Fichtner Electrical

FICHTNER Consulting Engineers ( India ) Private Limited Subject HJI Prop.
GMMCO LIMITED TECHNICAL SPECIFICATION FOR STEAM TURBINE GENERATOR & AUXILIARIES Doc. No. Rev. Section 3.0 2630720001-ME-SPC-120-001 R0 Sheet No. 1
SECTION - 3.0
DETAILED TECHNICAL SPECIFICATION - ELECTRICAL
FORMT9-P REV-B (MUM)
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FICHTNER Consulting Engineers ( India ) Private Limited Subject HJI Prop. GMMCO LIMITED TECHNICAL SPECIFICATION FOR STEAM TURBINE GENERATOR & AUXILIARIES Doc. No. Rev. Section 3.0 2630720001-ME-SPC-120-001 R0 Sheet No. 2
SECTION - 3.0 DETAILED TECHNICAL SPECIFICATION - ELECTRICAL
CLAUSE NO. 3.1.0 3.2.0 3.3.0
DESCRIPTION GENERATOR AND AUXILIARIES DC DRIVE STARTER PANEL FOR DC LUB OIL PUMP GENERATOR RELAY PANELS / GENERATOR CONTROL, METERING AND SYNCHRONISING PANELS
SHEET NO. 3 13 14
ANNEXES 3.1 3.2 3.3 3.4 APPENDIX - 1.0 SPECIFIED DESIGN DATA GENERATOR AND AUXILIARIES SPECIFICATION FOR TRANSDUCERS. LIST OF ANNUNCIATIONS APPROVED LIST OF SUB-VENDORS / MAKES DETAILED TECHNICAL SPECIFICATION FOR MISCELLANEOUS ELECTRICAL ITEMS 26 29 31 33 34
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SECTION 3.0 DETAILED TECHNICAL SPECIFICATION (ELECTRICAL) 3.1.0 3.1.1 GENERATOR & AUXILIARIES General The generator shall be of totally enclosed synchronous type with a forced, once through, air cooling system and complete with all required accessories. The relevant IEC regulations shall apply except where more stringent rules are stated below. Materials used in the manufacture shall be of the kind, composition, and physical properties best adapted to their various purposes to assure reliable operation, low maintenance and long life. The generator shall be rated for continuous running duty (Type S1) and shall be capable of operating in dusty and corrosive atmospheric condition. Heaters shall be provided to protect the generator against humidity during standstill and shall be wired to a separate dust and vermin proof terminal box to receive 240V AC single phase supply. The terminal box shall be located at a convenient place on the machine for ease of maintenance. The stator and rotor windings shall be designed for temperature rises within the limits of class B, but additional reliability shall be obtained by using insulation material of class F. The specified sub transient reactance of the machines shall be guaranteed without the use of any reactors. A clear indication of the direction of rotation shall be given on either end of generators. 3.1.2 Specific Requirements a. The generator design shall be coordinated with that of the turbine and shall result in a completely compatible installation. The generators shall be capable of operating either in isolated mode or in parallel with other generators and the state electricity board grid. The Bidder shall offer governor system, so that the inertia constants of the turbine-generator set would be as high as reasonable. b. The generators shall be able to handle all load situations in a satisfactory manner at both maximum and minimum auxiliary cooling water and ambient temperatures. Generator overload capability shall be as per relevant IEC. c. The generator shall be capable of withstanding continuos unbalanced negative phase sequence current of 8% of rated current with none of the phase currents exceeding the rated current, provided the (negative sequence current)2 x time does not exceed 20 times the (rated current)2 x time. i.e. I22 t 20 I 2 t.
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d. The generator should operate without mechanical damage on a 3 phase, a line to line, a line to earth or 2 lines to earth short circuit for 3 seconds with operating at rated speed and excitation corresponding to 5% over voltage at no load. e. The generator shall be capable of operating at its maximum continuous rating (MCR) at rated voltage and frequency subject to variation of 5% of nominal voltage with possible extension to 10% voltage and 5% for frequency In addition the bidder shall furnish the short time under frequency operating limits and permissible volts/ Hertz. Limit. f. In case of sudden application of full load at rated power factor the voltage drop shall not exceed 15%. The Generator shall operate satisfactorily under sudden full load rejection, and also shall be equipped for surge currents when relatively large squirrel cage motors are switched on directly.
g. Generator shall incorporate fully interconnected damper windings to prevent cyclic irregularities. g. The geometric dimension of the magnetic system shall be designed in such a way that the harmonic content of the voltage shall be less than 1% from phase to phase for load variation from no load to rated load and power factor variation from 0.1 (lag) to 1. h. The generator shall be sized taking into consideration the harmonic measurement details of the plant, as given in the Annexure 3.1. i. j. The maximum permissible deviation from sine wave shall be 1%. The telephone harmonic factor shall not exceed the values given in IEC:34-1.
k. Field winding shall be capable of withstanding 125% voltage for 1 minute. l. The Generator shall be able to operate only with the house loads.
m. Generator Remote Automation System Control Facilities In addition to local controls of features stated below, turbine driven generator set shall have features for interface with remote generator control/monitoring and remote automation system such as PMS and/or SCADA/DCS These shall include:
Local/Remote or Auto selection switch with their status indication to remote system Initiation of remote generator auto synchronizing.
Remote automatic and/or manual changeover of generating operating mode along with their remote status indication such as those associated with:-
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Generator excitation / AVR control in either of the Voltage Control or Power Factor or MVAR control mode. Generator Speed control in either of the droop or isochronous or isochronous load sharing or isochronous base load operation. Remote automatic and/or manual generator voltage and frequency control:Remote automatic and/or Generator power reference setting/Speed raise and lower control Generator voltage raise and lower control from remote Generator load acceptance and reduction rate change Remote automatic and/or manual equal or unequal load allocation/sharing between sets as required
Remote annunciation of all generator fault and alarm signals Generator capability diagram and generator operating point on the capability curve for mimic of generation capability and operating point at the HMI of the remote automation system Generator and the generator control system supplier shall: include and list all analogue inputs, analogue outputs, digital inputs, digital outputs, transducer input/outputs, pulse control inputs required and incorporated by them for remote automation system control. furnish details of communication protocol and access address of all analogue inputs, analogue outputs, digital inputs, digital outputs, transducer input/outputs, pulse control inputs as required for interface by the remote automation system supplier
3.1.3
Stator The stator laminations shall be so designed and assembled as to minimize noise and offer minimum resistance to the cooling airflow. Stator coil insulation and tapering of the coils shall be such as to provide adequate corona shielding. Coil ends shall be adequately braced to prevent distortion due to any abnormal operating condition. Stator supports shall be so designed as to withstand maximum short-circuit stresses according to IEC 34. The stator winding shall be fully insulated throughout and shall be suitable for operation with resistance earthed neutral. The stator windings shall be STAR connected with all the three phase and three neutral ends brought out through terminal bushings. The terminals shall be liberally sized for carrying the rated current of the generator and shall be provided with clearances specified for the terminal voltage under IEC standards. The terminals should accommodate CTs as required. Neutral connection box shall be separate.
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The stator windings shall be provided with not less than six (6) resistive duplex type temperature sensors (100 ohms at 0 C) located in accordance with the provisions of the relevant approved standards. In addition to the above, not less than six (6) resistive duplex type temperature sensors (100 ohms at 0 C) shall also be provided in the stator core. These temperature sensors shall be wired to a separate dust and vermin proof terminal box located at a convenient place on the machine for ease of maintenance. The generator winding insulation shall be based on full vacuum pressure impregnation (VPI) method or based on a method involving individual forming or curing of slot parts of windings with subsequent impregnation of complete winding according to VPI method. The generator shall be able to withstand a winding to earth peak voltage of at least 75 kV peak. 2 nos. of fire detectors shall be provided in the stator. 3.1.4 Rotor The rotor shall be built in accordance with the best modern practice and shall be designed to withstand safely all stresses due to overloads or maximum designed speed. The rotor shall be manufactured in one piece, the inertia constant of which shall be designed to give a large margin between the critical and running speeds under normal operating conditions. The rotor winding shall follow standard design and shall be provided with a complete damper winding or damper wedges with short-circuit rings on both sides. Generator shall be designed to withstand maximum over speed under any operating conditions with a 10% margin and shall as a minimum be rated to withstand an over speed of 20% above the rated value for one minute. 3.1.5 Bearings The generators shall have self-aligning type bearings which are accessible for inspection without dismantling of the generator. Duplex resistive type temperature sensors (100 ohms at 0C) for remote indication of the bearing metal temperatures shall be provided. Earthing brushes shall be provided on the rotor shaft and the bearings at the nondriven end shall be insulated, to prevent circulating eddy currents. The lubricating oil supply for the generators shall come from the same system provided for the turbine. Suitable measure shall be adopted for shielding the bearings as a precaution against carry-over of lubricating oil into the cooling area.
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3.1.6
Frame and Housing The generator housing shall be of welded steel plate with provision to prevent stator movement from causing undue vibration in the external frame and foundation.
3.1.7
Cooling System The generator cooling system shall be closed air circuit ventilation with intermediate cooling water system. The Bidder shall provide all the air ducting system required for air intake and air outlet from the generator to the air cooler with suitable sound attenuation silencers, if required. Generator shaft mounted fans shall circulate the air to cool the stator, rotor and rotating assemblies. The cooling shall be adequate to impose no operational restrictions over the whole ambient temperature range. The coolers shall be of withdrawable design. It shall be possible to isolate and withdraw the coolers without disturbing the generator air cooling circuit. The Air Coolers shall be suitable for water intake temperature upto 33.5C and working pressure of not less than 1.7 bar (170 kpa). Coolers shall be designed so that if one section is intended to be taken out of service for cleaning, the unit can carry at least two third of rated load continuously, without permissible temperatures of active part of machine being exceeded. The design of the generator cooling system shall be such that one (1) extra element / cooler section is provided to take care of continuous operation at maximum load with one (1) element out of operation. The temperature of the cooling air shall be monitored on both the inlet and outlet sides of the coolers by duplex resistive type temperature sensors (100 ohms at 0 C) which shall be designed for remote transmission. At outlet sides of windings, not less than three duplex resistive type temperature sensors shall be provided. The number and location of these temperature sensors shall represent the mean value of the air temperature Alarm contacts for water cooler leakages shall be provided separately for each cooler.
3.1.8
Rating Plate Details The rating plate shall be provided fixed to the frame of machine with the following information, which shall be legible and durable: a. Manufacturers name.
