Fichtner Electrical

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FICHTNER Consulting Engineers ( India ) Private Limited

Subject Doc. No. Rev. Section

3.0

Sheet No.

HJI Prop.

GMMCO

LIMITED

TECHNICAL SPECIFICATION

FOR

STEAM TURBINE GENERATOR & AUXILIARIES

2630720001-ME-SPC-120-001 R0

1

2630720001-STG-S3-R0 AVD / ELEC 24-09-2007

FORMT9-PREV-B

(MUM)

SECTION - 3.0

DETAILED TECHNICAL SPECIFICATION - ELECTRICAL


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FORMT9-PREV-B

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SECTION - 3.0

DETAILED TECHNICAL SPECIFICATION - ELECTRICAL

CLAUSE NO. DESCRIPTION SHEET NO.

3.1.0 GENERATOR AND AUXILIARIES 3

3.2.0 DC DRIVE STARTER PANEL FOR DC LUB OIL PUMP 13

3.3.0 GENERATOR RELAY PANELS / GENERATORCONTROL, METERING AND SYNCHRONISING PANELS 14

ANNEXES

3.1 SPECIFIED DESIGN DATAGENERATOR AND AUXILIARIES 26

3.2 SPECIFICATION FOR TRANSDUCERS. 29

3.3 LIST OF ANNUNCIATIONS 31

3.4 APPROVED LIST OF SUB-VENDORS / MAKES 33

APPENDIX - 1.0 DETAILED TECHNICAL SPECIFICATION FORMISCELLANEOUS ELECTRICAL ITEMS 34


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FORMT9-PREV-B

(MUM)

d. The generator should operate without mechanical damage on a 3 phase, a line toline, a line to earth or 2 lines to earth short circuit for 3 seconds with operating at

rated speed and excitation corresponding to 5% over voltage at no load.

e. The generator shall be capable of operating at its maximum continuous rating

(MCR) at rated voltage and frequency subject to variation of 5% of nominal

voltage with possible extension to 10% voltage and 5% for frequency In additionthe bidder shall furnish the short time under frequency operating limits andpermissible volts/ Hertz. Limit.

f. In case of sudden application of full load at rated power factor the voltage dropshall not exceed 15%. The Generator shall operate satisfactorily under sudden fullload rejection, and also shall be equipped for surge currents when relatively largesquirrel cage motors are switched on directly.

g. Generator shall incorporate fully interconnected damper windings to prevent cyclicirregularities.

g. The geometric dimension of the magnetic system shall be designed in such a waythat the harmonic content of the voltage shall be less than 1% from phase tophase for load variation from no load to rated load and power factor variation from0.1 (lag) to 1.

h. The generator shall be sized taking into consideration the harmonic measurementdetails of the plant, as given in the Annexure 3.1.

i. The maximum permissible deviation from sine wave shall be 1%.

j. The telephone harmonic factor shall not exceed the values given inIEC:34-1.

k. Field winding shall be capable of withstanding 125% voltage for 1 minute.

l. The Generator shall be able to operate only with the house loads.

m. Generator Remote Automation System Control Facilities

In addition to local controls of features stated below, turbine driven generator set shallhave features for interface with remote generator control/monitoring and remoteautomation system such as PMS and/or SCADA/DCS

These shall include:-

Local/Remote or Auto selection switch with their status indication to remotesystem

Initiation of remote generator auto synchronizing.

Remote automatic and/or manual changeover of generating operating mode alongwith their remote status indication such as those associated with:-


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Generator excitation / AVR control in either of the Voltage Control or Power Factoror MVAR control mode.

Generator Speed control in either of the droop or isochronous or isochronous loadsharing or isochronous base load operation.

Remote automatic and/or manual generator voltage and frequency control:-

Remote automatic and/or Generator power reference setting/Speed raise andlower control

Generator voltage raise and lower control from remote

Generator load acceptance and reduction rate change

Remote automatic and/or manual equal or unequal load allocation/sharing

between sets as required

Remote annunciation of all generator fault and alarm signals

Generator capability diagram and generator operating point on the capability curve formimic of generation capability and operating point at the HMI of the remoteautomation system

Generator and the generator control system supplier shall:-

include and list all analogue inputs, analogue outputs, digital inputs, digitaloutputs, transducer input/outputs, pulse control inputs required and incorporated

by them for remote automation system control.

furnish details of communication protocol and access address of all analogueinputs, analogue outputs, digital inputs, digital outputs, transducer input/outputs,pulse control inputs as required for interface by the remote automation systemsupplier

3.1.3 Stator

The stator laminations shall be so designed and assembled as to minimize noise andoffer minimum resistance to the cooling airflow. Stator coil insulation and tapering ofthe coils shall be such as to provide adequate corona shielding. Coil ends shall beadequately braced to prevent distortion due to any abnormal operating condition.

Stator supports shall be so designed as to withstand maximum short-circuit stressesaccording to IEC 34.

The stator winding shall be fully insulated throughout and shall be suitable foroperation with resistance earthed neutral. The stator windings shall be STARconnected with all the three phase and three neutral ends brought out throughterminal bushings. The terminals shall be liberally sized for carrying the rated currentof the generator and shall be provided with clearances specified for the terminalvoltage under IEC standards. The terminals should accommodate CTs as required.Neutral connection box shall be separate.


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FORMT9-PREV-B

(MUM)

The stator windings shall be provided with not less than six (6) resistive duplex typetemperature sensors (100 ohms at 0 C) located in accordance with the provisions of

the relevant approved standards. In addition to the above, not less than six (6)resistive duplex type temperature sensors (100 ohms at 0 C) shall also be providedin the stator core. These temperature sensors shall be wired to a separate dust andvermin proof terminal box located at a convenient place on the machine for ease ofmaintenance.

The generator winding insulation shall be based on full vacuum pressure impregnation(VPI) method or based on a method involving individual forming or curing of slot partsof windings with subsequent impregnation of complete winding according to VPImethod.

The generator shall be able to withstand a winding to earth peak voltage of at least75 kV peak.

2 nos. of fire detectors shall be provided in the stator.

3.1.4 Rotor

The rotor shall be built in accordance with the best modern practice and shall bedesigned to withstand safely all stresses due to overloads or maximum designedspeed.

The rotor shall be manufactured in one piece, the inertia constant of which shall bedesigned to give a large margin between the critical and running speeds under normaloperating conditions.

The rotor winding shall follow standard design and shall be provided with a completedamper winding or damper wedges with short-circuit rings on both sides.

Generator shall be designed to withstand maximum over speed under any operatingconditions with a 10% margin and shall as a minimum be rated to withstand an overspeed of 20% above the rated value for one minute.

3.1.5 Bearings

The generators shall have self-aligning type bearings which are accessible forinspection without dismantling of the generator. Duplex resistive type temperaturesensors (100 ohms at 0C) for remote indication of the bearing metal temperaturesshall be provided.

Earthing brushes shall be provided on the rotor shaft and the bearings at the non-driven end shall be insulated, to prevent circulating eddy currents.

The lubricating oil supply for the generators shall come from the same systemprovided for the turbine. Suitable measure shall be adopted for shielding the bearingsas a precaution against carry-over of lubricating oil into the cooling area.


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FORMT9-PREV-B

(MUM)

3.1.6 Frame and Housing

The generator housing shall be of welded steel plate with provision to prevent statormovement from causing undue vibration in the external frame and foundation.

3.1.7 Cooling System

The generator cooling system shall be closed air circuit ventilation with intermediatecooling water system.

The Bidder shall provide all the air ducting system required for air intake and air outletfrom the generator to the air cooler with suitable sound attenuation silencers, ifrequired.

Generator shaft mounted fans shall circulate the air to cool the stator, rotor androtating assemblies. The cooling shall be adequate to impose no operationalrestrictions over the whole ambient temperature range.

The coolers shall be of withdrawable design. It shall be possible to isolate andwithdraw the coolers without disturbing the generator air cooling circuit.

