DBR Elec CCPP

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DESIGN BASIS REPORT FOR ELECTRICAL SYSTEM CLAUSE NO. NO. 1.0.0 2.0.0 3.0.0 4.0.0 5.0.0 6.0.0 7.0.0 8.0.0 9.0.0 10.0.0 11.0.0 12.0.0 13.0.0 14.0.0 15.0.0 16.0.0 17.0.0 18.0.0 19.0.0 DESCRIPTION PAGE 2 2 3 4
GENERAL DESCRIPTION GENERAL PRINCIPLES OF DESIGN CONCEPT AUXILIARY POWER SYSTEM RATING OF MAJOR EQUIPMENT EQUIPMENT FOR HAZARDOUS AREAS 13 PROTECTIVE SYSTEM AND CONTROLS 13 GROUNDING & LIGHTNING PROTECTION 16 220 kV OVERHEAD LINES POWER AND CONTROL CABLES ILLUMINATION SYSTEM INTERCOMMUNICATION STATION DC SYSTEM UNINTERRUPTABLE POWER SUPPLY (UPS) 23 DG SET MOTORS LAYOUT OF ELECTRICAL EQUIPMENT CABLE INSTALLATION SYSTEM RIVER WATER PUMP HOUSE ELECTRICAL SYSTEM 27 APPLICABLE CODES AND STANDARDS 27 ANNEXURE-I ANNEXURE II
17 17 18 21 22 24 24 25 26
28 30
/VAR/WWW/APPS/CONVERSION/TMP/SCRATCH_5/160516951.DOC
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DESIGN BASIS REPORT FOR ELECTRICAL SYSTEM 1.0.0 1.0.0 GENERAL DESCRIPTION The basic design concepts for the electrical system and equipment, for the 355 MW CCPP, Kondapalli is described here below. The electrical scheme of connections single line diagram 8EB-201-24-E. are shown in the enclosed
1.1.0 2.0.0 2.0.0
GENERAL PRINCIPLES OF DESIGN CONCEPT The design concept of the electrical system as a whole is based on the requirements for the safe and reliable performance of Gas Turbine & Steam Turbine generator sets and the interconnected electrical system with provision for easy maintenance and overhauling. The total system has been analysed under the following headings to finalise the equipment ratings, to develop the power supply scheme and protection and interlock scheme for prevention of possible maloperation. a) The basic design of auxiliary power system System neutral grounding Busbar system Auto change-over scheme System interlocking Ratings of major equipment Generator Generator Transformer (HT) Unit Transformer (HT) Station Transformer (HT) Service Transformers (LT) Isolated Phase Busduct (HT) Busducts (LT) Selection of breakers 220 kV Switchyard 6.6 kV Switchgear Motor control centre and power control centre
2.2.0
b)
c)
Protection System Generator protection Generator Transformer protection Unit Transformer (HT) protection Station Transformer (HT) protection LT transformer protection
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d)
220 kV Line, Transformer, Bus coupler & Bus transfer feeders Protection Motor protection
Grounding and Lightning protection Technical requirement Testing requirement Power and control cables Type and construction Selection of sizes Special requirements Illumination system Normal AC lighting of the plant Normal and AC emergency lighting Normal AC and Emergency DC lighting General requirements and selection fittings Cabling / wiring Receptacles Illumination levels and type of fixtures Intercommunication Station DC system Technical requirements Layout of electrical equipment Cable installation system
e)
f)
of
lighting
g) h) I) j) 2.3.0
The design standard described herein is generally in compliance with Indian Standards (IS) and the code of practice already established in the country. Indian Electricity rules wherever applicable have also been complied with. In absence of relevant Indian Standard, the relevant IEC standard shall also be referred to. The design ambient temperature for all electrical equipment will be 50C. AUXILIARY POWER SYSTEM Auxiliaries of the Gas Turbine Generator & Steam Turbine Generator range from large capacity motors to small fractional horsepower motors. Larger motors (more than 160 kW) shall be fed from 6.6 kV buses and smaller motors from 415 V buses. System Neutral Grounding Generator neutral grounding Generator neutral is grounded through neutral grounding transformer with resistor to limit earth fault current to 10A.
2.4.0
2.5.0 3.0.0 3.1.0
3.2.0 3.2.1
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3.2.2
220 kV system grounding As per ANSI / IEEE standard 142 - 1982, systems with voltages above 15 kV are to be effectively grounded. Hence, the 220 kV system has been considered to be solidly earthed. 6.6 kV system grounding It has been proved by theoretical studies and field tests that arcing ground faults in the ungrounded system normally produce three times line to line surge voltages. Hence, resistance grounding is used at medium voltages primarily due to the following advantages. Electric shock hazards to personnel due to stray ground fault currents in the ground return path is reduced. Transient over voltages can be limited. Mechanical stresses in circuits and apparatus carrying fault current is reduced. Burning and melting effects in faulted electric equipment are reduced.
3.2.3
In view of the above and also advantage of immediate and selective tripping of grounded circuit, low resistance grounding is envisaged for limiting the theoretical ground fault current to 50 Amps. 3.2.4 415 V system grounding 415 V system is widely distributed and 3 phase, 4 wire system is required to meet the requirement of power supply (to various motors, some of which may be single phase), control, indication, annunciation, etc. According to Indian Electricity rule No. 61, the neutral conductor of a 3 phase, 4 wire low voltage and medium voltage system shall be earthed and there shall not be inserted in the connection with earth any impedance (other than required solely for the operation of switchgear or instruments), cut-out or circuit breaker. IEEE standard no.142 also recommends low voltage system (600 V and below) to be operated solidly grounded. In view of the above, 415 V system of this project is envisaged as solidly grounded. 3.3.0 3.3.1 Busbar System 220 kV system For the 220 kV outdoor switchyard, double main and transfer bus is proposed. Bus coupler breaker will be provided connecting main bus 1 & main bus 2. Bus transfer breaker will be provided between main & transfer bus. 220 kV switchyard will have provision for connecting three numbers generator transformers, two number station transformers and five numbers APSEB grid feeders. The busbars and buscoupler are rated considering the future addition of second stage 355 MW and short time current requirements.
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3.3.2