b. Manufacturers serial number and year of manufacture. c. No. of phases, rated frequency and rated voltage.
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d. Rated current. e. Rated output. f. Power factor.
g. Rated speed. h. Permissible over speed. i. j. 3.1.9 Permissible temperature rise. Design ambient temperature.
Exciter The excitation system shall be capable of operating the generator at maximum load, rated power factor and rated frequency. The excitation system shall have sufficient reserve and redundancy to permit effective utilization of generator capability over the entire operating range and under all service conditions without any restrictions. The generator excitation system shall meet following requirements:
It should be capable of producing steady state short circuit current of not less than 3 p.u with a 3 Ph. short circuit applied at the terminals. The excitation system shall have proper field suppression equipment with properly rated DC field breaker and field discharge facility. The ceiling voltage should not be less than 200% of maximum continuous rating (MCR) The excitation response ratio shall be equal to or greater than 1.0/second. The generator shall be provided with a brushless type rotating diode rectifier exciter system.
The excitation system should be capable of meeting above requirement and should also have sufficient gain & speed of response to maintain synchronous stability with the system under switching transients associated with short circuits or abrupt load changes. 3.1.10 Brushless Excitation System The brushless excitation system shall consist of a rotating armature AC exciter directly coupled to the generator rotor. The field of the main AC exciter shall be powered from a high frequency Permanent Magnet Generator (PMG) through a static Automatic voltage regulator. The output of the AC exciter shall be rectified by the rotating diodes connected as a three phase bridge and mounted on the generator shaft for feeding the generator field. The complete equipment shall be installed on a bed plate and enclosed by suitable exciter covers.
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The rectifier design shall be based on the basis of one high power diode and fuse per parallel path. Suitably rated heat sinks, which will also act as fans, shall be provided for each diode. The design of the rotating rectifiers shall be such that a short-circuit of a single diode unit shall not require the shutdown of the generator. The exciter shall be equipped with suitable alarm devices to detect diode failure. All busducts, cables and cable carriers required for the excitation system shall be deemed to be supplied against this specification. 3.1.11 Automatic Voltage Regulator Solid state type voltage regulator with automatic and manual control, with a control deviation limited to 0.5% from no-load to full load at rated frequency and with all necessary limitations against over / under-excitation shall be provided. A suitable transfer control system and necessary controls shall be provided for a smooth bumpless transfer from automatic to manual and manual to automatic voltage control. Bumpless and smooth transfer shall be automatically initiated in case of a sudden failure of the voltage regulator. Further more, manual control shall be possible from the remote control desk in the control room. Provision for connection of all necessary push buttons, balance meter, indicating lights, selector switches, etc., to the remote control desk shall be provided. The voltage regulators shall be complete with all limiters such as rotor current, stator current, load angle etc. compensators, monitors, etc. A power factor controller shall be provided to control the power factor of generator during parallel operation with grid. An ON/OFF switch shall be provided to switch ON/OFF automatic power factor controller. The Bidder shall supply all required auxiliaries such as generator field breaker, discharge/ suppression resistor, motor-operated voltage adjusting rheostat for both auto and manual control and others which will be required for safe and continuous operation. The AVR / Excitation system should include following Limiters, Fault Detectors & Protection features; a. b. c. d.
Under frequency. Short circuit Manual voltage control switch with adjuster. Cross current compensation for parallel operation. Voltage built up circuit. Over voltage. Stator current limiter.
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e. f. g.
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Minimum excitation limiter (Rotor angle limiter). Ripple detector for monitoring diode failure. Null balance detector. AVR accuracy 0.5% voltage from no load to full load. Response time < 0.25 msec AVR failure protection AVR power supply fail protection.
All essential indications/annunciation system required for AVR/excitation system shall be provided. Provision shall be made for remote operation with necessary controls, indications and annunciations. Provision shall be made in the generators for first and second rotor earth fault protection. All auxiliary equipment including necessary slip rings and brushes for brushless excitation system shall also be provided. 3.1.12 P.T. and S.P. cubicles P.T. and surge protection cubicles, shall be metal clad, dust and vermin proof, free standing, dead front assemblies. The cubicle shall have suitable compartments having front access doors with concealed hinges for accommodating the following equipment: Surge capacitor and lightning arrester Potential transformers with primary fuses and secondary MCBs for each set of PT. Seal-off bushings shall be used between the bus tap and cubicle. 3.1.12.1 Current Transformer Cubicle Current Transformer (CT) cubical shall be provided for mounting of all the CTs shall be as per enclosed single line diagram. This cubicle shall be mounted adjacent to Generator Terminals. The CTs shall be cast resin, ring type, with high stability under short circuit conditions and shall be suitable for continuous operation at an ambient temperature of 500c.
The CT shall be mounted in such a fashion that it will permit easy removal and replacement of CTs without dismantling the bus run or supports. The CT secondary leads shall be brought to a common terminal box. Along with CT shorting links, test links also shall be provided in the secondary circuits for carrying out
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current and phase angle measurements. Proper access to LT terminal box shall be provided. The cubicle shall be fabricated out of sheet steel and complete with removable gland plate for cable entry. The wiring shall be carried out by 2.5m2 Cu cable. VA burden shall be selected to suit the system requirement. 3.1.12.2 Potential Transformers Potential transformer shall be cast resin, draw out type, suitable for nominal operation connected from line to ground, and for 1.73 times rated line to ground voltage under sustained emergency condition. Suitable guide slots and stops shall be provided to permit easy withdrawal and positioning. Automatic safety shutters shall be provided to cover up the live terminals when PTs are drawn out. In the disconnected position, the potential transformer primary and secondary circuits shall be automatically disconnected and the primary fuses shall be visibly grounded. The drawout frame shall be grounded at all times. The high voltage winding of potential transformer shall be protected by current limiting fuse mounted on top of the primary bushing. The fuse will be accessible only in fully drawn out position. The secondary leads from the individual PTs shall be extended to a MCB and terminal cabinet flush mounted on the compartment. Potential transformers shall be housed in a phase separated sheet steel cubicle having degree of protection IP-54. 3.1.12.3 Surge Arrester and Surge Protection The surge arrestor and surge capacitor shall be located in separate compartments. Arrestor and capacitor shall be single pole type connected between line and ground terminals. The arrestor shall be station class, hermetically sealed type connected between line and ground. The arrestor and capacitor shall be especially suitable for generator protection and shall be sized accordingly. Sizing calculation for the same shall be submitted by Bidder for approval. A discharge counter shall be provided for each of the lightning arrestor. The discharge counter register shall be visible without opening the compartment grill cover.
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3.1.13
Neutral Grounding Resistor (NGR) The Generator shall be grounded through resistor, limiting the earth fault current to 300 Amps. The resistors shall be made of unbreakable, corrosion proof, joint less, stainless steel grid conforming to ASTM-A240-304 or Ferro chrome aluminium alloy conforming to ASTM-A-240-405. It shall be suitable for use in tropical climate. The resistor shall be designed for indoor service and shall be rated for carrying specified earth fault current for 60 sec. with temperature rise not exceeding 250 C over ambient temperature 50 C. The resistors shall be house in an sheet steel enclosure with minimum of IP 33 degree of protection. Resistors shall be capable of carrying 110% of its rated current continuously. The NGR cubicle shall also house an on load isolator rated for 630A, along with cast resin type neutral CT for Generator Earth Fault protection as indicated in SLD. The connection between NGR and generator neutral shall be done by means of busduct. The connection between NGR and earth pit shall be done by means of GI earth strip. NGR shall be natural air-cooled. Space heater along with DP switch, fuse and thermostat shall be provided in NGR. 4 NO + 4 NC potential free contacts shall be provided for status monitoring & interlocking of neutral branch isolator.
3.1.14
Painting All equipment shall be finished with two (2) under coats of high quality phosphate paint and a coat of yellow zinc chromate primer. The shade of exterior surface finish shall be light grey, shade-631 of IS-5. The bus conductor and inside surface shall be treated with matt black paint for efficient heat dissipation. All supporting structures shall be hot dip galvanised.
3.1.15
Tests The generators shall be subjected to routine tests as per IS/IEC. Temperature rise test shall also be conducted in addition to the above. Test certificates shall be furnished for all the type tests. In addition to the routine tests, the following tests shall also be carried out::a) Insulation resistance (before and after high voltage test) and determination of PI of, Generator Exciter Resistance, temperature detector
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b) c) d)
Dielectric test. Temperature rise at rated voltage, current, power factor and frequency. Vibration test. At 100% of synchronous speed and at 120% during over speed test. At site at 100% of synchronous speed with driver. Noise measurement test. Response of voltage and frequency with sudden shedding of 25%, 50%, 75% and 100% rated load respectively. Response of voltage and frequency with sudden application of 25%, 50%, 75% and 100% rated load respectively. General dimensional alignment checks.
e) f) g) h) 3.1.16
Drawing and Data The following data / drawings shall be submitted along with the offer. a. b. c. d. GA drawing of Generator Generator characteristic curves Catalogues & related literature. Following mathematical models as per IEEE required for Electrical System Studies. i) ii) iii) iv) e. General Block Diagram. Turbine Block Diagram. Turbine Governor Block Diagram. Exciter Block Diagram.
Generator Droop characteristics.
3.1.17 3.2.0 3.2.1
Post contract award drawing and documents shall be submitted as per Annex 1.5 of Section-1 D.C DRIVE STARTER PANEL FOR DC LUB OIL PUMP The starting resistors for the DC motors shall be enclosed in a metal clad naturally ventilated self-standing panel(s) with sheet steel material of minimum 2.0 mm thick with degree of protection IP-33. It shall be dust and vermin-proof. The number of resistance steps shall be decided by the supplier depending on application. Alternatively, permanent connected resistor is also acceptable. The resistor elements shall be made of unbreakable, corrosion-proof, jointless stainless steel grids. The grids shall be in punched form and suitable for use in tropical climate.
3.2.2
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3.3.0 3.3.1
