SCT 1466 - Vol. G Techno Commercial Bid - Technical For Electrical Vol-G

TENDER SPECIFICATION
BHEL: PSSR: SCT: 1466 FOR Pre-bid tie up on back to back basis for Civil, Structural & Balance of Plant for 1x 700 MW Combined Cycle Power Plant of Andhra Pradesh Power Development Company Limited at Nedunoor, Karimnagar Dist, AP TECHNOCOMMERCIAL BIDVOLUME-G TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL
BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking) Power Sector Southern Region 690, Anna Salai, Nandanam, Chennai 600 035.
BHARAT HEAVY ELECTRICALS LIMITED (A Government of India Undertaking) Power Sector, Southern Region 690, Anna Salai, Nandanam, Chennai 35
Tender Specification No. BHEL: PSSR: SCT: 1466 For
Pre-bid tie up on back to back basis for Civil, Structural & Balance of Plant for 1x700 MW Combined Cycle Power Plant of Andhra Pradesh Power Development Company Limited (APPDCL) at Nedunoor, Karimnagar Dist, AP One set of Tender documents consisting of Volume - A to Volume- L (details as below)
BOOK SLNO_________________ Issued to M/s
Refer NIT for Last date of submission Please note this tender document is not transferable For and on behalf of BHARAT HEAVY ELECTRICALS LIMITED
ADDL GENERAL MANAGER / CONTRACTS Place: Chennai -35
Tender Specification BHEL PSSR SCT 1466 comprise of Volume-A to Volume -L as below: Sl no of Volumes BHEL Vol -A NIT Project information, schedules, QA, Other requirements Scope TP, Exclusions Proposed scope split of Electrical between BHEL & EPC contractor Scope split BHEL & EPC contractor dt 29-06-2011 Scope of lifting equipments SCC- BHEL Consolidated GCC- BHEL-PEM APPDCL Volume -1,SECTION A1 TO A4 Geo tech investigations Tech requirements for General Civil works Additional civil drgs Scope of Cooling tower Tech requirements for General Electrical works Technical spec for Mechanical packages- Bought out packages NOT APPLICABLE Amendments & clarifications Schedules Price schedule Description No. of pages (including Remarks drawings)
BHEL Vol -B
BHEL Vol -C BHEL Vol -D BHEL Vol -E BHEL Vol -F BHEL Vol -G BHEL Vol -H BHEL Vol -I BHEL Vol -J BHEL Vol -K BHEL Vol -L
TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL

VOLUME -G
Bharat Heavy Electricals Limited
1X700 MW CCPP AT NEDUNOOR, KARIMNAGAR ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.
TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL WORKS
DOCUMENT NO. PE-TS-I59-888-E001 REV 0
BHARAT HEAVY ELECTRICALS LIMITED

POWER SECTOR, PROJECT ENGINEERING MANAGEMENT NOIDA 201301
Doc. No. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. : Page : 0 of
CONTENTS
SL. NO. 1. 2. 3. 4. 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 6. 7. 8. 9. 10. 11. DESCRIPTION INTENT OF SPECIFICATION SCOPE OF WORKS DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER THE AWARD OF CONTRACT ELECTRICAL TECHNICAL SPECIFICATION: GENERAL REQUIREMENT LT BUS DUCTS 400V SWITCHGEAR & MCC NEUTRAL EARTHING EQUIPMENT DC SYSTEM CABLING SYSTEM LIGHTING SYSTEM EARTHING & LIGHTNING PROTECTION SYSTEM PUBLIC ADDRESS SYSTEM ELECTRICAL LAB EQUIPMENT INSULATING MATS CATHODIC PROTECTION CUSTOMER DRGS.-ANNEXURE-II BHEL ELECTRICAL SINGLE LINE DIAGRAM- PE-DG-I59-565-E001 QUALITY ASSURANCE, INSPECTION & TESTING BHEL CLARIFICATIONS (ENCLOSED AS ANNEXURE-B) SCHEDULE OF TECHNICAL DEVIATION SPARES 15 16 16 3 13 18 16 7 15 7 1 2 5 1 77 2 1 3 PAGES 1 1 1 2
IT IS CONFIRMED THAT OUR TECHNICAL OFFER COMPLIES WITH THE SPECIFICATION IN TOTO.
--------------------------------------------------------------------BIDDERS STAMP & SIGNATURE
1. INTENT OF SPECIFICATION
1.1 The owner Andhra Pradesh Power Development Company Ltd has invited bids for the EPC package of 1X700 MW CCPP at Nedunoor Karimnagar Dist. BHARAT HEAVY ELECTRICALS LIMITED (BHEL) intends to bid for this project and invites quotations for design and execution of the work for electrical systems of the project mentioned in relevant clauses. 1.2 At the outset the bidder must understand that this offer is to be submitted on back to back basis which means that the bidder assumes total and unconditional responsibility for all electrical works as per owners requirements and subject to owner/ owners consultant approval. 1.3 Timely submission of drawings & documents / obtaining approval of drawings / documents from owner / owners consultant shall be the responsibility of the bidder. 1.4 It is specifically emphasized that the bidder quoting for Electrical Works package shall be comprehensively responsible for complete scope of work stated or unstated including preparation of design and drawings, obtaining necessary approvals, materials, execution as per codes, best engineering practices and to the satisfaction of the owner.
2. SCOPE OF WORKS 2.1 It shall be Contractors responsibility to provide all the equipment / systems / services and interfacing between various systems for the completeness of the 700 MW Combined Cycle Power Plant (CCPP). The following configuration shall be considered. 2 GTs + 2 HRSGs + 1 STG in Multishaft configuration. The requirements described here are for 700 MW CCPP. All equipment in the plant shall operate without any limitation upto the full load of Gas Turbine offered. This shall be applicable to all regimes of GT operation including the temperature range, frequency range, voltage range, with evaporative cooler etc. However for the purpose of the PG test, the evaporative cooler shall be switched off. The Plant electrical systems for proposed combined cycle power plant shall essentially comprise but not be limited to the following: 1. HT power cables, LT Power cables, LT Control cables & instrumentation cables 2. Cabling & installation equipment(cable trays & accessories, cable tray support, trefoil clamps, termination kits, jointing kits cable glands & lugs etc). 3. Earthing & lightning protection(including above & below grade grounding material) 4. Station lighting system. 5. Neutral grounding resistors for Unit auxiliary transformers. 6. 220V DC battery, battery chargers, DC switchboards and their accessories. 7. 400V AC switchgear, LV power distribution boards and accessories. 8. Public address system equipment. 9. Electrical laboratory equipment 10. Insulating mats 11. Cathodic protection 12. Drawing & Document submission for all packages : System design, Design Calculations, Design Memorandums, Layout drgs., Electrical load list, cable schedules, cable interconnections, Data sheets, OGA, Quality plans, test certificate etc. Detailed scope of work shall be as per scope chart enclosed as Annexure-A.
2.2
2.3
Any deviation to technical specification is to be clearly mentioned in schedule of technical deviation & undeclared technical deviation is not acceptable at any stage of project.
3. DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID:

BIDDER TO SUBMIT SIGNED & STAMPED COPY OF FOLLOWING SHEETS: i) CONTENTS ii) INTENT OF SPECIFICATION iii) SCOPE OF WORKS( ALONG WITH SCOPE CHART IN ANNEXURE-A & TABLE-1)
4. MASTER LIST OF DRAWINGS/ DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER AWARD OF CONTRACT (INDICATIVE)
S.No. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE DESIGN PHILOSOPHY FOR ELECTRICAL EQUIPMENT LAYOUT LAYOUT OF TRANSFORMER YARD LAYOUT OF ELECTRICAL EQUIPMENT IN CW PUMP HOUSE LAYOUT OF ELECTRICAL EQUIPMENT IN RW PUMP HOUSE LAYOUT OF MAIN SWITCHGEAR ROOM EQUIPMENT LAYOUT IN STATIC EXCITATION ROOM(GTG) EQUIPMENT LAYOUT IN STATIC EXCITATION ROOM (STG) (AB BAY 13.5M EL) LAYOUT OF DC BATTERY ROOM CABLING LAYOUT BELOW MAIN SWITCHGEAR ROOM CABLING LAYOUT BELOW DC BATTERY ROOM CABLING TRAY LAYOUT AT 9.5M EL. CABLE VAULTBC BAY CABLE TRAY LAYOUT IN TG HALL IN BELOW 8.5M EL CABLE TRAY LAYOUT IN TG HALL IN ABOVE 8.5M EL CABLE TRAY LAYOUT ON HRSG PLATFORMS IPB LAYOUT-GT IPB LAYOUT-STEAM TURBINE GENERATOR 0.0M CABLE TRAY LAYOUT AT EL 0 0M FLOOR IN BFP BUILDING (SHEET 1 OF 3) CABLE TRAY LAYOUT AT EL 6.7M & 10.0M FLOOR IN BFP BUILDING (SHEET 2 OF 3) CABLE TRAY LAYOUT AT EL 14.500M FLOOR IN BFP BUILDING (SHEET 3 OF 3) CABLE TRENCH LAYOUT IN GAS TURBINE BUILDING ELECTRICAL EQUIPMENT LAYOUT OF BFP BUILDING CABLE TRENCH LAYOUT IN STEAM TURBINE BUILDING INTERPLANT CABLING LAYOUT (2 SHEETS) CABLE TRAY LAYOUT IN AIR WASHER ROOM STG BUILDING CABLE TRAY LAYOUT IN AIR WASHER ROOM - STG BUILDING OUTSIDE A ROW CABLE TRAY LAYOUT ON STORM WATER PUMP HOUSE CABLE TRAY LAYOUT ON PORTABLE WATER PUMP HOUSE CABLE TRAY LAYOUT IN AC PLANT ROOM (FACILITY BUILDING) CABLE TRAY LAYOUT IN A.H.U ROOM (FACILITY BUILDING) CABLE TRAY LAYOUT IN A.H.U ROOM (STG BUILDING) ELECTRICAL EQUIPMENT AND CABLE TRAY LAYOUT IN ETP MCC ROOM ELECTRICAL EQUIPMENT AND CABLE TRAY LAYOUT IN WATER TREATMENT MCC ROOM CABLE TRAY LAYOUT IN CW PUMP HOUSE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33
ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE
100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100
ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT
PE-DC-I59-100-E999 PE-DG-I59-100-E001 PE-DG-I59-100-E003 PE-DG-I59-100-E004 PE-DG-I59-100-E006 PE-DG-I59-100-E007 PE-DG-I59-100-E008 PE-DG-I59-100-E009 PE-DG-I59-100-E013 PE-DG-I59-100-E016 PE-DG-I59-100-E020 PE-DG-I59-100-E021 PE-DG-I59-100-E022 PE-DG-I59-100-E038 PE-DG-I59-100-E050 PE-DG-I59-100-E051 PE-DG-I59-100-E060 SH 1 OF 3 PE-DG-I59-100-E060 SH 2 OF 3 PE-DG-I59-100-E060 SH 3 OF 3 PE-DG-I59-100-E063 PE-DG-I59-100-E065 PE-DG-I59-100-E067 PE-DG-I59-100-E071 PE-DG-I59-100-E072 PE-DG-I59-100-E073 PE-DG-I59-100-E074 PE-DG-I59-100-E075 PE-DG-I59-100-E076 PE-DG-I59-100-E077 PE-DG-I59-100-E078 PE-DG-I59-100-E079 PE-DG-I59-100-E080 PE-DG-I59-100-E081
4. MASTER LIST OF DRAWINGS/ DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER AWARD OF CONTRACT (INDICATIVE)
S.No. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE
34 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64
ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE
100 506 506 507 507 507 507 507 507 507 507 507 507 507 508 509 509 509 509 509 509 509 557 558 561 565 565 565
ELE LAYOUT LV SWGR LV SWGR CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING DC SYSTEM LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION PUBLIC ADDRESS SYSTEM LIGHTING & LOW VOLTAGE SERVICES EMERGENCY DG ELECTRICAL SYSTEM DESIGN ELECTRICAL SYSTEM DESIGN ELECTRICAL SYSTEM DESIGN
PE-DG-I59-100-E082 PE-DC-I59-506-E004 PE-DG-I59-506-E003 PE-DC-I59-507-E001 PE-DC-I59-507-E002 PE-DC-I59-507-E004 PE-DC-I59-507-E005 PE-DG-I59-507-E005 PE-DG-I59-507-E006 PE-DG-I59-507-E007 PE-DG-I59-507-EXXX PE-DG-I59-507-EXXX PE-DG-I59-507-EXXX PE-DG-I59-507-EXXX PE-DC-I59-508-E001 PE-DC-I59-509-E001 PE-DC-I59-509-E002 PE-DG-I59-509-E003 PE-DG-I59-509-E004 PE-DG-I59-509-E005 PE-DG-I59-509-E007 PE-DG-I59-509-E008 PE-DC-I59-557-E001 PE-DC-I59-558-E001 PE-DC-I59-561-E001 PE-DC-I59-565-E004 PE-DC-I59-565-E002 PE-DG-I59-565-E001
CABLE TRAY LAYOUT IN RAW WATER PUMP HOUSE ELECTRICAL LOAD DATA (BOARD WISE) CONTROL LOGIC FOR 415V SWGR DESIGN CALCULATIONS FOR HT CABLES SELECTION & SIZING DESIGN CALCULATIONS FOR LV CABLES SELECTION & SIZING CABLING PHILOSOPHY CABLE NUMBERING SCHEME TYPICAL DETAILS OF CABLE TRAYS AND ACCESSORIES TYPICAL INSTALLATION DETAILS FOR CABLE TRAY SUPPORT SYSTEM TYPICAL DETAILS FOR CABLE TRAY SUPPORT SYSTEM LAYOUT FOR ALL AREAS CABLE TRAY LAYOUT FOR ALL AREAS CABLE SCHEDULES FOR ALL AREAS CABLE INTERCONNECTION FOR ALL CABLE SCHEDULES DESIGN MEMORANDUM FOR 220V DC SYSTEM DESIGN MEMORANDUM FOR EARTHING SYSTEM DESIGN MEMORANDUM FOR LIGHTNING PROTECTION SYSTEM TYPICAL BELOW GROUND EARTHING DETAILS TYPICAL ABOVE GROUND EARTHING DETAILS BELOW GRADE GROUNDING SYSTEM LAYOUT FOR MAIN POWER PLANT AREA BELOW GRADE EARTHING LAYOUT FOR OFFSITE PLANTS LIGHTNING PROTECTION FOR OFFSITE PLANTS DESIGN MEMORANDUM FOR PUBLIC ADDRESS SYSTEM DESIGN MEMORANDUM FOR LIGHTING & LV POWER SERVICES DESIGN CALCULATION FOR EMERGENCY SUPPLY DG SIZING RELAY SETTINGS CHART FOR LV/HV MOTORS DESIGN CALCULATION FOR GENERATOR AND MV SYSTEM ELECTRICAL SINGLE LINE DIAGRAM FOR AUXILIARY POWER DISTRIBUTION DRG./DOC.(I.E. DATA SHEET/ OGA/ SCHEME/ TEST CERTIFICATES/ QUALITY PLANS ETC.) FOR ALL ELECTRICAL PACKAGES
65
ELE
565
ELECTRICAL SYSTEM PE-DG-I59-XXX-EXXX
SPEC.NO. TCE.5960A-H-500001
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

TITLE
VOLUME III SECTION: CONTENT SHEET SHEET 1 OF 2
700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. EPC SPECIFICATION -ELECTRICAL SYSTEMS
VOLUME-III CONTENTS ELECTRICAL SYSTEM

SECTION NO. SPECIFICATION NO. REV.NO. TITLE
NO. OF SHEETS 15 39 06 09 03 16 08
D3.0 D3.1 D3.2 D3.3 D3.4 D3.5 D3.6
TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01
R0 R0 R0 R0 R0 R0 R0
GENERAL REQUIREMENT GENERATOR AND ACCESSORIES GENERATOR CIRCUIT BREAKER GENERATOR TRANSFORMERS UNIT AUXILIARY TRANSFORMERS BUS DUCTS GENERATOR, GENERATOR, TRANSFORMER AND UAT PROTECTIONS 400 kV SWITCHYARD GENERATOR CONTROL PANEL 6.6 kV SWITCHGEAR SERVICE TRANSFORMERS 400V SWITCHGEAR & MCC NEUTRAL EARTHING EQUIPMENT DC SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM CABLING SYSTEM LIGHTING SYSTEM EARTHING & LIGHTNING PROTECTION SYSTEM COMMUNICATION SYSTEM FIRE DETECTION AND ALARM SYSTEM
D3.7 D3.8 D3.9 D3.10 D3.11 D3.12 D3.13 D3.14 D3.15 D3.16 D3.17 D3.18 D3.19
TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01
R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0
49 09 15 05 16 03 13 07 18 16 07 15 05 ISSUE R0 TCE FORM NO. 329 R5
SPEC.NO. TCE.5960A-H-500001

TITLE
VOLUME III SECTION: CONTENT SHEET SHEET 2 OF 2
700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. EPC SPECIFICATION -ELECTRICAL SYSTEMS
D3.20 D3.21 D3.22 D3.23 D3.24 D3.25 BID DRAWING

SL NO.
TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01
R0 R0 R0 R0 R0 R0
MOTORS ELEVATORS ELECTRICAL LABORATORY EQUIPMENT MISCELLANEOUS ELECTRICAL EQUIPMENT CONSTRUCTION POWER SUPPLY TRANSDUCERS
10 08 07 03 04 02
DRAWING NO.
REV.NO.
TITLE
NO. OF SHEETS 01 01 01 01 01 01 01 01
1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0
TCE.5960A-EL-2001 TCE.5960A-EL-2003 TCE.5960A-EL-2003 TCE.5960A-EL-2004 TCE.5960A-EL-2005 TCE.5960A-EL-2006 TCE.5960A-EL-2007 TCE.5960A-EL-2008
P0 P0 P0 P0 P0 P0 P0 P0
KEY ONE LINE DIAGRAM MAIN ONE LINE DIAGRAM (SH. 1 OF 2) MAIN ONE LINE DIAGRAM (SH. 2 OF 2) SWITCHYARD SCADA ARCHIETCTURE DIAGRAM PARALLEL REDUNDANT UPS WITH STATIC BYPASS TO REGULATED SUPPLY FLOAT CUM BOOST CHARGER WITH 2x100% BATTERY 400kV SWITCHYARD PLAN 400kV SWITCHYARD SECTIONS
ISSUE R0 TCE FORM NO. 329 R5

8
5.1

TITLE
SECTION: D3.0 SHEET 1 OF 17
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.
ELECTRICAL SYSTEMS GENERAL REQUIREMENTS
SPEC. NO. TCE.5960A-H-500-001
1.0
General Requirements (a) For the purpose of design of equipment / systems, an ambient temperature of 500C and relative humidity of 95% shall be considered. The equipment shall operate in a highly polluted and highly corrosive environment. However, for equipment in air-conditioned areas, design ambient temperature shall be 350C, if 2x100% air conditioning system is provided. All equipments shall be suitable for rated frequency of 50 Hz with a variation of +3% to -5% and 10% combined variation of voltage and frequency unless specifically brought out in the specification. The step up voltage of the project shall be 400 kV as applicable. Contractor shall provide fully compatible electrical system, equipments, accessories and services for the entire station/plant in his scope as well as those specifically required by the Owner. All the equipment, material and systems shall, in general, conform to the latest edition of relevant National and International Codes & Standards, especially the Indian Statutory Regulations. The accompanying specifications also indicate the applicable codes and standards. The equipment/material/systems conforming to other equivalent national and international standards shall also be considered provided the same ensures equal or better features compared to standards listed in accompanying specification. Control supply voltage for all the switchgear for the GTG, HRSG, Cooling tower & STG shall be 220 V DC & 110 V AC. However the area where the DC control supply is required shall be finalized during the detailed engineering. Fault level shall be limited to 44 kA rms for 6.6 kV systems and 50 kA rms for 400 V system. However the three phase symmetrical short circuit fault current value shall be based on load flow and fault studies, to be carried out as a part of this contract. The nominal voltage of main DC system shall be 220V and 24V DC system for I& C application. To cater the 400kV switchyard PLCC load, separate 48V DC system shall be provided. Any other voltage required shall be derived from 220V DC or 230V AC UPS distribution board for catering to the control & instrumentation loads.
9
(b)
(c)
(d)
(e)
(f)
(g)

TITLE
SPEC. NO. TCE.5960A-H-500-001
(h)
The Contractor shall furnish calculations of maximum loading and fault levels under the most onerous conditions for the various equipment/systems to prove adequacy of their parameters. In case any equipment or system is found to be inadequate, it shall be changed / modified without any additional liability to the Owner. Transformer voltage ratios, taps, impedances and tolerances thereon, shall be so optimized so that the auxiliary system voltages (6.6 kV & 400 V) under various grid and loading conditions are always within permissible limits and equipment are not subjected to unacceptable voltages during operation and starting of motors. The vector groups of the transformers shall be so selected that all the buses of particular voltage level have same vector through out the plant. The responsibility of coordination with electrical agencies and obtaining all necessary clearances from all the statutory authorities, shall be by the Contractor. All control and protection panels, 6.6 kV switchgear, 400 V switchgear, MCCs, DC and AC distribution board and battery charger panels shall be painted by powder coating process. External surfaces of all equipments shall be painted with Epoxy paint. Paint shade shall be opaline green (external) & semi-glossy white (internal). The electrical scheme for the project shall be as per the enclosed drawings: Key one line diagram Main one line diagram Main one line diagram Switchyard SCADA Architecture diagram UPS scheme Float cum boost charger with 2 x 100% battery : TCE.5960A-EL-SK-2001 : TCE.5960A-EL-SK-2003 (Sh. 1 of 2) : TCE.5960A-EL-SK-2003 (Sh. 1 of 2)
: TCE.5960A-EL-SK-2004
(i)
(j)
(k)
(l)
: TCE.5960A-EL-SK-2005 : TCE.5960A-EL-SK-2006

10

TITLE
SPEC. NO. TCE.5960A-H-500-001
400kV Switchyard plan
: TCE.5960A-EL-SK-2007
400kV Switchyard sections : TCE.5960A-EL-SK-2008
1.1
Generator and its auxiliaries
1.1.1 The generator shall be three phase, horizontal, two pole, cylindrical rotor, Wye connected machine with phase and neutral terminals brought out for connection to isolated phase bus duct. The Gas turbine generators /steam turbine generators and their excitation systems shall have a capability at least matching the declared maximum continuous output of the associated gas turbine /steam turbine at the outside ambient air temperature ranging from 00C to 500C, at all power factor between 0.85 lagging and 0.95 leading. The contractor shall ensure that when the generator is working at this capability, no part of the generator shall attain a temperature in excess of the temperature limit specified in IEC 60034. The Insulation class of the machine shall be Class-F but its temperature rise shall be limited to Class-B. 1.1.2 The Gas Turbine Generator and Steam turbine Generator shall be of hydrogen & water cooled. The Stator core & Rotor winding shall be hydrogen cooled. The Stator winding shall be DM water cooled. 1.1.3 The Contractor shall offer 2 nos. Static Frequency Converter (SFC) for starting of one gas turbine generator at a time. It shall be ensured that either of SFC can be used for cranking any of the Gas turbines without any limitation on successive starts of all gas turbines and restarts thereon. 1.2 Generator Circuit Breaker (GCB) The continuous current rating of the GCB shall be arrived at considering the maximum output of the generator and at specified minimum voltage. The voltage class of the Generator circuit breaker shall be same as that of the generator. The GCB shall be of SF6, metal enclosed, outdoor and freestanding type. 1.3 Generator Transformers
1.3.1 The continuous rating of the generator transformers shall be such that the declared maximum continuous output of the respective turbine unit at any ambient temperature between 00C and 500C can be delivered at the rated
11

TITLE
SPEC. NO. TCE.5960A-H-500-001
power factors and allowable generator voltage variations without exceeding the permissible temperature rise limits set by the applicable Indian Codes and Standards for these equipment. Further a margin of 5% on the rating shall be provided considering the maximum Generator output. The Bidder shall furnish the rating of the equipments. 1.3.2 The GT shall be with voltage ratio of generator voltage / 420kV, two winding, 50 Hz, ONAN / ONAF / OFAF cooled transformer, with On Load Tap Changer with +10% to -10% of in steps of 1.25% on the HV side. 1.4 Unit Auxiliary Transformer 2 Nos. Unit auxiliary transformer shall be capable of supplying auxiliary power requirement of complete station system. UAT shall be a * MVA, */6.9kV, three phase, two winding, 50 Hz, ONAN/ONAF cooled transformer with * % impedance with OLTC +10% in steps of 1.25% on HV side (*By Bidder). Further a 10 % margin on rating shall be provided after considering final load requirement. UAT shall be suitable for medium resistance earthing with earth fault current limited to 300A. 1.5 Bus duct
1.5.1 The continuous current rating of the generator bus duct shall be arrived at considering the maximum output of the generator and at specified minimum voltage. 1.5.2 The M.V. / L.V. Bus duct shall be sized based on the transformer rating at minimum tap. 1.6 Protection Fully graded protection system with requisite speed, sensitivity and selectivity shall be provided for the entire plant. Critical equipments/systems shall be provided with double protection. Contractor shall recommend the relay settings to be adopted along with back-up calculations. 1.7 400 kV Switchyard (a) A 400 kV switchyard shall be provided for evacuation of power generated in the plant through four (4) nos. 400kV transmission lines. The 400 kV switchyard shall have one and half breaker switching scheme.
12

TITLE
SPEC. NO. TCE.5960A-H-500-001
(b)
The layout of the switchyard shall be such that adequate space for maintenance of prime equipment like circuit breakers and current transformers is available. Approach road shall be provided. Approach road all around the switchyard shall also be provided for maintenance and patrolling. Earth mat The earth mat shall be extended 2 m beyond fence for the switchyard. The earth mat of 400kV switchyard shall be inter connected with main plant. The earth mat shall be designed for short time rating of 1 second rating and shall be considered for calculation of step & touch potential. For the Earthing system design System fault current to be considered is 50 kA.
(c)
(d)
The EMVT/CVT and LA shall be connected to earth pit through pipe electrodes. The Conductor tensions shall be 2 Tonnes per conductor. All tension insulator strings shall have double tension string arrangement. Air conditioned outdoor kiosks will be suitably located in switchyard, housing various Intelligent Electronic Devices (IEDs) such as Bay Control Units (BCUs), Protection Panels, Fault Disturbance Recorders, PLCC Panels, etc. for each dia. The connections from LA to transformer shall be through shortest electrical distance. The coolers shall preferably be arranged on side, other than LA. The receptacles of 63 A ratings shall be provided on the gantries at suitable location for connection to welding sets/other emergency equipments. The aluminium tubular busbar conductors wherever if used shall have maximum one joint per span.
(e) (f)
(g)
(h)
(i) (j)
(k)

13

TITLE
SPEC. NO. TCE.5960A-H-500-001
(l)
Corona rings & corona bells shall be used wherever required and same shall be of non-magnetic material. The requirements regarding RIV and corona extinction voltage shall include terminal fittings. All equipments shall be suitable for hot line washing. The connectors for termination of conductor on equipment shall be either of rigid or expansion type suitable for aluminium tube or Moose ACSR conductor. The switchyard shall be provided with suitable phase markers and danger plates. Insulation Co-ordination
(m) (n)
(o)
(p)
The Contractor shall be fully responsible for complete insulation coordination of switchyard. Contractor shall carry out detailed calculations to evolve the required parameters, locations, energy capability etc. of surge arrestors such that an adequate protective margin exits between the peak impulse voltage occurring due to other connected sub stations. Bidder to note that surge arrester parameters given at D3.7 are indicative and shall be finalised after insulation coordination studies. The quantity of surge arresters shown in the drawings are minimum required. Additional arresters, if required based on the insulation coordination study, shall be provided by the Contractor. The Contractor shall provide surge arrestors and other devices as required to protect all the equipments from fundamental frequency, harmonics, ferro-resonance, switching surges, and lightning impulse over voltages under steady state, dynamic & transient conditions. The Contractor shall furnish the system studies like load flow, short circuit and transient stability studies of the complete system including the transmission lines during detail engineering stage for Owners approval. In addition to the above, Contractor shall submit the relay co-ordination, motor starting studies for the complete plant for Owners approval. (r) 400 kV System
14

TITLE
SPEC. NO. TCE.5960A-H-500-001
(i) (ii) (iii)
Max voltage Rated frequency Rated short time current withstand capacity Rated one minute power frequency withstand voltage Rated lightning impulse withstand voltage Clearance Phase to phase Phase to earth Sectional clearance Ground clearance
420 kV 50 Hz 50 kA rms for one (1) second
iv)
630 kV rms
v)
1425 kVp
vi)
4200 mm 3400 mm 6500 mm 8000 mm
(s) (t)
System neutral earthing Auxiliary contacts
Effectively earthed The contacts shall have continuous rating of 10A and breaking capacity of 2A with circuit time constant of minimum 20 ms at 220 V DC. SF6 Spring / Spring charge mechanism
(u) (v)
Type of circuit breaker Operating mechanism Circuit breaker
(w) (x)
Type of isolator Instrument transformer
Horizontal centre break/Pantograph Outdoor, Oil filled hermetically sealed with SS bellow.
15

TITLE
SPEC. NO. TCE.5960A-H-500-001
(y)
Creepage distance for insulators
31mm/kV
1.8
Control philosophy of electrical system (a) Control of L.V. and M.V. auxiliary power system, covered under the scope of this package shall be provided through the DCS system. Control, Protection, monitoring, indication, annunciation and metering of complete 400 kV switchyard under Bidder's scope shall be through SCADA. PLCC panels for lines shall be located in the outdoor kiosk panels. The control, monitoring, measurement, annunciation, synchronizing and sequential event logging for each generator and its subsystem shall be provided on the DCS. SCADA shall have communication with plant DCS for providing measurement, monitoring, annunciation etc of 400kV switchyard.
(b)
(c)
(d)
e)
1.9
6.6kV Switchgear The 6.6 kV switchgear and its accessories shall conform to all latest editions of national and international standards. For feeding the plant auxiliaries rated for 6.6 kV and service transformers, adequately rated switchgears shall be provided. The fault level for the switchgear, circuit breakers, isolators, earth switch, bus bars, etc., shall be arrived at, on the basis of short circuit current contribution from UAT plus short circuit contribution by the motors running on the bus. A margin of 5% over higher of the above S.C current, shall be applied and rounded off to the next higher standard ratings and this value shall be adopted for the breakers and switchgears. The momentary current ratings shall be 2.55 times this value.
1.10
Service transformer Adequate number of 6.6 kV / 420V epoxy cast resin dry type service transformers shall be provided to meet the demand on 400V systems, with the criteria that each 400 V switchgear / MCC / DB shall be fed by 2x100% transformers / feeders, and these shall be rated to carry the maximum load expected to be imposed with 10% margin at all ambient. Each of the
16

TITLE
SPEC. NO. TCE.5960A-H-500-001
switchgear / MCC / DB shall be sectionalised. Highest efficiency operating point shall be designed near to the normal loading of the transformer i.e. when the bus coupler is open. The service transformers shall be two winding, three phase, 50 Hz, 6600 / 420 Volts, Dry type AN cooled with off-circuit taps of 5% in steps of 2.5%. 1.11 400 V Switchgear The 400 V switchgear and its accessories shall conform to all latest editions of national and international standards. For feeding the 400V / 230V AC loads of the plant, 400V switchgear / motor control centres (MCCs) and AC distribution boards (ACDBs) shall be provided. The switchgears shown in Key One Line Diagram drg. No. TCE.5960A-EL-SK-2001 is tentative. Any additional switchgear / MCCs as required shall also be provided. 1.12 Neutral Earthing Equipment (a) 400 kV system is solidly earthed. The neutral of GTs are independently connected to earth. Generator neutral shall be high resistance earthed. The neutral shall be connected to a suitably rated neutral earthing transformer with secondary loading resistor, limiting the earth fault current to about 510 A. The neutral earthing equipment shall be rated to carry this current for at least 30 seconds considering the generator terminal voltage under maximum field forcing conditions. 6.6 kV systems shall be medium resistance earthed. The neutral of the unit auxiliary transformers shall be independently connected to the earth through a suitable resistance designed for 30secs. The earth fault current shall be limited to 300A. 400V system shall be a solidly earthed system. The neutral of service transformers shall be independently connected to the earth. 220 V DC system & UPS system shall be kept ungrounded. Diesel generator shall be of solidly earthed system.
(b)
(c)
(d)
(e) (f) 1.13
DC System

17

TITLE
SPEC. NO. TCE.5960A-H-500-001
(a)
DC power supply with high discharge Lead acid plante type battery cells forming bank shall be the source of the power supply for control, protection, interlock, annunciation of the complete plant including I&C system during the running of the plant as well as for a safe shutdown at the time of the total power supply failure. 220V, DC 2 x 100% battery bank with associated float cum boostcharger, 1 No. DC switchboard shall be provided for each gas turbine generator (GTG) unit. The GTG unit DC system with 100% capacity shall be sized to cater complete unit loads for atleast 10 hrs. 220V, DC 2 x 100% battery banks with associated float cum boostchargers and 1 No. DC switchboard shall be provided for station DC system. The station DC system shall be sized to cater STG, HRSG and station loads for at least 10 hrs. 220V, DC 2 x 100% battery banks with associated float cum boostchargers and 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for 400kV system (switchyard) auxiliaries. The switchyard DC system shall be sized to cater loads for at least 10 hrs. 48V, DC 2 x 100% battery banks with associated float cum boostchargers and 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for 400kV switchyard PLCC application. 24V, DC 2 x 100% battery banks with associated float cum boostchargers and 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for I& C , DCS system. The boost charger unit shall be rated such that the battery can be fully charged from fully discharged condition within 8 hours. Each battery charger shall be capable of float charging the two batteries while supplying the normal DC loads. Sizing criteria shall include design margin of 10%, 25% margin on ageing and ambient temperature compensation as per IS.
(b)
(c)
(d)
(e)
(f)
(g)
(h)
(i)
1.14
Uninterruptible Power Supply (UPS)

18

TITLE
SPEC. NO. TCE.5960A-H-500-001
Parallel redundant UPS shall be with duplicate charger, inverter & battery system and standby supply to cater the UPS loads of complete plant Instrumentation and control system loads such as HMI, SWAS etc. The UPS shall be sized considering full load plus spare loops plus 20% margin. 1.15 Cabling System Cables shall be derated for the site ambient and ground temperatures, grouping and soil resistivity. Contractor shall furnish detailed cable selection/sizing criteria for Owners approval. Cables shall be selected to limit maximum voltage drop at equipment terminals during normal operation and starting conditions well within permissible values. Voltage grade of cables shall be of earthed grade when used in solidly earthed systems, and unearthed grade when used in non-effectively earthed systems. 1.16 Lighting System Lighting system shall be provided for the entire plant covering all the buildings, outdoor areas, roads, yards, boundary, etc. The lighting system design shall comply with the acceptable norms and the best engineering practices. The lighting layout shall be designed to provide uniform illumination with minimum glare. The layout design shall meet all the statutory requirement, local rules etc. 1.17 Earthing System The earthing system shall be designed for a life expectancy of at least forty (40) years, for maximum fault current of 50kA for 1.0 sec. The minimum rate of corrosion of steel for selection of earthing conductor shall be 0.12mm per year. Grounding and lightning protection for the entire power plant, switchyard and other areas or buildings covered in the specification shall be provided in accordance with IS:3043, IS:2309 & IEEE : 80 and IEEE : 665. 1.18 Motors (a) Wherever the basis for motor ratings are not specified in the corresponding mechanical specification sections, maximum continuous motor ratings shall be at least 10% above the maximum load demand of the driven equipment under entire operating range including voltage and frequency variations.

19

TITLE
SPEC. NO. TCE.5960A-H-500-001
(b)
All M.V. motors shall be suitable for 6.6 kV, 3 phase, 50 Hz and LV motors shall be suitable for 400 V, 3 Phase, 50 Hz power supply. The voltage for M.V. and L.V. motors shall be 10%. The motors rated 175 kW and above shall be 6.6kV and motors rated upto 175 kW shall be 400 V.
(c)
1.19
Emergency Diesel Generator Set Each Emergency Diesel Generating set shall be sized at an ambient temperature of 500C for all essential auxiliaries and emergency loads of all gas turbines, steam turbines, station service and switchyard loads.
1.20
Islanding Scheme The plant shall be designed to operate in islanding mode of operation by tripping all the lines and generators except for one pre-selected unit, which shall run with the available plant load under such condition.
1.21
Auxiliary System (a) 6.6 kV incomers and ties from transformers to switchgear shall be through 6.6 kV segregated phase bus duct (SPBD) only. If adequately rated cables shall be provided then Owners permission shall be obtained. For 400V system, non-segregated phase bus duct (NSPBT) assemblies shall be preferred for incoming connection from transformers to the switchboard. The 6.6 kV system shall incorporate a microprocessor based numerical fast auto change over scheme which will restore supplies to the 6.6kV unit board from other unit board, on loss of supplies from unit transformer. Manual live changeover and slow changeover shall also be arranged for all 6.6 kV buses & 400V buses. Automatic changeover to the reserve supply source shall be arranged for 400V critical switchgear/MCC sections as necessary to prevent the loss of a unit or to ensure the equipment safety. 6.6kV and 400V switchgear, MCCs and DBs shall have positive foolproof interlocking to ensure that different supplies and transformers are never operated in parallel and fault level does not exceed the switchgear capability. For 400V switchgear, contribution from emergency DG set shall be considered while designing the fault level.
20
(b)
(c)

TITLE
SPEC. NO. TCE.5960A-H-500-001
(d)
During Grid black-out condition, it shall be ensured that only the essential auxiliaries of all units are fed from emergency Diesel generator & non- essential loads are automatically tripped. DC scheme shall provide at least two feeds through diode sharing to critical consumers e.g. all protection panels / control desks, circuit breakers, GCB, 6.6 kV / 400 V unit and emergency switchgear panels, generator excitation system, generator oil seal system, etc. The details shall be subject to Owners approval. For generator protection and protection panels for all 400 kV switchyard feeders, duplicated DC feeders shall be provided, one from each battery system.
(e)
1.22
The insulation level for the transformer windings and bushings shall be as follows: Winding Highest System Voltage Rated Power Freq. withstand voltage (kVrms) 20 28 38 95 630 Rated lightning impulse withstand voltage (kVp) 60 75 95 250 1300 Bushing Rated Power freq. withstand voltage (kVrms) 20 28 38 95 630 Rated lighting impulse withstand voltage (kVp) 60 75 95 250 1425
7.2 kV 12 kV 17.5 kV 34.5 kV 420 kV
Note: for 400kV system switching impulse of 1050 kVp shall be considered.
1.23
Degree of protection Degree of protection for various enclosures as per IS: 13947 shall be as follows:

21

TITLE
SPEC. NO. TCE.5960A-H-500-001
(a)
6.6 kV switchgear i) ii) iii) VT/relay compartments Other compartments Switchgear in air-conditioned areas (all compartments) - IP 52 - IP 42 - IP 32
(b)
400V switchgear / MCC / DBs / Fuse Boards i) Compartments and busbar chambers upto 1600A Compartments and busbar chambers above 1600A All compartments in case switchgear in air-conditioned areas Switchgear located out door - IP 52
ii)
- IP 42
iii)
- IP 32
iv) (c)
- IP 54
Busduct enclosure / GCB i) ii) iii) Indoor portion including VT & SP cubicle - IP 52 Outdoor portion GCB - IP 65 - IP 65
(d)
Motors i) ii) Indoor motors Outdoor motors - IP 54 - IP 55
(e)
Control and relay panel i) ii) In air-conditioned areas In other areas - IP 32 - IP 52
(f)
Transformers
22

TITLE
SPEC. NO. TCE.5960A-H-500-001
i) ii) iii) iv) v) (g)
Indoor Transformers Cable box - indoor area Cable box - outdoor area Indoor kiosks and marshalling boxes Outdoor kiosks and marshalling boxes
- IP 31 - IP 52 - IP 55 - IP 52 - IP 55
Push button stations and any other kiosk / box / panel / enclosure i) ii) Indoor Outdoor - IP 54 - IP 55 - IP 55 - IP 55 - IP 22 - IP 33
(h) (i) (j) (k) 1.24
Junction boxes for cables/wires Outdoor lighting fixtures Gen. Neutral grounding resistor 6.6 kV Neutral grounding resistor
FAULT LEVEL Equipment through fault withstand capabilities under worst operating conditions duly taking into account tolerances on transformer, generator & maximum fault levels of source etc. shall be as follows : i) ii) All other transformers Generator busduct main run, GCB, (higher of generator or EHV system fault contribution) Tap off run busduct (sum of generator and EHV system fault contribution) 6.6 kV Busduct Switchgears - 2 seconds - 1 second
iii)
- 1 second
iv) v)
- 1 second - 1 second
23

TITLE
SPEC. NO. TCE.5960A-H-500-001
vi)
Cables to the feeders protected by breakers
Main protection fault clearing time with 0.16 seconds minimum
vii)
Cables of all other feeders
As per fuse operating time - 2 seconds for the adopted ground fault current - 1 second
viii)
6.6 kV cable screen
ix) 1.25
EHV systems
Type Test All equipment / systems to be supplied shall conform to type tests as per relevant standards / relevant chapters of this specification and shall be of proven type.
1.26 Communication System For effective communication in the plant, public address system, private automatic branch exchange system (EPABX), radio paging system, walkietalkie and P&T telephone system with the features described below will be provided: a) Public Address System This system will have paging and party channels comprising handset stations with amplifiers, transmitters, receivers, and loud speakers. This system will facilitate paging, communication and also private conversation as in conventional telephone. b) EPABX System This system will have adequate number of push button type handset stations, central automatic telephone exchange, etc. The handsets in the control room would be provided with priority service facility to enable them to have immediate access to any handset even if it is already engaged.
24

TITLE
SPEC. NO. TCE.5960A-H-500-001
c) Landline Telephones, Broadband connectivity Necessary number of ISDN / PSTN landlines would be provided at strategic locations within the plant boundary. Broadband connectivity would be provided at strategic locations for online access of data from remote station.
d) Wireless System (Walkie-Talkie System) Walkie-Talkie system will be provided for mobile communications. These systems will be of particular use during commissioning stage as well as subsequently during maintenance. e) GPRS/CDMA mobile system of any reputed service provider can be provided for wireless system. The mobile system coverage in the power plant area should be 100%. f) Interface between the EPABX, PA and Wireless systems shall be provided to enable communication between these systems.

25
SECTION:
D3.1
SHEET 1 OF 42
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES
SPEC. NO. TCE.5960A-H-500-001
1.0
GENERATOR & ACCESSORIES The generator and its accessories such as the cooling system excitation system, automatic voltage regulator, static start up systems for gas turbine generator etc. shall generally comply with the requirements specified in the national and international standards indicated as per Data sheet A 3.1 and shall additionally comply with the specific requirements of Data sheet A 3.1 and as indicated below:
1.1 1.1.1
Generator The MW out put of generator of the Gas turbine generator unit and Steam turbine generator unit shall be sufficient to evacuate the normal and peak power output of gas turbine power over the complete range of site ambient conditions specified in Section-B and at rated casing (Hydrogen) pressure and temperature. The Maximum Continuous Rating (MCR) of the generator shall correspond to the maximum MVA, MW and minimum associated over-excited power factor that it is guaranteed to deliver continuously (without exceeding its specified temperatures or temperature rises at rated casing (hydrogen) pressure and temperature. The generator shall be three phase, horizontal, two pole, cylindrical rotor, Wye connected machine with phase and neutral terminals brought out for connection to isolated phase bus duct. The generators shall conform to IEC60034-1, IEC60034-3 or other equivalent international standards. The generator shall be capable of satisfactory continuous operation at rated MVA and power factor at any voltage from 95% to 105% of rated voltage and within a frequency range of 47.5 to 51.5 Hz (and a combined frequency and voltage variation of 5%) even if frequency and voltage variations occur simultaneously, without exceeding safe temperature rises, but not necessarily in accordance with the standards established for operation at rated voltage and frequency. The generators shall be provided with Class-F insulation with temperature rise limited to that of Class-B at full load and at rated voltage & frequency. However, for abnormal operating conditions of voltage and frequency, the temperature rise shall in no case exceed that of Class-F when the machine is operating continuously at full load and at rated power factor at any working voltage and any frequency in the range stipulated above.
1.1.2
1.1.3
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TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 2 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.1.4
The generator unit shall be capable of withstanding 3 phase short circuit at the generator terminals when operating at rated MVA and power factor, 5% over voltage and with rated excitation for 3 seconds. The line charging capability of the generator shall not be less than 30% of its rated MVA at zero power factor. The generator shall be non-effectively earthed through a singlephase distribution transformer provided with secondary loading resistor. The sizing of the transformer and the value of the resistance shall be such as to restrict the maximum earth fault current to 1.5 times the capacitive current at normal working voltage. The generator shall be capable of operating alone or in parallel with other generators and / or utility grid. The core of the generator shall be designed such that it permit the flow of earth fault current of at least 15 amperes for one (1) second without any core damage. The generator phase and neutral side terminals shall be brought out through seal off bushings. The bearings shall be lubricated by oil from the turbine lube oil system. Non-hygroscopic insulation shall be provided to prevent any damage due to the circulation of shaft current to the bearing surfaces and the lubricating oil. At least one of the bearings shall be suitably insulated with arrangements for checking the insulation resistance while the machine is in operation. On-line shaft leakage current monitoring system shall be provided to detect any leakage current through the shaft. Abnormal leakage current shall trigger an alarm in the control room. The generator and its components shall be designed to avoid resonance over the entire range of operating frequency or their multiples. The noise (sound) power level emitted by the generator as measured one (1) metre from the surface of the generator and at 1.5 metre height above floor level shall be limited to 85 dB(A).
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1.1.5
1.1.6
1.1.7
1.1.8
1.1.9
1.1.10
1.1.11
1.1.12
1.1.13
27
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 3 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.1.14
The generator unit shall be capable of withstanding the electrical, mechanical and thermal stresses developed during fast auto reclosing of high voltage line, transmission line switching, grid faults, out of step operation, out of phase synchronisation, etc. The vibration severity when measured on generator and main exciter bearings shall not exceed 2.8mm / sec. When tested on open circuit and at rated speed and voltage, the telephone influence factor of the turbine generator shall not exceed 1.5 %. The generator winding shall withstand test voltage of 4 U + 5 (where U is the rated voltage in kV). Lightning arrestors of suitable rating shall be provided for the surge protection of generator winding. In addition to the above if surge capacitors are recommended, the same shall be included in the offer. All components of the generator requiring inspection and maintenance shall be designed for easy access and replacement. Resistance / thermocouple type temperature detectors shall be provided where the highest temperatures are expected. The approximate number and location of temperature detectors shall be as follows: (a) Twelve (12) duplex RTDs (Four per phase) distributed equally around the periphery of the stator winding and also between three phases shall be provided. The geometry of the detectors shall be such that hot spots anywhere in the stator winding can be detected. (b) Twelve (12) duplex RTDs for stator core out of which six shall be located in the end zones where maximum temperatures are expected. (c) Two (2) duplex RTDs for each hydrogen cooler section at inlet and outlet (if applicable). (d) Two (2) thermostats per hydrogen cooler section for gas inlet and outlet (if applicable). (e) Two (2) duplex RTDs for hydrogen cooler water inlet and outlet (if applicable).
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1.1.15
1.1.16
1.1.17
1.1.18
1.1.19
28
TCE FORM NO. 329 R5
SECTION:
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SHEET 4 OF 42
SPEC. NO. TCE.5960A-H-500-001
(f) Two (2) duplex thermocouples per bearing. (g) Two (2) duplex RTDs for cold air temperature and two (2) duplex RTDs each for air temperature in the exciter air passage and rectifier wheel along with thermostats for cold and hot air. (h) Set of duplex RTDs and thermostats for shaft seal system (if applicable). (i) Rotor winding temperature measurement is also to be done through 2 Nos. of duplex RTDs located at the locations where the temperature is likely to be maximum. (j) Additional RTDs / Thermocouples / Thermostats if required or if required at additional locations shall be provided as found necessary. 1.1.20 All RTDs shall be of platinum duplex four wire type and shall have a resistance of 100 Ohms at zero degree centigrade and calibrated as per DIN standards. Termination of RTD leads shall be at terminal box after grouping of signals. Terminal box shall be at an easily accessible position so as to enable maintenance / testing of the devices when the machine is under operation. Termination box of the temperature measuring devices shall be of IP-55. All the above temperature measurement devices shall be hooked to DCS. One (1) generator condition monitoring system shall be supplied along with all piping and accessories to continuously sample the generator hydrogen for detection of thermally produced particulates / aerosols which indicates overheating. Generator auxiliary system like cooling, excitation, hydrogen gas handling system, etc., shall be provided with respective local control panels with required control, indication / annunciation and necessary main control system interfacings with DCS. Generator rating shall be on the basis of continuous operation with guaranteed temperature, or temperature rises, not exceeding those given in IEC 60034-1. Insulation and Temperature Limits
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1.1.21
1.1.22
1.1.23
1.1.24
1.1.25
29
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 5 OF 42
SPEC. NO. TCE.5960A-H-500-001
The generator stator and rotor windings inclusive of main and neutral leads, shall be provided with Class F insulation but temperature rise shall be limited to class B. The maximum permissible temperatures of different parts of the generator shall be as specified in IEC-60034. 1.1.26 Short Circuit Withstand Capability during Unbalanced Faults The generator shall be capable of withstanding, without injury, any short circuit at its terminals provided the integrated product of I22t does not exceed the value stipulated in IEC60034-1, where I2 is per unit negative sequence current and t is the duration of fault in seconds. 1.1.27 Overload Capability With balanced current, the short time thermal capability of the generator armature shall permit operation at 150% of the rated armature current for at least 30 seconds, starting from stability temperature at rated load. 1.1.28 Capacity with one Gas Cooler Out of Service Hydrogen coolers would be built into the stator frame of the generator and would be sized to ensure at least 80% of the rated output continuously with 10% of tubes in each coolers are plugged and one of the hydrogen cooler is out of service then also the temperatures rises shall be limited to class B. 1.2 1.2.1 Stator Housing The stator housing shall be of totally enclosed gas tight construction, having sufficient mechanical strength and rigidity to withstand internal gas pressure, 100 percent vacuum and vibrations and also internal hydrogen explosion without any damage or permanent deformation. Suitable numbers of trunions shall be provided for handling the stator by means of crane. The Bidder to clearly bring out in the proposal the features provided in the generator body construction to enable generator stator to be lifted/dragged in case of nonavailability of suitable crane. The housing shall have suitable provision for handling, lifting and / or jacking the stator. Manholes with sealing arrangement shall be
1.2.2
1.2.3
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TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 6 OF 42
SPEC. NO. TCE.5960A-H-500-001
provided at suitable locations to facilitate inspection of terminals, internals such as back of the core, end winding area, etc. 1.2.4 End plates of the generator frame shall be suitably shielded from stray flux. Stray current insulation shall be provided so that all paths of stray current will be broken at two places in series at one end of the generator with provision made for determining the insulation resistance at each place of insulation with the unit in operation. The frame shall be stress relieved and then subjected to an extended hydraulic test at a pressure not less than 1.5 times the maximum design pressure. All leads, including power, control and instrumentation shall be suitably supported to contain vibrations and shall be brought out of the generator housing to terminal boxes through gas tight seals. The instrumentation terminal box shall have IP55 protection class and shall be located at an easily accessible position so as to enable maintenance / testing of the devices when the machine is under operation. Location may be preferably on the TG Deck. A drawing indicating the location of the temperature detectors and the terminal box shall be enclosed with the proposal. The dimensions of the generator stator body to be within the maximum permissible rail transportation dimensions within the country taking into account the special wagons available / being made available for transporting such heavy over sized consignment. Stator Core The stator core shall be fabricated out of high permeability best quality cold rolled silicon steel so that losses are minimum. The core assembly and mounting arrangement shall be such that the transmission of the forced vibration of the core to the housing and foundation is effectively restricted. The end packets shall be adequately strengthened to minimise the magnetic vibration due to end leakage flux. The core assembly shall have adequate ventilation ducts for cooling by hydrogen. Press plates and fastening elements shall be made of non-magnetic material and shall be with proper locking arrangement.
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1.2.5
1.2.6
1.2.7
1.3 1.3.1
1.3.2
31
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SECTION:
D3.1
SHEET 7 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.3.3
The stator core mounting arrangement shall be such that radial and tangential magnetic vibrations of the stator core due to electromagnetic loading transferred to stator frame are minimised. The stator core, frame and mounting shall be designed to avoid resonance at 50, 100 and 200 Hz. Stator Winding The stator winding shall consist of three phase, double layer, short chorded, bar type lap winding having two parallel paths. The strands making up the stator bar shall be Roebel transposed to minimise eddy current losses. The winding and all connections inclusive of phase and neutral leads shall be insulated for full voltage to ground. In order to reduce the corona in the slot and where the stator bar leaves the stator core, a surface treatment corona grading system shall be applied which shall be carried into the end turn area. Firm seating of the stator bar in the slot shall be ensured by proper wedging and fillers. Ripple springs shall be provided below the slot wedges to compensate for any future shrinkage and ensure permanent firm seating of the bars in the slot during operation. The end turns shall be suitably braced and supported to withstand forces during normal operation and sudden short circuit at generator terminals when the machine is operating at rated MVA, power factor and permissible maximum over voltage. The stator windings shall be designed for connection in single /double star with three (3) phase and three (3) / six (6) neutral terminals brought out. At least six (6) numbers of vibration pickups at each end of over hang portion of the winding shall be provided, symmetrically located around the periphery with connection to Turbine Supervisory system. Provision shall also be made available to connect the same to DCS. Bidder shall wire up all the pickups to a junction box outside the generator casing. Terminal Connection All phase and neutral terminals shall be brought out from the top of the generator (non-drive end) and located in a non-magnetic steel terminal box. Phase terminal bushing shall be spaced to
1.4
1.4.1
1.4.2
1.4.3
1.4.4
1.4.5
1.4.6
1.5 1.5.1
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SECTION:
D3.1
SHEET 8 OF 42
SPEC. NO. TCE.5960A-H-500-001
permit connection to isolated phase bus duct to provide complete phase isolation directly upto the generator housing. Adequate spacing shall be provided between phase and neutral bushings to permit connection of the neutral enclosure. 1.5.2 The bushing shall be preferably of porcelain type or of epoxy based material with non-hygroscopic property. The terminal bushing shall be cooled by suitable arrangement with cooling medium/system envisaged for the generator. Silver coated copper terminal connectors suitable for connection to the busduct through flexibles shall be provided for which the operating conductor temperature shall not exceed 105OC. Rotor The generator rotor shall be machined from a single alloy steel forging to ensure required mechanical strength and magnetic properties. Adequate margin shall be provided between critical speed and the running speed to ensure smooth running. Facilities shall be provided for inserting at least two radial and one axial probe into the rotor shaft for carrying out ultrasonic and residual stress measurements during the life of the rotor. The forging shall be subjected to elaborate ultrasonic and mechanical tests to ensure freedom from any internal defect. After assembly, the rotor shall be dynamically balanced and subject to 20% over speed for 2 minutes. Rotor Winding Rotor winding shall be made of hard drawn silver bearing solid copper conductors. Winding insulation shall correspond to Class-F (i.e. epoxy glass based material) with temperature limited to Class -B. Rotor winding shall be secured in the slots by suitable slot wedges and fillers. The overhung portion of rotor winding shall be held in position against centrifugal force by retaining rings when the rotor is running at upto 20% above its normal speed. The retaining rings shall be machined from high strength, nonmagnetic alloy steel forging with the material specification X8CrMnNi1818 resistant to stress corrosion. The retaining rings shall be floating type, shrunk on rotor body and prevented from axial movement by snap rings / locknuts.
ISSUE
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1.6 1.6.1
1.6.2
1.6.3
1.7 1.7.1
1.7.2
33
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 9 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.7.3
Suitable damper winding shall be provided on the rotor to permit increased asymmetrical electrical loading. The rotor shall be suitable for operation without requiring preheating of the rotor or rotor winding or pre-warming of the rotor forging. Bearing The generator shall be provided with self-aligning type sleeve bearings either mounted on separate pedestals or on the end shields. The bearings shall be of horizontally split construction and forced lubricated from turbine oil system. The bearing shells shall be lined with tin based babbitt metal. Oil buffers shall be provided to prevent leakage of oil and oil vapours along the shaft. All the intermediate support pieces of the bearing shall have complete interchange ability with those of similar type and size of TG bearing. Non-hygroscopic insulation shall be provided between bearing and frame to prevent any damage due to circulation of shaft currents to the bearing surfaces and the lubricating oil. Arrangement shall be provided to measure the insulation of the generator bearing with the machine in operation. This shall be achieved by having two layers of insulation with a metallic plate in between. Build-up of shaft voltage beyond permissible limits as well as a short in the bearing insulation shall trigger an alarm. Each bearing shall be provided with a well for thermometer in the return line and a sight glass with illumination to observe bearing oil flow. Redundant vibration pick-ups and transducers for bearing shall be provided. The vibration sensors shall be installed on X and Y dimensions. RTDs for measurement of metal temperature and bearing drain oil temperature shall be provided. Provision shall be made for hydraulic jacking of the shaft during start up and turning gear operation. Shaft Seals Labyrinth shaft seals shall be provided. Shaft seals, preferably of double flow ring type shall be fitted to the end-shields to prevent hydrogen leakage from generator housing. To ensure effective sealing, seal oil pressure in the annular gap between the rotating shaft and seal ring shall be maintained at a higher level than the
1.7.4
1.8 1.8.1
1.8.2
1.8.3
1.8.4
1.9
1.9.1
ISSUE
R0
34
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 10 OF 42
SPEC. NO. TCE.5960A-H-500-001
gas pressure in the generator casing. The face of the sealing ring shall be lined with babbitt metal.
1.9.2
The hydrogen side seal oil housing shall be provided with oil baffle rings to prevent intrusion of seal oil into the generator along the rotor shaft. Shaft seals and oil piping shall be suitably insulated to prevent circulation of shaft current. Arrangement shall be made to measure the insulation of the shaft seals while the machine is in operation. Fans Hydrogen shall be circulated in the generator in closed circuit by the axial fans located on rotor shaft. The fans shall be shrunk on to their seats on the rotor shaft and locked against tangential or axial movement.
1.10
1.11
Brushes The rotor winding insulation and shaft voltage shall be monitored through a brush, suitably mounted and sliding on an oil free surface. Shaft grounding brushes shall be provided at the turbine end bearing pedestal. It should be possible to increase the brush pressure while generator is working. Brush holders shall be of constant pressure type, which can be adjusted as per requirement. Suitable insulation shall be provided to prevent passage of current through pressure device. Carbon brushes for the measurement of the rotor winding temperature is also to be provided on the oil free surface similar to the carbon brush used for shaft voltage measurement
1.12
1.12.1 1.12.1.1
Excitation System Type A complete generator excitation and voltage regulating system shall be provided with the generator. The system shall be a brushless excitation system. The excitation system offered shall be of proven design and shall have a satisfactory field service record on machines of similar size and construction incorporating the type of excitation. The excitation system shall have matching characteristics suitable for satisfactory parallel operation with other generators in the plant.
1.12.1.2
ISSUE
R0
35
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 11 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.12.1.3
The various change over relays and other equipment, which are not controlled by the control supply required by AVR shall be such that the loss of their control supply does not lead to the excitation system outage. The necessary inputs and interface equipment shall be provided with Generator Excitation and Automatic Voltage Regulator for hooking up with Turbine Automatic Run up system and Electro Hydraulic Governing System. The excitation system shall also requirement specified hereinafter. Performance Requirements The excitation system shall have two (2) 100% channels including independent AVRs, power converters and controls. Each shall be equipped for auto operation with the facility for selecting either channel in Auto or Manual mode. The system shall function without hunting and shall be capable of preventing any abnormal change or oscillation in the generator voltage. The system shall have high initial response to improve steady state and dynamic stability of the generator. The excitation system response time shall be less than 0.5 sec. The excitation system shall be capable of maintaining generator voltage within + 0.5 % of the preset value over the entire load range of the machine. When the generator is subjected to a sudden loss of rated output at rated power factor, the system shall be capable of restoring the voltage within 2% of the nominal preset value within negligible time. The reference voltage set point shall be adjustable over a range of 70% of no load to 110% of the nominal rated voltage at MCR. The excitation system shall be rated to continuously carry current at least 20% above the rated generator field current at MCR output. The excitation system shall also be capable of supplying higher current to meet the short time duty mentioned above.
ISSUE
R0
1.12.1.4
1.12.1.5
meet
the
performance
1.12.2 1.12.2.1
1.12.2.2
1.12.2.3
1.12.2.4
1.12.2.5
1.12.2.6
36
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 12 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.12.2.7
The ceiling voltage shall not be less than 150% of the machine excitation voltage at MCR condition. The system shall be capable of supplying the field-forcing requirement for at least 10 seconds even for close-in faults on high voltage outgoing lines or bolted faults at generator terminals. The nominal exciter response ratio shall not be less than 2. The excitation system shall have proper field suppression arrangement, so as to limit the voltages across the rotor winding to a safe value. In excitation system monitoring facilities with self-diagnostic features to indicate faulty cards and abnormalities shall be available. In case of failure of the PMG, the field of the main exciter shall be transferred to the supply derived from the auxiliary 400V station supply. This changeover shall be such that it does not result into the tripping of the generator. An alarm shall be generated if the difference in the set point of the Auto-1 & Auto-2 is more than a 0.5% with a 1sec time delay. i.e. failure in the follow-up circuit. Automatic Voltage Regulator Continuous acting, non dead-band type microprocessor based digital automatic voltage regulators with accessories mounted in a suitable panel shall be provided for the generator. The automatic voltage regulator shall be capable of working over the whole load and voltage range of the generator. All rectifying elements shall have over voltage and short circuit protection. The automatic voltage regulating equipment shall control the generator voltage under steady state load conditions and over the whole of the operating range of the exciter within 0.5 percent of the setting value without hunting. The voltage regulator shall be automatic, high speed, continuously acting, high response, digital type and shall be complete with the following limiters, compensators etc. a) Maximum Excitation Limiter, adjustable type
ISSUE
R0
1.12.2.8
1.12.2.9 1.12.2.10
1.12.2.11
1.12.2.12
1.12.2.13
1.12.3 1.12.3.1
1.12.3.2
1.12.3.3
37
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 13 OF 42
SPEC. NO. TCE.5960A-H-500-001
b) Maximum Stator Current Limiter (The stator current limiter shall act immediately in under-excited range. The time delay in overexcited range shall enable a temporary overloading of the machine) c) Reactive Drop Compensator (Suitable feedback proportional to transformer drop shall be provided for compensation and the range of compensation shall be 0-15%) d) Over Fluxing (volts / hertz) Limiter (To limit the ratio of generator voltage and frequency at all operating conditions to such a value that the maximum generator transformer core flux density does not exceed the value specified.) e) Load Angle Limiter (This shall enable to keep the angle between the direct axis of the machine and network vector within the set reference value as determined by stability, by adjusting the excitation.) f) Minimum Excitation Limiter g) Adaptive Power System Stabiliser (PSS shall be suitable for damping the various modes of electro-mechanical oscillations at all frequencies in the range of 0 to 3 Hz under varying generator loading and power system network configurations. PSS shall automatically adapt itself to varying operating conditions with features to compute optimum stabilising signal along with suitable scheme for identifying external reactance of the generator. Facility for remote manual switch off-on along with indication shall be incorporated. Automatic supervision and Blocking/Switch off facility along with indications, etc. shall also be provided.) h) Rotor Current Limiter (The regulator shall act with time delay, so that the regulation dynamics are not impaired in case of a fault.) i) Ramp generation circuit to enable gradual rise of reference signal applied to the comparator circuit to avoid sudden voltage build up shall be provided. j) The channel reference control shall be either solid state control or microprocessor control.
1.12.3.4
All the above conditions of limiter operations shall be annunciated in local panel as well as in DCS. Local AVR panel shall be complete with necessary facia windows, sequence logic, power supplies, accept-reset-test push buttons, indicating lamps, control
ISSUE
R0
38
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 14 OF 42
SPEC. NO. TCE.5960A-H-500-001
switches, local/remote switches, programmable logic controllers, etc.

1.12.4 1.12.4.1
auxiliary
relays
and
Auto / Manual Channels Two fully equipped independent automatic regulators with one acting as Master and the other as Slave shall be provided. On failure of the Master control, the Slave control, which follows the Master control, shall take over automatically. Either channel shall be capable of being the main or stand-by. Either channel shall be capable of being selected as manual also. In auto mode, the range of regulation shall be 70% of no-load to 110% full load excitation. In manual mode the range of regulation shall be 0 to 110% of nominal rated voltage. Automatic change over from Auto-1 to Auto-2 channel or vice versa shall be possible in case of trouble in the running channel. Automatic change over shall be possible from Auto to Manual in case of: 1. 2. 3. 4. 5. 6. 7. Generator protection circuit operation i. e. after field forcing and over excitation condition with a time delay Loss of terminal voltage feedback by way of any of the VT fuse blowing up Faulty over excitation condition Loss of automatic channel reference signal Power supply failure in the automatic channel Manual intervention Any other condition as considered necessary by the Bidder
1.12.4.2
1.12.4.3
1.12.4.4
In order to avoid a sudden change in generator voltage when voltage regulation is transferred from Main to Standby or from Auto to Manual, a suitable arrangement shall be provided to follow up changes in Auto mode along with follow up indication in Unit Control Panel. An alarm and visual indication shall be provided to indicate change over from Auto channel-1 to Auto channel-2 or from Auto to Manual.
ISSUE
R0
39
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 15 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.12.4.5
The maximum change in generator voltage when AVR is transferred from Auto to Manual under all conditions of excitation shall be less than 0.5%. A negative sequence component filter to permit response only to the positive sequence component of the regulated voltage shall be provided. At least, the following instruments and control devices suitably clubbed on a plate/console shall be supplied for being mounted on unit control panel. Further, it shall be possible to exchange information with DCS through suitable protocol. 1. 2. 3. 4. 5. 6. 7. 8. A center zero balance indicator to indicate the channel difference signal Generator field current indicator Rotor winding temperature recorder Auto Channel-1 to Auto Channel-2 & Auto/Manual changeover indications Generator field breaker/exciter field breaker control & instrumentation PSS control and instrumentation Auto and manual channel control of excitation level Speed set point control
1.12.4.6
1.12.4.7
1.12.5 1.12.5.1
Brushless Excitation System The complete equipment shall be mounted on a bed plate and enclosed by suitable enclosure. The system shall consist of : 1. 2. 3. 4. 5. 6. 7. Permanent Magnet Generator (PMG) type Pilot Exciter. Rectifier Unit for PMG Brushless Main Exciter Rotating Rectifier Unit Regulator Cubicle Complete instrumentation and protection system. Inter-connecting cables between different components of the system
ISSUE
R0
1.12.6
Pilot Exciter
40
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 16 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.12.6.1
The pilot exciter shall be revolving field, salient pole, permanent magnet high frequency type. The armature shall be stationary 3 phases feeding current to the static rectifier assembly and excitation control equipment. The rotor shall be magnetized and stabilised by the Manufacturer to give stable magnetisation characteristic during operation. The stator winding shall be of class F insulation or better but its temperature rise shall be limited to Class-B, suitable for operation at 500C ambient temperature. The machine shall be fitted with fans for self-ventilation. Rectifier Unit for PMG Fully controlled three phase, full wave bridge type thyristor converter facilitating fast and high ceiling performance shall be provided. They shall be suitable to ensure trouble free service of the cells under all fault conditions. The converter shall have redundant thyristors for satisfactory operation even in the event of failure of any of the thyristors. The thyristors shall be selectively protected against short circuits by ultra high speed fuses. Suitable lamp indication shall also be provided to indicate the defective thyristor. Brushless Main Exciter The rotating armature shall be 3-phase, star connected, feeding current to the rotating diodes mounted on the exciter shaft. The armature core shall be made from silicon sheet lamination to reduce eddy losses and shall be suitably varnished on both sides. The exciter shall be totally enclosed, self ventilated, frame supported on the generator foundation having journal bearings. Integrally mounted air fan shall be provided for the cooling of the exciter. The armature conductor in the overhang portion shall be adequately held to withstand the electro-dynamic forces during field forcing condition. Rotor end winding retaining ring shall be made up of stress corrosion resistant material. The stator and rotor winding insulation shall be of class F with the temperature rise limited to class B limits of IEC 60034. Rotating Rectifier Assembly
ISSUE
R0
1.12.6.2
1.12.7 1.12.7.1
1.12.8 1.12.8.1
1.12.8.2
1.12.8.3
1.12.9
41
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 17 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.12.9.1
The rotating rectifier assembly shall have the following essential features : 1. The rectifier assembly made of silicon diodes shall be arranged as two distinct rings with opposite polarity diodes on respective rings. The diodes shall be connected in a conventional threearm full wave rectifier bridge. Rectifier assembly shall have one complete bridge as redundant. Alternatively a single three phase rectifier bridge having at least one redundant parallel rectifier branch in each of the six arms of the bridge may also be considered. Rectifier assembly shall have same requirements as regards the component features and rating as detailed out for the thyristor assembly. Diodes shall be cooled by forced air circulation by means of fans mounted on the main exciter. Each diode shall be provided with a fuse together with visual indication in the event of diode failure. The output from the rectifier shall be fed to the generator field through the bore of the rotor shaft and necessary plug in type of shaft connection. The axial copper connector shall be designed such that it shall be possible to disconnect this connector at the point where the exciter shaft couples to the generator so that, if necessary, the generator and exciter can be tested individually.
2.
3. 4. 5.
1.12.10
Regulator Cubicle Self-supporting, sheet metal enclosed with swing doors and ventilating louvers with wire gauge shall be furnished for the excitation and voltage regulating equipment. Natural ventilation shall be provided for the cooling of excitation cubicles.
1.12.11
Instrumentation The instrumentation for excitation system shall generally include, but not be limited to the following: i) Suitable duplex RTDs for measuring hot and cold air temperature of exciter with necessary provisions for protection tripping/interlocks.
ISSUE
R0
42
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 18 OF 42
SPEC. NO. TCE.5960A-H-500-001
ii) Instruments and devices for the measurement of rotor winding temperature. iii) Stroboscope or suitable alternative device for detection of faulty rotating diode element. iv) Suitable arrangement for exciter field suppression. v) A pair of auxiliary slip rings shall be provided to give access to the rotor circuit allowing an earth fault detector circuit to be connected. vi) For all alarms in the system, contacts shall be taken from the temperature switches, etc. provided at suitable points. The system shall be provided with transmitters for the above indicators. 1.13
1.13.1 1.13.1.1
Hydrogen Cooling System System Requirements The hydrogen gas cooling system comprises a hydrogen circuit for cooling the stator core, stator winding, lead terminal bushings and rotor windings, carbon-dioxide scavenging system and compressed air supply system. The system is required to fill the generator with hydrogen, maintain it under pressure, monitor and control gas purity and to empty the hydrogen from generator. Also the system shall permit emptying of the generator casing with help of CO2 purging. The design has to be such as to ensure safe filling / emptying by preventing formation of explosive H2 air mixture. For filling, air is first displaced by CO2, which in turn is replaced by H2. While emptying H2 is first displaced by CO2 before admission of air in the machine in order to obviate possibility of any explosion. For removing CO2, instrument quality air supply shall be used. The major system components are H2 and CO2 gas manifolds, CO2 heating system, hydrogen pressure regulator, H2 gas coolers, H2 drying equipment, inter-connecting pipings, fittings, valves, gauges, thermometers, pressure transmitters and other instrumentations, control & monitoring panel. Annunciation and electrical instruments shall be located in a separate electric panel common with seal oil system outside the hazardous area.
ISSUE
R0
1.13.1.2
1.13.1.3
43
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 19 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.13.1.4
Hydrogen supply of 97-99% purity shall be obtained from H2 cylinders on rack through H2 distributor. The distributor shall be capable of connecting H2 cylinders to meet at least one shutdown & one start up of all the units & 30 days of normal operating requirement. Intermediate valves shall allow replacement of individual cylinders during operation. The high pressure H2 gas from the distribution header shall be provided with 2x100% pressure reducing valves. This shall be further reduced to generator pressure requirements by means of 2x100% pressure reducing circuit. Hydrogen shall be circulated in the generator in closed circuit by fan fitted on the rotor shaft. H2 gas is cooled by water/gas heat exchangers located in the generator housing. The coolers shall be of sectionalised design such that with one cooler section out of service & 10% of the tubes in other sections are plugged, the unit can deliver at least 80% of the rated load continuously without exceeding the permissible temperature limits of class B. The hydrogen coolers shall be provided with 10% excess tubes. Cooler shall be designed for at least 10 Kg/sq. cm. Gauge pressure on the gas side irrespective of a lower normal operating casing pressure. Corrosion resistant tubes with integral fins shall be provided and arranged in the stator casing so as to avoid the direct fall of water during leakage, if any, on the winding insulation. It shall be possible to clean/plug the cooler tubes of a section with the machine under operation. Water pressure in the coolers shall be maintained below the operating hydrogen pressure in the generator casing. The generator drying arrangement complete with all electrical/mechanical drives/equipment, accessories and controls to enable drying out operation of the generator with hot air circulation shall be provided. The system shall be complete with necessary pressure, temperature and flow gauges as well as thermostats as required.
1.13.1.5
1.13.1.6
1.13.1.7
1.13.1.8
1.13.1.9
1.13.1.10 A certain quantity of H2 circulating in the generator shall be
bypassed through gas drier for removing the moisture and maintaining the gas in dry condition. 2x100% capacity H2 dryers with in-situ reactivation facility shall be provided to maintain the H2 inside the machine dry with 0O C dew point at operating pressure.
ISSUE
R0
44
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 20 OF 42
SPEC. NO. TCE.5960A-H-500-001
The arrangement shall be such that one drier can be taken out of service for reactivation without affecting the system performance in any way. Glass indicator shall be provided to indicate humidity.
1.13.1.11 To run the gas system for short time during shut down of generator
(at standstill) for which gas circulation arrangement through drier with blower, piping valves and accessories along with required control equipment shall be provided. A suitable hot air blowing system complete with blower, heater and thermostatic control etc. shall be provided to prevent condensation during long shut down.
1.13.1.12 The design of the drier shall be such that it is possible to reactivate
the drying medium in-situ after isolation from the generator casing and connecting it to atmosphere. Arrangement for purging out entrapped air from the drier after regeneration shall also be provided, as applicable. For controlling the time/regime of reactivation, suitable thermometers, thermostats, timers etc. with a local control panel shall be provided.
1.13.1.13 On line dew point monitoring system shall be provided across the
inlet and outlet lines to the drying system along with alarm/annunciation in case of high moisture content in the generator casing hydrogen.
1.13.1.14 The cylinders of CO2 shall ensure complete emptying of the
cylinders as well as to avoid evaporation of liquid CO2 to gas in cylinder itself. The arrangement of CO2 distributor shall correspond to that of H2 distributor. The CO2 shall leave the cylinder in liquid state and shall be evaporated and expanded in a vaporiser. Thermostat controlled electrical heating system shall be provided for CO2 system so that the freezing of CO2 pipe is prevented.
1.13.1.15 Seamless steel tubes shall be used for valve piping. Valves shall
be glandless diaphragm type, wherever possible. The valves in gas system shall be of special design to minimise gas leakage. Safety relief valves shall be furnished at hydrogen manifold both on low and high pressure sides of the gas system. A manually operated vent valve shall be provided for discharging casing hydrogen to atmosphere (outside the TG hall) in case of emergency. The three way valves used along with the drier for interconnecting the hydrogen and airline (as applicable) shall preferably have mechanical interlocking such that closing of the hydrogen side port is positively ensured before opening of the air side port.
1.13.2
Instrumentation
ISSUE
R0
45
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 21 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.13.2.1
To ensure efficient and reliable operation of the generator gas system adequate instrumentation shall be provided. This shall include the following as a minimum: Dial type thermometers for CO2 vaporiser, and gas drier. Pressure gauges for gas cylinders, gas manifold, fan differential pressure, generator casings, gas flow meter. Required number of temperature, pressure and liquid level detector switches for alarm and interlock. Necessary sensors/transmitters for remote indication and recording in DCS. The local H2 panels shall include indicators for H2 gas cylinder pressure, H2 gas manifold pressure, generator casing pressure, H2 gas purity, H2 gas temperature (for hot and cold H2 inside casing), CO2 pressure inside generator, CO2 pressure in the manifold, air pressure in the air supply manifold and dew point level indicator for casing H2 across drier inlet and outlet lines. H2 pressure and purity shall be monitored in DCS. Gas Analyser shall be of thermal conductivity type and shall continuously analyse the gas discharged from the casing during purging and shall also analyse samples of the casing hydrogen during normal operation. The analyser shall measure the gas purity under the following three conditions: a) Normal % of purity of Hydrogen in air in the generator casing. Purity range shall include a low purity alarm. b) % of Hydrogen in CO2 leaving the casing when Hydrogen is being admitted or expelled. c) % of air in CO2 leaving the casing when CO2 is being admitted or expelled. Portable gas analyser as detailed above shall be provided for supervision of the gas purging operation. The Contractor shall provide instrument for on line monitoring of moisture content in hydrogen inside generator casing.
1.13.2.2
1.13.3 1.13.3.1
Annunciation The following annunciation shall be provided on the local electric panel and DCS. The local control and annunciation panel shall be complete with switches, lamps, indicators, facia annunciation, power supply, accept-reset-test push buttons, hooter, etc.
ISSUE
R0
46
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 22 OF 42
SPEC. NO. TCE.5960A-H-500-001
H2 Pressure in Generator Casing H2 Pressure in Cylinders H2 Pressure in Manifold Purity of H2 in Generator Casing
: : : :
High / Low Low Low Low High Low / High High High High Failure
Temp of Cold/Hot Gas in the Generator : Pressure of Cooling Water of H2 : Coolers Dew Point Level in H2 Gas across the : drier inlet & outlet lines H2 Leakage into Cooling Water Liquid Level in Generator Casing Power / Control Supply
1.13.3.2
: : :
Independent signals, analog and digital, shall be connected to DCS system. All instruments shall be mounted on a gas control cubicle to be located near the machine. H2 and CO2 Cylinders The number of H2 and CO2 cylinders shall be equal to total requirement for one start up and one shut down of a unit plus those required to be connected on manifolds of all units plus total requirements for seven days consumption of all units. The Contractor shall supply H2 and CO2 gas till completion of trial operation. Getting necessary approval from chief controller of explosives is in the scope of the Contractor. The Contractor shall also furnish the necessary test certificates and filling certificates. The cylinders to be supplied under this specification shall conform to IS:8198. Each gas cylinder shall be complete with cap and valve as per IS:3224. Volumetric (water) capacity of each cylinder shall be 45.0 litres. Each cylinder shall be hydro tested at pressure of 250 kg/cm (min.).
ISSUE
R0
1.13.4 1.13.4.1
1.13.4.2
1.13.4.3
47
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 23 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.14
1.14.1 1.14.1.1
Generator Shaft Seal Oil System System Requirements A complete seal oil supply and control system including AC and DC motor operated pump sets, coolers, filters, pressure regulators, oil tanks, de-gassification tanks, regulating and control valves, gauges, thermometers and other instruments, interconnecting piping including hangers and supports, valves and control/annunciation panel complete with all interlocking relays shall be provided. A shaft seal oil system shall be provided to prevent the leakage of hydrogen from the generator casing. The seal oil, when maintained at a pressure suitably in excess of the hydrogen gas pressure in the generator casing shall provide an effective gas seal and shall lubricate and cool the seals when the generator is running. Seamless steel piping shall be used in the system. A diaphragm operated regulating valve in the seal oil supply line shall control the seal oil pressure by a constant amount. The differential pressure shall be kept constant once set at the time of commissioning, at all hydrogen pressures and all regimes of generator operation. The pressure regulator or the regulating valve used for the purpose shall be adjustable type. The seal oil system shall be so designed that it is possible to run the machine at no load in air medium at a slightly positive air pressure without any modification in the system. The seal oil shall be cooled in two (2) 100% capacity water cooled heat exchangers along with necessary 3 way valves for isolating or bringing one cooler in service. These coolers shall be shell and tube type suitable for using DM water of condensate quality. Seal oil coolers shall be designed to have 15% excess tube surface area over and above designed tube surface area required for the rated load conditions while maintaining the design pressure drop on cooling water side. The oil pressure in the coolers shall be greater than water pressure under all operating conditions. 2x100% capacity filters shall be provided. Piping and valve arrangement shall be such that any cooler/filter can be taken out for cleaning and maintenance without affecting the operation of the system. Seal oil system shall have connection to turbine oil system
ISSUE
R0
1.14.1.2
1.14.1.3
1.14.1.4
1.14.1.5
1.14.1.6
1.14.1.7
48
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 24 OF 42
SPEC. NO. TCE.5960A-H-500-001
for make up and also excess return and also shall serve as 100% back up.
1.14.1.8
For the seal oil system, 2x100% capacity motor driven AC pumps shall be provided of which one pump shall always be in operation. Upon failure of the normal service pump due to a mechanical or electrical fault, the standby pump shall automatically take over the supply. On of the seal oil pumps shall be fed from the emergency DG bus. Upon the failure of both AC driven pumps, the seal oil supply shall be taken over by the emergency DC seal oil pump without any interruption. The seal oil system shall thus be selfcontained. The auto starting of standby seal oil pumps shall be interlocked with seal oil pressure. During short time emergency, which may arise due to non availability of both AC & DC pumps, unit may be tripped and seal oil supply for such coasting down period shall be from a suitable arrangement from lubrication oil system or a damper tank.
1.14.1.9
1.14.1.10 The seals shall be designed so that minimum oil enters the
hydrogen side of the machine and the oil drained from this part of the machine passes to a suitable hydrogen detraining tank. 2 x 100% Blowers for venting out Hydrogen gas liberated from oil shall be provided suitably mounted at places where such gas accumulation is likely to occur. Also H2 diffusion loss through seal oil shall be minimum to maintain H2 purity level inside generator at a high level. The hydrogen dilution blower shall have the following features: HYDROGEN DILUTION BLOWER Type Capacity Air intake filter type Suction pressure Discharge pressure m3/hr Bar Bar Centrifugal/Twin lobes By bidder Simplex / Duplex type Atmospheric pressure By bidder
ISSUE
R0
49
TCE FORM NO. 329 R5
SECTION:
D3.1
SHEET 25 OF 42
SPEC. NO. TCE.5960A-H-500-001
Mounting type
Skid mounted
MATERIAL OF CONSTRUCTION Impeller/Lobes Shaft Casing AISI Type SS 316 AISI Type SS 410 (Duplex SS) AISI Type SS 316/ AISI Type SS 304/ 2% Nickel Cast Iron. IS:2062 Gr.B with epoxy coated. 400V, 50 Hz & 3 Shall be provided (If applicable) 85 @ 1.5 meter distance
Base Plate Prime mover details Silencer Noise level Pressure drop across the lobes Performance test
dB(A)
mmWc By Bidder Shall be conducted as per standard
1.14.1.11 Necessary hydraulic sealing arrangement shall be provided in H2
side oil discharge line to prevent circulation of gas due to any possible difference of heads developed by fans mounted at the end of the generator.
1.14.1.12 A water detector with sight glass and drain valves shall be mounted
adjacent to the gas manifolds at the end of a pipe connected to the bottom of the generator casing.
1.14.1.13 The oil which is used for the hydrogen sealing shall be same as the
lubricating oil for the turbine & generator bearing & governing system.
1.14.2
Instrumentation
ISSUE
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SHEET 26 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.14.2.1
To ensure efficient and reliable operation of the seal oil system adequate instrumentation shall be provided. This will include the following as a minimum: i) ii) Dial type thermometers for inlet and outlet temperature of the seal oil and cooling water to each cooler. Pressure gauges at inlet and outlet of pumps, at outlet of coolers, at inlet and outlet of pressure regulators and filters, seal oil inlet to hydrogen and airside seals, hydrogen-casing pressure, across each strainer and H2 seal oil differential pressure and at oil supply header.
iii) Seal oil tank level indicator and flow meters for flow through seals. iv) Required numbers of temperature, pressure and level gauges for alarms and interlocks. Necessary sensors / transmitters for remote indication and recording in DCS.
1.14.2.2
Local seal oil control panels shall be provided with indicators for pump discharge pressure, seal oil pressure at the seals (for both hydrogen and air side streams), thrust oil pressure, hydrogen / seal oil differential pressure, seal oil flow, seal oil temperature at the seals and status indications for seal oil pumps. The remote instrumentation at Unit Control Room shall include seal oil temperature recording and seal oil / H2 differential pressure recording in DCS. Annunciation The following annunciations shall be provided on the local electric panel and in DCS system. Seal Oil Tank Level Seal Oil Temperature Pressure of Seal Oil Pressure of Thrust Oil Seal Oil Pressure H2 : High / Low / Very Low : High : Low : Low
1.14.2.3
1.14.3 1.14.3.1
Differential : High / Low : Low

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Oil Level in Damper Tank (if applicable)
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SHEET 27 OF 42
SPEC. NO. TCE.5960A-H-500-001
Oil Level in Damper Tank : Very Low Emergency (if applicable) Oil Level in Hydraulic Seal Oil Level in Hydraulic Seal Seal Oil Filter Seal Oil Pump Standby Seal Oil Pump DC Seal Oil Pump : High : Low : Choked : Failure : Running : Running
AC Seal Oil Motor Power : Failure Supply DC Seal Oil Motor Power : Failure Supply Power / Control Supply Seal Oil Pressure Cooler : Failure Water : High / Low Water : High / Low
Seal Oil Cooler Temperature.

