Sub Section VI Ajmer Push-17.03.10

7/31/2019 Sub Section VI Ajmer Push-17.03.10

1/83

VOLI:SECTIONV):EMPLOYERS REQUIREMENT:SUB SECTION VI UITAJMER JNNURM/AJMER-PUSHKAR/W

W/02

URBANIMPROVEMENTTRUST,AJMER SIGNATURE OF CONTRACTOR 1

Sub Section-VI: Electrical

Part I: Specific Requirements

TECHNICAL SPECIFICATIONS ELECTRICAL

1.0 Scope

The bidder's /contractor's scope covers the design, shop testing, supply, transport, storing at site,

erection, testing and commissioning of all electrical and instruments required for the plant, as per

enclosed General Specification, Specific Requirement, typical power distribution scheme and typical

control system architecture.

Where there is any contradiction between General Specification and Specific requirements mentioned

in this document, the specific requirements will rule the project requirement.

2.0 Design Basis

2.1 The Bidder/ Contractor shall strictly follow the typical power distribution single line diagram

which is to be proposed by him and approved and accepted by UIT.

The bidder shall visit the site to satisfy himself about availability of voltage level, its condition,

its probable route', etc. before quoting. The UIT will provide one source of 11 K.V, 50 c/s, 3

phase electrical power up to electrical meter within the premises. From this metering point

onwards the successful bidder shall extend 11KV supply up to main substation and further 433

V(step down) supply up to MCC room (Motor Control Center)

2.2 All the incomers of substations shall be suitably electrically as well as mechanicallyinterlocked as per scheme.

2.3 Bidders shall follow the BIS guideline-'for voltage rating of motors while designing and

selection of electrical motors. All the motors shall be of squirrel cage type and Energyefficient high performance type motors (Min eff. Class 2 )for optimum utilization of energy.

2.4 All motors shall be provided with class-F insulation and their temperature rise shall be limited

up to Class-B.

2.5 All HT & LT cables shall be designed and selected after considering a minimum de-rating

factor of 0.65. Exact de-rating shall be calculated taking into consideration designed ambient temperature,

grouping and minimum size as per fault level calculations of synchronised DG with grid) ..

2.6 Bidder shall carry out the earth resistivity test on his own and based on this result they should

design the total earthing system to maintain a overall resistance value less than one ohm.

2.7 The electrical and instrumentation in gas handling area like compressors etc. shall be flame

proof type and strictly adhere to CMRI/Explosive deptt. Norms.

2.8 Substation design shall incorporate all safety aspects and shall be provided with powerdistribution agency metering room, switchgear room, separate fence, gates, internal access

roads, lighting, earthing, power factor correction, lightning protection, cable trenches,


2/83


W/02


equipment foundations, transformer oil soak/drain pits, galvanized steel latticed

structures/gantries, gravel etc.

2.9 Noise level (db levels & insertion level) inside and outside blower room shall be strictly as per

latest amended pollution control board norms applicable at installation time. Whatever extra

equipments required like scrubber, acoustic shall be provided to meet statutory guide lines aswell as building should be able to accommodate all equipments.

2.10 The Contractor shall submit proposed/offered system architecture along with the offer.

2.11 HT cabling shall be done underground with top of HT cable minimum 1.0 meter below plant

ground level. The protection above HT cable shall be provided as per latest revision of IS

standard.

.

2.12 Bidder shall get the short circuit fault level data at 11kV,from power distribution agency and

.shall do the fault level calculation and Relay co-ordination scheme for the entire plant

accordingly. Bidder shall provide minimum protection on HT side as per standard relay

protection scheme enclosed herewith as annexure-2 In case some additional protections other

than indicated in drawing, are required; same should be added. Wherever transformer size is 2

MVA or bigger, than differential protection shall be provided.

.

2.13 Measuring instruments shall be provided by bidder as per standard measurement scheme

enclosed here with annexure-2.

2.14 LT capacitor bank shall be provided with automatic power factor correction system. Its panelshall incorporate timer circuit to allow capacitor to discharge at minimum 50V before re-energisation of

any individual bank.

2.15. Capacitor bank shall consist of many small capacitors so that banks can be in circuit as per

system p.f requirement with the help of Automatic Power Factor Correction relay. Minimum0.95 p.f will be maintained at power distribution agency meter on H.T. Side. Capacitor bank

calculations submitted along with bid shall also take into consideration the transformer

impedence. Each capacitor should be able to switch ON either in manual or auto mode

independently.

2.16. All the protection relay of 11 KV and 415 Volts panels shall be of microprocessor based

except master tripping relay and check supervision relay.

3.0 Bidders Obligation

Bidder shall provide preliminary details for the items given below. However, if UIT-AJMER

requires any further details during technical bid evaluation stage, the bidder shall provide thesame.

3.1 Load list (as per enclosed typical format)3.2 Maximum demand in KVA with duration (period) of the plant.3.3 Minimum demand in KVA with duration (period) of the plant

3.4 Normal demand in KVA of the plant.3.5 Detailed Bill of material for electrical as well as instrumentation scope of work.3.6 P & I diagram of the total plant.3.7 Instrument index (as per enclosed typical format)3.8 Input/ Output List (as per enclosed typical format)

3.9 Instrument Data sheet for each tag No.


3/83


W/02


3.10 Interlock logic diagram3.11 Control system architecture.

3.12 Instrument air requirement.3.13 Uninterrupted power supply (UPS) capacity requirement.3.14 UPS capacity and its battery backup calculation sheet.

3.15 Lighting fixture capacity and quantity calculation.3.16 Single line diagram for HT Power, LT Power. (main panel), L T distribution boards.

3.17 Single line diagram for lighting and small power.3.18 Cable schedule of total plant, along with voltage drop calculation and deratings.3.19 Operating power factor of each equipment.3.20 Power factor improvement capacitor calculation.3.21 H.T Panel Board Data Sheets.

3.22 LT Panel board (NDAC, MCC etc) Data Sheets.3.23 HT Cable, LT cable, control cable, telecommunication cable Data Sheet.

3.24 Transformer Data Sheet.3.25 UPS Data Sheet.3.26 Battery and Battery Charger Data Sheet.

3.27 ACSR Conductor Data Sheet.3.28 Guaranteed Power generation by Gas Engine.

3.29 Bus Duct Data Sheet3.30 Power mounted Isolator Data Sheet.3.31 Maximum Power consumption of the plant per day.

3.32 Minimum power consumption of the plant per day.

3.33 Guaranteed power consumption of the plant per day.3.34 Transformer capacity calculation sheet.3.35 Battery Charger Capacity Calculation Sheet.

3.36 Battery Capacity Calculation Sheet.3.37 Motor List (as per typical format enclosed herewith).

3.38 Control Valve sizing calculation sheet.3.39 DDC sizing calculation sheet.3.40 GA drawings of all electrical panels like HT panel, Transformer, Diesel Generators,

NDAC, MCC, Battery chargers and batteries, AC distribution board, DC distributionBoards, UPS and its batteries, Pole mounted Isolators, Lighting Arrestors etc.

3.44 Typical drawings of Earthing station.3.45 A drawings of all analysers, control room equipments etc.3.46 Typical drawing HT cable laying under the ground.3.47 Typical structural drawing showing LT cable tray for power, control etc in outdoor

areas.

3.48 Substation layout for each section, D G layout with appropriate clearances as per IERand appropriate clearances for maintenance.

3.49 Control room layout.3.50 Room size and quantity for total plant electrical and instrumentation work.3.51 List of Safety Items.

4.0 Indian Standards / Other International Standards

For the benefit of bidders, a few Indian Standards and Codes of practices and other international

standards are listed below. Unless otherwise noted, equipment/devices/accessories /installations/

testing etc. shall comply with relevant standards/codes mentioned herein. Where Indian Standards are

not available equipment/ devices etc. complying with relevant British or IEC standard or ISO standards


4/83


W/02


shall be proposed. While referring to any standard, the latest revision/edition shall govern. Bidders

are advised to include in their bid a list of equipment/devices and corresponding standards to which

they conform. Translation in English of standards, which are available in other languages, shall be

furnished along with the bid, in such cases the English translation shall govern.

4.1 List Of IS & Other International Codes (For Electrical Equipment / Accessories)

1. IS 5 - Colours for ready mixed paints and enamels.

2. IS 3 - Three phase induction motors.

3. IS 374 - Electric ceiling type fans and regulators.

4. IS 694 - PVC insulated cables for working voltages upped andincluding 1100V.

5. IS 722 - AC electricity meters.

6. IS 1248 - Direct acting indicating analogue electrical measuring

instruments and their accessories.

