
f) The Employer shall indemnify and hold harmless the Contractor and its employees, officers
and Subcontractors from any liability for loss of or damage to property of the Employer, other
than the Facilities not yet taken over, that is caused by fire, explosion or any other perils, in
excess of the amount recoverable from insurances procured under GCC Clause (Insurance),
provided that such fire, explosion or other perils were not caused by any act or failure of the
Contractor.
g) The party entitled to the benefit of an indemnity under this Clause shall take all
reasonable measures to mitigate any loss or damage which has occurred. If the party fails to
take such measures, the other party’s liabilities shall be correspondingly reduced

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3.15 Completion Schedule

The Bidder shall submit Time Bar chart indicating completion date of major activities such as
submission of design data / calculations and drawings for approval, manufacturing of
components / units, supply, inspection etc. without which the Tender shall not be considered.
Time Bar Chart furnished shall afterwards form part of the contract and cannot be altered
arbitrarily except Force Majeure conditions as may be agreed with the Owner.

3.16 Drawings & Documents for Owner’s use and Archives

The Bidder shall submit all final drawings, documents, manuals for Owner’s use and for
reference / record required during course of operation and maintenance of the plant.
Numbers of copies and their form (hard copy, electronic form, reproducible) to be submitted
and the details of the documents, drawings, manual etc. to be furnished by the Bidder are
described elsewhere in the specification.

Drawings, documents, calculation, data & Information to be submitted by the Bidder
along with the offer:

Technical Data to be submitted with the Tender
1) List of performance tests proposed by the Bidder to demonstrate the guaranteed
parameters for generator and other electrical equipment.
2) Specific energy consumption.
3) Type test certificates for major categories of equipment, issued by independent
testing authority.
4) Guaranteed Technical Parameters.
5) Technical catalogues.
6) Manufacturing Quality Plan

Operation & Maintenance Manuals

Instruction manuals, presenting the basic categories of information for the operating and/or
maintenance personnel, as detailed herein below shall be furnished by Bidder.
The instruction manuals shall present the following basic categories of information in
particular complete and comprehensive manner and prepared for the use by operating
and/or maintenance personnel.

i. Instructions for initial commissioning, short duration and long duration shut down.
ii. Instruction for operation, routine inspection and maintenance including preventive
maintenance.
iii. Recommendation for inspection points, method of inspection and period of inspection.
iv. Information on detection, cause and rectification of troubles and faults.
v. Instructions on normal repairs and overhaul.
vi. Complete parts list with proper and complete identification (Tag nos./Serial nos. as
shown in the respective approved drawings) and ordering information for all

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replaceable parts. The identification details of equivalent and alternative makes for
these spare parts which are not manufacturer's own product shall also be listed.
vii. List of all special tools and tackle & spares and instructions for use of such tools and
tackle & spares.
viii. One complete set of as built drawings of the entire systems.
ix. The information shall be organized in a logical and orderly sequence. A general
description of equipment including significant technical characteristics shall be
included to familiarize operating and maintenance personnel with the equipment.
Such description and technical characteristics shall not differ from the approved data.
x. Necessary drawings, curves and other illustrations shall be included or copies of
appropriate approved drawings shall be bound in the manuals. Tests, adjustment and
calibration information, as appropriate, shall be included. Safety and other warning
notices and installation, maintenance and operating cautions shall be emphasized.
xi. Write‐up, figures, part list etc., shall be clearly legible. The manuals shall be prepared
on good quality paper securely bound in durable folders.
xii. The instruction manuals shall be subject to Consultant's approval in the same fashion
as that for drawings.
xiii. Instruction manual shall give step by step procedure for Erection, testing and
commissioning
xiv. Operation, Maintenance and Repair Instruction manual shall also contain:
xv. List of spare parts with ordering specifications and manufacturer's catalogues
xvi. List of consumables, lubricants, chemicals with specifications, brand names and annual
consumption figures.
xvii. Drawings relevant for erection, operation, maintenance and repair of the equipment.
xviii. Procedure for ordering spares.
xix. Maintenance Manual shall also include:
xx. Diagnostic trouble shooting / fault location charts
xxi. Tests for checking of proper functioning.

Drawings / documents for approval
Quality Control & Quality Assurance plan.
G.A. and Cross Sectional drawings of all equipment indicating weights, material of
construction, bill of material, dimension, specification etc.
Final design calculations and assumptions.
Actual performance data and characteristic curves based on the testing at site.

Technical specification of all equipment, motors, for all system and all other accessories.
Final list of drawings.
As built drawings.

Miscellaneous

i. General arrangement and cross sectional drawings of all major components with bill of
material.

ii. Foundation drawings, load data & design calculation for all equipment.

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iii. Erection drawings for all equipment and structures showing complete erection details.

iv. Engineering and design calculations of installations and units.

v. QAPs

vi.Detailed procedures of shop testing of all the items applicable shall be submitted to the
Owner/ Consultant for approval before conducting tests.
vii. Following shop test certificates/test curves/data, shall be furnished.

 Materials and components test certificates.
 Performance test results and characteristic curves of all fans, pumps, and electric
drive motors etc.
 Non‐destructive test results as applicable.
 Reports and test certificates of shop tests.
 Type test & routine test certificates.

viii. Detailed quality assurance program along with quality plan shall be submitted.

Following data shall be furnished:‐

a) Technical data of all the plant, equipment, drive motors, instruments, panels, etc.
shall be furnished.

b) Following lists/tables / write ups shall be furnished, complete with tag nos. and brief
specification. Proper numbering system as approved by Consultant/Owner shall be
adopted.

i) Instrument schedule (with service, range, make of instrument).
ii) Flow element schedule.
iii) Valve schedule.
iv) Pipe schedule.
v) Cable schedule (Power & Control).
vi) Schedule of actuators (electric/pneumatic)

The scheduled dates for the submission of these as well as for, any data/information to be
furnished by the Employer would be discussed and finalized at the time of award. The supplier
shall also submit required no. of copies as mentioned in this specification of all
drawings/design documents/test reports for approval by the Employer.

Note: The contractor may please note that all resubmissions must incorporate, all comments
given in the submission by the Employer failing which the submission of documents is likely to
be returned. Every revision shall be a revision number, date and subject, in a revision block
provided in the drawing, clearly marking the changes incorporated.

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3.17 Workmanship and Quality Control

All moving parts of equipment, which can conceivably cause injury to the operator and
otherwise authorized personnel within the vicinity of working area shall be suitably guarded
and warning displays shall be put at prominent places.