1.14.3.2
All annunciations shall be duplicated in the Unit Control Room. For this purpose, separate alarm contacts shall be provided. Independent signals, analog and digital shall be made available for connection to DCS system. Stator Water Cooling System System Requirements
1.15 1.15.1
1.15.1.1 Generator stator winding shall be cooled by water. Water cooling shall be with a closed loop cooling system. The system shall generally include but not be limited to the following: 1.15.1.2 One (1) number primary water tank shall be provided and mounted on the stator frame on anti-vibration pads and covered by the generator cladding. The empty space in primary water tank may be filled with Nitrogen to minimise water evaporation. The Bidder shall indicate and provide devices to detect, trap, monitor and release the
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SPEC. NO. TCE.5960A-H-500-001
hydrogen that leaks into the stator water cooling system, to a safe place outside the building through suitable safety valves. 1.15.1.3 The make-up water for primary water system shall be tapped off from condensate extraction pump discharge header (before and after the condensate polisher) and from DM water make-up line to the condenser. The level in the tank shall be maintained by means of suitable valves in the make up line. 1.15.1.4 Two (2) 100% capacity water to water heat exchangers shall be provided. The water-to-water heat exchanger shall be designed to accept secondary DM water (condensate quality). The system shall be so designed that the pressure of primary DM water inside the cooler is always greater than that of secondary DM water (condensate quality). The exchanger shall be designed to have 10% excess tube surface area over and above the designed surface area required for the rated load condition while maintaining the design pressure drop on cooling water side. 1.15.1.5 Two (2) 100% capacity fine wire mesh filters with magnet bars of unlimited life shall be provided for removal of all magnetic particles. The permanent magnet bars shall be protected by sleeves of stainless steel. It shall be possible to clean easily the ferromagnetic particles adhering to the magnet bars during capital maintenance. 1.15.1.6 Two (2) 100% capacity AC motor driven cooling water circulating pumps shall be provided. Standby pump shall cut in automatically in case the working pump fails or the pressure of circulating water drops below a certain preset value. 1.15.1.7 One (1) mixed bed demineraliser (MBD) of adequate capacity shall be provided to maintain the required quality of water. The MBD shall remain continuously in service in order to retain high purity of stator cooling water with its associated electrical resistivity. The Bidder shall indicate in the proposal the capacity of MBD necessary to maintain the quality water at the desired level for time duration of six months or more. The system shall be designed such that the MBD could be taken out of service for refilling without untoward effect on the system which could necessitate load reduction/rejection. 1.15.1.8 Alkaliser unit shall be provided alongwith stator water required for ensuring a corrosion free operation system. 1.15.2 Control System
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SHEET 29 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.15.2.1 The following instruments shall be provided on the local panel : 1. 2. 3. 4. 5. Indicator for primary water flow in the stator winding. Indicators for primary water conductivity at the inlet of winding and after the demineraliser. Indicator for stator winding differential pressure. Indicators for primary water temperature at the inlet and outlet of stator winding. Indicator for primary water pressure at the inlet of stator winding
1.15.3
Instrumentation
1.15.3.1 The following minimum instrumentation shall be provided : 1. 2. Set of conductivity meters in the main water circuit and after the demineraliser. Set of flow switches (at least two nos.) to monitor the low distillate condition and flow transmitters/meters for primary water to stator winding and main bushing, make up water etc. Sets of pressure gauges at the inlet and outlet of stator water filters, differential pressure switches for the filters, differential pressure gauge across stator winding and pressure transmitters as required. Set of resistance temperature detectors/indicators for primary water before and after the generator winding, bushing and cooler. Vapour filled temperature detectors shall also be provided to give signals for high temperatures. Set of dial type thermometers for cooling water at the inlet and outlet of the cooler. Water gauge, transmitters, level switches for high and low level alarms and other accessories for primary water tank.
3.
4.
5. 6.
1.15.4
Annunciations The following minimum annunciations along with duplicate contacts for use in DCS shall be provided:
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SHEET 30 OF 42
SPEC. NO. TCE.5960A-H-500-001
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.
Water level in the primary water tank - low. Water level in the primary water tank - high Temp. of primary cooling water at outlet of stator wdg. high. Temp. of primary cooling water at inlet of stator wdg. high. Flow of primary cooling water to the stator winding - low. Conductivity of primary cooling water at the winding inlet high. Flow of primary cooling water to the stator winding - very low. Conductivity of primary cooling water at the winding outlet - high. Pressure of primary cooling water at the inlet of winding low. Differential pressure across the primary water strainer high. Stator water cooling pumps - tripped on overload. Reserve control supply for stator water cooling - failed. Differential pressure across stator winding - high. Leakage of hydrogen into primary water - high Primary stator bar water temperature - high. Any other critical parameter to be annunciated
A summary annunciation for the above shall be provided on the unit control panel 1.15.5 On line stator water temperature monitoring system for individual stator winding bars shall be complete with all software and hardware required to detect any abnormalities in the temperature at any given generator operating point and shall be sensitive to generator loads, header water flows, pressure etc. and shall be possible to exchange information with DCS through suitable protocols. On-line oxygen monitoring system shall be provided, if the manufacturer recommends continuous monitoring of dissolved oxygen content in the stator water, to prevent copper corrosion.
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1.15.6
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SHEET 31 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.15.7
Liquid leakage detector shall be provided at all the low level points inside the generator casing including end shields along with provisions of indication and alarm during leakage of liquid in generator. Stator coolant flow recorder shall be monitored in DCS. Cubicle and Motor Starters Cubicles shall be furnished as required for (a) Excitation System, (b) Automatic Voltage Regulator (c) Hydrogen Cooling System (d) Seal Oil System (e) Stator Water Cooling System, (f) DC Motor Starters. The panels shall be of the self-supporting, floor-mounted type. The panels for DC Motor starters shall house stainless steel starting resistors. Measurement / Alarms in Control Room Each alarm shall be individually available on the DCS HMI whereas set of alarms can be grouped into a group alarm on the window of Local Control Panel. All the required relays / contacts / devices shall be provided to achieve the same. All the measurements shown in the protection and metering one line diagram TCE.5960A-EL-SK-2002 shall be made available in DCS and also in Local Control Panel. The continuous measurement of the rotor winding temperature while the machine is running shall be provided in DCS. The turbine generator control VDU in the central control room shall have graphical display of various generator subsystems, process/flow diagrams such as seal oil, hydrogen, lube oil, generator stator and rotor parameters along with display of generator capability curves and operating points, generator temperatures and vibration parameters, etc. They shall also have limiting values for alarm/trips, tag numbers, etc. clearly displayed on DCS. In addition operator help features for control of these systems and historical and reference data shall also be made available for efficient operator guidance of these systems. All inputs including logics for recommended control and instrumentation system required to integrate with artificial intelligence based softwares pertaining to generator and its auxiliary system shall be furnished.
1.15.8 1.16
1.16.1
1.16.2
1.17
1.17.1
1.17.2
1.17.3
1.17.4
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SHEET 32 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.17.5
On line partial discharge measurement system. Permanently connected Independent sensing unit for each generator shall be provided. However evaluation unit for all generators shall be common. Latest software shall be provided to interpret the PD result. It shall also be suitably connected to DCS.
1.18 1.18.1
Gas Turbine Generator Unit Start-Up System 2 nos. Static start-up system for gas turbine unit complete in all respects shall be offered. Additional thyristors in converter / inverter units to take care of thyristor failure, redundancy for critical items and self monitoring features. The voltage to frequency ratio of the start-up system output shall be maintained constant throughout the start-up and shall not lead to overfluxing condition of generator transformer and neutral grounding transformer. Over fluxing shall be limited to 110%. The current transformers (CTs) in the busduct and voltage transformers (VTs) shall not temporarily or permanently saturate even after successive starts through the start-up system. Also, the protections shall not mal-operate during gas turbine starting. The Contractor shall note that all the protection shall be set for normal operation of the plant and the settings will not be altered during start-up. To this extent the Contractor shall provide suitable protections on the start-up system output to protect the generator, CTs, VTs, etc., and cut off the start-up system in the event of operation of these protections. In case any of the protections are to be blocked during start-up operation due to likelihood of mal-operation, the Contractor shall provide suitable blocking and de-blocking signals from the start-up system. Both these signals shall be suitably supervised and annunciated. Minimum electrical system requirements in respect of control, monitoring, measurement, annunciation, synchronising are indicated in I&C System Section No. D2.4.
1.18.2
1.18.3
1.18.4
1.18.5
1.18.6
1.19
Tests
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SHEET 33 OF 42
SPEC. NO. TCE.5960A-H-500-001
1.19.1
1.19.1.1
Tests on Generator The following Routine Tests shall be carried out at works on each generator: i) Measurement of insulation resistance of the following before and after high voltage test: a) Stator Winding Insulation b) Rotor Winding Insulation c) ii) iii) iv) Embedded Resistance Temperature Detectors d) Bearing Pedestal Insulation Polarisation Index for Stator Winding Insulation. Tan-delta measurement of Stator Winding Insulation. Measurement of the DC resistance of the following: a) Stator Winding b) Rotor Winding c) v) vi) vii) viii) ix) x) xi) xii) Embedded Resistance Temperature Detectors Determination of generator open circuit characteristics, short circuit characteristics and calculation of short circuit ratio. Stator Phase Sequence checking. Measurement of Core Losses Measurement of Mechanical Losses Determination of generator efficiency by the separation of losses at 100%, 80% and 60% load. AC High Voltage Test on Stator and Rotor Winding Measurement of Rotor Winding Impedance at standstill and at various speeds upto 3000rpm. Measurement of phase to neutral and phase to phase capacitance of all the three phases of the stator and the rotor and calculation of the equivalent generator capacitance as viewed from the generator terminals; also the measurement of the capacitance between the complete winding and the body. Measurement of bearing leakage current / shaft voltage. Overspeed Test Mechanical Run and measurement of Vibrations
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xiii) xiv) xv)
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SHEET 34 OF 42
SPEC. NO. TCE.5960A-H-500-001
xvi)
Retardation test to establish GD2
xvii) Hydrogen leakage test xviii) Partial discharge tests on stator windings.
1.19.1.2
The field tests to be conducted on each generator at the site shall include but not be limited to those listed below. Any other test considered necessary by the bidder shall also be carried out : i) Measurement of insulation resistance of the stator and the rotor windings to the frame and between phases, after drying out the machine, and measurement of polarisation index. Measurement of the DC resistance of all windings and embedded temperature detectors. Measurement of the insulation resistance of bearings Capacitance measurement and dissipation factor between the winding and body. Open circuit and short circuit tests. Measurement of temperature rise at the rated load. Performance capability of the machine. Line charging capacity Short Circuit tests on the generator end and the generator transformer HV end to check the stability and operation of the generator and the overall (i.e. generator, generator transformer and unit auxiliary transformers) differential protections and negative phase sequence protection. These tests will be carried out jointly with the commissioning engineers of other vendors whose equipment are under test. Hydrogen leakage test Vibration test Overspeed test Hydraulic tests on coolers Bearing and shaft current test
ii) iii) iv) v) vi) vii) viii) ix)
x) xi) xii) xiii) xiv)

1.19.1.3
One generator of each type and rating shall be assembled at works and shall be tested to verify/ensure design and workmanship in accordance with IEC-60034/VDE-0539/IEEE-43. The tests shall be carried out keeping all conditions/parameters as close as possible to site conditions with all the built in instrumentation (like RTD etc.)
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SHEET 35 OF 42
SPEC. NO. TCE.5960A-H-500-001
suitably wired and the readings recorded. During various tests bearing, shaft overhang vibrations shall also be measured with and without excitation. Recording of bearing and seal oil running conditions and environmental conditions (like temperature etc.) shall also be done. The tests to be carried out under the contract shall include the following : i) Instantaneous short circuit test shall be carried out to determine transient and sub-transient reactance parameters and to ensure stability of winding during sudden short circuit condition. Determination of negative sequence and zero sequence impedance. Determination of Telephone Influence Factor and Total Harmonic Distortion of the voltage waveform. Short circuit heat run test at rated pressure and cooling parameters with one cooler out of circuit at two third of rated stator current. Vibration measurement on all planes on stator overhang winding at minimum six (6) locations on each end and at other critical locations for the following conditions : a) Open circuit operation. b) Short circuit operation. c) Sudden short circuit conditions. d) Stand still condition- with hammer test. The test results of above shall prove that the values are within the normal operating limits for long satisfactory performance and that there are no components or parts, which have natural frequency of resonance near operating frequencies or 100Hz. 1.19.2 Tests on Exciter and AVR
ii) iii) iv)
v)
1.19.2.1 The following Routine Tests shall be carried out at works on each exciter and AVR: a) Pilot Exciter (PMG) i) ii) Measurement of output voltage at rated speed Checking of phase sequence and measurement of frequency
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SHEET 36 OF 42
SPEC. NO. TCE.5960A-H-500-001
iii) Measurement of load characteristics iv) Measurement of insulation resistance and high voltage test on stator winding v) b) Measurement of DC resistance of stator winding
Main Exciter (Brushless Exciter) i) ii) Measurement of open circuit characteristics Load magnetisation characteristics
iii) Measurement of insulation resistance and high voltage test on armature and field winding iv) Measurement of DC resistance of armature and field winding c) Voltage Regulator i) ii) Response ratio test Insulation resistance and high voltage test
iii) Performance test at reduced supply voltage iv) Auto 1 / Auto 2 channel follow up test v) Auto Manual channel follow up test vi) Thyristor load test (light load test at rated voltage and full current test) vii) Functional tests 1.19.2.2 The field tests to be conducted on each AVR at the site shall include but not be limited to those listed below. Any other test considered necessary by the bidder shall also be carried out : i) ii) iii) iv) v) vi) vii) viii) Accuracy test Sensitivity test Performance tests on all limiters Impulse input response test Auto 1 / Auto 2 channel follow up test Auto Manual channel follow up test Range of voltage adjustment for both auto and manual channels Functional tests
1.19.2.3 The following type tests on Brushless excitation system of one machine of each rating shall be conducted.
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SHEET 37 OF 42
SPEC. NO. TCE.5960A-H-500-001
a)
Main Exciter : Temperature rise test at peak rating of excitation system and ceiling duty condition shall also be demonstrated. PMG : Temperature rise test at peak rating of excitation system shall be demonstrated. Field Breaker : Type tests on exciter field breaker shall be conducted as per IEEE/ANSI C 37-18. Converter Assembly (of the exciter field) : i) Temperature rise test at peak rating of excitation system and ceiling duty condition shall also be demonstrated. ii) Input and output surge withstand capability test. iii) Soak test for electronic modules.
b) c) d)
e)
Voltage Regulator : i) Soak test on electronic equipment ii) Surge withstand capability test on electronic equipment
1.19.3
The following test to be conducted on startup system a) SFC panels i) Temperature rise test ii) Surge withstand capability test iii) Noise level test b) SFC Transformer
The following type tests shall be conducted on one transformer i) Tank Pressure test ii) Tank vacuum Test iii) Short circuit test on one transformer to be selected by Owner. iv) Noise level v) Measurement of harmonics of no load current
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SHEET 38 OF 42
SPEC. NO. TCE.5960A-H-500-001
vi) PRD operation test vii) Degree of protection test on marshalling box viii) Zero sequence Impedance ( not applicable for Deltadelta transformer) ix) Temperature rise test x) Lightning impulse test on one limb xi) DGA test on oil before and after temperature rise test 1.19.4 All components of the excitation system shall be tested in accordance with the relevant standards and type and routine test certificates shall be furnished. All Type and Routine test certificates shall be furnished to the Owner for review and approval.
1.19.5
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DATA SHEET A3.1
SECTION: SHEET
D3.1
39 OF 42
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
VALUES / REQUIREMENTS
1.1 1.2 1.3 1.4 1.5
Generator and Excitation System Rated Output Rated terminal voltage Rated frequency (a) Rated power factor (b) Power factor variation No. of phases Continuous operation under unbalanced load Stator winding connections Speed Type of cooling (a) Stator Winding (b) Rotor Winding and Stator Core Water Hydrogen rpm Hz Ref clause 1.1.1 By Bidder 50 0.85 (lagging) 0.85 (lag) to 0.95(lead) 3 As per IEC: 60034-1
1.6 1.7
1.8 1.9 1.10
Star 3000
1.11
No. of line terminals to be brought out No. of neutral terminals to be
Nos.
Three (3) Six (6)-(In case of split brought out phase winding and having more than one conductor per phase or else three (3) )
1.12
1.13
Rated short circuit ratio at MCR not less than Operation under unsymmetrical fault Class of insulation of generator stator and rotor windings
R0 MAR 10 PPD. BY CKD.BY RKD HA JOB NO. 5960A
0.5 As per IEC-60034-1
1.14
1.15
Class F (temp. rise limited to that of class B)

CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3
64
REV. NO. DATE
REV. BY
DATE
TATA CONSULTING ENGINEERS LTD

DATA SHEET A3.1
SECTION: SHEET
D3.1
40 OF 42
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
1.16
Degree of protection for generator enclosure Excitation system response ratio Excitation system response time sec.
IP-54
1.17 1.18 1.19 1.20
Minimum 2.0 <0.5 <+0.5 <0.5
Accuracy of Gen. Terminal voltage % Manual channel shall follow auto channel within Telephone harmonic factor %
1.21 1.22
shall not exceed 1.5
Field forcing capability during bolted fault on generator terminals % Type of voltage regulator
Minimum 150 Two auto and one manual channel, Solid state, continuously adjustable Required (to be switched on automatically when turbine is shut down) As per VDE 2063 and shall meet requirements as per respective gas turbine and steam turbine sections. (Bidder shall indicate). As per IEC 60034 shall meet the requirements as per respective gas turbine and steam turbine sections (Bidder shall indicate)
1.23
1.24
Space heaters for generator
1.25
Maximum amplitude of vibrations (peak to peak)
1.26
Noise level from the surface of equipment
1.27
Limiters, compensators, monitoring devices for generator excitation system Minimum excitation limiter
1.27.1
REV. NO. DATE
Required
65
REV. BY
DATE

DATA SHEET A3.1
SECTION: SHEET
D3.1
41 OF 42
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
1.27.2 1.27.3 1.27.4 1.27.5 1.27.6 1.27.7 1.27.8 1.27.9 1.27.10 1.27.11
Maximum excitation limiter Maximum rotor current limiter Under/over excitation limiter Maximum stator current limiter Cross current compensator Overfluxing (V/Hz) limiter Load angle limiter Transformer drop compensation Power system stabiliser Two stage Field suppression facility Two stage Field earth fault monitor Automatic power factor controller Motorised manual control for remote parallel operation Manual control range of AVR
Required Required Required Required Required Required Required Required (adjustable between 0% & 15%) Required
Required
1.27.12
Required Required
1.27.13 1.27.14
Required 70% of no load to 110% full load of voltage range Ref. clause 1.1.20
1.27.15
1.28
Number of RTDs/Thermo-couples required for generator Efficiency at 100% load at rated power factor Maximum Inlet Temperature of Cooling Water available for Hydrogen / Air coolers Type of cooling water available
0
1.29
As per IS-4899 350 C
1.30
1.31
REV. NO. DATE
DM water
66
REV. BY
DATE

DATA SHEET A3.1
SECTION: SHEET
D3.1
42 OF 42
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
for Hydrogen coolers / Air coolers / water coolers (ordinary water / sea water) 1.32 1.32.1 Codes and Standards Specification for rotating electrical machines - rating & performance Guide for testing synchronous machines Method of determination of efficiency of rotating electrical machines Measurement and evaluation of vibration of rotating electrical machines Methods for determining synchronous machine quantities from tests Degree of protection provided by enclosures for rotating electrical machines Methods for cooling rotating machinery Terminal markings and direction of rotation of rotating machines Method of measurement of airborne noise emitted by rotating electrical machines
IS-4722 and IEC-60034-1,3 IS-7132
1.32.2
1.32.3
IS-4889
1.32.4
IS-12075 IS-7306 and IEC-60034-4/4A
1.32.5
1.32.6
IS-4691 and IEC-60034-5 IS-6362 and IEC-60034-6
1.32.7
1.32.8 1.32.9
IEC-60034-8
IS-6098 and IEC-60034-9
REV. NO. DATE
R0 MAR 10
PPD. BY CKD.BY
RKD HA
JOB NO. 5960A
REV. BY
DATE
67
SECTION: D3.2
SHEET
1 OF 8
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER
SPEC NO TCE.5960A-H-500-001
2.0 2.1
GENERATOR CIRCUIT BREAKER Generator circuit breaker shall be provided in single phase enclosures, all fully assembled on a common frame with operating mechanisms, supervisory and control equipment. The voltage class of the Generator circuit breaker shall be same as that of the generator. The continuous current rating of the Generator circuit breaker shall be arrived at considering the maximum output of the generator and at specified minimum voltage. The Generator Circuit Breaker (GCB) is installed indoor / outdoor and connected to Generator busduct (Isolated Phase) on both sides. Suitable provisions shall be made for connection with Isolated Phase Busduct (IPB) through flexible connection. The GCB movement during short circuit shall be restricted so as to limit the stresses on GCB support insulators within their capabilities. Support structure shall be designed to withstand the dynamic as well as static load of the GCB. Design calculations of support structure shall be furnished for Owner's approval. The Generator circuit breaker shall be integrated with seriesdisconnector, current and voltage transformers, grounding switches, surge arrestors and protective capacitors in three single phase enclosures, as shown in attached Main one line diagram TCE.5960A-EL-SK-2003. The short time and momentary current rating of the Generator circuit breaker shall be decided as follows: (a) Short time current rating for 1 second: (i) Higher of the short circuit current contribution from generator or the short circuit current contribution from 400 kV system through generator transformer (400 kV system fault level 50 kA) Plus (+)
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2.2 2.3
2.4
2.5
2.6
2.7
2.8
TCE FORM NO. 329 R5
SECTION: D3.2
SHEET
2 OF 8
(ii) (b)
Contribution of 6.6 kV auxiliary system through unit auxiliary transformers.
Momentary current rating: 2.55 times the short time current rating arrived as above.
2.9
The basic switchgear module shall include the following minimum equipment but shall not be limited to the same. a) Circuit breaker with disconnector for series isolation on Generator Transformer side. b) Grounding switches fitted both sides of unit and to all three phases. c) Generator side current transformers with upto two cores per phase towards GT side. d) Voltage transformers with two secondary windings; two per phase on generator side, one per phase on transformer side. e) Protective capacitors fitted to both sides of the unit and to all three phases. f) Surge arrestor with surge counter on generator transformer side
g) 0.25F surge capacitor on either side of circuit breaker as shown in the Main SLD. h) Supporting structures and suitable platform.
2.10
The system shall be extended by all of the following items: a) b) c) A switched (motor operated) short circuiting connection between the power circuit breaker and the series disconnector for maintenance and protection checking. A manually fitted grounding link for the above short circuiting connection. An isolator for the SFC connections
The accuracies of the CTs & PTs shall be as per the enclosed Main one line diagram TCE.5960A-EL-SK-2003. The CTs and VTs shall not temporarily or permanently saturate even after successive starts through the start up system. Also, the protections shall not mal-operate during gas turbine starting. 2.11 The GCB shall be of SF6, metal enclosed, indoor / outdoor and free standing type. It shall be provided with three pole gang operation
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SHEET
3 OF 8
and anti-pumping feature. All the three poles shall operate simultaneously. If all the poles do not close simultaneously the breaker shall trip on pole discrepancy. The Generator circuit breaker shall use SF6 gas both as its arc-extinguishing medium as well as for internal insulation. It shall be designed with separate contact systems for the current breaking and current carrying functions. Semaphore position indicators shall be provided for local indication of the position of the circuit breaker. 2.12 The GCB enclosure shall be non-magnetic aluminium alloy, minimum flux, and isolated phase type with degree of protection IP-65 and canopy shall be provided if installed outdoor. Insulators shall be of high strength, fine glazed porcelain or epoxy resin type. SF6 gas monitor for each phase shall be provided. Necessary interlocks are to be arranged to prevent breaker operation on fall of SF6 gas density. A series disconnector shall be fitted on the outgoing side of the circuit breaker and within the same enclosure. The disconnector shall be of a tubular telescopic unit with the moving contact tube connected on the transformer side, the fixed contact being on the circuit breaker side of the unit. Grounding switches shall be provided on both sides of the switchgear unit. The connections and the switches shall be rated for full fault current. The ground connections shall be made via the switchgear enclosure to the housings of the isolated phase busbars and then to their grounding connection. The short circuiting disconnector and its connections shall be designed to expedite the testing and adjustment of the power plant protection system. Closure of the disconnector shall establish a three phase short circuit on to the generator connections but without ground to save time, both during initial commissioning, as well as, when routine testing the protective relaying. The Main One Line diagram enclosed indicates the relays and meters to be connected to the current transformers and voltage transformers. The VA burden, knee point voltage, secondary resistance and the exciting currents of CTs and VA burden of the VTs shall suit the connected metering/protective equipment.
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70
2.13 2.14
2.15
2.16
2.17
2.18
TCE FORM NO. 329 R5
SECTION: D3.2
SHEET
4 OF 8
2.19
Locking bars or effective mechanical arrangement shall be provided to lock main and auxiliary contact in the open position to prevent inadvertent closing either in main breaker or on disconnecting switch. Duplicate shunt opening release coils suitable for operation with voltage upto 60% of rated voltage of coils along with status monitoring shall be provided. If the offered breaker is pneumatic operated then, on loss of compressed air supply breaker shall get locked in its current state. In case of pneumatic operating mechanism compressed air plant shall be provided with 2x100% compressors. Driers shall also have same capacity. Capacity of each high pressure receivers shall have stored energy for 2 close-open operations. Capacity of local air receivers shall meet one close-open operation. In case of hydraulic mechanism, the stored energy shall be suitable for two close open operations. The breaker shall have 2 x 100% hydraulic pumps. The bidder shall clearly bring out the details in respect to this offer. The operating mechanisum shall be spring operated both for closing and tripping operations. The stored energy in the spring shall be sufficient to permit at least two close-open operations. The spring charging motor shall be suitable for 220V DC and shall be fed from respective Unit DCDB. The spring charging motor shall be capable of charging the spring within 30 secs. The minimum number of auxiliary potential free contacts required to be wired up to the terminal strip for PURCHASERs use after BIDDERs use in all Control and Protection circuits shall be : 12 NC + 12 NO for Circuit Breaker 8 NC + 8 NO for Disconnector 8 NC + * NO for each Earthing Switch Contact wear monitoring shall also be offered along with the GCB.
2.20
2.21 2.22
2.23
2.24
2.25
2.26
Local control panel shall be provided near GCB to facilitate Local ON/OFF Control, status indication, alarm and annunciation of the breaker and all auxiliary equipments shall also be located in local control panel. Local control panel shall include a Local/Remote selector switch.
ISSUE R0
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TCE FORM NO. 329 R5
SECTION: D3.2
SHEET
5 OF 8
2.27
The GCB shall be suitable for synchronizing duty and capable of withstanding out of phase voltage across open contacts. The breaker shall also be capable of switching on to a fault and out of phase switching.
Main contacts shall have ample area and contact pressure for carrying the
2.28
rated current and the short time rated current of the breaker without excessive temperature rise which may cause pitting or welding. Contacts shall be easily replaceable and shall have a minimum of movable parts and adjustments to accomplish these results. Main contacts shall be the first to open and the last to close so that there will be little contact burning and wear. 2.29 Arcing contacts, if provided, shall be the first to close and the last to open and shall be easily accessible for inspection and replacement. Tips of arcing and main contacts shall be silver faced or have tungsten alloy tipping. The operating mechanism and associated accessories shall be enclosed in weather proof mechanism cabinet of hot dip galvanised sheet construction, thickness of which shall not be less than 2 mm. Hinged doors giving access to the mechanism at the front and sides shall be provided. Suitable gaskets shall be provided to make the mechanism housing water-proof and dust-proof. The housing latch shall accommodate padlock requiring a 12 mm diameter hole. Padlock and duplicate keys shall be included in the BIDDER's scope of supply. Working parts of the mechanism shall be of corrosion resisting material. Bearings which require grease shall be equipped with pressure type grease fittings. Bearing pin, bolts, nuts and other parts shall be adequately pinned or locked to prevent loosening or changing of adjustment with repeated operation of the breaker. Provision shall be made for connecting travel recorder to perform speed test of breakers at site. Motor operated mechanism shall be provided for Disconnectors & Earth switches with suitable Electrical & Mechanical interlocks. Normal operating mechanism shall also be provided for emergency purpose. The operating mechanism offered for GCB shall be in service for a minimum of 2 years in any of the power plant with trouble free operation.
ISSUE R0
72
2.30
2.31
2.32 2.33
2.34
TCE FORM NO. 329 R5
SECTION: D3.2
SHEET
6 OF 8
2.35
SF6 density monitoring, alarm on low density and close & Trip blocking on very low density shall be provided. Tests All acceptable & routine tests as per IEC-60056 and IEEE Std C37.013a-2007 standards shall be conducted on all the equipment/components of each of the generator circuit breaker. a) Power frequency voltage withstand dry tests on the main circuit. b) Voltage withstand tests on control and auxiliary circuits c) Measurement of the resistance of the main circuit. d) Mechanical operating tests. e) Design and visual checks.
3.0 3.1
3.2
Following type tests shall be conducted on each type & rating of the equipment. a) Rated dielectric strength tests (i) (ii) Rated low frequency withstand voltage dry test. Rated full wave impulse withstand voltage test.
b) Short circuit rating and transient recovery voltage tests (i) Test for rated symmetrical short circuit current interrupting capability, duty cycle and rated transient recovery voltage parameters. Test for rated closing, latching and short time current carrying capability. Test for rated Generator source asymmetrical short circuit interrupting capability.
(ii) (iii) d) e)
Load current switching test Out of phase switching current tests

ISSUE R0
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TCE FORM NO. 329 R5
SECTION: D3.2
SHEET
7 OF 8
f) g)
Rated excitation current switching tests. Type tests and oscillographic test records for closing and tripping timings for generator circuit breaker of the rating offered.
3.3
Test reports for the following type tests shall be submitted for each type & rating of equipment: a) b) c) Rated continuous current carrying tests Mechanical endurance life tests. Noise level tests.
ISSUE R0
74
TCE FORM NO. 329 R5
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER

Technical Parameters GCB shall comply with the technical particulars given below and the Contractor shall furnish the details wherever indicated as *. Sl. No. (a) Make (b) Description Unit * IEEE(ANSI) std C37.013a2007 , IEC60056 (1987), IEC 60694 (1980) & IEC 60298 (1990), IEC-60529, IEC60129, BS-5169 & BS-5500 Bidder to indicate 50 Bidder to indicate Bidder to indicate Bidder to indicate Bidder to indicate IP 54 IP 65 CO-30 min-CO Opaline Green(external) , Semi Glossy white (internal) Technical Particulars
Applicable Standards
(c) (d) (e) (f) (g) (h) (i)
Voltage rating Frequency Rated current Rated short circuit breaking current Rated short time withstand current for 1 sec. Rated short circuit making current Degree of protection Control cubicles and drives Enclosure Duty Panel paint shade
kV Hz A kA kA kAp
(j) (k)
ISSUE R0
75
TCE FORM NO. 329 R5
SECTION:
D3.3
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS
SHEET 1 OF 11 SPEC. NO. TCE.5960A-H-500-001
3.0
GENERATOR TRANSFORMERs (GTs) The generator transformer (GT) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet A 3.3. Also, the GT and its accessories shall comply with the requirements indicated in Data Sheet A 3.3 and specific requirements indicated below.
3.1
The MVA rating of the Generator Transformers (GTs) shall be sufficient to evacuate power generated by the respective gas turbine generators and steam turbine generators. The GT shall be so sized as to be able to evacuate power from the GTG / STG to which it is connected without exceeding the average winding temperature of 870C and hot spot temperature of 980C over the entire range of site ambient temperature as specified in Section - B of this specification. The GT shall be with voltage ratio of generator voltage / 420kV, two winding, 3 phase, 50 Hz, ONAN/ONAF/OFAF cooled transformer, with On Load Tap Changer with +10% to 10% in steps of 1.25% on the HV side. Three (3) of 50% capacity separately mounted radiator banks shall be provided. Each bank shall be provided with adequate number of fans and pumps and one oil pump and one fan spare. Each radiator bank shall be provided with uni-directional bypass valve to permit oil to bypass the pump in the event of pump failure. It shall be possible to completely isolate any one of the radiator banks for maintenance, while the transformer is in service. Flexible expansion joints, one each, on top and bottom pipe connections for each radiator shall be provided. Each radiator bank shall have atleast two (2) extra radiators to facilitate usage of the same in case of leakage in the other radiators. If radiators are arranged in groups, each group of radiator shall have upper and lower shut-off valves with blanking at either ends. Control scheme shall be suitable for both manual and automatic operation of each group of fans and oil pumps. Electrical Performance The transformers shall operate without injurious heating at the rated MVA at any voltage within 10% of the rated voltage of that particular tap.
3.2
3.3 3.3.1
ISSUE R0
76
TCE FORM NO. 329 R5
SECTION:
D3.3
3.3.2
The transformer shall be designed to deliver rated MVA continuously even at the lowest tap without exceeding specified temperature rise. The transformer shall be capable of remaining in operation without injurious heating at full load atleast 10 minutes when complete forced cooling equipment has failed. The dynamic ability to withstand short circuit shall be demonstrated by the Contractor by calculations. Generator transformers shall be suitable for back charging. It shall also be capable of being charged from HV side through circuit breakers without pre-insertion resistors and kept charged continuously with no load on the LV side without any adverse impact on the transformer life. Generator transformers shall be suitable for bi-directional power flow. Bidder shall furnish the guaranteed loss values of Transformer.
3.3.3
3.3.4
3.3.5 3.3.6
3.3.7
3.3.8
3.4 3.4.1 3.4.2
Constructional Features Bell type design shall be adopted for transformer tank. The magnetic circuit shall be constructed from high grade cold rolled non-ageing grain oriented silicon steel laminations. The flux density shall not exceed 1.7 Wb/m2 at rated voltage and Current density shall not exceed 3 A/mm2. For generator transformers the insulation of core to bolt and core to clamp plates shall be able to withstand a voltage of 10 kV rms for 1 minute. The windings shall be made of electrolyte grade copper. Tank shall be made of good commercial grade low carbon steel and shall be of welded construction. The tank of the transformer along with radiators, conservators, bushings and other fittings shall withstand full vacuum of 760 mm
ISSUE R0
77
3.4.3
3.4.4 3.4.5
3.4.6
TCE FORM NO. 329 R5
SECTION:
D3.3
of Hg while filling the oil under vacuum and also an excess internal pressure of 0.35 kg/cm2. 3.4.7 Tank shields shall be such that no magnetic fields shall exist outside the tank. They shall be of magnetically permeable material. If required, impermeable shields shall be provided at the coil ends. Tank shield shall not resonate when excited at the natural frequency of the equipment. Contractor shall conform use of tank shields in the additional information scheme. Bushing shall be of porcelain. No arcing horn to be provided. For 52 kV and above, bushing shall be oil filled porcelain condensor & non-oil communicating type with following fittings: i) ii) iii) 3.4.9 Oil level gauge Oil filling plug and drain valve if not hermetically sealed Tap for capacitance and Tan delta test
3.4.8
Bushing below 52 kV shall be soild porcelain/condensor/oil communicating type. Bushing CTs shall be of adequate rating for protection as required, WTI etc., These CTs shall be mounted in the turret of bushing. Busduct termination shall be suitable for high air temperature inside the bus duct and shall be provided with draining arrangement as lowest point for leaked oil / water. Fire protection system shall be provided for the GTs as per the requirement specified under relevant fire and safety codes/standards, TAC guidelines and as specified under section D1.11 of this specification Fittings and Accessories Transformers shall be provided with all accessories like, but not limited to inspection manholes / handholes, lifting lugs, jacking pads, bi-directional flanged wheels, haulage lugs, skids, earth pads, neutral earthing downcomers (2 nos.) supported on pin insulators, terminal marking, rating and diagram plates, marshalling boxes, conservators (breatherless) (flexible oil resistant air bag), valves for various purposes including draining, filtering, filling,
ISSUE R0
78
3.4.10
3.4.11
3.4.12
3.4.13
TCE FORM NO. 329 R5
SECTION:
D3.3
double float buchholz relay, oil and winding temperature indicators with high and very high contacts, magnetic (150 mm dia) and prismatic oil level gauges, anti-earthquake clamping arrangement, tank mounted radiators with accessories, and pressure relief valve (Min. 02Nos. & the adequacy of the number of PRDs and their location shall be established for any location of the fault inside the tank). 4-20mA signal for remote WTI & OTI. It shall be a repeater of local WTI & OTI. 3.4.14 On-line Gas Extractor Analyser shall be provided for each Generator transformer. It shall be hooked up to the plant DCS.
A device for measuring the hot spot temperature of the winding shall be provided.
3.4.15 3.4.16
For Top oil temperature measurement & Winding temperature

measurement RTDs / transducers shall be provided for remote indication in SCADA.
3.4.17 3.4.18 3.4.19 3.4.20
A flexible oil resistant air bag shall be provided in the conservator to prevent the air from coming into contact with the oil. Suitable shock recorders to record maximum shock forces during shipment/ transport shall be provided. A set of hydraulic jacks suitable for the transformers under supply.
Transformer oil shall be supplied in non-returnable oil drums ( with 10% extra oil). 3 Nos., 20 KLitres capacity Transformer oil tank and 1 No. 6 KLitres Transformer oil filter machine of reputed make approved by Owner shall be supplied. Impact recorder shall be provided to monitor the impact during transport on returnable basis. Transformer shall be transported with tank filled with pure inert gas at pressure of 2 2.5PSI. The temperature and pressure at the time of gas filling shall be marked. Necessary accessories including filled replenishment N2 shall be maintained at site also till the transformer is filled with oil. Two auxiliary power supplies, 400 V, 3 phase, 3 wire shall be drawn from two separate boards for the cooler control cabinet and OLTC cubicle. Cooler control equipments shall be divided in to
ISSUE R0
79
3.4.21
3.4.22
3.5
TCE FORM NO. 329 R5
SECTION:
D3.3
two halves, each having one power supply incomer with bus section between two halves. In case of one power supply failure, loads shall be automatically transferred to other. Indications are to be provided at cooler control cabinet and at OLTC cubicle along with remote annunciation in DCS for failure of normal source and for transfer to standby source, and also for failure to transfer. 3.6 Each cooling fan and pump motor shall be provided with isolating switch, starter, thermal overload, single phase preventer and short circuit protection. Separate on/off switch for each incoming power supply with MCCB shall be provided. All cooling equipment trouble shall be indicated in local control panel with repeat alarm in main control room, with remote annunciation in DCS. Status of each cooler fan/pump shall be available in DCS. On Load Tap Changer (OLTC) The OLTC gear shall be designed to complete successfully tap changes at 150% of rated current. Devices shall be incorporated to prevent tap change when the through current is in excess of the safe current that the tap changer can handle. The OLTC gear shall withstand through fault current without injury. The tap range shall be decided based on the voltage profile of the grid and following shall be complied with / provided. It shall permit operation of generator at full load and at rated terminal voltage & p.f. over the entire range of variation of grid voltage: (a) Complete its operation once commenced, independent of power supply, relays etc. Block reverse tap change command during the forward tap change in progress. Be such that the oil in the compartment containing making and breaking contacts does not mix with oil in other compartment of OLTC or transformer tank. Be equipped with separate conservator for OLTC oil temperature and oil surge relay with contacts. Cut off of power supply when manual handle is inserted.
3.7 3.7.1
3.7.2
(b)
(c)
(d)
(e)
ISSUE R0
80
TCE FORM NO. 329 R5
SECTION:
D3.3
(f)
Remote and local electrical operation & tap position indication. Be equipped with automatic and manual operation facility including hardware, relays as required. Be equipped with Digital type tap position indicator with inbuilt transducer for repeating the tap position in DCS. Be provided with necessary initiating contacts for annunciation of any abnormal condition in DCS and grouped alarm in control desk. A sheet steel, dust and vermin proof marshalling box shall be provided for each transformer and shall be provided with thermostatically controlled space heaters. The degree of protection shall be IP 55. All wiring for remote connection for OLTC control / indication / annunciation from OLTC cabinet shall be terminated in Marshalling box by providing separate terminal block.
(g)
(h)
(i)
(j)
3.8 3.8.1
Tests Following type tests and special tests as per IS 2026 (revision as applicable on date of submitting of offer) shall be conducted on one transformer :
ISSUE R0
81
TCE FORM NO. 329 R5
SECTION:
D3.3
(a)
Temperature rise test, Dissolved gas analysis of the oil, before and after the temperature rise test.
(b)
Vacuum withstand and deflection measurement on tank and radiators.
(c) (d) (e) (f) (g)
Pressure test on tank with deflection measurement. Determination of cooler losses. Partial discharge test. Radio influence voltage. Short circuit impedance of each limb with single phase voltage from each HV & LV sides.
(h)
Oil leakage test 12 hours (this test to be conducted after heat run test).
(i) 3.8.2
Auxiliary power measurement.
All routine tests as per IS : 2026 shall be conducted on each of the transformer. The following additional routine tests on each of the transformer shall be conducted. (a) (b) (c) (d) (e) (f) (g)
Impedance voltage shall be measured at principal and at all the taps No load loss and exciting current shall be measured at rated frequency at 90%, 100% and 110% rated voltage Calibration of temperature indicators and relays Impulse test on GTs shall include chopped wave test Sweep Frequency Response Test at factory and at site
Magnetic balance test. Measurement of tan delta and capacitance of each winding and bushing. Pressure test on PRD.
ISSUE R0
82
(h)
TCE FORM NO. 329 R5
SECTION:
D3.3
(i) (j) (k) (l) 3.9
Measurement of zero sequence impedance. Core isolation test Noise level measurement ACSD & ALD as per standards
Minimum electrical system requirements in respect of control, monitoring, measurement, annunciation, synchronising are indicated in I&C system Section No. D2.4. The following calculation shall be furnished for Owners approval: a) OLTC recovery voltage calculations in case of buck and boost type of OLTC (wherever applicable) Transfer surge calculations Short circuit withstand calculations
3.10
b) c) 3.11 3.11.1
Evaluation of Bids Bids will be evaluated based on the formula furnished in Data SheetA3.3 For the purpose of evaluation of Bids, the quoted load losses and iron losses shall be included to take into consideration tolerance as permitted by applicable standards. Liquidated Damages for Non-Performance Should the losses as measured on the transformer after manufacture be found to be in excess of the guaranteed losses including tolerance, if any, the VENDOR shall pay to the PURCHASER, liquidated damages based on the charges indicated in Data Sheet A3.3
3.11.2
3.12
ISSUE R0
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TCE FORM NO. 329 R5
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. DATA SHEET A3.3 GENERATOR TRANSFORMER
SECTION:
D3.3
SHEET
9 OF 11
SPEC NO: TCE.5960A-H-500-001
SL. NO. 1.0 1.1 1.1.1
DESCRIPTION Generator Transformers Type MVA Rating
UNITS
Outdoor, Two winding, 3 phase MVA 315MVA for GTG (tentative), 340MVA for STG (tentative)
1.2 1.2.1 1.2.2 1.2.3 1.3
Cooling method ONAN ONAF OFAF Overfluxing capability 60% 80% 100% 110% for continuous 125% for 1 minute 140% for 5 seconds
1.4
Winding connections HV LV Vector Star Delta Ynd1
1.5
Impulse (1.2 / 50 microsecond) / power frequency withstand voltage windings HV 1425 kVp / 630 kV (rms)
1.6
LV
0
* / * C 50
Maximum temperature rise of oil at 110% of full load for 24 hrs. Maximum temperature rise of winding at 110% of full load for 24 hrs. Tapping particulars Type Tap range Tapping step Category of voltage variation R0 JUNE 10 PPD. BY CKD.BY DATE RKD HA
1.7
55
1.8 1.8.1 1.8.2 1.8.3 1.8.4 REV. NO. DATE REV. BY
OLTC + 10% to 10% 1.25% CFVV JOB NO. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.
TCE FORM NO. 330 R3

84
SECTION:
D3.3
SHEET
10 OF 11
SPEC NO: TCE.5960A-H-500-001
SL. NO. 1.8.5 1.9 1.9.1 1.9.2 1.9.3 1.9.4
DESCRIPTION Tapping power Bushing particulars Voltage class HV / LV / HV (n) Standard applicable Creepage distance Clearance in air (a) (b) Phase-phase-HV/LV/HV(n) Phase-earth-HV/LV/HV(n)
UNITS Full
420 kV / --- / 36 kV IS : 2099 25 mm / kV
4200 mm / -- / 3400 mm / --- / - mm Opaline Green Not to exceed values specified in NEMA TR1
1.10 1.11 1.12 1.12.1
Paint shade Noise level Loss evaluation formula Formula for evaluation of Bids
Evaluated price + (A x guaranteed no-load loss in KW) + (B x guaranteed load loss in KW) + (C x guaranteed cooler loss in kW) A = Rs. 3,80,000 / kW B = Rs. 2,60,000 / kW C = Rs. 2,32000 / kW
1.12.2
Rates of liquidated damages for exceeding the guaranteed losses No load loss Load loss Load loss
Rs/kW Rs/kW Rs/kW
A = 3,80,000 B = 2,60,000 C = 2,32000
1.13 1.13.1 1.13.2 1.13.3 1.13.4 1.13.5 1.13.6 REV. NO. DATE REV. BY
Applicable codes and standards Power transformer Fittings and accessories Loading of oil immersed transformers Oil Bushings Degree of protections R0 JUNE 10 PPD. BY CKD.BY DATE TCE FORM NO. 330 R3
85
IS : 2026/IS:6600/IEC:60076 IS : 3639 IS : 6600 IS : 335 / IEC:60296 IS : 2099 / IEC:60185 IS : 2147 RKD HA JOB NO. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.
SECTION:
D3.3
SHEET
11 OF 11
SPEC NO: TCE.5960A-H-500-001
SL. NO. 1.13.7 1.13.8 1.13.9 1.13.10 Tests
DESCRIPTION
UNITS
VALUES / REQUIREMENTS IS : 2026 IS : 2026 IS : 3637
Tolerance on guaranteed particulars Buchholz relay Electrical insulation classified by stability thermal
IS : 1271
REV. NO. DATE REV. BY
R0 JUNE 10
PPD. BY CKD.BY DATE
RKD HA
JOB NO. 5960A
CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.
TCE FORM NO. 330 R3

86
ANDHRA PRADESH POWER DEVELPOPMENT COMPANY LTD.
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS UNIT AUXILIARY TRANSFORMERS
SPEC.NO. TCE-5960A-H-500-001
4.0
UNIT AUXILIARY TRANSFORMER (UAT) The Unit Auxiliary Transformer (UAT) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet - A 3.4. Also, the UAT and its accessories shall comply with the requirements indicated in Data SheetA3.4 and specific requirements indicated below:
4.1
UAT shall be a * MVA, */6.9kV, three phase, two winding, 50 Hz, ONAN/ONAF cooled transformer with *% impedance with OLTC 10% in steps of 1.25% on HV side (*By Bidder). 6.6kV system shall be suitable for medium resistance earthing with earth fault current limited to 300A. Impedance The impedance of the transformers at taps corresponding to nominal transformation ratio (primary taps) shall be selected keeping in view the short circuit level of the 6.6 kV and 400 V switchgear & the voltage dip at motor terminals not exceeding the limits specified in Section D 3.20
4.2
4.3 4.3.1
MVA rating UAT Each UAT shall be able to supply (100%) auxiliary running load of 700 MW power plant. It shall be able to start the largest motor at 80% base load. The Contractor shall provide the design calculations for arriving at the capacity of UAT during detail engineering stage. Additional margin of 10% shall be kept over & above all the loads due to variation in the loads i.e. 110% of the complete station load. Specific Requirements The unit auxiliary transformers shall comply with the specific requirements indicated in Section D-3.3 except for the following variations. The tank cover for the UAT can be of conventional type. The UAT shall be provided with 2 x 50% detachable built on radiator banks and if it is not possible to have built on radiator banks, the same can be separately mounted. Each radiator bank shall have at-least two extra radiators for use in case of leakage in any other radiator. All tests specified in Section D-3.3 shall be conducted on UAT.
ISSUE R0
87
4.4 4.4.1
4.4.1.1 4.4.1.2
4.4.1.3
TCE FORM NO. 329 R5

DATA SHEET A 3.4 UNIT AUXILIARY TRANSFORMER SL. NO. 1.0 2.0 Type No load voltage - HV - LV 2.1 3.0 Rating on ONAF Cooling method (a) (b) 4.0 ONAN ONAF % % 80% 100% kV kV MVA DESCRIPTION UNITS
SECTION : D 3.4 SHEET 2 OF 3

SPEC NO.
TCE-5960A-H-500-001
VALUES / REQUIREMENTS UAT Outdoor, two winding * 6.9 28 ( tentative)
Overfluxing capability
110% continuous, 125% for 1 minute, 140% for 5 seconds
5.0
Winding connections HV LV Vector group Delta Star Dynll
6.0
Impulse (1.2 / 50 microsecond) / power frequency withstand voltage windings HV LV HV (n)

0
*/* 60 kVP / 20 kV (rms) --C C 50 55
7.0 8.0 9.0
Maximum temperature rise of oil Maximum temperature rise of winding Tapping particulars (a) (b) (c) (d) (e) Tap Tapping range Tapping step Category of voltage variation Tapping power
ON LOAD CIRCUIT TAP CHANGER % % 10% 1.25 -
10.0
Bushing particulars (a) Voltage class HV / LV / HV (n) / tertiary R0 PPD. BY RKD JUNE 10 CKD.BY HA DATE TCE FORM NO. 330 R3
88
* / 7.2 kV / JOB NO. 5960A CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR, KARIMNAGAR DIST.

