GUJARAT ENERGY TRANSMISSION CORPORATION LTD. SARADAR PATEL VIDYUT BHAVAN, RACE COURSE, BARODA 390 007. TECHNICAL SPECIFICATIONS FOR 0.5 mh, 630 A LINE TRAP GETCO/E/TS-132KV WT 0903/R1, Dt: 10.06.2010 Page 1 of 17
(A) SPECIAL INSTRUCTIONS TO BIDDER Please read following instructions carefully before submitting your bid. 1. All the drawings, i.e. elevation, side view, plan, cross sectional view etc., in AutoCAD format and manuals in PDF format, for offered item shall be submitted. Also the hard copies as per specification shall be submitted. 2. The bidder shall submit Quality Assurance Plan for manufacturing process and Field Quality Plan with the technical bid. 3. The bidder shall have to submit all the required type test reports for the offered item. In case of non-submission of the type test reports with the offer, the bid shall be liable to be rejected. 4. The bidder must fill up all the point of GTP for offered item/s. Instead of indicating refer drawing, or as per IS/IEC, the exact value/s must be filled in. 5. All the points other than GTP, which are asked to confirm in technical specifications must be submitted separately with the bid. 6. The bidder is required to impart training in view of manufacture, assembly, erection, operation and maintenance for offered item, at his works, to the person/s identified by GETCO, in the event of an order, free of cost. The cost of logistics will be bear by GETCO. 7. Please note that the evaluation will be carried out on the strength of content of bid only. No further correspondence will be made. 8. The bidder shall bring out all the technical deviation/s only at the specified annexure. 9. The bidder should indicate manufacturing capacity by submitting latest updated certificate of a Chartered Engineer (CE). Page 2 of 17
(B) QUALIFYING REQUIREMENT DATA (For Supply) Bidder to satisfy all the following requirements. 1) The bidder shall be Original Equipment Manufacturer (OEM). The offered equipment have to be designed, manufactured and tested as per relevant IS/IEC with latest amendments. 2) The minimum requirement of manufacturing capacity of offered type, size and rating of equipment shall be 7 times tender / bid quantity. The bidder should indicate manufacturing capacity by submitting latest updated certificate of a Chartered Engineer (CE). 3) Equipment proposed shall be of similar or higher rating and in service for a minimum period of THREE (3) years and satisfactory performance certificate in respect of this is to be available and submitted. 4) The bidder should clearly indicate the quantity and Single Value Contract executed during last FIVE (5) years, for the offered equipment. Bidder should have executed one single contract during last five years for the quantity equivalent to tender / bid. The details are to be submitted in following format, Sr. No ITEMS SUPPLIED TO ORDER REFERENCE No. & DATE ITEMS QUANTITY ORDER FULLY EXECUTED YES/NO STATUS, IF ORDER UNDER EXECUTION REMARK 5) Equipment offered shall have Type Test Certificates from accredited laboratory (accredited based on ISO/IEC Guide 25 / 17025 or EN 45001 by the National accredition body of the country where laboratory is located), as per IEC / IS / technical specifications not older than FIVE (5) years and shall have validity till expiry of validity of technical bid. Page 3 of 17
1.0 SCOPE: 1.1 This specification provides for design, engineering, manufacture, stage testing, inspection and testing before dispatch, packing and delivery at destination of Line Trap along with all accessories specified herein. The line trap to be inserted into high voltage A.C transmission lines to prevent undue loss of carrier signal power, typical in the range 30KHz to 500KHz, under all power system conditions and to minimize interference from carrier signaling systems on adjacent transmission lines. 