7. IS 1271 - Thermal evaluation classification of insulating material.

8. IS 1293 - Plugs and socket outlets of rated voltage upped and

including 250V and rated current upped and including 16A.

9. IS 1364 - Hexagon head bolts, screws and nuts of product grades A

and B.

10. IS 1534 - Ballasts for fluorescent lamps.

11. IS 1554 - PVC insulated ( heavy duty ) electric cables.

12. IS 1777 - Industries luminaries with metal reflectors.

13. IS 1913 - General and safety requirements for luminaries.

14. IS 2086 - Carrier and bases used in rewire able type electric fuses

for voltages upped 650V.

15. IS 2223 - Dimensions of flange mounted AC induction motor.

16. IS 2253 - Designation for type of construction and mounting

arrangement of rotating electrical machines.

17. IS 2254 - Dimensions of vertical shaft motors for pumps.

18. IS 2259 - Methods of tests for determination of insulation

resistance of solid insulating materials.

19. IS 2419 - Dimensions for panel mounted indication and recording

electrical instrument.

20. IS 2544 - Porcelain post insulators for system with nominal

voltages greater than 1000V.


5/83


W/02


21. IS 2551 - Danger notice plates.

22. IS 2667 - Fitting for rigid steel conduits for electrical wiring.

23. IS 2705 - Current transformers.

24. IS 2713 - Tubular steel poles for overhead powerlines.

25. IS 2834 - Shunt capacitors for power systems.

26. IS 3156 - Voltage transformers.

27. IS 3231 - electrical relays for power system protection.

28. IS 3725 - Resistance wire, tapes and strips for heating elements.

29. IS 3854 - Switches for domestic and similar purposes.

30. IS 3961 - Recommended current rating for cables.

31. IS 4029 - Guide for testing 3 phase induction motors.

32. IS 4691 - Degree of protecting provided by enclosure for rotating

electrical machinery.

33. IS 4728 - Terminal marking and direction rotation for rotating

electrical machinery.

34. IS 4889 - Method for determination of efficiency of rotating

electrical machines.

35. IS 5216 - Guide for safety procedures and practices in electrical

works.

36. IS 5578 - Guide for marking for insulated conductors.

37. IS 6098 - Method of measurement of air borne noise emitted by

rotating electrical machinery.

38. IS 6875 - Control switches ( switching devices for control and

auxiliary circuits, including contractor relays )

for voltage upped and including 1000V AC and 1200

V DC.

39. IS 7098 - Cross linked polyethylene insulated PVC sheathed

cables.

40. IS 8623 - LV switchgear and controlgear assemblies.

41. IS 828 - Circuit breakers for over current protection for house

hold and similar installations.

42. IS 10322 - Luminaries.

43. IS 12729 - General requirement of switchgear and controller.


6/83


W/02


44. IS 13032 - MCB boards for voltage upped and including 1000V AC.

45. IS 13947 - Low voltage switcher and controller.

46. IS 732 - Code of practice for electrical wiring installations.

47. IS 3043 - Code of practice for earthing.

48. IS 3646 - Code of practice for interior illumination.

49. IS 10118 - Code for practice for selection, installation and

maintenance of switchgear and control gear.

50. IS IEC 309 - Plugs, socket outlets and couplers for industrial

purpose.

51. IS 2026 - Transformers

52. IS 13118 - Vacuum circuit breakers.

For all other process equipments and instruments contractor shall follow

IS / ISO specifications and submit a copy of the same.

5.0. Clearance from Statutory Authorities

Bidders shall note that the successful bidder shall be responsible for obtaining statutory clearances

from all the relevant bodies (such as electrical inspector, Safety, Pollution Control Board, Fire

Insurance and Explosive Department Authorities, etc.). Payment in respect of fees, deposit, etc., of

such bodies shall be made by successful bidder. UIT-AJMER shall assist the contractor in obtaining

such clearances expeditiously by way of issue of introductory letters to relevant bodies but this will not

absolve the Contractor from his responsibility of obtaining in writing clearances mainly from Electrical

Inspector, Chief Explosive Officer, Pollution Control Board or any other local/ central authority

entirely at his own cost. No extra sum will be paid for these services. However fee deposited to power

distribution agency will be reimbursed by UIT-AJMER.

6.0 Contractor S Licence:

It shall be the responsibility of the contractor to obtain necessary license / authorization / permit for

work for his personnel from the licensing board of the state. The persons deputed by the contracts firm

should also hold valid permits issued or recognized by licensing board of the state where the work is to

be carried out.

7.0 Workmanship:

The contractor shall ensure workmanship of good quality and shall assign qualifiedsupervisor/ engineers and competent labour who are skilled, careful and experienced in

carrying out similar works. UIT-AJMER shall reserve the right to reject non-competentperson/s employed by the contractor, if the workmanship is found unsatisfactory.

8.0 Power Distribution Philosophy:

The bidder shall design the power distribution scheme for this site on the basis of followingguidelines and single line diagram. Voltage drop from transformer output to last point in

electrical distribution shall not be more than 5%. Voltage drop in any cable for installed loador any single circuit for installed load shall not be more than 2%. Only aluminium conductor


7/83


W/02


with PVC insulation armoured cables shall be used for size 2.5mm and above. All powercables upto 2.5mm2shall be copper conductor PVC insulated armored cables.

8.1 An indoor substation shall be planned to house switchgears for incoming and outgoing

power supply circuits, metering equipments, communication equipment, control panels,

auxiliary power supply distribution boards, DC system equipment etc. The followingvoltage of load factor and diversity factor shall be considered for calculating themaximum running load. The sizing of transformer shall be included along with the bid.

LOAD FACTOR

Main Pump Motor : 0.9Aux. Loads : 0.9Lighting loads : 1.0

Socket outlet, receptacle Diversity Factor : 0.50

DIVERSITY

Main pump motor for working loads : 1.0

Lighting Loads : 1.2Socket outlet, receptacle : 1.2

8.2 Main incomer switchgear in various plant/process areas shall be fed by duplicate (two),100% capacity feeders and outgoing feeders shall be so designed that at least 20%spare subjected to minimum of one feeder of every type shall be available. All control

voltage inside switchgear panel shall be at 230V AC for Contactors and control supply.Single line diagram of all panels shall be attached with bid giving cable sizes in singleline diagram.

8.3 DC system equipment (comprising batteries, chargers & DC distribution board) with

adequate capacity shall be proposed for protection / control circuits and other vital

devices of each substation. Further, in plant areas / substation a few lighting fixtures asemergency lighting suitable for operation on battery voltage shall be proposed instrategic areas. DC system, calculation of DC Battery size, DC battery charger, Voltageshould be attached with the bid.

8.4 Following protections for incomer feeders in main MCC location for each process areaof the plant. Each MCC shall be provided with 4 Pole two incomers and bus sectionwith draw out ACB/MCCB as incomer. MCC's shall be metal clad floor mounted, withcable entry from bottom (preferred) and environmentally protected to IP-5X. MCC

shall have fault rating of not less than the applicable fault levels. The two incomerneutral shall completely be isolated by using 4 pole ACB/MCCB.

Indication light for run, trip, emergency stop operated, power On, run dry protectionoperated in case of submersible pumps

Mechanical and electrical interlocking shall be provided between the incomers and thebus section ACB/MCCB to prevent parallel operation of main switchgear feeders.


8/83


W/02


MCCs shall be housed within brick built buildings segregated from injurious effects ofprocess fluids/gases are present. The major components of each starter shall comprise:

Door interlocked isolator

Fuse gear/ MCCB

Contactor, overload relay with single phasing protection.

Start/ Stop push button.

Local/ remote selector switches (if applicable)

Manual / off/ auto sector switch.

Ammeter as per starter requirement

Indication light for run, trip, emergency stop operated, power On, run dry

protection operated (where such tanks are used)

i) Incomer feeder shall have electrostatic / microprocessor based controlreleases for over current, short circuit, earth fault with time delay and thesereleases shall directly work on tripping mechanism of drawout air circuit

breaker. Outgoing feeder up to 630 Amps shall be switch fuse unit / MCCBand beyond 630 Amps shall be air circuit breaker. All Outgoing Air Circuits

Breakers will be manual drawout type.

ii) Each motor upto 22 KW shall have DOL starter with O/C, short cktprotection, over load relay with single phasing protection along withammeter, provision for remote start/stop. Overload relay shall be reset type

from front of panel. All starters component shall follow type-II coordinationchart of established manufactures with components of same make. Eachstarter shall have On/Off/Trip indication. All necessary selector switches likeauto manual switch and local remote switches shall be installed.

iii) Motors above 22 KW and up to 75 KW shall have Star / Delta starter withO/C, short cut protection, over load relay with single phasing protectionalong with ammeter, provision for remote start / stop O/C relay shall be resetfrom front of panel. All starter components shall follow type-II coordinationchart of established manufactures with components of same make. Each

starter shall have on/off/trip indication. All necessary selector switches likeauto, manual switch and local, remote switches shall be installed.

