OHPC Balimela Volume 4

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PREPARED BY PREPARED BY PREPARED BY PREPARED BY

MECON LMTED, RANCH MECON LMTED, RANCH MECON LMTED, RANCH MECON LMTED, RANCH

DOCUMENT NO. MEC/11/83/10FX/T8/01 DOCUMENT NO. MEC/11/83/10FX/T8/01 DOCUMENT NO. MEC/11/83/10FX/T8/01 DOCUMENT NO. MEC/11/83/10FX/T8/01

ODISHA HYDRO POWER CORPORATION LIMITED
BALIMELA POWER HOUSE, BALIMELA
UNITS # 1 to 6 (6x60 MW)
R & M WITH NEW TG SET
ELECTRICS AND CONTROL & INSTRUMENTATION

INDEX TO VOLUMES

VOLUME I : NOTICE INVITING TENDER

VOLUME II : GENERAL CONDITIONS OF CONTRACT

VOLUME III: TECHNICAL SPECIFICATION
(MECHANICAL & CIVIL)

VOLUME IV : TECHNICAL SPECIFICATION
(ELECTRICS & C&I)

VOLUME V : TECHNICAL SPECIFICATION
(DRAWINGS)


TS VOL IV

VOLUME IV
TECHNICAL SPECIFICATION
ELECTRICS

ORISSA HYDRO POWER CORPORATION LIMITED
CHIPLIMA POWER HOUSE, CHIPLIMA
UNIT # 3
R&M WITH NEW TG SET

VOL. IV CONTENTS Page 1 of 3

CONTENTS

01. SPECIAL INSTRUCTIONS TO TENDERERS

01.01 Compliance with specification 1 of 5

01.02 Standards and Regulations 1 of 5

01.03 Make and Interchangeability 2 of 5

01.04 Safety 2 of 5

01.05 Coding/Numbering Scheme 4 of 5

01.06 Compliance with rules, regulations and obtaining
statutory approval 4 of 5

01.07 Instruction Manuals 5 of 5

02. BRIEF DESCIPTION OF SCOPE OF WORK AND
ELECTRICAL SYSTEM DESIGN CRITERIA

02.01 Description of Existing plant 1 of 21

02.02 Scope & Brief Description of work 2 of 21

02.03 Electrical System Design 8 of 21

03. PERFORMANCE REQUIREMENT
AND GUARANTEE 1 of 1

04. TECHNICAL SPECIFICATION

04.01 Generator Control Equipment 1 of 160

04.02 Metering and Protection System 10 of 160

04.03 Generator Transformer 27 of 160

04.04 220/11 kV Station Transformer 36 of 160

04.05 Unit Auxiliary Transformer 50 of 160

UNIT # 3
R&M WITH NEW TG SET


04.06 11 kV Switchboard 59 of 160

04.07 Unit Auxiliary Board / Station Auxiliary Board 74 of 160

04.08 Electric Motors 87 of 160

04.09 uninterruptible power supply (U.P.S.) 90 of 160

04.10 Battery ,charger and DC distribution board 91 of 160

04.11 Cables 97 of 160

04.12 Miscellaneous 101 of 160

04.13 220kV Switchyard Bay Extension 114 of 160

04.14 Erection specification 143 of 160

04.15 Overhauling of 1000kVA, 11/0.433V 154 of 160
Transformer
05. INSPECTION & TESTING
05.01 Inspection 1 of 17

05.02 Testing 4 of 17
`
06. LIST OF PREFERRED MAKE 1 of 5

07. LIST OF SPECIFICATION DRAWING 1 of 1

08. DRAWING & DOCUMENTS TO BE SUBMITTED
BY THE TENDERER 1 of 6

09. TECHNICAL PARTICULARS TO BE SUBMITTED
BY THE CONTRACTOR

09.01 General 1 of 32

09.02 Design Consideration 2 of 32

09.03 220 kV Equipment 3 of 32

09.04 HT Equipment 14 of 32

UNIT # 3
R&M WITH NEW TG SET


09.05 Relays 22 of 32

09.06 Transformer 22 of 32

09.07 Generator Busduct 26 of 32

09.08 LT Equipment 26 of 32

09.09 Motors 29 of 32

09.10 Cables 29 of 32

09.11 UPS System 30 of 32

09.12 DC System 31 of 32

ANNEXURE I SELECTION OF POWER COMPO
NENTS FOR MOTORS 1 of 1

ANNEXURE II LIST OF MANDATORY SPARES 1 of 7

SEC B CONTROL & INSTRUMENTATION

01.00 General 1 of 46

02.00 Scope of work and Supply 2 of 46

03.00 Design Criteria 6 of 46

04.00 General Technical Rules 18 of 46

05.00 List of Measurement 27 of 46

06.00 Drawings and Documents 36 of 46

07.00 List of Spares 40 of 46

08.00 Inspection 43 of 46

09.00 List of Preferred makes 43 of 46

UNITS # 1 to 6 (6x60MW)
R&M WITH NEW TG SET

TS VOL IV SEC. A Ch- 01 Page 1 OF 5
01. SPECIAL INSTRUCTIONS TO TENDERERS

01.01 Compliance with Specification

01.01.01 All equipment and accessories covered under this specification shall conform
to `Technical Specifications' given in this document.

01.01.02 All equipment shall be suitable for voltage/freq. variations and other data
given in Electrical System Design.

01.02 Standards and Regulations

01.02.01 The design, manufacture, performance , testing and installation (including
safety, earthing and other essential provisions) of equipment and
accessories covered under this specification shall, in general, comply with
the latest issue of:
Applicable Standards and Codes of Practices published by Bureau of
Indian Standards.
Central Board of Irrigation and Power
Indian Electricity Act.
Central Electricity Authority
Indian Electricity Rules.

01.02.02 Equipment complying with other recognised Standards such as IEC, BS,
VDE, DIN etc. will also be considered if it ensures performance equivalent to
or superior to Indian Standards.
01.02.03 Equipment and accessories for which Indian Standards are not available,
shall be designed, manufactured and tested in accordance with the latest
issues of recognised Standards such as IEC, BS, VDE, DIN etc.

R&M WITH NEW TG SET

01.02.04.1 In case of conflict between applicable Standards referred to in this part and
the Technical Specifications given in Chapter-04, the latter shall govern to
the extent of such difference.

01.03 Make & Interchangeability

01.03.01 The make of major equipment shall be limited to preferred makes indicated
under chapter `List of preferred makes'. Makes of all other equipment and
accessories are subject to prior approval by the purchaser.

01.03.02 Similar equipment and components shall be of same make; equipment of
same type and rating shall be interchangeable.

01.03.03 The purchaser has the option of selecting the manufacturers of electrical
equipment, instruments and controls and any other specialised items in the
interest of standardisation and the successful tenderer shall have to supply
equipment of the particular make, if so required.

01.03.04 The tenderer shall furnish division list of supplies from foreign and Indian
sources indicating the name of the agency or make against the respective
items. It shall be the responsibility of the successful tenderer to arrange the
import licence for the imported items offered and to Co-ordinate the supply of
equipment from foreign and Indian sources and execute the contract within
the agreed time schedule.

01.04 Safety
01.04.01 All equipment shall be complete with approved safety devices wherever a
potential hazard exists and with provision for safe access of personnel to and
around equipment for operational and maintenance functions. The design
shall include not only those usually furnished with elements of machinery

R&M WITH NEW TG SET

but also the additional covers, stairways , ladders, steel structural platforms
for operator's control panels , handrails, partitions etc. which are necessary
for safe operation of the plant.

01.04.02 All danger and caution notice boards' shall be both in English and Odiya
languages.

01.04.03 The Contractor must take sufficient care in moving his construction plants
and equipment from one place to another so that those may not cause any
damage to the property of the Purchaser particularly to the overhead and
underground cables and other service lines.

01.04.04 When the work is carried out at night or in the obscure day light, adequate
arrangements for flood lighting in the working area shall be made by
Contractor at his own cost and got approved by the Purchaser / consultant.

01.04.05 The safety posters/regulation for prevention of accidents shall be displayed
by the Contractor at appropriate places. Notices and warning signs shall be
displayed for all sources of dangers.

01.04.06 All electrical drives and equipment must be equipped with safety devices.
The safety provisions shall conform to the recognized standards, safety
codes and statutory regulations.

01.04.07 All safety measures as required to be adopted as per the statutory
regulations and the safety rules of the plant shall be strictly followed by the
Contractor during the execution of the Contract.

01.04.08 Adequate number of first aid boxes as defined in the State Factory Rules
shall be provided and maintained at all work sites.

R&M WITH NEW TG SET


01.05 Coding/Numbering Scheme

A coding scheme for identifying the drawings, plant and equipment,
structures, spares and shipping documents shall be adopted by the
contractor in a sequential manner. The objective shall be to provide the
following :

- Streamlined archives management
- Effective control with respect to identification of equipment and
drawings to be supplied by different contractors/sub-contractors.
- Identification of the spare parts for easier inventory control.

01.06 Compliance with rules, regulations, and obtaining statutory approval

All equipment/materials shall be installed in accordance with the
requirements of relevant standards, Indian electricity Rules and Acts and
also the Factories Act. It is the responsibility of the tenderer to see that the
electrical installation supplied and erected by him shall be to the entire
satisfaction of Chief Electrical Inspector, Central Electricity Authority or any
other statutory body having jurisdiction in the area and also to the owner/
consultant.

The responsibility for obtaining the Electrical Inspectorates approval for the
installation and modifications to be carried out rests entirely with the
contractor. It shall be the responsibility of the contractor to prepare and
submit all necessary drawings, calculations, test certificates and relevant
details (other than those given by the owner/consultant) to the Electrical
Inspector and obtain prior approval for commencing the work and for the
complete installation work done.

R&M WITH NEW TG SET


01.07 Instruction Manuals

01.07.01 Instruction manual shall give step by step procedure for :

1 Erection, testing and commissioning
2 Operation
3 Maintenance and
4 Repair.

01.07.02 Maintenance instruction shall include:

1 Diagnostic trouble shooting / fault location charts
2 Tests for checking of proper functioning.
3 Periodic Maintenance schedule.

01.07.03 Instruction manual shall also contain:

1 Manufacturer's catalogues with ordering specification for all items.
2 List of consumables with specifications, brand names and annual
consumption figures.
3 Drawings relevant for erection, operation, maintenance and repair of
the equipment.
4 Procedure for ordering spares.

UNITS # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET
ILICTRICS AN CONTROL & INSTRLMINTATION

TS VOL IV Sec.A Ch-02 Page 1 of 21

02. BRIEF DESCRIPTION OF SCOPE OF WORK AND ELECTRICAL
SYSTEM DESIGN CRITERIA

02.01 DESCRIPTION OF EXISTING PLANT

Balimela Power House at Balimela consists of eight units of which Units 1
to 6 each of 60 MW and units 7 & 8 each are of 75 MW. .

Existing units 1 to 6 (for which renovation and modernization with new TG
work is to be taken up) are connected to 220kV power system through
11/220 kV generator transformers. Generator transformers are located in
transformer yard towards downstream side of power house . The important
parameters of existing generator transformer for each unit are as follows.

Rating - 3x 23400 kVA (Three Single Phase Transformer per Unit

Type of cooling OFWF (Forced oil circulation with forced water
cooling)

Vector group - Delta/star-(DYn 11)

Location - Outdoor

Connection - Bus duct - 11kV side
- Overhead conductor - 220 kV side

Generator output is taken through isolated phase bus ducts and connected
to Generator step up transformer.. Neutral side terminal of generator has
been shorted. Tapping has been taken for LA PT panel. For auxiliary
supply, 11 kV is tapped from generator bus ducts of units 1,3,5 & 7 and
connected to 11kV bus of auxiliary supply system through isolator, reactor,
and MOCB. From the 11kV bus four auxiliary transformers ( named 11T,
12T, 13T and 14T) feed unit and station LT boards. These transformers are
located upstream side of the Power House in the LT transformer yard
Existing LT board is fixed type.

A common control room housing control, protection and annunciation
panels for generators, generator transformer, generator aux. and turbine
control desks is provided. For the indication & relays duplex type panels
are provided. Summation MW, MVAR meters are also located in this
control room. Generator is being synchronized at 220 kV through
synchronization arrangement.

R&M WITH NEW TG SET


The Main Control Room, Battery Room, Battery Charger Room and Unt
Control Room (one per unit) located at EL 174.65 m.The HT and LT
Switchgear room are located at EL 170.12m. Generator is synchronised at
220kV through synchronisation arrangement.

220 kV Switchyard has a switching scheme of double bus with bypass bus
arrangement..

02.02 SCOPE AND BRIEF DESCRIPTION OF WORK

The job shall be done on turnkey basis. The scope of work for the R&M of
Units- 1 to 6 with new TG and extension of 220kV Switchyard includes
dismantling and proper storage of the dismantled equipment/facility.

Design, detailed engineering, construction/manufacture or procurement of
new electrical equipment(refer 02.02.01 below), shop testing, packing,
transportation, loading and unloading, delivery at site, storage at site,
handling, erection, pre-commissioning tests and commissioning of all
equipment/system including preliminary acceptance test, performance
guarantee, post commissioning services.
Scope of contractor shall also include following :

Supply of mandatory spares, commissioning spares

Supply of special tools and tackles for the equipment/systems
supplied

Insurance during transit, storage, erection and commissioning

Minor civil works required for fixing of electrical
equipment/panels/cables, bus duct opening, support and
reinforcement of existing foundation etc.

Procurement of all necessary materials and also carrying out
fabrication work as specified in the respective sections of the
specification.

The Contractor shall be responsible for complete satisfactorily working of
system with guaranteed parameters. All the major equipment shall be
installed, tested and commissioned under supervision of representative of
manufacturer of respective equipment.

R&M WITH NEW TG SET


The Contractor shall also include in their scope of work the fault level
calculation for the complete network taking into account minimum/
maximum generation. The relay settings shall be recommended
accordingly.

Tenderer shall visit the site and make himself aware of existing units, space
for the aux. & Generator transformers, HT/LT Panels, Main Control Room
etc. and shall take care of all aspects while designing/executing the work.

Miscellaneous Activities
Following miscellaneous works shall also be included in the scope of tenderer;
Obtaining certificate from Chief Electrical Inspectorate of the state and CEA for
installation and energizing the complete electrical system and equipment
covered under the package. (Fees paid to statutory authorities shall be
reimbursed to the contractor against production of receipt).
Any modification or additional requirements by Statutory Authorities shall have
to be carried out without time and cost implication to the purchaser.
Arranging any other statutory approval, if required.

02.02.01 Supply, Erection, Testing Commissioning

The scope of tenderer shall include all electrical equipment required for the
power plant units and auxiliaries covered under their scope for R&M of units
1 to 6 with new TG and switchyard extension of Balimela Power House at
Balimela. The broad scope is envisaged below and shown in Electrical Single
line diagram.

The major equipment covered under scope of supply shall be as follows:
Generator 60 MW, 11kV, 375 rpm 0.9 PF 6 Nos.( Refer Vol III for scope of
work)
Static excitation system & Digital AVR with thyristor controlled dual channel 6
set.. (Refer Vol III for scope of work)
Generator line side terminal cubicles consisting of Surge suppressors, Voltage
transformer, surge capacitor, etc. 6 Nos.
11kV Current Transformers for metering, protection, AVR, synchronisation etc.
Generator neutral side with suitable bus duct links for formation of STAR
POINT. The Generator shall be grounded through neutral grounding

R&M WITH NEW TG SET

transformer.
Generator protection panel with numerical protection relays. Protection scheme
shall also be hard-wired.
Generator metering, synchronizing and annunciation panel.
Microprocessor based control system as elaborated in Sec B of this Volume
Unit control desk
HT Bus duct
11/220 kV, 3x 23.4 MVA Generator Transformer
220 kV Bay Eqipment including extension of Bus, overhead conductor and
associated hardwares
220 / 11kV, 20 MVA Station Transformer
control & protection panel with numerical protection relays for Generator
Transformer, 220/11 kV Station Transformer, Unit Auxiliary Transformer and
Station Auxiliary Transformer
High velocity water spray system for generator transformer and 20 MVA,
220/11kV Station Transformer.
11/ 0.433kV, 3 phase ,750 kVA cast resin dry type unit auxiliary transformer for
each unit
11 KV Switchboard
415 V Unit Auxiliary Board consisting of incomer, bus coupler and out going
feeders (Refer Single Line Diagram MEC/S/10FX/11/S3/E/01)
Refurbishment of 2 nos. 11/0.433 kV, 1000kVA transformers and reuse as
station service transformer.
415 V Station Switchboard consisting of incomers, bus couplers and outgoing
feeders (Refer single line diagram )
Electric Motors and Actuators including LT motors for drives and MOVs etc.
AC distribution board / Power Distribution Board
2 sets of . 220V. battery bank of adequate capacity.
1no. float and float cum boost battery charger for each battery bank
DC switchboard for each battery set
Local Push Button stations for drive motors, Junction boxes etc.
HT & LT Power and control cables, instrumentation and special cables as per
requirement and accessories including their termination at both ends
Cable supporting structures, GI cable trays (ladder type and perforated type),
cable racks, other associated accessories and fire sealing materials for laying,

R&M WITH NEW TG SET

termination and sealing of cables are under contractor's scope of supply. Cable
trestles, if needed within the battery limit for supporting contractors cables,
shall be in the contractors scope. Contractor shall lay separate trays for laying
different type of cables like power, control and screened cables.
All erection materials, required during erection of all types of electrical
equipment under contractors scope.
Complete earthing system for all the equipment/systems - equipment earthing
and electronic earthing as per actual requirement. Earthing connection of all
new equipment to existing network.
Welding sockets (415V), Power receptacles, 240 V sockets, , 240V Industrial
type sockets etc. are included in the scope of the contractor.
UPS system complete in all respect.
Illumination within battery limit including DC emergency lighting.
Lightening Protection for area under extension of 220 kV Switchyard

In addition to above following are also the scope of bidder :
.Supply of hand gloves and shock treatment charts in English and Oriya.
Supply of rubber mats in suitable sections to be provided in front of all switch
boards for their entire lengths.
Supply of danger / caution notice boards in English and Oriya as per IE Rules.
Supply of all foundation bolts, bolts of special design and special embedments
as required for installation of all equipment covered under this specification.
Preparation and submission of lists with specification and itemized prices for
various spares, special tools & tackles for operation, repair and maintenance.
Supply of all consumable materials such as lubricants, transformer oil, etc.
required for first filling, commissioning, start-up and performance test ad
submission of specification including brand names and quantities. The
Tenderer shall also furnish details of yearly requirement for the above
consumables or normal operation.
Preparation and submission of all drawings and documents including progress
reports as called or in this specification.
Determination of electrical soil resistivity at the location of sub-stations by
carrying out actual site test.
Testing of all equipment and accessories covered under this specification at
manufacturers works and / or recognized independent testing centers before
dispatch of same to site as well as all tests at site before handling over the
system, complete in all respects to the Owner.
Arrangement of temporary work yards, material depots and access as required,

R&M WITH NEW TG SET

as well as removal from site of all erection equipment, packing materials etc.
Any item not mentioned in the specification, but considered by the tenderer
necessary for satisfactory operation and maintenance of the plant shall be
included by the tenderer in his scope of supply and installation.
Supply of gravel of uniform size of 50 mm and spreading it to thickness of 100
mm in the expanded portion of the switchyard. Soil shall be treated chemically
to control growth of vegetation and sand shall be spread before spreading
gravels. Supervision of erection, testing and commissioning of TG sets, their
controls including electrics shall be by representatives of respective equipment
manufacturer.Installation & testing of cabling system, including cable,
trays/supports etc. Laying and termination of all interconnecting cabling
required for completeness and commissioning of the Units All control metering
and protection cables required for connection to relays, meters, signaling
alarm, control, monitoring etc. at main station building shall be provided, laid
and terminated at both ends by the tenderer e.g. control cables from HT
transformer's marshalling boxes to MCR, junction boxes of 220 kV isolator,
CB, earth switches, CT/PT of yard to marshalling box and marshalling box to
MCR.

A brief description of control philosophy and layout for complete power plant is
given in the subsequent chapter for understanding of tenderer. Tenderer shall
provide accordingly. Irrespective of the details provided, tenderer shall include
complete electrics for the Units under his scope of work.

The detailed specification and schedule of quantities also covering the minor
equipment shall be worked out by the tenderer for the total implementation of
the job.

The technical requirements of the main equipment involved as per the
scheme are covered in technical specification section and other appropriate
sections forming part of this specification.

The technical requirement of the main equipment involved are covered in
technical specification section and other appropriate sections forming part of
this specification.

All other existing equipment and structures necessary to complete the work
within battery limit.

02.02.02 Dismantling
The scope of the Tenderer shall also include the following;
Dismantling of all equipment within battery limit

R&M WITH NEW TG SET

Tenderer has to remove all the old/existing equipment along with cables. All
the unused existing equipment shall be removed, packed and placed in a
proper place as decided by the purchaser. Following major existing equipment
shall be dismantled
Generator Transformer
11 kV Isolators, Reactors
All electrical panels including 11 kV Switchboards, Unit Aux. Board, Station
Aux. Boards, and control cables pertaining to Units # 1 to 6
All station switchboard
Battery banks, battery chargers and DCDBs
HT, LT and Control cables
Cable trays, supporting structures, cable racks etc
Excitation-AVR-PT Panel
Generator Busducts
Generator control & relay panel, generator metering panel, generator
transformer control, relay & metering panel.
CTs, PTs, LAs etc
All steel structures required under battery limit to complete the job.

In addition to the above equipment dismantling and storage of other equipment /
structures etc as required to complete the job is In the scope of tenderer.

02.02.03 Battery Limits and termination points

a) Generator Transformer Side
Power evacuation up to generator transformer shall be included in tenderers
scope. Connection of EHT conductor from transformer to 220 kV transformer
LA is in the Tenderers scope. Control cable termination at both ends wherever
signals are required to be tapped/transmitted including control cable
termination in yard equipment as per the need.

Auxiliary Side
A new 220 kV Bay for Station Transformer including extension of existing 220
kV Buses to the new bay.
a. )

b) Existing DG set

R&M WITH NEW TG SET


02.02.04 Exclusions

The following equipment have been excluded from the scope :

Units 7 & 8.

02.03 ELECTRICAL SYSTEM DESIGN

02.03.01 General

Standards

The design, manufacture, assembly and testing as well as performance of
the equipment shall conform to the relevant IS specifications (latest
revision). In case the tenderer is not in a position to comply fully with
certain IS specifications, or in respect of certain items for which there are
no IS specifications, the tenderer may base his proposals on
IEC/BS/VDE/DIN recommendations or other reputed national or
international standards subject to the approval of the purchaser/Consultant.

All equipment supplied and all work done including system design and
detailed engineering shall also comply with the statutory requirements of
the Government of India, the Government of Odisha and with the Indian
Electricity Rules.

Climatic Conditions

The climatic conditions generally prevailing at BALIMELA have been
described in volume I.

Electrical Equipment selection and derating shall generally be based on
ambient temperature of 50 deg. C.

02.03.02 Design Criteria

Standard Voltage levels
The standardized voltage levels as given in table no. 02.02 shall be adopted.

R&M WITH NEW TG SET


Table 02.01
Standard Voltage levels

-------------------------------------------------------------------------------------------------------------------------
Sl.No. | Description | Voltage level |
------------------------------------------------------------------------------------------------------------------------

1. Generation 11kV, 3 Phase
2. Evacuation and Transmission 220kV, 3 phase, 3 wire
50 Hz, effectively earthed

3 11kV System 11 kV, 3 Phase, 50 Hz,
Non effectively earthed

2. Station supply 415 V, 3 phase, 4 wire,
50 Hz, effectively earthed.

3. A.C. Drive motors 415 V, 3 phase, 4 wire
effectively earthed

4. Metering 110 V, AC PT. voltage

5. Control & protection 220 V, DC 2 wire unearthed
of EHV, LT switch-
gear, D.C. drives

6. Panel lighting and 230V, 1 phase, 2 wires
space heaters 50 Hz, A.C. with
point earthed.

Permissible variations

The system unit/plant equipment shall be designed suitably for variation in
voltage and frequency as indicated in Table 02.03

Table 02.02

Variation in Voltage and Frequency
-----------------------------------------------------------------------------------------------------------------------
Sl.No| Description Voltage Frequency
-----------------------------------------------------------------------------------------------------------------------

R&M WITH NEW TG SET

1. Permissible variation + 6% to - 6% , + 3% to - 5% For LT
system with rated performance/
rated current and control + 6% to - 9% , + 3% to - 5% For HT
system effectiveness system
maintained +10% to -12.5% + 3% to - 5%For EHT
system

2. Permissible variations +/- 10% , +3% to - 5%
for control and regulation
equipment with rated
performance and control
quality maintained.

3. Permissible voltage dip - 5%
at LT switchgear bus for
starting of LT motors
----------------------------------------------------------------------------------------------------------------------

Basic Insulation Levels

Equipment shall be designed suitably for basic insulation levels as given in
Table 02.03.

Table 02.03
Basic Insulation Levels

----------------------------------------------------------------------------------------------
Sl.No | Nominal voltage kV | BIL kV (peak)
----------------------------------------------------------------------------------------------

1. 220 kV 1050
2. 11 kV 75
3. 415 V 1.1
----------------------------------------------------------------------------------------------
Symmetrical short circuit ratings

The three phase symmetrical short circuit ratings of the switchgear at different
voltage levels will be as indicated in Table 02.04.

R&M WITH NEW TG SET

Table 02.04

Symmetrical Short Circuit Ratings

-------------------------------------------------------------------------------------------------------------------------
Sl. Voltage Symmetrical Making
No. level Breaking capacity
-------------------------------------------------------------------------------------------------------------------------
1. 220 kV 40 kA 100 kA
2. 11 kV 40 kA 100 kA
3. 415 V 30 kA 75 kA
4. 220 V DC 10 kA -
-----------------------------------------------------------------------------------------------------------------------

The rated short circuit withstand duration for switchgear of 220kV is 1.0 sec
and for 11 kV it will be 3 Secs whereas for 415 V including MCCs it will be 1
sec.

Motor Starting and permissible voltage dips :

Voltage dip on starting of the largest motor shall be limited to 15% of the
nominal voltage at the motor terminals.

System Earthing

220 kV systems is effectively earthed.

11 kV System is non-effectively earthed.

415 V system will be effectively earthed in line with IE Rules.

Other Requirements

The electrical distribution scheme to be provided will be subject to approval of
purchaser/purchaser's consultants.

Miscellaneous items such as relays ,type of relays, relay ranges, number of
poles for relays, scale of meters, CT ratios, links, fuses, switches, indication
lamps, terminal blocks, aux. relays, timers associated with main relays, size of
control cables shall be supplied as per the approved scheme/to achieve
scheme requirements.

All HT and LT CTs shall be of 5A secondary and EHT CTs shall be 1 amp.
secondary. Control cable from CT to panel shall of 2.5 sq.mm. copper.

R&M WITH NEW TG SET

All erection/installation accessories, cable termination and jointing kits, cable
fixing, dressing, tag numbers, route markers, supporting materials for all
equipment shall be part of the tenderer's scope.

Motor space heater (if required) power supply shall be fed from respective
shop MCC/Distribution board. Space heaters will be interlocked with motor
main power supply.

Earthing mat is already provided for complete power plant area. Existing
earthing connections/ strips needs to be checked for continuity and to be
refurbished / extended if needed for making suitable to connect all equipment
in the scope of tenderer.

Earthing mat shall be provided for the area of switchyard to be extended and
it shall be joined with existing earthmat.
Selection of components and cable size for MCCs shall be as per chart given
in Annexure-I.

Tenderer to submit a system wise drive list indicating process interlocks,
permissive conditions etc. with places and mode of control for each drive
control system philosophy with provision of various control, indication,
measuring devices at various places. This shall be approved by the
purchaser/consultant. Based on above approved philosophy tenderer shall
have to provide all equipment/materials and prepare a control scheme/logic
diagram.

Above mentioned control philosophy and interlocking logic shall be prepared
as per the technological requirement.

Tenderer shall include in his scope dummy panels for switchgear and control
panels, wherever civil beam blocks cable entry to panel.

For control and protection requirement DC system shall be used.

220V DCDB shall be provided catering all the loads of units and tenderer to
include incoming cable for the same.

220 KV System
The relay and control panels for this transformer bay shall be provided in
existing switchyard control room.
A busbar differential protection scheme (analogue, not numeric
microprocessor based) for working bays of the existing switchyard is
functioning and the panel is installed in the control room of the existing
switchyard. It is proposed to extend this existing busbar differential protection

R&M WITH NEW TG SET

to cover the extension portion of the switchyard. The tenderer shall include in
his scope all the equipment/relays/modifications as per requirement. Tenderer
may use spare core of existing CTs. However, in case of non-availability,
tenderer shall include CTs suitably as per site requirement.

The design of steel structure in the switchyard shall in accordance with the
requirements of IS : 800 for steel. The design of concrete foundation for these
structures will be done as per IS : 456. Wind load shall be as per IS : 875
(Part III).

Outdoor yard shall be designed with consideration of following clearances.

Minimum height of live conductor above ground level (mm) : 7000
Sectional clearances (mm) : 4300
Ground clearances for vehicle movement (mm) : 8000
Phase to phase clearance between conductors (mm) : 4500

The basic system parameters for the 220 kV system are as follows.

Nominal system voltage : 220 kV
Highest system voltage : 245 kV
No. of phases : Three
System frequency : 50 Hz
System earthing : Solidly earthed
Fault level (3 Phase symmetrical) : 40 kA (for 15000 MVA)
Short time current rating (for all : 40 kA for 3 secs
current carrying parts) :
Power frequency withstand voltage : 460 kV RMS (Switch
gear)
Impulse withstand voltage : 1050 kV peak (switch
gear)
220 kV conductor : ACSR Zebra
Current carrying capability of bay bus : 1600 A

The Tenderer shall check the VA rating of metering and protective cores of all
current transformers and potential transformers and satisfy himself thoroughly
regarding their adequacy considering lead burden as well as burden of all
relays, meters ad instruments
offered. The successful Tenderer shall submit for Owners approval details of
relays,meters, instruments and associated circuits as well as calculations for
selecting knee point voltage of all PS class CTs.

Suitable interlocking shall be provided between various switchgear equipment
in the 220kV switchyard to ensure safety of maintenance personnel working
on one section of the equipment with other sections alive and to prevent

R&M WITH NEW TG SET

incorrect switching sequence which could lead to damage to plant and
equipment. The interlocking may be of electrical or mechanical or key type or
any combination thereof, but shall be effective when the equipment is
controlled remotely, locally or under emergency manual operation. However,
in the selection and design of the interlocking scheme, the Tenderer shall give
due consideration to the specific requirements of the Central Electricity
Authority.

The relay and control panel for 220 kV switchgear, and DC distribution board
for the 220 kV switchyard shall be located in the Switchyard control room and
all these are included in the scope of this specification. 415 V ACDB shall be
located at switchyard control room building.

02.03.03 Design of Electrical Auxiliary System.

The electrical auxiliary system shall be designed considering available short
circuit levels, switchgear duties and voltage dips on auxiliary buses for the
various operating conditions. The impedance values of transformer shall be
selected with a view to limit the fault levels and voltage dips.

Manual transfer of auxiliary loads shall be provided during unit starting and
during planned shutdowns, whereas fast automatic transfer shall be provided
between the two incomer. buses of 415V switch boards.

02.03.04 Power Distribution Scheme

The electrical power distribution and control scheme shall be based on the
scheme elaborated below. Tenderer shall follow the system design in general
on these lines and design the equipment based on criteria given in earlier
paragraphs. The generator shall generate power at 11 kV. The generator shall
be directly connected to 220 kV systems through 3 phase 11/220 kV
transformer. The electrical distribution scheme shall be based on unit and
station auxiliaries system feeding separately. The unit loads shall be fed
directly through 750 kVA, 11/0.433kV transformer for each unit. The scheme
is shown in single line diagram and is further elaborated in the following
paragraphs of this chapter.

Power Evacuation

The transformer yard and the switchyard are existing and located adjacent to
power plant building to interconnect the power plant to grid at 220 kV for the
purpose of power evacuation.

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02.03.05 Elaboration of Electrical Scope of Work

The scope of work and different design requirement have been given in
different chapters, however, for ease of understanding it is briefed in following
paragraphs.

01. Generator CT-PT- LA Cubicle
New Generator CT-PT- LA Cubicle shall be provided. All line side CT for
metering, protection and AVR shall be provided in this cubicle. 11/ 0.110kV
Potential transformer for metering, protection, AVR and for synchronization
shall be provided

02. Neutral Grounding Cubicle
New NGC shall be provided. The generator neutral grounding equipment shall
be housed in a metal enclosed cubicle. The high resistance grounding of a
generator neutral shall be adopted by connecting the primary of a single
phase distribution type earthing transformer between generator neutral and
ground with the transformer secondary being shunted by resistance with a
voltage relay and harmonic filter. Current transformers for metering &
protection shall be provided in this cubicle.

03. Generator Transformer including HVWS System
A new 3 phase, 23400kVA, 11/220/3 transformer for each unit shall be
provided by the tenderer. The new transformers shall be provided with the
microprocessor based numerical transformer management protection
systems.

High Velocity Water Spray System
High velocity water spray system shall be provided for generator transformer.
System shall be designed as per TAC guidelines and shall have auto as well
as manual starting features. For Detail specification refer Vol 3 of TS.

04. Electrical Protection System
The protection required for the various electrical equipment e.g generator,
generator transformer, 220/11 kV, 20 MVA Station transformer, unit aux.
transformers, station auxiliary transformer, , auxiliary motor etc. All the relays
including generator protection relays shall be microprocessor based numeric
type irrespective of their use with communication facilities

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05 220 kV SYSTEM

A new 220/11 kV, 3 phase, 20 MVA transformer shall be provided
Existing 220kV bus shall be extended to accommodate new station
transformer 220 /11 kV, 20 MVA.
New 220 kV transformer bay consisting of SF
6
breaker, Isolator,
earthing isolator, CT, PT etc as per requirement shall be provided.
Foundation of 220/11 kV , 3 phase, 20 MVA transformer, switchyard
bay equipment etc within battery limit is in the scope of bidder
Earthing mat for extended portion of switchyard and connectivity of it
with existing switchyard is in the scope of bidder.
Lightning protection for extended portion of switchyard is in the scope
of bidder.
Illumination for the extended portion of switchyard is in the scope of
bidder.
New cable trench for extended portion of switchyard and connectivity
with existing cable trench is in the scope of bidder.
Approach road for materials and inspection during normal operation of
new transformer bay is in the scope of bidder. Connectivity of new road
with existing road is in the scope of bidder.
Arrangement of refilling of SF
6
gas, compreesed air and fire fighting is
in the scope of bidder.
C& R panel for transformer bay shall be provided and modification in
cable trench, if required, shall be done by bidder.

06 Generator Busduct

11 kV generator busduct shall be isolated phase with tubular shaped
enclosure. Enclosure shall be continuous type. Tenderer shall include the
Generator busducts consisting of following minimum items;

a) Generator main Busduct from generator terminals to generator
transformers and tap offs to unit auxiliary transformer

b) Generator neutral busduct to the neutral grounding transformer

c) Generator busduct tap off to surge protection & VT cubicle

d) Generator busduct tap off to Excitation Transformer

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e) All associated equipment/items like flexible/rigid joints, required no. of
bends, silica gel breather, space heater, etc

f) Set of maintenance tools and tackles as required.

g) Earthing of busducts with continuous run of conductors

h) Necessary support structures, erection hardware

07. 11kV Switchboard
New 11kV Switch board shall be provided as per 11kV single line diagram.
The switchgear shall be of metal clad, single bus bar, self standing, dust proof
construction, indoor cubicle type fitted with vacuum/SF6 circuit breakers, in
fully draw out execution.

08 LT AUXILIARY SUPPLY SYSTEM
Dedicated cast resin dry type Unit Auxiliary Transfomers (UAT) shall be
provided for each unit. Each UAT shall be of 11/0.433kV, 750 kVA. Each UAT
shall feed the respective Unit Auxiliary Board(UAB). The UABs will have back
ups incoming supply from existing 11/0.4 kV auxiliary transformers (11T and
12T) and will be called Station Service Transformers(SSTs). The Station
Service Board will meet the station load requirements as well as auxiliary load
of one unit..

7.01 Unit Auxiliary Transformer
New 750kVA, 11/0.433 kV, cast resin dry type transformer shall be
provided for each unit.

7.02 11/0.433 kV Station Transformer
Existing 11/0.433 kV, 1000kVA transformers shall be reused after
refurbishment

7.03 415 V Unit Auxiliary Board
415V Unit Auxiliary Board shall be provided for each unit. It shall have air
circuit breakers & shall be metal clad, indoor type floor mounted (in fully draw

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out execution).Switchboard shall be in single tier execution for incomers & bus
couplers and two tiers for outgoing feeders.

7.04 Station Auxiliary Switchboard
New station auxiliary switchboard consisting of three incomers (incomers
from station transformers and from DG set), bus couplers and outgoing
feeders as per requirement shall be provided. The incomers will have auto
change over facilities. Switchboard shall be in single tier execution for
incomers & bus couplers and two tiers for outgoing feeders.

7.05 415V Switchgear (MCC, Aux. AC/DC Boards, Local Distribution
Station)

415V draw out type switchgear / MCC shall be provided for feeding different
auxiliaries, as required for the plant.

8 DC System
2x100%,220 V battery bank shall be provided to cater all the requirement of
DC loads of power plant. The battery bank shall also take into account DC
requirement of existing units 7 & 8.

One no. float and float cum boost charger shall be provided for each
battery bank.
.
One set with two sections DC distribution board shall be provided for each
unit.

9 UPS

A dedicated UPS system of adequate capacity and redundancy shall be
provided to cater all requirement of control & instrumentation of unit 1 to 6.
This shall be consisting of battery banks (VRLA, SMF type), battery chargers,
inverter banks, static switches, manual bypass switches, 3 phase to 1 phase
transformer, ACDB and all other associated cabling and accessories.
Sufficient nos. of spare feeders shall be provided in the ACDBs of the UPS for

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purchasers use. The exact number of feeders shall be decided during
detailed engineering

10 Cabling (Cables, Cable supporting materials, trays etc)

All HT/LT power, control cables and cable accessories supporting
structures, cable installation, cable terminations with necessary junction
boxes and fire sealing are under the scope of tenderer for all areas covered
in the package.

All control and protection cables required for connection to relays, meters,
signalling alarm, control, monitoring etc. at main station building shall be
provided, laid glanded and terminated at both ends by the tenderer.Existing
cables shall be removed and placed in proper condition in a place identified
by the purchaser's store.

All erection/installation accessories, cable termination and jointing kits,
cable fixing, dressing, tag numbers, route markers, supporting materials for
all equipment covered in the package shall be part of the tenderer's scope.

Selection of components and cable size for MCCs shall be as per chart
given in Annexure-I.

Tenderer shall have to submit the layout indicating location of all major
electrical equipment and cable routes including levels of floor, clearances,
entry/exit points, cable structure details during detailed engineering stage.

11. LT Motors

AC squirrel cage industrial motors shall be fed at 415V, 3 phase, 50 Hz,
with DOL start as applicable. For motors above 30 kW rating star delta
starter shall be provided.

415 V AC energy efficient motors shall be provided to all auxiliaries
covered under this package as per system requirement.

12 Illumination
Illumination of Power House Area, Main Control room and extended
switchyard area shall be in scope. Light fittings shall be selected considering
aesthetic look and requirement. Light fittings near all equipment within battery
limit shall be provided.

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13. Earthing Materials
New GI flexible/flats are to be provided for connecting all equipment within
battery limit to existing earth grid.

14 Ligtning Protection
Lightning protection for extended part of 220kV Switchyard shall be
provided. All required materials shielding wire, down conductor etc are In
the scope of tenderer.

15 Electrics of compressed air system, technical water facility, fire fighting
system, AC & ventilation system and EOT crane is in the scope of bidder

16 Control & Instrumentation

Control system shall be provided as detailed in Sec B of this Volume.
Electronic portion of governor and AVR control shall be compatible to the over
all system requirement.

The automation control shall have normal operation control, Governor control,
process protection control.

The Control System among other things shall have .

- Automatic Control of the unit
- Acquisition of operational data about generating units, transformer,
220 kV CBs. Unit Auxiliaries, Station Auxiliaries.
- On line monitoring of partial discharge, vibration Temp, and trend
indication.
- Indication & recording of faults
- HMI with Technological equipment
- Annunciation
- Operation Documents

The control desk in the main control room shall have one VDU screen with
keyboard, mouse etc. (OWS) for each unit with all the above controls and
one engineering work station (EWS). Each OWS shall have complete
computerized contriol facility. The main control desk of the unit in MCR shall
have the following minimum analogue control, metering and indication.

MANUAL CONTROL

- Normal Start
- Normal Stop
- Emergency Stop

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- GCB switch ON/OFF
- FCB switch ON/OFF
- Load lower / raise
- Speed Lower / raise
- Voltage Lower / raise
- Reactive power Lower raise
- Synchroscope / Bus Selector Switch.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

TS VOL IV Sec.A Ch - 03 Page 1 of 1

03. PERFORMANCE REQUIREMENT AND GUARANTEE

03.01 The tenderer shall study the specification and satisfy himself thoroughly
regarding the workability of the plant, equipment and systems offered and also
take full responsibility for the guaranteed operation and performance of the
same as well as for their smooth, safe and reliable working.

03.02 All equipment shall be guaranteed for workmanship, materials design and
satisfactory performance to the parameters in accordance with the specification
document and relevant clauses of the General Conditions of Contract (VOL II of
TS). The guarantee for performance shall cover individual items and systems
for their ratings / outputs.

03.03 The tenderer shall also guarantee the integrated operation of all the systems
and equipment covered in his scope as a whole including interfaces required to
be established with other related systems and equipment.

03.04 The supplier shall conduct performance / acceptance tests on each of the major
items of equipment supplied to demonstrate that the equipment and system
supplied are capable of achieving the performance parameters specified and
contracted for, in accordance with the General Conditions of Contract. The total
system performance shall also be guaranteed and demonstrated.

03.04 Should the tests specified show that the unit has failed to achieve the
guaranteed parameters, the supplier shall carry out necessary modifications or
part replacements to achieve the guaranteed parameters and for successful
demonstration the tests shall be repeated

UNIT # 1 TO 6 (6x60 MW)

TS VOL IV Sec .A Ch- 04 Page 1 of 160

04. TECHNICAL SPECIFICATION
04.01 GENERATOR TERMINAL CUBICLE
04.01.01 LINE SIDE TERMINAL CUBICLE
LAVT panel shall consist of Potential Transformer, surge protection
equipment, Protective capacitor and current transformers for AVR and
metering.
Current Transformer for Generator metering and Automatic voltage
Regulator shall be provided in isolated phase busduct
Panel specification shall be as follows :

1. Panel Construction : Sheet steel not less than 2.0 mm thick
2. Gland Plate : 3mm CRCA
3. Type : Indoor, Floor mounted
4. BusBar : Main 100x10x3R AL.(High tensile
fastners to be used for busbar joints.
Earth Bus 50x6 mm Cu. FLAT
5. Cable Entry : Bottom
6. Degree of Protection: IP-54
7. System Fault Level : 40 kA for 3 Sec
8. 11 kV clearance : Phase to Phase : 127 mm (Min)
Phase to earth : 90 mm (Min)
9. Name Plate : Black letters engraved on white
background Adhesive type
10. Wiring : 650 /1100 grade PVC insulated
multistranded Cu cable
11. Painting : Enclosure Interior / Exterior

Generator Voltage Transformer

To provide power supply for metering, synchronisation, AVR and protection
purposes voltage transformer shall be provided in LA-VT panel. These will
be connected after the generator outgoing terminals. VTs shall be of dry type
cast resin design mounted in separate panels. High voltage side of VTs shall
have fuses with MCBs on low voltage side. Low voltage star winding shall
have all three phases and neutral connections brought out to terminals.

UNIT # 1 TO 6 (6x60 MW)


Accuracy class of this shall be 0.2. The technical parameters shall be as
follows :

Rated continuous voltage : 11 kV

Ratio : 11 KV/3 : 0.110 kV/3

Burden : As per requirement Minimum
100 VA

Power frequency withstand voltage : As applicable for generator busduct

Impulse withstand voltage : -- do --
Surge Protection Equipment
The surge protection cubicle shall comprise of surge divertor and protective
capacitor on each phase to protect the generator from the effect of transient
over voltages. Surge protection equipment and VTs as described above
shall be mounted in dust proof isolated phase compartment with provision for
entry of main bus tap off into the compartments.
Protective capacitors shall be single pole units i.e. one per phase, non
inflammable synthetic liquid impregnated type connected between each
phase terminals and ground. Each capacitor shall be provided with a built in
discharge resistor to drain the residual charge after being de-energized.

Surge divertors shall be of station class type with 10 kA discharge current
and shall be of design specifically meant for protection of rotating machines,
other salient particulars of surge divertors should be chosen in accordance
with relevant IS-3070,Part-I, 1974.
Generator Current Transformer
To provide Protection and metering for generator, suitable current
transformers shall be provided in the busduct. Separate cores of CTs shall
be used for differential protection, over current protection and measurement
purposes. CTs shall be bar pirmary type . Generally the measurement CTs
shall have accuracy class as 0.2 whereas protection class shall be 5P30 and
for differential CTs the class shall be PS. The knee point characteristics of
differential CTs shall be matched with the relays. The technical parameters
are elaborated below :

UNIT # 1 TO 6 (6x60 MW)


Type : Epoxy cast resin

Rated continuous current : 5000 amps

Ratio : 5000/5A

No. of cores : As per requirement

Short time rating (3 sec) : 40 kA

Power frequency withstand voltage : As applicable for
generator
busduct

Impulse withstand voltage : -- do --

04.01.02 Generator Neutral Grounding Cubicle

The high resistance grounding of a generator neutral shall be adopted by
connecting the primary of a single phase distribution type earthing
transformer between generator neutral and ground with the transformer
secondary being shunted by resistance with a voltage relay and harmonic
filter. This will reduce transient overvoltage limit at the point of fault and
contribute to a positive selective relaying in the event of generator stator
E/F.
The value of resistance shall be so chosen that the energy loss in the
resistor equals the capacitive kVA of the generator windings, the generator
surge capacitance, the capacitance of the isolated phase busduct and the
associated generator transformer with respect to earth during ground fault
conditions.
The generator neutral grounding cubicle shall consist of Neutral grounding
distribution transformer, Off load manual Isolator, current transformers for
generator protection, resistance.

UNIT # 1 TO 6 (6x60 MW)


Panel specification shall be as follows :

1. Panel Construction : Sheet steel not less than 2.0 mm thick
2. Gland Plate : 3mm CRCA
3. Type : Indoor, Floor mounted
4. BusBar : Main 100x10x3R AL.(High tensile
fastners to
be used for
busbar joints.
Earth Bus 50x6 mm Cu. FLAT
5. Cable Entry : Bottom
6. Degree of Protection: IP-54
7. System Fault Level : 40 kA for 3 Sec
8. 11 kV clearance : Phase to Phase : 127 mm (Min)
Phase to earth : 90 mm (Min)
9. Name Plate : Black letters engraved on white
background
Adhesive type
10. Wiring : 650 /1100 grade PVC insulated
multistranded
Cu cable
11. Painting : Enclosure Interior / Exterior :- RAL
7035

Panel shall also have marshalling box, space heater, thermostat MCBs etc
as per requirement.