The Bidder shall clearly indicate and identify the plans and procedures, which shall be
followed in the design, manufacture and installation of plant and equipment to control and
assure to the Owner of the desired quality.

FUNGI STATIC VARNISH

Besides the space heaters, special moisture and fungus resistance varnish shall be applied on
parts which may be subjected or predisposed to the formation of fungi due to the presence
or deposit of nutrient substances. The varnish shall not be applied to any surface of part
where the treatment will interfere with the operation or performance of the equipment.
Such surfaces or parts shall be protected against the application of the varnish.

3.17.1 Equipment Mounting

All instruments, switches etc. mounted on the front face of the panels shall be of flush type.

All equipment shall be so mounted that removal and replacement may be accomplished
individually without interruption of service to others.

All equipment inside the panel shall be so located that their terminals and adjustments are
readily accessible for inspection and maintenance. Adequate ventilation shall be provided in
enclosed panel.

Each of the LV switchboards shall be designed for 1.1 times the required rating as a spare
capacity. Further all LV Switchboard shall be provided with 20 % spare modules of each
rating and type of module.

3.18 Performance Test:
If nothing unusual has been observed in load run and load rejection tests, the test service
period of 72 hours shall follow. During this test service period, the unit must operate
continuously at rated condition without any interruption except of those beyond the control
of the Contractor. However, such interrupted period shall not be counted for in the test
service period. There should be one‐month reliability run of the complete unit reckoned
from the date of taking over by employer. During reliability run, machine shall be operated
by employer and any problem observed during this run shall be attended by the contractor
including replacement of components and providing requisite manpower.

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3.18 Title Block :

Project 4x225MW Arun‐3 (HEP),Nepal

Customer SJVN Arun‐3 Power Development Company (P) Ltd. (SAPDC)

Consultant SJVN Ltd


Name   Sign
BHARAT HEAVY ELECTRICALS LTD.
Drawn
TRANSMISSION BUSINESS GROUP
Checked
NOIDA
Approved
Title Drawing Number : Rev

‐‐‐‐‐‐‐‐‐‐‐‐‐xxxx‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐

Section-3 Page 41 of 41
Bharat Heavy Electricals Limited SECTION‐4
Project: 4x225MW Arun‐3 (HEP), Nepal
Technical Specification:  400kV XLPE Cable & its Accessories
Doc No. TB‐405‐316‐002 Rev 00
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Technical Checklist
Sl. No. Particulars Confirmation by Bidder
1.0 Technical Qualifying Requirement
1.1 The bidder to furnish relevant documents for meeting the Confirmed Yes/ No
qualifying requirement. Documents shall be submitted in
English. Translated pages should be attested by the ultimate
customer, if attested only by the bidder it shall be notarized.
1.2 The bidder’s scope includes supply and services such as   Confirmed Yes/ No
‐ Installation,
‐ Testing and commissioning.
1.3 All the documents shall be submitted in English. Translated Confirmed Yes/ No
pages should be attested by the ultimate customer, if attested
only by the bidder it shall be notarized.

2.0 Un‐priced BOQ
2.1 Bidder to confirm that all BOQ items have been quoted. Any Confirmed Yes/ No
item, which is not quoted, the same shall be specifically
brought out in Schedule of technical deviation with technical
reasons of thereof. However, it shall be discretion of BHEL/
Customer/ Consultant to take final decision on this regards.
2.2 Any other item /service required for the execution for the List of Yes/ No
complete work is deemed to be included in the offer, whether items
specifically mentioned in the specification or not. Hence, required
bidder shall bring out such requirements during tendering to be
stage only. The bill of quantities included in the offer shall attached.
clearly reflect such additional items along with their respective
quantities & unit prices. Bidder to attach list of item (s), if
required, for completeness of work.
2.3 The specification entails complete solution to 400kV HV cabling Confirmed Yes/ No
system and hence, scope includes supply of all materials and
services i.e. cable installation, termination/ jointing, clamping,
testing and commissioning of the cable system, point to point,
necessary to execute the work to the satisfaction of BHEL/
Customer/ Consultant.
2.4 Supply & installation of support structure and minor civil works Confirmed. Yes/ No
for foundation for supporting the cable/ termination/ jointing (Details are
etc. transformer cable box end is in bidder’s scope. The supply submitted)
of cable clamps for fixing of the cable on structure shall be
bidder’s scope. The required drilling, fabrication and minor civil
works required for completion of cable laying work shall be in
bidder’s scope.
________________________________________________________________________________
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Bharat Heavy Electricals Limited SECTION‐4
Project: 4x225MW Arun‐3 (HEP), Nepal
Technical Specification:  400kV XLPE Cable & its Accessories
Doc No. TB‐405‐316‐002 Rev 00
-------------------------------------------------------------------------------------------------------------------
2.5 Bidder shall dispatch the consumables just before the start of Confirmed Yes/ No
the work at site and only after specific clearance from BHEL/ (List is
Customer. attached)
2.6 The cables shall be laid in cable trays fixed on cable racks Confirmed Yes/ No
assembly in cable trench/ tressle, as per site requirement.
Cable racks assembly in cable trench/ tressle shall be supplied
and fixed by BHEL based on detailed input design and drawing
provided by bidder. These details shall be furnished during
tender stage only. Installation and fixing of earthing grid with
suitable size of flats shall be done by BHEL, however, earthing
of cable system including earthing cable shall be in bidder’s
scope.
2.7 All the general and special tools & tackles, testing instruments/ Confirmed Yes/ No
kits required for carrying out termination/ jointing works shall (List is
be bidder’s scope. attached)
2.7 Any cable or accessories damaged during installation, testing & Confirmed Yes/ No
commissioning shall be made good/ repaired/ replaced by (List is
bidder to the satisfaction of BHEL/ Customer. attached)
3.0 Cable lengths
3.1 Bidder may please be noted that The exact cable length shall Confirmed Yes/ No
be decided after visiting site & making precise measurements
at contract stage. Manufacturing lengths and drum length shall
be determined with consultation & approval with BHEL/
Customer/ Consultant.
3.2 The Payment of cables length for supply shall be as per Confirmed Yes/ No
approved quantities by BHEL/ Customer/ consultant.
3.3 The Payment of cables length installation will be as per actual Confirmed Yes/ No
measurement at site which shall also include cable
terminations.