.

iv) Motor from 75KW and above shall have the soft starter and micro processorbased relays along with short circuit protection. Each starter shall haveon/off/trip indication. All necessary selector switches like auto manualswitch and local, remote switches shall be installed.

8.5. Cables proposed shall be suitable for operation on earthed/ unearthed system asapplicable. LV cables shall be armoured PVC insulated. Outer sheath of all cablesshall be of general purpose PVC and shall be of extruded type meeting latest IS-1554requirements. The cable shall be designed after taking de-rating factors of ambient,grouping into consideration for its design. Power cables of cross section above 2.5 sq.

mm shall be with aluminium conductors. All cables of cross section up to 2.5 sq. mmshall be with copper conductors. Unless otherwise stated all the cables shall be


9/83


W/02


armored. LV cables shall be of the armored heavy duty type and of 1100 V grade.Voltage drop on cable for installed current shall not exceed 2% on installed load.

Design ambient temperature shall be taken as 50OC. All cables shall also confirm tothe relevant fault level of switch board for one second and supporting calculations must

be submitted for fault level.

8.6 Cable Terminations

i) For termination of MV cables, single compression type glands shall be used forindoor locations. Glands shall be of brass, Lugs of Al / Cu or tinned copper shall beused as applicable, lugs shall be properly crimped on conductors. All glands usedmust be of heavy duty type.

ii) In outdoor areas, except within outdoor sub station area, cables shall be laiddirectly buried between building entry/exit points. Within buildings, cables shall be

laid on cable trays to be supported from building walls columns/ beams/floors /ceilings. In outdoor sub station area, cables shall be laid on cable trays in build upcable trenches. Ladder and perforated type cable trays shall be proposed. Ladder

type cable trays widths shall be restricted between 300 mm and 600 mm. perforatedcable trays widths shall be restricted between 100 mm and 250 mm. Side members

of ladder type cable trays shall be fabricated using structural steel angles of at least6 mm thick. Perforated cable trays shall be of the formed type made from 2 mmthick sheet steel. For supports, structural angles or channels of appropriate strength

shall be proposed. Vertical runs of cable trays shall be enclosed using perforatedsheets as above. Cable trays, supports and covers shall be painted with epoxy paint

of shade acceptable to UIT-AJMER. Tray width shall be so sized that at least 30%margin is available for addition at later date. This distance between the cables shall

be minimum equal to outer dia of cable.

iii) At road crossings hume pipe/s of adequate size shall be provided at a depth of 1000

mm (center line depth) of passage of cables, earthing conductors etc. At buildingentry points pipe sleeves of GI or PVC shall be provided for the passage of cablesand earthing conductors, such sleeves shall have projections on either side to

facilitate extension.

9.0 Illumination:

9.1 All internal and external areas shall be provided with lighting. The illuminationlevels to be achieved shall be as follows:AREA LUX

Office and labs : 300 LuxSwitchgear Room : 200 LuxControl Room : 300 Lux

Pump House : 200 LuxDG set room : 200 Lux

Chemical and general store : 150 LuxChemical Plant room : 200 LuxOther indoor areas : 100 LuxOutdoor plant from and walkways : 50 LuxBuilding entrance : 100 Lux

Indoor Plant Area : 200 LuxOutdoor Plant Area : 50 Lux


10/83


W/02


Transformer Area : 100 LuxRoads : 10 Lux

Fluorescent luminaries shall be used primarily for internal lighting. High pressurevapour or metal halide type luminaries shall be used in indoor application where

their use is appropriate. If mercury or metal halide is used in indoor then theyshould be supplemented with fluorescent luminaries to assure that minimum

illumination levels are maintained following momentary power dips. All otherinternal areas shall be lit with fluorescent luminaries. Where specificrecommendations of lux level are not covered above, illumination level in suchareas shall be finalized in consultation with UIT-AJMER. Contractor shall berequired to measure levels of illumination after completion of lighting installation

work and short fall in illumination level shall be made good by the contractor.Complete set of calculations showing, room, index, copy MF shall be given during

detailed engineering.. Lighting Fixtures should be of energy efficient type

9.2 Switches / sockets of piano type shall be used in general and in offices of staff,

control room, MMI room, decorative modular switches shall be used. Suitable fansshall be provided in rooms/ plant areas as per UIT-AJMER/CPWD standards. For

exhaust fans it must be provided in panel rooms, pump rooms, chemical rooms,stores, toilets and at least 20 air changes per hour must be maintained.

9.3 The following type of lighting fixtures shall be proposed:a) Decorative type 2x36W fixtures for fluorescent luminaries inside office/

administrative buildings and control rooms.

b) Corrosion resistant fixture with canopy made of FRP for fluorescent

luminaries for corrosive areas like chlorine handling or chemical store or areawith corrosive smell/gases etc.

c) Industrial type vitreous enameled fixture for fluorescent luminaries inside415V switchgear, MCC room and pump house.

d) In outdoor process areas, lighting fixtures shall be sodium vapour type

subjected to minimum of IP protection class.

e) All outside lights as plant field lights, building outside lights, flood lights etc.

which are to be switched on only during night hours should be controlledthrough photo cell/ clock switch installed at a central place. All lights shall

have minimum IP65 protection class.

f) Street lighting wiring shall be through buried underground.

g) All bulb fittings (except fluorescent lamps) will have screw type caps.

h) For outdoor lighting, the lighting feeder shall be operated through a

contactor, controlled by photocell/ clock switch and shall also have a manualby pass switch.


11/83


12/83


W/02


copper earth wire in GI rigid conduits along with 2.5 sq. mm earth wire. Notmore than two sockets shall be looped in one circuit. Alternatively they can

also be connected through armoured cable of 4 sq. mm running inappropriate cable trays.

9.8 Separate lighting panels and lighting distribution boards shall be installed and they shall nottake tapping for power from motor control centers or power distribution boards.

10.0. Earthing & Lightning Protection.

10.1 Bidders are advised to carry out soil resistivity measurement for designing theearthing system. Further, bidders are also required to study the guidelines in respectof lightning protection covered in relevant Indian Standards and accordingly

include proposals for the same. The bidder shall make sure that earthing resistancevalue for both neutral conductor & body earthing shall be less than one ohm. All

earthing station shall conform to latest amended IS 3043.

10.2 The Contractor shall provide an earthing installation at each site. Protective

conductors shall be provided for all electrical installations and associatedmechanical plant, exposed steel work and buildings. Protective conductors shall be

provided in accordance with the requirements of IS-3043 or equivalent. Theearthing system shall be designed for the earth fault current occurring at the pointof supply. The neutral point of the 11/0.433 KV transformer secondary windings

shall be solidly earthed. The calculation of earthing system and earthing valvesmust be submitted at detailed engineering stage.

10.3 The electrical installation shall be connected to the general mass of the earth by anearthing electrode. The earth electrode system shall be established adjacent to the

transformer compound. GI plate earth electrodes shall be proposed in earthingsystem. MS conductors with allowance for corrosion shall be used for conductors

to be buried in ground and they shall with stand fault for three seconds. GIconductors for earthing shall be used for above ground installations. Touch and

step potentials shall be kept within permissible limits as per IS and this should besupported with earthing calculations. No earthing resistance shall be less than oneohm. Size of earthing conductor shall be arrived as per calculations subjected to

minimum rating suggested below:a. Main switch board and stand bye : 50 x 6mm GI Flat

b. Interconnection to lighting protection system : 50 x 6mm GI Flatc. Interconnection to MCCs : 50 x 6mm GI Flatd. Interconnection to control panels : 25 x 3mm GI Flat

e. PF correction panel : 50 x 6mm GI Flatf. Local push button : 14 SWG GI

g. Lighting distribution boards : 4 SWG GIh. Lighting & receptacle system : 12 SWG GIi. Outdoor street lighting : 8 SWG GI

j. Ladder rack and cable tray at suitable points : 25 x 3mm GIk. Hand rails and metallic structure : 25 x 3mm GI

l. Steel structure comprising storage tanks : 25 x 3mm GI


13/83


W/02


10.4 The complete plants shall have lighting protection in the form of lighting finials, horizontal

earth continuity conductors, verticals risers, inspection links, earthing pits as per IS 3043.

As detailed lightning calculations shall be submitted at the detailed engineering stage.


14/83


W/02


1 SCOPE OF WORK

1.1 Design, manufacture, inspection and testing at works, supply at site, erection,

final check-up, painting, testing, and commissioning of the electrical equipmentsas detailed in the items with brief description shall form the scope of work of thesuccessful bidder.

