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SPEC NO.

TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 1 OF 62 36

TITLE

VARIABLE SPEED AC DRIVES

1.0

SCOPE (If VFD drives are provided)

1.1

The scope
system.

2.0

CODES AND STANDARDS

2.1

The design, material, construction, manufacture, inspection, testing and


performance of AC Drives shall comply with all currently applicable statutes,
regulations and safety codes in the locality where the equipment shall be
installed.
The equipment shall also conform to the latest applicable
standards.

3.0

DESIGN BASIS FOR POWER SEMICONDUCTORS

3.1

Power semiconductors of reputed make either in stud mounting form or


disc/flat pack type can be offered based on the duty requirements and on
techno-economic basis.

3.2

The peak reverse voltage rating of each power semiconductor shall be as


follows:

3.2.1

Power Semiconductors Protected by RC Snubber

includes transformers, cables, panels etc., required for the

The following factors of safety shall be observed:

3.2.2

a)

For converters operating in


rectifying mode only

2.0 times peak of the No


load source voltage.

b)

For converters operating


both in rectifying and
inverting modes

:
2.5 times peak of the No
load source voltage

Power Semiconductors Protected by Avalanche Diodes


The CONTRACTOR shall choose and recommend the factor of safety which
however, shall not be less than 1.5.

3.3

The current rating of the power semiconductor shall be estimated for the
specified duty class. In sizing the power semiconductor both the forward
voltage drop and the forward resistance shall be considered. Extra
semiconductors shall be provided for (N-1) operation.
ISSUE
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 2 OF 62 36

TITLE

VARIABLE SPEED AC DRIVES

3.4

The class of overload shall be one of the following:


- - - - - - - -- - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - Duty Class
Rated current values for converter (in percent of
rated direct current
- - - - - - - -- - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - I
100 % Continuous
II

100 % Continuous
150 % overload for 1 minute once in a period of 24

hours
III

100% continuous
150 % overload for 2 minute once in a period of 24

hours
200 % overload for 10 seconds once in a period of 24
hours
- - - - - - - -- - -- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3.5

For the cases where the power semiconductor chosen is of inadequate


current or voltage capacity the CONTRACTOR shall conform to the following
guidelines:

3.5.1

Inadequate Current Capacity


a)

If the power semiconductor is of stud mounting type, then current


sharing reactors shall be provided to prevent current missharing
between the power semiconductors connected in parallel.

b)

If the power semiconductors in parallel are of capsule type, then, one


of the following options may be exercised:
i)

Power semiconductors with adequate derating and the layout


configured so that current missharing between various power
semiconductors in parallel is minimised.

ii)

Selection of power semiconductors so that their forward


voltages are within a tolerance band of 100 mV to 300 mV.
ISSUE
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED

VOLUME II Part - III

BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL


POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

SECTION: D2 6

SHEET 3 OF 62 36

TITLE

VARIABLE SPEED AC DRIVES

3.5.2

Inadequate Voltage Capacity


In this case the power semiconductors shall be connected in series with
adequate protection to prevent irregular voltage grading across each power
semiconductor during turn-on.

4.0

QUADRANTS OF OPERATION
The Quadrant Operation of the Drive shall be according to the following
criteria.
a)

One Quadrant Operation -> (I) : One Quadrant of operation means


only Motoring is required & the drive should operate in the Ist Quad.

b)

Two Quadrant Operation -> (II) :- Two Quadrant Operation means the
drive should be able to control the motoring & Braking of the motor. It
can be of two types.

c)

i)

Voltage Positive & Current can change Polarity i.e. Operating


in First & Second Quad.

ii)

Current Positive & Voltage can change Polarity i.e. operating in


first & fourth Quad.

Four Quad Operation -> (IV) :- The drive should be able to operate in
all four Quadrant i.e. the motor requires forward motoring, forward
braking, Reverse motoring & Reverse braking.

5.0

FREQUENCY
MOTORS

CONVERTERS

5.1

Design And Performance

5.1.1

Configuration

FOR

SQUIRREL

CAGE

INDUCTION

Frequency converters shall have one of the two configurations given below:
a)

Current source inverter.

b)

Voltage source inverter.

ISSUE
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 4 OF 62 36

TITLE

VARIABLE SPEED AC DRIVES

5.2

DC Link

5.2.1

Current Source Inverter

5.2.2

a)

The smoothing inductor shall be sized to avoid conditions of


discontinuous current operation of the frequency converter at its
lowest frequency of operation, which shall not be less than 5 Hz.

b)

The smoothing reactor shall be uniformly insulated and shall be


protected for voltage surges occurring during sudden load throw-off.

c)

The smoothing reactor shall be made from electrolytic grade


copper/aluminium and shall be epoxy encapsulated with suitable class
of resin decided from techno-economic considerations and
performance requirements in conformity with IEC-146.

Voltage Source Inverter


a)

The smoothing reactor shall conform to requirements specified in


Clause 5.2.1

b)

The DC capacitor shall be shunt connected at the input to the inverter.


It shall be sized so that the reactive power requirements of the motor
during its total range of operation is met. Further, the following
aspects shall be observed:
i)

As per standards, the nominal value of capacitance referred to


the temperature of 300C shall be within tolerance range of
10%. At the design ambient temperature, the value of
capacitance and the tolerance range shall be such as to meet
the normal operation/performance requirements of the
frequency converter.

ii)

As per standards, the dissipation factor of each unit of the


capacitor shall be less than 1% at 300C. However, the design
ambient shall be such as to meet the normal
operational/performance requirements of the frequency
converter.

iii)

The impregnant used for the capacitor shall be noninflammable, non PCB dielectric liquid.

iv)

The voltage rating of each capacitor shall be selected based


on considerations of life expectancy, overvoltage during
ISSUE
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 5 OF 62 36

TITLE

VARIABLE SPEED AC DRIVES


regeneration of energy, design ambient temperature, ripple
voltage etc.
5.3

Inverter

5.3.1

The inverter system suitable for three phase output shall consist of the
following subsystems:
a)

The basic inverter circuit consisting of the switching device say


Thyristors/Transistors/IGBT/IGCT/MOSFET, connected so as to
supply three phase power.

b)

The logic network to enable rapid transition of the main inverter


switching devices from on-state to off-state.

c)

Suitable feedback system to allow balance of reactive power flow


during load power factor fluctuation as well as regeneration.

d)

The filter system of the inverter output to suppress 5 th, 7th, 11th, 13th
harmonics at the output of the inverter to less than 5% of the
fundamental amplitude.

e)

The ripple control system to limit current ripple to 4% at the input


terminals of the inverter caused by distorted current output.

