Sct 1466_ Vol. g Techno Commercial Bid- Technical for Electrical Vol-g

TENDER SPECIFICATIONBHEL: PSSR: SCT: 1466 FOR Pre-bid tie up on back to back basis for Civil, Structural & Balance of Plant for 1x 700 MW Combined Cycle Power Plant of Andhra Pradesh Power Development Company Limited at Nedunoor, Karimnagar Dist, AP TECHNOCOMMERCIAL BIDVOLUME-G –TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL BHARAT HEAVY ELECTRICALS LIMITED (A Government of India Undertaking) Power Sector – Southern Region 690, Anna Salai, Nandanam, Chennai – 600 035. BHARAT HEAVY ELECTRICALS LIMITED (A Government of India Undertaking) Power Sector, Southern Region 690, Anna Salai, Nandanam, Chennai – 35 Tender Specification No. BHEL: PSSR: SCT: 1466 For Pre-bid tie up on back to back basis for Civil, Structural & Balance of Plant for 1x700 MW Combined Cycle Power Plant of Andhra Pradesh Power Development Company Limited (APPDCL) at Nedunoor, Karimnagar Dist, AP One set of Tender documents consisting of Volume - A to Volume- L (details as below) BOOK SLNO_________________ Issued to M/s Refer NIT for Last date of submission Please note this tender document is not transferable For and on behalf of BHARAT HEAVY ELECTRICALS LIMITED ADDL GENERAL MANAGER / CONTRACTS Place: Chennai -35 Tender Specification BHEL PSSR SCT 1466 comprise of Volume-A to Volume -L as below: Sl no of Volumes BHEL Vol -A NIT Project information, schedules, QA, Other requirements Scope TP, Exclusions Proposed scope split of Electrical between BHEL & EPC contractor Scope split BHEL & EPC contractor dt 29-06-2011 Scope of lifting equipments SCC- BHEL Consolidated GCC- BHEL-PEM APPDCL Volume -1,SECTION A1 TO A4 Geo tech investigations Tech requirements for General Civil works Additional civil drgs Scope of Cooling tower Tech requirements for General Electrical works Technical spec for Mechanical packages- Bought out packages NOT APPLICABLE Amendments & clarifications Schedules Price schedule Description No. of pages (including Remarks drawings) BHEL Vol -B BHEL Vol -C BHEL Vol -D BHEL Vol -E BHEL Vol -F BHEL Vol -G BHEL Vol -H BHEL Vol -I BHEL Vol -J BHEL Vol -K BHEL Vol -L TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL VOLUME -G Bharat Heavy Electricals Limited 1X700 MW CCPP AT NEDUNOOR, KARIMNAGAR ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL WORKS DOCUMENT NO. PE-TS-I59-888-E001 REV 0 BHARAT HEAVY ELECTRICALS LIMITED POWER SECTOR, PROJECT ENGINEERING MANAGEMENT NOIDA 201301 Doc. No. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. : Page : 0 of CONTENTS SL. NO. 1. 2. 3. 4. 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 6. 7. 8. 9. 10. 11. DESCRIPTION INTENT OF SPECIFICATION SCOPE OF WORKS DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER THE AWARD OF CONTRACT ELECTRICAL TECHNICAL SPECIFICATION: GENERAL REQUIREMENT LT BUS DUCTS 400V SWITCHGEAR & MCC NEUTRAL EARTHING EQUIPMENT DC SYSTEM CABLING SYSTEM LIGHTING SYSTEM EARTHING & LIGHTNING PROTECTION SYSTEM PUBLIC ADDRESS SYSTEM ELECTRICAL LAB EQUIPMENT INSULATING MATS CATHODIC PROTECTION CUSTOMER DRGS.-ANNEXURE-II BHEL ELECTRICAL SINGLE LINE DIAGRAM- PE-DG-I59-565-E001 QUALITY ASSURANCE, INSPECTION & TESTING BHEL CLARIFICATIONS (ENCLOSED AS ANNEXURE-B) SCHEDULE OF TECHNICAL DEVIATION SPARES 15 16 16 3 13 18 16 7 15 7 1 2 5 1 77 2 1 3 PAGES 1 1 1 2 IT IS CONFIRMED THAT OUR TECHNICAL OFFER COMPLIES WITH THE SPECIFICATION IN TOTO. --------------------------------------------------------------------BIDDER’S STAMP & SIGNATURE 1 Doc. No. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. : Page : 0 of 1. INTENT OF SPECIFICATION 1.1 The owner Andhra Pradesh Power Development Company Ltd has invited bids for the EPC package of 1X700 MW CCPP at Nedunoor Karimnagar Dist. BHARAT HEAVY ELECTRICALS LIMITED (BHEL) intends to bid for this project and invites quotations for design and execution of the work for electrical systems of the project mentioned in relevant clauses. 1.2 At the outset the bidder must understand that this offer is to be submitted on back to back basis which means that the bidder assumes total and unconditional responsibility for all electrical works as per owner’s requirements and subject to owner/ owner’s consultant’ approval. 1.3 Timely submission of drawings & documents / obtaining approval of drawings / documents from owner / owner’s consultant shall be the responsibility of the bidder. 1.4 It is specifically emphasized that the bidder quoting for Electrical Works package shall be comprehensively responsible for complete scope of work stated or unstated including preparation of design and drawings, obtaining necessary approvals, materials, execution as per codes, best engineering practices and to the satisfaction of the owner. IT IS CONFIRMED THAT OUR TECHNICAL OFFER COMPLIES WITH THE SPECIFICATION IN TOTO. --------------------------------------------------------------------BIDDER’S STAMP & SIGNATURE 2 Doc. No. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. : Page : 0 of 2. SCOPE OF WORKS 2.1 It shall be Contractor’s responsibility to provide all the equipment / systems / services and interfacing between various systems for the completeness of the 700 MW Combined Cycle Power Plant (CCPP). The following configuration shall be considered. 2 GTs + 2 HRSGs + 1 STG in Multishaft configuration. The requirements described here are for 700 MW CCPP. All equipment in the plant shall operate without any limitation upto the full load of Gas Turbine offered. This shall be applicable to all regimes of GT operation including the temperature range, frequency range, voltage range, with evaporative cooler etc. However for the purpose of the PG test, the evaporative cooler shall be switched off. The Plant electrical systems for proposed combined cycle power plant shall essentially comprise but not be limited to the following: 1. HT power cables, LT Power cables, LT Control cables & instrumentation cables 2. Cabling & installation equipment(cable trays & accessories, cable tray support, trefoil clamps, termination kits, jointing kits cable glands & lugs etc). 3. Earthing & lightning protection(including above & below grade grounding material) 4. Station lighting system. 5. Neutral grounding resistors for Unit auxiliary transformers. 6. 220V DC battery, battery chargers, DC switchboards and their accessories. 7. 400V AC switchgear, LV power distribution boards and accessories. 8. Public address system equipment. 9. Electrical laboratory equipment 10. Insulating mats 11. Cathodic protection 12. Drawing & Document submission for all packages : System design, Design Calculations, Design Memorandums, Layout drgs., Electrical load list, cable schedules, cable interconnections, Data sheets, OGA, Quality plans, test certificate etc. Detailed scope of work shall be as per scope chart enclosed as Annexure-A. 2.2 2.3 Any deviation to technical specification is to be clearly mentioned in “schedule of technical deviation” & undeclared technical deviation is not acceptable at any stage of project. IT IS CONFIRMED THAT OUR TECHNICAL OFFER COMPLIES WITH THE SPECIFICATION IN TOTO. --------------------------------------------------------------------BIDDER’S STAMP & SIGNATURE 3 : Page : 0 of 3. DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID: BIDDER TO SUBMIT SIGNED & STAMPED COPY OF FOLLOWING SHEETS: i) CONTENTS ii) INTENT OF SPECIFICATION iii) SCOPE OF WORKS( ALONG WITH SCOPE CHART IN ANNEXURE-A & TABLE-1) 4 . No.Doc. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. 5M EL CABLE TRAY LAYOUT ON HRSG PLATFORMS IPB LAYOUT-GT IPB LAYOUT-STEAM TURBINE GENERATOR 0.H.7M & 10. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE DESIGN PHILOSOPHY FOR ELECTRICAL EQUIPMENT LAYOUT LAYOUT OF TRANSFORMER YARD LAYOUT OF ELECTRICAL EQUIPMENT IN CW PUMP HOUSE LAYOUT OF ELECTRICAL EQUIPMENT IN RW PUMP HOUSE LAYOUT OF MAIN SWITCHGEAR ROOM EQUIPMENT LAYOUT IN STATIC EXCITATION ROOM(GTG) EQUIPMENT LAYOUT IN STATIC EXCITATION ROOM (STG) (AB BAY 13.U ROOM (FACILITY BUILDING) CABLE TRAY LAYOUT IN A.U ROOM (STG BUILDING) ELECTRICAL EQUIPMENT AND CABLE TRAY LAYOUT IN ETP MCC ROOM ELECTRICAL EQUIPMENT AND CABLE TRAY LAYOUT IN WATER TREATMENT MCC ROOM CABLE TRAY LAYOUT IN CW PUMP HOUSE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT PE-DC-I59-100-E999 PE-DG-I59-100-E001 PE-DG-I59-100-E003 PE-DG-I59-100-E004 PE-DG-I59-100-E006 PE-DG-I59-100-E007 PE-DG-I59-100-E008 PE-DG-I59-100-E009 PE-DG-I59-100-E013 PE-DG-I59-100-E016 PE-DG-I59-100-E020 PE-DG-I59-100-E021 PE-DG-I59-100-E022 PE-DG-I59-100-E038 PE-DG-I59-100-E050 PE-DG-I59-100-E051 PE-DG-I59-100-E060 SH 1 OF 3 PE-DG-I59-100-E060 SH 2 OF 3 PE-DG-I59-100-E060 SH 3 OF 3 PE-DG-I59-100-E063 PE-DG-I59-100-E065 PE-DG-I59-100-E067 PE-DG-I59-100-E071 PE-DG-I59-100-E072 PE-DG-I59-100-E073 PE-DG-I59-100-E074 PE-DG-I59-100-E075 PE-DG-I59-100-E076 PE-DG-I59-100-E077 PE-DG-I59-100-E078 PE-DG-I59-100-E079 PE-DG-I59-100-E080 PE-DG-I59-100-E081 5 .5M EL.500M FLOOR IN BFP BUILDING (SHEET 3 OF 3) CABLE TRENCH LAYOUT IN GAS TURBINE BUILDING ELECTRICAL EQUIPMENT LAYOUT OF BFP BUILDING CABLE TRENCH LAYOUT IN STEAM TURBINE BUILDING INTERPLANT CABLING LAYOUT (2 SHEETS) CABLE TRAY LAYOUT IN AIR WASHER ROOM – STG BUILDING CABLE TRAY LAYOUT IN AIR WASHER ROOM .5M EL CABLE TRAY LAYOUT IN TG HALL IN ABOVE 8.4.STG BUILDING OUTSIDE A ROW CABLE TRAY LAYOUT ON STORM WATER PUMP HOUSE CABLE TRAY LAYOUT ON PORTABLE WATER PUMP HOUSE CABLE TRAY LAYOUT IN AC PLANT ROOM (FACILITY BUILDING) CABLE TRAY LAYOUT IN A.0M CABLE TRAY LAYOUT AT EL 0 0M FLOOR IN BFP BUILDING (SHEET 1 OF 3) CABLE TRAY LAYOUT AT EL 6. CABLE VAULTBC BAY CABLE TRAY LAYOUT IN TG HALL IN BELOW 8.No. MASTER LIST OF DRAWINGS/ DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER AWARD OF CONTRACT (INDICATIVE) S.H.0M FLOOR IN BFP BUILDING (SHEET 2 OF 3) CABLE TRAY LAYOUT AT EL 14.5M EL) LAYOUT OF DC BATTERY ROOM CABLING LAYOUT BELOW MAIN SWITCHGEAR ROOM CABLING LAYOUT BELOW DC BATTERY ROOM CABLING TRAY LAYOUT AT 9. /DOC. DATA SHEET/ OGA/ SCHEME/ TEST CERTIFICATES/ QUALITY PLANS ETC.(I. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE 34 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE 100 506 506 507 507 507 507 507 507 507 507 507 507 507 508 509 509 509 509 509 509 509 557 558 561 565 565 565 ELE LAYOUT LV SWGR LV SWGR CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING DC SYSTEM LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION PUBLIC ADDRESS SYSTEM LIGHTING & LOW VOLTAGE SERVICES EMERGENCY DG ELECTRICAL SYSTEM DESIGN ELECTRICAL SYSTEM DESIGN ELECTRICAL SYSTEM DESIGN PE-DG-I59-100-E082 PE-DC-I59-506-E004 PE-DG-I59-506-E003 PE-DC-I59-507-E001 PE-DC-I59-507-E002 PE-DC-I59-507-E004 PE-DC-I59-507-E005 PE-DG-I59-507-E005 PE-DG-I59-507-E006 PE-DG-I59-507-E007 PE-DG-I59-507-EXXX PE-DG-I59-507-EXXX PE-DG-I59-507-EXXX PE-DG-I59-507-EXXX PE-DC-I59-508-E001 PE-DC-I59-509-E001 PE-DC-I59-509-E002 PE-DG-I59-509-E003 PE-DG-I59-509-E004 PE-DG-I59-509-E005 PE-DG-I59-509-E007 PE-DG-I59-509-E008 PE-DC-I59-557-E001 PE-DC-I59-558-E001 PE-DC-I59-561-E001 PE-DC-I59-565-E004 PE-DC-I59-565-E002 PE-DG-I59-565-E001 CABLE TRAY LAYOUT IN RAW WATER PUMP HOUSE ELECTRICAL LOAD DATA (BOARD WISE) CONTROL LOGIC FOR 415V SWGR DESIGN CALCULATIONS FOR HT CABLES SELECTION & SIZING DESIGN CALCULATIONS FOR LV CABLES SELECTION & SIZING CABLING PHILOSOPHY CABLE NUMBERING SCHEME TYPICAL DETAILS OF CABLE TRAYS AND ACCESSORIES TYPICAL INSTALLATION DETAILS FOR CABLE TRAY SUPPORT SYSTEM TYPICAL DETAILS FOR CABLE TRAY SUPPORT SYSTEM LAYOUT FOR ALL AREAS CABLE TRAY LAYOUT FOR ALL AREAS CABLE SCHEDULES FOR ALL AREAS CABLE INTERCONNECTION FOR ALL CABLE SCHEDULES DESIGN MEMORANDUM FOR 220V DC SYSTEM DESIGN MEMORANDUM FOR EARTHING SYSTEM DESIGN MEMORANDUM FOR LIGHTNING PROTECTION SYSTEM TYPICAL BELOW GROUND EARTHING DETAILS TYPICAL ABOVE GROUND EARTHING DETAILS BELOW GRADE GROUNDING SYSTEM LAYOUT FOR MAIN POWER PLANT AREA BELOW GRADE EARTHING LAYOUT FOR OFFSITE PLANTS LIGHTNING PROTECTION FOR OFFSITE PLANTS DESIGN MEMORANDUM FOR PUBLIC ADDRESS SYSTEM DESIGN MEMORANDUM FOR LIGHTING & LV POWER SERVICES DESIGN CALCULATION FOR EMERGENCY SUPPLY DG SIZING RELAY SETTINGS CHART FOR LV/HV MOTORS DESIGN CALCULATION FOR GENERATOR AND MV SYSTEM ELECTRICAL SINGLE LINE DIAGRAM FOR AUXILIARY POWER DISTRIBUTION DRG.) FOR ALL ELECTRICAL PACKAGES 65 ELE 565 ELECTRICAL SYSTEM PE-DG-I59-XXX-EXXX 6 .4.E. MASTER LIST OF DRAWINGS/ DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER AWARD OF CONTRACT (INDICATIVE) S.No. 16 D3.10 D3.6 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 R0 R0 R0 R0 R0 R0 R0 GENERAL REQUIREMENT GENERATOR AND ACCESSORIES GENERATOR CIRCUIT BREAKER GENERATOR TRANSFORMERS UNIT AUXILIARY TRANSFORMERS BUS DUCTS GENERATOR.5 D3.3 D3.14 D3.19 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 49 09 15 05 16 03 13 07 18 16 07 15 05 ISSUE R0 TCE FORM NO.12 D3.4 D3.6 kV SWITCHGEAR SERVICE TRANSFORMERS 400V SWITCHGEAR & MCC NEUTRAL EARTHING EQUIPMENT DC SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM CABLING SYSTEM LIGHTING SYSTEM EARTHING & LIGHTNING PROTECTION SYSTEM COMMUNICATION SYSTEM FIRE DETECTION AND ALARM SYSTEM D3. SPECIFICATION NO.0 D3.15 D3. TITLE NO. GENERATOR.1 D3. TRANSFORMER AND UAT PROTECTIONS 400 kV SWITCHYARD GENERATOR CONTROL PANEL 6. TITLE VOLUME III SECTION: CONTENT SHEET SHEET 1 OF 2 700 MW CCPP AT NEDUNOOR.2 D3. EPC SPECIFICATION -ELECTRICAL SYSTEMS VOLUME-III – CONTENTS ELECTRICAL SYSTEM SECTION NO.18 D3. OF SHEETS 15 39 06 09 03 16 08 D3.9 D3. KARIMNAGAR DIST. REV. TCE.NO.13 D3.11 D3.NO.17 D3.SPEC. 329 R5 7 .8 D3.5960A-H-500001 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.7 D3. 0 4. TITLE VOLUME III SECTION: CONTENT SHEET SHEET 2 OF 2 700 MW CCPP AT NEDUNOOR.22 D3.5960A-EL-2006 TCE.0 3.NO. REV. TITLE NO. TCE.5960A-EL-2001 TCE.21 D3.24 D3.25 BID DRAWING SL NO.5960A-EL-2004 TCE.5960A-EL-2007 TCE.5960A-EL-2005 TCE.0 5.5960A-EL-2008 P0 P0 P0 P0 P0 P0 P0 P0 KEY ONE LINE DIAGRAM MAIN ONE LINE DIAGRAM (SH. 329 R5 8 .5960A-EL-2003 TCE.NO. KARIMNAGAR DIST.SPEC.23 D3.0 TCE. OF SHEETS 01 01 01 01 01 01 01 01 1.0 2.0 6.5960A-EL-2003 TCE. EPC SPECIFICATION -ELECTRICAL SYSTEMS D3.0 7. 1 OF 2) MAIN ONE LINE DIAGRAM (SH.0 8.5960A-H-500001 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.20 D3. 2 OF 2) SWITCHYARD SCADA ARCHIETCTURE DIAGRAM PARALLEL REDUNDANT UPS WITH STATIC BYPASS TO REGULATED SUPPLY FLOAT CUM BOOST CHARGER WITH 2x100% BATTERY 400kV SWITCHYARD PLAN 400kV SWITCHYARD SECTIONS ISSUE R0 TCE FORM NO. TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 R0 R0 R0 R0 R0 R0 MOTORS ELEVATORS ELECTRICAL LABORATORY EQUIPMENT MISCELLANEOUS ELECTRICAL EQUIPMENT CONSTRUCTION POWER SUPPLY TRANSDUCERS 10 08 07 03 04 02 DRAWING NO. 5. ISSUE R0 TCE FORM NO. The nominal voltage of main DC system shall be 220V and 24V DC system for I& C application. material and systems shall. Any other voltage required shall be derived from 220V DC or 230V AC UPS distribution board for catering to the control & instrumentation loads. All equipments shall be suitable for rated frequency of 50 Hz with a variation of +3% to -5% and 10% combined variation of voltage and frequency unless specifically brought out in the specification. Cooling tower & STG shall be 220 V DC & 110 V AC.1 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. in general. The equipment/material/systems conforming to other equivalent national and international standards shall also be considered provided the same ensures equal or better features compared to standards listed in accompanying specification. The step up voltage of the project shall be 400 kV as applicable. separate 48V DC system shall be provided. 329 R5 9 (b) (c) (d) (e) (f) (g) . conform to the latest edition of relevant National and International Codes & Standards. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. The accompanying specifications also indicate the applicable codes and standards. if 2x100% air conditioning system is provided. The equipment shall operate in a highly polluted and highly corrosive environment. To cater the 400kV switchyard PLCC load. All the equipment. design ambient temperature shall be 350C. Control supply voltage for all the switchgear for the GTG. to be carried out as a part of this contract. However the three phase symmetrical short circuit fault current value shall be based on load flow and fault studies. However the area where the DC control supply is required shall be finalized during the detailed engineering. TITLE SECTION: D3. accessories and services for the entire station/plant in his scope as well as those specifically required by the Owner. HRSG. an ambient temperature of 500C and relative humidity of 95% shall be considered. equipments. However.0 General Requirements (a) For the purpose of design of equipment / systems. Contractor shall provide fully compatible electrical system.6 kV systems and 50 kA rms for 400 V system. KARIMNAGAR DIST. TCE. NO.5960A-H-500-001 1.0 SHEET 1 OF 17 1X 700 MW CCPP AT NEDUNOOR. especially the Indian Statutory Regulations. Fault level shall be limited to 44 kA rms for 6. for equipment in air-conditioned areas. 1 of 2) : TCE.0 SHEET 2 OF 17 1X 700 MW CCPP AT NEDUNOOR. shall be by the Contractor.6 kV & 400 V) under various grid and loading conditions are always within permissible limits and equipment are not subjected to unacceptable voltages during operation and starting of motors. The vector groups of the transformers shall be so selected that all the buses of particular voltage level have same vector through out the plant. Transformer voltage ratios. TCE.5960A-EL-SK-2004 (i) (j) (k) (l) : TCE. NO. In case any equipment or system is found to be inadequate. The responsibility of coordination with electrical agencies and obtaining all necessary clearances from all the statutory authorities. Paint shade shall be opaline green (external) & semi-glossy white (internal). All control and protection panels.5960A-EL-SK-2003 (Sh. MCCs. shall be so optimized so that the auxiliary system voltages (6. The electrical scheme for the project shall be as per the enclosed drawings: Key one line diagram Main one line diagram Main one line diagram Switchyard SCADA Architecture diagram UPS scheme Float cum boost charger with 2 x 100% battery : TCE. impedances and tolerances thereon. 329 R5 10 .5960A-EL-SK-2005 : TCE. DC and AC distribution board and battery charger panels shall be painted by powder coating process.6 kV switchgear. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 400 V switchgear. External surfaces of all equipments shall be painted with Epoxy paint. it shall be changed / modified without any additional liability to the Owner. 1 of 2) : TCE. 6. TITLE SECTION: D3.5960A-H-500-001 (h) The Contractor shall furnish calculations of maximum loading and fault levels under the most onerous conditions for the various equipment/systems to prove adequacy of their parameters.5960A-EL-SK-2001 : TCE.5960A-EL-SK-2003 (Sh. taps.5960A-EL-SK-2006 ISSUE R0 TCE FORM NO. KARIMNAGAR DIST. 0 SHEET 3 OF 17 1X 700 MW CCPP AT NEDUNOOR.3 The Contractor shall offer 2 nos. The Stator core & Rotor winding shall be hydrogen cooled.2 The Gas Turbine Generator and Steam turbine Generator shall be of hydrogen & water cooled. It shall be ensured that either of SFC can be used for cranking any of the Gas turbines without any limitation on successive starts of all gas turbines and restarts thereon. at all power factor between 0. no part of the generator shall attain a temperature in excess of the temperature limit specified in IEC 60034. 1. KARIMNAGAR DIST.1 Generator and its auxiliaries 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE.5960A-EL-SK-2008 1. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC.85 lagging and 0. Wye connected machine with phase and neutral terminals brought out for connection to isolated phase bus duct. two pole.1.1. The voltage class of the Generator circuit breaker shall be same as that of the generator.2 Generator Circuit Breaker (GCB) The continuous current rating of the GCB shall be arrived at considering the maximum output of the generator and at specified minimum voltage. The Insulation class of the machine shall be Class-F but its temperature rise shall be limited to Class-B. Static Frequency Converter (SFC) for starting of one gas turbine generator at a time. The GCB shall be of SF6.1.1 The generator shall be three phase.95 leading.1 The continuous rating of the generator transformers shall be such that the declared maximum continuous output of the respective turbine unit at any ambient temperature between 00C and 500C can be delivered at the rated ISSUE R0 TCE FORM NO. horizontal. The Stator winding shall be DM water cooled. NO. 329 R5 11 . The Gas turbine generators /steam turbine generators and their excitation systems shall have a capability at least matching the declared maximum continuous output of the associated gas turbine /steam turbine at the outside ambient air temperature ranging from 00C to 500C.3 Generator Transformers 1. The contractor shall ensure that when the generator is working at this capability. metal enclosed. 1.3. outdoor and freestanding type. 1. 1. TITLE SECTION: D3.5960A-H-500-001 400kV Switchyard plan : TCE. cylindrical rotor.5960A-EL-SK-2007 400kV Switchyard sections : TCE. 1. 1.5.1 The continuous current rating of the generator bus duct shall be arrived at considering the maximum output of the generator and at specified minimum voltage.9kV. NO. ISSUE R0 TCE FORM NO. 1. TCE. Bus duct shall be sized based on the transformer rating at minimum tap. Further a margin of 5% on the rating shall be provided considering the maximum Generator output. KARIMNAGAR DIST.0 SHEET 4 OF 17 1X 700 MW CCPP AT NEDUNOOR.V. 50 Hz. Critical equipments/systems shall be provided with double protection. two winding. three phase.6 Protection Fully graded protection system with requisite speed.25% on the HV side. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. two winding. 1.25% on HV side (*By Bidder). TITLE SECTION: D3. ONAN/ONAF cooled transformer with * % impedance with OLTC +10% in steps of 1. Further a 10 % margin on rating shall be provided after considering final load requirement. 329 R5 12 .5960A-H-500-001 power factors and allowable generator voltage variations without exceeding the permissible temperature rise limits set by the applicable Indian Codes and Standards for these equipment. UAT shall be a * MVA. with On Load Tap Changer with +10% to -10% of in steps of 1. Unit auxiliary transformer shall be capable of supplying auxiliary power requirement of complete station system.2 The GT shall be with voltage ratio of generator voltage / 420kV. Contractor shall recommend the relay settings to be adopted along with back-up calculations.7 400 kV Switchyard (a) A 400 kV switchyard shall be provided for evacuation of power generated in the plant through four (4) nos. 400kV transmission lines. */6.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 The M. The Bidder shall furnish the rating of the equipments. ONAN / ONAF / OFAF cooled transformer.3. The 400 kV switchyard shall have one and half breaker switching scheme. 50 Hz. / L. sensitivity and selectivity shall be provided for the entire plant.V.5.5 Bus duct 1.4 Unit Auxiliary Transformer 2 Nos. UAT shall be suitable for medium resistance earthing with earth fault current limited to 300A. 1. 1. etc. 329 R5 13 . For the Earthing system design System fault current to be considered is 50 kA. The receptacles of 63 A ratings shall be provided on the gantries at suitable location for connection to welding sets/other emergency equipments. The connections from LA to transformer shall be through shortest electrical distance. The coolers shall preferably be arranged on side. The Conductor tensions shall be 2 Tonnes per conductor.5960A-H-500-001 (b) The layout of the switchyard shall be such that adequate space for maintenance of prime equipment like circuit breakers and current transformers is available. (c) (d) The EMVT/CVT and LA shall be connected to earth pit through pipe electrodes. housing various Intelligent Electronic Devices (IEDs) such as Bay Control Units (BCUs). TCE. (e) (f) (g) (h) (i) (j) (k) ISSUE R0 TCE FORM NO. Approach road all around the switchyard shall also be provided for maintenance and patrolling. The earth mat of 400kV switchyard shall be inter connected with main plant. Protection Panels. PLCC Panels. Earth mat The earth mat shall be extended 2 m beyond fence for the switchyard. All tension insulator strings shall have double tension string arrangement. The earth mat shall be designed for short time rating of 1 second rating and shall be considered for calculation of step & touch potential. The aluminium tubular busbar conductors wherever if used shall have maximum one joint per span. other than LA.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. for each dia. TITLE SECTION: D3. Approach road shall be provided. KARIMNAGAR DIST. Air conditioned outdoor kiosks will be suitably located in switchyard.0 SHEET 5 OF 17 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. Fault Disturbance Recorders. energy capability etc. TITLE SECTION: D3. KARIMNAGAR DIST. Additional arresters. dynamic & transient conditions. of surge arrestors such that an adequate protective margin exits between the peak impulse voltage occurring due to other connected sub stations. The requirements regarding RIV and corona extinction voltage shall include terminal fittings. Contractor shall carry out detailed calculations to evolve the required parameters. shall be provided by the Contractor. (r) 400 kV System ISSUE R0 TCE FORM NO. ferro-resonance. motor starting studies for the complete plant for Owner’s approval. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. and lightning impulse over voltages under steady state. The Contractor shall furnish the system studies like load flow. 329 R5 14 . locations. short circuit and transient stability studies of the complete system including the transmission lines during detail engineering stage for Owner’s approval. All equipments shall be suitable for hot line washing. The quantity of surge arresters shown in the drawings are minimum required.7 are indicative and shall be finalised after insulation coordination studies. Bidder to note that surge arrester parameters given at D3. harmonics. TCE. switching surges. Insulation Co-ordination (m) (n) (o) (p) The Contractor shall be fully responsible for complete insulation coordination of switchyard. The switchyard shall be provided with suitable phase markers and danger plates. In addition to the above.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. if required based on the insulation coordination study. Contractor shall submit the relay co-ordination. The Contractor shall provide surge arrestors and other devices as required to protect all the equipments from fundamental frequency. NO. The connectors for termination of conductor on equipment shall be either of rigid or expansion type suitable for aluminium tube or Moose ACSR conductor.5960A-H-500-001 (l) Corona rings & corona bells shall be used wherever required and same shall be of non-magnetic material.0 SHEET 6 OF 17 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST. TCE. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. Oil filled hermetically sealed with SS bellow.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 15 . SF6 Spring / Spring charge mechanism (u) (v) Type of circuit breaker Operating mechanism Circuit breaker (w) (x) Type of isolator Instrument transformer Horizontal centre break/Pantograph Outdoor. NO.5960A-H-500-001 (i) (ii) (iii) Max voltage Rated frequency Rated short time current withstand capacity Rated one minute power frequency withstand voltage Rated lightning impulse withstand voltage Clearance Phase to phase Phase to earth Sectional clearance Ground clearance 420 kV 50 Hz 50 kA rms for one (1) second iv) 630 kV rms v) 1425 kVp vi) 4200 mm 3400 mm 6500 mm 8000 mm (s) (t) System neutral earthing Auxiliary contacts Effectively earthed The contacts shall have continuous rating of 10A and breaking capacity of 2A with circuit time constant of minimum 20 ms at 220 V DC. TITLE SECTION: D3.0 SHEET 7 OF 17 1X 700 MW CCPP AT NEDUNOOR. ISSUE R0 TCE FORM NO. shall be applied and rounded off to the next higher standard ratings and this value shall be adopted for the breakers and switchgears. on the basis of short circuit current contribution from UAT plus short circuit contribution by the motors running on the bus.0 SHEET 8 OF 17 1X 700 MW CCPP AT NEDUNOOR. A margin of 5% over higher of the above S.V. with the criteria that each 400 V switchgear / MCC / DB shall be fed by 2x100% transformers / feeders. monitoring. Each of the ISSUE R0 TCE FORM NO. synchronizing and sequential event logging for each generator and its subsystem shall be provided on the DCS. covered under the scope of this package shall be provided through the DCS system. circuit breakers. and these shall be rated to carry the maximum load expected to be imposed with 10% margin at all ambient.6kV Switchgear The 6. (b) (c) (d) e) 1. PLCC panels for lines shall be located in the outdoor kiosk panels. KARIMNAGAR DIST. The control.5960A-H-500-001 (y) Creepage distance for insulators 31mm/kV 1. adequately rated switchgears shall be provided. SCADA shall have communication with plant DCS for providing measurement.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. earth switch.. annunciation etc of 400kV switchyard. monitoring. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. bus bars. shall be arrived at.6 kV and service transformers. 329 R5 16 .C current. annunciation and metering of complete 400 kV switchyard under Bidder's scope shall be through SCADA. The momentary current ratings shall be 2. 1. Control. TITLE SECTION: D3. Protection.9 6. and M. auxiliary power system. indication.55 times this value.6 kV / 420V epoxy cast resin dry type service transformers shall be provided to meet the demand on 400V systems. NO. annunciation.V. For feeding the plant auxiliaries rated for 6. etc. monitoring. The fault level for the switchgear. measurement. TCE.10 Service transformer Adequate number of 6.6 kV switchgear and its accessories shall conform to all latest editions of national and international standards. isolators.8 Control philosophy of electrical system (a) Control of L. The neutral shall be connected to a suitably rated neutral earthing transformer with secondary loading resistor. three phase. 50 Hz.0 SHEET 9 OF 17 1X 700 MW CCPP AT NEDUNOOR. The neutral earthing equipment shall be rated to carry this current for at least 30 seconds considering the generator terminal voltage under maximum field forcing conditions. No. TCE. 220 V DC system & UPS system shall be kept ungrounded. 1. For feeding the 400V / 230V AC loads of the plant. NO.e. Diesel generator shall be of solidly earthed system. Highest efficiency operating point shall be designed near to the normal loading of the transformer i. Any additional switchgear / MCCs as required shall also be provided. 6. (b) (c) (d) (e) (f) 1. 400V switchgear / motor control centres (MCCs) and AC distribution boards (ACDBs) shall be provided.11 400 V Switchgear The 400 V switchgear and its accessories shall conform to all latest editions of national and international standards. 400V system shall be a solidly earthed system. The service transformers shall be two winding. when the bus coupler is open.5960A-EL-SK-2001 is tentative. TCE. TITLE SECTION: D3. limiting the earth fault current to about 510 A. The neutral of the unit auxiliary transformers shall be independently connected to the earth through a suitable resistance designed for 30secs.13 DC System ISSUE R0 TCE FORM NO. The neutral of GTs are independently connected to earth. The switchgears shown in Key One Line Diagram drg.5960A-H-500-001 switchgear / MCC / DB shall be sectionalised.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 6600 / 420 Volts. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. 1.5%. KARIMNAGAR DIST. The neutral of service transformers shall be independently connected to the earth. The earth fault current shall be limited to 300A.6 kV systems shall be medium resistance earthed.12 Neutral Earthing Equipment (a) 400 kV system is solidly earthed. Dry type AN cooled with off-circuit taps of ±5% in steps of 2. 329 R5 17 . Generator neutral shall be high resistance earthed. annunciation of the complete plant including I&C system during the running of the plant as well as for a safe shutdown at the time of the total power supply failure. interlock. (b) (c) (d) (e) (f) (g) (h) (i) 1. DC 2 x 100% battery banks with associated float cum boostchargers and 1 No. The switchyard DC system shall be sized to cater loads for at least 10 hrs. DC 2 x 100% battery banks with associated float cum boostchargers and 1 No. 24V. 1 No. DC switchboard shall be provided for each gas turbine generator (GTG) unit. DCS system. The GTG unit DC system with 100% capacity shall be sized to cater complete unit loads for atleast 10 hrs. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. DC 2 x 100% battery banks with associated float cum boostchargers and 1 No. protection. DC switchboard having 2 Incomers & one bus coupler shall be provided for 400kV system (switchyard) auxiliaries. 48V. DC 2 x 100% battery bank with associated float cum boostcharger.14 Uninterruptible Power Supply (UPS) ISSUE R0 TCE FORM NO. Each battery charger shall be capable of float charging the two batteries while supplying the normal DC loads. HRSG and station loads for at least 10 hrs. KARIMNAGAR DIST.5960A-H-500-001 (a) DC power supply with high discharge Lead acid plante type battery cells forming bank shall be the source of the power supply for control. DC switchboard shall be provided for station DC system. DC switchboard having 2 Incomers & one bus coupler shall be provided for I& C .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. 220V. TCE. TITLE SECTION: D3. DC 2 x 100% battery banks with associated float cum boostchargers and 1 No. Sizing criteria shall include design margin of 10%. 25% margin on ageing and ambient temperature compensation as per IS. 220V. 329 R5 18 .0 SHEET 10 OF 17 1X 700 MW CCPP AT NEDUNOOR. The station DC system shall be sized to cater STG. The boost charger unit shall be rated such that the battery can be fully charged from fully discharged condition within 8 hours. 220V. DC switchboard having 2 Incomers & one bus coupler shall be provided for 400kV switchyard PLCC application. 0 SHEET 11 OF 17 1X 700 MW CCPP AT NEDUNOOR.15 Cabling System Cables shall be derated for the site ambient and ground temperatures. KARIMNAGAR DIST. roads. The lighting system design shall comply with the acceptable norms and the best engineering practices. local rules etc. The layout design shall meet all the statutory requirement. The minimum rate of corrosion of steel for selection of earthing conductor shall be 0. SWAS etc. TITLE SECTION: D3. The UPS shall be sized considering full load plus spare loops plus 20% margin. Voltage grade of cables shall be of earthed grade when used in solidly earthed systems. Grounding and lightning protection for the entire power plant. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. TCE. boundary.12mm per year.0 sec.18 Motors (a) Wherever the basis for motor ratings are not specified in the corresponding mechanical specification sections. inverter & battery system and standby supply to cater the UPS loads of complete plant Instrumentation and control system loads such as HMI. 1.5960A-H-500-001 Parallel redundant UPS shall be with duplicate charger.16 Lighting System Lighting system shall be provided for the entire plant covering all the buildings. 1. Contractor shall furnish detailed cable selection/sizing criteria for Owner’s approval.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 1. 1. The lighting layout shall be designed to provide uniform illumination with minimum glare.17 Earthing System The earthing system shall be designed for a life expectancy of at least forty (40) years. outdoor areas. 329 R5 19 . and unearthed grade when used in non-effectively earthed systems. grouping and soil resistivity. Cables shall be selected to limit maximum voltage drop at equipment terminals during normal operation and starting conditions well within permissible values. yards. for maximum fault current of 50kA for 1. maximum continuous motor ratings shall be at least 10% above the maximum load demand of the driven equipment under entire operating range including voltage and frequency variations. IS:2309 & IEEE : 80 and IEEE : 665. ISSUE R0 TCE FORM NO. switchyard and other areas or buildings covered in the specification shall be provided in accordance with IS:3043. NO. etc. 6 kV segregated phase bus duct (SPBD) only.6 kV system shall incorporate a microprocessor based numerical fast auto change over scheme which will restore supplies to the 6. For 400V system. The motors rated 175 kW and above shall be 6. If adequately rated cables shall be provided then Owner’s permission shall be obtained. station service and switchyard loads. 3 phase. which shall run with the available plant load under such condition.6 kV buses & 400V buses. 1.5960A-H-500-001 (b) All M.V. The 6.6kV and motors rated upto 175 kW shall be 400 V. and L.6kV and 400V switchgear. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. TITLE SECTION: D3.21 Auxiliary System (a) 6.19 Emergency Diesel Generator Set Each Emergency Diesel Generating set shall be sized at an ambient temperature of 500C for all essential auxiliaries and emergency loads of all gas turbines. steam turbines. on loss of supplies from unit transformer.6kV unit board from other unit board. 50 Hz power supply. The voltage for M. TCE. 50 Hz and LV motors shall be suitable for 400 V. motors shall be ±10%. ISSUE R0 TCE FORM NO. 6. KARIMNAGAR DIST. contribution from emergency DG set shall be considered while designing the fault level.20 Islanding Scheme The plant shall be designed to operate in islanding mode of operation by tripping all the lines and generators except for one pre-selected unit.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 kV incomers and ties from transformers to switchgear shall be through 6. NO. 329 R5 20 (b) (c) .V. Automatic changeover to the reserve supply source shall be arranged for 400V critical switchgear/MCC sections as necessary to prevent the loss of a unit or to ensure the equipment safety. non-segregated phase bus duct (NSPBT) assemblies shall be preferred for incoming connection from transformers to the switchboard. Manual live changeover and slow changeover shall also be arranged for all 6. 3 Phase.0 SHEET 12 OF 17 1X 700 MW CCPP AT NEDUNOOR.V. motors shall be suitable for 6. 1. MCCs and DBs shall have positive foolproof interlocking to ensure that different supplies and transformers are never operated in parallel and fault level does not exceed the switchgear capability.6 kV. For 400V switchgear. (c) 1. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TITLE SECTION: D3.0 SHEET 13 OF 17 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. NO. TCE.5960A-H-500-001 (d) During Grid black-out condition, it shall be ensured that only the essential auxiliaries of all units are fed from emergency Diesel generator & non- essential loads are automatically tripped. DC scheme shall provide at least two feeds through diode sharing to critical consumers e.g. all protection panels / control desks, circuit breakers, GCB, 6.6 kV / 400 V unit and emergency switchgear panels, generator excitation system, generator oil seal system, etc. The details shall be subject to Owner’s approval. For generator protection and protection panels for all 400 kV switchyard feeders, duplicated DC feeders shall be provided, one from each battery system. (e) 1.22 The insulation level for the transformer windings and bushings shall be as follows: Winding Highest System Voltage Rated Power Freq. withstand voltage (kVrms) 20 28 38 95 630 Rated lightning impulse withstand voltage (kVp) 60 75 95 250 1300 Bushing Rated Power freq. withstand voltage (kVrms) 20 28 38 95 630 Rated lighting impulse withstand voltage (kVp) 60 75 95 250 1425 7.2 kV 12 kV 17.5 kV 34.5 kV 420 kV Note: for 400kV system switching impulse of 1050 kVp shall be considered. 1.23 Degree of protection Degree of protection for various enclosures as per IS: 13947 shall be as follows: ISSUE R0 TCE FORM NO. 329 R5 21 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TITLE SECTION: D3.0 SHEET 14 OF 17 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. NO. TCE.5960A-H-500-001 (a) 6.6 kV switchgear i) ii) iii) VT/relay compartments Other compartments Switchgear in air-conditioned areas (all compartments) - IP 52 - IP 42 - IP 32 (b) 400V switchgear / MCC / DBs / Fuse Boards i) Compartments and busbar chambers upto 1600A Compartments and busbar chambers above 1600A All compartments in case switchgear in air-conditioned areas Switchgear located out door - IP 52 ii) - IP 42 iii) - IP 32 iv) (c) - IP 54 Busduct enclosure / GCB i) ii) iii) Indoor portion including VT & SP cubicle - IP 52 Outdoor portion GCB - IP 65 - IP 65 (d) Motors i) ii) Indoor motors Outdoor motors - IP 54 - IP 55 (e) Control and relay panel i) ii) In air-conditioned areas In other areas - IP 32 - IP 52 (f) Transformers ISSUE R0 TCE FORM NO. 329 R5 22 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TITLE SECTION: D3.0 SHEET 15 OF 17 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. NO. TCE.5960A-H-500-001 i) ii) iii) iv) v) (g) Indoor Transformers Cable box - indoor area Cable box - outdoor area Indoor kiosks and marshalling boxes Outdoor kiosks and marshalling boxes - IP 31 - IP 52 - IP 55 - IP 52 - IP 55 Push button stations and any other kiosk / box / panel / enclosure i) ii) Indoor Outdoor - IP 54 - IP 55 - IP 55 - IP 55 - IP 22 - IP 33 (h) (i) (j) (k) 1.24 Junction boxes for cables/wires Outdoor lighting fixtures Gen. Neutral grounding resistor 6.6 kV Neutral grounding resistor FAULT LEVEL Equipment through fault withstand capabilities under worst operating conditions duly taking into account tolerances on transformer, generator & maximum fault levels of source etc. shall be as follows : i) ii) All other transformers Generator busduct main run, GCB, (higher of generator or EHV system fault contribution) Tap off run busduct (sum of generator and EHV system fault contribution) 6.6 kV Busduct Switchgears - 2 seconds - 1 second iii) - 1 second iv) v) - 1 second - 1 second ISSUE R0 TCE FORM NO. 329 R5 23 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TITLE SECTION: D3.0 SHEET 16 OF 17 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. NO. TCE.5960A-H-500-001 vi) Cables to the feeders protected by breakers Main protection fault clearing time with 0.16 seconds minimum vii) Cables of all other feeders As per fuse operating time - 2 seconds for the adopted ground fault current - 1 second viii) 6.6 kV cable screen ix) 1.25 EHV systems Type Test All equipment / systems to be supplied shall conform to type tests as per relevant standards / relevant chapters of this specification and shall be of proven type. 1.26 Communication System For effective communication in the plant, public address system, private automatic branch exchange system (EPABX), radio paging system, walkietalkie and P&T telephone system with the features described below will be provided: a) Public Address System This system will have paging and party channels comprising handset stations with amplifiers, transmitters, receivers, and loud speakers. This system will facilitate paging, communication and also private conversation as in conventional telephone. b) EPABX System This system will have adequate number of push button type handset stations, central automatic telephone exchange, etc. The handsets in the control room would be provided with priority service facility to enable them to have immediate access to any handset even if it is already engaged. ISSUE R0 TCE FORM NO. 329 R5 24 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TITLE SECTION: D3.0 SHEET 17 OF 17 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. NO. TCE.5960A-H-500-001 c) Landline Telephones, Broadband connectivity Necessary number of ISDN / PSTN landlines would be provided at strategic locations within the plant boundary. Broadband connectivity would be provided at strategic locations for online access of data from remote station. d) Wireless System (Walkie-Talkie System) Walkie-Talkie system will be provided for mobile communications. These systems will be of particular use during commissioning stage as well as subsequently during maintenance. e) GPRS/CDMA mobile system of any reputed service provider can be provided for wireless system. The mobile system coverage in the power plant area should be 100%. f) Interface between the EPABX, PA and Wireless systems shall be provided to enable communication between these systems. ISSUE R0 TCE FORM NO. 329 R5 25 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.1 SHEET 1 OF 42 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. NO. TCE.5960A-H-500-001 1.0 GENERATOR & ACCESSORIES The generator and its accessories such as the cooling system excitation system, automatic voltage regulator, static start up systems for gas turbine generator etc. shall generally comply with the requirements specified in the national and international standards indicated as per Data sheet A 3.1 and shall additionally comply with the specific requirements of Data sheet A 3.1 and as indicated below: 1.1 1.1.1 Generator The MW out put of generator of the Gas turbine generator unit and Steam turbine generator unit shall be sufficient to evacuate the normal and peak power output of gas turbine power over the complete range of site ambient conditions specified in Section-B and at rated casing (Hydrogen) pressure and temperature. The Maximum Continuous Rating (MCR) of the generator shall correspond to the maximum MVA, MW and minimum associated over-excited power factor that it is guaranteed to deliver continuously (without exceeding its specified temperatures or temperature rises at rated casing (hydrogen) pressure and temperature. The generator shall be three phase, horizontal, two pole, cylindrical rotor, Wye connected machine with phase and neutral terminals brought out for connection to isolated phase bus duct. The generators shall conform to IEC60034-1, IEC60034-3 or other equivalent international standards. The generator shall be capable of satisfactory continuous operation at rated MVA and power factor at any voltage from 95% to 105% of rated voltage and within a frequency range of 47.5 to 51.5 Hz (and a combined frequency and voltage variation of 5%) even if frequency and voltage variations occur simultaneously, without exceeding safe temperature rises, but not necessarily in accordance with the standards established for operation at rated voltage and frequency. The generators shall be provided with Class-F insulation with temperature rise limited to that of Class-B at full load and at rated voltage & frequency. However, for abnormal operating conditions of voltage and frequency, the temperature rise shall in no case exceed that of Class-F when the machine is operating continuously at full load and at rated power factor at any working voltage and any frequency in the range stipulated above. 1.1.2 1.1.3 ISSUE R0 26 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.1 SHEET 2 OF 42 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. NO. TCE.5960A-H-500-001 1.1.4 The generator unit shall be capable of withstanding 3 phase short circuit at the generator terminals when operating at rated MVA and power factor, 5% over voltage and with rated excitation for 3 seconds. The line charging capability of the generator shall not be less than 30% of its rated MVA at zero power factor. The generator shall be non-effectively earthed through a singlephase distribution transformer provided with secondary loading resistor. The sizing of the transformer and the value of the resistance shall be such as to restrict the maximum earth fault current to 1.5 times the capacitive current at normal working voltage. The generator shall be capable of operating alone or in parallel with other generators and / or utility grid. The core of the generator shall be designed such that it permit the flow of earth fault current of at least 15 amperes for one (1) second without any core damage. The generator phase and neutral side terminals shall be brought out through seal off bushings. The bearings shall be lubricated by oil from the turbine lube oil system. Non-hygroscopic insulation shall be provided to prevent any damage due to the circulation of shaft current to the bearing surfaces and the lubricating oil. At least one of the bearings shall be suitably insulated with arrangements for checking the insulation resistance while the machine is in operation. On-line shaft leakage current monitoring system shall be provided to detect any leakage current through the shaft. Abnormal leakage current shall trigger an alarm in the control room. The generator and its components shall be designed to avoid resonance over the entire range of operating frequency or their multiples. The noise (sound) power level emitted by the generator as measured one (1) metre from the surface of the generator and at 1.5 metre height above floor level shall be limited to 85 dB(A). ISSUE R0 1.1.5 1.1.6 1.1.7 1.1.8 1.1.9 1.1.10 1.1.11 1.1.12 1.1.13 27 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.1 SHEET 3 OF 42 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. NO. TCE.5960A-H-500-001 1.1.14 The generator unit shall be capable of withstanding the electrical, mechanical and thermal stresses developed during fast auto reclosing of high voltage line, transmission line switching, grid faults, out of step operation, out of phase synchronisation, etc. The vibration severity when measured on generator and main exciter bearings shall not exceed 2.8mm / sec. When tested on open circuit and at rated speed and voltage, the telephone influence factor of the turbine generator shall not exceed 1.5 %. The generator winding shall withstand test voltage of 4 U + 5 (where U is the rated voltage in kV). Lightning arrestors of suitable rating shall be provided for the surge protection of generator winding. In addition to the above if surge capacitors are recommended, the same shall be included in the offer. All components of the generator requiring inspection and maintenance shall be designed for easy access and replacement. Resistance / thermocouple type temperature detectors shall be provided where the highest temperatures are expected. The approximate number and location of temperature detectors shall be as follows: (a) Twelve (12) duplex RTDs (Four per phase) distributed equally around the periphery of the stator winding and also between three phases shall be provided. The geometry of the detectors shall be such that hot spots anywhere in the stator winding can be detected. (b) Twelve (12) duplex RTDs for stator core out of which six shall be located in the end zones where maximum temperatures are expected. (c) Two (2) duplex RTDs for each hydrogen cooler section at inlet and outlet (if applicable). (d) Two (2) thermostats per hydrogen cooler section for gas inlet and outlet (if applicable). (e) Two (2) duplex RTDs for hydrogen cooler water inlet and outlet (if applicable). ISSUE R0 1.1.15 1.1.16 1.1.17 1.1.18 1.1.19 28 TCE FORM NO. 329 R5 (j) Additional RTDs / Thermocouples / Thermostats if required or if required at additional locations shall be provided as found necessary. One (1) generator condition monitoring system shall be supplied along with all piping and accessories to continuously sample the generator hydrogen for detection of thermally produced particulates / aerosols which indicates overheating. indication / annunciation and necessary main control system interfacings with DCS.1. (h) Set of duplex RTDs and thermostats for shaft seal system (if applicable). hydrogen gas handling system. Termination of RTD leads shall be at terminal box after grouping of signals.25 29 TCE FORM NO. 1.1. Generator auxiliary system like cooling. 329 R5 . excitation. KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.1. Generator rating shall be on the basis of continuous operation with guaranteed temperature.24 1.1.22 1.1. etc. (g) Two (2) duplex RTDs for cold air temperature and two (2) duplex RTDs each for air temperature in the exciter air passage and rectifier wheel along with thermostats for cold and hot air.23 1. of duplex RTDs located at the locations where the temperature is likely to be maximum.5960A-H-500-001 (f) Two (2) duplex thermocouples per bearing.1.21 1.1 SHEET 4 OF 42 1X 700 MW CCPP AT NEDUNOOR. Insulation and Temperature Limits ISSUE R0 1. Termination box of the temperature measuring devices shall be of IP-55. (i) Rotor winding temperature measurement is also to be done through 2 Nos. TCE. NO. All the above temperature measurement devices shall be hooked to DCS.20 All RTDs shall be of platinum duplex four wire type and shall have a resistance of 100 Ohms at zero degree centigrade and calibrated as per DIN standards. or temperature rises.. not exceeding those given in IEC 60034-1. shall be provided with respective local control panels with required control. Terminal box shall be at an easily accessible position so as to enable maintenance / testing of the devices when the machine is under operation. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. shall be provided with Class F insulation but temperature rise shall be limited to class B.1 Stator Housing The stator housing shall be of totally enclosed gas tight construction.1 SHEET 5 OF 42 1X 700 MW CCPP AT NEDUNOOR. The maximum permissible temperatures of different parts of the generator shall be as specified in IEC-60034.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 1.2. NO.5960A-H-500-001 The generator stator and rotor windings inclusive of main and neutral leads. 100 percent vacuum and vibrations and also internal hydrogen explosion without any damage or permanent deformation. starting from stability temperature at rated load. the short time thermal capability of the generator armature shall permit operation at 150% of the rated armature current for at least 30 seconds. TCE.26 Short Circuit Withstand Capability during Unbalanced Faults The generator shall be capable of withstanding. 329 R5 .2.27 Overload Capability With balanced current. 1. where I2 is per unit negative sequence current and t is the duration of fault in seconds. 1. Suitable numbers of trunions shall be provided for handling the stator by means of crane. 1.1. any short circuit at its terminals provided the integrated product of I22t does not exceed the value stipulated in IEC60034-1.2 1. The housing shall have suitable provision for handling. having sufficient mechanical strength and rigidity to withstand internal gas pressure.3 ISSUE R0 30 TCE FORM NO. without injury.28 Capacity with one Gas Cooler Out of Service Hydrogen coolers would be built into the stator frame of the generator and would be sized to ensure at least 80% of the rated output continuously with 10% of tubes in each coolers are plugged and one of the hydrogen cooler is out of service then also the temperatures rises shall be limited to class B.2. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. KARIMNAGAR DIST. Manholes with sealing arrangement shall be 1. 1.1. The Bidder to clearly bring out in the proposal the features provided in the generator body construction to enable generator stator to be lifted/dragged in case of nonavailability of suitable crane.1. lifting and / or jacking the stator. SECTION: D3. 2 31 TCE FORM NO.1 SHEET 6 OF 42 1X 700 MW CCPP AT NEDUNOOR. NO. etc. including power.5 times the maximum design pressure. SECTION: D3.3 1.2.5 1.6 1. Press plates and fastening elements shall be made of non-magnetic material and shall be with proper locking arrangement. KARIMNAGAR DIST.2. The frame shall be stress relieved and then subjected to an extended hydraulic test at a pressure not less than 1. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. The end packets shall be adequately strengthened to minimise the magnetic vibration due to end leakage flux.3. All leads. 329 R5 . The core assembly shall have adequate ventilation ducts for cooling by hydrogen. A drawing indicating the location of the temperature detectors and the terminal box shall be enclosed with the proposal.7 1. Stray current insulation shall be provided so that all paths of stray current will be broken at two places in series at one end of the generator with provision made for determining the insulation resistance at each place of insulation with the unit in operation. control and instrumentation shall be suitably supported to contain vibrations and shall be brought out of the generator housing to terminal boxes through gas tight seals. internals such as back of the core.1 1. Location may be preferably on the TG Deck.2.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The instrumentation terminal box shall have IP55 protection class and shall be located at an easily accessible position so as to enable maintenance / testing of the devices when the machine is under operation. The core assembly and mounting arrangement shall be such that the transmission of the forced vibration of the core to the housing and foundation is effectively restricted. Stator Core The stator core shall be fabricated out of high permeability best quality cold rolled silicon steel so that losses are minimum.2. The dimensions of the generator stator body to be within the maximum permissible rail transportation dimensions within the country taking into account the special wagons available / being made available for transporting such heavy over sized consignment. end winding area.3. TCE. 1. ISSUE R0 1.4 End plates of the generator frame shall be suitably shielded from stray flux.5960A-H-500-001 provided at suitable locations to facilitate inspection of terminals. 1 1. Provision shall also be made available to connect the same to DCS. a surface treatment corona grading system shall be applied which shall be carried into the end turn area. The end turns shall be suitably braced and supported to withstand forces during normal operation and sudden short circuit at generator terminals when the machine is operating at rated MVA. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.4.3.5 1.6 1.4. TCE. The stator core. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3 1.4. SECTION: D3. frame and mounting shall be designed to avoid resonance at 50.5 1.5960A-H-500-001 1. Terminal Connection All phase and neutral terminals shall be brought out from the top of the generator (non-drive end) and located in a non-magnetic steel terminal box. symmetrically located around the periphery with connection to Turbine Supervisory system. Phase terminal bushing shall be spaced to 1. Firm seating of the stator bar in the slot shall be ensured by proper wedging and fillers. Stator Winding The stator winding shall consist of three phase. bar type lap winding having two parallel paths.4 1. The strands making up the stator bar shall be Roebel transposed to minimise eddy current losses. The winding and all connections inclusive of phase and neutral leads shall be insulated for full voltage to ground. double layer.1 ISSUE R0 32 TCE FORM NO. power factor and permissible maximum over voltage.1 SHEET 7 OF 42 1X 700 MW CCPP AT NEDUNOOR.2 1.5.4 1.4. Ripple springs shall be provided below the slot wedges to compensate for any future shrinkage and ensure permanent firm seating of the bars in the slot during operation.4. short chorded. KARIMNAGAR DIST. Bidder shall wire up all the pickups to a junction box outside the generator casing.3 The stator core mounting arrangement shall be such that radial and tangential magnetic vibrations of the stator core due to electromagnetic loading transferred to stator frame are minimised. The stator windings shall be designed for connection in single /double star with three (3) phase and three (3) / six (6) neutral terminals brought out. 100 and 200 Hz.4. In order to reduce the corona in the slot and where the stator bar leaves the stator core. 329 R5 . At least six (6) numbers of vibration pickups at each end of over hang portion of the winding shall be provided. 1 1.3 1.7. The terminal bushing shall be cooled by suitable arrangement with cooling medium/system envisaged for the generator.5960A-H-500-001 permit connection to isolated phase bus duct to provide complete phase isolation directly upto the generator housing. The forging shall be subjected to elaborate ultrasonic and mechanical tests to ensure freedom from any internal defect. ISSUE R0 1.2 1. Rotor Winding Rotor winding shall be made of hard drawn silver bearing solid copper conductors.2 33 TCE FORM NO. 1.6 1.5. Rotor The generator rotor shall be machined from a single alloy steel forging to ensure required mechanical strength and magnetic properties. After assembly.7 1.6.e. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. the rotor shall be dynamically balanced and subject to 20% over speed for 2 minutes.1 1. Silver coated copper terminal connectors suitable for connection to the busduct through flexibles shall be provided for which the operating conductor temperature shall not exceed 105OC.2 The bushing shall be preferably of porcelain type or of epoxy based material with non-hygroscopic property. epoxy glass based material) with temperature limited to Class -B. Adequate spacing shall be provided between phase and neutral bushings to permit connection of the neutral enclosure.6.6. Rotor winding shall be secured in the slots by suitable slot wedges and fillers. The retaining rings shall be machined from high strength. The retaining rings shall be floating type. 329 R5 . Winding insulation shall correspond to Class-F (i. NO. TCE.1 SHEET 8 OF 42 1X 700 MW CCPP AT NEDUNOOR. shrunk on rotor body and prevented from axial movement by snap rings / locknuts. Adequate margin shall be provided between critical speed and the running speed to ensure smooth running. Facilities shall be provided for inserting at least two radial and one axial probe into the rotor shaft for carrying out ultrasonic and residual stress measurements during the life of the rotor. The overhung portion of rotor winding shall be held in position against centrifugal force by retaining rings when the rotor is running at upto 20% above its normal speed.7. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. nonmagnetic alloy steel forging with the material specification X8CrMnNi1818 resistant to stress corrosion. KARIMNAGAR DIST. 8.8 1. NO. Build-up of shaft voltage beyond permissible limits as well as a short in the bearing insulation shall trigger an alarm. TCE. Oil buffers shall be provided to prevent leakage of oil and oil vapours along the shaft.1 1. Shaft Seals Labyrinth shaft seals shall be provided. The bearings shall be of horizontally split construction and forced lubricated from turbine oil system. 329 R5 . The bearing shells shall be lined with tin based babbitt metal.3 1. RTDs for measurement of metal temperature and bearing drain oil temperature shall be provided.5960A-H-500-001 1.7.9.4 1. Each bearing shall be provided with a well for thermometer in the return line and a sight glass with illumination to observe bearing oil flow.7.8. KARIMNAGAR DIST. seal oil pressure in the annular gap between the rotating shaft and seal ring shall be maintained at a higher level than the 1.8. Non-hygroscopic insulation shall be provided between bearing and frame to prevent any damage due to circulation of shaft currents to the bearing surfaces and the lubricating oil. Shaft seals. Arrangement shall be provided to measure the insulation of the generator bearing with the machine in operation. Redundant vibration pick-ups and transducers for bearing shall be provided.1 ISSUE R0 34 TCE FORM NO.9 1. To ensure effective sealing.1 SHEET 9 OF 42 1X 700 MW CCPP AT NEDUNOOR.3 Suitable damper winding shall be provided on the rotor to permit increased asymmetrical electrical loading. Bearing The generator shall be provided with self-aligning type sleeve bearings either mounted on separate pedestals or on the end shields. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. Provision shall be made for hydraulic jacking of the shaft during start up and turning gear operation. The rotor shall be suitable for operation without requiring preheating of the rotor or rotor winding or pre-warming of the rotor forging.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.4 1. The vibration sensors shall be installed on X and Y dimensions. This shall be achieved by having two layers of insulation with a metallic plate in between. preferably of double flow ring type shall be fitted to the end-shields to prevent hydrogen leakage from generator housing.8. All the intermediate support pieces of the bearing shall have complete interchange ability with those of similar type and size of TG bearing.2 1. SECTION: D3. SECTION: D3. Fans Hydrogen shall be circulated in the generator in closed circuit by the axial fans located on rotor shaft.10 1.1 1. Shaft seals and oil piping shall be suitably insulated to prevent circulation of shaft current.12 1.2 The hydrogen side seal oil housing shall be provided with oil baffle rings to prevent intrusion of seal oil into the generator along the rotor shaft. Shaft grounding brushes shall be provided at the turbine end bearing pedestal. It should be possible to increase the brush pressure while generator is working.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The excitation system shall have matching characteristics suitable for satisfactory parallel operation with other generators in the plant. suitably mounted and sliding on an oil free surface. 1.2 ISSUE R0 35 TCE FORM NO. Suitable insulation shall be provided to prevent passage of current through pressure device.12.5960A-H-500-001 gas pressure in the generator casing.12. The system shall be a brushless excitation system. 329 R5 . NO. 1. The face of the sealing ring shall be lined with babbitt metal. Brush holders shall be of constant pressure type.11 Brushes The rotor winding insulation and shaft voltage shall be monitored through a brush. which can be adjusted as per requirement. TCE.1 SHEET 10 OF 42 1X 700 MW CCPP AT NEDUNOOR.1. KARIMNAGAR DIST.12. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.1. The excitation system offered shall be of proven design and shall have a satisfactory field service record on machines of similar size and construction incorporating the type of excitation.9. Carbon brushes for the measurement of the rotor winding temperature is also to be provided on the oil free surface similar to the carbon brush used for shaft voltage measurement 1. Arrangement shall be made to measure the insulation of the shaft seals while the machine is in operation. 1.1 Excitation System Type A complete generator excitation and voltage regulating system shall be provided with the generator. The fans shall be shrunk on to their seats on the rotor shaft and locked against tangential or axial movement. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.12.12.12. SECTION: D3.5 sec.2.3 The various change over relays and other equipment.2 1. 329 R5 .2.5 % of the preset value over the entire load range of the machine.1.4 1.1. The excitation system shall be capable of maintaining generator voltage within + 0.1.5960A-H-500-001 1. TCE.12.12. The reference voltage set point shall be adjustable over a range of 70% of no load to 110% of the nominal rated voltage at MCR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5 1.12.6 36 TCE FORM NO. Each shall be equipped for auto operation with the facility for selecting either channel in Auto or Manual mode.4 1. The excitation system response time shall be less than 0. the system shall be capable of restoring the voltage within 2% of the nominal preset value within negligible time. The system shall function without hunting and shall be capable of preventing any abnormal change or oscillation in the generator voltage.2. When the generator is subjected to a sudden loss of rated output at rated power factor. The system shall have high initial response to improve steady state and dynamic stability of the generator.12.2. The excitation system shall also be capable of supplying higher current to meet the short time duty mentioned above. NO.12. which are not controlled by the control supply required by AVR shall be such that the loss of their control supply does not lead to the excitation system outage. ISSUE R0 1. KARIMNAGAR DIST.12.1 1. The necessary inputs and interface equipment shall be provided with Generator Excitation and Automatic Voltage Regulator for hooking up with Turbine Automatic Run up system and Electro Hydraulic Governing System. The excitation system shall be rated to continuously carry current at least 20% above the rated generator field current at MCR output. power converters and controls.3 1.2 1. Performance Requirements The excitation system shall have two (2) 100% channels including independent AVR’s.2.2.5 meet the performance 1.12. The excitation system shall also requirement specified hereinafter.1 SHEET 11 OF 42 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST.11 1. non dead-band type microprocessor based digital automatic voltage regulators with accessories mounted in a suitable panel shall be provided for the generator.2.8 1.3 37 TCE FORM NO.3 1.13 1. i.12.12 1. An alarm shall be generated if the difference in the set point of the Auto-1 & Auto-2 is more than a ±0. digital type and shall be complete with the following limiters.3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 1.12.12.7 The ceiling voltage shall not be less than 150% of the machine excitation voltage at MCR condition.10 1.3. TCE.5% with a 1sec time delay.2. The nominal exciter response ratio shall not be less than 2.1 SHEET 12 OF 42 1X 700 MW CCPP AT NEDUNOOR.2.12. Automatic Voltage Regulator Continuous acting.5 percent of the setting value without hunting. The excitation system shall have proper field suppression arrangement.2.12. All rectifying elements shall have over voltage and short circuit protection. the field of the main exciter shall be transferred to the supply derived from the auxiliary 400V station supply. high speed.5960A-H-500-001 1.1 1. 329 R5 . adjustable type ISSUE R0 1. compensators etc.9 1.2. so as to limit the voltages across the rotor winding to a safe value. SECTION: D3. a) Maximum Excitation Limiter. This changeover shall be such that it does not result into the tripping of the generator.2. failure in the follow-up circuit.12. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.12.e. In excitation system monitoring facilities with self-diagnostic features to indicate faulty cards and abnormalities shall be available. The automatic voltage regulating equipment shall control the generator voltage under steady state load conditions and over the whole of the operating range of the exciter within ± 0.3. continuously acting. In case of failure of the PMG. The automatic voltage regulator shall be capable of working over the whole load and voltage range of the generator.12.12.2. high response.12. The system shall be capable of supplying the field-forcing requirement for at least 10 seconds even for close-in faults on high voltage outgoing lines or bolted faults at generator terminals. The voltage regulator shall be automatic. NO.12. etc.5960A-H-500-001 b) Maximum Stator Current Limiter (The stator current limiter shall act immediately in under-excited range. j) The channel reference control shall be either solid state control or microprocessor control. power supplies. sequence logic. indicating lamps. KARIMNAGAR DIST.4 All the above conditions of limiter operations shall be annunciated in local panel as well as in DCS.12. control ISSUE R0 38 TCE FORM NO.) h) Rotor Current Limiter (The regulator shall act with time delay.1 SHEET 13 OF 42 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3.) f) Minimum Excitation Limiter g) Adaptive Power System Stabiliser (PSS shall be suitable for damping the various modes of electro-mechanical oscillations at all frequencies in the range of 0 to 3 Hz under varying generator loading and power system network configurations.3. Facility for remote manual switch off-on along with indication shall be incorporated. The time delay in overexcited range shall enable a temporary overloading of the machine) c) Reactive Drop Compensator (Suitable feedback proportional to transformer drop shall be provided for compensation and the range of compensation shall be 0-15%) d) Over Fluxing (volts / hertz) Limiter (To limit the ratio of generator voltage and frequency at all operating conditions to such a value that the maximum generator transformer core flux density does not exceed the value specified. Local AVR panel shall be complete with necessary facia windows. by adjusting the excitation. so that the regulation dynamics are not impaired in case of a fault. 1.) e) Load Angle Limiter (This shall enable to keep the angle between the direct axis of the machine and network vector within the set reference value as determined by stability. PSS shall automatically adapt itself to varying operating conditions with features to compute optimum stabilising signal along with suitable scheme for identifying external reactance of the generator.) i) Ramp generation circuit to enable gradual rise of reference signal applied to the comparator circuit to avoid sudden voltage build up shall be provided. NO. accept-reset-test push buttons. shall also be provided.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Automatic supervision and Blocking/Switch off facility along with indications. 329 R5 . ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. TCE. 4.1 SHEET 14 OF 42 1X 700 MW CCPP AT NEDUNOOR. 6.12. SECTION: D3. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. On failure of the Master control. NO. programmable logic controllers. 3. the range of regulation shall be 70% of no-load to 110% full load excitation.12. Automatic change over from Auto-1 to Auto-2 channel or vice versa shall be possible in case of trouble in the running channel. e. Generator protection circuit operation i.12. An alarm and visual indication shall be provided to indicate change over from Auto channel-1 to Auto channel-2 or from ‘Auto’ to ‘Manual’. a suitable arrangement shall be provided to follow up changes in ‘Auto’ mode along with follow up indication in Unit Control Panel.5960A-H-500-001 switches. etc. 5. In auto mode.12. Automatic change over shall be possible from ‘Auto’ to ‘Manual’ in case of: 1. the Slave control. KARIMNAGAR DIST.4 1.4.4 In order to avoid a sudden change in generator voltage when voltage regulation is transferred from ‘Main’ to ‘Standby’ or from ‘Auto’ to ‘Manual’. 2.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3 1. 4. ISSUE R0 39 TCE FORM NO.2 1.4. TCE. In manual mode the range of regulation shall be 0 to 110% of nominal rated voltage. Either channel shall be capable of being the main or stand-by. 1. Either channel shall be capable of being selected as manual also. which follows the Master control.4. shall take over automatically. local/remote switches. 329 R5 . after field forcing and over excitation condition with a time delay Loss of terminal voltage feedback by way of any of the VT fuse blowing up Faulty over excitation condition Loss of automatic channel reference signal Power supply failure in the automatic channel Manual intervention Any other condition as considered necessary by the Bidder 1.12.1 auxiliary relays and Auto / Manual Channels Two fully equipped independent automatic regulators with one acting as Master and the other as Slave shall be provided. 7. A center zero balance indicator to indicate the channel difference signal Generator field current indicator Rotor winding temperature recorder Auto Channel-1 to Auto Channel-2 & Auto/Manual changeover indications Generator field breaker/exciter field breaker control & instrumentation PSS control and instrumentation Auto and manual channel control of excitation level Speed set point control 1. A negative sequence component filter to permit response only to the positive sequence component of the regulated voltage shall be provided.12.5 The maximum change in generator voltage when AVR is transferred from Auto to Manual under all conditions of excitation shall be less than 0.12. 7. 1. 3. NO.12. 8.4.12.4.4.5 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 Pilot Exciter 40 TCE FORM NO. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. 3. Rectifier Unit for PMG Brushless Main Exciter Rotating Rectifier Unit Regulator Cubicle Complete instrumentation and protection system. Permanent Magnet Generator (PMG) type Pilot Exciter. SECTION: D3. The system shall consist of : 1. TCE. At least.7 1.5. the following instruments and control devices suitably clubbed on a plate/console shall be supplied for being mounted on unit control panel.1 SHEET 15 OF 42 1X 700 MW CCPP AT NEDUNOOR.5960A-H-500-001 1. 329 R5 . 2. 2. 6. it shall be possible to exchange information with DCS through suitable protocol. 4.12. KARIMNAGAR DIST. 7. 6.6 1. Further. 5. 5.12.1 Brushless Excitation System The complete equipment shall be mounted on a bed plate and enclosed by suitable enclosure. Inter-connecting cables between different components of the system ISSUE R0 1.5%. 4. 2 1. Rotating Rectifier Assembly ISSUE R0 1. The rotor shall be magnetized and stabilised by the Manufacturer to give stable magnetisation characteristic during operation.1 The pilot exciter shall be revolving field. The armature conductor in the overhang portion shall be adequately held to withstand the electro-dynamic forces during field forcing condition.12.8. SECTION: D3. Brushless Main Exciter The rotating armature shall be 3-phase. self ventilated.12. KARIMNAGAR DIST.12.12. suitable for operation at 500C ambient temperature.7. permanent magnet high frequency type.1 1. Rectifier Unit for PMG Fully controlled three phase.7 1. salient pole.1 1. They shall be suitable to ensure trouble free service of the cells under all fault conditions. The stator and rotor winding insulation shall be of class ‘F’ with the temperature rise limited to class B limits of IEC 60034. star connected.8.12. The stator winding shall be of class ‘F’ insulation or better but its temperature rise shall be limited to Class-B.12.2 1. Suitable lamp indication shall also be provided to indicate the defective ‘thyristor’.6. frame supported on the generator foundation having journal bearings.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The armature core shall be made from silicon sheet lamination to reduce eddy losses and shall be suitably varnished on both sides. The exciter shall be totally enclosed.8. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.8 1.1 SHEET 16 OF 42 1X 700 MW CCPP AT NEDUNOOR. 329 R5 .12.3 1.5960A-H-500-001 1. The armature shall be stationary 3 phases feeding current to the static rectifier assembly and excitation control equipment. The thyristors shall be selectively protected against short circuits by ultra high speed fuses. NO.9 41 TCE FORM NO. Integrally mounted air fan shall be provided for the cooling of the exciter.12. The converter shall have redundant thyristors for satisfactory operation even in the event of failure of any of the thyristors. full wave bridge type thyristor converter facilitating fast and high ceiling performance shall be provided. TCE.6. Rotor end winding retaining ring shall be made up of stress corrosion resistant material. feeding current to the rotating diodes mounted on the exciter shaft.12. The machine shall be fitted with fans for self-ventilation. Rectifier assembly shall have same requirements as regards the component features and rating as detailed out for the thyristor assembly. 3.1 The rotating rectifier assembly shall have the following essential features : 1. sheet metal enclosed with swing doors and ventilating louvers with wire gauge shall be furnished for the excitation and voltage regulating equipment.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The rectifier assembly made of silicon diodes shall be arranged as two distinct rings with opposite polarity diodes on respective rings. The diodes shall be connected in a conventional threearm full wave rectifier bridge.11 Instrumentation The instrumentation for excitation system shall generally include. if necessary. ISSUE R0 42 TCE FORM NO.9. Diodes shall be cooled by forced air circulation by means of fans mounted on the main exciter. 329 R5 . Each diode shall be provided with a fuse together with visual indication in the event of diode failure.10 Regulator Cubicle Self-supporting. The output from the rectifier shall be fed to the generator field through the bore of the rotor shaft and necessary plug in type of shaft connection. the generator and exciter can be tested individually. KARIMNAGAR DIST. TCE.12.12. 2. 5. but not be limited to the following: i) Suitable duplex RTDs for measuring hot and cold air temperature of exciter with necessary provisions for protection tripping/interlocks.5960A-H-500-001 1. Alternatively a single three phase rectifier bridge having at least one redundant parallel rectifier branch in each of the six arms of the bridge may also be considered. Natural ventilation shall be provided for the cooling of excitation cubicles. SECTION: D3. 1.1 SHEET 17 OF 42 1X 700 MW CCPP AT NEDUNOOR. 4.12. The axial copper connector shall be designed such that it shall be possible to disconnect this connector at the point where the exciter shaft couples to the generator so that. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. 1. Rectifier assembly shall have one complete bridge as redundant. NO. 2 1.1 Hydrogen Cooling System System Requirements The hydrogen gas cooling system comprises a hydrogen circuit for cooling the stator core.13. Also the system shall permit emptying of the generator casing with help of CO2 purging. 329 R5 .13. instrument quality air supply shall be used.1 SHEET 18 OF 42 1X 700 MW CCPP AT NEDUNOOR. iv) Suitable arrangement for exciter field suppression.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The major system components are H2 and CO2 gas manifolds.1. H2 drying equipment. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. The system is required to fill the generator with hydrogen. valves. maintain it under pressure. inter-connecting pipings. thermometers.5960A-H-500-001 ii) Instruments and devices for the measurement of rotor winding temperature. hydrogen pressure regulator. TCE. contacts shall be taken from the temperature switches. While emptying H2 is first displaced by CO2 before admission of air in the machine in order to obviate possibility of any explosion. 1.1. NO.13.3 43 TCE FORM NO.13 1. air is first displaced by CO2. For removing CO2. control & monitoring panel. CO2 heating system. monitor and control gas purity and to empty the hydrogen from generator. KARIMNAGAR DIST.13. provided at suitable points. H2 gas coolers. vi) For all alarms in the system. The design has to be such as to ensure safe filling / emptying by preventing formation of explosive H2 – air mixture. For filling. etc. which in turn is replaced by H2. SECTION: D3. iii) Stroboscope or suitable alternative device for detection of faulty rotating diode element. gauges. pressure transmitters and other instrumentations. ISSUE R0 1. fittings. The system shall be provided with transmitters for the above indicators. stator winding. Annunciation and electrical instruments shall be located in a separate electric panel common with seal oil system outside the hazardous area. carbon-dioxide scavenging system and compressed air supply system. v) A pair of auxiliary slip rings shall be provided to give access to the rotor circuit allowing an earth fault detector circuit to be connected.1. lead terminal bushings and rotor windings.1 1. NO. The system shall be complete with necessary pressure. on the winding insulation. the unit can deliver at least 80% of the rated load continuously without exceeding the permissible temperature limits of class B.1. accessories and controls to enable drying out operation of the generator with hot air circulation shall be provided. Water pressure in the coolers shall be maintained below the operating hydrogen pressure in the generator casing.13. Gauge pressure on the gas side irrespective of a lower normal operating casing pressure. It shall be possible to clean/plug the cooler tubes of a section with the machine under operation. temperature and flow gauges as well as thermostats as required. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. Corrosion resistant tubes with integral fins shall be provided and arranged in the stator casing so as to avoid the direct fall of water during leakage. TCE.13. The generator drying arrangement complete with all electrical/mechanical drives/equipment.10 A certain quantity of H2 circulating in the generator shall be bypassed through gas drier for removing the moisture and maintaining the gas in dry condition. Cooler shall be designed for at least 10 Kg/sq. The distributor shall be capable of connecting H2 cylinders to meet at least one shutdown & one start up of all the units & 30 days of normal operating requirement.1.1.9 1.13.1.13.13. ISSUE R0 44 TCE FORM NO. The coolers shall be of sectionalised design such that with one cooler section out of service & 10% of the tubes in other sections are plugged.13. if any. Hydrogen shall be circulated in the generator in closed circuit by fan fitted on the rotor shaft.13. SECTION: D3.8 1. 2x100% capacity H2 dryers with in-situ reactivation facility shall be provided to maintain the H2 inside the machine dry with 0O C dew point at operating pressure. KARIMNAGAR DIST. cm.6 1. This shall be further reduced to generator pressure requirements by means of 2x100% pressure reducing circuit. 1. The hydrogen coolers shall be provided with 10% excess tubes.1 SHEET 19 OF 42 1X 700 MW CCPP AT NEDUNOOR. 329 R5 .1.4 Hydrogen supply of 97-99% purity shall be obtained from H2 cylinders on rack through H2 distributor.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5 1.1. H2 gas is cooled by water/gas heat exchangers located in the generator housing. Intermediate valves shall allow replacement of individual cylinders during operation. The high pressure H2 gas from the distribution header shall be provided with 2x100% pressure reducing valves.5960A-H-500-001 1.1.7 1. Thermostat controlled electrical heating system shall be provided for CO2 system so that the freezing of CO2 pipe is prevented. SECTION: D3.13.1 SHEET 20 OF 42 1X 700 MW CCPP AT NEDUNOOR. 1. Glass indicator shall be provided to indicate humidity. The valves in gas system shall be of special design to minimise gas leakage. thermostats.13. For controlling the time/regime of reactivation. heater and thermostatic control etc.15 Seamless steel tubes shall be used for valve piping. wherever possible.13.11 To run the gas system for short time during shut down of generator (at standstill) for which gas circulation arrangement through drier with blower. with a local control panel shall be provided.5960A-H-500-001 The arrangement shall be such that one drier can be taken out of service for reactivation without affecting the system performance in any way.1.1.14 The cylinders of CO2 shall ensure complete emptying of the cylinders as well as to avoid evaporation of liquid CO2 to gas in cylinder itself. piping valves and accessories along with required control equipment shall be provided.13 On line dew point monitoring system shall be provided across the inlet and outlet lines to the drying system along with alarm/annunciation in case of high moisture content in the generator casing hydrogen.1. The arrangement of CO2 distributor shall correspond to that of H2 distributor.13. Valves shall be glandless diaphragm type.12 The design of the drier shall be such that it is possible to reactivate the drying medium in-situ after isolation from the generator casing and connecting it to atmosphere. as applicable. shall be provided to prevent condensation during long shut down.2 Instrumentation ISSUE R0 45 TCE FORM NO. The CO2 shall leave the cylinder in liquid state and shall be evaporated and expanded in a vaporiser. NO. suitable thermometers. 1. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. KARIMNAGAR DIST. TCE. 1.13. The three way valves used along with the drier for interconnecting the hydrogen and airline (as applicable) shall preferably have mechanical interlocking such that closing of the hydrogen side port is positively ensured before opening of the air side port. 1. A suitable hot air blowing system complete with blower.1. Arrangement for purging out entrapped air from the drier after regeneration shall also be provided.1. 1. A manually operated vent valve shall be provided for discharging casing hydrogen to atmosphere (outside the TG hall) in case of emergency. 329 R5 .13. Safety relief valves shall be furnished at hydrogen manifold both on low and high pressure sides of the gas system.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. timers etc. 1. 1. etc. pressure and liquid level detector switches for alarm and interlock. H2 gas manifold pressure. accept-reset-test push buttons.13. Necessary sensors/transmitters for remote indication and recording in DCS. KARIMNAGAR DIST. The local control and annunciation panel shall be complete with switches.3 1.5960A-H-500-001 1. Required number of temperature. The local H2 panels shall include indicators for H2 gas cylinder pressure. fan differential pressure. H2 gas purity. SECTION: D3. The analyser shall measure the gas purity under the following three conditions: a) Normal % of purity of Hydrogen in air in the generator casing.2. TCE.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. gas manifold. The Contractor shall provide instrument for on line monitoring of moisture content in hydrogen inside generator casing. generator casings.3. CO2 pressure in the manifold.13. 329 R5 . ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. gas flow meter. Purity range shall include a low purity alarm. Gas Analyser shall be of thermal conductivity type and shall continuously analyse the gas discharged from the casing during purging and shall also analyse samples of the casing hydrogen during normal operation.1 To ensure efficient and reliable operation of the generator gas system adequate instrumentation shall be provided. and gas drier. Portable gas analyser as detailed above shall be provided for supervision of the gas purging operation. facia annunciation.13. This shall include the following as a minimum: Dial type thermometers for CO2 vaporiser. CO2 pressure inside generator. H2 pressure and purity shall be monitored in DCS. Pressure gauges for gas cylinders. lamps. ISSUE R0 46 TCE FORM NO. H2 gas temperature (for hot and cold H2 inside casing). c) % of air in CO2 leaving the casing when CO2 is being admitted or expelled. indicators.2. NO. generator casing pressure. power supply.1 SHEET 21 OF 42 1X 700 MW CCPP AT NEDUNOOR.2 1. b) % of Hydrogen in CO2 leaving the casing when Hydrogen is being admitted or expelled. hooter.13.1 Annunciation The following annunciation shall be provided on the local electric panel and DCS. air pressure in the air supply manifold and dew point level indicator for casing H2 across drier inlet and outlet lines. Volumetric (water) capacity of each cylinder shall be 45. Getting necessary approval from chief controller of explosives is in the scope of the Contractor. The cylinders to be supplied under this specification shall conform to IS:8198. NO.1 1.1 SHEET 22 OF 42 1X 700 MW CCPP AT NEDUNOOR.0 litres.2 1. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.13. Each cylinder shall be hydro tested at pressure of 250 kg/cm² (min. shall be connected to DCS system.5960A-H-500-001 H2 Pressure in Generator Casing H2 Pressure in Cylinders H2 Pressure in Manifold Purity of H2 in Generator Casing : : : : High / Low Low Low Low High Low / High High High High Failure Temp of Cold/Hot Gas in the Generator : Pressure of Cooling Water of H2 : Coolers Dew Point Level in H2 Gas across the : drier inlet & outlet lines H2 Leakage into Cooling Water Liquid Level in Generator Casing Power / Control Supply 1.13.3 47 TCE FORM NO. ISSUE R0 1.13. SECTION: D3.4.4 1.).4. H2 and CO2 Cylinders The number of H2 and CO2 cylinders shall be equal to total requirement for one start up and one shut down of a unit plus those required to be connected on manifolds of all units plus total requirements for seven days consumption of all units. Each gas cylinder shall be complete with cap and valve as per IS:3224.13. The Contractor shall supply H2 and CO2 gas till completion of trial operation. 329 R5 .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3. The Contractor shall also furnish the necessary test certificates and filling certificates.13.4. analog and digital. All instruments shall be mounted on a gas control cubicle to be located near the machine.2 : : : Independent signals. KARIMNAGAR DIST. TCE. 14.1. thermometers and other instruments. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. NO. 329 R5 . Seal oil system shall have connection to turbine oil system ISSUE R0 1.5960A-H-500-001 1.4 1. de-gassification tanks.1 1.1.14.1 SHEET 23 OF 42 1X 700 MW CCPP AT NEDUNOOR.1. when maintained at a pressure suitably in excess of the hydrogen gas pressure in the generator casing shall provide an effective gas seal and shall lubricate and cool the seals when the generator is running.14.5 1. Seal oil coolers shall be designed to have 15% excess tube surface area over and above designed tube surface area required for the rated load conditions while maintaining the design pressure drop on cooling water side.3 1. The pressure regulator or the regulating valve used for the purpose shall be adjustable type. filters. KARIMNAGAR DIST. valves and control/annunciation panel complete with all interlocking relays shall be provided. Seamless steel piping shall be used in the system. coolers. regulating and control valves.14. at all hydrogen pressures and all regimes of generator operation.1. The oil pressure in the coolers shall be greater than water pressure under all operating conditions. pressure regulators. The seal oil shall be cooled in two (2) 100% capacity water cooled heat exchangers along with necessary 3 way valves for isolating or bringing one cooler in service.1 Generator Shaft Seal Oil System System Requirements A complete seal oil supply and control system including AC and DC motor operated pump sets. A diaphragm operated regulating valve in the seal oil supply line shall control the seal oil pressure by a constant amount. The seal oil. Piping and valve arrangement shall be such that any cooler/filter can be taken out for cleaning and maintenance without affecting the operation of the system.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1. SECTION: D3. The seal oil system shall be so designed that it is possible to run the machine at no load in air medium at a slightly positive air pressure without any modification in the system. A shaft seal oil system shall be provided to prevent the leakage of hydrogen from the generator casing.14. gauges.2 1.14 1.14.14.14. The differential pressure shall be kept constant once set at the time of commissioning.1. interconnecting piping including hangers and supports. These coolers shall be shell and tube type suitable for using DM water of condensate quality. 2x100% capacity filters shall be provided. oil tanks.7 48 TCE FORM NO.1.6 1. TCE. 329 R5 .14.1. The seal oil system shall thus be selfcontained. Upon failure of the normal service pump due to a mechanical or electrical fault.14.8 For the seal oil system. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. unit may be tripped and seal oil supply for such coasting down period shall be from a suitable arrangement from lubrication oil system or a damper tank. The auto starting of standby seal oil pumps shall be interlocked with seal oil pressure. The hydrogen dilution blower shall have the following features: HYDROGEN DILUTION BLOWER Type Capacity Air intake filter type Suction pressure Discharge pressure m3/hr Bar Bar Centrifugal/Twin lobes By bidder Simplex / Duplex type Atmospheric pressure By bidder ISSUE R0 49 TCE FORM NO. Also H2 diffusion loss through seal oil shall be minimum to maintain H2 purity level inside generator at a high level.10 The seals shall be designed so that minimum oil enters the hydrogen side of the machine and the oil drained from this part of the machine passes to a suitable hydrogen detraining tank.1.1. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 1. On of the seal oil pumps shall be fed from the emergency DG bus. KARIMNAGAR DIST.9 1. 2 x 100% Blowers for venting out Hydrogen gas liberated from oil shall be provided suitably mounted at places where such gas accumulation is likely to occur. NO.1 SHEET 24 OF 42 1X 700 MW CCPP AT NEDUNOOR. TCE. the seal oil supply shall be taken over by the emergency DC seal oil pump without any interruption. 2x100% capacity motor driven AC pumps shall be provided of which one pump shall always be in operation. the standby pump shall automatically take over the supply.5960A-H-500-001 for make up and also excess return and also shall serve as 100% back up. which may arise due to non availability of both AC & DC pumps. During short time emergency. 1. Upon the failure of both AC driven pumps.14. 5 meter distance Base Plate Prime mover details Silencer Noise level Pressure drop across the lobes Performance test dB(A) mmWc By Bidder Shall be conducted as per standard 1. NO. 50 Hz & 3φ Shall be provided (If applicable) 85 @ 1.14.B with epoxy coated. 400V.13 The oil which is used for the hydrogen sealing shall be same as the lubricating oil for the turbine & generator bearing & governing system.1.2 Instrumentation ISSUE R0 50 TCE FORM NO. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. KARIMNAGAR DIST. IS:2062 Gr. 329 R5 . TCE. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.12 A water detector with sight glass and drain valves shall be mounted adjacent to the gas manifolds at the end of a pipe connected to the bottom of the generator casing.14. 1.5960A-H-500-001 Mounting type - Skid mounted MATERIAL OF CONSTRUCTION Impeller/Lobes Shaft Casing AISI Type SS 316 AISI Type SS 410 (Duplex SS) AISI Type SS 316/ AISI Type SS 304/ 2% Nickel Cast Iron.1 SHEET 25 OF 42 1X 700 MW CCPP AT NEDUNOOR.11 Necessary hydraulic sealing arrangement shall be provided in H2 side oil discharge line to prevent circulation of gas due to any possible difference of heads developed by fans mounted at the end of the generator. 1.14.1.1.14. 1. 2 Local seal oil control panels shall be provided with indicators for pump discharge pressure. seal oil flow. hydrogen-casing pressure. Annunciation The following annunciations shall be provided on the local electric panel and in DCS system. 1. hydrogen / seal oil differential pressure.3 1. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.14. across each strainer and H2 seal oil differential pressure and at oil supply header. SECTION: D3. iv) Required numbers of temperature. pressure and level gauges for alarms and interlocks. Pressure gauges at inlet and outlet of pumps.2. 329 R5 . Necessary sensors / transmitters for remote indication and recording in DCS.1 SHEET 26 OF 42 1X 700 MW CCPP AT NEDUNOOR. seal oil pressure at the seals (for both hydrogen and air side streams). iii) Seal oil tank level indicator and flow meters for flow through seals. seal oil inlet to hydrogen and airside seals. NO.2.1 Differential : High / Low : Low ISSUE R0 Oil Level in Damper Tank (if applicable) 51 TCE FORM NO. Seal Oil Tank Level Seal Oil Temperature Pressure of Seal Oil Pressure of Thrust Oil Seal Oil Pressure H2 : High / Low / Very Low : High : Low : Low 1. at outlet of coolers.1 To ensure efficient and reliable operation of the seal oil system adequate instrumentation shall be provided. This will include the following as a minimum: i) ii) Dial type thermometers for inlet and outlet temperature of the seal oil and cooling water to each cooler.14. seal oil temperature at the seals and status indications for seal oil pumps.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3.2. at inlet and outlet of pressure regulators and filters.3 1. KARIMNAGAR DIST.14.14. thrust oil pressure. The remote instrumentation at Unit Control Room shall include seal oil temperature recording and seal oil / H2 differential pressure recording in DCS. TCE.5960A-H-500-001 1.14. 1. monitor and release the ISSUE R0 52 TCE FORM NO. trap. The system shall generally include but not be limited to the following: 1.15.1 Generator stator winding shall be cooled by water.2 One (1) number primary water tank shall be provided and mounted on the stator frame on anti-vibration pads and covered by the generator cladding. Independent signals. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. TCE.5960A-H-500-001 Oil Level in Damper Tank – : Very Low Emergency (if applicable) Oil Level in Hydraulic Seal Oil Level in Hydraulic Seal Seal Oil Filter Seal Oil Pump Standby Seal Oil Pump DC Seal Oil Pump : High : Low : Choked : Failure : Running : Running AC Seal Oil Motor Power : Failure Supply DC Seal Oil Motor Power : Failure Supply Power / Control Supply Seal Oil Pressure Cooler : Failure Water : High / Low Water : High / Low Seal Oil Cooler Temperature.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.15 1. SECTION: D3. The empty space in primary water tank may be filled with Nitrogen to minimise water evaporation. 329 R5 .15. analog and digital shall be made available for connection to DCS system. Stator Water Cooling System System Requirements 1.1 SHEET 27 OF 42 1X 700 MW CCPP AT NEDUNOOR. For this purpose.1.3.2 All annunciations shall be duplicated in the Unit Control Room.14.1. The Bidder shall indicate and provide devices to detect.15. KARIMNAGAR DIST.1 1. separate alarm contacts shall be provided. Water cooling shall be with a closed loop cooling system. NO. 1. It shall be possible to clean easily the ferromagnetic particles adhering to the magnet bars during capital maintenance.1.15.1. KARIMNAGAR DIST. The water-to-water heat exchanger shall be designed to accept secondary DM water (condensate quality).1 SHEET 28 OF 42 1X 700 MW CCPP AT NEDUNOOR. The permanent magnet bars shall be protected by sleeves of stainless steel. TCE. The MBD shall remain continuously in service in order to retain high purity of stator cooling water with its associated electrical resistivity. 1. 1.15. The system shall be so designed that the pressure of primary DM water inside the cooler is always greater than that of secondary DM water (condensate quality).5960A-H-500-001 hydrogen that leaks into the stator water cooling system.3 The make-up water for primary water system shall be tapped off from condensate extraction pump discharge header (before and after the condensate polisher) and from DM water make-up line to the condenser.4 Two (2) 100% capacity water to water heat exchangers shall be provided.6 Two (2) 100% capacity AC motor driven cooling water circulating pumps shall be provided. 1. The level in the tank shall be maintained by means of suitable valves in the make up line. to a safe place outside the building through suitable safety valves.1.1.8 Alkaliser unit shall be provided alongwith stator water required for ensuring a corrosion free operation system. Standby pump shall cut in automatically in case the working pump fails or the pressure of circulating water drops below a certain preset value. 1. The Bidder shall indicate in the proposal the capacity of MBD necessary to maintain the quality water at the desired level for time duration of six months or more.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.15. NO. SECTION: D3.15. 1.5 Two (2) 100% capacity fine wire mesh filters with magnet bars of unlimited life shall be provided for removal of all magnetic particles. The system shall be designed such that the MBD could be taken out of service for refilling without untoward effect on the system which could necessitate load reduction/rejection.15. The exchanger shall be designed to have 10% excess tube surface area over and above the designed surface area required for the rated load condition while maintaining the design pressure drop on cooling water side.1.2 Control System ISSUE R0 53 TCE FORM NO. 1. 329 R5 .7 One (1) mixed bed demineraliser (MBD) of adequate capacity shall be provided to maintain the required quality of water.1.15.15. level switches for high and low level alarms and other accessories for primary water tank.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Set of conductivity meters in the main water circuit and after the demineraliser. 6. 4.) to monitor the low distillate condition and flow transmitters/meters for primary water to stator winding and main bushing.1 The following instruments shall be provided on the local panel : 1. Indicators for primary water conductivity at the inlet of winding and after the demineraliser.5960A-H-500-001 1.15. Indicator for primary water flow in the stator winding. Set of flow switches (at least two nos. 2. Indicator for primary water pressure at the inlet of stator winding 1.1 The following minimum instrumentation shall be provided : 1. KARIMNAGAR DIST. 3. 1. differential pressure gauge across stator winding and pressure transmitters as required. make up water etc.2. Set of resistance temperature detectors/indicators for primary water before and after the generator winding. Water gauge. TCE. 329 R5 . differential pressure switches for the filters. Indicator for stator winding differential pressure.4 Annunciations The following minimum annunciations along with duplicate contacts for use in DCS shall be provided: ISSUE R0 54 TCE FORM NO. 4.15. 3.15.1 SHEET 29 OF 42 1X 700 MW CCPP AT NEDUNOOR. bushing and cooler. 5.3. 5. transmitters. Sets of pressure gauges at the inlet and outlet of stator water filters. Set of dial type thermometers for cooling water at the inlet and outlet of the cooler. SECTION: D3. Indicators for primary water temperature at the inlet and outlet of stator winding.15. 2. Vapour filled temperature detectors shall also be provided to give signals for high temperatures. NO.3 Instrumentation 1. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. Any other critical parameter to be annunciated A “summary annunciation” for the above shall be provided on the unit control panel 1. of primary cooling water at outlet of stator wdg.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Temp.tripped on overload.high Primary stator bar water temperature . Flow of primary cooling water to the stator winding . 11.5960A-H-500-001 1.high. TCE. ISSUE R0 1. Differential pressure across stator winding . 6. Water level in the primary water tank . and shall be possible to exchange information with DCS through suitable protocols. 13. 4. 7. Flow of primary cooling water to the stator winding . Pressure of primary cooling water at the inlet of winding low.15. 5. pressure etc. of primary cooling water at inlet of stator wdg. Reserve control supply for stator water cooling .high Temp. 2. SECTION: D3. 14. high. NO.5 On line stator water temperature monitoring system for individual stator winding bars shall be complete with all software and hardware required to detect any abnormalities in the temperature at any given generator operating point and shall be sensitive to generator loads.15.6 55 TCE FORM NO. 9. 10.1 SHEET 30 OF 42 1X 700 MW CCPP AT NEDUNOOR. Water level in the primary water tank . to prevent copper corrosion. Stator water cooling pumps . 12. 3. Conductivity of primary cooling water at the winding outlet . On-line oxygen monitoring system shall be provided. 329 R5 . Differential pressure across the primary water strainer high.high. if the manufacturer recommends continuous monitoring of dissolved oxygen content in the stator water. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.very low. 15.high.low. KARIMNAGAR DIST.failed. high.low. Conductivity of primary cooling water at the winding inlet high. 16. 8. header water flows. Leakage of hydrogen into primary water . floor-mounted type.1 1.2 1. All the measurements shown in the protection and metering one line diagram TCE. The panels for DC Motor starters shall house stainless steel starting resistors.5960A-EL-SK-2002 shall be made available in DCS and also in Local Control Panel. In addition operator help features for control of these systems and historical and reference data shall also be made available for efficient operator guidance of these systems. TCE. Cubicle and Motor Starters Cubicles shall be furnished as required for (a) Excitation System.1 1.17 1. hydrogen. etc. Measurement / Alarms in Control Room Each alarm shall be individually available on the DCS HMI whereas set of alarms can be grouped into a group alarm on the window of Local Control Panel. (b) Automatic Voltage Regulator (c) Hydrogen Cooling System (d) Seal Oil System (e) Stator Water Cooling System. 329 R5 .17.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 SHEET 31 OF 42 1X 700 MW CCPP AT NEDUNOOR.16 1. lube oil.15.5960A-H-500-001 1. All inputs including logics for recommended control and instrumentation system required to integrate with artificial intelligence based software’s pertaining to generator and its auxiliary system shall be furnished. Stator coolant flow recorder shall be monitored in DCS. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.2 1.17.17. SECTION: D3.16.7 Liquid leakage detector shall be provided at all the low level points inside the generator casing including end shields along with provisions of indication and alarm during leakage of liquid in generator.15. tag numbers. The turbine generator control VDU in the central control room shall have graphical display of various generator subsystems. generator stator and rotor parameters along with display of generator capability curves and operating points. clearly displayed on DCS.4 ISSUE R0 56 TCE FORM NO. The continuous measurement of the rotor winding temperature while the machine is running shall be provided in DCS. generator temperatures and vibration parameters. All the required relays / contacts / devices shall be provided to achieve the same. (f) DC Motor Starters. process/flow diagrams such as seal oil.17. KARIMNAGAR DIST. The panels shall be of the self-supporting. 1.3 1.8 1.16. They shall also have limiting values for alarm/trips. etc. NO. monitoring.18 1. The voltage to frequency ratio of the start-up system output shall be maintained constant throughout the start-up and shall not lead to overfluxing condition of generator transformer and neutral grounding transformer.18. KARIMNAGAR DIST. Also. Both these signals shall be suitably supervised and annunciated. The current transformers (CTs) in the busduct and voltage transformers (VTs) shall not temporarily or permanently saturate even after successive starts through the start-up system. measurement. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. Static start-up system for gas turbine unit complete in all respects shall be offered.17. annunciation. Permanently connected Independent sensing unit for each generator shall be provided. TCE. In case any of the protections are to be blocked during start-up operation due to likelihood of mal-operation. VTs.1 Gas Turbine Generator Unit Start-Up System 2 nos.1 SHEET 32 OF 42 1X 700 MW CCPP AT NEDUNOOR. 1. However evaluation unit for all generators shall be common. NO. It shall also be suitably connected to DCS.18. etc.18.2 1.4 1. the Contractor shall provide suitable blocking and de-blocking signals from the start-up system.5 On line partial discharge measurement system. CTs.. SECTION: D3. synchronising are indicated in I&C System Section No. Minimum electrical system requirements in respect of control.4. Over fluxing shall be limited to 110%. the protections shall not mal-operate during gas turbine starting.5 1.18.18.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 1. Additional thyristors in converter / inverter units to take care of thyristor failure. 1.19 Tests ISSUE R0 57 TCE FORM NO. The Contractor shall note that all the protection shall be set for normal operation of the plant and the settings will not be altered during start-up.6 1. D2. and cut off the start-up system in the event of operation of these protections. redundancy for critical items and self monitoring features. To this extent the Contractor shall provide suitable protections on the start-up system output to protect the generator. Latest software shall be provided to interpret the PD result.3 1. 329 R5 .18. 80% and 60% load. 329 R5 . NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Stator Phase Sequence checking. Overspeed Test Mechanical Run and measurement of Vibrations ISSUE R0 xiii) xiv) xv) 58 TCE FORM NO. AC High Voltage Test on Stator and Rotor Winding Measurement of Rotor Winding Impedance at standstill and at various speeds upto 3000rpm. Measurement of phase to neutral and phase to phase capacitance of all the three phases of the stator and the rotor and calculation of the equivalent generator capacitance as viewed from the generator terminals. Tan-delta measurement of Stator Winding Insulation.1 1.19. short circuit characteristics and calculation of short circuit ratio. KARIMNAGAR DIST. Measurement of Core Losses Measurement of Mechanical Losses Determination of generator efficiency by the separation of losses at 100%. Measurement of bearing leakage current / shaft voltage.5960A-H-500-001 1. SECTION: D3. TCE.1.1 SHEET 33 OF 42 1X 700 MW CCPP AT NEDUNOOR.19. Measurement of the DC resistance of the following: a) Stator Winding b) Rotor Winding c) v) vi) vii) viii) ix) x) xi) xii) Embedded Resistance Temperature Detectors Determination of generator open circuit characteristics. also the measurement of the capacitance between the complete winding and the body.1 Tests on Generator The following Routine Tests shall be carried out at works on each generator: i) Measurement of insulation resistance of the following before and after high voltage test: a) Stator Winding Insulation b) Rotor Winding Insulation c) ii) iii) iv) Embedded Resistance Temperature Detectors d) Bearing Pedestal Insulation Polarisation Index for Stator Winding Insulation. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. These tests will be carried out jointly with the commissioning engineers of other vendors whose equipment are under test. Line charging capacity Short Circuit tests on the generator end and the generator transformer HV end to check the stability and operation of the generator and the overall (i. Open circuit and short circuit tests.19. KARIMNAGAR DIST. after drying out the machine.19. 1.3 One generator of each type and rating shall be assembled at works and shall be tested to verify/ensure design and workmanship in accordance with IEC-60034/VDE-0539/IEEE-43.1.5960A-H-500-001 xvi) Retardation test to establish GD2 xvii) Hydrogen leakage test xviii) Partial discharge tests on stator windings. generator. Performance capability of the machine. The tests shall be carried out keeping all conditions/parameters as close as possible to site conditions with all the built in instrumentation (like RTD etc. Hydrogen leakage test Vibration test Overspeed test Hydraulic tests on coolers Bearing and shaft current test ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) 1. TCE.1 SHEET 34 OF 42 1X 700 MW CCPP AT NEDUNOOR. Measurement of the insulation resistance of bearings Capacitance measurement and dissipation factor between the winding and body.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Measurement of the DC resistance of all windings and embedded temperature detectors. NO. Measurement of temperature rise at the rated load.e. 329 R5 . SECTION: D3.1.) ISSUE R0 59 TCE FORM NO. generator transformer and unit auxiliary transformers) differential protections and negative phase sequence protection.2 The field tests to be conducted on each generator at the site shall include but not be limited to those listed below. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. Any other test considered necessary by the bidder shall also be carried out : i) Measurement of insulation resistance of the stator and the rotor windings to the frame and between phases. and measurement of polarisation index. 1 The following Routine Tests shall be carried out at works on each exciter and AVR: a) Pilot Exciter (PMG) i) ii) Measurement of output voltage at rated speed Checking of phase sequence and measurement of frequency ISSUE R0 60 TCE FORM NO.1 SHEET 35 OF 42 1X 700 MW CCPP AT NEDUNOOR. TCE. Short circuit heat run test at rated pressure and cooling parameters with one cooler out of circuit at two third of rated stator current. The test results of above shall prove that the values are within the normal operating limits for long satisfactory performance and that there are no components or parts. b) Short circuit operation.) shall also be done. c) Sudden short circuit conditions. Recording of bearing and seal oil running conditions and environmental conditions (like temperature etc. Vibration measurement on all planes on stator overhang winding at minimum six (6) locations on each end and at other critical locations for the following conditions : a) Open circuit operation.5960A-H-500-001 suitably wired and the readings recorded. KARIMNAGAR DIST.19. shaft overhang vibrations shall also be measured with and without excitation. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.with hammer test.2 Tests on Exciter and AVR ii) iii) iv) v) 1. 329 R5 . 1. which have natural frequency of resonance near operating frequencies or 100Hz. Determination of Telephone Influence Factor and Total Harmonic Distortion of the voltage waveform.19.2. SECTION: D3. Determination of negative sequence and zero sequence impedance. The tests to be carried out under the contract shall include the following : i) Instantaneous short circuit test shall be carried out to determine transient and sub-transient reactance parameters and to ensure stability of winding during sudden short circuit condition. d) Stand still condition. During various tests bearing. NO. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 .1 SHEET 36 OF 42 1X 700 MW CCPP AT NEDUNOOR.2. NO. SECTION: D3. ISSUE R0 61 TCE FORM NO. Any other test considered necessary by the bidder shall also be carried out : i) ii) iii) iv) v) vi) vii) viii) Accuracy test Sensitivity test Performance tests on all limiters Impulse input response test Auto –1 / Auto –2 channel follow up test Auto – Manual channel follow up test Range of voltage adjustment for both auto and manual channels Functional tests 1.19.2.5960A-H-500-001 iii) Measurement of load characteristics iv) Measurement of insulation resistance and high voltage test on stator winding v) b) Measurement of DC resistance of stator winding Main Exciter (Brushless Exciter) i) ii) Measurement of open circuit characteristics Load magnetisation characteristics iii) Measurement of insulation resistance and high voltage test on armature and field winding iv) Measurement of DC resistance of armature and field winding c) Voltage Regulator i) ii) Response ratio test Insulation resistance and high voltage test iii) Performance test at reduced supply voltage iv) Auto –1 / Auto –2 channel follow up test v) Auto – Manual channel follow up test vi) Thyristor load test (light load test at rated voltage and full current test) vii) Functional tests 1. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.19. KARIMNAGAR DIST.2 The field tests to be conducted on each AVR at the site shall include but not be limited to those listed below. TCE.3 The following type tests on Brushless excitation system of one machine of each rating shall be conducted. KARIMNAGAR DIST. Field Breaker : Type tests on exciter field breaker shall be conducted as per IEEE/ANSI C 37-18.3 The following test to be conducted on startup system a) SFC panels i) Temperature rise test ii) Surge withstand capability test iii) Noise level test b) SFC Transformer The following type tests shall be conducted on one transformer i) Tank Pressure test ii) Tank vacuum Test iii) Short circuit test on one transformer to be selected by Owner. SECTION: D3.1 SHEET 37 OF 42 1X 700 MW CCPP AT NEDUNOOR. b) c) d) e) Voltage Regulator : i) Soak test on electronic equipment ii) Surge withstand capability test on electronic equipment 1. NO.5960A-H-500-001 a) Main Exciter : Temperature rise test at peak rating of excitation system and ceiling duty condition shall also be demonstrated. 329 R5 .19. iv) Noise level v) Measurement of harmonics of no load current ISSUE R0 62 TCE FORM NO. Converter Assembly (of the exciter field) : i) Temperature rise test at peak rating of excitation system and ceiling duty condition shall also be demonstrated.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. PMG : Temperature rise test at peak rating of excitation system shall be demonstrated. ii) Input and output surge withstand capability test. iii) Soak test for electronic modules. TCE. 19.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE. SECTION: D3. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.5960A-H-500-001 vi) PRD operation test vii) Degree of protection test on marshalling box viii) Zero sequence Impedance ( not applicable for Deltadelta transformer) ix) Temperature rise test x) Lightning impulse test on one limb xi) DGA test on oil before and after temperature rise test 1.19. NO. KARIMNAGAR DIST. 1.5 ISSUE R0 63 TCE FORM NO.4 All components of the excitation system shall be tested in accordance with the relevant standards and type and routine test certificates shall be furnished. All Type and Routine test certificates shall be furnished to the Owner for review and approval. 329 R5 .1 SHEET 38 OF 42 1X 700 MW CCPP AT NEDUNOOR. 4 1.5 As per IEC-60034-1 1.3 1. BY DATE TATA CONSULTING ENGINEERS LTD . KARIMNAGAR DIST. of line terminals to be brought out No.85 (lag) to 0.95(lead) 3 As per IEC: 60034-1 1. BY CKD. of neutral terminals to be Nos.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 1.1 By Bidder 50 0.8 1.1 39 OF 42 SPEC.1 1. NO. TCE.11 No. rise limited to that of class B) CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR.12 1.1 SECTION: SHEET D3. DATA SHEET – A3.14 1.BY RKD HA JOB NO. NO.5960A-H-500-001 SL.85 (lagging) 0.13 Rated short circuit ratio at MCR not less than Operation under unsymmetrical fault Class of insulation of generator stator and rotor windings R0 MAR’ 10 PPD. DATE REV. 5960A 0.9 1.10 Star 3000 1. 330 R3 64 REV. DESCRIPTION UNITS VALUES / REQUIREMENTS 1.5 Generator and Excitation System Rated Output Rated terminal voltage Rated frequency (a) Rated power factor (b) Power factor variation No. TCE FORM NO.1. of phases Continuous operation under unbalanced load Stator winding connections Speed Type of cooling (a) Stator Winding (b) Rotor Winding and Stator Core Water Hydrogen rpm Hz Ref clause 1. Three (3) Six (6)-(In case of split brought out phase winding and having more than one conductor per phase or else three (3) ) 1.15 Class F (temp. NO.6 1.7 1. As per IEC 60034 shall meet the requirements as per respective gas turbine and steam turbine sections (Bidder shall indicate) 1. 5960A 1.19 1.24 Space heaters for generator 1. BY CKD.1 SECTION: SHEET D3. BY DATE TATA CONSULTING ENGINEERS LTD . compensators.5 <+0.27 Limiters. Terminal voltage % Manual channel shall follow auto channel within Telephone harmonic factor % 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 40 OF 42 SPEC. NO. monitoring devices for generator excitation system Minimum excitation limiter R0 MAR’ 10 PPD. continuously adjustable Required (to be switched on automatically when turbine is shut down) As per VDE 2063 and shall meet requirements as per respective gas turbine and steam turbine sections.5 Field forcing capability during bolted fault on generator terminals % Type of voltage regulator Minimum 150 Two auto and one manual channel.25 Maximum amplitude of vibrations (peak to peak) 1.0 <0. DESCRIPTION UNITS VALUES / REQUIREMENTS 1.26 Noise level from the surface of equipment 1.BY RKD HA JOB NO.16 Degree of protection for generator enclosure Excitation system response ratio Excitation system response time sec.5 <0. NO.18 1.21 1.27.5 Accuracy of Gen.5960A-H-500-001 SL.17 1. KARIMNAGAR DIST.1 REV.23 1.22 % shall not exceed 1.20 Minimum 2. Solid state. DATA SHEET – A3. DATE Required CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR. IP-54 1. TCE. 330 R3 65 REV. NO. TCE FORM NO. (Bidder shall indicate). 30 C 1.1 SECTION: SHEET D3.3 1.7 1.28 Number of RTDs/Thermo-couples required for generator Efficiency at 100% load at rated power factor Maximum Inlet Temperature of Cooling Water available for Hydrogen / Air coolers Type of cooling water available R0 MAR’ 10 PPD. DATA SHEET – A3.20 1. NO.9 1.5960A-H-500-001 SL.10 1.14 Required 70% of no load to 110% full load of voltage range Ref.27.27.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.4 1.31 REV.27.BY RKD HA JOB NO.5 1.6 1.29 As per IS-4899 350 C 1.1 41 OF 42 SPEC.1. 330 R3 66 REV.27. TCE FORM NO. NO.27.12 Required Required 1. clause 1. KARIMNAGAR DIST. NO.27. DESCRIPTION UNITS VALUES / REQUIREMENTS 1.27.11 Maximum excitation limiter Maximum rotor current limiter Under/over excitation limiter Maximum stator current limiter Cross current compensator Overfluxing (V/Hz) limiter Load angle limiter Transformer drop compensation Power system stabiliser Two stage Field suppression facility Two stage Field earth fault monitor Automatic power factor controller Motorised manual control for remote parallel operation Manual control range of AVR Required Required Required Required Required Required Required Required (adjustable between 0% & 15%) Required Required 1.15 1.27.27.27.13 1. BY CKD.27. DATE DM water CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR. 5960A 0 1.2 1. BY DATE TATA CONSULTING ENGINEERS LTD . TCE.27.27.27.8 1. 1 SECTION: SHEET D3.5 1.1 42 OF 42 SPEC.9 IEC-60034-8 IS-6098 and IEC-60034-9 REV.32. BY DATE 67 TATA CONSULTING ENGINEERS LTD .5960A-H-500-001 SL. TCE FORM NO. TCE.32. 5960A CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR.4 IS-12075 IS-7306 and IEC-60034-4/4A 1.3 IS-7132 1.rating & performance Guide for testing synchronous machines Method of determination of efficiency of rotating electrical machines Measurement and evaluation of vibration of rotating electrical machines Methods for determining synchronous machine quantities from tests Degree of protection provided by enclosures for rotating electrical machines Methods for cooling rotating machinery Terminal markings and direction of rotation of rotating machines Method of measurement of airborne noise emitted by rotating electrical machines IS-4722 and IEC-60034-1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.32. DATE R0 MAR’ 10 PPD. NO.32. KARIMNAGAR DIST.6 IS-4691 and IEC-60034-5 IS-6362 and IEC-60034-6 1. NO.BY RKD HA JOB NO.1 Codes and Standards Specification for rotating electrical machines .32 1. DATA SHEET – A3.32. DESCRIPTION UNITS VALUES / REQUIREMENTS for Hydrogen coolers / Air coolers / water coolers (ordinary water / sea water) 1.8 1. NO.2 1. 330 R3 REV.3 IS-4889 1.32.7 1.32.32. BY CKD.32. Design calculations of support structure shall be furnished for Owner's approval. The Generator circuit breaker shall be integrated with seriesdisconnector. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The GCB movement during short circuit shall be restricted so as to limit the stresses on GCB support insulators within their capabilities. The voltage class of the Generator circuit breaker shall be same as that of the generator. The short time and momentary current rating of the Generator circuit breaker shall be decided as follows: (a) Short time current rating for 1 second: (i) Higher of the short circuit current contribution from generator or the short circuit current contribution from 400 kV system through generator transformer (400 kV system fault level 50 kA) Plus (+) ISSUE R0 68 2. Suitable provisions shall be made for connection with Isolated Phase Busduct (IPB) through flexible connection. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SPEC NO TCE.8 TCE FORM NO. The continuous current rating of the Generator circuit breaker shall be arrived at considering the maximum output of the generator and at specified minimum voltage.. Support structure shall be designed to withstand the dynamic as well as static load of the GCB. all fully assembled on a common frame with operating mechanisms. current and voltage transformers. SECTION: D3. surge arrestors and protective capacitors in three single phase enclosures.2 2. grounding switches.2 SHEET 1 OF 8 1X 700 MW CCPP AT NEDUNOOR. as shown in attached Main one line diagram TCE.0 2. supervisory and control equipment.5960A-EL-SK-2003.1 GENERATOR CIRCUIT BREAKER Generator circuit breaker shall be provided in single phase enclosures.7 2.5 2.6 2. The Generator Circuit Breaker (GCB) is installed indoor / outdoor and connected to Generator busduct (Isolated Phase) on both sides. KARIMNAGAR DIST. 329 R5 .5960A-H-500-001 2.4 2.3 2. 2 SHEET 2 OF 8 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3. 2.11 The GCB shall be of SF6. 2. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. d) Voltage transformers with two secondary windings.9 The basic switchgear module shall include the following minimum equipment but shall not be limited to the same. two per phase on generator side. KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SPEC NO TCE. b) Grounding switches fitted both sides of unit and to all three phases. metal enclosed.5960A-H-500-001 (ii) (b) Contribution of 6. The CTs and VTs shall not temporarily or permanently saturate even after successive starts through the start up system.. indoor / outdoor and free standing type. A manually fitted grounding link for the above short circuiting connection. f) Surge arrestor with surge counter on generator transformer side g) 0.10 The system shall be extended by all of the following items: a) b) c) A switched (motor operated) short circuiting connection between the power circuit breaker and the series disconnector for maintenance and protection checking. a) Circuit breaker with disconnector for series isolation on Generator Transformer side. one per phase on transformer side. It shall be provided with three pole gang operation ISSUE R0 69 TCE FORM NO.25μF surge capacitor on either side of circuit breaker as shown in the Main SLD. 329 R5 .5960A-EL-SK-2003. c) Generator side current transformers with upto two cores per phase towards GT side. An isolator for the SFC connections The accuracies of the CTs & PTs shall be as per the enclosed Main one line diagram TCE. Also.6 kV auxiliary system through unit auxiliary transformers. the protections shall not mal-operate during gas turbine starting. 2. h) Supporting structures and suitable platform. e) Protective capacitors fitted to both sides of the unit and to all three phases. Momentary current rating: 2.55 times the short time current rating arrived as above. .12 The GCB enclosure shall be non-magnetic aluminium alloy. Closure of the disconnector shall establish a three phase short circuit on to the generator connections but without ground to save time. and isolated phase type with degree of protection IP-65 and canopy shall be provided if installed outdoor. Semaphore position indicators shall be provided for local indication of the position of the circuit breaker. A series disconnector shall be fitted on the outgoing side of the circuit breaker and within the same enclosure.14 2. If all the poles do not close simultaneously the breaker shall trip on pole discrepancy. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.15 2. SF6 gas monitor for each phase shall be provided. All the three poles shall operate simultaneously.16 2. It shall be designed with separate contact systems for the current breaking and current carrying functions. 329 R5 . as well as. The Generator circuit breaker shall use SF6 gas both as its arc-extinguishing medium as well as for internal insulation. Grounding switches shall be provided on both sides of the switchgear unit. Necessary interlocks are to be arranged to prevent breaker operation on fall of SF6 gas density. The Main One Line diagram enclosed indicates the relays and meters to be connected to the current transformers and voltage transformers. The short circuiting disconnector and its connections shall be designed to expedite the testing and adjustment of the power plant protection system. fine glazed porcelain or epoxy resin type.18 TCE FORM NO. the fixed contact being on the circuit breaker side of the unit. 2. The connections and the switches shall be rated for full fault current.2 SHEET 3 OF 8 1X 700 MW CCPP AT NEDUNOOR. secondary resistance and the exciting currents of CTs and VA burden of the VTs shall suit the connected metering/protective equipment. knee point voltage.5960A-H-500-001 and anti-pumping feature. both during initial commissioning.13 2. The disconnector shall be of a tubular telescopic unit with the moving contact tube connected on the transformer side. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SPEC NO TCE. minimum flux. when routine testing the protective relaying. SECTION: D3. The ground connections shall be made via the switchgear enclosure to the housings of the isolated phase busbars and then to their grounding connection. KARIMNAGAR DIST.17 2. ISSUE R0 70 2. Insulators shall be of high strength. The VA burden. 5960A-H-500-001 2. The breaker shall have 2 x 100% hydraulic pumps. The stored energy in the spring shall be sufficient to permit at least two close-open operations.. the stored energy shall be suitable for two close open operations. on loss of compressed air supply breaker shall get locked in its current state. status indication. SECTION: D3.23 2.21 2. The minimum number of auxiliary potential free contacts required to be wired up to the terminal strip for PURCHASER’s use after BIDDER’s use in all Control and Protection circuits shall be : 12 NC + 12 NO for Circuit Breaker 8 NC + 8 NO for Disconnector 8 NC + * NO for each Earthing Switch Contact wear monitoring shall also be offered along with the GCB.19 Locking bars or effective mechanical arrangement shall be provided to lock main and auxiliary contact in the open position to prevent inadvertent closing either in main breaker or on disconnecting switch. In case of hydraulic mechanism.22 2.25 2. Capacity of each high pressure receivers shall have stored energy for 2 close-open operations. Duplicate shunt opening release coils suitable for operation with voltage upto 60% of rated voltage of coils along with status monitoring shall be provided. The spring charging motor shall be suitable for 220V DC and shall be fed from respective Unit DCDB. KARIMNAGAR DIST.2 SHEET 4 OF 8 1X 700 MW CCPP AT NEDUNOOR. alarm and annunciation of the breaker and all auxiliary equipments shall also be located in local control panel. In case of pneumatic operating mechanism compressed air plant shall be provided with 2x100% compressors. Local control panel shall include a Local/Remote selector switch. 2. The bidder shall clearly bring out the details in respect to this offer. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.24 2. ISSUE R0 71 TCE FORM NO.26 Local control panel shall be provided near GCB to facilitate Local ON/OFF Control.20 2. Capacity of local air receivers shall meet one close-open operation. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SPEC NO TCE. The operating mechanisum shall be spring operated both for closing and tripping operations. If the offered breaker is pneumatic operated then. Driers shall also have same capacity. 329 R5 . The spring charging motor shall be capable of charging the spring within 30 secs. . ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.2 SHEET 5 OF 8 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SPEC NO TCE.5960A-H-500-001 2.27 The GCB shall be suitable for synchronizing duty and capable of withstanding out of phase voltage across open contacts. The breaker shall also be capable of switching on to a fault and out of phase switching. Main contacts shall have ample area and contact pressure for carrying the 2.28 rated current and the short time rated current of the breaker without excessive temperature rise which may cause pitting or welding. Contacts shall be easily replaceable and shall have a minimum of movable parts and adjustments to accomplish these results. Main contacts shall be the first to open and the last to close so that there will be little contact burning and wear. 2.29 Arcing contacts, if provided, shall be the first to close and the last to open and shall be easily accessible for inspection and replacement. Tips of arcing and main contacts shall be silver faced or have tungsten alloy tipping. The operating mechanism and associated accessories shall be enclosed in weather proof mechanism cabinet of hot dip galvanised sheet construction, thickness of which shall not be less than 2 mm. Hinged doors giving access to the mechanism at the front and sides shall be provided. Suitable gaskets shall be provided to make the mechanism housing water-proof and dust-proof. The housing latch shall accommodate padlock requiring a 12 mm diameter hole. Padlock and duplicate keys shall be included in the BIDDER's scope of supply. Working parts of the mechanism shall be of corrosion resisting material. Bearings which require grease shall be equipped with pressure type grease fittings. Bearing pin, bolts, nuts and other parts shall be adequately pinned or locked to prevent loosening or changing of adjustment with repeated operation of the breaker. Provision shall be made for connecting travel recorder to perform speed test of breakers at site. Motor operated mechanism shall be provided for Disconnectors & Earth switches with suitable Electrical & Mechanical interlocks. Normal operating mechanism shall also be provided for emergency purpose. The operating mechanism offered for GCB shall be in service for a minimum of 2 years in any of the power plant with trouble free operation. ISSUE R0 72 2.30 2.31 2.32 2.33 2.34 TCE FORM NO. 329 R5 . ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.2 SHEET 6 OF 8 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SPEC NO TCE.5960A-H-500-001 2.35 SF6 density monitoring, alarm on low density and close & Trip blocking on very low density shall be provided. Tests All acceptable & routine tests as per IEC-60056 and IEEE Std C37.013a-2007 standards shall be conducted on all the equipment/components of each of the generator circuit breaker. a) Power frequency voltage withstand dry tests on the main circuit. b) Voltage withstand tests on control and auxiliary circuits c) Measurement of the resistance of the main circuit. d) Mechanical operating tests. e) Design and visual checks. 3.0 3.1 3.2 Following type tests shall be conducted on each type & rating of the equipment. a) Rated dielectric strength tests (i) (ii) Rated low frequency withstand voltage dry test. Rated full wave impulse withstand voltage test. b) Short circuit rating and transient recovery voltage tests (i) Test for rated symmetrical short circuit current interrupting capability, duty cycle and rated transient recovery voltage parameters. Test for rated closing, latching and short time current carrying capability. Test for rated Generator source asymmetrical short circuit interrupting capability. (ii) (iii) d) e) Load current switching test Out of phase switching current tests ISSUE R0 73 TCE FORM NO. 329 R5 . ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.2 SHEET 7 OF 8 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SPEC NO TCE.5960A-H-500-001 f) g) Rated excitation current switching tests. Type tests and oscillographic test records for closing and tripping timings for generator circuit breaker of the rating offered. 3.3 Test reports for the following type tests shall be submitted for each type & rating of equipment: a) b) c) Rated continuous current carrying tests Mechanical endurance life tests. Noise level tests. ISSUE R0 74 TCE FORM NO. 329 R5 . ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SECTION: D3.2 SHEET 8 OF 8 SPEC NO TCE.5960A-H-500-001 Technical Parameters GCB shall comply with the technical particulars given below and the Contractor shall furnish the details wherever indicated as ‘*’. Sl. No. (a) Make (b) Description Unit * IEEE(ANSI) std C37.013a2007 , IEC60056 (1987), IEC 60694 (1980) & IEC 60298 (1990), IEC-60529, IEC60129, BS-5169 & BS-5500 Bidder to indicate 50 Bidder to indicate Bidder to indicate Bidder to indicate Bidder to indicate IP 54 IP 65 CO-30 min-CO Opaline Green(external) , Semi Glossy white (internal) Technical Particulars Applicable Standards (c) (d) (e) (f) (g) (h) (i) Voltage rating Frequency Rated current Rated short circuit breaking current Rated short time withstand current for 1 sec. Rated short circuit making current Degree of protection • Control cubicles and drives • Enclosure Duty Panel paint shade kV Hz A kA kA kAp (j) (k) ISSUE R0 75 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.3 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 1 OF 11 SPEC. NO. TCE.5960A-H-500-001 3.0 GENERATOR TRANSFORMERs (GTs) The generator transformer (GT) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet – A 3.3. Also, the GT and its accessories shall comply with the requirements indicated in Data Sheet – A 3.3 and specific requirements indicated below. 3.1 The MVA rating of the Generator Transformers (GTs) shall be sufficient to evacuate power generated by the respective gas turbine generators and steam turbine generators. The GT shall be so sized as to be able to evacuate power from the GTG / STG to which it is connected without exceeding the average winding temperature of 870C and hot spot temperature of 980C over the entire range of site ambient temperature as specified in Section - B of this specification. The GT shall be with voltage ratio of generator voltage / 420kV, two winding, 3 phase, 50 Hz, ONAN/ONAF/OFAF cooled transformer, with On Load Tap Changer with +10% to –10% in steps of 1.25% on the HV side. Three (3) of 50% capacity separately mounted radiator banks shall be provided. Each bank shall be provided with adequate number of fans and pumps and one oil pump and one fan spare. Each radiator bank shall be provided with uni-directional bypass valve to permit oil to bypass the pump in the event of pump failure. It shall be possible to completely isolate any one of the radiator banks for maintenance, while the transformer is in service. Flexible expansion joints, one each, on top and bottom pipe connections for each radiator shall be provided. Each radiator bank shall have atleast two (2) extra radiators to facilitate usage of the same in case of leakage in the other radiators. If radiators are arranged in groups, each group of radiator shall have upper and lower shut-off valves with blanking at either ends. Control scheme shall be suitable for both manual and automatic operation of each group of fans and oil pumps. Electrical Performance The transformers shall operate without injurious heating at the rated MVA at any voltage within ±10% of the rated voltage of that particular tap. 3.2 3.3 3.3.1 ISSUE R0 76 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.3 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 2 OF 11 SPEC. NO. TCE.5960A-H-500-001 3.3.2 The transformer shall be designed to deliver rated MVA continuously even at the lowest tap without exceeding specified temperature rise. The transformer shall be capable of remaining in operation without injurious heating at full load atleast 10 minutes when complete forced cooling equipment has failed. The dynamic ability to withstand short circuit shall be demonstrated by the Contractor by calculations. Generator transformers shall be suitable for back charging. It shall also be capable of being charged from HV side through circuit breakers without pre-insertion resistors and kept charged continuously with no load on the LV side without any adverse impact on the transformer life. Generator transformers shall be suitable for bi-directional power flow. Bidder shall furnish the guaranteed loss values of Transformer. 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 3.3.8 3.4 3.4.1 3.4.2 Constructional Features Bell type design shall be adopted for transformer tank. The magnetic circuit shall be constructed from high grade cold rolled non-ageing grain oriented silicon steel laminations. The flux density shall not exceed 1.7 Wb/m2 at rated voltage and Current density shall not exceed 3 A/mm2. For generator transformers the insulation of core to bolt and core to clamp plates shall be able to withstand a voltage of 10 kV rms for 1 minute. The windings shall be made of electrolyte grade copper. Tank shall be made of good commercial grade low carbon steel and shall be of welded construction. The tank of the transformer along with radiators, conservators, bushings and other fittings shall withstand full vacuum of 760 mm ISSUE R0 77 3.4.3 3.4.4 3.4.5 3.4.6 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.3 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 3 OF 11 SPEC. NO. TCE.5960A-H-500-001 of Hg while filling the oil under vacuum and also an excess internal pressure of 0.35 kg/cm2. 3.4.7 Tank shields shall be such that no magnetic fields shall exist outside the tank. They shall be of magnetically permeable material. If required, impermeable shields shall be provided at the coil ends. Tank shield shall not resonate when excited at the natural frequency of the equipment. Contractor shall conform use of tank shields in the additional information scheme. Bushing shall be of porcelain. No arcing horn to be provided. For 52 kV and above, bushing shall be oil filled porcelain condensor & non-oil communicating type with following fittings: i) ii) iii) 3.4.9 Oil level gauge Oil filling plug and drain valve if not hermetically sealed Tap for capacitance and Tan delta test 3.4.8 Bushing below 52 kV shall be soild porcelain/condensor/oil communicating type. Bushing CT’s shall be of adequate rating for protection as required, WTI etc., These CT’s shall be mounted in the turret of bushing. Busduct termination shall be suitable for high air temperature inside the bus duct and shall be provided with draining arrangement as lowest point for leaked oil / water. Fire protection system shall be provided for the GTs as per the requirement specified under relevant fire and safety codes/standards, TAC guidelines and as specified under section D1.11 of this specification Fittings and Accessories Transformers shall be provided with all accessories like, but not limited to inspection manholes / handholes, lifting lugs, jacking pads, bi-directional flanged wheels, haulage lugs, skids, earth pads, neutral earthing downcomers (2 nos.) supported on pin insulators, terminal marking, rating and diagram plates, marshalling boxes, conservators (breatherless) (flexible oil resistant air bag), valves for various purposes including draining, filtering, filling, ISSUE R0 78 3.4.10 3.4.11 3.4.12 3.4.13 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.3 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 4 OF 11 SPEC. NO. TCE.5960A-H-500-001 double float buchholz relay, oil and winding temperature indicators with high and very high contacts, magnetic (150 mm dia) and prismatic oil level gauges, anti-earthquake clamping arrangement, tank mounted radiators with accessories, and pressure relief valve (Min. 02Nos. & the adequacy of the number of PRDs and their location shall be established for any location of the fault inside the tank). 4-20mA signal for remote WTI & OTI. It shall be a repeater of local WTI & OTI. 3.4.14 On-line Gas Extractor Analyser shall be provided for each Generator transformer. It shall be hooked up to the plant DCS. A device for measuring the hot spot temperature of the winding shall be provided. 3.4.15 3.4.16 For Top oil temperature measurement & Winding temperature measurement RTDs / transducers shall be provided for remote indication in SCADA. 3.4.17 3.4.18 3.4.19 3.4.20 A flexible oil resistant air bag shall be provided in the conservator to prevent the air from coming into contact with the oil. Suitable shock recorders to record maximum shock forces during shipment/ transport shall be provided. A set of hydraulic jacks suitable for the transformers under supply. Transformer oil shall be supplied in non-returnable oil drums ( with 10% extra oil). 3 Nos., 20 KLitres capacity Transformer oil tank and 1 No. 6 KLitres Transformer oil filter machine of reputed make approved by Owner shall be supplied. Impact recorder shall be provided to monitor the impact during transport on returnable basis. Transformer shall be transported with tank filled with pure inert gas at pressure of 2 – 2.5PSI. The temperature and pressure at the time of gas filling shall be marked. Necessary accessories including filled replenishment N2 shall be maintained at site also till the transformer is filled with oil. Two auxiliary power supplies, 400 V, 3 phase, 3 wire shall be drawn from two separate boards for the cooler control cabinet and OLTC cubicle. Cooler control equipments shall be divided in to ISSUE R0 79 3.4.21 3.4.22 3.5 TCE FORM NO. 329 R5 relays etc. Be equipped with separate conservator for OLTC oil temperature and oil surge relay with contacts. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 5 OF 11 SPEC. NO. All cooling equipment trouble shall be indicated in local control panel with repeat alarm in main control room. thermal overload.7.5960A-H-500-001 two halves. 3. Block reverse tap change command during the forward tap change in progress. and also for failure to transfer. On Load Tap Changer (OLTC) The OLTC gear shall be designed to complete successfully tap changes at 150% of rated current.f. Be such that the oil in the compartment containing making and breaking contacts does not mix with oil in other compartment of OLTC or transformer tank. 329 R5 .1 3. The OLTC gear shall withstand through fault current without injury. loads shall be automatically transferred to other. The tap range shall be decided based on the voltage profile of the grid and following shall be complied with / provided.7 3. It shall permit operation of generator at full load and at rated terminal voltage & p. KARIMNAGAR DIST. single phase preventer and short circuit protection. Cut off of power supply when manual handle is inserted. TCE. starter. In case of one power supply failure.6 Each cooling fan and pump motor shall be provided with isolating switch. Status of each cooler fan/pump shall be available in DCS.7. Devices shall be incorporated to prevent tap change when the through current is in excess of the safe current that the tap changer can handle.2 (b) (c) (d) (e) ISSUE R0 80 TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. independent of power supply. Indications are to be provided at cooler control cabinet and at OLTC cubicle along with remote annunciation in DCS for failure of normal source and for transfer to standby source. 3. with remote annunciation in DCS. over the entire range of variation of grid voltage: (a) Complete its operation once commenced. Separate on/off switch for each incoming power supply with MCCB shall be provided. each having one power supply incomer with bus section between two halves.3 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3. 3 1X 700 MW CCPP AT NEDUNOOR. 329 R5 .8 3. SECTION: D3. relays as required. KARIMNAGAR DIST. A sheet steel. The degree of protection shall be IP 55. TCE. Be equipped with automatic and manual operation facility including hardware.1 Tests Following type tests and special tests as per IS 2026 (revision as applicable on date of submitting of offer) shall be conducted on one transformer : ISSUE R0 81 TCE FORM NO. (g) (h) (i) (j) 3. Be provided with necessary initiating contacts for annunciation of any abnormal condition in DCS and grouped alarm in control desk. Be equipped with Digital type tap position indicator with inbuilt transducer for repeating the tap position in DCS. NO.8.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 (f) Remote and local electrical operation & tap position indication. All wiring for remote connection for OLTC control / indication / annunciation from OLTC cabinet shall be terminated in Marshalling box by providing separate terminal block. dust and vermin proof marshalling box shall be provided for each transformer and shall be provided with thermostatically controlled space heaters. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 6 OF 11 SPEC. (a) (b) (c) (d) (e) (f) (g) Impedance voltage shall be measured at principal and at all the taps No load loss and exciting current shall be measured at rated frequency at 90%. Dissolved gas analysis of the oil. Determination of cooler losses.3 1X 700 MW CCPP AT NEDUNOOR. 100% and 110% rated voltage Calibration of temperature indicators and relays Impulse test on GTs shall include chopped wave test Sweep Frequency Response Test at factory and at site Magnetic balance test. (b) Vacuum withstand and deflection measurement on tank and radiators.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (h) Oil leakage test – 12 hours (this test to be conducted after heat run test). (i) 3. 329 R5 . The following additional routine tests on each of the transformer shall be conducted. TCE.2 Auxiliary power measurement. ISSUE R0 82 (h) TCE FORM NO. before and after the temperature rise test. NO. Pressure test on PRD. KARIMNAGAR DIST.8. Partial discharge test. Short circuit impedance of each limb with single phase voltage from each HV & LV sides. Measurement of tan delta and capacitance of each winding and bushing. (c) (d) (e) (f) (g) Pressure test on tank with deflection measurement. SECTION: D3. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 7 OF 11 SPEC.5960A-H-500-001 (a) Temperature rise test. All routine tests as per IS : 2026 shall be conducted on each of the transformer. Radio influence voltage. 4. Core isolation test Noise level measurement ACSD & ALD as per standards Minimum electrical system requirements in respect of control. liquidated damages based on the charges indicated in Data Sheet A3. The following calculation shall be furnished for Owner’s approval: a) OLTC recovery voltage calculations in case of buck and boost type of OLTC (wherever applicable) Transfer surge calculations Short circuit withstand calculations 3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. the quoted load losses and iron losses shall be included to take into consideration tolerance as permitted by applicable standards. NO.5960A-H-500-001 (i) (j) (k) (l) 3.3 1X 700 MW CCPP AT NEDUNOOR.11 3. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 8 OF 11 SPEC.3 3.9 Measurement of zero sequence impedance. annunciation.3 For the purpose of evaluation of Bids. the VENDOR shall pay to the PURCHASER.11. TCE. SECTION: D3. D2.2 3.1 Evaluation of Bids Bids will be evaluated based on the formula furnished in Data SheetA3. Liquidated Damages for Non-Performance Should the losses as measured on the transformer after manufacture be found to be in excess of the guaranteed losses including tolerance.11. monitoring.12 ISSUE R0 83 TCE FORM NO. KARIMNAGAR DIST. measurement. synchronising are indicated in I&C system Section No.10 b) c) 3. if any. 329 R5 . 2 1. Two winding. 1.6 LV 0 * / * C 50 Maximum temperature rise of oil at 110% of full load for 24 hrs. 330 R3 84 . BY OLTC + 10% to – 10% 1.8.1 DESCRIPTION Generator Transformers Type MVA Rating UNITS VALUES / REQUIREMENTS Outdoor.2.1.3 GENERATOR TRANSFORMER SECTION: D3. DATA SHEET – A3.3 SHEET 9 OF 11 SPEC NO: TCE. NO.8. DATE REV. BY CKD.1 1.1 1.7 0 C 55 1.4 REV.2.2 / 50 microsecond) / power frequency withstand voltage windings HV 1425 kVp / 630 kV (rms) 1. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.5 Impulse (1.4 Winding connections HV LV Vector Star Delta Ynd1 1.1 1. KARIMNAGAR DIST.BY DATE RKD HA 1.3 1. Tapping particulars Type Tap range Tapping step Category of voltage variation R0 JUNE’ 10 PPD.25% CFVV JOB NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Maximum temperature rise of winding at 110% of full load for 24 hrs. TCE FORM NO.2 1. 3 phase MVA 315MVA for GTG (tentative).8. 340MVA for STG (tentative) 1.5960A-H-500-001 SL.0 1.3 Cooling method ONAN ONAF OFAF Overfluxing capability 60% 80% 100% 110% for continuous 125% for 1 minute 140% for 5 seconds 1.8.3 1.2. NO.8 1.2 1. 4 1.10 1.9.1 1.13. .13.1 1. 2./ 3400 mm / --.3 GENERATOR TRANSFORMER SECTION: D3.12 1.12.000 B = 2.000 C = 2.2 1.mm Opaline Green Not to exceed values specified in NEMA TR1 1.80.32000 1.9.3 1.60.9.80. NO. 3.6 REV.BY DATE TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD./ . 1.11 1.12.3 1.9 1.8.13. BY CKD.13./ 36 kV IS : 2099 25 mm / kV 4200 mm / -.2 Rates of liquidated damages for exceeding the guaranteed losses No load loss Load loss Load loss Rs/kW Rs/kW Rs/kW A = 3.32000 / kW 1.60.13.3 SHEET 10 OF 11 SPEC NO: TCE.1 Paint shade Noise level Loss evaluation formula Formula for evaluation of Bids Evaluated price + (A x guaranteed no-load loss in KW) + (B x guaranteed load loss in KW) + (C x guaranteed cooler loss in kW) A = Rs.000 / kW C = Rs. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.13 1.5 1.000 / kW B = Rs. NO. 2.5 1.9.13.2 1. KARIMNAGAR DIST.5960A-H-500-001 SL.4 DESCRIPTION Tapping power Bushing particulars Voltage class HV / LV / HV (n) Standard applicable Creepage distance Clearance in air (a) (b) Phase-phase-HV/LV/HV(n) Phase-earth-HV/LV/HV(n) UNITS Full VALUES / REQUIREMENTS 420 kV / --. DATE REV. BY Applicable codes and standards Power transformer Fittings and accessories Loading of oil immersed transformers Oil Bushings Degree of protections R0 JUNE’ 10 PPD. DATA SHEET – A3. 330 R3 85 IS : 2026/IS:6600/IEC:60076 IS : 3639 IS : 6600 IS : 335 / IEC:60296 IS : 2099 / IEC:60185 IS : 2147 RKD HA JOB NO. 3 SHEET 11 OF 11 SPEC NO: TCE.13.13.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. DATA SHEET – A3.7 1.8 1. 330 R3 86 . NO.3 GENERATOR TRANSFORMER SECTION: D3. DATE REV.13. BY CKD.13. BY R0 JUNE’ 10 PPD. 1. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.10 Tests DESCRIPTION UNITS VALUES / REQUIREMENTS IS : 2026 IS : 2026 IS : 3637 Tolerance on guaranteed particulars Buchholz relay Electrical insulation classified by stability thermal IS : 1271 REV. TCE FORM NO.9 1.BY DATE RKD HA JOB NO.5960A-H-500-001 SL. KARIMNAGAR DIST. 4.ANDHRA PRADESH POWER DEVELPOPMENT COMPANY LTD. 50 Hz.9kV. 329 R5 . three phase. The Contractor shall provide the design calculations for arriving at the capacity of UAT during detail engineering stage.2 4. the same can be separately mounted.0 UNIT AUXILIARY TRANSFORMER (UAT) The Unit Auxiliary Transformer (UAT) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet .1 MVA rating UAT Each UAT shall be able to supply (100%) auxiliary running load of 700 MW power plant.20 4.1.4 4.3 4.1 UAT shall be a * MVA.25% on HV side (*By Bidder). Also.4. Additional margin of 10% shall be kept over & above all the loads due to variation in the loads i. TCE-5960A-H-500-001 4. It shall be able to start the largest motor at 80% base load. ISSUE R0 87 4. two winding.3.3 shall be conducted on UAT.3 TCE FORM NO. 110% of the complete station load. the UAT and its accessories shall comply with the requirements indicated in Data Sheet–A3.NO.1 4.4 and specific requirements indicated below: 4. ELECTRICAL SYSTEMS UNIT AUXILIARY TRANSFORMERS SPEC. Impedance The impedance of the transformers at taps corresponding to nominal transformation ratio (primary taps) shall be selected keeping in view the short circuit level of the 6. The tank cover for the UAT can be of conventional type.3 except for the following variations. Each radiator bank shall have at-least two extra radiators for use in case of leakage in any other radiator. ONAN/ONAF cooled transformer with *% impedance with OLTC ±10% in steps of 1. */6.4.A 3.2 4.4 SHEET 1 OF 3 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3.1 4. The UAT shall be provided with 2 x 50% detachable built on radiator banks and if it is not possible to have built on radiator banks.e. Specific Requirements The unit auxiliary transformers shall comply with the specific requirements indicated in Section D-3. KARIMNAGAR DIST. All tests specified in Section D-3.1.6kV system shall be suitable for medium resistance earthing with earth fault current limited to 300A.4.4. 6.6 kV and 400 V switchgear & the voltage dip at motor terminals not exceeding the limits specified in Section D 3.1. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. DATA SHEET – A 3.4 UNIT AUXILIARY TRANSFORMER SL. NO. 1.0 2.0 Type No load voltage - HV - LV 2.1 3.0 Rating on ONAF Cooling method (a) (b) 4.0 ONAN ONAF % % 80% 100% kV kV MVA DESCRIPTION UNITS SECTION : D 3.4 SHEET 2 OF 3 SPEC NO. . TCE-5960A-H-500-001 VALUES / REQUIREMENTS UAT Outdoor, two winding * 6.9 28 ( tentative) Overfluxing capability 110% continuous, 125% for 1 minute, 140% for 5 seconds 5.0 Winding connections HV LV Vector group Delta Star Dynll 6.0 Impulse (1.2 / 50 microsecond) / power frequency withstand voltage windings HV LV HV (n) 0 */* 60 kVP / 20 kV (rms) --C C 50 55 7.0 8.0 9.0 Maximum temperature rise of oil Maximum temperature rise of winding Tapping particulars (a) (b) (c) (d) (e) Tap Tapping range Tapping step Category of voltage variation Tapping power 0 ON LOAD CIRCUIT TAP CHANGER % % ±10% 1.25 - 10.0 Bushing particulars (a) Voltage class HV / LV / HV (n) / tertiary R0 PPD. BY RKD JUNE’ 10 CKD.BY HA DATE TCE FORM NO. 330 R3 88 * / 7.2 kV / JOB NO. 5960A CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR, KARIMNAGAR DIST. REV. NO. DATE REV. BY ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. DATA SHEET – A 3.4 UNIT AUXILIARY TRANSFORMER SL. NO. DESCRIPTION UNITS SECTION : D 3.4 SHEET 3 OF 3 SPEC NO. . TCE-5960A-H-500-001 VALUES / REQUIREMENTS (b) (c) Standard applicable Creepage distance IS-2099 31 mm / kV based on line to line highest system voltage (d) Clearance in air (i) (ii) Phase-Phase-HV / LV Phase-Earth-HV/LV/HV(n) * / 127 * / 127/Opaline Green Not to exceed values specified in NEMA TR-1 11.0 12.0 13.0 13.1 Paint shade Noise level Loss evaluation formula Formula for evaluation of Bids Evaluated price + (A x guaranteed no-load loss in KW) + (B x guaranteed load loss in KW) + (C x guaranteed cooler loss in kW) A = Rs. 3,80,000 / kW B = Rs. 2,60,000 / kW C = Rs. 2,32000 / kW 13.2 Rates of liquidated damages for exceeding the guaranteed losses No load loss Load loss Load loss Rs/kW Rs/kW Rs/kW A = 3,80,000 B = 2,60,000 C = 2,32000 Note: - (*) By Bidder REV. NO. DATE REV. BY R0 JUNE’ 10 PPD. BY CKD.BY DATE RKD HA JOB NO. 5960A CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3 89 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.5 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS SHEET 1 OF 15 SPEC. NO. TCE.5960A-H-500-001 A) ISOLATED PHASE BUS DUCTS (IPBD) The Isolated phase bus duct (IPBD) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet – A 3.5 IPBD. Also, the IPBD and its accessories shall comply with the requirements indicated in Data Sheet–A 3.5 and specific requirements indicated below: 5.1 Isolated phase bus duct forming the main current carrying leads shall be used in following circuits: Generator phase side terminals to respective GCB, GCB to Generator transformer LV terminals for GTG and generator phase side terminals to generator transformer LV terminals in the case of STG. Tap-off bus duct for Unit Auxiliary Transformers in the case of GTG. Tap-off bus ducts for VT and SP cubicle, static excitation transformer (if applicable) Bus duct to generator neutral side terminals to neutral grounding equipment panel, which shall house a neutral earthing transformer and neutral earthing resistor. The CTs etc., to be located in the Isolated phase bus duct shall be as per the enclosed Main one line diagram – Drg. No. TCE.5960A-EL-SK-2003. Current transformers as required shall be located in the above bus duct. If the generator transformer is three numbers single phase units, then the delta formation of the LV Windings shall be carried out with Isolated Bus Duct. The voltage class of the bus duct shall be as follows: Generator voltage (a) Upto 12 kV (b) More than 12 kV upto 21 kV Bus duct voltage class 12 kV 24 kV 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.1.6 5.1.7 5.2 Sizing and Design ISSUE R0 90 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.5 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS SHEET 2 OF 15 SPEC. NO. TCE.5960A-H-500-001 5.2.1 Sizing of the bus duct shall be arrived based on the continuous and short time rating of the respective circuit. The continuous current rating of the main (generator) bus duct shall be arrived at considering the maximum output of the generator and at specified minimum voltage. Short time current rating of the main busduct shall be for 1 second and shall be decided as follows:. (a) Higher of the short circuit current contribution from generator OR the short circuit current contribution from 400 kV system through generator transformer (400 kV system fault level 50 kA) Plus (+) Contribution of 6.6kV auxiliary power supply system through UAT. (b) Momentary current rating shall be 2.55 times the short time current rating arrived as above. 5.2.2 5.2.3 5.2.4 The short time and momentary current rating of all tap-off bus ducts (to VT and SP cubicle) shall be as follows: (a) Short time current rating for 1 second: (i) Short circuit current contribution from generator Plus (+) (ii) Short circuit current contribution from 400 kV system NOTE: Negative tolerance allowed in the standards shall be considered for generator and generator transformer impedance for calculation of short time ratings in clauses 5.2.3 and 5.2.4 above. 5.2.5 The bus duct shall be designed to withstand the internal or external forces resulting from the following: (a) (b) Normal operating conditions Momentary short circuit currents ISSUE R0 91 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.5 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS SHEET 3 OF 15 SPEC. NO. TCE.5960A-H-500-001 (c) Rigorous / adverse weather conditions as detailed in project information section B Seismic forces as detailed in project information section B. (d) 5.2.7 The degree of protection shall meet the requirements of water and air tightness test specified in IS-8084 and the degree of protection shall be IP-55 or better. The outside of the busduct shall be painted with 631 of IS-5. Specific Requirements The bus enclosure shall be of continuous bonded type. The material of bus conductor & enclosure for main run shall be Al alloy grade 19501 (H2) of IS-5082. The material of bus conductor for tap-off shall be Al alloy grade 63401 WP (range 2) & for enclosure material shall be Al alloy grade 19501 (H2). Inspection covers for periodic inspection of the insulators shall be provided. There shall be no joints or fixing bolts on top of the enclosure through which water can seep. The outdoor portion of the bus duct shall take into account heating effect due to solar radiation and shall be provided with a continuous rain hood of non-magnetic material suitably supported from the bus duct support structure. The bus conductor shall be given a coat of matt black paint to facilitate heat dissipation. However, the sizing of the bus conductor shall consider the conductor as bare. The process of silver plating shall be approved by the owner. Each phase shall be enclosed in weatherproof, dust tight, non-magnetic metal enclosure. The enclosure shall be designed for welded connections. The enclosure shall be of minimum flux type to permit not more than five (5) percent of total, magnetic flux outside enclosure. The enclosure shall be insulated at the connections to various equipment so that the longitudinal current will not flow through or be transmitted to any connecting equipment. The insulation shall be nondeteriorating and shall be clearly indicated on the Contractor’s drawings. ISSUE R0 92 5.3 5.3.1 5.3.2 5.3.3 5.3.4 5.3.5 5.3.6 5.3.7 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.5 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS SHEET 4 OF 15 SPEC. NO. TCE.5960A-H-500-001 5.3.8 The Contractor should ensure that no load is transferred on electrical equipments transformers, generator terminals etc. by the busducts. The bus conductor shall be designed for welded connections except at equipment terminations, bolted disconnect links, and bolted flexible. Detailed welding procedure adopted by the manufacturer should be furnished along with the offer and approved by the Owner. Flexible connections shall be provided between bus sections to allow for expansion and contraction of the conductor. Flexible connections shall also be provided at all equipment terminations. The bus support insulators shall be mounted on resilient pads. The bus support insulator shall be interchangeable, high strength & fine glazed porcelain manufactured by wet process or high strength epoxy resin cast. The voltage rating shall depend upon generation voltage. The spacing of the bus support insulators shall be considered by giving due factor of safety to withstand the forces due to the momentary short circuit assigned for the bus duct. Wall frame assembly and seal-off bushings shall be provided where the bus duct passes from indoor to outdoor area to prevent condensation due to air temperature variation between indoor and outdoor portion. Wall frame assembly shall be fabricated out of aluminium angles and sheets. It shall be ensured that no load of the bus duct is imparted on the walls. The bus duct supports shall be fabricated from standard steel sections. The support structures shall be hot dip galvanised. Thermostatically controlled space heaters shall be provided along the length of the bus duct. Duplex RTD shall be provided for measurement of ambient air inside the bus duct. The same shall be hooked upto the DCS. The equipment terminal connections shall be readily accessible and shall provide sufficient air gap for safe isolation of requirement during electrical testing. 5.3.9 5.3.10 5.3.11 5.3.12 5.3.13 5.3.14 5.3.15 5.3.16 5.3.17 5.3.18 ISSUE R0 93 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.5 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS SHEET 5 OF 15 SPEC. NO. TCE.5960A-H-500-001 5.3.19 If the material of bus conductor and that of the equipment terminal is different, then suitable bi-metallic connectors shall be provided by the Contractor. The electrically continuous bus enclosure shall be used as the grounding bus. All parts of the bus enclosure, supporting structure and equipment frames shall be grounded to earthing mat. Neoprene Rubber bellows shall be provided at the termination point of the bus duct at various equipment. Rubber bellows shall also be provided in the run of the bus duct after gas turbine generator foundation block to avoid transfer of vibrations of GTG pedestal. In case of rubber bellows at intermediate locations flexible braids copper connection, shall be provided across the bellows to establish continuity of bus duct from end to end. Provision shall be made in bus duct at an approved location for installation of shorting bar having rated current carrying capacity same as that of main bus duct for carrying out generator stator dryout. A set of shorting bar along with requisite hardware shall be supplied for this purpose. A set of shorting bars along with requisite hardware shall be supplied for this purpose. Disconnecting links with rating same as that of the main bus conductor shall be provided in the run of the bus duct as required to facilitate disconnection of the bus conductor during testing. The IPBD shall be of natural air cooled type. Silica gel filters shall be provided both in indoor and outdoor portions of the bus duct for absorption of moisture. Seal off bushings (a) Seal-off bushings shall be provided at the entry of tap-off bus duct to the VT and SP cubicle, static start-up, unit auxiliary transformers, neutral grounding cubicle, etc. One set of seal-off bushings shall be provided in the bus duct after the generator bushings to prevent hydrogen leakage into the bus duct. Arrangement shall be provided to vent the trapped hydrogen in the portion between generator bushings and these seal off bushings (applicable for hydrogen cooled generators). 5.3.20 5.3.21 5.3.22 5.3.23 5.3.24 5.3.25 (b) 5.3.26 Two numbers earthing terminals with bi-metallic connectors shall be brought out at termination points of the bus duct, main and cross ISSUE R0 94 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.5 1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS SHEET 6 OF 15 SPEC. NO. TCE.5960A-H-500-001 supporting structures, terminal boxes, adapter boxes, unit auxiliary transformer, VT and SP cubicle, etc., and for further connection to earthing grid. 5.3.27 5.4 5.4.1 5.5 All steel supporting structures and hardware shall be hot dip galvanised after fabrication. Pressurisation System Not used. Current Transformer The current transformers shall be epoxy cast-resin, single core ring type, mounted within the bus duct enclosure and suitable for operation at an ambient temperature existing within the bus duct enclosure which may be in range of 900C to 1000C. Mounting arrangement of CT shall be so designed so as to avoid equalizing connections between live conductor and CT inner surface. CT secondary leads shall be brought out through non-magnetic metallic conduits to a marshalling box (MB) with degree of protection IP-55 (IS:13947 Pt.1). The MB shall be provided with removable aluminium gland plate. The facility for shorting and grounding shall be provided at the terminal blocks. All CTs shall be tested for partial discharge. The partial discharge at 10 percent over voltage of the highest system voltage shall not exceed 50 pico coulombs. Arrangement shall be made to maintain potential of inner surface of busduct CTs at the same value as the conductor to prevent partial discharge. Protection CTs shall be rated for 5A secondary current and shall be of Class PS & Class 5P20. Metering CTs shall be rated for 5A secondary current and shall be of 0.2S accuracy class with instrument security factor less than 5. Voltage Transformer and Surge protection Cubicles The V.T and S.P cubicles for each phases shall be metal clad, dust and vermin proof, free standing, dead front assemblies housing VTs, surge capacitor, lightning arrester, V.T. L.V. side fuses etc. Lightning arrester shall be Gapless type station class, hermetically sealed, connected between line and ground, specifically suitable for ISSUE R0 95 5.5.1 5.5.2 5.5.3 5.5.4 5.6 5.6.1 5.6.2 TCE FORM NO. 329 R5 9 5. & S.6. provided in the instrument transformer marshalling boxes. The degree of ISSUE R0 96 5.8 5. Cubicle Construction (V.6. The draw out frame shall be grounded at all times.6. SECTION: D3.1 TCE FORM NO. A reliable automatically operated shutter mechanism shall be provided for isolating and shrouding the bus bar live parts when the VT is in drawn out position.BUS DUCTS SHEET 7 OF 15 SPEC. Suitable guide slots and stops shall be provided to ensure easy withdrawal and positioning.T. and as per Technical Parameters given in the specifications. connected from line to ground.5 5. 329 R5 .6 5. with isolating links for testing of instrument transformers. Mineral oil filled/Askarel (PCBS) filled surge capacitor shall not be acceptable. VT and CT secondary neutral or common lead shall be earthed at one place only at the terminal blocks. shall be visible without having to open the compartment door. Facility of making star points and undrilled gland plate for cable connections shall be provided in the marshalling box. Cubicle etc. The discharge counter register & leakage current measurement meter with suitable environmental protection covering.7 5.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. to accommodate all VT leads. suitable for nominal voltage operation.5960A-H-500-001 generator protection as per technical parameters given elsewhere in the specifications. The secondary side of voltage transformer shall be provided with MCB.5 1X 700 MW CCPP AT NEDUNOOR.) All cubicle shall be fabricated from cold rolled sheet steel for minimum 2mm thick suitably reinforced to ensure structural rigidly.3 A discharge counter along with the ampere meter shall be provided for each lightning arrester.. The fixed and draw out contacts of voltage transformer primary shall be tinned or silver plated.6.G. shall be provided by the Contractor through suitable connectors in the marshalling box. N. In the disconnected position. the voltage transformer primary and secondary circuits shall be automatically disconnected.P.7. ELECTRICAL SYSTEMS . The voltage transformer shall be epoxy cast-resin type.4 5.6.6. From phase cabinets the VT secondary leads shall be brought to marshalling box having sufficient number of terminals with 20% spare. KARIMNAGAR DIST. 5. TCE.6. The facility for connecting with earthing grid.7 5. NO. TCE.3 5.8.5960A-H-500-001 protection for all indoor cubicle shall be IP:52 except for neutral grounding resistor enclosure which shall be minimum IP:23. shorting and grounding. voltage transformer compartment.1 5.9 5. Each cubicle shall be equipped with space heater with thermostat.1 5.2 5. The wiring inside the bus duct enclosure (i.8.8. ELECTRICAL SYSTEMS .5 1X 700 MW CCPP AT NEDUNOOR.5 mm² cross-section with suitable lugs on both sides. Name plate Name plates shall be furnished for each equipment.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.9. SECTION: D3. Not more than two wires shall be connected to a terminal. KARIMNAGAR DIST.) shall be suitable for operating in the ambient temperature existing inside the bus duct. Spare terminals equal in number to 20% of active terminals shall be furnished and these shall be uniformly distributed through out the cubicle CT terminal blocks shall be of stud type and suitable for round type lugs with a facility for isolation. Illumination and Grounding. Ground bus suitable for receiving two (2) numbers of 50x6mm galvanised steel flats shall be provided on each cubicle. etc.7. 5.3 Space heater.9.2 5. 329 R5 . internal illumination lamp. for CT etc.10. lightning arrester compartment and fuse block.BUS DUCTS SHEET 8 OF 15 SPEC.7. disconnect link.e. 5A receptacle.1 ISSUE R0 97 TCE FORM NO. 5. Wiring All wiring shall be done with insulated stranded copper conductor of not less than 2. Hot Air Blowing Equipment Suitable facility shall be provided to blow hot air into the bus duct to evacuate moisture inside the bus duct during initial start-up and also after subsequent shutdowns for maintenance on the bus ducts. Material for nameplate shall be embossed on SS plate & letters filled with indelible black ink. current transformer TB.10 5.8 5. NO.2 5. 230 V AC. It shall be Elmex type CATD or equivalent. combination starter. shall be provided with the necessary control.8 5.BUS DUCTS SHEET 9 OF 15 SPEC. The tap off air ducting from IPB to mobile trolley delivery flange is included in Bidder’s scope of supply. necessary ducting.10. The system shall be sized to completely dry the entire bus duct installation within two hours. 329 R5 . thermostats. Ambient air will be drawn in through inlet dampers and dry air filters and then forced through thermostat controlled heaters. heaters.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. b) Impulse withstand test ISSUE R0 98 TCE FORM NO.1 Type Tests a) One minute power frequency withstand voltage test.10. The bus duct assembly tested shall include bolted connections.7 5. control.10. all mounted on a mobile trolley.11.10. Tests & Test Reports The following type and routine tests shall be conducted on representative section of the bus duct assembly.5 5. washable filters. The hot air blowing system shall be complete with motor blower unit. A local control cabinet mounted on the trolley. Suitable provision shall be made to isolate this system after the drying operation is complete. ELECTRICAL SYSTEMS .5 1X 700 MW CCPP AT NEDUNOOR. The system shall be suitable for operation at low voltage 3 phase AC supply indicated under project information.5960A-H-500-001 5.11 5.10. capable of blowing hot air simultaneously in the indoor and outdoor portions of the bus duct.6 5. dampers.10. SECTION: D3. TCE.2 The hot air blowing system shall be open loop type.4 5. flexible connections and current transformers. NO. instrumentation and monitoring system. piping. indication and monitoring devices.3 5.10. valves. Hot air shall be let out through suitably directed outlets provided at the indoor and outdoor portions of the bus duct and at each equipment suitably. 5. KARIMNAGAR DIST. The bus duct of each unit shall be provided with suitably supported inlet ducting with blanking plates. The mobile trolley shall be common for the specified number of bus duct units. Hot air shall be distributed by properly sized ducts and dampers to the indoor and outdoor portions of the bus duct. 5. ELECTRICAL SYSTEMS . TCE. a) b) c) d) Conductor size Guaranteed kW losses in conductor & enclosure Supporting span Dynamic and static forces transferred to TG foundation.12.2 Routine Tests a) One minute power frequency withstand voltage test b) IR measurement 5. SECTION: D3.5 1X 700 MW CCPP AT NEDUNOOR.1 ISSUE R0 99 TCE FORM NO. Temperature rise at rated current considering effect of solar radiation.5960A-H-500-001 c) Temperature rise test of black matt painted conductors & enclosures d) Short time current test e) Dynamic current withstand test f) Water-tightness test g) Air tightness test h) Milli-volt drop test 5. 329 R5 . KARIMNAGAR DIST.11. NO.12 Bidder shall furnish the following calculations for main run and tap off run busduct.