VARDHMAN FABRICS, UNIT: BUDHNI, M.

P
(A UNIT OF VARDHMAN TEXTILES LIMITED)
ADDITION OF STEAM CAPACITY, BACK PRESSURE TG & RICE HUSK HANDLING SYSTEM

AMENDMENT – I DATED 04.04.2018 TO TURBO GENERATOR & AUXILIARIES PACKAGE

Reference :

i) Request for Quotation (RFQ) for Turbo Generator and Auxiliaries : Doc. No. 4-16287-600-0014, Rev. 0 dated 17.01.2018

Volume / Chapter / Clause

No. Bid Description Amendment Description
Reference
1) Volume – II / Chapter 4 : Generation Voltage : 415V ± 10 % Generation Voltage : 11 kV ± 10 %
Equipment Design Basis and Fault Level : 50 kA for 1 Sec Fault Level : 40 kA for 1 Sec
selection Basis / 4.6.2 Control Supply : 230 V AC Control Supply : 110 V AC
2) Volume – II / Chapter 4 : Generator and its Auxiliaries : The alternator Generator and its Auxiliaries : The generator
Equipment Design Basis and shall be of Synchronous Generator type rated for shall be of Induction Generator type rated for
selection Basis / 4.6.3 415V. 11 kV. Attached Annexure – A shall be referred
to for the Specification for Induction Generator.
3) Volume – II / Chapter 4 : Generator Control and Relay Panel Generator Control and Relay Panel : Attached
Equipment Design Basis and Annexure – A shall be referred to.
selection Basis / 4.6.4
4) Volume – II / Chapter 4 : LT Switchboard Power Plant Switchboard (PCC) is deleted from
Equipment Design Basis and the BIDDER’s scope.
selection Basis / 4.6.5
5) Volume – II / Chapter 4 : LT Busduct LT Busduct is deleted from the BIDDER’s
Equipment Design Basis and scope.
selection Basis / 4.6.6

TURBO GENERATOR & AUXILIARIES Page 1 of 2 AVANT-GARDE

PACKAGE
 VARDHMAN FABRICS, UNIT: BUDHNI, M.P
(A UNIT OF VARDHMAN TEXTILES LIMITED)
ADDITION OF STEAM CAPACITY, BACK PRESSURE TG & RICE HUSK HANDLING SYSTEM

Volume / Chapter / Clause

No. Bid Description Amendment Description
Reference
6) Volume – II / Chapter 4 : Protection, Interlock and Inter Tripping Protection, Interlock and Inter Tripping
Equipment Design Basis and Requirements Requirements : Attached Annexure – A shall be
selection Basis / 4.6.7 referred to.

Enclosure :

a) Annexure – A (Specification for various items.)

b) Single Line Diagram for TG : Drg. No. 2-16287-900-0454, Rev. 01.

TURBO GENERATOR & AUXILIARIES Page 2 of 2 AVANT-GARDE

PACKAGE
 VARDHMAN FABRICS, UNIT: BUDHNI, M.P
(A UNIT OF VARDHMAN TEXTILES LIMITED)
ADDITION OF STEAM CAPACITY, BACK PRESSURE TG & RICE HUSK HANDLING SYSTEM

ANNEXURE – A

4.6.3 SPECIFICATION FOR INDUCTION GENERATOR

4.6.3.1 Schedule of Equipment

4.6.3.1.1 The equipment shall include one (1) number horizontal shaft three phase
alternating current induction generator to have MCR to deliver the maximum
output of the turbine at 0.8 PF, 11 kV, 50 Hz, 1500 rpm at site condition of 50
Deg. C ambient with all accessories, spares and special tools that will be required
for satisfactory erection and efficient operation of the system. The equipment
shall be supplies as per the requirement of latest revision of IS 325 / IS 8789.

4.6.3.1.2 The generator to be coupled to the turbine shall match in respect of speed, over
speed, moment of inertia, overload capacities, coupling and other relevant
requirements.