DATA SHEET A 3.4 UNIT AUXILIARY TRANSFORMER SL. NO. DESCRIPTION UNITS

SPEC NO.
TCE-5960A-H-500-001
(b) (c)
Standard applicable Creepage distance
IS-2099 31 mm / kV based on line to line highest system voltage
(d)
Clearance in air (i) (ii) Phase-Phase-HV / LV Phase-Earth-HV/LV/HV(n) * / 127 * / 127/Opaline Green Not to exceed values specified in NEMA TR-1
11.0 12.0 13.0 13.1
Paint shade Noise level Loss evaluation formula Formula for evaluation of Bids
Evaluated price + (A x guaranteed no-load loss in KW) + (B x guaranteed load loss in KW) + (C x guaranteed cooler loss in kW) A = Rs. 3,80,000 / kW B = Rs. 2,60,000 / kW C = Rs. 2,32000 / kW
13.2
Rates of liquidated damages for exceeding the guaranteed losses No load loss Load loss Load loss
Rs/kW Rs/kW Rs/kW
A = 3,80,000 B = 2,60,000 C = 2,32000
Note: - (*) By Bidder
R0 JUNE 10
PPD. BY CKD.BY DATE
RKD HA
JOB NO. 5960A
89
SECTION:
D3.5
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS
A)
ISOLATED PHASE BUS DUCTS (IPBD) The Isolated phase bus duct (IPBD) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet A 3.5 IPBD. Also, the IPBD and its accessories shall comply with the requirements indicated in Data SheetA 3.5 and specific requirements indicated below:
5.1
Isolated phase bus duct forming the main current carrying leads shall be used in following circuits: Generator phase side terminals to respective GCB, GCB to Generator transformer LV terminals for GTG and generator phase side terminals to generator transformer LV terminals in the case of STG. Tap-off bus duct for Unit Auxiliary Transformers in the case of GTG. Tap-off bus ducts for VT and SP cubicle, static excitation transformer (if applicable) Bus duct to generator neutral side terminals to neutral grounding equipment panel, which shall house a neutral earthing transformer and neutral earthing resistor. The CTs etc., to be located in the Isolated phase bus duct shall be as per the enclosed Main one line diagram Drg. No. TCE.5960A-EL-SK-2003. Current transformers as required shall be located in the above bus duct. If the generator transformer is three numbers single phase units, then the delta formation of the LV Windings shall be carried out with Isolated Bus Duct. The voltage class of the bus duct shall be as follows: Generator voltage (a) Upto 12 kV (b) More than 12 kV upto 21 kV Bus duct voltage class 12 kV 24 kV
5.1.1
5.1.2 5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.2
Sizing and Design
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5.2.1
Sizing of the bus duct shall be arrived based on the continuous and short time rating of the respective circuit. The continuous current rating of the main (generator) bus duct shall be arrived at considering the maximum output of the generator and at specified minimum voltage. Short time current rating of the main busduct shall be for 1 second and shall be decided as follows:. (a) Higher of the short circuit current contribution from generator OR the short circuit current contribution from 400 kV system through generator transformer (400 kV system fault level 50 kA) Plus (+) Contribution of 6.6kV auxiliary power supply system through UAT. (b) Momentary current rating shall be 2.55 times the short time current rating arrived as above.
5.2.2
5.2.3
5.2.4
The short time and momentary current rating of all tap-off bus ducts (to VT and SP cubicle) shall be as follows: (a) Short time current rating for 1 second: (i) Short circuit current contribution from generator Plus (+) (ii) Short circuit current contribution from 400 kV system
NOTE: Negative tolerance allowed in the standards shall be considered for generator and generator transformer impedance for calculation of short time ratings in clauses 5.2.3 and 5.2.4 above. 5.2.5 The bus duct shall be designed to withstand the internal or external forces resulting from the following: (a) (b) Normal operating conditions Momentary short circuit currents
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D3.5
(c)
Rigorous / adverse weather conditions as detailed in project information section B Seismic forces as detailed in project information section B.
(d)
5.2.7
The degree of protection shall meet the requirements of water and air tightness test specified in IS-8084 and the degree of protection shall be IP-55 or better. The outside of the busduct shall be painted with 631 of IS-5. Specific Requirements The bus enclosure shall be of continuous bonded type. The material of bus conductor & enclosure for main run shall be Al alloy grade 19501 (H2) of IS-5082. The material of bus conductor for tap-off shall be Al alloy grade 63401 WP (range 2) & for enclosure material shall be Al alloy grade 19501 (H2). Inspection covers for periodic inspection of the insulators shall be provided. There shall be no joints or fixing bolts on top of the enclosure through which water can seep. The outdoor portion of the bus duct shall take into account heating effect due to solar radiation and shall be provided with a continuous rain hood of non-magnetic material suitably supported from the bus duct support structure. The bus conductor shall be given a coat of matt black paint to facilitate heat dissipation. However, the sizing of the bus conductor shall consider the conductor as bare. The process of silver plating shall be approved by the owner. Each phase shall be enclosed in weatherproof, dust tight, non-magnetic metal enclosure. The enclosure shall be designed for welded connections. The enclosure shall be of minimum flux type to permit not more than five (5) percent of total, magnetic flux outside enclosure. The enclosure shall be insulated at the connections to various equipment so that the longitudinal current will not flow through or be transmitted to any connecting equipment. The insulation shall be nondeteriorating and shall be clearly indicated on the Contractors drawings.
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5.3 5.3.1
5.3.2
5.3.3
5.3.4
5.3.5 5.3.6
5.3.7
TCE FORM NO. 329 R5
SECTION:
D3.5
5.3.8
The Contractor should ensure that no load is transferred on electrical equipments transformers, generator terminals etc. by the busducts. The bus conductor shall be designed for welded connections except at equipment terminations, bolted disconnect links, and bolted flexible. Detailed welding procedure adopted by the manufacturer should be furnished along with the offer and approved by the Owner. Flexible connections shall be provided between bus sections to allow for expansion and contraction of the conductor. Flexible connections shall also be provided at all equipment terminations. The bus support insulators shall be mounted on resilient pads. The bus support insulator shall be interchangeable, high strength & fine glazed porcelain manufactured by wet process or high strength epoxy resin cast. The voltage rating shall depend upon generation voltage. The spacing of the bus support insulators shall be considered by giving due factor of safety to withstand the forces due to the momentary short circuit assigned for the bus duct. Wall frame assembly and seal-off bushings shall be provided where the bus duct passes from indoor to outdoor area to prevent condensation due to air temperature variation between indoor and outdoor portion. Wall frame assembly shall be fabricated out of aluminium angles and sheets. It shall be ensured that no load of the bus duct is imparted on the walls. The bus duct supports shall be fabricated from standard steel sections. The support structures shall be hot dip galvanised. Thermostatically controlled space heaters shall be provided along the length of the bus duct. Duplex RTD shall be provided for measurement of ambient air inside the bus duct. The same shall be hooked upto the DCS. The equipment terminal connections shall be readily accessible and shall provide sufficient air gap for safe isolation of requirement during electrical testing.
5.3.9
5.3.10
5.3.11 5.3.12
5.3.13
5.3.14
5.3.15
5.3.16
5.3.17 5.3.18
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SECTION:
D3.5
5.3.19
If the material of bus conductor and that of the equipment terminal is different, then suitable bi-metallic connectors shall be provided by the Contractor. The electrically continuous bus enclosure shall be used as the grounding bus. All parts of the bus enclosure, supporting structure and equipment frames shall be grounded to earthing mat. Neoprene Rubber bellows shall be provided at the termination point of the bus duct at various equipment. Rubber bellows shall also be provided in the run of the bus duct after gas turbine generator foundation block to avoid transfer of vibrations of GTG pedestal. In case of rubber bellows at intermediate locations flexible braids copper connection, shall be provided across the bellows to establish continuity of bus duct from end to end. Provision shall be made in bus duct at an approved location for installation of shorting bar having rated current carrying capacity same as that of main bus duct for carrying out generator stator dryout. A set of shorting bar along with requisite hardware shall be supplied for this purpose. A set of shorting bars along with requisite hardware shall be supplied for this purpose. Disconnecting links with rating same as that of the main bus conductor shall be provided in the run of the bus duct as required to facilitate disconnection of the bus conductor during testing. The IPBD shall be of natural air cooled type. Silica gel filters shall be provided both in indoor and outdoor portions of the bus duct for absorption of moisture. Seal off bushings (a) Seal-off bushings shall be provided at the entry of tap-off bus duct to the VT and SP cubicle, static start-up, unit auxiliary transformers, neutral grounding cubicle, etc. One set of seal-off bushings shall be provided in the bus duct after the generator bushings to prevent hydrogen leakage into the bus duct. Arrangement shall be provided to vent the trapped hydrogen in the portion between generator bushings and these seal off bushings (applicable for hydrogen cooled generators).
5.3.20
5.3.21
5.3.22
5.3.23 5.3.24
5.3.25
(b)
5.3.26
Two numbers earthing terminals with bi-metallic connectors shall be brought out at termination points of the bus duct, main and cross
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SECTION:
D3.5
supporting structures, terminal boxes, adapter boxes, unit auxiliary transformer, VT and SP cubicle, etc., and for further connection to earthing grid. 5.3.27 5.4 5.4.1
5.5
All steel supporting structures and hardware shall be hot dip galvanised after fabrication. Pressurisation System Not used. Current Transformer The current transformers shall be epoxy cast-resin, single core ring type, mounted within the bus duct enclosure and suitable for operation at an ambient temperature existing within the bus duct enclosure which may be in range of 900C to 1000C. Mounting arrangement of CT shall be so designed so as to avoid equalizing connections between live conductor and CT inner surface. CT secondary leads shall be brought out through non-magnetic metallic conduits to a marshalling box (MB) with degree of protection IP-55 (IS:13947 Pt.1). The MB shall be provided with removable aluminium gland plate. The facility for shorting and grounding shall be provided at the terminal blocks. All CTs shall be tested for partial discharge. The partial discharge at 10 percent over voltage of the highest system voltage shall not exceed 50 pico coulombs. Arrangement shall be made to maintain potential of inner surface of busduct CTs at the same value as the conductor to prevent partial discharge. Protection CTs shall be rated for 5A secondary current and shall be of Class PS & Class 5P20. Metering CTs shall be rated for 5A secondary current and shall be of 0.2S accuracy class with instrument security factor less than 5. Voltage Transformer and Surge protection Cubicles The V.T and S.P cubicles for each phases shall be metal clad, dust and vermin proof, free standing, dead front assemblies housing VTs, surge capacitor, lightning arrester, V.T. L.V. side fuses etc. Lightning arrester shall be Gapless type station class, hermetically sealed, connected between line and ground, specifically suitable for
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5.5.1
5.5.2
5.5.3
5.5.4
5.6 5.6.1
5.6.2
TCE FORM NO. 329 R5
SECTION:
D3.5
generator protection as per technical parameters given elsewhere in the specifications. 5.6.3 A discharge counter along with the ampere meter shall be provided for each lightning arrester. The discharge counter register & leakage current measurement meter with suitable environmental protection covering, shall be visible without having to open the compartment door. Mineral oil filled/Askarel (PCBS) filled surge capacitor shall not be acceptable. The voltage transformer shall be epoxy cast-resin type, suitable for nominal voltage operation, connected from line to ground, and as per Technical Parameters given in the specifications. The secondary side of voltage transformer shall be provided with MCB. Suitable guide slots and stops shall be provided to ensure easy withdrawal and positioning. The fixed and draw out contacts of voltage transformer primary shall be tinned or silver plated. In the disconnected position, the voltage transformer primary and secondary circuits shall be automatically disconnected. The draw out frame shall be grounded at all times. A reliable automatically operated shutter mechanism shall be provided for isolating and shrouding the bus bar live parts when the VT is in drawn out position. From phase cabinets the VT secondary leads shall be brought to marshalling box having sufficient number of terminals with 20% spare, to accommodate all VT leads. Facility of making star points and undrilled gland plate for cable connections shall be provided in the marshalling box. VT and CT secondary neutral or common lead shall be earthed at one place only at the terminal blocks, provided in the instrument transformer marshalling boxes. The facility for connecting with earthing grid, shall be provided by the Contractor through suitable connectors in the marshalling box, with isolating links for testing of instrument transformers. Cubicle Construction (V.T. & S.P., N.G. Cubicle etc.) All cubicle shall be fabricated from cold rolled sheet steel for minimum 2mm thick suitably reinforced to ensure structural rigidly. The degree of
ISSUE R0
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5.6.4
5.6.5
5.6.6
5.6.7
5.6.8
5.6.9
5.7 5.7.1
TCE FORM NO. 329 R5
SECTION:
D3.5
protection for all indoor cubicle shall be IP:52 except for neutral grounding resistor enclosure which shall be minimum IP:23. 5.7.2 5.7.3 Space heater, Illumination and Grounding. Each cubicle shall be equipped with space heater with thermostat, internal illumination lamp, 230 V AC, 5A receptacle. Ground bus suitable for receiving two (2) numbers of 50x6mm galvanised steel flats shall be provided on each cubicle. Wiring All wiring shall be done with insulated stranded copper conductor of not less than 2.5 mm cross-section with suitable lugs on both sides. The wiring inside the bus duct enclosure (i.e. for CT etc.) shall be suitable for operating in the ambient temperature existing inside the bus duct. Not more than two wires shall be connected to a terminal. Spare terminals equal in number to 20% of active terminals shall be furnished and these shall be uniformly distributed through out the cubicle CT terminal blocks shall be of stud type and suitable for round type lugs with a facility for isolation, shorting and grounding. It shall be Elmex type CATD or equivalent. Name plate Name plates shall be furnished for each equipment, disconnect link, voltage transformer compartment, lightning arrester compartment and fuse block, current transformer TB, etc. Material for nameplate shall be embossed on SS plate & letters filled with indelible black ink. Hot Air Blowing Equipment Suitable facility shall be provided to blow hot air into the bus duct to evacuate moisture inside the bus duct during initial start-up and also after subsequent shutdowns for maintenance on the bus ducts.
5.8 5.8.1
5.8.2
5.8.3
5.9 5.9.1
5.9.2
5.10 5.10.1
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SECTION:
D3.5
5.10.2
The hot air blowing system shall be open loop type, capable of blowing hot air simultaneously in the indoor and outdoor portions of the bus duct. The system shall be suitable for operation at low voltage 3 phase AC supply indicated under project information. Ambient air will be drawn in through inlet dampers and dry air filters and then forced through thermostat controlled heaters. Hot air shall be distributed by properly sized ducts and dampers to the indoor and outdoor portions of the bus duct. Hot air shall be let out through suitably directed outlets provided at the indoor and outdoor portions of the bus duct and at each equipment suitably. The hot air blowing system shall be complete with motor blower unit, combination starter, washable filters, necessary ducting, piping, dampers, valves, heaters, thermostats, control, instrumentation and monitoring system, all mounted on a mobile trolley. A local control cabinet mounted on the trolley, shall be provided with the necessary control, indication and monitoring devices. The system shall be sized to completely dry the entire bus duct installation within two hours. Suitable provision shall be made to isolate this system after the drying operation is complete. The mobile trolley shall be common for the specified number of bus duct units. The bus duct of each unit shall be provided with suitably supported inlet ducting with blanking plates. The tap off air ducting from IPB to mobile trolley delivery flange is included in Bidders scope of supply. Tests & Test Reports The following type and routine tests shall be conducted on representative section of the bus duct assembly. The bus duct assembly tested shall include bolted connections, flexible connections and current transformers.
5.10.3
5.10.4
5.10.5 5.10.6
5.10.7
5.10.8
5.11
5.11.1
Type Tests a) One minute power frequency withstand voltage test. b) Impulse withstand test
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SECTION:
D3.5
c) Temperature rise test of black matt painted conductors & enclosures d) Short time current test e) Dynamic current withstand test f) Water-tightness test g) Air tightness test h) Milli-volt drop test 5.11.2 Routine Tests a) One minute power frequency withstand voltage test b) IR measurement
5.12
Bidder shall furnish the following calculations for main run and tap off run busduct. Temperature rise at rated current considering effect of solar radiation. a) b) c) d) Conductor size Guaranteed kW losses in conductor & enclosure Supporting span Dynamic and static forces transferred to TG foundation.
5.12.1
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5.2
SECTION:
D3.5
B) 5.13 5.13.1
HV & LV Bus ducts Segregated Phase Bus Ducts [SPBD] 7.2 kV class segregated phase bus duct and accessories shall be provided for connection of the two winding unit auxiliary transformer to 6.6 kV switchgear. The continuous rating of the bus duct from UAT to 6.6 kV Switchgear shall be same as the rated current of 6.6 kV switchgear bus. The short time and momentary current ratings of the bus ducts shall be same as that of associated 6.6 kV switchgear. Non-Segregated Phase Bus Ducts [NSPBD] 1.1 kV class non-segregated phase bus duct and accessories shall be provided for connection between all service transformers and their respective 400V switchgear. NSPBD shall also be considered for connections between other switchgear / MCCs to suit the layout. The continuous rating of the bus duct shall be same as the rated current of respective switchgear bus. The short time and momentary current ratings of the bus ducts shall be same as that of associated 400V switchgear. The busbars in the bus-duct shall be sleeved with FRLS heat shrinkable, colour coded XLPE sleeves. Specific Requirements The bus conductor shall be of Aluminium alloy grade 63401 WP (range 2) as per IS: 5082. The enclosure shall be rectangular and shall be made of aluminium alloy sheets for SPBD and for NSPBD the same shall be of mild steel. In case of segregated phase busduct, the phase segregation shall be of either aluminium or non-hygroscopic insulating material like fibreglass.
5.13.2
5.13.3
5.14 5.14.1
5.14.2
5.14.3
5.14.4
5.15 5.15.1
5.15.2
5.15.3
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SECTION:
D3.5
5.15.4
Flexible expansion joints shall be provided for the conductor and enclosure along the run of the bus duct length to take care of expansion. Also flexible joints shall be provided at the termination points. Inspection covers for periodic inspection of the insulators shall be provided. There shall be no joints or fixing bolts on top of the enclosure through which water can seep. The outdoor portion of the bus duct shall be provided with a continuous rain hood of non-magnetic material suitably supported from the bus duct support structure. The bus conductors shall be given a coat of matt black paint to facilitate heat dissipation. However the sizing of the bus conductor shall consider the conductor as bare. The adjacent sections of the bus conductor shall be welded or bolted. The joints along the conductors shall be of highest quality and the temperature rise test shall be conducted including the joints. The bus support insulators shall be of 7.2 kV class (as required) for segregated phase bus ducts and 1.1 kV class for non-segregated phase bus ducts and shall be mounted on resilient pads. The material of insulator shall be epoxy resin cast. The spacing of the bus support insulators shall be considered by giving due factor of safety to withstand the forces due to the momentary short circuit current assigned for the bus duct. Wall frame assembly and seal off bushings shall be provided where the bus duct passes through walls (indoor to indoor). These shall be fabricated out of aluminium angles and sheets. Wall frame assemblies with seal off bushing shall be provided where bus ducts pass through walls (outdoor to indoor). The bus duct supports shall be fabricated from standard steel sections. The support structures shall be hot dip galvanised. Thermostatically controlled space heaters shall be provided along the run of bus duct.
5.15.5
5.15.6
5.15.7
5.15.8 5.15.9
5.15.10
5.15.11 5.15.12
5.15.13
5.15.14
5.15.15
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SECTION:
D3.5
5.15.16
At the factory, on one typical section of SPBD containing bends, joints etc., following type tests shall be conducted (a) (b) (c) (d) (e) air tightness test water tightness test Temperature rise test Short circuit current withstand Impulse withstand test
For NSPBD, type test certificates shall be furnished. 5.15.17 On all the pieces of SPBD & NSPBD applicable routine tests shall be conducted. Also, test certificates shall be furnished for bought out items. HV voltage test, air tightness test and water tightness tests shall be conducted at site on fully assembled bus duct. Technical Requirements Segregated/non-segregated phase bus ducts shall comply with the particulars indicated in the following table. Sl. No. Description Requirement for Segregated Phase Bus duct Natural air 40oC 30oC Non-segregated Phase Bus duct Natural air 40oC 20oC
5.15.18
5.16 5.17.1
(a) Type of cooling (b) Maximum temperature rise of conductor over 50oC ambient (c) Maximum temperature rise of enclosure over 50oC ambient 5.18 5.18.1
Data to be furnished with the Bid Technical particulars for the segregated/non-segregated phase bus ducts as per Table below. Typical calculation for arriving at the size of the conductor and the insulator spacing. Experience list of the make of bus duct proposed.
ISSUE R0
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5.18.2
5.18.3
TCE FORM NO. 329 R5
SECTION:
D3.5
5.18.4
Type test report (short circuit, impulse withstand, temperature rise test) for similar bus duct manufactured by the proposed manufacturer. Technical Particulars (To be separately furnished for each rating of segregated and nonsegregated phase bus ducts.) Sl.No. (a) (b) (c) (d) Description Designation (from & to) Manufacturer Applicable standard Momentary short circuit withstand current (as per clauses 5.13.3 & 5.14.3) kA peak Unit Technical Particulars
5.19
(e)
One second short circuit kA rms withstand rating (as per clauses 5.13.3) Continuous current rating at 50oC design ambient air temperature (as per clauses 5.13.2 & 5.14.2) Amps
(f)
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DATA SHEET A 3.5 SL. NO. DESCRIPTION UNITS
SECTION: SHEET
D3.5
15 OF 15
SPEC. NO. TCE.5960A-H-500-001
Isolated Phase Bus Duct 1.0 2.0 3.0 Type of bus duct Type of cooling Maximum temperature rise of over an ambient temperature of 500C Conductor (Hot spot) Enclosure (Cold spot) Applicable codes and standards Bus conductor material Porcelain bushing Porcelain post insulators Hot dip galvanising Interconnecting busbars Creepage distance for insulators and bushing Voltage of : (i) Acc. class (ii) Rated voltage factor 7.0 Type of insulation for current trf. and neutral grounding transformer Duty rating (i) NGT (ii) NGR 30 Secs. 30 Secs. Refer Main Line Dia TCE.5960A-EL-SK2003 1.2 Cont., 1.9 for 30 seconds. Cast epoxy resin IS :5082 IS : 2099 IS : 2544 IS : 2629 IS : 8084 25 mm/kV of rated voltage
0
Isolated Phase Bus Duct - Continuous Natural air cooled
3.1 3.2 4.0 4.1 4.2 4.3 4.4 4.5 5.0 6.0
C C
55 30
8.0
R0 JUNE 10
PPD. BY CKD.BY DATE
RKD HA
JOB NO. 5960A
CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3
104
SECTION:
D3.6
SHEET 1 OF 8
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR, GENERATOR TRANSFORMER AND UAT PROTECTIONS
SPEC. NO. TCE.5960A-H-500-001
6.0 6.1
GENERATOR PROTECTION Complete protection system consisting of protective relays, auxiliary relays, timers, etc., shall be provided to protect the generator, its subsystems, generator transformer and unit auxiliary transformer. Generator Protection All the protective relays, auxiliary relays, timers, transducers etc., to protect the complete generator, its subsystems shall be housed in generator relay panel (GRP). This panel will be located in the Main control room.
6.2
6.3 6.3.1
Protection Philosophy The protection philosophy of every equipment shall be divided into two 100% groups namely two main protection groups. Complete protection of the respective equipment shall be fully available even if either of the group is not available. Hence, both groups shall be mechanically, physically and electrically separated into two separate and independent systems. One group shall be receiving all AC and DC signals from one set of devices and the other from another set of devices. Similarly, these two groups will derive DC supply from two separate feeders. However, the relays in each group shall be tripping the circuit breaker through both trip coils I & II. Monitoring devices such as supervision of DC supplies, supervision of protective relays, supervision of trip relays, CT and PT supervision and supervision of both trip circuits shall be provided. Dead machine protection shall receive their DC power supply from station DCDB as appropriate. The generator protection system relays shall be classified into three categories viz., Class A trip shall be classified into GCB & field breaker trips (Class-A1) and GT HV breaker Trip (Class-A2). Class-B shall trip GCB or GT breaker on reverse power through Class A1 or A2. Class- C shall trip GT HV circuit breaker. Both groups of protection shall be divided into these three modes of tripping. The breaker failure relays connected with 400 kV generator transformer bay and relays connected with 400 kV bus bar protection shall be housed in separate relay panels which will form part of 400 kV switchyard protection system.
6.3.2
6.4.3
105
SECTION:
D3.6
SHEET 2 OF 8
SPEC. NO. TCE.5960A-H-500-001
6.4.4
The protections envisaged in GRP are listed below. Also, Main One Line Diagram drg. No.TCE.5960A-EL-SK-2003 indicates various protections envisaged. Both the list and the drawing shall be considered Complementary to each other and all the protections indicated shall be provided. Contractor shall include any additional protections deemed necessary by him for the equipment offered even if not indicated in the list and the drawings. Numerical relays shall be provided for main protection of Generator, GT and UAT. However, static relays have to be provided for PT supervision, dead machine protection and pole slipping protection. Numerical relays shall have adequate output contacts for tripping, annunciation, etc., contact multiplication relays shall be provided if necessary. They should likewise have adequate number of opto couplers for external trip inputs, interlocking etc., Two identical numerical relays shall be provided for generator protection. A dedicated operator station shall be provided in the Main control room for setting the numerical relays of Generator protection and 6.6 kV switchgear. (a) (b) (c) (d) (e) (f) Generator differential protection (87G) Generator stator 100% earth fault protection (64 G1). Generator stator 95% earth fault protection (64G2). Generator stator 95% back-up earth fault protection (64 G3). Pole slipping relay protection (78G). Loss of excitation protection (40 G). Loss of excitation relays shall be with two independent outputs for conditions with and without under voltage. (g) Negative phase sequence protection (46 G). It shall have a definite time stage for alarm and inverse stage for trip. In addition they shall have an output of 4-20 mA for remote indication of negative phase sequence current. (h) Back-up impedance protection (21G).
106
SECTION:
D3.6
SHEET 3 OF 8
SPEC. NO. TCE.5960A-H-500-001
(i)
Stator over-load alarm relay (50 GS). It shall be provided with timer to detect actual over load.
(j)
Generator VT fuse failure protection (60 G11, 60 G12, 60G13 / 60 G21, 60 G22, 60G23) Reverse power/ Low forward power protection (32 G/37G). Under frequency protection (81 G). 4 stage with independent time and frequency adjustment.
(k) (l)
(m)
Over voltage protection (59 G). Over voltage protection shall have an instantaneous stage and a definite time stage with independent voltage settings.
(n) (o) (p)
Under voltage protection (27G) Dead machine relay (61 B). Islanding protection schemes to isolate power plant from grid for disturbances in the grid. Generator field over voltage protection (can be a part of excitation system) Over fluxing protection (99G) with inverse time characteristics. Rotor earth fault (64F) 2 stage Inter turn fault protection through differential current measurement in case generator has six terminals brought out on neutral side Or Through residual voltage (Vo) with neutral biasing in case three terminals are brought on the neutral side. Local breaker back up protection (50 LBB) with its own trip relay.
(q)
(r) (s) (t)
(u)
107
SECTION:
D3.6
SHEET 4 OF 8
SPEC. NO. TCE.5960A-H-500-001
(v)
Generator, generator transformer overall differential protection (87GTU) for STG and generator, generator transformer, UAT overall differential protection for GTG (87 G/GT/UAT). Generator transformer restricted earth fault protection (64 GT) Generator transformer back-up earth fault protection (51 NGT). Tripping relays for protection devices of Generator Transformer (GT) and 63X / 49X for multiplying the contacts of protection. (aa) For trip function (63X1/49X1) GT buchholz II stage (63TX) GT OLTC buchholz II stage (63 OLTC TX) GT winding temperature very high (49 WTX) GT oil temperature very high (49 OTX) GT pressure relief device operated (63 PTX) GT fire protection trip (63 FRTX)
(w) (x) (y)
(bb) For annunciation function (63x2/49x2) GT Buchholz I stage (63AX) GT OLTC buchholz I stage (63 OLTC AX) GT winding temperature high (49 WAX) GT oil temperature high (490AX) GT oil level low (OLAX) GT cooler supply failure GT cooler trouble GT OLTC trouble
108
SECTION:
D3.6
SHEET 5 OF 8
SPEC. NO. TCE.5960A-H-500-001
(z) (aa) (bb)
UAT IDMT overcurrent protection on HV and LV sides (51) UAT Instantaneous over current protection on HV side (50) UAT Buchholz (63), winding temperature (49 WT) and oil temperature (49 OT) protections Auxiliary relays for protection devices of UAT 63 x 1/49 x 1 and 63 x 2 / 49 x 2 for multiplying their contacts. UAT differential protection (87 UAT). UAT restricted earth fault protection (64 UAT). UAT instantaneous earth fault relay (51N UAT) High speed trip relays (86 G1 to GX): Adequate number of high speed trip relays for each category tripping and separately for each group shall be provided for the protection of the unit. The quantity of the trip relays shall also consider the requirement due to the following: (i) Contact requirements from these relays to various systems covered under the scope of this contract. Contacts from each category of tripping relay for annunciation, data acquisition, and sequential event recorder and fault disturbance recorder. Contacts for control, protection and interlock in system viz., 400 kV circuit breakers tripping / close permissive, 6.6 kV auxiliary supply breakers trip / close permissive, transformer cooler circuit interlocks, LBB protection, etc., 10% spare contacts (both N/O and N/C).
(cc)
(dd) (ee) (ff) (gg)
(ii)
(iii)
(iv) (hh) (ii) (jj)
Supervision relays for tripping relays (98 GL1 to GLX). Open delta VT for Pre-synchronising Earth fault (59NGT) 400 kV generator breaker trip coil supervision relays (98G1 to G4).
109
SECTION:
D3.6
SHEET 6 OF 8
SPEC. NO. TCE.5960A-H-500-001
(kk)
Auxiliary relays, timers in adequate number to make the protection & the scheme complete, relays required for the discrepancy switch scheme in Generator control panel. Auxiliary VTs and Auxiliary CTs required for the protection systems. The parameters of the same shall be selected to suit the application and the same is subject to approval of Owner.
(ll)
6.6
The characteristics and relay setting ranges shall be decided by the Contractor and shall be such as to provide complete protection for the generator under normal and all abnormal operating conditions. Trip Matrix required for implementing class A/B/C tripping schemes shall be provided by the Contractor and shall be indicated in block interlock diagrams to be submitted. Specific Requirements The protection system shall comprise pre-engineered modular or discrete self-contained systems comprising preferably of static relays. In addition to the relays/protections mentioned in this specification, any additional protections/relays considered necessary by the Contractor for his system shall be included and offered by the Contractor. Two Nos. DC supplies shall be arranged for the GRP. These supplies shall be taken through a selector switch with the positions, viz., independent, source-1 & source-2. In the Independent position Group-1 & 2 protection system will be fed by source 1 & 2 respectively and the common services from any one of the sources. In case of failure of any one source (say source 1) switch shall be changed over to the other source (source 2) and complete DC supply requirement of GRP will be fed from the other source. DC auxiliary supply shall be supervised by supply supervising relays. The NC contact of the relays shall be delayed on drop off by approximately 100 to 200 m sec. for annunciation in Operator station/Generator control panel. The relay shall be provided with flag indicators wherever required. White colour supervision lamps of clustered LED type shall be provided on GRP to indicate availability of DC supply. All LEDs shall be 22.5 mm size self coloured.
6.7
6.8 6.8.1
6.8.2
6.8.3
The relay panels shall be provided with supervisory system facilities to indicate the location of the failed component when pre-engineered
110
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SHEET 7 OF 8
SPEC. NO. TCE.5960A-H-500-001
protection system is offered. Self checking facility In-Built in the relay panel shall be provided with watch dog contact for remote annunciation and DCS. 6.8.4 Either hand reset mechanically operated operation indicator or LED with reset push button shall be provided for protective relays. They shall be arranged to operate only when tripping current passes through output circuit of the relay. One laptop of high configuration shall be provided with necessary software & hardware (with multiple licences) for setting the parameters & evaluation of numerical relays. In addition to the contacts required as per schemes, Contractor shall wire out to the terminal block atleast all NO & NC spare contacts of each of the relays. The protection scheme shall include all the necessary contacts to achieve the schemes required, alarms in Operator Station, annunciation windows, sequence event recorder and for switchyard control panel annunciation wherever required. Contact multiplication relays for generator circuit breaker and associated isolators shall be provided for this purpose. Testing Unit Two Nos. of test kits shall be offered to test all of generator, transformer, line and motor protection relays, timers by secondary injection. This is in addition to self monitoring and watch dog facilities that will be built into these protective relays. Control room alarms/indications/SER points Each of the alarms, trip conditions, abnormal conditions through the protection relays, shall be individually indicated in Operator station and also individually or appropriately grouped available in the annunciation windows in generator control desk / panel. Selected alarm/trip conditions finalised during the detailed engineering stage shall be used for SER system. (Further the lockout relay operation and certain grouped alarms shall be available in the SCADA/400kV-switchyard control system. Operator station/SER shall have a time resolution of 1 (one) ms. Minimum electrical system requirements in respect of control, monitoring, measurement, annunciation, synchronising are indicated in I&C system section No. D2.4.
6.8.5
6.9
6.10
6.11 6.11.1
6.12
111
SECTION:
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SHEET 8 OF 8
SPEC. NO. TCE.5960A-H-500-001
6.13
Fault disturbance recorder Microprocessor based fault disturbance recorder shall be provided for each generator to record the graphic form of instantaneous values of voltage and current in all three phases and neutral, open and close positions of relay contacts and breaker during disturbance etc., Facility of fast scan as well as slow scan feature to be provided to record transient as well as dynamic performance of the system.
6.14
Tests Tests shall be as mentioned in Section D3.7 for Switchyard Relay Panels.
112
SECTION:
D3.7
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - 400 kV SWITCHYARD
SHEET 1 OF 51
SPEC. NO. TCE.5960A-H-500-001
7.0 7.1
400 kV SWITCHYARD A 400 kV switchyard shall be provided for evacuation of power generated in the plant through four (4) nos. 400 kV transmission lines. The necessary line bay equipment, generator transformer bay equipment with associated equipment, controls, monitoring, protection and SCADA system shall be provided by the Contractor. The 400 kV switchyard shall have one and a half breaker switching scheme. The Main One Line Diagram sketch no. TCE.5960A-EL-SK2003 shows the switchyard scheme and arrangement of major equipment in the switchyard. The 400 kV switchyard shall consists of various bays for different configuration as follows: Description Generator Transformer 400 kV Line Bus Reactor Future bay (Spare) Total No. of Bays 3 4 2 1 10
7.2
7.3
7.4
The switchyard equipment shall be supplied and installed with all accessories to make the switchyard complete in all respects. The switchyard shall include the equipment indicated below but not limited to the following. 420 kV circuit breakers 420 kV isolators 420 kV current transformers (CTs) 420 kV capacitor voltage transformer (CVTs) and electromagnetic voltage transformers (EMVTs). 360 kV lightning arresters (LAs) Wave traps & Coupling capacitors.
ISSUE R0
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7.4.1 7.4.2 7.4.3 7.4.4
7.4.5 7.4.6
TCE FORM NO. 329 R5
SECTION:
D3.7
SHEET 2 OF 51
SPEC. NO. TCE.5960A-H-500-001
7.4.7 7.4.8 7.4.9
Power line carrier communication (PLCC) system for 4 lines. Bus bars, insulators, clamps and connectors. SCADA (Supervisory Control and Data Acquisition) system for entire switchyard with bay control units for each bay including event logging. Protection panels for all bays/equipment, communication and interfacing panels as required. Stand alone disturbance recorders with associated network cabling, PC, HMI, Printer and evaluation software. ABT (Availability Based Tariff) meters including necessary software & hardware for monitoring on dedicated PCs with suitable networking. RTU (Remote Transmission Unit) for transfer of data to SLDC (State Load Dispatch Centre) and RLDC (Remote Load Dispatch Centre). Outdoor kiosks housing BCUs, protection panels, PLCC/OLTE panels, fault disturbance recorders, etc. Air conditioning and ventilation system for control building and outdoor kiosks. Fire alarm, detection & protection system for switchyard. Switchyard structures, switchyard fences, earthing, trenches and complete civil works including switchyard floors with RCC blocks. Bus Reactor Design Criteria The switchyard shall be generally designed based on the following codes and standards. (a) IS 10118 1982 : Code of practice for selection installation and maintenance of switchgear and control gear part-3 (Installation).
7.4.10
7.4.11
7.4.12
7.4.13
7.4.14
7.4.15
7.4.16 7.4.17.
7.4.18 7.5 7.5.1
(b) (c)
CBIP Technical Manual on layout of substation report No.3 IEC 61850 (universal): Substation automation protocol
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SECTION:
D3.7
SHEET 3 OF 51
SPEC. NO. TCE.5960A-H-500-001
7.5.2
A creepage distance of 31 mm/kV on 400 kV shall be provided for circuit breakers, isolators, Bus reactor, CTs, CVTs, EMVTs, LAs, bus post insulators, string insulators and 420 kV transformer bushings. The switchyard main buses shall be designed for continuous rating. Bay buses shall be rated according to the circuit rating. The switchyard shall be designed for a fault level of 50 kA for 1 sec. and dynamic rating of 130 kA. The 400 kV system shall be designed to withstand the power frequency over voltage to 1.5 p.u and surge over voltage to 2.3 p.u. The busbars shall be of standard ACSR or tubular aluminium / copper according to standard metricised iron pipe size (IPS) of suitable size. The conductor size of tubular bus and stranded conductors shall be based on the maximum load current, suitability under short circuit conditions, corona / voltage gradient and effect of solar radiation. Calculation shall be submitted for Owners approval. The final temperature of the conductor when carrying full load current shall not exceed 850C with a maximum ambient temperature of 500C. The size and spacing of strung bus, tubular bus and clamps connections shall be checked to limit the voltage gradient to 17 kV/cm to reduce corona effect. The size of shield wire shall be based on the lightning impulse current expected and the time duration for which it is likely to flow. Allowance shall be given in the final size to account for corrosion of the shield wire during service at rate of 0.03 mm per annum, if galvanised steel wires are used. However, minimum size of the shield wire shall not be less than 70mm2. Insulators (a) Design of insulator shall avoid stresses due to expansion and contraction in any part of the insulator leading to deterioration. All ferrous parts shall be hot dip galvanized. The associated metal part shall be permanently secured to the insulator, air tight and shall be designed to withstand all shocks and stresses to which they may be subjected to during operation and maintenance.
ISSUE R0
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7.5.3
7.5.4
7.5.5
7.5.6
7.5.7
7.5.8
7.5.9
(b)
TCE FORM NO. 329 R5
SECTION:
D3.7
SHEET 4 OF 51
SPEC. NO. TCE.5960A-H-500-001
(c)
The design shall ensure uniform compressive pressure on the joints. All insulators shall be of homogeneous glazed porcelain or composite type with silicon shed profile, free from laminations, cavities and other flaws or imperfections, and shall be thoroughly vitrified, tough and impervious to moisture. Porcelain glazing shall be uniform brown in colour, free from blisters, burns and other similar defects. Composite insulators can be of grey in colour. There shall be no electric discharge between conductor and insulators, when operating at normal voltage, which would cause corrosion or injury to any of the material. Tension and suspension insulator strings shall be anti-fog type selected based on the voltage, insulation level, pollution level and electro-mechanical strength. Creepage chosen shall be suitable for high pollution, i.e., 31 mm / kV. Electro-mechanical strength shall be selected with factor of safety of 2.5. Bus post insulators shall be solid / post insulator anti-fog type and shall be selected based on the system voltage, insulation level mechanical strength and pollution level requirements. Insulator hardware shall be corona free upto a falling power frequency visible discharge test voltage of 1.1 times the maximum system voltage.
(d)
(e)
(f)
(g)
(h)
(i)
7.5.10
The lightning protection of switchyard shall be provided by lightning masts and shield wires. The zone of coverage for the shield wire shall be considered as 60 deg. between the two shield wires and 45 deg. for the end shield wires. The criteria for deciding phase to phase clearance in case of strung conductors shall take into account that the conductor swing of one of the conductors (say R phase) with maximum wind velocity and the adjacent conductor (say Y phase) with 80% of maximum wind velocity at maximum sag conditions.
7.5.11
ISSUE R0
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SECTION:
D3.7
SHEET 5 OF 51
SPEC. NO. TCE.5960A-H-500-001
7.5.12
For the layout proposed by the Contractor the adequacy of the cantilever strength specified shall be checked considering the following factors of safety. (a) Sum of all permanent normal loads (wind load on tubular bus + wind load on stack + dead weight of the tubes) x 2.5 (factor of safety). (b) Combination of all normal loads plus either maximum short circuit or earthquake load whichever is higher x 1 (factor of safety).
7.5.13
The switchyard shall be designed for the seismic coefficient and wind pressure as indicated in Section-B. All structural steel and steel components in the switchyard equipment shall be of hop dip galvanised. Switchyard Layout Requirements The Contractor shall adopt bolted type connectors for tubular bus conductors, fixed type of terminal connectors for isolator terminals, flexible type of terminal connector for circuit breakers, current transformers and power transformers and flexible jumper connectors for connecting lightning arresters and voltage transformers. The Contractor shall consider suitable bay width, phase spacing, clearances, etc., depending on the actual dimensions of the equipment keeping in view the design criteria / requirements and without sacrificing any maintenance space / conveniences. In the transformer yard, the power conductor termination shall not be tapped off directly to the Generator transformer from the strung bus between the TG building and switchyard. The tap off conductor shall be routed through a bus post insulator located near the transformer. The Contractor shall note that the sequence of bays shall be so arranged that the maximum horizontal angle of deviation of the incoming power and shielding conductors from Generator transformers do not exceed 300C. Similarly, the point of anchoring on TG building shall be such that the vertical angle of deviations is limited to 300C from horizontal plane. The switchyard shall be provided with access ways near the current transformers and circuit breakers.
ISSUE R0
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7.5.14
7.6 7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
TCE FORM NO. 329 R5
SECTION:
D3.7
SHEET 6 OF 51
SPEC. NO. TCE.5960A-H-500-001
7.6.6
The cable trenches for the equipment shall be run as close to their foundations as possible even preferably touching. The switchyard shall be enclosed in fence or wall around for safety and to prohibit unauthorised persons from entering. Lockable gates for personnel entry and equipment shall be provided at convenient locations. The fence provided around switchyard shall be of 2500 mm minimum height and at a minimum distance such that section clearance is available from any live part. The fence shall be suitably earthed as per relevant Indian standards. Earth mat of suitable size with closely spaced earth conductor shall be provided below the operating handle of individual switchyard equipment As per the allowed step & touch potential values in IS. Design criteria for civil works and structures shall be as specified in Section-D4.0, civil works. Switchyard Equipment Circuit Breaker (a) The 420 kV circuit breakers shall be of SF6 outdoor type. The circuit breaker and its accessories viz. marshalling box / junction box shall be with IP 55 degree of protection. The SF6 circuit breakers shall be single pressure type and utilise puffer cylinder for interrupting currents. The breaker shall be so designed that upon loss of pressure, the gap between open contacts shall be suitable to withstand at least rated voltage at zero gauge pressure of gas. Each SF6 circuit breaker pole shall be provided with its own self-contained gas system. The circuit breakers shall comprise three identical single phase units with operating mechanism suitable for single pole operation. Tie beams between foundations of breakers of different phases are recommended as during closing / opening operation additional load in the form of vibrations may be transferred to the foundations.
7.6.7
7.6.8
7.6.9
7.6.10
7.7 7.7.1 7.7.1.1
(b)
(c)
(d)
ISSUE R0
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SECTION:
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SHEET 7 OF 51
SPEC. NO. TCE.5960A-H-500-001
(e)
Design of circuit breaker shall be such that contacts shall not close automatically upon loss of gas / air pressure. SF6 breakers shall be provided with temperature compensated SF6 density switches for individual poles with separate lockout, alarm and blocking contacts. Temperature compensated SF6 Density monitor to be provided for each phase at such a level so as to enable viewing and reading. The operating mechanism shall also have pressure switches for low alarms, high alarm, trip, lock out switches for close, open and reclose operation. D.C. circuits for two trip coils shall be separate and each of them shall be monitored separately. Manually operated emergency trip push button or any other device, conveniently located for mechanical tripping of all the three phases simultaneously shall be provided. Duty cycle for the breakers shall be O-0.3sec-CO3min-CO under all normal and fault conditions. Circuit breakers shall be suitable for rapid auto re-closing duty. All the circuit breakers in the switchyard shall be of identical make and type with interchangeable components to maximum possible.
(f)
(g)
(h)
(i)
(j)
(k) (l)
(m) The middle breakers and the outgoing line breakers shall be provided with PIR.
7.7.1.2
Operating mechanism (i) Circuit breakers shall be operated by spring / spring charged mechanism. It shall be anti-pumping type and trip-free. One O-C-O operation shall be possible with failure of AC supply. Two trip coils shall be provided for greater reliability. The trip coils shall have sufficient continuous rating to cater to the trip coil supervision relay current.
(ii)
ISSUE R0
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TCE FORM NO. 329 R5
SECTION:
D3.7
SHEET 8 OF 51
SPEC. NO. TCE.5960A-H-500-001
(iii) Separate pole discrepancy circuit with proper relay and other accessories shall be provided. Disagreement circuit shall be provided which shall detect pole position discrepancy. (iv) A closing release shall operate correctly at all values of voltage between 80% and 110% of the rated voltage. A shunt trip shall operate correctly under all operating conditions of the circuit breaker upto the rated breaking capacity of the circuit breaker and at all value of supply voltage between 50% and 110% of rated voltage. (v) Mechanical interlocks shall be provided in the operating mechanism to prevent discharging of closing springs when the breaker is already in the closed position. Provision shall be made to prevent a closing operation to be carried out with the springs partially charged.
7.7.1.3
One set of SF6 gas filling, evacuation and refilling equipment consisting of trolley mounted compressed SF6 cylinder, gas regulator with manometer and necessary coupling for filling gas in the breaker shall be provided. The equipment shall be trolley mounted. 2 nos. of gas leak detector shall be included in the scope of supply. Detectors shall be of reputed make and have Visual as well as Audible sound facility when leakage is detected. Contractor shall supply spare SF6 gas equal to 20% of the total requirement for the station. All circuit breakers controlling the lines shall be provided with either closing resistors or proven controlled switching devices to reduce over voltages and in-rush currents. All routine tests on the circuit breakers shall be carried out as per IEC62271-100. Type test certificates for all tests carried out on identical circuit breaker as per IEC-62271-100 shall be furnished. Isolators & Earth Switch (a) Isolators shall be horizontal centre break type suitable for horizontal upright type of mounting. (b) Isolators & Earth switch shall be suitable for operation on 400V, 3 phase, AC motor. However, it shall also be possible to operate them manually in the event of failure of power supply or outage of the drive motor with proper interlock provision for isolation of motor in case of manual operation. Earth switches shall be motor
ISSUE R0
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7.7.1.4
7.7.1.5
7.7.2
TCE FORM NO. 329 R5
SECTION:
D3.7
SHEET 9 OF 51
SPEC. NO. TCE.5960A-H-500-001
operated with proper interlock so that it shall not operate in case respective isolator is ON and other requisite conditions are not met. Tripping of drive, loss of AC drive supply and DC control supply shall be wired for giving alarm. The Disconnecting switches and earth switches shall be independent pole and gang operated. (c) Isolators shall be electrically interlocked with the circuit breakers in accordance with the switchyard safety interlocking scheme. The interlocks shall be effective for all modes of operation i.e. Electrical remote, Electrical local and Manual local. Bolt type interlock and any special accessories required on the isolator side for satisfactory operation of scheme shall be included. Interlocking scheme shall be so designed as to ensure absolute safety maximum flexibility and proper switching of CT and PT circuits. (d) The design of the auxiliary switches for the isolators shall be such that signalling of the closed position shall not take place unless the contact system has reached such a position that the rated current and the rated short time current can be carried safely; signalling of the open position shall not take place unless the contact system has reached a position of at least 80 percent of the clearance distance of the isolating distance. Contacts used for CT switching shall make before the isolator closed and starts carrying current. Similarly they shall open after isolator opens and breaks the primary current. (e) Base channels and other structural steel members such as operating pipes, phase coupling rods, operating mechanism boxes, bolts, pins, etc. shall be hot dip galvanised or metallised. All castings except current carrying parts shall be made of malleable cast iron or cast steel. Manual operating handles shall be galvanised steel. (f) The isolator and earthing switch shall be provided with high current carrying contacts on the hinge and jaw ends and all contact surfaces shall be of silver faced copper.
(g) Each pole of the isolator shall be provided with two earthing pads of non-corrodible material at opposite ends, brazed to the channel base. Flexible copper earth connectors shall be provided for connecting operating handles of isolators and earthing switches to the earthing system. The poles of the isolators shall be mechanically ganged.
ISSUE R0
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SECTION:
D3.7
SHEET 10 OF 51
SPEC. NO. TCE.5960A-H-500-001
(h) Earthing switch shall be provided with some isolators as indicated in main one line diagram. Two independent earthing pads each with flexible copper braids (tinned or suitably treated against corrosion) and suitable connectors for the specified size of earth conductor lead shall be provided at the hinge end of the switch. The flexible copper connections between rotating shaft of earth switch and frame shall have a cross section suitable to withstand the short time current. (i) Isolator and earthing switch shall be mechanically interlocked such that it will not be possible to close the earthing switch when the isolator is closed and vice-versa. Isolator shall be provided with electrical interlocking feature in all modes of operation. This shall be in the form of bolt interlock comprising an interlock coil of latch in type to lock the isolator driving shaft and hence prevent isolator operation in the latch-in condition. It shall be possible to release the latch by energising the interlock coil when certain pre-set conditions of interlocking scheme are fulfilled.
(j)
(k) Electrical interlocking arrangements shall be fail-safe type. (l) Isolator shall be provided with mechanical interlocking feature in addition to electrical interlocking feature described above.
(m) Operating Mechanism and Controls (i) The manual operating handles shall be mounted on the base of supporting structure. A weather-proof galvanised sheet steel cabinet with gasket hinged door and padlocking facility shall be provided to house the driving mechanism, motor starters, control valve solenoids, auxiliary switches etc. The operating mechanism box shall have enclosures conforming to IP 55. Arrangement shall be provided to permit manual operation of power isolators. The arrangement shall be such that when manual operating handles is in the engaged position, the power operation shall be made inoperative. Pad-locking facility shall be provided for the manual operating handle.
(ii)
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SECTION:
D3.7
SHEET 11 OF 51
SPEC. NO. TCE.5960A-H-500-001
(n) All routine tests as per IEC 60129 shall be carried out. Type test certificates for all tests carried out on identical isolators as per IEC60129 shall be furnished. (o) All tests shall be made on completely assembled isolators, earthing switches, their operating devices and auxiliary equipment. One assembled isolator shall be subjected to 1000 operations for checking mechanical endurance. 7.7.3 Current transformers (CTs), capacitor voltage transformers (CVTs) and Electromagnetic Voltage Transformers (EMVTs) (a) Electromagnetic VTs shall be provided for tariff metering (if required by grid) and CVTs for other metering and protection. Metering cores of CTs and EMVTs/CVTs shall be with accuracy class 0.2S and 0.2 respectively. Tariff metering CT & PT should comply with the requirements of CEA regulations on installation and operation of energy meters & respective grid authorities which will be intimated to successful bidder during detailed engineering. A separate 2 core CT (for Main and Check Meters) of accuracy class 0.2S for tariff metering for each line. The VA burden of the tariff metering CTs shall be subject to the approval of grid authorities. A separate 2 winding EMVT (for Main and Check Meters) of accuracy class 0.2S for tariff metering for each line. Tariff metering EMVT terminals shall be housed in separately sealable terminal boxes. Separate CT cores for Main-1 and Main-2 Carrier aided Distance Protection (21) for each line. The CTs and EMVTs shall be either oil filled hermetically sealed or SF6 gas filled single phase type. The CVTs shall be oil filled single phase type. In case of SF6 filled CTs and EMVTs, gas density monitors with remote alarm facility shall be provided. The rated burden for the metering and protection cores shall be decided considering all the loads/relays connected, future additions, lead burden etc.
(b)
(c)
(d)
(e)
(f)
(g)
ISSUE R0
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SECTION:
D3.7
SHEET 12 OF 51
SPEC. NO. TCE.5960A-H-500-001
(h)
The knee point voltage for PS class cores shall be decided considering the total connected burden with adequate margin. The magnetising current at Vk/2 shall be as minimum as possible (say 15 mA). Shall have a rated extended primary current of 120% of rated primary current. The core lamination shall be of cold rolled grain oriented silicon steel or other equivalent alloys. The cores shall produce undistorted secondary current under transient conditions at all ratios with specified parameters. Insulator shall be one piece without any metallic flange joint. Expansion chamber at top shall be provided with oil sight glass. Shall have provision for taking oil samples from bottom of CT without exposure to atmosphere to carry out dissolved gas analysis periodically. The CVT secondary shall include necessary MCBs with auxiliary contacts for alarm for protecting the secondary winding. Further, for the purpose of supervision on remote panel, line terminals of the CVTs shall be brought out through second set of MCBs. All the terminal boxes shall be powder coated with IP-55 degree of protection. Secondary terminals of CTs shall be brought out in a weather proof power coated terminal box. Facility shall be provided for short circuiting and grounding the CT secondary at the terminal box. All the taps of each core shall be wired to Marshalling Box to facilitate ratio changing. The box shall have a degree of protection IP-55. Tariff metering core terminals (for connecting main and check meters) shall be housed in a separate sealable terminal box. CT/CVT/EMVT assembly shall be suitably braced to withstand stresses induced due to seismic disturbances. The tank/base and all exposed ferrous parts shall be hot dip galvanised conforming to applicable standards.
(i)
(j)
(k) (l) (m)
(n)
(o)
(p)
(q)
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SECTION:
D3.7
SHEET 13 OF 51
SPEC. NO. TCE.5960A-H-500-001
(r)
Each CT shall be equipped with an over voltage protective device to limit the voltage developed across the secondary terminals to a safe value not exceeding 3 kV under open circuit condition. It shall be possible to select the ratio on any core independent of the setting in the other cores, for which purpose, tappings will have to be provided on the secondary windings. Oil filled insulator/bushings shall be hermetically sealed to prevent ingress of moisture. A cushion of nitrogen gas shall be provided to allow for expansion. Each CT/CVT/EMVT shall be supplied with suitable G.I supporting structure. All CTs/EMVTs shall be provided with stainless steel bellows. One MB for each set of 3 CTs/CVTs/EMVTs shall be provided. The MB shall be fixed to the supporting structure of CT/CVT/ EMVT. The MBs shall be fitted with adequate no. of disconnector type of test terminal boards suitable for terminating 2 nos. of 2.5 sq mm multi-strand copper wires. At least 20% spare terminals shall be provided. The instrument transformers shall be provided with filling and drain plugs. Polarity marks shall indelibly be marked on each instrument transformer and at the secondary terminals at the associated terminal block. Neutral of all cores of CTs, CVTs and EMVTs shall be formed in marshalling box of the respective equipment. Cables with sufficient number of cores are run from these marshalling boxes to protection panels. The neutral of CTs, CVTs, and EMVTs shall be earthed only at protection panels by means of a disconnecting link.
(s)
(t)
(u)
(v) (w)
(x)
(y)
(z)
(w) Tests & Test Reports All routine tests on the 400 kV voltage and current transformers shall be carried out as per relevant standards. Type test certificates for all tests carried out on identical voltage and current
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SECTION:
D3.7
SHEET 14 OF 51
SPEC. NO. TCE.5960A-H-500-001
transformers shall be furnished. If test reports are not in line with the requirement of IS/IEC then the Contractor shall carry out type test at no additional cost to the Owner. 7.7.4 BUS REACTORS a) 400 kV, 50 MVAR Three Phase Oil Filled Bus Reactors are considered in the switchyard. However, the exact requirement for these Bus reactors will be confirmed during detailed engineering based on the system study to be carried out by the bidder. However, at present, the bidder shall consider these Bus reactors in their offer. Bus reactors shall operate continuously at the highest system voltage without exceeding the guaranteed temperature rise. The total harmonic content in the phase current of a star connected reactor and zero sequence components appearing in the neutral shall be below 3% of the crest value of rated current. The impedance of reactor shall have a constant value upto about 1.5 times rated highest system voltage. Further the impedance shall be accurately balanced between the three-phase system. The magnetic circuit of reactor shall be so designed that the audio sound level shall be minimum. The losses of the reactor shall be limited to the values to permit ONAN type of cooling. Bus reactors shall be designed for 110% continuous over-fluxing withstand capability. The reactors shall be either gapped core type or coreless type. Special measures shall be taken by providing non-magnetic shielding to combat the effects of stray/leakage flux. Windings shall be of copper unless specifically approved by the PURCHASER. The conductors shall be transposed at sufficient intervals in order to minimise eddy currents and equalise the distribution of currents and temperatures along the windings. Tank shall be made from good commercial grade low carbon steel and shall be of welded construction.
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b)
c)
d)
e)
f)
g)
h) i)
j)
k)
TCE FORM NO. 329 R5
SECTION:
D3.7
SHEET 15 OF 51
SPEC. NO. TCE.5960A-H-500-001
l)
Tank shall be provided with a pressure release device which shall operate at a pressure below the test pressure for the tank and radiators. The device shall be rain-proof after blowing and shall be provided with a device visible from ground to indicate operation. An equaliser pipe connecting the pressure relief device to the conservator shall be supplied. Valves shall be of forged carbon steel upto 50 mm size and of gun-metal or of cast iron bodies with gun-metal fittings for sizes above 50 mm. They shall be of full-way type with screwed ends and shall be opened by turning counter clockwise when facing the hand wheel. There shall be no oil leakage when the valves are in closed position. The under-carriage of the reactor shall be provided with detachable steel flanged wheels. Separately mounted radiator banks shall have bolted flanged connections and pipe extensions to permit withdrawal of reactor tank without disturbing the radiators. Bushings shall be of the oil-filled condenser type with a central tube and draw-in conductor, which shall be connected to the connector housed in the helmet of the bushings. The pull through lead shall be fitted with a gas bubble deflector. Condenser type bushings shall be equipped The angle of inclination to vertical shall not exceed 30 deg. (a) (b) (c) Provision for power factor testing without disconnecting main leads. Stress rings and lower and shields. Current transformers shall be provided and the bushing shall be so arranged that it can be removed without disturbing the current transformers and secondary terminals. Bushing turrets shall be provided with vent pipes, which shall be connected to route any gas collection through the Buchholz relay.
m)
n)
o)
p)
(d)
q)
The Bushing CTs for protection shall be provided as per the enclosed Main One Line Diagram TCE.5960A-EL-SK-2002.It shall be possible to remove turret mounted Bushing CT's from the reactor tank, without removing the cover. Lightning Arrester
7.7.5
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(a)
360 kV, 20 kA nominal discharge current, class IV pressure relief class-A, metal oxide, gap less lightning arrester shall be provided as per the Main one line diagram No. TCE.5960A-EL-SK-2003.
Operational requirements (i)
(b)
Shall protect power transformers, circuit breakers, disconnecting switches, instrument transformers etc. with insulation levels specified in this specification. Shall be suitable for circuit breaker duty cycle in the given system.
(ii)
(iii) The reference current shall be high enough to eliminate the influence of grading and stray capacitance on the measured reference voltage. Values and calculations shall be furnished with offer. (iv) Shall be fully stabilized thermally to give a life expectancy of one hundred (100) years under site conditions and take care of effect of direct solar radiation. (v) Shall be capable of discharging over-voltages occurring due to switching of unloaded transformers and long lines,
(c)
Specific Requirements Arrester shall be suitable for installation in effectively earthed system. The Contractor shall carry out the insulation coordination studies for deciding the exact location and voltage levels of the LAs. (i) (ii) Shall be hermetically sealed single phase unit. Shall be robust with excellent mechanical and electrical properties.
(iii) Shall be capable of withstanding meteorological and short circuit forces under site conditions. (iv) Each lightning arrestor shall be complete with insulating base for mounting on structure.
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(v)
LAs shall be provided with grading and/or corona rings as required.
(vi) LAs shall not fail due to porcelain contamination. (vii) Porcelain shall be so coordinated that external flashover will not occur due to application of any impulse or switching surge voltage upto maximum design value for LA. (viii) The end fittings shall be non-magnetic and of corrosion proof material. (ix) Surge monitor shall be provided for each arrester and the same shall be mounted at a suitable height to facilitate easy reading of the counter mechanism and leakage current detectors. (x) Insulated copper conductor of adequate size and length shall be used for connecting discharge counter, terminal and lightning arrester earth terminal. Insulation level of the same shall not be less than 3.6 kV.
(xi) Suitably sized bypass copper shunts shall be provided for bypassing the discharge counter for removal / maintenance of the counter. 7.7.6 Line Traps (a) Line trap shall be of pedestal mounted, wound coil, broad band tuned. Line trap shall prevent undue loss of carrier signal for all conditions. It shall have negligible impedance at power frequency, which shall be relatively high over the frequency band appropriate to carrier transmission. It shall be suitable for outdoor pedestal mounting and mechanically strong to withstand the stresses due to wind pressure. It shall be mounted on a tripod structure formed by three solid core bus post insulators.
(b)
(c)
(d)
(e)
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(f)
Line trap shall consist of a main coil designed to carry continuously the rated current without exceeding the limit of temperature rise limits. It shall be equipped with bird barriers and shall be spray painted as per IS. It shall be provided with protective device and tuning device. Suitable corona rings shall be provided to meet corona and radio interference performance as specified for 400kV equipment if required. Even though the line traps shall be installed in two phases, the foundation shall be constructed in all the three phases to facilitate the change of location of line trap between the phases. Suitable surge arresters shall be provided. Shall be designed and arranged such that neither significant alternation in its protective function nor physical damage shall result from either temperature rise or the magnetic field of the main coil at continuous rated current or rated short time current.
(g)
(h)
(i) (j)
7.7.7 Clamps and Connectors (a) Shall be Aluminium alloy casting conforming to designation A6 of IS:617 for connecting to equipment terminals and conductors of aluminium. In case the terminals are of copper, the same clamps/ connectors shall be used with 2mm thick bimetallic liner. Shall be Galvanized mild steel for connecting to shield wire. Bolts, nuts and plain washers shall be hot dip galvanized mild steel for sizes M12 and above. For sizes below M12, they shall be electro-galvanized mild steel. The spring washers shall be electro-galvanized mild steel. All castings shall be free from blow holes, surface blisters, cracks and cavities. All sharp edges and corners shall be rounded off to meet specified corona and radio interference requirements. Shall have same current rating as that of the connected equipment with temperature rise limited to 350C over 500C.
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(b) (c)
(d) (e)
(f)
(g)
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(h) (i) (j)
All current carrying parts shall be at least 10 mm thick. Shall be manufactured to have minimum contact resistance. Flexible connectors, braids or laminated strips shall be made up of copper/ aluminium. Current rating and size of terminal/conductor for which connector is suitable shall be embossed/punched on each component.
(k)
7.7.8
Insulator String Hardware (a) Shall be of bolted type and forged steel except for insulator cap, which can be of malleable cast iron. Shall also generally meet the requirements of clamps and connectors as specified above. In one span, Tension string assembly at one end shall be supplied with suitable turn buckle. Suitable sag compensating spring shall be supplied in case the design calculations show excessive variation of the sag over the temperature range of 0 to 80 deg. C.
(b)
(c)
(d)
7.7.9
Spacers (a) Shall be non-magnetic material except nuts and bolts, which shall be of hot dip galvanized mild steel. Shall generally meet the requirement of clamps and connectors specified above. Design shall take care of fixing and removing during installation and maintenance.
(b)
(c)
7.8 7.8.1
Switchyard Control and Relay Panel Bidder shall offer air conditioned outdoor kiosks suitably located in switchyard, housing various IEDs such as Bay Control Units (BCUs), Protection Panels, Fault Disturbance Recorders, PLCC/OLTE Panels, etc. However, SCADA servers and associated equipment, SCADA Operator Station, RTU for SLDC/RLDC, DC battery, battery chargers,
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DCDB, 400 V ACDBs, UPS system, etc. shall be located in the switchyard control building for overall optimization in respect of cabling and control room building size. One kiosk shall be considered per diameter (comprising of two circuits in one and half breaker scheme) of 400kV switchyard. In case of incomplete diameter, the kiosk shall have necessary space for accommodating the future bay IEDs. One additional kiosk, if required, shall be provided for housing busbar protection panels at suitable location in switchyard. The layout of equipment/panels shall be subject to Purchasers approval. The kiosk shall be provided with fire alarm system with at least two detectors and shall be wired to fire alarm panel as described elsewhere in the specification. All CT, PT, control cables, etc. from switchyard equipment shall be connected to respective IEDs located in kiosks. Two optical fibre cables (OFC) shall be laid to connect BCUs to SCADA for data exchange. Different routes shall be adopted for OFC. Technical requirements of outdoor kiosks are detailed elsewhere in the specification. The switchyard protection shall consist of: (a) One complete set of relay panels for 400 kV equipment switchyard
(b)
System fault locaters as a part of Main-1 numerical relay (BCU) Stand alone Disturbance recorders - as a part of BCU
(c) 7.8.2
The control and interlocking scheme suitable for one and a half breaker switching scheme shall be provided. Contractor shall furnish block interlock diagrams for the switchyard for Owners approval. The scheme as approved by Owner shall be provided. All the auxiliary relays, timers, switches, hardware, etc., required for the scheme are deemed to be included in the Contractor scope. Line bays shall be provided with single phase and three phase auto reclosing feature. The auto re-closing scheme shall be available in one of the numerical line protection relays but shall get independently actuated by the operation of both the protective relays. All the necessary relays, trip relays, auxiliary relays shall be provided. Provisions shall be made to accord higher reclosing priority to main breakers, or to issue reclosing command to both breakers simultaneously. Rapid reclosing & delayed reclosing features shall be
7.8.3
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provided. All conditions requiring blocking auto reclosure shall be considered. 7.8.4 Live linedead bus closing and dead line-live bus closing facilities shall be provided using dedicated relays for this purpose. Indicating lamps for fulfilment of the permissive condition shall be provided. Synchronizing function shall be through BCU for GTG units and a separate synchronizing equipment along with check synchronizing facility to be provided for STG units. Synchronising facility shall be provided for all lines in DCS. In check synchronising position, the synchronising criteria shall be fulfilled as indicated by the closing permissive provided by check synchronising relay. In manual mode, closure is possible only if either the line or the bus is dead. It shall not be possible to close in manual mode if both line and bus are live. Control and indication shall be provided for each of the breaker and isolator. The measurement requirements for each of the bays shall be as per the Main one line drawing TCE.5960A-EL-SK-2003 and Section D2.4 I & C requirements. Monitoring-Indication, abnormal conditions, Measurement required in DCS shall be as given in Section D2.4 All relay panels shall be located in outdoor kiosk and these kiosks shall be located in switchyard. In the event of shortage of contacts in main circuit breakers, isolators and earth switches, contact multiplying relays shall be used. The same shall be two coil, latching type with electrical reset and shall be mounted in switchyard relay panels. At least 2NO + 2NC spare contacts shall be wired to terminal block after fully utilising for control, protection, annunciation, etc., It shall be possible to control (including synchronising) all the 400 kV switchyard breakers and isolators from SCADA . Relay setting calculations shall be furnished by the Contractor to the Owner for his approval. All main protections shall be of numerical type. The functional requirements and characteristics of the relays specified are the
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7.8.5
7.8.6
7.8.7
7.8.8
7.8.9
7.8.10
7.8.11
7.8.12
7.8.13
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minimum required. The responsibility of establishing the equivalence or superiority of relays offered vis-a-vis the stipulation of the specification rests with the Contractor. 7.8.14 The Contractor shall provide licensed copy of software on CD for relay setting software and calculations for future use of the Purchaser. Relay setting calculations shall be furnished by the Contractor to the Purchaser and the grid authorities for their approvals. The numerical protection relays shall be able to be configured locally. For this, Contractor shall provide a laptop and the necessary software for relay settings, data transfer and parameterization. This laptop shall be common for SCADA BCU (Bay Control Unit) parameterization and protective relay parameterization. The configuration/specification of the laptop shall be the latest as available in the market as on date of supply. It shall also be possible to configure the SCADA BCUs remotely from the SCADA Engineering Station. The relay settings, parameterisation and the retrieval of data from the relay and relay operations shall be possible from SCADA operator station in addition to the laptop. The communication between the numerical relays and SCADA system shall be through serial link with fibre optic cable connection. The communication protocol between the numerical relays and SCADA system shall be IEC-61850. The interlocking scheme shall be hard wired and shall be suitable for one and a half breaker switching scheme. Contractor shall furnish block interlock diagrams for the switchyard for Purchasers approval. The scheme as approved by Purchaser shall be provided. All the auxiliary relays, timers, switches, hardware, etc. required for the scheme are deemed to be included in the Contractors scope. Protection Philosophy The protection philosophy indicated in section D3.6 for Generator protection shall be followed for switchyard protection as well. Numerical relays shall be provided for main and secondary protection of lines, Buses, etc. However, static relays have to be provided for breaker protection, PT supervision. (a) The protections envisaged for each 400 kV switchyard bay are listed below and also in Main one line diagram Drg. No.
7.8.15
7.8.16
7.8.17
7.9
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TCE.5960A-EL-SK-2003. It shall be read in conjunction with the following and all protection indicated shall be provided. (b) Line Bay Relay panel (Each Line Bay) (i) Main-1- 3-zone carrier aided distance protection (21-1) with in-built back-up directional over current and earth fault protection (67/67N). Main-2- 3-zone carrier aided distance protection (21-2) with in-built back-up directional over current and earth fault protection (67/67N). Both main-1 & main-2 protections shall be
(ii)
mechanically, physically and electrically separated into two separate and independent systems. Both main-1 and main-2 protections shall work on different principles/algorithms. 21-1 & 21-2 line protection relays shall have all the basic protection like SITF, PSB etc. (iii) Identical distance relays shall be supplied loose for four (4) 400kV lines (iv) Fuse fail relay (FFR) for each secondary of CVT / EMVT (v) Two stage over voltage relay (instantaneous & time delayed)
(vi)
Stub protection (50STB) as part of main-1 & main-2 protections for 400 kV lines to protect the stub portion of line bays during line outages Distance to fault locator (DFL) Fault disturbance recorder (FDR) with 8 analog and 16 digital channels.
(vii) (viii)
(ix)
Under voltage relays for live line/dead bus, dead bus/live line closing and safe grid re-establishment (271, 27-2, 27S)
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(x)
Auto reclosing scheme relays with single phase & three phases reclosing, dead line charging and live line reclosing.
(c)
Busbar Protection Relay Panel Numerical type, distributed busbar protection scheme based onlow impedance principle for selected bus arrangement shall be provided. It shall have check and discriminating zones, CT supervision and In-Out switch. Each breaker shall be provided with its own trip relay. Each trip relay shall be supervised and contacts shall be made available for annunciation/SCADA.
(d)
Over head line differential protection (between GT HV bushing & switchyard gantry) (87OH) shall be part of switchyard relay panel (SRP). Common Items/protections to be included in all relay panels (i) Local breaker back up protection with its own trip relay (50 LBB for each breaker). LBB in-out switch shall also be provided. Pre and Post close Trip circuit supervision relay for each trip circuit (98L) High speed trip relays (86L). Supervision relays for tripping relay (98 LT1 to LTX) to supervise the coil of each trip relay. Auxiliary relays and timers in adequate numbers to make the protection scheme and discrepancy switch scheme complete. Auxiliary CTs and auxiliary VTs with characteristics and accuracy as required. suitable
(e)
(ii)
(iii) (iv)
(v)
(vi)
f) Reactor Protection
Over Current Protection (50 and 51) Neutral Over Current Protection (51N) High Impedance type Differential Protection (87R)
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7.9.1
The functional requirements and characteristics of the relays specified are the minimum required. Any additional protection considered necessary by the Contractor shall also be provided by him. The responsibility of establishing the equivalence or superiority of relays offered vis-a-vis the stipulation of the specification rests with the Contractor. The protective relays shall be of integrated numerical type with serial interface for communication with SCADA system. The numerical protective relays shall be based on internationally accepted Open Protocol IEC-61850. If any of the protections are not covered in the main numerical relay, separate discrete numerical/microprocessor/static relays shall be provided. All hardware, auxiliary relays, timers etc. required for tripping/interlock schemes shall be provided by the Contractor. Numerical relays shall have self diagnostics and watch dog feature for remote annunciation in SCADA. Protective relays shall have adequate number of site configurable LEDs and output relays. Push buttons for testing and resetting the LEDs shall also be provided. All protective relays and meters shall be provided with test terminal blocks for secondary injection testing of protection relays and meters. In addition to the contacts required as per the schemes, Contractor shall wire out to the terminal block at least one NO & one NC spare contacts of each of the relays. The protection schemes shall include all the necessary contacts for interlocks, alarms in SCADA, sequence event recorder wherever required. Contact multiplication relays for 400kV circuit breakers and associated isolators shall be provided for this purpose. All SCADA alarms shall be categorized into different categories (typically 5). For each category, a different tone shall be sounded on the hooter and the alarm shall be represented in a different colour on the screen. All digital inputs shall have a time resolution of 1 (one) ms. All numerical relays and SCADA clock shall be time synchronised with the GPS master clock. The contact rating of contactors provided in SCADA Panels shall be suitable for making/breaking of control circuit currents of the respective devices being controlled.
Supervisory Control and Data Acquisition (SCADA) System
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7.9.2
7.9.3
7.9.4
7.9.5
7.9.6
7.10
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7.10.1
SCADA system comprising of various controls, metering, indication, annunciation, synchronising, remote control functions, mimic diagram, sequence of events recording, etc., shall be provided for the switchyard. The controller shall be configured with redundant CPU. The redundant CPU shall be configured to operate as hot standby. The SCADA system shall be generally in line with the details shown in SCADA System Configuration Drawing, TCE.5960A-EL-SK-2004. All the SCADA switches and servers shall be located in switchyard control room. All SCADA servers & Front End Processor servers (if any) shall be rack mounted. The Controller shall also be configured with double redundant power supply units. The switchyard equipment shall be remote controlled from Central Control Room (CCR) of the Power Plant through the SCADA HMI in order to enable the Switchyard Control Room being totally un-attended. The SCADA system shall be based on a de-centralised concept with bay oriented distributed intelligence devices, for safety and availability reasons. The offered SCADA system shall be of latest state of art design with capability to interface with bay control units (separate for each bay). The offered SCADA system shall be based on internationally accepted Open Protocol IEC 61850, Scalability and Open Architecture. The communication between the numerical relays and SCADA system shall be with fibre optic cable. SCADA system shall be fail safe design. The Contractor shall furnish documents to establish and prove that the system is highly reliable with very high MTBF (Mean Time between Failures). One (1) no. Operator Station(OS) for SCADA (for control and monitoring of complete 400 kV switchyard equipment) shall be located in Central Control Room (CCR) of power plant and one (1) no. in Switchyard Control Room. One (1) no. Engineering Station shall be provided in the Switchyard control room to make the SCADA configuration changes and system settings. The Engineering Station(ES) located in Switchyard control room shall also be configured as Operator Station to act as standby in case of failure of the Operator Station in Switchyard control room. The OS and ES display/monitors shall be dual headed, 24 inches size, LCD type and the make shall be finalised during detailed engineering so as to match with those
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7.10.2
7.10.3
7.10.4
7.10.5 7.10.6
7.10.7
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provided for Main Plant DCS. In the CCR, necessary printers as shown in SCADA Configuration Drawing shall also be provided for SCADA system. All printers shall be equipped with USB port and enough USB cables (minimum 5m length) to enable the printers to be placed in a convenient location. It shall be possible to configure the printers to print on demand/online or at specified intervals. Control room furniture for mounting the operator station along with 3 nos. chairs shall be provided in the switchyard control room. The console on which the operator station is mounted shall be properly ventilated (forced cooled if required). 7.10.8 The control location for the switchyard equipments shall be Switchyard control room by default. But provision shall be made available in the SCADA to control the switchyard equipments from Centre control room (CCR) also. It shall not be possible to control the switchyard equipments from both the locations simultaneously. The required selection shall be provided in the operator station of Switchyard control room. Information exchange shall be provided from SCADA to plant DCS through suitable, fast, reliable and redundant serial communication interface. Synchronising facility shall be provided for all lines in SCADA. In check synchronising position, the synchronising criteria shall be fulfilled as indicated by the closing permissive provided by check synchronising relays in-built in BCUs (separate sync check relays are not envisaged). In dead bus/line mode, closure is possible only if either the line or the bus is dead. The synchronising of the line shall be possible through both main breaker and the middle breaker. Display of voltages and frequencies of incoming and running supplies, synchroscope and the sync. permissive signal shall be simulated in the SCADA operator station. The synchronism and energizing check functions shall be bay oriented and distributed to the bay control units and/or protection devices. All features shall be available viz. a) Setting voltage, phase angle, and frequency difference b) Energizing for dead line - live bus, live line - dead bus or dead line dead bus with no synchro-check function c) Synchronising between live line and live bus with synchrocheck function. The correct voltage for synchronizing and energizing is derived from the auxiliary switches of the circuit breakers and the isolators and shall be selected automatically by the bay control and protection IEDs. The closing operation of line breaker shall involve the following steps, viz. a) selection of the breaker to be closed, b) mode of closing operation i.e. whether both the line and the bus are
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7.10.9
7.10.10
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live or only one of them is dead as sensed by voltage relays connected to the respective CVTs. In live-bus/live-line case, synchronisation between the two voltages is checked by the check synchronisation relay which generates permissive only if the synchronisation criterion is met. If either the line or the bus is dead, the logic develops using the contacts of bus voltage and line voltage relays which generates permissive for closing of the breaker, c) issuing the closing command after obtaining the synchro permissive or live-bus/dead-line or liveline/dead-bus permissive as the case may be. This permissive shall be displayed on the SCADA HMI. 7.10.11 The generator transformer main breaker will be controlled from main plant DCS. It shall be possible to control the middle breaker from both DCS (through auto/manual synchronisation) and SCADA with the help of a selection available in the SCADA software. The selection shall have two positions i.e. SCADA and DCS. If SCADA is selected, all the required signals including PT signals for synchronising shall be transferred to SCADA system. If DCS is selected, all the required signals shall be transferred to DCS/GRP (Generator Relay Panel). The control of middle breaker from SCADA shall be suitably interlocked such that its closure is not possible when it is used as generator synchronising breaker. Transducers shall be provided, wherever necessary, for the indication of electrical parameters related to switchyard bays as required. Transducers shall be used only for monitoring of non electrical quantities such as Bus reactor oil and winding temperature and for electrical quantities such as battery charger voltage, battery charger current, 400 kV bus voltages. For monitoring of all other bay wise electrical quantities, IEDs such as BCUs shall be used. The exact no. of analog and digital IO (input/output) points shall be dicided during detailed engineering. All the auxiliary contacts of main equipment such as circuit breakers, isolators, earth switches shall be brought to the protection panels for indications, interlocks, SER function, etc. In case of shortage of auxiliary contacts, contact multiplying relays shall be used. The same shall be two coil, latching type with electrical reset and shall be mounted in switchyard protection panels. At least 2NO + 2NC spare contacts shall be wired to terminal block after fully utilising for control, protection, annunciation, etc. It shall be possible to control and monitor (including synchronising) all the 400kV switchyard breakers & isolators from SCADA except main
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7.10.12
7.10.13
7.10.14
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circuit breakers of generators. Main circuit breakers of generators are controlled from Central Control Room through Plant DCS and monitored both in DCS and SCADA. Earth switches shall be operated only from local but is monitored in SCADA. Isolators and earth switches pertaining to generator transformer bay shall be monitored both in DCS and SCADA. 7.10.15 Monitoring SCADA a) Indication status of all breakers, isolators and earth switches of all 400 kV bays, local/remote selector switch positions, synchronising switch positions, voltage selection, Auto re closing selection, selection of control from SCADA/DCS, etc. shall be available in SCADA. The selection of control of middle breaker of generator bay from DCS/SCADA shall be displayed both in DCS and SCADA. Abnormal conditions to be considered for alarm inputs are 400 kV system operation of each line protection, Busbar protection, Trip circuit unhealthy of each equipment, protection unhealthy of each equipment, Trip relay unhealthy of each equipment, VT circuit unhealthy of each VT, LBB operation of each breaker, DC supply failure of each protection / control scheme as appropriate, wrong selection of PT supply, abnormal conditions of breakers, successful /unsuccessful auto reclosure, DC & UPS system alarms, etc. The alarm states are not exhaustive. The Contractor shall include all alarm states deemed necessary for the safe operation of the system. c) Event register with time stamping Opening or closing of all breakers, isolators and earth switches, opening and closing commands, change of positions of switches such as Local/Remote selection, synchronising selection, voltage selection, auto reclosing selection, selection of control from SCADA/DCS, operation of all protection and trip relays, VT fuse fail relay operation, auto re-closing operation, direct trip send and receive, pole discrepancy relay operation, trip circuit faulty, trip relay faulty, DC supply fail, SF6 pressure Low, LBB operated, etc. shall be available in SCADA. As stated at b) above, this list shall include all events and operation of switchyard equipment that are considered essential for analysis of faults. Mimic
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b)
7.10.16
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A mimic diagram depicting the entire electrical system being controlled from the system with different colours for different voltage levels shall be provided in SCADA operator stations. The colours of different voltage levels shall be as per relevant IS applicable for mimic on panels. 7.10.17 Measurement The measurement requirements for each of the bays shall be as per the Main one line drawing TCE.5960A-EL-SK-2003 and as given below:
Feeder Description (a) GT bays
DCS Operator Station V (All phases) A (All phases) MW MVAR Tap position, Winding & Oil temperature TVM V(All phases) A(All phases) MW MVAR MWH MVARH TVM V(bus 1&2) F(bus 1&2)
(b) 400 kV line bays
(c)
400 kV Bus PT
7.10.18 Event logging and trending facilities shall be provided in SCADA system. It shall be possible to trend different parameters on the same trend. It shall be possible to store historical data for a minimum of two years. SCADA system shall have provision for expansion and shall be capable of communicating with other systems through open protocol. 7.10.19 The Contractor shall make provision for terminating 4-20 mA analog signals and potential free digital signals for the following data on a terminal block in a suitable interface panel located in switchyard control building for transmission to SLDC (State Load Despatch Centre) and RLDC (Regional Load Despatch Centre) through RTU (Remote
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Transmission Unit). The energy meters(EM) shall not be connected to the RTUs. The specification of RTU provided for this purpose by the Contractor shall be subject to approval by the SLDC/RLDC authorities. The actual data to be transmitted to SLDC/RLDC shall be finalised during detailed engineering and the following is the minimum data to be transmitted through RTU.
MW and MVAR of all lines MW and MVAR of HV side of all generator transformers Voltage and frequency of 400 kV buses ON/OFF positions of all breakers and isolators of all line bays, Generator transformer bays, Bus PT bays. Tap positions of GTs & UATs
7.11
Bay Control Unit (BCU) a) The BCU shall be an intelligent unit and shall be state of the art technology. It shall perform control functions in accordance with control commands from SCADA and shall also do monitoring of the respective bays. The BCUs shall be installed in the respective protection panels of each circuit breaker in the switchyard relay room (Outdoor Kiosk). The control voltage for the BCU shall be 220V DC. The degree of protection of the panel shall be IP-52. The BCU shall comply with relevant IEC/BIS standards. BCU shall have adequate number of ports for communication and interface with switchyard control system for bay control and monitoring. The BCU shall provide direct connection to the switchyard equipment for control (with or without interposing relays) and shall perform control and monitoring functions, including live-line/dead-bus, dead-line/live-bus and live-line/livebus breaker closing. The communication link between BCU and SCADA shall be redundant. The BCUs shall be independent of each other and functioning shall not be affected by any fault occurring in any of the other BCUs. Protection relays shall be separate and shall not be part of BCU. Direct hard wiring shall be employed for critical tripping. Numerical protection relays shall also be connected to the SCADA bus for retrieval of data.
b)
c)
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d)
Atleast one bay control unit (BCU) shall be provided for each breaker. The analog and digital signals pertaining to a circuit shall be taken through the BCU provided for that circuit. One no. licensed software for configuration and parameterization of SCADA shall be delivered on CD along with BCUs. The configuration shall be carried out from local or from laptop computer but operation shall be from SCADA operator station. Configuration of BCUs shall also be possible from remote through engineering work station. The lap top computer provided for the switchyard shall be loaded with this software. The BCU shall have at least the following features: i) Monitoring The following monitoring functions shall be provided as a minimum : Status monitoring and failure monitoring (in SCADA HMI) of bay equipment like breaker, isolators, earth switches, instrument transformers, protection relays and ancillary equipment metering (measured-value acquisition) Signal and command indications Switching statistics in BCU (breaker ON/OFF, breaker auto-reclose, pole discrepancies) and data stored in SCADA server Energy metering values
e)
f)
ii)
Control The following control functions shall be provided as a minimum: Control of circuit breakers and isolators Interlocking for isolators and circuit breakers, isolators and earth switches (The interlocks for earth switches shall be hard wired)
iii)
Recording The event recording function shall be provided and processed in the BCU and the record stored in SCADA. Each BCU shall contain an event recorder capable of storing at least 200 time tagged events.
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iv)
Human Machine Interface (HMI) Following local human machine interface inbuilt in BCU shall be provided as a minimum : The local HMI is a monitoring and maintenance tool for bay control unit and data communication unit during commissioning and/or maintenance. Position of switching elements (Feeder control diagram) shall be shown on the graphic display.
v)
Time Synchronizing Feature BCU shall be time synchronized with GPS based Master Clock of the Facility Self diagnostic and Supervision Features BCU shall have self diagnostic and supervision features. Failure of IEDs connected to the SCADA System such as BCUs, Numerical Relays and Tariff Meters shall be indicated in the SCADA HMI
vi)
vii) Operating Mode Selection
Operation mode selection (local or remote) shall be provided in BCU.
7.12
Bay Marshalling Box(s) Adequate number of outdoor mounted, free standing type, power coated bay marshalling boxes shall be provided in switchyard. The pretreatment of the sheet steel shall involve degreasing rust/scale removal, phosphating and oven drying. The phosphate coating shall be sealed by the application of two coats of ready mixed, stoving type zinc chromate primer followed by two coats of synthetic enamel paint by powder coating process. The paint shade of the panels shall be Opaline Green(external) and semi glossy white(Internal). Bay marshalling box shall be provided with two subsections namely: Terminal box and auxiliary supply distribution box. (a) Terminal box: Providing intermediate termination of all auxiliary contacts of breaker, isolator and earthing switches (whether used or not) and preparing interlocking. (CT & PT marshalling boxes shall be provided with respective CTs & PTs.)
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(b)
Auxiliary supply distribution box from where both AC auxiliary supply, heating/lighting supplies and DC auxiliary control supply shall be distributed to various motors of all CBs, isolators/ earthing switches local marshalling box/equipment marshalling box and heating and lighting supply to various bay marshalling boxes. The marshalling boxes shall be provided with doors on both sides with key lockable handle for each door. The key shall be removable only in door locked position.
All auxiliary contacts of the CBs, isolators and earthing switches shall be terminated in terminal box section of bay marshalling boxes. All hardwired interlocking shall be wired in the above box. All auxiliary contacts and interlocked scheme contacts shall be wired to respective panels in the control room. Provision for terminating two number of 3 phase, 3 wire AC 50 Hz power supply called supply I & II, shall be provided in each auxiliary supply bay marshalling box. The AC distribution scheme shall be wired to manually select any one of the supplies by manually operated selector switch. After the manual selector switch, MCB controlled AC distribution shall be provided in such a way that individual and radial feeder supplies to driving mechanism/motor of every equipment is arranged. Contacts for remote alarm for supply fail shall be provided. Similarly provision for terminating 2 Nos. DC supplies and selection feature to select any one of the two supplies as supply-I and other as supply II shall be provided. Either of them shall be used after distributing it via suitably rated HRC fuses to feed, control supply of all isolators and earthing switches. Remote independent alarm for failure of all AC and DC outgoing feeders shall be provided by supply supervision relays having delayed dropout NC contact. Single phase 230V heating and lighting supply shall be provided in a loopin / loopout mode at bay marshalling box. The heating and lighting supply shall be sub-distributed in radial way to provide heating and lighting supplies for all HV equipment marshalling boxes and each bay marshalling box. The scheme for all protections, controls, indications, interlocking, metering, AC and DC distribution and all other schemes shall be prepared in such a way that cables shall be laid in radial pattern. Loop formulation of cables shall be completely avoided. Neutral of all cores of CTs, CVTs and EMVTs shall be formed in marshalling box of the respective equipment. Cables with sufficient
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number of cores are run from these marshalling boxes to control and relay panels as appropriate. The neutral of CTs, CVTs, EMVTs shall be earthed only at control/relay panel by means of a disconnecting link. 7.13 DC Distribution Philosophy for Controls, protection, Indication, Annunciation, Fault-Recording and Event Recording Systems The DC distribution scheme in various panels shall be prepared based on following DC distribution philosophy for various functions. (a) Protective Functions Two nos. DC supplies shall be arranged from two sections of switchyard DCDB to each of the protection panels. These supplies shall be taken through a selector switch with three positions, viz. independent, source-1 & source-2. In the independent position main-1 & main-2 protection systems will be fed by source-1 & source-2 respectively and the common services from any one of the sources. In case of failure of any one source (say source-1), the switch shall be changed over to the other source (source-2) and complete DC supply requirement of protection panels will be fed from the other source. DC auxiliary supply shall be supervised by supply supervising relays. The NC contact of the relays shall be delayed on drop off by approximately 100 to 200msec for annunciation in SCADA. The selector switch and the fuses shall be mounted inside the panel. These DC supplies shall be separated from DC supplies in the control panel by provision of interposing relays (IPRS) in protection relay panels. (b) Similarly, Bus bar protection scheme and indications shall be provided with two (2) nos. of 220V DC supplier through three (3) position selector switch fused and supervised by supply supervision relays having time delayed drop off type NC contact. Loss of supply shall be wired for annunciation at SCADA indication and annunciation supplies shall be separately fused. The selector switch and fuses, etc. shall also be mounted internally inside the panel. (c) Control Functions Control circuit of each breaker circuit will be provided with 2 independent 220V DC control supplies. Each of the above
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feeders shall be fed from separate section of DC board. Manually operated 8 pole, 3 position selector switch for positions called source I, independent and source II shall be used to select any one as closing/synchronizing and trip coil I supplies and other as trip coil II and auxiliary supply for contact multiplication/follower relay supplies, etc. Each incoming supply before select switch and outgoing supply after selector switch shall be separately fused and supervised by supply supervision relay having time delayed type NC contact. Loss of supply shall be wired for annunciation at SCADA. The DC supplies shall be isolated from DC supplies in relay panels as specified in a) above. One separate 220V DC annunciation supply for upto half number of the control panel shall be provided. Remaining half shall be supplied by separate but similar 220V DC supply. The Contractor shall tap annunciation supply through fuses and after supervision relays use it for all annunciation in respective panels. The supervision relay shall have time delayed drop off type NC contact for annunciation, failure of annunciation supply shall also be combined and annunciated on 230V AC operated annunciation system. In turn the failure of AC annunciation supply shall be annunciated in normal DC operated annunciate. It shall all be provided with additional contacts for event recording and remote annunciation. d) The RTUs and the PLCC located in the Switchyard control room for SLDC/RLDC shall be provided with 48V dual DC supply.
7.14
Specific Requirements The specific requirements listed in Sec. D3.6 for generator protection shall apply for switchyard protection system also in addition to the following: (a) The panels shall have a degree of protection not less than IP52 and shall be fabricated with 3 mm thick cold rolled sheet steel for front and rear equipment bearing surfaces and bottom gland plates, and 2.5 mm for sides and top. The doors and removable covers shall be gasketed. The panels shall be provided with anti vibration pads. The paint shade of panels shall be of shade opaline green (External) and semi-glosy white (Internal).
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(b)
The pre-treatment of the sheet steel shall involve degreasing rust / scale removal, phosphating and oven drying. The phosphate coating shall be sealed by the application of two coats of ready mixed, stoving type zinc chromate primer followed by two coats of synthetic enamel paint by powder coating process. The paint shade of panels shall be of shade opaline green (External) and semi-glosy white (Internal). All relays and measuring instruments shall be flush mounted type & the equipment on the front of panel shall be flush mounted. The centre line of switches, push buttons and indicating lamps shall be not less than 750 mm and centre lines of relays, meters and recorders shall not be less than 450 mm from the bottom of the panel. Control switches / push buttons / selectors and relay resetting knobs shall be located at a height between 1.0 m and 1.2 m from the bottom of the panel. No auxiliary relay shall be mounted on front of the control panel. They shall be mounted either internally or on the respective relay panel. All the internal wiring shall be carried out with 1100V grade stranded copper conductor wires with PVC insulation. For CT / PT circuits the wire size shall be 2.5 mm2 / lead and other circuits it shall be 1.5 mm2 / lead. All wiring meant for power supply to transducers, recorders shall be suitably MCBs or designed to limit short circuit currents. Means for detection of blown or open circuited fuses shall be provided. Terminal blocks shall be 650V grade, 10 amps rated, stud type terminals with terminal marking. The insulation between any two terminals and terminal to framework shall withstand 2 kV rms for one minute. Terminal blocks for CT & VT secondary leads shall be disconnecting, stud type. Terminal blocks for SCADA control commands shall be of disconnecting type. Terminal blocks for SCADA digital inputs shall be with knife type isolation. CT secondary leads shall also be provided with short circulating and earthing facility. A clearance of 250 mm shall be maintained between terminal blocks and gland plate and 150 mm between two rows of terminal blocks. At least 20% spare terminals shall be provided.
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(c)
(d)
(e)
(f)
(g)
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SECTION:
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SPEC. NO. TCE.5960A-H-500-001
(h)
Provision shall be made to mount Tariff meters supplied by grid in the switchyard itself in the grid tie lines as per requirement of grid authorities. All indicating lamps shall be of self-coloured clustered LED type of size 22.5mm. Colour of the lamps shall be different for different purposes. All the push buttons shall be momentary contact type, the colour of PBs shall be different for various functions. Push buttons shall be suitably shrouded to prevent inadvertent operation. All PBs shall have 2 NO + 2 NC contacts. Each of the control & relay panels shall be provided with thermostat-controlled space heaters, CFL type cubicle illuminating lamps and a 5A, 3 pin receptacle. Each control & relay panel shall be provided with necessary arrangement for receiving, distributing, isolating and short circuit protection by use of MCBs/MCCBs of D.C. and A.C. supplies for various control, signalling, lighting and space heater circuits. If miniature circuit breakers (MCBs) are used in VT secondary circuits, they shall have adequate auxiliary contacts for blocking trip circuits of voltage dependent protection and annunciation. Where high-speed protections are involved, the speed of operation of MCB shall be less than 5 milli seconds. All the panels shall be equipped with a continuous earth bus with connectors and clamps between panels for interpanel connection of the earth bus. All the metallic cases of relays, instruments and other panel-mounted equipments shall be connected to the earth bus by 2.5 mm2 copper wires. CT and PT secondary neutral or common lead shall be earthed at one point only at the terminal block and such earthing shall be made through links. Separate copper earthing flat shall be provided in the panel for cable screens of static equipment. All PT circuits shall be provided with HRC fuses having special holders such that they cannot be interchanged with other types of fuse holders and other fuse holders cannot be inserted into them.
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(i)
(j)
(k)
(l)
(m)
(n)
(o)
TCE FORM NO. 329 R5
SECTION:
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SHEET 39 OF 51
SPEC. NO. TCE.5960A-H-500-001
(p)
Tests (i) relay panels shall be subject to the following tests : Mechanical operation test High voltage test (2000V for 1 minute) Megger test Verification of wiring as per approved drawings Electrical control, Interlock and sequential operation tests
(ii)
Type tests and routine tests Type tests and routine tests shall be carried out on all associated components / equipment as per relevant standards and test certificates shall be furnished.
(III)
Acceptance Tests The equipment shall be demonstrated for proper operation, including operation of meters, relays, alarms and indications. Certified copies of all type and routine test certificate shall be submitted for the Owners approval before dispatching the control / relay panel.
7.15 7.15.1
Fault Disturbance Recorder Stand alone Fault Disturbance Recorder with associated cabling, PC, HMI, Printer and evaluation software shall be provided for the 400 kV Switchyard. The HMI and PC loaded with evaluation software shall be located in Switchyard Control Room/Central Control Room. It shall have 8 analog and 16 digital channels. The equipment shall be complete with disturbance recorder, control / display unit, junction box and accessories like auxiliary CTs and shunts. The FDRs shall be modular and shall be suitable for expansion. Provision shall be made to synchronise the electronic clock of each disturbance recorder with external master clock which GPS based. Also, a number of disturbance recorders in the particular location shall
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be capable of being synchronised with any one of the recorders as master. 7.15.2 Specific Requirements of the Equipment (a) The microprocessor based fault recorder shall be designed to continuously monitor analogue, digital signals and contacts of all protective / lockout relays. Recording shall be self started or triggered by dI / dt, dV / dt, or change of state of any of the digital input signals. The data acquisition unit of the fault recorder shall be provided with self-test diagnostic feature, which annunciates and alters the operator to rectify the defect or fault, if any. The number of channels / recorders offered shall cover the following: (i) Analog channels: (a) Currents in 3 phases and neutral (b) Voltages of 3 phases and their vector sum wherever VTs are provided. Digital channels: Protective relay contacts, lock out relay contacts, breaker contacts. The total number of channels offered shall be such that 20% spare channels are available. The fault recorder and all its peripherals shall be designed for operation on 220V DC. Recorders shall be provided with pre-history recording feature with pre-history recording time not less than 0.5 or 1 sec. The sampling rate of the wave shall be between 1.2kHz to 10kHz. Auxiliary CTs while catering for the required VA burdens shall not saturate under maximum fault current conditions. Auxiliary multi ratio PTs shall be provided to facilitate tap selection in voltage signal recording. The accuracy of analog channel recording shall be less than +3% for current channels and +1% for voltage channels.
(b)
(ii)
(iii)
(iv)
7.16
Synchronising Scheme The closing schemes of the CB shall be prepared and wired in such a way that only one CB is selected at a time for synchronising. It shall be possible to bypass synchronising relay only through a bypass switch
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SPEC. NO. TCE.5960A-H-500-001
and under voltage relays to sense dead-line / live-bus and live-line / dead-bus conditions. While preparing the scheme, it shall be noted that key operated auto / off / manual selector synchronising switch provides command from control panel. The synchronising and guard relay scheme shall be designed in such a way that when closing impulse is given, the CB can be closed only after the operation of synchronising check relay. If closing impulse is initiated before synchronising check relay operates, the CB shall not be closed on operation of the check relay. Live line-dead bus and dead line / live bus closing facility shall be provided using dedicated relays on CVT. The closing shall be possible only in manual position of synchro selection switch. Live-line / dead bus and dead-line / live-bus relays shall be one set per CB. Isolating transformer shall be provided in each incoming AC and running AC potential circuit of the synchronising scheme. The technical details of each isolating transformer shall be 30 VA, 110 / 110V with accuracy class of 0.5 All AC circuits, DC power supply, synchronising check relay permissive output contact and synchronising check relay indicating lamp contacts shall all be switched to respective circuit after synchronising selection scheme for any equipment is switched on. After synchronising selection is switched on, all synchronising indicators (e.g., double voltmeter, double frequency meter, synchroscope, bright lamps, etc.) synchronising check relay, live line / dead bus, dead line / live bus and guard relay outputs shall all be started and permissive conditions be generated for closing the respective circuit breaker. 7.17 7.17.1 Sequence of events recording System (SER) The SER system shall be a part of SCADA system. SER shall be designed with 1 ms resolution for digital input events with time stamping from each phase of all breakers, isolators and earth switches, opening and closing commands, change of positions of switches such as Local/Remote selection, synchronising selection, voltage selection, auto re-closing selection, selection of control from SCADA/DCS, operation of all protection and trip relays, VT fuse fail relay operation, direct trip send and receive, pole discrepancy relay operation, trip circuit faulty, trip relay faulty, DC supply fail, SF6 pressure Low, LBB operated, etc. shall be available in SCADA. Critical interlocks and
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those SER points which are not covered by numerical relays shall be hard wired to SCADA. The chronological printout facility shall be provided for any of the first 100 occurrences. Further occurrences shall be printed chronologically. This list is only indicative and not exhaustive. The clock shall have resolution of 1 ms and first up feature. It shall be possible to synchronise the clock with an external master clock. 7.17.2 7.18 The event recorder shall be suitable for operation on 220V DC supply. PLCC System PLCC system shall be provided for four nos. of 400kV outgoing lines. 100% redundancy shall be provided in hardware for protection signalling. 1 no. dedicated channel shall be provided for speech/data necessary hardware & software & accessories shall be included, however exact requirement of APTRANSCO grid authorities shall be intimated to successful bidder. 7.19 7.19.1 Control, Indication, Alarm and SER Points Minimum electrical requirements in respect of control, monitoring measurement, annunciation, synchronising are indicated in I&C system section D2.4. ABT Metering System ABT compliant energy meters for main & check with accuracy class of 0.2S shall be provided with suitable communication port for interfacing the same with SCADA system. In SCADA system separate work station shall be provided for accessing the Energy Meter readings. Separate core for main & check tariff metering with 0.2S accuracy class shall be provided for all the lines. Energy meters must be provided with a pair of suitably rated potential free contacts to generate signal for annunciation and SCADA, if voltage supply to the meters are interrupted. Provision shall be made to amount Tariff meters supplied by grid in the switchyard itself in the grid tie lines as per requirement of grid authorities. Test & Test Reports The Contractor shall conduct all the routine, type and acceptance tests as per the relevant standards and as specified in this specification in the presence of the Owner. The test certificates shall be furnished for Owners approval.
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7.20 7.20.1
7.21 7.21.1
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SECTION:
D3.7
SHEET 43 OF 51
SPEC. NO. TCE.5960A-H-500-001
If, in case of circuit breaker, isolators, current transformers, voltage transformers, lighting arresters insulators strings, bus post insulators, control & relay panels and other components of all the main equipment type tests are already conducted on identical equipment to the one offered and found to be acceptable, such tests will normally be waived. However if due to any reason Owner requires the same to be conducted again, conducting the tests are included in the scope. In case of hardware such as clamps the temperature rise test material composition test and mechanical test shall be conducted on one sample of each type even if test reports are already available. Disturbance recorder shall comply with the test requirements as per IEC-60255-5&6.
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DATA SHEET A3.7
SECTION: SHEET
D3.7
44 OF 51
SL. NO.
DESCRIPTION
UNITS
1.0 1.1 1.2 1.3 1.4
400 kV SWITCHYARD Nominal voltage Highest System voltage Short circuit breaking current Making current kV kV kA kA (peak) kV (Peak) 400 kV 420 kV 50 kA for 1 sec. 130
1.5
Impulse withstand voltage
1425
1.6
One minute power frequency withstand voltage Reference ambient temperature Creepage distance
kV (rms) 630
o
1.7 1.8
50 31 mm / kV based on highest system voltage
mm
1.9
Clearances i) Phase to phase ii) Phase to earth iii) Sectional clearance iv) Ground clearance mm mm mm mm 4200 3400 6500 8000
2.0 2.1 2.2 2.3 2.4