1.2 The scope of work also includes civil work such as excavation, laying of sandand bricks on cables, laid, closing the excavation, making earthing pit chambers,foundation and pedestal for electrical equipment, grouting of cable tray supportsin walls, making entries for cable conduits in walls and making good the surfaceto the original one, embedding concealed conduits, junction boxes, etc. in wallsand ceilings and making good the surface, foundation for street lighting poles,providing covers, chequered plates on cable trenches, etc.

1.3 Co-ordination with local authorities, such as CONCERNING VVNL, Electrical

Inspectorate the State Government, chief electrical authority, etc. for obtaining allthe statutory approvals needed, preparing, submitting and obtaining approval ofall electrical drawings and documents as well as obtaining approval of theelectrical installation from these authorities shall also form the scope of the work.

1.4 Preparation and submission of As-Built drawings on soft-copy installation,operation and maintenance manuals of the equipments supplied along with theircatalogues shall also be furnished by the successful bidder.

2 ITEM WITH BRIEF DESCRIPTION.

S

No Item with Brief Description Qty.

1.11 KV four pole structure with gang operated disconnecting switches,drop off fuses, LA, earthing system, and other electrical items /equipments, etc.

1 Sets

2. 11 KV indoor CTPT metering Panel 1 Set

3.11 KV switchgear panels with VCBs, relays, metering and annunciationsystems and equipments / items

1 Set

4. Power Transformer 2 Nos.

5. LT PMCC 1 No.

6. LT MCCAsrequired


15/83


W/02


7. Local Start / Stop PB Station 1 Lot

8. Power capacitor with APFC board / panelAsrequired

9. LT motorsAsRequired

10.Cabling system, comprising of HT and LT cables, glanding andtermination kits/ accessories, cable trays with accessories.

AsRequired

11.

Lighting system for internal and external lighting of plant area comprisingof distribution boards, lighting fixtures, poles, switches, sockets, conduits,receptacles, wires, cables, and other required hardware necessary forcomplete lighting work, ceiling fan, exhaust fans.

AsRequired

12.Earthing system comprising of required number of earth pit stations,earthing strips of required sizes, and conductor lightning system /materials

AsRequired

13.Safety equipment comprising of fire extinguishers, fire buckets, safetycharts, danger boards/label, first aid box with medicines, rubber mats,safety gloves, etc. to be provided in substation, LT room, etc.

AsRequired

14. AC,3Phase and neutral,415V,50c/s,outdoor busduct 2 sets

Note :

The manufacture testing at works and supply of above electrical equipments alongwith their accessories / hardwares shall conform to technical specification andother requirements listed in the following pages.

3 SYSTEM DESIGN PARAMETERS

The electrical equipments / items selected for this project shall be suitable foroperation of technical parameters specified below:

a) Incoming Power Supply : AC, 11KV, 3Ph, 50 Hertz

b) Plant power distribution voltage : AC, 415 V, 3Ph, 4 wire, 50Hz

c) Lighting and space heating : AC, 230 V, 1Ph, 2 wire

d) D-C alarm, control and protection : 24 V, 2 wire, d-c

e) AC control : AC, 230 V, 1Ph, 2 wire

f) Potential transformer secondaries : AC, 110 V, 3Ph, 50 Hertz


16/83


W/02


g) Ambient temperature : 50 deg. Centigrade

h) System earthing : Solidly earthed

i) Voltage Variation : 10% of rated voltage

j) Frequency Variation : 5% of rated frequencyk) Combined voltage and frequency variation : 10%

l) Fault level : 350 MVA ( 11 KV) , 40 KA

( 415V), 6 KA (230 V)

DG sets

The DG Sets requirement shall be assessed by the bidder to run the plants inemergency during power failure. However DG set requirement at differentinstallation are as under

1 No. DG set of capacity to operate 1 no- air blower, one raw sewagepumps ( higher capacity) and return sludge pumps in emergency at 13 MLDSTP at Ajmer

1 No. DG set of capacity to operate pumping set of average flow dischargeat Ajmer pumping station.

1 No. DG set of capacity to operate pumping set of average flow dischargeat Pushkar pumping station.

Specifications of DG set:-

Supplying, Installation, Testing & commissioning of DG Set with auto change overswitch, EP281200 SITC of Silent DG Set complete with 1500 RPM Diesel Engine of

suitable BHP & AC Brush less SPDP Alternator mounted on a common baseFrame & coupled through a flexible coupling or close coupled. Alternator shall beself regulated with standard Alternator Protection (Over voltage, over speed &under voltage). Engine shall have residential silencer, up to 10 M exhaust pipingelectronic / Mechanical governor, Manual & electric Start, Batteries, Fuel tank(with Stand) & piping, control panel (16 G) with MCCB (4P, 25KA) Ammeter,Voltmeter, Frequency Meter Energy Meter & Hour Meter, Engine instrumentspanel, AVM and with Weatherproof, powder coated Accoustic enclosure for DGset for sound attenuation fabricated from 2.0 mm CRCA sheet steel (structure)with side wall fabricated form 2.0 mm CRCA Sheet & filled with 100 Sheet & filledwith 100 mm thick glass wool (96 Kg/m3) as per IS 8183 the doors of 100 mm thickand fabricated from 1.6 mm CRCA sheet packed with acoustic material, floor of

MS chequerred plate 5.0 mm thick, canopy fixed with axial flow fan of Alstom, CG,Almonard make. All doors/ opening are sealed with neoprene/EPDN gaskets. Theenclosure has buile in fuel tank, residential silencer (isolated form main DGchamber) with protection and tripping of DG set against temperature of more than50 degree centigrade. All controls for operation of DG set are form outside theenclosure with DG control panel mounted inside enclosure, visible and accessibleform outside. The enclosure should be suitable for following capacity DG sets andalternator. Noise level shall be less than 75 db (A) at a distance of 1 Mtrs. Dulycertified by authorized agency etc.


17/83


W/02


Note:- In the event of power failure DG sets is to run. The cost of Diesel shall beworked out on the basis of Energy meter installed on DG set and the payment ofdiesel shall be made by the contractor on the basis of diesel consumption per unitof energy generated and utilized.


18/83


W/02


Part II: Particular Specifications

4 11 KV VCB SWITCH GEAR PANEL WITH CIRCUIT BREAKER ANDASSOCIATED ELECTRICAL EQUIPMENTS:

The manufacture and supply of 11 kV switchgear panel with vacuum circuitbreakers and associated electrical equipments shall conform to the followingrequirements.

4.1. 11 KV VCB switchgear panel shall have separate fully segregatedcompartments to house the circuit breaker, bus bar, cables, relays andinstruments potential transformer and current transformers it shall ensure that noarc or foreign body can travel from or to other compartments. The switchgearpanel enclosure shall be dust and vermin proof. The construction shall be of the

metal clad type using high-grade CRCA steel ensuring safety and security.

4.2. VCB circuit breaker trolley comprising of vacuum interrupter, mechanism, etc.shall be engaged to the enclosure to facilitate horizontal isolation and horizontaldraw out. The trolley shall have distinct service and test positions with latchingand locking facilities. The interlocking facilities shall be provided through limitswitches.

4.3. The operating mechanism shall be of conventional design for operation of veryshort stroke required in vacuum interruption. The mechanism shall be fitted witha motorised spring charged closing mechanism with manual release. Manual

charging facilities shall also be provided for the operation. Quick O-C-O operation shall be possible. The closing spring when charged shall be held bya latch which shall be released either by manual means or by a solenoid to closethe circuit breaker. During motor charging the spring shall automatically getrecharged immediately after a closing operation. The mechanism shall beretained in the "ON" position (circuit breaker closed) by an over toggle linkageand trip solenoid to open circuit breaker. These springs shall be incorporated inthe drive assembly and shall be fully encapsulated. The trip free mechanismshall be suitable for repeated auto reclosing duty. The spring charging timeshall be less then ten seconds. The spring charging motor shall be in totallyenclosed construction.

4.4. The bus bars shall be higher grade copper material and shall be rated for 400

amps. The bus bars and jumpers shall be covered by special heat shrinkinsulating sleeves. The bolted connection shall be covered by flexible insulatingshrouds and the bus bars support shall be rigid enough for all thermal andelectro dynamic stresses created out of three second short time current.

4.5. A screw type racking arrangement for easy insertion and withdrawal of thebreaker shall render perfect contact pressure independent of the operator force.

4.6. A positive interlock to ensure the circuit breaker insertion to or withdrawal fromthe SERVICE position only when it is open.