5.3.2

The output frequency of inverter shall be controlled to within the limits


specified.

5.4

Inverter for AC drive

5.4.1

Current Source Inverter


a)

Constant Torque Operation


The current output by the DC link shall be accurately monitored so
that the ratio of the terminal voltage of the motor and the
corresponding frequency remains constant and the duty cycle
requirements indicated in Data Sheet A are met.
Necessary
protective features for tripping the frequency converter,
alarm/annunciation and fault diagnostics shall be provided.

b)

Constant Horsepower Operation


In this type of operation, the motors internal voltage shall be
maintained within + 1% while the frequency of the inverter is varied to
meet the duty cycle requirements. Necessary protective features for
ISSUE
R0

CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 6 OF 62 36

TITLE

VARIABLE SPEED AC DRIVES


tripping the frequency converter, alarm/annunciation and fault
diagnostics shall be provided.
5.4.2

Voltage source Inverter


a)

Constant Torque Operation


The DC voltage input to the inverter shall be accurately monitored to
maintain the ratio of the terminal voltage of the motor to frequency at
the rated/design value so that the duty cycle requirements as required
are met. The DC voltage input shall be maintained within + 1% of the
required value. Should this fall for any reason, necessary action for
tripping the frequency converter, and initiation of annunciation/alarm
and fault diagnostic shall be provided.

b)

Constant Horsepower Operation


In this type of operation, the voltage at the terminals of the motor shall
be maintained within +1% of the rated value while the frequency of the
inverter is varied to meet the duty cycle requirements indicated in Data
Sheet.
Necessary protective features for tripping the frequency
converter, initiation of alarm/annunciation and fault diagnostic shall be
provided.

5.5

Output Overcurrent Limit


Unless otherwise stated, the inverter shall be capable of being temporarily
overloaded to 150% of its full load ampere capacity for sixty (60) seconds
beyond which a current limit action shall be initiated and an alarm contact
initiated for annunciation.

5.6

Control Modules

5.6.1

All elements of the control system shall be mounted on epoxy laminate


boards and each board shall be a plug in module mounted on a standard
nineteen inch rack which shall be accessible from the front. Each card shall
have LED indication on its front plate to indicate normal condition of the card.
Readily accessible and clearly marked test pins shall be provided at the
important points on the cards to enable signal analysis. The CONTRACTOR
shall furnish the signal input to the card.

5.6.2

The epoxy laminates shall be free from manufacturing errors and shall be
designed to prevent incorrect insertion in the card rack. The copper side of
the card shall be suitably lacquered to prevent oxidation. The gap between
two cards shall be sufficient to permit adequate ventilation.
ISSUE
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 7 OF 62 36

TITLE

VARIABLE SPEED AC DRIVES


5.6.3

Adjustments susceptible to change by accidental contact shall be lockable.

6.0

CONTROL SYSTEM

6.1

Short time voltage dips upto 80% of nominal (e.g. in case of large motor startup connected to same bus) shall not cause the control system to stop
functioning and shall not trip the drive system.

6.2

The drive motor shall be speed regulated corresponding to 4-20mA or 0-10V


reference input signal. Upon complete loss of users speed reference signal,
the drive shall automatically run at constant speed as determined by the last
speed reference available prior to loss of the signal.

6.3

The required provision for interfacing with PLC/DCS, including details of


communication module and data transfer facility, I/O details shall be furnished
by the Bidder.

7.0

PROTECTION

7.1

Protection of Power Semiconductor

7.2

a)

Each power semiconductor shall be protected against short circuit.


The fuse shall be sized so that its I 2t does not exceed the I2t
characteristic of the power semiconductor itself. The voltage and
current rating of the fuse shall match the duty on the power
semiconductor. The arc voltage, due to melting of the fuse shall not
exceed the repetitive peak reverse voltage of the power
semiconductor.

b)

All fuses shall have a trip indicator to operate a suitable microswitch


with at least 1 NO + 1 NC potential free contacts for annunciation
and/or tripping.

c)

A fast tripping feeder circuit breaker shall be used in case fuses for
short circuit protection of thyristors are not used.

Protective Systems for AC Inverter Drive


a)

Fuses for all power semiconductors and/or other devices like


commutation chokes, capacitors etc. which are not adequately
protected against flow of abnormal currents.

b)

Under voltage and over voltage protection on the input side. Loss of
input voltage to inverter shall entail tripping of the inverter.
ISSUE
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 8 OF 62 36

TITLE

VARIABLE SPEED AC DRIVES


c)

Protection for all control cards, power supply stabilisers, filter circuits
etc. Protection shall be provided such that failure of a part does not
cause damage elsewhere in the system.

d)

Polarising relay to prevent reversal of polarity on the input side of the


inverter.

e)

Protection of inverter thyristor, commutating circuits and other inverter


elements during regenerative operation of the inverter and also during
sudden load throw-off.

f)

Besides the above, the following protective systems shall be supplied .

g)

i)

Current limit fuses at the output of the inverter.

ii)

Commutation circuit under-voltage

iii)

Inverter over-frequency

iv)

Commutation circuit over-current

v)

Phase sequence/loss of phase protection

vi)

Earth fault protection

vii)

DC link over-voltage protection

The system monitoring shall be interfaced with DCS with necessary


hardware & software & suitable protocol.

8.0

COOLING OF POWER CONVERTERS

8.1

Power semiconductors shall be mounted on heatsink, which can be individual


or common to a number of devices. Adequate provision for clamping and
mounting the power semiconductors shall be available.

8.2

Cooling of power semiconductors with 100% redundant cooling units can


either be natural air cooled or forced air cooled. The CONTRACTOR shall
recommend the type of cooling. However, for power converters which exceed
capacities of 2 kA continuous load,
alternative cooling method as water cooling shall be considered. The power
semiconductors shall preferably be double side cooled.

8.3

All equipment required for safe and correct operation as drive motor,
blower/pump, cooling water/oil header, water/oil distribution piping, De ioniser
ISSUE
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 9 OF 62 36

TITLE

VARIABLE SPEED AC DRIVES


system, flow monitors etc. as applicable shall be considered in the
CONTRACTORs scope of supply.
9.0

SWITCHING DEVICES

9.1

Switching devices as circuit breakers, isolators, contactors; switch-fuse units


etc. shall be considered in the scope of supply.

9.1.2

The switching devices shall be enclosed in a separate enclosure forming the


set of panels for the power converters. They shall have adequate clearance
both with adjacent devices and metalwork at earth potential. Connection
between devices shall be by adequate size of electrolytic grade of
copper/aluminium strips. These connections shall be adequately braced and
insulated.