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.BUS DUCTS SHEET 10 OF 15 SPEC. 2 5. The enclosure shall be rectangular and shall be made of aluminium alloy sheets for SPBD and for NSPBD the same shall be of mild steel. NSPBD shall also be considered for connections between other switchgear / MCCs to suit the layout.3 5.14.1 5.6 kV switchgear.1 5.13.2 kV class segregated phase bus duct and accessories shall be provided for connection of the two winding unit auxiliary transformer to 6.2 5.2 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The short time and momentary current ratings of the bus ducts shall be same as that of associated 400V switchgear.6 kV switchgear. The busbars in the bus-duct shall be sleeved with FRLS heat shrinkable.5 1X 700 MW CCPP AT NEDUNOOR.14.6 kV switchgear bus.1 kV class non-segregated phase bus duct and accessories shall be provided for connection between all service transformers and their respective 400V switchgear. TCE.15 5.15.15.2 5.15.14.14 5. 5. Non-Segregated Phase Bus Ducts [NSPBD] 1.13. Specific Requirements The bus conductor shall be of Aluminium alloy grade 63401 WP (range 2) as per IS: 5082.5.3 5.1 HV & LV Bus ducts Segregated Phase Bus Ducts [SPBD] 7. the phase segregation shall be of either aluminium or non-hygroscopic insulating material like fibreglass.13 5. 329 R5 . In case of segregated phase busduct.4 5. KARIMNAGAR DIST. ELECTRICAL SYSTEMS .6 kV Switchgear shall be same as the rated current of 6.13. colour coded XLPE sleeves. The continuous rating of the bus duct from UAT to 6. NO. SECTION: D3.3 ISSUE R0 100 TCE FORM NO.BUS DUCTS SHEET 11 OF 15 SPEC. The continuous rating of the bus duct shall be same as the rated current of respective switchgear bus.14.5960A-H-500-001 B) 5. The short time and momentary current ratings of the bus ducts shall be same as that of associated 6. 4 Flexible expansion joints shall be provided for the conductor and enclosure along the run of the bus duct length to take care of expansion.5960A-H-500-001 5.15. The adjacent sections of the bus conductor shall be welded or bolted. The material of insulator shall be epoxy resin cast.14 5.5 1X 700 MW CCPP AT NEDUNOOR. TCE. ELECTRICAL SYSTEMS . The joints along the conductors shall be of highest quality and the temperature rise test shall be conducted including the joints.7 5. SECTION: D3.5 5. Wall frame assembly and seal off bushings shall be provided where the bus duct passes through walls (indoor to indoor). Also flexible joints shall be provided at the termination points.10 5.12 5. Inspection covers for periodic inspection of the insulators shall be provided.15.1 kV class for non-segregated phase bus ducts and shall be mounted on resilient pads. 5.BUS DUCTS SHEET 12 OF 15 SPEC.11 5.6 5. These shall be fabricated out of aluminium angles and sheets. The bus conductors shall be given a coat of matt black paint to facilitate heat dissipation. Thermostatically controlled space heaters shall be provided along the run of bus duct.15. The bus duct supports shall be fabricated from standard steel sections.8 5.15.15 ISSUE R0 101 TCE FORM NO. Wall frame assemblies with seal off bushing shall be provided where bus ducts pass through walls (outdoor to indoor). There shall be no joints or fixing bolts on top of the enclosure through which water can seep. 329 R5 . The spacing of the bus support insulators shall be considered by giving due factor of safety to withstand the forces due to the momentary short circuit current assigned for the bus duct.13 5.15.15.15. The bus support insulators shall be of 7.2 kV class (as required) for segregated phase bus ducts and 1.15. NO. The support structures shall be hot dip galvanised.9 5.15.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. However the sizing of the bus conductor shall consider the conductor as bare.15. The outdoor portion of the bus duct shall be provided with a continuous rain hood of non-magnetic material suitably supported from the bus duct support structure.15.15. KARIMNAGAR DIST. Typical calculation for arriving at the size of the conductor and the insulator spacing.5 1X 700 MW CCPP AT NEDUNOOR.3 TCE FORM NO.5960A-H-500-001 5. 5.2 5.BUS DUCTS SHEET 13 OF 15 SPEC.15. test certificates shall be furnished for bought out items.1 (a) Type of cooling (b) Maximum temperature rise of conductor over 50oC ambient (c) Maximum temperature rise of enclosure over 50oC ambient 5. NO.16 At the factory. 329 R5 .16 5.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. air tightness test and water tightness tests shall be conducted at site on fully assembled bus duct. HV voltage test. Sl. on one typical section of SPBD containing bends.15. Technical Requirements Segregated/non-segregated phase bus ducts shall comply with the particulars indicated in the following table. SECTION: D3. ISSUE R0 102 5. following type tests shall be conducted (a) (b) (c) (d) (e) air tightness test water tightness test Temperature rise test Short circuit current withstand Impulse withstand test For NSPBD.18.18. Experience list of the make of bus duct proposed.17.17 On all the pieces of SPBD & NSPBD applicable routine tests shall be conducted.18 5.. Also.1 Data to be furnished with the Bid Technical particulars for the segregated/non-segregated phase bus ducts as per Table below.18.18 5. joints etc. Description Requirement for Segregated Phase Bus duct Natural air 40oC 30oC Non-segregated Phase Bus duct Natural air 40oC 20oC 5. type test certificates shall be furnished. TCE. No. KARIMNAGAR DIST.15. ELECTRICAL SYSTEMS . 3 & 5. 329 R5 .3) Continuous current rating at 50oC design ambient air temperature (as per clauses 5. (a) (b) (c) (d) Description Designation (from & to) Manufacturer Applicable standard Momentary short circuit withstand current (as per clauses 5.13.18. temperature rise test) for similar bus duct manufactured by the proposed manufacturer.BUS DUCTS SHEET 14 OF 15 SPEC.5 1X 700 MW CCPP AT NEDUNOOR.No.14. NO. impulse withstand.13.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 5.) Sl. ELECTRICAL SYSTEMS .2 & 5. TCE. SECTION: D3.13.14.3) kA peak Unit Technical Particulars 5.4 Type test report (short circuit. KARIMNAGAR DIST.19 (e) One second short circuit kA rms withstand rating (as per clauses 5.2) Amps (f) ISSUE R0 103 TCE FORM NO. Technical Particulars (To be separately furnished for each rating of segregated and nonsegregated phase bus ducts. 3 4.5 5. class (ii) Rated voltage factor 7.2 4.2 4. KARIMNAGAR DIST. TCE FORM NO.0 C C 55 30 0 8.1 3. Cast epoxy resin IS :5082 IS : 2099 IS : 2544 IS : 2629 IS : 8084 25 mm/kV of rated voltage 0 Isolated Phase Bus Duct .1 4. NO. NO.5960A-H-500-001 VALUES / REQUIREMENTS Isolated Phase Bus Duct 1.0 6.5 15 OF 15 SPEC. 1.. BY CKD. TCE.2 Cont.0 2.9 for 30 seconds.0 Type of insulation for current trf. DESCRIPTION UNITS SECTION: SHEET D3. 30 Secs. DATE REV.0 4.0 3. DATA SHEET – A 3.Continuous Natural air cooled 3. 330 R3 104 . 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.4 4. Refer Main Line Dia TCE. and neutral grounding transformer Duty rating (i) NGT (ii) NGR 30 Secs. NO.5960A-EL-SK2003 1.BY DATE RKD HA JOB NO.5 SL.0 Type of bus duct Type of cooling Maximum temperature rise of over an ambient temperature of 500C Conductor (Hot spot) Enclosure (Cold spot) Applicable codes and standards Bus conductor material Porcelain bushing Porcelain post insulators Hot dip galvanising Interconnecting busbars Creepage distance for insulators and bushing Voltage of : (i) Acc. BY R0 JUNE’ 10 PPD.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.0 REV. timers. However. auxiliary relays. NO. 6. its subsystems shall be housed in generator relay panel (GRP).6 SHEET 1 OF 8 1X 700 MW CCPP AT NEDUNOOR.. SECTION: D3.2 6.3 6. One group shall be receiving all AC and DC signals from one set of devices and the other from another set of devices. timers. auxiliary relays. its subsystems. CT and PT supervision and supervision of both trip circuits shall be provided. Both groups of protection shall be divided into these three modes of tripping.3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD... transducers etc. physically and electrically separated into two separate and independent systems. both groups shall be mechanically. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. the relays in each group shall be tripping the circuit breaker through both trip coils I & II.1 GENERATOR PROTECTION Complete protection system consisting of protective relays. This panel will be located in the Main control room.C shall trip GT HV circuit breaker. supervision of trip relays. Hence. Monitoring devices such as supervision of DC supplies. etc. KARIMNAGAR DIST. Dead machine protection shall receive their DC power supply from station DCDB as appropriate. Class. Class-B shall trip GCB or GT breaker on reverse power through Class A1 or A2. Complete protection of the respective equipment shall be fully available even if either of the group is not available. Class – A trip shall be classified into GCB & field breaker trips (Class-A1) and GT HV breaker Trip (Class-A2).0 6. supervision of protective relays. 329 R5 105 . TCE.1 Protection Philosophy The protection philosophy of every equipment shall be divided into two 100% groups namely two main protection groups.3. these two groups will derive DC supply from two separate feeders. The breaker failure relays connected with 400 kV generator transformer bay and relays connected with 400 kV bus bar protection shall be housed in separate relay panels which will form part of 400 kV switchyard protection system. shall be provided to protect the generator. to protect the complete generator. 6.3 ISSUE R0 TCE FORM NO. ELECTRICAL SYSTEMS – GENERATOR. Generator Protection All the protective relays. Similarly.4.5960A-H-500-001 6. generator transformer and unit auxiliary transformer. The generator protection system relays shall be classified into three categories viz.2 6. NO. (h) Back-up impedance protection (21G). dead machine protection and pole slipping protection.6 SHEET 2 OF 8 1X 700 MW CCPP AT NEDUNOOR. GT and UAT. Two identical numerical relays shall be provided for generator protection.4 The protections envisaged in GRP are listed below.5960A-H-500-001 6. ISSUE R0 TCE FORM NO. Generator stator 95% back-up earth fault protection (64 G3). GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. Both the list and the drawing shall be considered Complementary to each other and all the protections indicated shall be provided. annunciation. ELECTRICAL SYSTEMS – GENERATOR. (a) (b) (c) (d) (e) (f) Generator differential protection (87G) Generator stator 100% earth fault protection (64 G1). interlocking etc. KARIMNAGAR DIST. Main One Line Diagram drg. SECTION: D3. contact multiplication relays shall be provided if necessary. However.. (g) Negative phase sequence protection (46 G). Generator stator 95% earth fault protection (64G2). Numerical relays shall be provided for main protection of Generator. Contractor shall include any additional protections deemed necessary by him for the equipment offered even if not indicated in the list and the drawings. Also.TCE. TCE. They should likewise have adequate number of opto couplers for external trip inputs. In addition they shall have an output of 4-20 mA for remote indication of negative phase sequence current.5960A-EL-SK-2003 indicates various protections envisaged.6 kV switchgear.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. static relays have to be provided for PT supervision.. 329 R5 106 . Numerical relays shall have adequate output contacts for tripping. A dedicated operator station shall be provided in the Main control room for setting the numerical relays of Generator protection and 6.4. Loss of excitation relays shall be with two independent outputs for conditions with and without under voltage. etc. It shall have a definite time stage for alarm and inverse stage for trip. Pole slipping relay protection (78G). Loss of excitation protection (40 G). No. It shall be provided with timer to detect actual over load. Over voltage protection shall have an instantaneous stage and a definite time stage with independent voltage settings. (k) (l) (m) Over voltage protection (59 G). 60G23) Reverse power/ Low forward power protection (32 G/37G).5960A-H-500-001 (i) Stator over-load alarm relay (50 GS). 60 G22. TCE. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. 329 R5 107 . Generator field over voltage protection (can be a part of excitation system) Over fluxing protection (99G) with inverse time characteristics. NO. KARIMNAGAR DIST. Islanding protection schemes to isolate power plant from grid for disturbances in the grid. 4 stage with independent time and frequency adjustment. (j) Generator VT fuse failure protection (60 G11.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (q) (r) (s) (t) (u) ISSUE R0 TCE FORM NO. 60 G12. 60G13 / 60 G21. Under frequency protection (81 G). ELECTRICAL SYSTEMS – GENERATOR. Local breaker back up protection (50 LBB) with it’s own trip relay. (n) (o) (p) Under voltage protection (27G) Dead machine relay (61 B). Rotor earth fault (64F) 2 stage Inter turn fault protection through differential current measurement in case generator has six terminals brought out on neutral side Or Through residual voltage (Vo) with neutral biasing in case three terminals are brought on the neutral side. SECTION: D3.6 SHEET 3 OF 8 1X 700 MW CCPP AT NEDUNOOR. Tripping relays for protection devices of Generator Transformer (GT) and 63X / 49X for multiplying the contacts of protection. Generator transformer restricted earth fault protection (64 GT) Generator transformer back-up earth fault protection (51 NGT). NO.5960A-H-500-001 (v) Generator. (aa) For trip function (63X1/49X1) • • • • • • GT buchholz II stage (63TX) GT OLTC buchholz II stage (63 OLTC TX) GT winding temperature very high (49 WTX) GT oil temperature very high (49 OTX) GT pressure relief device operated (63 PTX) GT fire protection trip (63 FRTX) (w) (x) (y) (bb) For annunciation function (63x2/49x2) • • • • • • • • GT Buchholz I stage (63AX) GT OLTC buchholz I stage (63 OLTC AX) GT winding temperature high (49 WAX) GT oil temperature high (490AX) GT oil level low (OLAX) GT cooler supply failure GT cooler trouble GT OLTC trouble ISSUE R0 TCE FORM NO. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 SHEET 4 OF 8 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS – GENERATOR. TCE. 329 R5 108 . generator transformer. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. SECTION: D3. generator transformer overall differential protection (87GTU) for STG and generator. UAT overall differential protection for GTG (87 G/GT/UAT). .6 SHEET 5 OF 8 1X 700 MW CCPP AT NEDUNOOR. transformer cooler circuit interlocks. Contacts from each category of tripping relay for annunciation.6 kV auxiliary supply breakers trip / close permissive. etc. (cc) (dd) (ee) (ff) (gg) (ii) (iii) (iv) (hh) (ii) (jj) Supervision relays for tripping relays (98 GL1 to GLX). UAT restricted earth fault protection (64 UAT).5960A-H-500-001 (z) (aa) (bb) UAT IDMT overcurrent protection on HV and LV sides (51) UAT Instantaneous over current protection on HV side (50) UAT – Buchholz (63). UAT differential protection (87 UAT). LBB protection.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 400 kV circuit breakers tripping / close permissive. data acquisition. protection and interlock in system viz. winding temperature (49 WT) and oil temperature (49 OT) protections Auxiliary relays for protection devices of UAT 63 x 1/49 x 1 and 63 x 2 / 49 x 2 for multiplying their contacts. 6. ELECTRICAL SYSTEMS – GENERATOR. 329 R5 109 . KARIMNAGAR DIST. SECTION: D3. TCE.. UAT instantaneous earth fault relay (51N UAT) High speed trip relays (86 G1 to GX): Adequate number of high speed trip relays for each category tripping and separately for each group shall be provided for the protection of the unit. Contacts for control. 10% spare contacts (both N/O and N/C). NO. and sequential event recorder and fault disturbance recorder. Open delta VT for Pre-synchronising Earth fault (59NGT) 400 kV generator breaker trip coil supervision relays (98G1 to G4). ISSUE R0 TCE FORM NO. The quantity of the trip relays shall also consider the requirement due to the following: (i) Contact requirements from these relays to various systems covered under the scope of this contract. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 SHEET 6 OF 8 1X 700 MW CCPP AT NEDUNOOR. Two Nos. NO. independent. Auxiliary VTs and Auxiliary CTs required for the protection systems.5 mm size self coloured. 6. The parameters of the same shall be selected to suit the application and the same is subject to approval of Owner. (ll) 6. In addition to the relays/protections mentioned in this specification. 329 R5 110 . viz. any additional protections/relays considered necessary by the Contractor for his system shall be included and offered by the Contractor.8.1 6. DC supplies shall be arranged for the GRP.3 The relay panels shall be provided with supervisory system facilities to indicate the location of the failed component when pre-engineered ISSUE R0 TCE FORM NO. In case of failure of any one source (say source 1) switch shall be changed over to the other source (source 2) and complete DC supply requirement of GRP will be fed from the other source.. The relay shall be provided with flag indicators wherever required. These supplies shall be taken through a selector switch with the positions.6 The characteristics and relay setting ranges shall be decided by the Contractor and shall be such as to provide complete protection for the generator under normal and all abnormal operating conditions. Trip Matrix required for implementing class A/B/C tripping schemes shall be provided by the Contractor and shall be indicated in block interlock diagrams to be submitted. source-1 & source-2. ELECTRICAL SYSTEMS – GENERATOR. The NC contact of the relays shall be delayed on drop off by approximately 100 to 200 m sec.5960A-H-500-001 (kk) Auxiliary relays. In the Independent position Group-1 & 2 protection system will be fed by source 1 & 2 respectively and the common services from any one of the sources.8 6. SECTION: D3. TCE. DC auxiliary supply shall be supervised by supply supervising relays. KARIMNAGAR DIST.2 6. timers in adequate number to make the protection & the scheme complete. Specific Requirements The protection system shall comprise pre-engineered modular or discrete self-contained systems comprising preferably of static relays.8.8. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC.7 6. relays required for the discrepancy switch scheme in Generator control panel. All LEDs shall be 22. for annunciation in Operator station/Generator control panel. White colour supervision lamps of clustered LED type shall be provided on GRP to indicate availability of DC supply. Self checking facility ‘In-Built’ in the relay panel shall be provided with watch dog contact for remote annunciation and DCS. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. They shall be arranged to operate only when tripping current passes through output circuit of the relay.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.12 111 . Contractor shall wire out to the terminal block atleast all NO & NC spare contacts of each of the relays. sequence event recorder and for switchyard control panel annunciation wherever required.9 6. Testing Unit Two Nos.4. annunciation windows. trip conditions. SECTION: D3.8. line and motor protection relays. KARIMNAGAR DIST. Control room alarms/indications/SER points Each of the alarms. 329 R5 6.11 6.11. timers by secondary injection. This is in addition to self monitoring and watch dog facilities that will be built into these protective relays. Contact multiplication relays for generator circuit breaker and associated isolators shall be provided for this purpose.10 6. shall be individually indicated in Operator station and also individually or appropriately grouped available in the annunciation windows in generator control desk / panel. transformer. D2. In addition to the contacts required as per schemes. The protection scheme shall include all the necessary contacts to achieve the schemes required. ISSUE R0 TCE FORM NO. of test kits shall be offered to test all of generator. ELECTRICAL SYSTEMS – GENERATOR. Operator station/SER shall have a time resolution of 1 (one) ms.5 6.4 Either hand reset mechanically operated operation indicator or LED with reset push button shall be provided for protective relays. NO.1 6. measurement. 6. TCE. Selected alarm/trip conditions finalised during the detailed engineering stage shall be used for SER system. monitoring. alarms in Operator Station. Minimum electrical system requirements in respect of control. (Further the lockout relay operation and certain grouped alarms shall be available in the SCADA/400kV-switchyard control system. synchronising are indicated in I&C system section No.5960A-H-500-001 protection system is offered. abnormal conditions through the protection relays.6 SHEET 7 OF 8 1X 700 MW CCPP AT NEDUNOOR.8. One laptop of high configuration shall be provided with necessary software & hardware (with multiple licences) for setting the parameters & evaluation of numerical relays. annunciation. TCE.7 for Switchyard Relay Panels. SECTION: D3.14 Tests Tests shall be as mentioned in Section D3. KARIMNAGAR DIST. NO.. 6.13 Fault disturbance recorder Microprocessor based fault disturbance recorder shall be provided for each generator to record the graphic form of instantaneous values of voltage and current in all three phases and neutral. open and close positions of relay contacts and breaker during disturbance etc.5960A-H-500-001 6. 329 R5 112 . ELECTRICAL SYSTEMS – GENERATOR. Facility of fast scan as well as slow scan feature to be provided to record transient as well as dynamic performance of the system. ISSUE R0 TCE FORM NO. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 SHEET 8 OF 8 1X 700 MW CCPP AT NEDUNOOR. protection and SCADA system shall be provided by the Contractor. SECTION: D3. monitoring.4. KARIMNAGAR DIST.3 7. 400 kV transmission lines.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 7. The 400 kV switchyard shall have one and a half breaker switching scheme. ISSUE R0 113 7. TCE. 329 R5 . generator transformer bay equipment with associated equipment. of Bays 3 4 2 1 10 7. The necessary line bay equipment.4.2 7. NO. ELECTRICAL SYSTEMS .5960A-EL-SK2003 shows the switchyard scheme and arrangement of major equipment in the switchyard.1 400 kV SWITCHYARD A 400 kV switchyard shall be provided for evacuation of power generated in the plant through four (4) nos.0 7.4.4.3 7.4 The switchyard equipment shall be supplied and installed with all accessories to make the switchyard complete in all respects. The Main One Line Diagram sketch no.6 TCE FORM NO.7 1X 700 MW CCPP AT NEDUNOOR. The 400 kV switchyard shall consists of various bays for different configuration as follows: Description Generator Transformer 400 kV Line Bus Reactor Future bay (Spare) Total No.5 7. TCE.2 7.4.4 7. 360 kV lightning arresters (LA’s) Wave traps & Coupling capacitors. The switchyard shall include the equipment indicated below but not limited to the following. controls. 420 kV circuit breakers 420 kV isolators 420 kV current transformers (CTs) 420 kV capacitor voltage transformer (CVTs) and electromagnetic voltage transformers (EMVTs).5960A-H-500-001 7.400 kV SWITCHYARD SHEET 1 OF 51 SPEC.4. 17. NO.3 IEC 61850 (universal): Substation automation protocol ISSUE R0 114 TCE FORM NO. (a) IS 10118 – 1982 : Code of practice for selection installation and maintenance of switchgear and control gear – part-3 (Installation).4. Bus bars.4. Air conditioning and ventilation system for control building and outdoor kiosks.7 1X 700 MW CCPP AT NEDUNOOR.9 Power line carrier communication (PLCC) system for 4 lines.5 7. HMI. ABT (Availability Based Tariff) meters including necessary software & hardware for monitoring on dedicated PCs with suitable networking. 7. SCADA (Supervisory Control and Data Acquisition) system for entire switchyard with bay control units for each bay including event logging.4.1 (b) (c) CBIP Technical Manual on layout of substation report No. Stand alone disturbance recorders with associated network cabling. TCE.11 7. 7. fault disturbance recorders.4.13 7.5960A-H-500-001 7.16 7. Bus Reactor Design Criteria The switchyard shall be generally designed based on the following codes and standards.4. ELECTRICAL SYSTEMS .400 kV SWITCHYARD SHEET 2 OF 51 SPEC. Printer and evaluation software. Switchyard structures. SECTION: D3. RTU (Remote Transmission Unit) for transfer of data to SLDC (State Load Dispatch Centre) and RLDC (Remote Load Dispatch Centre).14 7. Fire alarm. protection panels. communication and interfacing panels as required.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.8 7. clamps and connectors. detection & protection system for switchyard.4.10 7. Outdoor kiosks housing BCUs.4. trenches and complete civil works including switchyard floors with RCC blocks. switchyard fences. 329 R5 . PLCC/OLTE panels. insulators.4. Protection panels for all bays/equipment.4.12 7.4.5.18 7.4.7 7. PC. KARIMNAGAR DIST. earthing.4.15 7. etc. 5.7 7. TCE.5 p.3 7. The switchyard shall be designed for a fault level of 50 kA for 1 sec. The final temperature of the conductor when carrying full load current shall not exceed 850C with a maximum ambient temperature of 500C.u.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. However. bus post insulators.5.3 p.5. SECTION: D3.5 7.03 mm per annum.2 A creepage distance of 31 mm/kV on 400 kV shall be provided for circuit breakers. ELECTRICAL SYSTEMS . The conductor size of tubular bus and stranded conductors shall be based on the maximum load current.5960A-H-500-001 7. Calculation shall be submitted for Owner’s approval. The 400 kV system shall be designed to withstand the power frequency over voltage to 1.5. LA’s.5. KARIMNAGAR DIST.5.9 (b) TCE FORM NO.400 kV SWITCHYARD SHEET 3 OF 51 SPEC.5. ISSUE R0 115 7. air tight and shall be designed to withstand all shocks and stresses to which they may be subjected to during operation and maintenance. The size and spacing of strung bus. minimum size of the shield wire shall not be less than 70mm2. isolators. if galvanised steel wires are used. The size of shield wire shall be based on the lightning impulse current expected and the time duration for which it is likely to flow.8 7. Bus reactor. Allowance shall be given in the final size to account for corrosion of the shield wire during service at rate of 0. The associated metal part shall be permanently secured to the insulator. corona / voltage gradient and effect of solar radiation.5.4 7. Bay buses shall be rated according to the circuit rating.6 7.u and surge over voltage to 2. NO. string insulators and 420 kV transformer bushings. EMVTs. CVTs. All ferrous parts shall be hot dip galvanized. CTs. The switchyard main buses shall be designed for continuous rating. Insulators (a) Design of insulator shall avoid stresses due to expansion and contraction in any part of the insulator leading to deterioration. The busbars shall be of standard ACSR or tubular aluminium / copper according to standard metricised iron pipe size (IPS) of suitable size.7 1X 700 MW CCPP AT NEDUNOOR. 329 R5 . and dynamic rating of 130 kA. tubular bus and clamps connections shall be checked to limit the voltage gradient to 17 kV/cm to reduce corona effect. suitability under short circuit conditions. 1 times the maximum system voltage. 31 mm / kV. 329 R5 . SECTION: D3. i. Tension and suspension insulator strings shall be anti-fog type selected based on the voltage. NO. ELECTRICAL SYSTEMS . free from blisters.5. (d) (e) (f) (g) (h) (i) 7. which would cause corrosion or injury to any of the material.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. pollution level and electro-mechanical strength.. TCE. Insulator hardware shall be corona free upto a falling power frequency visible discharge test voltage of 1. for the end shield wires.e. insulation level.10 The lightning protection of switchyard shall be provided by lightning masts and shield wires. and shall be thoroughly vitrified. All insulators shall be of homogeneous glazed porcelain or composite type with silicon shed profile.5.5960A-H-500-001 (c) The design shall ensure uniform compressive pressure on the joints. Composite insulators can be of grey in colour.400 kV SWITCHYARD SHEET 4 OF 51 SPEC. The zone of coverage for the shield wire shall be considered as 60 deg. Bus post insulators shall be solid / post insulator anti-fog type and shall be selected based on the system voltage. Electro-mechanical strength shall be selected with factor of safety of 2.11 ISSUE R0 116 TCE FORM NO. between the two shield wires and 45 deg. 7. tough and impervious to moisture. Porcelain glazing shall be uniform brown in colour. The criteria for deciding phase to phase clearance in case of strung conductors shall take into account that the conductor swing of one of the conductors (say R phase) with maximum wind velocity and the adjacent conductor (say Y phase) with 80% of maximum wind velocity at maximum sag conditions. There shall be no electric discharge between conductor and insulators. free from laminations. burns and other similar defects. insulation level mechanical strength and pollution level requirements. Creepage chosen shall be suitable for high pollution.5. cavities and other flaws or imperfections. when operating at normal voltage.7 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST. 5960A-H-500-001 7. NO. depending on the actual dimensions of the equipment keeping in view the design criteria / requirements and without sacrificing any maintenance space / conveniences. Similarly. 329 R5 .13 The switchyard shall be designed for the seismic coefficient and wind pressure as indicated in Section-B. The tap off conductor shall be routed through a bus post insulator located near the transformer.6. KARIMNAGAR DIST. The Contractor shall consider suitable bay width.6.5.5 (factor of safety). Switchyard Layout Requirements The Contractor shall adopt bolted type connectors for tubular bus conductors.6.5. The switchyard shall be provided with access ways near the current transformers and circuit breakers.6 7. ISSUE R0 117 7. the point of anchoring on TG building shall be such that the vertical angle of deviations is limited to 300C from horizontal plane. etc.6.14 7. SECTION: D3. current transformers and power transformers and flexible jumper connectors for connecting lightning arresters and voltage transformers.12 For the layout proposed by the Contractor the adequacy of the cantilever strength specified shall be checked considering the following factors of safety. (b) Combination of all normal loads plus either maximum short circuit or earthquake load whichever is higher x 1 (factor of safety). flexible type of terminal connector for circuit breakers.. fixed type of terminal connectors for isolator terminals. All structural steel and steel components in the switchyard equipment shall be of hop dip galvanised. 7. phase spacing.7 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 7.1 7. ELECTRICAL SYSTEMS .6.3 7.4 7. the power conductor termination shall not be tapped off directly to the Generator transformer from the strung bus between the TG building and switchyard. The Contractor shall note that the sequence of bays shall be so arranged that the maximum horizontal angle of deviation of the incoming power and shielding conductors from Generator transformers do not exceed 300C.5. (a) Sum of all permanent normal loads (wind load on tubular bus + wind load on stack + dead weight of the tubes) x 2.5 TCE FORM NO. clearances. TCE.400 kV SWITCHYARD SHEET 5 OF 51 SPEC. In the transformer yard. civil works.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The SF6 circuit breakers shall be single pressure type and utilise puffer cylinder for interrupting currents.7.5960A-H-500-001 7. SECTION: D3.1.7.7 7.6 The cable trenches for the equipment shall be run as close to their foundations as possible even preferably touching.6.400 kV SWITCHYARD SHEET 6 OF 51 SPEC. The switchyard shall be enclosed in fence or wall around for safety and to prohibit unauthorised persons from entering.7 7. The circuit breaker and its accessories viz.6.6. the gap between open contacts shall be suitable to withstand at least rated voltage at zero gauge pressure of gas. ELECTRICAL SYSTEMS .0. Tie beams between foundations of breakers of different phases are recommended as during closing / opening operation additional load in the form of vibrations may be transferred to the foundations. The fence shall be suitably earthed as per relevant Indian standards. Switchyard Equipment Circuit Breaker (a) The 420 kV circuit breakers shall be of SF6 outdoor type. Design criteria for civil works and structures shall be as specified in Section-D4. 7. Each SF6 circuit breaker pole shall be provided with its own self-contained gas system. The circuit breakers shall comprise three identical single phase units with operating mechanism suitable for single pole operation.1 (b) (c) (d) ISSUE R0 118 TCE FORM NO. Lockable gates for personnel entry and equipment shall be provided at convenient locations.6. The fence provided around switchyard shall be of 2500 mm minimum height and at a minimum distance such that section clearance is available from any live part.10 7.8 7.9 7. 329 R5 . NO. The breaker shall be so designed that upon loss of pressure.6. KARIMNAGAR DIST. TCE. Earth mat of suitable size with closely spaced earth conductor shall be provided below the operating handle of individual switchyard equipment As per the allowed step & touch potential values in IS.1 7. marshalling box / junction box shall be with IP 55 degree of protection.7 1X 700 MW CCPP AT NEDUNOOR. (f) (g) (h) (i) (j) (k) (l) (m) The middle breakers and the outgoing line breakers shall be provided with PIR. SF6 breakers shall be provided with temperature compensated SF6 density switches for individual poles with separate lockout. D. high alarm. SECTION: D3. Circuit breakers shall be suitable for rapid auto re-closing duty. circuits for two trip coils shall be separate and each of them shall be monitored separately.1. Duty cycle for the breakers shall be O-0.3sec-CO–3min-CO under all normal and fault conditions.7 1X 700 MW CCPP AT NEDUNOOR. lock out switches for close. Temperature compensated SF6 Density monitor to be provided for each phase at such a level so as to enable viewing and reading. open and reclose operation. The operating mechanism shall also have pressure switches for low alarms. ELECTRICAL SYSTEMS .7.5960A-H-500-001 (e) Design of circuit breaker shall be such that contacts shall not close automatically upon loss of gas / air pressure. conveniently located for mechanical tripping of all the three phases simultaneously shall be provided. alarm and blocking contacts. The trip coils shall have sufficient continuous rating to cater to the trip coil supervision relay current. All the circuit breakers in the switchyard shall be of identical make and type with interchangeable components to maximum possible. (ii) ISSUE R0 119 TCE FORM NO. Two trip coils shall be provided for greater reliability. KARIMNAGAR DIST. TCE. Manually operated emergency trip push button or any other device.400 kV SWITCHYARD SHEET 7 OF 51 SPEC. It shall be anti-pumping type and trip-free. trip. 7.C.2 Operating mechanism (i) Circuit breakers shall be operated by spring / spring charged mechanism. NO. One O-C-O operation shall be possible with failure of AC supply.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 . 4 7. evacuation and refilling equipment consisting of trolley mounted compressed SF6 cylinder.1. However. Isolators & Earth Switch (a) Isolators shall be horizontal centre break type suitable for horizontal upright type of mounting. NO. 2 nos. Type test certificates for all tests carried out on identical circuit breaker as per IEC-62271-100 shall be furnished. 3 phase.2 TCE FORM NO.1. of gas leak detector shall be included in the scope of supply. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. All routine tests on the circuit breakers shall be carried out as per IEC62271-100.7. The equipment shall be trolley mounted. it shall also be possible to operate them manually in the event of failure of power supply or outage of the drive motor with proper interlock provision for isolation of motor in case of manual operation.5960A-H-500-001 (iii) Separate pole discrepancy circuit with proper relay and other accessories shall be provided. Provision shall be made to prevent a closing operation to be carried out with the springs partially charged. A shunt trip shall operate correctly under all operating conditions of the circuit breaker upto the rated breaking capacity of the circuit breaker and at all value of supply voltage between 50% and 110% of rated voltage. Detectors shall be of reputed make and have Visual as well as Audible sound facility when leakage is detected. (b) Isolators & Earth switch shall be suitable for operation on 400V. (v) Mechanical interlocks shall be provided in the operating mechanism to prevent discharging of closing springs when the breaker is already in the closed position. 7. AC motor.7.7. ELECTRICAL SYSTEMS . All circuit breakers controlling the lines shall be provided with either closing resistors or proven controlled switching devices to reduce over voltages and in-rush currents. Contractor shall supply spare SF6 gas equal to 20% of the total requirement for the station.400 kV SWITCHYARD SHEET 8 OF 51 SPEC. (iv) A closing release shall operate correctly at all values of voltage between 80% and 110% of the rated voltage. 329 R5 .7 1X 700 MW CCPP AT NEDUNOOR.3 One set of SF6 gas filling. SECTION: D3.7. Earth switches shall be motor ISSUE R0 120 7. gas regulator with manometer and necessary coupling for filling gas in the breaker shall be provided.5 7. Disagreement circuit shall be provided which shall detect pole position discrepancy. TCE.1. (e) Base channels and other structural steel members such as operating pipes. phase coupling rods. All castings except current carrying parts shall be made of malleable cast iron or cast steel.e.5960A-H-500-001 operated with proper interlock so that it shall not operate in case respective isolator is ON and other requisite conditions are not met. SECTION: D3. The Disconnecting switches and earth switches shall be independent pole and gang operated. signalling of the open position shall not take place unless the contact system has reached a position of at least 80 percent of the clearance distance of the isolating distance. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. brazed to the channel base. ISSUE R0 121 TCE FORM NO. The poles of the isolators shall be mechanically ganged. Interlocking scheme shall be so designed as to ensure absolute safety maximum flexibility and proper switching of CT and PT circuits. 329 R5 . Flexible copper earth connectors shall be provided for connecting operating handles of isolators and earthing switches to the earthing system. Tripping of drive. Similarly they shall open after isolator opens and breaks the primary current. (g) Each pole of the isolator shall be provided with two earthing pads of non-corrodible material at opposite ends. loss of AC drive supply and DC control supply shall be wired for giving alarm. Contacts used for CT switching shall make before the isolator closed and starts carrying current. pins. (c) Isolators shall be electrically interlocked with the circuit breakers in accordance with the switchyard safety interlocking scheme. ELECTRICAL SYSTEMS .7 1X 700 MW CCPP AT NEDUNOOR. TCE. Manual operating handles shall be galvanised steel. NO. Electrical remote. (f) The isolator and earthing switch shall be provided with high current carrying contacts on the hinge and jaw ends and all contact surfaces shall be of silver faced copper. bolts. (d) The design of the auxiliary switches for the isolators shall be such that signalling of the closed position shall not take place unless the contact system has reached such a position that the rated current and the rated short time current can be carried safely. shall be hot dip galvanised or metallised. The interlocks shall be effective for all modes of operation i. Electrical local and Manual local. etc. operating mechanism boxes.400 kV SWITCHYARD SHEET 9 OF 51 SPEC. Bolt type interlock and any special accessories required on the isolator side for satisfactory operation of scheme shall be included. A weather-proof galvanised sheet steel cabinet with gasket hinged door and padlocking facility shall be provided to house the driving mechanism. This shall be in the form of bolt interlock comprising an interlock coil of latch in type to lock the isolator driving shaft and hence prevent isolator operation in the latch-in condition. Pad-locking facility shall be provided for the manual operating handle. (j) (k) Electrical interlocking arrangements shall be fail-safe type. TCE.5960A-H-500-001 (h) Earthing switch shall be provided with some isolators as indicated in main one line diagram. NO. 329 R5 . motor starters.7 1X 700 MW CCPP AT NEDUNOOR. the power operation shall be made inoperative. It shall be possible to release the latch by energising the interlock coil when certain pre-set conditions of interlocking scheme are fulfilled. Arrangement shall be provided to permit manual operation of power isolators. Isolator shall be provided with electrical interlocking feature in all modes of operation. auxiliary switches etc. (l) Isolator shall be provided with mechanical interlocking feature in addition to electrical interlocking feature described above. (ii) ISSUE R0 122 TCE FORM NO. The arrangement shall be such that when manual operating handles is in the engaged position. (m) Operating Mechanism and Controls (i) The manual operating handles shall be mounted on the base of supporting structure. Two independent earthing pads each with flexible copper braids (tinned or suitably treated against corrosion) and suitable connectors for the specified size of earth conductor lead shall be provided at the hinge end of the switch. control valve solenoids. SECTION: D3. ELECTRICAL SYSTEMS . KARIMNAGAR DIST. The operating mechanism box shall have enclosures conforming to IP 55. (i) Isolator and earthing switch shall be mechanically interlocked such that it will not be possible to close the earthing switch when the isolator is closed and vice-versa.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.400 kV SWITCHYARD SHEET 10 OF 51 SPEC. The flexible copper connections between rotating shaft of earth switch and frame shall have a cross section suitable to withstand the short time current. capacitor voltage transformers (CVTs) and Electromagnetic Voltage Transformers (EMVTs) (a) Electromagnetic VTs shall be provided for tariff metering (if required by grid) and CVTs for other metering and protection. 7. ELECTRICAL SYSTEMS . The CVTs shall be oil filled single phase type. In case of SF6 filled CTs and EMVTs. SECTION: D3. (b) (c) (d) (e) (f) (g) ISSUE R0 123 TCE FORM NO. 329 R5 .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. their operating devices and auxiliary equipment. Metering cores of CTs and EMVTs/CVTs shall be with accuracy class 0. One assembled isolator shall be subjected to 1000 operations for checking mechanical endurance. The VA burden of the tariff metering CTs shall be subject to the approval of grid authorities.7.2S for tariff metering for each line.7 1X 700 MW CCPP AT NEDUNOOR. Separate CT cores for Main-1 and Main-2 Carrier aided Distance Protection (21) for each line.3 Current transformers (CTs). The CTs and EMVTs shall be either oil filled hermetically sealed or SF6 gas filled single phase type. Tariff metering CT & PT should comply with the requirements of CEA regulations on installation and operation of energy meters & respective grid authorities which will be intimated to successful bidder during detailed engineering. A separate 2 core CT (for Main and Check Meters) of accuracy class 0.5960A-H-500-001 (n) All routine tests as per IEC 60129 shall be carried out. future additions. (o) All tests shall be made on completely assembled isolators. Tariff metering EMVT terminals shall be housed in separately sealable terminal boxes.2 respectively. KARIMNAGAR DIST.2S for tariff metering for each line. A separate 2 winding EMVT (for Main and Check Meters) of accuracy class 0. gas density monitors with remote alarm facility shall be provided. Type test certificates for all tests carried out on identical isolators as per IEC60129 shall be furnished. The rated burden for the metering and protection cores shall be decided considering all the loads/relays connected.400 kV SWITCHYARD SHEET 11 OF 51 SPEC. earthing switches.2S and 0. TCE. lead burden etc. NO. The core lamination shall be of cold rolled grain oriented silicon steel or other equivalent alloys. SECTION: D3. Secondary terminals of CTs shall be brought out in a weather proof power coated terminal box. TCE. ELECTRICAL SYSTEMS . Further. The box shall have a degree of protection IP-55. NO. The magnetising current at Vk/2 shall be as minimum as possible (say 15 mA). CT/CVT/EMVT assembly shall be suitably braced to withstand stresses induced due to seismic disturbances. The CVT secondary shall include necessary MCBs with auxiliary contacts for alarm for protecting the secondary winding. Facility shall be provided for short circuiting and grounding the CT secondary at the terminal box. Expansion chamber at top shall be provided with oil sight glass. for the purpose of supervision on remote panel. Shall have a rated extended primary current of 120% of rated primary current.5960A-H-500-001 (h) The knee point voltage for PS class cores shall be decided considering the total connected burden with adequate margin. KARIMNAGAR DIST. 329 R5 . (i) (j) (k) (l) (m) (n) (o) (p) (q) ISSUE R0 124 TCE FORM NO. The cores shall produce undistorted secondary current under transient conditions at all ratios with specified parameters. Shall have provision for taking oil samples from bottom of CT without exposure to atmosphere to carry out dissolved gas analysis periodically. Insulator shall be one piece without any metallic flange joint.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.7 1X 700 MW CCPP AT NEDUNOOR. line terminals of the CVTs shall be brought out through second set of MCBs. All the terminal boxes shall be powder coated with IP-55 degree of protection. The tank/base and all exposed ferrous parts shall be hot dip galvanised conforming to applicable standards.400 kV SWITCHYARD SHEET 12 OF 51 SPEC. Tariff metering core terminals (for connecting main and check meters) shall be housed in a separate sealable terminal box. All the taps of each core shall be wired to Marshalling Box to facilitate ratio changing. ELECTRICAL SYSTEMS . tappings will have to be provided on the secondary windings. The neutral of CTs. The MB shall be fixed to the supporting structure of CT/CVT/ EMVT. KARIMNAGAR DIST.5960A-H-500-001 (r) Each CT shall be equipped with an over voltage protective device to limit the voltage developed across the secondary terminals to a safe value not exceeding 3 kV under open circuit condition. 329 R5 . CVTs and EMVTs shall be formed in marshalling box of the respective equipment. (s) (t) (u) (v) (w) (x) (y) (z) (w) Tests & Test Reports All routine tests on the 400 kV voltage and current transformers shall be carried out as per relevant standards. The instrument transformers shall be provided with filling and drain plugs.I supporting structure. All CTs/EMVTs shall be provided with stainless steel bellows. CVTs. The MBs shall be fitted with adequate no.7 1X 700 MW CCPP AT NEDUNOOR. A cushion of nitrogen gas shall be provided to allow for expansion. At least 20% spare terminals shall be provided. of 2. Type test certificates for all tests carried out on identical voltage and current ISSUE R0 125 TCE FORM NO. for which purpose. SECTION: D3. It shall be possible to select the ratio on any core independent of the setting in the other cores. of disconnector type of test terminal boards suitable for terminating 2 nos.5 sq mm multi-strand copper wires. Neutral of all cores of CTs. TCE.400 kV SWITCHYARD SHEET 13 OF 51 SPEC. Oil filled insulator/bushings shall be hermetically sealed to prevent ingress of moisture. Each CT/CVT/EMVT shall be supplied with suitable G. Polarity marks shall indelibly be marked on each instrument transformer and at the secondary terminals at the associated terminal block. NO. One MB for each set of 3 CTs/CVTs/EMVTs shall be provided.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. and EMVTs shall be earthed only at protection panels by means of a disconnecting link. Cables with sufficient number of cores are run from these marshalling boxes to protection panels. Further the impedance shall be accurately balanced between the three-phase system. 50 MVAR Three Phase Oil Filled Bus Reactors are considered in the switchyard. ELECTRICAL SYSTEMS . Bus reactors shall be designed for 110% continuous over-fluxing withstand capability. TCE.7. Bus reactors shall operate continuously at the highest system voltage without exceeding the guaranteed temperature rise.7 1X 700 MW CCPP AT NEDUNOOR.4 BUS REACTORS a) 400 kV. The losses of the reactor shall be limited to the values to permit ONAN type of cooling. KARIMNAGAR DIST. at present. ISSUE R0 126 b) c) d) e) f) g) h) i) j) k) TCE FORM NO. Windings shall be of copper unless specifically approved by the PURCHASER. the exact requirement for these Bus reactors will be confirmed during detailed engineering based on the system study to be carried out by the bidder. The reactors shall be either gapped core type or coreless type.5 times rated highest system voltage. the bidder shall consider these Bus reactors in their offer. The conductors shall be transposed at sufficient intervals in order to minimise eddy currents and equalise the distribution of currents and temperatures along the windings.400 kV SWITCHYARD SHEET 14 OF 51 SPEC. 7. If test reports are not in line with the requirement of IS/IEC then the Contractor shall carry out type test at no additional cost to the Owner. However. Special measures shall be taken by providing non-magnetic shielding to combat the effects of stray/leakage flux. NO. The magnetic circuit of reactor shall be so designed that the audio sound level shall be minimum. The total harmonic content in the phase current of a star connected reactor and zero sequence components appearing in the neutral shall be below 3% of the crest value of rated current. However. 329 R5 . The impedance of reactor shall have a constant value upto about 1. SECTION: D3.5960A-H-500-001 transformers shall be furnished.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Tank shall be made from good commercial grade low carbon steel and shall be of welded construction. KARIMNAGAR DIST. Lightning Arrester 7. ELECTRICAL SYSTEMS .7 1X 700 MW CCPP AT NEDUNOOR. which shall be connected to route any gas collection through the Buchholz relay. The device shall be rain-proof after blowing and shall be provided with a device visible from ground to indicate operation.5960A-H-500-001 l) Tank shall be provided with a pressure release device which shall operate at a pressure below the test pressure for the tank and radiators.5960A-EL-SK-2002. m) n) o) p) (d) q) The Bushing CT’s for protection shall be provided as per the enclosed Main One Line Diagram TCE. without removing the cover.5 ISSUE R0 127 TCE FORM NO. Condenser type bushings shall be equipped The angle of inclination to vertical shall not exceed 30 deg. SECTION: D3. NO. 329 R5 . Bushings shall be of the oil-filled condenser type with a central tube and draw-in conductor. The under-carriage of the reactor shall be provided with detachable steel flanged wheels.400 kV SWITCHYARD SHEET 15 OF 51 SPEC. Current transformers shall be provided and the bushing shall be so arranged that it can be removed without disturbing the current transformers and secondary terminals.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE. They shall be of full-way type with screwed ends and shall be opened by turning counter clockwise when facing the hand wheel. An equaliser pipe connecting the pressure relief device to the conservator shall be supplied. There shall be no oil leakage when the valves are in closed position. Separately mounted radiator banks shall have bolted flanged connections and pipe extensions to permit withdrawal of reactor tank without disturbing the radiators.7.It shall be possible to remove turret mounted Bushing CT's from the reactor tank. (a) (b) (c) Provision for power factor testing without disconnecting main leads. Stress rings and lower and shields. which shall be connected to the connector housed in the helmet of the bushings. Valves shall be of forged carbon steel upto 50 mm size and of gun-metal or of cast iron bodies with gun-metal fittings for sizes above 50 mm. Bushing turrets shall be provided with vent pipes. The pull through lead shall be fitted with a gas bubble deflector. Operational requirements (i) (b) Shall protect power transformers. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS . (iii) Shall be capable of withstanding meteorological and short circuit forces under site conditions. instrument transformers etc. (iv) Each lightning arrestor shall be complete with insulating base for mounting on structure. 329 R5 . circuit breakers. gap less lightning arrester shall be provided as per the Main one line diagram No. KARIMNAGAR DIST. class – IV pressure relief class-A.5960A-H-500-001 (a) 360 kV. TCE. 20 kA nominal discharge current. (c) Specific Requirements Arrester shall be suitable for installation in effectively earthed system.7 1X 700 MW CCPP AT NEDUNOOR. NO. Values and calculations shall be furnished with offer. Shall be suitable for circuit breaker duty cycle in the given system. (iv) Shall be fully stabilized thermally to give a life expectancy of one hundred (100) years under site conditions and take care of effect of direct solar radiation. (i) (ii) Shall be hermetically sealed single phase unit. (v) Shall be capable of discharging over-voltages occurring due to switching of unloaded transformers and long lines. The Contractor shall carry out the insulation coordination studies for deciding the exact location and voltage levels of the LA’s. with insulation levels specified in this specification. TCE. disconnecting switches.400 kV SWITCHYARD SHEET 16 OF 51 SPEC. ISSUE R0 128 TCE FORM NO. (ii) (iii) The reference current shall be high enough to eliminate the influence of grading and stray capacitance on the measured reference voltage. metal oxide.5960A-EL-SK-2003. Shall be robust with excellent mechanical and electrical properties. TCE. Line trap shall prevent undue loss of carrier signal for all conditions. terminal and lightning arrester earth terminal. NO. It shall be mounted on a tripod structure formed by three solid core bus post insulators.6 Line Traps (a) Line trap shall be of pedestal mounted. ELECTRICAL SYSTEMS . wound coil. Insulation level of the same shall not be less than 3. (ix) Surge monitor shall be provided for each arrester and the same shall be mounted at a suitable height to facilitate easy reading of the counter mechanism and leakage current detectors. (vi) LA’s shall not fail due to porcelain contamination. (xi) Suitably sized bypass copper shunts shall be provided for bypassing the discharge counter for removal / maintenance of the counter.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (viii) The end fittings shall be non-magnetic and of corrosion proof material.6 kV. KARIMNAGAR DIST. (vii) Porcelain shall be so coordinated that external flashover will not occur due to application of any impulse or switching surge voltage upto maximum design value for LA.7. (x) Insulated copper conductor of adequate size and length shall be used for connecting discharge counter. It shall have negligible impedance at power frequency.5960A-H-500-001 (v) LAs shall be provided with grading and/or corona rings as required. 329 R5 . which shall be relatively high over the frequency band appropriate to carrier transmission. 7. (b) (c) (d) (e) ISSUE R0 129 TCE FORM NO.7 1X 700 MW CCPP AT NEDUNOOR. It shall be suitable for outdoor pedestal mounting and mechanically strong to withstand the stresses due to wind pressure. SECTION: D3.400 kV SWITCHYARD SHEET 17 OF 51 SPEC. broad band tuned. TCE. 329 R5 .5960A-H-500-001 (f) Line trap shall consist of a main coil designed to carry continuously the rated current without exceeding the limit of temperature rise limits. The spring washers shall be electro-galvanized mild steel. SECTION: D3. the foundation shall be constructed in all the three phases to facilitate the change of location of line trap between the phases. the same clamps/ connectors shall be used with 2mm thick bimetallic liner. Suitable corona rings shall be provided to meet corona and radio interference performance as specified for 400kV equipment if required. ELECTRICAL SYSTEMS . cracks and cavities. Shall be designed and arranged such that neither significant alternation in its protective function nor physical damage shall result from either temperature rise or the magnetic field of the main coil at continuous rated current or rated short time current. All castings shall be free from blow holes. (g) (h) (i) (j) 7.400 kV SWITCHYARD SHEET 18 OF 51 SPEC. For sizes below M12. nuts and plain washers shall be hot dip galvanized mild steel for sizes M12 and above. KARIMNAGAR DIST.7.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. Suitable surge arresters shall be provided. It shall be equipped with bird barriers and shall be spray painted as per IS. surface blisters. Bolts. ISSUE R0 130 (b) (c) (d) (e) (f) (g) TCE FORM NO. they shall be electro-galvanized mild steel. Shall be Galvanized mild steel for connecting to shield wire.7 1X 700 MW CCPP AT NEDUNOOR. All sharp edges and corners shall be rounded off to meet specified corona and radio interference requirements. In case the terminals are of copper.7 Clamps and Connectors (a) Shall be Aluminium alloy casting conforming to designation A6 of IS:617 for connecting to equipment terminals and conductors of aluminium. Shall have same current rating as that of the connected equipment with temperature rise limited to 350C over 500C. It shall be provided with protective device and tuning device. Even though the line traps shall be installed in two phases. 329 R5 . Flexible connectors.8 7.7. (b) (c) 7.8 Insulator String Hardware (a) Shall be of bolted type and forged steel except for insulator cap. etc. housing various IEDs such as Bay Control Units (BCUs). KARIMNAGAR DIST. DC battery. (b) (c) (d) 7. RTU for SLDC/RLDC. ISSUE R0 131 TCE FORM NO. Design shall take care of fixing and removing during installation and maintenance. Shall be manufactured to have minimum contact resistance. ELECTRICAL SYSTEMS .7. PLCC/OLTE Panels. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (k) 7.8.1 Switchyard Control and Relay Panel Bidder shall offer air conditioned outdoor kiosks suitably located in switchyard. Protection Panels. which can be of malleable cast iron. C. SCADA servers and associated equipment.400 kV SWITCHYARD SHEET 19 OF 51 SPEC. battery chargers. braids or laminated strips shall be made up of copper/ aluminium. Current rating and size of terminal/conductor for which connector is suitable shall be embossed/punched on each component. Shall also generally meet the requirements of clamps and connectors as specified above. Tension string assembly at one end shall be supplied with suitable turn buckle.5960A-H-500-001 (h) (i) (j) All current carrying parts shall be at least 10 mm thick. SCADA Operator Station. TCE.9 Spacers (a) Shall be non-magnetic material except nuts and bolts. However. which shall be of hot dip galvanized mild steel. In one span.7 1X 700 MW CCPP AT NEDUNOOR. Fault Disturbance Recorders. SECTION: D3. Shall generally meet the requirement of clamps and connectors specified above. Suitable sag compensating spring shall be supplied in case the design calculations show excessive variation of the sag over the temperature range of 0 to 80 deg. 329 R5 . required for the scheme are deemed to be included in the Contractor scope. All the auxiliary relays. The layout of equipment/panels shall be subject to Purchaser’s approval. KARIMNAGAR DIST.2 The control and interlocking scheme suitable for one and a half breaker switching scheme shall be provided. All CT.5960A-H-500-001 DCDB. etc. PT. Rapid reclosing & delayed reclosing features shall be 7.7 1X 700 MW CCPP AT NEDUNOOR. Provisions shall be made to accord higher reclosing priority to main breakers.3 ISSUE R0 132 TCE FORM NO. trip relays. Technical requirements of outdoor kiosks are detailed elsewhere in the specification. etc. One kiosk shall be considered per diameter (comprising of two circuits in one and half breaker scheme) of 400kV switchyard. timers.400 kV SWITCHYARD SHEET 20 OF 51 SPEC. 400 V ACDBs. TCE. or to issue reclosing command to both breakers simultaneously.as a part of BCU (c) 7. Contractor shall furnish block interlock diagrams for the switchyard for Owner’s approval. All the necessary relays. etc. ELECTRICAL SYSTEMS . control cables. In case of incomplete diameter.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Different routes shall be adopted for OFC. UPS system. The auto re-closing scheme shall be available in one of the numerical line protection relays but shall get independently actuated by the operation of both the protective relays. auxiliary relays shall be provided. The kiosk shall be provided with fire alarm system with at least two detectors and shall be wired to fire alarm panel as described elsewhere in the specification.8. SECTION: D3. The switchyard protection shall consist of: (a) One complete set of relay panels for 400 kV equipment switchyard (b) System fault locaters – as a part of Main-1 numerical relay (BCU) Stand alone Disturbance recorders . Line bays shall be provided with single phase and three phase auto reclosing feature.8. hardware.. The scheme as approved by Owner shall be provided. from switchyard equipment shall be connected to respective IEDs located in kiosks. shall be provided for housing busbar protection panels at suitable location in switchyard. switches. if required. NO. Two optical fibre cables (OFC) shall be laid to connect BCUs to SCADA for data exchange. the kiosk shall have necessary space for accommodating the future bay IEDs. shall be located in the switchyard control building for overall optimization in respect of cabling and control room building size. One additional kiosk. 10 7.8. It shall not be possible to close in manual mode if both line and bus are live.6 7. isolators and earth switches. 7. Synchronising facility shall be provided for all lines in DCS. SECTION: D3.7 1X 700 MW CCPP AT NEDUNOOR. Relay setting calculations shall be furnished by the Contractor to the Owner for his approval. the synchronising criteria shall be fulfilled as indicated by the closing permissive provided by check synchronising relay. Measurement required in DCS shall be as given in Section D2.4 Live line–dead bus closing and dead line-live bus closing facilities shall be provided using dedicated relays for this purpose.8.11 7.5 7.12 7.13 TCE FORM NO. In check synchronising position. closure is possible only if either the line or the bus is dead. At least 2NO + 2NC spare contacts shall be wired to terminal block after fully utilising for control. All main protections shall be of numerical type. The functional requirements and characteristics of the relays specified are the ISSUE R0 133 7.9 7. etc.8. NO.8.8. 329 R5 . It shall be possible to control (including synchronising) all the 400 kV switchyard breakers and isolators from SCADA . KARIMNAGAR DIST.5960A-H-500-001 provided. Synchronizing function shall be through BCU for GTG units and a separate synchronizing equipment along with check synchronizing facility to be provided for STG units. In manual mode.7 7. protection.5960A-EL-SK-2003 and Section D2.. In the event of shortage of contacts in main circuit breakers. Control and indication shall be provided for each of the breaker and isolator. Monitoring-Indication.8.400 kV SWITCHYARD SHEET 21 OF 51 SPEC.8 7.8.8.8. contact multiplying relays shall be used. Indicating lamps for fulfilment of the permissive condition shall be provided. latching type with electrical reset and shall be mounted in switchyard relay panels. All conditions requiring blocking auto reclosure shall be considered.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE. annunciation. The measurement requirements for each of the bays shall be as per the Main one line drawing TCE. The same shall be two coil. abnormal conditions.4 All relay panels shall be located in outdoor kiosk and these kiosks shall be located in switchyard.8. ELECTRICAL SYSTEMS .4 I & C requirements. KARIMNAGAR DIST. The scheme as approved by Purchaser shall be provided. Contractor shall provide a laptop and the necessary software for relay settings. However.5960A-H-500-001 minimum required. The configuration/specification of the laptop shall be the latest as available in the market as on date of supply. 329 R5 . PT supervision. hardware.16 7. data transfer and parameterization. etc. This laptop shall be common for SCADA BCU (Bay Control Unit) parameterization and protective relay parameterization. parameterisation and the retrieval of data from the relay and relay operations shall be possible from SCADA operator station in addition to the laptop. Contractor shall furnish block interlock diagrams for the switchyard for Purchaser’s approval. required for the scheme are deemed to be included in the Contractor’s scope. switches.17 7. All the auxiliary relays. 7. SECTION: D3.8. static relays have to be provided for breaker protection. The relay settings. etc.400 kV SWITCHYARD SHEET 22 OF 51 SPEC. Buses. timers. For this.7 1X 700 MW CCPP AT NEDUNOOR. The interlocking scheme shall be hard wired and shall be suitable for one and a half breaker switching scheme. The numerical protection relays shall be able to be configured locally. It shall also be possible to configure the SCADA BCUs remotely from the SCADA Engineering Station.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The responsibility of establishing the equivalence or superiority of relays offered vis-a-vis the stipulation of the specification rests with the Contractor. 7. The communication protocol between the numerical relays and SCADA system shall be IEC-61850.15 7.8. (a) The protections envisaged for each 400 kV switchyard bay are listed below and also in Main one line diagram Drg.6 for Generator protection shall be followed for switchyard protection as well. ELECTRICAL SYSTEMS . Protection Philosophy The protection philosophy indicated in section D3. Numerical relays shall be provided for main and secondary protection of lines. NO.8.9 ISSUE R0 134 TCE FORM NO. The communication between the numerical relays and SCADA system shall be through serial link with fibre optic cable connection.14 The Contractor shall provide licensed copy of software on CD for relay setting software and calculations for future use of the Purchaser.8. TCE. No. Relay setting calculations shall be furnished by the Contractor to the Purchaser and the grid authorities for their approvals. dead bus/live line closing and safe grid re-establishment (271.3-zone carrier aided distance protection (21-2) with in-built back-up directional over current and earth fault protection (67/67N). 329 R5 . (iii) Identical distance relays shall be supplied loose for four (4) 400kV lines (iv) Fuse fail relay (FFR) for each secondary of CVT / EMVT (v) Two stage over voltage relay (instantaneous & time delayed) (vi) Stub protection (50STB) as part of main-1 & main-2 protections for 400 kV lines to protect the stub portion of line bays during line outages Distance to fault locator (DFL) Fault disturbance recorder (FDR) with 8 analog and 16 digital channels. It shall be read in conjunction with the following and all protection indicated shall be provided. NO. Both main-1 & main-2 protections shall be (ii) mechanically. SECTION: D3. (vii) (viii) (ix) Under voltage relays for live line/dead bus. 21-1 & 21-2 line protection relays shall have all the basic protection like SITF. ELECTRICAL SYSTEMS . Main-2.400 kV SWITCHYARD SHEET 23 OF 51 SPEC. Both main-1 and main-2 protections shall work on different principles/algorithms. TCE.5960A-H-500-001 TCE. 27S) ISSUE R0 135 TCE FORM NO.3-zone carrier aided distance protection (21-1) with in-built back-up directional over current and earth fault protection (67/67N).5960A-EL-SK-2003. KARIMNAGAR DIST. (b) Line Bay Relay panel (Each Line Bay) (i) Main-1. PSB etc. physically and electrically separated into two separate and independent systems. 27-2.7 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. dead line charging and live line reclosing. suitable (e) (ii) (iii) (iv) (v) (vi) f) Reactor Protection Over Current Protection (50 and 51) Neutral Over Current Protection (51N) High Impedance type Differential Protection (87R) ISSUE R0 136 TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (c) Busbar Protection Relay Panel Numerical type. KARIMNAGAR DIST.400 kV SWITCHYARD SHEET 24 OF 51 SPEC. Auxiliary relays and timers in adequate numbers to make the protection scheme and discrepancy switch scheme complete. Each breaker shall be provided with its own trip relay. CT supervision and In-Out switch.5960A-H-500-001 (x) Auto reclosing scheme relays with single phase & three phases reclosing. 329 R5 . Supervision relays for tripping relay (98 LT1 to LTX) to supervise the coil of each trip relay. LBB in-out switch shall also be provided. ELECTRICAL SYSTEMS . Pre and Post close Trip circuit supervision relay for each trip circuit (98L) High speed trip relays (86L). Each trip relay shall be supervised and contacts shall be made available for annunciation/SCADA.7 1X 700 MW CCPP AT NEDUNOOR. NO. Auxiliary CTs and auxiliary VTs with characteristics and accuracy as required. distributed busbar protection scheme based on”low impedance” principle for selected bus arrangement shall be provided. (d) Over head line differential protection (between GT HV bushing & switchyard gantry) (87OH) shall be part of switchyard relay panel (SRP). It shall have check and discriminating zones. TCE. SECTION: D3. Common Items/protections to be included in all relay panels (i) Local breaker back up protection with its own trip relay (50 LBB for each breaker). Push buttons for testing and resetting the LEDs shall also be provided.5960A-H-500-001 7.1 The functional requirements and characteristics of the relays specified are the minimum required. Numerical relays shall have self diagnostics and watch dog feature for remote annunciation in SCADA. NO.10 TCE FORM NO. If any of the protections are not covered in the main numerical relay.4 7. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. a different tone shall be sounded on the hooter and the alarm shall be represented in a different colour on the screen. Contact multiplication relays for 400kV circuit breakers and associated isolators shall be provided for this purpose.7 1X 700 MW CCPP AT NEDUNOOR. The contact rating of contactors provided in SCADA Panels shall be suitable for making/breaking of control circuit currents of the respective devices being controlled. separate discrete numerical/microprocessor/static relays shall be provided. The numerical protective relays shall be based on internationally accepted Open Protocol IEC-61850. KARIMNAGAR DIST.9. Supervisory Control and Data Acquisition (SCADA) System ISSUE R0 137 7. The protective relays shall be of integrated numerical type with serial interface for communication with SCADA system.6 7. The responsibility of establishing the equivalence or superiority of relays offered vis-a-vis the stipulation of the specification rests with the Contractor.5 7.9.9. required for tripping/interlock schemes shall be provided by the Contractor.9. For each category. ELECTRICAL SYSTEMS .400 kV SWITCHYARD SHEET 25 OF 51 SPEC. All hardware. In addition to the contacts required as per the schemes. timers etc.2 7.3 7. All numerical relays and SCADA clock shall be time synchronised with the GPS master clock. alarms in SCADA.9. Any additional protection considered necessary by the Contractor shall also be provided by him. sequence event recorder wherever required. All SCADA alarms shall be categorized into different categories (typically 5). 329 R5 . All digital inputs shall have a time resolution of 1 (one) ms. The protection schemes shall include all the necessary contacts for interlocks. auxiliary relays. Contractor shall wire out to the terminal block at least one NO & one NC spare contacts of each of the relays.9. All protective relays and meters shall be provided with test terminal blocks for secondary injection testing of protection relays and meters. TCE. Protective relays shall have adequate number of site configurable LEDs and output relays. SCADA system shall be fail safe design.2 7.10. The communication between the numerical relays and SCADA system shall be with fibre optic cable.4 7. The offered SCADA system shall be based on internationally accepted Open Protocol IEC 61850. synchronising..5 7.10.7 1X 700 MW CCPP AT NEDUNOOR. All the SCADA switches and servers shall be located in switchyard control room. 329 R5 . remote control functions. One (1) no.400 kV SWITCHYARD SHEET 26 OF 51 SPEC. annunciation. The controller shall be configured with redundant CPU. Engineering Station shall be provided in the Switchyard control room to make the SCADA configuration changes and system settings. The SCADA system shall be generally in line with the details shown in SCADA System Configuration Drawing. ELECTRICAL SYSTEMS . mimic diagram. The OS and ES display/monitors shall be dual headed.10. in Switchyard Control Room. The redundant CPU shall be configured to operate as hot standby.7 TCE FORM NO. Operator Station(OS) for SCADA (for control and monitoring of complete 400 kV switchyard equipment) shall be located in Central Control Room (CCR) of power plant and one (1) no. shall be provided for the switchyard. Scalability and Open Architecture. TCE. indication. LCD type and the make shall be finalised during detailed engineering so as to match with those ISSUE R0 138 7. etc.10. The Controller shall also be configured with double redundant power supply units.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.10. The SCADA system shall be based on a de-centralised concept with bay oriented distributed intelligence devices.6 7. sequence of events recording.10. The Engineering Station(ES) located in Switchyard control room shall also be configured as Operator Station to act as standby in case of failure of the Operator Station in Switchyard control room. All SCADA servers & Front End Processor servers (if any) shall be rack mounted. The Contractor shall furnish documents to establish and prove that the system is highly reliable with very high MTBF (Mean Time between Failures). for safety and availability reasons.10. NO. metering. One (1) no.5960A-EL-SK-2004. SECTION: D3.5960A-H-500-001 7. 24 inches size. The offered SCADA system shall be of latest state of art design with capability to interface with bay control units (separate for each bay).3 7. TCE. The switchyard equipment shall be remote controlled from Central Control Room (CCR) of the Power Plant through the SCADA HMI in order to enable the Switchyard Control Room being totally un-attended.1 SCADA system comprising of various controls. KARIMNAGAR DIST. It shall be possible to configure the printers to print on demand/online or at specified intervals. phase angle.7 1X 700 MW CCPP AT NEDUNOOR.400 kV SWITCHYARD SHEET 27 OF 51 SPEC. The closing operation of line breaker shall involve the following steps. The required selection shall be provided in the operator station of Switchyard control room. It shall not be possible to control the switchyard equipments from both the locations simultaneously. SECTION: D3. a) Setting voltage. In dead bus/line mode.10.10 TCE FORM NO. Synchronising facility shall be provided for all lines in SCADA.live bus. the synchronising criteria shall be fulfilled as indicated by the closing permissive provided by check synchronising relays in-built in BCUs (separate sync check relays are not envisaged). Information exchange shall be provided from SCADA to plant DCS through suitable. All printers shall be equipped with USB port and enough USB cables (minimum 5m length) to enable the printers to be placed in a convenient location.5960A-H-500-001 provided for Main Plant DCS. fast. a) selection of the breaker to be closed. ELECTRICAL SYSTEMS .8 The control location for the switchyard equipments shall be Switchyard control room by default.e. The correct voltage for synchronizing and energizing is derived from the auxiliary switches of the circuit breakers and the isolators and shall be selected automatically by the bay control and protection IEDs. Display of voltages and frequencies of incoming and running supplies. closure is possible only if either the line or the bus is dead. permissive signal shall be simulated in the SCADA operator station. reliable and redundant serial communication interface. The synchronising of the line shall be possible through both main breaker and the middle breaker. synchroscope and the sync. Control room furniture for mounting the operator station along with 3 nos.10. 329 R5 . The console on which the operator station is mounted shall be properly ventilated (forced cooled if required). NO. All features shall be available viz. KARIMNAGAR DIST. necessary printers as shown in SCADA Configuration Drawing shall also be provided for SCADA system. The synchronism and energizing check functions shall be bay oriented and distributed to the bay control units and/or protection devices. In check synchronising position. and frequency difference b) Energizing for dead line . chairs shall be provided in the switchyard control room. TCE. whether both the line and the bus are ISSUE R0 139 7. 7.9 7. In the CCR.dead bus or dead line – dead bus with no synchro-check function c) Synchronising between live line and live bus with synchrocheck function. viz. But provision shall be made available in the SCADA to control the switchyard equipments from Centre control room (CCR) also. b) mode of closing operation i.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. live line .10. annunciation. etc.5960A-H-500-001 live or only one of them is dead as sensed by voltage relays connected to the respective CVTs. At least 2NO + 2NC spare contacts shall be wired to terminal block after fully utilising for control. Transducers shall be provided. earth switches shall be brought to the protection panels for indications. The exact no. NO.7 1X 700 MW CCPP AT NEDUNOOR. The same shall be two coil. the logic develops using the contacts of bus voltage and line voltage relays which generates permissive for closing of the breaker. If either the line or the bus is dead. all the required signals including PT signals for synchronising shall be transferred to SCADA system.e.400 kV SWITCHYARD SHEET 28 OF 51 SPEC. 7. It shall be possible to control the middle breaker from both DCS (through auto/manual synchronisation) and SCADA with the help of a selection available in the SCADA software.13 7. For monitoring of all other bay wise electrical quantities. If “SCADA” is selected.10. etc. interlocks. This permissive shall be displayed on the SCADA HMI. In live-bus/live-line case. battery charger current. SECTION: D3. The selection shall have two positions i. 400 kV bus voltages.10. Transducers shall be used only for monitoring of non electrical quantities such as Bus reactor oil and winding temperature and for electrical quantities such as battery charger voltage. contact multiplying relays shall be used. SER function. protection. TCE. “SCADA” and “DCS”. KARIMNAGAR DIST.12 7. It shall be possible to control and monitor (including synchronising) all the 400kV switchyard breakers & isolators from SCADA except main ISSUE R0 140 7.10. All the auxiliary contacts of main equipment such as circuit breakers.11 The generator transformer main breaker will be controlled from main plant DCS.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. isolators. synchronisation between the two voltages is checked by the check synchronisation relay which generates permissive only if the synchronisation criterion is met. The control of middle breaker from SCADA shall be suitably interlocked such that its closure is not possible when it is used as generator synchronising breaker. of analog and digital IO (input/output) points shall be dicided during detailed engineering. wherever necessary. for the indication of electrical parameters related to switchyard bays as required. In case of shortage of auxiliary contacts.10. latching type with electrical reset and shall be mounted in switchyard protection panels. IEDs such as BCUs shall be used.14 TCE FORM NO. If “DCS” is selected. c) issuing the closing command after obtaining the synchro permissive or live-bus/dead-line or liveline/dead-bus permissive as the case may be. ELECTRICAL SYSTEMS . all the required signals shall be transferred to DCS/GRP (Generator Relay Panel). 329 R5 . wrong selection of PT supply. Main circuit breakers of generators are controlled from Central Control Room through Plant DCS and monitored both in DCS and SCADA. voltage selection. VT fuse fail relay operation. LBB operated. selection of control from SCADA/DCS. VT circuit unhealthy of each VT. auto re-closing operation. DC supply fail. shall be available in SCADA. The selection of control of middle breaker of generator bay from DCS/SCADA shall be displayed both in DCS and SCADA. etc. LBB operation of each breaker.5960A-H-500-001 circuit breakers of generators. local/remote selector switch positions. opening and closing commands. shall be available in SCADA. Trip circuit unhealthy of each equipment. etc. 7. trip relay faulty. synchronising selection. protection unhealthy of each equipment. DC supply failure of each protection / control scheme as appropriate.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.400 kV SWITCHYARD SHEET 29 OF 51 SPEC. change of positions of switches such as Local/Remote selection. isolators and earth switches. etc. TCE. NO. DC & UPS system alarms. synchronising switch positions. Trip relay unhealthy of each equipment. Busbar protection. this list shall include all events and operation of switchyard equipment that are considered essential for analysis of faults. pole discrepancy relay operation. Mimic ISSUE R0 141 b) 7.15 Monitoring – SCADA a) Indication – status of all breakers. c) Event register with time stamping – Opening or closing of all breakers. SF6 pressure Low. successful /unsuccessful auto reclosure. abnormal conditions of breakers. trip circuit faulty. isolators and earth switches of all 400 kV bays. SECTION: D3. operation of all protection and trip relays. As stated at b) above. 329 R5 .10. selection of control from SCADA/DCS. The alarm states are not exhaustive. Auto re closing selection.16 TCE FORM NO.10.7 1X 700 MW CCPP AT NEDUNOOR. Earth switches shall be operated only from local but is monitored in SCADA. The Contractor shall include all alarm states deemed necessary for the safe operation of the system. auto reclosing selection. ELECTRICAL SYSTEMS . Isolators and earth switches pertaining to generator transformer bay shall be monitored both in DCS and SCADA. voltage selection. Abnormal conditions to be considered for alarm inputs are 400 kV system operation of each line protection. direct trip send and receive. KARIMNAGAR DIST. 10. KARIMNAGAR DIST. TCE.5960A-H-500-001 A mimic diagram depicting the entire electrical system being controlled from the system with different colours for different voltage levels shall be provided in SCADA operator stations.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.18 Event logging and trending facilities shall be provided in SCADA system.5960A-EL-SK-2003 and as given below: Feeder Description (a) GT bays DCS Operator Station V (All phases) A (All phases) MW MVAR Tap position.400 kV SWITCHYARD SHEET 30 OF 51 SPEC. Winding & Oil temperature TVM V(All phases) A(All phases) MW MVAR MWH MVARH TVM V(bus 1&2) F(bus 1&2) (b) 400 kV line bays (c) 400 kV Bus PT 7. SCADA system shall have provision for expansion and shall be capable of communicating with other systems through open protocol. NO. ELECTRICAL SYSTEMS . 329 R5 . The colours of different voltage levels shall be as per relevant IS applicable for mimic on panels. It shall be possible to store historical data for a minimum of two years.10. 7.7 1X 700 MW CCPP AT NEDUNOOR.10.17 Measurement The measurement requirements for each of the bays shall be as per the Main one line drawing TCE. SECTION: D3. It shall be possible to trend different parameters on the same trend. 7.19 The Contractor shall make provision for terminating 4-20 mA analog signals and potential free digital signals for the following data on a terminal block in a suitable interface panel located in switchyard control building for transmission to SLDC (State Load Despatch Centre) and RLDC (Regional Load Despatch Centre) through RTU (Remote ISSUE R0 142 TCE FORM NO. 329 R5 . • • • • MW and MVAR of all lines MW and MVAR of HV side of all generator transformers Voltage and frequency of 400 kV buses ON/OFF positions of all breakers and isolators of all line bays. Generator transformer bays. The energy meters(EM) shall not be connected to the RTU’s. Tap positions of GTs & UATs • 7. b) c) ISSUE R0 143 TCE FORM NO. dead-line/live-bus and live-line/livebus breaker closing. The actual data to be transmitted to SLDC/RLDC shall be finalised during detailed engineering and the following is the minimum data to be transmitted through RTU. The BCU shall comply with relevant IEC/BIS standards.5960A-H-500-001 Transmission Unit). The BCUs shall be installed in the respective protection panels of each circuit breaker in the switchyard relay room (Outdoor Kiosk). The BCUs shall be independent of each other and functioning shall not be affected by any fault occurring in any of the other BCUs. including live-line/dead-bus.11 Bay Control Unit (BCU) a) The BCU shall be an intelligent unit and shall be state of the art technology. The specification of RTU provided for this purpose by the Contractor shall be subject to approval by the SLDC/RLDC authorities. TCE. NO. ELECTRICAL SYSTEMS . KARIMNAGAR DIST. Bus PT bays. Direct hard wiring shall be employed for critical tripping. The BCU shall provide direct connection to the switchyard equipment for control (with or without interposing relays) and shall perform control and monitoring functions.7 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The degree of protection of the panel shall be IP-52. Numerical protection relays shall also be connected to the SCADA bus for retrieval of data. The communication link between BCU and SCADA shall be redundant. The control voltage for the BCU shall be 220V DC. It shall perform control functions in accordance with control commands from SCADA and shall also do monitoring of the respective bays. Protection relays shall be separate and shall not be part of BCU. BCU shall have adequate number of ports for communication and interface with switchyard control system for bay control and monitoring.400 kV SWITCHYARD SHEET 31 OF 51 SPEC. instrument transformers. 329 R5 . licensed software for configuration and parameterization of SCADA shall be delivered on CD along with BCUs. isolators. The analog and digital signals pertaining to a circuit shall be taken through the BCU provided for that circuit. earth switches. The BCU shall have at least the following features: i) Monitoring The following monitoring functions shall be provided as a minimum : • Status monitoring and failure monitoring (in SCADA HMI) of bay equipment like breaker. NO. ELECTRICAL SYSTEMS . The configuration shall be carried out from local or from laptop computer but operation shall be from SCADA operator station. ISSUE R0 144 TCE FORM NO. breaker auto-reclose.5960A-H-500-001 d) Atleast one bay control unit (BCU) shall be provided for each breaker.400 kV SWITCHYARD SHEET 32 OF 51 SPEC. KARIMNAGAR DIST. protection relays and ancillary equipment metering (measured-value acquisition) Signal and command indications Switching statistics in BCU (breaker ON/OFF. One no. SECTION: D3. pole discrepancies) and data stored in SCADA server Energy metering values e) f) • • • ii) Control The following control functions shall be provided as a minimum: • • Control of circuit breakers and isolators Interlocking for isolators and circuit breakers. The lap top computer provided for the switchyard shall be loaded with this software. Each BCU shall contain an event recorder capable of storing at least 200 time tagged events. Configuration of BCUs shall also be possible from remote through engineering work station. TCE. isolators and earth switches (The interlocks for earth switches shall be hard wired) iii) Recording The event recording function shall be provided and processed in the BCU and the record stored in SCADA.7 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 7 1X 700 MW CCPP AT NEDUNOOR.5960A-H-500-001 iv) Human Machine Interface (HMI) Following local human machine interface inbuilt in BCU shall be provided as a minimum : • The local HMI is a monitoring and maintenance tool for bay control unit and data communication unit during commissioning and/or maintenance. The paint shade of the panels shall be Opaline Green(external) and semi glossy white(Internal). NO. (a) Terminal box: Providing intermediate termination of all auxiliary contacts of breaker. phosphating and oven drying. The pretreatment of the sheet steel shall involve degreasing rust/scale removal. KARIMNAGAR DIST. SECTION: D3. • v) Time Synchronizing Feature • BCU shall be time synchronized with GPS based Master Clock of the Facility Self diagnostic and Supervision Features • BCU shall have self diagnostic and supervision features. stoving type zinc chromate primer followed by two coats of synthetic enamel paint by powder coating process. free standing type.400 kV SWITCHYARD SHEET 33 OF 51 SPEC. TCE. 7. (CT & PT marshalling boxes shall be provided with respective CTs & PTs. isolator and earthing switches (whether used or not) and preparing interlocking. Numerical Relays and Tariff Meters shall be indicated in the SCADA HMI vi) vii) Operating Mode Selection • Operation mode selection (local or remote) shall be provided in BCU.12 Bay Marshalling Box(s) Adequate number of outdoor mounted. The phosphate coating shall be sealed by the application of two coats of ready mixed. 329 R5 . ELECTRICAL SYSTEMS .