Sub Section VI Ajmer Push-17.03.10

VOL I: SECTION V ): EMPLOYERS REQUIREMENT: SUB SECTION VI W/02
UIT AJMER JNNURM/AJMER-PUSHKAR/ W
Sub Section-VI: Electrical Part I: Specific Requirements

TECHNICAL SPECIFICATIONS ELECTRICAL 1.0 Scope The bidder's /contractor's scope covers the design, shop testing, supply, transport, storing at site, erection, testing and commissioning of all electrical and instruments required for the plant, as per enclosed General Specification, Specific Requirement, typical power distribution scheme and typical control system architecture. Where there is any contradiction between General Specification and Specific requirements mentioned in this document, the specific requirements will rule the project requirement. 2.0 Design Basis 2.1 The Bidder/ Contractor shall strictly follow the typical power distribution single line diagram which is to be proposed by him and approved and accepted by UIT. The bidder shall visit the site to satisfy himself about availability of voltage level, its condition, its probable route', etc. before quoting. The UIT will provide one source of 11 K.V, 50 c/s, 3 phase electrical power up to electrical meter within the premises. From this metering point onwards the successful bidder shall extend 11KV supply up to main substation and further 433 V(step down) supply up to MCC room (Motor Control Center)
2.2
2.3
All the incomers of substations shall be suitably electrically as well as mechanically interlocked as per scheme.
Bidders shall follow the BIS guideline-'for voltage rating of motors while designing and selection of electrical motors. All the motors shall be of squirrel cage type and Energy efficient high performance type motors (Min eff. Class 2 )for optimum utilization of energy.
2.4
All motors shall be provided with class-F insulation and their temperature rise shall be limited up to Class-B.
2.5 All HT & LT cables shall be designed and selected after considering a minimum de-rating factor of 0.65. Exact de-rating shall be calculated taking into consideration designed ambient temperature, grouping and minimum size as per fault level calculations of synchronised DG with grid)..
2.6
Bidder shall carry out the earth resistivity test on his own and based on this result they should design the total earthing system to maintain a overall resistance value less than one ohm. The electrical and instrumentation in gas handling area like compressors etc. shall be flame proof type and strictly adhere to CMRI/Explosive deptt. Norms. Substation design shall incorporate all safety aspects and shall be provided with power distribution agency metering room, switchgear room, separate fence, gates, internal access roads, lighting, earthing, power factor correction, lightning protection, cable trenches,
SIGNATURE OF CONTRACTOR
2.7
2.8
URBAN IMPROVEMENT TRUST, AJMER
equipment foundations, transformer structures/gantries, gravel etc. 2.9
oil
soak/drain
pits,
galvanized
steel
latticed
Noise level (db levels & insertion level) inside and outside blower room shall be strictly as per latest amended pollution control board norms applicable at installation time. Whatever extra equipments required like scrubber, acoustic shall be provided to meet statutory guide lines as well as building should be able to accommodate all equipments.
2.10 The Contractor shall submit proposed/offered system architecture along with the offer. 2.11 HT cabling shall be done underground with top of HT cable minimum 1.0 meter below plant ground level. The protection above HT cable shall be provided as per latest revision of IS standard. . 2.12 Bidder shall get the short circuit fault level data at 11kV,from power distribution agency and .shall do the fault level calculation and Relay co-ordination scheme for the entire plant accordingly. Bidder shall provide minimum protection on HT side as per standard relay protection scheme enclosed herewith as annexure-2 In case some additional protections other than indicated in drawing, are required; same should be added. Wherever transformer size is 2 MVA or bigger, than differential protection shall be provided. . 2.13 Measuring instruments shall be provided by bidder as per standard measurement scheme enclosed here with annexure-2.
2.14 LT capacitor bank shall be provided with automatic power factor correction system. Its panel shall incorporate timer circuit to allow capacitor to discharge at minimum 50V before re-energisation of any individual bank. 2.15. Capacitor bank shall consist of many small capacitors so that banks can be in circuit as per
system p.f requirement with the help of Automatic Power Factor Correction relay. Minimum 0.95 p.f will be maintained at power distribution agency meter on H.T. Side. Capacitor bank calculations submitted along with bid shall also take into consideration the transformer impedence. Each capacitor should be able to switch ON either in manual or auto mode independently.
2.16. All the protection relay of 11 KV and 415 Volts panels shall be of microprocessor based except master tripping relay and check supervision relay.
3.0 Bidders Obligation
Bidder shall provide preliminary details for the items given below. However, if UIT-AJMER requires any further details during technical bid evaluation stage, the bidder shall provide the same. 3.1 Load list (as per enclosed typical format) 3.2 Maximum demand in KVA with duration (period) of the plant. 3.3 Minimum demand in KVA with duration (period) of the plant 3.4 Normal demand in KVA of the plant. 3.5 Detailed Bill of material for electrical as well as instrumentation scope of work. 3.6 P & I diagram of the total plant. 3.7 Instrument index (as per enclosed typical format) 3.8 Input/ Output List (as per enclosed typical format) 3.9 Instrument Data sheet for each tag No.
URBAN IMPROVEMENT TRUST, AJMER SIGNATURE OF CONTRACTOR
3.10 3.11 3.12 3.13 3.14 3.15 3.16 3.17 3.18 3.19 3.20 3.21 3.22 3.23 3.24 3.25 3.26 3.27 3.28 3.29 3.30 3.31 3.32 3.33 3.34 3.35 3.36 3.37 3.38 3.39 3.40
Interlock logic diagram Control system architecture. Instrument air requirement. Uninterrupted power supply (UPS) capacity requirement. UPS capacity and its battery backup calculation sheet. Lighting fixture capacity and quantity calculation. Single line diagram for HT Power, LT Power. (main panel), L T distribution boards. Single line diagram for lighting and small power. Cable schedule of total plant, along with voltage drop calculation and deratings. Operating power factor of each equipment. Power factor improvement capacitor calculation. H.T Panel Board Data Sheets. LT Panel board (NDAC, MCC etc) Data Sheets. HT Cable, LT cable, control cable, telecommunication cable Data Sheet. Transformer Data Sheet. UPS Data Sheet. Battery and Battery Charger Data Sheet. ACSR Conductor Data Sheet. Guaranteed Power generation by Gas Engine. Bus Duct Data Sheet Power mounted Isolator Data Sheet. Maximum Power consumption of the plant per day. Minimum power consumption of the plant per day. Guaranteed power consumption of the plant per day. Transformer capacity calculation sheet. Battery Charger Capacity Calculation Sheet. Battery Capacity Calculation Sheet. Motor List (as per typical format enclosed herewith). Control Valve sizing calculation sheet. DDC sizing calculation sheet. GA drawings of all electrical panels like HT panel, Transformer, Diesel Generators, NDAC, MCC, Battery chargers and batteries, AC distribution board, DC distribution Boards, UPS and its batteries, Pole mounted Isolators, Lighting Arrestors etc. Typical drawings of Earthing station. A drawings of all analysers, control room equipments etc. Typical drawing HT cable laying under the ground. Typical structural drawing showing LT cable tray for power, control etc in outdoor areas. Substation layout for each section, D G layout with appropriate clearances as per IER and appropriate clearances for maintenance. Control room layout. Room size and quantity for total plant electrical and instrumentation work.
3.44 3.45 3.46 3.47 3.48 3.49 3.50
3.51 List of Safety Items. 4.0 Indian Standards / Other International Standards For the benefit of bidders, a few Indian Standards and Codes of practices and other international standards are listed below. Unless otherwise noted, equipment/devices/accessories /installations/ testing etc. shall comply with relevant standards/codes mentioned herein. Where Indian Standards are not available equipment/ devices etc. complying with relevant British or IEC standard or ISO standards
shall be proposed. While referring to any standard, the latest revision/edition shall govern. Bidders are advised to include in their bid a list of equipment/devices and corresponding standards to which they conform. Translation in English of standards, which are available in other languages, shall be furnished along with the bid, in such cases the English translation shall govern. 4.1 List Of IS & Other International Codes (For Electrical Equipment / Accessories)
1.
2. 3.
IS 5
IS 3 IS 374
Colours for ready mixed paints and enamels.