4.0 Technical
4.1 Compliance to technical specification Confirmed Yes/
No
4.2 Calculations
4.2.1 Bidder will submit short circuit current calculation, continuous Confirmed Yes/
current rating calculation and sheath standing voltage No
calculation for justifying the size of cable in line with proposed
laying conditions and customer requirements. Any other
detailed calculations, if required/ envisaged during detailed
engineering stage shall also be in bidder’s scope.
4.2.2 Bidder shall furnish calculations of cable for following during Confirmed Yes/
tendering stage only,   No

________________________________________________________________________________
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Bharat Heavy Electricals Limited SECTION‐4
Project: 4x225MW Arun‐3 (HEP), Nepal
Technical Specification:  400kV XLPE Cable & its Accessories
Doc No. TB‐405‐316‐002 Rev 00
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‐ Screen/ sheath voltage under full load condition,
‐ Screen/ sheath voltage during an external three phase
symmetrical through‐fault.
4.2.3 Bidder shall furnish calculations for screen/ sheath voltage/ Confirmed Yes/
current and the recommended method for metallic screen No
bonding and screen sizing shall be designed in such a manner
so that it can carry the earth fault current level of the system,
considering 400kV system is solidly grounded.
4.3 Technical deviations
4.3.1 Confirm that the complete system has been offered as per the Confirmed Yes/
requirements of technical specification and in this regard, No
compliance certificate to technical specification is duly signed
and sealed.
4.3.2 If there is certain clarification/ deviations, same is to be filled, Confirmed Yes/
signed and sealed in the schedule of technical deviation and No
hence deviations/ clarifications mentioned elsewhere in bid
shall not be considered.
5.0 Schedule
5.1 Bidder shall submit detailed bar chart indicating all the Confirmed Yes/
milestones from engineering till manufacturing/ testing, No
dispatch to site, installation, testing and commissioning.
6.0 Store & Office Arrangement
6.1 Open store & Closed store area shall be provided by BHEL, Confirmed Yes/
however, bidder shall provide their requirement of space in No
open store during tender stage only. In addition to this, bidder
shall also provide their standard recommendations for
precautions to be taken during unloading and storage etc for
approval of BHEL/ Customer/ Consultant.
6.2 Office facilities & accommodation for bidder’s staff along with Confirmed Yes/
conveyance, transportation of all special tools & plants, testing No
kits etc. shall be in bidder’s scope.
6.3 For construction purpose, the necessary power supply at site Confirmed Yes/
shall be provided by BHEL at one point only, however supply No
requirements for testing etc. shall be arranged by bidder only.
7.0 Site Supervisor and Jointers
7.1 Termination/ jointing of cables shall be done by skilled and Confirmed Yes/
experienced jointer certified by OEM of the joints/ end No
terminations and duly approved by Engineer‐in charge
7.2 Provision of site supervisor and skilled technician, qualified Confirmed Yes/

________________________________________________________________________________
Section 4: Check List          Page 3 of 4
Bharat Heavy Electricals Limited SECTION‐4
Project: 4x225MW Arun‐3 (HEP), Nepal
Technical Specification:  400kV XLPE Cable & its Accessories
Doc No. TB‐405‐316‐002 Rev 00
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jointer etc. along with tools & tackles, testing instruments/ No
kits etc. shall be deemed to be included in bidder’s scope.
7.3 Any special tools and tackles required to complete the cable Confirmed Yes/
installation/ laying, termination, testing and commissioning No
etc. shall be included in the offer. However, general tools
and tackles for laying of cables shall be provided by BHEL.
8.0 Site Test
8.1 Special tools & tackles for site testing kits for testing & Confirmed Yes/ No
commissioning shall be in bidder's scope, however, it shall be
brought at site on returnable basis only.

8.2 All field tests including tests during installation, pre‐ Confirmed Yes/ No
commissioning, commissioning, field acceptance tests shall be
conducted by the bidder, in presence of representative of the
BHEL/ Customer.  No separate site test will be conducted by
BHEL/ Customer
9.0 Type Test Requirements
9.1 Compliance to Type Test Requirement Confirmed Yes/ No
9.2 In case any of Type tests have not been conducted on the Confirmed Yes/ No
offered design or there has been a change in the design after
the type tests. The requisite tests shall be conducted by bidder
on the offered design without any extra cost and delivery
impact to BHEL/ Customer.

Date:     Bidder’s Stamp & Signature

________________________________________________________________________________
Section 4: Check List          Page 4 of 4
Bharat Heavy Electricals Limited                                         Doc No. TB‐405‐316‐002
4x225MW Arun‐3 (HEP),Nepal
Technical Specification for 400kV XLPE Cable

ANNEXURE - A
SCHEDULE OF TECHNICAL DEVIATIONS

Bidder shall list out all technical potential deviation/ change request (s) along with clause
with respect to technical specifications.(To be provided in editable format along with signed
copy)

Sno Page Clause Extract from Bidders

No No. Specification Comment/Clarification

Bill of

Quantity
(Annexure 1)

Section 1

Section 2

Section 3

Any deviation not specifically brought out in this section shall not be admissible for any
commercial implication at later stage. Except to the technical deviations listed in this
schedule, bidder’s offer shall be considered in full compliance to the tender specifications
irrespective of any such deviation indicated / taken elsewhere in the submitted offer.

Date:
Bidder’s Stamp & Signature

Annexure – A Page 1 of 1

Bharat Heavy Electricals Limited Doc No. TB-405-316-002
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Technical Specification for 400kV EHV XLPE Cable

ANNEXURE-B:
COMPLIANCE CERTIFICATE OF TECHNICAL SPECIFICATION
The bidder shall confirm compliance to the following by signing/ stamping this compliance certificate
and furnishing same with the offer.

1. The scope of supply, technical details, construction features, design parameters etc. shall be as per
technical specification & there are no exclusion/ deviation with regard to same.

2. There are no deviation(s) with respect to specification other than those furnished in the ‘schedule
of deviations’.

3. Only those technical submittals which are specifically asked for in NIT to be submitted at tender
stage shall be considered as part of offer. Any other submission, even if made, shall not be
considered as part of offer.

4. Any comments/ clarifications on technical/ inspection requirements furnished as part of bidder’s

covering letter shall not be considered by BHEL, and bidder’s offer shall be construed to be in
conformance with the specification.

5. Any changes made by the bidder in the price schedule with respect to the description/ quantities
from those given in ‘BOQ’ of the specification shall not be considered (i.e., technical description &
quantities as per the specification shall prevail).