The Air Coolers shall be suitable for water intake temperature upto 33.5C andworking pressure of not less than 1.7 bar (170 kpa). Coolers shall be designed so thatif one section is intended to be taken out of service for cleaning, the unit can carry atleast two third of rated load continuously, without permissible temperatures of activepart of machine being exceeded.

The design of the generator cooling system shall be such that one (1) extra element /cooler section is provided to take care of continuous operation at maximum load withone (1) element out of operation.

The temperature of the cooling air shall be monitored on both the inlet and outlet sidesof the coolers by duplex resistive type temperature sensors (100 ohms at 0 C) whichshall be designed for remote transmission. At outlet sides of windings, not less thanthree duplex resistive type temperature sensors shall be provided. The number andlocation of these temperature sensors shall represent the mean value of the airtemperature

Alarm contacts for water cooler leakages shall be provided separately for each cooler.

3.1.8 Rating Plate Details

The rating plate shall be provided fixed to the frame of machine with the followinginformation, which shall be legible and durable:

a. Manufacturers name.

b. Manufacturers serial number and year of manufacture.

c. No. of phases, rated frequency and rated voltage.


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FORMT9-PREV-B

(MUM)

d. Rated current.

e. Rated output.

f. Power factor.

g. Rated speed.

h. Permissible over speed.

i. Permissible temperature rise.

j. Design ambient temperature.

3.1.9 Exciter

The excitation system shall be capable of operating the generator at maximum load,rated power factor and rated frequency. The excitation system shall have sufficientreserve and redundancy to permit effective utilization of generator capability over theentire operating range and under all service conditions without any restrictions.

The generator excitation system shall meet following requirements:-

It should be capable of producing steady state short circuit current of not less than3 p.u with a 3 Ph. short circuit applied at the terminals.

The excitation system shall have proper field suppression equipment with properlyrated DC field breaker and field discharge facility.

The ceiling voltage should not be less than 200% of maximum continuous rating(MCR)

The excitation response ratio shall be equal to or greater than 1.0/second.

The generator shall be provided with a brushless type rotating diode rectifierexciter system.

The excitation system should be capable of meeting above requirement and shouldalso have sufficient gain & speed of response to maintain synchronous stability withthe system under switching transients associated with short circuits or abrupt loadchanges.

3.1.10 Brushless Excitation System

The brushless excitation system shall consist of a rotating armature AC exciter directlycoupled to the generator rotor. The field of the main AC exciter shall be powered froma high frequency Permanent Magnet Generator (PMG) through a static Automaticvoltage regulator. The output of the AC exciter shall be rectified by the rotating diodesconnected as a three phase bridge and mounted on the generator shaft for feedingthe generator field. The complete equipment shall be installed on a bed plate andenclosed by suitable exciter covers.


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FORMT9-PREV-B

(MUM)

The rectifier design shall be based on the basis of one high power diode and fuse perparallel path. Suitably rated heat sinks, which will also act as fans, shall be provided

for each diode.

The design of the rotating rectifiers shall be such that a short-circuit of a single diodeunit shall not require the shutdown of the generator. The exciter shall be equippedwith suitable alarm devices to detect diode failure.

All busducts, cables and cable carriers required for the excitation system shall bedeemed to be supplied against this specification.

3.1.11 Automatic Voltage Regulator

Solid state type voltage regulator with automatic and manual control, with a controldeviation limited to 0.5% from no-load to full load at rated frequency and with all

necessary limitations against over / under-excitation shall be provided. A suitabletransfer control system and necessary controls shall be provided for a smoothbumpless transfer from automatic to manual and manual to automatic voltage control.Bumpless and smooth transfer shall be automatically initiated in case of a suddenfailure of the voltage regulator.

Further more, manual control shall be possible from the remote control desk in thecontrol room. Provision for connection of all necessary push buttons, balance meter,indicating lights, selector switches, etc., to the remote control desk shall be provided.

The voltage regulators shall be complete with all limiters such as rotor current, statorcurrent, load angle etc. compensators, monitors, etc. A power factor controller shallbe provided to control the power factor of generator during parallel operation with grid.

An ON/OFF switch shall be provided to switch ON/OFF automatic power factorcontroller.

The Bidder shall supply all required auxiliaries such as generator field breaker,discharge/ suppression resistor, motor-operated voltage adjusting rheostat for bothauto and manual control and others which will be required for safe and continuousoperation.

The AVR / Excitation system should include following Limiters, Fault Detectors &Protection features;

a. Under frequency.

b. Short circuit

c. Manual voltage control switch with adjuster.

d. Cross current compensation for parallel operation.

e. Voltage built up circuit.

f. Over voltage.

g. Stator current limiter.


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FORMT9-PREV-B

(MUM)

h. Minimum excitation limiter (Rotor angle limiter).

i. Ripple detector for monitoring diode failure.

j. Null balance detector.

k. AVR accuracy 0.5% voltage from no load to full load.

l. Response time < 0.25 msec

m. AVR failure protection

n. AVR power supply fail protection.

All essential indications/annunciation system required for AVR/excitation system shallbe provided. Provision shall be made for remote operation with necessary controls,indications and annunciations.

Provision shall be made in the generators for first and second rotor earth faultprotection. All auxiliary equipment including necessary slip rings and brushes forbrushless excitation system shall also be provided.

3.1.12 P.T. and S.P. cubicles

P.T. and surge protection cubicles, shall be metal clad, dust and vermin proof, freestanding, dead front assemblies.

The cubicle shall have suitable compartments having front access doors withconcealed hinges for accommodating the following equipment:

Surge capacitor and lightning arrester

Potential transformers with primary fuses and secondary MCBs for each set of PT.

Seal-off bushings shall be used between the bus tap and cubicle.

3.1.12.1 Current Transformer Cubicle

Current Transformer (CT) cubical shall be provided for mounting of all the CTs shallbe as per enclosed single line diagram.

This cubicle shall be mounted adjacent to Generator Terminals.

The CTs shall be cast resin, ring type, with high stability under short circuit conditionsand shall be suitable for continuous operation at an ambient temperature of 500c.

The CT shall be mounted in such a fashion that it will permit easy removal andreplacement of CTs without dismantling the bus run or supports.

The CT secondary leads shall be brought to a common terminal box. Along with CTshorting links, test links also shall be provided in the secondary circuits for carrying out


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(MUM)

current and phase angle measurements. Proper access to LT terminal box shall beprovided.

The cubicle shall be fabricated out of sheet steel and complete with removable glandplate for cable entry.

The wiring shall be carried out by 2.5m2Cu cable.VA burden shall be selected to suit the system requirement.

3.1.12.2 Potential Transformers

Potential transformer shall be cast resin, draw out type, suitable for nominaloperation connected from line to ground, and for 1.73 times rated line to groundvoltage under sustained emergency condition. Suitable guide slots and stops shallbe provided to permit easy withdrawal and positioning.

Automatic safety shutters shall be provided to cover up the live terminals when PTsare drawn out. In the disconnected position, the potential transformer primary andsecondary circuits shall be automatically disconnected and the primary fuses shallbe visibly grounded. The drawout frame shall be grounded at all times.

The high voltage winding of potential transformer shall be protected by currentlimiting fuse mounted on top of the primary bushing. The fuse will be accessible onlyin fully drawn out position.

The secondary leads from the individual PTs shall be extended to a MCB andterminal cabinet flush mounted on the compartment.

Potential transformers shall be housed in a phase separated sheet steel cubiclehaving degree of protection IP-54.

3.1.12.3 Surge Arrester and Surge Protection

The surge arrestor and surge capacitor shall be located in separate compartments.Arrestor and capacitor shall be single pole type connected between line and groundterminals.

The arrestor shall be station class, hermetically sealed type connected between lineand ground. The arrestor and capacitor shall be especially suitable for generatorprotection and shall be sized accordingly. Sizing calculation for the same shall besubmitted by Bidder for approval.

A discharge counter shall be provided for each of the lightning arrestor. Thedischarge counter register shall be visible without opening the compartment grillcover.