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Bay marshalling box shall be provided with two subsections namely: Terminal box and auxiliary supply distribution box. Position of switching elements (Feeder control diagram) shall be shown on the graphic display. Failure of IEDs connected to the SCADA System such as BCUs. power coated bay marshalling boxes shall be provided in switchyard.) ISSUE R0 145 TCE FORM NO. isolators and earthing switches shall be terminated in terminal box section of bay marshalling boxes. The marshalling boxes shall be provided with doors on both sides with key lockable handle for each door. SECTION: D3. isolators/ earthing switches local marshalling box/equipment marshalling box and heating and lighting supply to various bay marshalling boxes. KARIMNAGAR DIST.7 1X 700 MW CCPP AT NEDUNOOR. metering. Either of them shall be used after distributing it via suitably rated HRC fuses to feed. After the manual selector switch. shall be provided in each auxiliary supply bay marshalling box. Provision for terminating two number of 3 phase. Single phase 230V heating and lighting supply shall be provided in a loopin / loopout mode at bay marshalling box.5960A-H-500-001 (b) Auxiliary supply distribution box from where both AC auxiliary supply.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The key shall be removable only in door locked position. Cables with sufficient ISSUE R0 146 TCE FORM NO. The AC distribution scheme shall be wired to manually select any one of the supplies by manually operated selector switch. NO. interlocking. All hardwired interlocking shall be wired in the above box. indications. Neutral of all cores of CTs. Remote independent alarm for failure of all AC and DC outgoing feeders shall be provided by supply supervision relays having delayed dropout NC contact. 329 R5 .400 kV SWITCHYARD SHEET 34 OF 51 SPEC. controls. All auxiliary contacts of the CBs. All auxiliary contacts and interlocked scheme contacts shall be wired to respective panels in the control room. CVTs and EMVTs shall be formed in marshalling box of the respective equipment. Contacts for remote alarm for supply fail shall be provided. MCB controlled AC distribution shall be provided in such a way that individual and radial feeder supplies to driving mechanism/motor of every equipment is arranged. ELECTRICAL SYSTEMS . Loop formulation of cables shall be completely avoided. heating/lighting supplies and DC auxiliary control supply shall be distributed to various motors of all CBs. 3 wire AC 50 Hz power supply called supply I & II. TCE. The scheme for all protections. Similarly provision for terminating 2 Nos. AC and DC distribution and all other schemes shall be prepared in such a way that cables shall be laid in radial pattern. control supply of all isolators and earthing switches. The heating and lighting supply shall be sub-distributed in radial way to provide heating and lighting supplies for all HV equipment marshalling boxes and each bay marshalling box. DC supplies and selection feature to select any one of the two supplies as supply-I and other as supply II shall be provided. the switch shall be changed over to the other source (source-2) and complete DC supply requirement of protection panels will be fed from the other source. The neutral of CTs. ELECTRICAL SYSTEMS . 329 R5 . EMVTs shall be earthed only at control/relay panel by means of a disconnecting link. (c) Control Functions Control circuit of each breaker circuit will be provided with 2 independent 220V DC control supplies. Fault-Recording and Event Recording Systems The DC distribution scheme in various panels shall be prepared based on following DC distribution philosophy for various functions.13 DC Distribution Philosophy for Controls. In case of failure of any one source (say source-1). These DC supplies shall be separated from DC supplies in the control panel by provision of interposing relays (IPRS) in protection relay panels. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Annunciation. The selector switch and the fuses shall be mounted inside the panel. shall also be mounted internally inside the panel. SECTION: D3. Each of the above ISSUE R0 147 TCE FORM NO. DC auxiliary supply shall be supervised by supply supervising relays. CVTs. TCE. etc. Indication. NO. source-1 & source-2. 7. The selector switch and fuses. independent. viz.5960A-H-500-001 number of cores are run from these marshalling boxes to control and relay panels as appropriate. protection. These supplies shall be taken through a selector switch with three positions.400 kV SWITCHYARD SHEET 35 OF 51 SPEC. DC supplies shall be arranged from two sections of switchyard DCDB to each of the protection panels.7 1X 700 MW CCPP AT NEDUNOOR. Loss of supply shall be wired for annunciation at SCADA indication and annunciation supplies shall be separately fused. The NC contact of the relays shall be delayed on drop off by approximately 100 to 200msec for annunciation in SCADA. (b) Similarly. of 220V DC supplier through three (3) position selector switch fused and supervised by supply supervision relays having time delayed drop off type NC contact. Bus bar protection scheme and indications shall be provided with two (2) nos. In the independent position main-1 & main-2 protection systems will be fed by source-1 & source-2 respectively and the common services from any one of the sources. (a) Protective Functions Two nos. ELECTRICAL SYSTEMS . 329 R5 . Manually operated 8 pole.400 kV SWITCHYARD SHEET 36 OF 51 SPEC. Each incoming supply before select switch and outgoing supply after selector switch shall be separately fused and supervised by supply supervision relay having time delayed type “NC” contact. SECTION: D3. failure of annunciation supply shall also be combined and annunciated on 230V AC operated annunciation system. d) The RTU’s and the PLCC located in the Switchyard control room for SLDC/RLDC shall be provided with 48V dual DC supply. and 2. etc. The doors and removable covers shall be gasketed. The supervision relay shall have time delayed drop off type NC contact for annunciation. NO. The panels shall be provided with anti vibration pads. The DC supplies shall be isolated from DC supplies in relay panels as specified in a) above. In turn the failure of AC annunciation supply shall be annunciated in normal DC operated annunciate.14 Specific Requirements The specific requirements listed in Sec. TCE. The paint shade of panels shall be of shade opaline green (External) and semi-glosy white (Internal). KARIMNAGAR DIST. independent and source II shall be used to select any one as closing/synchronizing and trip coil I supplies and other as trip coil II and auxiliary supply for contact multiplication/follower relay supplies. ISSUE R0 148 TCE FORM NO. One separate 220V DC annunciation supply for upto half number of the control panel shall be provided. 3 position selector switch for positions called source I. Remaining half shall be supplied by separate but similar 220V DC supply. 7. The Contractor shall tap annunciation supply through fuses and after supervision relays use it for all annunciation in respective panels. Loss of supply shall be wired for annunciation at SCADA. D3.5960A-H-500-001 feeders shall be fed from separate section of DC board.6 for generator protection shall apply for switchyard protection system also in addition to the following: (a) The panels shall have a degree of protection not less than IP52 and shall be fabricated with 3 mm thick cold rolled sheet steel for front and rear equipment bearing surfaces and bottom gland plates. It shall all be provided with additional contacts for event recording and remote annunciation.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.7 1X 700 MW CCPP AT NEDUNOOR.5 mm for sides and top. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The phosphate coating shall be sealed by the application of two coats of ready mixed. recorders shall be suitably MCBs or designed to limit short circuit currents. stud type.5 mm2 / lead and other circuits it shall be 1. The centre line of switches. 10 amps rated. CT secondary leads shall also be provided with short circulating and earthing facility.0 m and 1. Terminal blocks for CT & VT secondary leads shall be disconnecting. All relays and measuring instruments shall be flush mounted type & the equipment on the front of panel shall be flush mounted. They shall be mounted either internally or on the respective relay panel. Terminal blocks for SCADA digital inputs shall be with knife type isolation. Means for detection of blown or open circuited fuses shall be provided. TCE. Terminal blocks for SCADA control commands shall be of disconnecting type. ELECTRICAL SYSTEMS . stud type terminals with terminal marking. No auxiliary relay shall be mounted on front of the control panel. Terminal blocks shall be 650V grade. ISSUE R0 149 (c) (d) (e) (f) (g) TCE FORM NO. stoving type zinc chromate primer followed by two coats of synthetic enamel paint by powder coating process. meters and recorders shall not be less than 450 mm from the bottom of the panel. The insulation between any two terminals and terminal to framework shall withstand 2 kV rms for one minute. Control switches / push buttons / selectors and relay resetting knobs shall be located at a height between 1. At least 20% spare terminals shall be provided. All the internal wiring shall be carried out with 1100V grade stranded copper conductor wires with PVC insulation.2 m from the bottom of the panel.5 mm2 / lead.7 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST. A clearance of 250 mm shall be maintained between terminal blocks and gland plate and 150 mm between two rows of terminal blocks. phosphating and oven drying. The paint shade of panels shall be of shade opaline green (External) and semi-glosy white (Internal). All wiring meant for power supply to transducers. push buttons and indicating lamps shall be not less than 750 mm and centre lines of relays. For CT / PT circuits the wire size shall be 2.5960A-H-500-001 (b) The pre-treatment of the sheet steel shall involve degreasing rust / scale removal. NO. 329 R5 .400 kV SWITCHYARD SHEET 37 OF 51 SPEC. SECTION: D3. 329 R5 . 3 pin receptacle. and A. Where high-speed protections are involved. distributing. ELECTRICAL SYSTEMS . Each of the control & relay panels shall be provided with thermostat-controlled space heaters. All the push buttons shall be momentary contact type. SECTION: D3. NO. ISSUE R0 150 (i) (j) (k) (l) (m) (n) (o) TCE FORM NO. Push buttons shall be suitably shrouded to prevent inadvertent operation.C. TCE.400 kV SWITCHYARD SHEET 38 OF 51 SPEC. the speed of operation of MCB shall be less than 5 milli seconds. supplies for various control. CT and PT secondary neutral or common lead shall be earthed at one point only at the terminal block and such earthing shall be made through links.7 1X 700 MW CCPP AT NEDUNOOR.5 mm2 copper wires. All PT circuits shall be provided with HRC fuses having special holders such that they cannot be interchanged with other types of fuse holders and other fuse holders cannot be inserted into them. they shall have adequate auxiliary contacts for blocking trip circuits of voltage dependent protection and annunciation. Colour of the lamps shall be different for different purposes. All PBs shall have 2 NO + 2 NC contacts. All the panels shall be equipped with a continuous earth bus with connectors and clamps between panels for interpanel connection of the earth bus.C. CFL type cubicle illuminating lamps and a 5A. If miniature circuit breakers (MCBs) are used in VT secondary circuits. isolating and short circuit protection by use of MCBs/MCCBs of D. KARIMNAGAR DIST. All indicating lamps shall be of self-coloured clustered LED type of size 22. lighting and space heater circuits.5mm. All the metallic cases of relays.5960A-H-500-001 (h) Provision shall be made to mount Tariff meters supplied by grid in the switchyard itself in the grid tie lines as per requirement of grid authorities. Separate copper earthing flat shall be provided in the panel for cable screens of static equipment. Each control & relay panel shall be provided with necessary arrangement for receiving. signalling. the colour of PBs shall be different for various functions.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. instruments and other panel-mounted equipments shall be connected to the earth bus by 2. 15 7. including operation of meters. 329 R5 . The FDRs shall be modular and shall be suitable for expansion. NO.7 1X 700 MW CCPP AT NEDUNOOR. control / display unit. alarms and indications. The equipment shall be complete with disturbance recorder. Printer and evaluation software shall be provided for the 400 kV Switchyard. (III) • • Acceptance Tests The equipment shall be demonstrated for proper operation.1 Fault Disturbance Recorder Stand alone Fault Disturbance Recorder with associated cabling. Interlock and sequential operation tests (ii) Type tests and routine tests Type tests and routine tests shall be carried out on all associated components / equipment as per relevant standards and test certificates shall be furnished. It shall have 8 analog and 16 digital channels. Certified copies of all type and routine test certificate shall be submitted for the Owner’s approval before dispatching the control / relay panel. 7. relays.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.15. The HMI and PC loaded with evaluation software shall be located in Switchyard Control Room/Central Control Room. a number of disturbance recorders in the particular location shall ISSUE R0 151 TCE FORM NO. Provision shall be made to synchronise the electronic clock of each disturbance recorder with external master clock which GPS based. PC. HMI. ELECTRICAL SYSTEMS . Also. KARIMNAGAR DIST.400 kV SWITCHYARD SHEET 39 OF 51 SPEC.5960A-H-500-001 (p) Tests (i) relay panels shall be subject to the following tests : • • • • • Mechanical operation test High voltage test (2000V for 1 minute) Megger test Verification of wiring as per approved drawings Electrical control. junction box and accessories like auxiliary CTs and shunts. SECTION: D3. TCE. KARIMNAGAR DIST. NO.16 Synchronising Scheme The closing schemes of the CB shall be prepared and wired in such a way that only one CB is selected at a time for synchronising. 7. if any. The accuracy of analog channel recording shall be less than +3% for current channels and +1% for voltage channels. The data acquisition unit of the fault recorder shall be provided with self-test diagnostic feature. Recording shall be self started or triggered by dI / dt. SECTION: D3.2kHz to 10kHz. Auxiliary CTs while catering for the required VA burdens shall not saturate under maximum fault current conditions. TCE. dV / dt. lock out relay contacts.7 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS .15.5 or 1 sec. The fault recorder and all its peripherals shall be designed for operation on 220V DC. The sampling rate of the wave shall be between 1. digital signals and contacts of all protective / lockout relays.2 Specific Requirements of the Equipment (a) The microprocessor based fault recorder shall be designed to continuously monitor analogue. (b) (ii) (iii) (iv) 7. breaker contacts.5960A-H-500-001 be capable of being synchronised with any one of the recorders as master.400 kV SWITCHYARD SHEET 40 OF 51 SPEC. Auxiliary multi ratio PTs shall be provided to facilitate tap selection in voltage signal recording. Digital channels: Protective relay contacts. 329 R5 . or change of state of any of the digital input signals. The number of channels / recorders offered shall cover the following: (i) Analog channels: (a) Currents in 3 phases and neutral (b) Voltages of 3 phases and their vector sum wherever VTs are provided. The total number of channels offered shall be such that 20% spare channels are available. Recorders shall be provided with pre-history recording feature with pre-history recording time not less than 0. which annunciates and alters the operator to rectify the defect or fault.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. It shall be possible to bypass synchronising relay only through a bypass switch ISSUE R0 152 TCE FORM NO. synchroscope. operation of all protection and trip relays. SECTION: D3. the CB shall not be closed on operation of the check relay. VT fuse fail relay operation. 110 / 110V with accuracy class of 0. etc. Live-line / dead bus and dead-line / live-bus relays shall be one set per CB. NO. KARIMNAGAR DIST.5960A-H-500-001 and under voltage relays to sense dead-line / live-bus and live-line / dead-bus conditions.g. pole discrepancy relay operation.1 Sequence of events recording System (SER) The SER system shall be a part of SCADA system. bright lamps. voltage selection. 7. The closing shall be possible only in manual position of synchro selection switch. The synchronising and guard relay scheme shall be designed in such a way that when closing impulse is given. etc. ELECTRICAL SYSTEMS . shall be available in SCADA. After synchronising selection is switched on. double frequency meter. direct trip send and receive. selection of control from SCADA/DCS. auto re-closing selection. Critical interlocks and ISSUE R0 153 TCE FORM NO.17. LBB operated. TCE. live line / dead bus.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. synchronising check relay permissive output contact and synchronising check relay indicating lamp contacts shall all be switched to respective circuit after synchronising selection scheme for any equipment is switched on. DC supply fail. trip circuit faulty. synchronising selection. double voltmeter.400 kV SWITCHYARD SHEET 41 OF 51 SPEC.. the CB can be closed only after the operation of synchronising check relay. it shall be noted that key operated auto / off / manual selector synchronising switch provides command from control panel. dead line / live bus and guard relay outputs shall all be started and permissive conditions be generated for closing the respective circuit breaker. DC power supply. Live line-dead bus and dead line / live bus closing facility shall be provided using dedicated relays on CVT. all synchronising indicators (e. While preparing the scheme. opening and closing commands.5 All AC circuits. 329 R5 . The technical details of each isolating transformer shall be 30 VA.17 7. change of positions of switches such as Local/Remote selection. SER shall be designed with 1 ms resolution for digital input events with time stamping from each phase of all breakers. SF6 pressure Low. trip relay faulty.) synchronising check relay.7 1X 700 MW CCPP AT NEDUNOOR. isolators and earth switches. If closing impulse is initiated before synchronising check relay operates. Isolating transformer shall be provided in each incoming AC and running AC potential circuit of the synchronising scheme. Test & Test Reports The Contractor shall conduct all the routine. annunciation.19 7. The chronological printout facility shall be provided for any of the first 100 occurrences. The clock shall have resolution of 1 ms and first up feature. It shall be possible to synchronise the clock with an external master clock. 100% redundancy shall be provided in hardware for protection signalling. 1 no. In SCADA system separate work station shall be provided for accessing the Energy Meter readings.17.19. ISSUE R0 154 7. monitoring measurement.20 7.400 kV SWITCHYARD SHEET 42 OF 51 SPEC. ABT Metering System ABT compliant energy meters for main & check with accuracy class of 0. 7. 329 R5 . Provision shall be made to amount Tariff meters supplied by grid in the switchyard itself in the grid tie lines as per requirement of grid authorities.18 The event recorder shall be suitable for operation on 220V DC supply. Further occurrences shall be printed chronologically.21.20. 7. type and acceptance tests as per the relevant standards and as specified in this specification in the presence of the Owner. synchronising are indicated in I&C system section D2.5960A-H-500-001 those SER points which are not covered by numerical relays shall be hard wired to SCADA. Separate core for main & check tariff metering with 0.4. The test certificates shall be furnished for Owner’s approval. dedicated channel shall be provided for speech/data necessary hardware & software & accessories shall be included. Energy meters must be provided with a pair of suitably rated potential free contacts to generate signal for annunciation and SCADA.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. PLCC System PLCC system shall be provided for four nos. SECTION: D3. KARIMNAGAR DIST. ELECTRICAL SYSTEMS .2S shall be provided with suitable communication port for interfacing the same with SCADA system.1 7. NO.21 7.2S accuracy class shall be provided for all the lines. of 400kV outgoing lines.1 Control.2 7.1 TCE FORM NO. TCE. Indication. however exact requirement of APTRANSCO grid authorities shall be intimated to successful bidder.7 1X 700 MW CCPP AT NEDUNOOR. if voltage supply to the meters are interrupted. Alarm and SER Points Minimum electrical requirements in respect of control. This list is only indicative and not exhaustive. isolators. conducting the tests are included in the scope. However if due to any reason Owner requires the same to be conducted again. In case of hardware such as clamps the temperature rise test material composition test and mechanical test shall be conducted on one sample of each type even if test reports are already available. Disturbance recorder shall comply with the test requirements as per IEC-60255-5&6. 329 R5 . NO. ELECTRICAL SYSTEMS .400 kV SWITCHYARD SHEET 43 OF 51 SPEC.5960A-H-500-001 If. SECTION: D3. current transformers.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. lighting arresters insulators strings. ISSUE R0 155 TCE FORM NO. control & relay panels and other components of all the main equipment type tests are already conducted on identical equipment to the one offered and found to be acceptable. bus post insulators. TCE. in case of circuit breaker. voltage transformers.7 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST. such tests will normally be waived. 7 44 OF 51 SL.1 1. 330 R3 156 SF6 Nos. single pole * O-0.8 C 50 31 mm / kV based on highest system voltage mm 1. BY 400 KV CIRCUIT BREAKERS Type Execution of poles Rated current Operating duty R0 JUNE’ 10 PPD.2 2.4 400 kV SWITCHYARD Nominal voltage Highest System voltage Short circuit breaking current Making current kV kV kA kA (peak) kV (Peak) 400 kV 420 kV 50 kA for 1 sec. DATE REV. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.6 One minute power frequency withstand voltage Reference ambient temperature Creepage distance kV (rms) 630 o 1.3 sec-CO-3 min-CO RKD HA JOB NO.5 Impulse withstand voltage 1425 1.7 1. 130 1.2 1.BY DATE TCE FORM NO.0 2.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. BY CKD. KARIMNAGAR DIST. . DESCRIPTION UNITS VALUES / REQUIREMENTS 1. DATA SHEET – A3.4 REV.0 1.3 2.7 SECTION: SHEET D3.9 Clearances i) Phase to phase ii) Phase to earth iii) Sectional clearance iv) Ground clearance mm mm mm mm 4200 3400 6500 8000 2. A 3 nos.1 2.3 1. NO. NO.. NO.10 2.0 3.2 REV.BY DATE RKD HA Horizontal centre Pantograph type IS 9921 JOB NO. Two (2) 4200 mm 15 NO + 15 NC (minimum) Not required Required kgs 600 Required.11 2. 330 R3 157 .6 2. NO.3 m. TCE FORM NO. BY No.17 2. BY CKD.18 2. A * * * From 0.7 SECTION: SHEET D3.16 2.13 2. DATA SHEET – A3. m.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. of trip coils per pole Phase to phase spacing No.7 45 OF 51 SL. 2.7 Auto Reclosing First pole clear factor Breaker opening time Breaker closing time Line charging breaking current Small inductive current breaking Type of operating mechanism Operating mechanism to be suitable for (a) Control voltage (b) Spring Charging - Required 1.sec. DESCRIPTION UNITS VALUES / REQUIREMENTS 2.5 2.19 3.12 220V DC 220V DC Nos.15 2.8 2.14 2.5A to 10A Spring / Spring charged 1 Phase operation 2.sec. KARIMNAGAR DIST.9 2. 5960A break / CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR. DATE REV.1 3. of auxiliary contacts SF6 Gas filling plant Gas evacuation and filling unit Cantilever strength Out of phase switching 400 kV ISOLATORS Type Reference standard R0 JUNE’ 10 PPD. NO.4.2 3. DATE REV.1 3.4. 5960A 3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE FORM NO.F wet withstand voltage (a) (b) Between poles and earth Across isolating distance kV(rms) 1425 kV(rms) 1425 3.8.2 Impulse withstand voltage (a) (b) Between poles and earth Across isolating distance kVp kVp 1050 1200 Cu Yes 3.1 3.9 3. DATA SHEET – A3.8.7 SECTION: SHEET D3. BY CKD.1 3.5 3. KARIMNAGAR DIST.3 3.8 IS 2544 3.7 46 OF 51 3.9.7 3.1 Motor & Manual Motor & Manual kg 600 220V DC for control and interlock.10.7.6 Material of main contact Whether contacts are to be silver faced Insulators Codes and Standards Operating mechanism (motor/ manual) Main blade Earth blade Insulation Data Minimum cantilever strength Miscellaneous Auxiliary supply (a) Electrical PPD.3 SL. Rated current DESCRIPTION UNITS A * VALUES / REQUIREMENTS Insulation Test values One minute P. NO.1 3.BY DATE RKD HA JOB NO. 330 R3 158 REV.10 3. CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR. BY R0 JUNE’ 10 . 3 phase for motor drive For both Electrical and manual operation. Bolt interlock electrically operated VALUES / REQUIREMENTS 3.8 4.5 4.2 4.2 3.11. 330 R3 159 . rise of winding above ambient of 50°C Cantilever strength of CT at the terminal Applicable Standards Current transformers Insulating oil Bushings Large hollow porcelains R0 JUNE’ 10 PPD. BY IS 2705 IS 335 IS 2099 IS 5621 JOB NO.8.6 4.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 5960A-EL-SK-2003 A 1 Oil immersed Class A 0 4. DESCRIPTION UNITS 400V AC. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.7 SECTION: SHEET D3.BY DATE RKD HA C 500 C 600 kg 4.0 4.3 No. SF6/oil filled hermetically sealed with SS bellow Refer Main one line diagram Drg.8.2 4. DATE REV.7 Secondary current Class of insulation Maximum temp.10.3 4. DATA SHEET – A3.8. KARIMNAGAR DIST.11.4 REV. TCE. of cores Primary current ratio 4.8. NO. BY CKD.2 4.4 4. NO.11 3.1 Type of interlock Codes and Standards Insulators Isolators 400 kV CURRENT TRANSFORMER Type IS : 2544 IS : 9921 Outdoor.1 4.1 3. TCE FORM NO. No.7 47 OF 51 SL. 0 5.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. 330 R3 160 . oil filled/ SF6 gas filled. BY R0 JUNE’ 10 PPD. hermetically sealed CVT: Oil filled only Solidly earthed 5.8. DATA SHEET – A3. BY CKD. 5960A-EL-SK-2003 5. rise of winding above ambient of 50°C Cantilever strength of CVT at the terminal Rated voltage factor Oil immersed Class A 50°C 5. KARIMNAGAR DIST.3 System neutral earthing No.12 Tolerance High frequency range High frequency capacitance For entire carrier frequency range Within 80% to 150% of rated capacitance REV.10 5.2 continuous and 1.5 5.5 for 30 seconds Contractor to furnish depending upon frequency selected for PLCC + 10% to – 5% k.6 5.Hz 40 – 500 5.6 Class of insulation Maximum temp.1 SL.7 48 OF 51 4.4 Refer Main one line diagram Drg. Insulators DESCRIPTION UNITS IS 2544 VALUES / REQUIREMENTS Hot dip galvanising IS 2633 and IS 2629 400 kV CAPACITOR VOLTAGE TRANSFORMERS / EMVT Type EMVT: Outdoor.8 1.5 4. TCE FORM NO. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.8.BY DATE RKD HA JOB NO.7 600 kg 5.2 5. of primary / secondary windings Primary / secondary winding voltage 5. NO.11 5. No. DATE REV. TCE.9 Rated capacitance 5.7 SECTION: SHEET D3. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.0 6.6 6.19. NO.15.15.05 Cn Pf. KARIMNAGAR DIST.15. Where Cn is rated capacitance mho 50 - 5.3 6. 330 R3 161 .7 SECTION: SHEET D3.13 Stray capacitance and conductance of low voltage terminal Stray capacitance of low voltage terminal over entire carrier frequency range Stray conductance of the low voltage terminal over entire carrier frequency range 300 + 0.3 5.5 5.BY DATE RKD HA kV 320 IS 3156 IS 335 IS 2099 IS 5621 IS 2544 IS 2633 and IS 2629 Solidly earthed Metal Oxide Gapless 20 kA. BY Corona extinction voltage Applicable Standards Voltage transformers Insulating oil Bushings Large hollow porcelains Insulators Hot dip galvanising 360 KV LIGHTNING ARRESTORS System Earthing Type of arrester Discharge class Minimum cantilever strength of arrestor assembly R0 JUNE’ 10 PPD.1 6.1 5. 5960A 600 CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.15 5.2 6.15. TCE FORM NO. - Equivalent series resistance over the entire carrier frequency range DESCRIPTION UNITS Less than 40 ohm VALUES / REQUIREMENTS 5. BY CKD. DATA SHEET – A3.2 5.14 5. Class .7 49 OF 51 SL.4 5.IV kg JOB NO.4 REV.19. DATE REV. NO. 3 8. IS : 398 IS : 282 IS : 4826 BS : 159 IS : 5082 JOB NO. BY CKD.4 7.1 7. 330 R3 162 IS 2544 IS 731 IS 2486 IS 5561 8.7 SECTION: SHEET D3. KARIMNAGAR DIST. NO.3 times corresponding flash over voltage.1 7.4. DATE REV. IS .2 IS . CLAMPS & CONNECTORS Applicable Standards AAC.5 6.5. BY R0 JUNE’ 10 PPD.5.0 Applicable standard Post insulators Suspension insulators Insulator fittings BUS CONDUCTORS.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5.0 7.1 Codes and Standards Lightning arrester for alternating current systems Insulators Large Hollow Porcelain insulators INSULATOR Type Cantilever strength kg Solid core / post type / string 600 kg minimum for bus post insulator.4.4.60099 6. DATA SHEET – A3.3070 and IEC . TCE FORM NO.3 7. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR. ACSR conductors Copper conductors Galvanisation of steel wires Copper tubes Aluminium / Aluminium Alloys Bars.1 REV.2544 IS – 5621 7.2 7. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS 6.7 50 OF 51 SL. 1.BY DATE RKD HA .3 Puncture voltage 7.2 6. DATE REV.7 51 OF 51 SL. DATA SHEET – A3.7 9. BY CKD.8 9.11 9. NO. 330 R3 163 .BY DATE RKD HA JOB NO.0 9. Rods. TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 9.3 9. BY R0 JUNE’ 10 PPD. Sections for Electrical Purposes Fittings for Aluminium and steel cored aluminium conductors for overhead lines Electric power connectors Hot dip galvanised process DESCRIPTION UNITS VALUES / REQUIREMENTS IS : 2121 IS:5561 IS : 2629 & 2633 9.9 9.7 SECTION: SHEET D3.13 LINE TRAPS Installation Type of earthing Line trap arrester discharge current Band width Tuning device required Maximum tapping loss Type of tuning Winding material Line traps Methods of test for line traps dB kA kHz Outdoor Effectively earthed 20 40-500 Required 2. IEC :60353 IS : 8793. IEC:60353 REV. Tubes. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.1 9.12 9. NO. KARIMNAGAR DIST.10 9.6 Wide band Copper IS : 8792. 1 8. synchronising and sequential event logging for each generator and its subsystem shall be provided on the Operator stations (plant DCS through HMI). 329 R5 .1 GENERATOR CONTROL The control. monitoring. The raise/lower commands for the same also be done through the trolley itself. NO. TCE. its subsystems and 6. Auto synchronisers shall connect the generators to the 400 kV grid either through generator circuit breaker or 400kV generator transformer breakers automatically after synchronising the two systems. double frequency meter. alarm. TCE.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. double voltmeter.5960A-H-500-001 8. In the GCP.6 kV & 400V auxiliary power supply system shall be provided. The equipment shall be supplied to control both the voltage and frequency of turbine generator set to match with those of the grid.2. synchronising lamp. operation and annunciation on GCP and monitoring.0 8. The minimum requirements of the measurements are indicated in the Main One Line Diagram drg no. recording and sequential event recording for generator and its excitation system from the Operator stations (plant DCS through HMI). shall be provided in the hardwired GCP as follows: (a) One No.2.3 (b) TCE FORM NO. Auto synchroniser relay for generator (25A): The Auto synchronising facility shall be made available to auto synchronise the above breakers through DCS. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC.2 8. the mimic of the generator. annunciation.SECTION: D3. Generator and Auxiliary Power Supply System Control & Monitoring Provision in the plant control system shall be made for the starting. ISSUE R0 164 8. measurement.. KARIMNAGAR DIST. data logging.5960A-EL-SK-2003. of synchronising panel/trolley shall be provided through which the synchronising of all the GCB & breakers in 400kV switchyard can be synchronised (GCB in the case of GTGs and 400 kV GT breakers in the case of STGs) by plugging the control cable into a socket provided on each Control panel of the respective breaker. SHEET 1 OF 10 1X 700 MW CCPP AT NEDUNOOR. synchroscope. check synchronising relay. Synchronising.2. essential controls and annunciation shall also be available from the Generator control panel (GCP).2 8. This synchronising trolley shall have all the necessary equipments & meters for carrying out the manual synchronisation. initiation of synchronising. etc. bringing upto rated voltage and speed. Synchronising equipment consisting of Auto synchroniser. 5 8.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The interlocks for the auxiliary power supply system shall be hardwired interlocks. 400 kV generator transformer breakers along with grouped alarms of generator and generator transformer shall be made available for indication/annunciation in 400kV system SCADA switchyard Control Room as well as main control room.2. In case of failure of any OS. When the “Remote” mode is selected. The GCP shall be provided with all the synchronising switches. Synchronising. it shall be possible to carry out the necessary operation from one of the healthy OS. selector switches.3. essential controls. check synchronising relay. measurement. SHEET 2 OF 10 1X 700 MW CCPP AT NEDUNOOR. monitoring.5960A-H-500-001 8. However. the 400kV system SCADA shall be interfaced with the plant DCS through serial link for monitoring of 400 kV system from DCS.6 8. the status of generator circuit breakers.). KARIMNAGAR DIST. synchroscope. push buttons.2. When the “Manual” mode is selected. annunciation.SECTION: D3.2.6 8. Hard wired emergency trip push buttons for tripping of generator circuit breakers of GTGs shall be mounted on the operator console. Remote/Manual selection shall be provided in DCS. breaker control switches. metering and annunciation shall also be available from the Respective control panels for the lines.2. Further. The 400kV system controls shall be implemented in an independent SCADA system. TCE. The push buttons shall be suitably protected to prevent inadvertent operation. guard relay. synchronising lamp. etc. 329 R5 . synchronising shall be initiated from DCS through auto synchroniser.4.1 TCE FORM NO.3 8.4 Manual synchronising facility common to all the units shall be provided for manual synchronisation of the generators. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. etc.2. NO. ISSUE R0 165 8.2. The synchronising panel shall be located in the control equipment room. breaker selector switch. CONTROL AND MONITORING IN DCS Control.5 8. This shall be read in conjunction requirements with requirements indicated in I&C Section D2. indicating lamps as needed for the control of the systems envisaged.4 8. synchronising shall be done from the stand-alone synchronising panel which houses the required synchronising gear (consisting of dv & df meters with associated transducers. synchronising of complete electrical system supplied under this contract shall be possible from plant DCS system. 1 CONTROLS (i) Control of all the Incomers.3. OFF.5960A-H-500-001 8. Selector switch for the operation of equipment shall be at respective control panel. All the necessary controls required for synchronising the DG set & stopping of DG set after resumption of Normal power shall be included in the DCS. DCDB & UPS DB. bus ties of all the electrical switchboards except outgoing feeders from the main Lighting Distribution Board. issuing raise / lower command to OLTC from plant DCS system. MW. MVAR & P.3. It shall also have the facility to carryout the live changeovers at all the switchboards at 6. 329 R5 . permissive for interlock set shall be considered as input to the DCS system. Local / remote and auto / manual selection will be done at DG set control panel. service. Selector switch for the operation of equipment shall be at respective control panel. DG start.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 Monitoring (a) Indication-Status of GCB.2. other breakers (ON. spring charged indication etc. TCE. test) position of Local/Remote selector switches. (ii) (iii) (iv) (v) (vi) 8. Synchronising gear shall be housed in the respective switchboards. Abnormal conditions to be considered for alarm inputs to DCS are: ISSUE R0 166 (b) TCE FORM NO. Remote position. KARIMNAGAR DIST. SHEET 3 OF 10 1X 700 MW CCPP AT NEDUNOOR. DG breaker closing shall be possible from DCS. NO. controls.SECTION: D3.F. Initiation of auto synchroniser. service position. Control of generator excitation and governor system shall be possible from plant DCS including mode selection and set point control for various parameters viz. All transformers with OLTC shall have provision for control viz. breaker health. speed raise/lower.3. voltage raise/lower. shall be carried out from the DCS.2 DCS System Minimum functional requirement of plant DCS system in respect of electrical system shall be as below: 8.2.6kV & 400V. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. Monitoring of winding & oil temperature of all the transformers & of all temperatures & pressure parameters related to Generator. DC supply failure. Successful/Unsuccessful changeover of 6. Trip circuit unhealthy. VT circuit unhealthy of each VT. (v) UPS System All normal & abnormal conditions of UPS system with details. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. LBB operation of each breaker. and normal operating parameters of the DC system etc. (ii) LV System (400V) Breaker auto trip. motor protection. unit auxiliary transformers and service transformers.SECTION: D3. Successful/Unsuccessful changeover of 400V supplies. (iv) DC System DC earth fault. TCE. Trip relay unhealthy of each equipment. (vi) Battery charger Group trouble alarm for chargers with details as available from equipment. DC under voltage. 6. Trip circuit unhealthy of each equipment.6 kV supplies. individual protective relay operation. Tap position of GT & UATs shall also be monitored from DCS. SHEET 4 OF 10 1X 700 MW CCPP AT NEDUNOOR.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. trip relay failure. signals generated in Transformer MB about abnormal operating conditions of Transformer. 329 R5 . KARIMNAGAR DIST. ISSUE R0 167 TCE FORM NO. VT fuse failure. group faults in case of DC boards. bus under voltage. Unit Auxiliary & Service Transformers All alarm and trip conditions of generator transformers. NO.6kV and 400kV breaker) Operation of each of Generator protection.5960A-H-500-001 (i) HV System (Generator CB. GT and UAT condition shall be monitored from DCS. protection unhealthy of each equipment. (iii) Generator. DC supply failure of each protection/control scheme as appropriate. (viii) DG Set DG operating parameters. Energy parameters on HV side of GTs & UATs shall also be monitored. field current and 400kV bus voltages & frequency. Temperatures of all the >= 100KW motors. SLD shall also show the Generator phase currents.2. All the energy parameters of the lines. (ix) Alarm for the running hours of 30KW & above motors shall be generated after achieving predefined set points. TCE. KARIMNAGAR DIST. More than one frame can be used if all the details cannot be represented on a single frame. SHEET 5 OF 10 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC.5960A-H-500-001 (vii) Excitation System and generator Each of protection relay alarm and trip conditions. breaker and isolator positions shall be available on DCS/SCADA.3. generator & auxiliary consumption shall be taken from the ABT compliant energy meters through communication. alarm and trip conditions.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3 Measurement Feeder Description (a) 400 kV line bays DCS MW MVAR A V MWH MVARH Pf MVA Control Panel ISSUE R0 168 TCE FORM NO. (x) (xi) (xii) (c) Single line diagram showing Voltage. frequency. 8. abnormal conditions in excitation system and generator. NO. 329 R5 .SECTION: D3. MW and MVAR flows. Monitoring of the complete electrical system during the normal operation. 329 R5 . SHEET 6 OF 10 1X 700 MW CCPP AT NEDUNOOR.MW -MVAR -Frequency -pf -MWH - MVAR MVARH* Frequency MW trending MVAR trending pf MWH * (d) 400 kV Bus V(Bus –1& 2) Frequency(Bus –1& 2) * By pulse output from TVM /Meters (e) Unit Auxiliary A(All phases) Transformer (HV side) MW MVAR MWh Tap position winding & oil temperature (f) Incomer.A (All phases) .V (All phases) .8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6kV switchgear and Incomer. KARIMNAGAR DIST. One phase for others MW MVAR MWH ISSUE R0 169 TCE FORM NO. TCE. NO. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC.SECTION: D3.5960A-H-500-001 (b) 400 kV GT bays A(All phases) MW MVAR MWh Tap position winding & oil temperature V(All phases) A(All phases) MW -A (All phases) -MW MWh - (c) Generator . Tie feeders & Outgoing feeders of 6. Buscoupler & outgoing feeders of 400V switchgear -A (All phases) -MW MWh - A-All phases for I/C & Ties. TCE. . A V & Hz for UPS V (All phases) F (j) Generator stator winding and bearing Temperature - NOTE : DCS Input current and voltage shall be considered for all three (3) phases.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.SECTION: D3. 329 R5 . ISSUE R0 170 TCE FORM NO. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. NO. These power meters shall have the local display also. electrical parameters & Energy reading shall also be measured through numerical protection relay provided at the DG set. The metering data for the 400kV bays shall be through the ABT compliant energy meter provided except the tariff meters.3.4 Event logging shall be provided for all manual operations and relay operations as detailed below: (a) Status of each breaker of all equipment being controlled. SHEET 7 OF 10 1X 700 MW CCPP AT NEDUNOOR. Running hours. Running hours of the motors decided during the detailed engineering shall be calculated or taken from the numerical relays.6kV & 400V Buses (h) Emergency DG set (i) DC and UPS System All energy metering shall be through the power meters provided on the incomers & tie feeders on the DCS.3. KARIMNAGAR DIST. 8.5960A-H-500-001 (g) 6. isolators and earth switches. fuse fail alarm. Capturing of momentary values of all these parameters shall also be possible triggered either by a protective relay or by a manual keyboard command. battery charger. SHEET 8 OF 10 1X 700 MW CCPP AT NEDUNOOR. Synchronising (a) Generator (Manual and through Auto synchroniser) Synchronising facility shall be provided for the generator through auto synchroniser in auto mode and with the help of double voltmeter. Each protective relay.3. all transformer. etc. all electrical switchboards etc. UPS. 8. Generator.0 sec. 3-poles of line circuit breaker.5/1. KARIMNAGAR DIST. Event logging for each phase shall be provided wherever applicable (eg..2. are to be included.6 (c) ISSUE R0 171 TCE FORM NO. trip relay.5 Trending of parameters during disturbance shall be with a resolution of 0. alarm relay operation. (b) 6. Selector switch positions. Trip contacts of the complete electrical installation/equipments in the station viz. 329 R5 . NO. synchroscope and check synchronising relay permissive condition in the manual mode.5960A-H-500-001 (b) (c) (d) Close and open commands.2. double frequency meter. distance relay output contacts. (e) (f) 8.3.SECTION: D3. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. The change from normal mode to disturbance mode shall be through threshold/gradient settings provided in the system for analog quantities and external binary signals obtained from selected protective relays. and at 15 minutes during normal operation.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. It shall have a time resolution of 1 ms. 400V switch board / MCC incomer and bus coupler breakers shall have facility for dead bus auto change over / manual live transfer.) Event logger shall be a part of the DCS with first up feature. generator protections.6 kV Incomer & tie circuit breakers shall have facility for fast and slow auto changeover/manual synchronising and dead bus closing. TCE. any additional requirement arising during detailed engineering shall be provided by the Bidder without any additional cost to the Owner.3 The functional requirement indicated above are minimum. etc.4.2 8.4. All the transducers shall be self-powered.3. synchroniser with lockable only in ' off ' position.6 8. double frequency meter. synchroscope. synchronising lamps. Also. ISSUE R0 172 8. check synchronising relay.SECTION: D3. interlocks & devices required for the system offered by him.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5 Amp breaking at 220V DC and 6 Amp make and continuous current at 220 V DC.3.3.5 8. NO. The transducers shall comply with the requirements specified for transducers in Electrical section D3. UAT & generator metering shall be provided. Interposing relays used for 400 kV circuit breaker closing shall be adequately rated for the making current. The control / selector switches & meters shall be of miniaturised version. Interposing Relays The interposing relays required for the switchgear / equipment being supplied under this contract shall be located in separate IPR panels located in the control room.1 8. 329 R5 .1 8.3 TCE FORM NO.. Transducers The Contractor shall provide all the transducers for electrical system either in respective switchgear / control panels. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC.5.5.2 8.5 8. Check & main Meters – ABT compliant Tri-vector energy meters of Accuracy class 0.25. the Bidder shall provide all necessary controls indications. KARIMNAGAR DIST. The coupling relays shall be rated for 0. SHEET 9 OF 10 1X 700 MW CCPP AT NEDUNOOR.4 8.5960A-H-500-001 (d) One (1) set of synchronising equipment consisting of double voltmeter. shall be provided for each of the following: (1) Generators (2) Breakers associated with Emergency DG synchronising 8.4 8.2S for lines. TCE. The time critical controls and interlocks shall be hardwired system only.3.5. 6 Tests Tests for control desk shall be as indicated in Section D3. KARIMNAGAR DIST. TCE. 329 R5 . NO. ISSUE R0 173 TCE FORM NO.7 for Switchyard relay and control panels.SECTION: D3. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. SHEET 10 OF 10 1X 700 MW CCPP AT NEDUNOOR.5960A-H-500-001 8.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS . KARIMNAGAR DIST. NO.9 and specific requirements indicated below.6 kV and service transformers.1 For feeding the plant auxiliaries rated for 6.6 kV SWITCHGEAR The 6. 329 R5 .2. Changeover shall be blocked if incomer has tripped due to bus fault.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.9. adequately rated switchgears shall be provided. an automatic “slow” transfer shall be initiated. The Bus transfer system ISSUE R0 174 TCE FORM NO. Also.5960A-H-500-001 9. Manual & Automatic Transfer of Loads The station switchgear shall be provided with manual live changeover scheme for planned changeover of supply from one incomer to another and vice versa. SECTION: D3.6.41 (1982) criterion.3 The bus voltage and incoming source voltage should be monitored on a continuous basis for magnitude and phase angle to ensure that transfer operation is carried out under conditions conducive to fast bus transfer as per high speed sync-check supervision and ANSI C50. If fast auto change over fails for whatever reason.9 1X 700 MW CCPP AT NEDUNOOR. the switchgear and its accessories shall comply with the requirements indicated in Data Sheet – A 3.2 9. ii) In Phase Transfer The breaker power contacts shall close when the decaying and drifting bus voltage synchronizes with the incoming source voltage within acceptable voltage and frequency parameters. TCE.2. The FBTS should have following transfer modes: i) Fast Transfer 9. The high-speed transfer shall be completed in not more than 40 ms.1 9. Automatic fast changeover scheme for changeover of supply from one source to another in the event of supply failure from upstream end shall be provided.2.6 kV SWITCHGEAR SHEET 1 OF 15 SPEC.6 kV switchgear and its accessories shall conform to all latest editions of national and international standards indicated in Data Sheet – A 3.Ts. 9. The closure of the unit supply breaker shall be supervised by a synchrocheck relay permanently connected to and energised by the secondary voltages of the unit bus P. The fast changeover scheme shall be such that the running motors are not tripped or there is only allowable inrush current due to motor reacceleration.2 9.0 6. transformer feeder on each bus (colony supply) for Owner’s use shall be provided. KARIMNAGAR DIST. etc.3 9.4 The bus transfer scheme shall be totally microprocessor based numerical system with in-phase transfer facility and communication facility to DCS. shall be arrived at.5960A-H-500-001 shall continuously process the bus voltage and the drifting phase angle dynamics to determine in real-time the exact moment of sending a command to the breaker-closing coil to achieve the above.1 Short Circuit Current Ratings The fault level for the switchgear. under supervision of the bus voltage and incoming source voltage for magnitude and phase angle. isolators. 329 R5 . NO.4.6kV switchgear. bus bars. circuit breakers.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.4.C current breaking capacity of the breaker shall consider the higher time constant for decay of current in the vicinity of power generating stations and the breaker offered shall be suitable for this duty. the new source breaker is closed before opening the old source breaker. ISSUE R0 175 9. The auxiliary drives are selectively tripped simultaneously to limit the transformer inrush current. Normally not recommended for unplanned transfers and auto/protective transfers from the system safety considerations 9. A margin of 5% over higher of the above S. earth switch. iii) Slow Transfer The breaker power contacts shall close when the falling bus voltage shall reach an acceptable safe value.6 kV SWITCHGEAR SHEET 2 OF 15 SPEC. iv) Momentary Paralleling Transfer This is a “Make before Break” transfer for a very short duration of the order of few cycles where.C current. TCE. SECTION: D3. Additionally One (1) no. thus calculated shall be applied and rounded off to the next higher standard ratings and this value shall be adopted for the breakers and switchgears.4 9.55 times this value.6. ELECTRICAL SYSTEMS . Asymmetrical S. on the basis of short circuit current contribution from UAT plus short circuit contribution by the motors running on the bus. The momentary current ratings shall be 2..9 1X 700 MW CCPP AT NEDUNOOR.2 9. Spare Feeders One motor and one transformer type spare feeder of highest rating shall be provided on both sections of Bus-A & Bus-B of 6.3 TCE FORM NO.2.4. 9. SECTION: D3.5.6.6.1. NO. supervision relays. All circuit breaker compartments shall be provided with separate door so that circuit breaker front cover shall not be used as front door. contact multiplication relays. (b) circuit breakers. All live parts shall be provided with isolating barriers between phases to avoid exposure to live parts. metal clad having separate metal enclosed compartments for (a) control.2 9. The switchgear assembly shall be rodent and vermin proof..2 Required number of high speed trip relays. 329 R5 . Constructional Measurements The switchboard shall be indoor. The bottom of each panel shall be covered by sheet steel and necessary glands plates. The continuous current rating of the feeders shall be based on the name plate current rating of the connected equipment with 20% margin rounded off as indicated in 9. incomer breaker shall be the rated LV winding current of UAT's respectively with 20% margin rounded off to the next higher standard rating.6 kV unit switchgear buses. shall be provided in the ISSUE R0 176 TCE FORM NO. (c) phase bus bars.9 1X 700 MW CCPP AT NEDUNOOR. timers. vertical droppers and connectors to the fixed end of isolating contacts. KARIMNAGAR DIST. A fixed type checkered net shall be provided between cable termination and door to avoid accidental contact to live termination. 9.1 9. (d) instrument transformers and (e) power cable terminations and adjacent cubicles (panels) shall have sheets on either side to ensure complete isolation. Conductor shall be of high conductivity aluminium alloy for the horizontal busbars.1 9. This arrangement is required to take Thermographic measurement using Infrared thermometer. metering and relaying devices. auxiliary relays. TCE.4 Calculations for arriving at the time constant at this plant shall be furnished to justify breaker selection in accordance with IEC-62271-100 and contractor shall furnish calculation during detailed engineering stage to establish the adequacy of support insulators and busbar sizes for the declared continuous and short time current rating. etc.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Door enclosing the cable termination shall be with hinge.6 9. ELECTRICAL SYSTEMS .6 kV SWITCHGEAR SHEET 3 OF 15 SPEC.6.5.4. Switchgear shall be suitable for extension on both sides.5960A-H-500-001 9. Switchgear shall be suitable for extension on both sides.5 9.5. Continuous Current Ratings The continuous current rating of the 6. KARIMNAGAR DIST.5mm² for all circuit and 2. ELECTRICAL SYSTEMS .6. In test position the circuit breaker shall be capable of being tested for operation without energising power circuits. 9.All non-current carrying metal work of the switchgear shall be effectively bonded to the earth bus. service and isolated positions. The circuit and bus bar earthing facility with earthing trucks shall be provided for each type of breaker. Suitable mechanical interlocks shall be provided to prevent the closing of earth switch on live circuit.5 9. Withdrawal of circuit breaker shall not be possible unless it is in open position and operation of circuit breaker shall not be possible unless it is fully in service position. SECTION: D3. NO. At least 5NO+5NC spare contacts shall be wired to the terminal block after fully utilising for protection.6. The sizes of wire in the panel shall be stranded copper conductor.6.6.6. Automatic safety shutters shall cover live parts when the breaker is withdrawn and all other standard safety features shall be provided. Terminal blocks for CTs and VTs shall be provided with test links and isolating faciliting and CT terminals with short circuiting and earthing facility. Adequate space shall be available for termination using heat shrinkable type cable termination in cable compartment and for mounting of zero sequence current transformers (core balance current transformers). interlocking. ISSUE R0 177 9.11 TCE FORM NO. Switchgear shall be supplied completely wired and inter panel wiring between cubicles of same switchgear shall be provided.9 9. annunciation.3 The circuit breaker shall be drawout type and it shall have test.5960A-H-500-001 panels to meet the system requirements and to meet the system operation philosophy indicated in the specification elsewhere.5 mm² for CT circuits.8 9.6. Hinged doors shall be earthed through flexible earthing braid for each type of breaker. etc.10 9.7 9. 1.6.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 . 650 volts grade.9 1X 700 MW CCPP AT NEDUNOOR. Terminal blocks shall be of stud type. TCE.4 9. or is fully in test position and drawn out position. 10 amps rated complete with insulated barriers.6 9. All spare contacts and terminals of cubicle mounted equipment and devices shall be wired to terminal blocks with 20% spare terminals.6.6 kV SWITCHGEAR SHEET 4 OF 15 SPEC. The current transformers shall be mounted in the fixed portion of the switchgear. Not more than 2 wires shall be connected at a one terminal.6. Earth bus of size 50x6 mm Cu shall be provided at the bottom and shall extend throughout the length of the switchboard .6. 5 amps. Space heaters of adequate capacity shall be provided. contact multiplying relays shall be used. trip relays. Two numbers DC feeders shall be provided for 6. In case of smaller rated CTs (say 200 Amp and less) at the expected fault level the CT saturation may result in the non operation of the instantaneous short circuit protection.6. instrument selector switches shall be of maintained stay put type. NO. 329 R5 . SECTION: D3.16 9. Single phase loads for motor space heating etc. black. The same shall be two coil.6. 3 pin receptacle with switch located in a convenient position. ELECTRICAL SYSTEMS .6.12 All relays protective. distribution. Each switchgear panel shall be provided with 230 Volts.5960A-H-500-001 9. DC supply supervision lamps (self coloured clustered LED type of size 22. shall be distributed between different phases to keep the loading on all the phases uniform..6 kV SWITCHGEAR SHEET 5 OF 15 SPEC. and timers shall be in draw out cases with built in test facilities. 50 Hz.6. changes during engineering stage and adequate margin at the time of handing over the plant: (a) The CTs shall withstand momentary and short time current ratings of the associated switchgear. lead burdens.15 9. Breaker control switches shall be 3 position spring return to neutral. contacts shall be gold flashed with 20 micron thick plating. Externally operated hand reset indicators shall be provided on all relays and timers. isolating and fusing of auxiliary DC and AC supplies for controls. 1 phase. etc.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ISSUE R0 178 9. auxiliary.6.5 mm) shall be provided and the same shall be on AC supply. Necessary test plugs shall be supplied loose and is included in the scope of supply. Breaker control switches shall be pistol grip black and selector switches shall be oval or knob. CTs and VTs shall be of the cast resin type and completely encapsulated. Provision shall be made for receiving.14 9.6kV switchgear with selector switch for selecting any one supply. TCE. KARIMNAGAR DIST.18 (b) TCE FORM NO.9 1X 700 MW CCPP AT NEDUNOOR. Atleast 1NO + 1NC spare contacts of all relays / timers shall be wired to terminal block. All relays shall be of self reset type unless otherwise specified.6. In such cases separate protection CT core with higher ratio shall be selected to avoid saturation at high fault currents. latching type with electrical reset. Timers shall be of electromagnetic or electronic type only. The ratings of instrument transformers shall be decided by Bidder based on connected load.13 9.17 9.6. In the event of shortage of contacts in circuit breakers. Push buttons provided shall be shrouded.6. space heating. etc.6. Contractor shall furnish calculation during detailed engineering stage to establish the adequacy of support insulator and busbar sizes for the declared continuous & short time current ratings. Those terminals required to be connected to earth shall be earthed by an isolating link without a fuse. The cable glands shall be of double compression type brass glands. separate transducers shall be provided. Bidder shall supply and mount transducers as per Main One Line diagram and philosophy of control defined elsewhere in the specification. Cable lugs for all power.5%. VTs shall be provided with HRC fuses on both primary and secondary sides under voltage relays.6. NO. KW.5960A-H-500-001 (c ) Service transformers and motor feeders shall be provided with 50/1 A core balance CTs for connecting earth fault relays. SECTION: D3. ELECTRICAL SYSTEMS . For the analog parameters (i.6.25 9.20 9. A. Rubber mats suitable for 7. 9.6.f. timers. drawout type and housed in a separate sheet metal enclosure.9 1X 700 MW CCPP AT NEDUNOOR. Fuses on primary side shall have rupturing capacity equal to the switchgear rating. running hours etc) required in DCS. The transducers shall have 4–20 mA dual output and accuracy class shall be less than 0. Those terminals required to be connected to earth shall be earthed by an isolating link without a fuse.6.e. Primary fuse replacement shall be possible with VT in isolated position only. Wherever not available.6. Switchgear panel shall be suitable for bottom cable entry and provided with removable gland plates.22 9.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 9.19 VTs shall be single phase. Adequate space shall be available for the termination of the heat shrinkable cable termination & mounting of the CT & CBCT.21 9.6.6. KARIMNAGAR DIST. The lugs shall be tinned copper/Aluminium depending on cable conductor and of solderless crimping type.6 kV SWITCHGEAR SHEET 6 OF 15 SPEC. for motor tripping and remote annunciation on supply failure.2kV grade shall be provided at front and rear of switchgear. in the individual switchgear panels.23 9. 4-20mA outputs for parameters available in numerical relays shall be used.6.24 9.26 ISSUE R0 179 TCE FORM NO. suitable mechanical/ electromechanical interlocks to ensure that earth switch is not closed/truck is not inserted with the bus live or cable side energised. TCE. All breakers of identical ratings shall be interchangeable. control and instrumentation cables connections shall be supplied. 329 R5 . p. Surge arrestors shall be provided for motor and transformer feeders and shall be as per manufacturer’s recommended type and generally in accordance with IEC 99-1.Close' spring return to neutral position. Bidder shall furnish temporary overvoltage capability curve and pressure relief device shall be provided for relieving internal pressure and preventing violent shattering of the housing following prolonged passage of follow current or internal flashover of arrestor. They shall be mounted within the switchgear cubicle between line and earth preferably in cable compartment and shall be suitable for indoor duty. NO.Neutral . shall be sufficient for carrying the connected load currents without exceeding the permissible temperature limits or reduction in service life. ‘Amber’ for breaker auto trip indication 'White' for breaker closing spring 'Charged'.5 times the peak line to neutral voltage of the system.5960A-H-500-001 9. CTs etc. KARIMNAGAR DIST. TCE. ‘Amber' for breaker in 'Test' position.Remote' switchgear control stay put type. One two position control selector switch `Local .9 1X 700 MW CCPP AT NEDUNOOR.27 Current ratings of all switchgears. 329 R5 . Use of two breakers in parallel to meet the required rating shall not be acceptable. ‘Red' for breaker ON indication at the back of the switchgear at cable box door (b) (c) ISSUE R0 180 TCE FORM NO.6.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Blue' for breaker in 'Service' position.6. The connection between the start up transformer and 6. Surge arrestors shall be suitable for non effectively earthed system and the maximum switching overvoltage shall not be more than 2. 'White' supervision lamp for lockout relays.6.6. SECTION: D3.6 kV SWITCHGEAR SHEET 7 OF 15 SPEC. ELECTRICAL SYSTEMS . Indicating lamps (i) (ii) (iii) (iv) (v) (v) (vi) (vii) `Red' for breaker `ON' indication and trip coil supervision. 9. `Green' for breaker `OFF' indication. circuit breakers.29 9.28 9.28 Cubicle Components Each circuit breaker cubicle shall be provided with the following minimum standard accessories: (a) One control switch `Trip .6.6kV switchgear shall preferably be by means of segregated phase bus ducts. 5960A-H-500-001 The indicating lamps shall be self coloured clustered LED type of size 22. NO. Relay setting ISSUE R0 181 TCE FORM NO. One breaker operation counter.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Suitable labels/Name plates for feeders and cubicle mounted components. One double pole control supply switch and set of fuses. Closing from local shall be possible only in test position whereas closing from remote shall be possible in either service or test position..They shall be bright and visible from any angle. Mechanical indication for spring charged/discharged status.6 kV SWITCHGEAR SHEET 8 OF 15 SPEC. such that it can be surfed by standing at ground.7 Metering & Protection Adequate protection / metering shall be provided for the switchgear panels. The push button shall be shrouded type.5mm. Location of relays in the switchgear shall be at convenient height. 329 R5 . Tripping from local shall be possible only when local/remote selector switch is in local position. KARIMNAGAR DIST.9 1X 700 MW CCPP AT NEDUNOOR. All indicating lamps shall be on DC. TCE.6. heater with thermostat and plug point. Separate meters shall be provided for each of the feeders mentioned below. PT fuse failure shall be numerical with RS232/RS485 port. SECTION: D3. if the same is not available in the numerical relay. ELECTRICAL SYSTEMS . (d) Mechanical trip push button to trip the breaker when control supply is lost. (e) (f) (g) (h) (i) (j) (k) (l) (m) 9. Tripping from remote shall be possible only when either breaker in service position or selector switch being in remote position One electrical antipumping relay. Castle key interlocks shall be provided to prevent opening of cable compartment door when breaker is closed and busbar compartment when any of the incomers to bus are closed. Cubicle lamp. Closing coils shall operate satisfactorily in the control voltage range of 85-110% and tripping coil shall operate satisfactorily in the control voltage range of 70-110%. Mechanical close push button provided shall be accessible only after opening of the front door. All relays except for LBB. All numerical relays shall be time synchronized with the GPS master clock. current transducer (Y-Phase) 1 no. watt meter (or) Multifunction meter with all the metering parameters 1 no. and shall be suitable for efficient and reliable operation of the protective schemes. A combination of electromechanical & numerical communicable type relays for main protections is not acceptable. All the protective relays. MW transducer 1 no. The Bidder shall include in his bid a list of installations where the relays offered are in trouble free operation for last two years.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 kV SWITCHGEAR SHEET 9 OF 15 SPEC.6 kV switchgear and generator protection panels shall be loaded in a dedicated operator station in the main control room. MVAR transducer Local breaker backup protection Fuse failure relay 9.9 1X 700 MW CCPP AT NEDUNOOR. which shall provide the annunciation to the DCS. SECTION: D3. 329 R5 . ELECTRICAL SYSTEMS . except for auxiliary relays shall have – remote/local reset facility.7.6. On failure of any of the numerical relay a contact shall be generated. NO.2 Tie breakers Protections Composite numerical feeder protection relay Local breaker backup protection Metering Ammeter and voltmeter with selector switch 1 no. TCE. kWh meter 1 no. KARIMNAGAR DIST. MW transducer ISSUE R0 182 TCE FORM NO.1 Incomers Protections Composite numerical feeder protection relay Under voltage relay Metering Ammeter and voltmeter with selector switch Wattmeter (or) Multifunction meter with all the metering parameters Current transducer for each phase 1 no.7. but not be limited to the following: 9.5960A-H-500-001 software for setting all the numerical relays in 6. The minimum protections / metering shall be provided required for various typical feeders shall include. 5 Service Transformer Feeders Protections Composite numerical transformer protection relay Local Breaker backup protection Winding temperature and Buchholtz protection Metering Ammeter with switch 1 no.6.3 Bus PT Feeders Protections Under voltage protection Fuse failure protection Metering Voltmeter switch Voltage Nos.9 1X 700 MW CCPP AT NEDUNOOR.6 kV SWITCHGEAR SHEET 10 OF 15 SPEC.7. kWh meter selector 1 no. 329 R5 . with selector transducers–3 9. power factor meter 1 no. Means shall be provided to prevent access to the live part to avoid accidents during service as well as maintenance period. TCE.8 The switchgears shall be designed to offer adequate level of safety to operating/ maintenance personnel.7. Bidder shall bring out the safety means provided to achieve above. watt meter (or) Multifunction meter with all the metering parameters 1 no. Wattmeter (or) Multifunction meter with all the metering parameters 1 no. current transducer 9. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. current transducer (Y Phase) * For motor feeders separate ammeters shall be provided.5960A-H-500-001 9. kWh meter selector 1 no. A detailed instruction plate suitable for wall mounting shall be provided for each switchgear/MCC room describing various safe operating procedure/safety precautions for safe operation and maintenance of the switchgear.7. SECTION: D3.4 Motor feeders Protections Composite motor protection relay (99) Differential protection for motor feeders (rated 1000kW or above) Local Breaker backup protection Time delayed under voltage trip Metering Ammeter* with switch 1 no. Tests ISSUE R0 183 9. ELECTRICAL SYSTEMS . 9. NO.9 TCE FORM NO. 10 Minimum electrical system requirements in respect of control.5960A-H-500-001 All relevant routine tests and acceptance test shall be conducted as per applicable standards and typical type test certificates of identical switchgear shall be furnished.9 1X 700 MW CCPP AT NEDUNOOR. annunciation.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. measurements.6 kV SWITCHGEAR SHEET 11 OF 15 SPEC. and synchronization are indicated in I & C system section no. SECTION: D3. monitoring. 9. NO. KARIMNAGAR DIST.4. ELECTRICAL SYSTEMS . D2. ISSUE R0 184 TCE FORM NO. TCE. 329 R5 .6. BY DATE RKD HA JOB NO.11 1. connectors and contacts at continuous current rating under site ref. BY CKD.8 Tin coated Copper Heat shrinkable PVC sleeve.2kV insulation 7. DATE REV. doors and covers Thickness of gland plate for 1 core cable Degree of protection mm mm mm Cold rolled Hot rolled - 2 2. phases and frequency System neutral earthing Maximum system voltage One minute power frequency withstand voltage 1. DATA SHEET – A 3. KARIMNAGAR DIST. NO.3 3.0.5 REV.5 Switchboard cubicles and Bus bar ratings Nominal system voltage.6 kV SWITCHGEAR UNITS VALUES / REQUIREMENTS 1.2 1.3 1.9 1.0 1. NO. BY Material of earthing bus R0 JUNE’ 10 PPD. 100kA 1.2 2. NO.6 C As per IEC-60694 . TCE.9 SECTION: SHEET D3.13 2. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.9 12 OF 15 SPEC. ph.2 kV Silver faced By Bidder RMS Peak 44 kA* for 1 sec.1 1. droppers.5 2. DESCRIPTION 6. Removable bus bar joints with shrouds of 7. 330 R3 185 .5960A-H-500-001 SL.4 1.ANDHRA PRADESH POWER DEVELPOMENT COMPANY LTD. ambient temperature Material of bus bars Material of bus bar insulation V kV(rms) kV(peak) 0 V.0 2. Non-magnetic material VT/relay compartments – IP52 Other compartments – IP42 Air conditioned area – IP32 Interior: Semi glossy white Exterior: Opaline Green Galvanised steel – 50 x 6 mm Copper 2. Hz 6600 / 3 / 50 Non-effectively earthed 7200 20 60 1.2 / 50 microsecond impulse withstand voltage Maximum temperature of bus bars. table 3 1.4 Colour finished shade (Enamel / epoxy) 2.10 1.12 1.1 Bus bar support insulator Bus bar joints / connection Bus bar rating Short circuit current rating and duration Momentary withstand current Switchboard Constructional Details Thickness of sheet steel enclosures. TCE FORM NO.7 1. 9 3.ANDHRA PRADESH POWER DEVELPOMENT COMPANY LTD.3 4. BY Cast resin bar primary 6600 / 50 Class ‘B’ or better 44 kA* for 1 sec.10 Anti pumping feature Short circuit current rating and duration Momentary withstand current Auxiliary control voltage: (a) For closing / tripping coil / spring charging motor For space heaters and lighting and plug point V. ph. TCE. To be provided rms kA(peak) 44 kA* for 1 sec. DATA SHEET – A 3. NO. Hz Vacuum 7.7 3. DATE REV.2 Breaker details Circuit breaker type Voltage.5960A-H-500-001 SL.8 3.3 3. Manual trip and close facility to be provided. TCE FORM NO. DC 220 (b) V.0 3.1 3.2 / 3 / 50 3.1 4.5 3. of phases and frequency kV.6 Rated operating duty Total opening time Total closing time Trip free operating mechanism type O-3 min-CO-3 min-CO 3 cycles 5 cycles Motor charged spring. Phase 230 V. 330 R3 186 . NO. BY CKD.9 SECTION: SHEET D3. Hz NA 4. Ratio 50/ 1 (As per consumer rating) CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.4 3. Current transformer details Type System voltage and frequency Class of insulation Short circuit withstand current and duration Core balance CT for all outgoing feeders Voltage transformer details R0 JUNE’ 10 PPD.6 DESCRIPTION Clearance in air of live parts UNITS mm mm VALUES / REQUIREMENTS Phase to Phase – 120 Phase to Earth – 120 3.11 Pressure switch with two potential free contacts for monitoring SF6 gas. NO. 100 3. 5960A V.0 4.4 4. No. 1 phase 3.0 REV. KARIMNAGAR DIST.5 5.9 13 OF 15 SPEC. 2.2 4.BY DATE RKD HA JOB NO. 1 Type DESCRIPTION UNITS VALUES / REQUIREMENTS Cast resin 5. BY .0 8. BY CKD.9 14 OF 15 SPEC.2 7. 5960A IEC : 62271-100 IS : 3427 IS : 2705 IS : 3156 IS : 5578 IS : 11353 IS : 2544 IS : 2147 IS : 3231 CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR. DC 220 6. TCE. NO.2 Rated voltage - Primary Secondary Primary Secondary V V 6600 / 110 / Star 3 3 / 110 / 3 . NO.5 5.2 continuous 1.2 for energy meters on the switchgear incomers) 1.6 5.7 Class of insulation One minute power frequency withstand voltage 1. NO. 330 R3 187 8. DATE REV.6 8.5 Type of meters Spring charging motor supply voltage Codes and Standards Circuit breakers Metal enclosed switchgear Current transformers Potential transformers Arrangement for switchgear bus bars.1 0.BY DATE RKD HA JOB NO. 5.3 8.9 SECTION: SHEET D3.0 8.9 for 30 seconds Class ‘B’ or better kV(rms) kV(peak) 20 60 5.2 / 50 micro second impulse withstand voltage Meters Accuracy class 6. DATA SHEET – A 3.4 Rated voltage factor 5.5960A-H-500-001 SL.4 8. KARIMNAGAR DIST.2 8.8 REV.ANDHRA PRADESH POWER DEVELPOMENT COMPANY LTD.0 6.1 8.3 Method of connection - Star / Open 1. TCE FORM NO. main connection and auxiliary wiring Bus bar support insulators Degree of protection Electrical relays for power system protection R0 JUNE’ 10 PPD.0 for others Digital V. 110/3 for open delta 5.7 8.5S for energy meters (0. 11 8. NO. 8.BY DATE RKD HA JOB NO.14 8. 330 R3 188 .9 SECTION: SHEET D3.10 8. DATE REV. DATA SHEET – A 3.9 15 OF 15 SPEC.12 8. KARIMNAGAR DIST.9 8. NO. BY CKD. TCE FORM NO.15 DESCRIPTION Electrical indicating instruments High voltage fuses AC electricity meters Aluminium bus bars Code of practice for phosphating iron and steel (Off-load) isolators HRC fuses UNITS VALUES / REQUIREMENTS IS : 1248 IS : 5792 IS : 722 IS : 5082 IS : 6005 IS : 6005 IS : 1818 REV. TCE.ANDHRA PRADESH POWER DEVELPOMENT COMPANY LTD.13 8. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.5960A-H-500-001 SL. BY R0 JUNE’ 10 PPD. NO. Also..SERVICE TRANSFORMERS SPEC.1 Dry Type Transformers The cast resin transformers shall be housed in naturally ventilated floor mounted cubicle with louvers backed by fine brass wire mesh. The service transformers shall be two winding. 50 Hz. Each of the above boards shall be sectionalised. with off-circuit taps of + 5% in steps of 2. valve actuators etc. An appropriate load factor with a minimum of 0.4.1 11. 10.2 for intermittent loads like cranes.3 MVA Rating Each transformer shall be rated to feed of the entire load on the respective switchgear considering the outage of another transformer.8 for continuously running loads and 0.10 and specific requirements indicated below.1.3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5%.4 Specific Requirements All service transformers shall be cast resin dry type (indoor).10 SHEET 1 OF 4 1X 700 MW CCPP AT NEDUNOOR. An additional margin of 20% over the rating thus established shall be provided for load variations during the detail engineering stage. 11. ISSUE R0 TCE FORM NO.2 11.0 SERVICE TRANSFORMER The service transformer shall conform to the latest editions of national and international standards indicated in Data Sheet A .5960A-H-500001 10. Impedance The impedance of the transformers shall be selected such that the fault level on the switchgear do not exceed its short circuit capability including the motor contributions and also voltage dip while starting any auxiliary does not exceed the limit acceptable for the equipment concerned but in no case shall exceed 15%. ELECTRICAL SYSTEMS .4. TCE. Adequate number of service transformers shall be provided as required to meet the demand on 400V system based on the criteria that each 400 V switchgear / PCC / MCC / Distribution board shall be fed by 2 x 100% transformer / feeders. plug points. 10. three phase. 11. shall be considered. Degree of protection of enclosure shall be atleast IP32. KARIMNAGAR DIST. NO. SECTION: D3. 329 R5 189 .1 The number and rating of service transformers shall be decided based on the geographical location of loads without sacrificing the unit and common load concept. the service transformer shall comply with the requirements indicated in Data sheet A3. sump pumps. 6600 / 420 Volts.10 Service Transformers. 5960A-H-500001 11. ISSUE R0 TCE FORM NO.SERVICE TRANSFORMERS SPEC.4 11.7 11.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.4. KARIMNAGAR DIST. The insulation class for cast resin transformers shall be class-F.1. Off-circuit tap changers with lockable operating handle.4.6 11. and with a variation of 2.1. SECTION: D3. The HV connections shall be through cables. TCE. with temperature high alarm and very high trip contacts.5% per step and a range of + 5% shall be provided.5 Tests and test reports All routine tests shall be conducted as per relevant IS standards. mechanical tap position indicator.1.4. ELECTRICAL SYSTEMS . NO.4.4. The core and windings shall be provided with embedded temperature detectors for remote indication in DCS.4.1. 329 R5 190 .3 11. Type test certificates carried out on similar transformer shall be submitted for review.2 The transformer cubicle shall be located right next to respective 400V switchgear and LV side shall be connected through cables or bus duct.10 SHEET 2 OF 4 1X 700 MW CCPP AT NEDUNOOR. 11.5 11.1.1. Noise level shall not exceed the values specified in NEMA TR-1. The dry type transformers shall be provided with core and winding temperature detectors. 0 2. DESCRIPTION Service Transformers UNITS VALUES / REQUIREMENTS 1.1 10.10 3 OF 4 SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A3.0 LV Maximum temperature rise of winding a) Dry type transformer -/3 Class-F (155 oC) C 8. TCE FORM NO.1 5.0 5.2 5.3 8.1 60 / 20 6.10 SECTION: SHEET D3.2 8.BY DATE RKD HA JOB NO.2 7.0 Cooling method Overfluxing capability Winding connections HV LV Vector group Impulse (1.0 REV.1 Not to exceed values specified in NEMA TR1 Shade 631 of IS-5/RAL 7032/eqt. load voltage HV LV Volts Volts Cast resin dry type . CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR.0 Type No. 330 R3 191 Off-load % % +5 2. BY Paint shade R0 JUNE’ 10 PPD. TCE. NO. 3-ph.5 CFVV Full 11. NO.0 4. NO.0 5.5960A-H-500-001 SL.2 / 50 micro second) / Power frequency withstand voltage windings HV kVp.0 8.0 Tapping particulars Type Tap range Tapping step Category of voltage variation Tapping power Bushing particulars Voltage class – HV / LV Noise level kV 7.5 9. 5960A .1 8.4 8. two winding 6600 420 AN 110% continuous 3. BY CKD.3 6. DATE REV.2/1. KARIMNAGAR DIST. kV(rms) kV(rms) 0 Delta Star Dyn11 6.0 9. 330 R3 192 . BY R0 JUNE’ 10 PPD. NO.8 DESCRIPTION Codes and Standards Service transformer Fittings and accessories Bushings Degree of protection Tests Tolerance on guaranteed particulars Buchholz relay Electrical insulation classified by thermal stability UNITS VALUES / REQUIREMENTS IS : 11171 IS : 3639 IS : 2099 IS : 2147 IS : 2026/ IS: 11171 IS : 2026 IS : 3637 IS : 1271 REV. KARIMNAGAR DIST.0 12.BY DATE RKD HA JOB NO. 5960A CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR.3 12.4 12. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A3.2 12. TCE.5 12.1 12. 12. TCE FORM NO.10 4 OF 4 SPEC. DATE REV.7 12.6 12.5960A-H-500-001 SL. NO. BY CKD.10 SECTION: SHEET D3. 6 193 .1 no.1 no. on each bus ISSUE R0 TCE FORM NO. 11. the 400 V switchgear / MCC and its accessories shall comply with the requirements indicated in Data Sheet – A 3. Switchboard 230V. TCE.2 11.3. TCE.11 1X 700 MW CCPP AT NEDUNOOR.5960A-ELSK-2001.5 11.3.3 11. The Bidder shall provide additional switchboards as required without sacrificing the standby philosophy.0 400V SWITCHGEAR & MCC The 400V switchgear and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet A 3. KARIMNAGAR DIST. Bus VT module .3 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 1 phase motor space heating supply module . NO. Spare feeders .5960A-H-500-001 400V SWITCHGEAR & MCC 11. Power Sources for 400V Switchgear The switchboard shall derive power from the designated auxiliary transformers as shown in the Key One Line Diagrams TCE. 400V switchgear / motor control centres (MCCs) and AC distribution boards (ACDBs) shall be provided.20% of each type and each rating with minimum of one no. MCCs & ACDBs shall be procured from the same source in order to ensure interchangeability of components. Any additional switchgear / MCCs as required shall also be provided. feeder. 230V. Any additional quantity required for any increase/changes during detailed engineering stage also shall be duly considered).3 11. on each bus. reliability and flexibility of operation and with unit and common loads demarcation.11 400 V Switchgear / MCC. 1 phase space heating .3.4 11. The switchgear shown in Key One Line Diagram drg. on each bus section.11 and specific requirements indicated below: 11. The switchgear / MCC shall be provided with suitable numbers and type of outgoing feeders as required. All 400 V switchgear.1 no. SECTION: D3. Also. No.1 Feeder Details The switchgear / MCC shall be provided with two incomers and a bus coupler (100% each).1 For feeding the 400V/230V/110V AC loads of the plant.3.3.5960A-EL-SK-2001 are tentative. 329 R5 11.2 11.3.5. (Above quantity is the minimum requirement at the time of handing over the plant. ELECTRICAL SYSTEMS - SHEET 1 OF 17 SPEC. The circuit breaker and feeder modules in switchboard and MCCs shall be of fully drawout construction.5960A-H-500-001 400V SWITCHGEAR & MCC 11. In this type of construction it shall be possible to drawout the chassis without having to unscrew or unbolt any connections to the equipment mounted on the withdrawable chassis. Proper gasketing shall be provided all around the perimeter of adjacent panels. Any of the system/equipment which requires power supply.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.8 11. Switchgear / MCCs shall be single or double front as execution needed.4. ELECTRICAL SYSTEMS - SHEET 2 OF 17 SPEC.52 degree of protection.7 11. 400V.4.4.3 ISSUE R0 TCE FORM NO. Individual feeder modules in multitier arrangement. 329 R5 194 . KARIMNAGAR DIST. floor mounted modular type of uniform height not more than 2450 mm. 400 kV isolator motorised operating mechanism.1 no. 11. All drawout contacts.3.3.1 Control transformer on each bus section: 01Nos Construction Switchgear/MCCs shall be metal enclosed. TCE. Switchgear shall be designed for the bottom entry of cables however.11 1X 700 MW CCPP AT NEDUNOOR. easily extensible on both sides having switchboard designation indicating labels.10 11. One feeder for maximum of 3 Nos. The power and control drawout type connections shall be of sliding type.2 11.3. Enclosed vertical busbars serving all modules in vertical section. dust and vermin proof construction with IP . the incomers shall be suitable for NSPBD.4 11.9 Alarm module for common alarm for out going feeder fault . For each auxiliary or load. one feeder shall be provided except for the following cases: (a) (b) One feeder for maximum of 2 Nos. Switchgear/MCC shall be divided into distinct vertical sections of: (a) (b) (c) Completely enclosed busbar compartment running horizontally. removable covers and doors. panel and base frame.3. NO. 11. including for auxiliary and control wiring shall be of self-aligning type. indoor. 3 phase plug points. SECTION: D3. 4. and with proper clearances. drawout construction for easy replacement and testing facility.9 11. adequately supported to withstand stresses developed due to short circuits.4. A horizontal separate enclosure for all auxiliary power and control bus. Switchgear/MCC shall be designed such that all component equipment and busbars operate satisfactorily without exceeding their respective maximum permissible temperature limits of 105oC. All doors shall be with concealed type hinges and captive screws. Busbar joints shall be shrouded with moulded epoxy removable shrouds. The auxiliary relays and timer may be provided in fixed cases. Cable alley shall be provided with suitable hinged doors. ELECTRICAL SYSTEMS - SHEET 3 OF 17 SPEC. Rear of single front switchboard shall be provided with removable panels. The switchgears / MCC shall be designed to offer adequate level of safety to operating / maintenance personnel.7 11. 329 R5 11.4. All types of relays and timer shall be flush mounted with connections from inside.11 11. and shall have transparent & dust tight cover.8 11. if required.5 11.4. KARIMNAGAR DIST.4 Each vertical section shall be equipped with space heater and thermostat.4. a separately enclosed cable compartment shall also be acceptable. Stop Push buttons shall be of latch type with mushroom knobs.5960A-H-500-001 400V SWITCHGEAR & MCC (d) Vertical cable alley covering entire height and minimum 250mm wide. (e) (f) 11. Switchgear/MCC busbars shall be of uniform cross section throughout the length and made of high conductivity. Busbars shall be sleeved. NO. The busbar rating of the 400V switchgear / MCC shall be rated for LV (400V) side current of auxiliary transformer plus 20% margin rounded off to the next standard rating. Supports shall be of glass reinforced phynolic material or cast resin.12 195 . TCE. Means shall be provided to ISSUE R0 TCE FORM NO.4.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.4. For cable connection to circuit breaker.6 11. SECTION: D3.10 11.11 1X 700 MW CCPP AT NEDUNOOR.4. removable from front. aluminium alloy of E91 grade.4. Material used for sleeving shall be capable of withstanding maximum temperatures specified in technical requirements table. Rubber mats shall be provided in front & back of each panel.5960A-H-500-001 400V SWITCHGEAR & MCC prevent access to the live part to avoid accidents during service as well as maintenance period. test and Isolate positions. KARIMNAGAR DIST.3 ISSUE R0 TCE FORM NO. 1-ph.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.4. NO.6.11 1X 700 MW CCPP AT NEDUNOOR. Bidder shall bring out the safety means provided to achieve above. Control supply for the SFU operated motor feeders shall be 110V AC and for all ACB feeders. Breakers shall have inherent fault making and breaking capacities. it shall be 220V DC. SECTION: D3. transformers shall be provided in each main plant switchgear for deriving control supply. ELECTRICAL SYSTEMS - SHEET 4 OF 17 SPEC. Control Supply Individual two (2) nos. panels. The auxiliary bus bars for control supply shall be segregated from main bus bars.6 Specific Requirements Switchgear / MCC shall comply with specification requirements indicated below: 11. (100%) 400/110V. 329 R5 196 .5 11. The control supplies shall be monitored. modules. They shall have shunt trip coils. 11.6. All air circuit breakers (ACBs) shall be of short circuit performance category P2 as per IS 2516 parts I & II. TCE. Rating transformers each transformer shall be adequate to cater both the bus sections.1 The breaker / feeder modules shall have service. DBs. A detailed instruction plate suitable for wall mounting shall be provided for each switchgear / MCC room describing various safe operating procedure / safety precautions for safe operation and maintenance of switchgear / MCC. Control circuits shall operate at suitable voltage of 220V DC. MCCs.13 All switchgears. All breakers shall have built in interlocks for equipment and personnel safety. Suitable trolley arrangement shall be provided for breaker modules. Additionally one such trolley shall be kept at each switchgear room. Two trolleys in the main switchgear room shall be provided so that breaker module of all types. local starters and push buttons shall have prominent engraved identification plates. 11.6. A changeover switch shall be provided for selection.2 11. sizes and rating can be withdrawn on trolley and lowered for maintenance purpose. 11. 12 11.17 11.6. All protective relays shall be of numerical type.5mm. Mechanically operated.6. easy and safe maintenance. Minimum of two NO and two NC spare contacts of all contactors & relay devices shall be wired to terminal block. future additions of cables. contactors and other power devices shall consider a margin of about 20% over the nameplate current rating of the respective load. KARIMNAGAR DIST.13 11. For each vertical section a separate set of vertical bus bars shall be provided to serve the modules.6. NO. shrouded to prevent accidental operation.10 11. The switches. 220V DC control supply shall be provided with a manual selection for changing over to either supply. 329 R5 11.15 11. TCE.5960A-H-500-001 400V SWITCHGEAR & MCC 11. red 'trip' push button.11 11.5 11. Module details (a) Incomers & bus couplers ISSUE R0 TCE FORM NO.6.6. Interposing relays shall be provided for control from remote. For breaker control.6.6.7 11.14 11.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The cable alleys shall be liberally designed considering the size and number of cables.11 1X 700 MW CCPP AT NEDUNOOR. indication lamps shall be provided. ELECTRICAL SYSTEMS - SHEET 5 OF 17 SPEC. 20% spare terminals shall be provided for each module.6.6.4 Paralleling of two supplies shall be avoided by interlocking except for switchgear where auto-changeover or live changeover is provided. SECTION: D3.6. All indicating lamps shall be self-coloured clustered LED type of size 22.18 197 . For CT & VT circuits disconnecting type of terminals shall be provided. Transducers required for remote metering shall be provided.6.6 11.9 11.6.6.16 11.6. Breaker contact multiplication if required shall be through latch relays. Necessary voltage monitoring contactors. 2 nos. Space heater with MCB and thermostat shall be provided for each vertical panel.8 11.6. SECTION: D3. fuses for 220V DC control supply Breaker control switch Local remote control switch. for checking synchronising during live manual changeover Switch. Incomer from Emergency D. However the metering shall be done through the numerical relay and shall be communicated to the DCS. E/F relay connected to the bushing CT provided in transformer neutral circuit Lock out relay with supervisory lamp Indicating lamps for on. trip circuit healthy etc ISSUE R0 TCE FORM NO.11 1X 700 MW CCPP AT NEDUNOOR. TCE. spring charged. KARIMNAGAR DIST. Tripping from local shall be possible only when local/remote selector switch is in local position. Closing from local shall be possible only in test position whereas closing from remote shall be possible in either service or test position.G set shall also be provided with composite numerical feeder protection relay. Tripping from remote shall be possible when either breaker in service position or selector switch being in remote position. E/F relay 1 no. Line VT 400/110V. of contacts. off and fault. 3 phase inverse time over current relays & 1 no. NO. Service & test position limit switches with required no. 329 R5 • • • • • • • • • • • 198 . CT shall be used for the Numerical protection relay.