400 KV CIRCUIT BREAKERS Type Execution of poles Rated current Operating duty
R0 JUNE 10 PPD. BY CKD.BY DATE TCE FORM NO. 330 R3
156
SF6 Nos. A 3 nos., single pole * O-0.3 sec-CO-3 min-CO

RKD HA JOB NO. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

DATA SHEET A3.7
SECTION: SHEET
D3.7
45 OF 51
SL. NO.
DESCRIPTION
UNITS
2.5 2.6 2.7
Auto Reclosing First pole clear factor Breaker opening time Breaker closing time Line charging breaking current Small inductive current breaking Type of operating mechanism Operating mechanism to be suitable for (a) Control voltage (b) Spring Charging
Required 1.3
m.sec. m.sec. A
* * * From 0.5A to 10A Spring / Spring charged 1 Phase operation
2.8 2.9 2.10 2.11
2.12
220V DC 220V DC Nos. Two (2) 4200 mm 15 NO + 15 NC (minimum) Not required Required kgs 600 Required.
2.13 2.14 2.15 2.16 2.17 2.18 2.19 3.0 3.1 3.2
No. of trip coils per pole Phase to phase spacing No. of auxiliary contacts SF6 Gas filling plant Gas evacuation and filling unit Cantilever strength Out of phase switching 400 kV ISOLATORS Type Reference standard
R0 JUNE 10 PPD. BY CKD.BY DATE RKD HA
Horizontal centre Pantograph type IS 9921

JOB NO. 5960A
break
157

DATA SHEET A3.7
SECTION: SHEET
D3.7
46 OF 51
3.3 3.3
SL. NO.
Rated current
DESCRIPTION
UNITS
Insulation Test values One minute P.F wet withstand voltage (a) (b) Between poles and earth Across isolating distance kV(rms) 1425 kV(rms) 1425
3.4.1
3.4.2
Impulse withstand voltage (a) (b) Between poles and earth Across isolating distance kVp kVp 1050 1200 Cu Yes
3.5 3.6
Material of main contact Whether contacts are to be silver faced Insulators Codes and Standards Operating mechanism (motor/ manual) Main blade Earth blade Insulation Data Minimum cantilever strength Miscellaneous Auxiliary supply (a) Electrical
PPD. BY CKD.BY DATE RKD HA JOB NO. 5960A
3.7 3.7.1 3.8
IS 2544
3.8.1 3.8.2 3.9 3.9.1 3.10 3.10.1
Motor & Manual Motor & Manual
kg
600
220V DC for control and interlock;

158
R0 JUNE 10

DATA SHEET A3.7
SECTION: SHEET
D3.7
47 OF 51
SL. NO.
DESCRIPTION
UNITS
400V AC, 3 phase for motor drive For both Electrical and manual operation. Bolt interlock electrically operated
3.10.2 3.11 3.11.1 3.11.2 4.0 4.1
Type of interlock Codes and Standards Insulators Isolators 400 kV CURRENT TRANSFORMER Type
IS : 2544 IS : 9921
Outdoor, SF6/oil filled hermetically sealed with SS bellow Refer Main one line diagram Drg. No. TCE. 5960A-EL-SK-2003 A 1 Oil immersed Class A
0
4.2 4.3
No. of cores Primary current ratio
4.4 4.5 4.6 4.7
Secondary current Class of insulation Maximum temp. rise of winding above ambient of 50C Cantilever strength of CT at the terminal Applicable Standards Current transformers Insulating oil Bushings Large hollow porcelains
500 C 600
kg
4.8 4.8.1 4.8.2 4.8.3 4.8.4

IS 2705 IS 335 IS 2099 IS 5621

JOB NO. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3
159

DATA SHEET A3.7
SECTION: SHEET
D3.7
48 OF 51
4.8.5 4.8.6 5.0 5.1
SL. NO.
Insulators
DESCRIPTION
UNITS
IS 2544
Hot dip galvanising
IS 2633 and IS 2629
400 kV CAPACITOR VOLTAGE TRANSFORMERS / EMVT Type EMVT: Outdoor, oil filled/ SF6 gas filled, hermetically sealed CVT: Oil filled only Solidly earthed
5.2 5.3
System neutral earthing No. of primary / secondary windings Primary / secondary winding voltage
5.4
Refer Main one line diagram Drg. No. TCE. 5960A-EL-SK-2003
5.5 5.6
Class of insulation Maximum temp. rise of winding above ambient of 50C Cantilever strength of CVT at the terminal Rated voltage factor
Oil immersed Class A 50C
5.7
600 kg
5.8
1.2 continuous and 1.5 for 30 seconds Contractor to furnish depending upon frequency selected for PLCC + 10% to 5% k.Hz 40 500
5.9
Rated capacitance
5.10 5.11 5.12
Tolerance High frequency range High frequency capacitance For entire carrier frequency range
Within 80% to 150% of rated capacitance
R0 JUNE 10
PPD. BY CKD.BY DATE
RKD HA
JOB NO. 5960A
160

DATA SHEET A3.7
SECTION: SHEET
D3.7
49 OF 51
SL. NO.
Equivalent series resistance over the entire carrier frequency range
DESCRIPTION
UNITS
Less than 40 ohm
5.13
Stray capacitance and conductance of low voltage terminal Stray capacitance of low voltage terminal over entire carrier frequency range Stray conductance of the low voltage terminal over entire carrier frequency range 300 + 0.05 Cn Pf, Where Cn is rated capacitance mho 50
5.14 5.15 5.15.1 5.15.2 5.15.3 5.15.4 5.19.5 5.19.6 6.0 6.1 6.2 6.3 6.4
Corona extinction voltage Applicable Standards Voltage transformers Insulating oil Bushings Large hollow porcelains Insulators Hot dip galvanising 360 KV LIGHTNING ARRESTORS System Earthing Type of arrester Discharge class Minimum cantilever strength of arrestor assembly
kV
320
IS 3156 IS 335 IS 2099 IS 5621 IS 2544 IS 2633 and IS 2629
Solidly earthed Metal Oxide Gapless 20 kA, Class - IV kg

JOB NO. 5960A
600
161

DATA SHEET A3.7
SECTION: SHEET
D3.7
50 OF 51
SL. NO.
DESCRIPTION
UNITS
6.5 6.5.1
Codes and Standards Lightning arrester for alternating current systems Insulators Large Hollow Porcelain insulators INSULATOR Type Cantilever strength kg Solid core / post type / string 600 kg minimum for bus post insulator. 1.3 times corresponding flash over voltage. IS - 3070 and IEC - 60099
6.5.2 6.5.3 7.0 7.1 7.2
IS - 2544 IS 5621
7.3
Puncture voltage
7.4 7.4.1 7.4.2 7.4.3 8.0
Applicable standard Post insulators Suspension insulators Insulator fittings BUS CONDUCTORS, CLAMPS & CONNECTORS Applicable Standards AAC, ACSR conductors Copper conductors Galvanisation of steel wires Copper tubes Aluminium / Aluminium Alloys Bars, IS : 398 IS : 282 IS : 4826 BS : 159 IS : 5082
JOB NO. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3
162
IS 2544 IS 731 IS 2486 IS 5561
8.1
R0 JUNE 10
PPD. BY CKD.BY DATE
RKD HA

DATA SHEET A3.7
SECTION: SHEET
D3.7
51 OF 51
SL. NO.
Rods, Tubes, Sections for Electrical Purposes Fittings for Aluminium and steel cored aluminium conductors for overhead lines Electric power connectors Hot dip galvanised process
DESCRIPTION
UNITS
IS : 2121
IS:5561 IS : 2629 & 2633
9.0 9.1 9.3 9.6 9.7 9.8 9.9 9.10 9.11 9.12 9.13
LINE TRAPS Installation Type of earthing Line trap arrester discharge current Band width Tuning device required Maximum tapping loss Type of tuning Winding material Line traps Methods of test for line traps dB kA kHz Outdoor Effectively earthed 20 40-500 Required 2.6 Wide band Copper IS : 8792, IEC :60353 IS : 8793, IEC:60353
R0 JUNE 10
PPD. BY CKD.BY DATE
RKD HA
JOB NO. 5960A
163
SECTION:
D3.8

SHEET 1 OF 10
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR CONTROL PANEL
SPEC. NO. TCE.5960A-H-500-001
8.0 8.1
GENERATOR CONTROL The control, monitoring, measurement, annunciation, synchronising and sequential event logging for each generator and its subsystem shall be provided on the Operator stations (plant DCS through HMI). Synchronising, essential controls and annunciation shall also be available from the Generator control panel (GCP). Generator and Auxiliary Power Supply System Control & Monitoring Provision in the plant control system shall be made for the starting, bringing upto rated voltage and speed, initiation of synchronising, operation and annunciation on GCP and monitoring, alarm, data logging, recording and sequential event recording for generator and its excitation system from the Operator stations (plant DCS through HMI). The minimum requirements of the measurements are indicated in the Main One Line Diagram drg no. TCE.5960A-EL-SK-2003. In the GCP, the mimic of the generator, its subsystems and 6.6 kV & 400V auxiliary power supply system shall be provided. Synchronising equipment consisting of Auto synchroniser, double voltmeter, double frequency meter, synchroscope, check synchronising relay, synchronising lamp, etc., shall be provided in the hardwired GCP as follows: (a) One No. of synchronising panel/trolley shall be provided through which the synchronising of all the GCB & breakers in 400kV switchyard can be synchronised (GCB in the case of GTGs and 400 kV GT breakers in the case of STGs) by plugging the control cable into a socket provided on each Control panel of the respective breaker. This synchronising trolley shall have all the necessary equipments & meters for carrying out the manual synchronisation. The raise/lower commands for the same also be done through the trolley itself. Auto synchroniser relay for generator (25A): The Auto synchronising facility shall be made available to auto synchronise the above breakers through DCS. Auto synchronisers shall connect the generators to the 400 kV grid either through generator circuit breaker or 400kV generator transformer breakers automatically after synchronising the two systems. The equipment shall be supplied to control both the voltage and frequency of turbine generator set to match with those of the grid.
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8.2 8.2.1
8.2.2
8.2.3
(b)
TCE FORM NO. 329 R5
SECTION:
D3.8

SHEET 2 OF 10
SPEC. NO. TCE.5960A-H-500-001
8.2.4
Manual synchronising facility common to all the units shall be provided for manual synchronisation of the generators. Remote/Manual selection shall be provided in DCS. When the Remote mode is selected, synchronising shall be initiated from DCS through auto synchroniser. When the Manual mode is selected, synchronising shall be done from the stand-alone synchronising panel which houses the required synchronising gear (consisting of dv & df meters with associated transducers, synchroscope, check synchronising relay, guard relay, synchronising lamp, etc.), breaker selector switch, breaker control switches, etc. The synchronising panel shall be located in the control equipment room. Hard wired emergency trip push buttons for tripping of generator circuit breakers of GTGs shall be mounted on the operator console. The push buttons shall be suitably protected to prevent inadvertent operation. The 400kV system controls shall be implemented in an independent SCADA system. However, the 400kV system SCADA shall be interfaced with the plant DCS through serial link for monitoring of 400 kV system from DCS. Further, the status of generator circuit breakers, 400 kV generator transformer breakers along with grouped alarms of generator and generator transformer shall be made available for indication/annunciation in 400kV system SCADA switchyard Control Room as well as main control room. The GCP shall be provided with all the synchronising switches, selector switches, push buttons, indicating lamps as needed for the control of the systems envisaged. The interlocks for the auxiliary power supply system shall be hardwired interlocks. This shall be read in conjunction requirements with requirements indicated in I&C Section D2.4. CONTROL AND MONITORING IN DCS Control, monitoring, measurement, annunciation, synchronising of complete electrical system supplied under this contract shall be possible from plant DCS system. In case of failure of any OS, it shall be possible to carry out the necessary operation from one of the healthy OS. Synchronising, essential controls, metering and annunciation shall also be available from the Respective control panels for the lines.
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8.2.5
8.2.6
8.2.4
8.2.5
8.2.6
8.3 8.3.1
TCE FORM NO. 329 R5
SECTION:
D3.8

SHEET 3 OF 10
SPEC. NO. TCE.5960A-H-500-001
8.3.2
DCS System Minimum functional requirement of plant DCS system in respect of electrical system shall be as below:
8.3.2.1
CONTROLS (i) Control of all the Incomers, bus ties of all the electrical switchboards except outgoing feeders from the main Lighting Distribution Board, DCDB & UPS DB, shall be carried out from the DCS. It shall also have the facility to carryout the live changeovers at all the switchboards at 6.6kV & 400V. Remote position, service position, breaker health, permissive for interlock set shall be considered as input to the DCS system. Synchronising gear shall be housed in the respective switchboards. All transformers with OLTC shall have provision for control viz. issuing raise / lower command to OLTC from plant DCS system. Control of generator excitation and governor system shall be possible from plant DCS including mode selection and set point control for various parameters viz. MW, MVAR & P.F. controls. Selector switch for the operation of equipment shall be at respective control panel. Initiation of auto synchroniser. DG start, voltage raise/lower, speed raise/lower, DG breaker closing shall be possible from DCS. Local / remote and auto / manual selection will be done at DG set control panel. Selector switch for the operation of equipment shall be at respective control panel. All the necessary controls required for synchronising the DG set & stopping of DG set after resumption of Normal power shall be included in the DCS.
(ii)
(iii)
(iv)
(v) (vi)
8.3.2.2
Monitoring (a) Indication-Status of GCB, other breakers (ON, OFF, service, test) position of Local/Remote selector switches, spring charged indication etc. Abnormal conditions to be considered for alarm inputs to DCS are:
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(b)
TCE FORM NO. 329 R5
SECTION:
D3.8

SHEET 4 OF 10
SPEC. NO. TCE.5960A-H-500-001
(i) HV System (Generator CB, 6.6kV and 400kV breaker) Operation of each of Generator protection, motor protection. Trip circuit unhealthy of each equipment, protection unhealthy of each equipment, Trip relay unhealthy of each equipment, VT circuit unhealthy of each VT, signals generated in Transformer MB about abnormal operating conditions of Transformer, LBB operation of each breaker, DC supply failure of each protection/control scheme as appropriate, Successful/Unsuccessful changeover of 6.6 kV supplies. GT and UAT condition shall be monitored from DCS. (ii) LV System (400V) Breaker auto trip, individual protective relay operation, trip relay failure, DC supply failure, bus under voltage, VT fuse failure, Trip circuit unhealthy. Successful/Unsuccessful changeover of 400V supplies. (iii) Generator, Unit Auxiliary & Service Transformers All alarm and trip conditions of generator transformers, unit auxiliary transformers and service transformers. Monitoring of winding & oil temperature of all the transformers & of all temperatures & pressure parameters related to Generator. Tap position of GT & UATs shall also be monitored from DCS. (iv) DC System DC earth fault, DC under voltage, group faults in case of DC boards, and normal operating parameters of the DC system etc. (v) UPS System All normal & abnormal conditions of UPS system with details. (vi) Battery charger Group trouble alarm for chargers with details as available from equipment.
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TCE FORM NO. 329 R5
SECTION:
D3.8

SHEET 5 OF 10
SPEC. NO. TCE.5960A-H-500-001
(vii) Excitation System and generator Each of protection relay alarm and trip conditions, abnormal conditions in excitation system and generator. (viii) DG Set DG operating parameters, alarm and trip conditions. (ix) Alarm for the running hours of 30KW & above motors shall be generated after achieving predefined set points. Monitoring of the complete electrical system during the normal operation. Temperatures of all the >= 100KW motors. All the energy parameters of the lines, generator & auxiliary consumption shall be taken from the ABT compliant energy meters through communication. Energy parameters on HV side of GTs & UATs shall also be monitored.
(x)
(xi) (xii)
(c)
Single line diagram showing Voltage, frequency, MW and MVAR flows, breaker and isolator positions shall be available on DCS/SCADA. SLD shall also show the Generator phase currents, field current and 400kV bus voltages & frequency. More than one frame can be used if all the details cannot be represented on a single frame.
8.3.2.3
Measurement
Feeder Description (a) 400 kV line bays DCS MW MVAR A V MWH MVARH Pf MVA Control Panel
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TCE FORM NO. 329 R5
SECTION:
D3.8

SHEET 6 OF 10
SPEC. NO. TCE.5960A-H-500-001
(b) 400 kV GT bays
A(All phases) MW MVAR MWh Tap position winding & oil temperature V(All phases) A(All phases) MW
-A (All phases) -MW MWh -
(c)
Generator
- V (All phases) - A (All phases) - MW -MVAR -Frequency -pf -MWH -
MVAR MVARH* Frequency MW trending MVAR trending pf MWH * (d) 400 kV Bus V(Bus 1& 2) Frequency(Bus 1& 2) * By pulse output from TVM /Meters (e) Unit Auxiliary A(All phases) Transformer (HV side) MW MVAR MWh Tap position winding & oil temperature (f) Incomer, Tie feeders & Outgoing feeders of 6.6kV switchgear and Incomer, Buscoupler & outgoing feeders of 400V switchgear
-A (All phases)
-MW MWh -
A-All phases for I/C & Ties, One phase for others MW MVAR MWH
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TCE FORM NO. 329 R5
SECTION:
D3.8

SHEET 7 OF 10
SPEC. NO. TCE.5960A-H-500-001
(g) 6.6kV & 400V Buses
(h) Emergency DG set
(i)
DC and UPS System
All energy metering shall be through the power meters provided on the incomers & tie feeders on the DCS. These power meters shall have the local display also. Running hours of the motors decided during the detailed engineering shall be calculated or taken from the numerical relays. Running hours, electrical parameters & Energy reading shall also be measured through numerical protection relay provided at the DG set. . A V & Hz for UPS
V (All phases) F
(j)
Generator stator winding and bearing
Temperature
NOTE : DCS Input current and voltage shall be considered for all three (3) phases.
The metering data for the 400kV bays shall be through the ABT compliant energy meter provided except the tariff meters. 8.3.3.4 Event logging shall be provided for all manual operations and relay operations as detailed below: (a) Status of each breaker of all equipment being controlled, isolators and earth switches.
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TCE FORM NO. 329 R5
SECTION:
D3.8

SHEET 8 OF 10
SPEC. NO. TCE.5960A-H-500-001
(b) (c) (d)
Close and open commands. Selector switch positions. Each protective relay, trip relay, alarm relay operation. Event logging for each phase shall be provided wherever applicable (eg. 3-poles of line circuit breaker, distance relay output contacts, generator protections, fuse fail alarm, etc.) Event logger shall be a part of the DCS with first up feature. It shall have a time resolution of 1 ms. Trip contacts of the complete electrical installation/equipments in the station viz. battery charger, UPS, Generator, all transformer, all electrical switchboards etc. are to be included.
(e)
(f)
8.3.2.5
Trending of parameters during disturbance shall be with a resolution of 0.5/1.0 sec., and at 15 minutes during normal operation. The change from normal mode to disturbance mode shall be through threshold/gradient settings provided in the system for analog quantities and external binary signals obtained from selected protective relays. Capturing of momentary values of all these parameters shall also be possible triggered either by a protective relay or by a manual keyboard command. Synchronising (a) Generator (Manual and through Auto synchroniser) Synchronising facility shall be provided for the generator through auto synchroniser in auto mode and with the help of double voltmeter, double frequency meter, synchroscope and check synchronising relay permissive condition in the manual mode. (b) 6.6 kV Incomer & tie circuit breakers shall have facility for fast and slow auto changeover/manual synchronising and dead bus closing. 400V switch board / MCC incomer and bus coupler breakers shall have facility for dead bus auto change over / manual live transfer.
8.3.2.6
(c)
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TCE FORM NO. 329 R5
SECTION:
D3.8

SHEET 9 OF 10
SPEC. NO. TCE.5960A-H-500-001
(d)
One (1) set of synchronising equipment consisting of double voltmeter, double frequency meter, synchroscope, check synchronising relay, synchronising lamps, synchroniser with lockable only in ' off ' position, etc., shall be provided for each of the following: (1) Generators (2) Breakers associated with Emergency DG synchronising
8.3.3
The functional requirement indicated above are minimum, the Bidder shall provide all necessary controls indications, interlocks & devices required for the system offered by him. Also, any additional requirement arising during detailed engineering shall be provided by the Bidder without any additional cost to the Owner. The time critical controls and interlocks shall be hardwired system only. The control / selector switches & meters shall be of miniaturised version. Check & main Meters ABT compliant Tri-vector energy meters of Accuracy class 0.2S for lines, UAT & generator metering shall be provided. Transducers The Contractor shall provide all the transducers for electrical system either in respective switchgear / control panels. All the transducers shall be self-powered. The transducers shall comply with the requirements specified for transducers in Electrical section D3.25. Interposing Relays The interposing relays required for the switchgear / equipment being supplied under this contract shall be located in separate IPR panels located in the control room. The coupling relays shall be rated for 0.5 Amp breaking at 220V DC and 6 Amp make and continuous current at 220 V DC. Interposing relays used for 400 kV circuit breaker closing shall be adequately rated for the making current.
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8.3.4 8.3.5 8.3.6
8.4 8.4.1
8.4.2
8.5 8.5.1
8.5.2
8.5.3
TCE FORM NO. 329 R5
SECTION:
D3.8

SHEET 10 OF 10
SPEC. NO. TCE.5960A-H-500-001
8.6
Tests Tests for control desk shall be as indicated in Section D3.7 for Switchyard relay and control panels.
ISSUE R0
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TCE FORM NO. 329 R5
SECTION:
D3.9
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - 6.6 kV SWITCHGEAR
9.0
6.6 kV SWITCHGEAR The 6.6 kV switchgear and its accessories shall conform to all latest editions of national and international standards indicated in Data Sheet A 3.9. Also, the switchgear and its accessories shall comply with the requirements indicated in Data Sheet A 3.9 and specific requirements indicated below.
9.1
For feeding the plant auxiliaries rated for 6.6 kV and service transformers, adequately rated switchgears shall be provided. Manual & Automatic Transfer of Loads The station switchgear shall be provided with manual live changeover scheme for planned changeover of supply from one incomer to another and vice versa. Automatic fast changeover scheme for changeover of supply from one source to another in the event of supply failure from upstream end shall be provided. Changeover shall be blocked if incomer has tripped due to bus fault. The closure of the unit supply breaker shall be supervised by a synchrocheck relay permanently connected to and energised by the secondary voltages of the unit bus P.Ts. The high-speed transfer shall be completed in not more than 40 ms. If fast auto change over fails for whatever reason, an automatic slow transfer shall be initiated. The fast changeover scheme shall be such that the running motors are not tripped or there is only allowable inrush current due to motor reacceleration. The FBTS should have following transfer modes: i) Fast Transfer
9.2 9.2.1
9.2.2
9.2.3
The bus voltage and incoming source voltage should be monitored on a continuous basis for magnitude and phase angle to ensure that transfer operation is carried out under conditions conducive to fast bus transfer as per high speed sync-check supervision and ANSI C50.41 (1982) criterion. ii) In Phase Transfer
The breaker power contacts shall close when the decaying and drifting bus voltage synchronizes with the incoming source voltage within acceptable voltage and frequency parameters. The Bus transfer system
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TCE FORM NO. 329 R5
SECTION:
D3.9
shall continuously process the bus voltage and the drifting phase angle dynamics to determine in real-time the exact moment of sending a command to the breaker-closing coil to achieve the above. iii) Slow Transfer The breaker power contacts shall close when the falling bus voltage shall reach an acceptable safe value. The auxiliary drives are selectively tripped simultaneously to limit the transformer inrush current. iv) 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. Normally not recommended for unplanned transfers and auto/protective transfers from the system safety considerations 9.2.4 The bus transfer scheme shall be totally microprocessor based numerical system with in-phase transfer facility and communication facility to DCS. Spare Feeders One motor and one transformer type spare feeder of highest rating shall be provided on both sections of Bus-A & Bus-B of 6.6kV switchgear. Additionally One (1) no. transformer feeder on each bus (colony supply) for Owners use shall be provided. 9.4 9.4.1 Short Circuit Current Ratings The fault level for the switchgear, circuit breakers, isolators, earth switch, bus bars, etc., shall be arrived at, on the basis of short circuit current contribution from UAT plus short circuit contribution by the motors running on the bus. A margin of 5% over higher of the above S.C current, thus calculated shall be applied and rounded off to the next higher standard ratings and this value shall be adopted for the breakers and switchgears. The momentary current ratings shall be 2.55 times this value. Asymmetrical S.C current breaking capacity of the breaker shall consider the higher time constant for decay of current in the vicinity of power generating stations and the breaker offered shall be suitable for this duty.
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9.3
9.4.2
9.4.3
TCE FORM NO. 329 R5
SECTION:
D3.9
9.4.4
Calculations for arriving at the time constant at this plant shall be furnished to justify breaker selection in accordance with IEC-62271-100 and contractor shall furnish calculation during detailed engineering stage to establish the adequacy of support insulators and busbar sizes for the declared continuous and short time current rating. Continuous Current Ratings The continuous current rating of the 6.6 kV unit switchgear buses, incomer breaker shall be the rated LV winding current of UAT's respectively with 20% margin rounded off to the next higher standard rating. The continuous current rating of the feeders shall be based on the name plate current rating of the connected equipment with 20% margin rounded off as indicated in 9.5.1. Constructional Measurements The switchboard shall be indoor, metal clad having separate metal enclosed compartments for (a) control, metering and relaying devices, (b) circuit breakers, (c) phase bus bars, (d) instrument transformers and (e) power cable terminations and adjacent cubicles (panels) shall have sheets on either side to ensure complete isolation. The bottom of each panel shall be covered by sheet steel and necessary glands plates. Switchgear shall be suitable for extension on both sides. Switchgear shall be suitable for extension on both sides. The switchgear assembly shall be rodent and vermin proof. Conductor shall be of high conductivity aluminium alloy for the horizontal busbars, vertical droppers and connectors to the fixed end of isolating contacts. All circuit breaker compartments shall be provided with separate door so that circuit breaker front cover shall not be used as front door. All live parts shall be provided with isolating barriers between phases to avoid exposure to live parts. Door enclosing the cable termination shall be with hinge. A fixed type checkered net shall be provided between cable termination and door to avoid accidental contact to live termination. This arrangement is required to take Thermographic measurement using Infrared thermometer.
9.5 9.5.1
9.5.2
9.6 9.6.1
9.6.2
Required number of high speed trip relays, supervision relays, auxiliary relays, timers, contact multiplication relays, etc., shall be provided in the
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TCE FORM NO. 329 R5
SECTION:
D3.9
panels to meet the system requirements and to meet the system operation philosophy indicated in the specification elsewhere. 9.6.3 The circuit breaker shall be drawout type and it shall have test, service and isolated positions. In test position the circuit breaker shall be capable of being tested for operation without energising power circuits. At least 5NO+5NC spare contacts shall be wired to the terminal block after fully utilising for protection, interlocking, annunciation, etc. The current transformers shall be mounted in the fixed portion of the switchgear. Adequate space shall be available for termination using heat shrinkable type cable termination in cable compartment and for mounting of zero sequence current transformers (core balance current transformers). Withdrawal of circuit breaker shall not be possible unless it is in open position and operation of circuit breaker shall not be possible unless it is fully in service position, or is fully in test position and drawn out position. Automatic safety shutters shall cover live parts when the breaker is withdrawn and all other standard safety features shall be provided. Earth bus of size 50x6 mm Cu shall be provided at the bottom and shall extend throughout the length of the switchboard .All non-current carrying metal work of the switchgear shall be effectively bonded to the earth bus. Hinged doors shall be earthed through flexible earthing braid for each type of breaker. The circuit and bus bar earthing facility with earthing trucks shall be provided for each type of breaker. Suitable mechanical interlocks shall be provided to prevent the closing of earth switch on live circuit. Switchgear shall be supplied completely wired and inter panel wiring between cubicles of same switchgear shall be provided. The sizes of wire in the panel shall be stranded copper conductor, 1.5mm for all circuit and 2.5 mm for CT circuits. Terminal blocks shall be of stud type, 650 volts grade, 10 amps rated complete with insulated barriers. Terminal blocks for CTs and VTs shall be provided with test links and isolating faciliting and CT terminals with short circuiting and earthing facility. All spare contacts and terminals of cubicle mounted equipment and devices shall be wired to terminal blocks with 20% spare terminals. Not more than 2 wires shall be connected at a one terminal.
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9.6.4
9.6.5
9.6.6
9.6.7
9.6.8
9.6.9
9.6.10
9.6.11
TCE FORM NO. 329 R5
SECTION:
D3.9
9.6.12
All relays protective, auxiliary, and timers shall be in draw out cases with built in test facilities. Necessary test plugs shall be supplied loose and is included in the scope of supply. Externally operated hand reset indicators shall be provided on all relays and timers. Timers shall be of electromagnetic or electronic type only. Atleast 1NO + 1NC spare contacts of all relays / timers shall be wired to terminal block. All relays shall be of self reset type unless otherwise specified. In the event of shortage of contacts in circuit breakers, trip relays, contact multiplying relays shall be used. The same shall be two coil, latching type with electrical reset, contacts shall be gold flashed with 20 micron thick plating. Breaker control switches shall be pistol grip black and selector switches shall be oval or knob, black. Breaker control switches shall be 3 position spring return to neutral, instrument selector switches shall be of maintained stay put type. Push buttons provided shall be shrouded. Space heaters of adequate capacity shall be provided. Each switchgear panel shall be provided with 230 Volts, 1 phase, 50 Hz, 5 amps, 3 pin receptacle with switch located in a convenient position. Provision shall be made for receiving, distribution, isolating and fusing of auxiliary DC and AC supplies for controls, space heating, etc. Two numbers DC feeders shall be provided for 6.6kV switchgear with selector switch for selecting any one supply. DC supply supervision lamps (self coloured clustered LED type of size 22.5 mm) shall be provided and the same shall be on AC supply. Single phase loads for motor space heating etc., shall be distributed between different phases to keep the loading on all the phases uniform. The ratings of instrument transformers shall be decided by Bidder based on connected load, lead burdens, changes during engineering stage and adequate margin at the time of handing over the plant: (a) The CTs shall withstand momentary and short time current ratings of the associated switchgear. CTs and VTs shall be of the cast resin type and completely encapsulated. In case of smaller rated CTs (say 200 Amp and less) at the expected fault level the CT saturation may result in the non operation of the instantaneous short circuit protection. In such cases separate protection CT core with higher ratio shall be selected to avoid saturation at high fault currents.
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9.6.13
9.6.14 9.6.15 9.6.16
9.6.17
9.6.18
(b)
TCE FORM NO. 329 R5
SECTION:
D3.9
(c )
Service transformers and motor feeders shall be provided with 50/1 A core balance CTs for connecting earth fault relays.
9.6.19
VTs shall be single phase, drawout type and housed in a separate sheet metal enclosure. VTs shall be provided with HRC fuses on both primary and secondary sides under voltage relays, timers, etc. for motor tripping and remote annunciation on supply failure. Those terminals required to be connected to earth shall be earthed by an isolating link without a fuse. Those terminals required to be connected to earth shall be earthed by an isolating link without a fuse. Fuses on primary side shall have rupturing capacity equal to the switchgear rating. Primary fuse replacement shall be possible with VT in isolated position only. Switchgear panel shall be suitable for bottom cable entry and provided with removable gland plates. Adequate space shall be available for the termination of the heat shrinkable cable termination & mounting of the CT & CBCT. Cable lugs for all power, control and instrumentation cables connections shall be supplied. The lugs shall be tinned copper/Aluminium depending on cable conductor and of solderless crimping type. The cable glands shall be of double compression type brass glands. All breakers of identical ratings shall be interchangeable, suitable mechanical/ electromechanical interlocks to ensure that earth switch is not closed/truck is not inserted with the bus live or cable side energised. Bidder shall supply and mount transducers as per Main One Line diagram and philosophy of control defined elsewhere in the specification, in the individual switchgear panels. For the analog parameters (i.e. A, p.f, KW, running hours etc) required in DCS, 4-20mA outputs for parameters available in numerical relays shall be used. Wherever not available, separate transducers shall be provided. The transducers shall have 420 mA dual output and accuracy class shall be less than 0.5%. Rubber mats suitable for 7.2kV grade shall be provided at front and rear of switchgear. Contractor shall furnish calculation during detailed engineering stage to establish the adequacy of support insulator and busbar sizes for the declared continuous & short time current ratings.
9.6.20
9.6.21
9.6.22
9.6.23
9.6.24
9.6.25
9.6.26
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SECTION:
D3.9
9.6.27
Current ratings of all switchgears, circuit breakers, CTs etc. shall be sufficient for carrying the connected load currents without exceeding the permissible temperature limits or reduction in service life. Use of two breakers in parallel to meet the required rating shall not be acceptable. The connection between the start up transformer and 6.6kV switchgear shall preferably be by means of segregated phase bus ducts. Surge arrestors shall be provided for motor and transformer feeders and shall be as per manufacturers recommended type and generally in accordance with IEC 99-1. They shall be mounted within the switchgear cubicle between line and earth preferably in cable compartment and shall be suitable for indoor duty. Surge arrestors shall be suitable for non effectively earthed system and the maximum switching overvoltage shall not be more than 2.5 times the peak line to neutral voltage of the system. Bidder shall furnish temporary overvoltage capability curve and pressure relief device shall be provided for relieving internal pressure and preventing violent shattering of the housing following prolonged passage of follow current or internal flashover of arrestor.
9.6.28
9.6.29
9.6.28
Cubicle Components Each circuit breaker cubicle shall be provided with the following minimum standard accessories: (a) One control switch `Trip - Neutral - Close' spring return to neutral position. One two position control selector switch `Local - Remote' switchgear control stay put type. Indicating lamps (i) (ii) (iii) (iv) (v) (v) (vi) (vii) `Red' for breaker ÒN' indication and trip coil supervision. `Green' for breaker ÒFF' indication. Blue' for breaker in 'Service' position. Amber' for breaker in 'Test' position. Amber for breaker auto trip indication 'White' for breaker closing spring 'Charged'. 'White' supervision lamp for lockout relays. Red' for breaker ON indication at the back of the switchgear at cable box door
(b)
(c)
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TCE FORM NO. 329 R5
SECTION:
D3.9
The indicating lamps shall be self coloured clustered LED type of size 22.5mm.They shall be bright and visible from any angle. All indicating lamps shall be on DC. (d) Mechanical trip push button to trip the breaker when control supply is lost. The push button shall be shrouded type. Mechanical close push button provided shall be accessible only after opening of the front door. Castle key interlocks shall be provided to prevent opening of cable compartment door when breaker is closed and busbar compartment when any of the incomers to bus are closed. Closing from local shall be possible only in test position whereas closing from remote shall be possible in either service or test position. Tripping from local shall be possible only when local/remote selector switch is in local position. Tripping from remote shall be possible only when either breaker in service position or selector switch being in remote position One electrical antipumping relay. One double pole control supply switch and set of fuses. One breaker operation counter. Cubicle lamp, heater with thermostat and plug point. Closing coils shall operate satisfactorily in the control voltage range of 85-110% and tripping coil shall operate satisfactorily in the control voltage range of 70-110%. Suitable labels/Name plates for feeders and cubicle mounted components.. Mechanical indication for spring charged/discharged status.
(e)
(f)
(g) (h) (i) (j) (k)
(l)
(m)
9.7
Metering & Protection Adequate protection / metering shall be provided for the switchgear panels. Location of relays in the switchgear shall be at convenient height, such that it can be surfed by standing at ground. All relays except for LBB, PT fuse failure shall be numerical with RS232/RS485 port. Separate meters shall be provided for each of the feeders mentioned below, if the same is not available in the numerical relay. Relay setting
ISSUE R0
181
TCE FORM NO. 329 R5
SECTION:
D3.9
software for setting all the numerical relays in 6.6 kV switchgear and generator protection panels shall be loaded in a dedicated operator station in the main control room. All numerical relays shall be time synchronized with the GPS master clock. On failure of any of the numerical relay a contact shall be generated, which shall provide the annunciation to the DCS. All the protective relays, except for auxiliary relays shall have remote/local reset facility, and shall be suitable for efficient and reliable operation of the protective schemes. A combination of electromechanical & numerical communicable type relays for main protections is not acceptable. The Bidder shall include in his bid a list of installations where the relays offered are in trouble free operation for last two years. The minimum protections / metering shall be provided required for various typical feeders shall include, but not be limited to the following: 9.7.1 Incomers
Protections Composite numerical feeder protection relay Under voltage relay Metering Ammeter and voltmeter with selector switch Wattmeter (or) Multifunction meter with all the metering parameters Current transducer for each phase 1 no. MW transducer 1 no. MVAR transducer
Local breaker backup protection Fuse failure relay
9.7.2
Tie breakers
Protections Composite numerical feeder protection relay Local breaker backup protection Metering Ammeter and voltmeter with selector switch 1 no. kWh meter 1 no. watt meter (or) Multifunction meter with all the metering parameters 1 no. current transducer (Y-Phase) 1 no. MW transducer
ISSUE R0
182
TCE FORM NO. 329 R5
SECTION:
D3.9
9.7.3
Bus PT Feeders
Protections Under voltage protection Fuse failure protection Metering Voltmeter switch Voltage Nos. with selector
transducers3
9.7.4
Motor feeders
Protections Composite motor protection relay (99) Differential protection for motor feeders (rated 1000kW or above) Local Breaker backup protection Time delayed under voltage trip Metering Ammeter* with switch 1 no. kWh meter selector
1 no. power factor meter 1 no. watt meter (or) Multifunction meter with all the metering parameters 1 no. current transducer (Y Phase)
* For motor feeders separate ammeters shall be provided.
9.7.5
Service Transformer Feeders

Protections Composite numerical transformer protection relay Local Breaker backup protection Winding temperature and Buchholtz protection Metering Ammeter with switch 1 no. kWh meter
selector
1 no. Wattmeter (or) Multifunction meter with all the metering parameters 1 no. current transducer
9.8
The switchgears shall be designed to offer adequate level of safety to operating/ maintenance personnel. Means shall be provided to prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate suitable for wall mounting shall be provided for each switchgear/MCC room describing various safe operating procedure/safety precautions for safe operation and maintenance of the switchgear. Tests
ISSUE R0
183
9.9
TCE FORM NO. 329 R5
SECTION:
D3.9
All relevant routine tests and acceptance test shall be conducted as per applicable standards and typical type test certificates of identical switchgear shall be furnished. 9.10 Minimum electrical system requirements in respect of control, monitoring, measurements, annunciation, and synchronization are indicated in I & C system section no. D2.4.
ISSUE R0
184
TCE FORM NO. 329 R5
ANDHRA PRADESH POWER DEVELPOMENT COMPANY LTD.

DATA SHEET A 3.9
SECTION: SHEET
D3.9
12 OF 15
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION 6.6 kV SWITCHGEAR
UNITS
1.0 1.1 1.2 1.3 1.4 1.5
Switchboard cubicles and Bus bar ratings Nominal system voltage, phases and frequency System neutral earthing Maximum system voltage One minute power frequency withstand voltage 1.2 / 50 microsecond impulse withstand voltage Maximum temperature of bus bars, droppers, connectors and contacts at continuous current rating under site ref. ambient temperature Material of bus bars Material of bus bar insulation V kV(rms) kV(peak)
0
V, ph, Hz
6600 / 3 / 50 Non-effectively earthed 7200 20 60
1.6
As per IEC-60694 , table 3
1.7 1.8
Tin coated Copper Heat shrinkable PVC sleeve. Removable bus bar joints with shrouds of 7.2kV insulation 7.2 kV Silver faced By Bidder RMS Peak 44 kA* for 1 sec. 100kA
1.9 1.10 1.11 1.12 1.13 2.0 2.1
Bus bar support insulator Bus bar joints / connection Bus bar rating Short circuit current rating and duration Momentary withstand current Switchboard Constructional Details Thickness of sheet steel enclosures, doors and covers Thickness of gland plate for 1 core cable Degree of protection mm mm mm
Cold rolled Hot rolled
2 2.5
2.2 2.3
3.0, Non-magnetic material VT/relay compartments IP52 Other compartments IP42 Air conditioned area IP32 Interior: Semi glossy white Exterior: Opaline Green Galvanised steel 50 x 6 mm Copper
2.4
Colour finished shade (Enamel / epoxy)
2.5 REV. NO. DATE REV. BY
Material of earthing bus R0 JUNE 10 PPD. BY CKD.BY DATE RKD HA JOB NO. 5960A
CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3
185

DATA SHEET A 3.9
SECTION: SHEET
D3.9
13 OF 15
SPEC. NO. TCE.5960A-H-500-001
SL. NO. 2.6
DESCRIPTION Clearance in air of live parts
UNITS mm mm
VALUES / REQUIREMENTS Phase to Phase 120 Phase to Earth 120
3.0 3.1 3.2
Breaker details Circuit breaker type Voltage, No. of phases and frequency kV, ph, Hz Vacuum 7.2 / 3 / 50
3.3 3.4 3.5 3.6
Rated operating duty Total opening time Total closing time Trip free operating mechanism type
O-3 min-CO-3 min-CO 3 cycles 5 cycles Motor charged spring. Manual trip and close facility to be provided. To be provided rms kA(peak) 44 kA* for 1 sec. 100
3.7 3.8 3.9 3.10
Anti pumping feature Short circuit current rating and duration Momentary withstand current Auxiliary control voltage: (a) For closing / tripping coil / spring charging motor For space heaters and lighting and plug point V, DC
220
(b)
V, Phase
230 V, 1 phase
3.11
Pressure switch with two potential free contacts for monitoring SF6 gas. Current transformer details Type System voltage and frequency Class of insulation Short circuit withstand current and duration Core balance CT for all outgoing feeders Voltage transformer details R0 JUNE 10 PPD. BY CKD.BY DATE RKD HA JOB NO. 5960A V, Hz
NA
4.0 4.1 4.2 4.3 4.4 4.5 5.0 REV. NO. DATE REV. BY
Cast resin bar primary 6600 / 50 Class B or better 44 kA* for 1 sec. Ratio 50/ 1 (As per consumer rating)
186

DATA SHEET A 3.9
SECTION: SHEET
D3.9
14 OF 15
SPEC. NO. TCE.5960A-H-500-001
SL. NO. 5.1 Type
DESCRIPTION
UNITS
VALUES / REQUIREMENTS Cast resin
5.2
Rated voltage
Primary Secondary Primary Secondary
V V
6600 / 110 / Star
3 3 / 110 / 3 , 110/3 for open delta
5.3
Method of connection -
Star / Open 1.2 continuous 1.9 for 30 seconds Class B or better kV(rms) kV(peak) 20 60
5.4
Rated voltage factor
5.5 5.6 5.7
Class of insulation One minute power frequency withstand voltage 1.2 / 50 micro second impulse withstand voltage Meters Accuracy class
6.0 6.1
0.5S for energy meters (0.2 for energy meters on the switchgear incomers) 1.0 for others Digital V, DC 220
6.2 7.0 8.0 8.1 8.2 8.3 8.4 8.5
Type of meters Spring charging motor supply voltage Codes and Standards Circuit breakers Metal enclosed switchgear Current transformers Potential transformers Arrangement for switchgear bus bars, main connection and auxiliary wiring Bus bar support insulators Degree of protection Electrical relays for power system protection R0 JUNE 10 PPD. BY CKD.BY DATE RKD HA JOB NO. 5960A
IEC : 62271-100 IS : 3427 IS : 2705 IS : 3156 IS : 5578 IS : 11353 IS : 2544 IS : 2147 IS : 3231 CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3
187
8.6 8.7 8.8 REV. NO. DATE REV. BY

DATA SHEET A 3.9
SECTION: SHEET
D3.9
15 OF 15
SPEC. NO. TCE.5960A-H-500-001
SL. NO. 8.9 8.10 8.11 8.12 8.13 8.14 8.15
DESCRIPTION Electrical indicating instruments High voltage fuses AC electricity meters Aluminium bus bars Code of practice for phosphating iron and steel (Off-load) isolators HRC fuses
UNITS
VALUES / REQUIREMENTS IS : 1248 IS : 5792 IS : 722 IS : 5082 IS : 6005 IS : 6005 IS : 1818
R0 JUNE 10
PPD. BY CKD.BY DATE
RKD HA
JOB NO. 5960A
188
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - SERVICE TRANSFORMERS
SPEC. NO. TCE.5960A-H-500001
10.0
SERVICE TRANSFORMER The service transformer shall conform to the latest editions of national and international standards indicated in Data Sheet A - 3.10 Service Transformers. Also, the service transformer shall comply with the requirements indicated in Data sheet A3.10 and specific requirements indicated below.
10.1
The number and rating of service transformers shall be decided based on the geographical location of loads without sacrificing the unit and common load concept. Adequate number of service transformers shall be provided as required to meet the demand on 400V system based on the criteria that each 400 V switchgear / PCC / MCC / Distribution board shall be fed by 2 x 100% transformer / feeders. Each of the above boards shall be sectionalised. Impedance The impedance of the transformers shall be selected such that the fault level on the switchgear do not exceed its short circuit capability including the motor contributions and also voltage dip while starting any auxiliary does not exceed the limit acceptable for the equipment concerned but in no case shall exceed 15%.
10.2
11.3
MVA Rating Each transformer shall be rated to feed of the entire load on the respective switchgear considering the outage of another transformer. An appropriate load factor with a minimum of 0.8 for continuously running loads and 0.2 for intermittent loads like cranes, plug points, sump pumps, valve actuators etc., shall be considered. An additional margin of 20% over the rating thus established shall be provided for load variations during the detail engineering stage.
11.4
Specific Requirements All service transformers shall be cast resin dry type (indoor). The service transformers shall be two winding, three phase, 50 Hz, 6600 / 420 Volts, with off-circuit taps of + 5% in steps of 2.5%.
11.4.1 11.4.1.1
Dry Type Transformers The cast resin transformers shall be housed in naturally ventilated floor mounted cubicle with louvers backed by fine brass wire mesh. Degree of protection of enclosure shall be atleast IP32.
189
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - SERVICE TRANSFORMERS
SPEC. NO. TCE.5960A-H-500001
11.4.1.2
The transformer cubicle shall be located right next to respective 400V switchgear and LV side shall be connected through cables or bus duct. The HV connections shall be through cables. The dry type transformers shall be provided with core and winding temperature detectors, with temperature high alarm and very high trip contacts. The insulation class for cast resin transformers shall be class-F. The core and windings shall be provided with embedded temperature detectors for remote indication in DCS. Noise level shall not exceed the values specified in NEMA TR-1. Off-circuit tap changers with lockable operating handle, mechanical tap position indicator, and with a variation of 2.5% per step and a range of + 5% shall be provided.
11.4.1.3
11.4.1.4 11.4.1.5
11.4.1.6 11.4.1.7
11.5
Tests and test reports All routine tests shall be conducted as per relevant IS standards. Type test certificates carried out on similar transformer shall be submitted for review.
190
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED

DATA SHEET A3.10
SECTION: SHEET
D3.10
3 OF 4
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION Service Transformers
UNITS
1.0 2.0
Type No. load voltage HV LV Volts Volts
Cast resin dry type , 3-ph, two winding 6600 420 AN 110% continuous
3.0 4.0 5.0 5.1 5.2 5.3 6.0
Cooling method Overfluxing capability Winding connections HV LV Vector group Impulse (1.2 / 50 micro second) / Power frequency withstand voltage windings HV kVp, kV(rms) kV(rms)
0
Delta Star Dyn11
6.1
60 / 20
6.2 7.0
LV Maximum temperature rise of winding a) Dry type transformer
-/3 Class-F (155 oC)
8.0 8.1 8.2 8.3 8.4 8.5 9.0 9.1 10.0
Tapping particulars Type Tap range Tapping step Category of voltage variation Tapping power Bushing particulars Voltage class HV / LV Noise level kV 7.2/1.1 Not to exceed values specified in NEMA TR1 Shade 631 of IS-5/RAL 7032/eqt. CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3
191
Off-load % % +5 2.5 CFVV Full
11.0 REV. NO. DATE REV. BY
Paint shade R0 JUNE 10
PPD. BY CKD.BY DATE
RKD HA
JOB NO. 5960A

DATA SHEET A3.10
SECTION: SHEET
D3.10
4 OF 4
SPEC. NO. TCE.5960A-H-500-001
SL. NO. 12.0 12.1 12.2 12.3 12.4 12.5 12.6 12.7 12.8
DESCRIPTION Codes and Standards Service transformer Fittings and accessories Bushings Degree of protection Tests Tolerance on guaranteed particulars Buchholz relay Electrical insulation classified by thermal stability
UNITS
IS : 11171 IS : 3639 IS : 2099 IS : 2147 IS : 2026/ IS: 11171 IS : 2026 IS : 3637 IS : 1271
R0 JUNE 10
PPD. BY CKD.BY DATE
RKD HA
JOB NO. 5960A
192
5.3
SECTION:
D3.11
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS -
400V SWITCHGEAR & MCC
11.0
400V SWITCHGEAR & MCC The 400V switchgear and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet A 3.11 400 V Switchgear / MCC. Also, the 400 V switchgear / MCC and its accessories shall comply with the requirements indicated in Data Sheet A 3.11 and specific requirements indicated below:
11.1
For feeding the 400V/230V/110V AC loads of the plant, 400V switchgear / motor control centres (MCCs) and AC distribution boards (ACDBs) shall be provided. The switchgear shown in Key One Line Diagram drg. No. TCE.5960A-EL-SK-2001 are tentative. Any additional switchgear / MCCs as required shall also be provided. All 400 V switchgear, MCCs & ACDBs shall be procured from the same source in order to ensure interchangeability of components. Power Sources for 400V Switchgear The switchboard shall derive power from the designated auxiliary transformers as shown in the Key One Line Diagrams TCE.5960A-ELSK-2001. The Bidder shall provide additional switchboards as required without sacrificing the standby philosophy, reliability and flexibility of operation and with unit and common loads demarcation.
11.2
11.3 11.3.1
Feeder Details The switchgear / MCC shall be provided with two incomers and a bus coupler (100% each). The switchgear / MCC shall be provided with suitable numbers and type of outgoing feeders as required. Spare feeders - 20% of each type and each rating with minimum of one no. feeder. (Above quantity is the minimum requirement at the time of handing over the plant. Any additional quantity required for any increase/changes during detailed engineering stage also shall be duly considered). Bus VT module - 1 no. on each bus section. Switchboard 230V, 1 phase space heating - 1 no. on each bus. 230V, 1 phase motor space heating supply module - 1 no. on each bus
11.3.2
11.3.3
11.3.4 11.3.5 11.3.6
193
SECTION:
D3.11
11.3.7 11.3.8 11.3.9
Alarm module for common alarm for out going feeder fault - 1 no. Any of the system/equipment which requires power supply. For each auxiliary or load, one feeder shall be provided except for the following cases: (a) (b) One feeder for maximum of 2 Nos. 400V, 3 phase plug points. One feeder for maximum of 3 Nos. 400 kV isolator motorised operating mechanism.
11.3.10 11.4 11.4.1
Control transformer on each bus section: 01Nos Construction Switchgear/MCCs shall be metal enclosed, indoor, floor mounted modular type of uniform height not more than 2450 mm, dust and vermin proof construction with IP - 52 degree of protection, easily extensible on both sides having switchboard designation indicating labels. Proper gasketing shall be provided all around the perimeter of adjacent panels, panel and base frame, removable covers and doors. Switchgear shall be designed for the bottom entry of cables however, the incomers shall be suitable for NSPBD. Switchgear / MCCs shall be single or double front as execution needed. The circuit breaker and feeder modules in switchboard and MCCs shall be of fully drawout construction. In this type of construction it shall be possible to drawout the chassis without having to unscrew or unbolt any connections to the equipment mounted on the withdrawable chassis. The power and control drawout type connections shall be of sliding type. All drawout contacts, including for auxiliary and control wiring shall be of self-aligning type. Switchgear/MCC shall be divided into distinct vertical sections of: (a) (b) (c) Completely enclosed busbar compartment running horizontally. Individual feeder modules in multitier arrangement. Enclosed vertical busbars serving all modules in vertical section.
11.4.2
11.4.3
194
SECTION:
D3.11
(d)
Vertical cable alley covering entire height and minimum 250mm wide. A horizontal separate enclosure for all auxiliary power and control bus, if required. For cable connection to circuit breaker, a separately enclosed cable compartment shall also be acceptable.
(e)
(f)
11.4.4
Each vertical section shall be equipped with space heater and thermostat. Cable alley shall be provided with suitable hinged doors. Rear of single front switchboard shall be provided with removable panels. All doors shall be with concealed type hinges and captive screws. Stop Push buttons shall be of latch type with mushroom knobs. Switchgear/MCC shall be designed such that all component equipment and busbars operate satisfactorily without exceeding their respective maximum permissible temperature limits of 105oC. Switchgear/MCC busbars shall be of uniform cross section throughout the length and made of high conductivity, aluminium alloy of E91 grade. Busbars shall be sleeved, and with proper clearances, adequately supported to withstand stresses developed due to short circuits. Material used for sleeving shall be capable of withstanding maximum temperatures specified in technical requirements table. Supports shall be of glass reinforced phynolic material or cast resin. Busbar joints shall be shrouded with moulded epoxy removable shrouds. The busbar rating of the 400V switchgear / MCC shall be rated for LV (400V) side current of auxiliary transformer plus 20% margin rounded off to the next standard rating. All types of relays and timer shall be flush mounted with connections from inside, and shall have transparent & dust tight cover, removable from front, drawout construction for easy replacement and testing facility. The auxiliary relays and timer may be provided in fixed cases. The switchgears / MCC shall be designed to offer adequate level of safety to operating / maintenance personnel. Means shall be provided to
11.4.5 11.4.6
11.4.7
11.4.8
11.4.9
11.4.10
11.4.11
11.4.12
195
SECTION:
D3.11
prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate suitable for wall mounting shall be provided for each switchgear / MCC room describing various safe operating procedure / safety precautions for safe operation and maintenance of switchgear / MCC. Rubber mats shall be provided in front & back of each panel. 11.4.13 All switchgears, MCCs, DBs, panels, modules, local starters and push buttons shall have prominent engraved identification plates. Control Supply Individual two (2) nos. (100%) 400/110V, 1-ph, transformers shall be provided in each main plant switchgear for deriving control supply. Rating transformers each transformer shall be adequate to cater both the bus sections. A changeover switch shall be provided for selection. Control supply for the SFU operated motor feeders shall be 110V AC and for all ACB feeders, it shall be 220V DC. Control circuits shall operate at suitable voltage of 220V DC. The auxiliary bus bars for control supply shall be segregated from main bus bars. The control supplies shall be monitored. 11.6 Specific Requirements Switchgear / MCC shall comply with specification requirements indicated below: 11.6.1 The breaker / feeder modules shall have service, test and Isolate positions. Suitable trolley arrangement shall be provided for breaker modules. Two trolleys in the main switchgear room shall be provided so that breaker module of all types, sizes and rating can be withdrawn on trolley and lowered for maintenance purpose. Additionally one such trolley shall be kept at each switchgear room. All air circuit breakers (ACBs) shall be of short circuit performance category P2 as per IS 2516 parts I & II. Breakers shall have inherent fault making and breaking capacities. They shall have shunt trip coils. All breakers shall have built in interlocks for equipment and personnel safety.
11.5
11.6.2
11.6.3
196
SECTION:
D3.11
11.6.4
Paralleling of two supplies shall be avoided by interlocking except for switchgear where auto-changeover or live changeover is provided. Breaker contact multiplication if required shall be through latch relays. The cable alleys shall be liberally designed considering the size and number of cables, future additions of cables, easy and safe maintenance. For each vertical section a separate set of vertical bus bars shall be provided to serve the modules. The switches, contactors and other power devices shall consider a margin of about 20% over the nameplate current rating of the respective load. For breaker control, 2 nos. 220V DC control supply shall be provided with a manual selection for changing over to either supply. Necessary voltage monitoring contactors, indication lamps shall be provided. Minimum of two NO and two NC spare contacts of all contactors & relay devices shall be wired to terminal block. 20% spare terminals shall be provided for each module. For CT & VT circuits disconnecting type of terminals shall be provided. Space heater with MCB and thermostat shall be provided for each vertical panel. Transducers required for remote metering shall be provided. Interposing relays shall be provided for control from remote. All protective relays shall be of numerical type. All indicating lamps shall be self-coloured clustered LED type of size 22.5mm. Mechanically operated, red 'trip' push button, shrouded to prevent accidental operation. Module details (a) Incomers & bus couplers
11.6.5
11.6.6
11.6.7
11.6.8
11.6.9
11.6.10 11.6.11 11.6.12
11.6.13 11.6.14 11.6.15 11.6.16
11.6.17
11.6.18
197
SECTION:
D3.11
(i)
The incomer modules and bus coupler modules of 400V switchgear/ MCC shall be air circuit breaker controlled from local and DCS. They shall be provided with: One no. CT shall be used for the Numerical protection relay. However the metering shall be done through the numerical relay and shall be communicated to the DCS. Line VT 400/110V, for checking synchronising during live manual changeover Switch, fuses for 220V DC control supply Breaker control switch Local remote control switch. Closing from local shall be possible only in test position whereas closing from remote shall be possible in either service or test position. Tripping from local shall be possible only when local/remote selector switch is in local position. Tripping from remote shall be possible when either breaker in service position or selector switch being in remote position. Service & test position limit switches with required no. of contacts. Composite Numerical feeder protection relay shall be provided for breaker feeders other than motor feeders. Incomer from Emergency D.G set shall also be provided with composite numerical feeder protection relay. 3 phase inverse time over current relays & 1 no. E/F relay 1 no. E/F relay connected to the bushing CT provided in transformer neutral circuit Lock out relay with supervisory lamp Indicating lamps for on, off and fault, spring charged, trip circuit healthy etc
198
SECTION:
D3.11
Synchronising switches, a set of double voltmeter, double frequency meter, synchroscope shall be provided. Necessary circuitry and devices for auto trip, fault alarm, and for control/ alarm of the breaker as required. Selector switch for tripping selected breaker after live changeover (in bus coupler for locally controlled switchboards) All incomers for MCCs and DBs rated from 630A shall be ACBs and for <630A MCCBs shall be provided. However for MCCs with important feeders like LOPs and where auto change over is required, ACBs shall be provided for the incomers & Bus couplers. The continuous current rating of the bus bars, incomers, bus couplers of the switchgear fed from other switchgears shall be the maximum load on the bus due to all the running auxiliaries during any operation condition plus 20% margin rounded off to the next higher standard rating. For the load calculation, load factors to be considered shall be 0.9 for continuous loads, 0.4 for intermittent loads.
(ii)
The incomer modules shall be interlocked with their upstream breakers such that they can be closed only when upstream breaker is closed and trips automatically when upstream breaker is tripped or faulted. Changeover scheme The switchgear with sectionalised buses will be normally operated with the bus coupler breaker open. Auto changeover facility shall be provided for switchgear/MCC, such that if there is a prolonged under voltage on any one of the bus sections, the respective incoming breaker shall trip and the bus coupler breaker shall close, provided voltage is available on the other bus section. Total changeover time shall not exceed 1 seconds. This auto changeover shall be blocked if the incoming breaker had tripped either on a bus fault or manually. Changeover back to the normal source of supply shall be effected manually. Manual live changeover
(iii)
199
SECTION:
D3.11
facility shall be provided for the switchgear/MCC. When planned outage of one of the normal incoming supplies is required, the respective incomer shall be tripped automatically after the bus section breaker has been closed manually. After carrying out the changeover within 1sec., all the critical motors which are identified during the detailed engineering shall be re-accelerated automatically. (iv) For this purpose, a selection shall be provided by the Contractor suitably on the DCS in plant control room for selecting the incomer to be tripped. Thus, depending on the selection made, incomer to bus section A or to bus section B will be tripped once bus section breaker has been closed manually, thus maintaining continuity of supply. A timer with a time delay on pick up of 0.5 5 sec for annunciation of the running breaker failing to trip within a preset time, (i.e if the two sources remain paralleled for more than a preset time) shall be provided. When the normal supply is to be brought back into operation, the incomer breaker shall be closed where upon the bus coupler shall trip automatically. (v) All hardware required for meeting the functional requirements stated above, whether specifically listed out in the specification or not, shall be included in the Contractors scope of supply.
(b)
VT modules Each bus section of main switchboard and MCCs shall be provided with a bus VT module along with one voltmeter with selector switch and energy meter. The accuracy class of VT shall be 1.0 with adequate VA burden. (i) Bus VT modules shall be provided with suitable 400/3 / 110/3V VTs with primary and secondary fuses, interposing VTs for synchronising circuit, etc. V.T. modules in 400V main switchboard/MCC shall be provided with all necessary relay devices for auto changeover function like under voltage relays (2 nos), voltage available relays (2 nos.), under voltage timer, fuse failure relay, 220V DC control supply switch & fuses.
(ii)
200
SECTION:
D3.11
(iii)
Earth fault alarm with voltage relay connected to open delta formed on secondary side of VTs shall be provided on each bus.
(iv) In case of fuse failure, the under voltage timer operation shall be blocked. (v) In the 400V main switchboard buses an additional timer (with a higher time delay) shall be provided for sending signal for AMF start of the DG sets.
(c)
Feeders provided for supplying lighting distribution boards, local control panels, power sockets etc., shall be provided with suitably rated switch & fuses. The modules rated 200Amp & above shall be provided with a CT and ammeter. 230V, 1 phase, space heating module (for motor, panel, space heating) shall be provided with incoming side switch, fuse, suitably rated 400/230V cast resin type transformer (expected heating loads of the switchboard + 30% margin) Secondary fuse, and supply indicating lamp and connection to the space heating buses in the particular bus section. The 400V power supply for these modules shall be obtained from the other bus (i.e the supply for the module in bus A shall be from bus B and vice versa.) Suitably rated 400 / 230 V, 1-ph cast resin transformer, incoming side switch fuse, secondary side fuse, supply indication, 1-ph, MCB outlets shall be provided for feeding 230 V space heating / lighting supply required by other panels in the plant. Suitably rated 400V / 420V, 3 ph cast resin transformers incoming side switch fuse, secondary side fuse, supply indication 3 ph, 4 wire outlets MCBs shall be provided for providing space heating supply for 400V switchboards. Motor modules (i) The motor modules shall be provided with Switch, fuses, air break contactors (For motors above 100kW, remote controlled electrical circuit breakers, and for smaller motors, switch-fuse contactor feeders shall be
(d)
(e)
(f)
(g)
201
SECTION:
D3.11
provided. The other outgoing feeders would be switchfuse units or moulded case circuit breakers) Thermal overload relays with integral single phase preventors. (Thermal overload relays for all motor feeders upto 100kW and with integral single phase preventors for motor feeders >45kW). Instantaneous short circuit protection on all phases through HRC cartridge type fuses rated for 80 kA rms (prospective breaking capacity at 400V) On, Off and fault indicating lamps Necessary auxiliary contactors for fault alarm circuit, 230V space heating circuit Isolating switches shall be of AC 23A category when used in motor circuit, and AC 22A category for other applications. Module on, off PBs for non reversible modules and forward reverse and Off PBs for reversible modules Appropriate circuitry for receiving the on, off and forwardreverse commands from remote panels/ systems, interlocks, off command from local push buttons, etc. MCB for space heating/winding heating circuit. Interposing relays for control from remote. Transducers shall be provided for remote metering for all motors rated18 KW and above. Any additional motor, for which monitoring is required, shall be added during detailed engineering. Isolating switches and MCCBs shall have door interlocks and padlocking facility The motor modules rated 30 KW and above shall be provided with 230V, 1 phase space heating arrangement. The modules for motors rated 50 KW and above shall have a CT and an ammeter. The CT connection shall be so wired to the terminal block so that provision for remote current indication is available. For modules of motor rated 100 kW and above ACBs shall be provided.
(ii)
(iii)
(iv)
202
SECTION:
D3.11
(v)
(vi)
For modules of motors rated 100 kW and above shall be provided with composite numerical motor protection relay. Motor modules Remote start/Stop and ON/OFF /Trip indication shall be provided from DDCMS for all motors of the main plant. All abnormal conditions shall be alarmed to DDCMS. Motor in other areas shall be controlled from respective PLCs. Local operations shall be provided for motors like sump pumps etc which are neither controlled from DDCMS nor PLCs. Essential service modules During auto changeover of the supply the contactors in the affected bus would have dropped off. The services which shall be restarted immediately without time lapse to keep the unit running are considered essential services. (for eg. seal oil pumps, lube oil pumps, auxiliary cooling water pumps etc.). Such auxiliaries shall restart automatically without any action by the operator after an auto changeover. These modules shall have additionally hardware like timer, aux contactors and associated circuitry in the module. Such essential services shall be identified during the detailed engineering stage and suitable module/scheme shall be provided.
(vii)
(viii)
The 400V single phase connection control supply transformer, space heating, winding heating modules etc., shall be distributed between different phases to keep the loading on all phases uniform 400V/230V control transformer.
11.7
The internal wiring shall be with 1.5 mm2 stranded copper conductor for control wiring and 2.5mm2 for CTs and suitably sized for power wiring with a minimum of 2.5 mm2 copper. Outdoor switchgears and switchgears/ panels located in close proximity to gas turbine shall be provided with HR PVC cables.
11.8 11.8.1
400 V A C Distribution Board / Control Panel Bidder shall include in his scope required no. of 400V AC power supply distribution board/control panel for feeding packaged auxiliary load like centrifuge, etc. Bidder shall provide one or two (depending on the
203
SECTION:
D3.11
criticality of the service) incomer from 400V main switchboard to feed the distribution board/control panel. All the incoming and outgoing feeders shall be of switch fuse controlled, if it is <400A other wise ACB shall be used. 11.8.2 A.C. distribution boards/control panels shall be provided with thermostatically controlled space heater, cubicle lamp and power plug. The A.C. distribution board/control panel shall comply with technical requirements table. Also applicable clauses of 400V switchboard and MCCs shall be complied with for these boards/panels. Required ACDB shall be provided to cater to the auxiliary power requirements of 400kV switchyard. 2x100% capacity feeders shall be provided in the main switchgear for serving this ACDB. Separate 400V welding distribution boards along with Isolation Transformer (2x100%) shall be provided in each area. Each circuit of welding distribution board shall feed maximum of 2 Nos. welding / Power receptacles.
11.8.3
11.8.4
11.8.5
11.9 11.9.1
Emergency Power Supply To enable safe unit shutdown during complete A.C supply failure in the station, certain important plant auxiliaries (such as the A.C. emergency bearing lube oil pumps, turning gear motor, battery chargers, emergency lights, essential instrument power supply feeders, etc.) shall be provided with a reliable A.C. power supply through a separate source. For this purpose, 400V, quick starting emergency diesel generator sets with automatic mains failure (AMF) feature shall be provided. Each DG set shall cater to the emergency loads of each of the GTG units (i.e. 100%Unit+ 50% STG + 50% station emergency loads). These DG sets are provided with one stand-by generator of same rating as a back up. The DG sets shall be connected to emergency switchgear with required interconnections to GTG and STG switchgears. When the normal station A.C. supply fails, the DG sets will start automatically and feed the essential loads connected to GTG and STG switchgears. When the normal A.C supply is restored, these essential loads will be manually changed over to the normal power supply. Tests
11.9.2
11.9
204
SECTION:
D3.11
Switchboard/MCCs shall be subjected to routine tests as spelt out in Indian Standards and typical type test certificates for identical switchgear / MCC shall be furnished. 11.10 Minimum electrical system requirements in respect of control, monitoring, measurement, annunciation, synchronising are indicated in I&C system section No. D2.4.
205

DATA SHEET A 3.11
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION 400V SWITCHGEAR / MCC
UNITS
1.0 1.1 1.2 1.3 1.3.1 1.3.2 1.3.3 1.4 1.5 1.6
Switchboard & Bus bars Rated voltage, phases & frequency System neutral earthing One minute power frequency voltage withstand Power circuits Control circuits Auxiliary circuits Reference ambient air temperature Material of bus bars Maximum temperature of bus bars contacts, droppers at site reference ambient of 500C Short circuit withstand Short time current (1 sec.) Momentary current Switchboard / MCC Construction Fully draw out Double front / single front Cable entry (Power & Control) rms Peak 50 kA for 1 Sec. 105kA Switchboard / MCC Yes Single front / Double front Cable : Bottom Entry NSPBD: Top Entry Yes IP 54 Frame Door Cover mm mm mm PPD. BY CKD.BY DATE TCE FORM NO. 330 R3
206
0
V/P/Hz
400, 3ph, 50, 3 wire Solidly earthed
V V V
0
2500 1500 2000 50 Aluminium
90
1.7 1.7.1 1.7.2 1.8 1.8.1 1.8.2 1.8.3
1.8.4 1.9 1.10 1.10.1 1.10.2 1.10.3 REV. NO. DATE REV. BY
Modular construction Degree of protection for as per IS : 2147 Thickness of sheet steel Cold rolled Hot rolled Gland plate thickness R0 JUNE 10 RKD HA
2.5 2.5 3
1.6 2.0
1.6 2.0
JOB NO. 5960A
CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

DATA SHEET A 3.11
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
1.11
Clearances in air for live parts
1.11.1 1.11.2 1.12
Phase to phase Phase to earth Paint shade
mm mm
25.4 19.4 External : Opaline Green Internal : Semi Glossy white.
2.0 2.1 2.2 2.3 2.4 3.0 3.1 3.2 3.3 3.4 3.5
Contactors & O/L relay Utilisation category for contactors Contactor rated duty Reset feature for thermal O/L relay Starter type Circuit breakers Circuit breaker type Rated operated duty Type of operating mechanism Short circuit rating Control voltage for spring charging motor and tripping & closing Emergency manual operation required in addition to electrical operating devices For spring charging & closing For tripping Anti-pumping feature CTs and VTs Short time withstand current and duration for CT Breaker controlled R0 JUNE 10 PPD. BY CKD.BY DATE TCE FORM NO. 330 R3
207
AC3 for non-reversible & AC4 for reversible Uninterrupted Hand DOL
Air break with shunt trip B-3min-MB-3min-MB Motor wound spring charged 50 kA for 1 sec. V/DC 220
3.6
3.6.1 3.6.2 3.6.3 4.0 4.1
Required Required Required
50 kA for 1 sec.
4.1.1 REV. NO. DATE REV. BY
Based on breaker short circuit current rating and duration RKD HA JOB NO. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

DATA SHEET A 3.11
SPEC. NO. TCE.5960A-H-500-001
SL. NO. 4.1.2
DESCRIPTION Switchfuse controlled
UNITS
VALUES / REQUIREMENTS To match with fuse withstand
4.2
Overvoltage withstand capacity for VT
4.2.1 4.2.2 5.0 5.1 6.0 6.1 6.2 6.3
Continuous 30 seconds Meters Class of accuracy Applicable Standards Switchboard general requirements AC circuit breakers Factory built assemblies of switchboard and control gear for voltages upto & including 1000V AC & 1200 V DC
pu pu
1.2 1.5 Digital 0.5 for energy meters and 1.0 for others
IS : 4237 IS : 13118
6.4 6.5 6.6 6.7 6.8 6.9 6.10
Air break switches Miniature circuit breakers HRC cartridge fuses D type fuses Contactors Starters Control switches / push buttons and maintenance of switchboard Code of practice for phosphating iron and steel Wrought aluminium & aluminium alloys for electrical purposes R0 JUNE 10 PPD. BY CKD.BY DATE RKD HA JOB NO. 5960A
IS : 4064 & IEC 60947-3 IS : 8828 IS : 9224 IS : 8187 IS : 29259 IS : 8544 IS : 6875
6.11 6.12 REV. NO. DATE REV. BY
IS : 6005 IS : 5082 CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3
208

DATA SHEET A 3.11
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
6.13
Control transformer for switchboard and control gear for voltages not exceeding 1000V AC
IS : 12021
7.0
Technical requirements Table for 400V AC Distribution Boards / Control Panels Location / mounting Current rating Cable entry Design ambient temperature Codes and standards
0
7.1 7.2 7.3 7.4 7.5
Indoor / floor mounted Max. expected load current + 20% margin Bottom Cable entry C 50 As indicated for 400V switchboards / MCCs.
R0 JUNE 10
PPD. BY CKD.BY DATE
RKD HA
JOB NO. 5960A
209
5.4
SECTION: D3.12 SHEET 1 OF 3 SPEC. NO. TCE.5960A-H-500-001
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS NEUTRAL EARTHING EQUIPMENT
12.0
METHODS OF EARTHING The neutral earthing equipment shall conform to the latest editions of relevant national and international standards. These shall comply with the specific requirements indicated below.
12.1
400 kV system is solidly earthed. The neutral of GTs are independently connected to earth. Generator neutral shall be high resistance earthed. The neutral shall be connected to a suitably rated neutral earthing transformer. The neutral earthing resistor will be connected across the secondary of the neutral earthing transformer. 6.6 kV systems shall be medium resistance earthed. The neutral of the unit auxiliary transformers shall be independently connected to the earth through a suitable resistance. The earth fault current shall be limited to 300A. 400V system shall be a solidly earthed system. The neutral of service transformers shall be independently connected to the earth. 230V systems for lighting and the space heating shall be solidly earthed system. The neutral of the transformers shall be connected to the earth bus through a link in the respective board, which is in turn connected to the plant earth grid. 230V AC control supply shall be a solidly earthed system. The mid point of the secondary winding of the transformers shall be connected solidly through a link to the earth bus in the respective modules of switchgear / control panels. Sizing of Neutral Earthing Equipment The neutral grounding resistor ohmic value for generator neutral earthing shall be so selected that during an earth fault on one of the phases of the generator, the kW power consumed in the resistor shall be atleast equal to 1.5 times, the capacitive kVA due to capacitance of generator, generator bus duct and associated equipment including surge protection capacitor, generator transformer. The neutral earthing resistor ohmic value for unit aux. transformer neutral earthing shall be such that earth fault current is limited to 300A.
ISSUE R0
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12.2
12.3
12.4
12.5
12.6
12.7 12.7.1
12.7.2
TCE FORM NO. 329 R5
12.8 12.8.1
Specific Requirements Duty rating of the earthing resistor for generator neutral and UATs shall be 30 seconds. Cable boxes shall be provided for receiving the cables from the transformers. The resistor cubicle shall be mounted on suitably rated insulators. The resistor cubicle shall be located in transformer yard at a height of 2.5m. If located at ground level the resistor area shall be fenced separately, even though located within the fenced transformer yard. The transformer and resistor shall be located in separate cubicles/compartment adjacent to each other. The cubicles shall have hinged access doors capable of being pad locked. For outdoor cubicle, canopy shall be provided. Each neutral earthing resistor unit shall be air cooled and self supporting type. The minimum degree of protection for the resistor element shall be IP 34. The transformer cubicle shall be made of angle frame steel construction with formed sheet sides. The resistor cubicle shall be made of angle frame steel construction with hot dip galvanised screen sides. Alternatively it can be painted with heat resistant paint suitable for 2500C the neutral grounding equipment shall be completely assembled, wired and connected to the neutral bus tap through seal-off bushing. The neutral grounding transformer shall be cast epoxy resin type natural air cooled single phase connected between generator neutral and ground. The loading resistor shall be formed of non-aging, corrosion resistant punched stainless steel grid element provided with necessary insulation and designed for indoor service for a temperature rise not exceeding 3000C. All alarm, protection and indication leads shall be wired upto terminal blocks shall be mounted in a IP:54 enclosure suitable for flush mounting and having a fully hinged cover with lock.
12.8.2
12.8.3 12.8.4
12.8.5
12.8.6 12.8.7
12.8.8
12.8.9
12.8.10
12.8.11
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TCE FORM NO. 329 R5
12.8.12
Enclosure shall not be earthed, so as to prevent bypassing of resistor in case of shorting of resistor from inside.
12.9
12.9.1
TESTS All Acceptance and routine tests as per IS/IEEE shall be conducted on NGR assembly. The following tests on resistors shall be performed and test certificate shall be furnished prior to dispatch: i) ii) High voltage withstand test Ohmic value test on off-load on complete resistor
12.9.2
iii) Heat run test on complete assembly iv) Insulation resistance measurement test
ISSUE R0
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TCE FORM NO. 329 R5
5.5
700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM
SPEC. NO. TCE.5960A-H-500-001
13.0
DC SYSTEM The DC System and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet A 3.13 Also, the DC system and its accessories shall comply with the requirements indicated in Data Sheet A 3.13 and specific requirements indicated below:
13.1
DC power supply with high discharge plante lead acid cells forming bank shall be the source of the power supply for control, protection, interlock, annunciation of the complete plant including I&C system during the running of the plant as well as for a safe shutdown at the time of the total power supply failure. For feeding the DC supply for the above, the following shall be provided. 220V DC, 2 x 100% battery bank with associated float cum boostcharger, 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for each gas turbine generator (GTG) unit. The GTG unit DC system shall be sized to cater complete unit GTG loads. The scheme shall be as per sketch TCE.5960A-EL-SK-2006. 220V DC, 2 x 100% battery bank with associated float cum boostcharger, 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for each steam turbine generator (STG) unit loads, HRSG system loads and common station auxiliaries (excluding 400 kV system auxiliaries). The scheme shall be as per sketch TCE.5960A-ELSK-2006. (a) (b) (c) (d) Loads of Steam Turbine Generator (STG) unit Loads of HRSG UPS loads catering to the I&C requirements Other DC supply loads as required by I&C system which shall be derived from 220 V DC through DC/DC converters. 6.6 kV switchgear and 400 V switchgear. Common station DC auxiliaries and emergency lighting loads.
13.1.1
13.1.2
(e) (f) 13.1.3
220V DC, 2 x 100% battery banks with associated float cum boostchargers and 1 No. DC switchboard having 2 Incomers & one bus
ISSUE R0
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TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
coupler shall be provided for 400kV system (switchyard) auxiliaries. The switchyard DC system shall be sized to cater the following loads: (a) (b) DC load of 400kV switchyard Emergency lighting building
The 400 kV system DC battery, battery chargers and DCDB shall be located in the switchyard control building. 13.1.4 48V DC, 2 x 100% battery banks with associated float cum boostchargers and 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for PLCC system of 400kV switchyard. 24V DC, 2 x 100% battery banks with associated float cum boostchargers and 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for catering the I& C and DCS system application.
13.1.5
13.2
Scheme for earth fault detection shall be provided for each DC bus and feeders. Battery shall be sized to cater for the following loads with minimum duration as indicated. The voltage at the end of duty cycle shall be 1.85 V/cell for lead acid batteries. Detailed sizing / selection calculation shall be subject to Owners approval. Momentary Load (For duration upto 1 minute). (a) (b) (c) (d) Tripping / closing load of 400 kV, 6.6 kV & 400V breakers. Starting current of all automatically started DC drives. Solenoid valves. In rush current of excitation system.
13.3
13.3.1
13.3.2
Emergency & Continuous Load (For 10 hours duration) (a) (b) (c) Running currents of essential DC motors. Emergency lighting Indicating lamps on switchgears and control panels
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TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
(d) (e)
Control room emergency lighting Auxiliary relays
13.3.3 13.3.4 13.4
I & C system loads UPS requirement for 4 hours. Further, for arriving at the battery capacity, the following shall be considered. The temperature correction factor as given in IS. For this purpose, electrolyte temperature shall be considered as 10 deg. C above the ambient temperature. 25% margin for ageing as per IEEE guidelines. A design margin of 10% shall be considered for each of the GTG Unit Batteries & Common Station Batteries and 20% margin shall be considered for the 400 kV System Batteries. Battery Chargers Float charger will be rated to cater the following: (a) (b) (c) Trickle charging current of the battery 10 hours load indicated above. Standing load due to all units running, starting or tripping whichever is higher. 20 % spare capacity over above loads The float voltage output of the float charger shall be automatically adjusted depending upon the ambient temperature such that the batteries remain floating through out the range of variation of temperature as specified in Section B.
13.4.1
13.4.2 13.4.3
13.5 13.5.1
(d) (e)
13.5.2
The boost charger unit shall be rated such that the battery can be fully charged from fully discharged condition within 8 hours.
ISSUE R0
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SPEC. NO. TCE.5960A-H-500-001
13.6 13.6.1
Specific Requirements 220V Batteries (a) The battery offered shall be High Discharge plante Lead Acid batteries confirming to IS: 1652 suitable for indoor application. The battery shall be of closed top or sealed in type. Open type cells are not acceptable. The battery shall be complete with accessories and devices, including but not limited to the following: (i) (ii) (iii) (iv) (d) Battery racks Porcelain insulators, rubber pads etc. Set of lead coated intercell, inter-tier and inter bank connectors as required for the complete installation. Electrolyte (KOH) for first filling +10% extra.
(b)
(c)
One set of variable resistor load suitable for carrying out discharge tests at 5 hour discharge rate & suitable shunt for measuring current on all batteries shall be supplied. Alternatively, electronic controls for carrying out discharge test of the batteries at selectable rate can also be provided. The battery should be periodically charged/discharged to avoid loss of performance due to memory effect.
(e)
13.6.2
220V Battery charger (a) The float cum boost charger offered shall be static type composed of silicon controlled rectifiers and diodes (complete with resistor/capacitor network for surge protection) connected in three phase wave bridge circuit. It shall be provided with an adequately rated isolation transformer and filters on input to minimise harmonics on the output to keep ripple factor within acceptable limits. Charger shall have provision for manual control if the automode fails. Load limiting features shall be provided. The same shall be designed for adequate short time over load to take care of the starting of the largest DC motor/testing of lamps, etc. with other DC loads connected to bus. The rectifier shall utilise power semiconductors and heat sinks rated to carry 200% of the load
ISSUE R0
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(b)
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
current continuously. The heat sink temperature shall not be permitted to exceed 85C irrespective of the panel temperature. The chargers shall be suitable for operation from remote. (c) The chargers shall be provided with automatic voltage regulation in float mode and automatic constant current regulation in boost mode. The charger shall essentially comprise the following items but not limited to: (i) One (1) moving coil DC voltmeter of size 96mm x 96 mm of suitable range with selector switch for float, boost, and load voltage. One (1) moving coil DC ammeter, with shunts, size 96 mm x 96 mm to read output current of float-cum-Boost charger. One (1) moving coil centre zero ammeter, with shunt, size 96 x 96 mm to read discharge/charge current of the battery, with suitable range. One (1) cubicle space heater suitable for 230V AC, 50Hz, single phase supply. One (1) 230V AC lamp for cubicle internal lighting. Two (2) - On/Off switches with fuses for space heater and internal lighting. One LED lamp on DC load side to indicate DC "On" condition. One (1) set of LED lamps on AC main input to indicate mains AC "ON" condition. All indicating lamps shall be self-coloured clustered LED type with less than 0.5 W burden. Indication lamps for battery on boost charge & load limiter operated.
(d)
(ii)
(iii)
(iv)
(v) (vi)
(vii)
(viii)
(ix)
(e)
Fault indicating lamps shall be provided on the charger cubicle and initiating contacts shall be provided for remote alarm for each of the following faults:
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TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (f)
Mains AC failure Float charger AC input fuse blown Charger DC output fuse blown Charger U/V and current limit protection Charger over voltage protection Charger overcurrent protection Charger filter condenser fuse blown Charger rectifier fuse blown
Type of cooling for the charger panel shall be such that no external fans are required to dissipate the heat developed within the panel. The adequate number of dropper diodes shall be used in order to meet the load voltage & maintaining the battery float charging voltage as per the battery manufacturer recommendations. Suitable scheme shall also be made that during the power failure, the dropper diodes shall be bypassed, thereby giving the required voltage to the connected load. One complete set of all accessories and devices required for maintenance and testing of batteries shall be supplied for each battery bank. Each set include at least the following: (i) (ii) Hydrometer Set of hydrometer syringes suitable for the vent holes in different cells Thermometer for measuring electrolyte temperature Specific gravity correction chart Wall mounting type holder for hydrometer thermometer Cell testing voltmeter (3-0-3 V). Rubber apron Pair of rubber hand gloves 2 nos. 2 nos.
(g)
(h)
(iii)
5 nos.
(iv) (v)
2 nos. 2 nos.
(vi) (vii) (viii)
2 nos. 2 nos. 2 nos.