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FORMT9-PREV-B

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3.1.13 Neutral Grounding Resistor (NGR)

The Generator shall be grounded through resistor, limiting the earth fault current to300 Amps. The resistors shall be made of unbreakable, corrosion proof, joint less,stainless steel grid conforming to ASTM-A240-304 or Ferro chrome aluminium alloyconforming to ASTM-A-240-405. It shall be suitable for use in tropical climate.

The resistor shall be designed for indoor service and shall be rated for carrying

specified earth fault current for 60 sec. with temperature rise not exceeding 250 C

over ambient temperature 50 C. The resistors shall be house in an sheet steelenclosure with minimum of IP 33 degree of protection. Resistors shall be capable ofcarrying 110% of its rated current continuously.

The NGR cubicle shall also house an on load isolator rated for 630A, along with cast

resin type neutral CT for Generator Earth Fault protection as indicated in SLD.

- The connection between NGR and generator neutral shall be done by means ofbusduct.

- The connection between NGR and earth pit shall be done by means of GI earthstrip.

- NGR shall be natural air-cooled. Space heater along with DP switch, fuse andthermostat shall be provided in NGR.

- 4 NO + 4 NC potential free contacts shall be provided for status monitoring &interlocking of neutral branch isolator.

3.1.14 Painting

All equipment shall be finished with two (2) under coats of high quality phosphatepaint and a coat of yellow zinc chromate primer. The shade of exterior surface finishshall be light grey, shade-631 of IS-5. The bus conductor and inside surface shall betreated with matt black paint for efficient heat dissipation.

All supporting structures shall be hot dip galvanised.

3.1.15 Tests

The generators shall be subjected to routine tests as per IS/IEC. Temperature rise

test shall also be conducted in addition to the above. Test certificates shall befurnished for all the type tests.

In addition to the routine tests, the following tests shall also be carried out::-

a) Insulation resistance (before and after high voltage test) and determination of PIof,- Generator- Exciter- Resistance, temperature detector


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b) Dielectric test.

c) Temperature rise at rated voltage, current, power factor and frequency.

d) Vibration test.- At 100% of synchronous speed and at 120% during over speed test.- At site at 100% of synchronous speed with driver.

e) Noise measurement test.

f) Response of voltage and frequency with sudden shedding of 25%, 50%, 75%and 100% rated load respectively.

g) Response of voltage and frequency with sudden application of 25%, 50%, 75%and 100% rated load respectively.

h) General dimensional alignment checks.

3.1.16 Drawing and Data

The following data / drawings shall be submitted along with the offer.

a. GA drawing of Generator

b. Generator characteristic curves

c. Catalogues & related literature.

d. Following mathematical models as per IEEE required for Electrical SystemStudies.

i) General Block Diagram.ii) Turbine Block Diagram.iii) Turbine Governor Block Diagram.iv) Exciter Block Diagram.

e. Generator Droop characteristics.

3.1.17 Post contract award drawing and documents shall be submitted as per Annex 1.5of Section-1

3.2.0 D.C DRIVE STARTER PANEL FOR DC LUB OIL PUMP

3.2.1 The starting resistors for the DC motors shall be enclosed in a metal clad naturallyventilated self-standing panel(s) with sheet steel material of minimum 2.0 mmthick with degree of protection IP-33. It shall be dust and vermin-proof. The numberof resistance steps shall be decided by the supplier depending on application.Alternatively, permanent connected resistor is also acceptable.

3.2.2 The resistor elements shall be made of unbreakable, corrosion-proof, jointlessstainless steel grids. The grids shall be in punched form and suitable for use intropical climate.


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3.3.0 GENERATOR RELAY PANELS / GENERATOR CONTROL, METERING ANDSYNCHRONISING PANELS

3.3.1 General

One set of Generator Relay and generator control, metering and synchronising panelshall be provided for Generator to cater to the protection, metering & synchronisationrequirement of generator.

Relay panel shall be provided with all the relays as per typical metering and protectiondrawing no. 30-2630720001-E-202.

The generator control panel shall have the control facility as following:

a . Control of Generator Breaker / AVR control / Governor Control.

b. Synchronisation of generator / grid incomer / existing 11kV bus coupler / Tiefeeder breaker / one spare breaker shall be considered

c. Mimic & semaphor indication & indicating lamps shall be provided.

d. In addition to above, control, metering and indication of generator parametersand associated equipment shall be possible from DCS system envisaged for theplant. Bidder shall ensure necessary hardware arrangements in control relaypanels for the same.

3.3.2 Constructional features & General Arrangement

Panel shall be of sheet enclosed dust and vermin proof simplex type. Panels shall befloor mounting free standing formed on a frame work of standard sections. Theenclosure shall be made out of cold rolled sheet steel of 2.5 mm thick front, back andequipment bearing surfaces and 2 mm for others. Panel supporting structures shall beso designed to form a rigid structure. The panel enclosure shall provide a degree ofprotection not less than IP:31.

All doors and openings shall be provided with neoprene gaskets.

All panels shall be suitable to be installed on base frame supplied in one piece alongwith foundation bolts. Adequate holes shall be provided at the bottom of all the panelsfor their installation on base frame. Anti vibration pad of 25 mm thick shall beprovided between base frame and panel through its entire width on the front/rear side.

A suitable removable undrilled gland plate shall be provided for cable entry frombottom.

The relays and meters shall be provided as per enclosed generator metering andprotection drawing no. 30-2630720001-E-202. The specification and drawingssupplement each other. Only the main equipments are listed here.

However, provision of all minor items such as links, terminals, control fuses, aux.relays, timers, transducers & indicating lamps shall be made by the bidder.


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The bidder shall be solely responsible for completeness and correctness of internalwiring and for proper functioning of the connected equipment.

The panels shall be of vertical front type with equipment mounted in the front andhaving wiring access from the rear. It shall have double leaf door with lift off hinges atthe back. Door shall have built-in locking facility. The relay panels shall have a glassdoor to observe relays from the front.

No equipment shall be mounted on the removable cover plate to avoid the means ofaccess.

All instruments, relays and control gears shall be mounted on the front of the panel.All equipment mounted on the panel shall be of flush type.

It should be possible to accomplish all settings easily from the front of the relays.

The centre line of relays, meters and recorders shall not be less than 450 mm fromthe bottom of the panel.

Checking and removal of components shall be possible without disturbing theadjacent equipment. It shall be possible to set all the measuring relays at site.Mounting of terminal blocks, transducers, interposing CTs etc. shall be done in such away so as to be readily accessible but without impending the access to internal wiringand components.

3.3.3 Wiring:

Panels shall be supplied completely wired internally and ready for Owner's external

cable connections at the terminal block. When panels are arranged to be mountedadjacent to each other, all inter panel wiring and connection between panels shall bedone by the Supplier.

All wiring shall be done with PVC insulated, 650V grade, single core multi stranded(minimum 7 strands) annealed copper conductors suitable for temperature andhumidity specified. The minimum sizes are given below:

a) CT circuit : 2.5 sq. mmb) For all others : 1.5 sq. mmc) Earthing : 2.5 sq. mm

Each wiring shall be identified at both ends with wire numbers by means of PVC

ferrules. Colour coding of the wires shall be as per IS:5578 and IS: 11353.

Panel wiring shall be securely supported, neatly installed by lacing and tying, readilyaccessible and connected to equipment terminals and terminal blocks. Flameretardant, plastic wiring channels / troughs with strap on plastic covers shall be usedfor this purpose.

All equipment spare contacts shall be wired up to the terminal box.

3.3.4 Terminal Blocks


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The terminals shall be stud type.

The terminals shall be suitable to receive crimped wire to give positive connection. Allterminals shall be properly shrouded against accidental contact. Sufficient terminalsshall be provided, so that not more than two wires is connected to each terminal.

Protective covers of transparent plastic shall be provided over the live parts of theterminal blocks. Terminal block for CT and PT secondary leads shall be provided withtest links and isolating facilities. Also CT secondary leads shall be provided with safeshort-circuiting and earthing facilities.