The earthing transformers shall be dry type for indoor installation. The
generator neutral grounding equipment shall be housed in a metal enclosed
cubicle. The metal enclosed neutral grounding cubicle shall be connected to
the neutral compartment of the star point of the generator. Technical
parameters of earthing transformer shall be as follows:

Primary voltage : 11.0 kV
Secondary voltage : *

UNIT # 1 TO 6 (6x60 MW)


Continuous capacity based on 30 min. duty cycle : *
* Final values to be decided during detail engg. stage.

04.01.03 GENERATOR BUS DUCT
The 11 kV generator busduct shall be phase isolated type. The busduct
shall be installed inside machine hall.

The generator busduct shall comply with the requirements of the latest
version of relevant IS / IEC standards. The busduct shall be designed to
carry maximum continuous current under normal conditions without
exceeding temperature rise limits

The bus assembly shall be designed to mechanically withstand a rated
continuous current as well as the specified short circuit current without
damage or permanent deformation of any part of the bus structure.

Tenderer shall include the Generator busducts consisting of following
minimum items:

1. Generator main Busduct from generator terminals to generator
transformer with tap off to unit auxiliary transformer and excitation
transformer.
2. Generator neutral busduct to the neutral grounding transformer through
link.
3. Generator busduct tap off to LAVT panel.
4. All associated equipment/items like flexible/rigid joints, required no. of
bends, silica gel breather, space heater, etc
5. Surge protection, VT cubicles and Current Transformers located inside
busducts
6. Set of maintenance tools and tackles as required.
7. Earthing of busducts with continuous run of conductors
8. Necessary support structures, erection hardwares

9. Suitable canopy with proper slope for outdoor portion of the busduct

UNIT # 1 TO 6 (6x60 MW)


GENERAL TECHNICAL REQUIREMENT

1. Applicable Standard IS : 8084
2. Rated system voltage and frequency 11 kV, 50 Hz
3. System earthing Non effectively earthed
4. System short-circuit level, kA (rms)

85 kA (for 3 sec) for main
run
152 kA (for 3 sec) for tap off
5. Type of busduct Phase Isolated

6. Service Indoor / Outdoor Indoor
7. Maximum voltage at which the
busduct can operate continuously
12 kV
8. Busbar material - Conductor Aluminium Alloy
9. Busduct support structure required To be provided
10. Current ratings
11. Rated continuous current 5000A

12. short time Current Rating for 1 sec

40kA
13 Dynamic current withstand rating kA
(peak)
100 kA
14 Type of Cooling AN
15. One min. dry power frequency
withstand voltage
28 kV
16. Impulse withstand voltage 75 kV
17 Supporting insulator
a) Type Porcelain
b) Max. distance between supports To be worked out based on
short circuit calculation
c) Rated Voltage 12 kV
d) One minute power frequency
withstand voltage
35 kV
e) Impulse voltage withstand value with
1.2/50 micro sec. wave shape
75 kV

UNIT # 1 TO 6 (6x60 MW)


f) Minimum Creepage Distance 240 mm
18 Earth Bus
a) Material Al
b) Size As per requirement
19 Enclosure
a) Type Phase Isolated
b) Degree of Protection IP 52
c) Material of Enclosure Al
d) Thickness 3 mm min.
20 Design Ambient Temperature 50
o
C
21 Maximum temperature when carrying
rated current continuously

a) - Conductor
a) 1 Bolted Joints (Plain or tinned) 90
o
C
a) 2 Bolted Joints (Silver Plated) 105
o
C
b) Busduct Enclosure 80
o
C
22 Accessories
a) Seal-off bushings As per requirement
b) Silica gel breather To be provided

Length of the busduct shall be calculated by the tenderer based on approved
layout and location of the generators and generator transformers.

Generator bus duct shall be suitable for air and water tightness test as per IS :
8084

Rating, type and detailed technical particulars of the generator neutral bus duct
shall be as per requirement and as per standards prevailing.

GENERAL ARRANGEMENT

1. 11 kV generator busduct shall be phase isolated with tubular shaped
enclosure. Enclosure shall be continuous type.
2. Comprising of following sections, as applicable, to make the installation
complete and to match with the terminal equipment :

Generator lead-in section with flexible hood and links.

UNIT # 1 TO 6 (6x60 MW)


Straight section in standard length.
Matching section (length as required).
Generator transformer lead-in section with flexible links
Corner sections (horizontal and vertical)
Phase cross-over section (If required to match phase sequence of the
board).
Link section.
3. Silica gel breathers at appropriate locations.

4. Space heaters and power supply arrangement for the space heaters

5. Earthing of busducts with continuous run of conductors
6. Generator neutral bus duct along with all the generator CTs, SAPT, NGT
and loading resistor, all associated accessories, etc
CONSTRUCTION DETAILS

1. Degree of protection for enclosure IP 52 or better inside machine
hall.
2. Enclosure material : Aluminium of minimum thickness 3 mm.
Tenderer shall include enclosure with the thickness required for the
rectangular shape and mechanical/ electrical strength point of view.

3. Maximum temperature of enclosure under rated operating
conditions limited to 80
0
C

4. Bolted covers with gaskets for easy inspection and access to
insulators and bus bar joints.

5. Rubber bellows at transformer end to take care of vibration (Flange
on which rubber bellow shall be seated shall seam welded to avoid
ingress of water into the transformer).
6. Hinged and gasketed inspection access cover at suitable intervels.
7. Seal off bushings and frames complete with bolts

8. Provision for draining moisture.

9. Provision for mounting on brackets.

UNIT # 1 TO 6 (6x60 MW)


10. Supply of GI supporting structures with necessary hardwares.
Supporting structures shall be fabricated from standard steel
sections and shall be hot dipped galvanised after fabrication.

11. For termination at generator end, suitable seal off bushings shall be
provided, if required
12. Necessary supporting foundation including civil works to be
provided
Surface treatment
Two coats of epoxy paint for outdoor and synthetic enamel paint for indoor
application, preceded by de-rusting, cleaning chemically, degreasing,
pickling in acid, cold rinsing, phosphating, passivating and spraying with two
coats of zinc oxide primer.
Shade of paint

Interior : Black/white/light yellow

Exterior : Light grey shade 631 of IS - 5 1978 (unless otherwise specified)
and further stoved.

BUSBARS AND CONNECTIONS

1. Material EC grade aluminium alloy equivalent to E91E WP conforming
to IS 5082-1981.

2. Final operating temperature of both bus bars and joints under
continuous operation in enclosure limited to 90
0
C by thermometer
method.
3. Bus bar arrangement as per IS 5578 (1991).
4. Phase identification by colour at ends and at regular intervals.
5. Busbars shall be of welded construction.
6. Copper flexible busbars surface shall be tinned
7. Contact surfaces shall be silver plated.
8. Flexible connections for termination on equipment.
9. Expansion joints on straight runs with joints staggered in adjacent
phases.

UNIT # 1 TO 6 (6x60 MW)


10. Bimetallic joints for jointing between dissimilar metals.
11. Busbar conductors shall be given coat of black mat.
12. Busbar support insulators of non-hygroscopic material having high
impact and di-electric strength with an anti-tracking contour.
PROTECTIVE EARTHING
1. GI/Aluminium earth bus of size 50 x 10 mm running throughout the
length of the busduct, positively connected to the body of the busduct.

2. Provision at each end of busduct for terminating external earth
conductor.
INSULATORS

1. Bus support insulators shall be interchangeable.

2. The insulator shall be designed and mounted in such a manner so as to
facilitate easy inspection, removal and replacement without disturbing
the conductor.

SPACE HEATER
Adequate number of thermostatically controlled space heater shall be
provided to maintain internal temperature above the dew point to prevent
moisture condensation within the busduct. Supply for space heater shall be
240V, single phase, 50Hz.

BUSDUCT SUPPORT

The busduct shall be supported from floor / roof beams or steel inserts.All
hardware shall be galvanised.
04.02 METERING AND PROTECTION SYSTEM
Control, Relay and Mimic Panel
Complete control, monitoring, interlocking, sequencing, metering,
annunciation and protection of complete TG sets and complete electrics of
the unit shall be performed in DCS. Hardwired back up panels shall also be
provided for turbines and generators.

UNIT # 1 TO 6 (6x60 MW)


Complete control, operation and metering requirements for the following :
- Generator, generator transformer, 220/11 kV station transformer,
Station Auxiliary transformer, unit auxiliary transformers and
associated circuit breakers, Turbine shutoff valve,
- 220 kV transformer bay equipment
- 11kV Switchboard
- 415V incomers and bus-coupler of unit Aux. Board
- 415V incomers of Station Aux. BoardControl Requirement
Refer Chapter 6
Metering
i) Generator
The ammeters, voltmeters, MW meter, MVAR meter, frequency
meter, power factor meter, energy meter (MWH) meter, MVARH
meter, exciter field voltage and exciter field current meters
including necessary transducers shall be provided in the generator
control desk located in control room.

Generator protection panel shall consist of numeric type protective
relays (microprocessor based communicable on open protocol like
MODBUS/IEC, Password protected with fault recording facility and
time stamping) and associated wiring.
Tenderer shall provide state of art equipment system in the control
room fulfilling the functional requirement of all the equipment for
smooth and trouble free operation of the units. Minimum no. of control
desks/panels shall be as per requirement to have control, monitoring,
interlocking, sequencing, metering, annunciation and protection of
complete TG set, and complete electrics of the unit.

Tenderer shall provide above annunciator windows at the top of
operator's console. Number of annunciation alarm/trip points shall be
finalised during detailed engineering stage and 20% spare windows
shall be included for future use. Annunciations shall also be provided
in the DCS / PLC.

Interlocking arrangement shall also be provided to take care of all the

UNIT # 1 TO 6 (6x60 MW)


approved logic schemes. Tenderer shall provide necessary wiring,
control and required items to achieve the approved logic/ scheme.
Local mode operation of the drives for test/trial etc. shall be carried
out by selecting local/remote selector switch of panel in local position.
Permissive conditions for start and tripping of various mechanism
shall be provided as per approved logic diagrams.

A separate synchronization panel/desk shall be provided with
synchroscope and necessary meters, indications, control switches,
relays, etc.
04.02.01 Panel/Desks
Constructional Features
Panels shall be arranged to form a continuous board with the mimic and
control equipment type with rear hinged door except in MCR. Side terminal
blocks, control signaling circuit breakers, resistors, fuses, links, isolating
switches etc.

- Flush mounted meters, relays, switches, recorder, level indicators,
temp. scanner, signal lamps etc. on front of the panel.

- Made of cold rolled pressed sheet steel thickness of not less than 2
mm.

- Provided with 75 mm base channel & 15 mm anti vibration pad.

- shall have bottom cable entry, double compression cable glands, lugs
and gland plates.

- Provided with space heater and interior illumination lamp with
switches.

- Anodised aluminium inscription plate both at back and front side of
size to enable a person to read from 5 meter shall be provided.

- Painted after proper degreasing, pickling and chemical phosphatising

UNIT # 1 TO 6 (6x60 MW)


- Lamp test facility to test all indicating lamps of the panel
simultaneously.

- Earth bus securely fixed. 50 x 6 copper ground bus for all panels
-Control desk will have mosaic type construction and for relay panel
rack type construction shall also be acceptable.
Technical Particulars

1. Panel : Sheet steel not less than 2.0 mm
thick
2. Enclosure : IP 41
3. Provision of cable glands : Yes
4. Inscription front & rear : Both sides
5. Control supply : 220 V DC
6. Signalling bus isolation : ON/OFF switch
7. Control buses : As per circuit requirement
8. Relays : Numeric (self-diagnostic feature)
With communication facility
9. Protective relays : Drawout type
10. Auxiliary relays : Non-drawout
11. Master trip relay : Yes
12. Auxiliary relays : As per circuit requirement
13. Instrument size : Minimum as per requirement
14. PT secondary voltage : 110 V
15. CT secondary current : 1A
Number of Panels
Details of main control, monitoring, protection, interlocking, sequencing, etc
have been described elsewhere. Tenderer shall prepare panel wise bill of
materials considering SLD and the scheme requirement. Number of control
relay and metering panel and their respective positions shall be finalised
during detail engineering stage.
Wiring
- Wired with 1100 volt grade multistranded copper wire PVC insulation
having area 2.5sq.mm. External CT connections shall be made with 2.5
sq. mm copper wires. The

- CT & PT wiring shall be done with colour coded wires.

UNIT # 1 TO 6 (6x60 MW)


- Wire shall not be joined or tied between the terminal points. All wire
termination shall be made with insulated sleeved crimping type lugs.

- No bunch will contain more than 12 wires.

- Wire end shall be fitted with moisture and oil resistant insulating
material having glass finish with identification number clearly engraved
in black.
Terminal Blocks

- Stud type terminal blocks vertically mounted.

- Stud type terminal blocks shall be provided with brass studs.

- In each terminal block 10% spare terminals shall be provided.

- CT terminal shall be suitable to terminate 4 sq.mm cable and shall be
link type to facilitate shorting of CT wires during testing etc.
Control Supply

- The control voltage shall be 220V DC

- For switching off supply disconnecting devices with aux.contacts for
indication of control supply.

- One number 240 V single phase 5 A point in all panels for testing
purpose. AC supply shall have single feeder

- DC supply shall have duplicate feeders with selection arrangement.
DC supply monitoring shall be provided in both control rooms.

UNIT # 1 TO 6 (6x60 MW)


Transducers

Various transducers (4-20 mA range) shall be provided either in separate
transducer panels or mounted in control panels to facilitate remote
monitoring of the parameters and to hook up with DCS/PLC /SCADA system.

TRANSDUCER RATINGS

General
1. Make : Approved make
2. Output : 4-20 mA DC
3. Load Resistance capability : Suitable for DDC hookup
4. Accuracy : 0.5% of full scale
5. Repeatability : 0.1% of full scale
6. Linearity : 0.05% of full scale
7. Residual ripple in output current : 5% max.
8. Power frequency withstand voltage : 2 KV rms for 1 minute
between wires and case

9. Maximum burden on CT/PT : 1.0 VA
Current Transducer
1. Nominal Input/Rated current : 1 Amp AC
2. Overload capacity without loss in accuracy
Continuous : 120% of rated current
Short time : 10 times rated current for
0.5 sec.
Voltage Transducer

1. Nominal Input/Rated voltage : 110/(sq.rt of 3) V AC
2. Overload capacity without loss of accuracy
Continuous : 120% of rated voltage
Short time : 2 times the rated value
for 0.5 sec.
Power Transducer

1. Nominal Input

UNIT # 1 TO 6 (6x60 MW)


Rated voltage : 110VAC (3 ph PT supply)
Rated current : 1 A AC (3 ph CT supply)
2. Overload capacity without loss of accuracy
Continuous : 120% of rated voltage
Short time : 2 times the rated value
for 0.5 sec.

Auxiliary power supply, if required, shall be derived by tenderer from the 415
VAC, 3 ph/4-wire or 220V DC power supply provided at each switchgear.

04.02.02 Specification of Items
Indication lamps
- Shall be panel mounted with rear terminal connection
- Shall withstand 120% of rated voltage on continuous basis.
- Bulbs and lenses shall be replaceable from the front.
- Shall be LED type.

Semaphore indicators

- Shall rotate + 45 deg. on energisation.

- Shall be mounted in such a way that it forms part of mimic.

- Shall withstand 120% of rated voltage on continuous basis.
Control switches

- Generator breaker control switch shall have four position viz. Trip,
Close, Neutral after trip and neutral after close.
- Other switches shall be as per the requirement of the scheme.
- Type of operation handles of switches shall be spring return pistol
grip type.
- All switches shall be provided with inscription labels.
- All switches shall have a rating 10A/500V.
- Switches shall be dust protected, heavy duty switch board type
- Contacts shall be silver surfaced
- Stay put type selector switch shall be provided for auto/manual, DC
source selection, local/remote etc.

UNIT # 1 TO 6 (6x60 MW)


Aux Relays

- Shall be contained in dust and moisture proof cases.
- Close/trip circuit supervision relays (to be provided if features are
not available in numeric relays) shall be suitable for connection in
series with close and trip coil of breaker and trip supervision relay
shall be suitable for monitoring the healthiness of tripping circuit on
both breaker open and close conditions. In protection circuit DC
failure supervision relay shall be provided.
- The relays shall be suitable for operation between 70-110% of rated
voltage.
Numeric relays

- Stringent measures including shielding of long internal wiring shall
be taken to make relays immune to voltage spikes.

- Shall withstand 5 kV, 1/150 microseconds as per IEC.

- Shall be protected against transient/induced over voltage by
providing suitable surge arresting device.
Annunciation

All electrical annunciations connectd with generator, generator systems
and unit system Shall be displayed in DCS system.

The main annunciation points shall be as follows :

1. Generator - alarm/trip indication (separate for each electrical protection
/discrepancy).

FCB trip, Bearing-Stator temp. high/trip, overspeed alarm/trip, CO2
release, AVR failure, cooling coil temp, Duplicate annunciation shall be
provided in UCR on occurrence of alarm/trip conditions as `warning' in
MCR, and `Emergency in MCR'.
2. Generator transformer
Buchholz, oil/winding temperature, oil level low - alarm
Buchholz, oil/winding temperature - trip condition, oil pump trip, PRD

UNIT # 1 TO 6 (6x60 MW)


operated / cooling water valve closed / fire fighting operated.
3. Alarm/trip condition for 220 kV side protection
(Protection points and low air pressure alarm).
List of points shall be finalised during detail engg. stage, tenderer to
include all required points with accessories/wiring transducers etc
needed to meet above requirement.
04.02.03 Electrical Protection System
This section covers the details of the protection adopted for various
electrical equipment, viz. generators and their auxiliaries, generator
transformers, 220/11 kV Transformer, Station transformer, unit auxiliary
transformers and all associated electrical equipment, etc.

The protective relays used for protecting various equipment shall be
numerical type with communication facilities and shall provide adequate
redundancy. They shall be selected or grouped that in the event of non-
availability of any relay or any one group, for any reason, e.g. power supply
failure, on-line testing of any relay or many relays or any other reason
whatsoever, the relays in other group shall completely protect the respective
equipment since the same is expected to be energized / running.

Selection of protective scheme will be based mainly on reliability (main &
standby), sensitivity, selectivity. All main protections shall be fast acting type
in order to clear the faulty system from the healthy system in earliest
possible time to minimize damage to equipment and ensure continuity of
power supply, if possible. Tenderer shall suitably design tripping system
covering different protection under different class of trippings of generator
and turbine.

Numeric microprocessor based relays shall be provided suitable for
communication to DCS / PLC / SCADA consisting of comprehensive
protection with fault recording facility, metering provision and self testing
facilities in line with present state-of-the-art system. The protection system
will be in modular design comprising digital signal processing and a data bus
for signal exchange, digital input / output units, analogue input-units,
analogue / digital conversion units, field interface units, etc.

All numeric relays shall be password protected and shall have sufficient

UNIT # 1 TO 6 (6x60 MW)


binary input/output contacts as per actual requirement plus 10 % spare. No
auxiliary relays shall be used for contact multiplication. The relays shall
have capability of capturing waveforms and disturbance recording at the
time of fault. Moreover, all the relays shall have real time stamping facility.

Complete relay co-ordination for the various systems and sub-systems shall
be done by the tenderer.

The system shall have necessary interface and compatibility with distributed
digital type process control system.

Protections for the various electrical equipment and generators are enlisted
below;
1. Generator Protection
The following protective schemes are proposed for the generators.
a) Generator differential protection : This will offer selective and high
speed protection for generators against internal faults like phase to
phase and three phase faults. The relay shall be ultra high speed,
high-impedance type, immune to transients with operating time as
short as 8 milliseconds for ultra high speed and 30 m sec for high
impedance type relays. The relay shall be stable for all external
faults.
b) Generator interturn fault protection : This protection will be provided
for faults between turns of the same phase only if generator stator
winding are double star type and leads of the same phase are
separately brought out on the neutral side. For the above protection
cross-connected CTs will be ultilised. The recommended relay shall
be high speed, high impedance type, through fault stabilised, similar
to generator differential relay.
b) Generator stator 100% earth fault protection : The neutral of the
generator will be earthed through a distribution transformer, whose
low voltage winding will be loaded by a suitably rated resistor. The
recommended protection scheme shall detect earth fault at any point
on stator winding to provide 100% protection. This relaying shall also
be made to supervise the integrity of grounding system healthiness.

c) Standby stator earth fault (0-95%) protection : The protection scheme

UNIT # 1 TO 6 (6x60 MW)


shall include an inverse time or definite time neutral voltage
displacement relay connected to the open-delta winding of the
generator VT. This relay shall be immune to third and higher
harmonics. This relay protects the winding only upto 95% from the
phase side. This relay will also give earth fault protection for 11kV
system during back charging of the generator transformer.

d) Generator field winding earth fault protection: The protection scheme
shall be in two stages. The field power supply is derived from
unearthed DC source. The relay will be operating on the basis of
monitoring insulation resistance by injecting subharmonic currents in
field system. The first stage, shall operate when insulation resisance
goes below 80 Kohms and gives alarm. The second stage will
operate below 5 Kohms and will initiate tripping of the unit.

e) Generator negative sequence protection : Protection envisaged shall
protect the generator from harmful effects of negative phase
sequence currents. Each negative phase sequence relay shall be
having two stages of protection.

First stages shall iniate alarm and trip the unit after a definite time lag
(e.g. 1000 seconds). Similarly, second stage shall trip the unit when I
sq.t = k exceeds preset value. The present limits shall be
co-ordinated with that of the generator and also among themselves.

f ) Loss of excitation protection : The protection for loss of excitation
shall comprise of two stages. Both stages shall have offset mho relay
characteristics. Stage I shall be set to respond for loss of excitation
condition when load on the machine is 30-100% of rated value. The
unit shall be tripped after a short time delay. The second stage shall
trip the unit after longer time delay. It shall cater for loss of excitation
condition when unit is lightly loaded (e.g 0-30%). Required
undervoltages relay interlocks shall be provided.

g) Generator under frequency protection : Under frequency protection is
provided to protect the unit from prolonged under frequency with
definite time delay plus cummulative time delays. Stepped under

UNIT # 1 TO 6 (6x60 MW)


frequency protections shall be provided for TG. No. of steps and their
respective time delays shall be selected based on % of acceptable
loss of life and load shedding/recovery curve of the grid.
h) Generator over voltage protection : The protection scheme shall
envisage provision of two stage type definite time, high drop-off to
pick up ratio over voltage relays. 1st stage shall be short time delayed
high set type and second stage shall be long time delayed low set
relay. The protection settings shall be choosen depending upon
voltage regulator response characteristic and generator withstand
capability. The setting of this relay alsoshall be based on withstand
capability given by the manufacturer.

i) Generator stator over-current protection : This relay is voltage
restrain over current used for tripping of generators on short circuit.

j) Generator Reverse Power Protection: This protection is provided
against motoring of the generator. Timer shall be provided in the
scheme.

k) Generator VT fuse failure protection : The protection scheme shall
consist of voltage balances type relays whereby voltage between two
sets of VTs shall be continuously monitored. The scheme shall be
able to detect open circuit in any phase of the VT secondaries as well
as primaries or fuse failure. This will give an annunciation and block
the operation of AVR and voltage operated relays.

l) Generator field over voltage protection : This protection gives
protection of generator rotor due to rotor overcurrents caused by
sustained system voltage depression or malfunction of the control
system. The relay will be DC operated definite time delay over
voltage relay and shall be used for alarm. Surge voltage protection
shall also be provided for the field.
m) Generator, generator transformer over-fluxing protection : This
protection shall be provided for overfluxing protection of generator,
generator transformer. For this purpose two relays shall be provided
(one high set and other low set). Both relays shall operate on the
V/Hz ratio. The highset unit shall trip the unit for very high overfluxing

UNIT # 1 TO 6 (6x60 MW)


conditions after a short time delay and low set unit shall trip the unit
inlonger time delay. Complete protection characteristics shall be
coordinated with composite V/Hz withstand characteristics of all three
equipment. If AVR is provided with under excitation limiters in manual
mode, control functions shall be arranged from overfluxing
protection to limit/control over- excitation at first stage and if V/Hz still
persists tripping function shall be taking over.
n) Bearing failure protection : This is an alarm function. Upon occurence
of alarm, bearings shall be inspected at the earliest opportunity.
o) Generator Overspeed : Two electrically operated and one
mechanically operated Over speed shall be provided. Settings shall
be finalized during drawing approval stage.
p) Generator breaker back up protection : Tenderer is to provide this
protection system after study of existing system and (dedicated
relays need) to be provided on scheme to be hooked up with existing
protection system.
2. Protection for Generator Transformer

a) Generator transformer differential protection
b) Overall generator & generator trafo and UAT differential protection
(for gen. Transformer only)
c) Over current and earth fault protection on HV & LV side
d) Backup over current and earth fault protection on HV & LV side
e) Back-up earth fault protection on HV neutral
f) Restricted earth fault protection on HT side
g) Buchholz relay (alarm & trip)
h) Winding temperature protection (alarm & trip)
i) Oil temperature Protection (alarm & trip)
j) Oil level alarm and trip
k) Auxiliary relays for generator transformer for receiving transformer
alarm and trip (for generator transformer)
l) Lightning arrestors on the HV side.
m) Pressure release device with trip contact
3. Protection of 220 kV switchyard bays
a) Time over current ground protection
b) Directional over current protection
c) Directional over current ground protection

UNIT # 1 TO 6 (6x60 MW)


d) Local breaker back up protection
e) Bus differential protection
f) Protections of transformers as indicated above
g) REF for transformers
Protection for Unit Auxiliary Transformer/ Station Auxiliary Transformer
i) Back up over current protection
ii) stand by earth fault protection
iii) Restricted earth fault on LV side
iv) Auxiliary relays for UAT for receiving transformer alarm and trip.
v) Winding temperature protection (alarm & trip)
vi) Oil temperature Protection (alarm & trip only)
4 Comprehensive motor protection for motors of 75 kW and above

Comprehensive numeric motor protection including but not limited to the
following;

a) Instantaneous over current protection
b) Differential protection (for rating above 1000 kW)
c) Instantaneous time over current protection in two phases and
definite time delayed over current alarm on the third phase
d) Negative phase sequence protection
e) Thermal overload taking -ve and +ve phase sequence into account
f) Earth fault
g) Locked rotor protection
h) Winding temp monitoring and alarm for rating beyond 1000 kW
i) Under voltage protection
5 LT motor protection (for motors less than 75 kW)
The motors rated below 75 kW shall have bimetallic relays for thermal over
load protection and MCCB for short circuit protection. Single phasing
protection shall also be provided in the MCC modules
6 Generator Excitation System
Excitation transformer
- Overload
- Over current protection
- Winding temp

UNIT # 1 TO 6 (6x60 MW)


Excitation system

- Load angle limiter
- kVA & kVAR limiter
- Stator current limiter
- Rotor current limiter
- Volt/Hz ratio controller
- Slip stabilization
- Cross current compensation

Thyristors
- Fuse failure / fan failure (Alarm)
- Over current
- Thyristor failure supervision &
- thyristor overload

7. 415 V Switchboard

i) 415V Incomer

- Overcurrent
- Earth fault Timers
ii) 415V Outgoing (MCC feeder)

- Overcurrent
- Earth fault relays for selective tripping of feeder
iii) 415 V Motor Feeders (Above 110 kW)
- Comprehensive motor protection relay
(Microprocessor based)
iv) 415 V Motor Feeder (less than 110 kW)
,
- Undervoltage
- overload
- single phase
v) Bus PT
- U/V relays
415 V incomers shall have under voltage/timer relays for auto-

UNIT # 1 TO 6 (6x60 MW)


changeover as described in clause 04.05.
04.02.04 Protective Scheme Requirement

General

- All required protection relays shall be provided. Auxiliary relays,
timers switches etc. required to make the scheme complete shall be
considered as part of the scope of work. Details of major relays and
meters are highlighted in clause 04.02.03.(indicative)

- All CT-PT shall be suitable for the relay-meter requirement - lead
burden and as shown in the enclosed single line diagram.

- All interfacing/essential interlocking cabling from existing units as well
as from 220 kV switchyard and bays are in the scope of tenderer.

- Aux. Relays shall be provided for each transformer fault.

- Contact arrangement and number of poles/ways in control/selector
switches shall be as per the requirement/approved scheme.

- Generator tripping system shall be designed such a way so that on
electrical faults only generators shall be tripped and on mechanical
fault generator with turbine shall be tripped with signal to close the
gate. Details of the scheme shall be finalized during detailed
engineering stage.

- For control supply distribution, panel to panel separate set of terminal
blocks shall be provided at top of the control panel. All
items/accessories required for above in each panel and in incoming
panels shall be provided by the supplier.

- Wherever required supplier shall provide aux. relays for contact
multiplication.

UNIT # 1 TO 6 (6x60 MW)


-
04.02.05 Synchronisation Scheme

1. Synchronization arrangement shall be provided in control room for
closing of generator breaker.

2. Lockable syn-selector switches shall be provided on control panel.

3. One syn-bypass lockable type switch shall be provided to facilitate by
passing of scheme if required.

4. Syn. complete and faulty indications shall be annunciated.

5. Required busbar/bus wires shall be provided in all panels (wherever
required) for synchronization scheme.

6. Generator control panel shall have voltmeter, frequency meter, to
measure incoming and running voltage/ frequency and one
synchroscope (with reversing voltage transformer RVT).

7. Check synchronisation relay shall be used to avoid human error
during breaker closing and shall be suitable to compare two signals
(for measuring of voltage, frequency and phase).

8. One guard relay shall be provided with check-syn. relay to ensure
operation of check syn. relay during breaker closing moment.
Auto/manual synchronization selector switch shall be provided

9. In addition to above for generator closing automatic synchronising
shall be provided with facilities to hook up automatic operation of
AVR and governor motor through DCS / PLC / SCADA.
Above technical features of synchronizing scheme shall be finalized during
detailed engineering stage to suit the generator being offered.

UNIT # 1 TO 6 (6x60 MW)


04.03 GENERATOR TRANSFORMER
04.03.01 Electrical Design
- Generally as per IS 2026.
- 3x single phase core type
- Rated output voltage ratio, vector group shall be as specified in
Technical Particulars for design.
- Rated frequency 50 Hz, +3% , -5%
- Insulation level shall be designed according to the voltages specified
below.

Nominal System voltage 11 kV 220 kV

--------------------------------------------------------------------------------------------------------------------
----------

1. Max. system voltage (kV) 12 245

2. One minute power 28 460
frequency withstand
voltage (kV)
3. Peak impulse test 75 1050
withstand voltage (kV)
4. Clearance in Air (mm)
Phase to Earth 110 5500
Phase to Phase 127 4500

--------------------------------------------------------------------------------------------------------------------
--------

- Transformers shall be capable of delivering rated current at an
applied voltage upto 105% rated voltage without exceeding the
temperature limits specified below.

- Overload capacity as per IS 6600 unless otherwise specified.

- Shall be operable at its rated capacity at any voltage within + 10% of

UNIT # 1 TO 6 (6x60 MW)


rated voltage of the particular tap.
- Transformer shall be Bi-directional
- Temperature rise shall be as per IS 2026 Part-II.

a) Top oil (by thermometer) : 45 deg. C
b) Windings (by resistance : 50 deg. C
method)
c) Maximum hot spot temp. : 55 deg. C

- Transformers shall be designed to withstand the thermal and dynamic
stresses due to short circuits at its terminals. Unless otherwise
specified the duration of short circuit shall be 5 seconds.

- The max. temperature at the end of the specified duration shall not be
more than 250 deg. C with the temperature prior to short circuit
corresponding to maximum permissible overload.
Magnetic Circuit

- Low loss CRGO silicon steel shall be used.

- Laminations shall be annealed in a non-oxidising atmosphere to
relieve stresses and restore the original magnetic properties of
CRGO sheets after the cutting and punching operations.

- CRGO sheets shall be coated with insulation varnish compatible with
the sealing liquid.

- Ducts to be provided to ensure adequate cooling.

- Core, framework and clamps arranged and tightened to securely hold
laminations in order to prevent any settling of displacement in case of
heavy shocks during transport, handling or short circuits.

- Flux density at normal over voltage or frequency shall be such that
under 10% over voltage condition it shall not exceed 1.6 tesla.

UNIT # 1 TO 6 (6x60 MW)


Windings
- Material shall be electrolytic grade work hardened copper of high
proof stress with more numbers of radial supports.
- Shall be pre-compressed, press board, pre-stabilization of coil.

- Completed core and winding to be vacuum dried in full vacuum and
impregnated immediately.

- Shall be braced to withstand shocks due to rough handling and forces
due to short circuit, switchings or other transients.

- Permanent current carrying joints in winding and leads shall be
brazed.

- Coils shall be supported using dried and high pressure compressed
wedge type insulation spacers.

- Insulating materials shall be compatible with transformer liquid under
all service conditions.

- Leads to the terminal board and bushings shall be rigidly supported.
Insulation
- Interturn and inter coil insulation shall be designed such that
di-electric stress is uniformly distributed throughout the windings
under all operating conditions.
Tank
- Welded thick gauge plates stiffened and reinforced to withstand
without deformation all stresses applied during transport and
operation or short circuit conditions.
- Oil tight welds and joints
- Construction shall be bell type.
- Fully assembled transformer with its radiators, conservator and other
fittings shall withstand for one hour a pressure corresponding to twice
the normal head of liquid or to the normal pressure plus 35 kN/sq. m,
whichever is lower, measured at the base of the tank.
- Plates shall be protected internally against corrosion due to insulating
liquid.

UNIT # 1 TO 6 (6x60 MW)


- Provided with inspection opening and cover/with handling equipment)
to provide acces to bushing connections.
- Form of cover shall be such as to prevent any stagnant water deposit
and to drain gas bubbles towards the buchholz relay
- Transformer tank shall withstand the vacuum test for pressure of
100.64 kN/sq.mm.
Necessary type test certificate shall be furnished in respect of above.
Conservator and Breather
- Conservator mounted on frame, integral with tank in such a manner
that under all conditions and the lowest oil level the bushings remain
under the head of liquid.
- Conservator volume shall be sufficient to maintain oil seal from
ambient to oil temp. of 90 deg. C
- Oil filling hole with cap, a drain valve to drain the oil completely shall
be provided one end of conservator shall be bolted into position so
that it can be removed for cleaning purposes.
- Silica gel breather with inspection window and oil seal shall be
mounted at suitable height from ground level and connected to
conservator.
- Prismatic type oil level gauge with max. and min. levels marked. Tap
and values shall not be fitted to oil gauge. 150 mm diameter dial type
magnetic level gauge with alarm and trip contacts shall also be
provided.
Buchholz Relay
- Double float relay as per IS 3677.

- 50 mm diameter of connecting pipe for transformers and shall have
minimum number of bends.
- Shut off valves on either sides of the buchholz relay.
- Pot cocks at the top and bottom of relay drain plug, inspection
window, calibrated scale, terminal box with oil tight double
compression type brass gland.
- Potential free, self reset independent alarm and trip contacts rated to
make, break and carry 2 amps at 220 V DC. No auxiliary relay shall
be used to multiply the contacts. Contacts are to be wired to the
marshalling box.

UNIT # 1 TO 6 (6x60 MW)


Cooling
The cooling system shall be OFWF
Cooling system shall be designed and supplied with a concept of 2 x100%
configuration to facilitate one working and one stand by. On tripping of oil
pump, cooling water valve shall also be tripped to avoid ingress of water.

The oil circuit of oil coolers shall be provided with the following :
1. A valve at each point of connection to the transformer tank
2. Removable blanking plates to permit the blanking off the main oil
connection of each cooler
3. A drain valve 25 mm lowest point of each bank cooler
4. A thermometer pocket fitted with a captive screwed cap on the inlet and
outlet oil branches of each separately mounted cooler bank
5. Air filter valve at the top and bottom of each cooler
6. Air release plug
In addition , the following are to be provided as per IS : 6088
a) A suitable differential pressure gauge fitted with electrical contacts
b) Oil and water flow switches fitted with electrical contact
c) Flow indicator
2 nos. Pump motor set (1 working and 1 standby) shall be provided along with
pipes, valves etc to facilitate water for cooling of oil
Transformer Oil Cooling System
Complete new transformer oil cooling plant shall be installed / provided for all six
units except embedded piping. Embedded piping if any to be reused after cleaning.
Each new transformer oil cooling plant shall have four nos. oil coolers (3W+1S), 4
nos. oil circulating pumps(3W+1S) of suitable capacity with electric driven motor
along with accessories, oil filters, adsorbent filters, necessary piping, valves.
Provision for oil filter bypass system shall be provided. If any one of the working
pump is failed then the standby pump shall be automatically started to maintain the
oil level in the transformers.
Latest BIS code/ international standards shall be followed for designing of the
above system. Cooler tube materials shall be of Cupro-Nickel. Oil pipeline material
shall be of stainless steel.
Pressure gauge, flowmeter, flow relay etc instruments for local as well as remote
shall be provided. Auxiliary relay, timer relay etc as per scheme requirement shall
be provided.
Auto change over power supply system shall be provided to have availability of

UNIT # 1 TO 6 (6x60 MW)


supply for operation of pumps as well as control.
Draining of oil from oil coolers, adsorbent filters of each transformer shall be done
to existing transformer oil tanks located at SRV floor. All pipes and valves shall be
replaced by new one.
Cooling water for coolers shall be tapped from nearest technical cooling water
supply header. Tapping arrangement is in the scope of tenderer.
Embedded pipelines shall be chemically cleaned.
New Control panel /cubicle of transformer cooling plant shall be provided for
complete control of pumps operation, emergency shutting down of pumps. It shall
also have following protection
Transformer cooling failure
Transformer cooling control circuit failure
Transformer Cooler failure Low water pressure, Oil temperature above the line
Reserve supply failure
Indication of pump operation shall be provided.
valves.
Valves and Connections
Valves shall be of sluice type with hand wheels. They shall be made of
gun metal and shall be provided with padlocking facility to lock in
closed/open position, blanking plates or screwed plugs and clear
indication of open and closed position
Terminations

It shall be possible to withdraw the transformer easily after disconnecting the
connections without disturbing the OH line/cable/busduct terminations. For
cable termination, air insulated cable box shall be provided which shall be
suitable for the type and number of cables specified. Cable end box shall be
self-supporting. For OH line termination, proper bushing shall be provided.
For bus duct termination, proper matching flange arrangement shall be
provided.
Bushings
- Conform to IS 3347 and 2099.
- Minimum rated current of line and bushings shall be 1.5 times rated
current of the corresponding windings
- Clamps and fittings made of steel or malleable iron shall be hot dip

UNIT # 1 TO 6 (6x60 MW)


galvanised.

-
- Neutral bushings shall be provided as required for earthing of neutral
point. Bushing current Transformers (Where applicable)
- Removable at site without opening transformer tank cover/active part
- Secondary leads of 4 sq.mm shall be brought to a weather proof
terminal box and from there to the marshalling box.
Bushing Current Transformers
Bushing CT shall be removable at site without opening transformer tank
cover/active part. Secondary leads of 4 sq.mm shall be brought to a
weatherproof terminal box and from there to the marshalling box
Oil temperature Indicator
150 mm dial type thermometer with manual reset maximum reading pointer.
there shall also be two potential free contacts for alarm and trip signals. The
alarm and trip settings shall be independently adjustable. The temp. sensing
element mounted in a pocket of oil, shall be connected to the indicator
through capillary tubing. Contact rating at DC shall be minimum 0.5 amps.
Winding Temperature Indicator
Local winding temperature indicator (WTI) shall have a 150 mm diameter
dial type indicator with a manual reset max. reading pointer. there shall be
two potential free contacts for alarm and trip signals. Contact rating at DC11,
220V DC shall be minimum 0.5 amps. The device shall be complete with
lamp, sensing element, image coil, calibration device, aux. CTs etc. as
required.
Marshalling box & Cooler Control Panel
- All outgoing conections from the transformer i.e buchholz relay, temp.
indicators, level indicators, CT secondaries, alarm contacts for
annunciations, including forced cooling system and OLTC, etc. shall be
wired to a marshalling box.
- Degree of protection of enclosure shall be IP 52 for indoor and IP 55 for
outdoor type respectively.
- Removable bottom gland plate with cable glands and cubicle illumination
lamps.
The cooling system shall have duplicate power supply from two
different sources with auto changeover arrangement.
- Cooler control box and motorized tap changer arrangement shall be

UNIT # 1 TO 6 (6x60 MW)


provided along with all the transformers
Tenderer shall also provide dedicated remote cooler control cum tap
chnager control panel for all the transformers with all indications, control,
annunciations, etc.
Earthing

- All metal parts of the transformer with the exception of individual core
laminations, core bolts, and clamping plates shall be maintained at
fixed potential by earthing.
- Two tinned copper earthing terminals
- One end of bushing CTs shall be earthed.
List of fittings and Accessories
- Name plate
- First fill of oil as per IS - 335 with 10% excess in drums
- Cooling system complete with accessories as per requirement
including radiators with shut off valves, filter valves, drain and
sampling devices and air release device. For generator transformer,
water cooling circuit shall be suitably connected to existing pipe
network.
- Conservator
- Dehydrating breather
- Buchholz relay
- Oil filter valves at top and bottom of tank
- Off-circuit tap changer
- HV side bushings for connection to overhead conductor.
- Drain off valve at lowest location to allow complete draining.
- Oil sampling device at top and bottom
- Explosion vent with double diaphram
- Pockets with thermometers for oil temp. and winding temperature
indicators.
- Bushing CTs
- Dial type oil and winding temp. indication(150 mm
dia.) and alarm and trip contacts. Remote WTI/OTI shall be provided
in addition to local indicators.
- Lifting lugs and jacking pads
- Rating and diaphram plates
- Earthing terminals

UNIT # 1 TO 6 (6x60 MW)


- Bidirectional wheel (flange type)
- Inspection cover
- Flat base and foundation bolts.
- Marshalling kiosk
04.03.02 Technical requirements(indicative) For transformer

Voltage HV/LV : 220 kV/11 kV
- Duty : Outdoor
- Specification to be : IS 2026
compiled with
- Continuous rating : 3x 23.4MVA
- Cooling : OFWF
- Vector group : YNd11
- Neutral grounding : 11 kV -High resistance grounded &
132kV
Effectively grounded
- Percentage impedance : 10%
- Termination HT : ACSR conductor
LT : Busduct
- Bushing mounted CTs : PS class According
to requirement
- Tap changer on primary : Off circuit type

a) Range +5%
b) Total tap positions : 5
c) Taps above nominal : 2
voltage
d) Taps below nominal : 2
voltage
e) Voltage per step : 2.5%
variation
f) Tap change controls : Local- manual
- Impulse test withstand voltage : As per IS 2026
- One minute dry and wet power : - do -
frequency withstand voltage
- Induced over voltage : - do -
withstand voltage

UNIT # 1 TO 6 (6x60 MW)


- Withstand time without injury for : 5 secs.
3 phase short circuit at terminals
- Temp. rise above maximum
ambient in oil by thermo meter. : 45 deg. C
- In winding by resistance : 50 deg. c
- Auxiliary supply voltage : 220 V DC
- Parallel operation : Suitable for parallel operation
with
transformers of similar Ratings
- Overload capacity : As per IS 6600
- Radiator : Detachable type
- Painting : Dark admiralty grey
shade 632 of IS: 5.
Epoxy based
OVER VOLTAGE LIMIT

- Generator transformer shall be suitable for 140% over voltage for 5
seconds and 125% over voltage for one minute.

Note : Transformer design data and accessories shall be provided as per
CBIP manual (Publication 275) except the data details mentioned
here.
04.04 220/11kV STATION TRANSFORMER
One (1) number 220/11 kV, 20 MVA ONAN / ONAF station transformer fitted with
off-load tap changer and all other accessories shall be provided.

The Station Transformer shall be provided with the following;
Neural Grounding Resistor
Oil collecting pit for the station transformer and its interconnection with owners
common sump pits
Complete civil works including foundations of adequate capacities along with
cable trench, road, fencing and gate etc
Rail for transportation of the transformer and its interconnection with existing
network
All the transformer accessories
Complete earthing and shielding system

UNIT # 1 TO 6 (6x60 MW)


The core construction of station transformer shall preferably be of boltless
technology. Construction/clamping shall be adopted so that hole through core
laminations is avoided. Suitable tie plates and clamps shall be used so that core
holes and core bolts are totally eliminated.

Tenderer shall clearly indicate in his offer whether he has considered and offered
boltless core for the transformer in offer.
Design
Design shall be generally as per IS 2026. Transformer shall be suitable for rated
frequency 50 Hz, -5%, +5%. Insulation level shall be designed according to the
voltages specified below.

Sl.
No.
Description 220 kV 11 kV
1 Nominal voltage (kV) 220 kV 11 kV
2 Max system voltage (kV) 245 kV 12 kV
3 Power frequency withstand
voltage (kV)
395
4 System Earthing Solidly earthed Non-effectively
earthed
5 No. of phases 3 3
6 Frequency 50 Hz 50 Hz
7 Impulse test withstand voltage
(kV)
1050 75
8 Short time current rating (for all
current
carrying parts)
40 kA for 3 sec 40 kA for 3 sec
9 Fault level (3 phase
symmetrical)
40 kA
(15000 MVA)
40 kA

10 Clearance in air (mm)
Phase to earth 2150 As per IS
Phase to phase 2350 As per IS

Transformers shall be capable of delivering rated current at an applied voltage up to

UNIT # 1 TO 6 (6x60 MW)


105% rated voltage without exceeding the temperature limits specified below. Overload
capacity shall be as per IS 6600. Transformers shall be operable at its rated capacity at
any voltage within + 10% of rated voltage of the particular tap. The transformers shall be
suitable for parallel operation with existing station transformers.
Permissible maximum temperature at rated output and principal tap over an ambient
temperature of 50
o
C.

Top oil (by thermometer) : 45
o
C
Windings (by resistance method) : 50
o
C.

Transformer shall be designed to withstand the thermal and dynamic stresses due to
short circuits at its terminals. Unless otherwise specified the duration of short circuit shall
be 5 seconds.
The max. temperature at the end of the specified duration shall not be more than 250
o
C
with the temperature prior to short circuit corresponding to maximum permissible
overload. Tenderer shall submit the calculation proving the same.

Design for suppression of harmonics especially 3rd and 5th. Over voltage capability of
the transformers shall be as per IS.

Frequency response analysis shall be done on transformer during routine testing.

COPS (Constant Oil Pressure System) shall be provided to avoid direct contact of oil
with atmospheric air.

One more drain valve with pipe of approximate diameter of 150 mm (for 10-15 mtr long)
with bends shall be provided to facilitate draining of transformer oil in case of emergency.
The exact arrangement shall be as per drawing to be furnished by the tenderer and
approved by the owner during detailed engineering.
Magnetic circuit
The core construction of station transformer shall preferably be of boltless technology.
Magnetic Circuit shall be made of low loss CRGO silicon steel shall be used. CRGO
sheets shall be coated with insulation varnish compatible with the sealing liquid.
Laminations shall be annealed in a non-oxidising atmosphere to relieve stresses and
restore the original magnetic properties of CRGO sheets after the cutting and punching
operations. Insulation shall be able to withstand annealing temperature as high as 850
o
C and shall reduce eddy current to the minimum.