Three phase induction motors. Electric ceiling type fans and regulators.
4.
5. 6.
IS 694
IS 722 IS 1248
PVC insulated cables for working voltages upped and including 1100V.
AC electricity meters. Direct acting indicating analogue electrical measuring instruments and their accessories. Thermal evaluation classification of insulating material.
7. 8.
IS 1271 IS 1293
Plugs and socket outlets of rated voltage upped and including 250V and rated current upped and including 16A. Hexagon head bolts, screws and nuts of product grades A and B. Ballasts for fluorescent lamps. PVC insulated ( heavy duty ) electric cables. Industries luminaries with metal reflectors.
9.
IS 1364
10. 11. 12. 13. 14.
IS 1534 IS 1554 IS 1777 IS 1913 IS 2086
-General and safety requirements for luminaries. Carrier and bases used in rewire able type electric fuses for voltages upped 650V. Dimensions of flange mounted AC induction motor.
15. 16.
IS 2223 IS 2253
Designation for type of construction and mounting arrangement of rotating electrical machines. Dimensions of vertical shaft motors for pumps. Methods of tests for determination of insulation resistance of solid insulating materials. Dimensions for panel mounted indication and recording electrical instrument.
17. 18.
IS 2254 IS 2259
19.
IS 2419
20.
IS 2544
Porcelain post insulators for system with nominal voltages greater than 1000V.
21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.
IS 2551 IS 2667 IS 2705 IS 2713 IS 2834 IS 3156 IS 3231 IS 3725 IS 3854 IS 3961 IS 4029 IS 4691 IS 4728
Danger notice plates. Fitting for rigid steel conduits for electrical wiring. Current transformers. Tubular steel poles for overhead powerlines. Shunt capacitors for power systems. Voltage transformers. electrical relays for power system protection. Resistance wire, tapes and strips for heating elements. Switches for domestic and similar purposes. Recommended current rating for cables. Guide for testing 3 phase induction motors.
Degree of protecting provided by enclosure for rotating electrical machinery. Terminal marking and direction rotation for rotating electrical machinery. Method for determination of efficiency of rotating electrical machines. Guide for safety procedures and practices in electrical works. Guide for marking for insulated conductors. Method of measurement of air borne noise emitted by rotating electrical machinery.
34.
IS 4889
35.
IS 5216
36. 37.
IS 5578 IS 6098
38.
IS 6875
Control switches ( switching devices for control and auxiliary circuits, including contractor relays ) for voltage upped and including 1000V AC and 1200
V DC. 39. IS 7098 Cross linked polyethylene insulated PVC sheathed cables. LV switchgear and controlgear assemblies.
40. 41.
IS 8623 IS 828
Circuit breakers for over current protection for house hold and similar installations. Luminaries. General requirement of switchgear and controller.
42. 43.
IS 10322 IS 12729
44. 45. 46. 47. 48. 49.
IS 13032 IS 13947 IS 732 IS 3043 IS 3646 IS 10118
MCB boards for voltage upped and including 1000V AC. Low voltage switcher and controller. Code of practice for electrical wiring installations. Code of practice for earthing. Code of practice for interior illumination. Code for practice for selection, installation and maintenance of switchgear and control gear. Plugs, socket outlets and couplers for industrial purpose.
50.
IS IEC 309
51. 52.
IS 2026 IS 13118
Transformers Vacuum circuit breakers.
For all other process equipments and instruments contractor shall follow IS / ISO specifications and submit a copy of the same.
5.0. Clearance from Statutory Authorities Bidders shall note that the successful bidder shall be responsible for obtaining statutory clearances from all the relevant bodies (such as electrical inspector, Safety, Pollution Control Board, Fire Insurance and Explosive Department Authorities, etc.). Payment in respect of fees, deposit, etc., of such bodies shall be made by successful bidder. UIT-AJMER shall assist the contractor in obtaining such clearances expeditiously by way of issue of introductory letters to relevant bodies but this will not absolve the Contractor from his responsibility of obtaining in writing clearances mainly from Electrical Inspector, Chief Explosive Officer, Pollution Control Board or any other local/ central authority entirely at his own cost. No extra sum will be paid for these services. However fee deposited to power distribution agency will be reimbursed by UIT-AJMER. 6.0 Contractor S Licence: It shall be the responsibility of the contractor to obtain necessary license / authorization / permit for work for his personnel from the licensing board of the state. The persons deputed by the contracts firm should also hold valid permits issued or recognized by licensing board of the state where the work is to be carried out. 7.0 Workmanship:
The contractor shall ensure workmanship of good quality and shall assign qualified supervisor/ engineers and competent labour who are skilled, careful and experienced in carrying out similar works. UIT-AJMER shall reserve the right to reject non-competent person/s employed by the contractor, if the workmanship is found unsatisfactory.
8.0 Power Distribution Philosophy:
The bidder shall design the power distribution scheme for this site on the basis of following guidelines and single line diagram. Voltage drop from transformer output to last point in electrical distribution shall not be more than 5%. Voltage drop in any cable for installed load or any single circuit for installed load shall not be more than 2%. Only aluminium conductor
with PVC insulation armoured cables shall be used for size 2.5mm and above. All power cables upto 2.5mm2 shall be copper conductor PVC insulated armored cables. 8.1 An indoor substation shall be planned to house switchgears for incoming and outgoing power supply circuits, metering equipments, communication equipment, control panels, auxiliary power supply distribution boards, DC system equipment etc. The following voltage of load factor and diversity factor shall be considered for calculating the maximum running load. The sizing of transformer shall be included along with the bid. LOAD FACTOR Main Pump Motor Aux. Loads Lighting loads Socket outlet, receptacle Diversity Factor DIVERSITY Main pump motor for working loads Lighting Loads Socket outlet, receptacle 8.2
: : : :
0.9 0.9 1.0 0.50
: : :
1.0 1.2 1.2
Main incomer switchgear in various plant/process areas shall be fed by duplicate (two), 100% capacity feeders and outgoing feeders shall be so designed that at least 20% spare subjected to minimum of one feeder of every type shall be available. All control voltage inside switchgear panel shall be at 230V AC for Contactors and control supply. Single line diagram of all panels shall be attached with bid giving cable sizes in single line diagram. DC system equipment (comprising batteries, chargers & DC distribution board) with adequate capacity shall be proposed for protection / control circuits and other vital devices of each substation. Further, in plant areas / substation a few lighting fixtures as emergency lighting suitable for operation on battery voltage shall be proposed in strategic areas. DC system, calculation of DC Battery size, DC battery charger, Voltage should be attached with the bid. Following protections for incomer feeders in main MCC location for each process area of the plant. Each MCC shall be provided with 4 Pole two incomers and bus section with draw out ACB/MCCB as incomer. MCC's shall be metal clad floor mounted, with cable entry from bottom (preferred) and environmentally protected to IP-5X. MCC shall have fault rating of not less than the applicable fault levels. The two incomer neutral shall completely be isolated by using 4 pole ACB/MCCB. Indication light for run, trip, emergency stop operated, power On, run dry protection operated in case of submersible pumps
8.3
8.4
Mechanical and electrical interlocking shall be provided between the incomers and the bus section ACB/MCCB to prevent parallel operation of main switchgear feeders.
MCCs shall be housed within brick built buildings segregated from injurious effects of process fluids/gases are present. The major components of each starter shall comprise: Door interlocked isolator Fuse gear/ MCCB Contactor, overload relay with single phasing protection. Start/ Stop push button. Local/ remote selector switches (if applicable) Manual / off/ auto sector switch. Ammeter as per starter requirement Indication light for run, trip, emergency stop operated, power On, run dry protection operated (where such tanks are used) i) Incomer feeder shall have electrostatic / microprocessor based control releases for over current, short circuit, earth fault with time delay and these releases shall directly work on tripping mechanism of drawout air circuit breaker. Outgoing feeder up to 630 Amps shall be switch fuse unit / MCCB and beyond 630 Amps shall be air circuit breaker. All Outgoing Air Circuits Breakers will be manual drawout type. Each motor upto 22 KW shall have DOL starter with O/C, short ckt protection, over load relay with single phasing protection along with ammeter, provision for remote start/stop. Overload relay shall be reset type from front of panel. All starters component shall follow type-II coordination chart of established manufactures with components of same make. Each starter shall have On/Off/Trip indication. All necessary selector switches like auto manual switch and local remote switches shall be installed.
ii)
iii) Motors above 22 KW and up to 75 KW shall have Star / Delta starter with O/C, short cut protection, over load relay with single phasing protection along with ammeter, provision for remote start / stop O/C relay shall be reset from front of panel. All starter components shall follow type-II coordination chart of established manufactures with components of same make. Each starter shall have on/off/trip indication. All necessary selector switches like auto, manual switch and local, remote switches shall be installed. . iv) Motor from 75KW and above shall have the soft starter and micro processor based relays along with short circuit protection. Each starter shall have on/off/trip indication. All necessary selector switches like auto manual switch and local, remote switches shall be installed. 8.5. Cables proposed shall be suitable for operation on earthed/ unearthed system as applicable. LV cables shall be armoured PVC insulated. Outer sheath of all cables shall be of general purpose PVC and shall be of extruded type meeting latest IS-1554 requirements. The cable shall be designed after taking de-rating factors of ambient, grouping into consideration for its design. Power cables of cross section above 2.5 sq. mm shall be with aluminium conductors. All cables of cross section up to 2.5 sq. mm shall be with copper conductors. Unless otherwise stated all the cables shall be
armored. LV cables shall be of the armored heavy duty type and of 1100 V grade. Voltage drop on cable for installed current shall not exceed 2% on installed load. Design ambient temperature shall be taken as 50OC. All cables shall also confirm to the relevant fault level of switch board for one second and supporting calculations must be submitted for fault level. 8.6 Cable Terminations i) For termination of MV cables, single compression type glands shall be used for indoor locations. Glands shall be of brass, Lugs of Al / Cu or tinned copper shall be used as applicable, lugs shall be properly crimped on conductors. All glands used must be of heavy duty type. ii) In outdoor areas, except within outdoor sub station area, cables shall be laid directly buried between building entry/exit points. Within buildings, cables shall be laid on cable trays to be supported from building walls columns/ beams/floors / ceilings. In outdoor sub station area, cables shall be laid on cable trays in build up cable trenches. Ladder and perforated type cable trays shall be proposed. Ladder type cable trays widths shall be restricted between 300 mm and 600 mm. perforated cable trays widths shall be restricted between 100 mm and 250 mm. Side members of ladder type cable trays shall be fabricated using structural steel angles of at least 6 mm thick. Perforated cable trays shall be of the formed type made from 2 mm thick sheet steel. For supports, structural angles or channels of appropriate strength shall be proposed. Vertical runs of cable trays shall be enclosed using perforated sheets as above. Cable trays, supports and covers shall be painted with epoxy paint of shade acceptable to UIT-AJMER. Tray width shall be so sized that at least 30% margin is available for addition at later date. This distance between the cables shall be minimum equal to outer dia of cable. iii) At road crossings hume pipe/s of adequate size shall be provided at a depth of 1000 mm (center line depth) of passage of cables, earthing conductors etc. At building entry points pipe sleeves of GI or PVC shall be provided for the passage of cables and earthing conductors, such sleeves shall have projections on either side to facilitate extension.
9.0 Illumination:
9.1
All internal and external areas shall be levels to be achieved shall be as follows: AREA Office and labs : Switchgear Room : Control Room : Pump House : DG set room : Chemical and general store : Chemical Plant room : Other indoor areas : Outdoor plant from and walkways : Building entrance : Indoor Plant Area : Outdoor Plant Area :
provided with lighting. The illumination LUX 300 200 300 200 200 150 200 100 50 100 200 50
Lux Lux Lux Lux Lux Lux Lux Lux Lux Lux Lux Lux
Transformer Area Roads
: :
100 10
Lux Lux
Fluorescent luminaries shall be used primarily for internal lighting. High pressure vapour or metal halide type luminaries shall be used in indoor application where their use is appropriate. If mercury or metal halide is used in indoor then they should be supplemented with fluorescent luminaries to assure that minimum illumination levels are maintained following momentary power dips. All other internal areas shall be lit with fluorescent luminaries. Where specific recommendations of lux level are not covered above, illumination level in such areas shall be finalized in consultation with UIT-AJMER. Contractor shall be required to measure levels of illumination after completion of lighting installation work and short fall in illumination level shall be made good by the contractor. Complete set of calculations showing, room, index, copy MF shall be given during detailed engineering. . Lighting Fixtures should be of energy efficient type 9.2 Switches / sockets of piano type shall be used in general and in offices of staff, control room, MMI room, decorative modular switches shall be used. Suitable fans shall be provided in rooms/ plant areas as per UIT-AJMER/CPWD standards. For exhaust fans it must be provided in panel rooms, pump rooms, chemical rooms, stores, toilets and at least 20 air changes per hour must be maintained. The following type of lighting fixtures shall be proposed: a) Decorative type 2x36W fixtures for fluorescent luminaries inside office/ administrative buildings and control rooms. b) Corrosion resistant fixture with canopy made of FRP for fluorescent luminaries for corrosive areas like chlorine handling or chemical store or area with corrosive smell/gases etc. Industrial type vitreous enameled fixture for fluorescent luminaries inside 415V switchgear, MCC room and pump house. In outdoor process areas, lighting fixtures shall be sodium vapour type subjected to minimum of IP protection class. All outside lights as plant field lights, building outside lights, flood lights etc. which are to be switched on only during night hours should be controlled through photo cell/ clock switch installed at a central place. All lights shall have minimum IP65 protection class. Street lighting wiring shall be through buried underground. All bulb fittings (except fluorescent lamps) will have screw type caps. For outdoor lighting, the lighting feeder shall be operated through a contactor, controlled by photocell/ clock switch and shall also have a manual by pass switch.
9.3
c)
d)
e)
f) g) h)
10
9.4
Luminaires shall be installed to permit ease of maintenance i.e. it shall not be necessary to shut down plant in order to carryout maintenance or to access luminaries located over areas of water etc. The contractor shall provide all equipment necessary to carryout maintenance on the lighting installation and demonstrate its operation to the satisfaction of UIT-AJMER. Indoor lighting circuit will be arranged in such a way that 50% lighting can be put off in each room through switches. All lighting circuits will be wired with 2.5sq.mm. stranded copper wire or through 2.5 sq.mm. armoured :cable laid in cable trays. Sub circuit from switch to fixture could be wired with 1.5 sq.mm. stranded copper wire in GI conduits on surface or armoured copper cable o;, similar size provided total voltage drop in any lighting distribution board to last lighting point shall not exceed 2%. All lighting circuits will have separate neutral, separate earth from Lighting Distribution Board
9.5
. 9.6 For illumination of roads, outdoors areas where operation of equipment or units required and sub station area, lighting fixtures of appropriate type ( such as street lighting type, flood lighting type, post top lanterns etc.) incorporating high pressure sodium vapour lamps shall be proposed. Street light poles shall not have less than 7500 mm height above the finished road level and the arm shall not project more than 1200 mm along the road width. Poles of bigger heights may also be used if some outdoor areas are to be illuminated. Poles of 4 / 4.5 Mtrs using post top lantern may be used in gate office, walk way or in front of office area. Complete area, streets, lanes, boundary shall be covered with street lighting. Receptacles (Lighting & Small Power) : a. Decorative and industrial type units of above shall be proposed in all plant areas, offices, stores, workshop, plant room and they shall be located at least two numbers in each room. Distance between two receptacles shall not be more than 8 10 mtr. All small 5 amps 5 pin lighting & small power sockets shall be wired by multi stranded copper wire of 2.5 sq. mm laid in rigid MS conduits along with earth wire of 1.5 sq.mm flexible copper wire or equivalent size armoured cables. All wiring shall be coded with Red, Yellow, Blue & Black as per the phase used. If required, wiring can be done alternatively through armoured copper cables of similar size laid in MS perforated trays of minimum 2.0 mm thick. b. Three phase power receptacles (convenience outlets) suitable for operation of 415V, 3 Phase 4 wire, 50 Hz power supply shall be proposed. In indoor areas one such unit shall be provided to cover areas of 20 meter radius (or at least one in each room housing plant items ) and in outdoors areas on such unit shall be provided at 50 meter interval. Actual requirement of such units shall be finalized by UIT-AJMER during detailed engineering. One three phase receptacle shall be provided near entrance of each building for utilities like welding. Single phase 15 Amp 5 Pin / 6 Pin receptacles will be provided in each room and in halls they will be provided in such a way that with 15 meter cord we should reach every place in building. These shall be wired with 4 sq. mm
9.7
c.
11
copper earth wire in GI rigid conduits along with 2.5 sq. mm earth wire. Not more than two sockets shall be looped in one circuit. Alternatively they can also be connected through armoured cable of 4 sq. mm running in appropriate cable trays.
9.8 Separate lighting panels and lighting distribution boards shall be installed and they shall not take tapping for power from motor control centers or power distribution boards. Earthing & Lightning Protection.
10.0.
10.1
Bidders are advised to carry out soil resistivity measurement for designing the earthing system. Further, bidders are also required to study the guidelines in respect of lightning protection covered in relevant Indian Standards and accordingly include proposals for the same. The bidder shall make sure that earthing resistance value for both neutral conductor & body earthing shall be less than one ohm. All earthing station shall conform to latest amended IS 3043. The Contractor shall provide an earthing installation at each site. Protective conductors shall be provided for all electrical installations and associated mechanical plant, exposed steel work and buildings. Protective conductors shall be provided in accordance with the requirements of IS-3043 or equivalent. The earthing system shall be designed for the earth fault current occurring at the point of supply. The neutral point of the 11/0.433 KV transformer secondary windings shall be solidly earthed. The calculation of earthing system and earthing valves must be submitted at detailed engineering stage. The electrical installation shall be connected to the general mass of the earth by an earthing electrode. The earth electrode system shall be established adjacent to the transformer compound. GI plate earth electrodes shall be proposed in earthing system. MS conductors with allowance for corrosion shall be used for conductors to be buried in ground and they shall with stand fault for three seconds. GI conductors for earthing shall be used for above ground installations. Touch and step potentials shall be kept within permissible limits as per IS and this should be supported with earthing calculations. No earthing resistance shall be less than one ohm. Size of earthing conductor shall be arrived as per calculations subjected to minimum rating suggested below: Main switch board and stand bye : 50 x 6mm GI Flat Interconnection to lighting protection system : 50 x 6mm GI Flat Interconnection to MCCs : 50 x 6mm GI Flat Interconnection to control panels : 25 x 3mm GI Flat PF correction panel : 50 x 6mm GI Flat Local push button : 14 SWG GI Lighting distribution boards : 4 SWG GI Lighting & receptacle system : 12 SWG GI Outdoor street lighting : 8 SWG GI Ladder rack and cable tray at suitable points : 25 x 3mm GI Hand rails and metallic structure : 25 x 3mm GI Steel structure comprising storage tanks : 25 x 3mm GI
10.2
10.3
a. b. c. d. e. f. g. h. i. j. k. l.
12
10.4
The complete plants shall have lighting protection in the form of lighting finials, horizontal earth continuity conductors, verticals risers, inspection links, earthing pits as per IS 3043. As detailed lightning calculations shall be submitted at the detailed engineering stage.
13
1 1.1
SCOPE OF WORK Design, manufacture, inspection and testing at works, supply at site, erection, final check-up, painting, testing, and commissioning of the electrical equipments as detailed in the items with brief description shall form the scope of work of the successful bidder. The scope of work also includes civil work such as excavation, laying of sand and bricks on cables, laid, closing the excavation, making earthing pit chambers, foundation and pedestal for electrical equipment, grouting of cable tray supports in walls, making entries for cable conduits in walls and making good the surface to the original one, embedding concealed conduits, junction boxes, etc. in walls and ceilings and making good the surface, foundation for street lighting poles, providing covers, chequered plates on cable trenches, etc. Co-ordination with local authorities, such as CONCERNING VVNL, Electrical Inspectorate the State Government, chief electrical authority, etc. for obtaining all the statutory approvals needed, preparing, submitting and obtaining approval of all electrical drawings and documents as well as obtaining approval of the electrical installation from these authorities shall also form the scope of the work. 1.4 Preparation and submission of As-Built drawings on soft-copy installation, operation and maintenance manuals of the equipments supplied along with their catalogues shall also be furnished by the successful bidder.
1.2
1.3
2 S No
ITEM WITH BRIEF DESCRIPTION.
Item with Brief Description
Qty.
1.
11 KV four pole structure with gang operated disconnecting switches, drop off fuses, LA, earthing system, and other electrical items / 1 Sets equipments, etc. 11 KV indoor CTPT metering Panel 1 Set
2. 3. 4. 5. 6.
11 KV switchgear panels with VCBs, relays, metering and annunciation 1 Set systems and equipments / items Power Transformer LT PMCC LT MCC 2 Nos. 1 No. As required
14
7. 8.
Local Start / Stop PB Station Power capacitor with APFC board / panel
1 Lot As required As Required
9.
LT motors
10.
Cabling system, comprising of HT and LT cables, glanding and As termination kits/ accessories, cable trays with accessories. Required Lighting system for internal and external lighting of plant area comprising of distribution boards, lighting fixtures, poles, switches, sockets, conduits, As receptacles, wires, cables, and other required hardware necessary for Required complete lighting work, ceiling fan, exhaust fans. Earthing system comprising of required number of earth pit stations, As earthing strips of required sizes, and conductor lightning system / Required materials Safety equipment comprising of fire extinguishers, fire buckets, safety As charts, danger boards/label, first aid box with medicines, rubber mats, Required safety gloves, etc. to be provided in substation, LT room, etc. AC,3Phase and neutral,415V,50c/s,outdoor busduct 2 sets
11.
12.
13.
14.
Note : The manufacture testing at works and supply of above electrical equipments along with their accessories / hardwares shall conform to technical specification and other requirements listed in the following pages. 3 SYSTEM DESIGN PARAMETERS The electrical equipments / items selected for this project shall be suitable for operation of technical parameters specified below: a) b) c) d) e) f) Incoming Power Supply Plant power distribution voltage Hz Lighting and space heating D-C alarm, control and protection AC control Potential transformer secondaries : AC, 11KV, 3Ph, 50 Hertz : AC, 415 V, 3Ph, 4 wire, 50 : AC, 230 V, 1Ph, 2 wire : 24 V, 2 wire, d-c : AC, 230 V, 1Ph, 2 wire : AC, 110 V, 3Ph, 50 Hertz
15
g) h) i) j) k) l) DG sets
Ambient temperature System earthing Voltage Variation Frequency Variation Fault level
: 50 deg. Centigrade : Solidly earthed : 10% of rated voltage : 5% of rated frequency : 350 MVA ( 11 KV) , 40 KA ( 415V), 6 KA (230 V)
Combined voltage and frequency variation : 10%
The DG Sets requirement shall be assessed by the bidder to run the plants in emergency during power failure. However DG set requirement at different installation are as under 1 No. DG set of capacity to operate 1 no- air blower, one raw sewage pumps ( higher capacity) and return sludge pumps in emergency at 13 MLD STP at Ajmer 1 No. DG set of capacity to operate pumping set of average flow discharge at Ajmer pumping station. 1 No. DG set of capacity to operate pumping set of average flow discharge at Pushkar pumping station.
Specifications of DG set:Supplying, Installation, Testing & commissioning of DG Set with auto change over switch, EP281200 SITC of Silent DG Set complete with 1500 RPM Diesel Engine of suitable BHP & AC Brush less SPDP Alternator mounted on a common base Frame & coupled through a flexible coupling or close coupled. Alternator shall be self regulated with standard Alternator Protection (Over voltage, over speed & under voltage). Engine shall have residential silencer, up to 10 M exhaust piping electronic / Mechanical governor, Manual & electric Start, Batteries, Fuel tank (with Stand) & piping, control panel (16 G) with MCCB (4P, 25KA) Ammeter, Voltmeter, Frequency Meter Energy Meter & Hour Meter, Engine instruments panel, AVM and with Weatherproof, powder coated Accoustic enclosure for DG set for sound attenuation fabricated from 2.0 mm CRCA sheet steel (structure) with side wall fabricated form 2.0 mm CRCA Sheet & filled with 100 Sheet & filled with 100 mm thick glass wool (96 Kg/m3) as per IS 8183 the doors of 100 mm thick and fabricated from 1.6 mm CRCA sheet packed with acoustic material, floor of MS chequerred plate 5.0 mm thick, canopy fixed with axial flow fan of Alstom, CG, Almonard make. All doors/ opening are sealed with neoprene/EPDN gaskets. The enclosure has buile in fuel tank, residential silencer (isolated form main DG chamber) with protection and tripping of DG set against temperature of more than 50 degree centigrade. All controls for operation of DG set are form outside the enclosure with DG control panel mounted inside enclosure, visible and accessible form outside. The enclosure should be suitable for following capacity DG sets and alternator. Noise level shall be less than 75 db (A) at a distance of 1 Mtrs. Duly certified by authorized agency etc.
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Note:- In the event of power failure DG sets is to run. The cost of Diesel shall be worked out on the basis of Energy meter installed on DG set and the payment of diesel shall be made by the contractor on the basis of diesel consumption per unit of energy generated and utilized.
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Part II:
4
Particular Specifications
11 KV VCB SWITCH GEAR PANEL WITH CIRCUIT BREAKER AND ASSOCIATED ELECTRICAL EQUIPMENTS: The manufacture and supply of 11 kV switchgear panel with vacuum circuit breakers and associated electrical equipments shall conform to the following requirements. 4.1. 11 KV VCB switchgear panel shall have separate fully segregated compartments to house the circuit breaker, bus bar, cables, relays and instruments potential transformer and current transformers it shall ensure that no arc or foreign body can travel from or to other compartments. The switchgear panel enclosure shall be dust and vermin proof. The construction shall be of the metal clad type using high-grade CRCA steel ensuring safety and security. 4.2. VCB circuit breaker trolley comprising of vacuum interrupter, mechanism, etc. shall be engaged to the enclosure to facilitate horizontal isolation and horizontal draw out. The trolley shall have distinct service and test positions with latching and locking facilities. The interlocking facilities shall be provided through limit switches. 4.3. The operating mechanism shall be of conventional design for operation of very short stroke required in vacuum interruption. The mechanism shall be fitted with a motorised spring charged closing mechanism with manual release. Manual charging facilities shall also be provided for the operation. Quick O-CO operation shall be possible. The closing spring when charged shall be held by a latch which shall be released either by manual means or by a solenoid to close the circuit breaker. During motor charging the spring shall automatically get recharged immediately after a closing operation. The mechanism shall be retained in the "ON" position (circuit breaker closed) by an over toggle linkage and trip solenoid to open circuit breaker. These springs shall be incorporated in the drive assembly and shall be fully encapsulated. The trip free mechanism shall be suitable for repeated auto reclosing duty. The spring charging time shall be less then ten seconds. The spring charging motor shall be in totally enclosed construction. 4.4. The bus bars shall be higher grade copper material and shall be rated for 400 amps. The bus bars and jumpers shall be covered by special heat shrink insulating sleeves. The bolted connection shall be covered by flexible insulating shrouds and the bus bars support shall be rigid enough for all thermal and electro dynamic stresses created out of three second short time current. 4.5. A screw type racking arrangement for easy insertion and withdrawal of the breaker shall render perfect contact pressure independent of the operator force. 4.6. A positive interlock to ensure the circuit breaker insertion to or withdrawal from the SERVICE position only when it is open.
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4.7. Automatic safety shutters shall cover the live parts when circuit breaker is not in the SERVICE position. Independent safety shutters shall be provided for upper and lower disconnect contact, each independently padlockable in open or closed condition. Pressure release flaps at the stop of the panel at a suitable safe height shall be provided. Separate flaps in circuit breaker, bus bar, cable compartment shall be provided. Foolproof interlocks shall be provided as per IS / IEC. 4.8. Epoxy molded stationery disconnect contacts shall provide effective segregation between phases and phases to earth. 4.9. A Separate segregated compartment for the potential transformer shall be provided. The potential transformer connections shall be through molded contact. The potential transformer shall be housed in a withdrawable truck arrangement. Automatic shutters shall be provided to cover the live parts when the potential transformer is withdrawn outside the cubicle. Adequate space for entry and termination of two sets of three core or six numbers (two per phase) of single core XLPE cable connections and mounting shall be considered in the cable chamber for terminations of cables. 4.10. Fully segregated separate compartments for low voltage devices like relays, meters, control switches, and indicating lamps shall be provided in the top portion of the switch gear panel. The relays and meters or shall be mounted in the hinged door. 4.11. Fully rated earth switches shall be provided as an integral part of the equipment / switchgear. The earth switches shall be independent in operation to the main closing mechanism and shall be interlocked to prevent use when the VCB is connected into its service position to prevent the circuit breaker being racked on to a circuit that has been earthed. Indicators shall be provided to warn if the earth switch is in the ON or OFF position, with the additional security that the design has been tested against a full fault current making of three seconds. Driving handles for drawing out / insertion of circuit breaker, rectifier unit for the spring charging motor, power pack unit for tripping, CR surge suppressor, and transport trolley shall be provided in the breaker. 4.12. Circuit breaker shall be provided with anti pumping features, breaker close / trip control switch, local remote switch, local ON/OFF switch, operation counter, indication lamps for CB on, CB off, trip circuit healthy, spring charged discharged condition, and space heater with toggle switch. In addition to above, the breakers shall be provided with mechanical close / trip knobs, mechanical ON/OFF indicators and mechanical spring charged / free indicators. 4.13. Annunciators (1 set), voltmeters (0-15 KV, 144 sq.mm size) with selector switchs, ammeters (0-630 amps, 144 sq.mm size) with selector switchs, and digital micro processor-based monitor for all electrical parameters (kW, KVA, kWhr, frequency, pf, md, voltage, current, etc.) shall be provided. 4.14. Three instantaneous phase over current relays with IDMT characteristic for phase faults and one instantaneous relay for ground fault, under voltage relay, auxiliary relay for bucholz trip, auxiliary relay for winding and oil temp entail
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trip, lockout relay, and all other relays as indicated in the single line diagram shall be provided. 4.15. Brief technical particulars of 11 KV switch gear panel are listed below Location Quantity Rated voltage, frequency and phase Fault level Reference Ambient Temperature Continuous Current Rating Bus bar material Bus bar insulation : : : : : : : : Indoor 1 Set 11 KV, 50 Hz, 3 Phase 350 MVA 50 Deg. C 400 Amps copper Fully insulated by encapsulation in epoxy resin with mould caps protecting all joints. Cable entries : Suitable for 11 KV 3C 150 sq.mm. XLPE (Bottom entry) Degree of Protection Earthing bus Circuit Breaker Type Circuit Breaker Voltage Circuit Breaker Frequency Rated normal current Rated short circuit making current Circuit Breaker Phases Auxiliary control voltage for (i) Closing / tripping coil (ii) Spring charging motor : : 24 VDC 240 VAC : : : : : : : : IP 54 Aluminium (50 x 6 sq.mm.) Vacuum 11KV 50 c/s 400 amps 18.37 KA peak 3 aluminium
Potential transformer : : : 11000 110 200 VA (minimum)