Minimum clearance of 250 mm between the first row of terminal block and associatedcable gland plate shall be provided. Also the clearance between two rows of terminalblocks shall be minimum of 150 mm.

At least 20% spare terminals shall be provided in each panel and shall be distributedon all rows of terminal blocks.

3.3.5 Painting

All metal surfaces shall be thoroughly cleaned and degreased to remove mill scale,rust, grease and dirt. Fabricated structure shall be pickled and then rinsed to removeany trace of acid. The under surface shall be prepared by applying a coat ofphosphate paint and a coat of yellow zinc chromate primer. The under surface shallbe made free from all imperfections before undertaking finishing coat.

After preparation of the under surface, the relay and control panel shall be powdercoated with two coats of final paint. The colour of the finishing paint shall be light grey

to shade 631 of IS:5. The finished panel shall be dried in stoving oven in dust freeatmosphere. Panel finish shall be free from imperfections like pin holes, orange peels,run off paint etc. Final thickness of paint film on sheet steel shall be about 60microns.

All unpainted steel parts shall be galvanised or suitably treated to prevent rust andcorrosion. If these parts all are moving element, the same shall be greased.

3.3.6 Panel/Illumination

Fluorescent lamp working on 240 V AC operated by door switches shall be providedfor panel internal illumination.

One 240 V, single phase, 15A, 3 pin socket shall be provided in the panel/deskinterior with On/Off switch for connection of hand lamps. This socket shall be metalclad type with a spring load flap.


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3.3.7 Earthing

A continuous 25 mm x 6 mm tinned copper bus shall be provided running along fulllength of the panels. Suitable arrangement provided at the two ends for connectionsto the plant earthing system.

Each panel and the equipment mounted on each panel shall be securely connected tothe earth bus by copper wires of size 2.5 mm. This shall be of green in colour. Forthis purpose the earth wire shall be looped from equipment to equipment and bothends of the earth wire shall be connected to earth bus by a suitable clamp connectors.Soldering shall not be permitted.

Insulation between the live terminal and earth prior to connection of the earth to thePurchaser's earth grid shall withstand a test voltage of 500 V for 1 minute (or have

resistance of not less than one mega ohm at 500 V).

3.3.8 Space Heaters

Strip type space heaters of adequate capacity shall be provided inside each panelcomplete with ON/OFF switch fuse and thermostat. Heaters shall not be mountedclose to wiring or panel mounted equipment. All accidental contact with heaters byoperators shall not be possible.

3.3.9 Instruments

Instrument shall be furnished as per enclosed SLD.

a. Indicating instruments

All indicating meters shall be of moving coil type. The meters shall be of 240scale (except for Double voltmeter and double frequency meter),96 sq mm in size and having an accuracy class of 1.5.

All auxiliary equipment such as shunts, interposing CT/VT etc. that are requiredshall be included in the scope of supply. All the instruments shall be subjectedto an applied potential test of 2 kV for one minute.

b. Integrating Meters

Energy meters shall be of three phase, two element type, suitable for measuring

unbalanced loads in 3 phase, 3 wire circuits. They shall be of flush type, withreverse running stop and with test terminal block for testing. Meters shall readMWH without the use of additional multiplying factors. Number of digits providedshall be adequate to cover at least 1000 hours. Accuracy class shall be one(1.0).

Current coils of the meters shall have a continuous over load capacity of 120%of both accuracy as well as thermal limits. Also current coil shall withstand ten(10) times rated current for 0.5 sec. without loss of accuracy.

c. Transducers


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Bidders shall offer transducers with specification as listed in Annexure-3.3 for

DCS systems. The transducers shall be mounted inside the generator controlpanel. The list of transducers to be provided and shall be as per SLD -protection and metering.

d. Recorders

Recorders shall be of drawout type for chart replacement and suitable for backconnection. Provision shall be made for automatic shorting of CT leads, whenthe recorder is drawn out.

Recorders shall have accuracy of 0.5%. Recorders shall employ ink on paperand shall be provided with gears and shall have a variable chart speed. Electricmotor driven charts with automatic spring winding is preferred. Alternatively,

built-in synchronous motor drive with spring reserve may be provided. Chartsand inks, sufficient for two (2) years continuous operation of each recorder shallbe supplied.

Watt and Var recorders shall be suitable for 3 phase, 3 wire, unbalanced loads.

All recorders as shown in enclosed generator metering and protection single linediagram shall be suitable for 110V AC PT supply and 1 amp CT secondarycurrent.

All auxiliary equipment such as shunts, transducers, interposing CT/VT etc. thatare required shall be included in the scope of supply.

Alternatively bidder may offer multipen recorder with one pen spare.

3.3.10 Push Buttons

Push buttons shall be heavy duty, shrouded, push to actuate type with colouredbutton and inscription plate marked with its function. Each push button shall have 2NO + 2 NC contacts.

3.3.11 Indicating Lamps

Indicating lamps shall be LED type with clear terminal connections with seriesresistors. They shall be provided with nameplates.

3.3.12 Control Fuses

All control fuses shall be of HRC cartridge link type confirming to IS: 2208. Fuses shallgenerally be mounted on the top half of the panels. All fuses and links shall beprovided with suitable identification labels.


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3.3.13 Control Switches

All control switches shall be rotary, back connected type having cam operatedoperating mechanism with pistol grip.

Breaker control switches shall be of 3 position, 6 pole discrepancy type.

The contact faces shall be of silver/silver alloy. The contacts shall have the followingcapability.

Continuous rating : 10A

Breaking current atinductive load of L/R : 10 ohms and at PF = 0.3 to 0.4

at 240 V AC = 3Aat 110 V DC = 2A

Rated switching operation shall be of 120 cycles / hour.

All synchronising switches shall have one common knob with keyed shaft removablein off position only to prevent more than one switch being in ON position at a time.The switch shall be 3 position (off, dead bus closing and synchronizing ) 12 pole type.

3.3.14 Position Indicators

Position indicators of 'Semaphore' type shall be provided as part of the mimic busbarson panels for automatic indication of the position of circuit breakers, isolating

switches, etc. The indicator shall be suitable for semi-flush mounting with only thefront disc projecting out and with terminal connection from the rear.

When the supervised object is in the closed position, the pointer of the indicator shalltake up a position in line with the mimic busbars and at right angles to them when theobject is in the open position. The pointer shall take up an intermediate position toindicate the supply failure. It shall not be possible to displace the position of theindicator disc due to accidental touch during cleaning of the panel.

3.3.15 Relays

All protective relays shall be numerical type only and switchboard pattern, backconnected, drawout type suitable for flush mounting and fitted with dust tight covers.

A set of test block and test lead or test switch for necessary secondary injection testshall be included.

Relays shall be provided with hand reset/self reset type contacts and flag indicators.The flag indicators shall be suitable for external hand resetting and mechanicallyinterlocked to prevent falling when relay is subjected to vibration.

The rating of auxiliary contacts shall not be less than 5 amp at 240 V AC and2 amp for 110 V, DC. Minimum one set of spare contact shall be provided in all relaysfor SCADA / DCS system.


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FORMT9-PREV-B

(MUM)

3.3.16 Specification For Protections

The tenderers shall furnish, the settings of all relay functions to suit the requirement ofprotection, operation and interlock.

Following protection functions shall be provided :

a. Generator differential protection (87G)

Triple pole, high speed, high sensitivity circulating current high impedance relayshall be offered.

The relay shall have minimum setting of 5 -10% of generator rated current.

The relay shall maintain its stability for any external faults.

The relay shall remain insensitive to harmonics and DC components of faultcurrents.

Suitable non-linear resistors shall be provided to limit peak voltage impressedacross the relay coil within permissible limits.

b. Generator negative phase sequence relay (46G)

Relay shall be of 3 phase relay, capable of detecting excessive rotor heating dueto unbalance phase currents with 2 stage negative sequence relays.

This relay shall have a sensitive alarm unit with a continuously adjustable setting

and minimum 5% of stator rated current. The trip unit shall have variable timeand current setting to match the generator thermal capability.