UNIT # 1 TO 6 (6x60 MW)


Suitable ducts shall be provided to ensure adequate cooling.
Core, framework and clamps shall be arranged and tightened to securely hold
laminations in order to prevent any settling of displacement in case of heavy shocks
during transport, handling or short circuits.
Flux density at normal over voltage or frequency shall be such that under 10% over
voltage condition it shall not exceed 1.9 Tesla.
Transformers shall be designed to withstand 110% over fluxing corresponding to rated
voltage for 20 minutes.

Windings

Material shall be electrolytic grade work hardened copper of high proof stress with more
numbers of radial supports. Completed core and winding shall be vacuum dried in full
vacuum and impregnated immediately.

Insulating materials shall be compatible with transformer liquid under all service
conditions. Leads to the terminal board and bushings shall be rigidly supported.
Winding shall be pre-compressed, press board, pre-stabilization of coil.

Windings shall be braced to withstand shocks due to rough handling and forces due to
short circuit, switchings or other transients.

Permanent current carrying joints in the windings shall be brazed type. Joints outside the
winding shall be crimped. Coils shall be supported using dried and high pressure
compressed wedge type insulation
spacers.

Insulation
Interturn and inter coil insulation shall be designed such that dielectric stress is uniformly
distributed throughout the windings under all operating conditions.

Tank
Conventional tank design shall be provided. Welded thick gauge plates shall be stiffened
and reinforced to withstand without deformation all stresses applied during transport and
operation or short circuit conditions. Welds and joints shall be oil tight. Plates shall be
protected internally against corrosion due to insulating liquid.

UNIT # 1 TO 6 (6x60 MW)


Fully assembled transformer with its radiators, conservator and other fittings shall
withstand for one hour a pressure corresponding to twice the normal head of liquid or to
the normal pressure plus 35 KN/sq. m, whichever is lower, measured at the base of the
tank. Tank shall be provided with inspection opening and cover/with handling equipment)
to provide access to bushing connections. Form of cover shall be such as to prevent any
stagnant water deposit and to drain gas bubbles towards the buchholz relay.
Transformer tank shall withstand the vacuum test for pressure as per CBIP guidelines.
Necessary type test certificates shall be furnished in respect of above.

Transformer tank shall withstand vacuum test for minimum pressure of 100.64kN/sq.m.
Necessary type test certificates shall be furnished in respect of above.
Conservator and Breather
Conservator mounted on frame, integral with tank in such a manner that under all
conditions and the lowest oil level the bushings remain under the head of liquid.
Conservator volume shall be sufficient to maintain oil seal from ambient to oil temp. of
90
o
C Oil filling hole with cap and a drain valve to drain the oil completely shall be
provided on one end of conservator. Conservator shall be bolted into position so that it
can be removed for cleaning purposes.
Silica gel breather with inspection window and oil level shall be mounted at 1.4 m from
ground level and connected to conservator.
Prismatic type oil level gauge shall be provided with max. and min. levels marked on it.
Tap and valves shall not be fitted to oil gauge. 150 mm diameter dial type magnetic level
gauge with alarm and trip contacts shall also be provided.
Breather shall be connected with rubber bellow inside the conservator tank for expansion
and contraction of oil.
Buchholz Relay
Buchholz relays shall be double float relay as per IS 3677. Shut off valves shall be
provided on either sides of the buchholz relay.

Pipe connecting the relay and tank shall be of suitable diameter for the capacity of the
proposed transformers. Minimum diameter shall be 80 mm.

Pot cocks at the top and bottom of relay drain plug, inspection window, calibrated scale
and terminal box with oil tight double compression type brass gland shall also be
provided.

Potential free, self reset independent alarm and trip contacts rated to make, break and

UNIT # 1 TO 6 (6x60 MW)


carry 2 amps at 240 V AC shall be provided. No auxiliary relay shall be used to multiply
the contacts. Contacts are to be wired to the marshalling box.
Cooling
The cooling system provided shall be ONAN/ONAF.
Radiators shall be detachable type directly mounted and shall have flexible earthing
arrangement. Bolted, gasketted and flanged connections shall be used for connecting
the radiators to the tank.
Additional spare radiator fins with isolation valves shall be provided with the
transformers.
The following accessories shall be provided for each radiator/radiator bank.

Top and bottom shut off valves and blanking plates
Pumps and fans as required
Bottom drain plug and top filling plug, air release plug
Lifting lugs
Neutral bushing CTs
Thermometer pockets with thermometers in the inlet and outlet pipes (for
separately mounted radiator banks).
Top and bottom filter valves for each separately mounted radiator bank.
Pressure reducing devices with alarm
Air release devices
Earthing arrangement
Bi-directional rollers/rails
Rail for transportation with provision for extension for transformer
Spare radiator fins along with isolation valves
Any other accessories required.
Valves and connections
Valves shall be of sluice type with hand wheels. They shall be made of stainless steel
and shall be provided with padlocking facility to lock in closed/open position, blanking
plates or screwed plugs and clear indication of open and closed position.
Terminations
connections without disturbing the OH line/cable terminations. For cable termination, air
insulated cable box shall be provided which shall be suitable for the type and number of
cables specified. Cable end box shall be self-supporting. For OH line termination, proper
bushing shall be provided.

UNIT # 1 TO 6 (6x60 MW)


Bushings
Bushing shall conform to IS 3347 and 2099. Minimum rated current of line and bushings
shall be 1.5 times rated current of the corresponding windings.
Clamps and fittings shall be made of steel or malleable iron shall be hot dip galvanized.
Neutral bushings shall be provided as required for earthing of neutral point.
All the bushings shall be provided with suitable connectors and clamps. Bushings shall
have non magnetic clamps and fittings only.
Neutral Bushing Current Transformers
CTs for REF protection and back up earth fault shall be provided on the neutral end.
Neutral Bushing CT shall be removable at site without opening transformer tank
cover/active part. Secondary leads of 4 sq.mm shall be brought to a weatherproof
terminal box and from there to the marshalling box. Neutral Bushing CTs of suitable ratio
and adequate burden shall be provided by the tenderer to cater to the requirement of
above earth fault protection associated with the transformer of this capacity.
Separate bushing CTs may be used for winding temperature indications, if required and
applicable.
For differential protection of station transformer, CT in incomer of station board and CT in
220 kV station transformer bay shall be used.
Oil temperature Indicator (OTI)
150 mm dial type thermometer with manual reset maximum reading pointer. there shall
also be two potential free contacts for alarm and trip signals. The alarm and trip settings
shall be independently adjustable. The temp. sensing element mounted in a pocket of oil,
shall be connected to the indicator through capillary tubing. Contact rating at DC shall be
minimum 0.5 amps. Remote oil temp. indication shall be provided. Additional 4-20mA
signal for remote signal shall be provided.
Winding Temperature Indicator (WTI)
Local winding temperature indicator (WTI) shall have a 150 mm diameter dial type
indicator with a manual reset max. reading pointer. there shall be two potential free
contacts for alarm and trip signals. For transformers with forced cooling another two sets
of contacts shall be provided to start / stop the forced cooling system automatically. The
setting of closing / opining of each contact shall be independently adjustable. Contact
rating at DC11, 220V DC shall be minimum 0.5 amps. The device shall be complete with
lamp, sensing element, image coil, calibration device, aux. CTs etc. as required.
Remote winding temperature indicator with resistance type temperature detector shall be
provided additionally. Additional 4-20 mA signal for remote signal shall be provided.
Marshalling box
All outgoing connections from the transformer i.e buchholz relay, temp. indicators, level

UNIT # 1 TO 6 (6x60 MW)


indicators, CT secondaries, alarm contacts for annunciations including forced cooling
system and OLTC etc. shall be wired to a marshalling box. Marshalling box shall be
sheet steel vermin proof and weather proof. Degree of protection of enclosure shall be IP
55. Rain canopy shall also be provided over the marshalling box. Removable bottom
gland plate with cable glands, cubicle illumination lamps and space heater shall be
provided.
Marshalling box shall be having following major accessories;

Temperature indicators
Control and protection equipment
Terminal board and gland plate
Earthing
All metal parts of the transformer with the exception of individual core laminations, core
bolts, and clamping plates shall be maintained at fixed potential by earthing. Two tinned
copper earthing terminals shall be provided. One end of bushing CTs shall be earthed.
Off-Circuit Tap Switch
- Externally hand operated
- Designed for sustained over current of at least 150% of the rated current of the
winding.
- Shall not occupy any intermediate position between clearly marked tap position.
- Capable of repeated operation and withstanding short circuit forces.
- Integral handle with pad locking facility at every tap position.
- Tap position indicator
- Inspection and/or repair shall not require removal of transformer from tank nor
major draining.
Fitting & Accessories
Transformers shall be provided with following auxiliary equipment/systems and
accessories;
1. First fill of oil as per IS - 335 with 10% excess in drums
2. Cooling system complete with accessories as per requirement including
radiators with shut off valves, filter valves, oil filling valves, drain and sampling
devices, air release device, lifting lugs, etc.
3. Off circuit tap changer with accessories as specified with tap position indicator
and locking arrangement.
4. Bushing CTs, neutral bushing CT with terminal arrangement
5. Conservator with oil filling hole, cap and drain valve sump , drain valve and
detachable end plate.

UNIT # 1 TO 6 (6x60 MW)


6. Magnetic type oil gauge with low oil level alarm contacts
7. Dehydrating silica gel breather with oil-seal - 2 Nos., 100 per cent (In addition
to the silica gel breather, more advanced oil preservation system like air dryers
like molecular sieve flexible membrane can also be considered.)
8. Buchholz relay with oil seal independent alarm and trip contacts with isolating
valves on either sides
9. Required Nos. of pressure relief valves/vents or spring operated pressure relief
devices with trip contacts
10. Pockets on tank cover for thermometers for WTI and OTI
11. Oil temperature Indicator with maximum pointer
12. Repeater dial of oil temperature indicator for remote indication (The remote
indication shall be a separate measuring system)
13. Winding temperature indicator with maximum pointer
14. Repeater dial of winding temperature indicator for remote indication (The
remote indication shall be a separate measuring system)
15. Oil filling hole with flange and bolted cover
16. Valves (made of stainless steel)
Oil valve between cooler and main tank
Drain valve at lowest location to allow complete draining
2 Nos. filter valves on diagonally opposite corner at top and bottom of tank
with locking arrangement
2 Nos. sampling valves at top and bottom of main tank. The sampling valve
shall be provided with provision for fixing PVC pipe
17. Two nos. earthing terminals
18. Rating & diagram plate (One spare Rating and diagram plate shall also be
supplied loose)
19. Valve schedule plate
20. Jacking pads
21. Approach ladder to climb up the transformer tank
22. Air release devices
23. Inspection cover with neoprene gaskets
24. Haulage lugs
25. Earthing terminals
26. Marshalling kiosk
27. Flange wheel/rollers (bi-directional with lock and bolting device)
28. Special cables (other than standard power and control cables)
29. Bus and cable trays

UNIT # 1 TO 6 (6x60 MW)


The following minimum remote control/signaling provisions are to be made as applicable.
Voltmeter to read secondary side voltage of transformer
Signal lamps for tap changing in progress for OLTC.
Remote winding and oil temperature indicators
Status indications for cooler fans running/off/tripped
Status indication of cooling pumps
Control supply fail, cooler fan bank fails to start, standby cooler bank running,
cooler pump fails to start, etc.
Audio-visual annunciations for the following abnormal operating conditions shall be
provided as applicable.
Oil level in transformer low (from magnetic level gauge)
Buchholz relay operation for transformer
High oil temperature in transformer
High winding temperature
Pressure relief device operated
Aux. AC supply failed.

A solid state facia window type annunciation system having first sequence recording
shall be provided for this purpose, with the following features.

On incidence of fault, a hooter comes on and window lamp starts flashing
On pressing ACCEPT button, hooter stops, lamp becomes steady
On pressing RESET button, lamp goes off if fault is removed
Lamp continues to glow, if fault persists
The required alarm/trip contacts shall be wired to the marshalling box for connection to
the annunciation system.
INSTALLATION AND COMMISSIONING
Installation of transformer shall generally conform to the requirements of Code of
Practice for Selection, Installation and Maintenance of Transformers IS : 10028 as well
as Manual on Transformers published by he Central Board of Irrigation and Power. The
installation shall have to be approved by statutory government authorities like Central
Electrical Authority, Factory Inspector, Insurance officials etc. Any modification in the
equipment or installation that may be demanded by them shall have to be carried out by
the successful Tenderer at no extra cost to the Purchaser. The responsibility of obtaining
clearance from the Electrical Inspectorate of Orissa for commissioning of the complete
electrical equipment / system covered under this specification shall lie solely with the
contractor. The contractor shall carry out any modification if the same is required by the

UNIT # 1 TO 6 (6x60 MW)


statutory authority though their work is complete as per approval of the Purchaser /
consultant.

Technical requirement of transformer

1. Rated capacity : 12.5/20 MVA

2. Cooling : ONAN/ONAF

3. Nominal voltage (HV/LV) : 220 kV / 11 kV

4. Highest voltage (HV/LV) : 245kV/12 kV

5. Impedance : 12.5 %

6. Duty : Outdoor in open yard

7. Winding connection : Star/star

8. Vector group : YNyn

9. Specification to be complied with : IS 2026

10. Termination : HV : O/H ACSR conductor
LV : Cables

11. Tap changer : off Circuit Tap on HV

12. Range of tap changer : +2.5% to -7.5%in
2.5%Steps

13. Tap changer control : Local manual

14. Short circuit level : 40 kA at 220 kV for 3 sec

15. Neutral grounding (220 kV) : Effectively earthed

UNIT # 1 TO 6 (6x60 MW)


16. Insulation class : A

17. Bushing CTs : Required for HVN & LVN

18. Ratio of bushing CTs : HVN : To be provided by
tenderer
: LVN : To be provided by
tenderer
19. Protection class of bushing CTs : PS for REF
PS for differential
5P20 for back up E/F
20. Impulse test withstand voltage (220/11) : 1050 kVp / 75 kVp

21. Power frequency rated short duration : 460 kVrms / 35 kVrms
withstand voltage (220 kV/11 kV)

22. Withstand time without injury for 3 phase : 5 Sec
short circuit

23. Induced over voltage with stand voltage : 2xRated voltage

24. Temp. rise above 50
o
C
In oil by thermometer : 45
O
C
In winding by resistance : 50
o
C

25. Overload capacity : As per IS 6600

26. Type of radiator : Detachable

27. Auxiliary supply voltage : 220 V DC / 240V AC
28. Suitable for parallel operation : Yes

29. Painting : Approved shade - 632
of IS-5 (Epoxy based)
NEUTRAL GROUNDING RESISTOR
The neutral of 11 kV winding of station transformer shall be grounded through low

UNIT # 1 TO 6 (6x60 MW)


resistance.
NGR shall be used in 11 kV system to limit earth fault current within permissible limit of
the plant.

NGR shall be located in transformer yard fencing and connected to secondary side of
transformer.

Enclosure shall be of outdoor duty and with rain protection. Temp. shall be limited to
375
o
C at maximum ambient of 50
o
C. Temperature rise of enclosure shall be within safe
limit.

Material of the resistance grid shall be punched steel. NGR shall be designed for 30
second duty for current rating.

Single pole isolator shall be provided on incoming side. Porcelain insulators shall be
used to support the resistance grid. Isolator shall have locking provision. One end of the
resistance shall be connected to ground grid by means of separate grounding conductor
of sufficient size suitable for the above duty. The other end of the resistor shall be
connected through a current transformer for earth fault protection to the transformer 11
kV winding neutral by means of cable of required size suitable for the above duty.

NGR panel shall be supplied along with single core Aluminium HT cable and termination
kits to connect primary side and to connect earth electrode.
Technical Requirement of NGR

1. Rated system voltage : 11 kV

2. System earthing : Non effectively earthed

3. Resistance value : To be provided by tenderer

4. System short circuit level : 40 kA

5. Rating : To be provided by tenderer

6. Supporting /fixing structures : To be provided by the tenderer

UNIT # 1 TO 6 (6x60 MW)


7. Impulse withstand voltage : As per IS

8. Power freq. withstand voltage : As per IS

INTERCONNECTION OF SWITCHYARD TRANSFORMER BAY WITH STATION
TRANSFORMER

22O kV transformer bays of the extended portion of the switchyard shall be
interconnected shall be connected with Station Transformer

The above interconnection shall be consisting of the following major equipment/systems

Conductors
Gantries
198 kV lightning arrestors for station transformer (supply & erection)
Droppers
Insulators
Clamps and connectors
All the accessories

Complete civil and structural works for the above interconnection shall be under scope of
the tenderer. Tenderer shall include all the civil works associated with these
interconnections including foundations, sand, gravels, etc as per requirement. All the
foundations required for the gantries, supporting structures of lightning arrestors, NGR,
etc shall be under scope of the tenderer. Tenderer shall also include complete civil and
structures work for fastening of overhead conductor (single Zebra) ST bays.

Complete civil work of station transformer yard shall also be included.

Complete interconnection of 220 kV switchyard bays with HT terminals of station
transformer shall be done by the tenderer. Adequate quantity of GI structures for take off
gantry at switchyard end and gantries at transformer end shall be provided. All other
items like overhead conductors, jumpers, connectors, guard wire for road crossing shall
be provided in adequate quantities as per actual requirement.

The Tenderer shall supply and install lightning arrestors in all three phases near station
transformer just below the gantry. All supporting structures for the lightning arrestors

UNIT # 1 TO 6 (6x60 MW)


shall be provided by the tenderer.

The overhead interconnections shall be comprising aluminum conductor steel reinforced
(ACSR). The sizes of the conductors shall be adequate to carry the required continuous
current as well as to withstand the specified short-circuit currents. ACSR conductors
shall conform to IS:398.

The supporting structures shall be having adequate mechanical strength as required for
the specified short-circuit level. Necessary jumpers, connectors, insulators, structural
steelwork, hardware as required shall be supplied to make the installation complete in all
respects. Fittings and accessories shall be in accordance with IS : 2121.

Insulators shall be made of best quality porcelain and shall be brown glazed. All
insulators shall be suitable for heavily polluted atmosphere and shall be able to
withstand the duty requirements of the related equipment. Insulators shall be designed,
manufactured and tested as per IS:731 and IS:3188.

All fittings and accessories shall conform to IS:2486. The steel structures for gantries
and for supporting lightning arrestors, etc. shall be designed, fabricated and supplied as
a part of the work covered by this specification to make the installation complete in all
respects. The structures shall be of adequate mechanical strength designed to meet the
requirement of the equipment specified and shall be suitable for site and loading
conditions as called for in this specification. The structures shall be of lattice type
construction, fabricated from rolled mild steel sections and hot dip galvanised. Only
bolted connections will be permitted. Steel members, bolts, nuts, fittings shall be hot dip
galvanised except spring washers which shall be electro-galvanised.

04.05 UNIT AUXILIARY TRANSFORMER
Standards
Copper wound Transformers shall comply with the following Indian Standards.

IS: 11171(1985) / IEC 60726 - Dry Type Transformers
Mechanical Design

01 Transformer enclosure shall be welded/ bolted sheet steel construction, free
standing, with suitable size of louvers. Base shall be suitably reinforced to prevent

UNIT # 1 TO 6 (6x60 MW)


any distortion during lifting. Base channels shall be provided with flat wheels with
pulling eyes and lifting hooks to facilitate handling.

02 All fasteners and bolts etc. shall be galvanised or zinc passivated. All surfaces to
be painted shall be thoroughly cleaned, made free from rust and given a primary
coat of rust resisting paint followed by two finishing coats of approved shade.
Paint shall be suitable to withstand specific climatic conditions.
03 The transformer shall be provided with separate weatherproof HV/LV terminal
boxes and disconnecting links on the side of transformer so as to facilitate
withdrawal of transformer without disturbing the HT busduct and LT cables
connected to transformer.
04 Tank shall be suitably designed to withstand harmonics available in the system as
well as generated by the transformer.

Electrical Design
01 3 Phase, Core type cast resin
02 Insulation level shall be designed according to the voltages specified as
applicable and as below.
SN Description 11 kV System

1 Nominal system voltage (kV) 11

2 Max. system voltage (kV) 12

3 One minute power frequency withstand voltage (kV) 35

4 Peak impulse test withstand voltage (kV) 75

03 Transformers shall be capable of delivering rated current at an applied voltage up
to 105% of rated voltage without exceeding the temperature limits.

04 Overload capacity of the transformer shall be as per IS 6600 1972 unless
otherwise specified.

05 Shall be operable at its rated capacity at any voltage within + 10% of rated
voltage of the particular tap.

UNIT # 1 TO 6 (6x60 MW)


06 Permissible maximum temperature at rated output and principal tap at the ambient
temperature of 50C .
Windings (by resistance method) 120C
Core and other parts not adjacent of winding Within safe limits of core and
adjacent materials

07 Transformers shall be designed to withstand the thermal and dynamic stresses
due to short circuits at its terminals or symmetrical/asymmetrical fault on any
winding. Short circuit withstand capacity for the bolted fault at the terminals shall
not be less than 5 second duration with respect to fault level specified.

08 The maximum temperature at the end of the short circuit duration shall not be
more than 250C with the temperature prior to short circuit corresponding to
maximum permissible overload.

09 Transformer shall be designed for minimum no-load and load losses within the
economic limit.

010 Rated output, voltage ratio, vector group shall be as specified in technical
particulars for design.

MAGNETIC CIRCUIT

i) Low loss CRGO silicon steel shall be used.

ii) Laminations shall be annealed in a non-oxidizing atmosphere to relieve
stresses and restore the original magnetic properties of CRGO sheets after
the cutting and punching operations.

iii) CRGO sheets shall be coated with insulation varnish compatible with the
sealing liquid.
iv) Insulation to withstand annealing temperature as high as 850 Deg. C and
shall reduce eddy current to minimum.

v) Ducts to be provided to ensure adequate cooling.

UNIT # 1 TO 6 (6x60 MW)


vi) Core, framework and clamps arranged and tightened to securely hold
laminations in order to prevent any settling or displacement in case of
heavy shocks during transport, handling or short circuits.

vii) Flux density under specified over voltage or frequency conditions shall be
within the maximum permissible for the laminations. However it shall not
exceed 1.6 tesla.

viii) Transformers shall be designed to withstand 110% over fluxing
corresponding to rated voltage.

ix) Magnetising current shall be maximum 1% of the rated current.

WINDINGS

i) Material shall be electrolytic grade copper with 99.9% purity.

ii) Shall be subjected to shrinkage treatment.

iii) Completed core and winding to be vacuum dried in full vacuum,
impregnated immediately, then dried before casting in resin.

iv) Shall be braced to withstand shocks due to rough handling and forces due
to short circuit, switching or other transients.

v) Permanent current carrying joints in winding and leads shall be brazed.

vi) Coils shall be supported using dried and high-pressure compressed wedge
type insulation spacers.
vii) Insulating materials shall be compatible with transformer liquid under all
service conditions.
viii) Leads to the terminal board and bushings shall be rigidly supported.
ix) Neutral shall be solidly earthed in case of Distribution Transformer.
TERMINATIONS
connections without disturbing the Busduct/cable terminations. Cable termination box
shall be bolted type and supported from bottom so that after withdrawing the transformer,

UNIT # 1 TO 6 (6x60 MW)


it remains at its same position. Winding shall be brought out and terminated on external
/cable boxes as specified in the Technical Particulars.

i) In case of Cable termination
a) Air insulated cable end box suitable for the type and number of
cables specified.

b) LV side terminal arrangement : Three insulated terminals housed
within a flanged intermediate Air insulated disconnecting chamber
(with inspection opening ) for connecting cable. It shall be possible
to remove the transformer without disturbing the cable terminal
chamber.

c) Shall be provided with earthing bus for termination of XLPE cable
screen and shall be with necessary disconnecting link.
d) Compression type brass cable glands with finned copper lugs of
non soldering crimped type.

e) Bolted type gland plated ( non magnetic material wherever
specified).

f) Sealing kits with associated accessories like stress reliving ,
insulating type, bi-fercating boot, HT insulating tape etc.

ii) Bus duct termination

HV side termination arrangement : When bus bar termination is
required -

Provided with Porcelain bushing suitable for termination of HT open
bus bars with flanged termination .

iii) Neutral terminal arrangement
Full capacity LV terminal to be brought out side as a fully insulated
terminal for solid earthing and provided with a CT for standby earth fault
protection.

UNIT # 1 TO 6 (6x60 MW)


iv) Aux Terminal Box
Embedded thermistors/ RTD's for winding temperature monitoring with
alarm and trip contacts shall be provided in a separate aux. terminal box.
BUSHINGS
j) Conforming to IS 3347 part-1,2 & 3 1979, Part 3&4-1988 and IS:2099-
1986 for HT and IS 7421 for LT system.
ii) Minimum rated current of line end bushings shall be 1.5 times rated current
of the corresponding windings.

iii) Clamps and fittings made of steel or malleable iron shall be hot dip
galvanized.

iv) Bushings rated 400 amps and above shall have non- magnetic clamps and
fittings only.

v) Bushings shall be solid porcelain type. In case rating of porcelain type
bushings exceeds beyond IS rating & not available from approved
manufacture, Epoxy type to be used.

vi) Neutral bushings shall be provided as required for earthing of neutral
point. This shall be connected to brass/tinned copper bar and brought to
outside the body through porcelain insulator.
NEUTRAL CURRENT TRANSFORMERS
i) Removable at site without opening transformer enclosure cover/active part.

ii) Secondary leads shall be brought to a weatherproof terminal box and from
there to the Marshalling box with 4 sq.mm copper armoured cable.
WINDING TEMPERATURE INDICATOR
i) Local winding temperature indicator (WTI) shall have a 150-mm diameter
dial type indicator with a manual reset maximum reading pointer. There
shall be two potential free contacts for alarm and trip signals. The settings
for closing/opening of each contact shall be independently adjustable.
Contact rating at DC11, 110V DC shall be minimum 5 Amps. The device
shall be complete with lamp, temperature sensing element, image coil,
calibration device, aux. CTs etc. as required Temperature indicator dials
shall have linear gradations to clearly read atleast every 2C. Accuracy
shall be better than 1.5%.

UNIT # 1 TO 6 (6x60 MW)


ii) Remote Winding temperature indicator with Resistance type temperature
detector shall be provided additionally. Output in terms of 4-20 mA signal
corresponding to temperature measurement shall be interfaced with plant
automation system.
MARSHALLING BOX
i) All outgoing connections from the transformer viz temperature indicators,
level indicators, CT secondaries, fault contacts for annunciation, etc. shall
be wired to a Marshalling Box.

ii) Degree of protection of enclosure shall be IP55 .

iii) Removable gland plate with cable glands , illumination lamp and space
heater shall be provided.
RATING PLATE
Each transformer shall be provided with a rating plate giving the details as per IS:2026
(Part-I). The marking shall be indelible and the rating plate shall be located on the front
side. Exact value of transformer % impedance, as determined by tests shall be engraved
on it and also on the final submission of name plate drawing.
NOISE
Noise level shall be low and shall be within limit depending on the rating of the
transformer as per IEEE-141.
EARTHING
i) All metal parts of the transformer with the exception of individual core lamination
core bolts and clamping plates shall be maintained of fixed by earthing.
ii) Two nos. of tinned copper earthing terminals shall be provided.
iii) One end of bushing CTs shall be earthed.

LIST OF FITTINGS AND ACCESSORIES

i) Identification plate
ii) Rating and diagram plates.
iii) Off-circuit tap switch as specified.
iv) Dial type winding temperature indicators with max reading pointer and
alarm & Trip contacts.
v) Bushing CTs with terminal arrangement in Neutral.

UNIT # 1 TO 6 (6x60 MW)


vi) Bi-directional rollers/flanged wheels with loading arrangement.
vii) Lifting lugs and jacking pads
viii) Earthing terminals.
ix) Inspection cover with neoprene gaskets
x) Pockets for thermometer for winding temperature indicator (WTI).
xi) HV, LV and Neutral bushings
xii) Marshalling box.
xiii) Winding temperature indicator with remote indication
xiv) Provision of skidding , lifting and jacking
xv) Any other accessories required as per IS-2026.
TECHNICAL PARTICULARS

Sl. No. Particulars Specifications

1 Type Three phase, core type, cast
resin dry type
2 Duty Indoor
3 Degree of Protection of
Enclosure
IP42
4 Voltage
HV 11 kV
LV 0.433 kV
5 Frequency 50Hz
6 No. of Phases 3
7 Continuous Rating 750 kVA
8 Conductor Copper
9 Insulation Class Class F but temperature rise
limited to Class B
10 Cooling AN
11 Winding Connection Delta / Star
12 Vector Group DYn 11
13 Neutral Grounding Solidly earthed
14 System Earthing
HT Resistance Eatrthed
LT Effectively Earthed
15 Permissible temperature rise Refer Clause 3(Electrical

UNIT # 1 TO 6 (6x60 MW)


Design) above
16 Bushing mounted CTs CT in LV Neutral bushing for
standby earth fault
protection
Ratio : Primary calculated as
per fault current requirement
with secondary as 5 amp.
Class : 10P15
17 Off Circuit tap changer bolted link type
a Range 2.5% , 5%
b Total tap positions 5
c Taps above nominal
voltage
2
d Taps below nominal voltage 2
e Voltage per step
variation
2.5 %

f Tap change controls Manual (Shall not occupy
any intermediate position
between clearly marked tap
position)
g Rating Designed for sustained over
current of at least
150% of the rated current of
the winding and
withstanding short circuit
forces
18 . Impulse test withstand voltage As per IS 2026, Part III
1981

19 One minute dry and wet power frequency
withstand voltage
- do -

20 Short circuit level on HV side 40 kA for 3 Seconds
21 Time duration to withstand 3 phase short circuit
at secondary terminals, without any injury.
5 Sec
22 Auxiliary supply voltage 240 V
23 . Parallel operation Suitable for parallel
operation with transformers

UNIT # 1 TO 6 (6x60 MW)


of similar ratings
24 Overload capacity As per IS 6600 1972

04.06 11 kV SWITCH BOARD

The switchgear shall be of metal clad, single busbar, self standing, dust proof
construction, indoor cubicle type fitted with vacuum circuit breakers, in fully
drawout execution.

- The circuit breakers shall be suitable for the duties :

i) To withstand in rush magnetizing currents of transformers, and capacitor
bank 'ON' and 'OFF' operation.

- The controls, indicating lamps, shall be mounted on breaker cubicle itself
and relays & meters shall be mounted in the remote cubicle in the control
room..
- Operation counter, close/open mechanical indications spring
charged/dischared indication shall be provided.

- All circuit breakers shall have motor operated spring charged independent
closing and shunt tripping from 220V DC. Closing coil shall be suitable to
operate between 85-110% of voltage and tripping coil between 60-110% of
rated voltage. Spring charging motor shall operate between 80-110%.
- A manually operated device to enable charging of closing springs.
- All circuit breaker trucks shall have service, test and draw out positions.
Test position shall engage only the auxiliary (control) contacts to close the
CB during testing.
- Anti pumping features shall be provided.
- All live parts shall be insulated by tapping supported by suitably designed
insulators. Proper insulation of bus bars upper and lower contacts of
breakers, vacuum bottles (for VCB) and sealing of opening of bushings
shall be provided to eliminate accidental contacts. Switchboard busbars
shall be tapped by proper grade of insulating material by Reychem
sleeving.
- The cubicles shall be provided with a position changing gear arrangement
in such a way that by engaging detachable device from outside the front

UNIT # 1 TO 6 (6x60 MW)


door, it shall be possible to move the breaker truck and change positions
without opening the cubicle door. Facilities for pad-locking in each position
shall be provided.
In the design of the switchgear the following positive interlocking shall be
provided.
- It shall not be possible to move the truck from the Isolated to the Service
Position unless low voltage plug and socket connections have been made.
- It shall not be possible to disconnect the low voltage plug and socket as
long as the circuit breaker truck is in service position.
- It shall not be possible to withdraw the truck past the Isolated Position
without disconnecting the low voltage plug and socket.
- It shall not be possible to move the truck from the service to the Isolated
position or vice-versa with the circuit breaker in the ON position.
- It shall not be possible to switch on the circuit breaker when the truck is in
between the Isolated and the service positions (except in Test position).
- It shall be possible to switch on the earthing switch only when the truck is
in the isolated position, where an integral earth switch is provided.
- It shall not be possible to open the circuit breaker enclosure when the
breaker is ON on to have access to any part of the drawout assembly
which is live when the circuit breaker is in the Service position.
- Shutters shall be lockable in closed position.
- Where local/remote selector switches are called for, it shall be ensured
that:

The breaker can be closed locally only if the breaker truck is in the
test position and the local/remote selector switch is in local position.

The breaker can be operated from remote panel (in control room)
only when the breaker truck is in service position and the
local/remote selector switch is in remote position.

the breaker can be tripped locally regardless of the position of the
breaker truck.
- Each cubicle shall have mimic diagram with metal strip.

- Each cubicle shall be of compartmentalized construction and shall have
separate compartments for busbars, CTs and outgoing cables, metering

UNIT # 1 TO 6 (6x60 MW)


protection devices.
- All circuit breaker trucks of same rating shall be identical in all respects
(except metering and protective devices) and shall be interchangeable with
similar breaker panel.
- Continuous earth bus shall be provided throughout the board.
Operating Mechanism
- The operating mechanism parts shall be designed to give longer life
trouble free operation, and minimum maintenance.

- The material and components used shall have chopping current limited to
minimum.
Insulation Level
- Corresponding to the rated voltage as below :
- Nominal voltage (kV) : 11.0
- Highest system voltage (kV) : 12.0

- One minute power freq- : 28.0
uency withstand voltage
(kV)
- 1.2/50 micro second : 75.0
impulse withstand voltage
(kV)
Short Circuit Strength
- Rated short time withstand current not less than the system short circuit
level specified for the stipulated duration.
- Rated peak withstand current not less than 2.5 times the system short
circuit level.
- Auxiliary buses for control & protection
- Buses shall be formed by wire looping.
- Control supply buses for AC and DC
- Signalling supply
- PT secondary voltage
- Spare buses - 2 nos.
Provision of surge suppressor

- In case of breakers like VCB that give rise to overvoltage surges due to
current chopping phenomenon, surge suppressors to be provided at the

UNIT # 1 TO 6 (6x60 MW)


load side terminals of the breakers to limit the switching surges to value
limited for as per IEC.
Annunciation scheme
- Flag indications for all faults for which individual protective relays have
been specified.
- 'Alarm' signalling (as applicable) on individual panels :

a) All transformer warning/signalling condi-tions (group signal from
corresponding transformer control panel/substation)
b) Loss of trip circuit supply
c) Earthfault
d) Control supply failure
e) PT fuse failure/MCB tripping
- 'Emergency' signalling for tripping of HT breakers on fault

- One common signal for alarm and one signal for emergency from each
panel to be wired to a common annunciation panel of the switchboard,
where specified.

- Annunciators for alarm warning and emergency signalling conditions on
individual panels of solid state facia window type. Common audio
signalling with Accept, 'Reset' and 'Test' push buttons for the switchboard
where common annunciation panel not specified. Audio signalling to have
distinct tones for 'warning' and 'emergency'.
Busbar and connections

- Power buses of EC grade aluminium alloy equivalent to E91E WP as per
IS 5082 - 1981 or high conductivity electrolytic grade copper as per IS :
613 - 1984.
- Control and auxiliary buses of electrolytic grade copper
- The continuous rating of the main horizontal bus not less than the rating of
the incomer specified, where not specified, the rating to be selected for at
least 125% of the maximum demand of the switchboard taking into account
spare feeders.
- The vertical bus rating :

= For incomer : Not less than that of

UNIT # 1 TO 6 (6x60 MW)


horizontal bus

= For outgoing : not less than that of the
outgoing breaker, irres-
pective of releases
setting.
- Final operating temperature under continuous operation in enclosure
limited to 90 deg. C by thermometer method.
- Both horizontal and vertical bus bars to be designed and supported to
withstand the thermal anddynamicstresses corresponding to rated short
time and peak withstand current specified.
- Cross section of main horizontal bus to be uniform throughout the
switchboard and continuous in one transport unit.
- Bus bar arrangement as per IS-11353 - 1985, IS-5578 - 1985.
- Phase identification by colour in each panel.
- Busbar joints and tap off connections of bolted type with zinc bichromated
high tensile steel bolts, nuts and spring washers, fish plates with
accessories at the end of a transport unit for site connections.
- Busbar support insulators of non-hygroscopic material having high impact
and dielectric strength with an anti tracking contour.
Internal control wiring
- Control wiring by 1100V grade PVC insulated, single core copper wire of
minimum cross section 2.5 sq. mm
- Flexible wires protected against mechanical damage for wiring to door
mounted devices.
- Wires identified at each and in accordance with schematic diagrams by
interlocked type ferrules.

- Color code for control wiring : AC - black
DC - light Grey
- All connections external to a feeder, all the auxiliary contacts of the HV
breaker and at least 1 NO + 1 NC spare contacts of the relays, brought on
to terminal blocks.
- Interconnection between panels of adjacent shipping sections to be
brought out to a separate terminal block.
- Control wires shall be run in earthed metallic flexible conduits when laid in
HV bus chamber.

UNIT # 1 TO 6 (6x60 MW)


- Not more than two connections on any one terminal.
- All telemetering signals wired to terminal strips.

External Terminations
Control Terminations
= 650V grade multi-way terminal blocks of non-tracking moulded
plastic complete with insulated barriers, stud type terminals,
washers, nuts and lock nuts and identification strips.
= Control terminals of minimum rating 10 amps and suitable to
receive 2.5 sq. mm copper conductor.
= 20% spare terminals in each control terminal block.
Power Terminations
= Suitable for accepting cable/bus trunking as specified.
= Sufficient space and support arrangement inside each panel to accomodate
HT cable termination kits and sealing kits suitable for the type, size and
number of cables to be terminated.

= Dummy panels to be provided adjacent to the switch panel, where the required
number of cable terminations can not be accomodated in the cabling chamber
of the main panel
= Where more than one cable have to be terminated per unit, the
arrangement shall permit connection and disconnection of cables separately
without disturbing other cables.
= Where specified, the following cable termination accessories, suitable for the
type, size and number of cables to be terminated, to be supplied with the
switchboard.
= Cable sockets with all HT terminals. (socket set at such an angle that cable
tails can be brought up for termination with minimum bending and setting.)
= HT cable termination and sealing kits.
= Double compression type, brass cable glands and crimping type tinned heavy
duty copper lugs for HT, LT power and control cables.
Current Transformers
- Separate sets of current transformers shall be used for differential
protection, over current protection and measurement purposes.
- Short time rating and insulation levels of CTs shall be similar to the rating
of associated breakers.
- CT ratios specified are provisional. Where outputs and accuracies are not

UNIT # 1 TO 6 (6x60 MW)


specified, these shall be such as may be required by the circuits in which
they are used. Generally the protection CTs and metering CTs shall have
10P15 and 1.0 class respectively.
- CTs shall be window/bar primary type
- CTs shall have shorting link on secondary side to facilitate insertion of
meters on secondary side without opening CT circuits.
Voltage Transformers
- Voltage transformers shall be provided in incomer panel of the
switchboard.
- High voltage side of VTs shall have fuses and low voltage side shall be
provided with MCCBs.
- Low voltage star winding shall have all three phase and neutral
connections brought out to terminals and one phase shall be earthed.
- Insulation levels shall be similar to the rating of associated board.
- Accuracy class 1.0 shall be used.
- Shall be mounted on withdrawable truck.
- Preferred VA burden 100.
Relays
- All relays shall be flush mounted in dust proof cases and shall be mounted
on rear side of cubicle. The relays shall be micro processor based
numerical relays with communication system.
- All protective relays shall be draw out type.

- All timers and protection relays shall have flag indicators.

- Master trip relay shall be hand reset type and shall have 3 NO and 3 NC
contacts in addition to those required by the protection/control scheme.

Indicating instruments

- All indicating instruments shall conform to IS : 1248 - 1983 and IS - 2419 -
1973.

- Shall be capable of withstanding system fault current taking account CT
saturation.

- Shall be located in the upper part of the panel.

UNIT # 1 TO 6 (6x60 MW)


- Shall have 144 sq. mm square flush case, non-reflecting bezels, clearly
divided and indelibly marked scales, sharply out lined pointers and zero
adjusting device.

- The full load reading of each ammeter shall occur at the most prominent
part of the scale. The minimum scale reading shall not be more than 10%.
Maximum reading shall be 15% full load for transformers panels and 600%
full load for motor panels.

- Each voltmeter shall be calibrated with coil hot. The scale shall be open
between 60% to 125% of normal volts and shall be suppressed below 60%
of normal volts.

Annunciators

- Solid state facia window type with white heat resistant plastic material,
inscriptions, engraved in black.

- Lighting unit with dual lamps in parallel.

- Facia window and lighting unit in `plugin'type assembly.

- Control circuits of individual channels on glas epoxy coated plug in type
PCBs in bin assembly, plug/sockets mechanically coaded, to avoid wrong
insertion.

- Fault ACCEPT, system RESET and TEST push buttons common for the
system.

- Sequence of operation

- On incidence of fault - hooter ON, lamp FLASH

. On pressing ACCEPT PB - Hooter OFF, lamp STEADY

- On pressing RESET PB LAMP OFF if fault has been cleared. Otherwise

UNIT # 1 TO 6 (6x60 MW)


LAMP Persists
Control Supply
- Control supply buses shall run through the switchgear.

- Two DC feeders shall be taken in each board controlled by MCBs.

- In each panel for controlling of its DC supply MCCB shall be used.

- 240V AC supply shall be taken from a substation aux. board.

- Each section shall have separate feed with automatic changeover scheme.

- Each panel shall have one MCB for controlling its AC supply.

- Sub circuits shall be protected with HRC fuses.

Voltage Selection Circuit

- Voltage selection circuit shall be formed to ensure that only one PT feeds
the entire load of PT consumers. This shall be necessary to avoid
paralleling of PTs, when more than one voltage source in 'ON'.

Earthing Devices

- Either integral earthing switch or a separate earthing switch shall be
provided to facilitate earthing of busbars and any feeder circuit.

- Earthing truck (if included) shall have PT and alarm provision.

- Rating of earthing device shall be in line with associated board.

Terminal Blocks

- Stud type suitable to accommodate 2 cores of 2.5 sq. mm copper control
cables.

- Size of terminals for bus wires - AC/DC incoming supplies shall be as per

UNIT # 1 TO 6 (6x60 MW)


requirements.

- 20% spare terminals shall be provided in each panel.

- All terminals going out of the switchboard shall be brought to a separate
terminal board marked 'External Connections'.

Small wiring and ferrules

- All small wiring shall be carried out with 650 V grade single core cable
having copper conductor, preferably stranded, of not less than 1.5 sq. mm
cross section. However, wires going outside the switchboard shall have
minimum 2.5 sq. mm cross section.

- Wiring across the hinges shall be through flexible cables.

- The wires shall be identified by numbered ferrules at each and, all in
accordance with connection diagram.

- All ferrules shall be made of non-deteriorating materials.

- The ferrules shall be firmly located on each wire so that they cannot move freely on the
wire.

Transducers for telemetering

- DC analogue signal output of 4-20 mA for continuous parameters like
voltage, current, power etc.

- Pulse/BCD output for energy monitoring.

- Provision of adjustments to compensate errors in primary circuit.

Indicating Lamps

- 7 watts, screw type filament lamps with series connected resistors,
preferably built in the lamp assembly.

UNIT # 1 TO 6 (6x60 MW)


- Color : ON - RED

OFF - GREEN

CIRCUIT HEALTHY - WHITE

FAULT/WARNING - AMBER

Control and selector switches

- Control switches for circuit breaker ON/OFF control-3 position spring
return to neutral with lost motion device and pistol grip handle.

- Other control and selector switches - stay put type with wing type knobs.

- Ammeter selector switches - 4 position, make before break

- Voltmeter selector switches - 4 or 7 position as required.

- Rating : continuous - 10 amps

AC - 4 amps, 240V

DC 11 - 0.5A, 220V, L/R - 40 ms

Colour : Black

Push Buttons

- Rating : continuous - 10 amps

AC : 1.5 amps, at 240V

DC 11 : 0.5A, 220V, L/R - 40 ms

-Color : ACCEPT - BLUE

UNIT # 1 TO 6 (6x60 MW)


RESET - BLACK

TEST - YELLOW

Control Circuit Protection

- Preferably with MCBs, alternatively HRC link type conforming to IS 9224.

Protective Earthing

- Continuous earth bus of minimum size 50 x6 mm copper or equivalent
aluminum/galvanized steel section, designed to carry the peak short circuit
and short time fault current as specified.

- Provided at the bottom extending throughout the length of the board,
bolted/brazed to the frame work ofeach panel, with an earthing terminal at
each end, for terminal at each end for terminating external earth conductor.

- Vertical earth bus for earthing individual functional units.

- All non-current carrying metal work (including metallic cases of instruments
and other panel mounted components) effectively bonded to the earth
bus.

- Hinged doors earthed through flexible earthing braid.

- Looping of earth connection resulting in loss of earth connection to other
devices when the loop is broken, not permitted.

- Withdrawable units provided with selfaligning, spring loaded, silver plated
copper, scrapping earth contacts, of make before/break after type,ensuring
earth continuity from service to the test position.

Test and maintenance equipment

- Each board to be supplied with

UNIT # 1 TO 6 (6x60 MW)


1 set of test plugs

1 common transport trolley for interchanging with drawable units, height of
the trolley lifting arm adjustable for raising/lowering the units.

Any other special purpose tools for maintenance.

Construction features : Mechanical Design

Mechanical Design

- Sheet steel clad, floor mounted, free standing design.

- Minimum sheet steel thickness : doors & covers - 2 mm cold rolled, other
members - 2.5 mm

- Degree of protection IP53

- Assembled on base channel of structural steel of minimum height 50 mm,
painted black.

- Earthed metallic barriers between compartments and between vertical
sections.

- Seal-off bushings wherever bus bars pass through metallic partitions.

- Zinc bichromated and passivated hardwares.

- Transport unit not larger than 3.2 meters.

- Removable lifting arrangement for each transport unit

- Lockable front doors with concealed hinges with the door not forming part
of the drawout truck.

- Extensibility on both sides of the panel.

UNIT # 1 TO 6 (6x60 MW)


- Screwed wire mesh for bus bar and CT chambers to prevent accidental
contact with live parts.

- Removable sheet steel covers at rear

- Explosion vents for different chambers.

- Pressure relief flaps which can not be opened from outside to release
pressure that builds up in the event of arcing faults inside the cubicle.

- All similar units should be electrically and mechanically interchangeable.

Labels

- Switchboard designation name plate at the center of the board with letters
not less than 25 mm high.

- Panel designation number on each panel, both in front and rear

- Inscription plate for each feeder on the door.

- Door/front mounted devices to have labels directly below them.

- Labels made on non-rusting metal or 3 ply lamicoid with engraved
inscriptions of white letters (minimum 3 mm high) on black ground.

- Label designation and size of lettering subject to approval.

- Bus side and cable side shutters labeled for identification.