10.0

CONSTRUCTIONAL FEATURES

10.1

Busbars

10.1.1 Power connections shall be of the bolted type and mating surfaces shall be
tinned.
10.1.2 The bus bars running to various converters shall be suitably designed to
ensure equal sharing between the parallel strings and prevent mechanical
stress on the fuse.
10.1.3 All bus bars shall be adequately insulated for full circuit voltage by insulating
tapes and similar insulating material.
10.1.4 In case aluminium bus bars are specified, care shall be taken to ensure that
bimetallic connections are provided wherever necessary.
10.1.5 All cubicles shall have copper earth buses of adequate size running the entire
cubicle height along the sides.
10.2

Cubicle

10.2.1 Cubicles housing the power semiconductors and drive level control system
shall conform to IP 42 degree of protection to enclosures.
10.2.2 Panels shall be free standing, floor mounting type and shall comprise rigid
welded structural frames enclosed completely with sheet steel enclosure of
thickness 2mm minimum for load bearing and 1.6mm for other members.
There shall be sufficient re-inforcement to provide level surfaces, resistance
to vibrations and rigidity during transportation and installation.
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 10 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES


10.2.3 All doors, removable covers and panels shall be gasketed all round with
neoprene gaskets. Ventilating louvers shall have screens and filters. The
screens shall be made of either brass or GI wire mesh.
10.2.4 Design, material selection and workmanship shall be such as to result in a
neat appearance inside and outside with no welds, rivets or belt heads
apparent from outside, with all exterior surfaces true and smooth.
10.3

PLC System
EPROM programme reader & provision for modifying the programme of
system control. Necessary software and hardware are to be supplied.

10.4

Painting

10.4.1 All sheet steel work shall be phosphated in accordance with the following
procedure and in accordance with IS:6005 Code of Practice for Phosphating
Iron and Steel.
10.4.2 Oil, grease, dirt and swarf shall be thoroughly removed by emulsion cleaning.
10.4.3 Rust and scale shall be removed by pickling with dilute acid followed by
washing with running water, rinsing with slightly alkaline hot water and drying.
10.4.4 After phosphating, thorough rinsing shall be carried out with clean water
followed by final rinsing with dilute dichromate solution and even drying.
10.4.5 The phosphate coating shall be followed by the application of two coats of
ready mixed stoving type zinc chromate primer. The first coat may be flash
dried while the second coat shall be stoved.
10.4.6 After application of the two coats of primer finishing synthetic enamel paint
shall be applied, each coat followed by stoving. The second finishing coat
shall be applied after completion of tests.
10.4.7 The final finished thickness of paint film on steel shall not be less than 100
microns and shall not be more than 150 microns.
10.4.8 Finished painted surface of panels shall present an aesthetically pleasing
appearance free from dents and uneven surface.
10.4.9 A small quantity of finishing paint shall be supplied for minor touching up
required at site after the installation of the panels.

ISSUE
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 11 OF 62 36

TITLE

VARIABLE SPEED AC DRIVES

10.5

Bins and Printed Circuit Cards

10.5.1 Individual bins shall be mounted on a swingable frame so that the


connections at the rear are also accessible.
10.5.2 Self retaining thumb head screws shall be needed for holding the bins in
position.
10.5.3 Adequate number of card/bin extenders for testing of PCBs shall be provided,
each with flexible cables at least two metres long. These extenders shall be
of a universal type suitable for use with any card / bin as the case may be.
10.5.4 All adjustments which are to be made while changing a card shall be outside
in a separate module preferably plugged into the regulator bin.
10.5.5 Locking of individual cards in a bin shall preferably be through self retaining
thumb-head screws.
10.5.6 Control modules shall be in the form of plug in packages, plugged into a
module bin. Each plug in unit shall consist of a strong frame on which a
printed circuit board would be permanently screwed. The plug connections
shall only be of the pin type.
10.5.7 The printed circuit board (P.C.B.) shall be made of glass fibre filled with epoxy
laminates. The plug in unit shall be screwed to the basic socket in the
module bin with long through bolts and knurled heads.
10.5.8

The front plates of the plug in unit shall have the switches, the
potentiometers, miniature monitoring meters, test points etc. Each plug in
unit shall have its own identification legend.

10.5.9

All plug in units shall be polarised to prevent incorrect insertions into the
module bin.

10.5.10 The gap between two plug in units inside a bin shall be sufficient to permit
adequate ventilation.
10.5.11 The copper side of the printed circuit board shall be lacquered to prevent
oxidation.
10.5.12 Each side of the printed circuit board shall have a shield cover to prevent
inter circuit and external interference.
ISSUE
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 12 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES


10.5.13 The P.C.B. shall be mounted on P.C.B. guides fixed on standard racks and
the shield properly grounded.
10.5.14 Control circuit test points shall be easily accessible for monitoring and
maintenance.
10.6

Annunciation

10.6.1

The annunciator shall work on DC power supply as specified.

10.6.2

Each annunciator window shall have two lamps connected in parallel which
operate at not more than 75% of their rated voltage.

10.6.3

Window shall be arranged in a logical group.

10.6.4

The annunciator shall have a module construction with glass epoxy plug in
cards.

10.6.5

Alarm bell/siren shall be continuously rated and shall have a series


resistance.

10.6.6

The annunciator shall have the following facilities.


a)
b)
c)

First in sequence, memory reset.


Fleeting faults shall be memorised.
Test Feature.

10.6.7 There shall be a three tier system of protection and annunciation:

10.7

a)

Alarm both audible and visual.

b)

Warning with delayed shut down time delay through a timer of range
0-60 sec.

c)

Disturbance associated with failures of systems elsewhere.

