Beruflich Dokumente
Kultur Dokumente
2X660MW SUPER CRITICAL THERMAL POWER PLANT
AT
THARANGAMBADINAGAPATTINAM DIST.TAMIL NADU
BID SPECIFICATION NO. : 11Z02SPCG001
MAIN PLANT PACKAGE
[BOILER TURBINE GENERATOR]
VOLUME : IIF/1
TECHNICAL SPECIFICATIONS
FOR
ELECTRICAL EQUIPMENT & ACCESSORIES
CONSULTANT
MAIN PLANT PACKAGE
[BOILER TURBINE GENERATOR]
OVERALL CONTENTS
VOLUME-I : COMMERCIAL & GENERAL CONDITIONS OF CONTRACT
CONTENTS
VOLUME II-D : SPECIFICATIONS FOR POWER CYCLE & OTHER PIPING, VALVES
& SPECIALTIES
VOLUME : II-F/1
TECHNICAL SPECIFICATIONS
FOR
ELECTRICAL EQUIPMENT & ACCESSORIES
CONTENT
& ACCESSORIES
SECTION-V HT SWITCHGEARS
SECTION-I
CONTENT
ATTACHMENTS
SECTION-I
1.01.00 The scope of work shall cover detailed design and engineering of electrical
works related to main plant generation system, in plant power distribution,
main plant cabling, grounding, lightning protection etc for construction,
installation, testing and putting into successful commercial operation of the
main plant electrical system (BTG).
1.02.00 Scope of work shall cover the design, manufacture, assembly, testing at
manufacturer's works/laboratory, supply, delivery, properly packed for transport
to site, storing at site of all equipment, material and accessories related to
above electrical work along with mandatory spares, as detailed hereinafter in
subsequent sections of Volumes II-F/1,II-F/2 as required for efficient and
trouble free operation.
1.04.00 Scope of work shall also include detailed design & engineering, supply and
erection, in line with foregoing clauses 1.01.00, 1.02.00 and 1.03.00, of
electrical works associated with equipment, systems and subsystems
described in relevant sections of other volumes of this specification.
1.05.00 Scope of work shall also cover civil, structural and architectural works, including
design engineering, associated with the entire electrical system.
1.06.00 Broad scope of electrical equipment & systems for main plant are listed below
and these are detailed in relevant sections of Volumes II-F/1, II-F/2:
f) 415 V Power Control Centres (PCCs), Power cum motor control centres
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐I : 1 DCPL-11Z02
[2 x 660 MW] Main Plant Package
(PMCCs), Motor Control Centres (MCCs), AC distribution boards &
Fuse boards, 220 V DC distribution boards & fuse boards, 415 V
Non-segregated phase bus duct in BTG scope.
h) Generator Transformers
n) HT, LT power & control Cables, FS cable, FO cables & any special
Cables, instrumentation cables for electrical equipments within BTG
area.
1.07.00 Electrical equipment & systems integral with mechanical equipment, systems
and subsystems, even if not specifically referred to in the sections listed under
clause no. 1.06.00 above, shall also be provided as per relevant sections of
mechanical specifications. In absence of any stipulation in the mechanical
specifications, such equipment and systems shall be supplied as per applicable
clauses of the electrical specifications listed under clause no. 1.06.00 above,
proven engineering practice and applicable codes and standards. These shall
include electrical works associated with the followings but not limited to :
i) Boiler Elevator
The scope of design work shall include detail design for supply, erection
construction and installation, commissioning of entire electrical system of Main
Plant Package.
a) The terminal point shall be upto the EHV terminal bushing for GT and
Station transformer. Further work from EHV bushing upto switchyard
shall be in Switchyard vendor scope.
c) For interfacing /terminal point between Main Plant package (BTG) and
Balance of Plant (BOP) Bidder has to consider the following:-
i) All cable trays in pipe cum Cable Bridge up to the battery limit of
BTG as specified in relative Mechanical section shall be done by
BTG contractor. BTG contractor shall provide required no cable
trays within BTG area including in Power House for laying
interfacing HT power cables, LT power & Control,
instrumentation cables , special cables with BOP package.
3.01.00 Equipment
3.01.02 Equipment and material conforming to any other standard, which ensures equal
or better quality, may be accepted. In such cases, copies of the English version
of the standard adopted shall be submitted along with the bid.
3.02.00 Installation
3.02.01 All electrical installation work shall comply with the provisions of the Indian
Electricity Act, the Indian Electricity Rules as amended up to date, relevant IS
Codes of Practice and recommendations of the Tariff Advisory Committee
(TAC). In addition, other rules or regulations applicable to the work shall be
followed. In case of any discrepancy, the more restrictive rules shall be binding.
4.01.00 The equipment will be installed in hot humid and tropical atmosphere highly
polluted with coal dust, fly ash.
Relative Humidity :
4.03.00 Sensitive relay and other electrical and electronic devices shall be located in
controlled environment such as control room, electronic equipment room etc.
as applicable.
4.04.00 For equipment installed outdoor and exposed to direct sun rays, the effect of
solar heat shall be considered in determining the design ambient temperature.
5.01.00 Electrical Systems and equipment shall cover all items related to Main plant
excluding EHV (400 KV/230KV) AIS Switchyard.
5.03.00 Power must also be made available for starting the station when station
generation is not available and at all times to essential equipment &
instrumentation to ensure safe shutdown of the plant.
5.04.00 The Electrical Single Line Diagram for Auxiliary Power Distribution is shown in
drawing no CPCPL-11Z02-DWG-E-241.
5.06.00 The system configuration will be developed on the concept that failure of any
auxiliary transformer or supply feeder will not affect full load operation or
start-up/shut down of any unit.
5.07.01 This system provides generation, transformation to the 400 KV EHV systems
and evacuation of electric power to the 400 KV & 230KV EHV systems.
5.07.02 The connection of the generator transformer (GT) to the generator shall be by
isolated phase bus duct, through Generator Circuit Breaker and high voltage
terminals of the transformer shall be connected to the 400KV AIS through over
head conductor.
5.07.03 The neutral of each generator will be high resistance grounded through a
distribution transformer and secondary loading resistor.
This method permits sensitive ground fault protection and at the same time
limits the ground fault current to a low value, thus minimizing damage at fault
point.
5.07.05 400 KV system shall have two (2) main buses with one and half breaker
scheme (I-type layout) and 230KV system shall have two main bus scheme. The
Synchronizing of G e n e r a t o r t h r o u g h G C B o r t h r o u g h Generator
Transformer HT breaker & protection scheme for GT, UT , ST that shall be
developed by the bidder.
5.08.01 This system distributes power to 11000 Volt and 3300 Volt plant auxiliaries,
both for unit and station loads.
5.08.02 Unit loads are fed through two (2) no.35 MVA (minimum) Unit transformers
(UT) connected directly to isolated phase generator bus duct of respective
units ( The actual rating to be decided during detail engineering. In case higher
size transformer is required to meet the unit and station loads, the rating to be
changed without cost implication. The bidder shall indicate the rating in the bid
based on their experience on the similar size supercritical units).
Each 35 MVA unit transformer (UT) will be connected to one (1) no.11000V unit
M.V switchgear through segregated phase bus duct and to neutral grounding
resistor through 1 no. single core 70 Sq.mm. Al XLPE cable.
5.08.03 Common station loads, unit start-up/shut-down power & contingency unit loads
will be fed from Unit Transformer a n d s t a t i o n t r a n s f o r m e r through the
11000 V switchgears.
5.08.05 The connection of the above Station Transformer to the station switchgear will
be through segregated phase bus duct. Connection to neutral grounding
5.08.06 The 3.3 KV. switchgear shall have duplicate supply source through two
incoming line breakers and one bus section breaker, with provision of auto
changeover from one source to the other in case of failure of one source.
Manual provision of planned in-phase transfer, supervised by synchro-check
relay, shall also be provided.
BTG contractor shall submit design calculation for sizing of GT, U T , ST,
UAT for client approval. However, station auxiliary loads (BOP scope)
which are required for sizing UT & ST shall be furnished to BTG contractor
during detailed engineering..The rating of UT and ST indicated in the SLD is
approximate only. BOP auxiliary loads shall be furnished during detailed
engineering. The bidder shall consider approximate UT rating based on their
experience with similar size supercritical 2X660MW units. The cost implication
for increase in the UT rating which may be required during detailed engineering
need to be included in the bid.
5.08.08 Main plant package (BTG) supplier has to arrange the feeders in his 11KV and
3.3 KV Station Switchgears for Balance of Plant systems mainly for CW
pumps, CW pump house, Coal Handling system, Ash Handling System, In
Plant Water System, Compressor house, and 400KV/230KV Switchyard,
Fuel Oil handling system as shown in the Key SLD Drg no CPCPL-11Z02-
DWG-E-241. BOP Vendor shall be responsible for taking power from these
feeders including supplying, laying and termination of all power and control
cables instrumentation cables etc. (including termination at HT switchgear
end provided by BTG vendor). However, cable trays shall be provided upto
battery limits of BTG area including power house by the BTG vendor for
laying BOP cables.
5.08.09 Power and control , instrumentation cables required for CHP HT drives which
are located in Power House shall be supplied and laid under BOP package and
the termination and connection of all cables at 3300 V station switchgear end
shall be under BOP Package. All cable trays required for laying these cables
shall also be provided under Main Plant Package contractor up to Bunker floor.
The work of extending these trays (including supply) above bunker conveyor
floor up to HT drives & Bunker floor switchgear shall be under the scope of
BOP package.
5.09.01 L.V. distribution system shall supply power to all 415 Volt loads during normal
operation and emergency condition of the plant.
5.09.02 Unit and station L T loads will be fed through L.T. dry type transformers
connected to the respective 11000V system buses.
5.09.03 Connection of the L.T. dry type transformers to 11000V M.V. switchgear will be
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐I : 8 DCPL-11Z02
[2 x 660 MW] Main Plant Package
through cable and to L.V. Boards through non-segregated phase bus duct.
5.09.04 L.V. system will be solidly grounded to ensure sufficient ground current for
ground fault protection.
5.09.05 L.V. switchgear shall have duplicate supply source through two incoming line
breakers and one bus section breaker, with provision of auto changeover from
one source to the other in case of failure of one source. Manual provision of
planned in-phase transfer, supervised by synchro-check relay, shall also be
kept for all L.V. Switchgear.
5.09.06 The feeders required for the following purpose ( covered in different packages) of
that service area need to be provided in the MCC/PMCC as required.
a. Ventilation and air conditioning
b. Lighting Transformers
c. Welding transformers power receptacles
d. Power sockets
e. Portable and sump pumps
f. Hoist and cranes
g. Any other purpose
.
For each unit, twelve (12) nos dry type LT Transformers, connected to ESP LT
PCC by non-segregated phase bus duct, are envisaged. LT transformers shall
be fed from 11KV unit switchgear feeder, six (6) from each unit switchgear,
through cable.
5.10.01 220 V D.C. system provides reliable source of D.C. power for control, indication
and protection of plant equipment.
d) Emergency Lighting
e) DC scanner fan
a) Two(2) sets of battery with two(2) sets float- cum - boost charger for
each Unit
DC power required for BTG scope shall be supplied from above mentioned
DCDB..
5.10.04 On failure of A.C. input supply to the charger, the battery shall take over and
cater to all the loads connected to the D.C. system, including emergency loads.
5.10.05 Further distribution of D.C. system shall be through a number of fuse boards
being distributed in various areas.
6.01.02 Flexibility shall be kept for removal of any transformer on rail track without
affecting other transformer/equipment and structure.
6.01.03 One main rail track parallel to power house building A-row shall be provided. It
will be interconnected with the rail track in unloading bay. From main track,
several branch tracks will be laid up to individual transformer location. The
successful bidder needs to review the rail track arrangement drawing prepared
by the civil agency and give their acceptance.
6.01.04 Jacking pads will be provided at each right-angled connection of rail track right
up to unloading bay.
6.01.05 GT & UT centre lines will be fixed duly matching with generator busduct
centreline keeping reasonable spacing in between the transformer and from
Power House wall, that would be convenient for easy handling. The successful
bidder need to submit the layout. The busduct support structural work shall be
in bidder scope. The EPs location drawing need to be submitted by the
successful bidder during detailed engineering.
6.01.08 Symmetry shall be maintained for transformer layouts to achieve more or less
identical arrangement for each unit.
6.01.09 The details of equipment layout and cable routing will be designed by the
successful bidder during detail engineering stage and these shall be subject to
approval by purchaser/consultant. Changes as required to achieve a neat
layout with adequate working space all around, for better aesthetics as well as
to meet statutory regulation and codes shall be done by the successful bidder
without any commercial implication.
6.01.10 11 KV and 3.3 KV segregated phase busducts will be routed in the transformer
yard from UTs, UATs and STs, up to unit and station switchgear within Power
house. Routing of busducts both inside and outside Power house will be so
designed as to cause no interference with any other equipment, cable trays,
pipe racks etc.
6.01.11 Support locations of generator bus ducts and 11KV&3.3 KV busducts shall be
properly coordinated with other equipment, piping, civil and structural work.
6.01.12 Number of rails and rail gauge will be well coordinated with number of wheels
and orientation of all large transformers including those in switchyard right from
unloading bay of Power House.
For oil filled transformer containing 2000litre or more, oil soak pit under the
transformer and a common oil pit (unitized) outside the building at a distance
not less than 2.5 meter from the fencing shall be provided.
a) Gravel filled open oil pit will be provided under each transformer and its
cooler bank. The pit shall be such that it can take oil /water surge of 1/3
of the volume of the transformer oil when filled with gravel of size 60
mm.
b) Each pit will be connected to the drain line of at least 150mm diameter
stoneware pipe with a minimum slope of 1:96 leading to common oil pit.
Level of the pit under the transformer shall be such that there will not be
permanent accumulation of oil/water.
A common oil pit (unitized) shall be provided for all the transformers in
transformer yard.
a) The volume of the oil pit upto bottom level of the oil pit shall be
calculated based on the following:
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐I : 11 DCPL-11Z02
[2 x 660 MW] Main Plant Package
• Oil quantity of the largest transformer.
c) Pit will be provided with two (2) sump-pumps such that discharge rate of
each pump shall be at least equal to the discharge rate of high velocity
water spray system provided for fire fighting of the transformer.
h) Pit will be provided with 2 x 100 percent sump-pump for common oil
sump.
6.03.01 Cable spreader/ vault rooms will be provided below electrical Switchgear/MCC
rooms /control room at ESP control building,
, fuel oil pressuring pump house etc.
6.03.03 ESP control building. Control rooms will be generally provided at the same
floor level of switchgear room.
6.03.04 Separate rooms shall be provided for batteries with lay down space for one
identical battery set. Battery charger and D.C. distribution board will be located
in different room.
6.04.01 Flexibility shall be kept for handling of equipment without obstruction both
during erection and maintenance. Adequate handling facilities, space,
door/rolling shutter of adequate width and height shall be provided for the
purpose.
All the LT switch board shall be double front type, minimum clearance shall be
given 1500mm. No trench shall be used below the Switch board. Cable vault
spreader room shall be provided below LT/HT switch Board.
6.04.03 For installations with two rows of boards facing each other, minimum clearance
of 2000 mm will be maintained in between fronts of boards. Where the above
clearance causes obstruction for handling any electrical equipment like dry type
L.T. transformers, the same shall be increased to suit transformer dimensions.
While fixing the clearance, the requirement of handling of equipment of other
rooms/areas shall also be considered where applicable.
6.04.04 For installations with more than two rows of panels the breadth of the
switchgear room shall be increased accordingly.
6.04.05 Generally all electrical room shall be provided with 2 doors in addition to the
shutters provided for handling transformer, switchgear, panels etc.
6.04.06 During design stage adequate space shall be provided for expansion of board
on either side to accommodate addition of panel to take care of unforeseen
factors.
6.04.08 All busduct shall enter the PCC/PMCC from either top or from bottom.
6.04.09 Clearance of between adjacent panels in a row shall not be less than 800 mm.
This clearance shall also be guided by equipment handling space where
applicable and space required for movement of personnel.
6.04.10 Clearances of 1500mm in between adjacent panels in a row or from the side
wall/door shall be so decided that handling of shipping section of any board is
not obstructed.
6.04.11 Cable spreader floors shall have all openings properly ridged to prevent water
drainage into the room below. In addition proper facilities shall be provided at
cable spreader floor to drain the water in case of operation of sprinkler system.
6.05.01 Interplant cable routing will be on overhead cable trays on pipe cum cable
trestle or only cable trestle except where approved by purchaser/consultant.
Major overhead outdoor interplant cable routes are :
b) From Power House to Ash slurry and Ash water pump house
complex
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐I : 13 DCPL-11Z02
[2 x 660 MW] Main Plant Package
c) From Power House to C.W./Cooling Tower area, Fire water Building
Major routes in boiler area to individual boiler drives, to and from ESP
Building, Fly ash conveying compressor building, vacuum pump house
& F.O. pump house, will be on overhead Cable trays on pipe cum cable
trestle or on only cable trestle.
Motor shall be provided with suitable expansion terminal box with proper
arrangement for termination of aluminium power conductor when motor
terminal box is not adequate for terminating the aluminimum power cable
Following auxiliary voltages will be envisaged for auxiliary power control and
instrumentation.
a) 240 V, 1 Ph, 50 Hz
On the basis of the transformer capacity and impedance chosen, unit loads,
station loads calculated, voltage regulation and short circuit levels are to be
calculated to determine the followings.
a) MDBFP Starting 75
b) CWP Starting 80
c) Coal mill 85
8.02.00 For fault on 11KV station bus at 110% voltage, the total of system contribution
and motor contribution shall be limited to breaking current of 44 KA rms and
momentary current of 112 KA peak under following conditions.
The 400 KV Station transformer EHV rating shall be twice the rating of HV1 rating.
The 220KV station transformer rating (OBTA02) shall be 50% of OBTA01 EHV
rating
The successful bidder shall determine Battery Duty Cycle curve. Important
loads to be considered while deciding duty cycle of station batteries are to be
tabulated below :
2. 415V Switchgear
8. Valve Drives
14. DC Lighting
15. Load of one (1) DC pump running due to prolong outage of A.C. Pump
16. Any other load (to be decided by successful bidder) and as required for
other Systems in the main plant area to be decided during detail
engineering.
10.01.01 In line with the present-day practice unitized control of the electrical
system/equipment has been envisaged for the plant.
10.01.03 Generators, G e n e r a t o r c i r c u i t b r e a k e r s a n d G T H V s i d e
b r e a k e r s will be controlled from unitized Control Room. However, the
400 KV bus selection for generators shall be done from Switchyard Control
Room by operation of associated disconnecting switches.
10.01.04 The 400KV and 230 KV side of Station Transformer feeders shall be
controlled from switchyard control room as well as Power house control room.
10.01.05 OLTC control for Station Transformers shall be done from Power House
Control room (ECP).
10.01.07 The control, indication, metering and monitoring of the electrical auxiliary
power distribution system comprising of 11 KV & 3.3 KV circuit breakers
(except those for motor feeders), LT transformers, 415 V switchgear breakers
for incomers and bus couplers, DG system etc. shall also be achieved from
operator’s consoles through D DCMIS. For details relevant section of C & I
shall be referred (Vol – II E-SEC-VI clause 6.14.00).
10.01.08 All equipment/components viz. Transducers (dual channel type) etc. required
to interface with plant D D C M I S system shall be provided in
Switchgear/control panels. The minimum protection required for different
equipment and system are indicated in Section-V of Volume : IIF/2.
10.01.09 One Back up electrical control panel (ECP) for each unit shall also be
provided in the respective control room. The back-up control panel shall be
stand-alone in mosaic grid configuration consisting of Generator manual
synchronizing equipments, governor and excitation control, metering
equipment, breaker control switches for GCB, GT HV breakers, 11KV,3.3 KV
& 415V Unit / station switchgear incomers, tie and outgoing non-motor feeder
breakers, synchronizing selector switches, Auto-Manual, Remote-Local
and other selector switches as required along with annunciation windows,
indications and mimic diagram (from 400KV , 230 KV level to 415V level).
Cooler control for Generator Transformers, Unit Auxiliary
transformer, Station auxiliary transformer, Cooler control & Tap
changer control for Station Transformers and Unit Transformers in Remote-
Manual mode shall also be provided in the Back-up Control Panel. DGs shall
also be controlled from DDCMIS/EDMS as well as Electrical control panel.
Number of non trip and trip annunciation facia shall also be provided. All the
switches and other equipments on the panel.shall be suitable for mosaic titles.
The generator synchronizing system components (check synchronizing relay,
Guard relay, synchroscope, Double voltmeter, double frequency meter) shall be
separate from synchronizing system components of 11 KV, 3.3KV and 415 V
system buses.
Each unit of 660 MW of the station would have its own super critical boiler,
turbine generator, directly connected to individual transformer. The generated
power will be boosted to 400 KV and fed to the grid. A 60% H.P. - L.P. bypass
has been provided to permit operation of the boiler to achieve required steam
temperature for turbine during hot re-start and to save condensate during
start-ups. With this bypass arrangement it is envisaged that as long as
adequate vacuum in the condenser, which serves as the heat sink for the
dumped steam, is within allowed limits, the boiler will continue to be in service
in case of faults with turbine and/or generator.
In case of internal faults of the turbine except for thrust bearing failure and low
lub. oil pressure, the turbine will trip and the generator will sequentially trip on
low forward power relay/reverse power relay. This is to avoid over-speeding of
the turbine in case of any mal-function or leakage past any of the stop and
control valve. The thrust bearing and low lub oil pressure trips would trip both
turbine and generator simultaneously. The boiler may, however, operate on
bypass and would have to be tripped manually as per Operator's discretion.
The over all scheme shall be finalized during detail engineering.
However, to protect the quenching of hot metal parts of the turbine any time the
boiler trips due to its protection logic, the turbine will trip and the generator
would sequentially trip by the action of low forward power relay. This would
also be backed up by a reverse power relay to cover the remote possibility of a
turbine generator coupling failure.
In case of tripping of the unit, Fast bus change over scheme has been
proposed to change supply of the Boiler and the Turbine Auxiliaries from Unit to
Station system automatically and thereby avoiding trip out of the Boiler and
providing uninterrupted supply to vital Turbine auxiliaries. Under this `Fast bus
change over' scheme the Boiler shall be operating with 60% HP-LP Bypass
even if there is trip out of Turbine and Generator.
Suitable operational logic shall be developed to operate and control the unit
from Central Control Room along with its sub-group and sub-loop control.
House load operation of this unit has been contemplated.
11.01.00 General
11.01.01 The primary objective is to mitigate the damage of the plant and equipment
during fault or system disturbances.
11.01.02 Automatic trip functions will be initiated for isolation of fault, which could cause
immediate and severe damage.
11.01.03 Every effort shall be made to avoid unnecessary trip. There will be annunciation
to alert the operator to take corrective action in time.
11.01.05 The major protections envisaged for the various equipment are listed under
relevant sections of this specification
The grounding requirement of the power station complex is divided into the
following three main categories :
a) System grounding
b) Equipment grounding
The 415 Volt System will be solidly grounded. The 220 V DC system will be
ungrounded.
A stable ground grid will be provided for grounding of equipment and structures
and for maintaining the step and touch potentials within safe limits. An earth
mat will be laid in and around the power station. This mat will be buried at a
suitable depth below the ground and provided with ground electrodes at
suitable spacing. All metallic parts of equipment, supposed to be kept at earth
potential, will be connected to the grounding mat. Buildings, structures,
transmission towers, plant railroad tracks, the perimeter fencing will also be
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐I : 19 DCPL-11Z02
[2 x 660 MW] Main Plant Package
connected to the grounding mat. This grounding mat will be interconnected
with the BOP grounding mats provided by the BOP Vendor.
Energy meters suitable shall be provided as per Meters for Energy Accounting
& Audit (MEAA) confirming to latest CEA’s regulations. The electrical system
parameters should be displayed in the HMI station provided in the Control
Room . The system should be fast to display electrical parameters at the
Operator Console in real time.
Electrical parameter data i.e. V, A, PF, MW, MWH, MVAR, F, Harmonics, etc.
from all the electrical power meters should be displayed on the HMI
station.. In addition real time waveforms and harmonics graphs should be
displayed on the each operator screen.
Data from power meters shall be converted from RS 485 to TCP/IP via
industrial grade converters. Each RS 485 loop shall have approx. 15 power
meters in the loop to maintain high-speed communication. All th e data
converters shall be isolated and industrial grade. The data converters shall be
main and Station for each loop.
TCP/IP data shall be transmitted via fiber optics cable via TCP/IP to fiber
optics converters. Data communication shall be done via RS 485 cable or
optical fiber cable depending on the site location to get maximum speed and
optimize the costs. This will ensure data communication at high speed without
corruption due to electrical noise.
TCP/IP switch shall be used at the central control room for interfacing the
data received from fiber optics cable to PC.
One of the servers PC shall be used to collect data from power meters
installed in other SCADA system. Data from these power meters should be
made available on TCP/IP network.
The proposed communication scheme shall provide real time electrical data
with in three to four seconds.
l. Item Specifications
No.
1 RS 485 to TCP/IP N port, multi client, isolated with automatic
converter (RTC) direction control, 10/100 MBPS, two port RS
with accessories 485, two wire, ESD protection 15 KV, power
supply 12 to 30V DC, operating temperature 0 to
55°C with installation and configuration software.
The primary coated fibres may be protected by loose packaging within a tube
or tubes, filled with thixotropic jelly.
Solid FRP non-metallic strength member / members in the cable core / sheath
shall be provided. The strength member (s) in the cable shall be for strength and
flexibility of the cable and shall have anti buckling properties. These shall also
keep the fibre strain within permissible values.
The non-metallic strength member (s) may be in the cable core or embedded
Primary coated fibres in loose tube / tubes and / or in groove stranded together
around a central strength member using helical or reverse lay techniques shall
form the cable core. Alternatively multiple units of fibres may be placed loosely
in a single tube with the strength members in the sheath
The main cable core containing fibres shall be wrapped by layer / layers of
polyester foil tape. The nylon / polyester binder tape or thread shall be used to
hold the tape if required.
The main cable core (containing fibres & core wrapping) shall be protected by
flooding compound (jelly) having properties of non-hygroscopic dielectric
material and water sweallable tape. The core wrapping shall not adhere to the
secondary fibre coating.
The filling compound used in the loose tube and in the cable core shall be
compatible to fibre, secondary protection of fibre, core wrapping etc. The drip
point shall not be lower than +70°C. The fibre movement shall not be
constrained by stickiness and shall be easily removable for splicing. Reference
material test method to measure drop point shall be as per ASTM D 556. The
filling and the flooding jelly compound shall be as per the GR No.G/ORM-01/02
MAR 99 and the subsequent amendments if any.
A non-metallic moisture barrier sheath may be applied over and above the
cable core. The core shall be covered with tough weather resistant High
Density Polyethylene (HDPE) sheath black in colour (UV Stabilized) and the
colour shall conform to Munsell Colour Standards. Thickness of the sheath
shall be uniform and shall not be less than 1.8 mm including the strength
members used in the sheath. The sheath shall be circular, smooth, and free
from pinholes, joints, mended pieces and other defects. Reference test method
to measure thickness shall be as per IEC 189 Para 2.2.1 and Para 2.2.2
13.04.08 Reinforcement
The aerial optical fiber cable shall be reinforced with Aramid Yarn in the
periphery over the inner sheath. The Aramid Yarn shall be uniformly and
equally distributed on the entire periphery (circumference) of the cable. The
quantity of the Aramid Yarn used per kilometre length of the cable with its D-
Tex value shall be indicated by the manufacturer.
