Installation of TR15 and PCC at substation 5

Dismantling of one no: of existing NEI make 1 MVA, 6.6/0.433 kV power transformer (TR-25) after disconnection of 1 X 3.5 X 150 Sq.mm, 6.6 kV XLPE AL cable from HT bushing, LV bus bar from LV bushings and bus duct from the transformer, L.V side neutral earthing cable and removing the cable (Approx: 20 meters) and all the control cables from marshalling box of the transformer along with 65 X 10 mm GI earth strip from the transformer body. Shifting the old transformer (The approximate weight of the transformer core with winding and oil is 5.734 MT) without any damage including its accessories from the transformer room after removing the locking arrangements in the roller and transport to the central stores/location (Apprx: 500 mtrs) shown by the concerned engineer. Before transportation, oil to be drained, collected in barrels and shifted to safe location as shown by the concerned engineer. Strengthening of the existing rails by replacing the corroded MS plate on the concrete beam with new MS base plate 10 mm thick and repair the foundation with minor civil work if any. Cleaning of oil soak pits and minor civil work shall be done. All jelly granules shall be removed and refilled in the soak pit after washing. The drainer grills if damaged shall be repaired/renewed.The required MS items and barrels shall be supplied by KMML, as per the scope of work.

Erection and installation including transporting one no of new 1.6 MVA 6.6/0.433KV transformers without any damage from the MSDS yard (Approx: 30 mtrs) and erection at the elevated civil foundation of the dismantled one. Necessary transporting vehicle like cranes, positioning mechanisms like hoists/ pulley etc shall be arranged by contractor. Positioning and alignment of the transformers on bidirectional wheels with existing bus duct. Assembling of all accessories supplied along with new transformer which includes radiators, neutral REF CT and marshalling box. Transformer shall be double earthed as per standards. .

Laying, clamping and dressing of 3.5 X 300 Sq.mm. 11 kV XLPE (earthed) cable between the HT porcelain bushings and MSDS 6.6 kV panel. The cables shall be laid at transformers end through new GI pipes if required. The power cable and GI pipe shall be supplied by KMML

Termination of 3.5 X 300 Sq.mm. 11 kV XLPE (earthed) cable to the HT porcelain bushings and 6.6 kV switch board. HT indoor end termination kit for XLPE cable to be supplied by the contractor (Make M-Seal, Denson and Raychem)

Laying, dressing, clamping and termination using AL lugs with out gland ( total 16 Nos:) of 3.5 X 185 AYFY cables along the trenches/structurals/walls for transformer neutral earthing as per scope of work. Cable shall be supplied by KMML, lugs/fasteners shall be in contractors scope

Glanding and termination of existing armoured copper control cables for all auxiliaries to the marshalling box up to the size of 10 core 1.5/2.5 Sq.mm. Cable glands and lugs to be supplied by the contractor.

Laying of 65 X 10 mm earth strip to for the earthing of transformers/LBS panels/bus duct for body earthing. All joints shall be welded and suitably protected by applying bitumen and jute.65X10 mm GI flats will be supplied by KMML. All other materials/consumables like SS bolts, nuts, washers, bitumin, jute etc included in the scope of the contractor.

Filling up of oil in the transformer tank/OFTC chamber to the required level and filtration of oil as per standards. Filtration equipment shall be under the scope of the contractor. Oil shall be supplied by KMML. Oil shall be filtered/circulated as per standard manufacturers “Erection and Commissioning instructions”.

Precommissioning checks, submission of check lists and commissioning of new transformer, as per scope of work. Testing of the Transformer and submission of Test Reports is also included in the scope of the contractor.

Dismantling the existing L&T make LV PCC-5 of dimension 4000 X 1550 X 2400 mm at substation-5 after disconnection/de-glanding the power and control cables, bus-duct and earth flat without damage.Disconnection and removal of existing AYFY power cables/control cables without any damage, includes, 3.5 X 400 sq mm AYFY power cables- 2 Runs, 3.5 X 240 sq mmm AYFY power cables-10 Runs, 3.5 X 300 sq mm AYFY power cables- 3 Runs, 7X2.5 sq mm YWY control cables - 4Nos, 10X2.5 sq mm YWY control cables- 6Nos. These cables after disconnection shall be properly tagged with outgoing feeder for the easy termination to the new LV PCC5. The PCC shall be dismantled into four panel sections and transported to the central store/location shown by the concerned engineer after segregating the ACBs with cradles, aluminium bus bars etc. Cleaning of the existing trench (1200 x 600 mm) with minor civil works and repair/replace the existing inserts/base channels, as required, after taking out all the cables.

