revision history sheet the information on this document is

P.S NO. : PS/445/2677 PURCHASE SPECIFICATION REV. NO: 00 GROUP: VFD ENGINEERING A4 – 12 PAGE 00 OF 24

REVISION HISTORY SHEET

REV. DATE NATURE OF CHANGE REASONS PREPARED BY APPROVED BY NO.

00 09-11-2020 FIRST ISSUE ------

REVISION 00 APPROVED BY L SUBBALAKSHMI

PREPARED BY ISSUED BY DATE

KAMALINI DEY VFD ENGG 09-11-2020

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REVISION 00 APPROVED BY L SUBBALAKSHMI



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TECHNICAL SPECIFICATION OF IGBT BASED VFD FOR SQUIRREL CAGE INDUCTION MOTOR FOR

BOILER FEED PUMP (BFP)

1. Project Details

Sl. No. Parameter Specification

1 Project Location JHAGADIA, BHARUCH, GUJARAT, INDIA

2 PROJECT 1 x 120 MW COAL BASED REHEAT TPP

3 CUSTOMER DCM SHRIRAM LTD.

4 CONSULTANT DEVELOPMENT CONSULTATIONS PVT.

LTD. (DCPL)

2. Environment Specifications

Sl. No. Parameter Specification 1 Maximum Ambient

Temperature 50 C

2 Minimum Ambient

Temperature 12C

3 Equipment Design

Temperature

(IS-9676)

50C

4 Relative Humidity 95%

5 Altitude Less than 1000 M above MSL

6 Seismic Zone Zone III as per IS : 1893 Part-1

8 Environment Polluted and Corrosive

9 Location of VFD panels Indoor, Air conditioned room


REVISION 00 APPROVED BY

L SUBBALAKSHMI



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3. Input and Transformer Data

Sl. No.

Parameter Specification

1 System Voltage / Frequency /Ph

11kV / 50Hz / 3

2 Voltage Variation +/-10% 3 Frequency Variation +/- 5% 4 Combined Voltage and

Frequency Variation +10%

5 Fault Level 50KA for 1 sec 6 Transformer Type Dry type integrated Transformer (In Vendor scope) 7 Rating Transformer must be designed to carry 110%

current of calculated VFD rating. Transformer sizing calculation shall be provided along with offer.

8 Power Cables Cable termination to be provided by the vendor for Transformer HV side cable termination suitable for 1Rx3Cx300 sqmm, 11kV, Al, XLPE cable. The exact sizes will be intimated during drawing approval stage. Cables, glands and termination kits in Customer /BHEL scope.

4. Motor Data

Sl. No.


1 Type Squirrel Cage Induction Motor

2 Scope Manufactured by BHEL-Bhopal

3 Rated Output 2200 kW, 2990 RPM 4 Rated Voltage and

Current 11 kV, 133 A

5 No load current 34 A 6 Fed from Variable Frequency Drive (V/f Control) with Bypass 7 Duty Class Continuous - S1 8 Efficiency and Power

Factor:

% of Load Efficiency Rated PF 50 94.5 0.91 75 95.5 100 95.8


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Sl. No.


9 Power Cables Cable termination to be provided by the vendor for VFD Output side cable termination suitable for 1Rx3Cx300 sqmm, 11kV, Al, XLPE cable. The exact sizes will be intimated during drawing approval stage. Cables, glands and termination kits in Customer /BHEL scope.

5. Scope:

Sl. No.

Scope of Supply Description

1 a) Fully Assembled Units of 11kV VFD Panels (IGBT/SGCT/IGCT), Air Cooled with integrated Dry type transformer. b) All interconnecting cables between the VFD and integrated Transformer. c) Local Control Station (LCS) mounted near motor (in safe area) for each VFD.

d) VFD Output Isolator (Motorised) .

e) Cable glands and lugs for LCS (Weather proof).

f) Any special cable other than power and control cables from VFD to other equipment. g) Any special tools and tackles h) Laptop (1 No.)

The vendor shall be responsible for engineering and functioning of the complete VFD system, meeting the intent and requirement of this specification & Customer specification. This shall include but not be limited to inverter sizing, transformer sizing, transformer impedance selection, vector group, input and output harmonic filter design and sizing, output dv/dt filter sizing, adequacy of motor cable size selected by BHEL etc. All necessary interlocks as required for safe and reliable operation of VFD system along with Input breaker, Output Isolator and Bypass breaker shall be provided in VFD system. If any special arrangement is required in Input breaker and output isolator, same shall be informed by the vendor in the offer. The machine shall normally run on VFD. In case of drive mal-operation, the motor could be taken on bypass control manually, while the drive could be attended independently. All other control and protections not included in owner’s scope but required for vendors supplied system shall be in vendor’s scope.


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6. VFD Specifications

Sl. No


1 Drive VFD for BFP 2 Input Voltage From Integrated dry type Transformer 3 Power/Torque vs Speed Torque α Speed2 , Power α Speed3 4 Single Line Diagram See Attachment 3-661-00-00978 5 Output Voltage of VFD 0 to 11kV (V/F = Constant) 6 Output Current of VFD 133 Amps at 50C (Design Ambient) 7 Output Frequency 0 to 50Hz , Resolution: +/- 0.01% under transient

conditions; +/- 0.5% under steady state conditions 8 Overload capacity 115% of rated current for 1 minute at rated voltage

9 Speed Regulation & Speed Accuracy

As per attached Customer Specification

10 Drive Control Sensorless Vector Control 11 Braking Operation Not Applicable 12 Output LC Sinusoidal

Filter Motor is designed for PWM operation. Distance between VFD and Motor is ~200 meters. Vendor to clarify and offer output Filter, if required.

