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Motor Control Center

I.6 SCOPE

6.1 This section of the specification covers the design, engineering, manufacture, testing
before dispatch and guarantee for two years of Station Power Supply Facilities for Umiam
Stage-II Hydro Electric Power Station as stated below:

6.1.1 The scope of supply shall include all parts, accessories, spares, etc., which are
necessary for construction, operation and maintenance of complete equipment though these
are not individually and specifically stated or enumerated. Corresponding parts of all the
equipments and the spares shall be of the same material, dimensions, workmanship and finish
and shall be interchangeable. All the materials and workmanship shall be of suitable
commercial quality as have proven successful in their respective uses in similar services and
under similar conditions.

6.1.2 The scope of the supply includes the following:

No.
Qty
(1)
Motor Control Center One (1) set

6.1.3 In addition to the above, the bidders shall offer following services:
The Contractor shall design the facilities without modification and/or changing the major
important relative locations and spaces for the MCCs. Refer to relevant drawings and
subsection of this specification.

I-6.3 QUANTITY AND RATINGS OF MCCs

6.3.1 Required number
One (1) set of Motor Control Center shall be supplied. The set shall be composed of
following cubicles and main components.

Name of Cubicle Required number Main Components
Motor Control Centers One(1) Molded case circuit breakers,
contactors, thermal overload
realys, control devices, relays,
switches, status & fault
indications. etc.

6.3.3 Ratings
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(1) AC 415 V circuits

(a) Operating Duty Continuous

(b) Rated Voltage AC 415 V

(c) Rated Frequency 50 Hz

(d) Rated Nominal Current for Bus 400 A

(e) Rated Short-time Withstand Current for bus 12 kA, 2 second

6.3.4 Temperature Rises

Limits of temperature and temperature rises for various parts, materials of the metal-
enclosed switchgear shall be complied with the latest edition of IEC 60947.

I-6.4 CONSTRUCTIONS OF STATION POWER SUPPLY FACILITIES
The station power supply facilities shall be designed to comply with the requirements in the
latest edition of the IEC 60947 & IEC 60439 standard.

The station power supply facilities shall be equipped with protection of equipment against
external influences and protection against approach to or contact with live parts and
against contact moving parts to meet with the requirement of IP 31 degree of the
protection.

The frame of the station power supply facilities shall be made of angle steel. The enclosure
and
separation of those, on the other hand, shall be made of hot or cold rolled steel of which
thickness
shall not be less than 2 mm. But, 1.6mm or more thickness could be acceptable for the-top
plate of those.

Ventilating openings and outlets, for the station power supply facilities shall be so
provided that IP 31 degree of the protection also required on the enclosure is obtained. The
wire mesh or the equivalent having suitable mechanical strength may be acceptable to
apply for the ventilating openings and outlets Lifting eyebolts or other means for handling
shall be provided at the top four corners of each board of the station power supply facilities
.An earthing copper-made conductor shall be provided extending the whole length of the
station power supply facilities.
The main bus shall be three-phase air insulated high-conductivity copper bars with ample
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continuous current-carrying capacity, supported by post insulators or other means having
suitable insulation. Silver plating shall be made on all the connecting surfaces of the bus
conductors, and all the connections of the bus bars shall be firmly bolted with lock washers
and nuts. All the joint parts shall be designed so as to prevent the bolt connection from
being loosened by vibration and/or thermal expansion and shrinking.


The cubicles shall be equipped with thermostatically controlled space heaters having
temporarily set to close on falling temperature at 15
o
C (ON) and open on rising
temperature at 30
o
C (OFF) in order to prevent condensation within the cubicle with
operating voltage at 200 V, 50Hz. These shall be facility for adjuster to keep range at air.

I 6.5. Design & Construction

(1) General

Service Conditions
All the Equipment shall be designed and manufactured for satisfactory operation at the
following conditions:

(1) Ambient temperature and humidity

(1-1) Maximum ambient temperature 35 C
(1-2) Minimum ambient temperature

(a) Outdoor 5 C
(b) lndoor 9C

(1-3) Maximum relative humidity 95%

(2) Earthquake acceleration

(1-1) Horizontal acceleration 0.66 g
(1-2) Vertical acceleration 0.44 g

Terminal Blocks and Wiring
(1) All insulating control and other auxiliary wiring for circuit of not more than
415/240 volts alternating current or 110 volts direct current shall be not smaller
than 1.5 mm2. All insulating wiring for secondary circuit of current
transformers shall not be less than 2.5 mm2. The conductors of wires shall be
stranded, tinned, copper with insulations.

