11V02-ACC-SPC-M-0001-V2-PART-B

BID DOCUMENT FOR AIR COOLED CONDENSER

PROJECT 1 x 300 MW COAL BASED THERMAL POWER

PLANT, CHHATTISGARH, INDIA

Doc. No. 11V02-201-SPC-M-0001, REV.R0

Date: 04.11.11 VOL-II PART-B, E0 Page 1 of 16

VOLUME – II

PART - B

ELECTRICAL




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VOLUME – II

PART - B

SPECIFICATION: E0

GENERAL ELECTRICAL SPECIFICATION




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I N D E X

SL.NO. DESCRIPTON 1.00.00 INTENT OF SPECIFICATION 2.00.00 CODES AND STANDARDS 3.00.00 SYSTEM DESCRIPTION 4.00.00 BASIS OF DESIGN 5.00.00 PURCHASER’S OBLIGATION 6.00.00 STATUTORY APPROVALS 7.00.00 DOCUMENTS TO BE SUBMITTED FOR APPROVAL 8.00.00 GENERAL REQUIREMENTS 9.00.00 ELECTRICAL VENDOR LIST ANNEXURE-A SCOPE MATRIX




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SPECIFICATION NO. E0

GENERAL ELECTRICAL SPECIFICATION 1.00.00 INTENT OF SPECIFICATION 1.01.00 This specification is intended to cover design, manufacture, assembly, testing

at manufacturer’s works, packing, inland transportation to site, handling for clearance, inland transit cum storing, insurance, erection, testing and commissioning of all equipment included in the specification related to electrical system of Air cooled condenser system.

1.02.00 This specification broadly covers following equipment/devices: i) Electric Motor (E1). ii) Motor Actuator (E2) iii) Variable Frequency drive (VFD) (E3) iv) 415V PCC, MCC, distribution board & Local control station (E4) v) Electrical Erection (E5) 2.00.00 CODES AND STANDARDS 2.01.00 Equipment 2.01.01 All electrical equipment supplied shall conform to latest applicable IS/IEC

Standards. 2.01.02 Equipment conforming to any other national standard which ensures

equivalent or better quality may be accepted. In such case, copies of the English version of the standard adopted shall be furnished along with the bid.

2.02.00 Installation 2.02.01 All electrical installation work shall comply with the provisions of the Indian

Electricity Act and the Indian Electricity Rules as amended up to date and relevant IS Codes of practice.

2.02.02 Nothing in this specification or in the equipment specification shall be

construed to relieve the contractor of his responsibility. 3.00.00 SYSTEM DESCRIPTION




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3.01.00 The power supply distribution system as envisaged is described below. 3.01.01 The electrical system shall comprise mainly distribution of power for fan,

pump and valves. The fan motors used in air cooled condenser will be controlled by variable frequency drive. % of VFD drive shall be indicated by vendor for the fans to optimise the power consumption during various operating conditions. The rating of such fan motors will be approx. 132 kW and will be finalized during detail engineering by successful bidder.

3.01.02 It is envisaged that for power distribution of above load, 2 no. 415V PMCC

will be employed. Each PMCC will have 3 incomer and 2 bus coupler. These PMCC will be located inside Electrical room located near Air cooled condenser area .Additionally there will be requirement of a separate MCC to feed the load of various pump & motor operated valve etc. Separate air conditioned room is envisaged for VFD drives adjoining to the switchgear room. The same room will also house input/output racks (I/O) for communication to DCS.

3.01.03 The PMCC as mentioned above will receive power from associated oil filled

6.6/.433kV step down transformer. This step down transformer will get feed from 6.6kV station switchgear of the plant.

3.01.04 The electrical system shall cover the above power distribution along with

associated PMCC, MCC, Transformers, HT and LT power & control cables. Further, necessary illumination, grounding, lightning protection etc. along with provision of routing the cable upto the motor terminal box and LCS shall be made.

3.01.05 VFD as employed for speed control of fan motor will be housed in air

conditioned environment. VFD shall be of minimum 12 pulse design having 2 channels, each channel with 6 pulse design, for each motor for speed control range 10- 100%

3.01.05 415 V MCC shall cater misc. pump motor loads for the plant. Miscellaneous

auxiliary loads shall be catered through distribution boards. All auxiliary loads shall be powered through MCCB outlets from distribution

boards. Local Push Button Station shall be provided near the drive for start/stop operation of motors.

3.01.06 It shall be possible to start and stop the motors from local Push Button

Station and from Operating station(OS) located in main plant control room for remote operation.. A Selector switch shall be provided in PCC for Selection of Control from DCS or field.

3.01.08 The earthing system of the Plant shall in general cover the following.

a) System neutral earthing




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b) Equipment earthing for Personnel safety.

c) Static equipment earthing.

d) Lightning Protection.

Plant area shall be provided with independent grounding system. Ground mat of 40mm MS rod shall be laid below ground and risers of same size shall be provided for equipment grounding. Size of grounding conductor for different equipments shall be as indicated in subsequent clauses. An independent earthing network shall be provided for lightning protection.

3.01.09 Power supply for lighting system shall be taken from main plant or switchyard

MLDB 3.01.10 All LT Boards shall have two bus-sections & one bus coupler. 10% spare

feeders(at least one in each bus section of each size and type) shall be provided in each board.

4.00.00 BASIS OF DESIGN Following criteria / data will be used in engineering the electrical system and

equipment.

4.01.00 Environmental Condition

The equipment will be installed in hot, humid and tropical atmosphere The design ambient for Electrical equipment shall be 50 deg C

4.02.00 System parameters and variations

All devices shall be suitable for continuous operation over the entire range of voltage and frequency variations indicated below without any change in their performance :

Sr. System Volt. & Frequency Fault Level Grounding

a) 6600 V ± 10%, 3Ph, 3 wire,

50 Hz ± 5%

40 KA (3

sec.)

Non effectively

earthed




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b) 415V ± 10%, 3Ph, 4 wire, 50

Hz ± 5%

50 KA (1

sec) Solidly earthed

Combined voltage and frequency variation 10% (Absolute sum)

c) 220 V DC (–) 15% to (+) 10%,

2 wire

25 KA (1

sec) Unearthed

4.03.00 Following Power Supplies are envisaged in the project for feeding various

loads: i) For motors rated above : 6.6kV, 3 Phase, 3 Wire, 50 Hz 160 kW Non-effectively earthed.

ii) AC motors (rated above 0.2kW up to 160kW) : 415V, 3 Phase, 4 Wire, 50 Hz solidly earthed.

iii) AC solenoids, panel : 240 V, 1 Phase, 2 Wire, 50 Hz illumination & panel/ motor space heaters, Lighting fixtures, AC motors (rated up to and including 0.2 KW) iv) Control & indication / : 110 V, 1 Phase, 2-wire, 50 HZ recorders for contactor (through 415/110V control operated MCC feeders transformer) v) Breaker control, : 220V, 2 Wire unearthed DC protective relay circuits, special application & DC Critical lighting. 4.04.00 Voltage at Load Terminal

a) At full unit load, the voltage will not drop below 90% of the rated voltage.

b) During large motor starting, the voltage will not drop below 80% of

the rated voltage.

4.05.00 Enclosure




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Unless otherwise specifically required equipment, enclosure of electrical

equipment under scope of ACC Vendor shall be as below: a) Indoor PMCC/ MCC/ MLDB/ DB etc. – IP-52 located in Switchgear

Room. b) Outdoor motor – IPW -55. 4.06.00 Sizing of, LT board i) ) 415 V PCC, MCC & distribution board Power Control Centre (PCC) Power and motor control centre (PMCC) and

motor control centre (MCC) shall have two bus sections and a bus coupler. Each section shall have 100% rated incomer fedder from service transformer.

The continuous current rating of the bus bars, incomers, bus couplers of the MCC shall be the maximum load on the board due to all the running

auxiliaries during any operating condition plus 10% margin and the biggest spare feeder rating.

The continuous current rating of the Incomers/ Bus coupler /Main Busbars of PCC, shall be based on the name plate rating of the upstream Transformer with 10% margin at above design ambient condition. For the Switchboards having two bus sections, each bus section & incomer shall be rated for load requirements of both the bus sections for continuous current rating. 4.07.00 Selection of Transformer Service transformer shall be rated to meet the loads connected on both the

bus section of Switchboard with 10 % design margin. . 4.08.00 Selection of Cable a) LT power cables shall be selected on the basis of current carrying

capacity, short circuit rating and permissible voltage drop. b) While sizing power cables, following aspects shall be reckoned : i) Ambient Air temperature ii) No of cables..




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iii) Power Cables touching each other. c) Cables, for circuit breaker controlled feeders, shall withstand the short

circuit current for the following fault clearing time. 0.16 Sec. d) For fuse protected circuits the conductor size shall depend upon full

load current subject to voltage drop limited to 3% during running of all feeders and 15 % during starting for motor feeders with rigid coupling. For motors with fluid coupling the starting voltage drop can be considered as 20%. In addition, transformer regulation shall also be considered for loads fed from LT board.

e) For loads fed from local panels, the total running voltage drop in cable

from 415V LT board to local panel and from local panel to individual motor shall be limited to 3% at full load motor current while the same during starting shall be limited to 15%.

g) For welding receptacle, 3% running drop shall only be considered. The minimum size of L.T cable to be chosen are as below : AL – 6 mm2 Cu - 2.5 mm2

4.09.00 Cable Types The type of cable envisaged for various systems are as under:

6.6 kV power cable supplying incomer to step down transformer is not envisaged in scope.

415 V Power Cables All 415 V power cables will be 1100 V grade, XLPE insulated, PVC inner sheathed (extruded), armoured, FRLS PVC outer sheathed, compacted aluminium conductor conforming to IS:7098 part-I. The minimum size of LV power cables shall be 2.5 Sq.mm. for copper. Power cables shall have aluminium conductor for 6 Sq.mm. and above (For lesser size copper conductor shall be provided). All LT cables will be armoured type.

Control Cables

Control cables will be 1100 V grade, multicore, PVC insulated, PVC inner sheathed, armoured, FRLS PVC outer sheathed stranded copper conductor conforming to IS:1554 part-I. The minimum size of copper conductor control cable shall be of 2.5Sq.mm.




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4.10.00 Cable Routing

Cables will generally be laid on cable trays either in trenches or overhead trestles supported from building steel/structures.

4.11.00 Cable Trays

Cable trays will be ladder type, prefabricated. Cable trays and fittings will be constructed from minimum 14 SWG sheet

steel and hot dip galvanized after fabrication. Tray rungs will be @ 250 mm and cable trays will be supported at an

interval of 1500 mm. Vertical distance between adjacent cable trays, measured from the

bottom of the upper tray to the bottom of the lower tray, will be 300 mm. A minimum vertical clearance of 250 mm will be maintained from top of

the cable tray to bottom of ceiling, beams and other obstructions. Vertical clearance of 1 m from top of MCC or switchgear will be

maintained, for cables routed over MCC/switchgear Maximum loading in kg per running meter length of cable tray will be

limited to 100 4.12.00 Grounding System

Necessary grounding shall be provided for all equipments in substation of ACC as well as outdoor structure housing ACC including fan motor, pump/valve motor etc. Necessary pig tail shall be used to create local outdoor grid for substation and condenser area

4.12.01 Above Grade Grounding

a) Enclosures of all electrical equipment as well as cabinets/boxes/panels, etc. are earthed by two separate and distinct earth connections. Risers will be brought through the ground floor and connected to the building steel and selected equipment. The grounding system will be extended by way of risers and conductors installed in cable tray. The earth connectivity leads from individual equipment will be connected to the nearest conductor running in the topmost tray of the cable raceway system in the vicinity. Taps from runway conductor will be taken to each section of other trays at an interval of about 30m. The runway conductor will be connected to the below ground grounding system at every available building column within plant building and through risers at approximately 20m interval in outdoor trestle / trenches.




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b) Galvanized steel flats will run as main earth conductor along building columns / walls and securely fixed to the same by welding/clamping at intervals not exceeding 1500 mm.

c) All structures, alternate columns and stairs, metallic hand rails, etc.

will be earthed at least at one point. Fence within the ground grid will be bonded to the plant grid system at regular interval not exceeding ten (10) metres.

d) Each street lighting pole, lighting mast and the respective junction

boxes will be connected at two points to an individual MS electrode buried in ground provided for each pole with a galvanized MS strip. This earth conductor will be connected to the main grounding grid at two extreme points.

e) Cable screens and armor (wherever applicable) will be earthed at

both ends for multi core cables. For single core cables, the same will be done at switchgear end only.

f) Above grade ground conductor connections will be welded except at

the equipment end, where the connections are bolted.

g) Two separate and distinct ground connections will be provided for each electrical equipment in compliance with I.E. Rules.

h) The sizes of conductors for above grade grounding are tabulated below.




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For electrical equipments, where the direct connection of GI flat is not possible, a green colour, PVC insulated single core Aluminium cable shall be used for connection to the electrical equipment from the GI flat.

4.13.00 Lightning Protection System

The main purposes of lightning protection system are as follows:

a) Protection of structures from lightning strokes. b) Provide a low resistance conducting path to lightning discharge.

Lightning protection will be ensured in the form of horizontal conductor network and/or vertical air terminal rod on the top of various buildings and

Sl. No. Item Material Size

1.0 415V PMCC, MCC, DB, Starter panel, NSPBD, Battery charger

Galvanised Steel Flat 50 x 6 mm

2.0 Motors above 110 KW up to 160 KW Galvanised Steel Flat 50 x 6 mm

3.0 Steel Column Galvanised Steel Flat 75 x 10 mm

4.0 Steel structure, metallic tanks & vessels, cable tray, fence, gate, rail


5.0 Motors above 22 KW up to 110 KW Galvanised Steel Flat 35 x 6 mm

6.0 Motors above 5.5 KW up to 22 KW Galvanised Steel Flat 25 x3 mm

7.0 Motors up to 5.5 KW Galvanised Steel Flat

25 x3 mm

8.0 Flood light tower, Street light pole Galvanised Steel Flat

25 x3 mm

9.0 Control, Metering and Protection Panel


10.0 PB station, Welding receptacles and Single phase DBs


11.0 Lighting fixture, Receptacles, Junction boxes, Pull boxes GI Wire 16 SWG

12.0 Conduits GI Wire 14 SWG




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structure housing ACC with suitable down-comers grounded through test terminal links.

For metal structures, which are electrically continuous down to the ground level, no lightning protection will be required except adequate grounding connections.

Lightning protection for plants and buildings/structures will generally be

provided based on the assessment of need for protection depending on the type, use and contents of the plant and buildings as laid down in IS - 2309.

Galvanized steel rods and flats will generally be used for air termination

and connections

4.14.00 Illumination System

4.14.01 These equipment and materials shall include but not limited to :

a. Lighting fixtures with lamps and accessories.

b. Receptacles & Switches etc.

c. Street light poles as required for area lighting.

d. Cables, wires, splicing/termination/connection accessories.

e. Conduit and accessories, junction and pull boxes, terminal blocks.

f. Grounding materials and connections.

g. All fittings, supports, brackets, anchors, clamps and connections.

h. Lighting Panels.

Sl. No.

Item Particulars Size/Details Material

1. Vertical Air Termination

20mm diameter, 1000mm long

Galvanized MS Rod

2. Horizontal Air Termination

50 x 6 mm 25 x 6 mm

Galvanized MS Strip

3. Down conductor 50 x 6 mm 25 x 6 mm

Galvanized MS Strip

4. Test Link 150 x 25 x 6 mm Galvanized MS Strip

5. Electrode in ground 40 mm dia. (min.), 3000 mm long

MS Rod




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Illumination will be provided for indoor substation housing PCC, MCC, VFD etc as well as outdoor area and structure of ACC.

Lighting fixtures shall be supplied from a local lighting panel, which in turn supplied from the main lighting distribution board. Normal AC lighting and battery backup emergency DC lighting shall be considered.

Following Average (Avg.) Lux levels on operating area are envisaged as applicable: a)

Switch gear & VFD Room

: 250 Lux

b)

Outdoor area locating ACC and platform : 30 Lux

4.14.02 Building Lighting All the fluorescent lighting fittings to be installed and/or supplied under this

contract wherever specified shall consist of choke, starters and capacitors. The lighting fittings shall be high power factor type and shall be supplied with white light fluorescent tubes (Philips or equivalent). All the lighting fittings shall be with 240 Volts lamps.

4.14.03 Outdoor Lighting Outdoor Lighting shall be provided for ACC area. The lighting as envisaged

for the area shall be taken care by installing street lighting fixture mounted on structure of ACC to illuminate the paved area. Additional lighting shall be provided on ACC structure at each platform to illuminate the staircase such lighting may be taken care by adopting 70W HPSV well glass fixture.

4.14.04 Lighting Panel/Receptacle System The lighting panels & receptacles shall be fixed at locations as per lighting

layout drawings. In general Lighting/Receptacles shall be mounted 1500 mm above the floor level in each room.

4.14.05 Receptacles To cater to welding and other low voltage power requirement of the plant

63A TPN welding socket fed from MCC or ACDB shall be provided. For other services 15A, 3pin socket shall be provided.

5.00.00 PURCHASER’S OBLIGATION 5.01.00 Purchaser will provide necessary procurement services for power

transformer & VFD. However sizing calculations for transformer & sizing/ scheme/ SLD for VFD shall be provided by bidder.