13 VFD Panel Construction

a) Protection Class: IP42 b) Panel: Free standing, floor mounting type,

comprising of rigid welded structural frames with Cold Rolled Sheet Steel enclosure of minimum thickness 2 mm for load bearing and 1.6 mm for other members. All doors and removable covers shall have neoprene gaskets. Ventilating louvers shall have easily removable and washable dust filters.

c) Cooling: Forced Air Cooled VFD should be considered. Cooling system shall include well dimensioned panel, adequate cooling air flow path. Vendor shall ensure that the panel dimensions and flow paths have been designed for continuous running at the specified ambient without overheating. Vendor to provide low noise redundant cooling fan for the VFD panels. The fans shall have 100% redundancy with provision for autostart of standby fan as per attached Customer Specification. Changeover scheme shall be submitted along with the offer. Suitable thermal switch for exit air temperature monitoring shall also be incorporated.

d) Earth Bus – minimum 50*6 mm Copper.


2.9 2.9

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Sl. Parameter Specification

13 VFD Panel Construction e) Busbar Material – Electrolytic grade Copper, colour coded. Sleeving/shrouding for safety purposes shall be done.

f) Door Interlock: The VFD shall have a door interlock for safety. This interlock system should ensure that none of the power cabinets can be opened until the main source of power is disconnected or will cause the main source of power to trip. Additionally the same interlock system should ensure that power cannot be initialized to the drive unless the doors are closed. Suitable shrouding mechanism shall be provided so that the DC capacitors cannot be touched till their voltage is zero.

g) Painting: 2 Coats of Primer and 2 Coats of Finish Paint to be given for all surfaces of enclosure. Paint shall be Epoxy Based with Powder Coated Finish – Battle ship grey IS:632 as per IS-5. Paint Thickness: 60 Microns (minimum). Exact paint shade will be confirmed during drawing approval stage.

h) Power and Control Wiring shall be done with Fire retardant (FRLS) cables.

i) Height of the terminal from cable gland plate shall be adequate to take care of the cable sizes and quantity mentioned. Minimum space for the power cable termination shall be 600mm clear from the cable gland plate. Cable entry will be from bottom only. Gland Plates shall be blank (undrilled) – to be drilled at site. Gland Plates shall be minimum 4 mm thick Aluminium (steel not allowed). Gland plate shall be of sufficient strength to handle all the cables.

j) All electronic modules and components shall be accessible from front of panel only. Modular assemblies for both the system control electronic equipment and power electronic equipments shall be used.

k) All low voltage compartment and cabling shall be electrically and physically separated from the high voltage compartment.

l) Lugs for all control cables shall be terminated in terminal block itself. This would avoid usage of different types of lugs at site during commissioning.

m) 20% spare terminals shall be provided.

14 Noise Level Shall be less than 85dB at a distance of 1 metre from the outline of VFD Panels at a height of 1.8 metres from the floor with all the fans running in the VFD Panels.


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Sl. No.


15 Storage Temperature -40C to +60 C

16 Vibration According to IEC68-2-6

17 Interference According to IEC801 parts 2,3,4 Immunity: The panels shall be designed so as to have low Radio Frequency Interference (RFl) and Electromagnetic Interference (EMl).

18 VFD Efficiency Shall be min 95%. Exact value to be specified by the Vendor.

19 Duty Cycle Class I Duty Cycle as per IEC 146-1

20 VFD Requirements a) Input Choke: Input chokes to be provided, if necessary.

b) Local/Remote: Selector switch shall be provided for operator to select type of operation: Local – Operation from VFD Panel for Speed Control from door mounted interface; Remote – Operation from DCS/LCS. If VFD is set for speed reference from Remote, it shall be possible to program the VFD to either shutdown, go to minimum speed or continue operation at its last known speed reference point whenever a loss of speed reference is detected.

c) Local Start/Stop Push Button to be provided either on Panel door or on keypad.

d) Door Mounted Lockable Push-Button with cover to be provided with 2NO + 2 NC contact for Emergency Stop. One normally open and close contact to be wired to Terminal Block for external Interlocking / Annunciation.

e) Every Panel shall be provided with CFL illumination Lamp with limit switch and MCB. Space heater shall be provided in panel with switch fuse and variable setting thermostat. 240V power socket with MCB shall be provided.


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Sl. No.


20 VFD Requirements f) 230V, 1phase, 50Hz (exact rating during drawing approval stage) Power Supply to the motor space heater shall be derived from VFD. Necessary interlocking arrangement for this supply shall also be made available in the VFD panels.

g) Vendor to clearly mention the dimension of VFD and Isolator Panel alongwith panel clearances in the technical offer.

h) PLC: PLC shall be provided for Interlocking and Protection (if required)

i) The expected life time of the drive system shall be minimum 20 years. The system including all individual components forming part of the system shall have an availability of minimum 0.997 and a minimum MTBF of 4 years.

j) Any special requirement regarding CT/ PT, protection relay or any other device, in input breaker, which is required for functioning of VFD system shall be considered by the VFD vendor in their scope.

21 VFD Features a) Soft Start and Auto Restart b) Auto Speed Search Facility (Catch on Fly) shall be

available for starting into rotating loads. c) Power loss ride through (Kinetic Buffering) and for

voltage dips over 20% or Power interruption for less than 2 secs.

d) Automatic VFD tuning during start-up. e) Flux optimisation function shall be provided to reduce

the total energy consumption and noise level in case drive is operated below nominal load.

f) Selectable reverse run prohibition g) Adjustable motor overload feature h) Settable minimum and maximum operating frequency i) VFD shall produce not greater than 1% torque

pulsation to the shaft of driven equipment. j) Field adjustable Torque limits and acceleration and

deceleration ramps k) Accelerate / Decelerate Times to be specified. l) Four (4) user programmable preset speeds. m) Earthing scheme should be provided by the vendor.