Primary Secondary Burden / phase

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Accuracy class Type Fuses (HRC) Side Current transformer
: : :
1 Epoxy To be provided on HT and LT
Quantity Ratio Burden Accuracy class Type Class of insulation 4.17. Applicable Standard
: : : : : :
Two sets (1 for measurement and other one for protection) 400/5 A 15 VA 1 for metering and 5 P 10 for Protection Cast resin E
The manufacture, testing and supply of 11 KV switchgear shall conform to IS 3427, IS 12729, IS 13118, IEC 298, IEC 694, and BS 5227. 4.18. Drawings and Documents Drawings and documents indicating details of front, plan, sectional views of the HT panel, single line diagram, power and control scheme, control wiring, terminal details, BOQ, calculation for bus bar sizing, etc. and installation of related drawings shall be furnished for approval. 4.19 The 11 KV VCB panel board shall be provided with one incomer and three outgoing VCB feeder panels. Out of three outgoing panels two shall be used in this package and third one shall be kept as spare for future use for Phase-II of 50 mld, SLD shall be read in conjunction with this stipulation.
5. POWER TRANSFORMER The manufacture and supply of the power transformer shall conform to the following requirements. 5.1 The transformer tank shall be made from high-grade plate steel, suitably reinforced by means of stiffeners made of structural steel sections and equipped with detachable radiators made from pressed steel. 5.2 The transformer core shall be constructed from high grade, non-ageing, coldrolled, grain oriented, silicon steel laminations coated with insulation varnish. 5.3 The framework and core shall be constructed from high grade, non-aging, coldrolled, grain oriented, silicon steel laminations coated with insulation varnish.
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5.4 Windings shall be of suitably insulated copper wire or copper strip. Windings and insulation shall be so arranged that free circulation of oil is possible between coils, between windings, and between windings and the core. High voltage end windings shall be suitably braced to withstand short circuit stresses and stresses set up by surges. 5.5 The HV & LV bushing sequences shall confirm to IS. Wherever neutrals are brought out, they shall be located to the left of the R phase bushing, when viewed from the HV side. Solid porcelain bushings with brown glaze shall be used up to 36 KV class service. Solid bushings shall have characteristics specified in IS : 2099. 5.6 The transformer shall be fitted with (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (j) (k) An inspection manhole in the cover Lifting lugs two earthing terminals on opposite ends of the transformer tank name plate, rating plate, diagram plate detachable radiator banks, complete with top and bottom shut-off valves, air release plug, drain valve and lifting lugs suitably located thermometer pockets for measuring inlet and outlet oil temperature one grounding terminal for connection of grounding conductor conservator complete with filling plug, sump, drain valve, shut-off valve on the pipe connection between transformer tank and conservator weather proof dehydrating breather with activated alumina or silica gel (Bluish Colour) as the dehydrating agent 150 mm diameter dial magnetic type oil level gauge with low oil level alarm contact mounted on the conservator The top filter valve and oil sampling device shall be provided on the tank gas detector relays with separate alarm and trip contacts complete with shut-off valves (l)explosion vent with diaphragm for relieving pressure within the transformer an equaliser pipe connecting the pressure relief device to the transformer adequate number of air vent for relieving trapped air during oil filling and during maintenance thermometer pocket, temperature sensing element and a 150 mm diameter dial type top oil temperature indicator with adjustable ungrounded alarm/trip contacts waterproof/ dustproof terminals boxes for magnetic oil level gauge separately mounted waterproof dust-proof marshalling box housing the oil temperature indicator and marshalling facilities for electrical devices mounted on transformer
(m) (n) (o)
(p) (q)
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(r) (s)
four jacking pads for lifting the transformer with jacks wheel with accessories for clamping the wheel mounted transformer to the foundation.
5.7 Transformer shall be supplied complete with insulating oil required for first filling. 5.8 The manufacture, testing and supply of the power transformer and accessories shall conform to IS 2026, IEC 76, BS 171, IS 2029, and IS 3639. 5.9 Brief Technical particulars of the power transformer are listed below. AC, 11 KV/433 V, Dyn 11, 50 Hz Outdoor located, suitable to operate at maximum ambient temp of 50 degree C and minimum ambient temperature of 2 degree Celsius. Copper winding (primary and secondary), delta connection on HV winding, Star connection on LT winding 5 % impedance at principal tap Solidly earthed neutral ONAN type of cooling, mineral oil filled. Full capacity off circuit tap changer (+5% to 10% tap range, 2.5% tap 7 steps) HV terminal side with cable box suitable for 11 KV XLPE 3C x 185 sq.mm U.E. aluminium conductor cable LT terminal side suitable for LT bus duct. LT neutral earthing shall be brought out through 1.1 KV-rated bushing both inside the cable box for forming the 3 phase, 4 wire system and outside the cable box for direct connection to earth by means of 50 x 6mm copper earthing conductor 5.9 Criteria to be followed in deciding the rating of the Transformer are described below. (a) The rating of the transformer shall be carefully selected, keeping in view of the anticipated maximum demand, connected load including lighting load, diversity factor, inrush current of large capacity motors, power factor of the motors and system as 0.85, overload factor for the transformer as per table 6, clause 3.4.7.2 of IS 6600, and loading of the transformer not exceeding 80% capacity of the transformer rating. However, the capacity of the transformer selected should not be less than half the capacity of the connected load allowing the diversity factor, excluding lighting load. (a) The noise and vibration level shall be maintained below the value specified in respective IS. (b) The temperature rise of oil and winding shall be 50 degrees Celsius and 55 degrees Celsius respectively.
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(c) The insulation class shall be A. 5.11 Drawings and documents indicating the complete construction details, general arrangement drawing showing front, plan and sectional views, elementary and schematic diagrams, installation, O & M manuals etc. shall be furnished for approval before manufacture. POWER CUM MOTOR CONTROL CENTRE The manufacture and supply of Power cum Motor Control Centre (PMCC) shall conform to the following requirements. a) Construction Features 1) Sheet steel used for the fabrication of the power and motor control centre (PMCC) shall be (minimum) 3 mm thick cold rolled. 2) All doors, panels, removable covers, gland plates, etc., shall be gasketed using Neoprene gaskets all round the perimeter. 3) All doors shall be provided with concealed type of hinges and captive screws. 4) The PMCC shall be provided with a minimum 50 mm high channel base frame. Total height shall be 2250 mm (max) . The minimum operating height shall be 300 mm and maximum operating height shall be 1800 mm. The PMCC shall be extendable on both sides. 5) Colour finish shade shall be as per IS 5. The colour of the interior shall be glossy white and the exterior shall be as suggested by the Employers representative. 6) Instruments, relays, and control devices shall be mounted flush on hinged door of the metering compartment located in the front portion of the module. Each module shall be fitted with a label on the front and rear. Each module shall also be fitted with a label indicating the rating and duty. Modules shall be complete with interpanel wiring. 7) The PMCC shall comprise separate, segregated modules for each circuit. 8) Busways, cableways and wireways shall be run in separate segregated compartments. b) Incomer Feeder and Bus Coupler Detail 1) Void
6.
2) The interlock shall be achieved mechanically as well as electrically between incomers and bus coulers. 3) The incomer feeder modules shall have the following features. Motorised operated spring charged ACB unit (3 P, 415 VAC).
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c)
Voltmeter with voltmeter selector switch. Ammeter with CTs and selector switch. KWhr and KW, meters, PF meter. On/Off indication lamps. R, Y, B indication lamps. Bus bars (RYB) extended down from the incomers for connection of incoming cables without any problem. Bus coupler unit shall have motorised operated spring charged ACB
Outgoing Feeder Modules Details 1) The outgoing motor starter feeder modules shall be any of the following depending upon the requirement of control (a) DOL starter (b) Auto star delta starter (c) Soft Starter (d) Variable frequency drive component starter (for compressor motors of 100 KW rating and above). 2) The DOL contactor starter module shall be considered for control of motors rated up to and including 7.5KW and shall be equipped with: Main load break switch (TPN) HRC Fuses for power circuit and control fuse for control circuit Power and auxiliary contactors as required Overload relay Start, stop and reset Push Butten On, off and trip indication Ammeter with set switch Power and control circuit wiring and termination accessories Local/remote selector switch Auto / off / manual selector switch as per requirement
3) The automatic star delta contactor starter module shall be considered for control of motors of rated from 10KW and upto 45KW.The starter module shall be equipped with Main Load Break Switch (TPN)
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HRC Fuses for power circuit and control fuse for control circuit Power and auxiliary contactors as required Overload Relay Start, stop and reset PB On, off and trip indication Ammeter with CTS and Sel Switch Power and control circuit wiring and termination accessories Electronic timer with relays Local/Remote Sel Switch Auto / off / manual sel switch as per requirement
4) The Soft starter module shall be considered for control of motors of rated from 50KW and above and shall be equipped with Electrical ratings a) b) c) 200 525 +/- 10Volts AC mains 50Hz +/- 10% 100-240+/- 10% Volts control voltage
The Controller shall be provided with the following starting modes: a) b) c) d) e) f) g) h) i) j) k) l) m) Linear Torque control for Start Quadratic Torque control for Start Pump Control Current Limit Start Voltage ramp Start Voltage ramp with current limit Start Full Voltage Director on line Start Remote analogue control Soft Start with Selectable Torque Boost Slow Speed time controlled Slow Speed external controlled Dual Ramp Start Bypass control
The Controller shall provide the following stopping modes: a) Linear Torque control for Stop
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b) Quadratic Torque control for Stop c) Pump Control d) Voltage ramp Stop e) DIRECT ON LINE/Coast to stop f) Remote analogue control Stop g) Dynamic DC-Brake and Soft brake (reverse brake) h) Slow Speed time controlled i) j) l) Slow Speed external controlled DC-Brake at slow speed Accurate positional stop control
k) Dual Ramp Stop m) Bypass control The following Additional features shall be provided in the Controller a) Jogging forward and reverse b) 4 parameter sets c) Analog output d) Built in Display The Operation features in the Controller shall be a) Keyboard b) Remote Protection features shall be provided in the Controller as detailed below. a) Motor Thermal Overload b) Soft Start thermal overload c) PTC input d) Motor Shaft Torque (Max) machine / process protection. e) Motor Shaft Torque (Min) machine / process protection. f) Phase imbalance g) Phase reversal h) Over voltage i) Under voltage
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j) l)
Locked Rotor Phase loss input / output
k) Excessive Starts per hour for application m) Motor output loss The Viewing functions in the controller shall be: a) Three Phase Current b) Three Phase Voltage c) Current in Line1,Line 2, Line 3 d) Voltage between L1-L2, L1-L3, L2-L3 e) Shaft Power in kW / HP (selectable) f) Motor thermal capacity g) Motor Energy consumption (kWh) h) Power factor i) j) Run time in hours Torque in Lbs./ft or Nm (selectable)
The Controller shall be provided with the following Fault Indication functions: a) Line failure n) Phase imbalance b) Over temperature motor c) Over temperature Soft Starter d) Shorted Thyristor e) Open Thyristor f) Locked Rotor g) Motor output loss h) Overload - Shaft Torque i) j) l) Under load Shaft Torque Phase imbalance Under voltage
k) Over voltage m) Excessive Starts n) Phase reversal