1.2 It is not the intent to specify completely herein all details of the design and construction of equipments. However, the equipment shall conform in all respects to high standards of engineering, design and workmanship and shall be capable of performing in continuous commercial operation up to the Bidder s guarantee acceptable to the Purchased, who will interpret in a manner the meanings of drawings and specification and shall have the power to reject any work or material which in his judgment is not in accordance therewith. The equipment offered shall be complete with all components necessary for it effective and trouble free operation. Such components shall be deemed to be within the scope of Bidder s supply, irrespective of whether these are specifically brought out in this specification and/or the commercial order or not. 2.0 STANDARDS: 2.1 Unless otherwise specified elsewhere in this specification, the rating as well as performance and testing of the line trap shall conform but not limited to the latest revisions and amendments available at the time of placement of order of all the relevant standards as listed hereunder. 2.1.1: LINE TRAP Sr.No. Standard No. Title 1. IEC 60353 Second Line Trap for A.C Power System edition, 1989-10 2. IS: 8792-1978 LINE TRAPS FOR AC POWER SPECIFICATION. SYSTEMS - ( First Revision ) 3. IS: 8793-1978 LINE TRAPS FOR AC POWER SYSTEMS 4. IS-9859 (Part- I) - 1981 METHODS OF TESTS ( First Revision ) CODE OF PRACTICE FOR INSTALLATION AND MAINTENANCE OF OUTDOOR POWER LINE CARRIER EQUIPMENT PART I LINE TRAPS (Incorporating Amendment No. 1) 5. IEC 99 Lightning Arresters 6. IEC 99 1(1970) Part-1, Non-linear resistor type arresters for a.c system. 7. IEC 60099-4/2006 Metal-oxide surge arresters without gaps for a.c. systems 10. IS: 5561-1970 Terminal Clamp/Connector Page 4 of 17
2.2 Equipment meeting with the requirement of other authoritative Standards, which ensure equal or better performance that the standards mentioned above, shall also be considered. When the equipments offered by the Bidder conforms to other standards, salient points of difference between standard adopted and the standards specified in this specification shall be clearly brought out in the relevant schedule. Four copies of such standards with authentic translation in English shall be furnished along with the offer. 3.0 CLIMATIC CONDITIONS: 3.1 The equipment to be supplied under these specifications shall function satisfactorily, under tropical, humid, hot, salty and chemically polluted climate with adverse temperature conditions. Equipment to be supplied against this specification shall be suitable for Satisfactory continuous operation under the following tropical conditions: i) Location in the state of GUJARAT ii) Max. Ambient air temp. ( C) 50 iii) Min. ambient air temp. ( C) 3.5 iv) Average daily ambient air temperature ( C) 35 v) Maximum relative humidity (%) 95 vi) Average annual rainfall (mm) 1150 vii) Max. Wind pressure (Kg. /sq. mtr.) 150 viii) Max. Altitude above mean sea level Not exceeding 1000 Mtrs. ix) Isoceraunic level (days/year) 15 x) Seismic level (horizontal acceleration) 0.08 x 2g. NOTE: Moderately hot and humid tropical climate conducive to rust and fungus growth. The climatic conditions are also prone to wide variations in ambient conditions. Smoke is also present in the atmosphere. Heavy lightning also occurs during June to October. 4.0 PRINCIPAL PARAMETERS: 4.1 The Line Trap covered in this specification shall meet the technical requirements listed hereunder. 4.1.1 PRINCIPAL TECHNICAL PARAMETERS OF LINE TRAP Sr. No. 1. ITEM Type of Line Trap Installation SPECIFICATION To be inserted into high voltage A.C transmission line phase in series 2. Type of mounting Suspension 3. Suitable for system Frequency M 50 Hz N Page 5 of 17
Sr. ITEM SPECIFICATION No. 4. Nominal System Voltage 132 KV 5. Highest System Voltage 145 KV 6. Rated Continuous Current 630 A 7. Rated Short time current for 1 20 KA second 8. Asymmetrical peak value of the 51 KAp First half wave of the rates short Time current 9. Rated inductance 0.5 mh 10. Type of Tuning Band tuned line trap 11. Blocking Band frequency range 150 to 500 KHZ 12. Minimum Guaranteed resistive 570 Ohm Component of impedance in Blocking Frequency range 11. Protective device a) Non-linear resistive type Gapped lightning arresters For a.c system. b) Polymer housed Metal oxide surge arrester without Gaps for a.c system. 12. Nominal discharge current of 10KA protective device 13. Rated voltage of protective 4.5 KV device 14. Minimum value of power 6.75 KV rms frequency spark over voltage (Dry & wet) of protective deice 15. Visual Corona Extinction Volt 97 KV rms 16. Radio influence Voltage (RIV) < 500 micro Volt. 17. Attenuation in tuned frequency > 7.5 db band 18. Maximum tapping loss over 2.6 db blocking Band I & II stated above. 19. Maximum tapping loss based on 2.6 db blocking resistance. 20. Insulation class Class F 21 Maximum working stress Twice the weight of wave trap + 500Kgs. Page 6 of 17