19/83


W/02


4.7. Automatic safety shutters shall cover the live parts when circuit breaker is not inthe SERVICE position. Independent safety shutters shall be provided for upperand lower disconnect contact, each independently padlockable in open or closedcondition. Pressure release flaps at the stop of the panel at a suitable safeheight shall be provided. Separate flaps in circuit breaker, bus bar, cable

compartment shall be provided. Foolproof interlocks shall be provided as per IS/ IEC.

4.8. Epoxy molded stationery disconnect contacts shall provide effective segregationbetween phases and phases to earth.

4.9. A Separate segregated compartment for the potential transformer shall beprovided. The potential transformer connections shall be through moldedcontact. The potential transformer shall be housed in a withdrawable truckarrangement. Automatic shutters shall be provided to cover the live parts whenthe potential transformer is withdrawn outside the cubicle.

Adequate space for entry and termination of two sets of three core or six

numbers (two per phase) of single core XLPE cable connections and mountingshall be considered in the cable chamber for terminations of cables.

4.10. Fully segregated separate compartments for low voltage devices like relays,meters, control switches, and indicating lamps shall be provided in the topportion of the switch gear panel. The relays and meters or shall be mounted inthe hinged door.

4.11. Fully rated earth switches shall be provided as an integral part of theequipment / switchgear. The earth switches shall be independent in operationto the main closing mechanism and shall be interlocked to prevent use whenthe VCB is connected into its service position to prevent the circuit breakerbeing racked on to a circuit that has been earthed. Indicators shall be providedto warn if the earth switch is in the ON or OFF position, with the additionalsecurity that the design has been tested against a full fault current making ofthree seconds. Driving handles for drawing out / insertion of circuit breaker,rectifier unit for the spring charging motor, power pack unit for tripping, CRsurge suppressor, and transport trolley shall be provided in the breaker.

4.12. Circuit breaker shall be provided with anti pumping features, breaker close / tripcontrol switch, local remote switch, local ON/OFF switch, operation counter,indication lamps for CB on, CB off, trip circuit healthy, spring chargeddischarged condition, and space heater with toggle switch. In addition toabove, the breakers shall be provided with mechanical close / trip knobs,mechanical ON/OFF indicators and mechanical spring charged / freeindicators.

4.13. Annunciators (1 set), voltmeters (0-15 KV, 144 sq.mm size) with selectorswitchs, ammeters (0-630 amps, 144 sq.mm size) with selector switchs, anddigital micro processor-based monitor for all electrical parameters (kW, KVA,kWhr, frequency, pf, md, voltage, current, etc.) shall be provided.

4.14. Three instantaneous phase over current relays with IDMT characteristic forphase faults and one instantaneous relay for ground fault, under voltage relay,auxiliary relay for bucholz trip, auxiliary relay for winding and oil temp entail


20/83


21/83


W/02


Accuracy class : 1

Type : Epoxy

Fuses (HRC) : To be provided on HT and LT

Side Current transformer

Quantity : Two sets (1 for measurement

and other one for protection)

Ratio : 400/5 A

Burden : 15 VA

Accuracy class : 1 for metering and 5 P 10 for

Protection

Type : Cast resin

Class of insulation : E

4.17. Applicable Standard

The manufacture, testing and supply of 11 KV switchgear shall conform toIS 3427, IS 12729, IS 13118, IEC 298, IEC 694, and BS 5227.

4.18. Drawings and Documents

Drawings and documents indicating details of front, plan, sectional viewsof the HT panel, single line diagram, power and control scheme, controlwiring, terminal details, BOQ, calculation for bus bar sizing, etc. and

installation of related drawings shall be furnished for approval.

4.19 The 11 KV VCB panel board shall be provided with one incomer andthree outgoing VCB feeder panels. Out of three outgoing panels two shallbe used in this package and third one shall be kept as spare for futureuse for Phase-II of 50 mld, SLD shall be read in conjunction with thisstipulation.

5. POWER TRANSFORMER

The manufacture and supply of the power transformer shall conform to thefollowing requirements.

5.1 The transformer tank shall be made from high-grade plate steel, suitablyreinforced by means of stiffeners made of structural steel sections and equippedwith detachable radiators made from pressed steel.

5.2 The transformer core shall be constructed from high grade, non-ageing, cold-rolled, grain oriented, silicon steel laminations coated with insulation varnish.

5.3 The framework and core shall be constructed from high grade, non-aging, cold-rolled, grain oriented, silicon steel laminations coated with insulation varnish.


22/83


W/02


5.4 Windings shall be of suitably insulated copper wire or copper strip. Windingsand insulation shall be so arranged that free circulation of oil is possiblebetween coils, between windings, and between windings and the core. Highvoltage end windings shall be suitably braced to withstand short circuit stressesand stresses set up by surges.

5.5 The HV & LV bushing sequences shall confirm to IS. Wherever neutrals arebrought out, they shall be located to the left of the R phase bushing, whenviewed from the HV side. Solid porcelain bushings with brown glaze shall beused up to 36 KV class service. Solid bushings shall have characteristicsspecified in IS : 2099.

5.6 The transformer shall be fitted with

(a) An inspection manhole in the cover

(b) Lifting lugs

(c) two earthing terminals on opposite ends of the transformer tank

(d) name plate, rating plate, diagram plate

(e) detachable radiator banks, complete with top and bottom shut-off valves,air release plug, drain valve and lifting lugs

(f) suitably located thermometer pockets for measuring inlet and outlet oiltemperature

(g) one grounding terminal for connection of grounding conductor

(h) conservator complete with filling plug, sump, drain valve, shut-off valve onthe pipe connection between transformer tank and conservator

(i) weather proof dehydrating breather with activated alumina or silica gel(Bluish Colour) as the dehydrating agent

(j) 150 mm diameter dial magnetic type oil level gauge with low oil levelalarm contact mounted on the conservator

(j) The top filter valve and oil sampling device shall be provided on the tank

(k) gas detector relays with separate alarm and trip contacts complete withshut-off valves (l)explosion vent with diaphragm for relieving pressurewithin the transformer

(m) an equaliser pipe connecting the pressure relief device to the transformer

(n) adequate number of air vent for relieving trapped air during oil filling andduring maintenance

(o) thermometer pocket, temperature sensing element and a 150 mmdiameter dial type top oil temperature indicator with adjustableungrounded alarm/trip contacts

(p) waterproof/ dustproof terminals boxes for magnetic oil level gauge

(q) separately mounted waterproof dust-proof marshalling box housing the oiltemperature indicator and marshalling facilities for electrical devicesmounted on transformer


23/83


24/83


W/02


(c) The insulation class shall be A.

5.11 Drawings and documents indicating the complete construction details, generalarrangement drawing showing front, plan and sectional views, elementary and

schematic diagrams, installation, O & M manuals etc. shall be furnished forapproval before manufacture.

6. POWER CUM MOTOR CONTROL CENTRE

The manufacture and supply of Power cum Motor Control Centre (PMCC) shallconform to the following requirements.

a) Construction Features

1) Sheet steel used for the fabrication of the power and motor control centre(PMCC) shall be (minimum) 3 mm thick cold rolled.

2) All doors, panels, removable covers, gland plates, etc., shall be gasketedusing Neoprene gaskets all round the perimeter.

3) All doors shall be provided with concealed type of hinges and captive screws.

4) The PMCC shall be provided with a minimum 50 mm high channel baseframe. Total height shall be 2250 mm (max) . The minimum operating heightshall be 300 mm and maximum operating height shall be 1800 mm. ThePMCC shall be extendable on both sides.

5) Colour finish shade shall be as per IS 5. The colour of the interior shall beglossy white and the exterior shall be as suggested by the Employers

representative.

6) Instruments, relays, and control devices shall be mounted flush on hingeddoor of the metering compartment located in the front portion of the module.Each module shall be fitted with a label on the front and rear. Each moduleshall also be fitted with a label indicating the rating and duty. Modules shallbe complete with interpanel wiring.

7) The PMCC shall comprise separate, segregated modules for each circuit.

8) Busways, cableways and wireways shall be run in separate segregatedcompartments.

b) Incomer Feeder and Bus Coupler Detail

1) Void

2) The interlock shall be achieved mechanically as well as electrically betweenincomers and bus coulers.

3) The incomer feeder modules shall have the following features.

Motorised operated spring charged ACB unit (3 P, 415 VAC).


25/83


W/02


Voltmeter with voltmeter selector switch.

Ammeter with CTs and selector switch.

KWhr and KW, meters, PF meter.

On/Off indication lamps.

R, Y, B indication lamps.

Bus bars (RYB) extended down from the incomers for connection of incomingcables without any problem.