6.6 kV system The 6.6kV unit switchgear of unit bus as well as 6.6kV station switchgear of station bus will be sectionalised into two sections each section being fed from individual 15/6.9 kV transformer (in case of unit bus) & 220/6.9 kV transformer (in case of station bus), 2 X 100% rated. The unit bus will feed unit auxiliaries for full load operation of both gas turbine generating units and unit auxiliaries of one steam generating unit. The station bus will supply power for start-up as well as station auxiliaries. 415 V system The 415 V unit as well as station switchboards will be sectionalised into two buses each being fed from 6.6kV/433V transformer, 2 X 100% rated. The 415V switchboards will cater to the 415V plant loads. A tie from station board will be provided to the unit board to provide the start up power of GTG LT loads. Auto Change over For 415V switchgear, adequate interlocking will be provided in the operation of incoming and bus coupler circuit breaker to prevent parallel operation of the two transformers. This interlock will prevent the fault level exceeding the rated short circuit level of the switchgear. In case of failure of any one transformer, the other transformer will automatically take over the entire load by auto closing of relevant bus coupler breaker. The two transformers feeding the 6.6kV switchgear will be operated with bus coupler being kept open. In case of failure of any one transformer, the other transformer will automatically take over the entire load by auto closing of bus coupler breaker System interlocking The unit auxiliaries are provided with appropriate protection interlock system to prevent inadvertent switching and to safeguard the equipment and plant in case of emergency operation. RATING OF MAJOR EQUIPMENT Generator The synchronous generator coupled with Gas Turbine & Steam Turbine will have the following technical features. Generator detail is as under : i) Standard IEC ii) Make GEC- Alsthom iii) Type T900 B iv) Nominal Rating 165 MVA v) Degree of protection IP 55 vi) Power factor 0.85 lagging vii) Frequency 50 Hz viii) Number of phases 3 - phase ix) Rated speed 3000 rpm
3.3.3
3.4.0 3.4.1
3.5.0
4.0.0 4.1.0 4.1.1
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x) xi) xii) xiii) xiv) xv)
F Air
Rated voltage Direct axis sub-transient reactance (saturated ) Xd Short circuit ratio Insulation class (stator, rotor) Cooling Excitation system shunt excitation features as under.
15 kV 5% 0.151 0.55
Class
Air in closed circuit and to water coolers Brushless type with having Regulation and control Power converter (Thyristor converter) Equipment for field flashing Excitation transformer Power System Stabiliser Field Circuit Breaker
4.2.0 4.2.1 4.2.2
Generator transformer The generators will be connected to the 220 kV switchyard through 15 kV / 220 kV step-up generator transformers. The generator transformer will be designed to deliver the total output of the generating unit into the system covering the entire operating range of generator capability and will have the following salient technical features. Type Voltage ratio Frequency Vector group % Impedance Capacity Type of cooling : : : : : : Oil filled, outdoor type 220 kV / 15 kV : 50 Hz YNd1 15% 160 MVA OFAF ONAN / ONAF / OFAF
The generator transformer will be provided with 10 % ON-LOAD Tap Changer on HV winding suitable for unidirectional power flow. 4.3.0 4.3.1 Unit Transformer It is proposed to provide two nos. (2 X 100%) Unit Transfomers. Each unit transformer will be sized to cater to unit auxiliaries for full load operation of both gas turbine generating units and unit auxiliaries of one steam generating unit. The load will be calculated on the basis of running load plus 10% margin. While arriving at the rating of transformer and impedance value, due consideration will
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be given to short circuit level at the unit HT bus and also the voltage drop at the unit buses when largest motor connected to unit bus is started with all other operating loads of unit bus in running condition. The unit transformer will have the following salient technical features: Type Voltage ratio Frequency Vector group % Impedance Capacity Type of cooling : : : : : : Oil filled, outdoor type 15 kV / 6.9 kV : 50 Hz Dyn 11 10% 15 MVA ONAN / ONAF
The unit transformer will be provided with 10% ON-LOAD Tap changer on HV winding suitable for unidirectional power flow. 4.4.0 4.4.1 Station Transformer It is proposed to provide two nos. (2 X 100%) station transformers. The transformers will be used to supply power for start-up as well as station auxiliaries. The load of the station transformer will be calculated on the basis of running load plus 10% margin. Salient features of Station Transformer. Type Voltage ratio Frequency Vector group % Impedance Capacity Type of cooling : : : : : : Oil filled, outdoor type 220 kV / 6.9 kV : 50 Hz Ynyn0 10% 12 MVA ONAN / ONAF
The station transformer will be provided with 10%. ON-LOAD Tap changer on HV winding suitable for unidirectional power flow. 4.5.0 4.5.1 LT Transformers LT Transformers will be sized for 2 X 100% capacity of the load connected to the switchboard to which the transformer is feeding power. During normal operation, each transformer will cater for about half the total load of the associated switchboard with the bus section breaker of the switchboard in open condition. In case of outage of one transformer, the other transformer will cater to the total load of the switchboard to which it is feeding power. For calculating the total load of the switchboard 20% margin will be considered. The maximum rating of the
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transformer will not exceed 2000 kVA. The kVA rating and impedance of the transformer will be decided based on the following conditions. a. b. c. Under full load conditions of the switchboard the voltage will not drop below 90% of the load voltage base. At lightly loaded conditions, the voltage will not exceed 100% of the load voltage base. During motor starting, the voltage in the largest motor terminal will not drop below 80% on the motor voltage base with an initial load of the transformer equal to full load on the LT bus less running load of the motor which is being started.
4.6.0 4.6.1
Busducts Generator isolated phase busduct a) The main run of the generator bus duct will be sized considering that the generator is loaded to 105 % with 95 % of rated voltage at its terminals. The short time rating of the main run will be based on symmetrical three phase short circuit current of the generator or combined fault contribution from the grid and the motor contribution from the LV side of the unit transformer whichever is higher. b) The continuous rating of the tap-offs will be based on 95% rated voltage at generator terminals and unit transformer under full load condition. c) The bus duct will be isolated phase, continuous type in aluminum enclosure, air cooled. The support of the bus will be designed to withstand electro-mechanical and thermal stress set-up during short circuit conditions without damage or deterioration of the material. d) For continuous operation at specified ratings as well as short time operation, the temperature rise of the bus bars and the enclosures will be limited to permissible values specified in the relevant standards. Salient Technical features of Generator Busduct are as follows: Type Rated voltage Current Rating (i) Main run (ii) Tap off Short time rating (i) (ii) Main run Tap off : : 56 kA for 3 sec. 103 kA for 3 sec. : : : : Isolated phase bus duct 15kV RMS 7500 Amps 750 Amps
