sct 1466_ vol. g techno commercial bid- technical for electrical vol-g

TENDER SPECIFICATION BHEL: PSSR: SCT: 1466 FOR

Pre-bid tie up on back to back basis for Civil, Structural & Balance of Plant for 1x 700 MW Combined Cycle Power Plant of Andhra Pradesh Power Development Company Limited at Nedunoor, Karimnagar Dist, AP TECHNOCOMMERCIAL BID-

VOLUME-G –TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL

BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking) Power Sector – Southern Region

690, Anna Salai, Nandanam, Chennai – 600 035.

BHARAT HEAVY ELECTRICALS LIMITED (A Government of India Undertaking)

Power Sector, Southern Region 690, Anna Salai, Nandanam, Chennai – 35

Tender Specification No. BHEL: PSSR: SCT: 1466

For

Pre-bid tie up on back to back basis for Civil, Structural & Balance of Plant for 1x700 MW Combined Cycle Power Plant of Andhra Pradesh Power Development Company Limited (APPDCL) at Nedunoor, Karimnagar Dist, AP

One set of Tender documents consisting of Volume - A to Volume- L (details as below) BOOK SLNO_________________ Issued to M/s Refer NIT for Last date of submission Please note this tender document is not transferable

For and on behalf of BHARAT HEAVY ELECTRICALS LIMITED

ADDL GENERAL MANAGER / CONTRACTS

Place: Chennai -35

Tender Specification BHEL PSSR SCT 1466 comprise of Volume-A to Volume -L as below:

Sl no of Volumes

Description No. of pages

(including drawings)

Remarks

BHEL Vol -A

NIT

BHEL Vol -B

Project information, schedules, QA, Other requirements

Scope TP, Exclusions

Proposed scope split of Electrical between BHEL & EPC contractor

Scope split BHEL & EPC contractor dt 29-06-2011

Scope of lifting equipments

BHEL Vol -C

SCC- BHEL

BHEL Vol -D

Consolidated GCC- BHEL-PEM

APPDCL Volume -1,SECTION A1 TO A4

BHEL Vol -E

Geo tech investigations

Tech requirements for General Civil works

Additional civil drgs

BHEL Vol -F

Scope of Cooling tower

BHEL Vol -G

Tech requirements for General Electrical works

BHEL Vol -H

Technical spec for Mechanical packages- Bought out packages

BHEL Vol -I

NOT APPLICABLE

BHEL Vol -J

Amendments & clarifications

BHEL Vol -K

Schedules

BHEL Vol -L

Price schedule

TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL VOLUME -G

Bharat Heavy Electricals Limited

1X700 MW CCPP AT NEDUNOOR, KARIMNAGAR

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL WORKS

DOCUMENT NO. PE-TS-I59-888-E001 REV 0

BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR, PROJECT ENGINEERING MANAGEMENT

NOIDA 201301

700MW KARIMNAGAR CCPP

Doc. No. PE-TS-I59-888-E001

TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS

Rev. : 0

Page : of

CONTENTS

SL. NO. DESCRIPTION PAGES1. INTENT OF SPECIFICATION 1

2. SCOPE OF WORKS 1

3. DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID 1

4. DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER THE AWARD OF CONTRACT

2

5. ELECTRICAL TECHNICAL SPECIFICATION:

5.1 GENERAL REQUIREMENT 15

5.2 LT BUS DUCTS 16 5.3 400V SWITCHGEAR & MCC 16 5.4 NEUTRAL EARTHING EQUIPMENT 3 5.5 DC SYSTEM 13 5.6 CABLING SYSTEM 18 5.7 LIGHTING SYSTEM 16 5.8 EARTHING & LIGHTNING PROTECTION SYSTEM 7 5.9 PUBLIC ADDRESS SYSTEM 15

5.10 ELECTRICAL LAB EQUIPMENT 7 5.11 INSULATING MATS 1 5.12 CATHODIC PROTECTION 2

6. CUSTOMER DRGS.-ANNEXURE-II 5

7. BHEL ELECTRICAL SINGLE LINE DIAGRAM- PE-DG-I59-565-E001 1

8. QUALITY ASSURANCE, INSPECTION & TESTING 77 9. BHEL CLARIFICATIONS (ENCLOSED AS ANNEXURE-B) 2 10. SCHEDULE OF TECHNICAL DEVIATION 1 11. SPARES 3

IT IS CONFIRMED THAT OUR TECHNICAL OFFER COMPLIES WITH THE SPECIFICATION IN TOTO.

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BIDDER’S STAMP & SIGNATURE

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1. INTENT OF SPECIFICATION 1.1 The owner Andhra Pradesh Power Development Company Ltd has invited bids for the EPC

package of 1X700 MW CCPP at Nedunoor Karimnagar Dist. BHARAT HEAVY ELECTRICALS LIMITED (BHEL) intends to bid for this project and invites quotations for design and execution of the work for electrical systems of the project mentioned in relevant clauses.

1.2 At the outset the bidder must understand that this offer is to be submitted on back to back

basis which means that the bidder assumes total and unconditional responsibility for all electrical works as per owner’s requirements and subject to owner/ owner’s consultant’ approval.

1.3 Timely submission of drawings & documents / obtaining approval of drawings / documents

from owner / owner’s consultant shall be the responsibility of the bidder. 1.4 It is specifically emphasized that the bidder quoting for Electrical Works package shall be

comprehensively responsible for complete scope of work stated or unstated including preparation of design and drawings, obtaining necessary approvals, materials, execution as per codes, best engineering practices and to the satisfaction of the owner.


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2. SCOPE OF WORKS 2.1 It shall be Contractor’s responsibility to provide all the equipment / systems / services and

interfacing between various systems for the completeness of the 700 MW Combined Cycle Power Plant (CCPP). The following configuration shall be considered.

2 GTs + 2 HRSGs + 1 STG in Multishaft configuration. 2.2 The requirements described here are for 700 MW CCPP. All equipment in the plant shall

operate without any limitation upto the full load of Gas Turbine offered. This shall be applicable to all regimes of GT operation including the temperature range, frequency range, voltage range, with evaporative cooler etc. However for the purpose of the PG test, the evaporative cooler shall be switched off.

2.3 The Plant electrical systems for proposed combined cycle power plant shall essentially

comprise but not be limited to the following: 1. HT power cables, LT Power cables, LT Control cables & instrumentation cables 2. Cabling & installation equipment(cable trays & accessories, cable tray support, trefoil clamps,

termination kits, jointing kits cable glands & lugs etc). 3. Earthing & lightning protection(including above & below grade grounding material) 4. Station lighting system. 5. Neutral grounding resistors for Unit auxiliary transformers. 6. 220V DC battery, battery chargers, DC switchboards and their accessories. 7. 400V AC switchgear, LV power distribution boards and accessories. 8. Public address system equipment. 9. Electrical laboratory equipment 10. Insulating mats 11. Cathodic protection 12. Drawing & Document submission for all packages : System design, Design Calculations,

Design Memorandums, Layout drgs., Electrical load list, cable schedules, cable interconnections, Data sheets, OGA, Quality plans, test certificate etc.

Detailed scope of work shall be as per scope chart enclosed as Annexure-A. Any deviation to technical specification is to be clearly mentioned in “schedule of technical deviation” & undeclared technical deviation is not acceptable at any stage of project.


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3. DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID: BIDDER TO SUBMIT SIGNED & STAMPED COPY OF FOLLOWING SHEETS:

i) CONTENTS ii) INTENT OF SPECIFICATION iii) SCOPE OF WORKS( ALONG WITH SCOPE CHART IN ANNEXURE-A & TABLE-1)

4

S.No. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE

1 ELE 100 ELE LAYOUT PE-DC-I59-100-E999DESIGN PHILOSOPHY FOR ELECTRICAL EQUIPMENT LAYOUT

2 ELE 100 ELE LAYOUT PE-DG-I59-100-E001 LAYOUT OF TRANSFORMER YARD

3 ELE 100 ELE LAYOUT PE-DG-I59-100-E003LAYOUT OF ELECTRICAL EQUIPMENT IN CW PUMP HOUSE

4 ELE 100 ELE LAYOUT PE-DG-I59-100-E004LAYOUT OF ELECTRICAL EQUIPMENT IN RW PUMP HOUSE

5 ELE 100 ELE LAYOUT PE-DG-I59-100-E006 LAYOUT OF MAIN SWITCHGEAR ROOM

6 ELE 100 ELE LAYOUT PE-DG-I59-100-E007EQUIPMENT LAYOUT IN STATIC EXCITATION ROOM(GTG)

7 ELE 100 ELE LAYOUT PE-DG-I59-100-E008EQUIPMENT LAYOUT IN STATIC EXCITATION ROOM (STG) (AB BAY 13.5M EL)

8 ELE 100 ELE LAYOUT PE-DG-I59-100-E009 LAYOUT OF DC BATTERY ROOM

9 ELE 100 ELE LAYOUT PE-DG-I59-100-E013CABLING LAYOUT BELOW MAIN SWITCHGEAR ROOM

10 ELE 100 ELE LAYOUT PE-DG-I59-100-E016 CABLING LAYOUT BELOW DC BATTERY ROOM

11 ELE 100 ELE LAYOUT PE-DG-I59-100-E020CABLING TRAY LAYOUT AT 9.5M EL. CABLE VAULT-BC BAY

12 ELE 100 ELE LAYOUT PE-DG-I59-100-E021CABLE TRAY LAYOUT IN TG HALL IN BELOW 8.5M EL

13 ELE 100 ELE LAYOUT PE-DG-I59-100-E022CABLE TRAY LAYOUT IN TG HALL IN ABOVE 8.5M EL

14 ELE 100 ELE LAYOUT PE-DG-I59-100-E038 CABLE TRAY LAYOUT ON HRSG PLATFORMS

15 ELE 100 ELE LAYOUT PE-DG-I59-100-E050 IPB LAYOUT-GT

16 ELE 100 ELE LAYOUT PE-DG-I59-100-E051 IPB LAYOUT-STEAM TURBINE GENERATOR

CABLE TRAY LAYOUT AT EL 0 0M FLOOR IN BFP

4. MASTER LIST OF DRAWINGS/ DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER AWARD OF CONTRACT (INDICATIVE)

17 ELE 100 ELE LAYOUT PE-DG-I59-100-E060 SH 1 OF 3CABLE TRAY LAYOUT AT EL 0.0M FLOOR IN BFP BUILDING (SHEET 1 OF 3)

18 ELE 100 ELE LAYOUT PE-DG-I59-100-E060 SH 2 OF 3CABLE TRAY LAYOUT AT EL 6.7M & 10.0M FLOOR IN BFP BUILDING (SHEET 2 OF 3)

19 ELE 100 ELE LAYOUT PE-DG-I59-100-E060 SH 3 OF 3CABLE TRAY LAYOUT AT EL 14.500M FLOOR IN BFP BUILDING (SHEET 3 OF 3)

20 ELE 100 ELE LAYOUT PE-DG-I59-100-E063 CABLE TRENCH LAYOUT IN GAS TURBINE BUILDING

21 ELE 100 ELE LAYOUT PE-DG-I59-100-E065ELECTRICAL EQUIPMENT LAYOUT OF BFP BUILDING

22 ELE 100 ELE LAYOUT PE-DG-I59-100-E067CABLE TRENCH LAYOUT IN STEAM TURBINE BUILDING

23 ELE 100 ELE LAYOUT PE-DG-I59-100-E071 INTERPLANT CABLING LAYOUT (2 SHEETS)

24 ELE 100 ELE LAYOUT PE-DG-I59-100-E072CABLE TRAY LAYOUT IN AIR WASHER ROOM – STG BUILDING

25 ELE 100 ELE LAYOUT PE-DG-I59-100-E073CABLE TRAY LAYOUT IN AIR WASHER ROOM - STG BUILDING OUTSIDE A ROW

26 ELE 100 ELE LAYOUT PE-DG-I59-100-E074CABLE TRAY LAYOUT ON STORM WATER PUMP HOUSE

27 ELE 100 ELE LAYOUT PE-DG-I59-100-E075CABLE TRAY LAYOUT ON PORTABLE WATER PUMP HOUSE

28 ELE 100 ELE LAYOUT PE-DG-I59-100-E076CABLE TRAY LAYOUT IN AC PLANT ROOM (FACILITY BUILDING)

29 ELE 100 ELE LAYOUT PE-DG-I59-100-E077CABLE TRAY LAYOUT IN A.H.U ROOM (FACILITY BUILDING)

30 ELE 100 ELE LAYOUT PE-DG-I59-100-E078CABLE TRAY LAYOUT IN A.H.U ROOM (STG BUILDING)

31 ELE 100 ELE LAYOUT PE-DG-I59-100-E079ELECTRICAL EQUIPMENT AND CABLE TRAY LAYOUT IN ETP MCC ROOM

32 ELE 100 ELE LAYOUT PE-DG-I59-100-E080ELECTRICAL EQUIPMENT AND CABLE TRAY LAYOUT IN WATER TREATMENT MCC ROOM

33 ELE 100 ELE LAYOUT PE-DG-I59-100-E081 CABLE TRAY LAYOUT IN CW PUMP HOUSE

5

S.No. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE

4. MASTER LIST OF DRAWINGS/ DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER AWARD OF CONTRACT (INDICATIVE)

34 ELE 100 ELE LAYOUT PE-DG-I59-100-E082 CABLE TRAY LAYOUT IN RAW WATER PUMP HOUSE

38 ELE 506 LV SWGR PE-DC-I59-506-E004 ELECTRICAL LOAD DATA (BOARD WISE)

39 ELE 506 LV SWGR PE-DG-I59-506-E003 CONTROL LOGIC FOR 415V SWGR

40 ELE 507 CABLES & CABLING PE-DC-I59-507-E001DESIGN CALCULATIONS FOR HT CABLES SELECTION & SIZING

41 ELE 507 CABLES & CABLING PE-DC-I59-507-E002DESIGN CALCULATIONS FOR LV CABLES SELECTION & SIZING

42 ELE 507 CABLES & CABLING PE-DC-I59-507-E004 CABLING PHILOSOPHY

43 ELE 507 CABLES & CABLING PE-DC-I59-507-E005 CABLE NUMBERING SCHEME

44 ELE 507 CABLES & CABLING PE-DG-I59-507-E005TYPICAL DETAILS OF CABLE TRAYS AND ACCESSORIES

45 ELE 507 CABLES & CABLING PE-DG-I59-507-E006TYPICAL INSTALLATION DETAILS FOR CABLE TRAY SUPPORT SYSTEM

46 ELE 507 CABLES & CABLING PE-DG-I59-507-E007TYPICAL DETAILS FOR CABLE TRAY SUPPORT SYSTEM

47 ELE 507 CABLES & CABLING PE-DG-I59-507-EXXX LAYOUT FOR ALL AREAS

48 ELE 507 CABLES & CABLING PE-DG-I59-507-EXXX CABLE TRAY LAYOUT FOR ALL AREAS

49 ELE 507 CABLES & CABLING PE-DG-I59-507-EXXX CABLE SCHEDULES FOR ALL AREAS

50 ELE 507 CABLES & CABLING PE-DG-I59-507-EXXXCABLE INTERCONNECTION FOR ALL CABLE SCHEDULES

51 ELE 508 DC SYSTEM PE-DC-I59-508-E001 DESIGN MEMORANDUM FOR 220V DC SYSTEM

52 ELE 509LIGHTNING PROTECTION PE-DC-I59-509-E001 DESIGN MEMORANDUM FOR EARTHING SYSTEM

53 ELE 509LIGHTNING PROTECTION PE-DC-I59-509-E002

DESIGN MEMORANDUM FOR LIGHTNING PROTECTION SYSTEM

54 ELE 509LIGHTNING PROTECTION PE-DG-I59-509-E003 TYPICAL BELOW GROUND EARTHING DETAILS

55 ELE 509LIGHTNING PROTECTION PE-DG-I59-509-E004 TYPICAL ABOVE GROUND EARTHING DETAILS

56 ELE 509LIGHTNING PROTECTION PE-DG-I59-509-E005

BELOW GRADE GROUNDING SYSTEM LAYOUT FOR MAIN POWER PLANT AREA

57 ELE 509LIGHTNING PROTECTION PE-DG-I59-509-E007

BELOW GRADE EARTHING LAYOUT FOR OFFSITE PLANTS

58 ELE 509LIGHTNING PROTECTION PE-DG-I59-509-E008 LIGHTNING PROTECTION FOR OFFSITE PLANTS

59 ELE 557PUBLIC ADDRESS SYSTEM PE-DC-I59-557-E001

DESIGN MEMORANDUM FOR PUBLIC ADDRESS SYSTEM

60 ELE 558LIGHTING & LOW VOLTAGE SERVICES PE-DC-I59-558-E001

DESIGN MEMORANDUM FOR LIGHTING & LV POWER SERVICES

61 ELE 561 EMERGENCY DG PE-DC-I59-561-E001DESIGN CALCULATION FOR EMERGENCY SUPPLY DG SIZING

62 ELE 565ELECTRICAL SYSTEM DESIGN PE-DC-I59-565-E004 RELAY SETTINGS CHART FOR LV/HV MOTORS

63 ELE 565ELECTRICAL SYSTEM DESIGN PE-DC-I59-565-E002

DESIGN CALCULATION FOR GENERATOR AND MV SYSTEM

64 ELE 565ELECTRICAL SYSTEM DESIGN PE-DG-I59-565-E001

ELECTRICAL SINGLE LINE DIAGRAM FOR AUXILIARY POWER DISTRIBUTION

65 ELE 565 ELECTRICAL SYSTEM PE-DG-I59-XXX-EXXX

DRG./DOC.(I.E. DATA SHEET/ OGA/ SCHEME/ TEST CERTIFICATES/ QUALITY PLANS ETC.) FOR ALL ELECTRICAL PACKAGES

6

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME III

TCE.5960A-H-500-001

700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

EPC SPECIFICATION -ELECTRICAL SYSTEMS

SECTION: CONTENT SHEET

SHEET 1 OF 2

ISSUE R0

TITLE

TCE FORM NO. 329 R5

VOLUME-III – CONTENTS

ELECTRICAL SYSTEM

SECTION NO. SPECIFICATION NO. REV.NO. TITLE NO. OF SHEETS

D3.0 TCE-5960A-H-500-01 R0 GENERAL REQUIREMENT 15

D3.1 TCE-5960A-H-500-01

R0

GENERATOR AND ACCESSORIES 39

D3.2 TCE-5960A-H-500-01 R0 GENERATOR CIRCUIT BREAKER 06

D3.3 TCE-5960A-H-500-01 R0 GENERATOR TRANSFORMERS 09

D3.4

TCE-5960A-H-500-01 R0 UNIT AUXILIARY TRANSFORMERS 03

D3.5 TCE-5960A-H-500-01 R0 BUS DUCTS 16

D3.6

TCE-5960A-H-500-01

R0 GENERATOR, GENERATOR, TRANSFORMER AND UAT PROTECTIONS

08

D3.7 TCE-5960A-H-500-01 R0 400 kV SWITCHYARD 49

D3.8 TCE-5960A-H-500-01 R0 GENERATOR CONTROL PANEL 09

D3.9 TCE-5960A-H-500-01 R0 6.6 kV SWITCHGEAR 15

D3.10 TCE-5960A-H-500-01 R0 SERVICE TRANSFORMERS 05

D3.11 TCE-5960A-H-500-01 R0 400V SWITCHGEAR & MCC 16

D3.12 TCE-5960A-H-500-01 R0 NEUTRAL EARTHING EQUIPMENT 03

D3.13 TCE-5960A-H-500-01 R0 DC SYSTEM 13

D3.14 TCE-5960A-H-500-01 R0 UNINTERRUPTIBLE POWER SUPPLY SYSTEM

07

D3.15 TCE-5960A-H-500-01 R0 CABLING SYSTEM 18

D3.16 TCE-5960A-H-500-01 R0 LIGHTING SYSTEM 16

D3.17 TCE-5960A-H-500-01 R0 EARTHING & LIGHTNING PROTECTION SYSTEM

07

D3.18 TCE-5960A-H-500-01 R0 COMMUNICATION SYSTEM 15

D3.19 TCE-5960A-H-500-01 R0 FIRE DETECTION AND ALARM SYSTEM 05

7

SPEC.NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME III

TCE.5960A-H-500-001


EPC SPECIFICATION -ELECTRICAL SYSTEMS

SECTION: CONTENT SHEET

SHEET 2 OF 2

ISSUE R0

TITLE

TCE FORM NO. 329 R5

D3.20 TCE-5960A-H-500-01 R0 MOTORS 10

D3.21 TCE-5960A-H-500-01 R0 ELEVATORS 08

D3.22 TCE-5960A-H-500-01 R0 ELECTRICAL LABORATORY EQUIPMENT 07

D3.23 TCE-5960A-H-500-01 R0 MISCELLANEOUS ELECTRICAL EQUIPMENT

03

D3.24 TCE-5960A-H-500-01 R0 CONSTRUCTION POWER SUPPLY 04

D3.25 TCE-5960A-H-500-01 R0 TRANSDUCERS 02

BID DRAWING

SL NO. DRAWING NO. REV.NO. TITLE NO. OF SHEETS

1.0 TCE.5960A-EL-2001 P0 KEY ONE LINE DIAGRAM 01

2.0 TCE.5960A-EL-2003 P0 MAIN ONE LINE DIAGRAM (SH. 1 OF 2) 01

3.0 TCE.5960A-EL-2003 P0 MAIN ONE LINE DIAGRAM (SH. 2 OF 2) 01

4.0 TCE.5960A-EL-2004 P0 SWITCHYARD SCADA ARCHIETCTURE DIAGRAM

01

5.0 TCE.5960A-EL-2005 P0 PARALLEL REDUNDANT UPS WITH STATIC BYPASS TO REGULATED SUPPLY

01

6.0 TCE.5960A-EL-2006 P0 FLOAT CUM BOOST CHARGER WITH 2x100% BATTERY

01

7.0 TCE.5960A-EL-2007 P0 400kV SWITCHYARD PLAN 01

8.0 TCE.5960A-EL-2008 P0 400kV SWITCHYARD SECTIONS 01

8

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.0

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS - GENERAL REQUIREMENTS

SHEET 1 OF 17

ISSUE R0

SPEC. NO. TCE.5960A-H-500-001

TITLE

TCE FORM NO. 329 R5

1.0 General Requirements

(a) For the purpose of design of equipment / systems, an ambient temperature of 500C and relative humidity of 95% shall be considered. The equipment shall operate in a highly polluted and highly corrosive environment. However, for equipment in air-conditioned areas, design ambient temperature shall be 350C, if 2x100% air conditioning system is provided.

(b) All equipments shall be suitable for rated frequency of 50 Hz with a

variation of +3% to -5% and 10% combined variation of voltage and frequency unless specifically brought out in the specification. The step up voltage of the project shall be 400 kV as applicable.

(c) Contractor shall provide fully compatible electrical system,

equipments, accessories and services for the entire station/plant in his scope as well as those specifically required by the Owner.

(d) All the equipment, material and systems shall, in general, conform to

the latest edition of relevant National and International Codes & Standards, especially the Indian Statutory Regulations. The accompanying specifications also indicate the applicable codes and standards. The equipment/material/systems conforming to other equivalent national and international standards shall also be considered provided the same ensures equal or better features compared to standards listed in accompanying specification.

(e) Control supply voltage for all the switchgear for the GTG, HRSG,

Cooling tower & STG shall be 220 V DC & 110 V AC. However the area where the DC control supply is required shall be finalized during the detailed engineering.

(f) Fault level shall be limited to 44 kA rms for 6.6 kV systems and 50 kA

rms for 400 V system. However the three phase symmetrical short circuit fault current value shall be based on load flow and fault studies, to be carried out as a part of this contract.

(g) The nominal voltage of main DC system shall be 220V and 24V DC

system for I& C application. To cater the 400kV switchyard PLCC load, separate 48V DC system shall be provided. Any other voltage required shall be derived from 220V DC or 230V AC UPS distribution board for catering to the control & instrumentation loads.

9

1294156

Text Box

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TCE FORM NO. 329 R5

(h) The Contractor shall furnish calculations of maximum loading and

fault levels under the most onerous conditions for the various equipment/systems to prove adequacy of their parameters. In case any equipment or system is found to be inadequate, it shall be changed / modified without any additional liability to the Owner.

(i) Transformer voltage ratios, taps, impedances and tolerances thereon,

shall be so optimized so that the auxiliary system voltages (6.6 kV & 400 V) under various grid and loading conditions are always within permissible limits and equipment are not subjected to unacceptable voltages during operation and starting of motors. The vector groups of the transformers shall be so selected that all the buses of particular voltage level have same vector through out the plant.

(j) The responsibility of coordination with electrical agencies and

obtaining all necessary clearances from all the statutory authorities, shall be by the Contractor.

(k) All control and protection panels, 6.6 kV switchgear, 400 V

switchgear, MCCs, DC and AC distribution board and battery charger panels shall be painted by powder coating process. External surfaces of all equipments shall be painted with Epoxy paint. Paint shade shall be opaline green (external) & semi-glossy white (internal).

(l) The electrical scheme for the project shall be as per the enclosed

drawings: Key one line diagram : TCE.5960A-EL-SK-2001

Main one line diagram : TCE.5960A-EL-SK-2003 (Sh. 1 of 2)

Main one line diagram : TCE.5960A-EL-SK-2003 (Sh. 1 of 2)

Switchyard SCADA : TCE.5960A-EL-SK-2004

Architecture diagram

UPS scheme : TCE.5960A-EL-SK-2005 Float cum boost charger : TCE.5960A-EL-SK-2006 with 2 x 100% battery

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TITLE

TCE FORM NO. 329 R5

400kV Switchyard plan : TCE.5960A-EL-SK-2007 400kV Switchyard sections : TCE.5960A-EL-SK-2008 1.1 Generator and its auxiliaries

1.1.1 The generator shall be three phase, horizontal, two pole, cylindrical rotor,

Wye connected machine with phase and neutral terminals brought out for connection to isolated phase bus duct. The Gas turbine generators /steam turbine generators and their excitation systems shall have a capability at least matching the declared maximum continuous output of the associated gas turbine /steam turbine at the outside ambient air temperature ranging from 00C to 500C, at all power factor between 0.85 lagging and 0.95 leading. The contractor shall ensure that when the generator is working at this capability, no part of the generator shall attain a temperature in excess of the temperature limit specified in IEC 60034. The Insulation class of the machine shall be Class-F but its temperature rise shall be limited to Class-B.

1.1.2 The Gas Turbine Generator and Steam turbine Generator shall be of

hydrogen & water cooled. The Stator core & Rotor winding shall be hydrogen cooled. The Stator winding shall be DM water cooled.

1.1.3 The Contractor shall offer 2 nos. Static Frequency Converter (SFC) for

starting of one gas turbine generator at a time. It shall be ensured that either of SFC can be used for cranking any of the Gas turbines without any limitation on successive starts of all gas turbines and restarts thereon.

1.2 Generator Circuit Breaker (GCB)

The continuous current rating of the GCB shall be arrived at considering the maximum output of the generator and at specified minimum voltage. The voltage class of the Generator circuit breaker shall be same as that of the generator. The GCB shall be of SF6, metal enclosed, outdoor and freestanding type.

1.3 Generator Transformers 1.3.1 The continuous rating of the generator transformers shall be such that the

declared maximum continuous output of the respective turbine unit at any ambient temperature between 00C and 500C can be delivered at the rated

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SPEC. NO. TCE.5960A-H-500-001

TITLE

TCE FORM NO. 329 R5

power factors and allowable generator voltage variations without exceeding the permissible temperature rise limits set by the applicable Indian Codes and Standards for these equipment. Further a margin of 5% on the rating shall be provided considering the maximum Generator output. The Bidder shall furnish the rating of the equipments.

1.3.2 The GT shall be with voltage ratio of generator voltage / 420kV, two winding,

50 Hz, ONAN / ONAF / OFAF cooled transformer, with On Load Tap Changer with +10% to -10% of in steps of 1.25% on the HV side.

1.4 Unit Auxiliary Transformer

2 Nos. Unit auxiliary transformer shall be capable of supplying auxiliary power requirement of complete station system. UAT shall be a * MVA, */6.9kV, three phase, two winding, 50 Hz, ONAN/ONAF cooled transformer with * % impedance with OLTC +10% in steps of 1.25% on HV side (*By Bidder). Further a 10 % margin on rating shall be provided after considering final load requirement. UAT shall be suitable for medium resistance earthing with earth fault current limited to 300A.

1.5 Bus duct 1.5.1 The continuous current rating of the generator bus duct shall be arrived at

considering the maximum output of the generator and at specified minimum voltage.

1.5.2 The M.V. / L.V. Bus duct shall be sized based on the transformer rating at

minimum tap. 1.6 Protection

Fully graded protection system with requisite speed, sensitivity and selectivity shall be provided for the entire plant. Critical equipments/systems shall be provided with double protection. Contractor shall recommend the relay settings to be adopted along with back-up calculations.

1.7 400 kV Switchyard

(a) A 400 kV switchyard shall be provided for evacuation of power generated in the plant through four (4) nos. 400kV transmission lines. The 400 kV switchyard shall have one and half breaker switching scheme.

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(b) The layout of the switchyard shall be such that adequate space for

maintenance of prime equipment like circuit breakers and current transformers is available. Approach road shall be provided. Approach road all around the switchyard shall also be provided for maintenance and patrolling.

(c) Earth mat

The earth mat shall be extended 2 m beyond fence for the switchyard.

The earth mat of 400kV switchyard shall be inter connected with main plant. The earth mat shall be designed for short time rating of 1 second rating and shall be considered for calculation of step & touch potential. For the Earthing system design System fault current to be considered is 50 kA.

(d) The EMVT/CVT and LA shall be connected to earth pit through pipe

electrodes. (e) The Conductor tensions shall be 2 Tonnes per conductor.

(f) All tension insulator strings shall have double tension string

arrangement.

(g) Air conditioned outdoor kiosks will be suitably located in switchyard, housing various Intelligent Electronic Devices (IEDs) such as Bay Control Units (BCUs), Protection Panels, Fault Disturbance Recorders, PLCC Panels, etc. for each dia.

(h) The connections from LA to transformer shall be through shortest

electrical distance.

(i) The coolers shall preferably be arranged on side, other than LA.

(j) The receptacles of 63 A ratings shall be provided on the gantries at suitable location for connection to welding sets/other emergency equipments.

(k) The aluminium tubular busbar conductors wherever if used shall have

maximum one joint per span.

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(l) Corona rings & corona bells shall be used wherever required and same shall be of non-magnetic material. The requirements regarding RIV and corona extinction voltage shall include terminal fittings.

(m) All equipments shall be suitable for hot line washing.

(n) The connectors for termination of conductor on equipment shall be

either of rigid or expansion type suitable for aluminium tube or Moose ACSR conductor.

(o) The switchyard shall be provided with suitable phase markers and

danger plates.

(p) Insulation Co-ordination

The Contractor shall be fully responsible for complete insulation co-ordination of switchyard. Contractor shall carry out detailed calculations to evolve the required parameters, locations, energy capability etc. of surge arrestors such that an adequate protective margin exits between the peak impulse voltage occurring due to other connected sub stations. Bidder to note that surge arrester parameters given at D3.7 are indicative and shall be finalised after insulation coordination studies.

The quantity of surge arresters shown in the drawings are minimum

required. Additional arresters, if required based on the insulation coordination study, shall be provided by the Contractor.

The Contractor shall provide surge arrestors and other devices as

required to protect all the equipments from fundamental frequency, harmonics, ferro-resonance, switching surges, and lightning impulse over voltages under steady state, dynamic & transient conditions.

The Contractor shall furnish the system studies like load flow, short

circuit and transient stability studies of the complete system including the transmission lines during detail engineering stage for Owner’s approval. In addition to the above, Contractor shall submit the relay co-ordination, motor starting studies for the complete plant for Owner’s approval.

(r) 400 kV System

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(i) Max voltage 420 kV (ii) Rated frequency 50 Hz (iii) Rated short time current 50 kA rms for one (1) second withstand capacity iv) Rated one minute power 630 kV rms

frequency withstand voltage

v) Rated lightning impulse 1425 kVp withstand voltage vi) Clearance Phase to phase 4200 mm Phase to earth 3400 mm Sectional clearance 6500 mm Ground clearance 8000 mm

(s) System neutral earthing Effectively earthed

(t) Auxiliary contacts The contacts shall have continuous rating of 10A and breaking capacity of 2A with circuit time constant of minimum 20 ms at 220 V DC.

(u) Type of circuit breaker SF6 (v) Operating mechanism Spring / Spring charge mechanism

Circuit breaker

(w) Type of isolator Horizontal centre break/Pantograph

(x) Instrument transformer Outdoor, Oil filled hermetically sealed with SS bellow.

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(y) Creepage distance for 31mm/kV insulators 1.8 Control philosophy of electrical system

(a) Control of L.V. and M.V. auxiliary power system, covered under the scope of this package shall be provided through the DCS system.

(b) Control, Protection, monitoring, indication, annunciation and metering

of complete 400 kV switchyard under Bidder's scope shall be through SCADA.

(c) PLCC panels for lines shall be located in the outdoor kiosk panels.

(d) The control, monitoring, measurement, annunciation, synchronizing

and sequential event logging for each generator and its subsystem shall be provided on the DCS.

e) SCADA shall have communication with plant DCS for providing

measurement, monitoring, annunciation etc of 400kV switchyard. 1.9 6.6kV Switchgear

The 6.6 kV switchgear and its accessories shall conform to all latest editions of national and international standards. For feeding the plant auxiliaries rated for 6.6 kV and service transformers, adequately rated switchgears shall be provided. The fault level for the switchgear, circuit breakers, isolators, earth switch, bus bars, etc., shall be arrived at, on the basis of short circuit current contribution from UAT plus short circuit contribution by the motors running on the bus. A margin of 5% over higher of the above S.C current, shall be applied and rounded off to the next higher standard ratings and this value shall be adopted for the breakers and switchgears. The momentary current ratings shall be 2.55 times this value.

1.10 Service transformer

Adequate number of 6.6 kV / 420V epoxy cast resin dry type service transformers shall be provided to meet the demand on 400V systems, with the criteria that each 400 V switchgear / MCC / DB shall be fed by 2x100% transformers / feeders, and these shall be rated to carry the maximum load expected to be imposed with 10% margin at all ambient. Each of the

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switchgear / MCC / DB shall be sectionalised. Highest efficiency operating point shall be designed near to the normal loading of the transformer i.e. when the bus coupler is open. The service transformers shall be two winding, three phase, 50 Hz, 6600 / 420 Volts, Dry type AN cooled with off-circuit taps of ±5% in steps of 2.5%.

1.11 400 V Switchgear

The 400 V switchgear and its accessories shall conform to all latest editions of national and international standards. For feeding the 400V / 230V AC loads of the plant, 400V switchgear / motor control centres (MCCs) and AC distribution boards (ACDBs) shall be provided. The switchgears shown in Key One Line Diagram drg. No. TCE.5960A-EL-SK-2001 is tentative. Any additional switchgear / MCCs as required shall also be provided.

1.12 Neutral Earthing Equipment

(a) 400 kV system is solidly earthed. The neutral of GTs are independently connected to earth.

(b) Generator neutral shall be high resistance earthed. The neutral shall

be connected to a suitably rated neutral earthing transformer with secondary loading resistor, limiting the earth fault current to about 5-10 A. The neutral earthing equipment shall be rated to carry this current for at least 30 seconds considering the generator terminal voltage under maximum field forcing conditions.

(c) 6.6 kV systems shall be medium resistance earthed. The neutral of

the unit auxiliary transformers shall be independently connected to the earth through a suitable resistance designed for 30secs. The earth fault current shall be limited to 300A.

(d) 400V system shall be a solidly earthed system. The neutral of

service transformers shall be independently connected to the earth.

(e) 220 V DC system & UPS system shall be kept ungrounded.

(f) Diesel generator shall be of solidly earthed system. 1.13 DC System

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(a) DC power supply with high discharge Lead acid plante type battery cells forming bank shall be the source of the power supply for control, protection, interlock, annunciation of the complete plant including I&C system during the running of the plant as well as for a safe shutdown at the time of the total power supply failure.

(b) 220V, DC 2 x 100% battery bank with associated float cum boost-charger, 1 No. DC switchboard shall be provided for each gas turbine generator (GTG) unit. The GTG unit DC system with 100% capacity shall be sized to cater complete unit loads for atleast 10 hrs.

(c) 220V, DC 2 x 100% battery banks with associated float cum boost-chargers and 1 No. DC switchboard shall be provided for station DC system. The station DC system shall be sized to cater STG, HRSG and station loads for at least 10 hrs.

(d) 220V, DC 2 x 100% battery banks with associated float cum boost-chargers and 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for 400kV system (switchyard) auxiliaries. The switchyard DC system shall be sized to cater loads for at least 10 hrs.

(e) 48V, DC 2 x 100% battery banks with associated float cum boost-chargers and 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for 400kV switchyard PLCC application.

(f) 24V, DC 2 x 100% battery banks with associated float cum boost-chargers and 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for I& C , DCS system.

(g) The boost charger unit shall be rated such that the battery can be fully charged from fully discharged condition within 8 hours.

(h) Each battery charger shall be capable of float charging the two batteries while supplying the normal DC loads.

(i) Sizing criteria shall include design margin of 10%, 25% margin on ageing and ambient temperature compensation as per IS.

1.14 Uninterruptible Power Supply (UPS)

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Parallel redundant UPS shall be with duplicate charger, inverter & battery system and standby supply to cater the UPS loads of complete plant Instrumentation and control system loads such as HMI, SWAS etc. The UPS shall be sized considering full load plus spare loops plus 20% margin.

1.15 Cabling System Cables shall be derated for the site ambient and ground temperatures,

grouping and soil resistivity. Contractor shall furnish detailed cable selection/sizing criteria for Owner’s approval. Cables shall be selected to limit maximum voltage drop at equipment terminals during normal operation and starting conditions well within permissible values. Voltage grade of cables shall be of earthed grade when used in solidly earthed systems, and unearthed grade when used in non-effectively earthed systems.

1.16 Lighting System

Lighting system shall be provided for the entire plant covering all the buildings, outdoor areas, roads, yards, boundary, etc. The lighting system design shall comply with the acceptable norms and the best engineering practices. The lighting layout shall be designed to provide uniform illumination with minimum glare. The layout design shall meet all the statutory requirement, local rules etc.

1.17 Earthing System The earthing system shall be designed for a life expectancy of at least forty

(40) years, for maximum fault current of 50kA for 1.0 sec. The minimum rate of corrosion of steel for selection of earthing conductor shall be 0.12mm per year. Grounding and lightning protection for the entire power plant, switchyard and other areas or buildings covered in the specification shall be provided in accordance with IS:3043, IS:2309 & IEEE : 80 and IEEE : 665.

1.18 Motors

(a) Wherever the basis for motor ratings are not specified in the corresponding mechanical specification sections, maximum continuous motor ratings shall be at least 10% above the maximum load demand of the driven equipment under entire operating range including voltage and frequency variations.

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(b) All M.V. motors shall be suitable for 6.6 kV, 3 phase, 50 Hz and LV motors shall be suitable for 400 V, 3 Phase, 50 Hz power supply. The voltage for M.V. and L.V. motors shall be ±10%.

(c) The motors rated 175 kW and above shall be 6.6kV and motors rated

upto 175 kW shall be 400 V. 1.19 Emergency Diesel Generator Set Each Emergency Diesel Generating set shall be sized at an ambient

temperature of 500C for all essential auxiliaries and emergency loads of all gas turbines, steam turbines, station service and switchyard loads.

1.20 Islanding Scheme The plant shall be designed to operate in islanding mode of operation by

tripping all the lines and generators except for one pre-selected unit, which shall run with the available plant load under such condition.

1.21 Auxiliary System

(a) 6.6 kV incomers and ties from transformers to switchgear shall be through 6.6 kV segregated phase bus duct (SPBD) only. If adequately rated cables shall be provided then Owner’s permission shall be obtained. For 400V system, non-segregated phase bus duct (NSPBT) assemblies shall be preferred for incoming connection from transformers to the switchboard.

(b) The 6.6 kV system shall incorporate a microprocessor based numerical fast auto change over scheme which will restore supplies to the 6.6kV unit board from other unit board, on loss of supplies from unit transformer. Manual live changeover and slow changeover shall also be arranged for all 6.6 kV buses & 400V buses. Automatic changeover to the reserve supply source shall be arranged for 400V critical switchgear/MCC sections as necessary to prevent the loss of a unit or to ensure the equipment safety.

(c) 6.6kV and 400V switchgear, MCCs and DBs shall have positive fool- proof interlocking to ensure that different supplies and transformers are never operated in parallel and fault level does not exceed the switchgear capability. For 400V switchgear, contribution from emergency DG set shall be considered while designing the fault level.

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(d) During Grid black-out condition, it shall be ensured that only the essential auxiliaries of all units are fed from emergency Diesel generator & non- essential loads are automatically tripped.

(e) DC scheme shall provide at least two feeds through diode sharing to critical consumers e.g. all protection panels / control desks, circuit breakers, GCB, 6.6 kV / 400 V unit and emergency switchgear panels, generator excitation system, generator oil seal system, etc. The details shall be subject to Owner’s approval. For generator protection and protection panels for all 400 kV switchyard feeders, duplicated DC feeders shall be provided, one from each battery system.

1.22 The insulation level for the transformer windings and bushings shall be as

follows: Winding Bushing Highest System Rated Rated Rated Rated Voltage Power lightning Power lighting Freq. impulse freq. impulse withstand withstand withstand withstand

voltage voltage voltage voltage (kVrms) (kVp) (kVrms) (kVp)

7.2 kV 20 60 20 60 12 kV 28 75 28 75 17.5 kV 38 95 38 95 34.5 kV 95 250 95 250 420 kV 630 1300 630 1425

Note: for 400kV system switching impulse of 1050 kVp shall be considered.

1.23 Degree of protection Degree of protection for various enclosures as per IS: 13947 shall be as

follows:

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(a) 6.6 kV switchgear

i) VT/relay compartments - IP 52

ii) Other compartments - IP 42 iii) Switchgear in air-conditioned areas - IP 32 (all compartments)

(b) 400V switchgear / MCC / DBs / Fuse Boards

i) Compartments and busbar chambers - IP 52 upto 1600A ii) Compartments and busbar chambers - IP 42 above 1600A iii) All compartments in case switchgear - IP 32

in air-conditioned areas iv) Switchgear located out door - IP 54

(c) Busduct enclosure / GCB

i) Indoor portion including VT & SP cubicle - IP 52 ii) Outdoor portion - IP 65 iii) GCB - IP 65

(d) Motors

i) Indoor motors - IP 54 ii) Outdoor motors - IP 55

(e) Control and relay panel

i) In air-conditioned areas - IP 32

ii) In other areas - IP 52

(f) Transformers

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i) Indoor Transformers - IP 31 ii) Cable box - indoor area - IP 52 iii) Cable box - outdoor area - IP 55 iv) Indoor kiosks and marshalling boxes - IP 52 v) Outdoor kiosks and marshalling boxes - IP 55

(g) Push button stations and any other kiosk / box / panel / enclosure i) Indoor - IP 54 ii) Outdoor - IP 55

(h) Junction boxes for cables/wires - IP 55 (i) Outdoor lighting fixtures - IP 55 (j) Gen. Neutral grounding resistor - IP 22 (k) 6.6 kV Neutral grounding resistor - IP 33

1.24 FAULT LEVEL

Equipment through fault withstand capabilities under worst operating conditions duly taking into account tolerances on transformer, generator & maximum fault levels of source etc. shall be as follows :

i) All other transformers - 2 seconds

ii) Generator busduct main run, GCB, (higher of - 1 second generator or EHV system fault contribution) iii) Tap off run busduct (sum of generator and - 1 second EHV system fault contribution) iv) 6.6 kV Busduct - 1 second v) Switchgears - 1 second

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vi) Cables to the feeders protected by breakers Main protection fault clearing time with 0.16 seconds minimum vii) Cables of all other feeders As per fuse operating time viii) 6.6 kV cable screen - 2 seconds for the

adopted ground fault current ix) EHV systems - 1 second

1.25 Type Test

All equipment / systems to be supplied shall conform to type tests as per relevant standards / relevant chapters of this specification and shall be of proven type.

1.26 Communication System

For effective communication in the plant, public address system, private automatic branch exchange system (EPABX), radio paging system, walkie-talkie and P&T telephone system with the features described below will be provided:

a) Public Address System

This system will have paging and party channels comprising handset stations with amplifiers, transmitters, receivers, and loud speakers. This system will facilitate paging, communication and also private conversation as in conventional telephone.

b) EPABX System

This system will have adequate number of push button type handset stations, central automatic telephone exchange, etc. The handsets in the control room would be provided with priority service facility to enable them to have immediate access to any handset even if it is already engaged.

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c) Landline Telephones, Broadband connectivity

Necessary number of ISDN / PSTN landlines would be provided at strategic locations within the plant boundary. Broadband connectivity would be provided at strategic locations for online access of data from remote station.

d) Wireless System (Walkie-Talkie System)

Walkie-Talkie system will be provided for mobile communications. These systems will be of particular use during commissioning stage as well as subsequently during maintenance.

e) GPRS/CDMA mobile system of any reputed service provider can be provided for wireless system. The mobile system coverage in the power plant area should be 100%.

f) Interface between the EPABX, PA and Wireless systems shall be provided to enable communication between these systems.

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ELECTRICAL SYSTEMS - GENERATOR AND ACCESSORIES

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1.0 GENERATOR & ACCESSORIES

The generator and its accessories such as the cooling system excitation system, automatic voltage regulator, static start up systems for gas turbine generator etc. shall generally comply with the requirements specified in the national and international standards indicated as per Data sheet A 3.1 and shall additionally comply with the specific requirements of Data sheet A 3.1 and as indicated below:

1.1 Generator 1.1.1 The MW out put of generator of the Gas turbine generator unit and

Steam turbine generator unit shall be sufficient to evacuate the normal and peak power output of gas turbine power over the complete range of site ambient conditions specified in Section-B and at rated casing (Hydrogen) pressure and temperature.

1.1.2 The Maximum Continuous Rating (MCR) of the generator shall correspond to the maximum MVA, MW and minimum associated over-excited power factor that it is guaranteed to deliver continuously (without exceeding its specified temperatures or temperature rises at rated casing (hydrogen) pressure and temperature.

1.1.3 The generator shall be three phase, horizontal, two pole, cylindrical rotor, Wye connected machine with phase and neutral terminals brought out for connection to isolated phase bus duct. The generators shall conform to IEC60034-1, IEC60034-3 or other equivalent international standards. The generator shall be capable of satisfactory continuous operation at rated MVA and power factor at any voltage from 95% to 105% of rated voltage and within a frequency range of 47.5 to 51.5 Hz (and a combined frequency and voltage variation of 5%) even if frequency and voltage variations occur simultaneously, without exceeding safe temperature rises, but not necessarily in accordance with the standards established for operation at rated voltage and frequency. The generators shall be provided with Class-F insulation with temperature rise limited to that of Class-B at full load and at rated voltage & frequency. However, for abnormal operating conditions of voltage and frequency, the temperature rise shall in no case exceed that of Class-F when the machine is operating continuously at full load and at rated power factor at any working voltage and any frequency in the range stipulated above.

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1.1.4 The generator unit shall be capable of withstanding 3 phase short

circuit at the generator terminals when operating at rated MVA and power factor, 5% over voltage and with rated excitation for 3 seconds.

1.1.5 The line charging capability of the generator shall not be less than 30% of its rated MVA at zero power factor.

1.1.6 The generator shall be non-effectively earthed through a single-phase distribution transformer provided with secondary loading resistor. The sizing of the transformer and the value of the resistance shall be such as to restrict the maximum earth fault current to 1.5 times the capacitive current at normal working voltage. The generator shall be capable of operating alone or in parallel with other generators and / or utility grid.

1.1.7 The core of the generator shall be designed such that it permit the flow of earth fault current of at least 15 amperes for one (1) second without any core damage.

1.1.8 The generator phase and neutral side terminals shall be brought out

through seal off bushings. 1.1.9 The bearings shall be lubricated by oil from the turbine lube oil

system. Non-hygroscopic insulation shall be provided to prevent any damage due to the circulation of shaft current to the bearing surfaces and the lubricating oil.

1.1.10 At least one of the bearings shall be suitably insulated with

arrangements for checking the insulation resistance while the machine is in operation.

1.1.11 On-line shaft leakage current monitoring system shall be provided to

detect any leakage current through the shaft. Abnormal leakage current shall trigger an alarm in the control room.

1.1.12 The generator and its components shall be designed to avoid resonance over the entire range of operating frequency or their multiples.

1.1.13 The noise (sound) power level emitted by the generator as measured one (1) metre from the surface of the generator and at 1.5 metre height above floor level shall be limited to 85 dB(A).

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1.1.14 The generator unit shall be capable of withstanding the electrical, mechanical and thermal stresses developed during fast auto reclosing of high voltage line, transmission line switching, grid faults, out of step operation, out of phase synchronisation, etc.

1.1.15 The vibration severity when measured on generator and main exciter bearings shall not exceed 2.8mm / sec.

1.1.16 When tested on open circuit and at rated speed and voltage, the telephone influence factor of the turbine generator shall not exceed 1.5 %.

1.1.17 The generator winding shall withstand test voltage of 4 U + 5 (where U is the rated voltage in kV). Lightning arrestors of suitable rating shall be provided for the surge protection of generator winding. In addition to the above if surge capacitors are recommended, the same shall be included in the offer.

1.1.18 All components of the generator requiring inspection and maintenance shall be designed for easy access and replacement.

1.1.19 Resistance / thermocouple type temperature detectors shall be

provided where the highest temperatures are expected. The approximate number and location of temperature detectors shall be as follows:

(a) Twelve (12) duplex RTDs (Four per phase) distributed equally

around the periphery of the stator winding and also between three phases shall be provided. The geometry of the detectors shall be such that hot spots anywhere in the stator winding can be detected.

(b) Twelve (12) duplex RTDs for stator core out of which six shall

be located in the end zones where maximum temperatures are expected.

(c) Two (2) duplex RTDs for each hydrogen cooler section at inlet

and outlet (if applicable). (d) Two (2) thermostats per hydrogen cooler section for gas inlet

and outlet (if applicable). (e) Two (2) duplex RTDs for hydrogen cooler water inlet and outlet

(if applicable).

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(f) Two (2) duplex thermocouples per bearing. (g) Two (2) duplex RTDs for cold air temperature and two (2)

duplex RTDs each for air temperature in the exciter air passage and rectifier wheel along with thermostats for cold and hot air.

(h) Set of duplex RTDs and thermostats for shaft seal system (if

applicable).

(i) Rotor winding temperature measurement is also to be done through 2 Nos. of duplex RTDs located at the locations where the temperature is likely to be maximum.

(j) Additional RTDs / Thermocouples / Thermostats if required or if

required at additional locations shall be provided as found necessary.

1.1.20 All RTDs shall be of platinum duplex four wire type and shall have a

resistance of 100 Ohms at zero degree centigrade and calibrated as per DIN standards. Termination of RTD leads shall be at terminal box after grouping of signals. Terminal box shall be at an easily accessible position so as to enable maintenance / testing of the devices when the machine is under operation. Termination box of the temperature measuring devices shall be of IP-55.

1.1.21 All the above temperature measurement devices shall be hooked to DCS.

1.1.22 One (1) generator condition monitoring system shall be supplied

along with all piping and accessories to continuously sample the generator hydrogen for detection of thermally produced particulates / aerosols which indicates overheating.

1.1.23 Generator auxiliary system like cooling, excitation, hydrogen gas

handling system, etc., shall be provided with respective local control panels with required control, indication / annunciation and necessary main control system interfacings with DCS.

1.1.24 Generator rating shall be on the basis of continuous operation with guaranteed temperature, or temperature rises, not exceeding those given in IEC 60034-1.

1.1.25 Insulation and Temperature Limits

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The generator stator and rotor windings inclusive of main and neutral leads, shall be provided with Class F insulation but temperature rise shall be limited to class B. The maximum permissible temperatures of different parts of the generator shall be as specified in IEC-60034.

1.1.26 Short Circuit Withstand Capability during Unbalanced Faults The generator shall be capable of withstanding, without injury, any short circuit at its terminals provided the integrated product of I2

2t does not exceed the value stipulated in IEC60034-1, where I2 is per unit negative sequence current and t is the duration of fault in seconds.

1.1.27 Overload Capability With balanced current, the short time thermal capability of the generator armature shall permit operation at 150% of the rated armature current for at least 30 seconds, starting from stability temperature at rated load.

1.1.28 Capacity with one Gas Cooler Out of Service Hydrogen coolers would be built into the stator frame of the generator and would be sized to ensure at least 80% of the rated output continuously with 10% of tubes in each coolers are plugged and one of the hydrogen cooler is out of service then also the temperatures rises shall be limited to class B.

1.2 Stator Housing 1.2.1 The stator housing shall be of totally enclosed gas tight

construction, having sufficient mechanical strength and rigidity to withstand internal gas pressure, 100 percent vacuum and vibrations and also internal hydrogen explosion without any damage or permanent deformation.

1.2.2 Suitable numbers of trunions shall be provided for handling the stator by means of crane. The Bidder to clearly bring out in the proposal the features provided in the generator body construction to enable generator stator to be lifted/dragged in case of non-availability of suitable crane.

1.2.3 The housing shall have suitable provision for handling, lifting and / or jacking the stator. Manholes with sealing arrangement shall be

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provided at suitable locations to facilitate inspection of terminals, internals such as back of the core, end winding area, etc.

1.2.4 End plates of the generator frame shall be suitably shielded from stray flux. Stray current insulation shall be provided so that all paths of stray current will be broken at two places in series at one end of the generator with provision made for determining the insulation resistance at each place of insulation with the unit in operation.

1.2.5 The frame shall be stress relieved and then subjected to an extended hydraulic test at a pressure not less than 1.5 times the maximum design pressure.

1.2.6 All leads, including power, control and instrumentation shall be suitably supported to contain vibrations and shall be brought out of the generator housing to terminal boxes through gas tight seals. The instrumentation terminal box shall have IP55 protection class and shall be located at an easily accessible position so as to enable maintenance / testing of the devices when the machine is under operation. Location may be preferably on the TG Deck. A drawing indicating the location of the temperature detectors and the terminal box shall be enclosed with the proposal.

1.2.7 The dimensions of the generator stator body to be within the maximum permissible rail transportation dimensions within the country taking into account the special wagons available / being made available for transporting such heavy over sized consignment.

1.3 Stator Core

1.3.1 The stator core shall be fabricated out of high permeability best quality cold rolled silicon steel so that losses are minimum. The core assembly and mounting arrangement shall be such that the transmission of the forced vibration of the core to the housing and foundation is effectively restricted. The end packets shall be adequately strengthened to minimise the magnetic vibration due to end leakage flux.

1.3.2 The core assembly shall have adequate ventilation ducts for cooling by hydrogen. Press plates and fastening elements shall be made of non-magnetic material and shall be with proper locking arrangement.

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1.3.3 The stator core mounting arrangement shall be such that radial and tangential magnetic vibrations of the stator core due to electromagnetic loading transferred to stator frame are minimised. The stator core, frame and mounting shall be designed to avoid resonance at 50, 100 and 200 Hz.

1.4 Stator Winding

1.4.1 The stator winding shall consist of three phase, double layer, short chorded, bar type lap winding having two parallel paths. The strands making up the stator bar shall be Roebel transposed to minimise eddy current losses.

1.4.2 The winding and all connections inclusive of phase and neutral leads shall be insulated for full voltage to ground.

1.4.3 In order to reduce the corona in the slot and where the stator bar leaves the stator core, a surface treatment corona grading system shall be applied which shall be carried into the end turn area.

1.4.4 Firm seating of the stator bar in the slot shall be ensured by proper wedging and fillers. Ripple springs shall be provided below the slot wedges to compensate for any future shrinkage and ensure permanent firm seating of the bars in the slot during operation. The end turns shall be suitably braced and supported to withstand forces during normal operation and sudden short circuit at generator terminals when the machine is operating at rated MVA, power factor and permissible maximum over voltage.

1.4.5 The stator windings shall be designed for connection in single /double star with three (3) phase and three (3) / six (6) neutral terminals brought out.

1.4.6 At least six (6) numbers of vibration pickups at each end of over hang portion of the winding shall be provided, symmetrically located around the periphery with connection to Turbine Supervisory system. Provision shall also be made available to connect the same to DCS. Bidder shall wire up all the pickups to a junction box outside the generator casing.

1.5 Terminal Connection

1.5.1 All phase and neutral terminals shall be brought out from the top of the generator (non-drive end) and located in a non-magnetic steel terminal box. Phase terminal bushing shall be spaced to

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permit connection to isolated phase bus duct to provide complete phase isolation directly upto the generator housing. Adequate spacing shall be provided between phase and neutral bushings to permit connection of the neutral enclosure.

1.5.2 The bushing shall be preferably of porcelain type or of epoxy based material with non-hygroscopic property. The terminal bushing shall be cooled by suitable arrangement with cooling medium/system envisaged for the generator. Silver coated copper terminal connectors suitable for connection to the busduct through flexibles shall be provided for which the operating conductor temperature shall not exceed 105OC.

1.6 Rotor

1.6.1 The generator rotor shall be machined from a single alloy steel forging to ensure required mechanical strength and magnetic properties. Adequate margin shall be provided between critical speed and the running speed to ensure smooth running. Facilities shall be provided for inserting at least two radial and one axial probe into the rotor shaft for carrying out ultrasonic and residual stress measurements during the life of the rotor.

1.6.2 The forging shall be subjected to elaborate ultrasonic and mechanical tests to ensure freedom from any internal defect.

1.6.3 After assembly, the rotor shall be dynamically balanced and subject to 20% over speed for 2 minutes.

1.7 Rotor Winding

1.7.1 Rotor winding shall be made of hard drawn silver bearing solid copper conductors. Winding insulation shall correspond to Class-F (i.e. epoxy glass based material) with temperature limited to Class -B. Rotor winding shall be secured in the slots by suitable slot wedges and fillers. The overhung portion of rotor winding shall be held in position against centrifugal force by retaining rings when the rotor is running at upto 20% above its normal speed.

1.7.2 The retaining rings shall be machined from high strength, non-magnetic alloy steel forging with the material specification X8CrMnNi1818 resistant to stress corrosion. The retaining rings shall be floating type, shrunk on rotor body and prevented from axial movement by snap rings / locknuts.

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1.7.3 Suitable damper winding shall be provided on the rotor to permit increased asymmetrical electrical loading.

1.7.4 The rotor shall be suitable for operation without requiring

preheating of the rotor or rotor winding or pre-warming of the rotor forging.

1.8 Bearing

1.8.1 The generator shall be provided with self-aligning type sleeve bearings either mounted on separate pedestals or on the end shields. The bearings shall be of horizontally split construction and forced lubricated from turbine oil system. The bearing shells shall be lined with tin based babbitt metal. Oil buffers shall be provided to prevent leakage of oil and oil vapours along the shaft. All the intermediate support pieces of the bearing shall have complete interchange ability with those of similar type and size of TG bearing.

1.8.2 Non-hygroscopic insulation shall be provided between bearing and frame to prevent any damage due to circulation of shaft currents to the bearing surfaces and the lubricating oil. Arrangement shall be provided to measure the insulation of the generator bearing with the machine in operation. This shall be achieved by having two layers of insulation with a metallic plate in between. Build-up of shaft voltage beyond permissible limits as well as a short in the bearing insulation shall trigger an alarm.

1.8.3 Each bearing shall be provided with a well for thermometer in the return line and a sight glass with illumination to observe bearing oil flow. Redundant vibration pick-ups and transducers for bearing shall be provided. The vibration sensors shall be installed on X and Y dimensions. RTDs for measurement of metal temperature and bearing drain oil temperature shall be provided.

1.8.4 Provision shall be made for hydraulic jacking of the shaft during start up and turning gear operation.

1.9 Shaft Seals

1.9.1 Labyrinth shaft seals shall be provided. Shaft seals, preferably of double flow ring type shall be fitted to the end-shields to prevent hydrogen leakage from generator housing. To ensure effective sealing, seal oil pressure in the annular gap between the rotating shaft and seal ring shall be maintained at a higher level than the

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gas pressure in the generator casing. The face of the sealing ring shall be lined with babbitt metal.

1.9.2 The hydrogen side seal oil housing shall be provided with oil baffle rings to prevent intrusion of seal oil into the generator along the rotor shaft. Shaft seals and oil piping shall be suitably insulated to prevent circulation of shaft current. Arrangement shall be made to measure the insulation of the shaft seals while the machine is in operation.

1.10 Fans

Hydrogen shall be circulated in the generator in closed circuit by the axial fans located on rotor shaft. The fans shall be shrunk on to their seats on the rotor shaft and locked against tangential or axial movement.

1.11 Brushes

The rotor winding insulation and shaft voltage shall be monitored through a brush, suitably mounted and sliding on an oil free surface. Shaft grounding brushes shall be provided at the turbine end bearing pedestal. It should be possible to increase the brush pressure while generator is working. Brush holders shall be of constant pressure type, which can be adjusted as per requirement. Suitable insulation shall be provided to prevent passage of current through pressure device. Carbon brushes for the measurement of the rotor winding temperature is also to be provided on the oil free surface similar to the carbon brush used for shaft voltage measurement

1.12 Excitation System

1.12.1 Type

1.12.1.1 A complete generator excitation and voltage regulating system

shall be provided with the generator. The system shall be a brushless excitation system. The excitation system offered shall be of proven design and shall have a satisfactory field service record on machines of similar size and construction incorporating the type of excitation.

1.12.1.2 The excitation system shall have matching characteristics suitable for satisfactory parallel operation with other generators in the plant.

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1.12.1.3 The various change over relays and other equipment, which are

not controlled by the control supply required by AVR shall be such that the loss of their control supply does not lead to the excitation system outage.

1.12.1.4 The necessary inputs and interface equipment shall be provided

with Generator Excitation and Automatic Voltage Regulator for hooking up with Turbine Automatic Run up system and Electro Hydraulic Governing System.

1.12.1.5 The excitation system shall also meet the performance requirement specified hereinafter.

1.12.2 Performance Requirements

1.12.2.1 The excitation system shall have two (2) 100% channels including independent AVR’s, power converters and controls. Each shall be equipped for auto operation with the facility for selecting either channel in Auto or Manual mode.

1.12.2.2 The system shall function without hunting and shall be capable of preventing any abnormal change or oscillation in the generator voltage.

1.12.2.3 The system shall have high initial response to improve steady state and dynamic stability of the generator. The excitation system response time shall be less than 0.5 sec.

1.12.2.4 The excitation system shall be capable of maintaining generator voltage within + 0.5 % of the preset value over the entire load range of the machine. When the generator is subjected to a sudden loss of rated output at rated power factor, the system shall be capable of restoring the voltage within 2% of the nominal preset value within negligible time.

1.12.2.5 The reference voltage set point shall be adjustable over a range of 70% of no load to 110% of the nominal rated voltage at MCR.

1.12.2.6 The excitation system shall be rated to continuously carry current at least 20% above the rated generator field current at MCR output. The excitation system shall also be capable of supplying higher current to meet the short time duty mentioned above.

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1.12.2.7 The ceiling voltage shall not be less than 150% of the machine excitation voltage at MCR condition.

1.12.2.8 The system shall be capable of supplying the field-forcing requirement for at least 10 seconds even for close-in faults on high voltage outgoing lines or bolted faults at generator terminals.

1.12.2.9 The nominal exciter response ratio shall not be less than 2.

1.12.2.10 The excitation system shall have proper field suppression arrangement, so as to limit the voltages across the rotor winding to a safe value.

1.12.2.11 In excitation system monitoring facilities with self-diagnostic features to indicate faulty cards and abnormalities shall be available.

1.12.2.12 In case of failure of the PMG, the field of the main exciter shall be transferred to the supply derived from the auxiliary 400V station supply. This changeover shall be such that it does not result into the tripping of the generator.

1.12.2.13 An alarm shall be generated if the difference in the set point of the Auto-1 & Auto-2 is more than a ±0.5% with a 1sec time delay. i.e. failure in the follow-up circuit.

1.12.3 Automatic Voltage Regulator

1.12.3.1 Continuous acting, non dead-band type microprocessor based digital automatic voltage regulators with accessories mounted in a suitable panel shall be provided for the generator. The automatic voltage regulator shall be capable of working over the whole load and voltage range of the generator. All rectifying elements shall have over voltage and short circuit protection.

1.12.3.2 The automatic voltage regulating equipment shall control the generator voltage under steady state load conditions and over the whole of the operating range of the exciter within ± 0.5 percent of the setting value without hunting.

1.12.3.3 The voltage regulator shall be automatic, high speed, continuously acting, high response, digital type and shall be complete with the following limiters, compensators etc.

a) Maximum Excitation Limiter, adjustable type

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b) Maximum Stator Current Limiter (The stator current limiter shall act immediately in under-excited range. The time delay in over-excited range shall enable a temporary overloading of the machine)

c) Reactive Drop Compensator (Suitable feedback proportional to transformer drop shall be provided for compensation and the range of compensation shall be 0-15%)

d) Over Fluxing (volts / hertz) Limiter (To limit the ratio of generator voltage and frequency at all operating conditions to such a value that the maximum generator transformer core flux density does not exceed the value specified.)

e) Load Angle Limiter (This shall enable to keep the angle between the direct axis of the machine and network vector within the set reference value as determined by stability, by adjusting the excitation.)

f) Minimum Excitation Limiter

g) Adaptive Power System Stabiliser (PSS shall be suitable for damping the various modes of electro-mechanical oscillations at all frequencies in the range of 0 to 3 Hz under varying generator loading and power system network configurations. PSS shall automatically adapt itself to varying operating conditions with features to compute optimum stabilising signal along with suitable scheme for identifying external reactance of the generator. Facility for remote manual switch off-on along with indication shall be incorporated. Automatic supervision and Blocking/Switch off facility along with indications, etc. shall also be provided.)

h) Rotor Current Limiter (The regulator shall act with time delay, so that the regulation dynamics are not impaired in case of a fault.)

i) Ramp generation circuit to enable gradual rise of reference

signal applied to the comparator circuit to avoid sudden voltage build up shall be provided.

j) The channel reference control shall be either solid state control

or microprocessor control.

1.12.3.4 All the above conditions of limiter operations shall be annunciated

in local panel as well as in DCS. Local AVR panel shall be complete with necessary facia windows, sequence logic, power supplies, accept-reset-test push buttons, indicating lamps, control

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switches, local/remote switches, auxiliary relays and programmable logic controllers, etc.

1.12.4 Auto / Manual Channels

1.12.4.1 Two fully equipped independent automatic regulators with one acting as Master and the other as Slave shall be provided. On failure of the Master control, the Slave control, which follows the Master control, shall take over automatically. Either channel shall be capable of being the main or stand-by. Either channel shall be capable of being selected as manual also.

1.12.4.2 In auto mode, the range of regulation shall be 70% of no-load to 110% full load excitation. In manual mode the range of regulation shall be 0 to 110% of nominal rated voltage.

1.12.4.3 Automatic change over from Auto-1 to Auto-2 channel or vice versa shall be possible in case of trouble in the running channel. Automatic change over shall be possible from ‘Auto’ to ‘Manual’ in case of: 1. Generator protection circuit operation i. e. after field

forcing and over excitation condition with a time delay

2. Loss of terminal voltage feedback by way of any of the VT fuse blowing up

3. Faulty over excitation condition

4. Loss of automatic channel reference signal

5. Power supply failure in the automatic channel

6. Manual intervention

7. Any other condition as considered necessary by the Bidder

1.12.4.4 In order to avoid a sudden change in generator voltage when

voltage regulation is transferred from ‘Main’ to ‘Standby’ or from ‘Auto’ to ‘Manual’, a suitable arrangement shall be provided to follow up changes in ‘Auto’ mode along with follow up indication in Unit Control Panel. An alarm and visual indication shall be provided to indicate change over from Auto channel-1 to Auto channel-2 or from ‘Auto’ to ‘Manual’.

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1.12.4.5 The maximum change in generator voltage when AVR is transferred from Auto to Manual under all conditions of excitation shall be less than 0.5%.

1.12.4.6 A negative sequence component filter to permit response only to the positive sequence component of the regulated voltage shall be provided.

1.12.4.7 At least, the following instruments and control devices suitably clubbed on a plate/console shall be supplied for being mounted on unit control panel. Further, it shall be possible to exchange information with DCS through suitable protocol. 1. A center zero balance indicator to indicate the channel

difference signal

2. Generator field current indicator

3. Rotor winding temperature recorder

4. Auto Channel-1 to Auto Channel-2 & Auto/Manual changeover indications

5. Generator field breaker/exciter field breaker control & instrumentation

6. PSS control and instrumentation

7. Auto and manual channel control of excitation level

8. Speed set point control

1.12.5 Brushless Excitation System

1.12.5.1 The complete equipment shall be mounted on a bed plate and enclosed by suitable enclosure. The system shall consist of :

1. Permanent Magnet Generator (PMG) type Pilot Exciter.

2. Rectifier Unit for PMG

3. Brushless Main Exciter

4. Rotating Rectifier Unit

5. Regulator Cubicle

6. Complete instrumentation and protection system.

7. Inter-connecting cables between different components of the system

1.12.6 Pilot Exciter

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1.12.6.1 The pilot exciter shall be revolving field, salient pole, permanent

magnet high frequency type. The armature shall be stationary 3 phases feeding current to the static rectifier assembly and excitation control equipment. The rotor shall be magnetized and stabilised by the Manufacturer to give stable magnetisation characteristic during operation.

1.12.6.2 The stator winding shall be of class ‘F’ insulation or better but its temperature rise shall be limited to Class-B, suitable for operation at 500C ambient temperature. The machine shall be fitted with fans for self-ventilation.

1.12.7 Rectifier Unit for PMG

1.12.7.1 Fully controlled three phase, full wave bridge type thyristor converter facilitating fast and high ceiling performance shall be provided. They shall be suitable to ensure trouble free service of the cells under all fault conditions. The converter shall have redundant thyristors for satisfactory operation even in the event of failure of any of the thyristors. The thyristors shall be selectively protected against short circuits by ultra high speed fuses. Suitable lamp indication shall also be provided to indicate the defective ‘thyristor’.

1.12.8 Brushless Main Exciter

1.12.8.1 The rotating armature shall be 3-phase, star connected, feeding current to the rotating diodes mounted on the exciter shaft. The armature core shall be made from silicon sheet lamination to reduce eddy losses and shall be suitably varnished on both sides. The exciter shall be totally enclosed, self ventilated, frame supported on the generator foundation having journal bearings.

1.12.8.2 Integrally mounted air fan shall be provided for the cooling of the exciter.

1.12.8.3 The armature conductor in the overhang portion shall be adequately held to withstand the electro-dynamic forces during field forcing condition. Rotor end winding retaining ring shall be made up of stress corrosion resistant material. The stator and rotor winding insulation shall be of class ‘F’ with the temperature rise limited to class B limits of IEC 60034.

1.12.9 Rotating Rectifier Assembly

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1.12.9.1 The rotating rectifier assembly shall have the following essential

features :

1. The rectifier assembly made of silicon diodes shall be arranged as two distinct rings with opposite polarity diodes on respective rings.

2. The diodes shall be connected in a conventional three-arm full wave rectifier bridge. Rectifier assembly shall have one complete bridge as redundant. Alternatively a single three phase rectifier bridge having at least one redundant parallel rectifier branch in each of the six arms of the bridge may also be considered. Rectifier assembly shall have same requirements as regards the component features and rating as detailed out for the thyristor assembly.

3. Diodes shall be cooled by forced air circulation by means of fans mounted on the main exciter.

4. Each diode shall be provided with a fuse together with visual indication in the event of diode failure.

5. The output from the rectifier shall be fed to the generator field through the bore of the rotor shaft and necessary plug in type of shaft connection. The axial copper connector shall be designed such that it shall be possible to disconnect this connector at the point where the exciter shaft couples to the generator so that, if necessary, the generator and exciter can be tested individually.

1.12.10 Regulator Cubicle Self-supporting, sheet metal enclosed with swing doors and ventilating louvers with wire gauge shall be furnished for the excitation and voltage regulating equipment. Natural ventilation shall be provided for the cooling of excitation cubicles.

1.12.11 Instrumentation The instrumentation for excitation system shall generally include, but not be limited to the following:

i) Suitable duplex RTDs for measuring hot and cold air temperature of exciter with necessary provisions for protection tripping/interlocks.

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ii) Instruments and devices for the measurement of rotor winding temperature.

iii) Stroboscope or suitable alternative device for detection of faulty rotating diode element.

iv) Suitable arrangement for exciter field suppression.

v) A pair of auxiliary slip rings shall be provided to give access to the rotor circuit allowing an earth fault detector circuit to be connected.

vi) For all alarms in the system, contacts shall be taken from the temperature switches, etc. provided at suitable points. The system shall be provided with transmitters for the above indicators.

1.13 Hydrogen Cooling System

1.13.1 System Requirements

1.13.1.1 The hydrogen gas cooling system comprises a hydrogen circuit for

cooling the stator core, stator winding, lead terminal bushings and rotor windings, carbon-dioxide scavenging system and compressed air supply system.

1.13.1.2 The system is required to fill the generator with hydrogen, maintain it under pressure, monitor and control gas purity and to empty the hydrogen from generator. Also the system shall permit emptying of the generator casing with help of CO2 purging. The design has to be such as to ensure safe filling / emptying by preventing formation of explosive H2 – air mixture. For filling, air is first displaced by CO2, which in turn is replaced by H2. While emptying H2 is first displaced by CO2 before admission of air in the machine in order to obviate possibility of any explosion. For removing CO2, instrument quality air supply shall be used.

1.13.1.3 The major system components are H2 and CO2 gas manifolds, CO2

heating system, hydrogen pressure regulator, H2 gas coolers, H2 drying equipment, inter-connecting pipings, fittings, valves, gauges, thermometers, pressure transmitters and other instrumentations, control & monitoring panel. Annunciation and electrical instruments shall be located in a separate electric panel common with seal oil system outside the hazardous area.

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1.13.1.4 Hydrogen supply of 97-99% purity shall be obtained from H2 cylinders on rack through H2 distributor. The distributor shall be capable of connecting H2 cylinders to meet at least one shutdown & one start up of all the units & 30 days of normal operating requirement. Intermediate valves shall allow replacement of individual cylinders during operation. The high pressure H2 gas from the distribution header shall be provided with 2x100% pressure reducing valves. This shall be further reduced to generator pressure requirements by means of 2x100% pressure reducing circuit.

1.13.1.5 Hydrogen shall be circulated in the generator in closed circuit by fan fitted on the rotor shaft. H2 gas is cooled by water/gas heat exchangers located in the generator housing. The coolers shall be of sectionalised design such that with one cooler section out of service & 10% of the tubes in other sections are plugged, the unit can deliver at least 80% of the rated load continuously without exceeding the permissible temperature limits of class B.

1.13.1.6 The hydrogen coolers shall be provided with 10% excess tubes. Cooler shall be designed for at least 10 Kg/sq. cm. Gauge pressure on the gas side irrespective of a lower normal operating casing pressure.

1.13.1.7 Corrosion resistant tubes with integral fins shall be provided and arranged in the stator casing so as to avoid the direct fall of water during leakage, if any, on the winding insulation. It shall be possible to clean/plug the cooler tubes of a section with the machine under operation.

1.13.1.8 Water pressure in the coolers shall be maintained below the operating hydrogen pressure in the generator casing.

1.13.1.9 The generator drying arrangement complete with all electrical/mechanical drives/equipment, accessories and controls to enable drying out operation of the generator with hot air circulation shall be provided. The system shall be complete with necessary pressure, temperature and flow gauges as well as thermostats as required.

1.13.1.10 A certain quantity of H2 circulating in the generator shall be bypassed through gas drier for removing the moisture and maintaining the gas in dry condition. 2x100% capacity H2 dryers with in-situ reactivation facility shall be provided to maintain the H2 inside the machine dry with 0O C dew point at operating pressure.

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The arrangement shall be such that one drier can be taken out of service for reactivation without affecting the system performance in any way. Glass indicator shall be provided to indicate humidity.

1.13.1.11 To run the gas system for short time during shut down of generator (at standstill) for which gas circulation arrangement through drier with blower, piping valves and accessories along with required control equipment shall be provided. A suitable hot air blowing system complete with blower, heater and thermostatic control etc. shall be provided to prevent condensation during long shut down.

1.13.1.12 The design of the drier shall be such that it is possible to reactivate the drying medium in-situ after isolation from the generator casing and connecting it to atmosphere. Arrangement for purging out entrapped air from the drier after regeneration shall also be provided, as applicable. For controlling the time/regime of reactivation, suitable thermometers, thermostats, timers etc. with a local control panel shall be provided.

1.13.1.13 On line dew point monitoring system shall be provided across the inlet and outlet lines to the drying system along with alarm/annunciation in case of high moisture content in the generator casing hydrogen.

1.13.1.14 The cylinders of CO2 shall ensure complete emptying of the cylinders as well as to avoid evaporation of liquid CO2 to gas in cylinder itself. The arrangement of CO2 distributor shall correspond to that of H2 distributor. The CO2 shall leave the cylinder in liquid state and shall be evaporated and expanded in a vaporiser. Thermostat controlled electrical heating system shall be provided for CO2 system so that the freezing of CO2 pipe is prevented.

1.13.1.15 Seamless steel tubes shall be used for valve piping. Valves shall be glandless diaphragm type, wherever possible. The valves in gas system shall be of special design to minimise gas leakage. Safety relief valves shall be furnished at hydrogen manifold both on low and high pressure sides of the gas system. A manually operated vent valve shall be provided for discharging casing hydrogen to atmosphere (outside the TG hall) in case of emergency. The three way valves used along with the drier for interconnecting the hydrogen and airline (as applicable) shall preferably have mechanical interlocking such that closing of the hydrogen side port is positively ensured before opening of the air side port.