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 400V SWITCHGEAR & MCC (i) The incomer modules and bus coupler modules of 400V switchgear/ MCC shall be air circuit breaker controlled from local and DCS. Composite Numerical feeder protection relay shall be provided for breaker feeders other than motor feeders. They shall be provided with: • One no. ELECTRICAL SYSTEMS - SHEET 6 OF 17 SPEC. 329 R5 (iii) 199 .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. double frequency meter. The continuous current rating of the bus bars. However for MCC’s with important feeders like LOPs and where auto change over is required. incomers. Changeover back to the normal source of supply shall be effected manually.9 for continuous loads. Necessary circuitry and devices for auto trip. TCE. Total changeover time shall not exceed 1 seconds. fault alarm. 0.4 for intermittent loads. NO. load factors to be considered shall be 0. For the load calculation. and for control/ alarm of the breaker as required. bus couplers of the switchgear fed from other switchgears shall be the maximum load on the bus due to all the running auxiliaries during any operation condition plus 20% margin rounded off to the next higher standard rating. Auto changeover facility shall be provided for switchgear/MCC. synchroscope shall be provided. such that if there is a prolonged under voltage on any one of the bus sections.5960A-H-500-001 400V SWITCHGEAR & MCC • • • Synchronising switches. Changeover scheme The switchgear with sectionalised buses will be normally operated with the bus coupler breaker open. KARIMNAGAR DIST. This auto changeover shall be blocked if the incoming breaker had tripped either on a bus fault or manually.11 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS - SHEET 7 OF 17 SPEC. the respective incoming breaker shall trip and the bus coupler breaker shall close. Selector switch for tripping selected breaker after live changeover (in bus coupler for locally controlled switchboards) All incomers for MCC’s and DB’s rated from 630A shall be ACB’s and for <630A MCCBs shall be provided. • • (ii) The incomer modules shall be interlocked with their upstream breakers such that they can be closed only when upstream breaker is closed and trips automatically when upstream breaker is tripped or faulted. SECTION: D3. Manual live changeover ISSUE R0 TCE FORM NO. ACB’s shall be provided for the incomers & Bus couplers. a set of double voltmeter. provided voltage is available on the other bus section. 329 R5 (ii) 200 . modules in 400V main switchboard/MCC shall be provided with all necessary relay devices for auto changeover function like under voltage relays (2 nos).5 – 5 sec for annunciation of the running breaker failing to trip within a preset time. TCE. the respective incomer shall be tripped automatically after the bus section breaker has been closed manually. After carrying out the changeover within 1sec. incomer to bus section – A or to bus section – B will be tripped once bus section breaker has been closed manually. thus maintaining continuity of supply.. ISSUE R0 TCE FORM NO.0 with adequate VA burden. under voltage timer. When the normal supply is to be brought back into operation.11 1X 700 MW CCPP AT NEDUNOOR. interposing VTs for synchronising circuit. (i) Bus VT modules shall be provided with suitable 400/√3 / 110/√3V VTs with primary and secondary fuses. the incomer breaker shall be closed where upon the bus coupler shall trip automatically. A timer with a time delay on pick up of 0. fuse failure relay. The accuracy class of VT shall be 1. ELECTRICAL SYSTEMS - SHEET 8 OF 17 SPEC. a selection shall be provided by the Contractor suitably on the DCS in plant control room for selecting the incomer to be tripped. voltage available relays (2 nos. Thus. When planned outage of one of the normal incoming supplies is required. V. (iv) For this purpose. (i. depending on the selection made. SECTION: D3. etc.T. whether specifically listed out in the specification or not. (v) All hardware required for meeting the functional requirements stated above. all the critical motors which are identified during the detailed engineering shall be re-accelerated automatically. 220V DC control supply switch & fuses. KARIMNAGAR DIST.5960A-H-500-001 400V SWITCHGEAR & MCC facility shall be provided for the switchgear/MCC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO.). (b) VT modules Each bus section of main switchboard and MCCs shall be provided with a bus VT module along with one voltmeter with selector switch and energy meter.e if the two sources remain paralleled for more than a preset time) shall be provided. shall be included in the Contractor’s scope of supply. ELECTRICAL SYSTEMS - SHEET 9 OF 17 SPEC. 4 wire outlets MCBs shall be provided for providing space heating supply for 400V switchboards.11 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3. (c) Feeders provided for supplying lighting distribution boards. KARIMNAGAR DIST.e the supply for the module in bus A shall be from bus B and vice versa. secondary side fuse. The 400V power supply for these modules shall be obtained from the other bus (i. switch-fuse contactor feeders shall be (d) (e) (f) (g) ISSUE R0 TCE FORM NO. TCE. Suitably rated 400V / 420V. 1-ph cast resin transformer. incoming side switch fuse. (iv) In case of fuse failure. the under voltage timer operation shall be blocked. fuse. secondary side fuse. 1-ph. air break contactors (For motors above 100kW. remote controlled electrical circuit breakers. Motor modules (i) • The motor modules shall be provided with Switch.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 3 – ph cast resin transformers incoming side switch fuse. fuses.5960A-H-500-001 400V SWITCHGEAR & MCC (iii) Earth fault alarm with voltage relay connected to open delta formed on secondary side of VTs shall be provided on each bus. space heating module (for motor. NO. supply indication. The modules rated 200Amp & above shall be provided with a CT and ammeter. space heating) shall be provided with incoming side switch. supply indication 3 – ph. shall be provided with suitably rated switch & fuses. 329 R5 201 .) Suitably rated 400 / 230 V. local control panels. and supply indicating lamp and connection to the space heating buses in the particular bus section.. 1 phase. MCB outlets shall be provided for feeding 230 V space heating / lighting supply required by other panels in the plant. panel. 230V. suitably rated 400/230V cast resin type transformer (expected heating loads of the switchboard + 30% margin) Secondary fuse. and for smaller motors. (v) In the 400V main switchboard buses an additional timer (with a higher time delay) shall be provided for sending signal for AMF start of the DG sets. power sockets etc. For modules of motor rated 100 kW and above ACB’s shall be provided. Module on. etc. KARIMNAGAR DIST. Off and fault indicating lamps Necessary auxiliary contactors for fault alarm circuit. for which monitoring is required. off PBs for non reversible modules and forward ‘reverse’ and ‘Off’ PBs for reversible modules Appropriate circuitry for receiving the on. and AC 22A category for other applications. interlocks. NO. 1 phase space heating arrangement. Any additional motor. ELECTRICAL SYSTEMS - SHEET 10 OF 17 SPEC. off and forwardreverse commands from remote panels/ systems. off command from local push buttons. Interposing relays for control from remote.5960A-H-500-001 400V SWITCHGEAR & MCC • • • • • • • • • • • provided. The CT connection shall be so wired to the terminal block so that provision for remote current indication is available. Transducers shall be provided for remote metering for all motors rated18 KW and above. (Thermal overload relays for all motor feeders upto 100kW and with integral single phase preventors for motor feeders >45kW). 230V space heating circuit Isolating switches shall be of AC 23A category when used in motor circuit. (ii) (iii) (iv) ISSUE R0 TCE FORM NO. TCE. shall be added during detailed engineering. Instantaneous short circuit protection on all phases through HRC cartridge type fuses rated for 80 kA rms (prospective breaking capacity at 400V) On.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Isolating switches and MCCBs shall have door interlocks and padlocking facility The motor modules rated 30 KW and above shall be provided with 230V. The modules for motors rated 50 KW and above shall have a CT and an ammeter. SECTION: D3.11 1X 700 MW CCPP AT NEDUNOOR. The other outgoing feeders would be switchfuse units or moulded case circuit breakers) Thermal overload relays with integral single phase preventors. 329 R5 202 . MCB for space heating/winding heating circuit. lube oil pumps.5 mm2 stranded copper conductor for control wiring and 2. Such essential services shall be identified during the detailed engineering stage and suitable module/scheme shall be provided. Essential service modules During auto changeover of the supply the contactors in the affected bus would have dropped off. Local operations shall be provided for motors like sump pumps etc which are neither controlled from DDCMS nor PLCs. aux contactors and associated circuitry in the module.. space heating.5mm2 for CTs and suitably sized for power wiring with a minimum of 2.11 1X 700 MW CCPP AT NEDUNOOR.8 11. Outdoor switchgears and switchgears/ panels located in close proximity to gas turbine shall be provided with HR PVC cables. SECTION: D3. (vii) (viii) The 400V single phase connection control supply transformer. These modules shall have additionally hardware like timer. The services which shall be restarted immediately without time lapse to keep the unit running are considered essential services. All abnormal conditions shall be alarmed to DDCMS.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. Such auxiliaries shall restart automatically without any action by the operator after an auto changeover. seal oil pumps. (for eg. ELECTRICAL SYSTEMS - SHEET 11 OF 17 SPEC. 11.).1 400 V A C Distribution Board / Control Panel Bidder shall include in his scope required no. of 400V AC power supply distribution board/control panel for feeding packaged auxiliary load like centrifuge. Bidder shall provide one or two (depending on the ISSUE R0 TCE FORM NO. Motor in other areas shall be controlled from respective PLCs. TCE. shall be distributed between different phases to keep the loading on all phases uniform 400V/230V control transformer. Motor modules – Remote start/Stop and ON/OFF /Trip indication shall be provided from DDCMS for all motors of the main plant. 329 R5 203 . winding heating modules etc.5960A-H-500-001 400V SWITCHGEAR & MCC (v) (vi) For modules of motors rated 100 kW and above shall be provided with composite numerical motor protection relay. etc. 11. KARIMNAGAR DIST.5 mm2 copper. auxiliary cooling water pumps etc.8.7 The internal wiring shall be with 1. 8.2 A. 100%Unit+ 50% STG + 50% station emergency loads).) shall be provided with a reliable A. power supply through a separate source. SECTION: D3.4 11.2 11. The A. 400V. welding / Power receptacles. These DG sets are provided with one stand-by generator of same rating as a back up. emergency bearing lube oil pumps.8. KARIMNAGAR DIST. battery chargers. distribution board/control panel shall comply with technical requirements table. Each DG set shall cater to the emergency loads of each of the GTG units (i. essential instrument power supply feeders.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. these essential loads will be manually changed over to the normal power supply. TCE.3 11. When the normal station A.8.C supply failure in the station. if it is <400A other wise ACB shall be used.9 11. Tests ISSUE R0 TCE FORM NO. The DG sets shall be connected to emergency switchgear with required interconnections to GTG and STG switchgears.C. turning gear motor. 11. etc.8.1 Emergency Power Supply To enable safe unit shutdown during complete A. cubicle lamp and power plug. For this purpose.e.C.9. Each circuit of welding distribution board shall feed maximum of 2 Nos.C. Also applicable clauses of 400V switchboard and MCCs shall be complied with for these boards/panels.5 11.C. NO.9 204 . certain important plant auxiliaries (such as the A.5960A-H-500-001 400V SWITCHGEAR & MCC criticality of the service) incomer from 400V main switchboard to feed the distribution board/control panel. When the normal A. ELECTRICAL SYSTEMS - SHEET 12 OF 17 SPEC. All the incoming and outgoing feeders shall be of switch fuse controlled.C supply is restored. distribution boards/control panels shall be provided with thermostatically controlled space heater. Required ACDB shall be provided to cater to the auxiliary power requirements of 400kV switchyard. the DG sets will start automatically and feed the essential loads connected to GTG and STG switchgears. quick starting emergency diesel generator sets with automatic mains failure (AMF) feature shall be provided.11 1X 700 MW CCPP AT NEDUNOOR. 2x100% capacity feeders shall be provided in the main switchgear for serving this ACDB. 11. emergency lights. 329 R5 11.C.9. supply fails. Separate 400V welding distribution boards along with Isolation Transformer (2x100%) shall be provided in each area. ELECTRICAL SYSTEMS - SHEET 13 OF 17 SPEC.5960A-H-500-001 400V SWITCHGEAR & MCC Switchboard/MCCs shall be subjected to routine tests as spelt out in Indian Standards and typical type test certificates for identical switchgear / MCC shall be furnished. ISSUE R0 TCE FORM NO. synchronising are indicated in I&C system section No. annunciation. NO. D2.4. TCE. monitoring.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 11. measurement. SECTION: D3.11 1X 700 MW CCPP AT NEDUNOOR. 329 R5 205 . KARIMNAGAR DIST.10 Minimum electrical system requirements in respect of control. 1 1. DESCRIPTION 400V SWITCHGEAR / MCC UNITS VALUES / REQUIREMENTS 1.8.5 2.4 1.11 SECTION : D 3.10 1. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A 3.3. droppers at site reference ambient of 500C Short circuit withstand Short time current (1 sec.5960A-H-500-001 SL.2 1.8 1. 105kA Switchboard / MCC Yes Single front / Double front Cable : Bottom Entry NSPBD: Top Entry Yes IP 54 Frame Door Cover mm mm mm PPD.0 1. NO.0 JOB NO. NO. . 50.6 2.10. 330 R3 206 0 V/P/Hz 400.BY DATE TCE FORM NO. 3ph.2 1.3 1.10.1 1.) Momentary current Switchboard / MCC Construction Fully draw out Double front / single front Cable entry (Power & Control) rms Peak 50 kA for 1 Sec. BY Modular construction Degree of protection for as per IS : 2147 Thickness of sheet steel Cold rolled Hot rolled Gland plate thickness R0 JUNE’ 10 RKD HA 2.0 1. BY CKD.8.7.8.10.5 3 1.6 Switchboard & Bus bars Rated voltage.3. NO.1 1.1 1.2 1.6 2.7.2 1. phases & frequency System neutral earthing One minute power frequency voltage withstand Power circuits Control circuits Auxiliary circuits Reference ambient air temperature Material of bus bars Maximum temperature of bus bars contacts.4 1.3 REV.7 1.5 1. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR. DATE REV.8.11 SHEET 14 OF 17 SPEC.9 1. TCE.2 1. 3 wire Solidly earthed V V V 0 2500 1500 2000 50 Aluminium C C 90 1.3.3 1.3 1.1 1. DESCRIPTION UNITS VALUES / REQUIREMENTS 1.4 3.3 3.5960A-H-500-001 SL.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A 3.4 External : Opaline Green Internal : Semi Glossy white.11. V/DC 220 3.11 SECTION : D 3.4 19. 4. BY Based on breaker short circuit current rating and duration RKD HA JOB NO.3 2.6.11.1 REV. 2. KARIMNAGAR DIST.2 2.6.1 Required Required Required 50 kA for 1 sec. NO.2 1.BY DATE TCE FORM NO. TCE.4 3. NO.6 3.12 Phase to phase Phase to earth Paint shade mm mm 25.11 Clearances in air for live parts 1.0 3.1 3. BY CKD. .1 1.2 3. NO.11 SHEET 15 OF 17 SPEC.0 4.3 4.6.5 Contactors & O/L relay Utilisation category for contactors Contactor rated duty Reset feature for thermal O/L relay Starter type Circuit breakers Circuit breaker type Rated operated duty Type of operating mechanism Short circuit rating Control voltage for spring charging motor and tripping & closing Emergency manual operation required in addition to electrical operating devices For spring charging & closing For tripping Anti-pumping feature CTs and VTs Short time withstand current and duration for CT Breaker controlled R0 JUNE’ 10 PPD.1. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR. DATE REV.1 3. 330 R3 207 AC3 for non-reversible & AC4 for reversible Uninterrupted Hand DOL Air break with shunt trip B-3min-MB-3min-MB Motor wound spring charged 50 kA for 1 sec.0 2.2 3.1 2. 11 SHEET 16 OF 17 SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A 3.12 REV. NO. 4.11 6.2.1.11 SECTION : D 3.BY DATE RKD HA JOB NO.10 Air break switches Miniature circuit breakers HRC cartridge fuses D type fuses Contactors Starters Control switches / push buttons and maintenance of switchboard Code of practice for phosphating iron and steel Wrought aluminium & aluminium alloys for electrical purposes R0 JUNE’ 10 PPD. DATE REV.1 6.6 6. NO.9 6. 330 R3 208 .5 6.0 for others IS : 4237 IS : 13118 6.0 5.1 6.2 5.0 6.2 1.5 Digital 0.1 4.2 DESCRIPTION Switchfuse controlled UNITS VALUES / REQUIREMENTS To match with fuse withstand 4.2. KARIMNAGAR DIST.2 Overvoltage withstand capacity for VT 4. NO. TCE FORM NO. 5960A IS : 4064 & IEC 60947-3 IS : 8828 IS : 9224 IS : 8187 IS : 29259 IS : 8544 IS : 6875 6. TCE. BY IS : 6005 IS : 5082 CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.7 6.8 6.3 Continuous 30 seconds Meters Class of accuracy Applicable Standards Switchboard general requirements AC circuit breakers Factory built assemblies of switchboard and control gear for voltages upto & including 1000V AC & 1200 V DC pu pu 1.4 6.2 6.5960A-H-500-001 SL.5 for energy meters and 1. BY CKD. 11 SECTION : D 3. 330 R3 209 . DATE REV. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.2 7. REV. NO. BY CKD. NO.5960A-H-500-001 SL.0 Technical requirements Table for 400V AC Distribution Boards / Control Panels Location / mounting Current rating Cable entry Design ambient temperature Codes and standards 0 7.3 7. expected load current + 20% margin Bottom Cable entry C 50 As indicated for 400V switchboards / MCCs.5 Indoor / floor mounted Max. NO.BY DATE RKD HA JOB NO.1 7. TCE FORM NO. BY R0 JUNE’ 10 PPD.13 Control transformer for switchboard and control gear for voltages not exceeding 1000V AC IS : 12021 7.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A 3.4 7. TCE.11 SHEET 17 OF 17 SPEC. DESCRIPTION UNITS VALUES / REQUIREMENTS 6. KARIMNAGAR DIST. The earth fault current shall be limited to 300A.0 METHODS OF EARTHING The neutral earthing equipment shall conform to the latest editions of relevant national and international standards.5 12. ISSUE R0 210 12. transformer neutral earthing shall be such that earth fault current is limited to 300A. The neutral shall be connected to a suitably rated neutral earthing transformer.5. Sizing of Neutral Earthing Equipment The neutral grounding resistor ohmic value for generator neutral earthing shall be so selected that during an earth fault on one of the phases of the generator. generator bus duct and associated equipment including surge protection capacitor.5960A-H-500-001 1X 700 MW CCPP AT NEDUNOOR. These shall comply with the specific requirements indicated below. The neutral of service transformers shall be independently connected to the earth. 400V system shall be a solidly earthed system. The neutral of the transformers shall be connected to the earth bus through a link in the respective board. 329 R5 . 12. 230V AC control supply shall be a solidly earthed system.2 TCE FORM NO. Generator neutral shall be high resistance earthed. 230V systems for lighting and the space heating shall be solidly earthed system. generator transformer.3 12. The neutral of GTs are independently connected to earth.7. The neutral earthing resistor will be connected across the secondary of the neutral earthing transformer. The mid point of the secondary winding of the transformers shall be connected solidly through a link to the earth bus in the respective modules of switchgear / control panels.5 times.12 SHEET 1 OF 3 SPEC.2 12.1 400 kV system is solidly earthed.6 12.6 kV systems shall be medium resistance earthed. The neutral of the unit auxiliary transformers shall be independently connected to the earth through a suitable resistance. the capacitive kVA due to capacitance of generator. 6. SECTION: D3.4 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.7 12. the kW power consumed in the resistor shall be atleast equal to 1. ELECTRICAL SYSTEMS NEUTRAL EARTHING EQUIPMENT 12. The neutral earthing resistor ohmic value for unit aux. which is in turn connected to the plant earth grid.4 12. NO. KARIMNAGAR DIST.1 12. TCE.7. Alternatively it can be painted with heat resistant paint suitable for 2500C the neutral grounding equipment shall be completely assembled.12 SHEET 2 OF 3 SPEC.5 12.8. The resistor cubicle shall be mounted on suitably rated insulators.8. protection and indication leads shall be wired upto terminal blocks shall be mounted in a IP:54 enclosure suitable for flush mounting and having a fully hinged cover with lock. The loading resistor shall be formed of non-aging. even though located within the fenced transformer yard.4 12. canopy shall be provided.8. The minimum degree of protection for the resistor element shall be IP 34.3 12. corrosion resistant punched stainless steel grid element provided with necessary insulation and designed for indoor service for a temperature rise not exceeding 3000C.8. KARIMNAGAR DIST.2 12.10 12. Each neutral earthing resistor unit shall be air cooled and self supporting type.11 ISSUE R0 211 TCE FORM NO.8.7 12. NO.9 12. For outdoor cubicle. If located at ground level the resistor area shall be fenced separately. The transformer and resistor shall be located in separate cubicles/compartment adjacent to each other.5m. 12.8 12.8 12.8. The cubicles shall have hinged access doors capable of being pad locked. The resistor cubicle shall be located in transformer yard at a height of 2.5960A-H-500-001 1X 700 MW CCPP AT NEDUNOOR. The neutral grounding transformer shall be cast epoxy resin type natural air cooled single phase connected between generator neutral and ground.8. The transformer cubicle shall be made of angle frame steel construction with formed sheet sides.1 Specific Requirements Duty rating of the earthing resistor for generator neutral and UATs shall be 30 seconds. 329 R5 . SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Cable boxes shall be provided for receiving the cables from the transformers.8. The resistor cubicle shall be made of angle frame steel construction with hot dip galvanised screen sides.8.8.8. wired and connected to the neutral bus tap through seal-off bushing. All alarm.6 12. TCE. ELECTRICAL SYSTEMS NEUTRAL EARTHING EQUIPMENT 12. ELECTRICAL SYSTEMS NEUTRAL EARTHING EQUIPMENT 12. TCE.5960A-H-500-001 1X 700 MW CCPP AT NEDUNOOR.1 TESTS All Acceptance and routine tests as per IS/IEEE shall be conducted on NGR assembly.9.8. so as to prevent bypassing of resistor in case of shorting of resistor from inside.12 Enclosure shall not be earthed.9 12.2 iii) Heat run test on complete assembly iv) Insulation resistance measurement test ISSUE R0 212 TCE FORM NO. 329 R5 . The following tests on resistors shall be performed and test certificate shall be furnished prior to dispatch: i) ii) High voltage withstand test Ohmic value test on off-load on complete resistor 12.12 SHEET 3 OF 3 SPEC. SECTION: D3.9. 12. KARIMNAGAR DIST. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. DC switchboard having 2 Incomers & one bus coupler shall be provided for each steam turbine generator (STG) unit loads. NO.13 SHEET 1 OF 14 700 MW CCPP AT NEDUNOOR.1.6 kV switchgear and 400 V switchgear.13 and specific requirements indicated below: 13.1 DC power supply with high discharge plante lead acid cells forming bank shall be the source of the power supply for control. 2 x 100% battery banks with associated float cum boostchargers and 1 No. 1 No. Common station DC auxiliaries and emergency lighting loads. interlock.1 13. The GTG unit DC system shall be sized to cater complete unit GTG loads. 220V DC.2 (e) (f) 13. ELECTRICAL SYSTEMS . HRSG system loads and common station auxiliaries (excluding 400 kV system auxiliaries).5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. protection.1.5.5960A-EL-SK-2006.3 220V DC.1. annunciation of the complete plant including I&C system during the running of the plant as well as for a safe shutdown at the time of the total power supply failure. the DC system and its accessories shall comply with the requirements indicated in Data Sheet – A 3.13 Also. the following shall be provided.5960A-ELSK-2006. 13. 2 x 100% battery bank with associated float cum boostcharger. DC switchboard having 2 Incomers & one bus coupler shall be provided for each gas turbine generator (GTG) unit. The scheme shall be as per sketch TCE. 6. 1 No.5960A-H-500-001 13. TCE. The scheme shall be as per sketch TCE.0 DC SYSTEM The DC System and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet – A 3. DC switchboard having 2 Incomers & one bus ISSUE R0 213 TCE FORM NO.DC SYSTEM SPEC. 220V DC. 2 x 100% battery bank with associated float cum boostcharger. KARIMNAGAR DIST. For feeding the DC supply for the above. SECTION: D3. 329 R5 . (a) (b) (c) (d) Loads of Steam Turbine Generator (STG) unit Loads of HRSG UPS loads catering to the I&C requirements Other DC supply loads as required by I&C system which shall be derived from 220 V DC through DC/DC converters. 6 kV & 400V breakers. Starting current of all automatically started DC drives.13 SHEET 2 OF 14 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS . Battery shall be sized to cater for the following loads with minimum duration as indicated.1. TCE.1. 2 x 100% battery banks with associated float cum boostchargers and 1 No. 13. 2 x 100% battery banks with associated float cum boostchargers and 1 No. DC switchboard having 2 Incomers & one bus coupler shall be provided for catering the I& C and DCS system application.5960A-H-500-001 coupler shall be provided for 400kV system (switchyard) auxiliaries. 24V DC. Momentary Load (For duration upto 1 minute). The switchyard DC system shall be sized to cater the following loads: (a) (b) DC load of 400kV switchyard Emergency lighting building The 400 kV system DC battery. Emergency lighting Indicating lamps on switchgears and control panels ISSUE R0 214 TCE FORM NO. DC switchboard having 2 Incomers & one bus coupler shall be provided for PLCC system of 400kV switchyard.DC SYSTEM SPEC. battery chargers and DCDB shall be located in the switchyard control building. SECTION: D3.3.5 13.85 V/cell for lead acid batteries.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 Scheme for earth fault detection shall be provided for each DC bus and feeders. Solenoid valves. NO.4 48V DC. 329 R5 . 6. In rush current of excitation system. 13. Detailed sizing / selection calculation shall be subject to Owner’s approval.1 13. (a) (b) (c) (d) Tripping / closing load of 400 kV.2 Emergency & Continuous Load (For 10 hours duration) (a) (b) (c) Running currents of essential DC motors. 13. KARIMNAGAR DIST. The voltage at the end of duty cycle shall be 1.3.3 13. 20 % spare capacity over above loads The float voltage output of the float charger shall be automatically adjusted depending upon the ambient temperature such that the batteries remain floating through out the range of variation of temperature as specified in Section – B. Further. KARIMNAGAR DIST.5.13 SHEET 3 OF 14 700 MW CCPP AT NEDUNOOR. starting or tripping whichever is higher.4 13.4. 13.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 13.2 The boost charger unit shall be rated such that the battery can be fully charged from fully discharged condition within 8 hours. for arriving at the battery capacity. The temperature correction factor as given in IS.3.4 I & C system loads UPS requirement for 4 hours.4.5.DC SYSTEM SPEC. the following shall be considered.5960A-H-500-001 (d) (e) Control room emergency lighting Auxiliary relays 13.3 13. A design margin of 10% shall be considered for each of the GTG Unit Batteries & Common Station Batteries and 20% margin shall be considered for the 400 kV System Batteries. C above the ambient temperature.4. For this purpose.3 13.3. ISSUE R0 215 TCE FORM NO. TCE.5 13. 25% margin for ageing as per IEEE guidelines. 329 R5 . NO. Standing load due to all units running.2 13. Battery Chargers Float charger will be rated to cater the following: (a) (b) (c) Trickle charging current of the battery 10 hours load indicated above. SECTION: D3. electrolyte temperature shall be considered as 10 deg. ELECTRICAL SYSTEMS .1 (d) (e) 13. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.13 SHEET 4 OF 14 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM SPEC. NO. TCE.5960A-H-500-001 13.6 13.6.1 Specific Requirements 220V Batteries (a) The battery offered shall be High Discharge plante Lead Acid batteries confirming to IS: 1652 suitable for indoor application. The battery shall be of closed top or sealed in type. Open type cells are not acceptable. The battery shall be complete with accessories and devices, including but not limited to the following: (i) (ii) (iii) (iv) (d) Battery racks Porcelain insulators, rubber pads etc. Set of lead coated intercell, inter-tier and inter bank connectors as required for the complete installation. Electrolyte (KOH) for first filling +10% extra. (b) (c) One set of variable resistor load suitable for carrying out discharge tests at 5 hour discharge rate & suitable shunt for measuring current on all batteries shall be supplied. Alternatively, electronic controls for carrying out discharge test of the batteries at selectable rate can also be provided. The battery should be periodically charged/discharged to avoid loss of performance due to memory effect. (e) 13.6.2 220V Battery charger (a) The float cum boost charger offered shall be static type composed of silicon controlled rectifiers and diodes (complete with resistor/capacitor network for surge protection) connected in three phase wave bridge circuit. It shall be provided with an adequately rated isolation transformer and filters on input to minimise harmonics on the output to keep ripple factor within acceptable limits. Charger shall have provision for manual control if the automode fails. Load limiting features shall be provided. The same shall be designed for adequate short time over load to take care of the starting of the largest DC motor/testing of lamps, etc. with other DC loads connected to bus. The rectifier shall utilise power semiconductors and heat sinks rated to carry 200% of the load ISSUE R0 216 (b) TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.13 SHEET 5 OF 14 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM SPEC. NO. TCE.5960A-H-500-001 current continuously. The heat sink temperature shall not be permitted to exceed 85°C irrespective of the panel temperature. The chargers shall be suitable for operation from remote. (c) The chargers shall be provided with automatic voltage regulation in float mode and automatic constant current regulation in boost mode. The charger shall essentially comprise the following items but not limited to: (i) One (1) moving coil DC voltmeter of size 96mm x 96 mm of suitable range with selector switch for float, boost, and load voltage. One (1) moving coil DC ammeter, with shunts, size 96 mm x 96 mm to read output current of float-cum-Boost charger. One (1) moving coil centre zero ammeter, with shunt, size 96 x 96 mm to read discharge/charge current of the battery, with suitable range. One (1) cubicle space heater suitable for 230V AC, 50Hz, single phase supply. One (1) 230V AC lamp for cubicle internal lighting. Two (2) - On/Off switches with fuses for space heater and internal lighting. One LED lamp on DC load side to indicate DC "On" condition. One (1) set of LED lamps on AC main input to indicate mains AC "ON" condition. All indicating lamps shall be self-coloured clustered LED type with less than 0.5 W burden. Indication lamps for battery on boost charge & load limiter operated. (d) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) (e) Fault indicating lamps shall be provided on the charger cubicle and initiating contacts shall be provided for remote alarm for each of the following faults: ISSUE R0 217 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.13 SHEET 6 OF 14 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM SPEC. NO. TCE.5960A-H-500-001 (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (f) Mains AC failure Float charger AC input fuse blown Charger DC output fuse blown Charger U/V and current limit protection Charger over voltage protection Charger overcurrent protection Charger filter condenser fuse blown Charger rectifier fuse blown Type of cooling for the charger panel shall be such that no external fans are required to dissipate the heat developed within the panel. The adequate number of dropper diodes shall be used in order to meet the load voltage & maintaining the battery float charging voltage as per the battery manufacturer recommendations. Suitable scheme shall also be made that during the power failure, the dropper diodes shall be bypassed, thereby giving the required voltage to the connected load. One complete set of all accessories and devices required for maintenance and testing of batteries shall be supplied for each battery bank. Each set include at least the following: (i) (ii) Hydrometer Set of hydrometer syringes suitable for the vent holes in different cells Thermometer for measuring electrolyte temperature Specific gravity correction chart Wall mounting type holder for hydrometer thermometer Cell testing voltmeter (3-0-3 V). Rubber apron Pair of rubber hand gloves 2 nos. 2 nos. (g) (h) (iii) - 5 nos. (iv) (v) - 2 nos. 2 nos. (vi) (vii) (viii) - 2 nos. 2 nos. 2 nos. ISSUE R0 218 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.13 SHEET 7 OF 14 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM SPEC. NO. TCE.5960A-H-500-001 (ix) (x) (xi) (xii) (xiii) Set of insulated spanners No smoking notice Goggles (industrial) Instruction card Minimum and maximum temperature indicator for each battery room Acid / Alkali mixing jar - 2 nos. 2 nos. 2 nos. 10 nos. 1 no. (xiv) (xv) (xvi) - 2 nos. 20 Nos. 2 nos Battery maintenance record book Safety gears - 13.7 13.7.1 D.C. Switchboards For feeding the 220V DC loads 220V DC Switchboard as per clause 13.1.1 to 13.1.3 shall be provided. The switchboards shall be provided with suitable quantity and type of outgoing feeders for the auxiliaries, control supplies to various panels/systems. For each load and auxiliary, one separate feeder shall be provided. In addition, the following feeders shall be provided in switchboard. (a) Spare feeders - 20% of each type and rating with a minimum of two nos. feeders. This is the minimum quantity at the time of handing over the plant. Switchboard 230V 1 phase space heating module - 1 No. 13.7.2 (b) 13.7.3 Current ratings The short circuit current rating of the switchboard shall be arrived considering the contribution from charger & battery with 5% margin, with a minimum of 25 kA. The continuous current rating of the bus bars, incomers, ties for 220V DC switchboards shall be the maximum D.C. load (excluding the momentary ISSUE R0 219 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.13 SHEET 8 OF 14 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM SPEC. NO. TCE.5960A-H-500-001 load) on the bus plus 20% margin rounded off to the next higher standard rating. 13.7.4 Specific requirements (a) DC switchboards shall comply with all the requirements of this specification and technical requirements table. Positive and negative bus bars in the DC switchgear shall be completely segregated from each other by sheet steel partitions. The DCDB incomers and Buscoupler shall be suitable for operation from remote. All the DCDB compartments shall have bottom cable entry through individual cable gland for each power, control and instrumentation cables. Metallic enclosure shall be provided between cable tray & cable entry. (b) (c) (d) (e) Module details (i) Incomer The incomer modules shall be MCCB controlled. Each incomer shall be provided with • • • • • • ammeter & voltmeter earth fault relay with potential free contact for remote annunciation. under voltage relay with timer indicating lamps for ON, OFF, earth fault, under voltage conditions (22.5 mm size LED) one no. current & voltage transducer for remote indication necessary hardware & circuitry for fault alarm and for lamp test & reset. (ii) Outgoing feeders & tie feeders/Bus coupler • These feeders shall have DC MCB/MCCB,"ON" & "Fault" indicating lamps, supply supervision relays, lamp test, accept & reset push button through common alarm module. ISSUE R0 220 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.13 SHEET 9 OF 14 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM SPEC. NO. TCE.5960A-H-500-001 • The feeders rated 200 Amps & above shall be provided with a shunt & ammeter. (iii) Motor modules • For motors, starters shall be preferably housed within the DC switchgear module. However the resistors can be separately located in boxes/panels within the DC switchgear room. The starting current of the motor shall be limited to 200% of full load current. The motor modules shall be provided with • • • • • • • • • Switch (rotary type suitable for DC application), fuses, air break contactors Thermal overload relays Starting resistors with associated timers ON, OFF, Fault indicating lamps Necessary auxiliary contactors for fault alarm circuit 230V space heating circuit ON, OFF PBs for testing purposes One shunt & ammeter Appropriate circuitry for receiving the ON, OFF commands from remote panels/systems, interlocks, 'OFF' command from local push buttons, etc. MCB for space heating circuit • (iv) Space heating module • 230V 1 ph, space heating module shall be provided with incoming side switch fuse, suitably rated 400/230V cast resin type transformer (expected heating loads of the switchgear and the connected motors + 30% margin) secondary fuse, and supply indicating lamp and connection to space heating buses. The 400V power supply for these modules shall be obtained from the 400V main switchboard. 13.8 Tests for Batteries ISSUE R0 221 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.13 SHEET 10 OF 14 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM SPEC. NO. TCE.5960A-H-500-001 All tests shall be conducted as per the relevant standards. Tests shall comprise: 13.8.1 Type Tests: Performed at Manufacturer's works or type test report on identical rating and type of cell issued by an authorised test house shall be furnished Acceptance Tests: Acceptance tests as per relevant standards shall be performed at vendor’s works. Also acceptance tests shall be performed at site after installation and commissioning of the battery including capacity test and test for voltage during discharge. A loading resistor bank which can be automatically controlled using time and current signals along with the charger shall be supplied to facilitate discharging of voltages as a part of routine maintenance tests. Tests for battery chargers The following routine tests shall be conducted at works 13.9.1 13.9.2 13.9.3 13.9.4 13.9.5 Visual checks for dimensions and general arrangement. Wiring checks Functional checks Voltage regulation for rated input supply for loads from 0-100%. Load test to show the charger can deliver the rated duty without the current limiter device operating. Ripple measurement by oscilloscope at different loads. Demonstration of guaranteed efficiency and power factor. Insulation test (with 500V megger) High voltage test, excluding electronic controller, at 2kV AC for one minute. Heat run test shall be conducted at full load for 24 hours at the vendor works on charger. Tests for DC distribution board ISSUE R0 222 13.8.2 13.8.3 13.9 13.9.6 13.9.7 13.9.8 13.9.9 13.9.10 13.10 TCE FORM NO. 329 R5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.13 SHEET 11 OF 14 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM SPEC. NO. TCE.5960A-H-500-001 13.10.1 All routine tests as per applicable standards shall be conducted on the board. Type test reports on identical switchgear issued by an authorised test house shall be furnished. 13.10.2 ISSUE R0 223 TCE FORM NO. 329 R5 4 3.1 2.2 2.0 3. 5960A CLIENT : APPDCL PROJECT: 700MW CCPP AT NEDUNOOR.0 1.5960A-H-500-001 SL.85V per cell By Bidder + 10% of nominal voltage 3. 1.f. .8 3. BY DC BOARD Reference ambient air temperature R0 JUNE’ 10 PPD. NO.3 DC current adjustment for boost charging 30% to 100% of maximum boost charging current + 2% 3.5 0. 330 R3 224 50 0C RKD HA JOB NO.13 SECTION: SHEET D3.1 REV.2 (i) +1% of set DC voltage for + 10% voltage and +5% frequency variation in power supply + 5% during transients (ii) 3.2 1. 4. NO.13 12 OF 14 SPEC. at rated continuous load Permissible ripple content at rated continuous load Degree of protection/paint shade 3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A3.4 2.0 4.0 2. NO. KARIMNAGAR DIST.1 DC SYSTEM DESCRIPTION UNITS VALUES / REQUIREMENTS Type of charger DC system voltage (Nominal) DC system earthing Ambient design temperature BATTERY DETAILS Maximum time for boost charging of battery Battery type Minimum end cell voltage Nickel / Lead Acid Battery capacity BATTERY CHARGER DETAILS DC voltage setting adjustment of AVR for float charging Voltage stabilisation for constant voltage regulator Hrs 0 float-cum-boost 220 V /48V /24V Unearthed C 50 8 High Discharge Plante Lead Acid 1.1 1.7 IP 42/ External : Opaline Green Internal : Semi Glossy White.3 2. TCE.6 1% maximum 3.4 Current stabilisation for constant current regulator for boost charger Minimum permissible p. BY CKD.BY DATE TCE FORM NO.3 1. DATE REV. 14 5. compartmentalised External : Opaline Green Internal : Semi Glossy White 5. DATE REV.9 5.13 13 OF 14 SPEC. RKD HA JOB NO.8 IS 4007 IS 8623 5.1 APPLICABLE STANDARDS Basic climatic and mechanical durability tests for components for electronic and electrical equipment Environmental tests for electronic and electrical equipment Metal clad base material for printed circuits for use in electronic and telecommunication equipment Transformers and inductors (power.17 REV.16 5.5960A-H-500-001 SL.13 5.2 4.3 IS 5921 5.BY DATE TCE FORM NO. NO.3 4.15 5. audio.5 5.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A3. 330 R3 225 IS 9000 5.4 DESCRIPTION Degree of protection for enclosure Type of construction Paint shade UNITS IP 54 VALUES / REQUIREMENTS Fully draw-out. NO.11 5. KARIMNAGAR DIST. BY JUNE’ 10 CKD.13 SECTION: SHEET D3. NO.0 5.4 IS 6297 5.12 5. TCE.7 5.10 5. pulse and switching) for electronic equipment Printed wiring boards Environmental requirements for semiconductor devices and integrated circuits Terminals for electronic equipment Factory build assemblies of switchgear and control gear for voltages upto and including 1100V AC and 1200V DC Air break switches Miniature circuit breakers HRC cartridge fuses Contactors Control switches / push buttons Indicating instruments Degree of protection Code of practice for phosphating iron and steel Semi-conductor converters R0 PPD. 5960A .6 IS 7405 IS 6553 5. BY IS 4064 IS 8828 IS 9224 IS 2959 IS 6875 IS 1248 IS 2147 IS 6005 IEC 60146-1-1/2/3 CLIENT : APPDCL PROJECT: 700MW CCPP AT NEDUNOOR.2 IS 9000 5. 4. TCE. TCE FORM NO. NO. BY R0 JUNE’ 10 PPD.5960A-H-500-001 SL.20 5.BY DATE RKD HA JOB NO.13 14 OF 14 SPEC. NO.13 SECTION: SHEET D3.23 DESCRIPTION Semi-conductor rectifier equipment safety code Stationary cells & batteries High Discharge Plante Lead acid Water for storage battery Pasted +ve plates General requirements UNITS VALUES / REQUIREMENTS IS : 6619 IS : 1652 IS : 1069 IS : 6071 IS : 8320 REV.19 5. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A3.22 5.21 5. DATE REV. 5. NO. 5960A CLIENT : APPDCL PROJECT: 700MW CCPP AT NEDUNOOR.18 5. BY CKD. 330 R3 226 . ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE. KARIMNAGAR DIST.3.14 and specific requirements indicated below: 14. apart from providing no-break power at constant frequency during normal ISSUE R0 227 TCE FORM NO.14 Also. SECTION: SHEET D. NO. The output shall confirm to stringent requirements in respect of voltage & frequency regulation. One set of parallel redundant UPS system shall be provided for the plant which will cater power to locations as indicated below: • • • UPS system for GTG UPS system for STG. the UPS system and its accessories shall comply with the requirements indicated in Data Sheet – A 3. Large Video Screens. inverter and static switch. except DCS & SCADA panel loads. 329 R5 . The UPS and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet – A 3. 14. The components of UPS shall isolate power line voltage transients.0 UNINTERRUPTIBLE POWER SUPPLY SYSTEM The Uninterruptible power supply system (UPS System) shall cater to the complete plant instrumentation and control system loads such as HMI.14 1 OF 13 1X 700 MW CCPP AT NEDUNOOR. DCS & SCADA panel lighting & other critical loads. HRSG & common station loads UPS system catering to the requirements of 400kV SCADA system. The UPS shall be sized considering full load plus spare loops plus 25% margin. Master clock.2 System Requirements UPS shall employ IGBTs as power components. harmonic content & transient recovery. AC distribution board.5960A-H-500-001 14. Microprocessor based controls shall be employed for rectifier.1 The UPS shall be of “parallel redundant with static bypass to regulated supply” type with 2 x 100% chargers & inverters and 2X100% battery bank. other necessary protection devices & accessories. The UPS system shall have static switches for added protection and transfer of loads with no break during under voltage condition to the healthy inverter or to standby regulated supply. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. bypass line transformer and voltage stabiliser. frequency variations and high/low voltage conditions from the critical load and act as a line filter and voltage regulator. The system shall have a combination of two inverters (UPS modules) operating in synchronism.3. TCE.14 2 OF 13 1X 700 MW CCPP AT NEDUNOOR. It shall be ensured by the contactor that the bandwidth selected for the UPS to remain locked with the SCVS frequency shall be maximum & the downstream instrumentation system should be capable of accepting the above frequency variations. KARIMNAGAR DIST.5960A-EL-SK-2005.3. Parallel redundant UPS with static bypass to regulated supply shall be as per sketch No. NO.3 TCE FORM NO. by using synchronising signal from the master inverter. the healthy inverter shall supply the full 100% load by the operation of the static switch. TCE. SECTION: SHEET D. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. In addition to the two inverter systems.3.3.5960A-EL-SK-2005. TCE. a backup from a regulated AC supply through transformer and voltage stabilizer derived from Station service switchgear shall be provided. ISSUE R0 228 14. the selector switch shall be suitably changed and the branch circuit supplying 100% load shall be synchronised with the frequency of the standby source. When any one of the UPS is under maintenance. the inverter shall use the frequency of the standby source as the synchronising signal.3 14. The output of the UPS shall feed all the essential loads through the ACDB. the respective UPS loads shall be supplied by its own inverter. When the selector switch is in bypass position the standby source shall cater 100% load. The operating inverter shall continuously monitor the frequency of standby source and upon restoration of proper frequency of the standby source. If one inverter fails.5960A-H-500-001 power outages. The UPS shall be sized considering full load plus spare loops plus 20% margin. isolating both inverters from the critical load bus.2 If the frequency of the standby source is beyond the preset limit. UPS Battery shall be High Discharge Lead Acid Plante type with 4 hour duration. each having isolating facility from the critical bus by a static switch. sharing 50% load each.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 . 14. 14. In the `Normal' position.1 Static UPS system provided shall be of the type described below: UPS shall derive power from station service switchgear and Normal/ Emergency switchgears as shown in the sketch for UPS scheme Drawing No. The system shall have a selector switch. with output of both inverters being automatically synchronized with each other. the inverter frequency control shall get disconnected from the standby synchronising signal. 7 Loss of inverter square wave/inverter failure Loss of inverter AC output Retransfer to the inverter circuit shall be manual. 14.14 3 OF 13 1X 700 MW CCPP AT NEDUNOOR. Automatic initiation of the transfer from a faulty branch circuit to the standby regulated source shall be accomplished during following conditions: (a) (b) (c) 14. SECTION: SHEET D. TCE. 14. The AH capacity of battery shall be chosen by BIDDER.3. The rectifier shall be capable of supplying the inverter full load. enabling loads to be connected to the standby regulated AC supply.3. The rectifier shall have features for temperature compensation charging of the batteries. based on the battery ISSUE R0 229 TCE FORM NO.3. Battery The batteries shall be 2 X100% rated with backup time of 10 hours.3. The rectifier shall be provided with soft start feature.6 Static Transfer Switch Inverter output shall be connected to the AC bus through a static switch and fast acting fuses. The BIDDER shall choose the required voltage of the battery. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC.5 Inverter PWM (Pulse Width Modulation) type. NO. 14. in addition to charging the fully discharged batteries in 8 hours or as recommended by battery manufacturer and then maintain the battery on trickle charge mode. adequately designed to meet the requirements as specified.4 Rectifier The rectifier shall essentially be a three phase 6 pulse design with input isolation transformer. The static switch comprises an interrupter and transfer switch. The type of batteries shall be High Discharge Lead acid Plante.5960A-EL-SK-2005.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 Typical scheme/connections to be adopted for the UPS is shown in the sketch TCE. KARIMNAGAR DIST. For Redundant UPS design the two rectifiers input isolation transformers shall have vector grouping and connections to ensure 12 pulse operation seen from the source side.3. 329 R5 . Each of the UPS AC Distribution Boards shall be provided with two bus sections and a bus coupler as shown in dwg. Necessary potential free contacts shall be provided from UPS to plant DCS/SCADA as appropriate. 14. 14. NO. TCE.3.3. TCE. Tests for components shall be as per relevant standards.10 14. 20% spare feeders shall be provided in each of the UPS distribution boards The UPS system shall be provided with necessary meters (accuracy class 1. The AC switchgear shall comply with the requirements indicated in section D3. 14.3. The guaranteed DC/AC efficiency of the UPS system offered shall be mentioned. Grouped alarms and analog parameters (4-20 mA) of each branch of parallel redundant UPS shall be made available in DCS/SCADA as appropriate.11 (b) ISSUE R0 230 TCE FORM NO. BIDDER shall furnish calculation for sizing of the battery based on the requirements of entire plant UPS loads.3. KARIMNAGAR DIST.3. etc.11 .3. 14. Protection The UPS system components and assemblies shall be provided with the necessary protection associated with all components.14 4 OF 13 1X 700 MW CCPP AT NEDUNOOR. no.5960A-H-500-001 backup time / duty cycle. SECTION: SHEET D.0 or better) mimic diagram. local indication/alarm conditions and protection as indicated below. spike arrester. Necessary logics shall be derived in the controlling microprocessor. Tests on the following equipment shall as per the relevant standards listed under the respective equipment specification.“400V Switchboard / MCC”. 329 R5 . and minimum ambient temperature as specified in Project Information. based on the UPS parameters including temperature protection.12 Tests (a) Type and routine tests certificates for all components made use in the UPS system shall be furnished.8 Regulated Stand-by AC Supply Regulated standby AC supply shall be derived from standby supply through a step-down transformer of appropriate rating and a servo controlled voltage stabiliser with isolation transformer and power conditioning equipment viz. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC.9 UPS system shall be connected to the AC switchgear.5960A-EL-SK-005. UPS load consumers shall be fed with redundant power supply feeders from each bus section..ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. measurement. Test certificates of type tests shall be submitted for review. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. 329 R5 . Contractor’s Details 2. Description Type Unit Specification Requirement Parallel redundant UPS with static bypass to regulated supply. The complete assembled UPS system shall be operated at rated load under relevant ambient conditions for not less than 96 hours continuously prior to release for shipment. annunciation.4.3. D2. voltage regulation. overload and under voltage conditions.3. LVS . Short circuit conditions etc.13 Minimum electrical system requirements in respect of control. synchronising are indicated in I&C system section No. No. Uninterruptible Power supply for loads of HMI. 1. (d) (e) (f) 14.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3 of IEC-60146-4 shall be conducted on the UPS system in addition to the system tests. Sl. Routine tests covered under clause 7. Endurance test on static switches shall be performed for not less than 10 transfer/ retransfer cycles at full load. TCE. monitoring. One parallel redundant UPS. NO. current limiting feature and harmonic content tests in addition to the tests to prove the functional requirements such as transfer of static switch for conditions of loss of square wave. System tests shall include frequency regulation. KARIMNAGAR DIST. 4. SECTION: SHEET D. Application 3.14 5 OF 13 1X 700 MW CCPP AT NEDUNOOR. Number required Ambient temperature 0 C 50 5 Output Voltage 230V. Master clock etc. 1–phase ISSUE R0 231 TCE FORM NO.5960A-H-500-001 (c) System tests shall be performed on the completely assembled UPS system at vendor’s works. 3. Semi glossy white (Internal). Input Supply Voltage 10.7 Voltage regulation ISSUE R0 232 TCE FORM NO. 9.0 12. Installation / paint shade (External). 50 Hz.C.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 12. 8. Single phase Combined Voltage regulation ± 2% from 0 to 100% load at 0.5960A-H-500-001 Sl. 50Hz supply from N/E switchgear and for bypass from station service switchgear Indoor. SECTION: SHEET D. 3 wire.5 12. 6 Description Output rating at 0. KARIMNAGAR DIST.8 power factor within 50 milli seconds 12. No. 11.8 p. Material of Enclosure 2. NO. shade Opaline Green 7.3 Inverters Type Number required Suitable for parallel operation Service Output rating of each Output Voltage Static Two per unit Yes 12.f lagging load.4 12.14 6 OF 13 1X 700 MW CCPP AT NEDUNOOR.6 Indoor * 230V A.2 12. TCE.. natural ventilated. Degree of protection Cable entry Unit kVA Specification Requirement Contractor’s Details * IP 32 Will be decided during detail engineering stage 400V. 329 R5 . ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. 3 Phase.0mm thick Cold rolled sheet steel 12. 12 Duty Overload capacity 12. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. KARIMNAGAR DIST.1 Hz for 0 to 100% load variation (continuous or step load change) and full range of input variation ± 8% Contractor’s Details 12. 12.to normal voltage ms 50 12. NO.16 Cooling 12.f.8 p. TCE. SECTION: SHEET D.8 Description Frequency regulation Unit Specification Requirement ± 0.9 a) Transient voltage regulation on application or removal of 100% load b) Time to recover from transient.11 12.17 Synchronization with alternate source required ISSUE R0 233 TCE FORM NO.14 Short circuit current withstandability 12.13 Short time rating 1 second for short circuit at inverter output terminals Shall be capable of withstanding short circuit current for the largest fuse to clear the fault in less than ¼ cycle Not less than 80% at rated load Natural air cooled / forced cooled Yes 12. No.15 Efficiency 12.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3. 329 R5 .14 7 OF 13 1X 700 MW CCPP AT NEDUNOOR. 150% for 10 sec.10 Total harmonic content 5% RMS maximum with not more than 3% distortion in any single harmonic Continuous 125% for 15 minutes at 0. 12.5960A-H-500-001 Sl. NO. Protection of all semiconductor devices against short circuit and transients.4 Type Voltage Short time rating 13. 13.3.3 13.f Make before break 230V. 13. TCE.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.14 8 OF 13 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST.5960A-H-500-001 Sl.0 Description Static Transfer Switch Capacity Continuous Unit Specification Requirement Contractor’s Details 13.1 Make and carry full load current of inverter at 0. No. Automatic retransfer shall occur after approximately 2 sec time delay during which normal source voltage must remain at 230V ± 2% I.2 13. SECTION: SHEET D. Indicating lamp for static switch in normal position.8 Indication protection / Annunciation II. ISSUE R0 234 TCE FORM NO.6 13.8 p. Indicating lamp for static switch connected to alternate source.5 13.7 Frequency Transfer time Retransfer 13. single phase Short circuit rating of the inverter for 1 second and 150% of full load current for 2 min. 329 R5 . Hz 50 Less than 5 milli sec. III. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. SECTION: SHEET D. Contractor’s Details 14.2 14. 329 R5 . a) Static switch connected to alternate source b) Alternate source voltage deviation greater than ± 2% from nominal. TCE. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 15.7 Natural Air cooled Class-H ISSUE R0 235 TCE FORM NO.1 Bypass Switch Capacity Continuous Make and carry full load current of inverters at 0.f Make before break Short time rating of the inverter for 1 second and 150% of full load current for 2 minutes. Description Unit Specification Requirement iv) Annunciations for the following conditions.3 Type Short time rating 15.3 15.14 9 OF 13 1X 700 MW CCPP AT NEDUNOOR.5960A-H-500-001 Sl. No.1 15.2 15.5 Dry type double wound * 15. 14.0 14.4 15.3. KARIMNAGAR DIST. NO.0 Standby AC supply with isolation transformer and servo controlled voltage stabilizer Number Rating Single or poly phase unit Type Voltage ratio at no load Type of cooling Winding insulation class One Same as UPS rating * 15.8 p. 0 7.1 Data to be furnished with the Bid Technical particulars as per Data Sheet ISSUE R0 236 TCE FORM NO. 7.14 10 OF 1X 700 MW CCPP AT NEDUNOOR. SECTION: SHEET D. 15.8 p.5960A-H-500-001 Sl.12 16.f Contractor’s Details 15. No. TCE.1 ** 16.10 System fault level on 400 V side Output voltage setting range Synchronising between inverter and standby supply ACDB Fully drawout/ Semidraw out/ fixed Dimensions of the board Degree of protection kA 50 ± 5% of nominal voltage Required Within ± 2.9 Description Location Voltage regulation Unit Specification Requirement Indoor ± 2% from 0 to 100% load at 0.2 ** IP52 16.11 15.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.0 16.8 15. KARIMNAGAR DIST. 329 R5 . ‘**’ Contractor shall furnish the data after placement of order. NO.3 Note: ‘*’ indicated above shall be filled by the Contractor. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM 13 SPEC.5 Hz 15.3. NO.C 50 10. load PF & DC voltage range Range of adjustment of AC output AC harmonic content By Bidder 8. 3-PH. 1 PH 3.A3.3 REV. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR. NO. BY Same as UPS rating Dry cast resin type. shade Opaline Green (External).ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET .8 Lagging Application By Bidder For supplying the loads of HMI.5960A-H-500-001 SL. TCE. Two winding RKD HA JOB NO.0 Type Static Parallel redundant UPS with static bypass to regulated supply as per sketch TCE.0 Power Rating at Load PF 0. TCE FORM NO. Ambient Standby AC supply with isolation transformer and servo controlled voltage stabilizer Rating Type Ratio & frequency R0 JUNE’ 10 PPD.2 11. Semi glossy white (Internal). NO. Ph.14 SHEET 11 OF 13 SPEC. BY CKD. natural ventilated.1 11. 400 kV system SCADA & other critical loads Indoor.0 11. V. DATE REV.0 9. 400V AC (From Normal cum Emergency board and Station service switchgear) V.5960A-EL-SK-2005 2.0 Input supply 6. 3% for any single harmonic Deg.0 Installation /paint shade 5.0 ±5% at rated load voltage 5% total. Ph 230V.0 4.0 Design Ref.BY DATE 237 11.0 Output Voltage AC voltage accuracy(steady state) over entire load. DESCRIPTION UNITS REQUIREMENTS 1.0 7. Common station. 330 R3 .13 SECTION: D3. KARIMNAGAR DIST. 0 16.A3.0 14. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.589 17. BY RKD HA JOB NO.13 SECTION: D3. DATE REV.5960A-H-500-001 SL.6297 REV.0 15. BY CKD.BY DATE 238 By Bidder 230 V.0 13.2 IS . TCE FORM NO.4 IS .2106 17. 330 R3 . DESCRIPTION UNITS REQUIREMENTS (a) Primary (b) Secondary 11. NO. 1 PH.5 Hz (47. audio pulse & switching) for electronic equipment R0 JUNE’ 10 PPD. KARIMNAGAR DIST.5Hz) % % % 12.3 IS . NO.0 17. load to inverter Required Required ±2. TCE.4 Automatic voltage regulator • Percentage voltage regulation • Transient response • Output voltage setting range Bypass transfer selection Manual bypass PBs Manual bypass switch Synchronising between inverter and standby supply Static switch Type Maximum transfer time Codes and Standards Basic Climatic & Mechanical durability tests for components for electronic & electrical equipment Environmental tests for electronic and electrical equipment Metal clad base material for printed circuits for use in electronic and telecommunication equipment Transformer and inductors (power.1 16. NO.0 16.5291 17. 50 Hz Required (servo-controlled) ±2 ±10 for bypass ±5 of nominal voltage Auto/manual switch Load to bypass.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET .2 17.1 Static Maximum of 1/4 cycle IS .5Hz to 52.14 SHEET 12 OF 13 SPEC. 6 Printed wiring boards Environmental requirements for semi-conductor devices and integrated circuits Terminals for electronic equipment Factory built assemblies of switchgear and control gear for voltages upto and including 1000 V AC and 1200 V DC Air break switches HRC catridge fuses Contactors Control switches/ push buttons Indicating Instruments Degree of protection Climatic proofing in electrical equipment Semiconductor converters Semiconductor rectifier equipment code Thyristor converters Emergency Standby power systems R0 JUNE’ 10 PPD.A3.10 17.11 17. BY CKD.8 IS .13 17.14 SHEET 13 OF 13 SPEC.12 17.7405 IS .5960A-H-500-001 SL.5 17. TCE.18 17. NO.60146 IS .2859 IS .16 17. DATE REV.15 IS . NO.13 SECTION: D3.3202 17.4064 IS . KARIMNAGAR DIST. TCE FORM NO.6553 17.6619 17.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET .6875 IS .17 IEC . DESCRIPTION UNITS REQUIREMENTS 17.19 IS – 5082 IEEE – 446 REV. 330 R3 .BY DATE 239 IS .7 17. BY RKD HA JOB NO.4007 IS .2208 IS .8263 17.2147 IS .1248 IS . 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.14 17. NO.9 17. 15. gas cured. inner sheathed with extruded PVC compound type ST2. extruded PVC compound type A insulated.0 15. triple extruded. screened by triple extruded semi conducting compound. stranded aluminium conductor. XLPE cables with following specification shall be provided. SECTION: D3.1 CABLING SYSTEM Cable Types For 6. ELECTRICAL SYSTEMS .6 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Part-1. and for digital signals from the field devices/junction boxes/switchgears to terminal cabinets of the control system etc.5. single or multi core. It shall not stick to insulation and inner sheath. tree retardant.6 kV services. PVC control cables with the following specifications shall be provided: 1100 volt grade. multi core. XLPE insulated. cross linked polyethylene insulated. cores identified by numerals. KARIMNAGAR DIST. outdoor lighting. stranded annealed high conductivity copper conductor (class 2 as per IS 8130). 6600 volts unearthed grade single or multi core.CABLING SYSTEM SPEC.5960A-H-500-001 15. The cable cores shall be laid up with fillers between the cores wherever necessary.1 15. with signal voltages more than 60 volts.. solenoids. inner sheathed with extruded PVC compound type ST2.1. 329 R5 . stranded aluminium conductor. NO. gas cooled. It shall not stick to insulation and inner sheath. TCE. power supplies to lighting panels etc. space heating. lighting in the hazardous areas. cores screened with triple extruded semi conducting compound in combination with copper tape. CT / PT connections and interlocks. XLPE insulation shall be suitable for continuous conductor temperature of 900C and short circuit conductor temperature of 2500C. ISSUE R0 240 TCE FORM NO. XLPE power cables with the following specifications shall be provided: 1100 volt grade.2 For 400 V power supply services. armoured with galvanised wire or strips for multicore cables and aluminium wire armoured for single core cables and overall sheathed with extruded FRLS PVC type ST2 cable complying with IS : 7098 part-2.1.. cores laid up.1. The cable cores shall be laid up with fillers between the cores wherever necessary. inner sheathed with extruded PVC compound type ST1. outer sheathed with extruded FRLS PVC compound type ST2 complying with IS: 7098. protection. armoured with galvanised single steel wire/strip and outer sheathed with extruded FRLS PVC compound type ST1 cable complying with IS: 1554.15 SHEET 1 OF 19 1X 700 MW CCPP AT NEDUNOOR. metering. cores laid up. armoured with galvanised steel wire or strip for multicore cables and aluminium wire or strip armoured for single core cables. laid up. 15.3 For control. 2. individual pair/triplet/quadruplet screened with aluminium mylar tape of 0. non metallic rip cord under wrapping. Current carrying capacity The cable shall be able to carry the full load current of the circuit continuously under the specified ambient temperature and other conditions of installation. cores wrapped by non hygroscopic material by taping or extrusion.04 mm thick or copper tape of 0.15 SHEET 2 OF 19 1X 700 MW CCPP AT NEDUNOOR. ISSUE R0 241 15. The design ambient air temperature and ground temperature for this plant shall be considered as 500C and 300C respectively. provided with 0.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 . annealed.5960A-H-500-001 15. extruded PVC compound type-A insulated.5 mm² tinned copper drain wire for each cabling element. Trailing power and control cables for cranes & hoist. SECTION: D3. suitable derating factors shall be considered due to: (a) Thermal resistivity of soil (b) Ambient ground / Air temperature (c) Derating factor for grouping of cables over the current ratings at normal conditions given in standards. TCE. jacking oil pump motors. instrumentation cables with following specification shall be provided : Single pair.1. individual pair/triplet/quadruplets twisted. multi pair or triplets or quadruplets as required. 15. colour coded. high conductivity copper conductor (class 2 as per IS 8130).04 mm thick or copper laminated plastic tape with 30% overlap. stranded tinned. cabling elements suitably grouped. DC cables from battery to charger and DCDB etc. NO. cables overall screened with tinned copper wire braids of 0.1 TCE FORM NO. KARIMNAGAR DIST. inner sheathed with extruded PVC compound type ST1.15 mm dia with minimum coverage of 85% or aluminium mylar tape of 0.CABLING SYSTEM SPEC.Part 1&2. armoured with steel strips/wires and outer sheathed with extruded FRLS PVC compound type ST1 complying with IEC 60189 . shall be of fire survival type (FRLS cables).2 15.1.04 mm thick with overlap of 30%. The HV & LV power cables shall be selected on the basis of current carrying capacity. barring gear motors. cores identified by colour and coding. For this purpose. short circuit rating and permissible voltage drop. ELECTRICAL SYSTEMS .5 Cables for important auxiliaries such as emergency lube oil pump motors.4 For low voltage digital signals to instrumentation and control system and for the analog signals. 2. All D.16 sec . for all other motors it shall be 15%. ELECTRICAL SYSTEMS .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 . power supply cables shall be single core cables. service transformer (Protected by instantaneous over current protection) (b)Tie feeders (with no IDMT relays on downstream) (c) Others . (b) 15.2. which are protected by fuse.6kV cable shall be capable of carrying the earth fault current of 6.4 Permissible voltage dip during starting (a) 400V system: The voltage dip during starting of individual 400V motors shall be limited to less than 15% of the full load voltage. Control cables 15.5960A-H-500-001 15. Further.1 sec For circuits.C.2.0. 15.5 mm2 copper.6kV system: The voltage drop during starting of HRSG cooling pump motors shall be limited to less than 20% of the full load voltage. the voltage drop in cables between PCC/MCC to the motor terminals for full load motor current shall be limited to 3%. short circuit rating capability need not be checked.2.3 Permissible voltage dip normal running 400V System: Voltage drop in cables between the transformer and the switchgear (PCC) or between PCC and MCC for full load current shall be limited to 2%.2. However. TCE. these voltage drops may be adjusted in specific cases so that total voltage drop is within 5%. 6. 15.0.2 Short circuit rating The cables for circuit breaker controlled circuits shall withstand the fault currents for the following fault clearing times.6 15. NO.6kV system for 2 sec. The screen of the 6.0 mm2 aluminium or 2. KARIMNAGAR DIST.15 SHEET 3 OF 19 1X 700 MW CCPP AT NEDUNOOR.5 sec .3 ISSUE R0 242 TCE FORM NO.5 Minimum conductors cross-section for the power cables shall be 4.CABLING SYSTEM SPEC. (a) Motor. SECTION: D3. KARIMNAGAR DIST.5 15.To be embossed Sequential marking of length of the cable in meters at every one meter . SECTION: D3. in line and marking shall be legible and indelible.5 mm2 Copper Conductor is not adequate.5. NO. The embossing / printing shall be progressive.1 Current transformer leads shall be checked for lead burden.CABLING SYSTEM SPEC. 329 R5 . Cables with more than 5 cores shall have printed numerals on each core.To be embossed Word 'FRLS' at every 5 meter . following marking shall also be provided over outer sheath: (a) (b) (c) Cable size and voltage grade . ISSUE R0 243 15. Instrumentation Cables The cross sectional area shall be 0. automatic.1 Core Identification Colour coding shall be acceptable for all cables upto 5 cores.4 TCE FORM NO.4. Specific Requirements of Cables The following aspects are applicable for all types of cables: 15.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.15 SHEET 4 OF 19 1X 700 MW CCPP AT NEDUNOOR. The instrumentation cables carrying digital signals shall have overall screening along with drain wire and analog signal carrying cables shall have each pair screening and overall screening along with each pair drain wire and overall drain wire. VA capacity and knee point voltage. In addition to manufacturer's identification on cables as per IS.5. 4 mm2 cross-section cables shall be used.4.2 15. 15. TCE.5.4 15.1 15. The name of the project shall be provided at regular intervals of the outer sheath.5. ELECTRICAL SYSTEMS .3.5960A-H-500-001 15.5mm2 based on the requirement of I&C system employed.To be embossed / printed. In case 2.3 15.2 Core numbers with a minimum letter size of 3 mm shall be printed serially on each core of the control cable at intervals of not more than 200 mm. Core numbers with a minimum letter size of 2 mm shall be printed serially on each core of the Instrumentation cable at intervals of not more than 200 mm and each core shall be colour coded as per IEC-60189 Part-2 FRLS PVC compound for outer sheaths of all the cables shall meet the following performance requirements and cables shall pass these tests. item number and type.5. The maximum total acid gas generation as determined by titration shall be less than 20% by weight. In addition it shall also pass flammability test as per class F3 of Swedish Standard S5-424-1475. Wooden drums shall comply with IS: 10418. SECTION: D3.5 The finished cables shall pass the flammability test as per IEC-60332-1 and IEC-60383. fish eye. (a) The critical oxygen index value shall be minimum 29 at room temperature and the temperature index value shall be minimum 250°C at oxygen index of 21 when tested as per ASTM-D-2863-77.6 15.8 15. Owner's name.15 SHEET 5 OF 19 1X 700 MW CCPP AT NEDUNOOR. Cables shall be supplied in non returnable wooden or steel drums of heavy construction.5. Wood preservative anti-termite treatment shall be applied to the entire drum. KARIMNAGAR DIST. NO.5. 15. The surface of the drum and the outer most cable layer shall be covered with water proof cover.CABLING SYSTEM SPEC. are not acceptable.7 15.9 ISSUE R0 244 TCE FORM NO.5.5. storage and erection. when tested as per IEC 60754-1. In plant repairs to the cables shall not be accepted. 329 R5 . An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The cables shall pass the hydrolytic stability and ultraviolet test as per DIN 53387.5960A-H-500-001 The bidder shall furnish the necessary type test certificates. The maximum smoke density rating expressed in percentage light absorption at any point on the curve during testing period shall not exceed 60 % when tested as per ASTM-D-2843-77. ELECTRICAL SYSTEMS . blow holes etc. TCE. The measured values of ultimate tensile strength and elongation after the test shall not be less than 60% of that measured before the test. A tag containing same information shall be attached to the leading end of the cable. address and contract number. The cross-sectional area of the metallic screen strip/tape shall be considered in design calculations. Each drum shall carry manufacturer's name. size and length of cable and net gross weight stenciled on both sides of the drum. Pimples. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation. (b) (c) (d) 15. Cable vault 15.6. Tests certificates of all type tests as per applicable standards conducted on similar cables shall be submitted for review. 329 R5 .3 15. flammability test.6.5960A-H-500-001 15.60189-1 for instrumentation cables Cable carrier system (a) Cables shall be always laid above ground to all locations including outgoing areas with cable trays supported on overhead steel structure works. KARIMNAGAR DIST. Following cable carrier system shall be adopted in various areas as indicated below.6 15. Any deviation may e subjected to Owner’s approval. Test for dielectric strength for one minute (as per IEC-60189-1) Insulation resistance test (as per IEC-60189-1) The vendor shall carry out all routine tests as per IEC. TCE.6.6. SECTION: D3. (i) Control room building . acid gas generation. temperature index values.Cable vault Switchgear room .5 : : Cable trays (ii) (iii) (iv) (v) GTG building STG building Switchyard and transformer yard : Cable trays : Cable trays / conduits : Cable trays / conduits : Cable trench ISSUE R0 245 TCE FORM NO. acceptance test on the cables as per applicable standards. Routine tests shall include but not limited to the following for instrumentation cables.CABLING SYSTEM SPEC. effects of light and water test as specified shall be conducted on specimen.4 15. smoke generation. NO. Also special tests for critical oxygen index.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 15. ELECTRICAL SYSTEMS . from different batches.6.15 SHEET 6 OF 19 1X 700 MW CCPP AT NEDUNOOR.1 Tests The Contractor shall conduct the routine tests on each drum length. Cable tranches shall be provided in switchyard and transformer yard. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Trench depth Width of Trays 600 mm 600 mm 600 mm 300 mm Working Space 750 mm 750 mm 750 mm 500 mm (c) (ii) 1500 mm (5 tiers) 1200 mm (4 tiers) 1000 mm (3 tiers) 700 mm (2 tiers) (iii) PCC flooring of buildup trenches shall be sloped for effective drainage with sump pits and sump pumps. Preferred working space between the cable support arms and the wall are as follows. KARIMNAGAR DIST. TCE.5960A-H-500-001 (vi) (vii) (viii) (ix) HRSG area HRSG platforms Road / Rail crossings Cable carrier system connecting outlying areas Off-side buildings and utilities : Cable rack : Cable trays : Hume or steel pipes : Cable Trays (x) : Cable trays (b) Cable tunnels shall have minimum head room of 1.15 SHEET 7 OF 19 1X 700 MW CCPP AT NEDUNOOR. Cable trench (i) Cable trenches shall be of different sizes depending on the number of cables laid in that route. ISSUE R0 246 TCE FORM NO.CABLING SYSTEM SPEC. SECTION: D3.8 m considering the obstruction due to light fittings. sprinkler piping. NO. etc. ELECTRICAL SYSTEMS . 329 R5 . Contractor shall design the trenches accordingly. 329 R5 . ELECTRICAL SYSTEMS . and hardware such as bolts. accessories and covers shall be hot dip galvanised.70 mm thick) MS sheets. Cable troughs shall be required for branching out few cables from main cable route.5 metre. SECTION: D3. The spacing of rungs for ladder type of trays shall be not more than 250 mm. TCE. fabricated of mild steel sheets of minimum thickness 2 mm and shall be hot dip galvanised as per relevant IS. elbows. Site fabricated cable trays shall be painted with cold galvanisation paint at site. washers. accessories and covers shall be epoxy painted. Cable tray shall be ladder type for power & control cables and perforated for instrumentation cables.. NO. accessories and covers shall be hot dip galvanised. brackets. bends. hook etc. Prefabricated cable trays. (iii) (iv) (v) (vi) (vii) ISSUE R0 247 TCE FORM NO. Troughs shall be standard width of 50 mm & 75 mm with depth of 25 mm. crosses etc. strap. reducers. In battery rooms and water treatment plant. (d) Cable trays (i) Cable trays of ladder and perforated types and the associated accessories such as coupler plates.0 mm thick) mild steel sheets. tees. KARIMNAGAR DIST. the cable trays.5960A-H-500-001 (iv) No sub zero level cable vault / trenches shall be provided below control building/ switchgears rooms in main plant.CABLING SYSTEM SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 300 mm & 600 mm and standard lengths of 2. shall be fabricated from 14 gauge (2. (ii) Cable trays.. nuts. The thickness of side coupler plates shall be minimum 3 mm. Vertical raceways shall be formed by either structural members and slotted angles or by running the prefabricated trays vertically. These shall be U-shaped.I. G. Cable trays shall have standard width of 150 mm.15 SHEET 8 OF 19 1X 700 MW CCPP AT NEDUNOOR. Cable tray covers shall be fabricated from 16 gauge (1. channel nut. Any cutting or welding of the galvanized surface shall be brushed and red lead primer. hard wares fittings and accessories shall be prefabricated factory galvanized. KARIMNAGAR DIST. bolts. drilling and other machining operation. ELECTRICAL SYSTEMS . nuts and other hardware etc. hexagon nuts. fittings. 329 R5 . The main support and cantilever arms shall be fixed at site using necessary brackets. TCE FORM NO. floor plates. The main support channel shall be of two types : (i) C1:. clamps. Cable supporting steel work for cable racks/cables shall comprise of various channel sections. insert plates or reinforcement bars will be permitted. e. clamps. oil primer & aluminium paint shall be applied All steel components. b. The support system shall be the type described hereunder. channel nut with springs. NO.5 thick rolled steel sheet ISSUE R0 248 (ix) a.e. hexagon head bolt. cantilever arms.CABLING SYSTEM SPEC. fittings and hardware shall be hot dip galvanized after completing welding. to form various arrangements required to support the cable trays.having provision of supporting cable trays on one side and (ii) C2:-having provision of supporting cable trays on both sides. stud nuts. SECTION: D3.5960A-H-500-001 (viii) Cable tray support system shall be pre-fabricated similar or equivalent to "Uninstrut make”. All cable supporting steel work. accessories.15 SHEET 9 OF 19 1X 700 MW CCPP AT NEDUNOOR. etc. However. The system shall be designed such that it allows easy assembly at site by using bolting.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. structural steel. welding of the bracket (to which the main support channel is bolted) to the overhead beams. Welding of the components shall not be allowed. main support channel and cantilever arms. various brackets. Support system for cable trays shall essentially comprise of the two components i. fixing studs. The typical arrangement of flexible support system is described briefly below: The main support channel and cantilever arms shall be fabricated out of minimum 2. d. all hard wares such as lock washers. cutting. c. TCE. hexagon head screw. support hooks. 600 mm and 750 mm in length are required. ELECTRICAL SYSTEMS . The pipes and fittings shall comply with IS. 3837. the components design modification shall be done by the Contractor without any additional cost to the Owner. 329 R5 . Galvanised steel pipes shall be used for sizes from 80mm on wards. The conduits shall be manufactured by electric resistance welding process and shall be hot dip galvanised. Cantilever arms of 300 mm. (ii) (iii) (iv) (f) Cable/Cable tray supports ISSUE R0 249 TCE FORM NO. They shall be medium duty class-B type as per IS. In case the system fails in the tests. KARIMNAGAR DIST. The bidder shall submit the detailed drawings of the system offered by him along with the bid. The size of structural steel members or thickness of sheet steel of main support channel and cantilever arms and other accessories as indicated above or in the enclosed drawings are indicative only. Flexible steel conduits shall be manufactured with electro galvanising process. Nevertheless. and 2667.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. The arm portion shall be suitable for assembling the complete arm assembly on to component constructed of standard channel section.15 SHEET 10 OF 19 1X 700 MW CCPP AT NEDUNOOR. The back plate shall allow sufficient clearance for fixing bolt to be tightened with tray in position. The flexible conduits and their fittings shall comply with IS: 3480. f. The hume pipes/RCC pipes shall comply with IS: 458. The conduits and fittings shall comply with IS: 1653. The pipes shall be manufactured by electric resistance welding and hot dip galvanized.5960A-H-500-001 conforming to IS. the support system shall be designed by the bidder to fully meet the requirements of type tests as specified. (e) Conduits & Pipes (i) The galvanised steel conduits shall be used for sizes upto 63. SECTION: D3. TCE.5 mm.CABLING SYSTEM SPEC. and shall be as shown in the enclosed drawing. 4649. 329 R5 . ELECTRICAL SYSTEMS .6 kV power. TCE. In vertical race ways with multi-tiers the tiers shall be located atleast with 400 mm intervals. 6.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. control cables and instrumentation & communication cables. DM plant .5960A-H-500-001 (i) Cable tray supports shall be fabricated from standard steel structures of different sizes.Hot dip galvanised. The steel members shall be cleaned thoroughly for rust and painted as follows: • For indoor . In trenches & tunnels the width of the cable tray shall be limited to 600 mm.One shop coat of red oxide zinc chromate primer and two site coats of aluminium alkyd paint. In case of horizontal trays it shall be limited to 800 mm. Vertical trays (raceways) and all outdoor cable trays shall be provided with removable 16 guage galvanised MS sheet covers. For outdoor & corrosive areas like battery room. SECTION: D3. (ii) (iii) (iv) (v) (vi) ISSUE R0 250 TCE FORM NO.CABLING SYSTEM SPEC. trenches shall be 300 mm.15 SHEET 11 OF 19 1X 700 MW CCPP AT NEDUNOOR. (ii) • (g) Cable Carrier Installation practice (i) Minimum level difference between two tiers of horizontal cable trays in building. 400V/230V power. KARIMNAGAR DIST. The sizes selected shall be adequate for the weight of cables/trays encountered. Cable trays shall be welded to the mounting/carrier structures. Separate cable trays/tiers shall be provided for different voltage grade cable viz. Communication links wherever redundant shall be run in different conduits and in separate trays. Cable trays shall be supported at every 1000 mm interval. Cable trenches around the transformer shall be filled with sand.. suitable pipe sleeves. nylon cord at an interval of 5000 mm and also at bends. the distance between earthing points shall not exceed 10 metres. When cables are taken in vertical raceways / trays and they pass from one floor & other floor pipe sleeves in concrete shall be provided. 329 R5 .7. SECTION: D3. Cable jointing and splicing shall be avoided. For road crossings. Jointing will be allowed only for the cases where the route length is more than the maximum possible drum length. ELECTRICAL SYSTEMS . KARIMNAGAR DIST. A working space of not less than 600mm shall be maintained on atleast on one side of each tray. oil.5960A-H-500-001 (vii) Each continuous laid out length of cable tray shall be earthed at minimum two places by MS flats of minimum size 25mm x 3mm.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Outdoor cable installation (a) Where cables cross roads and water. piping or other obstacles to facilitate installation of cables in the tray. Hume pipes shall be preferred to steel pipes from the point of view of corrosion. (viii) (ix) (x) 15. NO. At least 300mm clearance shall be maintained between the top tray and beams.7 15. etc. TCE. the cables shall be laid in hume or steel pipes.7.2 (b) (c) 15. steam pipe.7. adequate in number and of adequate sizes shall be provided in building walls/slabs for passage of cables into a building from cable trays/racks/cable trenches located outside the building.CABLING SYSTEM SPEC.15 SHEET 12 OF 19 1X 700 MW CCPP AT NEDUNOOR. 15. The cables shall be tied to tray rungs by means of 3mm dia. the pipe for the cable shall be buried at not less than 600 mm. For good sealing arrangement at entry points. gas or sewage pipes. No cables shall be mounted near hot zones like hot flue gas duct.1 Cable Installation Cables to each circuit shall be laid in one continuous length.3 Cables in Trays / on Racks ISSUE R0 251 TCE FORM NO. nylon cord at an interval of 5000 mm and also at bends. 3 core cables to be laid in touching formation.CABLING SYSTEM SPEC. (d) (e) (f) (g) Control cables and small power cables on racks shall be run in ladder type cable trays supported on rack carrier arms. SECTION: D3. NO. KARIMNAGAR DIST. Cables removed from one duct/conduit shall not be reused without approval of Owner. Smaller 1100V grade power cables below 120 mm² may be run in double layers. (b) (c) 1100V grade power cables of 120 mm² size and above shall normally be laid in single layer in trays/on racks. When trays are arranged in tiers. The cables shall be tied to tray rung by means of 3 mm dia.15 SHEET 13 OF 19 1X 700 MW CCPP AT NEDUNOOR. where required. Single core power cables for 3 phase AC circuits laid in trays/racks/ trenches in trefoil groups shall be held in trefoil clamps placed at an interval of 3 m. (h) ISSUE R0 252 TCE FORM NO. nylon cord as follows: (i) (ii) At an interval of 1m when laid in cable trays/racks. 329 R5 . TCE. The trefoil groups of cables shall be additionally tied by means of 3 mm dia. HV cables shall be laid in top trays and cables of subsequent voltage grades in lower tiers of trays.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. due to space restrictions. Approximately 10% space on the cable trays shall be provided for future. Single core cables to be laid in trefoil groups. All cables assigned to a particular duct / conduit shall be grouped and pulled in simultaneously using cable grips and suitable lubricants. ELECTRICAL SYSTEMS . The HV power cables shall be laid in trays/on racks as follows: i) ii) iii) In single layer only without exception. Control and instrumentation cables can be laid upto a maximum of three layers in each tray/rack. At an interval of 750 mm when laid in trenches without cable trays.5960A-H-500-001 (a) Different voltage grade cables shall be laid in separate trays. Cable terminations shall be done with double compression type brass cable glands. 329 R5 . 15. Tags shall be additionally put at an interval of 30 metres on long runs of cables and in pull boxes.CABLING SYSTEM SPEC.15 SHEET 14 OF 19 1X 700 MW CCPP AT NEDUNOOR. clamping and miscellaneous details (a) Cable entry to motors. KARIMNAGAR DIST. (b) (c) (d) ISSUE R0 253 TCE FORM NO.6 kV tray system From 400V tray system From control cable tray system 914 mm 610 mm 305 mm (j) The cables emanating from redundant equipment / devices shall be routed through different routes. Saddle type clamps to suit number of cables to be clamped at a particular location shall be used for clamping cables running along walls. at 750mm interval.5 Terminations.7. NO. The distance between instrumentation cables and those of other: system shall be as follows : From 6. Top entry of the cables is not acceptable particularly for outdoor equipments. All cable terminations shall be done with solderless crimping type lug. the higher voltage cable shall be in higher position and instrumentation cable shall be in bottom tier of the tray stack. TCE. provided in Owner's approved format at both the ends as well as at an interval of 5 meters.7. All cables shall be identified by tag.-422. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. In vertically stacked trays.4 Bending radii for cables The bending radii for various types of cables shall not be less than those values specified by the cable manufacturer. ELECTRICAL SYSTEMS . ceilings. etc. push button stations and other electrical devices shall be from the bottom as far as possible or from the sides. Nos. The above segregation of cables & wiring for redundant equipments/ devices shall be in accordance with IEEE-Std-422. Identification tags made from aluminium sheet shall be attached to each end of each cable by means of GI binding wire. 15.5960A-H-500-001 (i) Cables shall be segregated as per IEEE Std. structures. TCE.7. screens and armour of all multicore cables shall be earthed at both equipment and switchgear end. (b) 15.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. through brick or RCC walls/floors. High voltage testing All cables of 1. 15.CABLING SYSTEM SPEC. NO. For long lengths of cables multiple earthing may have to be adopted to safeguard against the presence of standing voltages under normal as well as fault conditions. KARIMNAGAR DIST.7 (b) 15. SECTION: D3. ISSUE R0 254 (ii) TCE FORM NO. Sheath and armour of single core power cables shall be earthed at switchgear end only.6 kV grade XLPE insulated cables shall be of proven design and make which have already been extensively used and type tested.15 SHEET 15 OF 19 1X 700 MW CCPP AT NEDUNOOR.9 Fire proof sealing system (FPS) (a) Fire proof sealing system shall consist of (i) Fire-stops/fire-seals for sealing of cable/cable tray and conduit/pipe penetrations. 