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4.6.2
LT Busduct The secondaries of LT transformers will be connected to the individual 415 V power control centres through 415 V busducts. The busducts will be non-phase segregated type with aluminium conductor in aluminium enclosure. The continuous current ratings of busducts is selected as 3150 Amps for 2000 kVA transformer.
4.7.0 4.7.1
Selection of breakers 220 kV breaker 220 kV outdoor breakers will be of SF6 filled type with the following parameters. Rated voltage : 220 kV rms Rated current : 2000 A for all feeders except bus coupler feeder 3150 A for bus coupler feeder Rated frequency : 50 Hz No. of poles(group operated) : 3 Symmetrical short circuit } rating at rated voltage } : 40 kA Short time duty rating : 40 kA for 3 sec Momentary duty : 100 kA Operating mechanism : Pneumatic Operating Duty : 0-0.3 sec. Co-3min.-Co for auto reclosure 0-3 min. Co-3min-Co for gang operation Dielectric withstand value a) One minute dry and wet power frequency withstand voltage b) 1.2/50 s impulse : withstand voltage c) Creepage Distance d) Applicable standards : :
: 1050 kVP
460 kV rms
6125 mm IEC 56
4.7.2
6.6 kV breakers According to the present international standards (IEC 56), all breaker capabilities are tied to the rated symmetrical breaking current, which is the value of current, the breaker is required to interrupt at rated voltage and on standard operating duty.
The breakers will be vacuum /SF6 circuit breakers with following salient technical features.
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Nominal Voltage : Highest system voltage : One minute power frequency withstand voltage 1.2/50 s, impulse withstand voltage Symmetrical breaking Capacity Breaker duty cycle 4.7.3 415 V breaker :
6.6 kV 7.2 kV :
20 kV (rms)
60 kV (Peak)
: :
40 kA (rms) 0-3 min Co- 3min Co.
The 415 V breakers shall be air break, trip free and draw-out type. The operating mechanism will be spring charged stored energy type. The breaker rupturing capacity is selected as 45 kA at 415 V considering the fault level on LT bus. 4.8.0 220 kV Switchyard
4.8.1 The substation will be designed considering the following design parameters. a. Design voltage level 1. Nominal : 220 kV rms 2. Highest : 245 kV rms 3. Basic impulse levels : 1050 kV peak b. Rated current : 2500A c. Short time current and duration : 40 kA for 3 sec. d. Dynamic rating : 100 kA peak e. Electrical Clearances 1. phase to phase : 2100mm 2. phase to earth : 2400mm 3. ground clearance : 2500mm 4. section clearance : 5000mm f. Bay width : 17000mm g. Conductor Details : i) Main Conductor : Quadruple Moose ii) Bay Crossover : Twin Moose iii) Bay buses : Al. Tube 63401WP grade as per IS h. i. Shield wire Insulator string 1. Type 2. Total creepage distance(minimum) : 7/3.66 mm dia GI wire (min) : Anti-fog : 6125 mm
j.
Maximum design tension at 16C for conductors
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1. 2. 3. k.
All bay buses in the substation Shield wires Line entry
: 1000kg / Sub-conductor : 800kg. / Sub-conductor : 2000 kg./ Sub conductor : solid core : 800kg. : 6125 mm : 241.5 m x 100 m
l. 4.8.2 4.8.3
Bus post insulator 1. Type 2. Ultimate cantilever strength 3. Total creepage distance (minimum) Area available
The 220 kV Circuit breaker will have salient technical parameters as described earlier. EHV isolators will have the following salient technical parameters; Application : Out door Nominal system voltage : 220 kV Highest system voltage : 245 kV Frequency : 50 Hz No. of phases : 3 Ph. Rated current : 2000 A for all feeders except bus coupler feeder 3150 A for bus coupler feeder Short time current rating Rated peak short circuit current Insulation level Inpulse with stand voltage Power frequency with stand voltage Type of isolator : 40 kA for 3sec. : 100 kA : 1050 kV (Peak) : 460 kV (rms) : (i) Double end break, center post rotating type with motorised earth switch (as per key SLD) for line side. (ii) Pantograph type with motorised earth switch (as per key SLD) for bus side. Motor operated
Operating mechanism
4.8.4
Current transformers will be outdoor, oil filled, self cooled hermitically sealed type with following technical parameters:
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No. of cores, accuracy class Short time rating Dynamic rating Class of Insulation 4.8.5
: : : :
As required 40 kA for 3 sec. 100 kA (Peak) Oil immersed (Class A)
Voltage transformers will broadly comply with following requirements: Rated primary voltage Rated secondary voltage Type : : : 220 kV/ 3 110 V/ 3 Electro magnetic type for bus PT Capacitive type for line PT
No. of secondary windings, accuracy Class, burden : As required Class of insulation : Oil immersed Class A Rated voltage factor : 1.2 Continous & 1.5 for 30 sec. 4.8.6 Lightning arresters will comply with the particulars indicated below : Application : Outdoor Type of arrestor : Heavy duty, station class, Non linear resistor, metal oxide type. Rated arrested voltage : 198 kV Rated frequency : 50 Hz Nominal discharge current : 10 kA Power line carrier communication system will be provided by using interphase coupling feature with following facilities : Fax, EPABX, protection, telex & provision for telemeter. HT Switchgear Design features of 6.6 kV switchgears are detailed below. Design Features 6.6 kV Switchgears will be of Indoor, metal clad, fully draw out type with SF6 Gas or vacuum circuit breaker. 6.6 kV Switchgear will have fault withstand capability of 40 kA (rms) for 1 sec. Temperature of busbars will be limited to 85C (ie. 35C rise over 50C ambient) while carrying continuous rated current.
4.8.7
4.9.0 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5
4.9.6
The salient technical parameters of 6.6 kV switchgear are as follows : a) Nominal voltage 6.6 kV 10%
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b) c) d) e) f) g) h) 4.10.0 4.10.1
Highest system voltage 7.2 kV Frequency 50 Hz 5% One minute power frequency withstand voltage 20 kV (rms) 1.2/50 Micro sec, impulse withstand voltage 60 kV (peak) Symmetrical breaking capacity 40 kA (rms) Breaker duty cycle 0 - 3 min-CO- 3 min-CO Degree of protection IP 4X