4.6.3.1.3 The generator shall be equipped with the following:

a) Stator assembly - 1 No.

b) Rotor assembly - 1 No.
c) End shield mounted bearings - 1 No. each for DE and NDE
d) Sole plate and holding down - 1 Set.
bolts etc.
e) Forced oil lubrication system - One number each of working and
standby in addition to DC Pump
f) Stator winding RTDs (duplex) - 2 per phase.
g) Stator winding temperature - 2 Nos.
Dial type indicator
h) Bearing RTDs (duplex) - 1 No. each for DE and NDE
i) Bearing temperature dial type - 1 No. each for DE and NDE
indicator

4.6.3.1.4 Adequately rated capacitor to maintain power factor of 0.95 at the generator
terminal shall be provided. The capacitor shall be of 12 kV class with surge
arrestor and required fuses. Suitable provision for detecting the fuse blown off
condition through open delta PT and neutral displacement relay shall be provided.
The capacitor shall be sized for not less than 25% of the generator kVA. It shall

ANNEXURE - A PAGE 1 AVANT-GARDE

 VARDHMAN FABRICS, UNIT: BUDHNI, M.P
(A UNIT OF VARDHMAN TEXTILES LIMITED)
ADDITION OF STEAM CAPACITY, BACK PRESSURE TG & RICE HUSK HANDLING SYSTEM

be the responsibility of the bidder to substantiate the rating selected with suitable
calculations, without affecting the generator performance. The capacitor shall be
mounted in a separate panel and not in the terminal box.

4.6.3.2 Design Requirement

 
4.6.3.2.1 The generator shall be designed so as to be capable of running at over speed of the
turbine, and all parts of the generator and other equipment shall fully and safely
withstand stresses resulting from over speed operation. The rotor shall be tested at
1.2 times the rated speed for two (2) minutes.
 
4.6.3.2.2 The generator shall be provided with efficiency of not less than 98%.

4.6.3.2.3 Generator shall be suitable for being switched on to a solid main even at phase
opposition at a maximum residual voltage of 50% i.e. the generator shall be
capable of withstanding 150% of the rated voltage.
 
4.6.3.2.4 The generator shall be provided with insulated bearing on NDE side to prevent
the circulation of shaft currents.

4.6.3.2.5 Pull-out torque shall be atleast three times the rated torque.

4.6.3.3 Stator

4.6.3.3.1 The stator shall consist of a frame which may be of cast iron, cast steel or
fabricated from mild steel plate to have the necessary rigidity both for normal and
abnormal operating conditions. The stator core shall consist of low loss magnetic
sheet steel punching securely clamped and fixed in the stator frame to provide a
solid structure for the stator winding. The clamping arrangement shall be such
that during the life of the generator, core looseness shall not set in due to frequent
start/stop thermal cycles.

4.6.3.4 Stator Winding

 

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 VARDHMAN FABRICS, UNIT: BUDHNI, M.P
(A UNIT OF VARDHMAN TEXTILES LIMITED)
ADDITION OF STEAM CAPACITY, BACK PRESSURE TG & RICE HUSK HANDLING SYSTEM

4.6.3.4.1 The stator winding shall be made out of fully insulated interchangeable coils
suitable for the class of voltage adopted. The insulation shall conform to Class F
material which shall include that of coils, wedges, separators and other winding
materials. However, the stator winding temperature rise shall be limited to class B
values as measured by resistance type embedded temperature detectors when
delivering full load at rated operating conditions with an ambient temperature not
exceeding 50 Deg. C. The winding shall be suitable for operation at 100 percent
humidity conditions. The insulation for the stator winding shall be of the VPI type
insulation system.

4.6.3.4.2 The generator shall be suitable for +10 % to -20% voltage variation (on rated
voltage) and 50 Hz ± 5% frequency variation with maximum temperature rise
limited to limits of ‘Class-B’ insulation.