6.00.00 STATUTORY APPROVALS




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The approval from any authority required as per the statutory rules and

regulations of Central/State Government shall be Contractor’s responsibility. The application on behalf of the owner for submission to relevant authorities along with copies of required certificates complete in all respect shall be prepared and submitted by the Contractor well ahead of time so that actual construction/commissioning of work is not delayed for want of the approval/inspection by the concerned authorities. The contractor shall arrange the inspection at works and necessary coordination liaison work in this respect shall be the responsibility of the contractor. Any change/addition required to be made to meet the requirement of statutory authorities shall be carried out by the contractor free of charge. The inspection and acceptance of the work by the statutory authorities shall however not absolve the contractor from any of his responsibilities under this contract

7.00.00 DOCUMENTS TO BE SUBMITTED FOR APPROVAL

a) Key Single Line Diagram b) Single line diagram of different system. c) Equipment Layout d) Cable tray/ trench layout inside the building & in ACC area. e) Lighting Layout f) Grounding and Lighting Protection Layout for building & ACC structure. g) VFD scheme and details for ACC drives h) Sizing Calculation of LT Transformer. i) SLD & Sizing Calculation of LT board along with cable size for feeders. j) Grounding Calculation. k) Lighting Calculation. l) Cable Sizing Calculation.

8.00.00 GENERAL REQUIREMENTS 8.01.00 For finalizing room size, following points shall be considered:

a) In case of cable vaults, minimum 2.5m clear height shall be maintained from finished ground floor level. For cable trench, adequate width shall be provided for installation & maintenance as required from rear of the switchgear.

b) Minimum clearance between two switchgear panels, facing each other shall

be maintained as 2500mm. These distances shall be maintained for all other panels located inside the room..

c) Clearance from any obstruction like column, wall, vertical raceway on back

side of switchgears/Panel shall be maintained as 1000mm (minimum) and shall also comply with manufacturer’s standard.




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d) Space between the sides of two switchgears/Panels or between switchgear/Panels and the wall shall be 1000 mm.

8.02.00 Oil soak pit below transformer and fore barrier wall shall be provided as per stationary requirement.

9.00.00 ELECTRICAL VENDOR LIST

Sr.No. ITEM/EQUIPMENT VENDOR

1 LT switchgears C&S/ SIEMENS/ L&T/ GE power / ABB /Schneider / Areva/ GE power

2 Cables & Cable accessories

Polycab/ Universal/ Torrent/ Incab/ RPG/ Nicco/ CCI/ Finolex/ KEI/ Delton/ Rallison

3 Dry type transformers

Voltamp/ Vijai electricals Ltd. / Univarsal magnetics / Kirloskar/ Bharat Bijlee

4 Oil filled transformer Voltamp/ Vijai electricals Ltd. / CGL / Kirloskar/ Bharat Bijlee

5 Busducts (NSPBD)

C&S /GE/ SpaceAge/ Powergear/ BHEL

6 LT Motors

CGL/ Alstom/ ABB/ Kirloskar/ BHEL/ GE

7 DCDB/MLDB/SLDB/LP& ACDB

Technocrats/ Intrelec/ MK Engineers/ Elec Mech/ Asian/ Hager/ maktel systems/ Venus/ Unilec

8 Local control panel/Local push button station

C&S / Intrelec/ popular switchgear/ MK Engineers

9 Lighting Systems Wipro/ Philips/ Bajaj

1 x 300 MW COAL BASED THERMAL POWER PLANT, CHHATTISGARH, INDIA.

SCOPE MATRIX

ANNEXURE-A

ACC - Scope Matrix-Electrical 1 of 3

(Legend : P.V. - Package Vendor, NA-Not Applicable )

A) Scope of Work

Sr. Description Engineering/ sizing Procurement

Installation/ Testing &

commissioningCable Laying Termination

No. by by by by by

1 6600/433 V Distribution Transformers1.1 6600/433 V Distribution Transformers P.V. IOTL IOTL -- --1.2 Cable Trays & Support Structures IOTL IOTL IOTL -- --1.3 6.6 kV Cables IOTL IOTL -- IOTL IOTL1.4 LV Power & control cable P.V. P. V. -- P. V. P. V.

2 415 V Bus Ducts2.1 415 V Bus Ducts P.V. P. V. P. V. -- P. V.

3. 415 V PMCC & 415 V MCC3.1 415 V PMCC & 415 V MCC P.V. P. V. P. V. -- --3.2 Cable Trays & Support Structures P.V. P. V. P. V. -- --3.3 1.1 kV Power & Control Cables (for 415 V System) P.V. P. V. -- P. V. P. V.


SCOPE MATRIX

ANNEXURE-A


A) Scope of Work




No. by by by by by

4. VFD

4.1 VFD P.V. IOTL P. V. -- --4.2 Cable Trays & Support Structures P.V. P. V. P. V. -- --4.3 1.1 kV Power & Control Cables (for 415 V System) P.V. P. V. -- P. V. P. V.

5 Local Push-button Stations5.1 Local Push-button Stations P.V. P.V. P.V. -- --5.2 Cable Trays & Support Structures P.V. P.V. P.V. -- --5.3 Control Cables (for 415 V System) P.V. P.V. -- P.V. P.V.

6. 415V ACDB, 220 V SUB-DCDB, Lighting DB, UPS SUB-DB

6.1 415V ACDB, 220 V SUB-DCDB, Lighting DB, UPS SUB-DB P.V. P.V. P.V. P.V. P.V.

6.2 Cable Trays & Support Structures P.V. P.V. P.V. -- --6.3 1.1 kV Power & Control Cables P.V. P.V. -- P.V. P.V.


SCOPE MATRIX

ANNEXURE-A


A) Scope of Work




No. by by by by by

7 Electric Motors7.1 Electric Motors P. V. P. V. P. V. -- --

8 Electric Motor Actuators8.1 Electric Motors Actuators P. V. P. V. P. V. -- --

9 Grounding Work (below ground)

9.1 Grounding Work (below ground) around ACC area for facility grid P. V. P. V. P. V. -- --

10 Grounding Work (above ground) 10.1 Grounding Work (above ground) P. V. P. V. P. V. -- P. V.

11 Illumination System

11.1 Illumination of ACC including cabling, wiring for indoor & outdoor area. P. V. P. V. P. V. P. V. P. V.

12 Installation, Testing and Commissioning

12.1 Installalation, Testing and Commissioning (of complete Electrical system/equipments). -- P. V. P. V. P. V. P. V.

Notes :

1. Terminations by Package Vendor shall include Glands, Lugs, etc.2. Cable Trays & Support Structures procured by Package Vendor shall include pre-fabricated galvanised cable trays / racks,

steel supports, steel structures, etc.3. Package Vendor's Scope of Work includes all erection consumables, hardware, material, accessories, labour, tools and

tackles, etc. as required.4. The above scope matrix is applicable for ACC system.

TERMINAL POINTS1. Electrical - From 6.6kV/ 0.433kV transformer LV cable box onward for ACC system electrification.2. Grounding - From Pigtail of 40mm Dia. M.S. ground conductor grid around ACC area3. Distribution boards (Lighting, DC & UPS) - From 220V SUB-DCDB, UPS SUB-DB, MLDB & local ELDB (if required) including routing & providing

necessary tray/ trench/ G.I. pipe




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VOLUME – II

PART - B

SPECIFICATION: E1

AC & DC MOTORS




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AC & DC MOTORS

CONTENT CLAUSE NO. DESCRIPTION .

1.00.00 SCOPE OF SUPPLY

2.00.00 CODES AND STANDRADS 3.00.00 SERVICE CONDITIONS

4.00.00 DESIGN CRITERIA 5.00.00 PERFORMANCE 6.00.00 SPECIFIC REQUIREMENTS 7.00.00 ACCESSORIES 8.00.00 TESTS 9.00.00 DRAWINGS, DATA, MANUALS




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SPECIFICATION NO. E1 FOR

AC & DC MOTORS 1.00.00 SCOPE OF SUPPLY 1.01.00 This section covers the general requirement of drive motors to be provided

under DM Plant package. 1.02.00 Motors shall be furnished in accordance with both this specification and the

accompanying driven equipment specification. In case of any discrepancy, the driven equipment specification shall govern.

2.00.00 CODES AND STANDARDS 2.01.00 All equipment and materials shall be designed, manufactured and tested in

accordance with the latest applicable Indian Standards (IS) except where modified and/or supplemented by this specification.

2.02.00 Equipment and materials confirming to any other standard which ensures

equal or better quality may be accepted. In such case, copies of the English version of the standard adopted shall be submitted along with the bid.

2.03.00 The electrical installation shall meet the requirements of Indian Electricity rules

as amended up to date and relevant IS Codes of Practice. In addition, other rules or regulations as applicable to the work shall be followed. In case of any discrepancy, the more restrictive rule shall be binding.

2.04.00 Indian Standards for the equipment covered under this specification are as

follows : IS 325 : Three phase induction motors IS 4722 : Rotating Electrical machines IS 4029 : Guide for testing three phase induction motors

IS 4691 : Degree of protection provided by enclosures for rotating electrical machinery

IS 15429 : Storage, installation and maintenance of DC motors

IS 8789 : Values of performance characteristics for 3 phase induction motor

IS 12802 : Temperature rise measurement of rotating electrical

machines IS 12065 : Permissible limits of noise level for rotating electrical

machines




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3.00.00 SERVICE CONDITIONS 3.01.00 Motors shall be installed in hot, humid and tropical atmosphere, highly

polluted at places with coal dust and/or fly ash. 3.02.00 Unless otherwise noted, electrical equipment / system design shall be based

on the service conditions and auxiliary power supply given elsewhere in this specification.

3.03.00 For motor installed outdoor and exposed to direct sun rays, the effect of solar

heat shall be considered in the determination of the design ambient temperature.

4.00.00 DESIGN CRITERIA 4.01.00 AC Motors 4.01.01 Motors shall be general purpose, constant speed, squirrel cage, three / single

phase, induction type. 4.01.02 All motors shall be rated for continuous duty. They shall also be suitable for

long period of inactivity. 4.01.03 Motors shall be suitable for both direction of rotation, unless otherwise

specified. 4.01.04 Motor nameplate rating at 50 0C shall have at least 10% margin over the

input power requirement of the driven equipment at rated duty point unless stated otherwise in driven equipment specification.

4.01.05 The motor characteristics shall match the requirements of the driven

equipment so that adequate starting, accelerating, pull up, break down and full load torques are available for the intended service.

4.01.06 Variable frequency drives shall be offered if specified in the accompanying

driven equipment specification. 4.01.07 Crane duty or lift duty motors can be slip ring type. 4.01.08 All HT motors shall have efficiency and power factor higher than 0.9 and 0.8

respectively. 4.01.09 VFD Duty Motor

The motor shall be suitable for operation with a solid-state power supply consisting of an adjustable frequency inverter for speed control.

a) The motor shall be suitable for the current waveforms produced by the power supply including the harmonics generated by the drive.




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b) The Motor shall be designed to operate continuously at any speed over the range 10-100 % of rated speed.

c) The permitted voltage variation should take into account the steady state voltage drop across the AC drive and all other system components upstream of the motor.

d) Motors required to be transferred to DOL, by-pass mode shall be rated for specified variations in system line voltage and frequency. Starting current of motor in DOL, bypass mode shall be limited to value specified for in motor.

e) The motor shall be constructed to withstand torque pulsations resulting from harmonics generated by the solid-state power supply.

f) The motor insulation shall be designed to accept the applied voltage waveform, within the Vpeak and dv/dt limits as per IEC-61800-4.

4.02.00 DC Motors 4.02.01 DC motor provided for emergency service shall be shunt / compound wound

type to suit the requirement of driven equipment. 4.02.02 Motor shall be sized for operation with fixed resistance starter for maximum

reliability. 4.02.03 Starter panel complete with all accessories shall be included in the scope of

supply. 4.02.04 D.C. starter panels for D.C. motors shall be fixed resistance type, designed

to provide fast acceleration during starting. 4.02.05 The starter shall be complete with switch-fuse units, contractors, resistors,

relays, meters, push buttons, lamps etc. 4.02.06 The starter shall be furnished in totally enclosed, floor mounting, sheet steel

cubicle complete with a hinged front access door. 4.02.07 The cubicle enclosure shall provide dust and damp protection, the degree of

protection being no less than IP-55(indoor)/IP-65 (outdoor & dusty area). The resistor enclosure shall be provided with ventilating louvres and wire

mesh guard and shall have a degree of protection IP-23. 4.02.08 The cubicle space heater shall be provided to maintain internal temperature

above dew point. The heater shall be furnished with switchfuse unit and thermostat control.

4.02.09 DC motors shall be provided with tacho-generator. 5.00.00 PERFORMANCE 5.01.00 Running Requirements




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5.01.01 Motor shall run continuously at rated output over the entire range of voltage and frequency variations as furnished elsewhere in the specification.

5.01.02 The motor shall be capable of operating satisfactorily at full load for 5

minutes without injurious heating with 75% rated voltage at motor terminals. 5.02.00 Starting Requirements 5.02.01 Motor shall be designed for direct on line starting at full voltage (except for

motors started through VFD). Starting current shall not exceed 6 times the full load current for motors rated up to and including 3000KW. For ratings above 3000KW motors shall be suitable for starting current limited to 4.5 times inclusive of all tolerances the full load current.

5.02.02 Motor shall be capable of withstanding the stresses imposed if started at

110% rated voltage. 5.02.03 Motor shall be capable of three equally spread starts per hour, the motor

initially being at a temperature not exceeding the rated load operating temperature.

5.02.04 Motor with rigid coupling shall start with rated load and accelerate to full

speed with 80% rated voltage at motor terminals. For motor with fluid coupling this can be considered as 75% of rated voltage.

5.02.05 With voltage and frequency within permissible limit, the motor shall be

capable of two starts in succession with coasting to rest between starts and the motor initially at rated operating temperature, all at full load.

5.02.06 Intermittent duty motors shall be selected where defined by the driven

equipment specification. 5.02.07 Pump motor subject to reverse rotation shall be designed to withstand the

stresses encountered when starting with non-energized shaft rotating at 125% rated speed in reverse direction.

5.03.00 Stress during Bus Transfer (if applicable) 5.03.01 The motor may be subjected to sudden application of 150% rated voltage

during bus transfer, due to the phase difference between the incoming voltage and motor residual voltage.

5.03.02 The motor shall be designed to withstand any torsional and / or high current

stresses which may result, without experiencing any deterioration in the normal life and performance characteristics.

5.04.00 Locked Rotor Withstand Time 5.04.01 The locked rotor withstand time under hot condition at 110% rated voltage

shall be more than motor starting time by at least 2.5 seconds for motors




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upto 20 seconds starting time and by 5 seconds for motor with more than 20 seconds starting time.

5.04.02 Starting time mentioned above is at minimum permissible voltage of 80%

rated voltage. 5.04.03 Hot thermal withstand curve shall have a margin of at least 10% over the full

load current of the motor to permit relay setting utilising motor rated capacity. 5.05.00 Torque Characteristics 5.05.01 Unless mentioned otherwise in the driven equipment specification the torque

characteristics of the motor shall be as required to accelerate the inertia loads of the motor and the driven equipment to full speed without damage to the motor of the equipment at any voltage varying from 80% to 110% of rated voltage.

6.00.00 SPECIFIC REQUIREMENTS 6.01.00 Enclosure 6.01.01 All motor enclosures shall conform to the degree of protection IP-55. Motor

for outdoor or semi-outdoor service shall be of weatherproof construction with canopy.

6.01.02 For hazardous area approved type of increased safety enclosure shall be

furnished. 6.01.03 Motor enclosures, bearing bracket, and fan guard shall be of ferrous material

unless otherwise specified. Aluminium enclosures are not acceptable for motors intended for use in hazardous areas.

6.01.04 All motors shall be equipped with a corrosion resistant drain in the low point of

the enclosure, accessible from the exterior of the motor except where the design is such as to make the collection of condensation within the casing impossible.

6.01.05 Vertical motors shall include a steel rain shield, rigidly mounted to the motor

frame unless the motor design is such as to make it unnecessary. The motor end shield shall be so shaped as to prevent water collecting in the region of the bearing housing.

6.01.07 For motors intended for use in hazardous areas, component parts of the motor

enclosure shall be provided with bonding conductors if necessary to prevent incendiary sparking.

6.02.00 Cooling




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6.02.01 The motor shall be self ventilated type, totally enclosed fan cooled (TEFC) or closed air circuit air cooled (CACA).

6.02.02 For large capacity motors, closed air circuit water cooled (CACW) may be

considered for acceptance. 6.03.00 Winding and Insulation 6.03.01 All insulated winding shall be of copper. 6.03.02 All motors shall have class F insulation, but limited to class B temperature

rise as per IS: 325. 6.03.03 All other motors shall have minimum class B insulation. 6.03.04 Windings shall be impregnated to make them non-hygroscopic and oil

resistant. 6.04.00 Rotor 6.04.01 Shaft ends shall be provided with threaded holes to facilitate the assembly or

removal of couplings and bearings etc. 6.04.02 The rotor and internal fan(s), if fitted, shall be dynamically balanced with the

key-way(s) fully filled with half key(s). The deviation shall not exceed 2.5 gm.cm.

6.04.03 The coupling half and external fan shall be independently balanced, also with

the key-way fully filled with a half key. 6.04.04 If additional weight is required for balancing, this material shall not be of lead

or similar soft material. The balancing material shall be secured in such a way that there is absolutely no possibility of it becoming loose during the lifetime of the motor.

6.04.05 Mechanical shaft runout shall not exceed 0.05 mm for horizontal motors and

0.025 mm for vertical motors. 6.04.00 Bearings 6.04.01 Motor shall be provided with antifriction bearings, unless sleeve bearings are

required by the motor application. 6.04.02 Vertical shaft motors shall be provided with thrust and guide bearings. Thrust

bearing of tilting pad type (Mitchel or kingsbury) are preferred. 6.04.03 Bearings shall be provided with seals to prevent leakage of lubricant or

entrance of foreign matter like dirt, water etc. into the bearing area.




