Beruflich Dokumente
Kultur Dokumente
Scope: This section of the specification cover the following scope of works: i) Dismantling/removing of existing four (4) No.s Butterfly type Turbine Main
Inlet Valves (MIV), and four (4) No.s sluice gates, all services, labour, tools
and tackles required for dismantling including carriage, stacking at Owners
store/ yard.
ii)Design, engineering, manufacture, shop assembly & testing before dispatch,
packing and forwarding, transportation, insurance, handling, delivery, storage
at site, erection, testing & commissioning of four (4) Nos. Butterfly type
Turbine Main Inlet Valves and four (4) No.s sluice valves, as detailed in this
specification and handing over to HPSEB LTD. complete with accessories,
equipment, devices, piping, instruments, cabling and wiring etc. including all
services, labour, tools and tackles.
1.2
Standards: The turbine main inlet valve to be supplied shall conform to the provision
contained in the latest edition of IS 7326 (Part 1, 2 & 3):1992 and other
relevant IEC and IS standards in all respect.
1. 3
Basic Parameters: The following basic parameters and other pertinent data shall apply to the
turbine inlet valve systems:
1.4
Type of valve
Butterfly
Valve diameter
Elevation of valve centreline
Design discharge
0.856 cumecs
Net head
79 m
Max. pressure
12 Kg/cm2
Penstock diameter
700 mm (internal)
supported on the concrete pedestal and secured by anchor bolts. The valve
body and operating mechanism shall be designed for installation and removal
from above by means of the powerhouse crane. The valve shall open through
oil operated hydraulic servomotor by means of a high-pressure oil system and
shall be capable of closing through counterweight under most adverse
conditions.
The oil servomotor shall be so designed that when the valve opens, the
counterweight should lift up and on reaching at the end position of travel, a
proximity switch shall trigger giving a signal to trigger the motor. The oil thus
trapped in the cylinder keeps the piston extended and the valve remains open
with counterweight raised.
The cylinder piston seal shall be dynamic type and may cause some leakage,
which may cause the counterweight to creep down over a period of time. This
will un-trigger proximity switch and start the pump to push back the
counterweight and keep the valve fully open.
The normal closure and emergency closure shall be initiated by operation of
the solenoid poppet valve. The pressure created by the counterweight acting
on all the trapped oil shall be transferred to the pilot operated check valve,
which opens and lets out the trapped oil back to the tank. The valve shall
close down due to the action of the counterweight. Means shall be provided to
control the valve closing speed by controlling the flow of oil back to the tank
via pressure and temperature compensated flow control valve.
1.5
Operating Conditions
1.5.1
Design
The operating mechanism shall be of sufficient capacity to close the valve in
not more than 60 seconds against the discharge and head conditions
indicated below. The opening time shall be approximately equal to the closing
time. The closing and opening time shall be adjustable between 45 and 120
seconds with positive means for locking these adjustments. The minimum
permissible closing time shall be controlled by a fixed orifice installed directly
at the servomotor outlet as to prevent fast closure of the valve in case of oil
piping failure. The valve should be capable of closing under most adverse
conditions at maximum flow.
The design pressure shall be 12 kg/cm2
1.5.2
Normal operation
The butterfly valve and its operating mechanism, extension pipes, coupling,
and related bypass system, sealing and drain system shall withstand safely
the maximum stresses from the following operating conditions, with stresses
in the materials not exceeding the maximum allowable stress for normal
operation specified in clause- 4.3 of Vol.- 2A.
1.
Continuous operation with valve in the open position passing the rated
discharge of the turbine of 0.856 cumecs under the rated operating
net head on the turbine of 79 m and a discharge of 0.96 cumecs while
running at 10% overload.
1.5.3
2.
3.
Emergency closing
The valve and its operating mechanism, extensions, by-pass system, seal,
drain and air release valves and couplings shall withstand the maximum
stresses from closing under a flow corresponding to the discharge of the
turbine of .856 cumecs.
1.6
Valve Body
1.6.1
General
The valve body shall be in two pieces, made of welded plate steel, or of cast
steel, or a combination of both, bolted together by hydraulically or thermally
pre-stressed bolts. It shall be of rigid construction and adequately ribbed as
necessary to minimize distortion under full load and maximum pressure and
designed to transmit the hydraulic thrust to the upstream valve body
extension and penstock. The trunnion bearing housings and the flanges for
the bypass line shall be integral with the valve body and supported by it. The
valve body shall be provided with flanges for bolted connections to similar
flanges on the valve body extensions. The valve body shall be machined only
after it has been subjected to a stress-relieving heat treatment.
1.6.2
Foundation
Foundation details shall match the existing valve foundations. This is a
replacement job as such new foundation shall not be casted. Contractor shall
collect the necessary details from the power house site. It shall be the
responsibility of contractor for accuracy of foundation detail measurements.
1.6.3
Permissible Leakage
Maximum permissible leakage from the main valve should not exceed
2litre/min/metre periphery of seal when valve is new.
1.7
1.7.1
General
The butterfly valve shall be furnished with two valve body extensions, one for
the inlet side of the valve and another for the outlet side. A sleeve type
coupling (not transmitting any axial loads) shall be provided for connecting the
outlet extension pipe to the turbine spiral case. The extensions shall be of
plate steel construction, designed for a hydraulic pressure of 12 kg/cm 2. All
necessary nuts, bolts and gaskets for the flanged connection between the
valve body and the extensions shall be furnished by the contractor. No special
supports will be provided for the extensions. Their weight, including contained
water shall be carried through the flanged joints to the valve body.
1.7.2
Upstream Connection
The valve body inlet extension pipe which shall be of conical shape shall be
provided with bolting flanges at one end for connection to the valve body.
Bolts, nuts, and gasket for connecting the inlet extension to the valve body
shall be included in the supply. The connections of the extension pipe to the
existing penstock shall be of welded type. The contractor shall cut, chamfer
and weld together the end of the penstock and the valve extension pipe
including all necessary NDT or heat treatment.
1.7.3
Tolerance on Dimensions
The extension pipes shall be sufficiently true to round so that the difference
between maximum and minimum diameters, with temporary bracing in place,
measured inside or outside, at any cross section along the length shall not
exceed one per cent of nominal diameter for that section. The ends shall be
within a tolerance of plus or minus 1.0 mm of the plane normal to the axis of
the extension. The length of complete extensions shall conform to the limiting
dimensions. The tolerances listed are exclusive of any allowance for
shrinkage or distortion.
1.7.4
Bypass Connection
Pipe connections shall be provided in the inlet and outlet extensions for the
by-pass valve, and for a duplex pressure gauge and differential pressure
switch.
1.7.5
Downstream Connection
An extension pipe with a sleeve type coupling of an approved type shall be
furnished to connect the valve to the spiral inlet pipe. The coupling shall allow
the valve to be displaced along the penstock axis due to hydraulic forces and
thermal expansion/contraction to facilitate erection and dismantling of the
extension pipe to allow for any small differences in distributor extension
length. The extension pipe shall be complete with all necessary steel flanges,
seals or gaskets and coupling bolts.
The surfaces of the coupling in contact with the seal and the seal groove shall
be fitted with stainless steel plate.
1.8
1.8.1
Valve Disc
The valve disc shall be made of cast steel or of welded plate steel or a
combination of both, ruggedly designed and heavily ribbed internally to
sustain full differential pressure across the closed valve disc with minimum
deflection. The disc shall be of the open-frame through flow type and shall be
shaped and finished to minimize flow disturbances. The disc shall be
accurately machined at its rim and provided with corrosion-resisting metal on
its periphery to protect it against corrosion and abrasion.
1.8.2
Valve Trunnion
The valve trunnion shall be of forged steel and shall extend into the valve disc
and shall be securely and rigidly attached to it. The outside ends of the
4
trunnion shall be carried by the bearings in the valve body. The trunnion and
seal areas shall be provided with renewable, stainless steel sleeves or
suitable corrosion resistant coatings. Seal shall be provided at the outside
ends of the trunnion to minimize leakage. The trunnion seals shall be
designed and constructed for dependability, long life, and convenient
replacement.
1.8.3
1.9
Main Bearings
1.9.1
General
The main bearings shall be of the sleeve type, supported integrally within the
valve body. The bearings shall be designed and constructed so that all
necessary adjustments may be made from outside the bearing housings. The
sleeve bearings shall be of corrosion resisting material and shall be designed
so that deflection and trunnion slope caused by the water load on the disc in
the closed position will not result in binding between the trunnion and sleeves.
The bearing shall be built into the valve body and shall transmit the loads to
body.
1.9.2
Bearing Type
The contractor shall determine from his own experience the most suitable
bearing design. The contractor shall submit his design to the Engineer-incharge for approval.
1.9.3
Lubrication
The disc trunnion bearing and all other points on the valve or operating
mechanism requiring lubrication shall be provided with self lubricating
bearing.
1.10
1.10.1
General
A by-pass line of not less than 50 mm nominal pipe size shall be provided and
shall be complete with hydraulically operated valve and necessary electrical
controls, hand gear operated guard valve on upstream side of by-pass valve and
piping, designed for a pressure of 12 kg/cm 2. The opening and closing of the
valve shall be controlled by hydraulic pressure from the pumping unit.
The needle type by-pass valves shall be of cast or forged steel with wearing
parts of corrosion resisting material.
"Open", "intermediate", "close", Proximity limit switches, each with two
electrically independent contacts, shall be provided as required to accomplish
the specified control and alarm functions. The by- pass line will be used for
filling the turbine spiral casing and equalizing the pressure on the inlet valve
disc before opening the valve.
1.10.2
Pressure Gauge
A duplex pressure gauge and differential pressure switch for showing the
difference between the water pressure upstream and downstream of the
valve disc shall be provided. The pressure switch shall be provided with
potential free contacts to accomplish the specified control and alarm
functions.
1.10.3
Piping
The by-pass piping shall be of seamless steel pipe with steel flanged
connections, the necessary bolts nuts and gaskets shall be furnished by the
contractor.
1.11
Valves
1.11.1
Air Valve
One automatic spring loaded float type air valve complete with necessary
bolts and gaskets shall be furnished for installation on top of the downstream
extension pipe. The size of the valve shall be as required to exhaust the air
trapped in the spiral case when the butterfly valve by-pass is opened for filling
the spiral case and to admit air when the butterfly valve is closed and the
spiral case in being drained. The air valve shall be designed to prevent any
water spray during its operation.
1.11.2
1.11.3
Sluice Valves :Four (4) No.s manually operated sluice valves operated by geared
mechanism shall be provided with main inlet valve package, so that the
maintenance on MIV, if any, required could be carried out easily. The gate
shall be suitable for operating under hydraulic parameters specified for main
inlet valves. The test pressures shall be same as indicated for main inlet
valve. Sluice valves shall have identical foundations and other details as
those of existing ones. Bidder shall collect the necessary details from the
power house site before bidding.
1.12
Set of Sundry Items: Comprising of foundation bolts, sole plate, lifting brackets etc.
6
1.13
Counter Weight
The counter weight shall be sized to provide net closing torque on the valve
disc under most adverse operating conditions and shall be of fabricated steel.
1.14
Operating Mechanism
The operating mechanism shall include suitable stops to limit the disc travel at
the fully opened and fully closed positions, and a manually operated locking
mechanism for holding the disc in the closed position. The lock shall be
capable of withstanding the full operating force of the operating mechanism.
Parts with sliding contact shall be self-lubricating bushings and corrosion
resistant shafts with surface finish and coating as required by the bushing
manufacturer.
A mechanical position-indicating device shall be provided on the operating
mechanism to indicate the position of the valve disc.
1.15
Control Devices
The operating mechanism shall be provided with at least the following control
facilities to accomplish the specified alarm, indication and interlocking
functions.
Oil pressure switch for sensing the operating mechanism oil pressure.
All the switches required shall be provided with at least two potential free
contacts.
1.16
Control System: The Inlet valve control system shall include all the sensory and operating
devices necessary to fulfil the functional requirement of the specification and
is to be provided by the bidder.
1.17
Oil and Water Piping: Oil piping shall be seamless, stainless steel pipes and shall include all piping
to the oil pressure supply system consisting of sump tank, pressure tank,
servomotor, actuator cabinet instrumentation etc. as required. The piping shall
be of such size that the maximum oil velocity shall not exceed 3.0 m/sec in
the pressure lines and 1.5 m/sec in the return lines. Minimum pressure
anywhere in the oil piping system during maximum speed of valve operation
shall not be less than 0.5 bars absolute. All oil piping shall be thoroughly
cleaned, oiled inside, and protected for shipment with flange protectors on all
flanges, screwed caps on threaded end and suitable plugs in plain ends.
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Water piping shall be made of heavy seamless stainless steel pipe and shall
be flanged.
1.18
1.18.1
Spares
Mandatory Spares : The below listed spare parts which comprise the total required for all turbine
inlet valves under this contract shall be supplied. The prices for the following
mandatory spare parts shall be stated separately in the offer. A set is defined
as the total number required for one butterfly valve.
1
2.
3.
4.
5.
6.
7.
8.
9.
1.18.2
1 Set.
1 Set
2 Sets.
1 Set.
1 Set.
1 Set.
2 Sets.
1Set
2 Sets.
2 Sets.
Recommended Spares : An itemized list of additional spare parts, including prices, which the
contractor recommends shall be included in the Bid. In preparing this list, the
contractor shall give due consideration to the time delay involved if it were
necessary to obtain spare parts due to failure of a critical valve component.
The purchase of any or all of the additional spare parts recommended shall
be at the discretion of the Owner.
1.19
Maintenance Equipment The following tools and miscellaneous erection and maintenance equipment
and devices shall be furnished which shall be included in the price for the
main inlet valves.
One complete set of case hardened wrenches for all sizes of nuts and
bolts used in inlet valve, suitably mounted and identified.
One or more lifting lugs or hanger pins and slings for attaching the
assembled valve to the powerhouse crane.