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TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
(ix) (x) (xi) (xii) (xiii)
Set of insulated spanners No smoking notice Goggles (industrial) Instruction card Minimum and maximum temperature indicator for each battery room Acid / Alkali mixing jar
2 nos. 2 nos. 2 nos. 10 nos. 1 no.
(xiv) (xv) (xvi)
2 nos. 20 Nos. 2 nos
Battery maintenance record book Safety gears -
13.7 13.7.1
D.C. Switchboards For feeding the 220V DC loads 220V DC Switchboard as per clause 13.1.1 to 13.1.3 shall be provided. The switchboards shall be provided with suitable quantity and type of outgoing feeders for the auxiliaries, control supplies to various panels/systems. For each load and auxiliary, one separate feeder shall be provided. In addition, the following feeders shall be provided in switchboard. (a) Spare feeders - 20% of each type and rating with a minimum of two nos. feeders. This is the minimum quantity at the time of handing over the plant. Switchboard 230V 1 phase space heating module - 1 No.
13.7.2
(b) 13.7.3
Current ratings The short circuit current rating of the switchboard shall be arrived considering the contribution from charger & battery with 5% margin, with a minimum of 25 kA. The continuous current rating of the bus bars, incomers, ties for 220V DC switchboards shall be the maximum D.C. load (excluding the momentary
ISSUE R0
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TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
load) on the bus plus 20% margin rounded off to the next higher standard rating. 13.7.4 Specific requirements (a) DC switchboards shall comply with all the requirements of this specification and technical requirements table. Positive and negative bus bars in the DC switchgear shall be completely segregated from each other by sheet steel partitions. The DCDB incomers and Buscoupler shall be suitable for operation from remote. All the DCDB compartments shall have bottom cable entry through individual cable gland for each power, control and instrumentation cables. Metallic enclosure shall be provided between cable tray & cable entry.
(b)
(c)
(d)
(e)
Module details (i) Incomer The incomer modules shall be MCCB controlled. Each incomer shall be provided with ammeter & voltmeter earth fault relay with potential free contact for remote annunciation. under voltage relay with timer indicating lamps for ON, OFF, earth fault, under voltage conditions (22.5 mm size LED) one no. current & voltage transducer for remote indication necessary hardware & circuitry for fault alarm and for lamp test & reset.
(ii)
Outgoing feeders & tie feeders/Bus coupler These feeders shall have DC MCB/MCCB,"ON" & "Fault" indicating lamps, supply supervision relays, lamp test, accept & reset push button through common alarm module.
ISSUE R0
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TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
The feeders rated 200 Amps & above shall be provided with a shunt & ammeter.
(iii) Motor modules For motors, starters shall be preferably housed within the DC switchgear module. However the resistors can be separately located in boxes/panels within the DC switchgear room. The starting current of the motor shall be limited to 200% of full load current.
The motor modules shall be provided with Switch (rotary type suitable for DC application), fuses, air break contactors Thermal overload relays Starting resistors with associated timers ON, OFF, Fault indicating lamps Necessary auxiliary contactors for fault alarm circuit 230V space heating circuit ON, OFF PBs for testing purposes One shunt & ammeter Appropriate circuitry for receiving the ON, OFF commands from remote panels/systems, interlocks, 'OFF' command from local push buttons, etc. MCB for space heating circuit
(iv) Space heating module 230V 1 ph, space heating module shall be provided with incoming side switch fuse, suitably rated 400/230V cast resin type transformer (expected heating loads of the switchgear and the connected motors + 30% margin) secondary fuse, and supply indicating lamp and connection to space heating buses. The 400V power supply for these modules shall be obtained from the 400V main switchboard.
13.8
Tests for Batteries

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SPEC. NO. TCE.5960A-H-500-001
All tests shall be conducted as per the relevant standards. Tests shall comprise: 13.8.1 Type Tests: Performed at Manufacturer's works or type test report on identical rating and type of cell issued by an authorised test house shall be furnished Acceptance Tests: Acceptance tests as per relevant standards shall be performed at vendors works. Also acceptance tests shall be performed at site after installation and commissioning of the battery including capacity test and test for voltage during discharge. A loading resistor bank which can be automatically controlled using time and current signals along with the charger shall be supplied to facilitate discharging of voltages as a part of routine maintenance tests. Tests for battery chargers The following routine tests shall be conducted at works 13.9.1 13.9.2 13.9.3 13.9.4 13.9.5 Visual checks for dimensions and general arrangement. Wiring checks Functional checks Voltage regulation for rated input supply for loads from 0-100%. Load test to show the charger can deliver the rated duty without the current limiter device operating. Ripple measurement by oscilloscope at different loads. Demonstration of guaranteed efficiency and power factor. Insulation test (with 500V megger) High voltage test, excluding electronic controller, at 2kV AC for one minute. Heat run test shall be conducted at full load for 24 hours at the vendor works on charger. Tests for DC distribution board
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13.8.2
13.8.3
13.9
13.9.6 13.9.7 13.9.8 13.9.9
13.9.10
13.10
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
13.10.1
All routine tests as per applicable standards shall be conducted on the board. Type test reports on identical switchgear issued by an authorised test house shall be furnished.
13.10.2
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DATA SHEET A3.13
SECTION: SHEET
D3.13
12 OF 14
SPEC. NO. TCE.5960A-H-500-001
SL. NO. 1.0 1.1 1.2 1.3 1.4 2.0 2.1 2.2 2.3 2.4 3.0 3.1 DC SYSTEM
DESCRIPTION
UNITS
Type of charger DC system voltage (Nominal) DC system earthing Ambient design temperature BATTERY DETAILS Maximum time for boost charging of battery Battery type Minimum end cell voltage Nickel / Lead Acid Battery capacity BATTERY CHARGER DETAILS DC voltage setting adjustment of AVR for float charging Voltage stabilisation for constant voltage regulator Hrs
0
float-cum-boost 220 V /48V /24V Unearthed C 50
8 High Discharge Plante Lead Acid 1.85V per cell By Bidder
+ 10% of nominal voltage
3.2
(i)
+1% of set DC voltage for + 10% voltage and +5% frequency variation in power supply + 5% during transients
(ii) 3.3 DC current adjustment for boost charging
30% to 100% of maximum boost charging current + 2%
3.4
Current stabilisation for constant current regulator for boost charger Minimum permissible p.f. at rated continuous load Permissible ripple content at rated continuous load Degree of protection/paint shade
3.5
0.8
3.6
1% maximum
3.7
IP 42/ External : Opaline Green Internal : Semi Glossy White.
4.0 4.1 REV. NO. DATE REV. BY
DC BOARD Reference ambient air temperature R0 JUNE 10 PPD. BY CKD.BY DATE TCE FORM NO. 330 R3
224
50 0C RKD HA JOB NO. 5960A CLIENT : APPDCL PROJECT: 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

DATA SHEET A3.13
SECTION: SHEET
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13 OF 14
SPEC. NO. TCE.5960A-H-500-001
SL. NO. 4.2 4.3 4.4
DESCRIPTION Degree of protection for enclosure Type of construction Paint shade
UNITS IP 54
Fully draw-out, compartmentalised External : Opaline Green Internal : Semi Glossy White
5.0 5.1
APPLICABLE STANDARDS Basic climatic and mechanical durability tests for components for electronic and electrical equipment Environmental tests for electronic and electrical equipment Metal clad base material for printed circuits for use in electronic and telecommunication equipment Transformers and inductors (power, audio, pulse and switching) for electronic equipment Printed wiring boards Environmental requirements for semiconductor devices and integrated circuits Terminals for electronic equipment Factory build assemblies of switchgear and control gear for voltages upto and including 1100V AC and 1200V DC Air break switches Miniature circuit breakers HRC cartridge fuses Contactors Control switches / push buttons Indicating instruments Degree of protection Code of practice for phosphating iron and steel Semi-conductor converters R0 PPD. BY JUNE 10 CKD.BY DATE TCE FORM NO. 330 R3
225
IS 9000
5.2
IS 9000
5.3
IS 5921
5.4
IS 6297
5.5 5.6
IS 7405 IS 6553
5.7 5.8
IS 4007 IS 8623
5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 REV. NO. DATE REV. BY
IS 4064 IS 8828 IS 9224 IS 2959 IS 6875 IS 1248 IS 2147 IS 6005 IEC 60146-1-1/2/3 CLIENT : APPDCL PROJECT: 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.
RKD HA
JOB NO. 5960A

DATA SHEET A3.13
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SPEC. NO. TCE.5960A-H-500-001
SL. NO. 5.18 5.19 5.20 5.21 5.22 5.23
DESCRIPTION Semi-conductor rectifier equipment safety code Stationary cells & batteries High Discharge Plante Lead acid Water for storage battery Pasted +ve plates General requirements
UNITS
VALUES / REQUIREMENTS IS : 6619
IS : 1652 IS : 1069 IS : 6071 IS : 8320
R0 JUNE 10
PPD. BY CKD.BY DATE
RKD HA
JOB NO. 5960A
CLIENT : APPDCL PROJECT: 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3
226
SECTION: SHEET
D.3.14
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1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM
SPEC. NO. TCE.5960A-H-500-001
14.0
UNINTERRUPTIBLE POWER SUPPLY SYSTEM The Uninterruptible power supply system (UPS System) shall cater to the complete plant instrumentation and control system loads such as HMI, Large Video Screens, Master clock, DCS & SCADA panel lighting & other critical loads, except DCS & SCADA panel loads. The UPS shall be sized considering full load plus spare loops plus 25% margin. The output shall confirm to stringent requirements in respect of voltage & frequency regulation, harmonic content & transient recovery. The UPS and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet A 3.14 Also, the UPS system and its accessories shall comply with the requirements indicated in Data Sheet A 3.14 and specific requirements indicated below:
14.1
The UPS shall be of parallel redundant with static bypass to regulated supply type with 2 x 100% chargers & inverters and 2X100% battery bank, bypass line transformer and voltage stabiliser, AC distribution board, other necessary protection devices & accessories. One set of parallel redundant UPS system shall be provided for the plant which will cater power to locations as indicated below: UPS system for GTG UPS system for STG, HRSG & common station loads UPS system catering to the requirements of 400kV SCADA system.
14.2
System Requirements UPS shall employ IGBTs as power components. Microprocessor based controls shall be employed for rectifier, inverter and static switch. The UPS system shall have static switches for added protection and transfer of loads with no break during under voltage condition to the healthy inverter or to standby regulated supply. The components of UPS shall isolate power line voltage transients, frequency variations and high/low voltage conditions from the critical load and act as a line filter and voltage regulator, apart from providing no-break power at constant frequency during normal
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power outages. The UPS shall be sized considering full load plus spare loops plus 20% margin. 14.3 14.3.1 Static UPS system provided shall be of the type described below: UPS shall derive power from station service switchgear and Normal/ Emergency switchgears as shown in the sketch for UPS scheme Drawing No. TCE.5960A-EL-SK-2005. UPS Battery shall be High Discharge Lead Acid Plante type with 4 hour duration. Parallel redundant UPS with static bypass to regulated supply shall be as per sketch No. TCE.5960A-EL-SK-2005.The system shall have a combination of two inverters (UPS modules) operating in synchronism, each having isolating facility from the critical bus by a static switch. In addition to the two inverter systems, a backup from a regulated AC supply through transformer and voltage stabilizer derived from Station service switchgear shall be provided. The system shall have a selector switch. In the `Normal' position, the respective UPS loads shall be supplied by its own inverter, sharing 50% load each, with output of both inverters being automatically synchronized with each other, by using synchronising signal from the master inverter. If one inverter fails, the healthy inverter shall supply the full 100% load by the operation of the static switch. When any one of the UPS is under maintenance, the selector switch shall be suitably changed and the branch circuit supplying 100% load shall be synchronised with the frequency of the standby source.
14.3.2
If the frequency of the standby source is beyond the preset limit, the inverter frequency control shall get disconnected from the standby synchronising signal. The operating inverter shall continuously monitor the frequency of standby source and upon restoration of proper frequency of the standby source, the inverter shall use the frequency of the standby source as the synchronising signal. It shall be ensured by the contactor that the bandwidth selected for the UPS to remain locked with the SCVS frequency shall be maximum & the downstream instrumentation system should be capable of accepting the above frequency variations. When the selector switch is in bypass position the standby source shall cater 100% load, isolating both inverters from the critical load bus. The output of the UPS shall feed all the essential loads through the ACDB.
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14.3.3
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Typical scheme/connections to be adopted for the UPS is shown in the sketch TCE.5960A-EL-SK-2005. 14.3.4
Rectifier
The rectifier shall essentially be a three phase 6 pulse design with input isolation transformer. For Redundant UPS design the two rectifiers input isolation transformers shall have vector grouping and connections to ensure 12 pulse operation seen from the source side. The rectifier shall be provided with soft start feature. The rectifier shall have features for temperature compensation charging of the batteries. The rectifier shall be capable of supplying the inverter full load, in addition to charging the fully discharged batteries in 8 hours or as recommended by battery manufacturer and then maintain the battery on trickle charge mode. 14.3.5 Inverter PWM (Pulse Width Modulation) type, adequately designed to meet the requirements as specified. 14.3.6 Static Transfer Switch Inverter output shall be connected to the AC bus through a static switch and fast acting fuses. The static switch comprises an interrupter and transfer switch, enabling loads to be connected to the standby regulated AC supply. Automatic initiation of the transfer from a faulty branch circuit to the standby regulated source shall be accomplished during following conditions: (a) (b) (c) 14.3.7 Loss of inverter square wave/inverter failure Loss of inverter AC output Retransfer to the inverter circuit shall be manual.
Battery
The batteries shall be 2 X100% rated with backup time of 10 hours. The type of batteries shall be High Discharge Lead acid Plante. The BIDDER shall choose the required voltage of the battery. The AH capacity of battery shall be chosen by BIDDER, based on the battery ISSUE
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backup time / duty cycle, and minimum ambient temperature as specified in Project Information. The guaranteed DC/AC efficiency of the UPS system offered shall be mentioned. BIDDER shall furnish calculation for sizing of the battery based on the requirements of entire plant UPS loads. 14.3.8 Regulated Stand-by AC Supply Regulated standby AC supply shall be derived from standby supply through a step-down transformer of appropriate rating and a servo controlled voltage stabiliser with isolation transformer and power conditioning equipment viz., spike arrester, etc. 14.3.9 UPS system shall be connected to the AC switchgear. The AC switchgear shall comply with the requirements indicated in section D3.11 - 400V Switchboard / MCC. Each of the UPS AC Distribution Boards shall be provided with two bus sections and a bus coupler as shown in dwg. no. TCE.5960A-EL-SK-005. UPS load consumers shall be fed with redundant power supply feeders from each bus section. 20% spare feeders shall be provided in each of the UPS distribution boards The UPS system shall be provided with necessary meters (accuracy class 1.0 or better) mimic diagram, local indication/alarm conditions and protection as indicated below. Grouped alarms and analog parameters (4-20 mA) of each branch of parallel redundant UPS shall be made available in DCS/SCADA as appropriate. Necessary potential free contacts shall be provided from UPS to plant DCS/SCADA as appropriate. Protection The UPS system components and assemblies shall be provided with the necessary protection associated with all components. Necessary logics shall be derived in the controlling microprocessor, based on the UPS parameters including temperature protection. 14.3.12 Tests (a) Type and routine tests certificates for all components made use in the UPS system shall be furnished. Tests for components shall be as per relevant standards. Tests on the following equipment shall as per the relevant standards listed under the respective equipment specification.
14.3.10
14.3.11
(b)
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(c)
System tests shall be performed on the completely assembled UPS system at vendors works. System tests shall include frequency regulation, voltage regulation, current limiting feature and harmonic content tests in addition to the tests to prove the functional requirements such as transfer of static switch for conditions of loss of square wave, overload and under voltage conditions, Short circuit conditions etc. Routine tests covered under clause 7.3 of IEC-60146-4 shall be conducted on the UPS system in addition to the system tests. Test certificates of type tests shall be submitted for review. Endurance test on static switches shall be performed for not less than 10 transfer/ retransfer cycles at full load. The complete assembled UPS system shall be operated at rated load under relevant ambient conditions for not less than 96 hours continuously prior to release for shipment.
(d)
(e)
(f)
14.3.13
Minimum electrical system requirements in respect of control, monitoring, measurement, annunciation, synchronising are indicated in I&C system section No. D2.4.
Sl. No. 1.
Description Type
Unit
Specification Requirement Parallel redundant UPS with static bypass to regulated supply. Uninterruptible Power supply for loads of HMI, LVS , Master clock etc. One parallel redundant UPS.
Contractors Details
2.
Application
3. 4.
Number required Ambient temperature

0
50
Output Voltage
230V, 1phase
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Sl. No. 6
Description Output rating at 0.8 p.f lagging load. Degree of protection Cable entry
Unit kVA
Specification Requirement
Contractors Details
* IP 32 Will be decided during detail engineering stage 400V, 3 Phase, 3 wire, 50Hz supply from N/E switchgear and for bypass from station service switchgear Indoor, natural ventilated, shade Opaline Green
7. 8.
9.
Input Supply Voltage
10.
Installation / paint shade
(External), Semi glossy white (Internal)..

11. Material of Enclosure 2.0mm thick Cold rolled sheet steel
12.0 12.1 12.2 12.3
Inverters Type Number required Suitable for parallel operation Service Output rating of each Output Voltage Static Two per unit Yes
12.4 12.5 12.6
Indoor * 230V A.C. 50 Hz, Single phase Combined Voltage regulation 2% from 0 to 100% load at 0.8 power factor within 50 milli seconds
12.7
Voltage regulation
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Sl. No. 12.8
Description Frequency regulation
Unit
Specification Requirement 0.1 Hz for 0 to 100% load variation (continuous or step load change) and full range of input variation 8%
Contractors Details
12.9
a) Transient voltage regulation on application or removal of 100% load b) Time to recover from transient- to normal voltage ms
50
12.10
Total harmonic content
5% RMS maximum with not more than 3% distortion in any single harmonic Continuous 125% for 15 minutes at 0.8 p.f, 150% for 10 sec.
12.11 12.12
Duty Overload capacity
12.13
Short time rating
1 second for short circuit at inverter output terminals Shall be capable of withstanding short circuit current for the largest fuse to clear the fault in less than cycle Not less than 80% at rated load Natural air cooled / forced cooled Yes
12.14
Short circuit current withstandability
12.15
Efficiency
12.16
Cooling
12.17
Synchronization with alternate source required
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Sl. No. 13.0
Description Static Transfer Switch Capacity Continuous
Unit
Specification Requirement
Contractors Details
13.1
Make and carry full load current of inverter at 0.8 p.f Make before break 230V, single phase Short circuit rating of the inverter for 1 second and 150% of full load current for 2 min. Hz 50 Less than 5 milli sec. Automatic retransfer shall occur after approximately 2 sec time delay during which normal source voltage must remain at 230V 2% I. Indicating lamp for static switch in normal position.
13.2 13.3 13.4
Type Voltage Short time rating
13.5 13.6 13.7
Frequency Transfer time Retransfer
13.8
Indication protection / Annunciation
II. Indicating lamp for static switch connected to alternate source. III. Protection of all semiconductor devices against short circuit and transients.
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Sl. No.
Description
Unit
Specification Requirement iv) Annunciations for the following conditions. a) Static switch connected to alternate source b) Alternate source voltage deviation greater than 2% from nominal.
Contractors Details
14.0 14.1
Bypass Switch Capacity Continuous Make and carry full load current of inverters at 0.8 p.f Make before break Short time rating of the inverter for 1 second and 150% of full load current for 2 minutes.
14.2 14.3
Type Short time rating
15.0
Standby AC supply with isolation transformer and servo controlled voltage stabilizer Number Rating Single or poly phase unit Type Voltage ratio at no load Type of cooling Winding insulation class One Same as UPS rating *
15.1 15.2 15.3
15.4 15.5
Dry type double wound *
15.6 15.7
Natural Air cooled Class-H
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Sl. No. 15.8 15.9
Description Location Voltage regulation
Unit
Specification Requirement Indoor 2% from 0 to 100% load at 0.8 p.f
Contractors Details
15.10
System fault level on 400 V side Output voltage setting range Synchronising between inverter and standby supply ACDB Fully drawout/ Semidraw out/ fixed Dimensions of the board Degree of protection
kA
50 5% of nominal voltage Required Within 2.5 Hz
15.11
15.12
16.0 16.1
**
16.2
** IP52
16.3 Note:
* indicated above shall be filled by the Contractor.
** Contractor shall furnish the data after placement of order.

7.0 7.1 Data to be furnished with the Bid
Technical particulars as per Data Sheet
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DATA SHEET - A3.13
SECTION:
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SHEET 11 OF 13
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
REQUIREMENTS
1.0
Type
Static Parallel redundant UPS with static bypass to regulated supply as per sketch TCE.5960A-EL-SK-2005
2.0
Power Rating at Load PF 0.8 Lagging Application
By Bidder For supplying the loads of HMI, Common station, 400 kV system SCADA & other critical loads Indoor, natural ventilated, shade Opaline Green (External), Semi glossy white (Internal). V, Ph, 3-PH, 400V AC (From Normal cum Emergency board and Station service switchgear) V, Ph 230V, 1 PH
3.0
4.0
Installation /paint shade
5.0
Input supply
6.0 7.0
Output Voltage AC voltage accuracy(steady state) over entire load, load PF & DC voltage range Range of adjustment of AC output AC harmonic content
By Bidder
8.0 9.0
5% at rated load voltage 5% total, 3% for any single harmonic Deg.C 50
10.0 11.0
Design Ref. Ambient Standby AC supply with isolation transformer and servo controlled voltage stabilizer Rating Type Ratio & frequency
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11.1 11.2 11.3

Same as UPS rating Dry cast resin type, Two winding

RKD HA JOB NO. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3

DATA SHEET - A3.13
SECTION:
D3.14
SHEET 12 OF 13
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
REQUIREMENTS
(a) Primary (b) Secondary 11.4 Automatic voltage regulator Percentage voltage regulation Transient response Output voltage setting range Bypass transfer selection Manual bypass PBs Manual bypass switch Synchronising between inverter and standby supply Static switch Type Maximum transfer time Codes and Standards Basic Climatic & Mechanical durability tests for components for electronic & electrical equipment Environmental tests for electronic and electrical equipment Metal clad base material for printed circuits for use in electronic and telecommunication equipment Transformer and inductors (power, audio pulse & switching) for electronic equipment
238
By Bidder 230 V, 1 PH, 50 Hz Required (servo-controlled) 2 10 for bypass 5 of nominal voltage Auto/manual switch Load to bypass, load to inverter Required Required 2.5 Hz (47.5Hz to 52.5Hz)
% % %
12.0 13.0 14.0 15.0
16.0 16.1 16.2 17.0 17.1
Static Maximum of 1/4 cycle
IS - 589
17.2
IS - 2106
17.3
IS - 5291
17.4
IS - 6297
RKD HA
JOB NO. 5960A

DATA SHEET - A3.13
SECTION:
D3.14
SHEET 13 OF 13
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
REQUIREMENTS
17.5 17.6
Printed wiring boards Environmental requirements for semi-conductor devices and integrated circuits Terminals for electronic equipment Factory built assemblies of switchgear and control gear for voltages upto and including 1000 V AC and 1200 V DC Air break switches HRC catridge fuses Contactors Control switches/ push buttons Indicating Instruments Degree of protection Climatic proofing in electrical equipment Semiconductor converters Semiconductor rectifier equipment code Thyristor converters Emergency Standby power systems
239
IS - 7405 IS - 6553
17.7 17.8
IS - 4007 IS - 8263
17.9 17.10 17.11 17.12 17.13 17.14 17.15
IS - 4064 IS - 2208 IS - 2859 IS - 6875 IS - 1248 IS - 2147 IS - 3202
17.16 17.17
IEC - 60146 IS - 6619
17.18 17.19
IS 5082 IEEE 446
RKD HA
JOB NO. 5960A
5.6
SECTION:
D3.15
SHEET 1 OF 19
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - CABLING SYSTEM
SPEC. NO.
TCE.5960A-H-500-001
15.0 15.1 15.1.1
CABLING SYSTEM Cable Types For 6.6 kV services, XLPE cables with following specification shall be provided. 6600 volts unearthed grade single or multi core, stranded aluminium conductor, screened by triple extruded semi conducting compound, gas cured, gas cooled, triple extruded, tree retardant, cross linked polyethylene insulated, cores screened with triple extruded semi conducting compound in combination with copper tape, laid up, inner sheathed with extruded PVC compound type ST2, armoured with galvanised wire or strips for multicore cables and aluminium wire armoured for single core cables and overall sheathed with extruded FRLS PVC type ST2 cable complying with IS : 7098 part-2. XLPE insulation shall be suitable for continuous conductor temperature of 900C and short circuit conductor temperature of 2500C. The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath.
15.1.2
For 400 V power supply services, space heating, outdoor lighting, lighting in the hazardous areas, power supplies to lighting panels etc., XLPE power cables with the following specifications shall be provided: 1100 volt grade, single or multi core, stranded aluminium conductor, XLPE insulated, cores laid up, inner sheathed with extruded PVC compound type ST2, armoured with galvanised steel wire or strip for multicore cables and aluminium wire or strip armoured for single core cables, outer sheathed with extruded FRLS PVC compound type ST2 complying with IS: 7098, Part-1. The cable cores shall be laid up with fillers between the cores wherever necessary. It shall not stick to insulation and inner sheath.
15.1.3
For control, protection, CT / PT connections and interlocks, metering, solenoids, and for digital signals from the field devices/junction boxes/switchgears to terminal cabinets of the control system etc., with signal voltages more than 60 volts, PVC control cables with the following specifications shall be provided: 1100 volt grade, multi core, stranded annealed high conductivity copper conductor (class 2 as per IS 8130), extruded PVC compound type A insulated, cores identified by numerals, cores laid up, inner sheathed with extruded PVC compound type ST1, armoured with galvanised single steel wire/strip and outer sheathed with extruded FRLS PVC compound type ST1 cable complying with IS: 1554.
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15.1.4
For low voltage digital signals to instrumentation and control system and for the analog signals, instrumentation cables with following specification shall be provided : Single pair, multi pair or triplets or quadruplets as required, stranded tinned, annealed, high conductivity copper conductor (class 2 as per IS 8130), extruded PVC compound type-A insulated, cores identified by colour and coding, individual pair/triplet/quadruplets twisted, cores wrapped by non hygroscopic material by taping or extrusion, non metallic rip cord under wrapping, individual pair/triplet/quadruplet screened with aluminium mylar tape of 0.04 mm thick or copper tape of 0.04 mm thick or copper laminated plastic tape with 30% overlap, provided with 0.5 mm tinned copper drain wire for each cabling element, cabling elements suitably grouped, colour coded, cables overall screened with tinned copper wire braids of 0.15 mm dia with minimum coverage of 85% or aluminium mylar tape of 0.04 mm thick with overlap of 30%, inner sheathed with extruded PVC compound type ST1, armoured with steel strips/wires and outer sheathed with extruded FRLS PVC compound type ST1 complying with IEC 60189 - Part 1&2.
15.1.5
Cables for important auxiliaries such as emergency lube oil pump motors, jacking oil pump motors, barring gear motors, Trailing power and control cables for cranes & hoist, DC cables from battery to charger and DCDB etc. shall be of fire survival type (FRLS cables). The HV & LV power cables shall be selected on the basis of current carrying capacity, short circuit rating and permissible voltage drop. Current carrying capacity The cable shall be able to carry the full load current of the circuit continuously under the specified ambient temperature and other conditions of installation. For this purpose, suitable derating factors shall be considered due to: (a) Thermal resistivity of soil (b) Ambient ground / Air temperature (c) Derating factor for grouping of cables over the current ratings at normal conditions given in standards. The design ambient air temperature and ground temperature for this plant shall be considered as 500C and 300C respectively.
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15.2
15.2.1
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SPEC. NO.
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15.2.2
Short circuit rating The cables for circuit breaker controlled circuits shall withstand the fault currents for the following fault clearing times. (a) Motor, service transformer (Protected by instantaneous over current protection) (b)Tie feeders (with no IDMT relays on downstream) (c) Others - 0.16 sec
- 0.5 sec - 1 sec
For circuits, which are protected by fuse, short circuit rating capability need not be checked. 15.2.3 Permissible voltage dip normal running 400V System: Voltage drop in cables between the transformer and the switchgear (PCC) or between PCC and MCC for full load current shall be limited to 2%. Further, the voltage drop in cables between PCC/MCC to the motor terminals for full load motor current shall be limited to 3%. However, these voltage drops may be adjusted in specific cases so that total voltage drop is within 5%. The screen of the 6.6kV cable shall be capable of carrying the earth fault current of 6.6kV system for 2 sec. 15.2.4 Permissible voltage dip during starting (a) 400V system: The voltage dip during starting of individual 400V motors shall be limited to less than 15% of the full load voltage. 6.6kV system: The voltage drop during starting of HRSG cooling pump motors shall be limited to less than 20% of the full load voltage, for all other motors it shall be 15%.
(b)
15.2.5
Minimum conductors cross-section for the power cables shall be 4.0 mm2 aluminium or 2.5 mm2 copper. All D.C. power supply cables shall be single core cables. Control cables
15.2.6 15.3
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15.3.1
Current transformer leads shall be checked for lead burden, VA capacity and knee point voltage. In case 2.5 mm2 Copper Conductor is not adequate, 4 mm2 cross-section cables shall be used. Instrumentation Cables The cross sectional area shall be 0.5mm2 based on the requirement of I&C system employed. The instrumentation cables carrying digital signals shall have overall screening along with drain wire and analog signal carrying cables shall have each pair screening and overall screening along with each pair drain wire and overall drain wire. Specific Requirements of Cables The following aspects are applicable for all types of cables:
15.4 15.4.1
15.4.2
15.5
15.5.1
Core Identification Colour coding shall be acceptable for all cables upto 5 cores. Cables with more than 5 cores shall have printed numerals on each core. In addition to manufacturer's identification on cables as per IS, following marking shall also be provided over outer sheath: (a) (b) (c) Cable size and voltage grade - To be embossed Word 'FRLS' at every 5 meter - To be embossed Sequential marking of length of the cable in meters at every one meter - To be embossed / printed.
The embossing / printing shall be progressive, automatic, in line and marking shall be legible and indelible. The name of the project shall be provided at regular intervals of the outer sheath. 15.5.2 Core numbers with a minimum letter size of 3 mm shall be printed serially on each core of the control cable at intervals of not more than 200 mm. Core numbers with a minimum letter size of 2 mm shall be printed serially on each core of the Instrumentation cable at intervals of not more than 200 mm and each core shall be colour coded as per IEC-60189 Part-2 FRLS PVC compound for outer sheaths of all the cables shall meet the following performance requirements and cables shall pass these tests.
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15.5.3
15.5.4
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SECTION:
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SHEET 5 OF 19
SPEC. NO.
TCE.5960A-H-500-001
The bidder shall furnish the necessary type test certificates. (a) The critical oxygen index value shall be minimum 29 at room temperature and the temperature index value shall be minimum 250C at oxygen index of 21 when tested as per ASTM-D-2863-77. The maximum total acid gas generation as determined by titration shall be less than 20% by weight, when tested as per IEC 60754-1. The maximum smoke density rating expressed in percentage light absorption at any point on the curve during testing period shall not exceed 60 % when tested as per ASTM-D-2843-77. The cables shall pass the hydrolytic stability and ultraviolet test as per DIN 53387. The measured values of ultimate tensile strength and elongation after the test shall not be less than 60% of that measured before the test.
(b)
(c)
(d)
15.5.5
The finished cables shall pass the flammability test as per IEC-60332-1 and IEC-60383. In addition it shall also pass flammability test as per class F3 of Swedish Standard S5-424-1475. In plant repairs to the cables shall not be accepted. Pimples, fish eye, blow holes etc. are not acceptable. Cables shall be supplied in non returnable wooden or steel drums of heavy construction. The surface of the drum and the outer most cable layer shall be covered with water proof cover. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation, storage and erection. Wood preservative anti-termite treatment shall be applied to the entire drum. Wooden drums shall comply with IS: 10418. Each drum shall carry manufacturer's name, Owner's name, address and contract number, item number and type, size and length of cable and net gross weight stenciled on both sides of the drum. A tag containing same information shall be attached to the leading end of the cable. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled. The cross-sectional area of the metallic screen strip/tape shall be considered in design calculations.
15.5.6
15.5.7
15.5.8
15.5.9
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SPEC. NO.
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15.6 15.6.1
Tests The Contractor shall conduct the routine tests on each drum length, acceptance test on the cables as per applicable standards. Tests certificates of all type tests as per applicable standards conducted on similar cables shall be submitted for review. Also special tests for critical oxygen index, temperature index values, acid gas generation, smoke generation, flammability test, effects of light and water test as specified shall be conducted on specimen, from different batches. Routine tests shall include but not limited to the following for instrumentation cables. Test for dielectric strength for one minute (as per IEC-60189-1) Insulation resistance test (as per IEC-60189-1) The vendor shall carry out all routine tests as per IEC.60189-1 for instrumentation cables Cable carrier system (a) Cables shall be always laid above ground to all locations including outgoing areas with cable trays supported on overhead steel structure works. Cable tranches shall be provided in switchyard and transformer yard. Any deviation may e subjected to Owners approval. Following cable carrier system shall be adopted in various areas as indicated below. (i) Control room building - Cable vault Switchgear room
- Cable vault
15.6.2 15.6.3 15.6.4
15.6.5
: : Cable trays
(ii)
(iii) (iv) (v)
GTG building STG building Switchyard and transformer yard
: Cable trays : Cable trays / conduits : Cable trays / conduits : Cable trench
ISSUE R0
245
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SECTION:
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SHEET 7 OF 19
SPEC. NO.
TCE.5960A-H-500-001
(vi) (vii) (viii) (ix)
HRSG area HRSG platforms Road / Rail crossings Cable carrier system connecting outlying areas Off-side buildings and utilities
: Cable rack : Cable trays : Hume or steel pipes : Cable Trays
(x)
: Cable trays
(b)
Cable tunnels shall have minimum head room of 1.8 m considering the obstruction due to light fittings, sprinkler piping, etc. Cable trench (i) Cable trenches shall be of different sizes depending on the number of cables laid in that route. Preferred working space between the cable support arms and the wall are as follows. Contractor shall design the trenches accordingly. Trench depth Width of Trays 600 mm 600 mm 600 mm 300 mm Working Space 750 mm 750 mm 750 mm 500 mm
(c)
(ii)
1500 mm (5 tiers) 1200 mm (4 tiers) 1000 mm (3 tiers) 700 mm (2 tiers) (iii)
PCC flooring of buildup trenches shall be sloped for effective drainage with sump pits and sump pumps.
ISSUE R0
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SECTION:
D3.15
SHEET 8 OF 19
SPEC. NO.
TCE.5960A-H-500-001
(iv)
No sub zero level cable vault / trenches shall be provided below control building/ switchgears rooms in main plant.
(d)
Cable trays (i) Cable trays of ladder and perforated types and the associated accessories such as coupler plates, tees, elbows, bends, reducers, brackets, crosses etc., and hardware such as bolts, nuts, washers, G.I. strap, hook etc., shall be fabricated from 14 gauge (2.0 mm thick) mild steel sheets. Cable tray covers shall be fabricated from 16 gauge (1.70 mm thick) MS sheets. The thickness of side coupler plates shall be minimum 3 mm. Cable tray shall be ladder type for power & control cables and perforated for instrumentation cables.
(ii)
Cable trays, accessories and covers shall be hot dip galvanised. Cable trays shall have standard width of 150 mm, 300 mm & 600 mm and standard lengths of 2.5 metre. In battery rooms and water treatment plant, the cable trays, accessories and covers shall be epoxy painted. The spacing of rungs for ladder type of trays shall be not more than 250 mm. Vertical raceways shall be formed by either structural members and slotted angles or by running the prefabricated trays vertically. Prefabricated cable trays, accessories and covers shall be hot dip galvanised. Site fabricated cable trays shall be painted with cold galvanisation paint at site. Cable troughs shall be required for branching out few cables from main cable route. These shall be U-shaped, fabricated of mild steel sheets of minimum thickness 2 mm and shall be hot dip galvanised as per relevant IS. Troughs shall be standard width of 50 mm & 75 mm with depth of 25 mm.
(iii)
(iv)
(v)
(vi)
(vii)
ISSUE R0
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SECTION:
D3.15
SHEET 9 OF 19
SPEC. NO.
TCE.5960A-H-500-001
(viii)
Cable tray support system shall be pre-fabricated similar or equivalent to "Uninstrut make. Support system for cable trays shall essentially comprise of the two components i.e. main support channel and cantilever arms. The main support channel shall be of two types : (i) C1:- having provision of supporting cable trays on one side and (ii) C2:-having provision of supporting cable trays on both sides. The support system shall be the type described hereunder. Cable supporting steel work for cable racks/cables shall comprise of various channel sections, cantilever arms, various brackets, clamps, floor plates, all hard wares such as lock washers, hexagon nuts, hexagon head bolt, support hooks, stud nuts, hexagon head screw, channel nut, channel nut with springs, fixing studs, etc. The system shall be designed such that it allows easy assembly at site by using bolting. All cable supporting steel work, hard wares fittings and accessories shall be prefabricated factory galvanized. The main support and cantilever arms shall be fixed at site using necessary brackets, clamps, fittings, bolts, nuts and other hardware etc. to form various arrangements required to support the cable trays. Welding of the components shall not be allowed. However, welding of the bracket (to which the main support channel is bolted) to the overhead beams, structural steel, insert plates or reinforcement bars will be permitted. Any cutting or welding of the galvanized surface shall be brushed and red lead primer, oil primer & aluminium paint shall be applied All steel components, accessories, fittings and hardware shall be hot dip galvanized after completing welding, cutting, drilling and other machining operation. The typical arrangement of flexible support system is described briefly below: The main support channel and cantilever arms shall be fabricated out of minimum 2.5 thick rolled steel sheet
ISSUE R0
248
(ix)
a.
b.
c.
d.
e.
TCE FORM NO. 329 R5
SECTION:
D3.15
SHEET 10 OF 19
SPEC. NO.
TCE.5960A-H-500-001
conforming to IS. f. Cantilever arms of 300 mm, 600 mm and 750 mm in length are required, and shall be as shown in the enclosed drawing. The arm portion shall be suitable for assembling the complete arm assembly on to component constructed of standard channel section. The back plate shall allow sufficient clearance for fixing bolt to be tightened with tray in position.
The size of structural steel members or thickness of sheet steel of main support channel and cantilever arms and other accessories as indicated above or in the enclosed drawings are indicative only. Nevertheless, the support system shall be designed by the bidder to fully meet the requirements of type tests as specified. In case the system fails in the tests, the components design modification shall be done by the Contractor without any additional cost to the Owner. The bidder shall submit the detailed drawings of the system offered by him along with the bid. (e) Conduits & Pipes (i) The galvanised steel conduits shall be used for sizes upto 63.5 mm. The conduits shall be manufactured by electric resistance welding process and shall be hot dip galvanised. The conduits and fittings shall comply with IS: 1653, 3837, and 2667. Galvanised steel pipes shall be used for sizes from 80mm on wards. They shall be medium duty class-B type as per IS. The pipes shall be manufactured by electric resistance welding and hot dip galvanized. The pipes and fittings shall comply with IS. Flexible steel conduits shall be manufactured with electro galvanising process. The flexible conduits and their fittings shall comply with IS: 3480, 4649. The hume pipes/RCC pipes shall comply with IS: 458.
(ii)
(iii)
(iv) (f)
Cable/Cable tray supports
ISSUE R0
249
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SECTION:
D3.15
SHEET 11 OF 19
SPEC. NO.
TCE.5960A-H-500-001
(i)
Cable tray supports shall be fabricated from standard steel structures of different sizes. The sizes selected shall be adequate for the weight of cables/trays encountered. The steel members shall be cleaned thoroughly for rust and painted as follows: For indoor - One shop coat of red oxide zinc chromate primer and two site coats of aluminium alkyd paint. For outdoor & corrosive areas like battery room, DM plant - Hot dip galvanised.
(ii)
(g)
Cable Carrier Installation practice (i) Minimum level difference between two tiers of horizontal cable trays in building, trenches shall be 300 mm. In vertical race ways with multi-tiers the tiers shall be located atleast with 400 mm intervals. In trenches & tunnels the width of the cable tray shall be limited to 600 mm. In case of horizontal trays it shall be limited to 800 mm. Separate cable trays/tiers shall be provided for different voltage grade cable viz., 6.6 kV power, 400V/230V power, control cables and instrumentation & communication cables. Communication links wherever redundant shall be run in different conduits and in separate trays. Cable trays shall be supported at every 1000 mm interval. Cable trenches around the transformer shall be filled with sand. Cable trays shall be welded to the mounting/carrier structures. Vertical trays (raceways) and all outdoor cable trays shall be provided with removable 16 guage galvanised MS sheet covers.
(ii)
(iii)
(iv)
(v)
(vi)
ISSUE R0
250
TCE FORM NO. 329 R5
SECTION:
D3.15
SHEET 12 OF 19
SPEC. NO.
TCE.5960A-H-500-001
(vii)
Each continuous laid out length of cable tray shall be earthed at minimum two places by MS flats of minimum size 25mm x 3mm, the distance between earthing points shall not exceed 10 metres. When cables are taken in vertical raceways / trays and they pass from one floor & other floor pipe sleeves in concrete shall be provided. At least 300mm clearance shall be maintained between the top tray and beams, piping or other obstacles to facilitate installation of cables in the tray. A working space of not less than 600mm shall be maintained on atleast on one side of each tray. No cables shall be mounted near hot zones like hot flue gas duct, steam pipe, etc.
(viii)
(ix)
(x)
15.7 15.7.1
Cable Installation Cables to each circuit shall be laid in one continuous length. Cable jointing and splicing shall be avoided. Jointing will be allowed only for the cases where the route length is more than the maximum possible drum length. Outdoor cable installation (a) Where cables cross roads and water, oil, gas or sewage pipes, the cables shall be laid in hume or steel pipes. For road crossings, the pipe for the cable shall be buried at not less than 600 mm. Hume pipes shall be preferred to steel pipes from the point of view of corrosion. The cables shall be tied to tray rungs by means of 3mm dia. nylon cord at an interval of 5000 mm and also at bends. For good sealing arrangement at entry points, suitable pipe sleeves, adequate in number and of adequate sizes shall be provided in building walls/slabs for passage of cables into a building from cable trays/racks/cable trenches located outside the building.
15.7.2
(b)
(c)
15.7.3
Cables in Trays / on Racks

ISSUE R0
251
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SECTION:
D3.15
SHEET 13 OF 19
SPEC. NO.
TCE.5960A-H-500-001
(a)
Different voltage grade cables shall be laid in separate trays. When trays are arranged in tiers, HV cables shall be laid in top trays and cables of subsequent voltage grades in lower tiers of trays. The HV power cables shall be laid in trays/on racks as follows: i) ii) iii) In single layer only without exception. 3 core cables to be laid in touching formation. Single core cables to be laid in trefoil groups.
(b)
(c)
1100V grade power cables of 120 mm size and above shall normally be laid in single layer in trays/on racks. Smaller 1100V grade power cables below 120 mm may be run in double layers, where required, due to space restrictions. Control and instrumentation cables can be laid upto a maximum of three layers in each tray/rack. Approximately 10% space on the cable trays shall be provided for future. Single core power cables for 3 phase AC circuits laid in trays/racks/ trenches in trefoil groups shall be held in trefoil clamps placed at an interval of 3 m. The trefoil groups of cables shall be additionally tied by means of 3 mm dia. nylon cord as follows: (i) (ii) At an interval of 1m when laid in cable trays/racks. At an interval of 750 mm when laid in trenches without cable trays.
(d)
(e)
(f)
(g)
Control cables and small power cables on racks shall be run in ladder type cable trays supported on rack carrier arms. The cables shall be tied to tray rung by means of 3 mm dia. nylon cord at an interval of 5000 mm and also at bends. All cables assigned to a particular duct / conduit shall be grouped and pulled in simultaneously using cable grips and suitable lubricants. Cables removed from one duct/conduit shall not be reused without approval of Owner.
(h)
ISSUE R0
252
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SECTION:
D3.15
SHEET 14 OF 19
SPEC. NO.
TCE.5960A-H-500-001
(i)
Cables shall be segregated as per IEEE Std.-422. In vertically stacked trays, the higher voltage cable shall be in higher position and instrumentation cable shall be in bottom tier of the tray stack. The distance between instrumentation cables and those of other: system shall be as follows : From 6.6 kV tray system From 400V tray system From control cable tray system 914 mm 610 mm 305 mm
(j)
The cables emanating from redundant equipment / devices shall be routed through different routes. The above segregation of cables & wiring for redundant equipments/ devices shall be in accordance with IEEE-Std-422.
15.7.4
Bending radii for cables The bending radii for various types of cables shall not be less than those values specified by the cable manufacturer.
15.7.5
Terminations, clamping and miscellaneous details (a) Cable entry to motors, push button stations and other electrical devices shall be from the bottom as far as possible or from the sides. Top entry of the cables is not acceptable particularly for outdoor equipments. All cables shall be identified by tag. Nos. provided in Owner's approved format at both the ends as well as at an interval of 5 meters. Identification tags made from aluminium sheet shall be attached to each end of each cable by means of GI binding wire. Tags shall be additionally put at an interval of 30 metres on long runs of cables and in pull boxes. All cable terminations shall be done with solderless crimping type lug. Cable terminations shall be done with double compression type brass cable glands. Saddle type clamps to suit number of cables to be clamped at a particular location shall be used for clamping cables running along walls, ceilings, structures, etc. at 750mm interval.
(b)
(c)
(d)
ISSUE R0
253
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SECTION:
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SHEET 15 OF 19
SPEC. NO.
TCE.5960A-H-500-001
15.7.6
Termination and jointing kits for 6.6 kV grade XLPE insulated cables shall be of proven design and make which have already been extensively used and type tested. Termination kits and jointing kits shall be heat shrinkable type/push on type. 6.6 kV grade joints and terminations shall be type tested as per IS:13573. Cable jointing shall be carried out only by Raychem certified jointers only. Straight through joint and termination shall be capable of withstanding the fault level for the system. 1.1 kV grade Straight Through Joint shall be of proven design. Testing and commissioning of cables (a) Cables shall be checked for insulation resistance before and after jointing. High voltage testing All cables of 1.1 kV grade 400 mm and above and all HV cables shall be subjected to DC or AC (preferably DC) high voltage test after terminating but before commissioning as per Table 4 in IS: 1255.
15.7.7
(b)
15.7.8
Earthing (a) Metallic sheaths, screens and armour of all multicore cables shall be earthed at both equipment and switchgear end. Sheath and armour of single core power cables shall be earthed at switchgear end only. For long lengths of cables multiple earthing may have to be adopted to safeguard against the presence of standing voltages under normal as well as fault conditions.
(b)
15.7.9
Fire proof sealing system (FPS) (a) Fire proof sealing system shall consist of (i) Fire-stops/fire-seals for sealing of cable/cable tray and conduit/pipe penetrations, both horizontal and vertical, through brick or RCC walls/floors, to prevent the spread of fire from one area, which is separated from others by fire-resistant barriers. `Fire-breaks' provided on long runs of cable racks/trays to prevent the propagation of fire along the cable rack, within a single fire-area or fire- zone.
ISSUE R0
254
(ii)
TCE FORM NO. 329 R5
SECTION:
D3.15
SHEET 16 OF 19
SPEC. NO.
TCE.5960A-H-500-001
(b)
The FPS system shall also include all the necessary accessories and equipment required for supporting, holding in position, fixing and installation of the fire-stop/fire-break. The FPS system shall comply in all respects with the requirements of the codes and standards listed below IEEE-634 ASTM-E-814 ANSI-IEEE-383 IEC-60331 IEC-60332
(c)
(d)
Fire Stop/Seal The FPS system adopted for cables or cable trays penetrating through walls and floor openings, or cables passing through embedded conduits/pipes/ pipe-sleeves, constitutes a `fire stop/seal', which is meant to prevent spreading of fire between areas separated by fire-resistant barriers.
(e)
Fire Break The fire proofing system, other than fire-stops, adopted to retard flame propagation along long runs of horizontal or vertical cable trays in the same fire zone or area, in an event of a fire, shall constitute a `fire-break' and shall be provided by applying a suitable fire-resistant coating on cables and cable trays for the required length, with or without a fire resistant panel, at the point of the fire break to obtain the fire-rating specified.
(f)
Performance Requirements (i) Requirement of fire stops The material, design and construction of the fire stops shall be such as to provide the fire rating of 120 minutes for a fire on any side and meet all requirements listed in this specification and the relevant codes and standards. The materials used in the fire stops shall be nonhygroscopic, compatible with the type of cables.
ISSUE R0
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SECTION:
D3.15
SHEET 17 OF 19
SPEC. NO.
TCE.5960A-H-500-001
The fire stops shall be suitable for retrofitting of cables through the penetration seal without disturbing the sealing of the cables already existing.
(ii)
Requirements of fire breaks Each firebreak shall have a fire rating of 30 minutes and shall be capable of withstanding for the duration specified, a fire on any side of the fire break.
(g)
Application of fire proof sealing system (i) Fire stops Fire stops shall be provided for cable penetration openings listed below The passage of cables/cable trays pipe sleeves/embedded conduits through walls / floors. Vertical raceways, which carry cables between successive floors, through openings provided in the RCC floor slab, shall be sealed by fire stops at each floor level. Cable entry through openings in floor slabs below MV/LV switchgear, MCCs, various control and relay panels and other bottom entry panels, shall be effectively sealed by fire stops.
(ii)
Location of fire breaks Fire breaks shall be provided on both cable rack and trenches at all cable tray intersections and tee-offs. On linear runs of cable trays between fire stops or fire breaks, fire breaks shall be provided at intervals of 15 metres on horizontal cable runs and 5 m on vertical cable runs.
ISSUE R0
256
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SECTION:
D3.15
SHEET 18 OF 19
SPEC. NO.
TCE.5960A-H-500-001
Fire breaks in linear runs of cable trenches between intersections and tee-offs shall be provided at intervals of 30 metres.
15.7.10
Contractor shall furnish the test certificates for the fire stops and fire breaks after award of contract for Owners review. If the certificates are not satisfactory all the tests shall be conducted free of cost. The offered system i.e. fire stops and fire breaks shall be identical (or better) with the system which is successfully type tested for the specified rating i.e. the composition density of the material, thickness of coating in case of fire breaks and any other properties of the material / system offered shall be identical or better than the tested system and shall be subject to Owners approval. Performance Tests: Tests on Fire Stops (a) The fire stops shall be subjected to the following type tests: (i) (ii) (b) Fire Rating Test Hose Stream Test
15.7.11
Type tests shall be conducted on different fire stop test specimens described above as per IEEE-634. The sizes of the fire stop test specimens shall be similar to the largest of the sizes being used in the plant. Preconditioning of fire stop test specimens Before conducting the fire rating and hose stream tests, each test specimen shall be preconditioned for thermal ageing, water immersion and vibration. Test on Fire Stops During the fire rating test, the transmission of heat through the cable penetration fire stop shall not raise the temperature on its unexposed surface above the self ignition temperature of the outer cable covering, the cable penetration fire stop material, or material in contact with the cable penetration fire stop, with a maximum temperature limit on the unexposed surface of 200oC.
(c)
(d)
(e)
Tests on fire breaks
ISSUE R0
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SECTION:
D3.15
SHEET 19 OF 19
SPEC. NO.
TCE.5960A-H-500-001
Fire breaks shall undergo the following tests as per ANSI-IEEE383: (i) (ii) Ampacity test Flame test
ISSUE R0
258
TCE FORM NO. 329 R5
5.7
SECTION:
D3.16
SHEET 1 OF 16
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - LIGHTING SYSTEM
SPEC. NO. TCE.5960A-H-500-001
16.0
LIGHTING SYSTEM Lighting system shall be provided for the proposed plant covering all the buildings, outdoor areas, roads, yards, boundary, etc. The lighting system shall be to owners approval, having good aesthetics and designed to provide the required illumination levels in all areas and to meet the fire and safety codes.
16.1 16.1.1
Categories of Lighting The plant lighting system shall comprise the following four (4) categories: (a) (b) (c) (d) Normal 230 V Single phase AC lighting system Normal-cum-Emergency 230 V Single phase AC lighting system Emergency 220V DC lighting system Maintenance 24V AC Lighting System
16.1.2
Normal 230V AC lighting system In this system, the lighting circuits shall be fed by the 400V, 3 phase, 4 wire, normal AC supply available from the normal lighting distribution boards. All the lighting fixtures connected to this system shall be available as long as supply is available from normal source viz., auxiliary transformer.
16.1.3
Normal cum emergency 230V AC lighting system Certain lighting fixtures considered essential shall be connected to this system. In this system the lighting circuits shall be fed from another lighting distribution board from normal/emergency section of the 400V main switchboard. The lighting fixtures connected to this system will be available whenever normal supply is available in the plant and also whenever emergency DG set supplies the power to this bus section during blackout conditions. During blackout conditions, the lighting fixtures connected to this system will go off and shall come back as soon as the DG set starts feeding power to the 400V normal-emergency bus section.
16.1.4
Emergency DC lighting system
ISSUE R0
259
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SECTION:
D3.16
SHEET 2 OF 16
SPEC. NO. TCE.5960A-H-500-001
(a)
During station emergency involving total AC failure, incandescent lamp DC lighting fixtures shall be provided for movement of personnel in GTG and STG buildings, Control & Switchgear Building, Switchyard Relay Building at strategic locations viz., near entrance, staircase, landings etc. and for lighting the control room and DG set area. These fixtures shall be connected to lighting panels supplied from 220V DC station battery. These lighting fixtures shall be normally kept ÒFF'. All the area in the plant shall have the same philosophy & DC lighting for these areas shall also be from the station battery. Lighted exit signs shall be provided and installed in the control & switchgear room, relay room, maintenance area etc. Minimum one number of instalite shall be provided in all switchgear rooms pump houses and control rooms where DC lighting not envisaged.
(b)
(c)
(d)
16.1.5
Maintenance 24V AC Lighting System For lighting facilities comprising portable hand lamps and/or connection of portable hand tools etc., required during the routine maintenance work, 24V single phase 3 pin sockets with switches shall be provided at selected points such as HRSG area, TG building Hall, Cable galleries and any other areas considered necessary by CONTRACTOR. Such sockets for routine maintenance shall be clearly identified by colour coding in order to distinguish them from the normal 230V power outlets. Necessary outlets shall be made on the inside walls of the building near equipments.
The area-wise distribution of lighting fixtures connected to the systems discussed above shall be as follows: ---------------------------------------------------------------------------------------------------------------Percentage wise distribution of Lighting Area /Building ------------------------------------------------------------------Normal Normal & Emergency 220 V DC ----------------------------------------------------------------------------------------------------------------GTG, STG, buildings Switchyard control room Switchgear and battery rooms, control
ISSUE R0
16.1.6
80% 80%
20% 20%
* *
260
TCE FORM NO. 329 R5
SECTION:
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SHEET 3 OF 16
SPEC. NO. TCE.5960A-H-500-001
room in Control & Switchgear building HRSG area Transformer area & 400kV switchyard Pump houses, Admin building Canteen Roads & out going areas
80% 80% 100% 100% 100%
20% 20% * -
DG set control room 80% 20% * ---------------------------------------------------------------------------------------------------------------* Adequate for personnel movement and also located at strategic locations. 16.2 16.2.1 Lighting Supply Distribution System Normal and normal emergency AC systems (a) For these systems, the distribution shall be by 400V, 3 phase, 4 wire, 50 Hz supply with effectively earthed neutral. This supply shall be derived from 400 V, 3 phase, 3 wire, 50 Hz unit service switchgear by providing a 400 / 400V delta/star lighting transformers. The secondaries of lighting transformers shall be connected to 400 V, 3 phase, 4 wire, AC lighting distribution boards (LDBs) having 2x100% incomers & a bus-coupler. The LDBs will be provided with number of outgoing circuits controlled by MCBs to feed the lighting panels and by MCCB/Contactors to feed around the plant as well as to directly feed three phase street lighting and yard lighting supplies. AC lighting panels shall have 3 phase, 4 wire incomer with ELCB and number of 1 phase outgoing circuits controlled by MCBs. Lighting panels feeding the Lighting fixtures in indoor areas shall be controlled from the respective lighting panels located in various buildings in the plant. Road, yard lighting and aviation warning lights also shall be contactor controlled. All outdoor lighting system and aviation warning lighting system shall be automatically controlled through photoelectric controllers. Provision to bypass the timer or photocell shall be provided in the panel. Also manual switching òn and off' facility shall be provided. The Infrared sensing system shall be used for the control of lighting in unmanned substations.
(b)
16.2.2
220 V DC lighting system

ISSUE R0
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SECTION:
D3.16
SHEET 4 OF 16
SPEC. NO. TCE.5960A-H-500-001
Emergency DC lighting supply distribution shall be on 220V DC, 2 wire unearthed system. Minimum 10% of 220V DC lighting shall be provided. This power supply shall be obtained from station 220V DC switchboard. DC lighting panel shall be provided for distribution of lighting supply. This panel shall have an incoming switch, undervoltage relay and number of outgoing circuits controlled by switch fuses. No voltage at the normal emergency switchgear shall be sensed and DC contactor shall be switched on thus extending DC supply to the lighting circuits. 16.3 Illumination levels and choice of lighting fixtures The area-wise distribution of average illumination levels and type of luminaires shall be as given below.
Sl. No.
Area/ Structure
Average Illumination Level in Lux.
Type of Fixture
Type of Luminaire
1. (a)
GTG, STG Building / Control & Switchgear building General (auxiliary equipment areas) 200 Medium /low bay fittings / Industrial well glass vitreous enamel reflector integral mounted control gear/ industrial bulk head with integral mounted control gear. All the lighting fittings shall have separate control & gear box arrangement. The control box shall be fixed on the wall/column for the easy maintenance. Industrial type with vitreous enamel reflector Industrial type with vitreous enamel reflector Industrial high bay with anodised aluminium reflector 1 x 70 W / 1 x 150 W HPSV lamp
(b)
Cable vault
150
2 x 36W fluorescent lamp (F.L)- Trulite 2X36W fluorescent lamp (F.L)-Trulite 1x400 W, Metal Halide Lamp,
ISSUE R0
(c)
All switchgear room area (including off-site building control room) GTG Building
250
(d)
200
262
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SECTION:
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SHEET 5 OF 16
SPEC. NO. TCE.5960A-H-500-001
Sl. No.
Area/ Structure
Type of Fixture
Type of Luminaire
Industrial High with Anodised Aluminium Reflector (e) Control room 500 Decorative recessed with wide angle mirror optic anti glare type Vapour proof Totally enclosed vapour proof with clear acrylic cover Industrial high bay Energy efficient Lamp T5 2X36W F.L.-Trulite 2 x 36W F.L -Trulite 1x400 W, Metal Halide Lamp, Industrial High with Anodised Aluminium Reflector 2X 36W F.L. -Trulite 2 X 36W F.L. -Trulite
(f) (g)
Battery rooms A/C plant room
250 200
(h)
Unloading and maintenance bay
250
(i)
Electrical / Instrument laboratory, chemical laboratory (air-conditioned) Chemical laboratory (non-air conditioned) HRSG area HRSG area and platforms (i) (ii) Indoor Outdoor
250
Decorative recessed with wide angle mirror optic anti-glare type Corrosion proof
(j)
250
2. (a)
150 50
Dust proof / dust tight well glass fixture
70W HPSV lamp
3. (a) (b) 4. (a) (b) (c)
Transformer Area General Near equipment Switchyard Area General Near equipment Switchyard Control room 30-35 35-50 500 Flood light medium beam type Post top lantern with HDP reflector Decorative recessed with wide angle mirror optic anti glare type 1 x 150W HPSV lamp 70W HPSV Energy efficient Lamp T5 30-35 35-50 Flood light medium beam type Dust proof / dust tight well glass on fire partition walls 1 x 150W HPSV lamp 1 x 70W HPSV
5. (a)
Various Off-site building Switchgear room (All pump 200 Industrial type with vitreous 2 x 36W F.L.
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Sl. No.
Area/ Structure
Type of Fixture
Type of Luminaire
house) (b) (c) Outside working areas Equipment room (Pump house, Compressor & DG house) DM Plant / Filtration Plant General Road and yard lighting Main roads Secondary roads 20 10 250 70 250
enamel reflector mounting height of 8M Flood light medium beam
upto
Industrial high bay / medium bay depending on height
1x400W / 1x150W Metal Halide Lamp (HPMV)
6. (a) 7. (a)
Corrosion proof
1 X 70 WHPSV
Street light with clear acrylic cover cut-off type with integral mounted control gear or LED fixtures with control gear. - do General purpose flood light, high/medium beam flood light Industrial type with vitreous enamel reflectors/industrial high bay
1 x 70W / 150W HPSV
(b) (c) 8.
Perimeter (compound) lighting Parking area (Indoor / sheds) Workshop building
20 70 300
- do 1 x 250 W HPSV 2X36W F.L x 250W HPSV
9. (a) (b)
Administration Building Main office areas cabins (air conditioned areas) Main office areas, cabins with false ceiling but non-airconditioned Main office areas, cabin non airconditioned areas without false ceiling Warehouse, canteen, medical centre General Corridors, walk-ways, staircase, etc. 150 Industrial type with vitreous enamel reflectors/channel mounted box type compact flourescent lamp Channel mounted box type Industrial well glass with integral mounted control gear/industrial bulk head with 2 x 36 W F.L. 200-250 200-250 Decorative recessed type with mirror optic reflector - do 2 x 36W F.L. - do -
(c)
200-250
Decorative with wide angle mirror optic reflector Industrial type with vitreous enameled reflector
- do -
(d) 10. (a)
150
2 x 36W F.L.
(b) (c)
Lockers, toilets, wash rooms, etc. Building periphery lighting
100 -
2 x 36 W F.L. 1 x 70 W HPSV lamp

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Sl. No.
Area/ Structure
Type of Fixture
Type of Luminaire
integral mounted control gear (d) 11. (a) (b) Security, Time office, Gate house, Executive canteen Elevator Elevator machine room Elevator well 100 20 Industrial type enamelled reflector vitreous 2 x 36W F.L. 1 x 100 W incandescent lamp / 1 x 70W HPSV 150 Decorative with louver 2x36W F.L
Industrial bulk head/ industrial bulk head with integral mounted control gear
12. (a) (b)
DC Light Fitting Control room Other areas Decorative recessed type with cylindrical reflector Industrial industrial reflector bulk head or well glass with 1 x 100 W incandescent lamp 1 x 100 W incandescent lamp
The illumination levels for areas, which are not specifically covered above, shall be decided based on illumination levels indicated for similar areas or in relevant standards. 16.4 Lighting System Design The lighting system design shall comply with the acceptable norms and the best engineering practices. The system design shall consider principles of lighting specified in following paragraphs. The lighting layout shall be designed to provide uniform illumination with minimum glare. The layout design shall meet all the statutory requirement, local rules etc. 16.4.1 Indoor lighting The illumination level for various areas in the plant is indicated in the table above. Following factors shall be considered while arriving at the utilisation factor to determine the number of fixtures for each area/building in the plant. (a) Maintenance factor (i) (ii) Control room and system cabinet room - 0.8 All other indoor areas - 0.7
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(iii) (b)
Out door areas
- 0.6
Reflection factor for wall and ceiling (i) Control room and system cabinet room - 0.7 ceiling, 0.5 wall Other areas - 0.5 ceiling 0.3 wall
(ii)
(c)
The value of the ratio of spacing (S) to mounting height (H) shall be commensurate with the type of fittings selected, uniformity of illumination. The suspension height for suspended fixtures shall not exceed 1 metre. The control room lighting shall be designed such that no glare from the lighting appears on the DCS-CRT from any angle.
(d)
16.4.2
Roadway lighting (a) Lighting design for roadways shall consider a maintenance factor of 0.6 for average conditions. Ratio of minimum to average illumination shall not be less than 0.3. The road lighting layout shall consider the width of the road to decide whether the lighting poles shall be located on one side, on either side or in the central reserve. The mounting height of the luminaires shall be generally 9 metres. The control gear for street light shall be of non integral type i.e., the control gear of the light fixture shall be mounted at the foot of the pole. The lighting poles shall be galvanised steel poles with reasonably thick layer of galvanising for ensuring long life.
(b)
(c)
(d)
(e)
16.4.3 16.4.3.1
Selection of lighting fixtures and accessories The type of luminaires and accessories like switches, receptacles etc., shall be selected based on the plant area in which they are intended to be used. Lighting fixtures shall be explosion proof in hazardous and fuel oil areas.
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16.4.3.2 All fluorescent fixtures, shall have electronic chokes with low harmonics & energy efficient 'T5' type fluorescent lamps except the fluorescent fixtures used for division 2 hazardous area. The louvers of these fixtures shall be designed for 'T5' type fluorescent lamps. All fluorescent lamps shall be have "Cool day light" colour designation. The mirror optics type fluorescent fixtures shall have no iridescence effect. 16.4.3.3 All HPSV and HPMV lamp fixtures or LED fixtures shall be provided with wire-wound ballasts. All fluorescent fixtures except for Class-I, Div-II fittings/ increased safety fittings (Div-II/Hazardous Area) shall be provided with electronic ballasts. 16.4.3.4 Conduits, Pipes and Accessories Galvanised heavy duty steel conduits for normal area and galvanised heavy duty steel conduits with an additional epoxy coating for corrosive area shall be offered. 16.4.3.5 Rigid steel conduits shall be heavy duty type, hot dip galvanised conforming to IS : 9537 Part-I & II shall be suitable for heavy mechanical stresses, threaded on both sides and threaded length shall be protected by zinc rich paint. Conduits shall be smooth from inside and outside. 16.4.3.6 Flexible conduit shall be water proof and rust proof made of heat resistant lead coated steel. 16.4.3.7 Pull out boxes shall be provided at approximately 4 (four) metre interval in a conduit run. Boxes shall be suitable for mounting on Walls, Columns, Structures, etc. Pull-out boxes shall have cover with screw and shall be provided with good quality gasket lining. Pull out boxes used outdoor shall be weather proof type suitable for IP :55 degree of protection and those used indoor shall be suitable for IP :52 degree of protection. Pull out box & its cover shall be hot dip galvanised. 16.4.3.8 The poles shall be of ERW tubes of specified lengths, swaged tubular and joined together. The complete pole shall be hot dip galvanised. The terminal boxes for the lighting pole shall be IP55 protected & of glass reinforced epoxy type. 16.4.3.9 Lighting Mast shall be of continuously tapered polygonal cross section hot dip galvanised. The Mast shall be of 30M height with lantern carriage to enable raising/lowering for ease of maintenance, including the Head Frame, Double Drum Winch, continuous stainless steel wire rope, in built power tool, luminaries, suitable aviation warning light, lightning along with necessary power cables within the mast. The mast shall be delivered only in three sections & shall be joined together by slip stressed fit method at site. No site welding or bolted joints shall be done on the mast.
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16.4.3.10 Suitable collapsible / telescopic ladder shall be provided to approach lighting fixture installed at height. 16.4.4 Switches and receptacles (a) In the plant areas, the lighting circuits shall be controlled directly from the MCBs in the lighting panels. Wherever the lighting panel is not in the same area, separate switches shall be provided. For cabins, rooms etc., separate switches shall be provided for each point. Similarly for entrances, building periphery lighting separate switches shall be provided. Receptacles with MCB (5A and 15A) shall be provided in all building/areas of the plant. Also inside a building, receptacles shall be provided at regular intervals so that any point of the building is not more than 10 m with a minimum of 2 nos., in an enclosed area. Inside each cabins atleast two receptacles shall be provided. The same shall be indoor/outdoor/flameproof as per the location. Suitable no. of 63A, 3 phase, 400VA.C industrial heavy duty receptacles shall be provided for outdoor plant for welding purpose. The industrial receptacle shall be provided at an average distance of 50 mts. At-least two 63A, 3 phase, 400V industrial heavy duty type receptacle shall be provided in each building. It shall be metal enclosed with SFU and housed inside with suitable connection for cabling and receptacles. Ceiling fans, to be provided in non air conditioned office/control room area, shall be suitable for operation on 230 V, 50 Hz, AC supply comprising of class F insulated copper wound single phase motor, 1200mm sweep, aerodynamically designed well balanced MS blades (3 Nos.), down rod, die cast aluminium housing, capacitor, suspension hook, canopies etc. finished in stove enamelled white. Power factor of fans shall not be less than 0.9. Each fan shall cover approximately 10m2 area.
(b)
(c)
16.4.5
Lighting distribution boards (LDB) & lighting panels (LP) Each of the LDBs shall be provided with voltmeter and ammeter along with selector switches, `Supply On' indicating lamps, etc. The LDBs and LPs shall be sheet steel enclosed and shall be fully dust and vermin proof, with a degree of protection of IP 54. Outdoor panels shall be weather proof type with IP - 54 degree of protection. LDBs, LPs shall be explosion proof wherever provided in hazardous and fuel oil areas. The
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switch boxes, receptacle boxes etc., shall be made up of 18 SWG sheet steel. 16.4.6 The distribution of lighting fixtures/receptacles shall be such that the loading on each phase of the LDB is approximately equal. Wiring (a) 1100 V grade stranded copper conductor, PVC insulated wires to IS: 694 laid in GI conduits shall be used for lighting in nonhazardous area. In the hazardous areas cable wiring with 1100 V grade stranded aluminium conductor, PVC insulated, PVC inner sheathed, GI wire armoured and overall PVC sheathed cables to IS: 1554 shall be adopted. For outdoor areas like transformer yard, switchyard and road lighting also cable wiring as above shall be adopted. Minimum size of wires in case of conduit wiring shall be 2.5 mm2 in case of lighting and 4 mm2 in case of receptacle wiring. Minimum cable size in case of cable wiring shall be 4 mm2 for lighting and 6 mm2 for receptacles. Wires of different phases shall be run in separate conduits. However wires of same phase but having different circuit nos. can be run in same conduit. Wires of lighting and power receptacles will be carried out in separate conduits and on separate circuits. Wires of AC and DC lighting systems shall be carried out in separate conduits. For outdoor lighting, the cable shall be buried at a minimum depth of 750 mm from ground level. The buried cables shall have suitable bedding, protective covers & markers. The wiring in the conduit shall be such that 20% space in the conduit is free.
16.4.7
(b)
(c)
(d)
(e)
16.4.8
Lighting circuit design (a) In an area, the lighting fixtures shall be arranged in different phases/LPs such that even in case one lighting panel goes faulty complete lighting is not affected. In case of room the lighting shall be arranged from two phases. The circuit loading on each circuit shall be restricted to 80% of the MCB rating.
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(c) (d)
The voltage drop from LDB and any fixture shall not exceed 3%. The contractor shall submit design calculation for sizing of LDBs and also provide lumen contour for the main road and other areas. Contractor shall demonstrate the same at location decided by Owner.
16.4.9
Earthing (a) Lighting fixtures, receptacles, switches, conduits and junction boxes shall be properly earthed using 12 SWG GI wire run along the entire length of the conduit between the fixture and the corresponding lighting panel where it will be connected to the station earth. For fixtures in hazardous areas, the third core of each singlephase armoured cable circuit shall be used as earthing conductor. For outdoor earthing of lighting poles, junction boxes on the poles, 25 X 6 GS Flat, shall be run buried in ground at a depth of 600 mm and tapped to each lighting pole. The earth conductor shall be connected to the nearby main earthing grid at the first and last poles of each feeder circuit and at some intermediate poles.
(b)
(c)
16.5 16.5.1
Tests Type test reports of the following items as per relevant standards shall be submitted for approval. i. ii. Lighting fixtures of each type Lamps of each type and rating.(life cycle and rating test only) Lighting panel of each type (Degree of Protection) Junction Box of each type Receptacles of each rating M.C.B. of each rating.
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16.5.2
All acceptance tests & routine tests for the lighting fixtures and accessories covered in this specification shall be carried out as per the relevant standards listed under "Codes and Standards given below for the respective fixtures/ components. Type test certificates shall be furnished for review. Applicable Standards
16.6
16.6.1
Electric Lighting Fittings General and Safety Requirements Code of Practice for Industrial Lighting Calculation of Co-efficient of Utilisation Industrial Lighting Fittings with Metal Reflectors Decorative Lighting Outfits Dust Proof Electric Lighting Fittings Dust Tight Electric Lighting Fittings Electric Lighting Fittings for Division 2 Areas as per IS:5572 (P1) Flame Proof Lighting Fittings
IS:1913
16.6.2 16.6.3 16.6.4
IS:6665 IS:3646 (Part-III) IS:1777
16.6.5 16.6.6 16.6.7 16.6.8
IS:5077 IS:4012 IS:4013 IS:8224
16.6.9
IS:4013 Part (I&II) IS:2148 IS:10322 Pt-V SECT-5 IS:10322 Pt-V SECT-3 IS:3528 IS:3553
ISSUE R0
16.6.10 16.6.11
Flame Proof Enclosure Flood Lights
16.6.12
Luminaries for Street Lighting
16.6.13 16.6.14
Waterproof Electric Lighting Fittings Watertight Electric Lighting Fittings
271
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16.6.15 16.6.16 16.6.17
Bayonet Lamp Holders Edison Screw Lamp Holders Bi-Pin Lamp Holders for Tubular Fluorescent Lamps Starters for Fluorescent Lamp Holders for Starters for Tubular Fluorescent Lamps Ballast for Use in Fluorescent Lighting Fittings Transistorised Ballast for Fluorescent Lamps Ballast for HP Mercury Vapour Lamp Capacitors for Use in Fluorescent, HPMV & LP Sodium Vapour Discharge Lamp Circuits Vitreous Enamel Reflector for Tungsten Filament Lamp Tubular Fluorescent Lamps High Pressure Mercury Vapour Lamps Tungsten Filament General Electric Lamps Cast Acrylic Sheets for Use in Luminaires Screwless Terminal and Electrical Connections for Lighting Fittings High Pressure Sodium Vapour Lamps Emergency Lighting Units Ignition Proof Enclosures, Dust-Tight for Electrical Equipment Luminaires (Part 1 to V) Arrangement for Busbars, Main Connections and Auxiliary Wiring and Marking
IS:1258 IS:10276 IS:3323
16.6.18 16.6.19 16.6.20 16.6.21 16.6.22 16.6.23
IS:2215 IS:3324 IS:1534 (Part 1) IS:7027 IS:6616 IS:1569
16.6.24
IS:8017
16.6.25 16.6.26 16.6.27 16.6.28 16.6.29
IS:2418 (Part 1) IS:9900 IS:418 IS:7569 IS:10322 Pt-III
16.6.30 16.6.31 16.6.32 16.6.33 16.6.34
IS:9974 IS:9583 IS:11005 IS:10322 IS 5578 IS 11353