1.13.2 Instrumentation

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1.13.2.1 To ensure efficient and reliable operation of the generator gas

system adequate instrumentation shall be provided. This shall include the following as a minimum:

1.13.2.2 Dial type thermometers for CO2 vaporiser, and gas drier. Pressure gauges for gas cylinders, gas manifold, fan differential pressure, generator casings, gas flow meter. Required number of temperature, pressure and liquid level detector switches for alarm and interlock. Necessary sensors/transmitters for remote indication and recording in DCS. The local H2 panels shall include indicators for H2 gas cylinder pressure, H2 gas manifold pressure, generator casing pressure, H2 gas purity, H2 gas temperature (for hot and cold H2 inside casing), CO2 pressure inside generator, CO2 pressure in the manifold, air pressure in the air supply manifold and dew point level indicator for casing H2 across drier inlet and outlet lines. H2 pressure and purity shall be monitored in DCS. Gas Analyser shall be of thermal conductivity type and shall continuously analyse the gas discharged from the casing during purging and shall also analyse samples of the casing hydrogen during normal operation. The analyser shall measure the gas purity under the following three conditions: a) Normal % of purity of Hydrogen in air in the generator casing. Purity range shall include a low purity alarm. b) % of Hydrogen in CO2 leaving the casing when Hydrogen is being admitted or expelled. c) % of air in CO2 leaving the casing when CO2 is being admitted or expelled. Portable gas analyser as detailed above shall be provided for supervision of the gas purging operation. The Contractor shall provide instrument for on line monitoring of moisture content in hydrogen inside generator casing.

1.13.3 Annunciation

1.13.3.1 The following annunciation shall be provided on the local electric panel and DCS. The local control and annunciation panel shall be complete with switches, lamps, indicators, facia annunciation, power supply, accept-reset-test push buttons, hooter, etc.

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H2 Pressure in Generator Casing : High / Low

H2 Pressure in Cylinders : Low

H2 Pressure in Manifold : Low

Purity of H2 in Generator Casing : Low

Temp of Cold/Hot Gas in the Generator : High

Pressure of Cooling Water of H2 Coolers

: Low / High

Dew Point Level in H2 Gas across the drier inlet & outlet lines

: High

H2 Leakage into Cooling Water : High

Liquid Level in Generator Casing : High

Power / Control Supply : Failure

1.13.3.2 Independent signals, analog and digital, shall be connected to DCS

system. All instruments shall be mounted on a gas control cubicle to be located near the machine.

1.13.4 H2 and CO2 Cylinders

1.13.4.1 The number of H2 and CO2 cylinders shall be equal to total requirement for one start up and one shut down of a unit plus those required to be connected on manifolds of all units plus total requirements for seven days consumption of all units. The Contractor shall supply H2 and CO2 gas till completion of trial operation.

1.13.4.2 Getting necessary approval from chief controller of explosives is in the scope of the Contractor. The Contractor shall also furnish the necessary test certificates and filling certificates.

1.13.4.3 The cylinders to be supplied under this specification shall conform to IS:8198. Each gas cylinder shall be complete with cap and valve as per IS:3224. Volumetric (water) capacity of each cylinder shall be 45.0 litres. Each cylinder shall be hydro tested at pressure of 250 kg/cm² (min.).

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1.14 Generator Shaft Seal Oil System


1.14.1.1 A complete seal oil supply and control system including AC and DC motor operated pump sets, coolers, filters, pressure regulators, oil tanks, de-gassification tanks, regulating and control valves, gauges, thermometers and other instruments, interconnecting piping including hangers and supports, valves and control/annunciation panel complete with all interlocking relays shall be provided.

1.14.1.2 A shaft seal oil system shall be provided to prevent the leakage of hydrogen from the generator casing. The seal oil, when maintained at a pressure suitably in excess of the hydrogen gas pressure in the generator casing shall provide an effective gas seal and shall lubricate and cool the seals when the generator is running. Seamless steel piping shall be used in the system. A diaphragm operated regulating valve in the seal oil supply line shall control the seal oil pressure by a constant amount.

1.14.1.3 The differential pressure shall be kept constant once set at the time of commissioning, at all hydrogen pressures and all regimes of generator operation. The pressure regulator or the regulating valve used for the purpose shall be adjustable type.

1.14.1.4 The seal oil system shall be so designed that it is possible to run the machine at no load in air medium at a slightly positive air pressure without any modification in the system.

1.14.1.5 The seal oil shall be cooled in two (2) 100% capacity water cooled heat exchangers along with necessary 3 way valves for isolating or bringing one cooler in service. These coolers shall be shell and tube type suitable for using DM water of condensate quality.

1.14.1.6 Seal oil coolers shall be designed to have 15% excess tube surface area over and above designed tube surface area required for the rated load conditions while maintaining the design pressure drop on cooling water side. The oil pressure in the coolers shall be greater than water pressure under all operating conditions.

1.14.1.7 2x100% capacity filters shall be provided. Piping and valve arrangement shall be such that any cooler/filter can be taken out for cleaning and maintenance without affecting the operation of the system. Seal oil system shall have connection to turbine oil system

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for make up and also excess return and also shall serve as 100% back up.

1.14.1.8 For the seal oil system, 2x100% capacity motor driven AC pumps shall be provided of which one pump shall always be in operation. Upon failure of the normal service pump due to a mechanical or electrical fault, the standby pump shall automatically take over the supply. On of the seal oil pumps shall be fed from the emergency DG bus. Upon the failure of both AC driven pumps, the seal oil supply shall be taken over by the emergency DC seal oil pump without any interruption. The seal oil system shall thus be self-contained. The auto starting of standby seal oil pumps shall be interlocked with seal oil pressure.

1.14.1.9 During short time emergency, which may arise due to non availability of both AC & DC pumps, unit may be tripped and seal oil supply for such coasting down period shall be from a suitable arrangement from lubrication oil system or a damper tank.

1.14.1.10 The seals shall be designed so that minimum oil enters the hydrogen side of the machine and the oil drained from this part of the machine passes to a suitable hydrogen detraining tank. 2 x 100% Blowers for venting out Hydrogen gas liberated from oil shall be provided suitably mounted at places where such gas accumulation is likely to occur. Also H2 diffusion loss through seal oil shall be minimum to maintain H2 purity level inside generator at a high level. The hydrogen dilution blower shall have the following features:

HYDROGEN DILUTION BLOWER

Type - Centrifugal/Twin lobes

Capacity m3/hr By bidder

Air intake filter type - Simplex / Duplex type

Suction pressure Bar Atmospheric pressure

Discharge pressure Bar By bidder

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Mounting type - Skid mounted

MATERIAL OF CONSTRUCTION

Impeller/Lobes - AISI Type SS 316

Shaft - AISI Type SS 410 (Duplex SS)

Casing - AISI Type SS 316/ AISI Type SS 304/ 2% Nickel Cast Iron.

Base Plate - IS:2062 Gr.B with epoxy coated.

Prime mover details - 400V, 50 Hz & 3φ

Silencer - Shall be provided (If applicable)

Noise level dB(A) 85 @ 1.5 meter distance

Pressure drop across the lobes

mmWc By Bidder

Performance test Shall be conducted as per standard

1.14.1.11 Necessary hydraulic sealing arrangement shall be provided in H2 side oil discharge line to prevent circulation of gas due to any possible difference of heads developed by fans mounted at the end of the generator.

1.14.1.12 A water detector with sight glass and drain valves shall be mounted adjacent to the gas manifolds at the end of a pipe connected to the bottom of the generator casing.

1.14.1.13 The oil which is used for the hydrogen sealing shall be same as the lubricating oil for the turbine & generator bearing & governing system.


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1.14.2.1 To ensure efficient and reliable operation of the seal oil system adequate instrumentation shall be provided. This will include the following as a minimum: - i) Dial type thermometers for inlet and outlet temperature of the

seal oil and cooling water to each cooler.

ii) Pressure gauges at inlet and outlet of pumps, at outlet of coolers, at inlet and outlet of pressure regulators and filters, seal oil inlet to hydrogen and airside seals, hydrogen-casing pressure, across each strainer and H2 seal oil differential pressure and at oil supply header.

iii) Seal oil tank level indicator and flow meters for flow through seals.

iv) Required numbers of temperature, pressure and level gauges for alarms and interlocks. Necessary sensors / transmitters for remote indication and recording in DCS.

1.14.2.2 Local seal oil control panels shall be provided with indicators for

pump discharge pressure, seal oil pressure at the seals (for both hydrogen and air side streams), thrust oil pressure, hydrogen / seal oil differential pressure, seal oil flow, seal oil temperature at the seals and status indications for seal oil pumps.

1.14.2.3 The remote instrumentation at Unit Control Room shall include seal oil temperature recording and seal oil / H2 differential pressure recording in DCS.

1.14.3 Annunciation

1.14.3.1 The following annunciations shall be provided on the local electric panel and in DCS system.

Seal Oil Tank Level : High / Low / Very Low

Seal Oil Temperature : High

Pressure of Seal Oil : Low

Pressure of Thrust Oil : Low

Seal Oil H2 Differential Pressure

: High / Low

Oil Level in Damper Tank (if applicable)

: Low

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Oil Level in Damper Tank – Emergency (if applicable)

: Very Low

Oil Level in Hydraulic Seal : High

Oil Level in Hydraulic Seal : Low

Seal Oil Filter : Choked

Seal Oil Pump : Failure

Standby Seal Oil Pump : Running

DC Seal Oil Pump : Running

AC Seal Oil Motor Power Supply

: Failure

DC Seal Oil Motor Power Supply

: Failure

Power / Control Supply : Failure

Seal Oil Cooler Water Pressure

: High / Low

Seal Oil Cooler Water Temperature.

: High / Low

1.14.3.2 All annunciations shall be duplicated in the Unit Control Room. For this purpose, separate alarm contacts shall be provided. Independent signals, analog and digital shall be made available for connection to DCS system.

1.15 Stator Water Cooling System


1.15.1.1 Generator stator winding shall be cooled by water. Water cooling shall be with a closed loop cooling system. The system shall generally include but not be limited to the following:

1.15.1.2 One (1) number primary water tank shall be provided and mounted on the stator frame on anti-vibration pads and covered by the generator cladding. The empty space in primary water tank may be filled with Nitrogen to minimise water evaporation. The Bidder shall indicate and provide devices to detect, trap, monitor and release the

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hydrogen that leaks into the stator water cooling system, to a safe place outside the building through suitable safety valves.

1.15.1.3 The make-up water for primary water system shall be tapped off from condensate extraction pump discharge header (before and after the condensate polisher) and from DM water make-up line to the condenser. The level in the tank shall be maintained by means of suitable valves in the make up line.

1.15.1.4 Two (2) 100% capacity water to water heat exchangers shall be provided. The water-to-water heat exchanger shall be designed to accept secondary DM water (condensate quality). The system shall be so designed that the pressure of primary DM water inside the cooler is always greater than that of secondary DM water (condensate quality). The exchanger shall be designed to have 10% excess tube surface area over and above the designed surface area required for the rated load condition while maintaining the design pressure drop on cooling water side.

1.15.1.5 Two (2) 100% capacity fine wire mesh filters with magnet bars of unlimited life shall be provided for removal of all magnetic particles. The permanent magnet bars shall be protected by sleeves of stainless steel. It shall be possible to clean easily the ferromagnetic particles adhering to the magnet bars during capital maintenance.

1.15.1.6 Two (2) 100% capacity AC motor driven cooling water circulating pumps shall be provided. Standby pump shall cut in automatically in case the working pump fails or the pressure of circulating water drops below a certain preset value.

1.15.1.7 One (1) mixed bed demineraliser (MBD) of adequate capacity shall be provided to maintain the required quality of water. The MBD shall remain continuously in service in order to retain high purity of stator cooling water with its associated electrical resistivity. The Bidder shall indicate in the proposal the capacity of MBD necessary to maintain the quality water at the desired level for time duration of six months or more. The system shall be designed such that the MBD could be taken out of service for refilling without untoward effect on the system which could necessitate load reduction/rejection.

1.15.1.8 Alkaliser unit shall be provided alongwith stator water required for ensuring a corrosion free operation system.

1.15.2 Control System

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1.15.2.1 The following instruments shall be provided on the local panel :

1. Indicator for primary water flow in the stator winding.

2. Indicators for primary water conductivity at the inlet of winding and after the demineraliser.

3. Indicator for stator winding differential pressure.

4. Indicators for primary water temperature at the inlet and outlet of stator winding.

5. Indicator for primary water pressure at the inlet of stator winding


1.15.3.1 The following minimum instrumentation shall be provided :

1. Set of conductivity meters in the main water circuit and

after the demineraliser.

2. Set of flow switches (at least two nos.) to monitor the low distillate condition and flow transmitters/meters for primary water to stator winding and main bushing, make up water etc.

3. Sets of pressure gauges at the inlet and outlet of stator water filters, differential pressure switches for the filters, differential pressure gauge across stator winding and pressure transmitters as required.

4. Set of resistance temperature detectors/indicators for primary water before and after the generator winding, bushing and cooler. Vapour filled temperature detectors shall also be provided to give signals for high temperatures.

5. Set of dial type thermometers for cooling water at the inlet and outlet of the cooler.

6. Water gauge, transmitters, level switches for high and low level alarms and other accessories for primary water tank.

1.15.4 Annunciations

The following minimum annunciations along with duplicate contacts for use in DCS shall be provided:

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1. Water level in the primary water tank - low.

2. Water level in the primary water tank - high

3. Temp. of primary cooling water at outlet of stator wdg. - high.

4. Temp. of primary cooling water at inlet of stator wdg. - high.

5. Flow of primary cooling water to the stator winding - low.

6. Conductivity of primary cooling water at the winding inlet - high.

7. Flow of primary cooling water to the stator winding - very low.

8. Conductivity of primary cooling water at the winding outlet - high.

9. Pressure of primary cooling water at the inlet of winding - low.

10. Differential pressure across the primary water strainer - high.

11. Stator water cooling pumps - tripped on overload.

12. Reserve control supply for stator water cooling - failed.

13. Differential pressure across stator winding - high.

14. Leakage of hydrogen into primary water - high

15. Primary stator bar water temperature - high.

16. Any other critical parameter to be annunciated

A “summary annunciation” for the above shall be provided on the unit control panel

1.15.5 On line stator water temperature monitoring system for individual

stator winding bars shall be complete with all software and hardware required to detect any abnormalities in the temperature at any given generator operating point and shall be sensitive to generator loads, header water flows, pressure etc. and shall be possible to exchange information with DCS through suitable protocols.

1.15.6 On-line oxygen monitoring system shall be provided, if the manufacturer recommends continuous monitoring of dissolved oxygen content in the stator water, to prevent copper corrosion.

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1.15.7 Liquid leakage detector shall be provided at all the low level points inside the generator casing including end shields along with provisions of indication and alarm during leakage of liquid in generator.

1.15.8 Stator coolant flow recorder shall be monitored in DCS.

1.16 Cubicle and Motor Starters

1.16.1 Cubicles shall be furnished as required for (a) Excitation System, (b) Automatic Voltage Regulator (c) Hydrogen Cooling System (d) Seal Oil System (e) Stator Water Cooling System, (f) DC Motor Starters.

1.16.2 The panels shall be of the self-supporting, floor-mounted type. The panels for DC Motor starters shall house stainless steel starting resistors.

1.17 Measurement / Alarms in Control Room

1.17.1 Each alarm shall be individually available on the DCS HMI whereas set of alarms can be grouped into a group alarm on the window of Local Control Panel. All the required relays / contacts / devices shall be provided to achieve the same.

1.17.2 All the measurements shown in the protection and metering one line diagram TCE.5960A-EL-SK-2002 shall be made available in DCS and also in Local Control Panel.

1.17.3 The continuous measurement of the rotor winding temperature while the machine is running shall be provided in DCS.

1.17.4 The turbine generator control VDU in the central control room shall have graphical display of various generator subsystems, process/flow diagrams such as seal oil, hydrogen, lube oil, generator stator and rotor parameters along with display of generator capability curves and operating points, generator temperatures and vibration parameters, etc. They shall also have limiting values for alarm/trips, tag numbers, etc. clearly displayed on DCS. In addition operator help features for control of these systems and historical and reference data shall also be made available for efficient operator guidance of these systems. All inputs including logics for recommended control and instrumentation system required to integrate with artificial intelligence based software’s pertaining to generator and its auxiliary system shall be furnished.

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1.17.5 On line partial discharge measurement system.

Permanently connected Independent sensing unit for each generator shall be provided. However evaluation unit for all generators shall be common. Latest software shall be provided to interpret the PD result. It shall also be suitably connected to DCS.

1.18 Gas Turbine Generator Unit Start-Up System 1.18.1 2 nos. Static start-up system for gas turbine unit complete in all

respects shall be offered. Additional thyristors in converter / inverter units to take care of thyristor failure, redundancy for critical items and self monitoring features.

1.18.2 The voltage to frequency ratio of the start-up system output shall be

maintained constant throughout the start-up and shall not lead to overfluxing condition of generator transformer and neutral grounding transformer. Over fluxing shall be limited to 110%.

1.18.3 The current transformers (CTs) in the busduct and voltage

transformers (VTs) shall not temporarily or permanently saturate even after successive starts through the start-up system. Also, the protections shall not mal-operate during gas turbine starting.

1.18.4 The Contractor shall note that all the protection shall be set for

normal operation of the plant and the settings will not be altered during start-up. To this extent the Contractor shall provide suitable protections on the start-up system output to protect the generator, CTs, VTs, etc., and cut off the start-up system in the event of operation of these protections.

1.18.5 In case any of the protections are to be blocked during start-up

operation due to likelihood of mal-operation, the Contractor shall provide suitable blocking and de-blocking signals from the start-up system. Both these signals shall be suitably supervised and annunciated.

1.18.6 Minimum electrical system requirements in respect of control,

monitoring, measurement, annunciation, synchronising are indicated in I&C System Section No. D2.4.

1.19 Tests

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1.19.1 Tests on Generator 1.19.1.1 The following Routine Tests shall be carried out at works on each

generator:

i) Measurement of insulation resistance of the following before and after high voltage test:

a) Stator Winding Insulation

b) Rotor Winding Insulation

c) Embedded Resistance Temperature Detectors

d) Bearing Pedestal Insulation

ii) Polarisation Index for Stator Winding Insulation.

iii) Tan-delta measurement of Stator Winding Insulation.

iv) Measurement of the DC resistance of the following:

a) Stator Winding

b) Rotor Winding

c) Embedded Resistance Temperature Detectors

v) Determination of generator open circuit characteristics, short circuit characteristics and calculation of short circuit ratio.

vi) Stator Phase Sequence checking.

vii) Measurement of Core Losses

viii) Measurement of Mechanical Losses

ix) Determination of generator efficiency by the separation of losses at 100%, 80% and 60% load.

x) AC High Voltage Test on Stator and Rotor Winding

xi) Measurement of Rotor Winding Impedance at standstill and at various speeds upto 3000rpm.

xii) Measurement of phase to neutral and phase to phase capacitance of all the three phases of the stator and the rotor and calculation of the equivalent generator capacitance as viewed from the generator terminals; also the measurement of the capacitance between the complete winding and the body.

xiii) Measurement of bearing leakage current / shaft voltage.

xiv) Overspeed Test

xv) Mechanical Run and measurement of Vibrations

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xvi) Retardation test to establish GD2

xvii) Hydrogen leakage test

xviii) Partial discharge tests on stator windings. 1.19.1.2 The field tests to be conducted on each generator at the site shall

include but not be limited to those listed below. Any other test considered necessary by the bidder shall also be carried out :

i) Measurement of insulation resistance of the stator and the

rotor windings to the frame and between phases, after drying out the machine, and measurement of polarisation index.

ii) Measurement of the DC resistance of all windings and embedded temperature detectors.

iii) Measurement of the insulation resistance of bearings

iv) Capacitance measurement and dissipation factor between the winding and body.

v) Open circuit and short circuit tests.

vi) Measurement of temperature rise at the rated load.

vii) Performance capability of the machine.

viii) Line charging capacity

ix) Short Circuit tests on the generator end and the generator transformer HV end to check the stability and operation of the generator and the overall (i.e. generator, generator transformer and unit auxiliary transformers) differential protections and negative phase sequence protection. These tests will be carried out jointly with the commissioning engineers of other vendors whose equipment are under test.

x) Hydrogen leakage test

xi) Vibration test

xii) Overspeed test

xiii) Hydraulic tests on coolers

xiv) Bearing and shaft current test

1.19.1.3 One generator of each type and rating shall be assembled at works

and shall be tested to verify/ensure design and workmanship in accordance with IEC-60034/VDE-0539/IEEE-43. The tests shall be carried out keeping all conditions/parameters as close as possible to site conditions with all the built in instrumentation (like RTD etc.)

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suitably wired and the readings recorded. During various tests bearing, shaft overhang vibrations shall also be measured with and without excitation. Recording of bearing and seal oil running conditions and environmental conditions (like temperature etc.) shall also be done. The tests to be carried out under the contract shall include the following :

i) Instantaneous short circuit test shall be carried out to

determine transient and sub-transient reactance parameters and to ensure stability of winding during sudden short circuit condition.

ii) Determination of negative sequence and zero sequence impedance.

iii) Determination of Telephone Influence Factor and Total Harmonic Distortion of the voltage waveform.

iv) Short circuit heat run test at rated pressure and cooling parameters with one cooler out of circuit at two third of rated stator current.

v) Vibration measurement on all planes on stator overhang winding at minimum six (6) locations on each end and at other critical locations for the following conditions :

a) Open circuit operation.

b) Short circuit operation.

c) Sudden short circuit conditions.

d) Stand still condition- with hammer test.

The test results of above shall prove that the values are within the normal operating limits for long satisfactory performance and that there are no components or parts, which have natural frequency of resonance near operating frequencies or 100Hz.

1.19.2 Tests on Exciter and AVR 1.19.2.1 The following Routine Tests shall be carried out at works on each

exciter and AVR:

a) Pilot Exciter (PMG)

i) Measurement of output voltage at rated speed

ii) Checking of phase sequence and measurement of frequency

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iii) Measurement of load characteristics

iv) Measurement of insulation resistance and high voltage test on stator winding

v) Measurement of DC resistance of stator winding

b) Main Exciter (Brushless Exciter)

i) Measurement of open circuit characteristics

ii) Load magnetisation characteristics

iii) Measurement of insulation resistance and high voltage test on armature and field winding

iv) Measurement of DC resistance of armature and field winding

c) Voltage Regulator

i) Response ratio test

ii) Insulation resistance and high voltage test

iii) Performance test at reduced supply voltage

iv) Auto –1 / Auto –2 channel follow up test

v) Auto – Manual channel follow up test

vi) Thyristor load test (light load test at rated voltage and full current test)

vii) Functional tests

1.19.2.2 The field tests to be conducted on each AVR at the site shall include but not be limited to those listed below. Any other test considered necessary by the bidder shall also be carried out :

i) Accuracy test ii) Sensitivity test iii) Performance tests on all limiters iv) Impulse input response test v) Auto –1 / Auto –2 channel follow up test vi) Auto – Manual channel follow up test vii) Range of voltage adjustment for both auto and manual

channels viii) Functional tests

1.19.2.3 The following type tests on Brushless excitation system of one

machine of each rating shall be conducted.

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a) Main Exciter : Temperature rise test at peak rating of

excitation system and ceiling duty condition shall also be demonstrated.

b) PMG : Temperature rise test at peak rating of excitation system shall be demonstrated.

c) Field Breaker : Type tests on exciter field breaker shall be conducted as per IEEE/ANSI C 37-18.

d) Converter Assembly (of the exciter field) :

i) Temperature rise test at peak rating of excitation system and ceiling duty condition shall also be demonstrated.

ii) Input and output surge withstand capability test.

iii) Soak test for electronic modules.

e) Voltage Regulator :

i) Soak test on electronic equipment

ii) Surge withstand capability test on electronic equipment 1.19.3 The following test to be conducted on startup system

a) SFC panels i) Temperature rise test

ii) Surge withstand capability test iii) Noise level test

b) SFC Transformer

The following type tests shall be conducted on one transformer

i) Tank Pressure test ii) Tank vacuum Test iii) Short circuit test on one transformer to be selected by

Owner.

iv) Noise level

v) Measurement of harmonics of no load current

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vi) PRD operation test vii) Degree of protection test on marshalling box viii) Zero sequence Impedance ( not applicable for Delta-

delta transformer) ix) Temperature rise test x) Lightning impulse test on one limb xi) DGA test on oil before and after temperature rise test

1.19.4 All components of the excitation system shall be tested in accordance with the relevant standards and type and routine test certificates shall be furnished.

1.19.5 All Type and Routine test certificates shall be furnished to the

Owner for review and approval.

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SECTION: D3.1

DATA SHEET – A3.1 SHEET 39 OF 42

SL. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS

REV. NO. R0 PPD. BY RKD JOB NO. CLIENT : APPDCL DATE MAR’ 10 CKD.BY HA 5960A PROJECT : 700MW CCCP AT

NEDUNOOR, KARIMNAGAR DIST.

REV. BY DATE

SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3 TATA CONSULTING ENGINEERS LTD

1.1 Generator and Excitation System 1.2 Rated Output Ref clause 1.1.1 1.3 Rated terminal voltage By Bidder 1.4 Rated frequency Hz 50 1.5 (a) Rated power factor 0.85 (lagging) (b) Power factor variation 0.85 (lag) to 0.95(lead) 1.6 No. of phases 3 1.7 Continuous operation under As per IEC: 60034-1 unbalanced load 1.8 Stator winding connections Star 1.9 Speed rpm 3000 1.10 Type of cooling (a) Stator Winding Water (b) Rotor Winding and Stator Core Hydrogen

1.11 No. of line terminals to be brought out Nos. Three (3) 1.12 No. of neutral terminals to be Six (6)-(In case of split brought out phase winding and having more than one conductor per phase or else three (3) ) 1.13 Rated short circuit ratio at MCR not less than 0.5 1.14 Operation under unsymmetrical As per IEC-60034-1 fault 1.15 Class of insulation of generator Class F (temp. rise limited stator and rotor windings to that of class B)

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REV. BY DATE

SPEC. NO. TCE.5960A-H-500-001


1.16 Degree of protection for generator IP-54 enclosure 1.17 Excitation system response ratio Minimum 2.0 1.18 Excitation system response time sec. <0.5 1.19 Accuracy of Gen. Terminal voltage % <+0.5 1.20 Manual channel shall follow auto % <0.5 channel within 1.21 Telephone harmonic factor % shall not exceed 1.5 1.22 Field forcing capability during bolted fault on generator terminals % Minimum 150 1.23 Type of voltage regulator Two auto and one manual channel, Solid state, continuously adjustable 1.24 Space heaters for generator Required (to be switched on automatically when turbine is shut down) 1.25 Maximum amplitude of vibrations As per VDE 2063 and shall meet (peak to peak) requirements as per respective gas turbine and steam turbine sections. (Bidder shall indicate). 1.26 Noise level from the surface of As per IEC 60034 shall meet the equipment requirements as per respective gas turbine and steam turbine sections (Bidder shall indicate) 1.27 Limiters, compensators, monitoring devices for generator excitation system 1.27.1 Minimum excitation limiter Required

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REV. BY DATE

SPEC. NO. TCE.5960A-H-500-001


1.27.2 Maximum excitation limiter Required 1.27.3 Maximum rotor current limiter Required 1.27.4 Under/over excitation limiter Required 1.27.5 Maximum stator current limiter Required 1.27.6 Cross current compensator Required 1.27.7 Overfluxing (V/Hz) limiter Required 1.27.8 Load angle limiter Required 1.27.9 Transformer drop compensation Required (adjustable between 0% & 15%) 1.27.10 Power system stabiliser Required 1.27.11 Two stage Field suppression facility Required 1.27.12 Two stage Field earth fault monitor Required 1.27.13 Automatic power factor controller Required 1.27.14 Motorised manual control for remote parallel operation Required 1.27.15 Manual control range of AVR 70% of no load to 110% full load of voltage range 1.28 Number of RTDs/Thermo-couples Ref. clause 1.1.20 required for generator 1.29 Efficiency at 100% load at rated As per IS-4899 power factor 1.30 Maximum Inlet Temperature 0 C 350 C of Cooling Water available for Hydrogen / Air coolers 1.31 Type of cooling water available DM water

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REV. BY DATE

SPEC. NO. TCE.5960A-H-500-001


for Hydrogen coolers / Air coolers / water coolers (ordinary water / sea water) 1.32 Codes and Standards 1.32.1 Specification for rotating electrical machines - rating & performance IS-4722 and IEC-60034-1,3 1.32.2 Guide for testing synchronous IS-7132 machines 1.32.3 Method of determination of efficiency of rotating electrical machines IS-4889 1.32.4 Measurement and evaluation of vibration of rotating electrical machines IS-12075 1.32.5 Methods for determining IS-7306 and synchronous machine quantities IEC-60034-4/4A from tests

1.32.6 Degree of protection provided by enclosures for rotating electrical machines IS-4691 and IEC-60034-5 1.32.7 Methods for cooling rotating IS-6362 and IEC-60034-6 machinery 1.32.8 Terminal markings and direction of rotation of rotating machines IEC-60034-8

1.32.9 Method of measurement of airborne noise emitted by rotating electrical machines IS-6098 and IEC-60034-9

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ELECTRICAL SYSTEMS - GENERATOR CIRCUIT BREAKER

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2.0 GENERATOR CIRCUIT BREAKER 2.1 Generator circuit breaker shall be provided in single phase

enclosures, all fully assembled on a common frame with operating mechanisms, supervisory and control equipment.

2.2 The voltage class of the Generator circuit breaker shall be same as

that of the generator. 2.3 The continuous current rating of the Generator circuit breaker shall

be arrived at considering the maximum output of the generator and at specified minimum voltage.

2.4 The Generator Circuit Breaker (GCB) is installed indoor / outdoor

and connected to Generator busduct (Isolated Phase) on both sides. Suitable provisions shall be made for connection with Isolated Phase Busduct (IPB) through flexible connection.

2.5 The GCB movement during short circuit shall be restricted so as to

limit the stresses on GCB support insulators within their capabilities.

2.6 Support structure shall be designed to withstand the dynamic as

well as static load of the GCB. Design calculations of support structure shall be furnished for Owner's approval.

2.7 The Generator circuit breaker shall be integrated with series-

disconnector, current and voltage transformers, grounding switches, surge arrestors and protective capacitors in three single phase enclosures, as shown in attached Main one line diagram TCE.5960A-EL-SK-2003.

2.8 The short time and momentary current rating of the Generator

circuit breaker shall be decided as follows: (a) Short time current rating for 1 second:

(i) Higher of the short circuit current contribution from

generator or the short circuit current contribution from 400 kV system through generator transformer (400 kV system fault level 50 kA)

Plus (+)

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(ii) Contribution of 6.6 kV auxiliary system through unit auxiliary transformers.

(b) Momentary current rating:

2.55 times the short time current rating arrived as above.

2.9 The basic switchgear module shall include the following minimum equipment but shall not be limited to the same.

a) Circuit breaker with disconnector for series isolation on

Generator Transformer side. b) Grounding switches fitted both sides of unit and to all three

phases. c) Generator side current transformers with upto two cores per

phase towards GT side. d) Voltage transformers with two secondary windings; two per

phase on generator side, one per phase on transformer side. e) Protective capacitors fitted to both sides of the unit and to all

three phases. f) Surge arrestor with surge counter on generator transformer

side g) 0.25μF surge capacitor on either side of circuit breaker as shown in

the Main SLD. h) Supporting structures and suitable platform.

2.10 The system shall be extended by all of the following items:

a) A switched (motor operated) short circuiting connection between the power circuit breaker and the series disconnector for maintenance and protection checking.

b) A manually fitted grounding link for the above short circuiting connection.

c) An isolator for the SFC connections

The accuracies of the CTs & PTs shall be as per the enclosed Main one line diagram TCE.5960A-EL-SK-2003. The CTs and VTs shall not temporarily or permanently saturate even after successive starts through the start up system. Also, the protections shall not mal-operate during gas turbine starting.

2.11 The GCB shall be of SF6, metal enclosed, indoor / outdoor and free standing type. It shall be provided with three pole gang operation

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and anti-pumping feature. All the three poles shall operate simultaneously. If all the poles do not close simultaneously the breaker shall trip on pole discrepancy. The Generator circuit breaker shall use SF6 gas both as its arc-extinguishing medium as well as for internal insulation. It shall be designed with separate contact systems for the current breaking and current carrying functions. Semaphore position indicators shall be provided for local indication of the position of the circuit breaker.

2.12 The GCB enclosure shall be non-magnetic aluminium alloy,

minimum flux, and isolated phase type with degree of protection IP-65 and canopy shall be provided if installed outdoor.

2.13 Insulators shall be of high strength, fine glazed porcelain or epoxy

resin type. 2.14 SF6 gas monitor for each phase shall be provided. Necessary

interlocks are to be arranged to prevent breaker operation on fall of SF6 gas density.

2.15 A series disconnector shall be fitted on the outgoing side of the

circuit breaker and within the same enclosure. The disconnector shall be of a tubular telescopic unit with the moving contact tube connected on the transformer side, the fixed contact being on the circuit breaker side of the unit.

2.16 Grounding switches shall be provided on both sides of the

switchgear unit. The connections and the switches shall be rated for full fault current. The ground connections shall be made via the switchgear enclosure to the housings of the isolated phase busbars and then to their grounding connection.

2.17 The short circuiting disconnector and its connections shall be

designed to expedite the testing and adjustment of the power plant protection system. Closure of the disconnector shall establish a three phase short circuit on to the generator connections but without ground to save time, both during initial commissioning, as well as, when routine testing the protective relaying.

2.18 The Main One Line diagram enclosed indicates the relays and

meters to be connected to the current transformers and voltage transformers. The VA burden, knee point voltage, secondary resistance and the exciting currents of CTs and VA burden of the VTs shall suit the connected metering/protective equipment.

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2.19 Locking bars or effective mechanical arrangement shall be provided to lock main and auxiliary contact in the open position to prevent inadvertent closing either in main breaker or on disconnecting switch.

2.20 Duplicate shunt opening release coils suitable for operation with voltage upto 60% of rated voltage of coils along with status monitoring shall be provided.

2.21 If the offered breaker is pneumatic operated then, on loss of compressed air supply breaker shall get locked in its current state.

2.22 In case of pneumatic operating mechanism compressed air plant shall be provided with 2x100% compressors. Driers shall also have same capacity. Capacity of each high pressure receivers shall have stored energy for 2 close-open operations. Capacity of local air receivers shall meet one close-open operation.

2.23 In case of hydraulic mechanism, the stored energy shall be suitable for two close open operations. The breaker shall have 2 x 100% hydraulic pumps. The bidder shall clearly bring out the details in respect to this offer.

2.24 The operating mechanisum shall be spring operated both for closing

and tripping operations. The stored energy in the spring shall be sufficient to permit at least two close-open operations. The spring charging motor shall be suitable for 220V DC and shall be fed from respective Unit DCDB. The spring charging motor shall be capable of charging the spring within 30 secs.

2.25 The minimum number of auxiliary potential free contacts required to

be wired up to the terminal strip for PURCHASER’s use after BIDDER’s use in all Control and Protection circuits shall be :

12 NC + 12 NO for Circuit Breaker 8 NC + 8 NO for Disconnector 8 NC + * NO for each Earthing Switch Contact wear monitoring shall also be offered along with the GCB.

2.26 Local control panel shall be provided near GCB to facilitate Local ON/OFF Control, status indication, alarm and annunciation of the breaker and all auxiliary equipments shall also be located in local control panel. Local control panel shall include a Local/Remote selector switch.

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2.27 The GCB shall be suitable for synchronizing duty and capable of withstanding out of phase voltage across open contacts. The breaker shall also be capable of switching on to a fault and out of phase switching.

2.28 Main contacts shall have ample area and contact pressure for carrying the

rated current and the short time rated current of the breaker without excessive temperature rise which may cause pitting or welding. Contacts shall be easily replaceable and shall have a minimum of movable parts and adjustments to accomplish these results. Main contacts shall be the first to open and the last to close so that there will be little contact burning and wear.

2.29 Arcing contacts, if provided, shall be the first to close and the last to

open and shall be easily accessible for inspection and replacement. Tips of arcing and main contacts shall be silver faced or have tungsten alloy tipping.

2.30 The operating mechanism and associated accessories shall be

enclosed in weather proof mechanism cabinet of hot dip galvanised sheet construction, thickness of which shall not be less than 2 mm. Hinged doors giving access to the mechanism at the front and sides shall be provided. Suitable gaskets shall be provided to make the mechanism housing water-proof and dust-proof. The housing latch shall accommodate padlock requiring a 12 mm diameter hole. Padlock and duplicate keys shall be included in the BIDDER's scope of supply.

2.31 Working parts of the mechanism shall be of corrosion resisting

material. Bearings which require grease shall be equipped with pressure type grease fittings. Bearing pin, bolts, nuts and other parts shall be adequately pinned or locked to prevent loosening or changing of adjustment with repeated operation of the breaker.

2.32 Provision shall be made for connecting travel recorder to perform

speed test of breakers at site.

2.33 Motor operated mechanism shall be provided for Disconnectors & Earth switches with suitable Electrical & Mechanical interlocks. Normal operating mechanism shall also be provided for emergency purpose.

2.34 The operating mechanism offered for GCB shall be in service for a minimum of 2 years in any of the power plant with trouble free operation.

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2.35 SF6 density monitoring, alarm on low density and close & Trip blocking on very low density shall be provided.

3.0 Tests 3.1 All acceptable & routine tests as per IEC-60056 and IEEE Std

C37.013a-2007 standards shall be conducted on all the equipment/components of each of the generator circuit breaker.

a) Power frequency voltage withstand dry tests on the main circuit. b) Voltage withstand tests on control and auxiliary circuits

c) Measurement of the resistance of the main circuit.

d) Mechanical operating tests.

e) Design and visual checks.

3.2 Following type tests shall be conducted on each type & rating of the

equipment. a) Rated dielectric strength tests

(i) Rated low frequency withstand voltage dry test.

(ii) Rated full wave impulse withstand voltage test. b) Short circuit rating and transient recovery voltage tests

(i) Test for rated symmetrical short circuit current interrupting capability, duty cycle and rated transient recovery voltage parameters.

(ii) Test for rated closing, latching and short time current

carrying capability.

(iii) Test for rated Generator source asymmetrical short circuit interrupting capability.

d) Load current switching test e) Out of phase switching current tests

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f) Rated excitation current switching tests.

g) Type tests and oscillographic test records for closing and tripping timings for generator circuit breaker of the rating offered.

3.3 Test reports for the following type tests shall be submitted for each

type & rating of equipment:

a) Rated continuous current carrying tests b) Mechanical endurance life tests.

c) Noise level tests.

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700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS -

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SHEET 8 OF 8

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Technical Parameters

GCB shall comply with the technical particulars given below and the Contractor shall furnish the details wherever indicated as ‘*’.

Sl. No.

Description Unit Technical Particulars

(a)

Make *

(b) Applicable Standards

IEEE(ANSI) std C37.013a-2007 , IEC60056 (1987), IEC 60694 (1980) & IEC 60298 (1990), IEC-60529, IEC-60129, BS-5169 & BS-5500

(c) Voltage rating kV Bidder to indicate

(d) Frequency Hz 50 (e) Rated current A Bidder to indicate (f) Rated short circuit breaking

current kA Bidder to indicate

(g) Rated short time withstand current for 1 sec. kA

Bidder to indicate

(h) Rated short circuit making current kAp Bidder to indicate

(i) Degree of protection • Control cubicles and

drives • Enclosure

IP 54 IP 65

(j) Duty CO-30 min-CO (k) Panel paint shade Opaline Green(external) ,

Semi Glossy white (internal)

75



ELECTRICAL SYSTEMS - GENERATOR TRANSFORMERS

SHEET 1 OF 11

ISSUE R0

SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 329 R5

3.0 GENERATOR TRANSFORMERs (GTs)

The generator transformer (GT) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet – A 3.3. Also, the GT and its accessories shall comply with the requirements indicated in Data Sheet – A 3.3 and specific requirements indicated below.

3.1 The MVA rating of the Generator Transformers (GTs) shall be

sufficient to evacuate power generated by the respective gas turbine generators and steam turbine generators. The GT shall be so sized as to be able to evacuate power from the GTG / STG to which it is connected without exceeding the average winding temperature of 870C and hot spot temperature of 980C over the entire range of site ambient temperature as specified in Section - B of this specification. The GT shall be with voltage ratio of generator voltage / 420kV, two winding, 3 phase, 50 Hz, ONAN/ONAF/OFAF cooled transformer, with On Load Tap Changer with +10% to –10% in steps of 1.25% on the HV side.

3.2 Three (3) of 50% capacity separately mounted radiator banks shall

be provided. Each bank shall be provided with adequate number of fans and pumps and one oil pump and one fan spare. Each radiator bank shall be provided with uni-directional bypass valve to permit oil to bypass the pump in the event of pump failure. It shall be possible to completely isolate any one of the radiator banks for maintenance, while the transformer is in service. Flexible expansion joints, one each, on top and bottom pipe connections for each radiator shall be provided. Each radiator bank shall have atleast two (2) extra radiators to facilitate usage of the same in case of leakage in the other radiators. If radiators are arranged in groups, each group of radiator shall have upper and lower shut-off valves with blanking at either ends. Control scheme shall be suitable for both manual and automatic operation of each group of fans and oil pumps.

3.3 Electrical Performance 3.3.1 The transformers shall operate without injurious heating at the

rated MVA at any voltage within ±10% of the rated voltage of that particular tap.

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3.3.2 The transformer shall be designed to deliver rated MVA continuously even at the lowest tap without exceeding specified temperature rise.

3.3.3 The transformer shall be capable of remaining in operation without

injurious heating at full load atleast 10 minutes when complete forced cooling equipment has failed.

3.3.4 The dynamic ability to withstand short circuit shall be demonstrated

by the Contractor by calculations. 3.3.5 Generator transformers shall be suitable for back charging. 3.3.6 It shall also be capable of being charged from HV side through

circuit breakers without pre-insertion resistors and kept charged continuously with no load on the LV side without any adverse impact on the transformer life.

3.3.7 Generator transformers shall be suitable for bi-directional power

flow. 3.3.8 Bidder shall furnish the guaranteed loss values of Transformer. 3.4 Constructional Features 3.4.1 Bell type design shall be adopted for transformer tank. 3.4.2 The magnetic circuit shall be constructed from high grade cold

rolled non-ageing grain oriented silicon steel laminations. The flux density shall not exceed 1.7 Wb/m2 at rated voltage and Current density shall not exceed 3 A/mm2.

3.4.3 For generator transformers the insulation of core to bolt and core to

clamp plates shall be able to withstand a voltage of 10 kV rms for 1 minute.

3.4.4 The windings shall be made of electrolyte grade copper. 3.4.5 Tank shall be made of good commercial grade low carbon steel

and shall be of welded construction. 3.4.6 The tank of the transformer along with radiators, conservators,

bushings and other fittings shall withstand full vacuum of 760 mm

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of Hg while filling the oil under vacuum and also an excess internal pressure of 0.35 kg/cm2.

3.4.7 Tank shields shall be such that no magnetic fields shall exist

outside the tank. They shall be of magnetically permeable material. If required, impermeable shields shall be provided at the coil ends. Tank shield shall not resonate when excited at the natural frequency of the equipment. Contractor shall conform use of tank shields in the additional information scheme.

3.4.8 Bushing shall be of porcelain. No arcing horn to be provided. For 52 kV and above, bushing shall be oil filled porcelain condensor & non-oil communicating type with following fittings: i) Oil level gauge ii) Oil filling plug and drain valve if not hermetically sealed iii) Tap for capacitance and Tan delta test

3.4.9 Bushing below 52 kV shall be soild porcelain/condensor/oil communicating type.

3.4.10 Bushing CT’s shall be of adequate rating for protection as required, WTI etc., These CT’s shall be mounted in the turret of bushing.

3.4.11 Busduct termination shall be suitable for high air temperature inside the bus duct and shall be provided with draining arrangement as lowest point for leaked oil / water.

3.4.12 Fire protection system shall be provided for the GTs as per the requirement specified under relevant fire and safety codes/standards, TAC guidelines and as specified under section D1.11 of this specification

3.4.13 Fittings and Accessories Transformers shall be provided with all accessories like, but not

limited to inspection manholes / handholes, lifting lugs, jacking pads, bi-directional flanged wheels, haulage lugs, skids, earth pads, neutral earthing downcomers (2 nos.) supported on pin insulators, terminal marking, rating and diagram plates, marshalling boxes, conservators (breatherless) (flexible oil resistant air bag), valves for various purposes including draining, filtering, filling,

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double float buchholz relay, oil and winding temperature indicators with high and very high contacts, magnetic (150 mm dia) and prismatic oil level gauges, anti-earthquake clamping arrangement, tank mounted radiators with accessories, and pressure relief valve (Min. 02Nos. & the adequacy of the number of PRDs and their location shall be established for any location of the fault inside the tank). 4-20mA signal for remote WTI & OTI. It shall be a repeater of local WTI & OTI.

3.4.14 On-line Gas Extractor Analyser shall be provided for each

Generator transformer. It shall be hooked up to the plant DCS.

3.4.15 A device for measuring the hot spot temperature of the winding shall be provided.

3.4.16 For Top oil temperature measurement & Winding temperature measurement RTDs / transducers shall be provided for remote indication in SCADA.

3.4.17 A flexible oil resistant air bag shall be provided in the conservator to prevent the air from coming into contact with the oil.

3.4.18 Suitable shock recorders to record maximum shock forces during shipment/ transport shall be provided.

3.4.19 A set of hydraulic jacks suitable for the transformers under supply.

3.4.20 Transformer oil shall be supplied in non-returnable oil drums ( with 10% extra oil). 3 Nos., 20 KLitres capacity Transformer oil tank and 1 No. 6 KLitres Transformer oil filter machine of reputed make approved by Owner shall be supplied.

3.4.21 Impact recorder shall be provided to monitor the impact during transport on returnable basis.

3.4.22 Transformer shall be transported with tank filled with pure inert gas at pressure of 2 – 2.5PSI. The temperature and pressure at the time of gas filling shall be marked. Necessary accessories including filled replenishment N2 shall be maintained at site also till the transformer is filled with oil.

3.5 Two auxiliary power supplies, 400 V, 3 phase, 3 wire shall be

drawn from two separate boards for the cooler control cabinet and OLTC cubicle. Cooler control equipments shall be divided in to

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two halves, each having one power supply incomer with bus section between two halves. In case of one power supply failure, loads shall be automatically transferred to other. Indications are to be provided at cooler control cabinet and at OLTC cubicle along with remote annunciation in DCS for failure of normal source and for transfer to standby source, and also for failure to transfer.

3.6 Each cooling fan and pump motor shall be provided with isolating

switch, starter, thermal overload, single phase preventer and short circuit protection. Separate on/off switch for each incoming power supply with MCCB shall be provided. All cooling equipment trouble shall be indicated in local control panel with repeat alarm in main control room, with remote annunciation in DCS. Status of each cooler fan/pump shall be available in DCS.

3.7 On Load Tap Changer (OLTC)

3.7.1 The OLTC gear shall be designed to complete successfully tap changes at 150% of rated current. Devices shall be incorporated to prevent tap change when the through current is in excess of the safe current that the tap changer can handle. The OLTC gear shall withstand through fault current without injury.

3.7.2 The tap range shall be decided based on the voltage profile of the grid and following shall be complied with / provided. It shall permit operation of generator at full load and at rated terminal voltage & p.f. over the entire range of variation of grid voltage:

(a) Complete its operation once commenced, independent of

power supply, relays etc. (b) Block reverse tap change command during the forward tap

change in progress. (c) Be such that the oil in the compartment containing making

and breaking contacts does not mix with oil in other compartment of OLTC or transformer tank.

(d) Be equipped with separate conservator for OLTC oil

temperature and oil surge relay with contacts. (e) Cut off of power supply when manual handle is inserted.

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(f) Remote and local electrical operation & tap position indication.

(g) Be equipped with automatic and manual operation facility

including hardware, relays as required. (h) Be equipped with Digital type tap position indicator with in-

built transducer for repeating the tap position in DCS. (i) Be provided with necessary initiating contacts for

annunciation of any abnormal condition in DCS and grouped alarm in control desk.

(j) A sheet steel, dust and vermin proof marshalling box shall

be provided for each transformer and shall be provided with thermostatically controlled space heaters. The degree of protection shall be IP 55. All wiring for remote connection for OLTC control / indication / annunciation from OLTC cabinet shall be terminated in Marshalling box by providing separate terminal block.

3.8 Tests 3.8.1 Following type tests and special tests as per IS 2026 (revision as

applicable on date of submitting of offer) shall be conducted on one transformer :

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(a) Temperature rise test, Dissolved gas analysis of the oil, before

and after the temperature rise test.

(b) Vacuum withstand and deflection measurement on tank and

radiators.

(c) Pressure test on tank with deflection measurement.

(d) Determination of cooler losses.

(e) Partial discharge test.

(f) Radio influence voltage.

(g) Short circuit impedance of each limb with single phase

voltage from each HV & LV sides.

(h) Oil leakage test – 12 hours (this test to be conducted after

heat run test).

(i) Auxiliary power measurement.

3.8.2 All routine tests as per IS : 2026 shall be conducted on each of the

transformer. The following additional routine tests on each of the transformer shall be conducted.

(a) Impedance voltage shall be measured at principal and at all the

taps

(b) No load loss and exciting current shall be measured at rated frequency at 90%, 100% and 110% rated voltage

(c) Calibration of temperature indicators and relays

(d) Impulse test on GTs shall include chopped wave test

(e) Sweep Frequency Response Test at factory and at site

(f) Magnetic balance test. (g) Measurement of tan delta and capacitance of each winding

and bushing.

(h) Pressure test on PRD.

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(i) Measurement of zero sequence impedance.

(j) Core isolation test

(k) Noise level measurement

(l) ACSD & ALD as per standards

3.9 Minimum electrical system requirements in respect of control,

monitoring, measurement, annunciation, synchronising are indicated in I&C system Section No. D2.4.

3.10 The following calculation shall be furnished for Owner’s approval: a) OLTC recovery voltage calculations in case of buck and

boost type of OLTC (wherever applicable) b) Transfer surge calculations c) Short circuit withstand calculations 3.11 Evaluation of Bids 3.11.1 Bids will be evaluated based on the formula furnished in Data Sheet-

A3.3 3.11.2 For the purpose of evaluation of Bids, the quoted load losses and

iron losses shall be included to take into consideration tolerance as permitted by applicable standards.

3.12 Liquidated Damages for Non-Performance

Should the losses as measured on the transformer after manufacture be found to be in excess of the guaranteed losses including tolerance, if any, the VENDOR shall pay to the PURCHASER, liquidated damages based on the charges indicated in Data Sheet A3.3

83


SECTION: D3.3


GENERATOR TRANSFORMER SPEC NO:

TCE.5960A-H-500-001


REV. NO. R0 PPD. BY RKD JOB NO. CLIENT : APPDCL DATE JUNE’ 10 CKD.BY HA 5960A PROJECT : 700MW CCPP AT NEDUNOOR,

KARIMNAGAR DIST. REV. BY DATE

TCE FORM NO. 330 R3

1.0 Generator Transformers 1.1 Type Outdoor, Two winding, 3 phase 1.1.1 MVA Rating MVA 315MVA for GTG (tentative),

340MVA for STG (tentative) 1.2 Cooling method 1.2.1 ONAN 60% 1.2.2 ONAF 80% 1.2.3 OFAF 100% 1.3 Overfluxing capability 110% for continuous 125% for 1 minute 140% for 5 seconds 1.4 Winding connections - HV Star - LV Delta - Vector Ynd1 1.5 Impulse (1.2 / 50 microsecond) / power

frequency withstand voltage windings

- HV 1425 kVp / 630 kV (rms)

- LV * / * 1.6 Maximum temperature rise of oil at 110% of

full load for 24 hrs. 0C 50

1.7 Maximum temperature rise of winding at

110% of full load for 24 hrs. 0C 55

1.8 Tapping particulars 1.8.1 Type OLTC 1.8.2 Tap range + 10% to – 10% 1.8.3 Tapping step 1.25% 1.8.4 Category of voltage variation CFVV

84


SECTION: D3.3



TCE.5960A-H-500-001




TCE FORM NO. 330 R3

1.8.5 Tapping power Full 1.9 Bushing particulars 1.9.1 Voltage class HV / LV / HV (n) 420 kV / --- / 36 kV 1.9.2 Standard applicable IS : 2099 1.9.3 Creepage distance 25 mm / kV 1.9.4 Clearance in air (a) Phase-phase-HV/LV/HV(n) 4200 mm / -- / (b) Phase-earth-HV/LV/HV(n) 3400 mm / --- / - mm 1.10 Paint shade Opaline Green 1.11 Noise level Not to exceed values specified in NEMA TR-

1 1.12 1.12.1

Loss evaluation formula Formula for evaluation of Bids

Evaluated price + (A x guaranteed no-load

loss in KW) + (B x guaranteed load loss in

KW) + (C x guaranteed cooler loss in kW)

A = Rs. 3,80,000 / kW B = Rs. 2,60,000 / kW C = Rs. 2,32000 / kW

1.12.2 1.13

Rates of liquidated damages for exceeding the guaranteed losses No load loss Load loss Load loss Applicable codes and standards

Rs/kW Rs/kW Rs/kW

A = 3,80,000 B = 2,60,000 C = 2,32000

1.13.1 Power transformer IS : 2026/IS:6600/IEC:60076 1.13.2 Fittings and accessories IS : 3639 1.13.3 Loading of oil immersed transformers IS : 6600 1.13.4 Oil IS : 335 / IEC:60296 1.13.5 Bushings IS : 2099 / IEC:60185 1.13.6 Degree of protections IS : 2147

85


SECTION: D3.3



TCE.5960A-H-500-001




TCE FORM NO. 330 R3

1.13.7 Tests IS : 2026 1.13.8 Tolerance on guaranteed particulars IS : 2026 1.13.9 Buchholz relay IS : 3637 1.13.10 Electrical insulation classified by thermal

stability IS : 1271

86

ANDHRA PRADESH POWER DEVELPOPMENT COMPANY LTD. SECTION: D3.4


ELECTRICAL SYSTEMS - UNIT AUXILIARY TRANSFORMERS

SHEET 1 OF 3

SPEC.NO. TCE-5960A-H-500-001

ISSUE R0

TCE FORM NO. 329 R5

4.0 UNIT AUXILIARY TRANSFORMER (UAT)

The Unit Auxiliary Transformer (UAT) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet - A 3.4. Also, the UAT and its accessories shall comply with the requirements indicated in Data Sheet–A3.4 and specific requirements indicated below:

4.1 UAT shall be a * MVA, */6.9kV, three phase, two winding, 50 Hz,

ONAN/ONAF cooled transformer with *% impedance with OLTC ±10% in steps of 1.25% on HV side (*By Bidder). 6.6kV system shall be suitable for medium resistance earthing with earth fault current limited to 300A.

4.2 Impedance The impedance of the transformers at taps corresponding to nominal

transformation ratio (primary taps) shall be selected keeping in view the short circuit level of the 6.6 kV and 400 V switchgear & the voltage dip at motor terminals not exceeding the limits specified in Section D 3.20

4.3 MVA rating 4.3.1 UAT Each UAT shall be able to supply (100%) auxiliary running load of 700

MW power plant. It shall be able to start the largest motor at 80% base load. The Contractor shall provide the design calculations for arriving at the capacity of UAT during detail engineering stage. Additional margin of 10% shall be kept over & above all the loads due to variation in the loads i.e. 110% of the complete station load.

4.4 Specific Requirements 4.4.1 The unit auxiliary transformers shall comply with the specific

requirements indicated in Section D-3.3 except for the following variations.

4.4.1.1 The tank cover for the UAT can be of conventional type. 4.4.1.2 The UAT shall be provided with 2 x 50% detachable built on radiator

banks and if it is not possible to have built on radiator banks, the same can be separately mounted. Each radiator bank shall have at-least two extra radiators for use in case of leakage in any other radiator.

4.4.1.3 All tests specified in Section D-3.3 shall be conducted on UAT.

87


SECTION : D 3.4

DATA SHEET – A 3.4 SHEET 2 OF 3

UNIT AUXILIARY TRANSFORMER SPEC.NO. TCE-5960A-H-500-001


REV. NO. R0 PPD. BY RKD JOB NO. CLIENT : APPDCL DATE JUNE’ 10 CKD.BY HA 5960A PROJECT : 700MW CCCP AT

NEDUNOOR, KARIMNAGAR DIST. REV. BY DATE

TCE FORM NO. 330 R3

UAT

1.0 Type Outdoor, two winding 2.0 No load voltage - HV kV *

- LV kV 6.9 2.1 Rating on ONAF MVA 28 ( tentative) 3.0 Cooling method (a) ONAN % 80% (b) ONAF % 100% 4.0 Overfluxing capability 110% continuous, 125% for 1 minute, 140%

for 5 seconds 5.0 Winding connections - HV Delta - LV Star - Vector group Dynll 6.0 Impulse (1.2 / 50 microsecond) / power


- HV * / * - LV 60 kVP / 20 kV (rms) - HV (n) --- 7.0 Maximum temperature rise of oil 0C 50 8.0 Maximum temperature rise of winding 0C 55 9.0 Tapping particulars (a) Tap ON LOAD CIRCUIT TAP CHANGER (b) Tapping range % ±10% (c) Tapping step % 1.25 (d) Category of voltage variation - (e) Tapping power - 10.0 Bushing particulars (a) Voltage class HV / LV / HV (n) /

tertiary * / 7.2 kV / -

88


SECTION : D 3.4


UNIT AUXILIARY TRANSFORMER SPEC.NO. TCE-5960A-H-500-001




TCE FORM NO. 330 R3

(b) Standard applicable IS-2099 (c) Creepage distance 31 mm / kV based on line to line highest

system voltage (d) Clearance in air (i) Phase-Phase-HV / LV * / 127 (ii) Phase-Earth-HV/LV/HV(n) * / 127/- 11.0 Paint shade Opaline Green 12.0 Noise level Not to exceed values specified in NEMA TR-1 13.0 Loss evaluation formula 13.1

Formula for evaluation of Bids

Evaluated price + (A x guaranteed no-load loss

in KW) + (B x guaranteed load loss in KW) +

(C x guaranteed cooler loss in kW)

A = Rs. 3,80,000 / kW B = Rs. 2,60,000 / kW C = Rs. 2,32000 / kW

13.2

Rates of liquidated damages for exceeding the guaranteed losses No load loss Load loss Load loss

Rs/kW Rs/kW

Rs/kW

A = 3,80,000 B = 2,60,000 C = 2,32000

Note: - (*) By Bidder

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ELECTRICAL SYSTEMS - BUS DUCTS

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A) ISOLATED PHASE BUS DUCTS (IPBD)

The Isolated phase bus duct (IPBD) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet – A 3.5 IPBD. Also, the IPBD and its accessories shall comply with the requirements indicated in Data Sheet–A 3.5 and specific requirements indicated below:

5.1 Isolated phase bus duct forming the main current carrying leads shall be

used in following circuits: 5.1.1 Generator phase side terminals to respective GCB, GCB to Generator

transformer LV terminals for GTG and generator phase side terminals to generator transformer LV terminals in the case of STG.

5.1.2 Tap-off bus duct for Unit Auxiliary Transformers in the case of GTG. 5.1.3 Tap-off bus ducts for VT and SP cubicle, static excitation transformer (if

applicable) 5.1.4 Bus duct to generator neutral side terminals to neutral grounding

equipment panel, which shall house a neutral earthing transformer and neutral earthing resistor.

5.1.5 The CTs etc., to be located in the Isolated phase bus duct shall be as per

the enclosed Main one line diagram – Drg. No. TCE.5960A-EL-SK-2003. Current transformers as required shall be located in the above bus duct. 5.1.6 If the generator transformer is three numbers single phase units, then the

delta formation of the LV Windings shall be carried out with Isolated Bus Duct.

5.1.7 The voltage class of the bus duct shall be as follows: Generator voltage Bus duct voltage class (a) Upto 12 kV 12 kV

(b) More than 12 kV upto 21 kV 24 kV 5.2 Sizing and Design

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5.2.1 Sizing of the bus duct shall be arrived based on the continuous and short time rating of the respective circuit.

5.2.2 The continuous current rating of the main (generator) bus duct shall be

arrived at considering the maximum output of the generator and at specified minimum voltage.

5.2.3 Short time current rating of the main busduct shall be for 1 second and

shall be decided as follows:.

(a) Higher of the short circuit current contribution from generator OR the short circuit current contribution from 400 kV system through generator transformer (400 kV system fault level 50 kA)

Plus (+) Contribution of 6.6kV auxiliary power supply system through

UAT. (b) Momentary current rating shall be 2.55 times the short time

current rating arrived as above.

5.2.4 The short time and momentary current rating of all tap-off bus ducts (to VT and SP cubicle) shall be as follows:

(a) Short time current rating for 1 second:

(i) Short circuit current contribution from generator Plus (+) (ii) Short circuit current contribution from 400 kV system

NOTE: Negative tolerance allowed in the standards shall be considered

for generator and generator transformer impedance for calculation of short time ratings in clauses 5.2.3 and 5.2.4 above.

5.2.5 The bus duct shall be designed to withstand the internal or external

forces resulting from the following:

(a) Normal operating conditions (b) Momentary short circuit currents

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(c) Rigorous / adverse weather conditions as detailed in project

information section B (d) Seismic forces as detailed in project information section B.

5.2.7 The degree of protection shall meet the requirements of water and air

tightness test specified in IS-8084 and the degree of protection shall be IP-55 or better. The outside of the busduct shall be painted with 631 of IS-5.

5.3 Specific Requirements 5.3.1 The bus enclosure shall be of continuous bonded type. The material of

bus conductor & enclosure for main run shall be Al alloy grade 19501 (H2) of IS-5082. The material of bus conductor for tap-off shall be Al alloy grade 63401 WP (range 2) & for enclosure material shall be Al alloy grade 19501 (H2).

5.3.2 Inspection covers for periodic inspection of the insulators shall be

provided. There shall be no joints or fixing bolts on top of the enclosure through which water can seep.

5.3.3 The outdoor portion of the bus duct shall take into account heating effect

due to solar radiation and shall be provided with a continuous rain hood of non-magnetic material suitably supported from the bus duct support structure.

5.3.4 The bus conductor shall be given a coat of matt black paint to facilitate

heat dissipation. However, the sizing of the bus conductor shall consider the conductor as bare.

5.3.5 The process of silver plating shall be approved by the owner. 5.3.6 Each phase shall be enclosed in weatherproof, dust tight, non-magnetic

metal enclosure. The enclosure shall be designed for welded connections. The enclosure shall be of minimum flux type to permit not more than five (5) percent of total, magnetic flux outside enclosure.

5.3.7 The enclosure shall be insulated at the connections to various

equipment so that the longitudinal current will not flow through or be transmitted to any connecting equipment. The insulation shall be non-deteriorating and shall be clearly indicated on the Contractor’s drawings.

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5.3.8 The Contractor should ensure that no load is transferred on electrical

equipments transformers, generator terminals etc. by the busducts. 5.3.9 The bus conductor shall be designed for welded connections except at

equipment terminations, bolted disconnect links, and bolted flexible. Detailed welding procedure adopted by the manufacturer should be furnished along with the offer and approved by the Owner.

5.3.10 Flexible connections shall be provided between bus sections to allow for

expansion and contraction of the conductor. Flexible connections shall also be provided at all equipment terminations.

5.3.11 The bus support insulators shall be mounted on resilient pads. 5.3.12 The bus support insulator shall be interchangeable, high strength & fine

glazed porcelain manufactured by wet process or high strength epoxy resin cast. The voltage rating shall depend upon generation voltage.

5.3.13 The spacing of the bus support insulators shall be considered by giving

due factor of safety to withstand the forces due to the momentary short circuit assigned for the bus duct.

5.3.14 Wall frame assembly and seal-off bushings shall be provided where the

bus duct passes from indoor to outdoor area to prevent condensation due to air temperature variation between indoor and outdoor portion. Wall frame assembly shall be fabricated out of aluminium angles and sheets. It shall be ensured that no load of the bus duct is imparted on the walls.

5.3.15 The bus duct supports shall be fabricated from standard steel sections.

The support structures shall be hot dip galvanised.

5.3.16 Thermostatically controlled space heaters shall be provided along the length of the bus duct.

5.3.17 Duplex RTD shall be provided for measurement of ambient air inside the

bus duct. The same shall be hooked upto the DCS. 5.3.18 The equipment terminal connections shall be readily accessible and

shall provide sufficient air gap for safe isolation of requirement during electrical testing.

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5.3.19 If the material of bus conductor and that of the equipment terminal is different, then suitable bi-metallic connectors shall be provided by the Contractor.

5.3.20 The electrically continuous bus enclosure shall be used as the grounding

bus. All parts of the bus enclosure, supporting structure and equipment frames shall be grounded to earthing mat.

5.3.21 Neoprene Rubber bellows shall be provided at the termination point of

the bus duct at various equipment. Rubber bellows shall also be provided in the run of the bus duct after gas turbine generator foundation block to avoid transfer of vibrations of GTG pedestal. In case of rubber bellows at intermediate locations flexible braids copper connection, shall be provided across the bellows to establish continuity of bus duct from end to end.

5.3.22 Provision shall be made in bus duct at an approved location for

installation of shorting bar having rated current carrying capacity same as that of main bus duct for carrying out generator stator dryout. A set of shorting bar along with requisite hardware shall be supplied for this purpose. A set of shorting bars along with requisite hardware shall be supplied for this purpose. Disconnecting links with rating same as that of the main bus conductor shall be provided in the run of the bus duct as required to facilitate disconnection of the bus conductor during testing.

5.3.23 The IPBD shall be of natural air cooled type.

5.3.24 Silica gel filters shall be provided both in indoor and outdoor portions of

the bus duct for absorption of moisture. 5.3.25 Seal off bushings

(a) Seal-off bushings shall be provided at the entry of tap-off bus duct to the VT and SP cubicle, static start-up, unit auxiliary transformers, neutral grounding cubicle, etc.

(b) One set of seal-off bushings shall be provided in the bus duct

after the generator bushings to prevent hydrogen leakage into the bus duct. Arrangement shall be provided to vent the trapped hydrogen in the portion between generator bushings and these seal off bushings (applicable for hydrogen cooled generators).

5.3.26 Two numbers earthing terminals with bi-metallic connectors shall be

brought out at termination points of the bus duct, main and cross

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supporting structures, terminal boxes, adapter boxes, unit auxiliary transformer, VT and SP cubicle, etc., and for further connection to earthing grid.

5.3.27 All steel supporting structures and hardware shall be hot dip galvanised

after fabrication.

5.4 Pressurisation System

5.4.1 Not used.

5.5 Current Transformer

5.5.1 The current transformers shall be epoxy cast-resin, single core ring type, mounted within the bus duct enclosure and suitable for operation at an ambient temperature existing within the bus duct enclosure which may be in range of 900C to 1000C. Mounting arrangement of CT shall be so designed so as to avoid equalizing connections between live conductor and CT inner surface.

5.5.2 CT secondary leads shall be brought out through non-magnetic metallic conduits to a marshalling box (MB) with degree of protection IP-55 (IS:13947 Pt.1). The MB shall be provided with removable aluminium gland plate. The facility for shorting and grounding shall be provided at the terminal blocks.

5.5.3 All CTs shall be tested for partial discharge. The partial discharge at 10 percent over voltage of the highest system voltage shall not exceed 50 pico coulombs. Arrangement shall be made to maintain potential of inner surface of busduct CTs at the same value as the conductor to prevent partial discharge.

5.5.4 Protection CTs shall be rated for 5A secondary current and shall be of

Class PS & Class 5P20. Metering CTs shall be rated for 5A secondary current and shall be of 0.2S accuracy class with instrument security factor less than 5.

5.6 Voltage Transformer and Surge protection Cubicles

5.6.1 The V.T and S.P cubicles for each phases shall be metal clad, dust and vermin proof, free standing, dead front assemblies housing VTs, surge capacitor, lightning arrester, V.T. L.V. side fuses etc.

5.6.2 Lightning arrester shall be Gapless type station class, hermetically sealed, connected between line and ground, specifically suitable for

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generator protection as per technical parameters given elsewhere in the specifications.

5.6.3 A discharge counter along with the ampere meter shall be provided for each lightning arrester. The discharge counter register & leakage current measurement meter with suitable environmental protection covering, shall be visible without having to open the compartment door.

5.6.4 Mineral oil filled/Askarel (PCBS) filled surge capacitor shall not be acceptable.

5.6.5 The voltage transformer shall be epoxy cast-resin type, suitable for nominal voltage operation, connected from line to ground, and as per Technical Parameters given in the specifications.

5.6.6 The secondary side of voltage transformer shall be provided with MCB. Suitable guide slots and stops shall be provided to ensure easy withdrawal and positioning. The fixed and draw out contacts of voltage transformer primary shall be tinned or silver plated.

5.6.7 In the disconnected position, the voltage transformer primary and secondary circuits shall be automatically disconnected. The draw out frame shall be grounded at all times. A reliable automatically operated shutter mechanism shall be provided for isolating and shrouding the bus bar live parts when the VT is in drawn out position.

5.6.8 From phase cabinets the VT secondary leads shall be brought to marshalling box having sufficient number of terminals with 20% spare, to accommodate all VT leads. Facility of making star points and undrilled gland plate for cable connections shall be provided in the marshalling box.

5.6.9 VT and CT secondary neutral or common lead shall be earthed at one place only at the terminal blocks, provided in the instrument transformer marshalling boxes. The facility for connecting with earthing grid, shall be provided by the Contractor through suitable connectors in the marshalling box, with isolating links for testing of instrument transformers.

5.7 Cubicle Construction (V.T. & S.P., N.G. Cubicle etc.)

5.7.1 All cubicle shall be fabricated from cold rolled sheet steel for minimum 2mm thick suitably reinforced to ensure structural rigidly. The degree of

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protection for all indoor cubicle shall be IP:52 except for neutral grounding resistor enclosure which shall be minimum IP:23.

5.7.2 Space heater, Illumination and Grounding.

5.7.3 Each cubicle shall be equipped with space heater with thermostat, internal illumination lamp, 230 V AC, 5A receptacle. Ground bus suitable for receiving two (2) numbers of 50x6mm galvanised steel flats shall be provided on each cubicle.

5.8 Wiring

5.8.1 All wiring shall be done with insulated stranded copper conductor of not less than 2.5 mm² cross-section with suitable lugs on both sides.

5.8.2 The wiring inside the bus duct enclosure (i.e. for CT etc.) shall be suitable for operating in the ambient temperature existing inside the bus duct.

5.8.3 Not more than two wires shall be connected to a terminal. Spare terminals equal in number to 20% of active terminals shall be furnished and these shall be uniformly distributed through out the cubicle CT terminal blocks shall be of stud type and suitable for round type lugs with a facility for isolation, shorting and grounding. It shall be Elmex type CATD or equivalent.

5.9 Name plate

5.9.1 Name plates shall be furnished for each equipment, disconnect link, voltage transformer compartment, lightning arrester compartment and fuse block, current transformer TB, etc.

5.9.2 Material for nameplate shall be embossed on SS plate & letters filled with indelible black ink.

5.10 Hot Air Blowing Equipment

5.10.1 Suitable facility shall be provided to blow hot air into the bus duct to evacuate moisture inside the bus duct during initial start-up and also after subsequent shutdowns for maintenance on the bus ducts.

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5.10.2 The hot air blowing system shall be open loop type, capable of blowing hot air simultaneously in the indoor and outdoor portions of the bus duct. The system shall be suitable for operation at low voltage 3 phase AC supply indicated under project information.

5.10.3 Ambient air will be drawn in through inlet dampers and dry air filters and then forced through thermostat controlled heaters. Hot air shall be distributed by properly sized ducts and dampers to the indoor and outdoor portions of the bus duct. Hot air shall be let out through suitably directed outlets provided at the indoor and outdoor portions of the bus duct and at each equipment suitably.

5.10.4 The hot air blowing system shall be complete with motor blower unit, combination starter, washable filters, necessary ducting, piping, dampers, valves, heaters, thermostats, control, instrumentation and monitoring system, all mounted on a mobile trolley.

5.10.5 A local control cabinet mounted on the trolley, shall be provided with the necessary control, indication and monitoring devices.

5.10.6 The system shall be sized to completely dry the entire bus duct installation within two hours. Suitable provision shall be made to isolate this system after the drying operation is complete.

5.10.7 The mobile trolley shall be common for the specified number of bus duct units. The bus duct of each unit shall be provided with suitably supported inlet ducting with blanking plates.

5.10.8 The tap off air ducting from IPB to mobile trolley delivery flange is included in Bidder’s scope of supply.

5.11 Tests & Test Reports

The following type and routine tests shall be conducted on representative section of the bus duct assembly. The bus duct assembly tested shall include bolted connections, flexible connections and current transformers.

5.11.1 Type Tests

a) One minute power frequency withstand voltage test. b) Impulse withstand test

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c) Temperature rise test of black matt painted conductors & enclosures

d) Short time current test

e) Dynamic current withstand test

f) Water-tightness test

g) Air tightness test

h) Milli-volt drop test 5.11.2 Routine Tests

a) One minute power frequency withstand voltage test b) IR measurement

5.12 Bidder shall furnish the following calculations for main run and tap off run busduct.

5.12.1 Temperature rise at rated current considering effect of solar radiation.

a) Conductor size

b) Guaranteed kW losses in conductor & enclosure

c) Supporting span

d) Dynamic and static forces transferred to TG foundation.

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B) HV & LV Bus ducts

5.13 Segregated Phase Bus Ducts [SPBD]

5.13.1 7.2 kV class segregated phase bus duct and accessories shall be

provided for connection of the two winding unit auxiliary transformer to 6.6 kV switchgear.

5.13.2 The continuous rating of the bus duct from UAT to 6.6 kV Switchgear

shall be same as the rated current of 6.6 kV switchgear bus. 5.13.3 The short time and momentary current ratings of the bus ducts shall be

same as that of associated 6.6 kV switchgear.

5.14 Non-Segregated Phase Bus Ducts [NSPBD] 5.14.1 1.1 kV class non-segregated phase bus duct and accessories shall be

provided for connection between all service transformers and their respective 400V switchgear. NSPBD shall also be considered for connections between other switchgear / MCCs to suit the layout.

5.14.2 The continuous rating of the bus duct shall be same as the rated current

of respective switchgear bus. 5.14.3 The short time and momentary current ratings of the bus ducts shall be

same as that of associated 400V switchgear. 5.14.4 The busbars in the bus-duct shall be sleeved with FRLS heat shrinkable,

colour coded XLPE sleeves.

5.15 Specific Requirements

5.15.1 The bus conductor shall be of Aluminium alloy grade 63401 WP (range 2) as per IS: 5082.

5.15.2 The enclosure shall be rectangular and shall be made of aluminium alloy

sheets for SPBD and for NSPBD the same shall be of mild steel. 5.15.3 In case of segregated phase busduct, the phase segregation shall be of

either aluminium or non-hygroscopic insulating material like fibreglass.

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5.15.4 Flexible expansion joints shall be provided for the conductor and enclosure along the run of the bus duct length to take care of expansion. Also flexible joints shall be provided at the termination points.

5.15.5 Inspection covers for periodic inspection of the insulators shall be

provided. There shall be no joints or fixing bolts on top of the enclosure through which water can seep.

5.15.6 The outdoor portion of the bus duct shall be provided with a continuous

rain hood of non-magnetic material suitably supported from the bus duct support structure.

5.15.7 The bus conductors shall be given a coat of matt black paint to facilitate

heat dissipation. However the sizing of the bus conductor shall consider the conductor as bare.

5.15.8 The adjacent sections of the bus conductor shall be welded or bolted. 5.15.9 The joints along the conductors shall be of highest quality and the

temperature rise test shall be conducted including the joints. 5.15.10 The bus support insulators shall be of 7.2 kV class (as required) for

segregated phase bus ducts and 1.1 kV class for non-segregated phase bus ducts and shall be mounted on resilient pads.

5.15.11 The material of insulator shall be epoxy resin cast. 5.15.12 The spacing of the bus support insulators shall be considered by giving

due factor of safety to withstand the forces due to the momentary short circuit current assigned for the bus duct.

5.15.13 Wall frame assembly and seal off bushings shall be provided where the

bus duct passes through walls (indoor to indoor). These shall be fabricated out of aluminium angles and sheets. Wall frame assemblies with seal off bushing shall be provided where bus ducts pass through walls (outdoor to indoor).

5.15.14 The bus duct supports shall be fabricated from standard steel sections.

The support structures shall be hot dip galvanised. 5.15.15 Thermostatically controlled space heaters shall be provided along the

run of bus duct.

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5.15.16 At the factory, on one typical section of SPBD containing bends, joints etc., following type tests shall be conducted

(a) air tightness test (b) water tightness test (c) Temperature rise test (d) Short circuit current withstand (e) Impulse withstand test

For NSPBD, type test certificates shall be furnished.

5.15.17 On all the pieces of SPBD & NSPBD applicable routine tests shall be

conducted. Also, test certificates shall be furnished for bought out items.

5.15.18 HV voltage test, air tightness test and water tightness tests shall be conducted at site on fully assembled bus duct.

5.16 Technical Requirements 5.17.1 Segregated/non-segregated phase bus ducts shall comply with the

particulars indicated in the following table.

Sl.No.

Description Requirement for

Segregated Phase Bus duct

Non-segregated Phase Bus duct

(a) Type of cooling Natural air Natural air (b) Maximum temperature

rise of conductor over 50oC ambient

40oC 40oC

(c) Maximum temperature rise of enclosure over 50oC ambient

30oC 20oC

5.18 Data to be furnished with the Bid

5.18.1 Technical particulars for the segregated/non-segregated phase bus

ducts as per Table below. 5.18.2 Typical calculation for arriving at the size of the conductor and the

insulator spacing. 5.18.3 Experience list of the make of bus duct proposed.

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5.18.4 Type test report (short circuit, impulse withstand, temperature rise test) for similar bus duct manufactured by the proposed manufacturer.

5.19 Technical Particulars

(To be separately furnished for each rating of segregated and non-segregated phase bus ducts.)