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6.04.04 Sleeve bearings shall be split type, ring oiled, with permanently aligned, close running shaft sleeves.

6.04.05 Grease lubricated bearings shall be pre-lubricated for low rating motors &

regreasable for higher rating and shall have provisions for in-service positive lubrication with drains to guard against over lubrication.

6.04.06 Oiled bearing shall have an integral self cooled oil reservoir with oil ring

inspection ports, oil sight glass with oil level marked for standstill and running conditions and oil fill and drain plugs.

6.04.07 Forced lubricated or water cooled bearing shall not be used without prior

approval of Purchaser. 6.04.08 Lubricant shall not deteriorate under all service conditions. The lubricant shall

be limited to normally available types with Indian Oil Corporation (IOC) or equivalent.

6.04.09 Bearings shall be insulated as required to prevent shaft current and resultant

bearing damage. 6.05.00 Noise & vibration

6.05.01 The Noise level shall not exceed 85db (A) at 1.5 meters from the motor. 6.05.02 The peak amplitude of the vibration shall be within IS specified limits. 6.05.03 6600V motor bearing shall have flats in both X and Y direction suitable for

mounting vibration pad. 6.06.00 Motor Terminal Box 6.06.01 Motor terminal box shall be detachable type and located in accordance with

Indian Standards clearing the motor base plate/foundation. 6.06.02 Terminal box shall be capable of being turned 360° in steps of 90°, unless

otherwise approved. 6.06.03 The terminal box shall be split type with removable cover with access to

connections and shall have the same degree of protection as motor. 6.06.04 The terminal box shall have sufficient space inside for termination connection

of 6600V / 415V XLPE insulated armored, aluminum conductor cables. 6.06.05 Terminals shall be stud or lead wired type, substantially constructed and

thoroughly insulated from the frame. 6.06.06 The terminals shall be clearly identified by phase markings, with

corresponding direction of rotation marked on the driving end of the motor.




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6.06.07 The terminal box shall be capable of withstanding maximum system fault current for a duration of 0.16 sec.

6.06.08 For 6600V motor, the terminal box shall be phase segregated type, the

neutral leads shall be brought out in a separate terminal box (not necessarily phase segregated type) with shorting star connection.

6.06.09 Motor terminal box shall be furnished with suitable cable lugs and double

compression brass glands. 6.06.10 The gland plate for single core cable shall be non-magnetic type. 6.07.00 Grounding 6.07.01 The frame of each motor shall be provided with two separate and distinct

grounding pads complete with tapped hole, GI bolts and washer. 6.07.02 The grounding connection shall be suitable for accommodation of ground

conductors as indicated elsewhere in the specification. 6.07.03 The cable terminal box shall have a separate grounding pad. 6.07.04 The earth connection points shall be protected against corrosion. 6.08.00 Rating Plate 6.08.01 In addition to the minimum information required by IS, the following

information shall be shown on motor rating plate : a) Temperature rise in Deg.C under rated condition and method of

measurement. b) Degree of protection. c) Bearing identification no. and recommended lubricant. d) Location of insulated bearings. 7.00.00 ACCESSORIES 7.01.00 General 7.01.01 Accessories shall be furnished, as listed below, or if otherwise required by

driven equipment specification or application. 7.02.00 Space Heater 7.02.01 Motor of rating 30 KW and above shall be provided with space heaters,

suitably located for easy removal or replacement.




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7.02.02 The space heater shall be rated 240 V, 1 phase 50 Hz and sized to maintain

the motor internal temperature above dew point when the motor is idle. However for space heaters rated above 1200 W shall be suitable for operation from 415 V, 3 ph, 50 Hz.

7.03.00 Temperature Detectors 7.03.01 6600V motors shall be provided with six (6) duplex type winding temperature

detectors, two (2) per phase. 7.03.02 6600V motor bearing shall be provided with duplex type embedded

temperature detectors on both DE and NDE. 7.03.03 The temperature detector mentioned above shall be resistance type, 3-wire,

platinum wound, 100 Ohms at 0 0C. 7.04.00 Indicator / Switch 7.04.01 Dial type local indicator shall be provided for the following: a) 6600V motor bearing temperature. b) Hot and cold air / water temperature of the closed air circuit for CACA

and CACW motor. 7.04.02 Flow switches shall be provided for monitoring, cooling water flow of CACW

motor, oil flow of forced lubrication bearing, if used. 7.05.00 Current Transformer for Differential Protection 7.05.01 Motor rated above 2000 KW shall be provided with three differential current

transformers mounted over the neutral leads within the neutral terminal box. For this purpose the motor manufacturer will be required to supply a separate terminal box mounted on the opposite side of the motor to the main terminal box, to accommodate three winding type current transformers and for terminating the neutral end of the winding. The current transformer shall be epoxy cast resin type of Class PS.

7.05.02 The arrangement shall be such as to permit easy access for CT testing and

replacement. 7.05.03 Current transformer characteristics shall match Purchaser’s requirements to

be intimated later. 7.06.00 Accessory Terminal Box 7.06.01 All accessory equipment such as space heater, temperature detector, current

transformers shall be wired to and terminated in terminal boxes, separate from and independent of motor (power) terminal box.




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7.06.02 Accessory terminal box shall be complete with double compression brass

glands and pressure type terminals. 7.07.00 Drain Plug 7.07.01 Motor shall have drain plugs so located that they shall drain the water,

resulting from the condensation or other causes from all pockets of the motor casing.

7.08.00 Lifting Provisions 7.08.01 Motor weighing 25 Kg or more shall be provided with eye-bolt or other

adequate provision of lifting. 7.09.00 Dowel Pins 7.09.01 The motor shall be designed to permit easy access for drilling holes through

motor feet or mounting flange for installation of dowel pins after assembling the motor and driven equipment.

7.10.00 Vertical jacking bolts shall be provided on all horizontal motors. 8.00.00 TESTS 8.01.00 Routine test 8.01.01 Shall be conducted for each motor as per IS. In addition any special test if

called for in the driven equipment specification shall be performed. 8.02.00 Type test 8.02.01 The motors shall be of type tested quality. Type test certificate on motors of

identical type and rating shall be furnished for approval. Otherwise type test shall be carried out free of charge within the contracted price and delivery schedule by the Bidder to prove the design.

9.00.00 DRAWINGS, DATA & MANUALS 9.01.00 To be Submitted with the Bid a) Individual motor data sheet as per Annexure. b) Type test report. 9.02.00 To be Submitted for Approval and Distribution (A) : ‘Approval’ Category




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(R) : ‘Reference’ Category a) Dimensional General Arrangement drawing, Foundation Plan and

Loading (A) b) Cable end box details (A) c) Space requirement for Rotor removal (R) d) Thermal-withstand curves hot & cold (R) e) Starting and speed torque characteristics at 80% & 100% voltage (R) f) Complete motor data sheet (A) g) Erection & Maintenance Manual (R) 9.03.00 The Bidder may note that the drawings, data and manuals listed herein are

minimum requirements only. The Bidder shall ensure that all other necessary write-ups, curves and information required to fully describe the equipment are submitted with his bid during execution of the contract.

9.04.00 The drawings and document marked with (A) above are of ‘Approval’

category and are subject to review by Purchaser. Those marked (R) are for ‘reference’ category.




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VOLUME – II

PART - B

SPECIFICATION: E2

ELECTRIC MOTOR ACTUATORS




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SPECIFICATION NO. E2 FOR ELECTRIC MOTOR ACTUATORS C O N T E N T S CLAUSE NO. DESCRIPTION 1.00.00 INTENT OF SPECIFICATION 2.00.00 SCOPE OF SUPPLY 3.00.00 DESIGN CRITERIA 4.00.00 SPECIFIC REQUIREMENTS 5.00.00 TESTS 6.00.00 DRAWINGS, DATA & MANUALS ATTACHMENTS ANNEXURE-A DESIGN DATA




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SPECIFICATIO NO. E2 FOR ELECTRIC MOTOR ACTUATORS 1.00.00 INTENT OF SPECIFICATION 1.01.00 This Specification is intended to cover the design, manufacture,

assembly, testing at manufacturer's works, supply and delivery properly packed for transport of ELECTRIC MOTOR ACTUATORS for valves, dampers and gates complete with all materials and accessories for efficient and trouble free operation.

2.00.00 SCOPE OF SUPPLY 2.01.00 The following equipment shall be furnished with all accessories required

in accordance with driven equipment specification: a) Integral type Motor actuators 2.02.00 One (1) set of Special tools and tackle. 2.03.00 Spare parts. 2.04.00 All relevant drawings, data and instruction manual. 3.00.00 DESIGN CRITERIA 3.01.0 General 3.01.01 All electric motor actuators shall be furnished in accordance with this

general specification and the accompanying driven equipment specification.

3.01.02 The actuator shall be suitable for operation in hot, humid and tropical

atmosphere, polluted at places with dust. Canopies to be provided to all outdoor motors. The actuator located in hazardous area shall be flameproof type.

3.01.03 Unless otherwise noted electrical equipment/system design shall be

based on the service conditions and auxiliary power supply given in the annexure of this specification.

3.02.00 Rating 3.02.01 For isolating service, the actuator shall be rated for three successive

open-close operation of the valve/damper or 15 minutes, whichever is longer.




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3.02.02 For regulating service, the actuator shall be suitably time- rated for the duty cycle involved with necessary number of starts per hour, but in no case less than 120 starts per hour.

3.03.00 Performance 3.03.01 The actuator shall meet the following performance requirements : a) Open and close the valve completely and make leak-tight valve

closure without jamming. b) Attain full speed operation before valve load is encountered and

impart an unseating blow to start the valve in motion (hammer blow effect).

c) Operate the valve stem at standard stem speed and shall

function against design differential pressure across the valve seat.

d) The motor reduction gearing shall be sufficient to lock the shaft

when the motor is de-energised and prevent drift from torque switch spring pressure.

e) The entire mechanism shall withstand shock resulting from

closing with improper setting of limit switches or from lodging of foreign matter under the valve seat.

4.00.00 SPECIFIC REQUIREMENTS 4.01.00 Construction 4.01.01 The actuator shall essentially comprise the drive motor, torque/limit

switches, gear train, clutch, hand wheel, position indicator/transmitter, space heater and internal wiring.

4.01.02 The actuator enclosure shall be totally enclosed, dust tight,

weather-proof or flameproof (as applicable) suitable for outdoor use without necessity of any canopy.

4.01.03 All electrical equipment, accessories and wiring shall be provided with

tropical finish to prevent fungus growth. 4.01.04 The actuator shall be designed for mounting in any position without any

lubricant leakage or operating difficulty. 4.02.00 Motor




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4.02.01 The drive motor shall be three phase, squirrel cage, induction machine with class F insulation and IPW-55 enclosure, designed for high torque and reversing service. For flameproof actuator, suitable motor shall be provided.

4.02.02 The motor shall be designed for full voltage direct on-line start, with

starting current limited to 6 times full-load current. 4.02.03 Motor shall be capable of starting at 85% of rated voltage and running

at 80% of rated voltage at rated torque and 85% rated voltage at 33% excess rated torque for a period of 5 minutes each.

4.02.04 Earthing terminals shall be provided on either side of the motor. 4.03.00 Limit Switches Each actuator shall be provided with following limit switches: - 4.03.01 2 torque limit switches, one for each direction of travel, self- locking,

adjustable torque type. 4.03.02 4 end-of-travel limit switches, two for each direction of travel. 4.03.03 2 position limit switches, one for each direction of travel, each

adjustable at any position from fully open to fully closed positions of the valve/damper.

4.03.04 Each limit switch shall have 1 NO + 1 NC potential free contacts.

Contact rating shall be 5A at 240V A.C. or 1A at 220V D.C. 4.04.00 Hand Wheel Each actuator shall be provided with a hand wheel for emergency

manual operation. The hand wheel shall declutch automatically when the motor is energized.

4.05.00 Position Indicator/Transmitter The actuator shall have : 4.05.01 One (1) built-in local position indicator for 0-100% travel. 4.05.02 One (1) position transmitter, potentiometer type, for remote indicator. 4.06.00 Space Heater A space heater shall be included in the limit switch compartment

suitable for 240V, 1 phase, 50 Hz supply.




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4.07.00 Wiring All electrical devices shall be wired upto and terminated in a terminal

box. The internal wiring shall be of sufficient size for the power rating involved but in no case less than 1.5 mm2 copper. All wiring shall be identified at both ends with ferrules.

4.08.00 Terminal Box The terminal box shall be weather proof, with removable front cover and

cable glands for cable connection. The terminal shall be suitable for connection of 2.5 mm2 copper conductor.

4.09.00 Accessories The actuators shall be furnished with integral starter mounted on the

actuator. This shall include: 4.09.01 One (1) triple pole fuse switch unit. 4.09.02 One (1) reversing starter, with mechanically interlocked contactors with

2 NO + 2 NC auxiliary contacts, thermal overload relay, LED type indication lamps etc.

4.09.03 One (1) remote-local selector switch. 4.09.04 CLOSE-STOP-OPEN push button. 4.09.05 Control transformer with primary & secondary fuses. 5.00.00 TESTS The actuator and all components thereof shall be subject to routine

factory tests as per relevant IS Standards. In addition, if any special test is called for in equipment specification, the same shall be performed.

6.00.00 DRAWINGS, DATA & MANUALS Data sheet for each type of actuator shall be furnished along with

internal wiring diagram, suggested control schematic and limit switch contact development and manufacturer's catalogues.




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ANNEXURE-A DESIGN DATA 1.0 AUXILIARY POWER SUPPLY Supply Description Consumer

L.T. Supply 415V, 3 Phase, 3W, 50 Hz,

effectively earthed.

Motors from 200W to below 160KW

Fault level 50 KA symm.

240V, 1 Phase, 2W, 50 Hz, effectively earthed.

Motors below 200W

2.0 RANGE OF VARIATION A.C. Supply Voltage : ± 10% Frequency : ± 5% Combined voltage : 10% (absolute sum) & frequency

SPECFICATION FOR AIR COOLED CONDENSER



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VOLUME – II

PART - B

SPECIFICATION: E3

VARIABLE FREQUENCY DRIVE




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FOR VARIABLE FREQUENCY DRIVE

CONTENTS

1.00.00 Codes And Standards 2.00.00 Type 3.00.00 Performance Requirement 4.00.00 Control Requirement 5.00.00 Panel Construction 6.00.00 Cooling 7.00.00 Equipment/Component Specification 8.00.00 Power Transformer 9.00.00 Power Converter 10.00.00 DC Link Reactor 11.00.00 Output Filter 12.00.00 By Pass Feature 13.00.00 CT/PT/Meters 14.00.00 Local Motor Control Stations 15.00.00 Protection, Control, Metering, Indication and Annunciation 16.00.00 Operator Control Panel 17.00.00 Protective Features 18.00.00 Control 19.00.00 Indicators 20.00.00 Metering 21.00.00 Audio-Visual Annunciation 22.00.00 Fault Diagnostic 23.00.00 External Power Supply for Auxiliary and control circuit 24.00.00 Reliability Features 25.00.00 Maintenance Feature 26.00.00 Painting 27.00.00 Mandatory spare list 28.00.00 Inspection, Testing and Acceptance




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SPECIFICATION NO. E3 FOR

VARIABLE FREQUENCY DRIVE 1.00.00 INTENT OF SPECIFICATION 1.01.00 This specification is intended to cover the design, manufacture, assembly, testing at

manufacturer's works, supply & delivery, properly packed for transport F.O.R. site of VFD complete with all materials and accessories for efficient and trouble-free operation of ACC fan motor. Bidder shall indicate optional takeoff price for supply of VFD to be decided during execution by owner.

2.00.00 CODES AND STANDARDS DC reactor – IEC 289 HT Circuit Breaker – IEC 56 Motors – IS 325 / IEC 34 / IS 4722 Transformers – IS 2026 Bushings – IS 2099 / IEC 137 Bushing CT – IEC 185 / IS 2705 LT Circuit Breaker-IEC 158 / 947 3.00.00 FEATURE

System shall be load commutated invertor type, 12-pulse design, having two channels (each channel with six pulse design) for each motor. VFD will receive incoming power from 415V PCC having air circuit breaker as outgoing feeder. VFD panel will have switch fuse unit as incoming supply & necessary input & output line choke & power contactor at the incomer & outgoing side of VFD before output is connected to motor. Bypass contactor with thermal overload relay will be provided across the VFD. VFD will have necessary feature for operation through DCS in addition to local operation at VFD panel.

4.00.00 PERFORMANCE REQUIREMENTS

4.01.00 The system shall be energy efficient, designed as standard product and shall provide very high reliability, high power factor, low harmonic distortion and low vibration/ wear/ noise.

4.02.00 The system shall be designed to deliver the motor input current and torque for the complete speed torque characteristics of the ACC fan motor with input supply

variation of +10% and frequency variation of +5%. It shall be capable of withstanding the thermal and dynamic stresses and the transient mechanical torque, resulting from short circuit.

4.03.00 The drive system shall be designed to operate in one or more of the following operating modes as to suit characteristics of the driven equipment

i. Variable torque changing as a function of speed i.e. speed squared ii. Constant torque over a specific speed range




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iii. Constant power over a specific speed range where the torque decreases when speed increases

4.04.00 The drive controller shall be equipped with microprocessor based digital regulator

with programmable functions. The power control regulator logic shall provide for an acceleration/deceleration current limit curve and shall be capable of field be separately programmable from 0.1 to 20 seconds.