Motor Control Centre and Power Control Centre Motor control centres (MCC) and power control centre (PCC) will be of sheet steel cubicle and fully draw out type construction. The PCC and MCC will consist of vertical sections, each section having separate compartment for individual motors/drives/MCC feeders. Each compartment will have a control unit for a circuit which will comprise switch fuse, contactors, relays, push buttons and indicating lamps in the case of MCCs and air circuit breakers, relays, push buttons and indicating lamps in the case of PCCs. The buses will be of aluminium alloy, and will be designed to withstand, without damage, for a fault of 45 kA RMS at 415 V for one (1) second duration. The voltage will be 415V 10% and frequency 50 Hz 5%. Switches shall be TP/TPN, air break type capable of safe breaking of the full load current on connected feeders. Fuses shall be HRC type with rupturing capacity of 80 kA at 415 V. Rating of the fuses shall be as per the requirement of individual feeders. EQUIPMENT FOR HAZARDOUS AREAS Electrical equipment in hazardous areas such as motors, push button stations, lighting fixtures, junction boxes etc., will be provided with flame proof type enclosures as per relevant standards. PROTECTIVE SYSTEM AND CONTROLS For protection of equipment against abnormal system conditions, adequate protective devices will be installed in the respective switchgears and/or control and relay panels. A group of such protective devices may be necessary to protect the equipment under different abnormal conditions arising in the system. Besides this, protection against lightning surges, will be provided with lightning arrestors at suitable locations for outdoor equipment over and above the shielding wires and lightning masts.
4.10.2
4.10.3 4.10.4 5.0.0 5.1.0
6.0.0 6.1.0
6.2.0
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6.3.0 6.4.0 6.5.0
In any case, proper discrimination shall be provided so as to isolate the faulty elements only, keeping the healthy part of the system in service. The major electrical equipment will be provided with the protections as listed below : Generator protection Differential protection - generator winding Over voltage protection Stator earth fault protection Neutral Displacement Low forward power protection Reverse power protection Negative phase sequence protection Field failure protection Rotor earth fault protection Generator overload alarm Voltage restrained over current relay Generator under frequency protection VT fuse failure protection Generator under voltage protection Diode failure relay Generator backup impedance Loss of synchronism Generator Transformer Differential protection HV restricted earth fault protection HV backup overcurrent protection HV backup earth fault protection Over fluxing protection LBB protection on HV side Buchholz protection Oil / winding temperature HI-HI protection Oil level very low Pressure relief device actuator LT Transformers Overcurrent protection (IDMTL & instantaneous) LV side restricted earth fault protection Buchholz protection Oil / winding temperature HI-HI protection Unit Transformer (HT) Transformer differential protection Overcurrent protection (IDMTL & instantaneous) LV side restricted earth fault protection LV side backup earthfault protection Buchholz protection Oil/winding temperature HI-HI protection
6.6.0
6.7.0
6.8.0
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6.9.0
Station -
Transformer (HT) Transformer differential protection HV Restricted Earth fault protection HV Backup overcurrent protection LBB protection on EHV side LV side restricted earth fault protection LV side back-up earthfault protection Bucchholz protection Oil / winding temperarue HIHI protection.
6.10.0
6.6 kV Motors Differential protection (for motors rated above 2000 kW) Thermal overload protection Instantaneous overcurrent and definite time - overcurrent protection Earth fault protection Single phase and phase unbalance protection RTDs for winding / bearing temperature HI-HI protection 220 kV line feeder Non switched type distance protection for operation with PLCC equipment. Directional inverse time phase over current protection. Directional inverse time earth fault protection. LBB protection. Auto reclosure facility.
6.11.0
6.12.0 6.13.0
220 kV Busbar differential protection Bus protection scheme main zone & check zone. 220 kV Bus coupler feeder protection Non directional IDMT phase over current protection Non directional earth fault protection Local breaker backup protection 220 kV Bus transfer protection Local breaker backup protection Other protection will be transferred from the relevant breaker (under maintenance) to the transfer breaker Necessary auxiliary relays, trip circuit supervision relays & lockout relays will be provided. Controls Control functions of all major Electrical equipment excepting switchyard will be carried out from the power house control room. Switchyard will be controlled from the switchyard control room. Switchyard will be provided with Supervisory Control and Data Acquisition System (SCADA). The control, metering and relay panels will house all the
6.14.0
6.15.0 6.16.0
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protection relays described above as well as control equipment to meet normal operation and maintenance conditions. 7.0.0 7.1.0 7.1.1 GROUNDING & LIGHTNING PROTECTION Technical Requirements The plant grounding system will be designed as per the requirement of IEEE - 80 & 142 and IS - 3043. The earth mat of the station shall be designed such that the total ground impedance does not exceed 1.0 ohm. 220 kV switchyard and plant grounding will utilise 40mm MS rods and earth pits with 3 m long GI pipe designed for 45 KA for one sec. In calculating the diameter of the grounding conductor, corrosion of the conductor is also considered. Equipment grounding conductor will be of galvanized steel flats / GI wire. Each large structure and building complex will have a ground loop around its perimeter. The ground loops around each structure will be connected to the ground grid. The fence within the ground grid will be bonded to the plant ground system. The power plant ground grid shall be tied together with the switchyard ground grid. Crushed stone will be used in the oil pits of HT transformers. switchyard area will be laid with metal. The
7.1.2
7.1.3
7.1.4
7.1.5 7.1.6