The manufacturer shall define the cable diameter. The finished cable
diameter shall be within + 0.5 mm from the defined cable diameter.
The two suitable (minimum) ripcords shall be provided which shall be used to
open the inner and outer (HDPE) sheath of the cable. It shall be capable of
consistently slitting the sheath without breaking for a length of 1 meter at the
installation temperature. The rip cord (s) shall be properly waxed to avoid
wicking action and shall not work as a water carrier.
The ripcord used in the cable shall be readily distinguishable from any other
components (e.g. Aramid Yarn etc.) utilized in the cable construction.
14.01.01 The major testing equipment that are required to be provided by the
Contractor are listed below :
c) High Potential Testing Set - roller mounted type for EHV equipment.
g) Digital Multimeters, test lamp, field telephone with buzzer set, different
gauges, etc.
14.01.02 Other test and erection equipment, as required, shall be arranged by the
Contractor.
The Contractor shall be fully responsible for carrying out all co- ordination and
liaison work with Electrical Inspectors, Factory Inspector, and other statutory
bodies for implementation of the work.
16.01.01 Before starting manufacture of any equipment, the Contractor shall have to
take approval of relevant drawings and data from the Purchaser/Consultant in
writing.
16.01.02 Any manufacture done prior to the approval of drawings/data shall be rectified
in accordance with the approved drawings/data by the Contractor at his own
cost and the equipment shall be supplied within the stipulated period.
16.02.01 All drawings and annexure appended to the specification shall form part of
this specification and supplement the requirements specified herein.
16.02.02 This specification shall be read and construed in conjunction with the
16.02.03 The quantities shown on drawings and annexure are tentative for bidding
purpose only. Any variation arising during detailed engineering stage shall be
taken into account by bidder without any price adjustment.
16.03.01 It is not the intent to specify completely herein all details of the equipment.
Nevertheless, the equipment shall be complete and operative in all aspects
and shall conform to highest standard of engineering, design and
workmanship.
16.03.02 Any material or accessory which may not have been specifically mentioned
but which is necessary or usual for satisfactory and trouble-free operation and
maintenance of the equipment shall be furnished without any extra charge.
16.03.03 The Contractor shall supply all brand new equipment and accessories as
specified herein with such modification and alteration as agreed upon in
writing after mutual discussion.
16.03.04 ‘Make’ of brought-out items are subject to Owner / Purchaser’s approval. The
contractor shall furnish relevant details to the Owner / Purchaser for his
concurrence before procurement.
]
16.04.00 Proposal Data
16.06.00 Deviation
16.06.01 Should the Bidder wish to deviate from this specification in any way, he shall
draw specific attention to such deviation.
16.06.02 All such deviations shall be clearly mentioned on the Deviation sheet
enclosed, with reference to the respective clause of the specification.
16.06.03 Unless such deviations are recorded in the Deviation sheets and submitted
with the offer, it shall be taken for granted that the offer is made in conformity
with this specification in all respects.
16.07.03 The bidder shall submit the documentary evidence that equipment of similar
rating has been manufactured by him and are in successful operation for
more than two (2) years in two or more projects of similar nature on the date set
for opening of the bid.
16.07.04 Not withstanding anything stated above, the Owner / Purchaser reserves the
right to assess bidder’s financial and other capabilities to execute the
contract.
16.08.01 The Contractor shall follow his standard procedures for quality assurance and
control. A copy of the said standard procedures shall be submitted to the
Owner / Purchaser for his reference. However, Owner / Purchaser reserves
the right to review the same and give his observations, if any, for compliance.
16.08.03 The Owner / Purchaser shall inform the Contractor as to which of the
inspection points and tests shall be witnessed. As a minimum, inspection and
testing of the finished equipment shall be made prior to shipment, unless
specifically waived by the Owner / Purchaser. The contractor shall give at
least fifteen (15) days advance notice regarding readiness of the equipment.
16.08.04 Manufacturing and quality control procedures shall be available for audit to
the Owner / Purchaser and/or its representative at the place of manufacture.
16.08.05 The Owner / Purchaser reserves the right to inspect the equipment at the
point of manufacture and witness factory and other such tests as may be
necessary to ensure conformance to the specification.
16.08.06 The Owner / Purchaser may inspect the Contractor's facilities prior to award
of contract.
16.08.07 The Owner / Purchaser may witness any or all of the tests stipulated in the
relevant standards and this specification.
16.08.08 The Owner / Purchaser may conduct surveillance of the Contractor's facilities
for compliance to his standard procedures of Quality Assurance and Quality
Control while work on the specified equipment is in progress.
16.09.01 The equipment complete with its accessories, spares, special tools and
tackles shall be suitably protected by respective packing for shipment
considering handling during transit, distance and weather conditions involved.
The Contractor shall submit the packaging method for shipment to be
adopted by him, if so desired by the Owner / Purchaser.
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐I : 27 DCPL-11Z02
[2 x 660 MW] Main Plant Package
16.09.02 Each consignment shall be marked with Equipment name, Owner /
Purchaser’s name & address, Project details, handling instruction etc. It shall
be complete with part list and identification details. The copies of the part list
of each consignment shall also be furnished to the Owner / Purchaser after
dispatch.
16.09.03 Equipment shall be packaged for transportation so as to meet the space and
weight limitation of transport facilities. The contractor shall obtain approval
from concerned authorities for transportation of over dimensioned
consignment/package, if any, before starting manufacture of such equipment.
17.01.00 The number of types and sizes of motor, controls, and other electrical
equipment shall be kept to a minimum so that the requirement of spares is
minimized.
17.02.00 Equipment shall be rated for the load and duty cycle of the intended service
Circuit breakers and fuses shall be rated to withstand and interrupt the
maximum fault current at the point of application in the circuit.
18.00.00 ENCLOSURE
18.01.00 Unless otherwise stated, enclosure of electrical equipment intended for indoor
service which are located in electrical switchgear room shall be dust-tight,
vermin proof with gasketted doors/covers, generally conforming to degree of
protection IP-4X. Equipment located in other areas shall have enclosure
conforming to degree of protection of at least IP-54 or as specified in particular
section.
18.03.00 For equipment located in hazardous areas, increased safety type enclosure,
such as flame/explosion proof type, shall be provided. Such enclosures shall be
certified by recognized authority as suitable for use in that particular
environment.
19.01.00 All electrical equipment, accessories and wiring shall have fungus protection
involving special treatment of insulation and metal against fungus, insects and
corrosion.
19.02.00 Fine mesh screen of corrosion resistant material shall be furnished on all
ventilating openings to prevent entry of insects.
20.01.00 General
20.01.03 Panels shall be adequately sized for installation of field cables and access for
maintenance. The working zone shall be limited between 450 mm and
1800 mm from floor level.
20.01.04 Each panel shall be provided with internal illumination lamp operated by door
switch, space heater with switchfuse unit, and plug socket with switch for hand
lamp.
20.02.00 Unless otherwise stated, equipment rating and module sizes shall be as per
annexure B. Module selection chart is specified for guidance of bidder in
respect to requirement of module space and component ratings.
20.03.01 All instruments, switches etc. mounted on the front face of the panels shall be
of flush type.
20.03.02 All equipment shall be so mounted that removal and replacement may be
accomplished individually without interruption of service to others.
20.03.03 All equipment inside the panel shall be so located that their terminals and
adjustments are readily accessible for inspection and maintenance. Adequate
ventilation shall be provided in enclosed panel.
20.03.04 At least 20% with a minimum of one spare feeders of each type shall be
provided in MCC/Switch Board.
20.04.01 All panels shall be fully wired at the factory to ensure proper functioning of all
control, protection and interlock schemes. All wiring for external connections
shall be brought to terminal blocks and numbered.
20.04.02 Panel wiring shall be carried out with flexible, heat resistant, 650V grade, PVC
insulated stranded copper wire of minimum 2.5 Sq.mm cross section.
20.04.03 Solderless compression/clamp type connection shall be used for wire terminals.
Wiring shall be continuous between terminals without splicing. Each wire shall
be identified at both ends with permanents markers having wire numbers as
per approved wiring drawings.
20.04.04 Terminal blocks shall be Box clamp type with marking strip. Not more than two
wires shall be connected to one terminal. Spare terminal equal in number to
20% of active terminals shall be furnished.
20.05.00 Grounding
20.06.00 Painting
All metal surface shall be cleaned, phosphated and given two coats of
rust-resistant primer followed by two coats of finish paint. Required colour
shade shall be RAL7032.
Nameplate of approved design shall be furnished on each panel and for each
instrument or device mounted on panel.
20.08.00 Tests
Each panel shall be completely assembled, wired, adjusted and tested at the
factory prior to shipment. The test shall include wiring continuity tests, insulation
tests and functional tests to ensure satisfactory operation and control of
individual equipment in presence of consultant/ owner’s representatives.
Special cables for specific purpose, as required, shall be supplied and installed
by the Contractor.
21.00.00 CONDUITS
21.01.00 Conduits shall be of heavy gauge rigid steel, hot-dip galvanized, cut square,
reamed, threaded and screwed tight at all joints.
21.02.00 Conduit entrances to pull boxes and switches shall have double lock nuts &
insulating bushings. No running thread shall be used.
21.03.0 Flexible metallic conduit shall be used for connection to equipment, which are
subject to vibration, and also for connection to level/limit/pressure switches.
21.03.0 HDPE PVC pipes shall be used for single core power cables.
All equipment/cables shall be of proven design and type tested as per relevant
standard. Type test certificates/specific type tests shall be furnished. If the
particular type test is not already conducted on similar size equipment the
same to be conducted. If asked for with reference to any specific equipment in
the respective sub-section of the Specification. However, bidder may note the
following :
23.01.01 All equipment shall be installed in a first class, neat workmanlike manner by
mechanics/electricians skilled in the trade involved.
23.01.04 The installation shall be carried out in such a manner as to preserve access to
other equipment installed.
23.02.01 For protection of this work, the Contractor shall provide fencing and lighting
arrangement, connect space heaters and provide heating arrangement as
necessary or as directed by the Owner/Consultant.
24.01.01 To be submitted after award of the Contract by bidder for owners approval.
a) Overall electrical System design basis report. Single line diagram giving
rating of each equipment.
d) Equipment layouts.
f) Cabling, cable trench and tray layouts with section and details with
cable sizing calculations.
i) DBR for all electrical equipment and system, overall Electrical and
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐I : 31 DCPL-11Z02
[2 x 660 MW] Main Plant Package
Control operation and synchronization philosophy for approval of the
owner..
DESIGN DATA
Relative Humidity :
* Indicative only; the actual value will be decided by the bidder, after
substantiating the same by calculation.
A.C. Supply
Voltage :+
_ 10% Frequency :+
_ 5% Combined Volt : 10%
+ frequency (absolute sum)
During starting of large motor, the voltage may drop to 80% of the rated voltage
for a period of 60 seconds. All electrical equipment, while running, shall
successfully ride over such period without affecting system performance.
D.C. Supply
MODULE SELECTION
MOTOR FEEDER
NOTE :
1. SFU, thermal overload relay, Contractor are to be coordinated (Type-2) with motor
rating by the Contractor.
MODULE SELECTION
OUTGOING FEEDER
TECHNICAL PARAMETERS
OF
ELECTRICAL SYSTEM
400 KV SYSTEM
1 Type of busbar scheme to be adopted Two main bus with one and
half breaker (I-Type)
230 KV SYSTEM
Capitalization of electrical losses per KW for the Power consumption and penalty purpose to
be considered for Chettinad power corporation (2x660MW – Super critical thermal power
plant) as per the details given below:-
Rate of Aux power consumption per KW for evaluation purpose = Rs. 2, 42,056/- Rate of
Loading for levy of penalty for power transformers losses (GT, UT, ST, UAT) after testing
The above mentioned rates of power consumption shall be applicable for BTG packages of
Chettinad power corporation (2x660MW – Super critical thermal power plant for the tender
evaluation and for imposing penalty clauses.
SECTION‐II TECHNICAL
SPECIFICATION
FOR
A.C. & D.C. MOTORS
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.00.00 SCOPE VOL.II-F1/SEC-II : 1
ATTACHMENT
SECTION‐II TECHNICAL
SPECIFICATION
FOR
A.C. & D.C. MOTORS
1.00.00 SCOPE
1.01.00 This section covers the general requirements of the drive motors for power
station auxiliary equipment.
1.02.00 Motors shall be furnished in accordance with both this general specification and
the accompanying driven equipment specification.
1.03.00 In case of any discrepancy, the driven equipment specification shall govern.
2.03.00 The electrical installation shall meet the requirements of Indian Electricity
Rules as amended upto date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall be followed.
2.04.00 Major standards, which shall be followed, are listed below other applicable
Indian Standards for any component part even if not covered in the listed
standards shall also be followed :
3.00.00 SERVICE CONDITIONS
3.01.00 The motors will be installed in hot, humid and tropical atmosphere, highly
polluted at places with coal dust and/or fly ash.
3.03.00 For motor installed outdoor and exposed to direct sunrays, the effect of solar
heat shall be considered in the determination of the design ambient
temperature.
4.00.00 TYPE AND RATING
4.01.00 A.C. Motors
4.01.01 Motors shall be general purpose, constant speed, squirrel cage, three/single
4.01.02 All motors shall be rated for continuous duty. They shall also be suitable for
long period of inactivity.
4.01.03 The motor name-plate rating at 50°C shall have at least 10% margin over the
input power requirement of the driven HT equipment at rated duty point unless
stated otherwise in driven equipment specification or in general electrical
specification.
4.01.04 The motor characteristics shall match the requirements of the driven equipment
so that adequate starting, accelerating, pull up, break down and full load
torques are available for the intended service.
4.01.06 The motor name plate rating shall have at least 10% margin over the input
power requirement of the HT driven equipment and 15% for LT driven
equipments at rated duty point.
4.02.00 D.C. Motors
4.02.01 D.C. motor provided for emergency service shall be shunt/compound wound
type.
4.02.02 Motor shall be sized for operation with fixed resistance starter for maximum
reliability.
Starter panel complete with all accessories shall be included in the scope of
supply.
5.00.00 PERFORMANCE
5.01.00 Running Requirements
5.01.01 Motor shall run continuously at rated output over the entire range of voltage and
frequency variations as given in the annexure
5.01.02 The motor shall be capable of operating satisfactorily at full load for 5 minutes
without injurious heating with 75% rated voltage at motor terminals.
5.01.03 The motor shall be designed to withstand momentary overload of 60% of full
load torque for 15 second without any damage.
5.02.00 Starting Requirements
Motor shall be designed for direct online starting at full voltage. Starting current
shall not exceed 6 times full load current for all auxiliaries except boiler feed
pump where the starting current shall be limited to 4.5 times. No further
tolerances are applicable on starting current specified above for HT motors.
5.02.01 The motor shall be capable of withstanding the stresses imposed if started at
110% rated voltage.
5.02.03 a) Motor shall be capable of three equally spread starts per hour, two
starts in quick succession from cold condition and one restart from hot
condition.
b) Cranking motor shall be capable of six equally spread starts per hour,
three starts in quick succession from cold condition and one restart
from hot condition. The coal conveyor and crusher motors shall be
suitable for 3 consecutive hot starts with maximum 20 starts per day.
5.02.05 The motors shall be designed to withstand 120% of rated speed for 2 minutes
without any mechanical damage.
5.03.00 Stress During Bus Transfer
5.03.01 The motor may be subjected to sudden application of 150% rated voltage
during bus transfer, due to the phase difference between the incoming voltage
and motor residual voltage.
5.03.02 The motor shall be designed to withstand any torsional and/or high current
stresses, which may result, without experiencing any deterioration in the normal
life and performance characteristics.
5.04.02 Starting time mentioned above is at minimum permissible voltage of 80% rated
voltage.
5.04.03 Hot thermal withstand curve shall have a margin of at least 10% over the full
load current of the motor to permit relay setting utilising motor rated capacity.
6.00.00 SPECIFIC REQUIREMENTS
6.01.00 Enclosure
CPCPL-Super Critical TPP-Tharangambadi VOL.II‐F1/SEC‐II : 4
DCPL-11Z02
[2 x 660 MW] Main Plant Package
6.01.01 All motor enclosures shall conform to the degree of protection IPW-55 unless
otherwise specified. Motor for outdoor or semi-outdoor service shall be of
weather-proof construction.
6.01.02 For hazardous area approved type of increased safety enclosure shall be
furnished.
6.02.00 Cooling
6.02.01 The motor shall be self ventilated type, either totally enclosed fan cooled
(TEFC) or closed air circuit air- cooled (CACA).
6.02.02 In case water cooling is required for very large motors, prior approval of the
customer is to be obtained before proceeding ahead with design &
manufacture.
6.03.00 Winding and Insulation
6.03.01 All insulated winding shall be of copper.
6.03.02 All motors shall have class F insulation but limited to class B temperature rise.
6.03.03 Windings shall be impregnated to make them non-hygroscopic and oil resistant.
6.04.00 Tropical Protection
6.04.01 All motors shall have fungus protection involving special treatment of insulation
and metal against fungus, insects and corrosion.
6.05.00 Bearings
6.05.01 Motor shall be provided with antifriction bearings, unless sleeve bearings are
required by the motor application.
6.05.02 Vertical shaft motors shall be provided with thrust and guide bearings. Thrust
bearing of tilting pad type is preferred.
6.05.04 Sleeve bearings shall be split type, ring oiled, with permanently aligned, close
running shaft sleeves.
6.05.05 Grease lubricated bearings shall be prelubricated and shall have provisions for
in-service positive lubrication with drains to guard against over lubrication.
6.05.06 Oiled bearing shall have an integral self cooled oil reservoir with oil ring
inspection ports, oil sight glass with oil level marked for standstill and running
conditions and oil fill and drain plugs.
6.05.07 Forced lubricated or water cooled bearing shall not be used without prior
approval of Owner.
CPCPL-Super Critical TPP-Tharangambadi VOL.II‐F1/SEC‐II : 5
DCPL-11Z02
[2 x 660 MW] Main Plant Package
6.05.08 Lubricant shall not deteriorate under all service conditions. The lubricant shall
be limited to normally available types with IOC equivalent.
6.05.09 Bearings shall be insulated as required to prevent shaft current and resultant
bearing damage.
6.06.00 Noise & Vibration
6.06.01 The noise level shall be as per statutory acceptance.
6.06.02 The peak amplitude of the vibration shall be within IS specified limits.
6.06.03 The motors rated above 135KW shall be provided with continuous vibration
monitoring and protection.
6.07.00 Motor Terminal Box
6.07.01 Motor terminal box shall be phase segregated (PSTB) type and located in
accordance with Indian Standards clearing the motor base- plate/ foundation
6.07.02 Terminal box shall be capable of being turned 360 Deg. in steps of 180 Deg. for
HT motors and 90 Deg. for LT motors unless otherwise approved.
6.07.03 The terminal box shall be split type with removable cover with access to
connections and shall have the same degree of protection as motor.
6.07.04 The terminal box shall have sufficient space inside for termination/connection of
XLPE insulated armoured aluminium cables.
6.07.05 Terminals shall be stud or lead wire type, substantially constructed and
thoroughly insulated from the frame.
6.07.06 The terminals shall be clearly identified by phase markings, with corresponding
direction of rotation marked on the non-driving end of the motor.
6.07.07 The terminal box shall be capable of withstanding maximum system fault
current for a duration of 0.25 sec.
6.07.08 For 11000V and 3300V motor, the terminal box shall be phase-segregated
type. The neutral leads shall be brought out in a separate terminal box (not
necessarily phase segregated type) with shorting links for star connection.
6.07.09 Motor terminal box shall be furnished with suitable cable lugs and double
compression brass glands to match with cable used.
6.07.10 The gland plate for single core cable shall be non-magnetic type.
6.08.00 Grounding
6.08.01 The frame of each motor shall be provided with two separate and distinct
grounding pads complete with tapped hole, GI bolts and washer.
6.08.03 The cable terminal box shall have a separate grounding pad.
6.09.00 Rating Plate
In addition to the minimum information required by IS, the following information
shall be shown on motor rating plate :
b) Degree of protection.
7.00.00 ACCESSORIES
7.01.00 General
Accessories shall be furnished, as listed below, or if otherwise required by
driven equipment specification or application.
7.02.00 Space Heater
7.02.01 Motor of rating 30 KW and above shall be provided with space heaters, suitably
located for easy removal or replacement.
7.02.02 The space heater shall be rated 240 V, 1 phase 50 Hz and sized to maintain
the motor internal temperature above dew point when the motor is idle.
7.03.02 11000V and 3300V motor bearing shall be provided with duplex type
temperature detectors.
7.03.03 The temperature detector mentioned above shall be resistance type, 3 wire,
platinum wound, 100 Ohms at 0°C.
7.03.04 Leads of all simplex type motor winding RTDS and motor bearing RTDS shall
7.04.00 Indicator/Switch
7.04.01 Dial type local indicator with alarm contacts shall be provided for the following :
b) Hot and cold air temperature of the closed air circuit for CACA and
CACW motor.
7.04.02 Flow switches shall be provided for monitoring cooling water flow of CACW
motor and oil flow of forced lubrication bearing, if used.
7.04.03 Alarm switch contact rating shall be minimum 0.5 A at 220V D.C. and 2A at
240V A.C.
7.05.02 The arrangement shall be such as to permit easy access for C.T. testing and
replacement. Current transformer characteristics shall match Owner's
requirements to be intimated later.
7.06.02 Accessory terminal box shall be complete with double compression brass
glands and pressure type terminals to suit cable connections.
7.07.00 Drain Plug
Motor shall have drain plugs so located that they will drain the water, resulting
from the condensation or other causes from all pockets of the motor casing.
7.08.00 Lifting Provisions
Motor weighing 25 Kg. or more shall be provided with eyebolt or other adequate
provision of lifting.
Electrical hoists shall be provided for motors above 100kgs for maintenance
work.
7.10.00 Painting
Motor including fan shall be painted with corrosion proof paints of colour
shade (RAL-7032).
8.00.00 TESTS
Routine and Type Tests are to be conducted in presence of customer’s
representative as per IS:325 and required copies of test certificates are to be
furnished for approval. In addition, the following tests shall have to be carried
out on the motors in presence of owner representative on 3.3kV/11kV motors.
e. Fault Withstand Test for main terminal box as type test. Type test
certificate shall be acceptable, if the test has been conducted on
exactly identical terminal box.
Tests indicated at (h), (i), (j) shall be carried out during manufacture of the
9.01.00 Along with the bid
a) List of the motors
b) Individual motor data sheet as per format of the proposal data sheets.
9.02.00 After Award of the Contract
a) Dimensional General Arrangement drawing
i) Test reports
DESIGN DATA
1.0 AUXILIARY POWER SUPPLY
Supply Description Consumer
H.T. Supply 11000 V, 3Ø, 3W, 50 Hz, Motors
non-effectively earthed above 1500 KW
* Indicative only, the actual value will be decided by the Bidder, after substantiating the
same by calculation.
2.0 RANGE OF VARIATION
A.C. Supply :
During starting of large motor, the voltage may drop to 80% of the rated voltage for a
period of 60 seconds. All electrical equipment while running shall successfully ride over
such period without affecting system performance.
D.C. Supply :
Voltage : 187 to 242 Volt
SECTION‐III TECHNICAL
SPECIFICATION
FOR
ELECTRIC MOTOR ACTUATORS
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
SECTION‐III
TECHNICAL SPECIFICATION
FOR
ELECTRIC MOTOR ACTUATORS
1.00.00 SCOPE
1.01.00 This Section covers the general requirements of Electric Motor Actuators for
valves, dampers and gates.
1.02.00 All electric motor actuators shall be furnished in accordance with this general
specification and the accompanying driven equipment specification.
2.00.00 STANDARDS
2.01.00 All electrical equipment shall conform to the latest editions including all
applicable amendments of IS, ANSI and NEMA Standards, except when stated
otherwise herein or in driven equipment specification.
2.02.00 Equipment and material conforming to any other standards, which ensure
equal or better quality, may be accepted. In such case, copies of the English
version of the standard adopted shall be submitted along with the bid.
2.03.00 The electrical installation shall meet the requirements of Indian Electricity
Rules as amended upto date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall be followed.
2.02.00 Major standards, which shall be followed, are listed below. Other applicable
Indian Standards for any component part even if not covered in the listed
standards shall also be followed
i) IS-9334
ii) IS-325
3.01.00 The actuator shall be suitable for operation in hot, humid and tropical
atmosphere, highly polluted at places with coal dust and/or fly ash.
4.00.00 RATING
4.01.00 For isolating service, the actuator shall be rated for three successive open-close
operation of the valve/damper or 15 minutes, whichever is longer.
4.02.00 For regulating service, the actuator shall be suitably time-rated for the duty
cycle involved with necessary number of starts per hour, but in no case less
than 150 starts per hour.
5.00.00 PERFORMANCE
5.01.00 Open and close the valve completely and make leak-tight valve closure without
jamming.
5.02.00 Attain full speed operation before valve load is encountered and impart an
unseating blow to start the valve in motion (hammer blow effect).
5.03.00 Operate the valve stem at standard stem speed and shall function against
design differential pressure across the valve seat.
5.04.00 The motor reduction gearing shall be sufficient to lock the shaft when the motor
is de-energised and prevent drift from torque switch spring pressure.
5.05.00 The entire mechanism shall withstand shock resulting from closing with
improper setting of limit switches or from lodging of foreign matter under the
valve seat.
6.01.00 Construction
6.01.01 The actuator shall essentially comprise the drive motor, torque/ limit switches,
gear train, clutch, hand wheel, position indicator/ transmitter, in-built thermostat
for over load protection, space heater and internal wiring. Actuator shall be
integral type. Integral starter shall have facility to hookup with Plant DCS for
position limit and torque switches.
6.01.02 The actuator enclosure shall be totally enclosed, dust tight, weather-proof
suitable for outdoor use without necessity of any canopy.
6.01.03 All electrical equipment, accessories and wiring shall be provided with tropical
finish to prevent fungus growth.
6.01.04 The actuator shall be designed for mounting in any position without any
lubricant leakage or operating difficulty.
6.02.00 Motor
6.02.02 The motor shall be designed for full voltage direct on-line start, with starting
current limited to 6 times full-load current.
6.02.03 The motor shall be capable of starting at 85 percent of rated voltage and
running at 80 percent of rated voltage at rated torque and 85 percent rated
voltage at 33 percent excess rated torque for a period of 5 minutes each.
6.03.01 2 torque limit switches, one for each direction of travel, self-locking, adjustable
torque type.
6.03.03 2 position limit switches, one for each direction of travel, each adjustable at any
position from fully open to fully closed positions of the valve/damper.
6.03.04 Each limit switch shall have 2 NO + 2 NC potential free contacts. Contact rating
shall be 5A at 240V A.C. or 0.5A at 220V D.C.
Each actuator shall be provided with a hand wheel for emergency manual
operation. The hand wheel shall declutch automatically when the motor is
energized.