4.05.00 Each channel and motor rating shall be rated to meet driven equipment

requirements. The system shall be designed for linear continuous speed control from 10% to 100% of fan rated speed and shall be of a modern proven design and fully compatible with excitation system offered.

4.06.00 The Total Harmonic Distortion (THD) of the voltage and current at inverter output

shall be as per IEC 61800-4 and it shall be considered in the design of the motor. 4.07.00 Harmonics at the supply side of the drive system at primary of the main input

transformer shall be restricted within the maximum allowable levels of current and voltage distortion as per recommendations in the latest edition of IEEE-519.

4.08.00 The overload capacity of the controller shall be 150% of rated current of motor for

one minute for constant torque applications, and 115% of rated current for one minute for variable torque application at rated voltage. If the motor load exceeds the limit, the drive shall automatically reduce the frequency and voltage to the motor to guard against overload. If the load demand exceeds the current limit for more than one (1) minute, the drive shall shut down to prevent overheating of the motor and damage to the drive.

4.09.00 During operation, the system shall be capable of developing sufficient torque under

all load condition to respond to a 20% alteration in speed set point within a time limit up to 60 seconds

4.10.00 The integrator action of the speed set point alteration shall be independently

adjustable for both an upward and downward alteration. The minimum time interval between set point adjustments by the distributed control system shall be considered as 10 second.

4.11.00 The drive shall trip incase the speed exceeds 105% of the maximum operational

speed or reduces to 95% of the minimum operational speed for more than 10 second.

4.12.00 Maximum noise level from the drive at 1meter distance, under rated load with all

normal cooling fans operating shall not exceed 85dBA. 4.13.00 Variable frequency drive shall be arranged so that it can be operated in a circuit

mode, disconnected from the motor for start up adjustment and troubleshooting/ maintenance.

4.14.00 Voltage at motor neutral terminal shall be maintained at ground potential for the

total operating condition.




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4.15.00 The drive system shall ensure following a) Harmful VFD induced harmonics which can create motor heating are

eliminated. b) VFD induced torque pulsation are limited to maximum 1% (even at low

speed) so there is minimal stress to the equipment c) Motor is protected from dv/dt stresses. d) No appreciable increase in motor audible noise.

4.16.00 Electrical performance of the system shall comply to IEEE, IEC and equivalent international standard.

5.00.00 CONTROL REQUIREMENT 5.01.00 The system shall operate on constant V/f supply with required voltage boost capability in low frequency mode of operation. 5.02.00 Short time voltage dip up to 20% of nominal voltage (e.g. in case of a large motor start up connected to the same bus as VFD) shall not cause the control system to

stop functioning and shall not trip the drive system. 5.03.00 The system shall also be equipped with a facility which will restart the system in

case of voltage dip over 20% or power interrupter for less than 2 seconds, with recovery of the voltage to its normal value. The drive shall have the facility to block this feature, if required by operator. Upon restart the converter shall be capable of synchronizing onto a rotating motor and develop full acceleration torque within 10 seconds.

5.04.00 The power controller shall be controlled to always start the motor in the forward

direction. Logic shall be provided to prevent the motor from being started in the reverse direction.

5.05.00 The drive motor shall be speed controlled corresponding to 4-20mA or 0-10V

reference input signal. Unless otherwise specified, upon complete loss of the users speed reference signal, the drive shall automatically run at constant speed as at 8-100% of the last speed reference available prior to the loss of signal.

5.06.00 It shall be possible to vary the speed of the drive in either manual or auto mode. Auto/manual selection shall be from VFD panel unless otherwise specified.

• With the selector switch in “manual” mode, the operator shall be able to set the speed through keypad, mounted on front of the drive panel or from speed increase/decrease push buttons from the field. Motor operated potentiometer shall be provided as a speed set point device.

• With selector switch in “auto” mode, speed of the motor shall be controlled from a 4-20mA signal, from owner’s PLC/DCS system. Necessary equipment like protocol converter as required for interfacing with PLC/DCS shall also be provided in the drive panel.




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5.07.00 The required provision for the interface with remote PLC/DCS located at control room shall be either through hardwired connection (with potential free contacts and transducers as described elsewhere in this specification).

5.08.00 Drive system shall have provision for interface with upper level automation such as

substation monitoring system or electrical control system. 5.09.00 The closed loop control feedback for the drive system having output transformer shall be tapped from the secondary side of the output transformer. 6.00.00 PANEL CONSTRUCTION 6.01.00 The panel shall include suitable semi conducting power devices (Diodes/IGBT). modules with protective devices, reactors (if required), filters (if required), control circuit, control accessories, indication and annunciation etc. The construction of the panel shall provide effective protection against electromagnetic radiation and shall meet design requirement of integrated standards. 6.02.00 Upstream breaker “ON/OFF/TRIP” indications and remote breaker closing and trip push button shall be provided on the front door. 6.03.00 Safety Interlock shall be provided so that power cabinet can’t be opened unless

the up stream breaker is disconnected, safety-grounding switch is closed and DC link capacitor is discharged. Power source breaker can only be closed once the earthing switch is open and panel door is closed with lock defeat facility.

6.04.00 Duplicate control supply with automatic changeover shall be provided. Protection

shall be provided against AC/DC transients, voltage surge etc. of power and control device.

6.05.00 The drive shall be housed in sheet steel panels fabricated with 2mm thick cold

rolled sheet steel. The panel shall be suitable for indoor installation, if not otherwise specified. The panel shall be free standing with degree of enclosure protection as IP-41. The maximum operating height shall be 1800mm approximately.

6.06.00 Bolted un-drilled gland plate shall be provided at bottom. Clamp type terminals

shall be used for connection of all wires up to 10mm2 and terminal for higher sizes shall be bolted type suitable for cable lugs. Minimum space for power cable termination shall be 600mm clear from bottom of the cable gland plate.

6.07.00 Bus bars shall be of electrolytic copper, color coded separately for AC and DC

system. All the live parts shall be sleeved/shrouded to ensure complete safety to personnel intending to carry out routine inspection by opening the panel doors. All the equipment inside the panel and on the doors shall be provided with suitable nameplate.

6.08.00 All the switches, component and accessories which are essential for normal and

emergency operation shall be mounted on the door and shall be operable




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externally. All the analog instruments, where provided, shall be switchboard type, back connected; 72x72mm.Scale shall have red mark indicating maximum permissible operating rating.

6.09.00 Each panel shall be provided with illuminating lamp/11W CFL with switch and

fuse. 6/16A, 250V power socket with switch and fuse shall be provided. Each panel shall have space heater with switch fuse and variable setting thermostat.

6.10.00 Copper earth bus of min. 50x6 mm size shall be provided in the panel with

provision for connection to purchaser’s plant earth grid. All the non-metallic components/parts shall be connected to the main earth bus bar. Separate earth bus bar and stud for electronic control system as required shall be provided.

6.11.00 All the metal parts shall be treated so as to ensure efficient anti-corrosive

protection. Hard wares shall be zinc passivated or electro-galvanized. Panel enclosure and structure supports shall be thoroughly cleaned and degreased to remove mill scale and rust etc. External surface shall be painted Siemens grey (RAL - 7032) with two coats of synthetic enamel paint.

6.12.00 All panels shall be of same height so as to form a uniform line-up, to give good

aesthetic appearance. 6.13.00 All the control wiring shall be enclosed in plastic/metal channel. Each wire shall be

identified at both ends by self-sticking wire marker tapes of PVC ferrules. Power and control wiring inside the panel shall be done with BIS approved, PVC insulated, fire retardant, copper conductor wire. 1.5mm2 size wire shall normally be used provided the control fuse rating is 10 Amps or less and 2.5mm2 size for control fuse rating above 16A for electrical circuits and 0.7 mm2 for electronic circuits. All wires shall be ferruled and terminals shall be properly numbered, minimum 20% spare terminal shall be provided.

6.14.00 All electronic modules and components shall be accessible from front of panel

only. Modular assemblies for both the system control electronic equipment and power electronic equipments shall be used.

6.15.00 All low voltage compartment and cabling shall be electrically and physically

separated from the high voltage compartment. 5.16.00 DC link capacitor and pre charging and discharging circuit shall be preferably

mounted in the rear of the panel. 5.17.0 Suitable removable type hooks shall be provided for lifting the panel. 5.18.00 Perspex type transparent insulating material shall be used for covering live

compartments. 5.19.00 Drive keypad, operator control panel required for control, monitoring and

measurements shall be supplied and installed outside the panel on the front door. It shall be accessible for operation without opening the front door and shall be non-removable type.




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5.20.00 All the equipment shall be complete with cable glands, lugs etc. and cable glands shall be single or double compression type for indoor and outdoor equipment respectively.

6.00.00 COOLING 6.01.00 The drive panel shall be naturally cooled type as per manufacturer’s

standards. If unavoidable, forced type cooling system shall be provided. Cooling system shall include well-dimensioned panel, adequate cooling airflow path, module cooling fan and if necessary, panel-cooling fan shall be considered. Vendor shall ensure that the panel dimensions and the flowpaths have been designed for continuous running at the specified ambient without overheating. For fan cooled drives, redundant ventilating fans (N+1) shall be provided.

6.02.00 Necessary starters shall be provided within the VFD panels for the ventilation fans,

any other auxiliary motor etc. The system provided shall be interfaced with drive starting and shut down such that safety interlocks such as start permit from cooling system to drive and trip signal from cooling system to drive in case of cooling system failure etc., shall be incorporated in the overall sequence logic.

6.03.00 MCB for motor space heater, auxiliary power supply if required for local panel,

drive panel space etc. shall be included and mounted in easy accessible location. 7.00.00 EQUIPMENT/COMPONENT SPECIFICATION 7.01.00 Motor

a) The motor shall be suitable for operation with a solid-state power supply consisting of an adjustable frequency inverter for speed control.

b) The motor shall be suitable for the current waveforms produced by the

power supply including the harmonics generated by the drive. c) The Motor shall be designed to operate continuously at any speed over the

range 10-100 % of rated speed. d) The permitted voltage variation should take into account the steady state

voltage drop across the AC drive and all other system components upstream of the motor.

e) Motors required to be transferred to DOL, by-pass mode shall be rated for specified variations in system line voltage and frequency. Starting current of motor in DOL,bypass mode shall be limited to value in motor specifications.

f) The motor shall be constructed to withstand torque pulsations resulting from harmonics generated by the solid-state power supply.

g) The motor insulation shall be designed to accept the applied voltage waveform, within the Vpeak and dv/dt limits as per IEC-61800-4.

h) The drive manufacturer shall be solely responsible for proper selection of the motor for the given load application and the output characteristics of the drive.

Other details shall be as given in specification E11 of Electric motors.




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8.00.00 POWER TRANSFORMER Indoor dry type. and shall be suitable for rating complying with system details. Other details as given in sub-section of LT Transformer 9.00.00 POWER CONVERTER

a. The static power shall consist of a line side power converter for operation as a rectifier and a load side power converter for operation as a fully controlled inverter. Power converter shall be fast switching, most efficient and low loss type.

b. Adequate short circuit and over voltage protection shall be provided for the converter and inverter system.

c. All power converter devices shall include protective devices, snubber networks and dv/dt networks as required.

d. The current rating of the converter’s semi-conductor components shall not be less than 120% of the nominal current flowing through the elements at full load of the VFD through the whole speed range.

e. All power diodes shall be of silicon type with minimum Vbo rating as 2.5 times the rated operating voltage.

f. The power converter circuit shall be designed so that motor can be powered at its full nameplate rating continuously without exceeding its rated temperature rise due to harmonic currents generated by the inverter operation.

g. The conversion devices and associated heat sinks shall be assembled such that individual devices can be replaced without requiring the use of any special precautions/tools.

h. The cooling system of the electronic components, if provided, shall be monitored and necessary alarms shall be provided to prevent any consequential damage to the power control devices.

i. Offered system shall also take in account the distance between drive panel and motor and system shall include all material and accessories to make system suitable for a distance of 350m.

10.00.00 DC LINK REACTOR

a. Smoothing reactors for the DC link shall be designed to sufficiently decouple the rectifier and inverter portion of the converter and to limit fault currents in this circuit.

b. Unless otherwise specified, the reactor shall be dry type, air cored, air-cooled or fan cooled type located within the panel.

c. Reactor shall be suitable for withstanding earth fault continuously and for operation with the non-sinusoidal current wave shapes and DC components under all operational conditions of the system without exceeding its temperature limits.

d. Noise level shall not exceed value specified in NEMA TR-1

11.00.00 OUTPUT FILTER




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VFD output current waveform should be inherently sinusoidal at all speeds, with harmonic limits as specified in this specification. Output filter shall be provided if required. Output filter capacitors shall be provided with discharge circuits to ensure that all residual stored charge is reduced to less than 50 V DC within 300 seconds after a loss of AC voltage. All capacitor shall be maintenance free and self-healing type. The VFD system shall inherently protect motor from high voltage dv/dt stress, independent of cable length to motor. Output filter shall be an integral part of the VFD system and included within the VFD enclosure.

12.00.0 BYPASS FEATURE

a. Bypass breaker / contactor-HRC fuse complete with protection, annunciation and metering shall be provided.

b. All Variable frequency drives (VFD) having bypass feature shall have motor protection relay along with necessary control and metering etc. Switching scheme shall be such that in case of drive mal-operation, the motor could be taken on bypass control manually, while the drive could be attended by opening its isolation devices.

c. Safety interlock between inverter and bypass breaker/contactor shall be provided such that closing of healthy device is inhibited in case of external fault.

13.00.0 CT/PT/METERS

As required for the system offered and shall be suitable for variable frequency operation.

14.00.00 LOCAL MOTOR CONTROL STATION

a. The local motor control station is to be installed in the field near the motor. Components and accessories that are required in the local motor control station may be mounted on the local field mounted panel envisaged for the driven equipment.

b. Meters in the local control station shall be suitable for 4-20mA transducer outputs and shall be calibrated for the actual motor current. Further, the drives with bypass facility, the meters shall be capable of reading bypass full load and starting currents, as well as the drive current.

15.00.00 PROTECTION, CONTROL, METERING, INDICATION AND ANNUNCIATION 15.01.00 The system vendor shall provide all the necessary system control,

protection; alarm equipment and metering for the entire drive system and its auxiliary equipment.




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15.02.00 Automatic sequence control shall include start-up of cooling system,

auxiliary system of the motor, interlock checking, automatic start and run-up of drive, planned and emergency shutdown. The same shall be processed through microprocessor-based system.

16.00.00 OPERATOR CONTROL PANEL

a. Each drive shall be equipped with a front mounted operator control panel consisting of a backlit alphanumeric display and a keypad with keys for parameterization and adjusting parameter which shall be limited to Start/Stop, Local/Remote, Auto/Manual, Increase/Decrease, menu navigation and protection and measurement parameter selection, etc.

b. All parameter names, fault messages, warnings and other information shall be displayed in complete English words or standard English abbreviations to allow the user to understand what is being displayed without the use of a manual or cross-reference table. This shall also be used for the modification of all electrical values, configuration parameters, drive menu parameters, application and activity function access, faults, local control, adjustment storage, self test and diagnostics. Keypad shall be operable with password for changing the protection setting, safety interlock etc. However the parameters such as measurements, setting, and mode of drive etc. Shall be allowed to be viewed without any password.

c. Operator console shall have facility / port to connect external hardware such as Lap-Top etc. Console shall have facility for upload and download of all parameter settings from one drive to another identical drive for start up and operation.

d. Drive system control also have facility to receive tripping signal from up stream breaker for tripping and also provision for closing upstream breaker after all required process parameters are achieved.

e. User-friendly software for operation and fault diagnostic shall be loaded in the drive system panel before commissioning.

17.00.00 PROTECTIVE FEATURES The system offered shall incorporate adequate features, properly coordinated for the drive control and for motor but not limited to the following:

i. Incoming line surge protection. ii. Under / Over voltage protection. iii. Phase loss, phase reversal protection. iv. Programmable Over current Protection and under load

protection.




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v. Inverter fault. vi. Over frequency operation. vii. Ventilation loss. viii. Over temperature of equipment. ix. Over speed of motor. x. Specific motor protection, including motor winding, bearing

temperatures, over current, Overload, negative phase sequence, locked rotor and earth fault protections etc.

xi. System Earth fault protection. xii. Over and under frequency, rotor earth fault, field failure

protection for synchronous motor xiii. Additional protection for drive system

18.00.00 CONTROL

The following controls shall be provided as a part of the operators control Panel or through separate switches.

i. Start/Stop ii. Speed Control (Raise/lower) iii. Auto/Manual/Test mode iv. Local/Remote v. Emergency Stop vi. Start/Stop for by pass starter (where specified) vii. Trip-Remote Breaker viii Sequential switching of filters

19.00.00 INDICATORS

Vendor shall provide indications as required for normal operation and for easy maintenance, which shall be limited to the following indications. i. Motor running ii. Motor stopped iii. VFD System Fault iv. System ready to start v. AC mains ON vi. Motor over speed vii. Rectifier output ‘ON’ viii. Motor zero speed ix. Rectifier breaker trip Above indications may be provided as a part of the operator control panel, i.e., door mounted keypad or through hardwired indicating lamps/LEDS. Potential free contacts of items i-iv shall be wired separately for remote indications in PLC/DCS system.