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. Sl. Parameter Specification 21 VFD Features n) The equipment may be stored outdoors for long

periods before installation. The packing should also be suitable for outdoor storage areas with heavy rains / high ambient temperatures.

o) Vendor shall certify readiness of system fit for commissioning. Vendor’s scope shall also include supply of all specialized tools and tackles required.

p) VFDs shall be installed in Air-conditioned area but it shall be suitable for operation in non-air-conditioned area also.

q) Any special cable other than power and control cables required to connect VFD to other equipment shall be in vendor scope.

r) All electronic PCBs/Modules must have conformal coating to take care of site conditions.

22 Controls and monitoring a) VFD shall be with an interactive and user-friendly door mounted digital operator interface with LCD display and sealed membrane type keypad.

b) The operator interface shall be used for drive programming, drive monitoring and drive trouble shooting. The operator interface must also be able to start and stop the drive, reset VFD faults and manually adjust the VFD's speed reference.

c) The operator interface shall have LED indicators for drive fault, drive run, and drive in current limit.

d) The operator interface shall allow monitoring of inverter operating conditions including speed, current, voltage, torque, power etc.

e) Messages shall be alphanumeric in nature. All the fault messages shall be in English.

f) Provision shall be made available for remote operation.

g) The operator interface shall be able to display all real time operating variables and all drive programming parameters.

h) The operator interface shall be capable of displaying a specific user selected parameter on power-up. This power-up parameter would typically be a parameter that is important to the operator such as motor speed or motor load

i) The following Control signals must be provided: 1) Local/Remote 2) Emergency stop 3) Trip/Close Input breaker


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Sl. No.


22 Controls and monitoring These are indicative. Vendor to suggest the interlocking scheme using these and other outputs as required for the system during detailed Engineering. These Outputs shall be provided with individual relay having 3 changeover potential free contacts wired to terminal blocks. j) All VFD operating parameter shall be stored in

nonvolatile memory. k) The drive shall have built in monitoring of following

parameters as minimum on its digital operator interface and these parameter shall also be displayed at Plant DCS through Modbus link:

i) Input & Output Frequency ii) Input & Output Current iii) Motor Speed iv) Input & Output Voltage v) DC Bus Voltage vi) Input & Output Power vii) Digital Input Status viii) Digital Output Status ix) Analog Input x) Drive Thermal state xi) Motor energy meter xii) Hour run xiii) Transformer Temperature for alarm & trip

l) Necessary transducer shall be provided with 4-20mA output for indicating Motor Speed and Motor Current in the DCS. Transducers shall be capable of driving 500 ohms load.

m) The following indications shall be provided on the VFD Panel Door/ Keypad: i) Motor Running/ VFD ON ii) Motor Stopped/Tripped iii) AC Mains ON iv) Auxiliary Control Supply ON v) VFD Ready vi) VFD Fault vii) External Fault viii) Emergency Stop Activated ix) Motor Overspeed x) Input Breaker Trip xi) Motor zero speed xii) Rectifier output ’ON’ xiii) Transformer winding temperature alarm & trip.

n) The VFD shall store fault logs of minimum last 10

faults in memory.


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22 Controls and Monitoring k) The drive shall have built in monitoring of following parameters as minimum on its digital operator interface and these parameter shall also be displayed at Plant DCS through Modbus link: i) Output Frequency ii) Output Current iii) Motor Speed iv) Output Voltage v) DC Bus Voltage vi) Motor Winding Temperature vii) Output Power (It shall be possible to display power output of the drive in kW) viii) Digital Input Status ix) Digital Output Status x) Analog Input Status xi) Drive Thermal state xii) Motor energy meter xiii) Hour run l) Necessary transducer shall be provided with 4-20 mA output for indicating Motor Speed and Motor Current in the DCS. Transducers shall be capable of driving 500 ohms load. m) The following indications shall be provided on the VFD Panel Door: i) Motor Running ii) Motor Stopped/Tripped iii) AC Mains ON iv) Auxiliary Control Supply ON v) VFD Ready vi) VFD Healthy vii) VFD ON viii) VFD Fault ix) External Fault x) DC Link charged and Ready to Operate xi) Emergency Stop Activated xii) Motor Overspeed xiii) Input Breaker Trip xiv) Motor zero speed xv) Rectifier output ’ON’

Sl. No.


22 Controls and Monitoring o) The interface details of VFD shall be incorporated as required for data communication with DCS system with serial interfaces with RS485 data links. Necessary hardware shall be included in the scope and the interface protocol (i.e. Modbus only) shall be provided.

The following Audio-visual annunciations must be provided.

1) Rectifier fuse failure / drive fault 2) Main AC failure 3) Inverter fuse failure / Drive fault 4) Inverter overload 5) Inverter high temperature / Drive fault 6) Cooling system failure 7) Motor failed to start / Drive fault 8) Transformer fault and alarm 9) Communication and measurement system

unhealthy

23 Protection Following protections shall be built in within the inverter and any other protection as required: a) Motor Overload / Over Torque b) Instantaneous Over current (This device shall

monitor the peak output current continuously and shall provide instantaneous shutdown without component failure whenever its trip point is surpassed. The trip point must be greater than or equal to 110% of the VFD's rated full load output current)

c) Ground Fault Protection – 5-10A within 300ms maximum.

d) Over Voltage/Under Voltage - VFD shall be able to withstand >20% dip in supply voltage for 2 secs without damage to semiconductors or fuses.

e) Output Short Circuit f) Output Phase Loss/Fuse Failure g) Phase Sequence Protection h) Input Phase Loss/Single Phasing Preventer i) Over Speed/Over frequency of motor j) Heat sink over temperature/VFD Panel

Temperature High Stall prevention (During acceleration, deceleration and constant speed operation)


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Sl. No.