Meters

10.7.1 Individual meters shall be provided for speed reference, speed feed back,
current reference, current feedback, pulse output, and regulated power supply
voltages.
10.7.2 All meters shall be identical and fed through individual buffer I.C. amplifiers.
10.7.3 All meters shall be the circular scale type having a full scale deflection of
2700.
ISSUE
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 13 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

10.7.4 All meters shall conform to at least accuracy class 1.0.


10.7.5 All meters with their individual buffer amplifier cards shall be housed in
separate bin. It is recommended that the buffer amplifiers all be housed on a
single/two card/s and this card/s be itself/themselves housed in the regulator
bin.
Sensitive signal leads in that case shall not have to traverse from one bin to
another, only noise insensitive buffer amplifier output leads shall need to go to
the meter bin.
10.7.6 Selector switches if used with any meters shall have pistol grip handles.
10.8

Wiring

10.8.1 Stranded, flexible copper cable of 2.5 sq.mm shall be used for C.T. circuits
and 1.5 sq.mm for other control circuits. However for PCB terminals 0.75
sq.mm may be accepted.
10.8.2 Ultra flexible cables shall be used for all connections from a fixed part to a
movable member. In addition, a hanging loop of sufficient length shall be
provided to avoid any cable stressing.
10.8.3 All terminal boards for outgoing connections shall be at a height of at least
300 mm from the cubicle floor, and preferably tilted at an angle of 45 0 to the
horizontal for ease of connections. Similarly, connection of the incoming
power cables to the bus bars shall be done at a height of at least 300 mm
from the cubicle floor.
10.8.4 Item designation and location marking shall be in line with IEC
recommendations.
10.8.5 Device labeling shall be on its fixed mounting and not on the device itself
such that labeling remains even when the device is replaced. Metallic
labels/paper labels or sticker shall be accepted.
11.0

TESTING
Routine tests for all the components shall be carried out as per relevant
standards in presence of Purchaser or his representative. Type test
certificates for similar equipment supplied by the Contractor shall be
submitted. In case Type test certificate for similar equipment is not available,
the same shall be conducted in presence of purchaser or his representative if
purchaser so desires.
ISSUE
R0

CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 14 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

11.1

Tests on Power Semiconductors


All power semiconductors selected shall be subject to quality assurance tests
to check on the characteristics on samples. All routine and type tests shall be
carried out as per relevant standards. The broad outlines of the tests to be
conducted are as follows:

11.2

a)

Off state voltage and reverse voltage

b)

Critical rate of rise of off state voltage

c)

On state voltage

d)

Thermal resistance

e)

Surge on-state current

f)

Triggering data

g)

Recovery charge and recovery time

h)

Critical rate of rise of on-state current

i)

Switching losses

j)

Environmental Tests

Tests on Converters
Converter with its enclosure and cooling system shall be connected to a
dummy load. A variable voltage source on the source side shall be adjusted
so that the specified current rating of the converter at no-delay of the firing
angle (in case thyristors) shall be passed. At the end of stipulated period of
test a timer shall cut-off the source. The load side and source side current
shall be measured/recorded during the testing phase. The temperature of the
case and the heat sink and wound components like chokes shall be suitably
recorded. The temperature decay measurement/recording shall continue for
the off-duty cycle at agreed intervals. During the course of test the cooling
system shall be operative.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 15 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

The following tests shall be conducted:

11.3

11.4

a)

Checking of the setting of the protection devices and their functioning.

b)

Checking of the auxiliary devices and their functioning.

c)

Speed regulation of the drive shall be observed at different output


voltage and frequency settings (for AC drives).

d)

Determination of the power losses at specified loads (By Calculation).

e)

Load test or current test for large converters (above 1 MW).

f)

Insulation test

g)

Observation of various wave forms i.e. current and voltage.

Other Composite Test at No-load


a)

Environmental tests on printed circuit boards, pulse transformers etc.

b)

Other tests as may be agreed on various converter subsystems.

Acceptance Test
These shall be conducted at the works of the VENDORS and/or his subvendor to ascertain that performance stipulated in this specification has been
honoured. Dummy loads as required for the purpose of simulating the
operation conditions at the VENDORs works shall be considered in scope of
this specification. However, should this not be possible, testing at site with
the actual load shall be conducted to prove the performance of the power
converters.

11.5

All the meter, instruments, devices used for the testing purpose shall be
properly calibrated by standard authorised agencies which shall be traceable
to National Standards. For each such instrument proper validity of calibration
shall be documented by Vendor.

12.0

HARMONICS LIMITATIONS
When specified in Data Sheet A, the harmonics generated on source (Input)
side and output side (For AC drive only) shall be restricted to the following
limits:
ISSUE
R0

CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 16 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES


a)

Voltage Harmonics

Source side
Load side
Maximum 5% Maximum 5%

b)

Current Harmonics
5th
7th
11th

Source side
Maximum 30%
Maximum 20%
Maximum 10%

Contractor shall indicate clearly the method of achieving above requirement.


13.0

TRANSFORMERS
Output Transformers required for the system can be chosen as per the
requirement. (Oil Filled Transformers / dry type cast resin transformers) If oil
filled transformers are used it shall confirm to the following specification.

13.1

General
The transformer shall be of suitable capacity with suitable voltage ratio, 3,
ONAN, oil filled Transformer suitable for outdoor installation with 5% off
circuit tap changer in steps of 2.5% as per Technical Specification and IS
2026 with all fittings and accessories. The transformer shall be fed from 6.6
kV unit bus. The LT side , shall be connected to Rectifier Banks of VFD drive
of Motor through suitable number of cable runs as per the design
requirement. The vector Group shall be suitably designed for the Variable
Frequency Drive system suitably.

13.2

Transformer Rating and Over loading


i)

Transformers shall be capable of delivering the rated current at a


voltage equal to 105 percent of the rated voltage without exceeding
the temperature limits specified for liquid, winding and hot spot.

ii)

Transformers shall operate satisfactorily without injurious heating at


rated kVA, at any voltage within 10% of the rated voltage of the
particular tap.

iii)

Transformers shall be designed for 50 Hz + 3%, - 5%.

iv)

Transformers for two or more limits of voltage or frequency or both


shall operate satisfactorily at its rated kVA without injurious heating
under all the rated conditions of voltage or frequency or both,
provided increased in voltage is not accompanied by decrease in
frequency.

v)

Transformers shall be suitable for over loading as per IS 6600, unless


ISSUE
R0

CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 17 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

specified otherwise. Off circuit tap switch, terminal bushings, other


auxiliary components / equipment shall be designed for maximum
permissible overloading. Short time over loading to the extent of
50% shall be considered for this purpose, for all transformers unless
specified otherwise.
13.3

13.4

Short Circuit withstand capability


i)

Transformers shall be capable of withstanding thermal and


mechanical stresses during 3 phase, line to line, double line to earth
and line to ground dead short circuits at the transformer terminals, for
a period specified, without any injury. Temperature of the windings
prior to the short circuit to be considered for this shall be that
corresponding to the maximum permissible value applicable to the
overloading cycle specified.

ii)

For this purpose, infinite supply system and solidly earthed systems
shall be considered.

Harmonics
The transformer shall be designed with particular attention to the suppression
of harmonics, especially the third and fifth.