6.05.01 One (1) built-in local position indicator for 0-100% travel.
6.05.02 One (1) position transmitter, non contact type, for remote indicator.
A space heater shall be included in the limit switch compartment suitable for
240V, 1 phase, 50 Hz supply.
6.07.00 Wiring
All electrical devices shall be wired up to and terminated in a terminal box. The
internal wiring shall be of sufficient size for the power rating involved but in no
The terminal box shall be weather proof, with removable front cover and cable
glands for cable connection. The terminal shall be suitable for connection of 2.5
Sq.mm copper conductor.
7.00.00 TEST
The actuator and all components thereof shall be subject to tests as per
relevant Standards. In addition, if any special test is called for in equipment
specification, the same shall be performed.
Following routine test shall be conducted as per IEC/IC standard. (a) Meggar
Test,(b) Continuity test, (c) Operational test. Test certificates duly signed by
inspecting agency shall be furnished.
Data sheet for each type of actuator shall be furnished along with internal wiring
diagram, suggested control schematic and torque limit switch contact
development and manufacturer's catalogues.
d) Manufacturer's Catalogue
8.02.00 The Bidder may note that the drawings, data and manuals listed herein are
minimum requirements only. The Bidder shall ensure that all other necessary
write-ups, curves and information required to fully describe the equipment are
submitted with his bid.
SECTION-IV
TECHNICAL SPECIFICATION
FOR GENERATOR BUS DUCT
CONTENT
ATTACHMENT
SECTION-IV
TECHNICAL SPECIFICATION
FOR GENERATOR BUS
DUCT
Generator busduct & associated equipment with accessories: Two (2) sets
b) One (1) set of phase segregated neutral terminal adopter box with
current transformers and neutral make-up connections.
One (1) set of isolated three-phase busduct with current transformers from main
run to the unit transformers.
One (1) set of isolated three-phase busduct from delta connection points to the
terminals of single-phase generator transformers
One (1) set of isolated three-phase busduct from main run to voltage
transformer and surge protection (V.T. & S.P.) cubicles.
One (1) set of single phase busduct from generator neutral make-up connection
to the neutral grounding (N.G.) cubicle.
One (1) set of voltage transformer and surge protection cubicles containing
voltage transformers for metering, relaying, automatic voltage regulator (AVR)
system, electro hydraulic governing (EHG) system; lightning arrestors and
surge capacitors.
One (1) generator neutral grounding cubicle containing disconnect link, neutral
grounding transformer, loading resistors and current transformer.
The vendor shall submit calculation of NGT & NGR to the application of 100%
stator earth fault relay type for min short time duration of 5mins
1.01.08 All supporting steel structures, fasteners hangers and necessary hardware for
complete busduct installation.
1.01.09 One (1) set of busbar shorting pieces for heat run/short circuit tests (common
for units of identical ratings.
1.01.12 One (1) set of pressurization unit complete with all piping and accessories
1.01.15 Flexible bellow and terminations, disconnecting links, wall frame assemblies,
seal off bushing and matching flanges.
1.01.18 IPBD should be designed without the requirement of Canopy in the outdoor area.
2.01.01 All equipment and materials shall be designed, manufactured and tested in
accordance with the latest e d i t i o n s i n c l u d i n g a l l applicable
amendments of relevant Indian Standards (IS) and IEC except where
modified and/or supplemented by this specification.
2.01.02 Equipment and material conforming to any other standard, which ensures
equal or better quality, may be accepted. In such case, copies of the English
version of the standard adopted shall be submitted along with the bid.
2.01.03 The electrical installation shall meet the requirements of Indian Electricity
Rules as amended upto date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall be followed.
IS:4759 Hot dip zinc coating on structural steel and allied products
3.02.00 The busduct will be installed partially indoor and partially outdoor in a hot,
humid and tropical atmosphere. The design of busduct shall take care of solar
effect. All cubicles, however, will be installed indoor.
3.03.00 Busduct, associated equipment and wiring shall be provided with tropical finish
to prevent fungus growth. All ventilation openings shall be screened and drains
shall be filtered to prevent entrance of dust and insects.
3.04.00 The portion of busduct at the generator end will be subject to vibration normally
prevalent for this type of installation in a power generating set. Suitable means
shall be provided to isolate the generator vibration from rest of the bus
structure.
3.05.00 For continuous operation at specified ratings, temperature rise of the busduct
and auxiliary equipment shall be limited to the site permissible values stipulated
in relevant standards and/or this specification.
4.01.00 General
4.01.01 The busduct shall be isolated phase, continuous (bonded enclosure) natural air
cooled type with positive pressure (+100mm water column) to prevent entry of
dust and moisture.
4.01.02 The layout of the busduct shall be generally in accordance with enclosed
drawing. The details shown however are only typical. Bidder may propose
changes to suit his particular design.
4.01.04 Design of the busduct and its supporting structure shall be such that it will
permit transformer removal after opening of the termination but without
dismantling busduct run or supporting structure.
4.02.00 Enclosures
4.02.02 The enclosure shall be minimum flux type to permit not more than five (5) per
cent of total conductor flux outside enclosure.
4.02.05 The bus enclosure shall have extended bellows or equivalent means to allow
for temperature changes and vibrations. Flexible joints shall be provided in
enclosures at all points where the busduct terminates at equipment to withstand
vibration, expansion/ contraction and at suitable intervals in any straight run of
the busduct where expansion and contraction would otherwise result in
stresses in the supporting structures.
4.02.06 Inspection opening/split covers shall be provided to allow easy access for
installation, inspection, replacement or repairs of the insulators, disconnects,
bus connections and terminations.
The inspection/split covers shall have reliable sealing arrangements with
neoprene/rubber gaskets in grooves.
4.02.07 Wall-frame with support plates shall be provided where the busduct penetrates
the building wall. For non-pressurised busduct, the wall frame shall be complete
with seal of bushings to prevent exchange of air between indoor and outdoor
portions of the busduct.
4.02.08 Silica-gel breather shall be provided on both indoor and outdoor portions of the
busduct. (shall not be required for pressurized busduct)
4.02.09 Filtered drains for drainage of condensate shall be provided at the lowest points
and at such locations where accumulation of condensate can be expected. .
(shall not be required for pressurized busduct)
4.02.11 Shipping length of the busduct shall be as long as practicable within transport
limitation to reduce field assembly work.
4.03.01 The bus conductor shall be of high conductivity, aluminium alloy, supported on
wet process porcelain insulators.
4.03.02 The bus conductor shall be designed for welded connections except at
equipment terminations and bolted disconnect links.
4.03.03 Flexible connections shall be provided between bus sections to allow expansion
and contraction of the conductor. Flexible connection shall also be provided at
all equipment terminations.
4.03.04 All contact surfaces shall be silver plated to ensure an efficient and trouble-free
connection. All connection hardware shall be non-magnetic and shall have high
corrosion resistance.
4.03.05 The bus conductor shall be sufficiently corona-free at rated voltage to eliminate
the possibility of igniting the potential accumulation of hydrogen gas.
4.04.01 Removable bolted disconnect link shall be provided in the bus for isolation of
the transformers and auxiliary equipment.
4.04.02 Disconnect link shall consist of a removable section of conductor and shall be
so constructed as to permit easy removal or reinsertion without alignment
difficulties.
4.04.03 The bus on both sides of the link shall be rigidly supported so that the
disconnect link is equal in mechanical strength to any other section of the bus.
A minimum clearance of 300 mm. (12") shall be provided between the
disconnected bus sections with the link removed.
4.05.00 Insulators
4.05.01 Bus support insulators shall be interchangeable, high strength, wet process,
fine glazed porcelain and shall be suitable for heavily polluted atmosphere.
4.05.03 The conductor shall be fastened on the insulator through fixed and slip joints so
as to allow conductor expansion or contraction without straining the insulator.
4.05.04 All ferrous metal part of the insulator shall be hot-dipped galvanized.
4.06.01 All matching flanges/ adopter boxes, seal-off bushings, gaskets, fittings, hard-
ware and supports required for termination of the busduct at the generator,
transformers and other equipment shall be furnished.
4.06.02 The contractor is required to co-ordinate through the Engineer with the
suppliers of the generator, generator circuit breaker, generator transformer,
unit transformers and different auxiliary equipment panels with regard
to connection details, mechanical and thermal stresses.
4.06.03 Flexible connections both for conductor and enclosure shall be furnished:
4.06.04 The equipment terminal connections shall be readily accessible and shall
provide sufficient air gap for safe isolation of equipment during testing.
4.06.05 If the material of bus conductor and that of the equipment terminal connectors
are different then suitable bi-metallic connectors shall be furnished.
4.06.06 Isolation barrier or seal off bushings shall be provided at the generator end of
the busduct to prevent migration of hydrogen into the busduct.
The space above the barrier at the generator side shall be ventilated through
filtered opening in the enclosure wall.
4.07.02 The links shall be suitable for shorting bus conductors/enclosures of three (3)
phases after generator phase current transformers in a prefixed location as
shown on drawing.
4.07.03 The links shall be so designed with flexible connections that the bus insulators
will not be unduly stressed due to expansion/ contraction during dry out or short
circuit tests.
4.08.00 Grounding
4.08.01 The electrically continuous bus enclosure shall be used as the ground bus. All
parts of the bus enclosure, supporting structures and equipment frames shall
be grounded.
4.08.02 Ground pad shall be bolted type to accommodate 75x10mm. galvanized steel
flats at following locations :
4.09.01 All supporting structures required for hanging and/or supporting the complete
busduct shall be furnished. These include all members, indoor/outdoor posts,
bolts, shims, base plates, beams, hangers, brackets, bracings and hardware.
4.09.02 All buses shall be adequately supported and braced to successfully withstand
normal operation, vibration, thermal expansion, short circuit forces and all
specified design loads.
4.09.04 The indoor support shall be in general of hanger supports while outdoor shall
be generally supported from the ground.
4.09.05 All steel members shall be hot-dip galvanized after fabrication. All hardware
shall be of high strength steel with weather resistant finish.
4.09.06 Concrete foundation, building steel, concrete, and inserts/plates will be provided
by Owner/Purchaser.
The Contractor shall co-ordinate with the Owner/Purchaser for this purpose
giving well in advance the details of his requirements so as to enable the
Owner/Purchaser to arrange for the same in time.
4.10.02 Hot air blowing system shall be of open loop type, capable of blowing hot air
simultaneously in the indoor and outdoor portions of the busduct. The system
shall be permanent arrangement for each unit.
4.10.03 The system shall be furnished complete with motor-blower unit, combination
starter, washable filters, piping, valves, heaters, thermostats, controls,
instrumentation and monitoring.
4.10.04 A control cabinet shall be furnished with mounted and wired control &
monitoring devices, indicating lights etc. Auxiliary contacts shall be provided for
4.10.05 Ambient air will be drawn in through inlet damper and dry air filter and forced
through thermostat controlled heaters. Hot air will be distributed by a set of
properly sized ducts and dampers to the indoor and outdoor portion of the
busduct. Hot air will be let out from busduct through suitably directed outlet
provided at each equipment termination.
4.10.06 The system will be put in operation only before start-up and shall be sized to
complete the drying operation in about one to one and half hour.( Minimum
rating of the Blower : 1250 m3 / hour , 120 mm WC and Heating Capacity: 9675
K.Cal / Hour) Once the drying up is complete, the system will be shut down.
The dampers and hot air outlets are to be kept closed when the system is not in
operation.
4.11.01 The current transformers shall be cast-resin, ring type, mounted within the
busduct enclosures and suitable for operation at an ambient temperature equal
to rated busbar temperature.
4.11.02 The bus design shall permit removal or replacement of C.T.s without
dismantling the bus run or supports.
4.11.03 The C.T.s shall have polarity markings indelibly marked on them.
C.T. secondary leads will be brought out to separate terminal box mounted on
or adjacent to C.T. enclosure. From phase terminal boxes, C.T. secondary
leads shall be brought out through non- magnetic metallic conduits to a master
terminal box for Owner/Purchaser’s cable connections.
4.11.04 The terminal boxes shall be dust-tight, weather-proof, fabricated from aluminum
alloy and complete with screwed cover for access to terminals and removable
gland plate for Owner/Purchaser’s cable connections.
4.11.05 The CT quantity, ratings and other CT parameters indicated in the Protection Key
SLD is tentative and it will be supplied as per approved SLD during detail
engineering.
4.12.01 The V.T. & S.P. cubicles, one for each phase, shall be metal-clad, dust and
vermin proof, free standing dead front assemblies.
4.12.02 Each phase cubicle shall house three (3) voltage transformers, one (1) lightning
arrestor and one (1) surge capacitor, in separate compartments. Seal-off
bushings shall be used between the bus tap and cubicle and between
compartments.
4.12.03 Lightning arrestor shall be station class, hermetically sealed type, connected
between line and ground, specifically suitable for generator protection.
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐IV : 9 DCPL-11Z02
[2 x 660 MW] Main Plant Package
The characteristic of the lightning arrestor shall be carefully chosen to provide a
low protective ratio for generator BIL.
4.12.04 A discharge counter shall be provided for each lightning arrestor. The
discharge counter register shall be visible without having to open the
compartment door.
4.12.05 The surge capacitor shall be non-inflammable and non-toxic type, single pole,
connected between line to ground.
4.12.06 The voltage transformer shall be cast-resin type, suitable for nominal operation
connected from line to ground, and for 1.73 times rated line to ground voltage
under sustained emergency condition.
4.12.07 The voltage transformer shall be mounted on drawout type carriage. Suitable
guide slots and stops shall be provided to ensure easy withdrawal and
positioning.
4.12.08 In the disconnected position, the voltage transformer primary and secondary
circuits shall be automatically disconnected and the primary fuse shall be visibly
grounded. The draw out frame shall be grounded at all times.
4.12.09 The high voltage winding of the voltage transformer shall be protected by
current limiting fuse mounted on top of the primary bushing. The fuse will be
accessible only in fully drawn out position.
4.12.10 The secondary leads from the voltage transformer shall be extended to a fuse
and terminal cabinet flush mounted on the compartment.
4.13.01 The transformer and resistor shall be located in separate cubicles adjacent to
each other. The cubicles shall have hinged access doors capable of being pad
locked.
4.13.02 The transformer cubicle and resistor cubicle shall be of sheet steel construction.
The resistor cubicle shall hot-dip galvanized screen sides.
4.13.03 The neutral grounding transformer shall be dry type, natural air cooled, single
phase connected between generator neutral and ground.
4.13.04 The neutral current transformer shall be cast-resin, ring type, suitably mounted
to permit easy removal or replacement.
4.13.05 The loading resistor shall be formed of non-aging, corrosion resistant steel,
4.13.06 All alarm, protection and indication leads shall be wired up to terminal blocks
that shall be mounted in a dust tight enclosure suitable for flush mounting and
having a fully hinged cover with lock.
4.14.01 Each busduct shall be provided with air pressurization system consisting of
two (2) 100% capacity oil free type air compressors with motors, necessary
filters, valves, driers, piping, solenoid valves, transmitters, drains, pressure
switch and gauges, fittings and necessary controls to ensure a continuous
supply of clean and dry pressurized air to the busduct enclosure maintaining a
positive air pressure (100 mm water column) inside the enclosures to prevent
any ingress of moisture from atmospheric air.
4.14.02 A tee-off connection with non-return valve and isolating valve, pressure reducer
etc shall be provided for a stand-by connection to station compressed air supply
header. The pressure range of the station compressed air system will be
intimated to the contractor.
4.14.03 The allowable air leakage shall be less than 5% of the total enclosure volume
per hour. The contractor shall demonstrate this guaranteed figure during factory
test as well as during site acceptance test.
4.14.04 In order to avoid any excess over pressure due to any abnormality the unit shall
be equipped with safety valves calibrated to open the circuit at about 2-3 times
the design pressure. All materials shall be designed to withstand more than
twice the safety valve set pressure.
4.14.05 One number control panel shall be provided for each air pressurization unit to
house motor starters, push buttons, interlock, protection and monitoring, alarm
and annunciation system. The control system shall perform automatic function
with manual start stop facility. Local as well as remote monitoring facility shall
be provided for both mechanical and electrical systems.
4.15.01 All cubicles, control panels and control cabinets shall be fabricated from sheet
steel of minimum 2 mm thickness suitably reinforced to ensure structural
rigidity.
4.15.02 The degree of protection for all indoor cubicles shall be IP 54 except for neutral
grounding resistor enclosure which shall be minimum IP 23.
4.15.03 Each cubicle shall be equipped with space heater, internal illumination lamp
and ground bus.
4.15.04 Space heater and lamp shall be provided with individual ON-OFF switches.
The space heater shall be provided with thermostat.
4.15.05 Space heater shall be so sized and located as to maintain the temperature
within cubicle at least 5°F above dew point.
4.16.00 Wiring
4.16.01 All wiring shall be done with insulated stranded copper conductor of not less
than 2.5 Sq.mm cross section. Each wire shall be identified at both ends with
wire designation as per contractor's wiring diagrams
4.16.02 Heat resistant type wires suitable to withstand specified busduct inside
temperature shall be used for wiring between CT secondary terminals to the
terminal box.
4.16.03 Terminal blocks shall be box-clamp type suitable for 2x2.5 Sq.mm copper
conductor with marking strips.
4.16.04 Not more than two wires shall be connected to one terminal. Spare terminals
equal in number to 20% active terminals shall be furnished.
Terminal for C.T. secondary leads shall have provision for shorting and
grounding.
4.17.02 Materials for nameplate shall be plastic / lamicoid, 3 mm thick, using white
letters on black background.
4.18.00 Finish
4.18.01 Except for supporting steel structures which shall be galvanized, all equipment
shall be finished with a undercoat of high quality primer followed by two coats of
synthetic enamel paints unless otherwise stated.
4.18.02 The interior surface finish shall be as per manufacturer's standard. The shade
of exterior surface finish for indoor and outdoor portion shall be as indicated in
the Annexure.
4.18.04 Paints shall be carefully selected to withstand heat and weather conditions.
The paint shall not scale-off or crinkle or get removed by abrasion due to
normal handling.
4.18.05 Sufficient quantities of all paints and preservatives required for touching up at
sites shall be furnished.
f. Test for radio active interference according to the procedure set forth in
NEMA publication No.107
5.05.01 Certified reports of all the tests carried out at the works shall be furnished in six
(6) copies for approval of the Owner/Purchaser.
5.05.02 The equipment shall be dispatched from works only after receipt of
Owner/Purchaser's written approval of the test reports.
6.01.00 Drawings, Data and Manuals shall be submitted with the bid and in quantities
and procedures as specified in General Condition of Contract and/or elsewhere
in this specification for approval and subsequent distribution after the issue of
Letter of Intent.
6.02.02 Typical details of V.T. & S.P. cubicles, N.G. cubicles, bus insulator assembly,
conductor/enclosure connections rigid & flexible, seal-off bushings etc.
6.02.05 General Arrangement Drawing of Hot Air Blowing System and air pressurization
unit
6.02.06 Type test reports on similar equipment. The type test certificates shall not be
more than 5 years old. If the particular type test is not already conducted on
similar equipment the same to be conducted.
6.03.01 Calculation for temperature rise for bus and enclosure as per IEEE No. 298 (A).
6.03.02 Calculation for short circuit forces justifying the proposed arrangement (A)
6.03.05 Dimensional equipment drawings for C.T., V.T., L.A., N.G. Transformer, loading
resistor, terminal connectors etc. (A)
6.03.07 Details of bus insulator assembly, C.T. assembly, rigid and flexible connections
of both bus conductor and enclosure, grounding provision, seal-off bushings,
equipment termination arrangement etc. (A)
6.03.13 Set up layout of the busduct for carrying out type test (A)
The manual shall clearly indicate method of installation, check ups and tests
to be carried out before commissioning of the equipment. The manual shall
also indicate detail procedure of field welding of conductor and enclosure
6.03.15 Any other relevant drawing or data necessary for satisfactory installation,
operation and maintenance.
6.03.16 The vendor shall submit calculation of NGT & NGR to the application of 100%
stator earth fault relay type for min short time duration of 5mins
6.04.00 The drawings and document marked with (A) above are of ‘Approval’
category and are subject to review by Owner/Purchaser. Those marked (R)
are for ‘reference’ category.
The Owner/Purchaser may also review the documents marked (R) if found
necessary. The contractor shall note that the approval of drawings &
documents by the Owner/Purchaser does not relieve him of his contractual
obligation.
6.05.00 The bidder may note that the drawings, data and manuals listed herein are
minimum requirement only. The bidder shall ensure that all other necessary
write-up, curves, etc require to fully describe the equipment are to be
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐IV : 15 DCPL-11Z02
[2 x 660 MW] Main Plant Package
submitted with the bid.
6.06.00 All drawings shall be prepared by using Auto CAD approved version and all
documents shall be generated using MS Office. The paper copy of the
drawings & document shall be submitted for approval & reference. All final
drawings and documents shall be submitted in CD in Auto CAD (approved
version) and MS Office format as applicable for Owner/Purchaser’s future
reference.
1.0 GENERAL
(Applicable to all Equipment)
c) Delta run ( for 3 off 1Ph GT) : 254 KA rms/ 705 KA peak
i) Bus conductor :
2.6 Material
The actual current to be verified and confirmed within above limit during detail
engineering by calculation and ETAP System Study.
2.7 Insulator
Creepage : 600mm
2.8 Painting
B1. Gen
Relaying 25000/5 75 5P20 - - - -
B2. Gen
Relaying 25000/5 75 5P20 - - - -
C. Performance Testing
& EHG system 25000/5 75 0.2 <5++ - - -
NOTE : The ratings indicated are tentative. The exact requirement will have to be coordinated on finalization of protection scheme.
* Not less than
** Nor more than
+ At maximum operating temperature.
++ISF must match with the capability of connected instruments/devices.
Line Side
TAP-OFFS C.T.S
A. LIGHTNING ARRESTOR
B. SURGE CAPACITOR
a. Continuous : 1.2
b. 30 seconds : 1.9
The sizing calculation need to be submitted during detail engineering for owners approval.
SECTION-V
TECHNICAL SPECIFICATION
FOR
HT SWITCHGEARS
CONTENT
ATTACHMENTS
SECTION-V
TECHNICAL SPECIFICATION
FOR
HT SWITCHGEARS
1.01.04 High speed microprocessor based Autobus Transfer panel as per write up
attached for each of the 11KV Unit and Station Switchboards for Incomers
and TIE Breakers changeover through BTS shall be included in the scope.
Auto bus transfer is not required from station to unit bus on station bus failure.
However planned changeover facility shall be provided for 11 KV tie as well as
incomer breakers.
1.01.05 Base channel frame of the switchgear with hardware in panel design.
a) Earthing truck for feeders : Two (2) Nos. each for 3.3 KV &
11 KV Switchgears
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐V : 1 DCPL-11Z02
[2 x 660 MW] Main Plant Package
b) Earthing truck for bus : Two (2) Nos. each for 3.3 KV &
11 KV Switchgears
1.01.07 One set of special tools and tackles for 3.3 KV switchgears & 11KV
switchgear.
1.01.09 Recommended spare parts for three (3) years continuous operation.
2.01.00 All equipment and materials shall be designed, manufactured and tested in
accordance with the latest editions including all applicable amendments of
relevant Indian Standards (IS) and IEC except where modified and/or
supplemented by this specification.
2.02.00 Equipment and material conforming to any other standards, which ensure
equal or better quality, may be accepted. In such case, copies of the English
version of the standard adopted shall be submitted along with the bid.
2.03.00 The electrical installation shall meet the requirements of Indian Electricity
Rules as amended upto date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall be followed.
2.04.00
S.No CODE Description
3. IS:5082 Specification for wrought Aluminum alloys bars, rods, tubes and
sections for electrical purposes.
4. IEC-62271 High Voltage alternating circuit breakers
IEC-60056
IS-13118
5. IEC-60044 Instrument transformers
8. IEC-60282
High voltage Fuses.
IS-9358
9. IS-3231 Electrical relays for power system protection
14. IS-2544 Specification for Porcelain post insulators for systems with
nominal voltage greater than 1000 V
18. IS-9046 AC contactors for voltages above 1000 volts and upto and
including 11000V.
19. IS-9431 Specification for indoor post insulators of organic material for
system with nominal voltages greater than 1000 volts upto and
including 300 kV.
20. IEC-60099 Metal oxide surge arrestor without gap for AC system.
(part 4)
22. CIGRE WG Recommendation for substitute test for switching over voltage
13.02 test.
Chapter-3
3.01.00 The switchgear shall be used to supply power to HV motors, transformers and
other loads for various plants.
3.02.00 Duty involves direct on line starting of large induction motors and also under
certain emergency conditions transfer of loads from normal to stand-by
source of supply.
The HT Switchgear need to be designed for motor starting current varies from
6 to 8 times the full-load current, with a maximum of 3 starts per hour.
3.03.00 The switchgear shall be located in a clean but hot, humid and tropical
atmosphere.
3.05.00 For continuous operation at specified ratings, temperature rise of the various
switchgear components shall be limited to the permissible values stipulated in
the relevant standards and/or this specification.
3.06.00 The Switchgear and components thereof shall be capable of withstanding the
mechanical forces and thermal stresses of the short circuit current listed in
the annexure without any damage or deterioration of material.
3.07.00 Circuit breaker shall not produce any harmful over-voltage during switching of
induction motors, unloaded lines and unloaded transformers. Surge protective
device shall be provided in the scope of supply to limit over-voltage.
4.01.00 Construction
4.01.01 The switchgear shall be indoor, metal-clad, floor mounted, draw out type.
Design and construction shall be such as to allow extension at either end.
4.01.02 The switchgear enclosure shall conform to the degree of protection IP-42 as
per IEC.
The minimum thickness of CRCA sheet steel used shall be 2 mm.
4.01.04 Switchgear cubicle shall be so sized as to permit closing of the front access
door when the breaker is pulled out to TEST position. The working zone shall
be restricted within 750 mm to 1950 mm from floor level.
4.01.05 Circuit breakers, instrument transformers, bus bars, cable compartment etc.,
shall be housed in separate compartments within the cubicle. The design
shall be such that failure of one equipment shall not affect the adjacent units.
4.01.06 All relays, meters, breaker control switches, selector switches and indicating
lamps shall be flush mounted on the respective cubicle door or on control
cabinet built on the front of the cubicle. AC/DC auxiliary supply switches /
4.01.07 Dummy panel shall be provided in the switchgear line up, if required, for easy
termination access of power and control cables. Dummy panel / bus trunking
panel shall be of full cubicle with closed roof and rear door similar to
enclosures for active cubicles.
4.01.08 In each of the 11KV and 3.3KV Switchgear one spare feeder for each type
shall be provided.
4.01.09 The motor space heater shall be controlled from separate module in MCC
with necessary interlocks with switchgear
4.01.10 The wiring for the space heater of switchgear compartments shall be
segregated from the control wiring. The sizes of wire in the panel shall be
stranded copper conductor, 1.5mm² for all circuit and 2.5 mm² for CT circuits
4.02.01 The main buses and connections shall be of high conductivity aluminum/
aluminum alloy, sized for specified current ratings with maximum temperature
limited to:
0 0 0
(a) For bolted joints (Plain or tinned) – 90 C ( i.e 40 C rise over 50 C
ambient)
4.02.02 Copper bus bars shall be used for bus bar current rating above 2000A, with
maximum temperature rise limits same as that for aluminum bus bar.