Surface Treatment

- All metal parts of the panel to undergo surface treatment that includes de-
rusting, cleaning, chemically degreasing, pickling in acid, cold rinsing,
phosphating and passivating followed by spraying with two coats of zinc

UNIT # 1 TO 6 (6x60 MW)


oxide primer and baking in oven.

- Shade of paint :

Panel interior : Off white shade

Exterior : 2 coats of light Grey enameled
paint of shade 631 of
IS-5 (unless otherwise
specified) and further
stoved.

Technical particulars and design parameters

1. Type & Service : Indoor, metal clad, Draw
out.

2. Enclosure : IP-4X

3. Nominal system voltage : 11 kV

4. Highest system voltage : 12.0 kV

5. No. of phases and : 3, 50 Hz
frequency

6. System earthing : Non effectively earthed
through
resistance.
7. Circuit breaker rating :

a) Continuous current :
rating at 45 deg. C

b) Short circuit rating : 40 kA
for 3 sec.

UNIT # 1 TO 6 (6x60 MW)


c) Dynamic system : 100 kA
stability

8. Bus-bar rating : 3000A, 40 kA (3 sec)

9. Power frequency with- : 28 kV rms for 1 min.
stand voltage

10. Impulse withstand voltage : 75 kV

11. Control voltage : 110V DC for s/s

12. Termination : XLPE cables

13. CT ratio : Secondary current 1A

14 PT ratio : 11000 110
- ------ / -------
Sq.rt 3 Sq.rt 3

15. No. of aux. contacts : 4 NO & 4 NC.
for purchaser's use.

16. Details and type of : As per details feeders
.indicated in schedule of
components
.

04.07 UNIT AUXILIARY BOARD /STATION AUXILIARY BOARD

Constructional Features :

- Metal clad, indoor type front mounted panels, free standing design,
with dust proof construction. The construction shall be
compartmentalised with metal / insulation partitions between
compartments.

UNIT # 1 TO 6 (6x60 MW)


- Sheet steel of not less than 2 mm thickness for cold rolled sheets cold
rolled and 2.5 mm for Hot rolled sheets.

- Circuit breaker shall be mounted on fully drawout truck with service,
test and isolated positions and complete with following safety
interlocks and safety shutters with padlock facility :

Truck cannot be moved in or out of cubicle when the breaker is
closed.

CB compartment door shall be mechanically interlocked so that it will
not be possible to close the CB in plug position when the door is
open.

Truck cannot be pushed in close position if either of the safety shutter
is not free and not in close position.

Name plate for each incoming, buscouplers and outgoing at front and
back both on the fixed portion of the panel.

- All panels shall have space heater with switch and cubicle
illumination lamp with door switch
- The back door shall be hinged type.
- Enclosure shall be confirm to IP54
- Operating height shall be 450-1800 mm
- All panels shall be suitable for pollution degree three environment.

Insulation Level :
- Rated insulation voltage 1100V

- One minute power frequency withstand voltage :

2.5 kV for power circuits
2 kV for control circuits
- Clearance in air (minimum) :

UNIT # 1 TO 6 (6x60 MW)


Phase to phase - 25.4 mm
Phase to earth - 19.0 mm

Short Circuit Strength :
- Rated short time withstand current not less than the specified short
circuit level for 1 second.
- Rated peak withstand current not less than 2.1 times the specified
short circuit level.
Busbars :
- Three phase, neutral (with atleast 50% rating of main buses) and
continuous earth bus. Bus bar and tapping shall be provided with
PVC sleeve.

- Rating of horizontal buses shall be in line with incomer rating and
vertical bus bar for the compartment shall commensurate with all
outgoing feeders.
- Temperature rise of bus bars shall not be more than 35o C above
ambient of 50o C.

- Bus bar and connection shall be of high conductivity Aluminium /
Aluminium alloy of suitable hardness and purity complying with as per
IS 5082.

- All bus connectors shall be Silver plated.

Cable Termination Requirement :
- Extension bus links properly spaced for terminating single cables of
size 120 sq. mm and above as well as for terminating multiple
cables of all sizes.

- Where more than one cable have to be terminated per unit, the

UNIT # 1 TO 6 (6x60 MW)


arrangement shall permit connection and disconnection of individual
cables separately without disturbing other cables.

- Double compression type brass cable glands and crimpping type,
tinned heavy duty copper lugs suitable for the type, size and
number of cables to be terminated, to the bottom to be supplied with
the switchboard for all LT power and control cables and cable
accessories.

AIR CIRCUIT BREAKERS :
Electrical Features :
- Air break triple pole drawout type conforming to IS 13947(1993).
- Rated continuous current as specified.
- Symmetrical breaking capacity and 1 second short time rating shall
be specified.
- Performance catagory : B (100%)
- Auxiliary contacts : 6 NO + 6 NC minimum convertible from NO to
NC and vice-versa at site.
Ratings : Continuous - 10 amps
AC - 4 amps at 240V
DC - 0.5 amps at 220V

Operating Mechanism :
- Motor operated mechanism as applicable
- Spring charged stored energy mechanism to ensure high speed
closing and tripping independent of the operating forces.
- Anti pumping and trip free feature.
- Emergency tripping by mechanically operated trip push button
(shrouded to prevent accidental closing) acting directly on the trip
bar.
- Closing operation of the breaker will charge the spring.
- Mechanical indication to show :

UNIT # 1 TO 6 (6x60 MW)


Closing spring charged
Breaker ON/OFF/TRIP indication.

- Breaker to close only when spring fully charged

- Non-reset type operation counter

Charging of closing spring by motor
Closing by closing coil (operating range 85% to 110% of rated
voltage)
Tripping by trip coil (operating range 70% to 110% of rated
voltage).
Spring charging motor and closing coil suitable for rated control
voltage.(220 V DC)
One opening and one closing operation without control supply.
Provision also for manual closing with spring charging motor
automatically decoupled as soon as charging handle is inserted.

Drawout Features :

- 3 distinct positions viz. service, test, and isolated with the door
closed.

- Mechanical position indication and locking/latching facility for all 3
positions.

- Power connections - self aligning, plug-in type contacts between
silver plated copper and silver plated copper.

- Control connections - sliding or plug socket type, mechanically
coupled to prevent wrong insertion, continuous rating 16 amps
minimum.

- Automatic safety shutters to prevent accidental contact with live parts
when the breaker is withdrawn.

- The break contact shall be on the breaker side.

UNIT # 1 TO 6 (6x60 MW)


Safety Interlocks :

- Breaker can not be closed in any intermediate position other than the
3 fixed positions.

- With the breaker closed, it cannot be racked in from any of the 3
position to another.

- Mechanical stopper to prevent accidental falling while withdrawing.

- Breaker cannot be racked in from isolated to `test' postion with the
door open together with provision for defeat of this interlocking,
however, the door can be closed only when the breaker is brought
back to 'isolated' position.

- Door can be opened only when

breaker is OFF and
is in `Isolated' position.

- Remote closing of breaker not permitted with door open.

- Insertion of breaker into 'Service' position not possible if the shutters
are not free.

Internal Control Wiring

- Control wiring by 1100V grade PVC insulated, single core stranded
copper conductor of minimum cross section 2.5 sq. mm.
- Flexible wires, protected against mechanical damage for wiring to
door-mounted devices.
- Wires identified at each end in accordance with schematic diagrams
by interlocked type ferrules.
- Colour code for control wiring : AC black
DC - light grey
- All connections external to a feeder, all the auxiliary contacts of the

UNIT # 1 TO 6 (6x60 MW)


LT breaker and at least 1 NO + 1 NC spare contacts of the relays
brought to terminal blocks.
- Interconnection between panels of adjacent shipping sections to be
brought out to a separate terminal block, wires for interconnection
properly labelled, looped and bunched inside the panel for
connection at site.
- Not more than two connections on any one terminal.
- All spare contacts wired upto terminal block of the panels

a) Protective relays - withdrawable type
b) Auxiliary, timer relays - fixed type

External Terminations
Control Terminations

- 500V grade multiway terminal blocks of non-tracking moulded plastic
complete with insulated barriers, stud type terminals, washers, nuts
and lock nuts and identification strips.

- Power and control terminals segregated.

- Open type control terminals of minimum rating 10 A suitable to
receive 2.5 sq. mm copper conductor.

- 20% spare terminals in each control terminal block.

Power Terminations:

- Suitable for accepting cables/bus trunking as specified.

Protective Devices

The circuit breaker shall be provided with the following protective devices
with suitable setting ranges. Alternatively self powered relays can be offered.
Preferably these shall be static type.

A. Incoming Circuit Breaker

UNIT # 1 TO 6 (6x60 MW)


Built-in direct acting type series over current release
instantaneously operating and tripping the circuit breaker
against short circuit with adjustable minimum definite time
delay 0.1 - 0.6 seconds through electornic - timer
independent of line current and voltage.

Built-in-direct-acting type series overcurrent release having
long time delayed inverse-time current characteristics for
protection against overloads.

Earth fault protection through an over current relay
connected across a CT mounted on the neutral busbar. The
earth fault relay shall operate to trip the breaker through the
shunt trip coil rated for 220V DC. The earth fault relay shall
have a mechanical operation indicator.

Under-voltage tripping shall be provided through
under-voltage relays/timer relays for the following operating
conditions.

a) The circuit breaker shall trip for voltage less than 50% of rated
system voltage (with an adjustable time delay in the range of 1-10
seconds).

b) The system under voltage shall not prevent manual closing of
circuit breaker above 80% of rated system voltage.

c) The relay shall not prevent remote closing of circuit breaker when
the control circuit voltage is 85% - 100% of nominal control circuit
voltage.

d) The under voltage relays shall not trip the breaker in case the
substation is operating on single transformer or with the control
selector switch set in MANUAL position.

UNIT # 1 TO 6 (6x60 MW)


Current Transformer

The thermal and dynamic stability current for CTs will be same as for the air
circuit breakers. CT ratio shall be as per requirement. Protection and
measuring current transformer shall be bar primary/ window type with 5A
secondary conforming to IS-2705 Part-II-1992 and Part-III-1992respectively.

Measuring CTs shall conform to accuracy class-I of IS 2705 part-II-1992 and
burden of CTs shall be as required by the associated measuring equipment.
The CT ratio shall be as required by the associated measuring instrument.
The CTs shall have saturation factor of not less than 1.5 and higher limit
shall be compatible with the overload capacity of the instrument connected
on the secondary side.

Protection CTs shall have their accuracy and burden as required by the
protection circuits in which they are used and shall have saturation factor of
not less than 10.

CT shall be of cast resin type.

Potential Transformers (PTs)

PTs provided on each incomer/ feeder shall be of draw out type. The PTs
shal be dry epoxy resin moulded type.

High voltage windings of voltage transformer shall be protected by current
limiting HRC fuses. The voltage transformer and fuses shall be completely
disconnected and visibly grounded in fully drawout position.

Low voltage fuses, sized to prevent overload, shall be installed in all
ungrounded secondary leads. Fuses shall be suitably located to permit easy
replacement while the switchgear is energised.

The technical particulars and accuracy class of the PT shall be as per
requirement.

UNIT # 1 TO 6 (6x60 MW)


Relays:

- All the Aux. relays to suit the requirement of scheme operation and
interlock of equipment

- Flush mounted type.

- Shall withstand impulse voltage in accordance with IS/IEC
recommendation.

- Diagram plate at the back of case to identify connections.

- All spare contacts shall be wired upto terminal block.

Control Supply

Two DC feeders shall be provided in each board for power supply of control,
shunt tripping and annunciation purpose.

Control supply shall have supervision facility, alarm shall be provided for non
availability of any one of the control supply.

MCBs shall be provided on incoming sides of suplies

Control buses of two sections shall be connected through auto changeover
scheme.

L.E.D 's shall be provided for the indication purpose.

Isolation arrangement shall be provided on each panel to facilitate fault
location and testing. Separate fuses shall be provided for spring charging
motors, for indication lamps and for closing/tripping circuits of each cubicle.

Metering Instrument & other components/Equipment specification

Indicating Instruments( Ammeter, Voltmeter, Kilowatt hour meter :

UNIT # 1 TO 6 (6x60 MW)


- Square size : Incomer and sectionalizer - 144 sq. mm
Outgoing - 96 mm square
- Flush mounting : in front of the cubicle
- Accuracy class : 1.0
- Ammeters shall be compatible with CTs of 5A secondary and read
actual currents.
- For motor feeders ammeters shall have cramped scale after 1.2
times full load current and shall have red mark on full load value.

Contactors:

Contactors shall break without damage 10 times rated current upto 100 amp
rating and 8 times rated current for above 100 amp rating. Continuous
current shall not exceed 2 amp and initial pick up shall be limited to 9 amp.
Class of insulation shall be E or better. Drop out voltage shall be 45-65% of
rated voltage and pick up shall be 85-110% contactor duty shall be AC3
unless otherwise specified in design paramters.

Indicating Lamps:

- L.E.D indication shall be provided as detailed below:

- Colour : ON - RED

- OFF - GREEN

FAULT/WARNING - AMBER

TRIP HEALTHY - WHITE

Control and Selector Switches:

- Control switches for circuit breaker ON/OFF control 3 position, spring
return to neutral with lost motion devise and pistol grip handle.

UNIT # 1 TO 6 (6x60 MW)


- Other control and selector switches - stay put type with wing type
knobs.

- Auto/Manual selector switch shall be lockable

Push Buttons:

- Rating : Continuous - 10 amps

AC 11 - 1.5 amps at 240V
DC 11 - 0.5 amps at 220 V DC
L/R - 40 mS

- Colour : Red - ON

Green - OFF
Yellow - Test
Red - Emergency P.B

Protective Earthing

- Continuous earth bus of minimum size 50 x 6 mm copper or
equivalent aluminium/galvanised steel section, designed to carry
the peak short circuit and short time fault current as specified.

- Provision at the bottom extending throughout the length of the board,
bolted/brazed to the frame work of each panel with an earthing
terminal at each end for terminating external earth conductor
including provision for termination of cable armouring at earth bus.
- Vertical earth bus for earthing individual functional units.

- All non-current carrying metal work (including metallic cases of
instruments and other panel mounted components) effectively bonded
to the earth bus.

- Hinged doors earthed through flexible earthing braid.

UNIT # 1 TO 6 (6x60 MW)


- Looping of earth connection resulting in loss of earth connection to
other devices when the loop is broken, not permitted.

- Withdrawable units provided with self-aligning, spring loaded, silver
plated copper scrapping earth contacts of make before/break after
type ensuring earth continuity from service to the test position.

Auto-Changeover Scheme
Auto Changeover Scheme for Unit Aux. Supply
In case of failure of unit transformer incoming supply, to be sensed by under
voltage relay the incoming breaker of the de-energised section shall be
tripped after a pre-set time delay. Through the normally closed auxiliary
contacts of the tripped incoming breakers, the station supply breaker shall
close provided the other section is healthy.

The automatic transfer scheme shall be such that the automatic closing of
the bus section can be done only once and in case the reserve breaker trips
during auto-changeover, no further auto closing shall be permitted. Auto
changeover shall not take place if the incomer breaker trips on fault. The
restoration of power shall be manual.

The automatic transfer circuit shall be controlled over by an auto-manual
change-over switch located in MCR. The bus section breaker shall be
allowed to close only if there is no earth fault or O/C fault on affected section
of the 415V switchboard busbars.

Breaker Handling Truck

- One for each switch board, for withdrawing the breakers from the
switch board.

- Height of platform adjustable to suit the levels at which the breakers
are mounted.

- Adequate mechanical strength for handling the largest breaker.

UNIT # 1 TO 6 (6x60 MW)


- Guide rails and stops.

their work is complete as per approval of the owner / consultant.

04.08 ELECTRIC MOTORS

04.08.01 Low voltage squirrel cage induction motors :

Constructional features:

- Frame sizes and ratings and other facilities as per IEC

- For motor frames upto 315, cast iron or steel construction body; for
frames above 315,steel construction shall be used.
- Casing feet to be integral with the motor body.

- Degree of protection for motor, bearings and terminal box to be
IP-55.

- Cylindrical shaft ends, unless otherwise specified

- Shaft extension as per requirement.

- For motor of rating upto 5 kW, Ball bearings shall be used for both
DE & NDE end. For ratings above 5 kW the DE end shall be
provided with roller bearing and NDE end shall be provided with ball
bearing.

- Bearings shall be suitable for running of motor in either direction.
Terminal box:

- Terminal box suitable dimension to receive copper cables and
provided normally on the right side as viewed from drive side or on
the top as per the requirement.

- Terminal box frame with opening for cable rotatable by 4x90 deg.

UNIT # 1 TO 6 (6x60 MW)


- A suitable earthing stud shall be mounted inside the terminal box.

- Terminal Box shall be suitable to receive the aluminium cables as
given in Table-I.

- Extension of Terminal box as required shall be done to receive the
Aluminium cables to avoid cramping of the cables in the terminal
box.

Cooling:

- Motors shall be of TEFC design

- Ventilation shall be effective irrespective of direction of rotation.

Quality of operation:

- Motors shall be dynamically balanced with full key on the shaft- end
and fan.
- Vibration intensity shall be limited as per IS 4729.
- Continuous noise level should not exceed 85 db A at a distance of
1.0 m from motor body

Electrical design

- Suitable for DOL starting

- Motors suitable for being switched on to a solid main even at phase
opposition at a maximum residual voltage of 50% i.e. the motor shall
be capable of withstanding 150% of the rated voltage.

- Motors capable to start and run-up at a minimum of 85% of rated
voltage at its terminals with the driven mechanism/equipment
connected.

- Capable of operating satisfactorily at full load for 5 minutes without

UNIT # 1 TO 6 (6x60 MW)


injurious heating with 75% of the rated voltage at its terminals.

- Starting torque shall be not less than 160% of rated torque.

- Starting current shall be less than or equal to six times the rated
current.

- Motor shall be capable of withstanding locked rotor current for at least
5 seconds longer than the starting time at 80% voltage under rated
load conditions.

- Continuous duty motors shall be capable of three equally spread starts
per hour under normal condition or two starts in quick succession
from cold or one hot start, under rated load condition.
- All continuous duty motor (S1-100%) shall be of high efficiency to
Eff 1 class as per IS 12615- 2004.

- Motors provided with class 'B' or class ' F' insulation. Permissible
temperature shall be limited to 120 deg. C in case of
class'B'insulation and in case of class F insulation, permissible
temperature shall be 130 deg.C as measured by resistance method.
Class H insulation shall be considered in specific cases. Limiting
temperature shall also be limited to 130 deg C in case of Class H
insulation as measured by resistance method.

- Motors selected shall be of normal starting torque type, high starting
torque type, high slip type or stall torque type as required for the
specific application.

- Four pole motors to be used for all general applications, unless
specific drive requirement or economy calls for other poles.

Valve Actuators
- The actuator shall be designed for operation on 415V, 3 phase, 50 Hz
system.
- The actuators shall be suitable for voltage frequency variations as
indicated in Chapter Electrical design criteria.

UNIT # 1 TO 6 (6x60 MW)


- The actuators shall consists of motor, torque/ position limit switches,
clutch, hand wheel, position indicator, space heater.
- The actuators enclosure shall be totally enclosed dust tight, water
proof without the necessity of any canopy.
- Insulation of the drive shall be class `B'.
- Two torque limit switch one for each direction and four for end of
travel limit switch (two for each direction) shall be provided.
- Hand wheel shall declutch automatically when motor is energised.
- Position transmitter, potentiometer type shall be provided for remote
indications wherever required.

- Internal wiring shall be of 1.5 sq.mm copper wire, however, terminals
for external connections shall be suitable for 2.5 sq.mm
- Motor data sheet for each type of motor actuator shall be furnished
alongwith internal wiring diagram, suggested control schematic and
torque limit switches contact development.

04.09 UNINTERRUPTIBLE POWER SUPPLY(U.P.S.)

- A UPS of adequate capacity shall be provided for Control and
instrument system of Units 1 to 6 . The UPS shall be a static type
and shall have dual redundancy of electronic parts/system. UPS shall
be ON LINE back up facilities

- Two nos. 110% capacity converters shall be provided which shall
consist of dry type transformer and rectifier panels.

- Output of converters shall be connected to DC bus and through
rectifier DC battery supply shall also be connected to the above bus.
Battery capacity shall be for 2 hour back up

- Two nos. 110% rated inverters shall be connected to DC bus and
output of inverters (IGBT based) shall be connected to AC bus of
UPS.

- Tenderer to calculate the requirement/capacity of the system and

UNIT # 1 TO 6 (6x60 MW)


furnish alongwith the bid.

- UPS batteries shall be sealed maintenance free type (Lead Acid) and
shall be suitable for site condition.

- All equipment shall be naturally air cooled.

- All active device shall be solid state.

- The nominal AC input supply shall be 415 V 50 Hz, 3 Phase.

- A bypass static switch with transformer etc. shall be included to
provide continuity of supply in the event of UPS failure and transfer
time shall be less than 1/4 cycle.

- For abnormal operating conditions alarm shall be provided in CR
panel and as well as on UPS Panels.

System shall be suitable for 125% rated output for 15 minutes

04.10 BATTERY ,CHARGER AND DC DISTRIBUTION BOARD

04.10.01 Codes & standard

03.07.07.01 IS : 266 Specification for sulphuric acid
IS : 1069 Specification for water for storage batteries
IS : 1146 Specification for rubber and plastic containers for lead acid
storage batteries
IS : 1652 Specification for stationary cells and batteries, lead acid type
(with plant positive plates).
IS : 3116 Specification for sealing compound for lead acid batteries.
IS : 8320 General requirements and methods of tests for lead acid
storage batteries
IS : 6071 Specification for synthetic separators for lead acid batteries

ANSI-C 37.90a Guide for surge withstand capability tests
IS:5 Colours for ready mix paints.

UNIT # 1 TO 6 (6x60 MW)


IS : 694 PVC Insulated Cable for working voltages upto and including
100V
IS : 1248 Specification for Direct acting indicating analogue electrical
measuring instruments.
IS:13947 Pt-1 Degree of protection provided by enclosures for low voltage
switch gear and control gear.
IS : 13947 Specification for low voltage switch gear and control gear
IS : 3231 Electrical relays for power system protection.
IS : 3842 Application guide for Electrical relays for AC System
IS : 3895 Mono-crystalline semi-conductor Rectifier Cells and Stacks
IS : 4540 Mono crystalline semi-conductor Rectifier assemblies and
equipment.
IS:6005 Code of practice for phosphating of Iron and Steel
IS:6619 Safety Code for Semi-conductor Rectifier Equipment.
IS:6875 Control switches (switching devices for control and auxiliary
circuits including contactor relays) for voltages upto 1000
VAC or 1200VDC
IS : 9000 Basic environmental testing procedures for electronic and
electrical items.
IS:13703 Low voltage fuses for voltages not exceeding 1000 V AC,
1500VDC.
EEUA-45D Performance requirements for electrical Alarm Annunciation
system

04.10..02 Scope and mode of operation

The battery system will include:

DC 220V battery set (2 sets)

Identical automatic Float and float-cum-boost chargers 2 sets for
220V battery

DC distribution switchgear ( 1 set with two sections) for each 220 V
battery

All interconnecting cables/wiring with connection accessories and

UNIT # 1 TO 6 (6x60 MW)


other required items to make the system complete.

Complete battery maintenance equipment required for convenient
and safe handling and preparation of electrolyte will be supplied
with the battery bank. These will include but not be limited to items
like syringe type hydrometer, mercury in glass thermometer
calibrated 0 to 100
o
C, wall mounted holder for one hydrometer and
one thermometer, syringe, level testing tube, 150 mm dia glass
funnel, spanners, centre zero cell testing voltmeters 3-0-3 V, PVC
apron, PVC gloves, PVC jug, battery impedance tester, etc

Mode of operation:

i. Normally the chargers connected to the battery will supply the DC
load and also keep the battery under float charge. On failure of
supply from charger, the battery will be taken over without any
interruption.

ii. When the battery requires boost charging, the charger will operate
on boost charge mode while the second battery will supply the DC
load on float mode through changeover arrangement.

iii. The DC distribution switchgear will feed the power from the
charger/battery to the various consumers of the plant.

04.10.03 Battery and accessories

Nominal voltage is 220 V DC. The no. of cells will be chosen
accordingly. Battery cell will be Plante type lead acid. Ampere hour
capacity (minimum) will be as per requirements of the plant at 10
hours discharge rate. Each Battery bank shall be capable to cater
the 220 V DC loads of Units 1 to 6 and emergency lighting loads of
power house.

Following accessories will be supplied

UNIT # 1 TO 6 (6x60 MW)


Battery stand
Cell booster for charging 1 to 5 cells
Copper cell connectors (5 nos.)
Spanner for cells
Bridging clamps for cutting out individual cells in the event of defect
First aid box

04.10.04 Battery Chargers

i. Float and Float cum boost chargers for battery will be comprised of
the following;

a) Microprocessor based IGBT/thyristor based battery charger
b) MCCB, line contactor and overload relay on the AC side
c) Dry type double wound rectifier transformer with copper conductor
and class `B' insulation
d) Filter circuit at the output
e) MCCB on DC side
f) Control and protection circuits

ii. In float mode, the charger operates with a constant voltage
controller and the output voltage of the charger will be maintained
within + 1% of the set voltage for + 10% input AC voltage variation,
or 0 - 100% load variation, or both occurring simultaneously. The
output voltage required can be set externally through
potentiometers in the range 90-120% steplessly.

iii. In boost mode, the charger will be suitable to operate in a constant
current as well as constant voltage mode with manual selector
arrangement, controller suitable for two-rate charging. The charging
current will be externally adjustable from 20% to 100% steplessly.

iv. Provision of charging with manual control of output voltage will also
be provided. Electronic current limit, adjustable between 85-105
percent of rated current will be provided. During boost charging, the
charger will be cut-off as soon as over voltage occurs. Ripple

UNIT # 1 TO 6 (6x60 MW)


content in the charger's output voltage will not exceed 0.5% in float
mode and 3% in boost mode.

vii. The supply to the charger will be at 415V + 10%, 50 Hz +3% and
-5% unless otherwise specified.

viii. The following relays will be provided:

a) AC input supply to charger failure
b) Earth fault
c) Float bus over and under voltage
d) Boost bus over voltage
e) Boost over current for each charger circuit
f) All relays will be in draw out cases and with mechanical hand reset
operation indicator.

ix. The following indications will be provided.

a) AC supply ON (for 3 phases separately) for each charger
b) DC supply ON for charger
c) Boost/float mode ON for charger
d) Supply ON for each outgoing distribution feeder

x. Instruments for the following measurement will be provided;

a) AC input voltage and current of each charger (through
voltmeter/ammeter selector switches)
b) DC output voltage and current of each charger
c) Battery charging/drain current of each charger with necessary shunt
d) Battery trickle charging current (through amplifier)
e) DC bus voltage (through selector switch) to measure between
Positive to Earth, Negative to Earth & positive to negative.

xi. Static type annunciation will be provided for the following;

a) AC supply failure to charger

UNIT # 1 TO 6 (6x60 MW)


b) Battery earth fault (+ve & -ve separately)
c) Float bus over/under voltage
d) Boost bus over voltage
e) Boost over current for each charger
f) Failure of thyristor/diodes for each charger
g) Failure of blocking diode
h) Output MCCB open for each charger
i) Battery MCCB open
j) Battery room exhaust fan OFF
k) D.C.Voltage Low
l) D.C.Voltage High
m) A.C.Input Under Voltage

xii. One repeat alarm point for all above annunciations will be provided
to facilitate annunciation of "Fault in Charger" in control room.
.
04.10.05 DC Distribution board

i. The DC distribution board will have single bus bar arrangement.
The DCDB will be provided with all the instruments, AC/DC meters,
indicating lamps, relays and other accessories.

ii. Each outgoing circuit will be connected to bus bars. Each outgoing
circuit will have MCCB. The no. of outgoing circuits will be as per
the requirement plus 10 nos. for purchasers use and 20 % spare.

iii. Switch board will be floor mounting type sheet steel enclosed with
degree of protection IP 52 or better. Board will be
compartmentalized design.

iv. All power wiring will be done through single core PVC insulated
copper wires/buses. All control wiring will be done through single
core; PVC insulated copper wire of 2.5 sq. mm. All connections
external to the panel/switch board will be terminated in suitable
terminal blocks. Inter panel wiring will be only between terminal
blocks.

UNIT # 1 TO 6 (6x60 MW)


04.11 CABLES

04.11.01 Cable Specification

Types of cables of following grades and general specifications shall be used
taking into consideration the application requirements. All cables shall have
FRLS (Fire Retardant Low Smoke) PVC compound for inner and outer
sheath.

Type 1 : 11 kV (UE) XLPE Cables

11 kV (UE) heavy duty power cable, 3-core, with compact circular
stranded (rm/V) copper. conductor with extruded conductor shielding of
semiconducting material, XLPE insulated, with insulation shielding over
individual cores consisting of extruded semiconducting compound followed
by lapped semi conducting material and copper tape, cores
stranded together with a holding tape provided with a common covering of
extruded inner sheath, galvanised steel wire armoured and FRLS PVC
outer sheath of type ST2 compound as per IS : 7098 (Pt-II)-1973 as
ammended upto date. Copper screen shall be suitable to carry 1 kA E/F
current for one second.

Type 2 :
1.1 kV, heavy duty power cable multicore with standard sector shaped (sm)
or with compact circular stranded (rm/V) or circular stranded (rm) Aluminium
conductors as applicable, PVC insulated type A suitable for 70 deg. C.
operation, core stranded together provided with a common covering of FRLS
PVC inner sheath of type ST1 PVC compound, galvanised round steel
armoured and FRLS PVC outer sheathed of type ST1 PVC compound
conforming to IS:1554 (Part-I) - 1976, as ammended upto date.
Type 3 :
1.1kV circular stranded (rm) annealed copper conductor, PVC insulated of
type A PVC compound suitable for 70 deg.C operation,as per IS:5831 -
1970, cores stranded together provided with a common covering of PVC
inner sheath, galvanised steel armoured and overall FRLS PVC sheathed
of type ST1 PVC compound and multi-core to IS : 1554 (Part-I) - 1976,

UNIT # 1 TO 6 (6x60 MW)


04.11.02 Cable Selection

- In general, cables for LT drives shall be selected as per Annexure-I,
however, size and type of cables for specific applications shall be
selected giving due consideration for the following:

- Thermal heating effect/permissible current carrying capacity.

- Voltage drop

- Short time current/overload requirement

- Protection system grading and short circuit current carrying capacity.

- Ambient conditions

- Cable grouping factors

In selection of the cable following ambient conditions shall be taken into
account.

Cables laid directly in ground in single way ducts or pipes buried
underground.

- Thermal resistivity of soil : 150 deg.C cm/W

- Soil temperature : 40 deg.C

- Depth of laying (to the : 75 cm for 1.1kV
highest point of cable or grade cables and
top surfaces of ducts) 90 cm for HT cables

- Horizontal formation axial : 15 cm in case of spacing cables
laid
directly in ground in a group and
approximately touching in case

UNIT # 1 TO 6 (6x60 MW)


of single way ducts or pipes.
Cables laid in free air/in conduits in free air.

Ambient air temperature : 40 Deg.C & As specified
for the respective shops.

Cables laid in ventilated ducts/gallery

Ambient air temperature : 40 Deg.C.

The minimum cross sectional area for HT power cables shall be 185 sq.mm.

The minimum cross-sectional area of the cables used in LT power circuits
shall be 6 sqmm per core if with aluminium conductor or 4 sqmm per core if
with copper conductor. Maximum cable size shall be 185 sq mm for motors
and 240 sqmm for incomers to MCCs, PCCs etc.

For power supply to moving mechanisms subject to vibrations, flexible
copper cables preferably single core should be used. In these cases, a
separate core should be provided for earthing. Cables used for circuits of
tachogenerators, brakes, solenoids, field windings and secondary windings
of measuring transformers shall be copper conductor with cross-sectional
area not less than 2.5 sqmm per core. All control cables shall have copper
stranded conductors except for mobile and portable equipment where control
cables shall be of flexible type. Copper cables shall be used for all
cranes/hoists.

For control circuits, PVC insulated and FRLS PVC sheathed multicore
cables with copper conductors having a minimum cross-sectional area of
2.5 sqmm per core shall be used. The number of cores may be
standardized as 2,3,4,5,7,10,14,19,24.Each core of control cable with 7 core
and above shall be numbered at every 1 meter intervals.

In multi-core control cables, the following minimum reserve cores shall be
kept at the engineering stage:

Upto 7 cores - One reserve core

UNIT # 1 TO 6 (6x60 MW)


10 cores - Two reserve cores
14,19 & 24 cores - Three reserve cores

Sequential length marking shall be provided in outer sheath of all power and
control cables.

Standard drum length for all types of power and control cables shall be
offered.

ISI marking at every meter of cable length shall be provided.

Cores of multi-core control cables shall be serially numbered.

For all cables, extra length of 2 metres will be left before jointing.

Additional Tests on cable

To prove the fire retardent low smoke characteristics, the following
additional tests shall be conducted at works on any size of each type of
cable namely, H.T/ power, L.T. power, control and instrumentation cables.

Oxygen index test as per ASTM D 2863. Minimum value of Oxygen index
shall be 30.

Flammability tests on finished cable as per the requirements of IEEE-383
and IEC-332-1.

Smoke generation by inner/outer sheath fire as per ASTM D 2843. The
cables shall meet the requirements of light transmission of minium 40% after
the test.

04.11.03 Cable termination & joints

Following type of cable termination and joints shall be used for XLPE cables
in indoor and outdoor applications :

UNIT # 1 TO 6 (6x60 MW)


1. Tapex type
2. Heat shrinkable type
3. Pre moulded push on type

Tapex type system :

The stress grading material shall be wrapped around the cable core, over
lapping the edge of the outer conducting layer. The tape layer shall fuse
together to form a compact rubber body around the stress grading material
and cable core and thereby excert an active pressure on cable.

Heat Shrinkable type system :

The stress control and grading wherever necessary shall be by means of
semi conducting heat shrinkable tubing. Environmental sealing between heat
shrinakable material and cable surfaces shall be achieved by using hot
melted sealants or adhesives. Where such sealents or adhesives shall be
exposed to high electrical stress, same shall be track resistant type.

Premoulded Push On type system :

Premoulded refers to moulded Ethylene Propylene Diene monomer rubber
components. Sealing between the premoulded push on material and cable
surface shall be achieved by semi conducting pad which has cold flow
properties.

The termination and straight joints for HT/LT cables shall be supplied in kit
form. The kit shall include all insulating and sealing material apart from
conductors fittings and consumable items. Necessary devices required for
termination and joints shall be provided.

04.12 MISCELLANEOUS

04.12.01 Illumination

1.0 Genearal

UNIT # 1 TO 6 (6x60 MW)


The lighting system inside and outside power house units are designed
based on the desired minimum illumination levels recommended by IS and
the practices followed in industries, architectural arrangement, building
dimensions including mounting height, environmental considerations, ease
of maintenance and reliability of the lighting distribution network.

2.0 Illumination will be provided in all premises of power house peripheral
lighting, area lighting, street lighting, etc within battery limit.

The illumination system will include the following in required quantities;

Lighting DBs
Light fittings with lamps
Lighting fixtures and
accessories
Cables and wiring
Ceiling fans
Receptacles
Switches
Conduits
Brackets
Hangers
Clamps
JBs

3.0 The illumination system shall be designed as per IS:3646-1992. The
minimum
level of illumination, type of fittings, maintenance factor to be considered
is as given below:

Area Type of Light Fittings& Lamps Lux level (min)
Control room
with false
ceiling
Decorative mirror optic luminaire for
recessed mounting with energy
efficient CFL 2x36W of Philips type
FBS 450/236 M2 HF (with MASTER
PL-L 36W/840/4P ICT lamp) OR
equivalent.
300
Conference
room with false
ceiling
Decorative mirror optic luminaire for
recessed mounting with energy
efficient T5 lamps 2x28W of Philips
type TBS 669/228 D6 HF (with
MASTER high efficiency TL5-
300

UNIT # 1 TO 6 (6x60 MW)


28W/840 lamp) OR equivalent.
Office Room
without False
Ceiling
Surface mounting luminaire suitable
for 2x28 Watt TL-5 lamp ( Philips
model TCS 3502 XTL5 28Watt EB
C5 or Equivalnt)
300
Civil Staircases
of plant building

General purpose batten luminaire
with energy efficient T5 lamps 2x28W
of Philips type TMS 122/228 E HF
(with MASTER high efficiency TL5-
100
Flood lighting Weather proof non integral type
(integral type in case of high mast)
flood light fittings suitable for
1x250/400W HPSV lamps of Philips
type SNF 114 250/400W wide beam
/narrow beam as per requirement OR
equivalent.
70
Machine Hall Surface/Suspended type high
performance integral open medium
bay luminaire with prismatic diffuser
comprises of polycarbonate reflector
& separate control gearbox complete
with 1 No. HPIP 250 Watt Lamp etc
as required (Philips Model HPK 205
1xHPI BU250W PR or Similar)
200
Electrical rooms
without false
Ceiling
Surface mounted / Suspended
luminaires suitable for T5 lamps 2x28
W of Philips type TPS 814/228 D8
HF/ TPH 824/228 I HF (with MASTER
high efficiency TL5- 28W/840 lamp)
OR equivalent.
200
Battery Room Surface mounted luminaire with
energy efficient T5 lamps 2x28Watt of
Philips type TMS 122/228 E HF with
GMS 122 /228 Reflector (With
MASTER high efficiency TL5 28
W/840 lamp) OR Equivalent
100

UNIT # 1 TO 6 (6x60 MW)


Toilets General purpose batten luminaire
with energy efficient T5 lamps 1x28W
of Philips type TMS 122/128 HF (with
MASTER high efficiency TL5-
100

In addition to above following light fittings shall be used as per architectural
requirement / as per requirement
1. Recess mounting direct lighting luminaire suitable for Compact
fluorescent lamps PLL 36 Watt anti glare, D-6 optics, pearl white
wing (Philips model FBS 580 2xPL L36W EB TOD DF-WH or
Similar)
2. Recess mounting accent light suitable for 1 no. 50 Watt halogen
lamp (Philips Model QB 026 XMA/ 50 Watt/12GU5 3WH or Similar)
3. Surface mounting type mirror luminaire suitable for 13 Watt CFL
lamp (Philips model No. 13W / 34094 /11/86 or Similar)
4. Indoor Bulk head luminaire suitable for 1no. 9 Watt CFL lamp
complete with all accessories like reflector, protection guard, holders
(Philips model FXC 101 1xPL-5 Watt or Similar)

The light fittings shall be complete with all accessories like electronic ballast,
reflector etc. External area lighting including street/road lighting / tower lights
shall be fed from Out door type Feeder Pillar located at suitable places.
Automatic switching ON/OFF of these circuits shall be done through timers.

Flood light towers shall be fed through 415/240V, 3 phase, 4 wire circuit with
individual fittings distributed at 240V, single phase, with control and
protection located at bottom of each tower. DP MCB in a sheet steel box
shall be provided near each fitting to facilitate removal of lamp in off position.

4.0 Lighting Power distribution

The distribution of lighting power supply for the individual areas within
battery limit shall be done at 415V, 3 phase, 4 wire bus system through Main
Lighting Distribution Boards (MLDB). The outgoing feeders of the MLDB
shall feed the required numbers of Sub Lighting Distribution Boards (SLDB)

UNIT # 1 TO 6 (6x60 MW)


for lighting. Each SLDB shall receive power at 415V AC, 3 phase, 4 wire and
distribute it into 240V, 1 phase circuits for connection to the lighting fixtures
and 240V receptacles. The SLDBs shall be located in the rooms, bays, etc
preferably near entry/exit. covering the respective zone. The SLDBs shall be
located in the electrical rooms in the respective area. Separate neutral
chamber shall be provided for neutral busbar inside SLDB.

5.0 Control room illumination -

Control room illumination shall be provided with decorative fittings
mentioned in above table flushed to the false ceiling. Decorative type two
numbers 60 watt light fittings shall also be provided as emergency lights. Lux
level of control room shall be 400. Light fittings layout and their type shall be
approved during detail engineering.
Cables/Wiring and switches -

In control room, wiring shall be above the false ceiling and PVC conduits
shall be used on side walls. 3 nos, 240V, 3 pin socket outlets with plug tops
and switches shall be provided. In switch board 16 Amp MCB as incomer
shall be provided and decorative type ON/OFF switches shall provided for
each fitting.

6.0 Emergency lighting

Dedicated & separate Emergency lighting MLDBs & SLDBs shall be
provided for power house indoor & outdoor areas as per requirement to
feed emergency lighting circuits.

Emergency MLDBs shall be fed through DCDB so that in case of failure of
normal power also the Emergency SLDBs can be powered & Emergency
lights can continue to glow. 20% lights shall be connected through
Emergency SLDBs

7.0 Outdoor lighting

Flood lights for area lighting shall be mounted on towers/poles or building
structures. Tower height shall be kept to an average of 22m.

UNIT # 1 TO 6 (6x60 MW)


Street/road lighting and boundary wall lighting shall be provided with
HPSV/fluorescent lamp fittings mounted on poles of 9m to 11m height. For
street lighting, necessary control gear shall be provided for reduced voltage
running during off peak traffic for energy conservation .

8.0 Illumination of other areas

In existing power house indoor and outdoor illumination has been provided
however at certain locations within battery limit additional fittings needs to be
provided during erection stage to facilitate the work.

9.0 SPECIFICATION OF MAIN LIGHTING DISTRIBUTION BOARD (MLDB)

A. General

Type : - Metal clad
- Shall be suitable for 415/240V, 3
phase and neutral.
- Non draw out type

Construction : - Modular Construction.
- Fully Compartmentalized with
metal/ Insulating material
partition.
Enclosure class : - IP52 .

Type of execution : - Single front

Mounting : - Floor mounting
- Free standing with ISMC 75

Installation : - Indoor

UNIT # 1 TO 6 (6x60 MW)


B. Constructional Features

1.0 Sheet Steel Thickness : - 2 mm for load bearing members.
- 1.6 mm for non load bearing
members.

2.0 Cable entry
Incomer :- Bottom cable entry.
Outgoing :- Top / Bottom cable entry.

3.0 Design

- Separate bus alley and cable alley on opposite side of the
outgoing modules
- All the components shall be accessible from front
- Each module to have covering at the bottom.

- Minimum 200mm shall be left blank at bottom through the length
of panel

- Interlocking & protection : - Module door interlocked with
main powerIsolating devices.

- Power circuit isolation device to have
Pad locking in the OFF position with
door closed.
- Operating Height - Minimum : 300 mm
Maximum : 1800 mm
- Gland Plate - Undrilled removable bottom gland
plates (3 mm thick)

- Miscellaneous - Neosprene rubber gasket
shall be provided for all the
doors , removable covers &
between adjacent covers .

UNIT # 1 TO 6 (6x60 MW)


- Lifting hooks for the panel

- Doors shall have concealed
hinges
.
. - Earthing - - Two separate earthing terminals
shall be provided.
- Bolted joints with tooth spring washers
for good earth continuity.
- Earth bus to run in all cable alley of
the panel .
- Limiting dimensions
- Width of Module :- 500 mm (min)
- Width of Cable alley :- 300 mm (min)
- Depth of MLDB :- 600 mm
- Height of MLDB :- 2400 mm (max)
- Width of Bus alley :- 300 mm (min)
- Height of module :- 300 mm (min)

C. Busbars
(i) Main horizontal & vertical busbars
1.0 Arrangement - Three phase & neutral. Bus Bar chamber on
the
top.

2.0 Material - High conductivity electrolytic aluminium alloy
confirming to grade E91E as per IS-5082
1981.

3.0 Phase Busbar Rating - Minimum rating shall be same as incomer
MCCB rating
- Shall be able to carry continuously the
connected load (considering all derating
factors) plus a 25% margin .
4.0 Neutral Busbar Rating 50 % of phase busbar rating
5.0 Short circuit rating 50 KA for 1 sec.
6.0 Busbar configuration Red-yellow-blue from front to back or top to

UNIT # 1 TO 6 (6x60 MW)


bottom or left to right as viewed from front.
7.0 Busbar insulation Heat shrinkable PVC
- R,Y,B coloured sleeves for phases
- Black for neutral.
8.0 Max. temp. rise of bus - Not to exceed 35 deg. C. above ambient of
50
deg.C.

9.0 Air clearance for bare busbar
Phase to phase :- 25.4 mm (minimum)
Phase to earth :- 19.0 mm (minimum)
10.0 Joints and tap off points - Busbar joints and tap off points shall be
shrouded and bolted ( with cadmium coated
bolts with plain and spring washers and
locknuts).

(ii) Earth bus

1.0 Material GI/AL at bottom through the panel length.
2.0 Size Minimum 50 x 6 mm with extension at both
ends .

(iii) Control bus

1.0 Material Copper.
2.0 Size Minimum 25 x 3 mm or equivalant.

D. Insulation level

1.0 Rated insulation voltage 1100 V

2.0 Impulse withstand voltage 4 KV as per IS-13947 (Part I) 1993

3.0 One minute power 2.5 KV for power circuit & 500 V for control
circuit
frequency withstand voltage

UNIT # 1 TO 6 (6x60 MW)


F. Feeder arrangement
Incomers

1.0 Isolating Equipment 3 pole microprocessor based MCCB (for
rating
upto 630 A) with LSIG protection

2.0 Quantity Two incomers & One Bus coupler

3.0 Auto changeover - Through Power contactor logic with suitable
timer and auto manual selector switch.
- Power Contactors of AC3 rating same as
incoming MCCB

4.0 Indication Lamps LED type indicating lamps for :-
- MCCB ON/OFF/TRIP.
- Power ON R / Y / B .

5.0 Meters
- 144 sq.mm size voltmeter
- 144 sq.mm size ammeter
- MFM with communication features.

6.0 Current transformer 3 numbers for metering .

Outgoing feeder arrangements

1.0 Circuit breaker Three pole microprocessor based MCCB
with
LSIG release.

2.0 Indications ON/OFF/TRIP indication lamp.

G. Panel wiring

Power / current 1.1Kv grade single core, black colour PVC
transformer circuit insulated , stranded copper conductor of.

UNIT # 1 TO 6 (6x60 MW)


minimumsize 2.5 sq.mm

10.0 SPECIFICATION OF SUB LIGHTING DISTRIBUTION BOARD (SLDB)
A. General :-

Type : - Metal clad
- Shall be suitable for 415/240V, 3
phase and neutral.

Construction : - Totally enclosed.
- Dust & vermin proof.
- Welded back and sides
Enclosure class : - IP54 .
- IP 55 (with canopy) for outdoor
installation

Type of execution : - Single front

Mounting : - Wall mounting .

Installation : - Indoor / Outdoor (with canopy)

B. Constructional Features :-

1.0 Sheet steel CRCA, Thickness 2 mm .
2.0 Cable entry

- Incomer :- Bottom cable entry.
- Outgoing :- Top / Bottom cable entry.

3.0 Design

- One Incomer and outgoings .
- All the components shall be accessible from front
- Access to the operating handle of the incoming isolating switch
shall be from the front of the cubicle without opening the front

UNIT # 1 TO 6 (6x60 MW)


door.
- Operating knobs of outgoing MCBs shall be accessible only after
opening the front door of the cubicle.
- Protective insulated cover plate (3 mm thick bakelite sheet ) shall
be provided inside the cubicle to shroud all the live parts .