The grounding system will be connected to all metallic equipment, electrical as well as non-electrical (except underground pipelines), located at the plant site. This shall include all structures, buildings, towers, etc. The chimney, HRSG and power house building, will be equipped with lightning protection. Lightning protection for fuel oil tanks shall be provided, if required, as per the relevant standards / codes. Lightning protection conductors located on the top of the structures will be connected to the ground loop surrounding the structure with downcomers as per the provisions contained in the latest issues of Indian Electricity rules and IS 2309.
7.2.0 7.2.1 7.2.2
Testing Requirements The plant will be tested for soil resistivity and the result of these tests will be incorporated into the design of the grounding system. The resistance measurement of the grounding system will be made after installation and periodically thereafter.
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8.0.0 8.1.0
220 kV OVER HEAD LINES All the Generator transformers, Station transformers and APSEB grid connections will be connected to 220 kV switchyard by overhead ACSR conductors of suitable size. The 220 kV main bus & transfer bus will be of ACSR or stranded Copper or Copper / Aluminium tubular conductor. POWER AND CONTROL CABLES Type and construction 6.6 kV cables shall be of heavy duty XLPE insulated, each core screened on conductor as well as on insulation, colour coded, extruded bedding, extruded PVC inner sheathed, single round galvanised steel wire armoured (for multicore cables only) and overall FRLS PVC sheathed with stranded aluminium conductor. The cables shall be suitable for unearthed system. LT power cables shall be 1100 V grade with stranded aluminium conductor. HR PVC insulated, extruded PVC inner sheathed, round wire armoured and overall FRLS PVC sheathed. Control cables shall be multicore 1100 V grade, PVC insulated, PVC inner sheathed round wire armoured and overall FRLS PVC sheathed with 2.5 sq.mm stranded copper conductors. Power to small motors upto 5 kW will also be fed through 3 core, 2.5 sq.mm copper cable for ease of termination at small motor terminal box. Main factors which have been taken into consideration for selection of cable sizes are as follows : System short circuit current and a duration of 0.2 seconds for cables of Circuit Breaker controlled feeder. Derating factors due to higher ambient temperature and grouping of cables Continuous current rating Voltage drop during starting and continuous operation Standardisation of the cable size to minimize too many sizes of cables
9.0.0 9.1.0 9.1.1
9.1.2
9.1.3
9.1.4
9.2.0 9.2.1
Special requirements The cables shall conform to the relevant Indian / IEC standards in general with the following special, FRLS properties. Oxygen index of the outer sheath shall not be less than 30 when tested in accordance with ASTM-D-2863. Acid content in the outer sheath shall be less than 20% as per the requirements of IEC 754.
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10.0.0 10.1.0
Smoke generation shall not be more than 60% when tested as per ASTM-D-2843. The cable shall meet the flammability test as per IEEE-383.
ILLUMINATION SYSTEM The plant lighting system includes the normal lighting of the plant as well as emergency lighting to selected areas of the plant during plant emergency conditions. The plant lighting (illumination level) is varying at different locations of the plant depending on the utility and nature of work expected to be carried out at that area. The lighting distribution system of the plant will consist of : a) Normal AC lighting ON at all times with normal AC supply available b) c) Normal & emergency AC lighting Normal AC & Emergency times DC lighting ON at all times with normal & emergency AC supply available - These lights will be ON at all from normal AC supply & will be energised from DC source in case of grid failure.
10.2.0
10.3.0
10.4.0 10.4.1
Normal and AC Emergency Lighting of the Plant For general illumination, fluorescent fixtures are taken into consideration. However, in some places where fluorescent fixtures are not suitable, high intensity discharge (mercury vapour / sodium vapour lamps) and incandescent lighting fixtures of suitable design are considered. This lighting will be energised from 3-phase, 4-wire, 415 V main lighting distribution boards fed from suitably rated lighting transformers. These MLDBs will feed lighting panels for each individual area / room. 20 % of total AC light fittings in a particular area will be fed from 3 phase 4 wire, 415 V AC Emergency Lighting Distribution Board. The AC EMLDB will be continuously on whereas Normal MLDBs will be switched off during emergency conditions when DG set is delivering power. 240 V, 1-phase, AC receptacle system will be provided through out the station for maintenance and testing, portable tools and other services. Normal AC & Emergency DC Lighting Normal AC & Emergency DC lighting will be provided in specific areas such as control room, switchgear rooms, areas near local panels, staircases and other strategic areas. Normally MLDB will feed these
10.4.2 10.5.0 10.5.1
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lights and during Station emergency conditions it will be fed from DC lighting panels and will be supplied from the station 220 V battery. 10.6.0 10.6.1 General Requirements and Selection of Lighting Fittings Lighting fittings are selected to suit the surrounding atmosphere, height of mounting and special requirements if any. The areas being classified as indoor or outdoor, dusty, corrosive hazardous, etc. Medium bay / high bay light fittings will be used where the mounting height exceeds 6 to 8 metres. Where special requirement such as street lighting, switchyard lighting, flood lighting, decorative lighting, etc., are needed, suitable light fittings will be selected. General street lighting will be obtained from pole mounted high pressure mercury vapour lamps or high pressure sodium vapour lamps. Outdoor areas like transformer yard, outside of plant buildings, etc., will be illuminated by providing pole mounted weather proof light fittings to obtain the desired illumination levels indicated further on in this section. The circuit wires connected on different phases viz. R-phase, Bphase shall be run in separate conduits. All lighting fixtures, receptacles, switch boxes, lighting panels and DBs, street lighting poles, pole mounted junction boxes, etc., will be suitably earthed. Each lighting fixture will be provided with an earthing terminal for connection to a 16 SWG earthing conductor. Cabling / Wiring The cables from different main lighting distribution boards to lighting panels, receptacles, street lighting will be 1100 V grade armoured power cables with stranded aluminium conductor. The wiring from lighting panels to luminaries will be carried out by 650 V grade PVC insulated, unarmoured single core copper wire through galvanised iron conduits or three core armoured cables depending upon the area. The wiring in hazardous areas shall be carried out by wires in solid drawn conduit and using flame proof junction boxes. 10.8.0 10.8.1 Receptacles In general, receptacles to be installed in plant area will be of the following type : a) 5 A, 240 V, 2-pole, 3-pin type with third pin grounded, suitable for flush mounting in office area and control rooms. The switch shall be of piano type, flush mounted.