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o) Event List of 15 latest fault indications/occurrence CONSTRUCTION: a) The Controller shall be of modular construction, consisting of a Power Control Board (PCB) and Power Structure. b) The PCB shall be compatible the full range of power structures. c) In the sizes from 17 to1400 Amps all phases should be controlled during start/stop. d) The power structure shall consist of six SCRs mounted on a heat sink for ratings up to and including 1400 Amps. e) The Controller shall be DIN Rail mountable up to 250 A. f) DIN Rail mountable units should be mountable without space at side. CODES AND STANDARDS: The controller shall be designed to meet the applicable requirements of: a) b) c) d) EN 60204-1, EN 50081-1 (-2 from 170 A) EN 50082-2 IEC 947-4-2 UL 508 CUL
CONTROL MODULE DESIGN FEATURES: MECHANICAL: a) The PCB module shall consist of a power supply, logic control circuitry, silicon controlled rectifier (SCR) firing circuitry. I/O circuitry, a digital programming keypad, dual LED Displays and a serial communication port. The PCB shall be designed for integral mounting on the power structure and shall be compatible with the full range of current ratings-17 Amps to 1400 Amps. The PCB shall be easily removed from the power structure, without the need to disassemble associated printed circuit board assembles. Control terminals shall be easily accessible and located on the front bottom of the device. The terminals shall be UL rated for 300 Volts, 15 Amps maximum and accept a maximum of two wires, 0,2-4mm2 (#30-#12 AWG).
b)
c)
d)
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e) f)
Digital parameter adjustment shall be provided through a built-in keypad. Analog potentiometer adjustments are not acceptable. Dual built-in alphanumeric, LED displays shall be provided for controller set-up, diagnostics, status and monitoring. The Control Keypad and Display shall have the option for remote mounting. For safety reasons the controller should have 2 green lights for running and start/stop.
g)
ELECTRICAL: a) The PCB shall provide digital microprocessor control and supervision of all controller operation, including SCR pulse firing control. The PCB power supply shall be self-tuning to accept control power input from 100 to 240 or 380 to 500 VAC, 50/60 Hz. The SCR firing circuitry shall incorporate an RC snubber network to prevent false SCR firing. The logic circuitry shall incorporate a latch circuit for three-wire control.
b) c) d)
USER ADJUSTMENTS: a) b) c) d) e) f) The two acceleration start ramp timers shall have individual adjustments from 1 to 60 seconds. The two acceleration stop ramp timers shall have individual adjustments from 2 to 120 seconds. The initial torque setting shall be adjustable from 0 to 250% of motor torque. The end torque setting shall be adjustable from 50 to 250% of motor torque. Current limit starting shall be adjustable from 150% to 500% of the motors full load current. Slow speed shall be adjustable up to 60 seconds or up to 100 external pulses.
PROTECTION AND DIAGNOSTICS: a) Overload protection shall be as follows: 1) 2) Meets applicable standards as a motor thermal protection device. Shaft Power measurement without the use of external electro-mechanical sensors.
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3) 4)
Electronic memory shall be provided for enhanced motor protection. Shaft Overload and under load protection shall be available through the controller, even in a bypass configuration. Protections should be available if bypass is made.
5) b)
When fault conditions are detected, the controller shall inhibit starting or shut down SCR pulse firing.
CONTROL OF ELECTRICAL DRIVES WITH SPECIFIC TORQUE REQUIREMENT OF MECHANICAL EQUIPMENT: a) The standard feature shall be implemented to provide closed loop control of a motor to match the specific torque requirements of mechanical equipments for both starting and stopping. Methods utilizing Soft Start with Soft Stop shall not be acceptable. The soft start and soft stop programming should be independent of each other. Stop function shall be initiated without the need for a dedicated mechanical equipment Stop input. A coast-to-rest stop shall still be possible with a stop input. The Stop times shall be user adjustable from 0 to 120 seconds.
b)
c)
POWER STRUCTURE DESIGN FEATURES: Electrical: a) Back-to-back SCR pairs shall be the only power-switching semiconductor means acceptable. Diode & SCR combinations shall not be acceptable. There shall be separate power sections to operate from 200V to 525 V 50Hz. Semi conductor fuses should not be required for warranty in sizes17-1400 Amps. Soft starter should be built for continuous operation without need of by pass for any reason. SCRs shall have the following minimum repetitive peak inverse voltage ratings: 1. 2. 200 to 525V: 1600 V 200 to 690V: 1800V
b) c) d) e)
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Transient Protection: 17 Amps to 1400 Amps a) b) For controllers rated 17 Amps to 1400 Amps, transient protection with snubber circuit including RC-net shall be standard. Capacitors against electrical noise should be integrated as standard.
ENERGY SAVER: a) The Energy Saver feature shall operate to automatically cause the output voltage from the controller to be reduced when a motor is unloaded or lightly loaded.. The Energy Saver feature shall be defeatable. Additional mounting space or wiring shall not be required.
b) c)
ENVIRONMENTAL RATINGS: a) 1) 2) 3) b) 4) Temperature Ratings The Controller shall deliver its rated current in ambient temperature ranging from 0.C to +50C. The controller should be able to operate at 50 C. The ambient storage temperature shall range from 25C to +50C. Humidity Range The controller shall be operable in relative humidity of 5 to 95%, non-condensing.
NOTE: Vendor shall select the rating of the components based on the motor rating and other requirements. 5) Module Size (Min Requirement) 240 mm - For SFU 300 mm - For DOL starter 400 mm - For Star Delta starter Full vertical panel - for Soft starter and variable speed drive motor starter feeder. 6) The rating of the electrical items and components in the DOL, Star Delta, soft starter / variable speed drive motor feeder modules shall conform to the recommendations of the panel manufacturer with
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due regard given to the derating condition and operation factors. 7) 8) Incomers and bus coupler modules shall be fully draw out and all outgoing motor starter feeder modules shall be of fixed design Energy meters (KWHr) shall be provided in the lighting feeder (indoor and plant outdoor lighting) and power socket outlet feeder modules .This is required to estimate separately the actual power consumption of the process equipment load for the purpose of performance guarantee test and power consumption during operation and maintenance by deducting this auxiliary loads from the total power consumed. The bidder may propose redundant meters if deemed appropriate in view of above.
SPECIFICATIONS OF VARIABLE FREQENCY DRIVE (VFD): GENERAL REFERENCES The dive should be designed to meet the following specifications: NEMA ICS 3.1- Safety standards for Construction and Guide for Selection, Installation and Operation of Adjustable Speed Drive system. IEC 146 International Electrical Code PRODUCT RATINGS INPUT POWER: The drive should be self adjustable to accept an input supply voltage of AC, 3 phase & neutral of 415 V + /- 10%, 50C/s +/- 5%. ENVIRONEMENT: Storage ambient temperature range: -10 to 50 degree centigrade Operating ambient temperature range: 5 to 50 degree centigrade without derating. OUT POWER: The out voltage should be adjustable from 0 to rated input voltage. The output frequency range should adjustable from 0 to 100 Hz. The inverter section shall produce a pulse width modulated (PWM) waveform using latest generation techniques. DESIGN HARDWARE: The drive hardware shall be employ the following power components Diode or fully gated bridge on the input. DC bus inductor on all ratings as required.
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Switching logic power supply operating from the DC bus. Phase to phase and phase to ground MOV protection. Gold plated plug in connections on printed circuit boards. Micro procession based inverter logic isolated from power circuits. Latest generation inverter section. Inverter section shall not require communication capacitors. Customer interface common for all horsepower ratings, interface shall include an LCD digital display, programming keypad and operator keys option. Common control connection for all ratings. Optimized for 4 KHz carrier frequency at 44 KW (60 HP) or less, and 2KHz at 55 KW (75HP) and larger. Peripheral interface enable attaching common options.
CONTROL LOGIC: The drive should programmable or self adjusting for operation under the following conditions. Operate drive with motor disconnected. Controlled shut down, when properly fused with no component failure in the event of an output phase to phase or phase to ground short circuit and annunciation of the fault condition. Adjustable PWM carrier frequency within a range of 2-8 KHz. Selectable Sensor less Vector or V/Hz mode. Selectable fro variable of constant torque loads. Selection of variable torque shall provide 115% of rated VT current for up to one minute. Selection of constant torque shall provide 150% of rated CT current for up to one minute. Multiple programmable stop modes including- Ram, Coast, DC Brake, Ramp-to Hold and S-curve. Multiple accelerator and deceleration rates. All adjustments to be made with the door closed. Adjustable output frequency up to 100 Hz. POWER CONDITIONING: The drive should be designed to operate on an AC line which may contain line notching and up to 10% harmonic distortion. An input isolation transformer shall be required for protection from normal line transients and the K factor shall be 4.0 or less. PF shall after rectification if required for lower frequencies shall not be lower than 0.95. FEATURES INTERFACE: The drive shall provide a removable Human Interface Module with integral display to show drive operating conditions, adjustments and fault indications. The display should be removable under power without causing a fault and shall be visible and operable without opening the enclosure door. The display shall consist of 2 lines of 16 character alphanumeric, backlit LCD with the display being configurable for simultaneously
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displaying two values using customized multi-lingual text and user scaled units. The module also shall provide LED indication of drive direction and commanded direction. The display should be capable of remote mounting by means of cable connection up to 10 meters (33ft) from the drive and shall be capable of being used as a hand held terminal. CONTROL MODE: Programming shall provide the ability to select sensor less vector or v/hz mode. The sensor less vector mode shall use the motor nameplate data plus motor operating data, such as IR drop, nominal flux current and flux up time. The volts per hertz mode shall be programmed for squared, cubed, straight line, pre programmed or full custom patterns. CURRENT LIMIT: Programmable current limit shall be from 20% to 16% of constant torque rating. Current limit should be active for all drive states; accelerating, constant speed and decelerating. The drive shall employ Pl regulation with an adjustable gain for smooth transition in and out of current limit. ACCELERATION/DECELERATION: Accel/Decel settings shall provide separate adjustments to allow either selling to be adjusted from 0 seconds to 3600 seconds. A second set of remotely selectable Accel/Decel settings shall be accessible with Control Interface option. An adaptive current limit circuit shall be disabled in programming for fast acceleration of low inertia loads. SPEED REGULATION:
The programmable speed regulation modes shall include the following: Open Loop Slip Compensation with 0.5% speed regulation Droop Negative Slip Compensation with 0.5% speed regulation Traverse Function Closed loop encoder feedback with 0.1% speed regulation Process Pl control
SPEED PROFILES: Programming capability shall allow the user to produce speed profiles with linear acceleration/deceleration or S-Curve profiles that provide changing accel/decal rates. S-Curve profiles shall be selectable for fixed or adjustable values.
ADJUSTMENTS:
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The digital interface should be used for all set-up, operation and adjustment settings. All adjustments shall be stored in nonvolatile memory (EEPROM). No potentiometer adjustments shall be used. The drive shall provide EEPROM memory for factory default values. PROCESS Pl CONTROL: The internal process Pl regulator shall have bolt proportional and integral gain adjustments as well as error inversion and output clamping functions. The feedback shall be configured for normal or square root functions. If the feedback indicates that the process shall be moving away from the set point, the regulator shall adjust the drive output until the feedback equals the reference. Process control shall be enabled or disabled with a hardwire input. Transitioning in and out of process control shall be tuned for faster response by preloading the integrator. Protection should be provided for a loss of feedback or reference signal. FAULT RESET/RUN: The drive shall provide up to nine automatic fault reset and restarts following fault condition before locking out and inquiring manual restart. The automatic mode should be not applicable to a ground fault, shorted output faults and other internal microprocessor faults. The time between restarts shall be adjustable from 0-5 seconds to 30 seconds. SKIP FREQUENCIES: Three adjustable set points that lock out continuous operation at frequencies which may produce mechanical resonance shall be provided. The set points shall have bandwidth adjustable from 0 Hz to 15 Hz. RUN ON POWER UP: A user programmable restart function should be provided to automatically restart the equipment after restoration of power after an outage. A maintained 2-wire start input shall be provided for this function. LINE LOSS RESTART: This programmable function shall select the reconnect mode of the drive after recovery from a line loss condition. The reconnect modes shall be Last Speed, Speed Search, Track Volts, or Use Encoder. Disabling this feature will force the drive to start from zero hertz. FAULT MEMORY: The last four faults as wel, as operating frequency, drive status and power mode shall be stored at the time of fault. Information should be maintained in the event of a power loss. OVERLOAD PROTECTION:
36
The drive shall provide 20 motor overload protection. Overload protection should be speed sensitive and adjustable for motors with speed ranges of 2:1, 4:1 and 10:1. A viewable parameter shall store the overload usage in percent. An alarm bit shall be used to adjust a process to eliminate an overload trip. AUTO ECONOMIZER: This feature automatically shall reduce the output voltage when the drive shall be operating in an idle mode (drive output current less than programmed motor FLA ). The voltage should be reduced to minimize flux current in a lightly loaded motor thus reducing KW usage. If the load increase, the drive shall automatically return to normal operation. TERMINAL BLOCKS: Separate terminal blocks shall be provided for control and power wiring. FLYING START: The drive should be capable of determining the speed and direction of a spinning motor and adjusts its output to pick-up the motor at the rotating speed. The flying start feature should be operable with or without encoder feedback. RIDE THROUGH: The control logic should be capable of riding through a power outage of up to 2 seconds in duration.
ANALOG OUTPUT: An output signal should be jumper selectable for 0-10V DC or 0-20 mA which shall be user programmable such that it shall be proportional to one of 13 process parameters including output frequency, output current, encoder feedback, out power and others. A programmable offset should be provided to allow modification of the analog output to obtain 2- 10V DC or 4-20 mA. Programmable gain adjustments for both upper and lower settings shall allow for system calibration. REFERENCE SIGNALS: The drive should be capable of the following input reference signal: Digital pulse input * Digital MOP Remote potentiometer * Serial 0 10V DC * HIM ( Programme/ Control panel) 4 20 mA
37
The remote potentiometer should be also programmable to be used as a trim pot for the 0 10V DC or 4 -20 mA signals. Programmable gain adjustments for both upper and lower settings shall allow for system calibration. The analog inputs shall be programmable for normal, Inverted or square be root operation. LOSS OF REFERENCE: In the event of loss of the 4 20 mA reference signal, the drive should be user programmable to the following: Fault and stop. Alarm and maintain last reference within 10% Alarm and go to preset speed. Alarm and go to minimum speed. Alarm and go to maximum speed. Active for Process OI reference or feedback. DIGITAL I/O: Contact output ratings shall be 115V AC/30V DC, 5.0 Amp resistive, 2.0 Amp inductive. All four contacts shall be provided with programmable to 17 different conditions. Factory settings shall be as follows: Form A Run contact. Form C Fault contact. Form C Alarm contact. Form A At speed contact. OPERATOR DIVICES: The drive shall provide an option for start, stop, Jog Reverse and Speed Control as an integral part of the Human Interface Module.
CONTROL INTERFACE: All control interface cards shall provide input terminals for access to fixed drive functions that include start, stop, external fault, speed, and enable. Four additional inputs shall be to be programmed to one of 24 different input modes for factions such as reverse, preset speed access, jog, second accel/ decal time access, process trim, speed/ torque, and local control selection. Inputs shall be programmable to configure the drive or standard 3 wire, 2- wire, EC, 4-20 mA DC and serial operation requirements. REMOTE I/O COMMUNICATION: This be option shall provide a Single Point Remote I/O Interface board. The board should be configurable for 1/4, 1/2, 3/4 , or full rack with a baud rate of 57.6, 115, or 230k baud. The Remote I/O board may be set up to control drive logic and speed reference commands and monitor drive status and process parameters.
38