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20.00.00 METERING

Digital display of the following parameters shall be as a part of the Operator Control Panel, selected by the operator. i. Input AC voltage ii. Input AC frequency iii. Input AC current iv. Output voltage v. Output current VFD / Bypass vi. Output frequency vii. Motor thermal state viii. Drive thermal state ix. Motor speed x. Motor energy meter xi. DC Link voltage xii. Hour Run

Necessary transducer shall be provided with 4-20mA output for indicating motor speed and motor current in PLC/DCS unless otherwise specified for other parameters. 21.00.00 AUDIO-VISUAL ANNUNCIATIONS

a. The system shall incorporate audio-visual annunciations for protection, for various fault conditions, for the Drive motor, Supply cables, DC Reactor and the Converter, output transformer etc.

b. Alarms shall also be included for the failure of various auxiliaries together with identifications of the failing unit, loss of cooling system, various protections devices provided for converter transformer etc.

c. Audio-visual window annunciations shall be provided on the front of the panel. All annunciations as required for normal and satisfactorily operation of the drive system shall be included as per vendor standards. These annunciations can be part of operator console panel or separately mounted type.

d. Vendor shall include audio-visual alarm as required for normal operations and maintenance of the system but not limited to the following. 1. Rectifier fuse failure 2. Main AC failure 3. Inverter fuse failure 4. Inverter overload 5. Inverter high temperature 6. Cooling system failure 7. Motor failed to start 8. Transformer failure 9. Battery monitoring healthiness




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10. Communication and measurement system unhealthy 11. Motor temperature high 12. Harmonic filters monitoring

Common potential free contacts shall be provided for above annunciations and these shall be wired up to terminal block for owner’s use for remote alarm and monitoring.

22.00.00 FAULT DIAGNOSTIC

Fault diagnostic shall be built into the system to supervise the operation and failure of the system. The information regarding failure of any of the system including shut down of the system shall be available for a period of minimum 4 days (96 hours) after a shut down even though no supply would be available to the system. The system may be totally de-energized for maintenance or otherwise. It shall be possible to retrieve the record of events prior to tripping of the system or de-energisation. Auxiliary supply to the system components or to the electronics (firmware) for the diagnostics / display shall be taken care by the manufacturer for this purpose.

23.00.00 EXTERNAL POWER SUPPLY FOR AUXILIARY AND CONTROL CIRCUIT

Auxiliary power supply for devices external to VFD module, space heater supply for Motor, VFD panel space heater, auxiliary power supply for transformers, cubicle 11W CFL lamps etc. shall operate on 240 volts single phase AC provided by purchaser.

All control circuit shall operate at maximum voltage of 240V AC

Vendor shall include supply of all control transformers, protective

devices, required accessories etc. and any other control supply voltage as required for the system shall be derived from the power supply made available by other.

24.00.00 RELIABILITY FEATURES

The expected lifetime of the drive system shall be 25 years. The system

including all individual components forming part of the system shall have a minimum MTBF of 4 years.

25.00.00 MAINTENANCE FEATURES

The controller design shall incorporate the following maintenance features:

• Modular construction • All components shall be easily accessible




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Standard diagnostics to aid maintenance personnel. These shall include LED or alphanumeric displays, test or measurement points.

26.00.00 PAINTING

26.01.00 All metal surfaces shall be thoroughly cleaned and de-greased to remove

mill scale, rust, grease and dirt. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. The under-surface shall be prepared by applying a coat of phosphate paint and a coat of yellow zinc chromate primer. The under-surface shall be made free from all imperfections before undertaking the finishing coat.

26.02.00 After preparation of the under surface, the panel shall be provided with

epoxy based powder coating. Panel finish shall be free from imperfections like pinholes, orange peels, runoff painted.

26.03.00 All unpainted steel parts shall be zinc passivated, cadmium plated or

suitably treated to prevent rust and corrosion. If these parts are moving elements, then these shall be greased.

26.04.00 Final paint shade shall be Siemens grey (RAL - 7032).

27.00.00 MANDATORY SPARE LIST Bidder shall submit recommended mandatory spare parts along with bid. 28.00.00 INSPECTION, TESTING AND ACCEPTANCE 28.01.00 During fabrication, the drive shall be subject to inspection by owner, or by an

agency authorized by the owner, to assess the progress of work, as well as to ascertain that only quality raw material is used. The manufacturer shall furnish all necessary information concerning the supply to owner’s inspectors.

28.02.00 All tests shall be carried out at the manufacturer’s works under his care and expense. The tests shall be witnessed by an inspector of the owner or an agency authorized by the owner. Prior notice of minimum of 4 weeks shall be given to the inspector for witnessing the test.

28.03.00 The routine test shall be conducted on all the drive system. However type

test shall be performed on one system of each rating and type unless otherwise agreed between purchaser and manufacturer. For the purpose of testing, drive system shall include input/output transformer (where applicable), switchgears, converter, filters etc.

28.04.00 The routine and type tests to be performed on the drive system shall be as follows.

Routine tests




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a.Visual Inspection

It involves checking of the various equipments/components fault diagnostic unit, wiring, terminals, earthing ratings etc, in line with the approved drawings and visual inspection shall not be limited to the following;

i. Dimensions and door layout Vis-à-vis the approved drawings ii. Degree of protection of cubicles iii. Simulation facility of control signals for testing purposes iv. Memory function of fault diagnostic v. Voltage/Current rating power semiconductor elements vi. Cable termination size and number of terminals, cable-supporting etc. vii. Accessibility of components viii. External signals and indication/alarm signals on converter ix. Earthing of cubicles and cubicle doors

b. Insulation Test c. Light load and functional test d. Load characteristics test e. Load duty test f. Checking of Auxiliary devices g. Checking the properties of the control equipment h. Checking the protective devices i. Checking of control and functional requirements j. High voltage test k. Shaft current/bearing insulation l. Automatic restart/re-acceleration

Type Tests

a. Allowable full load current versus speed b. Efficiency c. Temperature rise d. EM Immunity e. EM Emission f. Current sharing g. Voltage division h. Line side current distortion content i. Power factor j. Audible noise k. Torque pulsation l. Motor vibration m. Dynamic performance n. Current limit and current loop test o. Speed loop test capability to ride through voltage less than 80% p. Test capability to restart the system and resynchronize converter

onto running motor after a voltage interruption




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Type test certificate from independent testing agency for similar equipment can be accepted for d, e, f, j, k and l.

BID DOCUMENT FOR FOR AIR COOLED CONDENSER



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VOLUME – II

PART - B

SPECIFICATION: E4

415V PCC, MCC, DISTRIBUTION BOARDS, LOCAL CONTROL STATIONS & NON SEGREGATED PHASE

BUSDUCT




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FOR

415V PCC, MCC, DISTRIBUTION BOARDS, LOCAL CONTROL STATIONS & NON SEGREGATED PHASE BUSDUCT

C O N T E N T S

CLAUSE NO. DESCRIPTION 1.00.00 INTENT OF SPECIFICATION 2.00.00 SCOPE OF SUPPLY 3.00.00 DESIGN CRITERIA 4.00.00 SPECIFIC REQUIREMENTS 5.00.00 TESTS 6.00.00 DRAWINGS, DATA & MANUALS ATTACHMENTS ANNEXURE-A RATINGS AND REQUIREMENTS




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SPECIFICATION NO. : E4

FOR

415V PCC, MCC, DISTRIBUTION BOARDS,

LOCAL CONTROL STATIONS & NON SEGREGATED PHASE BUSDUCT

1.00.00 INTENT OF SPECIFICATION 1.01.00 This specification is intended to cover the design, manufacture, assembly, testing

at manufacturer's works, supply & delivery, properly packed for transport F.O.R. site of 415V PCC, MCC, Distribution Boards, Local Control Stations (LCS) & Non segregated phase busduct complete with all materials and accessories for efficient and trouble-free operation.

2.00.00 SCOPE OF SUPPLY 2.01.00 The following equipment shall be furnished with all accessories.

a) 415V PCC : 2 No. (with 3 incommer & bus section for each PCC) with number of feeders as required.

b) 415V MCC : as required. c) A.C. Distribution board (ACDB) : 1 No. d) D.C. Distribution board (DCDB) : 1 No.

e) Lighting Distribution board (LDB) : 1 No. g) LCS : As required h) Non segregated Phase busduct : 6 No. 2.02.00 The base channel frame of the panels with hardware. 2.03.00 Set of accessories as detailed below :- a. Breaker lifting and handling truck : Two (2) nos. b. Breaker racking in/out handle : Two (2) nos. 2.04.00 One set of special tools & tackles.




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2.05.00 All relevant drawings, data and instruction manuals. 3.00.00 DESIGN CRITERIA 3.01.00 The PCC/MCC/DB will be used to supply power, Control and Protection for normal

and start-up operation of ACC system. 3.02.00 Duty involves direct-on-line starting of induction motors. Motor starting current varies from 6 times full load current with maximum of 3 starts per hour. 3.03.00 The panels will be located indoor, in a clean but hot, humid and tropical

atmosphere. 415 V PCC, MCC, Distribution boards shall have sectionalised bus. PCC will have three (3) incomer & 3 bus section with a concept that middle section will be common standby to both the extreme two (2) sections. Normally two (2) extreme bus section will feed load of outgoing feeders without paralleling of two (2) sources. It is envisaged that rating of each incomer will be fed from 2500kVA 6.6kV/ .433kV transformer & hence PCC shall be rated for 65kA as short circuit level. The load on two buses shall be distributed evenly in a manner to avoid total failure of all drives in a single system/area. Auto change-over and momentary paralleling facilities shall be provided in the panel having two incomer & one bus coupler breaker. MCC feeding other load than ACC fan motor will have conventional two (2) incomer & a bus coupler.

3.04.00 The panel ratings and quantities shall be decided by bidder duly substantiated with

calculation. Necessary layout with bottom cable entry concept shall be submitted along with suggested room size for locating all the above panels in single front execution. Bidders shall note that approx. 30% of the total fan motor will be VFD operated. Accordingly adjoining room shall be planed to accommodate VFD. The VFD room will be duly air conditioned.

3.05.00 For continuous operation at specified ratings, temperature rise of the various panel

components shall be limited to the permissible values stipulated in the relevant standards and/or this specification.

3.06.00 The panels and components thereof shall be capable of withstanding the

mechanical forces and thermal stresses of the short circuit current listed in the annexure without any damage or deterioration of material.




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3.07.00 The continuous current rating for incomers, bus coupler and bus bar shall be based on total continuous running load plus 25% of total connected intermediate loads like valves, dampers where ever applicable, plus 20% overall margin. 20% spare feeders and/or one for each rating and type shall be provided and considered in rating selection.

3.08.00 DCDB shall be suitable for continuous operation on 220V +10% to -15%. DCDB

will receive two(2) incoming feeder from main plant. 3.09.00 The design of Local Control Station shall be based on follows : Type-A LCS :- Local Control Station shall comprise of one start and one stop push

button and shall be provided for motors rated upto 15 kW. Type-B LCS :- Local Control Station shall comprise of one Start Push Button, one

Stop Push Button and ammeter. These LCS shall be provided for motors above 15 kW rating.

All Push Buttons shall have atleast 2 No. + 2 NC contacts. 4.00.00 SPECIFIC REQUIREMENTS 4.01.00 Construction 4.01.01 The PCC/MCC/DB shall be indoor, air insulated, metal-enclosed, floor mounting

type. The design and construction shall be such as to allow extension at either end. PCC & MCC shall be draw out type and DB shall be fixed type.

4.01.02 The Local Control Station shall be cast aluminium suitable for wall/column

mounting. 4.01.03 The PCC/MCC/DB enclosure shall conform to the degree of protection IP-52.

Minimum thickness of sheet metal used shall be 2 mm. All LCS shall have enclosure Protection IP 55.

4.01.04 The PCC/MCC/DB shall be single front comprising of a continuous line up of

single/multi-tier cubicles. The installations of circuit breakers however shall be limited to the bottom two tiers only.

4.01.05 The design shall be of fully compartmentalised execution with metal/ insulating

partitions. Working height shall be limited to 450 mm to 1800 mm from the floor level. LCS shall be mounted on structure/column at a height of 1500 mm.

4.01.06 Each Control Cubicle of PCC/MCC/DB shall be housed in a separate cubicle,

complete with an individual front access door. Each vertical section shall have a removable back cover. All doors and covers shall be gasketed.




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4.01.07 The PCC/MCC cubicle shall be so sized as to permit closing of the front access

door when the breaker is pulled out to ISOLATED position. 4.01.08 All switches, lamps and indicating instruments shall be flush mounted on the respective cubicle door whereas relays and other auxiliary devices may be mounted on a separate cubicle. 4.01.09 Compartment to compartment metal partition shall be provided to prevent fire/fire

product spreading from compartment to compartment. 4.01.10 A full height vertical cable chamber with cable supports shall be provided in each

section to facilitate unit wiring. The chamber shall be liberally sized to accommodate all cables and shall have removable cover at the front for access.

All the outgoing feeders shall be segregated individually and covered for safe

working on individual feeder terminations. Also all the feeder terminations shall be shrouded.

4.01.11 A horizontal wire way, extending the entire length, shall be provided at the top of

each PCC/MCC/DB for inter panel wiring. 4.02.00 Bus and Bus Taps 4.02.01 The main buses and connections shall be of high conductivity aluminium/

aluminium alloy, sized for specified current ratings with maximum temperature limited to 85oC (i.e., 35oC rise over 50oC ambient). All phase bus bars shall be of Uniform cross section through out the switchboard.

4.02.02 All bus connections shall be silver plated. Adequate contact pressure shall be

ensured by means of two bolt connection with plain & spring washers and locknuts.

Bimetallic connectors shall be furnished for connections between dissimilar metals.

4.02.03 Bus bars and connections shall be fully insulated for working voltage. Insulating

sleeves for bus bars and shrouds for joints shall be provided. No reduction in phase-to-phase or ground clearance will be allowed due to sleeving.

Bus insulators shall be flame-retardant, track resistant type with high creepage surface. 4.02.04 All buses and connections shall be supported and braced to withstand the stresses

due to maximum short-circuit current and also to take care of any thermal expansion.




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4.02.05 Bus bars shall be colour coded for easy identification and so located that the sequence R-Y-B shall be from left to right, top to bottom or front to rear, when viewed from the front of panel assembly.

4.02.06 Various module/compartment sizes shall be multiple of one basic unit to facilitate

modifications at site. Suitable provision for this purpose should also be incorporated in the vertical bus bars.

4.02.07 Draw out type Control modules of same size & type shall be electrically and

physically interchangeable. 4.02.08 Heat shrinkable PVC sleeves having flame retardant property shall be provided on

each busbar. 4.02.09 Vertical neutral busbar shall be brought for each panel. 4.03.00 Circuit Breaker 4.03.01 Circuit Breaker shall be triple pole except for incomers & bus couplers, single

throw, air break type with stored energy, trip free mechanism and shunt trip. 4.03.02 Circuit breakers shall be drawout type, having SERVICE, TEST & ISOLATED

positions with positive indication for each position. 4.03.03 Circuit breakers of identical rating shall be physically and electrically

interchangeable. 4.03.04 Circuit breaker shall have motor wound spring charged trip free mechanism with

anti-pumping feature and shunt trip. In addition, facility for manual charging of spring shall be provided.

4.03.05 For motor wound mechanism, spring charging shall take place automatically after

each breaker closing operation. One open- close-open operation of the circuit breaker shall be possible after failure of power supply to the motor.

4.03.06 Mechanical safety interlock shall be provided to prevent the circuit breaker from

being racked in or out of the service position when the breaker is closed and to prevent racking in the circuit breaker unless the control plug is fully engaged.

4.03.07 Safety interlock shall be provided for the followings :-

a. Operation of CB shall not be possible unless it is fully in service position, fully withdrawn to test position or fully drawn out.

b. Compartment door of the breaker shall not open unless the associated

breaker is in open position.




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c. The breaker of specific breaker rating shall be prevented from

engaging into the stationary portion of other higher rating.

d. The breaker carriage shall be earthed before main circuit breaker contacts are plugged in. The earthing shall be maintained in service position.

4.03.08 Automatic safety shutters shall be provided to fully cover the female primary

disconnects when the breaker is withdrawn. 4.03.09 Each breaker shall be provided with an emergency manual trip, mechanical ON-OFF indicator, an operation counter and mechanism charge/discharge indicator. 4.03.10 Each breaker shall be provided with followings :- a. Auxiliary switch, with 6NO+6NC contacts, mounted on the drawout portion. b. Position/cell switch with 3NO + 1NC contacts, one each for TEST and

SERVICE position.

c. Auxiliary switch, with 6NO + 6NC contacts, mounted on the stationary portion and operated mechanically by a sliding lever from the breaker in SERVICE position. Alternatively electrically latching relay may be used for the purpose.

4.03.11 Limit/auxiliary switches shall be convertible type, that is, suitable for changing NO.

contact to N.C. and vice-versa. Switch contact rated for 10A A.C. and 2A D.C. at operating voltage.

4.04.00 Control Modules 4.04.01 Draw out type control module shall have self-aligning power/control disconnects.

All disconnects shall be silver-plated to ensure good contacts. 4.04.02 The design shall be such as to permit easy withdrawal/reinsertion of the unit with

guide rails to ensure correct alignment. 4.04.03 Control Module shall house the control components for a circuit such as switch,

fuse, contactors, relays, push buttons, lamps etc. as detailed in the bill of materials.

4.04.04 Control supply for motor starters shall be taken from common 415/240 V control

transformer mounted within the panel. Separate control transformer shall be provided in each bus section of the panel.




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4.04.05 The equipment layout shall provide sufficient working space in between the

components and subject to Owner's approval. 4.04.06 Various module/compartment sizes shall be multiple of one basic unit to facilitate

modifications at site. Suitable provision for this purpose should also be incorporated in the vertical bus bars.