The generator thermal characteristic and the generator's continuous negativesequence current withstand capability details will be furnished to the successfulbidders.

(Suitable ICTs shall be provided, if required).

c. Generator loss of excitation relay (40 G)

Auxiliary relays required if any, for the above scheme shall be included in theoffer.

The relay shall trip at a small delay depending on the asynchronous runningcapability. In case of loss of excitation accompanied by undervoltage immediatetrip shall be provided.

d. Generator overload alarm relay (51 O/L)

This relay shall be of single pole, definite time over current relay with a reset topick up ratio greater than 95%. The relay should have high thermal capability.


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This relay shall have a continuously adjustable current setting of 50 - 200% ofrated current and of timer of 0 - 60 sec.

e. Generator PT fuse failure relay (97)

The relay shall be able to detect the open circuit in primary as well as secondaryof the PT. Voltage balance relay with adjustable setting shall be provided.

The relay shall remain completely stable for any transient voltage fluctuations.The relay shall not operate for any generator fault.

The scheme shall include necessary auxiliary relays and contacts to cut offrespective potential circuits of protective relays and AVR. Minimum three sparecontacts shall be available for future use. Detail scheme shall be submittedalong with the bid.

f. Generator reverse power relay (32G)

This relay shall be of three-phase relay to protect the turbine generator unitagainst motoring. This relay shall have a minimum setting of -0.5% of ratedpower. This will trip the generator in case reversal of power after the set timedelay.

g. Generator low forward power relay (37G)

A power Relay with sensitive setting of +0.5% of rated power shall be used. Forcertain protective trip conditions, the turbine is first tripped by closing the mainsteam stop valves by the relay to allow steam to be expanded with generator

connected to grid. This relay initiates an alarm after a time delay when electricalpower output has fallen down to a value below +0.5%.

h. Generator Over Voltage Relay (59G)

2 elements instantaneous over voltage relay with timer shall be offered to protectthe system against sudden load throw off, AVR malfunctioning or any other overvoltage conditions. The relay shall be connected between R-Y and Y-B phases.

The relay shall have power frequency filters and adjustable setting range of 100- 140% of rated voltage.

The drop off to pick up ratio shall not be less than 95%. This relay is intended to

trip the generator on over voltage.

i. Under Frequency Relay for Generator (81G)

2 stage under frequency relay with two different timers and with one df/dtsensing element shall be offered.

The relay shall initiate an alarm after a set time delay (0 - 10 sec) at 49 Hz. Itwill trip the turbine after the set time delay (0 - 10 sec) when it comes down to48.5 Hz or with a set df/dt.


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j. Generator under voltage relay (27G)

One single pole under voltage relay with a timer (0 - 10 sec) shall be provided.

k. Generator voltage restrained O/C relay (51GV)

This relay shall have two distinct characteristics for over load and faultconditions, which shall be monitored by the system voltage conditions. Thisshall have setting range of 50 - 200% for over current. Under voltage settingshall be of 60%. This shall be of 3-pole relay.

l. Generator Back-up E/F Relay (51 NG)

A single pole IDMT overcurrent with an adjustable current setting range of 10 -40% of rated current and with a definite minimum setting of 3 seconds at 10

times current setting shall be provided. The relay shall provide protection to 95%of stator winding. This shall be connected in the neutral grounding circuit.

m. Rotor E/F Relay (64 F)

n. Stator E/F Relay

o. Tripping Relay (86G and 86 T)

High speed tripping relay with 8 N/O + 4 N/C shall be provided. The relay shallbe of hand reset type with operating time not exceeding 10 milli seconds. Thecontacts shall be of heavy-duty type.

p. Check Synchronising Relay (25)

The relay scheme shall permit closing of the incoming breaker only aftermatching the voltages, frequencies and phase angles of the incoming andrunning buses with the preset settings. The response time of the relay shall notexceed 60 ms when the two system inputs are falling within the relay permitlimits. The maximum phase angle setting shall not exceed 20 and the voltagedifference setting shall not exceed 0.45% at rated value and at the minimumtime setting. The time setting shall be continuously adjustable between 0.5 and 3secs. The relay shall be rated for 110V AC operation. Synchro check relay shallbe complete with 2 lamps and auxiliary relays and guard relays. The same shallbe located at Generator Control panel.

Any other auxiliary relay that may be required to complete the scheme and aphase reversing VT for manual dark lamp synchronizing also shall be provided.

q. Auto synchroniser


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3.3.17 Relay Test Kit

The bidder shall offer his recommended relay test kit for use with various relaysspecified in this specification. This shall essentially comprise the following:

a) Current injection devicesb) Measuring instrumentsc) Stabilized power supply unitd) Test probese) Any special tools required for wiring, testing, removal adjustmentsf) Self-contained, durable carrying case.

3.3.18 Annunciator

Static type annunciators shall be provided. There shall be translucent windows withengraved inscription.

Unless stated otherwise - the annunciators shall be suitable for operation withnormally open contact, which closes on fault. They shall be suitable for operation at110 V DC.

One common audible alarm, acknowledge, reset and lamp test push buttons shall beprovided for annunciators. Trip and non-trip functions shall be segregated by red andwhite window colours.

On occurrence of fault the following sequence shall be followed :

Flashing alarm with manual reset

Alarm Initiation Visual Audiblecondition contact module lamps alarm

Normal Normal Off Off

Fault Abnormal Bright flashing On

Accept PB Abnormal or a) Steady on Offnormal

b) DIM

Back to normal Normal a) Steady on Off(non first up)

b) DIM

Reset PB Normal Off Off

Lamp test PB Normal Steady Off

A hooter shall be provided near the Annunciation windows for Annunciation purpose.


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Each window shall be provided with two lamps.

DC supply failure scheme shall be provided separately with DC under voltage relays.On failure of DC supply to the panel, a lamp and a horn operated by AC supply shouldoperate. There shall be provisions for canceling AC buzzer. The DC bell and AC hornshall have distinctly separate tones.

The annunciation windows shall be provided with first-up feature.

The list of annunciations to be provided shall be as per Annexure 3.3.

3.3.19 Tests

Generator Relay Panels / Generator Control, Metering And Synchronising Panelsshall be completely assembled, wired and tested at the factory prior to despatch.

These shall be subjected to the following tests.

a) Mechanical Operation Test

b) High voltage test (2KV for 1 minute)

c) Megger test

d) Functional test to check electrical control, interlock and sequential operation test.

e) Routine test certificates shall be furnished for all associated components/equipment as per relevant standards.

Certified reports of all the tests carried out at the works shall be furnished for theapproval of the Purchaser.

The equipment shall be despatched from works only after the receipt ofOwners/Consultants written approval of the test reports.

Type test certificates of any equipment, if so desired by Owner/Consultant shall befurnished. Otherwise the equipment shall have to be type tested free of charge toprove the design.

3.3.20 Data and Manuals

As part of the proposal, the bidder shall furnish the following drawing/data for

preliminary study.

a) Panel dimension, plan, front view, typical internal view etc.

b) Technical leaflets and catalogues for all equipment.

The following/data shall be furnished for approval after award of contract to theConsultant/Owner.

a. Dimensional general arrangement of the Panel showing equipment dispositionand identification.


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b. Foundation plan and loading details clearly showing panel-fixing arrangement,

floor opening for cable entry etc.

c. Bill of materials listing equipment rating, setting ranges, label inscription, contactcombination etc.

d. Detailed control schematics, clearly showing terminal and wire numbers.

e. Panel internal arrangement drawing.

f. Panel wiring diagram.

g. Data sheet and instruction manual for commissioning / operation / maintenance ofeach equipment.

h. Overall synchronising scheme, control panel scheme and wiring has to bedeveloped by vendor.

The bidder may note that the drawings, data and manuals listed are minimumrequirements only. The bidder shall ensure that all other necessary write-ups, curvesand information required to fully describe the equipment offered are submitted with hisbid.