4.02.03 Bus bars shall be of same size for the entire length of the switchgear.
4.02.04 All bus connections shall be silver plated. Adequate contact pressure shall be
ensured by means of two bolts connection with plain and spring washers and
locknuts. Bimetallic connectors shall be furnished for connections between
dissimilar metals.
4.02.05 Bus bars and connection shall be fully insulated for working voltage with
adequate phase/ground clearances. Insulating sleeves for bus bars and cast-
resin shrouds for joints shall be provided, suitable for maximum temperature
rise of bus bars.
4.02.06 Bus insulator shall be flame-retardant, track resistant type with creepage
distance suitable for heavily polluted atmosphere.
4.02.08 Bus bars shall be color coded for easy identification and so located that the
sequence R-Y-B shall be from left to right, top to bottom or front to rear, when
viewed from front of the switch-gear assembly.
4.03.01 Circuit breaker shall be triple pole, single throw and Vacuum type.
4.03.02 Circuit breakers shall be horizontal isolation and horizontal draw out type,
having SERVICE, TEST and DISCONNECTED positions with positive
indication for each position.
4.03.04 Circuit breaker shall have motor wound spring charged trip free mechanism
with anti pumping-feature and shunt trip. In addition facility for manual
charging of spring shall be provided.
4.03.05 For motor wound mechanism, spring charging shall take place automatically
after each breaker closing operation. One open-close-open operation of the
circuit breaker shall be possible after failure of power supply to the motor.
a) The circuit breaker from being racked in or out of the service position
when the breaker is closed.
b) Racking in the circuit breaker unless the control plug is fully engaged.
4.03.08 Each breaker shall be provided with an emergency manual trip, mechanical
ON-OFF, indication, an operation counter and mechanism charge/discharge
indicator.
Alternatively electrically reset type latching relay may be used for the
purpose.
4.03.11 For 3.3KV motor feeders contactor with fuse can be considered instead of
Circuit Breaker.
The circuit breaker shall be wired up for local & remote operation. Each
breaker cubicle shall be equipped with following :-
4.04.01 One (1) TEST-NORMAL-TRIAL selector switch stay put type with pistol grip
handle and key interlock.
4.04.02 Two (2) heavy-duty oil tight, push buttons for TRIP & CLOSE.
AMBER : Trip
Out of these, some shall be selected for the sequential events recording.For
each feeder, grouped alarm for any abnormal condition of that feeder shall be
provided on the control panels. The control / interlock schemes for various
types of feeders shall be commensurate with their application.
• Breaker on
• Breaker off
• Breaker in remote
• Breaker in service
• Breaker in test
• Circuit side earthed
• Bus side earthed (as applicable)
• Spring charger indication
• Local/Remote
(ii) Alarms
d) Motor Feeders
• Overload alarm
f) Tie Feeders
• Sources paralleled beyond preset time.
g) Analog Parameters
- Load current each phase
h) Control
ON / OFF control and ON / OFF & fault / discrepancy indication for each of
the breakers shall be provided in the CRTs. Control panel in the control
room shall be provided with control of all synchronizing breakers i.e.,
incomers and tie breakers with auto-off-manual switches.
4.04.04 Lamps shall be clustered type LED module pilot lights in thermoplastic
enclosure with polycarbonate lens and diffuser. LED shall be protected by in-
built fuse with surge suppressor and leakage voltage glow protection. Lamp
and lens shall be replaceable from front. LED’s used shall have pickup and
drop out voltage within -20% of operating voltage.
4.04.05 The general scheme of connection for control, interlock and protection is
shown in the enclosed drawings. Detailed requirements shall be intimated
later to the successful Bidder, who shall develop and furnish the schemes
accordingly.
4.05.01 Current transformers shall be cast resin type. All secondary connections shall
be brought out to terminal blocks where wye or delta connection shall be
made.
4.05.03 Current transformer secondary shall be rated for 1 A for protection and 5 A for
metering.
4.06.01 Voltage Transformer (VT) shall be cast-resin, draw out type and shall have an
accuracy class of 0.2 for MEAA and 0.5 for other measurements. Voltage
transformer shall be mounted in a separate vertical panel. Voltage
transformer on breaker carriage or at the top of cubicle is not acceptable.
4.06.03 Low voltage winding of voltage transformer shall have fuse installed in all
ungrounded secondary leads. Fuse shall be suitably located to permit easy
replacement while the switchgear is energized.
4.06.04 Voltage Transformer Insulation shall be of Class E or better.
4.07.00 Relays
4.07.01 Relays shall be of draw out design with built-in testing facilities and flush
mounted at the front of panel. Small auxiliary relays may be in non-draw out
execution and mounted within the cubicle.
4.07.02 Relays shall be rated for operation on 110V PT secondary voltage and CT
secondary current 1A for protection and 5 A for metering as shown on
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐V : 10 DCPL-11Z02
[2 x 660 MW] Main Plant Package
drawings. Number and rating of relay contacts shall suit the job requirements.
The protection Relay used for MV Switchgears i.e for Incomer/ Tie
feeders/outgoing feeder/Transformer feeder/Motor feeder shall be latest version
of Numerical relays having communication facility (RS 232, RS 485). Bidder
shall make necessary provision to make protection Relay data available at data
highway bus in plant Main control room. The polling time of relays shall be as
minimum as possible with real time tag. The protection relay used for
Incomer/Tie feeders/ Outgoing feeder/ Transformer feeder shall have facility to
select curves as per IEC, IEEE/ANSI protection Relay shall have event record
fault record and disturbance record facility. More facility and protection available
in the relay shall be accepted. System should be OPC complaint with
necessary hardwares and software, special cables. FO cables, required
Ethernet switches, data concentrator for hooking upto DDCMIS. Also the alarm
points shall be generated in the system which shall be transferred through OPC
complaint interface upto DDC/MIS. Make and type of all the relays shall be
subject to Owner/Consultant approval.
4.07.05 Separate numerical relay shall be provided for differential protection of motors
above 1000KW and E/F protection of motor shall be achieved through CBCT.
4.07.06 The Contractor shall furnish, install & co-ordinate all relays to suit the
requirements of protection, interlock schemes and bus transfer schemes.
4.08.00 Meter
4.08.01 Indicating instruments (96 x 96 mm) shall be switchboard type, with 240-
degree scale, anti-glare glass and accuracy class of ± 1% full scale. Each
meter shall have zero adjuster on the front.
4.08.02 Motor ammeter shall have extended suppressed end-scale range to indicate
starting current (6-8 times full load).
The meters shall be of 0.2S accuracy class and the associated CTs and PTs
shall be of 0.2S and 0.2 accuracy class respectively.
The meters for both HV and LV side of ST shall be located on Incomer panel
of respective switchgears.
For UT, meters for HV side shall be located on the Generator Metering Panel
at Central control room and the meters for LV side shall be located on
incomer panel of respective switchgears.
c) (1) The energy accounting and audit meters shall be suitable for
measurement, recording and display of cumulative active energy with date
and time.
(2) The energy accounting and audit meters may also have the facility to
measure, record and display one or more of the following parameters
depending upon the energy accounting and audit requirement. All parameters
excluding instantaneous electrical parameters shall also be stored in memory.
(3) The energy accounting and audit meter shall have data storage capacity
for at least 35 days in a non-volatile memory.
(4) Energy accounting and audit meters shall have facility to download the
parameters through meter reading instruments as well as remote
transmission of data over communication network
be automatically stored:
(b) Net Wh during each successive 15-minute block, upto second decimal,
with plus/minus sign.
(d) Cumulative VArh for voltage high condition, at each midnight, in six digits
including one decimal.
(e) Cumulative VArh for voltage low condition, at each midnight, in six digits
including one decimal.
(f) Date and time blocks of failure of VT supply on any phase, as a star(*)
mark.
(6) The meters shall store all the above listed data in their memories for a
period of at least ten days. The data older than ten days shall get erased
automatically. Each meter shall have an optical port on its front for tapping all
data stored in its memory using a hand held data collection device. The meter
shall be suitable for transmitting the data to remote location using appropriate
communication medium.
(7) The active energy (Wh) measurement shall be carried out on 3-phase, 4-
wire principle, with an accuracy as per class 0.2 S of IEC-687/IEC-62053-22.
The energy shall be computed directly in CT and VT secondary quantities,
and indicated in watt-hours.
(8) The Var and reactive energy measurement shall also be on 3-phase, 4-
wire principle, with an accuracy as per class 2 of IEC-62053-23 or better. The
Var and VArh computation shall be directly in CT and VT secondary
quantities. There shall be two reactive energy registers, one for the period
when average RMS voltage is above 103% and the other for the period the
voltage is below 97%.
.
(9) The meters shall also display (on demand), by turn, the following
parameters:
(11) The meters shall be totally sealed and tamper-proof, with no possibility of
any adjustment at site, except for a restricted clock correction. The harmonics
shall be filtered out while measuring Wh, Var and VArh, and only fundamental
frequency quantities shall be measured/computed.
4.09.00 Transducer
4.10.00 Switch
4.10.01 Switches shall be dust protected, heavy duty, switchboard type complete with
escutcheon plate. Contacts shall be silver surfaced, rated 10A at operating
voltage.
4.10.02 Lockable stay-put type switchgear / field / remote selector switch shall be
provided as per requirement and mounted on switchgear cubicle.
4.10.03 Meter selector switches shall be maintained contact, stay put type with knob
handle. Ammeter & voltmeter selector switches shall be four position type.
Ammeter selector switches shall have made before break feature to prevent
open circuiting of CT secondary.
4.10.04 Breaker control switch shall be multistage, spring return to normal, with lost
motion device and pistol grip handle.
4.11.01 Fuses shall be HRC, link type, with minimum interrupting capacity equal to
the listed short circuit current. Fuses shall be furnished complete with fuse
bases and fittings. Visible indication shall be provided on blowing of the fuse.
4.11.02 MCBs, if used, shall be three/four pole, trip free, with manual close / open
mechanism. Automatic tripping provision for over load and short circuit shall
also be provided. MCBs shall be rated for full fault level of the system. MCB
shall be provided with required number of auxiliary contacts as per circuit
requirement.
Push button shall be heavy duty, shrouded, push to actuate type with colored
button and inscription plate. Each push button shall have 2 NO + 2 NC
contacts, rated 10A and 0.5A at their respective AC and DC operating
voltage.
4.13.01 The switchgear shall be fully wired at the factory to ensure proper functioning
of control, protection, transfer and interlocking schemes.
4.13.02 Fuse, links and MCB shall be provided to permit individual circuit isolation
from bus wires without disturbing other circuits. All spare contacts of relays,
switches and other devices shall be wired upto terminal blocks.
4.13.03 Wiring shall be done with flexible, 650V grade, PVC insulated switchboard
wires with stranded copper conductors of 2.5 mm2 for control and current
circuits and 1.5 mm2 for voltage circuits.
4.13.04 Each wire shall be identified, at both ends, with interlocking type permanent
markers bearing wire numbers as per Contractor's Wiring Diagrams. AC / DC
wiring shall have separate color-coding.
4.13.05 Wire termination shall be made with crimping type connectors with insulating
sleeves. Wires shall not be spliced between terminals.
4.13.06 All spare contacts of relays, timers, auxiliary switches shall be wired up to the
terminal block.
4.14.01 650V grade, multi way terminal block complete with mounting channel,
binding screws and washers for wire connections and marking strip for circuit
identification shall be provided for terminating the panel wiring. Terminals
shall be stud type, suitable for terminating 2 nos. 2.5 mm2 stranded copper
conductor and provided with acrylic insulating cover. Terminals for C.T.
secondary leads shall have provision for shorting and grounding.
4.14.02 Not more than two wires shall be connected to any terminal. Spare terminals
equal in number to 20% active terminals shall be furnished. Separate terminal
blocks shall be used for AC/ DC wiring termination.
4.14.03 Terminal blocks shall be located to allow easy access. Wiring shall be so
arranged that individual wires of an external cable can be connected to
consecutive terminals.
4.14.04 Terminal blocks used for interface with DDCMIS via termination cabinet shall
be suitably sized to facilitate proper termination of interconnecting cables.
4.15.02 All provisions and accessories shall be furnished for termination and
connection of cables, including removable gland plates, cables supports,
crimp type tinned copper/ aluminum lugs, brass compression glands with
tapered washer (Power cables only) and terminal blocks.
4.15.03 Gland plates shall be minimum 3 mm thick. The gland plate and supporting
arrangement for 1/C power cables shall be of aluminum.
4.15.04 Sufficient space shall be provided between the power cable termination and
gland plate. Core balance CTs wherever specified, shall be accommodated
within this space, inside the cubicle.
4.16.01 Bus duct connections shall be furnished along with transition panel, if
required. Unless mentioned otherwise bus duct connections shall generally
be from the top.
4.16.02 All connecting bus work shall have the same continuous rating as associated
switchgear bus and shall be fully braced for the listed short circuit current.
4.16.03 All provisions such as matching flange and other accessories shall be
furnished for connection to bus duct supplied by others. Necessary details for
this purpose shall be furnished later.
4.17.01 A ground bus, rated to carry maximum fault current, shall extend for the full
length of the switchgear.
4.17.02 The ground bus shall be provided with two-bolt drilling with G.I. bolts and nuts
at each end to receive 75 x 10 mm G.I. flat.
4.17.03 Each stationary unit shall be connected directly to the ground bus. The frame
of each circuit breaker and draw out VT unit shall be grounded through heavy
multiple contacts at all times except when the primary disconnecting devices
are separated by a safe distance.
Earthing trucks shall be provided for earthing the switchgear bus bars as
well as outgoing cables. The trucks shall have a voltage transformer and an
interlock to prevent earthing of any live connection. The trucks shall have
audio-visual annunciation to warn the operator against earthing of live
connections. It shall not be possible to use bus-earthing truck for cable
CPCPL-Super Critical TPP-Tharangambadi
VOL.II‐F1/SEC‐V : 16 DCPL-11Z02
[2 x 660 MW] Main Plant Package
earthing & vice versa. Earthing truck shall be non- fault making type. Circuit
breakers provided with integral earth switch, as an alternative, is not
acceptable.
4.19.00 Nameplate
4.19.01 Nameplates of approved design shall be furnished at each cubicle (one no.
each at front as well as at backside of cubicle) and at each instruments &
device mounted on or inside the cubicle.
4.19.02 The material shall be lamicoid or approved equal, 3 mm thick with white letter
on black back ground.
4.19.03 The nameplate shall be held by self-tapping screws. Nameplate size shall be
minimum 20 x 75mm for instrument/device and 40 x 150mm for panels.
4.19.04 Caution notice on suitable metal plate shall be affixed at the back of each
vertical panel.
4.20.01 Each cubicle shall be provided with thermostat controlled space heaters and
5A, 3 pin plug socket.
4.20.02 In addition, motor feeder cubicle shall be wired-up for feeding the motor
space heater through suitable rated breaker auxiliary NC contact and/or
contactor.
4.20.03 Cubicle heater, Motor heater, Plug/socket circuits shall have individual switch
fuse units.
4.21.01 The following power supplies shall be made available to each switchgear :
4.21.02 Isolating switch fuse units shall be provided at each switchgear for the
incoming supplies, 4-pole, single throw for A.C. and 2-pole, double throw for
D.C. Molded case circuit breaker (MCCB) shall also be accepted as an
alternative for AC circuit only.
4.23.00 Painting
4.23.01 All surfaces shall be sand blasted, pickled and grounded as required to
produce a smooth, clean surface free of scale, grease and rust.
4.23.02 After cleaning, the surfaces shall be given a phosphate coating followed by 2
coats of high quality primer and stoved after each coat.
4.23.03 The switchgear shall be finished in light gray color (RAL7032)with two coats
of powder paint. The coating shall be done electro statically followed by
stoving.
4.23.04 Sufficient quantity of touch-up paint shall be furnished for application at site.
An automatic 32 bit or higher micro processor based real time operated fast
backed up by slow transfer scheme shall be provided for change over
between unit to station sources (11KV). All hardwares pertaining to above
transfers shall be mounted in Auto Bus transfer (ABT) panel. The bus transfer
module shall have features such as graphical user interface, virtual test
simulation, object oriented programming, on line viewing, sequence of event
logging, self diagnostic features and communication port for remote
communication. The ABT panel shall be indoor, simplex type construction,
vertical free standing, floor mounted type, metal clad suitable for installation at
50 degree centigrade ambient. Panel enclosure shall be fabricated from 2 mm
thick sheet steel and the same shall be IP 52 protected. Detail write up on
BTS shall be as per annexure. All 11 & 3.3KV boards (other than 11KV
Unit/Standby boards) shall have Auto (slow changeover) as well as Manual
changeover facility
4.25.00 Accessories
5.00.00 TESTS
5.01.00 The switchgear shall be completely assembled, wired, adjusted and tested at
the factory as per the relevant standards of IS & IEC.
The tests shall include but not necessarily limited to the following :
b) All wiring and current carrying part shall be given appropriate High
Voltage test.
a. Impulse Test
b. Temperature rise Test
c. Short circuit Test
d. STC
e. Switching Over Voltage Test
f. Mechanical Endurance Test
g. Degree of Enclosure Protection
h. Pressure relief device operation test
5.05.01 Certified reports of all the tests carried out at the works shall be furnished in
six (6) copies for approval of the Owner / Purchaser.
5.05.02 The equipment shall be dispatched from works only after receipt of Owner /
6.01.00 A set of special tools & tackle which are necessary or convenient for erection,
commissioning, maintenance and overhauling of the equipment shall be
supplied.
6.02.00 The tools shall be shipped in separate containers, clearly marked with the
name of the equipment for which they are intended.
7.01.00 Drawings, Data and Manuals shall be submitted with the bid and in quantities
and procedures as specified in General Conditions on Contract and / or
elsewhere in this specification for approval and subsequent distribution after
the issue of Letter of Intent.
7.02.01 Typical general arrangement drawing of the equipment and foundation plan.
7.02.04 Type test certificate of the offered model of the circuit breaker and
switchboard for the specified type tests. The type test certificates shall not be
more than 5 years old.
7.03.01 Guaranteed Technical Particulars (A) and Quality assurance plan (A)
The manual shall clearly indicate method of installation, check ups and tests
7.03.07 Any other relevant drawing or data necessary for satisfactory installation,
operation and maintenance.
7.04.00 The drawings and document marked with (A) above are of ‘Approval’
category and are subject to review by Owner / Purchaser. Those marked (R)
are for ‘reference’ category.
The Owner / Purchaser may also review the documents marked (R) if found
necessary. The contractor shall note that the approval of drawings &
documents by the Owner / Purchaser does not relieve him of his contractual
obligation.
7.05.00 All drawings shall be prepared by using Auto CAD, approved version and
documents shall be generated using MS Office. The soft copy and paper copy
of the drawings & document shall be submitted for approval & reference. All
7.06.0 The Bidder may note that the drawings, data and manuals listed herein are
minimum requirements only. The Bidder shall ensure that all other necessary
write-ups, curves and information required to fully describe the equipment are
submitted with his bid.
1.1 General
Service : ------------Indoor----------------
1.2 System
Phase : --------------Three----------------
PROTECTIONS
1.0 Minimum protections to be provided for different type of circuits are listed below -
f. VT fuse failure
h. Winding temperature
D. Auxiliary : a. IDMTL over current (50/51) with high set instantaneous units
Transformer for phase faults (Oil & Dry type transformer)
b. Definite time O/C (50G) with timer for earth fault (through
CBCT) (Oil & Dry type transformer)
2.0 In case any trip function is not available in a single relay, separate numerical
relays shall be provided to achieve the requirement.
3.0 All protective relays shall be provided with self reset type of contacts.
4.0 Apart from protection relays, each breaker shall be provided with separate
discrete auxiliary relays for anti-pumping (94), trip annunciation (30), trip
supervision (74), electrically reset type breaker contact multiplication (52X)
relay and lockout (86) functions. Lockout relay shall be hand reset type. For
multifunction relays however, trip circuit supervision function as an integral
feature of the relay is acceptable. Individual trip circuit supervision function
shall be provided with respect to each trip coil of circuit breaker.
5.0 Numerical under voltage relays (27) with time delay relay including VT fuse
failure relay shall be provided for Bus VTs.
6.0 IDMTL relay version shall be decided as per system requirement and the same
shall be finalized during detail engineering.
8.0 Separate locked rotor protection relay (50 LR) with auxiliary relay (50 LRX)
shall be furnished, if required.
Microprocessor Based Fast Bus Transfer System (BTS) shall be provided for
11KV Unit and Station Switchboards for Incomers and TIE Breakers changeover
The BTS s hall monito r and prevent paralleli ng of two sources and sh all
bedesigne d to be co m plete l y aut omati c, self- chec king and bu ilt in o nlin e test ing
mode to ensure h ighest degree of re liabi lity. Th e online test mode should test the
entire BTS scheme operation including tripping/closing contacts without actually
operating the breakers. The test should automa tic override facility incase of
occurrence of Pr otecti ve /Auto Transfer.
The BTS shall have BTS IN/O UT f acility from its front pane l. The tripping and
closing contacts of the BTS shall be connected to the switchgear circuits only when
BTS is in IN condition. The closing circuits of the switchgear shall be provided with
DC supply from BTS when BTS is in IN condition, and from the switchgear itself
when BTS is in OUT condition. The provision shall be made that, the DC supply of
the BTS is off, then BTS shall be in OUT condition irrespective of selection.
Transfer Direction: The BTS shall be capable of selecting all possible and
appropriate bus transfer directions based on the existing status of the concerned
switchgear.
Manual Transfer: Used for planned transfer during normal operations of the
plant. This transfer shall be initiated from the front of the panel and shall be user
friendly. Manual Transfer shall be possible through remote communication
via the communication port.
Protective transfer: The protective transfer shall be initiated automatically through
operation of protective master trip relay in specified viable transfer directions.
‰ In phase Transfer: The breaker power contacts shall close when the
decaying and drifting bus voltage synchronizes with the incoming source voltage on
the completion of first slip cycle within acceptable voltage and frequency parameters.
The Bus transfer shall continuously process the bus voltage and the drifting phase
angle dynamics to determine using intelligent real time second order predictive
algorithm, the exact moment of sending a command to the breaker-closing coil to
achieve the above.
‰ Slow Transfer: The breaker power contacts shall close when the failing bus
voltage shall reach an acceptable safe value. The auxiliary drives are selectively
tripped simultaneously to limit the transformer inrush current.
‰ Momentary Paralleling Transfer: This is a “Make before Break” transfer for
a very short duration of the order of few cycles where, under supervision of the bus
voltage and incoming source voltage for magnitude and phase angle, the new source
breaker is closed before opening the old source breaker. This mode is however not
recommended from the system safety considerations due to high fault levels above
withstand ratings.
Transfer Readiness and BTS blocking: This BTS shall perform several integrated
system interlock checks to determine system readiness by continuously monitoring
schemes IN/OUT selection, breaker in service, breaker status NO/NC contact
integrity, master trip relay lockout condition, trip/close coil healthiness and breaker
configuration with NO/NC consistently checks, PT in service and PT fuse failure
condition, and new source voltage healthiness. Further, the BTS shall be blocked on
occurrence of self-test failure, breaker failure transfer failure or occurrence of a
protective/auto transfer in order to demand operator attention. An operator reset shall
be required to reset the blocked condition. The BTS shall have intelligent breaker
failure detection and corrective action. The system quantities like phase difference
between bus voltage and new source, magnitude of vectorial difference between bus
voltage and new source, voltage magnitudes frequency all at the instant of closing of
new source breaker and breaker closing and tripping timings shall be recorded for
every event and displayed on the HMI.
SECTION-VI
TECHNICAL SPECIFICATION
FOR
3.3 KV & 11 KV SEGREGATED PHASE BUS DUCT
CONTENT
ATTACHMENT
SECTION-VI
TECHNICAL
SPECIFICATION
FOR
3.3 KV & 11 KV SEGREGATED PHASE BUS DUCT
1.01.01 3.3kV &11kV Bus duct and associated equipment with all necessary accessories
for connection between equipment as listed below :
A. 11 KV BUSDUCT
1) Unit Transf. #1BAT01 and Unit SWGR # 1BA : One (1) set
2) Unit Transf. #1BBT01 and Unit SWGR # 1BB : One (1) set
3) Unit Transf. #2BAT01 and Unit SWGR # 2BA : One (1) set
4) Unit Transf. #2BBT01 and Unit SWGR # 2BB : One (1) set
5) Standby Transf. #OBAT01 and Station. SWGR #0BA : One (1) set
6) Unit SWGR #1BA and Station Switchgear # 0BA : One (1) set
7) Unit SWGR #1BB and Station Switchgear # 0BA : One (1) set
8) Unit SWGR #2BA and Station Switchgear # 0BA : One (1) set
9) Unit SWGR #2BB and Station Switchgear # 0BA : One (1) set
B. 3.3 KV BUSDUCT
4) Unit Aux. Transf. #2CAT02 and 3.3 kV Unit
Aux SWGR #2CA
: One (1) set
1.01.02 Necessary segregated phase terminal adopter boxes with all necessary
accessories for connection to Switchgear Incomer panel and for termination on
the Unit/Station transformer.
1.01.03 All supporting steel structures, fasteners and necessary hardware for complete
bus-duct installation.
1.01.04 One set of space heater panel (wall mounted type) for supplying power to all
internally mounted space heaters of each Bus-duct.
2.01.00 All equipment and materials shall be designed, manufactured and tested in
accordance with the latest e d i t i o n s i n c l u d i n g a l l applicable
amendments of relevant Indian Standards (IS) and IEC, except where modified
and/or supplemented by this specification.
2.02.00 Equipment and material conforming to any other standard, which ensures
equal or better quality, may be accepted. In such case, copies of the English
version of the standard adopted shall be submitted along with the bid.
2.03.00 The electrical installation shall meet the requirements of Indian Electricity
Rules as amended up to date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall be followed.
2.04.00 All works shall be carried out as per the following standards and codes.
Specification for wrought aluminum and aluminum alloys, sheet and strip
IS:737
(for engineering purpose).
IS:13947
Low voltage switchgear & control gear
PART-1
Porcelain post Insulators for system with normal voltage greater than
IS:2544
1000 volts.
IS:4759 Hoot dip zinc coating on structural steel and allied products.
Specification for wrought Aluminum alloys bars, rods, tubes and sections
IS:5082
for electrical purposes.
IS:8084
Interconnecting bus bars for A.C. voltage above 1KV upto and including
Updated
36KV.
upto:1992
3.01.00 The segregated phase duct will serve as interconnection between the MV.
Indoor Switchgear and outdoor transformer terminals as well as between
Switchgears as listed elsewhere in the specification.
3.02.00 The bus ducts will be installed partially indoor and partially outdoor in a hot,
humid and tropical atmosphere. All panels associated with bus ducts will be
located indoor.
3.03.00 Bus duct, associated equipment and wiring shall be provided with tropical finish
to prevent fungus growth. All ventilation openings shall be screened and drains
shall be filtered to prevent entrance of dust and insects
3.04.00 The portion of bus duct at the transformer end will be subject to vibration
normally prevalent for this type of installation in a power generating station.
Suitable means shall be provided to isolate the transformer vibration from rest
of the bus structure/bus duct.