13.5

Flux Density
i)

The maximum flux density in any part of the core and yokes at normal
voltage and frequency shall be such that the flux density under over
voltage condition shall not exceed the maximum permissible values
for the type of laminations used and core construction adopted.

ii)

In case of transformers with variable flux, the voltage variation, which


would affect flux density at every tap, shall be kept in view while
designing the transformer.

iii)

Transformers shall be designed to withstand the following overfluxing


conditions:
110% of maximum density
corresponding to rated voltage

: Continuous for all


transformers

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 18 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

13.6

Magnetic Circuit
i)

The cores shall be constructed from high grade, low loss, high
permeability cold rolled non-ageing grain oriented silicon steel
laminations.

ii)

Thickness of laminations shall be 0.3 mm or less. Surface insulation of


laminations shall be rust resistant and have high interlaminar
resistance. Insulation shall withstand annealing temperature as high
as 850 deg.C. The insulation shall be resistant to the action of hot
cooling medium.

iii)

The insulation structure for the core to bolts and core to clamp plates
shall be such as to withstand a voltage of 2000V AC for one minute.

iv)

Wherever the CRGO sheets are punched or sheared into laminations,


laminations shall be annealed in a non-oxidising atmosphere to relieve
stresses and restore the original magnetic properties of CRGO sheets.
The laminations shall be free of all burrs and sharp projections.

v)

The design of magnetic circuit shall be such as to avoid static


discharges, development of short circuit paths within itself or to the
earthed clamping structure and production of flux components at right
angles to the plane of the laminations which may cause local heating.

vi)

Ducts shall be provided where necessary to ensure adequate cooling.


The winding structure and major insulation shall not obstruct the free
flow of cooling medium through such ducts.

vii)

All steel sections used for supporting the core shall be shot or sand
blasted after fabrication.

viii)

The finally assembled core and coil assembly shall be rigidly fixed to
the tank to avoid shifting during transport, handling and short circuits.
Adequate provision shall be made for lifting the complete core and coil
assembly.

ix)

The supporting frame work of the cores shall be so designed as to


avoid the presence of pockets which would prevent complete emptying
of the tank through the drain, valve or cause trapping of air during
filling.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 19 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

13.7

Windings
i)

The vector Group of the winding shall be suitably designed for the
operation of Electronic Rectifier Bank Circuit.

ii)

The coil clamping arrangement and the finished dimensions of any


ducts shall be such as to not impede the free circulation of cooling
media through the ducts.

iii)

The windings and connection of transformer shall be braced to


withstand shocks, which may occur during transport or due to short
circuits, repeated peak load and other transient conditions during
service.

iv)

Windings shall be subjected to a shrinkage treatment before final


assembly, so that no further shrinkage occurs during service.
Adjustable device shall be provided for taking up any possible
shrinkage of coils in service if required.

v)

The conductors shall be transposed at sufficient intervals in order to


minimise eddy currents and equalize the distribution of currents and
temperature along the windings.

vi)

Coil clamping rings shall be of steel or of a suitable insulating material.


Axially laminated material other than bakelised paper shall not be
used.

vii)

Completed core and winding assembly shall be dried in full vacuum to


eliminate presence of moisture. After drying process, the full assembly
shall be impregnated immediately

viii)

No strip conductor, wound on edge shall have a width exceeding six


times its thickness.

ix)

The winding material shall be copper

x)

Windings shall not have sharp bends, which might damage insulation
and produce high dielectric stresses.

xi)

Coils shall be supported using dried and high pressure compressed


wedge type insulation spacers at frequent intervals.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 20 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

13.8

xii)

All threaded connections shall be locked. Leads from the winding to


the terminal board and bushing shall be rigidly supported to prevent
injury during short circuits / vibration.

xiii)

Permanent current carrying joints in the windings and leads shall be


welded or brazed.

ix)

Clamping bolts for current carrying parts inside the transformer shall
be compatible with liquid under all service conditions.

Tappings as specified shall be provided on the higher voltage winding of


each transformer and shall be arranged so as to maintain as far as possible
the electromagnetic balance of the windings.
i)

Off circuit tap switch


Off circuit tap switch shall be externally operated type. The tap switch
contacts shall be silver plated having adequate rating as applicable to
the transformer. The tap switch and contacts shall have spring action.
The switch shall not occupy any intermediate position. The operating
handle shall be easily accessible and can be locked in any position.
Tap numbers shall be engraved on non-corrodable metal sheet,
screwed to the tank. Tap switch indicator shall be permanently fixed
to the operating handle.

13.9

Transformer oil
All transformers shall be supplied along with first filling of Transformer oil
and 10% excess quantity in non-returnable drums and the liquid shall
comply with the latest issue of IS 335. All components, insulating materials
used in the transformer construction shall be compatible with the liquid
under all operating conditions.

13.10

Transformer cooling
i)

Radiators
Radiators shall be detachable type. Radiators shall be provided with
flanges, bottom and top shut off valves for connection, necessary
drain plug, air release vents etc., in each.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 21 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

13.11

Tank
i)

Tank shall be made from high quality low carbon steel and shall have
oil tight welded construction.

ii)

The tanks of all transformers shall be complete with all accessories


and shall be designed so as to allow the complete transformer filled
with liquid to be lifted by cranes or jacks, transported by road, rail or
water without over straining any joints and without causing
subsequent leakage of liquid.

iii)

Fully assembled transformer together with its radiators, conservator


and other fittings shall withstand for one hour, a pressure of 35
KN/sq.m (5 lb / sq.inch), measured at the base of the tank.

iv)

Transformer tank with radiators shall be capable of withstanding 300


mm of mercury (34.7 KN/sq.m) vacuum.

v)

The base of each tank shall be so designed with Bi-Directional roller


wheels that it shall be possible to move the complete transformer unit
by rollers in any direction using plates or rails.

vi)

Tank cover shall be of adequate strength and shall not distort when
lifted. Tank covers shall be slightly projecting outside to prevent
ingress of rainwater. Inspection openings shall be provided as
necessary to give easy access to bushings, testing earthing
connection without removing tank cover. Atleast two openings of
adequate size shall be provided at each end of the tank. Inspection
covers shall have lifting arrangement. The tank top cover shall be
bridged with suitable size copper clamp for earthing.

vii)

Tank covers shall have pockets for probes of winding temperature


indicators and oil temperature indicator. The pockets shall be located
in the position of maximum liquid temperature and it shall be possible
to remove the instrument bulbs without lowering the liquid in the tank.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED

VOLUME II Part - III

BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL


POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

SECTION: D2 6

SHEET 22 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

14.12

Lifting and haulage facilities


Lifting lugs shall be suitable for lifting the transformer with liquid.
Minimum of 4 jacking lugs, in accessible positions shall be provided to raise
or lower the complete transformer with liquid using hydraulic or screw jacks.
Minimum height of the lugs above base shall be 300 mm excluding under
base dimensions, for transformers upto 10T. Transformers shall be
provided with detachable, bi-directional rollers as specified. Means shall be
provided for locking the 90 deg. Swivel movements in positions parallel to
and at right angles to the longitudinal axis of the tank.