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ANNEX - 3.1

SPECIFIED DESIGN DATA -GENERATOR AND AUXILIARIES

Sl. No. Description Unit Data

1.1.0. GENERATOR

1.1.1 Apparent power of generator MVA : To suit max. power output turbine output at of Turbine

1.1.2 Voltage of generator terminals kV : 11, 5%

1.1.3 Rated Frequency Hz : 50, 5%

1. 1.4 Rated Power factor - : 0.8

1.1.5 Rated Speed - : 1500 RPM

1.1.6 Overload capacity - : 110% continuously150% for 30 sec.

1.1.7 Over speed - : 120%

1. 1.8 Saturated sub-transient reactanceXd % : min.12.88

1.1.9 Short Circuit Ratio (SCR) - : Min.0.5

1.1.10 Maximum auxiliary cooling waterinlet temperature C : 33.5

1.1.11 Temperature rise in cooling water C : 9.0

1.1.12 Type of generator cooling - : CACW

1.1.13 Type of exciter cooling - : Air-cooled closed circuit

1.1.14 Star point design - : Protection requirements(Resistance earthed)

1.1.15 Type of excitation - : Brushless excitationsystem with PMG

1.1.16 Excitation system response ratio - : Not less than 1.0/sec

1.1.17 Insulation class for generator & exciter - : F


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Sl. No. Description Unit Data

1.1.18 Permissible operation under allcondition to insulation class - : B

1.1.19 Type of bar insulation - : Synthetic resin

1.1.20 Automatic voltage regulator

a. Voltage range of electronicvoltage regulator % : Phase segregated

b. Type - : Thyristor controlleddual channel

c. Accuracy % : 0.5

d. Response time m.sec : < 0.25

1.1.21 Requirement for parallel - : Generator shall be operationwith grid suitable for operating in

parallel with grid andthe other 15 MW TG set(Future 15 MW UNIT)having voltage & freqvariations as following:

v = + 10, - 15%

f = 3%

1.1.22 Current harmonics 8.5%

1.1.23 Voltage distortion 4.6%at 11kV

HARMONICS ANALYSIS DETAILS

(a) Total Harmonics generated by three Thyristor Rectifires:

Power 16500KW (approx)

_____________________________________________________________________________HARMONICS IN AMPS.

Rectifier of Make 50 Hz load 3rd 5th 7th 11th 13th

BHEL 180 2.5 25 16 6 3

MB 500 5 61 23 11 17.5

ABB 350 2 2 1 20 12

TOTAL 1030 9 88 40 37 32


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(b) Harmonics current & voltage distribution with all Rectifires, Harmonics

Filter and Capacitors ON:_____________________________________________________________________________________Harmonic 6 MVAR OFF 6 MVAR ON 6 MVAR OFF 6 MVAR -ONOrder Filter -OFF Filter -OFF Filter -ON Filter -ON

IH VH IH VH IH VH IH VH

3 30 54 30 54 33 60 8 145 56 169 15 46 14 42 14 427 34 144 66 28 37 157 33 14011 22 149 22 145 3 21 3 1813 15 120 13 105 2 14 1 8

____ ____ ____ ____Root mean 76.8 ----- 78.3 ----- 51.6 ---- 36.9 -----

square of IH

% Harmonics 8.5% ----- 8.7% ----- 5.7% ---- 4.1% -----current cons-idering totalload as 900 A

Root mean ----- 298 ----- 195 ----- 175 ----- 148square of VH

% THD 4.6% 3% 2.7% 2.3%

Points to be considered:

1. This Harmonics analysis was conducted on 30.10.1996 and that time available Powerwas 18 MW and all three Rectifiers remained ON.

2. At Present, the available Power is 14 MW and BHEL Rectifier remains OFF.3. The ABB Rectifier load will be remains same.4. The MB Rectifier load is 350 Amp.5. When DG sets was running on 12 MW with load of Rectifier 11 MW, Harmonics with 6

MVAR capacitor ON Total Harmonics with 3% .6. Total Harmonics when all Rectifiers and Capacitors are ON is 3%(Avg), which

constitutes:

3rdHarmonic 1% 5thHarmonic 2% 7thHarmonic 2% and whenever CapacitorsOFF 3rd Harmonics goes high to 10% and Total Harmonics goes to 10 ~ 11%.

However, we have following arrangements to switch ON the standby Capacitors.6 MVAR , 3 MVAR , 2 MVAR and 1 MVAR i.e. Total 12 MVAR Normally we keep ON6 ~ 7 MVAR.


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ANNEX - 3.2

SPECIFICATION FOR TRANSDUCERS

Sl. Description Unit DataNo.

1.0 General

1.1 Make - As per Annexure-3.5

1.2 Type - Dual output

1.3 Output mA DC 4-20

1.4 Load resistance Ohms 700capability

1.5 Accuracy % 0.5% of fullscale

1.6 Repeatability % 0.1% of fullscale

1.7 Linearity % 0.5% of fullscale

1.8 Residual ripple in % 5% maximumoutput current

1.9 Power frequency kV rms 2 kV rms for1 min between wires and cases

1.10 Auxiliary supply V 110 V DCvoltage

1.11 Overload capacity withoutloss in accuracy

a) Continuous % 120% of ratedcurrent

b) Short time - 10 times ratedcurrent for 0.5 sec


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Sl. Description Unit Data

No.

2.0 Current transducers

2.1 Nominal input/rated Amps 1 amp ACcurrent

3.0 Voltage transducer

3.1 Nominal input /rated Volts 110/3 V ACvoltage

4.0 Frequency transducer

4.1 Nominal input/rated Volts 110/3 V ACvoltage

5.0 Power transducers/powerfactor transducers

5.1 Nominal input

a. Rated voltage Volts 110 V AC(3 phase PT supply)

b. Rated current Amps 1 Amps AC(3 phase CT supply)


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ANNEX - 3.3

LIST OF ANNUNCIATIONS

A minimum list of annunciation is given under. The bidder may add any otherannunciation as per his equipment requirement.