4.0 Gland plate :

Undrilled detachable gland plates (3 mm thick) shall be provided
at the top and bottom with suitable gaskets for cable entry

5.0 Earthing

Two separate earthing terminals shall be provided

04.12.02 Power Distribution Board (PDB) / ACDB / DCDB
- 415V, 3 phase, 4 wire, 250A, 40 kA (short time rating for 1 sec.)
indoor type.

- Board shall be single front, metal clad, front matched, dust and
vermin proof fully compartmentalized and extensible on both sides,
IP51 type enclosure.

- Shall have base channel of size ISM 75.

- Shall have isolated busbar chamber for main busbar at the top,
running through out the length of the board. Chamber shall have
removable cover.

- Cable alley shall have sufficient space for aluminium power cables
and bottom cable chamber shall be left free completely isolated from
the vertical busbars.

- Busbars shall have same cross section through out the length .
Rating of the neutral busbar shall be 50% of the main busbar. Earth
bus bar shall run in bottom chamber throughout the length of the

UNIT # 1 TO 6 (6x60 MW)


panel.

- The number of PDBs and their locations shall be decided based on
consumers and shall be finalised during drawing approval stage.

- Generally all boards will have following feeder arrangement :

Incomer - 250A load break switch

Outgoings - 32A - 4 nos. MCB (TPN)
16A - 4 NOS. MCB (TPN)
other as per the need of tenderer.

DCDB shall have two incomers with ammeter, voltmeter, & in outgoing
one of each type of feeder shall be provided as spares.

04.12.03 Local Control Stations

- Near all drives local control stations shall be provided.

- Sheet steel construction, dust and vermin proof, wall/structure
mounting.

- Control switches, push buttons and indication lamps mounted on front
hinged gasketted and lockable door.

- Suitable knockouts with glands on the bottom or top cover for cable
entry.

- Terminals to be suitable for 2 cores of 2.5 sq.mm conductors with
20% spare terminals.

- Readily accessible shrouded terminals.

- Wiring with extra flexible wires.

- Stop push button to be lockable type with mushroom head.

UNIT # 1 TO 6 (6x60 MW)


- Inscription in English on corrosion resistant metal strips.

- Enclosure conforming to IP-54 class for indoor and IP55 with canopy
for outdoor.

04.12.04 Erection, installation accessories

All support structures required for cables, busducts and for electrical
equiment including conduits, inserts, shall be provided to complete the
erection job in all respect. Cable tag markers, clamps, sealing compound,
pull boxes, marshalling boxes etc. shall be considered as part of the
tenderers scope.

04.12.05 Other items

- All required safety items like rubber mats in front of LT board, shock
treatment chart, Two nos. first aid boxes shall be provided in each
electrical premises.

04.13 220kV Switchyard Bay Extension
General
The supply of equipment and services covered by this specification shall
include, but not be limited to, the following :

1. 220 kV SF6 breakers
2. 220 kV isolators and earth switches (all types as specified and as
per existing bays)
3. 220 kV CTs
4. 198 kV Lightning arrestors
5. Control and protection panels for the switchyard bay/equipment
6. Main bus conductors
7. Bay bus conductors
8. Insulators
9. clamps and connectors
10. Marshalling box
11. Complete structural work within battery limit including supply and

UNIT # 1 TO 6 (6x60 MW)


erection of all GI Structures, bus work and gantries
12. Complete civil works for the above including foundation, cable
trenches, Roads, Boundary wall, etc
13. Complete earthing and shielding system
14. All hardware including jumpers, connectors, etc. as per requirement
15. Any other equipment/systems required for smooth functioning of the
switchyard bays/equipment
16. DC distribution board as per requirement
17. AC distribution board as per requirement
18. Lighting Distribution Board as per requirement
19. HT & LT power and control cabling including their termination at
both ends and cable accessories
20. Cables other than power and control cables
21. Power socket cabinet and lighting cabinet
22. All erection materials, required during erection of various equipment
under scope of tenderer
23. Safety items

220 kV SF6 CIRCUIT-BREAKER
The 220 kV circuit-breaker located in the outdoor switchyard shall be outdoor,
SF6, electrically operated, remote controlled, trip free design, complete with local
control, operating mechanism with all associated auxiliaries.

220 kV SF6 circuit breaker operating mechanism shall be pneumatic type with
individual compressor. The compressor mechanism shall be provided with AC
motors.

Circuit breakers shall be totally restrike-free under all duty conditions and shall be
capable of performing their duties without opening resistor.

Circuit breaker shall be capable of making and breaking any fault currents up to
and including those specified without any undue strain. Interrupting capacity for
short line faults shall not be less than the rated rupturing capacity for terminal
faults.

The circuit breaker shall be capable of;

UNIT # 1 TO 6 (6x60 MW)


Breaking the steady and transient magnetising current of transformer of
rating shown in single line diagram
Breaking line charging current as per IEC 56-2, 1987 with a temporary
over-voltage of 1.5 p.u. without the use of opening resistors
Breaking inductive currents of 1 to 10A without switching over-voltage
exceeding 2.3 p.u.
Breaking 25% of the rated fault current at twice rated voltage under phase
pposition condition
Clearing short time faults (Kilo metric faults) with source impedance behind
bus
equivalent to specified symmetrical fault current.

The circuit-breaker shall have specified current ratings and shall be capable of
making and breaking the specified fault current. No part of the circuit-breaker or
any other part of the equipment carrying the fault current or any supporting
structures shall be unduly strained or damaged when making or breaking fault
current up to and including that specified.

All current carrying parts of the circuit-breaker shall be of adequate size. Are
control devices shall be capable of rapidly and effectively extinguishing the arc
with negligible stresses on the enclosure. The circuit-breaker shall satisfactorily
interrupt transformer magnetizing current, line charging current and short-line
faults.

Each circuit-breaker shall operate as one complete 3-phase unit with minimum
vibration. It shall be possible to make independent adjustments of each phase
unit. The arrangement shall allow for easy access to all contacts for inspection,
repair and replacement. Insulating barriers and arc control devices shall be of
approved material not affected by tropical climate.

Constructional Features

All making and breaking contacts shall be sealed and free from atmospheric
effects. The contacts shall be permanently under pressure of SF6. The gap
between open contacts shall be such that it can withstand the rated dielectric
stresses at zero gauge pressure of SF6 gas due to its leakage.

UNIT # 1 TO 6 (6x60 MW)


Main contacts shall be the first to open and the last to close so that there will be
little contact burning and wear. Arcing contacts shall be the first to close and the
last to open and shall be easily accessible for inspection and replacement. Main
contacts shall have ample area and contact pressure for carrying the rated current
and the short time rated current of the breaker without excessive temperature rise
which cause pitting or welding. Tips of arcing and main contacts shall be silver
plated or have a tungsten alloy tipping.

Operating mechanism
The operating mechanism of outdoor circuit-breaker shall be housed in weather-
proof and dust-tight sheet steel cabinet with padlocking facilities. Suitable space
heaters with automatic thermostat control and ON / OFF switch shall be provided
inside the cabinet. The cubicle shall be complete with control circuit isolating
switch, lockable stay-put type local / remote selector switch to select local or
remote electrical control of breaker, pushbuttons for local electrical OPEN /
CLOSE as well as manual tripping operation, ON and OFF position indicators,
operation counter, 3-pin, 240 V, 5 A plug socket with ON / OFF switch, necessary
number of auxiliary contacts for protection, interlocking and signaling purposes
suitably wired and terminated in control cable terminal board with 10% spare
terminal, provision for cable entry for multi-core, PVC insulated, PVC sheathed
and armored, power and control cables etc.

Operating mechanism shall be of electro-pneumatic, electric motor-wound spring
charged type. Failure of any auxiliary spring shall not prevent tripping and shall
not cause trip or closing operation of the power operated closing devices.

Means shall be provided for manual operation of the breaker under emergency or
for testing and adjustments. Only well tried-out and robust operating mechanism
which is proved and tested for frequent operations shall be provided. Anti-
pumping and trip-free electrically and either mechanically or pneumatically under
every method of closing (except during manual closing for maintenance ) shall
also be provided. Trip circuit healthiness shall be continuously monitored and in
the case of fault, an alarm shall be generated.

The mechanism shall be suitable for remote control from the electrical control
room and electrical tripping by shunt trip coils. A local control switch with locking
arrangement shall be provided for each breaker for local operations i.e. tripping

UNIT # 1 TO 6 (6x60 MW)


and closing during maintenance, test etc. It shall be possible to trip the breaker
even in the event of auxiliary supply failure. Local/remote selector switch shall be
provided in the mechanism cabinet. No. of tripping coil shall be two.

Breaker shall be interlocked to prevent remote operation when the selector switch
is in the local position. Provision shall be provided for individual pole
closing/opening for maintenance purpose shall be provided.

Cabinet for operating mechanism and its accessories shall be of IP-55 protection
with pad-locking facility and suitable space heaters with automatic thermostat
control.

Closing circuit to operate correctly from 80% to 120% of the rated control voltage.
Each circuit-breaker shall have duplicate shunt trip coils. The trip coils shall be
designed to operate satisfactorily when the voltage at the terminals of the shunt trip coils
is between 50% and 110% of the specified control power supply voltage.

Following features shall be provided in SF6 Gas Circuit Breakers;

There should not be any condensation of SF6 gas on internal insulating
surfaces

In the interrupter assembly, absorption filters shall be provided for absorbing
gaseous SF6 decomposition products resulting from arcing and for limiting
residual moisture content.

Each pole shall form an enclosure filled with SF6 independent of the other two
poles and the pressure of each pole shall be monitored and regulated by
individual pressure switches.

Double O-ring seals with test holes for leakage test of the internal seal shall be
provided on each static joint.

Shall include facilities for remote low pressure/density alarm over suitable
temperature compensated monitoring devices when SF6 gas pressure/density
of any pole falls below a predetermined value.

UNIT # 1 TO 6 (6x60 MW)


Provision shall also be made for automatic tripping of the breaker and to
prevent further breaker operation if the pressure/density decreases to a value
below which the breaker cannot perform satisfactory operation at the specified
rating.

The position of vents, diaphragms and pressure relief devices shall be so
arranged to minimise danger to the operators in the event of gas or vapour
escaping under pressure.

Sufficient gas shall be provided to fill all the circuit breakers plus an additional
20% of the quantity to compensate for losses.

Circuit-breaker shall be provided with necessary auxiliary switches for indication,
control, interlocking, protection or other purposes. Four spare sets of auxiliary
contacts, six normally closed and six normally open, shall be left free in each unit
wired up to the control cable terminal board. The auxiliary contacts shall be
mounted in an accessible position and the design of the contacts shall be such that
they can be easily converted from normally open to normally closed type and vice
versa.

The circuit-breaker shall be of single pressure puffer type and shall consist of three
separate identical phase units linked together for simultaneous operation of all
three phases. The circuit-breaker shall have adequate hermetically sealed are
quenching and operating system as well as gas-tight and arc-proof bushings. All
relevant devices for pressurising, controlling and monitoring the gas pressure shall
be provided with facilities for remote alarm over suitable temperature compensated
monitoring devices when SF6 gas pressure / density of any pole falls below a
predetermined value. Provision shall also be made for automatic tripping of the
breaker and to prevent further breaker operation if the pressure/density decreases
to a value below which the breaker cannot perform satisfactory operation at the
specified rating. The circuit-breaker shall be provided with such safety devices as
gas density monitor for SF6, pressure switches to block closing / opening / re-
closing in the event of low pressure, phase discrepancy control, antipumping device
and mechanical close interlocking.

Operation of circuit-breaker shall comprise pneumatic controlled mechanism. The
mechanism shall be complete with all accessories as required. Each mechanism

UNIT # 1 TO 6 (6x60 MW)


shall be so designed as to enable a continuous sequence of circuit-breaker opening
and closing operations.

The various parts forming the operating mechanism shall be of robust construction
and carefully fitted so as to ensure free and definite operation. The design shall be
such as to reduce mechanical shock to a minimum and to prevent inadvertent
operation due to vibrations or any other causes.

Insulators/bushings
Insulators/bushings shall be of either oil filled condenser type, hermetically sealed
to prevent ingress of moisture and with leak proof magnetic indicator at the top to
indicate oil level or polycone or solid core type or SF6 gas filled depending upon
application. Insulators/bushings shall be free from radio interference. All iron parts
shall be hot dip galvanized and all joints shall be airtight.

All current carrying contact surfaces shall be silver plated. Silver plating shall not be
less than 25 microns in thickness.

Sulphur Hexafluoride Gas ( SF6 Gas )
SF6 gas shall comply with IEC : 376 and be suitable in all respects for use in the
switchgear under the operating conditions.
Means shall be provided for treating the SF6 gas by the use of desiccants, driers,
filters etc to remove impurities in the gas. These shall be provided as permanent
facilities. Portable plant for filling and evacuating the SF6 gas, shall be supplied.
This shall include
all the necessary devices for measurement of moisture content of SF6 gas and gas
cylinders of adequate capacity for temporarily storing the evacuated SF6 gas.
Suitable SF6 gas pressure monitoring device to give Low Pressure Alarm if SF6
gas pressure falls to a predetermined value. If pressure falls further, it shall block
the breaker
operation at certain value.

Technical Particulars of 220 kV Breaker

1. Type : Outdoor

2. Construction : Three identical single pole units linked

UNIT # 1 TO 6 (6x60 MW)


Together for simultaneous operation

3. Arc quenching medium : SF6 gas

4. Standards : IEC Publications 56 - BS116 & IS:2516

5. Rated voltage, kV (rms) : 245

6. Rated frequency, HZ : 50

7. Current rating, A : 2000 A

8. Number of poles : Three

9. Continuous current : As per SLD

10. Rated short circuit capacity : 40 kA for 3 sec

11. Rated peak withstand capacity : 105 kA

12. Pole discrepancy relay : Required

13. Rated operating duty cycle : O-0.3 sec - CO - 3min CO
as per IEC-561987

14. System neutral earthing : Effectively earthed

Operating mechanism

1. Type : Electro-pneumatic with electrical and
mechanical trip free device

2. Number : One per 3 - pole group/One per pole

3. Trip coil and closing voltage : 220 V DC

4. ON/OFF indicator : Mechanical as well as electrical

UNIT # 1 TO 6 (6x60 MW)


5. Emergency tripping mechanism : Mechanical

6. Anti pumping relay, operation ctr : Shall be provided
7. Local control panel, L/R S/S : Shall be provided

220 kV ISOLATOR (DISCONNECTING SWITCH)
The isolators shall be outdoor, triple-pole, off-circuit, fault make, horizontally mounted,
gang-operated and double-break type, designed, manufactured and tested as per
IS:9921. The switches shall be center post rotating type. The switch contacts shall be
high pressure, self aligning, self-cleaning, adjustable type, made of corrosion resistant
copper alloy and silver plated. The switch blades shall be one-piece, corrosion resistant,
copper alloy. The isolators shall be electrical motor operated with provision of local
manual operation also. All isolators shall have provision for padlocking both in open and
closed position.

Isolators shall be capable of carrying rated current continuously as well as specified
short-circuit current for the duration stipulated, without causing mechanical damage to
any part and undue temperature rise damaging the insulation.

Isolator shall be suitable for interrupting small inductive and capacitive currents such as
those, which occur while disconnecting lines at no-load, busbars/voltage transformers
under energized condition.

Isolators shall be electrically interlocked with the associated breaker and earth switches
to prevent their operation when the breaker is in closed position.

The isolators shall be complete with supporting insulators, adjustable double point arcing
horns, galvanised steel bases, operating down rod of requisite length, phase and
earthing terminals etc. The operating mechanism shall be housed in a weather-proof and
dust tight sheet steel cabinet with padlocking facilities. Suitable space heaters with
automatic thermostat control shall be provided inside the cabinet. The cubicles shall be
complete with control circuit isolating switch, lockable stayput type local / remote isolator,
push-buttons for local electrical control of isolator , push-buttons for local electrical
OPEN / CLOSE operation, ON and OFF position indicators, 3-pin, 240 V, 5. A plug
socket with ON-OFF switch, necessary number of auxiliary contacts for protection,
interlocking and signalling purpose suitably wired and terminated in control cable

UNIT # 1 TO 6 (6x60 MW)


terminal board with 10% spare terminals and provision for cable entry for multi-core, PVC
insulated, PVC sheathed and armoured, power and control cables etc. Necessary
provision shall be made for disconnecting the motor control circuit as well as the motor
drive from the linkage mechanism in case of manual operation.

All the interlocks shall be of fail - safe type. Suitable individual interlocking coil
arrangements shall be provided. The interlocking coil shall be suitable for continuous
operation from DC supply to the voltage variations stipulated.

Isolators shall be able to bear on the terminals the total forces including wind loading and
electrodynamic forces on the attached conductor without impairing reliability or current
carrying capacity.

Where required, isolators shall be provided with single or double earthing switches as
specified and as per existing bays. Types of isolators shall also be as per existing bays
and as specified in the specification. Following types may be applicable here;

- Isolators (normal) with two numbers earth switches
- Isolators (normal) with one number earth switch
- Isolators (normal) without earth switch
- Isolators (tandem) with earth switch
- Isolators (tandem) without earth switch

Tenderer shall design as per requirement and include the isolators/earth switches
accordingly.

The earthing switch shall have independent operating mechanism with suitable
mechanical interlock so that it will not be possible to operate the earthing switch with the
isolator in CLOSE position and vice versa. The earthing switches shall be manually
operated and single-break type.

Earthing switches to be provided on both sides or on one side of isolator, as per
requirement, forming an integral part of the isolator. Earthing switches shall be only
locally operated and shall be power operated but interlocked with the isolator.

Earthing switches shall be able to carry the same maximum fault current as the main
blades of the isolators and shall be able to withstand the same dynamic stresses. Each

UNIT # 1 TO 6 (6x60 MW)


earth switch shall be provided with flexible copper braids for connection to ground mat.
These braids shall have the same short time current carrying capacity as the earth blade.

Following features shall be provided for isolators;

Triple - pole, off-circuit, fault make, horizontally mounted, gang operated, suitable
for outdoor installation, in open yard Centrally rotated, double break type with
contacts moving in horizontal
Common actuating mechanism shall be provided for all the poles.
Single pole units shall be interchangeable.
Supply shall be complete with supporting insulators, adjustable double point
arcing horns, galvanized steel bases, operating down rod of requisite length,
phase and earthing terminals etc.
Switch contacts shall be of high - pressure self-aligning, self-cleaning, adjustable
type, made of corrosion resistant copper alloy and silver-plated.
Contact pressure shall be released before any movement of the blades in the
opening direction takes place and shall be applied after the closing travel is
completed.
Sufficient wiping action to make contacts self cleaning

Operating Mechanism of isolators shall have following features;

Motor (3 phase, 415V, 50 Hz) operated including reversible starter cum hand
operated.

Shall be suitable for remote and local electrical operation with provision for
manual operation in case of necessity

Each pole of isolator shall have individual drive for main blades and earth switch.
The operating mechanism of the three poles shall be well synchronized and
interlocked.

Operating mechanism and its controls shall be so designed that under no
circumstances the travel of the switchblades is interrupted before it reaches the
fully closed or open position.

UNIT # 1 TO 6 (6x60 MW)


Signaling device for all poles both for closed position and open position for
remote as well as local indication.

Housing for the operating mechanism and its controls shall be of sheet steel,
weather and dust-proof construction with rubber gaskets conforming to enclosure
protection class IP-55, and with padlocking facilities.

Suitable reduction gearing shall be provided between the motor and the drive
shaft of the isolator.

Shall be complete with a quick-acting electromechanical brake on the higher
speed shaft to effect rapid braking.

Limit switches shall be provided on the isolator shaft, within the cabinet, to sense
the open and closed positions of the isolator.

Space heater with thermostat, panel illumination lamp, 240 V socket in local
control panel.

Technical Particulars of Isolators

1. Type of isolators : Outdoor duty, centre post rotating blade vertical plane

2. Pole : 3 pole

3. System Voltage
Nominal : 220 kV
Rated : 235 kV

4. Short time rating : 40 kA for 3 sec

5. Peak short time current : 105 kA

6. Rated current : 2000 A

7. Standard : IS 9921

UNIT # 1 TO 6 (6x60 MW)


8. Operating mechanism : Motor operated/manual reversible starter

9. Earth switch : Hand operated

10. Control voltage : 220V DC

11. Auxiliary supply : 240V AC

12. Auxiliary supply for motor : AC 415V

13. Standards : IEC-129/IS:1818, IS-9921-1985

14. Installation : Outdoor

Required NO/NC auxiliary contacts of isolator shall be provided along with 20 % spare
contactor.

220 kV CURRENT TRANSFORMER
Current transformer shall be of electro-magnetic wound type, dead tank type, single-
pole, separately mounted, hermetically sealed, oil filled units, designed, manufactured
and tested as per IS:2705. Bottom tank shall be made of GI. The current transformers
shall be complete with bushing insulators, adjustable double point arcing horns, oil
gauge, pressure release device, nitrogen filling valve and cover, spark gaps, pressure
release device, nitrogen filling valve and cover, spark gaps, suitable phase and earthing
terminals, power factor testing terminals, drain valve, lifting lugs, rating and diagram
plate, secondary terminal box etc.

Explosion vent provision at top shall be there to minimize the destructive effect on
surrounding equipment in event of any CT bursting.

The current transformer shall be suitable for instruments, meters and relays offered as
well as burden of secondary leads. Knee-point voltage, resistance and magnetizing
current of class PS cores of CTs shall be suitably matched with the requirements of
relevant relays offered and secondary leads used. The instruments security factor of
metering cores shall be such as not to cause any damage to the related meters and
instruments in the event of system fault current flowing through the primary.

UNIT # 1 TO 6 (6x60 MW)


The current transformer shall be provided with weather-proof and dust-tight sheet steel
secondary terminal box complete with secondary terminals, shorting links, entry and
termination of multi-armoured control cables etc.

All CT metering cores shall be of 0.2 accuracy class.

The technical parameters of the current transformer shall be as follows:

Design Outdoor single-pole, electro-magnetic wound type
current transformer to be mounted on steel structures
and suitable for short-time rating of 40 kA for 3-secs. and
dynamic current of 105 kA peak, complete with all
associated fittings and accessories.
Standard followed IS:2705

Ratio, accuracy class
and VA burden
As per single line drawing enclosed

198 kV LIGHTING ARRESTORS
LA shall be designed to provide maximum protection against over voltages occurring
during switching of unloaded transformers against lightning and switching surges.

Lightning arrestor shall be station class, heavy-duty, gapless, zinc-oxide type for use on
solidly grounded system. LA shall be self-supporting type in single-pole assembly for line
to earth connection. The dismountable units of the arrestors shall have the characteristic
elements hermetically sealed under dry air or inert gas.

The isolator shall be designed, manufactured and tested as per IS:3070 (Part-1). The
installation shall be complete with line and earth connections, operation counter, leakage
current indicator and other accessories and devices, including grading rings for
improving voltage distribution.

The discountable units of the arrestors shall have the characteristic elements
hermetically sealed under dry air or inert gas. The lightning arresters shall be fitted with
pressure relief devices and arc diverting ports suitable for preventing shattering of
porcelain housing and providing path for the flow of rated fault current in the event of
arrester failure. Grading corona rings shall be provided on each complete arrester unit as

UNIT # 1 TO 6 (6x60 MW)


required for proper stress distribution. Magnetic blowout coils shall also be provided for
effective extinction of power frequency follow current.

The insulator housing of the arrestor shall be made of brown glazed, wet process,
electrical porcelain, free from all manufacturing defects.

Spacers for and non-linear resistor elements or non-linear resistor blocks shall be of
ceramic material. These shall be provided in such a way as to obtain robust construction,
with excellent mechanical and electrical properties even after repeat operations. The
grading network should contain both capacitors and non-linear resistors. Uniform voltage
distribution should be maintained under all service conditions.

Following fittings and accessories shall be provided along with LAs;

Discharge counter with ammeter
Guarding rings
Pressure relief device
Supporting structures
Mounting insulators
Clamps and connectors on arrestor terminals : Suitable for existing conductor
Insulating bases having provision for bolting to flat surface of structure.

Technical Particulars
1. Standards : IEC 99-4/IS:3070-1993 for LA IS 5621-1980 for LA housing

2. Service : Outdoor in open yard

3. Class : Station class heavy duty

4. Type : Gapless nonlinear resistor

5. Nominal system voltage : 220 kV

6. Max. cont. op. voltage kV (rms) : 198 kV

7. Nominal discharge current rating : 10 KA

UNIT # 1 TO 6 (6x60 MW)


8. Standard : IS:3070 (Part-I)

BUSWORK
The overhead busbars / jumpers shall be swing type comprising aluminum conductor
steel reinforced (ACSR) 54+7/3.18 ZEBRA. ACSR conductors shall be used for both
Main bus-I and Bus-II . The sizes of the conductors shall be adequate to carry the
required continuous current as well as to withstand the specified short-circuit currents.
ACSR conductors shall conform to IS:398

The busbars shall be supported with fully insulated support having adequate mechanical
strength as required for the specified short-circuit level. Necessary bus-supports,
jumpers, connectors, insulators, structural steelwork, hardware as required shall be
supplied with the busbars to make the installation complete in all respects. Provision
shall be made in the busbar installation to allow for expansion and contraction of the
busbars.

The busbar system shall be so designed as to prevent any visual corona formation and
possibility of causing radio interference. The busbar system shall be so supported and
fastened as to withstand forces likely to be developed by the specified 3-phase
symmetrical short-circuit current.

INSULATORS
Supporting insulators of circuit-breaker, isolators and lighting arrestor, bushing insulators
for instrument transformers as well as well post type insulators and string insulator
assemblies for supporting buswork shall be made of best quality porcelain and shall be
brown glazed. Porcelain shall be homogenous, free from any laminations, cavities, flaws
and imperfections and shall be thoroughly vitreous so that the insulation does not
depend on the glaze. The glaze shall be of uniform shade, smooth, hard and shall
completely cover all exposed parts of insulators. All insulators shall be suitable for
heavily polluted atmosphere. All insulators shall be suitable for heavily polluted
atmosphere and shall be able to withstand the duty requirements of the related
equipment.

Individual disc insulators as well as complete insulator strings for supporting ACSR
busbars shall be designed, manufactured and tested as per IS:731 and IS:3188. All
fittings and accessories shall conform to IS:2486. Insulators shall be of ball and socket
type. The socket shall be malleable cast iron and the pin shall be of steel. After

UNIT # 1 TO 6 (6x60 MW)


machining is completed, the balls and sockets shall be of steel. After machining is
completed, the balls and sockets shall be hot dip galvanised. The zinc coating shall be
smooth, clean, of uniform thickness and free from defects. Ball and socket connections
shall be provided with adequately strong retaining pins of locking devices of suitable
material. Individual units of each string shall be identical and interchangeable and shall
so designed as to prevent formation of any defect due to expansion or contraction in
porcelain or metal fittings. Porcelain shall not exchange directly with metal but shall be
mounted with suitable non-deteriorating interposing material.

STEEL STRUCTURES
Complete structures of the 220 kV switchyard shall be made of galvanized Iron. Tenderer
shall include accordingly.

The steel structures for mounting various equipment such as circuit-breaker, isolators,
instrument transformers, lightning arrestor, busbars, and accessories etc. as required
shall be designed, fabricated and supplied as a part of the work covered by this
specification to make the installation complete in all respects. The structures shall be of
adequate mechanical strength designed to meet the requirement of the equipment
specified and shall be suitable for site and loading conditions as called for in this
specification. The structures shall be of lattice type construction, fabricated from rolled
mild steel sections and hot dip galvanised. Only bolted connections will be permitted.
Necessary nuts, bolts, washers including foundation bolts etc. shall be supplied with the
structures.

Steel members, bolts, nuts, fittings shall be hot dip galvanised except spring washers
which shall be electro-galvanised. Galvanising shall be done after fabrication is
completed but the nuts may be tapped or re-run after galvanising. Threads of the bolts
may be under cut to provide for increase in diameter because of galvanising. Re-running
of the bolt threads is not permitted.

Before galvanising, the steel section shall be thoroughly cleaned of any paint, grease,
rust, scale, acid or alkali or such other foreign matters as are likely to interfere with the
galvanising process or with the quality or durability of the zinc coating. Galvanising of
each member shall be carried out in one complete immersion. The galvanising bath shall
contain only the approved standard spelter.

The galvanised surface shall consist of a continuous and uniformly thick bright coating of

UNIT # 1 TO 6 (6x60 MW)


zinc, minimum weight of coating being 910 gm / sq m, firmly adhering to the surface of
steel. The galvanising shall be from any defect which may affect or tend to affect its
anticorrosive properties. The finished surface shall be clean and smooth and shall be
free from defects like discoloured patches, bad spots, uneven coating, zinc which is
loosely attached to the steel globules of zinc, spiky deposits of zinc, blistered surface,
flaking or peeled off zinc etc. The presence of any of the above defects or deformation
noticed on visual inspection even without carrying out any test shall render the material
liable for rejection. Defective galvanised steel sections requiring re-galvanising shall
have the zinc coating entirely removed by suitable acid treatment without damaging the
steel surface and regalvanised only after proper picking.

Galvanised articles, zinc to be used for galvanising, method of testing etc. shall conform
to the relevant standards.

MARSHALLING KIOSK
Marshalling kiosk shall conform to IS : 5039.

Size of marshalling kiosk shall be adequate to work freely during maintenance. It shall be
minimum of size 1600 mm x 970 mm x 600 mm.

Marshalling kiosk shall be sheet enclosed and shall be dust, weather and vermin proof.
Sheet steel used shall be at least 2.0 mm thick cold rolled/2.5 mm hot rolled and properly
braced to prevent wobbling.

The enclosures of the marshalling kiosk shall provide a degree of protection of not less
than IP 55 (as per IS :2147) and one kiosk of each type shall be tested for the same.

Lighting arrangement inside the marshalling kiosk shall be provided which shall be
interlocked with kiosk door.

Marshalling kiosk shall be of free standing floor mounting type or pedestal mounting type
as per requirement.

Marshalling kiosk shall be provided with double hinged doors with padlocking
arrangement. The distance between two hinges shall not exceed 350 mm to ensure
uniform sealing pressure against atmosphere.

UNIT # 1 TO 6 (6x60 MW)


All doors, removable cover and plates shall be gasketed all around with neoprene
gaskets. Ventilating louvers if provided shall have screen and filters. The screen shall be
fine wire mesh made of brass or GI wires. The neoprene gaskets shall be tested in
presence of Owner's representatives.

The cable entries to the marshalling kiosk shall be from the bottom. Suitable cable gland
plate, projecting at least 150 mm above the base of the marshalling kiosk shall be
provided for this purpose. Necessary number of cable glands shall be supplied and fitted
on this gland plate. The gland shall project at least 25 mm above gland plate to prevent
entry of moisture in cable crutch. Gland plate shall have provision for some future glands
to be provided later, if required. The glands shall be dust proof screw on, double
compression type for outdoor use and made of brass. The gland shall have provision for
securing armour of the cable separately and shall be provided with earthing tag. The
glands shall conform to BS 4121. The gland shall be cadmium plated.

All sheet steel work shall be phosphated in accordance with IS : 6005, Code of Practice
for phosphating Iron & Steel. Oil, grease and dirt shall be thoroughly removed by
emulsion cleaning. Rust and scales shall be removed by pickling with dilute acid followed
by washing with running water rinsing with slightly alkaline hotwater and drying. After
phosphating thorough rinsing shall be carried out with clean water followed by final
rinsing with dilute dichromate solution and oven drying. Then two coats of zinc cromate
primer and two coats of oil and weather resistant varnish of a colour distant from primer
shall be applied. Final coats of glossy, oil and weather resistant nonfading paint be
applied. Primer paint shall be as per IS : 104 and intermediate and final coat of paint
shall be as per IS-2932. All paint shall be carefully selected to withstand heat and
extremes of weather. The paint shall not scale off or wrinkle or be removed by abrasion
due to normal handling.
Suitable heaters shall be mounted in every compartment of the kiosk so that cubicle
temperature is always maintained approximately 10 deg.C above the outside air
temperature to prevent condensation. On-off switch and fuse shall be provided. Heater
shall be suitable for 240V AC supply.

Marshalling kiosk shall be supplied complete with inter-connecting wiring provided
between all electrical devices mounted therein. All internal wiring shall be carried out
with 650V grade single core 2.5 sq.mm stranded copper conductor, PVC armoured
insulated wire. The internal wiring shall be securely supported neatly arranged and
readily accessible.

UNIT # 1 TO 6 (6x60 MW)


The wiring shall be colour coded. For illumination each compartment of the kiosk shall be
provided with door switch controlled incandescent lamp. The marshalling kiosk shall also
be provided with incoming switch-fuse or MCB and one 15 Amp interlocked switched
socket in addition to a MCCB.

The terminals shall be numbered as desired by Engineer-in-Charge and shall be so
staggered that the connection of external cable to any terminal block should be possible
without disturbing the rest of the connection. The terminal block arrangements shall be
such as to provide maximum accessibility to all conductor terminations and any
arrangement preventing ready access to other terminal screws shall not be accepted.

The terminal block shall be made of moulded, non flammable thermosetting plastic. The
terminal block to be provided shall be fully enclosed with transparent removable covers
and made of moulded, non-inflammable thermosetting plastic material with blocks and
barriers moulded integrally. The material of terminal block moulding shall not deteriorate
because of varied conditions of heat, cold humidity, dryness etc. Such blocks shall have
a white marking strip for circuit identification and moulded plastic cover. All terminals
shall be clearly marked with identification numbers or letters to facilitate connection to
external wiring.

The terminals shall be made such that maximum contact area is achieved when a cable
is terminated. the terminal shall have a locking characteristic to prevent cable from
escaping from the terminal clamp unless it is done intentionally. The conducting part in
contact shall be tinned or silver plated.

Bay marshalling kiosk shall have three separate distinct compartments for the following
purposes;

To receive two incoming and distribute three outgoing 220V DC supply for various
elements in switchyard.
To receive two incoming 415V, 3 phase AC 100A supplies with auto changeover
and MCCB units and distribute five outgoing supplies, 3 nos. 63A and 2 nos. 32A
controlled by MCCB with remote, indication for tripping.
To receive one incoming 240V, 1 phase, AC supply and distribute ten outgoing
supplies.
200 nos. terminal blocks in vertical formation for interlocking facilities.

UNIT # 1 TO 6 (6x60 MW)


CT terminal shall have disconnecting type shorting links.

CLAMPS & CONNECTORS
Clamps & connectors shall conform to IS : 5561.

The clamps and connectors shall be made of materials listed below :

For connecting ACSR conductor : Aluminium alloy casting conforming to
designation A6 of IS : 617 and shall be tested for all tests as per IS : 617.
For connecting equipment terminals made of copper or ACSR conductor :
Bimetallic connectors made from aluminium alloy or casting, conforming to
designation A6 of IS:617 with 4 mm thick Cast copper liner.
For connecting G I Shield wire : Malleable iron casting
Bolts, nuts and plain washers - Hot dip galvanized mild steel
Spring washers : Electrogalvanised mild steel as per service conditions at least 3
of IS:1573.

All casting shall be free from blow holes, surface blishters, cracks and cavities. All sharp
edges and corners shall be blurred and rounded off.

No part of a clamp or connector shall be less than 15 mm thick.

All ferrous parts shall be hot dip galvanised conforming to IS : 2633.

For bimetallic clamps or connectors, copper alloy, liner of minimum thickness-2mm shall
be cast integral with aluminium alloy body.

Flexible connectors, braids or laminated strips shall be made from tinned copper sheets
or aluminium laminates depending on the clamp. The terminal clamps for busposts shall
be suitable for both expansion as well as fixed/sliding connection.

Size of the terminal/conductor for which the clamp/ connector is suitable shall be
embossed/punched (i.e indelibly marked) on each components of the clamp/connector,
except on the hardware.

Clamp shall be designed to carry the same current as the conductor and the temperature
rise shall be equal or less than that of the conductor at the specified ambient

UNIT # 1 TO 6 (6x60 MW)


temperature. The rated current for which the clamp/connector is designed with respect to
the specified reference ambient temperature, shall also be indelibly marked on each
component of the clamp/ connector, except on the hardware.

All current carrying parts shall be designed and manufactured to have minimum contact
resistance.

Clamps and connectors shall be designed corona controlled. Corona extinction voltage
for 220 kV clamps shall be 154 kV.

OTHER HARDWARE
Tenderer shall include complete 220 kV transformer bay including all conductors,
jumpers, bus bars, supporting structures, connectors, clamps, and other accessories
required for completion of job.

CIVIL WORK
Complete civil works shall be included for the switchyard extension including new bays in
existing portion of the switchyard, Extension of cable trenches and road of existing
switchyard to the extended portion, illumination, rail track for transportation of station
transformer ,foundations, gravels, oil pits, cable channels, pipe grouting, cable ducts etc
as per requirement Construction of foundation for the station transformer and bay
equipment is in the scope of tenderer. Fencing and structural gate of 20 MVA, 220/11kV
Transformer is in the scope of tenderer. Dismantling of existing wall and gate for
extension of bay and construction of wall alongwith fixing of dismantled gates is in the
scope of tenderer. Approach road upto extended part of the wall is in the scope of
tenderer.

RELAY AND CONTROL PANELS
All equipment required for control, monitoring, interlocking, sequencing, metering and
protection shall integrated in separate control cum protection panels to be installed in the
existing switchyard Control Room. The panels shall be provided with required mimic,
indications, control equipment, indicating meters, annunciators, protective relays, etc.The
relays shall be numeric type with communication port.

Relay and control panel shall have provision for metering, relaying, alarm annunciation,
control and mimic diagrams for the double main bus with bypass bus arrangement and

UNIT # 1 TO 6 (6x60 MW)


220 kV bay. This shall be of duplex design and shall be installed in the Switchyard
control building. Dimension (height and width) of relay and control panels shall match
with existing panels.

The relays and control panel shall be of floor mounted, free standing, dead front design
fabricated out of minimum 2 mm thick sheet steel and with IP50 degree of protection.

All meters, mimic diagrams, control switches, indicating lamps, annunciator facia
etc.shall be provided on the front of the panel and all protective and auxiliary relays shall
be mounted at the rear.

NIT (Normal, Intermediate, Tie) switch shall be provided in control panel. NIT switch shall
be lockable at N position. Key shall be able to come out only at Normal position not at
I or T position.

All internal wiring of panel shall be carried out with 1.1 kV grade stranded copper
conductor, PVC insulated wiring cable of core size 2.5 sq mm for control circuit wiring.
Terminal blocks shall be located in easily accessible positions and more than two wires
shall not be connected to one terminal. Each terminal block shall be provided with at
least 20% spare terminals.

Space heater shall be provided in cubicle at the bottom with necessary thermostat switch
to prevent condensation. Internal illumination with fluorescent lamp for convenience of
access and maintenance work shall be provided. These lamps shall be provided with
door operated switch. Four (4) Nos. 5 A, 240 V single-phase AC, 3-pin socket outlet shall
also be provided.

Earth bus of bare aluminum strip of adequate size shall be provided all along the length
of the panel at the bottom. The structure of cubicle and non-current carrying metallic
parts of all panel mounted devices shall be connected to earth bus for effective earthing.

All protective and auxiliary relays, instrument, indicating lamps, push-buttons, control
switches, alarm annunciators, semaphore indicators etc. shall be provided in the relay
and control panel.

Energy meters shall be of 0.2 accuracy class.

UNIT # 1 TO 6 (6x60 MW)


All instruments shall be robust design vibration-proof and suitable for flush mounting on
vertical panels. Indicating instruments shall be 144 mm x 144 mm size of parallax free
design with glare front glass covers. The instrument shall be provided with zero
adjustment facility and magnetic screening.

Solid state alarm annunciator with flasher and horn shall be provided for drawing
attention of operator abnormal operating conditions.

Annunciation window shall be mounted on the top of the control panel with black
engraving on milk white translucent covers. Separate windows shall be provided to
annunciate the following abnormal conditions:

Trip and alarm annunciations shall be differentiated in separate alarm facias with
different type of buzzers.

Circuit-breaker auto trip.
Operation of each type of protective relay including inter-trip relay.
PT fuse failure.
Fault in DC control power supply equipment.
Circuit-breaker tripped due to transformer fault.
Buchholz relay-alarm.
Buchholz relay- trip.
Winding temperature-alarm.
Winding temperature-trip.
Oil temperature-alarm.
Oil temperature-trip.
Oil level low-alarm.
Oil level low-trip.
Earth-fault-trip.
Trip circuit faulty (Pre-close and post-close annunciation)
Air pressure low-alarm
Air pressure low-trip
SF6 gas pressure low-alarm (in each phase).
SF6 gas pressure low-trip (in each phase)
Trip relay circuit faulty (for supervision of lock out relay)
Breaker tripped on Pole Out of Step

UNIT # 1 TO 6 (6x60 MW)


The above is indicative and minimum. The same shall be finalized during detailed
engineering.
Alarm and annunciation shall be immune to Radio Frequency noise.
Each annunciation window shall be provided with two lamps and a minimum of 20%
spare window shall be provided. The annunciation system shall have push-button for
alarm acknowledgement, re-set and test purpose.

The annunciation system shall be built on plug-in type glass epoxy printed circuit boards
of modular design.

The alarm annunciator shall be immune to RE noise and hum noise of 50 cycles. The
annunciator must be tested for impulse voltage withstand and high frequency
disturbance tests as per IS:8686 and Tenderer shall furnish test certificates to this effect.

The indicating watt meters and VAR meters shall be digital meters. These meters shall
have the facility to communicate to a PC. The MWH & MVARH meters shall be of
numeric type with facility to communicate to PC. The accuracy class shall be 0.2.

In addition to various indicating meters, a multifunction meter with load read out facility
and remote communication facility shall be provided. The multifunction meters shall have
battery back up for memory.

In addition to the metering and protection requirements as stated above, the relay and
control panel shall be provided complete with mimic, diagram, semaphore indicators for
position indication of circuit-breaker, isolators and earthing switches, spring-return to
neutral type OPEN / CLOSE control switches for circuit-breakers and disconnecting
switches, stayput type bus selection switches, lockable stayput type trip transfer
switches, ON / OFF / AUTO TRIP / READY FOR OPERATION indication lamps for
circuit-breaker, space-heater, illumination lamps and all other accessories as required to
make up a complete installation. The mimic diagram with semaphore indicators shall be
so arrange as to give the actual position of 220 kV circuit-breakers, isolators, etc. The
arrangement adopted shall be subject to approval by the Purchaser / Consultant. The
mimic shall be made of 12.5 mm wide and 3 mm thick enamel painted aluminum strips
and different colours shall be used to identify different voltages fuses. The semaphore
indicator shall have two separate operating units with provision of holding the semaphore
disc in neutral position when both units are de-energised.

UNIT # 1 TO 6 (6x60 MW)


All standard protections shall be as per requirement for the 220 kV switchyard bay. The
same shall be finalized during detailed engineering.

MISCELLENEOUS
Minimum sizes of GI structures for the proposed 220 kV system shall be as per existing
220 kV switchyard. The new system shall match with existing corresponding one in
height, width, clearances, etc. Difference in FFLs shall be bridged by making the main
bus with proper slope above road between existing and extended switchyard keeping all
the statutory clearances.

STATION AUXILIARY POWER SUPPLY EQUIPMENT
The 415 V AC distribution board (to fed from the Owners 415 V station PCC) shall be
floor mounted metal clad, totally enclosed cubicle type. It shall be single front drawout
type.

The AC distribution board shall be suitable for 415 / 240 V, 3-phase, 50 Hz, 4-wire
system and shall have two incoming feeders. The incoming feeders shall be
mechanically interlocked such that only one of the two can be closed at a time. The
board shall have adequate number of feeders to cater to the station auxiliary power
requirements. Feeders shall also be provided to cater to future equipment envisaged in
the outdoor yard. Additional minimum six (6) Nos. fully wired spare feeders for owners
use shall be provided in the AC distribution board. The board shall also have a minimum
of 10% spare feeders (with minimum one number of each type and rating) in addition to
feeders for owners use.

DC CONTROL POWER SUPPLY EQUIPMENT
220 V DC shall be adopted as control voltage for the operation of circuit-breakers.
One (1) set of floor mounted, cubicle type DC distribution board shall be provided with
requisite number of incoming and outgoing feeders for supply of DC power to various
equipment in the new yard. The feeders shall comprise adequately rated Moulded Case
Circuit Breaker (MCCB) units. The minimum rating of MCCB units shall be 25 A. The
board shall have minimum four (4) Nos. fully wired spare outgoing feeders for owners
use. The board shall also have minimum 10% spare feeders (with minimum one number
of each type and rating) in addition to feeders for owners use. The board shall be single
front design.

UNIT # 1 TO 6 (6x60 MW)


AUXILIARY POWER AND CONTROL CABLING
The Tenderer shall include in his scope, laying of one (1) lot of power and control cables
required for complete interconnection of all equipment supplied which are included in the
scope of this specification.

The power and control cabling shall be complete with all laying, supporting, jointing and
termination materials and accessories including cable racks, trays, supporting brackets
for trays and racks, conduits, conduit fittings, cable tags, identification ferrules etc. as
required to make the installation complete in all respects. All cabling materials and
accessories shall be of quality to be approved by the Owner.

EARTHING
One (1) lot of earthing stations, earth conductors and accessories shall be offered for
providing complete earthing of the following systems and equipment as required to meet
the stipulations of Indian Electricity Rules to the full satisfaction of Chief Electrical
Inspector to the Government of Orissa (CEIG) Central Electrical Authority (CEA) and the
Owner.

System Earthing
Primary and secondary side neutrals of transformer are bought out and while primary
side neutral is solidly earthed secondary side is earthed through resistance.

Equipment Earthing
All indoor and outdoor equipment and devices covered under the scope of this section
including lightning arrestors, shielding spikes, outdoor steel structures, transformer rails,
substation fencing and gate, cable boxes, trays, racks, conduits etc. Individual earth pit
for each lightning arrestor shall be provided.

Earthing system shall be designed as per the requirements of IS : 3043. The earthing
system shall be so designed as to keep the touch and step potentials within permissible
limits. The substation main earth mat shall be extended up to 1.5 meter beyond the
substations in order to avoid dangerous potential difference developing between he
fence and the surrounding ground. The electrical resistivity of soil shall be measured at
site and taken accordingly.

All earthing system shall be so designed as to ensure effective operation of protective
gears in case of earth faults. Actual measurement of soil resistivity shall be done to

UNIT # 1 TO 6 (6x60 MW)


determine the number of earth electrodes to be provided. The total earth resistance at
any point of the earthing system for the substation shall not be more than one ohm.

The method of earthing the substation fence shall be considered from the view point of
touch and step potentials in the area outside the fence. All fencing shall be separately
earthed with the earth grid completely segregated from the station earth mat.

Shielding and Lighting Protection
The outdoor switchyards shall be properly protected against direct lighting strokes in
accordance with IS : 2309. Vertical air terminations (lighting masts) shall be adopted for
the outdoor switchyards erected on sub-station gantry column as well as on separate
structures erected for masts.

The size of shielding wire used in case of 220 kV transmission line shall be 7/9 SWG
galvanised steel conductor.