Sl.No. Description Unit Technical

Particulars

(a) Designation (from & to)

(b) Manufacturer

(c) Applicable standard

(d) Momentary short circuit withstand current (as per clauses 5.13.3 & 5.14.3)

kA peak

(e) One second short circuit withstand rating (as per clauses 5.13.3)

kA rms

(f) Continuous current rating at 50oC design ambient air temperature (as per clauses 5.13.2 & 5.14.2)

Amps

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SECTION: D3.5

SHEET 15 OF 15 DATA SHEET – A 3.5


REV. NO. R0 PPD. BY RKD JOB NO. CLIENT : APPDCL DATE JUNE’ 10 CKD.BY HA 5960A PROJECT : 700 MW CCPP AT


SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

Isolated Phase Bus Duct

1.0 Type of bus duct Isolated Phase Bus Duct - Continuous 2.0 Type of cooling Natural air cooled 3.0 Maximum temperature rise of over an ambient

temperature of 500C

3.1 Conductor (Hot spot) 0C 55 3.2 Enclosure (Cold spot) 0C 30 4.0 Applicable codes and standards 4.1 Bus conductor material IS :5082 4.2 Porcelain bushing IS : 2099 4.3 Porcelain post insulators IS : 2544 4.4 Hot dip galvanising IS : 2629 4.5 Interconnecting busbars IS : 8084 5.0 Creepage distance for insulators and bushing

25 mm/kV of rated voltage

6.0 Voltage of : (i) Acc. class (ii) Rated voltage factor

Refer Main Line Dia TCE.5960A-EL-SK-2003 1.2 Cont., 1.9 for 30 seconds.

7.0 Type of insulation for current trf. and neutral grounding transformer

Cast epoxy resin

8.0 Duty rating (i) NGT

(ii) NGR

30 Secs. 30 Secs.

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1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS – GENERATOR, GENERATOR

TRANSFORMER AND UAT PROTECTIONS

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6.0 GENERATOR PROTECTION 6.1 Complete protection system consisting of protective relays, auxiliary

relays, timers, etc., shall be provided to protect the generator, its subsystems, generator transformer and unit auxiliary transformer.

6.2 Generator Protection All the protective relays, auxiliary relays, timers, transducers etc., to

protect the complete generator, its subsystems shall be housed in generator relay panel (GRP). This panel will be located in the Main control room.

6.3 Protection Philosophy 6.3.1 The protection philosophy of every equipment shall be divided into two

100% groups namely two main protection groups. Complete protection of the respective equipment shall be fully available even if either of the group is not available. Hence, both groups shall be mechanically, physically and electrically separated into two separate and independent systems. One group shall be receiving all AC and DC signals from one set of devices and the other from another set of devices. Similarly, these two groups will derive DC supply from two separate feeders. However, the relays in each group shall be tripping the circuit breaker through both trip coils I & II. Monitoring devices such as supervision of DC supplies, supervision of protective relays, supervision of trip relays, CT and PT supervision and supervision of both trip circuits shall be provided. Dead machine protection shall receive their DC power supply from station DCDB as appropriate.

6.3.2 The generator protection system relays shall be classified into three

categories viz., Class – A trip shall be classified into GCB & field breaker trips (Class-A1) and GT HV breaker Trip (Class-A2). Class-B shall trip GCB or GT breaker on reverse power through Class A1 or A2. Class- C shall trip GT HV circuit breaker. Both groups of protection shall be divided into these three modes of tripping.

6.4.3 The breaker failure relays connected with 400 kV generator transformer

bay and relays connected with 400 kV bus bar protection shall be housed in separate relay panels which will form part of 400 kV switchyard protection system.

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6.4.4 The protections envisaged in GRP are listed below. Also, Main One Line Diagram drg. No.TCE.5960A-EL-SK-2003 indicates various protections envisaged. Both the list and the drawing shall be considered

Complementary to each other and all the protections indicated shall be provided. Contractor shall include any additional protections deemed necessary by him for the equipment offered even if not indicated in the list and the drawings.

Numerical relays shall be provided for main protection of Generator, GT

and UAT. However, static relays have to be provided for PT supervision, dead machine protection and pole slipping protection. Numerical relays shall have adequate output contacts for tripping, annunciation, etc., contact multiplication relays shall be provided if necessary. They should likewise have adequate number of opto couplers for external trip inputs, interlocking etc., Two identical numerical relays shall be provided for generator protection. A dedicated operator station shall be provided in the Main control room for setting the numerical relays of Generator protection and 6.6 kV switchgear.

(a) Generator differential protection (87G)

(b) Generator stator 100% earth fault protection (64 G1).

(c) Generator stator 95% earth fault protection (64G2). (d) Generator stator 95% back-up earth fault protection (64 G3).

(e) Pole slipping relay protection (78G). (f) Loss of excitation protection (40 G). Loss of excitation relays shall be with two independent outputs for

conditions with and without under voltage. (g) Negative phase sequence protection (46 G).

It shall have a definite time stage for alarm and inverse stage for trip. In addition they shall have an output of 4-20 mA for remote indication of negative phase sequence current.

(h) Back-up impedance protection (21G).

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(i) Stator over-load alarm relay (50 GS). It shall be provided with timer to detect actual over load. (j) Generator VT fuse failure protection (60 G11, 60 G12, 60G13 /

60 G21, 60 G22, 60G23) (k) Reverse power/ Low forward power protection (32 G/37G). (l) Under frequency protection (81 G). 4 stage with independent time and frequency adjustment. (m) Over voltage protection (59 G).

Over voltage protection shall have an instantaneous stage and a definite time stage with independent voltage settings.

(n) Under voltage protection (27G) (o) Dead machine relay (61 B).

(p) Islanding protection schemes to isolate power plant from grid for

disturbances in the grid.

(q) Generator field over voltage protection (can be a part of excitation system)

(r) Over fluxing protection (99G) with inverse time characteristics.

(s) Rotor earth fault (64F) 2 stage

(t) Inter turn fault protection through differential current

measurement in case generator has six terminals brought out on neutral side

Or Through residual voltage (Vo) with neutral biasing in case three terminals are brought on the neutral side.

(u) Local breaker back up protection (50 LBB) with it’s own trip relay.

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(v) Generator, generator transformer overall differential protection (87GTU) for STG and generator, generator transformer, UAT overall differential protection for GTG (87 G/GT/UAT).

(w) Generator transformer restricted earth fault protection (64 GT)

(x) Generator transformer back-up earth fault protection (51 NGT).

(y) Tripping relays for protection devices of Generator Transformer

(GT) and 63X / 49X for multiplying the contacts of protection.

(aa) For trip function (63X1/49X1)

• GT buchholz II stage (63TX)

• GT OLTC buchholz II stage (63 OLTC TX)

• GT winding temperature very high (49 WTX)

• GT oil temperature very high (49 OTX)

• GT pressure relief device operated (63 PTX)

• GT fire protection trip (63 FRTX)

(bb) For annunciation function (63x2/49x2)

• GT Buchholz I stage (63AX)

• GT OLTC buchholz I stage (63 OLTC AX)

• GT winding temperature high (49 WAX)

• GT oil temperature high (490AX)

• GT oil level low (OLAX)

• GT cooler supply failure

• GT cooler trouble

• GT OLTC trouble

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(z) UAT IDMT overcurrent protection on HV and LV sides (51)

(aa) UAT Instantaneous over current protection on HV side (50)

(bb) UAT – Buchholz (63), winding temperature (49 WT) and oil temperature (49 OT) protections

(cc) Auxiliary relays for protection devices of UAT 63 x 1/49 x 1 and

63 x 2 / 49 x 2 for multiplying their contacts.

(dd) UAT differential protection (87 UAT).

(ee) UAT restricted earth fault protection (64 UAT).

(ff) UAT instantaneous earth fault relay (51N UAT)

(gg) High speed trip relays (86 G1 to GX): Adequate number of high speed trip relays for each category tripping and separately for each group shall be provided for the protection of the unit. The quantity of the trip relays shall also consider the requirement due to the following:

(i) Contact requirements from these relays to various

systems covered under the scope of this contract. (ii) Contacts from each category of tripping relay for

annunciation, data acquisition, and sequential event recorder and fault disturbance recorder.

(iii) Contacts for control, protection and interlock in system

viz., 400 kV circuit breakers tripping / close permissive, 6.6 kV auxiliary supply breakers trip / close permissive, transformer cooler circuit interlocks, LBB protection, etc.,

(iv) 10% spare contacts (both N/O and N/C).

(hh) Supervision relays for tripping relays (98 GL1 to GLX).

(ii) Open delta VT for Pre-synchronising Earth fault (59NGT) (jj) 400 kV generator breaker trip coil supervision relays (98G1 to

G4).

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(kk) Auxiliary relays, timers in adequate number to make the protection & the scheme complete, relays required for the discrepancy switch scheme in Generator control panel.

(ll) Auxiliary VTs and Auxiliary CTs required for the protection

systems. The parameters of the same shall be selected to suit the application and the same is subject to approval of Owner.

6.6 The characteristics and relay setting ranges shall be decided by the

Contractor and shall be such as to provide complete protection for the generator under normal and all abnormal operating conditions.

6.7 Trip Matrix required for implementing class A/B/C tripping schemes shall

be provided by the Contractor and shall be indicated in block interlock diagrams to be submitted.

6.8 Specific Requirements 6.8.1 The protection system shall comprise pre-engineered modular or discrete

self-contained systems comprising preferably of static relays. In addition to the relays/protections mentioned in this specification, any additional protections/relays considered necessary by the Contractor for his system shall be included and offered by the Contractor.

6.8.2 Two Nos. DC supplies shall be arranged for the GRP. These supplies

shall be taken through a selector switch with the positions, viz., independent, source-1 & source-2. In the Independent position Group-1 & 2 protection system will be fed by source 1 & 2 respectively and the common services from any one of the sources. In case of failure of any one source (say source 1) switch shall be changed over to the other source (source 2) and complete DC supply requirement of GRP will be fed from the other source.

DC auxiliary supply shall be supervised by supply supervising relays. The NC contact of the relays shall be delayed on drop off by approximately 100 to 200 m sec. for annunciation in Operator station/Generator control panel. The relay shall be provided with flag indicators wherever required. White colour supervision lamps of clustered LED type shall be provided on GRP to indicate availability of DC supply. All LEDs shall be 22.5 mm size self coloured.

6.8.3 The relay panels shall be provided with supervisory system facilities to indicate the location of the failed component when pre-engineered

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protection system is offered. Self checking facility ‘In-Built’ in the relay panel shall be provided with watch dog contact for remote annunciation and DCS.

6.8.4 Either hand reset mechanically operated operation indicator or LED with

reset push button shall be provided for protective relays. They shall be arranged to operate only when tripping current passes through output circuit of the relay.

6.8.5 One laptop of high configuration shall be provided with necessary

software & hardware (with multiple licences) for setting the parameters & evaluation of numerical relays.

6.9 In addition to the contacts required as per schemes, Contractor shall wire

out to the terminal block atleast all NO & NC spare contacts of each of the relays.

6.10 The protection scheme shall include all the necessary contacts to achieve

the schemes required, alarms in Operator Station, annunciation windows, sequence event recorder and for switchyard control panel annunciation wherever required. Contact multiplication relays for generator circuit breaker and associated isolators shall be provided for this purpose.

6.11 Testing Unit 6.11.1 Two Nos. of test kits shall be offered to test all of generator, transformer,

line and motor protection relays, timers by secondary injection. This is in addition to self monitoring and watch dog facilities that will be built into these protective relays.

6.12 Control room alarms/indications/SER points

Each of the alarms, trip conditions, abnormal conditions through the protection relays, shall be individually indicated in Operator station and also individually or appropriately grouped available in the annunciation windows in generator control desk / panel. Selected alarm/trip conditions finalised during the detailed engineering stage shall be used for SER system. (Further the lockout relay operation and certain grouped alarms shall be available in the SCADA/400kV-switchyard control system. Operator station/SER shall have a time resolution of 1 (one) ms. Minimum electrical system requirements in respect of control, monitoring, measurement, annunciation, synchronising are indicated in I&C system section No. D2.4.

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6.13 Fault disturbance recorder

Microprocessor based fault disturbance recorder shall be provided for each generator to record the graphic form of instantaneous values of voltage and current in all three phases and neutral, open and close positions of relay contacts and breaker during disturbance etc., Facility of fast scan as well as slow scan feature to be provided to record transient as well as dynamic performance of the system.

6.14 Tests Tests shall be as mentioned in Section D3.7 for Switchyard Relay Panels.

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7.0 400 kV SWITCHYARD 7.1 A 400 kV switchyard shall be provided for evacuation of power

generated in the plant through four (4) nos. 400 kV transmission lines. The necessary line bay equipment, generator transformer bay equipment with associated equipment, controls, monitoring, protection and SCADA system shall be provided by the Contractor.

7.2 The 400 kV switchyard shall have one and a half breaker switching

scheme. The Main One Line Diagram sketch no. TCE.5960A-EL-SK-2003 shows the switchyard scheme and arrangement of major equipment in the switchyard.

7.3 The 400 kV switchyard shall consists of various bays for different

configuration as follows:

Description No. of Bays

Generator Transformer 3

400 kV Line 4

Bus Reactor 2

Future bay (Spare) 1

Total 10

7.4 The switchyard equipment shall be supplied and installed with all

accessories to make the switchyard complete in all respects. The switchyard shall include the equipment indicated below but not limited to the following.

7.4.1 420 kV circuit breakers 7.4.2 420 kV isolators 7.4.3 420 kV current transformers (CTs) 7.4.4 420 kV capacitor voltage transformer (CVTs) and electromagnetic

voltage transformers (EMVTs). 7.4.5 360 kV lightning arresters (LA’s) 7.4.6 Wave traps & Coupling capacitors.

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7.4.7 Power line carrier communication (PLCC) system for 4 lines. 7.4.8 Bus bars, insulators, clamps and connectors. 7.4.9 SCADA (Supervisory Control and Data Acquisition) system for entire

switchyard with bay control units for each bay including event logging. 7.4.10 Protection panels for all bays/equipment, communication and interfacing

panels as required. 7.4.11 Stand alone disturbance recorders with associated network cabling, PC,

HMI, Printer and evaluation software. 7.4.12 ABT (Availability Based Tariff) meters including necessary software &

hardware for monitoring on dedicated PCs with suitable networking. 7.4.13 RTU (Remote Transmission Unit) for transfer of data to SLDC (State

Load Dispatch Centre) and RLDC (Remote Load Dispatch Centre). 7.4.14 Outdoor kiosks housing BCUs, protection panels, PLCC/OLTE panels,

fault disturbance recorders, etc. 7.4.15 Air conditioning and ventilation system for control building and outdoor

kiosks. 7.4.16 Fire alarm, detection & protection system for switchyard. 7.4.17. Switchyard structures, switchyard fences, earthing, trenches and

complete civil works including switchyard floors with RCC blocks. 7.4.18 Bus Reactor 7.5 Design Criteria 7.5.1 The switchyard shall be generally designed based on the following

codes and standards.

(a) IS 10118 – 1982 : Code of practice for selection installation and maintenance of switchgear and control gear – part-3 (Installation).

(b) CBIP Technical Manual on layout of substation report No.3

(c) IEC 61850 (universal): Substation automation protocol

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7.5.2 A creepage distance of 31 mm/kV on 400 kV shall be provided for circuit

breakers, isolators, Bus reactor, CTs, CVTs, EMVTs, LA’s, bus post insulators, string insulators and 420 kV transformer bushings.

7.5.3 The switchyard main buses shall be designed for continuous rating.

Bay buses shall be rated according to the circuit rating. The switchyard shall be designed for a fault level of 50 kA for 1 sec. and dynamic rating of 130 kA.

7.5.4 The 400 kV system shall be designed to withstand the power frequency

over voltage to 1.5 p.u and surge over voltage to 2.3 p.u. The busbars shall be of standard ACSR or tubular aluminium / copper according to standard metricised iron pipe size (IPS) of suitable size.

7.5.5 The conductor size of tubular bus and stranded conductors shall be

based on the maximum load current, suitability under short circuit conditions, corona / voltage gradient and effect of solar radiation. Calculation shall be submitted for Owner’s approval.

7.5.6 The final temperature of the conductor when carrying full load current

shall not exceed 850C with a maximum ambient temperature of 500C. 7.5.7 The size and spacing of strung bus, tubular bus and clamps

connections shall be checked to limit the voltage gradient to 17 kV/cm to reduce corona effect.

7.5.8 The size of shield wire shall be based on the lightning impulse current

expected and the time duration for which it is likely to flow. Allowance shall be given in the final size to account for corrosion of the shield wire during service at rate of 0.03 mm per annum, if galvanised steel wires are used. However, minimum size of the shield wire shall not be less than 70mm2.

7.5.9 Insulators

(a) Design of insulator shall avoid stresses due to expansion and contraction in any part of the insulator leading to deterioration.

(b) All ferrous parts shall be hot dip galvanized. The associated

metal part shall be permanently secured to the insulator, air tight and shall be designed to withstand all shocks and stresses to which they may be subjected to during operation and maintenance.

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(c) The design shall ensure uniform compressive pressure on the

joints.

(d) All insulators shall be of homogeneous glazed porcelain or composite type with silicon shed profile, free from laminations, cavities and other flaws or imperfections, and shall be thoroughly vitrified, tough and impervious to moisture.

(e) Porcelain glazing shall be uniform brown in colour, free from

blisters, burns and other similar defects. Composite insulators can be of grey in colour.

(f) There shall be no electric discharge between conductor and

insulators, when operating at normal voltage, which would cause corrosion or injury to any of the material.

(g) Tension and suspension insulator strings shall be anti-fog type

selected based on the voltage, insulation level, pollution level and electro-mechanical strength. Creepage chosen shall be suitable for high pollution, i.e., 31 mm / kV. Electro-mechanical strength shall be selected with factor of safety of 2.5.

(h) Bus post insulators shall be solid / post insulator anti-fog type and

shall be selected based on the system voltage, insulation level mechanical strength and pollution level requirements.

(i) Insulator hardware shall be corona free upto a falling power

frequency visible discharge test voltage of 1.1 times the maximum system voltage.

7.5.10 The lightning protection of switchyard shall be provided by lightning

masts and shield wires. The zone of coverage for the shield wire shall be considered as 60 deg. between the two shield wires and 45 deg. for the end shield wires.

7.5.11 The criteria for deciding phase to phase clearance in case of strung

conductors shall take into account that the conductor swing of one of the conductors (say R phase) with maximum wind velocity and the adjacent conductor (say Y phase) with 80% of maximum wind velocity at maximum sag conditions.

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7.5.12 For the layout proposed by the Contractor the adequacy of the cantilever strength specified shall be checked considering the following factors of safety.

(a) Sum of all permanent normal loads (wind load on tubular bus +

wind load on stack + dead weight of the tubes) x 2.5 (factor of safety).

(b) Combination of all normal loads plus either maximum short circuit

or earthquake load whichever is higher x 1 (factor of safety).

7.5.13 The switchyard shall be designed for the seismic coefficient and wind pressure as indicated in Section-B.

7.5.14 All structural steel and steel components in the switchyard equipment

shall be of hop dip galvanised. 7.6 Switchyard Layout Requirements 7.6.1 The Contractor shall adopt bolted type connectors for tubular bus

conductors, fixed type of terminal connectors for isolator terminals, flexible type of terminal connector for circuit breakers, current transformers and power transformers and flexible jumper connectors for connecting lightning arresters and voltage transformers.

7.6.2 The Contractor shall consider suitable bay width, phase spacing,

clearances, etc., depending on the actual dimensions of the equipment keeping in view the design criteria / requirements and without sacrificing any maintenance space / conveniences.

7.6.3 In the transformer yard, the power conductor termination shall not be

tapped off directly to the Generator transformer from the strung bus between the TG building and switchyard. The tap off conductor shall be routed through a bus post insulator located near the transformer.

7.6.4 The Contractor shall note that the sequence of bays shall be so

arranged that the maximum horizontal angle of deviation of the incoming power and shielding conductors from Generator transformers do not exceed 300C. Similarly, the point of anchoring on TG building shall be such that the vertical angle of deviations is limited to 300C from horizontal plane.

7.6.5 The switchyard shall be provided with access ways near the current

transformers and circuit breakers.

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7.6.6 The cable trenches for the equipment shall be run as close to their

foundations as possible even preferably touching. 7.6.7 The switchyard shall be enclosed in fence or wall around for safety and

to prohibit unauthorised persons from entering. Lockable gates for personnel entry and equipment shall be provided at convenient locations.

7.6.8 The fence provided around switchyard shall be of 2500 mm minimum

height and at a minimum distance such that section clearance is available from any live part. The fence shall be suitably earthed as per relevant Indian standards.

7.6.9 Earth mat of suitable size with closely spaced earth conductor shall be

provided below the operating handle of individual switchyard equipment As per the allowed step & touch potential values in IS.

7.6.10 Design criteria for civil works and structures shall be as specified in

Section-D4.0, civil works. 7.7 Switchyard Equipment 7.7.1 Circuit Breaker 7.7.1.1 (a) The 420 kV circuit breakers shall be of SF6 outdoor type. The

circuit breaker and its accessories viz. marshalling box / junction box shall be with IP 55 degree of protection.

(b) The SF6 circuit breakers shall be single pressure type and utilise

puffer cylinder for interrupting currents. The breaker shall be so designed that upon loss of pressure, the gap between open contacts shall be suitable to withstand at least rated voltage at zero gauge pressure of gas. Each SF6 circuit breaker pole shall be provided with its own self-contained gas system.

(c) The circuit breakers shall comprise three identical single phase

units with operating mechanism suitable for single pole operation.

(d) Tie beams between foundations of breakers of different phases are recommended as during closing / opening operation additional load in the form of vibrations may be transferred to the foundations.

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(e) Design of circuit breaker shall be such that contacts shall not close automatically upon loss of gas / air pressure.

(f) SF6 breakers shall be provided with temperature compensated SF6

density switches for individual poles with separate lockout, alarm and blocking contacts. Temperature compensated SF6 Density monitor to be provided for each phase at such a level so as to enable viewing and reading.

(g) The operating mechanism shall also have pressure switches for

low alarms, high alarm, trip, lock out switches for close, open and reclose operation.

(h) D.C. circuits for two trip coils shall be separate and each of them

shall be monitored separately.

(i) Manually operated emergency trip push button or any other device, conveniently located for mechanical tripping of all the three phases simultaneously shall be provided.

(j) Duty cycle for the breakers shall be O-0.3sec-CO–3min-CO under

all normal and fault conditions.

(k) Circuit breakers shall be suitable for rapid auto re-closing duty.

(l) All the circuit breakers in the switchyard shall be of identical make and type with interchangeable components to maximum possible.

(m) The middle breakers and the outgoing line breakers shall be

provided with PIR. 7.7.1.2 Operating mechanism

(i) Circuit breakers shall be operated by spring / spring charged mechanism. It shall be anti-pumping type and trip-free. One O-C-O operation shall be possible with failure of AC supply.

(ii) Two trip coils shall be provided for greater reliability. The trip

coils shall have sufficient continuous rating to cater to the trip coil supervision relay current.

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(iii) Separate pole discrepancy circuit with proper relay and other accessories shall be provided. Disagreement circuit shall be provided which shall detect pole position discrepancy.

(iv) A closing release shall operate correctly at all values of

voltage between 80% and 110% of the rated voltage. A shunt trip shall operate correctly under all operating conditions of the circuit breaker upto the rated breaking capacity of the circuit breaker and at all value of supply voltage between 50% and 110% of rated voltage.

(v) Mechanical interlocks shall be provided in the operating

mechanism to prevent discharging of closing springs when the breaker is already in the closed position. Provision shall be made to prevent a closing operation to be carried out with the springs partially charged.

7.7.1.3 One set of SF6 gas filling, evacuation and refilling equipment consisting

of trolley mounted compressed SF6 cylinder, gas regulator with manometer and necessary coupling for filling gas in the breaker shall be provided. The equipment shall be trolley mounted. 2 nos. of gas leak detector shall be included in the scope of supply. Detectors shall be of reputed make and have Visual as well as Audible sound facility when leakage is detected. Contractor shall supply spare SF6 gas equal to 20% of the total requirement for the station.

7.7.1.4 All circuit breakers controlling the lines shall be provided with either closing resistors or proven controlled switching devices to reduce over voltages and in-rush currents.

7.7.1.5 All routine tests on the circuit breakers shall be carried out as per IEC-

62271-100. Type test certificates for all tests carried out on identical circuit breaker as per IEC-62271-100 shall be furnished.

7.7.2 Isolators & Earth Switch

(a) Isolators shall be horizontal centre break type suitable for horizontal upright type of mounting.

(b) Isolators & Earth switch shall be suitable for operation on 400V, 3

phase, AC motor. However, it shall also be possible to operate them manually in the event of failure of power supply or outage of the drive motor with proper interlock provision for isolation of motor in case of manual operation. Earth switches shall be motor

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operated with proper interlock so that it shall not operate in case respective isolator is ON and other requisite conditions are not met. Tripping of drive, loss of AC drive supply and DC control supply shall be wired for giving alarm. The Disconnecting switches and earth switches shall be independent pole and gang operated.

(c) Isolators shall be electrically interlocked with the circuit breakers in

accordance with the switchyard safety interlocking scheme. The interlocks shall be effective for all modes of operation i.e. Electrical remote, Electrical local and Manual local. Bolt type interlock and any special accessories required on the isolator side for satisfactory operation of scheme shall be included. Interlocking scheme shall be so designed as to ensure absolute safety maximum flexibility and proper switching of CT and PT circuits.

(d) The design of the auxiliary switches for the isolators shall be such

that signalling of the closed position shall not take place unless the contact system has reached such a position that the rated current and the rated short time current can be carried safely; signalling of the open position shall not take place unless the contact system has reached a position of at least 80 percent of the clearance distance of the isolating distance. Contacts used for CT switching shall make before the isolator closed and starts carrying current. Similarly they shall open after isolator opens and breaks the primary current.

(e) Base channels and other structural steel members such as

operating pipes, phase coupling rods, operating mechanism boxes, bolts, pins, etc. shall be hot dip galvanised or metallised. All castings except current carrying parts shall be made of malleable cast iron or cast steel. Manual operating handles shall be galvanised steel.

(f) The isolator and earthing switch shall be provided with high current

carrying contacts on the hinge and jaw ends and all contact surfaces shall be of silver faced copper.

(g) Each pole of the isolator shall be provided with two earthing pads

of non-corrodible material at opposite ends, brazed to the channel base. Flexible copper earth connectors shall be provided for connecting operating handles of isolators and earthing switches to the earthing system. The poles of the isolators shall be mechanically ganged.

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(h) Earthing switch shall be provided with some isolators as indicated in main one line diagram. Two independent earthing pads each with flexible copper braids (tinned or suitably treated against corrosion) and suitable connectors for the specified size of earth conductor lead shall be provided at the hinge end of the switch. The flexible copper connections between rotating shaft of earth switch and frame shall have a cross section suitable to withstand the short time current.

(i) Isolator and earthing switch shall be mechanically interlocked such

that it will not be possible to close the earthing switch when the isolator is closed and vice-versa.

(j) Isolator shall be provided with electrical interlocking feature in all

modes of operation. This shall be in the form of bolt interlock comprising an interlock coil of latch in type to lock the isolator driving shaft and hence prevent isolator operation in the latch-in condition. It shall be possible to release the latch by energising the interlock coil when certain pre-set conditions of interlocking scheme are fulfilled.

(k) Electrical interlocking arrangements shall be fail-safe type.

(l) Isolator shall be provided with mechanical interlocking feature in

addition to electrical interlocking feature described above. (m) Operating Mechanism and Controls

(i) The manual operating handles shall be mounted on the base of supporting structure. A weather-proof galvanised sheet steel cabinet with gasket hinged door and padlocking facility shall be provided to house the driving mechanism, motor starters, control valve solenoids, auxiliary switches etc. The operating mechanism box shall have enclosures conforming to IP 55.

(ii) Arrangement shall be provided to permit manual operation of

power isolators. The arrangement shall be such that when manual operating handles is in the engaged position, the power operation shall be made inoperative. Pad-locking facility shall be provided for the manual operating handle.

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(n) All routine tests as per IEC 60129 shall be carried out. Type test certificates for all tests carried out on identical isolators as per IEC-60129 shall be furnished.

(o) All tests shall be made on completely assembled isolators,

earthing switches, their operating devices and auxiliary equipment. One assembled isolator shall be subjected to 1000 operations for checking mechanical endurance.

7.7.3 Current transformers (CTs), capacitor voltage transformers (CVTs)

and Electromagnetic Voltage Transformers (EMVTs)

(a) Electromagnetic VTs shall be provided for tariff metering (if required by grid) and CVTs for other metering and protection. Metering cores of CTs and EMVTs/CVTs shall be with accuracy class 0.2S and 0.2 respectively. Tariff metering CT & PT should comply with the requirements of CEA regulations on installation and operation of energy meters & respective grid authorities which will be intimated to successful bidder during detailed engineering.

(b) A separate 2 core CT (for Main and Check Meters) of accuracy class 0.2S for tariff metering for each line. The VA burden of the tariff metering CTs shall be subject to the approval of grid authorities.

(c) A separate 2 winding EMVT (for Main and Check Meters) of accuracy class 0.2S for tariff metering for each line. Tariff metering EMVT terminals shall be housed in separately sealable terminal boxes.

(d) Separate CT cores for Main-1 and Main-2 Carrier aided Distance Protection (21) for each line.

(e) The CTs and EMVTs shall be either oil filled hermetically sealed or

SF6 gas filled single phase type. The CVTs shall be oil filled single phase type.

(f) In case of SF6 filled CTs and EMVTs, gas density monitors with remote alarm facility shall be provided.

(g) The rated burden for the metering and protection cores shall be decided considering all the loads/relays connected, future additions, lead burden etc.

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(h) The knee point voltage for PS class cores shall be decided considering the total connected burden with adequate margin.

(i) The magnetising current at Vk/2 shall be as minimum as possible

(say 15 mA). Shall have a rated extended primary current of 120% of rated primary current.

(j) The core lamination shall be of cold rolled grain oriented silicon

steel or other equivalent alloys. The cores shall produce undistorted secondary current under transient conditions at all ratios with specified parameters.

(k) Insulator shall be one piece without any metallic flange joint.

(l) Expansion chamber at top shall be provided with oil sight glass.

(m) Shall have provision for taking oil samples from bottom of CT

without exposure to atmosphere to carry out dissolved gas analysis periodically.

(n) The CVT secondary shall include necessary MCBs with auxiliary

contacts for alarm for protecting the secondary winding. Further, for the purpose of supervision on remote panel, line terminals of the CVTs shall be brought out through second set of MCBs. All the terminal boxes shall be powder coated with IP-55 degree of protection.

(o) Secondary terminals of CTs shall be brought out in a weather

proof power coated terminal box. Facility shall be provided for short circuiting and grounding the CT secondary at the terminal box. All the taps of each core shall be wired to Marshalling Box to facilitate ratio changing. The box shall have a degree of protection IP-55. Tariff metering core terminals (for connecting main and check meters) shall be housed in a separate sealable terminal box.

(p) CT/CVT/EMVT assembly shall be suitably braced to withstand

stresses induced due to seismic disturbances.

(q) The tank/base and all exposed ferrous parts shall be hot dip galvanised conforming to applicable standards.

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(r) Each CT shall be equipped with an over voltage protective device to limit the voltage developed across the secondary terminals to a safe value not exceeding 3 kV under open circuit condition.

(s) It shall be possible to select the ratio on any core independent of

the setting in the other cores, for which purpose, tappings will have to be provided on the secondary windings.

(t) Oil filled insulator/bushings shall be hermetically sealed to prevent

ingress of moisture. A cushion of nitrogen gas shall be provided to allow for expansion.

(u) Each CT/CVT/EMVT shall be supplied with suitable G.I supporting

structure.

(v) All CTs/EMVTs shall be provided with stainless steel bellows.

(w) One MB for each set of 3 CTs/CVTs/EMVTs shall be provided. The MB shall be fixed to the supporting structure of CT/CVT/ EMVT. The MBs shall be fitted with adequate no. of disconnector type of test terminal boards suitable for terminating 2 nos. of 2.5 sq mm multi-strand copper wires. At least 20% spare terminals shall be provided.

(x) The instrument transformers shall be provided with filling and

drain plugs. (y) Polarity marks shall indelibly be marked on each instrument

transformer and at the secondary terminals at the associated terminal block.

(z) Neutral of all cores of CTs, CVTs and EMVTs shall be formed in marshalling box of the respective equipment. Cables with sufficient number of cores are run from these marshalling boxes to protection panels. The neutral of CTs, CVTs, and EMVTs shall be earthed only at protection panels by means of a disconnecting link.

(w) Tests & Test Reports All routine tests on the 400 kV voltage and current transformers

shall be carried out as per relevant standards. Type test certificates for all tests carried out on identical voltage and current

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transformers shall be furnished. If test reports are not in line with the requirement of IS/IEC then the Contractor shall carry out type test at no additional cost to the Owner.

7.7.4 BUS REACTORS a) 400 kV, 50 MVAR Three Phase Oil Filled Bus Reactors are considered in

the switchyard. However, the exact requirement for these Bus reactors will be confirmed during detailed engineering based on the system study to be carried out by the bidder. However, at present, the bidder shall consider these Bus reactors in their offer.

b) Bus reactors shall operate continuously at the highest system voltage

without exceeding the guaranteed temperature rise. c) The total harmonic content in the phase current of a star connected reactor

and zero sequence components appearing in the neutral shall be below 3% of the crest value of rated current.

d) The impedance of reactor shall have a constant value upto about 1.5 times

rated highest system voltage. Further the impedance shall be accurately balanced between the three-phase system.

e) The magnetic circuit of reactor shall be so designed that the audio sound

level shall be minimum. f) The losses of the reactor shall be limited to the values to permit ONAN type

of cooling. g) Bus reactors shall be designed for 110% continuous over-fluxing withstand

capability. h) The reactors shall be either gapped core type or coreless type. i) Special measures shall be taken by providing non-magnetic shielding to

combat the effects of stray/leakage flux. j) Windings shall be of copper unless specifically approved by the

PURCHASER. The conductors shall be transposed at sufficient intervals in order to minimise eddy currents and equalise the distribution of currents and temperatures along the windings.

k) Tank shall be made from good commercial grade low carbon steel and

shall be of welded construction.

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l) Tank shall be provided with a pressure release device which shall operate

at a pressure below the test pressure for the tank and radiators. The device shall be rain-proof after blowing and shall be provided with a device visible from ground to indicate operation. An equaliser pipe connecting the pressure relief device to the conservator shall be supplied.

m) Valves shall be of forged carbon steel upto 50 mm size and of gun-metal or

of cast iron bodies with gun-metal fittings for sizes above 50 mm. They shall be of full-way type with screwed ends and shall be opened by turning counter clockwise when facing the hand wheel. There shall be no oil leakage when the valves are in closed position.

n) The under-carriage of the reactor shall be provided with detachable steel

flanged wheels. o) Separately mounted radiator banks shall have bolted flanged connections

and pipe extensions to permit withdrawal of reactor tank without disturbing the radiators.

p) Bushings shall be of the oil-filled condenser type with a central tube and

draw-in conductor, which shall be connected to the connector housed in the helmet of the bushings. The pull through lead shall be fitted with a gas bubble deflector. Condenser type bushings shall be equipped The angle of inclination to vertical shall not exceed 30 deg.

(a) Provision for power factor testing without disconnecting main leads. (b) Stress rings and lower and shields. (c) Current transformers shall be provided and the bushing shall be so

arranged that it can be removed without disturbing the current transformers and secondary terminals.

(d) Bushing turrets shall be provided with vent pipes, which shall be

connected to route any gas collection through the Buchholz relay.

q) The Bushing CT’s for protection shall be provided as per the enclosed Main One Line Diagram TCE.5960A-EL-SK-2002.It shall be possible to remove turret mounted Bushing CT's from the reactor tank, without removing the cover.

7.7.5 Lightning Arrester

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(a) 360 kV, 20 kA nominal discharge current, class – IV pressure relief class-A, metal oxide, gap less lightning arrester shall be provided as per the Main one line diagram No. TCE.5960A-EL-SK-2003.

(b) Operational requirements

(i) Shall protect power transformers, circuit breakers,

disconnecting switches, instrument transformers etc. with insulation levels specified in this specification.

(ii) Shall be suitable for circuit breaker duty cycle in the given

system. (iii) The reference current shall be high enough to eliminate the

influence of grading and stray capacitance on the measured reference voltage. Values and calculations shall be furnished with offer.

(iv) Shall be fully stabilized thermally to give a life expectancy of

one hundred (100) years under site conditions and take care of effect of direct solar radiation.

(v) Shall be capable of discharging over-voltages occurring due

to switching of unloaded transformers and long lines, (c) Specific Requirements Arrester shall be suitable for installation in effectively earthed

system. The Contractor shall carry out the insulation coordination studies for deciding the exact location and voltage levels of the LA’s.

(i) Shall be hermetically sealed single phase unit. (ii) Shall be robust with excellent mechanical and electrical

properties. (iii) Shall be capable of withstanding meteorological and short

circuit forces under site conditions.

(iv) Each lightning arrestor shall be complete with insulating base for mounting on structure.

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(v) LAs shall be provided with grading and/or corona rings as required.

(vi) LA’s shall not fail due to porcelain contamination.

(vii) Porcelain shall be so coordinated that external flashover will

not occur due to application of any impulse or switching surge voltage upto maximum design value for LA.

(viii) The end fittings shall be non-magnetic and of corrosion proof

material.

(ix) Surge monitor shall be provided for each arrester and the same shall be mounted at a suitable height to facilitate easy reading of the counter mechanism and leakage current detectors.

(x) Insulated copper conductor of adequate size and length shall

be used for connecting discharge counter, terminal and lightning arrester earth terminal. Insulation level of the same shall not be less than 3.6 kV.

(xi) Suitably sized bypass copper shunts shall be provided for

bypassing the discharge counter for removal / maintenance of the counter.

7.7.6 Line Traps

(a) Line trap shall be of pedestal mounted, wound coil, broad band tuned.

(b) Line trap shall prevent undue loss of carrier signal for all

conditions. (c) It shall have negligible impedance at power frequency, which shall

be relatively high over the frequency band appropriate to carrier transmission.

(d) It shall be suitable for outdoor pedestal mounting and mechanically

strong to withstand the stresses due to wind pressure.

(e) It shall be mounted on a tripod structure formed by three solid core bus post insulators.

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(f) Line trap shall consist of a main coil designed to carry continuously the rated current without exceeding the limit of temperature rise limits. It shall be equipped with bird barriers and shall be spray painted as per IS. It shall be provided with protective device and tuning device.

(g) Suitable corona rings shall be provided to meet corona and radio

interference performance as specified for 400kV equipment if required.

(h) Even though the line traps shall be installed in two phases, the

foundation shall be constructed in all the three phases to facilitate the change of location of line trap between the phases.

(i) Suitable surge arresters shall be provided.

(j) Shall be designed and arranged such that neither significant

alternation in its protective function nor physical damage shall result from either temperature rise or the magnetic field of the main coil at continuous rated current or rated short time current.

7.7.7 Clamps and Connectors

(a) Shall be Aluminium alloy casting conforming to designation A6 of IS:617 for connecting to equipment terminals and conductors of aluminium. In case the terminals are of copper, the same clamps/ connectors shall be used with 2mm thick bimetallic liner.

(b) Shall be Galvanized mild steel for connecting to shield wire. (c) Bolts, nuts and plain washers shall be hot dip galvanized mild steel

for sizes M12 and above. For sizes below M12, they shall be electro-galvanized mild steel.

(d) The spring washers shall be electro-galvanized mild steel.

(e) All castings shall be free from blow holes, surface blisters, cracks

and cavities.

(f) All sharp edges and corners shall be rounded off to meet specified corona and radio interference requirements.

(g) Shall have same current rating as that of the connected equipment

with temperature rise limited to 350C over 500C.

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(h) All current carrying parts shall be at least 10 mm thick.

(i) Shall be manufactured to have minimum contact resistance.

(j) Flexible connectors, braids or laminated strips shall be made up of

copper/ aluminium.

(k) Current rating and size of terminal/conductor for which connector is suitable shall be embossed/punched on each component.

7.7.8 Insulator String Hardware

(a) Shall be of bolted type and forged steel except for insulator cap, which can be of malleable cast iron.

(b) Shall also generally meet the requirements of clamps and

connectors as specified above.

(c) In one span, Tension string assembly at one end shall be supplied with suitable turn buckle.

(d) Suitable sag compensating spring shall be supplied in case the

design calculations show excessive variation of the sag over the temperature range of 0 to 80 deg. C.

7.7.9 Spacers

(a) Shall be non-magnetic material except nuts and bolts, which shall be of hot dip galvanized mild steel.

(b) Shall generally meet the requirement of clamps and connectors

specified above.

(c) Design shall take care of fixing and removing during installation and maintenance.

7.8 Switchyard Control and Relay Panel 7.8.1 Bidder shall offer air conditioned outdoor kiosks suitably located in

switchyard, housing various IEDs such as Bay Control Units (BCUs), Protection Panels, Fault Disturbance Recorders, PLCC/OLTE Panels, etc. However, SCADA servers and associated equipment, SCADA Operator Station, RTU for SLDC/RLDC, DC battery, battery chargers,

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DCDB, 400 V ACDBs, UPS system, etc. shall be located in the switchyard control building for overall optimization in respect of cabling and control room building size. One kiosk shall be considered per diameter (comprising of two circuits in one and half breaker scheme) of 400kV switchyard. In case of incomplete diameter, the kiosk shall have necessary space for accommodating the future bay IEDs. One additional kiosk, if required, shall be provided for housing busbar protection panels at suitable location in switchyard. The layout of equipment/panels shall be subject to Purchaser’s approval. The kiosk shall be provided with fire alarm system with at least two detectors and shall be wired to fire alarm panel as described elsewhere in the specification. All CT, PT, control cables, etc. from switchyard equipment shall be connected to respective IEDs located in kiosks. Two optical fibre cables (OFC) shall be laid to connect BCUs to SCADA for data exchange. Different routes shall be adopted for OFC. Technical requirements of outdoor kiosks are detailed elsewhere in the specification.

The switchyard protection shall consist of:

(a) One complete set of relay panels for 400 kV switchyard

equipment

(b) System fault locaters – as a part of Main-1 numerical relay (BCU)

(c) Stand alone Disturbance recorders - as a part of BCU

7.8.2 The control and interlocking scheme suitable for one and a half breaker

switching scheme shall be provided. Contractor shall furnish block interlock diagrams for the switchyard for Owner’s approval. The scheme as approved by Owner shall be provided. All the auxiliary relays, timers, switches, hardware, etc., required for the scheme are deemed to be included in the Contractor scope.

7.8.3 Line bays shall be provided with single phase and three phase auto

reclosing feature. The auto re-closing scheme shall be available in one of the numerical line protection relays but shall get independently actuated by the operation of both the protective relays. All the necessary relays, trip relays, auxiliary relays shall be provided. Provisions shall be made to accord higher reclosing priority to main breakers, or to issue reclosing command to both breakers simultaneously. Rapid reclosing & delayed reclosing features shall be

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provided. All conditions requiring blocking auto reclosure shall be considered.

7.8.4 Live line–dead bus closing and dead line-live bus closing facilities shall

be provided using dedicated relays for this purpose. Indicating lamps for fulfilment of the permissive condition shall be provided.

7.8.5 Synchronizing function shall be through BCU for GTG units and a

separate synchronizing equipment along with check synchronizing facility to be provided for STG units. Synchronising facility shall be provided for all lines in DCS. In check synchronising position, the synchronising criteria shall be fulfilled as indicated by the closing permissive provided by check synchronising relay. In manual mode, closure is possible only if either the line or the bus is dead. It shall not be possible to close in manual mode if both line and bus are live.

7.8.6 Control and indication shall be provided for each of the breaker and

isolator. 7.8.7 The measurement requirements for each of the bays shall be as per

the Main one line drawing TCE.5960A-EL-SK-2003 and Section D2.4 - I & C requirements.

7.8.8 Monitoring-Indication, abnormal conditions, Measurement required in

DCS shall be as given in Section D2.4 7.8.9 All relay panels shall be located in outdoor kiosk and these kiosks shall

be located in switchyard. 7.8.10 In the event of shortage of contacts in main circuit breakers, isolators

and earth switches, contact multiplying relays shall be used. The same shall be two coil, latching type with electrical reset and shall be mounted in switchyard relay panels. At least 2NO + 2NC spare contacts shall be wired to terminal block after fully utilising for control, protection, annunciation, etc.,

7.8.11 It shall be possible to control (including synchronising) all the 400 kV

switchyard breakers and isolators from SCADA . 7.8.12 Relay setting calculations shall be furnished by the Contractor to the

Owner for his approval. 7.8.13 All main protections shall be of numerical type. The functional

requirements and characteristics of the relays specified are the

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minimum required. The responsibility of establishing the equivalence or superiority of relays offered vis-a-vis the stipulation of the specification rests with the Contractor.

7.8.14 The Contractor shall provide licensed copy of software on CD for relay

setting software and calculations for future use of the Purchaser. Relay setting calculations shall be furnished by the Contractor to the Purchaser and the grid authorities for their approvals.

7.8.15 The numerical protection relays shall be able to be configured locally.

For this, Contractor shall provide a laptop and the necessary software for relay settings, data transfer and parameterization. This laptop shall be common for SCADA BCU (Bay Control Unit) parameterization and protective relay parameterization. The configuration/specification of the laptop shall be the latest as available in the market as on date of supply. It shall also be possible to configure the SCADA BCUs remotely from the SCADA Engineering Station.

7.8.16 The relay settings, parameterisation and the retrieval of data from the

relay and relay operations shall be possible from SCADA operator station in addition to the laptop. The communication between the numerical relays and SCADA system shall be through serial link with fibre optic cable connection. The communication protocol between the numerical relays and SCADA system shall be IEC-61850.

7.8.17 The interlocking scheme shall be hard wired and shall be suitable for

one and a half breaker switching scheme. Contractor shall furnish block interlock diagrams for the switchyard for Purchaser’s approval. The scheme as approved by Purchaser shall be provided. All the auxiliary relays, timers, switches, hardware, etc. required for the scheme are deemed to be included in the Contractor’s scope.

7.9 Protection Philosophy The protection philosophy indicated in section D3.6 for Generator

protection shall be followed for switchyard protection as well. Numerical relays shall be provided for main and secondary protection of

lines, Buses, etc. However, static relays have to be provided for breaker protection, PT supervision.

(a) The protections envisaged for each 400 kV switchyard bay

are listed below and also in Main one line diagram Drg. No.

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TCE.5960A-EL-SK-2003. It shall be read in conjunction with the following and all protection indicated shall be provided.

(b) Line Bay Relay panel (Each Line Bay)

(i) Main-1- 3-zone carrier aided distance protection (21-1) with in-built back-up directional over current and earth fault protection (67/67N).

(ii) Main-2- 3-zone carrier aided distance protection (21-2)

with in-built back-up directional over current and earth

fault protection (67/67N).

Both main-1 & main-2 protections shall be

mechanically, physically and electrically separated into

two separate and independent systems. Both main-1

and main-2 protections shall work on different

principles/algorithms. 21-1 & 21-2 line protection relays

shall have all the basic protection like SITF, PSB etc.

(iii) Identical distance relays shall be supplied loose for

four (4) 400kV lines

(iv) Fuse fail relay (FFR) for each secondary of CVT /

EMVT

(v) Two stage over voltage relay (instantaneous & time delayed)

(vi) Stub protection (50STB) as part of main-1 & main-2 protections for 400 kV lines to protect the stub portion of line bays during line outages

(vii) Distance to fault locator (DFL)

(viii) Fault disturbance recorder (FDR) with 8 analog and 16

digital channels.

(ix) Under voltage relays for live line/dead bus, dead

bus/live line closing and safe grid re-establishment (27-

1, 27-2, 27S)

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(x) Auto reclosing scheme relays with single phase & three phases reclosing, dead line charging and live line reclosing.

(c) Busbar Protection Relay Panel

Numerical type, distributed busbar protection scheme based on”low impedance” principle for selected bus arrangement shall be provided. It shall have check and discriminating zones, CT supervision and In-Out switch. Each breaker shall be provided with its own trip relay. Each trip relay shall be supervised and contacts shall be made available for annunciation/SCADA.

(d) Over head line differential protection (between GT HV bushing & switchyard gantry) (87OH) shall be part of switchyard relay panel (SRP).

(e) Common Items/protections to be included in all relay

panels

(i) Local breaker back up protection with its own trip relay (50 LBB for each breaker). LBB in-out switch shall also be provided.

(ii) Pre and Post close Trip circuit supervision relay for

each trip circuit (98L)

(iii) High speed trip relays (86L).

(iv) Supervision relays for tripping relay (98 LT1 to LTX) to

supervise the coil of each trip relay.

(v) Auxiliary relays and timers in adequate numbers to make the protection scheme and discrepancy switch scheme complete.

(vi) Auxiliary CTs and auxiliary VTs with suitable

characteristics and accuracy as required.

f) Reactor Protection Over Current Protection (50 and 51) Neutral Over Current Protection (51N) High Impedance type Differential Protection (87R)

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7.9.1 The functional requirements and characteristics of the relays specified

are the minimum required. Any additional protection considered necessary by the Contractor shall also be provided by him. The responsibility of establishing the equivalence or superiority of relays offered vis-a-vis the stipulation of the specification rests with the Contractor.

7.9.2 The protective relays shall be of integrated numerical type with serial

interface for communication with SCADA system. The numerical protective relays shall be based on internationally accepted Open Protocol IEC-61850. If any of the protections are not covered in the main numerical relay, separate discrete numerical/microprocessor/static relays shall be provided. All hardware, auxiliary relays, timers etc. required for tripping/interlock schemes shall be provided by the Contractor.

7.9.3 Numerical relays shall have self diagnostics and watch dog feature for

remote annunciation in SCADA. Protective relays shall have adequate number of site configurable LEDs and output relays. Push buttons for testing and resetting the LEDs shall also be provided. All protective relays and meters shall be provided with test terminal blocks for secondary injection testing of protection relays and meters. In addition to the contacts required as per the schemes, Contractor shall wire out to the terminal block at least one NO & one NC spare contacts of each of the relays.

7.9.4 The protection schemes shall include all the necessary contacts for

interlocks, alarms in SCADA, sequence event recorder wherever required. Contact multiplication relays for 400kV circuit breakers and associated isolators shall be provided for this purpose.

7.9.5 All SCADA alarms shall be categorized into different categories

(typically 5). For each category, a different tone shall be sounded on the hooter and the alarm shall be represented in a different colour on the screen. All digital inputs shall have a time resolution of 1 (one) ms.

7.9.6 All numerical relays and SCADA clock shall be time synchronised with

the GPS master clock. The contact rating of contactors provided in SCADA Panels shall be suitable for making/breaking of control circuit currents of the respective devices being controlled.

7.10 Supervisory Control and Data Acquisition (SCADA) System

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7.10.1 SCADA system comprising of various controls, metering, indication,

annunciation, synchronising, remote control functions, mimic diagram, sequence of events recording, etc., shall be provided for the switchyard.

7.10.2 The controller shall be configured with redundant CPU. The redundant

CPU shall be configured to operate as hot standby. The SCADA system shall be generally in line with the details shown in SCADA System Configuration Drawing, TCE.5960A-EL-SK-2004. All the SCADA switches and servers shall be located in switchyard control room. All SCADA servers & Front End Processor servers (if any) shall be rack mounted. The Controller shall also be configured with double redundant power supply units.

7.10.3 The switchyard equipment shall be remote controlled from Central

Control Room (CCR) of the Power Plant through the SCADA HMI in order to enable the Switchyard Control Room being totally un-attended.

7.10.4 The SCADA system shall be based on a de-centralised concept with

bay oriented distributed intelligence devices, for safety and availability reasons. The offered SCADA system shall be of latest state of art design with capability to interface with bay control units (separate for each bay). The offered SCADA system shall be based on internationally accepted Open Protocol IEC 61850, Scalability and Open Architecture.

7.10.5 The communication between the numerical relays and SCADA system

shall be with fibre optic cable. 7.10.6 SCADA system shall be fail safe design. The Contractor shall furnish

documents to establish and prove that the system is highly reliable with very high MTBF (Mean Time between Failures).

7.10.7 One (1) no. Operator Station(OS) for SCADA (for control and

monitoring of complete 400 kV switchyard equipment) shall be located in Central Control Room (CCR) of power plant and one (1) no. in Switchyard Control Room. One (1) no. Engineering Station shall be provided in the Switchyard control room to make the SCADA configuration changes and system settings. The Engineering Station(ES) located in Switchyard control room shall also be configured as Operator Station to act as standby in case of failure of the Operator Station in Switchyard control room. The OS and ES display/monitors shall be dual headed, 24 inches size, LCD type and the make shall be finalised during detailed engineering so as to match with those

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provided for Main Plant DCS. In the CCR, necessary printers as shown in SCADA Configuration Drawing shall also be provided for SCADA system. All printers shall be equipped with USB port and enough USB cables (minimum 5m length) to enable the printers to be placed in a convenient location. It shall be possible to configure the printers to print on demand/online or at specified intervals. Control room furniture for mounting the operator station along with 3 nos. chairs shall be provided in the switchyard control room. The console on which the operator station is mounted shall be properly ventilated (forced cooled if required).

7.10.8 The control location for the switchyard equipments shall be Switchyard

control room by default. But provision shall be made available in the SCADA to control the switchyard equipments from Centre control room (CCR) also. It shall not be possible to control the switchyard equipments from both the locations simultaneously. The required selection shall be provided in the operator station of Switchyard control room.

7.10.9 Information exchange shall be provided from SCADA to plant DCS

through suitable, fast, reliable and redundant serial communication interface.

7.10.10 Synchronising facility shall be provided for all lines in SCADA. In check

synchronising position, the synchronising criteria shall be fulfilled as indicated by the closing permissive provided by check synchronising relays in-built in BCUs (separate sync check relays are not envisaged). In dead bus/line mode, closure is possible only if either the line or the bus is dead. The synchronising of the line shall be possible through both main breaker and the middle breaker. Display of voltages and frequencies of incoming and running supplies, synchroscope and the sync. permissive signal shall be simulated in the SCADA operator station. The synchronism and energizing check functions shall be bay oriented and distributed to the bay control units and/or protection devices. All features shall be available viz. a) Setting voltage, phase angle, and frequency difference b) Energizing for dead line - live bus, live line - dead bus or dead line – dead bus with no synchro-check function c) Synchronising between live line and live bus with synchrocheck function. The correct voltage for synchronizing and energizing is derived from the auxiliary switches of the circuit breakers and the isolators and shall be selected automatically by the bay control and protection IEDs. The closing operation of line breaker shall involve the following steps, viz. a) selection of the breaker to be closed, b) mode of closing operation i.e. whether both the line and the bus are

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live or only one of them is dead as sensed by voltage relays connected to the respective CVTs. In live-bus/live-line case, synchronisation between the two voltages is checked by the check synchronisation relay which generates permissive only if the synchronisation criterion is met. If either the line or the bus is dead, the logic develops using the contacts of bus voltage and line voltage relays which generates permissive for closing of the breaker, c) issuing the closing command after obtaining the synchro permissive or live-bus/dead-line or live-line/dead-bus permissive as the case may be. This permissive shall be displayed on the SCADA HMI.

7.10.11 The generator transformer main breaker will be controlled from main

plant DCS. It shall be possible to control the middle breaker from both DCS (through auto/manual synchronisation) and SCADA with the help of a selection available in the SCADA software. The selection shall have two positions i.e. “SCADA” and “DCS”. If “SCADA” is selected, all the required signals including PT signals for synchronising shall be transferred to SCADA system. If “DCS” is selected, all the required signals shall be transferred to DCS/GRP (Generator Relay Panel). The control of middle breaker from SCADA shall be suitably interlocked such that its closure is not possible when it is used as generator synchronising breaker.

7.10.12 Transducers shall be provided, wherever necessary, for the indication

of electrical parameters related to switchyard bays as required. Transducers shall be used only for monitoring of non electrical quantities such as Bus reactor oil and winding temperature and for electrical quantities such as battery charger voltage, battery charger current, 400 kV bus voltages. For monitoring of all other bay wise electrical quantities, IEDs such as BCUs shall be used. The exact no. of analog and digital IO (input/output) points shall be dicided during detailed engineering.

7.10.13 All the auxiliary contacts of main equipment such as circuit breakers,

isolators, earth switches shall be brought to the protection panels for indications, interlocks, SER function, etc. In case of shortage of auxiliary contacts, contact multiplying relays shall be used. The same shall be two coil, latching type with electrical reset and shall be mounted in switchyard protection panels. At least 2NO + 2NC spare contacts shall be wired to terminal block after fully utilising for control, protection, annunciation, etc.

7.10.14 It shall be possible to control and monitor (including synchronising) all

the 400kV switchyard breakers & isolators from SCADA except main

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circuit breakers of generators. Main circuit breakers of generators are controlled from Central Control Room through Plant DCS and monitored both in DCS and SCADA. Earth switches shall be operated only from local but is monitored in SCADA. Isolators and earth switches pertaining to generator transformer bay shall be monitored both in DCS and SCADA.

7.10.15 Monitoring – SCADA

a) Indication – status of all breakers, isolators and earth switches of all 400 kV bays, local/remote selector switch positions, synchronising switch positions, voltage selection, Auto re closing selection, selection of control from SCADA/DCS, etc. shall be available in SCADA. The selection of control of middle breaker of generator bay from DCS/SCADA shall be displayed both in DCS and SCADA.

b) Abnormal conditions to be considered for alarm inputs are

400 kV system operation of each line protection, Busbar protection, Trip circuit unhealthy of each equipment, protection unhealthy of each equipment, Trip relay unhealthy of each equipment, VT circuit unhealthy of each VT, LBB operation of each breaker, DC supply failure of each protection / control scheme as appropriate, wrong selection of PT supply, abnormal conditions of breakers, successful /unsuccessful auto reclosure, DC & UPS system alarms, etc. The alarm states are not exhaustive. The Contractor shall include all alarm states deemed necessary for the safe operation of the system.

c) Event register with time stamping – Opening or closing of all breakers, isolators and earth switches, opening and closing commands, change of positions of switches such as Local/Remote selection, synchronising selection, voltage selection, auto re-closing selection, selection of control from SCADA/DCS, operation of all protection and trip relays, VT fuse fail relay operation, auto re-closing operation, direct trip send and receive, pole discrepancy relay operation, trip circuit faulty, trip relay faulty, DC supply fail, SF6 pressure Low, LBB operated, etc. shall be available in SCADA. As stated at b) above, this list shall include all events and operation of switchyard equipment that are considered essential for analysis of faults.

7.10.16 Mimic

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A mimic diagram depicting the entire electrical system being

controlled from the system with different colours for different voltage levels shall be provided in SCADA operator stations. The colours of different voltage levels shall be as per relevant IS applicable for mimic on panels.

7.10.17 Measurement The measurement requirements for each of the bays shall be as per

the Main one line drawing TCE.5960A-EL-SK-2003 and as given below:

Feeder Description DCS Operator Station (a) GT bays V (All phases)

A (All phases) MW MVAR Tap position, Winding

& Oil temperature TVM (b) 400 kV line bays V(All phases) A(All phases) MW MVAR

MWH MVARH

TVM

(c) 400 kV Bus PT V(bus 1&2) F(bus 1&2)

7.10.18 Event logging and trending facilities shall be provided in SCADA system.

It shall be possible to trend different parameters on the same trend. It shall be possible to store historical data for a minimum of two years. SCADA system shall have provision for expansion and shall be capable of communicating with other systems through open protocol.

7.10.19 The Contractor shall make provision for terminating 4-20 mA analog

signals and potential free digital signals for the following data on a terminal block in a suitable interface panel located in switchyard control building for transmission to SLDC (State Load Despatch Centre) and RLDC (Regional Load Despatch Centre) through RTU (Remote

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Transmission Unit). The energy meters(EM) shall not be connected to the RTU’s. The specification of RTU provided for this purpose by the Contractor shall be subject to approval by the SLDC/RLDC authorities. The actual data to be transmitted to SLDC/RLDC shall be finalised during detailed engineering and the following is the minimum data to be transmitted through RTU.

• MW and MVAR of all lines

• MW and MVAR of HV side of all generator transformers

• Voltage and frequency of 400 kV buses

• ON/OFF positions of all breakers and isolators of all line bays, Generator transformer bays, Bus PT bays.

• Tap positions of GTs & UATs

7.11 Bay Control Unit (BCU)

a) The BCU shall be an intelligent unit and shall be state of the art technology. It shall perform control functions in accordance with control commands from SCADA and shall also do monitoring of the respective bays. The BCUs shall be installed in the respective protection panels of each circuit breaker in the switchyard relay room (Outdoor Kiosk). The control voltage for the BCU shall be 220V DC. The degree of protection of the panel shall be IP-52. The BCU shall comply with relevant IEC/BIS standards.

b) BCU shall have adequate number of ports for communication and

interface with switchyard control system for bay control and monitoring. The BCU shall provide direct connection to the switchyard equipment for control (with or without interposing relays) and shall perform control and monitoring functions, including live-line/dead-bus, dead-line/live-bus and live-line/live-bus breaker closing. The communication link between BCU and SCADA shall be redundant. The BCUs shall be independent of each other and functioning shall not be affected by any fault occurring in any of the other BCUs.

c) Protection relays shall be separate and shall not be part of BCU.

Direct hard wiring shall be employed for critical tripping. Numerical protection relays shall also be connected to the SCADA bus for retrieval of data.

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d) Atleast one bay control unit (BCU) shall be provided for each breaker. The analog and digital signals pertaining to a circuit shall be taken through the BCU provided for that circuit.

e) One no. licensed software for configuration and parameterization

of SCADA shall be delivered on CD along with BCUs. The configuration shall be carried out from local or from laptop computer but operation shall be from SCADA operator station. Configuration of BCUs shall also be possible from remote through engineering work station. The lap top computer provided for the switchyard shall be loaded with this software.

f) The BCU shall have at least the following features:

i) Monitoring The following monitoring functions shall be provided as a minimum :

• Status monitoring and failure monitoring (in SCADA HMI) of bay equipment like breaker, isolators, earth switches, instrument transformers, protection relays and ancillary equipment metering (measured-value acquisition)

• Signal and command indications

• Switching statistics in BCU (breaker ON/OFF, breaker auto-reclose, pole discrepancies) and data stored in SCADA server

• Energy metering values

ii) Control The following control functions shall be provided as a minimum:

• Control of circuit breakers and isolators

• Interlocking for isolators and circuit breakers, isolators and earth switches (The interlocks for earth switches shall be hard wired)

iii) Recording The event recording function shall be provided and processed in the BCU and the record stored in SCADA. Each BCU shall contain an event recorder capable of storing at least 200 time tagged events.

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iv) Human Machine Interface (HMI) Following local human machine interface inbuilt in BCU shall be provided as a minimum :

• The local HMI is a monitoring and maintenance tool for bay control unit and data communication unit during commissioning and/or maintenance.

• Position of switching elements (Feeder control diagram) shall be shown on the graphic display.

v) Time Synchronizing Feature • BCU shall be time synchronized with GPS based Master

Clock of the Facility

vi) Self diagnostic and Supervision Features

• BCU shall have self diagnostic and supervision features. Failure of IEDs connected to the SCADA System such as BCUs, Numerical Relays and Tariff Meters shall be indicated in the SCADA HMI

vii) Operating Mode Selection

• Operation mode selection (local or remote) shall be provided in BCU.

7.12 Bay Marshalling Box(s)

Adequate number of outdoor mounted, free standing type, power coated bay marshalling boxes shall be provided in switchyard. The pre-treatment of the sheet steel shall involve degreasing rust/scale removal, phosphating and oven drying. The phosphate coating shall be sealed by the application of two coats of ready mixed, stoving type zinc chromate primer followed by two coats of synthetic enamel paint by powder coating process. The paint shade of the panels shall be Opaline Green(external) and semi glossy white(Internal). Bay marshalling box shall be provided with two subsections namely: Terminal box and auxiliary supply distribution box.

(a) Terminal box: Providing intermediate termination of all auxiliary

contacts of breaker, isolator and earthing switches (whether used or not) and preparing interlocking. (CT & PT marshalling boxes shall be provided with respective CTs & PTs.)

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(b) Auxiliary supply distribution box from where both AC auxiliary supply, heating/lighting supplies and DC auxiliary control supply shall be distributed to various motors of all CBs, isolators/ earthing switches local marshalling box/equipment marshalling box and heating and lighting supply to various bay marshalling boxes. The marshalling boxes shall be provided with doors on both sides with key lockable handle for each door. The key shall be removable only in door locked position.

All auxiliary contacts of the CBs, isolators and earthing switches shall be terminated in terminal box section of bay marshalling boxes. All hardwired interlocking shall be wired in the above box. All auxiliary contacts and interlocked scheme contacts shall be wired to respective panels in the control room.

Provision for terminating two number of 3 phase, 3 wire AC 50 Hz power supply called supply I & II, shall be provided in each auxiliary supply bay marshalling box. The AC distribution scheme shall be wired to manually select any one of the supplies by manually operated selector switch. After the manual selector switch, MCB controlled AC distribution shall be provided in such a way that individual and radial feeder supplies to driving mechanism/motor of every equipment is arranged. Contacts for remote alarm for supply fail shall be provided. Similarly provision for terminating 2 Nos. DC supplies and selection feature to select any one of the two supplies as supply-I and other as supply II shall be provided. Either of them shall be used after distributing it via suitably rated HRC fuses to feed, control supply of all isolators and earthing switches. Remote independent alarm for failure of all AC and DC outgoing feeders shall be provided by supply supervision relays having delayed dropout NC contact. Single phase 230V heating and lighting supply shall be provided in a loopin / loopout mode at bay marshalling box. The heating and lighting supply shall be sub-distributed in radial way to provide heating and lighting supplies for all HV equipment marshalling boxes and each bay marshalling box. The scheme for all protections, controls, indications, interlocking, metering, AC and DC distribution and all other schemes shall be prepared in such a way that cables shall be laid in radial pattern. Loop formulation of cables shall be completely avoided.

Neutral of all cores of CTs, CVTs and EMVTs shall be formed in marshalling box of the respective equipment. Cables with sufficient

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number of cores are run from these marshalling boxes to control and relay panels as appropriate. The neutral of CTs, CVTs, EMVTs shall be earthed only at control/relay panel by means of a disconnecting link.

7.13 DC Distribution Philosophy for Controls, protection, Indication, Annunciation, Fault-Recording and Event Recording Systems

The DC distribution scheme in various panels shall be prepared based on following DC distribution philosophy for various functions. (a) Protective Functions

Two nos. DC supplies shall be arranged from two sections of

switchyard DCDB to each of the protection panels. These supplies shall be taken through a selector switch with three positions, viz. independent, source-1 & source-2. In the independent position main-1 & main-2 protection systems will be fed by source-1 & source-2 respectively and the common services from any one of the sources. In case of failure of any one source (say source-1), the switch shall be changed over to the other source (source-2) and complete DC supply requirement of protection panels will be fed from the other source. DC auxiliary supply shall be supervised by supply supervising relays. The NC contact of the relays shall be delayed on drop off by approximately 100 to 200msec for annunciation in SCADA. The selector switch and the fuses shall be mounted inside the panel. These DC supplies shall be separated from DC supplies in the control panel by provision of interposing relays (IPRS) in protection relay panels.

(b) Similarly, Bus bar protection scheme and indications shall be

provided with two (2) nos. of 220V DC supplier through three (3) position selector switch fused and supervised by supply supervision relays having time delayed drop off type NC contact. Loss of supply shall be wired for annunciation at SCADA indication and annunciation supplies shall be separately fused.

The selector switch and fuses, etc. shall also be mounted

internally inside the panel. (c) Control Functions

Control circuit of each breaker circuit will be provided with 2 independent 220V DC control supplies. Each of the above

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feeders shall be fed from separate section of DC board. Manually operated 8 pole, 3 position selector switch for positions called source I, independent and source II shall be used to select any one as closing/synchronizing and trip coil I supplies and other as trip coil II and auxiliary supply for contact multiplication/follower relay supplies, etc. Each incoming supply before select switch and outgoing supply after selector switch shall be separately fused and supervised by supply supervision relay having time delayed type “NC” contact. Loss of supply shall be wired for annunciation at SCADA. The DC supplies shall be isolated from DC supplies in relay panels as specified in a) above.

One separate 220V DC annunciation supply for upto half number of the control panel shall be provided. Remaining half shall be supplied by separate but similar 220V DC supply. The Contractor shall tap annunciation supply through fuses and after supervision relays use it for all annunciation in respective panels. The supervision relay shall have time delayed drop off type NC contact for annunciation, failure of annunciation supply shall also be combined and annunciated on 230V AC operated annunciation system. In turn the failure of AC annunciation supply shall be annunciated in normal DC operated annunciate. It shall all be provided with additional contacts for event recording and remote annunciation.

d) The RTU’s and the PLCC located in the Switchyard control room for SLDC/RLDC shall be provided with 48V dual DC supply.


The specific requirements listed in Sec. D3.6 for generator protection shall apply for switchyard protection system also in addition to the following:

(a) The panels shall have a degree of protection not less than IP-

52 and shall be fabricated with 3 mm thick cold rolled sheet steel for front and rear equipment bearing surfaces and bottom gland plates, and 2.5 mm for sides and top. The doors and removable covers shall be gasketed. The panels shall be provided with anti vibration pads. The paint shade of panels shall be of shade opaline green (External) and semi-glosy white (Internal).

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(b) The pre-treatment of the sheet steel shall involve degreasing rust / scale removal, phosphating and oven drying. The phosphate coating shall be sealed by the application of two coats of ready mixed, stoving type zinc chromate primer followed by two coats of synthetic enamel paint by powder coating process. The paint shade of panels shall be of shade opaline green (External) and semi-glosy white (Internal).

(c) All relays and measuring instruments shall be flush mounted

type & the equipment on the front of panel shall be flush mounted.

(d) The centre line of switches, push buttons and indicating lamps

shall be not less than 750 mm and centre lines of relays, meters and recorders shall not be less than 450 mm from the bottom of the panel. Control switches / push buttons / selectors and relay resetting knobs shall be located at a height between 1.0 m and 1.2 m from the bottom of the panel.

(e) No auxiliary relay shall be mounted on front of the control

panel. They shall be mounted either internally or on the respective relay panel.

(f) All the internal wiring shall be carried out with 1100V grade

stranded copper conductor wires with PVC insulation. For CT / PT circuits the wire size shall be 2.5 mm2 / lead and other circuits it shall be 1.5 mm2 / lead. All wiring meant for power supply to transducers, recorders shall be suitably MCBs or designed to limit short circuit currents. Means for detection of blown or open circuited fuses shall be provided.

(g) Terminal blocks shall be 650V grade, 10 amps rated, stud

type terminals with terminal marking. The insulation between any two terminals and terminal to framework shall withstand 2 kV rms for one minute. Terminal blocks for CT & VT secondary leads shall be disconnecting, stud type. Terminal blocks for SCADA control commands shall be of disconnecting type. Terminal blocks for SCADA digital inputs shall be with knife type isolation. CT secondary leads shall also be provided with short circulating and earthing facility. A clearance of 250 mm shall be maintained between terminal blocks and gland plate and 150 mm between two rows of terminal blocks. At least 20% spare terminals shall be provided.

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(h) Provision shall be made to mount Tariff meters supplied by

grid in the switchyard itself in the grid tie lines as per requirement of grid authorities.

(i) All indicating lamps shall be of self-coloured clustered LED

type of size 22.5mm. Colour of the lamps shall be different for different purposes.

(j) All the push buttons shall be momentary contact type, the

colour of PBs shall be different for various functions. Push buttons shall be suitably shrouded to prevent inadvertent operation. All PBs shall have 2 NO + 2 NC contacts.

(k) Each of the control & relay panels shall be provided with

thermostat-controlled space heaters, CFL type cubicle illuminating lamps and a 5A, 3 pin receptacle.

(l) Each control & relay panel shall be provided with necessary

arrangement for receiving, distributing, isolating and short circuit protection by use of MCBs/MCCBs of D.C. and A.C. supplies for various control, signalling, lighting and space heater circuits.

(m) If miniature circuit breakers (MCBs) are used in VT secondary

circuits, they shall have adequate auxiliary contacts for blocking trip circuits of voltage dependent protection and annunciation. Where high-speed protections are involved, the speed of operation of MCB shall be less than 5 milli seconds.

(n) All the panels shall be equipped with a continuous earth bus

with connectors and clamps between panels for interpanel connection of the earth bus. All the metallic cases of relays, instruments and other panel-mounted equipments shall be connected to the earth bus by 2.5 mm2 copper wires. CT and PT secondary neutral or common lead shall be earthed at one point only at the terminal block and such earthing shall be made through links. Separate copper earthing flat shall be provided in the panel for cable screens of static equipment.

(o) All PT circuits shall be provided with HRC fuses having

special holders such that they cannot be interchanged with other types of fuse holders and other fuse holders cannot be inserted into them.

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(p) Tests

(i) relay panels shall be subject to the following tests :

• Mechanical operation test • High voltage test (2000V for 1 minute) • Megger test • Verification of wiring as per approved

drawings • Electrical control, Interlock and sequential operation tests

(ii) Type tests and routine tests

Type tests and routine tests shall be carried out on all

associated components / equipment as per relevant standards and test certificates shall be furnished.

(III) Acceptance Tests

• The equipment shall be demonstrated for proper operation, including operation of meters, relays, alarms and indications.

• Certified copies of all type and routine test certificate shall be submitted for the Owner’s approval before dispatching the control / relay panel.

7.15 Fault Disturbance Recorder 7.15.1 Stand alone Fault Disturbance Recorder with associated cabling, PC,

HMI, Printer and evaluation software shall be provided for the 400 kV Switchyard. The HMI and PC loaded with evaluation software shall be located in Switchyard Control Room/Central Control Room. It shall have 8 analog and 16 digital channels. The equipment shall be complete with disturbance recorder, control / display unit, junction box and accessories like auxiliary CTs and shunts.

The FDRs shall be modular and shall be suitable for expansion. Provision shall be made to synchronise the electronic clock of each disturbance recorder with external master clock which GPS based. Also, a number of disturbance recorders in the particular location shall

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be capable of being synchronised with any one of the recorders as master.

7.15.2 Specific Requirements of the Equipment

(a) The microprocessor based fault recorder shall be designed to continuously monitor analogue, digital signals and contacts of all protective / lockout relays. Recording shall be self started or triggered by dI / dt, dV / dt, or change of state of any of the digital input signals. The data acquisition unit of the fault recorder shall be provided with self-test diagnostic feature, which annunciates and alters the operator to rectify the defect or fault, if any.

(b) The number of channels / recorders offered shall cover the

following:

(i) Analog channels: (a) Currents in 3 phases and neutral (b) Voltages of 3 phases and their vector sum wherever VTs are provided.

(ii) Digital channels: Protective relay contacts, lock out relay

contacts, breaker contacts. The total number of channels offered shall be such that 20% spare channels are available.

(iii) The fault recorder and all its peripherals shall be designed

for operation on 220V DC. Recorders shall be provided with pre-history recording feature with pre-history recording time not less than 0.5 or 1 sec. The sampling rate of the wave shall be between 1.2kHz to 10kHz.

(iv) Auxiliary CTs while catering for the required VA burdens

shall not saturate under maximum fault current conditions. Auxiliary multi ratio PTs shall be provided to facilitate tap selection in voltage signal recording. The accuracy of analog channel recording shall be less than +3% for current channels and +1% for voltage channels.

7.16 Synchronising Scheme The closing schemes of the CB shall be prepared and wired in such a

way that only one CB is selected at a time for synchronising. It shall be possible to bypass synchronising relay only through a bypass switch

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and under voltage relays to sense dead-line / live-bus and live-line / dead-bus conditions. While preparing the scheme, it shall be noted that key operated auto / off / manual selector synchronising switch provides command from control panel. The synchronising and guard relay scheme shall be designed in such a way that when closing impulse is given, the CB can be closed only after the operation of synchronising check relay. If closing impulse is initiated before synchronising check relay operates, the CB shall not be closed on operation of the check relay.

Live line-dead bus and dead line / live bus closing facility shall be

provided using dedicated relays on CVT. The closing shall be possible only in manual position of synchro selection switch.

Live-line / dead bus and dead-line / live-bus relays shall be one set per

CB. Isolating transformer shall be provided in each incoming AC and

running AC potential circuit of the synchronising scheme. The technical details of each isolating transformer shall be 30 VA, 110 / 110V with accuracy class of 0.5

All AC circuits, DC power supply, synchronising check relay permissive

output contact and synchronising check relay indicating lamp contacts shall all be switched to respective circuit after synchronising selection scheme for any equipment is switched on. After synchronising selection is switched on, all synchronising indicators (e.g., double voltmeter, double frequency meter, synchroscope, bright lamps, etc.) synchronising check relay, live line / dead bus, dead line / live bus and guard relay outputs shall all be started and permissive conditions be generated for closing the respective circuit breaker.

7.17 Sequence of events recording System (SER) 7.17.1 The SER system shall be a part of SCADA system. SER shall be

designed with 1 ms resolution for digital input events with time stamping from each phase of all breakers, isolators and earth switches, opening and closing commands, change of positions of switches such as Local/Remote selection, synchronising selection, voltage selection, auto re-closing selection, selection of control from SCADA/DCS, operation of all protection and trip relays, VT fuse fail relay operation, direct trip send and receive, pole discrepancy relay operation, trip circuit faulty, trip relay faulty, DC supply fail, SF6 pressure Low, LBB operated, etc. shall be available in SCADA. Critical interlocks and

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those SER points which are not covered by numerical relays shall be hard wired to SCADA. The chronological printout facility shall be provided for any of the first 100 occurrences. Further occurrences shall be printed chronologically. This list is only indicative and not exhaustive. The clock shall have resolution of 1 ms and first up feature. It shall be possible to synchronise the clock with an external master clock.

7.17.2 The event recorder shall be suitable for operation on 220V DC supply.

7.18 PLCC System

PLCC system shall be provided for four nos. of 400kV outgoing lines. 100% redundancy shall be provided in hardware for protection signalling. 1 no. dedicated channel shall be provided for speech/data necessary hardware & software & accessories shall be included, however exact requirement of APTRANSCO grid authorities shall be intimated to successful bidder.

7.19 Control, Indication, Alarm and SER Points

7.19.1 Minimum electrical requirements in respect of control, monitoring measurement, annunciation, synchronising are indicated in I&C system section D2.4.