GENERATOR RELAY PANELS / GENERATOR CONTROL, METERING AND SYNCHRONISING PANELS General One set of Generator Relay and generator control, metering and synchronising panel shall be provided for Generator to cater to the protection, metering & synchronisation requirement of generator. Relay panel shall be provided with all the relays as per typical metering and protection drawing no. 30-2630720001-E-202. The generator control panel shall have the control facility as following: a. b. c. d. Control of Generator Breaker / AVR control / Governor Control. Synchronisation of generator / grid incomer / existing 11kV bus coupler / Tie feeder breaker / one spare breaker shall be considered Mimic & semaphor indication & indicating lamps shall be provided. In addition to above, control, metering and indication of generator parameters and associated equipment shall be possible from DCS system envisaged for the plant. Bidder shall ensure necessary hardware arrangements in control relay panels for the same.
3.3.2
Constructional features & General Arrangement Panel shall be of sheet enclosed dust and vermin proof simplex type. Panels shall be floor mounting free standing formed on a frame work of standard sections. The enclosure shall be made out of cold rolled sheet steel of 2.5 mm thick front, back and equipment bearing surfaces and 2 mm for others. Panel supporting structures shall be so designed to form a rigid structure. The panel enclosure shall provide a degree of protection not less than IP:31. All doors and openings shall be provided with neoprene gaskets. All panels shall be suitable to be installed on base frame supplied in one piece along with foundation bolts. Adequate holes shall be provided at the bottom of all the panels for their installation on base frame. Anti vibration pad of 25 mm thick shall be provided between base frame and panel through its entire width on the front/rear side. A suitable removable undrilled gland plate shall be provided for cable entry from bottom. The relays and meters shall be provided as per enclosed generator metering and protection drawing no. 30-2630720001-E-202. The specification and drawings supplement each other. Only the main equipments are listed here. However, provision of all minor items such as links, terminals, control fuses, aux. relays, timers, transducers & indicating lamps shall be made by the bidder.
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The bidder shall be solely responsible for completeness and correctness of internal wiring and for proper functioning of the connected equipment. The panels shall be of vertical front type with equipment mounted in the front and having wiring access from the rear. It shall have double leaf door with lift off hinges at the back. Door shall have built-in locking facility. The relay panels shall have a glass door to observe relays from the front. No equipment shall be mounted on the removable cover plate to avoid the means of access. All instruments, relays and control gears shall be mounted on the front of the panel. All equipment mounted on the panel shall be of flush type. It should be possible to accomplish all settings easily from the front of the relays. The centre line of relays, meters and recorders shall not be less than 450 mm from the bottom of the panel. Checking and removal of components shall be possible without disturbing the adjacent equipment. It shall be possible to set all the measuring relays at site. Mounting of terminal blocks, transducers, interposing CTs etc. shall be done in such a way so as to be readily accessible but without impending the access to internal wiring and components. 3.3.3 Wiring: Panels shall be supplied completely wired internally and ready for Owner's external cable connections at the terminal block. When panels are arranged to be mounted adjacent to each other, all inter panel wiring and connection between panels shall be done by the Supplier. All wiring shall be done with PVC insulated, 650V grade, single core multi stranded (minimum 7 strands) annealed copper conductors suitable for temperature and humidity specified. The minimum sizes are given below: a) b) c) CT circuit For all others Earthing : : : 2.5 sq. mm 1.5 sq. mm 2.5 sq. mm
Each wiring shall be identified at both ends with wire numbers by means of PVC ferrules. Colour coding of the wires shall be as per IS:5578 and IS: 11353. Panel wiring shall be securely supported, neatly installed by lacing and tying, readily accessible and connected to equipment terminals and terminal blocks. Flame retardant, plastic wiring channels / troughs with strap on plastic covers shall be used for this purpose.
All equipment spare contacts shall be wired up to the terminal box. 3.3.4 Terminal Blocks
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The terminals shall be stud type. The terminals shall be suitable to receive crimped wire to give positive connection. All terminals shall be properly shrouded against accidental contact. Sufficient terminals shall be provided, so that not more than two wires is connected to each terminal. Protective covers of transparent plastic shall be provided over the live parts of the terminal blocks. Terminal block for CT and PT secondary leads shall be provided with test links and isolating facilities. Also CT secondary leads shall be provided with safe short-circuiting and earthing facilities. Minimum clearance of 250 mm between the first row of terminal block and associated cable gland plate shall be provided. Also the clearance between two rows of terminal blocks shall be minimum of 150 mm. At least 20% spare terminals shall be provided in each panel and shall be distributed on all rows of terminal blocks. 3.3.5 Painting All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale, rust, grease and dirt. Fabricated structure shall be pickled and then rinsed to remove any trace of acid. The under surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The under surface shall be made free from all imperfections before undertaking finishing coat. After preparation of the under surface, the relay and control panel shall be powder coated with two coats of final paint. The colour of the finishing paint shall be light grey to shade 631 of IS:5. The finished panel shall be dried in stoving oven in dust free atmosphere. Panel finish shall be free from imperfections like pin holes, orange peels, run off paint etc. Final thickness of paint film on sheet steel shall be about 60 microns. All unpainted steel parts shall be galvanised or suitably treated to prevent rust and corrosion. If these parts all are moving element, the same shall be greased. 3.3.6 Panel/Illumination Fluorescent lamp working on 240 V AC operated by door switches shall be provided for panel internal illumination. One 240 V, single phase, 15A, 3 pin socket shall be provided in the panel/desk interior with On/Off switch for connection of hand lamps. This socket shall be metal clad type with a spring load flap.
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3.3.7
Earthing A continuous 25 mm x 6 mm tinned copper bus shall be provided running along full length of the panels. Suitable arrangement provided at the two ends for connections to the plant earthing system. Each panel and the equipment mounted on each panel shall be securely connected to the earth bus by copper wires of size 2.5 mm. This shall be of green in colour. For this purpose the earth wire shall be looped from equipment to equipment and both ends of the earth wire shall be connected to earth bus by a suitable clamp connectors. Soldering shall not be permitted. Insulation between the live terminal and earth prior to connection of the earth to the Purchaser's earth grid shall withstand a test voltage of 500 V for 1 minute (or have resistance of not less than one mega ohm at 500 V).
3.3.8
Space Heaters Strip type space heaters of adequate capacity shall be provided inside each panel complete with ON/OFF switch fuse and thermostat. Heaters shall not be mounted close to wiring or panel mounted equipment. All accidental contact with heaters by operators shall not be possible.
3.3.9
Instruments Instrument shall be furnished as per enclosed SLD. a. Indicating instruments All indicating meters shall be of moving coil type. The meters shall be of 240 scale (except for Double voltmeter and double frequency meter), 96 sq mm in size and having an accuracy class of 1.5. All auxiliary equipment such as shunts, interposing CT/VT etc. that are required shall be included in the scope of supply. All the instruments shall be subjected to an applied potential test of 2 kV for one minute. b. Integrating Meters Energy meters shall be of three phase, two element type, suitable for measuring unbalanced loads in 3 phase, 3 wire circuits. They shall be of flush type, with reverse running stop and with test terminal block for testing. Meters shall read MWH without the use of additional multiplying factors. Number of digits provided shall be adequate to cover at least 1000 hours. Accuracy class shall be one (1.0).
Current coils of the meters shall have a continuous over load capacity of 120% of both accuracy as well as thermal limits. Also current coil shall withstand ten (10) times rated current for 0.5 sec. without loss of accuracy. c. Transducers
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Bidders shall offer transducers with specification as listed in Annexure-3.3 for DCS systems. The transducers shall be mounted inside the generator control panel. The list of transducers to be provided and shall be as per SLD protection and metering. d. Recorders Recorders shall be of drawout type for chart replacement and suitable for back connection. Provision shall be made for automatic shorting of CT leads, when the recorder is drawn out. Recorders shall have accuracy of 0.5%. Recorders shall employ ink on paper and shall be provided with gears and shall have a variable chart speed. Electric motor driven charts with automatic spring winding is preferred. Alternatively, built-in synchronous motor drive with spring reserve may be provided. Charts and inks, sufficient for two (2) years continuous operation of each recorder shall be supplied. Watt and Var recorders shall be suitable for 3 phase, 3 wire, unbalanced loads. All recorders as shown in enclosed generator metering and protection single line diagram shall be suitable for 110V AC PT supply and 1 amp CT secondary current. All auxiliary equipment such as shunts, transducers, interposing CT/VT etc. that are required shall be included in the scope of supply. Alternatively bidder may offer multipen recorder with one pen spare. 3.3.10 Push Buttons Push buttons shall be heavy duty, shrouded, push to actuate type with coloured button and inscription plate marked with its function. Each push button shall have 2 NO + 2 NC contacts. 3.3.11 Indicating Lamps Indicating lamps shall be LED type with clear terminal connections with series resistors. They shall be provided with nameplates. 3.3.12 Control Fuses All control fuses shall be of HRC cartridge link type confirming to IS: 2208. Fuses shall generally be mounted on the top half of the panels. All fuses and links shall be provided with suitable identification labels.
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3.3.13
Control Switches All control switches shall be rotary, back connected type having cam operated operating mechanism with pistol grip. Breaker control switches shall be of 3 position, 6 pole discrepancy type. The contact faces shall be of silver/silver alloy. The contacts shall have the following capability. Continuous rating Breaking current at inductive load of L/R : 10A : 10 ohms and at PF = 0.3 to 0.4 at 240 V AC = 3A at 110 V DC = 2A
Rated switching operation shall be of 120 cycles / hour. All synchronising switches shall have one common knob with keyed shaft removable in off position only to prevent more than one switch being in ON position at a time. The switch shall be 3 position (off, dead bus closing and synchronizing ) 12 pole type. 3.3.14 Position Indicators Position indicators of 'Semaphore' type shall be provided as part of the mimic busbars on panels for automatic indication of the position of circuit breakers, isolating switches, etc. The indicator shall be suitable for semi-flush mounting with only the front disc projecting out and with terminal connection from the rear. When the supervised object is in the closed position, the pointer of the indicator shall take up a position in line with the mimic busbars and at right angles to them when the object is in the open position. The pointer shall take up an intermediate position to indicate the supply failure. It shall not be possible to displace the position of the indicator disc due to accidental touch during cleaning of the panel. 3.3.15 Relays All protective relays shall be numerical type only and switchboard pattern, back connected, drawout type suitable for flush mounting and fitted with dust tight covers. A set of test block and test lead or test switch for necessary secondary injection test shall be included. Relays shall be provided with hand reset/self reset type contacts and flag indicators. The flag indicators shall be suitable for external hand resetting and mechanically interlocked to prevent falling when relay is subjected to vibration.