Any special tools and equipment or devices that may be required or
which may be useful for the most expeditious assembling or
dismantling of any part of the valves.
A complete list of special tools and equipment to be supplied with the butterfly
valves shall be submitted.
1.20
1.20.1
The butterfly valve with extensions, by-pass valve and piping, operating
mechanism controls, locks and indicators shall be completely assembled in
the contractor's shop to assure satisfactory fit, and the assembly shall be
match-marked and doweled, where required, to assure correct re-assembly
and alignment in the field.
1.20.2.1
Shop Tests: -
1.20.2.2
General The completely assembled butterfly valve and by-pass valve with operating
mechanism and control mechanism shall be given an operating test, pressure
test and leakage test.
1.20.2.3
Operating Test: The completely assembled valve shall be operated through several opening
and closing cycles to demonstrate satisfactory operation.
1.20.2.4
Pressure Tests: With both ends of the valve extensions closed by means of test heads and
with the rotor disc in slightly open position, the valve body and by-pass
system shall be subjected to a hydrostatic test pressure of 18 kg/cm 2 to
determine the soundness of the valve body and whether or not there are any
leaks. The pressure in the valve body shall be maintained for at least 30
minutes. Upon completion of the leakage test specified below, the pressure
on the upstream side of the valve disc (in closed position) shall be kept at
hydrostatic test pressure of 18 kg/cm2 for not less than 30 minutes with zero
pressure on the downstream side and the downstream cover removed, to
determine the soundness of the valve disc.
1.20.2.5
Leakage Tests: Leakage tests shall be performed on the valve seal under a hydrostatic
pressure of 12 kg/cm2 for not less 30 minutes. The leakage at this pressure
shall be measured.
1.20.2.6
Witnessing of Shop Assembly and Tests: The shop assembly and tests shall be witnessed by the Engineer-in-charge or
his representative as per the requirements of approved inspection and quality
assurance document.
1.21
Installation: The contractor shall assemble (if required), erect, place and level the valve
body servomotor and control system on the existing foundation. The
contractor shall install interconnecting piping between equipment including
support and hangers. All rust preventive compounds shall be removed, and
any rust that may have formed on the parts shall be carefully removed. The
oil piping shall be thoroughly cleaned and flushed before the oil is placed in
the system. Extensions shall be fitted and welded. Flanged extensions and
erection joint, and all welds shall be radio graphically examined. The bidder
has to do all the works related to erection, testing and commissioning of
butterfly valves complete in all respects. Supply of all types of consumables
9
1.22
and other materials required for erection including welding electrodes etc.
shall be in the scope of the bidder.
Field Testing: The contractor shall furnish a complete outline of the proposed methods and
procedures to be followed for the main inlet valve field assembly, erection,
testing, including a list of equipment and instruments to be used, to the
Owner's Representative for review at least 60 days before the scheduled, first
valve testing.
All testing equipment and instruments shall be furnished by the contractor and
will remain the Contractor's property after the fulfilment of all field tests.
The contractor shall furnish a complete report of the field tests of the
equipment.
The tests at site should at least include the following:
Pressure test of all field installed piping for oil and air at 1.5 times the
maximum working pressure.
Leakage test of all field piping with pressurized air and soap solution.
The bidder shall provide all necessary material and labour for performing all
the above tests.
1.23
Civil Engineering Works :Civil Engineering works related to addition and alteration of foundations of
Main Inlet Valve shall be in the scope of contractor. Contractor shall quote the
prices inclusive of civil works. Contractor shall be liable for correct
assessment of civil works before bidding. No deviation of civil works shall be
allowed after price bid is opened.
10
SECTION - II
REPLACEMENT OF TURBINE RUNNERS
2.1
Scope: This section of the specification cover the following scope of works: i) Dismantling/removing of existing four (4) No.s runners of Francis type
Turbine, all services, labour, tools and tackles required for dismantling
including carriage, stacking at Owners store/ yard.
ii)Design, engineering, manufacture, shop assembly & testing before dispatch,
packing and forwarding, transportation, insurance, handling, delivery, storage
at site, erection, testing & commissioning of four (4) Nos. runners of Francis
type Turbine as detailed in this specification and handing over to HPSEB LTD.
complete with runner templates. including all services, labour, tools and
tackles.
2.2
Technical requirements: The runner shall be made of cast stainless steel having a material
composition of 13% chromium and 4% nickel. The contractor shall assure that
a higher degree of quality finish and control is maintained during the
manufacture of the runner, including bar test specimens, non-destructive flow
detecting inspection, stress relieving of the casting and balancing. All surfaces
of the runner shall be finished smooth without any humps or hollows,
depressions, cracks and projections.
The contours of the runner blades shall be accurate and shall be finished, so
that the blade profile precisely conforms to the model design within the
tolerance set out in IEC Publication-193. The blades shall be evenly and
symmetrically spaced. Before shipment/despatch, manufacturer shall check
the hydraulic surfaces with templates and submit proof that the finished
runner contours and shape meet with the tested model and the design
requirement. Templates for guidance in restoring blade shapes to original
contour shall be supplied with runners.
The runner shall be designed to safely withstand the stresses due to
operation at runaway speed under condition of maximum head with no load
on generator and any position of the wicket gates. Special attention shall be
paid to reduce stress concentration at the fillet of the blade outlet edge with
the band and crown.
Replaceable stainless steel labyrinth seal shall be fixed to the runner on both
ends with the help of stainless steel fasteners to reduce the leakage.
The runner shall be statically and dynamically balanced at the works and shall
be designed and constructed to withstand safely the stresses developed due
to operation at runaway speed under conditions of maximum head including
pressure rise due to water hammer.
The runner shall be attached to the generator/turbine shaft through bolts with
nuts and locking devices. The coupling bolt holes in the runner shall be line
11
reamed with the runner and shaft assembled. The connection shall be
designed for tightening and holding from the above as required for
incremental assembly. The equipment required for the assembly and
disassembly of the runner shall be included in the offer.
Runner inspection and quality control shall be according to CCH-70-2.
Acceptance criteria shall be in accordance with these specifications and shall
be subject to approval by owner's representative.
2.3
Performance Requirements: Bidder shall quote with the understanding that supply of runner is a part of the
complete renovation job including the overhauling of turbine. Bidder may have
to do reverse engineering wherever required. Accordingly efficiencies are to
be quoted for complete turbine including runner.
Guarantees for Unit Output, Efficiency & Penalties for Shortfall
The bidders shall offer runners having the specified rating and highest
feasible efficiencies in the permissible range of operation. The bidder on the
bidding stage shall supply supporting documents for the prescribed
guarantees by means of displaying results from earlier model tests of the
runner which conforms as much as possible to the one now being offered.
The output and efficiencies shall be guaranteed under penalty as given below.
The turbine Output & Efficiency shall be guaranteed by the bidder in
respect of the following:
Output at minimum net head of 79 m shall not be less than 530 kW.
60
Penalties and Rejection Limit for Shortfall in overall Output and overall
Weighted Average Efficiency of unit :
Field acceptance test as per IEC code shall be carried out to
determine the actual output and the efficiencies of the unit at various points of
operation of the unit.
Penalties to be levied for any shortfall in the tested values of rated unit
output and of the weighted overall average efficiency of unit vis--vis the
guaranteed values respectively shall be computed as follows:
a)
Output
Rs. 8000
(Rs. eight thousand
for each unit)
Rs. 8,000
(Rs. Eight thousand
for each unit.)
13
SECTION-III
REPLACEMENT OF GOVERNING SYSTEM AND TURBINE CONTROL PANEL
3.2.1
Scope
This section of the specification cover the following scope of works: i) Dismantling/removing of existing four (4) No.s mechanical governors, Turbine
Auxiliary Control Panels, associated sensing/feedback instruments, all
services, labour, tools and tackles required for dismantling including carriage,
stacking at Owners store/ yard.
ii)Design, engineering, manufacture, shop assembly & testing before dispatch,
packing and forwarding, transportation, insurance, handling, delivery, storage
at site, erection, testing & commissioning of four (4) Nos. Digital governors,
Turbine Auxiliary Control Panels, associated sensing/feedback instruments as
detailed in this specification and handing over to HPSEB LTD. complete with
accessories, equipment, devices, piping, instruments, cabling and wiring etc.
including all services, labour, tools and tackles.
3.2.2
General
Governor for each unit shall be supplied and shall be of the digital
programmable electronic type. Governor module shall be mounted in Turbine
Auxiliary Control Panel. All equipment shall be suitable for continuous duty
and interchangeable between the units. All control functions of generating unit
shall be implemented from the Turbine Auxiliary Control Panel. A touch screen
in addition to control switches and push buttons shall be provided on each
TACP for unit control. Any equipment/hardware not mentioned, but required
for unit control shall also be provided.
Each governor shall be complete with speed sensing elements, restoring
mechanism, pressure system, oil piping, shut down and speed-no-load
solenoids, oil pressure level failure relays, gate position switches, speed
switches, automatic brake valve and all parts & accessories required to
constitute a completely automatic assembly for regulating the speed and
controlling the gates of the turbine with which it is to be used.
It is in the scope of these specifications that the governor shall be
complete with all necessary devices for completely automatic and remote
control, synchronising, and supervisory load frequency control and shut down.
Remote control shall be from the control room of the power house.
The normal pressure for operation of the pumps, pressure tank and
servomotors of the turbine shall be 40 to 90 kg/cm 2 .The speed sensing
element shall be capable of causing the actuator relay valve to pass oil in the
direction to effect corrective movement of the turbine wicket gate in
consequence of a speed variation of less than 1/100th of 1 percent.
All actuators and control assemblies shall be enclosed in a metal cabinet of
rigid construction and neat appearance, which shall be dust proof and
properly ventilated. All gauges, indicating and control devices shall be
mounted on the front panels of the actuator cabinet in a symmetrical and
convenient manner and shall present a pleasing appearance in size shape
and arrangement. Inspection doors shall be provided on all exposed sides
14
and on the top for access to the actuator equipment and these doors shall be
fitted with locking arrangement, handles and latches. Instruments within the
cabinet shall be readily accessible for adjustment and maintenance through
the inspection doors.
Layout of governor actuator cabinet and pump set equipment shall meet the
approval of Engineer-in-charge.
3.2.3
Capacity of Governor:
The rating of the governor shall not be less than the capacity of the
servomotors for operation of the turbine wicket gates. The governor shall be
capable of supplying sufficient oil to the servomotors to operate the turbine
gates to give an effective time from a complete closing or opening stroke for
the range of operating times with a minimum oil pressure under the maximum
net head on the turbine. The oil velocity in the pipes shall not exceed 3m/sec.
The governor oil pressure system shall be designed for the extreme case of
closing, opening and final closing of the wicket gates with both oil pumps and
compressed air admission valve inoperative.
3.2.4
Sensitivity speed
b)
c)
d)
e)
f)
g)
h)
Adjustable, 20 to 60 sec.
The turbine wicket gate closing time shall be specified. For the closing
operation a dual rate of closure has been considered to be required to restrict
transient speed rise of the turbine to within reasonable limit. The governors
shall therefore provide a dual rate of closure for the wicket gates, faster in the
first half of the closing period and slower in the second half. The governor
15
closing and opening time has the dual rates of closure & shall be adjustable
within the specified range.
3.2.5
Provisions in Governors.
1. The digital governor shall have provisions for setting/adjusting and
indication display of the set values of various governor
characteristics/parameters with the help of the keyboard viz.
a) Permanent speed droop.
b) Temporary speed droop.
c) Temporary speed droop decay time constant.
d) Sensitivity.
e) Frequency dead band
f) Speed regulation.
g) Power regulation.
h) Opening limitation.
i) Speed set point.
j) Output set point.
k) Monitoring and supervision of speed, power and position feed back
signals.
l) Other essential devices for smooth operation, protection and safety of the
units.
2. It shall also have other essential provisions and devices as protective
devices for locking out on failure of the regulator, for transfer to emergency
manual control on UCB.
3. The hydraulic actuator units shall have various devices, control indications
as given below: a) Two nos. remotely controlled from control room shut down devices for
normal and emergency closure of wicket gates. For emergency closure,
two solenoid-operated valves shall be fed from two independent 110V dc
sources.
b) Independent emergency solenoid valve which operates in emergencies
and catastrophic condition and send the pressurised oil directly to the
wicket gate servomotors bypassing the governor.
c) Manual control devices acting directly on the actuator hydraulic system
allowing opening and closing of wicket gates to any position. The actuator
of valve shall have provision for manual operation also.
d) Wicket gate maximum opening limiting device remotely operatable.
16
e) Wicket gate position and gate limit transmitters for remote indication.
f) Direct indication of gate limit and position on actuator units.
g) Other essential devices not specified but required for smooth operation,
protection and safety of the units.
4) Rong Tong Power station is located in remote area and nearest grid
(22 Kv) is available at 220 Km away. Most of the time power station
shall run in isolated mode (Speed control mode). Governor shall be
capable of operating under such conditions in isolated mode.
Necessary hard ware and software provisions to this effect shall be
made in governor.
3.2.6.
3.2.7
3.2.8
3.2.9
Other Provisions:
The speed governor shall be provided with the following provisions:
a) Facility of data communication i.e. exchanging information through serial
communication link.
b) Provision for data exchange with automatic systems or the power station
for remote indication logic information & remote control etc. if there are
17
any data exchange that can not be realised through the serial
communication link.
3.2.10
3.2.11
3.2.12
3.2.13
Tachometer
The following controls shall be provided on the front face of the actuator
cabinet:
Unit start.
Unit excite.
Unit spinning.
Unit synchronised/paralleled.
Unit loaded.
Auto/manual indication.
MIV open.
MIV closed.
MIV in transit
19
Brake 'Off'.
Brake 'ON'.
wicket gates at any time by action of the gate limit or the shut down
solenoids. The automatic shut down protection shall be maintained during
actuator lock.