4.6.3.5 Rotor

4.6.3.5.1 The rotor core shall also be made out of low loss magnetic sheet steel punchings
suitably clamped to withstand the centrifugal forces. The rotor shaft shall be made
out of forged steel having sufficient mechanical strength so as to give minimum
deflection due to static weight and dynamic forces due to normal and abnormal
running conditions. Squirrel cage rotor winding shall be made out of electrolytic
grade copper/copper alloys. The design of the squirrel cage winding shall be such
that a 10 % unbalance in load current shall not cause overheating of the squirrel
cage winding due to negative sequence currents.

4.6.3.5.2 The complete rotor shall be designed to withstand the centrifugal forces under the
maximum run away speed conditions with a factor of safety of not less than 1.5
reckoned on yield point of the material. The critical speed of the shaft system
shall be designed to be atleast 20% more than the maximum runaway speed of the
turbine.

4.6.3.6 Enclosure

4.6.3.6.1 The enclosure shall be of CACA (closed air circuit air cooled) or TETV (totally
enclosed tube ventilated) type.

4.6.3.7 Terminals

4.6.3.7.1 The terminal box shall be phase segregated type.

4.6.3.8 Bearings

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 VARDHMAN FABRICS, UNIT: BUDHNI, M.P
(A UNIT OF VARDHMAN TEXTILES LIMITED)
ADDITION OF STEAM CAPACITY, BACK PRESSURE TG & RICE HUSK HANDLING SYSTEM

4.6.3.8.1 The generator shall be provided with end shield mounted anti-friction bearings of
long life for continuous use. However, where necessary, sleeve type bearings
mounted in end shield are also acceptable.

4.6.3.9 Base Plate

4.6.3.9.1 The generator supplied shall be complete with fabricated / cast base plate for
mounting the generator.
 
4.6.3.10 Testing
 
4.6.3.10.1 The generator shall be completely assembled at works and tests as specified
below shall be conducted on the assembled unit and auxiliaries, as per the latest
edition of IS 325. Detailed test reports shall be furnished.
 
4.6.3.10.2 The following tests shall be carried out on the machine:
 
a) Measurement of DC resistance of stator and rotor windings.
b) Insulation resistance of stator winding (before and after high voltage tests),
bearings and embedded temperature detectors.
c) High voltage test of stator at power frequency.
d) Polarization Index.
e) Phase sequence measurement.
f) Determination of open circuit characteristics.
g) Determination of short circuit characteristics.
h) Determination of efficiency by separation of losses methods.
i) Vibration measurement.
j) Over speed at 120% for 2 minutes and measurement of vibration there of.
k) Runaway speed test for 15 minutes.
l) Shaft voltage measurement.
m) Shaft vibration measurement.
n) Noise test.
o) Air gap measurement.
p) Mechanical run test for temperature rise.
q) Temperature rise test at iron loss, copper loss with equivalent method
r) Momentary over current test for 150% of rated current for 30 Secs.
s) Stator winding capacitance and tan delta measurement.
 
4.6.3.11 Make
 
4.6.3.11.1 The make of generator shall be ABB / CGL / SIEMENS.
 

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 VARDHMAN FABRICS, UNIT: BUDHNI, M.P
(A UNIT OF VARDHMAN TEXTILES LIMITED)
ADDITION OF STEAM CAPACITY, BACK PRESSURE TG & RICE HUSK HANDLING SYSTEM

4.6.4 GENERATOR CONTROL AND RELAY PANEL

4.6.4.1 The colours for various voltages in the mimic diagram shall be as below:
 
Voltage Level  Mimic Colour Shade as per IS:5 
11 V  Signal Red 537 
 
4.6.4.2 Trip annunciations shall be provided for the following:
 
- Differential protection operated. 
- Directional Earth Fault
- Non directional instantaneous / IDMT over current. 
- Low forward power 
- Reverse active / reactive Power 
- Non directional instantaneous / IDMT earth fault 
- Accidental energisation protection 
- Local breaker backup 
- Negative phase sequence : stage - II 
- Under voltage  
- Over voltage  
- Under frequency  
- Over frequency  
- Master trip operated (Dedicated windows for heavy, medium and light
faults, as applicable) 
- Emergency trip 
- EOP trip 
- Generator trip due to turbine trip. 
- Turbine tripped due to mechanical fault (Feedback generated from DCS) 
- Winding temperature trip 
- Bearing temperature trip 
 