The rating of auxiliary contacts shall not be less than 5 amp at 240 V AC and 2 amp for 110 V, DC. Minimum one set of spare contact shall be provided in all relays for SCADA / DCS system.
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3.3.16
Specification For Protections The tenderers shall furnish, the settings of all relay functions to suit the requirement of protection, operation and interlock. Following protection functions shall be provided : a. Generator differential protection (87G) Triple pole, high speed, high sensitivity circulating current high impedance relay shall be offered. The relay shall have minimum setting of 5 -10% of generator rated current. The relay shall maintain its stability for any external faults. The relay shall remain insensitive to harmonics and DC components of fault currents. Suitable non-linear resistors shall be provided to limit peak voltage impressed across the relay coil within permissible limits. b. Generator negative phase sequence relay (46G) Relay shall be of 3 phase relay, capable of detecting excessive rotor heating due to unbalance phase currents with 2 stage negative sequence relays. This relay shall have a sensitive alarm unit with a continuously adjustable setting and minimum 5% of stator rated current. The trip unit shall have variable time and current setting to match the generator thermal capability. The generator thermal characteristic and the generator's continuous negative sequence current withstand capability details will be furnished to the successful bidders. (Suitable ICTs shall be provided, if required). c. Generator loss of excitation relay (40 G) Auxiliary relays required if any, for the above scheme shall be included in the offer. The relay shall trip at a small delay depending on the asynchronous running capability. In case of loss of excitation accompanied by undervoltage immediate trip shall be provided. d. Generator overload alarm relay (51 O/L) This relay shall be of single pole, definite time over current relay with a reset to pick up ratio greater than 95%. The relay should have high thermal capability.
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This relay shall have a continuously adjustable current setting of 50 - 200% of rated current and of timer of 0 - 60 sec. e. Generator PT fuse failure relay (97) The relay shall be able to detect the open circuit in primary as well as secondary of the PT. Voltage balance relay with adjustable setting shall be provided. The relay shall remain completely stable for any transient voltage fluctuations. The relay shall not operate for any generator fault. The scheme shall include necessary auxiliary relays and contacts to cut off respective potential circuits of protective relays and AVR. Minimum three spare contacts shall be available for future use. Detail scheme shall be submitted along with the bid. f. Generator reverse power relay (32G) This relay shall be of three-phase relay to protect the turbine generator unit against motoring. This relay shall have a minimum setting of -0.5% of rated power. This will trip the generator in case reversal of power after the set time delay. g. Generator low forward power relay (37G) A power Relay with sensitive setting of +0.5% of rated power shall be used. For certain protective trip conditions, the turbine is first tripped by closing the main steam stop valves by the relay to allow steam to be expanded with generator connected to grid. This relay initiates an alarm after a time delay when electrical power output has fallen down to a value below +0.5%. h. Generator Over Voltage Relay (59G) 2 elements instantaneous over voltage relay with timer shall be offered to protect the system against sudden load throw off, AVR malfunctioning or any other over voltage conditions. The relay shall be connected between R-Y and Y-B phases. The relay shall have power frequency filters and adjustable setting range of 100 - 140% of rated voltage. The drop off to pick up ratio shall not be less than 95%. This relay is intended to trip the generator on over voltage. i. Under Frequency Relay for Generator (81G) 2 stage under frequency relay with two different timers and with one df/dt sensing element shall be offered.
The relay shall initiate an alarm after a set time delay (0 - 10 sec) at 49 Hz. It will trip the turbine after the set time delay (0 - 10 sec) when it comes down to 48.5 Hz or with a set df/dt.
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j.
Generator under voltage relay (27G) One single pole under voltage relay with a timer (0 - 10 sec) shall be provided.
k.
Generator voltage restrained O/C relay (51GV) This relay shall have two distinct characteristics for over load and fault conditions, which shall be monitored by the system voltage conditions. This shall have setting range of 50 - 200% for over current. Under voltage setting shall be of 60%. This shall be of 3-pole relay.
l.
Generator Back-up E/F Relay (51 NG) A single pole IDMT overcurrent with an adjustable current setting range of 10 40% of rated current and with a definite minimum setting of 3 seconds at 10 times current setting shall be provided. The relay shall provide protection to 95% of stator winding. This shall be connected in the neutral grounding circuit.
m. n. o.
Rotor E/F Relay (64 F) Stator E/F Relay Tripping Relay (86G and 86 T) High speed tripping relay with 8 N/O + 4 N/C shall be provided. The relay shall be of hand reset type with operating time not exceeding 10 milli seconds. The contacts shall be of heavy-duty type.
p.
Check Synchronising Relay (25) The relay scheme shall permit closing of the incoming breaker only after matching the voltages, frequencies and phase angles of the incoming and running buses with the preset settings. The response time of the relay shall not exceed 60 ms when the two system inputs are falling within the relay permit limits. The maximum phase angle setting shall not exceed 20 and the voltage difference setting shall not exceed 0.45% at rated value and at the minimum time setting. The time setting shall be continuously adjustable between 0.5 and 3 secs. The relay shall be rated for 110V AC operation. Synchro check relay shall be complete with 2 lamps and auxiliary relays and guard relays. The same shall be located at Generator Control panel. Any other auxiliary relay that may be required to complete the scheme and a phase reversing VT for manual dark lamp synchronizing also shall be provided.
q.
Auto synchroniser
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3.3.17
Relay Test Kit The bidder shall offer his recommended relay test kit for use with various relays specified in this specification. This shall essentially comprise the following: a) b) c) d) e) f) Current injection devices Measuring instruments Stabilized power supply unit Test probes Any special tools required for wiring, testing, removal adjustments Self-contained, durable carrying case.
3.3.18
Annunciator Static type annunciators shall be provided. There shall be translucent windows with engraved inscription. Unless stated otherwise - the annunciators shall be suitable for operation with normally open contact, which closes on fault. They shall be suitable for operation at 110 V DC. One common audible alarm, acknowledge, reset and lamp test push buttons shall be provided for annunciators. Trip and non-trip functions shall be segregated by red and white window colours. On occurrence of fault the following sequence shall be followed : Flashing alarm with manual reset Alarm condition Normal Fault Accept PB Initiation contact Normal Abnormal Abnormal or normal Normal Visual module lamps Off Bright flashing a) Steady on b) DIM Back to normal a) Steady on (non first up) b) DIM Reset PB Normal Normal Off Steady Off Off Off Audible alarm Off On Off
Lamp test PB
A hooter shall be provided near the Annunciation windows for Annunciation purpose.
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Each window shall be provided with two lamps. DC supply failure scheme shall be provided separately with DC under voltage relays. On failure of DC supply to the panel, a lamp and a horn operated by AC supply should operate. There shall be provisions for canceling AC buzzer. The DC bell and AC horn shall have distinctly separate tones. The annunciation windows shall be provided with first-up feature. The list of annunciations to be provided shall be as per Annexure 3.3. 3.3.19 Tests Generator Relay Panels / Generator Control, Metering And Synchronising Panels shall be completely assembled, wired and tested at the factory prior to despatch. These shall be subjected to the following tests. a) Mechanical Operation Test b) High voltage test (2KV for 1 minute) c) Megger test d) Functional test to check electrical control, interlock and sequential operation test. e) Routine test certificates shall be furnished for all associated components/ equipment as per relevant standards. Certified reports of all the tests carried out at the works shall be furnished for the approval of the Purchaser. The equipment shall be despatched from works only after the receipt of Owners/Consultants written approval of the test reports. Type test certificates of any equipment, if so desired by Owner/Consultant shall be furnished. Otherwise the equipment shall have to be type tested free of charge to prove the design. 3.3.20 Data and Manuals As part of the proposal, the bidder shall furnish the following drawing/data for preliminary study. a) Panel dimension, plan, front view, typical internal view etc. b) Technical leaflets and catalogues for all equipment.
The following/data shall be furnished for approval after award of contract to the Consultant/Owner. a. Dimensional general arrangement of the Panel showing equipment disposition and identification.
2630720001-STG-S3-R0 AVD / ELEC 24-09-2007
b. Foundation plan and loading details clearly showing panel-fixing arrangement, floor opening for cable entry etc. c. Bill of materials listing equipment rating, setting ranges, label inscription, contact combination etc. d. Detailed control schematics, clearly showing terminal and wire numbers. e. Panel internal arrangement drawing. f. Panel wiring diagram.
g. Data sheet and instruction manual for commissioning / operation / maintenance of each equipment. h. Overall synchronising scheme, control panel scheme and wiring has to be developed by vendor. The bidder may note that the drawings, data and manuals listed are minimum requirements only. The bidder shall ensure that all other necessary write-ups, curves and information required to fully describe the equipment offered are submitted with his bid.
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ANNEX - 3.1 SPECIFIED DESIGN DATA GENERATOR AND AUXILIARIES Sl. No. 1.1.0. 1.1.1 1.1.2 1.1.3 1. 1.4 1.1.5 1.1.6 1.1.7 1. 1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.13 1.1.14 1.1.15 1.1.16
Description GENERATOR Apparent power of generator turbine output at Voltage of generator terminals Rated Frequency Rated Power factor Rated Speed Overload capacity Over speed Saturated sub-transient reactance Xd Short Circuit Ratio (SCR) Maximum auxiliary cooling water inlet temperature Temperature rise in cooling water Type of generator cooling Type of exciter cooling Star point design Type of excitation Excitation system response ratio Insulation class for generator & exciter
Unit
Data
MVA kV Hz % C C -
: : : : : : : : : : : : : : : : :
To suit max. power output of Turbine 11, 5% 50, 5% 0.8 1500 RPM 110% continuously 150% for 30 sec. 120% min.12.88 Min.0.5 33.5 9.0 CACW Air-cooled closed circuit Protection requirements (Resistance earthed) Brushless excitation system with PMG Not less than 1.0/sec F
1.1.17
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Sl. No. 1.1.18 1.1.19 1.1.20
Description Permissible operation under all condition to insulation class Type of bar insulation Automatic voltage regulator a. Voltage range of electronic voltage regulator b. Type c. Accuracy d. Response time
Unit : :
Data B Synthetic resin
% % m.sec -
: : : : :
Phase segregated Thyristor controlled dual channel 0.5 < 0.25 Generator shall be operation suitable for operating in parallel with grid and the other 15 MW TG set (Future 15 MW UNIT) having voltage & freq variations as following: v = + 10, - 15% f = 3%
1.1.21
Requirement for parallel with grid
1.1.22 1.1.23
Current harmonics Voltage distortion
8.5% 4.6% at 11kV
HARMONICS ANALYSIS DETAILS

