Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9035 Date 18-Jul-12 Page 1 of 12

METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT

Project Document No: G3IR105065SP9035

Unit: Discipline: Document Type:

General Electrical Specification

Document Title: SPECIFICATION FOR METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT (6.6 kV, 1600 A)

ISSUED FOR DESIGN

08 Aug 2012
DISCLAIMER THIS DOCUMENT DEVELOPED BY FLUOR DANIEL INDIA PRIVATE LIMITED, IS THE PROPERTY OF BASF INDIA LIMITED AND THIS DOCUMENT CANNOT BE REPRODUCED, COPIED, DISTRIBUTED DIRECTLY OR INDIRECTLY OR OTHERWISE USED WITHOUT EXPRESS WRITTEN PERMISSION OF BASF INDIA LIMITED FOR ANY PURPOSE OTHER THAN FOR THE PROJECT FOR WHICH IT IS FURNISHED.

1 0 Revision

30-Jul-12 18-Jul-12 Date

Issued for Design Issued for RFQ Purpose

RR RR Prepared By

NG NG Checked By

VP VP Fluor BASF

Approved By

G3IR-1050-65-SP-9035_R0

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9035 Date 18-Jul-12 Page 2 of 12

METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. 0 1 Date Description

18-Jul-12 30-Jul-12

Issued for Design (RFQ) Issued for Design

G3IR-1050-65-SP-9035_R0

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9035 Date 18-Jul-12 Page 3 of 12

METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT

TABLE OF CONTENTS

1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 3.0 4.0 4.1 4.2 4.3 4.4 4.5 5.0

GENERAL .................................................................................................................................................. 4 Scope......................................................................................................................................................... 4 References ................................................................................................................................................ 4 System Description.................................................................................................................................. 5 TECHNICAL REQUIREMENTS ................................................................................................................ 5 General ...................................................................................................................................................... 5 Rating ........................................................................................................................................................ 6 Basic Construction .................................................................................................................................. 6 INSPECTION AND TESTS ...................................................................................................................... 10 MISCELLANEOUS REQUIREMENTS .................................................................................................... 11 Painting ................................................................................................................................................... 11 Rating Plate, Labels & Serial Number .................................................................................................. 11 ACCESSORIES ....................................................................................................................................... 11 SUPPORT STRUCTURE......................................................................................................................... 12 Product Delivery and Handling ............................................................................................................. 12 DRAWINGS & DOCUMENTS ................................................................................................................. 12

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9035 Date 18-Jul-12 Page 4 of 12

METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT 1.0 GENERAL 1.1 Scope 1.1.1 This specification is intended to cover design, engineering, procurement,

manufacture, inspection and testing at manufacturers works, packing, loading, forwarding, transport and delivery to site, testing and commissioning at site of Metal enclosed Phase-segregated MV bus duct. 1.1.2 The specific requirements for Metal enclosed Phase-segregated MV bus duct shall be given on data sheets. 1.1.3 The bus duct shall connect power transformer (66/6.6 kV, 16 MVA), located outside the substation, to MV Switchgear (6.6 kV), inside the substation. Supplier shall provide all necessary terminations, fittings ,thermal expansion, splice plates, flexible connectors, and required hardware including supporting structure. 1.1.4 1.2 Seller shall furnish any special tools and tackles for installation and maintenance.

References 1.2.1 Following are the standards that have been consulted in this specification: Colours for ready mixed paints and enamels Copper Rods and Bars for general engineering purpose Interconnecting bus-bars for ac voltage above 1kV upto and including 36kV Degrees of protection provided by enclosures 1.2.2 IEC 60529 IS 5 IS 4171 IS 8084

In case of any contradiction between various referred standards/specification/data sheets and statutory regulations, it shall be brought to the notice of Client for resolution, before taking a decision. Generally the following order of priority shall govern : Statutory regulations BASF Guidelines Data Sheets This specification Codes and standards

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9035 Date 18-Jul-12 Page 5 of 12

METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT 1.2.3 The supplier shall inform/consult the owner / consultant in case there is a conflict among the above documents at the bid stage itself. 1.2.4 The components and materials used and the equipment supplied shall conform to high standards of design, engineering and workmanship and shall be suitable for efficient operation and reliable service in ambient conditions. 1.3 System Description 1.3.1 The system voltage and frequency shall be as per datasheets and variation in these will not be more than: Voltage: Frequency: 1.3.2 6.6kV 10% 50 Hz 5 %

The equipment shall be designed for a design ambient temperature of +45oC and an altitude not exceeding 1000 meters above mean sea level. Relative humidity of 92% shall be considered for design.