14.13

Terminations
Terminations as mentioned in this specification shall be provided.
i)

Cable Box & Disconnecting Chamber


The Transformer shall be provided with Cable boxes with air insulated
disconnecting chamber. Bushings & bus bar metal parts shall be
suitable for the type and number of cables specified.
The
Disconnecting chamber shall be suitably supported. The size of cable
box shall meet the minimum dimensional requirement of cable
termination. Double compression type brass cable glands and tinned
copper lugs shall be supplied. Cable boxes shall be air-insulated type
with clearances in air between phases and between phases and
ground as applicable for the impulse level specified as per CBIP / IS.
Further, air insulated disconnecting chamber shall be provided with
inspection opening. Transformer may thus be withdrawn from its
position without disturbing cable connection. The gland plate shall be
bolted type and shall be sufficiently bid to remove the trifurcated cable
from the cable box, without damaging the termination.
Min. clearances in air in mm

6.6 kV

Between phases

120

Between phases and ground

100

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 23 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

ii)

14.14

14.15

Cable sealing kits of specified type along with associated


accessories, like stress relieving cones, insulating tapes, trifurcating
boot, HT insulating paste etc. shall be supplied along with transformer
for HT cable termination. Projecting lips shall be provided at the joints
of cable box disconnecting chamber etc., to prevent ingress of
rainwater.

Bushings
i)

Electrical characteristics of bushings shall be in accordance with IS


3347 and IS 2099. Minimum rated current of the line end bushing
shall be 1.2 times the rated current of the corresponding winding.
Where repeated peak loads are specified, bushing rating shall be
selected accordingly.

ii)

7.2 kV / 1.1 kV bushings shall be used for the HV side and suitably
rated bushings shall be used for LV sides & LV neutral respectively.

iii)

Clamps and fittings made of steel or malleable iron shall be hot dip
galvanized. Bushings rated more than 400 A shall have non-magnetic
clamps and fitting only.

Bushing current transformer


i)

Where bushing CTs are specified, the same shall conform to the
specification indicated in data sheet. Hot spot temperature of CTs
shall be specified for transformers.

ii)

It shall be possible to remove the CTs at site, without opening the


transformer tank cover / active part.

iii)

All secondary leads, including tappings shall be brought to a


weatherproof terminal box. Rating and terminal marking plate of the
CTs shall be screwed near the terminal box. CTs shall be wired from
terminal box to the marshalling box.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 24 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

14.16

14.17

Conservator
i)

Conservator shall be located in such a position as not to obstruct the


electrical connections to the transformer. The conservator volume
shall be sufficient to maintain the oil seal from ambient temperature of
44 deg. C to all temperature of 90 deg C., with oil level varying within
minimum and maximum levels.

ii)

Prismatic type oil level gauge with minimum and maximum levels
marked shall be provided. Taps or valves shall not be fitted to the oil
gauge.

iii)

Magnetic oil Gauge (MOG) shall be provided with oil level low alarm
mercury contact.

iv)

Drain valve shall drain the conservator oil completely. One end of
conservator shall be bolted into position so that it can be removed for
cleaning purposes. If the sump is formed by extending, the same
shall be for atleast 25 mm. Oil filling hole with cap shall be provided.

v)

A silica gel breather with inspection window and oil seal shall be
mounted at 1.4m above transformer base and connected to the
conservator.

Buchholz relay
All transformers shall be provided with double float buchholz relay fitted in
the pipe connecting the transformer tank to the conservator. The diameter
of pipe shall be suitably designed. The pipe shall be arranged at a rising
angle of 3 to 9 degrees to the horizontal, upto buchholz relay. Valves shall
be provided on either side of relay after providing necessary length of
straight pipes. The relay shall have pet cocks at the top and bottom, drain
plug, inspection window, calibrated scale to indicate gas present, built-in
test facility and terminal box with oil tight gland. The relay shall have
electrically separate, potential free self reset contacts for alarm and trip.
Contacts shall be rated to make, carry and break 5 A at 110 V AC. The
contacts shall be wired to marshalling box. The relay shall conform to IS
3677.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 25 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

14.18

Valves and connections


All valves shall be of gun metal / cast steel, full way type with internal screw
and shall be opened by turning counter clockwise when facing the hand
wheel. All valves opening to atmosphere shall be fitted with blank flanges.
Means shall be provided for locking the bottom valves in open and closed
positions. All valves shall be provided with an indicator to show clearly the
position of the valve. Oil sampling valves shall be provided at top and
bottom of the main tank and these shall not be fitted on the filter valves. All
transformers shall have bottom drain valve, top and bottom filter valves
suitable for connecting to oil filtration unit.

14.19

Joints and gaskets


All gaskets used for making oil tight joints shall be of proven material such
as granulated cork bonded with synthetic rubber or synthetic rubber gaskets
for oil filled transformers. Gaskets used for liquid filled transformers shall be
compatible to the liquid used.

14.20

Pressure relief device


i)

Pressure relief device provided shall be of sufficient size of rapid


release of any pressure that may be generated within the tank and
which might result in damage to the equipment. The device shall
operate at a static pressure of less than the hydraulic test pressure
for transformer tank. Means shall be provided to prevent the ingress
of rainwater.

ii)

The relief device shall be mounted on the main tank and if on the
cover, shall be fitted with skirt projecting 25 mm inside the tank and of
such a design to prevent gas accumulation

iii)

The device shall be provided with Trip contact for Tripping the
Transformer in cases of any pressure that may be generated within
the Tank.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 26 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

14.21

14.22

Thermometers
i)

150 mm dial type oil temperature indicators for measuring top oil
temperature & winding temperature indicator shall be provided.

ii)

Each thermometer shall have potential free Normally Open Contacts


for alarm and trip contacts. Temperature setting of each contact shall
be independently adjustable at site. A manual reset type maximum
temperature indicator shall be provided for each thermometer. `

iii)

Winding temperature indicator shall have temperature sensing


element and image coil

iv)

All contacts shall be rated to make 0.5 A (min) and break 0.2 A (min)
at 110 VAC. All contacts shall be wired to marshalling box.