3.2.15
Electronic Section:
The electronic cards shall be housed in the actuator cabinet and shall be
accessible from the front of the cabinet after opening the cabinet door.
The governor shall be Proportional, Integral and Derivative (PID) type. The
following adjustment range shall be provided:
Integral gain
0 - 10 second
Proportional gain
0 - 20
Derivative gain
0 - 2 second
Speed Switches:
A mechanical over-speed switch shall be provided on the turbine-generator
shaft to operate automatically as the unit speed rises slightly above the
maximum speed rise allowed on full load rejection and shall trigger directly an
emergency shut down valve in the hydraulic pressure circuit. The operation of
the switch shall bypass all the electrical signals and action of other protective
devices and give command to close the wicket gates. An auxiliary contact
switch on the governor cubicle shall be provided to annunciate operation of
the mechanical over speed switch.
The electronic speed switch shall be provided and mounted on the electronic
cabinet of governor for following functions:
(a) Over-speed Protection:
i)
ii)
iii)
b)
Brake Control:
The generator brake shall be arranged to activate at 20% of the rated
speed and the wicket gates are closed when unit CB is open.
d)
Forced lubrication;
To cause forced lubrication of thrust bearing from zero speed to
predetermined speed and vice-versa.
e)
Zero Speed:
The necessary set of contacts shall be provided and wired upto the
terminal block of governor cubicle to indicate unit stopped and creep
indication. The creep indication is to be provided by the supplier.
3.2.18
3.2.19
the sump or accumulator. Necessary oil strainer shall be fitted in the suction
line of each pump.
The motor pump unit shall be fitted on the sump tank and control switches/
indicating lamps shall be mounted on the front panel of actuator. The motor
shall conform to IEC standard, with class 'F' insulation and having low starting
current.
The automatic pressure operated controls shall be provided to start and stop
the pumps when the pressure rises or drops to pre-determined points.
The two main oil pumps shall be arranged with echelon controls to be
operated either independently or together with one pump used for normal
operation and the other arranged to start with a drop in oil pressure. Manual
control switch shall be provided to select one of the two pumps as the lead
pump. An alarm shall be provided to indicate continuous running of the lag
pump over on adjustable period of time. All valves and mechanisms shall be
accurately set and tested in the shop before delivery.
Each governor pump shall be provided with an adjustable temperature switch
with two electrically separate contacts suitable for operation at 110 V dc.
located in the pump suction side for governor oil high temperature alarm.
3.2.20
Pressure Tank:
A pressure accumulator tank of steel plate welded construction shall be
provided for each governor in accordance with the requirement of the relevant
International Code for Pressure Vessels. The size of the tank shall be such
that it shall be possible to operate the wicket gates and MIV 3 times (2
'C'+1'O') without re-charging the pressure accumulator. The pressure tank
shall be pressure tested in the shop in accordance to the requirement of
relevant standards.
The necessary pressure gauge, sight gauges, manual shutoff and ball check
valve and safety relief valve shall be provided on the pressure tank.
The pressure tank shall be provided with nitrogen piston/bladder accumulator
of suitable capacity. The manufacturer shall supply all necessary piping,
fittings, solenoid controlled valves, pressure and level switches required for
this system. The solenoid shall be suitable for operation at 110 V dc and
completely wired.
An adequate sized manhole with suitable oil resistant gasket shall be
provided. The tank shall be painted on both sides.
In addition to pressure switches required for echelon control the following
pressure switches shall be provided and connected to each pressure tank.
All contacts shall be adjustable, electrically separated and suitable for 110 V
dc operation.
All pressure and level switches shall be provided with individual shut off
valves and bleed valves as necessary.
3.2.21
Sump Tank:
The governor system shall be supplied with a sump tank of sufficient capacity
to hold at least 10 percent more than the total quantity of oil in the entire
governor system. The sump tank shall be provided with a manhole,
connection for venting and overflow. Suitable connection for oil purifier,
draining and filling shall be provided. A vertical filter screen shall be arranged
to divide the sump tank into 'clean' and 'dirty' oil compartments. All the
strainers shall be readily removable for cleaning. Low and high level switches
and oil temperature switch shall be provided on the oil sump tank.
3.2.22
3.2.23
Spares
The following spares which comprise the total required for all the four
governors under this contract shall be furnished. The price for the spare parts
shall be stated separately in the Bid. A set is defined as the total number
required for one governing system.
A. GOVERNOR
1.
1set
2.
4nos.
3.
1no.
4.
1set
5.
1set
6.
1set
1No.
2.
1No.
3.
Motor bearings
1set
4.
1No.
5.
Un-loader valve
1No.
26
6.
1No.
7.
1No.
8.
1No.
9.
Pressure relay
1No.
10.
1No.
1set
2.
1set
3.
1set
4.
1set
5.
1set
6.
1set
7.
1set
8.
1set
9.
2sets
The Bidder shall include with his bid an itemised list and prices of all of
additional spare parts he recommends to be purchased. Purchase of any or
all of the additional recommended spare parts shall be at the option of the
owner.
3.2.24
Maintenance Requirement.
One complete set of special tools, which may be necessary for convenient
assembly and dismantling of governors shall be furnished. The tools shall be
furnished in a suitable toolbox, or on a suitable wall mounted panel stamped
for identification and intended use.
3.2.25
3.2.25.1
General:
The governor and auxiliary equipment shall be completely assembled in the
manufacturer/bidder's shop and tested, in so far as practicable. The pressure
tanks and piping shall be shop hydrostatic pressure tested at a pressure 1.5
time the maximum allowable working pressure. Before painting, the sump
tank shall be tested for leakage by compressed air and a soap solution or
other approved means.
3.2.25.2
Operational Tests:
27
4.2.25.4
3.2.26
Installation:
The bidder shall place, level and fasten the governor equipment on the
concrete foundation. Interconnecting piping between various equipment, such
as between the actuator, oil pressure unit, and servomotors and restoring
mechanisms between the governors and servomotors, including supports and
hangers, shall be supplied and installed by the bidder. All rust preventive
compounds shall be removed from the equipment before initial operation, and
any rust which may have formed on the parts shall be carefully removed. The
oil piping, oil sump tank and pressure tank shall be thoroughly cleaned and
flushed before governor oil is placed in the system. The bidder has to do all
work related to erection, testing and commissioning of governor complete in
all respect. Supply of all consumable and other material required for
installation etc. shall be in the scope of bidder.
3.2.27
Field testing
The bidder shall furnish a complete outline of the proposed method and field
procedures to be followed for the turbine and governor tests, including a list of
equipment and instruments to be used, to the Engineer-in charge for review
not later than 60 days prior to the date on which the first turbine and governor
is to be ready for testing.
All necessary materials and labour for performing all the above tests shall be
provided by the bidder.
All test equipment and instruments, shall be furnished by the bidder and will
remain the bidder's property after the fulfilment of all field tests.
28
Tightness tests on all pressure oil piping in connection with the turbine
equipment
Pressure tests on all pressure oil piping (in connection with the
governor equipment) and all pressure piping system shall be
hydrostatic tested at a pressure 1.5 times than the maximum
operating pressure after installation.
Start-up, load rejection and load acceptance tests including speed and
power regulation test.
The tests shall be co-ordinated with the test for turbine, butterfly valve,
generator and other equipment.
Turbine speed
Servomotors stroke
The tests shall be carried out in accordance with IEC publications and the contractor
shall furnish a complete report of the field tests of the equipment.
29
SECTION-IV
OVERHAULING / REPAIR OF GENERATOR, TURBINE, TURBINE SHAFT,
BEARINGS AND REPLACEMENT OF BEARING SLEEVES
4.1
Scope
i)
ii)
iii)
4.2
i)
No. of turbines
4 (four)
ii)
Type of turbine
iii)
Setting
iv)
Turbine output
750 HP
v)
vi)
Net head
Rated speed
79 meters
1000 rpm
vii)
Runaway speed
1700 rpm
viii)
Specific speed
116.3 rpm
30
4.2.1
ix)
Runner Diameter
414 mm
x)
BF valve diameter
500 mm
xi)
414 mm
Spiral Casings:Spiral casing is cast fabricated with integral stay ring. The joints of spiral
casing with butterfly valve outlet pipe and draft tube bend pipe are leaking.
The outer and inner surfaces of the casing are severely corroded.
4.2.2
Guide Apparatus:Guide apparatus consists of turbine cover, lower ring, twelve guide vanes with
upper/lower bushes, levers, links and regulating ring. Guide vanes of all the
machines have been repaired a number of times resulting in change in their
original profile and other dimensions. It is observed that the guide vanes do
not close properly and openings between consecutive guide vanes are not
uniform. This leads to non uniform flow of water, reduced efficiency and
increased vibrations of the machines.
4.3
4.3.1
After overhauling/ repair as described in section 4.1 each turbine shall be able
to give, at rated net head of 79 m, rated output not less than 530 kW at rated
speed of 1000 rpm. Capacity test shall form the basis of successful
completion.
4.4
Performance Requirements of generators :After overhauling/ repair as described in section 4.1 each generator shall be
able to generate, rated output not less than 500 kW at rated frequency of 50
Hz. Capacity test shall form the basis of successful completion. Any
modification required to make compatible AVR with existing generator shall
also be carried out by contractor under this contract.
4.5
Bearing Sleeves
4.5.1
Scope: -
4.5.2
Technical requirements :Bearing sleeves shall have identical metallurgical properties as that of original
and should be capable of safe operation at all loads and operating conditions.
Details of the existing bearing sleeves shall be collected by contractor from
the site.
Bidders shall visit the site and assess the repair / overhauling
requirements of each machines and quote accordingly. No
deviation over the quoted overhauling / repair scope shall be
allowed at later stage.
31
SECTION-V
OIL LUBRICATING SYSTEM AND COOLING WATER SYSTEM
5.1
Scope
This section of the specification cover the following scope of works: i)
ii)
5.2
Dismantling/removing of existing four (4) No.s oil lubrication system and four
(4) No.s cooling water system of francis type Turbine all services, labour,
tools and tackles required for dismantling including carriage, stacking at
Owners store/ yard.
Design, engineering, manufacture, shop assembly & testing before dispatch,
packing and forwarding, transportation, insurance, handling, delivery, storage
at site, erection, testing & commissioning of four (4) Nos. oil lubrication
system and four (4) No.s cooling water system of francis type Turbine as
detailed in this specification and handing over to HPSEB LTD. complete with
accessories, equipment, devices, piping, instruments, cabling and wiring etc.
including all services, labour, tools and tackles.
Grease / oil lubricating system
Each turbine shall be provided with an automatic grease/oil lubricating system
complete with grease/ oil reservoir two motor operated grease / oil pumps
with motors, starters, switches, timers, pipes and fitting for lubricating all
points. One motor pump set shall operate on AC power supply and other
motor pump by DC power supply.
The system shall supply measured quantities of grease/ oil as often required
to all bearing surfaces of levers, links, rods, wicket gate stems and all other
parts to be lubricated. Different timing devices shall be used for fixing the
different periods required for points requiring frequent lubrication such as
wicket gate stems and points requiring in-frequent lubrication.
Indicators shall be provided at all greasing points to indicate that the
lubrication is being received.
A pressure switch shall be provided to shut down the system in case of any
block in the lubrication system resulting in high pressure. An alarm contact
shall be provided for giving alarm in case of system failure.
The grease reservoir shall have a capacity to store grease for 240 hours of
operation. An electrically operated transfer pump shall also be supplied for
transferring grease from barrels to the reservoir.
Suitable provisions shall be made at all greasing points to receive grease by
manual application. A portable grease pump shall be supplied for the station,
All material such as pipes, fittings, supports etc. which are necessary for
making the system complete in all respect shall be provided.
32
5.3
The control panel with control indication, starting buttons, fault indicator and
necessary contact for the PLC control shall be provided. The panel shall be of
wall mounted.
Cooling water system
The maximum temperature of the inlet water at site is 20 0C. The turbine
supplier shall design and supply the complete cooling water system catering
to the requirements of the entire turbine guide bearing, turbine seal and
generator bearings. Cooling water shall be tapped off from the penstock
through necessary pressure reducers/diffusers etc.
The system for each unit shall be complete with isolating valves, manual/self
cleaning type strainer, flow measuring device, pressure gauges, piping and
fittings. Self cleaning strainer, and associated items shall meet the cooling
water requirement of each unit .
Strainers shall be fitted with pressure switches to give alarm in case the
pressure differential across inlet outlet exceeds a preset value. Pressure
gauges shall also be provided to indicate water pressure at its inlet and outlet.
33
SECTION-VI
REPLACEMENT OF MANUAL VOLTAGE REGULATORS WITH AUTOMATIC
VOLTAGE REGULATORS
6.1
Scope: This section of the specification cover the following scope of works: i) Dismantling/removing of existing four (4) No.s manually controlled voltage
regulators, all services, labour, tools and tackles required for dismantling
including carriage, stacking at Owners store/ yard.
ii)Design, engineering, manufacture, shop assembly & testing before dispatch,
packing and forwarding, transportation, insurance, handling, delivery, storage
at site, erection, testing & commissioning of four (4) Nos. digital type
automatic voltage regulators as detailed in this specification and handing over
to HPSEB LTD. complete with accessories, equipment, devices, instruments,
cabling and wiring etc. including all services, labour, tools and tackles.
6.2
34
35
SECTION-VII
REPLACEMENT OF 30V, 400 AH BATTERY, BATTERY CHARGER AND
DCDB WITH 110 V, 200 AH BATTERY, BATTERY CHARGER AND DCDB
7.1
Scope
This section of the specification cover the following scope of works: i) Dismantling / removing of existing battery charger, battery bank and DCDB all
services, labour, tools and tackles required for dismantling including carriage,
stacking at Owners store/ yard.
ii)Design, engineering, manufacture, shop assembly & testing before dispatch,
packing and forwarding, transportation, insurance, handling, delivery, storage
at site, erection, testing & commissioning of battery bank, battery charger and
DCDB as detailed in this specification and handing over to HPSEB LTD.
complete with accessories, equipment, devices, instruments, cabling and
wiring etc. including all services, labour, tools and tackles.