If there is a deviation in value of Minimum Guaranteed resistive Component of impedance for require Blocking Frequency range Band-I and Band-II as above then clearly indicate the same 5.0 GENERAL TECHNICAL REQUIREMENTS: A line trap, consisting of a main coil in the form of a inductor, a tuning device and a protective device, is intended for insertion in a high voltage power transmission line between the point of connection of carrier frequency signals and adjacent power system elements such as busbar, transformers etc. The tuning device connected across the mail coil ensures, with proper adjustment, that the line trap presents relatively high impedance at one or more carrier frequencies or carrier frequency bands, whereas the impedance of the line trap at power frequencies is negligible. A line trap may also be used to limit the loss of carrier-frequency at a power system tee point. 5.1 Main Coil : An inductor which carries the power frequency current of the high voltage transmission line. 5.2 Tuning Device : The combination of capacitor, inductor and resistors connected across the main coil. All of these components may not be present at any one time, depending on the carrier frequency requirements of the line trap. 5.3 Protective Device : The device connected across the main coil and tuning device which prevents the line trap from being damaged by transient over voltages which may occur across it. The protective device shall be so designed and arranged that neither a significant alteration in its protective function nor physical damage shall result either from the temperature rise or magnetic field of the main coil at continuous rated current, rated short-time current or from emergency overload current. It shall neither enter into operation as a result of the power frequency voltage developed across the line trap by rated shorttime current nor shall it remain in operation after a response to a transient over voltage which is immediately followed by the power frequency voltage developed across the line trap by rated short-time current. Page 7 of 17
6.0 DESIGN REQUIREMETS : 6.1 Ability to withstand rated short-time current: The line trap so designed shall be capable to withstand the mechanical forces produce by asymmetrical peak value I km of the short-time current and the heating effect of the rated short-time current I kn. 6.2 Insulation level : The insulation level for the insulation between the terminals of a line trap is governed by the rated voltage of the protective device. The insulation of the mail coil and the tuning device shall be adequately rated for: a) The voltage developed across the line trap at the rated power frequency by the rated short-time current. The rated voltage of the protective device shall be higher than this voltage developed across the line trap. b) The front of wave impulse spark over voltage or the residual voltage caused by the nominal discharge current of the protective device, which ever is higher. 6.3 System voltage insulation: The system voltage insulation of a line trap is provided by insulator strings or post insulators. The line trap system voltage insulation shall be consistent with the other equipment in the associated high voltage transmission network. 6.4 Tensile strength of suspension system : The suspension system of a line trap shall be designed for a tensile stress of at least twice the mass of the line trap in kilograms, multiplied by 9.81 to convert to newtons, plus 5000 N. 7.0 Accessories : 7.1 Bird barriers: The bird barrier design shall be such that no entrance to the line trap shall admit a sphere having a diameter of 16mm. Page 8 of 17