Marshalling box
Sheet steel, dust and vermin proof marshalling box shall be provided for
mounting auxiliary component of transformer, viz., temperature indicator,
push buttons, signal lamps, auxiliary relays, terminal blocks. Marshalling
boxes for outdoor type transformer shall be weather proof. All protection
relays, instruments CTs mounting shall be wired to marshalling box.

14.23

Internal earthing arrangement


All metal parts of the transformer with the exception of individual core
laminations core bolts and associated individual clamping plates shall be
earthed.
i)

Earthing of bushing CTs


Where bushing CTs are provided, secondary winding shall not be
earthed inside. Both ends of winding shall be fully insulated and
terminated outside in weather proof terminal box. Magnetic core of
CTs shall be earthed.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 27 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

14.24

Fittings and Accessories


Transformer shall be provided with fittings and accessories as specified in
the data sheet.

14.25

Tests
All the transformers shall be subjected to the following routine tests and one
transformer shall be type tested as indicated, at the manufacturers works.
Test procedure as per IS 2026 shall be adopted.
i)

Routine tests
1.

Transformer shall be fully assembled with all fittings and


accessories including wheels to ascertain that all the parts fit
correctly

Resistance of each winding of each phase principal tap and at


all other taps.

Voltage ratio at all taps

Checking of voltage vector relationship

Impedance voltage at rated frequency and principal tap,


lowest and highest taps.

Load loss at rated current.

Zero sequence impedance at principal tap, rated frequency.

No load loss and no load current at rated frequency and


100%, 110% of rated voltage on HV side. Test shall be
repeated with 415V, 3 phase supply connected to LV side (if
the LV side rated voltage is more than 415 V). No load & load
losses shall be as per CBIP / IS with tolerance.

One minute power frequency withstand voltage test.

10

Induced over voltage withstand test.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED

VOLUME II Part - III

BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL


POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

SECTION: D2 6

SHEET 28 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

11

Polarity check, ratio check, measurement of secondary


winding resistance, excitation, characteristic curve, insulation
resistance of all bushing CTs.

12.

Calibration of winding and oil temperature indicators.

13.

Tests on liquid
Following tests shall be conducted on oil samples drawn from
transformer tank.
a) Break down voltage.
b) Tan delta
c)

Water content

Manufactures
test
certificates shall also
be furnished

d) Acidity
ii)

Type Test
1. Temperature rise test.
2. The Contractor shall submit Type Test Certificates for similar
capacity Transformer supplied by him elsewhere for (i) Short time
withstand capability Test and (ii) Impulse Voltage withstand Test.
In case Type Test certificates for similar equipment are not
available the same shall be conducted in the presence of the
Purchaser or his Representative if Purchaser so desires without
any financial implications to the Purchaser.

14.26

Drawings
The following drawings for the Transformers shall be submitted for approval.
a)

Dimensional GA drawing of transformer indicating maximum limiting


over all dimensions, location of fittings and accessories, weights,
shipping dimensions, accessories, dismantled for transportation,
dimensional drawing for cable box for HT & LT side, dimensions of
rollers, HV & LV flange details where busduct termination is specified,
clearances and insulation levels, bushing details etc.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED


BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL
POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

VOLUME II Part - III


SECTION: D2 6

SHEET 29 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

b)

Front view of marshalling box.

c)

Terminal plan of marshalling box.

d)

Specifications, excitation characteristics, terminal plan of bushing CTs


if applicable.

f)

GA drawing of HV, LV neutral bushings

g)

Manufacturers catalogues for all relays, WTI, OTI

h)

Operation and maintenance manual for transformer. (Schedule of


submission of drawing shall be as specified)

i)

Disconnecting chamber, cable box with clearances.

15.0

Drawings/Documents for the VFD to be furnished by the Contractor

15.1

General arrangement drawings showing outline dimensions, cable entry


openings, fixing/foundation details, weights and door openings.

15.2

Front & cross section views showing arrangement details of equipment and
terminals and with Bill of Material for all equipment.

15.3

Schematic diagram indicating terminal number for external connections &


block diagram of control system.

15.4

MANUFACTURERS technical literature on various equipments supplied.

15.5

Wiring diagram of complete inverter. This shall be based on approved


schematic drawing. The correctness of this drawing shall be the responsibility
of the VENDOR.

15.6

Test certificates for the cabinet and all individual equipments and performance
load tests shall be submitted atleast 2 weeks before despatch of equipment.

15.7

Operation and maintenance manuals shall be furnished with the equipment.

15.8

Detailed drawing of converter showing layout of power semiconductors,


fuses, heat sinks, cooling system etc.

15.9

Details of testing procedures for power semiconductors and power converters


as per Standards/Code of Practice for approval.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED

VOLUME II Part - III

BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL


POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

SECTION: D2 6

SHEET 30 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES


Technical Parameters
General requirement
1.0

Type of Drive

1.1
1.2
1.3
2.0
3.0
4.0
5.0
6.0

Rating of the drive


Type of duty (cl. 3.4)
Quadrants of operation
Quantity
Power supply
Variation voltage
Variation in Frequency
Combined voltage and
frequency variation
Environmental Conditions

7.0
8.0

Location
a) Whether in air conditioned room
b) If No :
Average ambient temperature 0 C
Design ambient temperature 0 C
Relative humidity
%
Vibration
9.0
Type of cooling for drive panel

10.0
11.0
12.0
12.1
12.2
12.3
12.4
12.5
13.0

If water cooled, is DM water required


If yes, quantity of DM water
Cable
a) Size and type
b) Entry
Dimensions
Degree of Protection
Instantaneous over current
Motor overload protection
Over voltage / under voltage
Momentary power loss
Stall protection

Inverter controlled ( PWM ) AC


drives/Synchronous drives
By Contractor
Class III
II
By Contractor
6.6kV, 3ph, 50Hz
6.6kV + 10 %
50 Hz + 5 %
+ 10%

Indoor
Yes / No
44 deg C
Natural cooling/forced cooling with
fan
Yes / NO
------ litres/minute
By Contractor
Bottom
By Contractor
IP 42
Required
Required
Required ( with timer )
Required ( Back up time upto 1 sec.)
Required

Control characteristics for


both AC/DC
a) Control Method
b) Freq. control range
c) Accelerate/decelerate time