Fabrication and erection of cable supports/stockades using MS items inside PCC 5. Additional base channels may be impeded so that the entire new PCC may be rested at an elevated foundation (atleast 600 mm from FGL). All the inserts and structures newly erected in trenches shall be properly shot blasted and painted with two coats of epoxy paint of different colours over one coat of epoxy primer. The paint shall be Shalimar / Berger / Asian / Nerolac brand and shall be supplied by the contractor. The required MS items shall be supplied by KMML from the central store.

Dismantling of the existing bus duct running from TR-15 to the LV PCC INCOMER I after disconnection from the transformer and PCC side. The bus bar specification for each incomer is Phase - 2 x 200 x 13 mm and Neutral- 1 x 200 x 13 mm. The total length of bus bar chamber to be dismantled is 10 meter. The entire chamber including the buses shall be seggregated and transported to central store/location shown by the concerned engineer in charge.

Installation including transportation of shipping sections from MSDS(Approx: 60 mtrs), leading, mounting, leveling and assembly of LV PCC-5 of dimension 7650 X 1754 X 2530 mm in substation 5, consisting of incomers and outgoing ACBs as per the SLD attached after coupling and bus bar connections of 5 shipping sections of LV PCC-5 as per the supervision/ instructions of L&T service engineers. The panel shall be double earthed as per standards from the nearest earth grid. The LV PCC-5, required GI strips for earthing shall be supplied by KMML. Necessary transportation facilities and material handling for positioning of PCC shall be arranged by the contractor. MS items and GI strips for earthing shall be supplied by KMML

Clamping and dressing of exisitng AYFY power cables of size from 3.5 X 240 sq. mm to 3.5 X 400 sq. mm through cables trays/pipes/trenches/stockades/walls.

Clamping and dressing of existing YWY control cables of size up to 10 core 1.5/2.5 sq. mm through cables trays/pipes/trenches/ walls.

Incomer I & II sandwich bus ducts from TR-15 & TR-25 shall be aligned with the new LV PCC-5 incomers by the OEM. However Minor supports if required for the interconnection of LV PCC-5 shall be under the scope of the contractor.All the supports shall be extended to OEM which includes cutting of bricks and gypsum board in MSDS control room/finishing of walls with minor civil works along the passage of sandwich bus duct from transformer room to PCC.

Dismantling of energy meter panel of size 830x500x310 mm located at rear side of PCC-5 including control cables of size 6 x 2.5 sq.mm YWY (total 14 runs). The energymeters shall be segregated and returned back to ERS for future use. The control cables shall be dismantled from PCC and metering kiosk end and cable shall be returned back to ERS (Total 190 mtr).

Glanding and termination at panel side of AYFY/YWY power/control cable using DC glands/ lugs including, as per the scope of work.Gland earthing as per standards shall be done by the contractor. Glands, lugs, SS fasteners shall be supplied by the contractor. 3.5 x 300 sq.mm AYFY/XLPE cable

3.5 x 240 sq mm AYFY Cable

3.5 x 400 sq. mm AYFY/XLPE cable

7 X 2.5 YWY control cable

10 X 2.5 YWY control cable

Pre commissioning checks and commissioning of LV PCC 5 which includes checking all inter connection of buses, electrical/mechanical operation of ACBs, control wirings, operation of relays as per standards. Testing of both REF and earth fault relays in PCC-5 from Kerala State Electrical Inspectorate shall be carried out and relevant test reports shall be submitted.

Preparation of all electrical drawings and obtaining approval from electrical inspectorate for transformers and LV PCC-5, complete.

VIJAYA ELE TECHS PRIVATE LTD. (BID ID -2114177)