The lighting protection for outdoor equipment shall comprise of air terminations installed
on sub-stations / structures / separate structures. Air terminations shall be copper rods
mounted on substation steel structures. The cone of protection shall be 450 maximum for
single masts and 600 maximum for multiple masts.

The Tenderer shall critically examine the layouts and include masts that may be required
to adequately protect the switchyards against direct strokes. The height of structures as
well as masts shall also be suitably selected. The Tenderer shall indicate in his offer
details of masts considered and height of masts.

Down conductors from lightning masts and shielding wires shall be as short as possible
and shall follow the most direct path possible between the air-termination and earth
termination avoiding sharp bends, up-turns and kinks. Joints shall be avoided in down
conductors. Each down conductor shall have an independent earth termination which
shall be interconnected with the station earth mat. Each gantry column shall be provided
with at least two earth connections to the station earth mat.

The base of lightning arrestors shall be directly connected to the earth by conductor
which shall be as short and as straight as practicable. Individual earth electrode shall be
provided for each lightning arrestor. These earth electrodes shall be connected not to be
taken through steel pipes. The size of the down conductor shall be 65 x 6 mm galvanized

UNIT # 1 TO 6 (6x60 MW)


MS flat.

The method adopted for protection of buildings and allied structures against lightning
shall be in accordance with IS : 2309.

INSTALLATION AND COMMISSIONING
The successful Tenderer shall carry out at site complete erection of equipment supplied
by him (including those procured from fabricated by others based on his drawings,
specification and bill of quantities) as well as start-up and commissioning including
performance tests of the same.

The contractor shall be completely responsible for the satisfactory erection, testing,
commissioning, start-up, and performance tests of the equipment notwithstanding that he
may be assisted by the Owners authorized representative.

For complete erection and commissioning the successful Tenderer shall be responsible
for providing at his cost all necessary tools, tackles and instruments as required.

The installation shall be carried out only by electrical contractor, holding a valid H.T.
electrical license, issued by he Government of Orissa for carrying out installation work of
220 kV voltage class under the direct supervision and person holding valid certificates of
competency for the same voltage classes, issued or recognized by the State
Government. The Tenderer shall furnish with his tender the particulars of the license
held by him / the electrical contractor he proposes to engage for carrying out the
installation work against this specification. The successful Tenderer shall furnish to the
Owner the names and particulars of certificates of competency of the supervisors and
workmen to be engaged for carrying out the installation work against this specification.

The work shall be executed in a workman like manner with the best engineering
practices.

The installation shall have to be approved by statutory government authorities like
Central Electrical Authority, Factory Inspector, Insurance officials etc. Any modification in
he equipment or installation that may be demanded by them shall have to be carried out
by the successful Tenderer at no extra cost to he Owner. The responsibility of obtaining
clearance from the Electrical Inspectorate of Orissa for commissioning of the complete
electrical equipment / system covered under this specification shall lie solely with the

UNIT # 1 TO 6 (6x60 MW)


contractor. The contractor shall carry out any modification if the same is required by the
statutory authority though

04.14 ERECTION SPECIFICATION

04.14.01 Guidelines for design of system and engineering the layout of electrical
equipment

General
The tenderer shall prepare the layout drawings taking into consideration the
requirement listed below.

Electrical premises
All electrical premises shall have adequate space to accommodate the
electrical equipment from the point of view of operation and maintenance,
and conform to IE Rules & Regulations.

The clearance between the ceiling of the electrical room and top of the
tallest equipment shall not be less than 1m, 2m where the equipment are to
be maintained from top and additional height of lifting tackle wherever
required.

Air tight door arrangement shall be provided for electrical control rooms.

Cable Installation
Cables will have to be run partly along the structures and columns of the
buildings, wherever it is necessary i.e. to a nearby shop cable trench /chan-
nel or surface duct shall be provided. Cable channels inside turbine floor
shall be avoided.

Installation of cables directly buried in ground shall generally conform to the
requirement given in IS: 255.

If the cables are crossing the road/rail track, cables shall be laid in concrete
cable ducts, G.I. pipes. 25 % spare conduits/pipes/duct openings shall be
provided.

UNIT # 1 TO 6 (6x60 MW)


Cables in trenches shall be laid on 8 cm of riddled sand and covered with 8
cm of riddled sand. RCC slabs shall be provided for covering these
trenches. The maximum trench depth shall normally be 1.5 m and thickness
of top cover of 75 mm. If the trench is to cross railway tracks/roads or any
load bearing area the cables shall be taken through suitable GI con-
duits/pipes/ducts.

Laying in surface ducts / on structures
Cable racks for cable trays shall be fixed at a maximum interval of 1.5 m.

Cables leaving the ground/floor shall be protected upto 2 m height by
conduits/metallic guards.

Galvanised prefabricated ladder type cable racks and trays shall be
provided to lay cables in shafts/cable basements. Cables shall be laid in
separate racks according to the voltage/application classification. The
cables shall be laid from top to bottom in order of HT on top rack followed by
LT cables and other cables on lower racks.

All necessary frame works and fixings for the support of cables and
accessories shall be supplied.

Cables shall be suitably protected against heat, and mechanical damages.

Structures for cable laying
Cables shall be laid on ladder type cable trays. Ladder type cable trays shall
be selected from sizes 200 mm, 400 mm & 600 mm and shall be fabricated
from 40x40x3.1 mm GI slotted angles for longitudinal members and 25x5 mm
perforated flats for cross members placed at an interval of 250 mm along the
length of cable tray.
Supporting vertical racks and horizontal hooks shall be of 50x50x6 mm
angles.Cable racks and hooks shall be of welded construction.

To avoid damage during cable laying, cable structures shall have no scales,
abbrasive or rough surfaces or cutting edges.

UNIT # 1 TO 6 (6x60 MW)


Transformer installation
Mineral oil filled transformer shall be installed at transformer yard.

Earthing
Entire system shall be earthed in accordance with the provisions of the
relevant IEC recommendations/ IS code of practice IS 3043-1987 and
Indian Electricity Rules, so that the values of the step and contact potentials
in case of faults are kept within safe permissible limits.

Parts of all electrical equipment and machinery not intended to be alive shall
have two seperate and distinct earth connections each to conform to the
stipulation of the Indian Electricity Rules and apparatus rated 240 V and
below may have single earth connections.

Earthing mat consisting of earthing electrodes and cross connecting
conductor is already provided by the purchaser and tenderer has to connect
equipment earthing to the grid. Existing earth pits shall be renovated and
rusted materials shall be replaced with equivalent material and bimetal
washers shall be provided wherever GI strips shall be connected to existing
copper network.

For protective earthing separate conductor shall be used for flow of earth
fault current as elaborated below.

The LV side neutrals of the distribution transformers shall be connected to
two separate earthing electrodes. They shall also be connected with the
neutral bus of the corresponding switchgear and in turn switchgear neutral
bus shall be connected to the earthing bus of the switchgear. The protective
conductor for connection from switchgear earthing bus to MCCs/DBs and
further to motors shall be either through fourth core of cable or armouring of
cable. In case of armouring on cable, same shall be double steel wire
armouring. The fourth core or armour of cables and all conduits for cables
shall also be connected to the earthing mains. A continuous earth strip shall
run in each side of cable channel and in cable ducts and trenches.

All joints in the run of the main earthing conductors will be welded or brazed

UNIT # 1 TO 6 (6x60 MW)


type. Connection to equipment structure shall be bolted type.

Conductor sizes for earth connections :

High voltage systems - 75 x 5 mm GI flat for :

- Transformers

- Earthing resistors

- Earthing leads to earth electrodes.

LT system where the voltage does not exceed 650V normally :

- 6 Sq.mm Stranded GI wire for :

- Motors and starters upto and including 2.2kW, shunt limit switches,
push buttons and master controllers, Light fitting,JBs,PBs, etc.

- Instruments and miscellaneous small items protected by fuses of
ratings not exceeding 15A.

- 16 Sq mm Stranded wire for :
Motors and starters above 3.7 kW and upto and including 15
kW.

25 x 3 mm GI flat for:

Motors and starters above 15 kW, and upto and including
45 kW
Control desks, cabinets, LCB, socket outlet isolators,
SLDBs/DBs.
50 x 6 mm GI flat for :

Motors and starters over 45 kW
Switchboards, MCC,PDB,PCC MLDB.

UNIT # 1 TO 6 (6x60 MW)


50 x 6 mm GI flat (minimum) for :

Main earthing ring in plant buildings
LT transformer neutral
LT Switchboards and other equipment protected by circuit
breakers.

Sheet metal enclosed panels control desks and boxes

The base frames of all panels, desks, posts etc., shall be welded to
structures or to the civil inserts provided on the floor/walls. Fabrication of
supports/frames, wherever required, shall be done by the tenderer.

The shipping section shall be placed in position before removing the
protective covering to eliminate scratch/damage. The shipping section shall
be moved by using rollers under the shipping skids wherever lifting cranes
are not available. The contractor shall do the assembly at site as per
manufacturer's general arrangement drawings and installation instruction.
While assembling a complete board comprising several unit type cubicles,
the board as a whole shall be aligned. The panels shall be properly levelled
prior to grouting the holding down bolts or welding the panels to the inserts.
All interconnection of busbars and wiring between the panels shall be done
as per manufacturer's instructions and drawings. Welding work on the
panels shall only be carried out after consultation with the purchaser.
Damage to the paint due to welding shall be rectified by the contractor.

Transformers
The transformer and its accessories and mountings like radiators,
conservator, thermometers, silicagel breathers, marshalling box, rollers etc.,
delivered at site in separate packages, shall be assembled at site after
cleaning by the contractor in proper sequence as per manufacturer's
drawings.

Jacks shall never be placed under valves or cooling tubes.

UNIT # 1 TO 6 (6x60 MW)


Suitable stopper shall be provided both in front as well as rear of transformer
to keep the transformer stationary in its position.

The oil conservator and the pipes shall be erected as shown in the
manufacturer's drawings. All radiator tubes shall be cleaned before
installation.

Before the transformer is filled/topped with oil, oil samples shall be checked
by the tenderer from each container. The oil shall possess the dielectric
strength as per relevant IS. Oil shall be filled upto the mark shown.

The contractor shall also test the oil from each transformer to determine its
suitability for use. If required, the contractor shall carry out drying and
filtering operations as per IS code of practice to ensure that moisture is
completely removed and the oil is free from impurities. This may be carried
out by using oil filtering equipment to be provided by the tenderer having
vacuum as well as heating arrangement. Only after the dielectric strength of
oil and other parameters are checked and approved, the external
connections shall be made to the transformers.

The dial thermometers shall be screwed to the thermometer pockets after
removal of the blind plugs.

All necessary cabling shall be connected before charging of the transformer.
This will include signalling cables upto marshalling box and from marshalling
box to meters, if not already done.

Any modifications to HT and LT terminal box to accommodate the number of
cables or bus duct to be terminated shall be carried out by the contractor.
Naked light and flame shall never be used near the transformer. Instructions
given by the manufacturers erection & commissioning manual shall also be
followed.

Busbar
Busbar installation shall be commenced from the middle section and the
buses shall be fastened without tightening the bolts. The buses shall lie
freely on the insulators without warping and if necessary, suitable packing

UNIT # 1 TO 6 (6x60 MW)


shall be provided at the insulators.

Final tightening of the bolts shall be done after the complete laying of buses.
Approved means shall be used for tightening of the bolts.

Bimetallic strips/washers shall be used wherever aluminium busbars or
aluminium cables are terminated on copper busbars.

Limit switches
The places of installation shall be seen from the engineering drawings and
the switch shall be secured by means of adjustable bars. Any modifications
required in positioning of limit switches as per site conditions shall be done
by the tenderer.

Miscellaneous equipment

Cables Installations
Cable shall be fixed to racks or trays or cleats as required for proper
support, accessibility and neatness of installation. Cable tags shall be
provided at a regular interval of 30M. For cable run shorter than 30M one
cable tag shall be provided in the middle. These tags shall be in addition to
end cable tags. The cable tags shall be marked with cable number, size and
voltage grade. Middle tag shall be indicated with destination. The end tag
shall be with second terminal point.

Cables shall be clamped rigidly at an interval of not more than 1500 mm in
horizontal,and 1000 mm in vertical & inclined run and at bends.

In the cable galleries, cable structures shall be properly arranged giving
sufficient clearance for movement of personnel from one part of the gallery
to the other. It shall also be possible to escape easily in case of fire.

Cables laid in over ground structures shall be protected from the direct solar
radiation. Road crossing points sufficient clearance shall be provided with
due consideration to road traffic. In outdoor structure cat ladder and
walkable platform shall be provided to facilitate cable removal/addition on
the cable trays.

UNIT # 1 TO 6 (6x60 MW)


Perforated trays shall only be used where necessary for the support of a
number of small cables. Each tray shall be firmly supported at suitable
intervalsand shall carry the weight of its cables without sagging. Trays shall
be painted and where the surfaces or edges are cut or otherwise impaired
during erection, they shall be made good by coating with aluminium paint.

Small cables may be bunched together under one saddle provided that in
any bunch all cables have sheaths of the same material. The number of
cables shall not exceed four wide and two deep.

Not more than one cable shall be drawn into one conduit unless otherwise
agreed. After the cable has been drawn in, the conduit shall be sealed by an
approved means.

All cables shall be tested for proper insulation before start of laying work.

Cables shall be laid in conduits, racks/trays, cable trenches, along with
structures or buildings, as per cable routing drawing and cable list.

Suitable adjustment shall be made in cable routes, if required at site, with a
view to avoid any interference with any part of building, structures,
equipment, utilities and services with the approval of the purchaser.

While laying cables, care shall be taken that kinks, twists or mechanical
damage do not occur to the cable.

All bends in cables shall be made with due consideration to the minimum
permissible bending radius of the cables.

On being pulled, the cable shall not be allowed to drag drawing along the
ground or over a second cable already laid. Special care shall be taken
while pulling through an opening where other cables have already been laid.
Only approved cable pulling devices shall be used.

No joints shall normally be made at any intermediate point in through run of
cables unless the length of the run is more than the standard drum length. In

UNIT # 1 TO 6 (6x60 MW)


such cases where jointing is unavoidable, the same shall be made inside
proper bases having plastic moulds and shall have moulded epoxy resin
construction. Provision shall be made for earthing continuity at the joint.
Cable splicing and jointing shall be done in accordance with the relevant IS
code of practice and manufacturer's instructions. Insulation resistance of
cables shall be checked before cable jointing.

Adequate length of cables shall be pulled inside the switch boards, control
panels, control desks, etc. so as to permit neat termination.

All cables shall be neatly dressed without interlocking or cross over. While
laying the cable vertically, these shall be clamped at suitable intervals.
Horizontal runs shall be rigidly secured to trays on racks/hangers in all the
places where the direction of the route changes as well as at cable
terminations or joints. The clamps shall not be done up so tight that the
insulation is damaged or deformed.

Cable markers shall be provided on either side of road crossing at each
turning and at 30 m intervals at straight runs for underground cables.

Where cables are required to cross roads, surface drains and water, oil, gas
or other pipe lines, they shall be taken through reinforced spun concrete or
steel pipes.

Entry of cables from underground to the buildings or trenches shall be
through pipe sleeves. After laying of cables, the sleeves shall be sealed
with bitumin or epoxy compound with sand matting and cement plaster to
make them fully water tight.

Special consideration shall be given for protection of cables against
chemical and mechanical damage.

All cable entry openings in the equipment shall be sealed with fire proof
materials. All cable openings in walls and floors shall be sealed after laying
of cables by water and fire proof materials.

UNIT # 1 TO 6 (6x60 MW)


All cables shall be provided with identification tags indicating the cable
number in accordance with cable lists. Tags shall be fixed at both ends of
the cable and at 30 m spacing for straight runs as well as on both sides
wherever cables are crossing walls/floors. The tags shall be of
aluminium/PVC with numbers punched/painted on them and securely
attached to the cables by non-corrosive wires. The shape of tags shall be
round, triangular and rectangular for control, medium voltage and high
voltage cables respectively.

Glanding shall be done for direct entry of both power and control cables into
the panels by the contractor. Double compression type brass cable glands
shall be used.

The cables shall be terminated in accordance with relevant connection
diagram. Termination and clamping shall be carried out in such a manner as
to avoid strain on the terminals.

All power cable terminations shall be by means of crimping type cable lugs.
For flexible conductors, soldered termination shall be adopted. In case of
aluminium power cables termination on copper bus bars, suitable aluminium
copper bimetallic washers shall be used. Corrosion inhibiting grease shall be
used for aluminium cable terminations.

Suitable numbered and coloured letter interlocking type ferrules shall be
provided for end termination of power and control cables.

Control cable entering switch boards, control panels, control desks etc. shall
be neatly bunched and strapped with PVC perforated straps and suitably
supported to keep it in position at the terminal blocks. All spare cores of
each cable shall be segregated, marked spare, neatly dressed and suitably
taped at both ends.

When the cores of two or more multicore cables take a common route, cores
of each cable shall be separately bound and the separate bundles neatly
bound together.

Individual cores of control cables shall have plastic interlocked type coloured

UNIT # 1 TO 6 (6x60 MW)


ferrules with engraved numbers at both ends of the circuit for identification.

The contractor shall be responsible for correct phasing of motor power
connections and shall interchange connections at the motor terminals box, if
necessary, after each motor is test run.

The trays shall be earthed and rendered electrically continuous by welding
the trays to the grounding strip at not less than two places from both sides of
the tray.

Exposed conduits
Exposed conduits shall be laid along walls, floors, ceilings, on steel supports
etc. as per working drawings/site requirements in consultation with the
supervisory personnel. The conduits shall be neatly run and evenly spaced.

Fixing of conduits to the supports on wall, column, structure shall not be
done by welding. Exposed conduits shall be adequately supported by racks,
clamps, straps etc.
Jointing of conduits shall be done only in straight portion and not in bend
portion.

The contractor shall have available at site bending facilities for conduits as
well as dies for threading conduits of diameters and threads corresponding
to the standards. The threaded ends of conduits shall be painted with
anticorrosive paint. The outer ends shall be smoothened free of burrs and
sharp edges. Sealing shall be at both ends of conduits.

Flexible metallic conduits shall be used for termination of connections to
motors and other electrical equipment like pressure switches etc. which need
to be disconnected at periodic intervals.

All conduits shall be effectively connected to the earth terminal of the
equipment where it terminates.

Both ends of conduits shall be suitable earthed. Earthing continuity to be
maintained by means of flexible wire wherever two conduits are joined with
sockets.

UNIT # 1 TO 6 (6x60 MW)


Approved conduit bending machines to be arranged by the contractor shall
be used for bending conduits in the field. The radius of any conduit bend
shall be as per standards for cabling. Bends shall be free from cracks,
crimps or other damage to the pipe or its coating.

04.15. OVERHAULING OF 1000 kVA, 11/0.415kV TRANSFORMER

2 Nos. 1000kVA, 11/0.415 kV transformer shall be overhauled and reused
as Station Auxiliary Transformers.

Before dismantling of transformer, oil shall be drained and handed over to
the Owner in Owners container.

04.15.01 The following work are to be carried out during overhauling of the
transformers to enhance the life of transformers for trouble free operation
in future.

04.15.01.01 Core and Winding
Core and winding shall be retained

04.15.01. 02 Bushing

All the bushings of the transformer shall be retained however all the
connectors shall be replaced.

04.15.01.03 Off-Circuit Tap Switch

Off Circuit shall be refurbished.

04.15.01.04 Tank, Radiator & Conservator

Cleaning of tank, radiator and conservator shall be done. Oil leakage shall
be completely sealed to prevent any loss of oil. Also ingress of moisture
into the tank shall be stopped.

UNIT # 1 TO 6 (6x60 MW)


Painting

The primers and finishing paint shall conform to latest Indian Standard or
equivalent International Standard.

Surface preparation shall be done properly.

Colour of finished painting shall be dark admiralty grey shade 632 of IS :5
(Epoxy based). The colour scheme, however, may be changed, if
necessary, by the purchaser at any stage before start of the painting of the
equipment.

A single coat paint when dry shall have minimum thickness of 25 to 30
microns.

Total thickness of 4 coats (2 Primer + 2 Finish) shall be 100 to 125
microns.

04.15.01.05 Pressure Relief Device

Pressure Relief Device shall be provided in place of Explosion vent of the
transformer.

04.15.01.06 Dehydrating Breather

Dehydrating breathers shall be replaced.

04.15.01.07 Pipes, fittings, Gaskets and valves

All pipes, valves and fittings shall be replaced by new one. All gaskets
shall be replaced with new neoprene gaskets.

04.15.01.08 Marshalling Box

Refurbishment of marshalling box, junction boxes etc. including
replacement of contactors, switch fuse units, terminal blocks etc shall be

UNIT # 1 TO 6 (6x60 MW)


carried out. Rewiring of all the cabinets/ boxes shall be done. All the
connecting clamps, cable lugs, ferules, cable markers, push buttons etc.
shall be replaced.

04.15.01.09 Oil

Transformer Oil as per IS: 335 1983 (with latest Amendment 1 & 2) shall
be replaced. 10% excess oil shall be provided by Contractor.

04.15.01.10 Other Accessories

All accessories like OTI, WTI, magnetic oil level gauge, Buchholz relay etc.
shall be replaced.

All the nuts & bolts, washers, valves, door locks etc. shall be replaced by
bidder.

Earthing strips shall be replaced.

Transformer specifications of some of the major items which are to be
replaced during overhauling are given in section 4.2 and shall be followed

04.15.02 General Technical Specification

Electrical Design

- Generally as IS 2026.

- Rated output, voltage ratio, vector group shall be as specified in
original design.

- The oil used shall be transformer oil confirming to IS 335 1983 (with
latest Amendment 1 & 2)

- Rated frequency 50 Hz, + 3%, - 5%.

UNIT # 1 TO 6 (6x60 MW)


Buchholz Relay

- Double float relays as per IS 3677.

- 50 mm diameter of connecting pipe for transformers and shall have
minimum number of bends.

- Shut off valves on either sides of the buchholz relay.

- Pot cocks at the top and bottom of relay drain plug, inspection window,
calibrated scale, terminal box with oil tight double compression type
brass galnd.

- Potential free, self reset independent alarm and trip contacts rated to
make, break and carry 2 amps at 110V DC. No auxiliary relay shall be
used to multiply the contacts. Contacts are to be wired to the
marshalling box.

Valves and connections

- Valves of sluice type hand wheels.
- Made of gun metal

- Clear indication of open and closed position.

- Provided with blanking plates or screwed plugs.

- Padlocking facility to lock in closed/ open position.

Oil temperature Indicator

150 mm dial type thermometer with manual reset maximum reset maximum
reading pointer. There shall also be two potential free contacts for alarm
and trip signals. The alarm and trip setting shall be independently
adjustable. The temp. sensing element mounted in a pocket of oil, shall be
connected to the indicator through capillary tubing. Contact rating at DC

UNIT # 1 TO 6 (6x60 MW)


shall be minimum 0.5 amps.

Winding temperature

Local winding temperature indicator (WTI) shall have a 150 mm diameter
dial type indicator with a manual reset max. reading pointer. There shall be
two potential free contacts for alarm and trip signals. The setting of closing
/ opining of each contact shall be independently adjustable. Contact rating
at 110V DC shall be minimum 0.5 amps. The device shall be complete
with lamp, sensing element, image coil, calibration device etc. as required.

Remote winding temperature indicator with resistance type temperature
detector shall be provided additionally.

Earthing

- All metal parts of the transformer with the exception of individual core
laminations, core bolts, and clamping plates shall be maintained at
fixed potential by earthing.

- Two tinned earthing terminals.

Painting

Dark admiralty gray shade 632 of IS : 5 (Exposed based).

Refurbished Transformer shall fulfil following design criteria.

Insulation level shall be according to the voltages specified below.

Nominal System voltage 11 kV 0.433 kV

1) Max. system voltage (kV) 12 kV 1.1 kV

2. One minute power 28 kV
frequency withstand

UNIT # 1 TO 6 (6x60 MW)


voltage (kV)

3. Peak impulse test 75 kV
withstand voltage (kV)

- Transformers shall be capable of delivering rated current at an
applied voltage upto 105% rated voltage without exceeding the
temperature limits.

- Overload capacity as per IS 6600 - 1972 unless otherwise specified.

- Shall be operable at its rated capacity at any voltage within + 10%
of rated voltage of the particular tap.

- Permissible maximum temperature at rated output and principal tap
Ambient temperature of 45 deg. C

a) Top oil (by thermometer) : 85 deg. C

b) Windings (by resistance : 95 deg. C
method)

c) Maximum hot spot temp. : 98 deg. C

- Transformers shall withstand the thermal and dynamic stresses due to
short circuits at its terminals. Unless otherwise specified the duration of
short circuit shall be 5 seconds.

- The max. temperature at the end of the specified duration shall not be
more than 250 deg. C with the temperature prior to short circuit
corresponding to maximum permissible overload.

04.15.03 Erection of Transformers

Jacks shall never be placed under valves or cooling tubes.

UNIT # 1 TO 6 (6x60 MW)


Suitable stopper shall be provided both in front as well as rear of
transformer to keep the transformer stationary in its position. For the front
wheels such stoppers shall be screwed on the rails.

The oil conservator and the pipes shall be erected. All radiator tubes shall
be cleaned before installation.

Before the transformer is filled/topped with oil, oil samples shall be
checked by the contractor from each container. The oil shall possess the
dielectric strength as per relevant IS. Oil shall be filled upto the mark
shown.

After filling oil in tank up to required level, it shall be filtered till moisture
content within permissible limit as per IS and dielectric strength as per IS
achieved.

Empty oil drums shall be handed over to Owner.

Filtration M/c, vacuum pump and heating arrangement, if required, shall be
arranged by contractor.

The dial thermometers shall be screwed to the thermometer pockets after
removal of the blind plugs.

All necessary cabling shall be connected before charging of the
transformer. This will include signalling cables upto marshalling box and
from marshalling box to meters, if not already done, as well as inter-cabling
between surge suppressor cubicle and transformer secondaries.

11kV and 0.433 kV terminal connection shall be done to form delta and
star connection respectively.

All neutral points shall be connected to earth grid.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

TS VOL IV Sec. A Ch 05 Page 1 of 17

05. INSPECTION AND TESTING

05.01 Inspection

05.01.01 General

Manufacturing progress review, inspection & testing of equipment covered under
the technical specification shall be carried out by the Purchaser at the
manufacturers' works/premises prior to despatch to ensure that their quality &
workmanship are in conformity with the contract specifications and approved
drawings.

These instructions are in addition to provisions laid down in other tender
documents of the Purchaser.

05.01.02 Inspection & testing stages and finalisation of quality assurance plan (QAP)

Within 12 weeks of the award of contract the Contractor shall furnish the quality
assurance plan as per proforma given to successful tenderer for electrical
equipment. separately with suggestive stages and hold points for undertaking
inspection and testing by the Purchaser/Consultant. Total list of plant &
equipment of the order shall be submitted to the Purchaser/consultant prior to
submission of QAP

After receipt, scrutiny and rendering into acceptable mode of above documents,
a mutually agreed programme of inspection & testing of equipment shall be fina-
lised with the Contractor by the Purchaser/consultant.

Inspection & testing of plant & equipment shall be undertaken by the
Puchaser/consultant after finalisation & approval of QAP.

05.01.03 Responsibility for inspection

Any inspection by the Purchaser does not replace the responsibility of quality
assurance and quality control functions, as expected of the Contractor to be
performed by him for supply of plant & equipment as part of the contractual
obligations. As such, any approval which the Inspecting Engineer of the
Purchaser may have given in respect of plant and equipment and other
particulars and the work or workmanship involved in the contract (whether with
or without test carried out) shall not bind the Purchaser to accept the plant and
equipment, should it on further test at site be found not to comply with the
requirements of the contract.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

The Contractor is to meet the inspection & testing requirements for the
equipment coming under statutory regulations e.g. weights & measures, safety,
IE rules, etc. and submit certificates and documents from appropriate authority to
Inspecting Engineer for the same.

05.01.04 Extent of inspection

The extent of inspection & testing by the Puchaser shall vary from equipment to
equipment as per design requirements.

However, indicative extent of inspection for electrical equipment is furnished
below.

Extent of inspection to be carried out shall be finalised withthe Contractor after
award of the contract on the basis of scope of supply, technical specification and
approved GA drawings. However, in case of similar bulk manufactured items,
methods of sampling for inspection of different lots shall be governed by relevant
Indian or international standards.

In case of critical components, the Purchaser reserves the right to undertake
100% inspection.

Extent of Inspection
Categories of (as applicable from
Equipment equipment to equipment)
------------- -----------------------

i) Bought-out items Following standard bought-out items shall be
accepted on the basis of manufacturers' test certificates:

- LV current transformers

- Standard AC motors

- AC /DC DBs

- Push button station in manu-facturers'
standard enclosure

- LT power, control & instrumentation cables
and cable termination / jointing kits

- Starters in manufacturer's standard
enclosure

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET


- Light fittings

- Field instruments

- Conduits

- Cable trays

ii) Final inspection & testing:

- Verification of test certi-ficates
- Visual & Workmanship
- Dimensional
- Witnessing of routine tests as per relevant
standards. Manufacturers' test certi-ficates
for type test to be submitted for verification.
- Witnessing of proto-type tests, as
applicable.

05.01.05 Tests, test certificates and documents

For each of the items being manufactured, following test certificates and
documents (as applicable for each of the equipment) in requisite copies shall be
prepared and submitted to the Inspecting Engineer for scrutiny & records.

i) Materials identification & physical and chemical test certificates for all
materials except IS:2062 -1992 and FG 150 IS:210-1978 materials used
in manufacture of the equipment.

ii) Welding procedures and welder's qualification test certificates, wherever
applicable.

iii) Routine/type/calibration/acceptance/special test certificates for electrical
items.

iv) Surface preparation and painting certificates.

v) Certificates from competent authority for the items coming under statutory
regulations.

The Contractor shall be required to produce the specimen and test pieces on
which tests were carried-out by his sub-contractors and if called for, samples
and specimen shall become the Purchaser's property.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET


Where facilities for testing do not exist in the Contractor/sub-contractor's
laboratories or in case of any dispute, samples and test pieces shall be drawn by
the contractor/sub-contractor in presence of Inspecting Engineer and sealed
samples shall be sent to any approved laboratories for necessary tests at
Contractor/sub-contractor's cost.

The Purchaser/consultant shall have the right to be present and witness all
tests being carried out by the Contractor/sub-contractor at their own laboratory
or approved laboratories. Also, the Purchaser/consultant shall reserve the right
to call for conformatory test on samples, at his discretion.

Should the result of tests not come within the margin specified, the tests shall, if
required, be repeated at Contractor's cost without any liability to the Purchaser.

05.01.06 Method of giving inspection calls

Inspection calls shall be given by the Contractor. All calls shall accompany four
sets of relevant test certificates and inspection report of the
Contractor/sub-contractor after satisfactory completion of internal inspection and
tests by them as per approved QAP.

05.01.07 Obligations of the Contractor

The Contractor shall provide all facilities and ensure full and free access of the
Inspecting Engineer of the Purchaser to the Contractor's or their sub-contractor's
premises at any time during contract period, to facilitate him to carryout
inspection & testing of equipment during manufacture of equipment.

This clause shall be read along with Vol.I for further details.

05.01.08 Stamping and issue of inspection memo & certificate & waiver

05.02 Testing

05.02.01 General

Test of all equipment shall be conducted as per latest IS. Tests shall also
confirm to International Standards IEC/VDE/DIN/BS.

All routine tests shall be carried out at manufacturer's works in presence of
purchaser or his representative.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET


The tenderer shall submit type test certificates for similar equipment supplied by
him elsewhere. In case type test certificates for similar equipment is not
available, the same shall be conducted in presence of purchaser or his
representative if purchaser so desires, without any financial implications to pur-
chaser. Heat run test shall be conducted in one of HT transformer. Special Test
on FRLS cables also to be carried out.

The site tests and acceptance tests to be performed by contractor are detailed
below.

The contractor shall be responsible for satisfactorily working of complete
integrated system and guaranteed performance.

05.02.02 Site Tests And Checks

General

All the equipments shall be tested at site to know their condition and to prove
suitability for required performance.

The test indicated in following pages shall be conducted after installation. All
tools, accessories and required instruments shall have to be arranged by
contractor. Any other test which is considered necessary by the manufacturer of
the equipment, contractor or mentioned in commissioning manual has to be
conducted at site.

In addition to tests on individual equipment some tests/ checks are to be
conducted / observed from overall system point of view. Such checks are
highlighted under miscellaneous tests but these shall not be limited to as
indicated and shall be finalised with consultation of client before charging of the
system.

The contractor shall be responsible for satisfactory working of complete
integrated system and guaranteed performance.

All checks and tests shall be conducted in the presence of client's representative
and test results shall be submitted in six copies to client and one copy to
Electrical Inspector. Test results shall be filled in proper proforma.

After clearance from Electrical Inspector system/ equipment shall be charged in
step by step method.

Based on the test results clear cut observation shall be indicated by testing

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

engineer with regard to suitability for charging of the equipment or reasons for
not chargings are to be brought by the contractor.

05.02.03 Site Tests

The tests to be carried out on the equipment at pre-commissioning stage shall
include following but not limited to the following :

1.0 Transformer

1. IR test on each winding to ground and between windings.

2. Turns ratio test on each tap

3. Polarity and vector group test

4. Measurement of winding resistance by Kelvin bridge

5. IR, wiring and operational tests on all control devices in control cabinet,
oil level indicator, winding and oil temp. indicators, cooling fan etc.

6. Checking of earthing wrt transformer tank (flexible from top cover to tank)
other parts, neutrals and tank to electrodes of LAs (for LAs located near
to transformer)

7. Testing of buchholz relay for alarm and trip conditions.

8. For bushing CTs, tests applicable shall be as for current transformers.

9. Setting of oil/winding temperature indicators, level gauge and checking of
alarm/trip circuits.

10. Check insulators for cracks.

11. Checking for oil leakage and arresting of leakages (if there)

12. Checking of operation of all valves.

13. Checking for open position of all the valves (except drain and filter valves)

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

14. Filteration of oil by using line filter, vacuum pump, and heater set.

15. BDV test on oil samples from top and bottom.

16. Checking of oil for acidity, water content tan delta etc. as per IS 335.

17. Measurement of magnetising current and no load loss.

18. Measurement of PI value.

19. Checking of silicagel breather.

20. Checking of noise level at no load and at full load.

21. Checking of air circulation conditions for indoor transformers.

22. Conducting magnetic balance test

23. Checking of other points given in manufacturer's commissioning manual.

24. Back charging of the transformer and checking of voltages at different tap
positions.

2.0 220 kV CIRCUIT BREAKER

1. IR test on each pole by Megger (Between poles and lower poles to
ground).
2. IR tests on control circuits.
3. Functional check of breaker operation on minimum and maximum
specified control voltages
4. Checking of interlocks with isolators & earthing switches.
5. Checking of remote operation and tripping from protection relays and
from other devices as per approved scheme.
6. Measurement of contact resistance
7. Checking tightness of termination connectors.
8. Checking tightness of earthing connections.
9. Checking of insulators for cracks etc.
10. Checking the settings of pressure switches.
11. Check operation of breaker at minimum specified pressure.
12. Check for closing and opening time and simultaneous closing of all poles
through oscillograph
13. Tripping of circuit breaker at reduced or over voltage i.e. at 70% & 110% .

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

3.0 220 kV ISOLATOR & EARTH SWITCH

1. IR test by HV Meggar on main poles.
2. IR test on control circuits.
3. Measurement of contact resistance for all three phases.
4. Functional checking for electrical and manual operation.
5. Checking of interlocking with breakers
6. Setting and checking of auto trip operation of motor on complete close /
open position of isolator (close/open operation are to be repeated ten
times to observe).
7. Testing of overload relay of motor
8. Checking for remote operation.
9. Checking of operation on minimum and maximum specified voltages
(local as well as remote).
11. Checking of insulators for cracks.

4.0 198 kV ARRESTOR

1. Continuity check (for metal oxide type only)
2. Check for connection to ground.
3. Check insulators for cracks.
4. Check working of counters
5. HT and IR test of each element

5.0 Current Transformer

1. IR test on each winding, winding to earth and between windings.

2. Checking of winding ratios by primary injection set.

3. Polarity check on each winding.

4. Continuity check for all windings.

5. Check for connections to correct taps.

6. Measurement of knee point voltage and secondary winding resitance for
the CTs used for differential protection.

7. Checking of continuity and IR values for cables from CT to Marshalling
box.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET



9. Check output after loading of the main circuit.

6.0 Potential Transformer

1. IR test of primary winding by HV megger between windings and earth

2. IR test of secondary winding by LV megger between windings and
winding to earth

3. Checking of voltage ratio

4. Verification of terminal markings and polarity

5 Checking of continuity and IR values for cables from PT to Marshalling
Box

6. Checking tightness of earthing connections

7. Checking of insulator for cracks

8. Check output on charging of the system with connected meters/relays

7.0 N G T
1. Measurement of resistance

2. IR test by HV megger between terminal and earth.

3. Checking of earth connection for terminal and for body

4. Check for isolator operation and continuity of aux. contacts (if applicable)

5. Check for temp. rise of enclosure and current flow in the resistances.

8.0 Bus duct

1. IR measurement before and after HV test
2. Checking tightness of bolts with torque wrench
3. Checking for phase sequence marking

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

4. Check for clearances between phase to phase and phase to earth
5. Check for minor damages/cracks in supporting insulators/bushings
6. Checking of busbar cracks on bends by DP method and rectification of
same
7. Checking for inspection openings/accessibility for replacement of
insulator etc.
8. Check tightness of earthing connections on enclosure
9. Checking of silica gel breather
10. Checking of working of space heater (if there)
11. Hot air blowing to remove moisture if required

9.0 HT Switchgear

1. IR test before and after HV test.

2. HV test with HV testing kit.

3. Functional test for all feeders

4. Testing and calibration of all meters

5. Checking and calibration of overload relays and protective relays as per
supplier's commissioning manuals.

6. Check operation of contactors from local and remote points

7. Checking of interlockings between incomers/bus coupler and other
feeders.

8. Test to prove interchangeability of similar parts

9. Tests to prove correct operation of breakers at minimum and maximum
specified control voltages.

10. Checking operation of RC circuit (if there) for tripping of circuit breaker
after disappearance of control voltage

11. Checking of earthing connection for neutral-earth bus, cable armour,

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

location of E/F CT etc. as per the scheme.

12. Check test, service and drawout position of all the breakers and
operations of mechanical flag indicator and electrical indication lamps.

13. Check functioning of various elect. schemes like autochangeover
signalling etc.

14. Contact pressure test

15. Testing of CT as per CT testing details given below.

16. Breaker : IR value checking with breaker ON.
Phase to phase & phase to earth
and between phases in off position

10.0 LT Switchgear/MCC

1. IR test

2. HV test with 1.1 kV megger

3. Functional test for all feeders

4. Testing of all meters

5. Checking and calibration of overload relays and protective relays as per
supplier's commissioning manuals.

6. Check operation of contactors from local and remote points

7. Checking of interlockings between incomers/bus coupler and other
feeders.

8. Test to prove interchangeability of similar parts

11.0 PDB/DCDB

1. IR test before and after HT test

2. HV test by 1.1 kV megger

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

3. Checking for functions of components for each module

4. Checking for interchangeability of similar components

5. Checking of tightness of earth connection.

6. Testing and calibration of all indicating meters

7. Check output of each feeder after energisation.

12.0 AC Motors

1. IR test of stator and rotor windings.

2. Check tightness of cable connection

3. Winding resistance measurement of stator and rotor.

4. Check tightness of earth connections.

5. Check space heaters and carryout heating of winding (if required)

6. Check direction of rotation indecoupledcondition during kick start

7. Measure no load current for all phases.

8. Measurement of temperature of body during no load and load conditions.

9. Check for tripping of motor from local/remote switches and from
electrical/technological protection including differential protection.

10. Checking of vibration.

11. Checking of noise level.

12. During load running , measurement of stator and bearing temperatures (if
applicable) for every half an hour interval till saturation comes.

13. Checking tightness of foundation bolts

14. Check continuity of temp. detectors.

15. For actuator drives following shall be checked/tested :

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

- Visual and dimensional
- IR and operation of limit switches
- Winding resistance

13.0 Battery

1. Checking for completion of civil/ventilation requirement of battery room.

2. Checking of adequacy of charger output/requirement wrt current required for
battery charging as per the manual.

3. Check availability of safety devices, water and first aid box.

4. Check polarity of connections between battery and charger.

5. Visul inspection test for level and leakages.

6. Checking of layout as per approved drawing.

7. Checking of IR value from positive to earth and negative to earth.

8. Checking of voltage per cell and total voltage between positive negative and
earth to positive/negative and also tap call voltage (as applicable).

9. Checking of tightness of connectors on each cell.

10. Checking of capacity test and hourly measurement of specific gravity and
voltage for each cell

14.0 Battery Charger

1. IR test

2. HV test

3. Checking voltage ratio of boost and float mode transformers

4. Checking for charging mode of batteries, constant current and constant
voltage mode.

5. Load test on chargers by running of DC drives and by liquid resistance
system.

6. Checking of tightness of earthing connections.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET


7. Check for all alarm conditions.

8. Checking and calibration of all indicating meters.

9. Check functional operation of charger, auto/manual change over from float to
boost and boost to float etc.

10. Checking and setting of all relays

11. Check AC ripple in boost and float mode after charging.

12. Check polarity of cables connected to battery.

15.0 UNINTERRUPTED POWER SUPPLY

1. Visual check

2. IR value by megger

3. Current limit test

4. Ripple test

5. Supply variation

6. Functional test

5. Capacity test wrt time

16.0 Cables & Cables Supporting Structures

1. Checking of continuity/phasing and IR values for all the cables before
and after HV test.

2. HV test and measurement of leakage current after termination of cable
kits (for HT cables).

3. Checking of earth continuity for armour and fourth core (if applicable).

4. Check for mechanical protection of cables.

5. Check for identification ( tag numbr system) distance placement of cable
marker, cable joint etc. as per the cable layout drawing.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET


6. Check earthing of cable structures.

7. Check clearances from ventilation duct and light fittings for cable
structures.

8. Check proper fixing of cable structures.

14.0 Indoor Lighting

1. Check dressing of cable

2. Measurement of lux level at various places

3. Check accessibility for replacement of lamps

4. Checking for black spots or poor visibility near operating and indicating
equipments

5. Check for mechanical protection of cables

6. Checking for adequacy of emergency DC light

7. Checking for starting system of periphery lighting

8. Check for auto switching of battery supply on failure of AC

9. Checking of earthing of light panel, socket boards, light fittings

10. Checking of type of fittings wrt specification at various locations

11. Check adequacy of support of fittings

12. Check water tightness of outdoor located panels

15.0 Earthing

1. Check tightness of all earth connections

2. Check earthing of all metallic equipments, cable trays, busbar supporting
structures, yard fencing steel structures of yard, rails, gates, building
column (if steel) all elect. equipments, gas/oil/water pipe lines etc. as per

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

the drawing /specification

3. Measurement of earth resistance for each electrode.

4. Measurement of total earth resistance.

5. Measurement of earth loop resistance for E/F path of biggest LT drive.

16.0 Control, Relay & Metering Panels

1. IR value test by megger

2. Checking of control cable connection.

3. Operational test of all components mounted on control panel.

4. Testing and calibration of indicating meters

5. Testing of all relays including aux. relays for their pick up drop up values,
operation at all taps (current, voltage and time) etc. as per the
manufactuerr's commissioning manuals with the help of relay testing kits.

6. Setting of relays as per approved setting table and checking its operation
for one below and one upper settings, in the scheme.

7. Measurement of current and voltage in relay operating coils by secondary
injection in CT and PT circuit at switchboard.

8. Measurement of current and voltage in relay and meter circuits during
loading of the primary circuit/system

9. Testing of all schemes for their functions as per approved drawings

10. Checking stability of differential protection schemes

11. Checking inter changeability of similar equipments

12. Verification of accessibility of all operating points including resetting knob
of relays

13. Check operation of each annunciation facias, operation of bell/hooter etc.
and sequence of the system

14. Check operation of relays at minimum/maximum control voltage as per

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

the specification

15. Integrated testing of protective relays for operation of master trip relays
and tripping of breakers from operatin of master trip relay

16. Check dressing of cables, sealing of openings in gland plate and for
provision of double compression glands

17. Check earthing connection of panels, fixing of panels and openings from
side and bottom.

18. Checking and adjustment in trivector meters as per the manufacturer's
instructions.

17.0 Miscellaneous

1. Checking of continuity of the system

2. Checking of phase sequence from overhead line to consumer end

3. Checking safe accessibility of all operating points

4. Check availability of emergency lighting

5. Check availability of control/aux. supply

6. Ensure availability of first aid box, fire fighting equipments, earth
discharge rods, rubber mats, rubber glove

7. Check working of ventilation system for battery room - transformer room
etc.
8. Check proper covering of cable channels.

9. Placement of shock treatment chart, danger boards, provision of boards
indicating 'Man on Work, Do not switch ON', 'Do not switch OFF',
'EARTHED' etc.