7.2
7.3
7.4
Standards: -
7.4.1
The equipment covered under this specification shall comply with the
requirements of latest editions of the following Indian Standards as amended
to date except where specified otherwise: IS : 1146
Rubber and plastic containers for lead acid batteries.
IS : 1652
Stationary cells and batteries lead acid type with Plante
positive plates.
IS : 266
Sulfuric acid.
IS : 8320
General requirement and method of tests for lead acid storage
batteries.
IS : 8320
General requirements and method of tests for lead acid
storage batteries.
IS : 6071
Synthetic separators for lead acid batteries.
IS : 3116
Sealing compound for lead acid batteries.
7.4.2
7.5
7.5.1
Type: 36
7.5.2
7.5.3
7.5.4
7.5.5
7.5.6
7.5.7
7.6
7.6.1
7.6.2
The Plante positive plates shall be of the pure lead lamelle type with plante
formation. The negative plates shall be of pasted construction and assembly
shall consist of sturdy lead alloy grid filled with active material. The
construction shall be used to ensure good mechanical retention of the active
material and maximum electrical conductivity throughout, the life of the cell.
Capacity: The capacity of each cell will be based on 10 hours discharge rate for an end
voltage of 1.85 volts at 270C. The nominal voltage will be 2 volts. Voltage of
each cell after complete discharge should not fall below 1.85 volts. The
overall voltage across the load during float as well as boost charging shall not
be more than 110% of the nominal voltage i.e. 110V.
Number of cells: The battery consists of a total of 55 cells. The Tenderer shall give the
optimum rate of charge for float charging the battery. The battery shall be
operated alongwith two rates charger.
Cell Terminals : All cell terminals shall have adequate current carrying capacity and shall be of
lead alloy or lead alloy reinforced with copper core insets. Cell terminal posts
shall be supplied with acid resistant connectors, bolts and nuts.
Containers: The containers for cell shall be of transparent plastic. They shall have a neat
finish and shall be free from leaks. The surface of container shall have a finish
substantially free from blisters, rough spots, scales, blowholes and other
imperfections or deformations. Electrolyte level lines shall be marked on all
four sides of each container.
Electrolyte: The electrolyte shall be battery grade sulphuric acid. The battery shall be
transported empty and dry. The required quantity of battery grade electrolyte
concentrated sulphuric acid, to be diluted at site to serve as electrolyte for first
filling of the cells, shall be supplied in separate non-returnable containers
including 10% extra quantity of electrolyte. The quantity of electrolyte
alongwith its specific gravity shall be specified.
Venting Device: Each cell shall be provided with a venting device at the top which shall be
anti-splash type with more than one exist hole and shall allow gases to
escape freely but shall effectively prevent acid particles or spray coming out.
These shall also provide an opening for addition of distilled water as required
to top up the electrolyte. The vent plugs shall be explosion proof. The
construction details of vent plug shall be provided in the tender.
Installation of Batteries: The battery shall be mounted on wooden racks in the battery room. Acid
resistant insulation between cell and racks shall be provided. The racks shall
be so arranged as to present a neat and aesthetic appearance. The
arrangement shall be subject to approval of the Purchaser. Each cell as well
as its location shall be numbered for proper record of maintenance and
operation. Termination polarity of each cell shall be clearly stamped as
positive and negative. The connections between the cells shall be bolted type.
The bolts and nuts and connectors will be effectively lead coated to prevent
corrosion and should be of adequate capacity to carry maximum current. As
powerhouse lies in a seismic zone, the Tenderer/Manufacturer shall give
specific recommendations in his offer for installation of batteries in such a
fashion that these are not damaged due to seismic forces. The battery bank is
required to be erected/installed on the existing wooden racks in two tier
formation in a room of 6 x 3.25 m size approximately.
Fitting and Accessories : 37
The Tenderer shall provide all the fittings and accessories required for the
satisfactory installation, operation and maintenance of the battery, even if
these are not specifically mentioned in this specification. The following
accessories shall, however be supplied with the battery set: Sr. Description
Quantity
No.
i)
Inter cell and inter row connector with nuts and bolts. 1 set
Inter cell connector shall provide about 12mm space
between cells. These shall be lead plated copper
connection.
ii) Hydrometers complete with accessories (Temperature 2 nos.
Correction charts).
iii) Thermometer for measuring electrolyte temp.
2 nos.
iv) Analogue type cell testing voltmeter scaled 3-0-3V, 2 nos.
complete with leads.
v) Glass funnels
2 nos.
vi) Acid resistant jug
2 nos.
vii) Rubber gloves
2 pairs
viii) Rubber aprons
2 nos.
ix) Rubber boots (knee high)
2 pairs
x) Nylon brushes with stout bristles for cleaning 2 nos.
connections
xi) Identification plates for cells with location number of cell
1 set
7.6.3
7.6.4
7.6.4.1
a)
i)
ii)
iii)
iv)
v)
b)
i)
ii)
iii)
iv)
v)
vi)
vii)
c)
i)
Distilled Water Still: Distilled water still, electricity operated having output of 2.5 litres/hour
Suitable for working on 230 volts, 50Hz. A.C. Single phase complete in all
respects. Necessary supporting stands shall also be supplied.
Tests: The battery shall comply with the requirement of routine, acceptance and type
tests as per IS: 1652 and 8320. The following shall be routine, type and
acceptance tests :Routine Tests :Verification of conformity of material.
Verification of constructional requirement.
Verification of dimensions.
Verification of marking and packing.
Air pressure test.
Type Tests :The following shall constitute type tests and shall be carried out in the
sequence given below: Verification of constructional requirements.
Verification of marking.
Verification of dimensions.
Test for capacity - Test for voltage during discharge.
Ampere-hour and watt-hour efficiency tests.
Test for retention of charge
Endurance test.
Type test shall be carried out on two cells. One cell shall undergo all tests
except endurance tests while the other would undergo endurance test
preceded by a capacity test.
Acceptance Tests :The following shall constitute the acceptance tests: Verification of marking.
38
ii)
iii)
iv)
Verification of dimensions.
Test for capacity.
Test for voltage during discharge.
Acceptance test shall normally be carried out at the discretion of the
Purchaser on each cell after installation at site. The date and place of testing
shall be subject to agreement between the Purchaser and the supplier.
In case the manufacturer has conducted Type test earlier on the similar
product, the type test certificate shall be submitted .
7.7
7.7.1
Equipment Description
(a)
The battery chargers as well as their automatic regulators shall be of static type.
Battery chargers shall be capable of continuous operation at the respective rated
load in Float mode, i.e. Float charging the associated Lead-acid plante high
discharge type Batteries while supplying the DC loads. The batteries shall be float
charged at 1.4 to 1.5 Volts per cell. The charger shall also be capable of Boost
charging the associated batteries at 1.42 to 1.7Volts per cell at the desired rate. The
chargers shall be designed to operate, as mentioned above, up to an ambient air
temperature of 500C. Tapping arrangement in the battery bank shall be provided to
limit the over voltage for supplying load within allowed voltage range under boost
charge conditions. The charger should automatically switchover to float charger & to
boost charger when the specified limit of voltage is approached. However, necessary
time circuit shall be used to allow a finishing charge before switching over to float
mode, as recommended by battery manufacturer in order to ensure that battery gets
fully charged.
Note:- Charger rating shall be arrived at with charger in boost mode and also supplying
100% float load i.e. charger current shall be sum of float & boost rating.
b)
Battery chargers shall automatically select the appropriate mode of operation i.e.
Float or Boost. Means shall be provided to avoid current/voltage surges of harmful
magnitude/nature, which may arise during changeover.
c)
Soft start feature shall be provided to build up the voltage to the set value slowly
within fifteen seconds. The chargers shall have load limiters, which shall cause, when
the voltage control is in automatic mode, a gradual lowering of the output voltage
when the DC load current exceeds the load limiter setting of the Charger. The load
limiter characteristic shall be such that any sustained overload or short circuit in DC
system shall neither damage the Charger nor shall it cause blowing of any of the
charger fuses. The charger shall not trip on overload or external short circuit. After
clearance of fault, the Charger voltage shall build up automatically when working in
automatic mode.
During external short circuit, output of the charger shall be automatically reduced to
near zero volt till it is not isolated/disconnected & normal output voltage shall be
restored by charger circuit on isolation with out any harm to source transformer/
protection/ regulator circuit.
d)
During Float charging, the charger output voltage shall remain within + 1% of the set
value for AC input voltage variation of 230+10%-15% frequency variation of + 5% a
combined voltage and frequency (absolute sum) variation of 10% and continuous DC
load variation from 5% to full load. Uniform and stepless adjustments of voltage
setting shall be provided on the front of the charger panel covering the entire float
charging output range specified. Stepless adjustment of the load limiter setting shall
39
also be possible from 80% to 100% of the rated output current for float charging
mode.
e)
During Boost charging, the Battery chargers shall operate on constant current mode
with maximum current limiter setting (When automatic regulator is in service).
f)
Energising the Charger with fully charged battery connected plus 10% load shall not
result in output voltage greater than 110% of the voltage setting. Time taken to
stabilize, to within the specified limits in clause 3.1 (d) shall be less than five
seconds.
g)
Momentary output voltage of the charger, with the Battery connected shall be within
90% to 110% of the voltage setting during sudden load change from 80% to 20% of
full load or vice-versa. Output voltage shall return to, and remain, within the limits
specified in clause 3.1(d) in less than 1 second after the above mentioned change.
h)
The charger manufacturer may offer an arrangement in which the voltage setting
device for float charging mode is used as output voltage limit setting device for Boost
charging mode, and the load limiter of the float charging mode is also used as Boost
charging current setting device.
i)
Suitable filter circuits shall be provided in all the chargers to limit the ripple content
(peak to peak) in the output voltage to 3% irrespective of the DC load, even when
they are not connected to a battery.
k)
l)
Battery test circuit shall be provided with suitable resistance for discharging the
battery for 30Sec at 5 hr rate.
m)
n)
7.7.2
MCB:
AC MCCB shall be provided at the incomer. DC MCCB with provision of auxiliary
contacts shall be provided at the output of the battery charger.
7.7.3
7.7.4
Rectifier Assembly:
The rectifier assembly shall be full wave bridge type and designed to meet the duty
as required by the respective charger. The rectifier cells shall be provided with their
own heat dissipation arrangement with natural air cooling. The rectifier shall utilize
diodes/ thyristors with heat sinks rated to carry 130% of the load current continuously
and the temperature of the heat sink shall not be permitted to exceed 85 0C absolute
40
duly considering the maximum temperature inside charger panel with ambient
temperature of 500C. The Contractor shall submit calculations to show what
maximum junction temperature will be and what the sink temperature will be when
operating at 130% and 100% load current continuously duly considering the
maximum surrounding air temperature for these devices inside the charger panel
assuming ambient temperature of 500C outside the panel. Necessary surge
protection devices and rectifier type fast acting fuses shall be provided in each arm of
the rectifier connections. Static silicon controlled rectifiers and diodes complete with
resistor/capacitor network for surge protection shall be provided.
Design having IGBT or superior technology shall also be acceptable for which full
justification & experience shall be required for acceptance.
7.7.5
Instruments:
Analogue or digital D.C. voltmeter, D.C. ammeter and A.C. voltmeter with 96mm
square display shall be provided for all chargers. The instruments shall be flush
mounted type, dust proof and moisture resistant. The instruments shall have easily
accessible means for zero adjustments. The instruments shall be of 1.5 accuracy
class.
7.7.6
7.7.7
Fuses:
Fuses shall be of HRC cartridge fuse link type. Fuses shall be mounted on fuse
carriers, which are mounted on fuse basis. Where ever it is not possible to mount
fuses on fuse carriers, they shall be directly mounted on plug in type bases. In such
cases one insulated fuse pulling handle shall be supplied for each charger. Suitable
fuse fail detector circuits with alarm contacts shall be provided for all D.C. fuses.
7.7.8
Indicating Lamps:
The indicating lamp shall be of panel mounting, LED type and capable of clear status
indication under the normal room illumination. The lamp covers shall be preferably
screwed type, unbreakable and moulded from heat resistant.
7.7.9
Blocking Diode:
Blocking diode, wherever required, with full redundancy shall be provided in the
output circuit of each charger to prevent current flow from the D.C. battery into the
Charger.
ix)
x)
xi)
xii)
xiii)
a)
b)
Battery on boost.
Charger trouble (this being a group alarm initiated by any of the faults other
than Battery on Boost).
Construction:
7.8.1
The Chargers shall be indoor, floor mounted, self-supporting sheet metal enclosed
cubicle type. The Contractor shall supply all necessary base frames, anchor bolts
and hardware. The Charger shall be fabricated using cold rolled sheet steel not less
than 1.6mm thick. The panel frame shall be fabricated using cold rolled sheet steel of
thickness not less than 2.0mm. Removable un-drilled gland plates of at least 3.0mm
sheet steel and lugs for all cables shall be supplied by the Contractor. The lugs for
cables shall be made of electrolytic copper with tin plating. Cable sizes shall be
advised to the Contractor at a later date for provision of suitable lugs and gland
plates. Ventilating louvers shall be backed with fine brass wire mesh. All doors and
covers shall be fitted with nitrile/neoprene/PU rubber gaskets. The Chargers shall
have hinged double leaf doors provided on front and/ or backside for adequate
access to the Charger internals. All the Charger cubicle doors shall be properly
earthed. The degree of protection of Charger enclosure shall be at least IP-42. The
construction shall meet the requirements of IS: 6619. All equipment mounted in the
cabinet shall be provided with individual labels with equipment designation engraved.