a. Trip

1. Generator differential relay operated

2. Over voltage relay operated (2nd stage)

3. Voltage restrained O/C relay operated

4. Negative phase sequence relay operated (2nd stage)

5. Reverse power relay operated

6. Field failure relay operated (with U/V)

7. Field failure relay operated (without U/V)

8. Generator under voltage relay operated

9. Generator Under frequency relay operated (2nd stage)

10. Generator lockout relay operated

11. Turbine lockout relay operated

12. Rotor earth fault relay operated (2nd stage)

13. Stator E/F relay operated14. Generator winding temperature very high

15. Generator bearing temp very high

16. Low forward power relay operated

17. Generator breaker auto trip.

18. Emergency push button operated.

19. Fire protection system actuated

20. Stator E/F relay operated.

21. Rate of change of frequency (df/dt) protection operated

22. Overall different protection operated

23. Local breaker back-up protection operated

24. AVR fault trip

25. Generator frame at 100C

26. Inadvertent energization protection operated.

27. 10% spare


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b. Alarm

1. Generator Under voltage 1st stage operated2. Over voltage relay operated

3. Over load alarm relay operated

4. Rotor earth fault relay (1st stage) operated

5. Negative phase sequence relay operated (1st stage)

6. Protection PT fuse failure

7. Metering PT fuse failure

8. Generator lockout relay circuit faulty

9. Turbine lockout relay circuit faulty

10. Under frequency relay operated (1st stage) (Generator)

11. Generator winding temperature high

12. Generator bearing temperature high

13. Generator inlet air temperature high

14. Generator outlet air temperature high

15. AVR faulty

16. Excitation limit reached

17. Auto changeover to manual mode

18. AVR auxiliary supply failed

19. AVR DC supply fail

20. AVR PT fuse fail.

21. AVR V/F high

22. Generator stator frame at 80C

23. Generator protection relay power fail

24. Generator protection relay soft-test fail

25. Overall differential protection faulty

26. AVR trip alarm

27. Rotating diode open circuit

28. Rotating diode short circuit

29. 10% spare


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ANNEX - 3.4

APPROVED LIST OF SUB-VENDORS / MAKES

RELAY & CONTROL PANEL : ABB / GECA

NGR : NARKHEDE / PIONEER /

PT & SP CUBICLE : BHEL / SWITCH CONTROL PANEL/ POWER GEAR

RELAYS : ABB / SIEMENS / AREVA

CONTROL SWITCHES : ABB / GECA / KAYCEE

SELECTOR SWITCHES : ABB / GECA / KAYCEE

PUSH BUTTONS : L&T / SIEMENS / TECKNICINDICATING LAMPS : ABB / GECA / L&T / SIEMENS / TECHNIC

CT/PT : AE/KAPPA/ PRECISE /PRAYOG /ABB/ PRAGAT

HRC FUSES : GECA / SIEMENS / L&T / S&S

CONTROL FUSES : GECA

AUXILLARY CONTACTORS : SIEMENS / L&T / SCHNEIDER ELECTRIC

CONTACTORS : SCHNEIDER ELECTRIC / SIEMENS / L&T

TERMINAL BLOCKS : ELMEX / CONNECTWELL / GECA

MCB : SCHNEIDER ELECTRIC / MDS / SIEMENS/ HAVELLS /ANCHOR

MOTORS : SIEMENS / CGL / KIRLOSKAR

CAPACITOR : MADHAV / MANOHAR

RECORDERS : AE / DIGITAL

METERS : AE / IMP / MECO

TRANDUCERS : ABB / SITU / AE / SIEMENS

ANNUNCIATOR : MINILEC/ BETA / IIC


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APPENDIX - 1.0

DETAILED TECHNICAL SPECIFICATION FOR

MISCELLANEOUS ELECTRICAL ITEMS

C O N T E N T

APPENDIX NO. DESCRIPTION PAGE NO.

1.1 SPECIFICATION FOR A.C. MOTORS 35

1.2 SPECIFICATION FOR MOTOR ACTUATORS 40

1.3 SPECIFICATION FOR L.T. POWER &CONTROL CABLES 42

1.4 SPECIFICATION FOR EARTHING &LIGHTNING PROTECTION 43

1.5 SPECIFICATION FOR LOCAL SWITCHBOARDS 44

1.6 SPECIFICATION FOR GENERATOR BUSDUCT 48


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FORMT9-PREV-B

(MUM)

APPENDIX-1.1

SPECIFICATION FOR A.C. MOTORS

1.0.0 GENERAL

1.1.1 All AC motors shall be general purpose, constant speed, squirrel cage threephase/single phase induction motors.

1.1.2 All motors shall conform to the latest edition of applicable IS, IEC and CBIPstandards/Publications except when otherwise stated herein or in the drivenequipment specification.

1.1.3 All motors shall have class 2 efficiency.

2.0.0 OPERATING CONDITIONS

2.1.1 The reference ambient temperature for the motors shall be taken as 50C.

2.1.2 All motors shall be rated for continuous duty. They shall also be suitable for longperiod of inactivity.

2.1.3 The motor nameplate rating shall have at least 15% margin over the input powerrequirement of the driven equipment at rated point.

2.1.4 The motor characteristics shall match the requirements of the drive equipment so thatadequate starting, accelerating, pull up, breakdown and full load torques are availablefor the intended service.

2.1.5 Motors below 200 watts, except otherwise required for reversible service, shall berated for use on a 240 V, Single phase, 50 Hz, resistance grounded system. Motorsabove 200 Watts, upto 160 kW shall be rated for use on a 415V, 3 phase, 50 Hzsolidly grounded system, Motors 160 kW and above shall be rated for use on a 11000V, 3 phase, 50 Hz. resistance grounded system.

2.1.6 Motor shall be designed for direct on line starting at full voltage.

2.1.7 Motors shall run continuously at rated output with the following variations in voltageand frequency:

Voltage 10%

Frequency 5%

Combined voltage and

Frequency (Absolute sum) 10%

2.1.8 The motor shall be capable of operating satisfactorily at full load for 5 minutes withoutinjurious heating with 75% rated voltage at motor terminals.


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FORMT9-PREV-B

(MUM)

3.0.0 PERFORMANCE

3.1.1 Starting current shall not exceed 6 times full load current for all auxiliaries includingtolerance. The motor shall be capable of withstanding the stresses imposed if startedat 110% rated voltage. Motor shall start with rated load and accelerate to full speedwith 80% rated voltage at motor terminals.

3.1.2 Motor shall be capable of three equally spread starts per hour, two starts in quicksuccession from cold condition and one restart from hot condition. Motors subject toreverse rotation shall be designed to withstand the stresses encountered whenstarting with non-energised shaft rotating at 125% rated speed in reverse direction.

3.2.0 Locked Rotor Withstand Time

3.2.1 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 with 20 secs. startingtime and by 5 secs. for motor with more than 20 secs. starting time. Starting time shallbe at the minimum permissible voltage of 80% rated voltage.

3.2.2 If the above conditions cannot be met in unavoidable cases, special provisions suchas motor shaft speed switch, etc. shall be provided subject to the approval of theOwner/Consultant.

3.2.3 Hot thermal withstand curve shall have a margin of at least 10% over the full loadcurrent of the motor to permit relay setting utilising motor rated capacity.

4.0.0 CONSTRUCTIONAL DETAILS

4.1.0 Enclosure

4.1.1 All motor enclosures shall conform to the degree of protection IP-55. Motor foroutdoor or semi-outdoor service shall be of weather-proof construction.

4.1.2 For hazardous areas, approved type of flameproof and increased safety enclosureshall be furnished.

4.1.3 Motors weighing 25 kg or more shall be provided with eye bolt or other adequateprovision of lifting.

4.2.0 Winding and Insulation

4.2.1 All insulated winding shall be of copper. 6600 V AND 415 V motors shall have class-F insulation but limited to Class -B temperature rise. Windings shall be impregnated tomake them non-hydroscopic and oil resistant.

4.2.2 The motors shall generally be of self-ventilated type totally enclosed fan-cooled(TEFC).

4.2.3 The windings, fittings and hardware shall be corrosion resistant. The windings shallbe tropicalized and suitably varnished, baked and treated with epoxy gel for operatingsatisfactorily in humid and corrosive atmosphere.


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FORMT9-PREV-B

(MUM)

4.3.0 Bearings

4.3.1 Motor shall be provided with antifriction bearings, unless sleeve bearings are requiredby the motor application. Vertical shaft motors shall be provided with thrust andguide bearings. Thrust bearing of tilting pad type (Mitchel or Kingsbury) are preferred.

4.3.2 Bearings shall be provided with seals to prevent leakage of lubricant or entrance offoreign matters like dirt, water etc. into the bearing area.

4.3.3 Sleeve bearings shall be split type, ring oiled with permanently aligned, close runningshaft sleeves. Grease lubricated bearings shall be prelubricated and shall haveprovisions for in-service positive lubrication with drains to guard against overlubrication. Oiled bearing shall have an integral self cooled oil reservoir with oil ringinspection ports, oil sight glass with oil level marked for standstill and runningconditions and oil fill and drain plugs. Forced lubricated or water cooled bearing shall

not be used without prior approval of Owner.

4.3.4 Lubricant shall not deteriorate under all service conditions. The lubricants shall belimited to normally available types with IOC or equivalent make.

4.3.5 Bearings shall be insulated as required to prevent shaft current and resultant bearingdamage.

4.4.0 Motor Terminal Box

4.4.1 Motor terminal boxes shall be detachable type and located in accordance with Indianstandards clearing the motor base plate/foundations.

4.4.2 Terminal box shall be capable of being turned 360 degree in steps of 90 degree,unless otherwise approved. The terminal boxes shall be split type with removablecover with access to connections and shall have the same degree of protection asmotor.

4.4.3 The terminal box shall have sufficient space inside for termination / connection ofXLPE insulated, armoured aluminium cables as applicable.

4.4.4 Terminals shall be stud type, substantially constructed and thoroughly insulated fromthe frame. The terminals shall be clearly identified by phase markings, withcorresponding direction of rotation marked on the non-driving end of the motor. Theterminal box shall be capable of withstanding maximum system fault current for aduration of 0.25 sec.