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The individual temperature detector leads shall comprise a three-conductor cable
which is oil, moisture, and heat resistant. The cable shall have armor protection
against mechanical damage. The conductors shall be stranded, tinned, copper with
insulation system having a temperature rating of at least 105 C.

The leads from speed signal devices to governor through terminal boxes and from
temperature detectors to thermometers and/or temperature recorders through terminal
boxes shall be shielded. Outlet leads from transducers shall also be shielded. In
addition, any other outlet cables that would be subject to induced signals should be
shielded.

All instruments, relays and auxiliary devices or equipment and accessories shall be
furnished, mounted and wired.

Wiring thereof shall be connected by crimp-type terminals (e.g. AMP terminal).

(2) The wirings shall be gathered to one place to facilitate the connection with
outgoing cable Connection of which shall be made at terminal blocks.

(3) Both ends of low voltage wires shall be terminated by crimp-type terminals with
insulation colored sleeve (e.g. AMP terminal pre-insulated) and provided with
the terminal number rings, and the number shall be recorded in the wiring
diagram.

(4) The interior wirings of the control cabinets, control boards, motor control
centers, metal-enclosed cubicles and switch boxes shall be concentrated to the
terminal blocks with removable transparent insulation cover and the terminal
numbers installed at the lower part of the equipment in order to be connected
easily to external cables.

(5) DC circuit shall be separated by a terminal block provided on each control
board, cubicle, motor control center, control cabinet and control box for easy
detection at grounding fault.

(6) The terminal blocks shall be of the 1100 V molded block type with insulating
barrier between terminals. The terminal block for current transformer
secondary circuit shall be of short-circuit type. The terminal block shall be
attached with a removable transparent insulation cover and the terminal
numbers.
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(7) Each terminal block shall have marking strips, and shall be equipped with the
crimp-type terminal (e.g. AMP terminal pre-insulated) for No. 12 AWG (3.5
mm2 equal) or larger to make connection with outgoing cable. The terminal
blocks shall be provided with twenty-five (25) per cent of the employed but not
less than ten (10) additional terminals as spares for each control boards,
cubicle and cabinet besides the necessary number. Two (2) or more external
wires shall not be connected at one (1) terminal.

(8) The terminals of motors or other equipment shall have pressure compression
type terminal lugs with which outgoing cables are to be connected.

(9) Test terminals shall be provided on all electrical enclosures where current and
voltage transformer secondary circuits are connected the terminal shall be of
the flush type for plug system with dust-proof cover.

2.13 Cables and Electrical Conduit

(1) Cable shall conform to IEC, ICEA, IS or JIS standards specified in the relevant
clause.

(2) The Bidder shall furnish all cables that will be used for controlling, operating
and supplying power for the Equipment of the Renovation and Modernization
Project, in quantity as required.

(3) The cables shall not have cut or scratches in the insulation or protective covering
or in the C conductors. No splices shall be made in the conductors except at the
terminal blocks of the Equipment. All cables shall be marked by the Bidder at
each end with mark bands attached by the cable code numbers at cable
installation. Such cable mark bands shall be provided by the Bidder. Drawings
indicating the cable routes and cable codes shall be submitted by the Bidder
before installation.

(4) The electrical conduits and the accessories shall conform to ANSI C80-l, NEMA
FB-l or JIS standards.

(5) The Bidder shall furnish all conduits, accessories and fitting which will be
required for laying the cables in quantity as required.

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(6) All bends of conduits shall be gradual and smooth to permit the pulling of
insulated electrical wires and cables without undue stress or damage of the
insulation covering or sheath. Ends of conduit shall be fitted with bushing in
order not to injure sheath of cables or insulation coverings.

2.14 Color Coding of Wiring
(1) The following color identification shall be applied to the insulation of wires used
for back wiring of control boards, cubicles, motor control centers, control
cabinets, control boxes and auxiliary equipment.

Secondary circuit of voltage transformer Red
Secondary circuit of current transformer Black
DC circuit Blue
AC circuit except power circuit Yellow
Neutral circuit Light grey
Grounding circuit Green

(2) Three (3) phase outgoing cables shall be color coded as follows:
Phase A (or Phase U, or R) Red
Phase B (or Phase V, or S) Yellow
Phase C (or Phase W, or T) Blue
Neutral Light grey
Ground Green

(3) DC supply shall be color coded as follows:
Positive White
Negative Black
Common Light grey

2.15. Name Plates and Marking

All nameplates, card-plates, and designation shall meet the requirement of actual usage.
Name plates, card-plates, instruction plates, warning signs, and any markings whatever
on the Equipment, parts and accessories thereof shall be in the English language.