Date: Bidder’s Stamp & Signature

_____________________________________________________________________________________________________
Section 4: Annexure-B Page 1 of 1
Annexure C
Manufacturing Quality Assurance Test Requirements
Project Name (MW): ARUN- III HEP (4X225 MW) Doc. No.: QAI/A/M/EM/CB/02 Rev. No.: 02

Item Description: 400 KV XLPE Cable Issue Date: 30.05.2016 Pages.: 2

Sr. No. Component, Operation & Characteristics Applicable Standard Remark

1 2 3 4
A 400 KV XLPE Cable
1 Incoming Material
1.1 Copper Rod
Make, Type & Grade, Diameter, Resistivity, Tensile Strength, Purity, Surface finish IEC 60228/ TS/ REL STD V

1.2 XLPE Compound

Packing, Compound grade IS 7098/ TS/ REL STD V
1.3 Semi conducting compounds
Packing, Compound grade TS/ REL STD V
1.4 PVC Compound
Make, Type & Grade, Physical Appearance, Tensile Strength, Elongation at break TS/ REL STD V

1.5 Semi conducting binder tape

Make, Type & Grade, Appearance & type, Thickness, Volumne Resistivity TS/ REL STD V
1.6 Water swellable semi conducting tape
Make, Type & Grade, Thickness, Swelling height (after 10 minute), Volumne Resisitivity TS/ REL STD V

1.7 Copper Woven SC Tape

Make, Type & Grade TS/ REL STD V
1.8 Aluminium Tape
Make, Type & Grade, Thickness, Tensile Strength, Elongation at break TS/ REL STD V
1.9 Bitument Compound
Softening Point, Specific density
1.10. Packing Drum
Material, Drum dimension, Surface finish, Preserve Paint
2 In process Stage
2.1 Wire Drawing & in-line annealing
Surface finish, diameter, Elongation (copper wires) TS/REL STD V
2.2 Stranding
No. of wires, diameter of wires, stranding lay, diameter of conductor,surface finish, conductor TS/REL STD V
weight, ovality of conductor
2.3 Semi conducting tape over conductor
Material grade, Application of tape TS/ REL STD V
2.4 Core Extrusion/ Rewinding
Thickness of insulation, thickness of extruded semi conducting layers, surface finish, core dia, TS/ REL STD V
eccentricity & ovality, Tensile strength of insulation, elongation of insulation, hot set test on
insulation
2.5 Taping
Material grade, Application of tape TS/ REL STD V
2.6 Corrugated aluminium sheathing
Thickness of sheath, pitch of corrugation, height of corrugation, integrity of welding TS/REL STD V

2.7 Bitumen Coating & Taping

Bitumen application TS/REL STD V
2.8 Outer Sheath (Extrusion/ Rewinding)
Material & Type, Thickness, Surface finish, Outer conducting layer, Overall diameter, Marking on
cable sheath, Cable length, Cable winding
3 Final Inspection
3.1 Type Test IEC 62067/ TS/ DRG/ REL STD W
3.2 Routine Tests
Conductor Examination, Measurement of Electrical Resistance of Conductor, Measurement of IEC 62067/ TS/ DRG/ REL STD W
thickness of XLPE insulation and over sheath, Measurement of thickness of metallic sheath,
Measurement of diameter, Hot set test for XLPE insulation, Measurement of Capacitance,
Lighting impluse voltage test followed by a power frequency voltage test, Water penetation test,
Performance test
Measurement of actual Losses TS/ DRG/ REL STD W
Dimensional check, Measurement of length of cable of each drum as per length approved by TS/ DRG/ REL STD W
SJVN, Verification of no joints in cables,
High Voltage Test, Partial Discharge test on XLPE Cables along with prefabricated accessories IEC 62067/ TS/ DRG/ REL STD W

Conductor Resistance and Capacitance test, DC test on outer sheath, Electrical tests on outer IEC 62067/ IEC 60229TS/ DRG/ REL W
sheath as per IEC 60229 STD
B Cable Racks
Dimesions, Galvanizing test, Mass of Zinc Coating, Thickness and uniformity of Coating, IS 2629/ DRG/ TS/ REL STD V
Adhesion test
C Cable Terminations, Sealing Ends, Cable Cleats, Tags, Disconnecting Link Box

Visual & Dimensional Verification, Finish & Smoothness DRG/ TS/ REL STD V
D Termination/ Sealing End Supporting Structure
Visual & Dimensional Verification, Finish & Smoothness, Galvanizing Test, Thickness of Zinc DRG/ TS/ REL STD V
Coating
LEGENDS
TS: TECHNICAL SPECIFICATIONS REL. TS/ DRG/ Rel STD.: RELEVENT STANDARD
V: VERIFICATION OF REPORTS/TCs DRG: DRAWING
W: CUSTOMER HOLD POINT (CHP)
NOTES
1 Any test at any stage not covered in Quaility Assurance Test Requirement (QATR), but part of technical specification of contract, shall also be carried out
2 QATR shall be read in conjunction with General Quality Assurance Requirement given as part of Technical Specification
3 Routine test on XLPE Cables shall be conducted on minimum samples as per the provision of IEC 62067
Field Quality Assurance Test Requirements
Project Name (MW): Arun-III HEP (4X225 MW) Doc. No.: QAI/A/F/EM/CB/02 Rev. No.: 02

Item Description: 400KV XLPE Cables Issue Date: 30.05.2017 Pages.: 1

S.No. Component, Operation & Characteristics Applicable Standard Remark

1 2 3 4
1 Material Received
1.1 Visual check of Drum TS/ DRG/ REL STD W*
1.2 Check for Transit damage TS/ DRG/ REL STD W*
1.3 Cross check with packing list & SJVN's dispatch clearance TS/ DRG/ REL STD W*
2 Storage of Material
2.1 Proper Placement of equipment as per the Instruction Manual. TS/ DRG/ REL STD W*
2.2 Ensure that no damage or rusting takes place during storage TS/ DRG/ REL STD W*
2.3 Ensure that all delicate Equipment are stored in protected area. TS/ DRG/ REL STD W*
3 Civil Works Pre Erection Activity
3.1 Embedments
3.1.1 Installation/fixing of embedments as per drawing DRG/TS/Plant std W*
3.1.2 Levelling & alignment before & after concreting DRG/TS/Plant std W*
3.2 Foundation
3.2.1 Check for alignment & level before & after concreting DRG/TS/Plant std W*
3.2.2 Check for correctness of foundation DRG/TS/Plant std W*
3.3 Blockout
3.3.1 Check for visual, dimensions & Co-ordinates of block out DRG/TS/Plant std W*
3 Erection Stage
3.1 Verifying the location & spacing between support TS/ DRG/ REL STD W*
3.2 Verifying spacing between racks TS/ DRG/ REL STD W*
3.3 Earthing of racks and support TS/ DRG/ REL STD W*
3.4 The dimensions of the rack . Support and spacing between them TS/ DRG/ REL STD W*
4 Laying of cables as per drawing
4.1 Clamping of cables with cleats at each support TS/ DRG/ REL STD W*
4.2 Alignment of cables TS/ DRG/ REL STD W*
4.3 Marking/ Identification of Cable Drums TS/ DRG/ REL STD W*
4.4 IR Value of Cables TS/ DRG/ REL STD W*
4.5 Cable Identification tag TS/ DRG/ REL STD W*
5 Commissioning Tests of Cables
5.1 High Voltage AC & DC Withstand Test TS/ DRG/ REL STD W*
5.2 Partial Discharge Measurement Test TS/ DRG/ REL STD W*
6 Performance Test as per TS TS W*