4.04.07 Draw out type control modules of same size and type shall be electrically and

physically interchangeable. 4.05.00 Push Button 4.05.01 Push button for start and stop operation shall be green and red colour

respectively. 4.05.02 Each push button shall have at least 2 NO + 2 NC contacts. All the push button

shall be identical and interchangeable. Stop push button shall be stay-put and mushroom type.

4.06.00 Switches 4.06.01 Switches shall be triple pole except for incomers & bus couplers, air break, AC23

motor duty for motor feeders and AC22 heavy duty for other feeders. Motor duty switches shall be capable of safety making and breaking the locked

rotor current of the associated motor circuit. 4.06.02 The switch shall have a quick-make, quick-break mechanism operated by a

suitable external handle, complete with position indicator. This handle shall have provision for padlocking in 'ON' and ‘OFF’ position.

4.06.03 The compartment door shall be interlocked mechanically with the switch such

that the door cannot be opened unless the switch is in 'OFF' position. Means shall be provided for releasing this inter-lock at any time.

4.06.04 Switches shall be capable of withstanding the let-through fault current of back-up

fuses or circuit breakers. 4.06.05 If two incoming switches are specified for any panel, these switches shall be

mechanically/key interlocked so as to ensure that only one switch can be closed at a time.




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4.06.06 All incoming and outgoing feeders shall be provided with bolted disconnect link for isolation of neutral if necessary.

4.06.07 All the selector switch shall have two position for location selection. The

Local/Remote selector switch shall have at least two contacts. It shall be lockable type in 'Local' or ‘Remote’ position.

4.07.00 Fuses 4.07.01 Fuses shall be HRC, preferably link type, with a minimum interrupting capacity

equal to the listed Short Circuit Current. 4.07.02 Fuses shall be furnished complete with fuse bases and fittings of such design as

to permit easy and safe replacement of fuse element. Visible indication shall be provided on blowing of the fuse.

4.07.03 Motor fuse characteristics and ratings shall be chosen to ride over starting period

without blowing. The fuse on incoming feeder, if specified, shall be chosen to provide discrimination with motor/feeder fuses.

4.08.00 A.C. Starter 4.08.01 Contactors

a. The contactors shall be three pole, air break type designed for duty class III - Category AC2 with non-bouncing silver/ silver alloy contacts.

b. Each contactor shall be provided with two (2) normally open and two (2) normally

closed auxiliary contacts rated 10 A at 240V A.C.

c. Reversing contacts shall be electrically and mechanically interlocked.

d. Contactors with delayed dropout feature shall be provided for some essential auxiliaries if so detailed in the annexures. These contactors shall not dropout on power failure if the voltage is restored within 3 seconds.

4.08.02 Thermal Overload

a. Thermal overload relays shall be three element, positive acting, ambient temperature compensated with adjustable settings.

b. Single phase preventor relay shall be provided, preferably as an inbuilt feature of

thermal overload.




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c. Relays shall be manual reset type with one changeover contact. Resetting of

relays shall be possible with compartment door closed.

d. Relays may be direct acting or C.T. operated, depending on current rating. C.T.s shall be included in the scope of supply.

4.09.00 Control & Indication The circuit breaker shall be wired up for local & remote operation. Each breaker

cubicle shall be equipped with following :- 4.09.01 One (1) ‘TRIP-NEUTRAL-CLOSE’ breaker control switch spring return to neutral

type pistol grip handle. 4.09.02 One (1) LOCAL REMOTE selector switch stay put type with pistol grip handle and

key interlock for all non-motor feeders. 4.09.03 One (1) 'TEST-NORMAL-TRIAL' selector switch stay put type with pistol grip

handle and key interlock only for motor feeders. 4.09.04 Seven (7) indicating lamps on front of compartment :- GREEN Breaker open & Spring charged RED Breaker closed AMBER Breaker tripped RED Trip circuit unhealthy Breaker in TEST WHITE Position Breaker in SERVICE WHITE Position Lockout Circuit RED unhealthy 4.09.05 Lamps shall be LED type with minimum ten (10) no. of LEDS in a lamp. Lamp and lens shall be replaceable from the front. 4.10.00 Current Transformer




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4.10.01 Current Transformers shall be cast-resin type. All secondary connections shall be brought out to terminal blocks where wye or delta connection will be made. 4.10.02 Accuracy class of the current transformers shall be :- move slightly. a. Class PS for differential b. Class 5P20 for other relaying. c. Class 1.0, ISF < 5 for metering. 4.11.00 Voltage Transformer 4.11.01 Voltage transformers shall be cast-resin, drawout type and shall have an accuracy

class of 1.0. Voltage transformer mounted on breaker carriage is not acceptable. 4.11.02 High voltage windings of voltage transformer shall be protected by current limiting

fuses. The voltage transformer and fuses shall be completely disconnected and visibly grounded in fully drawout position.

4.11.03 Low voltage fuses, sized to prevent overload, shall be installed in all ungrounded

secondary leads. Fuses shall be suitably located to permit easy replacement while the panel is energised.

4.12.00 Relays 4.12.01 Relays shall be of microprocessor based numerical (digital) type. Small auxiliary

relays may be static type and mounted with in the cubicle. 4.12.02 Relays shall be rated for operation on 1A secondary current and 110V secondary

voltage; number and rating of relay contacts shall suit the job requirements. 4.12.03 The Contractor shall furnish, install & co-ordinate all relays to suit the requirements

of protection, interlock and bus transfer scheme as broadly indicated in the annexures and drawings.

4.13.00 Meters 4.13.01 Metering shall be of 96x96 mm size, switchboard type flush mounted with 2400

scale and +2% accuracy class. Each meter shall have zero adjuster on the front. 4.13.02 Ammeter used for motor feeders shall have an extended suppressed end scale

range to indicate starting current. 4.13.03 Separate test terminal block (TTB) shall be provided for energy meter.




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4.14.00 Secondary Wiring 4.14.01 The panels shall be fully wired at the factory to ensure proper functioning of

control, protection, transfer and interlocking schemes. 4.14.02 Fuse and links shall be provided to permit individual circuit isolation from bus wires

without disturbing other circuits. All spare contacts of relays, switches and other devices shall be wired upto terminal blocks.

4.14.03 Wiring shall be done with flexible, 650V grade, PVC insulated switchboard wires

with stranded copper conductors of 2.5 mm2 for control & current circuits and 1.5 mm2 for voltage circuits.

4.14.04 Each wire shall be identified, at both ends, with permanent markers bearing wire

numbers as per Contractor's wiring diagrams. 4.14.05 Wire terminations shall be made with crimping type connectors with insulating sleeves. Wire shall not be spliced between terminals. 4.15.00 Terminal Blocks 4.15.01 Terminal blocks shall be 660V grade box-clamp type with marking strips, similar

to ELMEX 10 mm2 or equal. Terminals for C.T. secondary leads shall have provision for shorting.

4.15.02 Not more than two wires shall be connected to any terminal. Spare terminals

equal in number to 20% active terminals shall be furnished. 4.15.03 Terminal blocks shall be located to allow easy access. Wiring shall be so arranged

that individual wires of an external cable can be connected to consecutive terminals.

4.16.00 Cable & Bus duct Termination 4.16.01 PCC/MCC/DB shall be designed for cable entry from the bottom. Sufficient space

shall be provided for ease of termination and connection. For PCC, bus duct shall be terminated from top.

4.16.02 Cables shall be XLPE insulated, armoured, PVC overall sheathed with 2.5 mm2 stranded copper conductor for controls and stranded aluminium conductor for power circuits as detailed in annexures and drawings. 4.16.03 All provisions and accessories shall be furnished for termination and connection of

cables, including removable gland plates, cable supports, crimp type tinned copper lugs, brass compression glands with tapered washer (Power cables only) and terminal blocks.




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4.16.04 Gland plates shall be minimum 3 mm thick. The gland plate and supporting arrangement for 1/C power cables shall be such as to minimise flow of eddy current.

4.17.00 Ground Bus 4.17.01 A ground bus, rated to carry maximum fault current, shall extend full length of the

panel. 4.17.02 The ground bus shall be provided with two-bolt drilling with G.I. bolts and nuts at

each end to receive 50 x 6 mm G.I. flat. 4.17.03 Each stationary unit shall be connected directly to the ground bus for effective

grounding. 4.17.04 C.T. & V.T. secondary neutrals shall be earthed through removable links so that earth of one circuit may be removed without disturbing others. 4.18.00 Nameplates 4.18.01 Nameplates of approved design shall be furnished at each cubicle and at each instrument & device mounted on or inside the cubicle. 4.18.02 The material shall be lamicoid or approved equal, 3 mm thick with white letter on black background. 4.18.03 The name plate shall be held self-tapping screws. Name plate size shall be minimum 20 x 75 mm for instrument/devices & 40 x 150 mm for panels. 4.18.04 Caution notice on suitable metal plate shall be affixed at the back of each vertical panel. 4.19.00 Space Heaters and Plug Sockets 4.19.01 Each vertical section shall be provided with thermostat controlled space heater and 5A, 3 pin plug socket. 4.19.02 In addition, motor feeder cubicle shall be wired-up for feeding the motor space heater through suitably rated breaker auxiliary NC contact and/or contactor. 4.19.03 Cubicle heater, Motor heater, Plug-socket circuit shall have individual switch fuse units. 4.20.00 A.C./D.C. Power Supply 4.20.01 The following power supplies will be made available to PCC & MCC :




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D.C. supply : Double feeder, 220 V. 4.20.02 Isolating switch fuse units shall be provided at each PCC & MCC for the incoming

DC supplies, 2- pole, double throw. 4.20.03 Bus-wires of adequate capacity shall be provided to distribute the incoming supplies to different cubicles. Isolating switch-fuse units shall be provided at each cubicle for A.C./D.C. supplies. 4.20.04 A.C. load shall be so distributed as to present a balance loading on three-phase

supply system. 4.21.00 Tropical Protection 4.21.01 All equipment, accessories and wiring shall have fungus protection, involving special treatment of insulation and metal against fungus, insects & corrosion. 4.21.02 Screens of corrosion resistant material shall be furnished on all ventilating louvers to prevent the entrance of insects. 4.22.00 Painting 4.22.01 All surfaces shall be sand blasted, pickled and grounded as required to produce a smooth, clean surface free of scale, grease & rust. 4.22.02 After cleaning, the surfaces shall be given a phosphate coating followed by 2 coats of high quality primer and stoved after each coat. 4.22.03 The panels shall be finished with two coats of Siemens grey (RAL 7032) of epoxy

based paint. 4.22.04 Sufficient quantity of touch-up paint shall be furnished for application at site. 4.23.00 Accessories 4.23.01 The following accessories shall be furnished along with the panel : a. Breaker lifting and handling truck. b. Breaker racking in/out handle (if required). 5.00.00 DESIGN CRITERIA FOR NON PHASE SEGREGATED PHASE BUSDUCT 5.01.00 The 415V non-segregated phase bus duct will serve as interconnection between

the 415V Indoor Switchgear and Indoor transformer terminals. It is also used for trunking connection between two separate switchgear panels, wherever applicable.




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5.02.00 The 415V non-segregated phase bus duct shall be installed indoor unless

otherwise specifically indicated, in a hot, humid and tropical atmosphere. 5.03.00 The portion of bus duct at the transformer end will be subjected to vibration

normally prevalent for this type of installation in a power generating station/industrial plants. Suitable means shall be provided to isolate the transformer vibration from rest of the bus structure/ bus duct.

5.04.00 For continuous operation at specified ratings, temperature rise of the busduct

and auxiliary equipment shall be limited to the site permissible values indicated in the annexure of this specification

5.05.00 Bus duct shall be capable of withstanding the mechanical forces and thermal

stresses of the short-circuit currents listed in the annexure without any damage or deterioration of material.

5.06.00 The Busduct and supporting structures shall be designed & constructed so as to

withstand without damage the horizontal/ vertical ground accelerations due to earthquake.

5.07.00 The bus ducts shall be self cooled and shall not be equipped with blower or any

other type of forced ventilation. 6.00.00 SPECIFIC REQUIREMENTS 6.01.00 General 6.01.01 The 415V bus duct shall be non-segregated phase enclosure, natural air cooled

type. 6.01.02 All parts and accessories shall have appropriate match mark and part numbers

for easy identification and installation at site. 6.02.00 Enclosures 6.02.01 Phases shall be enclosed in a weather-proof, dust-tight enclosure without

any barrier between phases. It shall preferably rectangular in shape adequately rigid with stiffeners as required complying to enclosure protection specified in the datasheet.

The enclosure shall be made of sheet steel for rated continuous current upto and including 2000A at site condition. Above 2000A, busduct enclosure shall be made of aluminum alloy. The enclosure thickness shall not be less than 3mm




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6.02.02 Circumferential neoprene rubber gaskets (joint less type) shall be provided for dust tight joints with adjacent enclosure section.

6.02.03 The bus enclosure shall have extended bellows or equivalent means to allow for

temperature changes and vibrations. Flexible joints shall be provided in enclosures at all points where the bus duct terminates at equipment to withstand vibration, expansion/contraction and at suitable intervals in any straight run of the bus duct where expansion and contraction would otherwise result in stresses in the supporting structures.

6.02.04 All outdoor bus-enclosures shall be supplied with slopped roof to prevent ingress

of rain water. Similarly all gasketted-flanged joints shall be suitably protected against direct splashing of rainwater in case of outdoor runs.

6.02.05 Suitable inspection openings shall be provided for access to support insulators,

bus joints, transformer terminals, switch gear terminals etc. All inspection openings shall have reliable sealing arrangement with neoprene gaskets.

6.02.06 Filtered drains for drainage of condensate shall be provided at the lowest points

and at such locations where accumulation of condensate can be expected. 6.02.07 Shipping length of the bus duct shall be not more than three (3) meters in length. 6.03.00 Bus Conductor 6.03.01 The bus conductor shall be of high conductivity electrolytic grade copper or

aluminum alloy as indicated in the annexure, supported on fine glazed porcelain/ cast resin insulators fixed to enclosure.

6.03.02 The bus conductor shall be designed for bolted connections throughout the run. 6.03.03 Flexible connections shall be provided between bus sections to allow for

expansion and contraction of the conductor. Flexible connection shall also be provided at all equipment terminations.

6.03.04 All contact surfaces shall be silver plated to ensure an efficient and trouble-free

connection. All connection hardware shall be non- magnetic and shall have high corrosion resistance.

6.03.05 Bus bars shall be color coded at regular intervals for easy identification.

Markings on the bar shall be Red for R-phase, Yellow for Y-phase and Blu for B-phase.

6.03.06 All bolted joints shall be provided with high grade stainless steel nuts bolts , plain

and belle-ville washers.




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6.04.00 Insulators 6.04.01 Bus support insulators shall be bus post type, interchangeable, high creep, high

strength, flame retardant , non hygroscopic, wet processed, fine glazed porcelain. Alternatively good quality cast resin insulators may be offered.

6.04.02 Insulator shall be mounted in such a way so as to permit easy removal or

replacement without disassembly of the bus. The insulator mounting plate shall be designed for cantilever loading to withstand the short circuit. Support span shall be taken into consideration.

6.04.03 The conductor shall be fastened on the insulator through fixed and slip joints so

as to allow conductor expansion or contraction without straining the insulator. 6.05.00 Connections & Terminations 6.05.01 All matching flanges, seal-off bushings, gaskets, fittings, hardware and supports

required for termination of the bus duct at the switchgears, transformers and other equipment shall be furnished.

6.05.02 In this connection the contractor is required to co-ordinate through the Engineer

with the suppliers of the 415V Switchgears, transformers with regard to connection details, mechanical and thermal stresses.

6.05.03 Flexible connections both for conductor and enclosure shall be furnished : a. At all equipment termination to provide for misalignment upto 25 mm. (1")

in all directions. b. Between bus duct supported from building steel to prevent transmission

of vibration. 6.05.04 The equipment terminal connections shall be readily accessible and shall provide

sufficient air gap for safe isolation of equipment during testing. 6.05.05 If the material of bus conductor and that of the equipment terminal connectors

are different then suitable bi-metallic connectors shall be furnished. 7.00.00 TESTS 7.01.00 The panels shall be completely assembled, wired, adjusted and tested at the factory as per the relevant standards.