d) Bus bars 1) The PMCC shall be provided with three-phase and neutral bus-bars.(both vertical and horizontal) 2) Bus-bars shall be of copper with sleeving and rated for the total connected load of the plant including the lighting load. 3) Bus-bar joints shall be of the bolted type and shall be insulated. Spring washers shall be provided to ensure good contact at the joints. 4) Bus-Bars shall be located in air insulated enclosures. Direct access to or accidental contact with bus bars and primary connections shall not be possible. All apertures and slots shall be protected by baffles to prevent accidental shorting of bus bars by the entry of maintenance tools. Tight seals with shrouds between cubicles, bushings or insulating panels shall be provided for bus bars crossing from one cubicle to another. 5) The bus bars and primary connections shall have a short time rating. The mechanical strength of the bus bars and supports shall be able to withstand the electromagnetic forces arising under the most onerous short circuit condition. e) Contactor Type Motor Starter 1) Motor starter contactors shall be of the full voltages, star/delta or direct-on-line as the case may be. They shall also be all break single throw, electromagnetic type suitable for the motor. Three pole contactors shall be furnished for 3-phase motors and two pole contactors shall be furnished for single-phase motors. Reversing contactors shall be provided with electrical interlocks between forward and reverse contactors. 2) Contactors shall be suitable for uninterrupted duty as defined in IS:2959. Contactors for reversing motors shall be rated for Class AC 4 duty in accordance with IS 2959. All other contactors shall be rated for class AC 3 duty. 3) The main contacts of the contactors shall be silver faced. 4) The insulation class of coils shall be class B. 5) One number spare auxiliary contactor in addition to the required auxiliary contactor shall be considered. All power and auxiliary contactors shall be provided with at least two pairs of NO and NC auxiliary contacts as spare in addition to the required number of contacts. 6) Contactors shall not drop out at voltages down to 70% of the rated coil voltage. 7) Contactors shall be provided with a three element, positive acting, ambient temperature compensated, time lagged, hand reset type of thermal overload relay with adjustable settings. The hand reset button shall be flush with the front door of the control module, and shall be suitable for resetting the overload relay with the module door closed. Relays shall be either direct connected or CT operated With
39
Overload relay and the reset buttons. The setting range shall be properly selected in accordance with the rating of motor selected. 8) The test facility shall be provided in each motor starter for the purpose of testing the starter modules. e) Air circuit breakers (ACB) 1) Air circuit breakers shall be of the 3 pole air break type and shall be of the vertical isolating pattern with horizontal draw out facilities. These shall be power operated by a motor operator spring charging type of mechanism. The tripping spring shall be charged by the closing action to enable quick tripping. Closing of the circuit breaker shall automatically initiate recharging of the springs to enable the mechanism to be ready for the next closing stroke. The charging time for the springs shall not exceed 30 seconds. It shall be possible to charge the springs manually in an emergency. The transfer from motor to manual charging shall automatically disconnect the charging motor. The charging mechanism shall be provided with mechanical indicators to show charged and discharged conditions of the spring. Failure of any spring, vibration, or mechanical shock shall not cause tripping or closing of the circuit breaker. 2) Means shall be provided to open and close the breakers manually and slowly when the operating power is not available for maintenance and adjustments. 3) All operating mechanisms shall be provided with ON-OFF mechanical indicators in addition to ON-OFF electrical indicators. 4) A local manual trip device shall be provided on the operating mechanism. 5) Closing coils and other auxiliary devices shall operate satisfactorily at all voltages between 80 - 110% of the rated control voltage. Trip coils and associated trip relays shall operate satisfactorily between 50 - 110% of the rated control voltage. 6) The rated breaking capacity of the ACB shall not be less than 35 MVA and the short circuit withstand current for one second duration shall not be less than 40 KA. f) Switch and Fuse 1) Low voltage air-break switches shall be of the load break, fault make, group operated type. For use on three phase system, the switches shall be of the triple pole type with a link for the neutral wire. For use on single phase and D-C systems, the switches shall be of the two pole type. 2) Switches shall be of the heavy duty, quick make and quick break type. Switch contacts shall be silver plated and contact springs shall be of stainless steel. Switch handles shall have provision for locking in both fully open and fully closed positions. Mechanical ON-OFF indication shall be provided on the switches. 3) Switches for controlling motor circuits shall be of the load break, fault make type and shall be capable of breaking the locked rotor current of the associated motor. The life and no. of operation guaranteed shall be mentioned in the data sheet.
40
4) Low voltage switches and composite units of switches and fuses shall comply with the requirements of IS 4064. 5) Low voltage composite units of switches and fuses shall be provided with the following interlocks so that:
The fuses are not accessible unless the switch is in fully open condition. It shall not be possible to close the switch when the fuse cover is open, but an authorised person may override the interlock and operate the switch. After such an operation the cover shall be prevented from closing if the switch is left in the ON position.
6) Fuses and links shall be provided to enable any circuit to be isolated as necessary for maintenance and test purposes without isolating the whole panel. 7) All fuses shall be of the HRC cartridge type mounted on plug-in type of fuse bases. Fuses shall be provided with visible indicators to show that they have operated. Current vs time characteristics of all types of fuses shall be furnished for the approval of the Employers representative. Fuses shall comply with the requirements of IS 2208. 8) Fuse carriers and solid link carriers and bases shall be made of plastic moulded insulating material of an approved make. Ceramic materials will not be accepted. All accessible live connections shall be efficiently shrouded. Wherever fuses with high current ratings are directly plugged in to the circuit terminals without having to be mounted in fuse carriers, enshrouded terminals may be provided. However, in such cases an insulated fuse removal handle shall be furnished for each fuse carrier to enable changing of fuses with the circuit live, without danger of contact with live metal. The fuses shall be rated to give maximum protection to the apparatus in the circuit and the rating shall be inscribed on the fuse label. 9) Earthing and neutral links in main supply circuits shall be of solid silver plated copper and be of the bolted pattern. 10) Fuses and links functionally associated with the same circuit shall be mounted side by side. g) Current Transformers (CT) 1) Current transformers shall have polarity markings indelibly marked on each transformer and at the lead terminations at the associated terminals block. 2) Current transformer shall be able to withstand the thermal and mechanical stresses resulting from the maximum short circuit and momentary duties of the switchgear. 3) Current transformers for high voltage equipment shall be of the resin cast type. 4) Where multi-ratio current transformers are specified, a label shall be provided clearly indicating the connections required for the alternative ratio. These connections shall also be shown on panel wiring diagrams.
41
5) Identification labels shall be fitted giving the type, ratio, rating, output and serial numbers. Duplicate rating labels are to be fitted on the exterior of the mounting chambers and suitably located to enable reading without the removal of any cover or metal sheeting forming part of the structure of the switchboard. 6) Magnetisation characteristics, calculated performance and protection settings shall be provided by the Contractor. 7) Metering CTs shall have an accuracy class of 1.0 whereas protection CTs shall have an accuracy class 1.5. 8) The V/A burdens for metering and protection of CT's shall be 15 V/A each respectively. h) Relays 1) All relays shall be enclosed in rectangular shaped, dustproof cases. 2) All relays shall be suitable for flush mounting, with only the dust tight covers projecting from the front of the panel. 3) All relays shall be accessible for setting and resetting from the front. Access to setting devices shall be possible only after the front covers of the relays are removed. Resetting facilities shall however be accessible externally to the relay case. 4) All relays shall be provided with positive action flag indicators visible from the front. 5) Auxiliary relays shall be rated to operate satisfactorily between 70% and 110% of the rated voltage. Tripping relays shall be rated to operate satisfactorily between 50% and 110% of the rated voltage. i) Control and Selector Switches 1) Control and selector switches shall be of the rotary type and have enclosed contacts which are accessible by removal of the cover. 2) Control and selector switches for instruments shall be flush mounted on the front of the panels. Local and remote selector switches shall be located on modules. 3) All control switches shall be of the spring return to normal type. Circuit breaker control switches on switchgear cubicles shall be lockable in the trip position. 4) Control switches shall have momentary contacts. 5) Selector switches shall be of the stay-put maintained contact type. 6) Control switches shall be provided with pistol grip handles. Selector switches shall be provided with round, knurled handles. All handles shall be black in colour. 7) Properly designated escutcheon plates clearly marked to show the operating positions shall be provided with all switches. j) Indication Instruments and Meter
42
1) Indicating instruments shall be mounted flush on the panels with only flanges projecting outside the panel. 2) Instrument dials shall be white with black numbers and lettering. Dials shall be parallax free. 3) All indicating instruments shall have provision for the zero adjustment outside the cover. 4) Normal maximum meters reading shall be of the order of 60% of normal full scale deflection. 5) Watt-hour meters shall be of the induction type. 6) Instruments shall have an accuracy of class 1.5 or better. 7) Ammeters for motors shall have suppressed extended scale to read up to six times the rated current of the CT. k) Indicating Lamps 1) Indicating lamps shall be of the filament type with low watt consumption. Indicating lamps shall be of the double contact bayonet cap type rated for operation on 230V AC. Indicating lamps shall be provided with series resistances to avoid short circuiting of the control supplies in the event of fusing of the filament. Lamps shall be provided with translucent lamp covers. Alternatively LEDs may also be used. 2) Bulbs and lenses shall be interchangeable and easily replaceable from the front. l) Push Buttons 1) Start and stop push buttons shall be coloured green and red respectively. All other push buttons shall be black. 2) All push buttons shall be pushed to actuate the contact type. 3) Emergency stop push buttons shall be lockable in the operated position. The key shall be released form the push button in both the released and operated positions. Operation of the push button shall be possible in the key released position. Push button knobs for emergency stop-push buttons shall be recessed to prevent accidental operation. m) Space Heaters 1) Adequately rated anti-condensation space heaters shall be provided, one for each vertical cubicle of PMCC. 2) Space heaters shall be of the strip type, rated for operation on a 240 V single phase, 50 Hz AC system. 3) Each space heater shall be complete with on and OFF switch and with HRC fuse in the phase. It shall link in the neutral and thermostat to control space heater ON and OFF depending upon the temperature setting.
43
n) Cubicle Lighting 1) Each PMCC cubicle cable alley shall be provided with suitable interior lighting controlled by 5 amps SPNMCB. o) Interlocks 1) Interlocks in each module shall be such that (i) it should not be possible to close the switch when the fuse cover is open. (2) The fuses shall not be accessible unless the switch is in fully open condition.
p) Safety Shutters (applicable for draw out design) 1. MCC cubicles shall be provided with safety shutters operated automatically by the movement of the carriage to cover the stationary isolated contacts where the shutter is withdrawn. (Module padlocking facilities shall be provided for locking the shutters positively in the closed position. It shall, however, be possible to open the shutters intentionally against the spring pressure for testing purposes. 2. LT incoming switch and starter modules shall be provided with laminated insulating sheet partitions to cover the stationary contacts when the module is withdrawn. q) Starter module alignment (applicable for drawn out design) The moving portions shall be fitted with positive guides so as to ensure correct alignment of the isolating contacts in both circuit or earth positions. r) Contacts The contacts shall be made of silver faced copper. The contacts shall be adjustable for wear and tear, and shall be easily replaceable. s) Test Operation Facilities (applicable for drawout portion) All starter modules shall be provided with testing facilities to test the operation of the starter equipment. A separate test position shall be provided in the cubicle/ module. t) Wiring for Control and Protective Circuits 1) All wiring for control, protective, alarm and indication circuits on all equipments shall be carried out with at least 650V grade, PVC insulated, stranded tinned copper, 1.5 sqmm conductors. Wiring for CT circuits shall be carried out with a 2.5 sqmm copper wire. 2) All wiring shall be run on the sides of the panels and shall be neatly bunched and cleated without affecting access to equipment mounted on the panel.
44
3) All wiring shall be taken to terminal blocks without joints or tees in their runs. 4) Engraved core identification ferrules, marked to correspond with the wiring diagram shall be fitted to each wire and each core of multicore cables terminated on the panels. Ferrules shall fit tightly on the wires, without falling off when the wire is removed. Ferrules shall be of yellow colour with black lettering. 5) All wires forming part of a tripping circuit shall be provided with an additional red ferrule marked "T". Each wire shall be identified by a letter to denote its function followed by a number to denote its identity, at both ends. Unused cores of multicore cables shall be ferrules U1, U2, etc., at both ends and connected to spare terminals. 6) Spare auxiliary contacts of electrical equipment shall be wired to terminal blocks. 7) Wiring for future equipment shall be provided as far as possible and all wires shall be terminated. u) Control Wiring Terminal Blocks 1) Terminal blocks shall be of the 650 V grade, Clip-on type. 2) Terminals shall be numbered for identification and grouped according to function. 3) Terminals for circuits with voltage exceeding 125 V shall be shrouded. Terminal blocks at different voltages shall be segregated into groups and distinctively labelled. 4) Current transformer secondary leads shall be brought to terminals blocks, where a facility shall be provided for short circuiting and grounding the secondary leads. 5) Terminals blocks shall be arranged with at least 100 mm clearance between any two sets. 6) Separate terminal stems shall be provided for internal and external wiring respectively. 7) All wiring shall be terminated on terminal blocks, using crimping type of lugs or claw type terminations. v) Test Terminal Blocks 1) Test terminal blocks shall be provided for secondary injection and testing of relay equipment. A suitable metering block shall be provided where specified for the connection of a portable precision instrument to be operated when required for specific plant testing purposes. 2) The terminal blocks shall be provided with suitable shorting links or alternatively shall be of the type suitable for use with a portable test plug-in arrangement. w) Inspection and Testing
45
1) The MCC /PMCC shall be offered for inspection after assembly. The tests (routine and acceptance) indicated below shall be carried out. i. ii. Routine test on the component of the MCC/PMCC High voltage test on the power circuit and on the control circuit.
2) The following routine and acceptance tests shall be carried out on the MCC/PMCC during final inspection. i. ii. iii. Measurement of insulation resistance of the main circuit before and after HV test. Operation tests One minute power - frequency voltage dry withstand tests on auxiliary and power circuits.
3) Among other tests on switchgear and components, the following routine tests shall be carried out on assembled switchgear during the final inspection. i. ii. One minute power - frequency voltage dry withstand test for 2 KV on the main circuits. One minute power frequency voltage dry withstand test for 1.5 KV on the auxiliary circuits.
4) This item falls under inspection category-A x) Reference Drawings 1) The following drawings shall be submitted along with the tender: i. ii. Dimensioned layout drawing of the PMCC installation. General arrangement of the switchgear cubicles showing the arrangement of modules, isolators, CTs, PTs, bus bars, cable boxes, etc., (An adequate number of cross sections shall also be included).
2)
The following drawings shall be submitted for approval after the award of the contract. i. Complete assembly drawings of the PMCC showing plan, elevation, and typical sectional views and location of the cable boxes and control cable terminal blocks for external wiring connections. Foundation plans showing the location of channel sills, foundation, anchor bolts and anchors, floor plans, and openings. Schematic elementary diagrams (a-c and d-c) for the circuit breaker control, interlocks, relays, instruments, space heater, etc.
ii. iii.
46
iv. v. vi.
Complete wiring diagrams including terminal wiring designations. Dimensioned drawings showing the cable connection details to the switchgear incoming cubicles. Cable box drawings with dimensions and ratings.
3) The Contractor shall furnish the following items. i. ii. Technical literature for each equipment Operating and maintenance manuals.
y) Brief technical particulars of PMCC 1. 2. 3. 4. 5. Rated Voltage, phase and frequency Type of Construction Max System Voltage Continuous Current rating of bus bars (Both horizontal and Vertical) under site ref ambient temperature. Ref Ambient Temperature for design Maximum Temperature of bus bars, dropper and contacts at continuous current rating under site reference under site reference ambient temperature. Short circuit withstand for bus bars and droppers i. ii. 8. 9. Short time (1 Sec.) at 415 V Dynamic Rating : : : : 40 KA (rms) 102 KA (peak) Top Entry 1800 mm (Max) Incomers and bus coupler modules panels shall be fully drawn out and all outgoing motor feeders and SFU / FSU modules shall be fixed design : : : : : AC, 415V, TPN, 50Hz Single Front 470 V Shall be the same as that of incomers breakers of PMCC rating. 50C
6.
80C
7.
Bus duct Operating Height
10
Type
11
Thickness of sheet steel in mm(minimum requirement is 3mm)