LEGENDS
TS: TECHNICAL SPECIFICATIONS REL. STD.: RELEVENT STANDARD
V: VERIFICATION OF REPORTS/TCs DRG: DRAWING
W: CUSTOMER HOLD POINT W*: WITNESS BY SAPDC/ MAIN CONTRACTOR
NOTES
1 Any test at any stage not covered in Quaility Assurance Test Requirement (QATR), but part of technical specification of contract, shall also
be carried out by Contractor/ firm.
2 QATR shall be read in conjunction with General Quality Assurance Requirement given as part of Technical Specification
3 Responsibitiy for witnessing (W*) at site shall be decided mutually at the time of finalization of FQAP as per the criticality of test.

Page 1 of 1
Annexure-D
ATTACHMENT-13
Page 1 of 3

ELECTRO MECHANICAL PACKAGE FOR

ARUN-3 HYDRO ELECTRIC PROJECT 900 (4X225) MW

(CHECK LIST FOR DOCUMENT SUBMISSION BY BIDDER WITH REGARD TO QUALITY

ASSURANCE PROGERAMME)

Bidder’s Name and Address: To,

Addl. General Manager

Electrical Contract Department,
SJVN Limited,SJVN Complex,
2nd floor, Shanhan,
Shimla- 171 006 (HP)

Dear Sirs,

We hereby confirm that, we will follow the Quality Assurance Programme (containing overall Quality
Management and procedures), as provided in the bid documents and all relevant details/documents
required to be submitted alongwith the bid as per the QATR has been enclosed as per details given herein
under:

Sr.no. Document Description Submitted(yes/No)

1. Organization structure for the management and
implementation of the proposed quality assurance
programme.
2. Quality system manual.
3. Design control systems.
4. Documentation and Data control systems.
5. Qualification/experience of bidder’s key personnel.
6. Procedure for purchase of material, parts,
components and selection of sub-vendor’s services
including vendor analysis, source inspection,
incoming raw-material inspection, verification of
materials purchased, etc.
7. System for shop manufacturing and site erection
controls including process, fabrication and assembly.
8. Control of non-conforming items and system for
corrective actions and resolution of deviations.
9. Control of calibration and testing of measuring/testing
equipment.
10. System for quality audit.
11. System for identification and appraisal of inspection
status.

Section-VII
Bid Document for EM Works of AHEP (4x225) 900MW
No. SJVN/ECD/SAPDC/AHEP/EM/17 ( Attachments) Page 254 of 258
ATTACHMENT-13
Page 2 of 3

12. System for authorizing release of manufactured

product to the purchaser.
13. System for transportation /delivery, handling, storage
and preservation.
14. System for maintenance of records.

I hereby confirm that general Quality Assurance Requirements and Quality Assurance Test
Requirements (QATRs) have been read in detail and same are *accepted/accepted with deviations
mentioned in schedule for deviation.

Date: (Signature)…………………………………

Place : (Printed Name)……………………

(Designation) ……………………………..

(Common Seal)………………………

Note: Continuation sheets of like size and format may be used as per the Bidder’s requirements and shall
be annexed to this Schedule.

*strike whichever is not applicable

Section-VII
Bid Document for EM Works of AHEP (4x225) 900MW
No. SJVN/ECD/SAPDC/AHEP/EM/17 ( Attachments) Page 255 of 258
ARUN-III HEP

Annexure –E

QA&I Formats

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 164 of 175

ARUN-III HEP

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 165 of 175

ARUN-III HEP

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 166 of 175

ARUN-III HEP

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 167 of 175

ARUN-III HEP

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 168 of 175

ARUN-III HEP

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 169 of 175

ARUN-III HEP

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 170 of 175

ARUN-III HEP

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 171 of 175

ARUN-III HEP

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 172 of 175

ARUN-III HEP

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 173 of 175

ARUN-III HEP

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 174 of 175

ARUN-III HEP

Chapter 1: General Technical Specification ED/TS/ARUN/01.06.17 Page 175 of 175

Annexure F - Export-Worthy Packing
ANNEXURE - II
ANNEXURE-1
SEA WORTHY PACKING FOR EXPORT JOBS

1.0 SCOPE:

For export jobs, sea worthy packing capable of performing all necessary functions like prevention of
damage to the contents, sufficient to support frequent handling and lengthy periods of outdoor storage in
adverse weather conditions are required. Workmanship and material used shall meet the technical
requirements and be in accordance with best commercial export packing practices. Vendor shall be
responsible for the packing, however, it shall meet the minimum requirements specified herein.
Equivalent or better packing methods may be deployed subject to approval of the purchaser. Vendor
shall submit the packing procedure for its equipment for purchaser's approval during detailed
engineering.

2.0 TECHNICAL SPECIFICATION OF WOOD:

The wood shall be Fir, Chir, Silver Oak (Grevillea Robusta) or chemically treated mango with moisture
content not exceeding 50 %. The wood shall have flextural & compressive strength, stiffness, shock
absorption and nail retention properties. The wood shall be free from common defects such as warp,
bone, twist, knot, cracks, splits, end splits, bend, visible sign of infection and any kind of decay caused by
insects, fungus etc. Surface cracks with a maximum depth of 3 mm are permissible. A continuous crack
of any depth all along the length is not allowed.

The wood shall be chemically treated to provide protection against deterioration due to fungi and attack
by termites, borers, marine organism and any other kind of infection. It shall be treated only after final
processing like cutting, planing, joint grooving etc.

3.0 TYPE, DESIGN & DIMENSION OF WOODEN PACKING CASES:

3.1.1 PACKING OF EQUIPMENTS:

Various mechanical, electrical and C&I equipment e.g. pumps, motors, equipment skids, heat
exchangers, control panels, switch gears, transformers etc. shall be wrapped in weather proof packing
and then secured in wooden packing cases. The construction of wooden packing cases shall be as per
details given below and also in figures 1 to 11.