1.3.3

The equipment shall be suitable for operating satisfactorily outdoors in saline atmosphere.

2.0

TECHNICAL REQUIREMENTS 2.1 General 2.1.1 The bus duct shall be rectangular, metal enclosed, phase segregated type having insulated bus bars and shall consist of horizontal and vertical, straight and angle sections, outdoor type construction. 2.1.2 Bus Duct shall comprise of following sections, as applicable, to make the installation complete and to match with the terminal equipment: Switchgear lead-in section with flexible hood. Straight section in standard length Matching section (length as required) Transformer lead-in section Corner sections (horizontal and vertical) Phase cross-over section 240V AC space heater to be provided at suitable intervals and wired to external terminal box with heat resistant cables.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9035 Date 18-Jul-12 Page 6 of 12

METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT Silica gel breathers at appropriate locations. Horizontal bends to be avoided by positioning the switchboard incomers at appropriate place. 2.1.3 2.1.4 Bus-duct supports

Appropriate metal support components and hardware shall be furnished. The components described above shall be complete and fully factory assembled except for shipping split. Mounting and interconnection required in the field shall be minimum and simple.

2.1.5

The bus-duct shall be sectionalised for ease of handling and erection at site. All metallic non-current carrying parts of each section shall be connected to earth busbar and be terminated at both ends.

2.2

Rating 2.2.1 Rated continuous current capability shall be as specified in data sheet while in enclosure and at specified ambient temperature with maximum temperature of bus bars limited to 95 C. 2.2.2 The temperature rise of conductor shall be as per IS: 8084. Also the temperature of the bus shall not exceed 250C while carrying the specified short circuit current for one second when a fault occurs at the operating temperature. 2.2.3 System Insulation Level Insulation level / Rated insulation voltage One minute power frequency voltage Clearance in air (minimum) 2.2.4 Short circuit strength Rated short time withstand current not less than the system short circuit level specified for 1 sec. duration. Rated peak withstand current not less than 2.1 times the system short circuit level. Phase to phase (mm) Phase to earth (mm) : : 90 mm 90 mm : : 6.6kV / 7.2 kV 28 kV

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9035 Date 18-Jul-12 Page 7 of 12

METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT 2.3 Basic Construction 2.3.1 General The bus-ducts shall be of rectangular profile. The bus-bars shall be totally enclosed inside a 3mm thick M.S., dust and damp protecting, heavy duty, air filled enclosure with degree of protection IP55 minimum for outdoor locations and IP34 for indoor locations. The supplier shall provide flexible terminations and connecting flanges as required for the termination of the bus-bars to the transformer and switchgear. The termination arrangement drawings at the transformer and switchgear end shall be provided later to the bus-duct manufacturer. The bus-duct installation shall be suitably designed to accommodate expansion and contraction during all modes of operation and accommodate civil building tolerances and settlements. Bus-duct shall be provided with minimum 2 drain holes, one for outdoor section and one for indoor section. Drain holes shall be located on the underside of the duct. The drain holes shall be covered by drain plugs which shall be removed for drainage. Bus-duct shall be provided with two silica gel breathers, one on the outdoor section and one on the indoor section. Silica gel breather transparent material shall be UV stabilized type. The enclosure shall be equipped with anti-condensation heaters of sufficient capacity to prevent the formation of condensation within the enclosure under the service conditions. Bus-duct shall be supplied with suitable earth bus made of GI strip running along the length of the bus. Inspection doors shall be provided on top of the bus-duct on raised flanges. Inspection flanges shall be of bolted design with gaskets to provide the required enclosure protection. Flanges and covers shall have circumferential interlocked neoprene gaskets. Bus-ducts and connections shall be sized, braced and supported to withstand the mechanical forces and thermal effects equal to the connected switchgear rated short circuit current and carry certification from a recognized testing authority.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9035 Date 18-Jul-12 Page 8 of 12

METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT 2.3.2 Enclosure The bus duct shall have gasketed removable covers where required for assembly or inspection purposes. Buses directly supported on switchgear enclosures or building walls and at transformers mounted on separate pads shall have provisions to prevent undue strain on the transformer bushings Wall penetration fittings shall be provided by supplier as required and shall be weather resistant and watertight to wind driven rain. All mating surfaces of the enclosure shall be provided with rain hood. Outdoor horizontal section of the bus-duct shall be provided with rain canopy made of 2mm thick CRCA sheet steel. Support insulators shall be Solid core cast epoxy type for MV bus-ducts with minimum creepage distance of 31mm per kV. All bus-duct supports shall be hot dip galvanized. Indoor Bus-Duct Support shall be from ceiling / wall of the Substation. Outdoor bus-duct support shall be from the floor / Wall of the transformer yard / substation building. The supporting structures shall include supporting members, brackets, hangers, longitude longitudinal beams, channels, nuts, bolts, washers and all other hardware which are necessary for the erection and support of the entire bus duct installation. The bus-duct shall be designed for a maximum deflection of 0.0015 of the distance between support points. 2.3.3 Phase Bus-Bars The bus-bars shall be capable of withstanding the conditions imposed by the symmetrical short circuit currents indicated in the datasheet(s), the peak asymmetrical fault current shall be considered as 2.5 times the symmetrical R.M.S. fault current rating. The bus-bars shall be of Aluminum (EC grade aluminum alloy equivalent to E91E WP conforming to IS 5082) and completely insulated with an extruded insulation. Joints and splice plates shall be silver plated and enclosed by insulated boots or equivalent means The insulation of bus-bar shall be flame retardant, non-hygroscopic and corrosion resistant.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT Phase identification by color at both ends and at regular intervals shall be provided along the entire length of bus-duct. All bus-bar connections shall be bolted. Bolts shall pass through the bus bar conductors, capable of being properly torqued and locked in place, to provide and maintain full and uniform pressure under all operating conditions. Torque requirements in Kg-m or Nm shall be furnished by Manufacturer. Bus-bar shall have Flexible connections for termination on equipment side. Bus-bar expansion joints on straight runs with joints shall be staggered in adjacent phases. Bimetallic joints shall be used for jointing between dissimilar metals. The bus conductor shall be given a coat of matt black paint to facilitate heat dissipation. The bare conductor with above painting shall be designed to carry the normal rated current without exceeding temperature rise as specified in IS: 8084. 2.3.4 Phase Barriers In segregated phase bus duct, metal barriers shall be provided, the material shall be same as that of the bus duct enclosure material. Insulated phase barriers, when specified, shall be made of non-hygroscope insulating material such as fiber glass. 2.3.5 Space Heater The anti-condensation heaters shall be supplied from external 240V AC single phase supply provided by Client. The anti-condensation heaters shall be prewired in steel conduit and terminated in an IP54 marshalling box located at the switchgear end fitted with an undrilled gland plate and warning labels. A double pole MCB for switching on the heater and thermostat shall also be provided. 2.3.6 Wall Frame Assembly and Seal-Off Bushings Wall Frame Assembly Wherever the bus duct passes through the plant building wall, from indoors to outdoors, a wall frame assembly with seal-off bushings shall be provided to prevent any leakage of rain water, infiltration of dust and air temperature variations from indoors to outdoors. The wall frame shall be fabricated out of aluminum angles and sheet and shall be suitable for grouting in the wall. It shall be provided with flanges on both