4.4.5 For HT motor, the terminal box shall be phase segregated type and neutral leads shallbe brought out in a separate terminal box (not necessarily phase segregated type)with shorting links for star connection.

4.4.6 Motor terminal box shall be furnished with double compression type brass cableglands.


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FORMT9-PREV-B

(MUM)

4.5.0 Earthing Terminals

4.5.1 The frame of each motor shall be provided with two separate and distinct groundingpads complete with tapped hole, GI bolts and washer.

4.5.2 The grounding connection shall be suitable for accommodation of ground conductorsas follows:

4.5.3 HT Motors, LT motors above 90 kW : 2-1C x 150 sq.mm, PVC insulated,unarmoured AL cables or 50x 6 mm GI Flat

Motors above 30 kW upto 90 kW : 2-1 C x 50 sq.mm, PVC insulated,unarmoured AL cables or 35 x 6 mm GI Flat

Motor above 5 kW upto 30 kW : 1 C x 35 sq.mm, PVC insulated,

unarmoured AL cablesor 25 x 6 mm GI Flat

Motor upto 5 kW : 1 C x 10 sq.mm, PVC insulated,unarmoured AL cables or 8 SWG GI wire

4.5.4 The cable terminal box shall have a separate grounding pad.

5.0.0 ACCESSORIES

5.1.0 Space Heater

5.1.1 Motors of rating 30 kW and above shall be provided with space heaters, suitablylocated for easy removal or replacement. The space heater shall be rated for 240 V,single phase, 50 Hz, and sized to maintain the motor internal temperature above dewpoint when the motor is idle.

5.2.0 Temperature Detectors

5.2.1 All HT motors above 160 kW shall be provided with six(6) winding temperaturedetectors, two (2) per phase and the motor bearing shall be provided with duplex typetemperature detectors. These temperature detectors shall be resistance type, 3 wire,platinum wound, 100 Ohms at 00C.

5.3.0 Indicator/Switch

5.3.1 Dial type local indicator with alarm contacts shall be provided for the following :

i) HT motor - bearing temperature.

ii) Hot and cold air temperatures of the closed air circuit for motors.

5.3.2 Flow switches shall be provided for monitoring oil flow of forced lubrication bearings, ifused.

5.3.3 Alarm switch contact rating shall be minimum 0.5 A at 220 V D.C. and 5A at 240 VA.C.


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FORMT9-PREV-B

(MUM)

5.4.0 Accessory Terminal Box

5.4.1 All accessory equipment such as space heater temperature detector, etc., shall bewired to and terminated in terminal boxes, separate from motor (power) terminal box.

5.4.2 Accessory terminal box shall be complete with stud type terminals. If possible, theaccessory terminal boxes shall be located on the same side of the motor as the main(power) terminal box.

5.5.0 Drain Plug

5.5.1 Motors shall have drain plugs so located that they will drain the water, resulting fromthe condensation or other causes from all pockets of the motor casing.

5.6.0 Dowel Pins

5.6.1 The motor shall be designed to permit easy access for drilling holes through motorfeet or mounting flange for installation of dowel pins after assembling the motor anddriven equipment.

5.7.0 Noise & Vibration

5.7.1 The noise level shall not exceed 85db (A) at 1.5 m from the motor. The peakamplitude of the vibration shall be within I.S. specified limits.

5.8.0 Rating Plate

5.8.1 All rating plates shall be of stainless steel.

5.8.2 In addition to the minimum information required by IS/IEC, the following informationshall 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.

6.0.0 PAINTING

Motor including fan shall be painted with corrosion proof epoxy paint.

7.0.0 TESTS

Upon completion, each motor shall be subject to standard routine tests as per I.S.In addition, any special test required for the driven equipment shall be performed.


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FORMT9-PREV-B

(MUM)

APPENDIX-1.2

SPECIFICATION FOR MOTOR ACTUATORS

1.0.0 REQUIREMENTS FOR ACTUATOR

1.1.1 The actuators shall be rated so as to open/close the valve within 25 to 45 secondsunless otherwise noted. Actuator shall be designed for 33% excess torque over valvedesign torque even at 10% under voltage and 5% under frequency.

1.1.2 The actuators shall essentially comprise the drive motor, torque/limit switches, geartrain, clutch, hand wheel, position indicator/transmitter, space heater, internal wiringand junction box.

1.1.3 The actuator enclosure shall be IP 65 type.

1.1.4 The actuator shall be designed for mounting in any position without any lubricantleakage or operating difficulty.

1.1.5 The electric supply for operation and control requirements for the actuators shall be asfollows :

- LT incomer supply : (415 10%) V AC, (50 5%) Hz, 3 Phase.- General : Any other voltage required shall be generated by vendor.

1.1.6 Each actuator shall be provided with the following limit switches :

- Two torque limit switches - one for each direction of travel, self locking adjustabletorque type.

- Two position limit switches, adjustable type - one for each end position.- One position feedback transmittal (4-20mA) 24V DC 2-wire type (only inching

type)

1.1.7 Actuator shall be located in the field. The terminal box shall be weather-proof IP-65type with removable front cover and have provision for 1 No. 3/4 inch ET gland and 3Nos. 1/2 inch NPT cable gland entry.

1.1.8 An internally powered space heater shall be included in the limit switch compartment.

1.1.9 All electrical devices shall be wired upto and terminated in the terminal box. Theinternal wiring shall be sufficient size for the power rating involved but in no case lessthan 2.5 sq.mm copper and minimum Class F type insulation.

1.1.10 Actuator with non-integral starter shall be provided. The following limit switch contactsshall be provided:

1. Torque switch - open / close

2. Limit switch - open / close

3. Position feed-back transmitter 4-20 mA, 24V DC, 2-wire type (only inching type).


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FORMT9-PREV-B

(MUM)

1.1.11 All actuators shall be provided with position indicator.

1.1.12 All actuators shall be provided with local mechanical indication of ON/OFF status ofvalve.

2.0.0 TESTS

Upon completion, each motor actuator shall be subject to standard routine tests asper I.S. In addition, any special test required for the driven equipment shall beperformed.


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FORMT9-PREV-B

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APPENDIX-1.3

SPECIFICATION FOR L.T. POWER & CONTROL CABLES

1.0.0 CODES & STANDARDS

1.1.0 All LT power and control cables shall conform to the latest edition of applicable IS.

2.0.0 TECHNICAL REQUIREMENTS

2.1.0 L.T. Power Cables

2.1.1 The L.T. power cables shall be designed for use in 415 V 10%, 3-phase, 50 Hz 5%solidly grounded system.

2.1.2 The L.T. power cables shall be 1100 volt grade, 90 0C rating, heavy duty power cableswith stranded aluminium/copper conductors, XLPE insulated, extruded PVC innersheathed, galvanised steel round wire/flat strip armoured and extruded PVC outersheathed.

2.2.0 Control Cables

2.2.1 The control cables shall be designed for 240 V 10%, 1 Phase, 50 Hz 5% and 110 VAC unearthed system.

2.2.2 The control cables shall be 1100 V grade, 70C rating with annealed copperconductor having high conductivity, PVC insulated, cores laid up, extruded PVC inner

sheath, single round/flat galvanised steel wire armoured and extruded PVC outersheath.

3.0.0 TESTING

3.1.0 Testing on the L.T power and control cables shall be done as per IS and requisitenumber of test certificates shall be furnished.


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APPENDIX-1.4

SPECIFICATION FOR EARTHING & LIGHTNING PROTECTION

1.0.0 GENERAL

1.1.1 Underground earthing grid / earthing pits will be provided by the purchaser along withnecessary pig tails for above ground connection.

1.1.2 Earthing & Lightning protection system shall conform to the latest edition of applicableIS.

2.0.0 SPECIFIC REQUIREMENT FOR EARTHING

2.1.0 All equipment under scope of tender shall be grounded, at two points to the nearest

pig tail of the plant underground earthing grid. The earthing conductor for the differentmotors/panels shall have the following sizes :

2.1.1 H.T. motors : 75

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