(a) Total Harmonics generated by three Thyristor Rectifires: Power 16500KW (approx)
_____________________________________________________________________________ HARMONICS IN AMPS. Rectifier of Make 50 Hz load 3rd 5th 7th 11th 13th BHEL MB ABB TOTAL 180 500 350 1030 2.5 5 2 9 25 61 2 88 16 23 1 40 6 11 20 37 3 17.5 12 32
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(b) Harmonics current & voltage distribution with all Rectifires, Harmonics Filter and Capacitors ON: _____________________________________________________________________________________ Harmonic 6 MVAR OFF 6 MVAR ON 6 MVAR OFF 6 MVAR -ON Order Filter -OFF Filter -OFF Filter -ON Filter -ON
IH 3 5 7 11 13 Root mean square of IH 30 56 34 22 15 ____ 76.8
VH 54 169 144 149 120 -----
IH 30 15 66 22 13 ____ 78.3
VH 54 46 28 145 105 -----
IH 33 14 37 3 2 ____ 51.6 5.7%
VH 60 42 157 21 14 -------
IH 8 14 33 3 1 ____ 36.9 4.1%
VH 14 42 140 18 8 ---------
% Harmonics 8.5% ----current considering total load as 900 A Root mean ----square of VH % THD 298
8.7% -----
----3%
195
----2.7%
175
----2.3%
148
4.6%
Points to be considered: 1. 2. 3. 4. 5. 6. This Harmonics analysis was conducted on 30.10.1996 and that time available Power was 18 MW and all three Rectifiers remained ON. At Present, the available Power is 14 MW and BHEL Rectifier remains OFF. The ABB Rectifier load will be remains same. The MB Rectifier load is 350 Amp. When DG sets was running on 12 MW with load of Rectifier 11 MW, Harmonics with 6 MVAR capacitor ON Total Harmonics with 3% . Total Harmonics when all Rectifiers and Capacitors are ON is 3%(Avg), which constitutes: 3rd Harmonic 1% 5th Harmonic 2% 7th Harmonic 2% and whenever Capacitors rd OFF 3 Harmonics goes high to 10% and Total Harmonics goes to 10 ~ 11%. However, we have following arrangements to switch ON the standby Capacitors. 6 MVAR , 3 MVAR , 2 MVAR and 1 MVAR i.e. Total 12 MVAR Normally we keep ON 6 ~ 7 MVAR.
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ANNEX - 3.2 SPECIFICATION FOR TRANSDUCERS Sl. No. 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Description General Make Type Output Load resistance capability Accuracy Repeatability Linearity Residual ripple in Power frequency mA DC Ohms % % % % kV rms 1 min between V As per Annexure-3.5 Dual output 4-20 700 0.5% of full scale 0.1% of full scale 0.5% of full scale 5% maximum output current 2 kV rms for wires and cases 110 V DC voltage Unit Data
1.10 1.11
Auxiliary supply Overload capacity without loss in accuracy a) Continuous b) Short time
% -
120% of rated current 10 times rated current for 0.5 sec
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Sl. No. 2.0 2.1 3.0 3.1 4.0 4.1 5.0 5.1
Description
Unit
Data
Current transducers Nominal input/rated current Voltage transducer Nominal input /rated voltage Frequency transducer Nominal input/rated voltage Power transducers/power factor transducers Nominal input a. Rated voltage b. Rated current Volts Amps 110 V AC (3 phase PT supply) 1 Amps AC (3 phase CT supply) Volts 110/3 V AC Volts 110/3 V AC Amps 1 amp AC
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ANNEX - 3.3 LIST OF ANNUNCIATIONS A minimum list of annunciation is given under. annunciation as per his equipment requirement. a. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
The bidder may add any other
Trip Generator differential relay operated Over voltage relay operated (2nd stage) Voltage restrained O/C relay operated Negative phase sequence relay operated (2nd stage) Reverse power relay operated Field failure relay operated (with U/V) Field failure relay operated (without U/V) Generator under voltage relay operated Generator Under frequency relay operated (2nd stage) Generator lockout relay operated Turbine lockout relay operated Rotor earth fault relay operated (2nd stage) Stator E/F relay operated Generator winding temperature very high Generator bearing temp very high Low forward power relay operated Generator breaker auto trip. Emergency push button operated. Fire protection system actuated Stator E/F relay operated. Rate of change of frequency (df/dt) protection operated Overall different protection operated Local breaker back-up protection operated AVR fault trip Generator frame at 100C Inadvertent energization protection operated. 10% spare
26. 27.
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b. Alarm 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. Generator Under voltage 1st stage operated Over voltage relay operated Over load alarm relay operated Rotor earth fault relay (1st stage) operated Negative phase sequence relay operated (1st stage) Protection PT fuse failure Metering PT fuse failure Generator lockout relay circuit faulty Turbine lockout relay circuit faulty Under frequency relay operated (1st stage) (Generator) Generator winding temperature high Generator bearing temperature high Generator inlet air temperature high Generator outlet air temperature high AVR faulty Excitation limit reached Auto changeover to manual mode AVR auxiliary supply failed AVR DC supply fail AVR PT fuse fail. AVR V/F high Generator stator frame at 80C Generator protection relay power fail Generator protection relay soft-test fail Overall differential protection faulty AVR trip alarm Rotating diode open circuit Rotating diode short circuit 10% spare
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ANNEX - 3.4 APPROVED LIST OF SUB-VENDORS / MAKES RELAY & CONTROL PANEL NGR PT & SP CUBICLE RELAYS CONTROL SWITCHES SELECTOR SWITCHES PUSH BUTTONS INDICATING LAMPS CT/PT HRC FUSES CONTROL FUSES AUXILLARY CONTACTORS CONTACTORS TERMINAL BLOCKS MCB MOTORS CAPACITOR RECORDERS METERS TRANDUCERS ANNUNCIATOR : : : : : : : : : : : : : : : : : : : : : ABB / GECA NARKHEDE / PIONEER / BHEL / SWITCH CONTROL PANEL/ POWER GEAR ABB / SIEMENS / AREVA ABB / GECA / KAYCEE ABB / GECA / KAYCEE L&T / SIEMENS / TECKNIC ABB / GECA / L&T / SIEMENS / TECHNIC AE/KAPPA/ PRECISE /PRAYOG /ABB/ PRAGAT GECA / SIEMENS / L&T / S&S GECA SIEMENS / L&T / SCHNEIDER ELECTRIC SCHNEIDER ELECTRIC / SIEMENS / L&T ELMEX / CONNECTWELL / GECA SCHNEIDER ELECTRIC / MDS / SIEMENS/ HAVELLS / ANCHOR SIEMENS / CGL / KIRLOSKAR MADHAV / MANOHAR AE / DIGITAL AE / IMP / MECO ABB / SITU / AE / SIEMENS MINILEC/ BETA / IIC
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APPENDIX - 1.0 DETAILED TECHNICAL SPECIFICATION FOR MISCELLANEOUS ELECTRICAL ITEMS
CONTENT
APPENDIX NO.
DESCRIPTION
PAGE NO.
1.1 1.2 1.3 1.4 1.5 1.6
SPECIFICATION FOR A.C. MOTORS SPECIFICATION FOR MOTOR ACTUATORS SPECIFICATION FOR L.T. POWER & CONTROL CABLES SPECIFICATION FOR EARTHING & LIGHTNING PROTECTION SPECIFICATION FOR LOCAL SWITCHBOARDS SPECIFICATION FOR GENERATOR BUSDUCT
35 40 42 43 44 48
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APPENDIX-1.1 SPECIFICATION FOR A.C. MOTORS 1.0.0 1.1.1 1.1.2 GENERAL All AC motors shall be general purpose, constant speed, squirrel cage three phase/single phase induction motors. All motors shall conform to the latest edition of applicable IS, IEC and CBIP standards/Publications except when otherwise stated herein or in the driven equipment specification. All motors shall have class 2 efficiency. OPERATING CONDITIONS The reference ambient temperature for the motors shall be taken as 50C. All motors shall be rated for continuous duty. They shall also be suitable for long period of inactivity. The motor nameplate rating shall have at least 15% margin over the input power requirement of the driven equipment at rated point. The motor characteristics shall match the requirements of the drive equipment so that adequate starting, accelerating, pull up, breakdown and full load torques are available for the intended service. Motors below 200 watts, except otherwise required for reversible service, shall be rated for use on a 240 V, Single phase, 50 Hz, resistance grounded system. Motors above 200 Watts, upto 160 kW shall be rated for use on a 415V, 3 phase, 50 Hz solidly grounded system, Motors 160 kW and above shall be rated for use on a 11000 V, 3 phase, 50 Hz. resistance grounded system. Motor shall be designed for direct on line starting at full voltage. Motors shall run continuously at rated output with the following variations in voltage and frequency: Voltage Frequency Combined voltage and Frequency (Absolute sum) 2.1.8
1.1.3 2.0.0 2.1.1 2.1.2 2.1.3 2.1.4
2.1.5
2.1.6 2.1.7
10% 5% 10%
The motor shall be capable of operating satisfactorily at full load for 5 minutes without injurious heating with 75% rated voltage at motor terminals.
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3.0.0 3.1.1
PERFORMANCE Starting current shall not exceed 6 times full load current for all auxiliaries including tolerance. The motor shall be capable of withstanding the stresses imposed if started at 110% rated voltage. Motor shall start with rated load and accelerate to full speed with 80% rated voltage at motor terminals. Motor shall be capable of three equally spread starts per hour, two starts in quick succession from cold condition and one restart from hot condition. Motors subject to reverse rotation shall be designed to withstand the stresses encountered when starting with non-energised shaft rotating at 125% rated speed in reverse direction. Locked Rotor Withstand Time The locked rotor withstand time under hot condition at 110% rated voltage shall be more than motor starting time by at least 2.5 seconds for motors with 20 secs. starting time and by 5 secs. for motor with more than 20 secs. starting time. Starting time shall be at the minimum permissible voltage of 80% rated voltage. If the above conditions cannot be met in unavoidable cases, special provisions such as motor shaft speed switch, etc. shall be provided subject to the approval of the Owner/Consultant. Hot thermal withstand curve shall have a margin of at least 10% over the full load current of the motor to permit relay setting utilising motor rated capacity. CONSTRUCTIONAL DETAILS Enclosure All motor enclosures shall conform to the degree of protection IP-55. outdoor or semi-outdoor service shall be of weather-proof construction. Motor for
3.1.2
3.2.0 3.2.1
3.2.2
3.2.3 4.0.0 4.1.0 4.1.1 4.1.2 4.1.3 4.2.0 4.2.1
For hazardous areas, approved type of flameproof and increased safety enclosure shall be furnished. Motors weighing 25 kg or more shall be provided with eye bolt or other adequate provision of lifting. Winding and Insulation All insulated winding shall be of copper. 6600 V AND 415 V motors shall have classF insulation but limited to Class -B temperature rise. Windings shall be impregnated to make them non-hydroscopic and oil resistant. The motors shall generally be of self-ventilated type totally enclosed fan-cooled (TEFC). The windings, fittings and hardware shall be corrosion resistant. The windings shall be tropicalized and suitably varnished, baked and treated with epoxy gel for operating satisfactorily in humid and corrosive atmosphere.