7.8.2
The layout of Charger components shall be such that their losses do not give rise to
excessive temperature within the Charger panel, Location of the electronic modules
will be such that temperature rise, in no case, will exceed 10 oC over ambient air
temperature outside the Charger.
7.8.3
Charger panel shall be provided with an illuminating lamp (CFL or tube light) and one
5Amp socket. Switches and fuses shall be provided separately for each of the above.
7.8.4
7.8.5
Wiring
42
7.8.5.1 Each Charger shall be furnished completely wired upto power cable lugs and
terminals blocks, ready for external connection. The power wiring shall be carried out
with 1.1kV grade PVC insulated cables conforming to IS: 1554 (Part-I). The control
wiring shall be of 1.1kV grade PVC insulated stranded copper conductors of
1.5sq.mm. minimum, conforming to IS:694. Control wiring terminating at electronic
cards shall not be less than 0.75sq. mm. Control terminals shall be suitable for
connecting two wires of 1.5sq.mm stranded copper conductors. All terminals shall be
numbered for ease of connections and identification. At lease 20% spare terminals
shall be provided for circuits on terminal board.
7.8.5.2 Power and control wiring within panels shall be bundled separately. Any terminal or
metal work which remains alive at greater than 415V, when panel door is opened,
shall be fully protected by shrouding.
An air clearance of at least ten (10)mm shall be maintained throughout all circuits,
except low voltage electronic circuits, right upto the terminal lugs. Whenever this
clearance is not available, the live parts should be insulated or shrouded.
7.8.6
Painting:
Pre-treatment & phosphating shall be provided as per IS: 6005. The phosphate
coating shall be class-C as specified in IS:6005. Electrostatic powder painting with
final shade 692 (smoke grey) of IS: 5 shall be provided. The thickness shall not be
less than 50microns.
7.8.7
7.9
Tests:
Battery chargers including the components shall confirm to all type tests including
heat run test as per relevant Indian Standards. Performance test on the chargers as
per specification shall also be carried out on each charger.
7.9.1
Type Tests:
7.9.1.1 Following type tests, in addition to the requirement of IS: 4540, should have been
carried out on each rating and type of Batter Charger for which reports are to be
submitted.
i)
ii)
iii)
iv)
v)
a)
b)
c)
vi)
No load
Half load
Full load
43
vii)
viii)
Description
Current Rating
1
2
3
4
5
6
7
8
9
20 A
10A
7A
10A
7A
10 A
7A
20 A
10A/7a
Qty.
4 No.s
6No.s
5 Nos
4 No.s
2No.s
4 No.s
3 No.s
2 No.s
2 No.s EACH
Tests :Contractor shall offer the equipment for inspection and testing at works. All tests as per IS
shall be carried out.
44
SECTION-VIII
REPLACEMENT OF PROTECTION PANELS
8.1
Scope
This section of the specification cover the following scope of works: I)
II)
8.2.1
Generator Protection Scheme :The scheme consists for the four generator units.
The electrical protection systems to be provided for the individual generator, shall
comprise of at least following equipment :Four (4) sets of protection equipment for generating units:27G
32G
46G
51V
51 N
64 S
59G
81G
40G
Loss of field
The protection system shall consist of micro processor based numerical relays for
generator protection and generator transformer protection.
Each trip relay shall be arranged to operate trip coil on the 0.415 kV Air circuit
breaker.
A single line diagram of the main electrical equipment of the power house and its
protection scheme is shown on the drawings No. PHE-01-002.
Means shall be provided to prevent operation of protective equipment due to
magnetising current, in the case of switching-in the transformer from the high voltage
45
side. Precaution shall also be taken that the unavoidable inductive and capacitive
couplings from the power circuit do not cause disturbances.
Protection package shall be facilitated with following:
i)
Man machine communication interface shall be provided with alarm
and trip value
setting, displaying of service values, alarm/trip set values, alarmed/ tripped values
etc.
ii)
iii)
iv)
v)
vi)
8.2.2
Synchronising Trolley
Mobile Synchronising trolley consisting of but not limited to control switches, selector
switches, Check synchronising relay, guard relay, shall be supplied. Synchronising
equipment shall be capable of synchronising any of the generators at 415 V bus
through ACB. Alternatively synchronising panel consisting of above equipment can
also be proposed by the bidder.
8.3
8.3.1
General Arrangement
The system shall provide a high degree of selectivity and discrimination between
faulty and healthy circuits. A microprocessor based modular system associated with a
man machine communication interface shall be offered.
All devices shall remain inoperative during internal faults and transient phenomena.
They shall be insensitive to mechanical shocks, vibration and external magnetic
fields.
The protection systems shall be the standard product of a competent manufacturer,
with organized type test certificates and adequate record of satisfactorily working
plants.
All relays shall be suitable for local reset. They shall have self-monitoring facilities
and LED status indication.
Service voltage failure and any fault in relays and tripping circuitry shall be indicated.
Tripping circuits shall be operable at 70% nominal voltage.
CT's shall be shorted automatically, when relevant modules are withdrawn.
Two trip relays shall be provided to work as main and back trip relays.
The relays shall be provided with the following information, suitably located:
function of relay
phase identification
main characteristics
46
The protection system shall be divided into protection groups and subgroups, each
installed in a separate cubicle or cubicles. Each protection group shall consist of
solid-state protection relays preferably numerical, auxiliary relays, tripping unit and all
accessories as required and further specified in the following sections.
The protection groups are defined as follows:
Mechanical protection for the generating units
Generator protection for the generating unit
Transformer protection, for the main and
station transformers
The protection equipment for the generating unit shall be installed in the Power
house control room or near the UCB if, space is available.
Current transformers, where possible, are to be located so as to include the
associated circuit breaker within the protected zone and shall be located generally as
indicated on schematic drawings.
8.3.2
Relays
Relays shall be approved type with IEC 255 or BRITISH Standard 142 and 5992,
parts 1, 2 and 3 or IS certification, as appropriate, fully tropicalised and shall have
approved characteristics. Only protective relays from well established manufacturers
with a minimum of ten years successful experience in manufacturing protective
relays and with a minimum of five years of field experience shall only be accepted.
The owner will reject any design he considers unsatisfactory or having insufficient
field experience.
The protection relays, shall be located in conventional panels and shall be flush
mounted in dust and moisture proof cases with protection class IP54 and of the draw
out type with rear connections. The protection class of the cover for all relays or
protection systems, in which the modules are mounted shall not be inferior to IP53.
Relays shall be of approved construction and shall be arranged so that adjustments,
testing and replacement can be effected with the minimum of time and labour.
Relays contact shall be suitable for making and breaking the maximum currents,
which they may be required to control in normal service but where contacts of the
protective relays are unable to deal directly with the tripping currents, approved
auxiliary contacts, relays or auxiliary switches shall be provided. In such cases the
number of auxiliary contacts or tripping relays operating in tandem shall be kept to
the minimum in order to achieve fast fault clearance times. Relay contacts shall make
firmly without bounce and the whole of the relay mechanisms shall be as far as
possible unaffected by vibration or external magnetic fields.
Relays, where appropriate, shall be provided with LED or flag indications, phase
colored where applicable. LED or flag indicators shall be of the hand reset pattern
and shall be capable of being reset without opening the case. Where two or more
phase elements are included in one case, separate indicators shall be provided for
each element.
Relays, which rely for their operation, on an external DC supply, shall utilise for this
purpose the same DC supply battery as the trip supply of the associated circuit
47
breaker trip coils. The supply shall be monitored and an alarm provided in the event
of failure.
All DC breakers and relays for DC main switchgear protection shall be based on AC
operated trip and close coils and protection relays.
Any auxiliary supplies needed shall be drawn from the DC Distribution Board and not
from the separate internal batteries in the protection equipment.
Relays, whether mounted in panels or not, shall be provided with clearly inscribed
labels describing their functions and designation in addition to the general-purpose
labels.
To minimise the effect of electrolysis, relay coil operating on DC shall be so
connected that the coils are not continuously energised from the positive pole of the
battery.
Draw out type relay shall be so designed that when the relay is drawn out ,
associated CT's shall be automatically short-circuited and tripping circuits
disconnected.
All static relays shall be adequately protected against damages from incoming surge
and shall meet relevant IEC, BS, IS and ANSI SWC test standards.
The input circuit must be galvanically isolated from the electronic circuits. Potential
free output contacts must be suitable for the direct control of breaker trip coil.
The setting ranges of the protection devices and the performance of the CT's and
VT's shall fit the requirements of the individual circuits. Time delayed modules shall
have definite time characteristic with continuous adjusting range. The selectivity with
the other protection modules shall be proved by a protection setting study covering
the entire system. This study shall be based on a short circuit calculation for
maximum and minimum short circuit capacity and shall prove the selectivity of the
relay setting from the high voltage to the low voltage system, taking into
consideration the different modes of operation of the system. This study shall also
prove correct matching with the provided instrument transformers.
Trip circuit supervision relays shall be provided to monitor each circuit of 415 V air
circuit breakers and earth relay shall have sufficient contacts for visual/audible alarm
and indication purposes.
The trip circuit supervision scheme shall provide continuous supervision of the trip
coil and trip circuits with the circuit breaker in either the open or close position.
Relay elements shall be delayed on drop off to prevent false alarms during faults on
dc wiring on adjacent circuits or due to operation of a trip relay contact.
Series resistance shall be provided in trip circuit supervision circuits to prevent maltripping of a circuit breaker if a relay element is short-circuited.
Breaker failure protection shall be fitted to all air circuit breakers.
The breaker failure protection on a circuit breaker shall be initiated by all the other
protection devices, which normally initiated tripping of that breaker. In the event of
the circuit breaker failing to open within a pre selected time, the breaker failure
48
protection shall initiate tripping of all adjacent circuit breakers connected to the same
bus bar, transfer tripping of the line breakers.
The relays shall have an operating times of 10 ms, and a consistent reset time of less
than 15 ms. The relays shall be more sensitive than the most sensitive circuit
protection, both phase and earth fault. The relays shall be capable of remaining in
the operated position continuously and of carrying twice the circuit rated current
continuously.
The operating time of the breaker failure protection shall be selected by means of
timers with ranges of 50 to 500 ms. There shall be two timers per circuit breaker. The
timer tripping outputs shall be connected in a two out of two basis and shall energize
both tripping coils of the adjacent circuit breakers via two back tripping circuit from
separate dc supplies. The timers shall be of static design to minimise over travel.
8.3.3
Auxiliary Relays
Auxiliary relays for inputs from the protection sensors and devices such as thermal
relays, pressure switches etc. shall be provided as specified in the following sections
and as necessary for the installation.
The relays shall be equipped with a manually reset flag indicator when applicable.
Each relay shall have self-resetting potential free contacts of suitable rating as
needed for connection in the tripping circuits and at least two self-resetting potential
free contacts for local and remote alarm and supervision, both wired to terminals.
All relays shall be clearly marked with the corresponding relay function.
The tripping relays shall have contact ratings suitable for acting directly on the trip
coils and solenoids of the respective circuit breakers and shut down devices.
As an alternative a tripping matrix having provisions for easy selection of the tripping
scheme, and having means for manual and automatic testing of the trip circuits, can
be offered.
8.3.4
8.3.5
8.4
8.5
8.6
8.6.2
All instruments shall be designed for accurate measurement of the quantity or state
under all conditions of operation and any error due to change in ambient condition
shall be kept to minimum. The instrument shall be damped to comply with the
requirement of clause 7.2 of IS 1248 (Part-I) or equivalent. All the instruments shall
comply with the requirement of first grade instrument of switch board type as per
IS:1248 or equivalent standard. All instruments and meters shall be accurately,
adjustabled and calibrated before shipment and shall have means for calibration,
checking and adjustment at site.
50
8.6.3
The metric unit shall be used for displaying the values. The instrument shall be
capable of withstanding over loads applied in accordance with IS:1248 or equivalent.
The instrument shall be capable of withstanding the following tests, viz effect of
shock, vibration and effect of humidity.
8.7
Calculation requirements
The contractor is required to submit time setting for different relays and selection of
relay types to owner for approval. The contractor is required to submit the DC power
requirements. Contractor shall also submit a drawing of complete protection scheme.
8.8
Shop Tests
8.8.1
Type Tests
All standard components of the protection systems shall have passed appropriate
type tests in accordance with the relevant standards. The contractor is required to
submit type test certificates to the owner.
8.8.2
Routine Tests
These tests shall include material and tests during manufacture as per the
manufacturer's practice. The contractor is required to submit complete routine test
reports. The following inspections and tests shall be performed on the completely
assembled protection systems:
8.9
Visual inspection
Wiring test
Insulation test
Functional test
Field Tests
The contractor shall prepare a detailed test program based on the requirements of
the applicable standards and the specifications.
All test results shall be recorded including the details on the used test equipment and
instruments.
51
SECTION-IX
REPLACEMENT OF 24 KV SWITCHGEAR
9.1
Scope: This section of the specification cover the following scope of works: I) Dismantling/removing of existing oil circuit breakers and associated control and
protection panels all services, labour, tools and tackles required for dismantling
including carriage, stacking at Owners store/ yard.
II) Design, engineering, manufacture, shop assembly & testing before dispatch,
packing and forwarding, transportation, insurance, handling, delivery, storage at site,
erection, testing & commissioning of indoor type 630 A, 24 kv indoor type vacuum
circuit breakers (draw out type) control & Relay panel complete with protective
relays for two (2) transformers and four (4) feeders as detailed in this specification
and handing over to HPSEB LTD. complete with accessories, equipment, devices,
instruments, cabling and wiring etc. including all services, labour, tools and tackles.
9.2
9.2.1
Standards
The equipment including all accessories supplied under this Contract shall conform
to relevant IEC or IS or British Standards and shall be in accordance with the latest
edition or revision thereof.