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16.6.35
Enclosed Distribution Fuse Boards and Cut-outs for Voltages not exceeding 1000 V General Requirements for Switchgear and Control gear for Voltages not exceeding 1000V Code of Practice Installation and Maintenance of Switchgear Factory Built Assemblies of Switchgear and Controlgear for Voltages upto and including 1000 V AC and 1200 V DC Degree of Protection of enclosed equipment for Low Voltage Switchgear and Controlgear Switches, Disconnectors, Switch Disconnectors and Fuse Combination Units for Low Voltage Switchgear and Controlgear Miniature Air Break Circuit Breakers for AC Circuits HRC Cartridge Fuse Links upto 650 V Current Transformers Voltage Transformers Direct Acting Electrical Indicating Instruments AC Electricity Meters Electrical Relays for Power System Protection Flameproof Enclosures of Electrical Apparatus Guide for Selection of Electrical Equipment for Hazardous Areas Switches for Domestic and Similar Purposes Three-Pin Plugs and Socket Outlets Fans and Regulators, Ceiling Type, Electric
IS 2675
16.6.36
IS 4237
16.6.37
IS 10118
16.6.38
IS 8623
16.6.39
IS 13947
16.6.40
IS 13947 Part-3
16.6.41 16.6.42 16.6.43 16.6.44 16.6.45 16.6.46 16.6.47 16.6.48 16.6.49
IS 8828 IS 9224 IS 2705 IS 3156 IS 1248 IS 722 IS 3231 IS 2148 IS 5571
16.6.50 16.6.51 16.6.52
IS 3854 IS 1293 IS 374

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16.6.53 16.6.54
Rigid Steel Conduits for Electrical Wiring Accessories for Rigid Steel Conduits for Electrical Wiring Flexible Steel Conduits for Electrical Wiring Rigid Non-Metallic Conduits for Electrical Installations Fittings for Rigid Non-Metallic Conduits PVC Insulated Cables for Working Voltages upto and including 1100 V Tubular Steel Poles Wrought Aluminium and Aluminium Alloys, Bars, Rods, Tubes and Sections for Electrical Purposes Code of Practice for Phosphating Iron and Steel Fittings for Rigid Steel Conduits for Electrical Wiring Prestressed Concrete Circular Spun Poles for Overhead Power, Traction and Telecommunication Lines Methods of Test for Concrete Poles for Overhead Power and Telecommunication Lines
IS 9537 IS 3837
16.6.55 16.6.56
IS 3480 IS 9537 Part-2
16.6.57 16.6.58
IS 3419 Part-2 IS 694
16.6.59 16.6.60
IS 2713 IS 5082
16.6.61 16.6.62 16.6.63
IS 6005 IS 2667 IS 13158
16.6.64
IS 2905
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SECTION:
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1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM
SPEC. NO. TCE.5960A-H-500-001
17.0
EARTHING SYSTEM Earthing system shall consist of earth grids and electrodes buried in soil in the plant area, embedded in concrete inside the buildings to which all the electrical equipment, metallic structures are connected to have earth continuity for safety reasons. Earthing system shall be in strict accordance with IS:3043 and Indian Electricity Rules/Acts.
17.1 17.1.1
Design Criteria Fault Current & Duration The earthing conductor shall be designed for 50 kA for duration of 1 second.
17.1.2
Conductor Material The earthing system conductors and accessories as proposed are to be as follows : (a) Conductors above ground level : Galvanised steel and in trenches Conductors buried in ground or : Mild Steel embedded in concrete Electrodes : GS Pipe / Rod
(b)
(c) (d)
Lightning protection air termination : GS Flat and down conductors for buildings Exposed lightning protection air : Lead coated copper termination on chimney top
(e)
The Contractor shall undertake the soil resistivity measurements at site and select suitable type and cross section of conductors. 17.1.3 Size of Conductors (a) Main Earthing Conductors The earthing conductor sizes shall be calculated as per IS 3043 and shall comply with Indian Electricity rules and IEEE-80.
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The calculated size shall be suitably (depending on the resistivity of soil) increased as per table below to account for the loss of material (steel) due to corrosion in soil. Resistivity of Soil Ohm Metric >0 <10 >10 <25 >25 <50 >50 <75 >75 <100 >100 Reduction in thickness/diameter, mm 8.0 7.0 5.5 4.5 3.0 1.5
The minimum steel corrosion shall be 0.12 mm/year. (b) Rod Electrodes Galvanised steel rod electrodes of suitable diameter (min dia 40mm) and length shall be used as per the recommendation of IS-3043. For test pits electrodes shall be heavy duty type (Class C) GI pipe of suitable diameter with perforations. Electrodes installed in the test pits will have disconnecting facilities. (c) Equipment Earthing Leads The size of the earthing leads shall be decided based on the type of equipment and structure to be earthed and shall be provided generally as per IS-3043. However the min. size of the of equipment earthing lead shall be 65x10 mm GS flat. (d) Conductors for lightning protection system The size of conductors for lightning protection system shall be decided based on mechanical strength. 17.2 17.2.1 Earthing System Layout The earthing system design and installation shall generally comply with IS-3043, IEEE-80 and Indian Electricity Rules. General (a) Metallic frames of all current carrying equipment, supporting structures adjacent to current carrying conductors, lightning
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SPEC. NO. TCE.5960A-H-500-001
protection system conductors and neutral points of various systems shall be connected to a single earthing system. Two earthing leads shall be used if rated voltage of equipment is above 250V. If the rated voltage is 250V or below, one earth lead shall be provided. Metallic structures adjacent to electrical equipment shall be earthed by one earthing lead. Crane rails, tracks, metal pipes and conduits shall also be effectively earthed at two points. Steel RCC columns, metallic stairs, and rails etc. of the building housing electrical equipment shall be connected to the nearby earthing grid conductor by one earthing ensured by bonding the different sections of hand rails and metallic stairs. Metallic sheaths/screens, and armour of multi-core cables shall be earthed at both ends. Metallic Sheaths and armour of single core cables shall be earthed at switchgear end only unless otherwise instructed by the Owner. Every alternate post of the switchyard fence shall be connected to earthing grid by one GS flat and gates by flexible lead to the earthed post. Portable tools, appliances and welding equipment shall be earthed by flexible insulated cable (b) Earthing conductors in outdoor areas shall be installed at a minimum depth of 600 mm. All cable trays in the plant buildings as well as inside the trenches shall be connected to earth grid at an interval of about 10 m. Each side of the generator neutral earthing resistor shall be terminated at two nos. treated pipe earth electrodes. The earth pipe electrodes shall be further interconnected to the buried earth grid. Neutral of the auxiliary transformers shall be directly connected to two nos. treated pipe earth electrodes. The earth pipe electrodes shall be further interconnected to the buried earth grid.
(c)
(d)
(e)
17.2.3
Earthing Conductor Layout in Switchyard (a) Main earthing conductors shall be laid in the form of a grid. Spacing between conductors, number of parallel conductors, etc., shall be decided such that step and touch potential are within safe limits.
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(b)
The maximum permissible step and touch potentials shall be calculated in accordance with the formula, given in IEEE-80. Earthing conductors shall be provided around the outside edge of fence at a distance of approximately 6000 mm. This shall be connected to the switchyard earthing grid. An earthing mat comprising closely spaced (about 150 mm) conductors shall be provided below the operating handles of disconnecting switches and breaker operating kiosk for the additional safety of the operating personnel. Each earth leads of transformer neutral, lightning arrester earth leads, CVTs earth leads shall be directly connected to two separate electrodes, with treated earth pits. Lightning protection down conductor shall be directly connected to a separate earth electrode. All earth electrodes in turn shall be connected to station earthing system. The earth grids of different areas of the plant shall be interconnected through separate conductors & with 2 Nos. test pits, test pits to enable measurement of earth resistance for each area separately. Earthing grid design shall be done in such a manner that the grid resistance is less than 0.5 ohm.
(c)
(d)
(e)
(f)
17.2.4
Earthing Conductors Inside Building (a) Main earthing conductors shall be buried in earth around the building. Minimum two taps-off from this earthing loop shall be taken inside the building and connected to the earthing grid embedded in the floor slab with approximately 50 mm concrete cover. In case, the building has more than one floor, each floor shall be provided with earth grid. Floor earthing grids shall be interconnected. Each RCC / Steel column of the building shall be interconnected to the floor earthing grid in the ground floor. Cable trays, steel pipes / conduits, steel columns, etc., shall not be used as earth continuity conductors.
(b)
(c)
(d)
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(e)
Instrumentation system and computer system shall be provided with a dedicated earthing system suitable for the equipment and shall confirm to DCS manufacturers specification. Earthing grids of all the buildings, outdoor yards shall be interconnected to form a single grid for the plant. Earthing grid design shall be done in such a manner that the grid resistance is less than 0.5 ohm.
(f)
(g)
17.3 17.3.1
Earthing System Installation The spacing between two electrodes shall be atleast equivalent to twice the length of the electrode. Earthing conductor running exposed on column, walls, etc., shall be supported by suitable cleating, at intervals of 750 mm. The earthing conductor crossing the road / track shall be laid in hume pipe or laid at a greater depth to avoid damage. When earth conductor passes through floors, walls, etc., suitable pipe sleeves shall be provided and the same shall sealed after installation. The connection between earthing pads / terminal to the earth grid shall be made short and direct and shall be free from kinks & splices. Metallic conduits and pipes shall not be used as earth continuity conductor. Street lightning poles, flood light poles & towers, their junction boxes shall be connected to the earthing conductor to be run along with supply cable. This earth conductor shall be in turn connected to earth grid at two extreme points. Flexible earth conductors shall be provided at expansion joints for earthing the gates, operating handles, etc. Equipment bolted connection after being checked and tested shall be painted with anti-corrosive paint / compound. Connection between the equipment earth lead and the grid conductor shall be welded. For rust protection, the welds shall be treated with zinc chromate primer and coated with zinc rich paint.
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17.3.2
17.3.3
17.3.4
17.3.5
17.3.6
17.3.7
17.3.8
17.3.9
17.3.10
TCE FORM NO. 329 R5
SECTION:
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SHEET 6 OF 7
SPEC. NO. TCE.5960A-H-500-001
17.3.11
The cable sheaths, screens armour shall be earthed at both ends for multi-core cables. For single core cables the same shall be done at one end (switchgear end) only. All bimetallic connections shall be treated with suitable compound to prevent moisture ingression. Alternate switchyard fence posts shall be connected to the earth grid. Contractor shall demonstrate the effectiveness of earthing system by measurement of earth resistance, step and touch potential at different location. Lightning Protection System Lightning protection system shall consist of vertical air termination rods, horizontal roof conductors, down comers, test links and pipe electrodes.
17.3.12
17.3.13 17.3.14
17.4
17.4.1
Need for Protection The need for providing the lightning protection system shall be established by calculating risk index value for each building structure, etc., as per procedure given in IS-2309 and any building whose over all risk factor is more than 10-5 (as per IS-2309), shall be provided with lightning protection.
17.4.2
Lightning Protection System Layout (a) The lightning systems design and installation shall generally comply with IS: 2309 code of practice for the protection of building and allied structure against lightning. For stack air termination, rods interconnected by circumferential conductors will be provided at the apex of flue and also upon outer shell of the stack. The air termination system will be formed by lead coated copper conductors to prevent corrosion of conductors due to flue gas. For cooling towers, air termination system will comprise of horizontal circumferential conductors at the top. Lightning masts shall be provided for switchyard. Calculation for sizing, no. of lightning mast etc shall be furnished for approval of Owner. Shield wire shall be provided between gantry support & Power house building wall over phase conductors and shielding
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network shall be connected to switchyard earth mat. For switchyard down conductors from the shield wires shall be run along the tower and connected to rod / electrode. The zone of coverage for the shield wires and 450 on end conductor shall be considered as 600 between two conductors. (e) Down conductors shall be as short and straight as practicable and shall follow a direct path to earth electrode. All joints in the down conductors shall be welded type. Each down conductor shall be connected to a rod electrode which in turn shall be connected to the station earthing system through test links.
17.4.3
Lightning Protection System Installation (a) Conductors of lightning protection system shall not be connected with conductors of safety earthing system above ground level. The down conductors shall be welded to steel structures at 1000 mm interval or cleated to wall at 750 mm interval. Wherever welded, the weld locations shall be treated to provide rust protection. Each down conductor shall be provided with a test link at a height of about 1000 mm above ground level. All the metallic structures within a vicinity of 2000 mm shall be connected to the lightning protection conductors.
(b)
(c)
(d)
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SPEC. NO. TCE.5960A-H-500-001
18.0 18.1 18.1.1
COMMUNICATION SYSTEM Intrasite Communication System Intercom Telephone System (EPABX System) (a) Micro-processor based, fully integrated, modular construction type, modularly expandable digital electronics EPABX system with capacity of 600 ports extendable to 800 ports shall be supplied. The system shall be based on Pulse Code Modulation (PCM)/Time Division Multiplexing (TDM), fully non-blocking principle. The state of the art technology shall be used for designing the system. The system shall be equipped with necessary electronic cards for trunk lines and extension lines, housed in a weatherproof enclosure, suitable for mounting in a non-air-conditioned area. This EPABX shall be hooked to P&T system by 40 tie lines, which shall include 20 direct lines. These direct lines will be for the use of management cadre & control room staff for direct communication with P&T subscriber without operator intervention. The cable from P&T exchange to power plant EPBAX shall be included in the contractors scope. Additionally two cables of 50 pairs each shall be laid from the plant EPABX system to the colony utility building as mentioned in the section C2. These cables shall be laid in the suitable conduits. The entire job shall be the scope of Bidder. The quantity of the trunk cards and extension cards shall be selected in such a way so as to provide 10% spare capacity. Electronic cards with intelligent processors shall be provided. The system shall have compatibility for analogue telephone instruments, digital (key) telephone instruments, and the special feature telephones. The system shall be supplied with the operator console as an in-built feature. Operator console shall be equipped with a PC with tracking provision for all calls, call times etc. and PC shall have provision to come over office automation LAN. One spare port for operator console shall be provided. The system shall have 100% non-blocking feature. Redundancy for control and processor card shall be provided. The system shall be 100% fault tolerant. It should have computer (PC) compatibility for data transmission.
(b)
(c)
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(d)
The EPABX system shall have connectivity (hardware, software and any / all other accessories) for Integrated Digital Network (ISDN), Dual Tone Multi-Frequency (DTMF) Connectivity, Computer (Local Area Network) LAN & Wide Area Network (WAN), FAX as well as connectivity to Wireless System specified in this section. The system shall be so interconnected that it shall be possible to access any of the systems (Intercom/ Wireless) from any other system without human intervention in any way. EPABX system shall be provided with the following: (i) One (1) 48V DC High Discharge Plante Lead Acid battery of adequate AH capacity with 10% margin suitable for twelve (12) hours uninterrupted service of exchange working at 100% capacity including its allied systems. One (1) float-cum-boost charger of suitable capacity to supply power to the exchange. The battery charger shall be suitable for the High Discharge Plante Lead Acid battery specified above. One (1) operator console. Required number of telephone instruments. Two (2) dial testers for DC pulsing and DTMF telephone instruments. Three (3) line man hand held telephone sets with DC pulsing and DTMF switchable with built in ringer unit and crocodile clip.
(e)
(ii)
(iii) (iv) (v)
(vi)
(f)
Call Billing software shall be provided with dedicated personal computer with SVGA colour monitor, dedicated printer. Using this software, it shall be possible to read from screen/obtain a print out of calls made, called station, pager/wireless set with number called, date of each call, duration of each call, number of metered calls, extension/wireless/fax set from which call was made, time at which each call was made. Besides the above, the EPABX shall be provided with two Combo drives with provision and facility including software to store/retrieve all the above parameters to/from a disk. The call billing software shall
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also have facility for printing all / selected parameters listed above at regular (site adjustable) time intervals as well as facility to browse on screen/print any of the above parameters in any desired format eg. Number of calls made from a particular extension for a given period of time (selectable). Software lock shall be provided to prevent unauthorised personnel gaining entry to above. All above parameters shall be capable of being stored automatically for a minimum period of 3 months. Erasure of this information shall only be after adequate warning alerting operator to take back up. None of the stored data shall be lost for failure of power supply. (g) EPABX shall have full self-diagnostic feature. All faults, besides being annunciated by high intensity LED on the EPABX and audio alarm, shall be displayed on the PC with component level fault being displayed in English. The EPABX shall be provided with 120% capacity main power supply unit with 100% standby power supply unit. On failure of main unit, standby unit shall automatically cut-in. Annunciation (audio and visual) shall be provided for each power supply unit fail and also auto-changeover fail. Changeover time shall not affect the EPABX/its allied systems in any way. The EPABX system shall be capable to accommodate the EPABX system of the colony (which is not in scope of Bidder). It shall have provision of 100 lines for interfacing with colony. The Bidder shall provide all the telephone instruments in the plant areas at each working areas. The locations shall be decided during detailed engineering. But the Bidder shall supply at least 200 telephone instruments. Telephone Instruments (i) The telephone instruments shall be indoor desk type or indoor wall mounted type or outdoor wall mounted type as required. The type of handset shall be selected based on its location. All desk type instruments for all subscribers shall have keypad with push buttons.
(h)
(i)
(j)
(k)
(ii)
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(iii)
The instruments mounted outdoor shall be provided with weather proof type enclosure. Selected instruments shall be provided with additional features to meet the special facility requirements as mentioned below. Telephone instruments located in high ambient noise level area shall be provided with loud ringing device and sound proof booths.
(iv)
(v)
(l)
The following special features shall be provided on selected instruments: (i) Call interruption / priority the handsets shall be provided with a priority push button. After dialling from this handset station, if engaged tone is received, the caller can cut into the conversation by pressing the priority service button. Emergency alert Dialling a number shall intimate a fire or emergency alarm. The callers number shall be stored to reduce / prevent the incidence of mischievous calls. Automatic call back This shall enable the selected subscribers, who receive a busy tone when calling another extension to come on the busy extension. The call back equipment shall make the connection as soon as the called extension is free. While waiting for the call back, calling party can use his telephone for other calls as usual. Automatic call diversion - This feature shall re-route a call for an extension (A) to extension (B). This arrangement shall function for all calls till it is reset. Conference call - This shall enable the subscribers to set up telephonic conference involving atleast 5 parties.
(ii)
(iii)
(iv)
(v)
(m)
18.1.2
Cell phones with group arrangement to be provided.
Landline Telephones, Broadband connectivity
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a) Necessary number of ISDN / PSTN landlines would be provided at
strategic locations within the plant boundary. Broadband connectivity would be provided at strategic locations for online access of data from remote station.
18.1.3
Walkie Talkie( Wireless system)
18.1.3.1 This system shall include the following: (a) Base stations with antennae, power supply units, inverters, voltage stabilisers and all other accessories. Twenty (20) Nos. hand held two way transmitter receiver sets. Battery charger for hand-set batteries 20 Nos. The system shall be capable of being coupled with the EPABX and PA systems such that any wireless set can be contacted from any of the EPABX-intercom extensions or PA system and from the DTMF keypad of the portable radios it should be possible to contact any of the EPABX intercom number through the EPABX. The wireless sets shall be addressable type and light weight. The system shall have a minimum operating range of 15 kms between one base station to another base station. Range from base station to handset is about 8 kms. Handset to handset is about 3 kms. The power supply to the entire base stations shall be through the UPS, to allow the radio communications during Black Out conditions also. The exact details of requirements, installation design and specifications shall be worked out during detailed engineering. But the contractor shall consider the modern communications system with above specifications for the purpose of bidding.
(b) (c) (d)
(e) (f)
(g)
(h)
18.1.3.2
GPRS/CDMA mobile system of any reputed service provider can be provided for wireless system. The mobile system coverage in the power plant area should be 100%. The mobile system shall be interfaced with plant EPBX and PA systems.
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18.1.4
Cables The type of cables and their technical particulars shall be as per the requirement of the system for giving best performance.
18.1.5
Tests All the equipment covered in this specification shall be subjected to routine tests as per relevant standards. Type test certificates shall be submitted for review.
18.2 18.2.1
Public Address System General Requirements This specification covers requirements for selection, design, engineering, manufacture, shop testing, type testing, erection and commissioning of Public Address System as described below: (a) The Public Address System shall consist of zones, sub-zones and Exchanges to interface all these zones among them selves. The zones shall also cover all off-site Plant Auxiliary Systems and shall be finalized during detailed engineering, taking into consideration the configuration of the combined cycle plant. All the above-mentioned zones shall be connected with a central exchange to be located in Control room/ Control Equipment Room. The Contractors scope shall also include successful demonstration of performance testing specified herein complete in all respects along with cables, junction boxes, earth wire and accessories like standard brackets, nut-bolts, glands, lugs, conduit sleeves, etc., as required, to complete the proper installation conforming to IS: 1881, IS: 1882 of all the equipments supplied as covered in this specification. All equipment, accessories and facilities required for completeness of this system shall be furnished by the Contractor, whether these are specifically mentioned herein or not.
(b)
(c)
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(d)
The equipment furnished under this section shall meet the requirements of all-applicable codes and standards as specified or their equivalent international codes and standards. The Public Address System (PAS) offered by the Bidder shall be from reputed manufacturer who should have designed, manufactured, tested and commissioned a distributed amplifier type industrial Public Address systems as specified in power plants or large industrial installation as on the date of bid opening. The system shall be adequately protected from signal and power line noise and meet the Surge Withstand Capability (SWC) requirements of ANSI C37.90.1/ IEEE standard 472-1989 equivalent. The Bidder shall guarantee satisfactory performance of the equipment under stipulated variations of voltage and frequency. The design and manufacture shall be such that equipments/ components of same type and rating shall be interchangeable. In addition to the facilities to be provided by the Bidder as mentioned in relevant clauses of this section the Bidder shall make his own arrangements for any other requirements that are necessary to put the system in service. All the items, including Public Address system erection hardware, cables, cable erection hardware, telephone cables etc. as may be required to make the PA system complete and functional are to be furnished by the Contractor on as required basis.
(e)
(f)
(g)
(h)
(i)
18.2.2
Power supply arrangement The Bidder shall provide power to the Public Address System from UPS system as detailed in Section D3.14 of technical specifications. The details shall be finalized during detailed engineering stage. In case the Bidder's offered equipment is operating at any other voltage level, the Bidder shall provide all required hardware, to make the offered system compatible with specified power supply arrangement. The system shall be fully functional during the total power supply failure of the plant.
18.2.3
System description (a) Communication within a zone

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(i)
PAS shall have two modes, i.e., Paging mode and Party mode. Each of the two modes shall be open line, common talking type. Paging mode shall be used for locating a person and for general instructions. Party mode shall be used for conversation between individuals without broadcasting the same over the loudspeaker. Whenever the 'Press to page' push button is pressed on any of the handset stations, a pleasant chime shall be broadcast over all loudspeakers except the one associated with that handset station to attract attention. Conversation, in paging mode shall be heard over all loudspeakers except the loudspeaker associated with the handset station whose 'Press to Page' push button is being held in pressed condition. When 'Press to Page' push button is released, the associated handset shall return to party mode. When a handset station is being used for party mode, its associated loudspeaker shall be free to receive all paging calls. However, the operator shall have the option of silencing the associated loudspeaker by pressing "Loudspeaker mute' push button, should he find it disturbing his conversation on party mode. The loudspeaker shall return to normal operation automatically when the 'loudspeaker mute' push button is released. Simultaneous operation on both modes, i.e. some handsets on party channel and some handsets on paging channel, shall be possible without any crosswalk between the two channels. During conversation on 'page' mode within a zone, the centralized equipment/hardware of the associated zone shall have the feature to monitor and identify the handset from where conversation is being continued with the 'page' button depressed and the access code of the person. Further, suitable indication of 'Power Supply on' and 'Party channel busy' shall be provided on hand set stations. Portable type handsets with Multipin plugs shall be used at certain locations where operational personnel are not present normally. Necessary sockets, wiring, etc., shall be provided at these locations. The locations (distributed in each zone) etc. shall be finalized during detailed engineering. Unless requested, announcements/ communication within a zone shall not be audible in other zones.
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(ii)
(iii)
(iv)
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(b)
Inter Zone Communication (i) Each of the zones shall be connected to a Central exchange to be located in Central Control room/ Control Equipment Room. All the communication facilities like paging and party mode communication as described above between these two zones shall be possible as if they have now become a single zone. The Central Exchange shall have one master control unit for each of the modules and one more master control unit for Shift In charge Room. All the master control units shall be connected in parallel. Any inter-zone communication shall be possible through this master control unit. The exact type of the same shall be decided during detailed engineering. Further, it shall be possible to broadcast recorded speech, music etc. over the loudspeakers. Communication/ announcements within a zone shall not be heard in loudspeakers of other zones. It shall be possible to communicate from a station in one zone to another station in other zone through the master control unit(s) only. It shall be possible from a station in one zone to communicate with another station in a different zone, both in party/ page mode through the master control units located on each module control desk at Control room and Shift Incharge Room. Suitable built-in interface shall be provided for connection with Owner's main telephone exchange in the Central Exchange and/or Master Control Units through which it shall be possible to communicate with any station in any zone from any telephone set through Central Exchange and/or Master Control Unit.
(ii)
(iii)
(iv)
(v)
18.2.4
Handset Stations (a) Handset stations shall be of the following types: (i) (ii) Outdoor Wall/ column mounting type.(Type - A) Indoor desk-top mounting type. (Type - B)
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(iii) (iv) (b)
Indoor control desk flush mounting type. (Type - C) Mosaic grid compatible telephone set. (Type - D)
Each handset station shall have following: (i) (ii) (iii) (iv) (v) (vi) (vii) One (1) - telephone handset. One (1) - Cradle switch for resetting the handset. One (1) - "Press to Page" push button. One (1) -"Press to Mute Loudspeaker" push button. Pre-amplifier and Power amplifier. Indication for 'POWER SUPPLY ON'. Indication for 'PARTY CHANNEL BUSY'.
(c)
The outdoor wall/ column mounting type handset stations shall be dust-tight and weather-proof, with appropriate protection against direct rain, ingress of dust and moisture conforming to IP-55 degree of protection as per IS: 2147. The indoor desk-top mounting type handset stations shall have a degree of protection of at least IP-32. The outdoor wall/ column mounting type handset stations shall have covers with padlocking facility. All handset stations and their components shall be capable of continued satisfactory operation at an ambient temperature at 55C. The control-desk mounting type handset stations shall be suitable for flush mounting on Unit Control desk. Handset transmitter/ microphone shall be noise canceling type and all switches and push buttons provided on the handset station shall be of encapsulated contact type. Handset transmitter/microphone shall have filters to protect from dust. Each handset shall be provided with one meter (extended) retractable coiled type of cable. All handset stations shall have a compact, robust, rust resistant, shock-resistant body made of high impact polystyrene or
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(d)
(e)
(f)
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equivalent. The Type-A handset shall be inside an enclosure with transparent glass door, which can be opened through number padlock only. (g) The wall/column mounting handset stations shall be tamper-proof, using internal anchoring bolts and peculiar (e.g. triangular head, counter-sunk) screws which can be loosened only with special keys. Constructions where the entire electronic part shall be modular type and can be removed from the handset station enclosure for easy maintenance. Terminal connections of different PCBs should not be interchangeable. The handset stations in the noisy areas like Turbine Hall, BFPs, etc., shall be housed in Acoustic hoods. An industrial type free standing, floor mounted hood shall be used for providing the above requirements. The design noise level within the hood shall be limited to a maximum of 60 dB SIL.
(h)
18.2.5
Amplifiers (a) Amplifiers shall be solid state, class-B, Push-pull type, in built with the handset fully conforming to IS: 1301 & IS: 10426 or equivalent international standard. Amplifiers shall have 0-100% volume control setting. with facility for coarse and fine setting along with following controls which shall be located inside the Handset Station. (i) (ii) (iii) (iv) Input sensitivity control Receiver volume control Bass cut filter Anti side tone control feature
(b)
18.2.6
Loudspeakers (a) Indoor loudspeakers shall be cone type housed in sturdy metal cabinet suitable for wall/ column mounting. The cabinet shall be
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treated with acoustic under-coats to prevent resonance. They shall have IP-52 degree of protection as per IS: 2147. (b) Outdoor loudspeakers shall be industrial horn type and of pressure die cast aluminum construction. The mounting bracket shall be with adjustable base suitable for vertical and horizontal orientation. They shall have IP-55 degree of protection as per IS: 2147.
18.2.7
Central exchange & master control unit (a) Central exchange shall be wide band microprocessor based having associated circuitry for calling station identification and of modular design. This exchange shall consist of all the necessary control hardware, required for operation, monitoring, protection, indication, switching, testing, measurement of all the voltages and load conditions of the entire system, facility for checking of the operation of all the stations and quality of speech from the master control units etc. All the card etc. shall be plug in type. Solderless termination shall be provided for every wiring. Systems bandwidth shall be at least 200-10 kHz (10 dB) and shall not alter frequency response of the open line system. All the central exchange shall be enclosed in a freestanding cabinet to be located in control equipment room all the cable entries shall be from bottom only. This shall be able to cater all the specified zones along with the ability to interconnect at least ten (10) more zones for future expansion. Suitable hardware for communication between any handset of the Public Address System with Owner's Telephone Exchange shall be provided. All the handsets shall have the necessary arrangement for using it as a intercom telephone instrument. It shall be possible to call to any of the intercom number from any handset. Also, it shall be possible to announce any message from any intercom phone and then communicate with the handset selected by field user on party line. Further, all the programming tools that will be required to program/reprogram the system shall also be provided. Master Control Units shall be microprocessor based and of modular design. These units shall be mosaic grid compatible flush mountable type along with flexible goose neck type microphone, luminous miniature push buttons for inter-zone communications, alarm tone generation, fire alarm tone generation etc.
(b)
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18.2.8
Cables and junction boxes The Contractor shall supply the cables required for PA system on as required basis. The cables shall be of FRLS type. Colour of the outer sheath shall be YELLOW. Sizes and details of cables are given below : a. Mains cable : Multicore of minimum 1.5mm cross-section Copper conductor cable armoured with atleast two spare cores. : Multicore multistrand with at least two spare cores, twisted pair, minimum 0.5 mm cross section annealed copper (shielded and armoured) : Multicore multistrand with at least two spare cores, twisted pair, minimum 0.5 mm cross section annealed copper (shielded and armoured)
b.
Signal cable
c.
Loud Speaker cable
18.2.9
Junction boxes The junction boxes shall be supplied on as required basis.
18.2.10
Technical particulars Public Address Systems shall conform to the following technical parameters. (i) Overall Installation Band width ( 3 db) (ii) Amplifiers (a) (b) Band width ( 3 db) THD 200-10000 Hz not more than 1 % at 1 kHZ at rated output 60 dB 400-6000 Hz
(c)
Signal to Noise Ratio
(iii) Microphones
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(a) (b)
Band width (3 db) Type
200-7000 Hz Noise canceling type
(iv) Loudspeakers (a) Outdoor wall/column mounted Horn Type Capacity Bandwidth( 3 db) Indoor wall/column mounted Cone Type Capacity Bandwidth ( 3 dB) 4W (RMS) 200-7000 Hz 15W (RMS) 200-7000 Hz
(i) (ii) (b)
(i) (ii)
18.2.11
The quantities for PA system mentioned below are minimum required and will be finalised at the time of detailed engineering. ----------------------------------------------------------------------------------------------S.No Item Description PAS For Common Plant (for each module)
-------------------------------------------------------------------------------------------------1. Handset Stations (i) (ii) Outdoor wall/column 30 mounting type - (nos.) Indoor desktop mounting type with extension amplifier, (nos.) Indoor control desk 2 mounting type with extension amplifier.- (nos.) 10 3
(iii)
2.
Loudspeakers (i) Outdoor Industrial Horn type - (nos.) 30 10
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(ii)
Indoor wall mounted Cone type- (nos.) 2
3.
Mosaic grid compatible telephone set Portable handset stations with multi-pin plug and sockets (i) (ii) Sockets-(nos.) Portable handset stations with plug (nos.)
4.
10 2
5.
Cables (i) (ii) (iii) Mains cable - (km)- As required Signal cable - (km) As required Loudspeaker Cable-(km), for interconnection of loud speaker with handset station. only. As required
6. 7. 8.
G.I. earthling wire-(km) As required Junction boxes As required G.I. Rigid conduit on as required As Required (Sizes to suit the cable) Acoustic hood (nos.) Master Control Unit 8 1
9. 10.
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1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS FIRE DETECTION AND ALARM SYSTEM
19.0 19.1
FIRE DETECTION AND ALARM SYSTEM Fire Detection and alarm system shall be redundant Microprocessor based intelligent, analogue addressable type. Fire detection and alarm system comprising automatic fire detectors, manual call points, fire alarm panel, fire warning siren, cables, junction boxes, any other items to complete the system shall be provided for the power plant. The equipment/system supplied shall comply with the standards listed below: IS - 2189 NFPA - 72E IS - 2175 The system shall be approved by any or all the following bodies besides Tariff Advisory Committee (TAC) and Local Fire Authorities, National Fire Protection Association (NFPA), Underwriters Laboratory (UL), Fire Officers Committee (FOC), Factory Mutual (FM), Central Mining Research Institute (CMRI), Dhanbad. Fire alarm system shall be designed to provide continuous surveillance against fire in the areas covered by the system under all conditions. Fire detectors shall discriminate between false and real fire. It shall have automatic calibrating features by decreasing/ increasing sensitivity levels. It shall give a pre-alarm when it requires maintenance. The type of detectors to be provided in the various areas of the plant shall be as indicated below: Area GTG / STG Building Switchgear room, Battery charger room Control & electronic Cubicle rooms Battery room Type of Detector Manual call points (MCP) & UV detectors Multi sensor detector & MCPs
19.2
19.2.1 19.2.2 19.2.3 19.3
19.4
19.5
Rate of rise of temperature detector with fixed temperature element (corrosion proof) and MCPs
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Below false floor of Control room Above false ceiling of Control room Cable galleries
Photoelectric smoke detector and linear heat sensor cables Multi sensor detectors
Photoelectric smoke detectors and liner heat Sensing cables
Fuel gas pump house Flame proof type MCPs Transformer yard & switchyard 19.6 Pedestal mounted MCPs
Rate of Rise of Temperature Detector with Fixed Temp. Element These shall be resettable type i.e., the same detector shall be capable of being reset after it goes to the alarm state.
19.7 19.7.1
Multi Sensor Detectors This detector shall be capable of detecting a fire both in its incipient or smouldering stages as well as visible flames. To meet this requirement the detector shall respond to visible combustion products in the form of smoke as well as in visible particles, aerosols and pyrolysis products from a clear burning fire. Optical Smoke Detectors Optical smoke detectors shall work on light scattering principle.
19.8
19.9 19.9.1
Linear Heat Detection System (LHS) Linear heat detection system shall be provided in area below false floor & in cable galleries. Linear heat detection system shall essentially comprise sensor cables, interface units and necessary hardwares required for installation. The Sensor cable shall be Optical fibre LHS cables.
19.9.2
19.9.3
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D3.19
19.9.4
Linear heat sensor cables shall be run on all the trays below the false floor of the control room. The sensor cables in cable vault end shall be supported from ceiling to cover the top most tray and from underside of the cable trays for bottom tiers. The quantity of fire detectors and call points to be installed in each of the areas shall be based on an average coverage area mentioned below. The zones of individual detectors shall overlap and no blind zone shall be left. However, the actual quantity of detectors required, taking into consideration the obstruction due to floor beams, etc., so as to obtain complete coverage, shall be worked out by the Contractor based on the final drawings of the various buildings during detailed engineering. 35 to 40 sq.m per smoke detector for general application areas considering an average room height of 5.5m. 15 to 20 sq.m per detector for I&C panel room, control room, relay room, etc., in view of value concentration. Each detector shall be provided with an indicating lamp glowing steadily to indicate that it has operated which will otherwise flash intermittently to indicate the healthy condition of the detector and sensing circuits. When the detectors are mounted below the false floor or in inaccessible position, response indicator for each of the detectors and test switch shall be mounted on a separate box, which shall be suitable for mounting on the wall. If the detectors are mounted above the false ceiling, response indicators with test switch shall be mounted directly below the detector (on the false roof). Manual call points shall be provided as per the guidelines listed in NFPA 72E/IS 2189. Also, they shall generally be located near all the entrances/exists for all buildings. Contractor shall prepare layout drawings indicating the locations of detectors, manual call points duly taking into account the regulations of local fire authorities and submit for Owners approval. Main Fire Alarm Panel Fire alarm system shall be redundant Microprocessor based intelligent, analogue addressable type, shall be complete with annunciator (with windows) provided with necessary input modules, output modules, external hooter/lamp control, interface units wherever required for various control functions through relay contacts & communication
ISSUE R0
299
19.10
19.10.1
19.10.2
19.11
19.12
19.13
19.14
19.15 19.15.1
TCE FORM NO. 329 R5
SECTION:
D3.19
modules, etc. for satisfactory operation of the system. The panel shall be located in the control room. Necessary interface shall be provided between the fire alarm panel and plant DCS for monitoring the system. A dedicated operator station shall provide in the Main control room. The paint shade of panel shall be shade Opaline green (External) and semi glossy white (Internal). 19.15.2 The main fire alarm panel will continuously monitor the status of the detectors and the connecting lines. The annunciation system shall have visual and audible alarms, with acknowledge, test, reset, lamp test, etc. push buttons. The panel shall have 'ON / OFF' PBs for operation of fire siren. Main fire alarm panel shall be provided with necessary contacts for performing the following functions. (a) Tripping of the air conditioning and ventilation system in the - GTG hall, STG hall, switchgear room, Relay room - Control room, I&C panel room, battery room&any other area which is air conditioned /forced ventilated of the affected area. (b) 19.15.4 Contacts for initiating fire protection system.
19.15.3
Necessary grouping of the detectors/call points to actuate the above shall be done by the contractor and the same shall be subject to Owners approval. High discharge plante Lead Acid batteries and battery chargers adequate capacity shall be provided. The battery shall supply the normal power requirements for a period of 48 hours from the instant of charger AC supply failure, after which sufficient capacity would still be available to provide full load operation for atleast 30 minutes. Full load being defined as the load of all hooters sounding simultaneously along with operation of all the associated visual signals, interlocks etc. The detectors proposed to be provided for 400kV switchyard area shall be connected to an independent fire alarm panel (with battery back-up) located in Switchyard control room. This panel shall be suitably interfaced with the main fire alarm panel in power plant control room. All the constructional/functional features of this panel shall be same as the main fire alarm panel.
19.15.5
19.15.6
ISSUE R0
300
TCE FORM NO. 329 R5
SECTION:
D3.19
19.15.7
19.15.8
Visual alarm shall be povided in all the Control rooms, Electronic cubicle room, Canteen, offices, conference halls and any other place where the sound of the fire siren is not audible. Suitable size & number of the sirens shall be used so that is audible in all the direction & parts of the station. All the fire alarm panels in the plant shall be of the same make.
19.15.9
19.15.10 The main fire alarm panel in the control room shall communicate with all the fire alarm provided in the Gas / Steam Turbine area & in any other if any. 19.16 Repeater Panel All annunciation / indications in the main fire alarm panel shall be repeated in the repeater panel to be supplied by Contractor. This shall include the annunciations/indications of fire alarm panel located in switchyard control building. The repeater panel shall be located in the fire station. The cabling upto the repeater panel is included in the Contractors scope. The paint shade of panel shall be shade Opaline Green (External) and semi glossy white (Internal). 19.17 Junction Boxes (JB) Junction boxes required for indoor and outdoor installations shall be 2 mm thick sheet steel and shall be hot dip galvanised. Degree of protection shall be IP-65. 19.18 19.18.1 19.19 19.19.1 Cabling The cables shall conform to specification indicated in Section D3.15 Tests Contractor shall furnish test certificates/approval certificates for the equipment/ system offered from the Regulatory bodies indicated in the specification after the award of contract for Owners approval. Performance tests shall be conducted at site on the system to prove that the guarantees indicated for the individual components shall completely satisfy all specific requirements. All tests required by the relevant standards shall be conducted.
19.19.2
ISSUE R0
301
TCE FORM NO. 329 R5
1X700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - MOTORS
SPEC. NO. TCE.5960A-H-500-001
20.0 20.1
AC Motors The motor and its accessories shall generally comply with the requirements specified in the national and international standards indicated in Data sheetA3.20. Also Motors shall additionally comply with the specific requirements of data sheet A3.20 and specific requirements indicated below: All HT motors shall be suitable for 6.6 kV, 3 phase, 50 Hz and LV motors shall be suitable for 400 V, 3 Phase, 50 Hz power supply. The supply voltage and frequency variation for 6.6 kV & 400 V shall be 10% and +3/-5% respectively. The combined voltage and frequency variation shall be of 10%. The motors rated 175 kW and above shall be 6.6kV and motors rated upto 175 kW shall be 400 V. All LT motors shall be energy efficient. Motors shall be continuously rated (S1). However, crane motors shall be rated for S4 duty, 40% cyclic duration factor. Motors shall be capable of starting and accelerating the load with the applicable method of starting without exceeding acceptable winding temperatures when supply voltage is 80% of the rated voltage for HT motors and 85% for LV motors. HT motors shall also be capable of satisfactory operation at full load at a supply voltage of 80% of the rated voltage for 5 min. commencing from hot condition. The motors shall be suitable for starting at 110% of the rated voltage. Motors shall be capable of developing the rated full load torque even if the supply voltage drops to 70% of the rated voltage. If such operation is envisaged for a period of one second, the pull out torque of the motor shall be atleast 205% of full load torque. Motors shall withstand for 1 second the voltage and torque stresses developed due to the vector difference between the motor residual voltage and the incoming supply voltage equal to 150% of the rated voltage during fast change over of buses. Locked rotor current of motors rated 1500 kW and below shall be limited to 600% inclusive of 20% tolerance of the full load current of the motors and motor rated above 1500 kW shall be limited to 450% (inclusive of 20% tolerance) of full load current of the motor. The locked rotor withstand time under hot condition at 110% rated voltage shall be more than the starting time at minimum permissible voltage specified above by atleast three seconds or 15% of the accelerating time whichever is greater. Provision of speed switch shall be avoided to the extent possible.
20.1.1
20.1.2
20.1.3
20.1.4
20.1.5
20.1.6
ISSUE R0
302
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
20.1.7
The degree of protection for the motor enclosure shall be IP-55 and IP-54 for outdoor & indoor respectively and outdoor and indoor cable boxes shall be provided with IP-55 and IP-54 respectively. All HT motors shall be provided with vibration pads (in both X & Y directions and at both DE & NDE) for mounting vibration detectors. Requirements of vibration monitoring system shall be as specified in relevant I&C section of specification. Motors rated 1000 kW and above shall be provided with differential protection. These motors shall be provided with star connected stator windings. The 3 nos. current transformers, one for each phase shall be mounted in a separate compartment in the neutral side terminal box. The three phases shall be connected to form the star point after they pass through the CTs. The CTs shall be of relay accuracy and the CT characteristics shall be compatible with the differential relay. The additional 3 nos. CTs of identical characteristics shall be provided in the 6.6 kV switchgear panel. 6.6kV & 400V motors wherever their protection is through the numerical relay then energy meter reading shall be taken through relay itself by communicating with it.
20.1.8
20.1.9
20.1.10
The ring oiling system shall be adequate for starting and continuous operation of the motor for atleast one half hour without pressure oiling system in operation. For 6.6 kV motors, 6 nos. duplex RTDs for winding shall be provided. Each bearing shall be provided with duplex thermocouple for bearing temperature monitoring. These motors shall be designed to withstand atleast 2% unbalance in supply voltage. In addition to temperature monitoring & alarms in DCS local temperature indicators shall be provided for motor bearings. Motor bearing shall not be subjected to external thrust loads. The maximum double amplitude vibrations for motors upto 1500 rpm shall be 25 microns and 15 microns upto 3000 rpm. For 400 V motors, maximum double amplitude vibrations upto 1500 rpm shall be 40 microns and 15 microns upto 3000 rpm. Maximum noise level measured at a distance of 1.5 metre from the outer surface of the motor shall not exceed 85 db(A).
20.1.11
20.1.12
20.1.13
ISSUE R0
303
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
20.1.14
Cable boxes of all 6.6 kV motors shall be provided with quick disconnecting type terminal connectors to facilitate easy disconnection and removal of the motors without requiring unsealing or otherwise disturbing the external cable connections and leaving the phase segregated terminal box intact. Terminal boxes shall have fault withstand capacity equal to at least rated short circuit level of the system voltage for 0.25 sec. The terminal boxes shall be reversible to suit cable entry from bottom or top. Separate terminal boxes to be provided for space heater, RTDs for winding bearings temperature, vibration monitors etc. All terminal boxes shall be provided with two earthing studs for termination of protective earth conductor. Double compression type brass cable glands and crimping type copper lugs shall be provided for termination. The insulation system for 6.6 kV AC motors shall withstand the negative or positive 0.3 / 3.0 microsecond wave (2.7 pu rated peak line to earth operating voltage) switching surges originating from non-effectively earthed power system. All 6.6 kV AC motors shall have BIL of 36 kV (Peak) 1.2 / 50 microsecond wave and shall withstand a power frequency voltage of 14.2 kV (rms) for one minute. Canopy shall be provided for outdoor motors. Variable frequency controller shall be provided for motors requiring speed control. Torque speed characteristics of motor superimposed on torque speed characteristics of drive equipment at 100%, 90% and 80% shall be furnished by the contractor. DC Motors DC motors shall be suitable for the DC system voltage available in the plant. Motor shall be capable of starting and accelerating the load with the applicable method of starting, without exceeding acceptable winding temperatures, when the supply voltage is in the range of 85% to 110% of rated motor voltage.
20.1.15
20.1.16
20.1.17
20.1.18 20.1.19
20.1.20
20.2 20.2.1
20.3 20.3.1
Actuator Motors The actuator motors shall be designed for short time duty (S2) in accordance with IEC 60034-1.
ISSUE R0
304
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
20.3.2 20.3.3
Hand wheel operation shall be provided in addition to motor drive. The DC and AC actuator shall be provided with accessories viz., torque limit switch, end of travel switch, adjustable limit switch, hand wheel motor, thermostat, integral starter, etc. Complete actuator shall be tested at factory as per IS 9334. Two normally open and two normally closed or two changeover potential free contacts corresponding to open and close positions of the valve shall be provided. Open / Close limit switches used for interlock operation shall be of proximity type. Degree of protection for actuator motor enclosure shall be IP-55 and IP-67 for indoor and outdoor respectively. The remote position of the valve along with its status indication with trip shall also be shown in the DCS & local. Remote operation of the valve shall also be possible. All the valves shall be of Integral type with field bus compatible. General Requirements For small rating motors cooling shall be of TEFC type but for higher rating motor TETV, CACA & CACW type cooling shall be considered. All electric motors shall be chosen from the suppliers standard manufacturing program and in accordance with the absorbed load of the driven machine, using the API Recommendation No.610, 617 and 618 for the overrating ratio.
20.3.4
20.3.5
20.3.6
20.3.7 20.3.8 20.4 20.4.1 20.4.2
20.5 20.5.1 20.5.2
Tests Tests on all types of motors shall be conducted as per relevant standard. For 6.6 kV, 400 V motors and DC available for the same rating of the furnished, else it shall be conducted. tests shall be conducted on all 6.6 kV, standards. motors, if type test certificates are motors offered, the same shall be However, all routine and acceptance 400V and DC motors as per relevant
ISSUE R0
305
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
20.5.3
For 6.6 kV AC motors, in addition to all the tests specified above, partial discharge, C & Tan delta and polarisation index test shall be carried out as a routine test on each motor (the minimum value of polarisation index for all motors shall be 2 when determined according to IS : 7816). Noise level measurement test shall be conducted on one motor of each type. Di-electric tests to establish the insulation withstand level of motors as indicated in Clause 20.1.17 shall be performed on a sample coil (identical to those to be used in the motor quoted for) for each type of motor. These tested sample coils shall not be used in the motors to be supplied. List of tests to be conducted The following type tests shall be conducted on each type and rating of HT motor: (a) No load saturation and loss curves upto approximately 115% of rated voltage (b) (c) (d) (e) Measurement of noise at no load. Momentary overload test (subject to test bed constraint). Full load test Temperature rise test at rated conditions. During heat run test, bearing temp., winding temp., core temp., coolant flow and its temp. shall also be measured. In case the temperature rise test is carried at load other than rated load, specific approval for the test method and procedure is required to be obtained. Wherever ETD's are provided, the temperature shall be measured by ETD's also for the record purpose. Surge withstand test on the sample coil after placing it in stator core at (4U + 5 KV) and with at least five impulse of 1.2/50 micro sec. wave, for HV motors only, where U is the line to line voltage in kV. Surge-withstand test at 20 kV with 0.3/3 micro sec. wave on each type of motor coils with at least five such impulses, followed by one minute power frequency high voltage test on turn to turn insulation, after cutting the coil and bringing out the turns suitably. The power frequency test voltage shall be decided during detailed engineering.
20.5.4 20.5.5
20.5.6
(f)
(g)
20.5.7
List of tests for which reports have to be submitted The following type test reports shall be submitted for each type and rating of HT motor
ISSUE R0
306
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
(a)
Degree of protection test for the enclosure followed by IR, HV and no load run test. Terminal box-fault level withstand test for each type of terminal box of HT motors only. Type test report on Elastimold Termination kit as per relevant standard.
(b)
(c )
ISSUE R0
307
TCE FORM NO. 329 R5

DATA SHEET A3.20
SECTION: SHEET
D3.20
7 OF 10
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
1.0 1.1 1.2
AC Motors Type of Motors Supply (a) Rated voltage 6.6 kV for motors above 175 kW & 400V for rating upto 175 kW phases & 3 Phase, 50 Hz Squirrel cage except for cranes
(b)
Number of Frequency
(c)
System Neutral
Medium resistance earthing (6.6kV) / Effectively earthed (400V) Continuous / Intermittent depending on application. DOL For 6.6kV&400V-Class F with temperature limited to Class B
0
1.3
Type of duty (Clause 9.2 of IS:325 or equivalent) Method of starting Class of Insulation
1.4 1.5
1.6 1.7
Ref. Ambient temperature Temperature resistance Location (a) Hazardous area division (IS:5572 or equivalent) rise by winding
C C
50 70 for class-B
1.8
As per classification (for flame proof zone 1) TEFC/TETV/CACA/CACW IP 55 Opaline Green

JOB NO. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR,
KARIMNAGAR DIST.
1.9 1.10 1.11

Type of cooling (IS : 6362) Designation for degree of protection (IS : 4691) Colour shades of paint
R0 JUNE10 PPD. BY CKD.BY DATE RKD HA
TCE FORM NO. 330 R3

308

DATA SHEET A3.20
SECTION: SHEET
D3.20
8 OF 10
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
1.12
Space heaters for motors
Required for motors rated 30 kW and above for 400V motors and for all 6.6 kV motors
2 2.1 2.2
DC Motors Rated voltage Class of insulation

0
V, DC
220 Class F with temperature limited to Class B
2.3 2.4
Temperature rise Method of starting All items indicated above under AC motors are applicable here also except 1.2, 1.4
-doReduced voltage
Motors for Application
Hazardous
Area
3.1 3.2
Type of construction Degree of protection All items indicated above under AC motors are applicable here also.
Flame proof type IP-55
4 4.1 4.2
Valve Actuator & its Motor Application Degree of protection Valves as per requirement IP 55 for Indoor IP 67 for Outdoor As per requirement at the location where it is installed 400V, 3 Phase, 3 Wire
PPD. BY CKD.BY DATE TCE FORM NO. 330 R3
309
4.3
Indoor / Outdoor / Explosion proof
4.4
Power supply
R0 JUNE10 RKD HA JOB NO. 5960A
CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR,

KARIMNAGAR DIST.

DATA SHEET A3.20
SECTION: SHEET
D3.20
9 OF 10
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
4.5 4.6
Actuator type Typical connection applicable diagram
Bidder to decide No drawing is enclosed. Contractor to furnish his proposed scheme. Short time (15 minutes) or twice the valve stroking time whichever is higher As per 400V AC motors
4.7
Type of duty & duty designation for motor
4.8
Supply condition applicable for motor
variation
4.9
Class of insulation for motor
Class of insulation for motor Class F but limited to Class B
5 5.1 5.2
Codes and Standards Induction motors three phase Measurement and evaluation of vibration rotating electrical machines Code of proofing practice for climate IS : 325 IS : 12075
5.3
BS CP 1014
5.4
Degrees of protection provided by enclosures for rotating electrical machinery Classification of hazardous areas for electrical installation Terminal marking electrical machinery for rotating
IS 4691
5.5
IS 5572
5.6
IS 4728
5.7
Designation of methods of cooling for rotating electrical machines Guide

R0 JUNE10
IS 6362
5.8
for
testing
three
phase
RKD HA JOB NO. 5960A
IS 4029
KARIMNAGAR DIST.
PPD. BY CKD.BY DATE
TCE FORM NO. 330 R3

310

DATA SHEET A3.20
SECTION: SHEET
D3.20
10 OF 10
SPEC. NO. TCE.5960A-H-500-001
SL. NO.
DESCRIPTION
UNITS
induction motors 5.9 Dimensions of slide rails for electric motors Designations for types of construction & mounting arrangements of rotating electrical machines Classification of maximum surface temperatures of electrical equipment for use in explosive atmospheres Flame proof enclosure of electrical apparatus IS 2968
5.10
IS 2253
5.11
IS 8239
5.12
IS 2148
R0 JUNE10
PPD. BY CKD.BY DATE
RKD HA
JOB NO. 5960A

KARIMNAGAR DIST.
TCE FORM NO. 330 R3

311
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - ELEVATORS
SPEC. NO. TCE.5960A-H-500-001
21.0 21.1
ELEVATORS One (1) no. passenger lift of capacity 600 kg and speed of 0.75 m/sec shall be provided for proposed Control and Switchgear building. One (1) passenger-cum-goods lift of capacity 1500 kg and speed of 1.0 m/sec shall be provided in HRSG area.
21.2
The lift for control building shall cater to various floors of the control room building. Accordingly, Bidder shall decide the number of landings required and the total rise of the lift for both control building and HRSG area elevators.
21.3 21.3.1
Specific Requirements The capacity of the lift shall be 600 kgs (8 passengers) for passenger lift and 1500 kgs for goods cum passenger lift. Any code, statutory requirements, specific requirements at the place of installation shall be complied with in all respects. An enclosed machine room shall be provided for the control panel of the lift. The A.C motors of the lift shall comply with Section D3.20 of this specification. The car and counter weights shall be suspended by stainless steel wire ropes. Chain shall not be used for suspension. Not less than 4 (four) independent standard steel wire suspension ropes shall be used for car or counter weight and all these ropes shall be in one piece and without intermediate joints. The minimum diameter of the standard rope shall not be less than 12.5 mm and the minimum factor of safety shall not be less than 12. The suspension ropes shall conform to IS: 2365 latest edition "Specification for steel wire suspension ropes for lifts and hoists", or equivalent international standard. Special care and precaution shall be taken regarding handling of lift cable loops between the points of suspension as the loops are prone to twist / distortion.
ISSUE R0
312
21.3.2
21.3.3
21.3.4
21.3.5
21.3.5
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
21.3.6
The car shall be provided with fittings & accessories. Glass shall not be used in the roof except to protect electric light, which is to be fitted with safety glass / plastic transparent cover mounted inside the car. Glass exceeding 930 cm in area shall be of laminated type. The car floor shall be of smooth non-slip surface. The car platform shall be robust in construction and elegant in appearance. If there is any change/changes in the elevations of landing, the same shall be informed to successful Contractor. The successful Contractor shall comply with the changes in the elevation without claiming extra price. The car door shall be of hollow metal construction, 16 gauge thick stainless steel. Sides of the door shall flush with all seams continuously welded. Guide shoes shall be rubber of roller type designed for operation on un-lubricated guides. The car entrance shall be able to withstand the thrust of 35 kg. The entrance shall be securely fitted with car floor and frame in order to become working loose or becoming displaced during the service. The car door shall be provided with locking gear of heavy and robust construction so arranged mechanically and interlocked that the doors cannot under any circumstances be opened unless the lift car is within a particular landing zone. Conversely the lift will not move until all the landing doors are closed and interlocked properly. Car doors & landing doors shall be electrically operated by torque motor. The car doors shall be so designed that their closing and opening is not likely to injure a person, with scratch resistant coating. A retractable safety shoe shall extend to the full height and project beyond the front edge of each car to open the closing door if and when it touches a person or object that is Bidder to provide "Electro-Mechanical Pressure Detection". Besides this Bidder is also to provide "Electronic Door Detector". In the first method, slight body contact pressure is detected by sensors incorporated into door drive mechanisms. Actuation will check and reverse door movement, allowing passengers to pass. The second method will also take carry by the screen of Infrared beams as a safety curtain across the door entrance detects an obstacle when the doors are closing, the doors then revert to an open position. A load plate displaying the rated load of the lift in terms of persons and kilograms shall be fitted in the lift car in a conspicuous position.
ISSUE R0
313
21.3.7
21.3.8
21.3.9
21.3.10
21.3.11
21.3.12
21.3.13
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
21.3.14
All sheaves and pulleys fixed to and revolving with the shaft shall be fixed by means of sunk keys of sufficient strength and quality. Sheaves and pulleys shall be made of cast steel to IS:1030 and free from cracks, sand holes and other injurious defects. They shall have suitable flanges and smoothly machined rope grooves. The diameter of the sheave of pulley shall be as specified in the latest edition of Indian Standard of equivalent International Standard. Shafts and axles shall be of forged steel. They shall have sufficient rigidity and bearing surface. Any shaft when stepped, shall be turned to a reasonable radius at the point of reduction in diameter. The elevator shall be provided with suitable counter weights located in the lift shaft. The counter weight shall be designed for smooth and easy operation of the lift and shall be in accordance with Indian Standards referred earlier or equivalent. International Standards. The counter weight shall be provided in the lift shaft. The counter weight shall consist of cast iron weight contained in structural steel frame. It should preferably be equal to that of the car weight plus 40% of the rated load. The traction should be such that no appreciable slip may occur but that slip shall be free to take place upon the landing of either the car or the counter weight. Guide rails for the car and counter weights shall be machined 'T' sections and continuous throughout the entire length and shall be provided with adequate steel brackets or equivalent fixing of such design and spacing that avoid any deflection during the normal operation. Guide rails section shall be adequate to withstand the forces resulting from the application of the safety gear when stopping the counter weights or fully loaded car. The guide shoes or their lining shall be easily renewable, adjustable and self lubricated guides shall be of such length that it shall not be possible for any of the car or the counter weights shoes to run off the guides. Sufficient number of buffers of spring loaded/oil type shall be fitted below lift car and counter weights. The buffers shall be capable of stopping the car or counter-weights without permanent damage or deformation to itself or any part of the lift equipment. The number of buffers shall be so fixed as to ensure proper sharing of the impact loads by all of them. The lift shall be provided with safety device attached to the lift car frame and placed beneath the car. The safety device shall be capable of stopping and sustaining the lift car up at governor tripping speed with full rated load in car. The application of safety device shall not cause the lift platform to become out of level in excess of 3 cm/m measured in any direction. Slack rope switches if necessary, shall also be provided.
ISSUE R0
314
21.3.15
21.3.16
21.3.17
21.3.18
21.3.19
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
21.3.20
Contractor to provide a modern Advanced electronic drive system of ''RESCUING passenger Trapped in a ELEVATOR". This system should be able to rescue during main power failure and elevator control system failure. The system should be fully microprocessor control with latest IGBT power device. Governors shall be located where there is sufficient room for their proper operation and where they cannot be struck by the lift car or counterweight in the event of overrun. Each governor shall be marked with a tripping speed in terms of car speed in m/sec. and the motor control and brake control circuit shall be opened before or at the time of governor trips. Governor ropes shall not be less than 8mm in diameter and shall be of steel or phosphor bronze and of suitable construction. The ropes shall run clear of the governor jaws during normal operation of the lift. The drive system for the elevator should be variable voltage variable frequency Drive system. The lift drive controller and all other apparatus and equipment for lift installation, except such apparatus and equipment which function in the lift well or other portion shall be placed in the machine room which shall be located at the top of the lift well. Sound reducing materials shall be provided under the machine base by the bidder. The maximum load transmitted by the single heaviest equipment both during erection and maintenance of the lift to the machine room floor and other structures like guides etc. shall be furnished by the contractor within 30 days of placing the award letter. The lift drive shall be equipped with brakes. The lift shall be driven by a drive suitable for method of control offered by the bidder. No friction gearing or clutch mechanism shall be used for connecting the main driving gear to the sheaves. The lift shall be provided with upper and lower normal terminal switches arranged to stop the car automatically within the limit of top car clearance and bottom run from any speed attained in normal operation. Such limit switches are to act independently of the operating device, the final limit switches and buffers. Final limit switches shall be provided to stop the car automatically within the top and bottom clearance independently of the normal operating device and the terminal limit switches. The final limit switch shall not act to prevent motion of the car under power in both direction of travel and
ISSUE R0
315
21.3.21
21.3.22
21.3.23
21.3.24
21.3.25
21.3.26
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
shall after operation, remain open until the lift car has been moved by a hand winding within the limit of safe operation. 21.3.27 Emergency safety device and over speed governor and buffers shall be provided. Fireman's switch at ground floor shall be provided. The lift shall be provided with automatic levelling device to take care of over run and under run of the car and rope stretch such that any floor is within 6 mm from the landing level. To make the equipment/system complete in all respects, any requirement of supply & fixing of steel sections for door frame, fixtures in walls for indicators and push buttons etc. are included in the scope of the bidder. The scope of the bidder also includes supply of erection consumables, arranging the materials for scaffolding and for any other functional requirement of erection. The elevator is to provide service in power station. It is necessary for the equipment to be specifically treated. This shall include application of anticorrosion paint/zinc plating. The electrical equipment shall have enclosure meeting IP-54 and other relevant protection. An electric contact for the car door shall be provided which shall prevent elevator movement away from the landing unless the door is in the closed position. The mechanical interlock with auxiliary door closing device shall be provided so that the elevator can be operated only after the interlock circuit is established. The car door shall be provided with a protective device extending to the full height and shall be so arranged that should it touch a person or any obstruction in its path while the door is closing, it shall automatically cause the car door and hoistway door to return to open position. An emergency switch shall be provided to stop the elevator at a particular landing, cancelling all the registered calls. The contractor shall carryout all the tests necessary & take the clearances / permissions from the Electrical inspector or any other agencies who certify the operation of lift.
21.3.28 21.3.29
21.3.30
21.3.31
21.3.32
21.3.33
21.3.34
21.3.35
21.3.39
ISSUE R0
316
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
21.3.40
The following operating devices / indications shall be provided in the car / on the landing / in the machine room as indicated below: Operating devices
In the car In the landing In the m/c room Up PB On top of the car Up
(a)
Up push button (PB) Down PB Number PBs for each landing
Up PB
Down PB Lift PB
Down PB Hand cranking device
Down Stop
230V 1 receptacle Non-stop PB Door open PB Door close PB Alarm PB Emergency stop PB Key operated selector for attendant operation Bell PB Stop PB -
(b)
Indicating devices.
In the car Up direction of travel Down direction of travel Floor position indicator & voice inside and outside car (Illuminated numeral for each landing) Landing car registering unit On the landing Up direction of travel Down direction of travel Car position indicator with direction (Illuminated numeral for each landing) Call registered Up indicator
ISSUE R0
317
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
In the car Load plate in kg & no. of persons Over load indication
On the landing Call registered Down indicator
(c)
Additional requirement
(a)
Car ventilation fan with switch Fire extinguisher Telephone handset PB for emergency indication in control room Ventilation/pressurisation : 2 x 100% capacity blower of adequate size along with cyclonic filter for pressurising the machine room to make it dust proof. If AC is required for the lift control room, then it should be taken through the Main Control room Air Conditioning System only. Hoisting beam in machine room roof slab : To be provided by lift supplier. Hoist way machine room & pit lighting: To be provided by lift supplier. Individual ladder for access to inside pit : To be provided by lift supplier. Automatic rescue device including siren etc : To be provided by bidder as an emergency rescue measure. The contractor shall carryout all the necessary tests & take the clearances / permissions from the Lift inspector or any other agencies who certify the operation of lift.
(b) (c)
(d) (e)
(f)
(g)
(h)
(i)
(j)
The material of doors and lift rope shall be stainless steel. The enclosure for electrical equipment located outside the machine room shall be dust tight and the car shall be provided with fluoroscent lighting, blow out panels, etc. Emergency DC light shall be provided in car. Any other equipment / accessories required for satisfactory operation of the lift shall be supplied by the Contractor.
ISSUE R0
318
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
The interior decor of the lift shall be aesthetically pleasing, and the same shall be subject to approval by Owner. The contractor shall be responsible for obtaining the necessary License / Permission from the relevant authorities.
ISSUE R0
319
TCE FORM NO. 329 R5

DATA SHEET A3.21
SECTION: SHEET
D3.21
9 OF 10
SPEC. NO. TCE.5960A-H-500-001
SL. NO. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 8.1 8.2 8.3 9.0 9.1
DESCRIPTION Passenger Lift Installations Capacity Rated speed Levelling device Operation Automatic operation type Type of door & material Type of doors in car Emergency exit Speed control Degree of protection for lift motor Codes & standards Specification for electric passenger and goods lift. Specification for steel wire suspension ropes for lifts, elevators & hoists. Specification for carbon steel castings for general engg. purpose. Specification for lift door locking devices and contracts Material specification Goods Cum Passenger Lift Installations Capacity Rated speed Levelling device Operation R0 MAR 10 PPD. BY CKD.BY DATE
UNITS Indoor kg m/sec 600 0.75
Two way automatic maintaining Automatic microprocessor based Selective & Collective Centre opening sliding, steel 1 or 2 depends on layout Required VVVF IP-54
IS:14665 (Latest edition)
9.2
IS:2365-1977
9.3
IS:1030-1982
9.4
IS:7759-1975
9.5
ISS or approved equal.
1.0 2.0 3.0 4.0 5.0 REV. NO. DATE REV. BY
Indoor kg m/sec 1500 1.0 Two way automatic maintaining Automatic microprocessor based JOB NO. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3
320

DATA SHEET A3.21
SECTION: SHEET
D3.21
10 OF 10
SPEC. NO. TCE.5960A-H-500-001
6.0 NO. SL. 7.0 8.0 8.1 8.2 8.3 9.0 9.1
Automatic operation type ION DESCRIPT Type of door & material Type of doors in car Emergency exit Speed control Degree of protection for lift motor Codes & standards Specification for electric passenger and goods lift. Specification for steel wire suspension ropes for lifts, elevators & hoists. Specification for carbon steel castings for general engg. purpose. Specification for lift door locking devices and contracts Material specification
UNITS
Selective & Collective UIREMENTS VALUES / REQ Centre opening sliding, steel 1 or 2 depends on layout Required VVVF IP-54
IS:14665 (Latest edition)
9.2
IS:2365-1977
9.3
IS:1030-1982
9.4
IS:7759-1975
9.5
ISS or approved equal.
R0 MAR 10
PPD. BY CKD.BY DATE
JOB NO. 5960A

321
5.10
SECTION:
D3.22
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS ELECTRICAL LABORATORY EQUIPMENT
22.0 22.1
EQUIPMENT TO BE SUPPLIED The list of items / equipment to be supplied by the Contractor indicated here is only indicative. Any other equipment considered necessary by the Contractor for the installation, testing and commissioning of the plant shall be included in the offer. Also any additional equipment required or considered necessary during detailed engineering stage, shall form a part of the scope.
Category I High Voltage Test Instruments Instrument Range High potential test set AC / DC 0 50 kV
Sl. No. (a)
Qty. 1 No.
Sl. No. (a) (b)
(c)
Category II Miscellaneous Laboratory Instruments Instrument Range Qty. Automated oil BDV test set 0 75 kV 1 No. Rheostats of following ratings 650 Volts 1 Set (i) 25 Ohms, 10A-2 nos. (ii) 50 Ohms, 5A-2 nos. (iii) 100 Ohms, 2.5 A-2nos. (iv) 250 Ohms, 2.5A-2 nos. (v) 500 Ohms, 0.5A-2nos. Portable secondary injection test set 500VA, 1AMP/ 5AMPs Normal; 20AMPS / 100AMPS for 30 secs Digital Earth resistance tester with 0.01 Ohms, 500 resistivity test facility Ohms in three ranges Digital Insulation resistance tester (transistorised) 0-100, 000 Mega Ohms, 500-10002500-5000 Volts 1 No.
(d)
(e)
2 Nos.
(f) (g) (h) (i) (j)
Cable fault locator (HV, LV cable) Relay tool kit Hot stick with indication & audible alarm Temperature controlled soldering iron Thermovision equipment (INFRA RED CAMERA) Upto 11 kV Upto 400 kV 50W
1 No. 2 Nos. 1 No. 1 No. 2 Nos. 1 No.