3.1.1 BOTTOM FRAME:

The construction of bottom frame shall be as per fig. 2. The number of slides/runners for bottom frames
shall be selected depending upon the weight and overall dimension of the load to be carried. The
equipment shall be secured by fixing their base frame/plate with the help of bolt & nuts etc to the bottom
frame of the wooden packing cases. The equipment not provided with the base frame/plate like
cylindrical vessels etc. to be secured to the bottom frame of the wooden case with ‘C’ clamps fabricated
from steel channels/angle irons.

3.1.2 TOP FRAME:

The construction of top frame shall be as per fig. 3.

3.1.3 END PANELS:

The dimensions of the end and lateral panels shall be calculated according to overall dimensions of the
items to be packed.
Diagonal braces shall be used for packing cases having height exceeding 500 mm. Detail of bracing shall
be as per figure 5 to 8.

3.1.4 SLING PLATE:

To facilitate lifting of cases, longitudnal under slide boards shall be fixed. To avoid damage to the box
while lifting sling plates shall be provided. Refer fig. 11.

3.1.5 ANGLE IRON CLEATS :

Angle iron cleats shall be used for strengthening the joints as indicated in fig. 10.

3.1.6 OTHER REQUIREMENTS:

The thickness of planks for top, bottom, side and end panels shall be atleast 25 mm. Planks used for this
purpose shall be joined with each other by tongue & groove joint. The groove dimension shall be such
that tongue fits tightly into groove to make good joint.

Runners/slides, traverse bars etc. shall be of single length i.e. without any joint. Planks for sheathing,
diagonal bracing etc shall also be of single length upto 2400 mm. For sizes larger than 2400 mm, proper
jointing is permitted for planks for sheathing and diagonal bracing.

Each equipment to be individually covered with double polyethylene petticoat. Sheet thickness of
polyethylene sheet shall not be less than 0.175 mm (175 microns). The sealing shall be such so as not to
allow moisture inside.

The inner surface of 4 sides of shooks shall be nailed with bituminised water proof kraft paper.
Whereever 2 pieces of kraft paper are used, the joint shall have an overlap of minimum 20mm.

All the inner sides of the box shall be nailed with bitumen coated hessian polyethylene kraft paper. For
top frame it shall project on all sides by 100mm and shall be nailed on sides. Wherever 2 pieces of kraft
paper are used, the joint shall have an overlap of minimum 20mm.
For delicate equipment like control panels, switchgears etc suitable cushioning material like rubberized
coir shall be provided on their bottom support. The thickness of coir shall be 50 mm (minimum) and width
100 mm (minimum).

For control panels and switchgears, the gap between the panel and casing shall be filled with rubberized
coir with distance between consecutive supports less than 500 mm (ref fig 15). For other equipment
suitable support from sides of the casing to be provided.

Switchgear cubicles, control panels and control desks shall be packed and shipped in separate
convenient sections. The components e.g. circuit breakers relays and instruments etc. which are
removed from panels for shipping purpose shall be separately packed and shipped as per packing
instructions in clause 3.2.

Packing case for control panels & switchgear panels shall be finally covered with GI sheet of minimum
thickness of 0.4 mm.

Packing cases shall be bound at edges by nailing MS clamps/brackets at sufficient intervals. Further,
heavier boxes shall be strapped with 'C' clamps (ref fig 4) fabricated from steel channels/angles and
lighter boxes shall be strapped with hoop iron strips.

3.1.7 ALTERNATIVE PACKING CASES FOR CONTROL PANELS AND SWITCHGEARS

If required, for control and switchgear panels, construction of wooden packing cases may be provided as
per fig 14 & 15 and as detailed below:

Thickness of planks for all sides, binding and jointing battens shall be atleast 25 mm. Width of planks
shall be at least 125mm and that of binding and jointing planks shall be at least 100 mm.

Top frame shall be suitable so that it does not collapse due to sandwitching between slings while lifting.
Longitudnal and traverse bars for the bottom wooden pallet to be suitably selected.

Diagonal bracings shall be as per clause 3.1.3 and All other requirements shall be as per clauses 3.1.4 to
3.1.6.

3.2 PACKING OF LOOSE ITEMS:

Loose mechanical, electrical and C&I items eg valves, fittings, pressure/temperature gauges/switches,
circuit breakers, relays etc shall be individually wrapped using polyethylene sheets/U foam/thermocole
sheets/air bubbled sheets depending upon the item and then packed in wooden boxes. The left out
spaces and top of the boxes shall be filled with rubberized coir to get proper cushioning effect. Special
attention is to be paid to relays, instruments etc for arresting the movement of their operating
mechanisms during transportation.
The construction of wooden packing case shall be as per clause 3.1 retaining its all features concerning
strength of box. The construction of wooden packing case for loose electrical and C&I items shall be as
per fig. 16.

Inner surface of 6 sides of the box shall be lined with Bitumen coated hessian polyethylene kraft paper.
Rubberized coir of min. 25 mm thickness and 100 mm width shall be nailed to inner surfaces of bottom
and 4 sides of the box.

Loose items such as Galvanised Steel Structure, Cable support racks, Cable Trays and GI Pipes etc.
shall be individually wrapped using polyethylene sheets and further lots may be wrapped in Bitumen
coated hessian cloth.

4.0 MOISTURE ABSORBER:

Silica gel is used for this purpose to protect contents over sufficiently long time from corrosion. Silica
gel shall be of indicating type conforming to IS-304-1979 packed in cotton bags placed at different
positions inside the packing for absorbing moisture and shall not come directly into contact with the
equipment / material inside the package. The quantity of silica gel shall be enough for storage period
of one (1) year, however, it shall not be less than 4 gms per litre volume of case subject to minimum
of 400 gms per case.

5.0 INDICATION MARKS ON THE BOXES:

Markings shall be provided on the boxes indicating position of boxes for handling, storage and nature of
consignment. For guidelines refer figure 12. The ink used for this purpose as well as for marking
despatch instruction shall be indelible/nonwashable marking ink.

6.0 DESPATCH DETAILS:

External front and rear sides of the boxes to be planed for writing instructions.

Dispatch details such as consignor/consignee address, contract and case details, country of origin , port
of delivery, stacking instructions shall be written on one of the side of boxes. An anodised aluminium
plate shall be provided on one side of the boxes.

One copy of packing slip wrapped in polyethylene bag covered with aluminium packing slip holder to be
nailed on the external surface of the box. One more copy of the packing slip wrapped in polyethylene bag
to be kept inside the box at the prominent place.