23 Protection k) Loss of Cooling Fans l) External faults like Transformer Fault and Alarm m) Incoming Line surge protection n) Under/Over voltage protection o) Inverter fault p) System earth fault protection q) The system shall be designed to deliver the motor

input current and torque for the complete speed torque characteristics of the driven equipment.

r) If the motor load exceeds the limit, the drive shall automatically reduce the frequency and voltage to the motor to guard against overload. If load demands exceed the current limit for more than 1 min, the drive shall shut down to prevent over heating of the motor and damage to the drive.

s) The drive shall trip in case the speed exceeds 105% of the maximum operational speed or reduces to 95% of the minimum operational speed for more than 10 seconds.

t) Fault diagnostic shall be built into the system to supervise the operation and failure of the system. The information regarding failure of any of the system including shut down of the system shall be available for a period of minimum 4 days after a shut down even though no supply available.


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Sl. No


24 Dry type Transformer (Mounted in panel)

Dry type Transformer a) HV voltage: 11kV with Taps of ±5% in steps

of 2.5% b) LV voltage: Multi secondary type. Number of

secondaries and secondary voltage to be indicated by the vendor in technical offer.

c) Class of insulation: Class F or higher d) Winding material : Electrolytic grade Copper

Protection: RTDs (2 nos) to be provided in each limb for winding temperature measurement. Temperature scanner to be provided for winding temperature measurement of all limbs. Alarm and trip contacts required for annunciation for fault and tripping action. Construction: The dry type transformer shall be mounted in a panel which will be mounted along with the VFD panel Connection: HV Incomer: Termination arrangement to be provided for 1Rx3Cx300sqmm, 11kV, Al, XLPE Cable. The exact number and sizes will be intimated during drawing approval stage. Cables in BHEL/Customer scope. LV Connection: Cable between LV secondaries and VFD to be supplied by the Vendor. This shall be used for testing of the VFD and later bunched in the panel during dispatch and the same shall be connected at site. Necessary connection and routing arrangements to be made by vendor.


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Sl. Parameter Specification 25 Isolator Panel VFD Vendor to supply Isolator Panel (Motorised) for

connection at the VFD output and shall be suitable for variable frequency operation. The selection of Motorised Isolator Panel shall be governed by VFD manufacturer’s operational requirements. Adequate provision shall be provided for closing from remote through contacts and from local by switch provided on panel door. a) Rated Voltage = 11 kV

b) Rated Current = Shall be designed to carry 110% of VFD output Current. Isolator shall be suitable for overload requirements of the VFD.

c) Rated short time current rating for terminals = 50kA for 1 Sec

d) Termination shall be suitable for termination of 11kV, 03C x 300 Sq. mm, 11kV, Al, Cable at the input and output of the Isolator Panel. Provision shall be kept for O/P cable termination from Bypass breaker output as well as cable connection to motor.

e) Aux. supply = 110V 1 ph UPS supply will be provided by customer. Feeder rating to be confirmed by vendor.

f) Sheet Steel thickness = 2mm for doors and covers and 3mm for load bearing members and instrument panel (if any).

g) Degree of Protection = IP42 h) Paint shade & thickness : Shade Battle ship grey

IS:632 as per IS-5., Thickness: 60 Microns (min). i) Busbars = Electrolytic grade Tinned Copper

j) ON/OFF indications shall be provided on panel

door. All indicators shall be LED type.

k) All components shall be accessible from front side for easy maintenance.

l) Panel space heater shall be provided with Thermostat.


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Sl. Parameter Specification 25 Isolator Panel m) Facility for padlocking of panel doors shall be

provided. n) Provision shall be provided for charging of spring

charging motor manually. o) Suitable rating Surge Arrestors shall be used for

Isolator. p) Safety interlocks shall be provided in the panel so

that, panel cannot be opened when current is flowing in this circuit.

q) Sub vendor: Isolator shall be sourced from reputed approved sub vendor of VFD manufacturer.

26 Local Control Station (Weather proof) Features

a) The enclosure shall be made of cast light metal Alloy.

b) Degree of protection is IP55.LCS shall be provided with integral canopy.The canopy shall be made of atleast 2mm galvanized sheet steel or FRP.The canopy shall be suitable for providing protection against rain from top and two sides.

c) The LCS shall be provided with gaskets made of non-inflammable and self-extinguishing material.

d) Paint shade is Shade Battle ship grey IS:632 as per IS-5. Paint shade will be confirmed during drawing approval stage.

e) A warning inscription “Isolate power supply elsewhere before opening” shall be provided on the panel. The warning inscription shall be embossed on the enclosure or a separate warning plate fixed to the enclosure with screws. The warning plate shall be nickel plated brass or stainless steel.

f) The LCS shall be provided with two earthing studs with lugs on external surface of enclosures suitable for termination of 8 SWG GI wire.

g) The Emergency Stop push button shall be mushroom type with stay put feature and lockable in pressed position. h) Sub vendor: LCS shall be sourced from

reputed approved sub vendor of VFD manufacturer.