ISSUE R0
322
TCE FORM NO. 329 R5
SECTION:
D3.22
Sl. No. (k) (l)
(m) (n) (o) (p) (q) (r) (s) (u) (v) (w) (x) (y) (z) (aa)
Category II Miscellaneous Laboratory Instruments Instrument Range Primary Injection kit 5000 A, 7.5 kVA Milli volt drop test set 600A DC continuous variable Illuminometer 0 to 50,000 Lux. Circuit breaker analyser 1 ms to 999 secs Turn ratio meter with vector group 1 to 99000 ratio testing facility Online DC circuit fault locator Tan delta test kit for generator/transformer Vibrometer Capacitance and tan delta measurement kit Partial discharge measurement kit Earth loop tester Battery capacity test kit Battery impedance measurement kit Motor checker Capacitor measurement kit Live line detector Category III Meters & Accessories Instrument Range
Qty. 1 No. 1 No.
2 Nos 1 No. 1 No. 1 No. 1 No. 1 No.
Sl. No. (a) (b)
Qty. 3Nos 1 No. 1 No. 1 No. 2 Nos. 2 Nos. 1 No. 3 Nos. 1 No. 1 No.
Three Phase sequence testing meter Clip on Ammeters AC / DC
(100 600 V) (a) 0-2000-25003000A (b) 0-250-500A (c) 0-100-150-200A (d) 0-5A (e) 0-1A 0-500 Volts, 7KVA 0-270 Volts, 2-16KVA 0.1 micro-ohm-1999 Ohm, 100A Amp-1A/5A, Volt 600 V, for measurement of KW, KVA, KVAr, KWh, PF, Amp, Volt, in 1 ph & 3 ph, 3 wire & 3ph, 4 wire system
(c) (d) (e) (f)
Auto-transformers 3 Phase Auto-transformer 1 Phase Digital micro-ohm meter Portable power analyser meter Accuracy=0.2
ISSUE R0
323
TCE FORM NO. 329 R5
SECTION:
D3.22
(g)
(h) (i)
LCD type portable scope meter (Wave form analysis with Harmonic measurement facility) Analog voltmeter AC/DC Analog ammeter AC/DC
1 No.
0-5-10-25-50-100-500 V 0-5-10 A
1 No. 1 No.
Sl. No. (a)
Category IV Electronic Instruments Instrument Universal microprocessor based relay testing kit to test 1) Current relay 2) Voltage relay 3) Frequency relay 4) Differential relay 5) Distance relay 6) Synch. Relay 7) Timer relays Regulated DC power supply equipment
Range
Qty. 1 no
(b)
Voltage 0-+300V DC, 2 Amps, 0 - + 30V, DC, 2 Amps, 0-+5V 10 Amps, Current 0 2 AMPS DC, 100 VA 0,1500,3000,5000, 10000 rpm
2 Nos.
(c) (d) (e) (f) (g)
Digital tachometer (non-contact type)
2 Nos.
Digital multimeter (Class 0.5) 3 Nos. Hydrogen leak detectors 2 Nos. Naphtha & fuel gas leak detectors 2 Nos. All the necessary accessories shall also be supplied with the instruments. These shall include but not be limited to : (a) (b) Two meter length power supply cord with plug. All necessary accessories like jacks, probes, connectors, adapters, clips, rain jackets, protective covers, shields, carrying / transporting cases, etc., wherever applicable. Composite universal microprocessor based test kit with 0.02 accuracy for testing following: Distance relays, Differential relays, Over current relays, F/V/I relays, Ground fault relays, Synchronising devices, Transient playback, Harmonics generation, Transducers, Energy meters testing /calibration. Requsite software and Laptop shall be included as a part of test kit.
ISSUE R0
324
(h)
TCE FORM NO. 329 R5
SECTION:
D3.22
22.2
Specific Requirements
22.2.1 Category I High Voltage Test Instruments (a) The test transformers shall be supplied with: (i) A control desk incorporating all necessary indication, annunciation, protection and control equipment. All necessary cooling equipment if required. Mobile base with adequate no. of rollers for easy transport of the testing unit. All necessary accessories for erection, commissioning, normal operational / testing of all types of equipment, whether specified or not. Shall incorporate built-in safety features to ensure complete safety of operating personnel.
(ii) (iii)
(iv)
(v)
(b)
The insulating material used for bushings and top covers shall be as per BS for Class F/A installation.
22.2.2 Category II (a) Automatic Oil Test Sets (i) This equipment shall have an output voltage of 0 75 kV variable AC, continuously rated 1 kVA with class of insulation being A. The test set shall be so designed that the short circuit current drawn from the system exceeds 8 times the rated current. The transformer test set impedance shall be such that the input MCCB trips within a suitable time (0.02 sec.) for a secondary short circuit.
(ii)
(b)
Rheostats and Phantom Loads The rheostats shall be 650V grade wire wound type of copper nickel alloy having a low temperature co-efficient, totally enclosed type with louvers. Solid copper / graphite brushes with pressure springs shall be provided to ensure low contact resistance.
(c)
Portable Secondary Injection Test Set

ISSUE R0
325
TCE FORM NO. 329 R5
SECTION:
D3.22
This equipment shall be designed to deliver a normal continuously adjustable current with multirange selector switch for 1, 5, 10, 50 A etc. The instrument shall have built in ammeter and voltmeter having adequate range. (d) Earth Resistance tester with resistivity test facility This equipment shall be suitable for measuring the ground resistance, specific soil resistance and ohmic resistances. The equipment shall be supplied with all necessary accessories and in-built batteries. (e) Insulation Resistance Tester (Transistorised) The insulation resistance shall be measurable to a value of 1,00,000 m in five ranges. The test voltage shall be adjustable at 500V, 1000V, 2500V and 5000V. The tester shall be suitable for an input supply of 230 V, 50 Hz, single phase AC as well as in-built rechargeable batteries. A guard terminal shall be provided to eliminate error due to surface leakage. Accuracy shall be 5%, maximum short circuit terminal current 2.5 mA, nominal S.C current 2 mA. This tester shall also provide Polarisation Index Measurement. (f) Cable Fault Locator for LT Cables Portable cable fault locator which shall identify the fault in a LT cable distinctly. This kit shall work on in-built batteries. This kit shall include Time Domain Reflectometer (TDR) and cable identifying kit and all necessary accessories & transport cases. (g) Hot Stick The hot sticks shall be supplied in different ratings viz. For 6.6 kV, 400 kV. The insulating handle of stick shall be with Class F / H insulation as per IEC / BS specifications with scaled detector having high quality viewing windows. The hot stick should be light weight and portable. Should give audio visual indication of pressure of voltage.
(h)
Temperature Controlled Soldering Iron The soldering iron rated at 50 W having thermostatic temperature control shall be supplied complete with set of soldering bits of different sizes and shapes, three spare heating elements & separate stand to rest the soldering iron while in use.
ISSUE R0
326
TCE FORM NO. 329 R5
SECTION:
D3.22
(i)
Thermovision Equipment (Infra thermographic common) The system shall be very light weight, and single hand-operated instrument. This instrument shall have user friendly, broadly compatible software which is an image processing software to perform post-imaging analysis.
22.2.3 Category III

(a)
Phase sequence Testing Meter This shall be suitable for testing 3 phase 400V supply and shall be suitably marked for clockwise and anti-clockwise directions. Any conducting part of the meter/ shall withstand 2 kV for 1 minute. The operative range of the meter shall be 100V to 600V.
(b)
Clip on Ammeter The meter shall have a large digital display unit and the jaws shall open adequately to facilitate introduction of the conductor having a size corresponding to the maximum current range.
(c)
Digital low resistance ohm-meter The instrument shall be suitable for measuring the contact resistance of switch and circuit breaker contacts, winding resistance of transformer & motor, busbars, etc. They shall also be suitable to be used in finding ground faults in electrical equipment, determining temperature co-efficient and temperature rise by resistance methods, etc.
22.2.4 Category IV (a) Automatic Composite Relay Test Kit Relay test set shall be suitable for input voltage 230 V, 1 Phase, 50 Hz. Output current range shall be 1-5-50-100A. Overload and short circuit protection shall be provided. Phase angle adjustment shall be 0-360 deg. The kit shall be computerised, portable unit and used to test various types of protective relays quickly and more accurately. The software for testing, measurement and analysis of the different types of the relays shall be included.
ISSUE R0
327
TCE FORM NO. 329 R5
SECTION:
D3.22
(b)
Regulated DC Power Supply Voltage range (continuously controlled) Current range (continously variable) Indication meters Load regulation
0 to + 300 V DC 0 to 2A DC Digital voltage/current integral with the unit 0.1% variation in voltage 0.2% variation in current.
(c)
Digital Tachometer Tachometer shall be of the photoelectric type with a digital display, which does not necessitate mechanical contact with the machine shaft. A push to read push button shall be provided and also an LED to indicate when the light beam is on the target. Adequate memory shall be built-in to hold the last reading for atleast 1 minute.
(d)
Digital Multimeter These meters shall have built in overload protection and protection against HV transients. They shall have an audio alarm for continuity testing, a peak hold feature on current and voltage ranges, automatic polarity and over range indications. The instrument shall be complete with rechargeable batteries and charging equipment, adapters, probes, leads, padded carrying case, etc. It shall have safety features to prevent damage to instrument if voltage is applicable inadvertently current or resistance measuring range.
ISSUE R0
328
TCE FORM NO. 329 R5
700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS MISCELLANEOUS ELECTRICAL EQUIPMENT
SPEC. NO. TCE.5960A-H-500-001
23.0 23.1 23.1.1 23.1.2 23.1.3 23.1.4 23.1.5 23.1.6 23.1.7
MISCELLANEOUS ELECTRICAL EQUIPMENT Following equipment shall be included in the Contractors scope. Local push button stations Junction Boxes (JBs) 3 phase power receptacles Danger boards Rubber mats 50 nos. first aid charts shall be provided for display in the plant area. Minimum of fifty (50) nos. First aid boxes shall be provided at various locations in the plant. Sufficient quantity of gas masks shall be provided in line with rule no. 43 of IE rules. Local Push Button Stations (LPB) Local push button stations shall be provided for all the drive motors of the plant. LPBs for outdoor installation shall be weather proof type provided with a GI canopy and those intended to be used in hazardous areas shall be flameproof type and the degree of protection shall be IP 55 for both outdoor and indoor application. The LPBs shall be power coated with shade Opaline green (External) & semi glossy white (Internal). All stop push buttons shall be lockable type (provided with key for locking) Following types of LPBs shall be provided for the various drives as applicable. (a) Push button station type A - which shall comprise Three, Push buttons viz., Òpen', `Close' and `Stop' for control of reversible motors. Push button station type B - which shall comprise two push buttons viz., `Start' and `Stop' for control of the rest of the drives in the plant.
ISSUE R0
329
23.1.8
23.2 23.2.1
23.2.2
23.2.3
23.2.4
(b)
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
(c) 23.3 23.3.1
Type-C push button station: With start, stop & ammeter.
Junction Boxes (JBs) / Marshalling boxes (MBs) Junction boxes as required for the power plant shall be supplied as required for marshalling cables of devices located in an area/equipment. Junction Boxes with IP:55 degree of protection, shall comprise of a case with hinged door constructed from cold rolled sheet steel of minimum thickness 2mm. Top of the boxes shall be arranged to slope towards rear of the box. Gland plate shall be 3mm thick sheet steel with neoprene/synthetic rubber gaskets. All junction boxes shall be of adequate strength and rigidity, hot dip galvanised as per relevant IS, and suitable for mounting on wall, columns, structures etc. The boxes shall include brackets, bolts, nuts, screws M8 earthing stud etc. required for installation. Terminal blocks shall be 650 volts grade, rated for 10 Amps and in one piece moulding. The JBs used in outdoor areas shall be weatherproof type. Sheet steel thickness of the JBs shall be minimum 2 mm. JBs / MBs shall be hot dip galvanised and shall be powder coated with paint shade Opaline green (External) & Semi glossy white (Internal). Cable entry shall be bottom/side entry for indoor as well as outdoor mounted junction boxes. The junction boxes shall be installed at 1 m accessible height. 3 Phase Receptacles 32 A and 63 A, 3 phase, 4 pin heavy duty type power receptacles shall be provided in proposed building plant areas, transformer yard, 400 kV switchyard such that distance between any two of each rating in indoor and outdoor area does not exceed 15 m and 30 m respectively. Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot dipped galvanized or of die-cast aluminium alloy of thickness not less than 2.5 mm. The boxes shall be provided with two nos. earthing terminals, gasket to achieve IP55 degree of protection, terminal blocks for loop-in loop-out for cable of specified sizes, mounting brackets suitable for surface mounting on wall/column/structure, gland plate etc. The ONOFF switch shall be rotary type heavy duty, double break, AC23 category, suitable for AC supply. Plug and Socket shall be shrouded Diecast aluminium. Socket shall be provided with lid safety cover. Robust mechanical interlock shall be provided such that the switch can be put ON only when the plug is fully engaged and plug can be withdrawn only
ISSUE R0
330
23.3.2
23.3.3
23.4 23.5.1
23.5.2
TCE FORM NO. 329 R5
SPEC. NO. TCE.5960A-H-500-001
when the switch is in OFF position. Also cover can be opened only when the switch is in OFF position. Wiring shall be carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of adequate size. The Terminal blocks shall be of 750 V grade. 23.5 23.5.1 Danger Boards / Rubber Mats Danger boards and rubber mats shall be provided as required by the statutory Authorities. The thickness and length of the rubber mats shall be as per the guidelines of Indian Electricity Rules / local electrical inspectorate.
ISSUE R0
331
TCE FORM NO. 329 R5
SECTION:
D3.24
SHEET 1 OF 4
1X700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS CONSTRUCTION POWER SUPPLY
SPEC. NO. TCE.5960A-H-500-001
24.0 24.1
CONSTRUCTION POWER SUPPLY EQUIPMENT Construction power shall be made available at a single point at 11kV inside the plant premises from nearest substation of APTRANSCO by the Owner. The power shall be further extended by the Contractor to different users by armoured cables or overhead lines. All the equipments used in construction power shall ensure full safety to the working personnel and no live parts which are accessible shall be exposed. The Contractor shall estimate the construction power requirement and indicate the same to Owner to enable them to enter into an agreement with APTRANSCO for its supply. The Contractor shall obtain all necessary statutory clearance for the purpose. GA and layout drawings required for getting clearance from local electrical inspector / Electricity Board shall be prepared by the contractor and it will be the complete responsibility of the Contractor to obtain the approval for the installation and all related works in this regard. The Owner will not be responsible for power cuts, Power failure for whatever reason, fluctuation in voltage and frequency and consequences thereupon. To take care of failure of this supply, Contractor shall provide suitable DG sets. Contractor shall provide necessary protection for the construction power supply arrangement to ensure that any fault in his system, should not disturb 11kV power supply arrangement. The Contractor shall provide metering arrangement consisting of two CT, PT units and two trivector meters of suitable accuracy which shall have MD registering facility. The contractor shall be responsible for periodic payment of bills for the energy consumed by him. The Contractor shall make arrangements to receive power from the Owner line through DP structures with fuse protection. 2 x 100% suitably rated 11kV / 420V transformers, 400V switchgear with two incomer ACBs, two bus sections and bus coupler & required number of outgoing 400V, 3, 4 wire distribution lines to distribute power around plant area. Adequate metering and protection shall be provided for transformers and incomer feeders. Capacitor banks of automatic PF adjustment arrangement shall be provided by the Contractor depending on the actual load to maintain power factor at 0.95 for optimising the power bills. This shall be installed at each LT distribution board preferably. If APDISCOMS imposes any penalties to APGENCO , caused by low power factor, the same shall be paid by the contractor to the Owner. Contractor shall supply and install fire fighting equipment as per the regulations of the local electrical inspectorate / statutory bodies for the electrical installation.
ISSUE R0
332
24.2
24.3
24.4
24.5
TCE FORM NO. 329 R5
SECTION:
D3.24
SHEET 2 OF 4
SPEC. NO. TCE.5960A-H-500-001
24.6
On award of contract, the Contractor shall furnish the electrical scheme, for Owners approval. 02 Nos. of 400V, 250A feeder of adequate capacity for Administration building & Colony construction, shall be given by the Contractor at specified location. LT DISTRIBUTION BOARDS
24.7
24.8
24.8.1 In general, these shall meet the requirements covered in D3.11 section. However, the board shall be provided with outer enclosure so that access to individual compartments, busbar and cable alley shall be available only after the outer door is opened. 24.8.2 The distribution boards shall be provided with the following: a) b) c) d) 24.9 CABLES Pad locking arrangement with hinged door Sloped canopy to prevent ingress of rain water Caution notice Earthing at two points
24.9.1 Cables shall be armoured and suitable for direct underground buried installation. Cable armour shall be suitable for carrying system earth fault current. HT cables shall be XLPE insulated type. 24.10 EARTHING SYSTEM
24.10.1 Earthing of all substation equipment and overhead line shall be carried out as per IS:3043. Earthing system shall consist of adequate number of earth electrodes interconnected. Earth electrodes shall be of 40mm dia. galvanised steel pipe, buried in earth pit. 24.10.2 Number of earth electrodes for LT substation shall be decided considering soil resistivity. However, each LT substation shall have minimum two earth electrodes for neutral earthing, two earth electrodes for body earthing and two earth electrodes for lightning arrestor earthing. 24.10.3 All non-current carrying metal parts shall be connected to earth system at two points, each of 100% rating. Metallic supports, fencing, etc. shall also be connected to earth system.
ISSUE R0
333
TCE FORM NO. 329 R5
SECTION:
D3.24
SHEET 3 OF 4
SPEC. NO. TCE.5960A-H-500-001
24.10.4 Size of earthing conductor shall be selected considering fault current, duration of fault and corrosion rate. Earthing conductor shall be of galvanised steel strip/wires. 24.10.5 Overhead lines shall be earthed by continuous galvanised steel overhead earth wire fastened to each pole and connected with earth at minimum three points in every km length. Cross section of earth wire shall not be less than 25 mm2. 24.11 INSTALLATION
24.11.1 The electrical installation shall generally be carried out as per Indian electricity rules and acts. 24.11.2 For road crossing, protective guarding shall be provided. The clearance for the lowest conductor from ground shall be decided keeping in view the vertical clearance required for movement of vehicles/cranes, etc. 24.11.3 The LT substation area shall be graded and sloped to prevent any stagnation of rain water. Surface shall be covered with gravel of 15 to 20 mm size. 24.11.4 The LT substation shall be enclosed by barbed wire fencing on mild steel angle iron posts to a height of not less than 2500mm with suitable gates for entrance. 24.11.5 All cable connection parts within the switchgear shall be shrouded with insulating materials. 24.11.6 The extension boards provided for hand held equipments shall have 3 wire system i.e. phase, neutral & earth as per IE rules. The plug & socket arrangement provided shall be of industrial type with switch provided for proper isolation at the time of insertion or withdrawal of plugs. 24.11.7 The flexible cable used shall have heavy duty insulation. 24.11.8 All equipment used for construction activities shall be fed from separate switching/isolating devices. 24.11.9 All the working areas shall be adequately illuminated for safe working with proper fittings/fixtures. The wire shall be laid with proper fixing without any hindrance to personnel or vehicular movement. 24.12 WORKING PROCEDURES
ISSUE R0
334
TCE FORM NO. 329 R5
SECTION:
D3.24
SHEET 4 OF 4
SPEC. NO. TCE.5960A-H-500-001
24.12.1 Adequate safety equipments shall be provided to all the workers, like hand gloves, head gear, etc. Meggers & testers shall be provided in sufficient quantity. 24.12.2 Only ITI qualified workers shall be allowed to handle the electrical or electrically operated equipments.
ISSUE R0
335
TCE FORM NO. 329 R5
SECTION:
D3.25
SHEET 1 OF 2
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - TRANSDUCERS

SPEC. NO. TCE.5960A-H-500-001
25.0 25.1
GENERAL REQUIREMENT Bidders shall note that each and every device/equipment mounted in panels, switchgears, MCCs, chargers, distribution boards, etc,, shall be properly tagged, both inside and outside (if the equipment is mounted on door) for identification. Transducers The transducers supplied shall meet the following specifications. (a) Output range (b) No. of output channel (c) Accuracy (d) Repeatability (e) Linearity : : : : : 4-20 mA DC Two (2) 0.5% of full scale 0.1% of full scale 0.5% of full scale
25.2
(f) Residual ripple output

current (g) Over load capacity (i) (ii) Current Voltage : : : : 3 to 5% 10 times for 0.5 seconds 120% continuous 2 times for 0.5 seconds 120% continuous : : : : Galvanic Isolation Self powered Zero and span 500 Ohms
(h) Out put Isolation (i) Power (j) Adjustment (k) External resistance. (l) Power frequency withstand capability
2 kV rms for 1 minute
(m)Open circuit and short circuit protection shall be provided. (n) All transducers shall have local mA digital display.
ISSUE R0
336
TCE FORM NO. 329 R5
SECTION:
D3.25
SHEET 2 OF 2
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - TRANSDUCERS

SPEC. NO. TCE.5960A-H-500-001
25.3
Digital LED displays for the following parameters shall be provided in two (2) locations in the Main control room and three (3) locations in the administration building (*) (a) Total plant load for each block (b) Frequency (c) Ambient temperature For all outdoor equipment, which are not protected by sun cover, the heating effect due to solar radiation shall be considered while considering the temperature rise. LEDs shall be provided with Low Voltage Guard protection. Note:(*) - Administration building not in EPC scope. However the Bidder shall install the LED display and wire the same. Location of the building will be intimated later.
25.4
25.5
25.6
The following IS standards shall be followed: IS: 12784 : Electrical measuring transducers for converting AC electrical quantities into DC electrical quantities : Electrical measuring transducers for converting AC electrical quantities to analog or digital signals.
IS : 14570
ISSUE R0
337
TCE FORM NO. 329 R5
5.11 TECHNICAL SPECIFICATION FOR INSULATING MATS
SPECIFICATION NO. PE-TS-I59-888-E001
1.0 1.1
SCOPE The scope includes design, manufacturing, inspection, testing, packing and delivery to site of protective mats for placing in front of all 6.6kV/400V/220V Switchboards. TECHNICAL REQUIREMENTS The physical, chemical, mechanical and electrical properties of the insulating mats shall be as per IS: 15652. The mats should have been type tested in accordance with the applicable standards. Insulating mats to be supplied shall be BIS approved and the same shall be engraved on insulating mats also. Insulating mat to be supplied shall be type tested at ERDA. Mats shall be supplied preferably in units of 2X1 (length X width) metre. SPECIFIC QUALITY ASSURANCE REQUIREMENTS All type, routine and sampling tests shall be as per IS: 15652. Dispatch of materials shall be permitted only after acceptance of type test certificates, and inspection and testing of materials. The successful bidder shall submit the Quality Assurance Plan (QAP) in attached format for BHEL/ Customer approval after the award of contract. Packing and marking shall be as per IS 15652.
2.0 2.1 2.2 2.3 2.4 2.5 3.0 3.1 3.2

3.3
3.4
4.0
COMPLIANCE TO SPECIFICATION Bidder shall confirm total compliance to the specification without any deviations from the technical requirements stipulated. As a mark of technical conformance, all sheets of the specification shall be furnished by each bidder with the signature and company seal affixed thereon.
5.0
Wherever required, soft copy of all approved technical/ quality documentation shall be submitted as specified without any additional commercial implication. Soft copies may be required both in native file format (e.g. MS Word/ MS Excel) as well as PDF files.
338

5.12 TECHNICAL SPECIFICATION FOR CATHODIC PROTECTION SPECIFICATION NO. PE-TS-I59-888-E001
1. CODES & STANDARDS

I. II. IS: 8062 : Code of practice for cathodic protection of steel structure. IS: 8289 : Construction & testing of electrical apparatus with type of protection n
2. GENERAL REQUIREMENT:
2.1 All the metallic structures which are in contact with sea water & underground metallics shall be provided with Cathodic Protection (CP) system irrespective of the material of structures, to prevent corrosion due to any pin holes / holidays. The CP system shall only be of impressed current type. Preferably LIDA type anode shall be used. If the soil is very corrosive, all underground structures shall be protected against corrosion by providing suitable CP system. Bidders shall furnish in their BID a brief write up indicating the type of CP system envisaged for various metallic structures in contact with sea water & under ground metallics. During detailed engineering the Contractor shall furnish the following for Purchasers approval : 2.5.1 Calculations for arriving at the number and dimension of anodes. 2.5.2 Calculations for arriving at the rating of transformerrectifier set. 2.5.3 Layout of CP system. 2.5.4 Mounting arrangement of anode and reference electrode.
2.2 2.3 2.4
2.5
The following minimum design documentation [not essentially limited to these only] shall be furnished by the successful vendor (for review and approval) at contract stage.
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Corrosion survey report with interpretation. Basic design package and system optimisation studies. Material and equipment specifications, data sheets. Quality plans for all equipment/ items. Field Quality Plan covering site storage, handling, installation and commissioning checks. Detail engineering and final design report. Key diagrams of each discrete systems and complete CP system. Anode installation drawings representing all variations in type, environment, depth, placement, supports etc. including anode. Cable layout schedules and terminals. Foundation, weather protection cover details and support details for T/R sets, anodes, Test Station, distribution boxes and cables of all description. Installation details of T/R sets, test stations distribution boxes etc. Design package on T/R sets essentially incorporating circuit diagrams, fabrications and installation details, parts list, description on operation and maintenance. Design package on anodes essential incorporating composition, fabrication and installation details. Connection schemes for all applicable type of test stations and their schedules. Fabrication and installation details of test stations. Fabrication and installation details of anode and cathode junction boxes, schedules and connection schemes. Interconnection, sectionalisation, isolation schemes for all structures to be protected and those to be isolated but to be checked out for interaction. Power supply arrangement for each T/R set. Safety earthing details. Procedures for testing during installation, commissioning and monitoring of (after installation) complete CP system & each equipment. Design and drawings that may be required for mitigation purposes. Complete CP system layout drawings for each CP station.
339

5.12 TECHNICAL SPECIFICATION FOR CATHODIC PROTECTION 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. SPECIFICATION NO. PE-TS-I59-888-E001
Cable to pipe joint arrangement using thermite welding. Material test certificate for the materials purchased by the vendor along with copy of manuals. Inspection and test certificates for items fabricated and erected. Performance Test Report. Final check list and completion report. Composite Operation and Maintenance Manual. Monitoring formats. Monitoring schedules. List of E&C Spares. Billing break-up
Note : The list of deliverables shall be finalised during kick-off meeting at contract stage.
340
ANNEXURE-II
341
342
343
344
345
346
8. QUALITY ASSURANCE, INSPECTION & TESTING:

ALL MATERIALS, COMPONENTS AND EQUIPMENTS COVERED UNDER THIS SPECIFICATION SHALL BE PROCURED, MANUFACTURED, INSPECTED AND TESTED AS PER THE BHEL/ CUSTOMER APPROVED QUALITY PLAN. THERE SHALL BE NO COMMERCIAL IMPLICATION TO BHEL ON ACCOUNT OF QP APPROVAL. BHEL QPs ARE ENCLOSED FOR REFERENCE.
347
CUSTOMER : QUALITY PLAN SHEET 1 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. :
PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD
SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V
SL. NO.
TYPE/ METHOD OF CHECK
EXTENT OF CHECK
1
1.0
2
RAW MATERIAL & BROUGHT CONTROL SHEET STEEL, PLATES, SECTION, EYEBOLTS
10
11
1.1
1.SURFACE CONDITION
MA
VISUAL
100%
FREE FROM BLINKS, CRACKS, WAVINESS ETC MANFR'S DRG./SPEC -DO-
LOG BOOK
2.DIMENSIONS
MA
MEASUREMENT SAMPLE
MANFR'S DRG./SPEC -DO-
-DO-
3.PROOF LOAD TEST (EYE BOLT) 1.2 HARDWARES 1.SURFACE CONDITION
MA
MECH. TEST
-DO-
INSPEC. REPORT
MA
VISUAL
100%
FREE FROM CRACKS, UNEVENNESS ETC. MANFR'S DRG./SPEC BOOK RELEVENT IS/SPEC.
-DO-
2.PROPERTY CLASS
MA
VISUAL
SAMPLES
SUPPLIERS TC & LOG
PROPERTY CLASS MARKING SHALL BE CHECKED BY THE VENDOR
1.3
CASTING
1.SURFACE CONDITION
MA
VISUAL
100%
FREE FROM CRACKS, BLOW HOLES ETC. MANFR'S DRG./SPEC RELEVENT IS/
LOG BOOK
2.CHEM. & PHY. PROP.
MA
CHEM & MECH TEST
1/HEAT NO.
SUPPLIER'S TC
HEAT NO. SHALL BE VERIFIED
3.DIMENSIONS
MA
MEASUREMENT 100%
MANUFR'S DRG.
MANUFR'S DRG. MANFR'S DRG./SPEC
LOG BOOK
1.4
PAINT & VARNISH
1.MAKE, SHADE, SHELF LIFE & TYPE
MA
VISUAL
100% MANFR'S CONTINUOUS DRG./SPEC
LOG BOOK
BHEL
PARTICULARS NAME SIGNATURE DATE
BIDDER/VENDOR
348
BIDDER'S/VENDORS COMPANY SEAL
SL. NO.
EXTENT OF CHECK
1
1.5
2
SHAFT (FORGED OR ROLLED)
3
1. SURFACE COND. MA
4
VISUAL
5
100%
6
-
8
FREE FROM VISUAL DEFECTS RELEVANT IS -DO-
9
3
10
-
11
VENDOR'S APPROVAL IDENTIFICATION SHALL BE MAINTAINED
2. CHEM. & PHYSICAL PROPERTIES
MA
CHEM. & PHYSICAL TESTS
1/HEAT NO. OR HEAT TREATMENT BATCH NO
MFG. DRG. SPEC.
SUPPLIER'S TC
3. DIMENSIONS
MA
MEASUREMENT 100%
-DO-
MANUFR'S DRG. MANUFR'S SPEC. BHEL SPEC. MANUFR'S DRG. SPEC.
LOG BOOK
4.INTERNAL FLOWS
CR
UT
-DO-
ASTM-A388
-DO-
FOR DIA OF 55 MM & ABOVE
1.6
SPACE HEATERS, CONNECTORS, TERMINAL BLOCKS, CABLES, CABLE LUGS, CARBON BRUSH TEMP. DETECTORS, RTD, BTD'S
1. MAKE & RATING
MA
VISUAL
-DO-
MANUFR'S DRG. SPEC.
-DO-
2. PHYSICAL COND.
MA
-DO-
-DO-
NO BREAKAGE ON OTHER PHY. DESIGN MANUFR'S DRG. / SPEC.
-DO-
3.DIMENSIONS (WHEREVER APPLICABLE) 4.PERFORMANCE/ CALIBRATION
MA
MEASUREMENT SAMPLE
MANUFR'S DRG./ SPEC.
-DO-
MA
TEST
100%
-DO-
-DO-
INSP. REPORT
BHEL
BIDDER/VENDOR
349
SL. NO.
EXTENT OF CHECK
1
1.7
2
OTHER INSULATING MATERIALS LIKE SLEEVES, BINDINGS CORDS, PAPERS, PRESS BOARDS ETC.
3
1. SURFACE COND. MA
4
VISUAL
5
100%
6
-
8
NO VISUAL DEFECTS
9
INSPT. REPORT 3
10
-
11
2. OTHER CHARACTERISTICS MA
TEST
SAMPLE
MANUF'S SPEC.
MANUF'S SPEC.
LOG BOOK AND OR SUPPLIER'S TC LOG BOOK
1.8
SHEET STAMPING (PUNCHED)
1. SURFACE COND.
MA
VISUAL
100%
NO VISUAL DEFECTS (FREE FROM BURS) MANUFR'S DRG.
2.DIMENSIONS INCLUDING BURS HEIGHT 3. ACCEPTANCE TESTS
MA
MEASUREMENT SAMPLE
MANUFR'S DRG. .
-DO-
FOR MV MOTOR INSULATION/VARNISH THICKNESS SHALL BE MORE THAN THE BURS HEIGHT
MA
ELECT. & MECH TESTS
-DO-
MANUF'S SPEC./ RELEVANT IS -
RELEVANT IS
SUPPLIER'S TC
1.9
CONDUCTORS
1. SURFACE FINISH
MA
VISUAL
100%
FREE FROM VISUAL DEFECTS RELEVANT IS/ BS OR OTHER STANDARDS
LOG BOOK
2.ELECT. PROP, & MECH. PROP
MA
ELECT. & MECH.TEST
SAMPLES
RELEVANT IS/ BS OR OTHER STANDARDS
SUPPLIERS TC & VENDOR'S INSPN. REPORTS
3/2
BHEL
BIDDER/VENDOR
350
SL. NO.
EXTENT OF CHECK
3
3.DIMENSIONS MA MA MA
5
MEASUREMENT VISUAL
6
-DO100%
7
-DOMANFR'S DRG. BHEL DATA SHEET
8
-DOMANFR'S DRG. BHEL DATA SHEET BEARING MANUF'S CATALOGUES FREE FROM VISUAL DEFECTS
9
Log Book -DO-DO3 3 3
10
-
11
1.10
BEARINGS
1.MAKE & TYPE 2.DIMENSIONS
MEASUREMENT SAMPLE
3.SURFACE FINISH
MA
VISUAL
100%
-DO-
1.11
SLIP RING
1.SURFACE COND. 2.DIMENSIONS
MA
VISUAL
100%
-DO-
-DO-
MA
MEASUREMENT SAMPLE
MANUF'S DRG MANUF'S SPEC.
MANUF'S DRG MANUF'S SPEC.
-DO-
3.TEMP.WITHSTAND CAPACITY 4.HV/IR
MA
ELECT.TEST
-DO-
-DO-
MA
-DO-
100%
-DO-
-DO-
-DO-
1.12
OIL SEALS & GASKETS
1.MATERIAL OF GASKET 2.SURFACE COND.
MA
VISUAL
100%
MANUF'S DRG/SPECS -
MANUF'S DRG./ SPECS. FREE FROM VISUAL DEFECTS MANUF'S DRG
-DO-
MA
VISUAL
100%
-DO-
3.DIMENSIONS
MA
MEASUREMENT SAMPLE
MANUF'S DRG
-DO-
BHEL
BIDDER/VENDOR
351
SL. NO.
EXTENT OF CHECK
1
2.0 2.1 IN PROCESS
10
11
STATOR FRAME WELDING (IN CASE OF FABRICATED STATOR )
1.WORKMANSHIP & CLEANNESS
MA
VISUAL
100%
-DO-
GOOD FINISH
LOG BOOK
2.DIMENSIONS
MA
MEASUREMENT -DO-
MANUF'S DRG -DOMANUF'S DRG RELEVENT SPEC./ ASTM-E165 MANFR'S SPEC/BHEL SPEC./ RELEVANT STAND -DO-
MANUF'S DRG GOOD FINISH MANUF'S DRG MANUFR'S SPEC./ BHEL SPEC./ BHEL SPEC. SAME AS COL.7
-DO-
2.2
MACHINING
1.FINISH 2.DIMENSIONS
MA MA
VISUAL
100%
LOG BOOK -DO-
3 3
MEASUREMENT -DO-
3.SHAFT SURFACE MA FLOWS
PT
-DO-
-DO-
2.3
PAINTING
1.SURFACE PREPARATION
MA
VISUAL
100%
LOG BOOK
2.PAINT THICKNESS MA (BOTH PRIMER & FINISH COAT) 3.SHADE 4.ADHESION MA MA
MEASUREMENT SAMPLE BY ELCOMETER
-DO-
-DO-
VISUAL CROSS CUTTING & TAPE TEST
-DO-DO-
-DO-DO-
-DO-DO-
Log Book Log Book
3 3
BHEL
BIDDER/VENDOR
352
SL. NO.
EXTENT OF CHECK
1
2.4
2
SHEET STACKING
3
1.COMPLETENESS MA
7
MANUFR'S SPEC. -DO-
8
MANUFR'S SPEC. -DO-
9
Log Book 3
10
-
11
MEASUREMENT SAMPLE
2.COMPRESSION & TIGHTENING 3.CORE LOSS & HOTOPOT 2.5 WINDING 1.COMPLETENESS
MA
MEASUREMENT 100%
Log Book
MA
ELECT.TEST
-DO-
-DO-
-DO-
Log Book
(FOR MOTORS OF 2MW AND ABOVE)
CR
VISUAL
100%
MANUFR'S SPEC./BHEL SPEC. -DO-DO-DO-DO-
MANUFR'S SPEC./BHEL SPEC. -DO-DO-DO-DO-
Log Book
2.CLEANLINESS 3.IR-HV-IR 4.RESISTANCE 5.INTERTURN INSULATION 6.SURGE WITH STAND AND TAN. DELTA TEST 2.6 IMPREGNATION 1.VISCOSCITY 2.TEMP. PRESSURE VACCUM 3.NO. OF DIPS
CR CR CR CR
-DOELECT. TEST -DO-DO-
-DO-DO-DO-DO-
Log Book Log Book Log Book Log Book
3 3 3 3
2 -
CR
-DO-
-DO-
-DO-
-DO-
Log Book
FOR MV MOTOR
MA MA
PHY. TEST PROCESS CHECK
AT STARTING -DOCONTINUOUS -DO-
-DO-DO-
Log Book Log Book
3 3
MA
-DO-
-DO-
-DO-
-DO-
Log Book
THREE DIPS TO BE GIVEN
BHEL
BIDDER/VENDOR
353
SL. NO.
EXTENT OF CHECK
3
4.DURATION
4
MA MA -DOVISUAL
6
-DO100% -DO-DO-
7
-DO-DO-
9
Log Book Log Book 3 3
10
2 -
11
2.7
COMPLETE STATOR ASSEMBLY BRAZING/COMPRESSION JOINT
1.COMPACTNESS & CLEANLINESS 1.COMPLETENESS 2.SOUNDNESS
2.8
CR CR
-DOMALLET TEST & MV TEST ELECT. TEST DYN. BALANCE
-DO-DO-
-DO-DO-
-DO-DO-
Log Book Log Book
3 3
3.HV 2.9 COMPLETE ROTOR ASSEMBLY 1.RESIDUAL UNBALANCE 2.SOUNDNESS OF DIE CASTING 2.10 ASSEMBLY 1.ALIGNMENT 2.WORKMANSHIP 3.AXIAL PLAY 4.DIMENSIONS
MA CR
-DO-DO-
-DOMFG SPEC./ ISO 1940 MFG. SPEC.
-DOMFG. DWG.
Log Book Log Book
3 3
1 VERIFICATION FOR MV MOTOR ONLY
CR
ELECT. (GROWLER TEST) MEAS. VISUAL MEAS. -DO-
-DO-
MFG. SPEC.
Log Book
MA MA MA MA
-DO-DO-DO-DO-
-DO-DO-DOMFG.DRG./ MFG SPEC.
-DO-DO-DOMFG. DRG/ RELEVANT IS MFG SPEC. RELEVANT IS
Log Book Log Book Log Book Log Book
3 3 3 3
2 -
5.CORRECTNESS, COMPLETENESS TERMINATIONS/ MARKING/ COLOUR CODE
MA
VISUAL
100%
MFG SPEC. RELEVANT IS
Log Book
BHEL
BIDDER/VENDOR
354
SL. NO.
EXTENT OF CHECK
1
3.0 TESTS
3
1.TYPE TESTS INCLUDING SPECIAL TESTS AS PER BHEL SPEC. 2.ROUTINE TESTS INCLUDING SPECIAL TEST AS PER BHEL SPEC. 3.VIBRATION MA
5
ELECT.TEST
6
1/TYPE/SIZE
7
IS-325/ BHEL SPEC./ DATA SHEET
8
9
TEST REPORT 3
10
1
11
1,2 NOTE - 1
MA
-DO-
100%
-DO-
-DO-
-DO-
1,2
1,2 NOTE - 2
MA
-DO-
100%
IS-12075 APPROVED DRG/DATA SHEET
IS-12075 APPROVED DRG/DATA SHEET & RELEVANT IS BHEL SPEC. AND DATA SHEET IS-325 & DATA SHEET IS-3682 IS-8239 IS-8240
-DOINSPC. REPORT
3 3
1,2 2,1
4.OVERALL MA DIMENSIONS AND ORIENTATION
MEASUREMENT 100% & VISUAL
5.DEGREE OF PROTECTION
MA
ELECT. & MECH. TEST
1/TYPE/ SIZE
RELEVANT IS
TC
2,1 TC FROM AN INDEPENDENT LABORATORY NOTE-3 -
6.NAMEPLATE DETAILS 7.EXPLOSION FLAME PROOF NESS (IF SPECIFIED) 8.PAINT SHADE, THICKNESS & FINISH
MA
VISUAL
100%
IS-325 & DATA SHEET IS-3682 IS-8239 IS-8240
INSPC. REPORT TC
2,1
MA
EXPLOSION FLAME PROOF TEST
1/TYPE
2,1 NOTE-3
MA
VISUAL & SAMPLE MEASUREMENT BY ELKOMETER
BHEL SPEC. & DATA SHEET
BHEL SPEC. & DATA SHEET
TC
2,1
SAMPLING PLAN TO BE DECIDED BY INSPECTION AGENCY
BHEL
BIDDER/VENDOR
355
SL. NO.
EXTENT OF CHECK
2
NOTES:
10
11
1 DEPENDING UPON THE SIZE AND CRITICALLY, WITNESSING BY BHEL SHALL BE DECIDED. 2 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. HOWEVER, BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES. THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON. 3 IN CASE TEST CERTIFICATES FOR THESE TESTS ON SIMILAR TYPE, SIZE AND DESIGN OF MOTOR FROM INDEPENDENT LABORATORY ARE AVAILABLE, THESE TEST MAY NOT BE REPEATED. 4 WHEREVER CUSTOMER IS INVOLVED IN INSPECTION WITH THE CUSTOMERS, AGENCY (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER.
BHEL
BIDDER/VENDOR
356
CUSTOMER : BIDDER/ VENDOR SHEET 1 OF 2 SYSTEM COMPONENT/OPERATION CHARACTERISTICS CAT. CHECK QUALITY PLAN :
PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-006/0 ITEM AC ELECT. MOTORS BELOW 75KW (LV) EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD
SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V
SL. NO.
1
1.O PAINTING
2
1.SHADE
3
MA
4
VISUAL
6
SAMPLE
9
LOG BOOK 3 -
10
-
11
MANUFR'S BHEL SPEC. SPEC/BHEL SAME AS SPEC./RELEVANT COL.7 STANDARD MANUF'S SPEC MFG. DRG./ MFG. SPEC. MFG.SPEC./ RELEVANT IS MANUF'S SPEC MFG. DRG./ MFG. SPEC. MFG.SPEC. RELEVANT IS
2.0
ASSEMBLY
1.WORKMANSHIP 2.DIMENSIONS
MA MA
VISUAL -DO-
100% -DO-
-DO-DO-
3 3
3.CORRECTNESS COMPLETENESS TERMINATIONS/ MARKING/COLOUR CODE 3.0 TESTS 1.ROUTINE TEST INCLUDING SPECIAL TEST AS PER BHEL SPEC. 2.OVERALL DIMENSIONS & ORIENTATION
MA
VISUAL
100%
-DO-
MA
-DO-
100%
SAME AS COL.7
TEST REPORT
2,1
2,1
NOTE -1
MA
MEASUREMENT 100% & VISUAL
APPROVED DRG/DATA SHEET
APPROVED DRG/DATA SHEET & RELEVANT IS
INSPN. REPORT
BHEL
BIDDER/VENDOR
357
CUSTOMER : QUALITY PLAN BIDDER/ VENDOR SHEET 2 OF 2 SYSTEM COMPONENT/OPERATION CHARACTERISTICS CAT. CHECK :
SL. NO.
PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-006/0 ITEM AC ELECT. MOTORS BELOW 75KW (LV) EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD
SPECIFICATION : NUMBER : SPECIFICATION : TITLE : SECTION VOLUME III AGENCY REMARKS P W V
3
3.NAMEPLATE DETAILS MA
4
VISUAL
5
100%
7
IS-325 & DATA SHEET
8
IS-325 & DATA SHEET
9
INSPN. REPORT 3
10
1 -
11
NOTES: 1 2 3 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. HOWEVER, BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES. THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON WHERE EVER CUSTOMER IS INVOLVED IN INSPECTION, (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER. FOR EXHAUST/VENTILATION FAN MOTORS OF RATING UPTO 1.5KW , ONLY ROUTINE TEST CERTIFICATES SHALL BE FURNISHED FOR SCRUTINY.
BHEL
BIDDER/VENDOR
358
CUSTOMER :
PROJECT TITLE
SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V VOLUME III REMARKS
QUALITY PLAN SHEET 1 OF2 SL. NO. COMPONENT/OPERATION CHARACTERISTIC CHECK
BIDDER/ VENDOR SYSTEM CAT.
EXTENT OF CHECK
QUALITY PLAN NUMBER PED-507-00-Q-013/00 ITEM : CABLE TRAY SUPPORT MATERIAL & ACCESSORIES (BOLTABLE) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD
1
1.0 1.1
2
RAW MATERIAL ROLLED SHEET
10
11
1.CHEM.& PHY. PROPERTIES
MA
VERIFICATION OF TC'S
100%
IS1079 (for hot rolled) IS1079 (for hot rolled) IS-513 (for cold rolled IS-513 (for cold rolled)
MILL TC
3/2
AS PER CONTRACT & AS APPLICABLE IN TECH. SPECIFICATION
2.DIMENSIONS 3.SURFACE FINISH 1.2 2.0 2.1 ZINC IN-PROCESS FABRICATION 1.DIMENSIONS 2.WELDING QUALITY CHEM.COMP.
MA MA
MEASUREMENT 100% VISUAL 100%
IS-1730/ SPECIFICATION
IS-1730/ SPECIFICATION
QC RECORD QC RECORD
3/'2 3/'2
IS1079 (for hot rolled) IS1079 (for hot rolled) IS-513 (for cold rolled IS-513 (for cold rolled) IS-209 IS-209
MA
CHEM TEST
EACH HEAT
QC RECORD
3/2
1/2
MA MA
APPD. DRGS. GOOD WELDING PRACTICE
APPD. DRGS. FREE FROM DEFECTS & SLAG SPECIFICATION
QC RECORD QC RECORD
2 2
1 1 WELDING IS TO BE DONE BY QUALIFIED WELDERS
3.SURFACE FINISH 2.2 SURFACE PREPARATION 1.CLEANING, PICKLING, RINSING & FLUXING 2. SURFACE QUALITY 2.3 GALVANISING 1.TEMPERATURE OF BATH
MA
VISUAL
100%
SPECIFICATION
QC RECORD
MA
MEASUREMENT PERIODIC IN EACH SHIFT
IS:2629
IS:2629
QC RECORD
MA
VISUAL
100%
IS:2629
IS:2629
QC RECORD
MA
TEMPERATURE INDICATOR
CONTINUOUS
IS-2629
IS-2629
QC RECORD
BHEL
BIDDER/VENDOR
359
CUSTOMER :
PROJECT TITLE
SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V VOLUME III REMARKS
QUALITY PLAN SHEET 2 OF 2 SL. NO. COMPONENT/OPERATION CHARACTERISTIC CHECK
EXTENT OF CHECK
QUALITY PLAN NUMBER PED-507-00-Q-013/00 ITEM : CABLE TRAY SUPPORT MATERIAL & ACCESSORIES (BOLTABLE) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD
3
2. DROSS 3. RATE OF IMMERSION 4.SURFACE QUALITY
4
MA MA VISUAL
6
CONTINUOUS IS - 2629
7
IS - 2629
9
QC RECORD QC RECORD 2 3
10
2
11
VISUAL / 100% MEASUREMENT VISUAL 100%
IS - 2629 / MFR'S PRACTICE IS - 2629 /
IS - 2629 / MFR'S PRACTICE FREE FROM BURRS, SLAG, ROUGHNESS, FLUX. STAIN. ETC.
MA
QC RECORD
3.0 3.1
FINISHED ITEMS SINGLE / DOUBLE CHANNELS, CANTILEVER ARMS, CLAMPS 1.DIMENSIONS DISTORTION 2.SURFACE FINISH MA MEASUREMENT IS-2500 LEVEL IV VISUAL IS-2500 LEVEL IV APPD. DRG APPD. DRG INSP. REPORT 3 2, 1 FASTENERS SHALL BE OF REPUTED & APPROVED MAKE
MA
SPECIFICATION
FREE FROM BURRS, SLAG, ROUGHNESS, FLUX. STAIN. ETC. SPECIFICATION/
INSP. REPORT
2, 1
3.MASS OF ZINC COATING 4.UNIFORMITY OF ZINC COATING 5.THICKNESS OF ZINC COATING 6.ADHESION 3.1.1 TYPE TESTING
MA
CHEM. TEST
IS-4759 / SPECIFICATION IS-4759 / SPECIFICATION
IS-6745 / SPECIFICATION IS-2633
INSP. REPORT
2, 1
MA
CHEM. TEST
IS-2633
INSP. REPORT
MA
ELCOMETER
IS-4759 / SPECIFICATION
SPECIFICATION.
SPECIFICATION.
INSP. REPORT
2, 1
MA CR
MECH.TEST TEST
IS-4759 1 SAMPLE
IS-2629 SPECIFICATION./ APPD. TYPE TEST PROCEDURE
IS-2629 SPECIFICATION./ APPD. TYPE TEST PROCEDURE
INSP. REPORT INSP. REPORT
3 2
2, 1 1
3.1.2
WELD INTEGRITY TEST
SOUNDNESS
CR
MPI
SAMPLE TESTED SPECIFICATION. DURING TYPE TESTING
NO DEFECT
INSP. REPORT
AFTER CARRYING OUT TYPE TEST, WELD INTEGRITY TEST TO CHECK THE WELD SOUNDNESS/ ACCEPTANCE SHALL BE DONE BY MANUFACTURER
NOTE: INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE-1. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR
360
ANNEXURE 1 INSTRUCTIONS FOR QUALITY PLAN

The Quality Plan shall include all the Quality Control Measures and Checks adopted by the Vendor to ensure that the material/component/assembly/services supplied by him meet/will meet the requirements as per specifications and good practices. They shall include all stages of operation such as materials, processes, manufacture, assembly, packing and despatch. The following guide lines may be noted: Serial Number Component/Operation- The component and/or operation being checked shall be given here. Characteristics check- The characteristics being checked shall be given here, e.g., chemical composition, mechanical properties, leak tightness, surface defects etc.. Column 4Category -CR stands for critical characteristic - affecting safety of equipment and personnel MA stands for major Characteristic - affecting safety of equipment and personnel MI stands for minor characteristic - affecting appearance etc. Column 5Type/Method of check e.g. chemical analysis tensile testing, hydraulic test, visual examination radiography etc. Column 6Extent of check, such as, 100, 10, 1 percent etc. Column 7Reference Documents - Documents, such as technical specification, drawings, standard specifications (IS, BS ETC.) procedure, etc. according to which check is done. Column 8Acceptance Norms - Standards etc. according to which acceptability or otherwise of the characteristics being checked is decided. Column 9Format of Record - Formats, log shets, reports, etc. in which the observations are recorded. Standard log sheets, reports, formats etc. of the Vendors shall be numbered and such reference numbers shall be included here. Column 10- Agency - The agency which performs the test/instruction shall be written in sub-column W The agency which verifies test certificates/inspection records and carries out audit check of the components/operation shall be written in sub-column V The agencies are codified as 1,2 & 3 1 stands for (BHEL) 1 * means the operation shall be cleared by BHEL before the start of the next operation. 2 Stands for Vendor 3 stands for sub-Vendor of the Vendor and so on. Example : Entry 3 in column P means test./inspection to be performed by sub-Vendors QC Entry 2 in column W means test./inspection to be witnessed by Vendors QC Entry 1 in column V means verification shall be done by BHEL and next stage to be started only after the hold point is cleared by BHEL Column11I- Remarks - Any special remarks shall be given here. NOTES : 1. In absence of correlation with the test certificate(s) (e.g. material identification) samples shall be drawn bgy BHEL and all tests as per relevent specifications shall be carried out in their presence or in recognized Government Laboratory. 2. When materials and components are initially identified and stamped by BHEL QS engineer, the identification marks shall be presserved till despatch. Wherever this is not possible, the identification mark shall be transferred to the components in the presence of BHEL QS Engineer unless other wise agreed. For castings and forgings integral test specimens shall be provided, When this is not possible for casting, they shall be poured in the presence of BHEL QS Engineer unless otherwise, if witnessing of test by BHEL is called for. When welders qualified by reputed inspection agencies or statutory bodies are not available, qualification tests shall be conducted in the presence of BHEL QS Engineer. This Quality Plan is liable to be modified as per the requirements of approved drawings and changes in technical specifications/drawings. If there are contradictions in respect of column 7 & 8 between this Quality Plan and the approved drawings specifications, the latter shall prevail. Wherever inspection by BHELs Purchaser/Third Party/Statutory authorities are mandatory, this shall be compiled with. Inspection reports, log sheets, test reports/certificate. etc. shall be furnished to BHEL at the approproate stages or at the time of final inspection, as required. This Quality Plan is also applicable to spares, if any, under scope of supply of Vendor. The quality plan shall be submitted in minimum 4 copies with a soft copy of the same or in line with contract requirements. Column 1Column 2Column 3-
3. 4. 5.
6. 7. 8. 9.
361
FOREM NO. PEM-6041-0 CUSTOMER : QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-002/01 ITEM :BOUGHT OUT ITEMS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION AGENCY P W V
SL. NO.
FORMAT OF RECORD
VOLUME III REMARKS
1
1.0 1.1 MATERIAL
10
11
SECTIONS, HARDWARES, FLATS, ANGLES & CHANNEL
1. DIMENSIONS
MA
MEASUREMENT
SAMPLE
BHEL TECH. SPEC./ BHEL TECH. SPEC./ TEST DRG. /DATA SHEETS/ DRG. /DATA SHEETS/ CERT. & RELEVANT. IS RELEVANT. IS INSPN. REPORT -DONO VISUAL DEFECTS -DO-
3/2
NO VISUAL DEFECT
2. SURFACE CONDITION
MA
VISUAL
100%
3/2
TC FOR PLATING QUALITY TO BE PROVIDED
3. SURFACE PROTECTION (HARDWARES)
MA
VISUAL
SAMPLE
-DO-
BHEL SPEC.
-DO-
3/2
1.2
SWITCHGEAR COMPONENTS A) SWITCH, SFU'S SWITCH SFU'S. INSTRUMENT, TRANSF, FUSES, CONTACTORS AIR CIRCUIT BREAKERS, ISOLATORS. BIMETAL THERMAL RELAYS, MCB.S & MCCB.S
1. TYPE TESTS
MA
ELECTRICAL
EACH TYPE BHEL SPEC./ RELEVENT IS 100% -DO-
BHEL SPEC./ RELEVENT IS -DO-
TEST CERTIFICATE ROUTINE TEST CERTIFICATE
3/2
2,1
2. ROUTINE TESTS (FOR METERS CT'S & PT'S)
MA
ELECTRICAL
3/2
IF THESE ARE TAKEN FROM BHEL APPROVED SOURCE THEN TC NOT REQUIRED
3. PHYSICAL CONDITION 4. MAKE TYPE RATING ETC. 5. FUNCTIONAL TEST
MA
VISUAL
100%
NO BREAKAGES/ DAMAGES BHEL SPEC./ APPD. DRGS
NO. BREAKAGES/ DAMAGES BHEL SPEC./ APPD. DRGS
INSPN. REPORT -DO-
MA
VISUAL
100%
TO BE PROCURED FROM APPROVED MAKE
MA
ELECTRICAL
100%
RELEVENT IS
RELEVENT IS
-DO-
BHEL
BIDDER/VENDOR
BIDDER'S/VENDOR'S COMPANY SEAL
362
FOREM NO. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-002/01 ITEM :BOUGHT OUT ITEMS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION AGENCY P W V VOLUME III REMARKS
SL. NO.
FORMAT OF RECORD
10
11
1. B) INSTRUMENTS, GAUGES INSTRUMENTS GAUGES, 1 PHYSICAL CONNECTORS, LUGS, GLANDS CONDITION SPACE HEATER,THERMOSTAT, TERMINAL BLOCKS, LAMPS, 2. MAKE, TYPE, PUSHBUTTONS, SMALL , RATING ETC SWITCHES, NAMEPLATES, FERRULES, LABELS, 3. FUNCTIONAL STICKERS, PVC SLEEVES/ CHANNELS C) RELAYS & TIMERS 1. PHYSICAL CONDITION 2. MAKE, TYPE, RATING ETC 3. FUNCTIONAL TEST D) PCB ASSEMBLY 1.3 INSULATING MATERIALS (FRP,SMC,DMC,ETC.)
MA
VISUAL
100%
NO BREAKAGES/ DAMAGES BHEL SPEC./ APPD. DRGS. RELEVANT IS
INSPECTIONN REPORT -DO-
MA
VISUAL
100%
MA
ELECTRICAL
100%
-DO-
MA
VISUAL
100%
INSPECTION REPORT -DO-
MA
VISUAL
100%
MA
ELECTRICAL
100%
-DO-
REFER TO QP NOPED-557-00-Q-002 1. ELECTRICAL CR ELECT. TEST SAMPLE BHEL SPEC./ RELEVANT IS MANUFS. STD. -DO-DOBHEL SPEC./ RELEVANT IS MANUFS. STD. -DO-DOTEST CERTIFICATE 2 1
2. MECH. PROPS. 3. TRACKING INDEX 1.4 WIRES/CABLES 1. SURFACE FINISH 2. DIMENSIONS 3. HV TEST AT 80% OF ORIGINAL BHEL
MA MA
MECH. TEST ELECT. TEST
SAMPLE SAMPLE
-DO-DO-
2 3/2
1 1
MA
VISUAL
100%
NO VISUAL DEFECT BHEL SPECN. IS:694
NO VISUAL DEFECT BHEL SPECN. IS:694
LOG BOOK/ INSP. REPORT -DO-DO-
MA CR HV
MEASUREMENT ELECT. TEST
SAMPLE 100%
2 2
BIDDER/VENDOR
363
FOREM NO. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 3 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-002/01 ITEM :BOUGHT OUT ITEMS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION AGENCY P W V
SL. NO.
FORMAT OF RECORD
VOLUME III REMARKS
1
1.5 15 BUSBARS
3
1. 1 DIMENSION
4
MA
5
MEASUREMENT
6
SAMPLE
7
SPEC./ BHEL SPEC / APPD. DRGS. -DO-
8
SPEC./ BHEL SPEC / APPD. DRGS. -DO-
9
LOG BOOK/ INSP. REPORT -DO2
10
-
11
2. SURFACE FINISH 3. MATERIAL GRADE 4. 4 CONDUCTIVITY 1.6 SHEET STEEL 1. THICKNESS 2. WAVINESS 3. DUCTILITY
MA
VISUAL
100%
MA
VERIF. OF TC
1/LOT
-DO-
-DO-
TEST. CERT.
CR MA MA CR
ELECT. ELECT TEST MEASUREMENT MEASUREMENT BEND TEST
-DODO SAMPLE 100% SAMPLES
-DODO -DO-DO-DO-
-DODO -DO-DO-DO-
-DODO -DO-DOTEST. CERT./ INSP. REPORT TEST CERT. CERT
2 2 2 2
1 -
17 1.7
TRANSFORMER & REACTORS
1 ROUTINE TESTS 1.
MA
ELECT TEST ELECT.
100%
RELEVANT STD. & STD BHEL SPEC. -DO-
RELEVANT STD. & STD BHEL SPEC. -DO-
12 1,2
2. TEMP. RISE TEST 1.8 PAINTS SHELF LIFE
MA
ELECT. TEST
1/RATING
-DO-
1,2
MA
VISUAL
100%
.AS PER PAINTS MANUF'S. SPEC.
INSPN REPORT INSPN REPORT INSPN REPORT INSPN REPORT
1.9
GASKETS (SYN. RUBBER ( ONLY)
1. DIMENSION
MA
MEASUREMENT
SAMPLE
MANUFACTURER'S DRGS. MANUFACTURER'S STD. IS-3400/ BS-2752
MANUFACTURER'S DRGS. MANUFACTURER'S STD. IS-3400/ BS-2752
2. SHORE HARDNESS 3. AGEING
MA
TEST
-DO-
MA
TEST
-DO-
BHEL
PARTICULAR NAME SIGNATURE DATE
BIDDER / VENDOR
364
CUSTOMER : BIDDER/ VENDOR SHEET 1 OF 1 SYSTEM COMPONENT/OPERATION CHARACTERISTICS CAT. CHECK QUALITY PLAN :
PROJECT: TITLE : QUALITY PLAN NUMBER PED-507-00-Q-006/02 ITEM : GALVANISED RIGID STEEL CONDUITS & PIPES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD
SL. NO.
EXTENT OF CHECK
1
1.0 CONDUITS
3
1. MATERIAL
4
MA
5
VISUAL,MECH, & CHEMICAL
6
IS - 9537 IS:9537
7
IS:9537
9
INSPT. REPORT 3
10
2 1
11
2. DIMENSIONS
MA
MEASUREMENT IS - 9537
IS - 9537
IS - 9537
INSPT. REPORT
3. TESTS
MA
TESTING
IS - 9537
IS - 9537
IS - 9537
INSPT. REPORT
2.0 PIPES
1. MATERIAL
MA
IS - 1239
IS - 1239
IS - 1239
INSPT. REPORT
2. DIMENSIONS
MA
MEASUREMENT IS - 1239
IS - 1239
IS - 1239
INSPT. REPORT
3. TESTS
MA
TESTING
IS - 1239
IS - 1239
IS - 1239
INSPT. REPORT
NOTE : INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE - 1. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR
365

3. 4. 5.
6. 7. 8. 9.
366
CUSTOMER :
PROJECT TITLE
SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V
QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK
SL. NO.
EXTENT OF CHECK
QUALITY PLAN NUMBER PED 509 00 Q 001/01 PED-509-00-Q-001/01 ITEM : EARTHING COND. & ELECTRODES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD
VOLUME III REMARKS
1
1.0 1.1
2
RAW MATERIAL MILD STEEL & COPPER (AS SPECIFIED)
10
11
1.CHEMICAL & PHYSICAL PROPERTIES 2.SURFACE FINISH 3 3.DIMENSIONS SO S
MA
CHEM & PHYS TESTS
1/ LOT/SIZE
APPD. DRGS/ DATA SHEETS/ TECH. SPEC. -DO-
APPD. DRGS/ DATA SHEETS/ TECH. SPEC. -DO-
MILL TEST CERTIFICATE
MA
VISUAL
100%
IR
3/2
MA MA
MEASUREMENT 1/ LOT/SIZE SU / O /S MEASUREMENT 100%
-DOO TECH. SPEC. APPD. DRGS/ DATA SHEETS -DORELEVANT IS.
-DOO TECH. SPEC. APPD. DRGS/ DATA SHEETS -DORELEVANT IS.
-DOO -DO-
2 3/2
1.2
HARDWARES
1.DIMENSIONS
2.COATING 1.3 2.0 2.1 ZINC FOR GALVANISATION IN-PROCESS CUTTING, DRILLING 1.WORKMANSHIP DIMENSIONS & DISTORTION 1.WELDING QUALITY 1.CHEM.COMP.
MA MA
VISUAL CHEM.TEST
SAMPLE SAMPLE
-DOTC
3/2 3/2
2 2
MA
VISUAL & 100% MEASUREMENT
APPD. DRGS/ TECH. SPEC.
APPD. DRGS/ TECH. SPEC.
IR
2.2
WELDING
MA
VISUAL & MALLET TEST
SAMPLE
MFR'S. STD
MFR'S.STD.
IR
2.3
SURFACE PREPARATION FOR 1.CLEANING GALVANISING PICKLING & RINSING, BATH STRENGTH/ PURITY & TEMPERATURE BHEL
MA
CHEM. & PERIODIC MEASUREMENT IN EACH SHIFT
IS:2629/ RELEVENT:IS
IR
3/2
BIDDER/VENDOR
367
CUSTOMER :
PROJECT TITLE
SL. NO.
EXTENT OF CHECK
QUALITY PLAN NUMBER PED-509-00-Q-001/01 ITEM : EARTHING COND. & ELECTRODES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD
VOLUME III REMARKS
3
2.SURFACE QUALITY
4
MA VISUAL
5
100%
7
8
IS:2629/ RELEVENT:IS -DOIR
9
3/2
10
-
11
2.4
GALVANISING
1.TEMPERATURE OF BATH 2.DURATION OF DIP 3.ROSS QUANTITY AGITATION 4.BATH AGITATION 5.SURFACE QUALITY
MA
TEMPERATURE INDICATOR VISUAL
CONTINUOUS -DO-
-DO-
3/2
MA
PERIODIC
-DO-
-DO-
-DO-
3/2
MA
TEST
PERIODIC
RELEVENT:IS
RELEVENT:IS
-DO-
MA
VISUAL
PERIODIC
MFR'S STD
MFR'S STD
-DO-
MA
VISUAL
100%
-DO-
-DO-
IR
3/2
2.5
PAINTING
1.SURFACE PREPN. DEGREASING & DERUSTING 2.THICKNESS & ADHESION
MA
CHEM. TEST
100%
TECH.SPEC.
TECH.SPEC.
LOG BOOK
MA
MEASUREMENT SAMPLES
-DO-
-DO-
-DO-
3.0
FINAL TESTS
1.APPEARANCE
MA
VISUAL
SAMPLE
IS:2629
IS:2629 FREE FROM ROUGHNESS LUMPS ETC TECH.SPEC./ APPD.DRG. IS-2633
IR
2.DIMENSION
MA
MEASUREMENT -DO-
TECH.SPEC./ APPD.DRG. IS:4759
IR
3.UNIFORMITY OF COATING
MA
DIP TEST
SAMPLE AS PER IS-2633
IR
BHEL
BIDDER/VENDOR
368
PROJECT TITLE QUALITY PLAN NUMBER PED-509-00-Q-001/01 ITEM : EARTHING COND. & ELECTRODES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD
SL. NO.
EXTENT OF CHECK
VOLUME III REMARKS
3
4. WEIGHT OF COATING 5.ADHESION
4
MA
5
PREECE TEST HAMMER/ KNIFE ELKOMETER
6
IS-4739 IS-6745
8
TECH. SPEC. IR
9
2
10
1 -
11
MA
-DO-
IS-2629
IS-2629
IR
6.THICKNESS
MA
SAMPLES
TECH. SPEC.
TECH. SPEC. AND IS-2629
IR
BHEL
BIDDER / VENDOR
369
CUSTOMER :
PROJECT TITLE
SL. NO.
EXTENT OF CHECK
QUALITY PLAN NUMBER PED-509-00-Q-001/02 ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD
VOLUME III REMARKS
1
1.0 1.1
2
RAW MATERIAL MILD STEEL (FLATS & RODS) AS PER SPECIFICATION
10
11
1.CHEMICAL & PHYSICAL PROPERTIES
MA
VERIFICATION, OF TC'S
100%
IS:1079
IS:1079
MILL TC
STEEL SHALL BE PROCURED FROM SAIL/ TISCO/ RINL/ AUTHORISED RE-ROLLERS/ MANUFACTURERS AS PER BHEL APPROVED SOURCES.
2.DIMENSIONS 3.SURFACE FINISH 1.2 ZINC 1.CHEM.COMP.
MA MA
IS - 1730 IS : 1079
IS - 1730 IS : 1079
QC RECORD QC RECORD
3/2 3/2
MA
CHEM.TEST
SAMPLE
IS - 209
IS - 209
QC RECORD
3/2
1/2
2.0 2.1
IN-PROCESS CUTTING, DRILLING 1.DIMENSIONS 2.SURFACE FINISH MA MA MEASUREMENT 100% VISUAL 100% SPECIFICATION SPECIFICATION SPECIFICATION SPECIFICATION QC RECORD QC RECORD 2 2 1 1
2.2
SURFACE PREPARATION
1.CLEANING PICKLING, RINSING, & FLUXING
MA
IS:2629
IS:2629
QC RECORD
2.SURFACE QUALITY BHEL
MA
VISUAL
100%
IS:2629
IS:2629
QC RECORD
BIDDER/VENDOR
370
CUSTOMER :
PROJECT TITLE
SL. NO.
EXTENT OF CHECK
VOLUME III REMARKS
1
2.3 GALVANISING
3
1.TEMPERATURE OF BATH 2. DROSS
4
MA
5
6
7
IS - 2629
9
QC RECORD 2
10
-
11
MA
IS - 2629
QC RECORD
3. RATE OF IMMERSION
MA
VISUAL/ 100% MEASUREMENT
IS - 2629/ MFRS PRACTICE
QC RECORD
4.SURFACE QUALITY
MA
VISUAL
100%
IS - 2629
FREE FROM BURRS, ROUGHNESS, SLAG, FLUX, STAIN ETC.
QC RECORD
3.0
FINISHED ITEMS 1.DIMENSIONS MA MEASUREMENT RANDOM SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 -
2.SURFACE FINISH
MA
VISUAL
RANDOM
SPECIFICATION
FREE FROM BURRS, SLAG, ROUGHNESS, FLUX, STAIN, ETC. SPECIFICATION
INSP. REPORT
2, 1
3.MASS OF ZINC COATING 4.UNIFORMITY OF ZINC COATING 5.THICKNESS OF ZINC COATING 6.ADHESION
MA
CHEM. TEST
IS - 4759
INSP. REPORT
2, 1
MA
CHEM. TEST
IS - 4759
IS-2633
INSP. REPORT
2, 1
MA
ELCOMETER
IS - 4759
SPECIFICATION
SPECIFICATION
INSP. REPORT
2, 1
MA
MECH.TEST
IS-4759
IS-2629
IS-2629
INSP. REPORT
2, 1
371