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7.02.00 Routine Test The tests shall include but not necessarily limited to the following :

a. Operation under simulated service condition to ensure accuracy of wiring, correctness of control scheme & proper functioning of the equipment.

b. All wiring and current carrying part shall be given appropriate High Voltage Test. c. Primary current & voltage shall be applied to all instrument transformers. d. Routine test shall be carried out on all equipment such as circuit breakers, instrument transformers, relays, meters etc. 7.03.00 Type Test The following test shall be performed on a typical section of the bus assembly with

the breaker in cubicle. a. Temperature rise Test b. Short circuit Test The cost of such tests, if any, shall be quoted separately. 8.00.00 DRAWINGS, DATA & MANUALS 8.01.00 To be submitted with the Bid a. General arrangement drawing showing constructional features, space required in front for withdrawals, power & control cable entry points etc. b. Bill of Materials c. Typical foundation plan d. Typical breaker control schematic e. Matching flange & terminals for bus termination. f. Type test reports on circuit breaker g. Technical leaflets on i) Circuit breaker




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ii) Instrument transformers iii) Relays, meters, switches etc. h) The calculation for selection of bus bar ,sizing details like normal/S.C

current, mechanical strength of bus bar support & temperature rise. 8.02.00 To be submitted for Approval & Distribution a. Outline dimensional drawing of the panel showing general arrangement, space requirements and bus duct/cable entry points. b. Cross-section with parts list. c. Foundation plan & loading. d. Single line diagrams e. Control schematics. f. Wiring diagrams. g. Bill of material. 8.03.00 Instruction manuals of PCC & individual equipment. The manual shall clearly indicate the installation method, check- up and tests to be

carried out before commissioning of the equipment. ANNEXURE-A

RATINGS & REQUIREMENTS 1.0 PCC/MCC/DB 1.1 General AC Type : DB- fixed PCC/MCC - Drawout Service : Indoor Enclosure : IP-52 1.2 System




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Voltage : 415 Volt + 10% DC-220V (85% - 110%) Phase : 3 Frequency : 50 Hz + 5% Combined : 10% (Absolute) variation System : Solidly grounded. 1.3. Rated Current at 50oC Bus bar : As required, to be finalised by bidder. Circuit breaker : As required, to be finalised by bidder. 1.4 Short Circuit Rating Interrupting : 65/50 kA (as applicable based on calculation) Short Time for 1 : 65/ 50 kA for AC panel & 25 kA for DC panel Second 1.5 Insulation Level : 2.5 kV for 1 min. 1.6 A.C./D.C. Power Supply Control Voltage : 220V DC. (85% - 110%) Service Voltage : 240V + 10%, 1Ph, 50 Hz + 5% 2.0 CIRCUIT BREAKER 2.1 Duty Cycle : 0-3'-CO-3'-CO 2.2 Breaking Current A.C. Symmetrical : 65/50 kA A.C. Asymmetrical : As per IEC 2.3 Making Current : Based on breaking capacity (kA Peak) 2.4 Auxiliary Voltage




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Closing : 220V D.C. (85 - 110%) Tripping : 220V D.C. (70 - 110%) Spring Charging : 240V AC (+ 10%)




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VOLUME – II

PART - B

SPECIFICATION: E5

ERECTION OF ELECTRICAL EQUIPMENTS




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SPECIFICATION NO. E5 ERECTION OF ELECTRICAL EQUIPMENTS

C O N T E N T S CLAUSE NO. DESCRIPTION 1.0 SCOPE 2.0 SWITCH GEARS 3.0 BUSDUCT 4.0 TRANSFORMERS 5.0 H.T. AND L.T. MOTORS 6.0 BATTERY, BATTERY CHARGERS AND

D.C. BOARDS 7.0 UPS SYSTEM 8.0 CONTROL & RELAY PANELS 9.0 NEUTRAL GROUNDING RESISTOR 10.0 WELDING RECEPTACLES 11.0 PUSH BUTTON.CONTROL STATIONS 12.0 240/24 V TRANSFORMERS AND

FLAME PROOF - SOCKETS (24V) 13.0 MISCELLANEOUS SURFACE MOUNTED

CONTROL GEAR 14.0 EXHAUST FANS 15.0 EQUIPMENT COMMISSIONING 16.0 LIST OF CONSTRUCTION EQUIPMENT




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ERECTION OF ELECTRICAL EQUIPMENTS 1.0 SCOPE This standard specification defines the requirements of installation, testing,

commissioning and supply (wherever applicable) of electrical equipments. 2.0 SWITCHGEARS 2.1 This shall be applicable to MV/LV switchgear panels, motor control centres and

other power and lighting distribution boards, instrument distribution boards, DCDB, etc. Manufacturer’s instructions, drawings and instructions of the Engineer-in-Charge shall be studied and strictly followed during handling, erection, testing and commissioning of the switchgear. The switchgear shall be handled with care, avoiding impact to the equipment by the experienced riggers under the guidance of a competent supervisor. Dragging of the panels shall be avoided and use of a crane and trailer shall be made for the handling purposes while transporting to various sites. The switchboard shall be properly supported on the truck or trailer by means of ropes to avoid any chances of damage or tilting due to heavy vibration. The switchboards should be lifted by making use of lifting eyebolts only, fully tightened after ensuring that panel supports, nuts and bolts are all intact and tightened. When panels are to be lifted in packed conditions, utmost care shall be taken to avoid any damage to insulators, bushings, metering and protective equipment. The panels shall preferably be kept inside the packing cases till foundations are ready.

2.2 Base channels shall be grouted, leveled, in cement concrete pad for H.T. and

415 V switchgear panels and other cubicle panels. A level benchmark shall be given by the owner as reference level, and further all levels shall be checked and kept with theodolite by the Contractor. Pedestal type panels and MCCs shall be erected by grouting base channels by bolts. A proper bonding surface should be made by chipping the floor while making cement concreting. All foundations, grouted bolts shall be cured for a minimum period of 48 hours.

2.3 The switchboard panels should be taken out from the packed cases and moved

one by one to the proper place. All the panels should be assembled aligned leveled and it should be ensured that panel to panel coupling bolts, busbars links fit properly without any strain on any part. It should also be checked up that lowering, lifting, racking in and out operation of the breaker and all other motions are free from any obstruction. The fixing bolts should be grouted only after satisfying all these requirements.

The panels shall be checked for correct vertical position using pendulum weight

and spirit levels. H.T. & L.T. switchgear panels can be tack welded at suitable intervals for each shipping section.




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2.4 After completion of the panel erection, all the cubicles switches, starters, C.T. and P.T. chambers, busbars chamber should be cleaned and checked for tightness of all the components. All loosely supplied items shall be fitted up. All the wiring connections should also be checked with drawings and tightened. Metering and protective C.Ts., alarm, indications and protective relays should be fitted up. Phase sequence & polarity of PTs and CTs should be checked. Contact resistance of all busbar joints and contactors should be checked up. Every part or insulator should be checked for any possible damage. All the starters, switches, contacts should be cleaned with C.T.C. Silver tipped contacts should be checked for easy and free movement. Hinges of panel doors should be lightly lubricated to give free and noiseless movement. All openings shall be kept completely closed to avoid ingress of any foreign particles inside the panel.

Individual feeder functional scheme verification should be carried out and minor

wiring modifications in the panel wirings, as per requirement at site, should be done as per the directions of Engineer-in-Charge. Special attention is to be paid to CT circuits polarity, wiring continuity and correctness in the protection as well as measurement circuits. Auto transfer scheme should be simulated and verified. During the course of scheme verification tests, any defective part as well functionally improper components shall be taken out, after bringing to the notice of Engineer-in-Charge, and be replaced by components supplied by owner.

2.5 Should the switchgear be wet or having a low IR value due to bad wiring,

insulators, bushings or any other insulated parts, the entire switchgear should be dried-up according to the instructions of the Engineer-in-Charge and the IR value should improve to a safe level for commissioning the same. Care should be taken to protect the surrounding insulation from direct local heating during the drying up process.

2.6 All the metering instruments, protective relays and other relays and contactors

should be tested and cleaned as per manufacturer’s recommendations or according to the instructions of the Engineer-in-Charge.

2.7 All the control wiring, PTs, bushings, busbars, other live parts of switchgear, and

incoming and outgoing cables should be meggered with 500/1000V megger. 2.8 Electrical simulation tests should be carried out for all the protective, alarm and

annunciation relays along with the manual operation of the circuit breaker. 2.9 Panels must be cleaned with vacuum cleaner. 2.10 Pre-commissioning Check List :




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Before commissioning any switchgear panel, circuit breaker, motor starters, etc., the following points must be checked and ensured for safe energising of the switchboard :

i) Check that the erection of equipment to be commissioned is

complete in all respect with its auxiliaries and all other mountings including earthing. Openings in floor within and outside panels have been sealed off. All cover and door gaskets are intact to make enclosure vermin proof. Check also the wiring of the switchgear panel as per approved final vendor drawing.

ii) Check that all the metering instruments have been checked and calibrated. Indicating lamps are healthy and are in position. All power and control fuses are of proper rating and show continuity.

iii) Panel is supplied from correct level of voltage source. iv) Check termination of power cable and its size and type.

v) Check if unusual stress coming on cable glands and terminations due to improper bending and support of cable at the SWGR/MCC entry.

vi) Check continuity of power cables. vii) Check all mechanical operations - like racking in/out of breaker, drawing

in/out of MCC modules, operation of all position indicating limit switches for breakers, manual spring charging of breaker, mechanical on/off of breaker, spring charging limit switch, etc.

viii) Check all safety interlocks. ix) Check lubrication of operating/moving parts of breakers/MCC modules. x) Check scrapping earth connection for breaker. xi) Check spring charging by motor and spring charging time. xii) Check that the polarity test and ratio test of all the P.Ts and C.Ts is over

and phase sequence test of C.Ts conforms to the correct vector group connections. Wiring continuity and correctness are ensured in the protection and measurement circuits. Polarity of D.C. battery supply for all the circuits is correct.

Also check that the high voltage test of circuit breaker, bus bars and

outgoing and incoming cables have been conducted and results are satisfactory.




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xiii) Check that all the protective relays including thermal overload relays have

been tested for secondary injection tests and operation of all the current and voltage operated relays has been tested. (Primary injection tests are to be carried out for differential protection, Restricted Earth fault protection, etc., at full/reduced current to ensure total wiring correctness.). Simulation tests to check all protection, alarm and annunciation systems are functioning as per required settings. Check that all protections of breakers & MCC (of each module) are as per approved final vendor drawing. Check all interlocks.

xiv) Check that I.R. values have been recorded for bus bars, circuit breaker,

incoming and outgoing cables, control wiring and potential transformers. Joint resistance of bus bars have been recorded and found to be satisfactory. High voltage test of all circuit breakers, busbars and cables have been conducted and certificates approved by site incharge. All the surroundings and panels have been cleaned and temporary earth leads have been removed.

xv) Check all covers closed properly before energising the panels. xvi) Check control supply voltage is proper. xvii) Check space heater operation. xviii) Check for chattering of any relay or contactor. xix) Check antipumping feature of breaker. xx) Check operation of mechanical counter of the breaker if provided.

xxi) Check for proper operation of ventilation equipment in SWGR/MCC room to remove heat generated.

3.0 BUS DUCT The bus duct will be supplied in parts and all the parts shall be assembled and

the bus bar connections shall be made at site. The insulator in bus ducts shall be inspected for any possible damage during transit and the defective ones will be replaced. The insulators shall be cleaned with carbon tetrachloride. Contact surface of bus bars, bus-bar bolts and nuts shall be thoroughly cleaned with petrol and wiped. Petroleum jelly shall then be applied and bolted connection made. The bus duct enclosure shall be checked for earth continuity and then earthed at two places. The bus duct shall be duly supported between switchgear and transformer. The opening in the wall where the bus duct enters the switchgear room shall be completely sealed to avoid rainwater entry. Expansion




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joints, flexible connections etc. supplied by the manufacturer of the bus duct shall be properly connected. The bus duct leveling shall be checked with spirit level and pendulum weight.

4.0 TRANSFORMERS 4.1 Handling When lifting a transformer by the lifting lugs or shackles provided for the

purpose, simultaneous use should be made of all such lugs and shackles in order to avoid any unbalance while lifting. The lifting chain should never interfere, with any part of the transformer. Before lifting complete transformer, it should be ensured that all cover bolts are tightened fully. In case where it is necessary to use jacks for lifting, protections provided for the purpose of jacking should be used. Jacks should never be used under valve or cooling tubes. It may be necessary under certain circumstances to place jacks under stiffening curbs on the tank base. For transporting transformers from stores to site, the transformers shall be loaded on a suitable capacity truck or trailer. The transformers shall be properly supported by steel ropes and stoppers on the trailer to avoid tilting of the transformers in transit due to jerks and vibrations. At no instance a transformer shall be kept on bare ground. Where it is not possible to unload the transformer directly on a foundation, these shall be unloaded on a properly built wooden sleeper platform. A transformer shall never be left without putting stoppers to the wheels.

4.2 Transformers are liable to get damaged during transit and therefore they

should be examined, for any sign of damage in transit, particular attention being paid to the following,

i) Tank sides or cooling tubes dented. ii) Protruding tubes damaged. iii) Oil sight glass broken. iv) Bolts loosened due to vibration in transit. v) Bushing cracked or broken. vi) Oil leakage particularly along welds. 4.3 Except large power transformers, all the lighting and small distribution

transformers shall be placed on the prepared concrete bed. But all the high rating transformers shall be placed after grouting channels or rails, over concrete foundations. The transformers shall be leveled, aligned and checked for free movement on the rails. Stoppers shall be clamped to the transformers




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immediately to prevent any movement. All the accessories where supplied loose, like radiators, cooling fans, valves, conservator tanks, explosion-vent pipe, bushings and other devices should be cleaned tested before fixing on the transformer. All the connections for C.T.s, bushings and other wiring shall be checked for tightness and correctness before replacing the lid or tightening all the bolts.

4.4 Topping transformer with oil: Before topping up with oil, transformers should be fitted with all accessories such

as valves, gauges, thermometer and made oil tight. Oil samples should be taken from each drum and tested for determination of dielectric strength. Any sign of leakage of the barrel of it having been opened should be recorded and reported. It is necessary to filter the oil before the transformers are filled. It should be ensured in oil filling operation that no air packets are left in the tank and that no dust or moisture enters the oil. All air vents should be opened. Oil should be filled through a streamline oil filter using metal house. To prevent aeration of the oil, the transformers tank should be filled through the bottom drain valve. In a transformer with conservator tank, the rate of oil flow should be reduced when the level is almost upto the bottom of the main cover to prevent internal pressure from rupturing the pressure relief pipe diaphragm. Sufficient time should be allowed for the oil to permeate the transformers and also the locked-up air bubbles to escape. Any air accumulation in the Buchholz relay should be released.

4.5 Oil i) Samples of oil from the transformer should be taken from the bottoms of

the tank. ii) Testing of Oil For dielectric test, the oil should be tested as described in IS: 335-1972

& also IS: 6792-1972. This oil should also be tested for acidity in accordance with the methods described under Appendix `D' of IS: 1866.

4.6 Drying out of the transformer if required, shall be carried out and recorded in

accordance with IS: 1886 and any of the approved methods may be used as found suitable by the Engineer-in-Charge.

Normally streamline filters will be used for drying-up. Drying curve I.R. vs. time

of both windings shall be furnished. Precautions when drying :




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i) Only spirit type thermometers are to be used for temperature measurement. Mercury thermometers shall not be used anywhere except in the pockets provided for this purpose.

ii) The maximum sustained temperature to which transformer oil should be subject is 80oC.

iii) In no case should the transformer be left unattended during any part of the dry-out period. The transformer should be carefully watched throughout the drying out process and all observations shall be carefully recorded.

iv) Drying out shall be continued so that the insulation resistance as described in the standard code of practice is attained and the value remains constant for more than 12 hours. However, a minimum number of cycles shall be done for each transformer as found necessary by the Engineer-in-charge. Generally a megger reading of 2 megaohms/KV at 60oC temp. with 5KV megger shall be a rough indication for stopping the dehydration. Dielectric strength of the oil should be 45 KV for 1 minute.

4.7 The following work on transformers if required, shall be performed by the

contractor. 4.7.1 Before finally putting the transformer to commissioning, if required, it may be

desired to run it for a few hours on short-circuit, applying a low voltage approximately equal to the impedance voltage, of the transformer for releasing air bubbles. During this process, regular readings of the insulation resistance of the winding to earth and winding to winding and temperature against time should be recorded. The above operation may be required to be performed if found necessary by the Engineer-in-Charge. Otherwise a vacuum pressure, upto 635 mm of Hg shall be applied depending upon manufacturer’s recommendation for the purpose.

4.7.2 Testing of radiator tubes for any leakage and rectifying these by welding/brazing. 4.8 Pre-commissioning Check List: Before commissioning any transformer the following points must be checked and

ensured for safe energisation of the transformer : i) Check that all the accessories have been fixed properly. The transformer

dehydration is over and results are satisfactory and approved by the Engineer-in-Charge. In case transformers are idle for more than one month after dehydration, transformer oil has been given atleast two circulations. Check the dielectric strength of oil for top/bottom of tank,




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radiator & diverter switch. Check the requirement of rain protection or any other protection for outdoor area.

ii) Check grounding of main tank, marshalling box, tap changer gear,

cooling pump/cooling fan motor (as applicable). Check earth bus inside the bus duct & grounding of the bus duct enclosure. Check system grounding on the H.V. & L.V. side.

iii) Check that the oil level, in the transformer conservator tank and all the

bushings is upto the marked point and the oil have been tested for dielectric strength and acidity.

iv) Check that Silicagel is in reactivated condition. The breather pipe is clear

from any blocking and contains oil upto the proper level.

v) Check that the explosion vent diaphragm does not have any dents. Accumulation of any oil and air had been released.

vi) Check that the operations of off-load and on-load tap changer on all the

tap positions is satisfactory. The mechanical parts of the on-load tap changer are lubricated. Break shoes are O.K. Motor IR value taken and tap position mechanical indicator on the transformer and tap position indication meter on the control panel are reading the same tap positions. Tap changer limit switch are operating alright on the maximum and minimum tap position & on-load tap changer contact pressure and resistance is as per manufacturer’s recommendations. Oil level of tap changer tank is O.K. and oil has been tested for dielectric strength. Check winding resistance at all taps. Check voltage ratio at all taps. Check taps changer operation on both local & remote.

vii) Check that the Buchholz relay has been tested and checked up for any

friction in the movement, and floats are free. All the other protective relays, alarm and annunciation relays have been tested.

viii) Check that all the metering equipment has been tested. Polarity test of

P.Ts and transformer winding is alright. Phase sequence and connections have been checked for proper vector group. Check Neutral C.T. connections, NGR connections (if applicable), NGR resistance, NGR enclosure.

ix) Check that the ratio test and winding resistance on all the tap positions is

alright. x) Check that gaps of arcing horns for the bushings are alright and earth

connections for the surge diverters have been checked.