3.05.00 For continuous operation at specified ratings, temperature rise of the bus duct
and auxiliary equipment shall be limited to the site permissible values stipulated
in annexure to this specification.
3.06.00 Bus duct and auxiliary equipment shall be capable of withstanding the
mechanical forces and thermal stresses of the short-circuit currents listed in the
annexure without any damage or deterioration of material. Bus conductor
3.07.00 The bus ducts and supporting structures shall be designed & constructed so as
to withstand without damage the horizontal/ vertical ground accelerations due to
earthquake.
3.08.00 The bus ducts shall be self cooled and shall not be equipped with blower or any
other type of forced ventilation.
3.09.00 Bus-duct enclosure for bus conductor shall be Aluminium alloy.The barrier
between phase to phase shall be made of Al- alloy with 3mm thickness.
3.10.00 The equipment rating shall be based on an ambient temperature of 50°C. For
the portion of the bus-duct installed outdoor and exposed to direct sun-rays, the
effect of solar heat shall be considered in the determination of the design
ambient temperature. In addition, the outdoor section shall withstand the wind
loading as indicated elsewhere in the bid document of Main Plant Package.
Detail calculation of bus bar sizing considering the voltage drop, operating
temperature, short-circuit stress, power loss etc, need to be submitted.
4.01.00 General
4.01.01 The bus duct shall be segregated phase, enclosure natural air cooled type.
4.01.02 All parts and accessories shall have appropriate match mark and part numbers
for easy identification and installation at site.
4.02.00 Enclosures
4.02.02 Circumferential neoprene rubber gaskets shall be provided for dust tight joints
with adjacent enclosure sections.
4.02.03 The bus enclosure shall have extended bellows or equivalent means to allow
for temperature changes and vibrations. Flexible joints shall be provided in
enclosures at all points where the bus duct terminates at equipment to
withstand vibration, expansion/ contraction and at suitable intervals in any
straight run of the bus duct where expansion and contraction would otherwise
result in stresses in the supporting structures.
4.02.06 Epoxy resin cast seal-off bushings complete with wall-frame and support plates
shall be provided where the bus duct penetrates the building wall. The seal is to
prevent free exchange of air between indoor and outdoor portions of the bus
duct.
4.02.07 Silica-gel breather shall be provided on both indoor and outdoor portions of the
bus duct.
4.02.08 Filtered drains for drainage of condensate shall be provided at the lowest points
and at such locations where accumulation of condensate can be expected.
4.02.09 Shipping length of the bus duct shall be not more than three (3) metres in
length. Each shipping section shall have at least two (2) supports both for
conductor in each phase and enclosure.
4.02.10 Suitable blanked flanges with cover shall be provided on the enclosure of the
busduct (indoor and outdoor) to allow connection of hot air duct of hot air
blowing necessary to improve insulation level after long shut down etc.
4.03.01 The bus conductor shall be of high conductivity, aluminium alloy, supported on
wet process porcelain insulators.
4.03.02 The bus conductor shall be designed for bolted connections throughout the run.
4.03.03 Aluminium flexible connections shall be provided between bus sections to allow
for expansion and contraction of the conductor. Flexible connection shall also
be provided at all equipment terminations.
4.03.04 All contact surfaces shall be silver plated to ensure an efficient and trouble-free
connection. All connection hardware shall be non-magnetic and shall have high
corrosion resistance.
4.03.05 All bolted joints shall be provided with high grade stainless steel nuts bolts plain
and belle-ville washers.
4.04.00 Insulators
4.04.01 Bus support insulators shall be interchangeable, high creep, high strength, wet
processed, and fine glazed porcelain. Alternatively good equality cast resin
insulators may be offered.
4.04.04 Suitable space heater shall be provided preferably located near to each
insulator to avoid moisture condensation within bus-duct. No. and Wattage
rating of space heater shall be decided by the Tenderer.
4.06.01 All matching flanges, seal-off bushings, gaskets, fittings, hardware and supports
required for termination of the bus duct at the switchgears, transformers and
other equipment shall be furnished.
4.05.02 In this connection the contractor is required to co-ordinate with the Unit/Station
Switchgear, Unit/Station transformers with regard to connection details,
mechanical and thermal stresses.
4.05.03 Flexible connection both for conductor and enclosure shall be furnished :
b) Between the bus duct portions supported from building steel to prevent
transmission of vibration.
4.05.04 The equipment terminal connections shall be readily accessible and shall
provide sufficient air gap for safe isolation of equipment during testing.
4.05.05 If the material of bus conductor and that of the equipment terminal connectors
are different then suitable bi-metallic connectors shall be furnished.
4.06.00 Grounding
4.06.02 Ground pad shall be bolted type to accommodate 50 x 6 mm.. galvanized steel
flats. Complete with suitable tapped holes, bolts and washers.
4.07.01 All supporting structures required for hanging and/or supporting the complete
bus duct shall be furnished. These include all members, indoor/outdoor posts,
bolts, shims, base plates, beams, hangers, brackets, bracings and hardware.
4.07.02 All buses shall be adequately supported and braced to successfully withstand
normal operation, vibration, thermal expansion, short circuit forces and all
specified design loads.
4.07.04 All steel members shall be hot-dip galvanised after fabrication. All hardware
4.07.05 Concrete foundation, building steel, concrete, inserts/plates and all other
materials necessary will be provided by Bidder.
4.08.00 Wiring
4.08.01 All wiring for space heaters shall be done with insulated stranded copper
conductor of not less than 2.5 Sq.mm cross-section. Each wire shall be
identified at both ends with wire designation as per contractor's wiring diagram
and shall be brought out to a terminal box outside the bus duct.
4.08.02 Terminal blocks shall be box-clamp type, minimum 10 Sq.mm with marking
strips or approved equal.
4.08.03 At least 20% spare terminals shall be furnished in the terminal block. Not more
than two wires shall be connected to one terminal.
4.09.02 Materials for nameplate shall be Anodized Aluminium, 3 mm thick, using white
letters on black background.
4.10.01 Portable hot air blowing equipment mounted on a steel carriage (trolley) for
easy movement shall be provided. Hot air blowing system shall be complete
with blower, fan, electric heater, starter, MCCB’s, main incoming MCCB’s with
flexible cables and plugs etc. for connection to power receptacle.
4.10.02 The capacity of Hot Air Blowing system shall be such that dry out of complete
bus duct is possible within four (4) hours. During hot air blowing the bus duct
enclosure temperature shall not exceed 70°C.
OR ,
Space Heater
4.10.01 The bus duct shall be provide with adequate number of thermostatically
controlled space heaters of suitable capacity to maintain the internal
temperature above the dew point to prevent moisture condensation within the
bus duct.
4.10.02 Space heaters with thermostat shall be rated for 240 volts single phase 50 Hz
and shall be contactor controlled automatic switching through thermostat.
4.10.03 Space heater and thermostat shall wire up to terminals in suitably located
terminal boxes for external cable connections. The wiring inside the bus duct
shall be done with high temperature resistant cable suitable for the bus
maximum temperature specified. The conductor shall be stranded copper of
minimum size of 2.5 sq. mm. A separate ON-OFF switch with contactor shall be
provided for controlling the space heated in a marshalling box located at
convenient height adjacent to the bus duct.
4.11.01 Except for supporting steel structures, which shall be galvanised, all equipment
shall be finished with an undercoat of high quality primer followed by two coats
of synthetic enamel paints unless otherwise epoxy paints as specifically
required.
4.11.02 The interior surface finish shall be as per manufacturer's standard. The shade
of exterior surface finish shall be light grey shade number #631 for indoor and
battle ship grey shade number #632 outdoor unless otherwise stated.
4.11.04 Paints shall be carefully selected to withstand heat and weather conditions. The
paint shall not scale-off or crinkle or get removed by abrasion due to normal
handling.
4.11.05 Sufficient quantities of all paints and preservatives required for touching up at
sites shall be furnished.
5.00.00 TESTS
5.04.01 Type test certificate on any equipment, if so desired by the Owner, shall be
furnished. Otherwise the equipment shall have to be type tested, free of charge,
to prove the design.
6.01.05 Calculation for temperature rise for bus and enclosure as per IEEE No. 298.
6.01.06 Calculation for short circuit forces justifying the proposed arrangement.
6.02.03 Typical details of bus-insulator assembly, space heater mounting, rigid and
flexible connections of both bus conductor and enclosure, grounding provision,
seal-off bushings, equipment termination arrangement etc.
6.02.05 Supporting steel structure details with backup calculations and structural layout
- plan and section.
The manual shall clearly indicate the installation methods, check-ups and tests
to be carried out before commissioning of the equipment.
6.03.00 The Bidder may note that the drawings, data and manuals listed herein are
minimum requirements only. The Bidder shall ensure that all other necessary
write-ups, S i z i n g C a l c u l a ti o n s , curves and information required to fully
describe the equipment are submitted with his bid.
The sizing criteria shall also include voltage drop, operating temperature, short
circuit stress, power loss etc.
1.4 Frequency : 50 Hz
: 40 100
1.8 Service Voltage
2.4 Frequency : 50 Hz
: 44 2.54*44
a) Bus conductor :
3.5 Material
SECTION-VII
TECHNICAL SPECIFICATION
FOR
415 V PCC/PMCC/MCC, 415 V AC AND
220 V DC DB/SVB/FB, 220 V DC STARTER, AND
415 V NON-SEGREGATED PHASE BUSDUCT
CONTENT
ATTACHMENTS
SECTION-VII
TECHNICAL SPECIFICATION
FOR
415 V PCC/PMCC/MCC, 415V AC AND
220V DC DB/SVB/FB, 220V DC STARTER,
AND 415 V NON-SEGREGATED PHASE BUSDUCT
1.01.00 The following equipment shall be furnished complete with all accessories :
f) DC starters
A list of various 415V boards that have been envisaged to be supplied under
the main plant package is given in Annexure - E. This list is only for general
guidance of the Tenderers and the exact numbers shall be finalised by them.
1.02.00 Base channel frame of all boards along with necessary mounting hardware.
2.06.00 FUSE BOARD, hereinafter referred to as FB, shall mean a continuous line-up
of vertical sections housing switch fuse only. FBs Boards may be fed from DBs
and may have one incomer. ACFBs Boards shall be of two types - one with
415V, 4-wire, triple pole- and-neutral (TPN) outgoing feeders and the other with
240V, 2- wire, single-pole-and-neutral outgoing feeders. The incomers in either
case shall be 415V, 4-wire, TPN type. Incomers and outgoing feeders of
DCFBs shall be 220V, 2-wire type.
3.01.00 All equipment and materials shall be designed, manufactured and tested in
accordance with the latest e d i t i o n s i n c l u d i n g a l l a p p l i c a b l e
o f f i c i a l a m e n d m e n t s o f r e l e v a n t Indian Standards (IS) and IEC
except where modified and/or supplemented by this specification.
3.02.00 Equipment and material conforming to any other standards, which ensure
equal or better quality, may be accepted. In such case, copies of the English
version of the standard adopted shall be submitted along with the bid.
3.03.00 The electrical installation shall meet the requirements of Indian Electricity
Rules as amended up to date and relevant IS Code of Practice. In addition,
other rules and regulations applicable to the work shall be followed.
3.04.00 All works shall be carried out as per the following codes and standards
11. IS-13703 Specification for low voltage fuses for voltages not
exceeding 1000 V AC and 1500 V DC
13. IS- 6005 Code of practice for phosphating iron and steel
14. IS-694 694 PVC insulated cables for working voltages upto and
including 1100
4.01.00 415V power distribution within the powerhouse shall be by mean of PCCs,
MCCs, DBs, SVBs and FBs. PMCCs shall not be used within the powerhouse.
In ESP control building, C.W. pump house, cooling tower switchgear room, fuel
oil pump houses, and ash handling system auxiliary buildings, use of PMCCs
may be acceptable.
4.02.00 The PCCs/PMCCs shall be used to supply auxiliary power for normal and start
up operation of generation units.
4.03.00 The equipment will be located in a hot, humid, and tropical atmosphere, heavily
polluted at places with coal dust and/or fly ash.
4.04.00 Duty involves direct-on-line starting of large induction motors and also under
certain emergency conditions, automatic transfer of loads from one source of
supply to other.
4.07.00 Incomers rated up to and including 400 A, except for MCC and PMCCs, shall
be switch fuse controlled. Above 400 A, all incomers shall be breaker
controlled.
4.08.00 PCC/PMCCs shall be used to feed MCCs and motors rated 110 KW up to and
including 160 KW. All motors rated 75 kW up to and including 160 KW shall be
breaker controlled. For motors rated 75 kW up to and including 160 KW,
breaker shall be given with motor protection relay.
4.09.00 Motors rated below 75 KW shall be contactor operated and shall be fed from
MCCs. For all motors below 45 kW, switch fuse shall be given. For motors
between 45 kW to below 75 kW, switch fuse with SPPR protection should be
used.
4.10.00 For continuous operation at specified ratings, the temperature rise of various
equipment/components shall be limited to the permissible values specified in
relevant standards and/or this specification.
4.11.00 Circuit breakers shall not produce any harmful over voltage during switching off
of induction motors. If required, surge protective devices shall be included in the
scope of supply to limit over voltages.
4.12.00 Incomer and Bus-sections of all MCC/PMCCs shall have provisions for remote
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operation from the respective control room through electrical control desk /CRT
monitor.
4.13.00 The bus arrangement is shown in attached SLD. The main and bus-coupler
breakers shall make it possible for a switchgear bus to be fed from two separate
sources with auto & manual live changeover facilities. Normally each half section
of the switchgear will be fed by its own incomer with the bus-coupler being open.
In case of loss of supply from the incomer, under-voltage actuated dead
changeover to the other source shall take place by tripping of affected incomer
and closure of bus-coupler breaker. Upon restoration of normal supply, the
incomer breaker will be closed after paralleling and the pre-selected breaker will
be either automatically or manually tripped thus effecting a live changeover.
4.14.00 All LV switchgears and Motor Control Centres shall be intelligent type utilising
feeder management devices for protection, control, monitoring and
measurement on each breaker controlled incomer, bus coupler, tie-feeder and
breaker-controlled large motor feeders. The data shall be transmitted on a serial
fibre-optic cable link to an EDMS/DDCMIS system in the Main Plant Control
Room. The feeder units shall provide self-diagnostic and historical data logging
facilities. Each 415V switchgear will be served by 2x100% capacity service
transformers
4.15.00 Each ESP PCC will be fed from 11kV unit switchgear located in powerhouse
building via a pair of dry type LT transformers to be installed on either side of
ESP PCC. The PCC comprising of two incomer and one bus coupler with
adequate number of feeders for ESP, control building lighting, Air conditioning,
Ventilation system and equipment handling system (Hoists), fire fighting system
load shall be complete in all respect and will serve as power distribution center.
The welding power requirement shall be through separate service transformer as
shown in SLD.
5.01.00 Construction
The design shall be such that the specified degree of protection is achieved
even after a breaker control module has been taken out of the panel.
Working height shall be limited between 450mm and 1800mm from floor level.
5.01.09 Breaker cubicles shall be so sized as to permit closing of the front access door
when the breaker is pulled out to ISOLATED position. The breaker can be
operated both in service & test position with the door closed.
5.01.10 For breaker panels, all switches, lamps, and indicating instruments shall be
flush mounted on the respective compartment door whereas relays and other
auxiliary devices shall be mounted in a separate compartment.
5.01.11 For single-front assemblies, a full-height vertical cable alley with cable supports
shall be provided in each section to facilitate unit wiring.
The alley shall be liberally sized to accommodate all cables as per cable
schedule and shall have removable cover at the front for access.
5.01.12 Wherever two breaker compartments are provided in the same vertical section,
insulating barriers and shrouds shall be provided in the rear cable compartment
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to avoid accidental touch with the live parts of one circuit while working on the
other.
5.01.13 A horizontal wire way extending the entire length of the assembly shall be
provided of the top for inter-panel wiring.
5.01.14 Incomers shall be provided at the ends of an assembly and bus section,
wherever required, shall be provided at the middle of the assembly.
5.01.15 Four (4) Nos. lifting lugs shall be for each section, two (2) nos. on either end of
the section.
FBs Boards shall be supplied along with necessary hardware for mounting
against wall.
5.01.17 After isolation of power and control circuit connections, it shall be possible
safely carry out maintenance in a compartment with the busbar and adjacent
circuit live. Necessary shrouding arrangement shall be provided for this purpose
over the cable terminations located in cable alley.
5.01.18 The minimum clearance in air between phases and between phases and earth
for the entire run of horizontal and vertical busbars shall be 25mm. For all other
components, the clearance between two live parts, a live part and an earthed
part, and isolating distance shall be at least 10mm throughout. Wherever it is
not possible to maintain these clearances, insulation shall be provided by
barriers. However, for horizontal and vertical busbars, the clearances
mentioned above should be maintained even when these are sleeved or
insulated. All connections from busbars up to fuses shall be fully shrouded to
minimize the risk of phase to phase and phase to earth shorts.
5.01.20 20% spare feeders, minimum one of each rating and type shall be provided.
5.02.02 Horizontal and vertical busbars and bus connections shall be of high
conductivity copper/aluminium/aluminium alloy.
5.02.04 All bus connections shall be provided with anti-oxide grease. Adequate contact
pressure shall be ensured by means of two-bolt connection with plain and
spring washers and locknuts.
5.02.06 All busbars and bus connections shall be fully insulated for working voltage.
Insulating heat shrinkable sleeves shall be provided for all busbars. All joints
and tap-off points shall be shrouded.
5.02.07 Bus insulators shall be non-hygroscopic, flame retardant, track resistant, high
strength, sheet molded compound or equivalent polyester fibreglass molded
type. Separate supports shall be provided for each phase and neutral busbar.
5.02.08 Cross-section of the busbars shall be uniform throughout the length of the
assembly. All busbars and bus connections shall be supported and braced to
withstand the stresses due to maximum short circuit current and also to take
care of any thermal expansion.
5.02.09 Busbars shall be colour coded for easy identification and so located that the
sequence R-Y-B shall be from left-to-right, top- to-bottom, or front to rear when
viewed from the front of the assembly.
5.02.10 Bolted disconnecting links shall be provided for all incoming and outgoing
feeders for isolation of neutral, if necessary.
5.03.02 Modules of same size and type shall be physically and electrically
interchangeable.
5.03.04 Various module sizes should be multiples of one basic unit to facilitate
modifications at site. Suitable provision for this purpose should also be
incorporated in the vertical busbars.
5.03.05 Drawout modules shall have three distinct positions, namely, SERVICE, TEST
and ISOLATED.
In the SERVICE position, both power and control circuits shall be engaged. It
shall not be possible to open the module door when the module is in SERVICE
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position.
In the TEST position, the power circuits shall be disengaged but the control
circuits shall be engaged. It shall be possible to close the module door when
the module is in TEST position. Keeping the front access door of module in
closed condition, the Breaker can be placed in ISOLATED, TEST or SERVICE
position from outside.
In the ISOLATED position, both power and control circuits shall be disengaged.
5.03.06 Modules shall house the control components for a circuit such as switch, fuse,
contactors, relays, push-buttons, lamps, meters, etc. only the push-button
actuators, lens' of indicating lamps, and transparent windows for meters shall
be mounted on module door such that when the module is withdrawn, the
cubicle door shall provide specified IP-54 degree of protection when the module
door is closed.
5.03.07 Breaker operated incomes and bus sections shall be provided with one (1)
TEST-NORMAL selector switch.
Contactor operated motor feeder modules shall be provided with one (1)
LOCAL-REMOTE selector switch.
These selector switches shall be lockable type and shall be mounted inside the
panel.
5.03.08 The equipment layout shall provide sufficient working space in between the
components.
5.04.01 Circuit Breakers shall be three pole, single throw, air break type with stored
energy, trip free mechanism and shunt trip coil.
5.04.02 Circuit breakers shall be drawout type, having SERVICE, TEST & ISOLATED
positions with positive indication for each position.
5.04.04 All incomer breakers, bus-section breakers, and motor feeder breakers shall
have motor wound spring charging mechanism. All other outgoing feeders shall
generally have hand-operated spring charging mechanism. However, outgoing
feeders from unit. PCC to emergency MCC shall be breaker controlled with
motor wound spring charging mechanism.
5.04.05 Each breaker operated feeder shall be provided with protective devices as
specified in Annexure-B.
5.04.06 All breakers with motor wound spring charging mechanism shall have facility of
manual spring charging also.
5.04.07 For motor wound mechanism, spring charging shall take place automatically
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after each breaker closing operation. One open- close-open operation of the
circuit breaker shall be possible after failure of power supply to the motor.
5.04.08 Mechanical safety interlock shall be provided to prevent the circuit breaker from
being racked in or out of the service position when the breaker is closed.
5.04.09 Automatic safety shutters shall be provided to fully cover the female primary
disconnects when the breaker is withdrawn.
5.04.10 Each breaker shall be provided with an emergency manual trip, mechanical
ON-OFF indicator, an operation counter, mechanism charge/discharge
indicator, and electrical anti-pumping feature.
5.04.11 In addition to the auxiliary contacts required for normal breaker operation and
indication, each breaker shall be provided with the following for interlocking
purpose :
Alternatively, electrically reset-latching relay may be used for the purpose. The
exact requirement contacts of the position/cells switch, limit switch, auxiliary
switch and latching relay shall be decided by the Tenderers taking into account
the scheme requirements spares. Limit/auxiliary switches shall be convertible
type, that is, suitable for changing N.O. contact to N.C. and vice-versa.
5.04.12 Spring charge limit switch shall be provided for breakers with motor wound
spring charging mechanism. These limit switches shall be provided with
minimum 2NO + 2NC contact.
5.04.13 Limit/auxiliary switches shall be convertible type, that is, suitable for changing
N.O. contact to N.C. and vice-versa.
5.05.00 Switches
5.05.01 Switches shall be triple/double pole, air break type and designed for duties as
specified in Annexure-A. Motor duty switches shall be capable of safely making
and breaking the locked rotor current of the associated motor circuit.
5.05.03 The compartment door shall be interlocked mechanically with the switch such
that the door cannot be opened unless the switch is in OFF position. Means
shall be provided for releasing this interlock at any time.
Wherever two incoming switches are provided for an assembly, these shall be
mechanically/key interlocked to ensure that one of the two can be closed at
time.
5.06.00 Fuses
5.06.01 Fuses shall be HRC, preferably link type, with a minimum interrupting capacity
equal to the short circuit current of the LT system.
5.06.02 Fuses shall be furnished complete with fuse bases and fittings of such design
as to permit easy and safe replacement of fuse element.
5.06.03 Motor fuse characteristics and ratings shall be chosen to ride over starting
period without blowing. The fuse on incoming feeder wherever provided, shall
be chosen to provide discrimination with motor/feeder fuses.
5.07.01 Contactors
a) The contactors shall be three pole, air break type with non-bouncing
silver/silver alloy contacts. The contactor shall be designed for duty as
per Annexure-A attached.
b) Each contactor shall be provided with minimum (2) normally open and
two (2) normally closed auxiliary contacts rated 10A at 240V A.C. The
exact requirement of contacts shall be decided by the tenderer taking
into account the scheme requirements and spares.
e) Relays for fan motors having long starting time shall be saturable case
C.T operated.
5.08.03 The cubicle enclosure shall provide dust and humidity protection, the degree of
protection being not less than IP-54.
The resistor enclosure shall be provided with ventilating louvers and wire mesh
guard and shall have a degree of protection IP-23.
5.08.04 Cubicle space heater shall be provided to maintain internal temperature above
dew point. Heater shall be furnished with switch-fuse unit and thermostat
control.
5.09.01 Circuit breakers shall be wired up for local and remote operation. Each breaker
cubicle shall be equipped with the following :
5.09.02 The general scheme of connections for control, interlock, and protection is
shown in the enclosed drawings. Detailed requirements of individual circuits
shall be developed by the Tenderers.
5.09.03 Push buttons shall be heavy duty, oil tight, push to actuate type with integral
escutcheon plate marked with its function.
5.09.04 Each push-button shall have minimum two (2) NO and two (2) NC contacts
rated 10A at 240 V A.C.
5.09.05 Selectors switches shall be stay-put; rotary type with escutcheon plates marked
to indicate the function and positions, and shall be lockable in each position.
Selector switch contacts shall be rated for 10A at 240 V A.C.
5.09.06 Selector switches shall be provided with minimum three (3) contact blocks of
1 NO + 1 NC each.
The exact requirements contacts shall be decided by the Tenderers taking into
account the scheme requirement and spares.
5.09.07 Lamps shall be LED type. LED lamp shall be made in accordance with InP
Technology (Aluminium Indium Gallium Phosphide Technology). The body shall
be made of Poly Carbonate Unbreakable Lens. LED shall be protected by
inbuilt fuse with surge suppressor or leakage voltage glow protection. LED
circuit shall be PCB mounted. Intensity shall be greater than 200 mcd. All Push
Button lamp shall be as per LED indicating lamp.
5.09.08 For control supply, two (2) nos. adequately rated 415/240V control transformers
with necessary taps shall be provided. Auxiliary bus bars shall be used to
distribute 240V AC control supply. The control supply of different modules shall
be tapped individually from the auxiliary bus bars. Transformer ratings shall be
so selected to facilitate 100% standby arrangement with adequate spare
capacity.
5.09.09 DCDBs shall be provided with indication to monitor healthiness of the incoming
DC supplies.
5.09.10 All switchgear located in the TG building shall be controlled from CRTs
(EDMS) in the unit control room, other than those controlled from DDCMIS. The
switchgear of ash handling and coal handling systems shall be controlled
from the respective system control panels. Other MCCs viz. fuel oil pump
house MCC, water treatment plant MCC, clarifier/misc water pump house
MCC, ESP MCC, etc shall be locally controlled with synchronization
equipment facility mounted on the switchgear. These systems shall be
monitored from CRTS in CCR. For all switchgear/MCC where auto/manual
changeover facility is specified, breakers shall be provided for the incomers
and bus coupler.
The control room CRTs shall provide indication & alarms for the 415V
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auxiliary supply as given below. Any additional indications/alarms considered
necessary during detailed engineering shall also be provided. Some of these
shall be selected for sequential events recording. For each breaker and bus,
grouped alarm for any abnormal conditions shall be provided in the control
desk.
• Breaker on
• Breaker off
• Breaker fault
• Breaker service
• Breaker selected for remote
• Load current (Each Phase)
• Bus Voltage
• Trip Circuit Healthy
• Control DC ON
5.10.01 All indicating instruments (96 x 96 mm) shall be switchboard types, with 240
Deg. scale, anti-glare glass and accuracy class of ± 2% full scale. Each meter
shall have zero adjuster on the front.
5.10.03 All breaker operated incomers and motor feeders above 30 KW upto 160 KW
shall be provided with 3-phase electronic energy meter with pulse output for
interfacing with DDCMIS.
5.10.04 Meter selector switches shall be maintained contact, stay-put type, with knob
handle. Ammeter and voltmeter selector switches shall be four position type.
Ammeter selector switches shall have made before break contacts, to prevent
open circuiting of CT secondary.
5.10.05 Energy meters suitable shall be provided as per Meters for Energy
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Accounting & Audit (MEEA) confirming to latest CEA’s regulations
5.11.01 Current Transformers shall be cast-resin type. All secondary connections shall
be brought out to terminal blocks where wye or delta connection will be made.