4.2.2
4.2.3
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4.3.0 4.3.1
Bearings Motor shall be provided with antifriction bearings, unless sleeve bearings are required by the motor application. Vertical shaft motors shall be provided with thrust and guide bearings. Thrust bearing of tilting pad type (Mitchel or Kingsbury) are preferred. Bearings shall be provided with seals to prevent leakage of lubricant or entrance of foreign matters like dirt, water etc. into the bearing area. Sleeve bearings shall be split type, ring oiled with permanently aligned, close running shaft sleeves. Grease lubricated bearings shall be prelubricated and shall have provisions for in-service positive lubrication with drains to guard against over lubrication. Oiled bearing shall have an integral self cooled oil reservoir with oil ring inspection ports, oil sight glass with oil level marked for standstill and running conditions and oil fill and drain plugs. Forced lubricated or water cooled bearing shall not be used without prior approval of Owner. Lubricant shall not deteriorate under all service conditions. The lubricants shall be limited to normally available types with IOC or equivalent make. Bearings shall be insulated as required to prevent shaft current and resultant bearing damage. Motor Terminal Box Motor terminal boxes shall be detachable type and located in accordance with Indian standards clearing the motor base plate/foundations. Terminal box shall be capable of being turned 360 degree in steps of 90 degree, unless otherwise approved. The terminal boxes shall be split type with removable cover with access to connections and shall have the same degree of protection as motor. The terminal box shall have sufficient space inside for termination / connection of XLPE insulated, armoured aluminium cables as applicable. Terminals shall be stud type, substantially constructed and thoroughly insulated from the frame. The terminals shall be clearly identified by phase markings, with corresponding direction of rotation marked on the non-driving end of the motor. The terminal box shall be capable of withstanding maximum system fault current for a duration of 0.25 sec. For HT motor, the terminal box shall be phase segregated type and neutral leads shall be brought out in a separate terminal box (not necessarily phase segregated type) with shorting links for star connection. Motor terminal box shall be furnished with double compression type brass cable glands.
4.3.2 4.3.3
4.3.4 4.3.5 4.4.0 4.4.1 4.4.2
4.4.3 4.4.4
4.4.5
4.4.6
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4.5.0 4.5.1 4.5.2 4.5.3
Earthing Terminals The frame of each motor shall be provided with two separate and distinct grounding pads complete with tapped hole, GI bolts and washer. The grounding connection shall be suitable for accommodation of ground conductors as follows: HT Motors, LT motors above 90 kW : 2-1C x 150 sq.mm, PVC insulated, unarmoured AL cables or 50x 6 mm GI Flat Motors above 30 kW upto 90 kW Motor above 5 kW upto 30 kW : 2-1 C x 50 sq.mm, PVC insulated, unarmoured AL cables or 35 x 6 mm GI Flat : 1 C x 35 sq.mm, PVC insulated, unarmoured AL cables or 25 x 6 mm GI Flat : 1 C x 10 sq.mm, PVC insulated, unarmoured AL cables or 8 SWG GI wire
Motor upto 5 kW 4.5.4 5.0.0 5.1.0 5.1.1
The cable terminal box shall have a separate grounding pad. ACCESSORIES Space Heater Motors of rating 30 kW and above shall be provided with space heaters, suitably located for easy removal or replacement. The space heater shall be rated for 240 V, single phase, 50 Hz, and sized to maintain the motor internal temperature above dew point when the motor is idle. Temperature Detectors All HT motors above 160 kW shall be provided with six(6) winding temperature detectors, two (2) per phase and the motor bearing shall be provided with duplex type temperature detectors. These temperature detectors shall be resistance type, 3 wire, platinum wound, 100 Ohms at 00C. Indicator/Switch Dial type local indicator with alarm contacts shall be provided for the following : i) ii) HT motor - bearing temperature. Hot and cold air temperatures of the closed air circuit for motors.
5.2.0 5.2.1
5.3.0 5.3.1
5.3.2
Flow switches shall be provided for monitoring oil flow of forced lubrication bearings, if used. Alarm switch contact rating shall be minimum 0.5 A at 220 V D.C. and 5A at 240 V A.C.
5.3.3
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5.4.0 5.4.1 5.4.2
Accessory Terminal Box All accessory equipment such as space heater temperature detector, etc., shall be wired to and terminated in terminal boxes, separate from motor (power) terminal box. Accessory terminal box shall be complete with stud type terminals. If possible, the accessory terminal boxes shall be located on the same side of the motor as the main (power) terminal box. Drain Plug Motors shall have drain plugs so located that they will drain the water, resulting from the condensation or other causes from all pockets of the motor casing. Dowel Pins The motor shall be designed to permit easy access for drilling holes through motor feet or mounting flange for installation of dowel pins after assembling the motor and driven equipment. Noise & Vibration The noise level shall not exceed 85db (A) at 1.5 m from the motor. amplitude of the vibration shall be within I.S. specified limits. Rating Plate All rating plates shall be of stainless steel. In addition to the minimum information required by IS/IEC, the following information shall be shown on motor rating plate: a) b) c) d) Temperature rise in deg. C, under rated condition and method of measurement. Degree of protection. Bearing identification no. and recommended lubricant. Location of insulated bearings. The peak
5.5.0 5.5.1 5.6.0 5.6.1
5.7.0 5.7.1 5.8.0 5.8.1 5.8.2
6.0.0
PAINTING Motor including fan shall be painted with corrosion proof epoxy paint.
7.0.0
TESTS Upon completion, each motor shall be subject to standard routine tests as per I.S. In addition, any special test required for the driven equipment shall be performed.
2630720001-STG-S3-R0
AVD / ELEC
24-09-2007
APPENDIX-1.2 SPECIFICATION FOR MOTOR ACTUATORS 1.0.0 1.1.1 REQUIREMENTS FOR ACTUATOR The actuators shall be rated so as to open/close the valve within 25 to 45 seconds unless otherwise noted. Actuator shall be designed for 33% excess torque over valve design torque even at 10% under voltage and 5% under frequency. The actuators shall essentially comprise the drive motor, torque/limit switches, gear train, clutch, hand wheel, position indicator/transmitter, space heater, internal wiring and junction box. The actuator enclosure shall be IP 65 type. The actuator shall be designed for mounting in any position without any lubricant leakage or operating difficulty. The electric supply for operation and control requirements for the actuators shall be as follows : 1.1.6 LT incomer supply : (415 10%) V AC, (50 5%) Hz, 3 Phase. General : Any other voltage required shall be generated by vendor.
1.1.2
1.1.3 1.1.4 1.1.5
Each actuator shall be provided with the following limit switches : Two torque limit switches - one for each direction of travel, self locking adjustable torque type. Two position limit switches, adjustable type - one for each end position. One position feedback transmittal (4-20mA) 24V DC 2-wire type (only inching type)
1.1.7
Actuator shall be located in the field. The terminal box shall be weather-proof IP-65 type with removable front cover and have provision for 1 No. 3/4 inch ET gland and 3 Nos. 1/2 inch NPT cable gland entry. An internally powered space heater shall be included in the limit switch compartment. All electrical devices shall be wired upto and terminated in the terminal box. The internal wiring shall be sufficient size for the power rating involved but in no case less than 2.5 sq.mm copper and minimum Class F type insulation. Actuator with non-integral starter shall be provided. The following limit switch contacts shall be provided: 1. 2. 3. Torque switch - open / close Limit switch - open / close Position feed-back transmitter 4-20 mA, 24V DC, 2-wire type (only inching type).
1.1.8 1.1.9
1.1.10
2630720001-STG-S3-R0
AVD / ELEC
24-09-2007
1.1.11 1.1.12 2.0.0
All actuators shall be provided with position indicator. All actuators shall be provided with local mechanical indication of ON/OFF status of valve. TESTS Upon completion, each motor actuator shall be subject to standard routine tests as per I.S. In addition, any special test required for the driven equipment shall be performed.
2630720001-STG-S3-R0
AVD / ELEC
24-09-2007
APPENDIX-1.3 SPECIFICATION FOR L.T. POWER & CONTROL CABLES 1.0.0 1.1.0 2.0.0 2.1.0 2.1.1 2.1.2 CODES & STANDARDS All LT power and control cables shall conform to the latest edition of applicable IS. TECHNICAL REQUIREMENTS L.T. Power Cables The L.T. power cables shall be designed for use in 415 V 10%, 3-phase, 50 Hz 5% solidly grounded system. The L.T. power cables shall be 1100 volt grade, 90 0C rating, heavy duty power cables with stranded aluminium/copper conductors, XLPE insulated, extruded PVC inner sheathed, galvanised steel round wire/flat strip armoured and extruded PVC outer sheathed. Control Cables The control cables shall be designed for 240 V 10%, 1 Phase, 50 Hz 5% and 110 V AC unearthed system. The control cables shall be 1100 V grade, 70C rating with annealed copper conductor having high conductivity, PVC insulated, cores laid up, extruded PVC inner sheath, single round/flat galvanised steel wire armoured and extruded PVC outer sheath. TESTING Testing on the L.T power and control cables shall be done as per IS and requisite number of test certificates shall be furnished.
2.2.0 2.2.1 2.2.2
3.0.0 3.1.0
2630720001-STG-S3-R0
AVD / ELEC
24-09-2007
APPENDIX-1.4 SPECIFICATION FOR EARTHING & LIGHTNING PROTECTION 1.0.0 1.1.1 1.1.2 2.0.0 2.1.0 GENERAL Underground earthing grid / earthing pits will be provided by the purchaser along with necessary pig tails for above ground connection. Earthing & Lightning protection system shall conform to the latest edition of applicable IS. SPECIFIC REQUIREMENT FOR EARTHING All equipment under scope of tender shall be grounded, at two points to the nearest pig tail of the plant underground earthing grid. The earthing conductor for the different motors/panels shall have the following sizes : H.T. motors LT motors above 90 kW : : 75x10 /12 GI flat *2-1Cx150 sq.mm or 50 x 6 mm GI flat *2-1Cx50 sq.mm, or 35 x 6 mm GI flat *1Cx35sq.mm or 25 x 6 mm GI flat *1Cx10sq.mm or 8 SWG GI wire
2.1.1 2.1.2 2.1.2 2.1.3 2.1.4
LT motors above 30 kW upto 90 kW, local panels etc. : LT motors above 5 kW upto 30 kW LT motors upto 5 kW misc. devices etc. ( * PVC Insulated unarmoured AL Cables ) : :
3.0.0 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5