7.20 ABT Metering System 7.20.1 ABT compliant energy meters for main & check with accuracy class of

0.2S shall be provided with suitable communication port for interfacing the same with SCADA system. In SCADA system separate work station shall be provided for accessing the Energy Meter readings. Separate core for main & check tariff metering with 0.2S accuracy class shall be provided for all the lines. Energy meters must be provided with a pair of suitably rated potential free contacts to generate signal for annunciation and SCADA, if voltage supply to the meters are interrupted. Provision shall be made to amount Tariff meters supplied by grid in the switchyard itself in the grid tie lines as per requirement of grid authorities.

7.21 Test & Test Reports

7.21.1 The Contractor shall conduct all the routine, type and acceptance tests

as per the relevant standards and as specified in this specification in the presence of the Owner. The test certificates shall be furnished for Owner’s approval.

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If, in case of circuit breaker, isolators, current transformers, voltage transformers, lighting arresters insulators strings, bus post insulators, control & relay panels and other components of all the main equipment type tests are already conducted on identical equipment to the one offered and found to be acceptable, such tests will normally be waived. However if due to any reason Owner requires the same to be conducted again, conducting the tests are included in the scope. In case of hardware such as clamps the temperature rise test material composition test and mechanical test shall be conducted on one sample of each type even if test reports are already available. Disturbance recorder shall comply with the test requirements as per IEC-60255-5&6.

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TCE FORM NO. 330 R3

1.0

400 kV SWITCHYARD

1.1 Nominal voltage kV 400 kV 1.2 Highest System voltage kV 420 kV 1.3 Short circuit breaking current kA 50 kA for 1 sec. 1.4 Making current kA

(peak) 130

1.5 Impulse withstand voltage kV

(Peak) 1425

1.6 One minute power frequency

withstand voltage kV (rms) 630

1.7 Reference ambient temperature oC 50 1.8 Creepage distance mm 31 mm / kV based on highest

system voltage 1.9 Clearances

i) Phase to phase mm 4200

ii) Phase to earth mm 3400

iii) Sectional clearance mm 6500

iv) Ground clearance mm 8000 2.0 400 KV CIRCUIT BREAKERS 2.1 Type SF6 2.2 Execution of poles Nos. 3 nos., single pole 2.3 Rated current A * 2.4 Operating duty O-0.3 sec-CO-3 min-CO

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TCE FORM NO. 330 R3

2.5 Auto Reclosing - Required 2.6 First pole clear factor 1.3 2.7 Breaker opening time m.sec. * Breaker closing time m.sec. *

2.8 Line charging breaking current A * 2.9 Small inductive current breaking From 0.5A to 10A 2.10 Type of operating mechanism Spring / Spring charged 2.11 Operating mechanism to be

suitable for 1 Phase operation

2.12 (a) Control voltage

(b) Spring Charging

220V DC 220V DC

2.13 No. of trip coils per pole Nos. Two (2) 2.14 Phase to phase spacing 4200 mm 2.15 No. of auxiliary contacts 15 NO + 15 NC (minimum) 2.16 SF6 Gas filling plant Not required 2.17 Gas evacuation and filling unit Required 2.18 Cantilever strength kgs 600 2.19 Out of phase switching Required. 3.0 400 kV ISOLATORS 3.1 Type Horizontal centre break /

Pantograph type 3.2 Reference standard IS 9921

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SL. NO. RIPTION UNITS VALUES / REQUIREMENTS DESC



TCE FORM NO. 330 R3

3.3 Rated current A * 3.3 Insulation Test values 3.4.1 One minute P.F wet withstand

voltage

(a) Between poles and earth kV(rms) 1425 (b) Across isolating distance kV(rms) 1425 3.4.2 Impulse withstand voltage (a) Between poles and earth kVp 1050 (b) Across isolating distance kVp 1200 3.5 Material of main contact Cu 3.6 Whether contacts are to be silver

faced Yes

3.7 Insulators 3.7.1 Codes and Standards IS 2544 3.8 Operating mechanism (motor/

manual)

3.8.1 Main blade Motor & Manual 3.8.2 Earth blade Motor & Manual 3.9 Insulation Data 3.9.1 Minimum cantilever strength kg 600 3.10 Miscellaneous

3.10.1 Auxiliary supply (a) Electrical 220V DC for control and interlock;

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400V AC, 3 phase for motor drive For both Electrical and manual

operation. 3.10.2

Type of interlock

Bolt interlock electrically operated

3.11

Codes and Standards

3.11.1 Insulators IS : 2544 3.11.2 Isolators IS : 9921 4.0 400 kV CURRENT TRANSFORMER 4.1 Type Outdoor, SF6/oil filled hermetically

sealed with SS bellow 4.2 No. of cores Refer Main one line 4.3 Primary current ratio diagram Drg. No. TCE.

5960A-EL-SK-2003

4.4 Secondary current A 1 4.5 Class of insulation Oil immersed Class A 4.6 Maximum temp. rise of winding

above ambient of 50°C

0C 500 C

4.7 Cantilever strength of CT at the

terminal kg 600

4.8 Applicable Standards 4.8.1 Current transformers IS 2705 4.8.2 Insulating oil IS 335 4.8.3 Bushings IS 2099 4.8.4 Large hollow porcelains IS 5621

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4.8.5 Insulators IS 2544 4.8.6 Hot dip galvanising IS 2633 and IS 2629 5.0 400 kV CAPACITOR VOLTAGE TRANSFORMERS / EMVT 5.1 Type EMVT: Outdoor, oil filled/ SF6 gas

filled, hermetically sealed CVT: Oil filled only 5.2 System neutral earthing Solidly earthed 5.3 No. of primary / secondary

windings

Refer Main one line diagram Drg. No. TCE. 5.4 Primary / secondary winding voltage 5960A-EL-SK-2003

5.5 Class of insulation Oil immersed Class A 5.6 Maximum temp. rise of winding

above ambient of 50°C 50°C

5.7 Cantilever strength of CVT at the

terminal 600 kg

5.8 Rated voltage factor 1.2 continuous and 1.5 for 30

seconds 5.9 Rated capacitance Contractor to furnish depending

upon frequency selected for PLCC

5.10 Tolerance + 10% to – 5% 5.11 High frequency range k.Hz 40 – 500 5.12 High frequency capacitance - For entire carrier frequency

range Within 80% to 150% of rated

capacitance

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SL. NO. UNITS REMENTS DESCRIPTION VALUES / REQUI



TCE FORM NO. 330 R3

- Equivalent series resistance over the entire carrier frequency range

Less than 40 ohm

5.13

Stray capacitance and conductance of low voltage terminal

- Stray capacitance of low voltage

terminal over entire carrier frequency range

300 + 0.05 Cn Pf, Where Cn is rated capacitance

- Stray conductance of the low voltage terminal over entire carrier frequency range

mho 50

5.14

Corona extinction voltage

kV

320

5.15 Applicable Standards 5.15.1 Voltage transformers IS 3156 5.15.2 Insulating oil

IS 335

5.15.3 Bushings IS 2099 5.15.4 Large hollow porcelains IS 5621 5.19.5 Insulators IS 2544 5.19.6 Hot dip galvanising IS 2633 and IS 2629 6.0 360 KV LIGHTNING ARRESTORS 6.1 System Earthing Solidly earthed

6.2 Type of arrester Metal Oxide Gapless

6.3 Discharge class 20 kA, Class - IV

6.4 Minimum cantilever strength of

arrestor assembly kg 600

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TCE FORM NO. 330 R3

6.5 Codes and Standards

6.5.1 Lightning arrester for alternating current systems

IS - 3070 and IEC - 60099

6.5.2 Insulators IS - 2544

6.5.3 Large Hollow Porcelain insulators IS – 5621 7.0 INSULATOR 7.1 Type Solid core / post type / string 7.2 Cantilever strength kg 600 kg minimum for bus post

insulator. 7.3 Puncture voltage 1.3 times corresponding flash

over voltage. 7.4 Applicable standard 7.4.1 Post insulators IS 2544 7.4.2 Suspension insulators IS 731 7.4.3 Insulator fittings IS 2486 8.0 BUS CONDUCTORS, CLAMPS &

CONNECTORS IS 5561

8.1 Applicable Standards AAC, ACSR conductors IS : 398 Copper conductors IS : 282 Galvanisation of steel wires IS : 4826 Copper tubes BS : 159 Aluminium / Aluminium Alloys Bars, IS : 5082

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SL. NO. UNITS VALUES / REQUIREMENTS DESCRIPTION



TCE FORM NO. 330 R3

Rods, Tubes, Sections for Electrical Purposes

Fittings for Aluminium and steel

cored aluminium conductors for overhead lines

IS : 2121

Electric power connectors

Hot dip galvanised process IS:5561

IS : 2629 & 2633 9.0 LINE TRAPS 9.1 Installation Outdoor 9.3 Type of earthing Effectively earthed 9.6 Line trap arrester discharge current kA 20 9.7 Band width kHz 40-500 9.8 Tuning device required Required 9.9 Maximum tapping loss dB 2.6 9.10 Type of tuning Wide band 9.11 Winding material Copper 9.12 Line traps IS : 8792, IEC :60353 9.13 Methods of test for line traps IS : 8793, IEC:60353

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ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL

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8.0 GENERATOR CONTROL 8.1 The control, monitoring, measurement, annunciation, synchronising and

sequential event logging for each generator and its subsystem shall be provided on the Operator stations (plant DCS through HMI). Synchronising, essential controls and annunciation shall also be available from the Generator control panel (GCP).

8.2 Generator and Auxiliary Power Supply System Control & Monitoring 8.2.1 Provision in the plant control system shall be made for the starting,

bringing upto rated voltage and speed, initiation of synchronising, operation and annunciation on GCP and monitoring, alarm, data logging, recording and sequential event recording for generator and its excitation system from the Operator stations (plant DCS through HMI). The minimum requirements of the measurements are indicated in the Main One Line Diagram drg no. TCE.5960A-EL-SK-2003.

8.2.2 In the GCP, the mimic of the generator, its subsystems and 6.6 kV &

400V auxiliary power supply system shall be provided. 8.2.3 Synchronising equipment consisting of Auto synchroniser, double

voltmeter, double frequency meter, synchroscope, check synchronising relay, synchronising lamp, etc., shall be provided in the hardwired GCP as follows:

(a) One No. of synchronising panel/trolley shall be provided through

which the synchronising of all the GCB & breakers in 400kV switchyard can be synchronised (GCB in the case of GTGs and 400 kV GT breakers in the case of STGs) by plugging the control cable into a socket provided on each Control panel of the respective breaker. This synchronising trolley shall have all the necessary equipments & meters for carrying out the manual synchronisation. The raise/lower commands for the same also be done through the trolley itself.

(b) Auto synchroniser relay for generator (25A): The Auto

synchronising facility shall be made available to auto synchronise the above breakers through DCS. Auto synchronisers shall connect the generators to the 400 kV grid either through generator circuit breaker or 400kV generator transformer breakers automatically after synchronising the two systems. The equipment shall be supplied to control both the voltage and frequency of turbine generator set to match with those of the grid.

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8.2.4 Manual synchronising facility common to all the units shall be provided

for manual synchronisation of the generators. Remote/Manual selection shall be provided in DCS. When the “Remote” mode is selected, synchronising shall be initiated from DCS through auto synchroniser. When the “Manual” mode is selected, synchronising shall be done from the stand-alone synchronising panel which houses the required synchronising gear (consisting of dv & df meters with associated transducers, synchroscope, check synchronising relay, guard relay, synchronising lamp, etc.), breaker selector switch, breaker control switches, etc. The synchronising panel shall be located in the control equipment room.

8.2.5 Hard wired emergency trip push buttons for tripping of generator circuit

breakers of GTGs shall be mounted on the operator console. The push buttons shall be suitably protected to prevent inadvertent operation.

8.2.6 The 400kV system controls shall be implemented in an independent

SCADA system. However, the 400kV system SCADA shall be interfaced with the plant DCS through serial link for monitoring of 400 kV system from DCS. Further, the status of generator circuit breakers, 400 kV generator transformer breakers along with grouped alarms of generator and generator transformer shall be made available for indication/annunciation in 400kV system SCADA switchyard Control Room as well as main control room.

8.2.4 The GCP shall be provided with all the synchronising switches, selector

switches, push buttons, indicating lamps as needed for the control of the systems envisaged.

8.2.5 The interlocks for the auxiliary power supply system shall be hardwired

interlocks. 8.2.6 This shall be read in conjunction requirements with requirements

indicated in I&C Section D2.4. 8.3 CONTROL AND MONITORING IN DCS 8.3.1 Control, monitoring, measurement, annunciation, synchronising of

complete electrical system supplied under this contract shall be possible from plant DCS system. In case of failure of any OS, it shall be possible to carry out the necessary operation from one of the healthy OS. Synchronising, essential controls, metering and annunciation shall also be available from the Respective control panels for the lines.

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8.3.2 DCS System Minimum functional requirement of plant DCS system in respect of

electrical system shall be as below: 8.3.2.1 CONTROLS

(i) Control of all the Incomers, bus ties of all the electrical switchboards except outgoing feeders from the main Lighting Distribution Board, DCDB & UPS DB, shall be carried out from the DCS. It shall also have the facility to carryout the live changeovers at all the switchboards at 6.6kV & 400V. Remote position, service position, breaker health, permissive for interlock set shall be considered as input to the DCS system. Synchronising gear shall be housed in the respective switchboards.

(ii) All transformers with OLTC shall have provision for control viz.

issuing raise / lower command to OLTC from plant DCS system.

(iii) Control of generator excitation and governor system shall be possible from plant DCS including mode selection and set point control for various parameters viz. MW, MVAR & P.F. controls.

(iv) Selector switch for the operation of equipment shall be at

respective control panel.

(v) Initiation of auto synchroniser.

(vi) DG start, voltage raise/lower, speed raise/lower, DG breaker closing shall be possible from DCS. Local / remote and auto / manual selection will be done at DG set control panel. Selector switch for the operation of equipment shall be at respective control panel. All the necessary controls required for synchronising the DG set & stopping of DG set after resumption of Normal power shall be included in the DCS.

8.3.2.2 Monitoring

(a) Indication-Status of GCB, other breakers (ON, OFF, service, test) position of Local/Remote selector switches, spring charged indication etc.

(b) Abnormal conditions to be considered for alarm inputs to DCS are:

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(i) HV System (Generator CB, 6.6kV and 400kV breaker) Operation of each of Generator protection, motor protection. Trip circuit unhealthy of each equipment, protection unhealthy of each equipment, Trip relay unhealthy of each equipment, VT circuit unhealthy of each VT, signals generated in Transformer MB about abnormal operating conditions of Transformer, LBB operation of each breaker, DC supply failure of each protection/control scheme as appropriate, Successful/Unsuccessful changeover of 6.6 kV supplies. GT and UAT condition shall be monitored from DCS.

(ii) LV System (400V)

Breaker auto trip, individual protective relay operation, trip relay failure, DC supply failure, bus under voltage, VT fuse failure, Trip circuit unhealthy. Successful/Unsuccessful changeover of 400V supplies.

(iii) Generator, Unit Auxiliary & Service Transformers All alarm and trip conditions of generator transformers, unit auxiliary transformers and service transformers. Monitoring of winding & oil temperature of all the transformers & of all temperatures & pressure parameters related to Generator. Tap position of GT & UATs shall also be monitored from DCS.

(iv) DC System DC earth fault, DC under voltage, group faults in case of DC boards, and normal operating parameters of the DC system etc.

(v) UPS System All normal & abnormal conditions of UPS system with details.

(vi) Battery charger Group trouble alarm for chargers with details as available from equipment.

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(vii) Excitation System and generator

Each of protection relay alarm and trip conditions, abnormal conditions in excitation system and generator.

(viii) DG Set DG operating parameters, alarm and trip conditions.

(ix) Alarm for the running hours of 30KW & above motors shall be generated after achieving predefined set points.

(x) Monitoring of the complete electrical system during the normal operation.

(xi) Temperatures of all the >= 100KW motors.

(xii) All the energy parameters of the lines, generator & auxiliary consumption shall be taken from the ABT compliant energy meters through communication. Energy parameters on HV side of GTs & UATs shall also be monitored.

(c) Single line diagram showing Voltage, frequency, MW and MVAR flows, breaker and isolator positions shall be available on DCS/SCADA. SLD shall also show the Generator phase currents, field current and 400kV bus voltages & frequency. More than one frame can be used if all the details cannot be represented on a single frame.

8.3.2.3 Measurement

Feeder Description DCS Control Panel (a) 400 kV line bays MW MVAR - A - V - MWH - MVARH - Pf - MVA -

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(b) 400 kV GT bays A(All phases) -A (All phases) MW -MW MVAR - MWh MWh Tap position

winding & oil temperature

-

(c) Generator V(All phases) - V (All phases) A(All phases) - A (All phases) MW - MW MVAR -MVAR MVARH* - Frequency -Frequency MW trending - MVAR trending - pf -pf MWH * -MWH (d) 400 kV Bus V(Bus –1& 2) - Frequency(Bus

–1& 2) -

* By pulse output from TVM /Meters (e) Unit Auxiliary

Transformer (HV side)

A(All phases) -A (All phases)

MW -MW MVAR - MWh MWh Tap position

winding & oil temperature

-

(f) Incomer, Tie feeders

& Outgoing feeders of 6.6kV switchgear and Incomer, Bus-coupler & outgoing feeders of 400V switchgear

A-All phases for I/C & Ties, One phase for others MW MVAR MWH

-

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(g) 6.6kV & 400V Buses

V (All phases) F

All energy metering shall be through the power meters provided on the incomers & tie feeders on the DCS. These power meters shall have the local display also. Running hours of the motors decided during the detailed engineering shall be calculated or taken from the numerical relays.

(h) Emergency DG set Running hours, electrical parameters & Energy reading shall also be measured through numerical protection relay provided at the DG set. .

-

(i) DC and UPS System A V & Hz for UPS

-

(j) Generator stator

winding and bearing Temperature -

NOTE :

DCS Input current and voltage shall be considered for all three (3) phases. The metering data for the 400kV bays shall be through the ABT compliant energy meter provided except the tariff meters.

8.3.3.4 Event logging shall be provided for all manual operations and relay operations as detailed below:

(a) Status of each breaker of all equipment being controlled,

isolators and earth switches.

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(b) Close and open commands.

(c) Selector switch positions.

(d) Each protective relay, trip relay, alarm relay operation. Event

logging for each phase shall be provided wherever applicable (eg. 3-poles of line circuit breaker, distance relay output contacts, generator protections, fuse fail alarm, etc.)

(e) Event logger shall be a part of the DCS with first up feature. It shall have a time resolution of 1 ms.

(f) Trip contacts of the complete electrical installation/equipments in the station viz. battery charger, UPS, Generator, all transformer, all electrical switchboards etc. are to be included.

8.3.2.5 Trending of parameters during disturbance shall be with a resolution of 0.5/1.0 sec., and at 15 minutes during normal operation. The change from normal mode to disturbance mode shall be through threshold/gradient settings provided in the system for analog quantities and external binary signals obtained from selected protective relays. Capturing of momentary values of all these parameters shall also be possible triggered either by a protective relay or by a manual keyboard command.

8.3.2.6 Synchronising

(a) Generator (Manual and through Auto synchroniser) Synchronising facility shall be provided for the generator through auto synchroniser in auto mode and with the help of double voltmeter, double frequency meter, synchroscope and check synchronising relay permissive condition in the manual mode.

(b) 6.6 kV Incomer & tie circuit breakers shall have facility for fast and slow auto changeover/manual synchronising and dead bus closing.

(c) 400V switch board / MCC incomer and bus coupler breakers shall have facility for dead bus auto change over / manual live transfer.

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(d) One (1) set of synchronising equipment consisting of double voltmeter, double frequency meter, synchroscope, check synchronising relay, synchronising lamps, synchroniser with lockable only in ' off ' position, etc., shall be provided for each of the following: (1) Generators (2) Breakers associated with Emergency DG synchronising

8.3.3 The functional requirement indicated above are minimum, the Bidder

shall provide all necessary controls indications, interlocks & devices required for the system offered by him. Also, any additional requirement arising during detailed engineering shall be provided by the Bidder without any additional cost to the Owner.

8.3.4 The time critical controls and interlocks shall be hardwired system only. 8.3.5 The control / selector switches & meters shall be of miniaturised version. 8.3.6 Check & main Meters – ABT compliant Tri-vector energy meters of

Accuracy class 0.2S for lines, UAT & generator metering shall be provided.

8.4 Transducers 8.4.1 The Contractor shall provide all the transducers for electrical system

either in respective switchgear / control panels. All the transducers shall be self-powered.

8.4.2 The transducers shall comply with the requirements specified for

transducers in Electrical section D3.25. 8.5 Interposing Relays 8.5.1 The interposing relays required for the switchgear / equipment being

supplied under this contract shall be located in separate IPR panels located in the control room.

8.5.2 The coupling relays shall be rated for 0.5 Amp breaking at 220V DC and

6 Amp make and continuous current at 220 V DC. 8.5.3 Interposing relays used for 400 kV circuit breaker closing shall be

adequately rated for the making current.

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8.6 Tests Tests for control desk shall be as indicated in Section D3.7 for

Switchyard relay and control panels.

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ELECTRICAL SYSTEMS - 6.6 kV SWITCHGEAR

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9.0 6.6 kV SWITCHGEAR The 6.6 kV switchgear and its accessories shall conform to all latest

editions of national and international standards indicated in Data Sheet – A 3.9. Also, the switchgear and its accessories shall comply with the requirements indicated in Data Sheet – A 3.9 and specific requirements indicated below.

9.1 For feeding the plant auxiliaries rated for 6.6 kV and service

transformers, adequately rated switchgears shall be provided. 9.2 Manual & Automatic Transfer of Loads 9.2.1 The station switchgear shall be provided with manual live changeover

scheme for planned changeover of supply from one incomer to another and vice versa.

9.2.2 Automatic fast changeover scheme for changeover of supply from one

source to another in the event of supply failure from upstream end shall be provided. Changeover shall be blocked if incomer has tripped due to bus fault.

9.2.3 The closure of the unit supply breaker shall be supervised by a synchro-

check relay permanently connected to and energised by the secondary voltages of the unit bus P.Ts. The high-speed transfer shall be completed in not more than 40 ms. If fast auto change over fails for whatever reason, an automatic “slow” transfer shall be initiated. The fast changeover scheme shall be such that the running motors are not tripped or there is only allowable inrush current due to motor re-acceleration.

The FBTS should have following transfer modes:

i) Fast Transfer

The bus voltage and incoming source voltage should be monitored on a continuous basis for magnitude and phase angle to ensure that transfer operation is carried out under conditions conducive to fast bus transfer as per high speed sync-check supervision and ANSI C50.41 (1982) criterion.

ii) In Phase Transfer

The breaker power contacts shall close when the decaying and drifting

bus voltage synchronizes with the incoming source voltage within acceptable voltage and frequency parameters. The Bus transfer system

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shall continuously process the bus voltage and the drifting phase angle dynamics to determine in real-time the exact moment of sending a command to the breaker-closing coil to achieve the above.

iii) Slow Transfer

The breaker power contacts shall close when the falling bus voltage

shall reach an acceptable safe value. The auxiliary drives are selectively tripped simultaneously to limit the transformer inrush current.

iv) Momentary Paralleling Transfer

This is a “Make before Break” transfer for a very short duration of the

order of few cycles where, under supervision of the bus voltage and incoming source voltage for magnitude and phase angle, the new source breaker is closed before opening the old source breaker. Normally not recommended for unplanned transfers and auto/protective transfers from the system safety considerations

9.2.4 The bus transfer scheme shall be totally microprocessor based

numerical system with in-phase transfer facility and communication facility to DCS.

9.3 Spare Feeders One motor and one transformer type spare feeder of highest rating shall

be provided on both sections of Bus-A & Bus-B of 6.6kV switchgear. Additionally One (1) no. transformer feeder on each bus (colony supply)

for Owner’s use shall be provided. 9.4 Short Circuit Current Ratings 9.4.1 The fault level for the switchgear, circuit breakers, isolators, earth switch,

bus bars, etc., shall be arrived at, on the basis of short circuit current contribution from UAT plus short circuit contribution by the motors running on the bus.

9.4.2 A margin of 5% over higher of the above S.C current, thus calculated

shall be applied and rounded off to the next higher standard ratings and this value shall be adopted for the breakers and switchgears. The momentary current ratings shall be 2.55 times this value.

9.4.3 Asymmetrical S.C current breaking capacity of the breaker shall consider

the higher time constant for decay of current in the vicinity of power generating stations and the breaker offered shall be suitable for this duty.

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9.4.4 Calculations for arriving at the time constant at this plant shall be

furnished to justify breaker selection in accordance with IEC-62271-100 and contractor shall furnish calculation during detailed engineering stage to establish the adequacy of support insulators and busbar sizes for the declared continuous and short time current rating.

9.5 Continuous Current Ratings 9.5.1 The continuous current rating of the 6.6 kV unit switchgear buses,

incomer breaker shall be the rated LV winding current of UAT's respectively with 20% margin rounded off to the next higher standard rating.

9.5.2 The continuous current rating of the feeders shall be based on the name

plate current rating of the connected equipment with 20% margin rounded off as indicated in 9.5.1.

9.6 Constructional Measurements 9.6.1 The switchboard shall be indoor, metal clad having separate metal

enclosed compartments for (a) control, metering and relaying devices, (b) circuit breakers, (c) phase bus bars, (d) instrument transformers and (e) power cable terminations and adjacent cubicles (panels) shall have sheets on either side to ensure complete isolation. The bottom of each panel shall be covered by sheet steel and necessary glands plates. Switchgear shall be suitable for extension on both sides. Switchgear shall be suitable for extension on both sides. The switchgear assembly shall be rodent and vermin proof.

Conductor shall be of high conductivity aluminium alloy for the horizontal

busbars, vertical droppers and connectors to the fixed end of isolating contacts.

All circuit breaker compartments shall be provided with separate door so

that circuit breaker front cover shall not be used as front door. All live parts shall be provided with isolating barriers between phases to avoid exposure to live parts.

Door enclosing the cable termination shall be with hinge. A fixed type

checkered net shall be provided between cable termination and door to avoid accidental contact to live termination. This arrangement is required to take Thermographic measurement using Infrared thermometer.

9.6.2 Required number of high speed trip relays, supervision relays, auxiliary

relays, timers, contact multiplication relays, etc., shall be provided in the

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panels to meet the system requirements and to meet the system operation philosophy indicated in the specification elsewhere.

9.6.3 The circuit breaker shall be drawout type and it shall have test, service

and isolated positions. In test position the circuit breaker shall be capable of being tested for operation without energising power circuits. At least 5NO+5NC spare contacts shall be wired to the terminal block after fully utilising for protection, interlocking, annunciation, etc.

9.6.4 The current transformers shall be mounted in the fixed portion of the

switchgear. Adequate space shall be available for termination using heat shrinkable type cable termination in cable compartment and for mounting of zero sequence current transformers (core balance current transformers).

9.6.5 Withdrawal of circuit breaker shall not be possible unless it is in open

position and operation of circuit breaker shall not be possible unless it is fully in service position, or is fully in test position and drawn out position.

9.6.6 Automatic safety shutters shall cover live parts when the breaker is

withdrawn and all other standard safety features shall be provided. 9.6.7 Earth bus of size 50x6 mm Cu shall be provided at the bottom and shall

extend throughout the length of the switchboard .All non-current carrying metal work of the switchgear shall be effectively bonded to the earth bus. Hinged doors shall be earthed through flexible earthing braid for each type of breaker.

9.6.8 The circuit and bus bar earthing facility with earthing trucks shall be

provided for each type of breaker. Suitable mechanical interlocks shall be provided to prevent the closing of earth switch on live circuit.

9.6.9 Switchgear shall be supplied completely wired and inter panel wiring

between cubicles of same switchgear shall be provided. 9.6.10 The sizes of wire in the panel shall be stranded copper conductor,

1.5mm² for all circuit and 2.5 mm² for CT circuits. 9.6.11 Terminal blocks shall be of stud type, 650 volts grade, 10 amps rated

complete with insulated barriers. Terminal blocks for CTs and VTs shall be provided with test links and isolating faciliting and CT terminals with short circuiting and earthing facility. All spare contacts and terminals of cubicle mounted equipment and devices shall be wired to terminal blocks with 20% spare terminals. Not more than 2 wires shall be connected at a one terminal.

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9.6.12 All relays protective, auxiliary, and timers shall be in draw out cases with built in test facilities. Necessary test plugs shall be supplied loose and is included in the scope of supply. Externally operated hand reset indicators shall be provided on all relays and timers. Timers shall be of electromagnetic or electronic type only. Atleast 1NO + 1NC spare contacts of all relays / timers shall be wired to terminal block. All relays shall be of self reset type unless otherwise specified. In the event of shortage of contacts in circuit breakers, trip relays, contact multiplying relays shall be used. The same shall be two coil, latching type with electrical reset, contacts shall be gold flashed with 20 micron thick plating.

9.6.13 Breaker control switches shall be pistol grip black and selector switches

shall be oval or knob, black. Breaker control switches shall be 3 position spring return to neutral, instrument selector switches shall be of maintained stay put type.

9.6.14 Push buttons provided shall be shrouded. 9.6.15 Space heaters of adequate capacity shall be provided. 9.6.16 Each switchgear panel shall be provided with 230 Volts, 1 phase, 50 Hz,

5 amps, 3 pin receptacle with switch located in a convenient position. 9.6.17 Provision shall be made for receiving, distribution, isolating and fusing of

auxiliary DC and AC supplies for controls, space heating, etc. Two numbers DC feeders shall be provided for 6.6kV switchgear with selector switch for selecting any one supply. DC supply supervision lamps (self coloured clustered LED type of size 22.5 mm) shall be provided and the same shall be on AC supply. Single phase loads for motor space heating etc., shall be distributed between different phases to keep the loading on all the phases uniform.

9.6.18 The ratings of instrument transformers shall be decided by Bidder based

on connected load, lead burdens, changes during engineering stage and adequate margin at the time of handing over the plant:

(a) The CTs shall withstand momentary and short time current

ratings of the associated switchgear. CTs and VTs shall be of the cast resin type and completely encapsulated.

(b) In case of smaller rated CTs (say 200 Amp and less) at the

expected fault level the CT saturation may result in the non operation of the instantaneous short circuit protection. In such cases separate protection CT core with higher ratio shall be selected to avoid saturation at high fault currents.

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(c ) Service transformers and motor feeders shall be provided with

50/1 A core balance CTs for connecting earth fault relays. 9.6.19 VTs shall be single phase, drawout type and housed in a separate sheet

metal enclosure. VTs shall be provided with HRC fuses on both primary and secondary sides under voltage relays, timers, etc. for motor tripping and remote annunciation on supply failure. Those terminals required to be connected to earth shall be earthed by an isolating link without a fuse. Those terminals required to be connected to earth shall be earthed by an isolating link without a fuse. Fuses on primary side shall have rupturing capacity equal to the switchgear rating. Primary fuse replacement shall be possible with VT in isolated position only.

9.6.20 Switchgear panel shall be suitable for bottom cable entry and provided

with removable gland plates. Adequate space shall be available for the termination of the heat shrinkable cable termination & mounting of the CT & CBCT.

9.6.21 Cable lugs for all power, control and instrumentation cables connections

shall be supplied. The lugs shall be tinned copper/Aluminium depending on cable conductor and of solderless crimping type. The cable glands shall be of double compression type brass glands.

9.6.22 All breakers of identical ratings shall be interchangeable, suitable

mechanical/ electromechanical interlocks to ensure that earth switch is not closed/truck is not inserted with the bus live or cable side energised.

9.6.23 Bidder shall supply and mount transducers as per Main One Line

diagram and philosophy of control defined elsewhere in the specification, in the individual switchgear panels.

9.6.24 For the analog parameters (i.e. A, p.f, KW, running hours etc) required in

DCS, 4-20mA outputs for parameters available in numerical relays shall be used. Wherever not available, separate transducers shall be provided. The transducers shall have 4–20 mA dual output and accuracy class shall be less than 0.5%.

9.6.25 Rubber mats suitable for 7.2kV grade shall be provided at front and rear

of switchgear. 9.6.26 Contractor shall furnish calculation during detailed engineering stage to

establish the adequacy of support insulator and busbar sizes for the declared continuous & short time current ratings.

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9.6.27 Current ratings of all switchgears, circuit breakers, CTs etc. shall be sufficient for carrying the connected load currents without exceeding the permissible temperature limits or reduction in service life. Use of two breakers in parallel to meet the required rating shall not be acceptable.

9.6.28 The connection between the start up transformer and 6.6kV switchgear shall preferably be by means of segregated phase bus ducts.

9.6.29 Surge arrestors shall be provided for motor and transformer feeders and shall be as per manufacturer’s recommended type and generally in accordance with IEC 99-1. They shall be mounted within the switchgear cubicle between line and earth preferably in cable compartment and shall be suitable for indoor duty. Surge arrestors shall be suitable for non effectively earthed system and the maximum switching overvoltage shall not be more than 2.5 times the peak line to neutral voltage of the system. Bidder shall furnish temporary overvoltage capability curve and pressure relief device shall be provided for relieving internal pressure and preventing violent shattering of the housing following prolonged passage of follow current or internal flashover of arrestor.

9.6.28 Cubicle Components Each circuit breaker cubicle shall be provided with the following minimum

standard accessories:

(a) One control switch `Trip - Neutral - Close' spring return to neutral position.

(b) One two position control selector switch `Local - Remote' switchgear

control stay put type.

(c) Indicating lamps -

(i) `Red' for breaker `ON' indication and trip coil supervision. (ii) `Green' for breaker `OFF' indication. (iii) Blue' for breaker in 'Service' position. (iv) ‘Amber' for breaker in 'Test' position. (v) ‘Amber’ for breaker auto trip indication (v) 'White' for breaker closing spring 'Charged'. (vi) 'White' supervision lamp for lockout relays. (vii) ‘Red' for breaker ON indication at the back of the switchgear

at cable box door

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The indicating lamps shall be self coloured clustered LED type of size 22.5mm.They shall be bright and visible from any angle. All indicating lamps shall be on DC.

(d) Mechanical trip push button to trip the breaker when control

supply is lost. The push button shall be shrouded type. Mechanical close push button provided shall be accessible only after opening of the front door.

(e) Castle key interlocks shall be provided to prevent opening of

cable compartment door when breaker is closed and busbar compartment when any of the incomers to bus are closed.

(f) Closing from local shall be possible only in test position whereas closing from remote shall be possible in either service or test position. Tripping from local shall be possible only when local/remote selector switch is in local position. Tripping from remote shall be possible only when either breaker in service position or selector switch being in remote position

(g) One electrical antipumping relay.

(h) One double pole control supply switch and set of fuses.

(i) One breaker operation counter.

(j) Cubicle lamp, heater with thermostat and plug point.

(k) Closing coils shall operate satisfactorily in the control voltage

range of 85-110% and tripping coil shall operate satisfactorily in the control voltage range of 70-110%.

(l) Suitable labels/Name plates for feeders and cubicle mounted components..

(m) Mechanical indication for spring charged/discharged status. 9.7 Metering & Protection

Adequate protection / metering shall be provided for the switchgear panels. Location of relays in the switchgear shall be at convenient height, such that it can be surfed by standing at ground. All relays except for LBB, PT fuse failure shall be numerical with RS232/RS485 port. Separate meters shall be provided for each of the feeders mentioned below, if the same is not available in the numerical relay. Relay setting

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software for setting all the numerical relays in 6.6 kV switchgear and generator protection panels shall be loaded in a dedicated operator station in the main control room. All numerical relays shall be time synchronized with the GPS master clock. On failure of any of the numerical relay a contact shall be generated, which shall provide the annunciation to the DCS. All the protective relays, except for auxiliary relays shall have – remote/local reset facility, and shall be suitable for efficient and reliable operation of the protective schemes. A combination of electromechanical & numerical communicable type relays for main protections is not acceptable. The Bidder shall include in his bid a list of installations where the relays offered are in trouble free operation for last two years. The minimum protections / metering shall be provided required for various typical feeders shall include, but not be limited to the following:

9.7.1 Incomers

Protections Metering Composite numerical feeder protection relay

Ammeter and voltmeter with selector switch

Under voltage relay Wattmeter (or) Multifunction meter with all the metering parameters

Local breaker backup protection

Current transducer for each phase

Fuse failure relay 1 no. MW transducer 1 no. MVAR transducer

9.7.2 Tie breakers

Protections Metering Composite numerical feeder protection relay

Ammeter and voltmeter with selector switch

Local breaker backup protection

1 no. kWh meter

1 no. watt meter (or) Multifunction meter with all the metering parameters

1 no. current transducer (Y-Phase)

1 no. MW transducer

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9.7.3 Bus PT Feeders

Protections Metering Under voltage protection Voltmeter with selector

switch Fuse failure protection Voltage transducers–3

Nos.

9.7.4 Motor feeders

Protections Metering Composite motor protection relay (99)

Ammeter* with selector switch

Differential protection for motor feeders (rated 1000kW or above)

1 no. kWh meter 1 no. power factor meter

Local Breaker backup protection

1 no. watt meter (or) Multifunction meter with all the metering parameters

Time delayed under voltage trip

1 no. current transducer (Y Phase)

* For motor feeders separate ammeters shall be provided.

9.7.5 Service Transformer Feeders

Protections Metering Composite numerical transformer protection relay

Ammeter with selector switch

Local Breaker backup protection

1 no. kWh meter

Winding temperature and Buchholtz protection

1 no. Wattmeter (or) Multifunction meter with all the metering parameters

1 no. current transducer 9.8 The switchgears shall be designed to offer adequate level of safety to

operating/ maintenance personnel. Means shall be provided to prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate suitable for wall mounting shall be provided for each switchgear/MCC room describing various safe operating procedure/safety precautions for safe operation and maintenance of the switchgear.

9.9 Tests

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All relevant routine tests and acceptance test shall be conducted as per

applicable standards and typical type test certificates of identical switchgear shall be furnished.

9.10 Minimum electrical system requirements in respect of control, monitoring,

measurements, annunciation, and synchronization are indicated in I & C system section no. D2.4.

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SECTION: D3.9





SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

6.6 kV SWITCHGEAR

1.0 Switchboard cubicles and Bus bar ratings 1.1 Nominal system voltage, phases and frequency V, ph, Hz 6600 / 3 / 50 1.2 System neutral earthing Non-effectively earthed 1.3 Maximum system voltage V 7200 1.4 One minute power frequency withstand voltage kV(rms) 20 1.5 1.2 / 50 microsecond impulse withstand

voltage kV(peak) 60

1.6 Maximum temperature of bus bars, droppers,

connectors and contacts at continuous current rating under site ref. ambient temperature

0C As per IEC-60694 , table 3

1.7 Material of bus bars Tin coated Copper 1.8 Material of bus bar insulation Heat shrinkable PVC sleeve. Removable bus

bar joints with shrouds of 7.2kV insulation 1.9 Bus bar support insulator 7.2 kV 1.10 Bus bar joints / connection Silver faced 1.11 Bus bar rating By Bidder 1.12 Short circuit current rating and duration RMS 44 kA* for 1 sec. 1.13 Momentary withstand current Peak 100kA 2.0 Switchboard Constructional Details 2.1 Thickness of sheet steel enclosures, doors and

covers mm mm

Cold rolled - 2 Hot rolled - 2.5

2.2 Thickness of gland plate for 1 core cable mm 3.0, Non-magnetic material 2.3 Degree of protection VT/relay compartments – IP52 Other compartments – IP42 Air conditioned area – IP32 2.4 Colour finished shade (Enamel / epoxy) Interior: Semi glossy white

Exterior: Opaline Green 2.5 Material of earthing bus Galvanised steel – 50 x 6 mm Copper

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SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

2.6

Clearance in air of live parts

mm

Phase to Phase – 120

mm Phase to Earth – 120 3.0 Breaker details 3.1 Circuit breaker type Vacuum 3.2 Voltage, No. of phases and frequency kV, ph,

Hz 7.2 / 3 / 50

3.3 Rated operating duty O-3 min-CO-3 min-CO 3.4 Total opening time 3 cycles 3.5 Total closing time 5 cycles 3.6 Trip free operating mechanism type Motor charged spring. Manual trip and close

facility to be provided. 3.7 Anti pumping feature To be provided 3.8 Short circuit current rating and duration rms 44 kA* for 1 sec. 3.9 Momentary withstand current kA(peak) 100 3.10 Auxiliary control voltage: (a) For closing / tripping coil / spring

charging motor V, DC 220

(b) For space heaters and lighting and

plug point V, Phase 230 V, 1 phase

3.11 Pressure switch with two potential free

contacts for monitoring SF6 gas. NA

4.0 Current transformer details 4.1 Type Cast resin bar primary 4.2 System voltage and frequency V, Hz 6600 / 50 4.3 Class of insulation Class ‘B’ or better 4.4 Short circuit withstand current and duration 44 kA* for 1 sec. 4.5 Core balance CT for all outgoing feeders Ratio 50/ 1 (As per consumer rating) 5.0 Voltage transformer details

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TCE FORM NO. 330 R3

5.1

Type

Cast resin

5.2 Rated voltage - Primary V 6600 / 3 - Secondary V 110 / / 110 / 33 , 110/3 for open delta 5.3 Method of connection - Primary Star - Secondary Star / Open 5.4 Rated voltage factor 1.2 continuous 1.9 for 30 seconds 5.5 Class of insulation Class ‘B’ or better 5.6 One minute power frequency withstand voltage kV(rms) 20 5.7 1.2 / 50 micro second impulse withstand

voltage kV(peak) 60

6.0 Meters 6.1 Accuracy class 0.5S for energy meters (0.2 for energy meters

on the switchgear incomers) 1.0 for others 6.2 Type of meters Digital 7.0 Spring charging motor supply voltage V, DC 220 8.0 Codes and Standards 8.1 Circuit breakers IEC : 62271-100 8.2 Metal enclosed switchgear IS : 3427 8.3 Current transformers IS : 2705 8.4 Potential transformers IS : 3156 8.5 Arrangement for switchgear bus bars, main

connection and auxiliary wiring IS : 5578

IS : 11353 8.6 Bus bar support insulators IS : 2544 8.7 Degree of protection IS : 2147 8.8 Electrical relays for power system protection IS : 3231

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SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

8.9

Electrical indicating instruments

IS : 1248

8.10 High voltage fuses IS : 5792 8.11 AC electricity meters IS : 722 8.12

Aluminium bus bars

IS : 5082

8.13 Code of practice for phosphating iron and steel IS : 6005 8.14 (Off-load) isolators IS : 6005 8.15 HRC fuses IS : 1818

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1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - SERVICE TRANSFORMERS

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10.0 SERVICE TRANSFORMER The service transformer shall conform to the latest editions of national

and international standards indicated in Data Sheet A - 3.10 Service Transformers. Also, the service transformer shall comply with the requirements indicated in Data sheet A3.10 and specific requirements indicated below.

10.1 The number and rating of service transformers shall be decided based

on the geographical location of loads without sacrificing the unit and common load concept. Adequate number of service transformers shall be provided as required to meet the demand on 400V system based on the criteria that each 400 V switchgear / PCC / MCC / Distribution board shall be fed by 2 x 100% transformer / feeders. Each of the above boards shall be sectionalised.

10.2 Impedance The impedance of the transformers shall be selected such that the fault

level on the switchgear do not exceed its short circuit capability including the motor contributions and also voltage dip while starting any auxiliary does not exceed the limit acceptable for the equipment concerned but in no case shall exceed 15%.

11.3 MVA Rating Each transformer shall be rated to feed of the entire load on the

respective switchgear considering the outage of another transformer. An appropriate load factor with a minimum of 0.8 for continuously running loads and 0.2 for intermittent loads like cranes, plug points, sump pumps, valve actuators etc., shall be considered. An additional margin of 20% over the rating thus established shall be provided for load variations during the detail engineering stage.

11.4 Specific Requirements All service transformers shall be cast resin dry type (indoor). The service

transformers shall be two winding, three phase, 50 Hz, 6600 / 420 Volts, with off-circuit taps of + 5% in steps of 2.5%.

11.4.1 Dry Type Transformers 11.4.1.1 The cast resin transformers shall be housed in naturally ventilated floor

mounted cubicle with louvers backed by fine brass wire mesh. Degree of protection of enclosure shall be atleast IP32.

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11.4.1.2 The transformer cubicle shall be located right next to respective 400V switchgear and LV side shall be connected through cables or bus duct. The HV connections shall be through cables.

11.4.1.3 The dry type transformers shall be provided with core and winding

temperature detectors, with temperature high alarm and very high trip contacts.

11.4.1.4 The insulation class for cast resin transformers shall be class-F. 11.4.1.5 The core and windings shall be provided with embedded temperature

detectors for remote indication in DCS. 11.4.1.6 Noise level shall not exceed the values specified in NEMA TR-1. 11.4.1.7 Off-circuit tap changers with lockable operating handle, mechanical tap

position indicator, and with a variation of 2.5% per step and a range of + 5% shall be provided.

11.5 Tests and test reports All routine tests shall be conducted as per relevant IS standards. Type

test certificates carried out on similar transformer shall be submitted for review.

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SECTION: D3.10





SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

Service Transformers 1.0 Type Cast resin dry type , 3-ph, two winding 2.0 No. load voltage - HV Volts 6600 - LV Volts 420 3.0 Cooling method AN 4.0 Overfluxing capability 110% continuous 5.0 Winding connections 5.1 HV Delta 5.2 LV Star 5.3 Vector group Dyn11 6.0 Impulse (1.2 / 50 micro second) / Power


6.1 HV kVp,

kV(rms) 60 / 20

6.2 LV kV(rms) - / 3 7.0 Maximum temperature rise of winding

a) Dry type transformer

0C Class-F (155 oC)

8.0 Tapping particulars 8.1 Type Off-load 8.2 Tap range % + 5 8.3 Tapping step % 2.5 8.4 Category of voltage variation CFVV 8.5 Tapping power Full 9.0 Bushing particulars 9.1 Voltage class – HV / LV kV 7.2/1.1 10.0 Noise level Not to exceed values specified in NEMA TR-

1 11.0 Paint shade Shade 631 of IS-5/RAL 7032/eqt.

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SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

12.0 Codes and Standards 12.1 Service transformer IS : 11171 12.2 Fittings and accessories IS : 3639 12.3 Bushings IS : 2099 12.4 Degree of protection IS : 2147 12.5 Tests IS : 2026/ IS: 11171 12.6 Tolerance on guaranteed particulars IS : 2026 12.7 Buchholz relay IS : 3637 12.8 Electrical insulation classified by thermal

stability IS : 1271

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1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS -

400V SWITCHGEAR & MCC

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11.0 400V SWITCHGEAR & MCC The 400V switchgear and its accessories shall conform to the latest

editions of national and international standards indicated in Data sheet A 3.11 400 V Switchgear / MCC. Also, the 400 V switchgear / MCC and its accessories shall comply with the requirements indicated in Data Sheet – A 3.11 and specific requirements indicated below:

11.1 For feeding the 400V/230V/110V AC loads of the plant, 400V

switchgear / motor control centres (MCCs) and AC distribution boards (ACDBs) shall be provided. The switchgear shown in Key One Line Diagram drg. No. TCE.5960A-EL-SK-2001 are tentative. Any additional switchgear / MCCs as required shall also be provided. All 400 V switchgear, MCCs & ACDBs shall be procured from the same source in order to ensure interchangeability of components.

11.2 Power Sources for 400V Switchgear The switchboard shall derive power from the designated auxiliary

transformers as shown in the Key One Line Diagrams TCE.5960A-EL-SK-2001. The Bidder shall provide additional switchboards as required without sacrificing the standby philosophy, reliability and flexibility of operation and with unit and common loads demarcation.

11.3 Feeder Details 11.3.1 The switchgear / MCC shall be provided with two incomers and a bus

coupler (100% each).

11.3.2 The switchgear / MCC shall be provided with suitable numbers and type of outgoing feeders as required.

11.3.3 Spare feeders - 20% of each type and each rating with minimum of one

no. feeder. (Above quantity is the minimum requirement at the time of handing over the plant. Any additional quantity required for any increase/changes during detailed engineering stage also shall be duly considered).

11.3.4 Bus VT module - 1 no. on each bus section. 11.3.5 Switchboard 230V, 1 phase space heating - 1 no. on each bus. 11.3.6 230V, 1 phase motor space heating supply module - 1 no. on each bus

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11.3.7 Alarm module for common alarm for out going feeder fault - 1 no. 11.3.8 Any of the system/equipment which requires power supply. 11.3.9 For each auxiliary or load, one feeder shall be provided except for the

following cases: (a) One feeder for maximum of 2 Nos. 400V, 3 phase plug points.

(b) One feeder for maximum of 3 Nos. 400 kV isolator motorised

operating mechanism.

11.3.10 Control transformer on each bus section: 01Nos

11.4 Construction 11.4.1 Switchgear/MCCs shall be metal enclosed, indoor, floor mounted modular

type of uniform height not more than 2450 mm, dust and vermin proof construction with IP - 52 degree of protection, easily extensible on both sides having switchboard designation indicating labels. Proper gasketing shall be provided all around the perimeter of adjacent panels, panel and base frame, removable covers and doors. Switchgear shall be designed for the bottom entry of cables however, the incomers shall be suitable for NSPBD.

11.4.2 Switchgear / MCCs shall be single or double front as execution needed.

The circuit breaker and feeder modules in switchboard and MCCs shall be of fully drawout construction. In this type of construction it shall be possible to drawout the chassis without having to unscrew or unbolt any connections to the equipment mounted on the withdrawable chassis. The power and control drawout type connections shall be of sliding type. All drawout contacts, including for auxiliary and control wiring shall be of self-aligning type.

11.4.3 Switchgear/MCC shall be divided into distinct vertical sections of:

(a) Completely enclosed busbar compartment running horizontally. (b) Individual feeder modules in multitier arrangement. (c) Enclosed vertical busbars serving all modules in vertical section.

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(d) Vertical cable alley covering entire height and minimum 250mm wide.

(e) A horizontal separate enclosure for all auxiliary power and

control bus, if required. (f) For cable connection to circuit breaker, a separately enclosed

cable compartment shall also be acceptable. 11.4.4 Each vertical section shall be equipped with space heater and

thermostat. 11.4.5 Cable alley shall be provided with suitable hinged doors. 11.4.6 Rear of single front switchboard shall be provided with removable

panels. 11.4.7 All doors shall be with concealed type hinges and captive screws. Stop

Push buttons shall be of latch type with mushroom knobs. 11.4.8 Switchgear/MCC shall be designed such that all component equipment

and busbars operate satisfactorily without exceeding their respective maximum permissible temperature limits of 105oC.

11.4.9 Switchgear/MCC busbars shall be of uniform cross section throughout

the length and made of high conductivity, aluminium alloy of E91 grade. 11.4.10 Busbars shall be sleeved, and with proper clearances, adequately

supported to withstand stresses developed due to short circuits. Material used for sleeving shall be capable of withstanding maximum temperatures specified in technical requirements table. Supports shall be of glass reinforced phynolic material or cast resin. Busbar joints shall be shrouded with moulded epoxy removable shrouds. The busbar rating of the 400V switchgear / MCC shall be rated for LV (400V) side current of auxiliary transformer plus 20% margin rounded off to the next standard rating.

11.4.11 All types of relays and timer shall be flush mounted with connections

from inside, and shall have transparent & dust tight cover, removable from front, drawout construction for easy replacement and testing facility. The auxiliary relays and timer may be provided in fixed cases.

11.4.12 The switchgears / MCC shall be designed to offer adequate level of

safety to operating / maintenance personnel. Means shall be provided to

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prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate suitable for wall mounting shall be provided for each switchgear / MCC room describing various safe operating procedure / safety precautions for safe operation and maintenance of switchgear / MCC. Rubber mats shall be provided in front & back of each panel.

11.4.13 All switchgears, MCCs, DBs, panels, modules, local starters and push

buttons shall have prominent engraved identification plates. 11.5 Control Supply Individual two (2) nos. (100%) 400/110V, 1-ph, transformers shall be

provided in each main plant switchgear for deriving control supply. Rating transformers each transformer shall be adequate to cater both the bus sections. A changeover switch shall be provided for selection.

Control supply for the SFU operated motor feeders shall be 110V AC

and for all ACB feeders, it shall be 220V DC. Control circuits shall operate at suitable voltage of 220V DC. The auxiliary bus bars for control supply shall be segregated from main bus bars. The control supplies shall be monitored.

11.6 Specific Requirements Switchgear / MCC shall comply with specification requirements indicated

below: 11.6.1 The breaker / feeder modules shall have service, test and Isolate

positions. Suitable trolley arrangement shall be provided for breaker modules. Two trolleys in the main switchgear room shall be provided so that breaker module of all types, sizes and rating can be withdrawn on trolley and lowered for maintenance purpose. Additionally one such trolley shall be kept at each switchgear room.

11.6.2 All air circuit breakers (ACBs) shall be of short circuit performance

category P2 as per IS 2516 parts I & II. 11.6.3 Breakers shall have inherent fault making and breaking capacities. They

shall have shunt trip coils. All breakers shall have built in interlocks for equipment and personnel safety.

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11.6.4 Paralleling of two supplies shall be avoided by interlocking except for switchgear where auto-changeover or live changeover is provided. Breaker contact multiplication if required shall be through latch relays.

11.6.5 The cable alleys shall be liberally designed considering the size and

number of cables, future additions of cables, easy and safe maintenance.

11.6.6 For each vertical section a separate set of vertical bus bars shall be

provided to serve the modules. 11.6.7 The switches, contactors and other power devices shall consider a

margin of about 20% over the nameplate current rating of the respective load.

11.6.8 For breaker control, 2 nos. 220V DC control supply shall be provided

with a manual selection for changing over to either supply. Necessary voltage monitoring contactors, indication lamps shall be provided.

11.6.9 Minimum of two NO and two NC spare contacts of all contactors & relay

devices shall be wired to terminal block. 11.6.10 20% spare terminals shall be provided for each module. 11.6.11 For CT & VT circuits disconnecting type of terminals shall be provided. 11.6.12 Space heater with MCB and thermostat shall be provided for each

vertical panel. 11.6.13 Transducers required for remote metering shall be provided. 11.6.14 Interposing relays shall be provided for control from remote. 11.6.15 All protective relays shall be of numerical type. 11.6.16 All indicating lamps shall be self-coloured clustered LED type of size

22.5mm. 11.6.17 Mechanically operated, red 'trip' push button, shrouded to prevent

accidental operation. 11.6.18 Module details

(a) Incomers & bus couplers

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(i) The incomer modules and bus coupler modules of 400V

switchgear/ MCC shall be air circuit breaker controlled from local and DCS. They shall be provided with:

• One no. CT shall be used for the Numerical protection

relay. However the metering shall be done through the numerical relay and shall be communicated to the DCS.

• Line VT 400/110V, for checking synchronising during live

manual changeover • Switch, fuses for 220V DC control supply • Breaker control switch • Local remote control switch. Closing from local shall be

possible only in test position whereas closing from remote shall be possible in either service or test position. Tripping from local shall be possible only when local/remote selector switch is in local position. Tripping from remote shall be possible when either breaker in service position or selector switch being in remote position.

• Service & test position limit switches with required no. of

contacts.

• Composite Numerical feeder protection relay shall be provided for breaker feeders other than motor feeders.

• Incomer from Emergency D.G set shall also be provided

with composite numerical feeder protection relay. • 3 phase inverse time over current relays & 1 no. E/F relay • 1 no. E/F relay connected to the bushing CT provided in

transformer neutral circuit • Lock out relay with supervisory lamp • Indicating lamps for on, off and fault, spring charged, trip

circuit healthy etc

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• Synchronising switches, a set of double voltmeter, double

frequency meter, synchroscope shall be provided.

• Necessary circuitry and devices for auto trip, fault alarm, and for control/ alarm of the breaker as required.

• Selector switch for tripping selected breaker after live

changeover (in bus coupler for locally controlled switchboards)

• All incomers for MCC’s and DB’s rated from 630A shall be

ACB’s and for <630A MCCBs shall be provided. However for MCC’s with important feeders like LOPs and where auto change over is required, ACB’s shall be provided for the incomers & Bus couplers.

• The continuous current rating of the bus bars, incomers,

bus couplers of the switchgear fed from other switchgears shall be the maximum load on the bus due to all the running auxiliaries during any operation condition plus 20% margin rounded off to the next higher standard rating. For the load calculation, load factors to be considered shall be 0.9 for continuous loads, 0.4 for intermittent loads.

(ii) The incomer modules shall be interlocked with their upstream

breakers such that they can be closed only when upstream breaker is closed and trips automatically when upstream breaker is tripped or faulted.

(iii) Changeover scheme

The switchgear with sectionalised buses will be normally

operated with the bus coupler breaker open. Auto changeover facility shall be provided for switchgear/MCC, such that if there is a prolonged under voltage on any one of the bus sections, the respective incoming breaker shall trip and the bus coupler breaker shall close, provided voltage is available on the other bus section. Total changeover time shall not exceed 1 seconds. This auto changeover shall be blocked if the incoming breaker had tripped either on a bus fault or manually. Changeover back to the normal source of supply shall be effected manually. Manual live changeover

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facility shall be provided for the switchgear/MCC. When planned outage of one of the normal incoming supplies is required, the respective incomer shall be tripped automatically after the bus section breaker has been closed manually.

After carrying out the changeover within 1sec., all the critical motors which are identified during the detailed engineering shall be re-accelerated automatically.

(iv) For this purpose, a selection shall be provided by the

Contractor suitably on the DCS in plant control room for selecting the incomer to be tripped. Thus, depending on the selection made, incomer to bus section – A or to bus section – B will be tripped once bus section breaker has been closed manually, thus maintaining continuity of supply. A timer with a time delay on pick up of 0.5 – 5 sec for annunciation of the running breaker failing to trip within a preset time, (i.e if the two sources remain paralleled for more than a preset time) shall be provided. When the normal supply is to be brought back into operation, the incomer breaker shall be closed where upon the bus coupler shall trip automatically.

(v) All hardware required for meeting the functional requirements

stated above, whether specifically listed out in the specification or not, shall be included in the Contractor’s scope of supply.

(b) VT modules

Each bus section of main switchboard and MCCs shall be provided with a bus VT module along with one voltmeter with selector switch and energy meter. The accuracy class of VT shall be 1.0 with adequate VA burden.

(i) Bus VT modules shall be provided with suitable 400/√3 / 110/√3V VTs with primary and secondary fuses, interposing VTs for synchronising circuit, etc.

(ii) V.T. modules in 400V main switchboard/MCC shall be provided with all necessary relay devices for auto changeover function like under voltage relays (2 nos), voltage available relays (2 nos.), under voltage timer, fuse failure relay, 220V DC control supply switch & fuses.

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(iii) Earth fault alarm with voltage relay connected to open delta formed on secondary side of VTs shall be provided on each bus.

(iv) In case of fuse failure, the under voltage timer operation shall be blocked.

(v) In the 400V main switchboard buses an additional timer (with a higher time delay) shall be provided for sending signal for AMF start of the DG sets.

(c) Feeders provided for supplying lighting distribution boards, local

control panels, power sockets etc., shall be provided with suitably rated switch & fuses. The modules rated 200Amp & above shall be provided with a CT and ammeter.

(d) 230V, 1 phase, space heating module (for motor, panel, space heating) shall be provided with incoming side switch, fuse, suitably rated 400/230V cast resin type transformer (expected heating loads of the switchboard + 30% margin) Secondary fuse, and supply indicating lamp and connection to the space heating buses in the particular bus section. The 400V power supply for these modules shall be obtained from the other bus (i.e the supply for the module in bus A shall be from bus B and vice versa.)

(e) Suitably rated 400 / 230 V, 1-ph cast resin transformer, incoming side switch fuse, secondary side fuse, supply indication, 1-ph, MCB outlets shall be provided for feeding 230 V space heating / lighting supply required by other panels in the plant.

(f) Suitably rated 400V / 420V, 3 – ph cast resin transformers

incoming side switch fuse, secondary side fuse, supply indication 3 – ph, 4 wire outlets MCBs shall be provided for providing space heating supply for 400V switchboards.

(g) Motor modules

(i) The motor modules shall be provided with

• Switch, fuses, air break contactors (For motors above

100kW, remote controlled electrical circuit breakers, and for smaller motors, switch-fuse contactor feeders shall be

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provided. The other outgoing feeders would be switch-fuse units or moulded case circuit breakers)

• Thermal overload relays with integral single phase preventors. (Thermal overload relays for all motor feeders upto 100kW and with integral single phase preventors for motor feeders >45kW).

• Instantaneous short circuit protection on all phases through HRC cartridge type fuses rated for 80 kA rms (prospective breaking capacity at 400V)

• On, Off and fault indicating lamps

• Necessary auxiliary contactors for fault alarm circuit, 230V space heating circuit

• Isolating switches shall be of AC 23A category when used in motor circuit, and AC 22A category for other applications.

• Module on, off PBs for non reversible modules and forward ‘reverse’ and ‘Off’ PBs for reversible modules

• Appropriate circuitry for receiving the on, off and forward-reverse commands from remote panels/ systems, interlocks, off command from local push buttons, etc.

• MCB for space heating/winding heating circuit.

• Interposing relays for control from remote.

• Transducers shall be provided for remote metering for all motors rated18 KW and above. Any additional motor, for which monitoring is required, shall be added during detailed engineering.

• Isolating switches and MCCBs shall have door interlocks and padlocking facility

(ii) The motor modules rated 30 KW and above shall be provided with 230V, 1 phase space heating arrangement.

(iii) The modules for motors rated 50 KW and above shall have a CT and an ammeter. The CT connection shall be so wired to the terminal block so that provision for remote current indication is available.

(iv) For modules of motor rated 100 kW and above ACB’s shall be provided.

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(v) For modules of motors rated 100 kW and above shall be provided with composite numerical motor protection relay.

(vi) Motor modules – Remote start/Stop and ON/OFF /Trip indication shall be provided from DDCMS for all motors of the main plant. All abnormal conditions shall be alarmed to DDCMS. Motor in other areas shall be controlled from respective PLCs. Local operations shall be provided for motors like sump pumps etc which are neither controlled from DDCMS nor PLCs.

(vii) Essential service modules

During auto changeover of the supply the contactors in the affected bus would have dropped off. The services which shall be restarted immediately without time lapse to keep the unit running are considered essential services. (for eg. seal oil pumps, lube oil pumps, auxiliary cooling water pumps etc.). Such auxiliaries shall restart automatically without any action by the operator after an auto changeover. These modules shall have additionally hardware like timer, aux contactors and associated circuitry in the module. Such essential services shall be identified during the detailed engineering stage and suitable module/scheme shall be provided.

(viii) The 400V single phase connection control supply transformer, space heating, winding heating modules etc., shall be distributed between different phases to keep the loading on all phases uniform 400V/230V control transformer.

11.7 The internal wiring shall be with 1.5 mm2 stranded copper conductor for

control wiring and 2.5mm2 for CTs and suitably sized for power wiring with a minimum of 2.5 mm2 copper.

Outdoor switchgears and switchgears/ panels located in close proximity to gas turbine shall be provided with HR PVC cables.

11.8 400 V A C Distribution Board / Control Panel 11.8.1 Bidder shall include in his scope required no. of 400V AC power supply

distribution board/control panel for feeding packaged auxiliary load like centrifuge, etc. Bidder shall provide one or two (depending on the

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criticality of the service) incomer from 400V main switchboard to feed the distribution board/control panel. All the incoming and outgoing feeders shall be of switch fuse controlled, if it is <400A other wise ACB shall be used.

11.8.2 A.C. distribution boards/control panels shall be provided with

thermostatically controlled space heater, cubicle lamp and power plug. 11.8.3 The A.C. distribution board/control panel shall comply with technical

requirements table. Also applicable clauses of 400V switchboard and MCCs shall be complied with for these boards/panels.

11.8.4 Required ACDB shall be provided to cater to the auxiliary power

requirements of 400kV switchyard. 2x100% capacity feeders shall be provided in the main switchgear for serving this ACDB.

11.8.5 Separate 400V welding distribution boards along with Isolation

Transformer (2x100%) shall be provided in each area. Each circuit of welding distribution board shall feed maximum of 2 Nos. welding / Power receptacles.

11.9 Emergency Power Supply 11.9.1 To enable safe unit shutdown during complete A.C supply failure in the

station, certain important plant auxiliaries (such as the A.C. emergency bearing lube oil pumps, turning gear motor, battery chargers, emergency lights, essential instrument power supply feeders, etc.) shall be provided with a reliable A.C. power supply through a separate source. For this purpose, 400V, quick starting emergency diesel generator sets with automatic mains failure (AMF) feature shall be provided. Each DG set shall cater to the emergency loads of each of the GTG units (i.e. 100%Unit+ 50% STG + 50% station emergency loads). These DG sets are provided with one stand-by generator of same rating as a back up.

11.9.2 The DG sets shall be connected to emergency switchgear with required

interconnections to GTG and STG switchgears. When the normal station A.C. supply fails, the DG sets will start automatically and feed the essential loads connected to GTG and STG switchgears. When the normal A.C supply is restored, these essential loads will be manually changed over to the normal power supply.

11.9 Tests

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Switchboard/MCCs shall be subjected to routine tests as spelt out in

Indian Standards and typical type test certificates for identical switchgear / MCC shall be furnished.

11.10 Minimum electrical system requirements in respect of control,

monitoring, measurement, annunciation, synchronising are indicated in I&C system section No. D2.4.

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400V SWITCHGEAR / MCC

1.0 Switchboard & Bus bars 1.1 Rated voltage, phases & frequency V/P/Hz 400, 3ph, 50, 3 wire 1.2 System neutral earthing Solidly earthed 1.3 One minute power frequency voltage withstand 1.3.1 Power circuits V 2500 1.3.2 Control circuits V 1500 1.3.3 Auxiliary circuits V 2000 1.4 Reference ambient air temperature 0C 50 1.5 Material of bus bars Aluminium 1.6 Maximum temperature of bus bars contacts,

droppers at site reference ambient of 500C 0C 90

1.7 Short circuit withstand 1.7.1 Short time current (1 sec.) rms 50 kA for 1 Sec. 1.7.2 Momentary current Peak 105kA 1.8 Switchboard / MCC Construction Switchboard / MCC 1.8.1 Fully draw out Yes 1.8.2 Double front / single front Single front / Double front 1.8.3 Cable entry (Power & Control) Cable : Bottom Entry

NSPBD: Top Entry 1.8.4 Modular construction Yes 1.9 Degree of protection for as per IS : 2147 IP 54 1.10 Thickness of sheet steel Frame Door Cover 1.10.1 Cold rolled mm 2.5 1.6 1.6 1.10.2 Hot rolled mm 2.5 2.0 2.0 1.10.3 Gland plate thickness mm 3

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1.11 Clearances in air for live parts

1.11.1 Phase to phase mm 25.4 1.11.2 Phase to earth mm 19.4 1.12 Paint shade External : Opaline Green

Internal : Semi Glossy white. 2.0 Contactors & O/L relay 2.1 Utilisation category for contactors AC3 for non-reversible & AC4 for reversible 2.2 Contactor rated duty Uninterrupted 2.3 Reset feature for thermal O/L relay Hand 2.4 Starter type DOL 3.0 Circuit breakers 3.1 Circuit breaker type Air break with shunt trip 3.2 Rated operated duty B-3min-MB-3min-MB 3.3 Type of operating mechanism Motor wound spring charged 3.4 Short circuit rating 50 kA for 1 sec. 3.5 Control voltage for spring charging motor and

tripping & closing V/DC 220

3.6 Emergency manual operation required in

addition to electrical operating devices

3.6.1 For spring charging & closing Required 3.6.2 For tripping Required 3.6.3 Anti-pumping feature Required 4.0 CTs and VTs 4.1 Short time withstand current and duration for

CT 50 kA for 1 sec.

4.1.1 Breaker controlled Based on breaker short circuit current rating

and duration

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4.1.2 Switchfuse controlled To match with fuse withstand 4.2 Overvoltage withstand capacity for VT 4.2.1

Continuous

pu

1.2

4.2.2 30 seconds pu 1.5 5.0 Meters Digital 5.1 Class of accuracy 0.5 for energy meters and 1.0 for others 6.0 Applicable Standards 6.1

Switchboard general requirements

IS : 4237

6.2 AC circuit breakers IS : 13118 6.3 Factory built assemblies of switchboard and

control gear for voltages upto & including 1000V AC & 1200 V DC

6.4 Air break switches IS : 4064 & IEC 60947-3 6.5 Miniature circuit breakers IS : 8828 6.6 HRC cartridge fuses IS : 9224 6.7 D type fuses IS : 8187 6.8 Contactors IS : 29259 6.9 Starters IS : 8544 6.10 Control switches / push buttons and

maintenance of switchboard IS : 6875

6.11 Code of practice for phosphating iron and steel IS : 6005 6.12 Wrought aluminium & aluminium alloys for

electrical purposes IS : 5082

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6.13

Control transformer for switchboard and control gear for voltages not exceeding 1000V AC

IS : 12021

7.0

Technical requirements Table for 400V AC Distribution Boards / Control Panels

7.1 Location / mounting Indoor / floor mounted 7.2 Current rating Max. expected load current + 20% margin 7.3 Cable entry Bottom Cable entry 7.4 Design ambient temperature 0C 50 7.5 Codes and standards As indicated for 400V switchboards / MCCs.

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ELECTRICAL SYSTEMS - NEUTRAL EARTHING EQUIPMENT

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12.0 METHODS OF EARTHING The neutral earthing equipment shall conform to the latest editions of

relevant national and international standards. These shall comply with the specific requirements indicated below.

12.1 400 kV system is solidly earthed. The neutral of GTs are independently

connected to earth. 12.2 Generator neutral shall be high resistance earthed. The neutral shall be

connected to a suitably rated neutral earthing transformer. The neutral earthing resistor will be connected across the secondary of the neutral earthing transformer.

12.3 6.6 kV systems shall be medium resistance earthed. The neutral of the

unit auxiliary transformers shall be independently connected to the earth through a suitable resistance. The earth fault current shall be limited to 300A.

12.4 400V system shall be a solidly earthed system. The neutral of service

transformers shall be independently connected to the earth. 12.5 230V systems for lighting and the space heating shall be solidly earthed

system. The neutral of the transformers shall be connected to the earth bus through a link in the respective board, which is in turn connected to the plant earth grid.

12.6 230V AC control supply shall be a solidly earthed system. The mid point

of the secondary winding of the transformers shall be connected solidly through a link to the earth bus in the respective modules of switchgear / control panels.

12.7 Sizing of Neutral Earthing Equipment 12.7.1 The neutral grounding resistor ohmic value for generator neutral earthing

shall be so selected that during an earth fault on one of the phases of the generator, the kW power consumed in the resistor shall be atleast equal to 1.5 times, the capacitive kVA due to capacitance of generator, generator bus duct and associated equipment including surge protection capacitor, generator transformer.

12.7.2 The neutral earthing resistor ohmic value for unit aux. transformer neutral

earthing shall be such that earth fault current is limited to 300A.

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12.8 Specific Requirements 12.8.1 Duty rating of the earthing resistor for generator neutral and UATs shall

be 30 seconds. 12.8.2 Cable boxes shall be provided for receiving the cables from the

transformers. 12.8.3 The resistor cubicle shall be mounted on suitably rated insulators. 12.8.4 The resistor cubicle shall be located in transformer yard at a height of

2.5m. If located at ground level the resistor area shall be fenced separately, even though located within the fenced transformer yard.

12.8.5 The transformer and resistor shall be located in separate

cubicles/compartment adjacent to each other. The cubicles shall have hinged access doors capable of being pad locked.

12.8.6 For outdoor cubicle, canopy shall be provided.

12.8.7 Each neutral earthing resistor unit shall be air cooled and self supporting type. The minimum degree of protection for the resistor element shall be IP 34.

12.8.8 The transformer cubicle shall be made of angle frame steel construction

with formed sheet sides. The resistor cubicle shall be made of angle frame steel construction with hot dip galvanised screen sides. Alternatively it can be painted with heat resistant paint suitable for 2500C the neutral grounding equipment shall be completely assembled, wired and connected to the neutral bus tap through seal-off bushing.

12.8.9 The neutral grounding transformer shall be cast epoxy resin type natural

air cooled single phase connected between generator neutral and ground.

12.8.10 The loading resistor shall be formed of non-aging, corrosion resistant

punched stainless steel grid element provided with necessary insulation and designed for indoor service for a temperature rise not exceeding 3000C.

12.8.11 All alarm, protection and indication leads shall be wired upto terminal

blocks shall be mounted in a IP:54 enclosure suitable for flush mounting and having a fully hinged cover with lock.

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12.8.12 Enclosure shall not be earthed, so as to prevent bypassing of resistor in

case of shorting of resistor from inside.

12.9 TESTS 12.9.1 All Acceptance and routine tests as per IS/IEEE shall be conducted on

NGR assembly.

12.9.2 The following tests on resistors shall be performed and test certificate shall be furnished prior to dispatch:

i) High voltage withstand test

ii) Ohmic value test on off-load on complete resistor

iii) Heat run test on complete assembly

iv) Insulation resistance measurement test

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ELECTRICAL SYSTEMS - DC SYSTEM

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13.0 DC SYSTEM The DC System and its accessories shall conform to the latest editions of

national and international standards indicated in Data sheet – A 3.13 Also, the DC system and its accessories shall comply with the requirements indicated in Data Sheet – A 3.13 and specific requirements indicated below:

13.1 DC power supply with high discharge plante lead acid cells forming bank

shall be the source of the power supply for control, protection, interlock, annunciation of the complete plant including I&C system during the running of the plant as well as for a safe shutdown at the time of the total power supply failure. For feeding the DC supply for the above, the following shall be provided.

13.1.1 220V DC, 2 x 100% battery bank with associated float cum boost-

charger, 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for each gas turbine generator (GTG) unit. The GTG unit DC system shall be sized to cater complete unit GTG loads. The scheme shall be as per sketch TCE.5960A-EL-SK-2006.

13.1.2 220V DC, 2 x 100% battery bank with associated float cum boost-

charger, 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for each steam turbine generator (STG) unit loads, HRSG system loads and common station auxiliaries (excluding 400 kV system auxiliaries). The scheme shall be as per sketch TCE.5960A-EL-SK-2006.

(a) Loads of Steam Turbine Generator (STG) unit

(b) Loads of HRSG

(c) UPS loads catering to the I&C requirements

(d) Other DC supply loads as required by I&C system which shall be derived from 220 V DC through DC/DC converters.

(e) 6.6 kV switchgear and 400 V switchgear.

(f) Common station DC auxiliaries and emergency lighting loads. 13.1.3 220V DC, 2 x 100% battery banks with associated float cum boost-

chargers and 1 No. DC switchboard having 2 Incomers & one bus

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coupler shall be provided for 400kV system (switchyard) auxiliaries. The switchyard DC system shall be sized to cater the following loads:

(a) DC load of 400kV switchyard

(b) Emergency lighting building The 400 kV system DC battery, battery chargers and DCDB shall be located in the switchyard control building.

13.1.4 48V DC, 2 x 100% battery banks with associated float cum boost-chargers and 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for PLCC system of 400kV switchyard.

13.1.5 24V DC, 2 x 100% battery banks with associated float cum boost-

chargers and 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for catering the I& C and DCS system application.

13.2 Scheme for earth fault detection shall be provided for each DC bus and feeders.

13.3 Battery shall be sized to cater for the following loads with minimum

duration as indicated. The voltage at the end of duty cycle shall be 1.85 V/cell for lead acid batteries. Detailed sizing / selection calculation shall be subject to Owner’s approval.

13.3.1 Momentary Load (For duration upto 1 minute).

(a) Tripping / closing load of 400 kV, 6.6 kV & 400V breakers. (b) Starting current of all automatically started DC drives. (c) Solenoid valves. (d) In rush current of excitation system.

13.3.2 Emergency & Continuous Load (For 10 hours duration)

(a) Running currents of essential DC motors. (b) Emergency lighting

(c) Indicating lamps on switchgears and control panels

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(d) Control room emergency lighting

(e) Auxiliary relays

13.3.3 I & C system loads 13.3.4 UPS requirement for 4 hours. 13.4 Further, for arriving at the battery capacity, the following shall be

considered. 13.4.1 The temperature correction factor as given in IS. For this purpose,

electrolyte temperature shall be considered as 10 deg. C above the ambient temperature.

13.4.2 25% margin for ageing as per IEEE guidelines. 13.4.3 A design margin of 10% shall be considered for each of the GTG Unit

Batteries & Common Station Batteries and 20% margin shall be considered for the 400 kV System Batteries.

13.5 Battery Chargers 13.5.1 Float charger will be rated to cater the following:

(a) Trickle charging current of the battery (b) 10 hours load indicated above. (c) Standing load due to all units running, starting or tripping

whichever is higher. (d) 20 % spare capacity over above loads

(e) The float voltage output of the float charger shall be

automatically adjusted depending upon the ambient temperature such that the batteries remain floating through out the range of variation of temperature as specified in Section – B.

13.5.2 The boost charger unit shall be rated such that the battery can be fully

charged from fully discharged condition within 8 hours.

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13.6 Specific Requirements 13.6.1 220V Batteries

(a) The battery offered shall be High Discharge plante Lead Acid batteries confirming to IS: 1652 suitable for indoor application.

(b) The battery shall be of closed top or sealed in type. Open type

cells are not acceptable. (c) The battery shall be complete with accessories and devices,

including but not limited to the following:

(i) Battery racks (ii) Porcelain insulators, rubber pads etc. (iii) Set of lead coated intercell, inter-tier and inter bank

connectors as required for the complete installation. (iv) Electrolyte (KOH) for first filling +10% extra.

(d) One set of variable resistor load suitable for carrying out

discharge tests at 5 hour discharge rate & suitable shunt for measuring current on all batteries shall be supplied. Alternatively, electronic controls for carrying out discharge test of the batteries at selectable rate can also be provided.

(e) The battery should be periodically charged/discharged to avoid

loss of performance due to memory effect.

13.6.2 220V Battery charger

(a) The float cum boost charger offered shall be static type composed of silicon controlled rectifiers and diodes (complete with resistor/capacitor network for surge protection) connected in three phase wave bridge circuit. It shall be provided with an adequately rated isolation transformer and filters on input to minimise harmonics on the output to keep ripple factor within acceptable limits.