47
i. 12 13.
Cold rolled
: :
Degree of protection as per IS:2147 Colour finish shade, as per IS 5 i. ii. iii. Painting Interior Exterior
Frame:3mm, Doors:3mm, Covers /partitions:3mm. IP 52
: : : : : :
Epoxy Glossy White Shade no. 5, IS 631 or as approved by Engineer.
14.
Earthing Conductor i. ii. Material Size (mm x mm)
Copper 50 x 10
15.
Clearances in air of live parts i. ii. Phase to Phase Phase to Earth : : 25.4 mm(minimum) 19.4 mm(minimum)
MCC - 1 The technical particulars and specification details mentioned for PMCC are applicable for MCC 1 also. z) Applicable Standards 1. Circuit breakers : IS - 2516, 8828/ BS - 5311, 4752/ IEC - 65, 157 IS-4064/BS-5419/ IEC.408 IS-2705/BS-3998/ IEC-44, 186 IS-3156/BS-3941/ IEC-44, 186 IS-3231, 3842
48
2.
Air break switches air break disconnectors air break switch disconnectors and fuse combination units for voltage not : exceeding 1000 V AC or 1200 V DC Current transformer :
3.
4.
Voltage transformer
5.
Electrical relays
6.
Contactors for voltage not exceeding 1000 V AC or 1200 V DC
IS-2959, 8544/ BS-5424/IEC-158 IS-6875/BS-4794/ IEC-377 IS-9385/BS-2692/ IEC-282 IS-9224/BS-1362/ IEC-269 IS-1248/BS-89/ IEC-51 IS-722, 5685 8530/BS-
7.
Control switches
8.
High voltage fuse
9.
Low voltage fuse
10.
Electrical direct acting indicating instruments
11.
A.C. electricity meters of induction type
12
Porcelain post insulators for system with nominal voltages greater : than 1000 volts Resistance wire, tapes and strips for heating elements :
IEC-145, 211 IS-2544
13
IS-3725
14
Wrought aluminium and aluminium alloy bars, rods tubes and : sections for electrical purposes :
IS-5082
15. Toggle switches
IS-3452/BS-3676
16.
Metal enclosed switch gear and control gear for voltage above : 1000V, but not exceeding 11000V General requirement for switchgear and control gear for voltage : not exceeding 1000 volts Degree of protection provided by enclosures for low voltage : switchgear and control gear Dimensions for panel mounted indicating and recording electrical : instruments Marking and arrangement for switchgear, bus bars, main : connection and auxiliary wiring
IS-3427/BS-162 IS-4237/BS-5486/ IEC-439 IS-2747/IEC-144
17.
18.
19.
IS-2419
20.
IS-375
49
21.
Code of practice for selection, installations and maintenance of : fuses
IS-10118
7.
HT AND LT CABLES a) 11 KV HT cables 1) 11 KV unearthed aluminium conductor; XLPE, armoured power cable of size 3 Core x 185 sq.mm shall be used between 11 KV pole structures, HT metering panels, VCB panels and the HT side of the power transformers. 2) 11KV XLPE cables shall be manufactured with dry cure process and shall have (a) Conductor Stranded, Compacted circular or sector shaped and of electrolytic conductivity grade aluminum wires. (b) Conductor shield Conductors shall be shielded with an extruded, semi conducting compound applied in tandem with and firmly bonded to the insulation. (c) (d) Insulation Natural, Chemically cross linked poly ethylene conforming to IS:7098 Insulation Shield Shield shall consist of non-metallic semi conducting part in combination with a metallic part over the insulation. (e) (f) Core identification By colored stripes applied on the cores. Laying up The cores of the multicore cable shall be cabled with plastic filters in the interstices. (g) Inner sheath The laid up cores shall be provided with inner sheath by extruded PVC (h) Armour The armouring shall be applied directly over the inner sheath. Three core cables shall have galvanized steel round wire. (i) Outer sheath Three core cables shall be provided with extruded PVC outer sheath. The PVC compound for the outer sheath shall conform to type ST2 of IS 5831. The colour of the outer sheath shall be black
The manufacture and supply of cables shall conform to the following.
50
I. Standard condition of installation of these cables are (a) (b) (c) (d) (e) (f) Maximum conductor temp at continuous load Ambient Air temp Ground temp Thermal resistivity of the soil Thermal resistivity of XLPE Depth of laying in ground 90 deg C 50 deg C 40 deg C 150 deg C /w 350 deg C /w 1050 mm (min) Single cable in a
(g) Method of laying trench. b) LT CABLES (PVC Insulated Heavy Duty) c) General Requirement
1) Cables shall be capable of satisfactory performance when laid on trays, conduits, ducts and buried underground. 2) Cables shall be capable of operating satisfactorily under a power supply system voltage variation of +/- 5%, a frequency variation +/- 3% and a combined voltage and frequency variation of +/- 5%. 3) Cables shall normally be laid under the following conditions i. ii. iii. iv. v. In air In ground In conduits In conduits In trays not Ambient temperature of 50C Ground temperature of 40C 120C cm/watt Space factor of not more than 60% Single layer, touching each other but pressing with each other.
4) The conductor temperature when carrying rated current and under short circuit condition for 1100V PVC insulated cables shall be 70C and 160C respectively. 5) Current ratings of PVC cables shall be arrived on the basis of the circuits being protected by class fuse contactors with a setting not exceeding 1.5 times. The rated current, for installation in air, and not exceeding 1.3 times the rated current for installation in ground. 6) The following letter designations shall be used to specify type of cables i. ii. A C Aluminium conductor Copper conductor
51
iii. iv. v. i. ii. iii. iv. v. vi.
Y S W
PVC insulation of PVC sheath or overall PVC jacket (over armour) Bedding or serving Galvanised steel wire armour
Letter designations for cables shall be indicated in the following order Conductor Insulation Sheath Bedding where applicable Stemout Overall jacket
7) Cables for power circuits shall be of copper conductors with a minimum size of 2.5 sq.mm for motors of rating up to and including 4 HP and of aluminium conductors with a minimum size of 4 sq.mm for motor rating 5 HP. For motors of rating 7.5 HP.and above. Cables sizes shall be calculated taking in to account load factor and derating conditions as well as other factor maintioned in (d) rating below. 8) Cables for control circuits shall be of stranded copper conductors with a minimum size of 2.5 sq.mm. Copper conductor cables shall be designated by the absence of the letter indicating the aluminium conductor. 9) Power and control cables shall be laid from PMCC outgoing motor starter feeder modules to respective motors and local PB stations. Supply and laying of cables, glanding and termination at both the ends, testing and commissioning of motors with cables shall be carried out by the Contractor. d) Rating The Contractor shall ensure that the current rating of each cable selected is adequate for its duty under both normal and possible fault conditions. In accessing the rating and cross section required for each cable the following factors should be taken into account. a. b. c. d. e. Fault level and duration as governed by circuit protection relays and fuse gear. Conditions of ambient temperature and method of installation. Voltage drop under steady state and transient conditions (allowed voltage drop + 5% of the supply voltage 415V). Loading under steady state and transient conditions. Disposition of cables whether in air or laid in ground in groups or otherwise.
52
f.
Cable capacity should be at least one and half times of starting current of the motor.
e) Sizes of the control cables form MCC to local start/stop PB Station. (i) 7C 2.5 sqmm y w y cable (for local start / stop PB station with ammeter) (ii) 5C 2.5 Sq.mm y w y cable (for local start / stop PB Station. Without ammeter). f) Size of the lighting cable from LDB/Panel to Lighting circuit 3C 2.5 Sq.mm. copper conductor for each circuit from the respective DPMCB of the LDB/Panel (each single phase lighting circuit shall have a total of 1000 watts maximum only) and, for outdoor lighting, a suitable size aluminum conductor cable shall be provided as per requirement. g) Note 1) The bidder has to work out complete requirement of cables for the Plant. 2) The following tests shall be carried out at works. Construction tests Test for conductors Test for thickness of insulation Test for laying up Test for thickness of laying up Test for thickness of inner sheath Test for armoring Test for thickness of outer sheath. h) Applicable Standards i. ii. PVC insulated cables heavy duty Crosslinked polyethylene insulated PVC sheathed cables i) Cabling System for Complete Plant The cabling system covers the design as per relevant national and international standards. It shall be the responsibility of the Contractor to work out a detailed layout for the complete plant cable system. The layout drawing shall be furnished for the approval before commencement of installation including cable trays, cable racks, accessories, tray supports, conduits etc.
: :
IS : 1554 IS : 7098
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j) Cable Layout The following points shall be noted while planning cabling system for the plant 1) 2) Inside the building cables shall be laid in cable trays in a built -up RCC cable trench. Outside the building the cable from the PMCC to the drives and other electrical equipment shall be laid and buried underground.
k) Cable Trays, Accessories and Tray Supports 1) Cable racks/trays shall either be run in concrete trenches inside the building and on overhead supports, supported from building steel, or floor slab etc., as required. 2) Cables shall be clamped with GI strip to the cable trays at regular intervals. 3) Lines and grades for the trays may be measured from building steel and finished floor elevations. Changes in line or grade, or the addition of offsets by means of cutting standard tray sections and inserting additional tray fittings to match with the exiting arrangement shall be considered as a normal part of the work. 4) All cable trays and vertical raceways shall be hot dip galvanised (minimum Galvanishing thickness shall be 100 microns). 5) Installation work shall comprise installation of trays as per approved layout drawings prepared by the successful bidder. All steel sections such as angles, channels, brackets etc., required for supporting the trays shall be hot dip galvanised (100 micron thickness) and supplied by the Contractor. 6) GI cable trays shall be of perforated mild steel (2.5 mm thick) with formed flanges and duly hot dip galvanized (100 micron thick). Any damage caused by the Contractor to surfaces of buildings / structures etc., during the installation of the trays shall be made good by the Contractor to the satisfaction of the Employers representative.. 7) The scope of cable tray installation shall include the installation of accessories like GI coupler plates. Elbows, droputs, tees, and bends as required. The Contractor shall also include earthing of cable trays at distances not exceeding 10 m length by means of 25 x 3 mm GI flat which shall lead to the nearest earthing pit. Nuts, bolts and washers are also of GI (100 micron thick) flat. The Contractor shall also provide identification marks for cable trays. Only hot drip galvainised of cable trays and hardware as well as accessories are permitted. No other method of galvanising shall be allowed. l) Conduits, Pipes and Ducts 1) The Contractor shall supply and install conduits, pipes and ducts as per requirement. All accessories/fittings required for making the installation complete, including but not limited to, ordinary and inspection tees or galvanised steel bushings, male and female reducers and enlargers, wooden plugs, caps, square headed male plugs, nipples, gland sealing fittings, junction boxes, pull boxes, conduits, outlet boxes, splice boxes, terminal boxes, glands, gaskets and box
54
covers, saddles and all steel supporting work shall be supplied by the Contractor. Conduit fittings shall be of the same material as the conduits. 2) Flexible metallic conduits shall be used for termination of connections to equipment such as motors or other electrical equipment to be disconnected at periodic intervals. 3) GI conduits or pipes shall run along walls, floors, and ceilings, on steel supports, or shall be embedded in soil, floor, walls or foundations, in accordance with approved layout drawings. 4) Exposed GI conduits shall be adequately supported by racks and clamps or straps or by other approved means. Conduit supports shall be erected square, and true to line and grade with an average spacing of one support for every 2 meters of conduit length. 5) Each conduit run shall be marked with its designation. 6) All installed conduits shall have their ends temporarily closed by caps, wooden plugs, or other approved means until the cable is pulled. Closures shall be made in such a way that they do not get dislodged easily. 7) When one or more cables are trained through a conduit, the conduit size shall be such that the total cross sectional area of the cables does not exceed 60% of the internal cross sectional area of the conduit. 8) The Contractor shall be responsible for the bonding of metal pipes or conduits in which cables have been installed to the main earthing systems. Joints, metal sheaths and armour of the cables shall be bonded to the earth system in an approved manner. The entire system of conduit after installation shall be tested for mechanical and electrical continuity throughout and permanently connected to earth by means of a special approved type earthing clamp efficiently fastened to the conduit. Gas or water pipes shall not be used as an earth medium. 9) All conduits shall be hot dip galvanised. Conduits shall be run on the surface or embedded and shall be neatly arranged. When one or more cables are laid through a conduit, the conduit size shall be such that the total cross sectional area of the cables does not exceed 40% of the internal cross-sectional area of the conduit. 10) The conduits shall be screwed into spout outlets of conduit boxes, or, where fixed to boxes, drilled with properly sized clearance holes. They shall be secured by means of sockets and hexagon bushes. All threads shall be cut clean and all burrs removed with a reamer. 11) All bends and sets shall be formed in the conduit itself. Factory made bends are not to be installed. The radius of bends shall not be less than that given in the Indian Electricity Regulations or relevant Indian Standards. 12) Particular care must be taken to ensure that no water is allowed to enter the conduit at any time. Inaccessible junction boxes will not be allowed. 13) Only continuous lengths of buried conduit shall be installed between boxes. No joint boxes being allowed in the floors creeds. The ends of conduits laid or set in framework prior to concreting shall be temporarily sealed off with a coupler and a solid brass plug.
55
14) Fixing to surfaces of walls shall be by means of spacers and saddles securely fixed by screws. Where conduits are concealed or laid in constructional floors, they shall be held in position with substantial fixings. 15) Adaptor boxes shall be constructed of minimum 2 mm thick sheet steel and sized to prevent the undue packing of cables in them. 16) Weather proof boxes and accessories shall be used outdoors, where agreed on Site by the Employers representative. 17) Conduit shall be installed such as to permit complete rewiring without the need to remove false ceilings or carry out additional masonry work m) Installation of Cables 1) The Contractor shall install, test and commission the cables specified in the technical specification in accordance with approved drawings and instructions issued by the Employers representative. Cables shall be laid directly on cable racks, on cable trays and supports, in conduits and ducts, or bare on walls, ceilings etc., as per approved drawing. The Contractor's scope of work includes shifting from store to site, unloading, laying, fixing, jointing, bending, and terminating of the cables. The Contractor shall also supply the necessary materials and equipment required for jointing and terminating of the cables. 2) All apparatus, connections, and cable work shall be designed and arranged to minimise the risk of fire and any damage which might be caused in the event of fire. Wherever cables pass through floor or wall openings or other partitions, suitable bushes of an approved type shall be supplied and put into position by the Contractor. 3) Inspection on receipt, unloading, storage and handling of cables shall be in accordance with IS: 1255 and other Indian Standard Codes of Practice. 4) After pulling the cable, the Contractor shall record neatly with waterproof ink the cable identification and date pulled. The lines tags shall be securely attached... Identification tags shall be attached to each end of each cable with non-corrosive wire. This wire must be non-ferrous material on single conductor power cable. Tags may further be required at intervals on long runs of cables on cable trays and in pull boxes. Cable and joint markers as well as RCC warning covers shall be provided wherever required. 5) Sharp bending and kinking of cables shall be avoided. The bending radii for various types of cables shall not be less than those specified below: 650 / 1100 V PVC insulated cables 6) Power and control cables shall be laid in separate cable racks or trays. 7) Where groups of LV and control cables are to be laid along the same route, suitable barriers to segregate them physically shall be employed. 8) When power cables are laid in the proximity of communication cables, the minimum horizontal and vertical separation between power and communication cables shall normally be 600 mm, but in any case not less than 460 mm for single core cables
10 times the overall diameter of the cable.
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and 300 mm for multicore cables. Power and communication cables shall be far as possible and cross only at right angles to each other. 9) Where cables cross roads and water, oil, gas or sewage pipes, the cables shall be laid in reinforced spun concrete or steel pipes. For road crossings the pipe for the cable shall be buried at not less than one metre depth. 10) In each cable run some extra length shall be kept at a suitable point to enable one or two straight through joints to be made should the cable develop a fault at a later date. 11) At cable terminal points where the conductor and cable insulation will be terminated, terminations shall be made in a neat, workman like and approved manner by men specialised in this class of work. Terminations shall be made by the Contractor for each type of wire or cable in accordance with instructions issued by cable manufacturer's and the Employers Representative 12) Control cable terminations shall be made in accordance with wiring diagrams, using colour codes established by the Employers representative for the various control circuits. 13) When control cables are to be fanned out and cabled together with cord, the Contractor shall make connections to terminal blocks, and test the equipment for proper operation before the cables are corded together. 14) After installation and alignment of motors, the Contractor shall complete the conduit installation, including a section of flexible conduit between the motor terminal box and cable tray. The Contractor shall install and connect the power, control and heater supply cables as per equipment manufacturer's drawings if any. The Contractor shall be responsible for the correct phasing of the motor power connections and shall interchange connections at the motor terminal box if necessary, after each motor is test run. 15) Metal sheath and armour of the cable shall be bonded to the earthing system of the station. The size of the conductor for bonding shall be appropriate with the system fault current. 16) All new cables shall be megger tested before laying and termination. After laying and termination are completed all L.V. cables shall be megger tested again. 1100 / 650 Volt grade cables shall be tested by 1000 volt megger. 17) Cable cores shall be tested for Continuity, Absence of cross phasing, Insulation resistance to earth, Insulation resistance between conductors.
18) The Contractor shall furnish all testing kit and instruments required for field testing. n) Power and Control Cable Terminations
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1) Cable boxes shall be of approved design with adequate clearances between phases as well as between phases and earth in accordance with relevant standards. 2) Cable boxes shall be complete with combined armour and earthing clamps. 3) Suitable double compression type cable glands shall be provided for LV/MV power, lighting and control cables. 4) Provision shall be made for earthing the body of each cable box. 5) Equipment terminal blocks for power connections shall be complete with adequate phase segregating insulating barriers and suitable crimping type of lugs for connecting the insulated cable tails. 6) Where more than one core is terminated on each phase, unnecessary bending of cable cores shall be avoided, without decreasing the length of the insulated cable tail and the electrical clearances, which would normally be obtained when using one core per phase. 7) All switchboards shall, unless otherwise specified, facilitate bottom cable entry. Removable gland plates shall be mounted at least 300 mm above the base of the panel. If the gland plates are provided inside the PMCC cubicles, entries in the base of cubicle must be adequately vermin proofed. 8) The individual cores of power and control cables shall be neatly dressed and supported at regular intervals inside the PMCC, before connecting them to the relevant terminals. 9) Raychem or equivalent makes head shrinkable cable termination kits shall be used for glanding and termination of HT cables. o) Installation Methods 1) Electrical installation work shall comply with all currently applicable statutes, regulations, and safety codes applicable in, Rajasthan. 2) Installation of cable shall include unloading, storing, laying, fixing, jointing, termination, and all other work and material necessary to make the job complete. 3) All cables where required to be run on walls, ceiling or other building structures shall unless otherwise agreed by the Employers representative be secured on trays or enclosed in conduits 4) Where the building structure incorporates purpose built covered cable duct or trench systems for main cables, then power cables, control, and protection cables shall be segregated and installed on tray-work. 5) Where the structure incorporates general service ducts or trays containing pipe work, chemical lines, and other services, then all cabling shall be segregated from other services and run on the trench walls. 6) Throughout the installation the Contractor shall ensure the minimum spacing of cables to maintain current ratings, to prevent interference between power and signal cables and to avoid unnecessary crossovers.
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7) All cabling throughout the installation shall be fixed with purpose designed clamps, cleats, or saddles. 8) All floor openings for vertical cable tray or raceways shall be sealed by a fire proof compound. The scope of work shall also include supply, preparation, and laying of the compound. 9) Cable installation shall be tested as per relevant standards. 10) For cables buried underground, embedded in wall, flooring etc. the Contractor shall submit cable layout drawing and get it approved by client and then carry out the accordingly. 8. LT MOTORS
Manufacture and supply of LT motors shall conform to the following requirements. a) Design Requirements The motors shall conform to IS : 325,IS12615, BS 296, BS 170, BS 3979, BS 4999 and BS 5000 were applicable . Additionally, the specific requirements mentioned in the following clauses shall also apply. b) Performance and Characteristics Motors shall be capable of giving the rated output without reduction in the expected life span when operated continuously under the following supply conditions c) Insulation 1) Any joints in the motor insulation such as at coil connections or between slot and end winding sections shall have the strength equivalent to that of slot sections of the coil. 2) The insulation shall be given tropical and fungicidal treatment for successful operation of the motor in hot, humid, and tropical climate. 3) The motors shall be provided with Class F insulation with temperature rise limited to that of class B insulation. d) Enclosure
Variation in supply voltage Variation in supply frequency Combined voltage and frequency variation Ambient temperature
+/- 10% +/- 5% +/- 10% 50C