10. Check proper dressing of cables, mechanical protection of cables,
placement of cable markers

11. Check sealing of all cable openings including conduit opening with fire
resistance material

12. Check sealing of all openings at bottom of elect. panels.

R&M WITH NEW TG SET

TS VOL IV Sec. A Ch - 06 Page of

06. LIST OF PREFERED MAKES

HT(11KV) SWITCHGEAR ABB/ AREVA/ BHEL/SIEMENS

TRANSFORMERS

a) GENERATOR TRANSFORMER *CGL/BHEL /KEC / TR / EMCO /
ALSTOM

b) LT Transformer BBL/CGL/ALSTOM/ KEC/EMCO
/ INDCOIL / VOLTAMP/TR

CURRENT TRANSFORMER AE /ABB/ JYOTI / KAPPA /
WSI/INDCOIL

POTENTIAL TRANSFORMER AE /ABB/ JYOTI / KAPPA / WSI /
INDCOIL

415V SWITCHGEAR L&T / SIEMENS / CONTROL &
SWITCHGEAR /GE (ALSTHOM) /
SCHNEIDER

MOTOR CONTROL CENTRES SIEMENS/BCH/GE-POWER / L&T /
C&S/ECC/ SWITCHING CCIRCUIT/
HCE/TECHNOCRATS/TECHNO-
COMMERCE/SEN & SINGH/M K
Engineers/POWER &
PROTECTION/ SCHNEIDER

LT CIRCUIT BREAKER, SIEMENS/ BCH/ DISTRIBUTION
BOARD GE(ALSTHOM)/ L&T/
C&S/ SCHNEIDER /
FULLY DRAWOUT SINGLE FRONT

UPS SIEMENS / HIREL / EMERSON/GE /
DB POWER CONTROL

SOLID STATE ANNUNCIATOR APLAB/ L&T/ ELECMECH/
PROCON/ MINILEC/ CONTROL-

R&M WITH NEW TG SET

AND DYNAMICS

NUMERICAL PROTECTION RELAYS SIEMENS/ ABB/ AREVA
FOR LT SYSTEM SCHNEIDER/ L&T(MM30)/ ASIDA

NUMERICAL PROTECTION RELAYS AREVA / SIEMENS / ABB / L&T
FOR HT SYSTEM

AUXILIARY RELAYS AREVA/ EASUN/ ABB/ L&T/
GE/ SCHNEIDER/ SIEMENS/
BCH/ ROCKWELL

AMMETER/ VOLTMETER/ AEP/ IMP/ MECO AE/GEC//
L&T WATTMETER/ VAR-
METER

VOLTAGE/ POWER/ CURRENT/ ABB/ AEP/ SIEMENS/
FREQUENCY/ ENERGY TRANSDUCER ELSTER / ADEPT

MOULDED CASE CKT BREAKER SIEMENS/ GE POWER/ L&T/
ABB/ SCHNEIDER/ BCH/
ANDE-RW YULE

INDICATING LAMP SIEMENS/ VAISHNO/ TECHNIK/
(CLUSTER LED TYPE)
BINAY/ J-AUER

HOOTER/ BUZZER/ BELL GETCO/ KHERAJ/ EDISON/
KAKKU

HT CABLES RPG/ UNIVERSAL/ CCI/
NICCO/ TORRENT CABLES/
INDUSTRIAL/ INCAB/
CRYSTAL/ UNIFLEX / ASIAN /
CRYSTAL

LT CABLES RPG/ UNIVERSAL/ CCI/
NICCO/ TORRENT CABLES /
INCAB/ CRYSTAL/ UNIFLEX/
POLYCAB/ FINECAB/ INCAB/
RADIANT/ KEI

CONTROL CABLE RPG/ UNIVERSAL/ CCI/

R&M WITH NEW TG SET

NICCO/ TORRENT CABLES/
INDUSTRIAL/ INCAB/
CRYSTAL/ UNIFLEX/
POLYCAB/ FINECAB/ INCAB/
RADIANT/ KEI/ SPECIAL/
DELTON/ CORDS/ CAPCAB

LOCAL PUSH BUTTON STATIONS SIEMENS/ L&T/ BCH/ BHEL/
C&S/ TECHNOCRAT/ B&C/
MEDITRON/ ELECTRO
FABRIC/ HCE/ SEN & SINGH
/TECHNO COMMERCE/
SWITCHING CIRCUIT/ VIJAY
SWITCHGEAR

LIGHTING FITTINGS PHILIPS/ GE/ BAJAJ/
(SV/MV/MH/FLUROESCENT/CFL) CGL/ WIPRO/ FLOROCRAFT

HIGH MAST TOWER BAJAJ/ BP PROJECTS/
PHILIPS/ CGL/ VENTURA

STREET LIGHT POLE

- OCTAGONAL TYPE BAJAJ/ BP PROJECTS/
PHILIPS/ CGL/ BMW

- TUBULAR TYPE ELECTRO STEEL/ QUALITY
STEEL/ CULCUTTA POLES &
TUBES/STEEL POLE
CORPORATION/ BMW/
JINDAL

HT CABLE JOINTING KITS & RAYCHEM/ 3M/ DENSONS// M
SEAL
TERMINATION KITS

CONTACTORS SIEMENS / ALSTHOM / L&T /
CGL / SCHINDIR/BCH/ABB

HT HRC FUSES AREVA/ DP/ S&S/ COPPER-
BUSSMAN

R&M WITH NEW TG SET

TEMPERATURE SCANNER JYOTI / APLAB/SYNTECH /
MASIBUS

HV BUSDUCT ECC (KOLKATA)/ STAR DRIVE
NOW KGS ENGINEERING LIMITED
(CHENNAI)/ ENPRO (CHENNAI)/
BEST & CROMPTON/ SIEMENS/
BHEL/ CONTROL & SWITCHGEAR

MCCB SCHNEIDER (MG)/ L&T/ ABB/
SIEMENS/ GE POWER CONTROL /
CONTROL & SWITCHGEAR/ BCH
/MDS( LEGRAND

MINIATURE CIRCUIT BREAKER SIEMENS/ L&T/ GE POWER
CONTROL/SCHNEIDER (PROTEC /
MG)/ STANDARD/INDOASIAN/
HAVELLS/ MDS (LEGRAND)/ ABB

LT SQUIRREL CAGE MOTOR ABB/ BHARAT BIJLEE/ CGL/ KEC/
LAXMI HYDRAULICS PVT LTD./
MARATHON/
SIEMENS/ ELGI/ JYOTI/ WEG

TERMINAL BLOCK EPCC/ ELMEX/ PHOENIX
CONTACT/ CONNECT WELL/
ESSEN DEINKI/ WAGO/
LAPP/ S&S/ HANSEL

MIMIC PANELS & ANNUNCIATION
PANELS L&T / ADVANI OERLIKON / GE
POWER CONTROL/ BHEL/ BCH/
TRANSRECT/ MINLEC/ TIRUPATI
ELECTRONICS/ ADVANCE POWER
CONTOL/ CONTROL DEVICES

Battery (Lead Acid) CHLORIDE (EXIDE) /AMCO /
STANDARD /HBL-NIFE (SABNIFE)/
AMAR RAJA

Battery Charger HBL-NIFE(SABNIFE)/ CHHABI
ELECTRICALS/DEBIKAY/
CALDYNE / AMAR RAJA/ HCE

R&M WITH NEW TG SET

Sl. No. Items Preferred Make
1 220 kV Breaker 1. BHEL
2. Alstom
3. CGL
4. ABB
5 TELK
2 220 kV isolator 1. S&S
2. ELPRO INTERNATIONAL
3. HIVELM
4. GR POWER, Hyderabad
3 198 kV Lightning arrestor 1. CGL
2. Elpro
3. Oblum
4. WSI
5. ABB
4 220 kV CT 1. BHEL
2. TELK
3. WSI/ALSTOM
4. AEP
5 220 kV PT 1. BHEL
2. CGL
3. TELK
4. WSI
6 Insulator/Bushing 1. WSI
2. MODERN
3. BHEL
7 HT Transformer 1. Crompton Greaves Limited
2. BHEL
3. Alstom
4. ABB
5. TELK
8 Control and relay panel 1. Siemens
2. ALSTOM
3. L&T
4. BHEL
5. ABB
9 ACSR Zebra conductor 1. APAR, Mumbai
2. Smita Conductors
3. Deepak Cables
4. Gupta Conductors
5. Alind Corporation

UNITS # 1 TO 6(6x60 MW)
R&M WITH NEW TG SET

TS VOL IV Sec. A Ch- - 07 Page 1 of 1

07. LIST OF SPECIFICATION DRAWINGS

For specification drawings refer Volume V.

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TS VOL IV Sec. A Ch - 08 Page 1 of 6
08. DRAWINGS/DOCUMENT TO BE SUBMITTED BY THE TENDERER

08.01 Drawings/Data alongwith tender

1. Scope of work with general description of the system and equipment offered
specifying the important features.

The description to be accompanied by single line diagrams, and equipment
layout to enable the Purchaser to have a proper appreciation of the equipment
offered and its operation.

2. Bill of Quantities ( unpriced ) in specified format, with division list of supplies
from foreign and indigenous sources.

3 Specific exclusions, if any, from scope of work.

4. Questionnaire as asked in Vol III for generator and Chapter-09 of this volume
duly filled-in.

5. List of deviations from technical specifications, if not included under individual
equipment in Chapter 04.

6. List of commissioning spares and consumables included with the main offer.

7. List of 2 years operation spares, recommended by the tenderer equipment wise
(unpriced), in addition to the mandatory spares asked by the purchaser.

8. List of special tools and tackles, test jigs and special instruments required for
operation and maintenance of generator static excitation system, AVR,
protection relays. For all other electrical equipment, individual list of special
tools and accessories required is to be furnished for each item.

9. Phase-wise requirements of power for construction, erection/testing activities.

10. Technical catalogues of equipment offerd.

11. List of total aux. drives for unit and common system including Air condition etc.
for main plant with kW rating, enclosure class, class of insulation, cable size,
frame size, duty cycle, places of control, rpm, type of drive (cage, slip ring etc.)
starting method, technological interlocking etc. in a format.

12. Construction/ Erection Plan.

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16. Electrical layout of Control Room and main plant indicating location of all LT
switchgears, LT transformers control/relay panels and main cable routes, cable
gallery, cable shafts, with equipment entry approaches etc.

17. Dimensional details & weights of each equipment offered (tentative)

18. Any other information tenderer feels to submit to understand the quotation in
complete.

Note : FAILURE TO COMPLY WITH ABOVE MAY BE ITSELF SUFFICIENT REASON
TO REJECT THE OFFER.

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08.02 Data/Drawings to be submitted by supplier after placement of order

08.02.01 GENERAL

- Name of co-ordinators with address, telephone/FAX numbers for all
sub-contractors, pertaining to electrical job.

- List of equipment/tools and manpower proposed to be arranged for
installation erection and site handling of the equipment.

- Name of site incharge with office/organisation and date of opening of site
office.

- Quality control manuals

- Detailed list of drawings and documents containing information on current
state of the project.

- Monthly progress report furnishing status of

Planning
Manufacture
Transport
Erection
Testing & commissioning

08.02.02 FOR APPROVAL

A. Calculations

1. Relay settings with calculations and graph for justification of all relay settings
(current, voltage and time).

2. Calculation to justify generator CT/PT parameters like VA burden, knee point
voltage etc. for all cores.

3. Calculations for Required battery capacities of the UPS system.

5. Calculations for voltage drop and short time rating of cables to prove adequacy
of sizes.

6. Calculation of resistance values of NGTR & kVA of earthing transformer.

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7. Calculation of lux levels of Control Room.

8. calculation w.r.t. generator busduct sizing, temp rise and insulator spacing

9. Calculations for short time withstand of transformers.

10. Capacity calculation of Battery and charger

B. Drawings and Documents

1. Single line diagram indicating transformers , breaker, CT/PT, all relays, meters,
LA, cable sizes, details of CT/PT ratio, VA burden, Vk value, type and make of
all relays, their range, nominal and short time ratings of breakers, busbars etc.
for all equipment.

2. Front view and GA diagrams for all panels.

3. Control and schematics drgs. for local/remote control/protection for each
equipment and drives.

4. Drive list.

5. Synchronisation schemes.

6. Auto change over arrangement

7. Logic diagrams for start/stop of various mechanism/drives

8. Lighting layout for Control Room and other areas. Type of fittings, wiring
arrangement, switching of fittings and single line diagram from board to fittings.

9. Details of protection logic (class A,B&C tripping) indicating list of electrical and
mechanical protection leading to tripping of turbine generator, field breaker etc.

10. Equipment Earthing layout drawing

11. Electrical equipment layout for all electrical premises.

12. Cable structure layouts with size of structures for gallery and cable channels of
different places

R&M WITH NEW TG SET

13. Sequence of inspection plan and despatch of materials to site.

14. List of drawings, numbering system, size, proposed date of submission (To be
submitted just after LOI).

For Information

1. Details of painting for all equipment

2. Bus wire arrangement for control/signal/annuncia-tion and heater supplies of
control panels and switch boards.

3. Cable schedule indicating type of cables, from to via. route, total length, size of
each cable and a final summary sheet indicating total requirement of all types of
cables (for control and power both).

4. Core wise control cable termination details indicating ferrule no./terminal block
no. for each cable/each equipment.

5 .Internal wiring diagrams for all panels.

6. VI characteristics and RCT values of CTs used in differential protection.

7. Cable layout drawings.

8. Technical particulers of all LT motors and recommended protection.

9. Catalogues for each type of equipment, relays, meters etc.

10. Installation and commissioning manuals for each equipment, relay etc.

11. Operation and maint. manuals indicating trouble shooting procedure for all
equipment.

12. Type test certificates for all the major equipment.

13. Details of test results conducted at works for all equipment in bound Volume

14. Details of test results conducted at site for all equipment in bound Volume

15. Spare part list number and ordering procedure for all recommended spares.

R&M WITH NEW TG SET

16. Details of transport arrangement and maximum size of transportable section
(weight and overall dimensions).

17. Details of agency proposed to be fixed for doing erection commissioning job.

18. Panel wise bill of material indicating type make and brief technical particulars of
all items/ accesssories mounted on the panels.

19. Overall GA of all the panels/equipment

20. Fixing details of all the panels/equipment, supporting structures, etc.

21. Heat loss for each equipment.

22. Static and dynamic loading of each equipment

23 .Floor cutouts and wall opening details for cables bus duct, air conditioning
ducts, light conduits, exhaust fans etc.

24. Details and location of various inserts base plates, bolts etc. required to be
provided for support of cable structure, bus duct elect. panel etc.

25. Conduit layout drawing indicating type, size, length and locations of conduits
required to be placed in RCC wall/floor, brick wall.

26. Technical data sheet for each type of motors and characteristic curves for protection
settings.

27. As built drawings incorporating site changes along with soft copies in CD.

R&M WITH NEW TG SET

TS VOL IV Sec. A Ch -09 Page 1 of 32
09. TECHNICAL PARTICULARS TO BE SUBMITTED BY THE TENDERER

09.01 GENERAL

1. Instructions

The data called for below is to be furnished by the bidder and in case the bidder
becomes the supplier, the data shall form part of the contract covering the work.
The performance figures quoted shall be guaranteed within the tolerances
permitted in the relevant standards.

2. Bidder's Name (For Electrics)

1. Trade Name of Bidder :
2. Address for correspondence :

3. General conditions

Is it the Bidder's intention,
if awarded the contract, to
comply fully and in all res-
pects with the Owner's
specification ? Yes/No

If 'NO' is answered to any of
the above questions, the
biddershallstatethe exceptions
in details, clausewise, partwise
and chapter wise.

4. Tenderer to submit all data/ information / drawings / spare part list pertaining to
electrics, generator, static excitation &AVR system in one volume. -
Agreed

5. Tenderer visited the site and under stood the job & location of various stood.
equipment. - Yes

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09.02 DESIGN CONSIDERATIONS

1.0 Loading (unit wise) :

1.1 Cold start up :

1.2 Hot start up :

1.3 Full Aux. load on one unit :

2.0 Battery capacity required : Number AH
(for the equipment/system
of tenderer's scope)

3.0 Any other aux. supply required : Indicate with
(other than 415 V AC & 220 DC) purpose.

4.0 List of drives/mechanism with kW : List to be enclosed
needs DC power supply

Spares and tools & tackles

1. List of commissioning spares : List to be submitted
2. List of special tools and tackles : List to be submitted

Summary Of Technical Parameters Of Major Electrical Euqipment

Sl.
No.
Equipme
nt
Descripti
on
& Qty.
Make &
type
Country of
manufactu
re
Total
Weig
ht.
Single
largest
package
dimensions
& wt.
Applica
ble std.
Rating as
per design
conditions
of tender
Guarant
eed
tech.
Data

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09.03 220 kV EQUIPMENT

220 kV CIRCUIT BREAKER

1. T y p e :
2. Service :
3. P o l e :
4. Rated Voltage :
5. Maximum permissible voltage corresponding
to rated breaking current, kV :

6. Rated Frequency :
7. System Neutral Earthing :
8. Insulation Level :
8.1 Impulse withstand voltage :
8.2 One minute power frequency withstand voltage :
9. Rated Current :
9.1 Continuous at 50o C :
9.2 Short time current for 3 Secs. :

10. Rated transient recovery voltage for terminals
Faults :

11. Rated line charging breaking current :
12. Rated low power factor, small inductive
breaking current :
13. Rated Breaking Capacity :
13.1 Symmetrical :
13.2 Asymmetrical :
14. Rated making capacity :
15 Creepage distance :
16. Rated short-time current characteristics :
17. No. of breaks in series per phase :

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18. Total break time (from the instant of trip coil
energisation), ms :
19. Make time (from the instant of closing coil
energisation), ms :
20. Reclosing :
21 Operating Duty :
21.1 For gang - operation :
21.2 Operating Mechanism :
22. Auxiliary Voltage :
22.1 Closing :
22.2 Tripping :
22.3 Spring Charge Motor :
22.4 Compressor Motor :
22.5 Heater/Lamp/Socket :
23. Type of operating mechanism :
23.1 Motor operated spring charging :
23.2 Pneumatic :
23.3 Shunt trip coils :
23.4 No. of coils :
23.5 Voltage rating :
23.6 Permissible operating voltage limit :
23.7 Power requirement, W :
24. Mounting :
25. Phase to Phase spacing :
26 Terminal Connector :
27. Type :
28. Suitable for :
29. No. of spare NO & NC auxiliary contacts :
30. Whether specified interlocks provided :

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31. Total / protected creepage distance of
supporting insulators, mm / mm :
32. Photostat copies of type test certificates for :
32.1 Breaking capacity :
32.2 Short-time rating :
33. Weight of each complete circuit-breaker unit, kg :
34. Overall dimensions of circuit-breaker assembly,
mm x mm x mm :
35. Pneumatic operating mechanism :
35.1 Type (whether centralised) :
35.2 Make and model number :
35.3 Capacity of each compressor :
35.4 Type of compressor motor :
35.5 Voltage ratings of compressor motor, V :
35.6 Continuous kW rating of compressor motor :
35.7 Temperature rise of motor winding above 500 C
Ambient :
35.8 Protective devices provided for compressor
Motor :
35.9 Volume of air storage reservoir, cu m :
35.10 Normal operating pressure for closing the
circuit-breaker, kg / sq mm :
35.11 Minimum pressure at which the breaker will
operate, kg sq mm :

35.12 Quantity of free air required for one O-CO-CO
sequence of operation of one breaker at
minimum allowable operating pressure, cu m :

35.13 Quantity of free air required for one O-CO-CO
sequence of operation of one breaker at
minimum allowable operating pressure, cu m :

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35.14 Pressure in kg / sq mm at which low pressure
alarm is given :

35.15 Pressure in kg / sq mm at which circuit-breaker
is automatically tripped and locked out :

35.16 Whether duplicate piping system provided :

35.17 Material of air piping :

35.18 Enclosed catalouge No. for compressed air system :

BUSHINGS/SUPPORT INSULATOR
1. Rated Voltage :
2. Impulse withstand voltage :
3. Power frequency withstand voltage :
4. Creepage :
5. Pollution level as per IEC 71 :
6. Insulators shall also meet the requirement
Of IEC-815 having alternating sheds with
creepage factor less than or equal to four (4). :

220 kV ISOLATOR
1. Type :
2. Service :
3. Pole :
4. Rated voltage :
5. Rated Frequency :
6. System Neutral Earthing :
7. Insulation Level :
7.1 Impulse Withstand Voltage :
7.1a To Earth & Between Poles :

R&M WITH NEW TG SET

7.1b Across isolating distance :
7.2 One Minutes Power Frequency withstand Voltage :
7.2a To Earth & Between Poles :
7.2b Across isolating distance :
8. Rated Current :
8.1 Continuous at 50`C ambient :
8.2 Short time current for 3 Secs :
8.3 Peak Short time current :
9. Creepage distance :
10. Operating Mechanism :
10.1 Main blade :
10.2 Earth Switch :
11. Auxiliary Voltage :
11.1 Motor :
11.2 Control & Interlock :
11.3 Heater/Lamp/Socket :
12. Mounting :
13. Phase to Phase Spacing :
14. Operating type :
15. Corona extinction Voltage :
16. Terminal Connector
16.1 Type :
16.2 Suitable for :
17. Material of earth blade :
18. Whether specified interlocks provided :
19. Type of operating mechanism (whether motor
operated spring charged) :
20. Voltage rating of closing mechanism, V :
21. Permissible operating voltage limit :

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22. Power required by closing mechanism, W :
23. No. of spare NO & NC auxiliary contacts :
24. Total/protected creepage distance of
supporting insulators :
25. Photostat copies of type test certificates for :
25.1 Short time rating :
25.2 Peak short-circuit current :
26. Weight of each complete unit, kg :
27. Overall dimension of each complete unit, mm x
mm x mm :
28. Enclosed catalogue No. :
220 kV CURRENT TRANSFORMER
1. Type :
2. Service :
3. System Details :
3.1 Voltage :
3.2 Frequency :
3.3 System Neutral :
4. I nsulation Level :
4a 1 minute 50 Hz withstand :
4b Impulse withstand :
5. Short-time Current :
5a Rated 3-second current :
5b Rated dynamic current :
6. Type of insulation :
7. Creepage distance :
8. Mounting :
9. Terminal Connector :
9.a Ty pe :

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9.b Suitable for :
10. Make and model number :
11. Standards followed :
12. Temperature rise over 500 C ambient while
carrying rated primary current :
13. Total / protected creepage distance of
supporting bushing insulator, mm x mm :
14. Ratio, accuracy class, VA burden :
15. Photostat copy of type test certificate for shorttime
Rating :
16. Overall dimensions of one single- pole unit,
Mm x mm x mm :
17. Weight of one complete single-pole unit, kg :

198 kV LIGHTNING ARRESTOR
1. Type :
2. Service :
3. Make and model number :
4. Standards followed :
5. Voltage :
6. Nos. of phases :
7. Frequency :
8. L.A. Rating :
9. Nominal discharge current :
10. Discharges class :
11. Level :
11.1 1-minute 50 Hz withstand :
11.2 Impulse withstand :
12. Maximum continuous operative voltage ( MCOV) :

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13. Spark Over Voltage :
14. Minimum power frequency :
15. Maximum 1.2/50 micro sec :
16. Current for pressure relief test :
17. Mounting :
18. Terminal Connector :
19. Suitable for :
20. Ground terminal :
21. Whether the results of various tests like voltage
withstand tests etc. conform to those specified in
IS:3070 :
22. Whether all specified fittings and accessories,
leakage current indicator etc. have been provided :
23. Total / protected creepage distance of supporting
insulator, mm / mm :
24. Enclose catalogue No. :
25. Overall dimensions of one single-pole unit,
mm xmm x mm :
26. Weight of one complete single-pole unit, kg :

ACSR CONDUCTOR
1. Make :
2. Standard followed :
3. Diameter of complete conductor, mm :
4. Weight of complete conductor, kg / m :
5. Characteristics of protective grease :
6. Ultimate tensile strength, kg :
7. Modulus of elasticity, kg / sq cm :
8. Coefficient of linear expansion per 0 C :

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9. Standard drum length, m :

GALVANISED STEEL WIRE
1. Make :
3. Ultimate tensile strength, kg :
4. Diameter of complete wire, mm :
5. Weight of complete wire, kg / mm :
6. Modulus of elasticity, kg / sq cm :
7. Coefficient of linear expansion per 0C, kg / sqcm :
8. Standard drum length, m :

INSULATORS
1. Make :
3. Manufacturers type designation :
4. No. of discs used per string insulator assembly :
5. Total creepage distance of :
5.1 Each disc insulator unit, mm :
5.2 Complete string insulator assembly, mm :

STRUCTURAL STEELWORK
1. Grade of steel for :
1.1 Steel members :
1.2 Nuts and bolts :
1.3 Other fasteners :
2. Minimum thickness of steel used for various
Members :
3. Galvanized details :

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4. Minimum diameter of bolts :
5. Maximum tension considered, kg :
5.1 phase conductor :
5.2 Shield wire :

CONTROL & RELAY PANEL FOR 220 kV EQUIPMENT
Control Panel Relay panel
1 Make :
2 Type :
3 Reference Standard :
4 Degree of protection :
5 Equipment Mounting :
a. All relays, meters and switches are flush mounted:? :
b. Relays furnished in drawout cases with built-in test
facilities? :
6 Overall dimensions & weight :
7. Control switches for circuit breakers
a) Make :
b) Type :
c) Type of handle provided :
d) No. of positions :
e) No. of contacts
i. Normally closed :
ii. Normally open :
8. Indicating lamps
a) Make :
b) Type :
c) Operating voltage :
d) Size of lamps :

R&M WITH NEW TG SET

e) Wattage of lamps :
f) Colours of lamps :
9. Switch board wiring
a) Insulation of wiring :
b) Size of wiring conductor for the following :
i. PT circuits :
ii. CT circuits :
iii. DC supply circuits :
iv. Other circuits :
c) Size of earthing bar for safety earthing :
d) Type of terminals provided on wiring :
e) Wiring conductor material :
10. Indicating meters :
a) Type of instrument :
b) Size :
c) Whether magnetically shielded or not :
d) Limits of error in the effective range :
e) Max. scale length :
f) Whether tropicalised :
g) Short time over load capacity :
h) VA burden :
i) Temp. at which the instruments are
calibrated :
j) Makers name :
k) Description leaflets / references submitted :

11. PROTECTIVE RELAYS (To be furnished for each relay)
a) Make :
b) Type :

R&M WITH NEW TG SET

c) Current coil rating :
d) Tap range :
e) VA burden :
i) Highest tap :
ii) Lowest tap :
f) Power consumption
i) Highest tap :
ii) Lowest tap :
g) Time of operation of max. time setting at
i) 5 times tap setting current :
ii) 10 times tap setting current :
h) Type of characteristics (Amp) :
i) Trip contact rating :
j) Whether seal in contact provided or not :
12. Space heaters in control cubicle
a) Rated voltage :
b) Power consumption at rated voltage :
13. Enclosures
(a) Whether relevant drawings for all the
Equipments enclosed :
(b) Whether all the type test reports for all the
equipments enclosed :
(c) Whether descriptive technical features for
All the equipments enclosed :

09.04 HT EQUIPMENT

09.04.01 11kV Circuit Breaker

R&M WITH NEW TG SET

01 Make :
02 Type :
a) Manufacturers Type
Number
:
b) Type of Circuit Breaker :
c) Closing Mechanism : Motor operated spring
assisted
d) Trip free/fixed trip : Trip free
03 Standards followed :
04 Rated Current at
a) Design temp, Amp :
b) 50
o
C ambient temp,
Amp
:
05 Indoor/Outdoor : Indoor metal clad drawout
type
06 Service voltage :

07 Maximum voltage at which
breaker can operate
continuously
:
08 Making Capacity kA
(peak)
:
09 Breaking Capacity
a) Symmetrical kA (RMS) :
b) Asymmetrical kA
(RMS)
:
10 Short time current for 3
seconds kA (to be not less
than symmetrical breaking
:

R&M WITH NEW TG SET

current)
11 Total make time
Milliseconds
:
12 Total break time
Milliseconds (5 cycles or
less)
:
13 Make break time
Milliseconds
:
14 Poles : 3
a) No. of breaks in circuit
per pole
:
b) Total length of breaks
per pole
:
c) Speed of closing :
15 Insulation Level
a) One minute power
frequency with stand
voltage kV (RMS)
: 27
b) Impulse withstand
voltage (1.2 x 50 micro
sec. Wave) kV (PEAK)
: 60
16 No. of contacts with
auxiliary switch

a) Normally open (NO) :
b) Normally closed (NC) :
c) Whether it is possible
to change NO contact
to NC contact & vice
versa at site
:
17 Type of arc control device :

R&M WITH NEW TG SET

18 Arc duration time
a) 100% breaking
capacity
:
b) 10% breaking capacity :
19 Does magnetic effect of
load increase contact
pressure
:
20 Control supply voltage
and permissible operating
range

a) For spring charging
motor
: 220 V DC, 85% - 110%
b) For closing and
tripping coils
: 220 V DC, 85%-110% for
close coil 220 V DC, 70%-
110% for trip coil
21 Details of spring charging
motor

a) Rating of spring
charging motor at 220
V DC
:
b) Nominal current :
c) Starting current and
duration of run of
spring charging motor
for full charging of
closing spring
:
d) Type of spring
charging motor
:
22 Power required at 220 V
DC

a) For closing coil Watts :

R&M WITH NEW TG SET

b) For tripping coil Watts :
23 Weight of circuit breaker
and truck kg
:
24 Weight of cubicle (without
truck) kg
:
25 Minimum number of
operations for breaker
without need for
inspection or replacement
of circuit breaker pole
units

a) Off/On operation at
rated current
:
b) Off/On operation at
rated short circuit
current
:
26 Contacts type and
materials

a) Main :
b) Arcing :
c) If silver plates,
thickness of silver
plating
:
27 Maximum temperature rise
over designed ambient in
the cubicle
o
C
:
28 Overall dimensions
(LXDXH) for different type
of cubicles
:
29 Type of enclosures for
switchgear
:
30 Degree of protection :

R&M WITH NEW TG SET

offered by the cubicle

09,04.02 GENERATOR CT-PT-SURGE PANEL, NGTR

CURRENT TRANSFORMER Current Transformer
Gen. Gen.
Neu. Ph.
C.T. C.T.
---- -----
1. Name of the manufacturer :
2. Type & Service-Indoor/Outdoor :

3. Insulation level, KV :

4. Rated short time thermal
current for three (3) sec.
KA, rms :

5. Temperature rise over an
ambient temperature of
50 deg. c at -

a. Rated primary current :
b. Rated short time thermal
current for three(3) secs. :

Voltage transformer

1. Insulation class, KV :

2. Basic insulation level, KV
peak :

3. Rating

a. Voltage ratio :
b. Rated output, VA :
c. Accuracy class :

R&M WITH NEW TG SET

d. Connection :

4. Over voltage factor -
a. Continuous :
b. 30 seconds :

5. Temperature rise above 50
o
C ambient

a. At 1.2 x rated primary
voltage continuous :
b. At 1.9 x rated primary
voltage for 30 secs. :

LIGHTNING ARRESTOR

1. Make :

2. Service :

3. Type :

4. Voltage rating, KV rms :

5. Minimum power frequency spark-
over voltage, KV rms :

6. Arrestor insulation withstand
test voltage -
a. Impulse, KV crest :
b. Power frequency, KV rms
1 minute dry :
1 minute wet :

SURGE CAPACITORS


2. Service :

3. Type :

4. Rated voltage, KV :

R&M WITH NEW TG SET

5. Rating -

a. Capacity in micro farad/
pole :
b. Guaranteed tolerance :

6. Insulation class, KV :

7. Test voltage between terminals-

a. A.C. for 1 min. :
b. D.C. for 10 sec. :

8. Catalogue furnished? :

9. Details of Discharge resistor :

NEUTRAL GROUNDING TRANSFORMER


2. Service :

3. Type & catalogue no. :

4. Transformer cooling type :

5. Rating

a. Rated KVA :
b. Rated high voltage, KV :
c. Rated low voltage, Volt :
d. Rated frequency, C/s. :
e. Phase, No. :
f. Impedance, % :
g. Reactance, % :
h. Resistance, % :

6. Details of Tapping

a. Type :
b. Rating :
c. No. and range of taps :

R&M WITH NEW TG SET


7. Temperature rise above 50deg.c:

8. Basic impulse level, KV peak :

9. One (1) minute power frequency
test withstand voltage, KV rms :

RESISTOR


2. Type :

3. Service :

4. Referred standard :

5. Rating

a. Voltage, volts :
b. Current, Amps :
c. Time rating, min. :
d. Resistance, Ohms :
e. Guaranteed tolerance, % :

6. Temperature rise above 50deg.c :

7. Material used

09.05. RELAYS

Indicate type & make of relays proposed to be provided for

- Generator Protection
- Static excitation Transformer Protection
- Generator Transformer Protection
- Auxiliary Transformer Protection

09.06 TRANSFORMER

(Tenderer to fill up for HT & LT transformer separately)

R&M WITH NEW TG SET

A. Guaranteed data

Rating

a. Rated KVA :

2. a. Temperature rise above
50 deg. C ambient for
oil filled type

i. Oil by thermometer, Deg. C : ii. In winding by resistance deg.C :

b. Hot spot temperature in
winding limited to deg. C :

3. Losses

a. No.load loss at rated
voltage and frequency :

b. Load-loss at rated current
and at 75 deg.C :

4. Impedence at rated current
frequency at 75 deg. C, % :

5. Zero sequence impedance, % :

6. Efficiency at 75 deg. C and
0.8 p.f. lag % :

a. at 100% load :

b. at 75% load :

c. at 50% load :

B. General Details
LT
HT

1. Name of manufacturer :

R&M WITH NEW TG SET

2. a. Service-whether indoor or outdoor:

b. Type-core or shell :

3. Reference standard :

4. Type of cooling :

5. Rating

a. Rated current, amp (rms)

HV :
LV :

b. Rated voltage, KV

HV :
LV :

c. Generator Transformer capable of
withstanding 125% rated
voltage for 1 minute and
140%rated voltage for 5 secs.? : Yes/No

6. a. Terminal arrangement

i. HV :
ii. LV :

b. Winding insulation category

i. HV : Uniform/Non-uniform
ii.LV : Uniform/Non-uniform

c. Insulation level as per IS:2026
(Part-III) or IEC-76-3 :

7. Type of tap changer :

8. Taps

a. Capacity :

R&M WITH NEW TG SET


b. Steps and range :

c. Tapping provided on HV side ? : Yes/No

9. No load current referred to H.V
and 50 c/s 100 % rated current :
voltage.

10. Withstand time without injury for

a. Three phase dead short
circuit at terminal with
rated voltage maintained
on the other side, sec. :

b. Single phase short circuit
at terminal with rated
voltage maintained
on the other side, sec. :

11. Insulation strength

a. One minute power frequency
test KV rms

i. H.V. :
ii. L.V. :
iii. L.V.Neutral :

b. Impulse withstand voltage, KV

i. H.V. :
ii. L.V. :
iii. L.V.Neutral :

12. Insulation oil

a. Approx volume of oil, liter :

b. Whether first filling of oil
with 10% excess furnished ? :

R&M WITH NEW TG SET

c. Oil conforms to IS:335 ? :

13. Marshalling Box

a. Weatherproof, suitable for
outdoor for oil filled type ? : Yes/No

b. Degree of protection :

14. a. Type of valve :

b. No. of valve comprising one
complete set (break up of
valves shall be given) :

09.07 GENERATOR BUS DUCT

1. Make :
2. Rated voltage frequency :
3. Continuous current rating (main & tap off) :
4. Busduct material & cross section :
5. Bus duct enclosure material & thickness :
6. Heat loss in bus duct at rated current :

Middle phase kW/m :
Outer phase kW/m :
Total heat loss kW/m :
Loss in bus bar kW/3 phase/m :
Loss in busduct enclosure kW/3 phase/m :

7. Short circuit rating : KASec :
8. Insulation level KV (RMS)/KV peak :
9. Bus duct Wt/m :

09.08 LT SWITCHGEAR,MOTOR CONTROL CENTRES, AC DISTRIBUTION
BOARDS, DC DIST. BOARDS, DC STARTER PANEL & RESISTORS AND
LOCAL AC STARTERS

NOTE : Tenderer to furnish the following data separately for each of the above
equipment.

R&M WITH NEW TG SET


- EQUIPMENT ASSEMBLY

- Make:

- Type:

- Reference Standard:

- Short Circuit Rating:

a. Interrupting
Symmetrical KA rms.

b. Short-time
for 1 Sec. KA rms.

- Metal enclosed:
construction? Yes/No

- Degree of Protection:

- Thickness of sheet metal:
a. Front
b. Back
c. Side
d. Bottom/Top

- Dimensions of vertical:
section in mm (LxDxH)

- CONSTRUCTION:

- Drawout features provided for:

a. Circuit breaker with
SERVICE, TEST &
ISOLATED position Yes/No :
b. Voltage Transformers Yes/No :
c. Protective Relays Yes/No :
d. MCC modules Yes/No :

- MCC completely compart-:
mentalised ? Yes/No

R&M WITH NEW TG SET


- All meter, switch and relays
flush mounted type Yes/No :

- CIRCUIT BREAKER

- Make:

- Continuous current rating

a. As per manufacturer's
standard:
b. Derated factor (if any) for:
site condition

- Symmetrical interrupting :
capacity(MVA)

- Making current (peak), KA :

- Rated 1 second current, :
KA (rms)

- Whether drawout, semi-drawout, :
or non-drawout type ?

- Closing mechanism

a. Type:
b. Rated voltage of coil:
c. Emergency closing mechanism:
provided ?

- Rating of motor used in breaker
closing mechanism

- Shunt trip coil

a. Type :
b. Rated voltage of shunt trip :
coil

R&M WITH NEW TG SET

- Total opening time (measured from :
trip coil energisation) cyc/m.sec

09.09 MOTORS

09.09.01 LT MOTORS (AC)

1. Make and type, reference standard :

2. Class of insulation :

3. Enclosure class :

4. Frame size :

5. Temp. rise over max. site ambient :

for winding

for enclosure

6. Min. volt to start :

7. Whether all motors are from one
make

8. Type of protections envisaged : Electrical/Technological

9. Deviations if any on technical :
design data

09.10 CABLES (HT/LT Power control cables)

The bidder shall indicate the following for each type and size of cables:

1. Make :

2. Type :

3. Shielding on Conductor

R&M WITH NEW TG SET

(H.T. Cables)

a. Material :

b. Type :

c. Thickness mm :

d. Whether extruded : Yes/No

4. Insulation
a. Material :

b. Type :

c. Thickness mm :

09.10.01 Cable Termination kit
XLPE PVC
cable cable

Make :

Type :

Complete with all
accessories ? :

09.11 UPS SYSTEM:

Make :

Capacity :

Overload :

Capacity of convertor :

Overload capacity :
of Invertor

R&M WITH NEW TG SET


Battery

Make :

Type

AH Capacity

Harmonics at rated load

- with battery :

- without battery :

Overall dimensions of the :
panels

Schematic diagram :
(to be enclosed)

09.12 DC SYSTEM
09.12.01 DC BATTERY

1. Make & type & applicable standard :
2. No. of battery sets :
3. Rated cell voltage & no. of cells/battery :
4. AH capacity :

09.12.02 BATTERY CHARGER

1. Make & Type & applicable standard :
2. Rated input voltage :
3. Rated output voltage & current
a) Float :
b) Boost :
4. % Ripple content DC Bus
without battery :

R&M WITH NEW TG SET

At No load :
At full load :
5. Type of SCR control :
6. Control & Protection Features
Float charger :
Boost charger :
7. Enclosure type :
8. Overall dimensions :
9. No. of float cum boost chargers :

R&M WITH NEW TG SET

TS VOL IV SEC A ANX I Page 1 of 1

ANNEXURE-I

SELECTION OF POWER COMPONENTS & WIRING FOR
CONTINUOUS DUTY CAGE MOTOR DRIVES

Motor
Rating at S1
Duty
(KW)
Minimum
Rating of
MCCB
*
Minimum
rating of
Contractor
(AMPS)
AC3 duty
Minimum size for internal
power connections
Minimum
size power
cable
(Copper)
termination
(sq. mm)
Copper wire
(mm2)
Aluminum
Flat
**
( mm x mm)
Up to 3.7 25 4 4 x 2.5
(Copper)
5.5 100 40 4 4 x 2.5
(Copper)
7.5 100 40 6 3 x 6
11 100 40 6 3 x 16
15 100 63 10 3 x 16
18.5 100 63 16 12 x 2 3 x 35
22 100
30 100 100 25 12 x 2 3 x 35
37 100 100 35 15 x 3 3 x 70
45 200 160 50 15 x 3 3 x 70
55 200 160 70 20 x 3 3 x 95
75 200 200 95 20 x 5 3 x 150
90 400 400 - 20 x 5 3 x 150
100 400 400 - 30 x 5 2(3 x 95)
125/135 400 400 - 40 x 5 2(3 x 95)
160 400 400 - 40 x 5 2(3 x 150)

* MCCB rating shall be finalised in consultation with manufac turer of MCCB to
achieve type `2' protection.

** Copper flat of equivalent size can be used instead of aluminium flat

Number of cores on cables shall depend on earthing system.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET

TS VOL IV SEC A ANX II Page 1 of 7

ANNEXURE II

11. LIST OF MANDATORY SPARES FOR EACH UNIT (Six sets for six Units)

11.01 Generator LAVT

1. Lightning arrestor with complete : 1 set
assembly

2. PT assembly : 1 set

3. PT primary HT fuse : 5nos.

4. MCB : 10 nos.

5. Fuse : 20 Nos.

11.02 Generator CT

1. Phase CT of each class & type : 1 no. each

11.03 11 kV Bus Duct

1. Epoxy resin insulators used for main bus : 5 Nos.
2. Epoxy resin insulators used for tap off connection : 5 Nos.
3. Seal off bushings of each type in use : 2 Nos
4. Complete set of gaskets used in bus duct : 1 Set
assembly for 1 unit

11.04 Generator Transformer / 20MVA Transformer / Unit Auxiliary
Transformer (As Applicable)

1) H.V. side bushing. : 1 No.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET


2) L.V. side bushing. : 1 No.

3) H.V. neutral bushing. : 1 No.

4) Buchholz relay (with alarm/trip contacts). : 1 No.

5) Oil surge relay (with alarm/trip contacts). : 1 No.

6) Magnetic oil level gauge (with alarm/trip contact). : 1 No.

7) Current Transformer of WTI. : 1 No.

8) Dial type oil temp. indicator with alarm/trip contact. : 1 No.

9) Winding temperature indicator with alarm/trip contacts. : 1 No.

10) Silicagel breather with silicagel charger. : 1 No.

11) Set of Gaskets for bushings. : 1 No.

12) Differential Pressure gauge of each type : 1 Set

13) Pressure gauge of each type : 1 Set

11.05 Neutral Grounding Cubical

01. Supporting insulators : 5 nos.

02. Resistor unit : 2 sets of banks

11.06 Control Relay Panel / Desk

01. Indication Lamps 50 Nos.
02. Semaphor Indicator 4 Nos.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET


03. Control Fuse 50 Nos
04. Control Switches / Selector Switches (Each Type) 2 Nos.
05. Meters (Indication Only) (Each Type) 1 No.
06. PLC Card 1No. for each type
07. Relays (Protective and Aux.) (Each Type) 1 No.
08. Power Supply Card / units for relays (Each Type) 2 Nos.
(If applicable)
09. Hooter / bell etc 2 Nos. each type
10. Isolating switch

a) AC supply : 1 no. of each type

b) DC supply : 1 no. of each type

11. Terminal blocks : 3 sets
12. Timers of each range : 2 nos.

11.07 11 kV Switchgear

01. Breaker Closing coil & Trip Coil 1 each
02. Breaker Spring charge Motor 1No.
03. Breaker Contacts (Fixed & Moving) 1 each
04. Current Transformer of each type 1Set each
05. Potential Transformer 1Set
06. HT & PT Fuses 10 Nos.
07. Control Fuse 50 Nos.
08. Vacuum Interrupter 1 No.
09. Aux. Relays / Contactor (Each type) 2 Nos.
10. Push Buttons and selector Switch 1No. each type

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET


11. Indication Lamps, holder with resistance 15% of Qty. used
12. Test / Service Position Limit Switch 2 Nos.
13. Meters (each Type) 1 No.
14. Transducers (Each Type) 1 No.

11.08 LT Switchboard

01. Breaker Closing coil & Trip Coil 1 each
02. Spring charge Motor 1No.
03. ACB Contacts 1 Set
04. Current Transformer of each type 1Set each
05. Potential Transformer (Each Type) 1Set
06. Fuses 50 Nos.
07. ACB Arc Chutes 1 Set
08. MCCB / MPCB (Each Type) 5 Nos.
10. Push Buttons and selector Switch 1No. each type
12. Contactors Complete (each Type) 3 Nos.
13. Aux. Contacts of Contactors (each Type) 5 Nos.
14. Close Coil of Contactors (each Type) 5 Nos.
15. Transducers (Each Type) 1 No.

16. O/L Relay (each Type) 3 Nos.

17. Meters (each Type) 1 No.

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET


11.09 Uninterruptible Power Supply System

01. Electronic Cards (Each Type) 1 No.
02. Meters (Each Type) 1 No.
04. Switch / Push Buttons (Each Type) 2 Nos.
06. Control Fuse 50 Nos.
.
11.10 AC Motors

1. Valve drive 1 of each type

2. Bearings 3 set of each type

3. Fans 3 nos. each type

11.11 220 KV CIRCUIT BREAKER

Sl. No. Item Quantity
1 Compressor with motor 1 No.
2 Solenoids/valves 1 set
3 Support insulator 2 Nos. of each type
4 Closing coil 1 set
5 Tripping coil 1 set for complete
replacement

11.12 220 KV ISOLATOR

1 Moving blade 2 sets of each type and
rating
2 Fixed blade 2 sets of each type and
rating

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET


3 Earth switch moving blade 2 sets of each type and
rating
4 Earth switch Fixed blade 2 sets of each type and
rating
5 Arcing contacts 2 sets of each type and
rating
6 Support insulator assembly 2 sets of each type and
rating
7 Motorized operating assembly 1 set of each type and
rating

11.13 CONTROL AND RELAY PANEL FOR 220 kV EQUIPMENT

1 Control switches 2 Nos. of each type
2 Selector switches 2 Nos. of each type
3 Push buttons 2 Nos. of each type
4 Indication lamps assembly (LVGP LED
type)
10 Nos. of each type
5 Power and control contactors 2 nos. of each rating and
type
6 Multifunction meter 1 no. of each type

11.14 220 KV OVERHEAD LINE
1 Tension insulator string assembly complete
with deadend compression clamp etc.
suitable to Zebra ACSR

i. Single tension type
ii. Double suspension type

6 Sets
1 Set
2 Suspension insulator string assembly
complete with
suspension clamp suitable for Moose
conductors
covered with armour rods for :
I Single tension type

2 Sets

UNIT # 1 TO 6 (6x60 MW)
R&M WITH NEW TG SET


Ii Double suspension type 1 Set
3 Preformed armour rod suitable for :
a) 54/7/3.53mm Zebra ACSR

10 Nos.
4 Vibration damper suitable for Zebra
ACSR
10 Sets.

11.15 MAINTENANCE TOOLS & TACKLES

01. Breaker lifting/handling truck : 1 nos.

02. Breaker racking handle : 2 nos. of each board

03. MCC tray racking handle : 3 nos. of each board

04. Panel keys : 5 nos. for each board

05. Test cabinet with coupling cables : 2 nos. for each board
for testing breaker in withdrawn position

06. Indication lamp extractor : 2 nos. for each board

07. Programming device for programming
and changing setting of relays for numeric relay: 1 set


TS VOL IV

VOLUME IV
CONTROL & INSTRUMENTATION

BALIMELA POWER HOUSE, CHIPLIMA
UNIT #1 TO 6 (6X6OMW)

TS VOL IV Sec .B Page 1 of 46

CONTROL & INSTRUMENTATION

01.00.00 GENERAL

a) This specification is intended to define the basic requirements of
instrumentation & control system for R&M with New TG for the Unit- 1 to 6
along with their auxiliaries as specified in the tender document.

The basic philosophy of C&I system should cover entire 6 units in totality and
shall be based on the stateof theart microprocessor based control system.
The C&I system shall ensure safe, efficient and smooth operation of the plant
and equipment with minimum intervention of the operating personnel during
normal working of the plant, load fluctuation/shut-down and start-up of the
unit.