10.6.2 10.6.3
10.6.4
10.6.5
10.7.0 10.7.1
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b)
15 A, 240 V, 3-pin type with third pin grounded, Industrial metal clad type having 19 mm conduit entry and metallic screw type cover tied to it with a metallic chain and suitable for indoor installation. 15 A, 240 V, 3-pin type with third pin grounded, Industrial metal clad type with gasket having 19 mm conduit entry and metallic screw type cover tied to it with a metallic chain and suitable for installation in moist location and / or outdoor.
c)
All receptacles shall be of cast steel / aluminium, heavy duty type, suitable for fixing on wall / column and complete with individual plug and switch. The outdoor receptacles will have IP 55 degree of protection with weather-proof construction. 10.9.0 10.9.1 Illumination Levels and Type of Fixtures Suggested illumination levels and light fittings at various places are listed below : a) Normal AC lighting Area I) Indoor 1. Turbine Hall Illumination Lighting Fixture Level (Lux) 200 Mercury vapour or sodium vapour / fluorescent fixtures combination Illumination Lighting Fixture Level (Lux) 150 Fluorescent fixture with VE 100 Mercury vapour, glass fixture 70 Toilets etc 400 Fluorescent fixture with VE end Fluorescent fixtures (decorative
Area 2. Switchgear rooms,
industrial reflector. well
MCC rooms, Battery room 3. Boiler platforms General Indoor Area 4. Cable galleries,passages, Stair cases, Basements,
industrial openreflector
recessed
5. Plant Control room, Switchyard control room,
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FICHTNER India
Testing laboratories 6. Office areas 7. Air compressor house, 300 200
mounting type) Decorative type fluorescent Flourescent with vitreous reflector upto heights of 6/8M or highbay . fixture above 6/8M ht. 50 } switchyard
fixtures
Pump house, Water treatment enamel plant etc., ii) Outdoor 1. Transformer yard and outdoor Mercury/sodium } Vapour/fluorescent
10.9.2
The following maintenance factors will be used a) b) c) d) e) Control Room/Air-conditioned Areas Switchyard rooms / MCC rooms /General General indoor areas General outdoor Area Dusty area : : : : : 0.75 0.65 0.6 0.6 0.55
11.0.0 11.1.0
INTER COMMUNICATION The inter communication system is provided to facilitate operations by establishing quick communications among the operating personnel stationed at various locations of the plant. The system generally used for this purpose is of paging type. When one speaks in the system, it can be heard all over the area. The system shall be designed for two channel voice communication facilities in public / paging mode as well as private mode. The private mode is provided for conversation between two or more stations through a close talk channel with high discrimination against background noise. In addition to Public & Private modes, a call attention tone signal will also be provided over the entire plant system speakers of each group to warn the listeners that a message is to follow. The handset for transmitting message or to acknowledge the message will be installed at all important locations. The amplifier system shall be distributed type, i.e. each handset station / loud speaker shall have its own pre-amplifier, line amplifier
11.2.0 11.3.0
11.4.0
11.5.0 11.6.0
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FICHTNER India
suitable for long line signal transmission and power amplifier to suit loud speaking capacity. 11.7.0 In addition to above, telephone system will be provided for quick and reliable communication between different personnel located at various areas of the plant as well as with out side parties. Micro-processor based Digital Electronic Private Automatic Branch Exchange will be provided for telephone communication system. STATION DC SYSTEM The DC required of : a) b) c) power system provides reliable DC power to those loads to function on loss of AC power. The DC system is comprised DC battery Battery chargers (float and boost charger) DC distribution boards
12.0.0 12.1.0
12.2.0 12.2.1
Technical Requirements Battery The batteries will be sized for the required load and duration, taking into account approximate temperature correction, design margin and aging compensation factors. Normal requirement of the battery is to supply power for the following : 1. Control of major electrical equipment 2. Alarm and annunciation of plant condition During this first one (1) minute, the battery will be required to supply to the following services. 1. Tripping power for all major circuit breakers simultaneously 2. Starting of emergency loads requiring DC emergency power. 3. Plant emergency DC illumination system 4. Indication, alarm and annunciation 5. Other miscellaneous loads For the next 58 minutes, the battery will serve all the loads mentioned above except circuit breakers. Also only running requirements and not the starting duty of the pumps running on the DC source will be considered. In the last minute (i.e 60 th minute) the battery will serve all the loads of the last 58 minutes and closing power requirements of the breakers (whose number will be equal to the number of switch boards with the type of breakers). The duty cycle of battery in this one hour during the emergency condition determines the battery capacity. The battery shall be rated for 220 V.
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FICHTNER India