1.6 Termination and jointing kits for 6. Cable jointing shall be carried out only by Raychem certified jointers only. Termination kits and jointing kits shall be heat shrinkable type/push on type. 329 R5 .7. Straight through joint and termination shall be capable of withstanding the fault level for the system.7. `Fire-breaks' provided on long runs of cable racks/trays to prevent the propagation of fire along the cable rack.1 kV grade 400 mm² and above and all HV cables shall be subjected to DC or AC (preferably DC) high voltage test after terminating but before commissioning as per Table 4 in IS: 1255. to prevent the spread of fire from one area.zone. Testing and commissioning of cables (a) Cables shall be checked for insulation resistance before and after jointing.5960A-H-500-001 15.1 kV grade Straight Through Joint shall be of proven design. both horizontal and vertical. within a single fire-area or fire.7. 6.8 Earthing (a) Metallic sheaths. ELECTRICAL SYSTEMS .6 kV grade joints and terminations shall be type tested as per IS:13573. which is separated from others by fire-resistant barriers. The materials used in the fire stops shall be nonhygroscopic.CABLING SYSTEM SPEC. 329 R5 . with or without a fire resistant panel. fixing and installation of the fire-stop/fire-break. adopted to retard flame propagation along long runs of horizontal or vertical cable trays in the same fire zone or area. shall constitute a `fire-break' and shall be provided by applying a suitable fire-resistant coating on cables and cable trays for the required length. in an event of a fire. which is meant to prevent spreading of fire between areas separated by fire-resistant barriers.5960A-H-500-001 (b) The FPS system shall also include all the necessary accessories and equipment required for supporting. ISSUE R0 255 • TCE FORM NO. at the point of the fire break to obtain the fire-rating specified. other than fire-stops. TCE. SECTION: D3. or cables passing through embedded conduits/pipes/ pipe-sleeves. The FPS system shall comply in all respects with the requirements of the codes and standards listed below IEEE-634 ASTM-E-814 ANSI-IEEE-383 IEC-60331 IEC-60332 (c) (d) Fire Stop/Seal The FPS system adopted for cables or cable trays penetrating through walls and floor openings. KARIMNAGAR DIST. compatible with the type of cables. (e) Fire Break The fire proofing system. constitutes a `fire stop/seal'. NO. holding in position. (f) Performance Requirements (i) Requirement of fire stops • The material. ELECTRICAL SYSTEMS . design and construction of the fire stops shall be such as to provide the fire rating of 120 minutes for a fire on any side and meet all requirements listed in this specification and the relevant codes and standards.15 SHEET 16 OF 19 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. shall be sealed by fire stops at each floor level. various control and relay panels and other bottom entry panels. • • (ii) Location of fire breaks • Fire breaks shall be provided on both cable rack and trenches at all cable tray intersections and tee-offs. Vertical raceways. NO. 329 R5 . SECTION: D3. a fire on any side of the fire break. which carry cables between successive floors.5960A-H-500-001 • The fire stops shall be suitable for retrofitting of cables through the penetration seal without disturbing the sealing of the cables already existing.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.15 SHEET 17 OF 19 1X 700 MW CCPP AT NEDUNOOR. Cable entry through openings in floor slabs below MV/LV switchgear.CABLING SYSTEM SPEC. (ii) Requirements of fire breaks • Each firebreak shall have a fire rating of 30 minutes and shall be capable of withstanding for the duration specified. On linear runs of cable trays between fire stops or fire breaks. TCE. (g) Application of fire proof sealing system (i) Fire stops Fire stops shall be provided for cable penetration openings listed below • The passage of cables/cable trays pipe sleeves/embedded conduits through walls / floors. MCCs. through openings provided in the RCC floor slab. shall be effectively sealed by fire stops. KARIMNAGAR DIST. fire breaks shall be provided at intervals of 15 metres on horizontal cable runs and 5 m on vertical cable runs. ELECTRICAL SYSTEMS . ISSUE R0 256 • TCE FORM NO. 7. water immersion and vibration.15 SHEET 18 OF 19 1X 700 MW CCPP AT NEDUNOOR.e. or material in contact with the cable penetration fire stop. KARIMNAGAR DIST. 329 R5 . If the certificates are not satisfactory all the tests shall be conducted free of cost. TCE. fire stops and fire breaks shall be identical (or better) with the system which is successfully type tested for the specified rating i. the composition density of the material.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS . SECTION: D3. 15.e. Preconditioning of fire stop test specimens Before conducting the fire rating and hose stream tests. Test on Fire Stops During the fire rating test. the cable penetration fire stop material.11 Type tests shall be conducted on different fire stop test specimens described above as per IEEE-634.7.CABLING SYSTEM SPEC.10 Contractor shall furnish the test certificates for the fire stops and fire breaks after award of contract for Owner’s review. with a maximum temperature limit on the unexposed surface of 200oC.5960A-H-500-001 • Fire breaks in linear runs of cable trenches between intersections and tee-offs shall be provided at intervals of 30 metres. each test specimen shall be preconditioned for thermal ageing. The sizes of the fire stop test specimens shall be similar to the largest of the sizes being used in the plant. the transmission of heat through the cable penetration fire stop shall not raise the temperature on its unexposed surface above the self ignition temperature of the outer cable covering. NO. Performance Tests: Tests on Fire Stops (a) The fire stops shall be subjected to the following type tests: (i) (ii) (b) Fire Rating Test Hose Stream Test 15. thickness of coating in case of fire breaks and any other properties of the material / system offered shall be identical or better than the tested system and shall be subject to Owner’s approval. The offered system i. (c) (d) (e) Tests on fire breaks ISSUE R0 257 TCE FORM NO. SECTION: D3. 329 R5 .CABLING SYSTEM SPEC.5960A-H-500-001 Fire breaks shall undergo the following tests as per ANSI-IEEE383: (i) (ii) Ampacity test Flame test ISSUE R0 258 TCE FORM NO. ELECTRICAL SYSTEMS .15 SHEET 19 OF 19 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. KARIMNAGAR DIST. TCE. 3 phase.1.1. roads. During blackout conditions. SECTION: D3. 329 R5 .5. auxiliary transformer.0 LIGHTING SYSTEM Lighting system shall be provided for the proposed plant covering all the buildings.1.. the lighting circuits shall be fed by the 400V. boundary. All the lighting fixtures connected to this system shall be available as long as supply is available from normal source viz. yards.3 Normal cum emergency 230V AC lighting system Certain lighting fixtures considered essential shall be connected to this system. etc.1 Categories of Lighting The plant lighting system shall comprise the following four (4) categories: (a) (b) (c) (d) Normal 230 V Single phase AC lighting system Normal-cum-Emergency 230 V Single phase AC lighting system Emergency 220V DC lighting system Maintenance 24V AC Lighting System 16.16 SHEET 1 OF 16 1X 700 MW CCPP AT NEDUNOOR. normal AC supply available from the normal lighting distribution boards.7 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.LIGHTING SYSTEM SPEC. KARIMNAGAR DIST. 16.5960A-H-500-001 16. 4 wire. TCE. outdoor areas. The lighting system shall be to owner’s approval.1 16.1. In this system the lighting circuits shall be fed from another lighting distribution board from normal/emergency section of the 400V main switchboard. 16.2 Normal 230V AC lighting system In this system. 16. the lighting fixtures connected to this system will go off and shall come back as soon as the DG set starts feeding power to the 400V normal-emergency bus section. The lighting fixtures connected to this system will be available whenever normal supply is available in the plant and also whenever emergency DG set supplies the power to this bus section during blackout conditions. NO.4 Emergency DC lighting system ISSUE R0 259 TCE FORM NO. having good aesthetics and designed to provide the required illumination levels in all areas and to meet the fire and safety codes. ELECTRICAL SYSTEMS . The area-wise distribution of lighting fixtures connected to the systems discussed above shall be as follows: ---------------------------------------------------------------------------------------------------------------Percentage wise distribution of Lighting Area /Building ------------------------------------------------------------------Normal Normal & Emergency 220 V DC ----------------------------------------------------------------------------------------------------------------GTG. NO. required during the routine maintenance work. These fixtures shall be connected to lighting panels supplied from 220V DC station battery. relay room.5960A-H-500-001 (a) During station emergency involving total AC failure. Minimum one number of instalite shall be provided in all switchgear rooms pump houses and control rooms where DC lighting not envisaged. Lighted exit signs shall be provided and installed in the control & switchgear room. Control & Switchgear Building. TG building Hall. Cable galleries and any other areas considered necessary by CONTRACTOR. maintenance area etc.. and for lighting the control room and DG set area. control ISSUE R0 16. 329 R5 . near entrance. SECTION: D3. These lighting fixtures shall be normally kept `OFF'. incandescent lamp DC lighting fixtures shall be provided for movement of personnel in GTG and STG buildings. ELECTRICAL SYSTEMS . (b) (c) (d) 16. buildings Switchyard control room Switchgear and battery rooms. TCE.1. landings etc. Switchyard Relay Building at strategic locations viz.LIGHTING SYSTEM SPEC. 24V single phase 3 pin sockets with switches shall be provided at selected points such as HRSG area.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. staircase. Necessary outlets shall be made on the inside walls of the building near equipments.1.6 80% 80% 20% 20% * * 260 TCE FORM NO.. STG.16 SHEET 2 OF 16 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST.5 Maintenance 24V AC Lighting System For lighting facilities comprising portable hand lamps and/or connection of portable hand tools etc. All the area in the plant shall have the same philosophy & DC lighting for these areas shall also be from the station battery. Such sockets for routine maintenance shall be clearly identified by colour coding in order to distinguish them from the normal 230V power outlets. 3 phase. 3 phase. The LDBs will be provided with number of outgoing circuits controlled by MCBs to feed the lighting panels and by MCCB/Contactors to feed around the plant as well as to directly feed three phase street lighting and yard lighting supplies.2. Lighting panels feeding the Lighting fixtures in indoor areas shall be controlled from the respective lighting panels located in various buildings in the plant. NO. 329 R5 . The secondaries of lighting transformers shall be connected to 400 V. SECTION: D3. TCE. AC lighting distribution boards (LDBs) having 2x100% incomers & a bus-coupler. AC lighting panels shall have 3 phase. 3 phase.LIGHTING SYSTEM SPEC. Also manual switching `on and off' facility shall be provided. 4 wire.16 SHEET 3 OF 16 1X 700 MW CCPP AT NEDUNOOR. 3 wire. 16. 50 Hz unit service switchgear by providing a 400 / 400V delta/star lighting transformers. 4 wire incomer with ELCB and number of 1 phase outgoing circuits controlled by MCBs.2 16. 50 Hz supply with effectively earthed neutral. 4 wire. yard lighting and aviation warning lights also shall be contactor controlled. (b) 16. All outdoor lighting system and aviation warning lighting system shall be automatically controlled through photoelectric controllers. KARIMNAGAR DIST. This supply shall be derived from 400 V. the distribution shall be by 400V. Admin building Canteen Roads & out going areas 80% 80% 100% 100% 100% 20% 20% * - - - DG set control room 80% 20% * ---------------------------------------------------------------------------------------------------------------* Adequate for personnel movement and also located at strategic locations. Road. Provision to bypass the timer or photocell shall be provided in the panel.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 220 V DC lighting system ISSUE R0 261 TCE FORM NO.1 Lighting Supply Distribution System Normal and normal emergency AC systems (a) For these systems.2. The Infrared sensing system shall be used for the control of lighting in unmanned substations.5960A-H-500-001 room in Control & Switchgear building HRSG area Transformer area & 400kV switchyard Pump houses. ELECTRICAL SYSTEMS . SECTION: D3.5960A-H-500-001 Emergency DC lighting supply distribution shall be on 220V DC. ELECTRICAL SYSTEMS . 329 R5 .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Area/ Structure Average Illumination Level in Lux. Minimum 10% of 220V DC lighting shall be provided.Trulite 2X36W fluorescent lamp (F. The control box shall be fixed on the wall/column for the easy maintenance. undervoltage relay and number of outgoing circuits controlled by switch fuses. Industrial type with vitreous enamel reflector Industrial type with vitreous enamel reflector Industrial high bay with anodised aluminium reflector 1 x 70 W / 1 x 150 W HPSV lamp (b) Cable vault 150 2 x 36W fluorescent lamp (F. This power supply shall be obtained from station 220V DC switchboard.L). (a) GTG. TCE. 16. 2 wire unearthed system. NO. DC lighting panel shall be provided for distribution of lighting supply. Sl. No. STG Building / Control & Switchgear building General (auxiliary equipment areas) 200 Medium /low bay fittings / Industrial well glass vitreous enamel reflector integral mounted control gear/ industrial bulk head with integral mounted control gear. ISSUE R0 (c) All switchgear room area (including off-site building control room) GTG Building 250 (d) 200 262 TCE FORM NO. Metal Halide Lamp. Type of Fixture Type of Luminaire 1. KARIMNAGAR DIST. No voltage at the normal emergency switchgear shall be sensed and DC contactor shall be switched on thus extending DC supply to the lighting circuits. All the lighting fittings shall have separate control & gear box arrangement.LIGHTING SYSTEM SPEC.L)-Trulite 1x400 W.3 Illumination levels and choice of lighting fixtures The area-wise distribution of average illumination levels and type of luminaires shall be as given below.16 SHEET 4 OF 16 1X 700 MW CCPP AT NEDUNOOR. This panel shall have an incoming switch. TCE. (a) 150 50 Dust proof / dust tight well glass fixture 70W HPSV lamp 3. (a) Various Off-site building Switchgear room (All pump 200 Industrial type with vitreous 2 x 36W F. (a) (b) (c) Transformer Area General Near equipment Switchyard Area General Near equipment Switchyard Control room 30-35 35-50 500 Flood light medium beam type Post top lantern with HDP reflector Decorative recessed with wide angle mirror optic anti glare type 1 x 150W HPSV lamp 70W HPSV Energy efficient Lamp – T5 30-35 35-50 Flood light medium beam type Dust proof / dust tight well glass on fire partition walls 1 x 150W HPSV lamp 1 x 70W HPSV 5. -Trulite (f) (g) Battery rooms A/C plant room 250 200 (h) Unloading and maintenance bay 250 (i) Electrical / Instrument laboratory. Area/ Structure Average Illumination Level in Lux.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. (a) (b) 4. Industrial High with Anodised Aluminium Reflector 2X 36W F. chemical laboratory (air-conditioned) Chemical laboratory (non-air conditioned) HRSG area HRSG area and platforms (i) (ii) Indoor Outdoor 250 Decorative recessed with wide angle mirror optic anti-glare type Corrosion proof (j) 250 2. KARIMNAGAR DIST.LIGHTING SYSTEM SPEC.L.16 SHEET 5 OF 16 1X 700 MW CCPP AT NEDUNOOR. Type of Fixture Type of Luminaire Industrial High with Anodised Aluminium Reflector (e) Control room 500 Decorative recessed with wide angle mirror optic anti glare type Vapour proof Totally enclosed vapour proof with clear acrylic cover Industrial high bay Energy efficient Lamp – T5 2X36W F.L.L. ELECTRICAL SYSTEMS .L -Trulite 1x400 W.L. No.-Trulite 2 x 36W F.5960A-H-500-001 Sl. 329 R5 . SECTION: D3. -Trulite 2 X 36W F. ISSUE R0 263 TCE FORM NO. Metal Halide Lamp. KARIMNAGAR DIST. Building periphery lighting 100 - 2 x 36 W F. TCE. Area/ Structure Average Illumination Level in Lux.do - (c) 200-250 Decorative with wide angle mirror optic reflector Industrial type with vitreous enameled reflector . (b) (c) Lockers.5960A-H-500-001 Sl.L. staircase. (a) (b) Administration Building Main office areas cabins (air conditioned areas) Main office areas. cabins with false ceiling but non-airconditioned Main office areas. toilets.do - (d) 10.LIGHTING SYSTEM SPEC. wash rooms. . high/medium beam flood light Industrial type with vitreous enamel reflectors/industrial high bay 1 x 70W / 150W HPSV (b) (c) 8. Perimeter (compound) lighting Parking area (Indoor / sheds) Workshop building 20 70 300 . .do 2 x 36W F. Type of Fixture Type of Luminaire house) (b) (c) Outside working areas Equipment room (Pump house. 150 Industrial type with vitreous enamel reflectors/channel mounted box type compact flourescent lamp Channel mounted box type Industrial well glass with integral mounted control gear/industrial bulk head with 2 x 36 W F. medical centre General Corridors. cabin non airconditioned areas without false ceiling Warehouse. 329 R5 . ELECTRICAL SYSTEMS .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.L. etc. SECTION: D3. walk-ways.L x 250W HPSV 9. (a) Corrosion proof 1 X 70 WHPSV Street light with clear acrylic cover cut-off type with integral mounted control gear or LED fixtures with control gear. 1 x 70 W HPSV lamp ISSUE R0 264 TCE FORM NO. 200-250 200-250 Decorative recessed type with mirror optic reflector .do General purpose flood light.L. (a) 7. No.L. canteen.do 1 x 250 W HPSV 2X36W F. Compressor & DG house) DM Plant / Filtration Plant General Road and yard lighting Main roads Secondary roads 20 10 250 70 250 enamel reflector mounting height of 8M Flood light medium beam upto Industrial high bay / medium bay depending on height 1x400W / 1x150W Metal Halide Lamp (HPMV) 6. etc.16 SHEET 6 OF 16 1X 700 MW CCPP AT NEDUNOOR. (a) 150 2 x 36W F. NO. 8 All other indoor areas . Type of Fixture Type of Luminaire integral mounted control gear (d) 11.4.1 Indoor lighting The illumination level for various areas in the plant is indicated in the table above. local rules etc. Following factors shall be considered while arriving at the utilisation factor to determine the number of fixtures for each area/building in the plant. TCE. KARIMNAGAR DIST.LIGHTING SYSTEM SPEC. which are not specifically covered above. 16. No. (a) (b) Security.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.0. Executive canteen Elevator Elevator machine room Elevator well 100 20 Industrial type enamelled reflector vitreous 2 x 36W F. (a) (b) DC Light Fitting Control room Other areas Decorative recessed type with cylindrical reflector Industrial industrial reflector bulk head or well glass with 1 x 100 W incandescent lamp 1 x 100 W incandescent lamp The illumination levels for areas. The system design shall consider principles of lighting specified in following paragraphs. 1 x 100 W incandescent lamp / 1 x 70W HPSV 150 Decorative with louver 2x36W F.L. shall be decided based on illumination levels indicated for similar areas or in relevant standards.0. The lighting layout shall be designed to provide uniform illumination with minimum glare. 329 R5 .L Industrial bulk head/ industrial bulk head with integral mounted control gear 12. SECTION: D3. NO. 16.5960A-H-500-001 Sl. Area/ Structure Average Illumination Level in Lux. Gate house.16 SHEET 7 OF 16 1X 700 MW CCPP AT NEDUNOOR.4 Lighting System Design The lighting system design shall comply with the acceptable norms and the best engineering practices. Time office. The layout design shall meet all the statutory requirement. (a) Maintenance factor (i) (ii) Control room and system cabinet room .7 ISSUE R0 265 TCE FORM NO. ELECTRICAL SYSTEMS . The mounting height of the luminaires shall be generally 9 metres. (d) 16.. on either side or in the central reserve.LIGHTING SYSTEM SPEC.3.4. KARIMNAGAR DIST. The road lighting layout shall consider the width of the road to decide whether the lighting poles shall be located on one side.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (b) (c) (d) (e) 16.3.16 SHEET 8 OF 16 1X 700 MW CCPP AT NEDUNOOR. NO. TCE. Ratio of minimum to average illumination shall not be less than 0. the control gear of the light fixture shall be mounted at the foot of the pole.7 ceiling.2 Roadway lighting (a) Lighting design for roadways shall consider a maintenance factor of 0. 329 R5 .4.6 for average conditions.0.e.3 16.6 Reflection factor for wall and ceiling (i) Control room and system cabinet room .4. The control gear for street light shall be of non integral type i.. receptacles etc. The suspension height for suspended fixtures shall not exceed 1 metre. The control room lighting shall be designed such that no glare from the lighting appears on the DCS-CRT from any angle. The lighting poles shall be galvanised steel poles with reasonably thick layer of galvanising for ensuring long life. uniformity of illumination.0. shall be selected based on the plant area in which they are intended to be used. SECTION: D3.0. ELECTRICAL SYSTEMS .5960A-H-500-001 (iii) (b) Out door areas .1 Selection of lighting fixtures and accessories The type of luminaires and accessories like switches. Lighting fixtures shall be explosion proof in hazardous and fuel oil areas. ISSUE R0 266 TCE FORM NO. 0.5 ceiling 0.5 wall Other areas .3 wall (ii) (c) The value of the ratio of spacing (S) to mounting height (H) shall be commensurate with the type of fittings selected. Div-II fittings/ increased safety fittings (Div-II/Hazardous Area) shall be provided with electronic ballasts. Pipes and Accessories Galvanised heavy duty steel conduits for normal area and galvanised heavy duty steel conduits with an additional epoxy coating for corrosive area shall be offered. 16. The louvers of these fixtures shall be designed for 'T5' type fluorescent lamps.3. 16. The terminal boxes for the lighting pole shall be IP55 protected & of glass reinforced epoxy type.2 All fluorescent fixtures. 16. etc.4.5 Rigid steel conduits shall be heavy duty type.3. Pull-out boxes shall have cover with screw and shall be provided with good quality gasket lining. shall have electronic chokes with low harmonics & energy efficient 'T5' type fluorescent lamps except the fluorescent fixtures used for division 2 hazardous area.LIGHTING SYSTEM SPEC. swaged tubular and joined together.3.4.6 Flexible conduit shall be water proof and rust proof made of heat resistant lead coated steel. suitable aviation warning light.4. No site welding or bolted joints shall be done on the mast.4. ISSUE R0 267 TCE FORM NO.3 All HPSV and HPMV lamp fixtures or LED fixtures shall be provided with wire-wound ballasts. 329 R5 .4. The mirror optics type fluorescent fixtures shall have no iridescence effect.7 Pull out boxes shall be provided at approximately 4 (four) metre interval in a conduit run.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The complete pole shall be hot dip galvanised. ELECTRICAL SYSTEMS . KARIMNAGAR DIST. Structures.4 Conduits.5960A-H-500-001 16.3. threaded on both sides and threaded length shall be protected by zinc rich paint. lightning along with necessary power cables within the mast. in built power tool. Columns. All fluorescent fixtures except for Class-I. hot dip galvanised conforming to IS : 9537 Part-I & II shall be suitable for heavy mechanical stresses.4.3. SECTION: D3. The mast shall be delivered only in three sections & shall be joined together by slip stressed fit method at site. Boxes shall be suitable for mounting on Walls.16 SHEET 9 OF 16 1X 700 MW CCPP AT NEDUNOOR. including the Head Frame. 16.4. continuous stainless steel wire rope. Pull out box & its cover shall be hot dip galvanised. Conduits shall be smooth from inside and outside. All fluorescent lamps shall be have "Cool day light" colour designation. TCE.8 The poles shall be of ERW tubes of specified lengths. Double Drum Winch. The Mast shall be of 30M height with lantern carriage to enable raising/lowering for ease of maintenance. luminaries.4. 16.3. Pull out boxes used outdoor shall be weather proof type suitable for IP :55 degree of protection and those used indoor shall be suitable for IP :52 degree of protection. 16. 16.3.3.9 Lighting Mast shall be of continuously tapered polygonal cross section hot dip galvanised. NO. LIGHTING SYSTEM SPEC. 1200mm sweep. etc. aerodynamically designed well balanced MS blades (3 Nos. down rod.5960A-H-500-001 16.). 400VA. finished in stove enamelled white. Suitable no.3. Also inside a building. (b) (c) 16.4. of 63A. separate switches shall be provided for each point. The ISSUE R0 268 TCE FORM NO.4 Switches and receptacles (a) In the plant areas. SECTION: D3. The same shall be indoor/outdoor/flameproof as per the location. Receptacles with MCB (5A and 15A) shall be provided in all building/areas of the plant. rooms etc. At-least two 63A. in an enclosed area.C industrial heavy duty receptacles shall be provided for outdoor plant for welding purpose.54 degree of protection. 400V industrial heavy duty type receptacle shall be provided in each building... shall be suitable for operation on 230 V. Inside each cabins atleast two receptacles shall be provided. Outdoor panels shall be weather proof type with IP . receptacles shall be provided at regular intervals so that any point of the building is not more than 10 m with a minimum of 2 nos.4. Ceiling fans. ELECTRICAL SYSTEMS . The LDBs and LPs shall be sheet steel enclosed and shall be fully dust and vermin proof. building periphery lighting separate switches shall be provided.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Wherever the lighting panel is not in the same area. TCE. separate switches shall be provided. 16.10 Suitable collapsible / telescopic ladder shall be provided to approach lighting fixture installed at height. NO. capacitor. `Supply On' indicating lamps. KARIMNAGAR DIST. with a degree of protection of IP 54. 50 Hz. AC supply comprising of class ‘F’ insulated copper wound single phase motor. 329 R5 .9. It shall be metal enclosed with SFU and housed inside with suitable connection for cabling and receptacles. Similarly for entrances. die cast aluminium housing. to be provided in non air conditioned office/control room area. Power factor of fans shall not be less than 0. LPs shall be explosion proof wherever provided in hazardous and fuel oil areas. The industrial receptacle shall be provided at an average distance of 50 mts. 3 phase. canopies etc.16 SHEET 10 OF 16 1X 700 MW CCPP AT NEDUNOOR.4. suspension hook. Each fan shall cover approximately 10m2 area. For cabins. 3 phase. LDBs.5 Lighting distribution boards (LDB) & lighting panels (LP) Each of the LDBs shall be provided with voltmeter and ammeter along with selector switches. the lighting circuits shall be controlled directly from the MCBs in the lighting panels. ELECTRICAL SYSTEMS . Wiring (a) 1100 V grade stranded copper conductor.LIGHTING SYSTEM SPEC. NO. can be run in same conduit. The circuit loading on each circuit shall be restricted to 80% of the MCB rating.8 Lighting circuit design (a) In an area. TCE.7 (b) (c) (d) (e) 16. Wires of AC and DC lighting systems shall be carried out in separate conduits. PVC insulated. For outdoor lighting..5960A-H-500-001 switch boxes. In the hazardous areas cable wiring with 1100 V grade stranded aluminium conductor.4. Wires of lighting and power receptacles will be carried out in separate conduits and on separate circuits. the lighting fixtures shall be arranged in different phases/LPs such that even in case one lighting panel goes faulty complete lighting is not affected. For outdoor areas like transformer yard. However wires of same phase but having different circuit nos. PVC insulated wires to IS: 694 laid in GI conduits shall be used for lighting in nonhazardous area. PVC inner sheathed. The buried cables shall have suitable bedding. 329 R5 . KARIMNAGAR DIST. shall be made up of 18 SWG sheet steel.4. receptacle boxes etc.4. GI wire armoured and overall PVC sheathed cables to IS: 1554 shall be adopted.16 SHEET 11 OF 16 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Minimum cable size in case of cable wiring shall be 4 mm2 for lighting and 6 mm2 for receptacles. ISSUE R0 (b) 269 TCE FORM NO. SECTION: D3.5 mm2 in case of lighting and 4 mm2 in case of receptacle wiring. In case of room the lighting shall be arranged from two phases.6 The distribution of lighting fixtures/receptacles shall be such that the loading on each phase of the LDB is approximately equal. Wires of different phases shall be run in separate conduits. 16. protective covers & markers. the cable shall be buried at a minimum depth of 750 mm from ground level. Minimum size of wires in case of conduit wiring shall be 2. 16. The wiring in the conduit shall be such that 20% space in the conduit is free. switchyard and road lighting also cable wiring as above shall be adopted. 329 R5 . TCE. Lighting fixtures of each type Lamps of each type and rating. junction boxes on the poles. conduits and junction boxes shall be properly earthed using 12 SWG GI wire run along the entire length of the conduit between the fixture and the corresponding lighting panel where it will be connected to the station earth. v.5 16. shall be run buried in ground at a depth of 600 mm and tapped to each lighting pole. SECTION: D3. switches. KARIMNAGAR DIST. 16. of each rating.5. The contractor shall submit design calculation for sizing of LDBs and also provide lumen contour for the main road and other areas.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 Tests Type test reports of the following items as per relevant standards shall be submitted for approval.9 Earthing (a) Lighting fixtures. the third core of each singlephase armoured cable circuit shall be used as earthing conductor. 270 TCE FORM NO.4.B. ELECTRICAL SYSTEMS . ii.LIGHTING SYSTEM SPEC. vi. Contractor shall demonstrate the same at location decided by Owner.C. receptacles.5960A-H-500-001 (c) (d) The voltage drop from LDB and any fixture shall not exceed 3%. 25 X 6 GS Flat. (b) (c) 16. NO. For fixtures in hazardous areas. The earth conductor shall be connected to the nearby main earthing grid at the first and last poles of each feeder circuit and at some intermediate poles. For outdoor earthing of lighting poles.(life cycle and rating test only) Lighting panel of each type (Degree of Protection) Junction Box of each type Receptacles of each rating M.16 SHEET 12 OF 16 1X 700 MW CCPP AT NEDUNOOR. ISSUE R0 iii. i. iv. 6 16.12 Luminaries for Street Lighting 16.6. Type test certificates shall be furnished for review.6.3 16.6.6.10 16.6.14 Waterproof Electric Lighting Fittings Watertight Electric Lighting Fittings 271 TCE FORM NO.5 16.16 SHEET 13 OF 16 1X 700 MW CCPP AT NEDUNOOR.6.6.6.9 IS:4013 Part (I&II) IS:2148 IS:10322 Pt-V SECT-5 IS:10322 Pt-V SECT-3 IS:3528 IS:3553 ISSUE R0 16.6.6.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE.13 16.4 IS:6665 IS:3646 (Part-III) IS:1777 16.5.1 Electric Lighting Fittings General and Safety Requirements Code of Practice for Industrial Lighting Calculation of Co-efficient of Utilisation Industrial Lighting Fittings with Metal Reflectors Decorative Lighting Outfits Dust Proof Electric Lighting Fittings Dust Tight Electric Lighting Fittings Electric Lighting Fittings for Division 2 Areas as per IS:5572 (P1) Flame Proof Lighting Fittings IS:1913 16.6.8 IS:5077 IS:4012 IS:4013 IS:8224 16. NO.2 16. 329 R5 .6 16. KARIMNAGAR DIST.6.LIGHTING SYSTEM SPEC. Applicable Standards 16.6. SECTION: D3. ELECTRICAL SYSTEMS .11 Flame Proof Enclosure Flood Lights 16.7 16.2 All acceptance tests & routine tests for the lighting fixtures and accessories covered in this specification shall be carried out as per the relevant standards listed under "Codes and Standards” given below for the respective fixtures/ components.6.5960A-H-500-001 16. 16 SHEET 14 OF 16 1X 700 MW CCPP AT NEDUNOOR. HPMV & LP Sodium Vapour Discharge Lamp Circuits Vitreous Enamel Reflector for Tungsten Filament Lamp Tubular Fluorescent Lamps High Pressure Mercury Vapour Lamps Tungsten Filament General Electric Lamps Cast Acrylic Sheets for Use in Luminaires Screwless Terminal and Electrical Connections for Lighting Fittings High Pressure Sodium Vapour Lamps Emergency Lighting Units Ignition Proof Enclosures.6.LIGHTING SYSTEM SPEC.23 IS:2215 IS:3324 IS:1534 (Part 1) IS:7027 IS:6616 IS:1569 16.17 Bayonet Lamp Holders Edison Screw Lamp Holders Bi-Pin Lamp Holders for Tubular Fluorescent Lamps Starters for Fluorescent Lamp Holders for Starters for Tubular Fluorescent Lamps Ballast for Use in Fluorescent Lighting Fittings Transistorised Ballast for Fluorescent Lamps Ballast for HP Mercury Vapour Lamp Capacitors for Use in Fluorescent. KARIMNAGAR DIST.31 16.18 16.6.16 16.30 16.25 16.6.29 IS:2418 (Part 1) IS:9900 IS:418 IS:7569 IS:10322 Pt-III 16.6.27 16.34 IS:9974 IS:9583 IS:11005 IS:10322 IS 5578 IS 11353 ISSUE R0 272 TCE FORM NO. Main Connections and Auxiliary Wiring and Marking IS:1258 IS:10276 IS:3323 16.21 16.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS .6.22 16.5960A-H-500-001 16.6.6.6.6.6. SECTION: D3.6.20 16.24 IS:8017 16. TCE.6. NO. Dust-Tight for Electrical Equipment Luminaires (Part 1 to V) Arrangement for Busbars.6.6.32 16.15 16.6.19 16.6.6.6.26 16. 329 R5 .33 16.28 16.6.6. 6.49 IS 8828 IS 9224 IS 2705 IS 3156 IS 1248 IS 722 IS 3231 IS 2148 IS 5571 16.6.6.6.16 SHEET 15 OF 16 1X 700 MW CCPP AT NEDUNOOR.47 16. Electric IS 2675 16.6.44 16.37 IS 10118 16.45 16.38 IS 8623 16.46 16. KARIMNAGAR DIST.42 16. NO.6.6. Switch Disconnectors and Fuse Combination Units for Low Voltage Switchgear and Controlgear Miniature Air Break Circuit Breakers for AC Circuits HRC Cartridge Fuse Links upto 650 V Current Transformers Voltage Transformers Direct Acting Electrical Indicating Instruments AC Electricity Meters Electrical Relays for Power System Protection Flameproof Enclosures of Electrical Apparatus Guide for Selection of Electrical Equipment for Hazardous Areas Switches for Domestic and Similar Purposes Three-Pin Plugs and Socket Outlets Fans and Regulators.6.51 16.6.6.35 Enclosed Distribution Fuse Boards and Cut-outs for Voltages not exceeding 1000 V General Requirements for Switchgear and Control gear for Voltages not exceeding 1000V Code of Practice – Installation and Maintenance of Switchgear Factory Built Assemblies of Switchgear and Controlgear for Voltages upto and including 1000 V AC and 1200 V DC Degree of Protection of enclosed equipment for Low Voltage Switchgear and Controlgear Switches.50 16.5960A-H-500-001 16. SECTION: D3.6.6. Disconnectors.48 16. ELECTRICAL SYSTEMS . 329 R5 .52 IS 3854 IS 1293 IS 374 ISSUE R0 273 TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6.6.6. TCE.6.39 IS 13947 16.36 IS 4237 16.6.43 16.6.40 IS 13947 Part-3 16.LIGHTING SYSTEM SPEC. Ceiling Type.41 16. 6. NO.6. Rods.6. Traction and Telecommunication Lines Methods of Test for Concrete Poles for Overhead Power and Telecommunication Lines IS 9537 IS 3837 16.54 Rigid Steel Conduits for Electrical Wiring Accessories for Rigid Steel Conduits for Electrical Wiring Flexible Steel Conduits for Electrical Wiring Rigid Non-Metallic Conduits for Electrical Installations Fittings for Rigid Non-Metallic Conduits PVC Insulated Cables for Working Voltages upto and including 1100 V Tubular Steel Poles Wrought Aluminium and Aluminium Alloys. 329 R5 .6.6.6.16 SHEET 16 OF 16 1X 700 MW CCPP AT NEDUNOOR.59 16. ELECTRICAL SYSTEMS .6.5960A-H-500-001 16. SECTION: D3. Tubes and Sections for Electrical Purposes Code of Practice for Phosphating Iron and Steel Fittings for Rigid Steel Conduits for Electrical Wiring Prestressed Concrete Circular Spun Poles for Overhead Power.58 IS 3419 Part-2 IS 694 16.6.6.53 16.LIGHTING SYSTEM SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.56 IS 3480 IS 9537 Part-2 16.6. Bars.57 16.63 IS 6005 IS 2667 IS 13158 16.64 IS 2905 ISSUE R0 274 TCE FORM NO.60 IS 2713 IS 5082 16.55 16.62 16.6.6. TCE. KARIMNAGAR DIST.61 16. 1 17.0 EARTHING SYSTEM Earthing system shall consist of earth grids and electrodes buried in soil in the plant area. KARIMNAGAR DIST.5960A-H-500-001 17.1.17 SHEET 1 OF 7 1X 700 MW CCPP AT NEDUNOOR. 17. 17.3 Size of Conductors (a) Main Earthing Conductors The earthing conductor sizes shall be calculated as per IS 3043 and shall comply with Indian Electricity rules and IEEE-80. ISSUE R0 275 TCE FORM NO. 17. Earthing system shall be in strict accordance with IS:3043 and Indian Electricity Rules/Acts. embedded in concrete inside the buildings to which all the electrical equipment.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 Conductor Material The earthing system conductors and accessories as proposed are to be as follows : (a) Conductors above ground level : Galvanised steel and in trenches Conductors buried in ground or : Mild Steel embedded in concrete Electrodes : GS Pipe / Rod (b) (c) (d) Lightning protection air termination : GS Flat and down conductors for buildings Exposed lightning protection air : Lead coated copper termination on chimney top (e) The Contractor shall undertake the soil resistivity measurements at site and select suitable type and cross section of conductors. NO. SECTION: D3. metallic structures are connected to have earth continuity for safety reasons.5. TCE.1.1. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC. 329 R5 .1 Design Criteria Fault Current & Duration The earthing conductor shall be designed for 50 kA for duration of 1 second. (c) Equipment Earthing Leads The size of the earthing leads shall be decided based on the type of equipment and structure to be earthed and shall be provided generally as per IS-3043.2 TCE FORM NO. However the min. General (a) Metallic frames of all current carrying equipment. Electrodes installed in the test pits will have disconnecting facilities.12 mm/year.0 7.1 Earthing System Layout The earthing system design and installation shall generally comply with IS-3043. IEEE-80 and Indian Electricity Rules. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. TCE. For test pits electrodes shall be heavy duty type (Class – C) GI pipe of suitable diameter with perforations. mm 8. lightning ISSUE R0 276 17.2 17.5 3.2.0 1. Resistivity of Soil Ohm– Metric >0 <10 >10 <25 >25 <50 >50 <75 >75 <100 >100 Reduction in thickness/diameter. size of the of equipment earthing lead shall be 65x10 mm GS flat. (d) Conductors for lightning protection system The size of conductors for lightning protection system shall be decided based on mechanical strength.0 5.5960A-H-500-001 The calculated size shall be suitably (depending on the resistivity of soil) increased as per table below to account for the loss of material (steel) due to corrosion in soil.2. 17.5 The minimum steel corrosion shall be 0. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC.17 SHEET 2 OF 7 1X 700 MW CCPP AT NEDUNOOR. supporting structures adjacent to current carrying conductors. 329 R5 . (b) Rod Electrodes Galvanised steel rod electrodes of suitable diameter (min dia 40mm) and length shall be used as per the recommendation of IS-3043. SECTION: D3.5 4. . number of parallel conductors. Metallic sheaths/screens.3 Earthing Conductor Layout in Switchyard (a) Main earthing conductors shall be laid in the form of a grid. KARIMNAGAR DIST.17 SHEET 3 OF 7 1X 700 MW CCPP AT NEDUNOOR. If the rated voltage is 250V or below. The earth pipe electrodes shall be further interconnected to the buried earth grid. metallic stairs. etc. treated pipe earth electrodes. (c) (d) (e) 17. Neutral of the auxiliary transformers shall be directly connected to two nos. metal pipes and conduits shall also be effectively earthed at two points. All cable trays in the plant buildings as well as inside the trenches shall be connected to earth grid at an interval of about 10 m. TCE. 329 R5 . ISSUE R0 277 TCE FORM NO. Every alternate post of the switchyard fence shall be connected to earthing grid by one GS flat and gates by flexible lead to the earthed post. The earth pipe electrodes shall be further interconnected to the buried earth grid. Each side of the generator neutral earthing resistor shall be terminated at two nos. tracks. treated pipe earth electrodes. Crane rails. Spacing between conductors. Metallic Sheaths and armour of single core cables shall be earthed at switchgear end only unless otherwise instructed by the Owner.2. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC. Steel RCC columns. NO. Metallic structures adjacent to electrical equipment shall be earthed by one earthing lead. one earth lead shall be provided. SECTION: D3. Two earthing leads shall be used if rated voltage of equipment is above 250V.5960A-H-500-001 protection system conductors and neutral points of various systems shall be connected to a single earthing system. and armour of multi-core cables shall be earthed at both ends.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. and rails etc. appliances and welding equipment shall be earthed by flexible insulated cable (b) Earthing conductors in outdoor areas shall be installed at a minimum depth of 600 mm. Portable tools. shall be decided such that step and touch potential are within safe limits. of the building housing electrical equipment shall be connected to the nearby earthing grid conductor by one earthing ensured by bonding the different sections of hand rails and metallic stairs. All earth electrodes in turn shall be connected to station earthing system. Earthing grid design shall be done in such a manner that the grid resistance is less than 0. The earth grids of different areas of the plant shall be interconnected through separate conductors & with 2 Nos. steel pipes / conduits. Floor earthing grids shall be interconnected. TCE.4 Earthing Conductors Inside Building (a) Main earthing conductors shall be buried in earth around the building. each floor shall be provided with earth grid. shall not be used as earth continuity conductors. test pits. given in IEEE-80. An earthing mat comprising closely spaced (about 150 mm) conductors shall be provided below the operating handles of disconnecting switches and breaker operating kiosk for the additional safety of the operating personnel.5 ohm. the building has more than one floor. Minimum two taps-off from this earthing loop shall be taken inside the building and connected to the earthing grid embedded in the floor slab with approximately 50 mm concrete cover.17 SHEET 4 OF 7 1X 700 MW CCPP AT NEDUNOOR. This shall be connected to the switchyard earthing grid. steel columns.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.. KARIMNAGAR DIST.2. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC. test pits to enable measurement of earth resistance for each area separately. (b) (c) (d) ISSUE R0 278 TCE FORM NO.5960A-H-500-001 (b) The maximum permissible step and touch potentials shall be calculated in accordance with the formula. with treated earth pits. Each RCC / Steel column of the building shall be interconnected to the floor earthing grid in the ground floor. 329 R5 . SECTION: D3. NO. Each earth leads of transformer neutral. Lightning protection down conductor shall be directly connected to a separate earth electrode. etc. Cable trays. Earthing conductors shall be provided around the outside edge of fence at a distance of approximately 6000 mm. (c) (d) (e) (f) 17. CVT’s earth leads shall be directly connected to two separate electrodes. In case. lightning arrester earth leads. 5 ohm. KARIMNAGAR DIST. etc. operating handles. Flexible earth conductors shall be provided at expansion joints for earthing the gates..3. the welds shall be treated with zinc chromate primer and coated with zinc rich paint. When earth conductor passes through floors.7 17.3. Earthing grid design shall be done in such a manner that the grid resistance is less than 0. Equipment bolted connection after being checked and tested shall be painted with anti-corrosive paint / compound.3. SECTION: D3. ISSUE R0 279 17. The connection between earthing pads / terminal to the earth grid shall be made short and direct and shall be free from kinks & splices.3 17.. Connection between the equipment earth lead and the grid conductor shall be welded. Earthing conductor running exposed on column. walls.3. TCE.3. walls.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC.3.3. The earthing conductor crossing the road / track shall be laid in hume pipe or laid at a greater depth to avoid damage. etc. 329 R5 . suitable pipe sleeves shall be provided and the same shall sealed after installation.5960A-H-500-001 (e) Instrumentation system and computer system shall be provided with a dedicated earthing system suitable for the equipment and shall confirm to DCS manufacturer’s specification. (f) (g) 17.3. Street lightning poles. at intervals of 750 mm. outdoor yards shall be interconnected to form a single grid for the plant.6 17. Earthing grids of all the buildings.3 17. etc.10 TCE FORM NO. For rust protection.17 SHEET 5 OF 7 1X 700 MW CCPP AT NEDUNOOR.5 17.4 17.9 17. This earth conductor shall be in turn connected to earth grid at two extreme points. flood light poles & towers.3.3.2 17. shall be supported by suitable cleating.1 Earthing System Installation The spacing between two electrodes shall be atleast equivalent to twice the length of the electrode.8 17. their junction boxes shall be connected to the earthing conductor to be run along with supply cable. Metallic conduits and pipes shall not be used as earth continuity conductor. NO. shall be provided with lightning protection. screens armour shall be earthed at both ends for multi-core cables. NO. of lightning mast etc shall be furnished for approval of Owner. Lightning masts shall be provided for switchyard.3.14 17.17 SHEET 6 OF 7 1X 700 MW CCPP AT NEDUNOOR. 329 R5 .3. SECTION: D3. Lightning Protection System Lightning protection system shall consist of vertical air termination rods. no. Alternate switchyard fence posts shall be connected to the earth grid.1 Need for Protection The need for providing the lightning protection system shall be established by calculating risk index value for each building structure. air termination system will comprise of horizontal circumferential conductors at the top.4. Calculation for sizing. test links and pipe electrodes.2 Lightning Protection System Layout (a) The lightning systems design and installation shall generally comply with IS: 2309 code of practice for the protection of building and allied structure against lightning. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE. etc. All bimetallic connections shall be treated with suitable compound to prevent moisture ingression.5960A-H-500-001 17. down comers. Shield wire shall be provided between gantry support & Power house building wall over phase conductors and shielding ISSUE R0 280 (b) (c) (d) TCE FORM NO.4. horizontal roof conductors. rods interconnected by circumferential conductors will be provided at the apex of flue and also upon outer shell of the stack. The air termination system will be formed by lead coated copper conductors to prevent corrosion of conductors due to flue gas.4 17.13 17.11 The cable sheaths.. For cooling towers. For single core cables the same shall be done at one end (switchgear end) only. step and touch potential at different location.3.12 17. For stack air termination. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC. Contractor shall demonstrate the effectiveness of earthing system by measurement of earth resistance.3. as per procedure given in IS-2309 and any building whose over all risk factor is more than 10-5 (as per IS-2309). 17. 17. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC. SECTION: D3. All joints in the down conductors shall be welded type. KARIMNAGAR DIST. the weld locations shall be treated to provide rust protection. NO. 329 R5 . (b) (c) (d) ISSUE R0 281 TCE FORM NO.5960A-H-500-001 network shall be connected to switchyard earth mat.4. Wherever welded. Each down conductor shall be provided with a test link at a height of about 1000 mm above ground level. The down conductors shall be welded to steel structures at 1000 mm interval or cleated to wall at 750 mm interval.3 Lightning Protection System Installation (a) Conductors of lightning protection system shall not be connected with conductors of safety earthing system above ground level. The zone of coverage for the shield wires and 450 on end conductor shall be considered as 600 between two conductors.17 SHEET 7 OF 7 1X 700 MW CCPP AT NEDUNOOR. 17. TCE. (e) Down conductors shall be as short and straight as practicable and shall follow a direct path to earth electrode. Each down conductor shall be connected to a rod electrode which in turn shall be connected to the station earthing system through test links. All the metallic structures within a vicinity of 2000 mm shall be connected to the lightning protection conductors.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. For switchyard down conductors from the shield wires shall be run along the tower and connected to rod / electrode. 1. One spare port for operator console shall be provided. The system shall have 100% non-blocking feature. 329 R5 . Operator console shall be equipped with a PC with tracking provision for all calls. housed in a weatherproof enclosure. fully integrated. KARIMNAGAR DIST. modularly expandable digital electronics EPABX system with capacity of 600 ports extendable to 800 ports shall be supplied.0 18. The system shall be based on Pulse Code Modulation (PCM)/Time Division Multiplexing (TDM). Electronic cards with intelligent processors shall be provided. and the special feature telephones. The system shall be 100% fault tolerant. call times etc. The cable from P&T exchange to power plant EPBAX shall be included in the contractor’s scope. (b) (c) ISSUE R0 282 TCE FORM NO. Additionally two cables of 50 pairs each shall be laid from the plant EPABX system to the colony utility building as mentioned in the section C2. It should have computer (PC) compatibility for data transmission. digital (key) telephone instruments. Redundancy for control and processor card shall be provided.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. fully non-blocking principle. These cables shall be laid in the suitable conduits.18 SHEET 1 OF 15 1X 700 MW CCPP AT NEDUNOOR. TCE. which shall include 20 direct lines. modular construction type.1 18. The system shall be equipped with necessary electronic cards for trunk lines and extension lines. NO. The system shall have compatibility for analogue telephone instruments. This EPABX shall be hooked to P&T system by 40 tie lines. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. The quantity of the trunk cards and extension cards shall be selected in such a way so as to provide 10% spare capacity. SECTION: D3.1 COMMUNICATION SYSTEM Intrasite Communication System Intercom Telephone System (EPABX System) (a) Micro-processor based. The entire job shall be the scope of Bidder. and PC shall have provision to come over office automation LAN. The system shall be supplied with the operator console as an in-built feature. These direct lines will be for the use of management cadre & control room staff for direct communication with P&T subscriber without operator intervention. suitable for mounting in a non-air-conditioned area. The state of the art technology shall be used for designing the system.5960A-H-500-001 18. (e) (ii) (iii) (iv) (v) (vi) (f) Call Billing software shall be provided with dedicated personal computer with SVGA colour monitor. Using this software. date of each call.18 SHEET 2 OF 15 1X 700 MW CCPP AT NEDUNOOR. dedicated printer. Dual Tone Multi-Frequency (DTMF) Connectivity. Two (2) dial testers for DC pulsing and DTMF telephone instruments.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. Three (3) line man hand held telephone sets with DC pulsing and DTMF switchable with built in ringer unit and crocodile clip. Besides the above. called station. EPABX system shall be provided with the following: (i) One (1) 48V DC High Discharge Plante Lead Acid battery of adequate AH capacity with 10% margin suitable for twelve (12) hours uninterrupted service of exchange working at 100% capacity including its allied systems. The system shall be so interconnected that it shall be possible to access any of the systems (Intercom/ Wireless) from any other system without human intervention in any way. number of metered calls. extension/wireless/fax set from which call was made. One (1) float-cum-boost charger of suitable capacity to supply power to the exchange. software and any / all other accessories) for Integrated Digital Network (ISDN). Computer (Local Area Network) LAN & Wide Area Network (WAN). SECTION: D3. pager/wireless set with number called. The call billing software shall ISSUE R0 283 TCE FORM NO. Required number of telephone instruments. NO. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. FAX as well as connectivity to Wireless System specified in this section. One (1) operator console.5960A-H-500-001 (d) The EPABX system shall have connectivity (hardware. TCE. time at which each call was made. The battery charger shall be suitable for the High Discharge Plante Lead Acid battery specified above. the EPABX shall be provided with two Combo drives with provision and facility including software to store/retrieve all the above parameters to/from a disk. 329 R5 . duration of each call. it shall be possible to read from screen/obtain a print out of calls made. 5960A-H-500-001 also have facility for printing all / selected parameters listed above at regular (site adjustable) time intervals as well as facility to browse on screen/print any of the above parameters in any desired format eg. besides being annunciated by high intensity LED on the EPABX and audio alarm. The Bidder shall provide all the telephone instruments in the plant areas at each working areas. shall be displayed on the PC with component level fault being displayed in English. standby unit shall automatically cut-in. Changeover time shall not affect the EPABX/its allied systems in any way.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. All above parameters shall be capable of being stored automatically for a minimum period of 3 months. The type of handset shall be selected based on its location. But the Bidder shall supply at least 200 telephone instruments.18 SHEET 3 OF 15 1X 700 MW CCPP AT NEDUNOOR. TCE. The EPABX shall be provided with 120% capacity main power supply unit with 100% standby power supply unit. The EPABX system shall be capable to accommodate the EPABX system of the colony (which is not in scope of Bidder). ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. 329 R5 . Erasure of this information shall only be after adequate warning alerting operator to take back up. All desk type instruments for all subscribers shall have keypad with push buttons. Number of calls made from a particular extension for a given period of time (selectable). (h) (i) (j) (k) (ii) ISSUE R0 284 TCE FORM NO. Annunciation (audio and visual) shall be provided for each power supply unit fail and also auto-changeover fail. Telephone Instruments (i) The telephone instruments shall be indoor desk type or indoor wall mounted type or outdoor wall mounted type as required. The locations shall be decided during detailed engineering. SECTION: D3. All faults. On failure of main unit. Software lock shall be provided to prevent unauthorised personnel gaining entry to above. KARIMNAGAR DIST. (g) EPABX shall have full self-diagnostic feature. It shall have provision of 100 lines for interfacing with colony. NO. None of the stored data shall be lost for failure of power supply. Emergency alert – Dialling a number shall intimate a fire or emergency alarm. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. SECTION: D3. calling party can use his telephone for other calls as usual.5960A-H-500-001 (iii) The instruments mounted outdoor shall be provided with weather proof type enclosure. if engaged tone is received. the caller can cut into the conversation by pressing the priority service button. The caller’s number shall be stored to reduce / prevent the incidence of mischievous calls.This feature shall re-route a call for an extension (A) to extension (B).2 Cell phones with group arrangement to be provided. KARIMNAGAR DIST. Telephone instruments located in high ambient noise level area shall be provided with loud ringing device and sound proof booths.This shall enable the subscribers to set up telephonic conference involving atleast 5 parties. TCE. (ii) (iii) (iv) (v) (m) 18. Conference call . While waiting for the call back. Landline Telephones. 329 R5 . Automatic call back – This shall enable the selected subscribers.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. who receive a busy tone when calling another extension to come on the busy extension. After dialling from this handset station.18 SHEET 4 OF 15 1X 700 MW CCPP AT NEDUNOOR. This arrangement shall function for all calls till it is reset. (iv) (v) (l) The following special features shall be provided on selected instruments: (i) Call interruption / priority – the handsets shall be provided with a priority push button. Selected instruments shall be provided with additional features to meet the special facility requirements as mentioned below. The call back equipment shall make the connection as soon as the called extension is free.1. Broadband connectivity ISSUE R0 285 TCE FORM NO. Automatic call diversion . NO. 18. 329 R5 . ISSUE R0 286 TCE FORM NO. SECTION: D3. voltage stabilisers and all other accessories. Twenty (20) Nos. to allow the radio communications during “Black Out” conditions also.18 SHEET 5 OF 15 1X 700 MW CCPP AT NEDUNOOR.1. KARIMNAGAR DIST. The mobile system shall be interfaced with plant EPBX and PA systems. But the contractor shall consider the modern communications system with above specifications for the purpose of bidding. inverters.3. NO.3 Walkie Talkie( Wireless system) 18. The system shall have a minimum operating range of 15 kms between one base station to another base station. The power supply to the entire base stations shall be through the UPS. installation design and specifications shall be worked out during detailed engineering. The exact details of requirements. The mobile system coverage in the power plant area should be 100%. Battery charger for hand-set batteries – 20 Nos.1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 GPRS/CDMA mobile system of any reputed service provider can be provided for wireless system. Broadband connectivity would be provided at strategic locations for online access of data from remote station. power supply units.1 This system shall include the following: (a) Base stations with antennae. hand held two way transmitter receiver sets. The system shall be capable of being coupled with the EPABX and PA systems such that any wireless set can be contacted from any of the EPABX-intercom extensions or PA system and from the DTMF keypad of the portable radios it should be possible to contact any of the EPABX – intercom number through the EPABX. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. The wireless sets shall be addressable type and light weight. TCE. (b) (c) (d) (e) (f) (g) (h) 18. Handset to handset is about 3 kms.1.3.5960A-H-500-001 a) Necessary number of ISDN / PSTN landlines would be provided at strategic locations within the plant boundary. Range from base station to handset is about 8 kms. design.5 Tests All the equipment covered in this specification shall be subjected to routine tests as per relevant standards. nut-bolts. conduit sleeves.2. KARIMNAGAR DIST. taking into consideration the configuration of the combined cycle plant. glands. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. lugs.9 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 18. accessories and facilities required for completeness of this system shall be furnished by the Contractor.1.2 18. The zones shall also cover all off-site Plant Auxiliary Systems and shall be finalized during detailed engineering.5960A-H-500-001 18.1 Public Address System General Requirements This specification covers requirements for selection. erection and commissioning of Public Address System as described below: (a) The Public Address System shall consist of zones.1. 329 R5 . (b) (c) ISSUE R0 287 TCE FORM NO.5. sub-zones and Exchanges to interface all these zones among them selves. whether these are specifically mentioned herein or not. to complete the proper installation conforming to IS: 1881. SECTION: D3. etc.4 Cables The type of cables and their technical particulars shall be as per the requirement of the system for giving best performance. All equipment. as required.. NO. 18.18 SHEET 6 OF 15 1X 700 MW CCPP AT NEDUNOOR. IS: 1882 of all the equipments supplied as covered in this specification. engineering. junction boxes. All the above-mentioned zones shall be connected with a central exchange to be located in Control room/ Control Equipment Room. earth wire and accessories like standard brackets. shop testing. The Contractor’s scope shall also include successful demonstration of performance testing specified herein complete in all respects along with cables. type testing. manufacture. TCE. Type test certificates shall be submitted for review. SECTION: D3. 329 R5 . 18.2 Power supply arrangement The Bidder shall provide power to the Public Address System from UPS system as detailed in Section D3. including Public Address system erection hardware. NO.18 SHEET 7 OF 15 1X 700 MW CCPP AT NEDUNOOR. cables.90. (e) (f) (g) (h) (i) 18. tested and commissioned a distributed amplifier type industrial Public Address systems as specified in power plants or large industrial installation as on the date of bid opening. In case the Bidder's offered equipment is operating at any other voltage level.14 of technical specifications. The system shall be adequately protected from signal and power line noise and meet the Surge Withstand Capability (SWC) requirements of ANSI C37. The system shall be fully functional during the total power supply failure of the plant. telephone cables etc.1/ IEEE standard 472-1989 equivalent. In addition to the facilities to be provided by the Bidder as mentioned in relevant clauses of this section the Bidder shall make his own arrangements for any other requirements that are necessary to put the system in service. the Bidder shall provide all required hardware. The Public Address System (PAS) offered by the Bidder shall be from reputed manufacturer who should have designed.2.3 System description (a) Communication within a zone ISSUE R0 288 TCE FORM NO. TCE.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. cable erection hardware. to make the offered system compatible with specified power supply arrangement. All the items. manufactured. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC.2. The details shall be finalized during detailed engineering stage. KARIMNAGAR DIST.5960A-H-500-001 (d) The equipment furnished under this section shall meet the requirements of all-applicable codes and standards as specified or their equivalent international codes and standards. The Bidder shall guarantee satisfactory performance of the equipment under stipulated variations of voltage and frequency. as may be required to make the PA system complete and functional are to be furnished by the Contractor on as required basis. The design and manufacture shall be such that equipments/ components of same type and rating shall be interchangeable. ISSUE R0 289 (ii) (iii) (iv) TCE FORM NO. i.18 SHEET 8 OF 15 1X 700 MW CCPP AT NEDUNOOR. the associated handset shall return to party mode. common talking type. Whenever the 'Press to page' push button is pressed on any of the handset stations.e. Party mode shall be used for conversation between individuals without broadcasting the same over the loudspeaker. 329 R5 . When 'Press to Page' push button is released. etc. Each of the two modes shall be open line. the centralized equipment/hardware of the associated zone shall have the feature to monitor and identify the handset from where conversation is being continued with the 'page' button depressed and the access code of the person. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. During conversation on 'page' mode within a zone. should he find it disturbing his conversation on party mode.. When a handset station is being used for party mode. its associated loudspeaker shall be free to receive all paging calls. Simultaneous operation on both modes. announcements/ communication within a zone shall not be audible in other zones. TCE. i. Unless requested. NO. SECTION: D3. The locations (distributed in each zone) etc. Necessary sockets. wiring. Portable type handsets with Multipin plugs shall be used at certain locations where operational personnel are not present normally. Paging mode shall be used for locating a person and for general instructions. However. shall be possible without any crosswalk between the two channels..5960A-H-500-001 (i) PAS shall have two modes. The loudspeaker shall return to normal operation automatically when the 'loudspeaker mute' push button is released. KARIMNAGAR DIST. in paging mode shall be heard over all loudspeakers except the loudspeaker associated with the handset station whose 'Press to Page' push button is being held in pressed condition. Conversation. shall be finalized during detailed engineering. some handsets on party channel and some handsets on paging channel. a pleasant chime shall be broadcast over all loudspeakers except the one associated with that handset station to attract attention. Further. Paging mode and Party mode. shall be provided at these locations.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. the operator shall have the option of silencing the associated loudspeaker by pressing "Loudspeaker mute' push button.e. suitable indication of 'Power Supply on' and 'Party channel busy' shall be provided on hand set stations. B) ISSUE R0 290 TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. both in party/ page mode through the master control units located on each module control desk at Control room and Shift Incharge Room.A) Indoor desk-top mounting type. it shall be possible to broadcast recorded speech. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. KARIMNAGAR DIST. The Central Exchange shall have one master control unit for each of the modules and one more master control unit for Shift In charge Room. All the master control units shall be connected in parallel. It shall be possible from a station in one zone to communicate with another station in a different zone. SECTION: D3. (ii) (iii) (iv) (v) 18.18 SHEET 9 OF 15 1X 700 MW CCPP AT NEDUNOOR. It shall be possible to communicate from a station in one zone to another station in other zone through the master control unit(s) only.4 Handset Stations (a) Handset stations shall be of the following types: (i) (ii) Outdoor Wall/ column mounting type. Communication/ announcements within a zone shall not be heard in loudspeakers of other zones.2. music etc. Further. Any inter-zone communication shall be possible through this master control unit. 329 R5 . TCE. over the loudspeakers. (Type . NO. All the communication facilities like paging and party mode communication as described above between these two zones shall be possible as if they have now become a single zone. Suitable built-in interface shall be provided for connection with Owner's main telephone exchange in the Central Exchange and/or Master Control Units through which it shall be possible to communicate with any station in any zone from any telephone set through Central Exchange and/or Master Control Unit.(Type . The exact type of the same shall be decided during detailed engineering.5960A-H-500-001 (b) Inter Zone Communication (i) Each of the zones shall be connected to a Central exchange to be located in Central Control room/ Control Equipment Room. NO. KARIMNAGAR DIST. Indication for 'PARTY CHANNEL BUSY'. One (1) . SECTION: D3. rust resistant. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. Handset transmitter/ microphone shall be noise canceling type and all switches and push buttons provided on the handset station shall be of encapsulated contact type. The control-desk mounting type handset stations shall be suitable for flush mounting on Unit Control desk. All handset stations and their components shall be capable of continued satisfactory operation at an ambient temperature at 55°C. One (1) . (Type ."Press to Page" push button.telephone handset. Each handset shall be provided with one meter (extended) retractable coiled type of cable. The outdoor wall/ column mounting type handset stations shall have covers with padlocking facility. (c) The outdoor wall/ column mounting type handset stations shall be dust-tight and weather-proof. 329 R5 . with appropriate protection against direct rain.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. One (1) -"Press to Mute Loudspeaker" push button. ingress of dust and moisture conforming to IP-55 degree of protection as per IS: 2147.5960A-H-500-001 (iii) (iv) (b) Indoor control desk flush mounting type. TCE.D) Each handset station shall have following: (i) (ii) (iii) (iv) (v) (vi) (vii) One (1) .C) Mosaic grid compatible telephone set.18 SHEET 10 OF 15 1X 700 MW CCPP AT NEDUNOOR. The indoor desk-top mounting type handset stations shall have a degree of protection of at least IP-32. All handset stations shall have a compact. Indication for 'POWER SUPPLY ON'. shock-resistant body made of high impact polystyrene or ISSUE R0 291 (d) (e) (f) TCE FORM NO. (Type . Handset transmitter/microphone shall have filters to protect from dust. Pre-amplifier and Power amplifier. robust.Cradle switch for resetting the handset. floor mounted hood shall be used for providing the above requirements. using internal anchoring bolts and peculiar (e. BFPs. Amplifiers shall have 0-100% volume control setting.2. in built with the handset fully conforming to IS: 1301 & IS: 10426 or equivalent international standard.18 SHEET 11 OF 15 1X 700 MW CCPP AT NEDUNOOR. 329 R5 .. which can be opened through number padlock only. (h) 18. triangular head. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. with facility for coarse and fine setting along with following controls which shall be located inside the Handset Station. TCE. The Type-A handset shall be inside an enclosure with transparent glass door. (i) (ii) (iii) (iv) Input sensitivity control Receiver volume control Bass cut filter Anti side tone control feature (b) 18. The cabinet shall be ISSUE R0 292 TCE FORM NO.5 Amplifiers (a) Amplifiers shall be solid state. shall be housed in Acoustic hoods. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. The handset stations in the noisy areas like Turbine Hall. counter-sunk) screws which can be loosened only with special keys.2.5960A-H-500-001 equivalent.g. Constructions where the entire electronic part shall be modular type and can be removed from the handset station enclosure for easy maintenance. Terminal connections of different PCBs should not be interchangeable. etc. Push-pull type. (g) The wall/column mounting handset stations shall be tamper-proof.6 Loudspeakers (a) Indoor loudspeakers shall be cone type housed in sturdy metal cabinet suitable for wall/ column mounting. SECTION: D3. The design noise level within the hood shall be limited to a maximum of 60 dB SIL. class-B. An industrial type free standing. NO. fire alarm tone generation etc. required for operation. Also. testing.7 Central exchange & master control unit (a) Central exchange shall be wide band microprocessor based having associated circuitry for calling station identification and of modular design. all the programming tools that will be required to program/reprogram the system shall also be provided. Suitable hardware for communication between any handset of the Public Address System with Owner's Telephone Exchange shall be provided. All the central exchange shall be enclosed in a freestanding cabinet to be located in control equipment room all the cable entries shall be from bottom only. This exchange shall consist of all the necessary control hardware. measurement of all the voltages and load conditions of the entire system. luminous miniature push buttons for inter-zone communications. Solderless termination shall be provided for every wiring. All the card etc. 18. The mounting bracket shall be with adjustable base suitable for vertical and horizontal orientation. (b) ISSUE R0 293 TCE FORM NO. alarm tone generation. Further. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. TCE. (b) Outdoor loudspeakers shall be industrial horn type and of pressure die cast aluminum construction. indication. They shall have IP-55 degree of protection as per IS: 2147. protection.2. 329 R5 . shall be plug in type. This shall be able to cater all the specified zones along with the ability to interconnect at least ten (10) more zones for future expansion.5960A-H-500-001 treated with acoustic under-coats to prevent resonance. All the handsets shall have the necessary arrangement for using it as a intercom telephone instrument.18 SHEET 12 OF 15 1X 700 MW CCPP AT NEDUNOOR. NO. Systems bandwidth shall be at least 200-10 kHz (±10 dB) and shall not alter frequency response of the open line system. it shall be possible to announce any message from any intercom phone and then communicate with the handset selected by field user on party line. monitoring. They shall have IP-52 degree of protection as per IS: 2147. It shall be possible to call to any of the intercom number from any handset.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. switching. facility for checking of the operation of all the stations and quality of speech from the master control units etc. Master Control Units shall be microprocessor based and of modular design. SECTION: D3. These units shall be mosaic grid compatible flush mountable type along with flexible goose neck type microphone. 5 mm² cross section annealed copper (shielded and armoured) b. twisted pair.10 Technical particulars Public Address Systems shall conform to the following technical parameters. KARIMNAGAR DIST. minimum 0.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Colour of the outer sheath shall be YELLOW. SECTION: D3. twisted pair. (i) Overall Installation Band width (± 3 db) (ii) Amplifiers (a) (b) Band width (± 3 db) THD 200-10000 Hz not more than 1 % at 1 kHZ at rated output 60 dB 400-6000 Hz (c) Signal to Noise Ratio (iii) Microphones ISSUE R0 294 TCE FORM NO. Loud Speaker cable 18.2. 329 R5 . NO. TCE.9 Junction boxes The junction boxes shall be supplied on as required basis. minimum 0.5mm² cross-section Copper conductor cable armoured with atleast two spare cores. Sizes and details of cables are given below : a. 18.18 SHEET 13 OF 15 1X 700 MW CCPP AT NEDUNOOR. : Multicore multistrand with at least two spare cores.2. Mains cable : Multicore of minimum 1.2. The cables shall be of FRLS type. Signal cable c.5 mm² cross section annealed copper (shielded and armoured) : Multicore multistrand with at least two spare cores.8 Cables and junction boxes The Contractor shall supply the cables required for PA system on as required basis.5960A-H-500-001 18. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. Handset Stations (i) (ii) Outdoor wall/column 30 mounting type . (nos. NO.(nos. Loudspeakers (i) Outdoor Industrial Horn type . 329 R5 .(nos.5960A-H-500-001 (a) (b) Band width (±3 db) Type 200-7000 Hz Noise canceling type (iv) Loudspeakers (a) Outdoor wall/column mounted Horn Type Capacity Bandwidth(± 3 db) Indoor wall/column mounted Cone Type Capacity Bandwidth (± 3 dB) 4W (RMS) 200-7000 Hz 15W (RMS) 200-7000 Hz (i) (ii) (b) (i) (ii) 18.) Indoor desktop mounting type with extension amplifier.) 10 3 (iii) 2 2. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC.2.No Item Description PAS For Common Plant (for each module) -------------------------------------------------------------------------------------------------1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.) Indoor control desk 2 mounting type with extension amplifier.18 SHEET 14 OF 15 1X 700 MW CCPP AT NEDUNOOR.(nos. ----------------------------------------------------------------------------------------------S. KARIMNAGAR DIST. TCE. SECTION: D3.) 30 10 ISSUE R0 295 TCE FORM NO..11 The quantities for PA system mentioned below are minimum required and will be finalised at the time of detailed engineering. G. ISSUE R0 296 TCE FORM NO.) Master Control Unit 8 1 9. Rigid conduit on as required – As Required (Sizes to suit the cable) Acoustic hood (nos.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. 10.5960A-H-500-001 (ii) Indoor wall mounted Cone type.) Portable handset stations with plug (nos. only.(km).(nos.18 SHEET 15 OF 15 1X 700 MW CCPP AT NEDUNOOR. for interconnection of loud speaker with handset station. TCE. SECTION: D3.As required Signal cable . NO. 7. Cables (i) (ii) (iii) Mains cable . 8.(km) As required Loudspeaker Cable-(km). 10 2 5. KARIMNAGAR DIST.I. earthling wire-(km) As required Junction boxes – As required G.I.) 2 4. 329 R5 . As required 6.) 2 3 3. Mosaic grid compatible telephone set Portable handset stations with multi-pin plug and sockets (i) (ii) Sockets-(nos. National Fire Protection Association (NFPA).2. Underwriters Laboratory (UL). junction boxes.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. any other items to complete the system shall be provided for the power plant.19 1X 700 MW CCPP AT NEDUNOOR.5 Rate of rise of temperature detector with fixed temperature element (corrosion proof) and MCPs ISSUE R0 297 TCE FORM NO.72E IS . Fire alarm system shall be designed to provide continuous surveillance against fire in the areas covered by the system under all conditions. Fire detectors shall discriminate between false and real fire. Fire detection and alarm system comprising automatic fire detectors. fire warning siren. Battery charger room Control & electronic Cubicle rooms Battery room Type of Detector Manual call points (MCP) & UV detectors Multi sensor detector & MCPs 19. analogue addressable type. 329 R5 . TCE. The type of detectors to be provided in the various areas of the plant shall be as indicated below: Area GTG / STG Building Switchgear room. ELECTRICAL SYSTEMS FIRE DETECTION AND ALARM SYSTEM SHEET 1 OF 5 SPEC.2189 NFPA . SECTION: D3. Dhanbad. manual call points. Factory Mutual (FM). cables. Fire Officer’s Committee (FOC). fire alarm panel.2175 The system shall be approved by any or all the following bodies besides Tariff Advisory Committee (TAC) and Local Fire Authorities. KARIMNAGAR DIST.3 19.4 19.1 FIRE DETECTION AND ALARM SYSTEM Fire Detection and alarm system shall be redundant Microprocessor based intelligent. It shall have automatic calibrating features by decreasing/ increasing sensitivity levels.2 19. Central Mining Research Institute (CMRI).3 19.5960A-H-500-001 19.2 19.2. The equipment/system supplied shall comply with the standards listed below: IS . NO.0 19.2.1 19. It shall give a pre-alarm when it requires maintenance. 9 19. Element These shall be resettable type i.e. The Sensor cable shall be Optical fibre LHS cables.2 19. To meet this requirement the detector shall respond to visible combustion products in the form of smoke as well as in visible particles. aerosols and pyrolysis products from a clear burning fire.9.1 Linear Heat Detection System (LHS) Linear heat detection system shall be provided in area below false floor & in cable galleries. TCE. the same detector shall be capable of being reset after it goes to the alarm state. SECTION: D3. 329 R5 .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Optical Smoke Detectors Optical smoke detectors shall work on light scattering principle.6 Pedestal mounted MCPs Rate of Rise of Temperature Detector with Fixed Temp.3 ISSUE R0 298 TCE FORM NO.7 19. NO. Linear heat detection system shall essentially comprise sensor cables.1 Multi Sensor Detectors This detector shall be capable of detecting a fire both in its incipient or smouldering stages as well as visible flames.19 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS FIRE DETECTION AND ALARM SYSTEM SHEET 2 OF 5 SPEC.9.8 19. 19.9.7. 19..5960A-H-500-001 Below false floor of Control room Above false ceiling of Control room Cable galleries Photoelectric smoke detector and linear heat sensor cables Multi sensor detectors Photoelectric smoke detectors and liner heat Sensing cables Fuel gas pump house Flame proof type MCPs Transformer yard & switchyard 19. interface units and necessary hardwares required for installation. KARIMNAGAR DIST. 19. 14 19. response indicator for each of the detectors and test switch shall be mounted on a separate box. 35 to 40 sq. SECTION: D3. etc.1 TCE FORM NO.19 1X 700 MW CCPP AT NEDUNOOR.10 19. the actual quantity of detectors required. TCE. Main Fire Alarm Panel Fire alarm system shall be redundant Microprocessor based intelligent.12 19.. If the detectors are mounted above the false ceiling. control room. When the detectors are mounted below the false floor or in inaccessible position. Each detector shall be provided with an indicating lamp glowing steadily to indicate that it has operated which will otherwise flash intermittently to indicate the healthy condition of the detector and sensing circuits.5960A-H-500-001 19. interface units wherever required for various control functions through relay contacts & communication ISSUE R0 299 19.m per smoke detector for general application areas considering an average room height of 5.. in view of value concentration. 329 R5 . response indicators with test switch shall be mounted directly below the detector (on the false roof). The quantity of fire detectors and call points to be installed in each of the areas shall be based on an average coverage area mentioned below.1 19. analogue addressable type. external hooter/lamp control.13 19. NO.9.15.10. The zones of individual detectors shall overlap and no blind zone shall be left.15 19. KARIMNAGAR DIST. Manual call points shall be provided as per the guidelines listed in NFPA 72E/IS 2189. Contractor shall prepare layout drawings indicating the locations of detectors.4 Linear heat sensor cables shall be run on all the trays below the false floor of the control room. so as to obtain complete coverage.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. However.10. relay room. they shall generally be located near all the entrances/exists for all buildings.5m. manual call points duly taking into account the regulations of local fire authorities and submit for Owner’s approval. Also. which shall be suitable for mounting on the wall.m per detector for I&C panel room. The sensor cables in cable vault end shall be supported from ceiling to cover the top most tray and from underside of the cable trays for bottom tiers.11 19. taking into consideration the obstruction due to floor beams.2 19. shall be complete with annunciator (with windows) provided with necessary input modules. etc. ELECTRICAL SYSTEMS FIRE DETECTION AND ALARM SYSTEM SHEET 3 OF 5 SPEC. 15 to 20 sq. shall be worked out by the Contractor based on the final drawings of the various buildings during detailed engineering. output modules. 19. SECTION: D3. I&C panel room. This panel shall be suitably interfaced with the main fire alarm panel in power plant control room.3 Necessary grouping of the detectors/call points to actuate the above shall be done by the contractor and the same shall be subject to Owner’s approval.5 19. NO. Full load being defined as the load of all hooters sounding simultaneously along with operation of all the associated visual signals. etc. Necessary interface shall be provided between the fire alarm panel and plant DCS for monitoring the system. reset.4 Contacts for initiating fire protection system. with acknowledge. after which sufficient capacity would still be available to provide full load operation for atleast 30 minutes. switchgear room. The detectors proposed to be provided for 400kV switchyard area shall be connected to an independent fire alarm panel (with battery back-up) located in Switchyard control room. The panel shall have 'ON / OFF' PBs for operation of fire siren. 329 R5 .15. (a) Tripping of the air conditioning and ventilation system in the . (b) 19. All the constructional/functional features of this panel shall be same as the main fire alarm panel. interlocks etc.2 The main fire alarm panel will continuously monitor the status of the detectors and the connecting lines. 19.19 1X 700 MW CCPP AT NEDUNOOR. The annunciation system shall have visual and audible alarms.GTG hall. push buttons. TCE. The battery shall supply the normal power requirements for a period of 48 hours from the instant of charger AC supply failure. 19. The panel shall be located in the control room.5960A-H-500-001 modules. Main fire alarm panel shall be provided with necessary contacts for performing the following functions.6 ISSUE R0 300 TCE FORM NO. for satisfactory operation of the system. High discharge plante Lead Acid batteries and battery chargers adequate capacity shall be provided. Relay room .Control room. A dedicated operator station shall provide in the Main control room. ELECTRICAL SYSTEMS FIRE DETECTION AND ALARM SYSTEM SHEET 4 OF 5 SPEC. The paint shade of panel shall be shade Opaline green (External) and semi glossy white (Internal).15. battery room&any other area which is air conditioned /forced ventilated of the affected area. etc. test.15.15. STG hall.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.15. KARIMNAGAR DIST. lamp test. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 19.18 19.7 19.8 Visual alarm shall be povided in all the Control rooms.15. All the fire alarm panels in the plant shall be of the same make. SECTION: D3.18. NO.19 19. The cabling upto the repeater panel is included in the Contractor’s scope. offices. 19. All tests required by the relevant standards shall be conducted.1 Cabling The cables shall conform to specification indicated in Section D3. 19.15.19.5960A-H-500-001 19. Degree of protection shall be IP-65. The repeater panel shall be located in the fire station.10 The main fire alarm panel in the control room shall communicate with all the fire alarm provided in the Gas / Steam Turbine area & in any other if any. 329 R5 .15. 19.19.2 ISSUE R0 301 TCE FORM NO.17 Junction Boxes (JB) Junction boxes required for indoor and outdoor installations shall be 2 mm thick sheet steel and shall be hot dip galvanised.9 19. Performance tests shall be conducted at site on the system to prove that the guarantees indicated for the individual components shall completely satisfy all specific requirements. Canteen.1 19.19 1X 700 MW CCPP AT NEDUNOOR.16 Repeater Panel All annunciation / indications in the main fire alarm panel shall be repeated in the repeater panel to be supplied by Contractor. Electronic cubicle room. ELECTRICAL SYSTEMS FIRE DETECTION AND ALARM SYSTEM SHEET 5 OF 5 SPEC.15 Tests Contractor shall furnish test certificates/approval certificates for the equipment/ system offered from the Regulatory bodies indicated in the specification after the award of contract for Owner’s approval. 19. KARIMNAGAR DIST.15. TCE. conference halls and any other place where the sound of the fire siren is not audible. This shall include the annunciations/indications of fire alarm panel located in switchyard control building. Suitable size & number of the sirens shall be used so that is audible in all the direction & parts of the station. The paint shade of panel shall be shade Opaline Green (External) and semi glossy white (Internal). 6 ISSUE R0 302 TCE FORM NO.5 20.1 20. Locked rotor current of motors rated 1500 kW and below shall be limited to 600% inclusive of 20% tolerance of the full load current of the motors and motor rated above 1500 kW shall be limited to 450% (inclusive of 20% tolerance) of full load current of the motor. 50 Hz power supply.3 20. Provision of speed switch shall be avoided to the extent possible.0 20. ELECTRICAL SYSTEMS . Motors shall be capable of starting and accelerating the load with the applicable method of starting without exceeding acceptable winding temperatures when supply voltage is 80% of the rated voltage for HT motors and 85% for LV motors. 40% cyclic duration factor. 3 Phase. All LT motors shall be energy efficient. the pull out torque of the motor shall be atleast 205% of full load torque.20 SHEET 1 OF 10 1X700 MW CCPP AT NEDUNOOR. If such operation is envisaged for a period of one second. The supply voltage and frequency variation for 6. 329 R5 . The locked rotor withstand time under hot condition at 110% rated voltage shall be more than the starting time at minimum permissible voltage specified above by atleast three seconds or 15% of the accelerating time whichever is greater.6 kV & 400 V shall be ±10% and +3/-5% respectively. The motors shall be suitable for starting at 110% of the rated voltage.20.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 20.1 AC Motors The motor and its accessories shall generally comply with the requirements specified in the national and international standards indicated in Data sheetA3.6kV and motors rated upto 175 kW shall be 400 V.MOTORS SPEC.1. KARIMNAGAR DIST. The combined voltage and frequency variation shall be of 10%. 20. Motors shall withstand for 1 second the voltage and torque stresses developed due to the vector difference between the motor residual voltage and the incoming supply voltage equal to 150% of the rated voltage during fast change over of buses. NO.1. Motors shall be capable of developing the rated full load torque even if the supply voltage drops to 70% of the rated voltage. commencing from hot condition.1. HT motors shall also be capable of satisfactory operation at full load at a supply voltage of 80% of the rated voltage for 5 min.1. Also Motors shall additionally comply with the specific requirements of data sheet – A3. crane motors shall be rated for S4 duty. SECTION: D3. 50 Hz and LV motors shall be suitable for 400 V.1. TCE.6 kV.1. Motors shall be continuously rated (S1). However. 3 phase.20 and specific requirements indicated below: All HT motors shall be suitable for 6. The motors rated 175 kW and above shall be 6.2 20.4 20. 6 kV switchgear panel. The maximum double amplitude vibrations for motors upto 1500 rpm shall be 25 microns and 15 microns upto 3000 rpm. 6 nos. Requirements of vibration monitoring system shall be as specified in relevant I&C section of specification. duplex RTDs for winding shall be provided.11 20. 