Bus coupler unit shall have motorised operated spring charged ACB

c) Outgoing Feeder Modules Details

1) The outgoing motor starter feeder modules shall be any of the following

depending upon the requirement of control(a) DOL starter

(b) Auto star delta starter

(c) Soft Starter

(d) Variable frequency drive component starter (for compressor motors of100 KW rating and above).

2) The DOL contactor starter module shall be considered for control of motorsrated up to and including 7.5KW and shall be equipped with:

- Main load break switch (TPN)

- HRC Fuses for power circuit and control fuse for control circuit

- Power and auxiliary contactors as required

- Overload relay

- Start, stop and reset Push Butten

- On, off and trip indication

- Ammeter with set switch

- Power and control circuit wiring and termination accessories

- Local/remote selector switch- Auto / off / manual selector switch as per requirement

3) The automatic star delta contactor starter module shall be considered for controlof motors of rated from 10KW and upto 45KW.The starter module shall beequipped with

- Main Load Break Switch (TPN)


26/83


W/02


- HRC Fuses for power circuit and control fuse for control circuit

- Power and auxiliary contactors as required

- Overload Relay

- Start, stop and reset PB- On, off and trip indication

- Ammeter with CTS and Sel Switch

- Power and control circuit wiring and termination accessories

- Electronic timer with relays

- Local/Remote Sel Switch

- Auto / off / manual sel switch as per requirement

4) The Soft starter module shall be considered for control of motors of rated from

50KW and above and shall be equipped with Electrical ratingsa) 200 525 +/- 10Volts AC mains

b) 50Hz +/- 10%

c) 100-240+/- 10% Volts control voltage

The Controller shall be provided with the followingstarting modes:

a) Linear Torque control for Start

b) Quadratic Torque control for Start

c) Pump Controld) Current Limit Start

e) Voltage ramp Start

f) Voltage ramp with current limit Start

g) Full Voltage Director on line Start

h) Remote analogue control

i) Soft Start with Selectable Torque Boost

j) Slow Speed time controlled

k) Slow Speed external controlled

l) Dual Ramp Start

m) Bypass control

The Controller shall provide the followingstopping modes:

a) Linear Torque control for Stop


27/83


W/02


b) Quadratic Torque control for Stop

c) Pump Control

d) Voltage ramp Stop

e) DIRECT ON LINE/Coast to stopf) Remote analogue control Stop

g) Dynamic DC-Brake and Soft brake (reverse brake)

h) Slow Speed time controlled

i) Slow Speed external controlled

j) DC-Brake at slow speed

k) Dual Ramp Stop

l) Accurate positional stop control

m) Bypass control

The following Additional features shall be provided in the Controller

a) Jogging forward and reverse

b) 4 parameter sets

c) Analog output

d) Built in Display

The Operation features in the Controller shall be

a) Keyboard

b) Remote

Protection features shall be provided in the Controller as detailedbelow.

a) Motor Thermal Overload

b) Soft Start thermal overload

c) PTC input

d) Motor Shaft Torque (Max) machine / process protection.e) Motor Shaft Torque (Min) machine / process protection.

f) Phase imbalance

g) Phase reversal

h) Over voltage

i) Under voltage


28/83


W/02


j) Locked Rotor

k) Excessive Starts per hour for application

l) Phase loss input / output

m) Motor output loss

The Viewing functions in the controller shall be:

a) Three Phase Current

b) Three Phase Voltage

c) Current in Line1,Line 2, Line 3

d) Voltage between L1-L2, L1-L3, L2-L3

e) Shaft Power in kW / HP (selectable)

f) Motor thermal capacity

g) Motor Energy consumption (kWh)

h) Power factor

i) Run time in hours

j) Torque in Lbs./ft or Nm (selectable)

The Controller shall be provided with the following Fault Indicationfunctions:

a) Line failure

n) Phase imbalance

b) Over temperature motor

c) Over temperature Soft Starter

d) Shorted Thyristor

e) Open Thyristor

f) Locked Rotor

g) Motor output loss

h) Overload - Shaft Torque

i) Under load Shaft Torquej) Phase imbalance

k) Over voltage

l) Under voltage

m) Excessive Starts

n) Phase reversal


29/83


W/02


o) Event List of 15 latest fault indications/occurrence

CONSTRUCTION:

a) The Controller shall be of modular construction, consisting of a Power ControlBoard (PCB) and Power Structure.

b) The PCB shall be compatible the full range of power structures.

c) In the sizes from 17 to1400 Amps all phases should be controlled duringstart/stop.

d) The power structure shall consist of six SCRs mounted on a heat sink forratings up to and including 1400 Amps.

e) The Controller shall be DIN Rail mountable up to 250 A.

f) DIN Rail mountable units should be mountable without space at side.

CODES AND STANDARDS:

The controller shall be designed to meet the applicable requirements of:

a) EN 60204-1, EN 50081-1 (-2 from 170 A) EN 50082-2

b) IEC 947-4-2

c) UL 508

d) CUL

CONTROL MODULE DESIGN FEATURES:

MECHANICAL:

a) The PCB module shall consist of a power supply, logic controlcircuitry, silicon controlled rectifier (SCR) firing circuitry. I/Ocircuitry, a digital programming keypad, dual LED Displays and aserial communication port.

b) The PCB shall be designed for integral mounting on the powerstructure and shall be compatible with the full range of currentratings-17 Amps to 1400 Amps.

c) The PCB shall be easily removed from the power structure,without the need to disassemble associated printed circuit boardassembles.

d) Control terminals shall be easily accessible and located on thefront bottom of the device. The terminals shall be UL rated for 300Volts, 15 Amps maximum and accept a maximum of two wires,0,2-4mm2 (#30-#12 AWG).


30/83


W/02


e) Digital parameter adjustment shall be provided through a built-inkeypad. Analog potentiometer adjustments are not acceptable.

f) Dual built-in alphanumeric, LED displays shall be provided forcontroller set-up, diagnostics, status and monitoring. The Control

Keypad and Display shall have the option for remote mounting.g) For safety reasons the controller should have 2 green lights for

running and start/stop.

ELECTRICAL:

a) The PCB shall provide digital microprocessor control andsupervision of all controller operation, including SCR pulse firingcontrol.

b) The PCB power supply shall be self-tuning to accept controlpower input from 100 to 240 or 380 to 500 VAC, 50/60 Hz.

c) The SCR firing circuitry shall incorporate an RC snubber networkto prevent false SCR firing.

d) The logic circuitry shall incorporate a latch circuit for three-wirecontrol.

USER ADJUSTMENTS:

a) The two acceleration start ramp timers shall have individualadjustments from 1 to 60 seconds.

b) The two acceleration stop ramp timers shall have individual

adjustments from 2 to 120 seconds.c) The initial torque setting shall be adjustable from 0 to 250% of

motor torque.

d) The end torque setting shall be adjustable from 50 to 250% ofmotor torque.

e) Current limit starting shall be adjustable from 150% to 500% of themotors full load current.

f) Slow speed shall be adjustable up to 60 seconds or up to 100external pulses.

PROTECTION AND DIAGNOSTICS:

a) Overload protection shall be as follows:

1) Meets applicable standards as a motor thermal protectiondevice.

2) Shaft Power measurement without the use of externalelectro-mechanical sensors.


31/83


32/83


W/02


Transient Protection: 17 Amps to 1400 Amps

a) For controllers rated 17 Amps to 1400 Amps, transient protectionwith snubber circuit including RC-net shall be standard.

b) Capacitors against electrical noise should be integrated as

standard.

ENERGY SAVER:

a) The Energy Saver feature shall operate to automatically cause theoutput voltage from the controller to be reduced when a motor isunloaded or lightly loaded..

b) The Energy Saver feature shall be defeatable.

c) Additional mounting space or wiring shall not be required.

ENVIRONMENTAL RATINGS:

a) Temperature Ratings

1) The Controller shall deliver its rated current in ambient

temperature ranging from 0.C to +50C.

2) The controller should be able to operate at 50C.

3) The ambient storage temperature shall range from 25C to +50C.

b) Humidity Range

4) The controller shall be operable in relative humidity of 5 to 95%,non-condensing.

NOTE: Vendor shall select the rating of the components based on the motorrating and other requirements.

5) Module Size

(Min Requirement) - 240 mm - For SFU

300 mm - For DOL starter

400 mm - For Star Delta starter

Full vertical panel - for Soft starterand variable speed drive motorstarter feeder.

6) The rating of the electrical items and components in the DOL, StarDelta, soft starter / variable speed drive motor feeder modules shallconform to the recommendations of the panel manufacturer with


33/83


W/02


due regard given to the derating condition and operation factors.