9.2.2
9.2.3
9.3
9.4
22kV
ii)
24kV
iii)
50kV (rms)
iv)
95Kv (peak)
v)
System frequency
50Hz
vi)
No. of phases
Three
vii)
630 A
viii)
6.3 kA
ix)
15.75kA
x)
0-3min.-CO-3
min.-CO
xi)
9.5
xii)
xiii)
1 phase,240 V,50 Hz
9.6
24 KV Circuit Breakers
9.6.1
The electrical rating of the circuit breaker shall be as per clause 9.4 of this
section. The breaker offered shall be vacuum type conforming to all the
requirements of IEC/BS or Indian Standard.
The breaker compartment shall be designed to have fully draw-out self
contained truck arrangement with breaker mounted on the same. The devices
fitted on the breaker truck shall allow for easy insertions and withdrawal of
breaker from service position. The breaker truck shall have the following two
definite positions.
i)
ii)
The circuit breaker mobile truck shall be provided with additional metal barrier
i.e. front shield between the actual breaker housing and the front door. Front
door of the cubicle shall be provided with padlocking facilities. The front door
should be closed and pad-locked even when the breaker is in test position
Safety interlocks and automatic shutter shall be provided to ensure the
following:a)
The circuit breaker cannot be inserted into the service position when
in closed position.
b)
c)
9.6.2
The circuit breaker shall be provided with rapid and smooth interruption of
currents under all conditions completely suppressing all undesirable
phenomena on even under the most severe and persistent short circuit
conditions or when interrupting small leading and lagging currents. The detail
of any device or special feature incorporated to limit or control the rate of rise
of re-striking voltage across the circuit breaker contact shall be stated. The
over voltage caused by the circuit breaker switching on inductive and
capacitive loads shall not exceed 2.5 times the normal phase to neutral
voltage. The total break time for the circuit breaker throughout the range of its
operation duty shall be stated in the bid and it shall be guaranteed.
9.6.3
The circuit breaker shall be provided with suitable operating mechanism with
automatic recharging of spring with the help of geared motor. Provision shall
also exist for one detachable handle for manual charging in the event of
failure of auxiliary voltage. The switchgear shall be suitable for remote
operations in addition to auxiliary local operating mechanism. The operating
mechanism shall be trip-free. All working parts in the mechanism shall be of
corrosion resistant material and all bearings, which require greasing, shall be
equipped with pressure grease fitting. The mechanism, shall be strong, quick
in action with minimum noise and shall be removable without disturbing the
other parts of the circuit breaker. The operating mechanism alongwith its
accessories shall be housed in a weatherproof cabinet with hinged doors
installed just adjacent to the breakers. The circuit breaker shall also be
provided with means for manual operation for maintenance purpose and local
tripping and closing. A local/remote change over switch shall also be
provided. Operating mechanism shall also be provided with operation counter
and space heaters with suitable thermostat switch to avoid condensation.
9.6.4
The control circuit shall be designed to operate on 110 V.D.C. supply with a
variation from 70% to 110% of rated voltage. A.C power supply for auxiliaries
shall be available at 240 V, single phase, 50 c/s. Provision shall be made for
locking the breaker mechanism in open position and locking the doors in
closed position through pad locks. Lamp indication as well as mechanical
open and close indication shall be provided on the switchgear panels to
show the contact positions of circuit breakers. Twelve numbers of the
secondary auxiliary contacts shall be provided on mobile portion of circuit
54
Means shall be provided for easy access to the contacts and other parts of
the switchgear for inspection and repairs. When these facilities are obtained
by provision of manholes, the manhole shall be of adequate dimensions and
hinged type and located in convenient place.
9.7
Bus Bars
All the bus bars within the switchgear assembly shall be air insulated and
shall be housed in a separate compartment of the switchgear assembly
supported on insulated supports. It shall have rated current capacity of not
less than the rated capacity of the circuit breaker. Bus bar shall also have
mechanical and thermal capacity not less than that represented by the short
time current rating of the circuit breaker. The bus bar shall be of aluminum
conforming to relevant IEC, BS or Indian standard. Phase-to-earth and
Phase-to-Phase clearances shall also be in accordance with IEC standards
and corrections in the clearance on account of altitude correction factor shall
also be incorporated. No insulation sleeves shall be provided on the bus bars
to reduce the phase-to-earth and phase-to-phase clearances. Support
insulators shall be strong enough to take up dynamic forces on account of
short circuit. Temperature rise of the bus bars and joints shall also be as per
IEC standard. The bus bar phases shall be identified by painted bands of red,
yellow, & blue spaced at suitable distances.
9.8
Current Transformers
9.8.1
Current transformers shall be mounted with in the cubicle and shall comply
with the requirements of IS: 2705-1992 and its latest amendment. Current
Transformers as shown in drawings No. PHE-01-002 of Vol. 2C shall be
supplied by the contractor. The technical particulars shall be as given below: i)
22kV.
iii)
50 kV
iv)
95 kV Peak.
v)
24kV.
Necessary steel brackets for mounting these CTs inside the cubicle shall also
be provided. The required CT ratio, burden and accuracy class shall be as
mentioned in the schedule of requirement. The Bidders shall have the option
of offering multicore C.T.s of accuracy classes specified in place of single
core C.Ts inside the panel. The Bidder shall also furnish the knee point
voltages, magnetizing currents and secondary winding resistances of P.S.
class C.Ts. However, actual requirement will have to be worked out in coordination with other concerned suppliers and bidder should agree to
accommodate any change in requirement with regards to numbers and
characteristics of CTs at the stage of approval of drawings. In addition to
above technical particulars, the CTs shall have the following ratings also.
a)
b)
Thermal short time rating one second with secondary short circuit,
winding temperature shall not exceed the limit as per IEC 185.
c)
Frequency: - 50HZ
55
9.8.2
The secondary winding of the CTs shall be fully distributed around the core at
all nominal taps. The actual exciting current up to the knee point voltage shall
not vary beyond the permissible standard from the normal exciting current.
9.8.3
All the routine tests, type tests and tests at site shall be carried out on current
transformers in accordance with Indian standard with up to date amendments
thereof. The tests to be carried out by the Contractor shall clearly be stated in
the bid.
9.8.4
DESIGNATION
RATIO
PURPOSE
BURDEN
CT-6
50/1A
Directional O/C 50
&
E/F
Protection
5P10
CT-7 (CORE-I)
50/1 A
O/C
&
Protection
5P10
(CORE-II)
50/1A
Metering
E/F 50
50
ACCURACY
CLASS
0.5
9.9
Voltage Transformers
9.9.1
22kV.
iii)
50 kV
iv)
95 kV Peak.
v)
24kV.
All the routine tests, type tests and tests after installation given in relevant
Indian Standard shall be carried and Bidders shall give details of such tests
which shall be carried out, with their offer.
9.9.2
DESIGNATION
RATIO
BURDEN
CORE-I
22KV/3/110V/3
50 VA
56
ACCURACY
CLASS
3P
CORE-II
22KV/3/110V/3
50 VA
CORE-III
22KV/3/110V
50 VA
0.5
3P
9.10
Indicating Instruments
9.10.1
9.10.2
9.10.3
9.11
9.11.1
Transformer Protection :Four (4) sets of protection equipment for generating units:51T
50
67 & 67 N
9.11.2
9.11.2.1
The electrical protection systems to be provided for the four (4) no.s line
feeder, shall comprise of at least of the following equipment :Four (4) sets of protection equipment for feeders :50
51 & 51 N
Each trip relay shall be arranged to operate onto both trip coils of the 22 kV
vacuum circuit breaker
9.11.2.2
The relays shall be provided as per single line diagram depicted in drawing
No PHE-02-001 , Vol. 2C Relays shall be of Numerical type only. Relays
shall be Alstom/ABB/ Siemens make. All the relays shall be suitable for
operation over the range -70% to 110% of the nominal D.C. voltage. The
relays shall be designed to have the minimum possible quiescent drain on the
batteries.
9.11.2.3
9.12
Lightning Arrestors
9.12.1
The lightning arrestor shall be of distribution class with non linear resistance
arrestor and shall be mounted in the cubicle. The lightning arrestor should
conform to IS:3070/IEC-994 except where specified otherwise. Lightning
arrestors manufactured to any other standard which ensures an equal or
better quality than IS 3070 shall be also acceptable. Where the equipment
conforms to any other standards other than IS: 3070-difference between the
standard shall be clearly brought out.
9.12.2
9.13
Panels
All enclosures and Panels/Cubicles shall be of good quality Standard
production. Panels/cubicles shall be free floor standing type of rigid frame
covered with removal steel sheets. The frame should be bolted to floor. There
shall be provision and enough space for entrance of cables from below. The
cubicles shall be ventilated if needed, in this case removal filter inserts shall
be fitted to the air entrance openings. Provision for cable fastenings shall be
made inside the cubicles and enclosures and sufficient space for cable
fastenings to nearest terminals shall be kept. All control and indicating
instruments such as contactors, circuit breakers, auxiliary relays, indicating
instruments, switches etc. shall be functionally displayed in appropriate
locations. The layout is subject to approval of the Engineer in- charge,
58
Earthing Arrangement
Two separate copper earth buses of suitable cross-sectional areas shall be
provided in the 24 kV switchgear designed for a short circuit current of 25 kA.
One earth bus shall run along the entire rear length of the switchgear panels
and the lightning arrestors shall be connected to this earth bus. The other
earth bus shall be run along the entire front side of the switchgear panel and
the earth connections from the relays and control devices shall be made to
this bus. Both the earth buses shall be connected to the station M.S. earth
bus at the extreme ends using bi-metallic joints. The earthing inside the
panels shall be done using green coloured PVC flexible copper cables.
9.15
Terminal Blocks
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
off after one minute if the same is not acknowledged. However the
alarm window shall remain lighted till the same is reset or the fault
cleared.
9.16
Closing Coil
Trip Coil
TNC Switch
Overcurrent Relay
2 No.
2 No
2 No.
1 No.
9.17
9.17.1
The Contractor shall furnish all labour, tools, tackles, slings and support and
all other provisions or materials necessary to assemble, erect, install, test and
commission the 24kV VCBs in a thorough workmanlike manner following the
best modern practices. The VCBs and all their components shall be placed
with great care and shall be aligned correctly.
9.17.2
9.17.3
All test equipments and instruments shall be provided by the Contractor free
of charge and shall remain the Contractors properties after the fulfillment of
the field tests.
9.17.4
All civil works required for foundation shall be carried out by the Owner or his
representative. The Contractor is required to submit the foundation drawings
and supporting steel well in time.
9.18
Tests
9.18.1
Type test certificates, to ensure the quality and capability of the offered
equipment, must accompany the bid documents. The Bidder shall specify the
details of measurement and conducting of these tests alongwith the bid.
TYPE TEST shall only be carried out on switchgear only if manufacturer
has not conducted on the similiar equipment. However manufacturer
has to submit the type test reports.
9.18.2
All the tests to be carried out on all the equipment shall conform to IEC, BS
and Indian Standard. Bids not accompanied with the relevant type test
certificate confirming to IEC & IS shall be summarily rejected. Routine tests
shall be carried out on each equipment in the presence of Owners
representative at the manufacturers expenses at his works.
9.18.3
Circuit Breakers
TYPE TEST
1.
a)
b)
c)
Test duty.
d)
2.
a)
b)
c)
Operational tests.
a)
b)
ROUTINE TEST: -
9.18.4
Operation test.
2.
4.
5.
6.
ROUTINE TEST: -
9.18.5
2.
4.
2.
4.
5.
6.
7.
8.
ROUTINE TEST: 1.
2.
4.
5.
Accuracy test
ii)
9.18.6
i)
ii)
2.
4.
5.
6.
7.
8.
9.
10.
ROUTINE TEST: -
9.18.7
2.
Site Tests : All the equipments supplied shall be tested at site after successful installation
as per the recommendation of IEC or equivalent Indian Standard. Details of
the test and standard according to which these tests shall be carried out
should accompany the bid. Any other test specifically required to prove the
successful installation of the equipment shall also be carried out. The
Contractor shall indicate details of tools plants and instruments required for
site testing.
62
SECTION-X
REPLACEMENT OF 415 V SWITCHGEAR
10.1
10.2
10.2.1 The 415 volts air circuit breakers shall have the following ratings :A
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
B
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
C
i)
ii)
iii)
iv)
v)
vi)
vii)
viii)
63
10.2.2 Special Requirements :Circuit breakers for DG incomer and Bus coupler shall be provided with inbuilt
overcurrent and earth fault protection. LT Distribution Board shall be
connected with 415 V Bus through cable. A separate Chamber shall be
provided for cable connection for this purpose.
10.3
Standards :The circuit breaker shall comply in all respect with the requirement of latest issue of
Indian Standard No. 13947. Short circuit performance category P-2 except where
specified otherwise. Equipment meeting with any other authoritative standard which
ensures equal or better quality than the standard mentioned above is also
acceptable. Where the equipment offered conform to any other standard, the salient
features and points of difference between the standard adopted and the Indian
Standard shall be clearly brought out in the tender.
The L.T. switchgear shall comply in all respects with the latest editions of the
following Indian Standards:I.S. 13947, 2516
Specifications for Alternating current circuit breakers.
I.S. 8623
Specification for factory built assemblies of switchgear
and control gear ; Voltages up to and including 1000 V
A.C and 1200 V. D.C.
I.S. 4237
General requirement for switchgear and control gear for
voltages not exceeding 1000 volts
I.S. 2147
Degree of protection provided by enclosures for L.V.
Switchgear and Control gear.
I.S. 2705
Specification for current transformers.
I.S. 3156
Specification for voltage transformers.
I.S. 3231
Specification for electrical relays.
One number authorized copy of all the applicable standards (IS or IEC) shall be
supplied after the award of work.
10.4
Particulars of 415 V System :The single line diagram for 415 V system is depicted in Drawing No.PHE-02-001 of
Vol. 2C
10.5
Switchboards and Control Boards:The A.C switchgear shall consist of following switch boards :-
S.N.