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Enclosures for indoor use shall afford a degree of mechanical protection not less than IP 55 to IS 2147 and shall be self ventilating. For outdoor use, totally enclosed fan cooled motors shall be used having mechanical protection not less than IP55. Cooling standards shall be IC.41 in each case. For outdoor use the motors shall be provided with a rain hood to prevent direct rain water from falling on them. Totally enclosed motors shall be provided with suitable means of breathing and drainage to prevent accumulation of condensate. e) Constructional Features 1) The motor construction shall be suitable for easy disassembly and reassembly. The enclosure shall be sturdy and shall permit easy removal of any part of the motor for inspection and repairs. 2) Motors weighing more than 25 Kg shall be provided with eye bolts, lugs, or other means to facilitate safe lifting. 3) The motor bars shall not be insulated in the slot portion between the iron core lamination. f) Terminal Box 1) Terminal boxes shall be of weather proof construction designed for outdoor service. To eliminate the entry of dust and water, gaskets of neoprene or approved equivalent shall be provided at cover joints and between the box and motor frame. 2) The terminal box shall be suitable for the bottom entry of cables. 3) The terminal box shall be capable of being turned through 360 degrees in steps of 90 degrees. 4) The terminals shall be of the stud type with necessary plain washers, spring washers and check-nuts. They shall be designed for the current carrying capacity and shall ensure ample phase to phase and phase to ground clearances. 5) Suitable cable glands and cable lugs shall be supplied to match the specified cables. 6) Separate terminal boxes shall be provided for each of the following. Stator Leads Space Heaters. g) Accessories i) Two independent earthing points shall be provided on opposite sides of the motor, for bolted connections. These earthing points shall be in addition to earthing stud provided in the terminal box. Space heater shall be provided for motors of rating 37 KW and above. 1) Motors shall be suitable for starting and accelerating the load with the applicable method of starting, without exceeding acceptable winding temperatures, when the supply voltage is 80% of rated motor voltage.
ii)
h) Other Requirements
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2) The locked rotor current of the motor shall not exceed 600% of full load current (subject to tolerance as per the applicable standard). 3) Motors shall be designed to withstand 120% of rated speed for two minutes without any mechanical damage, in either direction of rotation. 4) Stator leads shall be brought to the terminal box as insulated cable through a suitable barrier and terminated in clamp type terminals. 5) All motors shall be suitable for continuous duty operations and all motors shall be energy efficient conforming to IS.12615 latest revision Parameters Type of motor Rated Voltage Rated Frequency Supply system fault level Supply neutral Type of duty Type of cooling Operating Ambient Temperature EEnvironment SStarting method Space heater : : : : : : : : : : : TEFC, Squirrel Cage, Induction 415 v AC 10% , 3 Phase 50 HZ 5% 16 MVA Solidly Earthed S1(Continuous) Air(Fan cooled) 50 deg C (max) and 5 deg C (min) Tropical DOL/Auto Star Delta/Soft start / variable frequency drive For motor rated 30 KW and above (separate terminal box shall be provided for space heater).
9.
LOCAL ON / OFF PUSH BUTTON STATIONS
Manufacture and supply of local ON / OFF push button stations shall conform to the following. 9.1 General
In order to make on and off operations of electrical drives, these stations shall be located near each drive. These push button stations shall be in die-cast aluminium enclosure conforming to IP55. These stations shall have on and off push buttons with
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elements. These stations shall be mounted in channels which shall be erected near each drive. 9.2 a. Construction Features Weather-proof, suitable for mounting on wall or steel structures. The enclosure shall be die cast aluminium (3 mm thickness) with two coatings of anti corrosive paint. Dust and vermin proof. Provided with a degree of protection of not less than IP:55. Metal parts shall be given tropicalising treatment as per standards and painted with two coats of epoxy primer and two coats of final epoxy paint. Provided with inscription plates of rear engraved perspex with white letters on black background. The letter size shall be 6 mm. Provided with two earthing terminals suitable for 12 SWG G.I. wire. Provided with removable undrilled gland plate and cable glands for two. 7C / 5C x 2.5 sq.mm copper conductor. PVC insulated armoured cable. The cable entry shall be from the bottom. Ammeters shall be provided in the local start / stop push button stations. Controlling motors of rating 30 HP and above. Push Buttons The Start/Stop push buttons shall be of the momentary contact push to actuate type. The stop push buttons shall be of stay put type with mushroom knobs. All push buttons shall be: i. ii. d. 9.4 Fitted with two normally open and two normally closed contacts rated to carry and break 6 Amps at 415 Volts A C. Provided with integral escutcheon plates marked with its function.
Local on-off push buttons shall have the following features.
b. c. d. e. f. g.
h.
9.3 a. b. c.
Start push buttons shall be green in colour. Stop push button shall be red in colour. Wiring The contacts of the push buttons shall be wired to a terminal board, the number. of terminals shall be minimum 7 and rated at 6 Amps 415 V AC.
10. 10.1
11 KV POLE STRUCTURE WITH ASSOCIATED ELECTRICAL EQUIPMENTS The supply of 11 KV pole structure includes double pole (DP) structure with ISMC 200 and with concrete foundation, gang-operated AB switch, operating down pipe with suitable guide, handle and lock, lightning arrester, dropout fuse,
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ACSR conductors, copper jumper, bimetallic clamps, porcelain insulator, bushings, stay wire, etc. 10.2 The DP structure yard shall be uniformly leveled and spread with 38 mm blue granite jelly to a depth of 15 cms over a layer of sand. Fencing shall be provided for the DP structure up to a height of 1.8 m with a suitable gate and lock. The supply and erection of the DP structure with associated electrical equipment shall confirm to rules and regulations of CEIG / CEA / CONCERNING VVNL. The 11 KV Gang operated disconnecting switches shall have isolator with copper blades suitable for 11 KV, 200 Amps, 350 MVA, triple pole, gang-operated three insulator stock per pole, tilting type, double break per phase, air break isolating suitable for operation 3 phase, 50 Hz 11,000 V AC supply, horizontal mounting type suitable for outdoor installation conforming to the latest IS 1818 and all the other required accessories shall also be provided. The Isolator shall be complete with, GI operating down pipe complete with hand padlock key, handle, earthing wire, etc., Drop out(DO) fuses shall be vertical mounting type and suitable for outdoor installation 11 KV, 3 phase, 50 Hz, 80 A. 350 MVA capacity high voltage explosion type `D fuse units with suitable capacity fuse along with operating hickory rod for operations of fuses from ground etc., complete with all the standard fittings. Lightning arresters shall be rated for 9 KV, 19 KA, Air Gap type for providing surge protection conforming to IS 3070. The air brake switch should be erected in such a way that the incoming supply is received at the fixed contactor of the switch. Locks should be provided for the AB switch operating handles. The minimum size of HV jumper should be O SWG copper. ( DOF) does not hit the jumper while the DOF cartridge drops. 10.11. Each DP structure shall be provided with a suitable stay. Each stay wire shall be earthed unless an insulator has been placed in it at a height of not less than 3 meters from the ground. The stay wire shall be stranded GI wire and the stay rod shall be protected at ground level by concrete muffing and by enclosing it in GI pipe to prevent corrosion. 10.12. Caution notices shall be fixed on the structure. 11. HT METERING PANEL: Electronic microprocessor based (static) meter shall be provided in a separate HT metering panel to measure the parameters like KW, KVA, V, .Amps, KWHr., MD, frequency, pf, total demand etc. Necessary inputs to this meter shall be provided from current transformers( CTs) and potential transformers( PTs) installed in the HT metering panel. This panel shall be installed in the HT room.
10.3 10.4.
10.5.
10.6. 10.7. 10.8. 10.9.
10.10. The HV jumper at outdoor structures shall be so aligned that the drop out fuse
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12.
LIGHTING SYSTEM
12.1. This section covers supply and installation of all equipment necessary for a complete lighting system. Equipment shall include lighting panels, lighting distribution boards, lighting fixtures, poles, and cables, switches, ceiling fans, receptacles, conduits, wires and miscellaneous hardware necessary to complete lighting work. 12.2. It shall be the responsibility of the Contractor to work out a detailed layout for the lighting fixtures offered by him in order to provide the specified level of illumination. The Contractor shall be responsible for measuring the levels of illumination after installation and establish compliance with the specification. The number and type of fixtures offered shall be indicated in his bid. Energy efficient lighting fixtures shall also be used wherever possible in place of the suggested ones and contractor shall furnish the details accordingly. The final layout of the lighting fixtures shall be furnished for the approval before commencement of installation. Control of lighting circuits should be with miniature circuit breakers. 12.3. Following points shall be taken into account while designing the lighting system. a) permitted. b) (i) (ii) In each lighting circuit only 1000 watts single phase lighting load is The lighting fixtures offered shall comply with the following requirements The fixtures shall be suitable for operation on a nominal supply of 230 volts. Single phase, 50 Hz A.C. 2 wire with a voltage variation of +/- 10%. All fixtures shall be designed for minimum glare. The finish of all parts of the fixtures shall be such that no bright spots are produced, either by direct light source or by reflection. For multilamp fluorescent fittings, the circuit should be designed in such a manner as to reduce the stroboscopic effect to the minimum. The lighting fixture ballasts shall comply with the following requirements : The ballasts shall be copper wound, have a long service line and low power loss. The ballasts shall be of the inductive and heavy duty type, filled with polyester or equivalent. They shall be free from hum and protected from the atmosphere. HPSV lamp ballasts shall be provided with taps. For multilamp fittings, a separate choke shall be provided for each lamp. All lighting fixtures shall be supplied complete with lamps and all necessary accessories and control gears for their satisfactory operation. Lighting fixtures shall be equipped with all components required for their satisfactory performance. Fluorescent lighting fixtures shall be of high power factor type and shall be supplied complete with lamps, control gear and accessories. All lighting fixtures shall be complete with necessary mounting accessories.
c) d) e) f)
g) h) i)
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j)
The outdoor lighting system shall be equipped with timer and associated electrical devices for automatic switching in and switching off operation at desired time .
12.4. A1
Fixtures Schedules. Decorative fluorescent fitting suitable for 2 x 40 w fluorescent tubes for wall, ceiling, pendent mounting. The fitting shall consists of perforated steel side panels, a pair of end plates, and a white egg box type polystyrene louvered or reversible type louvered screening at the bottom. Decorative fluorescent fitting suitable for 1 x 40 w fluorescent tubes. Other details same as above. Decorative recessed mounting type fluorescent fitting suitable for 2 x 40 w Fluorescent tubes with reflector and diffuser. Bulkhead fittings : 100 w, 240 V G.L.S. lamp industrial bulkhead fitting complete with cast aluminium alloy body, prismatic front glass, wire guard, tropicalised gasket, porcelain lamp holder and all other accessories. They shall be dust and weather-proof and shall be suitable for wall or ceiling mounting. Industrial fluorescent fitting suitable for 2 x 40 w fluorescent tubes with vitreous enameled reflector. Fitting comprises of basic channel and vitreous enameled open ended closed top reflector painted white inside and grey outside. Specially designed catches on the reflectors shall allow easy and quick removal for cleaning and shall provide access to the control gear. Industrial fluorescent fitting suitable for 1 x 40 w fluorescent tubes with vitreous enameled reflector. Other details same as C1. Industrial fluorescent fitting suitable for 1 x 40 w fluorescent tube with single tube channel (mounting rails) type. Industrial fluorescent fitting totally enclosed suitable for installation in a dust a vapour laden and corrosive atmosphere. The fitting shall have an aluminium housing. A clear acrylic cover in a frame shall be secured to the housing by toggles. Gaskets shall be provided to render the fitting dust, moisture and vapour proof. All steel parts shall be cadmium plated and passivated. The fitting shall be suitable for 2 x 40 watts, 4 feet fluorescent tubes with internal wiring and all accessories and two 19 mm conduit knockouts in the rear mounting surfaces. General purpose integral flood light fixture shall be suitable for 250 W HPSV lamp, the body of which is constructed of spun aluminium and the interior act as a reflector. This can have either a polished or matt finish to provide a narrow or wide angle beam as may be required. A heat-resisting front glass is provided fitted with a weather-proof gasket. The lamp holder is mounted on an adjustable rod to allow for focusing and the complete unit is mounted on a stir-up and cast aluminium base, finished in aluminium colour.
The fixtures to be supplied shall conform to the following schedule.
A2 A3 B1
C1
C2 C3 D1
E1
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F1
Industrial totally enclosed Lowbay fitting suitable for 125 watts HPSV lamp. The fixture shall consist of an anodised aluminium reflector, suspension assembly, and housing for its control gear. Street light fittings integral type and weather proof suitable for 250 watts, HPSV lamps. Fitting shall comprise of deep drawn reflector designed for semi cut-off light distribution and heat resistant glass reflector bowl for better light distribution without glare. Industrial outdoor type screw neck well glass light fitting of vapour proof and dusttight with cast iron body finished in shoving grey outside and white inside complete with clear screw neck well glass, tropicalised gasket, cadmium plated and passivated wire guard with BC lamp holder with top entry suitable for 125 W HPSV fixture with integral control gear. Enclosure of fixture shall be IP 55. Indoor corrosion proof industrial lighting fitting suitable for 2 x 40 W fluorescent tube consisting of seamless aluminium pipe type mounting rail, cast aluminium control gear box, cast gear box, cast aluminium end box accommodating starter holder, drip cum vapour proof lamp holder. Automatic emergency fixture (Instalite) for 230/250 V AC complete with two exide batteries of 6 Volts each, 18 watt lamps, magnetic relay and battery charging circuit to provide lighting continuously for about 8 hours. Lighting Fitting Location Details Type A1 and A2 shall be used in switchgear rooms and office areas where false ceiling is not provided. Type A3 shall be used in a limited way on the external walls of the buildings for illumination just around the buildings. Type C1 fittings shall be used in general stores, pump houses and compressor room. Type D1 shall be used in stores where chemicals of corrosive nature are stored. Type E1 shall be used for general outdoor area illumination. Type F1 shall be used in pump houses and machinery service area. Type J2 shall be used on out door platforms, walk ways and outdoor equipments. Type J1 shall be used for roads. Type D1 shall be used in chemical solution preparation areas. Type K1 shall be used in battery room and chlorine area. Type L1 shall be used in control room and MCC room.
J1
J2
K1.
L1.
12.5.
12.6
The following guidelines shall for the general guidelines of selection of light fittings in locations indicated therein.
For PMCC,MCC and Control Room 2 x 40W fluorescent white lamp fixtures with mirror optics suitable for installation in false ceiling shall be used.
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For chemical solution preparation areas 2 x 40W fluorescent white lamp corrosion resistance fixture shall be used. 160W MLL lamp well glass fitting shall be used for outdoor equipment lightings. 250W HPSV lamp street light fixtures shall be used for street lighting. 250W HPSV flood light fixture shall be used for flood / area lighting. One (1) No. main lighting distribution board and sub lighting panels as required shall be used for controlling lighting network. In all indoor rooms, lighting circuits shall have conduit wiring. All outdoor area lighting circuits shall be done through cabling. In the control room and switch gear room, lighting wiring shall be in concealed conduits. Note The Contractor has to furnish the make and type of lighting fixture, fans, lighting distribution boards, and all its components. The Contractor should submit calculations for illumination levels in various areas along with his lighting, fans, and receptacle layout drawings for approval.
12.7.
12.8.
Lighting System Requirements
a) The design, manufacture and performance of equipment shall comply with all currently applicable statutes, regulations, and safety applicable to the locality where the equipment will be installed. Nothing in this specification shall be construed to relieve the Contractor of his responsibility. b) The following shall be considered while designing lighting system. Maintenance factor Ceiling reflection factor Wall reflection factor Floor reflection factor Minimum mounting height 0.8 0.3 0.5 0.1 3.0 meters
c) The Contractor shall supply, install, test and commission a complete system of lighting, fans and power receptacles in accordance with the approved lighting drawings and in accordance with relevant Indian Standards. d) In addition to the above, the installation shall conform to other relevant Standard Codes of Practice and Indian Electricity Rules. e) The Contractor shall supply all lighting switches, ceiling fans, power receptacles, distribution boards and lighting panels complete with switch fuse, junction boxes, pull boxes, terminal blocks, glands, conduits and accessories (elbows, tees, crosses, bends etc),and supporting and anchoring materials to make the installation complete. The Contractor shall also supply all lighting fixtures complete
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with fluorescent tubes / incandescent lamps, sodium vapour lamps and lighting cables. All materials, fittings and appliances used in the electrical installation shall conform to the I.S Specifications. f) Wiring shall be colour coded so as to enable easy identification of phase, neutral, and DC conductors.
g) Main and sub-distribution board panels shall conform to the stipulations of I.S. 732 or as approved by the Engineer's Representative. h) Receptacle and lighting fixtures shall be fed from different circuits or lighting panels. i) All receptacles and switches to be installed in offices, control rooms and other decoratively finished areas shall be flush mounted within the wall .Those in other areas shall be wall or column mounted. Socket outlets shall not embody fuses as an integral part of them. The switch controlling the socket outlet shall be in the live conductor. Lighting Panels The lighting panels shall be dust-tight, vermin-proof, sheet steel, and enclosed type. Sheet steel for fabrication shall be minimum 2.0 mm thick and shall have a smooth surface free from flaws and warps. Louvers and vents if provided shall be properly screened to prevent the entry of insects and foreign materials. Sheet shall be degreased, pickled and phosphated before painting. Painting shall consist of two coats of suitable epoxy primer and two coats of approved final epoxy paint. The outgoing and incoming circuits shall be suitably arranged. The switches shall be heavy duty as per I.S.4047 and the fuses shall be of HRC type. The panels shall be provided with all accessories necessary and usual for their efficient operation and shall be provided with adequately sized cable glands for incoming circuits. Cable glands shall be of the compression type suitable for armoured cable. It shall be possible to take out outgoing circuits from top or bottom. The knock out plates for conduit entries at the top and bottom for outgoing circuits and for spare circuits on each panels shall be provided. Circuit identification tags shall be provided on each incoming and outgoing circuit and shall be engraved or screen painted, or anodised aluminum or plastic sheet. The panels shall be provided with two distinct earthing terminals for connecting earthing conductor of 25 mm x 3 mm glavanised iron flat.
j)
12.9. a)
b)
c) d)
e) f)
12.10. Receptacles a) Decorative and industrial type receptacle units of approved make of 5 A and 15 A rating with switches conforming to I.S. 3854 and sockets conforming to I.S. 1293 shall be provided in the MCC room. The units shall be mounted flush on stove enameled sheet steel boxes generally conforming to I.S. 5133.
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b) Three phase receptacles of 30 Amps rating with switches shall be provided in all the floors of STP buildings. They shall be connected by feeder cables from the nearby power distribution boards. 12.11. Lighting Installation a) Lighting Panel / Distribution Boards - Installation (i) Installation work shall include mounting of lighting panels and distribution boards at appropriate locations to be approved by Employers representative. All work and supply items including civil items required for mounting shall be included in the Contractor's scope of installation. All work and supply items necessary for completing earthing connections shall be included in the scope of work. Termination of incoming cables shall be part of this work. The main lighting distribution board shall have incomer and outgoing feeders with 3pole MCCBs. The sub lighting distribution boards shall have 3pole MCCB as incomer along with suitable rated ELCB for tripping on earth leakage. TPN/SPN MCBS shall be provided on the outgoing lighting feeder circuits as per requirement.
(ii) (iii)
b)
Installation of Lighting Fixtures, Ceiling Fans, Receptacles, etc The scope of installation work shall include mounting of lighting fixtures, ceiling fans, and receptacles units etc., at locations shown on relevant approved drawings. All work and supply items associated with installation, such as provision and fixing of wooden blocks, ball sockets, hooks etc., as required drilling holes in walls, ceilings, etc., or any civil work including scaffolding, provision of ladders, etc., shall form part of the Contractor's work.
c)
Wiring i) The work shall comprise wiring from lighting panel in suitably sized 2mm thick(minimum) pvc conduits, supported on walls, ceilings etc., at intervals of 600 mm, installation of light control switches and receptacles housed in stove enameled steel boxes, earthing with 14 SWG copper conductor continuous wire run outside along the conduit and clamped at every 1000 mm interval and termination of wires at lighting panel, light control switches, receptacles, lighting fixtures, etc., as required.
ii) The supply of all the items for the work detailed above such as 650 V grade. 2.5/4mm2, copper conductor PVC insulated wires, 5A/15A switches, pvc conduits and accessories (such as junction boxes fabricated from 16 SWG sheet and complete with gasket, knockouts for conduit, entire earthing terminal with bolt, nut and washer, 14 SWG copper earthing with flexible conduit etc., shall be included in the Contractor's scope. All work necessary for fixing of boxes, conduits etc., together with the supply of necessary hardware, is also to be included in the Contractor's work.
69
iii) Wiring for outdoor areas other than MCC room shall be carried out by means of 1.1. KV grade armoured cables with copper conductors. 12.12 Applicable Standards Industrial luminaire with Metal reflector Ballast for fluorescent lamp 3 pin plugs and sockets for luminaries Luminaries for street lighting : Code of practice for Interior illumination Switches for domestic and Similar purposes Ceiling roses Code of practice for lighting of public thoroughfares Electric ceiling type fans and : regulator 13. (i) EARTHING SCHEME The complete scope of work for earthing system shall be collection of data, design of the earthing system as per IS 3043 preparation of layout drawings, supply, installation testing, commissioning and approval to the satisfaction of Electrical Inspector and/or Employers Representative. The earthing system shall be provided to ensure equipment and personnel safety and shall comply with all currently applicable standards regulations and safety codes. Earthing conductors shall be of hot dip galvanized iron flats or strips with minimum 100 microns thickness and copper flats or strips as specified. The Contractor shall base his earthing calculations on actual measurements of soil resistivity to be carried out by him at site. The earthing system for the plant shall be provided with its own independent earthing pits and interconnections which in turn will be inter-connected to form an
: : :