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Sl. Parameter Specification 26 Local Control Station

(Weather proof) Features

i) All control switches shall be provided with a pistol grip handle.

j) Meters shall be suitable for the appropriate input and shall be calibrated for the actual parameters. Further, for Bypass operation, the meters shall be capable of reading bypass full load and starting currents, as well as the drive current.

1) 4-20mA Signals for Display from VFD: i. Actual Current (0-150A) ii. Actual Speed(0-3000rpm)

2) 0-1A signal for display of Bypass Current with suppressed scale 0-150A/900A

k) Nickel plated brass cable glands (Weather proof) and tinned Copper lugs for cable termination shall be provided by the vendor.

l) 230V Control supply to LCS shall be provided by customer.

27 Type of Control: Completely programmable by the user as: a) Flux vector control with speed feedback b) Flux vector control without speed feedback c) Scalar V/F.

VFD shall be capable of maintaining motor speed within ±0.5% without the use of a motor mounted encoder or tachometer. The drive shall have programmable V/F patterns along with user definable custom V/F patterns.

28 Harmonic Limitations – Source

Shall be as per latest IEEE 519 Voltage harmonics: Vendor to inform the values with calculations during detailed engineering stage. Current harmonics: Vendor to inform the source side 5th, 7th & 11th harmonics values with calculations during detailed engineering stage. Vendor to supply harmonic filters, if required, to filter the harmonics generated by VFD at input/ supply side.

29 Harmonics at VFD Output / Motor Input

Shall be as per latest IEC 61800-4 Vendor to specify the maximum amount of voltage and current harmonics at the VFD Output / Motor Input terminals. It should not be more than 5%. If it is more than 5%, vendor has to provide output filter.


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Sl. Parameter Specification 30 Switching frequency To be specified by the vendor 31 Auxiliary Supply a) 110V UPS feeder for VFD will be provided by

Customer. KVA Rating is to be given by the Vendor. Power supply for electronic modules has to be derived from the UPS.

b) 110V UPS feeder for Isolator panel will be provided by Customer.

c) Auxiliary Supply – 415V, 3, 50Hz, 4 wire will be provided by customer. Feeder Power rating (short time & continuous) to be specified by the Vendor.

d) Other supplies required by the VFD system to be generated internally within the VFD system.

e) 230V AC non-UPS feeder for LCS shall be provided by Customer. Feeder Power rating to be specified by the Vendor.

32 Testing and Quality Plan

a) Routine Tests shall be carried out on all VFD and transformer panels as per relevant standards.

b) Temperature rise test shall be conducted as Type test on one VFD along with Transformer.

c) For other type tests, Type Test reports conducted earlier on similar type of equipment to be furnished for verification during detailed engineering. If valid type test certificates for transformer and VFD panels are not available as per DCM Specification, vendor shall conduct the type tests without any cost implication to BHEL.

d) During fabrication, the drive and Transformer shall be subject to inspection by BHEL/ Customer, or by an agency authorized by the BHEL/ Customer to assess the progress of work, as well as to ascertain that only quality raw material is used.

P.S NO. : PS/412/ PURCHASE SPECIFICATION REV. NO: 00 GROUP: VFD ENGINEERING A4 – 11 PAGE 13 OF 17

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P.S NO. : PS/445/2677 PURCHASE SPECIFICATION REV. NO: 00 GROUP: TRACTION ENGINEERING A4 – 11 PAGE 17 OF 24

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Sl. No.


33 Inspection, Training and Commissioning Support

a) Final Inspection: BHEL / Customer representative will be present at manufacturer’s works for witnessing of final testing. This is to be incorporated in the Quality Plan. No charges shall be applicable for witnessing of final tests.

b) Training: Training for 4 (Four) persons from BHEL / Customer for a period of 1 week at manufacturer’s works/site free of cost.

c) Commissioning: Commissioning of all VFD Systems at site shall be in the scope of Vendor. Final Acceptance shall be based on successful completion of the same.

d) Any replacement of failed/damaged items during commissioning shall be exclusively at Vendor’s cost.

e) Vendor is advised to stock necessary spares and ensure easy availability to facilitate trouble free commissioning.

34 Laptop & Software for Computer Interface

Laptop shall be installed with Latest Compatible Licensed Operating System. The software must be loaded in the laptop & supplied along with interconnecting cables and accessories required for interface with the drive. The software should be an easy to use commissioning tool for drives and shall be provided along with the system. The interface details of VFD shall be incorporated as required for data communication with DCS system with serial interfaces with RS485 data links. Necessary hardware shall be included in the scope and the interface protocol shall be provided during detailed engineering.

35 Maintenance The procedure for maintenance of VFD panels and the schedule thereof shall be mentioned in the offer.

v


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36 Confirmations/Deviations to Specification

Point-wise confirmation to this specification to be given along with offer. Deviations, if any, shall be indicated separately. If there are no deviations to the specifications, supplier shall mention the same explicitly. A reply from vendor stating that “Equipment will generally meet the specifications” will not be accepted by BHEL. Clause-wise Confirmation / Clarifications of all Clauses in the Purchase Specifications 1 to 35 of Specification shall be furnished in the format below.

Point No. Page No. Confirmation / Clarification / Information / Deviation

Details Remarks, if any

7. Consolidated Scope of Supply and Services Sl. No. Items Quantity (Nos.)

1. a) Fully Assembled Units of 11kV VFD Panels (IGBT/SGCT/IGCT), Air Cooled with integrated Dry type transformer

2 Nos.

b) Weather proof Local control station 2 Nos. c) Isolator (Motorised) Panel 2 Nos.