7.0 INSPECTION:

There shall be a Customer Hold Point (CHP) for inspection of final assembly of packing. During above
inspection, the records for Chemical Treatment shall be reviewed.

--xx--
Overall Plan Layout showing Locations of Potheadyard and Powerhouse Building
CONSTRUCTION DRAWING

519250

519300

519350

519400

519450

519500

519550

519600

519650

519700

519750

519800

519850

519900

519950

520000

520050
3044000
NOTE:-

1. ALL DIMENSIONS AND ELEVATIONS ARE IN METRES

UNLESS OTHERWISE SPECIFIED.

2. NO DIMENSION SHALL BE MEASURED FROM THE DRAWING.

3043950

0
56

ER
ONLY WRITTEN DIMENSIONS SHALL BE FOLLOWED.

V
RI
3. THIS DRAWING SHOWS THE GENERAL LAYOUT PLAN OF THE

UN
POWER HOUSE COMPLEX.

AR
3043900

0
56
SUSP
ENSI
ON B
0

0
3043850 R IDGE
56

90
G& CO-ORDINATES & ELEVATIONS OF IMPORTANT POINTS
D SIT
E
S.No. DESCRIPTION POINTS EASTINGS NORTHINGS ELEVATION

5
MAT 1 519416.907 3043785.838 557.00
1.

0
POWER MAT 2 519522.234 570.00
3043566.688

95
HOUSE

0
0
MAT 3 519685.468 3043606.825 532.50
3043800

58
56
COMPLEX MAT 4 522.25
519788.824 3043476.354
MAT 5 519827.118 3043444.205 522.25

0
0

82
68
MAT 6 519676.943 3043500.055 539.00
MAT 7 519577.745 3043542.925 555.31

0
80
MAT 8 519653.473 3043505.071 555.00
MAT 1
MAT 9 519612.918 3043449.025 552.50
0
0
54
56

CAT 1 519532.446 3043516.584 557.00

0
3043750

62
CAT 2 519626.759 3043437.404 552.00

PH 1 3043513.687 539.00

0
SY 1 519660.700

85
72
PH 2 519646.240 3043496.454 539.00

0
60
PH 3 519798.182 3043398.271 539.00

SY 2 PH 4 519783.715 3043381.040 539.00

5
3043443.485 552.00

58
TH 1
3043700 519631.961

87
0

TH 2 519621.670 3043431.225 552.00

0
54

84
TH 3 519743.929 3043349.492 552.00
0

0
56

TH 4

0
62
519733.637 3043337.232 552.00

0
0
519544.240 3043268.786 520.00

90
TRT 1
SW

TAIL RACE

60
2.

0
88
TAT 1 519502.890 3043458.148 557.00
IT

TUNNEL
3043650
CH

TAT 2 519687.037 3043303.600 536.14

TAT 3 519691.345 3043254.290 531.37

TAT 4 3043234.453
EL.

519674.694 529.12
(20

BRANCH ADIT TO PS BOTTOM (8MX9M) TAT 5 3043230.647

519624.801 524.29
MAT 3
57.

ACESS ADIT TO TRANSFORMER 134.00+81.50=215.50 M LENGTH 516.85

106

TAT 6 519559.976 3043287.531

HALL (7MX7M), 177.58M LENGTH

3043600
m

3. OUTFALL OF 1 519506.801 3043224.191 532.00

)

ADIT-4 PORTAL VC 1 519881.921 3043533.862 780.00

BUTTER FLY VALVE CHAMER

End A
MAT 2 MAT TO PH (8MX9M) ( 83.05LX12WX21H ) VALVE VC 2 519870.423 3043530.429 780.00
ATS 2 4.
471.00 M LENGTH CHAMBER VC 3 519905.684 3043454.284 780.00
0

0
ATS 1
VC 4
54

519894.186 3043450.851 780.00

94
MAT 7

0
BRANCH ADIT TO CROWN 3043513.141 779.36
0

519985.000

92
SS1
3043550 VC1
56

OF PH (7MX7M) 85.23 M LENGTH VC2 5. SURGE

ATS1 519740.585 3043548.421 557.00
PRESSURE SHAFT-1(5.5MØ) ATS 3
15708 SHAFT
SY3 3043559.178 557.00

PR
ATS2 519868.100

SH
0

ES
21
PH1 9673 24 BEND B1
54

SU mØ
MAT 8 6 6 ATS3 520033.823 3043525.080 779.53

RE
CAT 1

.0
VERTICAL PRESSURE SY1 519427.546 3043730.041 557.00
SHAFT 5.5mØ
0

0
3397 6. SWITCH YARD
62

SURGE SHAFT 3043683.753 557.00

0
MAT 6 SS1 HRT SY2 519332.186

6
3043500

96
24
21
0
6569 SY3 3043543.820 557.00
519517.939
SY 4 BEND B2
22289 SY4 519422.580 3043497.532 557.00
6545

PH2 16 BEND B3/B4 8

418 70
MAT 4 15
CABLE TUNNEL
TH 1 NCH
-1
BRA 6967
3
(7MX7M) L-123.20M UNIT 1 MAT 5

9
28
22
-2
NCH 22289

0
6545 0
TAT 1 BRA 45 3397
3043450

94
65
0

16 VC3
R

293 16
UNIT 2 418
54

PRESSURE SHAFT-2(5.5MØ)
3
3610
VE

H-3
I

NC
T

BRA BEND B5/B6

TR
I

MAT 9
R

T-

9
VC4

0
UNIT 3
1

86
UN

0
UN

-4
NCH

84
TH 2 BRA 45
IT

65
0

0
R

16
TR

293
56

UNIT 4

90
T-

CAT 2
A

4.0mØ
2

UN
IT

0
ESCAPE TUNNEL
3043400
TR

95
T-
3

UN
0

PH 3
I
54

T
TR
0

End B
-4 T
56

POWER HOUSE
PH 4 (179.5L X 22.5W X 53H)

0
TH 3

96
0

3043350
62
0
54

TH 4 ESCAPE TUNNEL

0
0
0

94
72
58

TAT 6
0

TRANSFORMER HALL
0

3043300
68
64

TAT 2
TRT 1 (146.14LX16WX23H)
0

TRT10.0mØ TAT 3
76
0

0
56

92
80

TAT 4
TAT 5
0

ADIT TO TRT (7MX7M) 421.66 M LENGTH

3043250
0

OF 1
56

3043200
0
54

0
94
0
0
0
70
68
66
0
0

0
0
60
54

64
58

3043150

GENERAL LAYOUT POWER HOUSE COMPLEX

FIRST ANGLE PROJECTION (ALL DIMENSIONS ARE IN mm)
DRG. NO.