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The name plates provided on the top of the panel and/or the boards installed in the
power house, such as the cubicles for 11 -kV metal-enclosed switchgears, the panels for
control and protection boards, and the panels for station power supply facilities shall be
made of transparent materials with engraved from back-side and named- with black
letters and white ground.

The name plates provided on the surfaces of the turbines and generators shall be made
of stainless steel or bronze and the name plates of other equipments shall be preferably
made of stainless steel and indicated with the manufacturers standard indication
methods.

Aluminum photo name plates shall be acceptable for card-plates, instruction plates,
warning signs and, any marking on the panel and/or the boards installed in the power
house.

The name plates made of paper and/or corrosion-prone materials shall not be accepted.
The switch handles shall be engraved with the device function number colored in white.
The Bidder shall submit a list of the plates and/or designation for approval.

If the Bidder wants to provide to attach or affix some plates and/or labels on the
Equipment in order to give special cautions, information and/or instructions to all the
persons, visitors, operators, workers, etc. who will access the Equipment, the plates
and/or labels shall be written in English.

The detailed to be shown on the nameplates, etc. shall be indicated on the drawings for
approval.

2.16. General Requirements of the Equipment
(I) All the Equipment and parts shall be new and durable for long-term use, and
shall satisfy all requirements with which complete products should generally
comply even if such requirements are not provided in the Specifications.

(2) All the Equipment shall be of a convenient construction for disassembling,
inspection and erection. All the Equipment shall have markings, such as the
centerline mark, match mark, etc., in order to facilitate the Installation at the
Site.

(3) All surfaces of water passages shall be of even and smooth finish, and provided
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with a smooth-contoured hydraulic surface.

(4) The Bidder shall furnish all foundation materials necessary for Installation of the
Equipment including foundation base and foundation bolts and nuts.

(5) Conductors shall not be joined by soldering except for inevitable positions.

(6) Unless otherwise specified, induction motors shall be of the direct-on line starting,
drip-proof type. When these are operated, it shall not show any trouble at the rise
of both voltage and frequency of power source by 30%, resulting from the full load
rejection of the turbine-generator.

(7) Magnetic contactor used in various switches shall be made of arc resistant metal
and have sufficient capacity against closing of inrush current and tripping of over
load current, and the contact part shall be free from over-wearing and miss-contact
for a long period of service.

(8) Electric contact of dial type thermometers, thermal relays, oil level relays, oil
pressure relays, air pressure relays, limit switches, etc. shall be able to break a
current or possible maximum inductive load (2A) at 110 V DC safely.

(9) The contact surfaces (both male and female) for the circuit sheet (plug-in type
printed card) shall be gold-plated. All circuit sheets shall be suitably treated to
prevent damage to connection or components by hydrogen sulphide gas.

(10) The relays (control relays, protection relays and auxiliary relays) and meters shall
be air-sealed to prevent corrosion by hydrogen sulphide gas.

(11) The cubicles, boards, motor control centers and control cabinets shall be provided
with target type group fault indicators, unless otherwise specified in the
Specifications.

When any trouble is detected, the trouble shall be distinguished on these indicators and
contacts shall be provided in the indicators for indication.

(12) Each control board and cubicle shall be provided with at least one compact
fluorescent lamp (AC 240V, 50 Hz) inside for interior lighting, and shall be
provided with a door switch. Each cubicle, board, motor control center and control
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cabinet shall be provided with a moisture preventing heater (AC 240 V, 50 Hz) with
a switch and a thermostat, and with AC 240 V, 15 A, conventional receptacles.

(13) Each cubicle, board and control cabinet shall be provided with hinged door with
key-handle, which can be opened by a master key.

(14) The bushings, insulators and porcelain housing used in the Equipment shall have
sufficient mechanical and dielectric strength and shall meet the requirements of US
C38l4, JIS C3824, JIS C385l , ANSI C-76.l or relevant National/International
standards. The surface color of the porcelain shall be chocolate brown

(15) Parts of the Equipment which require inspection and/or replacement shall be
fastened with bolts and nuts instead of built-in bolts.

(16) The ground terminals of the Equipment shall be of the bolt-fastened type, suitable
for hard drawn copper stranded conductor.

For grounding connections in connected boards, such as control board in the
control room etc., an adequate ground bus of copper bar extending the full width of the
broad shall be provided on the lower part of the board, and the secondary circuits of
instrument transformers and shielded tapes of cables, etc. shall be connected to it.
Furthermore the ground bus of copper bar shall be connected mutually and firmly with
that of adjacent board.