7) Incomers and bus coupler modules shall be fully draw out and alloutgoing motor starter feeder modules shall be of fixed design

8) Energy meters (KWHr) shall be provided in the lighting feeder(indoor and plant outdoor lighting) and power socket outlet feedermodules .This is required to estimate separately the actual powerconsumption of the process equipment load for the purpose ofperformance guarantee test and power consumption duringoperation and maintenance by deducting this auxiliary loads fromthe total power consumed. The bidder may propose redundantmeters if deemed appropriate in view of above.

SPECIFICATIONS OF VARIABLE FREQENCY DRIVE (VFD):

GENERAL REFERENCES

The dive should be designed to meet the following specifications:

NEMA ICS 3.1- Safety standards for Construction andGuide for Selection, Installation and Operation of AdjustableSpeed Drive system.

IEC 146 International Electrical Code

PRODUCT RATINGS

INPUT POWER:

The drive should be self adjustable to accept an input supply voltage ofAC, 3 phase & neutral of 415 V + /- 10%, 50C/s +/- 5%.

ENVIRONEMENT:

Storage ambient temperature range: -10 to 50 degree centigradeOperating ambient temperature range: 5 to 50 degree centigrade without derating.

OUT POWER:

The out voltage should be adjustable from 0 to rated input voltage. The outputfrequency range should adjustable from 0 to 100 Hz. The inverter section shallproduce a pulse width modulated (PWM) waveform using latest generationtechniques.

DESIGN HARDWARE:

The drive hardware shall be employ the following power components

Diode or fully gated bridge on the input.

DC bus inductor on all ratings as required.


34/83


W/02


Switching logic power supply operating from the DC bus.

Phase to phase and phase to ground MOV protection.

Gold plated plug in connections on printed circuit boards.

Micro procession based inverter logic isolated from power circuits.

Latest generation inverter section.

Inverter section shall not require communication capacitors.

Customer interface common for all horsepower ratings, interface shall include anLCD digital display, programming keypad and operator keys option.

Common control connection for all ratings.

Optimized for 4 KHz carrier frequency at 44 KW (60 HP) or less, and 2KHz at 55KW (75HP) and larger.

Peripheral interface enable attaching common options.

CONTROL LOGIC:

The drive should programmable or self adjusting for operation under the

following conditions. Operate drive with motor disconnected.

Controlled shut down, when properly fused with no component failure in theevent of an output phase to phase or phase to ground short circuit andannunciation of the fault condition.

Adjustable PWM carrier frequency within a range of 2-8 KHz.

Selectable Sensor less Vector or V/Hz mode.

Selectable fro variable of constant torque loads. Selection of variable torque shallprovide 115% of rated VT current for up to one minute. Selection of constanttorque shall provide 150% of rated CT current for up to one minute.

Multiple programmable stop modes including- Ram, Coast, DC Brake, Ramp-toHold and S-curve.

Multiple accelerator and deceleration rates. All adjustments to be made with the door closed.

Adjustable output frequency up to 100 Hz.

POWER CONDITIONING:

The drive should be designed to operate on an AC line which may contain linenotching and up to 10% harmonic distortion. An input isolation transformer shall berequired for protection from normal line transients and the K factor shall be 4.0 or less.

PF shall after rectification if required for lower frequencies shall not be lower than 0.95.

FEATURES

INTERFACE:The drive shall provide a removable Human Interface Module with integral display toshow drive operating conditions, adjustments and fault indications. The display shouldbe removable under power without causing a fault and shall be visible and operablewithout opening the enclosure door. The display shall consist of 2 lines of 16 characteralphanumeric, backlit LCD with the display being configurable for simultaneously


35/83


W/02


displaying two values using customized multi-lingual text and user scaled units. Themodule also shall provide LED indication of drive direction and commanded direction.The display should be capable of remote mounting by means of cable connection up to10 meters (33ft) from the drive and shall be capable of being used as a hand heldterminal.

CONTROL MODE:

Programming shall provide the ability to select sensor less vector or v/hz mode. Thesensor less vector mode shall use the motor nameplate data plus motor operating data,such as IR drop, nominal flux current and flux up time. The volts per hertz mode shall beprogrammed for squared, cubed, straight line, pre programmed or full custom patterns.

CURRENT LIMIT:

Programmable current limit shall be from 20% to 16% of constant torque rating. Currentlimit should be active for all drive states; accelerating, constant speed and decelerating.

The drive shall employ Pl regulation with an adjustable gain for smooth transition in andout of current limit.

ACCELERATION/DECELERATION:

Accel/Decel settings shall provide separate adjustments to allow either selling to beadjusted from 0 seconds to 3600 seconds. A second set of remotely selectable

Accel/Decel settings shall be accessible with Control Interface option. An adaptivecurrent limit circuit shall be disabled in programming for fast acceleration of low inertialoads.

SPEED REGULATION:

The programmable speed regulation modes shall include the following:

Open Loop

Slip Compensation with 0.5% speed regulation

Droop Negative Slip Compensation with 0.5% speed regulation

Traverse Function

Closed loop encoder feedback with 0.1% speed regulation

Process Pl control

SPEED PROFILES:

Programming capability shall allow the user to produce speed profiles with linearacceleration/deceleration or S-Curve profiles that provide changing accel/decal rates.S-Curve profiles shall be selectable for fixed or adjustable values.

ADJUSTMENTS:


36/83


W/02


The digital interface should be used for all set-up, operation and adjustment settings. Alladjustments shall be stored in nonvolatile memory (EEPROM). No potentiometeradjustments shall be used. The drive shall provide EEPROM memory for factory defaultvalues.

PROCESS Pl CONTROL:

The internal process Pl regulator shall have bolt proportional and integral gainadjustments as well as error inversion and output clamping functions. The feedbackshall be configured for normal or square root functions. If the feedback indicates that theprocess shall be moving away from the set point, the regulator shall adjust the driveoutput until the feedback equals the reference. Process control shall be enabled ordisabled with a hardwire input. Transitioning in and out of process control shall be tunedfor faster response by preloading the integrator. Protection should be provided for a lossof feedback or reference signal.

FAULT RESET/RUN:

The drive shall provide up to nine automatic fault reset and restarts following faultcondition before locking out and inquiring manual restart. The automatic mode shouldbe not applicable to a ground fault, shorted output faults and other internalmicroprocessor faults. The time between restarts shall be adjustable from 0-5 secondsto 30 seconds.

SKIP FREQUENCIES:

Three adjustable set points that lock out continuous operation at frequencies which mayproduce mechanical resonance shall be provided. The set points shall have bandwidth

adjustable from 0 Hz to 15 Hz.

RUN ON POWER UP:A user programmable restart function should be provided to automatically restart theequipment after restoration of power after an outage. A maintained 2-wire start input shallbe provided for this function.

LINE LOSS RESTART:

This programmable function shall select the reconnect mode of the drive after recoveryfrom a line loss condition. The reconnect modes shall be Last Speed, Speed Search,Track Volts, or Use Encoder. Disabling this feature will force the drive to start from zero

hertz.

FAULT MEMORY:

The last four faults as wel, as operating frequency, drive status and power mode shall bestored at the time of fault. Information should be maintained in the event of a power loss.

OVERLOAD PROTECTION:


37/83


38/83


39/83


40/83


W/02


Overload relay and the reset buttons. The setting range shall be properly selectedin accordance with the rating of motor selected.

8) The test facility shall be provided in each motor starter for the purpose of testingthe starter modules.

e) Air circuit breakers (ACB)

1) Air circuit breakers shall be of the 3 pole air break type and shall be of thevertical isolating pattern with horizontal draw out facilities. These shall be poweroperated by a motor operator spring charging type of mechanism. The trippingspring shall be charged by the closing action to enable quick tripping. Closing ofthe circuit breaker shall automatically initiate recharging of the springs to enablethe mechanism to be ready for the next closing stroke. The charging time for thesprings shall not exceed 30 seconds. It shall be possible to charge the springsmanually in an emergency. The transfer from motor to manual charging shallautomatically disconnect the charging motor. The charging mechanism shall be

provided with mechanical indicators to show charged and discharged conditionsof the spring. Failure of any spring, vibration, or mechanical shock shall notcause tripping or closing of the circuit breaker.

2) Means shall be provided to open and close the breakers manually and slowlywhen the operating power is not available for maintenance and adjustments.

3) All operating mechanisms shall be provided with ON-OFF mechanical indicatorsin addition to ON-OFF electrical indicators.

4) A local manual trip device shall be provided on the operating mechanism.

5) Closing coils and other auxiliary devices shall operate satisfactorily at allvoltages between 80 - 110% of the rated control voltage. Trip coils and

associated trip relays shall operate satisfactorily between 50 - 110% of the ratedcontrol voltage.