4.6.4.3 Alarm annunciations shall be provided for the following:

 

- Negative phase sequence : stage - I

- TCS of master trip relay unhealthy
- Gen CB trip coil unhealthy
- GCP PT fuse fail
- GRP PT fuse fail
- GPR out of service
- DC fail
- UPS fail
- Winding temperature alarm

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 VARDHMAN FABRICS, UNIT: BUDHNI, M.P
(A UNIT OF VARDHMAN TEXTILES LIMITED)
ADDITION OF STEAM CAPACITY, BACK PRESSURE TG & RICE HUSK HANDLING SYSTEM

- Bearing temperature alarm

 
4.6.4.4 Trivector / power measurement metering
 
4.6.4.4.1 Integrating meters of the Trivector or equivalent types capable of indicating all
phase instantaneous parameters and recording kWH, kVARH and kVAH directly
shall be provided. They shall be capable of record / display of harmonic data upto
51st harmonics for PQM. kWHR meters shall also be capable of indicating the
total harmonic levels upto 25th harmonic in the system for current as well as in
voltage parameters, ie VTHD and ITHD.
 
4.6.4.4.2 These should be suitable for 3 phase, 4 wire 50 Hz circuits with unbalanced
loading and with two sets of elements connected to current and potential
transformers of specified ratio.
 
4.6.4.4.3 The meter shall be of digital type, class 0.2 or better with communication port,
RS485 interface - MODBUS RTU protocol, for hooking up to PC / DCS.
Necessary softwares for downloading of stored parameters and analysis shall also
be supplied. The meters shall have data retention facility in the event of supply
source failure for a month period. The meter shall also have digital and analog
outputs.
 
4.6.4.4.4 Meters for frequency, power factor and MW should be of digital type.
 
4.6.4.5 Dedicated TBs for DCS connectivity as below shall be provided.
 
- GPR - 1, 2 Out Of Service (DI) 
- DC Fail (DI) 
- Master Trip Relay Operated (Dedicated TBs for heavy, medium and light
faults, as applicable, shall be provided.) (DI) 
- Trip Circuit Unhealthy (Dedicated TBs as above shall be provided) 
- Breaker Trip Coil - 1, 2 Healthy (95/52) (DI) 
- Voltage (AI) 
- Current (AI) 
- Frequency (AI) 
- Mega Watt (AI) 

4.6.4.6 Connection configuration of the protective relays shall be as shown in the tender
Single Line Diagram.
 
4.6.4.7 The SUPPLIER shall provide a common PC / Laptop, loaded with necessary
software and interface units to receive signals from RS 485 and RS 232
communication ports, along with A4 laser colour printer. The PC shall be of
latest configuration available in the market with a minimum configuration of Intel

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 VARDHMAN FABRICS, UNIT: BUDHNI, M.P
(A UNIT OF VARDHMAN TEXTILES LIMITED)
ADDITION OF STEAM CAPACITY, BACK PRESSURE TG & RICE HUSK HANDLING SYSTEM

core-I7 processor, 8GB DDR3 SD RAM, 500 GB SATA Hard disk, DVD R/W
Drive, optical scroll mouse, 1 serial, 1 parallel, 4 USB ports with 17” LED
monitor. This system shall be suitable for processing & displaying the signals
from the generator digital relays & meters, from the RS485 communication ports
with MODBUS RTU protocol. The PC / Laptop shall be provided with Windows
– 7 OS and latest version of antivirus, MS office and Adobe reader / writer
software. All softwares shall be of life time licensed versions.
 