(b) Charger shall have provision for manual control if the automode

fails. Load limiting features shall be provided. The same shall be designed for adequate short time over load to take care of the starting of the largest DC motor/testing of lamps, etc. with other DC loads connected to bus. The rectifier shall utilise power semiconductors and heat sinks rated to carry 200% of the load

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current continuously. The heat sink temperature shall not be permitted to exceed 85°C irrespective of the panel temperature. The chargers shall be suitable for operation from remote.

(c) The chargers shall be provided with automatic voltage regulation

in float mode and automatic constant current regulation in boost mode.

(d) The charger shall essentially comprise the following items but not

limited to:

(i) One (1) moving coil DC voltmeter of size 96mm x 96 mm of suitable range with selector switch for float, boost, and load voltage.

(ii) One (1) moving coil DC ammeter, with shunts, size 96

mm x 96 mm to read output current of float-cum-Boost charger.

(iii) One (1) moving coil centre zero ammeter, with shunt,

size 96 x 96 mm to read discharge/charge current of the battery, with suitable range.

(iv) One (1) cubicle space heater suitable for 230V AC,

50Hz, single phase supply. (v) One (1) 230V AC lamp for cubicle internal lighting. (vi) Two (2) - On/Off switches with fuses for space heater

and internal lighting. (vii) One LED lamp on DC load side to indicate DC "On"

condition. (viii) One (1) set of LED lamps on AC main input to indicate

mains AC "ON" condition. All indicating lamps shall be self-coloured clustered LED type with less than 0.5 W burden.

(ix) Indication lamps for battery on boost charge & load

limiter operated. (e) Fault indicating lamps shall be provided on the charger cubicle

and initiating contacts shall be provided for remote alarm for each of the following faults:

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(i) Mains AC failure (ii) Float charger AC input fuse blown (iii) Charger DC output fuse blown (iv) Charger U/V and current limit protection (v) Charger over voltage protection (vi) Charger overcurrent protection (vii) Charger filter condenser fuse blown (viii) Charger rectifier fuse blown

(f) Type of cooling for the charger panel shall be such that no

external fans are required to dissipate the heat developed within the panel.

(g) The adequate number of dropper diodes shall be used in order

to meet the load voltage & maintaining the battery float charging voltage as per the battery manufacturer recommendations. Suitable scheme shall also be made that during the power failure, the dropper diodes shall be bypassed, thereby giving the required voltage to the connected load.

(h) One complete set of all accessories and devices required for

maintenance and testing of batteries shall be supplied for each battery bank. Each set include at least the following:

(i) Hydrometer - 2 nos. (ii) Set of hydrometer syringes - 2 nos.

suitable for the vent holes in different cells

(iii) Thermometer for measuring - 5 nos. electrolyte temperature

(iv) Specific gravity correction chart - 2 nos.

(v) Wall mounting type holder - 2 nos.

for hydrometer thermometer

(vi) Cell testing voltmeter (3-0-3 V). - 2 nos.

(vii) Rubber apron - 2 nos.

(viii) Pair of rubber hand gloves - 2 nos.

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(ix) Set of insulated spanners - 2 nos.

(x) No smoking notice - 2 nos.

(xi) Goggles (industrial) - 2 nos.

(xii) Instruction card - 10 nos.

(xiii) Minimum and maximum - 1 no. temperature indicator for each battery room

(xiv) Acid / Alkali mixing jar - 2 nos.

(xv) Battery maintenance record book - 20 Nos.

(xvi) Safety gears - 2 nos

13.7 D.C. Switchboards 13.7.1 For feeding the 220V DC loads 220V DC Switchboard as per clause

13.1.1 to 13.1.3 shall be provided. 13.7.2 The switchboards shall be provided with suitable quantity and type of

outgoing feeders for the auxiliaries, control supplies to various panels/systems. For each load and auxiliary, one separate feeder shall be provided. In addition, the following feeders shall be provided in switchboard.

(a) Spare feeders - 20% of each type and rating with a minimum of

two nos. feeders. This is the minimum quantity at the time of handing over the plant.

(b) Switchboard 230V 1 phase space heating module - 1 No.

13.7.3 Current ratings The short circuit current rating of the switchboard shall be arrived

considering the contribution from charger & battery with 5% margin, with a minimum of 25 kA.

The continuous current rating of the bus bars, incomers, ties for 220V DC

switchboards shall be the maximum D.C. load (excluding the momentary

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load) on the bus plus 20% margin rounded off to the next higher standard rating.

13.7.4 Specific requirements

(a) DC switchboards shall comply with all the requirements of this specification and technical requirements table.

(b) Positive and negative bus bars in the DC switchgear shall be

completely segregated from each other by sheet steel partitions. (c) The DCDB incomers and Buscoupler shall be suitable for

operation from remote. (d) All the DCDB compartments shall have bottom cable entry

through individual cable gland for each power, control and instrumentation cables. Metallic enclosure shall be provided between cable tray & cable entry.

(e) Module details

(i) Incomer The incomer modules shall be MCCB controlled. Each

incomer shall be provided with

• ammeter & voltmeter • earth fault relay with potential free contact for

remote annunciation. • under voltage relay with timer • indicating lamps for ON, OFF, earth fault, under

voltage conditions (22.5 mm size LED) • one no. current & voltage transducer for remote

indication • necessary hardware & circuitry for fault alarm

and for lamp test & reset. (ii) Outgoing feeders & tie feeders/Bus coupler

• These feeders shall have DC MCB/MCCB,"ON" & "Fault" indicating lamps, supply supervision relays, lamp test, accept & reset push button through common alarm module.

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• The feeders rated 200 Amps & above shall be provided with a shunt & ammeter.

(iii) Motor modules

• For motors, starters shall be preferably housed within the DC switchgear module. However the resistors can be separately located in boxes/panels within the DC switchgear room. The starting current of the motor shall be limited to 200% of full load current.

The motor modules shall be provided with • Switch (rotary type suitable for DC application),

fuses, air break contactors • Thermal overload relays • Starting resistors with associated timers • ON, OFF, Fault indicating lamps • Necessary auxiliary contactors for fault alarm

circuit • 230V space heating circuit • ON, OFF PBs for testing purposes • One shunt & ammeter • Appropriate circuitry for receiving the ON, OFF

commands from remote panels/systems, interlocks, 'OFF' command from local push buttons, etc.

• MCB for space heating circuit (iv) Space heating module

• 230V 1 ph, space heating module shall be provided with incoming side switch fuse, suitably rated 400/230V cast resin type transformer (expected heating loads of the switchgear and the connected motors + 30% margin) secondary fuse, and supply indicating lamp and connection to space heating buses. The 400V power supply for these modules shall be obtained from the 400V main switchboard.

13.8 Tests for Batteries

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All tests shall be conducted as per the relevant standards. Tests shall comprise:

13.8.1 Type Tests: Performed at Manufacturer's works or type test report on

identical rating and type of cell issued by an authorised test house shall be furnished

13.8.2 Acceptance Tests: Acceptance tests as per relevant standards shall be

performed at vendor’s works. Also acceptance tests shall be performed at site after installation and commissioning of the battery including capacity test and test for voltage during discharge.

13.8.3 A loading resistor bank which can be automatically controlled using time

and current signals along with the charger shall be supplied to facilitate discharging of voltages as a part of routine maintenance tests.

13.9 Tests for battery chargers The following routine tests shall be conducted at works 13.9.1 Visual checks for dimensions and general arrangement. 13.9.2 Wiring checks 13.9.3 Functional checks 13.9.4 Voltage regulation for rated input supply for loads from 0-100%. 13.9.5 Load test to show the charger can deliver the rated duty without the

current limiter device operating. 13.9.6 Ripple measurement by oscilloscope at different loads. 13.9.7 Demonstration of guaranteed efficiency and power factor. 13.9.8 Insulation test (with 500V megger) 13.9.9 High voltage test, excluding electronic controller, at 2kV AC for one

minute. 13.9.10 Heat run test shall be conducted at full load for 24 hours at the vendor

works on charger. 13.10 Tests for DC distribution board

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13.10.1 All routine tests as per applicable standards shall be conducted on the board.

13.10.2 Type test reports on identical switchgear issued by an authorised test

house shall be furnished.

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SECTION: D3.13



REV. NO. R0 PPD. BY RKD JOB NO. CLIENT : APPDCL DATE JUNE’ 10 CKD.BY HA 5960A PROJECT: 700MW CCPP AT NEDUNOOR,


SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

1.0 DC SYSTEM 1.1 Type of charger float-cum-boost 1.2 DC system voltage (Nominal) 220 V /48V /24V 1.3 DC system earthing Unearthed 1.4 Ambient design temperature 0C 50 2.0 BATTERY DETAILS 2.1 Maximum time for boost charging of battery Hrs 8 2.2 Battery type High Discharge Plante Lead Acid 2.3 Minimum end cell voltage Nickel / Lead Acid 1.85V per cell 2.4 Battery capacity By Bidder 3.0 BATTERY CHARGER DETAILS 3.1 DC voltage setting adjustment of AVR for

float charging + 10% of nominal voltage

3.2 Voltage stabilisation for constant voltage

regulator (i) +1% of set DC voltage for + 10%

voltage and +5% frequency variation in power supply

(ii) + 5% during transients 3.3 DC current adjustment for boost charging 30% to 100% of maximum boost charging

current 3.4 Current stabilisation for constant current

regulator for boost charger + 2%

3.5 Minimum permissible p.f. at rated continuous

load 0.8

3.6 Permissible ripple content at rated continuous

load 1% maximum

3.7 Degree of protection/paint shade IP 42/ External : Opaline Green

Internal : Semi Glossy White. 4.0 DC BOARD 4.1 Reference ambient air temperature 50 0C

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SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

4.2 Degree of protection for enclosure IP 54 4.3 Type of construction Fully draw-out, compartmentalised 4.4 Paint shade External : Opaline Green

Internal : Semi Glossy White 5.0 APPLICABLE STANDARDS 5.1 Basic climatic and mechanical durability tests

for components for electronic and electrical equipment

IS 9000

5.2 Environmental tests for electronic and

electrical equipment IS 9000

5.3 Metal clad base material for printed circuits for

use in electronic and telecommunication equipment

IS 5921

5.4 Transformers and inductors (power, audio,

pulse and switching) for electronic equipment IS 6297

5.5 Printed wiring boards IS 7405 5.6 Environmental requirements for semi-

conductor devices and integrated circuits IS 6553

5.7 Terminals for electronic equipment IS 4007 5.8 Factory build assemblies of switchgear and

control gear for voltages upto and including 1100V AC and 1200V DC

IS 8623

5.9 Air break switches IS 4064 5.10 Miniature circuit breakers IS 8828 5.11 HRC cartridge fuses IS 9224 5.12 Contactors IS 2959 5.13 Control switches / push buttons IS 6875 5.14 Indicating instruments IS 1248 5.15 Degree of protection IS 2147 5.16 Code of practice for phosphating iron and steel IS 6005 5.17 Semi-conductor converters IEC 60146-1-1/2/3

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SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

5.18 Semi-conductor rectifier equipment safety code IS : 6619 5.19 Stationary cells & batteries 5.20 High Discharge Plante Lead acid IS : 1652 5.21 Water for storage battery IS : 1069 5.22 Pasted +ve plates IS : 6071 5.23 General requirements IS : 8320

226

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D.3.14

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEM - UNINTERRUPTIBLE POWER SUPPLY SYSTEM

SHEET 1 OF 13

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14.0 UNINTERRUPTIBLE POWER SUPPLY SYSTEM The Uninterruptible power supply system (UPS System) shall cater

to the complete plant instrumentation and control system loads such as HMI, Large Video Screens, Master clock, DCS & SCADA panel lighting & other critical loads, except DCS & SCADA panel loads. The UPS shall be sized considering full load plus spare loops plus 25% margin. The output shall confirm to stringent requirements in respect of voltage & frequency regulation, harmonic content & transient recovery. The UPS and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet – A 3.14 Also, the UPS system and its accessories shall comply with the requirements indicated in Data Sheet – A 3.14 and specific requirements indicated below:

14.1 The UPS shall be of “parallel redundant with static bypass to

regulated supply” type with 2 x 100% chargers & inverters and 2X100% battery bank, bypass line transformer and voltage stabiliser, AC distribution board, other necessary protection devices & accessories. One set of parallel redundant UPS system shall be provided for the plant which will cater power to locations as indicated below:

• UPS system for GTG • UPS system for STG, HRSG & common station loads

• UPS system catering to the requirements of 400kV SCADA

system. 14.2 System Requirements UPS shall employ IGBTs as power components. Microprocessor

based controls shall be employed for rectifier, inverter and static switch. The UPS system shall have static switches for added protection and transfer of loads with no break during under voltage condition to the healthy inverter or to standby regulated supply. The components of UPS shall isolate power line voltage transients, frequency variations and high/low voltage conditions from the critical load and act as a line filter and voltage regulator, apart from providing no-break power at constant frequency during normal

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power outages. The UPS shall be sized considering full load plus spare loops plus 20% margin.

14.3 Static UPS system provided shall be of the type described below: 14.3.1 UPS shall derive power from station service switchgear and

Normal/ Emergency switchgears as shown in the sketch for UPS scheme Drawing No. TCE.5960A-EL-SK-2005. UPS Battery shall be High Discharge Lead Acid Plante type with 4 hour duration. Parallel redundant UPS with static bypass to regulated supply shall be as per sketch No. TCE.5960A-EL-SK-2005.The system shall have a combination of two inverters (UPS modules) operating in synchronism, each having isolating facility from the critical bus by a static switch. In addition to the two inverter systems, a backup from a regulated AC supply through transformer and voltage stabilizer derived from Station service switchgear shall be provided. The system shall have a selector switch. In the `Normal' position, the respective UPS loads shall be supplied by its own inverter, sharing 50% load each, with output of both inverters being automatically synchronized with each other, by using synchronising signal from the master inverter. If one inverter fails, the healthy inverter shall supply the full 100% load by the operation of the static switch. When any one of the UPS is under maintenance, the selector switch shall be suitably changed and the branch circuit supplying 100% load shall be synchronised with the frequency of the standby source.

14.3.2 If the frequency of the standby source is beyond the preset limit,

the inverter frequency control shall get disconnected from the standby synchronising signal. The operating inverter shall continuously monitor the frequency of standby source and upon restoration of proper frequency of the standby source, the inverter shall use the frequency of the standby source as the synchronising signal. It shall be ensured by the contactor that the bandwidth selected for the UPS to remain locked with the SCVS frequency shall be maximum & the downstream instrumentation system should be capable of accepting the above frequency variations.

14.3.3 When the selector switch is in bypass position the standby source

shall cater 100% load, isolating both inverters from the critical load bus.

The output of the UPS shall feed all the essential loads through the ACDB.

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Typical scheme/connections to be adopted for the UPS is shown in the sketch TCE.5960A-EL-SK-2005.

14.3.4 Rectifier The rectifier shall essentially be a three phase 6 pulse design with

input isolation transformer. For Redundant UPS design the two rectifiers input isolation transformers shall have vector grouping and connections to ensure 12 pulse operation seen from the source side. The rectifier shall be provided with soft start feature. The rectifier shall have features for temperature compensation charging of the batteries.

The rectifier shall be capable of supplying the inverter full load, in

addition to charging the fully discharged batteries in 8 hours or as recommended by battery manufacturer and then maintain the battery on trickle charge mode.

14.3.5 Inverter PWM (Pulse Width Modulation) type, adequately designed to meet

the requirements as specified. 14.3.6 Static Transfer Switch Inverter output shall be connected to the AC bus through a static

switch and fast acting fuses. The static switch comprises an interrupter and transfer switch, enabling loads to be connected to the standby regulated AC supply.

Automatic initiation of the transfer from a faulty branch circuit to the

standby regulated source shall be accomplished during following conditions:

(a) Loss of inverter square wave/inverter failure (b) Loss of inverter AC output (c) Retransfer to the inverter circuit shall be manual.

14.3.7 Battery The batteries shall be 2 X100% rated with backup time of 10 hours.

The type of batteries shall be High Discharge Lead acid Plante. The BIDDER shall choose the required voltage of the battery. The AH capacity of battery shall be chosen by BIDDER, based on the battery

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backup time / duty cycle, and minimum ambient temperature as specified in Project Information. The guaranteed DC/AC efficiency of the UPS system offered shall be mentioned.

BIDDER shall furnish calculation for sizing of the battery based on the

requirements of entire plant UPS loads. 14.3.8 Regulated Stand-by AC Supply Regulated standby AC supply shall be derived from standby supply

through a step-down transformer of appropriate rating and a servo controlled voltage stabiliser with isolation transformer and power conditioning equipment viz., spike arrester, etc.

14.3.9 UPS system shall be connected to the AC switchgear. The AC

switchgear shall comply with the requirements indicated in section D3.11 - “400V Switchboard / MCC”. Each of the UPS AC Distribution Boards shall be provided with two bus sections and a bus coupler as shown in dwg. no. TCE.5960A-EL-SK-005. UPS load consumers shall be fed with redundant power supply feeders from each bus section. 20% spare feeders shall be provided in each of the UPS distribution boards

14.3.10 The UPS system shall be provided with necessary meters

(accuracy class 1.0 or better) mimic diagram, local indication/alarm conditions and protection as indicated below. Grouped alarms and analog parameters (4-20 mA) of each branch of parallel redundant UPS shall be made available in DCS/SCADA as appropriate. Necessary potential free contacts shall be provided from UPS to plant DCS/SCADA as appropriate.

14.3.11 Protection The UPS system components and assemblies shall be provided

with the necessary protection associated with all components. Necessary logics shall be derived in the controlling microprocessor, based on the UPS parameters including temperature protection.

14.3.12 Tests

(a) Type and routine tests certificates for all components made use in the UPS system shall be furnished. Tests for components shall be as per relevant standards.

(b) Tests on the following equipment shall as per the relevant

standards listed under the respective equipment specification.

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(c) System tests shall be performed on the completely assembled

UPS system at vendor’s works. System tests shall include frequency regulation, voltage regulation, current limiting feature and harmonic content tests in addition to the tests to prove the functional requirements such as transfer of static switch for conditions of loss of square wave, overload and under voltage conditions, Short circuit conditions etc.

(d) Routine tests covered under clause 7.3 of IEC-60146-4 shall

be conducted on the UPS system in addition to the system tests. Test certificates of type tests shall be submitted for review.

(e) Endurance test on static switches shall be performed for not

less than 10 transfer/ retransfer cycles at full load. (f) The complete assembled UPS system shall be operated at

rated load under relevant ambient conditions for not less than 96 hours continuously prior to release for shipment.

14.3.13 Minimum electrical system requirements in respect of control,

monitoring, measurement, annunciation, synchronising are indicated in I&C system section No. D2.4.

Sl. No.

Description

Unit Specification Requirement

Contractor’s Details

1. Type Parallel redundant UPS with static bypass to regulated supply.

2. Application Uninterruptible Power supply for loads of HMI, LVS , Master clock etc.

3. Number required One parallel redundant UPS.

4. Ambient temperature 0C 50

5 Output Voltage 230V, 1–phase

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Description



6 Output rating at 0.8 p.f lagging load.

kVA *

7. Degree of protection IP 32

8. Cable entry Will be decided during detail engineering stage

9. Input Supply Voltage 400V, 3 Phase, 3 wire, 50Hz supply from N/E switchgear and for bypass from station service switchgear

10. Installation / paint shade

Indoor, natural ventilated, shade Opaline Green (External), Semi glossy white (Internal)..

11. Material of Enclosure 2.0mm thick Cold rolled sheet steel

12.0 Inverters

12.1 Type Static

12.2 Number required Two per unit

12.3 Suitable for parallel operation

Yes

12.4 Service Indoor

12.5 Output rating of each *

12.6 Output Voltage 230V A.C. 50 Hz, Single phase

12.7 Voltage regulation Combined Voltage regula-tion ± 2% from 0 to 100% load at 0.8 power factor within 50 milli seconds

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Description



12.8 Frequency regulation ± 0.1 Hz for 0 to 100% load variation (continuous or step load change) and full range of input variation

12.9 a) Transient voltage regulation on application or removal of 100% load

b) Time to recover from transient- to normal voltage

ms

± 8%

50

12.10 Total harmonic content

5% RMS maximum with not more than 3% distortion in any single harmonic

12.11 Duty Continuous

12.12 Overload capacity 125% for 15 minutes at 0.8 p.f, 150% for 10 sec.

12.13 Short time rating 1 second for short circuit at inverter output terminals

12.14 Short circuit current withstandability

Shall be capable of withstanding short circuit current for the largest fuse to clear the fault in less than ¼ cycle

12.15 Efficiency Not less than 80% at rated load

12.16 Cooling Natural air cooled / forced cooled

12.17 Synchronization with alternate source required

Yes

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Description



13.0 Static Transfer Switch

13.1 Capacity Continuous Make and carry full load current of inverter at 0.8 p.f

13.2 Type Make before break

13.3 Voltage 230V, single phase

13.4 Short time rating Short circuit rating of the inverter for 1 second and 150% of full load current for 2 min.

13.5 Frequency Hz 50

13.6 Transfer time Less than 5 milli sec.

13.7 Retransfer Automatic retransfer shall occur after approximately 2 sec time delay during which normal source voltage must remain at 230V ± 2%

13.8 Indication protection / Annunciation

I. Indicating lamp for

static switch in normal position.

II. Indicating lamp for static switch connected to alternate source.

III. Protection of all semiconductor devices against short circuit and transients.

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Sl. No.

Description



iv) Annunciations for the following conditions.

a) Static switch connected to alternate source

b) Alternate source voltage deviation greater than ± 2% from nominal.

14.0 Bypass Switch

14.1 Capacity Continuous Make and carry full load current of inverters at 0.8 p.f

14.2 Type Make before break

14.3 Short time rating Short time rating of the inverter for 1 second and 150% of full load current for 2 minutes.

15.0 Standby AC supply with isolation transformer and servo controlled voltage stabilizer

15.1 Number One

15.2 Rating Same as UPS rating

15.3 Single or poly phase unit

*

15.4 Type Dry type double wound

15.5 Voltage ratio at no load

*

15.6 Type of cooling Natural Air cooled

15.7 Winding insulation class

Class-H

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Sl. No.

Description



15.8 Location Indoor

15.9 Voltage regulation ± 2% from 0 to 100% load at 0.8 p.f

15.10 System fault level on 400 V side

kA 50

15.11 Output voltage setting range

± 5% of nominal voltage

15.12 Synchronising between inverter and standby supply

Required Within ± 2.5 Hz

16.0 ACDB

16.1 Fully drawout/ Semidraw out/ fixed

**

16.2 Dimensions of the board

**

16.3 Degree of protection IP52

Note: ‘*’ indicated above shall be filled by the Contractor.

‘**’ Contractor shall furnish the data after placement of order.

7.0 Data to be furnished with the Bid

7.1 Technical particulars as per Data Sheet

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SECTION: D3.14

DATA SHEET - A3.13 SHEET 11 OF 13

SL. NO. DESCRIPTION UNITS REQUIREMENTS



SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

1.0 Type Static Parallel redundant UPS with static bypass to regulated supply as per sketch TCE.5960A-EL-SK-2005 2.0 Power Rating at Load PF 0.8 Lagging By Bidder 3.0 Application For supplying the loads of HMI, Common station, 400 kV system SCADA & other critical

loads 4.0 Installation /paint shade Indoor, natural ventilated, shade Opaline Green (External), Semi

glossy white (Internal). 5.0 Input supply V, Ph, 3-PH, 400V AC (From Normal cum

Emergency board and Station service switchgear)

6.0 Output Voltage V, Ph 230V, 1 PH 7.0 AC voltage accuracy(steady state)

over entire load, load PF & By Bidder DC voltage range 8.0 Range of adjustment of AC output ±5% at rated load voltage 9.0 AC harmonic content 5% total, 3% for any single harmonic 10.0 Design Ref. Ambient Deg.C 50 11.0 Standby AC supply with isolation transformer and servo controlled voltage stabilizer 11.1 Rating Same as UPS rating

11.2 Type Dry cast resin type, Two winding

11.3 Ratio & frequency

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SECTION: D3.14





SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

(a) Primary By Bidder (b) Secondary 230 V, 1 PH, 50 Hz 11.4 Automatic voltage regulator Required (servo-controlled)

• Percentage voltage regulation % ±2 • Transient response % ±10 for bypass • Output voltage setting range % ±5 of nominal voltage

12.0 Bypass transfer selection Auto/manual switch 13.0 Manual bypass PBs Load to bypass, load to inverter 14.0 Manual bypass switch Required 15.0 Synchronising between inverter Required and standby supply ±2.5 Hz (47.5Hz to 52.5Hz) 16.0 Static switch 16.1 Type Static 16.2 Maximum transfer time Maximum of 1/4 cycle 17.0 Codes and Standards 17.1 Basic Climatic & Mechanical IS - 589 durability tests for components for electronic & electrical equipment 17.2 Environmental tests for electronic IS - 2106 and electrical equipment 17.3 Metal clad base material for printed IS - 5291 circuits for use in electronic and telecommunication equipment 17.4 Transformer and inductors IS - 6297 (power, audio pulse & switching) for electronic equipment

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SECTION: D3.14





SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

17.5 Printed wiring boards IS - 7405 17.6 Environmental requirements for IS - 6553 semi-conductor devices and integrated circuits 17.7 Terminals for electronic equipment IS - 4007 17.8 Factory built assemblies of IS - 8263 switchgear and control gear for voltages upto and including 1000 V AC and 1200 V DC 17.9 Air break switches IS - 4064 17.10 HRC catridge fuses IS - 2208 17.11 Contactors IS - 2859 17.12 Control switches/ push buttons IS - 6875 17.13 Indicating Instruments IS - 1248 17.14 Degree of protection IS - 2147 17.15 Climatic proofing in electrical IS - 3202 equipment 17.16 Semiconductor converters IEC - 60146 17.17 Semiconductor rectifier equipment IS - 6619 code 17.18 Thyristor converters IS – 5082 17.19 Emergency Standby power IEEE – 446 systems

239



ELECTRICAL SYSTEMS - CABLING SYSTEM

SHEET 1 OF 19

ISSUE R0

SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 329 R5

15.0 CABLING SYSTEM 15.1 Cable Types 15.1.1 For 6.6 kV services, XLPE cables with following specification shall be

provided. 6600 volts unearthed grade single or multi core, stranded aluminium

conductor, screened by triple extruded semi conducting compound, gas cured, gas cooled, triple extruded, tree retardant, cross linked polyethylene insulated, cores screened with triple extruded semi conducting compound in combination with copper tape, laid up, inner sheathed with extruded PVC compound type ST2, armoured with galvanised wire or strips for multicore cables and aluminium wire armoured for single core cables and overall sheathed with extruded FRLS PVC type ST2 cable complying with IS : 7098 part-2. XLPE insulation shall be suitable for continuous conductor temperature of 900C and short circuit conductor temperature of 2500C. The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath.

15.1.2 For 400 V power supply services, space heating, outdoor lighting, lighting

in the hazardous areas, power supplies to lighting panels etc., XLPE power cables with the following specifications shall be provided:

1100 volt grade, single or multi core, stranded aluminium conductor,

XLPE insulated, cores laid up, inner sheathed with extruded PVC com-pound type ST2, armoured with galvanised steel wire or strip for multicore cables and aluminium wire or strip armoured for single core cables, outer sheathed with extruded FRLS PVC compound type ST2 complying with IS: 7098, Part-1. The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath.

15.1.3 For control, protection, CT / PT connections and interlocks, metering,

solenoids, and for digital signals from the field devices/junction boxes/switchgears to terminal cabinets of the control system etc., with signal voltages more than 60 volts, PVC control cables with the following specifications shall be provided:

1100 volt grade, multi core, stranded annealed high conductivity copper conductor (class 2 as per IS 8130), extruded PVC compound type A insulated, cores identified by numerals, cores laid up, inner sheathed with extruded PVC compound type ST1, armoured with galvanised single steel wire/strip and outer sheathed with extruded FRLS PVC compound type ST1 cable complying with IS: 1554.

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1294156

Text Box

5.6




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TCE FORM NO. 329 R5

15.1.4 For low voltage digital signals to instrumentation and control system and

for the analog signals, instrumentation cables with following specification shall be provided :

Single pair, multi pair or triplets or quadruplets as required, stranded

tinned, annealed, high conductivity copper conductor (class 2 as per IS 8130), extruded PVC compound type-A insulated, cores identified by colour and coding, individual pair/triplet/quadruplets twisted, cores wrapped by non hygroscopic material by taping or extrusion, non metallic rip cord under wrapping, individual pair/triplet/quadruplet screened with aluminium mylar tape of 0.04 mm thick or copper tape of 0.04 mm thick or copper laminated plastic tape with 30% overlap, provided with 0.5 mm² tinned copper drain wire for each cabling element, cabling elements suitably grouped, colour coded, cables overall screened with tinned copper wire braids of 0.15 mm dia with minimum coverage of 85% or aluminium mylar tape of 0.04 mm thick with overlap of 30%, inner sheathed with extruded PVC compound type ST1, armoured with steel strips/wires and outer sheathed with extruded FRLS PVC compound type ST1 complying with IEC 60189 - Part 1&2.

15.1.5 Cables for important auxiliaries such as emergency lube oil pump motors,

jacking oil pump motors, barring gear motors, Trailing power and control cables for cranes & hoist, DC cables from battery to charger and DCDB etc. shall be of fire survival type (FRLS cables).

15.2 The HV & LV power cables shall be selected on the basis of current

carrying capacity, short circuit rating and permissible voltage drop. 15.2.1 Current carrying capacity The cable shall be able to carry the full load current of the circuit

continuously under the specified ambient temperature and other conditions of installation. For this purpose, suitable derating factors shall be considered due to:

(a) Thermal resistivity of soil (b) Ambient ground / Air temperature

(c) Derating factor for grouping of cables over the current ratings at normal conditions given in standards. The design ambient air temperature and ground temperature for this plant shall be considered as 500C and 300C respectively.

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15.2.2 Short circuit rating The cables for circuit breaker controlled circuits shall withstand the fault

currents for the following fault clearing times.

(a) Motor, service transformer (Protected by - 0.16 sec instantaneous over current protection) (b)Tie feeders (with no IDMT relays on downstream) - 0.5 sec (c) Others - 1 sec For circuits, which are protected by fuse, short circuit rating capability need not be checked.

15.2.3 Permissible voltage dip normal running

400V System: Voltage drop in cables between the transformer and the switchgear (PCC) or between PCC and MCC for full load current shall be limited to 2%. Further, the voltage drop in cables between PCC/MCC to the motor terminals for full load motor current shall be limited to 3%. However, these voltage drops may be adjusted in specific cases so that total voltage drop is within 5%. The screen of the 6.6kV cable shall be capable of carrying the earth fault current of 6.6kV system for 2 sec.

15.2.4 Permissible voltage dip during starting

(a) 400V system: The voltage dip during starting of individual 400V motors shall be limited to less than 15% of the full load voltage.

(b) 6.6kV system: The voltage drop during starting of HRSG cooling

pump motors shall be limited to less than 20% of the full load voltage, for all other motors it shall be 15%.

15.2.5 Minimum conductors cross-section for the power cables shall be

4.0 mm2 aluminium or 2.5 mm2 copper. 15.2.6 All D.C. power supply cables shall be single core cables. 15.3 Control cables

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15.3.1 Current transformer leads shall be checked for lead burden, VA capacity and knee point voltage. In case 2.5 mm2 Copper Conductor is not adequate, 4 mm2 cross-section cables shall be used.

15.4 Instrumentation Cables 15.4.1 The cross sectional area shall be 0.5mm2 based on the requirement of

I&C system employed. 15.4.2 The instrumentation cables carrying digital signals shall have overall

screening along with drain wire and analog signal carrying cables shall have each pair screening and overall screening along with each pair drain wire and overall drain wire.

15.5 Specific Requirements of Cables The following aspects are applicable for all types of cables: 15.5.1 Core Identification Colour coding shall be acceptable for all cables upto 5 cores. Cables with

more than 5 cores shall have printed numerals on each core. In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath:

(a) Cable size and voltage grade - To be embossed

(b) Word 'FRLS' at every 5 meter - To be embossed

(c) Sequential marking of length of the cable in meters at every one meter - To be embossed / printed.

The embossing / printing shall be progressive, automatic, in line and marking shall be legible and indelible. The name of the project shall be provided at regular intervals of the outer sheath.

15.5.2 Core numbers with a minimum letter size of 3 mm shall be printed serially

on each core of the control cable at intervals of not more than 200 mm. 15.5.3 Core numbers with a minimum letter size of 2 mm shall be printed serially

on each core of the Instrumentation cable at intervals of not more than 200 mm and each core shall be colour coded as per IEC-60189 Part-2

15.5.4 FRLS PVC compound for outer sheaths of all the cables shall meet the

following performance requirements and cables shall pass these tests.

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The bidder shall furnish the necessary type test certificates.

(a) The critical oxygen index value shall be minimum 29 at room temperature and the temperature index value shall be minimum 250°C at oxygen index of 21 when tested as per ASTM-D-2863-77.

(b) The maximum total acid gas generation as determined by titration

shall be less than 20% by weight, when tested as per IEC 60754-1. (c) The maximum smoke density rating expressed in percentage light

absorption at any point on the curve during testing period shall not exceed 60 % when tested as per ASTM-D-2843-77.

(d) The cables shall pass the hydrolytic stability and ultraviolet test as

per DIN 53387. The measured values of ultimate tensile strength and elongation after the test shall not be less than 60% of that measured before the test.

15.5.5 The finished cables shall pass the flammability test as per IEC-60332-1

and IEC-60383. In addition it shall also pass flammability test as per class F3 of Swedish Standard S5-424-1475.

15.5.6 In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable.

15.5.7 Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof cover. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS: 10418.

15.5.8 Each drum shall carry manufacturer's name, Owner's name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled.

15.5.9 The cross-sectional area of the metallic screen strip/tape shall be considered in design calculations.

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15.6 Tests 15.6.1 The Contractor shall conduct the routine tests on each drum length,

acceptance test on the cables as per applicable standards. Tests certificates of all type tests as per applicable standards conducted on similar cables shall be submitted for review. Also special tests for critical oxygen index, temperature index values, acid gas generation, smoke generation, flammability test, effects of light and water test as specified shall be conducted on specimen, from different batches. Routine tests shall include but not limited to the following for instrumentation cables.

15.6.2 Test for dielectric strength for one minute (as per IEC-60189-1) 15.6.3 Insulation resistance test (as per IEC-60189-1) 15.6.4 The vendor shall carry out all routine tests as per IEC.60189-1 for

instrumentation cables

15.6.5 Cable carrier system

(a) Cables shall be always laid above ground to all locations including outgoing areas with cable trays supported on overhead steel structure works. Cable tranches shall be provided in switchyard and transformer yard. Any deviation may e subjected to Owner’s approval. Following cable carrier system shall be adopted in various areas as indicated below.

(i) Control room building :

- Cable vault : Cable trays (ii) Switchgear room - Cable vault : Cable trays (iii) GTG building : Cable trays / conduits (iv) STG building : Cable trays / conduits (v) Switchyard and transformer

yard : Cable trench

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(vi) HRSG area : Cable rack (vii) HRSG platforms : Cable trays (viii) Road / Rail crossings : Hume or steel pipes (ix) Cable carrier system

connecting outlying areas : Cable Trays

(x) Off-side buildings and

utilities : Cable trays

(b) Cable tunnels shall have minimum head room of 1.8 m considering the obstruction due to light fittings, sprinkler piping, etc.

(c) Cable trench

(i) Cable trenches shall be of different sizes depending on the number of cables laid in that route.

(ii) Preferred working space between the cable support arms

and the wall are as follows. Contractor shall design the trenches accordingly.

Trench depth Width of

Trays

Working Space

1500 mm (5 tiers) 600 mm 750 mm

1200 mm (4 tiers) 600 mm 750 mm

1000 mm (3 tiers) 600 mm 750 mm

700 mm (2 tiers) 300 mm 500 mm (iii) PCC flooring of buildup trenches shall be sloped for

effective drainage with sump pits and sump pumps.

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(iv) No sub zero level cable vault / trenches shall be provided below control building/ switchgears rooms in main plant.

(d) Cable trays

(i) Cable trays of ladder and perforated types and the associated accessories such as coupler plates, tees, elbows, bends, reducers, brackets, crosses etc., and hardware such as bolts, nuts, washers, G.I. strap, hook etc., shall be fabricated from 14 gauge (2.0 mm thick) mild steel sheets. Cable tray covers shall be fabricated from 16 gauge (1.70 mm thick) MS sheets. The thickness of side coupler plates shall be minimum 3 mm. Cable tray shall be ladder type for power & control cables and perforated for instrumentation cables.

(ii) Cable trays, accessories and covers shall be hot dip

galvanised. Cable trays shall have standard width of 150 mm, 300 mm & 600 mm and standard lengths of 2.5 metre.

(iii) In battery rooms and water treatment plant, the cable

trays, accessories and covers shall be epoxy painted. (iv) The spacing of rungs for ladder type of trays shall be not

more than 250 mm. (v) Vertical raceways shall be formed by either structural

members and slotted angles or by running the prefabricated trays vertically.

(vi) Prefabricated cable trays, accessories and covers shall

be hot dip galvanised. Site fabricated cable trays shall be painted with cold galvanisation paint at site.

(vii) Cable troughs shall be required for branching out few

cables from main cable route. These shall be U-shaped, fabricated of mild steel sheets of minimum thickness 2 mm and shall be hot dip galvanised as per relevant IS. Troughs shall be standard width of 50 mm & 75 mm with depth of 25 mm.

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(viii) Cable tray support system shall be pre-fabricated similar or equivalent to "Uninstrut make”.

(ix) Support system for cable trays shall essentially comprise

of the two components i.e. main support channel and cantilever arms. The main support channel shall be of two types : (i) C1:- having provision of supporting cable trays on one side and (ii) C2:-having provision of supporting cable trays on both sides. The support system shall be the type described hereunder.

a.

Cable supporting steel work for cable racks/cables shall comprise of various channel sections, cantilever arms, various brackets, clamps, floor plates, all hard wares such as lock washers, hexagon nuts, hexagon head bolt, support hooks, stud nuts, hexagon head screw, channel nut, channel nut with springs, fixing studs, etc.

b. The system shall be designed such that it allows easy assembly at site by using bolting. All cable supporting steel work, hard wares fittings and accessories shall be prefabricated factory galvanized.

c. The main support and cantilever arms shall be fixed at site using necessary brackets, clamps, fittings, bolts, nuts and other hardware etc. to form various arrangements required to support the cable trays. Welding of the components shall not be allowed. However, welding of the bracket (to which the main support channel is bolted) to the overhead beams, structural steel, insert plates or reinforcement bars will be permitted. Any cutting or welding of the galvanized surface shall be brushed and red lead primer, oil primer & aluminium paint shall be applied

d. All steel components, accessories, fittings and hardware shall be hot dip galvanized after completing welding, cutting, drilling and other machining operation.

e. The typical arrangement of flexible support system is described briefly below: The main support channel and cantilever arms shall be fabricated out of minimum 2.5 thick rolled steel sheet

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conforming to IS.

f. Cantilever arms of 300 mm, 600 mm and 750 mm in length are required, and shall be as shown in the enclosed drawing. The arm portion shall be suitable for assembling the complete arm assembly on to component constructed of standard channel section. The back plate shall allow sufficient clearance for fixing bolt to be tightened with tray in position.

The size of structural steel members or thickness of sheet steel

of main support channel and cantilever arms and other accessories as indicated above or in the enclosed drawings are indicative only. Nevertheless, the support system shall be designed by the bidder to fully meet the requirements of type tests as specified. In case the system fails in the tests, the components design modification shall be done by the Contractor without any additional cost to the Owner. The bidder shall submit the detailed drawings of the system offered by him along with the bid.

(e) Conduits & Pipes

(i) The galvanised steel conduits shall be used for sizes upto 63.5 mm. The conduits shall be manufactured by electric resistance welding process and shall be hot dip galvanised. The conduits and fittings shall comply with IS: 1653, 3837, and 2667.

(ii) Galvanised steel pipes shall be used for sizes from

80mm on wards. They shall be medium duty class-B type as per IS. The pipes shall be manufactured by electric resistance welding and hot dip galvanized. The pipes and fittings shall comply with IS.

(iii) Flexible steel conduits shall be manufactured with electro

galvanising process. The flexible conduits and their fittings shall comply with IS: 3480, 4649.

(iv) The hume pipes/RCC pipes shall comply with IS: 458.

(f) Cable/Cable tray supports

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(i) Cable tray supports shall be fabricated from standard steel structures of different sizes. The sizes selected shall be adequate for the weight of cables/trays encountered.

(ii) The steel members shall be cleaned thoroughly for rust

and painted as follows:

• For indoor - One shop coat of red oxide zinc chromate primer and two site coats of aluminium alkyd paint.

• For outdoor & corrosive areas like battery room,

DM plant - Hot dip galvanised. (g) Cable Carrier Installation practice

(i) Minimum level difference between two tiers of horizontal cable trays in building, trenches shall be 300 mm. In vertical race ways with multi-tiers the tiers shall be located atleast with 400 mm intervals.

(ii) In trenches & tunnels the width of the cable tray shall be

limited to 600 mm. In case of horizontal trays it shall be limited to 800 mm.

(iii) Separate cable trays/tiers shall be provided for different

voltage grade cable viz., 6.6 kV power, 400V/230V power, control cables and instrumentation & communication cables. Communication links wherever redundant shall be run in different conduits and in separate trays.

(iv) Cable trays shall be supported at every 1000 mm

interval. Cable trenches around the transformer shall be filled with sand.

(v) Cable trays shall be welded to the mounting/carrier

structures. (vi) Vertical trays (raceways) and all outdoor cable trays shall

be provided with removable 16 guage galvanised MS sheet covers.

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(vii) Each continuous laid out length of cable tray shall be earthed at minimum two places by MS flats of minimum size 25mm x 3mm, the distance between earthing points shall not exceed 10 metres.

(viii) When cables are taken in vertical raceways / trays and

they pass from one floor & other floor pipe sleeves in concrete shall be provided.

(ix) At least 300mm clearance shall be maintained between the top tray and beams, piping or other obstacles to facilitate installation of cables in the tray. A working space of not less than 600mm shall be maintained on atleast on one side of each tray.

(x) No cables shall be mounted near hot zones like hot flue gas duct, steam pipe, etc.

15.7 Cable Installation 15.7.1 Cables to each circuit shall be laid in one continuous length. Cable

jointing and splicing shall be avoided. Jointing will be allowed only for the cases where the route length is more than the maximum possible drum length.

15.7.2 Outdoor cable installation

(a) Where cables cross roads and water, oil, gas or sewage pipes, the cables shall be laid in hume or steel pipes. For road crossings, the pipe for the cable shall be buried at not less than 600 mm. Hume pipes shall be preferred to steel pipes from the point of view of corrosion.

(b) The cables shall be tied to tray rungs by means of 3mm dia. nylon

cord at an interval of 5000 mm and also at bends. (c) For good sealing arrangement at entry points, suitable pipe

sleeves, adequate in number and of adequate sizes shall be provided in building walls/slabs for passage of cables into a building from cable trays/racks/cable trenches located outside the building.

15.7.3 Cables in Trays / on Racks

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(a) Different voltage grade cables shall be laid in separate trays. When

trays are arranged in tiers, HV cables shall be laid in top trays and cables of subsequent voltage grades in lower tiers of trays.

(b) The HV power cables shall be laid in trays/on racks as follows:

i) In single layer only without exception. ii) 3 core cables to be laid in touching formation. iii) Single core cables to be laid in trefoil groups.

(c) 1100V grade power cables of 120 mm² size and above shall

normally be laid in single layer in trays/on racks. (d) Smaller 1100V grade power cables below 120 mm² may be run in

double layers, where required, due to space restrictions. (e) Control and instrumentation cables can be laid upto a maximum of

three layers in each tray/rack. Approximately 10% space on the cable trays shall be provided for future.

(f) Single core power cables for 3 phase AC circuits laid in

trays/racks/ trenches in trefoil groups shall be held in trefoil clamps placed at an interval of 3 m. The trefoil groups of cables shall be additionally tied by means of 3 mm dia. nylon cord as follows:

(i) At an interval of 1m when laid in cable trays/racks. (ii) At an interval of 750 mm when laid in trenches without

cable trays. (g) Control cables and small power cables on racks shall be run in

ladder type cable trays supported on rack carrier arms. The cables shall be tied to tray rung by means of 3 mm dia. nylon cord at an interval of 5000 mm and also at bends.

(h) All cables assigned to a particular duct / conduit shall be grouped

and pulled in simultaneously using cable grips and suitable lubricants. Cables removed from one duct/conduit shall not be reused without approval of Owner.

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(i) Cables shall be segregated as per IEEE Std.-422. In vertically stacked trays, the higher voltage cable shall be in higher position and instrumentation cable shall be in bottom tier of the tray stack. The distance between instrumentation cables and those of other:

system shall be as follows :

From 6.6 kV tray system - 914 mm

From 400V tray system - 610 mm

From control cable tray system - 305 mm

(j) The cables emanating from redundant equipment / devices shall be routed through different routes. The above segregation of cables & wiring for redundant equipments/ devices shall be in accordance with IEEE-Std-422.

15.7.4 Bending radii for cables The bending radii for various types of cables shall not be less than those

values specified by the cable manufacturer. 15.7.5 Terminations, clamping and miscellaneous details

(a) Cable entry to motors, push button stations and other electrical devices shall be from the bottom as far as possible or from the sides. Top entry of the cables is not acceptable particularly for outdoor equipments.

(b) All cables shall be identified by tag. Nos. provided in Owner's

approved format at both the ends as well as at an interval of 5 meters. Identification tags made from aluminium sheet shall be attached to each end of each cable by means of GI binding wire. Tags shall be additionally put at an interval of 30 metres on long runs of cables and in pull boxes.

(c) All cable terminations shall be done with solderless crimping type

lug. Cable terminations shall be done with double compression type brass cable glands.

(d) Saddle type clamps to suit number of cables to be clamped at a

particular location shall be used for clamping cables running along walls, ceilings, structures, etc. at 750mm interval.

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15.7.6 Termination and jointing kits for 6.6 kV grade XLPE insulated cables shall be of proven design and make which have already been extensively used and type tested. Termination kits and jointing kits shall be heat shrinkable type/push on type. 6.6 kV grade joints and terminations shall be type tested as per IS:13573. Cable jointing shall be carried out only by Raychem certified jointers only. Straight through joint and termination shall be capable of withstanding the fault level for the system. 1.1 kV grade Straight Through Joint shall be of proven design.

15.7.7 Testing and commissioning of cables

(a) Cables shall be checked for insulation resistance before and after jointing.

(b) High voltage testing All cables of 1.1 kV grade 400 mm² and above and all HV cables

shall be subjected to DC or AC (preferably DC) high voltage test after terminating but before commissioning as per Table 4 in IS: 1255.

15.7.8 Earthing

(a) Metallic sheaths, screens and armour of all multicore cables shall be earthed at both equipment and switchgear end.

(b) Sheath and armour of single core power cables shall be earthed at

switchgear end only. For long lengths of cables multiple earthing may have to be adopted to safeguard against the presence of standing voltages under normal as well as fault conditions.

15.7.9 Fire proof sealing system (FPS)

(a) Fire proof sealing system shall consist of

(i) Fire-stops/fire-seals for sealing of cable/cable tray and conduit/pipe penetrations, both horizontal and vertical, through brick or RCC walls/floors, to prevent the spread of fire from one area, which is separated from others by fire-resistant barriers.

(ii) `Fire-breaks' provided on long runs of cable racks/trays

to prevent the propagation of fire along the cable rack, within a single fire-area or fire- zone.

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(b) The FPS system shall also include all the necessary accessories

and equipment required for supporting, holding in position, fixing and installation of the fire-stop/fire-break.

(c) The FPS system shall comply in all respects with the

requirements of the codes and standards listed below IEEE-634 ASTM-E-814 ANSI-IEEE-383 IEC-60331 IEC-60332 (d) Fire Stop/Seal The FPS system adopted for cables or cable trays penetrating

through walls and floor openings, or cables passing through embedded conduits/pipes/ pipe-sleeves, constitutes a `fire stop/seal', which is meant to prevent spreading of fire between areas separated by fire-resistant barriers.

(e) Fire Break The fire proofing system, other than fire-stops, adopted to retard

flame propagation along long runs of horizontal or vertical cable trays in the same fire zone or area, in an event of a fire, shall constitute a `fire-break' and shall be provided by applying a suitable fire-resistant coating on cables and cable trays for the required length, with or without a fire resistant panel, at the point of the fire break to obtain the fire-rating specified.

(f) Performance Requirements (i) Requirement of fire stops

• The material, design and construction of the fire stops shall be such as to provide the fire rating of 120 minutes for a fire on any side and meet all requirements listed in this specification and the relevant codes and standards.

• The materials used in the fire stops shall be non-

hygroscopic, compatible with the type of cables.

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• The fire stops shall be suitable for retrofitting of

cables through the penetration seal without disturbing the sealing of the cables already existing.

(ii) Requirements of fire breaks

• Each firebreak shall have a fire rating of 30 minutes and shall be capable of withstanding for the duration specified, a fire on any side of the fire break.

(g) Application of fire proof sealing system (i) Fire stops

Fire stops shall be provided for cable penetration openings listed below • The passage of cables/cable trays pipe

sleeves/embedded conduits through walls / floors.

• Vertical raceways, which carry cables between

successive floors, through openings provided in the RCC floor slab, shall be sealed by fire stops at each floor level.

• Cable entry through openings in floor slabs

below MV/LV switchgear, MCCs, various control and relay panels and other bottom entry panels, shall be effectively sealed by fire stops.

(ii) Location of fire breaks

• Fire breaks shall be provided on both cable rack and trenches at all cable tray intersections and tee-offs.

• On linear runs of cable trays between fire stops

or fire breaks, fire breaks shall be provided at intervals of 15 metres on horizontal cable runs and 5 m on vertical cable runs.

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• Fire breaks in linear runs of cable trenches

between intersections and tee-offs shall be provided at intervals of 30 metres.

15.7.10 Contractor shall furnish the test certificates for the fire stops and fire

breaks after award of contract for Owner’s review. If the certificates are not satisfactory all the tests shall be conducted free of cost. The offered system i.e. fire stops and fire breaks shall be identical (or better) with the system which is successfully type tested for the specified rating i.e. the composition density of the material, thickness of coating in case of fire breaks and any other properties of the material / system offered shall be identical or better than the tested system and shall be subject to Owner’s approval.

15.7.11 Performance Tests: Tests on Fire Stops

(a) The fire stops shall be subjected to the following type tests:

(i) Fire Rating Test (ii) Hose Stream Test

(b) Type tests shall be conducted on different fire stop test

specimens described above as per IEEE-634. The sizes of the fire stop test specimens shall be similar to the largest of the sizes being used in the plant.

(c) Preconditioning of fire stop test specimens Before conducting the fire rating and hose stream tests, each test

specimen shall be preconditioned for thermal ageing, water immersion and vibration.

(d) Test on Fire Stops During the fire rating test, the transmission of heat through the

cable penetration fire stop shall not raise the temperature on its unexposed surface above the self ignition temperature of the outer cable covering, the cable penetration fire stop material, or material in contact with the cable penetration fire stop, with a maximum temperature limit on the unexposed surface of 200oC.

(e) Tests on fire breaks

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Fire breaks shall undergo the following tests as per ANSI-IEEE-383:

(i) Ampacity test (ii) Flame test

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1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - LIGHTING SYSTEM

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16.0 LIGHTING SYSTEM Lighting system shall be provided for the proposed plant covering all the

buildings, outdoor areas, roads, yards, boundary, etc. The lighting system shall be to owner’s approval, having good aesthetics and designed to provide the required illumination levels in all areas and to meet the fire and safety codes.

16.1 Categories of Lighting 16.1.1 The plant lighting system shall comprise the following four (4) categories:

(a) Normal 230 V Single phase AC lighting system

(b) Normal-cum-Emergency 230 V Single phase AC lighting system

(c) Emergency 220V DC lighting system

(d) Maintenance 24V AC Lighting System

16.1.2 Normal 230V AC lighting system In this system, the lighting circuits shall be fed by the 400V, 3 phase, 4

wire, normal AC supply available from the normal lighting distribution boards. All the lighting fixtures connected to this system shall be available as long as supply is available from normal source viz., auxiliary transformer.

16.1.3 Normal cum emergency 230V AC lighting system Certain lighting fixtures considered essential shall be connected to this

system. In this system the lighting circuits shall be fed from another lighting distribution board from normal/emergency section of the 400V main switchboard. The lighting fixtures connected to this system will be available whenever normal supply is available in the plant and also whenever emergency DG set supplies the power to this bus section during blackout conditions. During blackout conditions, the lighting fixtures connected to this system will go off and shall come back as soon as the DG set starts feeding power to the 400V normal-emergency bus section.

16.1.4 Emergency DC lighting system

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(a) During station emergency involving total AC failure, incandescent lamp DC lighting fixtures shall be provided for movement of personnel in GTG and STG buildings, Control & Switchgear Building, Switchyard Relay Building at strategic locations viz., near entrance, staircase, landings etc. and for lighting the control room and DG set area.

(b) These fixtures shall be connected to lighting panels supplied

from 220V DC station battery. These lighting fixtures shall be normally kept `OFF'. All the area in the plant shall have the same philosophy & DC lighting for these areas shall also be from the station battery.

(c) Lighted exit signs shall be provided and installed in the control &

switchgear room, relay room, maintenance area etc. (d) Minimum one number of instalite shall be provided in all

switchgear rooms pump houses and control rooms where DC lighting not envisaged.

16.1.5 Maintenance 24V AC Lighting System For lighting facilities comprising portable hand lamps and/or connection

of portable hand tools etc., required during the routine maintenance work, 24V single phase 3 pin sockets with switches shall be provided at selected points such as HRSG area, TG building Hall, Cable galleries and any other areas considered necessary by CONTRACTOR. Such sockets for routine maintenance shall be clearly identified by colour coding in order to distinguish them from the normal 230V power outlets. Necessary outlets shall be made on the inside walls of the building near equipments.

16.1.6 The area-wise distribution of lighting fixtures connected to the systems

discussed above shall be as follows: ---------------------------------------------------------------------------------------------------------------- Percentage wise distribution of Lighting Area /Building ------------------------------------------------------------------- Normal Normal & Emergency 220 V DC -----------------------------------------------------------------------------------------------------------------

GTG, STG, buildings 80% 20% *

Switchyard control room 80% 20% *

Switchgear and battery rooms, control

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room in Control & Switchgear building 80% 20%

HRSG area 80% 20% *

Transformer area & 400kV switchyard 100% - -

Pump houses, Admin building

Canteen 100%

Roads & out going areas 100% - -

DG set control room 80% 20% * ---------------------------------------------------------------------------------------------------------------- * Adequate for personnel movement and also located at strategic

locations. 16.2 Lighting Supply Distribution System 16.2.1 Normal and normal emergency AC systems

(a) For these systems, the distribution shall be by 400V, 3 phase, 4 wire, 50 Hz supply with effectively earthed neutral. This supply shall be derived from 400 V, 3 phase, 3 wire, 50 Hz unit service switchgear by providing a 400 / 400V delta/star lighting transformers. The secondaries of lighting transformers shall be connected to 400 V, 3 phase, 4 wire, AC lighting distribution boards (LDBs) having 2x100% incomers & a bus-coupler. The LDBs will be provided with number of outgoing circuits controlled by MCBs to feed the lighting panels and by MCCB/Contactors to feed around the plant as well as to directly feed three phase street lighting and yard lighting supplies.

(b) AC lighting panels shall have 3 phase, 4 wire incomer with ELCB

and number of 1 phase outgoing circuits controlled by MCBs. Lighting panels feeding the Lighting fixtures in indoor areas shall be controlled from the respective lighting panels located in various buildings in the plant. Road, yard lighting and aviation warning lights also shall be contactor controlled. All outdoor lighting system and aviation warning lighting system shall be automatically controlled through photoelectric controllers. Provision to bypass the timer or photocell shall be provided in the panel. Also manual switching `on and off' facility shall be provided. The Infrared sensing system shall be used for the control of lighting in unmanned substations.

16.2.2 220 V DC lighting system

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Emergency DC lighting supply distribution shall be on 220V DC, 2 wire

unearthed system. Minimum 10% of 220V DC lighting shall be provided. This power supply shall be obtained from station 220V DC switchboard. DC lighting panel shall be provided for distribution of lighting supply. This panel shall have an incoming switch, undervoltage relay and number of outgoing circuits controlled by switch fuses. No voltage at the normal emergency switchgear shall be sensed and DC contactor shall be switched on thus extending DC supply to the lighting circuits.

16.3 Illumination levels and choice of lighting fixtures

The area-wise distribution of average illumination levels and type of luminaires shall be as given below.

Sl. No.

Area/ Structure Average Illumination Level in Lux.

Type of Fixture Type of Luminaire

1. GTG, STG Building / Control & Switchgear building

(a)

General (auxiliary equipment areas)

200 Medium /low bay fittings / Industrial well glass vitreous enamel reflector integral mounted control gear/ industrial bulk head with integral mounted control gear. All the lighting fittings shall have separate control & gear box arrangement. The control box shall be fixed on the wall/column for the easy maintenance.

1 x 70 W / 1 x 150 W HPSV lamp

(b) Cable vault 150 Industrial type with vitreous enamel reflector

2 x 36W fluorescent lamp (F.L)- Trulite

(c) All switchgear room area (including off-site building control room)

250 Industrial type with vitreous enamel reflector

2X36W fluorescent lamp (F.L)-Trulite

(d) GTG Building 200 Industrial high bay with anodised aluminium reflector

1x400 W, Metal Halide Lamp,

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Industrial High with Anodised Aluminium Reflector

(e) Control room 500 Decorative recessed with wide angle mirror optic anti glare type

Energy efficient Lamp – T5

(f) Battery rooms 250 Vapour proof 2X36W F.L.-Trulite

(g) A/C plant room 200 Totally enclosed vapour proof with clear acrylic cover

2 x 36W F.L

-Trulite

(h) Unloading and maintenance bay

250 Industrial high bay 1x400 W, Metal Halide Lamp, Industrial High with Anodised Alumi-nium Reflector

(i) Electrical / Instrument laboratory, chemical laboratory (air-conditioned)

250 Decorative recessed with wide angle mirror optic anti-glare type

2X 36W F.L.

-Trulite

(j) Chemical laboratory (non-air conditioned)

250 Corrosion proof 2 X 36W F.L.

-Trulite

2. HRSG area

(a) HRSG area and platforms

(i) Indoor

(ii) Outdoor

150

50

Dust proof / dust tight well glass fixture

70W HPSV lamp

3. Transformer Area

(a) General 30-35 Flood light medium beam type 1 x 150W HPSV lamp

(b) Near equipment 35-50 Dust proof / dust tight well glass on fire partition walls

1 x 70W HPSV

4. Switchyard Area

(a) General 30-35 Flood light medium beam type 1 x 150W HPSV lamp

(b) Near equipment 35-50 Post top lantern with HDP reflector

70W HPSV

(c) Switchyard Control room 500 Decorative recessed with wide angle mirror optic anti glare type

Energy efficient Lamp – T5

5. Various Off-site building

(a) Switchgear room (All pump 200 Industrial type with vitreous 2 x 36W F.L.

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house)

enamel reflector upto mounting height of 8M

(b) Outside working areas 70 Flood light medium beam

(c) Equipment room (Pump house, Compressor & DG house)

250 Industrial high bay / medium bay depending on height

1x400W / 1x150W Metal Halide Lamp (HPMV)

6. DM Plant / Filtration Plant

(a) General 250 Corrosion proof 1 X 70 WHPSV

7. Road and yard lighting

(a) Main roads

Secondary roads

20

10

Street light with clear acrylic cover cut-off type with integral mounted control gear or LED fixtures with control gear.

1 x 70W / 150W HPSV

(b) Perimeter (compound) lighting 20 - do - - do -

(c) Parking area (Indoor / sheds) 70 General purpose flood light, high/medium beam flood light

1 x 250 W HPSV

8. Workshop building 300 Industrial type with vitreous enamel reflectors/industrial high bay

2X36W F.L x 250W HPSV

9. Administration Building

(a) Main office areas cabins (air conditioned areas)

200-250 Decorative recessed type with mirror optic reflector

2 x 36W F.L.

(b) Main office areas, cabins with false ceiling but non-air-conditioned

200-250 - do - - do -

(c) Main office areas, cabin non air-conditioned areas without false ceiling

200-250 Decorative with wide angle mirror optic reflector

- do -

(d) Warehouse, canteen, medical centre

150 Industrial type with vitreous enameled reflector

2 x 36W F.L.

10. General

(a) Corridors, walk-ways, staircase, etc.

150 Industrial type with vitreous enamel reflectors/channel mounted box type compact flourescent lamp

2 x 36 W F.L.

(b) Lockers, toilets, wash rooms, etc.

100 Channel mounted box type 2 x 36 W F.L.

(c) Building periphery lighting - Industrial well glass with integral mounted control gear/industrial bulk head with

1 x 70 W HPSV lamp

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integral mounted control gear

(d) Security, Time office, Gate house, Executive canteen

150 Decorative with louver 2x36W F.L

11. Elevator

(a) Elevator machine room 100 Industrial type vitreous enamelled reflector

2 x 36W F.L.

(b) Elevator well 20 Industrial bulk head/ industrial bulk head with integral mounted control gear

1 x 100 W incandescent lamp / 1 x 70W HPSV

12. DC Light Fitting

(a) Control room - Decorative recessed type with cylindrical reflector

1 x 100 W incandescent lamp

(b) Other areas - Industrial bulk head or industrial well glass with reflector

1 x 100 W incandescent lamp

The illumination levels for areas, which are not specifically covered

above, shall be decided based on illumination levels indicated for similar areas or in relevant standards.

16.4 Lighting System Design The lighting system design shall comply with the acceptable norms and

the best engineering practices. The system design shall consider principles of lighting specified in following paragraphs. The lighting layout shall be designed to provide uniform illumination with minimum glare. The layout design shall meet all the statutory requirement, local rules etc.

16.4.1 Indoor lighting The illumination level for various areas in the plant is indicated in the

table above. Following factors shall be considered while arriving at the utilisation factor to determine the number of fixtures for each area/building in the plant.

(a) Maintenance factor

(i) Control room and system cabinet room - 0.8 (ii) All other indoor areas - 0.7

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(iii) Out door areas - 0.6

(b) Reflection factor for wall and ceiling

(i) Control room and system cabinet room - 0.7 ceiling, 0.5 wall (ii) Other areas - 0.5 ceiling

0.3 wall (c) The value of the ratio of spacing (S) to mounting height (H) shall

be commensurate with the type of fittings selected, uniformity of illumination. The suspension height for suspended fixtures shall not exceed 1 metre.

(d) The control room lighting shall be designed such that no glare

from the lighting appears on the DCS-CRT from any angle. 16.4.2 Roadway lighting

(a) Lighting design for roadways shall consider a maintenance factor of 0.6 for average conditions.

(b) Ratio of minimum to average illumination shall not be less than

0.3. The road lighting layout shall consider the width of the road to decide whether the lighting poles shall be located on one side, on either side or in the central reserve.

(c) The mounting height of the luminaires shall be generally 9

metres. (d) The control gear for street light shall be of non integral type i.e.,

the control gear of the light fixture shall be mounted at the foot of the pole.

(e) The lighting poles shall be galvanised steel poles with

reasonably thick layer of galvanising for ensuring long life. 16.4.3 Selection of lighting fixtures and accessories 16.4.3.1 The type of luminaires and accessories like switches, receptacles etc.,

shall be selected based on the plant area in which they are intended to be used. Lighting fixtures shall be explosion proof in hazardous and fuel oil areas.

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16.4.3.2 All fluorescent fixtures, shall have electronic chokes with low harmonics & energy efficient 'T5' type fluorescent lamps except the fluorescent fixtures used for division 2 hazardous area. The louvers of these fixtures shall be designed for 'T5' type fluorescent lamps. All fluorescent lamps shall be have "Cool day light" colour designation. The mirror optics type fluorescent fixtures shall have no iridescence effect.

16.4.3.3 All HPSV and HPMV lamp fixtures or LED fixtures shall be provided with

wire-wound ballasts. All fluorescent fixtures except for Class-I, Div-II fittings/ increased safety fittings (Div-II/Hazardous Area) shall be provided with electronic ballasts.

16.4.3.4 Conduits, Pipes and Accessories Galvanised heavy duty steel conduits

for normal area and galvanised heavy duty steel conduits with an additional epoxy coating for corrosive area shall be offered.

16.4.3.5 Rigid steel conduits shall be heavy duty type, hot dip galvanised

conforming to IS : 9537 Part-I & II shall be suitable for heavy mechanical stresses, threaded on both sides and threaded length shall be protected by zinc rich paint. Conduits shall be smooth from inside and outside.

16.4.3.6 Flexible conduit shall be water proof and rust proof made of heat resistant

lead coated steel. 16.4.3.7 Pull out boxes shall be provided at approximately 4 (four) metre interval in

a conduit run. Boxes shall be suitable for mounting on Walls, Columns, Structures, etc. Pull-out boxes shall have cover with screw and shall be provided with good quality gasket lining. Pull out boxes used outdoor shall be weather proof type suitable for IP :55 degree of protection and those used indoor shall be suitable for IP :52 degree of protection. Pull out box & its cover shall be hot dip galvanised.

16.4.3.8 The poles shall be of ERW tubes of specified lengths, swaged tubular and

joined together. The complete pole shall be hot dip galvanised. The terminal boxes for the lighting pole shall be IP55 protected & of glass reinforced epoxy type.

16.4.3.9 Lighting Mast shall be of continuously tapered polygonal cross section hot

dip galvanised. The Mast shall be of 30M height with lantern carriage to enable raising/lowering for ease of maintenance, including the Head Frame, Double Drum Winch, continuous stainless steel wire rope, in built power tool, luminaries, suitable aviation warning light, lightning along with necessary power cables within the mast. The mast shall be delivered only in three sections & shall be joined together by slip stressed fit method at site. No site welding or bolted joints shall be done on the mast.

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16.4.3.10 Suitable collapsible / telescopic ladder shall be provided to approach

lighting fixture installed at height. 16.4.4 Switches and receptacles

(a) In the plant areas, the lighting circuits shall be controlled directly from the MCBs in the lighting panels. Wherever the lighting panel is not in the same area, separate switches shall be provided. For cabins, rooms etc., separate switches shall be provided for each point. Similarly for entrances, building periphery lighting separate switches shall be provided.

(b) Receptacles with MCB (5A and 15A) shall be provided in all

building/areas of the plant. Also inside a building, receptacles shall be provided at regular intervals so that any point of the building is not more than 10 m with a minimum of 2 nos., in an enclosed area. Inside each cabins atleast two receptacles shall be provided. The same shall be indoor/outdoor/flameproof as per the location. Suitable no. of 63A, 3 phase, 400VA.C industrial heavy duty receptacles shall be provided for outdoor plant for welding purpose. The industrial receptacle shall be provided at an average distance of 50 mts. At-least two 63A, 3 phase, 400V industrial heavy duty type receptacle shall be provided in each building. It shall be metal enclosed with SFU and housed inside with suitable connection for cabling and receptacles.

(c) Ceiling fans, to be provided in non air conditioned office/control

room area, shall be suitable for operation on 230 V, 50 Hz, AC supply comprising of class ‘F’ insulated copper wound single phase motor, 1200mm sweep, aerodynamically designed well balanced MS blades (3 Nos.), down rod, die cast aluminium housing, capacitor, suspension hook, canopies etc. finished in stove enamelled white. Power factor of fans shall not be less than 0.9. Each fan shall cover approximately 10m2 area.

16.4.5 Lighting distribution boards (LDB) & lighting panels (LP) Each of the LDBs shall be provided with voltmeter and ammeter along

with selector switches, `Supply On' indicating lamps, etc. The LDBs and LPs shall be sheet steel enclosed and shall be fully dust and vermin proof, with a degree of protection of IP 54. Outdoor panels shall be weather proof type with IP - 54 degree of protection. LDBs, LPs shall be explosion proof wherever provided in hazardous and fuel oil areas. The

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switch boxes, receptacle boxes etc., shall be made up of 18 SWG sheet steel.

16.4.6 The distribution of lighting fixtures/receptacles shall be such that the

loading on each phase of the LDB is approximately equal. 16.4.7 Wiring

(a) 1100 V grade stranded copper conductor, PVC insulated wires to IS: 694 laid in GI conduits shall be used for lighting in non-hazardous area. In the hazardous areas cable wiring with 1100 V grade stranded aluminium conductor, PVC insulated, PVC inner sheathed, GI wire armoured and overall PVC sheathed cables to IS: 1554 shall be adopted. For outdoor areas like transformer yard, switchyard and road lighting also cable wiring as above shall be adopted.

(b) Minimum size of wires in case of conduit wiring shall be 2.5 mm2

in case of lighting and 4 mm2 in case of receptacle wiring. Minimum cable size in case of cable wiring shall be 4 mm2 for lighting and 6 mm2 for receptacles.

(c) Wires of different phases shall be run in separate conduits.

However wires of same phase but having different circuit nos. can be run in same conduit. Wires of lighting and power receptacles will be carried out in separate conduits and on separate circuits. Wires of AC and DC lighting systems shall be carried out in separate conduits.

(d) For outdoor lighting, the cable shall be buried at a minimum

depth of 750 mm from ground level. The buried cables shall have suitable bedding, protective covers & markers.

(e) The wiring in the conduit shall be such that 20% space in the

conduit is free. 16.4.8 Lighting circuit design

(a) In an area, the lighting fixtures shall be arranged in different phases/LPs such that even in case one lighting panel goes faulty complete lighting is not affected. In case of room the lighting shall be arranged from two phases.

(b) The circuit loading on each circuit shall be restricted to 80% of

the MCB rating.

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(c) The voltage drop from LDB and any fixture shall not exceed 3%.

(d) The contractor shall submit design calculation for sizing of LDBs

and also provide lumen contour for the main road and other areas. Contractor shall demonstrate the same at location decided by Owner.

16.4.9 Earthing

(a) Lighting fixtures, receptacles, switches, conduits and junction

boxes shall be properly earthed using 12 SWG GI wire run along the entire length of the conduit between the fixture and the corresponding lighting panel where it will be connected to the station earth.

(b) For fixtures in hazardous areas, the third core of each single-

phase armoured cable circuit shall be used as earthing conductor.

(c) For outdoor earthing of lighting poles, junction boxes on the

poles, 25 X 6 GS Flat, shall be run buried in ground at a depth of 600 mm and tapped to each lighting pole. The earth conductor shall be connected to the nearby main earthing grid at the first and last poles of each feeder circuit and at some intermediate poles.

16.5 Tests

16.5.1 Type test reports of the following items as per relevant standards shall be submitted for approval.

i. Lighting fixtures of each type

ii. Lamps of each type and rating.(life cycle and rating test only)

iii. Lighting panel of each type (Degree of Protection)

iv. Junction Box of each type

v. Receptacles of each rating

vi. M.C.B. of each rating.

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16.5.2 All acceptance tests & routine tests for the lighting fixtures and

accessories covered in this specification shall be carried out as per the relevant standards listed under "Codes and Standards” given below for the respective fixtures/ components. Type test certificates shall be furnished for review.

16.6

Applicable Standards

16.6.1 Electric Lighting Fittings General and Safety

Requirements IS:1913

16.6.2 Code of Practice for Industrial Lighting IS:6665

16.6.3 Calculation of Co-efficient of Utilisation IS:3646 (Part-III)

16.6.4 Industrial Lighting Fittings with Metal

Reflectors IS:1777

16.6.5 Decorative Lighting Outfits IS:5077

16.6.6 Dust Proof Electric Lighting Fittings IS:4012

16.6.7 Dust Tight Electric Lighting Fittings IS:4013

16.6.8 Electric Lighting Fittings for Division

2 Areas as per IS:5572 (P1) IS:8224

16.6.9 Flame Proof Lighting Fittings IS:4013

Part (I&II)

16.6.10 Flame Proof Enclosure IS:2148

16.6.11 Flood Lights IS:10322 Pt-V SECT-5

16.6.12 Luminaries for Street Lighting IS:10322

Pt-V SECT-3

16.6.13 Waterproof Electric Lighting Fittings IS:3528

16.6.14 Watertight Electric Lighting Fittings IS:3553

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16.6.15 Bayonet Lamp Holders IS:1258

16.6.16 Edison Screw Lamp Holders IS:10276

16.6.17 Bi-Pin Lamp Holders for Tubular Fluorescent Lamps

IS:3323

16.6.18 Starters for Fluorescent Lamp IS:2215

16.6.19 Holders for Starters for Tubular Fluorescent Lamps IS:3324

16.6.20 Ballast for Use in Fluorescent Lighting Fittings IS:1534 (Part 1)

16.6.21 Transistorised Ballast for Fluorescent Lamps IS:7027

16.6.22 Ballast for HP Mercury Vapour Lamp IS:6616

16.6.23 Capacitors for Use in Fluorescent, HPMV & LP

Sodium Vapour Discharge Lamp Circuits IS:1569

16.6.24 Vitreous Enamel Reflector for Tungsten Filament

Lamp IS:8017

16.6.25 Tubular Fluorescent Lamps IS:2418 (Part 1)

16.6.26 High Pressure Mercury Vapour Lamps IS:9900

16.6.27 Tungsten Filament General Electric Lamps IS:418

16.6.28 Cast Acrylic Sheets for Use in Luminaires IS:7569

16.6.29 Screwless Terminal and Electrical Connections for

Lighting Fittings IS:10322 Pt-III

16.6.30 High Pressure Sodium Vapour Lamps IS:9974

16.6.31 Emergency Lighting Units IS:9583

16.6.32 Ignition Proof Enclosures, Dust-Tight for Electrical Equipment

IS:11005

16.6.33 Luminaires (Part 1 to V) IS:10322

16.6.34 Arrangement for Busbars, Main Connections and Auxiliary Wiring and Marking

IS 5578 IS 11353

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16.6.35 Enclosed Distribution Fuse Boards and Cut-outs for Voltages not exceeding 1000 V

IS 2675

16.6.36 General Requirements for Switchgear and Control

gear for Voltages not exceeding 1000V IS 4237

16.6.37 Code of Practice – Installation and Maintenance of

Switchgear IS 10118

16.6.38 Factory Built Assemblies of Switchgear and

Controlgear for Voltages upto and including 1000 V AC and 1200 V DC

IS 8623

16.6.39 Degree of Protection of enclosed equipment for

Low Voltage Switchgear and Controlgear IS 13947

16.6.40 Switches, Disconnectors, Switch Disconnectors and

Fuse Combination Units for Low Voltage Switchgear and Controlgear

IS 13947 Part-3

16.6.41 Miniature Air Break Circuit Breakers for AC Circuits IS 8828

16.6.42 HRC Cartridge Fuse Links upto 650 V IS 9224

16.6.43 Current Transformers IS 2705

16.6.44 Voltage Transformers IS 3156

16.6.45 Direct Acting Electrical Indicating Instruments IS 1248

16.6.46 AC Electricity Meters IS 722

16.6.47 Electrical Relays for Power System Protection IS 3231

16.6.48 Flameproof Enclosures of Electrical Apparatus IS 2148

16.6.49 Guide for Selection of Electrical Equipment for

Hazardous Areas IS 5571

16.6.50 Switches for Domestic and Similar Purposes IS 3854

16.6.51 Three-Pin Plugs and Socket Outlets IS 1293

16.6.52 Fans and Regulators, Ceiling Type, Electric IS 374

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16.6.53 Rigid Steel Conduits for Electrical Wiring IS 9537

16.6.54 Accessories for Rigid Steel Conduits for Electrical Wiring

IS 3837

16.6.55 Flexible Steel Conduits for Electrical Wiring IS 3480

16.6.56 Rigid Non-Metallic Conduits for Electrical

Installations IS 9537 Part-2

16.6.57 Fittings for Rigid Non-Metallic Conduits IS 3419 Part-2

16.6.58 PVC Insulated Cables for Working Voltages upto

and including 1100 V IS 694

16.6.59 Tubular Steel Poles IS 2713

16.6.60 Wrought Aluminium and Aluminium Alloys, Bars,

Rods, Tubes and Sections for Electrical Purposes IS 5082

16.6.61 Code of Practice for Phosphating Iron and Steel IS 6005

16.6.62 Fittings for Rigid Steel Conduits for Electrical Wiring IS 2667

16.6.63 Prestressed Concrete Circular Spun Poles for

Overhead Power, Traction and Telecommunication Lines

IS 13158

16.6.64 Methods of Test for Concrete Poles for Overhead

Power and Telecommunication Lines IS 2905

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EARTHING & LIGHTNING PROTECTION SYSTEM

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17.0 EARTHING SYSTEM Earthing system shall consist of earth grids and electrodes buried in soil

in the plant area, embedded in concrete inside the buildings to which all the electrical equipment, metallic structures are connected to have earth continuity for safety reasons.

Earthing system shall be in strict accordance with IS:3043 and Indian

Electricity Rules/Acts. 17.1 Design Criteria

17.1.1 Fault Current & Duration

The earthing conductor shall be designed for 50 kA for duration of 1 second.

17.1.2 Conductor Material

The earthing system conductors and accessories as proposed are to be as follows :

(a) Conductors above ground level

and in trenches

: Galvanised steel

(b) Conductors buried in ground or embedded in concrete

: Mild Steel

(c) Electrodes : GS Pipe / Rod

(d) Lightning protection air termination and down conductors for buildings

: GS Flat

(e) Exposed lightning protection air termination on chimney top

: Lead coated copper

The Contractor shall undertake the soil resistivity measurements at site

and select suitable type and cross section of conductors. 17.1.3 Size of Conductors

(a) Main Earthing Conductors

The earthing conductor sizes shall be calculated as per IS 3043 and shall comply with Indian Electricity rules and IEEE-80.

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The calculated size shall be suitably (depending on the resistivity of soil) increased as per table below to account for the loss of material (steel) due to corrosion in soil.