2. Laptop 1 No. 3. Erection Supervision & Commissioning

(Vendor to quote lumpsum commissioning charges for 12 days per drive which shall be considered for bid evaluation) Payment shall be made for actual mandays consumed at Site with per day charges calculated on the basis of the lumpsum charges quoted above. Lumpsum charges quoted shall include travelling, boarding and lodging expenses.

02 lots (lumpsum)


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8. Documentation Sl. No. Parameter Specification 1 Attached Documents a) DCM SHRIRAM specification for VFD System

b) Motor datasheet c) Single Line Diagram : 3-661-00-00978 d) Pre-Qualification Criteria of Medium Voltage

Variable Frequency Drive (11 kV VFD) e) Datasheet for VFD system (Sheets 21 to 24)

2 Technical Information required along with Offer

a) Dimensional Drawing of Panels along with minimum clearance to be maintained for effective cooling, and Weight

b) Technical Catalogue of VFD System being offered.

c) Reference list for similar rating VFDs giving the following: Model number, Application, Rating, Year of supply and commissioning. Pre-Qualification Criteria of Medium Voltage Variable Frequency Drive (11 kV VFD) shall be used as qualifying criteria.

d) Confirmation / Clarification / Information / Deviation List as per Point 36 above.

e) Confirmation / Clarification / Deviation List to Specification and other documents in Sl No. (1) above.

f) Design Calculation for VFD and Transformer sizing.

g) Filled up Datasheet for VFD system.

3 Information / Confirmations required along with offer

a) Supply of the VFD shall be by OEM only. The name of the country from which the drive is sourced and the location of the manufacturing plant should be mentioned in the offer.

b) After Sales Service and Support shall be given by the Vendor for a minimum period of 15 (fifteen) years after commissioning. Address of the Sales and Service Representatives in India with complete contact details: Name/Telephone/Email are to be provided.

c) Vendor shall give a notice of at least 1 year to the end user of the equipment and BHEL before phasing out the product / spares to enable the end user for placement of order for spares and services.


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4 Technical (unpriced) and Commercial (priced) Bids – For Evaluation

Refer sheet no. 18 of 24. Unpriced and Priced bids for Sl. Nos. 7(1), 7(2) & 7(3).

5 Information required for

Customer / Consultant Approval (within 3 weeks from the date of Purchase Order)

a) Dimensional Drawing of Panels along with minimum clearance to be maintained for effective cooling, and Weight

b) Schematic Diagram c) Bill of Materials for equipment to be supplied d) Feeder Requirements – UPS and 415V supply e) Losses at Rated Load (including Fans) f) Heat Loss for Air Conditioning System sizing g) Technical Catalogue of VFD System being

offered h) Test Protocol and Quality Plan i) Type test certificates of similar or higher rating

equipment j) Filled up Data sheet for VFD system

6 Information Required along with Supply. Maintenance Manuals and Documentation

a) Erection, Commissioning and Maintenance Manuals along with Final Drawings and Documentation – 2 Copies

b) Test and Guarantee Certificates. c) Complete Bill of Material (item wise) for the

equipment supplied. d) 1 no. CD ROM consisting of the above.


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VFD SYSTEM DATA SHEET

A Environment Specifications 1 Maximum Ambient Temperature 50°C 2 Minimum Ambient Temperature 12°C 3 Equipment Design Temperature (IS-9676) 50°C 4 Relative Humidity 95% 5 Altitude Less than 1000m above mean sea level

6 Location of VFD Panels Indoor, Ventilated Room with Air Conditioning.

7 Seismic Zone As per IS-1893-Zone-II B Motor Data 1 Type Squirrel Cage Induction Motor 2 Scope Manufactured by BHEL-Bhopal 3 Rated Power (KW) 2200 KW 4 Rated Voltage and Current 11 KV & 133 A 5 Rated RPM 2990 RPM 6 Duty Class Continuous - S1 C Input Power Supply Data 1 System Voltage / Frequency / Phase 11kV / 50Hz / 3 2 Voltage Variation ±10% 3 Frequency Variation ±5%

4 Combined Voltage and Frequency Variation +10%

5 Fault Level 50kA for 1sec D System Requirements 1 Drive application BFP 2 Speed range required As per application requirement 3 Speed Adjustment Auto (from DCS) and Manual (From Drive) 4 Reference Signal 4-20 mA from DCS 5 Bypass Operation Yes (Manual) 6 Synchronous Bypass No 7 Input Breaker and Bypass Breaker Yes (in BHEL Scope) 8 Fault diagnostic Required Required

9 Cable distance between Input Breaker and VFD 30 meters (approx.)

10 Cable distance between VFD and Motor 200 meters (approx.)


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11

Separate PE Conductor between VFD & Motor (Vendor to Confirm)

12 Interface with DCS (Modbus) Required E VFD Data 1 Manufacturer 2 Model No. 3 Manufacturing Location 4 Rating 5 Applicable codes /standards 6 Speed reference 4-20 mA from DCS 7 Speed range 8 Switching Frequency 9 No. of Pulse

10 Total number of Diodes/ IGBTs/ IGCTs 11 Drive output Voltage 11kV 12 Overload capability at 115% over current 60 Secs. 13 Inrush current 250% In for

14 Combined efficiency (Transformer & Drive) at:

i) 100% Load ii) 75% Load iii) 50% Load iii) 25% Load

15 Overall power factor at: i) 100% Load ii) 75% Load iii) 50% Load iii) 25% Load

16 Output voltage range and Accuracy 17 Output Frequency range and Accuracy 18 Type of Cooling 19 Redundancy in Cooling 21 Output Filter/ Choke: i) Manufacturer ii) Type/ Model No. iii) Rated Current and Voltage