The Tenderer shall furnish the complete Control and Instrumentation system
including Distributed Control System (DCS) or Programmable Logic Control
(PLC) based system, Primary and Secondary Instruments, Panels, Control
Desks, Alarm Annunciation System, Electric Power Supply System, Actuators,
Instrumentation Cables and Process Connection impulse tubing,
Actuators/MOV(Motor Operated Valve),

b) The Tenderer shall provide all material, equipment and services so as to
make a totally integrated Instrumentation and Control System together with all
accessories, auxiliaries and associated equipments ensuring operability,
maintainability and reliability. This work shall be consistent with modern
power plant practices and shall be in compliance with all applicable codes,
standards, guides, statutory regulations and safety requirements in force.



c) Further, Tenderer shall also include in his proposal and shall furnish all
equipment, devices and services, which may not be specifically stated in the
specification but are needed for completeness of the equipment/systems
furnished by the Tenderer and for meeting the intent and requirements of the
specification.

d) Standardisation and Uniformity of Hardware to ensure smooth and optimal
maintenance, easy inter-changeability and efficient spare parts management
of various C&I instruments / equipment like vibration monitoring systems, all
4-20mA electronic transmitters/ transducers, control hardware, control valves,
actuators and other instruments/ local devices etc. being furnished by the
Tenderer for TG and station auxiliaries for similar applications, the Tenderer
shall ensure that they are of the preferable same make, series and family of
hardware.

f) The equipment shall employ latest- state- of theart technology to guard
against obsolescence. In any case, Tenderer shall be required to ensure
supply of spare parts for mininum10-15 years. In case, it is felt by the
Tenderer that equipment / component is likely to become obsolete, the
Tenderer shall clearly bring out the same in his offer and indicate steps
proposed to deal with such obsolescence

02.00.00 SCOPE OF WORK AND SUPPLY

The scope of work shall include design, engineering, procurement, inspection,
supply, packing, transportation to site, storage, calibration, erection, testing
and commissioning of all instrumentation and control equipment, cables,
pipes, auxiliaries and erection hardware necessary for completion and



handing over of instrumentation and control work for the unit after integrated
final commissioning.

02.01.00 The scope of work shall also include all civil works, like chipping, digging,
concreting including filling material etc. associated with erection of
instruments and associated equipment.

02.02.00 Measurement and control equipment offered will be complete in all respect
and any equipment / accessories not explicitly indicated in this specification,
but considered essential for proper functioning of equipment and process will
be included in the Contractors scope of supply and work

02.03.00 The scope of work and supply shall also include but not limited to the
following:

02.03.01 The instrumentation system shall cover for New TGs and its auxiliaries as
covered in this specification.

02.03.02 A proven dedicated 1:1 Hot redundant centralised Distributed Control System
(DCS)/ PLC based system for each unit shall be envisaged with this package.

02.03.03 Redundant Electro Hydraulic Turbine Control system with redundant actuator
shall be envisaged for each turbine.
02.03.04 Electro Hydraulic control unit will be envisaged for Servo Rotary Valves.

02.03.05 The instrumentation equipment for all units of hydel power plant with their
auxiliary facilities as covered in the specification and also as felt necessary by
the successful Tenderer for the completeness of the job.



02.03.06 Fully wired panels, cabinets, desks, racks, transmitter cabinets and junction
boxes

02.03.07 All signal, control & Power cables shall be FRLS armoured types or
manufacturer standards cables required for instrumentation work.

02.03.08 All field instruments (4-20mA) shall be replaced by new SMART type 2 wire
transmitters.

02.03.09 All local field mounted instruments for New TGs shall be newly envisaged.

02.03.10 Turbine Vibration monitoring system and measurements with sensor and
converter box shall be provided for New TGs as per manufacturer standards.

02.03.11 All existing Impulse tubes, conduits shall be replaced by new SS impulse
tubes and conduit.

02.03.12 All Erection materials Like as Cable tray, cables fittings joints etc shall be
under scope of bidder

02.03.13 Submission of drawings and documents as per clause no. 05.03.00

02.03.14 Arranging of inspection of DCS/PLC & governor, excitation system at the
Original equipment manufacturer premises (Refer electrical inspection clause)

02.03.15 Erection, calibration, testing and commissioning of the total equipment included
in this specification. All tools and tackles, special testing equipment and
consumables required for erection and commissioning activities shall be
arranged by the tenderer.



02.03.16 Supply of C&I Mandatory spares for trouble free operation as per the list
enclosed in clause no 06.02.00

02.03.17 Commissioning spares.

02.03.18 Maintenance platforms and access ladders for instrumentation equipment
installed at inaccessible heights.

02.03.19 Compliance with `General Technical Rules' as indicated under clause no.
04.00 of this specification.

02.03.20 Tenderer may please note that for all imported instrumentation /equipment
selection of vendors shall be made in such a way that the provision of after
sales service and supply of maintenance spares for at least for ten years shall
be ensured.

02.03.21 All skid mounted instruments shall be as per OEM standards

02.03.22 In case of offshore vendors, It is preferable to select offshore sub-vendors,
who already has an associate/subsidiary/service agency in India who will give
after-sales service.

02.03.23 Names of offshore vendors considered shall be given in tender.

02.03.24 The client reserves the right of selecting the manufacturer / model of control &
instrumentation items in the interest of standardization wherever necessary
and the Contractor will agree to supply equipment of particular make if so
desired by the client without any cost implication. Manufacturer / model of



control & instrumentation items will be as per Contract. Any specific
requirement for change shall be approved by the Customer before finalization.

02.03.25 Any C&I equipment required during any stages for the efficient / safe / reliable
operation of the plant either during detail engineering / commissioning will be
supplied, installed and commissioned by the successful Contractor without
any additional cost as per technological and operational requirement at any
stage of project implementation.

03.00.00 DESIGN CRITERIA

03.01.00 In general, instrumentation equipment considered shall be electronic type and
micro-processor based. Signal from primary field transmitters to remote
instruments in the control room shall be 4-20 mA DC. The pneumatic signals
from converters to actuators shall be 0.2 - 1.0 kg/cm
2
i.e.( 3-15 psi). if
required.

03.02.00 Same transmitters shall be used for measurements and control .
For critical measurements tenderer shall provide 2 out of 3 voting (Two out
of three philosophy shall be adopted for the control of all the critical loops).
The control system shall select the median value for the control purpose. .

03.03.00 Metering Bases

Pressure above 0.1 kg/sq. cm kg/sq. cm
Pressure below 0.1 kg/sq. cm
and draft
mm WC
Vacuum mm Hg or mm WC
Differential pressure mm WC



Temperature Degree Celsius
Flow (liquid) Cu.m/hr.
Flow (lub. oil) litres (totalised)
Level mm, cm, m

03.04.00 Instrument tapping points, root valves and connections shall
be followed as :

Root valves of reliable and rugged construction shall be provided at the
tapping points of process pipeline. Connection sizes to be adopted for the
instrumentation tapping points for measurement, control and test shall be as
follows:

Pressure measurement 1/2" NB SW
Temperature measurement On 1 1/2" flanged thermowell
with rating 300 # as minimum
Flow, level and differential
pressure measurements
1/2" NB SW
External displacer level
instrument
1 1/2" flanged 300 # minimum
Internal displacer level
instrument
4" flanged
Level gauge on vessel 1" flanged 300 # minimum
Level gauge on stand pipe 1" flanged / SW
Pneumatic connection for
signal and air supply
1/4" NPTF
Electrical connection 1/2" NPTF



03.05.00 Transmitters and Primary Elements

SMART transmitters providing a 2 wire output of 4 - 20mA DC shall be
provided with Digital local display indicators, for pressure, flow, level and
differential pressure measurements along with on line calibration and shall be
communicated with HART calibrator. The accuracy of these transmitters shall
be of minimum 0.1% of span or better. These shall be installed as close to
tapping points as possible from layout consideration for important signals
control and indication measurements shall be with separate transmitters.

The measuring elements of the transmitter shall be designed to withstand a
minimum static pressure of 1.5 times the maximum span without damage or
permanent deformation. For pressure / differential pressure transmitter, proof
pressure shall be 2 times of maximum static pressure of the process.

All pressure transmitters shall have easily accessible span and zero
adjustments. A range suppression/elevation facility shall be built-in.

Sensing elements and internal parts shall be made of material that is
corrosion resistant to process fluid. In general SS 316 may be used. All
pressure and differential pressure instruments shall be provided with block
and bleed, bypass, drain/vent valves etc. as per installation requirement of
the manufacturer. Direct mounted pressure switch shall be of either
diaphragm or bellow type of SS 316 or better with 1/2" NPT (F) connection.

For selection of level transmitters/controllers, the following type shall be
offered:



External displacer type instrument with routable head shall normally be
used for level measurement up to 1219 mm. Displacer shall be of SS-
316 with inconel torque tube. Side connections shall normally be used.

Differential pressure transmitters shall be used for level measurement
above 1219 mm or for services requiring purge or where liquid might
boil in external portion.

Level switches shall generally be external ball float types with flanged
head.

All level gauges / transmitters shall be provided with drain connection to be
ultimately taken to ground level.

For temperature measurement using Resistance Temperature detector (RTD)
or thermocouples, the measurement shall be provided with cold junction
compensation. Compensating cables shall be brought up to the control room.
All the thermocouples and RTD's shall be as per manufacturer standards.

Local temperature gauges shall generally be bimettalic type with 150-mm dial
size. Wherever chances of vibration are present, filled type gauges with
additional capillary extension shall be used.

Flow measurement shall normally be done with concentric orifice plate
mounted between a pair of weld neck flanges of minimum 300 lbs ANSI rating
with flange taps.



03.06.00 Instrument Cables

Fire retardant low smoke (FRLS) PVC cables (IEC-60332.1, 1993) having
solid 7 strand conductor of 1.0 sq. mm twisted pair have been considered for
control and signal cables from field /junction box (in field) to marshalling rack
in the control room. This signal cable shall be of overall screened or as per
manufacturer standards.

a. Instrument cables shall be 660V grade with annealed and tinned electrolytic
grade solid copper conductor of 1.0 sq. mm dia insulated with extruded
PVC, suitable for conductor temperature of 70 deg. C - outlet sheathed by
extruded FRLS PVC colour (Blue/Orange) as per manufacturer standard
practice.

03.07.00 Power Supply

Power supply for entire C&I system shall be from Un-interruptible Power
Supply System (UPS) with battery backed. The input power to UPS shall be
415 volts, 50 Hz from redundant source.

UPS Output Voltage 240V 1% AC
Frequency 50 Hz 0.5%
Total Harmonic
distortion
Less than 2%
Input Voltage 415 V 10%, 50 Hz

The detail UPS specification is furnished in the electrical part of this Technical
Specification.



03.08.01 Distributed Control System (DCS/PLC)

This clause defines the technical requirement to the Distributed Control
System (DCS)/PLC for the Hydel Power Plant. Bidder shall be responsible for
engineering, selection and connection of all components and sub-system to
form a complete system whose performance shall be in accordance with the
functional, hardware, software and other requirements of the specification.
The successful bidders activities in compliance with the present specification
shall include design, analysis, issue of drawings / documents, manufacturing,
inspection and testing, packing, shipping, storage and commissioning as well
as furnishing of instruction & maintenance manuals. The main purpose of the
DCS/PLC shall allow the plant to be automatically managed in all the foreseen
operative conditions, while generating the reliability, availability,
maintainability requirements relative to the entire plant.
The system shall be placed in an air-conditioned environment, the
temperature may vary 21 deg. C to 36 deg. C with 55% + 5% relative
humidity. If the air conditioning system breaks down, the DCS/PLC shall be
able to operate, without any problem caused to the functions, with an outside
temperature between 18 deg C to 52 deg C and a non-condensing humidity
between 40% and 80%.
All dedicated systems like EHTC, SRV unit Turbine supervisory system will
also be connected to the DCS/PLC through soft link/Hard wire link, so that all
required parameters are suitably monitored and controlled from the DCS/PLC
based HMI system. All required I/O cards and other processing modules etc.
shall be provided for this purpose.
All panels for DCS/PLC, Turbine supervisory instrumentation system, EHTC,
SRV unit etc will be located in the local control rooms for each unit at
generator hall (0 Mtr. level).
Local control room will be renovated with adequate Air conditioning,
illumination and proper glass partitions.



All controller panels shall have inbuilt LCD display with touch screen to
monitor and configure locally with proper security level.
DCS/PLCs of all units shall be connected to eathernet switch located in
networking panel at centralized control room through FO cable.

03.08.02. DCS (Distributed Control System)/PLC (Programmable logic controller)
for Unit- 1 to 6

DCS/PLC shall be latest State-of-the-Art microprocessor based system which
shall be used to execute all the process and safety shut-down logics of the
plant. Every unit shall have individual independent DCS/PLC. This shall be
an independent unit.

i) 1:1 hot standby Redundancy level shall be envisaged for the following items:
CPU 32 bit level
Communication card level
Critical I/Os
24V DC Power Supply .However detailed of rating & Power distribution
shall be done during detailed engineering.
Communication Bus, Ethernet Switches for Connectivity, redundant
modbus

ii) Switch for connectivity with 8/16 port.

iii) Memory will be non volatile. However , in case volatile memory is provided by
battery backup shall be provided with minimum of 3 months life time to keep
the program safe. Battery drain indication shall be provide before final drain

iv) Watch dog timer will be software device.



v) DI,DO and AI/AO Marshalling cabinet shall be finalised during detailed
engineering.

vi) DCS/PLC panel shall be as per manufacturer standards, however panel
dimension shall be finalised during detail engineering.

vii) Interposing Relay 24V ( 1NO+1NC) with LED indication

viii) 240V AC,50Hz UPS Parallel redundant (Refer Electrical TS)

ix) Inside panel minimum 250mm space shall be left from bottom plate

x) Panel shall be fitted with Proper illumination with 2nos. CFL at Front and rear
and 2nos fans.
xi) Tenderer shall ensure full co-ordination of the colour of various components of
the control room viz. walls, ceiling, floor, control desk & other furniture,
which shall be aesthetically appealing. A comprehensive proposal for the
control room & colour coordination shall be furnished to Client/Consultant
during detailed engineering for approval.

xii) Control desk shall be modular type and composition of MDF board and
Aluminum Composite Panel (ACP).
xiii) Colour Combination : Customized during Detailed engineering
xiv) Light Lux Level : As per International norms &Specification
xv) Control room shall be false flooring or granite floor shall be decided during
detailed engineering or Bidder shall proposed as per site condition.
xvi) Designer False Ceiling Combination of Gypsum & Ceiling tiles,
xvii) ES & Operator console shall be finalised during detailed engineering



xviii) Multiple window facilities/face plate in all the operating station.
xix) 20% installed spare need to be considered in I/Os over and above basic count
xx) 20% spare I/O channels on each card level equally distributed and
20 % I/O channels of actual used shall be provided as spare with wired.
10% spare installed I/O modules
20 % spare module space shall be provided in all the panels.
30% spare TBs space with wiring for future use.

xxi) 40% spare in CPU memory even in worst loading condition
xxii) Soft link Communication from DCS/PLC to switch yard SCADA system (if any)
shall be provided.
xxiii) OPC Interfacing facility shall be provided with unit- 7 & 8 DCS/PLC/SCADA
for MIS and level-2 automation system with all necessary software as well as
hardwires (Like cards, converters fiber optical cables etc.) for effective
communication. Minimum 02 nos. of OPC gateway shall be provided.
xxiv) 32/16 channel for all DI/DO in each card wise
xxv) 8/16 channel for all AI/AO in each card wise (AI/AO in same card is not
acceptable) AI module accepting 4-20mA to avoid ground loop formation and
noise pickup.
xxvi) RTD and Thermocouple card shall be separate.
DCS/PLC engineering and application Licensed Software details to
be handed over to client along with Part no. and with latest
version after commissioning etc.

Watch dog timer shall be software based. The healthiness of processor shall
be continuously monitored by watch dog timer. Any hardware or software
problem in the processor system which shall include CPU, memory, power
supply, communication etc. shall cause the watch dog timer to report the
failure of processor and switch over to the bumpless redundant processor.



xxvii) Report/Long Term/Event data archival package/self documentation/test
function/stand builder function/Alarms shall be provided for all operating
station as well as Engineering Station.
xxviii) Report/Long term data archival package/ Shift report package/self
documentation/ Software Manual/
xxix) On line replacement of any module in the DCS/PLC shall be possible in such
a way that removal and addition of a module shall be possible without de-
energizing the system. Further there should not be any interruption in the
system while replacing a faulty module wherever redundant modules are
provided.
xxx) Online logic can be edited/changed and down load without interruption of
DCS/PLC.
xxxi) For communication Fiber optic cable including laying ,termination and its
convertor etc shall be in tenderer scope.
xxxii) Logic chart control loop display/Trending/Graphics/ electronic documentation
History/Alarms software shall be considered for all operating station as well
as ES cum operating stations

03.08.03. Human Machine Interface (HMI)

1. The Human Machine Interface (HMI) system is the primary interface to the
DCS/PLC functionality. It is critical to the operation of the DCS/PLC/PLC. A
secure, flexible and user friendly HMI shall be provided by which engineers,
supervisors & the operators shall interact with the system. The HMI shall
exploit the best characteristics of 22TFT, Key boards, Cursor control devices
and character / graphic printers.
2. The System Configuration of the proposed DCS/PLC shall be as per Drawing
enclosed with the tender document. Six nos.(6) of 22TFT Operator Work



Stations (OWS) with one no. (1) of dot Matrix Printer & three (03) nos. of
colour laser printer (A4), three(03) nos. 22 TFT Engineering work station
(EWS) and one number (1) Large Video Screen LCD type 65 with one no.
(1) of colour laser printer(A3) shall be provided at the Main Central Control
Room.
3. The OWS shall consist of computers with 22TFT, printer, keyboard & . The
computers shall be of commercial grade IBM compatible based on latest and
industry-proven processors. Sufficient memory capacity as per system
requirement with necessary spare capacity shall be provided. All OWS shall
be fully interchangeable i.e. all operator functions including control, monitoring
and operation of any plant area or drive shall be possible from any of the
OWS at any point of time without the necessity of any action like downloading
of additional files. Each OWS shall be able to access all control / information
related data under all operating conditions including a single processor /
computer failure in the HMI. Further, simultaneous operation from a single
display without calling additional displays for multiple drive operation shall be
possible.

The EWS with plant supervision and management capabilities equal to those
of the OWS shall be provided. The EWS shall be able to access the system
data base and modify the elements. The EWS shall have programming
facilities for Control System as well as for HMI system. The system shall have
in-build safety features which shall protect the system against inadvertent and
unauthorized use of these tools. Necessary hard key-locks & software locks
etc. shall be provided for this. The EWS shall allow for the management of
process variables, of the input and output signal address, of the control loop
and control logic structure, of the modalities in which information is presented
to the operator, of the synoptic graphics, of the printing and archiving
protocols and of all those characteristics which are needed to carry out the



tasks assigned to the control system. The engineer shall be able to manage
the systems memory devices through the EWS in order to save the
configuration files. EWS shall also act as Diagnostic Station for automatic
display and recording of any system disturbance to enhance the system
availability. For these all processors, modules / cards, operator console etc.
shall have on-line self-diagnostic features which shall be displayed at
equipment / module level and inform to the EWS to display the fault with
equipment / module identification in clean text. All types of faults and
disturbances in all modules used in the system shall be automatically
displayed and printed. A graphic system that supports the systems self-
diagnosing system shall be created. These graphic pages shall allow for the
identification of any system component that is not functioning perfectly. The
diagnostic pages of the system shall be arranged according to a hierarchical
structure. This self-diagnosis level in the DCS/PLC shall run continuously and
automatically without requesting any type of action to be taken by the
operator.
1 no. of PC with 22 TFT monitor shall be provided for Inventory management
system. Necessary hardware and software shall be provided for the same.

03.08.04. Synchronization System (Master Clock)

The DCS/PLC shall be equipped with a master clock system for the
synchronization of modules through a satellite signal (GPS). The system shall
also foresee an adequate number of interfaces for the connection and
synchronization of the other plant control system if required. Facilities for GPS
system shall be provided.
03.08.05. Sequence of Events Recording System (SOER)



The DCS/PLC shall be able to guarantee the chronological recording of the
events (SOE function) relative to the plant & electrical equipment. The time
resolution for this function must be 1 ms or better. The integral SOER system
shall provide the operators with a time-logged log of all conditions which can
directly trip the Turbine-Generator, its auxiliaries, electrical system and other
electrical equipment as well as other conditions which require better time
resolution than the standard alarm printer offers. The SOE system shall be
sized to accept the inputs (minimum 64 nos. for each unit) with 20% spare
capacity for additional inputs.

04.00.00 GENERAL TECHNICAL RULES

04.01.00 The general engineering and calculations shall be made as per prevailing
Indian/ International standards acceptable to Purchaser. Wherever such
standards are not available, they shall be as per practice in India and abroad.

04.02.00 All measurements shall be in metric units.

04.03.00 Scale range shall be selected so that normal process parameter is
approximately 75 % of full scale. The gauges shall be provided with zero and
over range mechanical and over range protection of 125%.

04.04.00 Maintenance platforms with suitable approach shall be provided for flow
elements, control valves, servo valves, critical switches used for
protection and interlocks, annunciation and other equipment installed at
inaccessible locations.

04.05.00 The field instruments shall be of reliable and rugged in construction and of
proven design, suitable for following conditions:



Temperature : 65 deg. C
Relative humidity : 100 % max.

04.06.00 Instruments installed in the open shall be weather proof, dust tight, shock
proof and splash proof. If such instruments are not available, these shall be
housed in weather proof enclosures having IP 65 protection.

04.07.00 Instrument with following accuracys shall be offered:

Flow/ pressure /differential
pressure/ temperature
transmitters
:
0.1% of calibrated span or better
Panel mounted indicator/
recorder
: 0.5% of full scale or better with
minimum denomination of 1% marking
Digital indicator : 0.1% of full scale 1 count
Pressure gauges : 1% or better
Temperature gauges : 1% or better
Pressure switch : Repeatability 1% or better.
Temperature switch : 2% or better
RTD : Response time < 20 secs with
thermowell
Thermocouple

: Response time < 20 secs with
thermowell Limit of error
K type thermocouple
3 deg. C < 400 deg. C

04.08.00 Transmitters shall be positioned as close as possible to the measuring points.



04.09.00 Flow transmitters shall be fitted with 3 valves manifold and pressure
transmitters with 2 valve manifold.

04.10.00. Direct pressure measuring instruments shall be diaphragm, bourdon or
bellows type elements depending upon the service conditions. In general,
diaphragm elements shall be used in the range of 0-1000 mmWC
pressure, bellows type elements for ranges of 0-1kg/sq.cm and bourdon tube
elements for ranges greater than 1 kg/sq. cm.

04.11.00. Primary element material shall be corrosion resistant to process fluid or
diaphragm seal shall be provided for protection.

04.12.00 Pressure gauges shall be provided with SS 3 way gauge cocks, single
coil siphons and shall also be with snubbers, diaphragm seal wherever
applicable.

04.13.00. Pressure switches shall be installed with SS 2 way valves with detachable
handles. Electrical connection from pressure switches shall be properly
glanded and bottom entry.
04.14.00 Directly mounted pressure switch shall have elements either diaphragm,
bellows or bourdon type depending on the service conditions. Material of the
element shall be minimum SS 316 & with 1/2" NPTF connections.

04.15.00 For low pressure application where long elements are used, well supported
protecting tube shall be installed to prevent mechanical damage and erosion
of the elements.

04.16.00. Minimum dial sizes of pressure and receiver gauges shall be 150 mm for local
as well as panel mounted gauges.



04.17.00 All the remote monitoring/controlling instruments shall be located in main
control room, which should be dust proof.

04.18.00. Gauge glasses shall normally be reflex or transparent type depending upon
service, with over all length not exceeding 1500 mm.

04.19.00. For liquid level measurements, float, displacer, or differential pressure type
shall be used depending upon the vessel/tank is closed or open type and
the medium for which it is used. Accuracy of measurement shall be 1% of full
scale or better. Wherever necessary standpipes or float chambers shall be
provided and also make up line for filling up the constant vessel shall be
provided.

04.20.00. All flanged end connections of instruments shall be of minimum 150-300 lbs
ANSI standard.

04.21.00. For measurement of Penstock water flow Winter Keneddy type flow meter shall
be used.

04.22.00. Duplex type Thermocouples/RTD should be complete with compensating
leads, installation fittings. The indicators, controllers shall have broken
sensor protection.

04.23.00. Interconnections to/from thermocouples to temperature transmitters shall be
made via compensating cables having thermoelectric characteristics
compatible with thermocouple to which they connect.
04.24.00. In case of compensating leads that are to be laid on the top of any heated
zone, they shall be covered with suitable insulating materials except asbestos



04.25.00. Compensating cables connected to transmitters shall not be through terminal
blocks but shall be directly connected.

04.26.00. Thermocouple/RTD calibration shall conform to relevant IS/DIN standards of
latest revision.

04.27.00. Thermowell shall be drilled out of bar stock and the length and construction
shall comply with process requirement/relevant standards. Material of
construction of thermowells shall be stainless steel /hastelloy/ inconel suitable
for the application..

04.28.00. Self-actuating controllers may be used wherever appropriate.

04.29.00 The panels shall be upright, floor mounted and dead front type and shall have
ventilation with steel mesh. The outside colour of all instrumentation panels,
control desks, consoles, local panels, marshalling cabinets, system cabinets
etc. shall be finalised during detailed engineering stage. The inside colour of
all these panels shall be brilliant white. This shall hold good for
instrumentation panel of all auxiliary units also.

04.30.00 15mm Anti-vibration mounting and shock absorbers shall be provided for all
panels and Control Desks.

04.31.00 The panel surface shall be thoroughly degreased, smoothed, filled and
painted with rust resistant two coats of primer and three coats of paint to
present a smooth and flat finish.



04.32.00 Front of panels shall be primed and filled as required giving at least two
coats of primer and minimum three coats of final colour above the primer
coating to present a smooth and mat finish.

04.33.00. Legend plates shall be provided on the panel face, desk face and for
instruments behind panel/desk to identify equipment.

04.34.00. Overall dimensions of nameplates shall be decided by the text of legend,
maintaining overall consistency and clarity and avoiding size variations.

04.35.00 On the panels, equipment shall not be mounted below 300mm from the gland
plate level. Alarm bells/hooters etc. shall be mounted on the panel top.

04.36.00 Equipment inside the panel shall be so located that their terminals and
adjustments are readily accessible for inspection and maintenance.

04.37.00 Instrument power supply (see clause 04.10) shall be through circuit breaker
(with adjustable short circuit and over load release facility) and 1:1 isolating
transformer. Miniature circuit breakers with fuse shall be provided on the
secondary side for providing power supply to group of 2 3 instruments. All
instruments shall have individual switch fuse units mounted on control
desk/panel. Plug and socket shall be provided for each panel and desk for
portable lamp.

04.38.00 The power supply equipment for instruments shall be installed inside the
instrument panel, with proper heat dissipation facility.

04.39.00 Electrical accessories e.g. circuit breakers, control switches, push buttons,
panel lighting fixtures, light switches, hooters etc. required for the panel shall



be from acceptable reputed make and these shall be supplied with the
panels/desks. These should be suitable for the application and environmental
conditions.

04.40.00 All panel wiring, except power and thermocouple circuits, shall be made with
660 V grade PVC insulated 0.5 to 1.0 sq. mm multi strand copper conductor.
Power supply wiring shall be done with 2.5 sq.mm copper conductor.

04.41.00 All terminal blocks shall be provided with minimum 20% spare terminals.
Terminal blocks shall not have smaller than 4 mm terminal connecting screws.

04.42.00 Wires shall run in suitable plastic wiring sleeves between terminal ends and
tagged.

04.43.00 Wires shall run in suitable flexible metallic conduits under the false floor
between terminal ends.

04.44.00 No instrument contact shall be used directly in any alarm or interlock circuits.
It should be always be through relay contacts.

04.45.00 Wherever screened cables will be used for signal transmission, these shall
be of cross twisted pair, shield type shield shall be earthed one end only
inside the control room.

04.46.00 The various flexible cores, within the cables shall be PVC insulated and
numbered and/or identified by a colour code. All cables shall be in accordance
with applicable standards and codes.



04.47.00 Shield shall have 25% overlap and 100% coverage. Shield thickness shall
be 0.06 mm (min.) and tinned copper drain wire of 0,8 mm dia nominal.

04.48.00 Separate cables shall be used for low and high voltages. All the equipment
fed from electrical system and installations shall meet the statutory
requirements of Indian Electricity Rules.

04.49.00 For cable laying, cable trays shall be made of hot dip galvanised steel plates
of minimum thickness of 5.0 mm. Each tray shall be provided with 20% spare
space.

04.50.00 A minimum clearance of 250mm shall be kept between instrument and
power/signal cables.

04.51.00 Cables shall be properly dressed and clamped with the cable trays as per
standards.

04.52.00 Cables which are not laid in the cable trays shall be laid through protective G I
conduits.

04.53.00 Sharp bends in cables should be avoided. Wherever necessary, junction
and pull boxes with proper gland shall be used. Cables shall be laid neatly
and crossing in trays shall be avoided.

04.54.00 Conduits, junction boxes and pull boxes shall be properly grounded.



04.55.00 All instrument cables shall be glanded and terminated both in field
(instruments, JB etc.) and at control room (marshalling cabinet etc.) using
double compression glands.

04.56.00 All the cores of the cables shall be marked with ferrules. Acrylic tags shall be
provided at both the ends of the cables for identification.

04.57.00 After completion of cable laying work, all cable bushings on panels, desks and
cabinets shall be filled with fire resistant sealing compound against the floor.
The instrumentation earthing system wherever necessary must run to a
common pit as per standard.

04.58.00 Erection fittings shall be rust proof.

04.59.00 Seamless SS tubes of size 1/2" (12 mm) dia (1.5 mm thick) or as per
manufacturer standard shall be used for impulse lines. As far as possible
impulse lines shall be welded. Swage-lock or equivalent compression type
joints shall be provided wherever it necessary to open the lines frequently. For
proper drainage, impulse lines from primary point to transmitter shall be laid
with proper gradient

04.60.00 Instrument shall be of SS, provided with expansion loops, isolating valves,
equalising valves, drain valves at suitable places and shut off valves at
tapping points wherever applicable. Process fluids shall not be piped directly
to instruments in the control room.

04.61.00 Integrated control with other Units



05.00.00 List of Measurements, Controls, Alarms And Interlocks

Following are the indicative list of measurements, controls, alarms and
interlocks for the Unit. These Electrical & process measurements shall be
made available at the control room DCS/PLC and local as detailed below.
However the tenderer shall provide these and other measurements as felt
necessary for their system offered as per their standard proven make

05.01.00 Remote measurement

1. Generator

i) Stator Voltage
ii) Stator Current
iii) Field Current
iv) Field Voltage
v) MW
vi) MVAR
vii) Frequency
viii) Power factor
ix) Temperature in different segment of stator wdg and stator core
x) Rotor temperature
xi) Partial Discharge
xii) speed**
xiii) breaking air pressure
xiv) jacking oil pressure
xv) kWh meter



2. Excitation

i) Excitation current
ii) Excitation voltage
iii) Null detector
iv) Excitator winding temp.
v) Kwh meter
3. Generator Thrust Bearing/Upper Guide Bearing/Lower Guide Bearing

i) Bearing pad metal temp. Thrust pads and guide pads
ii) Bearing lube oil temp.
iii) Oil level in bearing lube oil housing
iv) Lube oil pressure
v) Water in oil detector
4. Generator Air Cooler
i) CW inlet temperature
ii) CW outlet temperature
iii) CW inlet pressure
iv) Hot air temp. of each cooler
v) Cold air temp. of each cooler

5. Turbine
i) Turbine Governing Valve opening in % and in mm
ii) Guide vane opening in % and in degree
iii) Guide vane locking indication
iv) Spiral case inlet pressure
v) Draft tube pressure



vi) Turbine speed ( 2 out of 3)
vii) Head cover water level
viii) Shaft seal CW pressure and flow.
ix) Turbine inlet water flow.
x) Turbine inlet water pressure.
6. Governor Oil Pressure Unit
i) Oil level in sump tank
ii) Flow of water to oil cooler
iii) OPU tank oil level
iv) OPU tank oil temperature
v) Gov. Oil pressure
7. Turbine Guide Bearing (TGB)

i) Lube oil temp.
ii) Guide bearing metal temperature
iii) Vibration
**

iv) Oil level
v) Water in oil detector

8. CW system

i) CW pump discharge header pressure, flow and temperature.
ii) Cooling water outlet temperature at Oil coolers outlet.

9. Drainage
i) Sump level



10. Air Compressor

i) Compressor delivery pressure

11. Generator Transformer

i) MW
ii) MWH
iii) A
iv) V
v) oil temp
vi) winding temperature
vii) Transformer oil header pressure

12. Unit Auxiliary Transformer

i. A
ii. V
iii. KWH

13. Station Transformer

i. A
ii. V
iii. KWH

** measurements shall be as per manufacturer standards



05.02.00 Local Measurements

Following local gauges shall be envisaged for each unit as a
`minimum :
i) Inlet pressure of spiral casing.
ii) Draft tube pressure.
iii) Spiral casing winter kennedy differential pressure.
iv) Local turbine speed indicator.
v) Guide vane opening indication.
vi) Guide vane servomotor stroke indication (scale).
vii) Governor oil pressure.
viii) Pressure receiver tank oil pressure.
ix) Oil level in pressure receiver tank (gauge glass).
x) Turbine servomotor oil pressure.
xi) Hydrostatic lube oil pressure.
xii) Differential pressure across oil filter.
xiii) Generator thrust bearing/upper guide bearing/lower guide bearing lube oil
inlet pressure.
xiv) Generator thrust bearing/upper guide bearing/lower guide bearing lube oil
temperature.
xv) Generator thrust bearing/upper guide bearing/lower guide bearing metal
temperature.
xvi) Turbine guide bearing oil and metal temperature.
xvii) Turbine guide bearing lube oil inlet pressure.
xviii) Oil level in bearing lube oil housing.
xix) Jacking oil pressure.
xx) Shaft seal cooling water pressure.
xxi) Cooling water system main inlet pressure at inlet to lube oil coolers and
generator air coolers.



xxii) Cooling water system strainer / filter differential pressure.
xxiii) Cooling water discharge header pressure.
xxiv) Cooling water pump suction and discharge pressure.
xxv) Vacuum pump discharge pressure.
xxvi) Circulating tank level.
xxvii) Drainage and dewatering pump discharge pressure.
xxviii) Air compressor pressure.
xxix) Braking air pressure.
xxx) Transformer oil cooler inlet flow and pressure.
xxxi) Transformer oil cooler outlet temperature.

05.03.00 List of Alarms

Sl.No. Items Description
1 Generator All electrical Protection operated
*
2 Generator All non electrical protection
*

operated
3 Generator Brake Air Pressure Low
4 Generator PT fuse failure
5 Generator Rotor earth fault
6 Generator (TB, LGB, UGB) Bearing temperature high
7 Generator Bearing temperature very high
*
8 Generator Stator winding temperature high
9 Generator Stator winding temperature very
high
*
10 Generator Creeping
11 Generator Overspeed
12 Turbine guide bearing Bearing temperature high



13 Turbine guide bearing Bearing temperature very high
*
14 Turbine guide bearing Bearing oil level low
15 Turbine guide bearing Bearing oil level very low
*
16 Bearing Oil Contaminated
17 Generator lower guide bearing
cooler
Water flow low
18 Generator upper guide bearing
cooler
Water flow low
19 Generator air cooler Water flow low
20 Shaft Seal Water pressure low
21 Turbine guide bearing cooler Water flow low
22 Governor Oil Level Low
23 Governor Oil Pressure low
*
24 Excitation Transformer Temperature high
25 Generator Transformer Oil temperature high
26 Generator Transformer Oil temperature very high
27 Generator Transformer Winding temperature high
28 Generator Transformer Winding temperature very high
*
29 Generator Transformer Buchholz Alarm
30 Generator Transformer Buchholz Trip
*
31 Station Transformer Oil temperature high
32 Station Transformer Oil temperature very high
33 Station Transformer Winding temperature high
34 Station Transformer Winding temperature very high
*
35 Gen. Circuit Breaker Auto Closed
35 Auto Syn. Lock out
36 11 kV Feeder breaker Fault trip



37 415 V feeders Fault trip
38 Auxiliary DC Supply Under Voltage
39 Auxiliary DC Supply Earth fault
40 UPS Fault in System
41 Head Cover Water Level high
42 Air Compressor Low press
43 CO
2
bank Released
44 Differential pressure across oil
filter
High
45 Differential pressure across
side stream filter
High
46 CW supply header pressure &
flow
low
47 CW pumps (individual)
discharge pressure.
low
48 Circulating tank level low
49 Brake air pressure low
50 Drainage sump level High and low

NOTES : * Astrick mark points to be used for tripping purpose als

05.04.00 Control & Interlocks

Sl.
No.
Description Interlocks
1 Unit start /stop Satndard interlocking arrangement shall be
provided for starting, emergency shut down
and normal shutdown



Sl.
No.
2 Governor opening and
closing
Start / stop provision
3 Governor oil pump Start on Low pressure alarm & stop on high
pressure
4 Turbine Speed Raise / Lower Provision
5 11 kV Breaker closing Syn. Closing with checking of incoming /
running voltage, frequency and phase angle
in auto mode, Manual mode operator will
close manually but check command will be
there from SCADA to avoid wrong closing
6 11 kV Breaker closing Check syn. Closing provision
7 Generator Voltage Raise/ Lower provision
8 11 kV breaker tripping Protection and for manual tripping
9 11 kV transformer
secondary side
breaker tripping
On tripping of 132kV breakers
10 11 kV Circuit breaker
closing/tripping
provision
Provision of tripping / closing
11 Compressor for
governing oil system
Start on low pressure and stop on high
pressure
12 De-watering Pump Start and stop based on sump level
13 Governing oil Control pressure at set value
14 Oil filter Auto change over with respect to the
differential pressure across the filter.
15 CW pump Interlock with circulating tank.
16 CW pump Stan by pump start on low pressure



Sl.
No.
17 Vacuum pump Start on circulating tank for CW pump level
low & stop on circulating tank level high
18 Drainage pump Start on drainage sump level high & stop on
drainage sump level low

The list of alarms, measurements, control & interlocks mentioned above are
minimum to provide and will be finalised during detail engineering stage

06.00.00 Drawings and Documents

Following drawing and documents shall be submitted for instrumentation.
All communication/descriptions in the drawings, documents, technical
literatures and manuals shall be
in English language only.

06.01.00 Along with the Offer

i) Process and instrumentation (P&I) diagrams for each unit with all auxiliaries
indicating all field mounted, local panel mounted, control room panel mounted
instruments using ISA symbols and using suitable tag numbers against each
instrumentation equipment. Also and interlock functions shall also be
indicated in the P&I diagrams.

ii) Specification of each instrumentation equipment indicating make, model no.,
application, , quantity, tag no. accuracy, etc. as per standard
specification sheets along with instrument schedule of complete C&I
package



iii) Detailed technical literature of each instrumentation equipment offered.

iv) System configuration Diagram for proposed DCS/PLC and shall have SCADA
compatible.

v) Technical specification with literatures of all the sub system of DCS/PLC & I/O
sizing considered

vi) Control schemes along with write-up for turbine governing system and
protection/interlock schemes for turbine and its auxiliaries and bill of materials.
vii) Quality and quantity of electric power requirement for
instrumentation and also instrument air requirement.

06.02.00 Drawings/documents to be submitted by the successful tenderer

A. For approval

i) Process and instrumentation (P&I) diagrams for the unit with all auxiliaries
indicating all field and panel mounted instruments using ISA symbols and
using suitable tag numbers against each instrumentation equipment Alarm
and interlock functions shall also be indicated in the P&I diagram.

ii) Specification of each instrumentation equipment indicating make, model no.,
application, scale range, quantity, tag no. (as per P&I diagram), accuracy,
power consumption etc. Data sheets for each instrument as per standard
format shall be submitted with all the required details filled in along with
detailed technical literature. Schedule of instruments/BOM shall be submitted
by the successful tenderer.



iii) Control schemes along with write-up for turbine governing system and
protection/interlock schemes for turbine and its auxiliaries and bill of materials.

Overall system configuration diagram along with write-up on the system
I/O list
Final technical specification of all sub system of DCS/PLC
OGA & GA of various cabinets/panels consoles with dimensional details of
DCS/PLC
QAP for DCS/PLC
FAT procedure for DCS/PLC

iv) Instrument power supply diagram along with bill of quantities (BOQ).
v) Instrument panel general arrangement drawings (both local and remote
panels) along with BOQ.

vi)Disposition of instrument panels, desk, cabinets etc. inside local control
room and unit control board.

viii)The protection and interlocking schemes for all equipment, general
interlocking schemes for turbo-generator protection system.

B. For Procedural Checking and Records

i) Instrument panel wiring diagrams

ii) Hook-up diagrams



iii) Erection/installation diagrams for all primary sensors and field
mounted equipment

iv) Alarm annunciation scheme
v) Sequential & safety interlock scheme
vi) Loop schematic diagrams
open/close loop list
DCS/PLC I/O hardware signal list
SOE input signals
Logic diagrams
Graphic display sheets
Measuring point list
DCS/PLC cubicle/panel power supply distribution single line
diagram
logging formats
Bus loading calculation

vii) Flow sensor sizing calculation sheets

viii) Instrumentation layout drawing showing location of sensors,
transmitters etc. and route of cables from these up to the
instrument panel in the control room.

ix) Cable and pipe schedules with specification, Manufacturer's
test, calibration and guarantee certificates for all the instruments

xi) Operation and maintenance manuals for each instrument

xii) Quality assurance plan for each instrument



The quantity of drawings listed above and to be submitted by the successful
tenderer shall be as per the general conditions of contract (GCC).
List of 2 years spares for operation and maintenance as per manufacturer's
recommendation and list of commissioning spares shall also be submitted.

07.00.00 List of spares

07.01.00 Operation & Maintenance Spares

Recommended list of spares for operation and maintenance for 5 years shall
be provided with unit rate along with the firm offer.

07.02.00 List of Mandatory Spare for Each Unit

A) Measuring Instruments/Field instruments.

i) 5% of total Temperature & Pressure gauges of each type & model
or a minimum of one of each type and model which ever is more.

ii) 10% of total temperature elements with thermowells for RTD/TC or
minimum one of each range & model which ever is more.
B) Distributed Control System (DCS/PLC)

i) 1 no. of colour laser printer
ii) 15 no. of each of black & colour in cartridges for each type of colour
iii) One no. of hard disk Drive unit of each type as offered in the main
Offer.
iv) 1no. of CD drive & CD writer & 10 nos. of CDs.



v) 20% of the total quality of each type & model of electronic modules or
a minimum of 2 nos. of each type & model of electronic modules, which ever is
more.

a) I/O cards/Modules
Analog input (4-20mA) -2nos.
Analog input RTD -2nos
Analog input T/C -2nos.
Analog out put (AO) -2nos.
Digital input cards (DI) -2nos
Digital output cards (DO) -2nos

b) Controller cards -2nos

c) CPU module -2nos

d) Communication card -2nos

e) Interposing relay & Coupling relay 10 nos.

f) 10% of the total quality of each type & model of batteries used for
battery backup of RAMs or a minimum of two (02)nos of each type &
model of battery, which ever is more , as offered in the main offer.

i) 100% of the total quality for each type model & rating of fuse.

j) Cooling fans for Power supplies/Panels 10% of total.
k) Power supply modules 20% or minimum 2 nos. of the total quantity
offered for each type & rating, which ever is more.



C) Electronic smart transmitters

i) 10% of total electronic transmitters of each type range and model or minimum
of one number of each type, range & model which ever is more.

D) Vibration Monitoring System

i) One no. of velocity coil type, accelerometer type and proximity
type vibration transducer
ii) One no. of power supply module.

E) Process Actuated switch devices

5% of total pressure switches , limit switches, differential switches,
temperature switches, flow switches of each type & model or minimum
of one number of each type & model which ever is more.

F) Local Instrument

i) 10 % of each type of Push buttons, indicating lamps, colour caps & control
sation for each type.

G) Alarm Annunciator

i) 10% of total electronic cards of each type & model or minimum of 2nos
of each type & model . This shall include all types of cards



07.03.00 Commissioning Spare

Commissioning spares list shall be furnished along with the firm offer . The left
out commissioning spares shall be handed over to client after commissioning.
The offer shall be submitted along with tender offer indicating unit price.

08.00.00 Inspection

For inspection of Instrumentation items procedure shall be governed as given
in chapter inspection & testing in Vol-IV. However C&I DCS/PLC integrated
FAT shall be inspected at manufacturers works.

FAT of PLC/DCS and governing control system shall also be conducted by
the bidder at their works and arrangement for witnessing the test for Three
(03) persons of the Employers and consultant are also to be arranged by the
Bidder free of cost i.e without any cost implication to the Employer.

09.00.00 List of Preferred Makes

PLC
Rockwell Automation Control Logix L73
GE Fanuc PAC Rx3i
Siemens S7-400H series
ABB 800XA
Schneider(Quantum) or better



DCS
Yokogawa Centum VP
ABB Simphony Harmony
Honeywell Experion Pks
METSO/BHEL MAX DNA
Emersion Ovation

TRANSMITTERS (PRESSURE, FLOW & LEVEL) :
YOKOGAWA INDIA LTD., EMERSON., HONEYWELL LTD,

DIGITAL INDICATORS :
YOKOGAWA BLUESTAR LTD., MASIBUS ELECTRONICS, RANUTROL
LTD.

PRESSURE/TEMPERATURE GAUGES :
WAIKA, WAREE ,GIC , A.N. INSTRUMENTS PVT. LTD

RTDs & THERMOCOUPLES :
GENERAL INSTRUMENTS, INDUSTRIAL INSTRUMENTATION,
INSTRUMENTATION LTD, NAGMAN SENSORS, TOSHNIWAL BROTHERS.

TEMPERATURE TRANSMITTER :
YOKOGAWA (I) LTD, EMERSON., HONEYWELL LTD.
DIGITAL SCANNER :
JYOTI, LECTROTEK, PROCON, MASIBUS.

PRESSURE SWITCH :
INDFOSS (INDIA) LTD., SWITZER INSTRUMENTATION PVT LTD.



FLOW TOTALISER :
YOKOGAWA (I) LTD., SIEMENS.

SOLID STATE ALARM ANNUNCIATOR :
APPLIED ELECTRONICS LTD. (APLAB), PROCON INSTRUMENTATION
PVT. LTD., PIRI SYSTEMS PVT LTD., IIC, MINILEC, MASIBUS.
.
POWER CABLES :
CABLE CORPORATION OF INDIA LTD., UNIVERSAL CABLES LTD., FORT
GLOSTER INDUSTRIES LTD., ASIAN CABLES LTD, FINOLEX CABLES
LTD., KEI.

INSTRUMENTATION SCREENED CABLES :
CABLE CORPORATION OF INDIA LTD., FINOLEX CABLES LTD.,
TOSHNIWAL CABLES, DELTON CABLES, KEI,MEM ASIAN CABLES,
UNIVERSAL CABLES.

COMPENSATING CABLES :
TOSHNIWAL CABLES, GENERAL INSTRUMENTS, UDAY RAJ, KEI.

ORIFIC / FLOW NOZZLE
ENGINEERING SPECIALITIES (PVT) LTD., MICRO PRECISSION, GIC

PC
HP, DELL, COMPAQ
ETHERNET SWITCH
CISCO,SIEMENS.

CONTROL VALVE



IL, MIL, Fisher-Xomox

PRESSURE SWITCH
WIKA, SWITZER, WAREE, ORION, INDFOSS

FLOW SWITCH
TRAC, CHEMTROL, D.K.INSTRUMENTATION, LEVCON

Note :
For those equipments/instruments whose make are not indicated in
TS prior approval of Purchaser/Consultant shall be obtained.

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