5.11.02 Motor feeders rated 30 KW to below 75KW, shall be provided with CTs for
metering. Motor feeders rated 75KW and above, separate CTs shall be
provided for metering and protection.
c) Class 1.0 ISF < 5 for metering other than MEAA metering
5.11.04 Other CT particulars like ratio, burden knee-point voltage, excitation current and
secondary resistance shall be decided by the Tenderers.
5.11.05 Feeders requiring remote metering and/or current monitoring shall be provided
with dual channel type current transducers with calibration for full scale reading.
The output shall be 4-20 mA DC of which shall correspond to the normal range.
5.11.06 CT secondary shall be rated for 1 A for metering and either 5 A or 1 A for
protection.
5.12.01 Voltage transformers shall be cast-resin and shall have an accuracy class of
1.0. Voltage transformer mounted on breaker carriage is not acceptable.
5.12.03 Low voltage fuses, sized to prevent overload shall be installed in all
ungrounded secondary leads. Fuses shall be suitably located to permit easy
replacement while the switchgear is energised.
5.13.00 Relays
I. General-A
a) All relays & timers in the protection circuit shall be flush mounted
with connection from inside. They shall have transparent, dust
tight covers, removable from the front. They shall have built-in
testing facilities. Except small auxiliary relays and timers all
relays shall be drawout type.
c) The Bidder shall furnish, install & co-ordinate all relays to suit the
requirements of protection, interlock and bus transfer schemes
as broadly indicated in the annexures and drawings. Application
check shall be made on all motor protection relay motor
characteristics furnished by the Owner for the motors in the BOP
area. The result of such check shall be furnished for approval.
II. General-B
ii) Relay shall have draw out feature with plug in type PCB
for easy replacement. In case of fixed type relay, the
terminals shall be easily accessible for testing and
commissioning.
ii) All relays shall have LED / LCD display for settings,
status, faults and events. LCD display shall be backlit
and temperature compensated up to 65°C for contrast
and legibility.
d) Software Security
ii) All IOs shall have galvanic isolation. Analog inputs shall
be protected against switching surges, harmonics etc.
i) Serial Communication
5.14.01 All boards shall be fully wired at the factory to ensure proper functioning of
control, protection, transfer and interlocking schemes.
5.14.02 Fuse and links shall be provided to permit individual circuit isolation from bus
wires without disturbing other circuits. All spare contacts of relays, switches and
other devices shall be wired up to terminal blocks.
5.14.03 Wiring shall be done with flexible, 1100 V grade, PVC insulated switchboard
wires with stranded copper conductors of 2.5 mm2 for control, current and
voltage circuits.
5.14.04 Each wire shall be ferruled by plastic tube with indelible ink print at both end
having terminal block no., terminal nos., destination no. as per approved
Drawing.
5.14.05 Wire terminations shall be made with crimping type connectors with solder as
insulating sleeves. Wires shall not be spliced between terminals.
5.15.01 Terminal blocks shall be 660V grade box-clamp type 10 mm2 minimum with
marking strips. Terminals for C.T. secondary leads shall have provision for
shorting.
5.15.02 Terminal blocks used for interface with DDCMIS via termination cabinet shall
be suitably sized to facilitate proper termination of interconnecting cables.
5.15.03 Not more than two wires shall be connected to any terminal. Spare terminals
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equal in number to 20% active terminals shall be furnished.
5.15.04 Terminal blocks shall be located to allow easy access. Wiring shall be so
arranged that individual wires of an external cable can be connected to
consecutive terminals.
5.16.01 Generally, all assemblies shall be designed for cable entry from the bottom.
Sufficient space shall be provided for all the cables as per cable schedule, for
ease of termination and connection.
5.16.02 All provisions and accessories shall be furnished for termination and connection
of cables as per cable schedule, including removable gland plates, cable
support, crimp type tinned copper/aluminium lugs, double compression brass
glands with tapered washer (Power cable only) and terminal blocks.
5.16.03 Gland plates shall be minimum 4 mm thick. The gland plate and supporting
arrangement for 1/C power cables shall be non-magnetic type to minimise the
flow of eddy current.
5.17.01 Bus duct connection, wherever provided, shall be furnished along with transition
panel, if required. Bus duct connections shall be from the top.
5.17.02 All connecting bus work shall have the same continuous rating as associated
PCC/PMCC/MCC/DB bus and shall be fully braced for the LT system short
circuit current.
5.17.03 All provisions such as matching flanges and other accessories required for
proper connection to bus duct shall also be supplied.
5.18.01 A ground bus, rated to carry maximum fault current, shall be provided which
shall extend the full length of the assembly.
5.18.02 The ground bus shall be provided with two-bolt drilling with G.I. bolts and nuts
at each end and shall be suitable to receive 50 x 6 mm G.S. flat.
5.18.03 All stationary units shall be directly connected to the ground bus for effective
grounding.
The frames of all circuit breakers and drawout V.T. units shall be grounded
through heavy multiple contracts at all times except when the primary
disconnecting devices are separated by a safe distance.
The frames of all other drawout modules shall be grounded at all times except
when the power disconnects are separated by a safe distance.
5.18.04 Wherever the schematic diagrams indicate a definite ground at the switchgear;
5.18.05 C.T. & V.T. secondary neutrals shall be earthed through removable links so that
earth of one circuit may be removed without disturbing others.
5.19.00 Nameplates
5.19.01 Nameplates of approved design shall be provided on each cubicle, at the top of
the assembly and on each instrument & device mounted on or inside the
cubicle.
5.19.02 The material shall be lamicoid or approved equal. 3 mm thick with white letters
on black background.
5.19.03 The name plates shall be held by self-tapping screws. Nameplate size shall be
minimum 20 x 75 mm for instrument/devices & 40 x 150 mm for panels.
5.19.04 Caution notice on suitable metal plate shall be affixed both at the front and back
of each vertical panel.
5.20.01 Each vertical section shall be provided with thermostat controlled space heater
and 5A, 3 pin plug socket.
5.20.02 In addition, motor feeders rated 30 KW and above shall be wired-up for feeding
the motor space heater through suitably rated breaker auxiliary NC contact
and/or contactor.
5.20.03 Cubicle heater. Motor heater, and Plug-socket circuit shall have individual
switch fuse units.
5.20.04 Two nos. 5KVA space heater transformer shall be provided for bus section- A &
B for catering space heater supply to respective bus, refer drawing no. E0106
sht. 5 of 10.
5.21.01 Necessary 415V AC and 220V DC power supplies as required for control and
service, shall be arranged by the contractor. Single feeder shall be arranged
for A.C. supply and duplicate feeder shall be arranged for D.C. supply.
5.21.02 Isolating switch fuse units shall be provided for the incoming supplies. These
shall be 4-pole, single throw for 415V AC and 2- pole double throw without off
position for 220V DC.
5.22.01 All equipment, accessories and wiring shall have fungus protection, involving
special treatment of insulation and metal against fungus, insects & corrosion.
5.23.00 Painting
5.23.01 All assemblies shall be finished with two coats of RAL7032 paint.
5.24.01 MCB shall be suitable for manual closing and opening and also automatic trip
on overload and short circuit.
6.00.00 TESTS
6.01.00 The switchgear shall be completely assembled, wired, adjusted and tested at
the factory as per the relevant standards.
The tests shall include but not necessarily limited to the followings :
Circuit Breaker Panel: In the main horizontal busbar and vertical bus bar
with ACB replaced by shorting link.
Vertical busbar.
7.01.01 All the meters provided on the panel shall be minimum 96 sq.mm with
an accuracy class of 1.5 unless otherwise specified.
7.01.03 The required 240V, 1 phase AC supply required for panel illumination,
receptacle and for space heating of panel shall be derived in the
control panel itself.
7.04.01 Local push button station shall be provided for all the drive motors of
the plant (415V motors and 3.3 kV motors) (start stop push buttons for
all motors; only start push button for emergency motors). The process
permissive interlocks for local start need to be ensured through
DDCMIS system.
7.04.02 The degree of protection of LPBs shall be IP55 with canopy for
7.04.03 All PBs shall be push to actuate type and the stop PB shall be lockable in
off position.
7.04.04 All push buttons shall be provided with 2 nos. NO and 2 nos. NC contacts
for various interlocking purposes. One contact of stop PB shall be
directly wired to the switchgear module for direct tripping and another
contact to the control system.
7.05.03 Rubber mats shall be provided to meet the safety and other statutory
requirements.
b) Bill of Materials
j) Technical leaflets of -
i) Circuit breaker
v) Contactors
e) Control schematics
f) Wiring diagrams
i) Test Certificates
8.03.00 The contractor shall also submit all instruction manuals clearly indicating the
installation method, check-up and tests that are to be carried out before
commissioning the equipment.
8.04.00 Tenderers shall note that the drawings, data and manuals listed herein are
minimum requirements only. The Tenderers shall ensure that other necessary
write-ups, curves and information required to fully describe the equipment are
submitted with their bids.
1.0 GENERAL
Service : Indoor
1.1 System AC DC
Frequency : 50 Hz ± 5% -
Circuit breaker : - Do -
Interrupting : 50 KA 25* KA
* Indicative only; the actual value will be decided by the Bidder, after substantiating the
same by calculation.
A.C. Symmetrical : 50 KA
PROTECTIONS
1.0 The minimum protections to be provided for circuit breaker controlled feeders are listed
below :
a) Incoming Feeders : 3-Inverse time O/C relays (51) for phase faults
& Instantaneous O/C(50) with timer
Bidder shall quote suitable digital/microprocessor based numerical relay for motor
protection with following minimum facility as indicated below :
- Overload protection.
- Current unbalance.
- Ground fault.
- Phase reversal.
Apart from above suitable provision for metering and monitoring such as voltage,
current, power factor, watt-hr, event record etc. shall be provided.
The relay shall have facility for user interface capability, character display, keypad, LED
indicator and communication port along with licensed version software.
c) Lighting transformer : 3-inverse time O/C relays with feeders high set
instantaneous unit (50/51) for phase faults
d) Outgoing Feeders : - 2-Inverse time O/C relay (51) for phase fault
2.0 Apart from protection relays, each electrically operated breaker shall be provided with
antipumping (94), trip annunciation (30), lockout (86) and trip circuit supervision (74)
relays. Lockout relay shall be hand reset type.
3.0 Fuse failure relay shall be provided on the secondary side of voltage transformer to
monitor H.V. & L.V. fuses.
1.1.0 General
1.1.1 The busduct will serve as interconnection between L.V. terminals of Auxiliary L.T.
Transformers to their respective PCC/PMCC and also for trunking connection between
each set of PCC/PMCC, if required.
1.1.2 The busduct shall be non-segregated type, self cooled. The cooling medium inside the
duct shall be air.
1.1.3 The busduct will be installed in a hot, humid and tropical atmosphere.
1.1.4 For continuous operation at specified rating, maximum temperature of the busduct shall
be limited to the following, considering 50°C as ambient temperature :
1.1.5 It shall be capable of withstanding the mechanical forces and thermal stresses of the
specified short-circuit currents without any damage or deterioration of material.
1.1.6 Wherever expansion joints are required neoprene rubber bellows shall be provided for
enclosure and flexible connectors for conductor.
1.1.7 Same phase disposition shall be maintained throughout the run of the bus duct. Phase
cross-over units, if required, shall also be provided.
1.2.0 Enclosure
1.2.1 All the three phases shall be enclosed in a weather proof, dust tight enclosure. Outdoor
section of the busduct shall be completely rain proof. For bus rating including and
above 2000 A, enclosure shall be of aluminium and for bus rating below 2000 A,
enclosure shall be of sheet steel fabricated type. Minimum Degree of protection of
busduct enclosure shall be IP-54 for indoor and IPW-55 for outdoor section of the
busduct.
1.2.2 Weather resistant type circumferential gaskets shall be provided for making the joints
with adjacent enclosures dust-proof and imperious to moisture.
1.2.3 The connection flanges shall be sufficiently stiffened so as not to bend while tightening
the bolts.
1.2.4 Suitable inspection opening with gaskets shall be provided for access to support
insulator, bus joints etc.
1.3.1 The conductor shall be of high conductivity aluminium /aluminium alloy sized for the
same rating as associated PCC/PMCC bus.
1.3.2 Joints made at the factory shall be welded type and the joints to be made at site shall
be bolted type.
1.3.3 For bolted rigid/expansion joints, necessary bolts, nuts, (cadmium plated) washers and
other hardwares shall be supplied.
1.3.4 Busbars shall be colour coded at regular intervals for easy identification. The markings
on the bars shall be Red for R-phase, Yellow for Y-phase, and Blue for B-phase.
1.3.5 For each shipping section, the bus conductor shall be supported at minimum two
positions.
1.4.1 All buses and connections shall be supported and braced to withstand stresses due to
maximum short circuit current.
1.4.2 The bus conductor supporting insulators shall be flame retardant, non-hygroscopic,
high strength track resistant type with high creepage surface.
1.4.3 The insulators shall be so located that they can be easily removed and replaced
without dismantling the busduct installation.
1.4.4 Space heater shall be provided near each insulator to avoid moisture condensation
within busduct.
1.4.5 The number and wattage of space heaters shall be decided by the Tenderers.
1.5.1 All supporting structures required for hanging and/or supporting the complete busduct
shall be furnished. These include all members, indoor/outdoor posts, bolts, shims, base
plates, beams, hangers, brackets, bracings and hardware.
1.5.2 All buses shall be adequately supported and braced to successfully withstand normal
operation, vibration, thermal expansion, short circuit forces, and all specified design
loads.
1.5.3 All steel members shall be hot-dip galvanised after fabrication. All hardware shall be of
high strength steel with weather resistant finish.
1.5.4 For each shipping section, the enclosure shall be supported at minimum two positions.
1.5.5 The enclosure supporting arrangement shall be such that the busduct load is not
transmitted onto the terminations.
1.6.1 All matching flanges, seal-off bushings, gaskets, fittings, hardware, and supports
required for termination of the busduct at PCC/PMCC, transformer, and any other
equipment shall be supplied.
All hardware used at conductor points shall be of non-magnetic, high tensile material.
1.6.2 Expansion joints for both conductor and enclosure shall be provided as follows:
1.6.3 Expansion joints shall be provided on bus conductor and enclosure to take care of
thermal expansion.
1.6.4 Seal-off bushing with wall frame assembly shall be provided wherever the busduct
penetrates the building wall from outdoor to indoor.
1.6.5 Equipment terminal connection shall be readily accessible and shall provide sufficient
air gap for isolation of equipment during testing.
1.6.6 If the material of bus conductor and that of the equipment terminal connectors are
different, suitable bi-metallic connectors shall be provided.
1.7.1 A ground bus rated to carry maximum fault current shall be provided running the entire
length of the busduct, grounding all parts of the supporting structure and each
enclosure section.
1.7.2 The ground bus shall be provided with two-bolt drilling with G.I. bolts and nuts at each
end to receive 50 x 6 mm G.S. flat.
1.8.0 Finish
1.8.1 Except for supporting steel structures, which shall be galvanised, all other material,
shall be finished with a undercoat of high quality primer followed by two coats of
synthetic enamel paint.
1.8.2 The interior surface finish shall be as per manufacturer's standard. The shade of
exterior surface finish will be light grey IS Shade # 631 for indoor and battle ship grey
IS Shade # 632 for outdoor.
1.8.3 Pretreatment consisting of degreasing, derusting etc. shall be done on all fabricated
parts before painting or galvanising.
1.8.4 Paints shall be carefully selected to withstand heat and weather conditions. The paint
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ANNEXURE-C
shall not scale off or crinkle or get removed by abrasion due to normal handling.
1.8.5 Sufficient quantities of all paints and preservatives required for touching up at site shall
be furnished.
1.9.0 TESTS
1.9.1 The busduct shall be completely assembled and checked at the factory for correctness
of alignment.
c) Short circuit test, mechanical test strengthen and thermal withstand test on
representative section of 3 phase bus duct. Including one bend, the section
shall be longest span between support insulators with CT mounted in position
d) Calculation for short circuit forces, sizing calculations justifying the proposed
arrangement and temperature rise for bus and enclosure.
d) Test report.
1.0 General
Type : Non-segregated
Service : Indoor/Outdoor
Frequency : 50 HZ+
_ 5%
a) Bus conductor
A. PCC/PMCC/MCC
B. 415V ACDBS
C. 220V DCDBS
D. SVBS
SECTION-VIII
TECHNICAL SPECIFICATION
FOR
GENERATOR CIRCUIT BREAKER
CONTENT
SECTION-VIII
TECHNICAL SPECIFICATION
FOR
GENERATOR CIRCUIT BREAKER
1.00.00 GENERAL
The Generator circuit breaker shall be used between the generator terminals
and the low voltage winding terminals of generator transformer. The
Generator circuit breaker is rated *kV, 25000A, 150 KA( to be finalized during
detailed engineering as per IEEE C37 .013), single pole Generator Circuit
Breaker assembly. The Generator circuit breaker shall be suitable for
synchronous duty and shall be capable of withstanding twice the voltage
impressed across open contacts during out of phase duty. It shall be capable
of switching on to fault and out phase switching duties. Also the GCB shall
be capable of breaking DC components of fault current and switching off GT.
The breaker shall comply with recommendations of IEEE/ANSI C.
Five (5) current transformer in each phase, for generator phase side for
protection, metering, automatic voltage regulator, and electro hydraulic
governing system.
1.03.01 Three (3) sets of voltage transformer mounted on the generator side of
Generator Circuit Breaker. Each set containing 3- single-phase voltage
transformers for relaying & performance testing, automatic voltage regulator
(AVR) & electro hydraulic governing (EHG) system; Metering & relaying.
One set of single phase VT s connected in open delta connection for 100%
earth fault relaying.
1.04.00 Each circuit breaker shall be complete with fittings and accessories
The electrical installation shall meet the requirements of Indian Electricity Rules
as amended up to date and relevant IS Codes of Practice. In addition, other
rules or regulations applicable to the work shall be followed. In case of any
discrepancy, the more restrictive rule shall be binding.
IS: 3427 AC metal enclosed switchgear and control gear for rated
Voltage 1kV up to and including 52 Kv.
IS: 13118 High Voltage Alternating Current Circuit Breakers
International Standards:
IEC 62271 Metal enclosed switchgear and control gear for rated
Part 200 Voltages up to and including 38 kV.
IEC 62271
Part 1 Common Specifications
IEC 60044 -1 Instrument transformers part 1: current transformers
b. The generator circuit breaker will be installed in hot, humid tropical and
heavily polluted atmosphere. All equipment, accessories and wiring shall be
provided with tropical finish to prevent fungus growth.
e. The enclosure shall be able to carry the 100% of return current during normal
operation at rated conditions and the rated short-circuit current.
f. The distance among the centre line of the phase enclosures shall be
adjustable in order to follow the bus bar spacing and allow their correct
connection.
• Start up of the turbo-generator auxiliaries via its unit transformer with the
CB open.
• Separate the generator from the system (switching off the unloaded
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VOL.II‐F1/SEC‐VIII : 3 DCPL-11Z02
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generator)
• Interrupt load currents (up to the full load current of the generator)
3.02.00 Calculation
b. In the event of calculated value being lower than any of the particulars
furnished in the annexure, the Tenderer shall offer the breaker as per the
data sheet furnished at clause no. 7.00.00
c. All the sizing calculations shall be furnished for owners approval during
engineering stage.
a. CIRCUIT BREAKER
General
The circuit breaker shall be three nos. single-pole, sulphur hexaflouride (SF6)
type, having internal isolation without any sequential interlock.
The duty of the circuit breaker shall involve satisfactory interruption of short
circuit currents as listed in the clause no. 7.00.00.
The breaker shall be suitable for operation even under condition of "phase
opposition" arising out of faulty synchronisation.
For the current breaking, the self-blast interrupting principle shall be applied.
That also in case of generator-source short circuit.
The CB shall have two separate power contact systems, one for carrying the
normal load current and one for arc interruption.
b. OPERATING MECHANISM
The CB operating mechanism shall be as manufacturer’s standard. This shall
operate on all poles (3 phase control). The operating mechanism shall have
electrical trip-free and anti-pumping devices.
There shall be no objectionable rebound and the mechanism shall not require
any critical adjustment. It shall be strong, rigid, positive and fast in operation.
The operating mechanism shall be such that the failure of any auxiliary
equipment will not prevent tripping and will not cause trip or closing operation
of the power operated closing devices.
Closing coil shall operate correctly at all values of voltage between 85% and
110% of the rated voltage.
Tripping coil shall operate correctly at all values of voltage between 70% and
110% of the rated voltage.
The auxiliary switch of the breaker shall be positively driven by the breaker-
operating rod.
When tripping impulse is received the operating mechanism shall ensure the
CB opening either with CB in fully closed nor in partially closed position.
The hydraulic oil used shall be fully compatible for the specified temperature
range.
The oil pressure switch controlling the pump and pressure in the high
pressure reservoir shall have adequate number of spare contacts to be used
for continuous monitoring of low pressure, high pressure etc.
The mechanism shall be suitable for at least two close open operations after
failure of AC supply to the motor starting at pressure equal to the lowest
pressure of auto reclose duty plus pressure drop for one close open
operation.
The mechanism shall be capable of operating the circuit breaker correctly and
performing the duty cycle specified under all conditions with the pressure of
hydraulic operated fluid in the operating mechanism at the lowest permissible
pressure before make up. The opening time at the lowest pressure for a
particular operation shall not exceed the guaranteed operating time within any
value of trip coil supply voltage as specified.
All hydraulic joints shall have no oil leakage under the site conditions and
joints shall be tested at factory against oil leakage at minimum of 1.5 times
maximum working pressure
The Tenderer may propose any other type of operating mechanism as per the
standard practice. However such operating mechanism shall be of proven
design, operation and shall be in successful and trouble free operation for
atleast two years in two power plants.
d. SF6 SUPERVISION
For SF6 density control, a density monitoring system shall be provided.. The
system shall consists of temperature compensate pressure element provided
with the following facilities:
e. CB CONTROL
For each CB, two tripping coils shall be provided. One tripping circuit
(primary) shall be wired in the CB local control panel suitable also for remote
control. The secondary circuit shall be wired up to the control panel terminal
blocks for remote control. In case of loss of drive energy on operating
mechanism, loss of control power supply or very low density of SF6, the
control circuit shall keep the CB in the fully closed or open position.
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f. DISCONNECTING AND EARTHING SWITCHES
The off load disconnecting switch shall be installed downstream the CB, line
side. It shall be air insulated, telescopic type, with sliding tubular contacts and
hinged point on the line side.
Earthing switches shall be installed one on the generator side (upstream the
CB) and the other on the line side (downstream the disconnecting switch).
They shall be air insulated, blade type and with hinged point connected to
earth.
The visual check of the position of the above switches shall be possible from
outside the phase enclosure by means of inspection windows.
The Tenderer may propose any other type of operating mechanism as per the
standard practice. However such operating mechanism shall be of proven
design, operation and shall be in successful and trouble free operation for
atleast two years in two power plants.
The CB system shall be equipped with short circuit link (for relay testing).
The short circuit link shall be installed between the circuit breaker and the
disconnecting switch in order to actuate the 3 phase unearthed short circuit
on the generator terminals by closing the CB.
The short circuit link shall be manually mounted by removing the specific
doors on the CB system phase enclosures.
For the interlocks, control and supervision of the complete CB system a local
control panel, installed on the CB system support framework, shall be
provided.
The control panel shall be wired up to suitable terminal blocks for incoming
The control panel shall be equipped with active mimic diagram for the control
and supervision of the main and auxiliary equipment of the system.
Control system shall be suitable for remote control and supervision. For
remote control the following operation shall be possible by using
LOCAL/REMOTE selector switches installed on the local control panel:
Auxiliary relays shall meet the requirements of IEC 60255; they shall be plug-
in type with the base suitable to avoid wrong insertions and shall be suitable
for permanent energisation without economy resistor
i. WIRING
Wiring shall be complete in all respects to ensure proper functioning of the
control, protection, and monitoring and interlocking schemes.
Wiring shall be done with flexible 1100 V grade, PVC insulated, switchboard
wires with 2.5 mm2 stranded copper conductor. Wiring between individual poles
and control cubicle shall be routed through G.I. conduits.
Each wire shall be identified at both ends with permanent markers bearing
wire numbers as per Contractor's wiring diagram.
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[2 x 660 MW] Main Plant Package
Wire termination shall be done with crimping type connectors with insulating
sleeves. Wires shall not be spliced between terminals.
All spare contacts of relays, push buttons, auxiliary switches etc. shall be
wired up to terminal blocks in the control cubicle.
j. TERMINAL BLOCKS
Terminal blocks shall be 1100 V grade, box - clamp type ELMEX 10mm2 or
approved equal.
Not more than two wires shall be connected to any terminal. Spare terminals
equal in number to 20% active terminals shall be furnished.
k. GROUNDING
Two grounding pads, located on the opposite sides of control box shall be
provided for connection to station ground mat.
Grounding pad shall have clean buffed surface with two tapped holes, M10
Brass bolts and spring washers for connection to 120 sq mm soft drawn bare
stranded tinned copper conductor..
l. AUXILIARY SUPPLY
Isolating switch fuse unit shall be provided for each of the incoming supply
along with automatic changeover scheme to switch on to the standby source
in case of failure of the normal supply.
m. PAINTING
The external surfaces, after cleaning, shall be given a coat of high quality
epoxy based primer followed by filler coats.
The CB assembly shall be finished with two coats of battle ship grey (IS
Shade # 632) epoxy based paint.
The paints shall be carefully selected to withstand tropical heat, rain etc. The
paint shall not scale off or crinkle or be removed by abrasion due to normal
handling.
The current transformers shall be cast-resin, ring type, mounted within the
generator circuit breaker enclosures and suitable for operation at an ambient
temperature equal to rated generator circuit breaker temperature.
C.T. secondary leads will be brought out to separate terminal box mounted on
or adjacent to C.T. enclosure. From phase terminal boxes, C.T. secondary
leads shall be brought out through non-magnetic metallic conduits to a master
terminal box.
o. VOLTAGE TRANSFORMER
The V.T. cubicles, one for each phase, shall be metal-clad, dust and vermin
proof, free standing dead front assemblies.
Each phase cubicle shall house three (3) voltage transformers, one (1) in
separate compartments.
The secondary leads from the voltage transformer shall be extended to a fuse
and terminal cabinet flush mounted on the compartment.
The following Input / Outputs shall be arranged in Generator Circuit breaker for
remote closing and opening and to meet interfacing requirements of DDCMIS.
h. Control cabinet
a. Motorised drive
e. Control cabinet
a. Motorised drive
d. Control cabinet.
With the ambient of 50 deg C the temperature rise limits for enclosure shall
be 20 deg C. Other components of the Generator Circuit breaker shall be
within the limits specified in IEC 600694
5.01.00 General
The equipments shall be tested as per the QAP submitted by the bidder at the
manufacturers works in presence of owner’s representative.
Only type tested equipments are acceptable. For type tests TENDERER shall
furnish test reports for the tests carried out on an identical machine, during
TENDER stage and also after award of contract
a. ROUTINE TESTS
• Verification of wiring
b. TYPE TESTS
• Tightness tests.
• Mechanical tests.
• Environmental tests.
a. ROUTINE TESTS
Tests as laid down in Indian Standard. List of major Routine tests are furnished
below.