22 VFD Panel Dimension i) Length (mm) ii) Height (mm) iii) Depth (mm)


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iv) Weight (kg)

(Dimensional details of all panels shall be furnished)

23 a) Acceleration time b) Deceleration time

24 Degree of protection 25 Paint Shade As per BHEL Specification 26 Heat Load (kW) 27 Auxiliary Power Requirement: 415V, 3Ph, 4 wire UPS supply i) KVA ii) Voltage & Phase

F Transformer Data 1 Manufacturer 2 Manufacturing Location

3 Type Dry type integrated Transformer 4 Duty Continuous (Converter Duty)

5 Rating (Transformer must be designed to carry 110% current of calculated VFD rating.)

6 Class of insulation and temp rise 7 Insulation level: P. f withstand i) HV Winding ii) LV Winding Impulse withstand i) HV Winding ii) LV Winding 8 Fault Level on HV Side 50kA for 1 Sec 9 HV Voltage and Phase 11kV and 3Ph.

10 LV Voltage/ Current 11 No. of LV Windings 12 Rated Frequency 50Hz 13 Impedance 14 Cooling Type 15 Winding Material Electrolytic grade Copper 16 Location of Tap Changer HV Winding 17 No. of Taps and Type 18 Vector Group 19 Neutral CT specification: 51G 64R Vk


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Im at Vk/2 RCT

20 Cable Size/Type i) HV Winding ii) LV Winding

21 No Load Loss i) At 100% Voltage ii) At 110% Voltage

22 Full Load Copper loss at 75°C 23 No Load Current i) At 100% Voltage ii) At 110% Voltage

24 Efficiency at 75°C and unity power factor i) At 100% of Full Load ii) At 75% of Full Load iii) At 50% of Full Load iv) At 25% of Full Load

25 Efficiency at 75°C and 0.8 power factor i) At 100% of Full Load ii) At 75% of Full Load iii) At 50% of Full Load iv) At 25% of Full Load

26 Load at which maximum efficiency occurs 27 Regulation at 75°C at full load i) At 0.8 pf ii) At UPF

28 Dimensions i) Length (mm) ii) Height (mm) iii) Depth (mm) iv) Weight (kg)

29 Degree of protection for enclosure. 30 Paint Shade 31 Heat Load (kW)

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SA Fan

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HT & LT Varia

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LIST OF

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VFD OPERA

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ATED HT MO

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13

HT

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600

650

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g (KW)

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DATA S

Sl. No.

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

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Uni

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kW

kV

kA

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kA

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Page 9 of

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Sl. No.

15.0

16.0

17.0

18.0

19.0

20.0

21.0

22.0

23.0

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HT & LT Varia

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n

rough time

ics

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acy

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s

cs

nical Writeup

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s Pvt. Ltd.

Uni

Sec

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Page 10 of

it Sp

Indoo

*

*

Bottom

*

IP42

c. 2

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W Coal Based Re

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25.0

25.0

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Descript

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buffering

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HT & LT Varia

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illed by the

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Page 11 of

it Sp

Maxim

Maxim

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Yes

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DATA S

Sl. No.

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

14.0

15.0

16.0

17.0

SHEET‐ HT V

Type

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on

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g

nical Writeup

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Sp

Metal

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IP 42

Motorshall

Motorshall

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11 kV

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Page 12 of

pecificatio

l Clad, draw

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r Manufactube referred

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18.0

19.0

20.0

21.0

22.0

23.0

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HT & LT Varia

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Page 13 of

pecificatio

rolytic type

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HT

n Requirem

or

1 X 120 MW

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W Coal Based Re

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eheat TPP

ujarat

ol. II

Drive

BHARAT HEAVY ELECTRICALS LIMITED, BHOPAL DATA SHEET FOR BFP MOTOR

Note1: Data given below is subject to tolerance as per IS/IEC 60034-1 unless specified otherwise.

A. AC MOTOR 1.0 GENERAL 1.1 Application : BFP 1.2 Quantity : 03 1.3 Make : BHEL, Bhopal 1.4 Frame Size : 2RQ 7632-2 1.5 Applicable Standard : IS/IEC 60034-1 2.0 TYPE AND RATING 2.1 Type of Motor : SCIM 2.2 Service : 1.0 2.3 Duty Cycle/Designation : Continuous, S1 2.4 Rated Continuous Output At 40 Deg.C ambient KW : 2350 At 50 Deg.C ambient KW : 2200 2.5 Rated Speed r.p.m. : 2990 2.6 Rated Voltage & % variation : 11kV ± 10% 2.7 Rated Frequency & % variation : 50 ± 5 % 2.7a Combined frequency and voltage : 10% 2.8 Full load current Amps : 133 2.9 No load current Amps : 34 2.10 Rated Power Factor : 0.91 2.11 Efficiency at rated voltage and frequency: a) Full load % : 95.8 b) 3/4 load % : 95.5 c) 1/2 load % : 94.5

Project Name DCM SHRIRAM 1X120MW STG

Client DCM SHRIRAM CONSOLIDATED LTD

BHEL WO :