(2) Design and Construction

The Motor Control Centre (MCC) shall be installed to supply low voltage power source from the AC
distribution board to auxiliary equipment for the generating units. Each circuit for auxiliary
equipment in the MCC shall be equipped with an individual breaker with an adequate frame and
over-current trip circuit.
The MCC shall also be equipped with automatic start & stop functions (sequence) for the auxiliary
equipment. The MCC shall be completely wired and equipped with sequential controllers, starters,
instruments, protective relays, switches, and lamps, indications and so on required for automatic
sequential controlling and for manual operating the auxiliary equipment to be installed in the power
station.

The auxiliary equipment to be controlled by the MCC are listed below (Refer to the drawing) :
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(2) Requirements for MCC

An independent auxiliary control cubicle shall be provided for the MCC, and shall be installed in
line with the MCC cubicles. The auxiliary control cubicle shall be equipped with all control devices,
relays and wiring necessary for auxiliary control. The status indications (30S) and fault indications
(30F) and manual/automatic changeover switch for each auxiliary shall be mounted on the front
panel of cubicle. Power Supply for MCC shall be through 225 AF/225A incomer from Common-2
AC Distribution Board.

All units in the MCC shall be completely accessible and removable from the front side.

All equipment in the power circuit shall be rated for 1100 volts. The main buses shall be rated for
400A and shall withstand 12,000A for 2 seconds under fault conditions without mechanical or
thermal damage.

A grounding bus shall be arranged on the back near the bottom of cubicle.
All starters shall be of combination type with moulded case circuit breakers. The magnetic starters
shall be equipped with three (3) overload relays (single phase) and also with at least two (2) spare
auxiliary contacts (normally open and normally close ones). All overload relays shall be of manually
reset type and adjustable for each motor current at site.
The control voltage shall be 220V AC. If necessary, control transformers with an adequate rating
and suitable protection shall be provided for the MCC cubicles. Counter-measure shall be taken for
each starter to reduce an inrush current at motor starting, if necessary.

i) Industrial type ammeters for each unit shall be mounted on the front panel of MCC
and shall have a suppressed scale for starting current and motor full load current
deflections at roughly two-thirds of the scale.

j) All ratings indicated in the MCC and name plates mounted on the MCC shall be written in
English. All indications and name plate shall be indicated in the approval drawings.

I 6.6 Description of the Operation

Refer to the control block diagrams & MCC SLD for details of Motors & Control Logic




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Two (2) governor oil pumping units for Unit 1 & Unit 2
The start and stop of the oil pumps shall be controlled automatically by the pressure relays
for the pressure oil tank. Pressure oil pumps shall have provision for starting (sequential
operation) during machine starting/stopping from Plant Control System. Changeover of the
oil pump from regular use to stand-by or vice versa shall be manually made by the selector
switch, and each pump shall start and stop manually by the switch mounted on the motor
control center(MCC). Motor capacity is 7.5 kW. Starting method is direct-on line.

One (1) automatic valve at intake line from penstock
MCC shall have facility for control of motor for automatic opening & closing of automatic
valve at intake line of penstock valve during machine starting/stopping.

One (1) sand discharge valve for filtering tank
Motor operated sand discharge valve shall be operated by a timer through the Motor Control
Center (MCC).
Motor rating is 0.2 kW.

Two (2) automatic main strainers & two(2) sand discharge valves for automatic main
strainers
Motor driven strainers shall be provided for the cooling water supply system. One (1)
strainer shall be used for normal (duty) operation, while the other shall serve as a stand-by.
The main strainer shall be operated by an adjustable timer and/or a differential pressure
switch through the Motor Control Center (MCC). Changeover of the strainer form normal
use to standby or vice versa shall be manually made by the selector switch, and each strainer
shall also start & stop manually by the switch mounted on the Motor Control Center.
Motor rating for automatic strainers is 0.4 kW and for sand discharge valves is 0.2 kW.

Two (2) L.P. air compressor units for common
One (1) compressor shall be used for normal (duty) operation, while the other shall service
as a stand-by. The standby compressor shall automatically start when main compressor will
fail to operate.
The start and stop of the compressor shall be controlled automatically by the pressure relays
for the main air tank. Changeover of the compressor from regular use to stand-by or vice
versa shall be manually operated by the selector switch mounted on the motor control center.


Two (2) drainage & dewatering pumping units for power house drain pit
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One (1) pump shall be used for normal (duty) operation, while the other shall service as a
stand-by. The stand-by pump shall start automatically when the water level in the pit
becomes higher than the predetermined level or the normal operating pump fails, and stop
automatically when the water level becomes lower than the predetermined level. Start and
stop operation for the pumps shall be controlled from the Motor Control Center (MCC).