7.2 Terminal clamp/connectors : The clamp shall be suitable for Zebra ACSR conductor. The clamp, connectors, nuts, bolts and hardware shall be of nonmagnetic material and shall conform to IS: 5561. The clamp shall be fitted on incoming and outgoing pad of Line Trap with four Nos. of Nuts & Bolts. The incoming and outgoing conductor shall be on other side of the clamp fitted with the help of six bolts and nuts arrangements. The clamps shall be suitable for horizontal and vertical take off with conductor diameter 28.62 mm. The clamp shall be designed to carry the continuous load of 630 Amp at 132KV and shall withstand a dynamic short circuit current of 20KA for 3 second. The temperature rise shall not exceed 35 C over 50 C ambient. All the castings shall be free from blowholes, surface blisters, cracks and cavities. All sharp edges shall be blurred, rounded off and buffed. Clamp and connectors shall be designed so as to avoid corona formation. The visual corona extinction voltage shall not exceed 97 KV (rms.). All nuts and bolts shall be suitably shrouded. Radio interference voltage for clamp and connectors shall not exceed 500 microvolt at 97 KV (rms.). No current carrying parts of the Clamps and connector shall be less than 10mm thickness. 8.0 RATING PLATES: The main coil, the tuning device and the protective device shall be provided with rating plates of weatherproof material fitted so that they are readily visible. The inscriptions shall be indelibly marked and include the following data: Rating plate of the main coil: a) Manufacturer s name & year of manufacture. b) Type. c) Serial number d) Rated inductance (mh) e) Power frequency inductance (mh) f) Rated continuous current (A) g) Rated power frequency (Hz) h) Rated short time current (ka) and duration (s) i) Total weight (kg) Page 9 of 17
Rating plate of tuning device: a) Manufacturer s name & year of manufacture. b) Type c) Serial number d) Frequency band(s) (KHz) e) Blocking impedance (minimum value) (Ohm) f) Blocking resistance (minimum value) (Ohm) g) Rated impulse protective level (kv) h) Belonging to main coil with rated inductance (mh) and serial number Rating plate of protective device: a) Manufacturer s name & year of manufacture b) Type c) Serial number d) Nominal discharge current (ka) e) Rated voltage of protective device f) Minimum value of power frequency spark over voltage (Dry & wet) of protective deice Special name plate: a) Manufacturer s name & year of manufacture Or Name of EPC Contractor if order for EPC project b) Name of Customer c) Name of Project ( In case of EPC project) d) A/T No. The Line Traps shall be of outdoor suspension type. Necessary suspension device together with all accessories including insulators shall be supplied along with line trap. The Line Trap shall be lightweight suitable for hanging on the gantry of Sub station without creating any clearance problem due to large diameter, length & weight of the Line Trap. The bird barrier shall be fitted on both the sides of Line Trap. Line trap shall be provided with single point single insulator string suspension type arrangement only. The Line Trap shall be supplied with fitted tuning pot and Lightening arrester. All the type test reports as per relevant IS/IEC of the Line Trap offered shall be invariably enclosed with the offer. The offer without type test report shall not be considered. Page 10 of 17
The Line Trap shall be fitted with top and bottom clamp with Connector etc. complete in all respect for connecting line trap to line side and equipment side respectively. The clamp, connector, nut, bolts, etc. which is affected by magnetic field of line trap shall be of nonmagnetic material. All iron parts shall be hot dip galvanized. The arrangement of minimum three nos. of tie rod assembly shall be required to avoid shearing from thread of tie rod assembly. 9. GENERAL REQUIREMENTS FOR BIDDERS : 1. The bidder shall furnish the full technical details, O&M manual, QAP & drawings for the Line Trap offered. 