40050A421-11

Rev.00 Date: 12-Oct-2020

3.0 PERFORMANCE 3.1 Method of Starting : DOL & VFD 3.2 Starting Current at rated voltage % flc. : 600% on DOL start 3.3 Starting Current at 110% voltage (% of full load current) : 660% on DOL start 3.4 Torque at rated voltage kg.m : a) Breakaway starting torque kg m : 358 (50% FLT)

b) Pull out torque kg. m : 1646 (230% FLT) c) Pull up torque kg m : 358 (50% FLT) d) Full load torque kg. m : 716 3.5 Starting time at : 80% 100% 110% Voltage Voltage Voltage a) Motor with coupling i) With load sec. : 13.0 7.0 6.0 ii) Without load (driven equipment coupled) sec : 7.0 4.5 3.5 3.6 Safe stall time at 80% 100% 110% Voltage Voltage voltage a) Hot condition sec. : 37 24 19 b) Cold condition sec. : 46 30 24 3.7 Frequency of start per hour

a) Hot condition : 2

b) Cold condition : 3

c) Equal spread start : 3 3.8 Heating Time Constant (min) : 30 3.9 Cooling Time constant (min) : 120 3.10 Negative sequence time constant (K=Ie

2t) : Refer Curve No. AM40051-11/05 3.11 Noise level : 90 dB at 1m. 3.12 (i) Bearing Vibration level : 2.3 mm/s(rms) 37 µ (rms) (ii) Shaft vibration : 65 µ (P-P)

4.0 CONSTRUCTION 4.1 Degree of Protection of Enclosure : IP55 4.2 Method of Cooling : CACA, IC611 4.3 Insulation :

a) Type : VPI, Resin Poor

b) Class : Class F (Temp. rise limited to Class B) 4.4 Temperature Rise Over 50 Deg.C ambient (by resistance) : 70 4.5 Tropicalized Yes/No : YES 4.6 Winding Connection : STAR 4.7 Bearings D.E. N.D.E. a) Make : DIN Bearing, BHEL Approved/ From GeM b) Type : Sleeve c) Recommended lubricant : ISO VG32 or equivalent

d. Duration of lubrication change : FOL system vendor to recommend. e. Life of bearing : Infinite (if properly maintained) f. For force oil lubrication system : Not in BHEL, Bhopal scope i) Oil flow per bearing (LPM) : 3.5 for each bearing ii) Max/ Min oil pressure (kg-m2) : 0.2-0.5 kg/cm2 4.8 Motor Terminal Box a) Type : PSTB b) Fault withstand Current KA : 50 (through fault) c) Fault Current Withstand Time Sec. : 0.25 d) Cable lugs & glands furnished Yes/No : Gland Furnished, Lug is not in BHEL,Bhopal scope.

e) Position : RHS from DE

f) Rotation 360 deg with

step of 90 deg. (yes/No) : Suitable for 360 º rotation in step of 180º g) Type of thread : BSC

4.9 Mounting a. Shaft extension : Refer OGA drawing b. Direction of rotation from DE side : CCW from DE 4.10 Motor Neutral Terminal Box a) Type : Non-PSTB b) Differential CT provided (Yes/No) : 3 Nos. 4.11 Rotor terminal box : NA 5.0 ACCESSORIES 5.1 Space Heaters a) No. x Watt : 2 X 600W b) Volt, phase, frequency : 240V, 1Ph, 50Hz 5.2 Winding temperature detector a) Type : PT100 Simplex, 3 lead b) Nos. furnished : 12 5.3 Bearing temperature detector a) Type : PT100 Duplex, 3+3 lead b) Nos. furnished : 2 5.4 Hot and cold air temperature detector a. Type : PT100 Duplex, 3+3 lead b. Nos furnished : 1 +1 5.5 Temperature Indicators a) Type : Gas filled Dial Type b) Nos. provided : 2 Nos. for Bearings. c) Locations : On bearing housing

5.6 Temperature Alarm Contact a) Nos. provided : 2 ‘NO’ b) Locations : In-built inside DTT c) Contact rating : 30W, 50VA

5.7 Flow Switch a. Type : NA b. Nos. provided :-- c. Locations : -- d. Contact Rating :-- 5.8 Current Transformer for differential protection a. Nos. provided : 3 Nos. b. Current Ratio : Customer to decide details. c. Class : PS 5.9 Speed Switch a. Type : NA b. Location of switch & terminal box. -- c. Auxiliary supply requirement : - d. Catalogue furnished : -- 5.10 Starting Resistance (slip ring motor) : NA a. Type : -- b. Rating : -- 5.11 Accessory Terminal Box a) No. provided : 1 b) Cable glands furnished : Yes/No: YES 5.12 Insulation of bearing : YES, at NDE 5.13 Lubrication oil level indicator : Sight glass on bearing housing. 5.14 Water flow indicator : NA 5.15 Water leakage detector : NA 5.16 Vibration Pad (Nos. size and location): 2 Nos., 80 X 80 X 80 mm3

5.17 Motor vibration sensor : Not in BHEL Bhopal Scope. 5.18 Any other fitment : NA

6.0 GROUNDING 6.1 No. of grounding pads provided a) On motor body : 2 b) On terminal box : 2 7.0 MISCELLANEOUS 7.1 Type of mounting : Horizontal, B3 7.2 Foundation bolts provided (Yes/No) : In Pump vendor scope. 7.3 Overall dimension (LxBxH) mm x mm x mm : ≈ 4200 X 3200 2800 7.4 Moment of Inertia (Sq.GD) a) Stator Kg.Sq.m : NA b) Rotor Kg.Sq.m : 296 c) Total Kg.Sq.m : 296 7.5 Weight a) Stator+Cooler Kg : 9500 + 1800 b) Rotor Kg : 2700 c) Total Kg : 14000 Motor Equivalent Circuit Parameters: Stator: R1 = 0.165 X1 = 6.48 Ohm Xm =195.72 Ohm Rotor: R2’=(referred to stator)=0.782 Ohm at starting = 0.242 Ohm during running X2’ (referred to stator) = 2.95 Ohm at starting = 4.19 Ohm during running