6) The rated breaking capacity of the ACB shall not be less than 35 MVA and theshort circuit withstand current for one second duration shall not be less than 40KA.

f) Switch and Fuse

1) Low voltage air-break switches shall be of the load break, fault make, groupoperated type. For use on three phase system, the switches shall be of the triplepole type with a link for the neutral wire. For use on single phase and D-Csystems, the switches shall be of the two pole type.

2) Switches shall be of the heavy duty, quick make and quick break type. Switchcontacts shall be silver plated and contact springs shall be of stainless steel.Switch handles shall have provision for locking in both fully open and fully closedpositions. Mechanical ON-OFF indication shall be provided on the switches.

3) Switches for controlling motor circuits shall be of the load break, fault make typeand shall be capable of breaking the locked rotor current of the associated motor.The life and no. of operation guaranteed shall be mentioned in the data sheet.


41/83


42/83


W/02


5) Identification labels shall be fitted giving the type, ratio, rating, output and serialnumbers. Duplicate rating labels are to be fitted on the exterior of the mountingchambers and suitably located to enable reading without the removal of any coveror metal sheeting forming part of the structure of the switchboard.

6) Magnetisation characteristics, calculated performance and protection settingsshall be provided by the Contractor.

7) Metering CTs shall have an accuracy class of 1.0 whereas protection CTs shallhave an accuracy class 1.5.

8) The V/A burdens for metering and protection of CT's shall be 15 V/A eachrespectively.

h) Relays

1) All relays shall be enclosed in rectangular shaped, dustproof cases.

2) All relays shall be suitable for flush mounting, with only the dust tight coversprojecting from the front of the panel.

3) All relays shall be accessible for setting and resetting from the front. Access tosetting devices shall be possible only after the front covers of the relays areremoved. Resetting facilities shall however be accessible externally to the relaycase.

4) All relays shall be provided with positive action flag indicators visible from thefront.

5) Auxiliary relays shall be rated to operate satisfactorily between 70% and 110% ofthe rated voltage. Tripping relays shall be rated to operate satisfactorily between50% and 110% of the rated voltage.

i) Control and Selector Switches

1) Control and selector switches shall be of the rotary type and have enclosedcontacts which are accessible by removal of the cover.

2) Control and selector switches for instruments shall be flush mounted on the frontof the panels. Local and remote selector switches shall be located on modules.

3) All control switches shall be of the spring return to normal type. Circuit breakercontrol switches on switchgear cubicles shall be lockable in the trip position.

4) Control switches shall have momentary contacts.

5) Selector switches shall be of the stay-put maintained contact type.

6) Control switches shall be provided with pistol grip handles. Selector switches shallbe provided with round, knurled handles. All handles shall be black in colour.

7) Properly designated escutcheon plates clearly marked to show the operatingpositions shall be provided with all switches.

j) Indication Instruments and Meter


43/83


W/02


1) Indicating instruments shall be mounted flush on the panels with only flangesprojecting outside the panel.

2) Instrument dials shall be white with black numbers and lettering. Dials shall beparallax free.

3) All indicating instruments shall have provision for the zero adjustment outside thecover.

4) Normal maximum meters reading shall be of the order of 60% of normal full scaledeflection.

5) Watt-hour meters shall be of the induction type.

6) Instruments shall have an accuracy of class 1.5 or better.

7) Ammeters for motors shall have suppressed extended scale to read up to sixtimes the rated current of the CT.

k) Indicating Lamps

1) Indicating lamps shall be of the filament type with low watt consumption. Indicatinglamps shall be of the double contact bayonet cap type rated for operation on 230V

AC. Indicating lamps shall be provided with series resistances to avoid shortcircuiting of the control supplies in the event of fusing of the filament. Lamps shallbe provided with translucent lamp covers. Alternatively LEDs may also be used.

2) Bulbs and lenses shall be interchangeable and easily replaceable from the front.

l) Push Buttons

1) Start and stop push buttons shall be coloured green and red respectively. All other

push buttons shall be black.

2) All push buttons shall be pushed to actuate the contact type.

3) Emergency stop push buttons shall be lockable in the operated position. The keyshall be released form the push button in both the released and operatedpositions. Operation of the push button shall be possible in the key releasedposition. Push button knobs for emergency stop-push buttons shall be recessed toprevent accidental operation.

m) Space Heaters

1) Adequately rated anti-condensation space heaters shall be provided, one for eachvertical cubicle of PMCC.

2) Space heaters shall be of the strip type, rated for operation on a 240 V singlephase, 50 Hz AC system.

3) Each space heater shall be complete with on and OFF switch and with HRC fusein the phase. It shall link in the neutral and thermostat to control space heater ONand OFF depending upon the temperature setting.


44/83


W/02


n) Cubicle Lighting

1) Each PMCC cubicle cable alley shall be provided with suitable interior lightingcontrolled by 5 amps SPNMCB.

o) Interlocks

1) Interlocks in each module shall be such that (i) it should not be possible to closethe switch when the fuse cover is open. (2) The fuses shall not be accessibleunless the switch is in fully open condition.

p) Safety Shutters (applicable for draw out design)

1. MCC cubicles shall be provided with safety shutters operated automatically by themovement of the carriage to cover the stationary isolated contacts where theshutter is withdrawn. (Module padlocking facilities shall be provided for locking theshutters positively in the closed position. It shall, however, be possible to open theshutters intentionally against the spring pressure for testing purposes.

2. LT incoming switch and starter modules shall be provided with laminatedinsulating sheet partitions to cover the stationary contacts when the module iswithdrawn.

q) Starter module alignment (applicable for drawn out design)

The moving portions shall be fitted with positive guides so as to ensure correctalignment of the isolating contacts in both circuit or earth positions.

r) Contacts

The contacts shall be made of silver faced copper. The contacts shall beadjustable for wear and tear, and shall be easily replaceable.

s) Test Operation Facilities (applicable for drawout portion)

All starter modules shall be provided with testing facilities to test the operation ofthe starter equipment. A separate test position shall be provided in the cubicle/module.

t) Wiring for Control and Protective Circuits

1) All wiring for control, protective, alarm and indication circuits on all equipments shallbe carried out with at least 650V grade, PVC insulated, stranded tinned copper, 1.5sqmm conductors. Wiring for CT circuits shall be carried out with a 2.5 sqmmcopper wire.

2) All wiring shall be run on the sides of the panels and shall be neatly bunched andcleated without affecting access to equipment mounted on the panel.


45/83


W/02


3) All wiring shall be taken to terminal blocks without joints or tees in their runs.

4) Engraved core identification ferrules, marked to correspond with the wiring diagramshall be fitted to each wire and each core of multicore cables terminated on thepanels. Ferrules shall fit tightly on the wires, without falling off when the wire is

removed. Ferrules shall be of yellow colour with black lettering.5) All wires forming part of a tripping circuit shall be provided with an additional red

ferrule marked "T". Each wire shall be identified by a letter to denote its functionfollowed by a number to denote its identity, at both ends. Unused cores of multicorecables shall be ferrules U1, U2, etc., at both ends and connected to spareterminals.

6) Spare auxiliary contacts of electrical equipment shall be wired to terminal blocks.

7) Wiring for future equipment shall be provided as far as possible and all wires shallbe terminated.

u) Control Wiring Terminal Blocks

1) Terminal blocks shall be of the 650 V grade, Clip-on type.

2) Terminals shall be numbered for identification and grouped according to function.

3) Terminals for circuits with voltage exceeding 125 V shall be shrouded. Terminalblocks at different voltages shall be segregated into groups and distinctivelylabelled.

4) Current transformer secondary leads shall be brought to terminals blocks, where afacility shall be provided for short circuiting and grounding the secondary leads.

5) Terminals blocks shall be arranged with at least 100 mm clearance between anytwo sets.

6) Separate terminal stems shall be provided for internal and external wiringrespectively.

7) All wiring shall be terminated on terminal blocks, using crimping type of lugs or clawtype terminations.

v) Test Terminal Blocks

1) Test terminal blocks shall be provided for secondary injection and testing of relayequipment. A suitable metering block shall be provided where specified for the

connection of a portable precision instrument to be operated when required forspecific plant testing purposes.

2) The terminal blocks shall be provided with suitable shorting links or alternativelyshall be of the type suitable for use with a portable test plug-in arrangement.

w) Inspection and Testing


46/83


W/02


1) The MCC /PMCC shall be offered for inspection after assembly. The tests (routineand acceptance) indicated below shall be carried out.

i. Routine test on the component of the MCC/PMCC

ii. High voltage test on the power circuit and on the control circuit.

2) The following routine and acceptance tests shall be carried out on the MCC/PMCCduring final inspection

Date post:	05-Apr-2018
Category:	Documents
Upload:	nik-pujara
View:	223 times
Download:	0 times