Battery will be of lead acid type with tubular positive plates. 220 VDC system is unearthed Switchyard will be provided with separator 220 VDC battery. A 125V DC battery of Nickel-cadmium type will be provided for GTG & auxiliaries. A 48V DC battery will be provided for PLCC equipment. 12.2.2 Battery Chargers The battery charger of suitable capacity shall be provided for quick boost and trickle charging. The battery charger unit shall be comprised of float charger and a boost charger unit. The battery charger shall be of solid state control rectifier type, completely automatic and self regulating. The float charger shall be capable of floating the battery at 2.15 volts per cell and at the same time supply the continuous DC load of the unit. The boost cum float charger shall be capable of quick charging the battery to 2.75 volts per cell. The charger shall have sufficient capacity to restore a fully discharged battery to a state of full charge in 10 hours with 10% spare margin over the maximum charging rate. All the elements used in the battery charging scheme shall be suitably rated for the duty involved. Automatic voltage regulation shall be provided to maintain the float charger DC output voltage within 1% from no load to full load and for AC line voltage variation of 10%. The float charge controller shall have load limit features which will come into operation under load limit condition and would provide overriding control over voltage sensing circuit. 12.2.3 DC Distribution Boards The main DC distribution boards and other DC switch boards shall be suitably designed to meet the requirement of the plant and these boards will have short circuit ratings consistent with the available short circuit current. The disconnecting switch fuse unit will be selected to have a continuous rating of not less than 125% of the nominal load current. 13.0.0 UNINTERRUPTABLE POWER SUPPLY (UPS) The UPS will be provided with 2 X 100% inverters ad DC power source from the battery as well as from converter. One inverter will have one dedicated converter Normally, each inverter will share 50% UPS load. On failure of any inverter, its load will get automatically transferred to the other inverter through a static transfer switch and this inverter will work with 100% load. On failure of this inverter, a standby AC source (a
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FICHTNER India
bypass transformer) will backup to supply the 100% UPS load automatically through a static transfer switch. A voltage stabiliser will be provided along with bypass transformer to supply power in the absence of the inverter. 14.0.0 14.1.0 DG SET In case of total loss of station supply from grid system, to maintain power supply to barring gear motor of TG, battery charger, UPS and other essential loads one no. DG set will be provided. DG set will be sized for catering to 100% of actual load thrown on DG set after the emergency. DG set will be connected to 415 V emergency switchgear. Upon loss of all main auxiliary power sources, the DG set shall automatically supply power to emergency switchgear. The emergency DG set will be provided with local control and relay panel located in DG set building. Also remote control will be furnished to control the DG set from electrical control panel located in main control room. MOTORS For power plant applications, AC squirrel cage induction motors are used and for certain drives, DC motors are also used. Special features of motors are discussed here. Design Features AC squirrel cage induction motors will be suitable for direct on line starting. Power supply for motors will be as follows : a) Upto 160 kW : 415 V, 3 Phase, 50 Hz. b) Above 160 kW : 6.6 kV, 3 Phase, 50 Hz. Motors of upto 110 kW will be contactor controlled and above 110 kW will be brekaer operated. For drives requiring frequent start/stops contactor control will be provided. Starting current of motors will be limited to 6 times the full load current generally. Motors will be capable of delivering its rated output with supply voltage variation of 10% and frequency variation of 5% and absolute sum of 10% variation. All LT Motors will be Class B insulated. All 6.6 kV motors will be class F insulated with temperature rise limited to Class B limits.
14.2.0 14.3.0
14.4.0
15.0.0 15.1.0
15.2.0 15.2.1
15.2.2
15.2.3 15.2.4
15.2.5
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FICHTNER India
15.2.6 15.2.7 15.2.8 15.2.9
Motors will generally be totally enclosed fan cooled (TEFC) type. motors of higher rating, CACA method of cooling may be provided.
For
Motor enclosures will have IP 55 degree of protection for outdoor service and IP 54 for indoor service. Motor terminal boxes will be capable of withstanding system fault current for a duration of not less than 0.25 sec. Motors of above 30 kW will be provided with space heaters.
15.2.10 HT motors will be provided with RTD and BTD to monitor the temperature of windings and bearings respectively. 15.2.11 The motor name plate rating will have atleast 15% margin over the input power requirement of the driven equipment at rated duty point. The type and duty of motors will be selected based on the service conditions of the driven equipment. 16.0.0 LAYOUT OF ELECTRICAL EQUIPMENT 16.1.0 16.2.0 The electrical switchgears shall be located at switchgear room. Cable spreader room will be provided below the switchgear room. The Generator Transformers, Unit Transformers and Station transformers will be installed in the transformer yard and LT Transformers will be located adjacent to control building. Plant hydrant system will provided as base protection for all outdoor transformers. For transformer of capacity 10 MVA and above, high velocity water spray protection will be provided. For transformer of capacity less than 10 MVA, mobile foam and dry chemical powder extinguishers will be provided. In view of layout constraint, the connections between 6.6 kV switchgear and unit / station transformers will be by cables instead of busducts. The 6.6 kV and 415 V switchgear assemblies shall have provision for future addition at both ends. The 6.6 kV switchgears will be mounted flush with the floor to facilitate breaker removal. 415 V switchgears will be laid out for top entry busduct and bottom entry cables. 6.6 kV switchgears will be laid out for bottom entry cables. A few miscellaneous motors will be controlled from local control panels. Local stop push buttons shall be provided, where required, near the motors inline with statutory requirements. 415 V MCCs shall be of indoor type and suitable for bottom cable entry or top cable entry which will be engineered separately for each MCC during detailed engineering stage. 415V GTG MCC will be located in
16.3.0
16.4.0 16.5.0
16.6.0
16.7.0
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FICHTNER India