Resistivity of Soil Ohm– Metric

Reduction in thickness/diameter, mm

> 0 <10 8.0 >10 <25 7.0 >25 <50 5.5 >50 <75 4.5 >75 <100 3.0 >100 1.5

The minimum steel corrosion shall be 0.12 mm/year.

(b) Rod Electrodes Galvanised steel rod electrodes of suitable diameter (min dia

40mm) and length shall be used as per the recommendation of IS-3043. For test pits electrodes shall be heavy duty type (Class – C) GI pipe of suitable diameter with perforations. Electrodes installed in the test pits will have disconnecting facilities.

(c) Equipment Earthing Leads The size of the earthing leads shall be decided based on the

type of equipment and structure to be earthed and shall be provided generally as per IS-3043. However the min. size of the of equipment earthing lead shall be 65x10 mm GS flat.

(d) Conductors for lightning protection system The size of conductors for lightning protection system shall be

decided based on mechanical strength. 17.2 Earthing System Layout

17.2.1 The earthing system design and installation shall generally comply with

IS-3043, IEEE-80 and Indian Electricity Rules. 17.2.2 General

(a) Metallic frames of all current carrying equipment, supporting structures adjacent to current carrying conductors, lightning

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protection system conductors and neutral points of various systems shall be connected to a single earthing system. Two earthing leads shall be used if rated voltage of equipment is above 250V. If the rated voltage is 250V or below, one earth lead shall be provided. Metallic structures adjacent to electrical equipment shall be earthed by one earthing lead. Crane rails, tracks, metal pipes and conduits shall also be effectively earthed at two points. Steel RCC columns, metallic stairs, and rails etc. of the building housing electrical equipment shall be connected to the nearby earthing grid conductor by one earthing ensured by bonding the different sections of hand rails and metallic stairs. Metallic sheaths/screens, and armour of multi-core cables shall be earthed at both ends. Metallic Sheaths and armour of single core cables shall be earthed at switchgear end only unless otherwise instructed by the Owner. Every alternate post of the switchyard fence shall be connected to earthing grid by one GS flat and gates by flexible lead to the earthed post. Portable tools, appliances and welding equipment shall be earthed by flexible insulated cable

(b) Earthing conductors in outdoor areas shall be installed at a

minimum depth of 600 mm. (c) All cable trays in the plant buildings as well as inside the

trenches shall be connected to earth grid at an interval of about 10 m.

(d) Each side of the generator neutral earthing resistor shall be

terminated at two nos. treated pipe earth electrodes. The earth pipe electrodes shall be further interconnected to the buried earth grid.

(e) Neutral of the auxiliary transformers shall be directly connected

to two nos. treated pipe earth electrodes. The earth pipe electrodes shall be further interconnected to the buried earth grid.

17.2.3 Earthing Conductor Layout in Switchyard

(a) Main earthing conductors shall be laid in the form of a grid. Spacing between conductors, number of parallel conductors, etc., shall be decided such that step and touch potential are within safe limits.

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(b) The maximum permissible step and touch potentials shall be calculated in accordance with the formula, given in IEEE-80.

(c) Earthing conductors shall be provided around the outside edge

of fence at a distance of approximately 6000 mm. This shall be connected to the switchyard earthing grid.

(d) An earthing mat comprising closely spaced (about 150 mm)

conductors shall be provided below the operating handles of disconnecting switches and breaker operating kiosk for the additional safety of the operating personnel.

(e) Each earth leads of transformer neutral, lightning arrester earth

leads, CVT’s earth leads shall be directly connected to two separate electrodes, with treated earth pits. Lightning protection down conductor shall be directly connected to a separate earth electrode. All earth electrodes in turn shall be connected to station earthing system. The earth grids of different areas of the plant shall be interconnected through separate conductors & with 2 Nos. test pits, test pits to enable measurement of earth resistance for each area separately.

(f) Earthing grid design shall be done in such a manner that the grid

resistance is less than 0.5 ohm.

17.2.4 Earthing Conductors Inside Building

(a) Main earthing conductors shall be buried in earth around the building. Minimum two taps-off from this earthing loop shall be taken inside the building and connected to the earthing grid embedded in the floor slab with approximately 50 mm concrete cover.

(b) In case, the building has more than one floor, each floor shall be

provided with earth grid. Floor earthing grids shall be interconnected.

(c) Each RCC / Steel column of the building shall be interconnected

to the floor earthing grid in the ground floor. (d) Cable trays, steel pipes / conduits, steel columns, etc., shall not

be used as earth continuity conductors.

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(e) Instrumentation system and computer system shall be provided with a dedicated earthing system suitable for the equipment and shall confirm to DCS manufacturer’s specification.

(f) Earthing grids of all the buildings, outdoor yards shall be

interconnected to form a single grid for the plant. (g) Earthing grid design shall be done in such a manner that the grid

resistance is less than 0.5 ohm.

17.3 Earthing System Installation 17.3.1 The spacing between two electrodes shall be atleast equivalent to twice

the length of the electrode. 17.3.2 Earthing conductor running exposed on column, walls, etc., shall be

supported by suitable cleating, at intervals of 750 mm. 17.3.3 The earthing conductor crossing the road / track shall be laid in hume

pipe or laid at a greater depth to avoid damage. 17.3.4 When earth conductor passes through floors, walls, etc., suitable pipe

sleeves shall be provided and the same shall sealed after installation. 17.3.5 The connection between earthing pads / terminal to the earth grid shall

be made short and direct and shall be free from kinks & splices. 17.3.6 Metallic conduits and pipes shall not be used as earth continuity

conductor. 17.3.7 Street lightning poles, flood light poles & towers, their junction boxes

shall be connected to the earthing conductor to be run along with supply cable. This earth conductor shall be in turn connected to earth grid at two extreme points.

17.3.8 Flexible earth conductors shall be provided at expansion joints for

earthing the gates, operating handles, etc. 17.3.9 Equipment bolted connection after being checked and tested shall be

painted with anti-corrosive paint / compound. 17.3.10 Connection between the equipment earth lead and the grid conductor

shall be welded. For rust protection, the welds shall be treated with zinc chromate primer and coated with zinc rich paint.

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17.3.11 The cable sheaths, screens armour shall be earthed at both ends for multi-core cables. For single core cables the same shall be done at one end (switchgear end) only.

17.3.12 All bimetallic connections shall be treated with suitable compound to

prevent moisture ingression. 17.3.13 Alternate switchyard fence posts shall be connected to the earth grid. 17.3.14 Contractor shall demonstrate the effectiveness of earthing system by

measurement of earth resistance, step and touch potential at different location.

17.4 Lightning Protection System Lightning protection system shall consist of vertical air termination rods,

horizontal roof conductors, down comers, test links and pipe electrodes. 17.4.1 Need for Protection The need for providing the lightning protection system shall be

established by calculating risk index value for each building structure, etc., as per procedure given in IS-2309 and any building whose over all risk factor is more than 10-5 (as per IS-2309), shall be provided with lightning protection.

17.4.2 Lightning Protection System Layout

(a) The lightning systems design and installation shall generally comply with IS: 2309 code of practice for the protection of building and allied structure against lightning.

(b) For stack air termination, rods interconnected by circumferential

conductors will be provided at the apex of flue and also upon outer shell of the stack. The air termination system will be formed by lead coated copper conductors to prevent corrosion of conductors due to flue gas.

(c) For cooling towers, air termination system will comprise of

horizontal circumferential conductors at the top. (d) Lightning masts shall be provided for switchyard. Calculation for

sizing, no. of lightning mast etc shall be furnished for approval of Owner. Shield wire shall be provided between gantry support & Power house building wall over phase conductors and shielding

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network shall be connected to switchyard earth mat. For switchyard down conductors from the shield wires shall be run along the tower and connected to rod / electrode. The zone of coverage for the shield wires and 450 on end conductor shall be considered as 600 between two conductors.

(e) Down conductors shall be as short and straight as practicable

and shall follow a direct path to earth electrode. All joints in the down conductors shall be welded type. Each down conductor shall be connected to a rod electrode which in turn shall be connected to the station earthing system through test links.

17.4.3 Lightning Protection System Installation

(a) Conductors of lightning protection system shall not be connected with conductors of safety earthing system above ground level.

(b) The down conductors shall be welded to steel structures at 1000

mm interval or cleated to wall at 750 mm interval. Wherever welded, the weld locations shall be treated to provide rust protection.

(c) Each down conductor shall be provided with a test link at a

height of about 1000 mm above ground level. (d) All the metallic structures within a vicinity of 2000 mm shall be

connected to the lightning protection conductors.

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18.0 COMMUNICATION SYSTEM 18.1 Intrasite Communication System 18.1.1 Intercom Telephone System (EPABX System)

(a) Micro-processor based, fully integrated, modular construction type, modularly expandable digital electronics EPABX system with capacity of 600 ports extendable to 800 ports shall be supplied. The system shall be based on Pulse Code Modulation (PCM)/Time Division Multiplexing (TDM), fully non-blocking principle. The state of the art technology shall be used for designing the system. The system shall be equipped with necessary electronic cards for trunk lines and extension lines, housed in a weatherproof enclosure, suitable for mounting in a non-air-conditioned area. This EPABX shall be hooked to P&T system by 40 tie lines, which shall include 20 direct lines. These direct lines will be for the use of management cadre & control room staff for direct communication with P&T subscriber without operator intervention. The cable from P&T exchange to power plant EPBAX shall be included in the contractor’s scope. Additionally two cables of 50 pairs each shall be laid from the plant EPABX system to the colony utility building as mentioned in the section C2. These cables shall be laid in the suitable conduits. The entire job shall be the scope of Bidder.

(b) The quantity of the trunk cards and extension cards shall be

selected in such a way so as to provide 10% spare capacity. Electronic cards with intelligent processors shall be provided. The system shall have compatibility for analogue telephone instruments, digital (key) telephone instruments, and the special feature telephones. The system shall be supplied with the operator console as an in-built feature. Operator console shall be equipped with a PC with tracking provision for all calls, call times etc. and PC shall have provision to come over office automation LAN. One spare port for operator console shall be provided.

(c) The system shall have 100% non-blocking feature. Redundancy

for control and processor card shall be provided. The system shall be 100% fault tolerant. It should have computer (PC) compatibility for data transmission.

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(d) The EPABX system shall have connectivity (hardware, software and any / all other accessories) for Integrated Digital Network (ISDN), Dual Tone Multi-Frequency (DTMF) Connectivity, Computer (Local Area Network) LAN & Wide Area Network (WAN), FAX as well as connectivity to Wireless System specified in this section. The system shall be so interconnected that it shall be possible to access any of the systems (Intercom/ Wireless) from any other system without human intervention in any way.

(e) EPABX system shall be provided with the following:

(i) One (1) 48V DC High Discharge Plante Lead Acid

battery of adequate AH capacity with 10% margin suitable for twelve (12) hours uninterrupted service of exchange working at 100% capacity including its allied systems.

(ii) One (1) float-cum-boost charger of suitable capacity to

supply power to the exchange. The battery charger shall be suitable for the High Discharge Plante Lead Acid battery specified above.

(iii) One (1) operator console.

(iv) Required number of telephone instruments.

(v) Two (2) dial testers for DC pulsing and DTMF telephone

instruments.

(vi) Three (3) line man hand held telephone sets with DC pulsing and DTMF switchable with built in ringer unit and crocodile clip.

(f) Call Billing software shall be provided with dedicated personal

computer with SVGA colour monitor, dedicated printer. Using this software, it shall be possible to read from screen/obtain a print out of calls made, called station, pager/wireless set with number called, date of each call, duration of each call, number of metered calls, extension/wireless/fax set from which call was made, time at which each call was made. Besides the above, the EPABX shall be provided with two Combo drives with provision and facility including software to store/retrieve all the above parameters to/from a disk. The call billing software shall

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also have facility for printing all / selected parameters listed above at regular (site adjustable) time intervals as well as facility to browse on screen/print any of the above parameters in any desired format eg. Number of calls made from a particular extension for a given period of time (selectable). Software lock shall be provided to prevent unauthorised personnel gaining entry to above. All above parameters shall be capable of being stored automatically for a minimum period of 3 months. Erasure of this information shall only be after adequate warning alerting operator to take back up. None of the stored data shall be lost for failure of power supply.

(g) EPABX shall have full self-diagnostic feature. All faults, besides

being annunciated by high intensity LED on the EPABX and audio alarm, shall be displayed on the PC with component level fault being displayed in English.

(h) The EPABX shall be provided with 120% capacity main power

supply unit with 100% standby power supply unit. On failure of main unit, standby unit shall automatically cut-in. Annunciation (audio and visual) shall be provided for each power supply unit fail and also auto-changeover fail. Changeover time shall not affect the EPABX/its allied systems in any way.

(i) The EPABX system shall be capable to accommodate the

EPABX system of the colony (which is not in scope of Bidder). It shall have provision of 100 lines for interfacing with colony.

(j) The Bidder shall provide all the telephone instruments in the

plant areas at each working areas. The locations shall be decided during detailed engineering. But the Bidder shall supply at least 200 telephone instruments.

(k) Telephone Instruments

(i) The telephone instruments shall be indoor desk type or

indoor wall mounted type or outdoor wall mounted type as required. The type of handset shall be selected based on its location.

(ii) All desk type instruments for all subscribers shall have

keypad with push buttons.

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(iii) The instruments mounted outdoor shall be provided with weather proof type enclosure.

(iv) Selected instruments shall be provided with additional

features to meet the special facility requirements as mentioned below.

(v) Telephone instruments located in high ambient noise

level area shall be provided with loud ringing device and sound proof booths.

(l) The following special features shall be provided on selected

instruments:

(i) Call interruption / priority – the handsets shall be provided with a priority push button. After dialling from this handset station, if engaged tone is received, the caller can cut into the conversation by pressing the priority service button.

(ii) Emergency alert – Dialling a number shall intimate a

fire or emergency alarm. The caller’s number shall be stored to reduce / prevent the incidence of mischievous calls.

(iii) Automatic call back – This shall enable the selected

subscribers, who receive a busy tone when calling another extension to come on the busy extension. The call back equipment shall make the connection as soon as the called extension is free. While waiting for the call back, calling party can use his telephone for other calls as usual.

(iv) Automatic call diversion - This feature shall re-route a

call for an extension (A) to extension (B). This arrangement shall function for all calls till it is reset.

(v) Conference call - This shall enable the subscribers to

set up telephonic conference involving atleast 5 parties.

(m) Cell phones with group arrangement to be provided.

18.1.2 Landline Telephones, Broadband connectivity

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a) Necessary number of ISDN / PSTN landlines would be provided at strategic locations within the plant boundary. Broadband connectivity would be provided at strategic locations for online access of data from remote station.

18.1.3 Walkie Talkie( Wireless system) 18.1.3.1 This system shall include the following:

(a) Base stations with antennae, power supply units, inverters, voltage stabilisers and all other accessories.

(b) Twenty (20) Nos. hand held two way transmitter receiver sets. (c) Battery charger for hand-set batteries – 20 Nos. (d) The system shall be capable of being coupled with the EPABX

and PA systems such that any wireless set can be contacted from any of the EPABX-intercom extensions or PA system and from the DTMF keypad of the portable radios it should be possible to contact any of the EPABX – intercom number through the EPABX.

(e) The wireless sets shall be addressable type and light weight. (f) The system shall have a minimum operating range of 15 kms

between one base station to another base station. Range from base station to handset is about 8 kms. Handset to handset is about 3 kms.

(g) The power supply to the entire base stations shall be through the

UPS, to allow the radio communications during “Black Out” conditions also.

(h) The exact details of requirements, installation design and

specifications shall be worked out during detailed engineering. But the contractor shall consider the modern communications system with above specifications for the purpose of bidding.

18.1.3.2 GPRS/CDMA mobile system of any reputed service provider can be provided for wireless system. The mobile system coverage in the power plant area should be 100%. The mobile system shall be interfaced with plant EPBX and PA systems.

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18.1.4 Cables The type of cables and their technical particulars shall be as per the

requirement of the system for giving best performance. 18.1.5 Tests All the equipment covered in this specification shall be subjected to

routine tests as per relevant standards. Type test certificates shall be submitted for review.

18.2 Public Address System

18.2.1 General Requirements

This specification covers requirements for selection, design, engineering, manufacture, shop testing, type testing, erection and commissioning of Public Address System as described below:

(a) The Public Address System shall consist of zones, sub-zones and Exchanges to interface all these zones among them selves. The zones shall also cover all off-site Plant Auxiliary Systems and shall be finalized during detailed engineering, taking into consideration the configuration of the combined cycle plant.

(b) All the above-mentioned zones shall be connected with a central exchange to be located in Control room/ Control Equipment Room.

(c) The Contractor’s scope shall also include successful demonstration of performance testing specified herein complete in all respects along with cables, junction boxes, earth wire and accessories like standard brackets, nut-bolts, glands, lugs, conduit sleeves, etc., as required, to complete the proper installation conforming to IS: 1881, IS: 1882 of all the equipments supplied as covered in this specification. All equipment, accessories and facilities required for completeness of this system shall be furnished by the Contractor, whether these are specifically mentioned herein or not.

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(d) The equipment furnished under this section shall meet the requirements of all-applicable codes and standards as specified or their equivalent international codes and standards.

(e) The Public Address System (PAS) offered by the Bidder shall be from reputed manufacturer who should have designed, manufactured, tested and commissioned a distributed amplifier type industrial Public Address systems as specified in power plants or large industrial installation as on the date of bid opening.

(f) The system shall be adequately protected from signal and power line noise and meet the Surge Withstand Capability (SWC) requirements of ANSI C37.90.1/ IEEE standard 472-1989 equivalent.

(g) The Bidder shall guarantee satisfactory performance of the equipment under stipulated variations of voltage and frequency. The design and manufacture shall be such that equipments/ components of same type and rating shall be interchangeable.

(h) In addition to the facilities to be provided by the Bidder as mentioned in relevant clauses of this section the Bidder shall make his own arrangements for any other requirements that are necessary to put the system in service.

(i) All the items, including Public Address system erection hardware, cables, cable erection hardware, telephone cables etc. as may be required to make the PA system complete and functional are to be furnished by the Contractor on as required basis.

18.2.2 Power supply arrangement

The Bidder shall provide power to the Public Address System from UPS system as detailed in Section D3.14 of technical specifications. The details shall be finalized during detailed engineering stage. In case the Bidder's offered equipment is operating at any other voltage level, the Bidder shall provide all required hardware, to make the offered system compatible with specified power supply arrangement. The system shall be fully functional during the total power supply failure of the plant.

18.2.3 System description

(a) Communication within a zone

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(i) PAS shall have two modes, i.e., Paging mode and Party mode. Each of the two modes shall be open line, common talking type. Paging mode shall be used for locating a person and for general instructions. Party mode shall be used for conversation between individuals without broadcasting the same over the loudspeaker.

(ii) Whenever the 'Press to page' push button is pressed on any of the handset stations, a pleasant chime shall be broadcast over all loudspeakers except the one associated with that handset station to attract attention. Conversation, in paging mode shall be heard over all loudspeakers except the loudspeaker associated with the handset station whose 'Press to Page' push button is being held in pressed condition. When 'Press to Page' push button is released, the associated handset shall return to party mode. When a handset station is being used for party mode, its associated loudspeaker shall be free to receive all paging calls. However, the operator shall have the option of silencing the associated loudspeaker by pressing "Loudspeaker mute' push button, should he find it disturbing his conversation on party mode. The loudspeaker shall return to normal operation automatically when the 'loudspeaker mute' push button is released. Simultaneous operation on both modes, i.e. some handsets on party channel and some handsets on paging channel, shall be possible without any crosswalk between the two channels. During conversation on 'page' mode within a zone, the centralized equipment/hardware of the associated zone shall have the feature to monitor and identify the handset from where conversation is being continued with the 'page' button depressed and the access code of the person. Further, suitable indication of 'Power Supply on' and 'Party channel busy' shall be provided on hand set stations.

(iii) Portable type handsets with Multipin plugs shall be used at certain locations where operational personnel are not present normally. Necessary sockets, wiring, etc., shall be provided at these locations. The locations (distributed in each zone) etc. shall be finalized during detailed engineering.

(iv) Unless requested, announcements/ communication within a zone shall not be audible in other zones.

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(b) Inter Zone Communication

(i) Each of the zones shall be connected to a Central exchange to be located in Central Control room/ Control Equipment Room. All the communication facilities like paging and party mode communication as described above between these two zones shall be possible as if they have now become a single zone.

(ii) The Central Exchange shall have one master control unit for each of the modules and one more master control unit for Shift In charge Room. All the master control units shall be connected in parallel. Any inter-zone communication shall be possible through this master control unit. The exact type of the same shall be decided during detailed engineering. Further, it shall be possible to broadcast recorded speech, music etc. over the loudspeakers.

(iii) Communication/ announcements within a zone shall not be heard in loudspeakers of other zones. It shall be possible to communicate from a station in one zone to another station in other zone through the master control unit(s) only.

(iv) It shall be possible from a station in one zone to communicate with another station in a different zone, both in party/ page mode through the master control units located on each module control desk at Control room and Shift Incharge Room.

(v) Suitable built-in interface shall be provided for connection with Owner's main telephone exchange in the Central Exchange and/or Master Control Units through which it shall be possible to communicate with any station in any zone from any telephone set through Central Exchange and/or Master Control Unit.

18.2.4 Handset Stations

(a) Handset stations shall be of the following types:

(i) Outdoor Wall/ column mounting type.(Type - A)

(ii) Indoor desk-top mounting type. (Type - B)

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(iii) Indoor control desk flush mounting type. (Type - C)

(iv) Mosaic grid compatible telephone set. (Type - D)

(b) Each handset station shall have following:

(i) One (1) - telephone handset.

(ii) One (1) - Cradle switch for resetting the handset.

(iii) One (1) - "Press to Page" push button.

(iv) One (1) -"Press to Mute Loudspeaker" push button.

(v) Pre-amplifier and Power amplifier.

(vi) Indication for 'POWER SUPPLY ON'.

(vii) Indication for 'PARTY CHANNEL BUSY'.

(c) The outdoor wall/ column mounting type handset stations shall be dust-tight and weather-proof, with appropriate protection against direct rain, ingress of dust and moisture conforming to IP-55 degree of protection as per IS: 2147. The indoor desk-top mounting type handset stations shall have a degree of protection of at least IP-32. The outdoor wall/ column mounting type handset stations shall have covers with padlocking facility. All handset stations and their components shall be capable of continued satisfactory operation at an ambient temperature at 55°C.

(d) The control-desk mounting type handset stations shall be suitable for flush mounting on Unit Control desk.

(e) Handset transmitter/ microphone shall be noise canceling type and all switches and push buttons provided on the handset station shall be of encapsulated contact type. Handset transmitter/microphone shall have filters to protect from dust. Each handset shall be provided with one meter (extended) retractable coiled type of cable.

(f) All handset stations shall have a compact, robust, rust resistant, shock-resistant body made of high impact polystyrene or

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equivalent. The Type-A handset shall be inside an enclosure with transparent glass door, which can be opened through number padlock only.

(g) The wall/column mounting handset stations shall be tamper-proof, using internal anchoring bolts and peculiar (e.g. triangular head, counter-sunk) screws which can be loosened only with special keys. Constructions where the entire electronic part shall be modular type and can be removed from the handset station enclosure for easy maintenance. Terminal connections of different PCBs should not be interchangeable.

(h) The handset stations in the noisy areas like Turbine Hall, BFPs, etc., shall be housed in Acoustic hoods. An industrial type free standing, floor mounted hood shall be used for providing the above requirements. The design noise level within the hood shall be limited to a maximum of 60 dB SIL.

18.2.5 Amplifiers

(a) Amplifiers shall be solid state, class-B, Push-pull type, in built with the handset fully conforming to IS: 1301 & IS: 10426 or equivalent international standard.

(b) Amplifiers shall have 0-100% volume control setting. with facility for coarse and fine setting along with following controls which shall be located inside the Handset Station.

(i) Input sensitivity control

(ii) Receiver volume control

(iii) Bass cut filter

(iv) Anti side tone control feature

18.2.6 Loudspeakers

(a) Indoor loudspeakers shall be cone type housed in sturdy metal cabinet suitable for wall/ column mounting. The cabinet shall be

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treated with acoustic under-coats to prevent resonance. They shall have IP-52 degree of protection as per IS: 2147.

(b) Outdoor loudspeakers shall be industrial horn type and of pressure die cast aluminum construction. The mounting bracket shall be with adjustable base suitable for vertical and horizontal orientation. They shall have IP-55 degree of protection as per IS: 2147.

18.2.7 Central exchange & master control unit

(a) Central exchange shall be wide band microprocessor based having associated circuitry for calling station identification and of modular design. This exchange shall consist of all the necessary control hardware, required for operation, monitoring, protection, indication, switching, testing, measurement of all the voltages and load conditions of the entire system, facility for checking of the operation of all the stations and quality of speech from the master control units etc. All the card etc. shall be plug in type. Solderless termination shall be provided for every wiring. Systems bandwidth shall be at least 200-10 kHz (±10 dB) and shall not alter frequency response of the open line system. All the central exchange shall be enclosed in a freestanding cabinet to be located in control equipment room all the cable entries shall be from bottom only. This shall be able to cater all the specified zones along with the ability to interconnect at least ten (10) more zones for future expansion. Suitable hardware for communication between any handset of the Public Address System with Owner's Telephone Exchange shall be provided. All the handsets shall have the necessary arrangement for using it as a intercom telephone instrument. It shall be possible to call to any of the intercom number from any handset. Also, it shall be possible to announce any message from any intercom phone and then communicate with the handset selected by field user on party line. Further, all the programming tools that will be required to program/reprogram the system shall also be provided.

(b) Master Control Units shall be microprocessor based and of modular design. These units shall be mosaic grid compatible flush mountable type along with flexible goose neck type microphone, luminous miniature push buttons for inter-zone communications, alarm tone generation, fire alarm tone generation etc.

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18.2.8 Cables and junction boxes

The Contractor shall supply the cables required for PA system on as required basis. The cables shall be of FRLS type. Colour of the outer sheath shall be YELLOW. Sizes and details of cables are given below :

a. Mains cable : Multicore of minimum 1.5mm² cross-section

Copper conductor cable armoured with atleast two spare cores.

b. Signal cable : Multicore multistrand with at least two spare

cores, twisted pair, minimum 0.5 mm² cross section annealed copper (shielded and armoured)

c. Loud

Speaker cable

: Multicore multistrand with at least two spare cores, twisted pair, minimum 0.5 mm² cross section annealed copper (shielded and armoured)

18.2.9 Junction boxes

The junction boxes shall be supplied on as required basis.

18.2.10 Technical particulars

Public Address Systems shall conform to the following technical parameters.

(i) Overall Installation

Band width (± 3 db) 400-6000 Hz (ii) Amplifiers (a) Band width (± 3 db) 200-10000 Hz

(b) THD not more than 1 % at 1 kHZ

at rated output

(c) Signal to Noise Ratio 60 dB (iii) Microphones

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(a) Band width (±3 db) 200-7000 Hz

(b) Type Noise canceling type (iv) Loudspeakers (a) Outdoor wall/column

mounted Horn Type

(i) Capacity 15W (RMS)

(ii) Bandwidth(± 3 db) 200-7000 Hz (b) Indoor wall/column

mounted Cone Type

(i) Capacity 4W (RMS)

(ii) Bandwidth (± 3 dB) 200-7000 Hz 18.2.11 The quantities for PA system mentioned below are minimum required

and will be finalised at the time of detailed engineering.

----------------------------------------------------------------------------------------------- S.No Item Description PAS For Common Plant (for each module)

-------------------------------------------------------------------------------------------------- 1. Handset Stations (i) Outdoor wall/column 30 10 mounting type - (nos.) (ii) Indoor desktop mounting 3 type with extension amplifier, (nos.) (iii) Indoor control desk 2 2 mounting type with extension amplifier.- (nos.) 2. Loudspeakers (i) Outdoor Industrial 30 10 Horn type - (nos.)

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(ii) Indoor wall mounted 3 Cone type- (nos.) 3. Mosaic grid compatible 2 2 telephone set 4. Portable handset stations with multi-pin plug and sockets (i) Sockets-(nos.) 10 (ii) Portable handset stations 2 with plug (nos.) 5. Cables (i) Mains cable - (km)- As required (ii) Signal cable - (km) As required (iii) Loudspeaker Cable-(km), for interconnection of loud speaker with handset station. only. As required 6. G.I. earthling wire-(km) As required 7. Junction boxes – As required 8. G.I. Rigid conduit on as required – As Required (Sizes to suit the cable) 9. Acoustic hood (nos.) 8 10. Master Control Unit 1

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19.0 FIRE DETECTION AND ALARM SYSTEM 19.1 Fire Detection and alarm system shall be redundant Microprocessor

based intelligent, analogue addressable type. Fire detection and alarm system comprising automatic fire detectors, manual call points, fire alarm panel, fire warning siren, cables, junction boxes, any other items to complete the system shall be provided for the power plant.

19.2 The equipment/system supplied shall comply with the standards listed

below: 19.2.1 IS - 2189 19.2.2 NFPA - 72E 19.2.3 IS - 2175 19.3 The system shall be approved by any or all the following bodies besides

Tariff Advisory Committee (TAC) and Local Fire Authorities, National Fire Protection Association (NFPA), Underwriters Laboratory (UL), Fire Officer’s Committee (FOC), Factory Mutual (FM), Central Mining Research Institute (CMRI), Dhanbad.

19.4 Fire alarm system shall be designed to provide continuous surveillance

against fire in the areas covered by the system under all conditions. Fire detectors shall discriminate between false and real fire. It shall have automatic calibrating features by decreasing/ increasing sensitivity levels. It shall give a pre-alarm when it requires maintenance.

19.5 The type of detectors to be provided in the various areas of the plant shall

be as indicated below: Area Type of Detector GTG / STG Building Manual call points (MCP) & UV detectors Switchgear room, Multi sensor detector & MCPs Battery charger room

Control & electronic Cubicle rooms

Battery room Rate of rise of temperature detector with fixed temperature element (corrosion proof) and MCPs

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Below false floor of Photoelectric smoke detector and

Control room linear heat sensor cables Above false ceiling of Multi sensor detectors Control room Cable galleries Photoelectric smoke detectors and liner heat Sensing cables

Fuel gas pump house Flame proof type MCPs Transformer yard Pedestal mounted MCPs & switchyard 19.6 Rate of Rise of Temperature Detector with Fixed Temp. Element These shall be resettable type i.e., the same detector shall be capable of

being reset after it goes to the alarm state. 19.7 Multi Sensor Detectors 19.7.1 This detector shall be capable of detecting a fire both in its incipient or

smouldering stages as well as visible flames. To meet this requirement the detector shall respond to visible combustion products in the form of smoke as well as in visible particles, aerosols and pyrolysis products from a clear burning fire.

19.8 Optical Smoke Detectors Optical smoke detectors shall work on light scattering principle. 19.9 Linear Heat Detection System (LHS) 19.9.1 Linear heat detection system shall be provided in area below false floor

& in cable galleries. 19.9.2 Linear heat detection system shall essentially comprise sensor cables,

interface units and necessary hardwares required for installation. 19.9.3 The Sensor cable shall be Optical fibre LHS cables.

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19.9.4 Linear heat sensor cables shall be run on all the trays below the false floor of the control room. The sensor cables in cable vault end shall be supported from ceiling to cover the top most tray and from underside of the cable trays for bottom tiers.

19.10 The quantity of fire detectors and call points to be installed in each of the

areas shall be based on an average coverage area mentioned below. The zones of individual detectors shall overlap and no blind zone shall be left. However, the actual quantity of detectors required, taking into consideration the obstruction due to floor beams, etc., so as to obtain complete coverage, shall be worked out by the Contractor based on the final drawings of the various buildings during detailed engineering.

19.10.1 35 to 40 sq.m per smoke detector for general application areas

considering an average room height of 5.5m. 19.10.2 15 to 20 sq.m per detector for I&C panel room, control room, relay room,

etc., in view of value concentration. 19.11 Each detector shall be provided with an indicating lamp glowing steadily

to indicate that it has operated which will otherwise flash intermittently to indicate the healthy condition of the detector and sensing circuits.

19.12 When the detectors are mounted below the false floor or in inaccessible

position, response indicator for each of the detectors and test switch shall be mounted on a separate box, which shall be suitable for mounting on the wall. If the detectors are mounted above the false ceiling, response indicators with test switch shall be mounted directly below the detector (on the false roof).

19.13 Manual call points shall be provided as per the guidelines listed in NFPA

72E/IS 2189. Also, they shall generally be located near all the entrances/exists for all buildings.

19.14 Contractor shall prepare layout drawings indicating the locations of

detectors, manual call points duly taking into account the regulations of local fire authorities and submit for Owner’s approval.

19.15 Main Fire Alarm Panel 19.15.1 Fire alarm system shall be redundant Microprocessor based intelligent,

analogue addressable type, shall be complete with annunciator (with windows) provided with necessary input modules, output modules, external hooter/lamp control, interface units wherever required for various control functions through relay contacts & communication

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modules, etc. for satisfactory operation of the system. The panel shall be located in the control room. Necessary interface shall be provided between the fire alarm panel and plant DCS for monitoring the system. A dedicated operator station shall provide in the Main control room. The paint shade of panel shall be shade Opaline green (External) and semi glossy white (Internal).

19.15.2 The main fire alarm panel will continuously monitor the status of the

detectors and the connecting lines. The annunciation system shall have visual and audible alarms, with acknowledge, test, reset, lamp test, etc. push buttons. The panel shall have 'ON / OFF' PBs for operation of fire siren.

19.15.3 Main fire alarm panel shall be provided with necessary contacts for

performing the following functions. (a) Tripping of the air conditioning and ventilation system in the - GTG hall, STG hall, switchgear room, Relay room - Control room, I&C panel room, battery room&any other area

which is air conditioned /forced ventilated of the affected area. (b) Contacts for initiating fire protection system.

19.15.4 Necessary grouping of the detectors/call points to actuate the above shall be done by the contractor and the same shall be subject to Owner’s approval.

19.15.5 High discharge plante Lead Acid batteries and battery chargers adequate

capacity shall be provided. The battery shall supply the normal power requirements for a period of 48 hours from the instant of charger AC supply failure, after which sufficient capacity would still be available to provide full load operation for atleast 30 minutes. Full load being defined as the load of all hooters sounding simultaneously along with operation of all the associated visual signals, interlocks etc.

19.15.6 The detectors proposed to be provided for 400kV switchyard area shall

be connected to an independent fire alarm panel (with battery back-up) located in Switchyard control room. This panel shall be suitably interfaced with the main fire alarm panel in power plant control room. All the constructional/functional features of this panel shall be same as the main fire alarm panel.

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19.15.7 Visual alarm shall be povided in all the Control rooms, Electronic cubicle room, Canteen, offices, conference halls and any other place where the sound of the fire siren is not audible.

19.15.8 Suitable size & number of the sirens shall be used so that is audible in all the direction & parts of the station.

19.15.9 All the fire alarm panels in the plant shall be of the same make. 19.15.10 The main fire alarm panel in the control room shall communicate with all

the fire alarm provided in the Gas / Steam Turbine area & in any other if any.

19.16 Repeater Panel All annunciation / indications in the main fire alarm panel shall be

repeated in the repeater panel to be supplied by Contractor. This shall include the annunciations/indications of fire alarm panel located in switchyard control building. The repeater panel shall be located in the fire station. The cabling upto the repeater panel is included in the Contractor’s scope. The paint shade of panel shall be shade Opaline Green (External) and semi glossy white (Internal).

19.17 Junction Boxes (JB) Junction boxes required for indoor and outdoor installations shall be 2

mm thick sheet steel and shall be hot dip galvanised. Degree of protection shall be IP-65.

19.18 Cabling 19.18.1 The cables shall conform to specification indicated in Section D3.15 19.19 Tests 19.19.1 Contractor shall furnish test certificates/approval certificates for the

equipment/ system offered from the Regulatory bodies indicated in the specification after the award of contract for Owner’s approval.

19.19.2 Performance tests shall be conducted at site on the system to prove that

the guarantees indicated for the individual components shall completely satisfy all specific requirements. All tests required by the relevant standards shall be conducted.

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1X700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS - MOTORS

SHEET 1 OF 10

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20.0 AC Motors

20.1 The motor and its accessories shall generally comply with the requirements

specified in the national and international standards indicated in Data sheet-A3.20. Also Motors shall additionally comply with the specific requirements of data sheet – A3.20 and specific requirements indicated below:

20.1.1 All HT motors shall be suitable for 6.6 kV, 3 phase, 50 Hz and LV motors shall be suitable for 400 V, 3 Phase, 50 Hz power supply. The supply voltage and frequency variation for 6.6 kV & 400 V shall be ±10% and +3/-5% respectively. The combined voltage and frequency variation shall be of 10%.

20.1.2 The motors rated 175 kW and above shall be 6.6kV and motors rated upto 175 kW shall be 400 V. All LT motors shall be energy efficient. Motors shall be continuously rated (S1). However, crane motors shall be rated for S4 duty, 40% cyclic duration factor. Motors shall be capable of starting and accelerating the load with the applicable method of starting without exceeding acceptable winding temperatures when supply voltage is 80% of the rated voltage for HT motors and 85% for LV motors. HT motors shall also be capable of satisfactory operation at full load at a supply voltage of 80% of the rated voltage for 5 min. commencing from hot condition. The motors shall be suitable for starting at 110% of the rated voltage.

20.1.3 Motors shall be capable of developing the rated full load torque even if the supply voltage drops to 70% of the rated voltage. If such operation is envisaged for a period of one second, the pull out torque of the motor shall be atleast 205% of full load torque.

20.1.4 Motors shall withstand for 1 second the voltage and torque stresses developed due to the vector difference between the motor residual voltage and the incoming supply voltage equal to 150% of the rated voltage during fast change over of buses.

20.1.5 Locked rotor current of motors rated 1500 kW and below shall be limited to 600% inclusive of 20% tolerance of the full load current of the motors and motor rated above 1500 kW shall be limited to 450% (inclusive of 20% tolerance) of full load current of the motor.

20.1.6 The locked rotor withstand time under hot condition at 110% rated voltage shall be more than the starting time at minimum permissible voltage specified above by atleast three seconds or 15% of the accelerating time whichever is greater. Provision of speed switch shall be avoided to the extent possible.

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20.1.7 The degree of protection for the motor enclosure shall be IP-55 and IP-54 for outdoor & indoor respectively and outdoor and indoor cable boxes shall be provided with IP-55 and IP-54 respectively.

20.1.8 All HT motors shall be provided with vibration pads (in both X & Y directions and at both DE & NDE) for mounting vibration detectors. Requirements of vibration monitoring system shall be as specified in relevant I&C section of specification.

20.1.9 Motors rated 1000 kW and above shall be provided with differential protection. These motors shall be provided with star connected stator windings. The 3 nos. current transformers, one for each phase shall be mounted in a separate compartment in the neutral side terminal box. The three phases shall be connected to form the star point after they pass through the CTs. The CTs shall be of relay accuracy and the CT characteristics shall be compatible with the differential relay. The additional 3 nos. CTs of identical characteristics shall be provided in the 6.6 kV switchgear panel. 6.6kV & 400V motors wherever their protection is through the numerical relay then energy meter reading shall be taken through relay itself by communicating with it.

20.1.10 The ring oiling system shall be adequate for starting and continuous operation of the motor for atleast one half hour without pressure oiling system in operation.

20.1.11 For 6.6 kV motors, 6 nos. duplex RTDs for winding shall be provided. Each bearing shall be provided with duplex thermocouple for bearing temperature monitoring. These motors shall be designed to withstand atleast 2% unbalance in supply voltage. In addition to temperature monitoring & alarms in DCS local temperature indicators shall be provided for motor bearings. Motor bearing shall not be subjected to external thrust loads.

20.1.12 The maximum double amplitude vibrations for motors upto 1500 rpm shall be 25 microns and 15 microns upto 3000 rpm. For 400 V motors, maximum double amplitude vibrations upto 1500 rpm shall be 40 microns and 15 microns upto 3000 rpm.

20.1.13 Maximum noise level measured at a distance of 1.5 metre from the outer surface of the motor shall not exceed 85 db(A).

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20.1.14 Cable boxes of all 6.6 kV motors shall be provided with quick disconnecting type terminal connectors to facilitate easy disconnection and removal of the motors without requiring unsealing or otherwise disturbing the external cable connections and leaving the phase segregated terminal box intact.

20.1.15 20.1.16 20.1.17

Terminal boxes shall have fault withstand capacity equal to at least rated short circuit level of the system voltage for 0.25 sec. The terminal boxes shall be reversible to suit cable entry from bottom or top. Separate terminal boxes to be provided for space heater, RTDs for winding bearings temperature, vibration monitors etc. All terminal boxes shall be provided with two earthing studs for termination of protective earth conductor. Double compression type brass cable glands and crimping type copper lugs shall be provided for termination. The insulation system for 6.6 kV AC motors shall withstand the negative or positive 0.3 / 3.0 microsecond wave (2.7 pu rated peak line to earth operating voltage) switching surges originating from non-effectively earthed power system. All 6.6 kV AC motors shall have BIL of 36 kV (Peak) 1.2 / 50 microsecond wave and shall withstand a power frequency voltage of 14.2 kV (rms) for one minute.

20.1.18 20.1.19 20.1.20

Canopy shall be provided for outdoor motors. Variable frequency controller shall be provided for motors requiring speed control. Torque speed characteristics of motor superimposed on torque speed characteristics of drive equipment at 100%, 90% and 80% shall be furnished by the contractor.

20.2 DC Motors

20.2.1 DC motors shall be suitable for the DC system voltage available in the plant. Motor shall be capable of starting and accelerating the load with the applicable method of starting, without exceeding acceptable winding temperatures, when the supply voltage is in the range of 85% to 110% of rated motor voltage.

20.3 Actuator Motors

20.3.1 The actuator motors shall be designed for short time duty (S2) in accordance with IEC 60034-1.

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20.3.2 Hand wheel operation shall be provided in addition to motor drive.

20.3.3 The DC and AC actuator shall be provided with accessories viz., torque limit switch, end of travel switch, adjustable limit switch, hand wheel motor, thermostat, integral starter, etc. Complete actuator shall be tested at factory as per IS 9334.

20.3.4 Two normally open and two normally closed or two changeover potential free contacts corresponding to open and close positions of the valve shall be provided. Open / Close limit switches used for interlock operation shall be of proximity type.

20.3.5 20.3.6 20.3.7 20.3.8 20.4 20.4.1 20.4.2

Degree of protection for actuator motor enclosure shall be IP-55 and IP-67 for indoor and outdoor respectively. The remote position of the valve along with its status indication with trip shall also be shown in the DCS & local. Remote operation of the valve shall also be possible. All the valves shall be of Integral type with field bus compatible. General Requirements For small rating motors cooling shall be of TEFC type but for higher rating motor TETV, CACA & CACW type cooling shall be considered. All electric motors shall be chosen from the supplier’s standard manufacturing program and in accordance with the absorbed load of the driven machine, using the API Recommendation No.610, 617 and 618 for the overrating ratio.

20.5 Tests

20.5.1 Tests on all types of motors shall be conducted as per relevant standard. 20.5.2 For 6.6 kV, 400 V motors and DC motors, if type test certificates are

available for the same rating of the motors offered, the same shall be furnished, else it shall be conducted. However, all routine and acceptance tests shall be conducted on all 6.6 kV, 400V and DC motors as per relevant standards.

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20.5.3 For 6.6 kV AC motors, in addition to all the tests specified above, partial discharge, C & Tan delta and polarisation index test shall be carried out as a routine test on each motor (the minimum value of polarisation index for all motors shall be 2 when determined according to IS : 7816).

20.5.4 Noise level measurement test shall be conducted on one motor of each type.

20.5.5 Di-electric tests to establish the insulation withstand level of motors as indicated in Clause 20.1.17 shall be performed on a sample coil (identical to those to be used in the motor quoted for) for each type of motor. These tested sample coils shall not be used in the motors to be supplied.

20.5.6 List of tests to be conducted

The following type tests shall be conducted on each type and rating of HT motor:

(a) No load saturation and loss curves upto approximately 115% of rated voltage

(b) Measurement of noise at no load.

(c) Momentary overload test (subject to test bed constraint).

(d) Full load test

(e) Temperature rise test at rated conditions. During heat run test, bearing temp., winding temp., core temp., coolant flow and its temp. shall also be measured. In case the temperature rise test is carried at load other than rated load, specific approval for the test method and procedure is required to be obtained. Wherever ETD's are provided, the temperature shall be measured by ETD's also for the record purpose.

(f) Surge withstand test on the sample coil after placing it in stator core

at (4U + 5 KV) and with at least five impulse of 1.2/50 micro sec. wave, for HV motors only, where U is the line to line voltage in kV.

(g) Surge-withstand test at 20 kV with 0.3/3 micro sec. wave on each type of motor coils with at least five such impulses, followed by one minute power frequency high voltage test on turn to turn insulation, after cutting the coil and bringing out the turns suitably. The power frequency test voltage shall be decided during detailed engineering.

20.5.7 List of tests for which reports have to be submitted

The following type test reports shall be submitted for each type and rating of HT motor

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(a) Degree of protection test for the enclosure followed by IR, HV and no load run test.

(b) Terminal box-fault level withstand test for each type of terminal box

of HT motors only.

(c ) Type test report on Elastimold Termination kit as per relevant standard.

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SECTION: D3.20



REV. NO. R0 PPD. BY RKD JOB NO. CLIENT : APPDCL DATE JUNE’10 CKD.BY HA 5960A PROJECT : 700 MW CCPP AT NEDUNOOR,

KARIMNAGAR DIST.REV. BY DATE

SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

1.0 AC Motors 1.1 Type of Motors Squirrel cage except for cranes 1.2 Supply (a) Rated voltage 6.6 kV for motors above 175 kW &

400V for rating upto 175 kW (b) Number of phases &

Frequency 3 Phase, 50 Hz

(c) System Neutral Medium resistance earthing

(6.6kV) / Effectively earthed (400V) 1.3 Type of duty (Clause 9.2 of IS:325

or equivalent) Continuous / Intermittent

depending on application. 1.4 Method of starting DOL 1.5 Class of Insulation For 6.6kV&400V-Class F with

temperature limited to Class B

1.6 Ref. Ambient temperature 0C 50 1.7 Temperature rise by winding

resistance

0C 70 for class-B

1.8 Location (a) Hazardous area division

(IS:5572 or equivalent) As per classification (for flame

proof zone – 1) 1.9 Type of cooling (IS : 6362) TEFC/TETV/CACA/CACW 1.10 Designation for degree of protection

(IS : 4691) IP 55

1.11 Colour shades of paint Opaline Green

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SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

1.12 Space heaters for motors Required for motors rated 30 kW and above for 400V motors and for all 6.6 kV motors

2 DC Motors 2.1 Rated voltage V, DC 220 2.2 Class of insulation Class F with temperature limited to

Class B 2.3 Temperature rise 0C -do- 2.4 Method of starting Reduced voltage All items indicated above under AC

motors are applicable here also except 1.2, 1.4

3 Motors for Hazardous Area

Application

3.1 Type of construction Flame proof type 3.2 Degree of protection IP-55 All items indicated above under AC

motors are applicable here also.

4 Valve Actuator & its Motor 4.1 Application Valves as per requirement 4.2 Degree of protection IP 55 for Indoor

IP 67 for Outdoor 4.3 Indoor / Outdoor / Explosion proof As per requirement at the location

where it is installed 4.4 Power supply 400V, 3 Phase, 3 Wire

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SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

4.5 Actuator type Bidder to decide 4.6 Typical connection diagram

applicable No drawing is enclosed.

Contractor to furnish his proposed scheme.

4.7 Type of duty & duty designation for

motor Short time (15 minutes) or twice

the valve stroking time whichever is higher

4.8 Supply condition variation

applicable for motor As per 400V AC motors

4.9 Class of insulation for motor Class of insulation for motor Class

F but limited to Class B 5 Codes and Standards 5.1 Induction motors – three phase IS : 325 5.2 Measurement and evaluation of

vibration rotating electrical machines

IS : 12075

5.3 Code of practice for climate

proofing BS – CP 1014

5.4 Degrees of protection provided by

enclosures for rotating electrical machinery

IS 4691

5.5 Classification of hazardous areas

for electrical installation IS 5572

5.6 Terminal marking for rotating

electrical machinery IS 4728

5.7 Designation of methods of cooling

for rotating electrical machines IS 6362

5.8 Guide for testing three phase IS 4029

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SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 330 R3

induction motors 5.9 Dimensions of slide rails for electric

motors IS 2968

5.10 Designations for types of

construction & mounting arrangements of rotating electrical machines

IS 2253

5.11 Classification of maximum surface

temperatures of electrical equipment for use in explosive atmospheres

IS 8239

5.12 Flame proof enclosure of electrical

apparatus IS 2148

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1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - ELEVATORS

SHEET 1 OF 10

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21.0 ELEVATORS 21.1 One (1) no. passenger lift of capacity 600 kg and speed of 0.75 m/sec

shall be provided for proposed Control and Switchgear building. One (1) passenger-cum-goods lift of capacity 1500 kg and speed of 1.0

m/sec shall be provided in HRSG area. 21.2 The lift for control building shall cater to various floors of the control room

building. Accordingly, Bidder shall decide the number of landings required and the total rise of the lift for both control building and HRSG area elevators.

21.3 Specific Requirements 21.3.1 The capacity of the lift shall be 600 kgs (8 passengers) for passenger lift

and 1500 kgs for goods cum passenger lift. 21.3.2 Any code, statutory requirements, specific requirements at the place of

installation shall be complied with in all respects. 21.3.3 An enclosed machine room shall be provided for the control panel of the

lift. 21.3.4 The A.C motors of the lift shall comply with Section D3.20 of this

specification. 21.3.5 The car and counter weights shall be suspended by stainless steel wire

ropes. Chain shall not be used for suspension. Not less than 4 (four) independent standard steel wire suspension ropes shall be used for car or counter weight and all these ropes shall be in one piece and without intermediate joints. The minimum diameter of the standard rope shall not be less than 12.5 mm and the minimum factor of safety shall not be less than 12. The suspension ropes shall conform to IS: 2365 latest edition "Specification for steel wire suspension ropes for lifts and hoists", or equivalent international standard.

21.3.5 Special care and precaution shall be taken regarding handling of lift

cable loops between the points of suspension as the loops are prone to twist / distortion.

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21.3.6 The car shall be provided with fittings & accessories. Glass shall not be used in the roof except to protect electric light, which is to be fitted with safety glass / plastic transparent cover mounted inside the car. Glass

exceeding 930 cm² in area shall be of laminated type. 21.3.7 The car floor shall be of smooth non-slip surface. The car platform shall

be robust in construction and elegant in appearance. If there is any change/changes in the elevations of landing, the same shall be informed to successful Contractor. The successful Contractor shall comply with the changes in the elevation without claiming extra price.

21.3.8 The car door shall be of hollow metal construction, 16 gauge thick

stainless steel. Sides of the door shall flush with all seams continuously welded. Guide shoes shall be rubber of roller type designed for operation on un-lubricated guides. The car entrance shall be able to withstand the thrust of 35 kg. The entrance shall be securely fitted with car floor and frame in order to become working loose or becoming displaced during the service.

21.3.9 The car door shall be provided with locking gear of heavy and robust

construction so arranged mechanically and interlocked that the doors cannot under any circumstances be opened unless the lift car is within a particular landing zone.

21.3.10 Conversely the lift will not move until all the landing doors are closed and

interlocked properly. Car doors & landing doors shall be electrically operated by torque motor.

21.3.11 The car doors shall be so designed that their closing and opening is not

likely to injure a person, with scratch resistant coating. A retractable safety shoe shall extend to the full height and project beyond the front edge of each car to open the closing door if and when it touches a person or object that is Bidder to provide "Electro-Mechanical Pressure Detection". Besides this Bidder is also to provide "Electronic Door Detector". In the first method, slight body contact pressure is detected by sensors incorporated into door drive mechanisms. Actuation will check and reverse door movement, allowing passengers to pass.

21.3.12 The second method will also take carry by the screen of Infrared beams

as a safety curtain across the door entrance detects an obstacle when the doors are closing, the doors then revert to an open position.

21.3.13 A load plate displaying the rated load of the lift in terms of persons and

kilograms shall be fitted in the lift car in a conspicuous position.

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21.3.14 All sheaves and pulleys fixed to and revolving with the shaft shall be fixed by means of sunk keys of sufficient strength and quality. Sheaves and pulleys shall be made of cast steel to IS:1030 and free from cracks, sand holes and other injurious defects. They shall have suitable flanges and smoothly machined rope grooves. The diameter of the sheave of pulley shall be as specified in the latest edition of Indian Standard of equivalent International Standard.

21.3.15 Shafts and axles shall be of forged steel. They shall have sufficient

rigidity and bearing surface. Any shaft when stepped, shall be turned to a reasonable radius at the point of reduction in diameter.

21.3.16 The elevator shall be provided with suitable counter weights located in

the lift shaft. The counter weight shall be designed for smooth and easy operation of the lift and shall be in accordance with Indian Standards referred earlier or equivalent. International Standards. The counter weight shall be provided in the lift shaft. The counter weight shall consist of cast iron weight contained in structural steel frame. It should preferably be equal to that of the car weight plus 40% of the rated load. The traction should be such that no appreciable slip may occur but that slip shall be free to take place upon the landing of either the car or the counter weight.

21.3.17 Guide rails for the car and counter weights shall be machined 'T' sections

and continuous throughout the entire length and shall be provided with adequate steel brackets or equivalent fixing of such design and spacing that avoid any deflection during the normal operation. Guide rails section shall be adequate to withstand the forces resulting from the application of the safety gear when stopping the counter weights or fully loaded car. The guide shoes or their lining shall be easily renewable, adjustable and self lubricated guides shall be of such length that it shall not be possible for any of the car or the counter weights shoes to run off the guides.

21.3.18 Sufficient number of buffers of spring loaded/oil type shall be fitted below

lift car and counter weights. The buffers shall be capable of stopping the car or counter-weights without permanent damage or deformation to itself or any part of the lift equipment. The number of buffers shall be so fixed as to ensure proper sharing of the impact loads by all of them.

21.3.19 The lift shall be provided with safety device attached to the lift car frame

and placed beneath the car. The safety device shall be capable of stopping and sustaining the lift car up at governor tripping speed with full rated load in car. The application of safety device shall not cause the lift platform to become out of level in excess of 3 cm/m measured in any direction. Slack rope switches if necessary, shall also be provided.

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21.3.20 Contractor to provide a modern Advanced electronic drive system of

''RESCUING passenger Trapped in a ELEVATOR". This system should be able to rescue during main power failure and elevator control system failure. The system should be fully microprocessor control with latest IGBT power device.

21.3.21 Governors shall be located where there is sufficient room for their proper

operation and where they cannot be struck by the lift car or counterweight in the event of overrun. Each governor shall be marked with a tripping speed in terms of car speed in m/sec. and the motor control and brake control circuit shall be opened before or at the time of governor trips. Governor ropes shall not be less than 8mm in diameter and shall be of steel or phosphor bronze and of suitable construction. The ropes shall run clear of the governor jaws during normal operation of the lift.

21.3.22 The drive system for the elevator should be variable voltage variable

frequency Drive system. 21.3.23 The lift drive controller and all other apparatus and equipment for lift

installation, except such apparatus and equipment which function in the lift well or other portion shall be placed in the machine room which shall be located at the top of the lift well. Sound reducing materials shall be provided under the machine base by the bidder. The maximum load transmitted by the single heaviest equipment both during erection and maintenance of the lift to the machine room floor and other structures like guides etc. shall be furnished by the contractor within 30 days of placing the award letter.

21.3.24 The lift drive shall be equipped with brakes. The lift shall be driven by a

drive suitable for method of control offered by the bidder. No friction gearing or clutch mechanism shall be used for connecting the main driving gear to the sheaves.

21.3.25 The lift shall be provided with upper and lower normal terminal switches

arranged to stop the car automatically within the limit of top car clearance and bottom run from any speed attained in normal operation. Such limit switches are to act independently of the operating device, the final limit switches and buffers.

21.3.26 Final limit switches shall be provided to stop the car automatically within

the top and bottom clearance independently of the normal operating device and the terminal limit switches. The final limit switch shall not act to prevent motion of the car under power in both direction of travel and

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shall after operation, remain open until the lift car has been moved by a hand winding within the limit of safe operation.

21.3.27 Emergency safety device and over speed governor and buffers shall be

provided. 21.3.28 Fireman's switch at ground floor shall be provided. 21.3.29 The lift shall be provided with automatic levelling device to take care of

over run and under run of the car and rope stretch such that any floor is within 6 mm from the landing level.

21.3.30 To make the equipment/system complete in all respects, any

requirement of supply & fixing of steel sections for door frame, fixtures in walls for indicators and push buttons etc. are included in the scope of the bidder.

21.3.31 The scope of the bidder also includes supply of erection consumables,

arranging the materials for scaffolding and for any other functional requirement of erection.

21.3.32 The elevator is to provide service in power station. It is necessary for the

equipment to be specifically treated. This shall include application of anti-corrosion paint/zinc plating. The electrical equipment shall have enclosure meeting IP-54 and other relevant protection.

21.3.33 An electric contact for the car door shall be provided which shall prevent

elevator movement away from the landing unless the door is in the closed position. The mechanical interlock with auxiliary door closing device shall be provided so that the elevator can be operated only after the interlock circuit is established.

21.3.34 The car door shall be provided with a protective device extending to the

full height and shall be so arranged that should it touch a person or any obstruction in its path while the door is closing, it shall automatically cause the car door and hoistway door to return to open position.

21.3.35 An emergency switch shall be provided to stop the elevator at a

particular landing, cancelling all the registered calls. 21.3.39 The contractor shall carryout all the tests necessary & take the

clearances / permissions from the Electrical inspector or any other agencies who certify the operation of lift.

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21.3.40 The following operating devices / indications shall be provided in the car / on the landing / in the machine room as indicated below:

(a) Operating devices

In the car In the landing In the m/c room

On top of the car

Up push button (PB)

Up PB Up PB Up

Down PB Down PB Down PB Down

Number PBs for each landing

Lift PB Hand cranking device

Stop

230V 1φ receptacle

Non-stop PB Bell PB Stop PB

Door open PB - - -

Door close PB - - -

Alarm PB - - -

Emergency stop PB

- - -

Key operated selector for attendant operation

- - -

(b) Indicating devices.

In the car On the landing

Up direction of travel Up direction of travel

Down direction of travel Down direction of travel

Floor position indicator & voice inside and outside car

Car position indicator with direction

(Illuminated numeral for each landing) (Illuminated numeral for each landing)

Landing car registering unit Call registered ‘Up’ indicator

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In the car On the landing

Load plate in kg & no. of persons Call registered ‘Down’ indicator

Over load indication

(c) Additional requirement

(a) Car ventilation fan with switch (b) Fire extinguisher (c) Telephone handset (d) PB for emergency indication in control room (e) Ventilation/pressurisation : 2 x 100% capacity blower of

adequate size along with cyclonic filter for pressurising the machine room to make it dust proof. If AC is required for the lift control room, then it should be taken through the Main Control room Air Conditioning System only.

(f) Hoisting beam in machine room roof slab : To be provided by lift

supplier. (g) Hoist way machine room & pit lighting: To be provided by lift

supplier. (h) Individual ladder for access to inside pit : To be provided by lift

supplier. (i) Automatic rescue device including siren etc : To be provided by

bidder as an emergency rescue measure. (j) The contractor shall carryout all the necessary tests & take the

clearances / permissions from the Lift inspector or any other agencies who certify the operation of lift.

The material of doors and lift rope shall be stainless steel. The enclosure

for electrical equipment located outside the machine room shall be dust tight and the car shall be provided with fluoroscent lighting, blow out panels, etc. Emergency DC light shall be provided in car. Any other equipment / accessories required for satisfactory operation of the lift shall be supplied by the Contractor.

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The interior decor of the lift shall be aesthetically pleasing, and the same shall be subject to approval by Owner.

The contractor shall be responsible for obtaining the necessary License /

Permission from the relevant authorities.

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SECTION: D3.21



REV. NO. R0 PPD. BY JOB NO. CLIENT : APPDCL DATE MAR’ 10 CKD.BY 5960A PROJECT : 700 MW CCPP AT


TATA CONSULTING ENGINEERS LTD TCE FORM NO. 330 R3

SPEC. NO. TCE.5960A-H-500-001

Passenger Lift 1.0 Installations

Indoor

2.0 Capacity

kg 600

3.0 Rated speed

m/sec 0.75

4.0 Levelling device

Two way automatic maintaining

5.0 Operation

Automatic microprocessor based

6.0 Automatic operation type

Selective & Collective

7.0 Type of door & material Centre opening sliding, steel

8.0 Type of doors in car

1 or 2 depends on layout

8.1 Emergency exit

Required

8.2 8.3

Speed control Degree of protection for lift motor

VVVF IP-54

9.0 Codes & standards

9.1 Specification for electric passenger and goods lift.

IS:14665 (Latest edition)

9.2 Specification for steel wire suspension ropes for lifts, elevators & hoists.

IS:2365-1977

9.3 Specification for carbon steel castings for general engg. purpose.

IS:1030-1982

9.4 Specification for lift door locking devices and contracts

IS:7759-1975

9.5 Material specification ISS or approved equal. Goods Cum Passenger Lift 1.0 Installations

Indoor

2.0 Capacity

kg 1500

3.0 Rated speed

m/sec 1.0

4.0 Levelling device

Two way automatic maintaining

5.0 Operation

Automatic microprocessor based

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SECTION: D3.21


SL. NO. ION UNITS UIREMENTS DESCRIPT VALUES / REQ

REV. NO. R0 PPD. BY JOB NO. CLIENT : APPDCL DATE MAR’ 10 CKD.BY 5960A PROJECT : 700 MW CCPP AT


TATA CONSULTING ENGINEERS LTD TCE FORM NO. 330 R3

SPEC. NO. TCE.5960A-H-500-001

6.0 Automatic operation type

Selective & Collective

7.0 Type of door & material Centre opening sliding, steel

8.0 Type of doors in car

1 or 2 depends on layout

8.1 Emergency exit

Required

8.2 8.3

Speed control Degree of protection for lift motor

VVVF IP-54

9.0 Codes & standards

9.1 Specification for electric passenger and goods lift.

IS:14665 (Latest edition)

9.2 Specification for steel wire suspension ropes for lifts, elevators & hoists.

IS:2365-1977

9.3 Specification for carbon steel castings for general engg. purpose.

IS:1030-1982

9.4 Specification for lift door locking devices and contracts

IS:7759-1975

9.5 Material specification ISS or approved equal.

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ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT

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22.0 EQUIPMENT TO BE SUPPLIED 22.1 The list of items / equipment to be supplied by the Contractor indicated

here is only indicative. Any other equipment considered necessary by the Contractor for the installation, testing and commissioning of the plant shall be included in the offer. Also any additional equipment required or considered necessary during detailed engineering stage, shall form a part of the scope.

Category – I – High Voltage Test Instruments

Sl. No.

Instrument Range Qty.

(a) High potential test set AC / DC 0 – 50 kV 1 No.

Category – II – Miscellaneous Laboratory Instruments

Sl. No. Instrument Range Qty. (a) Automated oil BDV test set 0 – 75 kV 1 No. (b) Rheostats of following ratings 650 Volts 1 Set (i) 25 Ohms, 10A-2 nos. (ii) 50 Ohms, 5A-2 nos. (iii) 100 Ohms, 2.5 A-2nos. (iv) 250 Ohms, 2.5A-2 nos. (v) 500 Ohms, 0.5A-2nos. (c) Portable secondary injection test set 500VA, 1AMP/

5AMPs Normal; 20AMPS / 100AMPS for 30 secs

(d) Digital Earth resistance tester with resistivity test facility

0.01 Ohms, 500 Ohms in three ranges

1 No.

(e) Digital Insulation resistance tester (transistorised)

0-100, 000 Mega Ohms, 500-1000-2500-5000 Volts

2 Nos.

(f) Cable fault locator (HV, LV cable) 1 No. (g) Relay tool kit 2

Nos. (h) Hot stick with indication & audible alarm Upto 11 kV 1 No. Upto 400 kV 1 No. (i) Temperature controlled soldering iron 50W 2

Nos. (j) Thermovision equipment (INFRA RED

CAMERA) 1 No.

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Category – II – Miscellaneous Laboratory Instruments

Sl. No. Instrument Range Qty. (k) Primary Injection kit 5000 A, 7.5 kVA 1 No. (l) Milli volt drop test set 600A DC

continuous variable

1 No.

(m) Illuminometer 0 to 50,000 Lux. 2 Nos (n) Circuit breaker analyser 1 ms to 999 secs 1 No. (o) Turn ratio meter with vector group

testing facility 1 to 99000 ratio 1 No.

(p) Online DC circuit fault locator 1 No. (q) Tan delta test kit for

generator/transformer 1 No.

(r) Vibrometer 1 No. (s) Capacitance and tan delta

measurement kit

(u) Partial discharge measurement kit (v) Earth loop tester (w) Battery capacity test kit (x) Battery impedance measurement kit (y) Motor checker (z) Capacitor measurement kit (aa) Live line detector

Category – III – Meters & Accessories Sl. No.


(a) Three Phase sequence testing meter

(100 – 600 V) 3Nos

(b) Clip on Ammeters AC / DC (a) 0-2000-2500- 3000A

1 No.

(b) 0-250-500A 1 No. (c) 0-100-150-200A 1 No. (d) 0-5A 2 Nos. (e) 0-1A 2 Nos. (c) Auto-transformers – 3 Phase 0-500 Volts, 7KVA 1 No. (d) Auto-transformer – 1 Phase 0-270 Volts, 2-16KVA 3 Nos. (e) Digital micro-ohm meter 0.1 micro-ohm-1999

Ohm, 100A 1 No.

(f) Portable power analyser meter Accuracy=0.2

Amp-1A/5A, Volt 600 V, for measurement of KW, KVA, KVAr, KWh, PF, Amp, Volt, in 1 ph & 3 ph, 3 wire & 3ph, 4 wire system

1 No.

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(g) LCD type portable scope meter (Wave form analysis with Harmonic measurement facility)

1 No.

(h) Analog voltmeter AC/DC 0-5-10-25-50-100-500 V

1 No.

(i) Analog ammeter AC/DC 0-5-10 A 1 No.

Category – IV – Electronic Instruments

Sl. No.


(a) Universal microprocessor based relay testing kit to test 1) Current relay 2) Voltage relay 3) Frequency relay 4) Differential relay 5) Distance relay 6) Synch. Relay 7) Timer relays

1 no

(b) Regulated DC power supply equipment Voltage 0-+300V DC, 2 Amps, 0 - + 30V, DC, 2 Amps, 0-+5V 10 Amps, Current 0 – 2 AMPS DC, 100 VA

2 Nos.

(c) Digital tachometer (non-contact type) 0,1500,3000,5000, 10000 rpm

2 Nos.

(d) Digital multimeter (Class 0.5) 3 Nos. (e) Hydrogen leak detectors 2 Nos. (f) Naphtha & fuel gas leak detectors 2 Nos. (g) All the necessary accessories shall also be supplied with the instruments.

These shall include but not be limited to :

(a) Two meter length power supply cord with plug. (b) All necessary accessories like jacks, probes, connectors, adapters,

clips, rain jackets, protective covers, shields, carrying / transporting cases, etc., wherever applicable.

(h) Composite universal microprocessor based test kit with 0.02 accuracy for testing following: Distance relays, Differential relays, Over current relays, F/V/I relays, Ground fault relays, Synchronising devices, Transient playback, Harmonics generation, Transducers, Energy meters testing /calibration. Requsite software and Laptop shall be included as a part of test kit.

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22.2.1 Category – I – High Voltage Test Instruments

(a) The test transformers shall be supplied with:

(i) A control desk incorporating all necessary indication, annunciation,

protection and control equipment.

(ii) All necessary cooling equipment if required.

(iii) Mobile base with adequate no. of rollers for easy transport of the testing unit.

(iv) All necessary accessories for erection, commissioning, normal operational / testing of all types of equipment, whether specified or not.

(v) Shall incorporate built-in safety features to ensure complete safety of operating personnel.

(b) The insulating material used for bushings and top covers shall be as per BS for Class F/A installation.

22.2.2 Category – II (a) Automatic Oil Test Sets

(i) This equipment shall have an output voltage of 0 – 75 kV variable

AC, continuously rated 1 kVA with class of insulation being ‘A’.

(ii) The test set shall be so designed that the short circuit current drawn from the system exceeds 8 times the rated current. The transformer test set impedance shall be such that the input MCCB trips within a suitable time (0.02 sec.) for a secondary short circuit.

(b) Rheostats and Phantom Loads

The rheostats shall be 650V grade wire wound type of copper nickel alloy having a low temperature co-efficient, totally enclosed type with louvers. Solid copper / graphite brushes with pressure springs shall be provided to ensure low contact resistance.

(c) Portable Secondary Injection Test Set

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This equipment shall be designed to deliver a normal continuously adjustable current with multirange selector switch for 1, 5, 10, 50 A etc. The instrument shall have built in ammeter and voltmeter having adequate range.

(d) Earth Resistance tester with resistivity test facility

This equipment shall be suitable for measuring the ground resistance,

specific soil resistance and ohmic resistances. The equipment shall be supplied with all necessary accessories and in-built batteries.

(e) Insulation Resistance Tester (Transistorised)

The insulation resistance shall be measurable to a value of 1,00,000 mΩ in five ranges. The test voltage shall be adjustable at 500V, 1000V, 2500V and 5000V. The tester shall be suitable for an input supply of 230 V, 50 Hz, single phase AC as well as in-built rechargeable batteries. A guard terminal shall be provided to eliminate error due to surface leakage. Accuracy shall be 5%, maximum short circuit terminal current 2.5 mA, nominal S.C current 2 mA. This tester shall also provide Polarisation Index Measurement.

(f) Cable Fault Locator for LT Cables

Portable cable fault locator which shall identify the fault in a LT cable distinctly. This kit shall work on in-built batteries. This kit shall include Time Domain Reflectometer (TDR) and cable identifying kit and all necessary accessories & transport cases.

(g) Hot Stick

The hot sticks shall be supplied in different ratings viz. For 6.6 kV, 400 kV.

The insulating handle of stick shall be with Class F / H insulation as per IEC / BS specifications with scaled detector having high quality viewing windows. The hot stick should be light weight and portable. Should give audio visual indication of pressure of voltage.

(h) Temperature Controlled Soldering Iron

The soldering iron rated at 50 W having thermostatic temperature control

shall be supplied complete with set of soldering bits of different sizes and shapes, three spare heating elements & separate stand to rest the soldering iron while in use.

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(i) Thermovision Equipment (Infra thermographic common)

The system shall be very light weight, and single hand-operated instrument. This instrument shall have user friendly, broadly compatible software which is an image processing software to perform post-imaging analysis.

22.2.3 Category – III

(a) Phase sequence Testing Meter

This shall be suitable for testing 3 phase 400V supply and shall be suitably

marked for clockwise and anti-clockwise directions. Any conducting part of the meter/ shall withstand 2 kV for 1 minute. The operative range of the meter shall be 100V to 600V.

(b) Clip on Ammeter

The meter shall have a large digital display unit and the jaws shall open adequately to facilitate introduction of the conductor having a size corresponding to the maximum current range.

(c) Digital low resistance ohm-meter The instrument shall be suitable for measuring the contact resistance of switch and circuit breaker contacts, winding resistance of transformer & motor, busbars, etc. They shall also be suitable to be used in finding ground faults in electrical equipment, determining temperature co-efficient and temperature rise by resistance methods, etc.

22.2.4 Category – IV (a) Automatic Composite Relay Test Kit

Relay test set shall be suitable for input voltage 230 V, 1 Phase, 50 Hz. Output current range shall be 1-5-50-100A. Overload and short circuit protection shall be provided. Phase angle adjustment shall be 0-360 deg. The kit shall be computerised, portable unit and used to test various types of protective relays quickly and more accurately. The software for testing, measurement and analysis of the different types of the relays shall be included.

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(b) Regulated DC Power Supply

Voltage range (continuously controlled) - 0 to + 300 V DC

Current range (continously variable) - 0 to 2A DC

Indication - Digital voltage/current meters integral with the unit

Load regulation - 0.1% variation in voltage

- 0.2% variation in current.

(c) Digital Tachometer

Tachometer shall be of the photoelectric type with a digital display, which does not necessitate mechanical contact with the machine shaft. A “push to read” push button shall be provided and also an LED to indicate when the light beam is on the target. Adequate memory shall be built-in to hold the last reading for atleast 1 minute.

(d) Digital Multimeter

These meters shall have built in overload protection and protection against HV transients. They shall have an audio alarm for continuity testing, a peak hold feature on current and voltage ranges, automatic polarity and over range indications. The instrument shall be complete with rechargeable batteries and charging equipment, adapters, probes, leads, padded carrying case, etc. It shall have safety features to prevent damage to instrument if voltage is applicable inadvertently current or resistance measuring range.

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MISCELLANEOUS ELECTRICAL EQUIPMENT

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23.0 MISCELLANEOUS ELECTRICAL EQUIPMENT

23.1 Following equipment shall be included in the Contractors’ scope.

23.1.1 Local push button stations 23.1.2 Junction Boxes (JBs) 23.1.3 3 phase power receptacles 23.1.4 Danger boards 23.1.5 Rubber mats 23.1.6 50 nos. first aid charts shall be provided for display in the plant area. 23.1.7 Minimum of fifty (50) nos. First aid boxes shall be provided at various

locations in the plant. 23.1.8 Sufficient quantity of gas masks shall be provided in line with rule no. 43

of IE rules. 23.2 Local Push Button Stations (LPB) 23.2.1 Local push button stations shall be provided for all the drive motors of the

plant. 23.2.2 LPB’s for outdoor installation shall be weather proof type provided with a

GI canopy and those intended to be used in hazardous areas shall be flameproof type and the degree of protection shall be IP 55 for both out-door and indoor application. The LPBs shall be power coated with shade Opaline green (External) & semi glossy white (Internal).

23.2.3 All stop push buttons shall be lockable type (provided with key for locking)

23.2.4 Following types of LPBs shall be provided for the various drives as

applicable.

(a) Push button station type A - which shall comprise Three, Push buttons viz., `Open', `Close' and `Stop' for control of reversible motors.

(b) Push button station type B - which shall comprise two push

buttons viz., `Start' and `Stop' for control of the rest of the drives in the plant.

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(c) Type-C push button station: With start, stop & ammeter.

23.3 Junction Boxes (JBs) / Marshalling boxes (MBs)

23.3.1 Junction boxes as required for the power plant shall be supplied as

required for marshalling cables of devices located in an area/equipment. Junction Boxes with IP:55 degree of protection, shall comprise of a case with hinged door constructed from cold rolled sheet steel of minimum thickness 2mm. Top of the boxes shall be arranged to slope towards rear of the box. Gland plate shall be 3mm thick sheet steel with neoprene/synthetic rubber gaskets. All junction boxes shall be of adequate strength and rigidity, hot dip galvanised as per relevant IS, and suitable for mounting on wall, columns, structures etc. The boxes shall include brackets, bolts, nuts, screws M8 earthing stud etc. required for installation.

23.3.2 Terminal blocks shall be 650 volts grade, rated for 10 Amps and in one

piece moulding. The JBs used in outdoor areas shall be weatherproof type. Sheet steel thickness of the JBs shall be minimum 2 mm. JBs / MBs shall be hot dip galvanised and shall be powder coated with paint shade Opaline green (External) & Semi glossy white (Internal).

23.3.3 Cable entry shall be bottom/side entry for indoor as well as outdoor

mounted junction boxes. The junction boxes shall be installed at 1 m accessible height.

23.4 3 Phase Receptacles 23.5.1 32 A and 63 A, 3 phase, 4 pin heavy duty type power receptacles shall be

provided in proposed building plant areas, transformer yard, 400 kV switchyard such that distance between any two of each rating in indoor and outdoor area does not exceed 15 m and 30 m respectively.

23.5.2 Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness

and hot dipped galvanized or of die-cast aluminium alloy of thickness not less than 2.5 mm. The boxes shall be provided with two nos. earthing terminals, gasket to achieve IP55 degree of protection, terminal blocks for loop-in loop-out for cable of specified sizes, mounting brackets suitable for surface mounting on wall/column/structure, gland plate etc. The ON-OFF switch shall be rotary type heavy duty, double break, AC23 category, suitable for AC supply. Plug and Socket shall be shrouded Die-cast aluminium. Socket shall be provided with lid safety cover. Robust mechanical interlock shall be provided such that the switch can be put ON only when the plug is fully engaged and plug can be withdrawn only

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when the switch is in OFF position. Also cover can be opened only when the switch is in OFF position. Wiring shall be carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of adequate size. The Terminal blocks shall be of 750 V grade.

23.5 Danger Boards / Rubber Mats 23.5.1 Danger boards and rubber mats shall be provided as required by the

statutory Authorities. The thickness and length of the rubber mats shall be as per the guidelines of Indian Electricity Rules / local electrical inspectorate.

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ELECTRICAL SYSTEMS – CONSTRUCTION POWER SUPPLY

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24.0 CONSTRUCTION POWER SUPPLY EQUIPMENT

24.1 Construction power shall be made available at a single point at 11kV inside the plant premises from nearest substation of APTRANSCO by the Owner. The power shall be further extended by the Contractor to different users by armoured cables or overhead lines. All the equipments used in construction power shall ensure full safety to the working personnel and no live parts which are accessible shall be exposed. The Contractor shall estimate the construction power requirement and indicate the same to Owner to enable them to enter into an agreement with APTRANSCO for its supply. The Contractor shall obtain all necessary statutory clearance for the purpose. GA and layout drawings required for getting clearance from local electrical inspector / Electricity Board shall be prepared by the contractor and it will be the complete responsibility of the Contractor to obtain the approval for the installation and all related works in this regard. The Owner will not be responsible for power cuts, Power failure for whatever reason, fluctuation in voltage and frequency and consequences thereupon. To take care of failure of this supply, Contractor shall provide suitable DG sets. Contractor shall provide necessary protection for the construction power supply arrangement to ensure that any fault in his system, should not disturb 11kV power supply arrangement.

24.2 The Contractor shall provide metering arrangement consisting of two CT, PT units and two trivector meters of suitable accuracy which shall have MD registering facility. The contractor shall be responsible for periodic payment of bills for the energy consumed by him.