4.6.7 PROTECTION, INTERLOCK AND INTER TRIPPING REQUIREMENTS

4.6.7.1 Following Protections shall be planned for the TG System:

 
4.6.7.1.1 Protection of the generator shall be achieved through microprocessor based,
composite protective digital relays, with one as primary and the other as back-up.
Both the relays shall include the following minimum protective functions:
 
- Accidental energisation protection
- Over & Under voltage
- Under & Over frequency
- Over Current & Earth Fault
- Directional Earth Fault
- Reverse Power
- Low forward power
- Generator differential
- Local breaker back-up / struck-up
- Negative sequence
- Voltage balance / PT fuse failure
- Over speed protection (from Governor)
 
4.6.7.1.2 Both the generator protection relays shall have the following minimum features:
 
- Communication port, RS485 interface - MODBUS protocol, for hooking-
up to DCS / PC, for down loading & parameter settings
- Necessary software, for processing of data.
- Event recording facility, for a minimum of 32 events.
- Disturbance recording & analysis facility
- All the events, disturbances and the fault records, generated both internally
and externally with time stampings, shall be stored in the internal memory
of the generator protection relays and shall be capable of being
downloaded when required. It shall be responsibility of the
SUPPLIER to demonstrate this feature to the PURCHASER’s engineers,
at site.

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 VARDHMAN FABRICS, UNIT: BUDHNI, M.P
(A UNIT OF VARDHMAN TEXTILES LIMITED)
ADDITION OF STEAM CAPACITY, BACK PRESSURE TG & RICE HUSK HANDLING SYSTEM

- Self diagnostic facility

 
4.6.7.1.3 Additional static / microprocessor based discrete relays for reverse active and
reactive power protections, with settable range of 0.5% connected from Class 0.2
core CT shall be provided.
 
4.6.7.1.4 Additional discrete relays shall also be provided for the following auxiliary
functions:
 
- Master trip relay for TG Incomer Breaker
- Master trip relay for Tie Breaker
- Master trip relay for Turbine Trip
- Trip circuit supervision relays for TG Incomer circuit breaker and all
master trip relays
- DC supply failure relay
- Auxiliary relays, if required

4.6.7.2 Following Interlocks shall be planned for the TG system

4.6.7.2.1 Generator shall be switched ON only after turbine reaches 95% of its rated speed.
Accordingly, the turbine speed shall be interlocked.

4.6.7.2.2 Generator shall be switched ON only when the residual voltage is less than 25%
of rated voltage. Required time delay shall be considered during successive
switching ON. Under voltage relay and timer shall be utilised for this purpose.

4.6.7.2.3 Master trip relays healthiness and trip circuit supervision relay healthiness of CB
and its master trip relays shall be used in the closing interlock.
 
4.6.7.2.4 All protections shall be planned as listed in the respective sections. The trip logic
for the TG to be as per recommendation of the TG Supplier.
 
4.6.7.2.5 Local breaker back up protection shall trip the Tie CB i.e. LV side CB of the
Power evacuation transformer.
 
4.6.7.2.6 First stage of under & over voltage functions, under & over frequency functions
and first stage of negative phase sequence function shall trip the Tie CB.
 
4.6.7.2.7 The following external signals shall be connected to the generator protection
relays for time stamping:
 
- Generator master trip relays

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 VARDHMAN FABRICS, UNIT: BUDHNI, M.P
(A UNIT OF VARDHMAN TEXTILES LIMITED)
ADDITION OF STEAM CAPACITY, BACK PRESSURE TG & RICE HUSK HANDLING SYSTEM

- Generator circuit breaker status

- Tie CB status
- Status of oil pump starters.
- Turbine tripped due to mechanical fault (Feedback generated from DCS)
- Any other contacts, which are all planned for tripping GCB from panels
other than GRP.
- Four (4) numbers of additional signals for PURCHASER’s use.

4.6.7.2.8 The healthiness of MCB or fuse shall be used in the interlock circuit, wherever
the under voltage function is used.

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