turbine control compartment near Gas turbine. STG MCC will be located in the the main LT switchgear room of power house building. 16.8.0 The space requirement and clearances around the equipment will be in accordance with the statutory requirement. Appropriate space shall be allocated for equipment removal. The battery chargers and DC distribution boards will be located in switchgear room adjacent to the battery room. Battery and Battery chargers, DCDB associated with switchyard will be located in Swtichyard control room CABLE INSTALLATION SYSTEM The system comprises of cable trays and concrete encased underground trenches. The tray and conduit system provides support and mechanical protection for cables. The cable trays will be of the steel pre-fabricated type, connected together as an integrated unit. The trays and conduit system will be designed to accommodate cable manufacturers maximum pulling tension and minimum bending radius. The cable trays in areas subject to excessive dust, mechanical damage or accessible to personnel contact will have sheet metal tray covers installed on the upper tray (horizontal run) or front tray (vertical run) keeping adequate space for heat dissipation. The vertical spacing between any two cable trays will be 250 mm minimum. Flexible conduit will be used between conduit and equipment junction boxes, where vibration is anticipated. Flexible conduit length should be as short as practicable. Where it is apprehended that water or other liquids may enter into conduits, sloping of conduit runs and drainage of low points will be considered. Installations where conduit enters electrical equipment enclosure, a drain fitting will be installed in the enclosure. The entire metallic conduit system, when embedded or exposed will be electrically continuous and grounded, preferably with ground clamps. Cable trays (ladder type) will be pre-fabricated type with structural steel. The cable trays will be constructed without sharp edges, burrs or projections that may injure the cable or the personnel. Conduits will be so sized that conduit fill (ratio of total cable area to conduit area) will not exceed the following : 1 No. cable : 53% 2 Nos. cables : 31% 3 Nos. cables & above : 40% Minimum conduit size will be 19 mm. Other conduit sizes will be 25 mm, 63 mm, 100 mm, 150 mm and 200 mm. Minimum bending radius of conduit will be eight times the external diameter of the conduit. Adequate space will be provided to facilitate the installation of the cable system and to allow routine inspection and modifications after installation. The cable trenches will be constructed to prevent the drainage of water into equipment or buildings. The cable tray support
16.9.0
17.0.0 17.1.0
17.2.0
17.3.0
17.4.0
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FICHTNER India
system and discipline. 17.5.0
wall / floor openings will be coordinated with structural
All outdoor runs of cables will be routed on overhead trays or trays in trenches or buried directly in ground depending upon the layout considerations to be worked out during detailed engineering. RIVER WATER PUMP HOUSE ELECTRICAL SYSTEM The river water pump house electrical system will be as per the scheme given in key single line diagram. The system will be complete with necessary battery/battery charger, lighting etc. APPLICABLE CODES AND STANDARDS The codes and standards for major equipment/system are listed below : IS 13118 IS 2026 IS 2705 IS 3156 IS 3043 IS 2309 IS 7098 IS IS IS IS IS 1554 2165 325 3070 9921 High voltage AC circuit breakers Specification for power transformers Specification for current transformers Specification for voltage transformers Code of practice for earthing Protection of buildings and allied structures against lightning code of practice Specification for XLPE insulated PVC sheathed cables Specification for PVC insulated Electrical cables Insulation co-ordination Specification for three phase induction motors Specification for surge arresters for AC systems. Specification for AC disconnectors (Isolators) and earthing swtiches for voltages above 1 kV Specification for porcelain post insulators for system with nominal voltages greater than 1000 V Rotating Electrical machines Code of safety in AC substation grounding IEEE recommended practice for sizing of large lead storage batteries for Generating stations and substation
18.0.0
19.0.0
IS 2544 IEC 34 IEEE 80 IEEE 485
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FICHTNER India
ANNEXURE-1 Voltage Drop During BFP Motor Starting Prior to BFP start the loads on 6.6 kV bus are as follows and the bus voltage is presumed to be 6.6 kV or 1 p.u. Load on 6.6 kV Bus Motor load p.f. { x P.F = 0.75 } = = 2.75 MW at 0.85 p.f. 2750 x 1.1 MVA at 0.85 0.75 = Taking 15 MVA as base Motor load = = = = Transformer load = = = = BFP starting load at 100% voltage and 0.2 p.f. = = = = BFP starting load at 90% voltage and 0.2 p.f. Pre-start Condition Voltage on 15 kV terminals of transformer = 4.033 MVA at 0.85 p.f. 4.033 -31.8 15 0.2689 -31.8 0.2285 - j 0.1417 p.u. 5.2 MVA at 0.85 p.u. 5.2 -31.8 15 0.3467 -31.8 0.2947 - j 0.1826 p.u. 1.5 x 4.5 x 1.2 MVA 0.75 10.8 -78.46 15 0.72 -78.46 0.144 -j 0.7054 0.1296-j 0.63486 1000
4.033 MVA at 0.85 p.f.
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FICHTNER India
0.1417+0.2947-j 0.1826)
= = = = =
1+J 0.1 x 1.1 (0.2285-j 1+j 0.11 (0.5232-j 0.3243) 1+j 0.0576 + 0.03567 1.03567 + j 0.0576 1.0373 3.18 ..(1)
Post start Condition (Assuming 6.6 kV bus voltage as 0.9 p.u.) It is assumed that during BFP starting the 6.6 kV bus voltage comes down to 90% or 0.9 p.u. Consequently current drawn by other motors connected to the bus will increase by 1/0.9 and the current drawn by transformers decrease by 10%. Total current during BFP motor starting motors) = Starting current + 1/0.9 (Current drawn by other + 0.9 (Current drawn by the transformer loads) = 0.1296 - j 0.63486 + 0.9 (0.2947 + 0.1826) + 1 (0.2285 - j 0-1417) 0.9 = 0.1296 + j 0.63486 + 0.26523-j 0.16434+0.254 -j 0.1574 064883-j 0.9566 0.90 + j 0.1 x 1.1 (0.64883 - j 0.9566) 0.90 + j 0.07137 + 0.10523 1.00523 + j 0.07137 1.0078 4.061 (2)
= Voltage on 15 kV bus = = = =
From (1) & (2) it can be seen that the voltage on 6.6 kV bus during BFP motor starting is more than 90%.
29

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1.1.0 2.0.0 2.0.0

2.5.0 3.0.0 3.1.0

4.0.0 4.1.0 4.1.1

x) xi) xii) xiii) xiv) xv)

4.2.0 4.2.1 4.2.2

40 kA (rms) 0-3 min Co- 3min Co.

Maximum design tension at 16C for conductors

All bay buses in the substation Shield wires Line entry

As required 40 kA for 3 sec. 100 kA (Peak) Oil immersed (Class A)

4.9.0 4.9.1 4.9.2 4.9.3 4.9.4 4.9.5

4.10.3 4.10.4 5.0.0 5.1.0

6.3.0 6.4.0 6.5.0

7.2.0 7.2.1 7.2.2

9.0.0 9.1.0 9.1.1

10.4.2 10.5.0 10.5.1

Area 2. Switchgear rooms,

industrial reflector. well

5. Plant Control room, Switchyard control room,

Testing laboratories 6. Office areas 7. Air compressor house, 300 200

15.2.6 15.2.7 15.2.8 15.2.9

system and discipline. 17.5.0

wall / floor openings will be coordinated with structural

IS 2544 IEC 34 IEEE 80 IEEE 485

4.033 MVA at 0.85 p.f.

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