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT sides to receive the bus duct flanges. A suitable size breather shall be provided for the two sections of the bus duct between the wall frame assemblies, if specified. Seal-off Bushings The bus duct shall be equipped wherever necessary with seal-off bushings to prevent interchange of air at different temperatures. The seal-off bushings shall be epoxy painted flanged type. Material The insulator for wall frame assembly and seal-off bushings shall be of porcelain. Also the bushings shall be designed for thermal

expansion/contraction due to temperature differential for outdoor / indoor use. 3.0 INSPECTION AND TESTS 3.1 Bus-ducts shall have been type tested by a recognized testing authority or short circuit withstand capability in accordance with the relevant standards. Copies of the type test certificates with the quotation to prove that tests have been carried out adequately to demonstrate the short circuit capability of each rating of bus-duct quoted shall be submitted. 3.2 All bus-ducts shall be subjected to the routine tests, except those that undergo type tests as indicated below. The bus-duct manufacturer shall provide certified test results of all the routine tests carried out on each bus-duct. Routine tests shall be witnessed by Client or Client's representative. Type tests if any specified in the requisition shall be carried out as indicated below: 3.2.1 Routine Tests Routine tests shall comprise of the tests listed below as a minimum. 3.2.2 Insulation Resistance Test High Voltage Power frequency withstand Test Phase sequence test Electrical and functional tests of all accessories.

Type Tests Type tests shall comprise of the tests listed below as a minimum. Short circuit withstand test. Temperature rise tests on one straight section of each rating. Partial discharge test Tests to indicate the IP rating of the indoor and outdoor enclosure sections.
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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR-1050-65-SP-9035 Date 18-Jul-12 Page 11 of 12

METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT 4.0 MISCELLANEOUS REQUIREMENTS 4.1 Painting 4.1.1 Bus-duct shall have two coats of epoxy paint for outdoor and synthetic enamel paint for indoor application, preceded by de-rusting, cleaning chemically, degreasing, pickling in acid, cold rinsing, phosphating, passivating and spraying with two coats of zinc oxide primer. 4.1.2 Shade of paint: 4.2 Interior : Black Exterior : RAL 7036 (unless otherwise specified)

Rating Plate, Labels & Serial Number 4.2.1 Every bus-duct shall be provided with two rating plates, one at transformer end and the other at switchgear end. Rating plates shall be made of stainless steel and shall be securely fixed to a non-removable part of the bus-duct enclosure by rivets. 4.2.2 4.2.3 Labels and danger plates shall be riveted and not fixed by adhesive. The rating plates shall be marked with data in accordance with Codes and Standards. The values provided shall, as far as possible, be those actually measured and shall be based on the specified operating conditions. 4.2.4 Following data shall be given in addition: Manufacturers name. Rated voltage. Rated frequency. Rated fault current. IP Rating of outdoor and indoor sections. Clients Purchase Order number and Order date. Bus-duct tag number. Manufacturer's order number, serial number, month and year of manufacture.

4.3

ACCESSORIES A complete set of any special tools required for operation, maintenance and testing of the bus-duct shall be provided by bus-duct supplier.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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METAL ENCLOSED PHASE SEGREGATED MV BUS DUCT 4.4 SUPPORT STRUCTURE The structure design shall be such that during operation of bus duct, vibrations are reduced to minimum. For steel support structure specification, refer G3IR-1050-65-SP-9042_R0 4.5 Product Delivery and Handling Upon successful completion of testing and inspection requirements delivery shall be made according to the following: 4.5.1 The site receiver shall be advised of space required for storage, equipment recommended for unloading, and measures needed for preventing damage during unloading and during storage before installations. 4.5.2 Protect the equipment from damage, dirt and weather during transporting. Provide touch-up paint for field use. 4.5.3 Each Shipping Section shall be provided with removable lifting angles, plates, or devices suitable for hooks, slings, or fork lifting as necessary. 4.5.4 In addition to required manufacturer's nameplate, each section shall be tagged with weatherproof tag showing equipment number. 4.5.5 Packaging and Crafting Assemblies shall be shipped fully assembled whenever feasible. When equipment must be disassembled for shipment, material and instructions shall be provided including all hardware necessary for reassembly. Packaging material to be removed prior to energization shall be clearly identified by distinctive colors, legends and instructions. 5.0 DRAWINGS & DOCUMENTS The Vendor shall furnish drawings in accordance with SDDC form, enclosed with the Bid.

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