DESCRIPTION
QTY.
CURRENT RATING
i)
ii)
iii)
iv)
Incoming generators
DG set incomer
Outgoing transformers
Bus Coupler
4
1
2
1
1000A
1000A
2000A
2000A
No.s
No.and
No.s
No.
Other technical requirements are listed under clause 10.2.1 of this section.
10.6
relevant IEC, BS or Indian Standard. Each switchgear shall be complete with air
circuit breaker mounted on draw out trolley, bus bars, instrument transformers, all
necessary wiring and auxiliary devices required to perform its functions. All the
instruments, control switches indicating devices and relays, should be mounted on
the front panel as a separate compartment. The design and arrangement of the
equipment shall be such that adequate space and access is provided for inspection
and maintenance of wiring, terminals,switches, cables and end boxes etc. The
switchgear shall be vermin proof and dust tight. Bus bars, CT & cable compartment
breaker compartment shall be provided with independently operated automatic
shutters to avoid accidental contact with live parts. The arrangement of bus bars shall
be such so as to provide ready extension for additional unit on either side.
10.7
i)
Service position: - In this position the circuit contacts as well as secondary contacts
and fixed secondary contacts should get engaged on to the fixed power contacts and
fixed secondary contacts respectively.
ii)
Test position: - In this position power contacts of the mobile portion of circuit breaker
shall remain isolated from the fixed position whereas secondary contacts shall
remain connected to the fixed secondary contacts.
The circuit breaker mobile truck shall be provided with additional metal barrier
i.e. front shield between the actual breaker housing and the front door. Front door of
the cubicle shall be provided with padlocking facilities. The front door should be
closed and pad-locked even when the breaker is in test position Safety interlocks and
automatic shutter shall be provided to ensure the following:-
10.8
a)
The circuit breaker cannot be inserted into the service position when in closed
position.
b)
The circuit breaker cannot be withdrawn from the service position unless it is
in open position.
c)
Access to the breaker chamber and circuit breaker shall not be possible
unless the breaker is withdrawn.
The circuit breaker shall be provided with rapid and smooth interruption of
currents under all conditions completely suppressing all undesirable phenomena on
even under the most severe and persistent short circuit conditions or when
interrupting small leading and lagging currents. The detail of any device or special
feature incorporated to limit or control the rate of rise of re-striking voltage across the
circuit breaker contact shall be stated. The over voltage caused by the circuit breaker
switching on inductive and capacitive loads shall not exceed 2.5 times the normal
phase to neutral voltage. The total break time for the circuit breaker throughout the
range of its operation duty shall be stated in the bid and it shall be guaranteed.
65
10.9
The circuit breaker shall be provided with suitable operating mechanism with
automatic recharging of spring with the help of geared motor. Provision shall also
exist for one detachable handle for manual charging in the event of failure of auxiliary
voltage. The switchgear shall be suitable for remote operations in addition to auxiliary
local operating mechanism. The operating mechanism shall be trip-free. All working
parts in the mechanism shall be of corrosion resistant material and all bearings,
which require greasing, shall be equipped with pressure grease fitting. The
mechanism, shall be strong, quick in action with minimum noise and shall be
removable without disturbing the other parts of the circuit breaker. The operating
mechanism alongwith its accessories shall be housed in a weatherproof cabinet with
hinged doors installed just adjacent to the breakers. The circuit breaker shall also be
provided with means for manual operation for maintenance purpose and local
tripping and closing. A local/remote change over switch shall also be provided.
Operating mechanism shall also be provided with operation counter and space
heaters with suitable thermostat switch to avoid condensation.
10.10 The control circuit shall be designed to operate on 110 V.D.C. supply with a variation
from 90% to 110% of rated voltage. A.C power supply for auxiliaries shall be
available at 240 V, single phase, 50 c/s. Provision shall be made for locking the
breaker mechanism in open position and locking the doors in closed position
through pad locks. Lamp indication as well as mechanical open and close
indication shall be provided on the switchgear panels to show the contact positions
of circuit breakers. Twelve numbers of the secondary auxiliary contacts shall be
provided on mobile portion of circuit breaker in any combination of NO and NC and
completely wired up to terminal blocks.
10.11
Means shall be provided for easy access to the contacts and other parts of the
switchgear for inspection and repairs. When these facilities are obtained by
provision of manholes, the manhole shall be of adequate dimensions and hinged
type and located in convenient place.
Current Transformers
Current transformers CT-3, CT-4, Ct-5 depicted in drawings No. PHE-01-002 of Vol.
2C shall be mounted with in the cubicle and CT-1, Ct-2 shall be mounted on
66
generator marshalling box. All CTs shall comply with the requirements of IS: 27051971 and its latest amendment.
Necessary steel brackets for mounting these CTs inside the cubicle shall also be
provided. The required CT ratio, burden and accuracy class shall be as mentioned
in section10.13.2. However, actual requirement will have to be worked out in coordination with other concerned suppliers and bidder should agree to accommodate
any change in requirement with regards to numbers and characteristics of CTs at
the stage of approval of drawings. In addition to above technical particulars, the
CTs shall have the following ratings also.
a)
b)
Thermal short time rating one second with secondary short circuit, winding
temperature shall not exceed the limit as per IEC 185.
c)
Frequency: - 50HZ
10.13.1 All the routine tests, and tests at site shall be carried out on current transformers in
accordance with Indian standard with up to date amendments thereof. The tests to
be carried out by the Contractor shall clearly be stated in the bid. Type test
certificates shall be furnished by the contractor.
10.13.2 Other requirement of different CTs are given below: S.N.
DESIGNATION
RATIO
PURPOSE
BURDEN
ACCURACY
CLASS
CT-1
1000/5
PROTECTION
50VA
5P10
CT-2
1000/5A
AVR SENSING
50VA
0.5
CT-3
1000/5A
METERING
50 VA
0.5
CT-4
1000/5A
PROTECTION
50 VA
5P10
CT-5
2000/5A
PROTECTION
30VA
5P10
10.14
10.14.1
Voltage Transformers
Voltage transformers shall confirm to IS: 4156-1965 and its latest
amendments. Voltage transformers shall be provided as shown in drawing
No. PHE-01-002 of Vol. 2C & as per the schedule of requirement and be of
magnetic type. The voltage transformer shall be single-phase type and shall
be mounted inside the cubicle. Each transformer shall be complete with its
own high and low tension fuses and current limiting resistances if required.
The fuses shall be so arranged that they are readily accessible and
easily/quickly replaced. The burdens of PTs are tentative only. The Bidder
shall indicate in his offer the actual burden imposed by relays, meters so that
modification, if required, in the rated burden of transformer can be done at the
time of placing of order. All the routine tests, type tests and tests after
installation given in relevant Indian Standard shall be carried and Bidders
shall give details of such tests which shall be carried out, with their offer.
10.14.2
A)
Bus PTs : Two No. Bus PTs shall be provided as per rating given below :
Sr.No.
DESIGNATION
CORE-I
RATIO
BURDEN
415V/3/110V/3
67
50 VA
ACCURACY
CLASS
1
CORE-II
B)
415V/3/110V/3
50 VA
3P
DESIGNATION
RATIO
BURDEN
ACCURACY
CLASS
CORE-I
415V/3/110V/3
50VA
3P
CORE-II
415V/3/110V/3
50VA
CORE-III
415V/3/110V/3
100VA
10.15
Indicating Instruments
10.15.1
10.15.2
10.15.3
10.16
Panels
10.16.1
10.17
MIMIC Diagram:
Overlaid mimic diagram using 10 x 2 mm aluminum strips to depict the circuit
as per the single line diagram shall be provided. The colour coding shall be as
per I.S. 11954 1987.
10.19
Earthing Arrangements
Two separate copper earth buses of suitable cross-sectional areas shall be
provided in the 500V switchgear designed for a short circuit current of 8 kA.
One earth bus shall run along the entire rear length of the switchgear panels
and the lightning arrestors shall be connected to this earth bus. The other
earth bus shall be run along the entire front side of the switchgear panel and
the earth connections from the relays and control devices shall be made to
this bus. Both the earth buses shall be connected to the station M.S. earth
bus at the extreme ends using bi-metallic joints. The earthing inside the
panels shall be done using green coloured PVC flexible copper cables.
10.20
Terminal Blocks
(i)
(ii)
(iii)
(iv)
(v)
(vi)
(vii)
(viii)
10.21
shall have automatic silencing facility i.e. the audio alarm shall silence
off after one minute if the same is not acknowledged. However the
alarm window shall remain lighted till the same is reset or the fault
cleared.
Mandatory Spares
Following mandatory spares shall be supplied :-
10.22
ACB
1000A
1 No.
ACB
2000A
1 No.
Trip Coil
2 No.s
Closing Coils
2 No.s
Erection and Commissioning at site : -
10.22.1
The Contractor shall furnish all labour, tools, tackles, slings and support and
all other provisions or materials necessary to assemble, erect, install, test and
commission the 415 V ACBs in a thorough workmanlike manner following the
best modern practices. The VCBs and all their components shall be placed
with great care and shall be aligned correctly.
10.22.2
10.22.3
All test equipments and instruments shall be provided by the Contractor free
of charge and shall remain the Contractors properties after the fulfillment of
the field tests.
10.22.4
All civil works required for foundation shall be carried out by the Owner or his
representative. The Contractor is required to submit the foundation drawings
and supporting steel well in time.
10.23
Tests
10.23.1
Type test certificates of tests listed in the subsequent clauses, to ensure the
quality and capability of the offered equipment, must accompany the bid
documents. The Bidder shall specify the details of measurement and
conducting of these tests alongwith the bid.
10.23.2
All the tests to be carried out on all the equipment shall conform to IEC, BS
and Indian Standard. Bids not accompanied with the relevant type test
certificate confirming to IEC & IS shall be liable to rejection.
10.23.3
Routine Tests : Routine tests shall be carried out on each equipment in the
presence of Owners representative at the manufacturers expenses at his
works.
10.23.4
Circuit Breaker
i)
TYPE TEST
1.
a)
b)
c)
d)
2.
70
10.23.5
10.23.6
Operational tests.
a)
b)
ii)
ROUTINE TEST
Operation test.
Potential Transformer :
i)
TYPE TEST
1.
2.
4.
5.
6.
ii)
ROUTINE TEST:
2.
4.
Current Transformer :
i)
TYPE TEST
2.
4.
5.
6.
7.
8.
ii)
ROUTINE TEST :
1.
2.
4.
5.
10.23.7
iii)
i)
Accuracy test
ii)
iv)
a)
i)
ii)
b)
For class PS
i)
ii)
Exciting current
iii)
iv)
Turn ratio
Site Tests: All the equipments supplied shall be tested at site after successful installation
as per the recommendation of IEC or equivalent Indian Standard. Details of
the test and standard according to which these tests shall be carried out
should accompany the bid. Any other test specifically required to prove the
successful installation of the equipment shall also be carried out. The
Contractor shall indicate details of tools plants and instruments required for
site testing.
72
SECTION-XI
TECHNICAL SPECIFICATION FOR 415 VOLTS AC DISTRIBUTION BOARD
11.1.0 Scope :This section of the specification cover the following scope of works: i)
ii)
11.2.0 Type and Rating of 415 V AC Distribution Board :A.C. incomer circuits shall be controlled through power contactors and MCCBs as
depicted in drawing No. PHE-01-002 of Vol.-II. The outgoing feeders shall be
moulded case circuit breakers (MCCB).
The 415 volts Power contactors shall have the following ratings:i)
ii)
iii)
iv)
No. of poles
Service voltage
Normal current
Frequency
3
415 V.
150 A.
50 Hz.
11.3.0 Standards:The power contactors and MCCBs shall comply in all respect with the requirement
of latest issue of Indian.
The L.T. switchgear shall comply in all resects with the latest editions of the following
Indian Standards:I.S. 8623
Specification for factory built assemblies of switchgear and
control gear ; Voltages up to and including 1000 V A.C and
1200 V. D.C.
I.S. 4237
General requirement for switchgear and control gear for
voltages not exceeding 1000 volts
I.S. 2147
Degree of protection provided by enclosures for L.V.
Switchgear and Control gear.
I.S. 2705
Specification for current transformers.
I.S. 3156
Specification for voltage transformers.
I.S. 3231
Specification for electrical relays.
One number authorized copy of all the applicable standards (IS or IEC) shall be
supplied after the award of work.
11.41 Particulars of 415 V System :The system for supplying A.C. power to the various auxiliaries of the generating units
and the station is as per the single line diagram No. PHE-02-001 of Vol. 2 C.
73
v)
vi)
vii)
viii)
ix)
x)
xi)
xii)
xiii)
xiv)
xv)
xvi)
xvii)
xviii)
xix)
xx)
Of the metal enclosed indoor, floor mounted, modular, free standing type.
Made up of requisite vertical sections.
Provided with a metal sill frame made of structural steel channel section properly
drilled for mounting the switchgear alongwith the necessary mounting hardware.
Hardware shall be zinc plated and passivated.
The switchgear shall be capable to withstand earthquake forces giving dynamic
accelerations of 0.5g in all the three directions at a frequency of the order of 10
cycles per second. The details of the calculations made for the designs of the various
equipments taking into account the above seismic forces shall be furnished to the
purchaser.
Provided with a degree of protection IP-51
Provided with labels on the front and rear indicating the switchgear designation
compartment wise and cubicle with the labels shall be fixed with the help of screws
and not with an adhesive.
Provided with cable entry facilities at bottom with 3mm thick removable gland plates
and necessary cable glands.
Of uniform height of not more than 2450mm including the base channels. The height
of pillar boxes can be different but not more than 2450 mm height.
Provided with gaskets all round the perimeter of adjacent panels, panel and base
frame, removable covers and doors.
Provided with bus bars running at the top as required all along the length of the
switchgear in separate sheet steel enclosures.
Operating devices shall be incorporated only in the front of the switchgear.
