Erection,Installation,Testing and commissioining of 6.6/0.433 KV 2 MVA transformer and LV PCC-1

Erection and installation including transporting one no: of new 2 MVA 6.6/0.433KV transformer without any damage from the IBP SR MCC area (Approx: 50 mtrs) and erection at the new elevated foundation in TR-21 chamber room. 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 conservator, radiators, buchholz relay, WTI/OTI/MOG/PRV, neutral CT and marshalling box. Providing connection for the transformer from LV bushing to the existing 0.433 kV bus duct with minor modifications if required. All jelly granules shall be refilled in the soak pit after washing. The drainer grills if damaged shall be repaired/renewed with new one. Installation and wiring of REF and EF CTs supplied by KMML in TR-21 neutral. The CTs shall be kept fixed inside the sheet steel enclosure. GI earth flat extension of 75 x 10 mm(Approx 2 mtrs) shall be used for placing the CTs in TR-21 neutral including termination of 2 x 3.5 x 185 sq.mm neutral cable connections. Transformer shall be double earthed as per standards. The required MS items and empty barrels shall be supplied by KMML, as per the scope of work

Erection and installation including transportation from SR MCC of one number of 6.6 kV, 630 Amps load break switch of dimension 1000x 1460x 2250 mm. The LBS panel to be double earthed as per standards. Operation of LBS shall be checked and corrected if required. GI earth flats shall be supplied by KMML. All the clamping materials including SS nuts and bolts shall be supplied by the contractor.

Laying, clamping and dressing of 3.5 X 300 Sq.mm. 11 kV XLPE (earthed) cable between the HT porcelain bushings and load break switch. 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 load break switch. HT indoor end termination kit for XLPE cable to be supplied by the contractor (Make M-Seal, 3M Raychem) .

Termination of 3 X 150 Sq.mm. 11 kV XLPE (unearthed) cable to the load break switch. HT indoor end termination kit for XLPE cable to be supplied by the contractor (Make M-Seal, 3M and Raychem) .

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 transformer/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/OLTC 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-1 of dimension 7800 X 1550 X 2400 mm at substation-1 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 185 sq mm AYFY power cables- 32 Runs, 3.5 X 240 sq mmm AYFY power cables-13 Runs, 3.5 X 300 sq mm AYFY power cables- 4 Runs, 7X2.5 sq mm YWY control cables - 4Nos, 10X2.5 sq mm YWY control cables- 4Nos. These cables after disconnection shall be properly tagged with outgoing feeder for the easy termination to the new LV PCC1. 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. The additional base channels (5 mtr) each, may be impeded and leveled with the existing base channels for mounting the new LV PCC-1. The required MS items and cement shall be provided by KMML. All the inserts and structures shall be properly cleaned 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.

Fabrication and erection of cable supports/stockades using MS items inside PCC 1. 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 shall be properly cleaned 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-11 and TR-21 to the LV PCC INCOMER-I and INCOMER II 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: 600 mtrs), leading, mounting, leveling and assembly of LV PCC-1 of dimension 11600 X 1754 X 2430 mm in substation 1, consisting of incomers and outgoing ACBs as per the SLD attached after coupling and bus bar connections of 7 shipping sections of LV PCC-1 as per the supervision/ instructions of L&T service engineers. The panel shall be erected at the elevated MS structures which shall be atleast 300 mm from the finished floor level. The panel shall be double earthed as per standards from the nearest earth grid. The LV PCC-1, 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 185 sq. mm to 3.5 X 300 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.

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 185 sq. mm AYFY/XLPE cable

7 X 2.5 YWY control cable

10 X 2.5 YWY control cable

Supplying and making straight through cable jointing with heat shrinkable jointing kit (Make M Seal, Denson, 3M and Raychem) complete with all accessories including ferrules suitable following AYFY/XLPE aluminium conductor cable of 1100 V grade 3.5 x 240 sq.mm

3.5 x 185 sq. mm AYFY/XLPE cable

3.5 x 120 sq. mm AYFY/XLPE cable

3.5 x 95 sq. mm AYFY/XLPE cable

3.5 x 35 sq. mm AYFY/XLPE cable

Incomer I & II sandwich bus ducts from TR-11 & TR-21 shall be aligned with the new LV PCC-1 incomers by the OEM. However Minor supports if required for the interconnection of LV PCC-1 shall be under the scope of the contractor.All the supports shall be extended to OEM which includes cutting of bricks /finishing of walls with minor civil works along the passage of sandwich bus duct from transformer room to PCC. Both the transformers shall be lifted and posioned on bi directional wheels for aligning with sandwich bus duct. and shall be in the scope of the contractor.

Shifting of existing LDB (2 nos) at the back side of PCC 1 from temporary supports to the rear wall of PCC-1. The LDB’s may be removed from the temporary supports and fixed on the newly welded supports at wall without disconnecting the cables. The necessary MS angles/channels shall be provided by KMML to support the LDB’s. All the tools, manpower, clamps and required paint shall be supplied by the contractor for the successful completion of work.

Dismantling of energy meter panel of size 830x500x310 mm located at rear side of PCC-1 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).

Pre commissioning checks and commissioning of LV PCC 1 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-1 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 LV PCC-1 and TR-21, complete.

VIJAYA ELE TECHS PRIVATE LTD.