Tenderer to note that the list is not exhaustive. All Routine test shall be carried
out as stipulated in latest Indian standard(s) though not specifically listed.
• Accuracy test
a. ROUTINE TESTS
• Knee point voltage and excitation current( for special class CTs)
b. TYPE TESTS
• Accuracy test & Instrument security current test (for measuring CTs)
The GCB shall be erected as per good engineering practice and all checks/tests
necessary to ensure receipt of correct material component, proper storage of
material/component, correctness of erection as per drawing/specification and the
following tests shall also be carried out in addition to the routine tests cited above
except (a)
b. Polarity of DC terminals.
i. Leakage test.
l. Operational checks.
c. Polarity test.
d. Ratio test.
c. Ratio test.
d. Polarity test.
Drawings, Data and Manuals shall be submitted in triplicate with the Tender
and in quantities and procedures as specified in General Conditions of
Contract and/or elsewhere in this specification for approval and subsequent
distribution after the issue of Letter of Intent.
6.02.04 Assembly drawing for erection at site with part numbers and schedule of
materials.
6.02.07 Any other relevant drawing or data necessary for satisfactory installation,
operation and maintenance.
The manual shall clearly indicate method of installation, check ups and tests to
be carried out before commissioning of the equipment.
7.01.00 General
7.01.06 Frequency : 50 Hz
SECTION‐IX TECHNICAL
SPECIFICATION
FOR
GENERATOR TRANSFORMERS
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.00.00 SCOPE OF SUPPLY VOL.II-F1/SEC-IX: 1
ATTACHMENTS
SECTION‐IX
TECHNICAL SPECIFICATION
FOR
GENERATOR TRANSFORMER
1.00.00 SCOPE OF SUPPLY
The GT shall be suitable for back charging operation for charging MV and LT
switchgear.
b) Auxiliary equipment
1.01.05 Recommended spare parts for three (3) years operation in addition to
mandatory spares
2.01.01 All equipment and materials shall be designed, manufactured and tested in
accordance with the latest editions including all applicable amendments of
relevant Indian Standards (IS) and IEC except where modified and/or
supplemented by this specification.
Bushing IS : 2099
3.01.00 The transformer will be used to connect up the generator to the extra high
voltage system for evacuation of power.
3.02.00 The transformer will be installed in hot, humid and tropical atmosphere. All
equipment, accessories and wiring shall be provided with tropical finish to
prevent fungus growth.
b) Frequency variation : ± 5%
3.05.00 The transformer shall be capable of withstanding the short circuit stresses
due to a terminal fault on one winding with full voltage maintained on the
other winding for minimum period of two (2) seconds.
3.06.00 The transformer shall be free from annoying hum or vibration. The design
CPCPL-Super Critical TPP-Tharangambadi VOL.II‐F1/SEC‐IX: 2
DCPL-11Z02
[2 x 660 MW] Main Plant Package
shall be such as not to cause any undesirable interference with radio or
communication circuits.
3.07.00 The noise level shall be limited to the value specified by NEMA Standard
Publication No. TR-1-1993 when measured in accordance with conditions
outlines in ANSI/IEEE C57.12.90-1999/IS13964/CBIP publication.
3.08.00 Generator Transformer should be sized to deliver the gross unit output of the
generator with turbine operation in VWO (Valve Wide Open) condition and
Unit Transformer out of service. The loads of this Unit Transformer will be
supplied from the station bus for an extended period of time.
4.01.00 Tanks
4.01.01 The tank shall be fabricated from good commercial grade low carbon steel of
adequate thickness. Transformer having capacity 100MVA and above shall
be bell type construction.
4.01.02 The tank wall shall be reinforced by stiffener to ensure rigidity so that it can
withstand without any deformation (a) mechanical shock during
transportation, (b) oil filling by vacuum, (c) Short circuit forces and (d)
continuous internal pressure of 35 kN/m2 over normal hydrostatic pressure of
oil.
4.01.03 All removable covers shall be provided with weatherproof, hot oil resistant,
resilient gaskets. The design shall be such as to prevent any ingress of water
into or oil from the tank.
4.01.04 The tank shall be provided with one set of bi-directional flanged wheels for
rolling the transformer parallel to either center line over 1676 mm rail gauge.
In case more than two rails are required to be provided the rail gauge of 1676
mm shall be maintained between two adjacent rails
4.01.05 Jacking pads, lifting eyes and pulling lugs shall be provided to facilitate
movement of the transformer. All heavy removal parts shall be provided with
eye bolt for ease of handling.
4.01.07 Suitable guide shall be provided in the tank for positioning the core and coil
assembly.
4.02.01 The core shall be built up with high grade, non-aging, low loss, high
permeability, grain oriented, cold-rolled silicon steel laminations especially
suitable for core material.
4.02.02 The coils shall be manufactured from electrolytic copper conductor and fully
insulated for rated voltage. However, HV winding shall be non-uniformly
4.02.03 Insulating material shall be of proven design. Coils shall be so insulated that
impulse and power frequency voltage stresses are minimum.
4.02.05 All leads from the windings to the terminal board and bushings shall be rigidly
supported to prevent injury from vibration or short circuit stresses. Guide tube
shall be used where practicable.
4.02.06 The core and coil assembly shall be securely fixed in position so that no
shifting or deformation occurs during movement of transformer or under short
circuit stresses.
4.03.00 Tappings
4.03.01 Off-circuit tap change (OCTC) as specified in the annexure shall be provided
on the high voltage winding.
4.03.02 The transformer shall be capable of operation at its rated KVA on any tap
provided the voltage does not vary by more than ±10% of the rated voltage
corresponding to the tap.
4.03.03 The winding including the tapping arrangement shall be designed to maintain
electromagnetic balance between HV and LV windings at all voltage ratios.
4.04.01 The off-circuit tap changing of 3nos. single phase transformer bank of a 3-
phase system shall be effected by individual tap change switch of each
transformer. Interlocks shall be provided for each tap position with limit
switches or a suitable arrangement such that transformers cannot be
energized unless the taps of all the transformers of the same bank are in the
same position. Contacts shall also be provided to give alarm and de-energize
the transformer in case any tap of any transformer of the same bank is in
different position.
Arrangement shall such that switch can be operated at standing height from
ground level.
4.04.02 The operating handle can be padlocked at any tap position. The design shall
be such that the lock cannot be inserted unless the contacts are correctly
engaged.
4.04.03 The mechanism shall be provided with a mechanical tap position indicator
and an operation counter.
4.04.04 All contacts shall be silver plated and held in position under strong contact
pressure to ensure low contact drop and avoid pitting.
4.05.01 The transformer shall be filled with mineral insulating oil suitably inhibited to
prevent sludging.
4.05.02 First filling of oil along with 10% excess shall be furnished for each
transformer. Oil shall be supplied in non-returnable containers suitable for
outdoor storage.
Sr.
PROPERTY PERMISSIBLE VALUES
No
4.06.00 Bushing
4.06.01 Bushing rated 52 KV class and above shall be oil impregnated paper
condenser bushings. Bushing rated below 52KV voltage class shall be solid
porcelain or oil communicating type.
4.06.02 Condenser type bushing shall be provided with oil level gauge, bottom drain
plug and test terminal for measurement of loss factor (tan-delta) and
capacitance.
4.06.03 Bushings shall be provided with terminal connectors of approved type and
size.
4.06.04 Bushing location shall provide adequate phase and ground clearances.
4.07.01 The physical position of the terminals and the markings shall be as per
relevant IS/IEC unless otherwise required to suit the layout.
4.07.02 High voltage terminals shall be brought out thru' top cover mounted bushings
for connection to overhead ACSR/AAAC/Al tube conductors.
4.07.03 High voltage winding neutral for each single-phase transformer shall be
brought out thru' top cover mounted bushing for neutral formation. All
necessary insulators, 10x125 mm hard copper flat, mounting hardwares will
be supplied along with one of three single phase transformer. However
provision for neutral grounding shall be provided in all transformers.
4.07.04 Two (2) nos. Low voltage terminals for each single phase transformer shall be
brought out thru' top cover mounted bushings with matching flanges around
each bushing for necessary delta connection by isolated phase bus duct. The
contractor shall furnish all necessary details in this connection for co-
ordination with the bus duct, and shall guarantee the matching dimensions
within close tolerance.
The cooling system shall comprise of two units of 50% each. Each cooling unit
shall be complete with its radiator banks, pumps, fans and other accessories.
Each cooling unit shall be provided with two (2) nos. 50% capacity oil pumps
and number of cooling fans.
a) for 10 minutes after failure of the oil and/or water circulating pumps and
blowers.
b) for 20 minutes in the event of failure of the oil and/or water circulating
pumps and blowers associated with one cooler unit
4.08.03 The radiators shall be detachable type with top and bottom isolation valves to
permit the removal of the same without drainage of oil from the tank.
4.08.04 All fans shall have safety guard. Pumps shall be provided with flow indicators
for visual indication of oil flow.
4.08.05 Convenient means shall be provided to remove or replace any pump or fan
with the transformer in service.
4.08.06 Complete control for pumps and fans inclusive of all switches, fuses, starters,
relays and wiring shall be furnished. Each motor circuit shall have over load
and short-circuit protection.
4.08.07 Pump and fan motor controls will be actuated automatically from winding
temperature indicator contacts. Provision shall however be kept for manual
operation from local cooler control panel and remote from central control
room by serial link communication with the plant DCCMIS and from ECP also.
4.08.08 Necessary auxiliary contacts i.e. NO and NC contacts shall be provided for
remote annunciation and SCADA connectivity for cooling fans and pumps,
OTI, WTI, Buchholz Relay, Surge Relay, PRV, MOG etc.
4.08.09 4-20mA signal to be provided for OTI & WTI for remote display and DCS/
SCADA connectivity.
4.09.01 The transformer cooler control panel shall be used for control, interlocking,
metering and indication of cooler control system of transformer and shall be
installed outdoor near the transformer coolers.
4.09.02 Control panels shall be of CRCA sheet steel construction with protection class
of IPW-55 for outdoor installation.
4.09.03 The frames and load bearing panels shall be fabricated of not less than 2 mm
thick sheet steel. The doors and covers shall not be less than 1.6mm thick.
All access doors shall be provided with channel rubber/ neoprene gaskets all
round.
4.09.04 The operating height shall be limited from 750mm to 1800mm. The total
height of the panel and its depth shall be matched with adjacent panel.
4.09.06 All instrument, relays, switches, etc. mounted on the front face of the panel
shall be flush or semi flush type. Switch contacts shall be silver faced and
rated at least 10 Amp at operating voltage. Push buttons shall have required
number of contacts.
4.09.07 Panel shall be provided with internal illumination lamp with door switch, space
heater with thermostat one 5A, 3 pin receptacles with plug.
4.09.08 The annunciation system shall be solid-state type with optical isolation for
input signals. It shall be complete with its own power supply, audible alarms,
acknowledge, reset, and test buttons and other necessary accessories.
4.09.09 The control panels shall be fully wired up at factory. All spare contacts of
relays and switches shall be wires up to the terminal blocks.
4.09.10 The panel shall have provision of cable entry from bottom. Bottom gland
plate shall be 3mm thick.
4.09.11 50 x 6 mm copper ground bus shall be provided on the panel extending along
the entire length of the assembly. The ground bus shall have two-bolt drilling
with GI bolts and nuts at each end to receive Owner/Purchaser's ground
connection of 75x10 mm G.I. flat.
4.10.01 A sheet steel, weatherproof, IPW55, marshalling box shall be provided for the
transformer. The box shall contain all auxiliary devices except those which
must be located directly on the transformer.
4.10.02 All terminal blocks for Owner/Purchaser's cable connection shall be located in
this box. The terminal blocks shall be ELMEX 10 mm2 or approved equal.
4.10.03 The marshalling box shall be provided with cubicle lamp with door switch,
space heater with thermostat and removable cable gland plate.
4.11.00 Wiring
4.11.01 All control, alarm and indication devices provided with the transformer shall
be wired upto the terminal blocks.
4.11.02 Wiring shall be done with flexible, 1100V/650V grade PVC wires in conduit or
PVC armored cable. Minimum wire size shall be 2.5-mm2 copper. Not more
than two wires shall be connected to a terminal. 10% spare terminals shall be
provided.
4.11.03 Multi-way terminal block complete with mounting channel, binding screws and
washers for wire connections and marking strip for circuit identification shall
be provided for terminating the panel wiring. Terminals shall be stud type,
suitable for terminating 2 nos. 2.5 mm2 stranded copper conductor and
4.11.04 All devices and terminal blocks shall be identified by symbols corresponding
to those used in applicable schematic or wiring diagram. Each wire shall be
identified, at both ends, with interlocking type permanent markers bearing
wire numbers as per Contractor's Wiring Diagrams. AC / DC wiring shall have
separate color-coding.
4.11.05 Wire termination shall be made with crimping type connectors with insulating
sleeves. Wires shall not be spliced between terminals.
4.12.00 Grounding
4.12.01 The grounding pads, located on the opposite sides of the tank, shall be
provided for connection to station ground mat.
4.12.02 Grounding pad shall have clean buffed surface with two tapped holes, M10
G.I. bolts and spring washers for connection to 75x10 mm G.I. flat.
4.12.03 Ground terminals shall be also provided on marshalling box to ensure its
effective earthing.
4.12.04 For continuity of earth connection, all gasketted joints shall be provided with
braided copper wire jumpers.
4.13.01 A.C. supply will be made available to each transformer by two separate
feeders one normal and the other standby.
4.13.02 Isolating switch fuse unit shall be provided for each of the incoming supply
along with automatic changeover scheme to switch on to the standby source
in case of failure of the normal supply.
4.14.01 Neutral bushing current transformers and phase bushing current transformers
shall be provided as per final approved SLD
4.14.02 The arrangement shall be such that the C.T. can be removed from the
transformer without removing the tank cover.
4.15.00 Painting
The cleaning and painting procedure shall be as indicated in CBIP Manual on
Transformer – Publication No: 275 clause 1.6.The procedure need to be
submitted during engineering and to be approved by owner/consultant
4.15.02 The internal surfaces in contact with insulating oil shall be painted with fully
glossy white paint which shall not react with and be soluble in the insulating
liquid used.
4.15.03 The external surfaces, after cleaning, shall be given a coat of high quality red
oxide or yellow chromate primer followed by filler coats.
4.15.04 The transformer shall be finished two coats of RAL7032 paint unless
otherwise specified.
4.15.05 The paints shall be carefully selected to withstand tropical heat, rain etc. The
paint shall not scale off or crinkle or be removed by abrasion due to normal
handling.
4.15.06 Sufficient quantity of touch up paint shall be furnished for application after
installation at site.
4.15.08 All supporting structures and hardware shall be hot dip galvanized.
4.16.00 Transportation
4.16.01 Transformer tank shall be dispatched filled with oil or pure dry inert Nitrogen
gas depending upon the transport weight limitations. A positive pressure of 2
to 2.5 Psi at temperature of 36oC approximate shall be kept. In case the tank
is filled with oil, sufficient space is left above the oil to take care of the
expansion of the oil. The space is filled with pure dry air or inert gas under
atmospheric pressure.
The temperature and pressure at the time of gas filling shall be marked on a
tag. A graph showing pressure vs. temperature shall be attached for reading
pressures at different temperatures. Necessary valves, two-stage pressure
regulators, filled up Nitrogen cylinder etc. along with other accessories
required shall be provided with the tank for intermittent replenishment during
transportation.
5.00.00 TESTS
5.01.01 Transformer tank with coolers shall be tested for leaks with normal head of oil
plus 35 KN/m2 for a period of 8 hours. If any leak occurs, the test shall be
conducted again after all leaks have been repaired.
5.01.02 During fabrication stage, the tank shall be pressure tested with air at a
pressure corresponding to twice the normal head of oil or normal pressure
plus 35KN/m2 whichever is lower for a period of one hour. Also the tank
designed for full vacuum shall be tested for maximum internal pressure of
3.33KN/m2 for one hour. The permanent deflection of flat plates shall not
exceed CBIP specified figures on release of excess pressure of pressure test
and on release of vacuum.
5.01.03 After assembly, each core shall be pressure tested for one minute at 2KV
(r.m.s.) A.C. between all bolts, side plates, structural steel works and the
core.
5.01.04 The wiring for auxiliary power and control circuitry shall be subjected to
withstand one minute power frequency test with 10KV (r.m.s.) to earth
5.01.05 Frequency Response Analysis test (This test shall also be undertaken by the
manufacturer at site after transformer is installed.)
Special test:
5.03.00 Miscellaneous
All component parts and auxiliary equipment such as oil, bushings, C.Ts
etc.shall be routine tested as per relevant Indian Standards.
5.05.01 Certified reports of all the tests carried out at the works shall be furnished in
six (6) copies for approval of the Owner/Purchaser.
5.05.02 The equipment shall be dispatched from works only after receipt of
Owner/Purchaser's written approval of the test reports.
6.01.00 A set of special tools & tackle which are necessary or convenient for erection,
commissioning, maintenance and overhauling of the equipment shall be
supplied. The tools and tackles generally available at site are sufficient for
erection and commissioning of transformers. However one set of standard
hand tools as required shall be supplied along with each transformer.
6.02.00 The tools shall be shipped in separate containers, clearly marked with the
name of the equipment for which they are intended.
7.01.00 Drawings, Data and Manuals shall be submitted with the bid and for approval
and subsequent distribution after the issue of Letter of Intent in quantities and
procedures as specified in General condition of contract and/or elsewhere in
this specification
7.02.02 Transport/shipping dimensions and weights, space required for handling parts
for maintenance.
7.02.03 Technical leaflets on major components and fittings.
7.02.05 Type test certificates including short circuit test report of a similar transformer
(as per the guidance for identification of a similar transformer as defined in
CPCPL-Super Critical TPP-Tharangambadi VOL.II‐F1/SEC‐II : 13
DCPL-11Z02
[2 x 660 MW] Main Plant Package
Annexure-A of IEC 60076-5). The type test certificates shall not be more than
5 years old.
7.03.05 Flow diagram of the cooling system showing the number of cooling banks,
Pumps, fans etc (A).
7.03.08 GA of Marshalling Box , Cooler control panel, OLTC cabinet, RTCC panel as
applicable (A).
7.03.14 Any other relevant drawing or data necessary for satisfactory installation,
operation and maintenance (R).
The manual shall clearly indicate method of installation, check-ups and tests
to be carried out before commissioning of the equipment.
7.04.00 The Bidder may note that the drawings, data and manuals listed are minimum
requirement only. The Bidder shall ensure that all other necessary write-ups,
curves and information required to fully describe the equipment offered are
submitted with his bid.
7.05.00 The drawings and documents marked with (A) above are of ‘Approval’
category and are subject to review by Owner. Those marked (R) are for
‘reference’ category.
7.06.00 All drawings shall be prepared by using AutoCAD and documents shall be
generated using Electronic version. The paper copy of the drawings &
document shall be submitted for approval & reference. All final drawings and
documents shall be submitted in CD in AutoCAD 2000 and MS office format
as applicable for Owner’s future reference.
L.V. : Unearthed
23.0 Max. Flux density in any part of core & : 1.9 Tesla
Yoke at 110% rated voltage
24.0 Max. Noise level in accordance with : As per NEMA Std. TR1
Conditions specified in NEMA Std. TR-1
FITTINGS AND ACCESSORIES
Transformer shall be equipped with fittings and accessories as listed below: -
1. Oil conservator with filler cap, drain plug, plain oil level gauge and alarm contacts for
rupturing of bellows/diaphragm.
4. Pressure release device with trip contacts. Explosion vent, if provided, should be
double diaphragm type.`
5. 150 mm dial magnetic oil level gauge with low level alarm contacts
6. 150 mm dial oil temperature indicator with maximum reading pointer and electrically
separate contacts for trip and alarm and embedded temperature detectors (PT-100)
with suitable output for remote indication (data logging).
7. 150 mm dial winding temperature indicator with maximum reading pointer and
electrically separate sets of contacts for trip, alarm and cooler control and embedded
temperature detectors (PT-100) with suitable output for remote indication (data
logging).
9. Thermometer pockets.
10. Double float Buchholz relay with gas release cock, shut-off valve on either sides with
separate sets of contacts for trip and alarm.
21. Ladder with safety device for access to the top of transformer tank.
22. Weather proof marshalling box for housing control equipment and terminal
connections.
25. Cooler units complete with valves, fans, pumps, oil flow indicators, supporting
structure with fixing and foundation bolts etc as required and Cooler Control panel.
26. Tap-changing gear complete with tap position indicator, operation counter etc. For
OCTC gear (where specified), oil surge relay(OSL) with shut-off valve, Local control
cabinet and Tap changer in ECP and also DDCMIS
Note: All indication, alarm, trip contacts provided shall be rated for 0.5A at 220 V D.C. and
5A at 240 V A.C.
AUXILIARY EQUIPMENT
Note: SLD to be referred for the CT requirement and the actual CT details to be decided
during detail engineering. The CT details to be submitted with the bid. The CT calculation
shall be submitted for approval.
SECTION‐X TECHNICAL
SPECIFICATION
FOR
UNIT TRANSFORMERS
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.00.00 SCOPE OF SUPPLY VOL.II-F1/SEC-X: 1
ATTACHMENTS
ANNEXURE-A RATINGS AND REQUIREMENTS VOL.II-F1/SEC-X: 15
1.03.00 MVA rating of the transformer, as indicated above, shall be considered as the
minimum requirement for the project. Transformer offered by the bidder shall
be sized according to the maximum demand at most stringent condition plus
minimum 10 % margin
b) Auxiliary equipment
* - Generator Voltage, KV
2.00.00 CODES AND STANDARDS
2.01.00 All equipment and materials shall be designed, manufactured and tested in
accordance with the latest e d i t i o n s i n c l u d i n g a l l applicable
amendments of relevant Indian Standards (IS) and IEC except where
modified and/or supplemented by this specification.
Bushing IS : 2099
3.00.00 DESIGN CRITERIA
3.01.00 The transformer will be used to supply power for units & auxiliaries.
3.02.00 The transformer will be installed in hot, humid and tropical atmosphere. All
equipment, accessories and wiring shall be provided with tropical finish to
prevent fungus growth.
b) Frequency variation : ± 5%
Continuous operation at rated MVA on any tap with voltage variation of ± 10%
corresponding to the voltage of the tap as well as in accordance with IS-6600.
In addition, all the transformers shall be able to operate at full load for at least
ten (10) minutes without exceeding the calculated winding hot spot
temperature of 150 deg.C in the event of complete failure of power supply to
cooling equipment. The transformer shall be capable of being loaded to a load
of 150% in accordance with IS 6600, IEC 60354 without any limitation
imposed by tap changer , bushing or any other equipment.
3.05.00 The transformer shall be capable of withstanding the short circuit stresses
due to a terminal fault on one winding with full voltage maintained on the
other winding for minimum period of two (2) seconds.
3.06.00 The transformer shall be free from annoying hum or vibration. The design
3.07.00 The noise level shall be limited to the value specified by NEMA Standard
Publication No. TR-1-1993 when measured in accordance with conditions
outlines in ANSI/IEEE C57.12.90-1999/IS13964/CBIP publication.
4.01.02 The tank wall shall be reinforced by stiffener to ensure rigidity so that it can
withstand without any deformation (a) mechanical shock during
transportation, (b) oil filling by vacuum, (c) Short circuit forces and (d)
continuous internal pressure of 35 kN/m2 over normal hydrostatic pressure of
oil.
4.01.03 All removable covers shall be provided with weatherproof, hot oil resistant,
resilient gaskets. The design shall be such as to prevent any ingress of water
into or oil from the tank.
4.01.04 The tank shall be provided with one set of bi-directional flanged wheels for
rolling the transformer parallel to either canter line over 1676 mm rail gauge.
In case more than two rails are required to be provided the rail gauge of 1676
mm shall be maintained between two adjacent rails
4.01.05 Jacking pads, lifting eyes and pulling lugs shall be provided to facilitate
movement of the transformer. All heavy removal parts shall be provided with
eyebolt for ease of handling.
4.01.07 Suitable guide shall be provided in the tank for positioning the core and coil
assembly.
4.02.00 Core & Coils
4.02.01 The core shall be built up with high grade, non-aging, low loss, high
permeability, grain oriented, cold-rolled silicon steel laminations especially
suitable for core material.
4.02.02 The coils shall be manufactured from electrolytic copper conductor and fully
insulated for rated voltage. Insulation shall be of Class A.
4.02.03 Insulating material shall be of proven design. Coils shall be so insulated that
impulse and power frequency voltage stresses are minimum.
4.02.06 The core and coil assembly shall be securely fixed in position so that no
shifting or deformation occurs during movement of transformer or under short
circuit stresses.
4.03.00 Tapping
4.03.01 On load tap changer (OLTC) as specified in the annexure shall be provided
on the high voltage winding.
4.03.02 The transformer shall be capable of operation at its rated KVA on any tap
provided the voltage does not vary by more than ±10% of the rated voltage
corresponding to the tap.
4.03.03 The winding including the tapping arrangement shall be designed to maintain
electromagnetic balance between HV and LV windings at all voltage ratios.
4.04.00 Not applicable
4.05.00 On‐Load Tap Changer (OLTC)
4.05.01 The OLTC switch contacts shall be located in a separate oil-filled chamber
complete with its own oil preservation system, Oil Surge relay, shut-off
valves, oil level gauge, gas vent etc.
4.05.03 The tap change equipment shall be so designed that if the mechanism is
stuck in an intermediate position, the transformer shall be capable of
delivering full load without any injury.
4.05.04 The OLTC gear shall be suitable for local and remote electrical control at
ECP and local manual control. Further, there shall be provision of automatic
operation through voltage sensing relay wherever specified.
4.05.05 The hand cranking arrangement shall be such that it can be operated at
standing height from ground level. Further the mechanism shall be provided
with a tap position indicator and an operation counter.
i) Annunciations for:
o Mechanism stuck
4.05.08 Provisions shall be kept in the RTCC at ECP for serial link communication
with the plant DDCMIS.
4.06.02 First filling of oil along with 10% excess shall be furnished for each
transformer. Oil shall be supplied in non-returnable containers suitable for
outdoor storage.
Sr.
PROPERTY PERMISSIBLE VALUES
No
4.07.00 Bushing
4.07.01 Bushing rated below 52KV voltage class shall be solid porcelain or oil
communicating type.
4.07.03 Bushing location shall provide adequate phase and ground clearances.
4.08.02 High voltage terminals shall be brought out thru' top cover mounted bushings
with matching flanges around each bushing for connection to isolated phase
bus. The contractor shall furnish all necessary details in this connection for
co-ordination with the bus duct and shall guarantee the matching dimensions
within close tolerance.
4.08.03 Low voltage terminals shall be brought out thru' sidewall mounted bushings.
For bus duct connection, bushings shall have matching flange around. For
cable connection, a detachable type cable end-box with disconnect links shall
be furnished.
4.08.04 Low voltage winding neutral shall be brought out thru' side wall mounted
bushing to a detachable cable end-box with disconnect link.
4.08.05 The cable end-box shall be self-supporting, weather-proof, air filled type,
complete with all hardware such as gland plate, brass glands, tinned copper
lugs, armour clamps etc.