Individual feeder modules shall be arranged in multitier formation.
Enclosed vertical bus bars serving all modules in the vertical section shall be
provided. For safety, isolation of the vertical bus bars, insulation barrier with cutouts
shall be provided to allow the power contacts to engage with vertical bus bars.
A vertical cable alley covering the entire height shall be provided. The cable alley
shall be minimum 200m wide.
A horizontal separate enclosure for all auxiliary and control buses, as required, shall
be located so as to enable easy identification, maintenance and segregation from the
main power buses. Tap off connections from these buses shall be arranged
separately for each vertical section.
Each vertical section shall be equipped with space heaters.
Metal sheet shall be provided between the adjacent vertical sections running the full
height of the switchgear except the horizontal bus bar compartment. Also each
shipping section shall have metal sheets at both ends.
All equipment associated with a single circuit shall be in a separate module
compartment of the vertical compartment shall be sheet steel enclosed on all sides
and for draw out type modules only the handles of control selector switches- push
buttons, knobs and cutouts for lamps and meters shall be arranged on the front door
respective compartments to permit operation without opening the door. On circuit
breaker controlled circuit protective relays shall be mounted on the front door the
compartment. All cut outs shall be provided with gaskets for the purpose of dust
proofing. The opening of the doors shall be restricted to 1100 only.
All current transformers on circuit breaker controlled circuits shall be mounted on the
fixed portion of the compartment.
In breaker compartment suitable barriers shall be between circuit breakers and all
control, protective indication circuit equipment including instrument transformers.
External cable connections shall be carried out separate cable compartments for
power and control cable.
74
xxi)
xxii)
xxiii)
xxiv)
xxv)
After isolation of the power and control connection of circuit, it shall be possible to
safely carryout main in a compartment with the bus bars and adjacent circuit live.
Cable alleys shall be provided with suitable hinged. It shall be possible to safely
carryout maintenance on cable connections to any one circuit with the bus and
adjacent circuits live. Adequate number of slot cable support arms shall be provided
for cleating the cables
Rear of the single front switchgear shall be provided removable panel covers hinged
on one side and bolted the other side.
All doors shall be provided with concealed type hinged captive screws.
The neutral bus shall run continuously in the bus bar chamber and shall be solidly
connected to ground bus bar. The housing shall be complete with adequate
ventilation and heaters with all openings screened. All switches shall be designed to
permit extension in either direct and shall be complete with all accessories including
fixtures, foundation bolt, base channel etc. for securing the switch board to the floor.
The switchyard and the service bay shall be weather proof and shall be of the same
specifications described above
11.6Earthing:The assembly comprising of chassis, framework and the fixed parts of the metal
casing of the switchgear or control gear shall be provided with separate earthing
terminals and should conform to IS- 4237.Bimettalic strips shall be provided for
connecting the earthing bus with the station earth mat.
11.7Power Cables and Sealing Ends :All power cables and control cables for connection to the switchgear will be brought
from the bottom of the switchboard. Crimping type cable sealing ends suitable for
aluminium cables of suitable sizes shall be supplied with each circuit of the
switchgear. The exact dimension and number of such cable sealing ends shall be
informed to the successful bidders after finalization of cable sizes. Cabling
terminations shall be staggered along the depth of the board to allow cabling without
difficult bends. Suitable arrangements shall be provided to hold the cables along the
height of the panel so that the weight of the cable does not come on the cable
sealing lugs. The terminals shall be of substantial mechanical construction and
should conform to clause 5.3 of IS- 4237-1967.
11.8Control Cables :All the control cables shall be terminated at the terminal blocks located in the
switchgear frame and should be in a separate compartment other than the
compartments where the power cables are terminated. These terminal blocks shall
be suitable for 2.5mm multistrand copper, P.V.C. insulated cable, 1.1KV conforming
to IS- 694 (1977)/IS-8130(1976). The terminal blocks used for cables from current
transformers and potential transformers shall be of disconnecting type.
11.8.1 The switchboards shall be completed with all accessories including bus bars, bus bar
chambers, supports, wiring, terminal blocks, labels, foundation fixture, earthing
conductors, cable sealing ends, cable glands and gland plates etc. These will be
climate proof as per the requirement of IS-3202
11.9 MCCBs :The MCCBs shall have inbuilt over current, earth fault and under voltage
protection.
75
11.9.1 Switch board shall be designed on flush fronted principle with circuits arranged in
multiple tier formation.
11.9.2 The incomer MCCBs shall be provided with inbuilt over current and earth fault
protection with settings to suit the full load values of the individuals currents of the
circuits.
11.9.3 Additional contacts or auxiliary relay with contacts shall be provided for interlocking
inclosing circuits. Also if sufficient number of auxiliary contacts are not available with
over current relays of these breakers, auxiliary relay shall be provided for use in
interlocking.
11.9.4 All the outgoing feeders shall be provided with moulded case circuit breakers
(MCCB) having suitably designed thermal magnetic overload protection. These
protections shall be ambient temperature compensated for operation between -37 0 C
to 400C.
11.9.5 The MCCB shall be manually operated. The operating handle shall give a clear trip
indication. It shall assume a point midway between 'ON' and 'OFF' positions on
tripping. To reset the trip mechanism, the handle shall be moved to the 'OFF'
position.
11.9.6 The MCCB shall be quick make/ quick break, trip free and independent of manual
speed for operation.
11.9.7 The breaking capacity shall be tested for P-2 class duty cycle as per IS- 2516. The
breaking capacity test report shall be from a Government recognized test laboratory.
MCCB shall be provided with direct acting magnetic thermal release for short circuit
and overload protections. Settings of the thermal release shall be independent
adjustable over a wide range percentage of nominal rating in all ranges.
11.9.8 The main contacts of the breakers shall be of appropriate silver alloys and
mere silver plating of the faces will not be acceptable.
11.9.9 The type of arcing contacts and arc contact device shall be silver alloy arc
chutes having profiles de-ion plate.
11.9.10 The mechanical life certificate shall be from Govt. recognized test house and shall be
accompanied with the offer.
11.9.11 The temperature rise of various parts of the MCCB shall be in conformity to IS: 2516
and test certificate from Govt. Recognized test house shall be produced at the time of
detailed engineering.
11.9.12 The power contactor shall be suitable for continuous current rating of 150 A .
11.9.13 The cubicles should comply with the requirement of relevant Indian Standard and
Electricity Rules for providing minimum clearances between phases of the bus, live
part from metalled cubicle. The drawing showing full dimensions of the cubicles
alongwith size of the sheet used for manufacture should be got approved from this
office before starting the fabrication of the cubicles. The colour of the paint to be
applied to the cubicles shall be got approved from this office before final painting.
The colour of the paint shall be RAL7032, pebble grey from outside and enamel
white from inside.
76
11.9.14 All control wiring of the cubicle shall be done with 2.5mm copper cable with suitable
numbering using plastic ferrules and suitable colour code for C.T. & P.T. cables. The
cables should be PVC insulated of 1.1KV class conforming to IS: 694/IS 8130.
11.9.15 The Power Contactors and MCCBs shall be either of ABB (E.max)/L&T (U
power)/Snider (Master pact)/Siemens (3VL)/C& S.
11.10
The 415 volts bus bars shall be of suitable cross section so as to carry the required
current within the limits of temperature rise at the site conditions. They shall be so
designed and mounted in the chamber that expansion or contraction does not subject
either the bus bar or the insulating supports to any undue stress.
11.10.1 The bus bars shall be designed to withstand safely the dynamic forces due to short
circuit.
11.10.2 Neutral links of suitable capacity shall be provided where ever necessary.
11.10.3 The bus bars shall be made of high conductivity aluminium grade 91-E (6101 A) high
strength ionized aluminium alloy of suitable size. Bus bar shrouds shall be easily
removable so that the joints are
accessible for maintenance. The connections
from bus bars to the ACB's shall be fully shrouded with PVC covers.
11.10.4 Adequate space shall be there to connect aluminium bars of different rating.
11.10.5 The bus bars shall withstand short circuit faults upto 16KA (rms.) for 1 sec. All the
bus bars shall be braced with non- deteriorating SRBP supports to withstand thermal
and electro-dynamic forces of fault current.
11.11 Temperature Rise :The switchgear shall be designed to operate satisfactorily under the site conditions
and the maximum temperature attained by any part of the equipment wherein service
at an ambient temperature of 40oC shall not exceed the limits specified under clause
6 of IS- 4237 corrected for the site conditions, when measured by variation of
resistance method as given in Appendix-C of the Indian Standard IS- 4237.
11.12 Auxiliary Relays, Contacts and Devices :Suitable number of auxiliary contacts or auxiliary relays shall be provided with air
circuit breaker for indication annunciation and automatic changeover and interlocking
scheme.
11.13 Current Transformers
Current transformers CT-8 depicted in drawings No. PHE-01-002 of Vol. 2C shall be
mounted with in the cubicle of incomer circuit and shall comply with the
requirements of IS: 2705-1971 and its latest amendment.
Necessary steel brackets for mounting these CTs inside the cubicle shall also be
provided. The required CT ratio, burden and accuracy class shall be as mentioned
in section11.13.2. However, actual requirement will have to be worked out in coordination with other concerned suppliers and bidder should agree to accommodate
any change in requirement with regards to numbers and characteristics of CTs at
the stage of approval of drawings. In addition to above technical particulars, the
CTs shall have the following ratings also.
a)
b)
Thermal short time rating one second with secondary short circuit, winding
temperature shall not exceed the limit as per IEC 185.
c)
Frequency: - 50HZ
11.13.1 All the routine tests, and tests at site shall be carried out on current transformers in
accordance with Indian standard with up to date amendments thereof. The tests to
be carried out by the Contractor shall clearly be stated in the bid. Type test
certificates shall be furnished by the contractor.
11.13.2 Other requirement of different CTs are given below: S.N.
1
DESIGNATION
RATIO
PURPOSE
BURDEN
ACCURACY
CLASS
CT-8
150 /1A
METERING
50 VA
0.5
11.14
Voltage Transformers
11.14.1
Voltage transformers (PT-5) shall confirm to IS: 4156-1965 and its latest
amendments. Voltage transformers shall be provided as shown in drawing
No. PHE-01-002 of Vol. 2C & as per the schedule of requirement and be of
magnetic type. The voltage transformer shall be single-phase type and shall
be mounted inside the cubicle. Each transformer shall be complete with its
own high and low tension fuses and current limiting resistances if required.
The fuses shall be so arranged that they are readily accessible and
easily/quickly replaced. The burdens of PTs are tentative only. The Bidder
shall indicate in his offer the actual burden imposed by relays, meters so that
modification, if required, in the rated burden of transformer can be done at the
time of placing of order. All the routine tests, type tests and tests after
installation given in relevant Indian Standard shall be carried and Bidders
shall give details of such tests which shall be carried out, with their offer.
11.14.2
Other requirement of Voltage transformer are given below: Incomer PTs : One No. PTs shall be provided on each incomer as per
details given below :
Sr.No.
DESIGNATION
PT-5
RATIO
415V/3/110V/3
BURDEN
50 VA
ACCURACY
CLASS
1
11.15
Indicating Instruments
11.15.1
11.15.2
comply with the requirement of clause 10.5 of IS 1248 or equivalent. All the
instruments shall comply with the requirement of first grade instrument of
switch board type vide IS:1248 or equivalent standard. All instruments and
meters shall be accurately, adjustable and calibrated before shipment and
shall have means for calibration, check and adjustment at site.
The metric unit shall be used for displaying the values. The instrument shall
be capable of withstanding over loads applied in accordance with IS:1248 or
equivalent. The instrument shall be capable withstanding the following tests,
viz effect of shock, vibration and effect of humidity.
11.15.3
11.16
11.16.1
The following routine tests shall be carried out :1. Mechanical operation test.
2. High voltage test.
3. Test for verification of calibration of release.
4. Milli-voltage drop test.
5.
11.16.2
The following type tests shall be carried out :-
1.
2.
3.
4.
5.
6.
11.17
Type test reports for proof of having tested the MCCBs in the recognized
Govt. Test house for the following type tests as per IS shall be furnished.
Temperature rise test for main contacts.
Temperature rise test for control circuits.
Temperature rise test of auxiliary contacts.
Verification of the rated short circuit making & breaking capacities.
Verification of the ability to carry rated short time current.
All test reports should be submitted and shall be got approved by the owner
before despatch of the equipment.
Test Certificates :Seven copies of instruction manual covering instructions for installation,
operation,
maintenance shall be supplied by the renderer.
11.18
Control Voltage :All the circuit breakers shall operate satisfactorily with the control voltage of
110
volts D.C. between the range of 85% to 110% of the rated voltage and
ambient temperature of -350C to + 400C.
11.18
Push buttons should be indelibly marked in words as per clause 10.1 and
colour of the push buttons shall be as per clause 10.2 of IS: 4237.
Selection and treatment of the materials use electrical equipment and
enclosures and
sealing of the equipment to ensure that it remains
serviceable under conditions which may encourage chemical, physical and
mechanical deterioration/ prevailing at
site and adequate climatic
proofing shall be as per IS : 3202. The bimetallic strips
shall be annealed
before assembly to climatic aging.
11.20
Spares :The Bidders shall quote for the following mandatory spares :1
2
3
4
3
11.21
Power Contactor
MCCB (TP)
MCCB (TP)
MCCB (DP)
MCCB (DP)
150A
30A
15A
30A
15A
1 No.
1 No
1 No
1 No
1 No
Qty
1 No
1 No
1 No
3 Nos
2No.s
4 Nos
1 No.s
1 No.s
1
2
3
4
6
7
8
4 No.s
4 No.s
1 No.
1 No
4No.s
4 No.s
1 No.s
1 No.s
of detailed
30 A
15 A
50 A
30 A
30 A
20 A
15 A
30 A
Above list is tentative. Actual quantity / rating may vary at the time
engineering.
80