6.7 Spare Parts

S. No. Description Quantity
1 Electromagnetic Contactor One(1) each type
2 Molded case circuit breaker One(1) each type
3 Lamp (In case of LED applied, LED shall be
supplied instead)
Two(2) sets
4 Thermal relay (Each type) Two(2) nos


6.8 Test

Supplier shall provide all type tests reports as per IEC. Routine tests shall be done as per suppliers
own test procedure. Supplier shall submit list of routine tests to be conducted in factory along with
the offer.

6.9 Painting

(1) All the Equipment shall be painted as herein specified. The painting of metalwork shall
include the preparation of the metal surfaces, paint application, protection and drying of the
paint coating as well as the supplying of materials necessary for the entire painting work.
Paints shall be the products of recognized and reputable manufacturers, and proposed
paints shall be approved by Owner.

No painting is required on bronze or corrosion-resisting steel, on rolling or sliding
surfaces or on metal surfaces to be embedded in concrete.

All finished mating surfaces of ferrous metal, including gear teeth, screw threads, bores of
servomotor cylinders, pistons, stems, etc., shall be protected with a heavy coating of
rust preventative compound which shall be readily removable with mineral spirits or
safety solvents.

(2) All metal surfaces to be painted shall be properly treated or cleaned as described herein
prior to the application of paints.
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The methods of surface preparation shall conform to the prescribed standards of the
latest edition of the Steel Structures Painting Manual, Volume 2, Systems and
Specifications as issued by SSPC.

(3) Synthetic resin paint shall be used for the finish paint of the exposed portion of all the
Equipment except for the portion embedded in concrete and the mechanical finished
surface thereof.

The primary coat shall be of the kind matching the finish paint mentioned above and shall have a rust
preventive effect.

(4) The exposed portion of all the Equipment except portion embedded in concrete and the
mechanical finished surface thereof shall be shop-coated with primary paint. The finish
coat of the Equipment shall be applied by the Bidder after the Equipment has been installed
at the Site. Paint needed for the finishing coat shall be furnished by the Bidder together
with the Equipment.

(5) Control cabinets, control boards, motor control centers, metal-enclosed cubicles and switch
boxes for auxiliary equipment, motors, pumps and other shop-finished manufacturers
standard products shall be shop-finished with spray painting and shall not undergo painting
at the Site.

However, the Bidder shall furnish paint for touch up in quantity as required.

The Bidder shall apply the touch up paint coat if requested.

(6) Control cabinets, control boards, metal-enclosed cubicles and control boxes shall be coated
with non-glossy paint.

(7) The color schedule for the Equipment should be as per IS/IEC and color notation will be
decided after award of the Contract.

(8) Surfaces exposed to water for the new pressure relief valve and new inlet valve shall be
sand blasted or ground to SSPC Specification SPIO in the shop and shop coated with one
coat of coal-tar-epoxy to a minimum dry film thickness of 30 microns.
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One coat of coal-tar-epoxy resin paint or equivalent shall be applied to all welded and damaged areas
to a minimum dry film thickness of 30 microns.

After completion of installation, the Bidder shall apply two or three coats of coal-tar-epoxy resin paint
or equivalent to a minimum dry film thickness of 300 microns.

Paint needed for the repair and finishing coat shall be furnished by the Bidder together with the
Equipment in quantity requited.

(9) Surfaces exposed to oil such as the interiors of bearing oil reservoirs shall be sand blasted
to SSPC Specification SP 10 and coated with four coats of oil resistant paint to a minimum
dry film thickness of 60 microns at the Site.

(10) All exterior surfaces of non-embedded piping shall be solvent cleaned and shall be given a
field-applied prime coat followed by a coat of finish paint to be selected. The Bidder shall
furnish the prime coat paint and finished paint as required.

The piping and valves shall be coated with appropriate color paint in compliance with color schedule.

6.10. Packing

(1) All the Equipment shall be carefully packed so as to withstand transportation by sea and
land in tropical moist climate. The electrical equipment shall be completely protected
against moisture and rust from salt water and rain. The same precaution and care shall be
taken for the Equipment and Components that cannot be packed or crated. Machine
finished surfaces of the Equipment shall be adequately protected by rust preventive means.

(2) The spare parts shall be packed and crated firmly to withstand storage for a long time, and
those in need of rust preventive treatment shall be so treated. The spare parts shall be
packed separately from other articles and absolute care shall be taken to prevent spare parts
being packed or crated in the same box or crated with the Equipment or the installation
materials. Packages of spare parts shall carry with notation, which clearly indicates that the
contents are spare parts and shall be accompanied by a list of contents, which sets forth
instruction for handling and storing