24.3 The Contractor shall make arrangements to receive power from the Owner line through DP structures with fuse protection. 2 x 100% suitably rated 11kV / 420V transformers, 400V switchgear with two incomer ACBs, two bus sections and bus coupler & required number of outgoing 400V, 3φ, 4 wire distribution lines to distribute power around plant area. Adequate metering and protection shall be provided for transformers and incomer feeders.

24.4 Capacitor banks of automatic PF adjustment arrangement shall be provided by the Contractor depending on the actual load to maintain power factor at 0.95 for optimising the power bills. This shall be installed at each LT distribution board preferably. If APDISCOMS imposes any penalties to APGENCO , caused by low power factor, the same shall be paid by the contractor to the Owner.

24.5 Contractor shall supply and install fire fighting equipment as per the

regulations of the local electrical inspectorate / statutory bodies for the electrical installation.

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24.6 On award of contract, the Contractor shall furnish the electrical scheme, for Owner’s approval.

24.7 02 Nos. of 400V, 250A feeder of adequate capacity for Administration

building & Colony construction, shall be given by the Contractor at specified location.

24.8 LT DISTRIBUTION BOARDS

24.8.1 In general, these shall meet the requirements covered in D3.11 section.

However, the board shall be provided with outer enclosure so that access to individual compartments, busbar and cable alley shall be available only after the outer door is opened.

24.8.2 The distribution boards shall be provided with the following:

a) Pad locking arrangement with hinged door b) Sloped canopy to prevent ingress of rain water c) Caution notice d) Earthing at two points

24.9 CABLES

24.9.1 Cables shall be armoured and suitable for direct underground buried

installation. Cable armour shall be suitable for carrying system earth fault current. HT cables shall be XLPE insulated type.

24.10 EARTHING SYSTEM

24.10.1 Earthing of all substation equipment and overhead line shall be carried out

as per IS:3043. Earthing system shall consist of adequate number of earth electrodes interconnected. Earth electrodes shall be of 40mm dia. galvanised steel pipe, buried in earth pit.

24.10.2 Number of earth electrodes for LT substation shall be decided considering soil resistivity. However, each LT substation shall have minimum two earth electrodes for neutral earthing, two earth electrodes for body earthing and two earth electrodes for lightning arrestor earthing.

24.10.3 All non-current carrying metal parts shall be connected to earth system at two points, each of 100% rating. Metallic supports, fencing, etc. shall also be connected to earth system.

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24.10.4 Size of earthing conductor shall be selected considering fault current, duration of fault and corrosion rate. Earthing conductor shall be of galvanised steel strip/wires.

24.10.5 Overhead lines shall be earthed by continuous galvanised steel overhead earth wire fastened to each pole and connected with earth at minimum three points in every km length. Cross section of earth wire shall not be less than 25 mm2.

24.11 INSTALLATION

24.11.1 The electrical installation shall generally be carried out as per Indian

electricity rules and acts.

24.11.2 For road crossing, protective guarding shall be provided. The clearance for the lowest conductor from ground shall be decided keeping in view the vertical clearance required for movement of vehicles/cranes, etc.

24.11.3 The LT substation area shall be graded and sloped to prevent any stagnation of rain water. Surface shall be covered with gravel of 15 to 20 mm size.

24.11.4 The LT substation shall be enclosed by barbed wire fencing on mild steel angle iron posts to a height of not less than 2500mm with suitable gates for entrance.

24.11.5 All cable connection parts within the switchgear shall be shrouded with insulating materials.

24.11.6 The extension boards provided for hand held equipments shall have 3 wire system i.e. phase, neutral & earth as per IE rules. The plug & socket arrangement provided shall be of industrial type with switch provided for proper isolation at the time of insertion or withdrawal of plugs.

24.11.7 The flexible cable used shall have heavy duty insulation.

24.11.8 All equipment used for construction activities shall be fed from separate switching/isolating devices.

24.11.9 All the working areas shall be adequately illuminated for safe working with proper fittings/fixtures. The wire shall be laid with proper fixing without any hindrance to personnel or vehicular movement.

24.12 WORKING PROCEDURES

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24.12.1 Adequate safety equipments shall be provided to all the workers, like hand gloves, head gear, etc. Meggers & testers shall be provided in sufficient quantity.

24.12.2 Only ITI qualified workers shall be allowed to handle the electrical or electrically operated equipments.

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ELECTRICAL SYSTEMS - TRANSDUCERS

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25.0 GENERAL REQUIREMENT

25.1 Bidders shall note that each and every device/equipment mounted in panels, switchgears, MCCs, chargers, distribution boards, etc,, shall be properly tagged, both inside and outside (if the equipment is mounted on door) for identification.

25.2 Transducers The transducers supplied shall meet the following specifications. (a) Output range : 4-20 mA DC (b) No. of output channel : Two (2) (c) Accuracy : 0.5% of full scale

(d) Repeatability : 0.1% of full scale

(e) Linearity : 0.5% of full scale (f) Residual ripple output current : 3 to 5% (g) Over load capacity : 10 times for 0.5 seconds (i) Current : 120% continuous (ii) Voltage : 2 times for 0.5 seconds 120% continuous (h) Out put Isolation : Galvanic Isolation (i) Power : Self powered (j) Adjustment : Zero and span (k) External resistance. : 500 Ohms (l) Power frequency withstand capability : 2 kV rms for 1 minute

(m)Open circuit and short circuit protection shall be provided.

(n) All transducers shall have local mA digital display.

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SHEET 2 OF 2

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SPEC. NO. TCE.5960A-H-500-001

TCE FORM NO. 329 R5

25.3 Digital LED displays for the following parameters shall be provided in two (2) locations in the Main control room and three (3) locations in the administration building (*)

(a) Total plant load for each block

(b) Frequency

(c) Ambient temperature

25.4 For all outdoor equipment, which are not protected by sun cover, the heating effect due to solar radiation shall be considered while considering the temperature rise.

25.5 LEDs shall be provided with Low Voltage Guard protection. Note:(*) - Administration building not in EPC scope. However the Bidder

shall install the LED display and wire the same. Location of the building will be intimated later.

25.6 The following IS standards shall be followed:

IS: 12784 : Electrical measuring transducers for converting AC electrical quantities into DC electrical quantities

IS : 14570 : Electrical measuring transducers for converting AC

electrical quantities to analog or digital signals.

337

1.0 SCOPE

1.1 The scope includes design, manufacturing, inspection, testing, packing and delivery to site of protective mats for placing in front of all 6.6kV/400V/220V Switchboards.

2.0 TECHNICAL REQUIREMENTS

2.1 The physical, chemical, mechanical and electrical properties of the insulating mats shall be as per IS: 15652.

2.2 The mats should have been type tested in accordance with the applicable standards.

2.3 Insulating mats to be supplied shall be BIS approved and the same shall be engraved on insulating mats also.

2.4 Insulating mat to be supplied shall be type tested at ERDA.

2.5 Mats shall be supplied preferably in units of 2X1 (length X width) metre.

3.0 SPECIFIC QUALITY ASSURANCE REQUIREMENTS 3.1 All type, routine and sampling tests shall be as per IS: 15652.

3.2 Dispatch of materials shall be permitted only after acceptance of type test certificates,

and inspection and testing of materials. 3.3 The successful bidder shall submit the Quality Assurance Plan (QAP) in attached

format for BHEL/ Customer approval after the award of contract. 3.4 Packing and marking shall be as per IS 15652. 4.0 COMPLIANCE TO SPECIFICATION Bidder shall confirm total compliance to the specification without any deviations from

the technical requirements stipulated. As a mark of technical conformance, all sheets of the specification shall be furnished by each bidder with the signature and company seal affixed thereon.

5.0 Wherever required, soft copy of all approved technical/ quality documentation shall be

submitted as specified without any additional commercial implication. Soft copies may be required both in native file format (e.g. MS Word/ MS Excel) as well as PDF files.

5.11 TECHNICAL SPECIFICATION FOR

INSULATING MATS SPECIFICATION NO. PE-TS-I59-888-E001

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CATHODIC PROTECTION SPECIFICATION NO. PE-TS-I59-888-E001

1. CODES & STANDARDS

I. IS: 8062 : Code of practice for cathodic protection of steel structure. II. IS: 8289 : Construction & testing of electrical apparatus with type of protection ‘n’

2. GENERAL REQUIREMENT:

2.1 All the metallic structures which are in contact with sea water & underground metallics shall be provided with Cathodic Protection (CP) system irrespective of the material of structures, to prevent corrosion due to any pin holes / holidays.

2.2 The CP system shall only be of impressed current type. Preferably LIDA type anode shall be used.

2.3 If the soil is very corrosive, all underground structures shall be protected against corrosion by providing suitable CP system.

2.4 Bidders shall furnish in their BID a brief write up indicating the type of CP system envisaged for various metallic structures in contact with sea water & under ground metallics.

2.5 During detailed engineering the Contractor shall furnish the following for Purchaser’s approval :

2.5.1 Calculations for arriving at the number and dimension of anodes. 2.5.2 Calculations for arriving at the rating of transformer–rectifier set. 2.5.3 Layout of CP system. 2.5.4 Mounting arrangement of anode and reference electrode.

The following minimum design documentation [not essentially limited to these only] shall be furnished by the successful vendor (for review and approval) at contract stage.

1. Corrosion survey report with interpretation. 2. Basic design package and system optimisation studies. 3. Material and equipment specifications, data sheets. 4. Quality plans for all equipment/ items. 5. Field Quality Plan covering site storage, handling, installation and commissioning checks. 6. Detail engineering and final design report. 7. Key diagrams of each discrete systems and complete CP system. 8. Anode installation drawings representing all variations in type, environment, depth, placement, supports etc. including anode. 9. Cable layout schedules and terminals. 10. Foundation, weather protection cover details and support details for T/R sets, anodes, Test Station, distribution boxes and cables of all description. 11. Installation details of T/R sets, test stations distribution boxes etc. 12. Design package on T/R sets essentially incorporating circuit diagrams, fabrications and installation details, parts list, description on operation and maintenance. 13. Design package on anodes essential incorporating composition, fabrication and installation details. 14. Connection schemes for all applicable type of test stations and their schedules. 15. Fabrication and installation details of test stations. 16. Fabrication and installation details of anode and cathode junction boxes, schedules and connection schemes. 17. Interconnection, sectionalisation, isolation schemes for all structures to be protected and those to be isolated but to be checked out for interaction. 18. Power supply arrangement for each T/R set. 19. Safety earthing details. 20. Procedures for testing during installation, commissioning and monitoring of (after installation) complete CP system & each equipment. 21. Design and drawings that may be required for mitigation purposes. 22. Complete CP system layout drawings for each CP station.

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CATHODIC PROTECTION SPECIFICATION NO. PE-TS-I59-888-E001

23. Cable to pipe joint arrangement using thermite welding. 24. Material test certificate for the materials purchased by the vendor along with copy of manuals. 25. Inspection and test certificates for items fabricated and erected. 26. Performance Test Report. 27. Final check list and completion report. 28. Composite Operation and Maintenance Manual. 29. Monitoring formats. 30. Monitoring schedules. 31. List of E&C Spares. 32. Billing break-up

Note : The list of deliverables shall be finalised during kick-off meeting at contract stage.

340

341

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Text Box

ANNEXURE-II




Rev. : 0

Page : of

8. QUALITY ASSURANCE, INSPECTION & TESTING: ALL MATERIALS, COMPONENTS AND EQUIPMENT’S COVERED UNDER THIS SPECIFICATION SHALL BE PROCURED, MANUFACTURED, INSPECTED AND TESTED AS PER THE BHEL/ CUSTOMER APPROVED QUALITY PLAN. THERE SHALL BE NO COMMERCIAL IMPLICATION TO BHEL ON ACCOUNT OF QP APPROVAL. BHEL QPs ARE ENCLOSED FOR REFERENCE.

347

CUSTOMER : PROJECT SPECIFICATION :

TITLE NUMBER :

QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION : VENDOR NUMBER PED-506-00-Q-007/2 TITLE

SHEET 1 OF 9 SYSTEM ITEM: AC ELECT. MOTORS 75KW & ABOVE (LV & MV) SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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1 3 4 5 6 7 8 9 111.0 RAW MATERIAL & BROUGHT

CONTROL

1.1 SHEET STEEL, PLATES, 1.SURFACE MA VISUAL 100% - FREE FROM LOG BOOK 3 - -SECTION, EYEBOLTS CONDITION BLINKS,

CRACKS,WAVINESSETC

2.DIMENSIONS MA MEASUREMENT SAMPLE MANFR'S MANFR'S -DO- 3 - -DRG./SPEC DRG./SPEC

3.PROOF LOAD MA MECH. TEST -DO- -DO- -DO- INSPEC. 3 - -TEST (EYE REPORTBOLT)

1.2 HARDWARES 1.SURFACE MA VISUAL 100% FREE FROM -DO- 3 - -CONDITION CRACKS, UN-

EVENNESS ETC.

2.PROPERTY MA VISUAL SAMPLES MANFR'S RELEVENT SUPPLIERS 3 - 2 PROPERTY CLASS CLASS DRG./SPEC IS/SPEC. TC & LOG MARKING SHALL BE

BOOK CHECKED BY THEVENDOR

1.3 CASTING 1.SURFACE MA VISUAL 100% FREE FROM LOG BOOK 3 - -CONDITION CRACKS,

BLOW HOLESETC.

2.CHEM. & MA CHEM & MECH 1/HEAT NO. MANFR'S RELEVENT SUPPLIER'S 3 - 2 HEAT NO. SHALL BEPHY. PROP. TEST DRG./SPEC IS/ TC VERIFIED

3.DIMENSIONS MA MEASUREMENT 100% MANUFR'S MANUFR'S LOG BOOK 3 - -DRG. DRG.

1.4 PAINT & VARNISH 1.MAKE, SHADE, MA VISUAL 100% MANFR'S MANFR'S LOG BOOK 3 - -SHELF LIFE & CONTINUOUS DRG./SPEC DRG./SPECTYPE

BHEL PARTICULARS BIDDER/VENDORNAMESIGNATUREDATE BIDDER'S/VENDORS COMPANY SEAL

2 10

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1.5 SHAFT 1. SURFACE MA VISUAL 100% - FREE FROM -DO- 3 - - VENDOR'S APPROVAL(FORGED OR ROLLED) COND. VISUAL IDENTIFICATION SHALL BE

DEFECTS MAINTAINED

2. CHEM. & MA CHEM. & 1/HEAT NO. MFG. DRG. RELEVANT SUPPLIER'S 3 - 2PHYSICAL PHYSICAL OR HEAT SPEC. IS TCPROPERTIES TESTS TREATMENT

BATCH NO

3. DIMENSIONS MA MEASUREMENT 100% -DO- MANUFR'S LOG BOOK 3 - -DRG.

4.INTERNAL CR UT -DO- ASTM-A388 MANUFR'S -DO- 3 2 1 FOR DIA OF 55 MM & FLOWS SPEC. ABOVE

BHEL SPEC.

1.6 SPACE HEATERS, CONNEC- 1. MAKE & MA VISUAL -DO- MANUFR'S MANUFR'S -DO- 3 - -TORS, TERMINAL BLOCKS, RATING DRG. SPEC. DRG. SPEC.CABLES, CABLE LUGS,CARBON BRUSH TEMP.DETECTORS, RTD, BTD'S

2. PHYSICAL MA -DO- -DO- - NO BREAKAGE -DO- 3 - -COND. ON OTHER

PHY. DESIGN

3.DIMENSIONS MA MEASUREMENT SAMPLE MANUFR'S MANUFR'S -DO- 3 - -(WHEREVER DRG./ SPEC. DRG. / SPEC.APPLICABLE)

4.PERFORMANCE/ MA TEST 100% -DO- -DO- INSP. 3 - -CALIBRATION REPORT


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1.7 OTHER INSULATING 1. SURFACE MA VISUAL 100% - NO VISUAL INSPT. 3 - -MATERIALS LIKE SLEEVES, COND. DEFECTS REPORTBINDINGS CORDS, PAPERS,PRESS BOARDS ETC.

2. OTHERCHARACTERISTICS MA TEST SAMPLE MANUF'S MANUF'S LOG BOOK 3 - 2

SPEC. SPEC. AND ORSUPPLIER'S

TC

1.8 SHEET STAMPING 1. SURFACE MA VISUAL 100% - NO VISUAL LOG BOOK 3 - -(PUNCHED) COND. DEFECTS

(FREE FROM BURS)

2.DIMENSIONS MA MEASUREMENT SAMPLE MANUFR'S MANUFR'S -DO- 3 - 2 FOR MV MOTOR INSULA-INCLUDING BURS DRG. . DRG. TION/VARNISH THICKNESSHEIGHT SHALL BE MORE THAN

THE BURS HEIGHT3. ACCEPTANCE MA ELECT. & MECH -DO- MANUF'S RELEVANT SUPPLIER'S 3 - 2TESTS TESTS SPEC./ IS TC

RELEVANTIS

1.9 CONDUCTORS 1. SURFACE MA VISUAL 100% - FREE FROM LOG BOOK 3 - -FINISH VISUAL

DEFECTS

2.ELECT. PROP, & MA ELECT. & SAMPLES RELEVANT IS/ RELEVANT IS/ SUPPLIERS 3/2 - 2MECH. PROP MECH.TEST BS OR BS OR TC &

OTHER OTHER VENDOR'SSTANDARDS STANDARDS INSPN.

REPORTS


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3.DIMENSIONS MA MEASUREMENT -DO- -DO- -DO- Log Book 3 - -

1.10 BEARINGS 1.MAKE & TYPE MA VISUAL 100% MANFR'S DRG. MANFR'S DRG. -DO- 3 - -

2.DIMENSIONS MA MEASUREMENT SAMPLE BHEL DATA BHEL DATA -DO- 3 - -SHEET SHEET BEARING

MANUF'SCATALOGUES

3.SURFACE MA VISUAL 100% - FREE FROM -DO- 3 - -FINISH VISUAL

DEFECTS

1.11 SLIP RING 1.SURFACE MA VISUAL 100% - -DO- -DO- 3 - -COND.

2.DIMENSIONS MA MEASUREMENT SAMPLE MANUF'S MANUF'S -DO- 3 - -DRG DRG

3.TEMP.WITH- MA ELECT.TEST -DO- MANUF'S MANUF'S -DO- 3 - -STAND SPEC. SPEC.CAPACITY

4.HV/IR MA -DO- 100% -DO- -DO- -DO- 3 - -

1.12 OIL SEALS & GASKETS 1.MATERIAL OF MA VISUAL 100% MANUF'S MANUF'S -DO- 3 - -GASKET DRG/SPECS DRG./ SPECS.

2.SURFACE MA VISUAL 100% - FREE FROM -DO- 3 - -COND. VISUAL

DEFECTS

3.DIMENSIONS MA MEASUREMENT SAMPLE MANUF'S MANUF'S -DO- 3 - -DRG DRG


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2.0 IN PROCESS

2.1 STATOR FRAME WELDING 1.WORKMANSHIP MA VISUAL 100% -DO- GOOD FINISH LOG BOOK 3 - -(IN CASE OF FABRICATED & CLEANNESSSTATOR )

2.DIMENSIONS MA MEASUREMENT -DO- MANUF'S MANUF'S -DO- 3 - -DRG DRG

2.2 MACHINING 1.FINISH MA VISUAL 100% -DO- GOOD FINISH LOG BOOK 3 - -

2.DIMENSIONS MA MEASUREMENT -DO- MANUF'S MANUF'S -DO- 3 - -DRG DRG

3.SHAFT SURFACE MA PT -DO- RELEVENT MANUFR'S -DO- 3 - 1FLOWS SPEC./ SPEC./

ASTM-E165 BHEL SPEC./

2.3 PAINTING 1.SURFACE MA VISUAL 100% MANFR'S BHEL LOG BOOK 3 - -PREPARATION SPEC/BHEL SPEC.

SPEC./ SAME ASRELEVANT COL.7STAND

2.PAINT THICKNESS MA MEASUREMENT SAMPLE -DO- -DO- -DO- 3 - 2(BOTH PRIMER & BY ELCOMETERFINISH COAT)

3.SHADE MA VISUAL -DO- -DO- -DO- Log Book 3 - -

4.ADHESION MA CROSS -DO- -DO- -DO- Log Book 3 - -CUTTING &TAPE TEST


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2.4 SHEET STACKING 1.COMPLETENESS MA MEASUREMENT SAMPLE MANUFR'S MANUFR'S Log Book 3 - -SPEC. SPEC.

2.COMPRESSION MA MEASUREMENT 100% -DO- -DO- Log Book 3 - -& TIGHTENING

3.CORE LOSS & MA ELECT.TEST -DO- -DO- -DO- Log Book 3 - 2 (FOR MOTORS OF 2MWHOTOPOT AND ABOVE)

2.5 WINDING 1.COMPLETENESS CR VISUAL 100% MANUFR'S MANUFR'S Log Book 3 - -SPEC./BHEL SPEC./BHEL SPEC. SPEC.

2.CLEANLINESS CR -DO- -DO- -DO- -DO- Log Book 3 - -

3.IR-HV-IR CR ELECT. TEST -DO- -DO- -DO- Log Book 3 - -

4.RESISTANCE CR -DO- -DO- -DO- -DO- Log Book 3 - 2

5.INTERTURN CR -DO- -DO- -DO- -DO- Log Book 3 2 -INSULATION

6.SURGE WITH CR -DO- -DO- -DO- -DO- Log Book 3 2 1 FOR MV MOTORSTAND ANDTAN. DELTATEST

2.6 IMPREGNATION 1.VISCOSCITY MA PHY. TEST AT STARTING -DO- -DO- Log Book 3 - -

2.TEMP. MA PROCESS CONTINUOUS -DO- -DO- Log Book 3 - -PRESSURE CHECKVACCUM

3.NO. OF DIPS MA -DO- -DO- -DO- -DO- Log Book 3 - 2 THREE DIPS TO BE GIVEN


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4.DURATION MA -DO- -DO- -DO- -DO- Log Book 3 - 2

2.7 COMPLETE STATOR 1.COMPACTNESS MA VISUAL 100% -DO- -DO- Log Book 3 - -ASSEMBLY & CLEANLINESS

2.8 BRAZING/COMPRESSION 1.COMPLETENESS CR -DO- -DO- -DO- -DO- Log Book 3 - -JOINT

2.SOUNDNESS CR MALLET TEST -DO- -DO- -DO- Log Book 3 - -& MV TEST

3.HV MA ELECT. TEST -DO- -DO- -DO- Log Book 3 - -

2.9 COMPLETE ROTOR 1.RESIDUAL CR DYN. BALANCE -DO- MFG SPEC./ MFG. DWG. Log Book 3 2 1 VERIFICATION FOR MVASSEMBLY UNBALANCE ISO 1940 MOTOR ONLY

2.SOUNDNESS CR ELECT. -DO- MFG. SPEC. MFG. SPEC. Log Book 3 2 -OF DIE (GROWLERCASTING TEST)

2.10 ASSEMBLY 1.ALIGNMENT MA MEAS. -DO- -DO- -DO- Log Book 3 - -

2.WORKMANSHIP MA VISUAL -DO- -DO- -DO- Log Book 3 - -

3.AXIAL PLAY MA MEAS. -DO- -DO- -DO- Log Book 3 - 2

4.DIMENSIONS MA -DO- -DO- MFG.DRG./ MFG. DRG/ Log Book 3 - -MFG SPEC. RELEVANT

IS

5.CORRECTNESS, MA VISUAL 100% MFG SPEC. MFG SPEC. Log Book 3 - -COMPLETENESS RELEVANT RELEVANT TERMINATIONS/ IS ISMARKING/COLOUR CODE


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3.0 TESTS 1.TYPE TESTS MA ELECT.TEST 1/TYPE/SIZE IS-325/ IS-325/ TEST 3 1 1,2 NOTE - 1INCLUDING BHEL SPEC./ BHEL SPEC./ REPORTSPECIAL DATA SHEET DATA SHEETTESTS AS PERBHEL SPEC.

2.ROUTINE MA -DO- 100% -DO- -DO- -DO- 3 1,2 1,2 NOTE - 2TESTS INCLUDINGSPECIAL TESTAS PER BHELSPEC.

3.VIBRATION MA -DO- 100% IS-12075 IS-12075 -DO- 3 1,2 -

4.OVERALL MA MEASUREMENT 100% APPROVED APPROVED INSPC. 3 2,1 -DIMENSIONS & VISUAL DRG/DATA DRG/DATA REPORTAND ORIENTATION SHEET SHEET &

RELEVANT IS

5.DEGREE OF MA ELECT. & 1/TYPE/ RELEVANT IS BHEL SPEC. TC 3 - 2,1 TC FROM AN PROTECTION MECH. TEST SIZE AND DATA INDEPENDENT

SHEET LABORATORY NOTE-3

6.NAMEPLATE MA VISUAL 100% IS-325 & IS-325 & INSPC. 3 2,1 -DETAILS DATA SHEET DATA SHEET REPORT

7.EXPLOSION MA EXPLOSION 1/TYPE IS-3682 IS-3682 TC 3 - 2,1 NOTE-3FLAME PROOF FLAME PROOF IS-8239 IS-8239NESS (IF TEST IS-8240 IS-8240SPECIFIED)

8.PAINT SHADE, MA VISUAL & SAMPLE BHEL SPEC. BHEL SPEC. TC 3 2,1 - SAMPLING PLAN TO BETHICKNESS MEASUREMENT & DATA & DATA DECIDED BY INSPECTION& FINISH BY ELKOMETER SHEET SHEET AGENCY


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NOTES:

1 DEPENDING UPON THE SIZE AND CRITICALLY, WITNESSING BY BHEL SHALL BE DECIDED.

2 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. HOWEVER, BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES.THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON.

3 IN CASE TEST CERTIFICATES FOR THESE TESTS ON SIMILAR TYPE, SIZE AND DESIGN OF MOTOR FROM INDEPENDENT LABORATORY ARE AVAILABLE, THESE TEST MAY NOT BE REPEATED.

4 WHEREVER CUSTOMER IS INVOLVED IN INSPECTION WITH THE CUSTOMERS, AGENCY (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER.


102

356

CUSTOMER : PROJECT

TITLE NUMBER :

QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION VENDOR NUMBER PED-506-00-Q-006/0 TITLE

SHEET 1 OF 2 SYSTEM ITEM AC ELECT. MOTORS BELOW 75KW (LV) SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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1.O PAINTING 1.SHADE MA VISUAL SAMPLE MANUFR'S BHEL SPEC. LOG BOOK 3 - -SPEC/BHEL SAME ASSPEC./RELEVANT COL.7STANDARD

2.0 ASSEMBLY 1.WORKMANSHIP MA VISUAL 100% MANUF'S SPEC MANUF'S SPEC -DO- 3 - -

2.DIMENSIONS MA -DO- -DO- MFG. DRG./ MFG. DRG./ -DO- 3 - -MFG. SPEC. MFG. SPEC.

3.CORRECTNESS MA VISUAL 100% MFG.SPEC./ MFG.SPEC. -DO- 3 - -COMPLETENESS RELEVANT IS RELEVANT ISTERMINATIONS/MARKING/COLOURCODE

3.0 TESTS 1.ROUTINE MA -DO- 100% IS-325/ SAME AS TEST 3 2,1 2,1 NOTE -1TEST INCLUDING BHEL SPEC./ COL.7 REPORTSPECIAL TEST DATA SHEETAS PER BHEL SPEC.

2.OVERALL MA MEASUREMENT 100% APPROVED APPROVED INSPN. 2 1 -DIMENSIONS & & DRG/DATA DRG/DATA REPORTORIENTATION VISUAL SHEET SHEET

& RELEVANT IS


2

SPECIFICATION :

357

CUSTOMER : PROJECT QUALITY PLAN TITLE NUMBER :

BIDDER/ : QUALITY PLAN SPECIFICATION :

VENDOR NUMBER PED-506-00-Q-006/0 TITLE :SHEET 2 OF 2 SYSTEM ITEM AC ELECT. MOTORS BELOW 75KW (LV) SECTION VOLUME III

SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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3.NAMEPLATE MA VISUAL 100% IS-325 & IS-325 & INSPN. 3 1 -DETAILS DATA SHEET DATA SHEET REPORT

NOTES:

1 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. HOWEVER, BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES. THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON

2 WHERE EVER CUSTOMER IS INVOLVED IN INSPECTION, (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER.3 FOR EXHAUST/VENTILATION FAN MOTORS OF RATING UPTO 1.5KW , ONLY ROUTINE TEST CERTIFICATES SHALL BE FURNISHED FOR SCRUTINY.


2

SPECIFICATION :

358


TITLE NUMBER :


SHEET 1 OF2 SYSTEM SECTION VOLUME III

SL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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1.0 RAW MATERIAL

1.1 ROLLED SHEET 1.CHEM.& PHY. MA VERIFICATION 100% IS1079 (for hot rolled) IS1079 (for hot rolled) MILL TC 3/2 - - PROPERTIES OF TC'S IS-513 (for cold rolled IS-513 (for cold rolled)

SPECIFICATION

2.DIMENSIONS MA MEASUREMENT 100%IS-1730/ SPECIFICATION

IS-1730/ SPECIFICATION

QC RECORD 3/'2 - -

3.SURFACE MA VISUAL 100% IS1079 (for hot rolled) IS1079 (for hot rolled) QC RECORD 3/'2 - - FINISH IS-513 (for cold rolled IS-513 (for cold rolled)

1.2 ZINC CHEM.COMP. MA CHEM TEST EACH HEAT IS-209 IS-209 QC RECORD 3/2 - 1/2

2.0 IN-PROCESS

2.1 FABRICATION 1.DIMENSIONS MA MEASUREMENT 100% APPD. DRGS. APPD. DRGS. QC RECORD 2 - 1

2.WELDING MA VISUAL 100% GOOD WELDING FREE FROM QC RECORD 2 - 1 QUALITY PRACTICE DEFECTS &

SLAG

3.SURFACE MA VISUAL 100% SPECIFICATION SPECIFICATION QC RECORD 2 - 1 FINISH

2.2 SURFACE PREPARATION 1.CLEANING, MA MEASUREMENT PERIODIC IS:2629 IS:2629 QC RECORD 2 - - PICKLING, IN EACH RINSING & SHIFT FLUXING

2. SURFACE MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - QUALITY

2.3 GALVANISING 1.TEMPERATURE MA TEMPERATURE CONTINUOUS IS-2629 IS-2629 QC RECORD 2 - - OF BATH INDICATOR

BHEL PARTICULARS BIDDER/VENDORNAMESIGNATURE

DATE BIDDER'S/VENDORS COMPANY SEAL

WELDING IS TO BE DONE BYQUALIFIED WELDERS

ITEM : CABLE TRAY SUPPORT MATERIAL & ACCESSORIES (BOLTABLE)

2 10

APPLICABLE IN TECH.AS PER CONTRACT & AS

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2. DROSS MA VISUAL CONTINUOUS IS - 2629 IS - 2629 QC RECORD 2 - -

3. RATE OF MA VISUAL / 100% IS - 2629 / IS - 2629 / QC RECORD 3 - 2 IMMERSION MEASUREMENT MFR'S PRACTICE MFR'S PRACTICE

4.SURFACE MA VISUAL 100% IS - 2629 / FREE FROM QC RECORD 2 - - QUALITY BURRS, SLAG,

ROUGHNESS,FLUX. STAIN. ETC.

3.0 FINISHED ITEMS

3.1 1.DIMENSIONS MA MEASUREMENT IS-2500 APPD. DRG APPD. DRG INSP. REPORT 3 2, 1 - FASTENERS SHALL BE OF DISTORTION LEVEL IV REPUTED & APPROVED MAKE

2.SURFACE FINISH MA VISUAL IS-2500 SPECIFICATION FREE FROM INSP. REPORT 3 2, 1 -LEVEL IV BURRS, SLAG,

ROUGHNESS,FLUX. STAIN.ETC.

3.MASS OF MA CHEM. TEST IS-4759 / IS-6745 / SPECIFICATION/ INSP. REPORT 3 2, 1 - ZINC COATING SPECIFICATION SPECIFICATION

4.UNIFORMITY MA CHEM. TEST IS-4759 / IS-2633 IS-2633 INSP. REPORT 2 1 - OF ZINC SPECIFICATION COATING

5.THICKNESS MA ELCOMETER IS-4759 / SPECIFICATION. SPECIFICATION. INSP. REPORT 3 2, 1 - OF ZINC SPECIFICATION COATING

6.ADHESION MA MECH.TEST IS-4759 IS-2629 IS-2629 INSP. REPORT 3 2, 1 -

3.1.1 TYPE TESTING CR TEST 1 SAMPLE SPECIFICATION./ SPECIFICATION./ APPD. INSP. REPORT 2 1 -APPD. TYPE TEST TYPE TESTPROCEDURE PROCEDURE

3.1.2 SOUNDNESS CR MPI SAMPLE TESTED SPECIFICATION. NO DEFECT INSP. REPORT 2 1 -DURING TYPE TEST, WELD INTEGRITY TEST TOTESTING CHECK THE WELD SOUNDNESS/

ACCEPTANCE SHALL BE DONE


WELD INTEGRITY TEST AFTER CARRYING OUT TYPE

10

ITEM : CABLE TRAY SUPPORT MATERIAL & ACCESSORIES (BOLTABLE)

2

BY MANUFACTURER

NOTE: INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE-1.

SINGLE / DOUBLE CHANNELS, CANTILEVER ARMS, CLAMPS

360

ANNEXURE – 1

INSTRUCTIONS FOR QUALITY PLAN

The Quality Plan shall include all the Quality Control Measures and Checks adopted by the Vendor to ensure that the material/component/assembly/services supplied by him meet/will meet the requirements as per specifications and good practices. They shall include all stages of operation such as materials, processes, manufacture, assembly, packing and despatch. The following guide lines may be noted:

Column 1- Serial Number

Column 2- Component/Operation- The component and/or operation being checked shall be given here.

Column 3- Characteristics check- The characteristics being checked shall be given here, e.g., chemical composition, mechanical properties, leak tightness, surface defects etc..

Column 4- Category -‘CR’ stands for critical characteristic - affecting safety of equipment and personnel

‘MA’ stands for major Characteristic - affecting safety of equipment and personnel

‘MI’ stands for minor characteristic - affecting appearance etc.

Column 5- Type/Method of check e.g. chemical analysis tensile testing, hydraulic test, visual examination radiography etc.

Column 6- Extent of check, such as, 100, 10, 1 percent etc.

Column 7- Reference Documents - Documents, such as technical specification, drawings, standard specifications (IS, BS ETC.) procedure, etc. according to which check is done.

Column 8- Acceptance Norms - Standards etc. according to which acceptability or otherwise of the characteristics being checked is decided.

Column 9- Format of Record - Formats, log shets, reports, etc. in which the observations are recorded. Standard log sheets, reports, formats etc. of the Vendors shall be numbered and such reference numbers shall be included here.

Column 10- Agency - The agency which performs the test/instruction shall be written in sub-column ‘W’ The agency which verifies test certificates/inspection records and carries out audit check of the components/operation shall

be written in sub-column ‘V’

The agencies are codified as 1,2 & 3

‘1’ stands for (BHEL)

‘1’ * means the operation shall be cleared by BHEL before the start of the next operation.

‘2’ Stands for Vendor

‘3’ stands for sub-Vendor of the Vendor and so on.

Example :

Entry ‘3’ in column ‘P’ means test./inspection to be performed by sub-Vendor’s QC

Entry ‘2’ in column ‘W’ means test./inspection to be witnessed by Vendor’s QC

Entry ‘1’ in column ‘V’ means verification shall be done by BHEL and next stage to be started only after the hold point is cleared by BHEL

Column11I- Remarks - Any special remarks shall be given here.

NOTES :

1. In absence of correlation with the test certificate(s) (e.g. material identification) samples shall be drawn bgy BHEL and all tests as per relevent specifications shall be carried out in their presence or in recognized Government Laboratory.

2. When materials and components are initially identified and stamped by BHEL QS engineer, the identification marks shall be presserved till despatch. Wherever this is not possible, the identification mark shall be transferred to the components in the presence of BHEL QS Engineer unless other wise agreed.

3. For castings and forgings integral test specimens shall be provided, When this is not possible for casting, they shall be poured in the presence of BHEL QS Engineer unless otherwise, if witnessing of test by BHEL is called for.

4. When welders qualified by reputed inspection agencies or statutory bodies are not available, qualification tests shall be conducted in the presence of BHEL QS Engineer.

5. This Quality Plan is liable to be modified as per the requirements of approved drawings and changes in technical specifications/drawings. If there are contradictions in respect of column 7 & 8 between this Quality Plan and the approved drawings specifications, the latter shall prevail.

6. Wherever inspection by BHELs Purchaser/Third Party/Statutory authorities are mandatory, this shall be compiled with.

7. Inspection reports, log sheets, test reports/certificate. etc. shall be furnished to BHEL at the approproate stages or at the time of final inspection, as required.

8. This Quality Plan is also applicable to spares, if any, under scope of supply of Vendor.

9. The quality plan shall be submitted in minimum 4 copies with a soft copy of the same or in line with contract requirements.

361

FOREM NO. PEM-6041-0CUSTOMER : PROJECT SPECIFICATION

TITLE NUMBERTITLE NUMBER


SHEET 1 OF 3 SYSTEM ITEM :BOUGHT OUT ITEMS SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 11102

1.0 MATERIAL

1.1 SECTIONS, HARDWARES, 1. DIMENSIONS MA MEASUREMENT SAMPLE BHEL TECH. SPEC./ BHEL TECH. SPEC./ TEST 3/2 - 2 NO VISUAL DEFECTFLATS, ANGLES & CHANNEL DRG. /DATA SHEETS/ DRG. /DATA SHEETS/ CERT. &

RELEVANT. IS RELEVANT. IS INSPN.REPORT

2. SURFACE MA VISUAL 100% -DO- NO VISUAL -DO- 3/2 - 2 TC FOR PLATING CONDITION DEFECTS QUALITY TO BE

PROVIDED

3. SURFACE MA VISUAL SAMPLE -DO- BHEL SPEC. -DO- 3/2 - 2 PROTECTION (HARDWARES)

1.2 SWITCHGEAR COMPONENTS 1. TYPE TESTS MA ELECTRICAL EACH TYPE BHEL SPEC./ BHEL SPEC./ TEST 3/2 - 2,1A) SWITCH SFU'S RELEVENT IS RELEVENT IS CERTIFICATEA) SWITCH, SFU'S. RELEVENT IS RELEVENT IS CERTIFICATE INSTRUMENT, TRANSF, FUSES, CONTACTORS AIR 2. ROUTINE TESTS MA ELECTRICAL 100% -DO- -DO- ROUTINE 3/2 - 2 IF THESE ARE TAKEN CIRCUIT BREAKERS, (FOR METERS TEST FROM BHEL APPROVED ISOLATORS. BIMETAL CT'S & PT'S) CERTIFICATE SOURCE THEN TC THERMAL RELAYS, MCB.S NOT REQUIRED & MCCB.S

3. PHYSICAL MA VISUAL 100% NO BREAKAGES/ NO. BREAKAGES/ INSPN. 2 - - CONDITION DAMAGES DAMAGES REPORT

4. MAKE TYPE MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ -DO- 2 - - TO BE PROCURED RATING ETC. APPD. DRGS APPD. DRGS FROM APPROVED

MAKE5. FUNCTIONAL TEST MA ELECTRICAL 100% RELEVENT IS RELEVENT IS -DO- 2 - -

BHEL PARTICULARS BIDDER/VENDORBHEL PARTICULARS BIDDER/VENDORNAMESIGNATUREDATE BIDDER'S/VENDOR'S COMPANY SEAL

362

FOREM NO. PEM-6041-0CUSTOMER PROJECT SPECIFICATION

TITLE NUMBER

QUALITY PLAN BIDDER/ QUALITY PLAN SPECIFICATION

VENDOR NUMBER PED-506-00-Q-002/01 TITLE SHEET 2 OF 3 SYSTEM ITEM :BOUGHT OUT ITEMS SECTION VOLUME III


CHECK P W V

1 3 4 5 6 7 8 9 11

B) INSTRUMENTS GAUGES 1 PHYSICAL MA VISUAL 100% NO BREAKAGES/ NO BREAKAGES/ INSPECTIONN 2

102

B) INSTRUMENTS, GAUGES, 1. PHYSICAL MA VISUAL 100% NO BREAKAGES/ NO BREAKAGES/ INSPECTIONN 2 - - CONNECTORS, LUGS, GLANDS CONDITION DAMAGES DAMAGES REPORT SPACE HEATER,THERMOSTAT, TERMINAL BLOCKS, LAMPS, 2. MAKE, TYPE, MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ -DO- 2 - - TO BE PROCURED FROM PUSHBUTTONS, SMALL , RATING ETC APPD. DRGS. APPD. DRGS. APPROVED MAKE SWITCHES, NAMEPLATES, FERRULES, LABELS, 3. FUNCTIONAL MA ELECTRICAL 100% RELEVANT IS RELEVANT IS -DO- 2 - - STICKERS, PVC SLEEVES/ CHANNELS

C) RELAYS & TIMERS 1. PHYSICAL MA VISUAL 100% NO BREAKAGES/ NO BREAKAGES/ INSPECTION 2 - - CONDITION DAMAGES DAMAGES REPORT

2. MAKE, TYPE, MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ -DO- 2 - - TO BE PROCURED FROM RATING ETC APPD. DRGS. APPD. DRGS. APPROVED MAKE

3. FUNCTIONAL MA ELECTRICAL 100% RELEVANT IS RELEVANT IS -DO- 2 - - TEST

D) PCB ASSEMBLY REFER TO QP NO………PED-557-00-Q-002

1.3 INSULATING MATERIALS 1. ELECTRICAL CR ELECT. TEST SAMPLE BHEL SPEC./ BHEL SPEC./ TEST 2 - 1(FRP,SMC,DMC,ETC.) RELEVANT IS RELEVANT IS CERTIFICATE

MANUFS. STD. MANUFS. STD.

2. MECH. PROPS. MA MECH. TEST SAMPLE -DO- -DO- -DO- 2 - 1

3. TRACKING MA ELECT. TEST SAMPLE -DO- -DO- -DO- 3/2 - 1 INDEX

1.4 WIRES/CABLES 1. SURFACE MA VISUAL 100% NO VISUAL NO VISUAL LOG BOOK/ 2 - - FINISH DEFECT DEFECT INSP. REPORT

2. DIMENSIONS MA MEASUREMENT SAMPLE BHEL SPECN. BHEL SPECN. -DO- 2 - -

3. HV TEST AT CR ELECT. TEST 100% IS:694 IS:694 -DO- 2 - - 80% OF ORIGINAL HV

BHEL PARTICULARS BIDDER/VENDORNAMESIGNATUREDATE BIDDER'S/VENDOR'S COMPANY SEAL

363

FOREM NO. PEM-6041-0CUSTOMER PROJECT SPECIFICATION

TITLE NUMBER

QUALITY PLAN BIDDER/ QUALITY PLAN SPECIFICATION VENDOR NUMBER PED-506-00-Q-002/01 TITLE

SHEET 3 OF 3 SYSTEM ITEM :BOUGHT OUT ITEMS SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 11

1 5 BUSBARS 1 DIMENSION MA MEASUREMENT SAMPLE BHEL SPEC / BHEL SPEC / LOG BOOK/ 2

102

1.5 BUSBARS 1. DIMENSION MA MEASUREMENT SAMPLE BHEL SPEC./ BHEL SPEC./ LOG BOOK/ 2 - -APPD. DRGS. APPD. DRGS. INSP. REPORT

2. SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - - FINISH

3. MATERIAL MA VERIF. OF TC 1/LOT -DO- -DO- TEST. CERT. 2 - 1 GRADE

4 CONDUCTIVITY CR ELECT TEST DO DO DO DO 2 14. CONDUCTIVITY CR ELECT. TEST -DO- -DO- -DO- -DO- 2 - 1

1.6 SHEET STEEL 1. THICKNESS MA MEASUREMENT SAMPLE -DO- -DO- -DO- 2 - -

2. WAVINESS MA MEASUREMENT 100% -DO- -DO- -DO- 2 - -

3. DUCTILITY CR BEND TEST SAMPLES -DO- -DO- TEST. CERT./ 2 - -INSP. REPORT

1 7 TRANSFORMER & REACTORS 1 ROUTINE TESTS MA ELECT TEST 100% RELEVANT STD & RELEVANT STD & TEST CERT 3 - 1 21.7 TRANSFORMER & REACTORS 1. ROUTINE TESTS MA ELECT. TEST 100% RELEVANT STD. & RELEVANT STD. & TEST CERT. 3 1,2BHEL SPEC. BHEL SPEC.

2. TEMP. RISE MA ELECT. TEST 1/RATING -DO- -DO- -DO- 3 - 1,2 TEST

1.8 PAINTS SHELF LIFE MA VISUAL 100% ….AS PER PAINTS MANUF'S. SPEC……. INSPN 2 - -REPORT

1.9 GASKETS (SYN. RUBBER 1. DIMENSION MA MEASUREMENT SAMPLE MANUFACTURER'S MANUFACTURER'S INSPN 2 - -(ONLY) DRGS. DRGS. REPORT

2. SHORE MA TEST -DO- MANUFACTURER'S MANUFACTURER'S INSPN 2 - - HARDNESS STD. STD. REPORT

3. AGEING MA TEST -DO- IS-3400/ IS-3400/ INSPN 2 - -BS-2752 BS-2752 REPORT

BHEL PARTICULAR BIDDER / VENDORNAMESIGNATUREDATE BIDDER'S/VENDOR'S COMPANY SEAL

364

CUSTOMER : PROJECT:

TITLE : NUMBER :

QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION : VENDOR NUMBER PED-507-00-Q-006/02 TITLE :

SHEET 1 OF 1 SYSTEM ITEM : GALVANISED RIGID STEEL CONDUITS & PIPES SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10 11

1.0 1. MATERIAL MA VISUAL,MECH, IS - 9537 IS:9537 IS:9537 INSPT. REPORT 3 2 1& CHEMICAL

2. DIMENSIONS MA MEASUREMENT IS - 9537 IS - 9537 IS - 9537 INSPT. REPORT 3 2 1

3. TESTS MA TESTING IS - 9537 IS - 9537 IS - 9537 INSPT. REPORT 3 2 1

2.0 1. MATERIAL MA VISUAL,MECH, IS - 1239 IS - 1239 IS - 1239 INSPT. REPORT 3 2 1& CHEMICAL

2. DIMENSIONS MA MEASUREMENT IS - 1239 IS - 1239 IS - 1239 INSPT. REPORT 3 2 1

3. TESTS MA TESTING IS - 1239 IS - 1239 IS - 1239 INSPT. REPORT 3 2 1


NOTE : INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE - 1.

PIPES

SPECIFICATION :

2

CONDUITS

365

ANNEXURE – 1





















Example :





NOTES :










366


TITLE NUMBER :

QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION : VENDOR NUMBER PED-509-00-Q-001/01 TITLEVENDOR NUMBER PED 509 00 Q 001/01 TITLE

SHEET 1 OF 3 SYSTEM ITEM : EARTHING COND. & ELECTRODES SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 11

1.0 RAW MATERIAL

2 10

1.1 MILD STEEL & COPPER 1.CHEMICAL & MA CHEM & PHYS 1/ LOT/SIZE APPD. DRGS/ APPD. DRGS/ MILL TEST 2 - -(AS SPECIFIED) PHYSICAL TESTS DATA SHEETS/ DATA SHEETS/ CERTIFICATE

PROPERTIES TECH. SPEC. TECH. SPEC.

2.SURFACE MA VISUAL 100% -DO- -DO- IR 3/2 - 2FINISH

3.DIMENSIONS MA MEASUREMENT 1/ LOT/SIZE -DO- -DO- -DO- 2 - -3 S O S SU / O /S O O O

1.2 HARDWARES 1.DIMENSIONS MA MEASUREMENT 100% TECH. SPEC. TECH. SPEC. -DO- 3/2 - 2APPD. DRGS/ APPD. DRGS/DATA SHEETS DATA SHEETS

2.COATING MA VISUAL SAMPLE -DO- -DO- -DO- 3/2 - 2

1.3 ZINC FOR GALVANISATION 1.CHEM.COMP. MA CHEM.TEST SAMPLE RELEVANT IS. RELEVANT IS. TC 3/2 - 2

2.0 IN-PROCESS

2.1 CUTTING, DRILLING 1.WORKMANSHIP MA VISUAL & 100% APPD. DRGS/ APPD. DRGS/ IR 2 - -DIMENSIONS MEASUREMENT TECH. SPEC. TECH. SPEC.& DISTORTION

2.2 WELDING 1.WELDING MA VISUAL & QUALITY MALLET TEST SAMPLE MFR'S. STD MFR'S.STD. IR 2 - -

2.3 SURFACE PREPARATION FOR 1.CLEANING MA CHEM. & PERIODIC IS:2629/ IS:2629/ IR 3/2 - -GALVANISING PICKLING & MEASUREMENT IN EACH RELEVENT:IS RELEVENT:IS

RINSING, BATH SHIFTSTRENGTH/PURITY &TEMPERATURE



367


TITLE NUMBER :


SHEET 2 OF 3 SYSTEM ITEM : EARTHING COND. & ELECTRODES SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 11

2.SURFACE MA VISUAL 100% IS:2629/ IS:2629/ IR 3/2 - -QUALITY RELEVENT:IS RELEVENT:IS

2 10

2.4 GALVANISING 1.TEMPERATURE MA TEMPERATURE CONTINUOUS -DO- -DO- -DO- 3/2 - -OF BATH INDICATOR

2.DURATION OF MA VISUAL PERIODIC -DO- -DO- -DO- 3/2 - -DIP

3.ROSS QUANTITY MA TEST PERIODIC RELEVENT:IS RELEVENT:IS -DO- 2 - -AGITATION

4.BATH MA VISUAL PERIODIC MFR'S STD MFR'S STD -DO- 2 - -AGITATION

5.SURFACE MA VISUAL 100% -DO- -DO- IR 3/2 - 2QUALITY

2.5 PAINTING 1.SURFACE MA CHEM. TEST 100% TECH.SPEC. TECH.SPEC. LOG BOOK 2 - -PREPN.DEGREASING &DERUSTING

2.THICKNESS & MA MEASUREMENT SAMPLES -DO- -DO- -DO- 2 - -ADHESION

3.0 FINAL TESTS 1.APPEARANCE MA VISUAL SAMPLE IS:2629 IS:2629 IR 2 1 -FREE FROM ROUGHNESSROUGHNESSLUMPS ETC

2.DIMENSION MA MEASUREMENT -DO- TECH.SPEC./ TECH.SPEC./ IR 2 1 -APPD.DRG. APPD.DRG.

3.UNIFORMITY MA DIP TEST SAMPLE IS:4759 IS-2633 IR 2 1 -OF COATING AS PER

IS-2633


368


TITLE NUMBER :


SHEET 3 OF 3 SYSTEM ITEM : EARTHING COND. & ELECTRODES SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSSL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 2 3 4 5 6 7 8 9 11

4. WEIGHT OF MA PREECE IS-4739 IS-6745 TECH. SPEC. IR 2 1 -COATING TEST

10

5.ADHESION MA HAMMER/ -DO- IS-2629 IS-2629 IR 2 1 -KNIFE

6.THICKNESS MA ELKOMETER SAMPLES TECH. SPEC. TECH. SPEC. IR 2 1 -ANDIS-2629

BHEL PARTICULAR BIDDER / VENDORNAMESIGNATUREDATE BIDDER'S/VENDORS COMPANY SEAL

369


TITLE NUMBER :


SHEET 1 OF 3 SYSTEM ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 11

1.0 RAW MATERIAL

1.1 MILD STEEL (FLATS & RODS) 1.CHEMICAL & MA VERIFICATION, 100% IS:1079 IS:1079 MILL TC 3 - 2AS PER SPECIFICATION PHYSICAL OF TC'S

PROPERTIES TISCO/ RINL/ AUTHORISEDRE-ROLLERS/MANUFACTURERS AS PERBHEL APPROVED SOURCES.

2.DIMENSIONS MA MEASUREMENT 100% IS - 1730 IS - 1730 QC RECORD 3/2 - -

3.SURFACE MA VISUAL 100% IS : 1079 IS : 1079 QC RECORD 3/2 - - FINISH

1.2 1.CHEM.COMP. MA CHEM.TEST SAMPLE IS - 209 IS - 209 QC RECORD 3/2 - 1/2

2.0

2.1 1.DIMENSIONS MA MEASUREMENT 100% SPECIFICATION SPECIFICATION QC RECORD 2 - 1


2.2 SURFACE PREPARATION 1.CLEANING MA MEASUREMENT PERIODIC IN IS:2629 IS:2629 QC RECORD 2 - - PICKLING, EACH SHIFT RINSING, & FLUXING

2.SURFACE MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - QUALITY



CUTTING, DRILLING

IN-PROCESS

ZINC

2

STEEL SHALL BE PROCURED FROM SAIL/

10

370


TITLE NUMBER :



CHECK P W V

1 3 4 5 6 7 8 9 11

2.3 1.TEMPERATURE MA TEMPERATURE CONTINUOUS IS - 2629 IS - 2629 QC RECORD 2 - - OF BATH INDICATOR


3. RATE OF MA VISUAL/ 100% IS - 2629/ IS - 2629/ QC RECORD 3 - 2 IMMERSION MEASUREMENT MFRS PRACTICE MFRS PRACTICE

4.SURFACE MA VISUAL 100% IS - 2629 FREE FROM BURRS, QC RECORD 2 - - QUALITY ROUGHNESS,

SLAG, FLUX, STAINETC.

3.0 FINISHED ITEMS

1.DIMENSIONS MA MEASUREMENT RANDOM SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 -

2.SURFACE FINISH MA VISUAL RANDOM SPECIFICATION FREE FROM INSP. REPORT 3 2, 1 -BURRS, SLAG,ROUGHNESS,FLUX, STAIN,ETC.

3.MASS OF MA CHEM. TEST IS - 4759 IS-6745 / SPECIFICATION INSP. REPORT 3 2, 1 - ZINC COATING SPECIFICATION

4.UNIFORMITY MA CHEM. TEST IS - 4759 IS-2633 IS-2633 INSP. REPORT 3 2, 1 - OF ZINC COATING

5.THICKNESS MA ELCOMETER IS - 4759 SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 - OF ZINC COATING




GALVANISING


2 10

371

ANNEXURE – 1





















Example :





NOTES :










372

FORM NO. PEM-6041-0CUSTOMER PROJECT

TITLE NUMBER


SHEET 1 OF 2 SYSTEM ITEM ELECTRICAL IN-PROCESS SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT GENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10 11

1.0 FABRICATION 1. DIMENSION MA MEASUREMENT 100% APPD. DRG. APPD. DRG. INSP.REPORT 2 - -

2. ALIGNMENT MA MEASUREMENT 100% -DO- -DO- -DO- 2 - -& VISUAL

3. FINISH/ MA VISUAL 100% -DO- -DO- -DO- 2 - -SURFACE

2

SPECIFICATION

SURFACE DEFECT

2.0 SURFACE PREPARATION 1. PROCESS CR PROCESS PERIODIC MFR. STD./ MFR. STD./ LOG BOOK 2 - -& PRE-TREATMENT PARAMETERS CHECK BHEL SPEC./ BHEL SPEC./

(SOLUTION RELEVANT IS RELEVANT IS STRENGTH, TEMPERATURE DIPPING TIME ETC.)

2. SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - - CONDITION

3.0 PRIMER & PAINTING 1. SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - -(SPRAYED & STOVED) FINISH &

COVERAGE

2. FILM MA MEASUREMENT SAMPLE -DO- -DO- -DO- 2 - - THICKNESS

3. SHADE MA VISUAL -DO- -DO- -DO- -DO- 2 - -

4. ADHESION MA CROSSOUT -DO- -DO- -DO- -DO- 2 - -TAPE


373

FORM NO. PEM-6041-0

CUSTOMER PROJECT

QUALITY PLAN TITLE NUMBER BIDDER/ QUALITY PLAN SPECIFICATION

VENDOR NUMBER PED-506-00-Q-003/01 TITLESHEET 2 OF 2 SYSTEM ITEM ELECTRICAL IN-PROCESS SECTION VOLUME III

SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT GENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10 11

4.0 MOUNTING OF VARIOUS 1. RIGIDITY MA VISUAL 100% MANUFACTURER MANUFACTURER LOG BOOK 2 - -ITEMS DRAWINGS DRAWINGS

2.TIGHTNESS MA VISUAL 100% -DO- -DO- -DO- 2 - -

3. CORRECTNESS MA VISUAL 100% APPD. DRG. APPD. DRG. -DO- 2 - -

2

SPECIFICATION

& COMPLETENESS

4. ACCESSIBILITY MA VISUAL 100% -DO- -DO- -DO- 2 - -

5.0 MARKING/LABELLING 1. CORRECTNESS MA VISUAL 100% -DO- -DO- INSPN 2REPORT

2. ADHESION/ MA VISUAL 100% -DO- -DO- -DO- 2 - - FIXING

6.0 PRE-FINAL INSPECTION 1. ALIGNMENT MA VISUAL 100% BHEL SPEC. BHEL SPEC. TEST 2 - -& RELEVANT. STD. & RELEVANT. STD. CERTIFICATE.

2. PERFORMANCE CR ELECTRICAL 100% -DO- -DO- -DO- 2 - -

3. IR & HV CR ELECTRICAL 100% -DO- -DO- -DO- 2 - -


374

CUSTOMER : PROJECT

TITLE NUMBER :


SHEET 1 OF 2 SYSTEM ITEM ELECTRONIC PCB ASSEMBLY SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 11

1.0 BOUGHT OUT ITEMS

1.1 ELECTRONIC COMPONENTS 1. MAKE/RATING MA VISUAL SAMPLE BHEL SPEC, BHEL SPEC, INSPC. 2 - 2ACTIVE, PASSIVE ICS, CMOS LCSO/ BARC LCSO/ BARC REPORTETC. COMPONENT TO COMPONENT TO

BE USED BE USED

2

SPECIFICATION :

10

1.2 POWER DIODES/THYRISTORS/ 1. MAKE/ RATING MA VISUAL 100% BHEL SPEC./DRG. BHEL SPEC./DRG. -DO- 2 - 1TRANSISTORS 2.ROUTINE MA ELECT. & 100% RELV. IS/ RELV. IS/ -DO- 2 - 1

TEST MECH BS/ BHEL SPEC BS/ BHEL SPEC

1.3 PCB CONNECTORS 1. MAKE/TYPE MA VISUAL SAMPLE BHEL SPEC, BHEL SPEC, -DO- 2 - 2LCSO/ BARC LCSO/ BARCCOMPONENT TO COMPONENT TOBE USED BE USED

2.0 PROCESS

2.1 COMPONENTS MOUNTING 1. CORRECTNESS MA VISUAL SAMPLE MANFR. STD MANFR. STD -DO- 2 - -& SOLDERING OF COMPONENTS

2. MOUNTING & MA VISUAL 100% -DO- -DO- -DO- 2 - -ORIENTATION

3. SOLDERING CR VISUAL AT 100% -DO- -DO- -DO- 2 - -DEFECTS & 10%FINISH


375

CUSTOMER : PROJECT

QUALITY PLAN TITLE NUMBER : BIDDER/ : QUALITY PLAN SPECIFICATION :

VENDOR NUMBER PED-557-00-Q-002/01 TITLE :SHEET 2 OF 2 SYSTEM ITEM ELECTRONIC PCB ASSEMBLY SECTION VOLUME III


CHECK P W V

1 3 4 5 6 7 8 9 10 11

2.2 ASSEMBLED PCBS (INTER- 1. FUNCTIONAL CR 1. ELECTRICAL 100% BHEL SPEC./ BHEL SPEC./ TEST 2 - 1 SOAKING AT 700C FOR CONNECTED TOGETHER CHECK BEFORE MFR. STD. MFR. STD. CERT 72 HRS. AT ENERGISED AS SYSTEM/ EQUIPMENT) SOAKING CONDITION

2 ELECTRICAL 100% -DO- -DO- -DO- 2 - 1 -DO-

2

SPECIFICATION :

2. ELECTRICAL 100% DO DO DO 2 1 DOAFTER SOAKINGOR3. ELECTRICAL 100% -DO- -DO- -DO- 2 - 1 TEMP. CYCLE: RAPID TEMP.

AFTER CYCLE AT+ 700C-200C FORTEMP. CYCLE 30 MINTS. AT EACH TEMP. TEST FIVE SUCH CYCLE

2. HV/ IR/ HV/ SWC MA ELECT. TESTS 100% RELEVANT IS/ -DO- -DO- 2 1 -ANSI-C-37-90-197

3. UNIFORMITY & CR VISUAL 100% BHEL SPEC./ BHEL SPEC./ INSPN. 2 - -FINISH OF MFR. STD MFR. STD REPORTCONFORMALCOATING ON BOTH SIDES


376


TITLE NUMBER :

QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION : VENDOR NUMBER PED 558 00 Q 001/01 TITLEVENDOR NUMBER PED-558-00-Q-001/01 TITLE

SHEET 1 OF 3 SYSTEM ITEM :ILLUMINATION SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9

1.0 CABLES & WIRES 1.SURFACE MA VISUAL SAMPLE BHEL SPEC. BHEL SPEC. INSPN. 3/2 2 1 TO BE PROCURED FROM

112 10

DEFECTS IS:694 IS:694 REPORT APPROVED SOURCEIS:1554 IS:1554 & TEST

REPORTFROM MANUFACTURER

2.DIMENSIONS MA MEASUREMENT SAMPLE -DO- -DO- -DO- 3/2 2 1

3 TYPE TESTS CR ELEC TESTS ONE/TYPE BHEL SPEC BHEL SPEC TEST CERT 3 2 13.TYPE TESTS CR ELEC.TESTS ONE/TYPE BHEL SPEC. BHEL SPEC. TEST CERT. 3 2 1& SIZE IS:694 IS:694

IS:1554 IS:1554

4.ACCEPTANCE MA -DO- SAMPLING -DO- -DO- -DO- 3 2 1TESTS

5.ROUTINE MA -DO- 100% -DO- -DO- -DO- 3 - 2,1TESTS

6.FRLS CR FRLS TESTS SAMPLES BHEL SPEC BHEL SPEC -DO- 3 2 1PROPS.

2.0 JUNCTION BOXES, LIGHTINGPANELS AND DISTRIBUTIONBOARDS

2.1 JUNCTION BOXES 1.DIMENSIONS MA MEASUREMENT 100% BHEL DRG. BHEL DRG. INSP. REPORT 3 - 2 COMPONENTS TO BE OFAPPROVED MAKE

2.PAINT SHADE/ MA VISUAL/MEAS. SAMPLE BHEL SPEC/DRG BHEL SPEC/DRG -DO- 3 - 2THICKNESS

3.HV/IR/HV MA ELECT.TESTS 100% 2KV AC FOR 2KV AC FOR -DO- 3 - 21 MINUTE 1 MINUTE

BHEL PARTICULARS BIDDER/VENDORBHEL PARTICULARS BIDDER/VENDORNAMESIGNATUREDATE BIDDER'S/VENDORS COMPANY SEAL

377


TITLE NUMBER :


SHEET 2 OF 3 SYSTEM ITEM :ILLUMINATION SECTION VOLUME IIISL COMPONENT/OPERATION CHARACTERISTIC CAT TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSSL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10

4.DEGREE OF MA TEST 1/SIZE IS:2147 IS:2147 TEST CERT. - - 2,1PROTECTION

112

5.SPECIAL TESTS MA TEST 1/SIZE IS:2148 IS:2148 TEST CERT. - - 2,1IF ANY,EXPLOSIONPROOF ETC.

2.2 LIGHTING PANELS AND 1.DIMENSIONS MA MEASUREMENT SAMPLE BHEL DRG. BHEL DRG. INSPT. REPORT 3 2,1 - COMPONENTS TO BE OFLIGHTING DISTRIBUTION APPROVED MAKEBOARDS 2.PAINT SHADE/ MA VISUAL/ -DO- BHEL SPEC/DRG BHEL SPEC/DRG INSPT. REPORT 3 2,1 -

THICKNESS MEASUREMENT

3.DEGREE OF MA TESTS 1/SIZE BHEL SPEC/ BHEL SPEC/ TEST CERT - - 2,1PROTECTION RELEVANT IS RELEVANT IS(INCLUDINGEXPLOSIONPROOF IF ANY)

4.PERFORMANCE MA ELECT. 100% BHEL SPEC. BHEL SPEC. INSPT. REPORT 3 2,1 - BHEL SHALL WITNESS ON TESTS RANDOM ONE SAMPLE,

THOUGH EACH ITEM SHALL BE CHECKED BYTHE MANUFACTURER

5.HV/IR/HV MA ELECT 100% 2.5KV AC FOR 2.5KV AC FOR INSPT. REPORT 3 2,1 - -DO-1 MINUTE 1 MINUTE

6.TEMP.RISE MA ELECT 1/RATING BHEL SPEC. BHEL SPEC. -DO- 3 2 1TEST (FOR COM-S ( O COPLETE ASSEMBLED LDB)

3.0 TUNGSTEN FILAMENT LAMPS, 1. ACCEPTANCE MA TESTS SAMPLE BHEL SPEC/ BHEL SPEC/ TEST CERT 3/2 - 1TUBULAR FLUORESCENT TESTS RELEVANT IS RELEVANT ISLAMPS, HP MERCURY VAPOUR LAMPS, SODIUMVAPOUR LAMPS, BALLASTS,LUMINAIRESLUMINAIRES


378


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SHEET 3 OF 3 SYSTEM ITEM :ILLUMINATION SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10

4.0 CONDUITS 1.MATERIAL MA VISUAL,MECH, AS PER IS:9537 IS:9537 INSPT. REPORT 3 2 1& CHEMICAL SPEC./

IS 9537

112

2.DIMENSIONS MA MEASUREMENT AS PER IS:9537 IS:9537 INSPT. REPORT 3 2 1SPEC./IS 9537

3.OTHER TESTS MA TEST AS PER AS PER IS:9537 INSPT. REPORT 3 2 1SPEC./ SPEC./IS 9537 IS 9537

5.0 ELECTRIC POLES

5.1 MATERIAL 1.CHEMICAL MA CHEM. SAMPLE IS-2713 IS-2713 -DO- 3/2 - 2,1COMP. ANALYSIS IS:228 & IS:228 &

IS:1894 IS:1894

2.PHYSICAL MA PHY.TESTS -DO- -DO- -DO- -DO- 3/2 - 2,1PROP.

5.2 FINAL INSPECTION 1.WORKMANSHIP MA VISUAL & MEAS SAMPLES BHEL DRG./ BHEL DRG./ -DO- 3/2 2,1 -AND FINISH IS:2713 IS:2713

2.DIMENSIONS MA -DO- -DO- -DO- -DO- -DO- 3/2 2,1 -

3.WEIGHT MA -DO- -DO- -DO- -DO- -DO- 3/2 2,1 -

4.TESTS AS MA -DO- -DO- IS-2713 IS-2713 -DO- 3/2 2,1 -PER IS 2713PER IS-2713

NOTE:

IN CASE TYPE TEST CERTIFICATE FOR DEGREE OF PROTECTION/EXPLOSION PROOFNESS FROM INDEPENDENT LAB. IS NOT AVAILABLE, THE ITEM SHALL BE TESTED AT AN INDEPENDENT LAB.

BHEL PARTICULAR BIDDER / VENDORNAMESIGNATUREDATE BIDDER'S/VENDORS COMPANY SEAL

379

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TITLE NUMBER :


SHEET 1 OF 5 SYSTEM ITEM :INSTRUMENTATION CABLES SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10 11

1.0 RAW MATERIAL

1.1 PVC Compound(for insulation 1. Physical properties MA Physical Tests Sample IS-5831/BHEL IS-5831/BHEL Log Book/ 3/2 - 2and sheath) Specification Specification Test Cert.

2. Elec.Properties MA Electrical Tests Sample -do- -do- -do- 3/2 - 2

3. Make & Type MA Visual 100% Plant Std. Plant Std. -do- 2 - -

2

SPECIFICATION :

1.2 Galvanised steel wire/strip 1. Phy.and Elec. MA Physical & Sample* IS-3975 BHEL IS-3975/BHEL -do- 3/2 - 2 * Sample from each Properties Electrical Tests Specification Specification Batch/Lot.

2. Dimension MA Measurement -do- -do- -do- -do- 3/2 - 2

3.Galvanization Quality MA Galv.Tests -do- -do- -do- -do- 3/2 - 2

1.3 Copper/Aluminium Rods/ 1. Physical Properties MA Physical Tests -do- IS-613 IS-613 -do- 3/2 - 2IS-5484 IS-5484

Wires IS-8130 IS-8130AND BHEL AND BHELSpecification Specification

2. Chemical Composition & purity MA Chemical analysis -do- -do- -do- -do- 3/2 - 2

3.Electrical properties MA Electrical Tests -do- -do- -do- -do- 3/2 - 2

4.Dimension MA Measurement -do- -do- -do- -do- 3/2 - 2

1.4 Screen & drain wire 1. Surface MA visual sample BHEL SPEC. BHEL SPEC. TC & IR 3/2 - 2Finish

2. Dimension MA Measurement -do- Appd. Data Appd. Data TC & IR 3/2 - 2Sheet ahwwt


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1 3 4 5 6 7 8 9 10 11

3.. Mech. Prop. MA Mech test -do- MFRS. STD. MFRS. STD. TC & IR 3/2 - 2

2.0 IN PROCESS

2.1 Wire Drawing , Tinning and 1. Physical, Electr. CR Phy.&Elect. Tests Sample BHEL Specn. BHEL Specn. Log Book 2 - 1Annealing Finish & dimension Visual & Meas. IS-8130 IS-8130

2

SPECIFICATION :

2. Chemical test for CR Chemical Test Sample -do- -do- -do- 2 - - Tinning

2.2 Stranding of wires 1. No.of wires MA Counting Sample Vendors/BHEL Vendors/BHEL -do- 2 - -Specn. & Apprd. Specn. & Apprd.Data Sheet & Data Sheet &Relevant IS Relevant IS

2. Sequence, lay length & Direction MA Visual, Meas Sample -do- -do- -do- 2 - -

3 Surface Finish MA Visual Sample -do- -do- -do- 2 - -

4.Dimension MA Measurement Sample -do- -do- -do- 2 - -

2.3 Core Insulation 1. Surface finish MA Visual 100% - Free from bulging -do- 2 - 1(No repair permitted) burnt particles

lumps, cuts & Scratches.

2 Insulation thickness CR Measurement Sample Appd.data sheet Appd.data sheet -do- 2 - -IS-1554 IS-1554

PARTICULARS BIDDER/VENDORBHEL NAME

SIGNATUREDATE BIDDER'S/VENDORS COMPANY SEAL

381

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1 2 3 4 5 6 7 8 9 10 113. Concentricity # CR Measurement Sample Mfr's Std./Appd. Mfr's Std./Appd. Log Book 2 - 1 # To be checked at

data sheet data sheet starting & finish end of Extruded Length

4 Dia over insulation MA Measurement Sample -do- -do- -do- 2 - -

5. Spark Test or Water CR Electrical 100% Mfr's Std. Mfr's Std. -do- 2 - 1 Immersion test

6. Core identification MA Visual 100% IS-1554 IS-1554 -do- 2 - -

2.4 Core pairing, screening 1. Pair identification MA Visual 100% BHEL Spec. BHEL Spec. Log Book 2 - -(provision of drain wire & appd. Data & appd. Data& laying) sheet sheet

SPECIFICATION :

2.Wire size & MA Measurement 100% -do- -do- -do- 2 - -tape size

3.Test for CR Elect. Test 100% -do- -do- -do- 2 - 1capacitance

4. Sequence of MA Visual meas Sample BHEL Spec. BHEL Spec. -do- 2 - 1lay and lay & MFRs. Std. & MFRs. Std.length

5. Screen overlap MA Measurement Sample -do- -do- -do- 2 - -& coverage

6. Dia over laid MA Measurement -do- -do- -do- -do- 2 - -up core

7. Continuity of MA Elect. Test 100% <--------No Discontinuity ----------> -do- 2 - -drain & drain wirewith alum. Screen

2.5 InnerSheath Extrusion 1. Surface finish MA Visual 100% -- Free from bulging, -do- 2 - -burnt particles,lumps cuts & scratches.

2. Sheath thickness MA Measurement Sample IS-5831, IS-1554 IS-5831, IS-1554 -do- 2 - -data sheet data sheet



382

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TITLE NUMBER :

QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION :VENDOR NUMBER PED-507-00-Q-004/01 TITLE


CHECK P W V

1 3 4 5 6 7 8 9 10 113.Dia over inner sheath MA Measurement Sample IS-5831, IS-1554 IS-5831, IS-1554 -do- 2 - -

data sheet data sheet

2.6 Armouring 1. No.of wires/Strips MA Counting At the start of BHEL Specn./ Appd. BHEL Specn./ Appd. -do- 2 - -the process Data sheet Data sheet

IS-3975 & IS-1554 IS-3975 & IS-1554

2. Lay Direction MA Visual -do- -do- -do- -do- 2 - -

3. Lay Length MA Visual, Meas. At the start of BHEL Specn./Appd. BHEL Specn./Appd. Log Book 2 - -the process Data sheet Data sheet

2

SPECIFICATION :

the process Data sheet Data sheetIS-3975 & IS-1554 IS-3975 & IS-1554

4. Coverage MA Measurement -do- -do- -do- -do- 2 - -

5. Dia over armouring MA Measurement -do- -do- -do- -do- 2 - -

2.7 Outer Sheath Extrusion 1. Surface Finish MA Visual 100% - Free from Bulging Log Book 2 - -Burnt particles,lumps, cuts &scratches

2.Sheath thickness MA Measurement Sample IS-5831 & IS-1554 IS-5831 & IS-1554 Log Book 2 - -Appd. Data Sheet Appd. Data Sheet

3. Dia over outer MA Measurement Sample -do- -do- -do- 2 - -sheath

4. Marking MA Visual 100% IS-1554 & BHEL IS-1554 & BHEL Test Report 2 - - Sequential marking shallSpecn. Specn. be done by printing

2.8 Finished Cable 1. Routine Test CR Elec. & Meas. 100% IS-1554 & BHEL IS-1554 & BHEL Test Report 2 - 1Specn Specn

2. Type & FRLS Tests CR Elec., Phy & Meas. Sample * -do-/Apprd.data -do-/Apprd.data Test Report 2 - 1 * One Drum/Size/Lotsheet sheet



383

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1 3 4 5 6 7 8 9 10 11

3.0 Final Inspection 1. Finish & Length MA Visual (See remark) BHEL specn. Free from Bulging Test Report 2 1 - One drum in a Lot IS-1554 Burnt particles,

lumps, cuts &scratches

2. Dimension MA Measurement Sample Appd.Data Sheet/ Appd.Data Sheet/ Test Report 2 1 -Lengths IS-1554 & IS-1554 &

IS-10810 IS-10810

3. Armouring - MA Visual & Meas. Sample -do- -do- -do- 2 1 -Coverage No of

2

SPECIFICATION :

Coverage No.of Wires/Strips

4. Marking/Colour/ MA Visual -do- -do- -do- -do- 2 1 -pair identification

5. Test for CR Elect. Test -do- -do- -do- -do- 2 1 -screening

6. Acceptance Tests CR Phy & Elect. Tests 20% -do- -do- -do- 2 1

7. Type & FRLS Tests CR Measurement Sample# BHEL Specn. BHEL Specn. -do- 2 1 - #Type Test shall be Apprd.Data Sheet Apprd.Data Sheet witnessed on one sample

of every lotNOTES:-(A) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. VENDOR TO CERTIFY THE SAME.(B) NO REPAIR OF CORE INSULATION PERMITTED(C) CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION(D) PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE(E) RECORD OF RAW MATERIAL, PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER.(F) FILLERS/DUMMY CORES ETC. SHALL BE AS PER BHEL SPECIFICATION(G) WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES, THE SAME SHALL BE AS PER VENDORS SAMPLING PLAN(H) VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION.

LEGEND : P : PERFORMER W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDOR



384

CUSTOMER PROJECT

TITLE NUMBER


SHEET 1 OF 6 SYSTEM ITEM :LCC'S / M. BOXES/ JN. BOXES SECTION VOLUME IIISL. ONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT GENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 2 3 4 5 6 7 8 9 10 11

1.0 RAW MATERIAL & BOUGHT OUT CONTROL

1.1 SHEET STEEL/CHANNELS 1. DUCTILITY CR BEND TEST SAMPLE IS-1079/IS-513/ IS-1079/IS-513/ LOG BOOK 3/2 - 2 FOR SHEET STEELIS-226 IS-226

2. SURFACE MA VISUAL 100% FACTORY STD NO RUSTING -DO- 3/2 - -FINISH

SPECIFICATION

FINISH DEFECTS

3. THICKNESS MA MEASUREMENT 100% BHEL SPEC./ BHEL SPEC./ -DO- 3/2 - 2IS-1730 IS-1730

1.2 WIRES 1. SURFACE MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ -DO- 3/2 - - ONLY APPROVED MAKES DEFECTS. IS-1554/IS-694/ IS-1554/IS-694/ TO BE USED

RELEVANT. IS RELEVANT. IS

2. IR, HV, IR MA ELECTRICAL SAMPLE -DO- -DO- -DO- 3/2 - -

3. TYPE / MA VERIFICATION 100% -DO- -DO- MFR'S 3 - 1,2 ROUTINE OF TYPE / TEST TESTS ROUTINE CERT.

TEST CERTI-FICATE

1.3 ZINC INGOT FOR CHEM. COMP. MA CHEM. TEST EACH IS-209 IS-209 TEST CERT 3/2 - 1,2GALVANISING


385


TITLE NUMBER


SHEET 2 OF 6 SYSTEM ITEM :LCC'S / M. BOXES/ JN. BOXES SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10 11

1.3 ELECTRICAL COMPONENTS 1. MAKE MA VISUAL SAMPLE BHEL SPEC. BHEL SPEC. LOG BOOK 3/2 - -LIKE FUSE, SWITCHES, TYPE & BOM & BOMINDICATING LAMPS, RATINGPUSH BUTTON,TERMINALS GASKETS 2 OPERATION/ CR ELECTRICAL SAMPLE RELEVANT IS AND RELEVANT IS AND DO 3/2 2 1 2

SPECIFICATION

2

TERMINALS, GASKETS 2.OPERATION/ CR ELECTRICAL SAMPLE RELEVANT IS AND RELEVANT IS AND -DO- 3/2 2,1 2CABLE GLANDS AND FUNCTIONAL TEST CATALOGUE CATALOGUELUGS CHECK

3. IR, HV, IR MA ELECTRICAL 100% -DO- -DO- -DO- 3/2 2,1 2

2.0 IN-PROCESS CONTROL

2.1 NIBBLING/PUNCHING 1. CUTOUT MA MEASUREMENT 100% APPD. DRGS APPD. DRGS LOG BOOK 3/2 - 2,1 STANDARD CUT OUTS SIZES TO BE DONE WITH DIES &

PUNCHES ONLY

2.DEBURRING MI VISUAL 100% -DO- -DO- -DO- 3/2 - -

2.2 PANEL FABRICATION 1. DIMENSIONS MA MEASUREMENT 100% APPR. DRGS APPR. DRGS LOG BOOK 3/2 2 -

2. ALIGNMENT MA MEASUREMENT 100% MFR'S STD MFR'S STD LOG BOOK 3/2 2 -

3. WELDING MI VISUAL 100% -DO- -DO- -DO- 3/2 2 - QUALITY


SIGNATUREDATE BIDDER'S/VENDOR'S COMPANY SEAL

386


TITLE NUMBER


SHEET 3 OF 6 SYSTEM ITEM :LCC'S / M. BOXES/ JN. BOXES SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT GENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10 11

2.3 SURFACE PREPARATION 1. PROCESS MA PROCESS PERIODIC BHEL SPEC., BHEL SPEC., LOG BOOK 3/2 - - IF SAND/SHOT BLASTING,AND PRE-TREATMENT PARAMETERS CHECK MFR. SPEC., MFR. SPEC., ACID PICKLINGS IS NOT(7 OR 8 TANK PROCESS) LIKE BATH TEMP, IS-6005 IS-6005 REQUIRED.