2. The bidder shall have the experience of at least 10 years of manufacture & supply of similar type of Line Trap. 3. The bidder shall furnish the full details of the orders executed. 4. Any deviation shall be clearly indicated separately. 5. The GETCO reserves right to increase or decrease the quantity at the time of placing the order. 6. The GETCO reserve right either to accept or reject any of the offers Without assigning the reason. 10. DRAWINGS : The following drawings indicating all the dimensions and weight etc. with complete technical details shall be enclosed together with technical bid: (i) General arrangement for Line Trap indicating dimensions, technical parameters, weight etc. (ii) Suspension arrangement indicating dimensions. (iii) Name plate for line trap (iv) Name plate for tuning pot (v) Name plate for protective device (vi) Special Name plate (vii) Tuning pot ckt arrangement (viii) Details of terminal clamp/connectors suitable for Zebra ACSR conductor. (ix) Suspension fittings (hardware) for line trap (x) Disc Insulator with general technical specification (xi) Lightning Arrestor as protective device for Tuning Pot. (xii) Bird barriers (xiii) Other accessories of Line Trap. (xiv) Any other components/drawings not covered. The offer without the above drawings and insufficient technical data will be evaluated accordingly or shall be liable to be rejected. Along with the drawings bidder shall have to submit the QAP with following details for the equipment offered. Page 11 of 17
a) Title page with details Manufacturer Name & Address Item QAP No. Rev. No. Date & Total No. of Pages Project Customer Order No. Or A/T No. Name of Contractor ( only in case of EPC project) b) Standard Quality Assurance PLAN for Line Traps with complete details about Raw-Material and Bought out Items to be used in manufacturing of wave trap and list of routine/ acceptance test (all that acceptance test mentioned at Sr. No. 12 here under). Also the QAP shall have details of Agency and type of function (perform or witness or verification) to be conducted by agency for each individual component and operation details given in the table. 11. TYPE TESTS: The Bidder shall have to submit following valid Type test reports. The offer without Valid Type test reports shall be liable to be rejected. LIST OF TYPE TEST REPORTS FOR 132KV, 0.5 mh, 630A Wave Trap: 1. Measurement of inductance of mail coil power frequency inductance Rated inductance 2. Temperature rise test 3. Short Time Current Test for both Mechanical & thermal behavior. 4. blocking impedance Measurement test 5. Measurement of blocking resistance 6. Tapping loss Measurement 7. High Voltage test Corona inception / Extinction test Radio Interference Voltage test Lightning impulse voltage withstand test. Power frequency voltage withstand test. Page 12 of 17
LIST OF TYPE TEST REPORTS FOR PROTECTIVE DEVICE: 1. Insulation withstand tests on the arrester housings 2 Residual voltage test a) Steep current impulse residual voltage test b) Lightning impulse residual voltage test c) Switching impulse residual voltage test 3 Long-duration current impulse withstand test 4 Operating duty test a) High-current impulse operating duty test b) Switching surge operating duty test 5 Short circuit 6 Arrester disconnector/fault indicator (when fitted) 7 Polluted housing test 8 Internal partial discharge test 9 Bending moment 10 Environmental tests 11 Seal leak rate 12 Radio interference voltage (RIV) 13 Power frequency Voltage Versus Time characteristics 14 Standard lightning Impulse spark over test 15 Front of Wave Impulse spark over test 16 Power Frequency spark over voltage test (dry & wet) 17 Moisture ingress test 18 Weather ageing test LIST OF TYPE TEST REPORTS FOR TERMINAL CLAMP/CONNECTOR (Suitable for Zebra ACSR conductor) : 1. Short time current test 2. Corona Inception/Extinction test 3. Radio Interference Voltage test 4. tension Load test (Tensile test) 5. Resistance test 6. Temperature rise test 7. Galvanizing test on Bolt, Nut & plain washer 8. Dimensional Check 12. ACCEPTANCE TESTS: 1. Measurement of blocking resistance & blocking impedence 2. Power frequency voltage test on tuning unit 3. Measurement of rated inductance of main coil 4. Measurement of Power frequency inductance of main coil 5. Measurement of tapping loss & tapping loss based on resistance 6. Dimensional & Visual check Page 13 of 17