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xi) Check that the winding and oil temperature thermometer pockets contain oil. That winding and oil temperature settings on dial gauges are O.K.

xii) Check the transformers fitted with fans for forced air-cooling have been

checked up, for automatic starting and stopping of the fans and fan's air-displacement has been verified.

xiii) Check that the simulation test for all the alarm, annunciation and trip

circuits have been checked and are alright. Check the stability of differential relay & restricted earth fault for out of zone fault.

xiv) Check that the insulation resistance of all the control circuits and IR value

of the transformer windings and all the incoming and outgoing cables have been checked with 1000V megger. Check also power cable for proper termination, busduct connections & busduct support.

xv) Check that all the valves in the cooling system and valve between the

Buchholz relay and the conservator tank are in open position. Check sample valves, drain valves etc. for their correct position.

xvi) Check that the setting of all the protective relays is at the desired valve and D.C. Trip supply is available.

xvii) Perform core balance test.

4.9 Observations after Commissioning: After switching on the transformer the following points must be observed and recorded. i) The inrush of magnetizing current and no-load current.

ii) Alarm, if any, or any relay flag has operated. All local & remote indications at no load.

iii) Voltage and current on all the three phases, and phase sequence. iv) Hum or abnormal noise. v) Circulation of oil and leakages.

vi) Record current, voltage, cooling air temperature, winding temperature, and oil temperature readings, hourly for 24 hours.

vii) Cable end boxes for any over-heating.




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viii) If the transformer is energised successfully, a minimum period of 24 hours should be allowed before taking it into service. Load should be increased gradually.

5.0 H.T. & L.T. MOTORS 5.1 All the motors generally would be erected by the mechanical contractor.

Electrical contractor will fix-up all the accessories like water pressure and temperature alarm detectors after testing and calibration. The insulation resistance of the H.T. Motors shall be tested and the motors treated as given in para `6' below.

5.2 Insulation resistance of the motors shall be measured between the winding of

the machine and its frame by means of a 500/1000V megger in case of 415V motors. A minimum value of 1 megaohm for 415V motors shall be considered a safe value. In case of lower I.R. Value, the insulation value shall be brought up by any of the following methods as desired by the Engineer-in-Charge.

i Blowing hot air in case of big motors. ii Putting the motor in electric oven in case of smaller motors. iii Placing heaters or lamps around and inside in case of small motors after

making suitable guarding and covering arrangements so as to conserve the heat.

6.6KV motors shall be tested for insulation by 500/1000V megger and its value

should not be less than: Safe minimum insulation: ≥ 20 MΩ resistance at 60 deg. C In case the insulation is low, the following method of drying has to be adopted: i By locking the motor so that it can not rotate and then applying such a

low voltage to the stator terminals that full load current flows in the stator, keeping the stator winding temperature below 90 deg. C. In this a close watch shall be kept for any possible overheating and I.R. Values vs. temperature shall be plotted and heating continued till I.R. Value becomes steady.

ii By blasting hot air from external source, Maximum temperature of

winding while drying should be 70 deg. C. to 80 deg. C. (Thermometer) or 90 deg. C. to95 deg. C. by resistance method. Heating should be done slowly till steady temperature of winding is reached after 4 to 5 hours, and for large machines after 10 hours. A record has to be kept for drying process, with half an hour readings and,




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after steady temperature is reached, at an interval of 2 hours. In case it is essential, the drying process can be supplemented by blower.

5.3 The motor leads shall be correctly connected to the outgoing leads in the

connection box, and the control circuit should be tested for proper functioning as per circuit diagram.

5.4 The mechanical checks and electrical checks before commissioning should be

exercised in accordance with IS: 900. The following points can be checked before commissioning the motor.

5.4.1 Check motor mounting. 5.4.2 Check motor is rotating freely by manual effort. 5.4.3 Check motor cooling fan installed properly. 5.4.4 Check motor body is grounded at two points. Check terminal box grounding. 5.4.5 Check all components installed as per approved final vendor drawing. 5.4.6 Check motor power supply cable connected to proper level of voltage. 5.4.7 Check termination of motor cable at motor end as well as at MCC/ SWGR

end. 5.4.8 Check terminal box cover closed properly and unused entries plugged. 5.4.9 Check terminations at auxiliary terminal box and unused entries plugged. 5.4.10 Check continuity of motor cable. 5.4.11 Check 'Megger' value of motor and power supply cable. 5.4.12 Check alignment of motor with the driven equipment. To ensure no undue force

is imposed on bearings. 5.4.13 Check greasing of bearings at both ends. 5.4.14 Check endplay in bearings. 5.4.15 Check oil level in gearbox. 5.4.16 Check bimetallic relay setting at MCC module. 5.4.17 For breaker fed motor check all relay settings and CT polarity.




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5.4.18 Check Local Control Station is properly wired and complete with all necessary control and indication. Check enclosure of local control station for hazardous atmosphere.

5.4.19 Check wiring of all the interlocks for proper wiring. 5.5 In case of synchronous machines, slip rings and brush gear should be polished

and brushes should be fixed in their holders with clearance and pressure as recommended by the manufacturers. The tolerance allowed is only 10%. The machine winding should be cleaned with carbon tetrachloride in case it is necessary.

5.6 Before commissioning any small or big motor, the ventilation and cooling system

of the motor must be inspected. In case of forced ventilation motor, the inlet of air trunking pipe should be examined to ensure that it is free from moisture and any foreign material. It should also be ensured that recommended flow and pressure of air is available to produce the required cooling effect.

5.7 The motor control gear should also be carefully examined, the over-load settings

may be reduced or time lags bypassed from protective gear to ensure rapid tripping of switchgear in event of faults. The direction of rotation of a new motor especially of large capacity, and phase sequence of supply should be kept in view while jointing and connecting to the motor terminals.

5.8 Finally the motor shall be started on no-load after decoupling and with all

overload setting at minimum. If the motor starts successfully it should be allowed to run for a minimum period of 4 hours, or for a time as instructed by Engineer-in-Charge. The following shall be checked during no load trial of the motor.

5.8.1 Check starting current. 5.8.2 Voltage, speed, no load current, stator winding and bearing temperatures should

be recorded after every one hour. 5.8.3 Check direction of rotation. 5.8.4 Check for abnormal noise & vibrations. 5.8.5 Check for all indications coming in proper panels. 5.8.6 Check operation of all interlock and relays. 5.8.7 Check for smooth reacceleration in case the motor is provided with

reacceleration scheme. 5.8.8 Check different speeds in case of double speed motors.




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5.8.9 Check space heater operation if provided. 5.8.10 Check motor body temperature at eyebolt and bearing temperatures. 5.9 After switching off the motor, the insulation resistance of the motor should be

recorded under hot and cold conditions. 5.10 If the no load trials are found satisfactory, the motor should be run on load after

adjusting the protective relay settings to 100% value and should be allowed to run for 8 hours and all readings be recorded.

5.11 The following works, if required, shall be performed by the contractor. 5.11.1 Before trial run, the contractor shall check rotor air gaps at three places at 120

deg.C apart on both sides of the drive and verify with the figures furnished by the makers. The variation should not exceed 10% of an average value.

5.11.2 The proper level of bearing oil has to be checked. The condition of grease in

bearings should be checked and in case it is necessary, complete replacement of bearing with specified grade of grease after proper cleaning of the bearing will have to be done. Wherever external greasing facility exists, check the condition of grease by pumping some new grease of specified grade at start. If the grease coming out is deteriorated, replace all old grease.

5.11.3 All the motors, motor exciter set and induction generators directly coupled or

coupled through reduction gears shall be checked for vibrations. If the vibration amplitude is more than the recommended figures given by the manufacturer, the motor must be adjusted with suitable balance weight to produce smooth running conditions. High rating motors with large journal type bearings are liable to get damaged from shock, rough handling during transit and erection. Any small defect in a race or roller may give rise to considerable amount of vibration and noise and it may require the investigation of the bearing condition and clearance.

6.0 BATTERY & BATTERY CHARGERS & DC BOARDS Battery shall be erected on MS angle frame stands and insulators supplied by

the manufacturer of the batteries. Electrolyte shall be filled as per manufacturer’s instructions. Inter row connections shall be made with the leads supplied by the manufacturer Supervision for preparation and filling of electrolyte, terminal connections etc. will be carried out by the manufacture of the batteries wherever specifically mentioned. Charging, discharging and recharging shall also be carried out under the supervision of the manufacturer. Lamp bank for discharging shall be provided by the contractor under this contract. Contractor shall have to erect these boards and make necessary external connections.




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The Contractor shall also carryout tests on the complete Battery, Charger. The following points shall be checked before commissioning.

6.1 Check mounting or battery bank and battery charger. 6.2 Check power cable termination/glands. 6.3 Check control cable termination, interlock, wiring, loose connections. 6.4 Check earthing of battery charger panel. 6.5 Check all safety interlocks. 6.6 Check specific gravity of electrolyte in battery bank. 6.7 Check battery voltage in charged condition. 6.8 Check rating and type of all power and control circuit fuses. 6.9 Check the `Megger’ value of power and control circuit. 6.10 Check supply voltage of battery charger. 6.11 Check operation of battery charger and load on the charger. Check all

annunciations under stimulated condition. 6.12 Check changeover from mains supply to battery and vice versa. 6.13 Check DC distribution board mounting, earthing. 6.14 Check feeder schedule of DC distribution board and their correct description. 6.15 Check all cable terminations/glands. 6.16 Check 'Megger' value. 6.17 Check all safety interlocks. 6.18 Check incoming supply to DC distribution board. 6.19 Check all fuse ratings in DC distribution. 7.0 UPS SYSTEM: UPS System shall generally comprise of Battery Charger, Inverter, Voltage

Stabiliser, bypass transformer, Static Switches, Filters, output isolation




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transformer, Battery Bank, Output ACDB, Input ACDB Different panels shall be placed properly on the base of the foundation prepared for the same in correct sequence. Top elevation of all panel sections shall be matched. No gap shall be left between adjacent panels. The panels shall be secured to foundation by means of nuts & bolts or foundation bolts grouted in the base. The contractor shall make all Inter section bus/wiring connections as per approved vendor drawing and directions of the Engineer-in-charge. The contractor shall clean the panels with the help of blower or vacuum cleaner. Conducting petroleum jelly shall be applied to all electrical contact surfaces. The battery bank shall be installed and checked as per clause 6.0 of this specification.

The following points shall be checked before commissioning the UPS System. 7.1 Check power cable termination/glands. 7.2 Check control cable termination, interlock, wiring, loose connections. 7.3 Check safety earthing and system earthing. 7.4 Check all safety interlocks. 7.5 Check rating and type of all power and control circuit fuses. 7.6 Check continuity of power supply cables, battery cables, and control cables. 7.7 Check `Megger' value of power and control circuit. 7.8 Check the voltage available at battery bank is adequate. 7.9 Check ACDB mounting, its feeder schedule, all cable connections and rating of

different outgoing feeders from ACDB. Check incoming connection to ACDB from UPS.

7.10 Check calibration of all indicating instruments. 7.11 Check UPS voltage & frequency on no load. 7.12 Check functionally all controls and alarms provided in the UPS system for correct

operation & setting. Check correct remote alarms also. 7.13 Check protective devices of the UPS. 7.14 Check the transient response of the UPS for the followings. 7.14.1 Simulation of AC Power failure. 7.14.2 Simulation of rectifier failure.




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7.14.3 Simulation of battery failure. 7.14.4 Simulation of one inverter failure. 7.14.5 Simulation of both inverter failure. 7.14.6 Manual return from bypass to inverter. It is not the intent to cover all the precommissioning checks exhaustively here.

Any checks/tests to be done as per manufacturer’s guidelines and/or directions of Engineer-in-charge shall be carried out by the contractor.

8.0 CONTROL & RELAY PANELS Control and relay panels shall generally cover relay panel, synchronising panel,

and metering panel. Annunciation panel, metering panel, DC starter panel etc. Various control panels may consists of number of boards/shipping sections, the contractor shall place all the sections of the panel correctly in proper sequence on the foundation prepared for the same, align them and bolt sections together to form one continuous panel. Top elevation of all sections shall be matched and no gap shall be left between adjacent sections of the same panel. The panel shall be secured to the foundation shall the panel with blower or vacuum cleaner, make all power and control cable terminations, all inter panel wiring.

Site testing and functional checks shall be carried out on all relays and their

associated CT & VTs and protection Circuits the confirm the correctness of operation of protection.

Testing & commissioning of the panel shall be done as per manufacturer’s

standard and/or direction of the engineer-in-charge. . 9.0 NEUTRAL GROUNDING RESISTOR The neutral grounding resistor shall be inspected for any damage to the resistor

grid and other components. The resistor shall be leveled and installed. All covers, etc. shall be checked for tightness to ensure that the enclosure of the resistor is dust, vermin and weatherproof. Two earthing conductors shall be taken from the neutral terminal of the resistor, one being directly connected to an earth electrode and the other being connected to the main grid. Proper connection is to be made between transformer neutral & NGR as per direction of engineer incharge. NGR enclosure is to be grounded at two distinct & separate points.




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10.0 WELLDING RECEPTACLES The welding receptacles shall be erected on steel structures/concrete as per the

drawings. In isolated places a separate support shall be fabricated and installed. Erection of welding receptacle shall be done by fixing the socket with screws

using rawl plug or by anchor fasteners. IR/HV test values shall be taken. Interlocks if any and switch operation shall be checked. Power cable shall be terminated properly and the receptacles shall be grounded at two separate points.

11.0 PUSH BUTTON/CONTROL STATIONS The push button/control stations shall be installed near the motors to be

controlled. Individual channel supports shall be used for each of the push button stations. These shall be installed as per approved erection detail drawing. Control station for hazardous areas shall be CMRS certified and CCE approved.

All push button/control stations shall have necessary canopies. Wiring of push

button control station shall be checked before giving control supply. 12.0 240/24V TRANSFORMERS AND FLAMEPROOF-SOCKETS (24V) ThE 230/24V transformers shall be an integral part of 24V flameproof hand lamp

socket and erected at places shown on the drawings. Necessary supporting structures shall be fabricated out of mild steel and the same shall be painted. Only galvanized steel bolts, nuts & washers shall be used. Power cable shall be properly terminated and switch operation and mechanical/electrical interlock shall be checked. Socket shall be properly grounded.

13.0 MISCELLANEOUS SURFACE MOUNTED CONTROL GEAR The contractor shall install, connect, test and commission miscellaneous surface

mounted control gear as per approved drawing and/or directions of Engineer-in-charge. The frame for mounting wall mounted DBs shall be fabricated out of MS sections. MS sections shall be cleaned and applied with two coats of red oxide primer and then finished with two coats of approved paint & shade. The contractor shall make necessary pockets in the Wall/Column for grouting the frame and finish with cement concrete to make the frame rigid. The frame shall be fixed on Wall/Column/Steel surface in such a way that minimum clearance of about 100 mm shall be kept between Wall/Column/Steel surface and the frame work. All miscellaneous control gear shall be installed, connected and tested as




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per approved installation drawings, layout drawings and/or directions of Engineer-in-charge.

14.0 EXHAUST FANS These shall be of GEC make or any other approved equivalent, suitable for

single phase supply and wall mounting type. The body & blades of the exhaust fans shall be painted with epoxy based paint. The exhaust fan shall be erected along with louvers assembly.

15.0 EQUIPMENT COMMISSIONING After the equipment is installed properly in accordance with drawings and

specifications, contractor shall thoroughly clean the equipment. All precommissioning checks and tests shall be carried out in the presence of Engineer-in-Charge and test readings shall be recorded.

Before energising any equipment contractor's standard 'COMMISSIONING

CLEARANCE FORM' shall be duly filled in and signed by the contractor. This shall be given to owner for clearance. Subsequent to equipment energisation, the defects/discrepancies if any pointed out, shall be attended within the reasonable time set out by Engineer-in-Charge.

16.0 LIST OF CONSTRUCTION EQUIPMENT The contractor shall have all necessary construction equipment, tools and

tackles & instruments, to carry out the erection works and to commission the system as specified. A list of construction equipments which contractor possesses with quantity shall be indicated in the bid along with model numbers and make. These shall include but not limited to the following and these shall be brought to site by contractor before the start of work.

A. Equipment

1. Portable grinder.

2. Portable welding machine

3. Portable gas cutting/welding set. 4. Pipe threading machine. 5. Pipe bending machine (hydraulic)




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6. Portable drill machine suitable to the take up drilling for drilling for different sizes as per requirement.

7. Dewatering pump sets (diesel driven). 8. Power Hacksaw. 9. Conduit dye set. 10. Hydraulic crimping machine. 11. Hand crimping tool. 12. Portable electric blowers, vacuum cleaners.

13. Miscellaneous items such as sling, D-shackles, pulleys, tarpaulins, wooden sleepers, ladders, etc. as required. 14. Safety belts, safety goggles, hand gloves. 15. Separate tool kit for each Electrician.

B. Test Instrument 1. Insulation tester 0-500-1000V hand driven.

2. Insulation tester 5000V motor driven. 5000 3. Phase sequence indicator. 4. 4 point earth tester for measuring the earth electrode resistance

as well as earth resistivity in compliance with stature. 5. Single Phase variac 6. 3 phase variac 7. AVO-meter/multimeter. 8. Portable Ammeter, Wattmeter, P.F. meter. 9. Portable Voltmeter. 10. Clip on meters of different ranges. 11. Tacho-meter.




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12. Kelvin's double bridge for measurement of very low resistance. 13. D.C. high-pot test kit. 14. LUX METER to measure illumination levels. 15. Oil filtration machine of adequate capacity. 16. Secondary injection test unit for checking CT circuit. 17. Polarity testing equipments for CT & PT circuits.

18. Time internal measuring meter for checking operating time of circuit breaking, protective relay etc.

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