SPECIFIC REQUIREMENT FOR LIGHTNING PROTECTION All metallic tanks, vessels and structures shall be provided with adequate lightning protection. Spikes of adequate size shall be provided at the highest point of the metallic structure / tank / vessel. A shield angle of 30 degree shall be considered for lightning protection of mechanical equipment. Every down conductor shall be provided with a test joint at about 1500 mm above ground level and connected to an individual earth pit provided by the Purchaser. Down conductors shall be cleated / welded / brazed along the equipment at an interval of 750 mm. All welded / brazed joints shall be coated with anti corrosive paint for rust protection.
3.1.6
2630720001-STG-S3-R0
AVD / ELEC
24-09-2007
APPENDIX-1.5 SPECIFICATION FOR LOCAL SWITCH BOARDS 1.0.0 1.1.0 1.1.1 1.1.2 BASIC TECHNICAL REQUIREMENT General The Local Switchboard shall be used to provide power, control, indication for the 415V drives for the package system under the scope of contractor. The switchboards shall be suitable for 415V +10%, 3 phase, 4 wire, 50 Hz +5% supply with neutral solidly grounded. The bus bars shall have a short time rating of 50 kA (rms) for 1 second. The equipment shall be kept in a hot, humid and tropical atmosphere and shall be made dust and vermin proof. The switchboard / panels shall conform to the latest edition of applicable IS. Construction The equipment shall be self standing, compartmentalised, or wall mounted type made of 2mm thick CRCA steel sheet. The switchboard shall be fixed type. The enclosures shall conform to IPW 55 protection for outdoor panels and IP 52 for indoor panels. The operating height of the equipment shall be limited to a maximum of 1800 mm and a minimum of 300 mm. Terminal blocks shall be provided at convenient location for cable terminations. A main horizontal aluminium grounding bus, rated to carry maximum fault current, extending along the entire length of the switchgear shall be provided. The ground bus shall be provided with two-bolt drilling with GI bolts and nuts at each end to receive the main earthing grid. Switch Fuse Units The switches shall be triple-pole, air-break, group-operated units capable of making and breaking the full load current of the load to which it is connected. Compartment doors shall be interlocked with operating handle to prevent opening of the door when the switch is closed. However, necessary interlocks for defeating the above interlock shall also be provided. Each switchfuse feeder shall be provided with removable type neutral link. Combined type fuse- switch of double break design may be offered wherever practicable. The fuses shall be of HRC link type with the minimum breaking capacity corresponding to the required short circuit level. The fuses shall be supplied complete with fuse base and fittings.
AVD / ELEC 24-09-2007
1.1.3 1.1.4 1.2.0. 1.2.1 1.2.2 1.2.3 1.2.4 1.2.5
1.3.0 1.3.1 1.3.2
1.3.3
1.3.4 1.3.5
2630720001-STG-S3-R0
1.4.0 1.4.1
Contactors The main motor contactors shall be DOL type, air break triple pole for AC. They shall be single throw double break, non-gravity type with non- bouncing silver/silver alloy contacts. The auxiliary contacts shall be rated for minimum 10 Amps at 240 V AC. The control supply shall be derived from the incoming feeder live. The short time rating of contactors shall be co-ordinated with the fuse preceding it. The ratings of switch, fuses & fuse switches, contactors and the cable sizes shall be as given below. Motor Rating (kW) Continuos current rating of switch (Amps) Fuse Rating (Amps) Continuos current rating of contactors (Amps) 9 to 16 Cable size / conductor material 3Cx2.5mm2 Cu to 3Cx10mm2 AL *
1.4.2 1.4.3
Upto 5.5 Kw
32
7.5 - 15 kW
63
About 3 times the full load current of each motor - do -
25 to 40
3Cx6 mm2 AL to 3Cx25 mm2 AL * 3Cx50mm2 AL and 3Cx70mm2 upto 30 kW, 3Cx95mm2 AL for 45 kW 3Cx120mm2 AL ( Min size ) 3Cx185mm2 AL to 3Cx240mm2 AL
18.5 - 45 kW
125 (fuse switch) - do -
50 to 95
55 kW 75 - 90 kW
250 (fuse switch) 250 (fuse switch)
- do - do -
140 170
Note : * Actual Cable size shall depend upon the cable route length. Combination of switch fuse unit ,contactor and over load relay shall be as per Type-2 co-ordination. 1.5.0 1.5.1 Thermal Overload Relay These relays shall be three element, ambient temperature compensated, timer lagged, bimetal thermal overload relays. Each overload relay shall be provided with a built in single phasing preventor. The relays shall be manually reset type with one (1) change over contact. These shall be generally adjustable from 60% to 120% of rated current. These shall not mal-operate during starting of motor. Thermal over load relays rated for 15A and above shall be CT operated and these CTs shall be built-in within the relay.
AVD / ELEC 24-09-2007
1.5.2
2630720001-STG-S3-R0
1.6.0 1.6.1 1.6.2 1.6.3 1.6.4 1.6.5 1.6.6 1.7.0 1.7.1 1.7.2
Indicating & Measuring Instruments Voltmeter with selector switch shall be provided for all incomers Ammeter shall be provided in all phases for all incomers Ammeter shall be provided for all outgoing feeders rated 15 kW and above. Dual output transducers shall be provided for V, I & p.f measurements. kW meter shall be provided for incomers Instrument shall be of Accuracy class 1.5. Cabling and Wiring The switchboard incoming and outgoing power cables shall be XLPE insulated & sheathed, armoured aluminium cables. The control wiring shall be complete in all respect so as to ensure proper function of control, protection and interlocking scheme. The control wiring shall be done with 650 V grade, PVC, switchboard wires of minimum 2.5 mm2 tinned stranded copper conductors. Local Control Stations / Push button stations The local control stations shall be supplied completely wired-up upto a terminal block located inside as per P.B. station scheme as approved by consultant. Suitable size nickel-plated brass cable gland shall also be supplied along with each local control station. The local control stations shall be of metal enclosed and of dust, vermin and weather proof construction, suitable for mounting on column / wall or on a steel pedestal support near to its drive equipment. For this purpose, necessary fixing arrangements, GI bolts, nuts, washers etc. steel supports wherever required shall also be supplied & erected by the contractor. All push buttons shall have 2 No +2 NC contacts rated 10 A and 240 V AC continuously. The start push buttons shall be spring return to normal type. The stop push buttons shall also be spring return type with a mechanical latch to hold it in the stayput condition (i.e., OFF condition) with pad locking provision. the push buttons / selector switches shall be provided with inscription plates showing its function. The push buttons shall be red in colour for stop and green in colour for start function. The push buttons shall be housed in a cast aluminium (LM 6) enclosure conforming to the degree of protection IP 55. The enclosure shall be provided with a cover / hinged door for opening and inspection. Outdoor mounted local push button stations shall be provided with sheet canopy. Metal parts shall be given tropicalising treatment as per standards and painted with one coat of epoxy primer and two coats of light grey epoxy paint.
2.0.0 2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2630720001-STG-S3-R0
AVD / ELEC
24-09-2007
2.1.6 2.1.7 2.1.8 2.1.9
The push button station shall be provided with two earthing terminals suitable for 8 SWG GI wire. The push button station shall be provided with removable undrilled gland plate and cable glands for 2 Nos. 7C x 2.5 mm2 Cu, PVC Armoured cables. Cable entry to the control stations shall be from bottom and weatherproof glands shall be provided for termination of the cables. The cables shall be terminated on a separate terminal block and not directly on the push buttons or ammeter. 20% spare terminals shall be provided in each local control station. The contacts of the push button shall be wired to a terminal board. The internal wiring shall be of 1100 / 650 V grade PVC insulated copper conductor of at least 2.5 mm2. Generally, the ammeter shall be of moving coil type with 2400C scale in 96 mm2 size having accuracy class of 1.5. The ammeters shall be suitable for 5A secondary current of CT. When specified, moving iron type ammeters shall be provided in the local control stations. These shall be suitable for operation with CTs having 5A secondary rated current. The ammeters shall be provided with suppressed scale to read the motor starting current and a red mark to indicate the full load current of the motor. The full load current of each motor will be furnished to the successful Contractor during detail engineering stage. Flame proof push stations and accessories specified also meet all the above specified requirements and shall fully conform to the latest applicable IS: 2148 and other applicable Indian Standards of Codes for flame proof electrical equipments. The flame proof P.B. station enclosure shall be of cast iron with IP-55 protection. The flame proof control stations shall be provided flame proof cable glands. The P.B. stations shall confirm to flame proof enclosure type d suitable for explosion group- IIA and temperature class T3.
2.1.10
2.1.11
2.1.12
3.0.0 3.1.0
TESTS Each equipment shall be routine tested in accordance with the rules and regulations laid down by the Indian Standards. Only type tested components shall be used in the fabrication /assembly of the switchgear. DRAWINGS, DATA AND INSTRUCTION MANUALS Relevant drawings, data and instruction manuals shall be provided by the contractor.
4.0.0 4.1.0
2630720001-STG-S3-R0
AVD / ELEC
24-09-2007
APPENDIX-1.6 SPECIFICATION FOR GENERATOR BUSDUCT 1.0.0 Generator Line side & Neutral side busduct The busduct shall comply with the latest edition of the following & other relevant Indian Standards & ANSI Standard : IS 8084 IS 2544 IS 2099 IS 2705 IS 3156 1.1.0 1.1.1 1.1.2 : : : : : Interconnecting busbars for AC voltages above 1kV upto & including 36 kV. Porcelain post insulators for voltages above 1000V. Bushings for alternating voltages above 1000 V. Current Transformer Potential Transformer
TECHNICAL REQUIREMENTS Busduct The 11 kV generator busduct shall be of copper, will serve as an interconnection between generator and 11 kV STG switchgear, in line with requirements specified in Annexe-3.1. Bus duct shall be metal enclosed, phase segregated type and natural air cooled. All the phases of busduct shall be enclosed in a waterproof, weatherproof, dust tight & vermin proof enclosure having IP-55 degree of protection. The enclosure shall be fabricated with aluminium alloy of adequate thickness. Suitable openings shall be provided for inspection and access to support insulators, bus joints, switchgear terminals etc. Individual phases shall be separated from each other by barriers of insulating material such as FRP or approved material. Busbars shall be of high conductivity copper in forms of straight extruded length with largest possible lengths and minimum interconnections, rigidly supported vertically on porcelain insulators. The joints made at the factory shall be of brazed type, whereas those to be made at site shall be of bolted type. The section of bus conductor used shall be double channel. Bus sections shall be capable of withstanding electro-mechanical and thermal stresses due to short circuit current specified without any damage or deterioration of the materials. Flexible connections shall be provided between the bus sections to allow for expansion and contraction of the conductor and enclosure. Flexible connections shall also be provided at all equipment/ panel terminations. All contact surfaces shall shall have efficient and trouble free connection.
AVD / ELEC 24-09-2007
1.1.3
1.1.4
1.1.5 1.1.6
1.1.7
1.1.8
1.1.9
2630720001-STG-S3-R0
1.1.10
For bolted rigid/expansion joints, jointing component, Belleville / flat washers, high tensile steel bolts and nuts (cadmium plated) and other hardwares with proper instructions for making the joints at site shall be furnished. The contact surface of copper shall be adequately protected against atmospheric corrosion. The bidder shall also provide rain hood or canopy, over the outdoor run of the busduct to prevent ingress of water through gasketed joints. The design & constructions of the bus duct shall be such as to limit the temperature rise above the ambient temperature of 500C within the following values considering the maximum continuous rated current and short circuit conditions. a) b) c) Hot spot temperature of bus conductor for rated current. Hot spot temperature of bus enclosure for rated current for rated current. Hot spot temperature of bus conductor for short circuit currents. : : : 40C for main conductors 40C for bolted joints (plain or tinned) 20C 150C
1.1.11 1.1.12 1.1.13
1.1.14
Each busduct shall be provided with a stainless steel rating plate indicating the manufacturers name, serial no., purchasers tag no., rated voltage, frequency, continuous and short time current and no. of phases. Calculations for determining sizes of conductors and enclosure, spacing of insulators, heat loss and temperature rise and also short circuit force withstand capability shall be furnished. The necessary derating factors shall be considered in sizing the busbars. All formulae and other information from which heat losses have been derived shall be furnished. Connection to 11kV Switchgear & NGR Busduct shall be suitable for connections with flanged enclosure of switchgear & to the NGR. Flexible connection shall be furnished by the bidder, which shall provide flexibility for both the conductor and the enclosure. All necessary connectors and accessories shall be furnished by the bidder for connecting bus conductor to busbar terminals. Wall Frame Assembly and Seal-off Bushing Suitable wall frame assembly with seal-off bushing shall be furnished for the busduct at locations where the busduct passes through building wall. The seal shall be such as to prevent interchange of air between either side of busduct portions. Flexible connectors shall be provided on both sides of wall bushings. The wall frame shall be fabricated out of aluminium angles and sheet suitable for grouting in the wall. It shall be provided with flanges on both sides to receive the busduct flanges.
1.1.15
1.2.0 1.2.1
1.3.0 1.2.1
2630720001-STG-S3-R0
AVD / ELEC
24-09-2007
1.2.2
All seal-off bushings shall be dry non-hygroscopic, porcelain/epoxy type. All plates, anchors and hard-wares, as may be required for fixing the frame, shall be furnished. The bushing shall withstand the maximum short circuit forces under short-circuit conditions. Breather and Drain Cock Silica gel breather shall be provided on both sides of wall seal-off bushings to release strain on gasket seals. Drain cock for drainage of water shall be provided at the lowest points and at such locations where accumulation of water can be expected. Grounding A continuous run of two GI ground bus of size as per specified design data (Annexure 3.1) shall be provided running along the entire length of busducts, solidly grounding all parts of the supporting structures and each enclosure section. Space Heaters Space heaters shall be provided in the busduct at suitable locations, with thermostatic control, to prevent condensation of moisture inside the enclosure when the busbars are not carrying any current. Terminals of all space heaters shall be rated for 240 V, 50 Hz, single phase AC supply. Painting All equipment except for supporting steel structures, which shall be hot dipped galvanized shall be finished with two (2) under coats of high quality epoxy based primer followed by two coats of epoxy painting. The interior surface of busduct enclosure shall be treated with black matt paint. The shade of exterior surface finish shall be light grey, shade RAL 7032. Pre-treatment consisting of degreasing, de-rusting etc., shall be done on all fabricated parts before painting or galvanizing. Sufficient quantities of all paints and preservation required for touching up at site shall be furnished. Layout and Support Structures The bus duct layout & length shown in drawings / specified design data are tentative. The actual bus duct layout / length will be finaslised at the time of detailed engineering. Price adjustments will be made for length and accessories based on unit rate quoted. Necessary bus duct support foundation / insert plate details & requirement shall be furnished by the contractor. All civil foundation etc. shall be provided by purchaser. All GI steel support structure shall be in contractors scope.
1.4.0 1.4.1 1.4.2 1.5.0 1.5.1
1.6.0 1.6.1
1.6.2 1.7.0 1.7.1
1.7.2 1.7.3 1.7.4
1.8.0 1.8.1
1.8.2 1.8.3
2630720001-STG-S3-R0
AVD / ELEC
24-09-2007
The details of supporting structure including all supporting members, brackets, hangers, beams, channels, nuts, bolts, insulating pads, washers and all other hardware which are necessary for the erection and support of the entire bus duct, shall be furnished by the contractor. 2.0.0 2.1.1 2.2.0 2.2.1 TESTS All routine and acceptance tests shall be carried out on all the equipment and components as per relevant IEC and IS standards. Routine Tests The following routine tests shall be conducted on the bus assembly as per relevant IS/IEC. The test assembly shall include bolted and flexible connections, accessories etc. a. b. c. d. 2.2.3 2.3.0 2.3.1 Visual inspection and verification of dimensions. One (1) minute dry power frequency voltage withstand test on all equipment. Millivolt drop tests of joints Water and air tightness test.
Routine tests on all equipment and materials such as current transformers, potential transformers, insulator, bushing etc. shall be done as specified in relevant Standards. Type Tests Type test certificates for the following tests conducted earlier on a similar section of the bus assembly shall be furnished for approval of Purchaser. a. b. c. Temperature rise test. Short Circuit test. IP 55 enclosure protection test.
2.3.3
In case above type tests have not been conducted earlier, the same shall have to be conducted by the Tenderer on a typical section of the bus duct at no extra cost to the purchaser.
2630720001-STG-S3-R0
AVD / ELEC
24-09-2007