4.09.02 Transformer fitted with multiple cooling units but without having stand-by
cooling unit/s, it shall be able to deliver its rated output not exceeding
specified temperature rise and calculated hot-spot temperature of 150°C
under following conditions:
4.09.03 The radiators shall be detachable type with top and bottom isolation valves to
permit the removal of the same without drainage of oil from the tank.
4.09.04 All fans shall have safety guard. Pumps shall be provided with flow indicators
for visual indication of oil flow.
4.09.06 Complete control for fans inclusive of all switches, fuses, starters, relays and
wiring shall be furnished. Each motor circuit shall have over load and short-
circuit protection.
4.09.07 Fan motor controls will be actuated automatically from winding temperature
indicator contacts. Provision shall however be kept for manual operation from
local cooler control panel and remote from respective control room by serial
link communication with the plant DCS in addition to ECP.
4.11.02 All terminal blocks for Owner/Purchaser's cable connection shall be located in
this box. The terminal blocks shall be ELMEX 10 mm2 or approved equal.
4.11.03 The marshalling box shall be provided with cubicle lamp with door switch,
space heater with thermostat and removable cable gland plate.
4.12.00 Wiring
4.12.01 All control, alarm and indication devices provided with the transformer shall
be wired upto the terminal blocks.
4.12.02 Wiring shall be done with flexible, 1100V/650V grade PVC wires in conduit or
PVC armored cable. Minimum wire size shall be 2.5-mm2 copper. Not more
than two wires shall be connected to a terminal. 10% spare terminals shall be
provided.
4.12.03 Multi-way terminal block complete with mounting channel, binding screws and
washers for wire connections and marking strip for circuit identification shall
be provided for terminating the panel wiring. Terminals shall be stud type,
suitable for terminating 2 nos. 2.5 mm2 stranded copper conductor and
provided with acrylic insulating cover. Terminals for C.T. secondary leads
shall have provision for shorting and grounding.
4.12.04 All devices and terminal blocks shall be identified by symbols corresponding
to those used in applicable schematic or wiring diagram. Each wire shall be
identified, at both ends, with interlocking type permanent markers bearing
wire numbers as per Contractor's Wiring Diagrams. AC / DC wiring shall have
separate color-coding.
4.12.05 Wire termination shall be made with crimping type connectors with insulating
sleeves. Wires shall not be spliced between terminals.
4.13.00 Grounding
4.13.02 Grounding pad shall have clean buffed surface with two tapped holes, M10
G.I. bolts and spring washers for connection to 75x10 mm G.I. flat.
4.13.03 Ground terminals shall be also provided on marshalling box to ensure its
effective earthing.
4.13.04 For continuity of earth connection, all gasketted joints shall be provided with
braided copper wire jumpers.
4.14.02 Isolating switch fuse unit shall be provided for each of the incoming supply
along with automatic changeover scheme to switch on to the standby source
in case of failure of the normal supply.
4.15.02 The arrangement shall be such that the C.T. can be removed from the
transformer without removing the tank cover.
4.16.00 Painting
The cleaning and painting procedure shall be as indicated in CBIP Manual on
Transformer – Publication No: 295 clause 1.6.The procedure need to be
submitted during engineering and to be approved by owner/consultant
4.16.01 All steel surfaces shall be thoroughly cleaned by sand blasting or chemical
agents as required, to produce a smooth surface free of scales, grease and
rust.
4.16.02 The internal surfaces in contact with insulating oil shall be painted with heat
resistant insulating varnish which shall not react with and be soluble in the
insulating liquid used.
4.16.03 The external surfaces, after cleaning, shall be given a coat of high quality red
oxide or yellow chromate primer followed by filler coats.
4.16.04 The transformer shall be finished with two coats of RAL7032 paint unless
otherwise specified.
4.16.06 Sufficient quantity of touch up paint shall be furnished for application after
installation at site.
4.16.08 All supporting structures and hardware shall be hot dip galvanized.
4.17.00 Transportation
4.17.01 Transformer tank shall be dispatched filled with oil or pure dry inert Nitrogen
gas depending upon the transport weight limitations. A positive pressure of 2
to 2.5 Psi at temperature of 36oC approximate shall be kept. In case the tank
is filled with oil, sufficient space is left above the oil to take care of the
expansion of the oil. The space is filled with pure dry air or inert gas under
atmospheric pressure.
The temperature and pressure at the time of gas filling shall be marked on a
tag. A graph showing pressure vs. temperature shall be attached for reading
pressures at different temperatures. Necessary valves, two-stage pressure
regulators, filled up Nitrogen cylinder etc. along with other accessories
required shall be provided with the tank for intermittent replenishment during
transportation.
4.17.02 Impact Recorder
Impact recorder/indicator shall be provided to monitor the impact experienced
by the transformer during transport.
5.00.00 TESTS
5.01.00 Routine Tests
During manufacture and on completion, all transformers shall be subjected to
the routine tests in accordance with latest IEC 60076 and its different parts.
5.01.01 Transformer tank with coolers shall be tested for leaks with normal head of oil
plus 35 KN/m2 for a period of 8 hours. If any leak occurs, the test shall be
conducted again after all leaks have been repaired.
5.01.02 During fabrication stage, the tank shall be pressure tested with air at a
pressure corresponding to twice the normal head of oil or normal pressure
plus 35KN/m2 whichever is lower for a period of one hour. Also the tank
designed for full vacuum shall be tested for maximum internal pressure of
3.33KN/m2 for one hour. The permanent deflection of flat plates shall not
5.01.03 After assembly, each core shall be pressure tested for one minute at 2KV
(r.m.s.) A.C. between all bolts, side plates, structural steel works and the
core.
5.01.04 The wiring for auxiliary power and control circuitry shall be subjected to
withstand one minute power frequency test with 2.0KV (r.m.s.) to earth
5.01.07 Frequency Response Analysis test (This test shall also be undertaken by the
manufacturer at site after transformer is installed.)
k. Current error, phase displacement and composite error (for protection CTs)
5.02.00 Type Tests
5.03.00 Miscellaneous
All component parts and auxiliary equipment such as oil, bushings, C.Ts
etc.shall be routine tested as per relevant Indian Standards.
5.04.00 Test Witness
Tests shall be performed in presence of Owner/Purchaser's representative if
so desired by the Owner/Purchaser. The Contractor shall give at least fifteen
(15) days' advance notice of the date when the tests are to be carried out
5.05.00 Test Certificates
5.05.01 Certified reports of all the tests carried out at the works shall be furnished in
six (6) copies for approval of the Owner/Purchaser.
5.05.02 The equipment shall be dispatched from works only after receipt of
Owner/Purchaser's written approval of the test reports.
6.02.00 The tools shall be shipped in separate containers, clearly marked with the
name of the equipment for which they are intended.
7.02.02 Transport/shipping dimensions and weights, space required for handling parts
for maintenance.
7.02.05 Type test certificates including short circuit test report of a similar transformer
(as per the guidance for identification of a similar transformer as defined in
Annexure-A of IEC 60076-5). The type test certificates shall not be more than
5 years old.
7.03.05 Flow diagram of the cooling system showing the number of cooling banks,
Pumps, fans etc (A).
7.03.08 GA of Marshalling Box, Cooler control panel, OLTC cabinet, RTCC panel as
applicable (A).
7.03.14 Any other relevant drawing or data necessary for satisfactory installation,
operation and maintenance (R).
The manual shall clearly indicate method of installation, check-ups and tests
to be carried out before commissioning of the equipment.
7.04.00 The Bidder may note that the drawings, data and manuals listed are minimum
requirement only. The Bidder shall ensure that all other necessary write-ups,
curves and information required to fully describe the equipment offered are
submitted with his bid.
7.05.00 The drawings and documents marked with (A) above are of ‘Approval’
category and are subject to review by Owner. Those marked (R) are for
‘reference’ category.
The Owner /Purchaser may review the documents marked (R) if thought
necessary. The contractor shall note that the approval of drawings &
documents by the owner does not relieve him of his contractual obligation.
7.06.00 All drawings shall be prepared by using AutoCAD and documents shall be
generated using Electronic version. The paper copy of the drawings &
document shall be submitted for approval & reference. All final drawings and
documents shall be submitted in CD in AutoCAD 2000 and M.S. Office format
as applicable for Owner’s future reference.
RATINGS AND REQUIREMENTS
UNIT TRANSFORMERS
1.0 Application : Unit Transformer
10.0 Cooling system
a) in oil by thermometer : 50 oC
b) in winding by resistance : 55 oC
d) Automatic : Yes
H.V. : Unearthed
LV Side : 44 KA (r.m.s.)
23.0 Max. Flux density in any part of core & : 1.9 Tesla
Yoke at 110% rated voltage
24.0 Max. Noise level in accordance with : As per NEMA std. TR-1
Conditions specified in NEMA Std. TR-1
FITTINGS AND ACCESSORIES
Transformer shall be equipped with fittings and accessories as listed below: -
1. Oil conservator with filler cap, drain plug, plain oil level gauge and alarm contacts for
rupturing of bellows/diaphragm.
4. Pressure release device with trip contacts. Explosion vent, if provided, should be
double diaphragm type.
5. 150 mm dial magnetic oil level gauge with low level alarm contacts
6. 150 mm dial oil temperature indicator with maximum reading pointer and electrically
separate contacts for trip and alarm and embedded temperature detectors (PT-100)
with suitable output for remote indication (data logging).
7. 150 mm dial winding temperature indicator with maximum reading pointer and
electrically separate sets of contacts for trip, alarm and cooler control and embedded
temperature detectors (PT-100) with suitable output for remote indication (data
logging).
9. Thermometer pockets.
10. Double float Buchholz relay with gas release cock, shut-off valve on either sides with
separate sets of contacts for trip and alarm.
21. Ladder with safety device for access to the top of transformer tank.
22. Weather proof marshalling box for housing control equipment and terminal
connections.
25. Cooler units complete with valves, fans, supporting structure with fixing and
foundation bolts etc as required and Cooler Control panel.
26. Tap-changing gear complete with tap position indicator, operation counter etc. For
OLTC gear , oil surge relay(OSL) with shut-off valve, Local control cabinet and
Remote Tap Changer Control (RTCC) at ECP
Note: All indication, alarm, trip contacts provided shall be rated for 0.5A at 220 V D.C. and
5A at 240 V A.C.
AUXILIARY EQUIPMENT
Transformer shall be provided with LV and Neutral bushing current transformers as per SLD.
The actual CT details shall be finalized during detail engineering
SECTION‐XI TECHNICAL
SPECIFICATION
FOR
STATION TRANSFORMERS
CONTENT
CLAUSE NO. DESCRIPTION PAGE NO.
1.00.00 SCOPE OF SUPPLY VOL.II-F1/SEC-XI: 1
ATTACHMENTS
ANNEXURE-A RATINGS AND REQUIREMENTS VOL.II-F1/SEC-XI: 15
1.02.00 MVA rating of the transformer, as indicated above, shall be considered as the
minimum requirement for the project. Transformer offered by the bidder shall
be sized according to the maximum demand at most stringent condition plus
minimum 10 % margin
b) Auxiliary equipment
2.00.00 CODES AND STANDARDS
2.01.00 All equipment and materials shall be designed, manufactured and tested in
Bushing IS : 2099
3.00.00 DESIGN CRITERIA
3.01.00 The transformer will be used to supply power for units & auxiliaries.
3.02.00 The transformer will be installed in hot, humid and tropical atmosphere. All
equipment, accessories and wiring shall be provided with tropical finish to
prevent fungus growth.
b) Frequency variation : ± 5%
Continuous operation at rated MVA on any tap with voltage variation of ± 10%
corresponding to the voltage of the tap as well as in accordance with IS-6600.
In addition, all the transformers shall be able to operate at full load for at least
ten (10) minutes without exceeding the calculated winding hot spot
temperature of 150 deg.C in the event of complete failure of power supply to
cooling equipment. The transformer shall be capable of being loaded to a load
of 150% in accordance with IS 6600, IEC 60354 without any limitation
imposed by tap changer , bushing or any other equipment.
3.06.00 The transformer shall be free from annoying hum or vibration. The design
shall be such as not to cause any undesirable interference with radio or
communication circuits.
3.07.00 The noise level shall be limited to the value specified by NEMA Standard
Publication No. TR-1-1993 when measured in accordance with conditions
outlines in ANSI/IEEE C57.12.90-1999/IS13964/CBIP publication.
4.01.02 The tank wall shall be reinforced by stiffener to ensure rigidity so that it can
withstand without any deformation (a) mechanical shock during
transportation, (b) oil filling by vacuum, (c) Short circuit forces and (d)
continuous internal pressure of 35 kN/m2 over normal hydrostatic pressure of
oil.
4.01.03 All removable covers shall be provided with weatherproof, hot oil resistant,
resilient gaskets. The design shall be such as to prevent any ingress of water
into or oil from the tank.
4.01.04 The tank shall be provided with one set of bi-directional flanged wheels for
rolling the transformer parallel to either canter line over 1676 mm rail gauge.
In case more than two rails are required to be provided the rail gauge of 1676
mm shall be maintained between two adjacent rails
4.01.05 Jacking pads, lifting eyes and pulling lugs shall be provided to facilitate
movement of the transformer. All heavy removal parts shall be provided with
eyebolt for ease of handling.
4.01.07 Suitable guide shall be provided in the tank for positioning the core and coil
assembly.
4.02.00 Core & Coils
4.02.01 The core shall be built up with high grade, non-aging, low loss, high
permeability, grain oriented, cold-rolled silicon steel laminations especially
suitable for core material.
4.02.02 The coils shall be manufactured from electrolytic copper conductor and fully
insulated for rated voltage. Insulation shall be of Class A.
CPCPL-Super Critical TPP-Tharangambadi VOL.II-F1/SEC-XI : 3 DCPL-11Z02
[2 x 660 MW] Main Plant Package
4.02.03 Insulating material shall be of proven design. Coils shall be so insulated that
impulse and power frequency voltage stresses are minimum.
4.02.05 All leads from the windings to the terminal board and bushings shall be rigidly
supported to prevent injury from vibration or short circuit stresses. Guide tube
shall be used where practicable.
4.02.06 The core and coil assembly shall be securely fixed in position so that no
shifting or deformation occurs during movement of transformer or under short
circuit stresses.
4.03.00 Tapping
4.03.01 On load tap changer (OLTC) as specified in the annexure shall be provided
on the high voltage winding.
4.03.02 The transformer shall be capable of operation at its rated KVA on any tap
provided the voltage does not vary by more than ±10% of the rated voltage
corresponding to the tap.
4.03.03 The winding including the tapping arrangement shall be designed to maintain
electromagnetic balance between HV and LV windings at all voltage ratios.
4.04.00 Not applicable
4.05.00 On‐Load Tap Changer (OLTC)
4.05.01 The OLTC switch contacts shall be located in a separate oil-filled chamber
complete with its own oil preservation system, Oil Surge relay, shut-off
valves, oil level gauge, gas vent etc.
4.05.03 The tap change equipment shall be so designed that if the mechanism is
stuck in an intermediate position, the transformer shall be capable of
delivering full load without any injury.
4.05.04 The OLTC gear shall be suitable for local and remote electrical control at
ECP and local manual control. Further, there shall be provision of automatic
operation through voltage sensing relay wherever specified.
4.05.05 The hand cranking arrangement shall be such that it can be operated at
standing height from ground level. Further the mechanism shall be provided
with a tap position indicator and an operation counter.
i) Annunciations for:
o Mechanism stuck
4.05.08 Provisions shall be kept in the RTCC at ECP for serial link communication
with the plant DDCMIS.
Sr.
PROPERTY PERMISSIBLE VALUES
No
4.07.00 Bushing
4.07.01 Bushing rated below 52KV voltage class shall be solid porcelain or oil
communicating type.
4.07.03 Bushing location shall provide adequate phase and ground clearances.
4.08.02 High voltage terminals shall be brought out thru' top cover mounted bushings
with matching flanges around each bushing for connection to isolated phase
bus. The contractor shall furnish all necessary details in this connection for
co-ordination with the bus duct and shall guarantee the matching dimensions
within close tolerance.
4.08.03 Low voltage terminals shall be brought out thru' sidewall mounted bushings.
For bus duct connection, bushings shall have matching flange around. For
cable connection, a detachable type cable end-box with disconnect links shall
be furnished.
4.08.04 Low voltage winding neutral shall be brought out thru' side wall mounted
bushing to a detachable cable end-box with disconnect link.
4.08.05 The cable end-box shall be self-supporting, weather-proof, air filled type,
complete with all hardware such as gland plate, brass glands, tinned copper
lugs, armour clamps etc.
4.09.02 Transformer fitted with multiple cooling units but without having stand-by
cooling unit/s, it shall be able to deliver its rated output not exceeding
specified temperature rise and calculated hot-spot temperature of 150°C
under following conditions:
4.09.03 The radiators shall be detachable type with top and bottom isolation valves to
permit the removal of the same without drainage of oil from the tank.
4.09.04 All fans shall have safety guard. Pumps shall be provided with flow indicators
for visual indication of oil flow.
4.09.06 Complete control for fans inclusive of all switches, fuses, starters, relays and
wiring shall be furnished. Each motor circuit shall have over load and short-
circuit protection.
4.09.07 Fan motor controls will be actuated automatically from winding temperature
indicator contacts. Provision shall however be kept for manual operation from
local cooler control panel and remote from respective control room by serial
link communication with the plant DCS in addition to ECP.
4.11.02 All terminal blocks for Owner/Purchaser's cable connection shall be located in
this box. The terminal blocks shall be ELMEX 10 mm2 or approved equal.
4.11.03 The marshalling box shall be provided with cubicle lamp with door switch,
space heater with thermostat and removable cable gland plate.
4.12.00 Wiring
4.12.01 All control, alarm and indication devices provided with the transformer shall
be wired upto the terminal blocks.
4.12.02 Wiring shall be done with flexible, 1100V/650V grade PVC wires in conduit or
PVC armored cable. Minimum wire size shall be 2.5-mm2 copper. Not more
than two wires shall be connected to a terminal. 10% spare terminals shall be
provided.
4.12.03 Multi-way terminal block complete with mounting channel, binding screws and
washers for wire connections and marking strip for circuit identification shall
be provided for terminating the panel wiring. Terminals shall be stud type,
suitable for terminating 2 nos. 2.5 mm2 stranded copper conductor and
provided with acrylic insulating cover. Terminals for C.T. secondary leads
shall have provision for shorting and grounding.
4.12.04 All devices and terminal blocks shall be identified by symbols corresponding
to those used in applicable schematic or wiring diagram. Each wire shall be
identified, at both ends, with interlocking type permanent markers bearing
wire numbers as per Contractor's Wiring Diagrams. AC / DC wiring shall have
separate color-coding.
4.12.05 Wire termination shall be made with crimping type connectors with insulating
sleeves. Wires shall not be spliced between terminals.
4.13.00 Grounding
4.13.02 Grounding pad shall have clean buffed surface with two tapped holes, M10
G.I. bolts and spring washers for connection to 75x10 mm G.I. flat.
4.13.03 Ground terminals shall be also provided on marshalling box to ensure its
effective earthing.
4.13.04 For continuity of earth connection, all gasketted joints shall be provided with
braided copper wire jumpers.
4.14.02 Isolating switch fuse unit shall be provided for each of the incoming supply
along with automatic changeover scheme to switch on to the station source
in case of failure of the normal supply.
4.15.02 The arrangement shall be such that the C.T. can be removed from the
transformer without removing the tank cover.
4.16.00 Painting
The cleaning and painting procedure shall be as indicated in CBIP Manual on
Transformer – Publication No: 295 clause 1.6.The procedure need to be
submitted during engineering and to be approved by owner/consultant
4.16.01 All steel surfaces shall be thoroughly cleaned by sand blasting or chemical
agents as required, to produce a smooth surface free of scales, grease and
rust.
4.16.02 The internal surfaces in contact with insulating oil shall be painted with heat
resistant insulating varnish which shall not react with and be soluble in the
insulating liquid used.
4.16.03 The external surfaces, after cleaning, shall be given a coat of high quality red
oxide or yellow chromate primer followed by filler coats.
4.16.04 The transformer shall be finished with two coats of RAL7032 paint unless
otherwise specified.
4.16.06 Sufficient quantity of touch up paint shall be furnished for application after
installation at site.
4.16.08 All supporting structures and hardware shall be hot dip galvanized.
4.17.00 Transportation
4.17.01 Transformer tank shall be dispatched filled with oil or pure dry inert Nitrogen
gas depending upon the transport weight limitations. A positive pressure of 2
to 2.5 Psi at temperature of 36oC approximate shall be kept. In case the tank
is filled with oil, sufficient space is left above the oil to take care of the
expansion of the oil. The space is filled with pure dry air or inert gas under
atmospheric pressure.
The temperature and pressure at the time of gas filling shall be marked on a
tag. A graph showing pressure vs. temperature shall be attached for reading
pressures at different temperatures. Necessary valves, two-stage pressure
regulators, filled up Nitrogen cylinder etc. along with other accessories
required shall be provided with the tank for intermittent replenishment during
transportation.
4.17.02 Impact Recorder
Impact recorder/indicator shall be provided to monitor the impact experienced
by the transformer during transport.
5.00.00 TESTS
5.01.00 Routine Tests
During manufacture and on completion, all transformers shall be subjected to
the routine tests in accordance with latest IEC 60076 and its different parts.
5.01.01 Transformer tank with coolers shall be tested for leaks with normal head of oil
plus 35 KN/m2 for a period of 8 hours. If any leak occurs, the test shall be
conducted again after all leaks have been repaired.
5.01.02 During fabrication stage, the tank shall be pressure tested with air at a
pressure corresponding to twice the normal head of oil or normal pressure
plus 35KN/m2 whichever is lower for a period of one hour. Also the tank
designed for full vacuum shall be tested for maximum internal pressure of
3.33KN/m2 for one hour. The permanent deflection of flat plates shall not
5.01.03 After assembly, each core shall be pressure tested for one minute at 2KV
(r.m.s.) A.C. between all bolts, side plates, structural steel works and the
core.
5.01.04 The wiring for auxiliary power and control circuitry shall be subjected to
withstand one minute power frequency test with 2.0KV (r.m.s.) to earth
5.01.07 Frequency Response Analysis test (This test shall also be undertaken by the
manufacturer at site after transformer is installed.)
k. Current error, phase displacement and composite error (for protection CTs)
5.03.00 Miscellaneous
All component parts and auxiliary equipment such as oil, bushings, C.Ts
etc.shall be routine tested as per relevant Indian Standards.
5.04.00 Test Witness
Tests shall be performed in presence of Owner/Purchaser's representative if
so desired by the Owner/Purchaser. The Contractor shall give at least fifteen
(15) days' advance notice of the date when the tests are to be carried out
5.05.00 Test Certificates
5.05.01 Certified reports of all the tests carried out at the works shall be furnished in
six (6) copies for approval of the Owner/Purchaser.
5.05.02 The equipment shall be dispatched from works only after receipt of
Owner/Purchaser's written approval of the test reports.
6.02.00 The tools shall be shipped in separate containers, clearly marked with the
name of the equipment for which they are intended.
7.02.02 Transport/shipping dimensions and weights, space required for handling parts
for maintenance.
7.02.05 Type test certificates including short circuit test report of a similar transformer
(as per the guidance for identification of a similar transformer as defined in
Annexure-A of IEC 60076-5). The type test certificates shall not be more than
5 years old.
7.03.05 Flow diagram of the cooling system showing the number of cooling banks,
7.03.08 GA of Marshalling Box, Cooler control panel, OLTC cabinet, RTCC panel as
applicable (A).
7.03.14 Any other relevant drawing or data necessary for satisfactory installation,
operation and maintenance (R).
The manual shall clearly indicate method of installation, check-ups and tests
to be carried out before commissioning of the equipment.
7.04.00 The Bidder may note that the drawings, data and manuals listed are minimum
requirement only. The Bidder shall ensure that all other necessary write-ups,
curves and information required to fully describe the equipment offered are
submitted with his bid.
7.05.00 The drawings and documents marked with (A) above are of ‘Approval’
category and are subject to review by Owner. Those marked (R) are for
‘reference’ category.
The Owner /Purchaser may review the documents marked (R) if thought
necessary. The contractor shall note that the approval of drawings &
documents by the owner does not relieve him of his contractual obligation.
7.06.00 All drawings shall be prepared by using AutoCAD and documents shall be
generated using Electronic version. The paper copy of the drawings &
document shall be submitted for approval & reference. All final drawings and
documents shall be submitted in CD in AutoCAD 2000 and M.S. Office format
as applicable for Owner’s future reference.
RATINGS AND REQUIREMENTS FOR 400KV STATION TRNASFORMER (OBAT01)
1.0 Application : Station Transformer
10.0 Cooling system
a) in oil by thermometer : 50 oC
b) in winding by resistance : 55 oC
d) Automatic : Yes
H.V. : Unearthed
HV Side : 40KA(r.m.s)
LV Side : 44 KA (r.m.s.)
23.0 Max. Flux density in any part of core & : 1.9 Tesla
Yoke at 110% rated voltage
24.0 Max. Noise level in accordance with : As per NEMA std. TR-1
Conditions specified in NEMA Std. TR-1
RATINGS AND REQUIREMENTS FOR 230KV STATION TRNASFORMER(OBAT02)
1.0 Application : Station Transformer
10.0 Cooling system
a) in oil by thermometer : 50 oC
b) in winding by resistance : 55 oC
d) Automatic : Yes
H.V. : Unearthed
HV Side : 40KA(r.m.s)
LV Side : 44 KA (r.m.s.)
23.0 Max. Flux density in any part of core & : 1.9 Tesla
Yoke at 110% rated voltage
24.0 Max. Noise level in accordance with : As per NEMA std. TR-1
Conditions specified in NEMA Std. TR-1
FITTINGS AND ACCESSORIES
Transformer shall be equipped with fittings and accessories as listed below: -
1. Oil conservator with filler cap, drain plug, plain oil level gauge and alarm contacts for
rupturing of bellows/diaphragm.
4. Pressure release device with trip contacts. Explosion vent, if provided, should be
double diaphragm type.
5. 150 mm dial magnetic oil level gauge with low level alarm contacts
6. 150 mm dial oil temperature indicator with maximum reading pointer and electrically
separate contacts for trip and alarm and embedded temperature detectors (PT-100)
with suitable output for remote indication (data logging).
7. 150 mm dial winding temperature indicator with maximum reading pointer and
electrically separate sets of contacts for trip, alarm and cooler control and embedded
temperature detectors (PT-100) with suitable output for remote indication (data
logging).
9. Thermometer pockets.
10. Double float Buchholz relay with gas release cock, shut-off valve on either sides with
separate sets of contacts for trip and alarm.
21. Ladder with safety device for access to the top of transformer tank.
22. Weather proof marshalling box for housing control equipment and terminal
connections.
25. Cooler units complete with valves, fans, supporting structure with fixing and
foundation bolts etc as required and Cooler Control panel.
26. Tap-changing gear complete with tap position indicator, operation counter etc. For
OLTC gear , oil surge relay(OSL) with shut-off valve, Local control cabinet and
Remote Tap Changer Control (RTCC) at ECP
Note: All indication, alarm, trip contacts provided shall be rated for 0.5A at 220 V D.C. and
5A at 240 V A.C.
AUXILIARY EQUIPMENT
Transformer shall be provided with LV and Neutral bushing current transformers as per SLD.
The actual CT details shall be finalized during detail engineering