SPECIFICATION

2

( ) , Q CONCENTRATION, DIPPING/ REMOVAL TIME

2. SURFACE MA VISUAL 100% -DO- -DO- -DO- 3/2 - - QUALITY AFTER EVERY DIP

2.4 PRIMER APPLICATION 1. SURFACE MA VISUAL 100% MFR. SPEC., MFR. SPEC., LOG BOOK 3/2 - -& PAINTING FINISH IS-6005 IS-6005

& COVERAGE

2. FILM MA MEASUREMENT 100% -DO- -DO- -DO- 3/2 - 2 THICKNESS

3. SHADE MA VISUAL 100% -DO- -DO- -DO- 3/2 - 2

4. ADHESION MA SCRATCH TEMPLATE -DO- -DO- -DO- 3/2 - 2TEST / CROSSOUT TAPE



387


TITLE NUMBER

QUALITY PLAN BIDDER/ QUALITY PLAN SPECIFICATION :VENDOR NUMBER PED-506-00-Q-005/01 TITLE

SHEET 4 OF 6 SYSTEM ITEM :LCC'S / M. BOXES/ JN. BOXES SECTION VOLUME IIISL. ONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT GENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10 11

2.5 WIRING, GASKET, NAME 1. WIRING LAYOUT MA VISUAL 100% APPD . DRGS & APPD . DRGS & LOG BOOK 3/2 - - PVC CHANNELS TO BEPLATE, COMPONENT SPEC. SPEC. USEDMOUNTING ETC.

2. WORKMANSHIP MA VISUAL 100% -DO- -DO- -DO- 3/2 - - AND FINISH CORRECTNESS

SPECIFICATION

2

COMPLETENESS

2.6 GALVANISATION 1. TEMP OF ZINC MA TEMP. CONTIN- IS-2629 IS-2629 QC RECORD 2 - -PROCESS BATH INDICATOR UOUS

2. DURATION OF DIP MA VISUAL -DO- MANUFACTURER MANUFACTURER -DO- 2 - -PRACTICE. PRACTICE.

3. SURFACE MA VISUAL 100% -DO- FREE FROM -DO- 2 - - QUALITY ROUGHNESS,

FLUX, STAIN ETC.

4. GROSS QUANTITY MA TESTS PERIODIC RELEVANT. IS RELEVANT. IS -DO- 2 - - & AGITATION

3 FINAL INSPECTION

3.1 COMPLETE JUNCTION 1. WORKMANSHIP MA VISUAL 100% BHEL SPEC. BHEL SPEC. INSPN 3/2 2,1 -BOX/ LCC'S & FINISH, PAINT APPD. DRG APPD. DRG REPORTMARSHALLING BOXES SHADE/GALV. RELEVANT. IS RELEVANT. IS

THICKNESS & ADHESION



388


TITLE NUMBER :

QUALITY PLAN BIDDER/ QUALITY PLAN SPECIFICATIONVENDOR NUMBER PED-506-00-Q-005/01 TITLE

SHEET 5 OF 6 SYSTEM ITEM :LCC'S / M. BOXES/ JN. BOXES SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10 11

2. UNIFORMITY MA CHEM. TEST IS-5358 IS-2633 IS-2633 INSPN 2 1 - OF ZINC REPORT COATING

3. THICKNESS MA ELCOMETER -DO- BHEL SPEC. BHEL SPEC. -DO- 2 1 -OF ZINC

SPECIFICATION

2

OF ZINC COATING

4. WIRING LAYOUT MA VISUAL 100% -DO- -DO- -DO- 3/2 2,1 -

5. COMPONENT MA VISUAL 100% -DO- -DO- -DO- 3/2 2,1 - LAYOUT & FIXING, ACCESSI- BILITY AND SAFETY

6. COMPONENT MA VISUAL 100% APPD. DRG. APPD. DRG. -DO- 3/2 2,1 - IDENTIFICATION (MARKING/ NAME PLATES)

7. PROPER WIRE MA PULLING SAMPLE -DO- NO LOOSE -DO- 3/2 2,1 - TERMINATION CONNECTIONS.

ALL TERMINATIONTO BE LUGGED

8. DOOR LOCK MA OPERATON 100% APPD. DRG NO MISMATCH -DO- 3/2 2,1 - FUNCTIONING



389


TITLE NUMBER


SHEET 6 OF 6 SYSTEM ITEM :LCC'S / M. BOXES/ JN. BOXES SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10 11

9.OVERALL MA MEASUREMENT 100% APPD. DRG. APPD. DRG. INSPN. 3/2 2,1 - DIMENSIONS REPORT

10. CONTINUITY CR ELECTRICAL 100% APPD. DRG., APPD. DRG., -DO- 3/2 2,1 -BHEL SPEC., BHEL SPEC.,& RELEVANT IS & RELEVANT IS

2

SPECIFICATION

11. IR-HV-IR CR ELECTRICAL 100% -DO- -DO- -DO- 3/2 2,1 - IR-HV-IRTEST TO BE DONE

12.OPERATION CR ELECTRICAL 100% -DO- -DO- -DO- 3/2 2,1 - BEFORE OPERATIONAL TESTS INTERLOCKS OPERATION ETC AND FUNCTION

IN ENERGISEDCONDITION

13. TEMP RISE CR ELECTRICAL ONE/ TYPE/ BHEL SPEC. BHEL SPEC. -DO- 3/2 2,1 - (IF APPLICABLE) SIZE RELEVANT IS RELEVANT IS

14. DEGREE OF CR WATER AND ONE/ TYPE -DO- -DO- -DO- 3/2 2 - FLAME/EXPLOSION PROOF PROTECTION & DUST TESTS, TEST, IF SPECIFIED IN FLAME/ FLAME/ BHEL SPEC. EXPLOSION EXPLOSION PROOF TESTS

NOTE:

IF TC'S FOR DEGREE OF PROTECTION/EXPLOSION PROOFNESS IS AVAILABLE FROM AN INDEPENDENT LABORATORY FOR IDENTICAL DESIGN (SIZE SHALL BESMALLER THAN THAT INDICATED IN THE TC) THESE TESTS NEED NOT BE REPEATED.



390

CUSTOMER : PROJECT

QUALITY PLAN TITLE NUMBER :

BIDDER/ : QUALITY PLAN SPECIFICATION :

VENDOR NUMBER PED-508-00-Q-002 TITLE :SHEET 1 OF 1 SYSTEM ITEM LEAD ACID BATTERY (DC SYSTEM) SECTION VOLUME III


CHECK P W V

1 3 4 5 6 7 8 9 10 11

1.0 FINISHED BATTERY / CELL 1.TYPE TEST MA TEST IS:1651 & IS:1651 & IS:1651 & INSPN 3,2 - 2,11652/BHEL 1652/BHEL 1652/BHEL REPORTSPEC SPEC SPECBSI:6290 BSI:6290 BSI:6290Pt-4 Pt-4 Pt-4

2 ACCEPTANCE MA TEST DO DO DO 2 2 1

2

SPECIFICATION :

2.ACCEPTANCE MA TEST -DO- -DO- -DO- 2 2,1 -TEST

2.0 ACCESSORIES 1.VISUAL AND MA TEST 100% BHEL DRG BHEL DRG INSPECTION 3,2 2,1 -DIMENSIONS


391


QUALITY PLAN TITLE NUMBER

BIDDER/ QUALITY PLAN SPECIFICATION VENDOR NUMBER PED-506-00-Q-001/01 TITLE

SHEET 1 OF 3 SYSTEM ITEM LT SWGR/CONTROL PNLS/DIST. BD SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10 11

1.0 BOUGHT OUT ITEMS REF. QUALITY PLAN NO. PED-506-00-Q-002

2.0 IN-PROCESS REF. QUALITY PLAN NO. PED-506-00-Q-003

3.0 FINAL INSPECTION1. PHYSICAL MA VISUAL 100% BHEL SPEC. BHEL SPEC. INSP. 2 1 -

SPECIFICATION

2

BLEMISHES REPORT

2. ALIGNMENT MA VISUAL 100% IS-8623 IS-8623 -DO- 2 1 -

3. DIMENSION MA MEASUREMENT 100% IS-3427 IS-3427 -DO- 2 1 - 1. SHIPPING SECTION JOINTSPLATES TO BE SUPPLIED

4. PAINT SHADE MA VISUAL 100% BHEL SPEC. BHEL SPEC. -DO- 2 1 -

5. PAINT MA MEASUREMENT FEW APPD. DRG/ APPD. DRG/ -DO- 2 1 - 2. GLANDS & LUGS TO BE THICKNESS PLACES APPD .DATA APPD .DATA SUPPLIED ALONG WITH BOARDS

SHEET.& OTHER SHEET.& OTHERRELEVANT IS RELEVANT IS

6. PAINT MA MECH. TESTS -DO- APPD. DRG. APPD. DRG. -DO- 2 1 - ADHESION

7. VERIFICATION MA VISUAL 100% -DO- -DO- -DO- 2 1 - OF B.O.M.

8. INTER MA MECH. TESTS 10% -DO- -DO- -DO- 2 1 - CHANGEABILITY


392


QUALITY PLAN TITLE NUMBER

BIDDER/ QUALITY PLAN SPECIFICATION VENDOR NUMBER PED-506-00-Q-001/01 TITLE

SHEET 2 OF 3 SYSTEM ITEM LT SWGR/CONTROL PNLS/DIST. BD SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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9. ROUTINE CR ELECT . TESTS 100% APPD. DRG. APPD. DRG. -DO- 2 1 - TESTS

10. FUNCTION CR ELECT. & MECH. 100% -DO- -DO- -DO- 2 1 - SHALL INCLUDE REMOTEPERFORMANCE TESTS SIMULATION

SPECIFICATION

2

PERFORMANCE TESTS SIMULATION

11. TYPE TESTS CR ELECT. TESTS 1/ITEM -DO- -DO- -DO- 2 - 1 SEE NOTE 'C'

12. INTERLOCKS, CR SECONDARY 100% -DO- -DO- -DO- 2 1 - PHYSICAL VERIFICATION PROTECTION & INJECTION DURING INSPECTION METERING

13. EASE OF MA MECH. TESTS 100% -DO- -DO- -DO- 2 1 - WITHDRAWAL & INSERTION

14. ACCESSIBILITY MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ -DO- 2 1 - OF COMPONENT APPD. DRG. APPD.DRG. & SAFETY (SHROUDING)

15. WIRING NEAT- CR PULLING SAMPLE -DO- -DO- -DO- 2 1 - NESS & FIRMNESS

16. BUS BAR MA MECH. TESTS SAMPLE MANUFACTURER'S MANUFACTURER'S -DO- 2 1 - TIGHTNESS STANDARD STANDARD



393


TITLE NUMBER

QUALITY PLAN BIDDER/ QUALITY PLAN SPECIFICATION

VENDOR NUMBER PED-506-00-Q-001/01 TITLE SHEET 3 OF 3 SYSTEM CABLE ITEM LT SWGR/CONTROL PNLS/DIST. BD SECTION VOLUME III


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NOTE :

A. ONLY APPROVED MAKE OF COMPONENTS ARE TO BE USED.

SPECIFICATION

2

A. ONLY APPROVED MAKE OF COMPONENTS ARE TO BE USED.B. TYPE TESTS WILL INCLUDE (BESIDES OTHERS)

1. TEMPERATURE RISE TEST2. DEGREE OF PROTECTION TEST AND EXPLOSION PROOF TEST, IF ANY3. SHORT TIME CURRENT TEST4. P & Q TEST

C. REGARDING ACCEPTANCE OF AVAILABLE TYPE TCS, REFER CL.NO. 9.4 OF SPECIFICATION NO. PES-506-01.D. INDIVIDUAL BREAKER SHALL BE TESTED AT VARIOUS POSITIONS AND AT NORMAL +10% AND -10% OF CONTROL SUPPLY.E. FUNCTIONAL/PERFORMANCE CHECKS TO BE CONDUCTED ON ENTIRE BOARD AND ALL POWER SUPPLIES SWITCHED ON.



394

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SHEET 1 OF 6 SYSTEM ITEM :LV & MV BUSDUCT SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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1 3 4 5 6 7 8 9 10 111.0 MATERIALS/COMPONENTS

1.1 ALUMINIUM AND COPPER 1. DIMENSION MA MEASUREMENT 100% BHEL SPECS./ BHEL SPECS./ TEST CERT 2 - -BARS & FLEXIBLES IS:5082/IS:736 IS:5082/IS:736

IS:737/IS:1897 IS:737/IS:1897

2.SURFACE FINISH MA VISUAL 100% -DO- -DO- -DO- 2 - -

3.FLATNESS MA VISUAL 100% -DO- -DO- -DO- 2 - -

4.ELECTRICAL MA ELECTRICAL SAMPLE -DO- -DO- -DO- 3,2 - 2,1CONDUCTIVITY

SPECIFICATION :

2

1.2 ENCLOSURE MATERIALS 1. DIMENSION MA MEASUREMENT 100% IS:513 / BHEL IS:513 / BHEL INSP REPORT 2 - -SPECS. SPECS.

2.SURFACE FINISH MA VISUAL 100% -DO- -DO- -DO- 2 - -

3.FLATNESS MA VISUAL 100% -DO- -DO- -DO- 2 - -

4.BEND TEST MA VISUAL 1PIECE/LOT -DO- -DO- -DO- 2 - -(MS ONLY)

1.3 INSULATORS, SEAL OFF 1.ROUTINE TEST MA ELECTRICAL/ 100% BHEL SPECS./ BHEL SPECS./ MRF TEST 3 - 2,1BUSHING, CABLES, WIRES, MEASUREMENT RELEV IS RELEV. IS CERT./LOGSPACE HEATERS BOOK

2.TYPE TEST MA ELECTRICAL/ 1/TYPE -DO- -DO- -DO- 3 - 2,1 FOR INSULATOR BUSHINGMEASUREMENT

3.SURFACE MA VISUAL 100% BHEL SPECS./ BHEL SPECS./ -DO- 2 - -CONDITION RELEV. IS/PHY. RELEV. IS/PHY.RATING & CONDITION CONDITIONMARKING

4.DIMENSIONS PHY. MA MEASUREMENT SAMPLE BHEL SPECS./ BHEL SPECS./ -DO- 2 - -CONDITION RELEV. IS/ NO PHY. RELEV. IS/ NO PHY.

DAMAGE DAMAGE


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5.TRACKING MA ELECTRICAL SAMPLE BHEL SPECS./ BHEL SPECS./ INSP. 3,2 - 1INDEX (FOR RELEV. IS RELEV. IS REPORTINSULATIONMATERIAL)

1.4 BELLEVILLI WASHERS, PLAIN 1.DIMENSION MA MEASUREMENT RANDOM -DO- -DO- LOG BOOK 2 - -& SPRING WASHERS & CHECK

SPECIFICATION :

2

& SPRING, WASHERS & CHECKFASTENERS, DISC WASHERS

2.SURFACE MA VISUAL -DO- -DO- -DO- -DO- 2 - -FINISH

3.SHORE MA MEASUREMENT SAMPLE MANUFS STD MANUFS STD INSP. 2 - 1HARDNESS REPORT

1.5 NEOPRENE RUBBER 1.OIL ABSORPTION MA MEASUREMENT 1PIECE/LOT IS-3400/BHEL IS-3400/BHEL TEST 3 - 1,2BELLOWS & GASKET SPEC./BS-2752 SPEC./BS-2752 REPORT

2.AGEING TEST MA AGEING TEST -DO- -DO- -DO- -DO- 3 - 1,2

1.6 BUS BAR SLEEVES 1. DIMENSION & MA MEAS & TESTS 1/LOT MANUFS STD MANUFS STD INSP. 3,2 - -MATERIAL RELV. STD RELV. STD REPORT &CERTIFICATE TC

2.0 IN-PROCESS

2.1 FABRICATION OF DIMENSION MA MEASUREMENT 100% APPD./MFG DRG APPD./MFG DRG INSP REPORT 2 - -ENCLOSURES



396

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BIDDER/ : QUALITY PLAN SPECIFICATION : VENDOR NUMBER PED-506-00-Q-004/01 TITLE


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2.FINISH MA VISUAL 100% MANUF'S STD MANUF'S STD INSP REPORT 2 - -

3.ALIGNMENT MA VISUAL & 100% -DO- -DO- -DO- 2 - -MEASUREMENT

4.ORIENTATION MA VISUAL 100% -DO- -DO- -DO- 2 - -

2.2 SURFACE PREPARATION 1.PROCESS MA PROCESS PERIODIC IS-6005 IS-6005 -DO- 2 - -INCLUDING PHOSPHATING PARAMETERS CHECKS RELV. IS RELV. IS

SPECIFICATION :

& PASSIVATION (SOLUTIONSTRENGTH TEMP.TIME ETC.

2.SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - -CONDITION

2.3 INITIAL PAINTING (PRIMER) 1.SURFACE FINISH MA VISUAL 100% -DO- -DO- -DO- 2 - -& COVERAGE

2.FILM MA MEASUREMENT 100% -DO- -DO- -DO- 2 - -THICKNESS

2.4 FINISHING OF BUSBARS/ 1.TYPE OF MA VISUAL 100% BHEL SPEC/FAB BHEL SPEC/FAB -DO- 2 - -FLEXIBLES (TINNING/ FINISH DRG/IS SPEC. DRG/IS SPEC.PLATING,/PAINTING/SLEEVING)

3.0 ASSEMBLY

3.1 BUSBAR ASSEMBLY 1.PHASE MA VERIFICATION 100% ASSEMBLY DRG/ ASSEMBLY DRG/ -DO- 2 - -SEQUENCE BHEL SPEC. BHEL SPEC.

BS-159/BS-162 BS-159/BS-162



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2.BUSBAR MARKING MA VISUAL 100% -DO- -DO- -DO- 2 - -

3.TIGHTNESS OF MA MECHANICAL 100% -DO- -DO- -DO- 2 - -SUPPORTS

4.SURFACE MA VISUAL 100% MANUF'S STD MANUF'S STD INSP REPORT 2 - -PREPARATION FORJT.PREPERATION& APPLYING

SPECIFICATION :

2

CONDUCTINGMEDIUM

5.TIGHTNESS OF MA MECHANICAL 100% BHEL SPEC. BHEL SPEC. INSP REPORT 2 - 1 ALUMINIUM BUS BARS JOINTSJOINTS AND MANUFS STD MANUFS STD WILL BE BOLTED WITH BILLETFLEXIBLE WASHER AND THIGHTENING

SHALL BE DONE BY TORQUE6.CLEARANCE TO MA MEASUREMENT 100% -DO- -DO- -DO- 2 - 1 WRENCH ALSO THE JOINTBODY /EARTH SURFACE SHALL HAVE& PHASE TO SUITABLE COMPOUNDPHASE

3.2 EARTHING 1.SIZE & MA MEASUREMENT 100% BHEL SPEC. BHEL SPEC. -DO- 2 - -MATERIAL ASSEMBLY DRG. ASSEMBLY DRG.

2.LOCATION MA VISUAL 100% -DO- -DO- - 2 - -

3.MARKINGS MA VISUAL 100% -DO- -DO- - 2 - -

4.TERMINATIONS MA VISUAL 100% -DO- -DO- - 2 - -

5.TIGHTNESS MA MECHANICAL 100% -DO- -DO- - 2 - -TO SUPPORTS



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3.3 IDENTIFICATION MARKINGS 1.SECTIONAL MA VISUAL 100% -DO- -DO- -DO- 2 - -& NAME PLATES IDENTIFICATION

2.EARTH MA VISUAL 100% -DO- -DO- -DO- 2 - -MARKING

3.BUSBAR MA VISUAL 100% -DO- -DO- -DO- 2 - -MARKING

4.NAME PLATES MA VISUAL 100% -DO- -DO- -DO- 2 - -

2

SPECIFICATION :

AND DANGERNAME PLATES

4.0 COMPLETE ASSEMBLY

4.1 APPEARANCE AND 1.DIMENSIONS MA MEASUREMENT 100% APPD.DRG. APPD..DRG. INSPN. 2 1 -CLEANLINESS LOG SHEET REPORT

2.COMPLETE MA VISUAL 100% BHEL SPEC BHEL SPEC 2 1 - ALL HARDWARES WHICH ARELAYOUT LAYOUT DRGS/ LAYOUT DRGS/ EXPOSED TO OUTDOOR SHALL

FAB.DRG. FAB.DRG. BE TOUCHED WITH ANTI CORROSSION RUST PREVENTION

3.GENERAL & MA VISUAL 100% -DO- -DO- -DO- 2 1 - SOLUTION, VARNISH BEFORE MARKING- PACKING REPORTS TO BEAPPEARANCE SUBMITTED TO BHEL

4.FITTING OF MA VISUAL 100% -DO- -DO- -DO- 2 1 - IT SHALL BE POSSIBLE TO INSPN.COVERS ADJUST TEMP KNOB

THERMOSTAT FROM 5.ALIGNMENT OF MA VISUAL 100% -DO- -DO- -DO- 2 1 - INSPECTION COVER.SECTION

6.EARTH BUS MA VISUAL 100% -DO- -DO- -DO- 2 1 -ALIGNMENTS &MARKING



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7.MARKINGS ON MA VISUAL 100% -DO- -DO- -DO- 2 1 -THE SECTIONS

8.PAINT MA VISUAL 100% APPD.DRGS/ APPD.DRGS/ LOG BOOK 3,2 - 2THICKNESS BHEL SPEC BHEL SPECSHADE MFR SPEC MFR SPEC

9.ADHESION MA SCRATCH TEST TEMPLATE -DO- -DO- -DO- 3,2 - 2

4.2 TESTS 1.ROUTINE MA ELECTRICAL 100% IS-8084 IS-8084 TEST CERT/ 2 1 -TESTS ANSI-C37-20/ ANSI-C37-20/ REPORT

2

SPECIFICATION :

TESTS ANSI C37 20/ ANSI C37 20/ REPORTBHEL SPEC. BHEL SPEC.

2.TEMPERATURE MA ELECTRICAL SAMPLE -DO- -DO- -DO- 2 1 -RISE

3.DEGREE OF MA AS PER SPEC SAMPLE -DO- -DO- -DO- 2 1 -PROTECTION

4.SHORT CKT MA ELECTRICAL SAMPLE -DO- -DO- -DO- 2 1 -TEST

5.IMPULSE MA ELECTRICAL SAMPLE -DO- -DO- -DO- 2 1 -TEST

6.OTHER TYPE MA AS PER SPEC SAMPLE -DO- -DO- -DO- 2 1 -TESTS, IF ANY

5.0 IDENTIFICATION, 1.IDENTIFICATION MA VISUAL 100% PURCHASER'S PURCHASER'S 2 - -PRESERVATION MARKING ON INSTRUCTION INSTRUCTION& PACKING PACKING

CASES



400


TITLE NUMBER


SHEET 1 OF4 SYSTEM ITEM NEUTRAL GROUNDING RESISTOR SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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1 3 4 5 6 7 8 9 10 11

1.0 MATERIALS

1.1 SHEET STEEL AND 1. DIMENSIONS MA MEASUREMENT 10% IS-1079 IS-1079 INSPN. 2 - -STRUCTURES IS-2026 IS-2026 REPORT

IS-513 IS-5132 SURFACE FINISH MI VISUAL 100% -DO- -DO- -DO- 2 - -

SPECIFICATION:

2

2. SURFACE FINISH MI VISUAL 100% DO DO DO 2

3. DUCTILITY OF MA BEND TEST SAMPLES SHEET

1.2 COPPER FLATS 1. DIMENSIONS MA MEASUREMENT 10% IS-1897 IS-1897 -DO- 2 - -

2. SURFACE FINISH MI VISUAL 100% -DO- -DO- -DO- 2 - -

3. CHEMICAL MA CHEM ANALYSIS 1/ MELT -do- -do- TEST CERT. 3/2 - 2COMPOSITION FROM

SUPPLIER

1.3 RESISTOR GRIDS 1. SURFACE FINISH CR VISUAL 100% BHEL DRG./SPEC. BHEL DRG./SPEC. INSPN. 3/2 - -MFG. DRAWING MFG. DRAWING REPORT

2. DIMENSIONS MA MEASUREMENT 100% -DO- -DO- -DO- 3/2 - -

3. RESISTANCE MA ELECTRICAL 10% -DO- -DO- -DO- 3/2 - - VALUE


401


TITLE NUMBER


SHEET 2 OF 4 SYSTEM ITEM NEUTRAL GROUNDING RESISTOR SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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1 3 4 5 6 7 8 9 10 11

4. CHEMICAL MA CHEM ANALYSIS 1/ LOT BHEL DRG./SPEC. BHEL DRG./SPEC. TEST 3/2 - 1 COMPOSITION MFG. DRAWING MFG. DRAWING CERTIFICATE

1.4 MICA INSULATED TIE-RODS 1. DIMENSIONS MA MEASUREMENT 100% MFR'S. STD. MFR'S. STD. -DO- 2 - -MICA WASHERS, STEEL WASHER 2 SURFACE MA VISUAL INSPN 100% DRAWING DRAWING DO 2

SPECIFICATION

2

WASHER 2. SURFACE MA VISUAL INSPN. 100% DRAWING DRAWING -DO- 2 - -

1.5 PORCELAIN INSULATORS 1. DIMENSIONS MA MEASUREMENT 10% MFR'S. STD. MFR'S. STD. -DO- 2 - - PORCELAIN INSULATORS(POST & BUSHING TYPES) SHALL BE OF APPROVED

2. SURFACE MA MEASUREMENT 100% DRAWING DRAWING -DO- 2 - - MAKE FINISH & DEFECTS

3. DRY P.F. HV MA ELEC. 100% BHEL SPECN. BHEL SPECN TEST CERT. 2 - 1 TEST IS IS

2 FABRICATION

2.1 CUTTING, BENDING, 1. DIMENSIONS MA MEASUREMENT 100% APPD./MFG APPD./MFG. INSPN 2 - -PUNCHING, DRILLING ETC REPORT

2. FINISH MA VISUAL 100% -DO- -DO- -DO- 2 - -

2.2 SURFACE PREPARATION 1. SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - - CONDITION

2.3 PAINTING 1. SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - - FINISH & COVERAGE



402


TITLE NUMBER


SHEET 3 OF 4 SYSTEM CABLE ITEM NEUTRAL GROUNDING RESISTOR SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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1 3 4 5 6 7 8 9 10 11

2. FILM THICKNESS MA MEASUREMENT 100% APPD./MFG APPD./MFG. INSPN 2 - -REPORT

3 SUB-ASSEMBLY

SPECIFICATION

2

3.1 RESISTOR UNIT FRAME 1. HV TEST CR ELECTRICAL 100% BHEL SPECN/ BHEL SPECN TEST 2 - -ASSEMBLED IS-1822/ IS-1822/ REPORT

BS-587 BS-587

2.RESISTANCE CR ELECTRICAL 100% -DO- -DO- -DO- 2 - - VALUE

3. DIMENSIONS MA MEASUREMENT 100% -DO- -DO- 2 - -

4 FINAL ASSEMBLY

4.1 COMPLETE NGR 1. HV TEST CR ELECTRICAL 100% BHEL SPECN/ BHEL SPECN TEST 2 1 -IS-1822 IS-1822 REPORTBS-587 BS-587

2.RESISTANCE CR ELECTRICAL 100% -DO- -DO- 2 1 - VALUE

3. DIMENSIONS MA MEASUREMENT 100% -DO- -DO- 2 1 -



403


TITLE NUMBER


SHEET 4 OF 4 SYSTEM ITEM NEUTRAL GROUNDING RESISTOR SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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1 3 4 5 6 7 8 9 10 11

4. SHORT TIME MA HEAT RUN 1/TYPE BHEL SPEC./ BHEL SPEC./ 3 1 - RATING/TEMPER- IS:1822 IS:1822 ATURE RISE TEST BS:587 BS:587

5. DEGREE OF MA AS PER 1/TYPE IS-2147 BHEL SPEC TEST 2 - 1PROTECTION IS 2147 REPORT

2

SPECIFICATION

PROTECTION IS-2147 REPORT

6. PAINT FINISH MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ 2 1 -IS-5 IS-5

7. PAINT MA GAUGE ALL -DO- -DO- 2 1 - THICKNESS

8. PAINT SHADE MI VISUAL-SHADE ALL -DO- -DO- 2 1 -CARD



404

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SHEET 1 OF 4 SYSTEM ITEM PUBLIC ADDRESS SYSTEM SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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1 3 4 5 6 7 8 9 10 11

1.0 MATERIAL/ AS PER QUALITY PLAN NO. PED-506-00-Q-002BOUGHT OUT ITEMS

2.0 IN-PROCESS AS PER QUALITY PLAN NO. PED-506-00-Q-003

3.0 PCB ASSEMBLY AS PER QUALITY PLAN NO. PED-557-00-Q-002

4.0 SPEAKERS 1. TYPE TEST MA ELECT. & 1/TYPE BHEL. SPEC. BHEL. SPEC. TEST CERT. 3/2 2 1MEAS IS7741, IS7527 IS7741, IS7527

2

SPECIFICATION :

2. ACCEPTANCE MA -DO- AS PER IS -DO- -DO- -DO- 3/2 2 1TEST

3. ROUTINE TEST MA -DO- 100% -DO- -DO- -DO- 3/2 2 -

4. DEGREE OF MA -DO- AS PER IS -DO- -DO- -DO- 3/2 - 1/2PROTECTION

5.0 HANDSET 1.WORKMANSHIP MA VISUAL 100% BHEL/SPEC BHEL/SPEC -DO- 3 1/2 -RELV.IS/BS/ RELV.IS/BS/IEC IEC

2. COLOUR MA VISUAL SAMPLE -DO- -DO- -DO- 3 1/2 -

3.INPUT CHARACT- MA ELECT. MEAS -DO- -DO- -DO- -DO- 3 1/2 -ERISTICS

4. OUTPUT CHARA- MA -DO- -DO- -DO- -DO- -DO- 3 1/2 -CTERISTICS

5. SIDE TONE MA -DO- -DO- -DO- -DO- -DO- 3 1/2 -

6.LIMITING MA -DO- -DO- -DO- -DO- -DO- 3 1/2 -


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7. OPERATION MA ELECT. MEAS SAMPLE BHEL/SPEC BHEL/SPEC -DO- 3 1,2RELV.IS/BS/ RELV.IS/BS/IEC IEC

8. DEGREE OF MA MEASUREMENT -DO- -DO- -DO- -DO- 3 - 1/2PROTECTION

9. RIGIDITY, SO- MA DROP & -DO- -DO- -DO- -DO- 3 - 1/2

SPECIFICATION :

102

UNDNESS OF VIBRATIONMOUNTING & TESTCONSTRUCTIONETC.

6 FINAL ASSEMBLY 1. WORKMANSHIP MA VISUAL 100% BHEL SPEC BHEL SPEC TC 2 1 -( SYSTEM ) APPD. DRG. APPD. DRG.

DATA SHEETS, DATA SHEETS,& RELV. IS/ BS & RELV. IS/ BS

2. WIRING LAYOUT MA -DO- -DO- -DO- -DO- -DO- 2 1 -

3.WIRE TERMINA- MA PULL TEST -DO- -DO- -DO- -DO- 2 1 -TION(SOLDERINGOR CRIMPEDLUGS)

4. FERRULE NUM- MA VISUAL -DO- -DO- -DO- -DO- 2 1 -BERING

5.TERMINAL MA -DO- -DO- -DO- -DO- -DO- 2 1 -BLOCKARRANGEMENT



406

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6.PROPER MA VISUAL 100% BHEL SPEC BHEL SPEC -DO- 2 1 -MOUNTING OF ITEM APPD. DRG. APPD. DRG.

DATA SHEETS, DATA SHEETS,& RELV. IS/ BS & RELV. IS/ BS

7.CORRECTNESS MA -DO- -DO- -DO- -DO- -DO- 2 1 -OF ITEM

8.SMOOTH MA -DO- -DO- -DO- -DO- -DO- 2 1 -OPERATION OF

SPECIFICATION :

2

OPERATION OFVARIOUS CONTROLS

9.COMPONENT MA -DO- -DO- -DO- -DO- -DO- 2 1 -LAYOUT

10.IDENTIFICA- MA -DO- -DO- -DO- -DO- -DO- 2 1 -TIONMARKS

11. PAINT SHADE MA -DO- -DO- -DO- -DO- -DO- 2 1 -& FINISH

12.PAINT THICK- MA MEASUREMENT -DO- -DO- -DO- -DO- 2 1 -NESS

13.DIMENSION MA MEASUREMENT -DO- -DO- -DO- -DO- 2 1 -

14 SCREENING MA SYSTEM -DO- 48HRS AT MAX NO FAILURE,DRIFT -DO- 2 1 -SOAKING 45 DEGREE C ETC

SITE TEMP

15.OPERATION/ CR ELECTRICAL -DO- -DO- -DO- -DO- 2 1 -FUNCTIONALCHECK



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16.INTER-CHANGE- CR ELECTRICAL -DO- -DO- -DO- -DO- 2 1 -ABILITY

17.EFFICIENCY CR -DO- -DO- -DO- -DO- -DO- 2 1 -

18.POWER SUPPLY- CR -DO- -DO- -DO- -DO- -DO- 2 1 -VARIOUSCHECKS

SPECIFICATION :

19.IR-MV IR CR -DO- -DO- -DO- -DO- -DO- 2 1

7 PACKING 1.WOOD SPECIES MA VISUAL 100% BHEL SPEC/ BHEL SPEC/ -DO- 2 - 1MFR STD MFR STD

2.WOOD PRESER- MA -DO- -DO- -DO- -DO- -DO- 2 - 1VATIVETREATMENT

3.STURDINESS MA -DO- -DO- -DO- -DO- -DO- 2 - 1

4.WATER PROOF MA -DO- -DO- -DO- -DO- -DO- 2 - 1COVER FOR EQUIPMENT

5.SILCAGEL MA -DO- -DO- -DO- -DO- -DO- 2 - 1PACKETS

6.MARKING MA -DO- -DO- -DO- -DO- -DO- 2 - 1

7.PACKING SLIP MA -DO- -DO- -DO- -DO- -DO- 2 - 1



408

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SHEET 1 OF 5 SYSTEM ITEM :PVC POWER & CONTROL CABLE SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

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1.0 RAW MATERIAL

1.1 PVC Compound(for insulation 1. Physical properties MA Physical Tests Sample IS-5831/BHEL IS-5831/BHEL Log Book/ 3/2 - 2and sheath) Specification Specification Test Cert.

2. Elec.Properties MA Electrical Tests Sample -do- -do- -do- 3/2 - 2

SPECIFICATION :

2

3. Make & Type MA Visual 100% Plant Std. Plant Std. -do- 2 - -

1.2 Galvanised steel wire/strip 1. Phy.and Elec. MA Physical & Sample* IS-3975 BHEL IS-3975/BHEL -do- 3/2 - 2 * Sample from each Properties Electrical Tests Specification Specification Batch/Lot.


3.Galvanization QualityMA Galv.Tests -do- -do- -do- -do- 3/2 - 2

1.3 Copper/Aluminium Rods/ 1. Physical Properties MA Physical Tests -do- IS-613 IS-613 -do- 3/2 - 2IS-5484 IS-5484

Wires IS-8130 IS-8130AND BHEL AND BHELSpecification Specification

2. Chemical Composition & purityMA Chemical analysis -do- -do- -do- -do- 3/2 - 2


4.Dimension MA Measurement -do- -do- -do- -do- 3/2 - 2


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2.0 IN PROCESS

2.1 Wire Drawing , Tinning and 1. Physical, Electr. CR Phy.&Elect. Tests Sample BHEL Specn. BHEL Specn. Log Book 2 - 1Annealing Finish & dimension Visual & Meas. IS-8130 IS-8130

2 Chemical test for CR Chemical Test Sample -do- -do- -do- 2 - -

SPECIFICATION :

2. Chemical test for CR Chemical Test Sample do do do 2 Tinning

2.2 Stranding of wires 1. No.of wires MA Counting Sample Vendors/BHEL Vendors/BHEL -do- 2 - -Specn. & Apprd. Specn. & Apprd.Data Sheet & Data Sheet &Relevant IS Relevant IS

2. Sequence, lay length & Direction MA Visual, Meas Sample -do- -do- -do- 2 - -

3 Surface Finish MA Visual Sample -do- -do- -do- 2 - -

4.Dimension MA Measurement Sample -do- -do- -do- 2 - -

2.3 Core Insulation 1. Surface finish MA Visual 100% - Free from bulging -do- 2 - 1(No repair permitted) burnt particles


2 Insulation thickness CR Measurement Sample Appd.data sheet Appd.data sheet -do- 2 - -IS-1554 IS-1554



410

CUSTOMER : PROJECT

TITLE NUMBER :



CHECK P W V

1 2 3 4 5 6 7 8 9 10 113. Concentricity # CR Measurement Sample Mfr's Std./Appd. Mfr's Std./Appd. Log Book 2 - 1 # To be checked at

data sheet data sheet starting & finish end of Extruded Length

4 Dia over insulation MA Measurement Sample -do- -do- -do- 2 - -

5. Spark Test or Water CR Electrical 100% Mfr's Std. Mfr's Std. -do- 2 - 1 Immersion test

6. Core identification MA Visual 100% IS-1554 IS-1554 -do- 2 - -

SPECIFICATION :

2.4 Core Laying 1. Dia over laidup core MA Measurement Sample -do- -do- Log Book 2 - -

2.Sequence of lay, MA Visual & Meas. Sample Mfrs.Std./relevant Mfrs.Std./relevant -do- 2 - - Lay length & direction IS ISup core


2. Sheath thickness MA Measurement Sample IS-5831, IS-1554 IS-5831, IS-1554 -do- 2 - -data sheet data sheet

3.Dia over inner sheathMA -do- -do- -do- -do- -do- 2 - -

2.6 Armouring 1. No.of wires/Strips MA Counting At the start of BHEL Specn./ Appd. BHEL Specn./ Appd. -do- 2 - -the process Data sheet Data sheet

IS-3975 & IS-1554 IS-3975 & IS-1554

2. Lay Direction MA Visual -do- -do- -do- -do- 2 - -



411

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CHECK P W V

1 3 4 5 6 7 8 9 10 113. Lay Length MA Visual, Meas. At the start of BHEL Specn./ Appd. BHEL Specn./ Appd. Log Book 2 - -

the process Data sheet Data sheetIS-3975 & IS-1554 IS-3975 & IS-1554

4. Coverage MA Measurement -do- -do- -do- -do- 2 - -


2.7 Outer Sheath Extrusion 1. Surface Finish MA Visual 100% - Free from Bulging Log Book 2 - -

SPECIFICATION :

2

Burnt particles,lumps, cuts &scratches

2.Sheath thickness MA Measurement Sample IS-5831 & IS-1554 IS-5831 & IS-1554 Log Book 2 - -Data Sheet Data Sheet

3. Dia over outer MA Measurement Sample -do- -do- -do- 2 - -sheath

4. Marking MA Visual 100% IS-1554 & BHEL IS-1554 & BHEL Test Report 2 - - Sequential marking shallSpecn. Specn. be done by printing

2.8 Finished Cable 1. Routine Test CR Elec. & Meas. 100% IS-1554 & BHEL IS-1554 & BHEL Test Report 2 - 1Specn Specn

2. Type & FRLS Tests CR Elec., Phy & Meas. Sample * -do-/Apprd.data -do-/Apprd.data Test Report 2 - 1 * One Drum/Size/Lotsheet sheet

3.0 Final Inspection 1. Finish & Length MA Visual (See remark) BHEL specn. Free from Bulging Test Report 2 1 - One drum each for IS-1554 Burnt particles, Power & control

lumps, cuts & cables in a Lotscratches



412

CUSTOMER : PROJECT

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CHECK P W V

1 3 4 5 6 7 8 9 10 11

2. Dimension MA Measurement As per IS Appd.Data Sheet/ Appd.Data Sheet/ Test Report 2 1 -IS-1554 & IS-1554 &IS-10810 IS-10810

3. Armouring - MA Visual & Meas. As per IS -do- -do- -do- 2 1 - Coverage No.of

Wires/Strips

2

SPECIFICATION :

Wires/Strips

4. Marking/Colour MA Visual -do- -do- -do- -do- 2 1 - Coding

5. Acceptance Tests CR Phy & Elect. Tests -do- -do- -do- -do- 2 1

6. Type & FRLS Tests CR Measurement (SEE REMARK) BHEL Specn. BHEL Specn. -do- 2 1 - Type Test shall be Apprd.Data Sheet Apprd.Data Sheet witnessed on one sample

per type(Power/control)NOTES:- of every lot(A) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. VENDOR TO CERTIFY THE SAME.(B) NO REPAIR OF CORE INSULATION PERMITTED(C) CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION(D) PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE(E) RECORD OF RAW MATERIAL, PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER.(F) FILLERS/DUMMY CORES ETC. SHALL BE AS PER BHEL SPECIFICATION(G) WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES, THE SAME SHALL BE AS PER VENDORS SAMPLING PLAN(H) VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION.

LEGEND : P : PERFORMER W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDOR



413

CUSTOMER : PROJECT

TITLE NUMBER :


SHEET 1 OF 1 SYSTEM ITEM RIGID STEEL CONDUITS & PIPES SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 10 11

FINISHED PRODUCT1. DIMENSIONAL MA MEASUREMENT 5 SAMPLES AS PER IS-9537 AS PER IS-9537 IR 2 1 -CONFORMITY PER SIZE PT I & II PT I & II

PER LOT AND OTHER IS AND OTHER IS

2.FINISH MI VISUAL -DO- -DO- -DO- -DO- 2 1 -

3. SCREW MI MEASUREMENT -DO- -DO- -DO- -DO- 2 1 -

SPECIFICATION :

2

THREAD

4. BEND TEST MA MECH. 1 SAMPLE -DO- -DO- -DO- 2 1 - OF EACHSIZE

5. COMPRESSION MA MECH. TEST -DO- -DO- -DO- -DO- 2 1 -TEST

6. WT. OF ZINC MA MEASUREMENT ONE SAMPLE IS-6745 IS-4736 -DO- 3 2,1 -COATING

7.UNIFORMITY MA CHEMICAL -DO- IS-2633 IS-2633 -DO- 3 2,1 -OF ZINC

8. ADHESION MA PIVOT/HAMMER -DO- IS2629 IS-2629 -DO- 3 2,1 -TEST TEST


414


TITLE NUMBER :




CHECK P W V

1 3 4 5 6 7 8 9 11

1.0 RAW MATERIAL

1.1 ROLLED SHEET 1.CHEM.& PHY. MA VERIFICATION 100% IS1079/ IS1079/ MILL TC 3/2 - - PROPERTIES OF TC'S SPECIFICATION SPECIFICATION

AUTHORISED RE-ROLLERS/MANUFACTURER AS PER BHEL APPROVED SOURCES.

2.DIMENSIONS MA MEASUREMENT 100%IS-1730/ SPECIFICATION

IS-1730/ SPECIFICATION

QC RECORD 3/2 - -

3.SURFACE MA VISUAL 100% IS1079/ IS1079/ QC RECORD 3/2 - - FINISH SPECIFICATION SPECIFICATION

1.2 ZINC CHEM.COMP. MA CHEM TEST EACH HEAT IS-209 IS-209 QC RECORD 3/2 - 1/2

2.0 IN-PROCESS

2.1 FABRICATION 1.DIMENSIONS MA MEASUREMENT 100% APPD.DRGS. APPD.DRGS. QC RECORD 2 - 1STAGE BY BHEL/ BHEL

AGENCY

2.WELDING MA VISUAL 100% GOOD WELDING FREE FROM QC RECORD 2 - 1 QUALITY PRACTICE DEFECTS &

SLAG


4.RIGIDITY MA DEFLECTION SAMPLE SPECIFICATION SPECIFICATION QC RECORD 2 - 1 (CABLE TRAYs) TEST

2.2 SURFACE PREPARATION 1.CLEANING, MA MEASUREMENT PERIODIC IS:2629 IS:2629 QC RECORD 2 - - PICKLING, IN EACH RINSING & SHIFT FLUXING

2. SURFACE MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - QUALITY



ITEM : CABLE TRAYS & ACCESSORIES

STEEL SHALL BE PROCUREDFROM SAIL/TISCO/RINL/

600 MM OR 450 MM WIDE CABLE TRAY SIZE TO BE

2

INSPECTION AT BLACK

10

TESTED

AUTHORISED INSPECTION

WELDING IS TO BE DONE BY QUALIFIED WELDERS

415


TITLE NUMBER :




CHECK P W V

1 3 4 5 6 7 8 9 11

2.3 GALVANISING 1.TEMPERATURE MA TEMPERATURE CONTINUOUS IS-2629 IS-2629 QC RECORD 2 - - OF BATH INDICATOR


3. RATE OF MA VISUAL 100% IS - 2629 / IS - 2629 / QC RECORD 3 - 2 IMMERSION MEASUREMENT MFR'S PRACTICE MFR'S PRACTICE

4.SURFACE MA VISUAL 100% IS - 2629 FREE FROM QC RECORD 2 - - QUALITY BURRS

ROUGHNESS,SLAG , FLUX. STAIN. ETC.

3.0 FINISHED ITEMS

3.1 (CABLE TRAY, ACCESSO- 1.DIMENSIONS MA MEASUREMENT IS-2500 APPD. DRGS. APPD. DRGS. INSP. REPORT 3 2, 1 - FASTENERS SHALL BE OFRIES & HARDWARES) LEVEL IV REPUTED & APPROVED

2.SURFACE FINISH MA VISUAL IS-2500 SPECIFICATION FREE FROM INSP. REPORT 3 2, 1 -LEVEL IV BURRS, SLAG,

ROUGHNESS,FLUX., STAIN.ETC.

3.RIGIDITY MA DEFLECTION 1/ LOT SPECIFICATION SPECIFICATION INSP. REPORT 2 1 - (FOR TRAYS) TEST

4.MASS OF MA CHEM. TEST IS-4759 / IS-6745 SPECIFICATION INSP. REPORT 3 2, 1 - ZINC COATING SPECIFICATION SPECIFICATION

5.UNIFORMITY MA CHEM. TEST IS-4759 / IS-2633 IS-2633 INSP. REPORT 2 1 - OF ZINC SPECIFICATION COATING

6.THICKNESS MA ELCOMETER IS-4759 / SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 - OF ZINC SPECIFICATION COATING


BHEL PARTICULARS BIDDER/VENDORNAMESIGNATUREDATE

ITEM : CABLE TRAYS & ACCESSORIES

MAKE.

102

BIDDER'S/VENDORS COMPANY SEAL


.

600 MM OR 450 MM WIDE CABLE TRAY TO BE TESTED

416


TITLE NUMBER :

QUALITY PLAN BIDDER/ QUALITY PLAN SPECIFICATION QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION : VENDOR NUMBER PED-509-00-Q-001/02 TITLE


CHECK P W V

1 3 4 5 6 7 8 9 112 10

1.0 RAW MATERIAL

1.1 MILD STEEL (FLATS & RODS) 1.CHEMICAL & MA VERIFICATION, 100% IS:1079 IS:1079 MILL TC 3 - 2AS PER SPECIFICATION PHYSICAL OF TC'S

PROPERTIES TISCO/ RINL/ AUTHORISEDRE-ROLLERS/MANUFACTURERS AS PERBHEL APPROVED SOURCES

STEEL SHALL BE PROCURED FROM SAIL/

SOURCES.

2.DIMENSIONS MA MEASUREMENT 100% IS - 1730 IS - 1730 QC RECORD 3/2 - -

3.SURFACE MA VISUAL 100% IS : 1079 IS : 1079 QC RECORD 3/2 - - FINISH

1.2 1.CHEM.COMP. MA CHEM.TEST SAMPLE IS - 209 IS - 209 QC RECORD 3/2 - 1/2ZINC

2.0

2.1 1.DIMENSIONS MA MEASUREMENT 100% SPECIFICATION SPECIFICATION QC RECORD 2 - 1


2.2 SURFACE PREPARATION 1.CLEANING MA MEASUREMENT PERIODIC IN IS:2629 IS:2629 QC RECORD 2 - -PICKLING EACH SHIFT

CUTTING, DRILLING

IN-PROCESS

PICKLING, EACH SHIFT RINSING, & FLUXING

2.SURFACE MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - QUALITY

BHEL PARTICULARS BIDDER/VENDORNAMENAMESIGNATURE


417


TITLE NUMBER :


SHEET 2 OF 3 SYSTEM ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO CHECK METHOD OF CHECK DOCUMENT NORM OF RECORDNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 11

2.3 1.TEMPERATURE MA TEMPERATURE CONTINUOUS IS - 2629 IS - 2629 QC RECORD 2 - - OF BATH INDICATOR


GALVANISING

2 10

3. RATE OF MA VISUAL/ 100% IS - 2629/ IS - 2629/ QC RECORD 3 - 2 IMMERSION MEASUREMENT MFRS PRACTICE MFRS PRACTICE

4.SURFACE MA VISUAL 100% IS - 2629 FREE FROM BURRS, QC RECORD 2 - - QUALITY ROUGHNESS,

SLAG, FLUX, STAINETC.

3.0 FINISHED ITEMS

1.DIMENSIONS MA MEASUREMENT RANDOM SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 -

2.SURFACE FINISH MA VISUAL RANDOM SPECIFICATION FREE FROM INSP. REPORT 3 2, 1 -BURRS, SLAG,, ,ROUGHNESS,FLUX, STAIN,ETC.

3.MASS OF MA CHEM. TEST IS - 4759 IS-6745 / SPECIFICATION INSP. REPORT 3 2, 1 - ZINC COATING SPECIFICATION

4.UNIFORMITY MA CHEM. TEST IS - 4759 IS-2633 IS-2633 INSP. REPORT 3 2, 1 -OF ZINC OF ZINC

COATING

5.THICKNESS MA ELCOMETER IS - 4759 SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 - OF ZINC COATING





418


TITLE NUMBER :

BIDDER/ : QUALITY PLAN SPECIFICATION : VENDOR NUMBER PED-507-00-Q-001, R-02 TITLE

SHEET 1 OF 5 SYSTEM ITEM XLPE P C bl SECTION VOLUME III

STANDARD QUALITY PLAN

SHEET 1 OF 5 SYSTEM ITEM : XLPE Power Cables SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD

CHECK P W V

1 3 4 5 6 7 8 9 11

1.0 RAW MATERIALS

2 10

1.1 XLPE Compound 1. Physical properties MA Physical Tests Sample/ Lot IS:7098 & Mfrs Std. IS:7098 & Mfrs Std. Test Report 3/2 - 1,2Log Book

2. Elec.Properties MA Electrical Tests -do- -do- -do- -do- 3/2 - 1,2

1.2 Semi Conducting Compound 1. Phy.and Elec. MA Phy.and Elec. -do- Manufacturer's Manufacturer's -do- 3/2 - 1,2Properties Tests standard standard

Raw material verification as per approved sub-vendor list

Properties Tests standard standard

1.3 Copper Foil 1. Dimensions MA Measurement -do- Manufacturer's std./ Manufacturer's std./ Log Book 2 - 2Appd. Data sheet Appd. Data sheet

2. Physical, Chemical MA Phy., Chem. -do- IS:1897 IS:1897 Supplier's 3/2 - 2 & Elect. Properities & Elect. Tests test report

& log book

1.4 PVC Compound (for sheath) 1. Physical properties MA Physical Tests Sample/ lot IS:5831/BHEL IS:5831/BHEL Log Book/ 3/2 - 2Specification Specification Test Report

2. Elec.Properties MA Electrical Test -do- -do- -do- -do- 3/2 - 2

1 5 Galvanised steel wire/strip 1 Phy and Elec MA Physical & Sample from IS:3975/ BHEL IS:3975/ BHEL Log Book/ 3/2 21.5 Galvanised steel wire/strip 1. Phy. and Elec. MA Physical & Sample from IS:3975/ BHEL IS:3975/ BHEL Log Book/ 3/2 - 2 Properties Electrical Tests each batch/ Specification Specification Test Cert.

lot


3. Galvanization MA Galv. -do- -do- -do- -do- 3/2 - 2requirement


419


TITLE NUMBER :


SHEET 2 OF 5 SYSTEM ITEM XLPE Power Cables SECTION VOLUME IIISL COMPONENT/OPERATION CHARACTERISTIC CAT TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS



CHECK P W V

1 3 4 5 6 7 8 9 111.6 Copper/Aluminium Rods/ 1. Physical MA Physical Tests -do- IS:613, IS-5484, IS:613, IS-5484, -do- 3/2 - 2

Wires Properties IS:8130 & IS:8130 & BHEL Specification BHEL Specification

2 Chemical

2 10

2. Chemical Composition MA Chemical -do- -do- -do- -do- 3/2 - 2 & purity analysis


4. Dimensions MA Measurement -do- -do- -do- -do- 3/2 - 2

2.0 IN PROCESS2.0 IN PROCESS

2.1 Wire Drawing , Tinning and 1. Physical, Electrical, CR Phy. & Elect. Tests Sample IS:8130 & IS:8130 & Log Book 2 - 1Annealing Finish & dimension Visual / Meas. BHEL Specn. BHEL Specn.

2. Chemical test for CR Chemical Test -do- -do- -do- -do- 2 - - Tinning

2.2 Stranding of wires 1. No. of wires MA Counting -do- BHEL Specn, Apprd. BHEL Specn, Apprd. -do- 2 - -Data Sheet & Data Sheet &Relevant IS Relevant IS

2. Sequence, lay MA Visual, Meas. -do- -do- -do- -do- 2 - - length & Direction

3 Surface Finish MA Visual do do do do 23 Surface Finish MA Visual -do- -do- -do- -do- 2 - -

4. Dimension MA Measurement -do- -do- -do- -do- 2 - -

2.3 Conductor Screening 1. Radial thickness MA -do- Sample BHEL Specn & Apprd. BHEL Specn & Apprd. Log Book 2 - -Data Sheet Data Sheet


420


TITLE NUMBER :



Q ,SHEET 3 OF 5 SYSTEM ITEM XLPE Power Cables SECTION VOLUME III


CHECK P W V

1 3 4 5 6 7 8 9 10 112.4 Core Insulation (XLPE) 1. Surface finish MA Visual 100% - -do- Log Book 2 - 1

(No repair permitted)

2

( p p )

2. Concentricity # CR Measurement Sample Mfr's Std./Appd. Mfr's Std./Appd. Log Book 2 - 1 # To be checked atdata sheet data sheet starting & finish end of

Extruded Length

3. Thickness of CR Measurement -do- BHEL specn./Apprd. BHEL specn./Apprd. Inspection 2 1 -I l i D Sh / IS 098 D Sh / IS 098 R Insulation Dats Sheet/ IS:7098 Dats Sheet/ IS:7098 Report

4 Dia over insulation MA Measurement -do- -do- -do- -do- 2 1 -

5. Test on XLPE MA Tests -do- -do- -do- -do- 2 1 1 (Tensile & Elongation, Hot Set

& Aging Test) & Aging Test)

2.5 Insulation Screening, 1. Surface finish MA Visual Sample - Free from bulging Log Book 2 - -(Non Metallic & Metallic ) burnt particles


2. Thickness MA -do- -do- BHEL Spec./ BHEL Spec./ -do- 2 - - data sheet data sheet

3 Overlap of MA Measurement -do- BHEL Spec./ BHEL Spec./ -do- 2 - - Tape Band data sheet data sheet

4 Tightness of MA Visual -do- Plant Std. Plant Std. -do- 2 - - Tape Band


421


TITLE NUMBER :


SHEET 4 OF 5 SYSTEM ITEM XLPE Power Cables SECTION VOLUME IIISL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKSNO CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD


NO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORDCHECK P W V

1 3 4 5 6 7 8 9 112.6 Core Laying 1. Dia over laid up core MA Measurement Sample Apprd. Data Sheet Apprd. Data Sheet Log Book 2 - -

2.Sequence of lay, MA Visual & Meas. Sample IS 7098/ Mfrs.Std. IS 7098/ Mfrs.Std. -do- 2 - -& direction

102

3. Lay Length MA Meas. -do- Mnfrs. Std. Mnfrs. Std. -do- 2 - -


2. Sheath thickness MA Measurement Sample Appd. Data Appd. Data -do- 2 - -2. Sheath thickness MA Measurement Sample Appd. Data Appd. Data do 2Sheet, IS:7098 Sheet, IS:7098

3. Dia over inner sheath MA -do- -do- -do- -do- -do- 2 - -

2.8 Armour 1. No.of wires/Strips MA Counting At the start of BHEL Specn./ BHEL Specn./ -do- 2 - -the process Apprd.Data sheet Apprd.Data sheet

2. Lay Direction MA Visual -do- IS:7098 IS:7098 -do- 2 - -

3. Lay Length MA Meas. -do- Plant Standard Plant Standard Log Book 2 - -

4. Coverage MA Measurement -do- BHEL Specn./ Appd. BHEL Specn./ Appd. -do- 2 - -Data Sheet Data Sheet


2 9 Outer Sheath Extrusion 1 Surface Finish MA Visual 100% Log Book 2Free from Bulging2.9 Outer Sheath Extrusion 1. Surface Finish MA Visual 100% - Log Book 2 - -

2.Sheath thickness MA Measurement Sample Appd. Data Sheet Appd. Data Sheet Log Book 2 - -

3. Dia over outer sheath MA -do- -do- -do- -do- -do- 2 - -

Free from Bulging, burnt particles, lumps, cuts & scratches

4. Marking MA Visual 100% IS:7098, BHEL Specn. IS:7098, BHEL Specn. Test Report 2 - - Sequential marking shall& Appd. Data Sheet & Appd. Data Sheet be done by printing


422


TITLE NUMBER :


SHEET 5 OF 5 SYSTEM ITEM XLPE Power Cables SECTION VOLUME IIISL COMPONENT/OPERATION CHARACTERISTIC CAT TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS



CHECK P W V

1 3 4 5 6 7 8 9 11

2.10 Finished Cable 1. Routine Test CR Elec. & Meas. 100% IS:7098 & BHEL specnIS:7098 & BHEL specn. Test Report 2 - 1

2 Type Tests * CR Physical & Sample * BHEL Specn BHEL Specn do 2 1 * As per specn

2 10

2. Type Tests * CR Physical & Sample * BHEL Specn. BHEL Specn. -do- 2 1 * As per specn.Electrical Tests Apprd. Data Sheet Apprd.Data Sheet

3.0 Final Inspection 1. Finish & Length MA Visual, (See remark) BHEL specn. & BHEL Specn./ -do- 2 1 - One drum in each LotMeasurement IS:7098 Free from Bulging

Burnt particles,lumps, cuts &scratches

2. Dimension MA Measurement As per IS Appd.Data Sheet/ Specn./ Appd. Data -do- 2 1 -IS:7098, IS:10810 Sheet/ IS:7098, IS:10810

3. Armouring - MA Visual & Meas. -do- -do- -do- -do- 2 1 - Coverage No.of Wires/Strips

4. Marking & Colour MA Visual -do- -do- -do- -do- 2 1 - Coding

5. Acceptance Tests CR Phy, Elect. Tests -do- BHEL Specn -do- -do- 2 1Apprd. Data Sheet

NOTES:-(A) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION, VENDOR TO CERTIFY THE SAME.(B) NO REPAIR OF CORE INSULATION PERMITTED(C) CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION(C) CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION(D) PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE(E) RECORD OF RAW MATERIAL, PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER.(F) FILLERS/DUMMY CORES ETC. SHALL BE AS PER BHEL SPECIFICATION(G) WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES, THE SAME SHALL BE AS PER SAMPLING PLAN AGREED BY PURCHASER.(H) VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION. IN EXPORT ORDE

PACKING SHALL BE AS PER BHEL SPECIFICATION & THE SAME SHALL BE WITNESSED.

LEGEND : P : PERFORMER W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDORLEGEND : P : PERFORMER W: WITNESSER V: VERIFIER (1) BHEL/BHEL s CUSTOMER: 2 VENDOR : 3 SUB VENDOR

BHEL PARTICULARS BIDDER/ VENDORNAMESIGNATUREDATE BIDDER'S/VENDORS COMPANY SEAL

423

700MW CCPP AT NEDUNOOR, KARIMNAGAR (job no. I-59) ANNEXURE-BBHEL Clarification (ELECTRICAL) submitted to customer

S. No. Volume Section Page No. Clause No. Technical Specification Clarification

1 III D3.0 1 OF 17

1.0(f) & Electrical key line diagram

dwg. No.: TCE.5960A-EL-SK-2001

Fault level shall be limited to 44 kA rms for 6.6 kV systems .... & as per key SLD, fault level at 6.6kV system is 40kA.

6.6 kV system with fault level limited to 40 kA rms has been offered.

1 III D3.0 12 OF 17 1.18( c)The motors rated 175 kW and above shall be 6.6kV and motors rated upto 175 kW shall be 400V.

The motors rated above 175 kW shall be 6.6kV and motors rated upto 175 kW shall be 400 V.

(c) Generator side current …………………….GT side.

(d) Voltage transformers with ……………transformer side.

(a) A switched short………..disconnector.(b) A manually fitted …………..connection.

4 III D3.9 2 OF 15

9.3 & Electrical key line diagram

dwg. No.: TCE.5960A-EL-SK-2001

Additionally One (1) no. transformer feeder on each bus (colony supply) for Owner’s use shall be provided.

Two nos. transformer feeders (One (1) no. on each bus), rated 2000kVA for Colony supply(in customer scope) are considered in BHEL scope as per clause no. 9.3 of section D3.9 Vol-III of customer specification. Further HT cable, LT service transformer, LT busduct, LT power/control cables & LT switchgear for the same are excluded from BHEL scope of supply.

Manual shorting link has been offered.

2 III D 3.2 2 OF 8 2.9 (c & d)

The generator side current transformer is envisaged as a part of the isolated phase busduct.

The voltage transformer, lightning arresters & surge capacitors are envisaged as a part of SPVT & VT cubicle provided as part of generator busduct & associated equipement.

3 III D 3.2 2 OF 8 2.10 (a & b)

424

700MW CCPP AT NEDUNOOR, KARIMNAGAR (job no. I-59)BHEL deviations (ELECTRICAL) submitted to customer

S. No. Volume Section Page No. Clause No. Technical Specification Deviation

1 III D3.13 2 OF 14 13.3.2Emergency & Continuous Load (For 10 hours duration)…..

DC battery is sized for Emergency DC loads for 1hour & continuous DC loads( ie. Indicating lamps, GRP, ECP7 AVR panel etc.) for 10 hours.

425




Rev. : 0

Page : of

10. SCHEDULE OF TECHNICAL DEVIATION

S. No.

Page No. Vol/ section/ Clause No. Technical Specification Clarification

426




Rev. : 0

Page : of

11. SPARES: BIDDER TO QUOTE FOR MANDATORY SPARES, ERECTION & COMMISSIONING SPARES & RECOMMENDED O&M SPARES (FOR 3 YEARS OF OPERATION). AN INDICATIVE LIST OF MANDATORY SPARES IS GIVEN BELOW FOR REFERENCE. S. No. Description Quantity 1 LT SWITCHGEAR & LT BUSDUCT

1.1 400V Switchgear

1.1.1 Complete pole of breaker 2 Nos. of each rating

1.1.2 Breaker complete with operating mechanism and truck mounted

1 No. of each rating

1.1.3 Closing & tripping coils 2 sets of each rating

1.1.4 Fixed and moving contact assemblies of each breaker 2Set

1.1.5 Spring charging motors 2No.

1.1.6 Set of gasket 5Set

1.1.7 Bus bar support insulators 10No.

1.1.8 Aux switch assembly, limit position switches, Local/ Remote selector switch, breaker control switches & other switches

5 No.s

1.1.9 Relays of each type used 1 No.

1.1.10 Clustered type LED 10 Nos. of each colour

1.1.11 CTs. of each ratio & type 2 Nos.

1.1.12 VTs. of each ratio & type 2 Nos.

1.1.13 Meters. of each type & rating. 1 No.

1.1.14 Fuses of each rating 5 Nos.

1.1.15 Transducers of each type & rating 2 Nos.

1.2 Non-Segregated Phase Busducts

1.2.1 Bus support insulator 1 No. for each rating

1.2.2 Seal-off bushing 2 No. for each rating

1.2.3 Flexible connector (for equipment connection) 1 No. for each rating

1.2.4 Gasket 1 set

2 DC System

( Spares applicable separately for each battery bank)

2.1 Battery

(a) Battery Cell of each type 1No.

(b) Positive Plate of each Type 1No.

(c) Negative Plate of each Type 1No.

(d) Connectors with Nuts & Bolts 1 Set

(e) Vent Plugs 1 Set

427




Rev. : 0

Page : of

(f) Terminal Post 1 Set

2.2 Battery Chargers

(a) Silicon Diodes 1 no. of each rating

(b) Control Switch 1 no.

(c) Current Regulator 1 no.

(d) Off-Load Tap Changing Device 1 no.

(e) Fuse of each type 2 nos. of each rating

(f) D.C. Ammeter 1 no.

(g) Miniature circuit Breaker 1 no.

(h) Neon Lamps 5 nos.

3 Lighting Fixtures

3.1 Lighting fixtures (along with lamps) 3% of each type

3.2 Lighting Panels 1 No. of each type.

3.3 MCBs 5 No. of 32A & 5 Nos of 63A.

428

700MW KARIMNAGAR CCPP PROJECT ANNEXURE-A

PROPOSED SCOPE SPLIT OF ELECTRICAL SYSTEMS BETWEEN BHEL & EPC PARTNER

SL. NO. ABBREVIATION EXPANSION

A. B BHEL

1 B(BP) BHEL(BHOPAL)

2 B(ED) BHEL(EDN), BANGALORE

3 B(HR) BHEL(HARDWAR)

4 B(HY) BHEL(HYDERABAD)

5 B(IS) BHEL(ISG), BANGALORE

6 B(JH) BHEL(JHANSI)

7 B(PC) BHEL(PIPING CENTRE), CHENNAI

8 B(PE) BHEL(PEM), NOIDA

9 B(RR) BHEL(RUDRAPUR)

10 B(RG) BHEL(REGION)

11 B(TY) BHEL(TRICHY)

B. P EPC-PARTNER

700MW KARIMNAGAR CCPP PROJECT

PROPOSED SCOPE SPLIT BETWEEN BHEL & EPC PARTNER

BA

SIC

EN

GIN

EE

RIN

G

DE

TA

ILE

D

EN

GIN

EE

RIN

G

SU

PP

LY

SU

PE

RV

ISIO

N O

F

ER

EC

TIO

N &

CO

MM

ISS

ION

ING

ER

EC

TIO

N

EX

EC

UT

ION

&

CO

MM

ISS

ION

ING

1 POWER EVACUATION EQUIPMENT / SYSTEM

1.1 Insulated phase busduct / Segregated phase

busduct

P/B(PE) B(RR) B(RR) P P

1.2 Generator Circuit Breaker B(PE) B(PE) B(PE) B(PE) B(PE)

1.3 Generator Transformer B(PE) B(BP) B(BP) P P

1.4 UAT P/B(PE) B(JH) B(JH) P P

1.5 Generator, GT & UAT protection panels B(PE) B(BP) B(BP) P P

1.6 Generator NGT & NGR P/B(PE) B(RR) B(RR) P P

1.7Electrical Control Panel(For main plant, located

in CCR), DDCMIS for electrical systems

P/B(PE)

B(ED) B(ED)

P P

1.8 DCS (station C&I) P/B(PE) B(ED) B(ED) P P

1.9 Diesel Generator P/B(PE) B(IS) B(IS) P P

2 AC/DC POWER- DISTRIBUTION CONTROL

2.1 MV (6.6 kV) Switch gear P/B(PE) B(BP) B(BP) P P

2.2 LT Aux. Transformers ( dry type) P/B(PE) B(JH) B(JH) P P

2.3 LT Switch gear {PMCC, PCC, MCC, ACDB

local PB stns for LT / HT Drives}

P P P P P

2.4 LV Bus Duct & Accessories P P P P P

2.5 NGR for MV system P P P P

2.6 DC Power Supply 220 V dc P P P P P

Sl.

no.SYSTEM / EQUIPMENT

SCOPE

TERMINAL

POINTREMARKS

Design & Layout by 'P'

based on inputs by

respective BHEL units.

2.7 DC Distribution 220 V dc P P P P P

2.8 DC Starter - for Boiler, Turbine and Generator B(HY/TY) B(HY/TY) B(HY/TY) P P

3 STATION -ELECTRICAL AUXILIARY PKG

3.1 Plant Lighting Equipment (Supply & E &C) P P P P P

3.2 PA System P P P P P

4 POWER / CONTROL /SCREENED CABLES

4.1 HT Power Cables P P P P P

4.2 LT Power Cables P P P P P

4.3 LT Control Cables P P P P P

4.4 Screen Cables (instrumentation) P P P P P

4.5 Spl. Cables [ for Cranes, Hoists etc.] P P P P P

4.6 Fire Survival Cables P P P P P

5 STATION CABLING, EARTHING & LIGHTING-MATERIAL

5.1 TG Trunk Cabling (Field-UCD) Material P P P P P

5.2 Boiler Trunk Cabling (Field - UCD) Material P P P P P

5.3Cabling Material (Cable trays & accessories,

cable tray support, trefoil clamps, cable glands

& lugs, jointing kits, Fire sealing material)

P P P P P

5.4 Equipment Earthing Material (Above ground &

below ground grade)

P P P P P

5.5 Electronic Earthing Material B(ED) P P P P

5.6 Lightning Protection Material P P P P P

5.7 Plant Lighting - erection material P P P P P

6 Main system design , Electrical single line

diagram & Design Memorandum for all

Electrical package

P P NA NA NA Drg./doc. shall be

prepared by 'P' in

consultaion with B(PE)

7 Electrical Layout/ Cable Listing/ cable

routing/ cable interconnection diagram

P P NA NA NA Interface among inputs

from respective BHEL

units is in 'P' scope.

For complete plant.

* As per Cable Scope

detailed matrix (Table-

1)

For main plant & BOP

areas.

8 Preparation of Electrical load data P P NA NA NA Load list shall be

prepared by 'P' in

consultaion with B(PE).

9 Submission of drg./doc.(i.e. Data sheet/

OGA/ scheme/ Test certificates/ Quality

Plans etc.) for all electrical packages

P P NA NA NA

10 Submission of drg. & doc./ follow-up with

customer/ obtaining approval from

customer

NA NA NA NA NA P' shall provide support

to 'B(PE)'.

Note:-Design & engineering of electrical system and equipment including layout / cable routing engineering and furnishing details/BOM/technical

particulars shall be in Partner's scope.

SL

No.ITEM CABLE TYPE

SCOPE OF

CABLE

LISTING

SCOPE OF

CABLE

SUPPLY

REMARKS REV

A

1 SWGR TO OUTGOING FEEDER MV PC P P 00

2 SWGR TO DDCMIS/ UCP G B(PE)-C&I P 00

3 SWGR TO LPBS CC P P 00

4INTERCONNECTING CABLES FOR MV

SWGRLV PC, CC,F,G P P 00

B

1 SWGR TO DRIVES LV PC P P 00

2 SWGR TO DDCMIS/ UCP G B(PE)-C&I P 00

3 SWGR TO LPBS F,G P P 00

C

1 SWGR TO DRIVES LV PC P P 00

2 SWGR TO PLC/ LCP G P P 00

3 SWGR TO LPBS F,G P P 00

4 LCP TO DRIVES LV PC P P 00

5 PLC/ LCP TO FIELD G P P 00

6 PLC/ LCP TO DDCMIS F, G B(PE)-C&I P 00

D

1 INCOMER CABLES LV PC B(HY) P

2ALL OUTGOING CABLES TO DRIVES/

MARK-VI PANESL/ FIELDPC, CC B(HY) B(HY) 00

3 SWGR TO LPBS F,G B(HY) B(HY) 00

E

1 BATTERY/ CHARGER TO DCDB LV PC P P 00

2 DCDB TO STARTER PANEL FOR DC DRIVE LV PC B(HR) B(HR) 00

3 DCDB TO PANEL/ DC LOAD LV PC P P 00

4 STARTER PANEL TO FIELD CC B(HR) B(HR) 00

F

1 BATTERY/ CHARGER TO DCDB LV PC B(HY) B(HY) 00

2 DCDB TO STARTER PANEL FOR DC DRIVE LV PC B(HY) B(HY) 00

3 DCDB TO PANEL/ DC LOAD LV PC B(HY) B(HY) 00

4 STARTER PANEL TO FIELD CC B(HY) B(HY) 00

G

1 415V SWGR TO BATTERY CHARGER LV PC P P 00

1 BATTERY/ CHARGER TO DCDB LV PC B(ED) P 00

3ALL OUTGOING POWER CABLES FROM

24V DCDB VARIOUS LOADSLV PC B(ED) P 00

4BIANRY & ANOLOG SIGNALS FROM 24V

SYSTEM TO DDCMISF,G B(PE)-C&I P 00

H

1INCOMING POWER CABLE FROM SWGR

TO UPSPC P P

LV SYSTEM (UNDER B(PE)- BOPs)

LV SYSTEM (GAS TURBINES)

220 V DC SYSTEM

125 V DC SYSTEM

24 V DC SYSTEM

UPS

LV SYSTEM (UNDER STATION C & I)

700MW KARIMNAGAR COMBINED CYCLE POWER PROJECT

TABLE-1: CABLE SCOPE DOCUMENT

ELECTRICAL SYSTEMS

MV SYSTEM

Page 1 of 2

2ALL OUTGING POWER CABLE FROM UPS

ACDB TO VARIOUS LOADPC B(ED) P 00

3BIANRY & ANOLOG SIGNALS FROM UPS

TO DDCMISF, G B(PE)-C&I P 00

4ALL INTERCONNECTING POWER CABLES

BETWEEN UPS, ACDB & BATTERYPC B(ED) P 00

I

1 BETWEEN DDCMIS CABINETS PC B(ED) P

2 DDCMIS CABINETS TO ELECTRONIS

EARTH PIT

PC B(ED) P 00

J

1EXCITATION TRANSFORMER TO

THYRISTOR CUBICLESPC B(ED) P

2THYRISTOR CUBICLES TO FF / FB

CUBICLESCC B(ED) P 00

3 FB CUBICLE TO GENERATOR SLIP RINGS CC B(ED) P 00

4 INTERCONNECTING CABLES WITHIN SEE CC B(ED) B(ED) 00

5 AUX AC SUPPLY FROM SWGR TO SEE PC P P 00

6 AUX DC SUPPLY FROM DCDB TO SEE PC P P 00

7CONTROL & INSTRUMENTION CABLES

BETWEEN SEE TO GRP, ECP, DDCMISCC P P 00

K

1 415 DG PCC TO DG TERMINALS LV PC P P 00

2 415 V SWGR TO DG AUX MCC CC P P 00

3DG AUX MCC TO DG ROOM (VENTILATION

FAN, LIGHTING ETC)F,G B(IS) B(IS) 00

4POWER & CONTROL CABLES WITH IN DG

SYSTEMPC/ CC B(IS) B(IS) 00

5CONTROL & INSTT. CABLES BETWEEN

DG EQPT TO ECP/ DDCMIS/TRANS. & AVT CC, F,G P P 00

L

1 LT SWGR TO BATTERY CHARGER LV PC P P

2 LT SWGR TO ACDB LV PC P P

3 ALL SAS/ SCADA CABLES CC, F, G, FO

4 ALL OUTGOING CABLES FROM SWYD

DCDB

LV PC

5 ALL OUTGOING CABLES FROM SWYD

ACDB

LV PC

6CONTROL CABLES BETWEEN SWYD

EQPT & GT, GRP, ECP, DDCMISCC, F, G P P

7ALL CONTROL CABLES TWO BETWEEN

SWYD EQPTCC, F, G P P

MALL INTERCONNECTING CABLES FOR

GRP, DCS, ECP, TRANSFORMERS, LV PC, CC,F,G P P

M ANY OTHER CABLEMV PC, LV PC,

CC,F,G, FSP P

MV PC: MV Power cable; LV PC: LV Power cable; CC: LV Control Cable; F: F-Type Instrumentation cable; G:

G-Type Instrumentation cable; FS: Fire Survival cables

SWYD. VENDOR SCOPE

STATIC EXCITATION EQUIPMENT (SEE)

415V EMERGENCY DG SYSTEM

SWITCHYARD

ELECTRONIC EARTHING

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