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FICHTNER Consulting Engineers ( India ) Private Limited Subject HJI Prop.

DETAILED TECHNICAL SPECIFICATION - ELECTRICAL

FORMT9-P REV-B (MUM)

SECTION - 3.0 DETAILED TECHNICAL SPECIFICATION - ELECTRICAL

CLAUSE NO. 3.1.0 3.2.0 3.3.0

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

d. Rated current. e. Rated output. f. Power factor.

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

Generator Droop characteristics.

3.1.17 3.2.0 3.2.1

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

Sl. No. 1.1.18 1.1.19 1.1.20

Data B Synthetic resin

Requirement for parallel with grid

Current harmonics Voltage distortion

8.5% 4.6% at 11kV

HARMONICS ANALYSIS DETAILS

FORMT9-P REV-B (MUM)

IH 3 5 7 11 13 Root mean square of IH 30 56 34 22 15 ____ 76.8

VH 54 169 144 149 120 -----

VH 54 46 28 145 105 -----

IH 33 14 37 3 2 ____ 51.6 5.7%

IH 8 14 33 3 1 ____ 36.9 4.1%

FORMT9-P REV-B (MUM)

120% of rated current 10 times rated current for 0.5 sec

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

The bidder may add any other

FORMT9-P REV-B (MUM)

FORMT9-P REV-B (MUM)

APPENDIX - 1.0 DETAILED TECHNICAL SPECIFICATION FOR MISCELLANEOUS ELECTRICAL ITEMS

1.1 1.2 1.3 1.4 1.5 1.6

FORMT9-P REV-B (MUM)

1.1.3 2.0.0 2.1.1 2.1.2 2.1.3 2.1.4

3.2.3 4.0.0 4.1.0 4.1.1 4.1.2 4.1.3 4.2.0 4.2.1

4.3.4 4.3.5 4.4.0 4.4.1 4.4.2

4.5.0 4.5.1 4.5.2 4.5.3

Motor upto 5 kW 4.5.4 5.0.0 5.1.0 5.1.1

5.4.0 5.4.1 5.4.2

5.5.0 5.5.1 5.6.0 5.6.1

5.7.0 5.7.1 5.8.0 5.8.1 5.8.2

FORMT9-P REV-B (MUM)

1.1.3 1.1.4 1.1.5

1.1.11 1.1.12 2.0.0

FORMT9-P REV-B (MUM)

2.2.0 2.2.1 2.2.2