3. 4. 5.
6. 7. 8. 9.
372
FORM NO. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 1 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-003/01 ITEM ELECTRICAL IN-PROCESS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V
SL. NO.
FORMAT OF RECORD
1
1.0 FABRICATION
3
1. DIMENSION 2. ALIGNMENT MA MA
5
MEASUREMENT MEASUREMENT & VISUAL VISUAL 100% 100%
7
APPD. DRG. -DO-
8
APPD. DRG. -DO-
9
INSP.REPORT 2 -DO2 -
10
-
11
3. FINISH/ SURFACE DEFECT 2.0 SURFACE PREPARATION & PRE-TREATMENT 1. PROCESS PARAMETERS (SOLUTION STRENGTH, TEMPERATURE DIPPING TIME ETC.) 2. SURFACE CONDITION 3.0 PRIMER & PAINTING (SPRAYED & STOVED) 1. SURFACE FINISH & COVERAGE 2. FILM THICKNESS 3. SHADE 4. ADHESION BHEL
MA
100%
-DO-
-DO-
-DO-
CR
PROCESS CHECK
PERIODIC
MFR. STD./ BHEL SPEC./ RELEVANT IS
MFR. STD./ BHEL SPEC./ RELEVANT IS
LOG BOOK
MA
VISUAL
100%
-DO-
-DO-
-DO-
MA
VISUAL
100%
-DO-
-DO-
-DO-
MA
MEASUREMENT
SAMPLE
-DO-
-DO-
-DO-
MA MA
VISUAL
-DO-DO-
-DO-DO-
-DO-DO-
-DO-DO-
2 2
CROSSOUT TAPE PARTICULARS NAME SIGNATURE DATE
BIDDER/VENDOR
373
FORM NO. PEM-6041-0 CUSTOMER QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-003/01 ITEM ELECTRICAL IN-PROCESS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V
SL. NO.
SHEET 2 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK
FORMAT OF RECORD
1
4.0
2
MOUNTING OF VARIOUS ITEMS
3
1. RIGIDITY MA
4
VISUAL
5
100%
7
MANUFACTURER DRAWINGS -DOAPPD. DRG.
8
MANUFACTURER DRAWINGS -DOAPPD. DRG.
9
LOG BOOK 2 -
10
-
11
2.TIGHTNESS 3. CORRECTNESS & COMPLETENESS 4. ACCESSIBILITY 5.0 MARKING/LABELLING 1. CORRECTNESS
MA MA
VISUAL VISUAL
100% 100%
-DO-DO-
2 2
MA MA
VISUAL VISUAL
100% 100%
-DO-DO-
-DO-DO-
-DOINSPN REPORT -DO-
2 2
2. ADHESION/ FIXING 6.0 PRE-FINAL INSPECTION 1. ALIGNMENT
MA
VISUAL
100%
-DO-
-DO-
MA
VISUAL
100%
BHEL SPEC. BHEL SPEC. TEST 2 & RELEVANT. STD. & RELEVANT. STD. CERTIFICATE. -DO-DO-DO-DO-DO-DO2 2
2. PERFORMANCE 3. IR & HV
CR CR
ELECTRICAL ELECTRICAL
100% 100%
BHEL
BIDDER/VENDOR
374
CUSTOMER : QUALITY PLAN SHEET 1 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. :
PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-002/01 ITEM ELECTRONIC PCB ASSEMBLY EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SL. NO.
FORMAT OF RECORD
1
1.0 1.1
2
BOUGHT OUT ITEMS ELECTRONIC COMPONENTS ACTIVE, PASSIVE ICS, CMOS ETC.
10
11
1. MAKE/RATING
MA
VISUAL
SAMPLE
BHEL SPEC, LCSO/ BARC COMPONENT TO BE USED
BHEL SPEC, LCSO/ BARC COMPONENT TO BE USED
INSPC. REPORT
1.2
POWER DIODES/THYRISTORS/ 1. MAKE/ RATING TRANSISTORS 2.ROUTINE TEST PCB CONNECTORS 1. MAKE/TYPE
MA MA
VISUAL ELECT. & MECH VISUAL
100% 100%
BHEL SPEC./DRG. BHEL SPEC./DRG. RELV. IS/ RELV. IS/ BS/ BHEL SPEC BS/ BHEL SPEC BHEL SPEC, LCSO/ BARC COMPONENT TO BE USED BHEL SPEC, LCSO/ BARC COMPONENT TO BE USED
-DO-DO-
2 2
1 1
1.3
MA
SAMPLE
-DO-
2.0 2.1
PROCESS COMPONENTS MOUNTING & SOLDERING 1. CORRECTNESS OF COMPONENTS 2. MOUNTING & ORIENTATION 3. SOLDERING DEFECTS & FINISH MA VISUAL SAMPLE MANFR. STD MANFR. STD -DO2 -
MA
VISUAL
100%
-DO-
-DO-
-DO-
CR
VISUAL AT 10%
100%
-DO-
-DO-
-DO-
BHEL
BIDDER/VENDOR
375
CUSTOMER : QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. :
SL. NO.
PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-002/01 ITEM ELECTRONIC PCB ASSEMBLY EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
FORMAT OF RECORD
10
11
SOAKING AT 700C FOR 72 HRS. AT ENERGISED CONDITION DO -DO-
2.2
ASSEMBLED PCBS (INTERCONNECTED TOGETHER AS SYSTEM/ EQUIPMENT)
1. FUNCTIONAL CHECK
CR
1. ELECTRICAL BEFORE SOAKING 2. 2 ELECTRICAL AFTER SOAKING OR 3. ELECTRICAL AFTER TEMP. CYCLE TEST
100%
BHEL SPEC./ MFR. STD.
BHEL SPEC./ MFR. STD.
TEST CERT
100%
DO -DO-
DO -DO-
DO -DO-
100%
-DO-
-DO-
-DO-
TEMP. CYCLE: RAPID TEMP. CYCLE AT+ 700C-200C FOR 30 MINTS. AT EACH TEMP. FIVE SUCH CYCLE
2. HV/ IR/ HV/ SWC
MA
ELECT. TESTS
100%
RELEVANT IS/ ANSI-C-37-90197 BHEL SPEC./ MFR. STD
-DO-
-DO-
3. UNIFORMITY & FINISH OF CONFORMAL COATING ON BOTH SIDES
CR
VISUAL
100%
BHEL SPEC./ MFR. STD
INSPN. REPORT
BHEL
BIDDER/VENDOR
376
PROJECT TITLE QUALITY PLAN PED-558-00-Q-001/01 NUMBER PED 558 00 Q 001/01 ITEM :ILLUMINATION EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SL. NO.
FORMAT OF RECORD
VOLUME III REMARKS
1
1.0
2
CABLES & WIRES
3
1.SURFACE DEFECTS
4
MA VISUAL
6
SAMPLE
7
BHEL SPEC. IS:694 IS:1554
8
BHEL SPEC. IS:694 IS:1554
9
INSPN. REPORT & TEST REPORT FROM MANUFACTURER -DOTEST CERT CERT. 3/2
10
2 1
11
TO BE PROCURED FROM APPROVED SOURCE
2.DIMENSIONS 3.TYPE 3 TYPE TESTS
MA CR
MEASUREMENT SAMPLE ELEC.TESTS ELEC TESTS ONE/TYPE & SIZE
-DOBHEL SPEC. SPEC IS:694 IS:1554 -DO-
-DOBHEL SPEC. SPEC IS:694 IS:1554 -DO-
3/2 3
2 2
1 1
4.ACCEPTANCE TESTS 5.ROUTINE TESTS 6.FRLS PROPS. 2.0 JUNCTION BOXES, LIGHTING PANELS AND DISTRIBUTION BOARDS JUNCTION BOXES 1.DIMENSIONS 2.PAINT SHADE/ THICKNESS 3.HV/IR/HV
MA
-DO-
SAMPLING
-DO-
MA
-DO-
100%
-DO-
-DO-
-DO-
2,1
CR
FRLS TESTS
SAMPLES
BHEL SPEC
BHEL SPEC
-DO-
2.1
MA MA
MEASUREMENT 100% VISUAL/MEAS. SAMPLE
BHEL DRG. BHEL SPEC/DRG
INSP. REPORT -DO-
3 3
2 2
COMPONENTS TO BE OF APPROVED MAKE
MA
ELECT.TESTS
100%
2KV AC FOR 1 MINUTE
2KV AC FOR 1 MINUTE
-DO-
BHEL
BIDDER/VENDOR
377
CUSTOMER : QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. CAT :
PROJECT TITLE QUALITY PLAN NUMBER PED-558-00-Q-001/01 ITEM :ILLUMINATION EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SL. SL NO.
FORMAT OF RECORD
VOLUME III REMARKS
3
4.DEGREE OF PROTECTION 5.SPECIAL TESTS IF ANY,EXPLOSION PROOF ETC.
4
MA TEST
6
1/SIZE IS:2147
7
IS:2147
9
TEST CERT.
10
2,1
11
MA
TEST
1/SIZE
IS:2148
IS:2148
TEST CERT.
2,1
2.2
LIGHTING PANELS AND LIGHTING DISTRIBUTION BOARDS
1.DIMENSIONS 2.PAINT SHADE/ THICKNESS 3.DEGREE OF PROTECTION (INCLUDING EXPLOSION PROOF IF ANY) 4.PERFORMANCE TESTS
MA MA
MEASUREMENT SAMPLE VISUAL/ -DOMEASUREMENT TESTS 1/SIZE
INSPT. REPORT INSPT. REPORT
3 3
2,1 2,1
COMPONENTS TO BE OF APPROVED MAKE
MA
BHEL SPEC/ RELEVANT IS
TEST CERT
2,1
MA
ELECT.
100%
BHEL SPEC.
BHEL SPEC.
INSPT. REPORT
2,1
BHEL SHALL WITNESS ON RANDOM ONE SAMPLE, THOUGH EACH ITEM SHALL BE CHECKED BY THE MANUFACTURER -DO-
5.HV/IR/HV
MA
ELECT
100%
2.5KV AC FOR 1 MINUTE BHEL SPEC.
2.5KV AC FOR 1 MINUTE BHEL SPEC.
INSPT. REPORT
2,1
6.TEMP.RISE TEST (FOR CO S ( O COMPLETE ASSEMBLED LDB) 3.0 TUNGSTEN FILAMENT LAMPS, 1. ACCEPTANCE TUBULAR FLUORESCENT TESTS LAMPS, HP MERCURY VAPOUR LAMPS, SODIUM VAPOUR LAMPS, BALLASTS, LUMINAIRES BHEL
MA
ELECT
1/RATING
-DO-
MA
TESTS
SAMPLE
TEST CERT
3/2
BIDDER/VENDOR
378
PROJECT TITLE QUALITY PLAN NUMBER PED-558-00-Q-001/01 ITEM :ILLUMINATION EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SL. NO.
FORMAT OF RECORD
VOLUME III REMARKS
1
4.0 CONDUITS
3
1.MATERIAL
4
MA
5
6
AS PER SPEC./ IS 9537 IS:9537
7
IS:9537
9
INSPT. REPORT
10
3 2 1
11
2.DIMENSIONS
MA
MEASUREMENT AS PER SPEC./ IS 9537 TEST AS PER SPEC./ IS 9537
IS:9537
IS:9537
INSPT. REPORT
3.OTHER TESTS
MA
AS PER SPEC./ IS 9537
IS:9537
INSPT. REPORT
5.0 5.1
ELECTRIC POLES MATERIAL 1.CHEMICAL COMP. MA CHEM. ANALYSIS SAMPLE IS-2713 IS:228 & IS:1894 -DOIS-2713 IS:228 & IS:1894 -DO-DO3/2 2,1
2.PHYSICAL PROP. 5.2 FINAL INSPECTION 1.WORKMANSHIP AND FINISH 2.DIMENSIONS 3.WEIGHT 4.TESTS AS PER IS-2713 IS 2713
MA
PHY.TESTS
-DO-
-DO-
3/2
2,1
MA
VISUAL & MEAS
SAMPLES
BHEL DRG./ IS:2713 -DO-DOIS-2713
BHEL DRG./ IS:2713 -DO-DOIS-2713
-DO-
3/2
2,1
MA MA MA
-DO-DO-DO-
-DO-DO-DO-
-DO-DO-DO-
3/2 3/2 3/2
2,1 2,1 2,1
NOTE: IN CASE TYPE TEST CERTIFICATE FOR DEGREE OF PROTECTION/EXPLOSION PROOFNESS FROM INDEPENDENT LAB. IS NOT AVAILABLE, THE ITEM SHALL BE TESTED AT AN INDEPENDENT LAB.
BHEL
BIDDER / VENDOR
379
PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-004/01 ITEM :INSTRUMENTATION CABLES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SL. NO.
FORMAT OF RECORD
1
1.0 1.1
2
RAW MATERIAL
10
11
PVC Compound(for insulation 1. Physical properties and sheath) 2. Elec.Properties 3. Make & Type
MA
Physical Tests
Sample
IS-5831/BHEL Specification -doPlant Std. IS-3975 BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-doBHEL SPEC.
IS-5831/BHEL Specification -doPlant Std. IS-3975/BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-doBHEL SPEC.
Log Book/ Test Cert. -do-do-do-
3/2
MA MA MA
Electrical Tests Visual Physical & Electrical Tests Measurement Galv.Tests Physical Tests
Sample 100% Sample*
3/2 2 3/2
2 2 * Sample from each Batch/Lot.
1.2
Galvanised steel wire/strip
1. Phy.and Elec. Properties 2. Dimension
MA
-do-do-do-
-do-do-do-
3/2 3/2 3/2
2 2 2
3.Galvanization Quality MA 1.3 Copper/Aluminium Rods/ Wires 1. Physical Properties MA
2. Chemical Composition & purity MA 3.Electrical properties 4.Dimension 1.4 Screen & drain wire 1. Surface Finish 2. Dimension MA MA MA
Chemical analysis -doElectrical Tests Measurement visual -do-dosample
-do-do-doTC & IR
3/2 3/2 3/2 3/2
2 2 2 2
MA
Measurement
-do-
Appd. Data Sheet
Appd. Data ahwwt
TC & IR
3/2
BHEL
BIDDER/VENDOR
380
SL. NO.
FORMAT OF RECORD
3
3.. Mech. Prop. MA
5
Mech test -do-
7
MFRS. STD.
8
MFRS. STD.
9
TC & IR 3/2 -
10
2
11
2.0 2.1
IN PROCESS Wire Drawing , Tinning and Annealing 1. Physical, Electr. Finish & dimension 2. Chemical test for Tinning CR Phy.&Elect. Tests Sample Visual & Meas. Chemical Test Sample BHEL Specn. IS-8130 -doBHEL Specn. IS-8130 -doLog Book 2 1
CR
-do-
2.2
Stranding of wires
1. No.of wires
MA
Counting
Sample
Vendors/BHEL Specn. & Apprd. Data Sheet & Relevant IS
-do-
2. Sequence, lay length & Direction MA 3 Surface Finish 4.Dimension 2.3 Core Insulation (No repair permitted) 1. Surface finish MA MA MA
Visual, Meas Visual Measurement Visual
Sample Sample Sample 100%
-do-do-do-
-do-do-doFree from bulging burnt particles lumps, cuts & Scratches. Appd.data sheet IS-1554
-do-do-do-do-
2 2 2 2
2 Insulation thickness
CR
Measurement
Sample
Appd.data sheet IS-1554
-do-
BHEL
BIDDER/VENDOR
381
SL. NO.
FORMAT OF RECORD
3
3. Concentricity # CR
5
Measurement
6
Sample
7
Mfr's Std./Appd. data sheet -doMfr's Std.
8
9
Log Book 2 -
10
1
11
# To be checked at starting & finish end of Extruded Length
4 Dia over insulation
MA
Measurement Electrical
Sample 100%
-do-do-
2 2
5. Spark Test or Water CR Immersion test 6. Core identification 2.4 Core pairing, screening (provision of drain wire & laying) 1. Pair identification MA MA
Visual Visual
100% 100%
IS-1554 BHEL Spec. & appd. Data sheet -do-
IS-1554 BHEL Spec. & appd. Data sheet -do-
-doLog Book
2 2
2.Wire size & tape size 3.Test for capacitance 4. Sequence of lay and lay length 5. Screen overlap & coverage 6. Dia over laid up core 7. Continuity of drain & drain wire with alum. Screen 2.5 InnerSheath Extrusion 1. Surface finish
MA
Measurement
100%
-do-
CR
Elect. Test
100%
-do-
-do-
-do-
MA
Visual meas
Sample
BHEL Spec. & MFRs. Std.
BHEL Spec. & MFRs. Std.
-do-
MA
Measurement
Sample
-do-
-do-
-do-
MA
Measurement
-do-
-do-
-do-
-do-
MA
Elect. Test
100%
<--------No Discontinuity ---------->
-do-
MA
Visual
100%
--
Free from bulging, burnt particles, lumps cuts & scratches. IS-5831, IS-1554 data sheet
-do-
2. Sheath thickness
MA
Measurement
Sample
IS-5831, IS-1554 data sheet
-do-
BHEL
BIDDER/VENDOR
382
SL. NO.
FORMAT OF RECORD
3
3.Dia over inner sheath MA
5
Measurement
6
Sample
7
IS-5831, IS-1554 data sheet
8
IS-5831, IS-1554 data sheet -do-
9
2 -
10
-
11
2.6
Armouring
1. No.of wires/Strips
MA
Counting
At the start of BHEL Specn./ Appd. BHEL Specn./ Appd. -dothe process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do-do-do-
2. Lay Direction
MA
Visual
3. Lay Length
MA
Visual, Meas.
At the start of BHEL Specn./Appd. BHEL Specn./Appd. the process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do100% -do-do-do-doFree from Bulging Burnt particles, lumps, cuts & scratches IS-5831 & IS-1554 Appd. Data Sheet -do-
Log Book
4. Coverage 5. Dia over armouring 2.7 Outer Sheath Extrusion 1. Surface Finish
MA MA MA
Measurement Measurement Visual
-do-doLog Book
2 2 2
2.Sheath thickness
MA
Measurement
Sample
IS-5831 & IS-1554 Appd. Data Sheet -do-
Log Book
3. Dia over outer sheath 4. Marking
MA
Measurement
Sample
-do-
MA
Visual
100%
IS-1554 & BHEL Specn. IS-1554 & BHEL Specn -do-/Apprd.data sheet
Test Report
Sequential marking shall be done by printing
2.8
Finished Cable
1. Routine Test
CR
Elec. & Meas.
100%
Test Report
2. Type & FRLS Tests
CR
Elec., Phy & Meas. Sample *
Test Report
* One Drum/Size/Lot
BHEL
BIDDER/VENDOR
383
CUSTOMER QUALITY PLAN SHEET 5 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.
: :
SL. NO.
FORMAT OF RECORD
1
3.0
2
Final Inspection
3
1. Finish & Length MA
4
Visual
8
Free from Bulging Burnt particles, lumps, cuts & scratches Appd.Data Sheet/ IS-1554 & IS-10810 -do-
9
Test Report 2
10
1 -
11
One drum in a Lot
(See remark) BHEL specn. IS-1554
2. Dimension
MA
Measurement
Sample Lengths
Appd.Data Sheet/ IS-1554 & IS-10810 -do-
Test Report
3. Armouring Coverage No of No.of Wires/Strips 4. Marking/Colour/ pair identification 5. Test for screening 6. Acceptance Tests 7. Type & FRLS Tests
MA
Visual & Meas.
Sample
-do-
MA
Visual
-do-
-do-
-do-
-do-
CR
Elect. Test
-do-
-do-
-do-
-do-
CR CR
Phy & Elect. Tests 20% Measurement Sample#
-doBHEL Specn. Apprd.Data Sheet
-do-do-
2 2
1 1 #Type Test shall be witnessed on one sample of every lot
NOTES:(A) (B) (C) (D) (E) (F) (G) (H)
JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. VENDOR TO CERTIFY THE SAME. NO REPAIR OF CORE INSULATION PERMITTED CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE RECORD OF RAW MATERIAL, PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER. FILLERS/DUMMY CORES ETC. SHALL BE AS PER BHEL SPECIFICATION WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES, THE SAME SHALL BE AS PER VENDORS SAMPLING PLAN VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION. W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDOR
LEGEND : P : PERFORMER
BHEL
BIDDER/VENDOR
384
CUSTOMER QUALITY PLAN SHEET 1 OF 6 CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.
PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. BOXES/ JN. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V
SL. ONENT/OPERATION NO.
FORMAT OF RECORD
1
1.0
2
RAW MATERIAL & BOUGHT OUT CONTROL SHEET STEEL/CHANNELS
10
11
1.1
1. DUCTILITY
CR
BEND TEST
SAMPLE
IS-1079/IS-513/ IS-226 FACTORY STD
IS-1079/IS-513/ IS-226 NO RUSTING
LOG BOOK
3/2
FOR SHEET STEEL
2. SURFACE FINISH DEFECTS 3. THICKNESS
MA
VISUAL
100%
-DO-
3/2
MA
MEASUREMENT
100%
BHEL SPEC./ IS-1730 BHEL SPEC./ IS-1554/IS-694/ RELEVANT. IS -DO-DO-
BHEL SPEC./ IS-1730 BHEL SPEC./ IS-1554/IS-694/ RELEVANT. IS -DO-DO-
-DO-
3/2
1.2
WIRES
1. SURFACE DEFECTS.
MA
VISUAL
100%
-DO-
3/2
ONLY APPROVED MAKES TO BE USED
2. IR, HV, IR 3. TYPE / ROUTINE TESTS
MA MA
ELECTRICAL VERIFICATION OF TYPE / ROUTINE TEST CERTIFICATE CHEM. TEST
SAMPLE 100%
-DOMFR'S TEST CERT.
3/2 3
1,2
1.3
ZINC INGOT FOR GALVANISING
CHEM. COMP.
MA
EACH
IS-209
IS-209
TEST CERT
3/2
1,2
BHEL
BIDDER/VENDOR
385
FORM NO. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 2 OF 6 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. BOXES/ JN. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V
SL. NO.
FORMAT OF RECORD
1
1.3
2
ELECTRICAL COMPONENTS LIKE FUSE, SWITCHES, INDICATING LAMPS, PUSH BUTTON, TERMINALS GASKETS TERMINALS, CABLE GLANDS AND LUGS 1. MAKE TYPE RATING
3
MA
4
VISUAL
6
SAMPLE
7
BHEL SPEC. & BOM
8
BHEL SPEC. & BOM
9
LOG BOOK 3/2 -
10
-
11
2 OPERATION/ 2.OPERATION/ FUNCTIONAL CHECK 3. IR, HV, IR
CR
ELECTRICAL TEST
SAMPLE
RELEVANT IS AND RELEVANT IS AND CATALOGUE CATALOGUE
DO -DO-
3/2
21 2,1
MA
ELECTRICAL
100%
-DO-
-DO-
-DO-
3/2
2,1
2.0 2.1
IN-PROCESS CONTROL NIBBLING/PUNCHING 1. CUTOUT SIZES MA MEASUREMENT 100% APPD. DRGS APPD. DRGS LOG BOOK 3/2 2,1 STANDARD CUT OUTS TO BE DONE WITH DIES & PUNCHES ONLY
2.DEBURRING 2.2 PANEL FABRICATION 1. DIMENSIONS 2. ALIGNMENT 3. WELDING QUALITY
MI MA MA MI
VISUAL MEASUREMENT MEASUREMENT VISUAL
100% 100% 100% 100%
-DOAPPR. DRGS MFR'S STD -DO-
-DOAPPR. DRGS MFR'S STD -DO-
-DOLOG BOOK LOG BOOK -DO-
3/2 3/2 3/2 3/2
2 2 2
BHEL
BIDDER/VENDOR
386
FORM NO. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 3 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. BOXES/ JN. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V
SL. NO.
FORMAT OF RECORD
1
2.3
2
SURFACE PREPARATION AND PRE-TREATMENT (7 OR 8 TANK PROCESS) ( )
3
1. PROCESS PARAMETERS LIKE BATH TEMP, , CONCENTRATION, DIPPING/ REMOVAL TIME 2. SURFACE QUALITY AFTER EVERY DIP MA
5
PROCESS CHECK
6
PERIODIC
7
BHEL SPEC., MFR. SPEC., IS-6005
8
BHEL SPEC., MFR. SPEC., IS-6005
9
LOG BOOK 3/2 -
10
-
11
IF SAND/SHOT BLASTING, ACID PICKLINGS IS NOT REQUIRED. Q
MA
VISUAL
100%
-DO-
-DO-
-DO-
3/2
2.4
PRIMER APPLICATION & PAINTING
1. SURFACE FINISH & COVERAGE 2. FILM THICKNESS 3. SHADE 4. ADHESION
MA
VISUAL
100%
MFR. SPEC., IS-6005
MFR. SPEC., IS-6005
LOG BOOK
3/2
MA
MEASUREMENT
100%
-DO-
-DO-
-DO-
3/2
MA MA
VISUAL SCRATCH TEST / CROSS OUT TAPE
100% TEMPLATE
-DO-DO-
-DO-DO-
-DO-DO-
3/2 3/2
2 2
BHEL
BIDDER/VENDOR
387
FORM NO. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 4 OF 6 CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. BOXES/ JN. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION : TITLE SECTION VOLUME III GENCY REMARKS P W V
SL. ONENT/OPERATION NO.
FORMAT OF RECORD
1
2.5
2
WIRING, GASKET, NAME PLATE, COMPONENT MOUNTING ETC.
3
1. WIRING LAYOUT MA
4
VISUAL
5
100%
7
APPD . DRGS & SPEC. -DO-
8
APPD . DRGS & SPEC. -DO-
9
LOG BOOK 3/2 -
10
-
11
PVC CHANNELS TO BE USED
2. WORKMANSHIP AND FINISH CORRECTNESS COMPLETENESS 2.6 GALVANISATION PROCESS 1. TEMP OF ZINC BATH 2. DURATION OF DIP
MA
VISUAL
100%
-DO-
3/2
MA
TEMP. INDICATOR VISUAL
CONTINUOUS -DO-
IS-2629
IS-2629
QC RECORD
MA
MANUFACTURER PRACTICE. -DO-
MANUFACTURER PRACTICE. FREE FROM ROUGHNESS, FLUX, STAIN ETC. RELEVANT. IS
-DO-
3. SURFACE QUALITY
MA
VISUAL
100%
-DO-
4. GROSS QUANTITY & AGITATION 3 3.1 FINAL INSPECTION COMPLETE JUNCTION BOX/ LCC'S MARSHALLING BOXES 1. WORKMANSHIP & FINISH, PAINT SHADE/GALV. THICKNESS & ADHESION
MA
TESTS
PERIODIC
RELEVANT. IS
-DO-
MA
VISUAL
100%
BHEL SPEC. APPD. DRG RELEVANT. IS
BHEL SPEC. APPD. DRG RELEVANT. IS
INSPN REPORT
3/2
2,1
BHEL
BIDDER/VENDOR
388
FORM NO. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 5 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. BOXES/ JN. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V
SL. NO.
FORMAT OF RECORD
3
2. UNIFORMITY OF ZINC COATING 3. THICKNESS OF ZINC COATING 4. WIRING LAYOUT 5. COMPONENT LAYOUT & FIXING, ACCESSIBILITY AND SAFETY 6. COMPONENT IDENTIFICATION (MARKING/ NAME PLATES) 7. PROPER WIRE TERMINATION MA
5
CHEM. TEST
6
IS-5358 IS-2633
7
IS-2633
9
INSPN REPORT 2
10
1 -
11
MA
ELCOMETER
-DO-
BHEL SPEC.
BHEL SPEC.
-DO-
MA MA
VISUAL VISUAL
100% 100%
-DO-DO-
-DO-DO-
-DO-DO-
3/2 3/2
2,1 2,1
MA
VISUAL
100%
APPD. DRG.
APPD. DRG.
-DO-
3/2
2,1
MA
PULLING
SAMPLE
-DO-
NO LOOSE CONNECTIONS. ALL TERMINATION TO BE LUGGED NO MISMATCH
-DO-
3/2
2,1
8. DOOR LOCK FUNCTIONING
MA
OPERATON
100%
APPD. DRG
-DO-
3/2
2,1
BHEL
BIDDER/VENDOR
389
FORM NO. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 6 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. BOXES/ JN. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V
SL. NO
FORMAT OF RECORD
3
9.OVERALL DIMENSIONS 10. CONTINUITY MA
5
MEASUREMENT 100%
7
APPD. DRG.
8
APPD. DRG.
9
INSPN. REPORT -DO3/2
10
2,1 -
11
CR
ELECTRICAL
100%
APPD. DRG., BHEL SPEC., & RELEVANT IS -DO-
APPD. DRG., BHEL SPEC., & RELEVANT IS -DO-
3/2
2,1
11. IR-HV-IR
CR
ELECTRICAL
100%
-DO-
3/2
2,1
IR-HV-IR TEST TO BE DONE BEFORE OPERATIONAL TESTS
12.OPERATION INTERLOCKS ETC
CR
ELECTRICAL OPERATION AND FUNCTION IN ENERGISED CONDITION ELECTRICAL
100%
-DO-
-DO-
-DO-
3/2
2,1
13. TEMP RISE (IF APPLICABLE) 14. DEGREE OF PROTECTION & FLAME/ EXPLOSION PROOF NOTE:
CR
ONE/ TYPE/ BHEL SPEC. SIZE RELEVANT IS ONE/ TYPE -DO-
BHEL SPEC. RELEVANT IS -DO-
-DO-
3/2
2,1
CR
WATER AND DUST TESTS, FLAME/ EXPLOSION TESTS
-DO-
3/2
FLAME/EXPLOSION PROOF TEST, IF SPECIFIED IN BHEL SPEC.
IF TC'S FOR DEGREE OF PROTECTION/EXPLOSION PROOFNESS IS AVAILABLE FROM AN INDEPENDENT LABORATORY FOR IDENTICAL DESIGN (SIZE SHALL BE SMALLER THAN THAT INDICATED IN THE TC) THESE TESTS NEED NOT BE REPEATED. PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR
BHEL
390
PROJECT TITLE QUALITY PLAN NUMBER PED-508-00-Q-002 ITEM LEAD ACID BATTERY (DC SYSTEM) EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD
SL. NO.
1
1.0
2
FINISHED BATTERY / CELL
3
1.TYPE TEST MA
4
TEST
6
IS:1651 & 1652/BHEL SPEC BSI:6290 Pt-4 -DODO
7
8
9
INSPN REPORT 3,2 -
10
2,1
11
2.ACCEPTANCE 2 ACCEPTANCE TEST 2.0 ACCESSORIES 1.VISUAL AND DIMENSIONS
MA
TEST
2,1 21
MA
TEST
100%
BHEL DRG
BHEL DRG
INSPECTION 3,2
2,1
BHEL
BIDDER/VENDOR
391
FORM NO. PEM-6041-0 CUSTOMER PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-001/01 ITEM LT SWGR/CONTROL PNLS/DIST. BD EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V
QUALITY PLAN
BIDDER/ VENDOR SHEET 1 OF 3 SYSTEM COMPONENT/OPERATION CHARACTERISTIC CAT. CHECK
SL. NO.
1
1.0 2.0 3.0
2
BOUGHT OUT ITEMS IN-PROCESS FINAL INSPECTION
10
11
REF. QUALITY PLAN NO. PED-506-00-Q-002 REF. QUALITY PLAN NO. PED-506-00-Q-003
1. PHYSICAL BLEMISHES 2. ALIGNMENT 3. DIMENSION 4. PAINT SHADE 5. PAINT THICKNESS
MA
VISUAL
100%
BHEL SPEC.
BHEL SPEC.
INSP. REPORT -DO-DO-DO-DO-
MA MA MA MA
VISUAL MEASUREMENT VISUAL MEASUREMENT
100% 100% 100% FEW PLACES
IS-8623 IS-3427 BHEL SPEC. APPD. DRG/ APPD .DATA SHEET.& OTHER RELEVANT IS
IS-8623 IS-3427 BHEL SPEC. APPD. DRG/ APPD .DATA SHEET.& OTHER RELEVANT IS
2 2 2 2
1 1 1 1
2. GLANDS & LUGS TO BE SUPPLIED ALONG WITH BOARDS 1. SHIPPING SECTION JOINTS PLATES TO BE SUPPLIED
6. PAINT ADHESION 7. VERIFICATION OF B.O.M. 8. INTER CHANGEABILITY
MA
MECH. TESTS
-DO-
APPD. DRG.
APPD. DRG.
-DO-
MA
VISUAL
100%
-DO-
-DO-
-DO-
MA
MECH. TESTS
10%
-DO-
-DO-
-DO-
BHEL
BIDDER/VENDOR
392
FORM NO. PEM-6041-0 CUSTOMER PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-001/01 ITEM LT SWGR/CONTROL PNLS/DIST. BD EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V
QUALITY PLAN
BIDDER/ VENDOR SHEET 2 OF 3 SYSTEM COMPONENT/OPERATION CHARACTERISTIC CAT. CHECK
SL. NO.
3
9. ROUTINE TESTS 10. FUNCTION PERFORMANCE 11. TYPE TESTS 12. INTERLOCKS, PROTECTION & METERING 13. EASE OF WITHDRAWAL & INSERTION CR
5
ELECT . TESTS
6
100%
7
APPD. DRG.
8
APPD. DRG. -DO-
9
2
10
1 -
11
CR
ELECT. & MECH. 100% TESTS ELECT. TESTS SECONDARY INJECTION 1/ITEM 100%
-DO-
-DO-
-DO-
SHALL INCLUDE REMOTE SIMULATION SEE NOTE 'C' PHYSICAL VERIFICATION DURING INSPECTION
CR CR
-DO-DO-
-DO-DO-
-DO-DO-
2 2
1 -
MA
MECH. TESTS
100%
-DO-
-DO-
-DO-
14. ACCESSIBILITY MA OF COMPONENT & SAFETY (SHROUDING) 15. WIRING NEATCR NESS & FIRMNESS 16. BUS BAR TIGHTNESS MA
VISUAL
100%
BHEL SPEC./ APPD. DRG.
BHEL SPEC./ APPD.DRG.
-DO-
PULLING
SAMPLE
-DO-
-DO-
-DO-
MECH. TESTS
SAMPLE
MANUFACTURER'S STANDARD
MANUFACTURER'S -DOSTANDARD
BHEL
BIDDER/VENDOR
393
FORM NO. PEM-6041-0 CUSTOMER PROJECT TITLE BIDDER/ VENDOR SHEET 3 OF 3 SYSTEM COMPONENT/OPERATION CHARACTERISTIC CAT. CHECK SPECIFICATION NUMBER
QUALITY PLAN
SL. NO.
CABLE TYPE/ METHOD OF CHECK
SPECIFICATION TITLE NUMBER PED-506-00-Q-001/01 SECTION VOLUME III ITEM LT SWGR/CONTROL PNLS/DIST. BD EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS CHECK DOCUMENT NORM OF RECORD P W V
QUALITY PLAN
2
NOTE : A. B.
10
11
C. D. E.
ONLY APPROVED MAKE OF COMPONENTS ARE TO BE USED. TYPE TESTS WILL INCLUDE (BESIDES OTHERS) 1. TEMPERATURE RISE TEST 2. DEGREE OF PROTECTION TEST AND EXPLOSION PROOF TEST, IF ANY 3. SHORT TIME CURRENT TEST 4. P & Q TEST REGARDING ACCEPTANCE OF AVAILABLE TYPE TCS, REFER CL.NO. 9.4 OF SPECIFICATION NO. PES-506-01. INDIVIDUAL BREAKER SHALL BE TESTED AT VARIOUS POSITIONS AND AT NORMAL +10% AND -10% OF CONTROL SUPPLY. FUNCTIONAL/PERFORMANCE CHECKS TO BE CONDUCTED ON ENTIRE BOARD AND ALL POWER SUPPLIES SWITCHED ON.
BHEL
BIDDER/VENDOR
394
PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SL. NO.
FORMAT OF RECORD
1
1.0 1.1
2
MATERIALS/COMPONENTS ALUMINIUM AND COPPER BARS & FLEXIBLES
3
1. DIMENSION MA
5
MEASUREMENT 100%
7
BHEL SPECS./ IS:5082/IS:736 IS:737/IS:1897 -DO-DO-DO-
8
BHEL SPECS./ IS:5082/IS:736 IS:737/IS:1897 -DO-DO-DO-
9
TEST CERT 2 -
10
-
11
2.SURFACE FINISH 3.FLATNESS 4.ELECTRICAL CONDUCTIVITY 1.2 ENCLOSURE MATERIALS 1. DIMENSION
MA MA MA
VISUAL VISUAL ELECTRICAL
100% 100% SAMPLE
-DO-DO-DO-
2 2 3,2
2,1
MA
MEASUREMENT
100%
IS:513 / BHEL SPECS.
IS:513 / BHEL SPECS.
INSP REPORT 2
2.SURFACE FINISH 3.FLATNESS 4.BEND TEST (MS ONLY) 1.3 INSULATORS, SEAL OFF BUSHING, CABLES, WIRES, SPACE HEATERS 1.ROUTINE TEST
MA MA MA
VISUAL VISUAL VISUAL
100% 100%
-DO-DO-
-DO-DO-DO-
-DO-DO-DO-
2 2 2
1PIECE/LOT -DO-
MA
ELECTRICAL/ MEASUREMENT
100%
BHEL SPECS./ RELEV IS
BHEL SPECS./ RELEV. IS
MRF TEST CERT./LOG BOOK -DO-
2,1
2.TYPE TEST
MA
ELECTRICAL/ MEASUREMENT VISUAL
1/TYPE
-DO-
-DO-
2,1
FOR INSULATOR BUSHING
3.SURFACE CONDITION RATING & MARKING
MA
100%
BHEL SPECS./ RELEV. IS/PHY. CONDITION
BHEL SPECS./ RELEV. IS/PHY. CONDITION
-DO-
4.DIMENSIONS PHY. MA CONDITION
MEASUREMENT
SAMPLE
BHEL SPECS./ BHEL SPECS./ -DORELEV. IS/ NO PHY. RELEV. IS/ NO PHY. DAMAGE DAMAGE
BHEL
BIDDER/VENDOR
395
SL. NO.
FORMAT OF RECORD
3
5.TRACKING INDEX (FOR INSULATION MATERIAL) MA
5
ELECTRICAL
6
SAMPLE
7
8
9
INSP. REPORT 3,2 -
10
1
11
1.4
BELLEVILLI WASHERS, PLAIN SPRING, & SPRING WASHERS & FASTENERS, DISC WASHERS
1.DIMENSION
MA
MEASUREMENT
RANDOM CHECK
-DO-
-DO-
LOG BOOK
2.SURFACE FINISH 3.SHORE HARDNESS 1.5 NEOPRENE RUBBER BELLOWS & GASKET 1.OIL ABSORPTION
MA
VISUAL
-DO-
-DO-
-DO-
-DO-
MA
MEASUREMENT
SAMPLE
MANUFS STD
MANUFS STD
INSP. REPORT TEST REPORT -DOINSP. REPORT & TC
MA
MEASUREMENT
1PIECE/LOT IS-3400/BHEL SPEC./BS-2752 -DO1/LOT -DOMANUFS STD RELV. STD
IS-3400/BHEL SPEC./BS-2752 -DOMANUFS STD RELV. STD
1,2
2.AGEING TEST 1.6 BUS BAR SLEEVES 1. DIMENSION & MATERIAL CERTIFICATE
MA MA
AGEING TEST MEAS & TESTS
3 3,2
1,2 -
2.0 2.1
IN-PROCESS FABRICATION OF ENCLOSURES BHEL DIMENSION MA MEASUREMENT 100% APPD./MFG DRG APPD./MFG DRG INSP REPORT 2 -
BIDDER/VENDOR
396
SL. NO.
FORMAT OF RECORD
2
2.FINISH
3
MA MA
4
VISUAL
5
100% 100%
7
MANUF'S STD -DO-
8
MANUF'S STD -DO-
9
INSP REPORT 2 -DO2 -
10
-
11
3.ALIGNMENT
VISUAL & MEASUREMENT VISUAL PROCESS CHECKS
4.ORIENTATION 2.2 SURFACE PREPARATION INCLUDING PHOSPHATING & PASSIVATION 1.PROCESS PARAMETERS (SOLUTION STRENGTH TEMP. TIME ETC. 2.SURFACE CONDITION 2.3 INITIAL PAINTING (PRIMER) 1.SURFACE FINISH & COVERAGE 2.FILM THICKNESS 2.4 FINISHING OF BUSBARS/ FLEXIBLES (TINNING/ PLATING,/PAINTING/ SLEEVING) ASSEMBLY BUSBAR ASSEMBLY 1.PHASE SEQUENCE 1.TYPE OF FINISH
MA MA
100% PERIODIC
-DOIS-6005 RELV. IS
-DOIS-6005 RELV. IS
-DO-DO-
2 2
MA
VISUAL
100%
-DO-
-DO-
-DO-
MA
VISUAL
100%
-DO-
-DO-
-DO-
MA
MEASUREMENT
100%
-DO-
-DO-
-DO-
MA
VISUAL
100%
BHEL SPEC/FAB DRG/IS SPEC.
BHEL SPEC/FAB DRG/IS SPEC.
-DO-
3.0 3.1
MA
VERIFICATION
100%
ASSEMBLY DRG/ BHEL SPEC. BS-159/BS-162
ASSEMBLY DRG/ BHEL SPEC. BS-159/BS-162
-DO-
BHEL
BIDDER/VENDOR
397
SL. NO.
FORMAT OF RECORD
3
2.BUSBAR MARKING MA 3.TIGHTNESS OF SUPPORTS MA
4
VISUAL
5
100% 100%
6
-DO-DO-
7
-DO-DO-
8
-DO-DO-
9
2 2 -
10
-
11
MECHANICAL
4.SURFACE MA PREPARATION FOR JT.PREPERATION & APPLYING CONDUCTING MEDIUM 5.TIGHTNESS OF JOINTS AND FLEXIBLE 6.CLEARANCE TO BODY /EARTH & PHASE TO PHASE 3.2 EARTHING 1.SIZE & MATERIAL 2.LOCATION 3.MARKINGS 4.TERMINATIONS 5.TIGHTNESS TO SUPPORTS MA
VISUAL
100%
MANUF'S STD
MANUF'S STD
INSP REPORT 2
MECHANICAL
100%
BHEL SPEC. MANUFS STD
BHEL SPEC. MANUFS STD
INSP REPORT 2
MA
MEASUREMENT
100%
-DO-
-DO-
-DO-
ALUMINIUM BUS BARS JOINTS WILL BE BOLTED WITH BILLET WASHER AND THIGHTENING SHALL BE DONE BY TORQUE WRENCH ALSO THE JOINT SURFACE SHALL HAVE SUITABLE COMPOUND
MA
MEASUREMENT
100%
BHEL SPEC. ASSEMBLY DRG. -DO-DO-DO-DO-
BHEL SPEC. ASSEMBLY DRG. -DO-DO-DO-DO-
-DO-
MA MA MA MA
VISUAL VISUAL VISUAL MECHANICAL
100% 100% 100% 100%
2 2 2 2
BHEL
BIDDER/VENDOR
398
: :
SL. NO.
FORMAT OF RECORD
1
3.3
2
IDENTIFICATION MARKINGS & NAME PLATES
3
1.SECTIONAL IDENTIFICATION 2.EARTH MARKING 3.BUSBAR MARKING 4.NAME PLATES AND DANGER NAME PLATES MA
4
VISUAL
5
100%
6
-DO-
7
-DO-
8
-DO-
9
2 -
10
-
11
MA
VISUAL
100%
-DO-
-DO-
-DO-
MA
VISUAL
100%
-DO-
-DO-
-DO-
MA
VISUAL
100%
-DO-
-DO-
-DO-
4.0 4.1
COMPLETE ASSEMBLY APPEARANCE AND CLEANLINESS 1.DIMENSIONS MA MEASUREMENT 100% APPD.DRG. LOG SHEET 100% BHEL SPEC LAYOUT DRGS/ FAB.DRG. -DOAPPD..DRG. INSPN. REPORT 2 1 -
2.COMPLETE LAYOUT
MA
VISUAL
BHEL SPEC LAYOUT DRGS/ FAB.DRG. -DO-DO-
3.GENERAL & MARKINGAPPEARANCE 4.FITTING OF INSPN.COVERS 5.ALIGNMENT OF SECTION 6.EARTH BUS ALIGNMENTS & MARKING
MA
VISUAL
100%
ALL HARDWARES WHICH ARE EXPOSED TO OUTDOOR SHALL BE TOUCHED WITH ANTI CORROSSION RUST PREVENTION SOLUTION, VARNISH BEFORE PACKING REPORTS TO BE SUBMITTED TO BHEL IT SHALL BE POSSIBLE TO ADJUST TEMP KNOB THERMOSTAT FROM INSPECTION COVER.
MA
VISUAL
100%
-DO-
-DO-
-DO-
MA
VISUAL
100%
-DO-
-DO-
-DO-
MA
VISUAL
100%
-DO-
-DO-
-DO-
BHEL
BIDDER/VENDOR
399
: :
SL. NO.
FORMAT OF RECORD
3
7.MARKINGS ON THE SECTIONS 8.PAINT THICKNESS SHADE 9.ADHESION MA
4
VISUAL
5
100%
6
-DO-
7
-DO-
8
-DO-
9
2
10
1 -
11
MA
VISUAL
100%
APPD.DRGS/ BHEL SPEC MFR SPEC -DOIS-8084 ANSI C37 20/ ANSI-C37-20/ BHEL SPEC. -DO-
APPD.DRGS/ BHEL SPEC MFR SPEC -DOIS-8084 ANSI C37 20/ ANSI-C37-20/ BHEL SPEC. -DO-
LOG BOOK
3,2
MA MA
SCRATCH TEST ELECTRICAL
TEMPLATE 100%
-DOTEST CERT/ REPORT
3,2 2
2 -
4.2
TESTS
1.ROUTINE TESTS
2.TEMPERATURE RISE 3.DEGREE OF PROTECTION 4.SHORT CKT TEST 5.IMPULSE TEST 6.OTHER TYPE TESTS, IF ANY 5.0 IDENTIFICATION, PRESERVATION & PACKING 1.IDENTIFICATION MARKING ON PACKING CASES
MA
ELECTRICAL
SAMPLE
-DO-
MA
AS PER SPEC
SAMPLE
-DO-
-DO-
-DO-
MA
ELECTRICAL
SAMPLE
-DO-
-DO-
-DO-
MA
ELECTRICAL
SAMPLE
-DO-
-DO-
-DO-
MA
AS PER SPEC
SAMPLE
-DO-
-DO-
-DO-
MA
VISUAL
100%
PURCHASER'S INSTRUCTION
PURCHASER'S INSTRUCTION
BHEL
BIDDER/VENDOR
400
CUSTOMER QUALITY PLAN SHEET 1 OF4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.
PROJECT TITLE QUALITY PLAN NUMBER PED-505-00-Q-002/01 ITEM NEUTRAL GROUNDING RESISTOR EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD
FORM NO. PEM-6041-0 SPECIFICATION: NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V
SL. NO.
1
1.0 1.1 MATERIALS
10
11
SHEET STEEL AND STRUCTURES
1. DIMENSIONS
MA
MEASUREMENT 10%
2. 2 SURFACE FINISH 3. DUCTILITY OF SHEET 1.2 COPPER FLATS 1. DIMENSIONS 2. SURFACE FINISH 3. CHEMICAL COMPOSITION
MI MA
VISUAL BEND TEST
100% SAMPLES
IS-1079 IS-2026 IS-513 -DODO
IS-1079 IS-2026 IS-513 -DODO
INSPN. REPORT -DODO
MA MI MA
IS-1897 -DO-do-
IS-1897 -DO-do-
-DO-DOTEST CERT. FROM SUPPLIER INSPN. REPORT
2 2 3/2
CHEM ANALYSIS 1/ MELT
1.3
RESISTOR GRIDS
1. SURFACE FINISH
CR
VISUAL
100%
BHEL DRG./SPEC. BHEL DRG./SPEC. MFG. DRAWING MFG. DRAWING
3/2
2. DIMENSIONS
MA
MEASUREMENT 100%
-DO-
-DO-
-DO-
3/2
3. RESISTANCE VALUE
MA
ELECTRICAL
10%
-DO-
-DO-
-DO-
3/2
BHEL
BIDDER/VENDOR
401
FORM NO. PEM-6041-0 SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V
SL. NO.
3
4. CHEMICAL COMPOSITION MA
9
TEST 3/2 CERTIFICATE -DO-DODO -DO-DO2 2 2 2 -
10
1
11
CHEM ANALYSIS 1/ LOT
BHEL DRG./SPEC. BHEL DRG./SPEC. MFG. DRAWING MFG. DRAWING MFR'S. STD. DRAWING MFR'S. STD. DRAWING MFR'S. STD. DRAWING MFR'S. STD. DRAWING
1.4
MICA INSULATED TIE-RODS MICA WASHERS, STEEL WASHER PORCELAIN INSULATORS (POST & BUSHING TYPES)
1. DIMENSIONS 2. 2 SURFACE 1. DIMENSIONS 2. SURFACE FINISH & DEFECTS 3. DRY P.F. HV TEST
MA MA MA MA
MEASUREMENT 100% VISUAL INSPN INSPN. 100%
PORCELAIN INSULATORS SHALL BE OF APPROVED MAKE
1.5
MEASUREMENT 10% MEASUREMENT 100%
MA
ELEC.
100%
BHEL SPECN. IS
BHEL SPECN IS
TEST CERT.
2 2.1
FABRICATION CUTTING, BENDING, PUNCHING, DRILLING ETC 1. DIMENSIONS 2. FINISH MA MA MA MEASUREMENT 100% VISUAL VISUAL 100% 100% APPD./MFG -DO-DOAPPD./MFG. -DO-DOINSPN REPORT -DO-DO2 2 2 -
2.2
SURFACE PREPARATION
1. SURFACE CONDITION 1. SURFACE FINISH & COVERAGE
2.3
PAINTING
MA
VISUAL
100%
-DO-
-DO-
-DO-
BHEL
BIDDER/VENDOR
402
SL. NO.
CABLE TYPE/ METHOD OF CHECK
3
2. FILM THICKNESS MA
5
MEASUREMENT 100%
7
APPD./MFG
8
APPD./MFG.
9
INSPN REPORT 2 -
10
-
11
3 3.1
SUB-ASSEMBLY RESISTOR UNIT FRAME ASSEMBLED 1. HV TEST CR ELECTRICAL 100% BHEL SPECN/ IS-1822/ BS-587 -DOBHEL SPECN IS-1822/ BS-587 -DOTEST REPORT 2 -
2.RESISTANCE VALUE 3. DIMENSIONS 4 4.1 FINAL ASSEMBLY COMPLETE NGR 1. HV TEST
CR
ELECTRICAL
100%
-DO-
MA
MEASUREMENT 100%
-DO-
-DO-
CR
ELECTRICAL
100%
BHEL SPECN/ IS-1822 BS-587 -DO-
BHEL SPECN IS-1822 BS-587 -DO-
TEST REPORT
2.RESISTANCE VALUE 3. DIMENSIONS
CR
ELECTRICAL
100%
MA
MEASUREMENT 100%
-DO-
-DOBIDDER/VENDOR
BHEL
403
SL. NO.
3
4. SHORT TIME RATING/TEMPERATURE RISE TEST 5. DEGREE OF PROTECTION 6. PAINT FINISH MA
5
HEAT RUN
6
1/TYPE
7
BHEL SPEC./ IS:1822 BS:587 IS-2147
8
BHEL SPEC./ IS:1822 BS:587 BHEL SPEC
9
3
10
1 -
11
MA
AS PER IS-2147 IS 2147 VISUAL
1/TYPE
TEST REPORT
MA
100%
BHEL SPEC./ IS-5 -DO-
BHEL SPEC./ IS-5 -DO-
7. PAINT THICKNESS 8. PAINT SHADE
MA
GAUGE
ALL
MI
VISUAL-SHADE CARD
ALL
-DO-
-DO-
BHEL
BIDDER/VENDOR
404
PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-001/01 ITEM PUBLIC ADDRESS SYSTEM EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SL. NO.
FORMAT OF RECORD
1
1.0
2
MATERIAL/ BOUGHT OUT ITEMS IN-PROCESS PCB ASSEMBLY SPEAKERS
10
11
AS PER QUALITY PLAN NO. PED-506-00-Q-002
2.0 3.0 4.0
AS PER QUALITY PLAN NO. PED-506-00-Q-003 AS PER QUALITY PLAN NO. PED-557-00-Q-002 1. TYPE TEST MA ELECT. & MEAS -DO1/TYPE BHEL. SPEC. IS7741, IS7527 -DOBHEL. SPEC. IS7741, IS7527 -DOTEST CERT. 3/2 2 1
2. ACCEPTANCE TEST 3. ROUTINE TEST 4. DEGREE OF PROTECTION 5.0 HANDSET 1.WORKMANSHIP
MA
AS PER IS
-DO-
3/2
MA MA
-DO-DO-
100% AS PER IS
-DO-DO-
-DO-DO-
-DO-DO-
3/2 3/2
2 -
1/2
MA
VISUAL
100%
BHEL/SPEC RELV.IS/BS/ IEC -DO-DO-
-DO-
1/2
2. COLOUR 3.INPUT CHARACTERISTICS 4. OUTPUT CHARACTERISTICS 5. SIDE TONE 6.LIMITING BHEL
MA MA
VISUAL ELECT. MEAS
SAMPLE -DO-
-DO-DO-
3 3
1/2 1/2
MA
-DO-
-DO-
-DO-
-DO-
-DO-
1/2
MA MA
-DO-DO-
-DO-DO-
-DO-DO-
-DO-DO-
-DO-DO-
3 3
1/2 1/2
BIDDER/VENDOR
405
SL. NO.
FORMAT OF RECORD
3
7. OPERATION MA
5
ELECT. MEAS
6
SAMPLE
7
BHEL/SPEC RELV.IS/BS/ IEC -DO-
8
9
3
10
1,2
11
8. DEGREE OF PROTECTION 9. RIGIDITY, SOUNDNESS OF MOUNTING & CONSTRUCTION ETC. 6 FINAL ASSEMBLY ( SYSTEM ) 1. WORKMANSHIP
MA
MEASUREMENT
-DO-
-DO-
1/2
MA
DROP & VIBRATION TEST
-DO-
-DO-
-DO-
-DO-
1/2
MA
VISUAL
100%
BHEL SPEC APPD. DRG. DATA SHEETS, & RELV. IS/ BS -DO-DO-
TC
2. WIRING LAYOUT 3.WIRE TERMINATION(SOLDERING OR CRIMPED LUGS) 4. FERRULE NUMBERING 5.TERMINAL BLOCK ARRANGEMENT
MA MA
-DOPULL TEST
-DO-DO-
-DO-DO-
2 2
1 1
MA
VISUAL
-DO-
-DO-
-DO-
-DO-
MA
-DO-
-DO-
-DO-
-DO-
-DO-
BHEL
BIDDER/VENDOR
406
SL. NO.
FORMAT OF RECORD
3
6.PROPER MA MOUNTING OF ITEM
4
VISUAL
5
100%
7
BHEL SPEC APPD. DRG. DATA SHEETS, & RELV. IS/ BS -DO-
8
9
2
10
1 -
11
7.CORRECTNESS OF ITEM 8.SMOOTH OPERATION OF VARIOUS CONTROLS 9.COMPONENT LAYOUT
MA
-DO-
-DO-
-DO-
MA
-DO-
-DO-
-DO-
-DO-
-DO-
MA
-DO-
-DO-
-DO-
-DO-
-DO-
10.IDENTIFICATIONMARKS 11. PAINT SHADE & FINISH 12.PAINT THICKNESS 13.DIMENSION 14 SCREENING
MA
-DO-
-DO-
-DO-
-DO-
-DO-
MA
-DO-
-DO-
-DO-
-DO-
-DO-
MA
MEASUREMENT
-DO-
-DO-
-DO-
-DO-
MA MA
MEASUREMENT SYSTEM SOAKING
-DO-DO-
-DO48HRS AT MAX 45 DEGREE C SITE TEMP -DO-
-DO-
-DO-
2 2
1 1
NO FAILURE,DRIFT -DOETC
15.OPERATION/ FUNCTIONAL CHECK BHEL
CR
ELECTRICAL
-DO-
-DO-
-DO-
BIDDER/VENDOR
407
SL. NO.
FORMAT OF RECORD
3
16.INTER-CHANGEABILITY 17.EFFICIENCY CR
5
ELECTRICAL -DO-
6
-DO-
7
-DO-
8
-DO-
9
2
10
1 -
11
CR
-DO-DO-
-DO-DO-
-DO-DO-
-DO-DO-
-DO-DO-
2 2
1 1
18.POWER SUPPLY- CR VARIOUS CHECKS 19.IR-MV IR 7 PACKING 1.WOOD SPECIES CR MA
-DOVISUAL
-DO100%
-DOBHEL SPEC/ MFR STD -DO-
-DOBHEL SPEC/ MFR STD -DO-
-DO-DO-
2 2
1 1
2.WOOD PRESERVATIVE TREATMENT 3.STURDINESS 4.WATER PROOF COVER FOR EQUIPMENT 5.SILCAGEL PACKETS 6.MARKING 7.PACKING SLIP
MA
-DO-
-DO-
-DO-
MA MA
-DO-DO-
-DO-DO-
-DO-DO-
-DO-DO-
-DO-DO-
2 2
1 1
MA
-DO-
-DO-
-DO-
-DO-
-DO-
MA MA
-DO-DO-
-DO-DO-
-DO-DO-
-DO-DO-
-DO-DO-
2 2
1 1
BHEL
BIDDER/VENDOR
408
PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/02 ITEM :PVC POWER & CONTROL CABLE EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SL. NO.
FORMAT OF RECORD
1
1.0 1.1
2
RAW MATERIAL
10
11
PVC Compound(for insulation 1. Physical properties MA and sheath) 2. Elec.Properties 3. Make & Type MA MA MA
Physical Tests
Sample
IS-5831/BHEL Specification -doPlant Std. IS-3975 BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-do-
IS-5831/BHEL Specification -doPlant Std. IS-3975/BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-do-
Log Book/ Test Cert. -do-do-do-
3/2
Electrical Tests Visual Physical & Electrical Tests Measurement Galv.Tests Physical Tests
Sample 100% Sample*
3/2 2 3/2
2 2 * Sample from each Batch/Lot.
1.2
1. Phy.and Elec. Properties 2. Dimension
MA
-do-do-do-
-do-do-do-
3/2 3/2 3/2
2 2 2
3.Galvanization Quality MA 1.3 Copper/Aluminium Rods/ Wires 1. Physical Properties MA
2. Chemical Composition & purityMA 3.Electrical properties MA 4.Dimension MA
Chemical analysis -doElectrical Tests Measurement -do-do-
-do-do-do-
3/2 3/2 3/2
2 2 2
BHEL
BIDDER/VENDOR
409
SL. NO.
FORMAT OF RECORD
1
2.0 2.1
2
IN PROCESS Wire Drawing , Tinning and Annealing
10
11
1. Physical, Electr. CR Finish & dimension 2. 2 Chemical test for Tinning CR
Phy.&Elect. Tests Sample Visual & Meas. Chemical Test Sample
BHEL Specn. IS-8130 do -do-
BHEL Specn. IS-8130 do -do-
Log Book
do -do-
2.2
Stranding of wires
1. No.of wires
MA
Counting
Sample
-do-
2. Sequence, lay length & Direction MA 3 Surface Finish 4.Dimension 2.3 Core Insulation (No repair permitted) 1. Surface finish MA MA MA
Visual, Meas Visual Measurement Visual
Sample Sample Sample 100%
-do-do-do-
-do-do-doFree from bulging burnt particles lumps, cuts & Scratches. Appd.data sheet IS-1554
-do-do-do-do-
2 2 2 2
2 Insulation thickness CR
Measurement
Sample
Appd.data sheet IS-1554
-do-
BHEL
BIDDER/VENDOR
410
SL. NO.
FORMAT OF RECORD
3
3. Concentricity # CR
5
Measurement
6
Sample
7
8
9
Log Book 2 -
10
1
11
4 Dia over insulation
MA
Measurement Electrical
Sample 100%
-do-do-
2 2
5. Spark Test or Water CR Immersion test 6. Core identification 2.4 Core Laying MA
Visual Measurement
100% Sample
IS-1554 -do-
IS-1554 -do-
-doLog Book
2 2
1. Dia over laidup core MA
2.Sequence of lay, MA Lay length & direction up core 2.5 InnerSheath Extrusion 1. Surface finish MA
Visual & Meas.
Sample
Mfrs.Std./relevant IS
Mfrs.Std./relevant IS
-do-
Visual
100%
--
Free from bulging, burnt particles, lumps cuts & scratches. IS-5831, IS-1554 data sheet -do-
-do-
2. Sheath thickness
MA
Measurement
Sample
IS-5831, IS-1554 data sheet -do-
-do-
3.Dia over inner sheathMA 2.6 Armouring 1. No.of wires/Strips MA
-doCounting
-do-
-do-
2 2
At the start of BHEL Specn./ Appd. BHEL Specn./ Appd. -dothe process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do-do-do-
2. Lay Direction
MA
Visual
BHEL
BIDDER/VENDOR
411
SL. NO.
FORMAT OF RECORD
3
3. Lay Length MA
5
Visual, Meas.
9
2 -
10
-
11
At the start of BHEL Specn./ Appd. BHEL Specn./ Appd. Log Book the process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do100% -do-do-do-doFree from Bulging Burnt particles, lumps, cuts & scratches IS-5831 & IS-1554 Data Sheet -do-do-doLog Book
4. Coverage
MA
Measurement Measurement Visual
2 2 2
5. Dia over armouring MA 2.7 Outer Sheath Extrusion 1. Surface Finish MA
2.Sheath thickness
MA
Measurement
Sample
IS-5831 & IS-1554 Data Sheet -do-
Log Book
3. Dia over outer sheath 4. Marking
MA
Measurement
Sample
-do-
MA
Visual
100%
IS-1554 & BHEL Specn. IS-1554 & BHEL Specn -do-/Apprd.data sheet Free from Bulging Burnt particles, lumps, cuts & scratches
Test Report
2.8
Finished Cable
1. Routine Test
CR
Elec. & Meas.
100%
Test Report
2. Type & FRLS Tests CR
Elec., Phy & Meas. Sample *
Test Report
* One Drum/Size/Lot
3.0
Final Inspection
1. Finish & Length
MA
Visual
(See remark) BHEL specn. IS-1554
Test Report
One drum each for Power & control cables in a Lot
BHEL
BIDDER/VENDOR
412
: :
SL. NO.
FORMAT OF RECORD
3
2. Dimension MA
5
Measurement
6
As per IS
7
8
9
Test Report 2
10
1 -
11
3. Armouring Coverage No.of Wires/Strips 4. Marking/Colour Coding 5. Acceptance Tests
MA
Visual & Meas.
As per IS
-do-
MA
Visual
-do-
-do-
-do-
-do-
CR
Phy & Elect. Tests -doMeasurement

(SEE REMARK)
-do-do-
2 2
1 1 Type Test shall be witnessed on one sample per type(Power/control) of every lot
6. Type & FRLS Tests CR
NOTES:(A) (B) (C) (D) (E) (F) (G) (H)
JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. VENDOR TO CERTIFY THE SAME. NO REPAIR OF CORE INSULATION PERMITTED CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE RECORD OF RAW MATERIAL, PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER. FILLERS/DUMMY CORES ETC. SHALL BE AS PER BHEL SPECIFICATION WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES, THE SAME SHALL BE AS PER VENDORS SAMPLING PLAN VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION. W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDOR
LEGEND : P : PERFORMER
BHEL
BIDDER/VENDOR
413
PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-006/01 ITEM RIGID STEEL CONDUITS & PIPES REFERENCE ACCEPTANCE DOCUMENT NORM
SL. NO.
EXTENT OF CHECK
FORMAT OF RECORD
2
FINISHED PRODUCT
3
1. DIMENSIONAL CONFORMITY MA
5
MEASUREMENT
6
5 SAMPLES PER SIZE PER LOT -DO-DO-
7
AS PER IS-9537 PT I & II AND OTHER IS -DO-DO-
8
AS PER IS-9537 PT I & II AND OTHER IS -DO-DOIR
9
2
10
1 -
11
2.FINISH 3. SCREW THREAD 4. BEND TEST
MI MI
VISUAL MEASUREMENT
-DO-DO-
2 2
1 1
MA
MECH.
1 SAMPLE OF EACH SIZE -DO-
-DO-
-DO-
-DO-
5. COMPRESSION TEST 6. WT. OF ZINC COATING 7.UNIFORMITY OF ZINC 8. ADHESION TEST
MA
MECH. TEST
-DO-
-DO-
-DO-
MA
MEASUREMENT
ONE SAMPLE IS-6745
IS-4736
-DO-
2,1
MA
CHEMICAL
-DO-
IS-2633
IS-2633
-DO-
2,1
MA
PIVOT/HAMMER TEST
-DO-
IS2629
IS-2629
-DO-
2,1
BHEL
BIDDER/VENDOR
414
CUSTOMER :
PROJECT TITLE
SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION FORMAT OF RECORD AGENCY P W V VOLUME III REMARKS
QUALITY PLAN NUMBER PED-507-00-Q-005/03 ITEM : CABLE TRAYS & ACCESSORIES
EXTENT OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORM
1
1.0 1.1
2
RAW MATERIAL ROLLED SHEET
10
11
1.CHEM.& PHY. PROPERTIES
MA
VERIFICATION OF TC'S
100%
IS1079/ SPECIFICATION
IS1079/ SPECIFICATION
MILL TC
3/2
STEEL SHALL BE PROCURED FROM SAIL/TISCO/RINL/ AUTHORISED RE-ROLLERS/ MANUFACTURER AS PER BHEL APPROVED SOURCES.
2.DIMENSIONS 3.SURFACE FINISH
MA MA
IS-1730/ SPECIFICATION IS1079/ SPECIFICATION
IS-1730/ SPECIFICATION IS1079/ SPECIFICATION
QC RECORD QC RECORD
3/2 3/2
1.2 2.0 2.1
ZINC IN-PROCESS FABRICATION
CHEM.COMP.
MA
CHEM TEST
EACH HEAT
IS-209
IS-209
QC RECORD
3/2
1/2
1.DIMENSIONS
MA
MEASUREMENT 100%
APPD.DRGS.
APPD.DRGS.
QC RECORD
INSPECTION AT BLACK STAGE BY BHEL/ BHEL AUTHORISED INSPECTION AGENCY WELDING IS TO BE DONE BY QUALIFIED WELDERS
2.WELDING QUALITY
MA
VISUAL
100%
GOOD WELDING PRACTICE
FREE FROM DEFECTS & SLAG SPECIFICATION
QC RECORD
3.SURFACE FINISH 4.RIGIDITY (CABLE TRAYs)
MA
VISUAL
100%
SPECIFICATION
QC RECORD
MA
DEFLECTION TEST
SAMPLE
SPECIFICATION
SPECIFICATION
QC RECORD
600 MM OR 450 MM WIDE CABLE TRAY SIZE TO BE TESTED
2.2
SURFACE PREPARATION
1.CLEANING, PICKLING, RINSING & FLUXING 2. SURFACE QUALITY
MA
IS:2629
IS:2629
QC RECORD
MA
VISUAL
100%
IS:2629
IS:2629
QC RECORD
BHEL
BIDDER/VENDOR
415
CUSTOMER :
PROJECT TITLE
SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION FORMAT OF RECORD AGENCY P W V VOLUME III REMARKS
QUALITY PLAN NUMBER PED-507-00-Q-005/03 ITEM : CABLE TRAYS & ACCESSORIES
EXTENT OF CHECK
REFERENCE DOCUMENT
ACCEPTANCE NORM
1
2.3 GALVANISING
3
1.TEMPERATURE OF BATH 2. DROSS 3. RATE OF IMMERSION 4.SURFACE QUALITY
4
MA
5
6
CONTINUOUS IS-2629
7
IS-2629
9
QC RECORD 2
10
-
11
MA MA
CONTINUOUS
IS - 2629 IS - 2629 / MFR'S PRACTICE IS - 2629
IS - 2631 IS - 2629 / MFR'S PRACTICE FREE FROM BURRS ROUGHNESS, SLAG , FLUX. STAIN. ETC.
QC RECORD QC RECORD
2 3
VISUAL 100% MEASUREMENT VISUAL 100%
MA
QC RECORD
3.0 3.1
FINISHED ITEMS (CABLE TRAY, ACCESSORIES & HARDWARES) 1.DIMENSIONS MA MEASUREMENT IS-2500 LEVEL IV APPD. DRGS. APPD. DRGS. INSP. REPORT 3 2, 1 FASTENERS SHALL BE OF REPUTED & APPROVED MAKE.
2.SURFACE FINISH
MA
VISUAL
IS-2500 LEVEL IV
SPECIFICATION
FREE FROM BURRS, SLAG, ROUGHNESS, FLUX., STAIN. ETC. SPECIFICATION
INSP. REPORT
2, 1
3.RIGIDITY (FOR TRAYS)
MA
DEFLECTION TEST
1/ LOT
SPECIFICATION
INSP. REPORT
600 MM OR 450 MM WIDE CABLE TRAY TO BE TESTED
MA
CHEM. TEST
IS-4759 / IS-6745 SPECIFICATION SPECIFICATION IS-4759 / IS-2633 SPECIFICATION
SPECIFICATION
INSP. REPORT
2, 1
MA
CHEM. TEST
IS-2633
INSP. REPORT
MA
ELCOMETER
IS-4759 / SPECIFICATION SPECIFICATION
SPECIFICATION
INSP. REPORT
2, 1
MA
MECH.TEST
IS-4759
IS-2629
IS-2629
INSP. REPORT
2, 1
416
CUSTOMER :
PROJECT TITLE
SL. NO.
EXTENT OF CHECK
VOLUME III REMARKS
1
1.0 1.1
2
RAW MATERIAL MILD STEEL (FLATS & RODS) AS PER SPECIFICATION
10
11
1.CHEMICAL & PHYSICAL PROPERTIES
MA
VERIFICATION, OF TC'S
100%
IS:1079
IS:1079
MILL TC
STEEL SHALL BE PROCURED FROM SAIL/ TISCO/ RINL/ AUTHORISED RE-ROLLERS/ MANUFACTURERS AS PER BHEL APPROVED SOURCES. SOURCES
2.DIMENSIONS 3.SURFACE FINISH 1.2 ZINC 1.CHEM.COMP.
MA MA
IS - 1730 IS : 1079
IS - 1730 IS : 1079
QC RECORD QC RECORD
3/2 3/2
MA
CHEM.TEST
SAMPLE
IS - 209
IS - 209
QC RECORD
3/2
1/2
2.0 2.1
IN-PROCESS CUTTING, DRILLING 1.DIMENSIONS 2.SURFACE FINISH MA MA MEASUREMENT 100% VISUAL 100% SPECIFICATION SPECIFICATION SPECIFICATION SPECIFICATION QC RECORD QC RECORD 2 2 1 1
2.2
SURFACE PREPARATION
1.CLEANING PICKLING, PICKLING RINSING, & FLUXING
MA
IS:2629
IS:2629
QC RECORD
2.SURFACE QUALITY BHEL
MA
VISUAL
100%
IS:2629
IS:2629
QC RECORD
BIDDER/VENDOR
417
CUSTOMER :
PROJECT TITLE
SL. NO. NO
EXTENT OF CHECK
VOLUME III REMARKS
1
2.3 GALVANISING
3
1.TEMPERATURE OF BATH 2. DROSS
4
MA
5
6
7
IS - 2629
9
QC RECORD 2
10
-
11
MA
IS - 2629
QC RECORD
3. RATE OF IMMERSION
MA
VISUAL/ 100% MEASUREMENT
QC RECORD
4.SURFACE QUALITY
MA
VISUAL
100%
IS - 2629
FREE FROM BURRS, ROUGHNESS, SLAG, FLUX, STAIN ETC.
QC RECORD
3.0
FINISHED ITEMS 1.DIMENSIONS MA MEASUREMENT RANDOM SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 -
2.SURFACE FINISH
MA
VISUAL
RANDOM
SPECIFICATION
FREE FROM BURRS, SLAG, , , ROUGHNESS, FLUX, STAIN, ETC. SPECIFICATION
INSP. REPORT
2, 1
MA
CHEM. TEST
IS - 4759
INSP. REPORT
2, 1
MA
CHEM. TEST
IS - 4759
IS-2633
INSP. REPORT
2, 1
MA
ELCOMETER
IS - 4759
SPECIFICATION
SPECIFICATION
INSP. REPORT
2, 1
MA
MECH.TEST
IS-4759
IS-2629
IS-2629
INSP. REPORT
2, 1
418
CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. :
PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001, R-02 ITEM : XLPE P Power C bl Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SL. NO.
SHEET 1 OF 5 COMPONENT/OPERATION CHARACTERISTIC CHECK
FORMAT OF RECORD
1
1.0 1.1
2
RAW MATERIALS XLPE Compound
10
11
1. Physical properties
MA
Physical Tests
Sample/ Lot
IS:7098 & Mfrs Std.
IS:7098 & Mfrs Std.
Test Report Log Book -do-
3/2
2. Elec.Properties
MA
Electrical Tests
-do-
-do-
-do-
3/2
1,2 Raw material verification as per approved subvendor list 1,2
1.2
Semi Conducting Compound
1. Phy.and Elec. Properties
MA
Phy.and Elec. Tests
-do-
Manufacturer's standard
Manufacturer's standard
-do-
3/2
1,2
1.3
Copper Foil
1. Dimensions
MA
Measurement
-do-
Manufacturer's std./ Appd. Data sheet IS:1897
Manufacturer's std./ Appd. Data sheet IS:1897
Log Book
2. Physical, Chemical & Elect. Properities
MA
Phy., Chem. & Elect. Tests
-do-
Supplier's test report & log book Log Book/ Test Report -do-
3/2
1.4
PVC Compound (for sheath)
1. Physical properties
MA
Physical Tests
Sample/ lot
IS:5831/BHEL Specification -do-
IS:5831/BHEL Specification -do-
3/2
2. Elec.Properties
MA
Electrical Test
-do-
3/2
1.5 15
1. Phy. 1 Phy and Elec Elec. Properties
MA
Physical & Electrical Tests
Sample from IS:3975/ BHEL each batch/ Specification lot -do-do-do-do-
IS:3975/ BHEL Specification
Log Book/ Test Cert.
3/2
2. Dimension 3. Galvanization
MA MA
Measurement Galv. requirement
-do-do-
-do-do-
3/2 3/2
2 2
BHEL
BIDDER/VENDOR
419
CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT CAT. :
PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001, R-02 ITEM XLPE Power Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SL SL. NO.
FORMAT OF RECORD
1
1.6
2
Copper/Aluminium Rods/ Wires
3
1. Physical Properties 2. 2 Chemical Composition & purity 3.Electrical properties 4. Dimensions
4
MA
5
Physical Tests -do-
7
IS:613, IS-5484, IS:8130 & BHEL Specification -do-
8
IS:613, IS-5484, IS:8130 & BHEL Specification -do-
9
-do3/2
10
2
11
MA
Chemical analysis Electrical Tests Measurement
-do-
-do-
3/2
MA MA
-do-do-
-do-do-
-do-do-
-do-do-
3/2 3/2
2 2
2.0 2.1
IN PROCESS Wire Drawing , Tinning and Annealing 1. Physical, Electrical, Finish & dimension CR Phy. & Elect. Tests Sample Visual / Meas. IS:8130 & BHEL Specn. IS:8130 & BHEL Specn. Log Book 2 1
2. Chemical test for Tinning 2.2 Stranding of wires 1. No. of wires
CR
Chemical Test
-do-
-do-
-do-
-do-
MA
Counting
-do-
BHEL Specn, Apprd. BHEL Specn, Apprd. Data Sheet & Data Sheet & Relevant IS Relevant IS
-do-
2. Sequence, lay length & Direction 3 Surface Finish 4. Dimension 2.3 Conductor Screening 1. Radial thickness
MA
Visual, Meas.
-do-
-do-
-do-
-do-
MA MA MA
Visual Measurement -do-
-dodo -doSample
-dodo -do-
-dodo -do-
-dodo -doLog Book
2 2 2
BHEL Specn & Apprd. BHEL Specn & Apprd. Data Sheet Data Sheet
BHEL
BIDDER/VENDOR
420
PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001, R-02 Q , ITEM XLPE Power Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM
SL. NO.
FORMAT OF RECORD
1
2.4
2
Core Insulation (XLPE) ( (No repair permitted) p p )
3
1. Surface finish
4
MA Visual
5
100%
6
-
7
-do-
9
Log Book
10
2 1
11
2. Concentricity #
CR
Measurement
Sample
Mfr's Std./Appd. data sheet
Mfr's Std./Appd. data sheet
Log Book
3. Thickness of Insulation I l i 4 Dia over insulation
CR
Measurement
-do-
BHEL specn./Apprd. Dats Sh / IS:7098 Sheet/ IS 098 D -do-
BHEL specn./Apprd. Dats Sh / IS:7098 Sheet/ IS 098 D -do-
Inspection Report R -do-
MA
Measurement
-do-
5. Test on XLPE (Tensile & Elongation, Hot Set & Aging Test) 2.5 Insulation Screening, (Non Metallic & Metallic ) 1. Surface finish
MA
Tests
-do-
-do-
-do-
-do-
MA
Visual
Sample
Free from bulging burnt particles lumps, cuts & Scratches. BHEL Spec./ data sheet BHEL Spec./ data sheet Plant Std.
Log Book
2. Thickness
MA
-do-
-do-
BHEL Spec./ data sheet BHEL Spec./ data sheet Plant Std.
-do-
3 Overlap of Tape Band 4 Tightness of Tape Band
MA
Measurement
-do-
-do-
MA
Visual
-do-
-do-
BHEL
BIDDER/VENDOR
421
SL. NO NO.
FORMAT OF RECORD
1
2.6 Core Laying
3
1. Dia over laid up core 2.Sequence of lay, & direction 3. Lay Length
4
MA MA
5
Measurement Visual & Meas.
6
Sample Sample
7
Apprd. Data Sheet IS 7098/ Mfrs.Std.
8
Apprd. Data Sheet IS 7098/ Mfrs.Std.
9
Log Book -do2 2
10
-
11
MA MA
Meas. Visual
-do100%
Mnfrs. Std. --
Mnfrs. Std. Free from bulging, burnt particles, lumps cuts & scratches. Appd. Data Sheet, IS:7098 -doBHEL Specn./ Apprd.Data sheet IS:7098 Plant Standard
-do-do-
2 2
2.7
InnerSheath Extrusion
1. Surface finish
2. Sheath thickness
MA
Measurement
Sample
Appd. Data Sheet, IS:7098 -do-
do -do-
3. Dia over inner sheath 2.8 Armour 1. No.of wires/Strips
MA MA
-doCounting
-do-
-do-do-
2 2
At the start of BHEL Specn./ the process Apprd.Data sheet -do-do-doIS:7098 Plant Standard
2. Lay Direction 3. Lay Length 4. Coverage
MA MA MA
Visual Meas. Measurement
-doLog Book -do-
2 2 2
BHEL Specn./ Appd. BHEL Specn./ Appd. Data Sheet Data Sheet -do-doFree from Bulging Bulging, burnt particles, lumps, cuts & scratches Appd. Data Sheet
5. Dia over armouring 2.9 29 Outer Sheath Extrusion 1. 1 Surface Finish
MA MA
Measurement Visual
-do100%
-doLog Book
2 2
2.Sheath thickness
MA
Measurement
Sample
Appd. Data Sheet
Log Book
3. Dia over outer sheath 4. Marking BHEL
MA MA
-doVisual
-do100%
-do-
-do-
-doTest Report
2 2
IS:7098, BHEL Specn. IS:7098, BHEL Specn. & Appd. Data Sheet & Appd. Data Sheet BIDDER/VENDOR
422
CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT CAT. :
SL SL. NO.
FORMAT OF RECORD
1
2.10
2
Finished Cable
3
1. Routine Test 2. 2 Type Tests *
4
CR CR
5
Elec. & Meas. Physical & Electrical Tests Visual, Measurement 100%
9
2 2
10
1 1
11
IS:7098 & BHEL specnIS:7098 & BHEL specn. Test Report BHEL Specn Specn. Apprd. Data Sheet BHEL Specn Specn. Apprd.Data Sheet BHEL Specn./ Free from Bulging Burnt particles, lumps, cuts & scratches Specn./ Appd. Data Sheet/ IS:7098, IS:10810 -do-dodo
Sample *
* As per specn specn.
3.0
Final Inspection
1. Finish & Length
MA
(See remark) BHEL specn. & IS:7098
-do-
One drum in each Lot
2. Dimension
MA
Measurement
As per IS
Appd.Data Sheet/ IS:7098, IS:10810 -do-
-do-
3. Armouring Coverage No.of Wires/Strips 4. Marking & Colour Coding 5. Acceptance Tests
MA
Visual & Meas.
-do-
-do-
MA
Visual
-do-
-do-
-do-
-do-
CR
Phy, Elect. Tests
-do-
BHEL Specn Apprd. Data Sheet
-do-
-do-
NOTES:(A) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION, VENDOR TO CERTIFY THE SAME. (B) NO REPAIR OF CORE INSULATION PERMITTED (C) CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION (D) PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE (E) RECORD OF RAW MATERIAL, PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER. (F) FILLERS/DUMMY CORES ETC. SHALL BE AS PER BHEL SPECIFICATION (G) WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES, THE SAME SHALL BE AS PER SAMPLING PLAN AGREED BY PURCHASER. (H) VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION. IN EXPORT ORDE PACKING SHALL BE AS PER BHEL SPECIFICATION & THE SAME SHALL BE WITNESSED. LEGEND : P : PERFORMER BHEL W: WITNESSER PARTICULARS NAME SIGNATURE DATE V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2 VENDOR : 3 SUB VENDOR BHEL/BHEL s 2-VENDOR
BIDDER/ VENDOR
423
700MW CCPP AT NEDUNOOR, KARIMNAGAR (job no. I-59) BHEL Clarification (ELECTRICAL) submitted to customer S. No. Volume Section Page No. Clause No. 1.0(f) & Electrical key line diagram dwg. No.: TCE.5960AEL-SK-2001 Technical Specification Clarification
ANNEXURE-B
III
D3.0
1 OF 17
Fault level shall be limited to 44 kA rms for 6.6 kV systems .... & as per key SLD, fault level at 6.6kV system is 40kA.
6.6 kV system with fault level limited to 40 kA rms has been offered.
III
D3.0
12 OF 17
1.18( c)
The motors rated 175 kW and The motors rated above 175 kW shall be above shall be 6.6kV and motors 6.6kV and motors rated upto 175 kW shall be rated upto 175 kW shall be 400V. 400 V. (c) Generator side current .GT side. The generator side current transformer is envisaged as a part of the isolated phase busduct. The voltage transformer, lightning arresters & surge capacitors are envisaged as a part of SPVT & VT cubicle provided as part of generator busduct & associated equipement. Manual shorting link has been offered.
III
D 3.2
2 OF 8
2.9 (c & d) (d) Voltage transformers with transformer side. (a) A switched short..disconnector. (b) A manually fitted ..connection.
III
D 3.2
2 OF 8
2.10 (a & b)
III
D3.9
2 OF 15
9.3 & Electrical key line diagram dwg. No.: TCE.5960AEL-SK-2001
Additionally One (1) no. transformer feeder on each bus (colony supply) for Owners use shall be provided.
Two nos. transformer feeders (One (1) no. on each bus), rated 2000kVA for Colony supply(in customer scope) are considered in BHEL scope as per clause no. 9.3 of section D3.9 Vol-III of customer specification. Further HT cable, LT service transformer, LT busduct, LT power/control cables & LT switchgear for the same are excluded from BHEL scope of supply.
424
700MW CCPP AT NEDUNOOR, KARIMNAGAR (job no. I-59) BHEL deviations (ELECTRICAL) submitted to customer S. No. Volume Section Page No. Clause No. Technical Specification Deviation
III
D3.13
2 OF 14
13.3.2
Emergency & Continuous Load (For 10 hours duration)..
DC battery is sized for Emergency DC loads for 1hour & continuous DC loads( ie. Indicating lamps, GRP, ECP7 AVR panel etc.) for 10 hours.
425
10. SCHEDULE OF TECHNICAL DEVIATION

S. No. Page No. Vol/ section/ Clause No. Technical Specification Clarification
426
11. SPARES:
BIDDER TO QUOTE FOR MANDATORY SPARES, ERECTION & COMMISSIONING SPARES & RECOMMENDED O&M SPARES (FOR 3 YEARS OF OPERATION). AN INDICATIVE LIST OF MANDATORY SPARES IS GIVEN BELOW FOR REFERENCE. S. No. 1 1.1 1.1.1 1.1.2 1.1.3 1.1.4 1.1.5 1.1.6 1.1.7 1.1.8 Description LT SWITCHGEAR & LT BUSDUCT 400V Switchgear Complete pole of breaker Breaker complete with operating mechanism and truck mounted Closing & tripping coils Fixed and moving contact assemblies of each breaker Spring charging motors Set of gasket Bus bar support insulators Aux switch assembly, limit position switches, Local/ Remote selector switch, breaker control switches & other switches Relays of each type used Clustered type LED CTs. of each ratio & type VTs. of each ratio & type Meters. of each type & rating. Fuses of each rating Transducers of each type & rating Non-Segregated Phase Busducts Bus support insulator Seal-off bushing Flexible connector (for equipment connection) Gasket DC System ( Spares applicable separately for each battery bank) 2.1 Battery (a) Battery Cell of each type (b) Positive Plate of each Type (c) Negative Plate of each Type (d) Connectors with Nuts & Bolts (e) Vent Plugs 1No. 1No. 1No. 1 Set 1 Set 1 No. for each rating 2 No. for each rating 1 No. for each rating 1 set 2 Nos. of each rating 1 No. of each rating 2 sets of each rating 2Set 2No. 5Set 10No. 5 No.s Quantity
1.1.9 1.1.10 1.1.11 1.1.12 1.1.13 1.1.14 1.1.15 1.2 1.2.1 1.2.2 1.2.3 1.2.4 2
1 No. 10 Nos. of each colour 2 Nos. 2 Nos. 1 No. 5 Nos. 2 Nos.
427
Doc. No. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. : Page : 1 Set 1 no. of each rating 1 no. 1 no. 1 no. 2 nos. of each rating 1 no. 1 no. 5 nos. 0 of
(f) Terminal Post 2.2 Battery Chargers (a) Silicon Diodes (b) Control Switch (c) Current Regulator (d) Off-Load Tap Changing Device (e) Fuse of each type (f) D.C. Ammeter (g) Miniature circuit Breaker (h) Neon Lamps 3 3.1 3.2 3.3 Lighting Fixtures Lighting fixtures (along with lamps) Lighting Panels MCBs
3% of each type 1 No. of each type. 5 No. of 32A & 5 Nos of 63A.
428
700MW KARIMNAGAR CCPP PROJECT
ANNEXURE-A
PROPOSED SCOPE SPLIT OF ELECTRICAL SYSTEMS BETWEEN BHEL & EPC PARTNER SL. NO. ABBREVIATION A. 1 2 3 4 5 B B(BP) B(ED) B(HR) B(HY) B(IS) EXPANSION BHEL BHEL(BHOPAL) BHEL(EDN), BANGALORE BHEL(HARDWAR) BHEL(HYDERABAD) BHEL(ISG), BANGALORE BHEL(JHANSI) BHEL(PIPING CENTRE), CHENNAI BHEL(PEM), NOIDA BHEL(RUDRAPUR) BHEL(REGION) BHEL(TRICHY)
6 B(JH) 7 B(PC) 8 B(PE) 9 B(RR) 10 B(RG) 11 B(TY)
B.
EPC-PARTNER
700MW KARIMNAGAR CCPP PROJECT PROPOSED SCOPE SPLIT BETWEEN BHEL & EPC PARTNER SCOPE BASIC ENGINEERING SUPERVISION OF ERECTION & COMMISSIONING ERECTION EXECUTION & COMMISSIONING DETAILED ENGINEERING
Sl. no.
SUPPLY
SYSTEM / EQUIPMENT
TERMINAL POINT
REMARKS
POWER EVACUATION EQUIPMENT / SYSTEM 1.1 Insulated phase busduct / Segregated phase busduct 1.2 Generator Circuit Breaker 1.3 Generator Transformer 1.4 UAT 1.5 Generator, GT & UAT protection panels 1.6 Generator NGT & NGR 1.7 Electrical Control Panel(For main plant, located in CCR), DDCMIS for electrical systems 1.8 DCS (station C&I) 1.9 Diesel Generator 2 AC/DC POWER- DISTRIBUTION CONTROL 2.1 MV (6.6 kV) Switch gear 2.2 LT Aux. Transformers ( dry type) 2.3 LT Switch gear {PMCC, PCC, MCC, ACDB local PB stns for LT / HT Drives} 2.4 LV Bus Duct & Accessories 2.5 NGR for MV system 2.6 DC Power Supply 220 V dc P/B(PE) B(PE) B(PE) P/B(PE) B(PE) P/B(PE) P/B(PE) B(RR) B(PE) B(BP) B(JH) B(BP) B(RR) B(ED) P/B(PE) P/B(PE) B(ED) B(IS) B(RR) B(PE) B(BP) B(JH) B(BP) B(RR) B(ED) B(ED) B(IS) P P P P P B(PE) P P P P P P B(PE) P P P P P Design & Layout by 'P' based on inputs by respective BHEL units.
P/B(PE) P/B(PE) P P P P
B(BP) B(JH) P P P P
B(BP) B(JH) P P P
P P P P P P
P P P P P P
2.7 DC Distribution 220 V dc 2.8 DC Starter - for Boiler, Turbine and Generator 3 STATION -ELECTRICAL AUXILIARY PKG 3.1 Plant Lighting Equipment (Supply & E &C) 3.2 PA System 4 POWER / CONTROL /SCREENED CABLES 4.1 4.2 4.3 4.4 4.5 4.6 HT Power Cables LT Power Cables LT Control Cables Screen Cables (instrumentation) Spl. Cables [ for Cranes, Hoists etc.] Fire Survival Cables
P P
P P
B(HY/TY) B(HY/TY) B(HY/TY)
P P
P P
P P
P P
P P For complete plant.
P P P P P P
P P P P P P
P P P P P P
P P P P P P
P P P P P P
* As per Cable Scope detailed matrix (Table1)
5 STATION CABLING, EARTHING & LIGHTING-MATERIAL 5.1 TG Trunk Cabling (Field-UCD) Material P 5.2 Boiler Trunk Cabling (Field - UCD) Material 5.3 Cabling Material (Cable trays & accessories, cable tray support, trefoil clamps, cable glands & lugs, jointing kits, Fire sealing material) 5.4 Equipment Earthing Material (Above ground & below ground grade) 5.5 Electronic Earthing Material 5.6 Lightning Protection Material 5.7 Plant Lighting - erection material 6 Main system design , Electrical single line diagram & Design Memorandum for all Electrical package Electrical Layout/ Cable Listing/ cable routing/ cable interconnection diagram P P
P P P
P P P
P P P
P P P
P B(ED) P P P
P P P P P
P P P P NA
P P P P NA
P P P P NA
For main plant & BOP areas.
Drg./doc. shall be prepared by 'P' in consultaion with B(PE) Interface among inputs from respective BHEL units is in 'P' scope.
NA
NA
NA
Preparation of Electrical load data
NA
NA
NA
Load list shall be prepared by 'P' in consultaion with B(PE).
P P NA NA NA Submission of drg./doc.(i.e. Data sheet/ OGA/ scheme/ Test certificates/ Quality Plans etc.) for all electrical packages NA NA NA NA NA 10 Submission of drg. & doc./ follow-up with P' shall provide support to 'B(PE)'. customer/ obtaining approval from customer engineering of electrical system and equipment including layout / cable routing engineering and furnishing details/BOM/technical Note:-Design & 9 particulars shall be in Partner's scope.
700MW KARIMNAGAR COMBINED CYCLE POWER PROJECT

TABLE-1: CABLE SCOPE DOCUMENT ELECTRICAL SYSTEMS
SCOPE OF CABLE LISTING P B(PE)-C&I P P SCOPE OF CABLE SUPPLY P P P P
SL No. A MV SYSTEM 1 2 3 4
ITEM
CABLE TYPE
REMARKS
REV
SWGR TO OUTGOING FEEDER SWGR TO DDCMIS/ UCP SWGR TO LPBS INTERCONNECTING CABLES FOR MV SWGR
MV PC G CC LV PC, CC,F,G
00 00 00 00
B LV SYSTEM (UNDER STATION C & I) 1 2 3 SWGR TO DRIVES SWGR TO DDCMIS/ UCP SWGR TO LPBS LV PC G F,G P B(PE)-C&I P P P P 00 00 00
C LV SYSTEM (UNDER B(PE)- BOPs) 1 2 3 4 5 6 SWGR TO DRIVES SWGR TO PLC/ LCP SWGR TO LPBS LCP TO DRIVES PLC/ LCP TO FIELD PLC/ LCP TO DDCMIS LV PC G F,G LV PC G F, G P P P P P B(PE)-C&I P P P P P P 00 00 00 00 00 00
D LV SYSTEM (GAS TURBINES) 1 INCOMER CABLES ALL OUTGOING CABLES TO DRIVES/ 2 MARK-VI PANESL/ FIELD 3 SWGR TO LPBS
LV PC PC, CC F,G
B(HY) B(HY) B(HY)
P B(HY) B(HY) 00 00
E 1 2 3 4
220 V DC SYSTEM BATTERY/ CHARGER TO DCDB DCDB TO STARTER PANEL FOR DC DRIVE DCDB TO PANEL/ DC LOAD STARTER PANEL TO FIELD
LV PC LV PC LV PC CC
P B(HR) P B(HR)
P B(HR) P B(HR)
00 00 00 00
F 125 V DC SYSTEM 1 2 3 4 BATTERY/ CHARGER TO DCDB DCDB TO STARTER PANEL FOR DC DRIVE DCDB TO PANEL/ DC LOAD STARTER PANEL TO FIELD LV PC LV PC LV PC CC B(HY) B(HY) B(HY) B(HY) B(HY) B(HY) B(HY) B(HY) 00 00 00 00
G 24 V DC SYSTEM 1 1 3 4 415V SWGR TO BATTERY CHARGER BATTERY/ CHARGER TO DCDB ALL OUTGOING POWER CABLES FROM 24V DCDB VARIOUS LOADS BIANRY & ANOLOG SIGNALS FROM 24V SYSTEM TO DDCMIS LV PC LV PC LV PC F,G P B(ED) B(ED) B(PE)-C&I P P P P 00 00 00 00
H UPS INCOMING POWER CABLE FROM SWGR 1 TO UPS
PC
Page 1 of 2
2 3 4
ALL OUTGING POWER CABLE FROM UPS ACDB TO VARIOUS LOAD BIANRY & ANOLOG SIGNALS FROM UPS TO DDCMIS ALL INTERCONNECTING POWER CABLES BETWEEN UPS, ACDB & BATTERY
PC F, G PC
B(ED) B(PE)-C&I B(ED)
P P P
00 00 00
I 1 2
ELECTRONIC EARTHING BETWEEN DDCMIS CABINETS DDCMIS CABINETS TO ELECTRONIS EARTH PIT STATIC EXCITATION EQUIPMENT (SEE) EXCITATION TRANSFORMER TO THYRISTOR CUBICLES THYRISTOR CUBICLES TO FF / FB CUBICLES FB CUBICLE TO GENERATOR SLIP RINGS INTERCONNECTING CABLES WITHIN SEE AUX AC SUPPLY FROM SWGR TO SEE AUX DC SUPPLY FROM DCDB TO SEE CONTROL & INSTRUMENTION CABLES BETWEEN SEE TO GRP, ECP, DDCMIS PC CC CC CC PC PC CC B(ED) B(ED) B(ED) B(ED) P P P P P P B(ED) P P P 00 00 00 00 00 00 PC PC B(ED) B(ED) P P 00
J 1 2 3 4 5 6 7
K 415V EMERGENCY DG SYSTEM 1 2 3 4 5 415 DG PCC TO DG TERMINALS 415 V SWGR TO DG AUX MCC DG AUX MCC TO DG ROOM (VENTILATION FAN, LIGHTING ETC) POWER & CONTROL CABLES WITH IN DG SYSTEM CONTROL & INSTT. CABLES BETWEEN DG EQPT TO ECP/ DDCMIS/TRANS. & AVT LV PC CC F,G PC/ CC CC, F,G P P B(IS) B(IS) P P P B(IS) B(IS) P 00 00 00 00 00
L 1 2 3 4 5 6 7
SWITCHYARD LT SWGR TO BATTERY CHARGER LT SWGR TO ACDB ALL SAS/ SCADA CABLES ALL OUTGOING CABLES FROM SWYD DCDB ALL OUTGOING CABLES FROM SWYD ACDB CONTROL CABLES BETWEEN SWYD EQPT & GT, GRP, ECP, DDCMIS ALL CONTROL CABLES TWO BETWEEN SWYD EQPT LV PC LV PC CC, F, G, FO LV PC LV PC CC, F, G CC, F, G P P P P
SWYD. VENDOR SCOPE P P P P
ALL INTERCONNECTING CABLES FOR GRP, DCS, ECP, TRANSFORMERS,
LV PC, CC,F,G
M ANY OTHER CABLE
MV PC, LV PC, CC,F,G, FS
MV PC: MV Power cable; LV PC: LV Power cable; CC: LV Control Cable; F: F-Type Instrumentation cable; G: G-Type Instrumentation cable; FS: Fire Survival cables
Page 2 of 2

SCT 1466 - Vol. G Techno Commercial Bid - Technical For Electrical Vol-G

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TENDER SPECIFICATION

BHARAT HEAVY ELECTRICALS LIMITED

Tender Specification No. BHEL: PSSR: SCT: 1466 For

ADDL GENERAL MANAGER / CONTRACTS Place: Chennai -35

TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL

Bharat Heavy Electricals Limited

TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL WORKS

DOCUMENT NO. PE-TS-I59-888-E001 REV 0

BHARAT HEAVY ELECTRICALS LIMITED

--------------------------------------------------------------------BIDDERS STAMP & SIGNATURE

--------------------------------------------------------------------BIDDERS STAMP & SIGNATURE

--------------------------------------------------------------------BIDDERS STAMP & SIGNATURE

3. DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID:

ELECTRICAL SYSTEM PE-DG-I59-XXX-EXXX

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

VOLUME III SECTION: CONTENT SHEET SHEET 1 OF 2

700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. EPC SPECIFICATION -ELECTRICAL SYSTEMS

VOLUME-III CONTENTS ELECTRICAL SYSTEM

D3.0 D3.1 D3.2 D3.3 D3.4 D3.5 D3.6

TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01

49 09 15 05 16 03 13 07 18 16 07 15 05 ISSUE R0 TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

VOLUME III SECTION: CONTENT SHEET SHEET 2 OF 2

700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. EPC SPECIFICATION -ELECTRICAL SYSTEMS

D3.20 D3.21 D3.22 D3.23 D3.24 D3.25 BID DRAWING

TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01

1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0

TCE.5960A-EL-2001 TCE.5960A-EL-2003 TCE.5960A-EL-2003 TCE.5960A-EL-2004 TCE.5960A-EL-2005 TCE.5960A-EL-2006 TCE.5960A-EL-2007 TCE.5960A-EL-2008

ISSUE R0 TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3.0 SHEET 1 OF 17

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS GENERAL REQUIREMENTS

SPEC. NO. TCE.5960A-H-500-001

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3.0 SHEET 2 OF 17

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS GENERAL REQUIREMENTS

SPEC. NO. TCE.5960A-H-500-001

ISSUE R0 TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3.0 SHEET 3 OF 17

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS GENERAL REQUIREMENTS

SPEC. NO. TCE.5960A-H-500-001

400kV Switchyard plan

400kV Switchyard sections : TCE.5960A-EL-SK-2008

Generator and its auxiliaries

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3.0 SHEET 4 OF 17

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS GENERAL REQUIREMENTS

SPEC. NO. TCE.5960A-H-500-001

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3.0 SHEET 5 OF 17

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS GENERAL REQUIREMENTS

SPEC. NO. TCE.5960A-H-500-001

ISSUE R0 TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3.0 SHEET 6 OF 17

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS GENERAL REQUIREMENTS