IS 1777/BS 5225 / IFC 162 IS 1554 IS 1293 IS 1913 IS 2149 IS 3646 and 6665 IS 3854 IS 371 / BS 67 IS 1944 IS 374
General safety requirements :
: : : :
a) Scope
(ii)
(iii) (iv) (v)
70
integrated system for the entire complex. Conductors required for interconnection with adjacent earthing grids shall also be supplied and installed by the Contractor. b) Installation Requirements (i) The installation work shall include unloading, storing, laying, fixing, jointing / termination, testing and commissioning associated with a safe earthing system of the plant. The Contractor shall supply and install GI steel wires or strips required for the system and individual equipment grounding. All work such as cutting, bending, supporting, coating, drilling, brazing, clamping, bolting, and connecting onto structures, pipes, equipment frames, terminals, rails or other devices shall be in the Contractor's scope of work. The excavation, trenching and backfilling shall be carried out by the Contractor as required, together with the supply of all material. Earthing shall conform to the Indian Standard Code of Practice I.S. 3043 and Indian Electricity Rules, 1956. All materials and fittings used in the earthing installation shall conform to the relevant Indian Standards. Installation work shall be in accordance with approved earthing drawings (to be prepared by Contractor). All earthing conductors to be buried in the ground shall be laid 600 mm below grade level and 1500 mm away from buildings. Backfill shall be placed in layers of 150 mm, uniformly spread along the trench and consolidated. Earth pits shall be constructed according to the stipulations of I.S. 3043. Except as noted, earth electrodes shall be fabricated in accordance with I.S.3043. The minimum spacing between two adjacent earth electrodes shall not be less than 6 meters. Earth electrodes shall be located in concrete inspection chambers with suitable lids. The chambers shall be provided with facilities for the periodic testing of the earth resistivity. Electrodes shall as far as practicable be embedded below the permanent moisture level. The metallic frame of all electrical equipment shall be earthed by two separate and distinct connections with the earthing system. Cable armour shall be bonded to the earthing system. Metal pipes and conduits through which cables run shall be efficiently bonded and earthed. Electrical conduits, pipes and cable tray sections shall be bonded ensure electrical continuity and connected to the earthing conductor at regular intervals. All underground connections for the earthing system shall be welded. Connection to equipment and devices shall be normally of the bolted type. Neutral connections shall never be used for equipment earthing. Metallic conduits and pipes shall not be used as earth continuity conductors. On completion of the installation, continuity of all conductors and efficiency of all bonds and joints shall be tested. The earth resistance shall be tested in the presence of Employers Representative. All equipment necessary for the test shall be furnished by the Contractor.
(ii)
(iii)
(iv)
(v)
(vi) (vii)
(viii) (ix)
(x)
71
(xi)
The work of embedment of earthing conductor in RCC floors and walls along with the provision of earth plate inserts, or pads or earth risers shall be done by the Contractor when the floors / walls are cast. The tap connections (earthing leads) from the floor embedded main earthing grid to the equipment of more than 500 mm away shall be embedded in the floor where required. The concrete cover over the conductor shall not be less than 50 mm. Earthing conductors along their run on walls and columns shall be supported by welding at intervals of 750 mm and 1000 mm respectively. Wherever earthing conductors cross underground service ducts and pipes, they shall be laid 300 mm below them. Wherever main earthing conductors cross cable trenches, they shall be buried below the trench floor. Earth pits shall be constructed and treated with salt and charcoal as per IS 3043. The following forms the guidelines on the selection of earthing stations with earth electrodes and earthing flats / wire Earth electrodes for LT system shall be with the Main earth electrodes 40mm dia, 3mm thick 3m long GI pipe provided with 12mm dia through holes at 150 mm intervals staggered along with the main electrode, and shall be coupled to a 19mm dia GI pipe of suitable of length at one end through a reducing socket of size 40mm x 19mm size. The other end of 19mm dia GI pipe is required to be provided with a funnel with a wire mesh, GI check nuts, GI nut washers, etc. Earth pit stations for Transformer neutral earthing and for the HT system shall be with GI plate electrodes and shall be of 600mm x 600mm x 12mm size. There shall be a 19mm dia GI pipe of suitable length with a funnel with wire mesh, GI checkouts, GI nut washers etc. A suitable pit of 200mm diameter shall be dug alround the main electrode. The pit shall be filled with alternate layer of coal or charcoal and salt in 150mm thick layers up to the entire length of the main electrode. An inspection chamber of 300mm x 300mm size in CC 1:3:6 with 150mm thick side walls and 100mm thick at bottom shall be provided. The inspection chamber shall be covered with MS or CI frame and cover. The cover shall be hinged to the frame and provided with padlocking arrangements. The inspection chamber frame and cover shall be furnished with anticorrosive primer and numbered. Earthing strip of the following sizes shall be provided for the various equipment : System runs Main earthing grid 11 KV panel Transformer Body Size mm x mm 50 x 6 50 x 6 50 x 6 Material GS GS GS No of 2 2 2
72
(xii)
(xiii) (xiv) (xv) (xvi) (C) (i)
(ii)
(iii)
(iv)
(v)
PMCC and MCC 415 LT Motors (a) 0-7.5KW (b) 10- 45KW (c) Above 50KW Lighting distribution board, panels, Auxiliary board sub boards etc. Street lighting poles Local push button stations, Junction boxes, lighting, Fixtures, small motors Transformer neutral
50 x 6
GS
8 SWG GI Wire 25 x 3 GI Flat 25 x 6 GI Flat 25 x 6 8 SWG 14 SWG 16 SWG 50 x 6
GS GS GS GS GS GS GS Copper
2 2 2 2 2 2 2 2
Earthing test pit with 1200 x 1200 x 12.5 mm GS plate electrode. Note: The galvanising of earth flats, wires and strips, shall be done by hot dip method and minimum thickness of the galvanising shall not be less than 100 Microns. d) Testing of Earthing System The Contractor shall ensure the continuity of all conductors and joints. The Contractor shall carry out earth continuity tests, earth resistance measurements and other tests, which are necessary to prove that the system is in accordance with the design, specifications, code of practice and I.E. Rules. The Contractor shall have to bear the cost of all such tests and provide necessary instrument, apparatus etc required for testing.
14.
FIRE FIGHTING EQUIPMENT AND SUBSTATION SAFETY ITEMS : 14.1.The following items shall be provided in the electrical rooms such as PMCC and MCC room, substation room, transformer yard and 11 KV double pole structure yard. The quantity of items indicated below is the total quantity put together required for the locations/areas mentioned above. (a) (b) (c) (d) Fire extinguishers ( 15 Nos. 3 Kg) Fire buckets with sand (10 Nos.) Stand made of steel for keeping items (a) and (b) above as required. First aid box with required medicines (4 sets) including oral rehydration electrolytes.
73
(e) (f) (g) (h) (i) (j) 15. 15.1. a. b.
Safety Rubber (insulated Gloves) (12 KV rating) (5 sets and each set with 2 gloves) Rubber mats (11 KV mats 3 Nos. of standard size 12 mm thick) (415 V mats 8 Nos. of standard size 8 mm thick) Danger labels (8 Nos.) Danger Board (4 Nos.) Safety charts (4 Nos.) Steel cupboard to provide items (d) and (e) (4Nos)
415 V POWER CAPACITORS and CONTROL PANEL General The capacitor banks shall be complete with all parts that are necessary or essential for efficient operation. The capacitor type shall be all polypropylene. The capacitor bank shall be complete with the required capacitors along with the supporting post insulators, steel rack assembly, copper bus bars, copper connecting strips, foundation channels, fuses, fuse clips, etc. The steel rack assembly shall be hot dip galvanized. The capacitor bank may comprise of a suitable number of single phase units in series and or parallel combination. However, the number of units in series shall be such that failure of one unit shall not create an over voltage on the units in parallel with it, which may result in the failure of the parallel units. The complete banks with their accessories shall be metal enclosed (in sheet cubicle), have indoor floor mounting, and be of free standing type. i. The assembly of the banks shall be such that it provides sufficient ventilation for each unit. Necessary louvers shall be provided in the cubicle to ensure proper ventilation. Each capacitor case and the cubicle shall be earthed to a separate earth bus in the cubicle.
c.
d.
ii.
e.
Each capacitor unit or bank shall be fitted with a directly connected continuously rated, low loss discharge device to discharge the capacitors to reduce the voltage to 50 volts within one minute in accordance with the provisions of IS:2834. Each unit shall be non-inflammable dielectric-immersed, self cooled, and hermetically sealed. Each unit shall satisfactorily operate at 135% of rated KVAR including factors of over voltage, harmonic currents, and manufacturing tolerance. The units shall be capable of continuously withstanding satisfactorily any over voltage up to a maximum of 10% above the rated voltage, excluding transients. Criteria for selection of capacitor bank rating and design of capacitors:
f. g.
15.2.
74
a.
The rating of the bank and the individual units shall be selected in a such a way that the improvement of p.f. from 0.8 lag to 0.98 lag is obtained and 0.98 lag is maintained throughout irrespective of an addition or deletion of load. The automatic p.f. control relay shall be put into operation and select the capacitors addition or deletion requirement based on the load at that particular moment or period to maintain the p.f. at 0.98 lag throughout. The capacitors shall be of the self healing type with a very low loss dielectric. All the material employed in the manufacture of capacitor shall be non toxic and biodegradable. The expected life of the capacitor shall not be less than 1,60,000 hours The p.f. correction capacitors shall be designed in such a way that they not only withstand high RMS current, but also work under sustained harmonic overloads. The capacitors shall be characterized by the dielectric impregnated with biodegradable synthetic oil. The dielectric plates shall consist of films of polypropylene and paper. Unit Protection
b. c. d. e. f. g. 15.3.
Each capacitor unit shall be individually protected by an HRC fuse suitably rated for load current and interrupting capacity, so that a faulty capacitor unit shall be disconnected by the fuse without causing the bank to be disconnected. Thus, the fuse shall disconnect only the faulty unit and shall leave the rest of the units undisturbed. An operated fuse shall give a visual indication so that it may be detected during periodic inspections. The fuse breaking time shall co-ordinate with the pressure built up within the unit to avoid explosion. Mounting of the individual fuse may be internal or external to the capacitor case.
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15.4.
Control Panel Requirement
The control equipment shall be mounted in a panel made of 14 gauge sheet steel. The panel shall be an indoor type conforming to IP55 class of enclosure. This panel shall consist of the following items a. b. MCCB (TPN, 415 V AC) for incomer supply isolation. The incomer panel shall be provided with pf meter, CTS and Ammeter with Ammeter selector switch, voltmeter with voltmeter set switch ON/OFF indication. Power Contactors suitable for capacitor ON/OFF duty. Relays responsive to currents /voltages /KVAR as required for automatic switching. Sequencing devices, timers, and automatic sequential switching of the capacitors in and out of circuit. Auto - manual selector switch Push button for opening and closing the power circuit. Red and Green lamps for each capacitor ON/OFF indication. Protective relays to protect the healthy capacitor units when one unit fails in a service connection.
c. d. e. f. g. h. i.
15.5.
A Power Factor Correction Relay
(a) The relay shall be micro processor based digital solid state type. The switching device shall be solid state relay giving signals to contactors for switching ON/OFF preset number of capacitor units. (b) The relay shall be suitable for automatic or manual control of the power factor correction capacitors on a three phase system. It shall detect the power factor lagging and leading reactive power (KVAR) component above present levels and then switch the appropriate number of capacitors "IN" or "OUT" to achieve the optimum average power factor without the system operating under a leading power factor condition. (c) This relay/device shall have low VA burden. Final switching of approximate capacitor banks shall be achieved by switching of Contactors and breakers through initiation of this device series connection. (d) The relay shall be provided with a facility for automatic self adjustment to any capacitor step value of minimum 10 KVAR. (e) The relay unit shall be provided with a digital indication of power factor, preset parameters and specified installation data, a no-volt relay feature to immediately disconnect all capacitors in the event of power failure, over temperature, over voltage, harmonic over load protection, remote fault alarm indicator, power factor correction fault. LEDs for banks on inductive loads, capacitive loads, manual mode indication, remote alarm tripped, multiplication factor indication, and power ON, manual bank and programming on button, manual bank and programming Off button, Manual / Automatic button, alarm reset button, data scrolling button and 3 digit display shall be provided.
76
(f) Technical characteristics 1. Voltage input 240 415 V 2. Voltage tolerance - + 10% 3. Frequency 50 Hz 4. voltage consumption 15 VA 5. Current input (by CT) 5A 6. Current consumption 0.2 VA 7. Max. admissible overload 30 A for 10 sec. 8. Switching interval 25 sec. and 60 sec. internally selected 9. Switching contacts 6A 250 VAC 10. Ambient temperature 50 deg C 11. Degree of Protection IP 54 15.6. a. b. c. d. e. f. g. h. I. j. k. l. m. Technical Particulars Quantity Rated Capacity Voltages Frequency Phases Ambient temperature (operating) Capacitance tolerance AC Voltage between terminals AC voltage between terminals and case Installation Service Protection class Discharge resistor : : : : : : : : : : : : : 2 Banks ( one on each side of the bus coupler To be decided by the vendor 450 V 550V AC 50 Hz Three (3) 50 deg C - 5 to + 10% 500 V 3 KV per 10 Internal Continuous IP 54 Internal (50 V after 1 min)
77
n. o. p. q.
Earthing bus Capacitor bank connection Type of switching Switching taps
: : : :
50 x 6 mm copper Delta Automatic switching responsive to p.f. through p.f. servicing relay. 8
r)
Each outgoing panel shall have a capacitor unit with suitably rated MCCB for power control of the capacitor unit, one ammeter with ASS, auto / manual selector switch, ON / OFF indication lamps, capacitor unit failed due to fault indication lamp, power contactor, etc. Indicating lamps (RYB) 3 shall be provided in the incomer. Auto / manual selector switch and ON/OFF push buttons Tests Inspection category - B Type test certificates for similar capacitor units shall be furnished. Drawings Drawings showing the general arrangement and control scheme shall be submitted for approval before proceeding with the fabrication works.
s) t) 15.7 a. b. 15.8
16.
MAINTENANCE FREE NiCad BATTERIES For PLC, other controls, annunciation and emergency lights and for DO sensors and flow meters, one bank of maintenance free lead acid batteries shall be provided. The specification of the maintenance free lead acid batteries shall conform to the following.
They shall be suitable to work in an ambient temperature of 50 C. The DC system voltage shall be 24 VDC. The capacity of batteries at 27 C at a 10-hour rate to give final cell voltage of 1.75 V/cell shall be 40Ampere hour. The momentary load / duration shall be 35 amps. Per minute. The continuous load / duration shall be 4 Amps. For ten hours. The initial / final cell voltage shall be 2.15 and 1.75 volts respectively. The method of charging shall be float cum boost charging.
78
17. 17.1. a) 17.2
BATTERY CHARGER AND DC DISTRIBUTION BOARD One battery charger and one. DC distribution board shall be provided. The manufacture and supply of these items shall conform to the following requirements. The nominal DC system voltage shall be 24 volts. The DC system earthing shall be unearthed. The ambient temperature for design shall be 50 C. The busbar shall be copper. The total continuous DC load shall be 4 Amps. Battery Details:
a) The float / trickle charging current of the battery shall be 200 mA. b) The boost charging current and voltage shall be 6 Amps and 24 V respectively. c) The maximum time for boost charging the battery shall be 10 hours. Note : (1) All required installation accessories and hardware along with battery racks, rubber mats and pads, accessories for testing and maintenance like center zero DC volt meter, hydro meters, pocket thermo meter, PVC aprons, PVC gloves, cell lifting straps, etc. shall be provided. (2) Drawings, documents, catalogs pertaining to batteries, battery charger, and DC distribution board shall be furnished for approval before manufacture. (3) Routine tests as per relevant IS shall be carried out on all the above items for approval before despatch. (4) Type test certificates carried out on similar rated items shall be furnished for approval before despatch. (5) The applicable standards shall be- IS 1651, IS 1652, IS 6304. 18. AC, 415V, 3PHASE AND NEUTRAL BUSDUCT. (a) Two sets of LT busducts shall be provided interlinking power transformers and PMCC. The busduct shall be suitable for out door installation and the class of enclosure shall be IP 55 . Galvanised Sheet steel canopy made of 3mm thick shall be provided over the busduct.The bus duct shall be nonseggregted type. The material of the bus bar of the phase and neutral shall be copper. The size of the bus bar shall be designed to carry the full load current of the power transformer secondary. The bus bar shall be designed for an ambient temperature of 50 degree centigrade and a fault level of 40KA.The busbars shall be supported on epoxy insulators. The sheet steel enclosure shall be epoxy painted in two coats.
79
(b)
LT bus duct shall also be provided for interlinking Gas genset and the PMCC.
19.
DRAWINGS AND DOCUMENTS SCHEDULE The Contractor shall be required to furnish drawings and documents for the purposes of both approvals and record. Prints shall be good quality photocopies of A4 to A0 sizes as reasonably necessary for clear reading without straining of the eye, even in the dull light inside enclosed and confined spaces. Reproducibles shall imply both the varieties of (1) Mylar prints in indelible black ink of the sizes defined above and (2) compact discs written up in AutoCAD Release 2000 version or both. The list and numbers of prints and reproducibles to be furnished by the Contractor shall conform to following table.
Titles
With Bid Type Nos
For approval Type P/C P/C Nos 6/1 6/1
Constn. Drg. "As built" Drg. after after approval Physical Completion Type P/C P/C Nos 6/1 6/1 Type P, R,C P, R,C Nos 12,1, 1 12,1, 1
All SLD and scheme P drgs. All other Elc. Drg. -
4 -
All Data Sheets, Design Calculations schedules for cable, lighting, earthing system Test Reports Vendor Drg. O and M Manual P - Prints; -
P/C
6/1
P/C
6/1
P, R,C
12,1, 1
P P -
6 6 -
P -
6 -
P, R P, R,C P,C
12, 1 12,1, 1 12,4
R Reproducibles;
C- On CD/DVD
20
ROTATING BRIDGE CLAIFIER CONTROL PANEL The manufacturer & supply of this panel shall confirm to the following requirements a) Constructional Features
80
1. Sheet steel used for the fabrication shall be (minimum) 3 mm thick cold rolled. 2. All doors, panels, removable covers, gland plates etc shall be gasketted using Neoprene gaskets, all round the perimeter to ensure proper air & water sealing. 3. All doors shall be provided with the concealed type of hinges & captive screws. 4. The panel shall be provided with a minimum 50 mm high channel base frame. Total height shall be 1000 mm (max). 5. Color finish shade shall be as per IS 5. The color of the interior shall be glossy white & exterior shall be battle ship grey or as approved by Employers representative. 6. Instruments, relays & control devices shall be mounted flush on hinged door of the metering compartment located in the front portion of the panel. Each item shall also be fitted with a label indicating the rating & duty. Panel shall be complete with interior panel wiring. b) Incomer Detail The incomer feeder shall have following features. AC, 3 phase, 4 wire, SF/FS unit with HRC fuses. Voltmeter with voltage selector switch. Ammeter with CTs & selector switch. On/off indication lamps. R, Y, B indication lamps. Bus bars (RYB) extended down from the incomer for connection of incoming cables without any problem. c) Outgoing Feeder Details 1. The outgoing motor starter feeder shall be equipped with DOL starter components. 2. The DOL contactor starter module shall be considered for control of motors rated up to & including 7.5 KW & shall be equipped with: Main load break switch (TPN). HRC fuses for power circuit & control fuse for control circuit. Power & auxiliary contactors as required. Overload relay. Start, stop & reset push button On, off & trip indication Ammeter with set switch Power & control circuit wiring & termination accessories. In addition to above, one number 32 Amps TPN SF unit with HRC fuses shall be provided for lighting of the clarifier zone & equipment. The above specifications are also applicable for Electrical works to be carried out at intermediate pumping stations & STP at Pushkar except their duty conditions.
81
Annexure-2
Protections:
The following protections are proposed for various switchboards, transformers, motors and other plant feeders. 1) 11 kV Switchboard i) IDMT over current and earth fault protection for incomers and bus coupler ii) PT fuses failure protection iii) IDMT and instantaneous over current and earth fault protection for outgoing transformer feeders iv) Transformer auxiliary protection (e.g. WTI, OTI, Buchhloz, etc.) v) Transformer auxiliaries for alarm (e.g. MOG, PVR, etc.) 2) LV switchboard i) Over current, short circuit and earth fault protection on ACBs/ MCCBs 3) Motors LV Motors i) Overload protection by thermal (bimetal) relays in all the three phases to trip with single phase preventer (SPP) and short circuit protection in all the three phases through motor protection circuit breakers/ MCCBs . ii) Thermal, locked rotor, short circuit, negative sequence, under voltage, over voltage and earth fault for each motor feeder of rating 90kW and above. 4 Metering The following metering shall be provided. 1) 11 kV Switchboard Multifunction meter (for incomer) containing i) Ammeter ii) Voltmeter iii) kW meter iv) Frequency meter v) Power factor meter vi) Kilowatthour meter vii) kVAr meter viii) kVA meter For outgoing feeder i) Ammeter with selector switch 2) LV Incomers i) Ammeters with selector switch ii) Voltmeter with selector switch iii) kW meter iv) Power factor meter vi) Kilowatt-hour meter vii) Frequency meter
82
3)
1)
LV Outgoing Feeders i) Ammeter with ammeter selector switch Multifunction meter shall be equipped with interfacing capability for RS-485 port. 4) Indicating Lamps The following indication shall be provided: 11 kV Incomer, Bus Coupler and Outgoing feeders i) Circuit breaker ON, OFF and TRIP, spring charged, control supply healthy and trip circuit healthy (Mains ON (R,Y,B) indication for incomer only) LV Incomers i) Mains ON (red, yellow and blue) LV Motor Feeders i) Motor ON, OFF and Trip indication (Red, green and Amber) ii) Motor ON, OFF and Trip indication (Red, green and Amber), control supply healthy and trip circuit healthy for breaker feeder.
2) 3)
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Sub Section-VI: Electrical Part I: Specific Requirements

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equipment foundations, transformer structures/gantries, gravel etc. 2.9

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3.44 3.45 3.46 3.47 3.48 3.49 3.50

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Colours for ready mixed paints and enamels.

10. 11. 12. 13. 14.

IS 1534 IS 1554 IS 1777 IS 1913 IS 2086

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44. 45. 46. 47. 48. 49.

IS 13032 IS 13947 IS 732 IS 3043 IS 3646 IS 10118

Transformers Vacuum circuit breakers.

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0.9 0.9 1.0 0.50

1.0 1.2 1.2

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Transformer Area Roads

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ITEM WITH BRIEF DESCRIPTION.

Item with Brief Description

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1 Lot As required As Required

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Combined voltage and frequency variation : 10%

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