End A.1

N-30
43

N-3
5
N-3

N-30

N-3

N-30
2 0.277

0
0

0
4
4

43
3
3

3
550.1
500.0

600.0

650.0

7
5

0
0

0
.000

.000
97
00

0 N-3
4 3 6 77.9
81

N
E-51

-
9350

3
.000

0 4370
.499 2
SY2
GATE

MAIN GATE
SY4 HVN

'U' 'V' 'W'

HVN

'U' 'V' 'W'

H.V.SIDE

E-51
9380
HVN HVN HVN

'U' 'V' 'W' 'U' 'V' 'W' 'U' 'V' 'W'

.269
H.V.SIDE H.V.SIDE H.V.SIDE

SPACE FOR
9R
9R

9F
9F

XLPE CABLE
8R
8R

11KV PANELS
8F
8F

7R
7R

DCDB
7F
7F

TRENCH
HT PANELS (33kV)

3F
ACDB

2R
5F

2F
1R
4F

FB-1 FB-2
3R

3F
2R

AC PDB
2F
1R

FFL:(+)450MM
1F

HV SIDE

LT Trf 33kv/11kv 3150KVA

AC PDB

LV SIDE
AC PDB

E-51
THE INFORMATION ON THIS DOCUMENT IS THE PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT MUST

HV SIDE

GT-1 GT-2 GT-3 GT-4 VT B/C LA 9400

.000
LT Trf 33kv/11kv 3150KVA

LV SIDE
NOT BE USED DIRECTLY OR INDIRECTLY IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

SPACE FOR
CULVERT

VENTILLATION ROOM

SPACE FOR CABLE TRENCH

El. 557.00

SPACE FOR L-1 (DHALKEBAR-1) L-2 (DHALKEBAR-2)

2x1 MVA,415V
SPACE FOR FUTURE EXTENSION WORKSHOP
12000

D.G SET

16000

SPACE FOR CABLE TRENCH

16000
SPACE FOR
50KL BOT
14000

Gantry
33kV
E-51
9443
B Y R B Y R SPACE FOR CABLE TRENCH
Iso cum
Earth Switch
.580

33KV D/C T/Line 33KV D/C T/Line

to Tirtire S/station to Dam site
E-51
SY3 E-51 SY1 9456
.419
9505
.452
E-51
9450
.000

S.No. DESCRIPTION POINTS EASTINGS NORTHINGS ELEVATION

SY1 519456.419 3043702.499 557.00

E-51 1. SWITCH YARD
9500 SY2 519380.269 3043677.981 557.00
.000
SY3 519505.452 3043550.197 557.00

SY4 519443.580 3043520.277 557.00

REV. DATE ALTERED REV. DATE ALTERED REV. DATE ALTERED

CHD/APPD 06 22/06/21 CHD/APPD 05 28/05/21 CHD/APPD

REV. DATE ALTERED REV. DATE ALTERED REV. DATE ALTERED REV. DATE ALTERED
04 20/10/20 CHD/APPD 03 10/03/20 CHD/APPD 02 07/06/19 CHD/APPD 01 30/03/19 CHD/APPD
1.Building for Inert Gas System included.
Revised Switchyard Layout -
2.Common Ventillation Room for Power House and GIS Building included.
3.Cable Trench shown for the CAT to Switchyard.
Sketch - Drg No. SJVN/ED/Arun-III/EM-2017-04
4. The Layout of the Tranformer Cavern shall be part of shown in "Cross
Section and Plan of Transformer Cavern - 1 200 00 20558.
5. Comments marked on Rev-01 incorporated.
FIRST ANGLE PROJECTION (ALL DIMENSIONS ARE IN mm)
DRG. NO.

End A.2
BILL OF QUANTITY OUTDOOR EQUIPMENT:-

MINIMUM CLEARANCE TABLE 400kV

'W' 'U'
'V'

Reactor Rail Track CL OF TANK

SF6/

GIS BUILDING
OIL

El. 555.50
XLPE Cable Trench

CO-ORDINATES & ELEVATIONS OF IMPORTANT POINTS

S.No. DESCRIPTION POINTS EASTINGS NORTHINGS INVERT REMARKS

CONDUCTOR SIZE DETAILS ELEVATION
SY1 519456.419 3043702.499 557.00 FINISHED LEVEL
1. SWITCH YARD
SY2 519380.269 3043677.981 557.00 -DO-

SY3 519505.452 3043550.197 557.00 -DO-

SY4 519443.580 3043530.277 557.00 -DO-

SECTION A-A SECTION B-B

LEGEND TABLE:-
THE INFORMATION ON THIS DOCUMENT IS THE PROPERTY OF BHARAT HEAVY ELECTRICALS LIMITED. IT MUST

SYSTEM PARAMETERS
NOT BE USED DIRECTLY OR INDIRECTLY IN ANY WAY DETRIMENTAL TO THE INTEREST OF THE COMPANY

NOTES:- 400KV SWITCHYARD

REV. DATE ALTERED REV. DATE ALTERED REV. DATE ALTERED

CHD/APPD 06 22/06/21 CHD/APPD 05 28/05/21 CHD/APPD

REV. DATE ALTERED REV. DATE ALTERED REV. DATE ALTERED REV. DATE ALTERED
04 20/10/20 CHD/APPD 03 10/03/20 CHD/APPD 02 07/06/19 CHD/APPD 01 30/03/19 CHD/APPD
1.Building for Inert Gas System included.
2.Common Ventillation Room for Power House and GIS Building included.
Revised Switchyard Layout -
3.Cable Trench shown for the CAT to Switchyard.
Sketch - Drg No. SJVN/ED/Arun-III/EM-2017-04
4. The Layout of the Tranformer Cavern shall be part of shown in "Cross
Section and Plan of Transformer Cavern - 1 200 00 20558.
5. Comments marked on Rev-01 incorporated.
End B.1

A1-LINE

A2-LINE

A-LINE

ARUN-3 HYDRO ELECTRIC PROJECT, NEPAL

(4x 225 MW)
SJVN ARUN-3 POWER DEVELOPMENT COMPANY PVT. LTD.
(SAPDC LTD.)
SJVN LIMITED
(A JOINT VENTURE OF GOVT. OF INDIA & GOVT. OF HP)
End B.2

EHV CABLE EHV CABLE EHV CABLE EHV CABLE

CABLE CUM
VENTILATION TUNNEL

ACCESS ADIT TO
TRANSFORMER HALL

ESCAPE TUNNEL

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