13. SCOPE OF SUPPLY: The bidder shall have to supply the wave trap offered with Tuning pot Lightning arrestors Single point suspension arrangement type insulator string assembly Clamps & Connectors suitable for Zebra ACSR conductor. Bird barriers Suspension hardwares & accessories O&M manual Any other accessories necessary for installation of wave trap. The Guaranteed technical particulars of Line Trap shall be furnished in separate schedule-a. Technical data for protective device in annexure- A1, Technical data for tuning device in annexure-a2, Line trap construction data in annexure-a3 and deviation in annexure-a4 shall be brought out separately. Page 14 of 17
GUARANTEED TECHNICAL PARTICULARS (To be furnished by the bidder) Sr.No. Particulars To be furnished by bidder Schedule - A 1 Name of Manufacturer and Country 2 Type / Model 3 System voltage rating 4 Continuous current rating at 50 deg centigrade 5 Maximum symmetrical short circuit current rating for 3 sec. Duration 6 Asymmetrical peak value of first half wave of rated short time current 7 Rated inductance 8 Blocking range 9 Minimum Guaranteed resistive component in blocking frequency range a) Centre Frequency b) Over Blocking Range 10 Type of tuning 11 Variation in 50Hz impedance over degree centigrade variation in ambient temperature. 12 Variation in resonant frequency band per degree centigrade variation in ambient temperature. 13 Impedance at tuned frequency. 14 Change in impedance per degree Centigrade change in ambient temp. 15 16 Attenuation in Tuned Frequency Band. Attenuation at the distance of 10 khz from the tuned frequency band. 17 Maximum Tapping loss 18 Type of Mounting 19 Class of insulation of line trap 20 Temperature rise in line trap under rated continuous current (Specify the value) 21 Visual corona Inception voltage 22 Visual corona Extinction voltage 23 Radio interference voltage 24 Type of incoming & outgoing terminal 25 Maximum working stress 26 Ultimate tensile strength Page 15 of 17
Sr.No. Particulars To be furnished by bidder Annexure A1 : Technical data for protective device 1 Type of Protective device provided for protection of capacitors and coil against voltage surges & type of class 2 Basic Insulation level Standard nominal discharge current of 3 protective device for 8/20 micro second wave impulse 4 Rated voltage of the protective device (Arrester) 5 Minimum value of power frequency spark over voltage (dry & Wet) of protective device 6 Impulse spark over voltage of protective device Virtual steepness and maximum front of wave 7 impulse spark over voltage of protective device Maximum residual discharge voltage of protective device for 8/20 micro second 8 impulse discharge current of a) 5000 A b) 10000 A Sr.No. Particulars To be furnished by bidder Annexure A2 : Technical data for Tuning device 1 Power frequency withstand voltage for 5 sec 2 Tuning band (Blocking band) Sr.No. Particulars To be furnished by bidder Annexure A3 : Line trap construction data 1 Material of main coil 2 Material of terminal connector 3 Material of suspension link 4 Material of mounting hard wares 5 Net weight 6 Whether corona rings are provided? 7 Whether Bird barriers are provided? 8 Overall diameter 9 Total height 10 No. of turns in Line trap main coil 11 Type of conductor whether solid or stranded 12 Cross sectional area of conductor 13 Overall conductor size Type of construction i.e. No. of coils and 14 whether open type or covered with insulating material 15 Type and material of spacers between turn to turn 16 No. of tie rods in tie rod Assembly Page 16 of 17
Sr.No. Particulars Annexure A4 : Deviation if any from technical requirement SCHEDULE OF REQUIREMENTS Sr.No. Description Quantity 1. 132kV, 0.5mH, 630 Amp line trap with blocking band 150 to 500KHz and Rmin=570 Ohm and single point suspension arrangement including suspension insulator string assembly, clamps/connectors and require hardware & accessories Page 17 of 17