Drive Level control using digital system


By Contractor
By Contractor
ISSUE
R0

CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED

VOLUME II Part - III

BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL


POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

SECTION: D2 6

SHEET 31 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

14.0

Harmonics Limitations
a) Load side for AC drives
b) Source side(with DC/AC
drives)
Current harmonics
Inverter Controlled A.C. Drives
Application
Quantity
a) Starting/rated torque

1.0
2.0
3.0

4.0
i)

ii)

Maximum within 5%
5th . 7th
11th .. 13th
By Contractor
By Contractor

b) Type of converters

PWM controlled . GTO,


MOSFETS/IGBT/IGCT

c)
d)
e)
f)
g)
h)
ij)

110% of motor rating


110% of motor full load current
By Contractor
By Contractor
50 Hz
6 pulse
Two quadrant

Inverter capacity at specified pf


Rated Current
Load power factor
Max. continuous current
Rated frequency
Converter Bridge
Single Quadrant/Two quadrant/
Four Quadrant

Control Characteristics
Speed Control
a) Rated speed
b) Speed ratio
c) Constant torque/constant power
d) Speed accuracy
e) Closed loop/open loop
f) If tachogenerator used (for
closed loop)
g) Accel./Deccel. time
- Type of tacho-generator
- If analogue, then reference signal
mA/mV
- Is remote operation required
- If yes, is it through
- Type of control
Braking
a) Type of braking
b) Braking Torque

Required
By Contractor
By Contractor
By Contractor
By Contractor
Closed Loop
No
By Contractor

Yes
DCS
Digital
By Contractor

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED

VOLUME II Part - III

BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL


POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

SECTION: D2 6

SHEET 32 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

5.0

Miscellaneous
Soft-start
Flying restart
Auto restart
Kinetic Buffering

Yes
Yes
Yes
Yes
( Preferably for a back up time
of 1 sec.)

Codes and Standards


Specification for metal clad base
materials for printed circuits for use
in electronic and telecommunication
equipment
Specification of Transformers and
Inductors (Power, Audio, Pulse and
Switching) for Electronic
Equipment
Semiconductor rectifier equipment
safety code
Specification for printed circuit
Board
Recommended practice for emergency and standby power systems for
industrial and commercial applic.
Semiconductor converters
Basic climate for mechanical
durability tests for electronic
components
Degree of protection provided by
enclosures for low voltage switchgears and control gears

IS:5921

Environmental requirements of
semiconductor devices and
integrated circuits
Ambient temp. of electronic
equipment

IS:6553

Environmental tests for electronic


equipment
Terminal for electronic equipment
Equipment accessories component
parts raw materials and test shall in
general conform to IS
IEC
Factory built assemblies
Of low voltage

IS:9000

CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

IS:6297

6619
IS:7405
IS :
IS
IS:9000

IEC :

IEEE::446

IEC:146

IS:2147

IS:9676

IS:4007

IS

BS:

IEC:439
ISSUE
R0
TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED

VOLUME II Part - III

BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL


POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

SECTION: D2 6

SHEET 33 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

Semiconductor rectifier assemblies and


thyristor converters
Busbars and busbar connections
Degree of protection
Provided by enclosures
Code of practice for
earthing
Control cabinet
Current transformers
Potential transformers
Power transformers

IS:3695
IS:4560
IS:5082
IS:2147

BS:4417

IEC:148

BS:159
BS:

IEC:
IEC:144

IS:3043

BS:CP:1013 IEC:

IS:4237
IS:2705
IS:3156
IS:2026

BS:
BS:3938
BS:3941
BS:171

Indicating meters
Wiring rectifiers
Pulse transformer
Semiconductor Converters
Basic climate and Mechanical
Durability Tests for Electronic
Components

IS:1248
IS:2274
IS:6297
IEC:146
IS:589

BS:89
BS:
BS:

Environmental tests for electronic


and electrical equipment

IS:2106 Parts 1 to 18

Degree of protection provided by


enclosures for low-voltage switchgear &
control gear

IS:2147

IEC:
IEC:185
IEC:185
IEC:75
IEC:51
IEC:
IEC:

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED

VOLUME II Part - III

BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL


POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

SECTION: D2 6

SHEET 34 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

DATA SHEET To be filled by the Contractor


1.0

Converter Designation

2.0

Control Method

2.1

Quadrant of Operation

3.0

Overload capacity & duration

% , Mins

3.1

Minimum duration required for two


successive overloads as specified above

Min/Hrs

4.0

Transient change in the nominal output


voltage for 100% change in motor load

5.0

Size of largest motor which can be started


direct on line

6.0

Max distortion factor of input current at I/P


of drive

7.0

CONTROL SYSTEM

7.1

Drive level control

7.1.1

Nature of system

/Digital

7.1.2

Detailed technical information enclosed

Yes/

7.2

Functional level Control

7.2.1

Nature of System

/Digital

7.2.2

Detailed technical information enclosed

Yes/

8.0

MONITORING AIDS

8.1

Power Semi-conductors

8.1.1

Are temperature sensing elements

Armature/Field

kW

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED

VOLUME II Part - III

BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL


POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

SECTION: D2 6

SHEET 35 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES

8.1.2

provided?
Technical write up enclosed

8.1.3

Extra semiconductors provided for (N-1)


operation

8.2

Cooling data for forced cooling


1. By air/by water

Yes/
Yes/

2. Flow rate
3. Inlet temperature of cooling media
4. Outlet temperature of cooling media
5. List of accessories/cooling equipment
6. Flow rate Transducer at inlet & outlet
Provided?
7. Temperature Transducer at inlet &
outlet provided?
8. Technical write up enclosed?
9. 110% Redundant cooling system
provided
9.0

Tentative Dimensions & weight

1.0

AC Drive
Rated Output Voltage

**
V

1.1

Accuracy of output voltage to maintain


constant V/f

2.0

Output Frequency

Hz

2.1

Setting range

Hz

2.2

Accuracy

%
ISSUE
R0

CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3

SPEC NO.
TCE. 4857A-C-510-01

JSW ENERGY LIMITED

VOLUME II Part - III

BTG PACKAGE FOR 2 x 300 MW COAL BASED THERMAL


POWER STATION AT TORANAGALLU, BELLARY
(KARNATAKA)300300300

SECTION: D2 6

SHEET 36 OF 62

36

TITLE

VARIABLE SPEED AC DRIVES


3.0

Designed Power factor

4.0

Output rating kVA at designed power


factor

5.0

Output transformer type, rating & details, if


provided

6.0

Transformer winding, secondary

kVA, V,
%Z

300300
All dimensions are in mms.

ISSUE
R0
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED

TCE FORM 329 R3