6.6kV & 400V motors wherever their protection is through the numerical relay then energy meter reading shall be taken through relay itself by communicating with it.1.13 ISSUE R0 303 TCE FORM NO. For 6. Each bearing shall be provided with duplex thermocouple for bearing temperature monitoring. The additional 3 nos. SECTION: D3. NO. Motor bearing shall not be subjected to external thrust loads. Maximum noise level measured at a distance of 1. The three phases shall be connected to form the star point after they pass through the CTs. The CTs shall be of relay accuracy and the CT characteristics shall be compatible with the differential relay. TCE. one for each phase shall be mounted in a separate compartment in the neutral side terminal box. 329 R5 .5 metre from the outer surface of the motor shall not exceed 85 db(A). CTs of identical characteristics shall be provided in the 6. For 400 V motors. These motors shall be provided with star connected stator windings. 20. ELECTRICAL SYSTEMS . 20.1. In addition to temperature monitoring & alarms in DCS local temperature indicators shall be provided for motor bearings.7 The degree of protection for the motor enclosure shall be IP-55 and IP-54 for outdoor & indoor respectively and outdoor and indoor cable boxes shall be provided with IP-55 and IP-54 respectively. All HT motors shall be provided with vibration pads (in both X & Y directions and at both DE & NDE) for mounting vibration detectors.1. KARIMNAGAR DIST.10 The ring oiling system shall be adequate for starting and continuous operation of the motor for atleast one half hour without pressure oiling system in operation. current transformers.9 20. maximum double amplitude vibrations upto 1500 rpm shall be 40 microns and 15 microns upto 3000 rpm.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 20.8 20.1.MOTORS SPEC.1.1. Motors rated 1000 kW and above shall be provided with differential protection.12 20.1.6 kV motors.20 SHEET 2 OF 10 1X700 MW CCPP AT NEDUNOOR. These motors shall be designed to withstand atleast 2% unbalance in supply voltage. The 3 nos. Torque speed characteristics of motor superimposed on torque speed characteristics of drive equipment at 100%.20 20. The terminal boxes shall be reversible to suit cable entry from bottom or top.6 kV AC motors shall have BIL of 36 kV (Peak) 1.3 / 3. The insulation system for 6. RTDs for winding bearings temperature. SECTION: D3.1. without exceeding acceptable winding temperatures. vibration monitors etc.17 20. KARIMNAGAR DIST. 329 R5 .1 Actuator Motors The actuator motors shall be designed for short time duty (S2) in accordance with IEC 60034-1.7 pu rated peak line to earth operating voltage) switching surges originating from non-effectively earthed power system.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE.1. Variable frequency controller shall be provided for motors requiring speed control. Separate terminal boxes to be provided for space heater. All 6.3 20. Motor shall be capable of starting and accelerating the load with the applicable method of starting. Terminal boxes shall have fault withstand capacity equal to at least rated short circuit level of the system voltage for 0.6 kV motors shall be provided with quick disconnecting type terminal connectors to facilitate easy disconnection and removal of the motors without requiring unsealing or otherwise disturbing the external cable connections and leaving the phase segregated terminal box intact. Double compression type brass cable glands and crimping type copper lugs shall be provided for termination.MOTORS SPEC.2.2 kV (rms) for one minute.25 sec.18 20.16 20. All terminal boxes shall be provided with two earthing studs for termination of protective earth conductor.3. Canopy shall be provided for outdoor motors. ISSUE R0 304 TCE FORM NO. DC Motors DC motors shall be suitable for the DC system voltage available in the plant.1.14 Cable boxes of all 6. NO. 20.1.15 20. when the supply voltage is in the range of 85% to 110% of rated motor voltage.1.2 / 50 microsecond wave and shall withstand a power frequency voltage of 14. ELECTRICAL SYSTEMS .1.5960A-H-500-001 20.1.20 SHEET 3 OF 10 1X700 MW CCPP AT NEDUNOOR.19 20.2 20.6 kV AC motors shall withstand the negative or positive 0. 90% and 80% shall be furnished by the contractor.0 microsecond wave (2.1 20. 610. if type test certificates are motors offered. SECTION: D3.3. For 6.2 20.5 20. motors. General Requirements For small rating motors cooling shall be of TEFC type but for higher rating motor TETV. Remote operation of the valve shall also be possible. else it shall be conducted. Two normally open and two normally closed or two changeover potential free contacts corresponding to open and close positions of the valve shall be provided.1 20.4 20. tests shall be conducted on all 6. The DC and AC actuator shall be provided with accessories viz. hand wheel motor. Degree of protection for actuator motor enclosure shall be IP-55 and IP-67 for indoor and outdoor respectively. All the valves shall be of Integral type with field bus compatible. NO. CACA & CACW type cooling shall be considered. 400 V motors and DC available for the same rating of the furnished.3 Hand wheel operation shall be provided in addition to motor drive.5 20.8 20.6 20.3.6 kV.3. The remote position of the valve along with its status indication with trip shall also be shown in the DCS & local. using the API Recommendation No. all routine and acceptance 400V and DC motors as per relevant ISSUE R0 305 TCE FORM NO. TCE. integral starter.20 SHEET 4 OF 10 1X700 MW CCPP AT NEDUNOOR. Complete actuator shall be tested at factory as per IS 9334.3.2 20.1 20. the same shall be However.6 kV. adjustable limit switch. Open / Close limit switches used for interlock operation shall be of proximity type.4..5. torque limit switch.4.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS . etc. 617 and 618 for the overrating ratio.7 20. standards.3. All electric motors shall be chosen from the supplier’s standard manufacturing program and in accordance with the absorbed load of the driven machine. 20. 329 R5 .5.MOTORS SPEC.3. thermostat.4 20. end of travel switch.5960A-H-500-001 20.2 Tests Tests on all types of motors shall be conducted as per relevant standard.3. KARIMNAGAR DIST. 20.6 kV AC motors. C & Tan delta and polarisation index test shall be carried out as a routine test on each motor (the minimum value of polarisation index for all motors shall be 2 when determined according to IS : 7816). partial discharge. These tested sample coils shall not be used in the motors to be supplied. The power frequency test voltage shall be decided during detailed engineering. where U is the line to line voltage in kV. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. bearing temp.17 shall be performed on a sample coil (identical to those to be used in the motor quoted for) for each type of motor. specific approval for the test method and procedure is required to be obtained.5 20. Wherever ETD's are provided..2/50 micro sec.1. wave. Surge-withstand test at 20 kV with 0. winding temp.3 For 6.5. for HV motors only. ELECTRICAL SYSTEMS . after cutting the coil and bringing out the turns suitably. Noise level measurement test shall be conducted on one motor of each type. In case the temperature rise test is carried at load other than rated load.7 List of tests for which reports have to be submitted The following type test reports shall be submitted for each type and rating of HT motor ISSUE R0 306 TCE FORM NO.5.4 20.. Di-electric tests to establish the insulation withstand level of motors as indicated in Clause 20.5. KARIMNAGAR DIST.3/3 micro sec..5. coolant flow and its temp. TCE. the temperature shall be measured by ETD's also for the record purpose. in addition to all the tests specified above. Momentary overload test (subject to test bed constraint). During heat run test. List of tests to be conducted The following type tests shall be conducted on each type and rating of HT motor: (a) No load saturation and loss curves upto approximately 115% of rated voltage (b) (c) (d) (e) Measurement of noise at no load. wave on each type of motor coils with at least five such impulses. SECTION: D3.MOTORS SPEC.20 SHEET 5 OF 10 1X700 MW CCPP AT NEDUNOOR. Full load test Temperature rise test at rated conditions. Surge withstand test on the sample coil after placing it in stator core at (4U + 5 KV) and with at least five impulse of 1. shall also be measured. core temp. followed by one minute power frequency high voltage test on turn to turn insulation. 329 R5 .6 (f) (g) 20.5.5960A-H-500-001 20. MOTORS SPEC. NO. Terminal box-fault level withstand test for each type of terminal box of HT motors only.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.20 SHEET 6 OF 10 1X700 MW CCPP AT NEDUNOOR. Type test report on Elastimold Termination kit as per relevant standard. KARIMNAGAR DIST. 329 R5 . (b) (c ) ISSUE R0 307 TCE FORM NO. ELECTRICAL SYSTEMS .5960A-H-500-001 (a) Degree of protection test for the enclosure followed by IR. TCE. HV and no load run test. SECTION: D3. 10 1. TCE. BY CKD. NO.20 7 OF 10 SPEC.BY DATE RKD HA TCE FORM NO.0 1.6 1.8 As per classification (for flame proof zone – 1) TEFC/TETV/CACA/CACW IP 55 Opaline Green JOB NO.1 1.2 AC Motors Type of Motors Supply (a) Rated voltage 6. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR. Ambient temperature Temperature resistance Location (a) Hazardous area division (IS:5572 or equivalent) rise by winding C C 50 70 for class-B 0 1. 50 Hz Squirrel cage except for cranes (b) Number of Frequency (c) System Neutral Medium resistance earthing (6.3 Type of duty (Clause 9.9 1. DATE REV. DOL For 6.6 kV for motors above 175 kW & 400V for rating upto 175 kW phases & 3 Phase. BY Type of cooling (IS : 6362) Designation for degree of protection (IS : 4691) Colour shades of paint R0 JUNE’10 PPD.2 of IS:325 or equivalent) Method of starting Class of Insulation 1. 1.20 SECTION: SHEET D3. 330 R3 308 .11 REV. DATA SHEET – A3.5960A-H-500-001 SL.5 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. DESCRIPTION UNITS VALUES / REQUIREMENTS 1. NO.6kV&400V-Class F with temperature limited to Class B 0 1.7 Ref. NO. KARIMNAGAR DIST.4 1.6kV) / Effectively earthed (400V) Continuous / Intermittent depending on application. . DATE REV.2 DC Motors Rated voltage Class of insulation 0 V.2.1 2. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.4 Temperature rise Method of starting All items indicated above under AC motors are applicable here also except 1.4 C -doReduced voltage 3 Motors for Application Hazardous Area 3.1 3. Flame proof type IP-55 4 4.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 330 R3 309 4. TCE.5960A-H-500-001 SL. BY Power supply R0 JUNE’10 RKD HA JOB NO. NO. 3 Wire PPD.3 Indoor / Outdoor / Explosion proof 4. 3 Phase. DATA SHEET – A3. NO. NO. KARIMNAGAR DIST.3 2.2 Type of construction Degree of protection All items indicated above under AC motors are applicable here also. BY CKD. DESCRIPTION UNITS VALUES / REQUIREMENTS 1.4 REV. DC 220 Class F with temperature limited to Class B 2.6 kV motors 2 2.1 4.20 SECTION: SHEET D3.2 Valve Actuator & its Motor Application Degree of protection Valves as per requirement IP 55 for Indoor IP 67 for Outdoor As per requirement at the location where it is installed 400V. 1.BY DATE TCE FORM NO.12 Space heaters for motors Required for motors rated 30 kW and above for 400V motors and for all 6.20 8 OF 10 SPEC. BY CKD.1 5.20 9 OF 10 SPEC.5960A-H-500-001 SL.4 Degrees of protection provided by enclosures for rotating electrical machinery Classification of hazardous areas for electrical installation Terminal marking electrical machinery for rotating IS 4691 5. 330 R3 310 . 5960A IS 4029 CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.5 IS 5572 5.7 Type of duty & duty designation for motor 4.BY DATE TCE FORM NO.6 Actuator type Typical connection applicable diagram Bidder to decide No drawing is enclosed. NO. DATE REV.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO.6 IS 4728 5.8 REV.9 Class of insulation for motor Class of insulation for motor Class F but limited to Class B 5 5.3 BS – CP 1014 5.8 Supply condition applicable for motor variation 4. KARIMNAGAR DIST. BY for testing three phase RKD HA JOB NO.7 Designation of methods of cooling for rotating electrical machines Guide R0 JUNE’10 IS 6362 5. DESCRIPTION UNITS VALUES / REQUIREMENTS 4. Short time (15 minutes) or twice the valve stroking time whichever is higher As per 400V AC motors 4. DATA SHEET – A3.5 4.20 SECTION: SHEET D3. TCE. NO. Contractor to furnish his proposed scheme. PPD.2 Codes and Standards Induction motors – three phase Measurement and evaluation of vibration rotating electrical machines Code of proofing practice for climate IS : 325 IS : 12075 5. 10 IS 2253 5. DATE REV. BY CKD.12 IS 2148 REV. DATA SHEET – A3. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. DESCRIPTION UNITS VALUES / REQUIREMENTS induction motors 5.11 IS 8239 5.20 10 OF 10 SPEC.BY DATE RKD HA JOB NO.20 SECTION: SHEET D3. BY R0 JUNE’10 PPD. TCE FORM NO. TCE. KARIMNAGAR DIST.5960A-H-500-001 SL.9 Dimensions of slide rails for electric motors Designations for types of construction & mounting arrangements of rotating electrical machines Classification of maximum surface temperatures of electrical equipment for use in explosive atmospheres Flame proof enclosure of electrical apparatus IS 2968 5. 330 R3 311 . NO. NO. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR. Bidder shall decide the number of landings required and the total rise of the lift for both control building and HRSG area elevators.3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 ELEVATORS One (1) no.75 m/sec shall be provided for proposed Control and Switchgear building.20 of this specification. One (1) passenger-cum-goods lift of capacity 1500 kg and speed of 1. The A.ELEVATORS SPEC. The car and counter weights shall be suspended by stainless steel wire ropes.3. 21.5 21.5960A-H-500-001 21. Special care and precaution shall be taken regarding handling of lift cable loops between the points of suspension as the loops are prone to twist / distortion. 21.1 Specific Requirements The capacity of the lift shall be 600 kgs (8 passengers) for passenger lift and 1500 kgs for goods cum passenger lift. SECTION: D3. KARIMNAGAR DIST. ISSUE R0 312 21. Not less than 4 (four) independent standard steel wire suspension ropes shall be used for car or counter weight and all these ropes shall be in one piece and without intermediate joints.2 21. Any code. Accordingly. 329 R5 .0 21. Chain shall not be used for suspension.0 m/sec shall be provided in HRSG area. NO.3. specific requirements at the place of installation shall be complied with in all respects.3. TCE. or equivalent international standard.2 The lift for control building shall cater to various floors of the control room building.5 mm and the minimum factor of safety shall not be less than 12.3.21 SHEET 1 OF 10 1X 700 MW CCPP AT NEDUNOOR. The minimum diameter of the standard rope shall not be less than 12.C motors of the lift shall comply with Section D3. An enclosed machine room shall be provided for the control panel of the lift. ELECTRICAL SYSTEMS . statutory requirements.3 21.3. passenger lift of capacity 600 kg and speed of 0.4 21. The suspension ropes shall conform to IS: 2365 latest edition "Specification for steel wire suspension ropes for lifts and hoists".3 21.5 TCE FORM NO. 13 TCE FORM NO. KARIMNAGAR DIST. In the first method.11 21.3. the doors then revert to an open position. 16 gauge thick stainless steel. NO. SECTION: D3.3. Guide shoes shall be rubber of roller type designed for operation on un-lubricated guides.10 21.3. A load plate displaying the rated load of the lift in terms of persons and kilograms shall be fitted in the lift car in a conspicuous position. Glass shall not be used in the roof except to protect electric light.3. Conversely the lift will not move until all the landing doors are closed and interlocked properly. Sides of the door shall flush with all seams continuously welded. slight body contact pressure is detected by sensors incorporated into door drive mechanisms.3.6 The car shall be provided with fittings & accessories. The car entrance shall be able to withstand the thrust of 35 kg. ELECTRICAL SYSTEMS . The car platform shall be robust in construction and elegant in appearance.8 21.3. 329 R5 .3. Besides this Bidder is also to provide "Electronic Door Detector".21 SHEET 2 OF 10 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Actuation will check and reverse door movement. The successful Contractor shall comply with the changes in the elevation without claiming extra price.5960A-H-500-001 21.3. The second method will also take carry by the screen of Infrared beams as a safety curtain across the door entrance detects an obstacle when the doors are closing. The car doors shall be so designed that their closing and opening is not likely to injure a person. If there is any change/changes in the elevations of landing. which is to be fitted with safety glass / plastic transparent cover mounted inside the car. the same shall be informed to successful Contractor. TCE. Glass exceeding 930 cm² in area shall be of laminated type. with scratch resistant coating.ELEVATORS SPEC.9 21. The car floor shall be of smooth non-slip surface.7 21. The entrance shall be securely fitted with car floor and frame in order to become working loose or becoming displaced during the service. The car door shall be of hollow metal construction.12 21. A retractable safety shoe shall extend to the full height and project beyond the front edge of each car to open the closing door if and when it touches a person or object that is Bidder to provide "Electro-Mechanical Pressure Detection". The car door shall be provided with locking gear of heavy and robust construction so arranged mechanically and interlocked that the doors cannot under any circumstances be opened unless the lift car is within a particular landing zone. ISSUE R0 313 21. Car doors & landing doors shall be electrically operated by torque motor. allowing passengers to pass. The traction should be such that no appreciable slip may occur but that slip shall be free to take place upon the landing of either the car or the counter weight. adjustable and self lubricated guides shall be of such length that it shall not be possible for any of the car or the counter weights shoes to run off the guides. International Standards. The guide shoes or their lining shall be easily renewable.5960A-H-500-001 21. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Shafts and axles shall be of forged steel. The diameter of the sheave of pulley shall be as specified in the latest edition of Indian Standard of equivalent International Standard. The number of buffers shall be so fixed as to ensure proper sharing of the impact loads by all of them. It should preferably be equal to that of the car weight plus 40% of the rated load. The counter weight shall be provided in the lift shaft. SECTION: D3. The buffers shall be capable of stopping the car or counter-weights without permanent damage or deformation to itself or any part of the lift equipment. Slack rope switches if necessary. The application of safety device shall not cause the lift platform to become out of level in excess of 3 cm/m measured in any direction. The counter weight shall consist of cast iron weight contained in structural steel frame.17 21. shall also be provided.21 SHEET 3 OF 10 1X 700 MW CCPP AT NEDUNOOR.3. They shall have suitable flanges and smoothly machined rope grooves. The lift shall be provided with safety device attached to the lift car frame and placed beneath the car.3.3. Guide rails section shall be adequate to withstand the forces resulting from the application of the safety gear when stopping the counter weights or fully loaded car. sand holes and other injurious defects. The elevator shall be provided with suitable counter weights located in the lift shaft.14 All sheaves and pulleys fixed to and revolving with the shaft shall be fixed by means of sunk keys of sufficient strength and quality. Guide rails for the car and counter weights shall be machined 'T' sections and continuous throughout the entire length and shall be provided with adequate steel brackets or equivalent fixing of such design and spacing that avoid any deflection during the normal operation. The safety device shall be capable of stopping and sustaining the lift car up at governor tripping speed with full rated load in car. shall be turned to a reasonable radius at the point of reduction in diameter. 329 R5 . Sufficient number of buffers of spring loaded/oil type shall be fitted below lift car and counter weights. Any shaft when stepped.3. ELECTRICAL SYSTEMS .ELEVATORS SPEC. TCE.3.18 21. ISSUE R0 314 21.3.15 21. The counter weight shall be designed for smooth and easy operation of the lift and shall be in accordance with Indian Standards referred earlier or equivalent.16 21. They shall have sufficient rigidity and bearing surface. NO. Sheaves and pulleys shall be made of cast steel to IS:1030 and free from cracks.19 TCE FORM NO. 21 SHEET 4 OF 10 1X 700 MW CCPP AT NEDUNOOR.3. The lift drive shall be equipped with brakes.26 TCE FORM NO.20 Contractor to provide a modern Advanced electronic drive system of ''RESCUING passenger Trapped in a ELEVATOR". The ropes shall run clear of the governor jaws during normal operation of the lift. The maximum load transmitted by the single heaviest equipment both during erection and maintenance of the lift to the machine room floor and other structures like guides etc.22 21.21 21. Each governor shall be marked with a tripping speed in terms of car speed in m/sec.24 21. No friction gearing or clutch mechanism shall be used for connecting the main driving gear to the sheaves.3. The final limit switch shall not act to prevent motion of the car under power in both direction of travel and ISSUE R0 315 21. Sound reducing materials shall be provided under the machine base by the bidder.23 21. ELECTRICAL SYSTEMS . the final limit switches and buffers.ELEVATORS SPEC. The lift shall be driven by a drive suitable for method of control offered by the bidder. KARIMNAGAR DIST.3. except such apparatus and equipment which function in the lift well or other portion shall be placed in the machine room which shall be located at the top of the lift well.3. Such limit switches are to act independently of the operating device. TCE.3. 329 R5 . This system should be able to rescue during main power failure and elevator control system failure.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. and the motor control and brake control circuit shall be opened before or at the time of governor trips.5960A-H-500-001 21.3. The system should be fully microprocessor control with latest IGBT power device. NO.25 21. Governor ropes shall not be less than 8mm in diameter and shall be of steel or phosphor bronze and of suitable construction. shall be furnished by the contractor within 30 days of placing the award letter. The lift shall be provided with upper and lower normal terminal switches arranged to stop the car automatically within the limit of top car clearance and bottom run from any speed attained in normal operation. The drive system for the elevator should be variable voltage variable frequency Drive system.3. Final limit switches shall be provided to stop the car automatically within the top and bottom clearance independently of the normal operating device and the terminal limit switches. The lift drive controller and all other apparatus and equipment for lift installation. SECTION: D3. Governors shall be located where there is sufficient room for their proper operation and where they cannot be struck by the lift car or counterweight in the event of overrun. 3. cancelling all the registered calls. KARIMNAGAR DIST.3. SECTION: D3.27 Emergency safety device and over speed governor and buffers shall be provided. are included in the scope of the bidder.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.21 SHEET 5 OF 10 1X 700 MW CCPP AT NEDUNOOR.3. It is necessary for the equipment to be specifically treated.29 21. NO.3.3.33 21.3. The lift shall be provided with automatic levelling device to take care of over run and under run of the car and rope stretch such that any floor is within 6 mm from the landing level. To make the equipment/system complete in all respects. 329 R5 . arranging the materials for scaffolding and for any other functional requirement of erection.39 ISSUE R0 316 TCE FORM NO.3. 21.28 21. This shall include application of anticorrosion paint/zinc plating.3. TCE.31 21.5960A-H-500-001 shall after operation. An emergency switch shall be provided to stop the elevator at a particular landing. The contractor shall carryout all the tests necessary & take the clearances / permissions from the Electrical inspector or any other agencies who certify the operation of lift. it shall automatically cause the car door and hoistway door to return to open position. any requirement of supply & fixing of steel sections for door frame. fixtures in walls for indicators and push buttons etc. The elevator is to provide service in power station.3.34 21. 21.3. The electrical equipment shall have enclosure meeting IP-54 and other relevant protection.32 21. The car door shall be provided with a protective device extending to the full height and shall be so arranged that should it touch a person or any obstruction in its path while the door is closing.30 21. Fireman's switch at ground floor shall be provided. The mechanical interlock with auxiliary door closing device shall be provided so that the elevator can be operated only after the interlock circuit is established. remain open until the lift car has been moved by a hand winding within the limit of safe operation. An electric contact for the car door shall be provided which shall prevent elevator movement away from the landing unless the door is in the closed position. ELECTRICAL SYSTEMS .35 21.ELEVATORS SPEC. The scope of the bidder also includes supply of erection consumables. ELECTRICAL SYSTEMS .3. 329 R5 .ELEVATORS SPEC. In the car Up direction of travel Down direction of travel Floor position indicator & voice inside and outside car (Illuminated numeral for each landing) Landing car registering unit On the landing Up direction of travel Down direction of travel Car position indicator with direction (Illuminated numeral for each landing) Call registered ‘Up’ indicator ISSUE R0 317 TCE FORM NO. TCE.21 SHEET 6 OF 10 1X 700 MW CCPP AT NEDUNOOR.40 The following operating devices / indications shall be provided in the car / on the landing / in the machine room as indicated below: Operating devices In the car In the landing In the m/c room Up PB On top of the car Up (a) Up push button (PB) Down PB Number PBs for each landing Up PB Down PB Lift PB Down PB Hand cranking device Down Stop 230V 1φ receptacle Non-stop PB Door open PB Door close PB Alarm PB Emergency stop PB Key operated selector for attendant operation Bell PB Stop PB - - - - (b) Indicating devices.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3. KARIMNAGAR DIST.5960A-H-500-001 21. NO. 21 SHEET 7 OF 10 1X 700 MW CCPP AT NEDUNOOR. 329 R5 . Any other equipment / accessories required for satisfactory operation of the lift shall be supplied by the Contractor. (b) (c) (d) (e) (f) (g) (h) (i) (j) The material of doors and lift rope shall be stainless steel. then it should be taken through the Main Control room Air Conditioning System only. Emergency DC light shall be provided in car. ISSUE R0 318 TCE FORM NO. SECTION: D3. blow out panels. Hoist way machine room & pit lighting: To be provided by lift supplier. Automatic rescue device including siren etc : To be provided by bidder as an emergency rescue measure.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. Individual ladder for access to inside pit : To be provided by lift supplier. The enclosure for electrical equipment located outside the machine room shall be dust tight and the car shall be provided with fluoroscent lighting. of persons Over load indication On the landing Call registered ‘Down’ indicator (c) Additional requirement (a) Car ventilation fan with switch Fire extinguisher Telephone handset PB for emergency indication in control room Ventilation/pressurisation : 2 x 100% capacity blower of adequate size along with cyclonic filter for pressurising the machine room to make it dust proof.5960A-H-500-001 In the car Load plate in kg & no.ELEVATORS SPEC. Hoisting beam in machine room roof slab : To be provided by lift supplier. The contractor shall carryout all the necessary tests & take the clearances / permissions from the Lift inspector or any other agencies who certify the operation of lift. If AC is required for the lift control room. ELECTRICAL SYSTEMS . NO. etc. TCE. SECTION: D3. ISSUE R0 319 TCE FORM NO. KARIMNAGAR DIST.5960A-H-500-001 The interior decor of the lift shall be aesthetically pleasing. 329 R5 . and the same shall be subject to approval by Owner.ELEVATORS SPEC. The contractor shall be responsible for obtaining the necessary License / Permission from the relevant authorities.21 SHEET 8 OF 10 1X 700 MW CCPP AT NEDUNOOR. TCE. NO. ELECTRICAL SYSTEMS .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 0 8.21 SECTION: SHEET D3.4 IS:7759-1975 9.21 9 OF 10 SPEC.0 3. KARIMNAGAR DIST. Specification for steel wire suspension ropes for lifts.1 8.0 4.0 8.3 IS:1030-1982 9. Specification for lift door locking devices and contracts Material specification Goods Cum Passenger Lift Installations Capacity Rated speed Levelling device Operation R0 MAR’ 10 PPD.0 2.75 VALUES / REQUIREMENTS Two way automatic maintaining Automatic microprocessor based Selective & Collective Centre opening sliding. steel 1 or 2 depends on layout Required VVVF IP-54 IS:14665 (Latest edition) 9. NO.0 9.0 4. purpose. DATE REV.0 6. 1.5960A-H-500-001 SL.0 3.5 ISS or approved equal. BY CKD.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 IS:2365-1977 9. BY Indoor kg m/sec 1500 1. TCE. 330 R3 320 TATA CONSULTING ENGINEERS LTD .2 8. NO.0 REV.0 5. Specification for carbon steel castings for general engg. NO.BY DATE UNITS Indoor kg m/sec 600 0. TCE FORM NO.1 DESCRIPTION Passenger Lift Installations Capacity Rated speed Levelling device Operation Automatic operation type Type of door & material Type of doors in car Emergency exit Speed control Degree of protection for lift motor Codes & standards Specification for electric passenger and goods lift. 1. elevators & hoists.0 5. DATA SHEET – A3.0 7.3 9.0 2. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.0 Two way automatic maintaining Automatic microprocessor based JOB NO. 0 NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.0 8. SL. purpose. BY CKD.0 9.0 8.5 ISS or approved equal.5960A-H-500-001 6. DATA SHEET – A3. Specification for steel wire suspension ropes for lifts. TCE FORM NO. NO. Specification for carbon steel castings for general engg. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.1 Automatic operation type ION DESCRIPT Type of door & material Type of doors in car Emergency exit Speed control Degree of protection for lift motor Codes & standards Specification for electric passenger and goods lift.BY DATE JOB NO.2 IS:2365-1977 9.21 SECTION: SHEET D3.1 8.3 9. 7. steel 1 or 2 depends on layout Required VVVF IP-54 IS:14665 (Latest edition) 9.21 10 OF 10 SPEC. BY R0 MAR’ 10 PPD.3 IS:1030-1982 9. Specification for lift door locking devices and contracts Material specification UNITS Selective & Collective UIREMENTS VALUES / REQ Centre opening sliding.2 8. REV. DATE REV. elevators & hoists. NO. 330 R3 TATA CONSULTING ENGINEERS LTD 321 .4 IS:7759-1975 9. TCE. KARIMNAGAR DIST. 5. 500-10002500-5000 Volts 1 No. 1AMP/ 5AMPs Normal. No. Also any additional equipment required or considered necessary during detailed engineering stage. (v) 500 Ohms. 2 Nos. 1 No.5A-2 nos. KARIMNAGAR DIST. Category – I – High Voltage Test Instruments Instrument Range High potential test set AC / DC 0 – 50 kV Sl. 500 resistivity test facility Ohms in three ranges Digital Insulation resistance tester (transistorised) 0-100. Any other equipment considered necessary by the Contractor for the installation. 10A-2 nos. No. ISSUE R0 322 TCE FORM NO. 2 Nos. (ii) 50 Ohms. 1 No. Sl. shall form a part of the scope.01 Ohms. Rheostats of following ratings 650 Volts 1 Set (i) 25 Ohms. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 1 OF 7 SPEC. 2. testing and commissioning of the plant shall be included in the offer.1 EQUIPMENT TO BE SUPPLIED The list of items / equipment to be supplied by the Contractor indicated here is only indicative. (iii) 100 Ohms. 000 Mega Ohms. Automated oil BDV test set 0 – 75 kV 1 No. 329 R5 . 5A-2 nos.5960A-H-500-001 22. 1 No.22 1X 700 MW CCPP AT NEDUNOOR. (f) (g) (h) (i) (j) Cable fault locator (HV.5A-2nos. TCE. (iv) 250 Ohms. (d) (e) 2 Nos. (a) Qty.5 A-2nos. Portable secondary injection test set 500VA. 2. 1 No. 20AMPS / 100AMPS for 30 secs Digital Earth resistance tester with 0. (a) (b) (c) Category – II – Miscellaneous Laboratory Instruments Instrument Range Qty. NO. LV cable) Relay tool kit Hot stick with indication & audible alarm Temperature controlled soldering iron Thermovision equipment (INFRA RED CAMERA) Upto 11 kV Upto 400 kV 50W 1 No.10 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 0.0 22. SECTION: D3. KARIMNAGAR DIST.5 kVA Milli volt drop test set 600A DC continuous variable Illuminometer 0 to 50. No. 1 No. Circuit breaker analyser 1 ms to 999 secs Turn ratio meter with vector group 1 to 99000 ratio testing facility Online DC circuit fault locator Tan delta test kit for generator/transformer Vibrometer Capacitance and tan delta measurement kit Partial discharge measurement kit Earth loop tester Battery capacity test kit Battery impedance measurement kit Motor checker Capacitor measurement kit Live line detector Category – III – Meters & Accessories Instrument Range Qty. PF. 4 wire system (c) (d) (e) (f) Auto-transformers – 3 Phase Auto-transformer – 1 Phase Digital micro-ohm meter Portable power analyser meter Accuracy=0. 7. Sl.000 Lux. NO. 3Nos 1 No. 1 No. in 1 ph & 3 ph.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 1 No. (a) (b) Qty. 1 No.1 micro-ohm-1999 Ohm. KVA. 1 No. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 2 OF 7 SPEC. 329 R5 . 2 Nos. for measurement of KW.22 1X 700 MW CCPP AT NEDUNOOR. No. 1 No. Volt. 1 No.2 ISSUE R0 323 TCE FORM NO. 7KVA 0-270 Volts. 100A Amp-1A/5A. TCE. 2-16KVA 0. (k) (l) (m) (n) (o) (p) (q) (r) (s) (u) (v) (w) (x) (y) (z) (aa) Category – II – Miscellaneous Laboratory Instruments Instrument Range Primary Injection kit 5000 A. 3 wire & 3ph. SECTION: D3.5960A-H-500-001 Sl. 1 No. Three Phase sequence testing meter Clip on Ammeters AC / DC (100 – 600 V) (a) 0-2000-25003000A (b) 0-250-500A (c) 0-100-150-200A (d) 0-5A (e) 0-1A 0-500 Volts. 2 Nos 1 No. 1 No. 3 Nos. Volt 600 V. 1 No. Amp. 1 No. KVAr. 2 Nos. KWh. Harmonics generation. ISSUE R0 324 (h) TCE FORM NO. Transducers.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Digital multimeter (Class 0. TCE. clips. Current 0 – 2 AMPS DC. Requsite software and Laptop shall be included as a part of test kit. Naphtha & fuel gas leak detectors 2 Nos. 1 No..5960A-H-500-001 (g) (h) (i) LCD type portable scope meter (Wave form analysis with Harmonic measurement facility) Analog voltmeter AC/DC Analog ammeter AC/DC 1 No. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 3 OF 7 SPEC. 2 Amps. carrying / transporting cases. 0-5-10-25-50-100-500 V 0-5-10 A 1 No. No. Differential relays.3000. wherever applicable. Hydrogen leak detectors 2 Nos. etc.1500.02 accuracy for testing following: Distance relays. 10000 rpm 2 Nos.+ 30V. 100 VA 0. 0 . connectors. Ground fault relays. These shall include but not be limited to : (a) (b) Two meter length power supply cord with plug. F/V/I relays. rain jackets. (c) (d) (e) (f) (g) Digital tachometer (non-contact type) 2 Nos. Over current relays. 329 R5 . adapters. protective covers. Energy meters testing /calibration.5000. (a) Category – IV – Electronic Instruments Instrument Universal microprocessor based relay testing kit to test 1) Current relay 2) Voltage relay 3) Frequency relay 4) Differential relay 5) Distance relay 6) Synch. KARIMNAGAR DIST. Composite universal microprocessor based test kit with 0.22 1X 700 MW CCPP AT NEDUNOOR. shields. SECTION: D3. Sl. Synchronising devices. Transient playback. DC. All necessary accessories like jacks.5) 3 Nos. Relay 7) Timer relays Regulated DC power supply equipment Range Qty. 2 Amps. 1 no (b) Voltage 0-+300V DC. probes. NO. All the necessary accessories shall also be supplied with the instruments. 0-+5V 10 Amps. 22 1X 700 MW CCPP AT NEDUNOOR. The test set shall be so designed that the short circuit current drawn from the system exceeds 8 times the rated current. Solid copper / graphite brushes with pressure springs shall be provided to ensure low contact resistance. continuously rated 1 kVA with class of insulation being ‘A’. The transformer test set impedance shall be such that the input MCCB trips within a suitable time (0. KARIMNAGAR DIST. Shall incorporate built-in safety features to ensure complete safety of operating personnel.02 sec. protection and control equipment. 22.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (ii) (iii) (iv) (v) (b) The insulating material used for bushings and top covers shall be as per BS for Class F/A installation.1 Category – I – High Voltage Test Instruments (a) The test transformers shall be supplied with: (i) A control desk incorporating all necessary indication. annunciation. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 4 OF 7 SPEC. Mobile base with adequate no.2. totally enclosed type with louvers. (c) Portable Secondary Injection Test Set ISSUE R0 325 TCE FORM NO. NO. of rollers for easy transport of the testing unit. All necessary accessories for erection.2. All necessary cooling equipment if required. whether specified or not.) for a secondary short circuit.5960A-H-500-001 22. (ii) (b) Rheostats and Phantom Loads The rheostats shall be 650V grade wire wound type of copper nickel alloy having a low temperature co-efficient.2 Specific Requirements 22. normal operational / testing of all types of equipment. commissioning. SECTION: D3. 329 R5 .2 Category – II (a) Automatic Oil Test Sets (i) This equipment shall have an output voltage of 0 – 75 kV variable AC. TCE. The insulating handle of stick shall be with Class F / H insulation as per IEC / BS specifications with scaled detector having high quality viewing windows.5 mA. This kit shall include Time Domain Reflectometer (TDR) and cable identifying kit and all necessary accessories & transport cases. The tester shall be suitable for an input supply of 230 V. 2500V and 5000V. nominal S. maximum short circuit terminal current 2. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 5 OF 7 SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. single phase AC as well as in-built rechargeable batteries. three spare heating elements & separate stand to rest the soldering iron while in use. 50 Hz. (e) Insulation Resistance Tester (Transistorised) The insulation resistance shall be measurable to a value of 1. (f) Cable Fault Locator for LT Cables Portable cable fault locator which shall identify the fault in a LT cable distinctly. specific soil resistance and ohmic resistances.000 mΩ in five ranges. 50 A etc. The test voltage shall be adjustable at 500V. KARIMNAGAR DIST.22 1X 700 MW CCPP AT NEDUNOOR. The instrument shall have built in ammeter and voltmeter having adequate range. 10. NO. This tester shall also provide Polarisation Index Measurement.C current 2 mA. This kit shall work on in-built batteries. Accuracy shall be 5%. A guard terminal shall be provided to eliminate error due to surface leakage. 400 kV. (h) Temperature Controlled Soldering Iron The soldering iron rated at 50 W having thermostatic temperature control shall be supplied complete with set of soldering bits of different sizes and shapes. ISSUE R0 326 TCE FORM NO. Should give audio visual indication of pressure of voltage. The equipment shall be supplied with all necessary accessories and in-built batteries. TCE. (d) Earth Resistance tester with resistivity test facility This equipment shall be suitable for measuring the ground resistance. The hot stick should be light weight and portable. 1000V. For 6. (g) Hot Stick The hot sticks shall be supplied in different ratings viz.5960A-H-500-001 This equipment shall be designed to deliver a normal continuously adjustable current with multirange selector switch for 1.00.6 kV. SECTION: D3. 5. 329 R5 . Phase angle adjustment shall be 0-360 deg. determining temperature co-efficient and temperature rise by resistance methods. Output current range shall be 1-5-50-100A. (b) Clip on Ammeter The meter shall have a large digital display unit and the jaws shall open adequately to facilitate introduction of the conductor having a size corresponding to the maximum current range. winding resistance of transformer & motor. 1 Phase. etc. The kit shall be computerised. 22. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 6 OF 7 SPEC. SECTION: D3.4 Category – IV (a) Automatic Composite Relay Test Kit Relay test set shall be suitable for input voltage 230 V. busbars. and single hand-operated instrument. (c) Digital low resistance ohm-meter The instrument shall be suitable for measuring the contact resistance of switch and circuit breaker contacts. NO. This instrument shall have user friendly. broadly compatible software which is an image processing software to perform post-imaging analysis.5960A-H-500-001 (i) Thermovision Equipment (Infra thermographic common) The system shall be very light weight.2. TCE. They shall also be suitable to be used in finding ground faults in electrical equipment. Any conducting part of the meter/ shall withstand 2 kV for 1 minute.2. Overload and short circuit protection shall be provided. KARIMNAGAR DIST. The operative range of the meter shall be 100V to 600V. 50 Hz. portable unit and used to test various types of protective relays quickly and more accurately. etc. The software for testing.3 Category – III (a) Phase sequence Testing Meter This shall be suitable for testing 3 phase 400V supply and shall be suitably marked for clockwise and anti-clockwise directions.22 1X 700 MW CCPP AT NEDUNOOR. 329 R5 .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 22. measurement and analysis of the different types of the relays shall be included. ISSUE R0 327 TCE FORM NO. They shall have an audio alarm for continuity testing.5960A-H-500-001 (b) Regulated DC Power Supply Voltage range (continuously controlled) Current range (continously variable) Indication meters Load regulation - 0 to + 300 V DC 0 to 2A DC Digital voltage/current integral with the unit 0. padded carrying case. SECTION: D3. a peak hold feature on current and voltage ranges. which does not necessitate mechanical contact with the machine shaft.22 1X 700 MW CCPP AT NEDUNOOR. ISSUE R0 328 TCE FORM NO. It shall have safety features to prevent damage to instrument if voltage is applicable inadvertently current or resistance measuring range.1% variation in voltage 0. adapters. - (c) Digital Tachometer Tachometer shall be of the photoelectric type with a digital display. leads. Adequate memory shall be built-in to hold the last reading for atleast 1 minute. TCE. automatic polarity and over range indications. probes.2% variation in current.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The instrument shall be complete with rechargeable batteries and charging equipment. (d) Digital Multimeter These meters shall have built in overload protection and protection against HV transients. etc. NO. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 7 OF 7 SPEC. KARIMNAGAR DIST. A “push to read” push button shall be provided and also an LED to indicate when the light beam is on the target. 329 R5 . `Start' and `Stop' for control of the rest of the drives in the plant.6 23.1.0 23.2.which shall comprise two push buttons viz. TCE.2. first aid charts shall be provided for display in the plant area.5960A-H-500-001 23.3 23. `Open'. LPB’s for outdoor installation shall be weather proof type provided with a GI canopy and those intended to be used in hazardous areas shall be flameproof type and the degree of protection shall be IP 55 for both outdoor and indoor application. All stop push buttons shall be lockable type (provided with key for locking) Following types of LPBs shall be provided for the various drives as applicable.1 23.1. 329 R5 .23 SHEET 1 OF 3 700 MW CCPP AT NEDUNOOR. (a) Push button station type A . ISSUE R0 329 23. `Close' and `Stop' for control of reversible motors. The LPBs shall be power coated with shade Opaline green (External) & semi glossy white (Internal)... 43 of IE rules. KARIMNAGAR DIST.which shall comprise Three. Local push button stations Junction Boxes (JBs) 3 phase power receptacles Danger boards Rubber mats 50 nos.1 23. Minimum of fifty (50) nos.4 (b) TCE FORM NO.1.1.2. Sufficient quantity of gas masks shall be provided in line with rule no.7 MISCELLANEOUS ELECTRICAL EQUIPMENT Following equipment shall be included in the Contractors’ scope. Push button station type B .1.4 23.8 23.1. Local Push Button Stations (LPB) Local push button stations shall be provided for all the drive motors of the plant.3 23. First aid boxes shall be provided at various locations in the plant.2 23.1 23.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2.5 23.2 23.1.1. Push buttons viz. SECTION: D3. NO.2 23. ELECTRICAL SYSTEMS MISCELLANEOUS ELECTRICAL EQUIPMENT SPEC. hot dip galvanised as per relevant IS. stop & ammeter. Cable entry shall be bottom/side entry for indoor as well as outdoor mounted junction boxes.1 Type-C push button station: With start.2 23. AC23 category.1 23.5960A-H-500-001 (c) 23.3 23.23 SHEET 2 OF 3 700 MW CCPP AT NEDUNOOR. Plug and Socket shall be shrouded Diecast aluminium. Gland plate shall be 3mm thick sheet steel with neoprene/synthetic rubber gaskets. The JBs used in outdoor areas shall be weatherproof type. mounting brackets suitable for surface mounting on wall/column/structure. Junction Boxes with IP:55 degree of protection.3. double break. columns. and suitable for mounting on wall. SECTION: D3. Socket shall be provided with lid safety cover. KARIMNAGAR DIST. earthing terminals. suitable for AC supply. NO. required for installation. Junction Boxes (JBs) / Marshalling boxes (MBs) Junction boxes as required for the power plant shall be supplied as required for marshalling cables of devices located in an area/equipment. Sheet steel thickness of the JBs shall be minimum 2 mm. gland plate etc.3. The boxes shall include brackets. Robust mechanical interlock shall be provided such that the switch can be put ON only when the plug is fully engaged and plug can be withdrawn only ISSUE R0 330 23.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Top of the boxes shall be arranged to slope towards rear of the box. bolts.5 mm. terminal blocks for loop-in loop-out for cable of specified sizes. shall comprise of a case with hinged door constructed from cold rolled sheet steel of minimum thickness 2mm. Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot dipped galvanized or of die-cast aluminium alloy of thickness not less than 2.4 23. gasket to achieve IP55 degree of protection.3. transformer yard. The junction boxes shall be installed at 1 m accessible height.3 23. The ONOFF switch shall be rotary type heavy duty. nuts. TCE. ELECTRICAL SYSTEMS MISCELLANEOUS ELECTRICAL EQUIPMENT SPEC.5. 3 Phase Receptacles 32 A and 63 A. The boxes shall be provided with two nos. 400 kV switchyard such that distance between any two of each rating in indoor and outdoor area does not exceed 15 m and 30 m respectively. screws M8 earthing stud etc. structures etc. All junction boxes shall be of adequate strength and rigidity. 3 phase. Terminal blocks shall be 650 volts grade. 4 pin heavy duty type power receptacles shall be provided in proposed building plant areas. 329 R5 . rated for 10 Amps and in one piece moulding.2 TCE FORM NO.5. JBs / MBs shall be hot dip galvanised and shall be powder coated with paint shade Opaline green (External) & Semi glossy white (Internal). The thickness and length of the rubber mats shall be as per the guidelines of Indian Electricity Rules / local electrical inspectorate. Also cover can be opened only when the switch is in OFF position. ELECTRICAL SYSTEMS MISCELLANEOUS ELECTRICAL EQUIPMENT SPEC. Wiring shall be carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of adequate size. TCE. KARIMNAGAR DIST.5960A-H-500-001 when the switch is in OFF position.5 23.23 SHEET 3 OF 3 700 MW CCPP AT NEDUNOOR. 329 R5 . NO. 23. ISSUE R0 331 TCE FORM NO.5.1 Danger Boards / Rubber Mats Danger boards and rubber mats shall be provided as required by the statutory Authorities. The Terminal blocks shall be of 750 V grade.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3. SECTION: D3. TCE. 329 R5 . The Contractor shall obtain all necessary statutory clearance for the purpose.95 for optimising the power bills. This shall be installed at each LT distribution board preferably. Contractor shall provide suitable DG sets. fluctuation in voltage and frequency and consequences thereupon.2 24. caused by low power factor.0 24. NO. 3φ. GA and layout drawings required for getting clearance from local electrical inspector / Electricity Board shall be prepared by the contractor and it will be the complete responsibility of the Contractor to obtain the approval for the installation and all related works in this regard. 4 wire distribution lines to distribute power around plant area. The Contractor shall provide metering arrangement consisting of two CT. Adequate metering and protection shall be provided for transformers and incomer feeders. Contractor shall provide necessary protection for the construction power supply arrangement to ensure that any fault in his system. ISSUE R0 332 24. All the equipments used in construction power shall ensure full safety to the working personnel and no live parts which are accessible shall be exposed. Capacitor banks of automatic PF adjustment arrangement shall be provided by the Contractor depending on the actual load to maintain power factor at 0. 2 x 100% suitably rated 11kV / 420V transformers.4 24.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. the same shall be paid by the contractor to the Owner. The power shall be further extended by the Contractor to different users by armoured cables or overhead lines.5 TCE FORM NO.1 CONSTRUCTION POWER SUPPLY EQUIPMENT Construction power shall be made available at a single point at 11kV inside the plant premises from nearest substation of APTRANSCO by the Owner. ELECTRICAL SYSTEMS – CONSTRUCTION POWER SUPPLY SPEC. two bus sections and bus coupler & required number of outgoing 400V. PT units and two trivector meters of suitable accuracy which shall have MD registering facility. To take care of failure of this supply. should not disturb 11kV power supply arrangement.3 24. The contractor shall be responsible for periodic payment of bills for the energy consumed by him. Power failure for whatever reason. The Contractor shall make arrangements to receive power from the Owner line through DP structures with fuse protection. KARIMNAGAR DIST. If APDISCOMS imposes any penalties to APGENCO .5960A-H-500-001 24. 400V switchgear with two incomer ACBs.24 SHEET 1 OF 4 1X700 MW CCPP AT NEDUNOOR. The Contractor shall estimate the construction power requirement and indicate the same to Owner to enable them to enter into an agreement with APTRANSCO for its supply. Contractor shall supply and install fire fighting equipment as per the regulations of the local electrical inspectorate / statutory bodies for the electrical installation. The Owner will not be responsible for power cuts. 250A feeder of adequate capacity for Administration building & Colony construction. two earth electrodes for body earthing and two earth electrodes for lightning arrestor earthing. KARIMNAGAR DIST. ISSUE R0 333 TCE FORM NO. the board shall be provided with outer enclosure so that access to individual compartments.10.9 CABLES Pad locking arrangement with hinged door Sloped canopy to prevent ingress of rain water Caution notice Earthing at two points 24.10. Cable armour shall be suitable for carrying system earth fault current. etc.1 Cables shall be armoured and suitable for direct underground buried installation.1 Earthing of all substation equipment and overhead line shall be carried out as per IS:3043.2 Number of earth electrodes for LT substation shall be decided considering soil resistivity. 24.10. Earth electrodes shall be of 40mm dia.11 section.9. 24. shall also be connected to earth system.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Metallic supports. buried in earth pit. these shall meet the requirements covered in D3. 24. 329 R5 .8. NO. shall be given by the Contractor at specified location.3 All non-current carrying metal parts shall be connected to earth system at two points. 24.24 SHEET 2 OF 4 1X700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS – CONSTRUCTION POWER SUPPLY SPEC.2 The distribution boards shall be provided with the following: a) b) c) d) 24. HT cables shall be XLPE insulated type. 02 Nos. fencing.7 24. LT DISTRIBUTION BOARDS 24. the Contractor shall furnish the electrical scheme. However. of 400V. each of 100% rating. busbar and cable alley shall be available only after the outer door is opened. for Owner’s approval.1 In general.5960A-H-500-001 24.8. each LT substation shall have minimum two earth electrodes for neutral earthing. Earthing system shall consist of adequate number of earth electrodes interconnected. SECTION: D3. galvanised steel pipe.10 EARTHING SYSTEM 24. However.8 24.6 On award of contract. TCE. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 The extension boards provided for hand held equipments shall have 3 wire system i.5960A-H-500-001 24.4 Size of earthing conductor shall be selected considering fault current. 24. 329 R5 .11. KARIMNAGAR DIST. The wire shall be laid with proper fixing without any hindrance to personnel or vehicular movement.4 The LT substation shall be enclosed by barbed wire fencing on mild steel angle iron posts to a height of not less than 2500mm with suitable gates for entrance. protective guarding shall be provided.5 Overhead lines shall be earthed by continuous galvanised steel overhead earth wire fastened to each pole and connected with earth at minimum three points in every km length. The plug & socket arrangement provided shall be of industrial type with switch provided for proper isolation at the time of insertion or withdrawal of plugs. 24. NO. The clearance for the lowest conductor from ground shall be decided keeping in view the vertical clearance required for movement of vehicles/cranes.9 All the working areas shall be adequately illuminated for safe working with proper fittings/fixtures.11.11.8 All equipment used for construction activities shall be fed from separate switching/isolating devices. 24.10. etc.1 The electrical installation shall generally be carried out as per Indian electricity rules and acts. TCE. Earthing conductor shall be of galvanised steel strip/wires. duration of fault and corrosion rate. SECTION: D3.5 All cable connection parts within the switchgear shall be shrouded with insulating materials. phase.7 The flexible cable used shall have heavy duty insulation.e.11 INSTALLATION 24. 24. ELECTRICAL SYSTEMS – CONSTRUCTION POWER SUPPLY SPEC.12 WORKING PROCEDURES ISSUE R0 334 TCE FORM NO. 24.11. Cross section of earth wire shall not be less than 25 mm2. 24. 24. Surface shall be covered with gravel of 15 to 20 mm size.11. 24. 24.10.11.3 The LT substation area shall be graded and sloped to prevent any stagnation of rain water.11.11. neutral & earth as per IE rules.11.2 For road crossing.24 SHEET 3 OF 4 1X700 MW CCPP AT NEDUNOOR. 24. 24. 24 SHEET 4 OF 4 1X700 MW CCPP AT NEDUNOOR. 24.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. like hand gloves. Meggers & testers shall be provided in sufficient quantity. 329 R5 .12. NO. head gear.2 Only ITI qualified workers shall be allowed to handle the electrical or electrically operated equipments. etc. ISSUE R0 335 TCE FORM NO. TCE.1 Adequate safety equipments shall be provided to all the workers. SECTION: D3.12.5960A-H-500-001 24. ELECTRICAL SYSTEMS – CONSTRUCTION POWER SUPPLY SPEC. KARIMNAGAR DIST. (a) Output range (b) No.2 (f) Residual ripple output current (g) Over load capacity (i) (ii) Current Voltage : : : : 3 to 5% 10 times for 0.5% of full scale 25. ELECTRICAL SYSTEMS . shall be properly tagged.1 GENERAL REQUIREMENT Bidders shall note that each and every device/equipment mounted in panels. TCE.5% of full scale 0.25 SHEET 1 OF 2 1X 700 MW CCPP AT NEDUNOOR.5 seconds 120% continuous : : : : Galvanic Isolation Self powered Zero and span 500 Ohms (h) Out put Isolation (i) Power (j) Adjustment (k) External resistance. distribution boards.TRANSDUCERS SPEC. of output channel (c) Accuracy (d) Repeatability (e) Linearity : : : : : 4-20 mA DC Two (2) 0. chargers.5960A-H-500-001 25. ISSUE R0 336 TCE FORM NO..ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. etc. NO. 329 R5 . (n) All transducers shall have local mA digital display. switchgears.0 25. MCCs.1% of full scale 0. both inside and outside (if the equipment is mounted on door) for identification. (l) Power frequency withstand capability : 2 kV rms for 1 minute (m)Open circuit and short circuit protection shall be provided. KARIMNAGAR DIST. SECTION: D3. Transducers The transducers supplied shall meet the following specifications.5 seconds 120% continuous 2 times for 0. 6 The following IS standards shall be followed: IS: 12784 : Electrical measuring transducers for converting AC electrical quantities into DC electrical quantities : Electrical measuring transducers for converting AC electrical quantities to analog or digital signals. TCE.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. which are not protected by sun cover. Location of the building will be intimated later. ELECTRICAL SYSTEMS .4 25. KARIMNAGAR DIST. IS : 14570 ISSUE R0 337 TCE FORM NO. 25. SECTION: D3.5960A-H-500-001 25.25 SHEET 2 OF 2 1X 700 MW CCPP AT NEDUNOOR.Administration building not in EPC scope.3 Digital LED displays for the following parameters shall be provided in two (2) locations in the Main control room and three (3) locations in the administration building (*) (a) Total plant load for each block (b) Frequency (c) Ambient temperature For all outdoor equipment. Note:(*) .5 25.TRANSDUCERS SPEC. 329 R5 . However the Bidder shall install the LED display and wire the same. the heating effect due to solar radiation shall be considered while considering the temperature rise. NO. LEDs shall be provided with Low Voltage Guard protection. Mats shall be supplied preferably in units of 2X1 (length X width) metre. Insulating mat to be supplied shall be type tested at ERDA.11 TECHNICAL SPECIFICATION FOR INSULATING MATS SPECIFICATION NO. Packing and marking shall be as per IS 15652. 338 . manufacturing. The successful bidder shall submit the Quality Assurance Plan (QAP) in attached format for BHEL/ Customer approval after the award of contract. The mats should have been type tested in accordance with the applicable standards. packing and delivery to site of protective mats for placing in front of all 6.0 2. SPECIFIC QUALITY ASSURANCE REQUIREMENTS All type. PE-TS-I59-888-E001 1. MS Word/ MS Excel) as well as PDF files.0 COMPLIANCE TO SPECIFICATION Bidder shall confirm total compliance to the specification without any deviations from the technical requirements stipulated. 2.6kV/400V/220V Switchboards. mechanical and electrical properties of the insulating mats shall be as per IS: 15652. chemical. Insulating mats to be supplied shall be BIS approved and the same shall be engraved on insulating mats also.4 2. all sheets of the specification shall be furnished by each bidder with the signature and company seal affixed thereon.2 3.5.3 3. As a mark of technical conformance.1 2.3 2. routine and sampling tests shall be as per IS: 15652.1 SCOPE The scope includes design.0 1.4 4.0 3. Dispatch of materials shall be permitted only after acceptance of type test certificates.1 3. Soft copies may be required both in native file format (e. inspection. testing. TECHNICAL REQUIREMENTS The physical.0 Wherever required. 5. and inspection and testing of materials.5 3.2 2.g. soft copy of all approved technical/ quality documentation shall be submitted as specified without any additional commercial implication. 7. Corrosion survey report with interpretation. Design package on T/R sets essentially incorporating circuit diagrams. 19.5. Procedures for testing during installation. installation and commissioning checks.3 Layout of CP system. 8. to prevent corrosion due to any pin holes / holidays. Material and equipment specifications.4 Mounting arrangement of anode and reference electrode.  5.2 Calculations for arriving at the rating of transformer–rectifier set. sectionalisation. test stations distribution boxes etc. 4. Key diagrams of each discrete systems and complete CP system. Foundation. Bidders shall furnish in their BID a brief write up indicating the type of CP system envisaged for various metallic structures in contact with sea water & under ground metallics. Fabrication and installation details of anode and cathode junction boxes. parts list. Safety earthing details. Connection schemes for all applicable type of test stations and their schedules. 2. 21. including anode. Cable layout schedules and terminals.5 The following minimum design documentation [not essentially limited to these only] shall be furnished by the successful vendor (for review and approval) at contract stage.3 2. weather protection cover details and support details for T/R sets. Design package on anodes essential incorporating composition. handling.1 All the metallic structures which are in contact with sea water & underground metallics shall be provided with Cathodic Protection (CP) system irrespective of the material of structures. 18. Fabrication and installation details of test stations. Test Station. depth. 5. fabrications and installation details. 2.5. If the soil is very corrosive. Preferably LIDA type anode shall be used. II. PE-TS-I59-888-E001   1.2 2. 11. 10. schedules and connection schemes. Complete CP system layout drawings for each CP station. GENERAL REQUIREMENT: 2. environment. anodes. 17. IS: 8289 : Construction & testing of electrical apparatus with type of protection ‘n’ 2. 9. 6. commissioning and monitoring of (after installation) complete CP system & each equipment. Installation details of T/R sets. 2. 14. Anode installation drawings representing all variations in type. Detail engineering and final design report. Design and drawings that may be required for mitigation purposes. 2. supports etc. 22. 13. data sheets. 2.12 TECHNICAL SPECIFICATION FOR CATHODIC PROTECTION  SPECIFICATION NO. 20. all underground structures shall be protected against corrosion by providing suitable CP system. 339 . Power supply arrangement for each T/R set. 16. distribution boxes and cables of all description. 12. Interconnection. fabrication and installation details.4 2. 15. Quality plans for all equipment/ items. 3.5.1 Calculations for arriving at the number and dimension of anodes. placement. CODES & STANDARDS I.5. Field Quality Plan covering site storage. 1. The CP system shall only be of impressed current type. During detailed engineering the Contractor shall furnish the following for Purchaser’s approval : 2. IS: 8062 : Code of practice for cathodic protection of steel structure. Basic design package and system optimisation studies. description on operation and maintenance. isolation schemes for all structures to be protected and those to be isolated but to be checked out for interaction. Performance Test Report. 32. 340 . 27. 26.  5. Monitoring schedules. Material test certificate for the materials purchased by the vendor along with copy of manuals. PE-TS-I59-888-E001   Cable to pipe joint arrangement using thermite welding.12 TECHNICAL SPECIFICATION FOR CATHODIC PROTECTION  23. Final check list and completion report. 29. Composite Operation and Maintenance Manual. Inspection and test certificates for items fabricated and erected. 31. 30. SPECIFICATION NO. Billing break-up Note : The list of deliverables shall be finalised during kick-off meeting at contract stage. 25. Monitoring formats. List of E&C Spares. 24. 28. ANNEXURE-II 341 . 342 . 343 . 344 . 345 . 346 . INSPECTED AND TESTED AS PER THE BHEL/ CUSTOMER APPROVED QUALITY PLAN. THERE SHALL BE NO COMMERCIAL IMPLICATION TO BHEL ON ACCOUNT OF QP APPROVAL. INSPECTION & TESTING: ALL MATERIALS. MANUFACTURED. QUALITY ASSURANCE. COMPONENTS AND EQUIPMENT’S COVERED UNDER THIS SPECIFICATION SHALL BE PROCURED. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev.Doc. No. BHEL QPs ARE ENCLOSED FOR REFERENCE. 347 . : Page : 0 of 8. -DO- 3 - - 2. WAVINESS ETC MANFR'S DRG. MANFR'S DRG.2 HARDWARES 1. TEST -DO- INSPEC.MAKE. & PHY./SPEC LOG BOOK 3 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR 348 BIDDER'S/VENDORS COMPANY SEAL .SURFACE CONDITION MA VISUAL 100% FREE FROM CRACKS. UNEVENNESS ETC. SUPPLIER'S TC 3 - 2 HEAT NO. BLOW HOLES ETC. MA CHEM & MECH TEST 1/HEAT NO. MANFR'S DRG. NO. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.4 PAINT & VARNISH 1. SECTION.0 2 RAW MATERIAL & BROUGHT CONTROL SHEET STEEL.CHEM. SHADE. MANUFR'S DRG. SHALL BE VERIFIED 3./SPEC BOOK RELEVENT IS/SPEC./SPEC -DO- LOG BOOK 3 - - 2.1 1./SPEC -DO- -DO- 3 - - 3. MANFR'S DRG.CUSTOMER : QUALITY PLAN SHEET 1 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.DIMENSIONS MA MEASUREMENT SAMPLE MANFR'S DRG.PROOF LOAD TEST (EYE BOLT) 1. CRACKS.PROPERTY CLASS MA VISUAL SAMPLES SUPPLIERS TC & LOG 3 - 2 PROPERTY CLASS MARKING SHALL BE CHECKED BY THE VENDOR 1./SPEC LOG BOOK 3 - - 1. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. SHELF LIFE & TYPE MA VISUAL 100% MANFR'S CONTINUOUS DRG. PROP. REPORT 3 - - MA VISUAL 100% FREE FROM CRACKS./SPEC RELEVENT IS/ LOG BOOK 3 - - 2.DIMENSIONS MA MEASUREMENT 100% MANUFR'S DRG.SURFACE CONDITION MA VISUAL 100% - FREE FROM BLINKS. EYEBOLTS 3 4 5 6 7 8 9 10 11 1.SURFACE CONDITION MA MECH. PLATES.3 CASTING 1. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 1. -DO- 3 - - 2. CONNECTORS.PERFORMANCE/ CALIBRATION MA MEASUREMENT SAMPLE MANUFR'S DRG. BTD'S 1. PHYSICAL COND. SURFACE COND. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. MANUFR'S DRG./ SPEC. / SPEC.CUSTOMER : QUALITY PLAN SHEET 2 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. MAKE & RATING MA VISUAL -DO- MANUFR'S DRG. LOG BOOK 3 - - 4. CARBON BRUSH TEMP. & PHYSICAL TESTS 1/HEAT NO.INTERNAL FLOWS CR UT -DO- ASTM-A388 -DO- 3 2 1 FOR DIA OF 55 MM & ABOVE 1. DETECTORS. CABLES. MANUFR'S SPEC. -DO- 3 - - 3. SUPPLIER'S TC 3 - 2 3. & PHYSICAL PROPERTIES MA CHEM.6 SPACE HEATERS. OR HEAT TREATMENT BATCH NO MFG. SPEC. MA -DO- -DO- - NO BREAKAGE ON OTHER PHY. REPORT 3 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 349 . MA 4 VISUAL 5 100% 6 - 7 8 FREE FROM VISUAL DEFECTS RELEVANT IS -DO- 9 3 10 - 11 VENDOR'S APPROVAL IDENTIFICATION SHALL BE MAINTAINED 2. SPEC. BHEL SPEC. TERMINAL BLOCKS. -DO- 3 - - MA TEST 100% -DO- -DO- INSP. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.5 2 SHAFT (FORGED OR ROLLED) 3 1. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 1. DRG.DIMENSIONS (WHEREVER APPLICABLE) 4. CHEM. CABLE LUGS. RTD. NO. DESIGN MANUFR'S DRG. DIMENSIONS MA MEASUREMENT 100% -DO- MANUFR'S DRG. SPEC. / RELEVANT IS - RELEVANT IS SUPPLIER'S TC 3 - 2 1. SURFACE COND. OTHER CHARACTERISTICS MA TEST SAMPLE MANUF'S SPEC. MA VISUAL 100% - NO VISUAL DEFECTS (FREE FROM BURS) MANUFR'S DRG. & MECH TESTS -DO- MANUF'S SPEC. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 1.ELECT. PRESS BOARDS ETC. -DO- 3 - 2 FOR MV MOTOR INSULATION/VARNISH THICKNESS SHALL BE MORE THAN THE BURS HEIGHT MA ELECT. PAPERS. LOG BOOK AND OR SUPPLIER'S TC LOG BOOK 3 - 2 1. PROP MA ELECT. 3 1. MA 4 VISUAL 5 100% 6 - 7 8 NO VISUAL DEFECTS 9 INSPT. REPORTS 3/2 - 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 350 . MANUF'S SPEC.TEST SAMPLES RELEVANT IS/ BS OR OTHER STANDARDS SUPPLIERS TC & VENDOR'S INSPN.9 CONDUCTORS 1. BINDINGS CORDS.7 2 OTHER INSULATING MATERIALS LIKE SLEEVES. REPORT 3 10 - 11 2. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. . PROP. ACCEPTANCE TESTS MA MEASUREMENT SAMPLE MANUFR'S DRG.CUSTOMER : QUALITY PLAN SHEET 3 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. 3 - - 2. & MECH.8 SHEET STAMPING (PUNCHED) 1. & MECH. SURFACE COND. NO.DIMENSIONS INCLUDING BURS HEIGHT 3. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. SURFACE FINISH MA VISUAL 100% FREE FROM VISUAL DEFECTS RELEVANT IS/ BS OR OTHER STANDARDS LOG BOOK 3 - - 2. BHEL DATA SHEET BEARING MANUF'S CATALOGUES FREE FROM VISUAL DEFECTS 9 Log Book -DO-DO3 3 3 10 - 11 1. NO.TEST -DO- -DO- 3 - - MA -DO- 100% -DO- -DO- -DO- 3 - - 1. 2.HV/IR MA ELECT.DIMENSIONS MEASUREMENT SAMPLE 3.WITHSTAND CAPACITY 4.SURFACE FINISH MA VISUAL 100% - -DO- 3 - - 1./ SPECS. MA VISUAL 100% MANUF'S DRG/SPECS - MANUF'S DRG. FREE FROM VISUAL DEFECTS MANUF'S DRG -DO- 3 - - MA VISUAL 100% -DO- 3 - - 3. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. -DO- 3 - - 3.TEMP.DIMENSIONS MA MEASUREMENT SAMPLE MANUF'S DRG -DO- 3 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 351 .SURFACE COND.CUSTOMER : QUALITY PLAN SHEET 4 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.10 BEARINGS 1.SURFACE COND.DIMENSIONS MA MA MA 4 5 MEASUREMENT VISUAL 6 -DO100% 7 -DOMANFR'S DRG.MATERIAL OF GASKET 2. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 2 3 3.12 OIL SEALS & GASKETS 1.MAKE & TYPE 2. MANUF'S DRG MANUF'S SPEC.DIMENSIONS MA VISUAL 100% - -DO- -DO- 3 - - MA MEASUREMENT SAMPLE MANUF'S DRG MANUF'S SPEC. BHEL DATA SHEET 8 -DOMANFR'S DRG. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT.11 SLIP RING 1. FINISH 2./ ASTM-E165 MANFR'S SPEC/BHEL SPEC./ BHEL SPEC.CUSTOMER : QUALITY PLAN SHEET 5 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT./ RELEVANT STAND -DO- MANUF'S DRG GOOD FINISH MANUF'S DRG MANUFR'S SPEC./ BHEL SPEC. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 2.7 -DO- 3 - - 2. NO.3 PAINTING 1.0 2.SHADE 4.ADHESION MA MA MEASUREMENT SAMPLE BY ELCOMETER -DO- -DO- 3 - 2 VISUAL CROSS CUTTING & TAPE TEST -DO-DO- -DO-DO- -DO-DO- Log Book Log Book 3 3 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 352 . : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. SAME AS COL.WORKMANSHIP & CLEANNESS MA VISUAL 100% -DO- GOOD FINISH LOG BOOK 3 - - 2. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.SHAFT SURFACE MA FLOWS PT -DO- -DO- 3 - 1 2.2 MACHINING 1.1 IN PROCESS 2 3 4 5 6 7 8 9 10 11 STATOR FRAME WELDING (IN CASE OF FABRICATED STATOR ) 1.DIMENSIONS MA MA VISUAL 100% LOG BOOK -DO- 3 3 - - MEASUREMENT -DO- 3.DIMENSIONS MA MEASUREMENT -DO- MANUF'S DRG -DOMANUF'S DRG RELEVENT SPEC.PAINT THICKNESS MA (BOTH PRIMER & FINISH COAT) 3.SURFACE PREPARATION MA VISUAL 100% LOG BOOK 3 - - 2. PRESSURE VACCUM 3. -DO- 8 MANUFR'S SPEC./BHEL SPEC.5 WINDING 1./BHEL SPEC.VISCOSCITY 2.RESISTANCE 5.COMPLETENESS MA MEASUREMENT 100% Log Book 3 - - MA ELECT.CLEANLINESS 3. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. TEST PROCESS CHECK AT STARTING -DOCONTINUOUS -DO- -DO-DO- Log Book Log Book 3 3 - - MA -DO- -DO- -DO- -DO- Log Book 3 - 2 THREE DIPS TO BE GIVEN BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 353 . OF DIPS CR CR CR CR -DOELECT.6 IMPREGNATION 1.COMPLETENESS MA 4 5 6 7 MANUFR'S SPEC.TEST -DO- -DO- -DO- Log Book 3 - 2 (FOR MOTORS OF 2MW AND ABOVE) CR VISUAL 100% MANUFR'S SPEC. DELTA TEST 2.SURGE WITH STAND AND TAN. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 2.CORE LOSS & HOTOPOT 2.CUSTOMER : QUALITY PLAN SHEET 6 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.INTERTURN INSULATION 6.IR-HV-IR 4. -DO- 9 Log Book 3 10 - 11 MEASUREMENT SAMPLE 2. NO.4 2 SHEET STACKING 3 1. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. -DO-DO-DO-DO- MANUFR'S SPEC.TEMP. -DO-DO-DO-DO- Log Book 3 - - 2.NO. TEST -DO-DO- -DO-DO-DO-DO- Log Book Log Book Log Book Log Book 3 3 3 3 2 2 - CR -DO- -DO- -DO- -DO- Log Book 3 2 1 FOR MV MOTOR MA MA PHY.COMPRESSION & TIGHTENING 3. TEST DYN. RELEVANT IS Log Book 3 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 354 . NO. VISUAL MEAS. COMPLETENESS TERMINATIONS/ MARKING/ COLOUR CODE MA VISUAL 100% MFG SPEC.10 ASSEMBLY 1. -DO-DO-DOMFG.COMPACTNESS & CLEANLINESS 1.SOUNDNESS 2.8 CR CR -DOMALLET TEST & MV TEST ELECT.DRG.DURATION 4 MA MA -DOVISUAL 5 6 -DO100% -DO-DO- 7 -DO-DO- 8 9 Log Book Log Book 3 3 10 2 - 11 2.SOUNDNESS OF DIE CASTING 2. (GROWLER TEST) MEAS.HV 2. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. RELEVANT IS Log Book Log Book Log Book Log Book 3 3 3 3 - 2 - 5.DIMENSIONS MA CR -DO-DO- -DOMFG SPEC./ ISO 1940 MFG./ MFG SPEC. BALANCE -DO-DO- -DO-DO- -DO-DO- Log Book Log Book 3 3 - - 3. -DO- -DO- MFG. -DOMFG.AXIAL PLAY 4.COMPLETENESS 2. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 2 3 4. SPEC.9 COMPLETE ROTOR ASSEMBLY 1. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.ALIGNMENT 2. Log Book 3 2 - MA MA MA MA -DO-DO-DO-DO- -DO-DO-DOMFG.7 COMPLETE STATOR ASSEMBLY BRAZING/COMPRESSION JOINT 1. DRG/ RELEVANT IS MFG SPEC.RESIDUAL UNBALANCE 2.CUSTOMER : QUALITY PLAN SHEET 7 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. DWG.CORRECTNESS.WORKMANSHIP 3. Log Book Log Book 3 3 2 1 VERIFICATION FOR MV MOTOR ONLY CR ELECT. SPEC. 3. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 3. THICKNESS & FINISH MA VISUAL 100% IS-325 & DATA SHEET IS-3682 IS-8239 IS-8240 INSPC.1 MA -DO- 100% -DO- -DO- -DO- 3 1. TEST 1/TYPE/ SIZE RELEVANT IS TC 3 - 2.NAMEPLATE DETAILS 7.DEGREE OF PROTECTION MA ELECT.1 - 4. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT.CUSTOMER : QUALITY PLAN SHEET 8 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.1 NOTE-3 MA VISUAL & SAMPLE MEASUREMENT BY ELKOMETER BHEL SPEC. REPORT 3 3 1.2 NOTE .2 MA -DO- 100% IS-12075 APPROVED DRG/DATA SHEET IS-12075 APPROVED DRG/DATA SHEET & RELEVANT IS BHEL SPEC. AND DATA SHEET IS-325 & DATA SHEET IS-3682 IS-8239 IS-8240 -DOINSPC.1 TC FROM AN INDEPENDENT LABORATORY NOTE-3 - 6. REPORT TC 3 2. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. 2.OVERALL MA DIMENSIONS AND ORIENTATION MEASUREMENT 100% & VISUAL 5.2 1.TEST 6 1/TYPE/SIZE 7 IS-325/ BHEL SPEC.1 MA EXPLOSION FLAME PROOF TEST 1/TYPE 3 - 2.EXPLOSION FLAME PROOF NESS (IF SPECIFIED) 8. & MECH. & DATA SHEET TC 3 2.ROUTINE TESTS INCLUDING SPECIAL TEST AS PER BHEL SPEC./ DATA SHEET 9 TEST REPORT 3 10 1 11 1.VIBRATION MA 4 5 ELECT./ DATA SHEET 8 IS-325/ BHEL SPEC.PAINT SHADE. NO.0 TESTS 2 3 1.2 NOTE .TYPE TESTS INCLUDING SPECIAL TESTS AS PER BHEL SPEC. & DATA SHEET BHEL SPEC.1 - SAMPLING PLAN TO BE DECIDED BY INSPECTION AGENCY BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 355 .2 2. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. 3 IN CASE TEST CERTIFICATES FOR THESE TESTS ON SIMILAR TYPE. 4 WHEREVER CUSTOMER IS INVOLVED IN INSPECTION WITH THE CUSTOMERS. AGENCY (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER. SIZE AND DESIGN OF MOTOR FROM INDEPENDENT LABORATORY ARE AVAILABLE. NO.CUSTOMER : QUALITY PLAN SHEET 9 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 356 . TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 2 NOTES: 3 4 5 6 7 8 9 10 11 1 DEPENDING UPON THE SIZE AND CRITICALLY. HOWEVER. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON. WITNESSING BY BHEL SHALL BE DECIDED. THESE TEST MAY NOT BE REPEATED. 2 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES. MFG./ MFG.SHADE 3 MA 4 VISUAL 5 6 SAMPLE 7 8 9 LOG BOOK 3 - 10 - 11 MANUFR'S BHEL SPEC./ MFG.0 TESTS 1.7 TEST REPORT 3 2.SPEC.ROUTINE TEST INCLUDING SPECIAL TEST AS PER BHEL SPEC. NO. 2. SPEC/BHEL SAME AS SPEC.O PAINTING 2 1./ DATA SHEET SAME AS COL. TYPE/ METHOD OF CHECK 1 1. RELEVANT IS 2./ RELEVANT IS MANUF'S SPEC MFG. SPEC. DRG.0 ASSEMBLY 1.CORRECTNESS COMPLETENESS TERMINATIONS/ MARKING/COLOUR CODE 3. MFG.OVERALL DIMENSIONS & ORIENTATION MA VISUAL 100% -DO- 3 - - MA -DO- 100% IS-325/ BHEL SPEC. SPEC.CUSTOMER : BIDDER/ VENDOR SHEET 1 OF 2 SYSTEM COMPONENT/OPERATION CHARACTERISTICS CAT.1 2.1 NOTE -1 MA MEASUREMENT 100% & VISUAL APPROVED DRG/DATA SHEET APPROVED DRG/DATA SHEET & RELEVANT IS INSPN.SPEC. REPORT 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 357 .WORKMANSHIP 2. DRG.7 STANDARD MANUF'S SPEC MFG./RELEVANT COL. CHECK QUALITY PLAN : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-006/0 ITEM AC ELECT.DIMENSIONS MA MA VISUAL -DO- 100% -DO- -DO-DO- 3 3 - - 3. MOTORS BELOW 75KW (LV) EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. NAMEPLATE DETAILS MA 4 VISUAL 5 100% 6 7 IS-325 & DATA SHEET 8 IS-325 & DATA SHEET 9 INSPN. (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER. BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES. TYPE/ METHOD OF CHECK PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-006/0 ITEM AC ELECT. HOWEVER. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 358 . NO.CUSTOMER : QUALITY PLAN BIDDER/ VENDOR SHEET 2 OF 2 SYSTEM COMPONENT/OPERATION CHARACTERISTICS CAT.5KW . FOR EXHAUST/VENTILATION FAN MOTORS OF RATING UPTO 1. REPORT 3 10 1 - 11 NOTES: 1 2 3 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON WHERE EVER CUSTOMER IS INVOLVED IN INSPECTION. MOTORS BELOW 75KW (LV) EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE : SECTION VOLUME III AGENCY REMARKS P W V 1 2 3 3. CHECK : SL. ONLY ROUTINE TEST CERTIFICATES SHALL BE FURNISHED FOR SCRUTINY. 1 ZINC IN-PROCESS FABRICATION 1.DIMENSIONS 3. FREE FROM DEFECTS & SLAG SPECIFICATION QC RECORD QC RECORD 2 2 - 1 1 WELDING IS TO BE DONE BY QUALIFIED WELDERS 3. DRGS.2 SURFACE PREPARATION 1.SURFACE FINISH 1.CHEM. SPECIFICATION 2. RINSING & FLUXING 2. COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V VOLUME III REMARKS QUALITY PLAN SHEET 1 OF2 SL.TEMPERATURE OF BATH MA VISUAL 100% SPECIFICATION QC RECORD 2 - 1 MA MEASUREMENT PERIODIC IN EACH SHIFT IS:2629 IS:2629 QC RECORD 2 - - MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - MA TEMPERATURE INDICATOR CONTINUOUS IS-2629 IS-2629 QC RECORD 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 359 .1 2 RAW MATERIAL ROLLED SHEET 3 4 5 6 7 8 9 10 11 1. PROPERTIES MA VERIFICATION OF TC'S 100% IS1079 (for hot rolled) IS1079 (for hot rolled) IS-513 (for cold rolled IS-513 (for cold rolled) MILL TC 3/2 - - AS PER CONTRACT & AS APPLICABLE IN TECH. SURFACE QUALITY 2.& PHY.SURFACE FINISH 2. : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-507-00-Q-013/00 ITEM : CABLE TRAY SUPPORT MATERIAL & ACCESSORIES (BOLTABLE) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD 1 1.CLEANING.2 2. PICKLING. MA MA MEASUREMENT 100% VISUAL 100% IS-1730/ SPECIFICATION IS-1730/ SPECIFICATION QC RECORD QC RECORD 3/'2 3/'2 - - IS1079 (for hot rolled) IS1079 (for hot rolled) IS-513 (for cold rolled IS-513 (for cold rolled) IS-209 IS-209 MA CHEM TEST EACH HEAT QC RECORD 3/2 - 1/2 MA MA MEASUREMENT 100% VISUAL 100% APPD.3 GALVANISING 1.DIMENSIONS 2. GOOD WELDING PRACTICE APPD.COMP. NO.WELDING QUALITY CHEM.0 1. DRGS.0 2. REPORT 2 1 - AFTER CARRYING OUT TYPE TEST.MASS OF ZINC COATING 4. 1 - MA CR MECH. REPORT 3 2. NO.2629 7 IS . ETC. FLUX. 1 - 3. DROSS 3.TEST TEST IS-4759 1 SAMPLE IS-2629 SPECIFICATION./ APPD. ETC. RATE OF IMMERSION 4. CLAMPS 1. SLAG.UNIFORMITY OF ZINC COATING 5. REPORT 3 2.2629 / MFR'S PRACTICE FREE FROM BURRS. TYPE TEST PROCEDURE INSP.THICKNESS OF ZINC COATING 6. SPECIFICATION.2 WELD INTEGRITY TEST SOUNDNESS CR MPI SAMPLE TESTED SPECIFICATION. MA QC RECORD 2 - - 3.SURFACE QUALITY 4 MA MA VISUAL 5 6 CONTINUOUS IS . INSP. TEST IS-4759 / SPECIFICATION IS-4759 / SPECIFICATION IS-6745 / SPECIFICATION IS-2633 INSP. CANTILEVER ARMS.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V VOLUME III REMARKS QUALITY PLAN SHEET 2 OF 2 SL. 1 1 - 3. WELD INTEGRITY TEST TO CHECK THE WELD SOUNDNESS/ ACCEPTANCE SHALL BE DONE BY MANUFACTURER NOTE: INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE-1. REPORT 2 1 - MA ELCOMETER IS-4759 / SPECIFICATION SPECIFICATION.0 3. COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.ADHESION 3. TYPE TEST PROCEDURE IS-2629 SPECIFICATION.2629 / IS ./ APPD. : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-507-00-Q-013/00 ITEM : CABLE TRAY SUPPORT MATERIAL & ACCESSORIES (BOLTABLE) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD 1 2 3 2. DURING TYPE TESTING NO DEFECT INSP. REPORT 3 2.2629 / MFR'S PRACTICE IS .1 FINISHED ITEMS SINGLE / DOUBLE CHANNELS. REPORT 3 2 2.DIMENSIONS DISTORTION 2. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 360 . DRG APPD.2629 8 9 QC RECORD QC RECORD 2 3 10 2 11 VISUAL / 100% MEASUREMENT VISUAL 100% IS . REPORT INSP. ROUGHNESS. ROUGHNESS. 1 FASTENERS SHALL BE OF REPUTED & APPROVED MAKE MA SPECIFICATION FREE FROM BURRS. STAIN.1 TYPE TESTING MA CHEM.1. REPORT 3 2. STAIN. SPECIFICATION/ INSP.SURFACE FINISH MA MEASUREMENT IS-2500 LEVEL IV VISUAL IS-2500 LEVEL IV APPD. TEST IS-2633 INSP. DRG INSP. FLUX. 1 - MA CHEM.1. SLAG. BS ETC. processes. such as. the identification marks shall be presserved till despatch. 1 percent etc. Standard log sheets. as required. Column 4Category -‘CR’ stands for critical characteristic . Column 7Reference Documents .g. chemical analysis tensile testing.. They shall include all stages of operation such as materials./inspection to be performed by sub-Vendor’s QC Entry ‘2’ in column ‘W’ means test. For castings and forgings integral test specimens shall be provided. if witnessing of test by BHEL is called for.Agency . Wherever inspection by BHELs Purchaser/Third Party/Statutory authorities are mandatory. surface defects etc. etc. hydraulic test. qualification tests shall be conducted in the presence of BHEL QS Engineer. 361 . etc. Characteristics check. material identification) samples shall be drawn bgy BHEL and all tests as per relevent specifications shall be carried out in their presence or in recognized Government Laboratory.The characteristics being checked shall be given here. 10. Column 10. according to which check is done. This Quality Plan is liable to be modified as per the requirements of approved drawings and changes in technical specifications/drawings. log shets. under scope of supply of Vendor./inspection to be witnessed by Vendor’s QC Entry ‘1’ in column ‘V’ means verification shall be done by BHEL and next stage to be started only after the hold point is cleared by BHEL Column11I. standard specifications (IS.Formats. chemical composition. if any. leak tightness. of the Vendors shall be numbered and such reference numbers shall be included here. 2. shall be furnished to BHEL at the approproate stages or at the time of final inspection. If there are contradictions in respect of column 7 & 8 between this Quality Plan and the approved drawings specifications. reports. Column 5Type/Method of check e. manufacture. visual examination radiography etc. Inspection reports..The component and/or operation being checked shall be given here.g. 7.Documents. The quality plan shall be submitted in minimum 4 copies with a soft copy of the same or in line with contract requirements. in which the observations are recorded. this shall be compiled with.affecting appearance etc. test reports/certificate. Wherever this is not possible.Remarks . The following guide lines may be noted: Serial Number Component/Operation. 8. the latter shall prevail.Any special remarks shall be given here. When this is not possible for casting. When welders qualified by reputed inspection agencies or statutory bodies are not available. formats etc.The agency which performs the test/instruction shall be written in sub-column ‘W’ The agency which verifies test certificates/inspection records and carries out audit check of the components/operation shall be written in sub-column ‘V’ The agencies are codified as 1. such as technical specification. 100. Example : Entry ‘3’ in column ‘P’ means test. e. This Quality Plan is also applicable to spares. ‘2’ Stands for Vendor ‘3’ stands for sub-Vendor of the Vendor and so on. 9. When materials and components are initially identified and stamped by BHEL QS engineer. the identification mark shall be transferred to the components in the presence of BHEL QS Engineer unless other wise agreed. etc. assembly.affecting safety of equipment and personnel ‘MA’ stands for major Characteristic . NOTES : 1.affecting safety of equipment and personnel ‘MI’ stands for minor characteristic . mechanical properties. log sheets. 5. In absence of correlation with the test certificate(s) (e. Column 6Extent of check.g. Column 9Format of Record .2 & 3 ‘1’ stands for (BHEL) ‘1’ * means the operation shall be cleared by BHEL before the start of the next operation.ANNEXURE – 1 INSTRUCTIONS FOR QUALITY PLAN The Quality Plan shall include all the Quality Control Measures and Checks adopted by the Vendor to ensure that the material/component/assembly/services supplied by him meet/will meet the requirements as per specifications and good practices. Column 1Column 2Column 3- 3. 4. 6. reports. they shall be poured in the presence of BHEL QS Engineer unless otherwise. Column 8Acceptance Norms .Standards etc. according to which acceptability or otherwise of the characteristics being checked is decided. packing and despatch. drawings.) procedure. NO. SPEC. DRGS NO./ BHEL TECH. 5. CONTACTORS AIR CIRCUIT BREAKERS. ANGLES & CHANNEL 1.S & MCCB.1 MATERIAL 2 3 4 5 6 7 8 9 10 11 SECTIONS. PEM-6041-0 CUSTOMER : QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT./ APPD. IS INSPN. TRANSF. -DO- 3/2 - 2 1. FUSES. MAKE TYPE RATING ETC. BREAKAGES/ DAMAGES BHEL SPEC. /DATA SHEETS/ CERT./ RELEVENT IS -DO- TEST CERTIFICATE ROUTINE TEST CERTIFICATE 3/2 - 2. BIMETAL THERMAL RELAYS. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-002/01 ITEM :BOUGHT OUT ITEMS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION AGENCY P W V SL./ APPD.0 1.1 2. INSTRUMENT. TYPE/ METHOD OF CHECK FORMAT OF RECORD VOLUME III REMARKS 1 1. SURFACE CONDITION MA VISUAL 100% 3/2 - 2 TC FOR PLATING QUALITY TO BE PROVIDED 3. ISOLATORS.2 SWITCHGEAR COMPONENTS A) SWITCH. DIMENSIONS MA MEASUREMENT SAMPLE BHEL TECH. REPORT -DO- 2 - - MA VISUAL 100% 2 - - TO BE PROCURED FROM APPROVED MAKE MA ELECTRICAL 100% RELEVENT IS RELEVENT IS -DO- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 362 . & RELEVANT. IS RELEVANT. FUNCTIONAL TEST MA VISUAL 100% NO BREAKAGES/ DAMAGES BHEL SPEC. SPEC. /DATA SHEETS/ DRG./ TEST DRG./ RELEVENT IS 100% -DO- BHEL SPEC. FLATS. SURFACE PROTECTION (HARDWARES) MA VISUAL SAMPLE -DO- BHEL SPEC.S 1. MCB.FOREM NO. PHYSICAL CONDITION 4. DRGS INSPN. SFU'S SWITCH SFU'S. ROUTINE TESTS (FOR METERS CT'S & PT'S) MA ELECTRICAL 3/2 - 2 IF THESE ARE TAKEN FROM BHEL APPROVED SOURCE THEN TC NOT REQUIRED 3. TYPE TESTS MA ELECTRICAL EACH TYPE BHEL SPEC. HARDWARES. REPORT -DONO VISUAL DEFECTS -DO- 3/2 - 2 NO VISUAL DEFECT 2. / APPD. NAMEPLATES. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-002/01 ITEM :BOUGHT OUT ITEMS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION AGENCY P W V VOLUME III REMARKS SL.4 WIRES/CABLES 1./ APPD.DMC./ APPD. FERRULES. RELEVANT IS NO BREAKAGES/ DAMAGES BHEL SPEC. DRGS.ETC. GAUGES INSTRUMENTS GAUGES. RELEVANT IS NO BREAKAGES/ DAMAGES BHEL SPEC. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. IS:694 LOG BOOK/ INSP. PUSHBUTTONS. PROPS. DRGS. SURFACE FINISH 2. FUNCTIONAL STICKERS. 3. STD. LUGS./ APPD. RELEVANT IS INSPECTIONN REPORT -DO- 2 - - MA VISUAL 100% 2 - - TO BE PROCURED FROM APPROVED MAKE MA ELECTRICAL 100% -DO- 2 - - MA VISUAL 100% NO BREAKAGES/ DAMAGES BHEL SPEC. RELEVANT IS INSPECTION REPORT -DO- 2 - - MA VISUAL 100% 2 - - TO BE PROCURED FROM APPROVED MAKE MA ELECTRICAL 100% -DO- 2 - - REFER TO QP NO………PED-557-00-Q-002 1. REPORT -DO-DO- 2 - - MA CR HV MEASUREMENT ELECT. 2. TEST SAMPLE 100% 2 2 - - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 363 . B) INSTRUMENTS. MAKE. TEST SAMPLE SAMPLE -DO-DO- 2 3/2 - 1 1 MA VISUAL 100% NO VISUAL DEFECT BHEL SPECN. MECH. TEST ELECT.FOREM NO. GLANDS CONDITION SPACE HEATER. TERMINAL BLOCKS. FUNCTIONAL TEST D) PCB ASSEMBLY 1. NO. PVC SLEEVES/ CHANNELS C) RELAYS & TIMERS 1. RATING ETC 3.THERMOSTAT. -DO-DOTEST CERTIFICATE 2 1 2. DIMENSIONS 3.SMC. TYPE. 1 PHYSICAL CONNECTORS. ELECTRICAL CR ELECT. SMALL . LAMPS. MAKE. STD. PHYSICAL CONDITION 2. IS:694 NO VISUAL DEFECT BHEL SPECN./ RELEVANT IS MANUFS. TYPE. TEST SAMPLE BHEL SPEC. DRGS. DRGS.3 INSULATING MATERIALS (FRP. -DO-DOBHEL SPEC. RATING ETC SWITCHES./ RELEVANT IS MANUFS. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 4 5 6 7 8 9 10 11 1. 3.) MA VISUAL 100% NO BREAKAGES/ DAMAGES BHEL SPEC. LABELS. HV TEST AT 80% OF ORIGINAL BHEL MA MA MECH. TRACKING INDEX 1. 2 MA VISUAL 100% …. -DO- 8 SPEC. IS-3400/ BS-2752 MANUFACTURER'S DRGS. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 3 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. WAVINESS 3. -DO- RELEVANT STD. DIMENSION MA MEASUREMENT SAMPLE MANUFACTURER'S DRGS. IS-3400/ BS-2752 2 - - 2. MA ELECT TEST ELECT./ BHEL SPEC / APPD. OF TC 1/LOT -DO- -DO- TEST. MANUFACTURER'S STD. SPEC……. AGEING MA TEST -DO- 2 - - MA TEST -DO- 2 - - BHEL PARTICULAR NAME SIGNATURE DATE BIDDER / VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 364 . RUBBER ( ONLY) 1. DRGS. SURFACE FINISH 3. REPORT -DO2 10 - 11 2./ INSP. MANUFACTURER'S STD. SHORE HARDNESS 3. -DO- 9 LOG BOOK/ INSP. 1 DIMENSION 4 MA 5 MEASUREMENT 6 SAMPLE 7 SPEC.5 15 BUSBARS 2 3 1.9 GASKETS (SYN.7 TRANSFORMER & REACTORS 1 ROUTINE TESTS 1. TYPE/ METHOD OF CHECK FORMAT OF RECORD VOLUME III REMARKS 1 1. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-002/01 ITEM :BOUGHT OUT ITEMS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION AGENCY P W V SL. REPORT TEST CERT.FOREM NO. 4 CONDUCTIVITY 1. CERT 2 2 2 2 - 1 - 17 1. & STD BHEL SPEC.6 SHEET STEEL 1. 2 - 1 CR MA MA CR ELECT.8 PAINTS SHELF LIFE MA ELECT. TEMP. DRGS. MATERIAL GRADE 4. TEST 1/RATING -DO- 3 - 1.AS PER PAINTS MANUF'S. INSPN REPORT INSPN REPORT INSPN REPORT INSPN REPORT 2 - - 1. 100% RELEVANT STD. CERT. NO. THICKNESS 2.2 2. ELECT TEST MEASUREMENT MEASUREMENT BEND TEST -DODO SAMPLE 100% SAMPLES -DODO -DO-DO-DO- -DODO -DO-DO-DO- -DODO -DO-DOTEST. -DO- 3 - 12 1. RISE TEST 1. CERT. & STD BHEL SPEC. DUCTILITY MA VISUAL 100% 2 - - MA VERIF./ BHEL SPEC / APPD. REPORT 3 2 1 NOTE : INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE . BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 365 .9537 IS . MATERIAL MA VISUAL.1239 INSPT. TESTS MA TESTING IS .MECH.1239 IS . NO. DIMENSIONS MA MEASUREMENT IS .9537 INSPT. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 1. MATERIAL 4 MA 5 VISUAL. DIMENSIONS MA MEASUREMENT IS .1239 INSPT. REPORT 3 2 1 2.1239 IS . CHECK QUALITY PLAN : PROJECT: TITLE : QUALITY PLAN NUMBER PED-507-00-Q-006/02 ITEM : GALVANISED RIGID STEEL CONDUITS & PIPES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE : SECTION VOLUME III AGENCY REMARKS P W V SL.9537 IS . REPORT 3 2 1 3.1239 IS . & CHEMICAL 6 IS .1239 IS .9537 IS:9537 7 IS:9537 8 9 INSPT.9537 IS .1239 IS . REPORT 3 10 2 1 11 2. REPORT 3 2 1 2.MECH.CUSTOMER : BIDDER/ VENDOR SHEET 1 OF 1 SYSTEM COMPONENT/OPERATION CHARACTERISTICS CAT. & CHEMICAL IS .1239 IS .9537 INSPT.0 PIPES 1.0 CONDUITS 2 3 1.1. TESTS MA TESTING IS . REPORT 3 2 1 3.1239 INSPT.9537 IS . such as technical specification. shall be furnished to BHEL at the approproate stages or at the time of final inspection.affecting safety of equipment and personnel ‘MI’ stands for minor characteristic . Column 4Category -‘CR’ stands for critical characteristic . Column 5Type/Method of check e.affecting safety of equipment and personnel ‘MA’ stands for major Characteristic . leak tightness..affecting appearance etc. visual examination radiography etc.Documents. They shall include all stages of operation such as materials. If there are contradictions in respect of column 7 & 8 between this Quality Plan and the approved drawings specifications. etc. this shall be compiled with.g.Formats. etc.. they shall be poured in the presence of BHEL QS Engineer unless otherwise. material identification) samples shall be drawn bgy BHEL and all tests as per relevent specifications shall be carried out in their presence or in recognized Government Laboratory. 10. Wherever this is not possible. 366 . manufacture. processes. as required. ‘2’ Stands for Vendor ‘3’ stands for sub-Vendor of the Vendor and so on.The agency which performs the test/instruction shall be written in sub-column ‘W’ The agency which verifies test certificates/inspection records and carries out audit check of the components/operation shall be written in sub-column ‘V’ The agencies are codified as 1. assembly.Remarks . chemical composition. Example : Entry ‘3’ in column ‘P’ means test. mechanical properties.g.Agency . if any. 2. etc. according to which check is done.g. This Quality Plan is liable to be modified as per the requirements of approved drawings and changes in technical specifications/drawings. drawings. Column 9Format of Record .The component and/or operation being checked shall be given here. the identification mark shall be transferred to the components in the presence of BHEL QS Engineer unless other wise agreed. formats etc. reports. in which the observations are recorded. log sheets. The quality plan shall be submitted in minimum 4 copies with a soft copy of the same or in line with contract requirements. reports.2 & 3 ‘1’ stands for (BHEL) ‘1’ * means the operation shall be cleared by BHEL before the start of the next operation. according to which acceptability or otherwise of the characteristics being checked is decided.ANNEXURE – 1 INSTRUCTIONS FOR QUALITY PLAN The Quality Plan shall include all the Quality Control Measures and Checks adopted by the Vendor to ensure that the material/component/assembly/services supplied by him meet/will meet the requirements as per specifications and good practices. When welders qualified by reputed inspection agencies or statutory bodies are not available.Standards etc. the identification marks shall be presserved till despatch.) procedure. Column 10. Wherever inspection by BHELs Purchaser/Third Party/Statutory authorities are mandatory. such as. BS ETC. 6. Characteristics check. 4. Inspection reports. Column 7Reference Documents . In absence of correlation with the test certificate(s) (e. log shets. When this is not possible for casting.Any special remarks shall be given here.The characteristics being checked shall be given here. 5. qualification tests shall be conducted in the presence of BHEL QS Engineer. For castings and forgings integral test specimens shall be provided. e. standard specifications (IS. surface defects etc. of the Vendors shall be numbered and such reference numbers shall be included here. The following guide lines may be noted: Serial Number Component/Operation. 8. if witnessing of test by BHEL is called for. the latter shall prevail. test reports/certificate. 100. Column 1Column 2Column 3- 3. Column 8Acceptance Norms . hydraulic test. packing and despatch. 9. under scope of supply of Vendor. Standard log sheets. 1 percent etc./inspection to be witnessed by Vendor’s QC Entry ‘1’ in column ‘V’ means verification shall be done by BHEL and next stage to be started only after the hold point is cleared by BHEL Column11I. NOTES : 1. 7. chemical analysis tensile testing. When materials and components are initially identified and stamped by BHEL QS engineer./inspection to be performed by sub-Vendor’s QC Entry ‘2’ in column ‘W’ means test. This Quality Plan is also applicable to spares. Column 6Extent of check. DRGS/ DATA SHEETS -DORELEVANT IS. BIDDER/ VENDOR SYSTEM CAT.CLEANING GALVANISING PICKLING & RINSING.0 1.1 ZINC FOR GALVANISATION IN-PROCESS CUTTING. SPEC. DRGS/ TECH. -DO- MILL TEST CERTIFICATE 2 - - MA VISUAL 100% IR 3/2 - 2 MA MA MEASUREMENT 1/ LOT/SIZE SU / O /S MEASUREMENT 100% -DOO TECH.COMP. & PERIODIC MEASUREMENT IN EACH SHIFT IS:2629/ RELEVENT:IS IS:2629/ RELEVENT:IS IR 3/2 - - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 367 . SPEC.STD. SPEC. APPD. MA MA VISUAL CHEM.2 WELDING MA VISUAL & MALLET TEST SAMPLE MFR'S.3 2. DRGS/ TECH. SPEC. -DOO -DO- 2 3/2 - 2 1.3 SURFACE PREPARATION FOR 1.1 2 RAW MATERIAL MILD STEEL & COPPER (AS SPECIFIED) 3 4 5 6 7 8 9 10 11 1. STD MFR'S. DRILLING 1. DRGS/ DATA SHEETS -DORELEVANT IS. DRGS/ DATA SHEETS/ TECH.CHEM. BATH STRENGTH/ PURITY & TEMPERATURE BHEL MA CHEM.WELDING QUALITY 1.DIMENSIONS 2. SPEC.DIMENSIONS SO S MA CHEM & PHYS TESTS 1/ LOT/SIZE APPD.COATING 1. : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED 509 00 Q 001/01 PED-509-00-Q-001/01 ITEM : EARTHING COND.WORKMANSHIP DIMENSIONS & DISTORTION 1.0 2.2 HARDWARES 1.SURFACE FINISH 3 3. SPEC. -DOO TECH. -DO- APPD. & ELECTRODES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 1.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL. IR 2 - - 2. DRGS/ DATA SHEETS/ TECH.CHEMICAL & PHYSICAL PROPERTIES 2. IR 2 - - 2. APPD.TEST SAMPLE SAMPLE -DOTC 3/2 3/2 - 2 2 MA VISUAL & 100% MEASUREMENT APPD. NO. APPD. LOG BOOK 2 - - MA MEASUREMENT SAMPLES -DO- -DO- -DO- 2 - - 3. IS-2633 IR 2 1 - 2. NO.SPEC.BATH AGITATION 5.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL.DRG.4 GALVANISING 1. BIDDER/ VENDOR SYSTEM CAT. IS:4759 IR 2 1 - 3. : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-509-00-Q-001/01 ITEM : EARTHING COND.DIMENSION MA MEASUREMENT -DO- TECH.APPEARANCE MA VISUAL SAMPLE IS:2629 IS:2629 FREE FROM ROUGHNESS LUMPS ETC TECH.THICKNESS & ADHESION MA CHEM.0 FINAL TESTS 1.SURFACE QUALITY 4 MA VISUAL 5 100% 6 7 IS:2629/ RELEVENT:IS 8 IS:2629/ RELEVENT:IS -DOIR 9 3/2 10 - 11 2.SURFACE PREPN.ROSS QUANTITY AGITATION 4./ APPD.5 PAINTING 1. TECH.SPEC. & ELECTRODES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 2 3 2. DEGREASING & DERUSTING 2.SPEC.SPEC. TEST 100% TECH.SURFACE QUALITY MA TEMPERATURE INDICATOR VISUAL CONTINUOUS -DO- -DO- 3/2 - - MA PERIODIC -DO- -DO- -DO- 3/2 - - MA TEST PERIODIC RELEVENT:IS RELEVENT:IS -DO- 2 - - MA VISUAL PERIODIC MFR'S STD MFR'S STD -DO- 2 - - MA VISUAL 100% -DO- -DO- IR 3/2 - 2 2./ APPD.DRG.UNIFORMITY OF COATING MA DIP TEST SAMPLE AS PER IS-2633 IR 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 368 .DURATION OF DIP 3.TEMPERATURE OF BATH 2. SPEC. NO. IR 9 2 10 1 - 11 MA -DO- IS-2629 IS-2629 IR 2 1 - 6. : PROJECT TITLE QUALITY PLAN NUMBER PED-509-00-Q-001/01 ITEM : EARTHING COND. SPEC. & ELECTRODES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V SL. AND IS-2629 IR 2 1 - BHEL PARTICULAR NAME SIGNATURE DATE BIDDER / VENDOR BIDDER'S/VENDORS COMPANY SEAL 369 . TYPE/ METHOD OF CHECK EXTENT OF CHECK VOLUME III REMARKS 1 2 3 4.ADHESION 4 MA 5 PREECE TEST HAMMER/ KNIFE ELKOMETER 6 IS-4739 IS-6745 7 8 TECH. TECH. WEIGHT OF COATING 5.THICKNESS MA SAMPLES TECH.CUSTOMER : QUALITY PLAN SHEET 3 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. SPEC. CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL.2 ZINC 1.0 1. OF TC'S 100% IS:1079 IS:1079 MILL TC 3 - 2 STEEL SHALL BE PROCURED FROM SAIL/ TISCO/ RINL/ AUTHORISED RE-ROLLERS/ MANUFACTURERS AS PER BHEL APPROVED SOURCES. & FLUXING MA MEASUREMENT PERIODIC IN EACH SHIFT IS:2629 IS:2629 QC RECORD 2 - - 2.SURFACE QUALITY BHEL MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 370 .SURFACE FINISH MA MA MEASUREMENT 100% VISUAL 100% SPECIFICATION SPECIFICATION SPECIFICATION SPECIFICATION QC RECORD QC RECORD 2 2 1 1 2.TEST SAMPLE IS .209 QC RECORD 3/2 - 1/2 2.COMP. 2.DIMENSIONS 2.SURFACE FINISH 1.1 IN-PROCESS CUTTING. BIDDER/ VENDOR SYSTEM CAT.209 IS . DRILLING 1.CHEMICAL & PHYSICAL PROPERTIES MA VERIFICATION.0 2.DIMENSIONS 3.2 SURFACE PREPARATION 1. MA MA MEASUREMENT 100% VISUAL 100% IS . : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-509-00-Q-001/02 ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 1.1 2 RAW MATERIAL MILD STEEL (FLATS & RODS) AS PER SPECIFICATION 3 4 5 6 7 8 9 10 11 1.CLEANING PICKLING.1730 IS : 1079 QC RECORD QC RECORD 3/2 3/2 - - MA CHEM.1730 IS : 1079 IS . NO.CHEM. RINSING. BIDDER/ VENDOR SYSTEM CAT. ETC.2629 IS .4759 IS-2633 INSP. 1 - NOTE: INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE-1.0 FINISHED ITEMS 1.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL. REPORT 3 2.DIMENSIONS MA MEASUREMENT RANDOM SPECIFICATION SPECIFICATION INSP.2629/ MFRS PRACTICE IS .SURFACE FINISH MA VISUAL RANDOM SPECIFICATION FREE FROM BURRS. NO.2629 7 IS . FLUX. 1 - MA ELCOMETER IS .UNIFORMITY OF ZINC COATING 5. STAIN ETC. 1 - MA MECH. REPORT 3 2.SURFACE QUALITY MA VISUAL 100% IS . STAIN.2629 FREE FROM BURRS.MASS OF ZINC COATING 4. 1 - 2. 1 - MA CHEM. RATE OF IMMERSION MA VISUAL/ 100% MEASUREMENT IS . SLAG. ROUGHNESS. REPORT 3 2.3 GALVANISING 2 3 1.4759 IS-6745 / SPECIFICATION IS-2633 INSP.2629 QC RECORD 3 - - 3. REPORT 3 2. SPECIFICATION INSP.2629 8 9 QC RECORD 2 10 - 11 MA CONTINUOUS IS .ADHESION MA CHEM.2629/ MFRS PRACTICE QC RECORD 3 - 2 4. FLUX. REPORT 3 2. SLAG. REPORT 3 2. QC RECORD 2 - - 3. ROUGHNESS. DROSS 4 MA 5 TEMPERATURE INDICATOR VISUAL 6 CONTINUOUS IS . 1 - 3.THICKNESS OF ZINC COATING 6. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 371 . TEST IS . : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-509-00-Q-001/02 ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 2.TEST IS-4759 IS-2629 IS-2629 INSP. TEST IS .4759 SPECIFICATION SPECIFICATION INSP.TEMPERATURE OF BATH 2. 372 .affecting safety of equipment and personnel ‘MI’ stands for minor characteristic .g.Formats.2 & 3 ‘1’ stands for (BHEL) ‘1’ * means the operation shall be cleared by BHEL before the start of the next operation. reports. If there are contradictions in respect of column 7 & 8 between this Quality Plan and the approved drawings specifications. visual examination radiography etc. 8. under scope of supply of Vendor. Column 4Category -‘CR’ stands for critical characteristic . Example : Entry ‘3’ in column ‘P’ means test. standard specifications (IS. log sheets. BS ETC. The quality plan shall be submitted in minimum 4 copies with a soft copy of the same or in line with contract requirements. test reports/certificate. Column 10. 6. This Quality Plan is also applicable to spares. chemical composition.Documents.Standards etc. hydraulic test. Standard log sheets.g. the latter shall prevail. Column 9Format of Record . according to which check is done. For castings and forgings integral test specimens shall be provided. Column 6Extent of check. 4. in which the observations are recorded. 100.The agency which performs the test/instruction shall be written in sub-column ‘W’ The agency which verifies test certificates/inspection records and carries out audit check of the components/operation shall be written in sub-column ‘V’ The agencies are codified as 1. When materials and components are initially identified and stamped by BHEL QS engineer. such as technical specification. the identification marks shall be presserved till despatch. 5. etc. Column 1Column 2Column 3- 3. of the Vendors shall be numbered and such reference numbers shall be included here. leak tightness. ‘2’ Stands for Vendor ‘3’ stands for sub-Vendor of the Vendor and so on. material identification) samples shall be drawn bgy BHEL and all tests as per relevent specifications shall be carried out in their presence or in recognized Government Laboratory. drawings./inspection to be performed by sub-Vendor’s QC Entry ‘2’ in column ‘W’ means test. surface defects etc. e.affecting appearance etc. qualification tests shall be conducted in the presence of BHEL QS Engineer. mechanical properties. according to which acceptability or otherwise of the characteristics being checked is decided./inspection to be witnessed by Vendor’s QC Entry ‘1’ in column ‘V’ means verification shall be done by BHEL and next stage to be started only after the hold point is cleared by BHEL Column11I.ANNEXURE – 1 INSTRUCTIONS FOR QUALITY PLAN The Quality Plan shall include all the Quality Control Measures and Checks adopted by the Vendor to ensure that the material/component/assembly/services supplied by him meet/will meet the requirements as per specifications and good practices. the identification mark shall be transferred to the components in the presence of BHEL QS Engineer unless other wise agreed. etc. Characteristics check. Column 8Acceptance Norms . chemical analysis tensile testing. if any.. assembly. Inspection reports. The following guide lines may be noted: Serial Number Component/Operation.affecting safety of equipment and personnel ‘MA’ stands for major Characteristic . Wherever this is not possible.g. shall be furnished to BHEL at the approproate stages or at the time of final inspection.Agency . They shall include all stages of operation such as materials. 9. 10. 1 percent etc. etc. log shets. Wherever inspection by BHELs Purchaser/Third Party/Statutory authorities are mandatory. reports.) procedure.. as required. manufacture. This Quality Plan is liable to be modified as per the requirements of approved drawings and changes in technical specifications/drawings. processes. In absence of correlation with the test certificate(s) (e. Column 7Reference Documents . NOTES : 1. 2.Any special remarks shall be given here.The characteristics being checked shall be given here. this shall be compiled with. When this is not possible for casting. packing and despatch. formats etc.Remarks . such as.The component and/or operation being checked shall be given here. if witnessing of test by BHEL is called for. 7. When welders qualified by reputed inspection agencies or statutory bodies are not available. Column 5Type/Method of check e. they shall be poured in the presence of BHEL QS Engineer unless otherwise. SHADE 4. TEMPERATURE DIPPING TIME ETC. SURFACE FINISH & COVERAGE 2./ RELEVANT IS LOG BOOK 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - MA MEASUREMENT SAMPLE -DO- -DO- -DO- 2 - - MA MA VISUAL -DO-DO- -DO-DO- -DO-DO- -DO-DO- 2 2 - - CROSSOUT TAPE PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 373 .0 SURFACE PREPARATION & PRE-TREATMENT 1. -DO- 9 INSP. ALIGNMENT MA MA 4 5 MEASUREMENT MEASUREMENT & VISUAL VISUAL 100% 100% 6 7 APPD. DRG.) 2. NO. PROCESS PARAMETERS (SOLUTION STRENGTH.0 PRIMER & PAINTING (SPRAYED & STOVED) 1. DRG. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1.0 FABRICATION 2 3 1. FILM THICKNESS 3. SURFACE CONDITION 3. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-003/01 ITEM ELECTRICAL IN-PROCESS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V SL.REPORT 2 -DO2 - 10 - 11 3./ RELEVANT IS MFR./ BHEL SPEC. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 1 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. STD. STD.FORM NO. DIMENSION 2. ADHESION BHEL MA 100% -DO- -DO- -DO- 2 - - CR PROCESS CHECK PERIODIC MFR./ BHEL SPEC. -DO- 8 APPD. FINISH/ SURFACE DEFECT 2. BHEL SPEC.TIGHTNESS 3.0 MARKING/LABELLING 1. 8 MANUFACTURER DRAWINGS -DOAPPD. CERTIFICATE. CORRECTNESS MA MA VISUAL VISUAL 100% 100% -DO-DO- 2 2 - - MA MA VISUAL VISUAL 100% 100% -DO-DO- -DO-DO- -DOINSPN REPORT -DO- 2 2 - - 2. 9 LOG BOOK 2 - 10 - 11 2. DRG. TEST 2 & RELEVANT. ACCESSIBILITY 5. ADHESION/ FIXING 6. CORRECTNESS & COMPLETENESS 4. -DO-DO-DO-DO-DO-DO2 2 - - 2. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-003/01 ITEM ELECTRICAL IN-PROCESS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V SL. IR & HV CR CR ELECTRICAL ELECTRICAL 100% 100% - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 374 . DRG. STD. RIGIDITY MA 4 VISUAL 5 100% 6 7 MANUFACTURER DRAWINGS -DOAPPD.0 PRE-FINAL INSPECTION 1.FORM NO. SHEET 2 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 4.0 2 MOUNTING OF VARIOUS ITEMS 3 1. PERFORMANCE 3. STD. NO. & RELEVANT. PEM-6041-0 CUSTOMER QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. ALIGNMENT MA VISUAL 100% -DO- -DO- 2 - - MA VISUAL 100% BHEL SPEC. STD MANFR.1 2 BOUGHT OUT ITEMS ELECTRONIC COMPONENTS ACTIVE.ROUTINE TEST PCB CONNECTORS 1.0 2. MAKE/TYPE MA MA VISUAL ELECT. IS/ RELV. IS/ BS/ BHEL SPEC BS/ BHEL SPEC BHEL SPEC. : PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-002/01 ITEM ELECTRONIC PCB ASSEMBLY EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.0 1. LCSO/ BARC COMPONENT TO BE USED INSPC. MOUNTING & ORIENTATION 3. SOLDERING DEFECTS & FINISH MA VISUAL SAMPLE MANFR. LCSO/ BARC COMPONENT TO BE USED -DO-DO- 2 2 - 1 1 1. MAKE/ RATING TRANSISTORS 2. PASSIVE ICS. STD -DO2 - MA VISUAL 100% -DO- -DO- -DO- 2 - - CR VISUAL AT 10% 100% -DO- -DO- -DO- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 375 .CUSTOMER : QUALITY PLAN SHEET 1 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. CMOS ETC. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. & MECH VISUAL 100% 100% BHEL SPEC.3 MA SAMPLE -DO- 2 - 2 2. NO. MAKE/RATING MA VISUAL SAMPLE BHEL SPEC. LCSO/ BARC COMPONENT TO BE USED BHEL SPEC. CORRECTNESS OF COMPONENTS 2. REPORT 2 - 2 1./DRG. BHEL SPEC. RELV./DRG. 3 4 5 6 7 8 9 10 11 1. LCSO/ BARC COMPONENT TO BE USED BHEL SPEC.2 POWER DIODES/THYRISTORS/ 1.1 PROCESS COMPONENTS MOUNTING & SOLDERING 1. REPORT 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 376 . CYCLE AT+ 700C-200C FOR 30 MINTS. : SL./ MFR. STD.2 ASSEMBLED PCBS (INTERCONNECTED TOGETHER AS SYSTEM/ EQUIPMENT) 1. FIVE SUCH CYCLE 2./ MFR. AT ENERGISED CONDITION DO -DO- 2. AT EACH TEMP. NO. BHEL SPEC./ MFR. STD INSPN. FUNCTIONAL CHECK CR 1. STD. ELECTRICAL AFTER TEMP. SHEET 2 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK TYPE/ METHOD OF CHECK PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-002/01 ITEM ELECTRONIC PCB ASSEMBLY EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM FORMAT OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE : SECTION VOLUME III AGENCY REMARKS P W V 1 2 3 4 5 6 7 8 9 10 11 SOAKING AT 700C FOR 72 HRS. CYCLE: RAPID TEMP. TESTS 100% RELEVANT IS/ ANSI-C-37-90197 BHEL SPEC.CUSTOMER : QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. TEST CERT 2 - 1 100% DO -DO- DO -DO- DO -DO- 2 - 1 100% -DO- -DO- -DO- 2 - 1 TEMP. STD -DO- -DO- 2 1 - 3. CYCLE TEST 100% BHEL SPEC. ELECTRICAL BEFORE SOAKING 2./ MFR. 2 ELECTRICAL AFTER SOAKING OR 3. UNIFORMITY & FINISH OF CONFORMAL COATING ON BOTH SIDES CR VISUAL 100% BHEL SPEC. HV/ IR/ HV/ SWC MA ELECT. BHEL SPEC/DRG BHEL DRG.ROUTINE TESTS 6. BHEL SPEC/DRG INSP.TESTS ELEC TESTS ONE/TYPE & SIZE -DOBHEL SPEC. REPORT & TEST REPORT FROM MANUFACTURER -DOTEST CERT CERT.FRLS PROPS.ACCEPTANCE TESTS 5. SAMPLE BHEL DRG.CUSTOMER : QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. 2.0 JUNCTION BOXES.TESTS 100% 2KV AC FOR 1 MINUTE 2KV AC FOR 1 MINUTE -DO- 3 - 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 377 .DIMENSIONS 2.TYPE 3 TYPE TESTS MA CR MEASUREMENT SAMPLE ELEC. IS:694 IS:1554 9 INSPN.0 2 CABLES & WIRES 3 1.SURFACE DEFECTS 4 MA VISUAL 5 6 SAMPLE 7 BHEL SPEC.PAINT SHADE/ THICKNESS 3. : PROJECT TITLE QUALITY PLAN PED-558-00-Q-001/01 NUMBER PED 558 00 Q 001/01 ITEM :ILLUMINATION EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V SL.1 MA MA MEASUREMENT 100% VISUAL/MEAS.DIMENSIONS 3.HV/IR/HV MA -DO- SAMPLING -DO- 3 2 1 MA -DO- 100% -DO- -DO- -DO- 3 - 2. SPEC IS:694 IS:1554 -DO- -DOBHEL SPEC.1 CR FRLS TESTS SAMPLES BHEL SPEC BHEL SPEC -DO- 3 2 1 2. 3/2 10 2 1 11 TO BE PROCURED FROM APPROVED SOURCE 2. NO. TYPE/ METHOD OF CHECK FORMAT OF RECORD VOLUME III REMARKS 1 1. REPORT -DO- 3 3 - 2 2 COMPONENTS TO BE OF APPROVED MAKE MA ELECT. SPEC IS:694 IS:1554 -DO- 3/2 3 2 2 1 1 4. LIGHTING PANELS AND DISTRIBUTION BOARDS JUNCTION BOXES 1. IS:694 IS:1554 8 BHEL SPEC. BHEL SPEC. CAT : PROJECT TITLE QUALITY PLAN NUMBER PED-558-00-Q-001/01 ITEM :ILLUMINATION EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V SL. 4 MA TEST 5 6 1/SIZE IS:2147 7 IS:2147 8 9 TEST CERT. LUMINAIRES BHEL MA ELECT 1/RATING -DO- 3 2 1 MA TESTS SAMPLE BHEL SPEC/ RELEVANT IS BHEL SPEC/ RELEVANT IS TEST CERT 3/2 - 1 PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 378 .1 11 MA TEST 1/SIZE IS:2148 IS:2148 TEST CERT. SODIUM VAPOUR LAMPS.1 - BHEL SHALL WITNESS ON RANDOM ONE SAMPLE.RISE TEST (FOR CO S ( O COMPLETE ASSEMBLED LDB) 3.PAINT SHADE/ THICKNESS 3.TEMP.DEGREE OF PROTECTION (INCLUDING EXPLOSION PROOF IF ANY) 4. REPORT 3 3 2. BHEL SPEC/DRG INSPT.PERFORMANCE TESTS MA MA MEASUREMENT SAMPLE VISUAL/ -DOMEASUREMENT TESTS 1/SIZE BHEL DRG. REPORT 3 2.5KV AC FOR 1 MINUTE BHEL SPEC. 100% BHEL SPEC.CUSTOMER : QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.DIMENSIONS 2. REPORT 3 2.SPECIAL TESTS IF ANY. INSPT. INSPT.2 LIGHTING PANELS AND LIGHTING DISTRIBUTION BOARDS 1. - - 2. ACCEPTANCE TUBULAR FLUORESCENT TESTS LAMPS.1 MA ELECT. THOUGH EACH ITEM SHALL BE CHECKED BY THE MANUFACTURER -DO- 5. 10 2. TYPE/ METHOD OF CHECK FORMAT OF RECORD VOLUME III REMARKS 1 2 3 4. HP MERCURY VAPOUR LAMPS. 1. REPORT INSPT.DEGREE OF PROTECTION 5.1 2.HV/IR/HV MA ELECT 100% 2.1 - 6.EXPLOSION PROOF ETC.1 2. BHEL SPEC/DRG BHEL DRG. 2.5KV AC FOR 1 MINUTE BHEL SPEC. SL NO. BALLASTS.0 TUNGSTEN FILAMENT LAMPS.1 - COMPONENTS TO BE OF APPROVED MAKE MA BHEL SPEC/ RELEVANT IS BHEL SPEC/ RELEVANT IS TEST CERT - - 2. THE ITEM SHALL BE TESTED AT AN INDEPENDENT LAB.0 CONDUITS 2 3 1.CHEMICAL COMP.DIMENSIONS MA MEASUREMENT AS PER SPEC./ IS 9537 TEST AS PER SPEC.WEIGHT 4.OTHER TESTS MA AS PER SPEC. BHEL PARTICULAR NAME SIGNATURE DATE BIDDER / VENDOR BIDDER'S/VENDORS COMPANY SEAL 379 .2 FINAL INSPECTION 1. REPORT 3 2 1 5.1 2. TYPE/ METHOD OF CHECK FORMAT OF RECORD VOLUME III REMARKS 1 4. MA CHEM.1 ELECTRIC POLES MATERIAL 1.PHYSICAL PROP. 5.TESTS -DO- -DO- 3/2 - 2.DIMENSIONS 3.1 - MA MA MA -DO-DO-DO- -DO-DO-DO- -DO-DO-DO- 3/2 3/2 3/2 2.1 - NOTE: IN CASE TYPE TEST CERTIFICATE FOR DEGREE OF PROTECTION/EXPLOSION PROOFNESS FROM INDEPENDENT LAB.1 2./ IS:2713 -DO-DOIS-2713 -DO- 3/2 2.MECH. : PROJECT TITLE QUALITY PLAN NUMBER PED-558-00-Q-001/01 ITEM :ILLUMINATION EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V SL. & CHEMICAL 6 AS PER SPEC. IS NOT AVAILABLE.TESTS AS PER IS-2713 IS 2713 MA PHY.0 5.MATERIAL 4 MA 5 VISUAL.1 2./ IS:2713 -DO-DOIS-2713 BHEL DRG. NO. ANALYSIS SAMPLE IS-2713 IS:228 & IS:1894 -DOIS-2713 IS:228 & IS:1894 -DO-DO3/2 2./ IS 9537 IS:9537 7 IS:9537 8 9 INSPT.WORKMANSHIP AND FINISH 2./ IS 9537 IS:9537 IS:9537 INSPT.CUSTOMER : QUALITY PLAN SHEET 3 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. REPORT 10 3 2 1 11 2. REPORT 3 2 1 3./ IS 9537 IS:9537 INSPT.1 MA VISUAL & MEAS SAMPLES BHEL DRG. Tests Physical Tests Sample 100% Sample* 3/2 2 3/2 - 2 2 * Sample from each Batch/Lot.1 2 RAW MATERIAL 3 4 5 6 7 8 9 10 11 PVC Compound(for insulation 1. Dimension MA -do-do-do- -do-do-do- 3/2 3/2 3/2 - 2 2 2 3. -do-do-do- 3/2 - 2 MA MA MA Electrical Tests Visual Physical & Electrical Tests Measurement Galv. NO.Electrical properties 4. Chemical Composition & purity MA 3. Elec. IS-3975 BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-doBHEL SPEC.2 Galvanised steel wire/strip 1. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-004/01 ITEM :INSTRUMENTATION CABLES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.and Elec.3 Copper/Aluminium Rods/ Wires 1. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. Surface Finish 2. Phy. Properties 2. Log Book/ Test Cert.4 Screen & drain wire 1.Galvanization Quality MA 1. Dimension MA MA MA Chemical analysis -doElectrical Tests Measurement visual -do-dosample -do-do-doTC & IR 3/2 3/2 3/2 3/2 - 2 2 2 2 MA Measurement -do- Appd.0 1. Data ahwwt TC & IR 3/2 - 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 380 . IS-3975/BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-doBHEL SPEC. IS-5831/BHEL Specification -doPlant Std.Dimension 1. Data Sheet Appd. 1.Properties 3. Make & Type MA Physical Tests Sample IS-5831/BHEL Specification -doPlant Std. Physical properties and sheath) 2.CUSTOMER : QUALITY PLAN SHEET 1 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. Physical Properties MA 2. Tinning and Annealing 1. STD. Finish & dimension 2. Chemical Test Sample BHEL Specn. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 3. Electr. Sequence. STD. IS-8130 -doBHEL Specn.0 2.data sheet IS-1554 -do-do-do-do- 2 2 2 2 - 1 2 Insulation thickness CR Measurement Sample Appd.&Elect. MA 4 5 Mech test -do- 6 7 MFRS. lay length & Direction MA 3 Surface Finish 4. NO. & Apprd. Chemical test for Tinning CR Phy. Meas Visual Measurement Visual Sample Sample Sample 100% -do-do-do- -do-do-doFree from bulging burnt particles lumps. Appd. Tests Sample Visual & Meas. Data Sheet & Relevant IS -do- 2 - - 2. IS-8130 -doLog Book 2 1 CR -do- 2 - - 2.of wires MA Counting Sample Vendors/BHEL Specn.2 Stranding of wires 1.Dimension 2. 8 MFRS.CUSTOMER : QUALITY PLAN SHEET 2 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. & Apprd. Data Sheet & Relevant IS Vendors/BHEL Specn.data sheet IS-1554 -do- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 381 . Mech. Surface finish MA MA MA Visual.1 IN PROCESS Wire Drawing . Physical.3 Core Insulation (No repair permitted) 1. Prop. cuts & Scratches. No. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-004/01 ITEM :INSTRUMENTATION CABLES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. 9 TC & IR 3/2 - 10 2 11 2.. Sequence of lay and lay length 5. burnt particles. & appd. Concentricity # CR 4 5 Measurement 6 Sample 7 Mfr's Std. NO. IS-1554 data sheet -do- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 382 . 8 Mfr's Std. Surface finish MA Measurement 100% -do- 2 - - CR Elect. Dia over laid up core 7.4 Core pairing. Continuity of drain & drain wire with alum. & MFRs. Test 100% -do- -do- -do- 2 - 1 MA Visual meas Sample BHEL Spec.CUSTOMER : QUALITY PLAN SHEET 3 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. Data sheet -do- -doLog Book 2 2 - - 2. data sheet -doMfr's Std. Pair identification MA MA Visual Visual 100% 100% IS-1554 BHEL Spec. 9 Log Book 2 - 10 1 11 # To be checked at starting & finish end of Extruded Length 4 Dia over insulation MA Measurement Electrical Sample 100% -do-do- 2 2 - 1 5. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-004/01 ITEM :INSTRUMENTATION CABLES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL./Appd. Core identification 2. data sheet -doMfr's Std./Appd. Data sheet -do- IS-1554 BHEL Spec. Test 100% <--------No Discontinuity ----------> -do- 2 - - MA Visual 100% -- Free from bulging. Spark Test or Water CR Immersion test 6. Sheath thickness MA Measurement Sample IS-5831. Screen overlap & coverage 6. lumps cuts & scratches. IS-1554 data sheet -do- 2 - - 2. Std. & appd. IS-5831.Wire size & tape size 3.5 InnerSheath Extrusion 1. & MFRs. Screen 2. screening (provision of drain wire & laying) 1. Std. -do- 2 - 1 MA Measurement Sample -do- -do- -do- 2 - - MA Measurement -do- -do- -do- -do- 2 - - MA Elect.Test for capacitance 4. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 3. BHEL Spec. data sheet IS-1554 & BHEL Specn.7 Outer Sheath Extrusion 1. Sample * Test Report 2 - 1 * One Drum/Size/Lot BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 383 . Dia over outer sheath 4. BHEL Specn. the process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do100% -do-do-do-doFree from Bulging Burnt particles.CUSTOMER : QUALITY PLAN SHEET 4 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT./Appd..data sheet Test Report 2 - - Sequential marking shall be done by printing 2. Data Sheet -do- Log Book 2 - - 3./ Appd. lumps. 100% Test Report 2 - 1 2. Data Sheet -do- Log Book 2 - - 4. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-004/01 ITEM :INSTRUMENTATION CABLES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.Dia over inner sheath MA 4 5 Measurement 6 Sample 7 IS-5831./Appd. Routine Test CR Elec. Phy & Meas.8 Finished Cable 1. & Meas. At the start of BHEL Specn. No.of wires/Strips MA Counting At the start of BHEL Specn. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 3. IS-1554 data sheet 8 IS-5831. -dothe process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do-do-do- 2 - - 2. Type & FRLS Tests CR Elec. BHEL Specn./ Appd. IS-1554 data sheet -do- 9 2 - 10 - 11 2.6 Armouring 1. NO. Surface Finish MA MA MA Measurement Measurement Visual -do-doLog Book 2 2 2 - - 2. Dia over armouring 2. IS-1554 & BHEL Specn -do-/Apprd. Meas. Lay Length MA Visual. Lay Direction MA Visual 2 - - 3. Coverage 5. IS-1554 & BHEL Specn -do-/Apprd.Sheath thickness MA Measurement Sample IS-5831 & IS-1554 Appd. Marking MA Measurement Sample -do- 2 - - MA Visual 100% IS-1554 & BHEL Specn. cuts & scratches IS-5831 & IS-1554 Appd. VENDOR TO CERTIFY THE SAME. NO. NO REPAIR OF CORE INSULATION PERMITTED CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE RECORD OF RAW MATERIAL. Type & FRLS Tests MA Visual & Meas. : : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-004/01 ITEM :INSTRUMENTATION CABLES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. Finish & Length MA 4 Visual 5 6 7 8 Free from Bulging Burnt particles. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER. cuts & scratches Appd. PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC. THE SAME SHALL BE AS PER VENDORS SAMPLING PLAN VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION. IS-1554 2. Apprd. W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDOR LEGEND : P : PERFORMER BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 384 . Sample -do- 2 1 - MA Visual -do- -do- -do- -do- 2 1 - CR Elect. Tests 20% Measurement Sample# -doBHEL Specn. Marking/Colour/ pair identification 5. Apprd. lumps.Data Sheet/ IS-1554 & IS-10810 -do- Test Report 2 1 - 3.of Wires/Strips 4.Data Sheet -do-do- 2 2 1 1 #Type Test shall be witnessed on one sample of every lot NOTES:(A) (B) (C) (D) (E) (F) (G) (H) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. Test -do- -do- -do- -do- 2 1 - CR CR Phy & Elect. FILLERS/DUMMY CORES ETC. Test for screening 6.CUSTOMER QUALITY PLAN SHEET 5 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. Acceptance Tests 7. SHALL BE AS PER BHEL SPECIFICATION WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES.Data Sheet -doBHEL Specn.0 2 Final Inspection 3 1. Armouring Coverage No of No. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 3. Dimension MA Measurement Sample Lengths Appd.Data Sheet/ IS-1554 & IS-10810 -do- 9 Test Report 2 10 1 - 11 One drum in a Lot (See remark) BHEL specn. 2 1. TEST SAMPLE 100% -DOMFR'S TEST CERT.CUSTOMER QUALITY PLAN SHEET 1 OF 6 CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. ONENT/OPERATION NO. COMP. IR./ IS-1554/IS-694/ RELEVANT. MA EACH IS-209 IS-209 TEST CERT 3/2 - 1.2 WIRES 1. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V SL./ IS-1730 BHEL SPEC. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. TYPE / ROUTINE TESTS MA MA ELECTRICAL VERIFICATION OF TYPE / ROUTINE TEST CERTIFICATE CHEM. 3/2 3 - 1. THICKNESS MA VISUAL 100% -DO- 3/2 - - MA MEASUREMENT 100% BHEL SPEC.3 ZINC INGOT FOR GALVANISING CHEM. SURFACE FINISH DEFECTS 3. DUCTILITY CR BEND TEST SAMPLE IS-1079/IS-513/ IS-226 FACTORY STD IS-1079/IS-513/ IS-226 NO RUSTING LOG BOOK 3/2 - 2 FOR SHEET STEEL 2. IS -DO-DO- BHEL SPEC. HV.1 1. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. IR 3. MA VISUAL 100% -DO- 3/2 - - ONLY APPROVED MAKES TO BE USED 2. BOXES/ JN.2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 385 ./ IS-1554/IS-694/ RELEVANT. SURFACE DEFECTS.0 2 RAW MATERIAL & BOUGHT OUT CONTROL SHEET STEEL/CHANNELS 3 4 5 6 7 8 9 10 11 1./ IS-1730 BHEL SPEC. IS -DO-DO- -DO- 3/2 - 2 1. OPERATION/ FUNCTIONAL CHECK 3. PUSH BUTTON.1 IN-PROCESS CONTROL NIBBLING/PUNCHING 1. DRGS MFR'S STD -DO- -DOAPPR. CUTOUT SIZES MA MEASUREMENT 100% APPD. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.0 2. IR CR ELECTRICAL TEST SAMPLE RELEVANT IS AND RELEVANT IS AND CATALOGUE CATALOGUE DO -DO- 3/2 21 2. WELDING QUALITY MI MA MA MI VISUAL MEASUREMENT MEASUREMENT VISUAL 100% 100% 100% 100% -DOAPPR.FORM NO. INDICATING LAMPS. HV. DRGS MFR'S STD -DO- -DOLOG BOOK LOG BOOK -DO- 3/2 3/2 3/2 3/2 2 2 2 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 386 . CABLE GLANDS AND LUGS 1. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1.2 PANEL FABRICATION 1. & BOM 8 BHEL SPEC. TERMINALS GASKETS TERMINALS.1 2 2.3 2 ELECTRICAL COMPONENTS LIKE FUSE.1 2 MA ELECTRICAL 100% -DO- -DO- -DO- 3/2 2. BOXES/ JN. SWITCHES. NO.DEBURRING 2. DRGS LOG BOOK 3/2 2. DRGS APPD. MAKE TYPE RATING 3 MA 4 VISUAL 5 6 SAMPLE 7 BHEL SPEC. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 2 OF 6 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. ALIGNMENT 3. DIMENSIONS 2. IR. & BOM 9 LOG BOOK 3/2 - 10 - 11 2 OPERATION/ 2.1 STANDARD CUT OUTS TO BE DONE WITH DIES & PUNCHES ONLY 2. IS-6005 MFR. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. SPEC.. SHADE 4. . TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2. MFR.. DIPPING/ REMOVAL TIME 2. SPEC. ACID PICKLINGS IS NOT REQUIRED.. SPEC. PROCESS PARAMETERS LIKE BATH TEMP.4 PRIMER APPLICATION & PAINTING 1. FILM THICKNESS 3. IS-6005 9 LOG BOOK 3/2 - 10 - 11 IF SAND/SHOT BLASTING. MFR. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 3 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. NO. SURFACE QUALITY AFTER EVERY DIP MA 4 5 PROCESS CHECK 6 PERIODIC 7 BHEL SPEC. SPEC. CONCENTRATION. BOXES/ JN.FORM NO. SURFACE FINISH & COVERAGE 2.... Q MA VISUAL 100% -DO- -DO- -DO- 3/2 - - 2. IS-6005 8 BHEL SPEC. IS-6005 LOG BOOK 3/2 - - MA MEASUREMENT 100% -DO- -DO- -DO- 3/2 - 2 MA MA VISUAL SCRATCH TEST / CROSS OUT TAPE 100% TEMPLATE -DO-DO- -DO-DO- -DO-DO- 3/2 3/2 - 2 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 387 . BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V SL. ADHESION MA VISUAL 100% MFR.3 2 SURFACE PREPARATION AND PRE-TREATMENT (7 OR 8 TANK PROCESS) ( ) 3 1. IS BHEL SPEC. DRG RELEVANT. -DO- 8 APPD . ONENT/OPERATION NO.1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 388 .6 GALVANISATION PROCESS 1.1 FINAL INSPECTION COMPLETE JUNCTION BOX/ LCC'S MARSHALLING BOXES 1. DRGS & SPEC.5 2 WIRING. PAINT SHADE/GALV. GASKET. TEMP OF ZINC BATH 2. GROSS QUANTITY & AGITATION 3 3. -DO- 9 LOG BOOK 3/2 - 10 - 11 PVC CHANNELS TO BE USED 2. DRG RELEVANT. APPD. FREE FROM ROUGHNESS.FORM NO. WORKMANSHIP & FINISH. IS -DO- 2 - - MA VISUAL 100% BHEL SPEC. WORKMANSHIP AND FINISH CORRECTNESS COMPLETENESS 2. THICKNESS & ADHESION MA TESTS PERIODIC RELEVANT. APPD. NAME PLATE. 3 1. DRGS & SPEC. INDICATOR VISUAL CONTINUOUS -DO- IS-2629 IS-2629 QC RECORD 2 - - MA MANUFACTURER PRACTICE. DURATION OF DIP MA VISUAL 100% -DO- 3/2 - - MA TEMP. IS -DO- 2 - - 3. WIRING LAYOUT MA 4 VISUAL 5 100% 6 7 APPD . SURFACE QUALITY MA VISUAL 100% -DO- 2 - - 4. IS INSPN REPORT 3/2 2. RELEVANT. STAIN ETC. BOXES/ JN. FLUX. -DO- MANUFACTURER PRACTICE. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 4 OF 6 CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION : TITLE SECTION VOLUME III GENCY REMARKS P W V SL. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2. COMPONENT MOUNTING ETC. DRG -DO- 3/2 2. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 2. ACCESSIBILITY AND SAFETY 6. -DO- 3/2 2. NO.FORM NO.1 - MA PULLING SAMPLE -DO- NO LOOSE CONNECTIONS.1 - 8. DOOR LOCK FUNCTIONING MA OPERATON 100% APPD. APPD. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M.1 - MA VISUAL 100% APPD. COMPONENT LAYOUT & FIXING. DRG. UNIFORMITY OF ZINC COATING 3. DRG. BHEL SPEC. ALL TERMINATION TO BE LUGGED NO MISMATCH -DO- 3/2 2. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. THICKNESS OF ZINC COATING 4. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 5 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. BOXES/ JN.1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 389 . COMPONENT IDENTIFICATION (MARKING/ NAME PLATES) 7. -DO- 2 1 - MA MA VISUAL VISUAL 100% 100% -DO-DO- -DO-DO- -DO-DO- 3/2 3/2 2.1 2. WIRING LAYOUT 5. TEST 6 IS-5358 IS-2633 7 IS-2633 8 9 INSPN REPORT 2 10 1 - 11 MA ELCOMETER -DO- BHEL SPEC. PROPER WIRE TERMINATION MA 4 5 CHEM. DRG. CONTINUITY MA 4 5 MEASUREMENT 100% 6 7 APPD. DEGREE OF PROTECTION & FLAME/ EXPLOSION PROOF NOTE: CR ONE/ TYPE/ BHEL SPEC.1 - 13.1 - 11.. & RELEVANT IS -DO- 3/2 2. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL...1 - IR-HV-IR TEST TO BE DONE BEFORE OPERATIONAL TESTS 12. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. DRG. IR-HV-IR CR ELECTRICAL 100% -DO- 3/2 2. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 6 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.. SIZE RELEVANT IS ONE/ TYPE -DO- BHEL SPEC.1 - CR WATER AND DUST TESTS. DRG. BHEL SPEC. IF SPECIFIED IN BHEL SPEC. DRG. IF TC'S FOR DEGREE OF PROTECTION/EXPLOSION PROOFNESS IS AVAILABLE FROM AN INDEPENDENT LABORATORY FOR IDENTICAL DESIGN (SIZE SHALL BE SMALLER THAN THAT INDICATED IN THE TC) THESE TESTS NEED NOT BE REPEATED. BHEL SPEC. RELEVANT IS -DO- -DO- 3/2 2. REPORT -DO3/2 10 2. 8 APPD. PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BHEL BIDDER'S/VENDOR'S COMPANY SEAL 390 . 9 INSPN.FORM NO.1 - 11 CR ELECTRICAL 100% APPD.OPERATION INTERLOCKS ETC CR ELECTRICAL OPERATION AND FUNCTION IN ENERGISED CONDITION ELECTRICAL 100% -DO- -DO- -DO- 3/2 2. NO TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 9. BOXES/ JN. & RELEVANT IS -DO- APPD.OVERALL DIMENSIONS 10. TEMP RISE (IF APPLICABLE) 14. FLAME/ EXPLOSION TESTS -DO- 3/2 2 - FLAME/EXPLOSION PROOF TEST. 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 391 .1 11 2.0 ACCESSORIES 1.CUSTOMER : QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT.2 2.VISUAL AND DIMENSIONS MA TEST 2 2.0 2 FINISHED BATTERY / CELL 3 1. SHEET 1 OF 1 COMPONENT/OPERATION CHARACTERISTICS CHECK TYPE/ METHOD OF CHECK 1 1.2 - 10 2.ACCEPTANCE 2 ACCEPTANCE TEST 2. NO. : PROJECT TITLE QUALITY PLAN NUMBER PED-508-00-Q-002 ITEM LEAD ACID BATTERY (DC SYSTEM) EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE : SECTION VOLUME III AGENCY REMARKS P W V SL.TYPE TEST MA 4 TEST 5 6 IS:1651 & 1652/BHEL SPEC BSI:6290 Pt-4 -DODO 7 IS:1651 & 1652/BHEL SPEC BSI:6290 Pt-4 -DODO 8 IS:1651 & 1652/BHEL SPEC BSI:6290 Pt-4 -DODO 9 INSPN REPORT 3.1 21 - MA TEST 100% BHEL DRG BHEL DRG INSPECTION 3. M. INSP.0 2. QUALITY PLAN NO. APPD. DRG/ APPD . QUALITY PLAN NO. TYPE/ METHOD OF CHECK 1 1.FORM NO.0 3. VERIFICATION OF B. REPORT -DO-DO-DO-DO- 2 1 - MA MA MA MA VISUAL MEASUREMENT VISUAL MEASUREMENT 100% 100% 100% FEW PLACES IS-8623 IS-3427 BHEL SPEC. DRG. BD EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V QUALITY PLAN BIDDER/ VENDOR SHEET 1 OF 3 SYSTEM COMPONENT/OPERATION CHARACTERISTIC CAT. PAINT SHADE 5. DRG/ APPD . TESTS -DO- APPD.DATA SHEET. PEM-6041-0 CUSTOMER PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-001/01 ITEM LT SWGR/CONTROL PNLS/DIST. PHYSICAL BLEMISHES 2. PAINT THICKNESS MA VISUAL 100% BHEL SPEC.& OTHER RELEVANT IS 2 2 2 2 1 1 1 1 2.O. APPD. BHEL SPEC. DRG. -DO- 2 1 - MA VISUAL 100% -DO- -DO- -DO- 2 1 - MA MECH. INTER CHANGEABILITY MA MECH. CHECK SL. GLANDS & LUGS TO BE SUPPLIED ALONG WITH BOARDS 1. PED-506-00-Q-003 1.0 2 BOUGHT OUT ITEMS IN-PROCESS FINAL INSPECTION 3 4 5 6 7 8 9 10 11 REF. PED-506-00-Q-002 REF. TESTS 10% -DO- -DO- -DO- 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 392 . DIMENSION 4. NO.& OTHER RELEVANT IS IS-8623 IS-3427 BHEL SPEC. PAINT ADHESION 7. ALIGNMENT 3. 8. APPD. SHIPPING SECTION JOINTS PLATES TO BE SUPPLIED 6.DATA SHEET. WIRING NEATCR NESS & FIRMNESS 16. TESTS SAMPLE MANUFACTURER'S STANDARD MANUFACTURER'S -DOSTANDARD 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 393 . PEM-6041-0 CUSTOMER PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-001/01 ITEM LT SWGR/CONTROL PNLS/DIST.FORM NO. TESTS SECONDARY INJECTION 1/ITEM 100% -DO- -DO- -DO- 2 1 - SHALL INCLUDE REMOTE SIMULATION SEE NOTE 'C' PHYSICAL VERIFICATION DURING INSPECTION CR CR -DO-DO- -DO-DO- -DO-DO- 2 2 1 1 - MA MECH./ APPD./ APPD. BD EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V QUALITY PLAN BIDDER/ VENDOR SHEET 2 OF 3 SYSTEM COMPONENT/OPERATION CHARACTERISTIC CAT. DRG. TYPE/ METHOD OF CHECK 1 2 3 9. FUNCTION PERFORMANCE 11. 100% TESTS ELECT. TESTS 6 100% 7 APPD. 8 APPD. DRG. ROUTINE TESTS 10. NO.DRG. INTERLOCKS. PROTECTION & METERING 13. CHECK SL. BHEL SPEC. & MECH. TYPE TESTS 12. DRG. BUS BAR TIGHTNESS MA VISUAL 100% BHEL SPEC. EASE OF WITHDRAWAL & INSERTION CR 4 5 ELECT . -DO- 9 2 10 1 - 11 CR ELECT. -DO- 2 1 - PULLING SAMPLE -DO- -DO- -DO- 2 1 - MECH. TESTS 100% -DO- -DO- -DO- 2 1 - 14. ACCESSIBILITY MA OF COMPONENT & SAFETY (SHROUDING) 15. TYPE TESTS WILL INCLUDE (BESIDES OTHERS) 1. ONLY APPROVED MAKE OF COMPONENTS ARE TO BE USED. D. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 394 . IF ANY 3. P & Q TEST REGARDING ACCEPTANCE OF AVAILABLE TYPE TCS. 3 4 5 6 7 8 9 10 11 C. PEM-6041-0 CUSTOMER PROJECT TITLE BIDDER/ VENDOR SHEET 3 OF 3 SYSTEM COMPONENT/OPERATION CHARACTERISTIC CAT. 9.4 OF SPECIFICATION NO. NO.NO. FUNCTIONAL/PERFORMANCE CHECKS TO BE CONDUCTED ON ENTIRE BOARD AND ALL POWER SUPPLIES SWITCHED ON. CABLE TYPE/ METHOD OF CHECK SPECIFICATION TITLE NUMBER PED-506-00-Q-001/01 SECTION VOLUME III ITEM LT SWGR/CONTROL PNLS/DIST. CHECK SPECIFICATION NUMBER QUALITY PLAN SL. PES-506-01. INDIVIDUAL BREAKER SHALL BE TESTED AT VARIOUS POSITIONS AND AT NORMAL +10% AND -10% OF CONTROL SUPPLY. REFER CL. TEMPERATURE RISE TEST 2. SHORT TIME CURRENT TEST 4. B.FORM NO. DEGREE OF PROTECTION TEST AND EXPLOSION PROOF TEST. E. BD EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS CHECK DOCUMENT NORM OF RECORD P W V QUALITY PLAN 1 2 NOTE : A. 1 2.BEND TEST (MS ONLY) 1./LOG BOOK -DO- 3 - 2. DAMAGE DAMAGE 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 395 .CUSTOMER : QUALITY PLAN SHEET 1 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. DIMENSION MA 4 5 MEASUREMENT 100% 6 7 BHEL SPECS. IS MRF TEST CERT.TYPE TEST MA ELECTRICAL/ MEASUREMENT VISUAL 1/TYPE -DO- -DO- 3 - 2./ RELEV.ELECTRICAL CONDUCTIVITY 1.SURFACE FINISH 3./ IS:5082/IS:736 IS:737/IS:1897 -DO-DO-DO- 8 BHEL SPECS.SURFACE CONDITION RATING & MARKING MA 100% BHEL SPECS.3 INSULATORS.0 1.1 2 MATERIALS/COMPONENTS ALUMINIUM AND COPPER BARS & FLEXIBLES 3 1.SURFACE FINISH 3.DIMENSIONS PHY./ IS:5082/IS:736 IS:737/IS:1897 -DO-DO-DO- 9 TEST CERT 2 - 10 - 11 2. IS/ NO PHY. NO./ RELEV. SEAL OFF BUSHING. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. WIRES. IS/PHY. IS:513 / BHEL SPECS. CONDITION BHEL SPECS. SPACE HEATERS 1. IS/PHY. CONDITION -DO- 2 - - 4./ -DORELEV. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. CABLES. MA CONDITION MEASUREMENT SAMPLE BHEL SPECS. IS/ NO PHY. DIMENSION MA MA MA VISUAL VISUAL ELECTRICAL 100% 100% SAMPLE -DO-DO-DO- 2 2 3./ RELEV.ROUTINE TEST MA MA MA VISUAL VISUAL VISUAL 100% 100% -DO-DO- -DO-DO-DO- -DO-DO-DO- 2 2 2 - - 1PIECE/LOT -DO- MA ELECTRICAL/ MEASUREMENT 100% BHEL SPECS.2 ENCLOSURE MATERIALS 1.FLATNESS 4./ BHEL SPECS.2 - 2. RELEV.1 FOR INSULATOR BUSHING 3./ RELEV IS BHEL SPECS. INSP REPORT 2 - - 2.1 MA MEASUREMENT 100% IS:513 / BHEL SPECS.FLATNESS 4. IS 8 BHEL SPECS. STD 3 - 1. DIMENSION & MATERIAL CERTIFICATE MA MA AGEING TEST MEAS & TESTS 3 3.2 - 10 1 11 1.DIMENSION MA MEASUREMENT RANDOM CHECK -DO- -DO- LOG BOOK 2 - - 2.2 - 2.SURFACE FINISH 3.5 NEOPRENE RUBBER BELLOWS & GASKET 1.SHORE HARDNESS 1. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 5./BS-2752 -DOMANUFS STD RELV.CUSTOMER : QUALITY PLAN SHEET 2 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. REPORT & TC 2 - 1 MA MEASUREMENT 1PIECE/LOT IS-3400/BHEL SPEC. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. NO./ RELEV. REPORT 3.AGEING TEST 1. REPORT TEST REPORT -DOINSP.1 IN-PROCESS FABRICATION OF ENCLOSURES BHEL DIMENSION MA MEASUREMENT 100% APPD./BS-2752 -DO1/LOT -DOMANUFS STD RELV. DISC WASHERS 1.OIL ABSORPTION MA VISUAL -DO- -DO- -DO- -DO- 2 - - MA MEASUREMENT SAMPLE MANUFS STD MANUFS STD INSP.2 - 1./MFG DRG INSP REPORT 2 - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 396 .6 BUS BAR SLEEVES 1. STD IS-3400/BHEL SPEC.TRACKING INDEX (FOR INSULATION MATERIAL) MA 4 5 ELECTRICAL 6 SAMPLE 7 BHEL SPECS.4 BELLEVILLI WASHERS./ RELEV. & SPRING WASHERS & FASTENERS.2 2. IS 9 INSP./MFG DRG APPD. PLAIN SPRING.0 2. TIME ETC.FILM THICKNESS 2./PAINTING/ SLEEVING) ASSEMBLY BUSBAR ASSEMBLY 1.4 FINISHING OF BUSBARS/ FLEXIBLES (TINNING/ PLATING.PHASE SEQUENCE 1.0 3.ORIENTATION 2.CUSTOMER : QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. BS-159/BS-162 ASSEMBLY DRG/ BHEL SPEC. SHEET 3 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 2.SURFACE CONDITION 2.TYPE OF FINISH MA MA 100% PERIODIC -DOIS-6005 RELV. -DO- 2 - - 3. IS -DOIS-6005 RELV.FINISH 3 MA MA 4 VISUAL 5 100% 100% 6 7 MANUF'S STD -DO- 8 MANUF'S STD -DO- 9 INSP REPORT 2 -DO2 - 10 - 11 3.PROCESS PARAMETERS (SOLUTION STRENGTH TEMP. BHEL SPEC/FAB DRG/IS SPEC. BS-159/BS-162 -DO- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 397 .3 INITIAL PAINTING (PRIMER) 1.2 SURFACE PREPARATION INCLUDING PHOSPHATING & PASSIVATION 1.1 MA VERIFICATION 100% ASSEMBLY DRG/ BHEL SPEC. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. IS -DO-DO- 2 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - MA MEASUREMENT 100% -DO- -DO- -DO- 2 - - MA VISUAL 100% BHEL SPEC/FAB DRG/IS SPEC. 2. NO.ALIGNMENT VISUAL & MEASUREMENT VISUAL PROCESS CHECKS 4.SURFACE FINISH & COVERAGE 2. ASSEMBLY DRG.CLEARANCE TO BODY /EARTH & PHASE TO PHASE 3. MANUFS STD BHEL SPEC.TIGHTNESS OF JOINTS AND FLEXIBLE 6. -DO-DO-DO-DO- -DO- 2 - - MA MA MA MA VISUAL VISUAL VISUAL MECHANICAL 100% 100% 100% 100% - 2 2 2 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 398 .MARKINGS 4. -DO-DO-DO-DO- BHEL SPEC. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 2.SURFACE MA PREPARATION FOR JT.LOCATION 3.SIZE & MATERIAL 2. MANUFS STD INSP REPORT 2 - 1 MA MEASUREMENT 100% -DO- -DO- -DO- 2 - 1 ALUMINIUM BUS BARS JOINTS WILL BE BOLTED WITH BILLET WASHER AND THIGHTENING SHALL BE DONE BY TORQUE WRENCH ALSO THE JOINT SURFACE SHALL HAVE SUITABLE COMPOUND MA MEASUREMENT 100% BHEL SPEC.TERMINATIONS 5.TIGHTNESS TO SUPPORTS MA VISUAL 100% MANUF'S STD MANUF'S STD INSP REPORT 2 - - MECHANICAL 100% BHEL SPEC.2 EARTHING 1.TIGHTNESS OF SUPPORTS MA 4 VISUAL 5 100% 100% 6 -DO-DO- 7 -DO-DO- 8 -DO-DO- 9 2 2 - 10 - 11 MECHANICAL 4.CUSTOMER : QUALITY PLAN SHEET 4 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.PREPERATION & APPLYING CONDUCTING MEDIUM 5. NO.BUSBAR MARKING MA 3. ASSEMBLY DRG. 0 4.NAME PLATES AND DANGER NAME PLATES MA 4 VISUAL 5 100% 6 -DO- 7 -DO- 8 -DO- 9 2 - 10 - 11 MA VISUAL 100% -DO- -DO- -DO- 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - 4. -DO-DO- 2 1 - 3. LOG SHEET 100% BHEL SPEC LAYOUT DRGS/ FAB.COMPLETE LAYOUT MA VISUAL BHEL SPEC LAYOUT DRGS/ FAB. INSPN. VARNISH BEFORE PACKING REPORTS TO BE SUBMITTED TO BHEL IT SHALL BE POSSIBLE TO ADJUST TEMP KNOB THERMOSTAT FROM INSPECTION COVER. NO. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 3.EARTH MARKING 3.BUSBAR MARKING 4.CUSTOMER QUALITY PLAN SHEET 5 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.3 2 IDENTIFICATION MARKINGS & NAME PLATES 3 1.DIMENSIONS MA MEASUREMENT 100% APPD. MA VISUAL 100% -DO- -DO- -DO- 2 1 - MA VISUAL 100% -DO- -DO- -DO- 2 1 - MA VISUAL 100% -DO- -DO- -DO- 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 399 .ALIGNMENT OF SECTION 6.DRG..COVERS 5. : : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.GENERAL & MARKINGAPPEARANCE 4. -DOAPPD.DRG.SECTIONAL IDENTIFICATION 2. REPORT 2 1 - 2.DRG.DRG.EARTH BUS ALIGNMENTS & MARKING MA VISUAL 100% 2 1 - ALL HARDWARES WHICH ARE EXPOSED TO OUTDOOR SHALL BE TOUCHED WITH ANTI CORROSSION RUST PREVENTION SOLUTION.FITTING OF INSPN.1 COMPLETE ASSEMBLY APPEARANCE AND CLEANLINESS 1. NO.IDENTIFICATION MARKING ON PACKING CASES MA ELECTRICAL SAMPLE -DO- 2 1 - MA AS PER SPEC SAMPLE -DO- -DO- -DO- 2 1 - MA ELECTRICAL SAMPLE -DO- -DO- -DO- 2 1 - MA ELECTRICAL SAMPLE -DO- -DO- -DO- 2 1 - MA AS PER SPEC SAMPLE -DO- -DO- -DO- 2 1 - MA VISUAL 100% PURCHASER'S INSTRUCTION PURCHASER'S INSTRUCTION 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 400 .TEMPERATURE RISE 3.MARKINGS ON THE SECTIONS 8.2 TESTS 1. : : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. -DO- LOG BOOK 3.2 - 2 MA MA SCRATCH TEST ELECTRICAL TEMPLATE 100% -DOTEST CERT/ REPORT 3.DRGS/ BHEL SPEC MFR SPEC -DOIS-8084 ANSI C37 20/ ANSI-C37-20/ BHEL SPEC. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 7.SHORT CKT TEST 5. PRESERVATION & PACKING 1.2 2 1 2 - 4.CUSTOMER QUALITY PLAN SHEET 6 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.OTHER TYPE TESTS. IF ANY 5.IMPULSE TEST 6.0 IDENTIFICATION.PAINT THICKNESS SHADE 9.DRGS/ BHEL SPEC MFR SPEC -DOIS-8084 ANSI C37 20/ ANSI-C37-20/ BHEL SPEC.ROUTINE TESTS 2.DEGREE OF PROTECTION 4.ADHESION MA 4 VISUAL 5 100% 6 -DO- 7 -DO- 8 -DO- 9 2 10 1 - 11 MA VISUAL 100% APPD. -DO- APPD. NO. DIMENSIONS MA MEASUREMENT 100% -DO- -DO- -DO- 3/2 - - 3. BHEL DRG. DIMENSIONS MA MEASUREMENT 10% 2. CHEMICAL COMPOSITION MI MA VISUAL BEND TEST 100% SAMPLES IS-1079 IS-2026 IS-513 -DODO IS-1079 IS-2026 IS-513 -DODO INSPN./SPEC. TYPE/ METHOD OF CHECK 1 1.3 RESISTOR GRIDS 1. DUCTILITY OF SHEET 1./SPEC. REPORT 2 2 3/2 - 2 CHEM ANALYSIS 1/ MELT 1. 2 SURFACE FINISH 3. MFG. DRAWING MFG. PEM-6041-0 SPECIFICATION: NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. SURFACE FINISH CR VISUAL 100% BHEL DRG.CUSTOMER QUALITY PLAN SHEET 1 OF4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. DRAWING 3/2 - - 2. SURFACE FINISH 3. DIMENSIONS 2. FROM SUPPLIER INSPN.0 1. REPORT -DODO 2 - - 2 - - MA MI MA MEASUREMENT 10% VISUAL 100% IS-1897 -DO-do- IS-1897 -DO-do- -DO-DOTEST CERT. RESISTANCE VALUE MA ELECTRICAL 10% -DO- -DO- -DO- 3/2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 401 . PROJECT TITLE QUALITY PLAN NUMBER PED-505-00-Q-002/01 ITEM NEUTRAL GROUNDING RESISTOR EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD FORM NO.2 COPPER FLATS 1.1 MATERIALS 2 3 4 5 6 7 8 9 10 11 SHEET STEEL AND STRUCTURES 1. PEM-6041-0 SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.1 FABRICATION CUTTING. PUNCHING. DRAWING MFR'S. STD.5 MEASUREMENT 10% MEASUREMENT 100% MA ELEC. DIMENSIONS 2. FINISH MA MA MA MEASUREMENT 100% VISUAL VISUAL 100% 100% APPD. DRAWING MFR'S.F. STD. DRILLING ETC 1. BENDING. IS BHEL SPECN IS TEST CERT. HV TEST MA MA MA MA MEASUREMENT 100% VISUAL INSPN INSPN. STD. TYPE/ METHOD OF CHECK 1 2 3 4. 2 SURFACE 1.4 MICA INSULATED TIE-RODS MICA WASHERS. 100% BHEL SPECN. DRAWING MFR'S.2 SURFACE PREPARATION 1. DRY P. 2 - 1 2 2. SURFACE FINISH & DEFECTS 3. DIMENSIONS 2./MFG./MFG -DO-DOAPPD. DRAWING MFR'S. DRAWING 1. SURFACE CONDITION 1. STEEL WASHER PORCELAIN INSULATORS (POST & BUSHING TYPES) 1./SPEC. -DO-DOINSPN REPORT -DO-DO2 2 2 - 2. CHEMICAL COMPOSITION MA 4 5 6 7 8 9 TEST 3/2 CERTIFICATE -DO-DODO -DO-DO2 2 2 2 - 10 1 11 CHEM ANALYSIS 1/ LOT BHEL DRG. MFG. SURFACE FINISH & COVERAGE 2. BHEL DRG. DIMENSIONS 2. STD.3 PAINTING MA VISUAL 100% -DO- -DO- -DO- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 402 ./SPEC. NO. DRAWING MFG. PROJECT TITLE QUALITY PLAN NUMBER PED-505-00-Q-002/01 ITEM NEUTRAL GROUNDING RESISTOR EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD FORM NO. 100% - PORCELAIN INSULATORS SHALL BE OF APPROVED MAKE 1.CUSTOMER QUALITY PLAN SHEET 2 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. NO. DIMENSIONS 4 4. HV TEST CR ELECTRICAL 100% -DO- 2 - - MA MEASUREMENT 100% -DO- -DO- 2 - - CR ELECTRICAL 100% BHEL SPECN/ IS-1822 BS-587 -DO- BHEL SPECN IS-1822 BS-587 -DO- TEST REPORT 2 1 - 2. 9 INSPN REPORT 2 - 10 - 11 3 3. HV TEST CR ELECTRICAL 100% BHEL SPECN/ IS-1822/ BS-587 -DOBHEL SPECN IS-1822/ BS-587 -DOTEST REPORT 2 - 2. FILM THICKNESS MA 4 5 MEASUREMENT 100% 6 7 APPD./MFG.RESISTANCE VALUE 3.RESISTANCE VALUE 3.CUSTOMER QUALITY PLAN SHEET 3 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. PEM-6041-0 SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. CABLE TYPE/ METHOD OF CHECK 1 2 3 2.1 FINAL ASSEMBLY COMPLETE NGR 1.1 SUB-ASSEMBLY RESISTOR UNIT FRAME ASSEMBLED 1. DIMENSIONS CR ELECTRICAL 100% 2 1 - MA MEASUREMENT 100% -DO- -DOBIDDER/VENDOR 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER'S/VENDOR'S COMPANY SEAL 403 . PROJECT TITLE QUALITY PLAN NUMBER PED-505-00-Q-002/01 ITEM NEUTRAL GROUNDING RESISTOR EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD FORM NO./MFG 8 APPD. TYPE/ METHOD OF CHECK 1 2 3 4. SHORT TIME RATING/TEMPERATURE RISE TEST 5.CUSTOMER QUALITY PLAN SHEET 4 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/01 ITEM NEUTRAL GROUNDING RESISTOR EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD FORM NO. NO. DEGREE OF PROTECTION 6. PAINT THICKNESS 8./ IS-5 -DO- BHEL SPEC./ IS:1822 BS:587 IS-2147 8 BHEL SPEC. PAINT SHADE MA GAUGE ALL 2 1 - MI VISUAL-SHADE CARD ALL -DO- -DO- 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 404 . PAINT FINISH MA 4 5 HEAT RUN 6 1/TYPE 7 BHEL SPEC. PEM-6041-0 SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL./ IS-5 -DO- 2 1 - 7./ IS:1822 BS:587 BHEL SPEC 9 3 10 1 - 11 MA AS PER IS-2147 IS 2147 VISUAL 1/TYPE TEST REPORT 2 - 1 MA 100% BHEL SPEC. PED-557-00-Q-002 1.0 HANDSET 1. DEGREE OF PROTECTION 5. ROUTINE TEST 4. SIDE TONE 6. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. : PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-001/01 ITEM PUBLIC ADDRESS SYSTEM EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. ACCEPTANCE TEST 3. IS7741.0 2 MATERIAL/ BOUGHT OUT ITEMS IN-PROCESS PCB ASSEMBLY SPEAKERS 3 4 5 6 7 8 9 10 11 AS PER QUALITY PLAN NO. MEAS SAMPLE -DO- -DO-DO- 3 3 1/2 1/2 - MA -DO- -DO- -DO- -DO- -DO- 3 1/2 - MA MA -DO-DO- -DO-DO- -DO-DO- -DO-DO- -DO-DO- 3 3 1/2 1/2 - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 405 . PED-506-00-Q-002 2.IS/BS/ IEC -DO-DO- BHEL/SPEC RELV. IS7527 -DOBHEL. SPEC. NO.WORKMANSHIP MA AS PER IS -DO- 3/2 2 1 MA MA -DO-DO- 100% AS PER IS -DO-DO- -DO-DO- -DO-DO- 3/2 3/2 2 - 1/2 MA VISUAL 100% BHEL/SPEC RELV. SPEC.0 4. TYPE TEST MA ELECT. PED-506-00-Q-003 AS PER QUALITY PLAN NO. OUTPUT CHARACTERISTICS 5. & MEAS -DO1/TYPE BHEL.0 3.IS/BS/ IEC -DO-DO- -DO- 3 1/2 - 2. COLOUR 3. IS7527 -DOTEST CERT.INPUT CHARACTERISTICS 4. IS7741.0 AS PER QUALITY PLAN NO. 3/2 2 1 2.CUSTOMER : QUALITY PLAN SHEET 1 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.LIMITING BHEL MA MA VISUAL ELECT. DATA SHEETS. DRG. : PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-001/01 ITEM PUBLIC ADDRESS SYSTEM EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. & RELV. WIRING LAYOUT 3. DATA SHEETS. SOUNDNESS OF MOUNTING & CONSTRUCTION ETC. RIGIDITY. & RELV.CUSTOMER : QUALITY PLAN SHEET 2 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. IS/ BS -DO-DO- BHEL SPEC APPD. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 7.TERMINAL BLOCK ARRANGEMENT MA MA -DOPULL TEST -DO-DO- -DO-DO- 2 2 1 1 - MA VISUAL -DO- -DO- -DO- -DO- 2 1 - MA -DO- -DO- -DO- -DO- -DO- 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 406 . OPERATION MA 4 5 ELECT.WIRE TERMINATION(SOLDERING OR CRIMPED LUGS) 4. 6 FINAL ASSEMBLY ( SYSTEM ) 1. IS/ BS -DO-DO- TC 2 1 - 2. MEAS 6 SAMPLE 7 BHEL/SPEC RELV.IS/BS/ IEC -DO- 8 BHEL/SPEC RELV. DEGREE OF PROTECTION 9.2 11 8.IS/BS/ IEC -DO-DO- 9 3 10 1. WORKMANSHIP MA MEASUREMENT -DO- -DO- 3 - 1/2 MA DROP & VIBRATION TEST -DO- -DO- -DO- -DO- 3 - 1/2 MA VISUAL 100% BHEL SPEC APPD. NO. FERRULE NUMBERING 5. DRG. PAINT SHADE & FINISH 12.PAINT THICKNESS 13.DRIFT -DOETC 15.OPERATION/ FUNCTIONAL CHECK BHEL CR ELECTRICAL -DO- -DO- -DO- 2 1 - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 407 . & RELV. DRG.COMPONENT LAYOUT MA -DO- -DO- -DO- 2 1 - MA -DO- -DO- -DO- -DO- -DO- 2 1 - MA -DO- -DO- -DO- -DO- -DO- 2 1 - 10. : PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-001/01 ITEM PUBLIC ADDRESS SYSTEM EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.IDENTIFICATIONMARKS 11. IS/ BS -DO- 8 BHEL SPEC APPD.PROPER MA MOUNTING OF ITEM 4 VISUAL 5 100% 6 7 BHEL SPEC APPD. DATA SHEETS. DRG.DIMENSION 14 SCREENING MA -DO- -DO- -DO- -DO- -DO- 2 1 - MA -DO- -DO- -DO- -DO- -DO- 2 1 - MA MEASUREMENT -DO- -DO- -DO- -DO- 2 1 - MA MA MEASUREMENT SYSTEM SOAKING -DO-DO- -DO48HRS AT MAX 45 DEGREE C SITE TEMP -DO- -DO- -DO- 2 2 1 1 - NO FAILURE. DATA SHEETS.CUSTOMER : QUALITY PLAN SHEET 3 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. NO.SMOOTH OPERATION OF VARIOUS CONTROLS 9.CORRECTNESS OF ITEM 8. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 6. & RELV. IS/ BS -DO-DO- 9 2 10 1 - 11 7. STURDINESS 4.WOOD SPECIES CR MA -DOVISUAL -DO100% -DOBHEL SPEC/ MFR STD -DO- -DOBHEL SPEC/ MFR STD -DO- -DO-DO- 2 2 1 1 2.WOOD PRESERVATIVE TREATMENT 3.EFFICIENCY CR 4 5 ELECTRICAL -DO- 6 -DO- 7 -DO- 8 -DO- 9 2 10 1 - 11 CR -DO-DO- -DO-DO- -DO-DO- -DO-DO- -DO-DO- 2 2 1 1 - 18.IR-MV IR 7 PACKING 1.CR VARIOUS CHECKS 19.MARKING 7.POWER SUPPLY. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 16.SILCAGEL PACKETS 6.CUSTOMER : QUALITY PLAN SHEET 4 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.WATER PROOF COVER FOR EQUIPMENT 5.INTER-CHANGEABILITY 17. NO. : PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-001/01 ITEM PUBLIC ADDRESS SYSTEM EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.PACKING SLIP MA -DO- -DO- -DO- 2 - 1 MA MA -DO-DO- -DO-DO- -DO-DO- -DO-DO- -DO-DO- 2 2 - 1 1 MA -DO- -DO- -DO- -DO- -DO- 2 - 1 MA MA -DO-DO- -DO-DO- -DO-DO- -DO-DO- -DO-DO- 2 2 - 1 1 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 408 . Phy. Properties 2. Dimension MA -do-do-do- -do-do-do- 3/2 3/2 3/2 - 2 2 2 3. IS-3975/BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-do- Log Book/ Test Cert. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/02 ITEM :PVC POWER & CONTROL CABLE EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. Physical Properties MA 2.Electrical properties MA 4.1 2 RAW MATERIAL 3 4 5 6 7 8 9 10 11 PVC Compound(for insulation 1. 1. IS-3975 BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-do- IS-5831/BHEL Specification -doPlant Std. Make & Type MA MA MA Physical Tests Sample IS-5831/BHEL Specification -doPlant Std.and Elec.Tests Physical Tests Sample 100% Sample* 3/2 2 3/2 - 2 2 * Sample from each Batch/Lot.Galvanization Quality MA 1. -do-do-do- 3/2 - 2 Electrical Tests Visual Physical & Electrical Tests Measurement Galv.3 Copper/Aluminium Rods/ Wires 1. Elec.Properties 3. Physical properties MA and sheath) 2.CUSTOMER : QUALITY PLAN SHEET 1 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.0 1. NO.Dimension MA Chemical analysis -doElectrical Tests Measurement -do-do- -do-do-do- 3/2 3/2 3/2 - 2 2 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 409 .2 Galvanised steel wire/strip 1. Chemical Composition & purityMA 3. 0 2. Meas Visual Measurement Visual Sample Sample Sample 100% -do-do-do- -do-do-doFree from bulging burnt particles lumps. Physical. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/02 ITEM :PVC POWER & CONTROL CABLE EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. & Apprd.of wires MA Counting Sample Vendors/BHEL Specn.CUSTOMER : QUALITY PLAN SHEET 2 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. Data Sheet & Relevant IS -do- 2 - - 2. Chemical Test Sample BHEL Specn. cuts & Scratches. Sequence. Tinning and Annealing 3 4 5 6 7 8 9 10 11 1. Surface finish MA MA MA Visual. IS-8130 do -do- Log Book 2 - 1 do -do- 2 - - 2. No.2 Stranding of wires 1. Data Sheet & Relevant IS Vendors/BHEL Specn.data sheet IS-1554 -do- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 410 . NO.data sheet IS-1554 -do-do-do-do- 2 2 2 2 - 1 2 Insulation thickness CR Measurement Sample Appd. Electr. Tests Sample Visual & Meas. lay length & Direction MA 3 Surface Finish 4. 2 Chemical test for Tinning CR Phy. IS-8130 do -do- BHEL Specn. CR Finish & dimension 2.&Elect. Appd. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2.1 2 IN PROCESS Wire Drawing .Dimension 2.3 Core Insulation (No repair permitted) 1. & Apprd. 6 Armouring 1. IS-5831. burnt particles. 8 Mfr's Std. lumps cuts & scratches. Concentricity # CR 4 5 Measurement 6 Sample 7 Mfr's Std. Dia over laidup core MA 2. Surface finish MA Visual & Meas.Std.Dia over inner sheathMA 2. -dothe process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do-do-do- 2. BHEL Specn. 9 Log Book 2 - 10 1 11 # To be checked at starting & finish end of Extruded Length 4 Dia over insulation MA Measurement Electrical Sample 100% -do-do- 2 2 - 1 5. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/02 ITEM :PVC POWER & CONTROL CABLE EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. NO. data sheet -doMfr's Std. Sheath thickness MA Measurement Sample IS-5831. data sheet -doMfr's Std.5 InnerSheath Extrusion 1. Spark Test or Water CR Immersion test 6. Sample Mfrs.Sequence of lay. IS-1554 data sheet -do- -do- 2 - - 2. MA Lay length & direction up core 2./Appd./relevant IS -do- 2 - - Visual 100% -- Free from bulging./ Appd.Std./ Appd./relevant IS Mfrs. Core identification 2. No.of wires/Strips MA -doCounting -do- -do- 2 2 - - At the start of BHEL Specn. IS-1554 data sheet -do- -do- 2 - - 3.CUSTOMER : QUALITY PLAN SHEET 3 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. Lay Direction MA Visual 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 411 ./Appd. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 3.4 Core Laying MA Visual Measurement 100% Sample IS-1554 -do- IS-1554 -do- -doLog Book 2 2 - - 1. & Meas. IS-1554 & BHEL Specn -do-/Apprd. lumps.. BHEL Specn. Meas.8 Finished Cable 1. Log Book the process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do100% -do-do-do-doFree from Bulging Burnt particles. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/02 ITEM :PVC POWER & CONTROL CABLE EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. Finish & Length MA Visual (See remark) BHEL specn. Marking MA Measurement Sample -do- 2 - - MA Visual 100% IS-1554 & BHEL Specn. Sample * Test Report 2 - 1 * One Drum/Size/Lot 3. cuts & scratches Test Report 2 - - Sequential marking shall be done by printing 2. Type & FRLS Tests CR Elec. lumps. 100% Test Report 2 - 1 2. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 3. Surface Finish MA 2.0 Final Inspection 1. Dia over armouring MA 2. cuts & scratches IS-5831 & IS-1554 Data Sheet -do-do-doLog Book 4. Coverage MA Measurement Measurement Visual 2 2 2 - - 5.data sheet Free from Bulging Burnt particles. Phy & Meas./ Appd. Lay Length MA 4 5 Visual. IS-1554 Test Report 2 1 - One drum each for Power & control cables in a Lot BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 412 . IS-1554 & BHEL Specn -do-/Apprd. 6 7 8 9 2 - 10 - 11 At the start of BHEL Specn.Sheath thickness MA Measurement Sample IS-5831 & IS-1554 Data Sheet -do- Log Book 2 - - 3.data sheet IS-1554 & BHEL Specn. NO.CUSTOMER : QUALITY PLAN SHEET 4 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT./ Appd. Dia over outer sheath 4.7 Outer Sheath Extrusion 1. Routine Test CR Elec. Apprd. : : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/02 ITEM :PVC POWER & CONTROL CABLE EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.CUSTOMER QUALITY PLAN SHEET 5 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. Armouring Coverage No. As per IS -do- 2 1 - MA Visual -do- -do- -do- -do- 2 1 - CR Phy & Elect. Marking/Colour Coding 5. FILLERS/DUMMY CORES ETC. THE SAME SHALL BE AS PER VENDORS SAMPLING PLAN VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION.Data Sheet/ IS-1554 & IS-10810 -do- 9 Test Report 2 10 1 - 11 3. Acceptance Tests MA Visual & Meas. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 2.Data Sheet -do-do- 2 2 1 1 Type Test shall be witnessed on one sample per type(Power/control) of every lot 6. Dimension MA 4 5 Measurement 6 As per IS 7 Appd. NO REPAIR OF CORE INSULATION PERMITTED CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE RECORD OF RAW MATERIAL. Tests -doMeasurement (SEE REMARK) -doBHEL Specn.Data Sheet -doBHEL Specn.Data Sheet/ IS-1554 & IS-10810 -do- 8 Appd. SHALL BE AS PER BHEL SPECIFICATION WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER. W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDOR LEGEND : P : PERFORMER BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 413 . PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC.of Wires/Strips 4. VENDOR TO CERTIFY THE SAME. Type & FRLS Tests CR NOTES:(A) (B) (C) (D) (E) (F) (G) (H) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. Apprd. NO. TYPE/ METHOD OF CHECK EXTENT OF CHECK FORMAT OF RECORD 1 2 FINISHED PRODUCT 3 1. NO.UNIFORMITY OF ZINC 8.1 - MA PIVOT/HAMMER TEST -DO- IS2629 IS-2629 -DO- 3 2. BEND TEST MI MI VISUAL MEASUREMENT -DO-DO- 2 2 1 1 - MA MECH. TEST -DO- -DO- -DO- 2 1 - MA MEASUREMENT ONE SAMPLE IS-6745 IS-4736 -DO- 3 2. SCREW THREAD 4. DIMENSIONAL CONFORMITY MA 4 5 MEASUREMENT 6 5 SAMPLES PER SIZE PER LOT -DO-DO- 7 AS PER IS-9537 PT I & II AND OTHER IS -DO-DO- 8 AS PER IS-9537 PT I & II AND OTHER IS -DO-DOIR 9 2 10 1 - 11 2. COMPRESSION TEST 6.FINISH 3.1 - MA CHEMICAL -DO- IS-2633 IS-2633 -DO- 3 2. 1 SAMPLE OF EACH SIZE -DO- -DO- -DO- -DO- 2 1 - 5. OF ZINC COATING 7.1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 414 . : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-006/01 ITEM RIGID STEEL CONDUITS & PIPES REFERENCE ACCEPTANCE DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. WT.CUSTOMER : QUALITY PLAN SHEET 1 OF 1 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. ADHESION TEST MA MECH. APPD.CHEM.DIMENSIONS MA MEASUREMENT 100% APPD.SURFACE FINISH MA MA MEASUREMENT 100% VISUAL 100% IS-1730/ SPECIFICATION IS1079/ SPECIFICATION IS-1730/ SPECIFICATION IS1079/ SPECIFICATION QC RECORD QC RECORD 3/2 3/2 - - 1.1 ZINC IN-PROCESS FABRICATION CHEM. PROPERTIES MA VERIFICATION OF TC'S 100% IS1079/ SPECIFICATION IS1079/ SPECIFICATION MILL TC 3/2 - - STEEL SHALL BE PROCURED FROM SAIL/TISCO/RINL/ AUTHORISED RE-ROLLERS/ MANUFACTURER AS PER BHEL APPROVED SOURCES. NO. QC RECORD 2 - 1 INSPECTION AT BLACK STAGE BY BHEL/ BHEL AUTHORISED INSPECTION AGENCY WELDING IS TO BE DONE BY QUALIFIED WELDERS 2.& PHY.RIGIDITY (CABLE TRAYs) MA VISUAL 100% SPECIFICATION QC RECORD 2 - 1 MA DEFLECTION TEST SAMPLE SPECIFICATION SPECIFICATION QC RECORD 2 - 1 600 MM OR 450 MM WIDE CABLE TRAY SIZE TO BE TESTED 2.WELDING QUALITY MA VISUAL 100% GOOD WELDING PRACTICE FREE FROM DEFECTS & SLAG SPECIFICATION QC RECORD 2 - 1 3. : QUALITY PLAN NUMBER PED-507-00-Q-005/03 ITEM : CABLE TRAYS & ACCESSORIES TYPE/ METHOD OF CHECK EXTENT OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORM 1 1.1 2 RAW MATERIAL ROLLED SHEET 3 4 5 6 7 8 9 10 11 1.DRGS. RINSING & FLUXING 2.2 SURFACE PREPARATION 1.COMP.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION FORMAT OF RECORD AGENCY P W V VOLUME III REMARKS QUALITY PLAN SHEET 1 OF 2 SL.0 1.SURFACE FINISH 4.2 2. 2. COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. MA CHEM TEST EACH HEAT IS-209 IS-209 QC RECORD 3/2 - 1/2 1.0 2.CLEANING.DIMENSIONS 3. SURFACE QUALITY MA MEASUREMENT PERIODIC IN EACH SHIFT IS:2629 IS:2629 QC RECORD 2 - - MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 415 . PICKLING.DRGS. NO. STAIN. REPORT 3 2. REPORT 3 2.UNIFORMITY OF ZINC COATING 6. ETC. 3. STAIN.0 3. COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.THICKNESS OF ZINC COATING 7.ADHESION MA CHEM. SLAG. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 416 . SPECIFICATION INSP. DRGS. TEST IS-4759 / IS-6745 SPECIFICATION SPECIFICATION IS-4759 / IS-2633 SPECIFICATION SPECIFICATION INSP. : QUALITY PLAN NUMBER PED-507-00-Q-005/03 ITEM : CABLE TRAYS & ACCESSORIES TYPE/ METHOD OF CHECK EXTENT OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORM 1 2.1 FINISHED ITEMS (CABLE TRAY. REPORT 3 2.2629 IS .RIGIDITY (FOR TRAYS) MA DEFLECTION TEST 1/ LOT SPECIFICATION INSP.DIMENSIONS MA MEASUREMENT IS-2500 LEVEL IV APPD. 1 FASTENERS SHALL BE OF REPUTED & APPROVED MAKE. DROSS 3. APPD.2631 IS . REPORT 2 1 - MA ELCOMETER IS-4759 / SPECIFICATION SPECIFICATION SPECIFICATION INSP.. ROUGHNESS. REPORT 2 1 - 600 MM OR 450 MM WIDE CABLE TRAY TO BE TESTED 4.2629 / MFR'S PRACTICE FREE FROM BURRS ROUGHNESS. 1 - NOTE: INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE-1. QC RECORD QC RECORD 2 3 - 2 VISUAL 100% MEASUREMENT VISUAL 100% MA QC RECORD 2 - - 3. INSP. ETC.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION FORMAT OF RECORD AGENCY P W V VOLUME III REMARKS QUALITY PLAN SHEET 2 OF 2 SL. 1 - MA CHEM. REPORT 3 2. SLAG . DRGS. 2.3 GALVANISING 2 3 1. 1 - MA MECH.SURFACE FINISH MA VISUAL IS-2500 LEVEL IV SPECIFICATION FREE FROM BURRS. FLUX.2629 IS . 1 - . ACCESSORIES & HARDWARES) 1. FLUX. TEST IS-2633 INSP.TEST IS-4759 IS-2629 IS-2629 INSP.SURFACE QUALITY 4 MA 5 TEMPERATURE INDICATOR VISUAL 6 CONTINUOUS IS-2629 7 IS-2629 8 9 QC RECORD 2 10 - 11 MA MA CONTINUOUS IS . RATE OF IMMERSION 4.TEMPERATURE OF BATH 2.2629 / MFR'S PRACTICE IS .MASS OF ZINC COATING 5. REPORT 3 2. 1 2 RAW MATERIAL MILD STEEL (FLATS & RODS) AS PER SPECIFICATION 3 4 5 6 7 8 9 10 11 1.0 1.CHEMICAL & PHYSICAL PROPERTIES MA VERIFICATION. NO. : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-509-00-Q-001/02 ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 1. SOURCES 2.2 ZINC 1.DIMENSIONS 2.1730 IS : 1079 QC RECORD QC RECORD 3/2 3/2 - - MA CHEM.DIMENSIONS 3.TEST SAMPLE IS . DRILLING 1. MA MA MEASUREMENT 100% VISUAL 100% IS . BIDDER/ VENDOR SYSTEM CAT.1730 IS : 1079 IS .SURFACE FINISH MA MA MEASUREMENT 100% VISUAL 100% SPECIFICATION SPECIFICATION SPECIFICATION SPECIFICATION QC RECORD QC RECORD 2 2 1 1 2. OF TC'S 100% IS:1079 IS:1079 MILL TC 3 - 2 STEEL SHALL BE PROCURED FROM SAIL/ TISCO/ RINL/ AUTHORISED RE-ROLLERS/ MANUFACTURERS AS PER BHEL APPROVED SOURCES.2 SURFACE PREPARATION 1. PICKLING RINSING.SURFACE QUALITY BHEL MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 417 .209 QC RECORD 3/2 - 1/2 2. & FLUXING MA MEASUREMENT PERIODIC IN EACH SHIFT IS:2629 IS:2629 QC RECORD 2 - - 2.SURFACE FINISH 1.209 IS .1 IN-PROCESS CUTTING.0 2.COMP.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL.CLEANING PICKLING.CHEM. REPORT 3 2. ROUGHNESS.2629 FREE FROM BURRS. 1 - 2. 1 - MA CHEM. SLAG.3 GALVANISING 2 3 1.4759 SPECIFICATION SPECIFICATION INSP. QC RECORD 2 - - 3. 1 - 3.2629 8 9 QC RECORD 2 10 - 11 MA CONTINUOUS IS . FLUX.0 FINISHED ITEMS 1.ADHESION MA CHEM. . ROUGHNESS. REPORT 3 2. STAIN. FLUX.MASS OF ZINC COATING 4.2629 QC RECORD 3 - - 3. 1 - NOTE: INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE-1.2629 IS .4759 IS-6745 / SPECIFICATION IS-2633 INSP. NO.TEMPERATURE OF BATH 2. REPORT 3 2.4759 IS-2633 INSP.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL.2629/ MFRS PRACTICE QC RECORD 3 - 2 4.2629/ MFRS PRACTICE IS .DIMENSIONS MA MEASUREMENT RANDOM SPECIFICATION SPECIFICATION INSP. . ETC. DROSS 4 MA 5 TEMPERATURE INDICATOR VISUAL 6 CONTINUOUS IS . TEST IS . RATE OF IMMERSION MA VISUAL/ 100% MEASUREMENT IS . 1 - MA MECH.SURFACE FINISH MA VISUAL RANDOM SPECIFICATION FREE FROM BURRS.UNIFORMITY OF ZINC COATING 5.TEST IS-4759 IS-2629 IS-2629 INSP. 1 - MA ELCOMETER IS .2629 7 IS . : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-509-00-Q-001/02 ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 2. STAIN ETC. REPORT 3 2. NO BIDDER/ VENDOR SYSTEM CAT. TEST IS . REPORT 3 2. SLAG. REPORT 3 2.SURFACE QUALITY MA VISUAL 100% IS .THICKNESS OF ZINC COATING 6. SPECIFICATION INSP. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 418 . requirement -do-do- -do-do- 3/2 3/2 - 2 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 419 . Properties MA Phy.2 1. Data sheet IS:1897 Manufacturer's std. R-02 ITEM : XLPE P Power C bl Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. Tests -do- Supplier's test report & log book Log Book/ Test Report -do- 3/2 - 2 1. Dimension 3./ Appd. Physical. Properties MA Physical & Electrical Tests Sample from IS:3975/ BHEL each batch/ Specification lot -do-do-do-do- IS:3975/ BHEL Specification Log Book/ Test Cert. 1 Phy and Elec Elec./ Appd.1 2 RAW MATERIALS XLPE Compound 3 4 5 6 7 8 9 10 11 1. Phy. Dimensions MA Measurement -do- Manufacturer's std.Properties MA Electrical Test -do- 3/2 - 2 1.. IS:7098 & Mfrs Std.2 Raw material verification as per approved subvendor list 1.CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. Galvanization MA MA Measurement Galv. Data sheet IS:1897 Log Book 2 - 2 2. Elec. Elec. Chemical & Elect. Chem.5 15 Galvanised steel wire/strip 1.and Elec.2 1.3 Copper Foil 1. Tests -do- Manufacturer's standard Manufacturer's standard -do- 3/2 - 1. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001.4 PVC Compound (for sheath) 1.2 Semi Conducting Compound 1. Physical properties MA Physical Tests Sample/ lot IS:5831/BHEL Specification -do- IS:5831/BHEL Specification -do- 3/2 - 2 2.Properties MA Electrical Tests -do- -do- -do- 3/2 - 1. Physical properties MA Physical Tests Sample/ Lot IS:7098 & Mfrs Std. Properities MA Phy. 3/2 - 2 2.0 1. NO. & Elect. Test Report Log Book -do- 3/2 - 2.and Elec. Phy. SHEET 1 OF 5 COMPONENT/OPERATION CHARACTERISTIC CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. 1 IN PROCESS Wire Drawing . BHEL Specn. Apprd. Data Sheet & Data Sheet & Relevant IS Relevant IS -do- 2 - - 2.2 Stranding of wires 1. Log Book 2 1 2. IS:8130 & BHEL Specification -do- 8 IS:613. No. of wires CR Chemical Test -do- -do- -do- -do- 2 - - MA Counting -do- BHEL Specn. IS:8130 & BHEL Specification -do- 9 -do3/2 10 2 11 MA Chemical analysis Electrical Tests Measurement -do- -do- 3/2 - 2 MA MA -do-do- -do-do- -do-do- -do-do- 3/2 3/2 - 2 2 2.0 2. Data Sheet Data Sheet BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 420 .CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT CAT. IS:8130 & BHEL Specn. Tinning and Annealing 1. Electrical. -do- -do- -do- -do- 2 - - MA MA MA Visual Measurement -do- -dodo -doSample -dodo -do- -dodo -do- -dodo -doLog Book 2 2 2 - - BHEL Specn & Apprd. 2 Chemical Composition & purity 3.Electrical properties 4. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001. SHEET 2 OF 5 COMPONENT/OPERATION CHARACTERISTIC CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. NO. Chemical test for Tinning 2. Sequence. IS-5484. Apprd. BHEL Specn & Apprd. R-02 ITEM XLPE Power Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL SL. Physical. Meas. Dimensions 4 MA 5 Physical Tests -do- 6 7 IS:613. & Elect. Tests Sample Visual / Meas. IS-5484. Radial thickness MA Visual. Dimension 2.6 2 Copper/Aluminium Rods/ Wires 3 1. lay length & Direction 3 Surface Finish 4. Finish & dimension CR Phy. IS:8130 & BHEL Specn. Physical Properties 2.3 Conductor Screening 1. ITEM XLPE Power Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. Thickness of Insulation I l i 4 Dia over insulation CR Measurement -do- BHEL specn. Hot Set & Aging Test) 2.CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. cuts & Scratches. Surface finish 4 MA Visual 5 100% 6 - 7 -do- 8 9 Log Book 10 2 1 11 2./ data sheet Plant Std. Surface finish MA Tests -do- -do- -do- -do- 2 1 1 MA Visual Sample - Free from bulging burnt particles lumps./ data sheet Plant Std./Appd. SHEET 3 OF 5 COMPONENT/OPERATION CHARACTERISTIC CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2. Thickness MA -do- -do- BHEL Spec.5 Insulation Screening. R-02 Q ./ data sheet BHEL Spec. Log Book 2 - - 2. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001. -do- 2 - - 3 Overlap of Tape Band 4 Tightness of Tape Band MA Measurement -do- -do- 2 - - MA Visual -do- -do- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 421 ./ data sheet BHEL Spec./Apprd. Concentricity # CR Measurement Sample Mfr's Std./Appd. data sheet Log Book 2 - 1 # To be checked at starting & finish end of Extruded Length 3. BHEL Spec. (Non Metallic & Metallic ) 1. NO. Test on XLPE (Tensile & Elongation.4 2 Core Insulation (XLPE) ( (No repair permitted) p p ) 3 1. Dats Sh / IS:7098 Sheet/ IS 098 D -do- BHEL specn./Apprd. data sheet Mfr's Std. Dats Sh / IS:7098 Sheet/ IS 098 D -do- Inspection Report R -do- 2 1 - MA Measurement -do- 2 1 - 5. / Apprd./ the process Apprd. Data Sheet BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 422 .Sequence of lay. Lay Length 4 MA MA 5 Measurement Visual & Meas. Sheath thickness MA Measurement Sample Appd.9 29 Outer Sheath Extrusion 1./ Appd. Dia over armouring 2. -- Mnfrs. Data Sheet. Data Sheet & Appd. IS:7098.7 InnerSheath Extrusion 1. 9 Log Book -do2 2 10 - 11 MA MA Meas. Data Sheet 5. Dia over laid up core 2. lumps cuts & scratches. Std. BHEL Specn. Dia over inner sheath 2. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001. burnt particles. 1 Surface Finish MA MA Measurement Visual -do100% -doLog Book 2 2 - - 2. Lay Direction 3.Std. 8 Apprd. & Appd. Data Sheet Data Sheet -do-doFree from Bulging Bulging.Std. Visual -do100% Mnfrs. BHEL Specn. Data Sheet IS 7098/ Mfrs. No.8 Armour 1. IS:7098 -do- do -do- 2 - - 3. Std. BHEL Specn. Surface finish 2. R-02 ITEM XLPE Power Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.Data sheet IS:7098 Plant Standard -do-do- 2 2 - - 2. Marking BHEL MA MA -doVisual -do100% -do- -do- -doTest Report 2 2 - Sequential marking shall be done by printing PARTICULARS NAME SIGNATURE DATE IS:7098. Data Sheet Log Book 2 - - 3.CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. cuts & scratches Appd./ Appd.Data sheet -do-do-doIS:7098 Plant Standard 2. IS:7098 -doBHEL Specn. Measurement -doLog Book -do- 2 2 2 - - BHEL Specn. Free from bulging. NO NO. Data Sheet IS 7098/ Mfrs.Sheath thickness MA Measurement Sample Appd. Lay Length 4. Appd. Data Sheet. lumps. SHEET 4 OF 5 COMPONENT/OPERATION CHARACTERISTIC CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2. burnt particles. 6 Sample Sample 7 Apprd.of wires/Strips MA MA -doCounting -do- -do-do- 2 2 - - At the start of BHEL Specn.6 Core Laying 2 3 1. Dia over outer sheath 4. Coverage MA MA MA Visual Meas. & direction 3. VENDOR TO CERTIFY THE SAME. R-02 ITEM XLPE Power Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL SL. Elect.of Wires/Strips 4. Acceptance Tests MA Visual & Meas. 3. Armouring Coverage No. Test Report BHEL Specn Specn./ Free from Bulging Burnt particles.Data Sheet/ IS:7098. LEGEND : P : PERFORMER BHEL W: WITNESSER PARTICULARS NAME SIGNATURE DATE V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2 VENDOR : 3 SUB VENDOR BHEL/BHEL s 2-VENDOR BIDDER/ VENDOR BIDDER'S/VENDORS COMPANY SEAL 423 . AND ARE LIABLE TO AUDIT CHECK BY PURCHASER. Marking & Colour Coding 5. Apprd.0 Final Inspection 1.10 2 Finished Cable 3 1. Physical & Electrical Tests Visual. PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC. 2 Type Tests * 4 CR CR 5 Elec. SHALL BE AS PER BHEL SPECIFICATION (G) WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES.CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT CAT. Dimension MA Measurement As per IS Appd. & Meas. THE SAME SHALL BE AS PER SAMPLING PLAN AGREED BY PURCHASER. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001. Data Sheet -do- -do- 2 1 NOTES:(A) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. Apprd. Data Sheet BHEL Specn Specn. Data Sheet/ IS:7098. IS:10810 -do- -do- 2 1 - 3. (F) FILLERS/DUMMY CORES ETC. Measurement 100% 6 7 8 9 2 2 10 1 1 11 IS:7098 & BHEL specnIS:7098 & BHEL specn. (B) NO REPAIR OF CORE INSULATION PERMITTED (C) CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION (D) PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE (E) RECORD OF RAW MATERIAL. cuts & scratches Specn. SHEET 5 OF 5 COMPONENT/OPERATION CHARACTERISTIC CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2. lumps. & IS:7098 -do- 2 1 - One drum in each Lot 2. Tests -do- BHEL Specn Apprd. IS:10810 -do-dodo Sample * * As per specn specn. (H) VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION./ Appd. Finish & Length MA (See remark) BHEL specn. Routine Test 2. NO. -do- -do- 2 1 - MA Visual -do- -do- -do- -do- 2 1 - CR Phy.Data Sheet BHEL Specn. IN EXPORT ORDE PACKING SHALL BE AS PER BHEL SPECIFICATION & THE SAME SHALL BE WITNESSED. Further HT cable.6 kV systems . 3 III D 3.6kV system is 40kA.disconnector. Clause No. (b) A manually fitted ………….10 (a & b) 4 III D3. I-59) BHEL Clarification (ELECTRICAL) submitted to customer S. transformer feeders (One (1) no. Manual shorting link has been offered..0(f) & Electrical key line diagram dwg. KARIMNAGAR (job no.0 12 OF 17 1. No.GT side. 6. 424 .5960AEL-SK-2001 Additionally One (1) no. LT service transformer.9 (c & d) (d) Voltage transformers with ……………transformer side. 1 III D3. The voltage transformer. 1.. LT busduct. 2 III D 3. 400 V. Volume Section Page No.: TCE. transformer feeder on each bus (colony supply) for Owner’s use shall be provided.. No. on each bus). (a) A switched short………. & as per key SLD. No.18( c) The motors rated 175 kW and The motors rated above 175 kW shall be above shall be 6. rated 2000kVA for Colony supply(in customer scope) are considered in BHEL scope as per clause no. lightning arresters & surge capacitors are envisaged as a part of SPVT & VT cubicle provided as part of generator busduct & associated equipement.2 2 OF 8 2.3 of section D3. fault level at 6.2 2 OF 8 2. The generator side current transformer is envisaged as a part of the isolated phase busduct.6 kV system with fault level limited to 40 kA rms has been offered.0 1 OF 17 Fault level shall be limited to 44 kA rms for 6... Two nos. (c) Generator side current …………………….9 2 OF 15 9.700MW CCPP AT NEDUNOOR. 9.6kV and motors 6.6kV and motors rated upto 175 kW shall be rated upto 175 kW shall be 400V.5960AEL-SK-2001 Technical Specification Clarification ANNEXURE-B 1 III D3.: TCE.9 Vol-III of customer specification.connection. LT power/control cables & LT switchgear for the same are excluded from BHEL scope of supply.3 & Electrical key line diagram dwg. No. DC battery is sized for Emergency DC loads for 1hour & continuous DC loads( ie. ECP7 AVR panel etc. Clause No.. I-59) BHEL deviations (ELECTRICAL) submitted to customer S.3. Indicating lamps. Technical Specification Deviation 1 III D3.700MW CCPP AT NEDUNOOR. Volume Section Page No. 425 .13 2 OF 14 13. GRP. KARIMNAGAR (job no.2 Emergency & Continuous Load (For 10 hours duration)….) for 10 hours. No. SCHEDULE OF TECHNICAL DEVIATION S. No. Vol/ section/ Clause No. Page No.Doc. Technical Specification Clarification 426 . PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. : Page : 0 of 10. 11 1.2 1. 1No.10 1. Fuses of each rating Transducers of each type & rating Non-Segregated Phase Busducts Bus support insulator Seal-off bushing Flexible connector (for equipment connection) Gasket DC System ( Spares applicable separately for each battery bank) 2.1 1.5 1. 2 Nos. AN INDICATIVE LIST OF MANDATORY SPARES IS GIVEN BELOW FOR REFERENCE. 10 Nos. of each ratio & type VTs. of each ratio & type Meters.1.1. 427 . SPARES: BIDDER TO QUOTE FOR MANDATORY SPARES.12 1.1 1. 5 No. of each colour 2 Nos.Doc.2.1.2 1.15 1. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. 5 Nos.2.1.4 1.7 1.s Quantity 1.3 1.1.1. 1 No. 2 Nos.8 Description LT SWITCHGEAR & LT BUSDUCT 400V Switchgear Complete pole of breaker Breaker complete with operating mechanism and truck mounted Closing & tripping coils Fixed and moving contact assemblies of each breaker Spring charging motors Set of gasket Bus bar support insulators Aux switch assembly.1 1.2. No.1.1.2 1.2.1. for each rating 1 No. : Page : 0 of 11. ERECTION & COMMISSIONING SPARES & RECOMMENDED O&M SPARES (FOR 3 YEARS OF OPERATION). for each rating 2 No. 5Set 10No.14 1. Local/ Remote selector switch. limit position switches. 1No. breaker control switches & other switches Relays of each type used Clustered type LED CTs. S.3 1. of each rating 2 sets of each rating 2Set 2No.1.1.4 2 1 No. of each rating 1 No.1.1.13 1.6 1. No.9 1.1. 1 Set 1 Set 1 No.1 Battery (a) Battery Cell of each type (b) Positive Plate of each Type (c) Negative Plate of each Type (d) Connectors with Nuts & Bolts (e) Vent Plugs 1No. of each type & rating. 1 1.1. for each rating 1 set 2 Nos. C. 5 No.3 Lighting Fixtures Lighting fixtures (along with lamps) Lighting Panels MCBs 3% of each type 1 No. 5 nos. 2 nos. 1 no. of 32A & 5 Nos of 63A. of each rating 1 no.2 Battery Chargers (a) Silicon Diodes (b) Control Switch (c) Current Regulator (d) Off-Load Tap Changing Device (e) Fuse of each type (f) D. No. of each rating 1 no. 0 of (f) Terminal Post 2. 1 no. Ammeter (g) Miniature circuit Breaker (h) Neon Lamps 3 3. 1 no. : Page : 1 Set 1 no.2 3. of each type.1 3. 428 . PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev.Doc. NOIDA BHEL(RUDRAPUR) BHEL(REGION) BHEL(TRICHY) 6 B(JH) 7 B(PC) 8 B(PE) 9 B(RR) 10 B(RG) 11 B(TY) B. BANGALORE BHEL(JHANSI) BHEL(PIPING CENTRE). CHENNAI BHEL(PEM). 1 2 3 4 5 B B(BP) B(ED) B(HR) B(HY) B(IS) EXPANSION BHEL BHEL(BHOPAL) BHEL(EDN). ABBREVIATION A. P EPC-PARTNER . NO.700MW KARIMNAGAR CCPP PROJECT ANNEXURE-A PROPOSED SCOPE SPLIT OF ELECTRICAL SYSTEMS BETWEEN BHEL & EPC PARTNER SL. BANGALORE BHEL(HARDWAR) BHEL(HYDERABAD) BHEL(ISG). GT & UAT protection panels 1. P/B(PE) P/B(PE) P P P P B(BP) B(JH) P P P P B(BP) B(JH) P P P P P P P P P P P P P P P .2 LT Aux.6 Generator NGT & NGR 1.4 UAT 1.5 NGR for MV system 2.DISTRIBUTION CONTROL 2.7 Electrical Control Panel(For main plant.3 Generator Transformer 1.1 MV (6.6 DC Power Supply 220 V dc P/B(PE) B(PE) B(PE) P/B(PE) B(PE) P/B(PE) P/B(PE) B(RR) B(PE) B(BP) B(JH) B(BP) B(RR) B(ED) P/B(PE) P/B(PE) B(ED) B(IS) B(RR) B(PE) B(BP) B(JH) B(BP) B(RR) B(ED) B(ED) B(IS) P P P P P B(PE) P P P P P P B(PE) P P P P P Design & Layout by 'P' based on inputs by respective BHEL units. PCC.1 Insulated phase busduct / Segregated phase busduct 1.5 Generator. no.8 DCS (station C&I) 1.3 LT Switch gear {PMCC.6 kV) Switch gear 2.4 LV Bus Duct & Accessories 2.9 Diesel Generator 2 AC/DC POWER. ACDB local PB stns for LT / HT Drives} 2. DDCMIS for electrical systems 1.2 Generator Circuit Breaker 1. SUPPLY SYSTEM / EQUIPMENT TERMINAL POINT REMARKS 1 POWER EVACUATION EQUIPMENT / SYSTEM 1.700MW KARIMNAGAR CCPP PROJECT PROPOSED SCOPE SPLIT BETWEEN BHEL & EPC PARTNER SCOPE BASIC ENGINEERING SUPERVISION OF ERECTION & COMMISSIONING ERECTION EXECUTION & COMMISSIONING DETAILED ENGINEERING Sl. Transformers ( dry type) 2. MCC. located in CCR). P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P * As per Cable Scope detailed matrix (Table1) 5 STATION CABLING.6 HT Power Cables LT Power Cables LT Control Cables Screen Cables (instrumentation) Spl. EARTHING & LIGHTING-MATERIAL 5.1 Plant Lighting Equipment (Supply & E &C) 3. 7 P P NA NA NA .8 DC Starter .1 4. cable glands & lugs.for Boiler. Electrical single line diagram & Design Memorandum for all Electrical package Electrical Layout/ Cable Listing/ cable routing/ cable interconnection diagram P P P P P P P P P P P P P P P B(ED) P P P P P P P P P P P P NA P P P P NA P P P P NA For main plant & BOP areas. Fire sealing material) 5./doc.3 Cabling Material (Cable trays & accessories. trefoil clamps.] Fire Survival Cables P P P P P P P B(HY/TY) B(HY/TY) B(HY/TY) P P P P P P P P P P For complete plant. shall be prepared by 'P' in consultaion with B(PE) Interface among inputs from respective BHEL units is in 'P' scope.erection material 6 Main system design .5 4.7 Plant Lighting .1 TG Trunk Cabling (Field-UCD) Material P 5.3 4.2 4.6 Lightning Protection Material 5. jointing kits.2.UCD) Material 5.2 Boiler Trunk Cabling (Field .5 Electronic Earthing Material 5.4 Equipment Earthing Material (Above ground & below ground grade) 5. Cables [ for Cranes. Drg. Turbine and Generator 3 STATION -ELECTRICAL AUXILIARY PKG 3.4 4.2 PA System 4 POWER / CONTROL /SCREENED CABLES 4. Hoists etc.7 DC Distribution 220 V dc 2. cable tray support. 8 Preparation of Electrical load data P P NA NA NA Load list shall be prepared by 'P' in consultaion with B(PE).e.) for all electrical packages NA NA NA NA NA 10 Submission of drg. Data sheet/ OGA/ scheme/ Test certificates/ Quality Plans etc.(i. . P P NA NA NA Submission of drg./ follow-up with P' shall provide support to 'B(PE)'./doc. & doc. customer/ obtaining approval from customer engineering of electrical system and equipment including layout / cable routing engineering and furnishing details/BOM/technical Note:-Design & 9 particulars shall be in Partner's scope. G LV PC G F. CC. G P P P P P B(PE)-C&I P P P P P P 00 00 00 00 00 00 D LV SYSTEM (GAS TURBINES) 1 INCOMER CABLES ALL OUTGOING CABLES TO DRIVES/ 2 MARK-VI PANESL/ FIELD 3 SWGR TO LPBS LV PC PC.G B(HY) B(HY) B(HY) P B(HY) B(HY) 00 00 E 1 2 3 4 220 V DC SYSTEM BATTERY/ CHARGER TO DCDB DCDB TO STARTER PANEL FOR DC DRIVE DCDB TO PANEL/ DC LOAD STARTER PANEL TO FIELD LV PC LV PC LV PC CC P B(HR) P B(HR) P B(HR) P B(HR) 00 00 00 00 F 125 V DC SYSTEM 1 2 3 4 BATTERY/ CHARGER TO DCDB DCDB TO STARTER PANEL FOR DC DRIVE DCDB TO PANEL/ DC LOAD STARTER PANEL TO FIELD LV PC LV PC LV PC CC B(HY) B(HY) B(HY) B(HY) B(HY) B(HY) B(HY) B(HY) 00 00 00 00 G 24 V DC SYSTEM 1 1 3 4 415V SWGR TO BATTERY CHARGER BATTERY/ CHARGER TO DCDB ALL OUTGOING POWER CABLES FROM 24V DCDB VARIOUS LOADS BIANRY & ANOLOG SIGNALS FROM 24V SYSTEM TO DDCMIS LV PC LV PC LV PC F.F. CC F.G P B(PE)-C&I P P P P 00 00 00 C LV SYSTEM (UNDER B(PE).G P B(ED) B(ED) B(PE)-C&I P P P P 00 00 00 00 H UPS INCOMING POWER CABLE FROM SWGR 1 TO UPS PC P P Page 1 of 2 .BOPs) 1 2 3 4 5 6 SWGR TO DRIVES SWGR TO PLC/ LCP SWGR TO LPBS LCP TO DRIVES PLC/ LCP TO FIELD PLC/ LCP TO DDCMIS LV PC G F.700MW KARIMNAGAR COMBINED CYCLE POWER PROJECT TABLE-1: CABLE SCOPE DOCUMENT ELECTRICAL SYSTEMS SCOPE OF CABLE LISTING P B(PE)-C&I P P SCOPE OF CABLE SUPPLY P P P P SL No.G 00 00 00 00 B LV SYSTEM (UNDER STATION C & I) 1 2 3 SWGR TO DRIVES SWGR TO DDCMIS/ UCP SWGR TO LPBS LV PC G F. A MV SYSTEM 1 2 3 4 ITEM CABLE TYPE REMARKS REV SWGR TO OUTGOING FEEDER SWGR TO DDCMIS/ UCP SWGR TO LPBS INTERCONNECTING CABLES FOR MV SWGR MV PC G CC LV PC. F. VENDOR SCOPE P P P P M ALL INTERCONNECTING CABLES FOR GRP. FS P P MV PC: MV Power cable. LV PC. DCS. F. G. G CC. CC. DDCMIS ALL CONTROL CABLES TWO BETWEEN SWYD EQPT LV PC LV PC CC. & AVT LV PC CC F. ECP. LV PC: LV Power cable. CC: LV Control Cable. CABLES BETWEEN DG EQPT TO ECP/ DDCMIS/TRANS. DDCMIS PC CC CC CC PC PC CC B(ED) B(ED) B(ED) B(ED) P P P P P P B(ED) P P P 00 00 00 00 00 00 PC PC B(ED) B(ED) P P 00 J 1 2 3 4 5 6 7 K 415V EMERGENCY DG SYSTEM 1 2 3 4 5 415 DG PCC TO DG TERMINALS 415 V SWGR TO DG AUX MCC DG AUX MCC TO DG ROOM (VENTILATION FAN. F. FO LV PC LV PC CC. TRANSFORMERS. G: G-Type Instrumentation cable. LIGHTING ETC) POWER & CONTROL CABLES WITH IN DG SYSTEM CONTROL & INSTT.G P P B(IS) B(IS) P P P B(IS) B(IS) P 00 00 00 00 00 L 1 2 3 4 5 6 7 SWITCHYARD LT SWGR TO BATTERY CHARGER LT SWGR TO ACDB ALL SAS/ SCADA CABLES ALL OUTGOING CABLES FROM SWYD DCDB ALL OUTGOING CABLES FROM SWYD ACDB CONTROL CABLES BETWEEN SWYD EQPT & GT. FS: Fire Survival cables Page 2 of 2 .G. G P P P P SWYD. F. ECP. F.G P P M ANY OTHER CABLE MV PC. CC.2 3 4 ALL OUTGING POWER CABLE FROM UPS ACDB TO VARIOUS LOAD BIANRY & ANOLOG SIGNALS FROM UPS TO DDCMIS ALL INTERCONNECTING POWER CABLES BETWEEN UPS. LV PC.G PC/ CC CC. G PC B(ED) B(PE)-C&I B(ED) P P P 00 00 00 I 1 2 ELECTRONIC EARTHING BETWEEN DDCMIS CABINETS DDCMIS CABINETS TO ELECTRONIS EARTH PIT STATIC EXCITATION EQUIPMENT (SEE) EXCITATION TRANSFORMER TO THYRISTOR CUBICLES THYRISTOR CUBICLES TO FF / FB CUBICLES FB CUBICLE TO GENERATOR SLIP RINGS INTERCONNECTING CABLES WITHIN SEE AUX AC SUPPLY FROM SWGR TO SEE AUX DC SUPPLY FROM DCDB TO SEE CONTROL & INSTRUMENTION CABLES BETWEEN SEE TO GRP.F. GRP. F: F-Type Instrumentation cable. ACDB & BATTERY PC F. ECP.